Case 921E Tier III Wheel Loader Operator's Manual 87538969 - PDF DOWNLOAD

OPERATOR’S MANUAL

WHEEL LOADER 921E TIER III

87538969 EUR

European English Part Number 87538969 EUR Printed in U.S.A. • Bur

Issued 02-2007

OPERATOR’S MANUAL

WHEEL LOADER 921E TIER III

87538969 EUR

European English Part Number 87538969 EUR Printed in U.S.A. • Bur

Issued 02-2007

921E TIER III WHEEL LOADERS OPERATOR’S MANUAL Part Number: 87538969

CASE TECHNICAL MANUALS Manuals are available from your Dealer for the operation, service, and repair of your machine. For prompt convenient service, contact your Dealer for assistance in obtaining the manuals for your machine.

Your Dealer can expedite your order for Operator’s Manuals, Parts Catalogs, Repair Manuals, and Maintenance records.

Always give the Machine Name, Model, and P.I.N. (Product Identification Number) or S.N. (Serial Number) of your machine so your Dealer can provide the correct manuals for your machine.

NOTE: CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF DEATH OR SERIOUS INJURY M171D

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

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

●

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

●

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

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

The first panel indicates the nature of the hazard.

●

The second panel indicates the appropriate avoidance of the hazard.

●

Background color is YELLOW

●

Prohibition symbols such as

and

STOP

if used, are RED.

IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR: ●

Is instructed in safe and proper use of the machine.

●

Reads and understands the Manual(s) pertaining to the machine.

●

Reads and understands ALL Safety Decals on the machine.

●

Clears the area of other persons.

●

Learns and practices safe use of machine controls in a safe, clear area before operating this machine on a job site.

It is your responsibility to observe pertinent laws and regulations and follow CNH America LLC instructions on machine operation and maintenance.

WARNING_01_NA

CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Battery post, terminals and related accessories contain lead and lead compounds.

Wash hands after handling.

Copyright © 2007 CNH America LLC All Rights Reserved

Bur 87538969EU Issued February 2007 Case is a registered trademark of CNH America LLC

TABLE OF CONTENTS CHAPTER 1 GENERAL INFORMATION To the Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 CHAPTER 2 SAFETY, AND DECALS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Utility Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 CHAPTER 3 INSTRUMENTS AND CONTROLS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Access Doors and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Front Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Instrument Panel Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Side Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 CHAPTER 4 OPERATING INSTRUCTIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 CHAPTER 5 LUBRICATION, FILTERS, AND FLUIDS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Servicing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Support Strut for Loader Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Releasing Pressure in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Engine Oil Viscosity / Temperature Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Daily Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Lubrication and Maintenance Quick Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Access Doors and Fill Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 CHAPTER 6 MAINTENANCE AND ADJUSTMENTS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Cab Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 CHAPTER 7 ELECTRICAL Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Machine Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

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CHAPTER 8 SPECIFICATIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 CHAPTER 9 INDEX

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CHAPTER 1 - GENERAL INFORMATION

Chapter 1 GENERAL INFORMATION TO THE OWNER

Figure 1

BD06F164

921E

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

Your dealer can give you help with Case approved service parts. Your dealer has experienced and 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.

CNH America LLC P.O. Box 6006 Fargo, ND 58102

Dealer’s Stamp

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1-1

CHAPTER 1 - GENERAL INFORMATION

Figure 2

BD06F005

921E

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

This Wheel Loader, with standard equipment and attachments is intended to be used for digging and general earth moving purposes 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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CHAPTER 1 - GENERAL INFORMATION

Figure 3

BD06F007

DO NOT use this machine for any application or purpose other than those described in this manual. If the loader is to be used in an application that involves special attachments or equipment, such as forestry, etc., consult an authorized dealer. Consult an authorized dealer on changes, additions or modifications that can be required for this machine to comply with various country regulations and safety requirements. Unauthorized modifications may cause serious injury or death. Anyone making such unauthorized modifications is responsible for the consequences.

This Operators Manual is to be stored in the manual compartment equipped on this machine. Make sure this manual is complete and in good condition. Contact your dealer to obtain additional manuals. Contact your dealer for any further information or assistance about your machine.

Before permitting a new operator on this machine, make certain:

• That the operator has received the necessary training to operate the machine correctly and safely.

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

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

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

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CHAPTER 1 - GENERAL INFORMATION RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE

FRONT

Figure 4

BD06F071

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

READ THIS MANUAL COMPLETELY and make certain 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.

LEFT

RIGHT

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.

When you see this symbol read your Operator’s Manual

When you see this symbol refer to your Repair Manual

REAR Figure 5

B891464

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

The terms Right-hand, Left-hand, Front, and Rear are used in this manual to indicate the sides as they are seen from the operator's seat.

The first panel indicates the nature of the hazard.

The second panel indicates the appropriate avoidance of the hazard.

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

1-4

and

STOP

if

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CHAPTER 1 - GENERAL INFORMATION

MACHINE COMPONENTS

6

1 5

7

4

1 1

2

8

3 Figure 6

BD06F164

MACHINE COMPONENTS 1.

2.

3.

4.

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CAB DOOR AND HAND HOLDS STEPS BUCKET BELLCRANK

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5.

6.

7.

8.

BUCKET CYLINDER ROPS CAB ENGINE HOOD LEFT BATTERY ACCESS

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CHAPTER 1 - GENERAL INFORMATION

5

4

2

6

3 1

9

8 7 Figure 7

BD06F166

MACHINE COMPONENTS

1. Right Side Battery Compartment 2. Engine Hood 3. Cab Air Filter Access

1-6

4. Front Console 5. Bucket Cylinder 6. Loader Lift Arm

7. Bucket 8.Windshield Washer Reservoir 9. Hood Switch and Disconnect Switch

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CHAPTER 1 - GENERAL INFORMATION OFFICIAL DOCUMENT AND COMPLIANCE INFORMATION EC Declaration of conformity and environmental noise conformity for an earth-moving machine.

Declaration of Conformity to Directive 98/37/EC Machinery, including conformity statement to Directive 2000/14/EC: Noise Emission - Environment - Equipment for use outdoors European harmonized standards by which conformity is declared:

• EN474-1:1994 • EN474-3:1996 Vibration Level The magnitude of vibration in the z-axis transmitted to the operator's seat does not exceed 1.25 m/s2 when tested per ISO 7096, Class 3 Guaranteed Sound Power Level 921E Wheel Loader....................................................................................................................................... 108 dBa

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CHAPTER 1 - GENERAL INFORMATION IDENTIFICATION NUMBERS

PRODUCT IDENTIFICATION NUMBER (P.I.N.)

MODEL, SERIAL NUMBER, AND YEAR OF MANUFACTURE When ordering par ts, obtaining infor mation or assistance, always supply your dealer with the type and serial number of your machine or accessories.

Write the following information in the spaces below: The type, serial number and year of manufacture of your machine, accessories and the serial numbers of the various hydraulic and mechanical components.

Make a record of the numbers and keep the record and your Manufacturer’s Statement of Origin in a safe place. If the machine is stolen, repor t the numbers to your local law enforcement agency.

Figure 8

BD07A165

ENGINE

PRODUCT IDENTIFICATION PLATE ➤ Model ➤ Serial Number ➤ Manufacturing Year

ENGINE ➤

Figure 9

BD07A056

TRANSMISSION Make and Model

➤ Serial Number

COMPONENT SERIAL NUMBERS ➤ Transmission ➤ Axle ➤

Figure 10

BD07A055

ROPS Cab

AXLE

➤

Figure 11

BD07A054

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CHAPTER 2 - SAFETY, AND DECALS

Chapter 2 SAFETY, AND DECALS TABLE OF CONTENTS SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 PERSONAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 UTILITY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Personal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Mounting and Dismounting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Fuel Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Burn Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Hazardous Chemical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Transporting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Seat Belt Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Specific Precautions to this Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

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NOTES

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CHAPTER 2 - SAFETY, AND DECALS

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

M171C

Most accidents involving machine operation 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.

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

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

• WARNING: Indicates a potentially hazardous situation which, if not avoided will result in serious injury. The color associated with Warning is ORANGE. Figure 1

BD06F071

OPERATOR’S MANUAL STORAGE SPACE

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

• CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW. ISO two panel pictorial symbol decals, if used are defined as follows:

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

• The first panel indicates the nature of the hazard.

• The second panel indicates the appropriate

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.

Prohibition symbols such as used, are RED.

avoidance of the hazard.

• Background color is YELLOW. and

STOP

if

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

IMPORTANT: The safety messages in this chapter point out conditions which can happen during the normal operation and maintenance of your machine.

These safety messages also give possible ways of dealing with these conditions.

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CHAPTER 2 - SAFETY, AND DECALS

UTILITY SAFETY Safety precautions MUST be followed when working near buried and overhead utility lines.

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

• • • •

Electrical Power Line Gas Line Water Line Communication Line - Telephone or Cable Television

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

Figure 2

RH99G001

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

In U.S.A. and Canada, call one of many “One Call System Directory” services. If you do not know the local number, call the national number (U.S.A. and Canada only): 1-888-258-0808.

IMPORTANT: Check with local authorities for laws, regulations and/or strict penalties requiring you to locate and avoid existing utilities.

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

Keep machine and attachments a safe distance from electrical power lines. Failure to comply could result in injury or death.

2-4

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION

Know the utility color code (U.S.A. and Canada): Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Gas, Oil, or Petroleum. . . . . . . . . . . . . . . . Yellow Communication, Telephone, Television. . Orange Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blue Sewer . . . . . . . . . . . . . . . . . . . . . . .Green/Brown Proposed Excavation . . . . . . . . . . . . . . . . .White Surveying . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink Reclaimed Water and Slurry . . . . . . . . . . . Purple After locating any buried utility lines, carefully dig a hole by hand and/or automatic vacuum equipment to the utility line to verify the location and depth of the line.

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CHAPTER 2 - SAFETY, AND DECALS PERSONAL

MOUNTING AND DISMOUNTING PRECAUTIONS

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

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

• Know and use the protective equipment that is to be worn when operating this machine. Hard hats, protective glasses, protective shoes, gloves, reflector type vests, respirators and ear protection are examples of equipment that may be required.

• Certain protective equipment should be replaced and renewed upon age and wear. Old hard hats may not afford the original intended protection.

Faded and soiled vests are no longer as highly visible as the original intent. See the manufacturer’s recommendation.

• Do not rush. Walk, do not run.

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

GENERAL

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

• Do not operate this machine or perform maintenance work if you have not had appropriate training. Read and fully understand all the instructions and warnings in this manual.

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

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

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

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

• Remove all loose objects stored in the machine.

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

BD07A003

Figure 3

• Use the recommended hand holds and steps with at least three points of support when getting on and off the machine. The door must be latched and secured in the open position before using the door hand hold. Keep steps and platform clean.

Face the machine and use the hand holds and steps adhering to a three-point access system when climbing up and down.

• Do not jump off the machine.

• Do not dismount while the machine is in motion.

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

STARTING AND STOPPING PRECAUTIONS

• Walk around the machine and warn all personnel who may be servicing the machine or are in the machine path prior to starting. Do not start until all personnel are clearly away from the machine.

Sound the horn, if equipped, before starting.

• Walk around the machine’s tool, attachment, or furthermost contact point to view operation danger area from the work site personnel’s view and angle.

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

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

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

• Do not bypass the machine’s neutral-start system.

The neutral-start system must be repaired if it malfunctions.

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CHAPTER 2 - SAFETY, AND DECALS

• Use battery booster cables only in the

• Know and understand the job site traffic flow

recommended manner. Improper use can result in battery explosion or unexpected machine motion.

Ventilate the battery area before using booster cables. Make sure that using jumper cables will not interfere or harm electronic processing or computer devices.

patterns and obey signalmen, road signs, and flagmen.

• Do not operate the engine in an enclosed area without adequate ventilation.

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

• Park the machine on level ground whenever

• Watch for bystanders and never allow anyone to

possible and apply the parking brake. On grades, park the machine with the wheels or track securely blocked.

be under or to reach through the machine and its equipment while operating.

• Before leaving the operator’s station, lower the bucket/attachment to the ground, shut off the engine.

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

• When roading a machine, know and use the

• Remove the starter key and/or use the disconnect

signaling devices required on the machine.

Provide an escort for roading where required.

switch when leaving the machine parked or unattended.

• On machines with independently operated wheel

OPERATING PRECAUTIONS

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

• If a failure that causes loss of control such as steering, service brakes, or engine occurs, stop the machine motion as quickly as possible, remove the starter key or disconnect switch key.

Place a DO NOT OPERATE tag on the machine, and keep it securely parked until the malfunction is corrected or the machine can be safely towed.

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

• Operate and drive the machine with care and at

brakes, lock the brake pedals together when roading to provide equalized brake application.

• Use the recommended transport devices when roading the machine. Proper lights, flashers, signals, and beacons may be required. Use reflective slow moving vehicle signs where necessary. Follow local, state, and federal regulations.

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

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

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

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

speed compatible with conditions. Use extra caution when operating over rough ground, on slopes, and when turning.

• Check all controls in a clear area and make sure

• Note and avoid all hazards and obstructions such

and cause an accident. Stop the machine or decrease the speed until you can see.

as ditches, underground lines, trees, cliffs, overhead electrical wires, or areas where there is danger of a slide.

• Carry loads in recommended positions for maximum stability.

• Never lift loads in excess of capacity.

• Use the recommended machine ballast and counterweighting.

2-6

the machine is operating correctly.

• Dust, fog, smoke, etc., can decrease your vision • Contact

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

• Before you drive or operate in an area with high voltage lines, cables, or a power station, tell the power or utility company what you are going to do.

You MUST HAVE THE POWER DISCONNECTED OR KEEP A SAFE WORKING DISTANCE from the lines, cables, or power station.

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• Keep all parts of the machine a safe distance

• Avoid lubrication or mechanical adjustments with

away from the power source. See the decal on the machine. You must also know any federal, state/provincial, or local safety codes or regulations that apply to the job site.

the machine in motion or the engine operating. If the engine must be in operation to make certain adjustments, place the transmission in neutral, apply the parking device, place the bucket/attachment in a safe position, securely block the wheels and use extreme caution.

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

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

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

• Do not operate the machine if you do not feel well.

This can be dangerous for you and for the people around you.

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

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

• Be alert and always know the location of all workers in your area. Keep all other persons completely away from your machine. Injury or death can result if you do not follow these instructions.

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

MAINTENANCE PRECAUTIONS

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

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

• Wear protective glasses and other required safety equipment machine.

when

servicing

or

repairing

the

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

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

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

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

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

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

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

• Towing this machine is not recommended.

• When absolutely necessary to tow the machine, do not exceed the recommended towing speed.

Be sure the towing machine has sufficient braking capacity to stop the towed load. If the towed machine cannot be braked, a towbar must be used or two towing machines must be used - one in front pulling and one in the rear to act as a brake.

Avoid towing over long distances.

• Observe proper maintenance procedures.

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

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

• Wear gloves to protect hands when handling cable.

• Disconnect the battery before working on the

• Replace all missing, illegible or damaged safety signs or decals as necessary. Keep all safety signs and decals clean and legible.

electrical system. Know the consequences of disconnecting any electronic or computer devices.

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CHAPTER 2 - SAFETY, AND DECALS

• Hot coolant can spray out if the cooling system

FUEL HANDLING PRECAUTIONS

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

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

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

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

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

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

• Never use fuel for cleaning purposes.

• Use the correct diesel fuel grade for the operating season.

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

Antidote: EXTERNAL - Flush with water.

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

DO NOT induce vomiting. Seek medical attention immediately.

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

WARNING: BATTERIES PRODUCE EXPLOSIVE GASES. Keep sparks, flame, cigars and cigarettes away. Ventilate when charging or using in enclosed area. Always wear eye protection when working near batteries. Wash hands after handling. KEEP OUT OF REACH OF CHILDREN. Failure to comply could result in serious injury or death.

cap is removed. To remove the cap, let the cooling system cool, turn to the first notch, wait until the pressure is released, then remove the cooling system tank cap.

HAZARDOUS CHEMICAL PRECAUTIONS

• 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.

• 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. This information is available from your dealer.

• 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.

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

• Check with your local environmental or recycling center or your information.

dealer

for

correct

disposal

TRANSPORTING PRECAUTIONS K n ow t h e r u l e s, l aw s, a n d s a fe t y e q u i p m e n t necessary for transporting this machine on a road or highway.

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

M144B

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

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CHAPTER 2 - SAFETY, AND DECALS SEAT BELT PRECAUTIONS WARNING: Before starting the engine insure seat belts are securely fastened. The seat belt can help insure your safety if it is used and properly maintained. Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members. Failure to comply could result in serious injury or death.

1

M422A

2 Figure 4

BD06G176

1. RIGHT-HAND BELT STRAP 2. LATCH MECHANISM

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

2. Tighten the seat belt by pulling on the loose end of the right-hand seat belt.

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. Failure to comply could result in serious injury or death.

M437

Figure 5

BD06G176

1. To unlatch the seat belt, press the red button on the left-hand side latch mechanism.

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CHAPTER 2 - SAFETY, AND DECALS SPECIFIC PRECAUTIONS TO THIS MACHINE

• Keep the load or bucket/attachment as low as possible while moving the machine around the jobsite.

• Never smoke while refueling.

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

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

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

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

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

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

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

M824

Figure 6

BD07A008

Figure 7

BD07A009

SUPPORT STRUT IN SERVICE POSITION

SUPPORT STRUT IN TRANSPORT POSITION

TRANSPORT SERVICE LINK

Figure 8

BD07A008

SERVICE LINK PIN

Figure 9

BD07A008

SERVICE LINK IN LOCKED POSITION

Prior to any maintenance, service work or transportation, lock the articulation transport service link. Remove the safety security pin to change positions of the service link.

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DECALS WARNING: An illegible or missing decal can have far-reaching consequences. Inspect decals daily. Clean and replace damaged decals as necessary. Failure to comply can result in machine damage, injury, or death.

CE-NA000

WARNING: Make sure that the decals are perfectly legible, clean them regularly and replace decals that are destroyed, lost, painted over or no longer legible with new ones. When parts bearing decals are replaced, be sure to put new decals on each new part. Failure to comply can result in machine damage, injury, or death.

CE-NA000

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

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

Figure 10

384270A1A

This symbol instructs you to refer the Operator’s Manual.

87538969 EU Bur

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BC00G075

Figure 11

This symbol instructs you to refer to the Repair Manual.

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CHAPTER 2 - SAFETY, AND DECALS DECALS WARNING: An illegible or missing decal can have far-reaching consequences. Inspect decals daily. Clean and replace damaged decals as necessary. Failure to comply can result in machine damage, injury, or death.

CE-NA000

WARNING: Make sure that the decals are perfectly legible, clean them regularly and replace decals that are destroyed, lost, painted over or no longer legible with new ones. When parts bearing decals are replaced, be sure to put new decals on each new part. Failure to comply can result in machine damage, injury, or death.

CE-NA000

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

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

1

1

Figure 12

BD07B150/326241A1

1. Wear seat belt

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3

2

2

3

Figure 13

BD07B147/329051A1/256147A1

2. Read the Operator’s Manual 3. Emergency exit

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CHAPTER 2 - SAFETY, AND DECALS

4 4 5 6

5

6

Figure 14

BD07B147 / 323695A1 / 87453136/404771A1/

4. Warns of crush hazard 5. Warns of crush hazard near articulation 6. Warns of crush hazard

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CHAPTER 2 - SAFETY, AND DECALS

7

9

8

8

7

9

Figure 15

BD07B148/333269A1/329048A1/87453136

7. Pressurized system hazard 8. Crush hazard 9. Crush hazard

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CHAPTER 2 - SAFETY, AND DECALS

10

11 10 12

11

12

Figure 16

BD07B142/3298903A1 / 3233269A1 / 329050A1

10. Pressurized system hazard 11. Pressurized system hazard 12. Block wheels

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CHAPTER 2 - SAFETY, AND DECALS

14

13

13

14

Figure 17

BD07B143/87353136/326995A1

13. Crush hazard warning 14. Crush hazard warning

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CHAPTER 2 - SAFETY, AND DECALS

16 16

15

15

Figure 18

BD07A076/3353269A1/329045A1

15. Hot liquid hazard

16. Pressurized system hazard

17

17

Figure 19

BD07B145/ 332511A

17. Entanglement hazard 2-18

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CHAPTER 2 - SAFETY, AND DECALS

18 18

19

19

Figure 20

BD07B146/ 332511A1/E134205

18. Do not step (one each side) 19. Battery explosion hazard (one each side)

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CHAPTER 2 - SAFETY, AND DECALS b

20

20

Figure 21

BD07B252/412426A1

20. Crush hazard

21

21

Figure 22

BD07B198/ 328752A1

21. Run over hazard

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CHAPTER 2 - SAFETY, AND DECALS

22

22

Figure 23

BD07B251/ 134402

22. Do not step

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CHAPTER 2 - SAFETY, AND DECALS

24

23

71477097/71477100

Figure 24

23. Sound level

Figure 25

251503A1

24. Hinge weight

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

Chapter 3 INSTRUMENTS AND CONTROLS TABLE OF CONTENTS ACCESS DOORS AND COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Hood Switch/Master Disconnect Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Steps and Hand Holds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Inside Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Window Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Steering Wheel Tilt Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Transmission Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Foot Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Parking Brake Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Air Louvers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 FRONT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 INSTRUMENT PANEL INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Critical Warning Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non - Critical Warning Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LCD Multi-function Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Navigating Through The LCD Multi-function Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Viewing Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Trip Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Entering The Service Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting Power Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Options And Preference Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Options Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-15 3-15 3-16 3-17 3-22 3-23 3-24 3-25 3-26 3-27 3-29 3-30

CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two Spool Valve - One Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two Spool Valve - Two Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three Spool Valve - Two Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three Spool valve - Three Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four Spool Valve - Three Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wrist Rest Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-31 3-31 3-32 3-33 3-34 3-35 3-36

SIDE CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 Climate Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 Engine Coolant Heater (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

NOTES

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

ACCESS DOORS AND COVERS HOOD SWITCH/MASTER DISCONNECT COVER

Figure 1

BD03J005

KEY CYLINDER LOCKS

The hood, left, and right side engine covers allow access to both engine sides, air cleaner and coolers.

A locking mechanism is provided for the hood switch cover. Use the machine key to open and close this cover.

HOOD SWITCH

BD06F42

Figure 2

3. The hood switch will automatically raise the hood o n t h e m a c h i n e . Ke e p a l l t o o l s , s e r v i c e equipment, and personnel away from the hood when opening and closing.

1. Insert the key. Make sure to completely insert the key for proper operation. Damage can occur to the key or locking mechanism if key is improperly inserted and turned.

2. After releasing the lock, remove the key and open the cover.

BD06F44

Figure 3

4. Push up on the switch to raise the hood. The switch will remain in the up position for hands free opening. To close the hood, push down on the switch. As a built in safety measure, the down control must be held in order to lower the hood.

WARNING: Before undertaking any travel, make sure the side doors are properly closed.

Failure to comply could result in injury or death.

CE-NA000

WARNING: Keep hands clear of the hood as it closes. Keep all personnel clear of the hood as it closes. Failure to comply could result in injury or death.

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3-3

CHAPTER 3 - INSTRUMENTS AND CONTROLS If the machine has no power or the battery is too low for the hood switch to function:

2. Raise the hood manually with a hoist. Block for safety. Do not allow the hood to swing over any personnel.

Method 2 1. Disconnect the actuator pin. The pin can be reached through the hood compartment door panel.

2. To manually open hood, drive the bottom of the actuator with a hex tool in a cordless drill. Block the hood for safety. Change position and continue to raise from beneath hood opening.

WARNING: When raising the hood manually use suitable blocking equipment and watch for sharp edges on machine. Failure to comply could result in machine damage, injury or death.

Figure 4

BD06G174

1. Use booster battery cables to provide power.

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

2. Connect the negative cable to a proper ground.

The hood may now be operated at the switch.

MASTER ELECTRICAL DISCONNECT SWITCH

WARNING: Do not use this procedure to start the engine. Attempting to jump start the engine from this location may cause electrical and/or harness damage to the machine.

If the machine has power, but the actuator is not functioning:

Figure 6

BD03J005

The master electrical disconnect switch has two positions: ON and OFF.

BD03A229

Figure 5

Keep all non-authorized personnel clear of the area.

Park the machine on firm, level ground, lower the attachment. Put the transmission in neutral and apply the parking brake. Turn the engine off.

MASTER ELECTRICAL SWITCH ON The master disconnect switch in the ON position energizes the entire electrical system. When the master disconnect BS00A2037 switch is ON and the key switch is OFF, the dome lamp, horn, stop lamps, four-way flashers, and rotary light switch are powered and functional.

MASTER ELECTRICAL SWITCH OFF In the OFF position, all machine power is interrupted.

There are two methods for opening the hood.

Method 1 1. Disconnect the actuator pin. The pin can be reached through the hood compartment door panel 3-4

BS00A017

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

CAB CAB DOOR

STEPS AND HAND HOLDS WARNING: Always maintain three point support while getting on and off the machine and entering or exiting the operator’s cab. A three point support system has been provided that enables a person to use simultaneously two hands and one foot or two feet and one hand while ascending, descending or moving about the machine.

Failure to comply could result in injury or death.

CE-NA000

WARNING: Clean the steps and access handles and remove all traces of grease, oil, mud, and ice in winter. Failure to comply could result in injury or death.

CE-NA000

Figure 8

BD06H085

DOOR HANDLE AND DOOR LOCK

Use the key to lock or unlock door from outside the machine. Use the door handle to open the door from the outside.

To lock in place, open the door completely until it latches in place against the cab. To close the door, use the door release knob.

IMPORTANT: The cab door must be locked into the full open or full closed position before using the door hand hold.

NOTE: The key provided with the machine can be used to lock and unlock the various panels and to activate the engine starter switch functions.

INSIDE DOOR LATCH

Figure 7

BD06F163A

When getting down from or getting onto the machine, use the steps and hand holds. Use at least three points of suppor t when getting on and off the machine. The cab door must be locked into the full open or full closed position before using the door hand hold.

BD06H086

Figure 9

To secure the door in the open position, push the door back until the door locks on the door catch at the rear of the cab.

Push the latch to open the door from the inside.

WARNING: Always lock the cab doors in the full open or full closed position before using the handgrips on them.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS WINDOW LATCH

1 Figure 12

BD06F158

Figure 10

BD06G177

1. LIFT TO OPEN

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

EMERGENCY EXIT

3 2

RD98K30

Figure 112

2. LATCH PIN 3. HOLD LATCH

The window can be kept partially open by lifting the hold latch and sliding it back on the latch pin until the hold latch locks in the latch pin.

The window may be opened and locked against the side of the cab. To open and lock the window, 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 in place.

3-6

Figure 13

BD06F177

EMERGENCY EXIT

The right hand window of the cab can be used as an emergency exit. Be proactive and open and close the emergency window exit as a safety measure to become familiar with its operation.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS OPERATOR’S SEAT STANDARD SEAT

1 4

Figure 17

RD06F052

Figure 14

RD06F051

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

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

2

5 2 BD06F048

Figure 15

BD06F047

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.

Figure 18

5. WEIGHT ADJUSTMENT KNOB: To adjust the seat for your weight, pull the release lever away from the knob. Use the release lever to turn the knob clockwise to increase the weight resistance. Turn the knob counterclockwise to decrease the weight resistance. Adjust the seat to operator preference and comfort.

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 position.

3

Figure 16

RD06F046

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS OPTIONAL AIR RIDE SEAT

1

2

4 Figure 21

BD06G182.

Figure 19

BD06G181

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

4. SLIDE ADJUSTMENT LEVER: Pull the slide adjustment lever and adjust the seat forward or backward as required. 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: Each armrest will pivot to the up position.

5 BD06G182.

3 5. HEIGHT ADJUSTMENT HANDLE:

BD06F046

Figure 20

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

A. (Automatic Adjustment): With the operator sitting in the seat, lift the handle UP until the desired height is reached. Release the weight adjustment tab. Perform a “hop” movement, briefly removing weight from the seat, then regain sitting position and reapply weight. This will reset the height latch.

B. To lower the seat, push down and hold the weight adjustment tab until the desired height is reached. Release the weight adjustment tab and perform the “hop” movement, briefly removing weight from the seat, then regain sitting position and reapply weight. This will reset the height latch.

NOTE: If the “hop” movement is not performed, the seat will return to its former latch point.

C. (Manual Adjustment): The seat can be raised or lowered by increasing or decreasing the air pressure in the seat. Lift the handle UP to increase the air pressure. Push the handle DOWN to decrease the air pressure and lower the seat.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS SEAT BELT

6 7

Figure 22

BD06G182.

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

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.

BD03J071

Figure 24

The seat belt must be worn and properly adjusted before starting the machine.

Insert the metal end of the right-hand belt strap into the latch mechanism on the left-hand side of the seat. Tighten the seat belt by pulling on the loose end of the right hand seat belt.

8

RD97F255

Figure 23

BD06G1823

8. RIDE CUSHION ADJUSTMENT LEVER

Figure 25

To unlatch, press the red button on the left-hand side latch mechanism.

The seat suspension can be adjusted to various operating conditions in order to gain the most comfortable ride for the operator.

The cushion adjustment lever has four positions from soft to hard in order to allow for maximum comfort over varying or rough terrain.

The first adjustment is with the small end of the adjustment lever pointing toward the front of the seat, as shown. The other three adjustments can be obtained by rotating the small end of the adjustment l ev e r o u t a w ay f r o m t h e s e a t . E a c h o f t h e adjustments has a slight detent.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS FOOT PEDALS

BD06F161

Figure 26 Figure 28

BD06H104

STEERING WHEEL TILT CONTROL The steering wheel tilt control allows the steering wheel to be adjusted to multiple positions. Pull the handle up, and adjust the steering wheel to the correct and most comfortable 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.

TRANSMISSION CONTROL LEVER The transmission control lever is used to shift the transmission gears from first through fourth gear.

Turn the transmission control lever away from you to select a higher gear. Turn the lever toward you to select a lower gear. This control lever is also used to put the transmission in FORWARD, NEUTRAL, and REVERSE (F-N-R).

BRAKE PEDAL The brake pedal will actuate the machine brakes when pushed.

NOTE: The pedal will work in conjunction with the transmission declutch switch for more efficient braking. See Declutch Switch in Operating Instructions- Chapter 4 for further information.

IMPORTANT: On steep slopes using the down shift mode of the transmission is recommended to aid braking and to help prevent brake overheating and premature disc wear.

NOTE: When the machine is shut off, the parking brake is automatically set.

Figure 29

BD06H104 BD06F160

Figure 27

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

FOOT THROTTLE Push the foot throttle to increase engine speed.

When the pedal is released the engine runs at low idle.

C. M ove t h e c o n t r o l l eve r t owa r d yo u fo r REVERSE. The F-N-R function of the transmission control lever may be moved to the loader control lever for operating efficiency.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS PARKING BRAKE

PARKING BRAKE RELEASE NOTE: The service brake must be at operating pressure before the parking brake can be released to move the machine. The brake pressure indicator lamp must not be illuminated when disengaging the parking brake. Attempting to move the machine prior to the service brake pressures being sufficient causing low operating pressure can result in premature parking brake pad wear.

A. When using transmission ForwardNeutral-Reverse (FNR) control on the left side of steering column

BD06H092

Figure 30

PARKING BRAKE SWITCH Make sure the machine has come to a complete stop before applying the parking brake.

The parking brake button engages the parking brake on the transmission output shaft.

IMPORTANT: The parking brake is a spring applied, hydraulic released brake which is applied to the drive shaft. It will effectively hold the machine in place when used correctly.

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

2. Transmission control lever must be in neutral.

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

NOTE: If the parking brake was NOT set when the machine was turned off, the parking brake switch must be cycled at step 3.

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

ENGAGING THE PARKING BRAKE To engage the parking brake, move the gearshift lever to neutral N, stop the machine and engage the brake by pushing down on the top of the switch. The parking brake will automatically engage when the machine is shut off.

IMPORTANT: A failure in the operating procedure or a failure in the electrical or hydraulic function can result in abrupt engagement of the parking brake.

Always wear your seat belt.

BS01E142A

Figure 31

B. When using transmission ForwardNeutral-Reverse (FNR) control on the hydraulic controller lever All the following steps are required: 1. Service brake pressure must be at operating pressure.

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

3. Right side FNR switch must be in Neutral.

4. Machine speed must be zero.

5. Engine must be running.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

Figure 32

BD07A250

6. Push down on the top of the transmission enable switch located on the side console. The indicator light on the bottom of the enable switch will illuminate when activated.

7. Push down on the bottom of the parking brake switch to release the parking brake. This must occur within 8 seconds of Enable. (If the parking brake was NOT set when the machine was turned off, the parking brake switch must be cycled at this step).

8. Place the right side FNR switch in either FORWARD or REVERSE to move the machine.

(This must occur within 8 seconds of Enable).

Figure 34

BD06H093

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

OFF POSITION In this position, all switch controlled current is OFF. Turn the key to OFF to stop the engine. Remove the key and turn the Master Disconnect Switch to OFF. ON POSITION This position will energize all electrical systems. The key will return to this position after you release the key from the START position.

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

HORN AND TURN SIGNAL

1 RADIO (IF EQUIPPED)

2

Figure 33

BD06F157

(1) HORN: Push the horn lever in to actuate the horn.

BC00B064

IMPORTANT: Always sound the horn prior to starting the machine.

(2) TURN SIGNAL LEVER

BC00B087

3-12

Push the control lever up to signal a left turn. Pull the lever down to signal a right turn. The lever must be moved manually to the center position to stop the signals.

Figure 35

BD06F053

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS AIR LOUVERS MAIN AIR LOUVERS

RECIRCULATION AIR LOUVER T h e r e c i r c u la t i o n a i r l o u ve r s a r e b e h i n d t h e operator’s seat next to the floor. When open, air is recirculated in the cab.

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

Figure 36

BD06F159

MAIN LOUVERS

The louvers on the console direct air flow toward the operator or toward the front window.

1

2

Figure 38

BD06F095

Loosen knob (1) and remove cover to access recirculation filter (2).

DEFROST AIR LOUVERS The upper louvers under the front windshield on the console and the louvers on the cab supports direct the air flow to defrost the windows. Additional louvers are located on the cab support posts.

Figure 37

BD06H097

LOUVERS

Louvers on the right and left hand cab supports direct air toward the operator.

Adjustments can be made to direct the air flow of the louvers.

To get maximum air flow on the windows, close all other louvers and turn the blower fan to the highest 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.

Figure 39

BD06F159

DEFROST LOUVERS

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

FRONT CONSOLE

1

2

3

Figure 40

BD07A171

1. PILOT CONTROL SWITCH:

BC00B048

Push on the left hand 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 right hand side of the switch to actuate the pilot controls. The hydraulic control levers will now function.

2. ETHER INJECTOR:

BS07A345

The ether injector switch is operable if the coolant temperature is below 50° F (10° C). Push on the switch to deliver a measured amount of ether directly into the engine to assist starting in cold temperatures. Use the ether switch only when starting the engine. See cold weather starting for additional information in Chapter 4 - Operating Instructions.

3. FOUR-WAY FLASHER SWITCH: Push the left hand side of the flasher switch to actuate the flashers. Push the right hand side of the flasher switch for the OFF position.

BC00B087

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CHAPTER 3 - INSTRUMENTS AND 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, 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, on some circuits the LED will flash and the warning alarm will sound for 5 seconds.

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

3 2

4 5

1

1

Figure 41

BD06F096

1.INDICATOR LAMP FOR FOUR-WAY FLASHER AND TURN SIGNALS: The green indicator lamps will flash when a turn is signaled or when the four-way flashers are activated.

BS96H049

2.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

Stop the machine and correct the problem.

3.LAMP INDICATOR: This indicator illuminates when the driving high beam lamps are ON.

BS98M062

4.SECONDARY STEERING INDICATOR (IF EQUIPPED): This indicator illuminates when the primary steering system pressure is too low. The alarm sounds continuously and the stop master indicator turns red.

BS00B111

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

5.PARKING BRAKE INDICATOR:

BS96H049

Issued 02-07

Bur

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS INSTRUMENT PANEL INDICATORS

7. STOP MASTER INDICATOR (RED, CRITICAL):

BC00B290

The Stop Master Indicator is a critical warning display. See Critical Warning Displays.

CRITICAL WARNING DISPLAY

7

Wh en t he St op M a ster in dica to r illu m in at es, IMMEDIATELY bring the machine safely to a stop, and turn the engine OFF. Failure to do so may result in personal injury and/or damage to the machine.

Figure 42

BD06F096

The following table is a listing of critical warning displays that may appear on the instrument cluster and the corrective action that is required. When a fault occurs, a continuous audible alarm will sound and the Stop Master Indicator will be RED. A warning message will be displayed in the message area.

CRITICAL WARNINGS Display

Description

Corrective Action

ENGINE OIL PRESSURE

Low Engine Oil Pressure.

Bring the machine to a safe stop, and turn the engine OFF immediately.

Contact your Dealer.

BRAKE PRESSURE

Low Brake Pressure

Bring the machine to a safe stop, and turn the engine OFF immediately.

Contact your Dealer.

STEERING PRESSURE (W/AUX STEERING)

Low Steering Pressure.

Bring the machine to a safe stop, and turn the engine OFF immediately.

Contact your Dealer.

COOLANT LEVEL

Low Coolant Level.

Bring the machine to a safe stop, and turn the engine OFF immediately.

Check the coolant levels after allowing the engine and the coolant to cool.

Contact your Dealer.

COOLANT TEMPERATURE

High Engine Coolant Temperature.

Bring the machine to a safe stop, and turn the engine OFF immediately.

Check the coolant levels after allowing the engine and the coolant to cool.

Contact your Dealer.

HYDRAULIC OIL TEMPERATURE

High Hydraulic Oil Temperature.

Bring the machine to a safe stop, and turn the engine OFF immediately.

Contact your Dealer.

TRANSMISSION OIL TEMPERATURE

High Transmission Oil Temperature.

Bring the machine to a safe stop, and turn the engine OFF immediately.

Contact your Dealer.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS INSTRUMENT PANEL INDICATORS

8. CAUTION MASTER INDICATOR (YELLOW, NON-CRITICAL):

BC00B291

T h e C a u t i o n M a s t e r I nd i c a t o r i s 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.

8

Figure 43

BD06F096

When a fault occurs, an audible alarm will sound for 3 seconds and the Caution Master Indicator will be YELLOW. The caution message will be displayed in the message area. If this occurs, return the machine to a service position, and turn the engine off, and take corrective action to help avoid expensive repairs.

NON - CRITICAL WARNINGS Display

Description

Corrective Action

PARKING BRAKE

Parking Brake engaged and machine shifted F or R

Release the parking Brake.

COOLANT TEMPERATURE

High engine coolant temperature

1. Idle machine and monitor temperature.

2. Clean radiator or operate fan reverser (If equipped).

3. Check coolant level and add coolant if necessary.

4. If condition persists, contact your dealer.

HYDRAULIC TEMPERATURE

High hydraulic temperature

1. Idle machine and monitor temperature.

2. Clean cooler or operate fan reverser (If equipped).

3. Check hydraulic fluid level.

4. If condition persists, contact your dealer.

TRANSMISSION TEMPERATURE

High transmission temperature

1. Idle machine and monitor temperature.

2. Clean cooler or operate fan reverser (If equipped).

3. Use a lower gear.

4. If condition persists, contact your dealer.

AIR FILTER

High air filter restriction

1. Clean air filter.

2. Replace primary and secondary filters.

3. If condition persists, contact your dealer.

TRANSMISSION FILTER

Transmission filter restriction

1. Replace transmission filter.

2. If condition persists, contact your dealer.

HYDRAULIC FILTER

Hydraulic filter restriction

1. Replace hydraulic filter.

2. If condition persists, contact your dealer.

ALTERNATOR

Alternator malfunction

1. Check electrical system.

2. Voltages are out of range.

3. Change operating procedure.

4. If condition persists, contact your dealer.

FUEL

Low fuel.

Fill fuel tank - do not allow tank to totally empty.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS INSTRUMENT PANEL INDICATORS 9. TRANSMISSION OIL TEMPERATURE GAUGE

9 BC00B291

T h e C a u t i o n M a s t e r In d i c a t o r i s a non-critical warning display. See Non Critical Warning Displays.

The transmission oil temperature gauge indicates the oil temperature of the transmission. Normal operating t e m p e ra t u r e i s i n t h e gr e e n zo n e. W h e n th e transmission oil temperature increases, the gauge will move into the yellow zone, the warning alarm sounds for three seconds, and the caution master indicator tur ns yellow. When the temperature continues to increase the gauge moves into the red zone, the warning alarm will sound continuously, and the stop master indicator turns red. DO NOT operate the machine when the temperature is in the red zone.

Figure 44

BD06F096 .

TRANSMISSION OIL TEMPERATURE GAUGE Gauge Indication

Condition

Master Indicator

Gauge Status

Alarm Status

68° F and below (20° C and below)

Oil temperature is very low

Caution (Yellow)

Flashes

3 Seconds

68 to 248° F (20 to 120° C)

Oil temperature is normal

248 to 257° F (120 to 125° C) (See the note below.)

Oil temperature is high

Caution (Yellow)

Flashes

3 Seconds

257° F and above (125° C and above)

Oil temperature is very high

Stop (Red)

Flashes

Continuous

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS INSTRUMENT PANEL INDICATORS

10

Figure 45

BD06F096

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

The stop master indicator turns red. DO NOT operate the machine when the temperature is in the red zone.

10

Figure 46

BD06H105

HYDRAULIC OIL TEMPERATURE GAUGE Gauge Indication

Condition

Master Indicator

Gauge Status

Alarm Status

68° F and below (20° C and below)

Hydraulic oil temperature is very low

Caution (Yellow)

Flashes

3 Seconds

68 to 221° F (20 to 105° C)

Hydraulic oil temperature is normal

221 to 230° F (105 to 110° C) (See note below.)

Hydraulic oil temperature is high

Caution (Yellow)

Flashes

3 Seconds

230° F and above (110° C and above)

Hydraulic oil temperature very high

Stop (Red)

Flashes

Continuous

NOTE: Do not operate the machine if the indicator turns red and the alarm sounds continuously. Stop the machine and correct the problem.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS INSTRUMENT PANEL INDICATORS

11

Figure 47

BD06F096

11. FUEL LEVEL GAUGE: The fuel level gauge indicates the fuel level.

Normal operating range is in the green zone. When the tank is almost empty the BS98M034 gauge will move into the yellow zone and the fuel indicator will begin to flash, the warning alarm sounds for three seconds, and the caution master indicator turns yellow.

11

IMPORTANT: Do not allow the machine to run completely out of fuel.

Figure 48

BD06H105

FUEL LEVEL GAUGE Gauge Indication

Condition

Master Indicator

Gauge Status

Alarm Status

10 percent and below

Fuel level low

Caution (Yellow)

Flashes

3 Seconds

10 percent and above

Fuel level normal

WARNING: If the machine runs out of fuel, do not attempt to work on pressurized hydraulic lines.

Lines are under high pressure. Failure to comply could result in injury or death.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS INSTRUMENT PANEL INDICATORS

12

Figure 49

BD06F096

12. ENGINE COOLANT TEMPERATURE GAUGE: The engine coolant temperature gauge indicates the coolant temperature of the engine.

BS98H053 Normal operating temperature is in the green zone. When the engine coolant temperature increases the gauge will move into the yellow zone, and the warning alarm sounds for three seconds. The caution master indicator turns yellow.

When the temperature continues to increase the gauge moves into the red zone and the warning alar m sounds continuously. The stop master indicator turns red. DO NOT operate the machine when the temperature is in the red zone.

12

Figure 50

BD06H105

ENGINE COOLANT TEMPERATURE GAUGE Gauge Indication

Condition

Master Indicator

Gauge Status

Alarm Status

68° F and below (20° C and below)

Coolant temperature is very low

Caution (Yellow)

Flashes

3 Seconds

68 to 221° F (20 to 105° C)

Coolant temperature is normal

221 to 230° F (105 to 110° C)

Coolant temperature is high

Caution (Yellow)

Flashes

3 Seconds

Coolant temperature is very high

Stop (Red)

Flashes

Continuous

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

NOTE: Do not operate the machine if the indicator turns red and the alarm sounds continuously. Stop the machine and correct the problem.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS LCD MULTI-FUNCTION DISPLAY

1

2

3 A

B Figure 2

BD06F185A

Figure 1

BD06F097A

LCD MULTI-FUNCTION DISPLAY

The LCD Multi-Function Display (liquid crystal display) is located at the center of the modular dashboard. On start up, the console indicator lamps will momentarily flash. The LCD Multi-Display will flash Case along with the machine model. The initial standard driving screen will then appear. Once operator preferences are set, the screen will reflect those selections.

NOTE: Upon initial startup, the operator can push the return/escape key, and the language selection screen will appear immediately. This allows the operator to make a language selection without having to use an unknown language to scroll through to preferences.

TYPICAL LCD MULTI-FUNCTION DISPLAY

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

1. Zone One: The top section of the LCD display will show the machine hours, speed, or RPM’s.

The display is controlled by machine technology and geared toward operator preferences. The screen shown above is the default screen.

In the example shown, the machine hours are d i s p l aye d . M a c h i n e h o u r s w i l l a l way s b e displayed briefly on start up. After the machine is started, the display will change to show engine RPM’s. When the machine is moving, this area will change to show speed or RPM’s. The operator can make a preference selection, programming the screen to show MPH, km/h, or RPM’s.

2. Zone Two: This center of the display is dedicated to transmission signals. The example above shows the transmission control lever in neutral (N), the gear numerically (4th), and the automatic transmission mode (A).

Fault codes will be displayed in Zone 2. As an example this section may list transmission fault codes. If the transmission is not operating correctly the display may show: • C - Substitute clutch • L - Limp home • S - Transmission shutdown • U - Transmission control unit shutdown 3. Zone Three: The lower section of the LCD display is divided in two sections. The left hand section indicates if the gearbox is clutched or unclutched. It also indicates the power mode Max/Std/Auto/Eco. The example above displays Auto.

The right hand section (B) displays the clock.

Time can be set in either 12 or 24 hour increments.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS USING THE ARROW KEYS

NAVIGATING THROUGH THE LCD MULTI-FUNCTION DISPLAY SCREENS

A

C

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

The following sequence shown uses the down key only.

NOTE: Pressing the escape key will return the LCD back to the normal driving screen. In order to lock the changes into memory, the operator must press the confirm key, then use the escape key to return to the main screen. Turning the machine off will also lock the settings into memory.

B

D Figure 3

BD06F186A

KEY PAD

The key pad is located on the console just below the steering wheel. Use this key pad to move from one screen to another, choose various selections, m o n i to r t h e m a c h i n e fu n ct i o n s, a n d r e t r i eve information.

All selections made with the computer ized technology of the LCD screen are essentially programmed in the same manner.

When using the screen, use the arrow keys (C and D) to scroll to the desired selection, highlight that selection and press the confirm/enter key (B).

BD06F188

Figure 4

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

Follow any screen prompts when given and use the confirm key to enter the selection. Use the escape key (A) to return to the main menu. This will lock the chosen selection into memory.

All functions can be accessed in the same basic manner.

A. Escape key: Use this key to exit and return to the driving screen. This key can be used anytime to start over and begin again or to exit a field. It can also be used to electronically check fault codes.

B. Enter/Confirm key: Use this key to confirm selec tions : After selec tions have been highlighted, use the enter/confirm key to choose selections.

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

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

NOTE: Arrows on the screen will indicate if selections are up or down from the current selection.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS VIEWING SCREENS

Figure 8

BD06F169 BD06F183

Figure 5

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

Press the down key again and the Trip 2 screen will display. The LCD provides two trip computers. These will display since last reset the total time in hours, the total fuel, and the average fuel consumption per hour.

Figure 9

BD06F170 BD06F027A

Figure 6

Press the down key again to display Info 2 screen.

This screen will display coolant temperature, turbocharger air temperature, engine oil temperature in either Farenheit or Celsius, as well as oil pressure PSI.

By continuing to scroll down, the fifth screen will display the Trip 1 screen. Trip 1 and Trip 2 screens can be reset independently.

Figure 10

BD06F169

The previous screen can be accessed by using the up arrow key.

BD06F184

Figure 7

Push the down key again to display the Info 3 screen.

This screen displays the temperature in Farenheit or Celsius of the transmission oil, hydraulic oil, sump oil, and radiator coolant temperature.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS SETTING TRIP SCREENS

BD06F172

Figure 11

BD06F170

Highlight the trip screen you wish to set. (Capacity can be set in U.S. gallons, Imperial gallons, or metric liters when setting measurement preferences).

Figure 13

The trip screen will indicate a reset message. At this screen, press the confirm key to clear the numbers and reset the trip information. The current date and time will display automatically. The hours, fuel consumption, and fuel used per hour will reset and revert to zero.

Figure 12

BD06F187A

Press the confirm key to reset to the desired trip screen.

BD06H108

Figure 14

Press the escape key to return to the main driving screen and lock settings into memory. The screen will begin to record time and fuel usage immediately.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS ENTERING THE SERVICE SCREENS After the machine has been started or the key switch has been turned to ON, the operator or service technician may use this service menu to adjust machine configurations to working conditions, to test components, view faults that may have occurred, or to select preferences.

5. Clock Menu

• • • • •

Hour Minute Day Month Year

6. Cluster Hardware Menu

• • • •

Hardware Part Number Hardware Serial Number Hardware ID Hardware Version

7. Cluster Software Menu BD06F177A

Figure 15

Press and hold the confirm key for two seconds to arrive at the Select service screen. The arrow keys can be used to scroll through menu selections.

Items and selections in this menu are: 1. Power Mode Menu

• Max - Maximum power possible • Standard - Normal operation • Auto - Will cycle between maximum and standard automatically

• Eco - Limited power for economy 2. Preferences Menu

• Language - English, French, German, Italian, Portuguese, Spanish

• Units - Metric, English, Imperial • Clock - 24 or 12 hour increments 3. Options Menu

• • • •

Fan Auto - manual or automatic Idle Auto - manual or automatic

3-26

Software Part Number Software Serial Number Software ID Software Version

8. Configuration Menu

• Change Model Number (indicates cluster serial number, not machine serial number)*

• • • • • • •

Slct Tires (Select tire size, etc.)

Calibrate clutch * Gear Limits (choose gear selection)* Park Brake (Park brake test)* Cold Start (choose cold start system)* Fan Test (sound level) Special (Reset error/factory set)*

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

Show RPM Show MPH or KPH

4. Display Menu

• • • •

• • • •

NOTE: Pressing the escape key will return the LCD back to the normal driving screen.

Day Display Day LED Night Display Night LED

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CHAPTER 3 - INSTRUMENTS AND CONTROLS SELECT SCREEN

SELECTING POWER MODES

The select screen will allow you to make time s e t t i n g s a s w e l l a s g i ve a c c e s s t o m a c h i n e information. Navigate this screen also by highlighting your selection and pressing confirm. This will allow you to change clock settings or view the hardware and software screens. No operator changes can be made to the hardware or software screens.

The power mode allows the operator to choose the most effective machine power for the current job conditions. Idling can be changed from automatic to a fixed rate.

Most commonly Auto is chosen, as the power will automatically incre ase or decrease be twee n maximum power and standard power while the machine is working. This allows for maximum power if necessary, but will switch to standard mode for economy. Maximum power can be chosen for more severe work conditions. Economy can be chosen for limited power and fuel efficiency.

Press and hold the confirm key for two seconds to arrive at the service screen.

Figure 16

BD06F192

NOTE: Pressing the escape key will return the LCD back to the normal driving screen. In order to lock the changes into memory, the operator must press the confirm key, then use the escape key to page back to the main screen. Turning the machine off will also lock the settings into memory.

BD06F177A

Figure 17

At the screen shown above, highlight the power mode, and press the confirm key to move to the Power Mode Selection Menu.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS ESCAPING FROM ERRORS NOTE: Selecting options and navigating through the screen menus are the same for all functions. The display will tell the operator if errors have occurred.

BD06F178

Figure 18

At the Power Mode Menu press the confirm key again to activate the selections. The highlighted section will flash to indicate a new selection can be made.

Press the up or down key to select the Power Mode, and then press the confirm key. Use the escape key to return to the main driving screen and to lock the mode selection into memory.

Figure 19

BD06F176

Should an error message display, press the escape key and begin again.

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS OPTIONS AND PREFERENCE SCREENS CLOCK Setting The Hour and Date From the select screen, choose the clock designation and press the confirm key. Use the arrow keys to show field for time and date by pressing the arrow key. When the correct time and date have been entered by using the up and down arrow keys (up increases the numbers - down decreases the numbers), press the confirm key to lock in correct time. Press the escape key to return to the main driving screen and lock selections into memory.

DISPLAY MENU Figure 20

BD06F179

LANGUAGE SCREEN, MEASUREMENT UNITS, AND CLOCK The LCD screen can be set with language, measurements, and/or clock preferences. Use the arrow keys to scroll to the preferences menu. Press the confirm key on the correct selection. Press the escape key to return to the main driving screen and lock the selection into memory.

The display menu can be used to change the background and brightness of the screen. Use the arrow keys to make your selection from the display menu and press the confirm key until the screen rever ts to the main driving screen to lock the selection into memory. The screen display can be changed to suit working conditions. The screen will change to night function illumination when the head lamps are turned on.

Choose the preferences desired: language in English, Spanish, Portuguese, Italian, German, French; measurement units in metric, English, or Imperial; and clock units in 12 or 24 hour cycles.

Highlight the preference you wish to change and press the confirm key. The preference will flash and allow you to scroll through the choices. When the correct preference is chosen, press the confirm key, then use the escape key to return to the main driving screen in order to lock the preference into memory.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS HARDWARE/SOFTWARE SCREENS The hardware and software screens cannot be changed by the operator.

BD06F180

Figure 21

OPTIONS MENU Use the arrow keys to choose the options menu.

Press the confirm key, and the options sub-menu will appear. The options menu will allow the operator to choose options for the fan, grid heater, etc.

FAN AUTO (If Equipped) The fan will run at maximum speed with no reversal in the default mode. Automatic is the more common or preferred setting. It will switch between high, low, or reverse as conditions require depending on actual temperature of the coolant, turbocharger air, transmission oil, and hydraulic oil.

Figure 22

BD106F193

The hardware selection will display the part number, ser ial number, ID number and version of the hardware cluster. The software selection will display the par t number, serial number, ID number and version of the software cluster. Press the escape key to exit from this field or use the up arrow key to scroll backwards for another selection from the select sub-menu.

The operator can choose fan speed or reversing capabilities. Highlight the fan auto selection by using the arrow keys, then press the confirm key. This will allow you scroll through the fan choices. When you have chosen the selection, lock the selection into memory by pressing the confirm key, then use the escape key until the screen displays the main driving screen. These steps apply only if the machine is equipped with an optional variable speed fan valve.

RPMS/SPEEDOMETER These settings allow the operator to show either speed or RPM’s on the main menu when operating the machine. If travel speed is the desired setting, the operator can choose between MPH or km/h for the display. Highlight the desired choice, press the confirm key, then escape back to the main screen to lock the selections into memory.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

CONTROL LEVERS TWO SPOOL VALVE - ONE CONTROL LEVER

E 1

2

B

A

C

D

Figure 23

BS01E136A

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

F Figure 24

BS00B353

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.

3

D. RAISE E. DUMP F. ROLLBACK 2. AUXILIARY F-N-R SWITCH: This switch will allow the operator to put the transmission in Forward, Neutral or Reverse. To activate this auxiliary F-N-R switch, the proper sequence must be followed. The primary shift lever must be in the Neutral position before using the auxiliary FNR switch. Push the switch forward to place the transmission in Forward, place the switch in the middle position to place the transmission in Neutral, and pull the switch rearward to put the transmission in Reverse.

BS06G091

Figure 25

3 . T R A N S M I S S I O N D OW N S H I F T BUTTON: Drops the transmission down one gear at a time.

BC00B118

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

NOTE: Control levers function as described with electromagnets off.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS TWO SPOOL VALVE - TWO CONTROL LEVERS

D

2

E

F

G

1

A

BD06F00RA

C

Figure 26

B

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

Figure 27

BS00B353

3 A

2. LIFT ARM CONTROL

4

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.

B

E. LOWER

C

F. HOLD G. RAISE Figure 28

BD06F004A

3 . T R A N S M I S S I O N D OW N S H I F T BUTTON: Drops the transmission down one gear at a time.

S e e Tra n s m is s io n O p e ra t i o n / I n i t i a l M a c h i n e Movement for moving the machine after start up.

BC00B118

4. FNR Switch: This switch will allow the operator to put the transmission in Forward, Neutral or Reverse. To activate this auxiliary F-N-R switch the proper BC00B124 sequence must be followed. The primary shift lever must be in the Neutral position before using the auxiliary FNR switch. Push the switch forward to place the transmission in Forward, place the switch in the middle position to place the transmission in Neutral, and pull the switch rearward to put the transmission in Reverse.

A. Forward (Transmission) B. Neutral (Transmission) C. Reverse (Transmission) 3-32

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CHAPTER 3 - INSTRUMENTS AND CONTROLS THREE SPOOL VALVE - TWO CONTROL LEVERS

G

H

4

2 A

E C

D

1

F Figure 29

BS01F271

1. LIFT ARM AND BUCKET CONTROL

B

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

Figure 30

BS00B353

4 3

D. FLOAT (Detent): This is a detent position.

When in the FLOAT (Detent) position, the loader bucket can follow the level of the ground without movement of the control lever.

E. LOWER F. RAISE 2. AUXILARY CONTROL G. AUXILIARY FUNCTION

S e e Tra n s m i s s io n O p e ra t i o n / I n i t i a l M a c h i n e Movement for moving the machine after start up.

Figure 31

BD06G091

H. AUXILIARY FUNCTION

3 . T R A N S M I S S I O N D OW N S H I F T BUTTON: Drops the transmission down one gear at a time.

BC00B118

4. FNR Switch: This switch will allow the operator to put the transmission in Forward, Neutral or Reverse. To activate this auxiliary F-N-R switch the proper BC00B124 sequence must be followed. The primary shift lever must be in the Neutral position before using the auxiliary FNR switch. Push the switch forward to place the transmission in Forward, place the switch in the middle position to place the transmission in Neutral, and pull the switch rearward to put the transmission in Reverse.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS THREE SPOOL VALVE - THREE CONTROL LEVERS

E 2

F

D

G

A

B

1 3 C H BD06F004

I

Figure 32

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

Figure 33

376629A1

A

4

5

2. LIFT ARM CONTROL

B

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.

C

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

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

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

Figure 34

BD06F004

4 . T R A N S M I S S I O N D OW N S H I F T BUTTON: Drops the transmission down one gear at a time.

BC00B118

5. FNR Switch: This switch will allow the operator to put the transmission in Forward, Neutral or Reverse. To activate this auxiliary F-N-R switch the proper BC00B124 sequence must be followed. The primary shift lever must be in the Neutral position before using the auxiliary FNR switch. Push the switch forward to place the transmission in Forward, place the switch in the middle position to place the transmission in Neutral, and pull the switch rearward to put the transmission in Reverse.

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS FOUR SPOOL VALVE - THREE LEVERS

I

J

G

H

2 2

A 33

1

D

E C F

Figure 35

BS01E142A

1. BUCKET AND LIFT ARM CONTROL A. DUMP

B

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.

Figure 36

87536096

5

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.

4

E. LOWER F. RAISE Figure 37

BD06G091

2. AUXILIARY CONTROL

4 . T R A N S M I S S I O N D OW N S H I F T BUTTON: Drops the transmission down one gear at a time.

G. AUXILIARY FUNCTION H. AUXILIARY FUNCTION BC00B118

3. AUXILIARY CONTROL I. AUXILIARY FUNCTION J. AUXILIARY FUNCTION

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

5. FNR Switch: This switch will allow the operator to put the transmission in Forward, Neutral or Reverse. To activate this auxiliary F-N-R switch the proper BC00B124 sequence must be followed. The primary shift lever must be in the Neutral position before using the auxiliary FNR switch.Push the switch forward to place the transmission in Forward, place the switch in the middle position to place the transmission in Neutral, and pull the switch rearward to put the transmission in Reverse.

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS WRIST REST ADJUSTMENTS

BD06F094

BS06H111

Figure 39

BS06H111

Figure 40

Figure 38

WRIST REST: Adjust the wrist rest to a comfor table height to operate the loader control levers.

ADJUSTMENT KNOBS: To adjust the wrist rest, loosen the adjustment knobs.

The wrist rest can be raised or lowered or moved back and forth. The top adjustment knob will allow the rest to slide back and forth. The lower adjustment knob will allow the wrist rest to be raised or lowered.

Adjust to the most comfortable working position, and tighten the knob.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

SIDE CONSOLE

Figure 41

BD07A250A

The side console allows the operator to make adjustments to machine operation and functions. It also houses the climate control system.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS CLIMATE CONTROL

3 2 1

Figure 42

BD06F093

1. AIR CONDITIONING/BLOWER FAN SWITCH (IF EQUIPPED): Push on the snowflake at the center of the dial to turn the air conditioning function on. When the air conditioner is on, the snowflake will illuminate. The blower fan switch has five positions: OFF, 1, 2, 3, and 4. Turn the switch to 4 for maximum speed and to 1 for the lowest speed.

BC00B087

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

3. CLIMATE CONTROL (IF EQUIPPED): Turn the control clockwise for warmer temperatures, and adjust the control to the desired temperature. Turn the control counter clockwise for cooler temperatures. (Red markings indicate warmer temperatures; blue markings indicate cooler temperatures). Turn completely counter clockwise for OFF. NOTE: Make sure the water inlet for the heater is in the full ON position. This inlet is located in the left rear of the engine compartment.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS SIDE CONSOLE

4

5 6

Figure 43

BD06H114

BC0G111

Figure 44

BD07A260

4. REAR WIPER SWITCH:

6. DRIVING LIGHT SWITCH:

A.Push switch to the center position for on.

Push on the top of the switch for roading machine. Pushing on the bottom of the switch will turn the lights off. The middle position is for marker/position lights.

B.Push on front of switch for washer fluid.

5. FRONT WIPER/WASHER TOGGLE SWITCH (IF EQUIPPED):

BC00B132

7

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

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

BS07A263

7. WORK LIGHT SWITCH: Push on the top of the switch for front and rear working lights. The middle position is for front work lights only.

BS96045 Pushing on the bottom of the switch will turn the lights off.

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

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

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS SIDE CONSOLE

8

9

10

11

Figure 45

BD07A250A

BC00B118

BC00B118

8. TRANSMISSION ENABLE SWITCH: Use the transmission enable switch by pushing down on the top of the enable switch. The indicator light on the bottom of the enable switch will illuminate when activated. By following the correct sequence and enabling the auxiliary F-N-R the operator may select FORWARD-NEUTRAL-REVERSE from the loader control lever or the auxiliary F-N-R switch. See Chapter 4 - Operating Instructions for further information.

9. 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).

10. DECLUTCH SWITCH: The declutch will disengage the transmission when maximum power is needed for the loader. Push down on the top of the declutch switch. The transmission declutch function is activated by brake pressure. See Chapter 4 - Operating Instructions for further information.

BS07A264

BC00B087

3-40

11. FAN REVERSER SWITCH (If equipped) To use the fan reverser let the machine idle in neutral. Depress the fan reverser switch and depress the throttle to high idle for a minimum of 10 seconds or until debris stops blowing out of the coolers.

Return the machine to idle and release the fan reverser switch. This is a three-position switch. Push the upper part of the switch for momentary reversal as described above. The center position of the switch is the automatic position, and the lower position disables the automatic fan.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS SIDE CONSOLE

12

13

14 15

Figure 46

BD06H116

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

BS07A2657

13. RETURN-TO-TRAVEL, DETENT SWITCH:

BC00B087

The Return-To-Travel switch is used to automatically return the loader bucket to the travel position after you have dumped the loader bucket. Push down on the top of the Return-To-Travel switch to engage the return to travel detent. Push the bottom of the switch for the Float Detent position.

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

BS07A266

15. RIDE CONTROL SWITCH (If Equipped): This is a 3-position switch. Push on the top of the switch for the manual ON position. Ride control can be left on at all times, whether loading or roading. The center position is the automatic and most commonly used position. In the automatic position, ride control will automatically activate when ground BC00B094 speed is above 5 km per hour (3.1 mph) and automatically shut off when ground speed is below 5 km per hour (3.1 mph). The indicator light on the switch will illuminate when ride control is activated. To turn ride control off, push on the bottom of the function switch for the OFF position.

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3-41

CHAPTER 3 - INSTRUMENTS AND CONTROLS SIDE CONSOLE

BD06H117

Figure 47

ROTATING BEACON (IF EQUIPPED)

To cancel the backup alarm, depress the switch.

BC00B079

Figure 48

BD06H118

BACK-UP ALARM (IF EQUIPPED)

BC00B082

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

ENGINE COOLANT HEATER (IF EQUIPPED)

Figure 49

BD07A204

The left side of the engine block has a connection for installing an optional coolant heater. See your Case Dealer for this cold weather option.

3-42

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CHAPTER 4 - OPERATING INSTRUCTIONS

Chapter 4 OPERATING INSTRUCTIONS TABLE OF CONTENTS Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Ether Cold Start (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two Spool Valve - Two Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three Spool Valve - Two Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three Spool Valve - Three Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four Spool Valve - Three Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loader Function Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Return-To-Dig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket Height Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Return-To-Travel Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loader Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Declutch Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Hydraulic Connection (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotating Beacon (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ride Control (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loader Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transport and Carry Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating On A Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the Machine in Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Moving A Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transporting The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transporting the Machine on a Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating In Cold Climate Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the Machine In Hot Climates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4-14 4-15 4-16 4-17 4-18 4-19 4-19 4-20 4-20 4-21 4-21 4-22 4-22 4-23 4-23 4-23 4-24 4-25 4-26 4-26 4-26 4-27 4-28 4-29 4-30 4-31 4-32

4-1

CHAPTER 4 - OPERATING INSTRUCTIONS

NOTES

4-2

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CHAPTER 4 - OPERATING INSTRUCTIONS BEFORE STARTING THE ENGINE Perform a daily walk around and visual inspection of the machine. Check for loose connections, faulty hoses, oil leaks, debris or trash buildup, loose bolts, damaged, or missing parts that could effect the normal and safe operation of the machine. Make any necessary corrections before operating the machine.

See the Quick Reference Maintenance Chart in this manual and complete the items in the daily - 10 hour section of the chart.

Check that the machine fuel tank is filled with clean fuel that matches the specifications given in this manual.

WARNING: Do not operate the machine while under the influence of alcohol or drugs.

Failure to comply could result in serious injury or death.

RUN-IN PERIOD Your machine will last longer, give better and more economical perfor mance, if you pay par ticular attention to the engine during the initial run-in period.

(See the Quick Reference Char t in Chapter 5 Lubrication and Maintenance for further information.)

During this period: Warm up the engine before using it under load.

BEFORE OPERATING THE MACHINE WARNING: Do not attempt to operate this machine unless you have first read and fully understand the safety messages and instructions appearing in this manual. Failure to comply could result in serious injury or death.

CE-NA000

Before operating this machine, complete the following procedures: 1. Check the level of all fluids (engine oil, hydraulic fluid, and coolant) and make sure that the fluids an d lubr icants ar e suitable for prevailing conditions.

2. Carry out the daily maintenance operations.

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

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

5. Check the tires for any visible damage. Replace or repair as necessary. Check for correct tire air pressure and adjust pressure if necessary.

6. Clean the steps and hand holds. Grease, oil, mud, or ice in winter on the steps and access handles can cause accidents. Make sure they are kept clean at all times.

Do not operate the engine at maximum power for prolonged periods of time.

7. Clean or replace any decals which are illegible.

See Decals in Chapter 2.

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

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

Frequently check the instruments on the instrument panel.

Check the oil levels and coolant solution level frequently.

During the run-in period, the following checks and servicing operations should be carried out in addition to those specified in the service schedule: IMPORTANT: For turbocharged engines, only shut the engine down from the low idle position to prevent damage to the turbocharger.

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

10. Remove any obstructions which hinder visibility.

Clean the windshield, the windows and the rear view mirrors.

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

12. Make sure no one is on or under the machine.

The operator must be alone on the machine.

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

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

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

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

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4-3

CHAPTER 4 - OPERATING INSTRUCTIONS 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. Failure to comply could result in serious injury or death.

SA040

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

18. Fasten and adjust the seat belt.

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

20. Check the loader controls for correct operation.

STARTING THE ENGINE NOTE: If the machine has been out of use for some time, see Starting Up After Storage in this chapter.

NOTE: If you need to start the engine using a booster battery, see Connecting A Booster Battery in Chapter 7.

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

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

3. Make certain 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 indicators. Use the cold start ether injection system, if needed. The system is designed to inject a measured amount of ether directly into the engine to assist starting in cold temperatures. See the Ether Cold Start in this section.

WARNING: Starting fluid (ether) can cause an explosion if sparks, flame, or extreme heat contacts 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. Failure to comply could result in serious injury or death.

5. Keep all non-authorized personnel clear of the area. Sound the horn to alert others of your intent to start the engine. Turn the key switch to the START position until the engine starts, then release the key.

IMPORTANT: Do not hold the starter key in the START position for more than 30 seconds. If the engine does not start, return the key switch to the OFF position, wait 120 seconds, and then try again.

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

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

ENGINE SPEED DO NOT OPERATE the engine at idle speed for long periods. This can cause a low operating temperature.

A low operating temperature can cause acids and deposits in the engine oil.

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

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

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

4-4

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CHAPTER 4 - OPERATING INSTRUCTIONS STOPPING THE ENGINE AND PARKING THE MACHINE AFTER OPERATIONS WARNING: Jumping on or off the machine can cause an injury. Always face the machine, use the hand holds and steps, and get on or off the machine slowly. Failure to comply could result in serious injury or death.

SA038

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

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

2. Lower the bucket to the ground.

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

to

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

NOTE: Always turn the engine off at low idle to prevent damage to the turbocharger.

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

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

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

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

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4-5

CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING THE MACHINE WARNING: Check all controls and safety devices in a safe, open area before starting work. Failure to comply could result in serious injury or death.

CE-NA000

Starting and Stopping the Loader

Figure 3

BD06H122

4. Sit in the operator’s seat with the seat belt correctly fastened. Make sure you can push the foot pedals completely down with your back against the seat cushion. Confir m that the parking brake switch is ON (Brake Engaged).

Keep all non-authorized personnel clear of the area.

BD07A004

Figure 1

F

1. Remove the transport/service link from the lock position, and secure it in the work position

N

R Figure 4

BS03K026 BD07A001

Figure 2

5. The gearshift lever must be in NEUTRAL.

2. Place the master disconnect into the ON position, as shown.

3. Make sure the equipment lock lever is all the way up with pilot controls neutralized.

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CHAPTER 4 - OPERATING INSTRUCTIONS

Figure 5

BD06H123

BD06H124

Figure 6

6. Sound the horn to warn those around the work area of your intentions.

8. Push the pilot control lock out down, to power the equipment.

7. Insert the key into the ignition switch and turn it into START position. In cold weather, if the machine is equipped with an ether start system, turn the key switch to ON and push the ether start switch. Warm the engine for at least 5 minutes.

9. Raise the loader arms so that the equipment is raised approximately 380 mm (15 inches).

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 motor cool for two minutes before cranking again.

10. To move the machine:

• Cycle the parking brake switch • Place the gearshift into forward position • Release the foot brake and accelerate smoothly

BD06H125

Figure 7

11. To shift gears manually: Use the transmission control lever to shift the transmission gears from first through fourth gear.

Turn the transmission control lever away from you to select a higher gear. Turn the lever toward you to select a lower gear. This control lever is also used to put the transmission in FORWARD, NEUTRAL, and REVERSE. A. Move the control lever away from you for FORWARD. B. The center position of the control lever is NEUTRAL. C. M ove t h e c o n tr o l l eve r towa r d yo u fo r REVERSE.

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4-7

CHAPTER 4 - OPERATING INSTRUCTIONS STOPPING THE ENGINE AND PARKING THE MACHINE AFTER OPERATIONS

N

Figure 10d

BD06H126 BS03K026

Figure 8

1. Stop the machine on hard, level ground and place the gearshift selector in NEUTRAL.

4. Slowly move the equipment levers through all rotations to insure that residual pressures in the hydraulic system are released.

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.

WARNING: Jumping on or off the machine can cause an injury. Always face the machine, use the hand holds and steps, and get on or off the machine carefully. Failure to comply could result in serious injury or death.

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

Figure 11

BD07A005 BD06127

Figure 9

3. Push the parking brake switch to the ON position. Turn the engine off.

4-8

5. Turn the master disconnect switch to OFF, close and lock the compartment.

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CHAPTER 4 - OPERATING INSTRUCTIONS ETHER COLD START (IF EQUIPPED) WARNING: Starting fluid (ether) can cause an explosion if sparks, flame, or extreme heat contacts 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. Failure to comply could result in serious injury or death.

STARTING THE ENGINE USING ETHER IMPORTANT: Ether is to be used for cold weather starting. Remove and store canister when temperatures are above 40° F (approximately 5° C).

Do not store ether container in the operator’s compartment.

The ether injection system on this machine is designed to deliver a specifically measured amount of ether directly into the engine to assist starting in cold temperatures. Do not manually spray or use ether in any unmeasured procedure, as this can cause damage to the engine and/or create a hazardous situation.

ETHER HANDLING SAFETY 1. Always read the instructions on the ether container.

2. Know the correct method for starting your engine with ether.

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

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

5. Do not store ether containers in the operator’s area.

6. Keep the starting fluid container out of the reach of children.

7. Before discarding an empty container, use rubber gloves and push the valve in the end of the container to remove any residual pressure.

DO NOT make a hole in the container or damage the container. DO NOT incinerate the container.

WARNING: Do not inject ether into a running engine. Failure to comply could result in machine damage, injury or death.

BD06F171

Figure 12

1. Read instructions for starting the engine at the b e g i n n i n g o f t h i s s e c t i o n fo r t h e c o r r e c t procedure to start the engine.

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

3. Keep all non-authorized personnel clear of the area. Sound the horn to alert others of your intent to start the engine. Turn the key switch to the START position. When cranking the engine, press and release the ether switch to inject a metered amount of ether into the engine.

Release the key after the engine is running.

IMPORTANT: Do not hold the ignition key in the START position for more than 30 seconds. If the engine does not start, return the key switch to the OFF position, wait 120 seconds, and retry starting the engine.

4. After the engine starts, check the instruments to make certain the machine is operating within normal range. Run the engine at low idle with the transmission in neutral until the engine coolant temperature is warm.

IMPORTANT: Operate the machine at reduced loads until all systems reach normal operating temperature.

This is extremely important during cold weather operation to protect both the engine and hydraulic system.

5. To replace ether bottle in the machine, see Section 6 - Maintena nce a nd Adjustme nt Section.

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4-9

CHAPTER 4 - OPERATING INSTRUCTIONS AUTOMATIC MODE OPERATION:

Figure 15

BD06F004

DOWN-SHIFT BUTTON, THREE LEVER CONTROL BD06H129

Figure 13

To put the transmission in the automatic mode, press the top of the auto shift switch.

AUTOMATIC SHIFTING MODE When the transmission is in the automatic mode, the transmission will start out in first gear or second gear (dependent upon gear minimum setting), and automatically up-shift until the gear selected has been reached. The transmission will also down-shift automatically as the speed decreases.

BD06G091

SHUTTLE SHIFTING (DIRECTION CHANGE) MANUAL OR AUTOMATIC It is not necessary to bring the machine to a complete stop when changing directions from forward to reverse or reverse to forward. For smooth operation and operator comfort, reduce engine speed before direction changes.

Figure 14

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, the transmission will shift down one gear range until first gear is reached. Once the down-shift button has been pressed down, the transmission maximum gear allowed is lowered. It will return to the automatic mode when (1) the transmission control lever gear changes, or (2) the transmission control lever is moved to NEUTRAL and then to FORWARD or to REVERSE. NOTE: When the Automatic Mode has been chosen by the operator, the Automatic Mode indicator will be shown in the multi-function display.

4-10

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CHAPTER 4 - OPERATING INSTRUCTIONS

TRANSMISSION ENABLE SWITCH

1

Figure 16

BD06F100

The Transmission Enable switch can be enabled after the following conditions have been completed: 1. Transmission controller is in neutral (left side).

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

3. The engine must be running.

4. Machine is stationary.

5. Parking brake is released.

Depressing the transmission enable switch allows the transmission to be controlled by the auxiliary F-N-R switch.

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

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

NOTE: Within 8 seconds from depressing the transmission enable switch the following actions must take place or the F-N-R enable switch must be reactivated.

1. The parking brake switch must be released.

2. Shift to forward or reverse from the neutral position on the F-N-R switch.

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CHAPTER 4 - OPERATING INSTRUCTIONS

AUXILIARY FORWARD, NEUTRAL, REVERSE (F-N-R) SWITCH FOR JOYSTICK CONTROL LEVER APPLICATIONS A 1

3

B

C Figure 17

BD06F165

1. AUXILIARY JOYSTICK F-N-R SWITCH

Figure 19

RD06F099

5. The Parking Brake must be released (3).

A. FORWARD B. NEUTRAL C. REVERSE To actuate the Auxiliary F-N-R switch the following conditions MUST be met: 1. The machine must be stopped.

4

2. The engine must be running.

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

Figure 20

BD06F103

When steps 1 through 5 have been completed the transmission enable switch may be enabled by pushing down on the top of the switch (4). The indicator light on the bottom of the switch will illuminate.

2

T h e t r a n s m i s s i o n e n a b l e sw i t c h w i l l b e DEACTIVATED and F-N-R control will default back to the Standard Transmission Control Lever if: 1. The engine is stopped.

BD06F160

Figure 18

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

4-12

2. The parking brake is applied.

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

AUXILIARY FORWARD, NEUTRAL, REVERSE (F-N-R) SWITCH WITH THREE SPOOL VALVE THREE LEVERS A B 3 C

1

Figure 21

BD06F004

1. THREE LEVER AUXILIARY F-N-R SWITCH

Figure 23

RD06F099

5. The Parking Brake must be released (3).

A. FORWARD B. NEUTRAL C. REVERSE To actuate the Auxiliary F-N-R switch the following conditions MUST be met: 1. The machine must be stopped.

4

2. The engine must be running.

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

BD06F103

Figure 24

When steps 1 through 5 have been completed the transmission enable switch may be enabled by pushing down on the top of the switch (4). The indicator light on the bottom of the switch will illuminate.

2

The transmission enable control will default back to the Standard Transmission Control Lever if: 1. The engine is stopped.

2. The parking brake is applied.

Figure 22

BD06F160

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

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

4-13

CHAPTER 4 - OPERATING INSTRUCTIONS

CONTROL LEVERS TWO SPOOL VALVE - ONE CONTROL LEVER NOTE: This page shows the basic loader control lever positions.

6 4 2

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

1

5 3

Figure 25

BD06H024

1

4

2

3

B1119A88

1.

2.

3.

4.

DUMP BUCKET ROLLBACK BUCKET RAISE LIFT ARMS LOWER LIFT ARMS

4-14

Figure 26 5. HOLD: THE LOADER ARMS AND BUCKET WILL NOT MOVE WHEN THE CONTROL LEVER IS IN THE HOLD POSITION. WHEN RELEASED, THE CONTROL LEVER MUST BE MANUALLY MOVED FROM THE FLOAT POSITION TO THE HOLD POSITION. (ONLY WITH MAGNETS ENGAGED.) 6. FLOAT (DETENT): THIS IS A DETENT POSITION. WHEN IN THE FLOAT (DETENT) POSITION, THE LOADER BUCKET CAN FOLLOW LEVEL OF THE GROUND WITHOUT MOVEMENT OF THE CONTROL LEVER. (ONLY WITH MAGNETS ENGAGED.)

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CHAPTER 4 - OPERATING INSTRUCTIONS TWO SPOOL VALVE - TWO CONTROL LEVERS NOTE: This page shows the basic loader control lever positions. The Detent Switch is in the Hold position.

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

6 4

1

3

3

5 2 Figure 27

BD06F004B

1

4

2

3

Figure 28 5. HOLD: THE LOADER ARMS AND BUCKET WILL NOT MOVE WHEN THE CONTROL LEVER IS IN THE HOLD POSITION. WHEN RELEASED, THE CONTROL LEVER MUST BE MANUALLY MOVED FROM THE FLOAT POSITION TO THE HOLD POSITION. (ONLY WITH THE MAGNETS ENGAGED.) 6. FLOAT (DETENT): THIS IS A DETENT POSITION. WHEN IN THE FLOAT (DETENT) POSITION, THE LOADER BUCKET CAN FOLLOW LEVEL OF THE GROUND WITHOUT MOVEMENT OF THE CONTROL LEVER. (ONLY WITH MAGNETS ENGAGED.)

B1119A88

1.

2.

3.

4.

DUMP BUCKET ROLLBACK BUCKET RAISE LIFT ARM LOWER LIFT ARM

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CHAPTER 4 - OPERATING INSTRUCTIONS THREE SPOOL VALVE - TWO CONTROL LEVERS NOTE: This page shows the basic control lever positions.

6

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

4 1

5

7 2 3 8

Figure 29

BD06F271

1

4

2

3

B1119A88

1.

2.

3.

4.

5.

DUMP BUCKET ROLLBACK BUCKET RAISE LIFT ARMS LOWER LIFT ARMS HOLD: THE LOADER ARMS AND BUCKET WILL NOT MOVE WHEN THE CONTROL LEVER IS IN THE HOLD POSITION. WHEN RELEASED, THE CONTROL LEVER MUST BE MANUALLY MOVED FROM THE FLOAT POSITION TO THE HOLD POSITION. (ONLY WITH MAGNETS ENGAGED.)

4-16

Figure 30 6. FLOAT (DETENT): THIS IS A DETENT POSITION. WHEN IN THE FLOAT (DETENT) POSITION, THE LOADER BUCKET CAN FOLLOW LEVEL OF THE GROUND WITHOUT MOVEMENT OF THE CONTROL LEVER. (ONLY WITH MAGNETS ENGAGED.) 7. AUXILIARY FUNCTION 8. AUXILIARY FUNCTION

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CHAPTER 4 - OPERATING INSTRUCTIONS THREE SPOOL VALVE - THREE CONTROL LEVERS NOTE: This page shows the basic loader control lever positions.

6

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

4 5

1 5

7

3

5 2 8

Figure 31

BD06F004

1

4

2

3

B1119A88

1.

2.

3.

4.

5.

DUMP BUCKET ROLLBACK BUCKET RAISE LIFT ARMS LOWER LIFT ARMS HOLD: THE LOADER ARMS AND BUCKET WILL NOT MOVE WHEN THE CONTROL LEVER IS IN THE HOLD POSITION. WHEN RELEASED, THE CONTROL LEVER MUST BE MANUALLY MOVED FROM THE FLOAT POSITION TO THE HOLD POSITION. (ONLY WITH MAGNETS ENGAGED.)

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Figure 32 6. FLOAT (DETENT): THIS IS A DETENT POSITION. WHEN IN THE FLOAT (DETENT) POSITION, THE LOADER BUCKET CAN FOLLOW LEVEL OF THE GROUND WITHOUT MOVEMENT OF THE CONTROL LEVER. (ONLY WITH MAGNETS ENGAGED.) 7. AUXILIARY FUNCTION 8. AUXILIARY FUNCTION

4-17

CHAPTER 4 - OPERATING INSTRUCTIONS FOUR SPOOL VALVE - THREE CONTROL LEVERS NOTE: This page shows the basic loader control lever positions. The Detent Switch is in the OFF position.

6 7

9

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

4 5 2

1 8

10

3

Figure 33

BD06H025

1

4

2

3

B1119A88

1.

2.

3.

4.

5.

DUMP BUCKET ROLLBACK BUCKET RAISE LIFT ARMS LOWER LIFT ARMS HOLD: THE LOADER ARMS AND BUCKET WILL NOT MOVE WHEN THE CONTROL LEVER IS IN THE HOLD POSITION. WHEN RELEASED, THE CONTROL LEVER MUST BE MANUALLY MOVED FROM THE FLOAT POSITION TO THE HOLD POSITION. (ONLY WITH MAGNETS ENGAGED.)

4-18

Figure 34 6. FLOAT (DETENT): THIS IS A DETENT POSITION. WHEN IN THE FLOAT (DETENT) POSITION, THE LOADER BUCKET CAN FOLLOW LEVEL OF THE GROUND WITHOUT MOVEMENT OF THE CONTROL LEVER. (ONLY WITH MAGNETS ENGAGED.) 7. FIRST AUXILIARY FUNCTION 8. FIRST AUXILIARY FUNCTION 9. SECOND AUXILIARY FUNCTION 10. SECOND AUXILIARY FUNCTION

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CHAPTER 4 - OPERATING INSTRUCTIONS LOADER FUNCTION SWITCHES

RETURN-TO-DIG

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

The Return-To-Dig function is used to automatically return the loader bucket to the dig position after you have dumped the loader bucket. To enable the Return-To-Dig function press the top of the switch (3).

1 2

2 3 1

Figure 35

BD06F274

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

Figure 36

BD06F004

1. FLOAT 2. ROLLBACK DETENT

1

BD06F271

Figure 37

1. FLOAT AND ROLLBACK DETENT

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

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CHAPTER 4 - OPERATING INSTRUCTIONS BUCKET HEIGHT CONTROL

RETURN-TO-TRAVEL FUNCTION

The bucket height control is used to automatically stop the loader arms at the height selected.

T h e R e t u r n - To - Tr a v e l f u n c t i o n i s u s e d t o automatically stop the loader bucket at the carry height that selected. To enable the Return-To-Travel function press the top of the return to Travel/Float switch.

1

1 2 Figure 38

BD06F004

1. RAISE Figure 40

BD06F004

1. ROLLBACK DETENT 2. FLOAT

1

1 BD06F271

Figure 39

1. RAISE

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.

Figure 41

BD06F271

1. FLOAT AND ROLLBACK DETENT

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

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CHAPTER 4 - OPERATING INSTRUCTIONS FLOAT

LOADER CONTROL

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

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

1. Start the engine.

Figure 42

B1128A88J

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

2. Raise the loader bucket.

3. Stop the engine.

4. Turn the key to RUN. 5. Verify that the right hand side of the pilot control switch is depressed, allowing the pilot controls to function.

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 Repair Manual for this machine or see your dealer.

1

Figure 43

BD06F004

1. Float

1

Figure 44

BD06F271

1. Float

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CHAPTER 4 - OPERATING INSTRUCTIONS BRAKE ACCUMULATORS

DECLUTCH FUNCTION

Two hydraulic accumulators are connected in the brake system.The accumulators provide the brake m o d u l a t i n g va l v e w i t h a p o s i t i v e s u p p l y o f pressurized hydraulic fluid.

Test the accumulators for correct operation every 100 hours.

1. Start the engine.

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

3. Stop the engine.

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

5. Repeatedly pump the brake pedal until the brake pressure lamp is illuminated. When pumping the brake pedal, there should be some resistance pressure felt. A slight increase should be felt in the pressure as the brakes are pumped.

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

Figure 45

RD06F100

DECLUTCH SWITCH

The Declutch function allows the engine to increase speed and supply the loader with more hydraulic oil for greater loader power and faster control function.

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS AUXILIARY HYDRAULIC CONNECTION (IF EQUIPPED)

BUCKET LEVEL INDICATOR

BD00N076

Figure 46

BD07A206

Figure 48

The bottom of the bucket is parallel with the ground when the flat portion of the bucket is horizontal.

ROTATING BEACON (IF EQUIPPED)

2

1

Figure 47

BD06F165

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

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BD06G089

Figure 49

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.

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CHAPTER 4 - OPERATING INSTRUCTIONS RIDE CONTROL (IF EQUIPPED) R i d e C o n t r o l i s a fe a t u r e t h a t 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 i n l o a d a n d c a r r y a p p l i c a t i o n s fo r i n c re a s e d 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.

The machine is equipped with a 3-position ride c o n t r ol sw i t c h ( m a nu a l , a u to, a n d o f f) . M o s t commonly, the operator will choose to leave this switch in the automatic (center) position. With ride control active, the green indicator light will illuminate anytime the machine is traveling faster than 3.1 mph (5 km/h) indicating that the ride control is functioning.

Ride control will disengage automatically at slower speeds for loading and unloading. 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.

The top position of the switch turns ride control on in the manual 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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CHAPTER 4 - 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

Figure 50

164L96

Figure 51

163L96

Figure 52

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.

WARNING: Impact Hazard - Bucket edge or teeth can catch on frozen surface or buried objects 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. Failure to comply could result in serious injury or death and/or damage to the machine.

M465

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CHAPTER 4 - OPERATING INSTRUCTIONS TRANSPORT AND CARRY OPERATION The bucket must be in the roll back position and the bottom of the bucket must not be more than 12 to 18 inches (305 to 457 mm) off the surface.

Figure 53

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. Failure to comply could result in injury or death.

SA041

OPERATING ON A SLOPE 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. Failure to comply could result in injury or death.

SB013

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

• Use extra caution on hillside operations.

• Make sure that the low speed travel is selected.

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

IMPORTANT: On steep slopes using the down shift mode of the transmission is recommended to aid braking and to help prevent brake over heating and premature disc wear.

OPERATING THE MACHINE IN WATER

• Make sure that the bottom of the stream, or water

• Before using the machine in water, inject large

in which you will work, can support the weight of the machine.

quantities of fresh grease into the appropriate grease fittings.

• Do not allow the water level to reach the top of the

• After completing the operation make sure to inject

axles.

fresh quantities of grease into any fitting that was in water.

WARNING: Do not operate the machine in a fast flowing stream. Failure to comply could result in injury or death.

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CHAPTER 4 - OPERATING INSTRUCTIONS MOVING A DISABLED MACHINE ENGINE STALLS WHILE TRAVELING Brake System: The brakes can be applied by pressing the pedal for four or five applications until the accumulator is discharged. The operator must limit use of the brakes in this situation. In the event the brakes cannot be applied by the pedal, apply the parking brake switch.

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

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

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

NEVER TOW THE MACHINE FROM THE FRONT

2

BD03A037A

Figure 56

d. Loosen the lock nut (2).

Figure 54

BD07A006

1. Attach a rigid drawbar to the machine.

IMPORTANT: Make certain the towing machine has adequate brake capacity to safely stop both machines.

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

e. Turn the adjusting screw counterclockwise until the parking brake is released. f. Tighten the lock nut and replace the cover.

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

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

1

Figure 55

BD03A036

b. Clean the area around the parking brake cover to eliminate contamination. c. Remove the parking brake cover (1).

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CHAPTER 4 - OPERATING INSTRUCTIONS TRANSPORTING THE MACHINE 2

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

SB042

WARNING: Before you put the machine on a trailer, remove all snow, ice, oil or grease from the trailer and ramp. Failure to comply could result in injury or death.

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. Failure to comply could result in injury or death.

84-13A

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

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

2. Carefully 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.

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

4-28

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

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

9. Use chains to fasten the machine to the trailer.

See the next page for tie down locations of the machine.

10. Put a cover over the exhaust pipe.

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

12. Advise driver of weights of machine and attachments if special permits or guidelines are necessary.

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CHAPTER 4 - OPERATING INSTRUCTIONS TRANSPORTING THE MACHINE ON A TRAILER Machine Tie Down Locations

Figure 57 CHAINS MUST BE SECURELY FASTENED TO THE FRONT LEFT AND RIGHT TIE DOWN HOLES.

BD07A032

Figure 58 CHAINS MUST BE SECURELY FASTENED TO THE LEFT AND RIGHT REAR TIE DOWN HOLES.

BD07A176

TRANSPORTING THE MACHINE

BY RAIL Transport by rail is subject to special regulations, consult an approved organization.

BY TRUCK OR TRAILER Make sure you know the safety rules and regulations before transporting the machine. Make sure both trailer and machine are fitted with the correct safety equipment.

1. Measure the distance between the ground and the highest point of the machine. You must know t h e o ve r a l l h e i g h t . S e e M a c h i n e o ve r a l l dimensions in the Chapter 8 (Specifications).

2. Make sure that all doors, hoods, and access panels are correctly locked.

3. There are two tie down locations forward and two at the rear.

4. Secure the machine to the trailer using the tie downs provided.

5. The transport lock must be secured.

6. Chains must be fastened around the left and right sides of the loader arm to secure it in place.

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CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING IN COLD CLIMATE CONDITIONS Cold weather conditions require special operating procedures. During these conditions your machine will require special start up, warm up and maintenance procedures for the best performance. Proper cold weather maintenance will extend the service life of your machine.

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

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

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

If water is added to the batteries and the temperature is below 0° C (32° F), charge the batteries or run the engine for approximately 2 hours. This will prevent battery freezing.

LUBRICANTS Follow the recommended oil and filter service for the engine and hydraulic system as shown in this manual. Use the correct viscosity oil in each component for the ambient temperatures the machine is operating in. For extreme cold conditions, contact your dealer for alternative lubricants for the hydraulic and transmission systems.

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

C h e c k fo r w a t e r i n t h e f u e l s y s t e m . C o l d temperatures can cause condensation to form in the fuel tank. Check and drain the fuel filter and fuel tank for water as required.

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

4-30

COLD TEMPERATURE STARTING AIDS This machine may be equipped with an ether injection system. See the directions for operating this system. This allows for easier starting during cold weather. Contact your Dealer for additional cold weather starting aids.

Turn the key switch to the ON position and check the instrument indicators. Use the cold star t ether injection system. The system is designed to inject a measured amount of ether directly into the engine to assist starting in cold temperatures. See the Ether Cold Start in this section.

WARNING: Starting fluid (ether) can cause an explosion if sparks, flame, or extreme heat contacts 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. Failure to comply could result in serious injury or death.

MACHINE WARM UP Once the engine has started, run the engine at about half throttle (1100 to1300 rpm) for a minimum of four minutes under no load. This will help stabilize the engine.

After engine warm up, enable the pilot control by pushing down on the control knob just to the rear of the loader control levers. At this time, place the lift arm into float and the bucket into roll back to load the engine in order to heat the hydraulic oil. Hold for approximately two minutes. This will yield approximately 20° C (68° F). Apply and hold the foot brake, cycle the lift arm and bucket. Repeat the f l o a t / r o l l b a c k h e a t i n g p r o c e d u r e a g a i n fo r approximately two minutes. Raise the lift arms enough to steer the unit full left and right to warm the oil in the steer ing cylinders. In extreme cold conditions, hold the float/roll back condition for five minutes maximum.

WARNING: Make sure there is clearance around the machine before steering the machine left and right. Keep all non-authorized personnel clear of the area.

Failure to comply could result in serious injury or death.

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CHAPTER 4 - OPERATING INSTRUCTIONS Even with the correct oil in the hydraulic/brake system the first few times the brakes are actuated there may be some delay before the brakes are applied. The operator must actuate the brake pedal a minimum of 8 to 10 times before the machine is moved to obtain proper heating. Actuating and releasing the brakes should occur in a cycle of 3 seconds full on and 3 seconds off to obtain exchange of the brake oil.

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

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

OPERATING THE MACHINE IN HOT CLIMATES 1. Keep the coolant at the correct level in the coolant reservoir and in the radiator.

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

3. Check the cooling system cap before hot weather starts. Replace the cap as required.

Replace with a genuine replacement part to insure correct the correct PSI rated cap.

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

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

6. Use lubricants of the correct viscosity. See Fluids and lubricants in the Chapter 5, Lubrication, Filters, and Fluids.

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 in first and second gear only.

If the machine has been left idling in cold temperature, the engine will stay warm, but the hydraulic/brake oil and the axle oil will not stay warm. The oil and components can become cold and slow brake function response time. If this should happen you MUST go through the complete warm up procedure.

NOTE: The transmission is equipped with internal protection that does not allow the transmission to engage below -12° C (10° F). If the transmission does not engage below these temperatures, allow 2 to 4 minutes of running in neutral and try again.

Warm up time necessary may vary depending on temperature and conditions.

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4-31

CHAPTER 4 - OPERATING INSTRUCTIONS STORAGE PREPARATION FOR STORAGE

PERIODIC CHECKS

The following procedure applies when the machine is to be stored for a month or more. Store the machine on firm, level ground, inside a building or, if not possible, outside and covered with a tarpaulin.

Before storing the machine, carry out the following operations:

Every month, check:

1. Clean the machine.

2. Retract the arm cylinder rod as far as possible, and lower the boom until the attachment is resting on the ground.

3. Grease the machine thoroughly. The exposed surfaces of the cylinder rods should be greased or covered with a protective film. See your Case Dealer.

NOTE: When the machine resumes service, the film will disappear automatically.

1. Drain the fuel tank, and fill with a mixture of 90% diesel fuel and 10% anti-corrosive oil. Run the engine at idle speed for five minutes to allow the anti-corrosive oil to reach the lines, filters, pump and injectors.

2. While the engine is still warm, drain the oil sump, fill with anti-corrosive oil, and replace the engine oil filter.

3. When the engine is cold, clean the outer parts of the engine with diesel fuel.

4. Clean or replace the air filter element.

5. Drain the cooling system, leave the drain valves open, and do not tighten the radiator cap.

6. Grease the cylinder rods.

7. Remove the batteries, clean the battery housings and make sure not to leave any traces of acid.

Store the batteries safely in a cool and dry location, where the temperature will be higher than 0° C (32° F).

8. Paint any areas where the paint shows signs of deterioration.

9. Plug the air filter inlet and the exhaust pipe.

10. Remove the starter switch key and place a “DO NOT OPERATE” label on the right-hand control arm.

11. Lock the hoods and the cab door.

4-32

1. The battery charge and battery electrolyte level.

Recharge the batteries if required.

2. The grease on the cylinder rods and/or perform attachment functions monthly.

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

4. The condition of all lines, connectors and clamps (rust). Grease if necessary.

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

STARTING UP AFTER STORAGE 1. Close the drain valves and fill the cooling system.

2. Drain the fuel reservoir and top up with suitable fuel, see “Fluids and Lubricants” in section 5.

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

4. Replace the filtering element of the fuel filters.

5. Install the batteries.

6. Grease the machine thoroughly.

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

8. Check the condition of the air conditioning drive belt and replace it if necessary.

9. Check the hydraulic fluid level, and add more fluid if necessary.

10. Check the travel reduction gears and swing reduction gear oil level, and add more oil if necessary.

11. Clean the cylinder rods.

12. Unplug the air filter inlet and the exhaust pipe.

13. Remove the “DO NOT OPERATE” tag and start the engine, following the starting up procedure.

Keep non-authorized personnel clear of the machine.

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

WARNING: Avoid running the engine in a confined place. Make certain there is adequate ventilation at all times. Failure to comply could result in injury or death.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

Chapter 5 LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS SERVICING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 SUPPORT STRUT FOR LOADER LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 RELEASING PRESSURE IN THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 921E Capacities and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 ENGINE OIL VISCOSITY / TEMPERATURE RANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Transmission Oil Viscosity / Temperature Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 DAILY INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 ACCESS DOORS AND FILL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Variable Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

250 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

500 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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5-12 5-14 5-15 5-16 5-18 5-24 5-26 5-28 5-33

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

NOTES

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

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

Keep all non-authorized personnel clear of the area.

Un less otherwise specified , all m aintenance operations should be carried out with:

• the engine stopped • the transport/service link locked into position to stop the machine from unexpected articulation

• • • • • •

the parking brake engaged the key removed from the key switch a DO NOT OPERATE tag on the key switch wheel chocks blocking the wheels all circuits cooled down prior to starting work all hydraulic pressure released in lift arm and bucket/attachment circuits

• any accumulator pressure released for the

When performing service work on the machine, place a Do Not Operate tag on the instrument panel or key switch. Turn off engine and remove key before leaving operator's compartment.

Any modification to this machine without prior authorization could cause serious injury. Do not make any modifications without authorization.

Consult your dealer.

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

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

IMPORTANT: Oils and fluids must be disposed of properly.

HOURMETER

appropriate circuit Clean the grease fittings before lubrication. Clean around plugs and filler holes before adding fluid. No dust or dirt must enter the components or the circuits.

Wear suitable clothing and remember to use the necessary safety equipment.

WARNING: There is a risk of serious injury if maintenance or repairs are not carried out correctly. If you do not understand maintenance procedures, consult your dealer. Failure to comply could result in machine damage, serious injury or death.

WARNING: Before attempting any service procedures on the machine it is your responsibility to know how many accumulators are on the machine and how to properly release pressure of each. Failure to comply could result in serious injury or death.

M959

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

Failure to comply could result in machine damage, serious personal injury or death.

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BD06F097

Figure 1

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

Ser vicing inter vals are carefully calculated to guarantee safe and efficient machine operation.

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

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

SUPPORT STRUT FOR LOADER LIFT ARMS WARNING: If you service the machine with the loader lift arms raised, always use the support strut.

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

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

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

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

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

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

M824

Figure 2

BD07A008

SUPPORT STRUT IN TRANSPORT POSITION

5-4

Figure 3

BD07A009

SUPPORT STRUT IN SERVICE POSITION

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

RELEASING PRESSURE IN THE HYDRAULIC SYSTEM IMPORTANT: Before carrying out any work on the hydraulic system, there should be no pressure in any of the circuits.

1. Park the machine on firm, level ground, lower the bucket/attachment to the ground and stop the engine.

BD06F271

Figure 5

3. Operate the control levers from right to left and front to rear approximately a dozen times. Turn the ignition key to the OFF position.

Figure 4

BD06H093

2. Keep all non-authorized personnel clear of the machine. Turn the ignition switch key to the “ON” position. Pilot control switch must be on.

WARNING: Hydraulic fluid or grease injected into your skin can cause severe injury or death. Keep your hands and body away from any pressurized leak. Use cardboard or paper to check for a leak. If fluid is injected into your skin, see a doctor immediately and have the fluid removed. Failure to comply with this warning could result in injury or death.

WARNING: Before carrying out any service work on the hydraulic system it is necessary to allow it to cool (the temperature should not be more than 40°C (104° F). Failure to comply with this warning could result in injury or death.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUIDS AND LUBRICANTS 921E CAPACITIES AND SPECIFICATIONS Engine Type of oil ....................................................................................................................Case Akcela (SAE 15W-40) Capacity (with filter change) ................................................................................................................ 36 qt. (34 L) Cooling System System capacity ..............................................................................................................................15 gal. (56.8 L) Fuel System Reservoir capacity.......................................................................................................................104 gal. (393.7 L) Hydraulic System Type of fluid ...................................................................................................................Case Akcela Hy-Tran Ultra Total system capacity .......................................................................................................................64 gal. (242 L) Reservoir capacity............................................................................................................................34 gal. (130 L) Transmission Type of oil ....................................................................................................................Case Akcela (SAE 15W-40) Service capacity - with filter change...............................................................................................7.5 gal. (28.4 L) Axles Type of oil ........................................................................................ Case Akcela Transaxle Fluid (SAE 80W-140) Front axle ............................................................................................................................................ 54 qt. (51 L) Rear axle............................................................................................................................................. 54 qt. (51 L) With axle coolers Front axle ............................................................................................................................................ 58 qt. (55 L) Rear axle............................................................................................................................................. 58 qt. (55 L) NOTE: Machines are shipped from the factory with break-in oil.

Grease fittings, as required ........................................................................................... Case Akcela Molydisulfide

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

ENGINE OIL VISCOSITY / TEMPERATURE RANGES

Figure 6

BC02N250

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

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

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS TRANSMISSION OIL VISCOSITY / TEMPERATURE RANGES

Figure 7

BC04F193

HYDRAULIC/BRAKE SYSTEM - TEMPERATURE RANGE

Figure 8

BC04F192

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS COOLANT SOLUTION

HYDRAULIC FLUID

Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point with no additives to prevent l e a k a g e. D o n o t u s e n o n - a p p r ove d a n t i - r u s t additives. Anti-rust additives and ethylene-glycol can m i x a n d w o r k a g a i n s t e a c h o t h e r, r e d u c i n g anti-corrosion protection, forming deposits in the cooling system, and causing damage to the cooling system and radiator. Contact your dealer who can supply you with the suitable coolant solution.

Case Ak cela H y-Tra n U ltra hy draulic fluid is specifically designed for high pressure applications and for Case hydraulic systems. Your Case Dealer can provide hydraulic fluid to fulfill different climate/temperature conditions. Refer to the charts at the beginning of this section.

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

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

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

FUEL Use diesel fuel suitable for the ambient temperature conditions (ASTM-D-975).

Use fuel which is to ASTM (American Society for Testing and Materials) D975 standard.

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

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

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

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

TRANSMISSION COMPONENT OIL Extreme pressure oil should be used for enclosed transmission components. Choose an oil that is m a n u fa c t u r e d fo r yo u r c l i m a t e / t e m p e r a t u r e conditions such as Case Akcela No. 1 SAE 15W-40, Hy-Tran Ultra, Hy-Tran Ultra SS. See charts at the beginning of this section.

GREASE The type of grease to use depends on ambient temperature such as: Case Akcela Molydisulfide Grease ENVIRONMENT Before you service this machine and dispose of oil, f l u i d s, a n d l u b r i c a n ts, a l way s re m e m b e r t h e environment. Do not drain oil or fluids on to the ground or into containers that leak. Check with your local environmental, recycling center or your dealer for correct disposal information.

ENGINE OIL Case Akcela engine oil is recommended for your engine. This oil insures correct lubrication of your engine in all working conditions. See charts at the beginning of this section to choose the correct oil for climate/temperatures.

If Case Akcela engine oil cannot be obtained, use only oil of the API SERVICE CI-4 category.

NOTE: Do not put any Performance Additive or other additive in the sump. Oil change intervals shown in this manual are based on tests carried out on Case lubricants.

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

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

BD03F002

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Figure 9

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

DAILY INSPECTIONS Every day, before starting work, it is necessary to inspect the machine and ser vice cer tain of its components.

WARNING: If the slightest defect is found, repair it immediately before using the machine or see your Dealer. Failure to comply with this warning could result in injury or death.

General Check for water or oil leaks.

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

Check for abnormal noise on the hydraulic components.

Check for water or oil leaks on the components.

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

Check that all hydraulic circuits are functioning correctly.

Check that all screws and nuts are correctly tightened.

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

Check tires for proper inflation.

Check for damage.

Engine Check the oil level an d ch ange the oil, if necessary.

Check the coolant level at sight gauge.

Check for clogging or damage to the radiator.

Check the engine accessory drive belt tension.

Check that air filter restriction warning is not illuminated on console cluster.

Check for water or oil leaks on the components.

Check the condition of all lines.

Check the fuel tank level.

Other Check the hydraulic reservoir level.

Check that the hydraulic oil is clean.

Check the condition of all lines.

Check for electrical short-circuits.

Check that all battery connections are properly tightened.

Adjust the rear view mirrors.

Check for oil leaks on the cylinders.

Check the condition of the bucket/attachment.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART

5-35

Air filter

AR

6-6

Tires

AR

5-15

Engine oil level

10

5-15

Air conditioner/alternator belt tension

10

5-15

Fuel water separator

6-8

Wheel torque check (until stable)

5-16

Grease machine attachment

5-16

Hydraulic reservoir level

50

5-17

Transmission fluid

50

5-17

Coolant level

50

5-18

Grease loader linkage

100

5-18

Grease steering pins

100

5-19

Drive shaft carrier bearing

100

5-20

Engine oil and filters (initial only)

Run-in

100

5-21

Fuel filter (initial only)

Run-in

100

5-21

Hydraulic oil return filter (initial only)

Run-in

100

5-22

Front and rear axle oil (initial only)

Run-in

100

5-23

Transmission oil and filter (initial only)

Run-in

100

5-24

Cab air filter

5-25

Coolant filter

250

5-25

Fuel filter

250

5-26

Engine oil and filter

500

5-27

Drain fuel tank condensation

5-27

Axle oil level

500

6-4

ROPS and seat belt

500

7-6

Battery fluid level

500

5-28

Pivot points/articulation fittings

5-29

Axle oil (front and rear)

1000

5-30

Axle oil cooler filter (if equipped)

1000

5-31

Transmission fluid and filter

1000

5-32

Hydraulic oil filter

1000

5-32

Cab air filter

1000

DRAIN

LUBRICATE

REPLACE

CHECK

PAGE

SERVICE POINTS

CLEAN

SERVICE INTERVALS

INITIAL NEW MACHINE

INTERVALS IN HOURS

AR

As Required

Every 10 hours or shift change

Every 50 hours

Every 100 hours

100 hours (Initial)

Every 250 hours

Every 500 hours

Every 1000 hours

Every 1500 hours

Every 2000 hours

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Engine valve clearances

10 Run-in

10 50

250

500

1000

See your Case Dealer

5-33

Hydraulic fluid

2000

5-34

Engine coolant and filter

2000

5-35

Primary air filter

2000

5-35

Secondary air filter

2000

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

ACCESS DOORS AND FILL LOCATIONS

Figure 10

BD07A010

ENGINE HOOD AND COMPARTMENT DOOR RIGHT SIDE

Figure 11

BD07A192

HYDRAULIC FLUID GAUGE AND ACCESS DOOR RIGHT SIDE

COOLANT AND HYDRAULIC FILLS

Figure 12

ENGINE HOOD / TRANSMISSION OIL COOLER, AIR FILTER LEFT SIDE

5-12

Figure 14

BD07A013

BATTERY ACCESS ONE EACH SIDE

BD07A011

Figure 13

BD07A012

Figure 15

BD07A193

AXLE OIL FILTER/ WINDSHIELD FLUID BOTTLE ACCESS RIGHT SIDE (IF EQUIPPED)

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

Figure 16

BD07A015

HYDRAULIC VALVE ACCESS

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Figure 17

BD06F014

ENGINE OIL FILL LOCATION

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS VARIABLE PERIODIC MAINTENANCE Some working environments require that maintenance be performed more frequently. Dust, dirt, moisture, extreme hot or cold and many other factors should be taken into consideration when servicing the machine. Certain equipment or auxiliary tools may cause more stress on hydraulics, drivetrain, engines or filters. The following maintenance should be performed on regular schedules, but often need special attention when conditions require.

Engine Air Filter

Fuel Filter

Replace the primary element if the air filter indicator lamp illuminates.

Raise the engine hood and drain water and sediment from the fuel pre filter. Slowly loosen the drain valve located under the filter until clean fuel runs out.

The primary element may be cleaned by using air, h oweve r a n ew e l e m e n t i s r e c o m m e n d e d , i f questionable.

The inner element must not be cleaned. It must be replaced.

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

Wheels should be checked for proper torque every twenty hours when new and until they remain tight.

See the Wheel Bolt Torque on page 6-8 for pressures and torques.

Retighten the valve, but do not overtighten.

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

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

NOTE: If a fuse blows, replace it at once. Locate the problem and if it re-occurs, have it checked by a service technican.

Air Conditioning Condenser Raise hood. The air conditioner condenser slides in front of charge air cooler. Use compressed air to remove debris and buildup on the condenser. See Chapter 6 Maintenance - Cab Air Conditioning for further information.

WARNING: Wear full coverage safety glasses with side panels when using compressed air. Limit the pressure to 29 psi (2 bar). Failure to comply may result in death or injury.

Figure 18

Fuel Cooler The fuel cooler is located below the charge air cooler.

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

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 10 HOUR MAINTENANCE ENGINE ACCESSORY BELT TENSION

ENGINE OIL Service Specifications Type of oil . . . . . . . . . . . Case Akcela (SAE 15W-40) Capacity (with filter change) . . . . . . . . . 36 qt. (34 L) The engine oil level should be checked every 10 hour shift or each day, whichever occurs first.

2 1

Figure 21

BD06F036

Visually check the engine accessory belt every 10 hour shift or each day which ever occurs first. Make certain the belt is not cracked or frayed.

Figure 19

BD07A058

DRAIN FUEL FILTER CONDENSATION

The engine oil dip stick (1) is located on the right side of the engine, above the fuel fill location.

Keep all non-authorized personnel clear of the area.

Park the machine on a firm, level surface and turn off the engine. Remove the dipstick, and check the engine oil level. This procedure is best performed at the beginning of the work day with the engine cool and all oil drained to the pan.

E

2 BD06F014

Figure 22

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

Turn the drain to open, and allow to drain until only clean fuel flows out. Close the valve being careful not to over tighten.

Figure 20

BD07A017

The fill location (2) is located in the main engine compartment. Do not overfill engine oil.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 50 HOUR MAINTENANCE BUCKET/ATTACHMENT GREASE FITTINGS

HYDRAULIC OIL LEVEL

Service Specifications Grease . . . . . . . . . . . . . . .Case Akcela Molydisulfide Grease the attachment fittings when the hour meter registers 50 hours of operation or sooner if conditions so require.

Figure 24

BD06F031

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

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

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

BS03J108A

Figure 23

Clean around the area to be greased before service.

In severe conditions, such as immersion in water, it may be necessary to grease more frequently.

WARNING: The hydraulic oil tank is pressurized. If removal of the cap is required, loosen it slowly to relieve residual pressure in the tank. Do not overfill. Failure to comply may result in death or injury.

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

Failure to comply could result in serious injury or death.

WARNING: Do not work under or near the bucket/attachment of a machine or components which are not adequately supported or blocked. Failure to comply could result in serious injury or death.

Figure 25

BD07A013

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

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 50 HOUR MAINTENANCE

ENGINE COOLANT

TRANSMISSION OIL LEVEL

Service Specifications System capacity . . . . . . . . . . . . . . . . .15 gal. (56.8 L)

Keep all non-authorized personnel clear of the area.

Park the machine on level ground, in neutral with the parking brake applied and the attachment lowered to the ground.

The transmission oil level sight gauge is on the left side of the machine.

WARNING: This check must be performed with the engine running! Comply with the following: 1. make sure the gear selector is in neutral and the parking brake is set 2. make sure the bucket or equipment is on the ground and the pilot lock out is engaged to neutralize hydraulic flow 3. the transport/service link must be in place to prevent accidental articulation 4. if this check must be performed in an enclosed area be sure to ventilate properly to reduce the deadly exhaust fumes

BD07A181

Figure 27

The machine does not have an overflow tank. The neck of the cooling system tank will act as an overflow. Do not fill the cooling system tank completely to the top at cap level. Check the tank when the hour meter registers 50 hours. Fluid must always appear in the sight glass on the right side of the machine.

5. Failure to comply may result in death or injury.

BD07A013

Figure 28

NOTE: In the event that the system needs topping off make sure to use the proper ratio of water and antifreeze/coolant. Do not overfill.

Figure 26

BD07A019

Cold Oil Level Check Before you start the engine, check the transmission oil level in the sight gauge. If the oil level is below the arrow, add oil to raise the oil level up to the arrow.

See Transmission Service Specifications in this section for the correct type of oil.

Idle Speed Oil Level Check

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

Scalding can result from fast removal of radiator cap. Check and service engine cooling system according to maintenance instructions. Failure to comply may result in death or injury.

Check the transmission oil level at idle speed with the oil temperature at 176° to 185° F (80° to 85° C).

Oil level should be in the cross hatched area. Do not overfill.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 100 HOUR MAINTENANCE

Figure 29

BS06B144

MACHINE GREASE FITTINGS SERVICE SPECIFICATIONS Grease Specification ......................................................................................................... Case Akcela Molydisulfide Grease the machine fittings when the hour meter registers 100 hours of operation or sooner if conditions so require.

Clean around the area to be greased before service. Grease the bucket/attachment pivot pins, front driveshaft support bearing (remote), and steering cylinder pins (rod end).

Grease the steering cylinder pins (remote), boom pivot pins, bucket cylinder pins (remote) and the boom pivot pins.

IMPORTANT: In severe conditions, such as immersion in water, it may be necessary to reduce the greasing service intervals.

WARNING: Prior to maintenance always have the machine on firm, level ground with the bucket/attachment on the ground. Make sure all residual pressure is relieved from circuits before beginning maintenance. Failure to comply could result in serious injury or death.

WARNING: Do not work under or near the bucket/attachment of a machine or components which are not adequately supported or blocked. Failure to comply could result in serious injury or death.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 100 HOUR MAINTENANCE

DRIVE SHAFT CARRIER BEARING

BD07A178

Figure 30

BD06F002

Bucket Cylinder Remote Grease Location

Figure 32

Grease the drive shaft carrier bearing at the remote grease location when the hour meter registers 100 hours of operation or sooner if conditions so require.

Figure 31

BD06F002

Loader Lift Arm Remote Grease Location

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5-19

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS REPLACE OIL FILTER

100 HOUR MAINTENANCE CHANGE ENGINE OIL AND FILTER (Initial) Service Specifications Type of oil . . . . . . . . . . . Case Akcela (SAE 15W-40) Capacity (with filter change) . . . . . . . . . . 36 qt. (34 L) Change the engine oil and filter when the hour meter registers 100 hours for a new machine during the initial run-in period. The engine oil and filter should be changed every 500 hours thereafter or more frequently when the engine operating conditions are severe.

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

Figure 35

BD07A029

5. Clean the area around the filter of dirt and debris.

6. Turn the filter counterclockwise to remove.

Remove and discard the filter following local environmental and waste regulations.

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

IMPORTANT: Never use a filter wrench to install a new filter.

8. Turn the new oil filter onto the base until the gasket makes contact with the base and then turn by hand an additional 3/4 turn.

9. Close the remote drain.

Figure 33

BD07A020

2

ENGINE OIL DRAIN

3. Attach the drain hose.

Figure 36

BD07A017

10. Fill the engine with the proper amount of oil.

11. Start the engine and run at idle speed. Check the engine oil filter and remote drain for leaks.

12. After two minutes stop the engine.

BD07A021

Figure 34

4. Use a suitable container to capture the used oil, and turn the drain valve to open. Drain the engine oil.

NOTE: When changing engine oil, the oil flow rate can be improved if the oil fill cap or dipstick is removed from the engine while draining.

5-20

13. Wait for the engine oil to drain down for an accurate reading on the dipstick.

14. Check the dipstick and add additional oil, if necessary.

15. Secure the engine access cover.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 100 HOUR MAINTENANCE

REPLACE HYDRAULIC OIL FILTERS (Initial)

REPLACE FUEL FILTER (Initial)

Replace the hydraulic oil filters when the hour meter registers 100 hours for a new machine during the initial run-in period. Filters should be changed every 1000 hours thereafter or more frequently when operating conditions are severe.

Change the fuel filter when the hour meter registers 100 hours for a new machine during the initial run-in period. Filters should be changed every 250 hours thereafter or more frequently when operating conditions are severe.

WARNING: Fluid under pressure. Always rest the hydraulic bucket/attachment on the ground. Shut the engine off, turn the key to on, and move the hydraulic control levers through all movements several times to relieve residual pressure in the system.

Failure to comply could result in serious injury or death.

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

Figure 37

BD07A023

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

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

WARNING: Never drain oil or remove the oil filter while the engine is running. Failure to comply could result in serious injury or death.

3. Slowly loosen the filler cap on the hydraulic reservoir to release pressure in the reservoir.

Leave it loose during the procedure.

4. Turn the filters counterclockwise to remove.

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

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

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

IMPORTANT: Never use a filter wrench to tighten a new filter on install.

BD07A024

WARNING: Engine fuel is flammable and can cause a fire or an explosion. Do not fill the fuel tank or service the fuel system near an open flame, welding, burning cigars, cigarettes, pipes, etc. Failure to comply could result in serious injury or death.

Figure 38

(COVER BRACKET REMOVED FOR VISUAL CLARITY)

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

IMPORTANT: Never use a filter wrench to tighten a new filter on install.

6. Tighten the cap on the hydraulic reservoir.

7. Start the engine and run at 1000 rpm. Have an assistant check for leaks around the filter area.

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

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5-21

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 100 HOUR MAINTENANCE CHANGE FRONT AND REAR AXLE OIL (Initial) Service Specifications Front axle . . . . . . . . . . . . . . . . . . . . . . . . 54 qt. (51 L) Rear axle . . . . . . . . . . . . . . . . . . . . . . . . 54 qt. (51 L) With axle coolers Front axle . . . . . . . . . . . . . . . . . . . . . . . . 58 qt. (55 L) Rear axle . . . . . . . . . . . . . . . . . . . . . . . . 58 qt. (55 L) Change the front and rear axle oil when the hour meter registers 100 hours for a new machine during the initial run-in period. Axle oil should be changed every 1000 hours thereafter or more frequently when operating conditions are severe.

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

Failure to comply could result in serious injury or death.

Figure 40

BD07A032

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

6. Reinstall the drain plugs of both axles and the four axle ends.

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

3. Clean the area around the drain and fill caps of both axles and all four axle ends.

Figure 41

BD06H045

7. Fill with axle oil to the proper level. Oil should come up to the bottom of the fill port. Replace the plug being careful not to damage the O-ring.

NOTE: The oil will take some time to fill each axle.

Allow time for the oil to circulate throughout the axle.

BD07A030

Figure 39

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

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 100 HOUR MAINTENANCE CHANGE TRANSMISSION FLUID AND FILTER (Initial)

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

Service Specifications With filter change. . . . . . . . . . . . . . . 7.5 gal. (28.4 L) Change the transmission fluid and filter when the hour meter registers 100 hours for a new machine during the initial run-in period. Transmission fluid and f i l t e r s s h o u l d b e c h a n g e d eve r y 1 0 0 0 h o u r s thereafter or more frequently when operating conditions are severe.

Figure 44

BD02N124

7. Remove the drain plug and drain the oil.

Figure 42

BD07A195

TRANSMISSION FILTERS (LEFT SIDE)

1. Keep all non-authorized personnel clear of the area. Park the machine on a level surface and apply the parking brake.

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

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

Figure 45

BD07A024

(COVER BRACKET REMOVED FOR VISUAL CLARITY)

8. Remove the filter.

9. Apply a film of clean transmission oil to the gasket of the new filter and install. Make certain proper contact is made with the base.

10. Spin the breather, located on the top of the transmission a few times.

11. If the breather is difficult to spin follow steps 12 and 13.

12. Remove the breather. Clean it with solvent and dry with compressed air.

WARNING: Wear full coverage safety glasses with side panels when using compressed air. Failure to comply could cause injury or death.

13. Install the breather.

Figure 43

BD07A031

(COVER BRACKET REMOVED FOR VISUAL CLARITY)

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

5. Remove the fill plug.

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14. Check the oil level at the sight gauge.

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

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

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE CAB AIR FILTER

CAB AIR FILTER The cab recirculation air filter is located behind the operator’s seat. Clean the cab air filters when the hour meter registers 250 hours.

Figure 47

BD07191

Figure 46

BD06F095

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

The cab filter is located on the right hand side of the machine, below the operator’s compar tment.

Remove the two screws from the cab air filter cover and remove the cover. Pull the filter forward at a slight angle.

2. Check the filter for debris or tears.

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

WARNING: Wear full coverage safety glasses with side panels when using compressed air to clean components. Limit the pressure to 29 psi (2 bar). Failure to comply may result in death or injury.

4. Reinstall the filter, and secure the access filter cover.

5-24

Figure 48

BD06F152

Check the filter for debris or tears. Wipe the inside of the filter housing. Clean dust from filter, using compressed air if necessary. Reinstall the filter and air filter cover.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE

REPLACE FUEL FILTER

COOLANT FILTER

Fuel filters should be changed when the hour meter registers 250 hours or more frequently when operating conditions are severe.

Check and clean the coolant filter when the hour meter registers 250 hours or more frequently if operating conditions so require.

BD06F014

Figure 49

BD07A029

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

Figure 50

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

3. To remove the filter, turn the clockwise.

3. Clean the filter head area, the outside of the filter and remove any dirt and debris around the area that might contaminate the system.

4. Clean and rinse all sediment collected in filter cartridge. Replace, making certain filter gasket comes in contact with the filter head.

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

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

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

IMPORTANT: Never use a filter wrench to tighten a new filter on install.

WARNING: Engine fuel is flammable and can cause a fire or an explosion. Do not fill the fuel tank or service the fuel system near an open flame, welding, burning cigars, cigarettes, pipes, etc. Failure to comply could result in serious injury or death.

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5-25

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE REPLACE OIL FILTER

CHANGE ENGINE OIL AND FILTER Service Specifications Type of oil . . . . . . . . . . . Case Akcela (SAE 15W-40) Capacity (with filter change) . . . . . . . . . . 36 qt. (34 L) The engine oil and filter should be changed every 500 hours or more frequently when the engine operating conditions are severe.

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

Figure 53

BD07A029

5. Clean the area around the filter of dirt and debris.

6. Turn the filter counterclockwise to remove.

Remove and discard the filter following local environmental and waste regulations.

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

IMPORTANT: Never use a filter wrench to install a new filter.

8. Turn the new oil filter onto the base until the gasket makes contact with the base and then turn by hand an additional 3/4 turn.

BD07A020

Figure 51

3. Attach the drain hose to the engine oil drain port.

9. Close the remote drain.

10. Fill the engine with the proper amount of oil.

11. Start the engine and run at idle speed. Check the engine oil filter and remote drain for leaks.

12. After two minutes stop the engine.

2 1 BD07A021

Figure 52

4. Use a suitable container to capture the used oil Open the drain valve and drain the engine oil.

NOTE: When changing engine oil, the oil flow rate can be improved if the oil fill cap or dipstick is removed from the engine while draining.

Figure 54

BD07A

13. Wait for the engine oil to drain down for an accurate reading on the dipstick.

14. Check the dipstick (1) and add additional oil (2), if necessary.

15. Secure the engine access cover.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS AXLE OIL LEVEL

500 HOUR MAINTENANCE

Service Specifications Front axle . . . . . . . . . . . . . . . . . . . . . . . . 54 qt. (51 L) Rear axle . . . . . . . . . . . . . . . . . . . . . . . . 54 qt. (51 L) With axle coolers Front axle . . . . . . . . . . . . . . . . . . . . . . . . 58 qt. (55 L) Rear axle . . . . . . . . . . . . . . . . . . . . . . . . 58 qt. (55 L)

DRAIN FUEL TANK CONDENSATION

Check the oil level in the front and rear axles when the hour meter registers 500 hours.

Figure 55

BD07A057

Drain condensation from the fuel tank when the hour meter registers 500 hours of operation or more frequently if conditions so require.

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

3. Have a suitable container ready to capture the condensation and fuel. Dispose of the waste following local regulations.

4. Place hose over fuel tank petcock and open slowly and allow the condensation to flow until only fuel is discharged.

5. Tighten the fuel tank petcock.

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

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BD07A030

Figure 56

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

3. Remove the oil plug from the center of the axle bowl. Oil level should be level with the bottom of the plug.

4. Add oil if required. Clean and install the plug.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE GREASE ARTICULATION FITTINGS

GREASE PIVOT POINTS

BS06B144A

BD07A182

Figure 58

BD07A183

Figure 59

Figure 57

Grease the upper and lower chassis pivot points when the hour meter registers 1000 hours or sooner if conditions so require.

Grease articulation fittings when the hour meter registers 1000 hours or more frequently if conditions so require.

1. Keep all non-authorized personnel clear of the area. Park the machine on a level surface. Lower the loader bucket/attachment to the ground and stop the engine. Apply the parking brake.

2. Place the transport/service link into the lock position to stop unexpected articulation of the machine.

3. Clean the area around each fitting and grease.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE CHANGE FRONT AND REAR AXLE OIL Service Specifications Service Specifications Front axle. . . . . . . . . . . . . . . . . . . . . . . .

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

With axle coolers Front axle. . . . . . . . . . . . . . . . . . . . . . . .

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

54 qt. (51 L) 54 qt. (51 L) 58 qt. (55 L) 58 qt. (55 L)

Drain and replace the front and rear axle oil every 1000 hours or more frequently when operating conditions are severe. .

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

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

BD07A032

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

4. Reinstall the drain plugs of both axles and the four axle ends.

NOTE: The oil will take some time to fill each axle.

Allow time for the oil to circulate throughout the axle.

BD01E136

Figure 60

BD07A030

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

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Figure 61

Figure 62

5. Fill the axle with new axle oil. Replace the plug, taking care not to damage the seal. Oil should reach the bottom of the fill plug.

5-29

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE REPLACE AXLE COOLER FILTERS (IF EQUIPPED)

Figure 64

BD07A041

(COVER REMOVED FOR VISUAL CLARITY)

BD07A193

Figure 63

On machines with axle cooling systems, the axle cooling filters should be changed every 1000 hours or when the axle oil is drained.

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

4. Turn the filter counter clockwise to remove.

Remove and discard the filter following local environmental and waste regulations.

5. Apply a thin coat of oil onto the new filter gasket.

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

6. After filling the axles with the correct amount of oil, start and run the engine at idle speed. Check the filters for leaks.

3. Clean the area around the filter of dirt and debris.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE TRANSMISSION FLUID AND FILTER Service Specifications With filter change. . . . . . . . . . . . . . . 7.5 gal. (28.4 L) Change the transmission fluid and filter every 1000 hours or more frequently when operating conditions are severe.

Figure 67

BD02N124

7. Remove the drain plug and drain the oil.

Figure 65

BD07A195

TRANSMISSION FILTERS (LEFT SIDE)

1. Keep all non-authorized personnel clear of the area. Park the machine on a level surface and apply the parking brake.

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

Figure 68

BD07A024

(COVER REMOVED FOR VISUAL CLARITY)

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

8. Remove the filter.

9. Apply a film of clean transmission oil to the gasket of the new filter and install. Make sure that the proper contact is made with the base.

10. Spin the breather, located on the top of the transmission a few times.

11. If the breather is difficult to spin follow steps 12 and 13.

12. Remove the breather. Clean it with solvent and dry with compressed air.

Figure 66

BD07A031

(COVER REMOVED FOR VISUAL CLARITY)

WARNING: Wear full coverage safety glasses with side panels when using compressed air. Failure to comply could cause injury or death.

13. Install the breather.

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

14. Check the oil level at the sight gauge.

5. Remove the dipstick.

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

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

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

5-31

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS REPLACE CAB AIR FILTER

1000 HOUR MAINTENANCE REPLACE HYDRAULIC OIL FILTER Replace the hydraulic oil filters every 1000 hours or more frequently when operating conditions are severe.

WARNING: Fluid under pressure. Always rest the hydraulic bucket/attachment on the ground. Shut the engine off, turn key to on position, and move the hydraulic control levers through all movements several times to relieve residual pressure in the system.

Failure to comply could result in serious injury or death.

1. Keep all non-authorized personnel clear of the area. Park the machine on a firm, level surface.

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

Figure 70

BD07A0191

The cab filter is located on the right hand side of the machine, below the operator’s compar tment.

Remove the two screws from the cab air filter cover and remove the cover. Pull the filter forward at a slight angle.

WARNING: Never drain oil or remove the oil filter while the engine is running. Failure to comply could result in serious injury or death.

2. Slowly loosen the filler cap on the hydraulic reservoir to release pressure in the reservoir.

Leave it loose during the procedure.

3. Remove the access cover. Turn the filters counterclockwise to remove.

Figure 71

BD07A190

Wipe the filter housing clean. Replace with a new filter. Replace cover and fasten in place with the two screws.

Figure 69

BD07A024

(COVER REMOVED FOR VISUAL CLARITY)

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

IMPORTANT: Never use a filter wrench to tighten a new filter on install.

5. Tighten the cap on the hydraulic reservoir.

6. Start the engine and run at 1000 rpm. Have an assistant check for leaks around the filter area.

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

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 2000 HOUR MAINTENANCE CHANGE HYDRAULIC OIL AND FILTERS Service Specifications Total system capacity . . . . . . . . . . . . 64 gal. (242 L) Type . . . . . . . . . . . . . . . . Case Akcela Hy-Tran Ultra Change the hydraulic oil ever y 2000 hours of op eration . Chan ge o il m ore fr eq uen tly w hen operating conditions are severe.

1. Keep all non-authorized personnel clear of the area. Park the machine on a firm, level surface, lower bucket/attachment to the ground and apply the parking brake.

Figure 73

BD07A031

2. Stop the engine. Put a Do Not Operate tag on the steering wheel or key switch.

3. Place the transport/service link into the lock position to prevent unexpected articulation.

4. Make sure the accumulators are completely discharged by pushing down on the brake pedal a minimum of 30 times.

(COVER REMOVED FOR VISUAL CLARITY)

10. Remove and replace the hydraulic oil filter. To remove the filters, turn counter clockwise. When installing new filters, apply a thin coat of oil to the gasket. Tighten the filters firmly to the filter head by hand. Do not use a filter wrench to tighten the filters.

5. Release pressure in ride control accumulators, if equipped.

6. With the ignition key in the ON position, cycle the bucket/attachment control levers repeatedly through their complete range of motion for at least 30 seconds.

7. Move the hydraulic controller to the float position and turn the key off.

BD07A013

Figure 74

11. Fill the reservoir with new hydraulic oil.

12. Install the reservoir filler cap.

13. Start the engine and run at 1000 rpm. Check for leakage around the filter and drain.

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

Figure 72

BD07A034

8. Open the hydraulic reservoir drain, and pump the oil into a suitable container.

9. Clean the area around the filler cap, and slowly remove the cap.

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15. Place the loader bucket/attachment on the ground and stop the engine. Check the hydraulic oil level.

16. If it is necessary to top off with more oil, remove the fill cap slowly to release pressure in the reservoir.

5-33

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 3. After all the coolant is drained, secure the drain valve.

2000 HOUR MAINTENANCE ENGINE COOLANT Service Specifications System capacity . . . . . . . . . . . . . . . . 15 gal. (56.8 L) Drain, flush and replace the engine coolant every 2000 hours of operation or each year, whichever occurs first. Clean the system and replace the coolant if it becomes dirty or is rust colored.

4. Use a system cleaning product to clean and flush the system. Contact your Dealer.

5. After, the system has been cleaned and flushed following the cleaning product instructions, close and secure the drain valve.

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

Scalding can result from fast removal of radiator cap. Check and service engine cooling system according to maintenance instructions. Failure to comply may result in death or injury.

SA023

Figure 77

BD06F036

6. Fill with the proper mix of antifreeze/coolant and water for the system and for the prevailing weather conditions. Do not fill to the top of the tank. Fill with the specified amount of coolant, and check the sight gauge on the right side of the machine.

IMPORTANT: Do not overfill.

7. Start the engine, and let it run at low idle until the engine reaches operating temperature. Recheck the level of the system.

BD07A013

Figure 75 COOLING SYSTEM CAP AND FILL ACCESS.

1. After the engine has cooled so the temperature of the coolant is safe, remove the cap.

COOLANT FILTER Replace the coolant filter when coolant is drained and replaced.

Figure 78

BD07A029 BS07A032

Figure 76

2. With a suitable container of the proper capacity under the drain, open the valve by tur ning counterclockwise and drain the coolant from the system.

5-34

1. Turn the filter cartridge clockwise to remove.

2. Apply a thin coat of oil to filter gasket. Replace with new filter, making certain gasket comes in contact with filter head.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 2000 HOUR MAINTENANCE REPLACE ENGINE AIR FILTER The air filter should be checked periodically for dirt and debris build up.

Replace the engine primary and secondary air filter every 2000 hours or each year, whichever occurs first.

NOTE: Replace the primary element if the filter warning lamp on the instrument cluster illuminates or the audible alarm sounds. Should the caution warnings continue after replacing the primary filter, replace the secondary filter as well.

2

Figure 81

BD07A197

5. Loosen the filter gasket seal by pushing down on the handle (2).

Figure 79

BD07A035

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

Figure 82

BD07A037

6. Remove the primary filter approximately a 5° angle.

by

tilting

at

3. Access the engine air filters by raising the hood.

The engine air filter is located on the left hand side of the machine, behind the main engine compartment.

1

1

BD07A038

Figure 83

7. Remove the secondary filter by pulling down on the filter handle. Wipe the inside of the filter housing body clean of dirt and debris before installing the new filters.

Figure 80

BD07A196

4. Release the four clips (1) that secure the filter cover. Remove the cover.

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5-35

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

3 4

BD07A196

Figure 84

8. Install the new secondary filter by inserting the filter tab (4) into the positioning slot (3). Slide filter in place at an angle, then use the plastic handle to firmly seat the secondary filter into the inlet housing.

Figure 86

BD07A040

10. Install the cover and lock the clips to secure the cover in place. If the cover does not secure in place properly, recheck filter installation. The cover will be difficult to install if filters are not properly installed.

11. Close the engine hood.

NOTE: Under normal conditions, the secondary filter should be replaced after three primary filter replacements. Replace filters more often if conditions so warrant.

BD07A197

Figure 85

9. Install the new primary filter by sliding in at a 5° angle until filter comes in contact with the bottom of the housing. Gradually straighten the filter, pushing the filter inward and up, until primary and secondary filters form an effective seal.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Chapter 6 MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS Roll-over Protection Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Torque Specifications for ROPS Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Wheel Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Check Engine Accessory Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Check Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Replacing the Ether Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Radiator/cooler Cleaning: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Checking for Cylinder Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Welding on the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Loader Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Height Control and Return To Travel Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Return To Dig Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Calibrating the Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Transmission Declutch Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Parking Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Secondary Steering Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 CAB SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Air Conditioning (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Cab Headliner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

NOTES

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ROLL-OVER PROTECTION STRUCTURE WARNING: Your machine is equipped with an operator Protective Structure, such as: a Rollover Protective Structure (ROPS) or Falling Object Protective Structure (FOPS). A ROPS may be a cab frame or a two-posted or four-posted structure used for the protection of the operator to minimize the possibility of serious injury. The mounting structure and fasteners forming the mounting connection with the machine are part of the ROPS.

T h e L o a d e r h a s a RO P S d e c a l s h ow i n g t h e certification of the ROPS, gross weight, approval, regulation, and model number of the machine.

Check and inspect the ROPS structure and the seat restraint system every 500 hours of operation.

The Protective Structure is a special safety component of your machine.

DO NOT attach any device to the Protective Structure for pulling purposes. DO NOT drill holes into the Protective Structure.

The Protective Structure and interconnecting components are a certified system. Any damage, fire, corrosion or modification will weaken the str ucture and reduce your protection. If this occurs, the Protective Structure MUST be replaced so that it will provide the same protection as a new Protective Structure. Contact your dealer for Protective Str ucture inspection and replacement.

BD06H167

Figure 1

The ROPS decal is located behind the operator’s seat.

After an accident, fire, tip or roll over, the following MUST be performed by a qualified technician before returning the machine to field or job site operation: The protective structure MUST be replaced.

T h e m o u n t i n g o r s u s p e n s i o n fo r t h e Protective Structure, operator seat and suspension, seat belts and mounting components and wiring within the operator’s p r o t e c t i ve s y s t e m M U S T b e c a r e f u l l y inspected for damage.

All damaged parts MUST be replaced.

DO NOT WELD, DRILL HOLES, ATTEMPT TO S T R A I G H T E N O R R E PA I R T H E P R OT E C T I V E STRUCTURE. M O D I F I C AT I O N I N A N Y WAY C A N REDUCE THE STRUCTURAL INTEGRITY OF THE STRUCTURE WHICH COULD CAUSE DEATH OR SERIOUS INJURY IN THE EVENT OF FIRE, TIP, ROLLOVER, COLLISION OR ACCIDENT.

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BD06G176

Figure 2

Before you operate this machine, always make sure the ROPS and operator’s seat belt is correctly installed.

The seat belt is an important part of the ROPS. You must wear the seat belt at all times when you operate the machine.

Make sure all hardware that secures the seat to the cab is properly torqued. Make sure all seat belt hardware is secure and torqued.

Keep seal belts away from objects that can damage the seat belts.

Keep the seat belts clean. Wash the seat belts only in soap and water. Do not put the seat belts in bleach or dye. This will weaken the seat belt composition.

6-3

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TORQUE SPECIFICATIONS FOR ROPS CAB

BD07A199

OPERATOR PROTECTIVE STRUCTURE

Figure 3

1. Check the torque of the ROPS mounting bolts. If necessary, tighten the bolts to the correct torque.

2. Check the operator’s seat and mounting components for the seat belt. Tighten the bolts to the correct torque. Replace any parts that have wear or damage.

3. Check for cracks, rust, or holes in the ROPS and ROPS components. Age, weather, and accidents can cause damage to the ROPS and ROPS parts. If you have any doubt about the integrity of the ROPS system, see your Case Dealer.

WARNING: Adding additional weight (bucket/attachments, etc.) to the machine can cause injury or death. Do not exceed the gross weight printed on the ROPS label.

Failure to comply could result in serious injury or death.

SA028

Figure 4

6397

Check the torque of the mounting bolts for the ROPS canopy and the ROPS cab during the run-in period of a n ew m a c h i n e , a s w e l l a s a t t h e 5 0 0 h o u r maintenance interval.

Check the torque of the ROPS mounting bolts. If necessary, tighten the bolts to the correct torque.

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 integrity of the ROPS system, see your dealer.

Torque Specifications ROPS cab mounting bolts (both sides) Torque to: 580 to 630 lb. ft. (773 - 854 Nm) NOTE: Torque specifications are for clean, dry threads.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 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.

SD020

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

84-113

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

SB134

BALLAST Adding ballast to the tires of your wheel loader is NOT recommended. Make sure tires are properly inflated.

Figure 5

B910410J

The above illustration show danger areas caused by exploding tires and / or rim parts. KEEP YOURSELF AND OTHERS OUT OF THESE DANGER AREAS. Keep all non-authorized personnel clear of the area.

The next page shows the correct methods that you MUST use when adding air or servicing a tire.

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6-5

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 250 HOUR MAINTENANCE TIRE PRESSURE Check tire pressure when the hour meter registers 250 hours or more frequently when operating conditions warrant.

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. Failure to comply could result in serious injury or death.

Figure 6

BD06H041

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

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

Keep all non-authorized personnel clear of the area.

To add air to a tire: 1. Use an air hose with a remote shutoff valve and a self-locking air chuck.

Service Specifications Normal Work Tire Inflations: Tire Type

Front Pressure

Rear Pressure

26.5 X 25 L3 Bias

50 psi (3.4 bar)

40 psi (2.8 bar)

26.5 R 25 L2 Radial

60 psi (4.1 bar)

50 psi (3.4 bar)

26.5 R 25 L3 Radial

60 psi (4.1 bar)

50 psi (3.4 bar)

6-6

2. Stand BEHIND the tread of the tire and make sure ALL personnel are away from the side of the tire before you start.

3. Inflate the tire to the recommended air pressure.

D O N OT i n f l a t e t h e t i r e m o r e t h a n t h e recommended pressure.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ADDING AIR TO THE TIRES

TIRE OR RIM SERVICE

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

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

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

Tire Tread Direction

Figure 7

B790490R

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

B770164R

Figure 8

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

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6-7

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS WHEEL BOLT TORQUE

8

15

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

18

1

4

10

Use a hand wrench (not an impact) to tighten wheel bolts to pull the wheel against the planetary housing.

11

19

13

5

6 20

14 9

3 17

7

16

2 Figure 9

BD07A043

Tighten the wheel bolts using the sequence shown.

First tighten the bolts to 278 Nm (220 pound-feet), then tighten to a final torque of 640 to 720 Nm (475-530 lb. ft.), using the same sequence.

8

11

4

15

13

1

6

10

9

5 2

14 12

3 16

7 Figure 10

BD06H168

20 BOLTS: M22 - 1.5

6-8

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK ENGINE ACCESSORY BELT Maintenance Specifications Visual check . . . . . . . . .Every 10 hours or every day Replace belts. . . . . . . . . . . . . . . . . Every 2000 hours Check the belt for correct tension, wear, and damage. Wrong belt tension may cause battery charge failure, engine overheating, or belt wear.

IMPORTANT: If the engine runs with the drive belt loose, the drive belt can slip and cause the engine to overheat or the battery to receive insufficient charge.

RD97F143

WARNING: Rotating parts can cause serious personal injury. Keep away from fan and belt when engine is running. Make sure to stop engine before servicing. Failure to comply could cause injury or death.

Figure 13

The correct tension for a new belt is: 140 to 160 pound force (623 to 712 N•m).

A used belt should have: 90 to 120 pound force (400 to 534 N•m) tension.

Adjust the belt if required.

Check Drive Belt

Loosen the strap bolt and the pivot bolt. Turn the adjusting bolt counterclockwise to loosen or clockwise to tighten the alternator belt.

To r e p l a c e b e l t , t u r n t h e a d j u s t i n g b o l t counterclockwise until the belt can be removed.

Install a new belt and retighten the adjusting belt to the correct tension.

CHECK VALVE ADJUSTMENT This should be performed by a qualified service technician when the hour meter registers 1500 hours. Contact your dealer.

Figure 11

BD07A044

The alternator belt is located on the left hand side of the machine behind the turbocharger. The air conditioner compressor belt is located on the right hand side of the machine.

Figure 12

BD07A045

Perform a visual inspection for cracks and damage.

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6-9

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REPLACING THE ETHER CONTAINER 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 with the machine.

Figure 15

BD02C047

1. To remove the container, loosen the clamp on the ether bracket securing the ether container in place.

2. Turn the ether container counter clockwise to remove the container.

3. Install the new ether container by inverting on the valve and turning clockwise in the bracket.

BD07A205

Figure 14

Before you discard an empty ether container, use rubber gloves and push the valve in the end of the container to remove any pressure. Do not puncture o r o t h e r w i s e d a m a g e t h e c o n t a i n e r. D o n o t incinerate the container. Dispose of properly in an environmentally correct manner.

4. Tighten the clamp to secure the ether container in place.

5. Discard old container properly.

STORAGE

If welding, grinding, or using a cutting torch on the machine, always remove the ether container from the machine. Use compressed air to remove any ether fumes from the area.

Figure 16

BD07A046

Remove the ether container when temperatures are above 35° F to 40° F (0 to 5° C). Install the cap on the solenoid valve.

Do Not store ether containers in the operator’s compartment. Wear rubber gloves when handling ether containers.

6-10

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS RADIATOR/COOLER CLEANING:

CHECKING FOR CYLINDER LEAKAGE

1. Additional access can be gained to the radiator/oil cooler from the right side of the machine by sliding the air conditioner condenser out.

2. The lower areas and radiator/cooler can be cleaned using a shop-vacuum and/or a pressure washer.

IMPORTANT: Be careful not to bend or damage radiator/cooler fins during cleaning. DO NOT exceed 6890 kPa (1000 psi) nozzle pressure when cleaning.

A cylinder rod should be slightly oily. Check that there are no leaks after a period of work, when the whole hydraulic system is at normal operating temperature.

1. Wipe the rod and bearing clean on the cylinder to be checked.

2. Operate normally for five or ten minutes.

3. Extend the cylinder rod.

4. Carry out the leak test.

ROD APPEARANCE

TEST

Slight traces of oil when a Dry piece of paper is wiped over 20 cm (7.8 in) of the rod.

Normal

Slightly Paper remains stuck to rod greasy when run over rod.

Normal

Oily Paper remains stuck when placed on rod.

Normal

Very oily or Each time the cylinder rod weeping is extended, a ring of oil can be seen on the rod.

Figure 17

BD07A047

WARNING: Wear face protection when using high pressure water jets. Failure to comply could cause injury or death.

CONCLUSION

Each time the rod retracts, Leakage the excess oil drips from the gland.

See your dealer

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

INSPECTING AND CLEANING THE MACHINE Maintenance Specifications Inspect and clean . . . . . . . . . . . . . . . . . . Periodically WARNING: Wear face protection when using high pressure water jets. Failure to comply could cause injury or death.

Clean immediately if oil or grease has been spilled on the machine. Clean with steam or a high pressure water jet.

Look for any leaks, and check the condition of all pipes and hoses.

Take the opportunity during this operation to make a visual check of all the welded components (in case of appearance of cracks), the bucket/attachment linkages and check the teeth and tooth tips for correct retention and for wear.

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6-11

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS FIRE EXTINGUISHER (NOT SUPPLIED)

WELDING ON THE MACHINE

It is strongly recommended a fire extinguisher be kept on the machine. An extinguisher is not supplied but can be purchased separately and placed in the rear left-hand side compartment. A specific bracket has been provided for this purpose.

Whenever carrying out a welding operation on the machine as authorized by the manufacturer and in accordance with manufacturer’s instr uctions, disconnect the batteries, disconnect the alternator B+ and D+ terminal wires, and connect the welding apparatus ground cable to the component on which the welding operation is to be performed.

Maintenance Specification Every month Examine the fire extinguisher and make sure it is not damaged.

Every six months Have an approved specialist empty and refill the fire extinguisher.

Every year Have an approved specialist examine the fire extinguisher.

Always connect the welding apparatus to the same structure that is being welded.

Never connect the welding apparatus ground to a component of the hydraulic system.

WARNING: Any unauthorized modifications made to this machine can cause serious injury or death. Do not undertake any modifications without first consulting your dealer.

PLASTIC AND RESIN PARTS When cleaning the plastic windows, the console, the instrument panel, the indicators, etc. do not use gasoline, kerosene, paint solvents, etc. Only use water, soap and a soft cloth.

The use of gasoline, kerosene, paint solvents, etc. will cause discoloration, cracks or deformation of these parts.

6-12

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS LOADER ADJUSTMENTS HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT PROCEDURE

1

2

3

4 5

6

Figure 18

87347924

1.

2.

3.

4.

5.

6.

LIFT ARM TARGET MOUNTING PLATE RETURN TO TRAVEL TARGET HEIGHT CONTROL TARGET FRONT CHASSIS (TOP LEFT HAND SIDE) PROXIMITY SWITCH

1. Keep all non-authorized personnel clear of the area. Park the machine on firm, level ground.

2. Start the engine, and apply the parking brake.

4. Position the return to travel target (3) opposite the proximity switch (6) and tighten it to the target mounting plate (2).

3. Lower the lift arms, and place the bucket flat on the ground. Stop the engine.

5. Adjust the proximity switch (6) out toward the return to travel target (3) until an air gap of 3.2 to 5.0 mm (1/8 to 3/16 inch) is obtained.

NOTE: To avoid damage to the proximity switch (6), it must be adjusted back away from the lift arm to clear everything on the lift arm as it sweeps past.

6. Lock the proximity switch (6) in this position with the jam nut. Torque the jam nut to 6 - 7.5 N•m (4.5 to 5.5 pound-feet).

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1 A

2

B

3

Figure 19

BS06N847

1. RETURN TO TRAVEL TARGET 2. TARGET MOUNTING PLATE 3. HEIGHT CONTROL TARGET

A in (mm)

Approximate resulting return to travel hinge pin height

B in (mm)

Approximate resulting height control hinge pin height in (mm)

2.24 in (57 mm)

14.09 in (358 mm)

2.12 in (54 mm)

13 0in (3302 mm)

Machine 921E Z-Bar

7. Refer to the table and the illustration. Position the height control target (3) on the target mounting plate (2) using the table above.

12. Place the pilot control switch in the ON position, and set the return to travel/float detent switch to the return to travel position.

NOTE: The higher the height control target (3) is positioned in its slot in the target mounting plate (2), the lower the lift arms will stop as they are raised.

NOTE: The top position on the switch is for return to travel, push the switch to the bottom position for float.

8. Tighten the height control target (3).

9. Position the return to travel target (1) using the table above.

NOTE: The higher the return to travel target (1) is positioned in its slot in the target mounting plate (2), the lower the lift arms will stop as they are lowered.

10. Check to make certain the proximity switch and all of the mounting bolts are tight.

13. Place the loader control lever in the raise position, and verify that the electromagnet holds it in that position until the height control target (1) passes in front of the proximity switch.

14. Repeat steps 8 through 14 until the desired heights are reached.

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

11. Start the engine.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS RETURN TO DIG ADJUSTMENT PROCEDURE

2 3

1

5 4 6

A

Figure 20

BSOON845

1.TARGET MOUNTING BRACKET

4. PROMIMITY SWTICH MOUNTING BRACKET

2. BUCKET CYLINDER

5. PROXIMITY SWITCH

3. TARGET BAR

6. PROXIMITY SWITCH GUARD A. 3.2 TO 5.0 MM (1/8 TO 3/16 INCH)

IMPORTANT: Before adjusting the return to dig, make certain that the target bar on the bucket linkage is not damaged. Slowly roll back and dump the bucket and make certain that the target bar stays the same distance from the switch. The switch mounting bracket protects the switch. Make certain the target bar cannot touch the switch when the bucket is dumped.

2. Loosen the bolts holding the target mounting bracket (3) to the tilt cylinder eye. Align the target mounting bracket (3) parallel to the tilt cylinder (2), and tighten the bolts.

1. Keep all non-authorized personnel clear of the area. Park the machine on firm, level ground.

Raise the lift arms until they are approximately horizontal. Fully dump the bucket. Lower the arms until bucket edge is on the ground. Apply the parking brake, and stop the engine.

4. Adjust the proximity switch (6) out toward the target bar (4), until an air gap of 3.2 to 5.0 mm (1/8 to 3/16 inch) (A) is obtained. Torque the jam nut to 6.0 to 7.5 N•m (4.5 to 5.5 pound-feet)

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3. Loosen the bolts holding the proximity switch mounting bracket (5) to the tilt cylinder (2).

Position the proximity switch (6) parallel to the target bar (4) and tighten the bolts.

NOTE: The proximity switch (6) must not protrude past the proximity switch guard (1).

6-15

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 5. Start the engine, position the bucket to the correct digging angle, and stop the engine.

6. Loosen the bolts holding the target bar (4) to the target mounting bracket (3). Slide the target bar (4) towards the proximity switch (6) until the face of the proximity switch (6) is completely covered.

7. Align the target bar (4) parallel to the tilt cylinder (2) and tighten the bolts.

8. Turn the ignition switch to the ON position. DO NOT start the engine.

9. Place the pilot control switch in the ON position, and place the return to travel/float detent switch to the TRAVEL position.

10. The top position on the switch is for return to travel, push the switch to the bottom position for float.

11. Place the bucket control lever in the ROLLBACK position.

12. Loosen the bolts holding the target bar (4) to the target mounting bracket (3).

13. Slide the target bar (4) slowly away from the proximity switch (6), until the control lever returns to the center position. Tighten the bolts holding the target bar (4).

14. Check to make certain that the 3.2 to 5.0 mm (1/8 to 3/16 inch) (A) gap is still maintained.

15. Start the engine.

16. Raise the lift arms approximately horizontal, and put the bucket in the fully dumped position.

17. Place the loader control lever in the ROLLBACK position, and verify that the electromagnet holds it in that position until the end of the target bar (4) passes in front of the proximity switch (6).

18. Lower the lift arms and verify that the bucket is at the correct digging angle.

6-16

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CALIBRATING THE GEAR BOX After running the machine to wa r m the oil temperature: 1. Keep all non-authorized personnel clear of the area. Park the machine on a firm, level surface.

2. Place the NEUTRAL.

transmission

control

lever

in

3. Set the parking brake.

4. With the engine running at idle, enter the service screen menu and scroll to Config screen. Press the confirm key.

BD06F196

Figure 23

If machine conditions are incorrect, an error message will appear. The calibration procedure will not complete. Follow the prompts to aid in correcting any machine conditions.

The screen may display the following prompts to guide the user to correct machine conditions:

Figure 21

BD06F202

Use down arrow button to scroll to Calib G/B. Highlight Calib. G/B, and press the confirm key.

Always follow the prompts on the screen. Should an error occur, use the escape key to start over again.

• • • • • • •

Not in neutral Parking Brake OFF Machine moving Oil temp too low Oil temp too high Engine RPM low Engine RPM high

If conditions are correct, the user will see six calibration screens displayed. They will appear in the following order: • Adjust K1 • Adjust K2 • Adjust K3 • Adjust K4 • Adjust KV • Adjust KR Once the calibration process is complete, the user will be prompted to turn the engine Off and restart the machine.

If the process is not completed, the screen will prompt the user to escape.

Figure 22

BD06F195

The screen will show a confirm prompt. If you doubt your ability to perform this operation, press the escape key and call your dealer.

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6-17

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 4. The adjustable declutch pressure switch is set to 150 psi (10.34 bar) plus or minus 8 psi (0.55 bar) from the factory. For every 1/4 turn of the outer body there is a 15 psi (1.03 bar) pressure change in the switch. The pressure change is the same in either the clockwise or counter clockwise direction.

TRANSMISSION DECLUTCH PRESSURE ADJUSTMENT

1

2

5. Tighten the set screw (1) located near the end of the adjustable transmission declutch pressure switch. Test the adjusted declutch function for desired effect in a clear open area away from obstacles. Readjust as desired.

6. The transmission declutch is activated by brake pressure. A higher brake pressure to activate the declutch function is desirable when operating on inclines. Higher brake pressure is the result of increasing brake pedal travel. A lower brake pressure to activate the declutch function is desirable when operating on firm, flat terrain.

Lower brake pressure is the result of limited brake pedal travel.

BD07A200

Figure 24

1. Keep all non-authorized personnel clear of the area. Park the machine on firm, level ground.

Lower the arms until bucket edge is on the ground. Apply the parking brake, and stop the engine.

2. Loosen the set screw (1) located near the end of the adjustable transmission declutch pressure switch.

3. Rotate the outer body (2) of the adjustable transmission declutch pressure switch in either the clockwise or counter clockwise direction.

Turning the outer body clockwise will increase the amount of brake pressure required to activate the declutch function. Turning the outer body counter clockwise will decrease the amount of brake pressure required to activate the d e c l u t c h f u n c t i o n . A d j u s t t h e a d j u s t a bl e transmission declutch pressure switch according to operator preference.

6-18

Issued 02-07

Bur

87538969 EU

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS PARKING BRAKE TEST

BD06F198

Figure 25

BD06F099

Parking brakes should be tested periodically. If you doubt your ability to perform this procedure correctly, call your dealer.

Figure 26

The screen will change to the test park brake screen and request confirmation. To confirm, press the confirm key again.

Keep all non-authorized personnel clear of the area when performing the parking brake test.

WARNING: Parking brake tests should only be performed by a skilled, qualified operator or technician. This test requires running the engine at high RPM’s. Failure to comply could result in machine damage, injury, or death.

Park the machine on a firm, level surface clear of any obstructions and any non-authorized personnel or vehicles. Run the machine at low idle in third gear neutral. Place the transmission auto switch to the manual position.

Place the parking brake switch to the ON position.

With the engine running at idle, enter the Service Screen Menu and scroll to the Config. menu.

Use the arrow key to scroll to the sub menu Park Brake. Highlight Park Brake on the menu and press the confirm key.

BD06F199

Figure 27

Follow the prompts on the screen to complete the park brake test. If all conditions are not met to test the brake, the monitor will display the condition that must be corrected prior to completion of the test. The parking brake must be engaged.

1. When all conditions are met, the monitor will display: Test Park Brake Ready 2. Shift the gear selector into third gear forward, and slowly increase the engine speed to full open throttle.

3. Verify that the machine does not move.

4. Reduce ending speed to low idle, and return the transmission to neutral.

5. Shift the gear selector to third gear reverse and slowly increase the engine speed to wide open throttle.

6. Verify that the machine does not move.

7. Reduce the engine speed to low idle and return the transmission to neutral.

8. Press the escape key on the key pad to exit the test mode.

Issued 02-07

Bur

87538969 EU

6-19

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS PARKING BRAKE CHECK NOTE: Test the parking brake at a maximum of every 250 hours.

Before you operate the machine, periodically test the parking brake functions.

E. Pump the service brakes, the low brake pressure warning light should come ON. Continue to pump the service brakes. Pump until the parking brake light comes ON, pump the brakes three more times. This could require as many as forty brake pumps.

F. Start the engine and allow the brake pressure to build until the warning light goes off.

G. Depress the service brake and release. The light must stay ON. H. Put the transmission in F or R and back to N the brake light must stay ON. I. Put the parking brake switch in the engaged position, attempt B and C in Step 1. The parking brake light must stay ON. 4. Put the parking brake switch in the release position, attempt B and C in Step 1. The parking brake light must turn OFF,

BD06H173

Figure 28

A. Push the Parking Brake switch to the release position.

A. Allow the machine to roll slowly forward with the transmission in F. Engage the parking brake. The machine must come to a stop immediately. Parking light ON. Transmission disengages.

B. Service brake depressed indicating brake lights.

If there is any problem with the parking brake test, contact your dealer.

1. To release the parking brake, all the following are required:

C. Transmission shifter positioned from N to F or R for a second, and back to N. D. Adequate service brake pressure to stop the machine.

2. The parking brake will engage under the following conditions. Always wear your seat belt in the event that the par king brake would unexpectedly engage.

A. Loss of service brake pressure in both axles.

B. Loss of system electrical power (key OFF).

C. Parking Brake switch in engaged position.

3. To test these functions: A. Start on a clear level surface.

B. With Step 1, A through C complete, start the engine, and release the parking brake. The red warning light should be out.

C. Turn the engine off. Turn the key switch to the ON position. With the engine off, the parking brake light should come ON. D. Release the parking brake using B and C in Step 1. Make sure the parking brake light is out.

6-20

Issued 02-07

Bur

87538969 EU

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS SECONDARY STEERING CHECK Check the secondary steering when the hour meter reads 250 hours or any time electronic warnings may so indicate.

IMPORTANT: Do not run the secondary steering pump/motor continuously for more than 20 seconds at a time without a 2 minute cool down.

7. Restart the engine. Confirm the secondary steering light stays on. The secondary steering motor should stop after approximately 3 seconds and the secondary steering light should go out.

8. If steps 2 through 7 function properly, the secondary steering is operating correctly. If not, repair and retest. If you have any problems with this procedure, call your dealer.

Figure 29

BD06H174

WARNING: Do not turn the key switch off if the machine is steered against either the right hand or left hand steering stop. The steering wheel may kick back. Failure to comply could cause machine damage, injury or death.

WARNING: The secondary steering system is electrically powered. This system allows you to steer the machine if the primary steering system stops working. Maintain the batteries to assure the system will function.

Failure to comply could cause machine damage, injury or death.

1. Keep all non-authorized personnel clear of the area. Park the machine on hard packed level ground with enough clearance around the machine to allow complete steering from side to side. Raise the bucket approximately 20 inches (500 mm) above the ground.

2. With the key switch on and the engine off, confirm the secondary steering light within the cluster is on. This indicates the steering pressure is low.

3. Start the machine and let the engine run for a few seconds. Confirm the secondary steering light is out after the first few seconds. This confirms the electrical function of the circuit is operating correctly and adequate pressure has built. The secondary steering module is now functional.

4. With the machine at low idle and steering straight ahead, turn the key switch to the OFF position to stop the engine. Immediately turn the key back to t h e O N p o s i ti o n ( n o t s ta r t p o s i ti o n ) . T h e secondary steering pump/motor should start running. Confirm the light is on and the motor is running.

5. Steer the machine full left and then full right to confirm that the secondary steering pump is working. Confirm there is no lack of steering function.

6. Look at the instrument cluster to verify that the secondary steering light comes on.

Issued 02-07

Bur

87538969 EU

6-21

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

CAB SERVICE AIR CONDITIONING (IF EQUIPPED) The components of the operator’s 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 familiar with air conditioning systems and the safety precautions which must be followed. Serious injury can result if you do not follow these instructions. Failure to comply could cause injury or death.

SA048

LUBRICATION OF THE AIR CONDITIONING COMPRESSOR SEALS WARNING: Use a safety type air tool and wear full coverage safety glasses with side panels when using compressed air. Failure to comply could cause injury or death.

Operate the air conditioning once every 250 hours to lub r icat e th e co m pr ess or s ea ls. Tu r n th e a ir conditioning control to MAXIMUM for at least 15 minutes. In temperatures below 0°C (32°F) put a cover over the air conditioning condenser. This will make sure the refrigerant and lubricants in the system will be at operating temperature.

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

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

DOOR HINGES Use graphite to lubricate all hinges. DO NOT use oil.

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

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. Failure to comply could cause injury or death.

SA049

Cleaning 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 dull knife.

Figure 30

BD07A048

CONDENSER

Keep the air conditioning condenser core clean. Use safety type compressed air tool or a rigid brush to clean the condenser. Also check and clean the grille screen.

Use a minimum amount of cleaner and a clean cloth.

Move the cloth from the outside of the stain towards the center. When the stain is removed, use a clean cloth to dry the area to prevent a cleaning fluid pattern.

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

6-22

Issued 02-07

Bur

87538969 EU

CHAPTER 7 - ELECTRICAL

Chapter 7 ELECTRICAL TABLE OF CONTENTS ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3 7-3 7-4 7-4 7-4 7-4

BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Access To The Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Booster Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Battery Fluid Level And Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-5 7-5 7-5 7-6 7-6

FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Replacement Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 MACHINE LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Driving Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Tail Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Rotating Beacon Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Auxiliary Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Issued 02-07

Bur

87538969 EU

7-1

CHAPTER 7 - ELECTRICAL

NOTES

7-2

Issued 02-07

Bur

87538969 EU

CHAPTER 7 - ELECTRICAL

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.

Failure to comply can cause injury or death.

SA046

WARNING: Batteries give off explosive gases. Keep all open flames, sparks and cigarettes away. Insure adequate ventilation when charging batteries or when using in a confined place. Always protect your face when working near batteries. Failure to comply can cause injury or death.

SAFETY_ID_1C02

WARNING: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing.

Failure to comply can cause injury or death.

Antidote - EXTERNAL: flush with water.

INTERNAL: drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately.

EYES: flush with water for 15 minutes and get prompt medical attention.

SB032

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

SA033

WARNING: Connecting jump start (booster battery) cables incorrectly or short- circuiting battery terminals can cause an accident.

Connect auxiliary starting cables as per the following instructions. Failure to comply can cause injury or death.

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.

Failure to comply can cause injury or death.

SB034

WARNING: Do not reverse battery terminals. Connect positive cable ends to positive (+) terminals and negative cable ends to negative terminals (-). Failure to comply can cause machine damage, injury or death.

SAFETY_ID_1C02

WARNING: Before any operation on the components of the electrical circuit, put the key switch in the off position. When disconnecting the battery cables, always disconnect the negative (-) cable first. When reconnecting the battery cables, always connect the negative (-) cable last. Failure to comply can cause machine damage, injury or death.

SAFETY_ID_1C02

WARNING: Whenever carrying out a welding operation on the machine (authorized by the manufacturer and in accordance with manufacturer’s instructions) or any repairs on the electrical system, disconnect the B+ and D+ wires from the alternator. When reconnecting, check the markings on the wires. Failure to comply with the following warnings could result in machine damage, serious injury, or death.

SAFETY_ID_1C02

Issued 02-07

Bur

87538969 EU

7-3

CHAPTER 7 - ELECTRICAL BATTERY SERVICE

BATTERY FLUID LEVEL

Before you service components of the electrical system, always disconnect the NEGATIVE (-) battery cable.

Check the fluid level of the batteries every 500 hours of operation. If the fluid level is low, add distilled water to each cell until the fluid level is at the split ring at the bottom of each cell opening.

Dirt, moisture, and corrosion on the battery will discharge the battery. Clean the battery with Case Battery Saver and Cleaner. Follow the instructions on the container.

Disconnect the alternator wires if you must run the engine with the battery wires disconnected.

Before you use an electric welder, disconnect the alternator wires, instrument cluster, and turn the master disconnect switch to OFF. Do not use a steam cleaner or cleaning solvent to clean the alternator.

In extreme heat conditions check battery fluid every 250 hours.

IMPORTANT: If the temperature is 0°C (32°F) or below and you have added water to the batteries, perform the following: Connect a battery charger to the batteries or operate the machine for approximately two hours. This procedure is necessary to mix the water with the electrolyte.

BATTERY VENTS Keep the battery vents clean, make sure the vents are not restricted.

CLEANING THE BATTERIES Check the batteries and batter y compar tment regularly for dirt, corrosion and damage. Dirt mixed with electrolyte or moisture on the top of the batteries can cause a discharged condition in the batteries.

Use one of the following methods to clean the batteries.

• Use Case Battery Saver. Follow the instructions on the container. This cleaner does not need water.

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.

7-4

Issued 02-07

Bur

87538969 EU

CHAPTER 7 - ELECTRICAL

BATTERIES ACCESS TO THE BATTERIES

CONNECTING BOOSTER BATTERIES

1

Figure 1

BD07A179

Service Specifications Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . Two 12 volt NOTE: If the machine needs to be started using a booster battery, see Connecting Booster Battery.

Batteries are enclosed in compartments on both the left and right hand rear of the machine. To access the batteries, loosen and remove the three bolts (1) that hold the cover in place. (One battery on each side of machine). Remove cover by sliding forward.

NOTE: When removing the right hand side battery cover, the disconnect switch door cover must be removed as well.

WARNING: Before carrying out any service work on electrical system components, turn the starter switch key to the “OFF” position. When disconnecting batteries, always disconnect the negative (-) cable first. When reconnecting batteries, always connect the negative (-) cable last. Failure to comply can cause machine damage, injury or death.

WARNING: Hydrogen gas may be present above the discharged battery. Do not make the negative connection directly to the discharged battery, as this may ignite the hydrogen gas. Failure to comply can cause machine damage, injury or death.

Issued 02-07

Bur

87538969 EU

Figure 2

BD07A254

Make sure that the voltage of the booster batteries is the same as that of the machine system (24 volts).

1. Turn off the ignition and all accessories on the machine(s). Remove the door cover from the hood switch on the r ight hand side of the machine. Remove the right battery terminal cover.

2. Connect one end of the positive (+) cable to the positive (+) terminal on the booster battery.

Connect the other end of the positive (+) cable to the positive (+) ter minal of the discharged battery.

3. Connect the negative (-) cable to the negative (-) terminal on the booster battery.

4. Connect the other end of the negative cable to the engine block or frame of the machine with the discharged battery. Do not connect it to sheet metal or any rotating part, as damage can result.

Do not connect to the negative terminal on the battery.

5. Start the engine.

6. Remove the booster battery negative (-) cable from the machine, then from the booster battery.

Remove the positive (+) cable from the machine and then from the booster battery.

7. Install the terminal covers.

IMPORTANT: Booster batteries should be connected on the right side only.

WARNING: Do not invert battery terminals.

Connect positive cable ends to positive (+) terminals and negative cable ends to negative terminals (−). Failure to comply with the following warnings could result in serious injury or machine damage.

7-5

CHAPTER 7 - ELECTRICAL CHECK BATTERY FLUID LEVEL AND SPECIFIC GRAVITY

REPLACING A BATTERY

The battery fluid can decrease with high temperatures.

Check the battery fluid level in the morning before starting operation.

Remove the cell caps and check the level in each batteries cell. The level should be between 10 and 15 mm (.3 to .5 in) above the plates. Add distilled water if necessary, then install the cell caps.

Continuous use of the battery with low fluid will lower battery performance.

Check the battery fluid level periodically, and if insufficient, refill the battery with distilled water before the engine start-up (before charging battery).

Figure 4

BD07A192

Remove the terminal protection caps, disconnect cables (negative terminals) and then cables (positive terminals). Remove the anti-sulfate pellets.

Remove the two screws, the washers, and retainer.

Remove the old battery.

Install new battery of the correct voltage and replace retainer, washers and screws.

Clean the cables and battery terminals, and coat with grease. Install new anti-sulfate pellets. Reconnect positive cable ends to positive ter minals first.

R e c o n n e c t n e g a t i ve c a bl e e n d s t o n e g a t i ve terminals, and install the terminal protection caps.

Figure 3

BD06H177A

BATTERY CAP

If the terminals (2) are dirty, wash with warm water, Reinstall the terminals, applying grease or spraying rust preventive solution to create good connections.

If the terminal is oxidized, polish it with a wire brush or emery paper.

NOTE: Measure the specific gravity of battery fluid with a gravimeter. The measured value will vary depending on the ambient temperature.

WARNING: Do not invert battery terminals.

Connect positive cable ends to positive (+) terminals and negative cable ends to negative terminals (−). Failure to comply with the following warnings could result in serious injury or machine damage.

NOTE: When removing the right hand side battery cover, the disconnect switch door cover must be removed as well.

ALTERNATOR Service Specification Check . . . . . . . . . . . . . . . . . . . . . . Every 1000 hours Ask your Dealer to check the alternator.

Make sure that the terminal protectors are correctly installed.

Do not use steam cleaning equipment or a cleaning solvent to clean the alternator.

STARTER MOTOR Service Specification

WARNING: An error when connecting booster battery cables or short-circuiting battery terminals can cause an accident. Be certain connections are correct. Failure to comply with the following warnings could result in serious injury or machine damage.

7-6

Check . . . . . . . . . . . . . . . . . . . . . . Every 1000 hours Ask your Dealer to check the starter motor.

Make sure that the terminal protectors are correctly installed.

Issued 02-07

Bur

87538969 EU

CHAPTER 7 - ELECTRICAL

FUSES AND RELAYS

ECC

ECD

ECA

ECB

Figure 7

BD06G174

POWER MODULE CENTERS

Figure 5

BD06G175

B

E

D

A

Fuses and relays can be found inside the access door on the right hand side of the machine.

If power does not come when the key switch is turned to the ON position, check the appropriate fuse.

If a fuse has failed, an indicator light will be illuminated at the location on the panel.

IMPORTANT: Before changing fuses or relays, turn the ignition key switch to the OFF (Shut Down) position.

IMPORTANT: Never replace a fuse with a fuse of a different amperage.

To replace, pull the old fuse straight out and push the new fuse straight in. The amperage for each fuse is stamped on the fuse. Refer to the fuse panel decal for correct location of each fuse.

Figure 8

87397077

FUSE

AMP

FUNCTION

Power Relay Module B F1

40

Time Delay Power

F2

Spare Relay Time Delay

Power Relay Module E F1

Power Converter

F2

Spare Relay Power Converter

1

Power Relay Module D F1

40

Accessory Power

F2

Spare Relay Accessory Power

PRMC

Power Relay Module A F1

40

Ignition Power

F2 PRMC - F1 ETHER 20 AMP - F2 BATTERY 20 AMP 1. CAB CIRCUIT BREAKER 105 AMP

Additional fuses and relays are located in the engine compartment area.

IMPORTANT: Never replace a fuse with a fuse of a different amperage.

Issued 02-07

Secondary Steering

Figure 6

BD07188

Bur

87538969 EU

Relay Ignition Power Power Relay Module C F1

20

Ether

F2

20

Voltmeter Relay Engine Compartment

7-7

CHAPTER 7 - ELECTRICAL

Figure 9

BD06F49

The fuse decal is located inside the access door.

7-8

Issued 02-07

Bur

87538969 EU

CHAPTER 7 - ELECTRICAL REPLACEMENT FUSES

ECD FUSE PANEL

ECC FUSE PANEL

FUSE AMP

FUSE

AMP

FUNCTION

FUNCTION

F1

7.5

TRANSMISSION CONTROL

F1

7.5

DOME LAMP - BEACON

F2

30

ENGINE STARTER

F2

15

WORK LIGHTS

F3

10

INSTRUMENT CLUSTER

10

12 VOLT AUX. PLUG

F3

15

ROAD LIGHTS

F4

F4

10

BRAKE LIGHTS - FLASHER

F5

10

12 VOLT AUX. PLUG

F5

10

ENGINE START

F6

10

RADIO

F6

7.5

HORN

F7

15

12 VOLT AUX. PLUG

F7

7.5

HOOD RAISE - LOWER

F8

F8

15

CIGARETTE LIGHTER

F9

BACKUP ALARM RELAY

F9

10

DIAGNOSTIC POWER

F10

BACKUP ALARM RELAY

F10 ECA FUSE PANEL

FUSE AMP F1

7.5

F2

5

F3

FUNCTION TRANSMISSION CONTROL

ECB FUSE PANEL

FUSE

AMP

FUNCTION

STEERING

F1

10

FRONT FLOOD LIGHTS

7.5

INSTRUMENT CLUSTER

F2

10

REAR FLOOD LIGHTS

F4

7.5

SECONDARY STEERING

F3

5

HIGH BEAM LEFT

F5

5

RIDE CONTROL

F4

5

HIGH BEAM RIGHT

F6

5

PARKING BRAKE

F5

5

LOW BEAM LEFT

F7

7.5

COUPLER/FAN REVERSER

F6

5

LOW BEAM RIGHT

F8

5

TURN SIGNAL/FLASHER

F7

5

LEFT TAIL LIGHTS

F9

10

ENGINE STOP

F8

5

RIGHT TAIL LIGHTS

F11

25

BLOWER SWITCH

F12

10

FRONT WIPER

F13

10

REAR WIPER

F14

5

BACK-UP ALARM

F15

7.5

F10

AIR CONDITIONING

F16

10

COMPRESSOR (SEAT)

F17

7.5

SECONDARY STEERING

F18 F19 F20

Issued 02-07

Bur

87538969 EU

7-9

CHAPTER 7 - ELECTRICAL

MACHINE LIGHTS WORK LIGHTS

1

2 3

Figure 11

BD06H180

To replace work lights, remove the two phillips screws from the rear of the light.

BD06H178

Figure 10

1. WORK LIGHTS 2. DRIVING LIGHTS 3. TAIL LIGHTS

Figure 12

BD06H180

Disconnect push on connectors, and replace the lamp assembly. Push the connectors on, making certain connections are firmly in place. Replace the two rear screws.

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CHAPTER 7 - ELECTRICAL DRIVING LIGHTS

ROTATING BEACON CONNECTION

1

Figure 13

BD06H181

Remove the screws fastening the light to the bracket.

Pull the light assembly away from the bracket. Do not lose rubber sealing gasket (1).

BD06H186

Figure 16

The rotating beacon is an optional feature. The plug-in connection for the beacon is located at the top right front of the cab.

2

Figure 14

BD06H182

Lift up on the wire clip (2) holding the bulb in place by pinching sides of clip together.

3

Figure 15

BD06H183

Disconnect the bulb at the wire connector (3) within the protective sleeve. Replace the bulb with a bulb of the same type and wattage. Reconnect and cover connection with the protective sleeve. Replace light assembly back in light bracket holder, and replace screws. Make certain rubber gasket is fitted correctly.

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7-11

CHAPTER 7 - ELECTRICAL AUXILIARY POWER OUTLET The Auxiliary Power Outlet socket (12 volt) can be used for the connection of a lighting device to help with service and maintenance procedures. There are two auxiliary power outlets, one in the right corner of the operator’s compartment, and one in the left corner of the operator’s compartment.

Figure 17

BD06F060A

AUXILIARY POWER EQUIPMENT MOUNTING BRACKET The auxiliary power equipment mounting brackets are located behind the right and left ROPS post covers. These brackets are for mounting radios, phones, etc.

To locate the bottom of the mounting bracket measure 11.8 inches (300 mm) from the bottom edge of the plastic panel. To locate the top of the mounting bracket measure 16.5 inches (420 mm) from the bottom edge of the plastic panel. The mounting bracket is approximately 2.75 inches (70 mm) wide.

Figure 18

BD00B009

RIGHT ROPS POST COVER

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CHAPTER 8 - SPECIFICATIONS

Chapter 8 SPECIFICATIONS TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 921E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 921E Z-Bar DIMENSIONS with 5.75 yd³ (4.4 M³) Bucket with Bolt-on Edge . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 921E Z-Bar DIMENSIONS with 5.75 yd³ (4.4 M³) Bucket with Teeth and Segments . . . . . . . . . . . . . . . . . . . 8-8 921E Z-Bar DIMENSIONS with 5.25 yd³ (4.00 M³) Bucket with Bolt-on Edge . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 921E Z-Bar DIMENSIONS with 5.25 yd³ (4.00 M³) Bucket with Teeth and Segments . . . . . . . . . . . . . . . . . 8-10 OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 TORQUE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

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8-1

CHAPTER 8 - SPECIFICATIONS

NOTES

8-2

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CHAPTER 8 - SPECIFICATIONS

SPECIFICATIONS Engine Model ...............................................................................................................Cummins QSM 11, Tier 3 Certified Type..........................................................................................................4-stroke, turbocharged, air-to-air cooled Cylinders ...............................................................................................................................................................6 Bore/stroke ................................................................................................... 125 mm x 147 mm (4.92 in x 5.79 in) Displacement .............................................................................................................................10. 8 L (661 cu in) Fuel Injection ........................................................................................................................................... Electronic Engine Speeds Rated speed, full load ..............................................................................................................................2100 rpm Horsepower - Rated Max Power Range Gross....................................................................................................................... 239 kW (320 hp) @ 1800 rpm Net........................................................................................................................... 224 kW (301 hp) @ 1800 rpm Torque - Peak Max Power Range Gross................................................................................................................. 1478 Nm (1090 lb ft) @ 1000 rpm Net..................................................................................................................... 1446 Nm (1066 lb ft) @ 1000 rpm Torque rise (max power only) ........................................................................................................................50.3% Electrical Batteries ................................................................................................................................................................2 Alternator.....................................................................................................................................................95 amp Voltage ............................................................................................................................ 24 volts, negative ground Ether injected cold weather assist starting system

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8-3

CHAPTER 8 - SPECIFICATIONS Drivetrain Transmission...........................................................................................................Hydrodynamic power shift 4F/3R, electronically controlled clutch modulation with automatic and manual shift modes Gears .................................................................................................................................................... Helical Cut Gear Ratios

Forward

Reverse

1st

3.712

3.712

2nd

2.206

2.062

3rd

1.064

1.064

4th

0.685

-----

Torque converter stall ratio .............................................................................................................................. 3.0:1 Differential .............................................................. limited slip with 30% transfer in front and 45% transfer in rear Rear axle oscillation ...................................................................................................................................24° total Axles ...............................................................................................................................................trunnion mount Axles Differential ratio Planetary ratio Final axle ratio Planetaries

Front and Rear 3.89 6.00 23.33 Outboard

Brakes Service brakes .............................................................. Hydraulically actuated, self adjusting (maintenance-free) multiple wet disc at all four wheels with accumulator for each axle Brake surface area ..................................................................................................... 900 in2 (0.58 m2) per front hub 682 in2 (0.44 m2) per rear hub Parking brakes ................................... spring-applied, hydraulic release disc caliper on transmission output shaft

Travel Speeds Travel Speeds

Forward, mph (km/h)

Reverse, mph (km/h)

1st

5.0 (8.0)

5.0 (8.0)

2nd

8.2 (13.2)

8.7 (14.1)

3rd

16.0 (25.8)

16.0 (25.8)

4th

23.2 (37.3)

-----

NOTE: Travel speeds @ full engine throttle

8-4

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CHAPTER 8 - SPECIFICATIONS Hydraulics Pump ...............................................................................................Closed centered pressure/flow compensated Variable displacement .............170 L/min @2100 rpm @ 248 bar (5.19 in³/rev44.8 gpm @2100 rpm @3600 psi) Pump ................................................................................................ closed centered pressure/flow compensated Variable displacement .............170 L/min @2100 rpm @ 248 bar (5.19 in³/rev44.8 gpm @2100 rpm @3600 psi) Loader control valve ..................................................... closed-center, sectional 2, 3, or 4-spool w/pilot control for lift, tilt and auxiliary hydraulics, electromagnetic detents in float, raise and rollback Loader auxiliary steering .......................................hydraulic orbital center-pivot articulating w/on-demand oil flow High pressure standby .............................................................................................................. 250 Bar (3625 psi) Filtration....................... 10-micron, full flow replaceable cartridges on return line, condition indicator light for filter Cylinders Lift cylinder Bore diameter .........................................................................................................................165.1 mm (6.5 in) Rod diameter ............................................................................................................................. 101.6 mm (4.0) Stroke....................................................................................................................................867.6 mm (34.2 in) Dump cylinder Bore diameter .........................................................................................................................177.8 mm (7.0 in) Rod diameter ..........................................................................................................................101.6 mm (4.0 in) Stroke....................................................................................................................................745.3 mm (29.3 in) Instrumentation Speedometer, Tachometer, Travel selected (F/N/R), Transmission modes, Gear position, Engine coolant temperature, Fuel level, Transmission oil temperature, Hydraulic oil temperature, Hourmeter, Work mode Operator Environment ROPS cab w/heat Key Start Articulated power steering w/tilt column Adjustable, suspension seat Single lever 2-spool loader control Cup holder Coat hook Rear view mirror (interior) 2 inch (52 mm) retractable seat belt Storage tray Cooled storage box Single brake pedal External rear view mirrors Lock box Dome light Sun screen Wipers - front and rear (intermittent front) Windshield washers - front and rear Right and left steps and platforms Fire extinguisher bracket Weight Operating Weight ...................................................................................................................22918 kg (50,525 lb) Unit equipped with ROPS cab, heater, air conditioner, counterweight, 26.5 -R25 XHA tires, wide front and rear fenders, 4.0 m3 (5.25 yd3) general purpose loader bucket, full fuel, 79 kg (175 lb) operator

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8-5

CHAPTER 8 - SPECIFICATIONS Lift Capacity 921E Z-Bar 4.4 m3 (5.75 yd3) Bucket w/Bolt on Edge

4.4 m3 (5.75 yd3) Bucket w/Teeth and segments

Full Height

13489 kg (29738 lb)

13398 kg (29537 lb)

Ground

22501 kg (49607 lb)

22370 kg (49316 lb)

Lift Capacity 921E Z-Bar

Full Height

8-6

4.00 m3 (5.25 yd3) Bucket w/Bolt on Edge

4.00 m3 (5.25 yd3) Bucket w/Teeth

13551 kg (29875 lb)

13450 kg (29652 lb)

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87538969 EU

CHAPTER 8 - SPECIFICATIONS 921E Z-BAR DIMENSIONS WITH 4.4 M³ (5.75 YD³) BUCKET WITH BOLT-ON EDGE

Figure 1

BS06C560

ISO bucket capacity Struck ......................................................................................................................................... 3.73 m³ (4.88 yd³) Heaped....................................................................................................................................... 4.42 m³ (5.78 yd³) A. Height to top of cab .................................................................................................................3.70 m (145.5 in) B. Wheelbase...............................................................................................................................3.40 m (134.0 in) C. Ground clearance ....................................................................................................................510 mm (20.1 in) D. Angle of departure ............................................................................................................................34 degrees Width Overall w/o bucket ...................................................................................................................2.99 m (117.7 in) Centerline tread .........................................................................................................................2.25 m (88.6 in) Turning radius - outside of bucket ................................................................................................6.86 m (270.3 in) Turning angle From center.......................................................................................................................................40 degrees Total angle.........................................................................................................................................80 degrees E. Operating height - fully raised w/spillguard ..............................................................................5.85 m (230.4 in) F. Hinge pin height - fully raised ...................................................................................................4.28 m (168.4 in) G. Overall length - bucket level on ground ...................................................................................8.80 m (346.3 in) H. Dump height - fully raised, 45 degree dump............................................................................3.08 m (121.2 in) J. Bucket reach - fully raised, 45 degree dump ..............................................................................1.27 m (50.1 in) K. Bucket reach - 7 ft 0 in (2.13 m) height, 45 degree dump .........................................................1.90 m (74.6 in) L. Dig depth....................................................................................................................................121 mm (4.8 in) Tipping load - ISO Machine straight..................................................................................................................19319 kg (42592 lb) 40 degree turn ....................................................................................................................16607 kg (36612 lb) Operating load - ISO......................................................................................................................8303 kg (18306 lb)

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8-7

CHAPTER 8 - SPECIFICATIONS 921E Z-BAR DIMENSIONS WITH 4.4 M³ (5.75 YD³) BUCKET WITH TEETH AND SEGMENTS

Figure 2

BS06C560

ISO bucket capacity Struck ......................................................................................................................................... 3.73 m³ (4.88 yd³) Heaped....................................................................................................................................... 4.42 m³ (5.78 yd³) A. Height to top of cab .................................................................................................................3.70 m (145.5 in) B. Wheelbase...............................................................................................................................3.40 m (134.0 in) C. Ground clearance ....................................................................................................................510 mm (20.1 in) D. Angle of departure ............................................................................................................................ 34 degrees Width Overall w/o bucket ...................................................................................................................2.99 m (117.7 in) Centerline tread .........................................................................................................................2.25 m (88.6 in) Turning radius - outside of bucket ................................................................................................6.95 m (273.7 in) Turning angle From center....................................................................................................................................... 40 degrees Total angle......................................................................................................................................... 80 degrees E. Operating height - fully raised w/spillguard ..............................................................................5.85 m (230.2 in) F. Hinge pin height - fully raised ...................................................................................................4.28 m (168.4 in) G. Overall length - bucket level on ground ...................................................................................9.02 m (355.3 in) H. Dump height - fully raised, 45 degree dump............................................................................2.93 m (115.3 in) J. Bucket reach - fully raised, 45 degree dump ..............................................................................1.43 m (56.2 in) K. Bucket reach - 7 ft 0 in (2.13 m) height, 45 degree dump .........................................................1.98 m (78.1 in) L. Dig depth....................................................................................................................................135 mm (5.3 in) Tipping load - ISO Machine straight.................................................................................................................. 19175 kg (42274 lb) 40 degree turn .................................................................................................................... 16463 kg (36294 lb) Operating load - ISO...................................................................................................................... 8231 kg (18147 lb)

8-8

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CHAPTER 8 - SPECIFICATIONS 921E Z-BAR DIMENSIONS WITH 4.00 M³ (5.25 YD³) BUCKET WITH BOLT-ON EDGE

Figure 3

BS06C560

ISO bucket capacity Struck ......................................................................................................................................... 3.41 m³ (4.46 yd³) Heaped....................................................................................................................................... 4.04 m³ (5.28 yd³) A. Height to top of cab .................................................................................................................3.70 m (145.5 in) B. Wheelbase...............................................................................................................................3.40 m (134.0 in) C. Ground clearance ....................................................................................................................510 mm (20.1 in) D. Angle of departure ............................................................................................................................34 degrees Width Overall w/o bucket ...................................................................................................................2.99 m (117.7 in) Centerline tread .........................................................................................................................2.25 m (88.6 in) Turning radius - outside of bucket ................................................................................................6.78 m (267.1 in) Turning angle From center.......................................................................................................................................40 degrees Total angle.........................................................................................................................................80 degrees E. Operating height - fully raised w/spillguard ..............................................................................5.83 m (229.6 in) F. Hinge pin height - fully raised ...................................................................................................4.28 m (168.4 in) G. Overall length - bucket level on ground ...................................................................................8.76 m (344.7 in) H. Dump height - fully raised, 45 degree dump............................................................................3.11 m (122.4 in) J. Bucket reach - fully raised, 45 degree dump ..............................................................................1.26 m (49.8 in) K. Bucket reach - 7 ft 0 in (2.13 m) height, 45 degree dump .........................................................1.90 m (74.8 in) L. Dig depth....................................................................................................................................102 mm (4.0 in) Tipping load - ISO Machine straight..................................................................................................................19579 kg (43165 lb) 40 degree turn ....................................................................................................................16847 kg (37142 lb) Operating load - ISO......................................................................................................................8424 kg (18571 lb)

Issued 02-07

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87538969 EU

8-9

CHAPTER 8 - SPECIFICATIONS 921E Z-BAR DIMENSIONS WITH 4.00 M³ (5.25 YD³) BUCKET WITH TEETH AND SEGMENTS

Figure 4

BS06C560

ISO bucket capacity Struck ......................................................................................................................................... 3.41 m³ (4.46 yd³) Heaped....................................................................................................................................... 4.04 m³ (5.28 yd³) A. Height to top of cab .................................................................................................................3.70 m (145.5 in) B. Wheelbase...............................................................................................................................3.40 m (134.0 in) C. Ground clearance ....................................................................................................................510 mm (20.1 in) D. Angle of departure ............................................................................................................................ 34 degrees Width Overall w/o bucket ...................................................................................................................2.99 m (117.7 in) Centerline tread .........................................................................................................................2.25 m (88.6 in) Turning radius - outside of bucket ................................................................................................6.87 m (270.5 in) Turning angle From center....................................................................................................................................... 40 degrees Total angle......................................................................................................................................... 80 degrees E. Operating height - fully raised w/spillguard ..............................................................................5.83 m (229.6 in) F. Hinge pin height - fully raised ...................................................................................................4.28 m (168.4 in) G. Overall length - bucket level on ground ...................................................................................8.98 m (353.7 in) H. Dump height - fully raised, 45 degree dump............................................................................2.96 m (116.5 in) J. Bucket reach - fully raised, 45 degree dump ..............................................................................1.42 m (55.9 in) K. Bucket reach - 7 ft 0 in (2.13 m) height, 45 degree dump .........................................................1.99 m (78.4 in) L. Dig depth....................................................................................................................................116 mm (4.6 in) Tipping load - ISO Machine straight.................................................................................................................. 19420 kg (42814 lb) 40 degree turn .................................................................................................................... 16688 kg (36791 lb) Operating load - ISO.....................................................................................................................(8344 kg (18396 lb)

8-10

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CHAPTER 8 - SPECIFICATIONS

Weight Adjustments Add (+) or deduct (-) lb. (kg) as indicated Select Option

Weight Adjustment

Tipping Load Adjustment Straight

Tipping Load Adjustment 40° Turn

26.5-25 L2 tires

-413 kg (-912 lb)

-338k (-746 lb)

-299 kg (-658 lb)

26.5-25 L4 tires

+320 kg (+704 lb)

+262 kg (+577 lb)

+230 kg (+508 lb)

26.5-25 L5 tires

+514 kg (+1132 lb)

+420 kg (+927 lb)

+370 kg (+817 lb)

NOTE: Machine equipped with Z-Bar loader arms, 5.25 yd³ (4.0 m³) general purpose pin on bucket with edge, 26.5-25 XHAT tires, ROPS cab with heater, standard counterweight, standard batteries, front and rear fenders, full fuel and 79 kg (175 lb) operator.

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8-11

CHAPTER 8 - SPECIFICATIONS OPTIONAL EQUIPMENT Cab group:

Hydraulics:

Cloth-covered air suspension seat

Auxiliary hydraulics

Air conditioning w/Heater

Ride Control

Cab heater

Secondary Steering

Radio

3 or 4-spool loader valves with 2 or 3 lever loader control

Radio-ready (12 volt) 12 volt auxiliary power Cab convenience package Rotating beacon Second brake pedal

Hydraulic reversing fan (Variable/Auto speed) Hydraulic cooler Axle coolers Auxiliary steering

Tool box Fire extinguisher

Loader Hydraulic attachment coupler

Engine Cold weather package Engine block heater Hydraulic cooler bypass Low temperature hydraulic oil Ether start

Attachment auxiliary hydraulics Buckets Other Lift and tie down brackets Spark arrest muffler Transmission belly guard Sound shield noise suppression package

8-12

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CHAPTER 8 - SPECIFICATIONS

MATERIAL WEIGHTS MATERIAL

kg/m3

lbs/ft3

MATERIAL

kg/m3

lbs/ft3

Alum-Lump.

881

55

Oats

416

26

Pulverized

769

48

Peanuts - Shelled

280

17

Ashes

561-833

35-52

Peas

769

48

Bauxite

1202-1922

75-120

Peat - solid

753

47

Beans

769

48

Phosphate - Granular

1442

90

Charcoal

368

23

Potash

1089

68

Chips

288

18

Potatoes

769

48

Coal

1282

80

Quartz - Granular

1762

110

Coke - Lump - Loose

849-1009

53-63

Rice

769

48

Clay

368-513

23-32

Rye

705

44

Concrete

1378-1778

86-111

Salt - Rock - Solid

2163

135

Copper Ore

1666

104

Sand & Gravel - Dry

1730

108

Corn - Shelled

673

42

Wet

2003

125

Cottonseed

401

25

Sand - Foundry

1522

95

Earth - Dry Loam

929-1089

58-68

Shale

1410

88

1602-1666

100-104

Slag - Crushed

1121

70

Earth - Sand Gravel

Wet

1570

98

Slate

2243

130

Ensilage

577

36

Snow

240-801

15-50

Granite

1490-1778

93-111

Soybeans

743

46

Gravel - Dry

1522

95

Sugar Beet Pulp - Wet

561

35

Wet

1906

119

Sugar - Raw

961

60

Ice - Crushed

593

37

Sulphur - Lumpy

1330

83

Iron Ore

2323

145

Taconite

1714

107

Limestone - Loose Crushed

1538-1602

96-100

Wheat

769

48

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8-13

CHAPTER 8 - SPECIFICATIONS TORQUE CHARTS Use these charts when special torques are not given. These torques apply to fasteners with both UNC and UNF threads as received from suppliers. Not applicable if special graphite, Molydisulfide greases, or other extreme pressure lubricants are used.

Grade 8 Bolts, Nuts, and Studs

Grade 5 Bolts, Nuts, and Studs

PoundInches 108 to 132 204 to 252 420 to 504 54 to 64 80 to 96 110 to 132 150 to 180 270 to 324 400 to 480 580 to 696 800 to 880 1120 to 1240 1460 to 1680 1940 to 2200

Size 1/4 inch 5/16 inch 3/8 inch 7/16 inch 1/2 inch 9/16 inch 5/8 inch 3/4 inch 7/8 inch 1.0 inch 1-1/8 inch 1-1/4 inch 1-3/8 inch 1-1/2 inch

Newton metres 12 to 15 23 to 28 48 to 57 73 to 87 109 to 130 149 to 179 203 to 244 366 to 439 542 to 651 787 to 944 1085 to 1193 1519 to 1681 1980 to 2278 2631 to 2983

Grade 8.8 Bolts, Nuts, and Studs

PoundNewton Size Inches metres 1/4 inch 144 to 180 16 to 20 5/16 inch 288 to 348 33 to 39 3/8 inch 540 to 648 61 to 73 7/16 inch 70 to 84 95 to 114 1/2 inch 110 to 132 149 to 179 9/16 inch 160 to 192 217 to 260 5/8 inch 220 to 264 298 to 358 3/4 inch 380 to 456 515 to 618 7/8 inch 600 to 720 814 to 976 1.0 inch 900 to 1080 1220 to 1465 1-1/8 inch 1280 to 1440 1736 to 1953 1-1/4 inch 1820 to 2000 2468 to 2712 1-3/8 inch 2380 to 2720 3227 to 3688 1-1/2 inch 3160 to 3560 4285 to 4827 NOTE: Use thick nuts with Grade 8 bolts.

Grade 10.9 Bolts, Nuts, and Studs

8.8

PoundInches 24 to 36 60 to 72 96 to 108 228 to 276 456 to 540 66 to 79 106 to 127 160 to 200 320 to 380 500 to 600 920 to 1100 1600 to 1950

Size M4 M5 M6 M8 M10 M12 M14 M16 M20 M24 M30 M36

10.9

Newton metres 3 to 4 7 to 8 11 to 12 26 to 31 52 to 61 90 to 107 144 to 172 217 to 271 434 to 515 675 to 815 1250 to 1500 2175 to 2600 Figure 5

PoundInches 36 to 48 84 to 96 132 to 156 324 to 384 54 to 64 93 to 112 149 to 179 230 to 280 450 to 540 780 to 940 1470 to 1770 2580 to 3090

Size M4 M5 M6 M8 M10 M12 M14 M16 M20 M24 M30 M36

Newton metres 4 to 5 9 to 11 15 to 18 37 to 43 73 to 87 125 to 150 200 to 245 310 to 380 610 to 730 1050 to 1275 2000 to 2400 3500 to 4200

Grade 12.9 Bolts, Nuts, and Studs 12.9

8-14

Usually the torque values specified for grade 10.9 fasteners can be used satisfactorily on grade 12.9 fasteners.

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87538969 EU

CHAPTER 9 - INDEX

Chapter 9

INDEX A Access Door Locations ...................................... 5-12 Access Doors and Covers ................................... 3-3 Accumulators, Brake ......................................... 4-22 Air Conditioning Compressor ................................................... 6-22 Condenser ..................................................... 6-22 Autoshift Switch ................................................. 3-40 Auxiliary Hydraulic Connection .................................................... 4-23 System Specifications ................................... 4-23 Auxiliary Power Equipment Mounting Bracket ........................ 7-12 Outlet ............................................................. 7-12

B Battery ................................................................. 7-5 Cleaning .......................................................... 7-4 Fluid Level ....................................................... 7-4 Safety .............................................................. 7-3 Service ............................................................ 7-3 Vents ............................................................... 7-4 Before Operating Machine ................................... 4-3 Blower Fan Switch ............................................. 3-38 Brake Pressure Indicator ......................................... 3-15 Brake Accumulators .......................................... 4-22 Bucket Height Control Function .................................................... 4-20 Bucket Level Indicator ....................................... 4-23 Burn Prevention ................................................... 2-8

C Cab Door ............................................................. 3-5 Cab Service ....................................................... 6-22 Caution Master Indicator ................................... 3-17 Checking for cylinder leakage ........................... 6-11 Components, Machine ......................................... 1-5 Control Levers ................................................... 4-14 Controls Blower Fan .................................................... 3-38 Heat, Cab ...................................................... 3-38 Lamp Switch .................................................. 3-39 Wiper/Washer Switch .................................... 3-39 Cylinder Leakage Check ................................... 6-11

D Daily inspections ................................................ 5-10 Issued 02-07

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Decals ...................................................... 2-11, 2-12 DeClutch .............................................................4-22 Declutch Switch ..................................................3-40 Displays, Warning Non - Critical Warning Displays .....................3-17 Door Latch ................................................................3-6

E Electrical Maintenance .........................................7-6 Electrical System ..................................................7-3 Engine Coolant Gauge ............................................................3-21 Engine Grid Heater ....................................... 4-6, 4-8 Engine Oil Type ....................................................5-9 Environment .........................................................5-9

F Fan Reverser (option) ........................................3-40 Fire Extinguisher ................................................6-12 Fluid Capacities ....................................................5-6 Fluids and Capacities ...........................................5-6 Foot Pedals ........................................................3-10 Four-Way Flasher Lamp ..............................................................3-15 Switch ............................................................3-14 Front Console ........................................... 3-14, 3-21 Four-Way Flasher ..........................................3-14 Key/Ignition Switch .........................................3-12 Pilot Control Switch ........................................3-14 Fuel Handling Precautions ...................................2-8 Fuel Level Gauge ...............................................3-20 Fuse Panel ...........................................................7-7 Fuses ....................................................................7-7 Fuses, Replacement ............................................7-9

G Gauges Engine Coolant ..............................................3-21 Fuel Level ......................................................3-20 Hydraulic Oil Temperature .............................3-19 General Information ..............................................1-1

H Hazardous Chemical Precautions ........................2-8 Heat Control, Cab ...............................................3-38 Hourmeter ............................................................5-3 Hydraulic Connection - Auxiliary ........................4-23 Hydraulic Oil 9-1

CHAPTER 9 - INDEX Temperature Gauge ...................................... 3-19

I Identification Numbers ......................................... 1-7 Indicator Brake Pressure ............................................. 3-15 Caution Master .............................................. 3-17 Lamp ............................................................. 3-15 Parking Brake ................................................ 3-15 Secondary Steering Master ........................... 3-15 Stop Master ................................................... 3-16 Indicator Lamps ................................................. 3-15 Inspecting and Cleaning the Machine ............... 6-11 Instrument Panel ............................................... 3-15 Indicator Gauges Engine Coolant ......................................... 3-21 Fuel Level ................................................. 3-20 Hydraulic Oil Temperature ........................ 3-19 Indicator Lamps Brake Pressure ......................................... 3-15 Caution Master .......................................... 3-17 Four-Way Flasher ..................................... 3-15 Lamp Indicator .......................................... 3-15 Parking Brake ........................................... 3-15 Secondary Steering .................................. 3-15 Stop Master ............................................... 3-16 Turn Signal ................................................ 3-15

K Key Switch, Ignition ........................................... 3-12

L Lamp Four-Way Flasher ......................................... 3-15 Turn Signal .................................................... 3-15 Lamp Indicator ................................................... 3-15 Lamp Switch, Cab ............................................. 3-39 Latch Door ................................................................ 3-5 Levers Control ................................................... 4-14 Lift Capacity ......................................................... 8-6 Loader Function Switches ................................. 4-19 Loader Operating Tips ....................................... 4-25 Pushing Operation ........................................ 4-25 Louvers, Air Recirculation ................................................. 3-13

M Machine Components .......................................... 1-5 Maintenance Precautions .................................... 2-7 Maintenance, 10 Hour ....................................... 5-15 Maintenance, 100 Hour ..................................... 5-18 Maintenance, 1000 Hour ................................... 5-28 Maintenance, 2000 Hour ................................... 5-33 9-2

Maintenance, 250 Hour ................... 5-22, 5-23, 5-24 Maintenance, 500 Hour ......................................5-26 Moving a Disabled Machine ...............................4-27

O Official Justifying Documents ...............................1-8 Operating ............................................................4-31 Operating In Cold Climates ................................4-30 Operating Precautions ..........................................2-6 Operating the machine .........................................4-6 Operating the Machine in Hot climates ..............4-31 Operating the machine in water .........................4-26 Operating Tips - Loader .....................................4-25 Operator Manual Storage Compartment ..............1-4

P Parking Brake Indicator .........................................................3-15 Personal Safety ....................................................2-3 Pilot Control Switch ............................................3-14 Plastic and resin parts ........................................6-12 POWER MODES ................................................3-27 Power Outlet, Auxiliary .......................................7-12 Product Identification Number ..............................1-7

R Releasing Hydraulic System Pressure .................5-5 Return-To-Dig Function .........................................................4-19 Return-To-Travel ................................................4-20 Switch ............................................................3-41 Ride Control .......................................................4-24 Switch ............................................................3-41 Rotating Beacon .................................................4-23 Run-In Period .......................................................4-3

S Safety and Decals Safety Rules .....................................................2-3 Safety, Battery ......................................................7-3 Seat Standard ..........................................................3-7 Seat Belt Precautions ...........................................2-9 Secondary Steering Master Indicator .................3-15 Serial Numbers .....................................................1-7 Side Console Autoshift Switch .............................................3-40 Blower Fan Switch .........................................3-38 Declutch Switch .............................................3-40 Heat Control ...................................................3-38 Lamp Switch ..................................................3-39 Return-To-Travel Switch ................................3-41 Issued 02-07

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CHAPTER 9 - INDEX Ride Control Switch ....................................... 3-41 Wiper/Washer Switch .................................... 3-39 Wrist Rest ...................................................... 3-36 Wrist Rest, Adjustment .................................. 3-36 Sides of the machine Right-hand, left-hand, front, and rear .............. 1-4 Specific machine precautions ............................ 2-10 Specifications ...................................................... 8-3 Auxiliary Hydraulic System ............................ 4-23 Specifications and Capacities............................... 5-6 Starter motor ........................................................ 7-6 Starting and Stopping Precautions ...................... 2-5 Starting Engine .................................................... 4-4 Steps and access handles ................................... 3-5 Stop Master Indicator ........................................ 3-16 Stopping and Parking ................................... 4-5, 4-8 Stopping the engine ............................................. 4-8 Storage Compartment Operator Manual ............................................. 1-4 Support Strut ....................................................... 5-4 Switch Autoshift ........................................................ 3-40 Blower Fan .................................................... 3-38 Declutch ........................................................ 3-40 Four-Way Flasher ......................................... 3-14 Key/Ignition ................................................... 3-12 Lamp ............................................................. 3-39 Loader Function ............................................ 4-19 Bucket Height Control ............................... 4-20 Return-To-Travel ....................................... 4-20 Pilot Control ................................................... 3-14 Return-To-Travel ........................................... 3-41 Ride Control .................................................. 3-41 Wiper/Washer ............................................... 3-39

W Warning Displays Non - Critical Warning Displays .....................3-17 Welding on the Machine .....................................6-12 Wheel Bolt Torque ................................................6-8 Wheels and Tires .................................................6-5 Wiper/Washer Switch .........................................3-39 Wrist Rest ...........................................................3-36 Adjustment Knob ............................................3-36

T Temperature Range, Hydraulic System .............. 5-8 Temperature Range, Oil Viscosity Engine ........... 5-7 Temperature Range, Transmission Oil Viscosity 5-8 Tie Down Locations ........................................... 4-29 Tire Pressure ....................................................... 6-6 Towing the machine .......................................... 4-27 Transporting The Machine ................................. 4-28 Transporting the machine .................................. 4-29 Turn Signal Lamp ............................................................. 3-15

U Utility Safety ......................................................... 2-4 Utility Safety Rules Message ............................... 2-4

V Variable Periodic Maintenance .......................... 5-14 Issued 02-07

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9-3

CHAPTER 9 - INDEX

9-4

Issued 02-07

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