Case 921B Wheel Loader Operators Manual 9-26564 - PDF DOWNLOAD

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SAFETY/DECALS/HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 BEFORE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 BURN PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 FIRE OR EXPLOSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 WHEELS AND TIRES SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 HAZARDOUS CHEMICALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 UNIVERSAL DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 INSTRUMENT/CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KEY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOADER CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

QUICK ATTACH COUPLER (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

25 25 34 35 36 38 39 49

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

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

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

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

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

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

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

LOADER CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

AUXILIARY HYDRAULIC CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

QUICK ATTACH COUPLER (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 52 52 53 54 56 59 61 63 65 66 67

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IDENTIFICATION NUMBERS/MACHINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 5 MACHINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Template Name: OM_1_col Template Date: 1994_05_26

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

921B LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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GENERAL TABLE OF CONTENTS

INTERMITTENT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

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JOB SITE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOADER OPERATING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MACHINE HITCH INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATING IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATING IN HOT WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIFTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71 71 73 74 76 78 79

WHEELS/TIRES/BALLAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 BALLAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

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LUBRICATION/MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 GENERAL SAFETY BEFORE YOU SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 PLASTIC AND RESIN PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 TRANSPORT/SERVICE LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 ENGINE HOURMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 ACCESS DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 SYSTEMGARD LUBRICATION ANALYSIS PROGRAM . . . . . . . . . . . . . . . . . . . . . . 92 GREASE FITTINGS - 50 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 GREASE FITTINGS - 100 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 GREASE FITTINGS - 100 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 GREASE FITTINGS - 1000 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 FLUID LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 AIR FILTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 CAB AIR FILTER (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 WINDSHIELD WASHER RESERVOIR (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . 129 MAINTENANCE/ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

LOADER CONTROL ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE ELECTRICAL CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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130 130 133 143 145 146 150 150

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 REPLACEMENT BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

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

OPERATING DATA AND DIMENSIONS - 921B . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATING DATA AND DIMENSIONS - 921B XR . . . . . . . . . . . . . . . . . . . . . . . .

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

TRAVEL SPEEDS (WITH 26.5 X 25 TIRES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NOISE LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VIBRATION LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

159 159 162 165 165 166 167 168 168 168 169

Template Name: OM_1_col Template Date: 1994_05_26

DETAIL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

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MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

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FIRE EXTINGUISHER MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 SECONDARY STEERING CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

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TO THE OWNER

RP95N003 DEALER’S STAMP

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921B Loader

Template Name: OM_1_col Template Date: 1994_04_29

522L94

CASE CORPORATION 3401 First Avenue North Fargo, ND 58102 U.S.A.

Rac 9-26564 March, 1995 (Revised December,1997)

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TO THE OWNER

TO THE OWNER Template Name: OM_1_col Template Date: 1994_04_29

This manual contains important information about the safe operation, adjustment and maintenance of your Case Wheel Loader. Refer to the Detail Index at the end of this manual for locating specific items about your machine. This Wheel Loader conforms to current safety regulations.

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

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

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

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DO NOT use this machine for any application or purpose other than those described in this manual. If this machine is to be used in an application that involves special attachments or equipment, such as forestry, etc., consult your authorized dealer or the Case Corporation.

Consult your authorized dealer or the Case Corporation on changes, additions or modifications that can be required for this machine to comply with various country regulations and safety requirements. Unauthorized modifications will cause serious injury or death. Anyone making such unauthorized modifications is responsible for the consequences.

This Operators Manual is to be stored in the manual compartment equipped on this machine.

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

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TO THE OWNER

Standard Test Certificate - Noise Level (86/662/EEC) - Special Safety Equipment - (86/295/EEC and 86/296/EEC) EEC Certificate of Conformity - Safety (Autocertified as per 89/392/EEC) - Electromagnetic Compatibility - (89/336/EEC) - Simple Pressure Vessels (87/404/EEC)

RD97D095

Template Name: OM_1_col Template Date: 1994_04_29

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OPERATORS MANUAL STORAGE COMPARTMENT

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Official Documents

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TO THE OWNER

AFTER DELIVERY CHECK Template Name: OM_1_col Template Date: 1994_04_29

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

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

RIGHT, LEFT, FRONT AND REAR SIDES OF THE MACHINE When you are in the operators seat looking FORWARD the Right and Left side of the Wheel Loader are the same as your Right and Left Hand.

RIGHT SIDE

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FRONT

REAR

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LEFT SIDE B891464J

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IDENTIFICATION NUMBERS/MACHINE COMPONENTS

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

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

921B Wheel Loader MACHINE MODEL NUMBER ___________________________________________ PRODUCT IDENTIFICATION NUMBER ___________________________________________ ENGINE SERIAL NUMBER _____________________________________________________

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

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TRANSMISSION MODEL AND SERIAL NUMBER ___________________________________

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IDENTIFICATION NUMBERS

RB97D044

A27768

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Product Identification Number (P.I.N.)

IDENTIFICATION NUMBERS/MACHINE COMPONENTS

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Engine

Loader Bucket

A27772

B4054091

Transmission

Axle

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B4030791

B4029991

ROPS Cab

RD97D097

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RB97D050

ROPS IDENTIFICATION PLATE

MACHINE COMPONENTS

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ENGINE ACCESS DOORS (UPPER AND LOWER) ROPS CAB BUCKET CYLINDER LOADER ARM STANDARD BUCKET LOADER CONTROLS CAB AIR FILTERS STEPS HAND RAILS

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RP95002

IDENTIFICATION NUMBERS/MACHINE COMPONENTS

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6 RP95N003

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HAND RAILS AIR CONDITIONING CONDENSER RADIATOR SIGHT GAUGE REAR ACCESS DOOR HITCH STEP ENGINE ACCESS DOORS, UPPER AND LOWER STEP TRANSPORT/SERVICE LINK HYDRAULIC FILTERS HYDRAULIC RESERVOIR SIGHT GAUGE

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SAFETY RULES

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

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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 inside of the rear cover of this manual.

The safety information given in this manual does not replace safety codes, insurance needs or, federal, state, and local laws.

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.

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Template Name: OM_1_col Template Date: 1994_04_29

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

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SAFETY/DECALS/HAND SIGNALS

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SAFETY/DECALS/HAND SIGNALS

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BEFORE OPERATION

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● Different jobs will require different

● Always use the hand rails when mounting

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

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

● Remove all loose objects from the ● Be prepared for emergencies. Always

operators area and from the machine.

Loose objects can jam controls and cause accidents.

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

● Operate controls only when seated in the Operators seat.

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● Know the hand signals used on your job. ● Before starting the engine, securely

Follow the instructions of the flagman, signs, etc.

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

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

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

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

● Make sure all persons are away from the

● Foreign material or grease on the steps

● Before starting the engine, be sure all

and hand rails can cause an accident.

Keep the steps and hand rails clean.

operating controls are in neutral and the parking brake is applied.

machine before you start the engine.

● Sound horn to alert persons in the work area.

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MACHINE OPERATION

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● Do not turn the steering wheel until

● Electrical cables, gas pipes, water pipes,

everyone is clear of the machine and the center pivot area.

● Check all controls in a clear area and

or other underground objects can cause injury or death. Learn the location of underground hazards before you operate your machine in a new area.

make sure the machine is operating correctly.

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

● A frequent cause of personal injury or death is persons falling off and being runover. Do not permit other persons to ride on the machine. Only one person the operator - should be on the machine when it is in operation.

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

● Engine exhaust fumes can cause death.

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

● 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.

● Dust, fog, smoke, etc, can decrease your vision and cause an accident. Stop the machine or decrease the speed until you can see everything around you in the work area.

● Keep the loader bucket low when moving

● DO NOT operate this machine while

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

under the influence of alcohol or drugs.

PARKING THE MACHINE

!

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

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Template Name: OM_1_col Template Date: 1994_04_29

around the work area. Be careful when you raise the load to dump.

● Contact with overhead power lines can

!

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!

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SAFETY/DECALS/HAND SIGNALS

SAFETY/DECALS/HAND SIGNALS

Template Name: OM_1_col Template Date: 1994_04_29

!

MAINTENANCE

!

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

B901248J

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● Improper service or repair can cause

● Metal chips or debris can cause eye

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

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

● Unauthorized

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modifications to this machine can cause injury or death. Do not make unauthorized modifications to this machine.

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

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

● If you must service the machine with the

● Keep clear of the center pivot area of this

● When you service this machine, always

machine when the engine is running unless the transport/service link is in the LOCKED position. After service, return the transport/service link to the OPERATING position.

wear face or eye protection, safety shoes, and other protective items as required.

loader raised, always block the loader arms.

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BURN PREVENTION

● Battery acid causes severe burns.

!

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.

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

Antidote - EXTERNAL: Flush with water.

INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil.

Call a doctor immediately. EYES: Flush with water for 15 minutes and get prompt medical attention.

● 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

battery can explode if, (1) you try to charge the battery, or (2) you try to jump

!

FIRE OR EXPLOSION PREVENTION

● Engine fuel can cause an explosion or

!

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● When the battery electrolyte is frozen, the

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

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

● Use nonflammable cleaning solvent to

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

clean parts.

● Sparks or flame can cause the hydrogen

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

gas in a battery to explode. To prevent an explosion, do the following:

● Sparks from the electrical system or 1. When disconnecting the battery cables, disconnect the negative (-) cable first; when connecting the battery cables, connect the negative (-) cable last.

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

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Template Name: OM_1_col Template Date: 1994_04_29

!

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SAFETY/DECALS/HAND SIGNALS

SAFETY/DECALS/HAND SIGNALS

● A fire can cause injury or death. Always Template Name: OM_1_col Template Date: 1994_04_29

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

protection when you remove or install a starting fluid container. Use starting fluid according to the instructions in this manual. See Cold Weather Starting in this manual.

● Remove all trash or debris from the

● Keep the starting fluid (ether) container

machine. Make sure that oily rags or other flammable materials are not stored on the machine.

out of the reach of children.

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

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

● Do not store starting fluid (ether) TRIM THIS EDGE

● If there has been any fuel, oil, brake fluid

containers in the operators area.

or hydraulic fluid leaks within the chassis, remove and inspect the sound panels which may have any fluid on them. If any fluid has penetrated or soaked into the panel the panel must be replaced.

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

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● Starting fluid (ether) can explode and can cause injury or death. Do not breathe starting fluid vapors. Wear face

!

WHEELS AND TIRES SAFETY

!

!

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

SB134

!

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

84-113 14

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SAFETY/DECALS/HAND SIGNALS

!

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

SC002

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

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

Template Name: OM_1_col Template Date: 1994_04_29

321-7028

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If a decal is on a part that is replaced, make sure you install a new decal on the new part.

See your dealer for new decals.

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

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SAFETY DECALS

A27752

321-7030

A27756 15

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SAFETY/DECALS/HAND SIGNALS

A27767

Template Name: OM_1_col Template Date: 1994_04_29

321-3206

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321-6666

A27741

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E133054

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RB97D043

RP95N017 321-6672

RP95N023

(One Each Side) 321-3596

17

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A27778

Template Name: OM_1_col Template Date: 1994_04_29

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SAFETY/DECALS/HAND SIGNALS

SAFETY/DECALS/HAND SIGNALS

321-6714

Template Name: OM_1_col Template Date: 1994_04_29

RP95N025

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321-7040

321-6718

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RP95N028

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321-6666

1

2

B911306J

19

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RIGHT PAGE 321-3596

2

101811A1

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A27739

Template Name: OM_1_col Template Date: 1994_04_29

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SAFETY/DECALS/HAND SIGNALS

L130061

1

SAFETY/DECALS/HAND SIGNALS

HAND SIGNALS Template Name: OM_1_col Template Date: 1994_04_29

It is recommended that you and the flagman on the mob use hand signals for communications.

Before you start, make sure that you both understand the signals that will be used.

Start Engine

Stop Engine

227L95

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Come To Me

Move Away from Me

Move hand forward and rearward (palms in).

Move hands forward and rearward (palms out).

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228L95

Go This Far

All Stop and Hold

229L95

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SAFETY/DECALS/HAND SIGNALS

Emergency Stop

Move one hand back and forth.

Move both hands rapidly back and forth.

222L95

Lower Load or Bucket TRIM THIS EDGE

Raise Load or Bucket

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Stop

223L95

Lower Load or Bucket Slowly

224L95

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Template Name: OM_1_col Template Date: 1994_04_29

Raise Load or Bucket Slowly

SAFETY/DECALS/HAND SIGNALS

Template Name: OM_1_col Template Date: 1994_04_29

Turn Machine Left (Swing Load Left)

Turn Machine Right (Swing Load Right)

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

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

225L95

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Roll Back Loader Bucket

Dump Loader Bucket

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AS110

!

HAZARDOUS CHEMICALS

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

!

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

Before your 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.

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SAFETY/DECALS/HAND SIGNALS

139879A1 E127520

Diesel Fuel

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Articulated Joint - Keep Clear of the Area

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UNIVERSAL DECALS

RB97D032

139728A1

187863A1

139729A1

Hydraulic Oil

Lift Point

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Template Name: OM_1_col Template Date: 1994_04_29

Key Switch Positions

Tie Down

SAFETY/DECALS/HAND SIGNALS

Template Name: OM_1_col Template Date: 1994_04_29

RB97D039 RB97D037

Lift Arm and Bucket Control

Lift Arm and Bucket Control

TRIM THIS EDGE 187864A1

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E134402

Grease Fitting Location

No Step

RB97D092 RB97D098

Noise Level Noise Level

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8

1

3 9 4

2

7 A19331.75 1.

2.

3.

4.

5.

6.

7.

8.

9.

TRANSMISSION CONTROL LEVER DOWN SHIFT BUTTON HORN INDICATOR LAMP FOR FOUR-WAY FLASHER AND TURN SIGNALS MASTER WARNING LAMP FOUR-WAY FLASHER SWITCH STEERING WHEEL TILT CONTROL TURN SIGNAL LEVER HIGH BEAM INDICATOR LIGHT

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5

6

Template Name: OM_1_col Template Date: 1994_04_29

FRONT CONSOLE Hand Controls (Prior to P.I.N. JEE0052701)

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INSTRUMENT/CONTROLS

INSTRUMENT/CONTROLS

Template Name: OM_1_col Template Date: 1994_04_29

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. Move the control lever away from you for F O RWA R D . T h e c e n t e r p o s i t i o n i s NEUTRAL. Move the control lever toward you for REVERSE.

1

2

A18049

BACK-UP ALARM - When the engine is running and the transmission control lever is placed in reverse, a signal horn sounds at intervals.

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2. DOWN SHIFT BUTTON - The down shift button is located in the end of the transmission control lever and on top of the loader control valve lever. The down shift button is used to automatically shift the transmission from 2nd gear to 1st gear. The transmission will automatically shift back to 2nd gear if (1) the down shift button is pressed again or (2) if the transmission control lever is moved to NEUTRAL and then to FORWARD or REVERSE (see Transmission Operation in this manual for complete information).

2

A19323

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3. HORN - Push the button at the end of the Turn Signal Lever (Ref 8) to actuate the horn.

3

4. INDICATOR LAMP FOR FOUR-WAY FLASHER AND TURN SIGNALS - This green indicator lamp will flash when you signal a turn (Ref 7) or when you actuate the four-way flashers (Ref 6).

4 6

5

A19328

6. FOUR-WAY FLASHER SWITCH (If Equipped) - Push the bottom of the four-way flasher switch to actuate the flashers. Push the top of the switch for OFF. 7. STEERING WHEEL TILT CONTROL This control has six 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.

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5. MASTER WARNING LAMP - This red warning lamp flashes when there is a problem with one or more of the machine systems. If this warning lamp flashes, stop the machine immediately. Stop the engine and check for the problem.

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INSTRUMENT/CONTROLS

A19329

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Template Name: OM_1_col Template Date: 1994_04_29

7

INSTRUMENT/CONTROLS 8. TURN SIGNAL LEVER - This lever has four (4) functions:

Template Name: OM_1_col Template Date: 1994_04_29

8 TURN SIGNAL - Push the lever forward to indicate a turn to the left. Push the lever backwards to indicate a turn to the right.

9 HIGH BEAM/LOW BEAM - When the light switch is in position 3 ROAD LIGHTS. Pull the lever upwards to change from low A19328 beam to high beam. The lever will return to its initial position. Pull the lever upwards again and the lights will change from high beam to low beam. When you start the machine and connect the road lights you will always have low beam.

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FLASHER LIGHTS - When the light switch is in position 1 OFF and the lever is pulled upwards the high beam lights will come ON. When the lever is released it will return to its initial position and the lights will go OFF. 9. HIGH BEAM INDICATOR LIGHT - This blue lamp illuminates when the high beam lights are ON.

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INSTRUMENT/CONTROLS

2

7

8 1

5 9 6

RD97D109 1.

2.

3.

4.

5.

6.

7.

8.

9.

TRANSMISSION CONTROL LEVER AUTOSHIFT SWITCH INDICATOR LAMP FOR FOUR-WAY FLASHER AND TURN SIGNALS MASTER WARNING LAMP FOUR-WAY FLASHER SWITCH STEERING WHEEL TILT CONTROL TURN SIGNAL LEVER HORN PARK BRAKE SWITCH

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4

Template Name: OM_1_col Template Date: 1994_04_29

3

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(P.I.N.JEE0052701 and After)

INSTRUMENT/CONTROLS

Template Name: OM_1_col Template Date: 1994_04_29

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. Move the control lever away from you for F O RWA R D . T h e c e n t e r p o s i t i o n i s NEUTRAL. Move the control lever toward you for REVERSE.

2

1 RD97D071

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2. AUTOSHIFT SWITCH - The autoshift switch is located on upper steering console. When the autoshift switch is in the ON position the transmission will shift automatic UP and DOWN between 2nd and the highest speed setting on the transmission lever (see Transmission Operation in this manual for complete operation).

3

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3. DOWN SHIFT BUTTON - The down shift button is located on top of the A19323 loader control valve lever. The down shift button is used to automatically shift the transmission from 2nd gear to 1st gear. The transmission will automatically shift back to 2nd gear if (1) the down shift button is pressed again or (2) if the transmission control lever is moved to NEUTRAL and then to FORWARD or REVERSE (see Transmission Operation in this manual for complete information).

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4. INDICATOR LAMP FOR FOUR-WAY FLASHER AND TURN SIGNALS - This green indicator lamp will flash when you signal a turn (Ref 7) or when you actuate the four-way flashers (Ref 6).

4 6

5. MASTER WARNING LAMP - This red warning lamp flashes when there is a problem with one or more of the machine systems. If this warning lamp flashes, stop the machine immediately. Stop the engine and check for the problem.

5 RD97D069

7. STEERING WHEEL TILT CONTROL This control has six 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.

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6. FOUR-WAY FLASHER SWITCH (If Equipped) - Push the bottom of the four-way flasher switch to actuate the flashers. Push the top of the switch for OFF.

7

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INSTRUMENT/CONTROLS

8. TURN SIGNAL LEVER - 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.

9

9. HORN - Push the horn button to actuate the horn.

8

RD97D069

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Template Name: OM_1_col Template Date: 1994_04_29

RD97D072

INSTRUMENT/CONTROLS

10. PARK BRAKE SWITCH - To engage and disengage the park brake.

RD97D071

Template Name: OM_1_col Template Date: 1994_04_29

10

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INSTRUMENT/CONTROLS

1. LEFT BRAKE PEDAL - When the left brake pedal is pushed down, the brakes are actuated and the brake light is illuminated. Then, if the left side of the DECLUTCH SWITCH is pushed down, the transmission clutch is disengaged when this brake pedal is pushed down.

3

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

1

2. RIGHT BRAKE PEDAL - When the right brake pedal is pushed down, the brakes are actuated and the brake light is illuminated. The transmission clutch will remain engaged.

2

RD97D072

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DECLUTCH SWITCH

3. FOOT THROTTLE - Push the foot throttle to increase the engine speed. Release the foot throttle to decrease the engine speed.

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Foot Pedals

Back-Up Alarm While driving backwards a signal horn sounds with intervals.

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Template Name: OM_1_col Template Date: 1994_04_29

RD97D059

INSTRUMENT/CONTROLS

KEY SWITCH Template Name: OM_1_col Template Date: 1994_04_29

The key switch has four positions: ACCESSORY POSITION - This position will energize the optional radio only. It will not energize the instruments or start the engine.

KEY SWITCH

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.

RP97D066

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

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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.

NOTE: The Ether Start System (if equipped) can only be actuated when the key switch is in the ON position and the engine temperature is below 50˚F (10˚C).

RB97D032

NOTE: The transmission control lever must be in the NEUTRAL position for the starter to engage.

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INSTRUMENT/CONTROLS

CLAM CONTROL (IF EQUIPPED)

LIFT ARM AND BUCKET CONTROL

LIFT ARM CONTROL

B1117A88J

B1115A88J

THREE SPOOL-TWO LEVERS

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CLAM CONTROL (IF EQUIPPED)

BUCKET CONTROL

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LOADER CONTROL PANEL

THREE SPOOL-THREE LEVERS

Template Name: OM_1_col Template Date: 1994_04_29

NOTE: See Loader Control Levers in this manual for complete information.

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INSTRUMENT/CONTROLS

QUICK ATTACH COUPLER (If Equipped) Template Name: OM_1_col Template Date: 1994_04_29

Electrical Control Switch in Cab Use the coupler system to change attachments quickly. A control switch for the system is located under the loader function switches.

LOCKING TAB

COUPLER SWITCH

A18117R TRIM THIS EDGE

Connecting Attachments to Quick Coupler 1. Push the locking tab on the coupler switch to the left and push down on the right side of the switch (PINS RETRACT). Release the locking tab. Actuate the auxiliary hydraulic control lever to retract the locking pins and indicator tabs.

2. Drive the wheel loader up to the bucket or attachment.

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3. Position the upper pins on the quick attach coupler directly below the large hooks on the bucket or attachment. Raise the quick attach coupler to securely latch the coupler pins in the hooks.

4. Tilt the coupler backward to be sure the lower retaining holes on the bucket or attachment align with the coupler locking pins.

5. Push the locking tab on the coupler switch to the left and push down on the left side of the switch (PINS ENGAGED). Release the locking tab. Actuate the auxiliary hydraulic control lever to extend the locking tabs and indicator tabs. The indicator tabs on the coupler extend when both coupler locking pins are fully extended.

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INSTRUMENT/CONTROLS

2. If there are no auxiliary hydraulic hoses connected to the attachment, go to step 5.

3. Disconnect the attachment hydraulic hoses from the auxiliary couplers.

4. Start the engine and release the parking brake.

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5. Push the locking tab on the coupler switch to the left and push down on the right side of the switch (PINS RETRACT). Release the locking tab. Actuate the auxiliary hydraulic control lever to retract the locking pins and the indicator tabs. Lower the lift arms and back the machine away from the bucket or attachment.

Wrist Rest WRIST REST: To adjust, loosen the adjustment knob and raise or lower the wrist rest to the correct height. Tighten the knob.

B4043588T

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Template Name: OM_1_col Template Date: 1994_04_29

1. Lower the bucket or attachment on a level surface. Move the bucket or attachment so it is flat on the surface.

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Disconnecting Attachments from Coupler

INSTRUMENT/CONTROLS

RIDE CONTROL Template Name: OM_1_col Template Date: 1994_04_29

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

Ride Control will reduce Fore and Aft pitching motion during travel to allow faster speeds in load and carry applications for increased 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.

A27738 Push the function switch to the ON position.

Pull back on the Loader Control Lever until the Green light under the Ride Control Switch is illuminated.

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

To turn Ride Control OFF, push function switch to the OFF position, Green light will not illuminate.

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

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

4

6

5

8

10

9 TRIM THIS EDGE

2

1

3

7

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INSTRUMENT/CONTROLS

11

14

RD97D051

1. TRANSMISSION OIL TEMPERATURE: This red LED will illuminate when the transmission oil temperature is too high. The warning alarm sounds for 3 seconds, the systems normal lamp is off, and the master warning lamp is flashing.

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. Find and correct the problem before continuing to operate the machine.

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Template Name: OM_1_col Template Date: 1994_04_29

12

13

INSTRUMENT/CONTROLS

Template Name: OM_1_col Template Date: 1994_04_29

2. BRAKE PRESSURE: This red LED will illuminate when the brake system pressure is too low. The alarm sounds continuously, the systems normal lamp is off, and the master warning lamp is flashing.

Stop the machine immediately. Find and correct the problem before continuing to operate the machine.

3. SECONDARY STEERING: This red LED will illuminate when the primary steering system does not work correctly. The alarm sounds continuously, the systems normal lamp is off, and the master warning lamp is flashing. Stop the machine immediately. Find and correct the problem.

4. PARKING BRAKE: This red LED will illuminate when the parking brake is applied. If the parking brake is applied and you shift the transmission to FORWARD and REVERSE, the warning alarm will sound continuously, the systems normal lamp is off, and the master warning lamp is flashing. Release the parking brake or shift the transmission to NEUTRAL. TRIM THIS EDGE

NOTE: If the parking brake switch is in the OFF position when the key switch is moved to the OFF position, the parking brake switch must be moved to the ON position and then to the OFF position to release the parking brake.

5. HYDRAULIC OIL FILTER: This amber LED will illuminate when the hydraulic filters are restricted and require service. The warning alarm sounds for three seconds. Service the hydraulic filters as required.

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NOTE: In order for the Hydraulic Oil Filter switch to operate correctly, the hydraulic oil must be at operating temperature.

6. LIGHTS: This green LED will illuminate when the lights are on.

7. AIR FILTER: This amber LED will illuminate when the air filter is restricted and requires service. The alarm sounds for three seconds.

Replace or clean air filters at the end of the shift or day.

8. HYDRAULIC TEMPERATURE: This red LED will illuminate when the hydraulic oil temperature is too hot. The warning alarm sounds for three seconds, the systems normal lamp is off, and the master warning lamp is flashing.

Stop the machine. Find and correct the problem.

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9. ENGINE OIL PRESSURE: This red LED will illuminate when there is low or no engine oil pressure. The warning alarm sounds continuously, the systems normal lamp is off, and the master warning lamp is flashing.

Stop the engine immediately. Find and correct the problem.

10. ALTERNATOR WARNING LAMP: This red LED will illuminate when the voltage is too low.

The warning alarm sounds for three seconds, the systems normal lamp is off, and the master warning lamp is flashing.

Stop the engine. Find and correct the problem.

11. HOURS: The engine hourmeter shows the hours and tenths of an hour the engine has run.

a. Transmission Temperature b. Secondary Steering c. Parking Brake (Parking Brake applied and the transmission in gear.) d. Hydraulic Temperature

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12. SYSTEMS NORMAL: This green lamp illuminates when all systems are normal. This lamp stops illuminating when one or more of the following LED’s are illuminated.

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INSTRUMENT/CONTROLS

e. Engine Oil Pressure

g. Engine Coolant Temperature (When top three bars of bar graph are illuminated.)

13. ENGINE COOLANT TEMPERATURE: The engine coolant temperature is shown on this gauge with black bars. The lower yellow and green zones of the gauge show normal engine coolant temperature. If the coolant temperature increases, and the bars move up to the upper yellow zone, the warning alarm sounds for three seconds, the systems normal lamp stops illuminating, and all of the bars flash rapidly. If the coolant temperature continues to increase, the bars move up into the red zone, the warning alarm sounds continuously, and all of the bars flash rapidly.

Stop the engine, find and correct the problem.

14. FUEL LEVEL: The fuel level is shown on this gauge with black bars. When the tank is almost empty, the warning alarm sounds for three seconds and the bottom bar on the gauge flashes rapidly.

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Template Name: OM_1_col Template Date: 1994_04_29

f. Alternator

INSTRUMENT/CONTROLS

Function Switches Template Name: OM_1_col Template Date: 1994_04_29

1 3

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A27738

A27738

1. D E C L U T C H S W I T C H : Tw o p o s i t i o n switch used to disengage transmission clutches when left brake pedal is pushed down. Push down on the left side of the switch to select Declutch. Push down on the right side for OFF.

3. BUCKET HEIGHT CONTROL SWITCH: Two position switch used to select the Bucket Height Control function. Push down on the left side of the switch to select the Bucket Height Control function.

Push down on the right side for OFF.

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2

4

A27738

A27738

2. RETURN-TO-DIG SWITCH: Two position switch used to select the Return-To-Dig function. Push down on the left side of the s w i t c h t o s e l e c t t h e R e t u r n - To - D i g function. Push down on the right side for OFF.

4. RETURN-TO-TRAVEL/FLOAT SWITCH: Three position switch used to select the Return-To-Travel or Float function. Push down on the left side of the switch to select the Return-To-Travel function. Put the switch in the middle position to select the Float function. Push down on the right side for OFF. NOTE: In order to select the Return-ToTravel function the Return-To-Dig function must also be selected.

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(3) DRIVE - Turn the switch to this position to illuminate the console lamps, driving lamps, and tail lamps. The key switch can be ON or OFF.

7

(4) ALL - Turn the switch to this position to illuminate the console lamps, driving lamps, and flood lamps. The key switch must be ON.

6

9

8

(5) WORK - Turn the switch to this position to illuminate the console lamps and flood lamps. The key switch must be ON.

A27738 5. AIR CONDITIONING TEMPERATURE CONTROL: Turn the air conditioning temperature control clockwise for ON. Adjust the control to the desired temperature. Turn the control counterclockwise for OFF.

7. AIR CONDITIONING WARNING LAMP: This warning lamp is illuminated when the air conditioning has stopped due to refrigerant pressures that are too high or low or when the system needs service or the outside air temperature is too cool for the system to work.

NOTE: For maximum cooling, See Air Louvers in this manual.

To start the air conditioning again, turn the air conditioning temperature control to OFF and back to ON again.

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

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5

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INSTRUMENT/CONTROLS

If the warning lamp stays on, see your Service Manual or your dealer.

8. H E AT C O N T R O L : Tu r n t h e c o n t r o l clockwise for ON. Adjust the control to the desired temperature. Turn the control completely counterclockwise for OFF.

4 3 2

NOTE: For maximum heat, See Air Louvers in this manual.

1

9. BLOWER FAN SWITCH: The blower fan switch has four positions; OFF, 1, 2, and 3. Turn the switch to 3 for maximum speed and to 1 for the slowest speed.

Turn the switch completely counterclockwise for OFF.

B890738J

(1) OFF - Turn the switch completely counterclockwise for OFF. The key switch can be ON or OFF. (2) PARK - Turn the switch to this position to illuminate the marker and tail lamps. The key switch can be ON or OFF.

NOTE: For maximum air flow, See Air Louvers in this manual.

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Template Name: OM_1_col Template Date: 1994_04_29

5

INSTRUMENT/CONTROLS

Template Name: OM_1_col Template Date: 1994_04_29

10

A27738 10. C I G A R L I G H T E R : P u s h I N t o h e a t element.

Air Louvers TRIM THIS EDGE

1 2

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A27748

A18060

1. MAIN AIR LOUVERS: Three louvers in the front of the cab direct air flow back to the operator.

NOTE: Open these louvers for maximum cooling with air conditioning or maximum heat with the heater.

2. RECIRCULATION AIR LOUVERS: The recirculation louvers are on the right side of the seat next to the floor. When open, air is recirculated in the cab.

3. DEFROST: AIR LOUVERS (Not Shown): Two louvers under the front windshield and one under the rear window direct the air flow to defrost the windows. To get maximum air flow on the windows, close the three main louvers and turn the blower fan to the fastest speed.

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INSTRUMENT/CONTROLS

2

3

4

A27762 1. TACHOMETER: The tachometer shows the engine speed in revolutions per minute (rpm).

Each number or mark on the gauge is equal to 100 rpm.

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1

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Gauges

ENGINE OIL PRESSURE GAUGE Gauge Indication Condition 0 to 15 psi Very low (too low to run engine) (0 to 103 kPa, 0 to 1 bar) (Master warning lamp flashes, the alarm sounds, and the systems normal lamp is off).

15 to 27 psi Low (above low idle) (103 to 186 kPa, 1 to 1.8 bar) Normal (at low idle) 28 psi and above Normal (above low idle) (193 kPa, 1.9 bar)

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Template Name: OM_1_col Template Date: 1994_04_29

2. ENGINE OIL PRESSURE GAUGE: This gauge indicates the oil pressure in the engine lubrication system.

INSTRUMENT/CONTROLS 3. TRANSMISSION OIL TEMPERATURE GAUGE: This gauge indicates the oil temperature of the transmission.

Template Name: OM_1_col Template Date: 1994_04_29

TRANSMISSION OIL TEMPERATURE GAUGE Gauge Indication Condition 100˚ to 150˚ F (38˚ to 60˚C) Oil temperature very low 150˚ to 220˚F (60˚ to 105˚C) Oil temperature normal 220˚ to 250˚F (105˚ to 120˚C) Oil temperature very high (Master warning lamp flashes, the warning alarm sounds, and the systems normal lamp is off.)

4. VOLTMETER GAUGE: This gauge indicates the condition of the batteries and charging system.

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Gauge Indication 0 to 21 Volts 22 to 24 Volts 24 to 26 Volts

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26 to 30 Volts 30 or more Volts

VOLTMETER GAUGE Engine Speed Condition of Charging System Stopped or low idle Very low battery charge Stopped or low idle Low to normal battery charge Above low idle Problem in charging system Stopped or low idle Normal battery charge Above low idle Problem in charging system Above low idle Normal operating range Above low idle Problem in charging system (overcharging)

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INSTRUMENT/CONTROLS

1

2

3

Radio (If Equipped)

4 FAR1058

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

1. WINDSHIELD WASHER SWITCH: Two position switch used to actuate the windshield washer. Push the bottom of the switch to actuate the windshield washer. When released, the switch returns to OFF automatically.

Template Name: OM_1_col Template Date: 1994_04_29

2. FRONT WIPER SWITCH: Three position switch used to actuate the front wiper.

Push the bottom of the switch for HIGH SPEED, the center position of the switch is SLOW SPEED, and the top position if OFF.

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B4042888T

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Windshield Wiper Controls (If Equipped)

3. REAR WIPER SWITCH: Three position switch used to actuate the rear wiper.

Push the bottom of the switch for HIGH SPEED, the center position of the switch is SLOW SPEED, and the top position is OFF. 4. R O TAT I N G B E A C O N : Tw o p o s i t i o n switch used to actuate the rotating beacon. Push the bottom of the switch for ON and push the top of the switch for OFF.

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INSTRUMENT/CONTROLS

Door Latch

Sliding Windows

Template Name: OM_1_col Template Date: 1994_04_29

To open the window (downward), push both latches as indicated. To close the window (upward) follow the same procedure. This window has four different positions.

A

A

A19341 Pull back the latch to open the door.

Emergency Exit TRIM THIS EDGE

PUSH INWARD TO OPEN THE WINDOW

171L93

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RP95N002 For emergency exit, pull the seal strip and push the front windshield out.

A19338 Push inward to open the window.

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INSTRUMENT/CONTROLS

3

1

4

B9109622

B9109618

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

3. SEAT CUSHION TILT ADJUSTMENT KNOB: Turn the knob clockwise to raise the front of the seat cushion, turn the knob counterclockwise to lower the front of the cushion.

2. A R M R E S T H E I G H T C O N T R O L ADJUSTMENT: Turn the knob clockwise to raise the armrest, turn the knob counterclockwise to lower the armrest

Template Name: OM_1_col Template Date: 1994_04_29

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

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2

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OPERATORS SEAT

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INSTRUMENT/CONTROLS

5 Template Name: OM_1_col Template Date: 1994_04_29

7

8

6 B9109614

RD97D077

5. SLIDE ADJUSTMENT LEVER: Push this lever down and adjust the seat forward or rearward as required. Release the lever to lock the seat in position.

7. H E I G H T A D J U S T M E N T L E V E R STANDARD SEAT: Lift this lever to raise or lower the seat. Release the lever to lock the seat into position.

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

8. HEIGHT ADJUSTMENT SWITCH AIR SEAT (IF EQUIPPED): The seat can raised or lowered by increasing or decreasing the air pressure in the seat.

Push the switch IN to increase the air pressure. Pull the switch OUT to decrease the air pressure and lower the seat.

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Seat Belt

B4054691

B4054791

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

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

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

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!

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

SA080

!

WARNING: Securely fasten your seat belt. Your machine is equipped with a ROPS cab, ROPS canopy or ROPS frame for your protection. The seat belt can help insure your safety if it is used and maintained. Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members. M437

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

3. Replace all parts that have damage or wear.

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

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

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

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

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INSTRUMENT/CONTROLS

7. Keep seat belts clean and dry.

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

Master Disconnect Switch 1. MASTER DISCONNECT SWITCH: The master disconnect switch has two positions, (1) ON, and (2) OFF. This switch controls the power from the batteries. When the switch is OFF, all power to the machine is off.

1

IMPORTANT: Do not use the master disconnect switch to stop the engine.

RP95N039

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Template Name: OM_1_col Template Date: 1994_04_29

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

OPERATING INSTRUCTIONS

BEFORE STARTING THE ENGINE Template Name: OM_1_col Template Date: 1994_04_29

1. Do a daily walk around, visual inspection of the machine. Check for such items as hoses rubbing against other components, oil leaks, debris or trash buildup, loose bolts, damaged, or missing parts that would effect the normal and safe operation of the machine. Make any necessary corrections before operating the machine.

!

2. S e e t h e M a i n t e n a n c e C h a r t i n t h i s manual and do the items in the 10 Hour section.

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

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

CM112

RUN-IN PROCEDURE TRIM THIS EDGE

It is important that the run-in instructions for a new engine be followed. Proper run-in will increase engine power and service life. If the engine is not run-in properly, the piston rings and cylinder bore can be damaged.

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

3. Monitor the engine instruments frequently during operation. Reduce throttle and/or load if the coolant temperature exceeds safe operating limits.

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

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OPERATING INSTRUCTIONS

AFTER FIRST 100 HOURS OF OPERATION Have your dealer do the After Delivery Check ............................................. See After Delivery Check in this manual AFTER FIRST 100 HOURS OF OPERATION Change the front and rear axle differential and planetary oil when the axles are new or repaired ...................................... See Axle Planetary in this manual

Check all hose clamps, tighten as required.

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

!

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

SA121

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Change the transmission oil and filter when the transmission is new or repaired ................................................See Transmission Specification in this manual

Template Name: OM_1_col Template Date: 1994_04_29

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

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First Service Intervals

OPERATING INSTRUCTIONS

STARTING THE ENGINE Template Name: OM_1_col Template Date: 1994_04_29

!

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

SC037

1. Turn the master disconnect switch to ON.

6. A f t e r t h e e n g i n e s t a r t s , c h e c k t h e 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.

2. Adjust the seat and fasten your seat belt.

Make sure you can push the foot pedals completely down with your back against the seat cushion.

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

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7. With the parking brake applied, move the transmission control lever to fourth gear.

Raise the loader bucket above the ground. Shift the transmission to FORWARD and increase the engine speed to 1/2 throttle. The machine must not move. If the machine moves, see your dealer and correct the problem. When the parking brake is applied, and the transmission control lever is in first or second gear the transmission is automatically shifted to NEUTRAL.

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

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

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

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

NOTE: If the engine starts and then stops, do not engage the starter motor again until the starter motor stops turning.

Do not operate the starter motor more than 30 seconds at one time. Let the starter motor cool for at least two minutes before you actuate the starter motor again.

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OPERATING INSTRUCTIONS

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.

B4032291T

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1. Disconnect the wire from the fuel injection pump solenoid.

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

Template Name: OM_1_col Template Date: 1994_04_29

3. Connect the wire to the fuel injection pump solenoid.

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Priming the Turbocharger Lines with Oil

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OPERATING INSTRUCTIONS

Template Name: OM_1_col Template Date: 1994_04_29

STOPPING THE ENGINE AND PARKING THE MACHINE

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

SA038

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

The machine must be on level ground before you do scheduled maintenance.

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

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

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

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

7. Turn the master disconnect switch to OFF.

2. Lower the loader to the ground.

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

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Secondary Steering (If Equipped) The secondary steering system will automatically engage to allow you to steer the machine if the primary steering system stops working. If the secondary is activated, move the machine to a safe area and then stop the machine immediately and repair the problem.

The secondary steering system will function only when the key switch is in the ON position.

Turn the key switch to the OFF position to stop the secondary steering motor.

NOTE: The secondary steering system is not intended for continuous use.

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OPERATING INSTRUCTIONS

Engine Coolant Heater An electric engine coolant heater is available for your machine. The heater will keep the engine coolant at a warm temperature for improved cold temperature starting. The heater rating is 1500 watts at 115 volts.

Connect the heater to a 120 volt grounded outlet. A heavy duty three wire extension cord is required.

3. Install the heater assembly.

4. Install the connector onto the heater assembly.

5. Refill engine coolant to proper level.

1

B910918J

RP95N037

1. CONNECTOR 2. HEATER ASSEMBLY

The heater is installed in the heater housing on the front left side of the engine. Do the following to install the heater:

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2

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2. Remove the threaded plug from the housing.

Template Name: OM_1_col Template Date: 1994_04_29

1. When engine is cool, remove some coolant from the engine.

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OPERATING INSTRUCTIONS

Booster Battery Connections to Machine Batteries Template Name: OM_1_col Template Date: 1994_04_29

!

!

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

SA006

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

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

M146B

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

7. S t a r t t h e e n g i n e a c c o r d i n g t o t h e instructions in this manual. See Starting the Engine in this manual.

8. Have the other person disconnect the negative (-) jumper cable first and positive (+) jumper cable last.

1. Open the rear door.

2. Sit in the operators seat and have the other person make the connections.

9. Close the rear door.

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

CONNECT POSITIVE JUMPER CABLE HERE

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

5. Connect the positive (+) jumper cable to the positive (+) battery terminal.

6. Connect the negative (-) jumper cable to a good frame ground away from the batteries.

B910919J

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OPERATING INSTRUCTIONS

!

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

CM112

!

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

M142A

!

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

M122B

!

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

SB013

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SA040

Template Name: OM_1_col Template Date: 1994_04_29

!

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.

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MACHINE OPERATION

OPERATING INSTRUCTIONS

Transmission Operation

Changing Machine Direction

Template Name: OM_1_col Template Date: 1994_04_29

The transmission in this machine has four gears forward and three gears reverse.

Always select the correct gear for the job. If you have frequent stalls (engine running at full throttle and the wheels not turning), select a lower gear.

You can change machine direction at any speed. If the transmission is in THIRD or FOURTH gear, the transmission will automatically shift to SECOND gear and then shift up at 2.5 second intervals until the selected gear has been reached. For smooth operation and operator comfort, reduce engine speed before changing direction.

Up-Shifts

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

Autoshift (P.I.N. JEE0052701and After) Push the switch on the left side of the switch to turn the switch ON, an indicator lamp on the switch will illuminate. The transmission will shift up from 2nd to the highest speed settling on the transmission lever. The transmission will down shift automatically under load from the highest gear lever setting to 2nd gear.

Down-Shifts

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The transmission can be shifted from FOURTH to FIRST gear without reducing machine or engine speed. If FIRST gear is to be selected from THIRD or FOURTH gear the transmission will down-shift to SECOND gear for approximately 1.2 seconds, and then shift to FIRST gear. For smooth operation and operator comfort, reduce engine speed before down-shifts.

The transmission can be shifted automatically from SECOND gear to FIRST gear without reducing machine or engine speed using the down-shift button (Prior to P.I.N. JEE0052701). See Loader Operating Tips in this manual.

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OPERATING INSTRUCTIONS

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

Three Spool Valve - Three Control Levers 5

3

NOTE: This page shows the basic loader control lever positions. The loader function switches are all in the OFF position.

7

7

1 7

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

2

B0403A88J

1

DUMP

2

ROLLBACK

3

LOWER

RAISE

4

5

CLAM OPEN (IF EQUIPPED)

6

CLAM CLOSED (IF EQUIPPED)

B1120A88J

7

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

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6 4

Template Name: OM_1_col Template Date: 1994_04_29

NOTE: The Loader Control Level illustration that follows shows the basic loader control lever positions. The loader function switches are all in the OFF position

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LOADER CONTROL LEVERS

OPERATING INSTRUCTIONS

Three Spool Valve - Two Control Levers Template Name: OM_1_col Template Date: 1994_04_29

3

7

4

2

NOTE: This page shows the basic loader control lever positions. The loader function switches are all in the OFF position.

1 5

7 6

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

B0404A88J

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1

DUMP

4

RAISE

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2

ROLLBACK

5

CLAM OPEN

3

LOWER

6

CLAM CLOSED

B1120A88J

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

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

FLOAT

FLOAT AND ROLLBACK DETENT

B1126A88J

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-ToDig position. See Loader Adjustments in this manual for Return-To-Dig Adjustment.

B1125A88J

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ROLLBACK DETENT

Template Name: OM_1_col Template Date: 1994_04_29

LOADER FUNCTION SWITCHES Return-To-Dig

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OPERATING INSTRUCTIONS

OPERATING INSTRUCTIONS

Bucket Height Control Template Name: OM_1_col Template Date: 1994_04_29

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

RAISE

RAISE

B1166A88J

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

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

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

FLOAT

FLOAT AND ROLLBACK DETENT ROLLBACK DETENT

B1126A88J

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-ToTravel position. See for Return-To-Travel Adjustment in this manual.

64

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OPERATING INSTRUCTIONS

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

B1128A88J

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

FLOAT FLOAT

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Float

Template Name: OM_1_col Template Date: 1994_04_29

B1346A88J

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

B4065588T 65

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OPERATING INSTRUCTIONS

AUXILIARY HYDRAULIC CONNECTION Template Name: OM_1_col Template Date: 1994_04_29

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.

A27748

FAR1048

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Auxiliary Hydraulic System Specifications 921B Wheel Loader Maximum System Pressure ...................................................................... 2 850 PSI (197 bar) Maximum Capacity at 2 850 Engine RPM .............................................. 106 GPM (401 L/Min)

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IMPORTANT: Restricting the Auxiliary Hydraulic System flow will result in overheating and damaging the Hydraulic System.

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OPERATING INSTRUCTIONS

Hydraulic Control Lever on the Coupler Connecting Attachments to the Coupler 1. Put the bucket or other attachment on a level surface.

4. Start the engine.

2. Apply the parking brake. Stop the engine.

TAB

FAR1050 FAR1049

5. Push the auxiliary hydraulics control lever forward to retract the locking pins and indicator tabs.

Template Name: OM_1_col Template Date: 1994_04_29

3. Open the coupler hydraulic cylinder locking valve by rotating the red control handle down to a vertical position.

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PIN

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QUICK ATTACH COUPLER (If Equipped)

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OPERATING INSTRUCTIONS

Template Name: OM_1_col Template Date: 1994_04_29

FAR1054

FAR1055

6. Close the coupler hydraulic cylinder locking valve by rotating the red control handle up to a horizontal position.

7. Connect the attachment to the auxiliary hydraulic couplers, if required.

Disconnecting Attachments from the Coupler TRIM THIS EDGE

1. Lower the bucket or other attachment onto a level surface. Tilt the bucket or attachment so that it is flat on the surface.

CONTROL LEVER

2. Apply the parking brake. Stop the engine.

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3. Disconnect the attachment hydraulic hoses from the auxiliary couplers, if connected.

FAR1046 6. Push the auxiliary hydraulics control lever forward to retract the locking pins and indicator tabs.

FAR1056 4. Open the coupler hydraulic cylinder locking valve by rotating the red control handle down to a vertical position.

FAR1051 7. Lower the lift arms and back away from the bucket or other attachment.

5. Start the engine.

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OPERATING INSTRUCTIONS

The control switch is on the upper right-hand instrument panel. Push the bottom of the switch for ON and push the top of the switch for OFF.

FAR1058 To adjust the light assembly for transport: TRIM THIS EDGE

1. Rotate the light assembly and mounting bar DOWNWARD until the spring loaded detents hold the light assembly and mounting bar in the INTERMEDIATE position.

2. Rotate the light assembly UPWARD until the spring loaded detents hold the light assembly in the TRANSPORT position.

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INTERMITTENT LIGHT

FAR1059

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Template Name: OM_1_col Template Date: 1994_04_29

FAR1060

OPERATING INSTRUCTIONS To adjust the light assembly for operation:

Template Name: OM_1_col Template Date: 1994_04_29

1. Rotate the light assembly DOWNWARD until the spring loaded detents hold the light assembly in the INTERMEDIATE position.

2. Rotate the light assembly and mounting bar UPWARD until the spring loaded detents hold the light assembly and m o u n t i n g b a r i n t h e O P E R AT I N G position.

FAR1060

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FAR1061

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Intermittent Light Transport and Operating Position OPERATING POSITION

TRANSPORT POSITION

FAR1059

FAR1061

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LOADER OPERATING TIPS Leveling Operation Always operate the machine in reverse when leveling the surface

163L96

Pushing Operation

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

164L96

Scraping Operation

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

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JOB SITE OPERATIONS

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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Template Name: OM_1_col Template Date: 1994_04_29

When Scraping hard or frozen surfaces the bucket must be level and flat to the surface.

Operate the machine at a slow speed.

JOB SITE OPERATIONS

Transport and Carry Operation Template Name: OM_1_col Template Date: 1994_04_29

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

165L96

Flat Ground

NOTE: Push down the left side of the Declutch switch and the left brake pedal to get maximum power for the loader. See Function Switches in this manual.

Adjust the position of the bucket so that the front edge is lower than the back. Bucket teeth will help you dig in this type of operation.

Loading Trucks

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Be very careful when you load trucks. Raise the load and move the machine toward the side of the truck. As you move the load toward the truck, use the loader height control to automatically position the bucket at the correct height. After you dump the load, use the Return-To-Dig to position the bucket for the next cycle.

Move the machine into the digging area with the transmission in FIRST gear and the engine speed at full throttle. Lower the bucket to the ground. When the bucket is at the correct depth, level the bucket and continue to move forward.

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When the bucket is full, roll the bucket back.

There is lost time when you push material in front of the bucket.

Load Handling Whenever load handling operations are to be carried out, it is IMPORTANT to strictly obey local regulations and instructions given in this manual.

Stock Piles Make sure the bottom of the bucket is level.

Move the machine forward into the material.

When the speed of the machine starts to decrease, push in the down-shift button on the Transmission Control Lever or on the Loader Control Level, push the left brake pedal, raise the loader, and roll back the bucket.

!

It is strictly forbidden to weld hooks or lugs on the bucket of this machine.

Do not allow anybody to stand in the machine working area.

Operate the controls smoothly to obtain precision movement and travel.

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 72

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JOB SITE OPERATIONS

Your machine is equipped with a hitch located on the rear of the machine.

NEVER TOW MACHINE FROM THE FRONT.

The hitch is to be used for retrieving or towing your machine if it becomes disabled.

The maximum horizontal force applied to the retrieval hitch must never exceed 20 000 kg (44 092 lb). The maximum vertical force applied to the hitch must never exceed 5 000 kg (11 023 lb).

The hitch may be used to temporarily pull loads. The maximum horizontal force applied must not exceed 13 000 kg. The maximum vertical force must not exceed 4 500 kg.

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

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

4. Attach a second machine to the REAR of disabled machine as close as possible.

This second machine is used to help stop the disabled machine.

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.

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

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A27726

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MACHINE HITCH INFORMATION

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

Template Name: OM_1_col Template Date: 1994_04_29

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

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

B. Loosen the jam nut at the clevis on the rod for the parking brake actuator.

C. Find the hex on the rod. Use the hex to turn the rod counterclockwise until the parking brake is released.

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JOB SITE OPERATIONS

TRANSPORTING THE MACHINE Template Name: OM_1_col Template Date: 1994_04_29

!

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

SB042

!

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

46-76C

!

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

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

84-13A

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You must know the rules or laws for transportation and safety that are used in each area that you will be in. Make sure that the truck and machine are equipped with the correct safety equipment.

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

7. Turn the battery disconnect switch to OFF.

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

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

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

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

3. Lower the loader bucket onto the trailer.

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

10. Put a cover over the exhaust pipe.

11. R o t a t e t h e i n t e r m i t t e n t l i g h t t o t h e TRANSPORT position. See Intermittent Light in this manual.

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

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

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Front Tie Down

139728A1

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FAR1069

Middle Tie Down

A27766

Rear Tie Down

A27765

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Template Name: OM_1_col Template Date: 1994_04_29

Transporting the Machine on a Trailer Machine Tie Down Locations

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JOB SITE OPERATIONS

JOB SITE OPERATIONS

OPERATING IN COLD WEATHER Template Name: OM_1_col Template Date: 1994_04_29

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

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

3. EQUIPMENT HYDRAULIC SYSTEM Wheel Loaders are shipped with Case TCH Hydraulic/Brake Fluid. Case TCH is formulated to provide top performance under most ambient temperature conditions. Case Low Temperature HyTr a n P l u s ® p r o v i d e s c o m p a r a b l e performance to TCH, but also provides superior viscosity characteristics at low temperatures. Choose the correct hydraulic/brake fluid for the ambient temperatures you will be working in (See Hydraulic/Brake System in this manual).

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

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Inspect the battery cables and terminals.

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

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If you add water to the batteries and the temperature is below 32˚F (0˚C), make sure you charge the batteries or run the engine for approximately two (2) hours.

This procedure will prevent battery freezing (See Batteries and Booster Battery connections in this manual).

4. FUEL SYSTEM - Check with your fuel supplier for the correct cold weather fuel.

Engine power will be reduced if wax particles are in the fuel filters.

Check for water in the fuel system. Cold temperatures can cause condensation to form in the fuel tank. Check the first stage fuel filter and fuel sediment bowl (if equipped) for water. If no water is found, extend the interval (see Diesel Fuel System in this manual).

Inspect the battery cables and terminals.

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

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

5. COOLING SYSTEM - Check the coolant mixture before you operate in cold temperatures. A mixture of 50% ethylene glycol and 50% water must be used in this machine. This mixture is used if the lowest ambient temperature is above 34˚F (-37˚C). If the ambient temperature i s l o w e r, a d j u s t t h e m i x t u r e . I t i s recommended that ethylene glycol and water be used in your machine all year (See Engine Cooling System in this manual).

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6. COLD TEMPERATURE STARTING AIDS See your dealer for extra starting aids ( S e e C o l d We a t h e r S t a r t i n g i n t h i s manual).

When the machine has been correctly warmed up, operate the machine in a clear safe area. Check the full operation of the machine. DO NOT operate the machine in third or forth gear until the transmission oil and axle oil have been warmed up and the machine moves freely.

7. MACHINE WARM-UP - Once the engine has started, run the engine at half throttle (1100 to 1300 RPM) for a minimum of 10 minutes under no load. This will help warm the hydraulic oil and the transmission oil.

After engine warm-up, cycle all hydraulic functions several times. In severe cold weather conditions, the hydraulic functions may be slow to respond.

Cycling all the hydraulic system functions several times will warm the hydraulic oil and the hydraulic stem components.

8. If the machine has been left idling in the 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 machine warm-up procedure.

The hydraulic steering can become slow in severe cold weather conditions. Cycle the steering from full right to left a minimum of 3 to 5 times before you drive the machine.

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

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JOB SITE OPERATIONS

Template Name: OM_1_col Template Date: 1994_04_29

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

In severe cold weather conditions the brakes response can be slow. The use of correct oil in the hydraulic/brake stem is required. Even with the correct oil in the hydraulic/brake system the first few times the brakes are actuated there may be some delay before the brakes are applied. The operator must actuate the brake pedal a minimum of 8 to 10 times before the machine is moved.

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JOB SITE OPERATIONS

OPERATING IN HOT WEATHER Template Name: OM_1_col Template Date: 1994_04_29

To prevent damage to the machine, do the following:

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

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

5. Check the condition of the drive belts.

6. Use lubricants of the correct viscosity.

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. See your dealer.

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JOB SITE OPERATIONS

ALWAYS put the transport/service link in the LOCKED position before lifting the machine.

ALWAYS use lifting equipment of an appropriate type and capacity to lift the machine. Refer to the Product Identification Number (P.I.N.) plate for the weight of a basic machine.

139729A1

Front Lifting Point

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The weight of your machine can vary depending on the options and attachments that you have selected for your machine. You must weigh your machine to determine the exact weight.

Rear Lifting Point

A27759

A27765

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Template Name: OM_1_col Template Date: 1994_04_29

The machine is equipped with four lifting points, identified by the decal symbol shown.

These lifting points are located at the FRONT and REAR of the machine.

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LIFTING THE MACHINE

WHEELS/TIRES/BALLAST

BALLAST Template Name: OM_1_col Template Date: 1994_04_29

It is the recommendation of the Case Corporation NOT to add Ballast to the tires of your machine.

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

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WHEELS/TIRES/BALLAST

!

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

84-113

!

WARNING: DO NOT weld to wheel or rim when a tire is installed. Welding will cause an explosive air/gas mixture that will be ignited with high temperatures. This can happen to tires inflated or deflated. Removing air or breaking bead is not adequate. Tire MUST be completely removed from SB134 the rim prior to welding.

Tire Pressure

Template Name: OM_1_col Template Date: 1994_04_29

DO NOT inflate the tires more than the recommended pressure. For recommended tire size air pressure, See Tire Pressure Chart in this manual.

Alt= to hide template information Alt+ to display template information

!

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

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

SD020

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WHEELS AND TIRES

81

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WHEELS/TIRES/BALLAST

Template Name: OM_1_col Template Date: 1994_04_29 KEEP OUT OF THESE DANGER AREAS

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B10410J

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

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WHEELS/TIRES/BALLAST

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

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

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

Tire or Rim Service

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

B790490R

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Always have a qualified tire mechanic service the tires and rims for this machine. It is recommended that you have this mechanic inflate the tires. To prevent accidents, use a restraining device (tire inflation cage), correct equipment, and correct procedure. Explosive separation of the tire (single piece rim) or the tire and/or rim parts (multi-piece rim) can cause serious injury or death.

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Adding Air to the Tires

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

FORWARD

B770164R

B4039288T

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Template Name: OM_1_col Template Date: 1994_04_29

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

WHEELS/TIRES/BALLAST

Wheel Nut Torque Template Name: OM_1_col Template Date: 1994_04_29

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

If a wheel is removed from the machine and installed, tighten the nuts using the sequence shown. First tighten the nuts to 150 poundfeet (203 Nm), then to a final torque of 450 to 500 pound-feet (612 to 680 Nm) in the same sequence.

B910920J

Tire Pressure Chart TIRE SIZE

TIRE PRESSURE

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PSI

(kPa)

(bar)

Front Tires

26.5 R 25

XHA TL★

60

414

4.1

Rear

26.5 R 25

XHA TL★

30

207

2.0

Front Tires

26.5 R25 XRDD1A TL★

60

414

4.1

Rear Tires

26.5 R25 XRDD1A TL★

30

207

2.0

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LUBRICATION/MAINTENANCE

!

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

SC021

!

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

SA044 Use the correct safety clothing and safety equipment. Understand how to use a fire extinguisher and first aid kit.

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

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GENERAL SAFETY BEFORE YOU SERVICE

B770996R

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

B901248J

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Template Name: OM_1_col Template Date: 1994_04_29

B801147T

LUBRICATION/MAINTENANCE

PLASTIC AND RESIN PARTS Template Name: OM_1_col Template Date: 1994_04_29

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

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

ENVIRONMENT Before you service this machine and before you dispose of the old fluids or 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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TRANSPORT/SERVICE LINK

!

WARNING: Keep clear of this area when engine is running. Machine could pivot unless the transport and service link is in its LOCKED position. After servicing is completed, unlock the transport and service link and secure in place on the rear frame pivot.

SA069

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A27758

A27757

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

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

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LUBRICATION/MAINTENANCE

RD97D051

Template Name: OM_1_col Template Date: 1994_04_29

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

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

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ENGINE HOURMETER

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LUBRICATION/MAINTENANCE

LUBRICATION/MAINTENANCE CHART Template Name: OM_1_col Template Date: 1994_04_29

N O .

O F

P A G E N O .

P O I N T S

SERVICE POINTS

FREQUENCY IN HOURS

C H E C K

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102 Air Cleaner (See Note 1)

*

113 Hydraulic Filter (See Note 2)

*

146 Fan Belt Condition

*

146 Alternator Drive Belt

*

146 Air Conditioning Compressor Belt (If Equipped)

*

99 Engine Oil Level (See Note 3)

10

107 Radiator Coolant Level (See Note 3)

10

122 Transmission Oil Level

50

C L E A N

L U B R I C A T E

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112 Fuel Filter

D R A I N W A T E R

50

114 Hydraulic Reservoir Fluid Level

50

93 Rear Axle Trunnion Pivots

2

50

93 Bucket Pivots

3

50

93 Center Drive Shaft Slip Joint

1

50

93 Front Drive Shaft Support Bearing

1

50

93 Rear Drive Shaft Slip Joint

1

50

94 Steering Cylinder Pivots - Closed End

2

100

94 Steering Cylinder Pivots - Rod End

2

100

94 Loader Lift Arm and Cylinder Pivots

10

100

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

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

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

88

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LUBRICATION/MAINTENANCE CHART N‘ O .

O F

P A G E

SERVICE POINTS

146 Fan Belt Tension

C H E C K

C H A N G E

R E P L A C E

L U B R I C A T E

D R A I N C L E A N

W A T E R

250

100 Engine Oil (See Note 3 page 90)

250 250

146 Alternator Drive Belt Tension

250

147 Air Conditioning Compressor Belt Tension (If Equipped)

250

154 Battery Fluid Level

250

81 Tire Condition and Air Pressure

250

94 Foot Throttle Pivot

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100 Engine Oil Filter

1

250

127 Cab Air Filter (If Equipped)

250

107 Engine Cooling System Filter (See Note 1)

250

112 Fuel Filter

250

111 Fuel Tank

500

145 ROPS and Seat Belt Mounting Bolts

500

110 Hydraulic Filters

1000

122 Transmission Filter

1000

122 Transmission Oil (See Note 3 page 90)

1000

122 Transmission Breather

1000

95 Upper and Lower Chassis Pivots

2

1000

126 Front Axle Differential and Planetary Oil

1000

126 Rear Axle Differential Oil and Planetary Oil

1000

NOTE 1: Use Case Filter A77544

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Template Name: OM_1_col Template Date: 1994_04_29

N O .

P O I N T S

FREQUENCY IN HOURS

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LUBRICATION/MAINTENANCE

LUBRICATION/MAINTENANCE

LUBRICATION/MAINTENANCE CHART Template Name: OM_1_col Template Date: 1994_04_29

N‘ O .

O F P A G E

P O I N T S

N O. SERVICE POINTS

FREQUENCY IN HOURS

C H E C K

C H A N G E

R E P L A C E

A D J U S T

SM Engine Valves

1500

SM Injectors

1500

SM Turbocharger Mounting Bolt Torque

C L E A N

2000

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117 Hydraulic Oil (See Note 3)

2000

108 Engine Coolant (See Note 1)

2000

104 Air Filter Elements

2000

SM Engine Injectors (See Note 2)

6000 6000

SM Fuel Pump (See Note 2)

6000 6000

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

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NOTE 2: Contact your dealer.

NOTE 3: As required by ambient temperature.

SM - See Service Manual.

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Template Name: OM_1_col Template Date: 1994_04_29

RP95N007 RP95N057

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LUBRICATION/MAINTENANCE

ACCESS DOORS

RP95N006

LUBRICATION/MAINTENANCE

SYSTEMGARD LUBRICATION ANALYSIS PROGRAM Template Name: OM_1_col Template Date: 1994_04_29

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

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B830752T

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1 1

1 B910922J

1. Bucket pivot points ........................................................................................................... 3 2. Rear axle trunnion ............................................................................................................ 2

6

5

4

B910921J

4. Center drive shaft slip joint ............................................................................................... 1 5. Front drive shaft support bearing ...................................................................................... 1 6. Rear drive shaft slip joint .................................................................................................. 1

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Template Name: OM_1_col Template Date: 1994_04_29

Use Case Molydisulfide Grease

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GREASE FITTINGS - 50 HOURS

LUBRICATION/MAINTENANCE

GREASE FITTINGS - 100 HOURS Template Name: OM_1_col Template Date: 1994_04_29

Use Case Molydisulfide Grease

3

1

1

3 2

2

2

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3

3

3

B910922J

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

GREASE FITTINGS - 100 HOURS Use Case Molydisulfide Grease

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4

B910921J

4. Foot throttle pedal ............................................................................................................ 1 NOTE: Remove right side cover for access.

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Use Case Molydisulfide Grease

1

B910921J

Template Name: OM_1_col Template Date: 1994_04_29

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

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GREASE FITTINGS - 1000 HOURS

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FLUID LEVELS Template Name: OM_1_col Template Date: 1994_04_29

10 HRS

1

10 HRS

2

RP95N048

RP95N008

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

RADIATOR COOLANT LEVEL ETHYLENE GLYCOL AND WATER

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1

B910922J

50 HRS

3

50 HRS

4

A27740

A27741

HYDRAULIC RESERVOIR CASE TCH FLUID

TRANSMISSION CASE NO. 1 ENGINE OIL (SAE 10W-30)

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RP95N026

RP95N018

BATTERIES DRINKING OR DISTILLED WATER

RADIATOR ETHYLENE GLYCOL AND WATER

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2 1

B910921J

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10 HRS

2

Template Name: OM_1_col Template Date: 1994_04_29

10 HRS

1

LUBRICATION/MAINTENANCE

Template Name: OM_1_col Template Date: 1994_04_29

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

If Case NO. 1 Multi-Viscosity engine oil is not available, use only oil meeting API engine oil service category CG-4 orCF-4.

A27273

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RB97E055

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

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

Oil Viscosity / Temperature Ranges

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RB97E054

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

NOTE: The use of low viscosity oils, such as 10W-30 can be used to aid in starting the engine and in providing sufficient oil flow at ambient temperatures below - 5˚C (23˚F).

The continuous use of low viscosity oils can decrease engine life due to wear. See the chart above for the correct oil for ambient temperatures.

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

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

Oil type ........................................................................ Case No. 1 Engine Oil (SAE 15W-40) Oil Capacity - with filter change ........................................................ 36 U.S. quarts (34 litres)

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To check the engine oil level put the machine on a level surface and stop the engine.

Remove engine oil dipstick and wipe clean with a cloth. Replace dipstick in tube and push the engine oil dipstick completely DOWN and then remove. If the oil level is below the ADD mark, add oil to raise the oil level to the FULL mark. It takes 4 quarts (3.78 litres) to raise the oil level from the ADD mark to the FULL mark.

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Engine Service Specifications

Template Name: OM_1_col Template Date: 1994_04_29

RP95N048

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Template Name: OM_1_col Template Date: 1994_04_29

Engine Oil Change and Filter Replacement

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

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

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

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

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

Continue to tighten the filter for 3/4 turn with your hand.

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

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

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

1. Before draining the oil, have a container that will hold at least 9 gallons (34 litres.)

8. Install the drain plug.

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

2. Remove the engine oil drain plug.

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3. Open the rear engine access doors.

RP95N048

RP95038 4. Turn the oil filter counterclockwise to remove. Discard the oil filter.

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12. Close the engine access doors.

B4032291T 10. Fill the turbocharger oil lines with oil. a. Disconnect the wire (Shown) from the injection pump solenoid. This will prevent the engine from starting.

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

b. Turn the key switch to the START and actuate the starter for 10 to 30 seconds. c. Connect the wire to the injection pump solenoid.

!

!

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

CM107

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

CM115

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Systemgard Lubrication Analysis Program

Template Name: OM_1_col Template Date: 1994_04_29

11. Start the engine and run at idle speed.

Check the engine oil filter for leaks. After two minutes, stop the engine, wait for 2 or 3 minutes, and check the engine oil level with the dipstick.

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LUBRICATION/MAINTENANCE

LUBRICATION/MAINTENANCE

Template Name: OM_1_col Template Date: 1994_04_29

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

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

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

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Cap for the Air Cleaner This cap removes coarse particles from the air entering the air intake pipe.

RP95N016 Wear face protection and clean the dust and dirt from the gap with compressed air. To clean oil and grease from the cap, wash the cap in hot water with a small amount of detergent.

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

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

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

5. Install the end cover and push the spring clamps into the locked position.

6. Close the access door.

RP95N029 2. Carefully remove the primary (outer) element.

RP95N030 3. Use a clean damp cloth and clean the inside of the filter body.

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

Template Name: OM_1_col Template Date: 1994_04_29

Primary (Outer) Element

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LUBRICATION/MAINTENANCE

LUBRICATION/MAINTENANCE

Template Name: OM_1_col Template Date: 1994_04_29

Secondary (Inner) Element

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

1. Remove the primary (outer) element.

2. Remove the secondary (inner) element.

Discard the secondary (inner) element.

RP95N032

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4. Install a new secondary (inner) element.

Make sure the element has full gasket contact before you tighten the wing nut.

RP95N031

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

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

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6. Close the access door.

!

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

CM115

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LUBRICATION/MAINTENANCE

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

1. Wear face protection and remove the loose dirt with compressed air at 30 psi (207 kPa, 2.1 bar) maximum. Hold the nozzle at least 1 inch (25 mm) from the element.

6. Use a light and inspect the element for holes or splits in the pleats. Check for damage to the metal parts and rubber gasket. Replace the element if damaged.

777L94

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

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

779L94

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

780L94

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778L94

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

Template Name: OM_1_col Template Date: 1994_04_29

Check the dirty element for damage and check the rubber seal on the end. Push the rubber seal with your finger. If the rubber seal feels hard and does not move back to original shape, discard the element.

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Cleaning the Element

LUBRICATION/MAINTENANCE

Template Name: OM_1_col Template Date: 1994_04_29

ENGINE COOLING SYSTEM Service Specifications Cooling system capacity ................................................................ 50 U.S. quarts (47.3 litres) Radiator coolant level check interval ................................. 10 hours of operation or each day, whichever occurs first Cooling system drain, flush, and refill interval .......................... Every 2000 hours of operation or each year, whichever occurs first.

Cooling system filter replacement interval ................................. Every 250 hours of operation with Case filter A77544, every time you drain, flush, and refill the cooling system with Case filter A77659.

Thermostat TRIM THIS EDGE

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

Coolant Mixture

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

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

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

!

Scalding can result from fast removal of radiator cap.

Check and service engine cooling system according to maintenance SA023 instructions.

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

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

SHUTOFF VALVE SHOWN IN THE ON POSITION

RP95N043 2. Turn the coolant filter counterclockwise to remove the old filter. Discard the filter.

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

RP95N008

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Check the coolant fluid level at the sight gauge. The extreme left side of the sight gauge indicates EMPTY, the extreme right side of the sight gauge indicates FULL. Add coolant as required to raise the coolant level to the FULL mark.

Coolant Filter after every draining and flushing of the Engine Cooling System.

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Radiator Fluid Level

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

IMPORTANT: DO NOT use a filter strap wrench to install the coolant filter. When the coolant filter is too tight you can cause damage to the gasket and coolant filter.

RP95N018

Replacing the Coolant Filter

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

Replace the Coolant Filter every 250 hours of operation. Drain and flush the Engine Cooling System every 2000 hours. Replace the 107

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Template Name: OM_1_col Template Date: 1994_04_29

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

LUBRICATION/MAINTENANCE

Template Name: OM_1_col Template Date: 1994_04_29

Cleaning the Cooling System Drain, flush, and replace the engine coolant every 2000 hours of operation or each year, whichever occurs first. Clean the system and replace the coolant if the coolant becomes dirty or has the color of rust.

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

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

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

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

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

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

6. Put a 50% mixture of Ethylene Glycol and water in the radiator. See Coolant Mixture in this manual.

7. Start the engine and run at idle speed for a few minutes. Check the radiator sight gauge. Add coolant as required.

8. Install the radiator cap, if removed.

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Fuel Tank Capacity ..................................................................... 104 U.S. gallons (394 litres) Interval for draining water from the fuel filter ......................................... 50 hours of operation Fuel filter replacement interval ............................................................ 250 hours of operation or once each year, whichever occurs first Adjust fuel injector ........................................................................ 1500 hours of operation or or once each year, whichever occurs first Clean and calibrate fuel injectors and fuel pump ........................... 6000 hours of operation or every 3 years, whichever occurs first.

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

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

The conditioner will:

3. Separate moisture from the fuel.

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

4. Stabilize the fuel in storage.

!

WARNING: Engine fuel is flammable and can cause a fire or an explosion.

Do not fill the fuel tank or service the fuel system near an open flame,welding, burning cigars, cigarettes, etc.

SA022

!

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

Never smoke while refueling.

M139C

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Fuel Conditioner

Template Name: OM_1_col Template Date: 1994_04_29

DIESEL FUEL SYSTEM Service Specifications

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LUBRICATION/MAINTENANCE

LUBRICATION/MAINTENANCE

Template Name: OM_1_col Template Date: 1994_04_29

Diesel Fuel

Fuel Storage

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

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

In very cold temperatures, a mixture of No. 1 and No. 2 diesel fuels is temporarily permitted. See the following Note.

Keep the fuel storage tank outside and keep the fuel as cool as possible. Remove water from the storage container at regular periods of time.

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

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

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

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

Specifications for Acceptable No. 2 Diesel Fuel

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API gravity, minimum .............................................................................................................................................. 34 Flash point, minimum ............................................................................................................................. 140˚F (60˚C) Cloud point (wax appearance point), maximum, ............................................................ -5˚F (-20˚C) See Note above Pour point, maximum .................................................................................................... -15˚F (-26˚C) See Note above Distillation temperature, 90% point .................................................................................. 540 to 640˚F (282 to 338˚C) Viscosity, at 100˚F (88˚C) Centistokes .............................................................................................................................................. 2.0 to 4.3 Saybolt Seconds Universal ......................................................................................................................... 32 to 40 Cetane number, minimum .............................................................................. 43 (45 to 55 for winter or high altitudes) Water and sediment, by volume, maximum ................................................................................................ 0.05 of 1% Sulfur, by weight, maximum ...................................................................................................................... 0.5% of 1% Copper strips corrosion, maximum .................................................................................................................... No. 2 Ash, by weight, maximum .......................................................................................................................... 0.01 of 1%

!

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 SA022 flame,welding, burning cigars, cigarettes, etc.

!

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

Never smoke while refueling.

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LUBRICATION/MAINTENANCE

2. Close the drain valve.

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

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

Dispose of water and sediment properly.

B4029591T

Template Name: OM_1_col Template Date: 1994_04_29

RP95N047

NOTE: There is a hex head plug with Oring seal on the right side of the fuel tank.

Loosen this plug to remove water from the fuel tank.

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

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Removing Water and Sediment from the Fuel System

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Fuel Filter Template Name: OM_1_col Template Date: 1994_04_29

Replace the fuel filter after every 250 hours of operation.

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

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

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

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

IMPORTANT: DO NOT use a filter wrench when installing a new filter.

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RP95N047

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Hydraulic reservoir refill capacity .................................................. 128 U.S. quarts (121 litres) Total system capacity ................................................................... 241 U.S. quarts (228 litres) Type of fluid .................................................................................................. Case TCH Fluid Hydraulic reservoir fluid level check interval .............................................................. 50 hours Filter replacement interval ................................................................... Replace both hydraulic filters every 1 000 hours of operation or if the hydraulic filter warning lamp illuminates.

Hydraulic fluid change interval ......................................................... 2 000 hours of operation or once each year, whichever occurs first.

Hydraulic System Fluid Chart Use the following chart as a guide for hydraulic fluid for your machine at various ambient air temperatures.

Case TCH fluid is formulated to provide optimum performance under most ambient conditions.

Case Low Temperature Hy -Tran Plus® fluid provides comparable performance to TCH but also provides superior viscosity characteristics at extremely low temperatures.

If Low Temperature Hy-Tran Plus® is installed, it is not normally necessary to reinstall TCH fluid during warmer ambient temperatures because Low Temperature HyTran Plus® maintains good viscosity characteristics at all normal temperatures.

Low Temperature Hy-Tran Plus® should not be used in abnormally extreme conditions, such as desert operations.

If ambient temperatures are -40˚C (-40˚F) and below, contact your dealer for fluid recommendations.

126L95

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Suction screen cleaning interval ........................................... 2 000 hours of operation or once each year, whichever occurs first.

Template Name: OM_1_col Template Date: 1994_04_29

HYDRAULIC SYSTEM Service Specifications

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LUBRICATION/MAINTENANCE

LUBRICATION/MAINTENANCE

Hydraulic Oil Level Template Name: OM_1_col Template Date: 1994_04_29

!

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

SA047 Check the oil level of the hydraulic reservoir every 50 hours of operation.

To check the oil level in the hydraulic reservoir do the following: 1. Park the machine on a level surface and lower the loader bucket to the ground.

2. Stop the engine.

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A27740

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LUBRICATION/MAINTENANCE b. After 15 seconds, move the control lever to the HOLD position. c. Repeat steps a and b until the side of the hydraulic reservoir feels very warm.

2. Increase the engine speed to full throttle.

If the LED for the hydraulic oil filters illuminates, replace both filters.

To add oil to the hydraulic reservoir do the following: 1. Clean the area around the filler cap.

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2. S l o w l y l o o s e n t h e fi l l e r c a p o n t h e hydraulic reservoir. This will release the air pressure in the hydraulic reservoir.

Remove the filler cap from the hydraulic reservoir.

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

4. Install the filler cap and hand tighten.

Hydraulic Filters Replace the two hydraulic filters every 1000 hours of operation or if the hydraulic oil LED illuminates.

Hydraulic Filter Replacement

Hydraulic Filter Test

IMPORTANT: Always replace hydraulic filters at the same time.

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3. Check the oil level in the sight gauge. If the oil is cold, the level is correct when you see oil in the lower 1/4 of the sight gauge. If the oil is at operating temperature, 120˚F (50˚C), the oil level must be in the upper 1/4 of the sight gauge. DO NOT over fill. See Hydraulic System in this manual for the correct oil.

RB97D051J

1. Start the engine. If the hydraulic oil is not at operating temperature or approximately 120˚F (50˚C) do the following. a. Hold the loader control lever in the ROLLBACK position until the loader bucket is against the stops, continue to hold the control lever in the ROLLBACK position for 15 seconds.

1. Park the machine on a level surface.

Lower the loader bucket to the ground and stop the engine.

2. S l o w l y l o o s e n t h e f i l l e r c a p o n t h e hydraulic reservoir. This will release the air pressure in the hydraulic reservoir.

3. Remove the access cover.

4. Use a strap wrench to remove the old filters. Turn the filters counterclockwise to remove.

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Template Name: OM_1_col Template Date: 1994_04_29

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

both

LUBRICATION/MAINTENANCE

Template Name: OM_1_col Template Date: 1994_04_29

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

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

6. Tighten the filler cap.

!

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!

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

8. Stop the engine and check the hydraulic oil level. Add oil as required. See Hydraulic System in this manual for correct specifications.

9. Install the access cover.

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

CM107

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

CM115

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1

2 TRIM THIS EDGE

3

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Hydraulic/Brake Oil Change

5

6

270L96 1. FILLER CAP 2. SUCTION SCREEN 3. RESERVOIR FILTER

4. DRAIN VALVE 5. ACCESS COVER 6. SEAL

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Template Name: OM_1_col Template Date: 1994_04_29

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LUBRICATION/MAINTENANCE

Template Name: OM_1_col Template Date: 1994_04_29

Change the hydraulic/brake oil every 2000 hours of operation or one time each year, or when ambient operating temperatures requires, whichever occurs first. When changing the hydraulic oil also replace both hydraulic oil filters and clean the suction screen.

7. Open the drain valve.

8. Replace the hydraulic oil filters (see Page 116).

9. Remove the access cover from the hydraulic reservoir and remove the suction screen. Turn the suction screen counterclockwise to remove.

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

2. Lower the loader bucket to the ground and apply the brake. Stop the engine. Put a DO NOT OPERATE tag on the steering wheel.

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3. M a k e s u r e t h e a c c u m u l a t o r s a r e completely discharged. Push down and release one of the brake pedals a minimum of 30 times.

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

10. Clean the inside of the hydraulic reservoir with clean cloths.

11. Clean the suction screen in solvent and dry the suction screen with compressed air. Install the suction screen.

12. Turn the reservoir drain valve to OFF. Remove the drain hose and install the plug in the drain valve (see Page 113 for the correct type and quantity of hydraulic oil). Put new oil into the reservoir

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NOTE: Fill the reservoir with the correct oil for your ambient temperature operating range.

13. Install the access cover with a new seal and tighten the mounting bolt.

14. Install the reservoir filler cap.

Start the engine and run at 1000 rpm. Check for oil leaks around the filters, access cover and the drain plug. When the balance pressure warning buzzer stops making noise, run the engine at 1500 rpm.

B9104220R 5. Remove the plug from the drain valve and install a hose on the drain valve.

6. Put the other end of the drain hose into a container that will hold 25 gallons (94.6 litres).

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15. Start the engine and run at 1000 rpm.

Check for oil leaks around the filters, access cover and the drain plug. When the balance pressure warning buzzer stops making noise, run the engine at 1500 rpm.

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

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

19. Add oil as required.

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

Template Name: OM_1_col Template Date: 1994_04_29

CM107

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!

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

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LUBRICATION/MAINTENANCE

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LUBRICATION/MAINTENANCE

Bleeding the Brake System Template Name: OM_1_col Template Date: 1994_04_29

BLEED SCREW

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980L92

1. Start and run the engine at idle. Open the bleed screw on the accumulator charge valve.

When there are no air bubbles in the oil that is flowing, close the bleed screw.

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NOTE: If any lines have been opened between the reservoir and the accumulator charge valve, immediately open the bleed screw after starting the engine.

2. Stop the engine. Open the left bleed screw on the front axle.

3. Slowly push down on the brake pedal until oil begins to flow from the bleed screw. Hold the brake pedal in position until 1 liter of oil has been bled and no air bubbles in the oil flowing from the bleed screw. Close the bleed screw and release the brake pedal.

IMPORTANT: DO NOT push the brake pedal farther than necessary to cause the oil to flow from the bleed screw. The farther you push the pedal the higher the pressure in the brake circuit. High pressure can cause injury or damage.

4. Open the right bleed screw on the front axle.

5. Start and run the engine at idle for 2 minutes.

6. Stop the engine. Open the left bleed screw on the rear axle. Repeat step 3.

7. Open the right bleed screw on the rear axle. Repeat step 3.

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LUBRICATION/MAINTENANCE

Transmission refill capacity with filter ............................................ 30 U.S. quarts (28.4 litres) Total system capacity ....................................................................... 46 U.S. quarts (44 litres) Type of oil .............................................................. Case Number 1 Engine Oil (SAE 10W-30) Alternate oil .............................................. Engine oil (SAE 20W,30W) API CC/CD (See Note) Alternate Oil(AutomaticTransmission Fluid) .................................. Dextron-HD/ -III, Mercon - M (See Chart Below) Oil lever check interval .............................................................................................. 50 hours Filter replacement interval ..................................................................................... 1000 hours Breather cleaning interval ..................................................................................... 1000 hours

NOTE: If the temperature is -4˚F (-20˚C) or below, use ATF fluid.

IMPORTANT: If the machine is new or the transmission has been replaced or rebuilt, change the transmission oil and replace the filter after the first 100 hours of operation.

RB97E002

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Oil change interval ................................................................................................ 1000 hours

Template Name: OM_1_col Template Date: 1994_04_29

Service Specifications

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TRANSMISSION

LUBRICATION/MAINTENANCE

Template Name: OM_1_col Template Date: 1994_04_29

Transmission Oil Level

1. Park the machine on a level surface.

See this page for the two methods to check the transmission oil level.

2. Apply the parking brake.

3. Shift the transmission to NEUTRAL. 4. Run the engine at idle speed.

5. If the oil level is at or below the ADD mark, put the transport/service link in the LOCKED position and add oil to raise the oil level up to the FULL mark. See Transmission Service Specifications in this manual for the correct oil.

B910924J

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Oil Change, Filter Replacement and Breather Cleaning Change the transmission oil and replace the filter after the first 100 hours of operation with a new machine or if the transmission has been replaced or rebuilt. Then, do the above service and clean the breather every 1000 hours or operation.

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A27741

Cold Oil Level Check Before you start the engine, check the transmission oil level in the sight gauge. If the oil level is below the arrow, add oil to raise the oil level up to the arrow. See Transmission Service Specifications in this manual for the correct type of oil.

If possible, drain the oil when the oil is at operating temperature. More contamination is removed when the oil is at operating temperature.

1. Put the transport/service link in the LOCKED position, apply the parking brake, and stop the engine.

2. Clean the area around the filter, drain plug, breather, and filler tube.

Warm Oil Level Check Check the transmission oil level every 50 hours of operation when the oil is at operating temperature. Do the following.

3. H a v e a c o n t a i n e r t h a t w i l l h o l d approximately 22 U.S. quarts (12 litres).

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LUBRICATION/MAINTENANCE 6. Remove the cap screws, flat washers, and cover.

7. Remove the filter. Discard the old filter.

8. Install the filter as shown. Make sure the filter is SEATED against the filter base.

9. Install a new O-ring on the cover. Apply clean engine oil to the O-ring. Install the cover, cap screws, and flat washers.

11. Install the breather.

3

12. Install the drain plug. Put new oil into the transmission. See Transmission Service Specifications in this manual.

4 12

13. Check the oil level in the sight gauge.

5

2

1. DRAIN PLUG 2. O-RING 3. CAP SCREW

6 B910925J 4. FLAT WASHER 5. COVER 6. FILTER

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

15. Increase the transmission oil temperature to operating temperature and check the oil level again.

16. Stop the engine and return the transport/ service link to the OPERATING position.

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Template Name: OM_1_col Template Date: 1994_04_29

5. Remove the drain plug and drain the oil from the transmission.

10. Remove the breather. Clean the breather with solvent and dry with compressed air.

Be sure to wear face protection when using compressed air.

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B4028891T

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4. Remove the filler tube plug.

LUBRICATION/MAINTENANCE

AXLES Template Name: OM_1_col Template Date: 1994_04_29

Service Specifications Front and rear axle capacity Center bowl (each) ..................................................................... 38.5 U.S. quarts (36.4 litres) Planetary end (each) .................................................................. 14.5 U.S. quarts (13.7 litres) Total axle capacity ...................................................................... 67.5 U.S. quarts (63.9 litres) Type of oil .............................................................. Case 135H EP gear lube (SAE 85W-140) Alternate oil .............................................................................................................. See note Oil change interval ................................................................................................ 1000 hours TRIM THIS EDGE

NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result of using an alternate oil.

Axle Oil Level To check the oil level at the center bowl and each planetary end, do the following.

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NOTE: The oil level and filler plugs in the center bowl and planetary ends are magnetic. Remove and clean these plugs after the first 50 and 100 hours of operation with a new or rebuilt axle.

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LUBRICATION/MAINTENANCE

1. Park the machine on a level surface.

Apply the parking brake and stop the engine.

1. Park the machine on a level surface.

Apply the parking brake and stop the engine.

2. Use acceptable lifting equipment and lift the axle until the tires are off the floor.

Support axle with jack stands.

2. Remove the oil level plug from the center bowl. The oil level must be level with the bottom of the oil level plug hole.

3. Rotate the tires until the filler plug is in the three o’clock position as shown.

B4029991T 3. Add oil as required. See Axle Service Specifications in this manual.

A27734 4. Remove the oil level and filler plugs from the planetary ends. The oil level must be level with the bottom of the oil level and filler plug hole.

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OIL LEVEL AND FILLER PLUG

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Center Bowl

4. Clean and install the oil level plug.

5. Add oil as required. See Axle Service Specifications in this manual.

6. Clean and install the filler plugs.

7. Remove jack stands. Lower the axle until the tires are on the floor and remove the lifting equipment.

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Template Name: OM_1_col Template Date: 1994_04_29

Axle Planetary

LUBRICATION/MAINTENANCE

Axle Oil Change Template Name: OM_1_col Template Date: 1994_04_29

Change the axle oil every 1000 hours of operation. Each axle has a common oil level between the planetary ends and the center bowl. The oil flow is restricted between these areas so you must follow the oil fill instructions.

1. Park the machine on a level surface.

Apply the parking brake and stop the engine.

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2. H a v e a c o n t a i n e r t h a t w i l l h o l d approximately 14.4 U.S. gallons (13.6 litres) for each planetary end and a container that will hold approximately 9.6 U.S. gallons (36.3 litres) for the center bowl.

3. With the oil warm from operation, remove the oil level and filler plug and the drain bolts from planetary ends and the oil level plug and oil drain bolt from the center bowl. Drain the oil from the axles.

B9109608T 4. Clean the oil level and oil filler plugs.

5. After all oil has been removed, install and tighten the drain bolts.

6. Install the exact amount of oil in each planetary end and in the center bowl. See Axle Service Specifications in this manual.

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7. Install the oil level and filler plug in the planetary ends and the oil level plugs in the center bowls.

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LUBRICATION/MAINTENANCE

Clean or replace the cab air filters (if equipped) every 250 hours of operation or if the air flow in the cab is reduced.

3. Disconnect and remove the small filter.

NOTE: If your machine is new, make sure the plastic cover is removed from the filters.

Removal and Installation Tool Required - Special T or Allen wrench 1. Use the special T or Allen wrench and open the access door.

A27777

IMPORTANT: Make sure that the arrows on the small filter point away from the cab and the arrows on the large filter point toward the cab.

5. Close the access door. Store Special T or Allen wrench in the Operators Manual Compartment for safe keeping.

2. Pull out the large air filter.

Cleaning the Filter Check the dirty element for damage and check the rubber seal on the end. Push the rubber seal with your finger. If the rubber feels hard and does not move back to original shape, discard the element.

A27776

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Template Name: OM_1_col Template Date: 1994_04_29

A27775

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4. Install cleaned or new filters.

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CAB AIR FILTER (If Equipped)

LUBRICATION/MAINTENANCE

Template Name: OM_1_col Template Date: 1994_04_29

1. Remove the loose dirt with compressed air, 30 psi (207 kPa, 2 bar) maximum.

Hold the nozzle at least one inch (25 mm) from the element. Make sure you wear face protection when using compressed air.

4. Use a water hose without a nozzle with pressure less than 40 psi (275 kPa, 2.7 bar) to flush all soap from the element.

788L94

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

786L94

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

6. Use a light and inspect the element for holes or splits in the pleats. Check for damage to the metal parts and rubber gasket.

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

789L94

787L94

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

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LUBRICATION/MAINTENANCE

The windshield washer reservoir is located in the cab on the left side. To add washer fluid, pull the cap up.

Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT: When the ambient temperature decreases to 32˚F (0˚C) and below, always use an antifreeze type washer solution.

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A27750.1

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WINDSHIELD WASHER RESERVOIR (If Equipped)

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MAINTENANCE/ADJUSTMENTS

CAB SERVICE Template Name: OM_1_col Template Date: 1994_04_29

Air Conditioning The components of the operators cab, including the components of the air conditioning system, require service at different intervals. Service the following items as required to maintain maximum operating efficiency.

!

WARNING: Liquid refrigerant can cause severe and painful frostbite to your skin. Do not attempt to service the air conditioning system on this machine unless you are completely familiarized with air conditioning and the safety precautions which must be followed. Serious injury can result if you do not follow these instructions.

SA048

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Lubrication of the Air Conditioning Compressor Seals

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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.

condenser. Also check and clean the grille screen.

IMPORTANT: Because the condenser fins bend easily, be careful when you clean the condenser.

10 Ampere Circuit Breakers for Condenser Blower Fans

Condenser

RP95N041 If one of the fans stop, remove the plug on that side and push the reset button on the circuit breaker. Install the plug. If fan still will not operate properly, see your dealer.

RP95N016 Keep the air conditioning condenser core clean. Use compressed air (wear face protection) or a rigid brush to clean the

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Cab Headliner

Door Hinges

The foam headliner in your cab decreases noise. To keep the headliner in good operating condition, remove dust with a vacuum cleaner.

Use graphite to lubricate the cab door hinges.

Do not use oil.

IMPORTANT: DO NOT wash the headliner with water because water can cause damage to the headliner and lower the noise control capacity of the headliner.

Check all hoses and wiring for damage. If damage occurred, see your dealer for repair or replacement.

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Hoses and Wiring

Template Name: OM_1_col Template Date: 1994_04_29

A27762

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MAINTENANCE/ADJUSTMENTS

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MAINTENANCE/ADJUSTMENTS

Operators Seat Template Name: OM_1_col Template Date: 1994_04_29

Remove dust and dirt from the seat with a vacuum cleaner or soft brush. Clean stains with the correct use of a material cleaner.

Before removing stains, try to find what type and how old the stains are. Some stains can be removed with water or soap solution.

!

WARNING: Never use gasoline, naptha or any other volatile material for any cleaning purposes. These materials may be toxic and/or flammable.

SA049

CLEANER FLUID - This type of cleaner can be used for grease or oil stains. Carefully remove the item that caused the stain with a scraper or a knife that is not sharp. Use very little cleaner, no pressure, and clean cloths. Move the cloth from the outside of the stain toward the center of the stain and constantly change to a clean section of cloth.

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When the stain is removed from the material, immediately use a cloth to make dry the area and to prevent a cleaner circle pattern. If a circle pattern occurs, clean the complete area.

NOTE: A difficult stain can need a second application of cleaner fluid followed immediately by the use of a soft brush to completely remove the stain.

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MAINTENANCE/ADJUSTMENTS

5. Loosen the cap screws that fasten the actuator.

1. Park the machine on a level surface.

2. Lower the loader frame and adjust the position of the bucket so the cutting edge is flat on the floor.

SWITCH

6. Move the actuator all the way to the rear.

RP95N002 3. Apply the parking brake and stop the engine.

4. Make sure the switch is even with the edge of the shield. Adjust the shield and actuator to get 1/8 to 3/16 inch (3.2 to 5.0 mm) clearance between the switch and the actuator. Make sure the actuator is parallel to the shield so that the 1/8 to 3/ 16 inch (3.2 to 5.0 mm) clearance is maintained through the full stroke of the cylinder.

SWITCH

SHIELD

B4037588T

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B4037288T

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B4037088T

Template Name: OM_1_col Template Date: 1994_04_29

Return-To-Dig Adjustment

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LOADER ADJUSTMENTS

MAINTENANCE/ADJUSTMENTS 7. Turn the key switch to the ON position but do not start the engine.

Template Name: OM_1_col Template Date: 1994_04_29

9. Have another person help you at this time. Slowly move the actuator forward until the bucket control lever returns to NEUTRAL.

B4043488T 8. Push down on the left side of the ReturnTo-Dig function switch.

B4037188T

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10. Tighten the cap screws that fasten the actuator. Make sure the 1/8 to 3/16 inch (3.2 to 5.0 mm) clearance is maintained through the full stroke of the cylinder.

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A27738

B4037088T 11. Start the engine. Raise the loader frame all the way and dump the bucket completely. Increase the engine speed to full throttle. Pull back the bucket control lever to the ROLLBACK position. The bucket will roll back automatically.

12. Lower the bucket to the floor and stop the engine.

13. If the bucket is not in the correct position, adjust the actuator as required.

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2. Raise the loader until the front actuator is even with the Return-To-Travel switch.

Make sure the clearance is 1/8 to 3/16 inch (3.2 to 5.0 mm).

1. Lower the loader bucket to the ground.

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

FRONT ACTUATOR

3. Stop the engine.

4. Loosen the front actuator.

RETURN-TO-TRAVEL SWITCH

3. Stop the engine.

4. Loosen and remove the screws and hardened washers that fasten the cover.

B4063388T 5. To increase the carry height, move the actuator down in the slot. To decrease the carry height, move the actuator up in the slot.

6. Tighten the actuator and check the adjustment.

Return-To-Travel Adjustment

B4196689T

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

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B4196789T

Template Name: OM_1_col Template Date: 1994_04_29

Return-To-Travel Minor Adjustment

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MAINTENANCE/ADJUSTMENTS

MAINTENANCE/ADJUSTMENTS 5. Remove the cover.

Template Name: OM_1_col Template Date: 1994_04_29

7. Have another person help you at this time. Start the engine and lower the loader frame until the bucket is at the desired height above the floor. Put a sufficient support under each end of the bucket and stop the engine.

8. Loosen the actuator.

B4196589T

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6. C h e c k t h e c l e a r a n c e b e t w e e n t h e actuator and the switch. This clearance is 1/8 to 3/16 inch (3.2 to 5.0 mm). If the clearance is not correct, loosen the nuts for the switch and adjust the nuts so there is 1/8 to 3/16 inch (3.2 to 5.0 mm) clearance between the switch and the actuator. Hold the switch in position and tighten the nuts.

B4196289T

9. Move the actuator up in the slot and hand tighten the actuator.

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B4196489T

B4196189T

10. Turn the key switch to ON but do not start the engine.

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11. Push down on the left side of the ReturnTo-Travel switch. Move the lift control lever from the HOLD position to the RAISE position several times to relieve all of the pressure in the accumulator. Move t h e l i f t c o n t r o l l e v e r t o t h e F L O AT position. The lift control lever will remain in this position and the loader frame will not move.

13. Tighten the actuator. Move the lift control lever to the FLOAT position. The loader frame will lower and stop at the adjusted height above the floor.

B4196289T

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14. When the adjustment is correct, install the cover.

A27738 12. Loosen the actuator and slowly move the actuator down the slot until the lift control lever returns to HOLD.

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MAINTENANCE/ADJUSTMENTS

15. Install the screws and hardened washers and tighten the screws.

B4196089T

B4196689T 16. Remove each support from under the bucket and lower the bucket to the floor.

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Template Name: OM_1_col Template Date: 1994_04_29

B4196589T

MAINTENANCE/ADJUSTMENTS

Template Name: OM_1_col Template Date: 1994_04_29

Bucket Height Control Minor Adjustment

Bucket Height Control Adjustment

1. Park the machine on a level surface.

Lower the loader bucket to the floor.

1. Park the machine on a level surface and lower the loader frame so the bucket is flat on the floor.

2. Apply the parking brake and stop the engine.

3. Loosen the rear actuator.

RP95N002

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2. Stop the engine and apply the parking brake.

3. Loosen and remove the screws and hardened washers that fasten the cover.

B4063488T

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4. To increase the dump height, move the actuator down in the slot. To decrease the dump height, move the actuator up.

5. Tighten the actuator.

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.

B4196689T

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4. Remove the cover.

6. Loosen the nuts of the switch and adjust the nuts so there is 1/8 to 3/16 inch (3.2 to 5.0 mm) clearance between the switch and the actuator. Hold the switch in position and tighten the nuts.

B4196589T

B4195989T

7. Disconnect the lifting equipment. Start the engine. Dump the bucket completely and raise or lower the loader frame for the bucket height required. Stop the engine. Connect the lifting equipment to the crossmember of the loader.

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5. Start the engine and raise the loader frame until the rear actuator is even with the Bucket Height Control switch. Stop the engine. Connect acceptable lifting equipment to the loader arms that will hold the loader in place.

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MAINTENANCE/ADJUSTMENTS

B4195489T

B4195789T

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Template Name: OM_1_col Template Date: 1994_04_29

8. Loosen the actuator.

MAINTENANCE/ADJUSTMENTS 9. Move the actuator down in the slot.

13. Tighten the actuator.

Template Name: OM_1_col Template Date: 1994_04_29 TRIM THIS EDGE

B4195689T

B4195789T

10. Turn the key switch to ON but DO NOT start the engine.

14. Disconnect the lifting equipment from the crossmember of the loader frame. Start the engine and lower the loader frame so the bucket is flat on the floor.

11. Push in the left side of the Bucket Height Control switch on the instrument panel.

Move the lift control lever to the RAISE position. The lift control lever will remain in this position and the loader frame will not move.

15. Put the lift control lever in the RAISE position. The loader frame will raise and stop at the adjusted bucket height.

16. Lower the loader frame so that the bucket is flat on the floor. Stop the engine.

17. Install the cover.

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B4063488T 12. Slowly move the actuator up the slot until the lift control lever returns to HOLD.

B4196589T 18. Install the screws and hardened washers and tighten the screws.

!

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

CM115

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MAINTENANCE/ADJUSTMENTS

1. Park the machine on a surface, articulate fully to the left and lower the loader to the ground.

2. Apply the parking brake and stop the engine.

3. Remove the key from the ignition and turn the master disconnect switch to the OFF position.

4. Check the clearance between the sensor and the bellcrank. The clearance must be 2.3 to 3.5 mm (0.08 to 0.14 inch).

BELLCRANK

RP96F043

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SENSOR

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Low Idle Position Switch

2.3 TO 3.5 mm 0.08 TO 0.14 BELLCRANK

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410L96

Template Name: OM_1_col Template Date: 1994_04_29

SENSOR

MAINTENANCE/ADJUSTMENTS

Template Name: OM_1_col Template Date: 1994_04_29

5. Position the accelerator pedal in the low idle position, there must be no pressure on the pedal and the pedal must be in the idle position. The distance must be 2.0 to 5.0 mm (0.08 to 0.20 inch).

BELLCRANK

SENSOR

RP96F042

BELLCRANK

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2.0 TO 5.0 mm 0.08 TO 0.20 SENSOR 409L96

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MAINTENANCE/ADJUSTMENTS

Your machine has a Roll-Over Protective Structure (ROPS). A ROPS label shows the serial number of the ROPS, gross weight, approval, regulation, and model numbers of the machine. See Identification Numbers in this manual.

1. Check the torque of the ROPS mounting bolts. If necessary, tighten the bolts to the correct torque. See torque specifications on this page.

Before you operate this machine, always make sure that the ROPS and operator’s seat belts are correctly installed.

Seat Belt

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.

The seat belt is an important part of your ROPS. You must wear the seat belt at all times when you operate the machine.

1. Keep the seat belts away from objects that can damage the seat belts.

2. C h e c k t h e s e a t b e l t s f o r d a m a g e .

Replace all parts that are damaged.

Torque Specifications for ROPS Cab

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2. C h e c k t h e o p e r a t o r s s e a t a n d t h e 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.

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ROLL-OVER PROTECTIVE STRUCTURE

4. Keep the seat belts clean. Wash the seat belts only in soap and water.

5. Do not put the seat belts in bleach or dye.

You will make the seat belts weak.

B9106416T

Maintenance and Inspection of ROPS

1. ROPS CAB MOUNTING BOLTS (BOTH SIDES), TIGHTEN TO 580 TO 620 POUNDFEET (786 TO 840 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.

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Template Name: OM_1_col Template Date: 1994_04_29

3. Make sure that the mounting bolts of the s e a t b e l t s a r e t i g h t . S e e To r q u e Specifications for Seat in this manual.

MAINTENANCE/ADJUSTMENTS

Template Name: OM_1_col Template Date: 1994_04_29

Damage to the ROPS

B. Operators seat.

If the machine has rolled over or the ROPS has been in some other type of accident (such as hitting an overhead object during transport), you must replace the damaged ROPS components to get as much protection as you had originally.

C. Seat belt mounting bolts and seat belt.

After an accident, check the following for damage.

A. ROPS cab.

Before you operate the machine, replace all ROPS components that are damaged.

See the Parts Catalog or your dealer for components that are replaceable.

DO NOT TRY TO WELD OR STRAIGHTEN THE ROPS.

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!

WARNING: Improper ROPS inspection or maintenance can cause injury or death. Do the recommended ROPS inspection shown in this manual. If you must replace the ROPS, ROPS parts, or ROPS mounting hardware, use only the replacement parts shown in the Case parts catalog for this SA029 machine.

!

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

SB026

!

WARNING: If you operate this machine without a ROPS and the machine rolls over, you can be injured or killed. Remove the ROPS only for service or replacement. Do not operate this machine with the ROPS removed.

SA027

!

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

SA028

!

WARNING: Always fasten the seat belt securely before starting the engine.

SA036

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2

1

B910929J 1. 54 TO 64 POUND-FEET (73 TO 87 Nm) 2. 35 TO 42 POUND-FEET (48 TO 57 Nm)

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1

Template Name: OM_1_col Template Date: 1994_04_29

TORQUE SPECIFICATIONS FOR SEAT AND SEAT BELTS

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MAINTENANCE/ADJUSTMENTS

MAINTENANCE/ADJUSTMENTS

Template Name: OM_1_col Template Date: 1994_04_29

FAN, BELT, ALTERNATOR BELT AND AIR CONDITIONING COMPRESSOR BELT Service Interval Fan belt service interval ....................................................................... Check every 250 hours Alternator belt service interval .............................................................. Check every 250 hours Air conditioning compressor belt service interval .................................. Check every 250 hours

Fan Belt Inspection and Adjustment 1. Check the fan belt for the correct tension with a belt tension gauge as shown in the illustration.

3. If the tension for the fan belt is not correct, loosen the lock nut and turn the adjusting bolt counterclockwise to loosen or clockwise to tighten the fan belt.

Tighten the lock nut to 120 to 140 poundfeet (165 to 190 Nm).

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RP95N022

B910926J

2. The correct tension for a new belt is 290 to 310 pound force (1290 to 1379 Newtons) for a used belt is 200 to 240 pound force (890 to 1067 Newtons).

4. Repeat steps 1, 2, and 3 until the fan belt tension is correct.

NOTE: A belt is considered used after 10 minutes of running.

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MAINTENANCE/ADJUSTMENTS

1. Loosen the lock nut and turn the adjusting bolt counterclockwise until the belt is loose. Remove and discard the old fan belt

Inspection and Adjustment 1. Check the alternator belt for the correct tension with a belt tension gauge as shown in the illustration.

ADJUSTING BOLT

LOCK NUT

B910927J

RP95N022 2. Install a new fan belt. See Fan Belt Inspection and Adjustment and adjust the fan belt to the correct tension.

2. The correct tension for a new belt is 140 to 160 pound force (623 to 712 Newtons) for a used belt is 90 to 120 pound force (400 to 534 Newtons).

NOTE: The illustrations are shown with the removal of the alternator shield to show service points. NEVER operate the machine without the shield in place.

3. If the tension for the alternator belt is not correct, loosen the strap bolt and the p i v o t b o l t . Tu r n t h e a d j u s t i n g b o l t counterclockwise to loosen or clockwise to tighten the alternator belt.

ADJUSTING BOLT

PIVOT BOLT

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RP95N022

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FAN BELT

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Alternator Belt

Template Name: OM_1_col Template Date: 1994_04_29

Replacement

MAINTENANCE/ADJUSTMENTS

Removal and Installation Template Name: OM_1_col Template Date: 1994_04_29

1. Loosen the strap bolt and the pivot bolt.

Turn the adjusting bolt counterclockwise until the belt is loose. Remove and discard the alternator belt.

Air Conditioning Compressor Belt Inspection and Adjustment 1. Check the air conditioning compressor belt for the correct tension with a belt tension gauge as shown in the illustration.

ADJUSTING BOLT

PIVOT BOLT

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RP95N022 2. I n s t a l l a n e w a l t e r n a t o r b e l t . S e e Alternator Belt Inspection and Adjustment and adjust the alternator belt to the correct tension.

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!

B910928J

2. The correct tension for a new belt is 130 to 150 pound force (578 to 667 Newtons) for a used belt is 80 to 120 pound force (356 to 534 Newtons).

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

CM115

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MAINTENANCE/ADJUSTMENTS

Removal and Installation 1. L o o s e n t h e p i v o t b o l t . L o o s e n t h e adjusting bolt and move the compressor until the belt is loose. Remove and discard the air conditioning compressor belt.

PIVOT BOLTS

PIVOT BOLTS

RP95N053

RP95N053

Template Name: OM_1_col Template Date: 1994_04_29

2. Install a new air conditioning compressor belt. See Air Conditioning Compressor Belt Inspection and Adjustment and adjust the air conditioning compressor belt to the correct tension.

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ADJUSTING BOLT

ADJUSTING BOLT

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3. If the tension for the air conditioning compressor belt is not correct, loosen the pivot bolts. Loosen the adjusting bolt and move the compressor as required to loosen or tighten the air conditioning compressor belt.

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MAINTENANCE/ADJUSTMENTS

LOADER CONTROL ACCUMULATOR Template Name: OM_1_col Template Date: 1994_04_29

A hydraulic accumulator is connected to the hydraulic circuit of the loader control levers.

The purpose of the accumulator is to (1) let the operator lower the loader arms if the engine stops with the loader raised or (2) give the control system hydraulic pressure assistance when you operate the machine at idle speed.

1. Raise the loader bucket.

2. Stop the engine.

3. Move the lift control to the LOWER position. The loader bucket must lower to the ground. See the Service Manual for this machine or see your dealer if the loader bucket did not move.

Periodically test the accumulator for correct operation.

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The cigar lighter socket can be used for the connection of a lighting device to help with service and maintenance procedures.

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A27738

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MAINTENANCE/ADJUSTMENTS

Space is provided for mounting a Fire Extinguisher on the console behind the Operators Seat. It is recommended that you have a fire extinguisher on your machine at all times.

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.

FAR1073

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.

Template Name: OM_1_col Template Date: 1994_04_29

ONCE EACH YEAR: Have the fire extinguisher completely inspected by a certified fire protection equipment person.

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See Fire or Explosion Prevention Information in the Safety Section of this manual.

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FIRE EXTINGUISHER MOUNTING

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MAINTENANCE/ADJUSTMENTS

SECONDARY STEERING CHECK Template Name: OM_1_col Template Date: 1994_04_29

The secondary steering system allows you to steer the machine if the primary steering system stops working.

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RD97D051

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1. Park the machine on a hard, level surface with enough clearance around the machine to allow you to completely steer from side to side. Raise the bucket approximately 500 mm (20 inches) above the ground.

NOTE: The secondary steering system will only function as long as there is sufficient battery capacity.

2. Start the engine.

3. With the machine at low idle and steering straight ahead, turn the steering wheel either left or right. DO NOT TURN THE STEERING WHEEL TO THE STEERING STOP. While steering, turn the key switch to the OFF position to stop the engine and then immediately back to the ON position (not the START position. Release the steering wheel. The secondary steering pump/motor should start running immediately.

IMPORTANT: DO NOT turn the key switch to the OFF position if the machine is steered against either the right hand or left hand steering stop. The steering wheel may kick back.

4. S t e e r t h e m a c h i n e l e f t a n d r i g h t t o confirm that the secondary steering motor is working. The secondary pump/motor should not be run continuously for more than 20 seconds at a time without a 2 minute cool down.

5. Look at the instrument cluster to verify that the secondary steering light comes on.

6. Turn the key switch to the OFF position.

The secondary steering motor should stop.

7. If Steps 2 through 6 function properly, the secondary steering system is operating correctly. Repair the secondary steering system if the secondary steering system does not operate correctly.

8. Restart the engine and allow the batteries to recharge for a minimum of 10 minutes.

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ELECTRICAL SYSTEM

!

WARNING: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote - EXTERNAL: flush with water. INTERNAL: drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately.

EYES: flush with water for 15 minutes and get prompt medical attention.

!

WARNING: When the battery electrolyte is frozen, the battery can explode if, (1) you try to charge the battery, or (2) you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others SA033 in the area can be injured.

!

WARNING: Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: 1. When you disconnect the battery cables, always disconnect the negative (1) battery cable first.

2. When you connect the battery cables, always connect the negative (-) cable last.

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

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

SB034

Battery Service NOTE: The electrical system in this machine is 24 volts. Each battery is 12 volts.

Before you use an electric welder, disconnect the alternator wires, instrument cluster, and turn the master disconnect switch to OFF.

Before you service components of the electrical system, always disconnect the NEGATIVE (-) battery cable.

Do not use a steam cleaner or cleaning solvent to clean the alternator.

Do not run the engine with the battery cables disconnected or with the alternator wires disconnected.

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SB032

Template Name: OM_1_col Template Date: 1994_04_29

!

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

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Battery Safety

ELECTRICAL SYSTEM

Template Name: OM_1_col Template Date: 1994_04_29

Battery Fluid Level

Cleaning the Batteries

Check the fluid level of the batteries every 250 hours of operation. If the fluid level is low, add clean or distilled water to each cell until the fluid level is at the split ring at the bottom of each cell opening.

Check the batteries regularly for dirt, corrosion and damage. Dirt mixed with electrolyte or moisture on the top of the batteries can cause a discharged condition in the batteries. Use one of the following methods to clean the batteries.

IMPORTANT: If the temperature is 32˚F (0˚C) or below and you have added water to the batteries, do the following; Connect a battery charger to the batteries or operate the machine for approximately two hours. This procedure is necessary to mix the water with the electrolyte.

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Keep the battery vents clean, make sure the vents are not restricted.

1. Use Case Battery Saver, Part Number M20376. Follow the instructions on the container. This cleaner does not need water.

2. Use baking soda or ammonia and flush the outside of the batteries with water. If you do not have Case Battery Saver, use other special cleaners to prevent corrosion on the battery terminals.

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B910919J

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ELECTRICAL SYSTEM

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B4042388T

1990800C2

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Template Name: OM_1_col Template Date: 1994_04_29

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 two fuse panel decals for correct location of each fuse.

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FUSES

ELECTRICAL SYSTEM

REPLACEMENT BULBS Template Name: OM_1_col Template Date: 1994_04_29 TRIM THIS EDGE

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Case Part Number

Industry Number

Driving Lamp

N9427

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Working Lamp

F45305

---

Stop and Tail Lamp

24005R1

1662

Directional Lamp

446914

1683

Flasher Lamp

190877

1251

Turn Signal

446914

1683

Dome Lamp

456602

1692

Master Warning Lamp

193067

313

Turn Signal Indicator Lamp

274019

1820

Rocker Switches

926645C1

---

Optional Gauges

T39215

1820

*Rotating Beacon

A187543 (Halogen)

---

*Do not touch the new halogen bulb with your fingers. Use gloves or use a tissue to hold the bulb.

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MACHINE STORAGE

Storage Preparation

10. Drain the cooling system. Leave the drain open and do not tighten the radiator cap.

Put a Do Not Operate tag in the cab.

11. Clean or replace the primary element for the air filter.

2. Lubricate the machine at all grease fittings.

3. Paint any areas where the paint has been damaged.

4. Move all hydraulic controls to relieve any pressure in the hydraulic circuits.

5. Drain the fuel tank.

6. Put approximately 2 U.S. gallons (8 litres) of diesel flushing oil in the fuel tank. Run the engine until the exhaust smoke is blue-white.

7. Drain the flushing oil from the fuel tank.

8. Put one tablespoon (15 ml) of Shell Oil Company VPI crystals in the fuel tank.

12. Cover the exposed steering cylinder rods, equipment valve spools with Case Rust and Corrosion Preventative (Part Number B17510).

13. C h a r g e t h e b a t t e r i e s . R e m o v e t h e batteries from the machine and put the batteries on a wooden pallet in a cool dry area. If possible, keep the batteries in a building where the temperature is above freezing (32˚F, 0˚C). Make sure the batteries are clean.

NOTE: Always wear face protection when checking batteries. Check the batteries periodically for the correct electrolyte level. Test the electrolyte with a hydrometer. When the hydrometer reading is near 1.215, charge the batteries.

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1. Wash the machine.

Template Name: OM_1_col Template Date: 1994_04_29

If the machine is to be in storage for more than 30 days, park the machine inside a building. If a building is not available, park the machine in a dry area on planks and cover the machine with a waterproof covering.

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9. Change the engine oil and replace the oil filter.

MACHINE STORAGE

Template Name: OM_1_col Template Date: 1994_04_29

Removal from Storage

7. Check the oil level of both axles.

Do not start the engine until steps 1 through 10 have been done.

8. Lubricate the machine at all grease fittings.

1. Change the fuel filter.

2. Put coolant in the engine cooling system.

9. Use petroleum base solvent and remove the Case Rust and Corrosion Preventive from the hydraulic cylinder rods.

3. Check the condition of the drive belts.

Replace if required.

10. See Battery Service in this manual and install the batteries.

4. Check the engine oil level.

11. Fill the fuel tank.

5. Check the hydraulic oil level.

12. Prime the turbocharger with clean engine oil. See your Service Manual or your dealer.

6. Check the transmission oil level.

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13. Start the engine. It is important that you use the Starting the Engine procedure in this manual for priming the turbocharger lines with oil.

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SPECIFICATIONS

D E

K L M

A CB

F G H J

B0769A88J

Machines with 3.6 m3 General Purpose Bucket A B C D E

F G H J K L M

Tipping load, machine straight ........................................................................19 267 kg Tipping load, 40 degree turn ...........................................................................15 403 kg Overall operating height, fully raised ...............................................................5 736 mm Height to bucket hinge pin, fully raised ...........................................................4 277 mm Dump height, 45 degree dump, full height ......................................................3 099 mm Bucket reach, 45 degree dump, full height ......................................................1 134 mm Bucket reach, 45 degree dump, 2 134 mm dump height ...................................................................................................1 766 mm Dump angle at full height .............................................................................. 50 degree Bucket rollback at ground line ....................................................................... 39 degree Digging Depth, bucket flat ...................................................................................39 mm Wheel Base ....................................................................................................3 404 mm Tread width ....................................................................................................2 210 mm Overall length (without bucket teeth) ..............................................................8 617 mm Overall height to top of ROPS cab ..................................................................3 564 mm Height to top of exhaust pipe ..........................................................................3 383 mm Height to top of steering wheel .......................................................................2 837 mm SAE operating weight .....................................................................................23 324 kg Turning angle from center ............................................................................. 40 degree

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2 134 mm

Template Name: OM_1_col Template Date: 1994_04_29

Specifications taken with 26.5 R25, XH★ tires, ROPS cab with heater, 2177 kg standard rear counterweight, fenders, standard battery, optional lights, full fuel, and a 75 kg operator.

Specifications per ISO 8313,5998 and 7446.

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OPERATING DATA AND DIMENSIONS - 921B

SPECIFICATIONS

Template Name: OM_1_col Template Date: 1994_04_29

D E

K L M

A C

B

2 134 mm

F G H J

B0769A88J

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Machines with 3.8 m3 General Purpose Bucket A B C D E

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F G H J K L M

Tipping load, machine straight ..........................................................................19 160 kg Tipping load, 40 degree turn .............................................................................15 299 kg Overall operating height, fully raised ................................................................ 5 736 mm Height to bucket hinge pin, fully raised ..............................................................4 276 mm Dump height, 45 degree dump, full height .........................................................3 099 mm Bucket reach, 45 degree dump, full height ........................................................1 134 mm Bucket reach, 45 degree dump, 2 134 mm dump height ......................................................................................................1 766 mm Dump angle at full height ................................................................................ 50 degree Bucket rollback at ground line .......................................................................... 39 degree Digging Depth, bucket flat ..................................................................................... 39 mm Wheel Base ......................................................................................................3 404 mm Tread width .......................................................................................................2 210 mm Overall length ...................................................................................................8 617 mm Overall height to top of ROPS cab ................................................................... 3 564 mm Height to top of exhaust pipe ............................................................................3 383 mm Height to top of steering wheel ..........................................................................2 837 mm SAE operating weight .......................................................................................23 414 kg Turning angle from center ............................................................................... 40 degree

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L M

A C

B

2 134 mm

F G H B0769A88J

Machines with 4.1 m3 General Purpose Bucket A B C D E F G H J K L M

Tipping load, machine straight ..........................................................................19 024 kg Tipping load, 40 degree turn .............................................................................15 150 kg Overall operating height, fully raised .................................................................5 808 mm Height to bucket hinge pin, fully raised ..............................................................4 276 mm Dump height, 45 degree dump, full height ........................................................ 3 042 mm Bucket reach, 45 degree dump, full height ........................................................1 192 mm Dump angle at full height ................................................................................ 50 degree Bucket reach, 45 degree dump, 2 134 mm dump height ......................................................................................................1 798 mm Bucket rollback at ground line ......................................................................... 39 degree Digging Depth, bucket flat ......................................................................................40 mm Wheel Base ......................................................................................................3 404 mm Tread width .......................................................................................................2 210 mm Overall length (without bucket teeth) .................................................................8 697 mm Overall height to top of ROPS cab ....................................................................3 564 mm Height to top of exhaust pipe ............................................................................3 383 mm Height to top of steering wheel ..........................................................................2 837 mm SAE operating weight .......................................................................................23 504 kg Turning angle from center ............................................................................... 40 degree

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SPECIFICATIONS

SPECIFICATIONS

OPERATING DATA AND DIMENSIONS - 921B XR Template Name: OM_1_col Template Date: 1994_04_29

Specifications taken with 26.5 R25, XH★ tires, ROPS cab with heater, 2177 kg standard rear counterweight, fenders, standard battery, optional lights, full fuel, and a 75 kg operator.

Specifications per ISO 8313,5998 and 7446.

D E

K L M

A CB 2 134 mm

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F G H J

B0769A88J

XR Machines with 3.6 m3 General Purpose Bucket

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A B C D E

F G H J K L M

Tipping load, machine straight ........................................................................15 059 kg Tipping load, 40 degree turn ...........................................................................12 017 kg Overall operating height, fully raised ...............................................................6 287 mm Height to bucket hinge pin, fully raised ...........................................................4 828 mm Dump height, 45 degree dump, full height .......................................................3 650 mm Bucket reach, 45 degree dump, full height ............................................. 1 211 mm Bucket reach, 45 degree dump,2 134 mm dump height ....................................................................................................2 253mm Dump angle at full height ............................................................................... 45 degree Bucket rollback at ground line ....................................................................... 39 degree Digging Depth, bucket flat ................................................................................... 53 mm Wheel Base ....................................................................................................3 404 mm Tread width ....................................................................................................2 210 mm Overall length (without bucket teeth) ...............................................................9 177 mm Overall height to top of ROPS cab ..................................................................3 564 mm Height to top of exhaust pipe ....................................................................... 13 383 mm Height to top of steering wheel .......................................................................2 837 mm SAE operating weight .....................................................................................23 324 kg Turning angle from center ............................................................................. 40 degree

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L

A C

B

7 FOOT 2 134 mm

M

F G H B0769A88J

XR Machines with 3.8 m3 General Purpose Bucket A B C D E

F G H J K L M

Tipping load, machine straight ..........................................................................14 595 kg Tipping load, 40 degree turn .............................................................................26 275 kg Overall operating height, fully raised ..................................................................6 287mm Height to bucket hinge pin, fully raised ..............................................................4 827 mm Dump height, 45 degree dump, full height .........................................................3 650 mm Bucket reach, 45 degree dump, full height ....................................................... 1 211 mm Bucket reach, 45 degree dump, 2 134 mm) dump height ......................................................................................................2 253 mm Dump angle at full height ................................................................................. 45 degree Bucket rollback at ground line .......................................................................... 39 degree Digging Depth, bucket flat ......................................................................................53 mm Wheel Base ......................................................................................................3 404 mm Tread width .......................................................................................................2 210 mm Overall length ...................................................................................................9 177 mm Overall height to top of ROPS cab ....................................................................3 564 mm Height to top of exhaust pipe ............................................................................3 383 mm Height to top of steering wheel ......................................................................... 2 837 mm SAE operating weight .......................................................................................23 848 kg Turning angle from center ............................................................................... 40 degree

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SPECIFICATIONS

SPECIFICATIONS

Template Name: OM_1_col Template Date: 1994_04_29

D E

K L M

A C

B

2 134 mm

F G H J

B0769A88J

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XR Machines with 4.1 m3 General Purpose Bucket A B C D

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E F G H J K L M

Tipping load, machine straight ..........................................................................14 822 kg Tipping load, 40 degree turn ............................................................................. 11 775 kg Overall operating height, fully raised ................................................................ 6 359 mm Height to bucket hinge pin, fully raised ............................................................. 4 827 mm Dump height, 45 degree dump, full height ........................................................ 3 593 mm Bucket reach, 45 degree dump, full height ....................................................... 1 268 mm Dump angle at full height ................................................................................ 45 degree Bucket reach, 45 degree dump, 2 134 mm dump height ......................................................................................................2 289 mm Bucket rollback at ground line ......................................................................... 39 degree Digging Depth, bucket flat ..................................................................................... 53 mm Wheel Base ..................................................................................................... 3 404 mm Tread width ...................................................................................................... 2 210 mm Overall length (without bucket teeth) ................................................................ 9 257 mm Overall height to top of ROPS cab ................................................................... 3 564 mm Height to top of exhaust pipe ........................................................................... 3 383 mm Height to top of steering wheel ......................................................................... 2 837 mm SAE operating weight ...................................................................................... 23 938 kg Turning angle from center ............................................................................... 40 degree

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WIDTH

CAPACITIES SAE Heaped Struck 3 3 3 yd m yd m3 4.71 (3.60) 3.80 (2.97) 4.97 (3.80) 4.19 (3.20) 5.36 (4.10) 4.58 (3.50)

118 inch (3 000 mm) 126 inch (3 200 mm) 126 inch (3 200 mm)

WEIGHT pounds kg 3 696 4 167 4 366

(1 800) (1 890) (1 980)

TRAVEL SPEEDS (with 26.5 x 25 Tires) SECOND

THIRD

FOURTH

mph

(km/h)

mph

(km/h)

mph

(km/h)

mph

(km/h)

Forward

5.1

(8.2)

8.5

(13.7)

18.0

(29.0)

25.2

(40.6)

Reverse

5.1

(8.2)

8.5

(13.7)

18.0

(29.0)

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ENGINE DATA Make and model ...................................................................................... Cummins MII-C270 Type ......................................................................................... six cylinder, four stroke cycle, turbocharger aftercooled in cylinder head Firing order ........................................................................................................... 1-5-3-6-2-4 Bore and stroke ................................................................... 4.92 x 5.79 inch (125 x 146 mm) Displacement ....................................................................................................... 661 cu inch Compression ratio ......................................................................................... 16.1 to 1 Horsepower SAE gross ............................................................ 282 at 1900 rpm (210 kW at 1900 r/min) SAE net ............................................................... 272 at 1900 rpm (203 kW at 1900 r/min) Engine speeds Full throttle - no load ............................................................................... 2200 to 2400 rpm Idle speed ................................................................................................... 850 to 900 rpm Hydraulic stall ......................................................................................... 2100 to 2250 rpm Converter stall ........................................................................................ 1900 to 2100 rpm Combined hydraulic and converter stall ................................................... 1400 to 1650 rpm Valve clearance - engine cold Intake valves ..................................................................................... 0.014 inch (0.35 mm) Exhaust valves .................................................................................. 0.027 inch (0.68 mm) Lubrication System Oil pressure at idle speed (minimum) .......................................................... 10 psi (70 kPa) Oil pressure at 1300 rpm ...................................................... 35 to 40 PSI (240 to 310 kPa) Type of system ..................................................................................... pressure and spray 165

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FIRST

Template Name: OM_1_col Template Date: 1994_04_29

Buckets

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SPECIFICATIONS

SPECIFICATIONS

OPERATING WEIGHT ADJUSTMENTS Template Name: OM_1_col Template Date: 1994_04_29

Optional Equipment Item

Pounds

(kg)

Ride Control

200

91

Right Access Steps

121

55

26.5 R 25 XLDD1A TL★

2836

1286

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SPECIFICATIONS

NOTE: All bolt torques are listed with dry threads. * See Wheel Nut Torque in this manual.

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(Nm) 2073 to 2209 658 to 739 1125 to 1274 386 to 434 397 to 447 928 to 1043 41 to 47 47 to 53 62 to 71 149 to 163 285 to 320 108 to 122 664 to 691 813 to 881 54 to 60 45 to 50 156 to 176 101 to 113 386 to 434 786 to 840 20 to 27 20 to 27 612 to 680

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pound-feet 1530 to 1630 485 to 545 830 to 940 285 to 320 293 to 330 685 to 770 30 to 35 35 to 39 46 to 52 110 to 120 210 to 235 80 to 90 490 to 510 600 to 650 40 to 44 33 to 37 115 to 130 75 to 83 285 to 320 580 to 620 15 to 20 15 to 20 450 to 500

Template Name: OM_1_col Template Date: 1994_04_29

Front mounting bolts Trunnion mounting (rear chassis) Transmission mount to transmission Engine support bracket to rear chassis Engine shock mount nuts (20 mm) Transmission shock mount nuts Steering wheel retaining nut Flywheel to flex plate (phosphate treated bolts) Flywheel to flex plate (zinc plated bolts) Carrier bearing bolt Trunnion rear inner plate to axle Rear trunnion bar to cover plate Front steering pin bolt Auxiliary counterweight bolt Transmission to flywheel housing Fan mounting bolts Universal Joints Hydraulic pump to transmission Loader linkage pin keeper 3/4 bolts Cab and canopy mounting bolts Hydraulic tank cover bolt Hydraulic oil filter head to mounting bolt * Wheel nuts

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SPECIAL BOLT TORQUES

SPECIFICATIONS

SPECIAL TOOL Template Name: OM_1_col Template Date: 1994_04_29

A Special T Wrench or Allen Wrench tool is supplied with the machine for various service operations. This Special Tool should be kept in the Operators Manual Compartment for safe keeping.

NOISE LEVEL The levels of airborne noise emitted by the Wheel Loader measured at the operator’s position (LpA) and machine exterior (LwA) do not exceed the following values:

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RD97D091 921B Wheel Loader: LpA .......................................... 79 dB(A) LwA ........................................ 110 dB(A)

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RB97D098

RB97D092

VIBRATION LEVEL The level of vibration emitted by the Wheel Loader and transmitted to the operators seat (posterior) does not exceed 1.25 m/s2 when tested per ISO 7096, Class 3.

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AFTER DELIVERY CHECK (After First 100 Hours of Operation of New Machine) MACHINE: 921B Product Identification Number____________________________________ OWNER: Name ___________________________________________________________ Address____________________________________________________________ DEALER: Name____________________________________________________________ Address____________________________________________________________ FUEL SYSTEM

HYDRAULIC SYSTEM

❑ Check for leaks. ❑ Drain water and sediment from the fuel tank and fuel

❑ Check the oil level. ❑ Check the pressure setting of the loader main relief

filter.

valve.

❑ Check the pressure setting of the steering relief valve and correct operation.

Check operation of starter, alternator, instruments, and warning lamps.

❑ Check condition of all lamps. ❑ Check fluid level of batteries.

GENERAL

❑ Check operation of loader. ❑ Check the operation of the foot and parking brakes. ❑ Service the air cleaner.

COOLING SYSTEM

❑ Check for oil leaks.

❑ Check radiator coolant level. ❑ Check for leaks.

❑ Check for loose parts. ❑ Tighten all hose clamps. ❑ Check condition of the drive belt. ❑ Check wheel nuts for correct torque.

LUBRICATION

❑ Lubricate all pivot points. ❑ Check engine oil level. ❑ Check the transmission oil level.

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ELECTRICAL SYSTEM

SAFETY

ENGINE

❑ Check valves for correct clearance. ❑ Check engine idle speed, full throttle, no load speed, full throttle, full load speed and engine stall speeds.

❑ Inspect the ROPS. Torque mounting bolts. ❑ Check the safety decals and replace if necessary. ❑ Check safety components (seat belt, lamps, backup alarm, etc.)

❑

Make sure the machine has the 921B Operators Manual and in the manual storage box.

DEALER: Learn whether the owner or operator has any problems with the machine.

Make sure the owner or operator understands all the information in this manual.

Technician (signature)___________________________________ Date_________________ Dealer (signature) ______________________________________ Date_________________ Owner (signature) _____________________________________ Date_________________ Owner Copy

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Template Name: OM_1_col Template Date: 1994_04_29

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Date of Check ____________________ Hourmeter Reading ______________________ hours

________________________________________________________________

Template Name: OM_1_col Template Date: 1994_04_29

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Date of Check ____________________ Hourmeter Reading ______________________ hours MACHINE: 921B Product Identification Number____________________________________ OWNER: Name ___________________________________________________________ Address____________________________________________________________ DEALER: Name____________________________________________________________ Address____________________________________________________________ FUEL SYSTEM

HYDRAULIC SYSTEM

❑ Check for leaks. ❑ Drain water and sediment from the fuel tank and fuel

❑ Check the oil level. ❑ Check the pressure setting of the loader main relief

filter.

valve.

❑ Check the pressure setting of the steering relief valve and correct operation.

Check operation of starter, alternator, instruments, and warning lamps.

❑ Check condition of all lamps. ❑ Check fluid level of batteries.

GENERAL

❑ Check operation of loader. ❑ Check the operation of the foot and parking brakes. ❑ Service the air cleaner.

COOLING SYSTEM

❑ Check for oil leaks.

❑ Check radiator coolant level. ❑ Check for leaks.

❑ Check for loose parts. ❑ Tighten all hose clamps. ❑ Check condition of the drive belt. ❑ Check wheel nuts for correct torque.

LUBRICATION

❑ Lubricate all pivot points. ❑ Check engine oil level. ❑ Check the transmission oil level.

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ELECTRICAL SYSTEM

SAFETY

ENGINE

❑ Check valves for correct clearance. ❑ Check engine idle speed, full throttle, no load speed, full throttle, full load speed and engine stall speeds.

❑ Inspect the ROPS. Torque mounting bolts. ❑ Check the safety decals and replace if necessary. ❑ Check safety components (seat belt, lamps, backup alarm, etc.)

❑

Make sure the machine has the 921B Operators Manual and in the manual storage box.

DEALER: Learn whether the owner or operator has any problems with the machine.

Make sure the owner or operator understands all the information in this manual.

Technician (signature)___________________________________ Date_________________ Dealer (signature) ______________________________________ Date_________________ Owner (signature) _____________________________________ Date_________________ Dealer Copy 171

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Template Name: OM_1_col Template Date: 1994_04_29

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AFTER DELIVERY CHECK (After First 100 Hours of Operation of New Machine)

________________________________________________________________

Template Name: OM_1_col Template Date: 1994_04_29

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172

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DETAIL INDEX

B Back-Up Alarm . . . . . . . . . . . . . . . . . . 26, 33 Ballast - Wheel . . . . . . . . . . . . . . . . . . . . . 80 Batteries Cold Weather Operations . . . . . . . . . 76 Battery Cleaning . . . . . . . . . . . . . . . . . . 154 Battery Connection - Booster . . . . . . . . . . 58

C Cab Air Filter . . . . . . . . . . . . . . . . . . . . . 127 Cab Air Filter Cleaning . . . . . . . . . . . . . 127 Cab Air Filter Removal . . . . . . . . . . . . . 127 Cab Headliner . . . . . . . . . . . . . . . . . . . . 131 Cab Service . . . . . . . . . . . . . . . . . . . . . 130 Cab Windows . . . . . . . . . . . . . . . . . . . . . 48 Cap - Air Cleaner . . . . . . . . . . . . . . . . . 102 Changing Machine Direction . . . . . . . . . . 60 Chart - Lubrication . . . . . . . . . . . . . . . . . 88 Chart - Maintenance . . . . . . . . . . . . . . . . 88 Chart - Tire Pressure . . . . . . . . . . . . . . . . 84 Charts Hydraulic System Fluid . . . . . . . . . 113 Chemicals - Hazardous . . . . . . . . . . . . . . 22 Cleaning The Air Filter . . . . . . . . . . . . . 105 Cleaning The Battery . . . . . . . . . . . . . . 154 Cleaning The Cooling System . . . . . . . . 108 Cold Start Button . . . . . . . . . . . . . . . . . . . 32 Cold Weather Operation . . . . . . . . . . . . . 76 Conditioner - Fuel . . . . . . . . . . . . . . . . . 109 Console Controls - Front . . . . . . . . . . . . . 25 Control Accumulator - Loader . . . . . . . . 150

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Battery Fluid Level . . . . . . . . . . . . . . . . 154 Battery Safety . . . . . . . . . . . . . . . . . . . . 153 Battery Service . . . . . . . . . . . . . . . . . . . 153 Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Before Starting The Engine . . . . . . . . . . . 52 Belt - Air Conditioning Compressor . . . . 146 Belt - Alternator . . . . . . . . . . . . . . . . . . . 146 Belt - Fan . . . . . . . . . . . . . . . . . . . . . . . 146 Belt - Seat . . . . . . . . . . . . . . . . . . . . . . . 143 Belt Removal . . . . . . . . . . . . . . . . . . . . . 148 Belt Replacement . . . . . . . . . . . . . . . . . 147 Belt, Seat . . . . . . . . . . . . . . . . . . . . . . . . 50 Belts - Seat . . . . . . . . . . . . . . . . . . . . . . . 53 Bleeding the Brake System . . . . . . . . . . 120 Bolt Torques - Special . . . . . . . . . . . . . . 167 Booster Battery Connection . . . . . . . . . . . 58 Brakes Pedals . . . . . . . . . . . . . . . . . . . . . . . 33 Bucket Height Control Adjustment . . . . . 138 Bucket Height Control Function . . . . . . . . 64 Bucket Level Indicator . . . . . . . . . . . . . . . 65 Bucket Specifications . . . . . . . . . . . . . . 165 Bulb - Lamp . . . . . . . . . . . . . . . . . . . . . 156

Template Name: OM_1_col Template Date: 1994_05_26

A Access Doors . . . . . . . . . . . . . . . . . . . . . . 91 Accumulator - Loader Control . . . . . . . . . 150 Adding Air To The Tires . . . . . . . . . . . . . . 83 Adding Ballast Weight To Machine . . . . . . 80 Adjustment Bucket Height Control . . . . . . . . . . . 138 Height Control - Bucket . . . . . . . . . . 138 Loader . . . . . . . . . . . . . . . . . . . . . . 133 Return-To-Dig . . . . . . . . . . . . . . . . . 133 Return-To-Travel . . . . . . . . . . . . . . 135 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . 102 Air Cleaner Cap . . . . . . . . . . . . . . . . . . . 102 Air Conditioning . . . . . . . . . . . . . . . . . . . 130 Air Conditioning Compressor . . . . . . . . . 130 Air Conditioning Compressor Belt . . . . . . 146 Air Conditioning Condenser . . . . . . . . . . 130 Air Filter - Cab . . . . . . . . . . . . . . . . . . . . 127 Air Filter Cleaning . . . . . . . . . . . . . . . . . 105 Air Filter Cleaning - Cab . . . . . . . . . . . . . 127 Air Filter Primary Element . . . . . . . . . . . 104 Air Filter Secondary Element . . . . . . . . . 104 Air Filter Service Specifications . . . . . . . 102 Air Filter System . . . . . . . . . . . . . . . . . . . 102 Air Louvers . . . . . . . . . . . . . . . . . . . . . . . . 44 Alarm, Back-Up . . . . . . . . . . . . . . . . . . . . 26 Alternator Belt . . . . . . . . . . . . . . . . . . . . 146 Attachment Coupler Connecting Attachments . . . . . . . . . . 67 Control Switch . . . . . . . . . . . . . . . . . 36 Disconnecting Attachments . . . . . . . . 68 Autoshift Switch . . . . . . . . . . . . . . . . . . . . 30 Auxiliary Electrical Service Connection . . 150 Auxiliary Hydraulic Connection . . . . . . . . . 66 Auxiliary Hydraulic System Specifications 66 Axle Oil Change . . . . . . . . . . . . . . . . . . . 126 Axle Oil Level . . . . . . . . . . . . . . . . . . . . . 124 Axle Service Specifications . . . . . . . . . . 124

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DETAIL INDEX

Template Name: OM_1_col Template Date: 1994_05_26

Control Gauges . . . . . . . . . . . . . . . . . . . . 45 Control Levers - Loader . . . . . . . . . . . . . . 61 Controls Hand . . . . . . . . . . . . . . . . . . 25, 29, 32 Coolant Filter - Engine . . . . . . . . . . . . . 107 Coolant Heater - Engine . . . . . . . . . . . . . 57 Coolant Mixture . . . . . . . . . . . . . . . . . . . 106 Cooling System Cold Weather Operations . . . . . . . . . 76 Coupler Attachment Connecting Attachments . . . . . . . . . 67 Control Switch . . . . . . . . . . . . . . . . . 36 Disconnecting Attachments . . . . . . . 68

D

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Danger Areas - Tire . . . . . . . . . . . . . . . . . 82 Decals - Safety . . . . . . . . . . . . . . . . . . . . 15 Decals - Universal . . . . . . . . . . . . . . . . . . 23 Diesel Fuel System . . . . . . . . . . . . . . . . 109 Disabled Machine Towing . . . . . . . . . . . . 73 Disconnect Switch - Master . . . . . . . . . . . 51 Door - Access . . . . . . . . . . . . . . . . . . . . . 91 Door Hinges Maintenance . . . . . . . . . . . 131 Door Latch . . . . . . . . . . . . . . . . . . . . 47, 48 Down Shift Button . . . . . . . . . . . . . . . 26, 30 Down-Shifting The Transmission . . . . . . . 60

E

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Emergency Exit-Cab . . . . . . . . . . . . . . . . 48 Engine Coolant Heater . . . . . . . . . . . . . . 57 Engine Coolant Mixture . . . . . . . . . . . . . 106 Engine Cooling System Specifications . . 106 Engine Data Specifications . . . . . . . . . . 165 Engine Hourmeter . . . . . . . . . . . . . . . . . . 87 Engine Lubrication . . . . . . . . . . . . . . . . . 98 Engine Oil Change . . . . . . . . . . . . . . . . 100 Engine Oil Filter . . . . . . . . . . . . . . . . . . 100 Engine Oil Level . . . . . . . . . . . . . . . . . . . 99 Engine Oil Selection . . . . . . . . . . . . . . . . 98 Engine Oil Viscosity . . . . . . . . . . . . . . . . 98 Engine Service Specification . . . . . . . . . . 99 Engine Speed . . . . . . . . . . . . . . . . . . . . . 55 Environment Protection . . . . . . . . . . . . . . 86 Exit, Cab Emergency . . . . . . . . . . . . . . . . 48 Extinguisher Mounting - Fire . . . . . . . . . 151

Cab Air . . . . . . . . . . . . . . . . . . . . . . 127 Coolant . . . . . . . . . . . . . . . . . . . . . . 107 Engine Coolant . . . . . . . . . . . . . . . . 107 Engine Oil . . . . . . . . . . . . . . . . . . . . 100 Fuel . . . . . . . . . . . . . . . . . . . . . . . . 112 Hydraulic Oil . . . . . . . . . . . . . . . . . . 115 Transmission Oil . . . . . . . . . . . . . . . 122 Filter Replacement - Air . . . . . . . . . . . . . 103 Filter Replacement - Engine Coolant . . . 107 Filter Replacement - Engine Oil . . . . . . . 100 Filter Replacement - Hydraulic Oil . . . . . 115 Filter Replacement - Transmission Oil . . 122 Fire Extinguisher Mounting . . . . . . . . . . . 151 Fire Prevention Information . . . . . . . . . . . 13 First Service Intervals . . . . . . . . . . . . . . . . 53 Fittings Grease 100 Hours . . . . . . . . . . . . . . . . . . . . . 94 1000 Hours . . . . . . . . . . . . . . . . . . . . 95 50 Hours . . . . . . . . . . . . . . . . . . . . . . 93 Flasher Lights . . . . . . . . . . . . . . . . . . . . . 28 Float Function . . . . . . . . . . . . . . . . . . . . . 65 Fluid Level . . . . . . . . . . . . . . . . . . . . . . . 107 Fluid Levels . . . . . . . . . . . . . . . . . . . . . . . 96 Foot Pedals . . . . . . . . . . . . . . . . . . . . . . . 33 Four-Way Flasher Lamp . . . . . . . . . . . 27, 31 Four-Way Flasher Switch . . . . . . . . . . 27, 31 Front Console Controls . . . . . . . . . . . . . . 25 Fuel Conditioner . . . . . . . . . . . . . . . . . . . 109 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . 112 Fuel Storage . . . . . . . . . . . . . . . . . . . . . 110 Fuel System Cold Weather Operations . . . . . . . . . 76 Fuel System Service Specifications . . . . 109 Function Switches . . . . . . . . . . . . . . . . . . 42 Function Switches - Loader . . . . . . . . . . . 63 Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . 155 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

G

F

Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . 45 General Safety . . . . . . . . . . . . . . . . . . . . . 85 Grease Fittings 100 Hours . . . . . . . . . . . . . . . . . . . . . 94 1000 Hours . . . . . . . . . . . . . . . . . . . . 95 50 Hours . . . . . . . . . . . . . . . . . . . . . . 93

Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . 146 Filter Air . . . . . . . . . . . . . . . . . . . . . . . . . 104

Hand Controls . . . . . . . . . . . . . . . . . . . . . 25 Hand Signals . . . . . . . . . . . . . . . . . . . . . . 20

H

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K Key Switch . . . . . . . . . . . . . . . . . . . . . . . . 34

L Lamp Bulb . . . . . . . . . . . . . . . . . . . . . . . 156 Lamps Four-Way Flasher . . . . . . . . . . . . 27, 31 Master Warning . . . . . . . . . . . . . 27, 31 Turn Signal . . . . . . . . . . . . . . . . . 27, 31 Latch - Door . . . . . . . . . . . . . . . . . . . . . . . 47 Latch, Cab Door . . . . . . . . . . . . . . . . . . . . 48 Level Indicator - Bucket . . . . . . . . . . . . . . 65 Lifting Points - Machine . . . . . . . . . . . . . . 79 Lifting The Machine . . . . . . . . . . . . . . . . . 79 Light - Intermittent . . . . . . . . . . . . . . . . . . 69 Link - Safety . . . . . . . . . . . . . . . . . . . . . . . 86 Link - Transport . . . . . . . . . . . . . . . . . . . . 86 Loader Adjustments . . . . . . . . . . . . . . . . 133 Loader Control Accumulator . . . . . . . . . . 150 Loader Control Levers . . . . . . . . . . . . . . . 61 Loader Control Panel . . . . . . . . . . . . . . . . 35 Loader Function Switches . . . . . . . . . . . . 63 Loader Operating Tips . . . . . . . . . . . . . . . 71 Louvers - Air . . . . . . . . . . . . . . . . . . . . . . 44 Low Idle Position Switch . . . . . . . . . . . . . 141 Lubrication - Engine . . . . . . . . . . . . . . . . . 98

N Noise Level . . . . . . . . . . . . . . . . . . . . . . 168

O Official Documents . . . . . . . . . . . . . . . . . . 3 Oil Change - Engine . . . . . . . . . . . . . . . 100 Oil Level Axle . . . . . . . . . . . . . . . . . . . . . . . . 124 Engine . . . . . . . . . . . . . . . . . . . . . . . 99 Hydraulic . . . . . . . . . . . . . . . . . . . . 114 Transmission . . . . . . . . . . . . . . . . . 122 Oil Level - Hydraulic . . . . . . . . . . . . . . . 114 Oil Level - Transmission . . . . . . . . . . . . 122 Oil Selection - Engine . . . . . . . . . . . . . . . 98 Oil Temperature Ranges . . . . . . . . . . . . . 98 Oil Viscosity . . . . . . . . . . . . . . . . . . . . . . 98 Operating Data Specifications . . . . .159, 162 Operating Dimensions Specifications 159,162 Operating In Cold Weather . . . . . . . . . . . 76 Operating In Hot Weather . . . . . . . . . . . . 78 Operating The Machine . . . . . . . . . . . . . . 59 Operating Tips - Loader . . . . . . . . . . . . . 71 Operating Weight Adjustments . . . . . . . 166 Operation - Transmission . . . . . . . . . . . . 60 Operators Seat . . . . . . . . . . . . . . . . 49, 132

P Parking The Machine . . . . . . . . . . . . . . . 56 Pedals, Foot . . . . . . . . . . . . . . . . . . . . . . 33 Plastic/Resin Parts . . . . . . . . . . . . . . . . . 86 Pressure - Tire . . . . . . . . . . . . . . . . . . . . 81 Primary Element - Air Filter . . . . . . . . . . 104 Priming The Turbocharger . . . . . . . . . . . . 55 Product Identification Number . . . . . . . . . . 5

R Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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M Machine Components . . . . . . . . . . . . . . . . 7 Machine Direction - Changing . . . . . . . . . 60 Machine Lifting Points . . . . . . . . . . . . . . . 79 Machine Operation . . . . . . . . . . . . . . . . . 59 Machine Storage Removal . . . . . . . . . . 158 Machine Tie Down Locations . . . . . . . . . . 75 Maintenance Chart . . . . . . . . . . . . . . . . . 88 Master Disconnect Switch . . . . . . . . . . . . 51 Master Warning Lamp . . . . . . . . . . . . 27, 31

Template Name: OM_1_col Template Date: 1994_05_26

I Identification Numbers . . . . . . . . . . . . . . . . 5 Instructions - General Safety . . . . . . . . . . 85 Instrument Cluster . . . . . . . . . . . . . . . . . . 39 Instrument Panel . . . . . . . . . . . . . . . . . . . 39 Intermittent Light . . . . . . . . . . . . . . . . . . . 69

Lubrication Analysis - Systemgard . 92, 101 Lubrication Chart . . . . . . . . . . . . . . . . . . . 88

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Hazardous Chemicals . . . . . . . . . . . . . . . 22 Heater - Engine Coolant . . . . . . . . . . . . . . 57 Height Control Adjustment - Bucket . . . . 138 High Beam Indicator Light . . . . . . . . . . . . 28 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . 27, 31 Hot Weather Operation . . . . . . . . . . . . . . 78 Hourmeter - Engine . . . . . . . . . . . . . . . . . 87 Hydraulic Connection - Auxiliary . . . . . . . . 66 Hydraulic Filter Test . . . . . . . . . . . . . . . . 115 Hydraulic Oil Change . . . . . . . . . . . . . . . 117 Hydraulic Oil Filter . . . . . . . . . . . . . . . . . 115 Hydraulic Oil Level . . . . . . . . . . . . . . . . . 114 Hydraulic System Cold Weather Operations . . . . . . . . . 76 Fluid Chart . . . . . . . . . . . . . . . . . . . 113 Hydraulic System Service Specifications 113

Template Name: OM_1_col Template Date: 1994_05_26

Remove From Storage . . . . . . . . . . . . . 158 Removing Water From The Fuel System 111 Replacement Bulb . . . . . . . . . . . . . . . . . 156 Reservoir - Windshield Washer . . . . . . . 129 Return-To-Dig Adjustment . . . . . . . . . . . 133 Return-To-Dig Function . . . . . . . . . . . . . . 63 Return-To-Travel Adjustment . . . . . . . . 135 Return-To-Travel Function . . . . . . . . . . . 64 Ride Control . . . . . . . . . . . . . . . . . . . . . . 38 Roll-Over Protective Structure . . . . . . . . 143 ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . 143 ROPS Cab Torque Specifications . . . . . 143 ROPS Damage Information . . . . . . . . . . 144 Run-In Procedure . . . . . . . . . . . . . . . . . . 52

S

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Safety Before Operation . . . . . . . . . . . . . . . 10 Burn Prevention . . . . . . . . . . . . . . . . 13 Machine Operation . . . . . . . . . . . . . . 11 Maintenance . . . . . . . . . . . . . . . . . . 12 Parking the Machine . . . . . . . . . . . . 11 Safety Rules . . . . . . . . . . . . . . . . . . . 9 Safety - Battery . . . . . . . . . . . . . . . . . . . 153 Safety Decals . . . . . . . . . . . . . . . . . . . . . 15 Safety Instructions - General . . . . . . . . . . 85 Safety Link - Service . . . . . . . . . . . . . . . . 86 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . 9 Seat - Operators . . . . . . . . . . . . . . . . . . 132 Seat Belt . . . . . . . . . . . . . . . . . . . . . 50, 143 Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . 53 Seat Torque Specifications . . . . . . . . . . 145 Seat, Operators . . . . . . . . . . . . . . . . . . . . 49 Secondary Element - Air Filter . . . . . . . . 104 Sediment Removal - Fuel System . . . . . 111 Serial Numbers . . . . . . . . . . . . . . . . . . . . . 5 Service Electrical Connection . . . . . . . . 150 Service Intervals - First . . . . . . . . . . . . . . 53 Service Safety Link . . . . . . . . . . . . . . . . . 86 Special Bolt Torques . . . . . . . . . . . . . . . 167 Special Tool . . . . . . . . . . . . . . . . . . . . . 168 Specifications Air Filter . . . . . . . . . . . . . . . . . . . . . 102 Auxiliary Hydraulic System . . . . . . . . 66 Axle . . . . . . . . . . . . . . . . . . . . . . . . 124 Bucket . . . . . . . . . . . . . . . . . . . . . . 165 Cooling System - Engine . . . . . . . . 106 Diesel Fuel System . . . . . . . . . . . . 109

Engine Cooling System . . . . . . . . . . 106 Engine Data . . . . . . . . . . . . . . . . . . 165 Engine Service . . . . . . . . . . . . . . . . . 99 Fuel System . . . . . . . . . . . . . . . . . . 109 Hydraulic System . . . . . . . . . . . . . . 113 Machine . . . . . . . . . . . . . . . . . 159, 162 Noise Level . . . . . . . . . . . . . . . . . . . 168 ROPS Torque . . . . . . . . . . . . . . . . . 143 Seat Torque . . . . . . . . . . . . . . . . . . 145 Special Bolt Torques . . . . . . . . . . . . 167 Thermostat . . . . . . . . . . . . . . . . . . . 106 Transmission . . . . . . . . . . . . . . . . . 121 Travel Speed . . . . . . . . . . . . . . . . . 165 Vibration Level . . . . . . . . . . . . . . . . 168 Weight Adjustments . . . . . . . . . . . . 166 Starting The Engine . . . . . . . . . . . . . . . . . 54 Steering Secondary . . . . . . . . . . . . . . . . . . . . 56 Steering Wheel Tilt Control . . . . . . . . . 27, 31 Steering, Secondary . . . . . . . . . . . . . . . . 152 Stopping The Engine . . . . . . . . . . . . . . . . 56 Storage - Fuel . . . . . . . . . . . . . . . . . . . . 110 Storage Removal - Machine . . . . . . . . . . 158 Switch - Master Disconnect . . . . . . . . . . . 51 Switch, Autoshift . . . . . . . . . . . . . . . . . . . 30 Switch, Low Idle Position . . . . . . . . . . . . 141 Switches Four-Way Flasher . . . . . . . . . . . . 27, 31 Switches - Function . . . . . . . . . . . . . . . . . 42 Systemgard Analysis . . . . . . . . . . . . 92, 101

T Thermostat Specifications . . . . . . . . . . . 106 Throttle, Foot . . . . . . . . . . . . . . . . . . . . . . 33 Tire Danger Areas . . . . . . . . . . . . . . . . . . 82 Tire Or Rim Service . . . . . . . . . . . . . . . . . 83 Tire Pressure . . . . . . . . . . . . . . . . . . . . . . 81 Tire Pressure Chart . . . . . . . . . . . . . . . . . 84 Tire Tread Direction . . . . . . . . . . . . . . . . . 83 To The Owner . . . . . . . . . . . . . . . . . . . . . . 2 Tool - Special . . . . . . . . . . . . . . . . . . . . . 168 Torque - Wheel Nut . . . . . . . . . . . . . . . . . 84 Towing The Machine . . . . . . . . . . . . . . . . 73 Transmission Control Lever . . . . . . . . . . . . . . . 26, 30 Transmission Breather Cleaning . . . . . . . 122 Transmission Oil Filter . . . . . . . . . . . . . . 122 Transmission Oil Level . . . . . . . . . . . . . . 122

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U Universal Decals . . . . . . . . . . . . . . . . . . . 23 Up-Shifting The Transmission . . . . . . . . . 60

V Vibration Level . . . . . . . . . . . . . . . . . . . . 168

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W Water Removal - Fuel System . . . . . . . . 111 Weight Adjustments - Operating . . . . . . . 166 Wheel And Tires . . . . . . . . . . . . . . . . . . . 81 Wheel Ballast . . . . . . . . . . . . . . . . . . . . . . 80 Wheel Nut Torque . . . . . . . . . . . . . . . . . . 84 Windows Cab . . . . . . . . . . . . . . . . . . . . . . 48 Windshield Washer Reservoir . . . . . . . . 129 Windshield Wiper Controls . . . . . . . . . . . . 47 Wiper Controls - Windshield . . . . . . . . . . . 47

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Transmission Oil Level Check . . . . . . . . 122 Transmission Operation . . . . . . . . . . . . . . 60 Transmission Service Specifications . . . 121 Transport Link . . . . . . . . . . . . . . . . . . . . . 86 Transporting The Machine . . . . . . . . . . . . 74 Transporting The Machine On A Trailer . . 75 Travel Speeds . . . . . . . . . . . . . . . . . . . . 165 Turbocharger Priming . . . . . . . . . . . . . . . . 55 Turn Signal Control Lever . . . . . . . . . . . . 28 Turn Signal Lever . . . . . . . . . . . . . . . . . . . 31

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