Case 921C Wheel Loader Operators Manual 6-36690NA - PDF DOWNLOAD

921 C Wheel Loader

Operators Manual P.I.N. JEE0155001 and After

Bur 6-36690NA

TABLE OF CONTENTS 1 3 3 4 6

SAFETY/DECALS/HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 UTILITY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 BEFORE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 BURN PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 FIRE OR EXPLOSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 WHEELS AND TIRES SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 HAZARDOUS CHEMICALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 INFORMATIONAL DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 INSTRUMENT/CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 FRONT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 - 34 INSTRUMENT PANEL INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . 35 - 48 INFORMATION CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 - 54 GAUGE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 - 61 TRANSMISSION DISPLAY CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . 62 - 64 FOOT PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 LOADER CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 SIDE CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 - 84 MASTER DISCONNECT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 OPERATORS SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 STOPPING THE ENGINE AND PARKING THE MACHINE . . . . . . . . . . . . . 99 MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 LOADER CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 LOADER FUNCTION SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 DECLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 I

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

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

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

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

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

TABLE OF CONTENTS RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

TOWING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

116 117 117 118 118 119 120 122 123 125 127

WHEELS/TIRES/BALLAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 BALLAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

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

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

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

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

ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

GREASE FITTINGS - 250 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

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

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

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

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133 133 134 135 135 135 136 137 138 139 140 141 142 142 143 143 144 147 152 156 159 162 169 172 175

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

ETHER CONTAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

DECLUTCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

ALTERNATOR BELT AND AIR CONDITIONING COMPRESSOR BELT .

FIRE EXTINGUISHER MOUNTING (If Equipped) . . . . . . . . . . . . . . . . . . .

179 179 180 183 184 186 187 189 197 199 200 203

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

AUXILIARY POWER EQUIPMENT MOUNTING BRACKET LOCATION .

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

205 205 207 207 208 208 209

MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 ENGINE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 OPERATING DATA AND DIMENSIONS 921C . . . . . . . . . . . . . . . . . . . . . 215 Machines with 3.63 m3 (4.75 yd3) General Purpose Bucket with Teeth and Bolt on Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 Machines with 3.82 m3(5.0 yd3) General Purpose Bucket . . . . . . . . . . . . . 217 OPERATING DATA AND DIMENSIONS 921C XR . . . . . . . . . . . . . . . . . . 218 XR Machines with 3.63 m3 (4.75 yd3) General Purpose Bucket . . . . . . . . 218 XR Machines with 3.63 m3 (4.75 yd3) General Purpose Bucket with Teeth and Bolt on Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 XR Machines with 3.82 m3 (5.0 yd3) General Purpose Bucket . . . . . . . . . 220 OPERATING WEIGHT ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 221 SPECIAL BOLT TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 AFTER DELIVERY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 AFTER DELIVERY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

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TABLE OF CONTENTS

TABLE OF CONTENTS

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TO THE OWNER

BD02B018

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

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

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

DO NOT operate or permit anyone to operate or service this machine until you or the other persons have rea d a nd understan d the safety, ope ra tio n a nd maintenance instructions in this manual. Use only trained operators who have demonstrated the ability to operate and service this machine correctly and safely.

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

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TO THE OWNER DO NOT use this machine for any application or purpose other than those described in this manual. If the loader is to be used in a application that involves special attachments or equipment, such as forestry, etc., consult an authorized dealer or the Case, LLC. Consult an authorized dealer or Case, LLC. on changes, additions or modifications that can be required for this machine to comply with various country regulations and safety requirements. Unauthorized modifications will c au se se riou s inju ry o r d e ath . An yon e mak in g suc h u n au tho rize d modifications is responsible for the consequences.

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

Call your dealer if you need any assistance or information.

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

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

1

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

RD98K305

1. OPERATORS MANUAL STORAGE COMPARTMENT

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TO THE OWNER

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

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

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

FRONT

REAR

LEFT SIDE B891464J

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

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

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

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

Product Identification Number (P.I.N.)

RB97D048 RD97F168

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Engine

Loader Bucket

RD97F151

RP95K195

ROPS Cab and Canopy TRIM THIS EDGE

Transmission

B4030791

RD98K304

Axle

BD02B043

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MACHINE COMPONENTS 2 5

3

8 9

4 6

1 1 10 TRIM THIS EDGE

7 7 BD02B019

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

ENGINE ACCESS DOORS ROPS CAB BUCKET CYLINDER STANDARD BUCKET LOADER CONTROLS CAB AIR FILTERS STEPS HAND RAILS REAR ACCESS DOOR REAR COUNTERWEIGHT

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1 2 1

4

9 8 4

3

6

5

BD02B018

1.

2.

3.

4.

5.

6.

7.

8.

9.

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

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NOTES

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

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

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

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

RD98K305

1. OPERATORS MANUAL STORAGE BOX

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

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

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

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

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SAFETY/DECALS/HAND SIGNALS

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

Electrical Power LIne

●

Gas Line

●

Water Line

●

Communication LIne - Telephone or Cable Television

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Before beginning any trenching, drilling or other construction work it is your responsibility to be aware of all such utility lines buried in the area of your project and to avoid them.

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

RH99G001

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU TRENCH/DRILL

Know the utility color code (U.S.A. and Canada): 1. Electric .................................... Red 2. Gas, Oil or Petroleum ..........Yellow 3. Communication, Telephone, Television ........................... Orange 4. Water ......................................Blue 5. Sewer .......................Green/Brown 6. Proposed Excavation............White 7. Surveying................................ Pink 8. Reclaimed Water and Slurry....................................... Purple

In U.S.A. and Canada call one of many “One Call System Directory” services. If you do not know the local number, call t h e n a t io n a l n u m b e r ( U . S .A . a n d Canada only): 1-888-258-0808.

Check with local authorities for laws, reg ulatio ns a nd/o r strict p ena lties re q u irin g y o u to lo ca t e a nd av o id existing utilities.

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

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SAFETY/DECALS/HAND SIGNALS

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

●

Be prepared for emergencies.

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

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

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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.

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

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

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

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

●

Operate controls only when seated in the Operators seat.

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

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

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

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

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Sound horn to alert persons in the work area.

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BEFORE OPERATION

SAFETY/DECALS/HAND SIGNALS

MACHINE OPERATION ●

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

●

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

●

A frequent cause of personal injury or death is persons falling off and being run over. 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.

●

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●

●

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

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

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

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

●

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

●

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

●

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

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

●

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

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

●

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

●

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

PARKING THE MACHINE ●

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

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SAFETY/DECALS/HAND SIGNALS

MAINTENANCE ●

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

●

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

●

Unauthorized modifications to this machine can cause injury or death.

Do not make unauthorized modifications to this machine.

●

●

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

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

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

●

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

●

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

●

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

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B901248J

●

SAFETY/DECALS/HAND SIGNALS

BURN PREVENTION ●

Battery acid causes severe burns.

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

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

●

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

●

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

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FIRE OR EXPLOSION PREVENTION ●

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

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

●

Use nonflammable cleaning solvent to clean parts.

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

●

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

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

1. When disconnecting the battery cables, disconnect the negative (-) cable first; when connecting the ba tter y cab le s, con nect th e negative (-) cable last.

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

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●

A fire can cause injury or death.

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

●

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

●

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

●

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

●

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

●

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

●

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

●

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

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

SB134

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

84-113

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SAFETY/DECALS/HAND SIGNALS

SAFETY/DECALS/HAND SIGNALS

HAZARDOUS CHEMICALS

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●

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

●

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

●

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

MSDS are available from your dealer.

●

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

●

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

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

●

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

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

Follow this information when servicing the machine.

R412

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SAFETY/DECALS/HAND SIGNALS

INFORMATIONAL DECALS Decals which display the “Read Op era to rs Man ual” symbo l a re intended to direct the operator to the Op era to rs Ma nua l fo r furth er information regarding maintenance, adjustments and/or procedures for particular areas of the Wheel Loader.

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

237187A1

“READ OPERATORS MANUAL”

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

SC002

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

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

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

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SAFETY DECALS

SAFETY/DECALS/HAND SIGNALS

2

2

3

1

1

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3

BD00B007/382622A1/364742A1/329051A

3.EMERGENCY EXIT

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SAFETY/DECALS/HAND SIGNALS

4

4

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4

RD98K298 / RD98K275 / 323694A1

5

5

RD98K323 / 3217030

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SAFETY/DECALS/HAND SIGNALS

6

6

TRIM THIS EDGE

RD98K297 / 329047A1

7

7

RD98K324 / 328754A1

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SAFETY/DECALS/HAND SIGNALS

8

RD98K294 / 329049A1

9 9

BD02B048 / 328752A1

21

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TRIM THIS EDGE

8

SAFETY/DECALS/HAND SIGNALS

10

10

TRIM THIS EDGE BD02B052/ 332512A1

11 11

BD02B027 / 334456A1

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SAFETY/DECALS/HAND SIGNALS

12

12

TRIM THIS EDGE

BD02B049 / 329044A1

13

13

13

BD02B075/BD02B0050/ 335889A1

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SAFETY/DECALS/HAND SIGNALS

14

14

15

15

TRIM THIS EDGE

BD02B047 / RB97D043 / 328904A1

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SAFETY/DECALS/HAND SIGNALS

16

RP98N349 / BD02B026 / 335886A1

17

17

MACHINE TIE DOWN RD98K288 / 94F25

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16

SAFETY/DECALS/HAND SIGNALS

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

BI97D059

BI97D025

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START ENGINE

STOP ENGINE

BP97D022

BP97D023

COME TO ME

ALL STOP AND HOLD

Move hands forward and rearward (palms in)

Move hands forward and rearward (palms out).

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SAFETY/DECALS/HAND SIGNALS

BP97D030

BP97D060

ALL STOP AND HOLD

TRIM THIS EDGE

GO THIS FAR

BI97D029

BI97D021

STOP

EMERGENCY STOP

Move one hand back and forth.

BI97D027

LOWER BLADE

BI97D028

RAISE BLADE

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SAFETY/DECALS/HAND SIGNALS

BI97D020

BI97D026

RAISE BLADE SLOWLY

LOWER BLADE SLOWLY

TRIM THIS EDGE BI97D034

BI97D033

TURN MACHINE LEFT SWING LOAD LEFT

TURN MACHINE RIGHT SWING LOAD RIGHT

To stop movement, stop moving hand and make a fist

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

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INSTRUMENT/CONTROLS FRONT CONSOLE 2

4

3

BD02B020

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

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

BC00B087

BC00B048

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

3. ENGINE STOP LAMP: The stop lamp provides critical operator messages. These messages require immediate and decisive operator responses.

BC02B174

4. ENGINE WARNING/MAINTENANCE LAMP: The w arning /main ten ance lamp provides important o perator messages. These messages require timely operator attention. The warning lamp is also used to delineate diagnostics fault codes.

BCO2B175

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1

INSTRUMENTS/CONTROLS

FRONT CONSOLE 5

6

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BD02B020

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

BC00B085

BS98M034

BC00B101

BS98M034

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

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INSTRUMENTS/CONTROLS

FRONT CONSOLE

8

RD98K322

RD98K321

7. 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 p ut th e transmission in FO RWA RD, NEUTRAL and REVERSE.

8. COLD START BUTTON (IF EQUIPPED): The cold start system puts ether into the engine intake each time the button is pushed and released. This system operates only when the key switch is in the position and the engine is cold (see Cold weather starting and ether Cold starting in this manual for the correct starting procedure).

A

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

B

C. Move the control lever to ward you for REVERSE.

C BS00B351

NOTE: If equipped, the F-N-R function of the Transmission Control Lever may be moved to the Loader Control Lever for operating efficiency. See pages 67 or 70 of this manual.

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7

INSTRUMENTS/CONTROLS

FRONT CONSOLE

10 9 11 RD97F213

RD98K311

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

10. HORN: Push the horn button to actuate the horn.

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

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INSTRUMENTS/CONTROLS

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

12

Push down on the bottom of the parking brake switch, hold pressure on the b rake ped als and pu t th e transmission control lever either in FO RWA RD or R E V E RS E t o DISENGAGE the parking brake.

RD98K313

12. PARKING BRAKE SWITCH:

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

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

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

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INSTRUMENTS/CONTROLS

FRONT CONSOLE

13 RB99J178

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

START POSITION Turn the key to this position to engage the starter motor to start the engine. The RB99J176 switch is spring loaded and will re tu rn to the O N position when released.

RD98K312

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

318764A

13. Key Switch The key switch has four positions:

RB98M031

ACCESSORY POSITION This position will energize the optional radio only. It will n ot en erg ize th e instruments or start th e engine.

OFF POSITION All switch controlled current is OFF. Turn the k e y to O FF to s to p t h e RB99J175 engine. Remove the key and turn the Master Disconnect Switch to OFF.

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INSTRUMENTS/CONTROLS

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

TRIM THIS EDGE

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

2

1

1

BD02B020

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

BS96H049

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

BC00B082

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INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS

4

5

6

3

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BD02B020

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

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

BC00B048

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

BC00B110

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

6. BRAKE PRESSURE INDICATOR: This indicator illuminates when the brake system pressure is too low. The alarm sounds continuously and the stop master indicator will be red.

BC00B108

NOTE: Stop the machine and correct the problem.

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INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS

BD02B020

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

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

BC00B290

Display

Description

Corrective Action

ENGINE OIL PRESSURE

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

BRAKE PRESSURE

Low Brake Pressure

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

Low Steering Pressure.

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

STEERING PRESSURE (W/ AUX STEERING)

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7

INSTRUMENTS/CONTROLS

COOLANT LEVEL

Low Coolant Level.

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

COOLANT TEMPERATURE

High Engine Coolant Temperature.

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

HYDRAULIC OIL TEMPERATURE

High Hydraulic Oil Temperature.

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

TRANSMISSION OIL TEMPERATURE

High Transmission Oil Temperature.

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

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INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS

BD02B020

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

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

BC00B291

Display PARKING BRAKE

Description

Corrective Action

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

COOLANT TEMPERATURE

High engine coolant temperature

1. Idle machine and monitor temperature.

2. Clean radiator.

3. If condition persists, contact your dealer.

HYDRAULIC TEMPERATURE

High hydraulic temperature

1.Idle machine and monitor temperature.

2. Clean cooler.

3. If condition persists, contact your dealer.

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8

INSTRUMENTS/CONTROLS

TRANSMISSION TEMPERATURE

AIR CONDITIONING

AIR FILTER

TRANSMISSION FILTER HYDRAULIC FILTER ALTERNATOR

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FUEL

High transmission temperature

1. Idle machine and monitor temperature.

2. Clean the cooler.

3. Use a lower gear.

4. If condition persists, contact your dealer.

High or Low air conditioning pressure.

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

3. Servicing required.

4. If condition persists, contact your dealer.

High air filter restriction

1. Clean air filter.

2. Replace primary and secondary filters.

3. If condition persists, contact your dealer.

Transmission filter restriction.

1. Replace transmission filter.

2. If condition persists, contact your dealer.

Hydraulic filter restriction.

1. Replace hydraulic filter.

2. If condition persists, contact your dealer.

Alternator malfunction.

1. Check electrical system.

2. Voltages are out of range.

3. Change operating procedure.

4. If condition persists, contact your dealer.

Low fuel.

1. Fill fuel tank within the next hour.

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INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS

10

11

BD02B020

9. SECONDARY STEERING INDICATOR (IF EQUIPPED):

BS00B111

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

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

10. PARKING BRAKE INDICATOR:

BS96H049

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

11. AIR CONDITIONING INDICATOR:

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

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

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9

INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS

12

13 14

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BD02B020

12. HYDRAULIC OIL FILTER INDICATOR:

BC00B113

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

13. AIR FILTER INDICATOR:

BS98M026

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

14. TRANSMISSION OIL FILTER INDICATOR

BS99J182

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

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INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS

BD02B020

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

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

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

TRANSMISSION OIL TEMPERATURE GAUGE Gauge Indication

Condition

Master Indicator

Gauge Status

Alarm Status

20°C and below (68°F and below)

Oil temperature is very low

20 to 120°C (68 to 248°F)

Oil temperature is normal

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

Caution (Yellow)

Flashes

3 Seconds

125°C and above (257°F and above)

Stop (Red)

Flashes

Continuous

Oil temperature is very high

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

Correct the problem before continuing to operate the machine 43

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15

INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS

16 TRIM THIS EDGE

BD02B020

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

HYDRAULIC OIL TEMPERATURE GAUGE Gauge Indication

Condition

Master Indicator

Gauge Status

Alarm Status

20°C and below (68°F and below)

Hydraulic oil temperature is very low

20 to 105°C (68 to 221°F)

Hydraulic oil temperature is normal

105 to 110°C (221 to 230°F)

Hydraulic oil temperature is high

Caution (Yellow)

Flashes

3 Seconds

110°C and above (230°F and above)

Hydraulic oil temperature very high

Stop (Red)

Flashes

Continuous

NOTE: Stop the machine and correct the problem.

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INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS

BD02B020

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

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

VOLTMETER GAUGE Gauge Indication 0 to 18 Volts

18 to 24 Volts

Engine Speed Condition of Charging System

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

Stopped or low idle Above low idle

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

Alarm Status 3 Seconds

Flashes

3 Seconds

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

24 to 26 Volts

Gauge Status Flashes

Above low idle

Problem system

in

charging

Normal battery charge Problem system

in

charging

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

NOTE: Stop the machine and correct the problem.

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INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS

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18 BD02B020

18. FUEL LEVEL GAUGE: The Fuel Level Gauge indicates the fuel level. The fuel level is shown on the gauge with indicator bars. Normal operating range is in the green zone. When the tank is almost empty the bars move into the BS98M034 yellow zone and begin to flash, the warning alarm sounds for three seconds, and the caution master indicator turns yellow.

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

FUEL LEVEL GAUGE Gauge Indication

Condition

Master Indicator

Gauge Status

Alarm Status

5 percent and below

Fuel level low

Caution (Yellow)

Flashes

3 Seconds

5 percent and above

Fuel level normal

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INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS

BD02B020

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

ENGINE OIL PRESSURE GAUGE Gauge Indication

Condition

Master Indicator

Gauge Status

Alarm Status

0 to 70 kPa (0 to 10 psi)

Very low (too low to run engine)

Stop (Red)

Flashes

Continuous

70 to 110 kPa (10 to 16 psi)

Low (above low idle)

110 kPa and above (16 psi and above)

Normal (above low idle)

NOTE: Stop the engine immediately and correct the problem.

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19

INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS

20 TRIM THIS EDGE

BD02B020

20. ENGINE COOLANT TEMPERATURE GAUGE: The Engine Coolant Temperature gauge indicates the coolant temperature of the engine. The engine coolant temperature is shown with indicator bars. Normal BS98H053 op erating te mpera tu re is in th e gre en z one . Wh en th e en gine coo lan t temperature increases the bars move into the yellow zone and begin to flash, the warning alarm sounds for three seconds. The caution master indicator turns yellow. When the temperature continues to increase the bars move into the red zone and continue to flash and the warning alarm sounds continuously. The stop master indicator turns red. The machine MUST NOT be operated when the temperature is in the red zone.

ENGINE COOLANT TEMPERATURE GAUGE Gauge Indication

Condition

20°C and below (68°F and below)

Coolant temperature is very low

20 to 105°C (68 to 221°F)

Coolant temperature is normal

105 to 110°C (221 to 230°F)

Coolant temperature is high

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

Master Indicator

Gauge Status

Alarm Status

Caution (Yellow)

Flashes

3 Seconds

Stop (Red)

Flashes

Continuous

NOTE: Stop the engine immediately and correct the problem.

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INSTRUMENTS/CONTROLS

INFORMATION CENTER

A

B

C

D

BD02B020

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

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

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

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

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

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

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

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

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INSTRUMENTS/CONTROLS

INFORMATION CENTER

A

B

C

D

1 TRIM THIS EDGE

BD02B020

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

TRA NSM ISSIO N O IL TEMPER ATU RE - D ispla ys t he tra ns mission o il temperature in Celsius with the transmission oil temperature bar graph flashing.

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

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

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

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

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

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

NOTE: The program/reset (C, D) switch is a three position rocker switch. The center position is OFF or NEUTRAL. 50

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INSTRUMENTS/CONTROLS

INFORMATION CENTER

A

B

C

D

BD02B020

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

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

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

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

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

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

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INSTRUMENTS/CONTROLS

INFORMATION CENTER

A

B

C

D

1

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BD02B020

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

To view the service hour interval locations: ●

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

●

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

●

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

●

Read the accumulated hours shown on the Display Center.

To reset the service interval hours: ●

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

●

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

●

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

●

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

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INSTRUMENTS/CONTROLS

INFORMATION CENTER

A

B

C

D

BD02B020

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

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

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

●

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

●

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

●

Read any fault codes on the Display Center.

●

Press the program (C) switch again.

●

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

●

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

●

Read the hours at which the previous code occurred.

The hour location will always follow the fault code location.

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INSTRUMENTS/CONTROLS

INFORMATION CENTER

A

B

C

D

1

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BD02B020

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

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

Press the program (C) switch.

●

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

●

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

●

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

●

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

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INSTRUMENTS/CONTROLS

GAUGE DISPLAY

B

2

C

D

BD02B020

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

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

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

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

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

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

NOTE: 05 is the setting from the factory.

06- (If Equipped) Automatically scrolls through Hourmeter (at startup) and Speedometer (km/h) in gear.

07- (If Equipped) Automatically scrolls through Hourmeter (at startup) and Speedometer (mph) in gear.

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A

INSTRUMENTS/CONTROLS

GAUGE DISPLAY

A

B

2

C

D

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BD02B020

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

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

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

●

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

●

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

●

Read the number (01-05 or 01-07) shown on the Display Center. If this is the Gauge Display you want, press the reset (D) switch (right side of the program/reset (C, D) switch) momentarily and you are done.

●

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

●

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

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INSTRUMENTS/CONTROLS

GAUGE DISPLAY

B

2

C

D

BD02B020

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

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

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

●

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

●

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

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

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

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A

INSTRUMENTS/CONTROLS

GAUGE DISPLAY

A

B

2

C

D

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BD02B020

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

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

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INSTRUMENTS/CONTROLS

GAUGE DISPLAY

B

2

C

D

BD02B020

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

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

●

Press the up count (A) switch until the display reads the function of your choice (000 - 099).

●

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

You will now see the function you’ve chosen.

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

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

●

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

●

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

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

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

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INSTRUMENTS/CONTROLS

GAUGE DISPLAY

A

B

2

C

D

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BD02B020

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

Press the program (C) switch.

●

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

●

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

●

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

●

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

●

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

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

●

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

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INSTRUMENTS/CONTROLS

GAUGE DISPLAY

B

2

C

D

BD02B020

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

Press the program (C) switch.

●

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

●

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

●

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

●

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

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A

INSTRUMENTS/CONTROLS

TRANSMISSION DISPLAY CENTER B A

C D

E

RD97F206

A. F - N - R B. DISPLAY CENTER

C. GEAR D. BAR

E. AUTOMATIC MODE

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

N - Flashing set control lever to neutral position.

R - Flashing reverse not engaged.

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

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

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

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INSTRUMENTS/CONTROLS

TRANSMISSION DISPLAY CENTER

B

C

D

BD02B020

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

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

Programming Minimum Gear Selection ●

Press the program (C) switch.

●

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

●

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

●

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

●

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

●

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

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A

INSTRUMENTS/CONTROLS

TRANSMISSION DISPLAY CENTER

A

B

C

D

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BD02B020

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

Programming Maximum Gear Selection ●

Press the program (C) switch.

●

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

●

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

●

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

●

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

●

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

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INSTRUMENTS/CONTROLS

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

1

3 2 RD97F194

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

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

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BD02B055

3. DECLUTCH SWITCH

INSTRUMENTS/CONTROLS

LOADER CONTROL LEVERS Two Spool - One Lever G

B

H

1

E

A I

2 3

1 C F

D

TRIM THIS EDGE

BC01E131/BS00B353

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

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

D. RAISE E. DUMP F. ROLLBACK 2. KICKDOWN BUTTON (DOWNSHIFT TRANSMISSION) 3. FNR SWITCH G. FORWARD (Transmission) H. NEUTRAL (Transmission) I. REVERSE (Transmission)

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INSTRUMENTS/CONTROLS

AUXILIARY F-N-R SWITCH FOR JOYSTICK CONTROL LEVERS B

A

C 3

1

BC01E131

1. AUXILIARY F-N-R SWITCH A. FORWARD B. NEUTRAL C. REVERSE

The Auxiliary F-N-R Switch will be DEACTIVATED and F-N-R control will d e f a u lt b a c k to th e Tr a n s m is si o n Control Lever if:

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

2. The engine must be running.

1. The engine is stopped.

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

2. The parking brake is applied.

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

NOTE: See Transmission Operation/ Initial Machine Movement for moving the machine after engine start up.

2

RD98K322

4. The Transmission Control Lever (2) must be in neutral.

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BD01E113

When steps 1 through 4 have been met the Auxiliary F-N-R Switch may be enabled by pushing down on the top of the switch (3). The indicator light on the bottom of the switch will illuminate.

INSTRUMENTS/CONTROLS

Two Spool - Two Levers E

D

5 4

F

5 G A 4 C B BC01E133/BS00B354

4. BUCKET CONTROL A. DUMP

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B. ROLLBACK C. HOLD: The bucket will not move when the control lever is in the HOLD position. When released, the control lever will automatically return to the HOLD position.

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

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

G. RAISE

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INSTRUMENTS/CONTROLS

Two Spool - Two Levers (Continued) 6 A B C

BC01E133

6. Kickdown Button (Downshift Transmission) 7. FNR Switch A. Forward (Transmission) B. Neutral (Transmission) C. Reverse (Transmission)

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7

INSTRUMENTS/CONTROLS

AUXILIARY F-N-R SWITCH FOR TWO SPOOL-TWO LEVER AND THREE SPOOL-THREE LEVER VALVES A

B

3 1

C BD01E113

When steps 1 through 4 have been met the Auxiliary F-N-R Switch may be enabled by pushing down on the top of the switch (3). The indicator light on the bottom of the switch will illuminate.

BC01E133

1. AUXILIARY F-N-R SWITCH A. FORWARD

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B. NEUTRAL C. REVERSE

The Auxiliary F-N-R Switch will be DEACTIVATED and F-N-R control will d e f a u lt b a c k to th e Tr a n s m is si o n Control Lever if:

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

1. The engine is stopped.

2. The engine must be running.

2. The parking brake is applied.

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

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

NOTE: See Transmission Operation/ Initial Machine Movement for moving the machine after engine start up.

2

RD98K322

4. The Transmission Control Lever (2) must be in neutral.

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INSTRUMENTS/CONTROLS

Three Spool - Two Levers E 8

D

9

A I

G

9 C

8

F

H BC01E130/BS00B355

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

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

E. LOWER F. RAISE 9. AUXILIARY CONTROL (IF EQUIPPED) IMPORTANT: If your machine is equipped with an auxiliary attachment, write the function of the control lever positions next to the letters below.

G. ______________________________________ H. ______________________________________ I. HOLD: There will not be any auxiliary function with the control lever in this position. When released, the control lever will automatically return to the HOLD position.

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B

INSTRUMENTS/CONTROLS

Three Spool - Two Levers (continued) A

B

10

11

C

10 11

BC01E130/BC01E131

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10. KICKDOWN BUTTON (Downshift Transmission) 11. F-N-R SWITCH A. FORWARD (Transmission) B. NEUTRAL (Transmission) C. REVERSE (Transmission) NOTE: See page 69 of this manual for the correct procedure to enable the F-N-R function for the loader control lever.

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INSTRUMENTS/CONTROLS

Three Spool - Three Levers A H

D 12 E

13

C

14

F

12 14

J I

B

G BC01E132/376629A1

12. BUCKET CONTROL B. ROLLBACK C. HOLD: The bucket will not move when the control lever is in the HOLD position. When released, the control lever will automatically return to the HOLD position.

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

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

G. RAISE 14. AUXILIARY CONTROL (IF EQUIPPED) IMPORTANT: If your machine is equipped with an auxiliary attachment, write the function of the control lever positions next to the letters below.

H. ______________________________________ I. ______________________________________ J. HOLD: There will not be any auxiliary function with the control lever in this position. When released, the control lever will automatically return to the HOLD position.

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A. DUMP

INSTRUMENTS/CONTROLS

Three Spool - Three Levers (continued) 15

A B C

16

BC01E132

TRIM THIS EDGE

15. Kickdown Button (Downshift Transmission.

16. FNR Switch A. Forward (Transmission)

C. Reverse (Transmission)

B. Neutral (Transmission) NOTE: See page 70 of this manual for the correct procedures to enable the F-N-R function on the side panel.

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INSTRUMENTS/CONTROLS

Four Spool - Two Levers E 17

18

A

D

I

K

G

18

17 J H F BC01E130/BS00B357

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

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

E. LOWER F. RAISE 18. AUXILIARY CONTROL (IF EQUIPPED) IMPORTANT: If your machine is equipped with an auxiliary attachment, write the function of the control lever positions next to the letters below.

G. ________________________________________ H. ________________________________________ I. ________________________________________ J. ________________________________________ K. HOLD: There will not be any auxiliary function with the control lever in this position. When released, the control lever will automatically return to the HOLD position.

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B

C

INSTRUMENTS/CONTROLS

Four Spool - Two Levers (continued) A

B

19

20

C

19 20

BC01E130/BC01E131

TRIM THIS EDGE

19. KICKDOWN BUTTON (Downshift Transmission) 20. F-N-R SWITCH A. FORWARD (Transmission) B. NEUTRAL (Transmission) C. REVERSE (Transmission) NOTE: See page 67 of this manual for the correct procedure to enable the F-N-R function on the Loader Control Lever.

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INSTRUMENTS/CONTROLS

SIDE CONSOLE

BD02B021

1. F-N-R ENABLE SWITCH This switch activates the F-N-R function enabling the operator to control the direction of the transmission from the F-N-R switch on either the Side Panel or the Loader Control Lever rather than the Transmission Control Lever.

To activate the F-N-R function all of the following conditions must be met: A. The machine must NOT be moving.

B. The engine must be running.

C. The Transmission Control Lever and the F-N-R switch both have to be in the NEUTRAL position.

D. The parking brake must be released.

If all of these conditions are met, the F-N-R function can be enabled by pushing down on the top of the F-N-R enable switch. The indicator light on the bottom of the F-N-R enable switch will illuminate when the F-N-R function is activated.

NOTE: If the engine is stopped, the parking brake applied or the transmission control lever is taken out of neutral the F-N-R function will deactivate and control of the transmission will revert back to the transmission control lever.

NOTE: See Auxiliary F-N-R Switch and Transmission Operation/Initial Machine Movement.

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1

INSTRUMENTS/CONTROLS

SIDE CONSOLE 4 2

5 3

TRIM THIS EDGE

BD02B016

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

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

BC00B128

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

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

BC00B127

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

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INSTRUMENTS/CONTROLS

SIDE CONSOLE

BD02B016

6. WIPER/WASHER SWITCH (IF EQUIPPED): Th e w ip e r / w a s h e r s w it c h h a s f iv e positions.

D C

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

B

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

A

E BC00B131

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

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

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6

INSTRUMENTS/CONTROLS

SIDE CONSOLE

7

TRIM THIS EDGE

BD02B016

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

E

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

D

C.DRIVE - Turn the switch to this p ositio n to illumina te th e co ns ole lamps, driving lamps, marker lamps and tail lamps.

C B

A BC00B133

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

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

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INSTRUMENTS/CONTROLS

SIDE CONSOLE 10

11

9

BD02B016

BS98M034

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

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

BC00B098

9. DECLUTCH SWITCH: The declutch disengages the transmission when maximum power is needed for the loader (the foot pressure required to disengage the transmission is adjustable, see Declutch Adjustment on page 184 of this manual). Push down on the top of the declutch switch and push on either brake pedal to operate the machine with the declutch.

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

BC00B097

BC00B086

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

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

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8

INSTRUMENTS/CONTROLS

SIDE CONSOLE

12

13

14 TRIM THIS EDGE

BD02B016

BC00B081

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

operation).

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

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

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

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

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INSTRUMENTS/CONTROLS

SIDE CONSOLE

BD02B016

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

BS98M034

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15

INSTRUMENTS/CONTROLS

SIDE CONSOLE

16

17

TRIM THIS EDGE

BD02B016

BC00B099

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

17. ENGINE ECONOMY SWITCH: Push the top of the switch to have the engine to the economy mode. The switch lamp will illuminate when in the economy mode. Depending on working conditions and operator use of the machine, fuel economy can be realized in this mode.

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INSTRUMENTS/CONTROLS

MASTER DISCONNECT SWITCH ON - This position en ergizes th e entire electrical system. When t h e m a s t e r D is c o n n e c t BS00A203 switch is ON and the key switch is OFF, the following electrical components have power: dome lamp, horn, stop lamps, four-way flashers and the rotary light switch.

1

OFF - This position disconnects all power to the machine.

BD02B030 BS00A017

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

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BS00A018

1. MASTER DISCONNECT SWITCH The Ma ste r Disco n ne ct Switch has two positions: ON and OFF.

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INSTRUMENTS/CONTROLS

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

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

2

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

3

BD00B005

2. KNOB- LOOSEN AND SLIDE KNOB AS REQUIRED TO OPEN OR CLOSE LOUVERS 3. RECIRCULATION LOUVERS (BEHIND FILTER)

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

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

1

RD98K303

1. MAIN LOUVERS

1

RD98K323

1. MAIN LOUVERS

1

RD97F194

1. MAIN LOUVERS

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INSTRUMENTS/CONTROLS

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

If a fogging condition occurs make sure the recirculation air louvers are CLOSED. If equipped with Air Conditioning, turn the Air Conditioning ON and turn the Heat Control completely clockwise.

1

1

RD97F194

RD98K323

1. DEFROST LOUVERS

1. DEFROST LOUVERS

Radio (If Equipped) 1

RD98K303

1. DEFROST LOUVERS RD97F215

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

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1

INSTRUMENTS/CONTROLS

Door Latch 1

RD97F218

1. PUSH TO OPEN DOOR

Window Latch TRIM THIS EDGE

The window can be kept partially open by lifting the Hold Latch and sliding it back on the Latch Pin until the Hold Latch locks in the Latch Pin. The window may be opened and locked against the side of the cab. To do this pull the hold latch toward the rear of the cab when the window is partially open.

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

1

To release the window from the full op en po sition , pu ll on the w in do w release in the right hand rear corner of the cab.

RD98K301

1. LIFT TO OPEN

Window Retainer Latch 1 2 1 RD98K302

1. LATCH PIN 2. HOLD LATCH

RD97F173

1. PULL TO RELEASE WINDOW

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INSTRUMENTS/CONTROLS

OPERATORS SEAT Standard Seat

4

1 2

5

2

6

4. SLIDE ADJUSTMENT LEVER: Pull this lever up and adjust the seat fo r w a r d o r r e a r w a r d a s r e q u ir e d .

Release the lever to lock the seat in position.

1. LUMBAR ADJUSTMENT KNOB: Turn the knob clockwise to increase the lu mb ar sup port, tu rn the kno b co un ter clo ckw ise to d ec re ase th e lumbar support.

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

Tu r n the knob co un ter clo ck wise to d ec re ase th e weight resistance.

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

NOTE: Each armrest will pivot to the up position.

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

3

RD98K266

3. RECLINER ADJUSTMENT HANDLE: Lift up on the handle, move the b a c k r e s t t o t h e d e s ir e d p o s i ti o n , release the handle to lock the backrest in position.

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RD98K266

RD98K267

INSTRUMENTS/CONTROLS

Optional Air Ride Seat

1 2

5

2 4

RD98K267

RD98K268

TRIM THIS EDGE

1. LUMBAR ADJUSTMENT KNOB: Turn the knob clockwise to increase the lu mbar sup port, tu rn the kno b co un ter clo ck wise to d ec re ase th e lumbar support.

4. SLIDE ADJUSTMENT LEVER: Pull this lever up and adjust the seat fo r w a r d o r r e a r w a r d a s r e q u ir e d .

Release the lever to lock the seat in position.

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

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

NOTE: Each armrest will pivot to the up position.

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

Lift the handle UP and release.

T h e s e a t w i ll a u to m a t i c a l ly adjust UP and then bleed off air pr ess ur e to the o ptimu m air pressure for the weight of the operator.

3

RD98K268

3. RECLINER ADJUSTMENT HANDLE: Lift up on the handle, move the b a c k r e s t t o t h e d e s ir e d p o s i ti o n , release the handle to lock the backrest in position.

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INSTRUMENTS/CONTROLS B. (Manual Adjustment): The seat can b e raised o r low ered by increasing or decreasing the air pressure in the seat. Lift the handle UP to increase the air press ure. Pus h the handle DO WN to decreas e the air pressure and lower the seat.

5

8

6 7 RD98K268

6. SEAT DEPTH HANDLE: Lift handle up and move the cushion to th e de sir ed p o sitio n. Re le as e th e handle to lock the cushion in position.

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

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BD00B010

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

INSTRUMENTS/CONTROLS

SEAT BELT

RD97F225

RD97F225

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

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

TRIM THIS EDGE

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

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

M437

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

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

3. Replace all parts that have damage or wear.

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

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

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

7. Keep seat belts clean and dry.

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

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

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INSTRUMENTS/CONTROLS

Emergency Exit

1

1

2

RD98K301

1. PIN 2. LATCH

BD02B046

1. EMERGENCY EXIT

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Lift and pull the latch out of the pin.

Push the Right hand window open.

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INSTRUMENTS/CONTROLS

NOTES

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OPERATING INSTRUCTIONS BEFORE STARTING THE ENGINE 2. See the Maintenance Chart in this manual and do the items in the 10 Hour section.

1. Do a daily walk around, visual inspection of the machine. Check for such items as hoses rubbing a ga in st o th e r co mp o n e nt s, o il leaks, debris or trash buildup, loose bolts, damaged, or missing parts that would effect the normal and safe operation of th e machine.

Make any necessary corrections before operating the machine.

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

CM112

RUN-IN PROCEDURE 2. Operate the machine with normal loads as much as possible.

It is impo rta nt that the ru n-in in s tr u c t io n s f o r a n e w e n g in e b e followed. Proper run-in will increase engine power and service life. If the engine is not run-in properly, the piston rings and cylinder bore c an be damaged.

3. Monitor the engine instruments frequently dur ing operation.

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

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

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

OPERATING INSTRUCTIONS

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

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

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

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

SA121

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OPERATING INSTRUCTIONS

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

SC037

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

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

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

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

6. After the engine starts, check the in s t r u me n ts t o m a k e s u r e th e indications are correct. Run the engine at approximately 1200 RPM with the transmission in neutral un til the e ngine co olant temperature is warm.

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

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

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

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

OPERATING INSTRUCTIONS

Priming the Turbocharger Lines with Oil

Engine Speed Do not operate the engine at idle speed for long periods. This can cause a low operating temperature. A low operating te mpe ra tu re ca n ca us e acid s a n d deposits in the engine oil.

BD02B031

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

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

3. Connect the wire to the injection pump solenoid.

fuel

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OPERATING INSTRUCTIONS

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

SA038

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

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.

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

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

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

2. Lower the loader to the ground.

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

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

OPERATING INSTRUCTIONS

Ether Cold Start (If Equipped) WARNING: Starting fluid (ether) can cause injury or death. An explosion can result if sparks, flame, or extreme heat contact the ether in the starting fluid container. Do not breathe starting fluid vapors. Wear face protection when you remove or install a starting fluid container. Use starting fluid according to instructions in this manual.

SB039

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

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

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

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

2. If you weld, grind or use a cutting to r c h o n th e ma ch i n e , a lw a y s remove the starting fluid container from the machine.

Use compre ssed air to remove a ny ether fumes from the area.

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

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

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

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

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

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

8. Always read the instructions on the ether container.

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OPERATING INSTRUCTIONS

Starting the Engine The ether cold start injects a measured amount of ether into the engine during cold weather starting.

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

2. Turn the key switch to the ON position.

RD98K321

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

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

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

Turn the key to the START position.

When the engine starts, quickly mov e th e th ro ttle to 1 /3 to 1 /2 throttle to prevent damage to the engine. If the engine does not start a f te r t w o a t te m p t s , c h e c k th e supply of ether in the container.

OPERATING INSTRUCTIONS

Engine Coolant Heater

4. Install the heater assembly.

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.

5. Refill engine coolant to proper level.

1

2 TRIM THIS EDGE

BD02B078

1. CORD 2. HEATER ASSEMBLY BD02B079

The heater is installed in the heater housing on the front left side of the engine. Do the following to install the heater: 1. When engine is cool remove some coolant from the engine.

2. Remove the cover plate from the block.

3. Reuse the mounting hardware and metal gasket from the cover plate.

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OPERATING INSTRUCTIONS

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

SA006

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

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

1. Open the side door.

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

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

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

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

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

8. Have the other person disconnect the jumper cables in the reverse order that the jumper cables were connected in.

9. Close the side door.

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

5. Connect the positive (+) jumper cable to the positive (+) battery terminals on the jumper batteries or the other machine. Connect the other end to the positive jumper stud.

1

BD02B030

1. CONNECT POSITIVE JUMPER CABLE HERE

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M146B

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

OPERATING INSTRUCTIONS

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

SA040

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

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

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

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3. Fasten and adjust the seat belt.

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

5. Check the loader controls for correct operation.

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

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

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

D. Raise the loader bucket above the ground.

E. Shift the transmission into first gear forward.

F. Take your foot off the brake pedal.

G. Increase the engine speed to 1/2 throttle. The machine must not move. If the machine moves, see the service manual or see your authorized dealer and correct th e problem. Wh en th e parking b rake is applied, th e transmission is automatically shifted into Neutral.

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

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

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

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

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

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

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

I. Raise the loader bucket above the ground.

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

L. Shift the transmission to the NEUTRAL position.

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

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

CM112

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

M142A

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

M122B

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

SB013

8. Release the parking brake.

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

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

B. Raise the loader bucket just above the ground.

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

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

D. Shift the transmission into 2nd gear forward.

E. Release the parking brake.

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

G. Reset the parking brake.

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

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

The transmission can be operated in Automatic or manual mode.

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

Initial Machine Movement 1. Hold the foot brake on.

2. Cycle the transmission control lever through forward, reverse and neutral.

3. Release the parking brake by pressing the bottom of the parking brake switch.

4. Shift the transmission control lever into forward or reverse.

5. Release the foot brake.

6. Depress the foot throttle and the machine will move.

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

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

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OPERATING INSTRUCTIONS

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

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

Automatic Mode Operation

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

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

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

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

OPERATING INSTRUCTIONS

LOADER CONTROL LEVERS Two Spool Valve - Two Control Levers NOTE: This page shows the basic loader control lever positions. The Detent Switch is in the OFF position.

3 1 5 5

See Loader Function Switches in this manual for RETURN-TO-DIG, BU C KE T H EIG H T CO N TR O L a n d R E T U R N - T O - T R AV E L / F L O AT switches.

4

2

BC01E133

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1

3

2

4

B1119A88J

1. DUMP

2. ROLLBACK

3. LOWER

4. RAISE

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

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OPERATING INSTRUCTIONS

Two Spool Valve - One Control Lever 1

5

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

4

3

See Loader Function Switches in this manual for RETURN-TO-DIG, BU C KET H EIG H T CO N TR O L a n d R E T U R N - T O - T R AV E L / F L O AT switches.

2

1

3

2

4

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BC01E131

B1119A88J

1. DUMP

2. ROLLBACK

3. LOWER

4. RAISE

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

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OPERATING INSTRUCTIONS

Three Spool Valve - Three Control Levers NOTE: This page shows the basic loader control lever positions. The Detent Switch for the loader functions is in the OFF position.

5 3 1 7 7 7

See Loader Function Switches in this manual for RETURN-TO-DIG, BU C KE T H EIG H T CO N TR O L a n d R E T U R N - T O - T R AV E L / F L O AT switches.

6

4

2

BC01E132

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1

4

2

5

3

6

BS00C008

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

3. DUMP 4. ROLLBACK

5. LOWER 6. RAISE

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

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OPERATING INSTRUCTIONS

Three Spool Valve - Two Control Levers 3

1 4

2 7

5

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

7 6

See Loader Function Switches in this manual for RETURN-TO-DIG, BU C KET H EIG H T CO N TR O L a n d R E T U R N - T O - T R AV E L / F L O AT switches.

1

4

2

5

3

6

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BC01E130

B1120A88J

1. DUMP 2. ROLLBACK

3. LOWER 4. RAISE

5. CLAM OPEN 6. CLAM CLOSED

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

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OPERATING INSTRUCTIONS

Four Spool Valve - Two Control Levers 3

1 4

2 9

5

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

9 6

See Next Page for RETURN-TO-DIG, BU C KE T H EIG H T CO N TR O L a n d R E T U R N - T O - T R AV E L / F L O AT switches.

4

BC01E130

1 TRIM THIS EDGE

B1121A88J

B1238A88J

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

5

2

6 7 B1239A88J

8

3 9 HOLD: The loader arms, bucket,

B1239A88J

and auxiliary attachment will not move when the control levers are in HOLD. When released, the control levers will return to HOLD automatically.

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OPERATING INSTRUCTIONS

LOADER FUNCTION SWITCHES Push down on the top of the detent switch to engage all detents. Push on th e b o tt o m o f sw i tc h fo r t h e O FF position.

1

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

2

BD02B029

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

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

1 2 1

BC01E131

BC01E133

1. FLOAT AND ROLLBACK DETENT

1. FLOAT 2. ROLLBACK DETENT

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

B1125A88J

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Return-To-Dig

OPERATING INSTRUCTIONS

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

1

1

BC01E131

BC01E133

1. RAISE

1. RAISE

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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-ToTravel function.

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

1 1 2

BC01E133

1. ROLLBACK DETENT 2. FLOAT

BC01E1312

1. FLOAT AND ROLLBACK DETENT

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

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OPERATING INSTRUCTIONS

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

B1128A88J

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

1

1

BC01E133

BC01E131

1. FLOAT

1. FLOAT

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OPERATING INSTRUCTIONS

DECLUTCH The Declutch function is used to allow the en gine to inc rea se s pe ed an d supply the loader with more hydraulic oil for greater loader power and faster control function. When the declutch switch is in the ON position, and you push down on the brake pedal, the transmission is disengaged from the drive wheels. Release the brake pedal to engage the transmission power. The machine can roll free wh en th e declutch switch is pushed. If required, use the brake to stop the machine. The Declutch Switch is adjustable. See Declutch Adjustment on page 184 of this manual.

1

BD02B029

1. DECLUTCH SWITCH

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

Ride Control will reduce Fore and Aft pitching motion during travel to allow faster speeds in load and carry applications for increased BC00B094 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.

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

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

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

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

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OPERATING INSTRUCTIONS

BUCKET LEVEL INDICATOR The bottom of the bucket is parallel with th e gr o un d w he n th e ma rk o n th e bucket linkage is even with the mark on the cylinder rod eye.

B4065588T

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.

BD02B028

FAR1048

Auxiliary Hydraulic System Specifications 921C Wheel Loader Maximum System Pressure ................................................... 2 850 PSI (196 bar) Maximum Capacity at 2 100 Engine RPM .............................................. 106 GPM (401 L/Min) IMPORTANT: Exceeding the Auxiliary Hydraulic System specifications can result in overheating and damaging the hydraulic system.

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AUXILIARY HYDRAULIC CONNECTION (IF EQUIPPED)

OPERATING INSTRUCTIONS

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

BD02B029

BRAKE ACCUMULATORS TRIM THIS EDGE

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

Tw o h y d r a u l i c a c c u m u l a t o r s a r e connected in the brake system. The pu rpo se o f the accu mulato rs is to provide the brake modulating valve with a positive supply of pres surized hydraulic fluid.

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

Periodically test the accumulators for correct operation.

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

1. Start the engine.

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

3. Stop the engine.

If you can complete six (6) full brake applications after the indicator lamp illu mina te s, the a cc um ula to rs ar e w o r k in g c o r r e c tl y. I f y o u c a n n o t complete six (6) applications, see the Service Manual for this machine or see your dealer.

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OPERATING INSTRUCTIONS

COUPLER PIN ENGAGEMENT (IF EQUIPPED) To connect an attachment, position the front coupler into the attachment, push and hold on the top of the COUPLER switch to RETRACT th e PINS an d release the switch (PINS ENGAGED).

Make s ure the Coupler Pins are engaged before you use the machine.

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Use the factory/field installed coupler system to change attachments quickly.

A co ntr ol sw itch for the sys tem is located on the RH console.

BD02B017

BC00B099

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

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

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

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

M781

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OPERATING INSTRUCTIONS

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

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

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

163L96

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

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

164L96

163L96

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

M465

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OPERATING INSTRUCTIONS

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

165L96

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

Operating on a Hill Before you operate this machine on a hill, always put the transmission in a lower range and test the brakes. DO NOT let the machine move down a hill with the transmission in NEUTRAL. The transmission is in NEUTRAL when the left brake pedal is pushed down and the left side of the declutch switch is pushed down.

Loader Control The loader control levers are connected to a hydraulic accumulator through a pressure reducing valve. The purpose of the reducing valve and accumulator combination is to: (1) allow the operator to lower the loader arms if the engine stops with the loader arms raised, or (2) give the control system hydraulic pressure assistance when op e ra tin g the ma ch in e at lo w id le s p e e d . To t e s t a c c u m u l a t o r performance, perform steps 1 through 5.

2. Raise the loader bucket.

3. Stop the engine.

4. Turn the key to RUN. 5. Move the lift arm control to LOWER. The loader bucket must lower to the ground. If the bucket does not lower to the ground, see the Service Manual for this machine or see your dealer.

1. Start the engine.

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SA041

OPERATING INSTRUCTIONS

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

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

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

1. Attach a rigid drawbar to a pin in the rear counterweight.

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

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

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B. Remove the Parking brake cover (1).

1

C. Loosen the lock nut (2).

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

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

2

3 300372A1

BD02B048

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OPERATING INSTRUCTIONS

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

SB042

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

46-76C

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

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

84-13A

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

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

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

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

3. Lower the loader bucket onto the trailer.

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

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

10. Put a cover over the exhaust pipe.

11. Rotate the beacon to the TR ANSPO RT po siti on. Se e beacon in this manual.

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

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

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

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

OPERATING INSTRUCTIONS

Transporting the Machine on a Trailer Machine Tie Down Locations

BD00B013

CHAINS MUST BE SECURELY FASTENED TO THE TIE DOWN SLOT.

BK00D002

CHAINS MUST BE SECURELY FASTENED AROUND LOADER FRAME.

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1

2

2 BD00B012

BD00B014

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

CHAINS MUST BE SECURELY FASTENED TO THE TIE DOWN SLOT.

FAR1069

CHAINS MUST BE SECURELY FASTENED.

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OPERATING INSTRUCTIONS

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

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

In spect the batte ry ca bles an d terminals. Clean the terminals and apply electrical terminal sealers (see your dealer) to prevent corrosion.

If you add water to the batteries and the temperature is below 32°F (0°C), make sure you charge the ba tte rie s or r un th e en gine for approximately two (2) hours. This pr oc ed ur e will p re ve nt ba tte ry freezing (see Batteries and Booster Battery C onnections in this manual.

In spect the batte ry ca bles an d 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 o il in e a c h c o m p o n e n t f o r t h e ambient temperatures the machine is operated in (see Lubrication in this manual).

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

Check for water in the fuel system.

C o ld te mp e r a t u r e s c a n c a u s e condensation to form in the fuel tank. Check the first stage fuel filter fo r water. If no water is fou nd, extend the interval (see Diesel Fuel System in this manual).

4. COOLING SYSTEM - Check the coolant mixture before you operate in cold temperatures. A mixture of 5 0 % e th y le n e g lyc o l a n d 5 0 % water must be used in this machine. This mixture is used if the lo wes t a mbient temp era ture is above -34°F (-37°C). If the ambient temperature is lower, adjust the mixture. It is recommended that ethylene glycol and water be used in y o u r ma c hin e a ll y e a r (S e e Eng in e C ooling S ystem in this manual).

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

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

OPERATING INSTRUCTIONS When the m achine has been correctly warmed up, apply the foot bra ke an d ho ld, sh ift th e transmission to forward push the park brake to the Off position and release the foot brake. Operate the ma c h in e in a c le a r s a f e a r e a .

Check th e full operation o f the machin e. D O NOT op erate th e machine in third or fourth gear until the transmission oil and axle oil have been warmed u p and th e machine moves freely.

6. MACHINE WARM-UP - Once the engine has started, run the engine at half thro ttle (1 10 0 to 1 30 0 RPM) for a minimum of 10 minutes under no load. This will help warm the h ydra ulic oil a nd th e transmission oil.

TRIM THIS EDGE

After engine warm-up, enable the pilot controls by pushing down on the right hand side of the switch on the instrument control panel. Apply and hold the foot brake, and cycle all hy dr au lic fu n ction s se ve ra l time s . In s e ve re co ld w e a th e r conditions, the hydraulic functions may be slow to respond. Cycling all th e hydraulic system fu nctions seve ral times will war m th e hyd raulic o il and the h ydra ulic system components.

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

The hydraulic steering can become slow in seve re cold wea th er conditions. Cycle the steering from full right to left a minimum of 3 to 5 times b efore you d rive th e machine.

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

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

The u se o f correct oi l in th e hydraulic/brake system is required.

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

7. If the machine has been left idling in cold temperature, the engine will stay warm. But the hydraulic/brake oil and the axle oil will not stay warm. The oil and components can become cold and slow brake fun ctio n res po n se tim e. If this s h o u ld h a p p e n y o u M U S T g o throu gh the complete ma chin e warm-up procedure.

8. The transmission is equipped with internal protection that does not allow the transmission to engage be low -12°C (10°F). If th e tra nsmission d oe s no t e ng ag e below these temperatures, allow 2 to 4 minutes of running in neutral (this time will vary with temperature), then try again.

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OPERATING INSTRUCTIONS

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

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

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

5. Check the condition of the drive belts.

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

6. Use lubricants viscosity.

of

the

correct

7. Check battery fluid levels monthly.

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

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OPERATING INSTRUCTIONS

NOTES

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

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

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

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

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

84-113

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

SB134

129

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TRIM THIS EDGE

SD020

WHEELS/TIRES/BALLAST

TRIM THIS EDGE B910410J

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

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WHEELS/TIRES/BALLAST

Adding Air to the Tires

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

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

Tire or Rim Service Always have a qualified tire mechanic se rvice th e tire s a n d r ims fo r this machine. It is recommended that you have this mechanic inflate the tires. To prevent accidents, use a restraining device (tire inflation cage), correct equipment, and correct procedure.

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

Tire Tread Direction

B790490R

When the tire is installed on the wheel ma k e su r e th e t ire tre a d is in th e direction shown.

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

3. Stand BEHIND the tread of the tire and make sure ALL persons are a wa y f ro m th e sid e o f th e tir e before you start to add air.

FORWARD

B770164R

B4039288T

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

WHEELS/TIRES/BALLAST

Wheel Nut Torque 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.

24

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

B910920J

Tire Pressure Chart TRIM THIS EDGE

TIRE

PLY

TREAD

TIRE PRESSURE

SIZE

RATING

TYPE

kPa

(PSI)

(bar)

26.5 X 25

F&R

20

L2

345

50

3.4

26.5 X 25

F&R

20

L3

345

50

3.4

26.5 X 25

F&R

20

L4

380

55

3.8

26.5 X 25

FRONT

20

L5

380

55

3.8

REAR

20

L5

276

40

2.8

26.5 R 25

FRONT

XHA TL*

414

60

4.1

REAR

XHA TL*

207

30

2.1

26.5 R 25

FRONT

XRD IA

414

60

4.1

REAR

XRD IA

207

30

2.1

750/65R25

FRONT

XLD L3

414

60

4.1

REAR

XLD L3

207

30

2.1

FRONT

VMT L3

414

60

4.1

REAR

VMT L3

310

45

3.1

26.5 R 25

NOTE: * For correct mounting of the Michelin radial tires, lubricate the tire beads with tire mounting lubricant. Inflate to 552 Kpa, (80 psi), (5.5 bar). After the tire beads are correctly seated, decrease the tire pressure to the correct pressure shown above.

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

SC021

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

SA044

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

TRIM THIS EDGE

Read the safety decals and information d ec a ls on th e ma c h ine . R ea d th e operators manual and safety manual.

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

B770996R

B801147T

Before you service the machine, put a Do Not Operate tag on the instrument pa nel. On e Do Not Opera te tag is included with your machine. Additional tags are available from your dealer.

B901248J

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LUBRICATION/FILTERS/FLUIDS

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

TRIM THIS EDGE B830752T

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LUBRICATION/FILTERS/FLUIDS

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

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

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

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

BK00D003

BK00D004

LOCKED POSITION

OPERATING POSITION

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

After servicing and before you move the machine, return the Transport/ S e r v i c e l i n k i n t h e O P E R AT I N G position.

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

LUBRICATION/FILTERS/FLUIDS

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

TRIM THIS EDGE

RD97F198

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

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LUBRICATION/FILTERS/FLUIDS

FLUIDS AND LUBRICANTS Engine Crankcase Oil Capacity - with filter change .............................................. 36.9 litres (39 U.S. Quarts) Specifications ............................................ See Engine Lubrication in this manual Cooling System Capacity ........................................................................ 57 litres (60 U.S. Quarts) Specifications .............................................. 50% water and 50% Ethylene Glycol Fuel Tank Capacity ................................................................... 394 litres (104 U.S. Gallons) Specifications ...........................................See Diesel Fuel System in this manual

Transmission Refill Capacity - with filter change ...............................27.4 litres (29 U.S. Quarts) Total System Capacity ...................................................46 litres (49 U.S. Quarts) Specifications ...........................................Case No. 1 Engine Oil (SAE 15W - 40) Axles Front Axle Capacity .............................................47.3 litres (50.0 U.S. Quarts) Rear Axle Capacity .................................................53 litres (56.0 U.S. Quarts) Specifications .............................. Case MS1317 Transaxle Fluid (SAE 80W-140) Grease Fittings Quantity..............................................................................................As Required Specifications ............................................................. Case Molydisulfide Grease

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Hydraulic/Brake System Reservoir Refill Capacity............................................121 litres (128 U.S. Quarts) Total System Capacity ...............................................242 litres (256 U.S. Quarts) Specification................................................................. MS-1209, Hy-Tran Ultra

LUBRICATION/FILTERS/FLUIDS

LUBRICATION/MAINTENANCE CHART 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

TRIM THIS EDGE

152 Air Cleaner (See Note 1)

❉

163 Hydraulic Filter (See Note 2)

❉

170 Transmission Filter (See Note 5)

❉

200 Alternator Drive Belt

10

201 Air Conditioning Compressor Belt Tension (If Equipped)

10

149 Engine Oil Level (See Note 3)

10

157 Deaeration Coolant Level (See Note 4)

50

170 Transmission Oil Level (engine running oil warm)

50

170 Hydraulic Reservoir Fluid Level

50

C L E A N

L U B R I C A T E

142 Rear Axle Trunnion Pivots

2

50

142 Bucket Pivots

3

50

142 Front Drive Shaft Support Bearing

D R A I N W A T E R

50

142 Steering Cylinder Pivots - Closed End

2

100

142 Steering Cylinder Pivots - Rod End

2

100

142 Loader Lift Arm and Cylinder Pivots

10

100

NOTE NOTE NOTE NOTE NOTE

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

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

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

4:Check the deaeration coolant level if the cooling level warning lamp illuminates.

5:Service transmission filter if transmission filter restriction warning lamp illuminates or 1000 hours whichever comes first. ❉ - As Needed

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LUBRICATION/FILTERS/FLUIDS

LUBRICATION/MAINTENANCE CHART N‘ O .

O F

P A G E

SERVICE POINTS

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

143 Center Drive Shaft Slip Joint

1

250

143 Rear Drive Shaft Slip Joint

1

250

150 Engine Oil (See Note 3)

D R A I N C L E A N

W A T E R

500

150 Engine Oil Filter

500

200 Alternator Drive Belt Tension

250

201 Air Conditioning Compressor Belt Tension (If Equipped)

250

206 Battery Fluid Level (See Note 2)

2

500

129 Tire Condition and Air Pressure

4

250

175 Cab Air Filter (If Equipped)

TRIM THIS EDGE

N O .

P O I N T S

FREQUENCY IN HOURS

250

157 Engine Cooling System Filter (See Note 1)

250

161 Fuel Filter

250

10

161 Fuel Tank

500

197 ROPS and Seat Belt Mounting Bolts

500

164 Hydraulic Filters

1000

170 Transmission Oil

1000

170 Transmission Breather

1000

143 Upper and Lower Chassis Pivots

2

172 Front Axle Differential and Planetary Oil

1000 1000

NOTE 1:Use Case Filter.

NOTE 2:In High Temperature conditions, check every 250 hours.

NOTE 3:Reduce to 250 hours or less if Case No. 1 Engine Oil is not used.

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LUBRICATION/FILTERS/FLUIDS

LUBRICATION/MAINTENANCE CHART 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

174 Rear Axle Differential Oil and Planetary Oil

C H A N G E

R E P L A C E

A D J U S T

C L E A N

1000

SM Turbocharger Mounting Bolt Torque

2000

165 Hydraulic Oil (See Note 3)

2000

158 Engine Coolant (See Note 1)

2000

153 Air Filter Elements

2000

TRIM THIS EDGE

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 Case coolant filter.

NOTE 2:Contact your dealer.

NOTE 3:Or when ambient operating temperatures require.

SM - See Service Manual.

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LUBRICATION/FILTERS/FLUIDS

ACCESS DOORS

BD02B036

TRIM THIS EDGE

BD02B034

BD02B035

141

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LUBRICATION/FILTERS/FLUIDS

GREASE FITTINGS - 50 HOURS Use Case Molydisulfide Grease

1

2

1

2

3

1 B910922J

TRIM THIS EDGE

1. Bucket pivot points ....................................................................................... 3 2. Rear axle trunnion (remote fitting) .............................................................................. 2 3. Front drive shaft support bearing .................................................................. 1

GREASE FITTINGS - 100 HOURS Use Case Molydisulfide Grease

2

3

3

1

2

1

2

3

3

3 B910922J

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

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LUBRICATION/FILTERS/FLUIDS

GREASE FITTINGS - 250 HOURS Use Case Molydisulfide Grease

1 BS02B177

1. Center drive shaft slip joint ........................................................................... 1 2. Rear drive shaft slip joint .............................................................................................. 1

GREASE FITTINGS - 1000 HOURS Use Case Molydisulfide Grease

1

1 BS02B177

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

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TRIM THIS EDGE

2

LUBRICATION/FILTERS/FLUIDS

FLUID LEVELS 10 Hours 1

2

BD02B030

RD98K317

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

2. RADIATOR COOLANT LEVEL ETHYLENE GLYCOL AND WATER

2 TRIM THIS EDGE

3

1 B910922J

3

1 BD02B063

DEAERATION TANK 1. SIGHT GLASS

Whenever the hood is opened to p e r f o r m m a in t e n a n c e , c h e c k t h e coolant level in the deaeration tank.

BD02B049 3. DEAERATION TANK The coolant must be above the level of ETHYLENE GLYCOL AND WATER the sight glass (1) when the engine is stopped and cool. If coolant is below the sight glass, remove the cap and fill to the neck with the specified coolant.

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LUBRICATION/FILTERS/FLUIDS

50 Hours 5

4

BD02B050

HYDRAULIC RESERVOIR MS-1209 HY-TRAN ULTRA

5 TRIM THIS EDGE

4

RD97F167

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

B910922J

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500Hours 1

BD02B037

BATTERIES (ONE ON EACH SIDE OF THE MACHINE) DRINKING OR DISTILLED WATER

TRIM THIS EDGE

1

BS02B177

146

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LUBRICATION/FILTERS/FLUIDS

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

If Case Multi-Viscosity Engine Oil is not available, use only oil meeting API e n g in e o il s e rv ic e c a te g o r y C H - 4 (preferred) or CG-4

BP97H064

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

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

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TRIM THIS EDGE

RH99K130

LUBRICATION/FILTERS/FLUIDS

Oil Viscosity/Temperature Ranges

TRIM THIS EDGE BS99M162

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

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

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LUBRICATION/FILTERS/FLUIDS

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

Oil Change interval .................................................. Every 500 hours of operation Oil filter change interval ........................................... Every 500 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 ..................................................... 36.9 litres (39 U.S. Quarts) NOTE: Reduce Engine oil and filter change intervals to 250 hours or less if Case No.1 Engine Oil is not used.

Engine Oil Level

TRIM THIS EDGE

To check the engine oil level put the machine on a level surface and stop the engine. Remove engine oil dipstick and w ip e cl e a n w ith a c lo t h . R e p la c e dipstick in tube and push the engine oil dipstick completely DOWN and then remove. If the oil level is below the ADD mark, add oil to raise the oil level to the FULL mark. It takes 4 quarts (3.78 litres) to raise the oil level from the ADD mark to the FULL mark.

BD02B030

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LUBRICATION/FILTERS/FLUIDS

Engine Oil Change and Filter Replacement Change the engine oil and replace the filter after every 500 hours of operation or once a year whichever occurs first.

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

NOTE: Reduce Engine oil and filter change intervals to 250 hours or less if Case No.1 Engine Oil is not used.

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

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

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

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

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

TRIM THIS EDGE

Change the engine oil more frequently when the engine operating conditions are se vere (fre quent stoppin g a nd sta rtin g and hi gh or low e ngin e temperatures.)

8. Install the drain plug.

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

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

2. Remove the engine oil drain plug.

3. Open the rear engine access doors.

BD02B062

BD02B061

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

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

12. Close the engine access doors.

BD02B031

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.

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

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

NOTE: Reduce Engine oil and filter change intervals to 250 hours or less if Case No.1 Engine Oil is not used.

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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TRIM THIS EDGE

Systemgard Lubrication Analysis Program

LUBRICATION/FILTERS/FLUIDS

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

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

TRIM THIS EDGE

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

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

RD97F158

Wear face protection and clean the du st an d dir t from th e cap with c o m p r e s se d a ir. To cl e a n o il a n d grease from the cap, wash the cap in h o t w a t e r w it h a s ma l l a m o u n t o f detergent.

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LUBRICATION/FILTERS/FLUIDS

Primary (Outer) Element

5. Install the end cover and push the sp rin g c la mp s in to th e lo c k e d position.

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

6. Close the access door.

7. Start the engine and check the air filter indicator lamp. If the air filter indicator lamp is still illuminated, re p la c e th e se c o n da r y ( in ne r ) element.

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

Secondary (Inner) Element the

primary

(outer)

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

RD97D078

2. Carefully remove (outer) element.

the

primary

RD97D080

RD97D079

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

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

153

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TRIM THIS EDGE

1. Remove element.

LUBRICATION/FILTERS/FLUIDS 3. Use a clean damp cloth and clean the inside of the filter body.

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

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

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

6. Close the access door.

RD97D081

TRIM THIS EDGE

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

CM115

154

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LUBRICATION/FILTERS/FLUIDS

Cleaning the Element

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

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

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

1. Wear face protection and remove the loose dirt with compressed air 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 d e te r g e n t ( C a se P a rt N u m b e r A4 09 1 0 ) w ith two g a llo n s ( 7 .6 litres) of wa ter, o ne cup for 1 6 gallons (60 litres) water.

3. Soak the element in the soap solution for 15 to 20 minutes and th en mo ve the eleme nt up an d 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

155

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778L94

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

LUBRICATION/FILTERS/FLUIDS

ENGINE COOLING SYSTEM Service Specifications Cooling System Capacity .................................................57 litres (60 U.S. Quarts) Cooling system drain, flush, and refill interval ....... Every 2000 hours of operation or each year, whichever occurs first.

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

Deaeration Tank Coolant Level Check Interval ........... Every 10 hours of operation

Thermostat Starts to open ................................................................................... 82°C (180°F) Completely open ....................................................................... 94°C (94°C202°F) Deaeration Tank cap ............................................... 103.4 kPa, 1 bar (15 psi)

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

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

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

WARNING: Hot coolant can spray out if deaeration tank cap is removed.

To remove deaeration tank cap: Let system cool, turn to first notch, then wait until all pressure is released.

Scalding can result from fast removal of deaeration tank cap.

Check and service engine cooling system according to maintenance instructions.

SA023

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LUBRICATION/FILTERS/FLUIDS

Radiator Fluid Level

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

The coolant fluid level is monitored at th e in st r u m e n t c lu s t e r. W h e n t h e coolant level indicator illuminates, add co o lan t to th e d ea e ra tio n ta nk a s required to raise the coolant level.

1

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

RD97F142

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

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

RD98K316

4. Apply a thin layer of clean grease or o il to the ga sket of the ne w coolant filter.

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

BD02B049

Replacing the Coolant Filter

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

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

Replace the Coolant Filter every 250 hours of operation. Drain and flush the Engine Cooling System every 2000 hours. Replace the Coolant Filter after eve ry draining a nd flushing o f th e Engine Cooling System.

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

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1. SHUTOFF VALVE SHOWN IN THE ON POSITION

LUBRICATION/FILTERS/FLUIDS

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

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

Cle an th e system and replace th e coolant if the coolant becomes dirty or has the color of rust.

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.

DO NOT remove the deaeration tank cap if the coolant is hot.

1. Open the cooling system drain valve and remove the deaeration tank cap. The drain valve is located at the lower left steel tube between the engine and the radiator.

7. Start the engine and run at idle spe ed un til the en gine is at operating temperature. Check the instrument cluster monitor, if the monitor illuminates. Add coolant as required.

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

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8. Install the deaeration tank cap, if removed.

3. Add cleaning solution to the cooling system and fill the cooling system w i t h c l e a n w a t e r. F o l l o w t h e directio ns in clu ded with th e cleaning solution.

Cleaning the Screens and Coolers 1. Clean the screens and coolers as necessary.

3. Open the left and right hand side doors to clean the front side of the radiator, b ack/fron t sid e of th e hydraulic/transmission oil cooler.

2. Use a pressure washer to clean the screens from the radiator rear.

IMPORTANT: Be careful not to bend or damage the fins during cleaning. DO NOT exceed 6890 kPa (1000 PSI) nozzle pressure when cleaning.

BD02B045

NOTE: After cleaning the coolers wash all trash from the top of the fuel tank.

BD02B044

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LUBRICATION/FILTERS/FLUIDS

DIESEL FUEL SYSTEM Service Specifications Fuel Tank Capacity ................................................... 394 litres (104 U.S. Gallons) Interval for draining water from the fuel filter ....................... 10 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

LUBRICATION/FILTERS/FLUIDS

Diesel Fuel

Fuel Storage

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

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

In very cold temperatures, a mixture of No. 1 and No. 2 d ie sel fu els is tempo rarily p ermitted . See th e following Note.

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

Keep the fuel storage tank outside and keep th e fuel as coo l as po ssib le.

Remove water from the storage container at regular periods of time.

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

Wh en a dding fue l to the ma chine, remove the fuel cap SLOWLY to reduce the air pressure build up.

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

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

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

SA022

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

Never smoke while refueling.

M139C

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LUBRICATION/FILTERS/FLUIDS

Removing Water and Sediment from the Fuel System

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

Drain the water for the fuel filter after every 10 hours of operation. Drain the water and sediment from the fuel tank after every 500 hours of operation.

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

RD97F147

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

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

RD97F147

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.

2. Close the drain valve.

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

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

B4029591T

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

LUBRICATION/FILTERS/FLUIDS

HYDRAULIC/BRAKE SYSTEM Service Specifications Hydraulic/Brake System Fluid Chart Hydraulic Reservoir Refill Capacity.............................121 Litres (128 U.S. Quarts) Total System Capacity .................................................242 litres (256 U.S. Quarts) Type of Fluid ................................................................... MS-1209, Hy-Tran Ultra® Hydraulic Reservoir Fluid Level Check Interval ..............................Every 50 Hours Filter Replacement Interval ................................Every 1000 Hours of Operation or if the Hydraulic Filter Warning Lamp Illuminates Suction Screen Cleaning Interval................................................Every 2000 Hours Hydraulic Fluid Change Interval ..................................................Every 2000 Hours or once each year, whichever occurs first.

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

SA047

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LUBRICATION/FILTERS/FLUIDS

Hydraulic Oil Level

2. Slowly loosen the filler cap on the h y d r a u l i c r e s e r v o i r. T h i s w i l l rele ase the air p ressure in th e hydraulic reservoir. Remove the filler cap from th e hydra ulic 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.

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

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

Hydraulic Filters Replace the two hydraulic filters every 1 0 0 0 h o u rs o f o p e r a ti o n o r i f t h e hydraulic oil filter LAMP illuminates.

Hydraulic Filter Test To check the condition of the hydraulic filters do the following.

2. Stop the engine.

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

3. Check the oil level in the sight gauge. If the oil is cold, the level is correct when you see oil in the lower 1/4 of the sight gauge. If the oil is at operating temperature, 50°C (120°F), the oil level must be in the upper 1/4 of the sight gauge.

DO NOT over fill. See Hydraulic Sy s te m in th is m a n u a l fo r t h e correct oil.

A. Hold the loader control lever in the ROLLBACK position until the lo ad er b ucke t is a gains t th e s t o p s , c o n t in u e t o h o ld th e control lever in the ROLLBACK position for 15 seconds.

To add oil to the hydraulic reservoir do the following:

C. Repeat steps a and b until the side of the hydraulic reservoir feels very warm.

B. After 15 seconds, move the con tro l leve r to the HOL D position.

1. Clean the area around the filler cap.

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BD02B050

LUBRICATION/FILTERS/FLUIDS 3. Remove the access cover.

2. Increase the engine speed to full throttle . If the LAMP for th e hydrau lic oil filters illuminate s, replace both filters.

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

5. Lubricate the gasket on each new filter with MS-1209, Hy-Tran Ultra® fluid. Turn the filter clockwise until the filter contacts the head of the filter assembly. Continue to tighten the filter 1/2 to 3/4 turn by hand.

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

6. Tighten the filler cap.

RD98K317

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Hydraulic Filter Replacement IMPORTANT: Always replace both hydraulic filters at the same time.

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

Apply the parking brake.

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

8. Stop the engine and check the h y d r a u l ic o il le ve l. A d d o i l a s required. See Hydraulic System in this manual for correct specifications.

9. Install the access cover.

2. Slowly loosen the filler cap on the h y d r a u l i c r e s e r v o i r. T h i s w i l l rele ase the air p ressure in th e hydraulic reservoir.

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

SA047

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

SA047

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LUBRICATION/FILTERS/FLUIDS

Hydraulic/Brake Oil Change 1

3

4 6 5

64L95

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

4. DRAIN VALVE 5. ACCESS COVER 6. SEAL

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2

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

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

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

3. Stop the engine. Put a DO NOT O PER ATE tag o n the s tee rin g wheel.

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

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

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

7. Put the other end of the drain hose into a container that will hold 32 gallons (121 litres).

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

13. Turn the reservoir drain valve to OFF. Remove the drain hose and install the plug in the drain valve.

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

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

16. Install the reservoir filler cap.

17. Start the engine and run at 1000 rpm. Check for oil leaks around the filters, access cover and the drain plug. When the balance pressure w a r n in g b u z z e r s t o p s m a k in g noise, run the engine at 1500 rpm.

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

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

8. Open the drain valve.

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

9. Replace the hydraulic oil filters.

21. Add oil as required.

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

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

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LUBRICATION/FILTERS/FLUIDS

Bleeding the Brake System

NOTE: Oil will begin to flow from the bleed screw when engine is started.

1. Park the machine on a level surface. Block the w heels.

Completely raise the loader frame, connect acceptable lifting equipment to the loader arms that will hold the loader arms in place.

Apply the parking brake. Stop the engine. Put a DO NOT OPERATE tag on the steering wheel.

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

2. Loosen the bleed screw on the accumulator charge valve a small amount. If possible attach a hose to the bleed screw to help prevent oil spillage.

7. Do procedure A or B to fully discharg e the two accumulator pistons.

5. Continue to run the engine at idle until the low brake pressure lamp is no long er illumin ate d a nd both accumulators are fully charged.

A. Push down and then release the brake pedal 15 to 20 times until there is no hydraulic pressure in the brake system.

B. See Step 9 of this procedure for location of the bleed screw on the axle. Loosen the bleed screw on the front axle, push down on the brake pedal until there is no forced flow from the open bleed screw. Tighten the bleed screw.

1

BD00C005

8. Start and run the engine at idle.

Apply the parking brake.

1. BLEED SCREW ON ACCUMULATOR CHARGE VALVE

3. Start and run the engine at idle.

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6. Stop the engine.

LUBRICATION/FILTERS/FLUIDS 9. Open the left bleed screw on the front axle.

1

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

11. Open the right bleed screw on the front axle. Repeat Step 10 12. Start and run the engine at idle for 2 minute.

13. Stop the engine. Open the left b le e d s cr e w o n th e r e a r a x le .

Repeat Step 10.

BD00B027

1. BLEED SCREW ON FRONT AXLE

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

14. Open the right bleed screw on the rear axle. Repeat Step 10.

15. Check the brake system for correct operation. If the brake system is not op era ting p rope rly see th e Service Manual or your Case Dealer.

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LUBRICATION/FILTERS/FLUIDS

TRANSMISSION Service Specifications Transmission refill capacity with filters ........................ 27.4 litres (29 U.S. Quarts) Total system capacity ..................................................... 46 litres (49 U.S. Quarts) Type of oil ................................................. Case No. 1 Engine Oil (SAE 15W - 40) Oil lever check interval ............................................................................ 50 hours Filter replacement interval ............................ After the first 100 hours of operation and then every 1000 hours there after.

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

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

CM107

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

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

LUBRICATION/FILTERS/FLUIDS

Transmission Oil Level

2. Apply the parking brake.

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

3. Shift the NEUTRAL.

transmission

to

4. Run the engine at idle speed.

5. If the oil level is at or below the 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 Tr a n s m i s s i o n Service Specifications in this manual for the correct oil.

B910924J

Oil Change, Filter Replacement, and Breather Cleaning

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C h a n g e th e t r a n s mi s s io n o i l a n d replace the filter after the first 100 hours of operation with a new machine or if the tran smissi on has bee n replaced or rebuilt. Then, do the above service and clean the breather every 1000 hours or operation.

RD97F167

Cold Oil Level Check

If possible, drain the oil when the oil is at operatin g te mp erature. Mo re contamination is removed when the oil is at operating temperature.

Before you start the engine, check the tra n sm is sio n o il lev el in the s igh t gauge. If the oil level is below the arrow, add oil to raise the oil level up to the a rr o w. Se e Tr a n s mis s io n S e rv ic e Specifications in this manual for the correct type of oil.

Warm Oil Level Check

1. Put the transport/service link in the LO CKED position, app ly th e parking brake, and stop the engine.

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

3. Have a container that will hold approximately 29 U.S. Quarts (27.4 litres).

Check the transmission oil level every 50 hours of operation when the oil is at op erating tempe rature . Do th e following.

1. Park the machine on a level surface.

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LUBRICATION/FILTERS/FLUIDS 4. Remove the filler tube plug.

7. Install the filter as shown. Make sure the filters are SEATED against the filter base.

B4028891T

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

9. Install the breather.

10. Install the drain plug. Put new oil in to the tran smissio n. Se e Tr a n s m i s s i o n Service Specifications in this manual.

2 1

RB97G074J

1. DRAIN PLUG

2. O-RING

6. Remove the transmission filters.

Discard the old transmission filters.

11. Check the oil level in the sight gauge.

12. Start the engine and check for oil leaks around the filters and drain plug.

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

14. Stop the engine and return the transp ort/service link to th e OPERATING position.

BD02B069

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RD98M046

8. Remove the breather. Clean the breather with solvent and dry with compressed air. Be sure to wear face protection when using compressed air.

LUBRICATION/FILTERS/FLUIDS

AXLES Service Specifications Front axle capacity ................................................... 47.3 litres (50.0 U.S. Quarts) Rear axle capacity ......................................................... 53 litres (56 U.S. Quarts) Type of oil .................................... Case MS1317 Transaxle Fluid (SAE 80W-140) Alternate oil ............................................................................................. See note Oil change interval ................................... After the first 100 hours of operation and then every 1000 hours there after.

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

Axle Oil Level To check the oil level, do the following procedure.

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

1. Park the machine on a level surface. Apply the parking brake and stop the engine.

4. Clean and install the filler plug.

2. Remove the oil level and filler plug from the center bowl of the axle.

The oil level must be level with the bottom of the oil level and filler plug hole.

1

BD02B074

1. OIL LEVEL AND FILLER PLUG

3. Add oil as required. See Axle S e r v ic e S p e ci fi c a t io n s i n th is manual.

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LUBRICATION/FILTERS/FLUIDS

Front Axle Oil Change After the first 100 hours of operation and then every 1000 hours there after.

1. Park the machine on a level surface. Apply the parking brake and stop the engine.

1

2. Have a container that will hold approximately 42.5 litres (45 U.S. Quarts) for the front axle and a con ta ine r tha t will hold approximately 45.4 litres (48 U.S. Quarts) for the rear axle.

BD00C007

1. DRAIN PLUG 2. DRAIN PLUG

5. Clean the oil level and oil filler plugs.

6. After all oil has been removed, install and tighten the drain plugs.

7. Install the exact amount of oil in the center bowl of the axle. See Axle Service Specifications on 172 in this manual.

1

8. Install the oil level and filler plug in the center bowl of the axle.

2 BD02B074

1. OIL LEVEL AND FILLER PLUG 2. DRAIN PLUG

4. Remove the drain plugs from the planetary ends of the axle. Drain the oil from both planetary ends of the axle. The drain plug can be located in either location, see the following photo.

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3. With the oil warm from operation, remove the oil level and filler plug and the drain plug from center bowl of the axle. Drain the oil from the axle.

2

LUBRICATION/FILTERS/FLUIDS

Rear Axle Oil Change After the first 100 hours of operation and then every 1000 hours there after.

1. Park the machine on a level surface. Apply the parking brake and stop the engine.

4. Remove the drain plug from center section of the axle. Drain the oil from the center section of the axle.

2. Have a container that will hold approximately 47.3 litres (50 U.S. Quarts) for the front axle and a con ta in er tha t will hold approximately 53 litres (56 U.S. Quarts) for the rear axle.

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3. With the oil warm from operation, remove the oil level and filler plug from the beam of the axle and the drain plugs from the planetary ends of the axle. Drain the oil from the planetary ends of the axle.

1 BD00B002

3. DRAIN PLUG FOR AXLE CENTER SECTION

5. Clean the oil level and oil filler plug and the drain plugs.

6. After all oil has been removed, install and tighten the drain plugs.

7. Install the exact amount of oil in the axle.

See Axle Service S p e c i fi c a ti o n s o n 1 7 2 i n th is manual.

1

1

BD00C010

2 BD00B002

1. OIL LEVEL AND FILLER PLUG

8. Install the oil level and filler plug in the beam of the axle.

2 BD00C007

1. OIL LEVEL AND FILLER PLUG 2. DRAIN PLUG FOR PLANETARY

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LUBRICATION/FILTERS/FLUIDS

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

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

Removal and Installation 1. Turn the handle and open the access door.

RD98K285

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4. Close the access door and turn the handle to the locked position.

RD97F156

2. Pull the air filter out.

RD97F156

5. Install the circulation cover.

Circulation Cover 1. Remove the air circulation filter.

RD98K285

3. Install a filter that has been cleaned or a new filter.

RD97F222

2. Install a filter that has been cleaned or a new filter.

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LUBRICATION/FILTERS/FLUIDS

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

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

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

1. Remove the loose dirt with compressed air, 30 psi (207 kPa, 2 bar) maximum. Hold the nozzle at least one inch (25 mm) from the element. Make sure you wear face protection when using compressed air.

787L94

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

786L94

2. Mix two tablespoons of D1400 detergent (Cas e part number A4 09 1 0 ) w ith two g a llo n s ( 7 .6 litres) of wa ter, o ne cup for 1 6 gallons (60 litres) of water.

788L94

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

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LUBRICATION/FILTERS/FLUIDS 6. Use a light and inspect the element for holes or splits in the pleats.

Check for damage to the metal parts and rubber gasket.

789L94

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

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WINDSHIELD WASHER RESERVOIR (If Equipped)

RD98K286

The windshield washer reservoir is located on the frame below the cab on the Right Hand side. To add washer fluid, pull the cap up.

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

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LUBRICATION/FILTERS/FLUIDS

NOTES

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MAINTENANCE/ADJUSTMENT ETHER CONTAINER IMPORTANT: Read the warnings and information on the ether container.

2. Remove (turn counterclockwise) the ether container.

DO NOT store ether containers in the operators area.

3. Install (turn clockwise) a new ether container.

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

4. Tighten the clamp.

When the ether container is removed for storage or b ecau se of warm weather, do the following to protect the solenoid valve.

1. Remove the ether container.

1. Loosen the clamp.

2. Install the cap on the solenoid valve.

BD02C047 BD02C048

WARNING: Starting fluid (ether) can cause injury or death. An explosion can result if sparks, flame, or extreme heat contact the ether in the starting fluid container. Do not breathe starting fluid vapors. Wear face protection when you remove or install a starting fluid container. Use starting fluid according to instructions in this manual.

SB039

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Replacing the Ether Container

Storage

MAINTENANCE/ADJUSTMENT

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

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

SA048

Lubrication of the Air Conditioning Compressor Seals TRIM THIS EDGE

Operate the air conditioning once every 250 hours to lubricate the compressor seals. Turn the air conditioning control to MAXIMUM for at least 15 minutes. In temperatures below 32°F (0°C) put a cove r ove r th e a ir co ndition in g condenser. This will make sure the refrigerant and lubricants in the system will be at operating temperature.

Keep the air conditioning condenser core clean. Use compressed air (wear face protection) or a rigid brush to clean the condenser. Also check and clean the grille screen.

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

10 Ampere Circuit Breakers for Condenser Blower Fans

Condenser

RD97F158

RD97F158

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

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MAINTENANCE/ADJUSTMENT

Cab Headliner

Door Hinges

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

Use graphite to lubricate the cab door hinges. DO NOT use oil.

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

Check all hoses and wiring for damage.

If damage occurred, see your dealer for repair or replacement.

RD97F215

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Hoses and Wiring

MAINTENANCE/ADJUSTMENT

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

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

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

SA049

CLEANER FLUID - This type of cleaner can be used for grease or oil stains.

Carefully remove the item that caused the stain with a scraper or a knife that is not sharp. Use very little cleaner, no pressure, and clean cloths. Move the cloth from the outside of the stain toward the center of the stain and constantly change to a clean section of cloth.

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

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

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MAINTENANCE/ADJUSTMENT

Transmission clutch calibration ensures optimum shifting of the transmission.

Make sur e o f th e fo llow in g b efor e proceeding with transmission clutch calibration.

●

The Modulation Cycle Number will be displayed in the 1st and 2nd spaces (2 00 XX - the XX represents the 1st and 2nd spaces).

●

During Clutch Calibration, the Clutch Calibration Main Code will change from 01 to 07 as the process is completed. The code 07 will indicate that the process is complete and the Information Center will return to normal working status.

●

If any of the Clutch Calibration parameters are incorrect, the display center will stop flashing and display the Clutch Calibration Main Code in the 1st, 2nd, 3rd, and 4th spaces.

A. The parking brake has been tested.

B. The transmission oil is warm.

C. The engine idle speed is correct.

D. The transmission is in neutral.

E. The parking brake is applied.

Do the following procedure to calibrate the transmission clutches: 1. Put the transmission in the machine shift mode and the gear selector in 3rd gear neutral.

2. Press the program switch.

3. Press the up-count switch until the display reads 011.

4. Return the program switch to the center position.

5. Press the up-count switch twice so the display reads 02.

In the event, the code in the 3rd and 4th spaces will be 09 to 14 and will indicate the process that the calibration was in when it was aborted.

The 1st and 2nd spaces will produce the Clutch Calibration Sub-Code, which is the code that will inform the operator of the reason process was aborted.

6. After completing the clutch calibratio n proced ure, tu rn th e engine off for 15 seconds to set the calibration in the controller.

At this time, 2 00 00 will begin flashing in the display center. ●

After one second, the Clutch Calibration Main Code status will be displayed in the 3rd and 4th spaces (2 XX 00 - the XX represents the 3rd and 4th spaces).

NOTE: See Clutch Calibration Main Code and Clutch Calibration Sub-Code on the following page.

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TRANSMISSION CLUTCH CALIBRATION

MAINTENANCE/ADJUSTMENT

Clutch Calibration Main Codes CLUTCH CALIBRATIO N MAIN CODE 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14

Clutch Calibration SubCodes CLUTCH CALIBRATIO N SUB-CODE

MEANING

MEANING Calibration in process

Clutch Calibration Mode was not initiated because one of the requirements was not met.

Adjusting 1st gear Adjusting 2nd gear Adjusting 3rd gear Adjusting 4th gear Adjusting Forward gear Adjusting Reverse gear Clutch Calibration Completed Operator aborted calibration procedure.

Aborted while adjusting 1st gear Aborted while adjusting 2nd gear Aborted while adjusting 3rd gear Aborted while adjusting 4th gear Aborted while adjusting Forward gear Aborted while adjusting Reverse gear

00 01 02 03 04 05 06 07 08

Fault present Shift lever not in neutral Park brake not applied Output speed not 0 kph/mph Low transmission oil temperature High transmission oil temperature Low engine RPM High engine RPM

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DECLUTCH ADJUSTMENT 1. Park the machine on a level surface.

2. Lower the loader bucket to the floor.

3. Apply the parking brake and stop the engine.

NOTE: The following photo shows the brake pedal/valve assembly removed for clarity. Do not remove the brake pedal/valve assembly from the machine.

2 1

BD00C006

1. PLUG 2. ADJUSTMENT SCREW

4. Remove the plug (1) from the base of the left hand brake pedal/valve assembly.

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MAINTENANCE/ADJUSTMENT 5. Turn the adjustment screw (2) in or out as required to adjust the d e c l u t c h p o i n t . Tu r n i n g t h e adjustment screw clockwise increases the brake force at the declutch. Turning the adjustment screw counterclockwise decreases the brake force at the declutch.

6. Install the plug (1) in the base of the left hand brake pedal/valve assembly.

7. If the declutch is not operating properly see the Service Manual or your Case Dealer

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NOTE: The declutch is set the at the factory at approximately 30 percent of full brake system pressure. Do not increase this setting more that 1 turn clockwise (approximately +325 psi) Do not reduce this setting more than 1/2 turn counterclockwise (approximately 75 psi).

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MAINTENANCE/ADJUSTMENT

SECONDARY STEERING CHECK NOTE: Test the secondary steering at a maximum of 250 hours.

The secondary steering system is electrically powered which allows you to steer the machine if the primary steering system stops working. Always maintain the batteries.

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RD98K316

1. Prior to checking the secondary steering system, park the machine on a hard packed, 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.

2. Turn the key switch in the ON position but do not start the engine. Confirm that the secondary steering lamp within the instrument cluster is illuminated. This indicates that the steering pressure is low.

3. Start the engine and let the engine run for a few seconds. Confirm that the secondary steering lamp within the instrument cluster is not illuminated. This confirms that steering pressure is built up and that the module is armed.

4. With the machine at low idle and steering straight ahead, turn the key switch to the OFF position to stop the engine and then immediately back to the ON position (not the START position). The secondary steering pump / motor should start running within 0.1 seconds. Confirm that the secondary steering lamp within the instrument cluster is illuminated and the secondary steering pump / motor is running.

5. Steer the machine full left into the end of travel and hold the pump at high pressure for 4 to 5 seconds to confirm that there is no leakage back to the pressure switch. Steer the machine to the full right position to confirm that the secondary steering system is working and there is no binding in the steering linkage. Confirm that there is no lack in the steering function.

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MAINTENANCE/ADJUSTMENT IMPORTANT: DO NOT turn the key switch to the OFF position if the machine is steered against either the right hand or left hand steering stop. The steering wheel may kick back.

NOTE: The secondary pump/motor should not be run continuously for more than 20 seconds at a time without a 2 minute cool down.

6. Restart the engine to build up steering pressure. Confirm that the secondary steering lamp within the instrument cluster is illuminated and that the secondary and that the secondary steering pump / motor is running. The secondary steering pump / motor should stop after approximately 3 seconds and the secondary steering lamp should go OFF. 7. If steps 2 through 6 function properly, the secondary steering system is operating correctly. If not, repair the secondary steering system and then retest the system.

NOTE: The secondary steering system will only function as long as there is sufficient battery capacity.

PARKING BRAKE CHECK NOTE: Test the parking brake at a maximum of 250 hours.

Before you operate the machine periodically test the parking brake functions.

RD98K316

1. To release the park brake, all the following are required:

A. Make sure that there is adequate service brake pressure. (Brake warning lamp is OFF)

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8. Start the engine and allow the batteries to recharge for a minimum of 10 minutes.

MAINTENANCE/ADJUSTMENT F. Depress the service brake and release. Confirm that the Park Brake lamp is illuminated.

B. Push the Park Brake switch to the release position.

C. Place the transmission shifter to F or R to direct movement of the machine.

D. Place your foot on the service brake to gain control and release.

Put the transmission in F or R and back to N. Confirm that the Park Brake lamp is illuminated.

G. Place the park brake switch in the engaged position. Depress the service brake and put the transmission in F or R and back to N . C o n f irm th a t t h e Pa r k Brake lamp is illuminated.

2. To engage the park brake, any of the following is required: E. Loss of service brake pressure in both axles pressure circuits.

H. Place the park brake switch in the released position. Depress the service brake and put the transmission in F or R and back to N . C o n f irm th a t t h e Pa r k Brake lamp is OFF.

F. Loss of system electrical power (key OFF).

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G. Placement of the Park Brake switch into the engaged position.

3. To test these functions:

4. Place the transmission in F and allow the machine to roll slowly forw ard . Pla ce th e Pa rk Bra ke switch to the engaged position. The ma c h in e mu s t c o me to a st o p immediately. Confirm that the Park Brake lamp is illuminated and that the transmission disengages.

A. Start the engine on a level flat surface, clear of other objects.

B. Perform Step 1, A through D. Con firm tha t the Pa rk Bra ke indicator lamp is OFF indicating the Park Brake is released.

C. Turn the key switch to the OFF position to stop the engine. After 5 seconds, turn the key switch to the ON position (not the START position). The Park Brake light should illuminate indicating the Park Brake is engaged.

If all steps above perform as indicated, then the Park Brake system works correctly. If there was a problem with the test contact your dealer.

D. Pump down the service brake pressure . Con firm the b ra ke warn ing lamp is illumin ated.

Co n tin ue t o pu mp do w n th e service brake pressure. Confirm th a t th e P ar k Br ak e la mp is illuminated.

E. Start the engine and allow the brake pressure to build until the warning light goes out.

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MAINTENANCE/ADJUSTMENT

LOADER ADJUSTMENTS Return-To-Dig Adjustment 1. Park the machine on a level surface.

5. Loosen the cap screws that fasten the actuator.

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

1

B4037088T

RP98N357

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

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 betw een the sw itch 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.

B4037288T

1 2 B4037588T

1. SWITCH 2. SHIELD

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1. SWITCH

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

B4037188T

RD98K312

8. Push down on the top side of the detent function switch.

10. Tighten the cap screws that fasten the actuator. Make sure the 1/8 to 3/16 inch (3.2 to 5.0 mm) clearance is m a in t a in e d th r o u g h th e fu l l stroke of the cylinder.

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1

BD02B029

1. DETENT OFF/ON SWITCH

B4037088T

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

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

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

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

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MAINTENANCE/ADJUSTMENT

Return-To-Travel Minor Adjustment

Return-To-Travel Adjustment

1. Lower the loader bucket to the ground.

2. Park the machine on a level su rfa ce a n d ap p ly th e p ar kin g brake.

3. Stop the engine.

4. Loosen the front actuator.

1. Park the machine on a level su rfa ce a n d ap p ly th e p ar kin g brake.

2. Raise the loader until the front actuator is even with the Return-ToTr a v e l s w it c h . M a k e s u r e t h e clearance is 1/8 to 3/16 inch (3.2 to 5.0 mm).

2

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.

B4196789T

1. FRONT ACTUATOR 2. RETURN-TO-TRAVEL SWITCH

3. Stop the engine.

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

B4196689T

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1

MAINTENANCE/ADJUSTMENT 8. Loosen the actuator.

5. Remove the cover.

TRIM THIS EDGE

B4196589T

B4196289T

6. Check the clearance between the a c t u a t o r a n d th e s w it c h . Th is 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.

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

B4196189T

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

B4196489T

7. Have another person help you at th is time. Start the en gine an d lower the loader frame until the bucket is a t the desired he ight above the floor. Put a sufficient supp ort und er ea ch end of th e bucket and stop the engine.

11. Push down on the top of the Return-To-Travel detent switch.

Move the lift control lever from the HOLD position to the RAISE position several times to relieve all of the pressure in the accumulator.

Tu rn the ke y s witch to the ON position. Move the lift control lever to th e FL OAT position. Th e lift control lever will remain in this position and the loader frame will not move.

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MAINTENANCE/ADJUSTMENT 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.

1

BD02B029

1. RETURN-TO-TRAVEL SWITCH B4196289T

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

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

B4196589T

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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MAINTENANCE/ADJUSTMENT

Bucket Height Control Minor Adjustment

Bucket Height Control Adjustment

1. Park the machine on a level surface. Lower the loader bucket to the floor.

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

2. Apply the parking brake and stop the engine.

3. Loosen the rear actuator.

RP98N357

TRIM THIS EDGE

2. Stop the engine and apply the parking brake.

B4063488T

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

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

5. Tighten the actuator.

6. Start the engine and pull the lift control lever to the RAISE detent position. When the loader arms s to p m o v in g , ch e c k t h e d u m p height.

B4196689T

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MAINTENANCE/ADJUSTMENT 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 be tw een the sw itch an d th e actuator. Hold the switch in position and tighten the nuts.

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 liftin g eq uipmen t to th e crossmember of the loader.

8. Loosen the actuator.

B4195489T

B4195789T

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B4196589T

5. Start the engine and raise the loader frame until the rear actuator is eve n with the Bu cket Height Control switch. Stop the engine.

Connec t acceptable lifting equipment to the loader arms that will hold the loader in place.

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

13. Tighten the actuator.

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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 lo w er th e lo a d e r fr a me so t h e bucket is flat on the floor.

11. Push in the left side of the Bucket Height Cont rol s witc h on the instru men t 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.

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/ADJUSTMENT

ROLL-OVER PROTECTIVE STRUCTURE 1. Check the torque of the ROPS m o u n t in g b o l ts . I f n e c e s s a r y, tighten the bo lts to the correct torque. See torque specifications on this page.

Yo u r m a c h i n e h a s a R o l l - O v e r Protective Structure (ROPS). A ROPS label shows the serial number of the ROPS, gross w eight, approval, regulation, and model numbers of the machine. See Identification Numbers in this manual.

Be fo re yo u o pe ra te th is ma ch in e, always make sure that the ROPS and opera tor ’s seat belts are correctly installed.

3. Check for cracks, rust, or holes in the ROPS and ROPS parts. Age, weather, and accidents can cause damage to the ROPS and ROPS parts. If you have any doubt about the ROPS system, see your dealer.

Seat Belt The seat belt is an important part of your ROPS. You must wear the seat belt at all times when you operate the machine.

1. Keep the seat belts away from objects that can damage the seat belts.

2. Check the seat belts for damage.

Replace all parts that are damaged.

Torque Specifications for ROPS Cab and ROPS Canopy

3. Make sure that the mounting bolts of the seat belts are tight. See Torque Specifications for Seat in this manual.

4. Keep the seat belts clean. Wash the seat belts only in soap and water.

5. Do not put the seat belts in bleach or dye. You will make the seat belts weak.

Maintenance and Inspection of ROPS

RD97F234

ROPS CAB AND ROPS CANOPY MOUNTING BOLTS (BOTH SIDES), TIGHTEN TO 786 TO 840 Nm (580 TO 62POUND-FEET)

NOTE: Torque specifications are for clean, dry threads.

After the first 20 hours of operation and after every 500 hours of operation, do the following:

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2. Check the operators seat and the mounting parts for the seat belt.

Tighten the bolts to the correct torque. See Torque Specifications in this manual. Replace parts that have wear or damage.

MAINTENANCE/ADJUSTMENT

Damage to the ROPS If the machine has rolled over or the ROPS has been in some other type of accident (such as hitting an overhead obje ct durin g transpo rt), yo u must replace the damaged ROPS components to get as much protection as you had originally.

After an accident, check the following for damage.

C. Seat belt mounting bolts and seat belt.

Be f o r e y o u o p e r a te th e ma c h in e , replace all ROPS components that are damaged.

See the Parts Catalog or your dealer for components that are replaceable.

DO NOT T RY TO W ELD O R STRAIGHTEN THE ROPS.

A. ROPS canopy or cab.

B. Operators seat.

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WARNING: Improper ROPS inspection or maintenance can cause injury or death. Do the recommended ROPS inspection shown in this manual. If you must replace the ROPS, ROPS parts, or ROPS mounting hardware, use only the replacement parts shown in the Case parts catalog for this machine SA029

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

SB026

WARNING: If you operate this machine without a ROPS and the machine rolls over, you can be injured or killed. Remove the ROPS only for service or replacement. Do not operate this machine with the ROPS removed.

SA027

WARNING: Adding additional weight (attachments, etc.) to the machine can cause injury or death. Do not exceed the gross weight printed on the ROPS label SA028

WARNING: Always fasten the seat belt securely before starting the engine SA036

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MAINTENANCE/ADJUSTMENT

TORQUE SPECIFICATIONS FOR SEAT AND SEAT BELTS 1

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1

2

6397

1. 73 TO 87 Nm

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MAINTENANCE/ADJUSTMENT

ALTERNATOR BELT AND AIR CONDITIONING COMPRESSOR BELT Service Interval Alternator belt service interval...............................................Check every 10 hours Air conditioning compressor belt service interval ..................Check every 10 hours

Alternator Belt Inspection and Adjustment

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1. Apply approximately 25 pound of f o r c e to t h e b e l t b e t w e e n t h e p u ll e y s w i th y o u r h a n d . I f th e deflection is more than one belt thickness per 300 mm (1 foot), use a belt tension gauge and adjust the be lt to th e va lu es liste d in th e engine manual.

2. If the tension for the alternator belt is not correct, loosen the strap bolt a n d t h e p i v o t b o l t . Tu r n t h e adjusting bolt counterclockwise to loosen or clockwise to tighten the alternator belt.

3

2

1 BD02B040

1. PIVOT BOLT 2. ADJUSTING BOLT

B910927

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3. STRAP BOLT

MAINTENANCE/ADJUSTMENT

Removal and Installation 1. Loosen the strap bolt and the pivot b o l t . Tu r n t h e a d j u s t i n g b o l t counterclockwise until the belt is loose. Remove and discard the alternator belt.

3

Air Conditioning Compressor Belt Inspection and Adjustment 1. Apply approximately 25 pound of f o r c e to t h e b e l t b e t w e e n t h e p u ll e y s w i th y o u r h a n d . I f th e deflection is more than one belt thickness per 300 mm (1 foot), use a belt tension gauge and adjust the be lt to th e va lu es liste d in th e engine manual.

2

BD02B040

1. PIVOT BOLT 2. ADJUSTING BOLT

3. STRAP BOLT

2. Install a new alternator belt. See Alter na to r Be lt Ins pe ctio n a n d Adjustment and adjust the alternator belt to the correct tension.

NOTE: The illustration is shown with the removal of the alternator shield to show service points. NEVER operate the machine without the shield in place.

B910928J

2. If the tension for the alternator belt is not correct, loosen the strap bolt a n d t h e p i v o t b o l t . Tu r n t h e adjusting bolt counterclockwise to loosen or clockwise to tighten the alternator belt.

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

MAINTENANCE/ADJUSTMENT 3. If the tension for the air conditioning compressor belt is not co r r ec t, lo o s e n th e p ivo t b o lt.

Lo osen th e strap bolt and nut, move the air conditioning compressor as required to loosen o r tig h te n th e a ir c on d itio n in g compressor belt.

Removal and Installation 1. Loosen the pivot bolt. Loosen the strap bolt and move th e a ir conditioning compressor down until the b elt is loo se . Re mo ve an d discard the air conditioning compressor belt.

1

1

2

2 TRIM THIS EDGE

BD02B041 BD02B041

1. PIVOT BOLT 2. STRAP BOLT

1. PIVOT BOLT 2. STRAP BOLT

2. Install a new air conditioning compr essor belt. See Air Co n ditio nin g Co mp re sso r Be lt Inspection and Adjustment and adjust the air conditioning comp resso r be lt to th e co rrect tension.

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MAINTENANCE/ADJUSTMENT

FIRE EXTINGUISHER MOUNTING (If Equipped) Type of Fire Extinguisher It is recommended that you have a fire extinguisher on your machine. The fire extinguisher shown below is available from your dealer and can be installed on the machine.

This dry chemical fire extinguisher has a 5 pound capacity and is approved for C la s s A , B a n d C t y p e f ir e s . Th e operating temperature is from -65° to 120°F (-54° to 49°C).

Inspection and Care EVERY MONTH - It is recommended that you inspect the fire extinguisher once each month for damage and to in s u r e th a t t h e g a u g e i s w o r k in g correctly.

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EVERY 6 MONTHS - Have the dry chemical removed and refilled by a fire equipment technician.

ONCE EACH YEAR - Have the fire equipment technician inspect the fire extinguisher.

153L95

IMPORTANT: DO NOT mount the Fire Extinguisher on any part of the ROPS or FOPS structure. DO NOT make any modifications to the ROPS or FOPS structure.

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MAINTENANCE/ADJUSTMENT

NOTES

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ELECTRICAL SYSTEM Battery Safety WARNING: Before you service a battery, always wear face protection, protective gloves and protective clothing. Battery acid or battery explosion can cause serious injuries.

SA046

WARNING: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote - EXTERNAL: flush with water. INTERNAL: drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately.

EYES: flush with water for 15 minutes and get prompt medical attention.

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

SA033

WARNING: Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: 1. When you disconnect the battery cables, always disconnect the negative (1) battery cable first.

2. When you connect the battery cables, always connect the negative (-) cable last.

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

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

SB034

BATTERY SERVICE NOTE: The electrical system in this machine is 24 volts. Each battery is 12 volts.

Before you service components of the electrical system, always disconnect the NEGATIVE (-) battery cable.

Before you use an electric welder, disc onnect the alt ernator wires, instrument cluster, and turn the master disconnect switch to OFF. Do not use a steam cleaner or cleaning solvent to clean the alternator.

Do not run the engine with the battery cables dis connec ted or with the alternator wires disconnected.

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SB032

ELECTRICAL SYSTEM

Battery Fluid Level

Cleaning the Batteries

Check the fluid level of the batteries every 500 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 ba tte rie s ca n c a us e a d isc ha rg e d 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.

Battery Vents TRIM THIS EDGE

Keep the battery vents clean, make sure the vents are not restricted.

1. Use Case Battery Saver, Part Numbe r M2 037 6. Follo w th e 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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ELECTRICAL SYSTEM

FUSES The fuses in this machine are blade type. To r eplace , p ull the o ld fu se straight out and push the new fuse straight in. The amperage for each fuse is stamped on the fuse. Refer to the fuse panel decal for correct location of each fuse.

RD97F154

449770A1/315096A1

SERVICE ELECTRICAL CONNECTOR (IF EQUIPPED) The cigar lighter socket (24 volt) can be used for the connection of a lighting device to help with service and maintenance procedures.

NOTE: This is a 24 volt outlet.

BD00B030

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449

ELECTRICAL SYSTEM

AUXILIARY POWER OUTLET (IF EQUIPPED) The Auxiliary Power Outlet socket (12 volt) can be used for the connection of a lighting device to help with service and maintenance procedures.

NOTE: This is a 12 volt outlet.

BD00B003

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AUXILIARY POWER EQUIPMENT MOUNTING BRACKET LOCATION The auxiliary power equipment mounting brackets are located behind the right and left ROPS post covers.

Th e se b r a c ke ts a r e fo r m o u n tin g radios, phones, etc.

To locate the bottom of the mounting bracket measure 300 mm (11.8 inches) from the bottom edge of the plastic panel. To locate the top of the mounting bracket measure 420 mm (16.5 inches) from the bottom edge of the plastic pa nel. The moun ting bracke t is approximately 70 mm (2.75 inches) wide.

1

BD00B009

1. RIGHT ROPS POST COVER

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ELECTRICAL SYSTEM

REPLACEMENT BULBS CASE PART NUMBER

INDUSTRY NUMBER

Driving Lamp

103654A1

----

Working Lamp

103653A1

----

Stop and Tail Lamp

24005R1

1662

Directional Lamp

446914

1683

Turn Signal

446914

Dome Lamp

395185A1

1683

Console Lamp

---

464

*Rotating Beacon

A187543 (Halogen)

----

Osvam 6429 Phillips 13866

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* DO NOT touch the new halogen bulb with your fingers. Use gloves or use a tissue to hold the bulb.

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ELECTRICAL SYSTEM

NOTES

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MACHINE STORAGE Storage Preparation

1. Wash the machine.

2. Lubricate the machine at all grease fittings.

3. Paint any areas where the paint has been damaged.

4. Move all hydraulic controls to reliev e any pressure in the hydraulic circuits.

5. Drain the fuel tank.

6. Put approximately 8 litres (2 U.S. Gallons) of diesel flushing oil in the fuel tank. Run the engine until the exhaust smoke is blue-white.

7. Drain the flushing oil from the fuel tank.

8. Put 15 ml (one tablespoon) of Shell Oil Company VPI crystals in the fuel tank.

10. Drain the cooling system. Leave the drain open and do not tighten the deaeration tank cap. Put a Do Not Operate tag in the cab.

11. Clean or replace the element for the air filter.

primary

12. Cover the exposed steering cylinder rods, equipment valve spools with Case Rust and Corrosion P revent ative (Part Number B17510).

13. Charge the batteries. Remove the batteries from the machine and put the batteries on a wooden pallet in a cool dry area. If possible, keep the batteries in a building where the temperature is above freezing (0°C [32°F]). Make su re th e batteries are clean.

NOTE: Always wear face protection when checking batteries. Check the batteries periodically for the correct electrolyte level. Test the electrolyte with a hydrometer. When the hydrometer reading is near 1.215, charge the batteries.

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If the machine is to be in storage for more than 30 days, park the machine inside a building. If a building is not available, park the machine in a dry area on planks and cover the machine with a waterproof covering.

9. Change the engine oil and replace the oil filter.

MACHINE STORAGE

Removal from Storage 9. Use petroleum base solvent and remove the Case Rust and Co rro sio n P reve ntive fr om th e hydraulic cylinder rods.

Do not start the engine until steps 1 through 10 have been done.

1. Change the fuel filter.

2. Put coolant in the engine cooling system.

3. Check the condition of the drive belts. Replace if required.

10. See Battery Service in this manual and install the batteries.

11. Fill the fuel tank.

12. Prime the turbocharger with clean engine oil. See your Servic e Manual or your dealer.

4. Check the engine oil level.

5. Check the hydraulic oil level.

6. Check the transmission oil level.

7. Check the oil level of both axles.

8. Lubricate the machine at all grease fittings.

13. Start the engine. It is important that you use the Starting the Engine procedure in this manual for priming the turbocharger lines with oil.

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SPECIFICATIONS ENGINE DATA

Make and model .................................................................... Cummins QSM11-C Type ........................................................................ six cylinder, four stroke cycle, turbocharger aftercooled air to air Firing order ........................................................................................... 1-5-3-6-2-4 Bore and stroke .................................................. 125 x 147 mm (4.92 x 5.79 inch) Displacement ..................................................................................... 661 cu. inch Compression ratio ..................................................................................... 16.3 to 1 Horsepower SAE gross .................................... 216.3 kW at 2 100 r/min (290 at 2100 rpm) Engine speeds Full throttle - no load ......................................................................... 2280 rpm Idle speed ........................................................................................... 970 rpm Hydraulic stall ...................................................................... 2110 to 2250 rpm Converter stall ..................................................................... 2040 to 2240 rpm Combined hydraulic and converter stall .............................. 1490 to 1720 rpm Valve clearance - engine cold Intake valves ................................................................. 0.35 mm (0.014 inch) Exhaust valves .............................................................. 0.68 mm (0.027 inch) Lubrication System Oil pressure at idle speed (minimum) ...................................... 70 kPa (10 psi) Oil pressure at 1 300 rpm ................................. 240 to 310 kPa (35 to 40 PSI) Type of system ............................................................ pressure and spray

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NOTE: All specifications are given according to SAE Standards or Recommended Practices where the specification applies.

SPECIFICATIONS

BUCKET DESCRIPTION

WIDTH

CAPACITIES SAE Heaped m

4.75 GP

3 048 mm (120 in)

4.75 GP W/S Segment Edges and Teeth 5.00 GP

3

WEIGHT

Struck

yd3

m3

kg

pounds

yd3

3.60

(4.75)

2.91

(3.81)

1.604

(3 537)

3 1 06 mm (122.3 in) 3.82

(5.00)

3.07

(4.02)

1 966

(4 335)

3 048 mm (120 in)

(5.00)

3.35

(4.38)

1 677

(3 698)

3.82

TRAVEL SPEEDS (with 26.5 x 25 Tires) FIRST km/h

(mph)

SECOND km/h

(mph)

THIRD km/h

FOURTH

(mph)

km/h

(mph) (24.1)

Forward

8.2

(5.1)

14.5

(9.0)

26.7

(16.6)

38.8

Reverse

8.2

(5.1)

14.5

(9.0)

26.7

(16.6)

-----

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SPECIFICATIONS

OPERATING DATA AND DIMENSIONS 921C Specifications taken with 26.5 x 25, 20 PR, L3 tires, ROPS cab with heater, 2450 kg (5 400 pound) rear counterweight, fenders, lights, full fuel, and a 80 kg (175 pound) operator. Specifications per SAE J732, J1234, J742, and J818.

K

D E

M

B 7 FT

(2.13mm)

L

C

A

F H

BS02B176

Machines with 3.63 m3 (4.75 yd3) General Purpose Bucket

A. B. C. D. E.

F. G. H. J. K. L. M.

Tipping load, machine straight ............................. 19 643 kg (43 305 pounds) Tipping load, 40 degree turn ................................ 15 675 kg (34 558 pounds) Overall operating height, fully raised .................. 5 635 mm (18 foot 5.9 inch) Height to bucket hinge pin, fully raised ............... 4 284 mm (14 foot 0.7 inch) Dump height, 45 degree dump, full height .......... 3 146 mm (10 foot 3.9 inch) Bucket reach, 45 degree dump, full height ........... 1 096 mm (3 foot 7.2 inch) Bucket reach, 45 degree dump, 7 foot (2134 mm) dump height ....................................... 1 747 mm (5 foot 8.8 inch) Dump angle at full height ................................................................ 50 degree Bucket rollback at ground line ......................................................... 39 degree Digging Depth, bucket flat .................................................... 30 mm (1.2 inch) Wheel Base ................................................................... 3 404 mm (134 inch) Tread width ...................................................................... 2 210 mm (87 inch) Overall length (without bucket teeth) .................. 8 612 mm (28 foot 3.0 inch) Overall height to top of ROPS cab ....................... 3 571 mm (11 foot 8.6 inch) Height to top of exhaust pipe ............................... 3 526 mm (11 foot 6.8 inch) Height to top of steering wheel ............................. 2 837 mm (9 foot 3.7 inch) Operating weight .................................................. 22 961 kg (50 621 pounds) Turning angle from center ........................................................ 40 degree

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G J

SPECIFICATIONS

D E

K

M

B 7 FT

(2.13mm)

L

C

A

F H

G J BS02B176

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Machines with 3.63 m3 (4.75 yd3) General Purpose Bucket with Teeth and Bolt on Edges A. B. C. D. E.

F. G. H. J. K. L. M.

Tipping load, machine straight .............................. 19 177 kg (42 278 pounds) Tipping load, 40 degree turn ................................ 15 215 kg (33 544 pounds) Overall operating height, fully raised ................... 5 634 mm (18 foot 5.8 inch) Height to bucket hinge pin, fully raised ................ 4 283 mm (14 foot 0.6 inch) Dump height, 45 degree dump, full height ............. 2 939 mm (9 foot 7.7 inch) Bucket reach, 45 degree dump, full height ............ 1 245 mm (4 foot 1.0 inch) Bucket reach, 45 degree dump, 7 foot (2134 mm) dump height ...................................... 1 806 mm (5 foot 11.1 inch) Dump angle at full height ................................................................ 50 degree Bucket rollback at ground line ........................................................ 40 degree Digging Depth, bucket flat .................................................... 71 mm (2.8 inch) Wheel Base .................................................................... 3 404 mm (134 inch) Tread width ....................................................................... 2 210 mm (87 inch) Overall length ...................................................... 8 895 mm (29 foot 2.2 inch) Overall height to top of ROPS cab ...................... 3 571 mm (11 foot 8.6 inch) Height to top of exhaust pipe ............................... 3 526 mm (11 foot 6.8 inch) Height to top of steering wheel .............................. 2 837 mm (9 foot 3.7 inch) Operating weight ................................................. 23 323 kg (51 418 pounds) Turning angle from center ........................................................ 40 degree

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SPECIFICATIONS

D E

K

M

B 7 FT

(2.13mm)

L

C

A

F H

G J

Machines with 3.82 m3(5.0 yd3) General Purpose Bucket A. B. C. D. E. F. G. H. J. K. L. M.

Tipping load, machine straight ...........................19 727 kg (43 491 pounds) Tipping load, 40 degree turn ............................... 15 708 kg (34 631 pounds) Overall operating height, fully raised ................ 5 857 mm (19 foot 2.6 inch) Height to bucket hinge pin, fully raised ............. 4 284 mm (14 foot 0.7 inch) Dump height, 45 degree dump, full height ........ 3 129 mm (10 foot 3.2 inch) Bucket reach, 45 degree dump, full height .......... 1 114 mm (3 foot 7.9 inch) Dump angle at full height ................................................................ 50 degree Bucket reach, 45 degree dump, 7 foot (2134 mm) dump height ..................................... 1 758 mm (5 foot 9.2 inch) Bucket rollback at ground line ......................................................... 39 degree Digging Depth, bucket flat .................................................... 30 mm (1.2 inch) Wheel Base ................................................................... 3 404 mm (134 inch) Tread width ...................................................................... 2 210 mm (87 inch) Overall length ...................................................... 8 637 mm (28 foot 4.0 inch) Overall height to top of ROPS cab ....................... 3 571 mm (11 foot 8.6 inch) Height to top of exhaust pipe ............................... 3 526 mm (11 foot 6.8 inch) Height to top of steering wheel ............................. 2 837 mm (9 foot 3.7 inch) Operating weight .................................................. 23 034 kg (50 782 pounds) Turning angle from center ........................................................ 40 degree

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BS02B176

SPECIFICATIONS

OPERATING DATA AND DIMENSIONS 921C XR Specifications taken with 26.5 x 25, 20 PR, L3 tires, ROPS cab with heater, 2450 kg (5 400 pound) rear counterweight, fenders, lights, full fuel, and a 80 kg (175 pound) operator. Specifications per SAE J732, J1234, J742, and J818.

K

D E

M

B 7 FT

(2.13mm)

L

C

A

F H

G

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J BS02B176

XR Machines with 3.63 m3 (4.75 yd3) General Purpose Bucket A. B. C. D. E.

F. G. H. J. K. L. M.

Tipping load, machine straight ............................. 15 375 kg (33 896 pounds) Tipping load, 40 degree turn ................................ 12 358 kg (27 245 pounds) Overall operating height, fully raised ................... 6 186 mm (20 foot 3.6 inch) Height to bucket hinge pin, fully raised .............. 4 835 mm (15 foot 10.4 inch) Dump height, 45 degree dump, full height ........... 3 698 mm (12 foot 1.6 inch) Bucket reach, 45 degree dump, full height .......... 1 174 mm (3 foot 10.2 inch) Bucket reach, 45 degree dump, 7 foot (2134 mm) dump height ........................................ 2 232 mm (7 foot 3.9 inch) Dump angle at full height ................................................................ 45 degree Bucket rollback at ground line ........................................................ 39 degree Digging Depth, bucket flat .................................................... 44 mm (1.7 inch) Wheel Base .................................................................... 3 404 mm (134 inch) Tread width ....................................................................... 2 210 mm (87 inch) Overall length (without bucket teeth) ................... 9 173 mm (30 foot 1.1 inch) Overall height to top of ROPS cab ...................... 3 571 mm (11 foot 8.6 inch) Height to top of exhaust pipe ............................... 3 526 mm (11 foot 6.8 inch) Height to top of steering wheel .............................. 2 837 mm (9 foot 3.7 inch) Operating weight ................................................. 23 392 kg (51 570 pounds) Turning angle from center ........................................................ 40 degree 218

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SPECIFICATIONS

D E

K

M

B 7 FT

(2.13mm)

L

C

A

F H

G J

XR Machines with 3.63 m3 (4.75 yd3) General Purpose Bucket with Teeth and Bolt on Edges A. B. C. D. E.

F. G. H. J. K. L. M.

Tipping load, machine straight .............................. 14 927 kg (32 908 pounds) Tipping load, 40 degree turn ................................. 11 914 kg (26 265 pounds) Overall operating height, fully raised .................. 6 186 mm (20 foot 3.5 inch) Height to bucket hinge pin, fully raised ............. 4 834 mm (15 foot 10.3 inch) Dump height, 45 degree dump, full height ........... 3 491 mm (11 foot 5.4 inch) Bucket reach, 45 degree dump, full height ........... 1 323 mm (4 foot 4.1 inch) Bucket reach, 45 degree dump, 7 foot (2134 mm) dump height ....................................... 2 305 mm (7 foot 6.7 inch) Dump angle at full height ................................................................ 45 degree Bucket rollback at ground line ......................................................... 40 degree Digging Depth, bucket flat .................................................... 84 mm (3.3 inch) Wheel Base ................................................................... 3 404 mm (134 inch) Tread width ...................................................................... 2 210 mm (87 inch) Overall length ...................................................... 9 451 mm (31 foot 0.0 inch) Overall height to top of ROPS cab ....................... 3 571 mm (11 foot 8.6 inch) Height to top of exhaust pipe ............................... 3 526 mm (11 foot 6.8 inch) Height to top of steering wheel ............................. 2 837 mm (9 foot 3.7 inch) Operating weight .................................................. 23 754 kg (52 368 pounds) Turning angle from center ........................................................ 40 degree

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BS02B176

SPECIFICATIONS

D E

K

M

B 7 FT

(2.13mm)

L

C

A

F H

G J BS02B176

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XR Machines with 3.82 m3 (5.0 yd3) General Purpose Bucket A. B. C. D. E. F. G. H. J. K. L. M.

Tipping load, machine straight .............................. 15 393 kg (33 937 pounds) Tipping load, 40 degree turn ................................. 12 359 kg (27 247 pounds) Overall operating height, fully raised ................... 6 408 mm (21 foot 0.3 inch) Height to bucket hinge pin, fully raised .............. 4 835 mm (15 foot 10.3 inch) Dump height, 45 degree dump, full height ........... 3 679 mm (12 foot 0.9 inch) Bucket reach, 45 degree dump, full height .......... 1 192 mm (3 foot 10.9 inch) Dump angle at full height ................................................................ 45 degree Bucket reach, 45 degree dump, 7 foot (2 134 mm) dump height ....................................... 2 243 mm (7 foot 4.3 inch) Bucket rollback at ground line ........................................................ 39 degree Digging Depth, bucket flat .................................................... 44 mm (1.7 inch) Wheel Base .................................................................... 3 404 mm (134 inch) Tread width ....................................................................... 2 210 mm (87 inch) Overall length (without bucket teeth) ................... 9 199 mm (30 foot 2.2 inch) Overall height to top of ROPS cab ...................... 3 571 mm (11 foot 8.6 inch) Height to top of exhaust pipe ............................... 3 526 mm (11 foot 6.8 inch) Height to top of steering wheel .............................. 2 837 mm (9 foot 3.7 inch) Operating weight ................................................. 23 465 kg (51 731 pounds) Turning angle from center ........................................................ 40 degree

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SPECIFICATIONS

OPERATING WEIGHT ADJUSTMENTS Optional Equipment Item ROPS Canopy

(kg) -134

Pounds -295

(kg) + 208 - 205 0 + 528 + 722 + 1 495

Pounds + 460 - 452 0 + 1 164 + 1 592 + 3 296

Item 26.5 R 25, XHA TL★ 26.5 x 25, 20 PR, L2 26.5 x 25, 20 PR, L3 26.5 x 25, 20 PR, L4 26.5 x 25, 20 PR, L5 26.5 R 25, XLDD1A TL★

NOTE: Case, LLC. recommends NOT to add ballast to the tires of your machine.

Keep tires inflated to the correct pressure. See Tire Pressure Chart in this manual.

VERTICAL HEIGHT ADJUSTMENT Item

mm

Inch

26.5 x 25, 20 PR, L3

+ 45.7

+ 1.8

26.5 x 25, 20 PR, L4

+ 45.7

+ 1.8

26.5 R 25 XHA TL★

+ 45.7

+ 1.8

26.5 R 25 XRDD1A TL★

+ 45.7

+ 1.8

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Tire Weight Adjustments

SPECIFICATIONS

SPECIAL BOLT TORQUES

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Nm Cover plate to rear trunnion bar ........................... 108 to 122 Trunnion rear inner plate to axle .......................... 285 to 319 Trunnion casting mounting ................................... 658 to 739 Engine support bracket to rear chassis................ 386 to 434 Transmission mounting to transmission ........... 1125 to 1274 Drive line mounting bolts...................................... 136 to 149 Transmission to flywheel housing ............................ 54 to 60 Fan mounting nut ................................................. 108 to 122 Wheel mounting nuts ........................................... 515 to 569 Carrier bearing bolt .............................................. 149 to 163 Hydraulic pump to transmission ........................... 237 to 258 Engine and transmission shock mount nuts....... 929 to 1044 Cab and canopy mounting bolts .......................... 786 to 841 Counterweight bolts ......................................... 1125 to 1261 Hydraulic tank cover bolt.......................................... 20 to 27 Flex plate to flywheel ............................................... 32 to 41 Hydraulic oil filter head to mounting bracket ............ 20 to 27 Engine shock mount nuts..................................... 397 to 447 Steering wheel retaining nut .................................... 41 to 47 Loader linkage pin keeper.................................... 386 to 434 Front axle mounting bolts................................. 1871 to 1979 Muffler clamp to elbow ............................................. 62 to 73 Muffler clamp at turbo .............................................. 16 to 19 Front steering pin bolt .......................................... 664 to 691 Articulation pivot mounting ................................... 205 to 235 Articulation mounting pin keeper.......................... 488 to 515 Upper articulation pin keeper bolt ........................ 386 to 434 Brake pump bolts ................................................... 88 to 100 Brake pump gear nut ........................................... 108 to 122 Brake pump suction line clamps .............................. 10 to 11 Muffler to bracket ..................................................... 66 to 85 Muffler bracket to engine.......................................... 60 to 76 Charge air cooler bolts ............................................. 28 to 34 Charge air hose clamps ............................................. 9 to 10 Exhaust stack to hood.............................................. 27 to 30 Cooler frame mounting bolts ................................ 118 to 149 NOTE: All torques are listed with dry threads.

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POUND-FOOT (80 to 90) (210 to 235) (485 to 545) (285 to 320) (830 to 940) (100 to 110) (40 to 44) (80 to 90) (380 to 420) (110 to 120) (175 to 190) (685 to 770) (580 to 620) (830 to 930) (15 to 20) (24 to 30) (15 to 20) (293 to 330) (30 to 35) (285 to 320) (1380 to 1460) (46 to 54) (12 to 14) (490 to 510) (151 to 173) (360 to 380) (285 to 320) (65 to 74) (80 to 90) (7.5 to 8.3) (49 to 63) (44 to 56) (20.6 to 25.2) (6.7 to 7.5) (19.8 to 22.3) (87 to 110)

INDEX Access Doors ................................ 141 Adding Air To The Tires ................ 131 Adding Ballast Weight To Machine 129 Adjustment Knob for Wrist Rest ...... 78 After Delivery Check ............. 231, 233 Air Cleaner .................................... 152 Air Cleaner Cap ............................. 152 Air Conditioning ............................. 180 Circuit Breakers for Condenser Blower Fans ..................... 180 Lubrication of the Air Conditioning Compressor Seals ............ 180 Temperature Control ................... 81 Air Conditioning Compressor ........ 180 Air Conditioning Compressor Belt . 200 Air Conditioning Condenser .......... 180 Air Conditioning Indicator ................ 41 Air Filter - Cab ............................... 175 Air Filter Indicator ............................ 42 Air Filter Primary Element ............. 153 Air Filter Secondary Element ........ 153 Air Filter Service Specifications ..... 152 Air Filter System ............................ 152 Air Filter, Cleaning ......................... 155 Air Louvers, Cab ............................. 86 Alternator Belt ............................... 200 Removal and Installation ........... 201 Autoshift Switch ......................... 82, 83 Auxiliary F-N-R Switch .............. 67, 70 Auxiliary Hydraulic Connection ..... 117 Auxiliary Hydraulic System Specifications .......................... 117 Auxiliary Power Equipment Mounting Bracket .................................... 208 Auxiliary Power Outlet ................... 208 Axle Late Production ZF Oil Change, Front Axle .............. 173 Axle Oil Change, Front .................. 173 Axle Oil Change, Rear .................. 174 Axle Oil Level ................................ 172 Axle Service Specifications ........... 172 Axle, Late Production ZF Oil Change, Rear Axle .............. 174

Axles Late Production ZF ........... 172, 173

B Ballast, Wheel ............................... 129 Batteries Cold Weather Operations ......... 125 Battery 206 Fluid Level ................................. 206 Master Disconnect Switch ........... 85 Safety ........................................ 205 Service ...................................... 205 Vents ......................................... 206 Battery Cleaning ............................ 206 Battery Connection - Booster ........ 103 Battery Fluid Level ........................ 206 Battery Safety ................................ 205 Battery Service .............................. 205 Battery Vents ................................. 206 Beacon Indicator ............................. 35 Before Starting The Engine ............. 95 Belt Alternator, Removal and Installation .. 201 Belt - Air Conditioning Compressor 200 Belt - Alternator ............................. 200 Belt - Fan ....................................... 200 Belt, Seat ....................................... 197 Belts Seat ............................................. 96 Belts, Seat ....................................... 92 Bleeding the Brake System ........... 167 Blower Fan Switch .......................... 78 Bolt Torques, Special .................... 222 Booster Battery Connection .......... 103 Brake Park, Switch ................................ 33 Parking, Check .......................... 187 Brake Pressure Indicator ................. 36 Brake System Bleeding .................................... 167 Brakes Pedals ......................................... 65

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A

INDEX Bucket Height Control Adjustment .........194 Height Control Minor Adjustment ..............194 Bucket Height Control Adjustment .194 Bucket Height Control Function .....114 Bucket Height Control Minor Adjustment ...............................194 Bucket Level Indicator ....................117 Bulbs, Replacement .......................209 Button Cold Start .....................................31

C

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Cab Cab Headliner ............................181 Door Hinges ...............................181 Hoses and Wiring ......................181 Operators Seat ..........................182 Cab Air Filter ..................................175 Circulation Cover Late Production .................175 Cleaning .....................................176 Removal and Installation ...........175 Cab Headliner ................................181 Cab Service ...................................180 Cap, Air Cleaner ............................152 Caution Master Indicator ..................39 Chart - Tire Pressure .....................132 Chart, Lubrication ...........138, 139, 140 Chart, Maintenance ........138, 139, 140 Charts Hydraulic System Fluid ..............162 Chemicals, Hazardous .....................16 Cleaning The Air Filter ...................155 Cleaning the Batteries ....................206 Cleaning The Battery .....................206 Cleaning The Cooling System .......158 Clutch Calibration Main Codes ................................184 Sub-Codes .................................184 Transmission .............................183 Cold Start Button ..............................31 Cold Weather Starting ....................179 Conditioner, Fuel ............................159

Console Front ..................................... 29, 30 Identification Front 29, 30, 31, 32, 33 Side Console ...... 77, 78, 79,80, 81, ................................ 82, 83, 84 Console Front ...................... 31, 32, 33 Control Steering Wheel Tilt ..................... 32 Control Levers Four Spool Valve - Two Control Levers .............................. 112 Three Spool Valve - Three Control Levers .............................. 110 Three Spool Valve - Three Control Levers - Optional Forestry Configuration .................... 110 Three Spool Valve - Two Control Levers .............................. 111 Two Spool Valve One Control Lever ............ 109 Two Spool Valve - Two Control Levers .............................. 108 Control Levers - Loader ................ 108 Controls Air Conditioning Temperature ..... 81 Blower Fan .................................. 78 Hand ................... 29, 30, 31, 32, 33 Heat, Cab .................................... 78 Lamp Switch ............................... 80 Wiper/Washer Switch ................. 79 Coolant Filter, Engine .................... 157 Cooling System Cold Weather Operations ......... 125 Coupler Pin Engage Switch ............ 84 Coupler Pin Engagement .............. 119

D Deaeration Tank ............................ 157 Decals, Safety ................................. 17 Declutch ........................................ 116 Declutch Switch ............................... 81 Defrost Air Louvers ......................... 87 Detent On/Off Switch ...................... 81 Diesel Fuel System ....................... 159 Disabled Machine Towing ............. 122

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INDEX

E Electrical Service Connector .................... 207 Electrical System ........................... 205 Emergency Exit ............................... 93 Engine Data .......................................... 213 Ether Starting of ................ 100, 101 Specifications ............................ 213 Engine Coolant Cleaning the Cooling System .... 158 Fluid Level ................................. 157 Engine Coolant Heater .................. 102 Engine Coolant Mixture ................. 156 Engine Coolant Temperature Gauge ................. 48 Engine Cooling System Coolant Mixture ......................... 156 Service Specifications ............... 156 Thermostat ................................ 156 Engine Cooling System Specifications .......................... 156 Engine Hourmeter ......................... 136 Engine Lubrication ........................ 147 Engine Oil Change ........................ 150 Engine Oil Filter ............................. 150 Engine Oil Level ............................ 149 Engine Oil Pressure Gauge, Late Production ................................. 47 Engine Oil Selection ...................... 147 Engine Service Specification ......... 149 Engine Speed .................................. 98 Environment .................................. 135 Ether Cold Start ............................. 100 Ether Container ............................. 179 Ether Container Replacement ....... 179 Ether Storage ................................ 179

Exit Emergency .................................. 93 Extinguisher Mounting, Fire ........... 203

F Fact Attachment ............................ 119 Fan Belt ......................................... 200 Filter Air .............................................. 153 Cab Air ...................................... 175 Coolant ...................................... 157 Engine Coolant ......................... 157 Engine Oil ................................. 150 Fuel ........................................... 161 Hydraulic Oil .............................. 164 Transmission Oil ....................... 170 Filter Replacement, Air .................. 153 Filter Replacement, Engine Coolant ....................... 157 Filter Replacement, Engine Oil ...... 150 Filter Replacement, Hydraulic Oil .. 164 Filter Replacement, Transmission Oil ..................... 170 Fire Extinguisher Mounting ............ 203 Fire Prevention Information ............. 14 First Service Intervals ...................... 96 Fittings, Grease 1000 Hours ............................... 143 50 Hours ................................... 142 Float .............................................. 115 Fluid and Lubricants ...................... 137 Fluid and Lubricants, Capacities ... 137 Fluid Level ..................................... 157 Fluid Levels ................................... 144 10 Hours ................................... 144 250 Hours ................................. 146 50 Hours ................................... 145 Foot Pedals Brake Pedals ............................... 65 Foot Throttle ................................ 65 Four-Way Flasher Lamp .................. 35 Four-Way Flasher Switch ................ 29 Front Console .......... 29, 30, 31, 32, 33 Four-Way Flasher ....................... 29 Pilot Control Switch ..................... 29 Program/Reset Switch ................ 30

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Display Center Transmission ................... 62, 63, 64 Displays Warning Non - Critical Warning Displays .. 39 Door Hinges .................................. 181 Door Hinges Maintenance ............. 181 Door Latch ....................................... 88 Door, Access ................................. 141

INDEX Up/Down Count Switch ................30 Fuel Conditioner .............................159 Fuel Filter .......................................161 Fuel Level Gauge .............................46 Fuel Storage ..................................160 Fuel System Cold Weather Operations ..........125 Diesel Fuel Specifications ..........160 Fuel Conditioner ........................159 Fuel Filter ...................................161 Fuel Storage ..............................160 Removing Water From The Fuel System ..............................161 Fuel System Service Specifications .............159 Function Switches - Loader ...........113 Fuse Panel .....................................207 Fuses .............................................207

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G Gauge Engine Coolant Temperature .......48 Engine Oil Pressure, Late Production ...................47 Fuel Level ....................................46 Hydraulic Oil Temperature ...........44 Transmission Oil Temperature ....43 Volt Meter ....................................45 General Safety ...............................133 Grease Fittings 1000 Hours ................................143 50 Hours ....................................142

H Hand Signals ....................................26 Heat Control, Cab ............................78 Horn .................................................32 Hoses and Wiring ...........................181 Hot Weather Operation ..................127 Hourmeter, Engine .........................136 Hydraulic Connection - Auxiliary ....117 Hydraulic Filter Test .......................163 Hydraulic Oil Filter ..........................164 Hydraulic Oil Filter Indicator .............42 Hydraulic Oil Temperature Gauge ...44

Hydraulic System Filter Replacement .................... 164 Fluid Chart ................................ 162 Hydraulic Filter Test .................. 163 Hydraulic/Brake Oil Change ..... 165 Hydraulic System Service Specifications ......................... 162 Hydraulic/Brake Oil Change .......... 165

I Identification Numbers ...................... 4 Indicator Air Conditioning .......................... 41 Air Filter ...................................... 42 Beacon ........................................ 35 Brake Pressure ........................... 36 Caution Master ........................... 39 Hydraulic Oil Filter ...................... 42 Lamp ........................................... 36 Low Coolant ................................ 36 Parking Brake ............................. 41 Pilot Lockout ............................... 36 Secondary Steering .................... 41 Stop Master ................................ 37 Transmission Oil Filter ................ 42 Indicator Lamps, Instrument Panel ... 35, 36, 37, 39, ......... 41, 42, 43, 44, 45, 46, 47, 48 Information Center .......................... 49 Programming ........................ 50, 56 Instructions, General Safety .......... 133 Instrument Cluster .. 35, 36, 37, 39, 41, ............... 42, 43, 44, 45, 46, 47, 48 Instrument Panel Indicator Lamps ...... .................... 35, 36, 37, 39, 41, 42, ..................... 43, 44, 45, 46, 47, 48

J Jump Start ..................................... 103

K Key Switch, Ignition ......................... 34

L Lamp Indicator ................................ 36 Lamp Switch, Cab ........................... 80

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INDEX Lubrication Analysis, Systemgard ....... ......................................... 134, 151 Lubrication Chart ........... 138, 139, 140 Lubrication, Engine ....................... 147

M Machine Components ....................... 6 Machine Operation ........................ 104 Before Operating ....................... 104 Transmission Operation ............ 106 Machine Storage ........................... 211 Removal From .......................... 212 Storage Preparation .................. 211 Machine Storage Removal ............ 212 Machine Tie Down Locations ........ 124 Main Air Louvers ............................. 86 Maintenance and Inspection of ROPS .................................. 197 Maintenance Chart ........ 138, 139, 140 Master Disconnect Switch ............... 85

O Oil Change, Engine ....................... 150 Oil Level Axle ........................................... 172 Engine ....................................... 149 Transmission ............................. 170 Oil Level, Transmission ................. 170 Oil Selection, Engine ..................... 147 Oil Viscosity/Temperature Ranges 148 Operating Data Specifications 921C ................ 215 Operating Data Specifications 921C -XR ......... 218 Operating Dimensions Specifications .................. 215, 218 Operating In Hot Weather ............. 127 Operating Instructions ..................... 95 Before Starting The Engine ......... 95 Operating The Machine ................. 104 Operating Tips - Loader ................ 120 Operating Weight Adjustments ...... 221 Operator Manual Storage Compartment ................ 2 Operators Seat ........................ 89, 182 Optional Equipment ....................... 221

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Lamps Four-Way Flasher ....................... 35 Turn Signal .................................. 35 Latch Door ............................................ 88 Window ....................................... 88 Window Retainer ......................... 88 Lever Transmission Control .................. 31 Turn Signal .................................. 32 Levers Loader Control ............................ 66 Link, Safety ................................... 135 Link, Transport .............................. 135 Loader Bucket Height Control Adjustment ........... 194 Bucket Height Control Minor Adjustment ....................... 194 Return-To- Travel Minor Adjustment ............. 191 Return-To-Dig Adjustment ........ 189 Loader Adjustments ...................... 189 Loader Control Levers ............. 66, 108 Four Spool - Two Levers ............. 75 Three Spool - Three Levers ........ 71 Three Spool - Two Levers ........... 71 Two Spool - One Lever ............... 66 Two Spool - Two Levers ............. 68 Loader Function Switches ............. 113 Bucket Height Control ............... 114 Float .......................................... 115 Return-To-Travel ....................... 114 Loader Operating Tips .................. 120 Leveling Operation .................... 120 Pushing Operation .................... 120 Scraping Operation ................... 120 Transport and Carry Operation . 121 Loader Operations Cold Weather ............................ 125 Louvers Defrost Air ................................... 87 Main ............................................ 86 Recirculation ............................... 86 Low Coolant Indicator ..................... 36

INDEX Owner, To The ...................................1

P

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Park Brake Switch ............................33 Parking Brake Check .....................187 Parking Brake Indicator ....................41 Parking The Machine .......................99 Pedals, Foot .....................................65 Pilot Control Switch ..........................29 Pilot Lockout Indicator ......................36 Plastic and Resin Parts ..................135 Power Outlet, Auxiliary ...................208 Pressure, Tire ................................129 Primary Element, Air Filter .............153 Priming the Turbocharger Lines with Oil .98 Product Identification Number ............4 Program/Reset Switch .....................30 Programming Gauge Displays ...........................55 Information Center .................50, 56 Setting Display Center Lamp .......60

R Radiator Fluid Level .................................157 Radio ................................................87 Rear Wiper/Washer Switch ..............82 Remove From Storage ...................212 Removing Water From The Fuel System .....................................161 Reservoir, Windshield Washer .......177 Return-To-Dig Adjustment .............189 Return-To-Dig Function .................113 Return-To-Travel ............................114 Return-To-Travel Minor Adjustment .....................191 Return-To-Travel Switch ..................81 Ride Control ...................................116 Ride Control Switch .........................82 Roll-Over Protective Structure .......197 ROPS .............................................197 Cab Torque ................................197 Canopy Torque ..........................197 Damage to .................................198 Maintenance and Inspection of ......................197

Seat and Seat Belt, Torque Specifications ................... 199 Seat Belt ................................... 197 ROPS Cab Torque Specifications . 197 ROPS Canopy Torque Specifications ............. 197 ROPS Damage Information .......... 198 Rotating Beacon ............................ 118 Rotating Beacon Switch .................. 83 Run-In Procedure ............................ 95

S Safety Decals ......................................... 17 Hand Signals .............................. 26 Hazardous Chemicals ................. 16 Utility ........................................... 10 Safety Instructions, General .......... 133 Safety Link, Service ...................... 135 Safety Rules ...................................... 9 Before Operation ........................ 11 Burn Prevention .......................... 14 Fire/Explosion Prevention ........... 14 Machine Operation ..................... 12 Maintenance ............................... 13 Parking the Machine ................... 12 Wheels and Tires ........................ 15 Safety, Battery ............................... 205 Safety/Decals/Hand Signals .............. 9 Seat Operators .................................... 89 Optional Air Ride ......................... 90 Standard ..................................... 89 Seat Belt ........................................ 197 Seat Belts .................................. 92, 96 Inspection and Care .................... 92 Seat Torque Specifications ........... 199 Seat, Operators ............................. 182 Secondary Element, Air Filter ....... 153 Secondary Steering Indicator .......... 41 Sediment Removal, Fuel System .. 161 Serial Numbers ................................. 4 Service Electrical Connector ......... 207 Service Intervals - First ................... 96 Service Safety Link ....................... 135 Setting Display Center Lamp .......... 60

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Special Bolt Torques ..................... 222 Specifications Air Filter ..................................... 152 Auxiliary Hydraulic System ....... 117 Axle ........................................... 172 Bucket ....................................... 214 Cooling System, Engine ............ 156 Diesel Fuel System ................... 159 Engine Cooling System ............. 156 Engine Service .......................... 149 Fuel System .............................. 159 Hydraulic System ...................... 162 Machine ............................ 215, 218 Machines with 4.75 yd3 (3.63 m3) General Purpose Bucket with Teeth and Bolt on Edges .. 216 Machines with 5.0 yd3 (3.82 m3) General Purpose Bucket .. 217 ROPS Torque ........................... 197 Seat Torque .............................. 199 Special Bolt Torques ................. 222 Thermostat ................................ 156 Tire Weight ................................ 221 Transmission ............................. 169 Travel Speeds ........................... 214 Vertical Height Adjustment ........ 221 Weight Adjustments .................. 221 XR Machines with 4.75 yd3 (3.63 m3) General Purpose Bucket .

218 XR Machines with 4.75 yd3 (3.63 m3) General Purpose Bucket with Teeth and Bolt on Edges .......................................... 219 XR Machines with 5.0 yd3 (3.82 m3) General Purpose Bucket .. 220 Specifications, Engine Data .......... 213 Starting The Engine ........................ 97 Steering Wheel Tilt Control ............. 32 Steering, Secondary ...................... 186 Stop Master Indicator ...................... 37 Stopping The Engine ....................... 99 Storage Compartment Operator Manual ........................... 2 Storage Removal, Machine ........... 212 Storage, Fuel ................................. 160

Switch ............................................ 116 Autoshift ...................................... 82 Blower Fan .................................. 78 Coupler Pin Engage .................... 84 Declutch .............................. 81, 116 Detent On/Off .............................. 81 F-N-R .................................... 67, 70 Four-Way Flasher ....................... 29 Key/Ignition ................................. 34 Lamp ........................................... 80 Master Disconnect ...................... 85 Master Disconnect Switch ........... 85 Park Brake .................................. 33 Pilot Control ................................ 29 Program/Reset ............................ 30 Rear Wiper/Washer .................... 82 Return-To-Travel ......................... 81 Ride Control ................................ 82 Rotating Beacon ......................... 83 Up/Down Count ........................... 30 Wiper/Washer ............................. 79 Systemgard Analysis ............. 134, 151

T Thermostat Specifications ............. 156 Throttle, Foot ................................... 65 Tire Or Rim Service ....................... 131 Tire Pressure ................................. 129 Tire Pressure Chart ....................... 132 Tire Tread Direction ....................... 131 Tire Weight Adjustments ............... 221 Torque - Wheel Nut ....................... 132 Towing The Machine ..................... 122 Towing, Machine ........................... 122 Transmission Breather Cleaning ..................... 170 Clutch Calibration ...................... 183 Clutch Calibration Main Codes . 184 Clutch Calibration Sub-Codes ... 184 Cold Oil Level Check ................ 170 Control Lever .............................. 31 Filter Replacement .................... 170 Oil Change ................................ 170 Oil Level .................................... 170 Operation of .............................. 106 Warm Oil Level Check .............. 170

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INDEX

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Transmission Breather Cleaning ....170 Transmission Clutch Calibration ....183 Transmission Display Center 62, 63, 64 Transmission Oil Filter ...................170 Transmission Oil Filter Indicator .......42 Transmission Oil Level ...................170 Transmission Oil Level Check ........170 Transmission Oil Temperature Gauge ..................43 Transmission Operation Automatic Mode Operation ........107 Declutch Operation ....................116 Down-shift Button, Automatic Mode ................107 Down-Shift Button, Manual Mode ....................107 Down-Shifts Manual Mode .........107 Initial Machine Movement ..........106 Manual Mode Operation ............106 Shifting, Automatic Mode ...........107 Up-Shifts Manual Mode .............106 Transmission Service Specifications ..........................169 Transport Link ................................135 Transporting The Machine .............123 Transporting The Machine On A Trailer .............................124 Turbocharger Priming the Lines with Oil ............98 Turn Signal Lever .............................32

Weight Adjustments - Operating ... 221 Wheel And Tires ............................ 129 Wheel Ballast ................................ 129 Wheel Nut Torque ......................... 132 Window Latch .................................. 88 Window Retainer Latch ................... 88 Windshield Washer Reservoir ....... 177 Wiper/Washer Switch ...................... 79 Wrist Rest ........................................ 78

U Up/Down Count Switch ....................30 Utility Safety .....................................10

V Vertical Height Adjustment .............221 Volt Meter Gauge .............................45

W Warm Oil Level Check ...................170 Warning Displays Non - Critical Warning Displays ...39 Water Removal, Fuel System ........161 Weight Adjustments Optional Equipment ...................221 Tire Weight ................................221 230

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AFTER DELIVERY CHECK AFTER FIRST 100 HOURS OF OPERATION OF NEW MACHINE

Owners Name: Address: Dealers Name: Address: Hourmeter Indication:

Machine Model Number: Machine Product Identification Number (P.I.N.): COOLING SYSTEM

HYDRAULIC SYSTEM

Check the coolant levels.

Check the oil level.

Check for leaks.

Check the pressure setting of the main relief valve.

Replace the hydraulic oil filter.

FUEL SYSTEM Check for leaks.

GENERAL

Drain water and sediment from the fuel tanks.

Check tire pressure.

ELECTRICAL SYSTEM Check battery.

Tighten all hose clamps.

Check operation of starter, alternator, and instruments.

Check drive chain tension.

Check operation of all lamps.

Check brake operation.

Check wheel nut torque.

Check the control levers for correct operation.

LUBRICATION

Check the operators seat bar for correct operation.

Lubricate all pivot points.

Engine Check condition of drive belt.

SAFETY

Check engine oil level.

Inspect the ROPS.

Check engine speed at idle and at full throttle.

Check the safety decals and replace if necessary.

Service air cleaner.

Check the operator restraint system.

Make sure the machine has the operators manual in the manual storage box.

DEALER: Make sure the owner and/or operator understands all the safety and information decals, the service information, and the service procedures in this manual.

Technician Signature: Dealer Signature: Owner Signature: Dealer Copy

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Look for oil leaks and loose parts.

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AFTER DELIVERY CHECK AFTER FIRST 100 HOURS OF OPERATION OF NEW MACHINE

Owners Name: Address: Dealers Name: Address: Hourmeter Indication:

Machine Model Number: Machine Product Identification Number (P.I.N.): ENGINE

HYDRAULIC SYSTEM

Check the engine oil level.

Check for leaks.

Check air cleaner.

Tighten all hose clamps.

Check the reservoir oil level.

COOLING SYSTEM Tighten all hose clamps.

GENERAL

Check the coolant level of radiator and coolant reservoir.

Check the control levers for correct operation.

SAFETY

Check for leaks.

Check the safety and information decals.

Drain water and sediment from the fuel tanks.

Check the torque of ROPS and seat belt mounting bolts.

ELECTRICAL SYSTEM

Make sure the Operator’s Manual and Safety Manual are in the Manual Storage Box.

Check operation of starter, alternator, and instruments.

Check operation of all lamps.

LUBRICATION Lubricate all pivot points.

Check oil level of final drives.

Check transmission oil level.

DEALER: Make sure the owner and/or operator understands all the safety and information decals, the service information, and the service procedures in this manual.

Technician Signature: Dealer Signature: Owner Signature: Owner Copy

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FUEL SYSTEM

Check the operation of the brakes.

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