Case 921 C Wheel Loader operating manual

921C WHEELLOADER

Operators Manual

P.I.N. JEE0126216 and AFTER

Bur 6-34090 EN

M171D

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANTSAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THISSYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWSAND BE ALERT TO THE POSSIBILITY OF DEATH OR SERIOUSINJURY.

Safety Decals on this machine 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 an potentially hazardous situation which if not avoided,will result in serious injury. The color associated with Warning is ORANGE.

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

If 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 if used, are RED.STOP

IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH ORSERIOUS INJURY. BEFORE USING THIS MACHINE, MAKE CERTAINTHAT 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 areabefore operating this machine on a job site.

It is your responsibility to observe pertinent laws and regulations and followCase, LLC instructions on machine operation and maintenance.

Copyright © 2005 Case, LLC. Bur 6-34090 ENAll Rights Reserved Issued January, 2005

CASE is a registered trademark of Case, LLC.

TABLE OF CONTENTS

TO THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1AFTER DELIVERY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4RIGHT, LEFT, FRONT AND REAR SIDES OF THE MACHINE . . . . . . . . . . 4IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4MACHINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SAFETY/DECALS/HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9UTILITY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10BEFORE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13BURN PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14FIRE OR EXPLOSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14WHEELS AND TIRES SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15HAZARDOUS CHEMICALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16INFORMATIONAL DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17INTERNATIONAL SYMBOL DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

INSTRUMENT/CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33FRONT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 - 37INSTRUMENT PANEL INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . 38 - 51INFORMATION CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 - 57GAUGE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 - 64TRANSMISSION DISPLAY CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . 65 - 67FOOT PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68LOADER CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69SIDE CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 - 87MASTER DISCONNECT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88OPERATORS SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99STOPPING THE ENGINE AND PARKING THE MACHINE . . . . . . . . . . . . 101MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104LOADER CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108LOADER FUNCTION SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

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LOADER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116DECLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117BUCKET LEVEL INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117AUXILIARY HYDRAULIC CONNECTION (IF EQUIPPED) . . . . . . . . . . . . 118QUICK ATTACH COUPLER (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . 119COUPLER PIN ENGAGEMENT (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . 121ROTATING BEACON (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122LOADER OPERATING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123LIFTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125TOWING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127OPERATING IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129OPERATING IN HOT WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

WHEELS/TIRES/BALLAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133BALLAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

LUBRICATION/FILTERS/FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137GENERAL SAFETY BEFORE YOU SERVICE . . . . . . . . . . . . . . . . . . . . . 137SYSTEMGARD LUBRICATION ANALYSIS PROGRAM . . . . . . . . . . . . . . 138PLASTIC AND RESIN PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139TRANSPORT/SERVICE LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139ENGINE HOURMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141LUBRICATION/MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . 142 - 144ACCESS DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145GREASE FITTINGS - 50 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146GREASE FITTINGS - 100 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146GREASE FITTINGS - 250 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147GREASE FITTINGS - 1000 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147FLUID LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151AIR FILTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163HYDRAULIC/BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173AXLES

ZF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176CAB AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

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MAINTENANCE/ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183CAB SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183LOADER ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186TRANSMISSION CLUTCH CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . 194DECLUTCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195SECONDARY STEERING CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197PARKING BRAKE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198ROLL-OVER PROTECTIVE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . 200TORQUE SPECIFICATIONS FOR SEAT AND SEAT BELTS . . . . . . . . . . 202ALTERNATOR BELT AND AIR CONDITIONING COMPRESSOR BELT . 203ALTERNATOR BELT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) . . . . . . . . . . . . . . . . . 206

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209SERVICE ELECTRICAL CONNECTOR (IF EQUIPPED) . . . . . . . . . . . . . . 209AUXILIARY POWER OUTLET (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . 210AUXILIARY POWER EQUIPMENT MOUNTING BRACKET LOCATION . 210REPLACEMENT BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215ENGINE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215OPERATING DATA AND DIMENSIONS 921C . . . . . . . . . . . . . . . . . . . . . 217Machines with 3.63 m3 (4.75 yd3) General Purpose Bucket with Teeth and Bolt

on Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218Machines with 3.82 m3(5.0 yd3 ) General Purpose Bucket . . . . . . . . . . . . 219OPERATING DATA AND DIMENSIONS 921C XR . . . . . . . . . . . . . . . . . . 220XR Machines with 3.63 m3 (4.75 yd3) General Purpose Bucket . . . . . . . . 220XR Machines with 3.63 m3 (4.75 yd3) General Purpose Bucket with Teeth and

Bolt on Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221XR Machines with 3.82 m3 (5.0 yd3) General Purpose Bucket . . . . . . . . . 222OPERATING WEIGHT ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 223SPECIAL BOLT TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224AFTER DELIVERY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233AFTER DELIVERY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

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NOTES

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TO THE OWNER

BDO2B023

BS00A165

CASE CORPORATION

3401 First Avenue North

Fargo, ND 58102

U.S.A.

DEALERS STAMP

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TO THE OWNER

This manual contains important information about the safe operation, adjustmentand maintenance of you Case Wheel Loader. Refer to the Detailed Index at theend of this manual for locating specific items about your machine. this WheelLoader conforms to current safety regulations.

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

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

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

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

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

DO NOT use this machine for any application or purpose other than thosedescribed in this manual. If the loader is to be used in a application that involvesspecial attachments or equipment, such as forestry, etc., consult an authorizeddealer or the Case Corporation. Consult an authorized dealer or CaseCorporation on changes, additions or modifications that can be required for thismachine to comply with various country regulations and safety requirements.Unauthorized modifications will cause serious injury or death. Anyone makingsuch unauthorized modifications is responsible for the consequences.

This Operators Manual is to be stored in the manual compartment equipped onthis machine. Make sure this manual is complete and in good condition. Contactyou dealer to obtain additional manuals. Contact your dealer for any furtherinformation or assistance about your machine. Your dealer has Case Corporationapproved service parts. Your dealer has technicians with special training thatknow best methods of repair and maintenance for your Wheel Loader.

Call your dealer if you need any assistance or information.

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Operator Manual Storage CompartmentREAD THIS MANUAL COMPLETELYand make sure you understand thecontrols. All equipment has a limit.Make sure you understand the speed,brakes, steering, stability and loadcharacteristics of this machine beforeyou start to operate.

DO NOT remove this manual or thesafety manual from the machine. Seeyour dealer for additional manuals.Also see the manual information on theinside of the rear cover of this manual.

Standard Test Certificate

● Noise Level (2000/14/EC)

● Special Safety Equipment (86/295/EEC and 86/296/EEC)

EC and/or EEC Certificate of Conformity

● Safety (Autocertified as per 98/37/EC)

● Electromagnetic Compatibility (89/336/EEC)

● Simple Pressure Vessels (87/404/EEC)

RD98K3051. OPERATORS MANUAL STORAGE

COMPARTMENT

1

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

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

RIGHT, LEFT, FRONT AND REAR SIDES OF THE MACHINE

Right-hand and left-hand, when used in this manual, indicate the right and leftsides of the machine as seen from the operators seat.

B891464J

RIGHT SIDE

LEFT SIDE

REARFRONT

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IDENTIFICATION NUMBERSWrite your machine Product Identification Number (P.I.N.) and Serial numbers onthe lines provided. If needed, give these numbers to your dealer when you needparts or information for your machine.

Make a record of the numbers. Keep the record and your Manufacturer�sStatement of Origin in a safe place. If the machine is stolen, report the numbers toyour local law enforcement agency.

MACHINE MODEL NUMBER

PRODUCT IDENTIFICATION NUMBER

ENGINE SERIAL NUMBER

TRANSMISSION MODEL AND SERIAL NUMBER

ROPS CAB OR CANOPY SERIAL NUMBER

FRONT AXLE MODEL AND SERIAL NUMBER

REAR AXLE MODEL AND SERIAL NUMBER

BUCKET OR ATTACHMENT PART NUMBER

Product Identification Number (P.I.N.)

RD97F168

BC00D212

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Engine

BD02B059

Transmission

B4030791

Axle

BD02B043

Loader Bucket

RP95K195

ROPS Cab and Canopy

RD98K304

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MACHINE COMPONENTS

BD02B024

1. ENGINE ACCESS DOORS 2. ROPS CAB3. BUCKET CYLINDER4. STANDARD BUCKET5. LOADER CONTROLS6. CAB AIR FILTERS7. STEPS8. HAND RAILS9. REAR ACCESS DOOR

10. REAR COUNTERWEIGHT

23

4

5

6

77

8

9

10

1

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BD02B023

1. HAND RAILS2. AIR CONDITIONER CONDENSER3. STEP4. ENGINE ACCESS DOORS5. STEP6. TRANSPORT/SERVICE LINK7. HYDRAULIC FILTERS8. HYDRAULIC RESERVOIR SIGHT GAUGE9. LOADER ARM

112

3

56

7

8

4

9

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SAFETY/DECALS/HAND SIGNALS

SAFETY RULESMost accidents involving machine operating and maintenance can be avoided byfollowing basic safety rules and precautions. Read and understand all the safetymessages in this manual, the safety manual and the safety signs on the machinebefore you operate or service the machine. See your dealer if you have anyquestions.

READ THIS MANUAL COMPLETELYand make sure you understand thecontrols. All equipment has a limit.Make sure you understand the speed,brakes, steering, stability and loadcharacteristics of this machine beforeyou start to operate.

DO NOT remove this manual or thesafety manual from the machine. Seeyour dealer for additional manuals.Also see the manual information on theinside of the rear cover of this manual.

RD98K3051. OPERATORS MANUAL STORAGE BOX

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

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

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

M171B

1

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

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UTILITY SAFETYSafety precaution MUST be followed when working near buried Utility Lines

During operation it is likely that you willbe working around or near buried utilitylines which may include, but are notlimited to:

● Electrical Power LIne

● Gas Line

● Water Line

● Communication LIne - Telephone orCable Television

Before beginning any trenching, drillingor other construction work it is yourresponsibility to be aware of all suchutility lines buried in the area of yourproject and to avoid them.

ALWAYS have a l l l oca l u t i l i t ycompanies mark the location of theirlines.

Check with local authorities for laws,regulations and/or strict penaltiesrequir ing you to locate and avoidexisting utilities.

RH99G001CALL ALL LOCAL UTILITY COMPANIES

BEFORE YOU TRENCH/DRILL

After locating the utility lines, carefullydig a hole by hand and/or automaticvacuum equipment to the utility line toverify the location and depth of the line.

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BEFORE OPERATION● Different jobs will require different

protective equipment. Items such ashard hats, protective shoes, heavygloves, reflector type vests,respirators, and ear protection canbe required. Know and use theequipment that is required beforeyou start the job.

● Be prepared for emergencies.Always have a first aid kit and a fireextinguisher on the machine. Besure that the extinguisher is properlymaintained and be familiar with itsproper use.

● Know the hand signals used on yourjob. Follow the instructions of theflagman, signs, etc.

● Know the rules, laws, and safetyequipment necessary fortransporting or driving this machineon a road or highway. Rotatingbeacon, backup alarm, SMV, andother items are available from yourdealer.

● Avoid loose fitting clothing, loose oruncovered long hair, jewelry, andloose personal articles.

● Foreign material or grease on thesteps and hand rails can cause anaccident. Keep the steps and handrails clean.

● Always use the hand rails whenmounting or dismounting from themachine. Always face the machinewhen mounting or dismounting. Thiswill provide more secure hand andfoot mobility to help prevent slippingand possible injury.

● Remove all loose objects from theoperators area and from themachine. Loose objects can jamcontrols and cause accidents.

● Operate controls only when seated inthe Operators seat.

● Before starting the engine, securelyfasten your seat belt. Your machineis equipped with a ROPS cab orcanopy for your protection. The seatbelt can help insure your safety if itis used correctly and maintained.Never wear a seat belt loosely orwith slack in the belt system. Neverwear the belt in a twisted conditionor pinched between the seatstructural members.

● Make sure all persons are away fromthe machine before you start theengine.

● Before starting the engine, be sureall operating controls are in neutraland the parking brake is applied.

● Sound horn to alert persons in thework area.

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MACHINE OPERATION● Do not turn the steering wheel until

everyone is clear of the machineand the center pivot area.

● Check all controls in a clear area andmake sure the machine is operatingcorrectly.

● A frequent cause of personal injuryor death is persons falling off andbeing runover. Do not permit otherpersons to ride on the machine.Only one person - the operator -should be on the machine when it isin operation.

● Engine exhaust fumes can causedeath. If you operate this machine inan enclosed area, make sure thereis good ventilation to replace theexhaust fumes with fresh air.

● Dust, fog, smoke, etc, can decreaseyour vision and cause an accident.Stop the machine or decrease thespeed until you can see everythingaround you in the work area.

● Contact with overhead power linescan cause severe electrical burns ordeath from electrocution. Make surethere is enough clearance betweenthe machine and overhead powerlines.

● Electrical cables, gas pipes, waterpipes, or other underground objectscan cause injury or death. Learn thelocation of underground hazardsbefore you operate your machine ina new area.

● If this machine rolls over, you can beinjured or killed. You must make ajudgment if weather, road, or earthconditions will permit safe operationon a hill ramp, or rough ground.

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

● Be alert and always know thelocation of all workers in your area.Keep all other persons completelyaway from your machine. Injury ordeath can result if you do not followthese instructions.

● Keep the loader bucket low whenmoving around the work area. Becareful when you raise the load todump.

● DO NOT operate this machine whileunder the influence of alcohol ordrugs.

PARKING THE MACHINE● Park the machine on level ground and before you leave the operators area,

always lower the loader bucket to the ground, apply the parking brake, andstop the engine.

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MAINTENANCE● Before you service the machine, put a Do Not Operate tag on the steering

wheel. A Do Not Operate tag is available from your dealer. The Do NotOperate tag is included with your new machine.

B901248J

● Improper service or repair can causeinjury or death. If you do notunderstand a service or adjustmentprocedure, see the service manualfor this machine or see your dealer.

● Unauthorized modifications to thismachine can cause injury or death.Do not make unauthorizedmodifications to this machine.

● If you must service this machine withthe engine running, have anotherperson help you. Follow theinstructions in this manual or the service manual. Donot leave the operators seat with theengine running.

● Keep clear of the center pivot area ofthis machine when the engine isrunning unless the transport/servicelink is in the LOCKED position. After service,return the transport/service link tothe OPERATING position.

● Metal chips or debris can cause eyeinjury. Always wear eye or faceprotection when you use a hammeron this machine. Use a hammer witha soft face, such as brass, to drivehardened pins.

● Hydraulic fluid or grease injected intoyour skin can cause severe injury ordeath. Keep your hands and bodyaway from any pressurized leak. Ifthe fluid is injected into your skin,see a doctor immediately and havethe fluid removed.

● If you must service the machine withthe loader raised, always block theloader arms.

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

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BURN PREVENTION● Battery acid causes severe burns.

Batteries contain sulfuric acid. Avoidcontact with skin, eyes, or clothing.Antidote - EXTERNAL: Flush withwater. INTERNAL: Drink largequantities of water or milk. Followwith milk of magnesia, beaten eggor vegetable oil. Call a doctorimmediately. EYES: Flush withwater for 15 minutes and get promptmedical attention.

● When the battery electrolyte isfrozen, the battery can explode if,(1) you try to charge the battery, or(2) you try to jump start and run theengine. To prevent the batteryelectrolyte from freezing, try to keepthe battery at full charge. If you donot follow these instructions, you orothers in the area can be injured.

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

FIRE OR EXPLOSION PREVENTION● Engine fuel can cause an explosion

or fire. Do not fill the fuel tank withthe engine running, if you are nearan open fire, or if you are welding,smoking, etc.

● Use nonflammable cleaning solventto clean parts.

● Sparks or flame can cause thehydrogen gas in a battery toexplode. To prevent an explosion,do the following:

1. When disconnecting the batterycables, disconnect the negative (-)cable first; when connecting thebat te ry cab les , connec t thenegative (-) cable last.

2. When connecting jumper cables tostart the engine, use the procedureshown in this manual. See BoosterBa t te r y Connec t ions i n th i smanual.

3. Do not short circuit the batteryposts with metal items.

4. Do not weld, grind, or smoke neara battery.

● Sparks from the electrical system orengine exhaust can cause anexplosion and fire. Before youoperate this machine in an area withflammable dust or vapors, makesure there is good ventilation toremove the flammable dust orvapors before you start.

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● A fire can cause injury or death.Always have a fire extinguisher nearor on the machine. Make sure thefire extinguisher is serviced according to themanufacturers instructions.

● Remove all trash or debris from themachine. Make sure that oily rags orother flammable materials are notstored on the machine.

● Check for fuel, oil, and hydraulic fluidleaks. Replace worn or damagedhoses or lines. After repairs aremade, clean the machine before youoperate.

● Starting fluid (ether) can explode andcan cause injury or death. Do notbreathe starting fluid vapors. Wearface protection when you remove orinstall a starting fluid container. Usestarting fluid according to theinstructions in this manual. See ColdWeather Starting in this manual.

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

● Before you discard an empty startingfluid (ether) container, use rubbergloves and push in on the valve inthe end of the container to removeany pressure. Do not make a hole inthe container and do not put thecontainer in a fire.

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

● If you weld, grind, or use a cuttingtorch on this machine, alwaysremove the starting fluid (ether)container from the machine. Usecompressed air to remove any etherfumes from the area.

WHEELS AND TIRES SAFETY

SB134

84-113

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

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

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HAZARDOUS CHEMICALS● If you are exposed to or come in

contact with hazardous chemicals,you can be seriously injured. Thefluids, lubricants, paints, adhesives,coolants, etc., used with yourmachine can be hazardous.

● Material Safety Data Sheets (MSDS)provide information about thechemical substances within aproduct, safe handling procedures,first aid measures and proceduresto be taken when the product isaccidentally spilled or released.MSDS are available from yourdealer.

● Before you service your machine,check the MSDS for each fluidlubricant, etc., used in this machine.This information indicates what therisks are and how to service themachine safely. Follow thisinformation when servicing themachine.

● Before you service this machine andbefore you dispose of the old fluidsand lubricants, always rememberthe environment. DO NOT put oil orfluids into the ground or intocontainers that can leak.

● Check with your local environmentalor recycling center or your dealer forcorrect disposal information.

● Fluids such as Gasoline, Kerosene,Diesel Fuel, Hydraulic Oil, etc.contain chemicals that can bedangerous to your health and cancause cancer and/or birth defects.Contact either internally orexternally can cause infection orother injury. If any internal orexternal contact occur, see yourlocal Poison Control Center ordoctor IMMEDIATELY.

R412

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INFORMATIONAL DECALSDeca ls wh ich d isp lay the �ReadOpera to rs Manua l � symbol a reintended to direct the operator to theOpera to rs Manua l f o r fu r the rinformation regarding maintenance,adjustments and/or procedures forparticular areas of the Wheel Loader.When a decal displays this symbolrefer to the Operators Manual.

237187A1�READ OPERATORS MANUAL�

SAFETY DECALS

SC002

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

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

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

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

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BD00B032/329051A1A1/364917A1A1/329051A3.EMERGENCY EXIT

1

2

3

1

2

3

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RD98M011

4

4

RD98K362

4

5

323695A1

CRUSH HAZARDKeep Clear

RD98K363

5

5

329048A1

CRUSH HAZARDEngage Lock Link Before Service or Transport

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328755A1

CRUSH HAZARDKeep Clear

Support During maintenance or Repair.

6

RD98K363

6

6

329045A1

HAZARDHot Liquid Under Pressure Service When Cool.

7

BD02B067

7

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329050A1

RUNOVER HAZARDBlock wheels to prevent machine movement before disengaging park brake for towing.

8

RD98M010

8

328753A1

RUNOVER HAZARDKeep Clear

9

BD02B066

9

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RB97D043

328903A1

HAZARDPressurized System

Relieve Pressure Before Maintenance.

10

11BD02B065

1011

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33269A1



BD02B076

12

RD98M010

12

12

23

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332511A1

HAZARDEntanglement

Keep Clear

BD02B068

13

13

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33269A1



BD02B053

15

332510A1

EXPLOSION HAZARDAvoid surprise cylinder rod action and damage. Disassemble with rod fully extended..

15

14

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334455A1

Start Engine from Operator�s Seat Only, Transmission in Neutral.

BD02B054

16

16

386241A1

Use Seat Belt. Avoid Crushing Do Not Jump if Machine Tips.

RP98N335

17

17

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INTERNATIONAL SYMBOL DECALS

139879A1DIESEL FUEL

318764A1KEY SWITCH POSITIONS

187863A1HYDRAULIC OIL

139728A1TIE DOWN POINT

139729A1LIFT POINT

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BS00B355LIFT ARM AND BUCKET CONTROL

187864A1REMOTE GREASE FITTING LOCATION

E134402NO STEP

NOISE LEVEL EXTERIOR (LWA)

BS99K006

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HAND SIGNALSIt is recommended that you and the flagman on the job use hand signals forcommunications. Before you start, make sure that you both understand thesignals that will be used.

BI97D059START ENGINE

BP97D022COME TO ME

Move hands forward and rearward(palms in)

BI97D025STOP ENGINE

BP97D023ALL STOP AND HOLD

Move hands forward and rearward(palms out).

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BP97D030GO THIS FAR

BI97D029STOP

Move one hand back and forth.

BI97D028RAISE BUCKET

BP97D060ALL STOP AND HOLD

BI97D021EMERGENCY STOP

BI97D027LOWER BUCKET

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BI97D020RAISE BLADE SLOWLY

BI97D026LOWER BLADE SLOWLY

BI97D034TURN MACHINE LEFT

SWING LOAD LEFT

To stop movement, stop moving handand make a fist

BI97D033TURN MACHINE RIGHT

SWING LOAD RIGHT

To stop movement, stop moving handand make a fist.

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NOTES

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INSTRUMENT/CONTROLS

FRONT CONSOLE

BD02B020

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

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

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

4. ENGINE WARNING/MAINTENANCE LAMP:The warning/maintenance lamp provides important operatormessages. These messages require timely operator attention. Thewarning lamp is also used to delineate diagnostics fault codes.

12 3 4

BC00B087

BC00B048

BC02B174

BCO2B175

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INSTRUMENTS/CONTROLS

FRONT CONSOLE

BD02B020

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

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

56

BC00B085 BC00B101

BS98M034 BS98M034

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FRONT CONSOLE

RD98K322

7. TRANSMISSION CONTROL LEVER:The transmission control lever is usedto shift the transmission gears from 1stthrough 4th gear. Turn the transmissioncontrol lever away from you to select ahigher gear or toward you to select alower gear. This control lever is alsoused to pu t the t ransmiss ion i nFORWARD, NEUTRAL andREVERSE.

A. Move the control leveraway f rom you fo rFORWARD.

B. The center position isNEUTRAL.

C. Move the control levertoward you fo rREVERSE.

NOTE: The F-N-R function of theTransmission Control Lever may bemoved to the Loader Control Lever foroperating efficiency. See pages 70 or73 of this manual.

RD97F213

8. STEERING WHEEL TILT CONTROL:

This control has multiple positions. Pullthe handle up and adjust the steeringwheel to the correct angle. Release thecontrol to hold in that position. Tilt thesteering wheel completely up whenleaving the machine. Always adjust thesteering wheel to the correct positionbefore starting the engine.

7

BS00B351

A

C

B

8

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FRONT CONSOLE

RD98K311

9. HORN:Push the horn button toactuate the horn.

10. TURN SIGNAL LEVER:Push the control lever upto signal a left turn. Pull thecontrol down to signal aright turn. You must move

the control lever to the center positionto stop the signal.

RD98K313

11. PARKING BRAKE SWITCH:

NOTE: Make sure themachine has come to acomplete stop before

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

IMPORTANT: The Parking Brake is aspring applied, hydraulic releasedbrake. When the key switch is turned tothe OFF position or the brake systemloses pressure the Park Brake willengage. Always wear your seat beltwhen operating.

NOTE: The service brake must be atoperating pressure before the parkingbrake can be released. The BrakePressure Indicator Lamp must not beilluminated when disengaging theparking brake. See Parking Brake inOperating Instructions in this manual.

Push down on the bot tom o f theparking brake switch, hold pressure onthe b rake peda ls and pu t t hetransmission control lever either inFORWARD or REVERSE toDISENGAGE the parking brake

9

10

BS00B352

11

BC00B095

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FRONT CONSOLE

RD98K312

318764A

12. Key SwitchThe key switch has four positions:

ACCESSORY POSITIONThis position will energizethe optional radio only. Itw i l l no t energ ize theinstruments or start theengine.

OFF POSITIONAl l sw i tch con t ro l l edcurrent is OFF. Turn thekey to OFF to stop theengine. Remove the keyand tu rn the Mas te r

Disconnect Switch to OFF.

ON POSITIONThis position energizes allelectrical systems. The keywill return to this positionafter you release the keyfrom the START position.

START POSITIONTurn the key to th i sposi t ion to engage thestarter motor to start theeng ine. The sw i tch i sspr ing loaded and wi l l

re tu rn to the ON pos i t i on whenreleased.

NOTE: The Ether Star t System (ifequipped) can only be actuated when thekey switch is in the ON position and theengine temperature is below 50°F(10°C).The transmission control levermust be in the NEUTRAL position for thestar ter to engage.

12

RB98M031

RB99J175

RB99J178

RB99J176

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INSTRUMENT PANEL INDICATORS

Instrument ClusterThe instrument cluster will check each monitored system when you turn the keyswitch to the ON position. All LED�s (Light Emitting Diodes) will illuminate, six bargraphs will energize for three seconds, and the warning alarm will sound for threeseconds. At the end of this check all monitored systems will return to normaloperation. If there is an open circuit between a sensor and the instrument cluster,the LED will flash and the warning alarm will sound for 5 seconds.

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

BD02B020

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

2. BEACON INDICATOR:

This indicator illuminates when the Beacon is in the ON position.

1 1

2

BS96H049

BC00B082

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BD02B020

3. LAMP INDICATOR:

This indicator illuminates when the lamp are ON.

4. PILOT LOCKOUT INDICATOR

This indicator illuminates when the pilot lockout is actuated.

5. LOW COOLANT INDICATOR:

This indicator illuminates when the engine coolant is low. The alarmsounds continuously and the master indicator lamp will be red.

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

6. BRAKE PRESSURE INDICATOR:

This indicator illuminates when the brake system pressure is too low. The alarmsounds continuously and the stop master indicator will be red.

NOTE: Stop the machine and correct the problem.

34

56

BS98M062

BC00B048

BC00B110

BC00B108

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BD02B020

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

Critical Warning DisplaysWhen the Stop Master indicator illuminates you must bring the

machine safely to a stop and immediately turn OFF the engine. Failure to do somay result in injury and/or damage to the machine. The following table is a listingof critical warning displays that may appear on the instrument cluster and thecorrective action required. When a fault occurs, a continuous audible alarm willsound and the Stop Master Indicator will be RED and the display indicator will beilluminated.

Display Description Corrective ActionENGINE OILPRESSURE

Low Engine Oil Pressure. Below10 PSI

Bring the machine to a safe stop and shutthe engine OFF immediately. Contact yourDealer.

BRAKEPRESSURE

Low Brake Pressure Bring the machine to a safe stop and shutthe engine OFF immediately. Contact yourDealer.

STEERINGPRESSURE (W/

AUX STEERING)

Low Steering Pressure. Bring the machine to a safe stop and shutthe engine OFF immediately. Contact yourDealer.

7

BC00B290

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COOLANT LEVEL Low Coolant Level. Bring the machine to a safe stop and shutthe engine OFF immediately. Check thecoolant levels after allowing the engine andthe coolant to cool down. Contact yourDealer.

COOLANTTEMPERATURE

High Engine Coolant Temperature.

Bring the machine to a safe stop and shutthe engine OFF immediately. Check thecoolant levels after allowing the engine andthe coolant to cool down. Contact yourDealer.

HYDRAULIC OILTEMPERATURE

High Hydraulic OilTemperature.


TRANSMISSIONOIL

TEMPERATURE

High Transmission OilTemperature.


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BD02B020

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

Non - Critical Warning DisplaysWhen the caution is �on�, change your operating method, schedule a

shutdown for maintenance or if the condition persists, contact your dealer. Thefollowing table is a listing of warning displays that may appear on the instrumentcluster and the corrective action required. When a fault occurs, an audible alarmwill sound for 3 seconds and the Caution Master Indicator will be YELLOW andthe display indicator will be illuminated. When this occurs return the machine to aservice position and shutdown the engine to help avoid expensive repairs.

Display Description Corrective ActionPARKING BRAKE Parking Brake engaged and

shifts to F or R.Release the parking Brake.

COOLANTTEMPERATURE

High engine coolanttemperature

1. Idle machine and monitor temperature.2. Clean radiator.3. If condition persists, contact your dealer.

HYDRAULICTEMPERATURE

High hydraulic temperature 1.Idle machine and monitor temperature.2. Clean cooler.3. If condition persists, contact your dealer.

8

BC00B291

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TRANSMISSIONTEMPERATURE

High transmission temperature 1. Idle machine and monitor temperature.2. Clean the cooler.3. Use a lower gear.4. If condition persists, contact your dealer.

AIRCONDITIONING

High or Low air conditioning pressure.

1. Turn air conditioning OFF.2. Low outside temperature.3. Servicing required.4. If condition persists, contact your dealer.

AIR FILTER High air filter restriction 1. Clean air filter.2. Replace primary and secondary filters.3. If condition persists, contact your dealer.

TRANSMISSIONFILTER

Transmission filter restriction. 1. Replace transmission filter.2. If condition persists, contact your dealer.

HYDRAULICFILTER

Hydraulic filter restriction. 1. Replace hydraulic filter.2. If condition persists, contact your dealer.

ALTERNATOR Alternator malfunction. 1. Check electrical system.2. Voltages are out of range.3. Change operating procedure.4. If condition persists, contact your dealer.

FUEL Low fuel. 1. Fill fuel tank within the next hour.

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BD02B020

9. SECONDARY STEERING INDICATOR (IF EQUIPPED):

This indicator illuminates when the primary steering system pressureis too low. The alarm sounds continuously and the stop masterindicator turns red.

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

10. PARKING BRAKE INDICATOR:

This indicator illuminates when the parking brake is applied. Whenthe parking brake is applied and you shift the transmission intoFORWARD or REVERSE the alarm sounds for 3 seconds and thecaution master indicator turns yellow.

11. AIR CONDITIONING INDICATOR:

This indicator illuminates when the air conditioner has stopped due torefrigerant pressures that are too high or too low. The alarm soundsfor 3 seconds and the caution master indicator turns yellow. Thesystem needs service or the outside air temperature is too cool for the

system to work.

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

9 10 11

BS00B111

BS96H049

BC00B112

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BD02B020

12. HYDRAULIC OIL FILTER INDICATOR:

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

13. AIR FILTER INDICATOR:

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

14. TRANSMISSION OIL FILTER INDICATOR:

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

1213

14

BC00B113

BS98M026

BS99J182

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BD02B020

15. TRANSMISSION OIL TEMPERATURE GAUGE:The transmission oil temperature gauge is shown with indicator bars.Normal operating temperature is in the green zone. When thetransmission oil temperature increases, the bars move into the yellowzone and begin to flash, the warning alarm sounds for three seconds,and the caution master indicator turns yellow. When the temperature

continues to increase the bars move into the red zone and continue to flash, thewarning alarm will sound continuously, and the stop master indicator turns red.The machine must not be operated when the temperature is in the red zone..

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

TRANSMISSION OIL TEMPERATURE GAUGEGaugeIndication

Condition MasterIndicator

GaugeStatus

AlarmStatus

20°C and below(68°F and below)

Oil temperature is very low

20 to 120°C(68 to 248°F)

Oil temperature is normal

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

Oil temperatureis high

Caution(Yellow)

Flashes 3 Seconds

125°C and above(257°F and above)

Oil temperatureis very high

Stop(Red)

Flashes Continuous

15

BS98M028

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BD02B020

16. HYDRAULIC OIL TEMPERATURE GAUGE:The Hydraulic Oil Temperature Gauge indicates the oil temperatureof the hydraulic system. The hydraulic oil temperature gauge isshown with indicator bars. Normal operating temperature is in thegreen zone. When the hydraulic oil temperature increases the barsmove into the yellow zone and begin to flash, the warning alarm

sounds for three seconds, and the caution master indicator turns yellow. Whenthe temperature continues to increase the bars move into the red zone andcontinue to flash and the warning alarm sounds continuously. The stop masterindicator turns red. The machine must not be operated when the temperature is inthe red zone.


HYDRAULIC OIL TEMPERATURE GAUGEGaugeIndication


GaugeStatus

AlarmStatus


Hydraulic oiltemperature is very low

20 to 105°C(68 to 221°F)

Hydraulic oiltemperature is normal

105 to 110°C(221 to 230°F)

Hydraulic oiltemperature is high

Caution(Yellow)

Flashes 3 Seconds

110°C and above(230°F and above)

Hydraulic oiltemperature very high

Stop(Red)

Flashes Continuous

16

BC00B123

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BD02B020

17. VOLT METER GAUGE:

The volt meter gauge indicates the condition of the batteries andcharging system. The amount of voltage is shown with indicator bars.Normal operating range is in the green zone. When the voltageincreases or decreases the bars move into the yellow zone and begin

to flash, the warning alarm sounds for three seconds, and the caution masterindicator turns yellow.


VOLTMETER GAUGEGauge Indication Engine Speed Condition of charging

systemMasterIndicator

GaugeStatus

AlarmStatus

0 to 18 Volts Stopped or lowidle

Very low battery charge Caution(Yellow)

Flashes 3 Seconds

18 to 24 VoltsStopped or lowidle

Low to normal batterycharge

Above low idle Problem in charging system

24 to 26 VoltsStopped orlow idle

Normal battery charge

Above low idle Problem in chargingsystem

26 to 32 Volts Above low idle Normal operating range32 Volts and above(See the note below.)

Problem in chargingsystem (overcharging)

Caution(Yellow)

Flashes 3 Seconds

17

BS98M032

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BD02B020

18. FUEL LEVEL GAUGE:

The Fuel Level Gauge indicates the fuel level. The fuel level is shownon the gauge with indicator bars. Normal operating range is in thegreen zone. When the tank is almost empty the bars move into theyellow zone and begin to flash, the warning alarm sounds for three

seconds, and the caution master indicator turns yellow.

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

FUEL LEVEL GAUGEGaugeIndication


GaugeStatus

AlarmStatus

5 percent and below Fuel level low Caution(Yellow)

Flashes 3 Seconds

5 percent and above Fuel level normal

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BD02B020

19. ENGINE OIL PRESSURE GAUGE

The engine oi l pressure gauge indicates the oi l pressure in the enginelubrication system. The engine oil pressure is shown with indicator bars. Normaloperation is in the green zone. When the oil pressure decreases below a safeoperating pressure, the bars move into the red zone and flash and the warning

alarm sounds continuously. The stop master indicator turns red. The machine must not beoperated when the oil pressure is in the red zone.

NOTE: Stop the engine immediately and correct the problem.

ENGINE OIL PRESSURE GAUGE GaugeIndication


GaugeStatus

AlarmStatus

0 to 70 kPa(0 to 10 psi)

Very low (too low to run engine)

Stop(Red)

Flashes Continuous

70 to 110 kPa(10 to 16 psi)

Low(above low idle)

110 kPa and above(16 psi and above)

Normal(above low idle)

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BD02B020

20. ENGINE COOLANT TEMPERATURE GAUGE:

The Engine Coolant Temperature gauge indicates the coolant temperature of theengine. The engine coolant temperature is shown with indicator bars. Normaloperat ing temperature is in the green zone. When the engine coolanttemperature increases the bars move into the yellow zone and begin to flash, the

warning alarm sounds for three seconds. The caution master indicator turns yellow. When thetemperature continues to increase the bars move into the red zone and continue to flash andthe warning alarm sounds continuously. The stop master indicator turns red. The machineMUST NOT be operated when the temperature is in the red zone.

NOTE: Stop the engine immediately and correct the problem.

ENGINE COOLANT TEMPERATURE GAUGEGaugeIndication


GaugeStatus

AlarmStatus


Coolant temperature is very low

20 to 105°C(68 to 221°F)

Coolant temperature is normal

105 to 110°C(221 to 230°F)

Coolant temperatureis high

Caution(Yellow)

Flashes 3 Seconds

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

note below.)

Coolant temperatureis very high

Stop(Red)

Flashes Continuous

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INFORMATION CENTER

BD02B020

1. INFORMATION CENTER

You can display many of the machine functions on your ProgrammableInformation Center. It can be programmed to display all functions, or only thefunctions that are important to you.

Here are the functions you may choose to see on your Information Center:

HOURMETER - Displays the accumulated running time of the engine in hours andtenths of an hour with an �hour glass� symbol.

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

TACHOMETER - Displays the engine speed in revolutions per minute along withan �n/min� symbol.

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

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

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

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

A. UP COUNT C. PROGRAMB. DOWN COUNT D. RESET

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INFORMATION CENTER

BD02B020

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

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

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

Programming Your Information Center

NOTE: To program your instrument cluster the machine must be off.

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

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

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

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


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INFORMATION CENTER

BD02B020

To program your information center do the following:

1. Turn the key switch to the ON position.

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

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

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

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

Service Interval Hours

Locations 61 through 70 are service interval hour settings. The service intervalhours will accumulate hours until they are reset. Once they are reset, they willbegin accumulating hours independent from the machine hours until they arereset again.


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INFORMATION CENTER

BD02B020

Example: If the operator wanted location 061 to indicate engine oil serviceintervals, when the engine oil is changed, location 061 would be reset to beginaccumulating hours for the next oil change. The operator could then go intolocation 061 and monitor the accumulating hours. When location 061 reaches theengine oil change interval, the operator would change the oil and reset location061 again.

To view the service hour interval locations:

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

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

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

● Read the accumulated hours shown on the Display Center.

To reset the service interval hours:




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


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INFORMATION CENTER

BD02B020

Fault Code StatusLocations 071 through 090 displayed fault codes and the hours the faultsoccurred. the Information Center continuously monitors the machines conditionand records any fault codes; however, it will only record a duplicate code onceevery hour. When a fault code is written, the service indicator icon (a manual witha wrench) will be displayed on the Information Center.

To view the fault codes and the hours they occurred:




● Read any fault codes on the Display Center.

● Press the program (C) switch again.

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


● Read the hours at which the previous code occurred.The hour location will always follow the fault code location.


1A B C

D

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INFORMATION CENTER

BD02B020

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

You can monitor a particular location without going into the programmingmode by performing the following procedure:

● Press the program (C) switch.

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


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

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

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GAUGE DISPLAY

BD02B020

2. Gauge Displays

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

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

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

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

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

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

NOTE: 05 is the setting from the factory.


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GAUGE DISPLAY

BD02B020

Programming Your Gauge Display

When you start your machine you will see the Hourmeter in the Display Center.Your wheel loader is shipped from the factory with Gauge Display 05. To checkwhat Gauge Display your machine currently is using do the following:


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


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

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

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


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GAUGE DISPLAY

BD02B020

Manual Scrolling Gauge Displays (01, 02 or 05)

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

Example: Lets say you�ve chosen Gauge Display 01. You will first see theHourmeter in the Display Center.

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

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

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

Automatically Scrolling Gauge Displays (03 or 04)

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

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


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GAUGE DISPLAY

BD02B020

Displaying Individual Functions

You also may choose to display any individual function at anytime, regardless ofthe Gauge Display you�ve chosen. You may show the following functions at anytime on your Display Center.

000 - Hourmeter

001 - Tachometer

002 - Speedometer (mph)

003 - Speedometer (km/h)

004 - Engine Coolant Temperature

005 - Engine Oil Pressure

006 - Fuel Level

007 - Transmission Oil Temperature

008 - Hydraulic Oil Temperature

009 - Voltmeter


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GAUGE DISPLAY

BD02B020

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


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

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

You will now see the function you�ve chosen.

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

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



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

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


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GAUGE DISPLAY

BD02B020

Setting Display Center Lamp

You can set the brightness of your display lights for two separate conditions. Thefirst is with your work lights OFF, and the second is with the work lights ON.


● Press the up count (A) switch until the display reads 012 (for lamps OFF) or013 (for lamps ON).


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

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

● The brightness can be varied between 001 - 100, with 100 being the brightest.Your machine is shipped from the factory with brightness setting of 070 forworking lights OFF and 020 for lamps ON.

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


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GAUGE DISPLAY

BD02B020

Setting Master Reset

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




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

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


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TRANSMISSION DISPLAY CENTER

RD97F206

The Transmission Display will show the status of the transmission control. TheDisplay contains the following information:Direction Selected, shown at the top of the display center:

F - ForwardN - NeutralR - ReverseF - Flashing forward not engaged.N - Flashing set control lever to neutral position.R - Flashing reverse not engaged.

Requested Gear (gear position on shift lever), shown in the center of the gearsymbol:

1 - 1st Gear2 - 2nd Gear3 - 3rd Gear4 - 4th Gear

Actual Gear, shown with bars to the right of the gear symbol.The number of bars indicates the gear the transmission is actually in. This mayvary from the requested gear when the transmission is in the Automatic Mode.Transmission Mode (Automatic or Manual), shown in the lower left of the displaycenter. A gear symbol with an �A� in the center will be displayed in the lower left ofthe display when the transmission is in the Automatic Mode. When thetransmission is in the Manual Mode no symbol will be displayed.

A. F - N - R C. GEAR E. AUTOMATIC MODEB. DISPLAY CENTER D. BAR

E

A

B

C

D

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BD02B020

Minimum Gear Selection, Automatic ModeThe transmission can be programmed for the lowest gear possible in theautomatic mode. The operator can select 1st or 2nd gear. The gear that is chosenwill be the gear that the transmission is in when the machine begins to move.Machines shipped from the factory will have the minimum gear set a 1.

Programming Minimum Gear Selection




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

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

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


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BD02B020

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

Programming Maximum Gear Selection




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

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

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


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FOOT PEDALS

RD97F194

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

2. BRAKE PEDALS:Push down on the bot tom o f theDeclutch switch (3). This turns OFF theDeclutch feature. When either pedal ispushed down, the brakes are actuated,the brake light is illuminated, and thet ransmiss ion c lu tch w i l l rema inengaged. Push down on the top of theDeclutch switch and this will turn on theDeclutch feature. When either brakepedal is pushed down the brakes areactuated, the brake light is illuminatedand the t ransmiss ion c lu tch i sdisengaged.

NOTE: Use the DECLUTCH SWITCHwhen you need maximum power(speed) for the loader lift arms andbucket (see Declutch in this manual).

BD02B0553. DECLUTCH SWITCH

1

2 3

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LOADER CONTROL LEVERS

Two Spool - One Lever

BC01E131/BS00B353

1. LIFT ARM AND BUCKET CONTROLA. FLOAT (Detent): This is a detent position. When in the FLOAT (Detent)

position, the loader bucket can follow the level of the ground withoutmovement of the control lever.

B. LOWERC. HOLD: The loader arms and bucket will not move when the control lever is

in the HOLD position. When released, the control lever will automaticallyreturn to the HOLD position. You must manually move the control leverfrom the FLOAT position to the HOLD position.

D. RAISEE. DUMPF. ROLLBACK

2. KICKDOWN BUTTON (DOWNSHIFT TRANSMISSION)

3. FNR SWITCHG. FORWARD (Transmission)H. NEUTRAL (Transmission)I. REVERSE (Transmission)

1

AE

C

DF

B

1

2

3

I

HG

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AUXILIARY F-N-R SWITCH FOR JOYSTICK CONTROL LEVERS

BC01E131

1. AUXILIARY F-N-R SWITCHA. FORWARDB. NEUTRALC. REVERSE

To actuate the Auxiliary F-N-R switchthe following conditions MUST be met:

1. The machine must be stopped.2. The engine must be running.

RD98K322

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

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

RD98K313

5. The parking brake (3) must bereleased.

BD01E113

When steps 1 through 5 have been metthe Auxiliary F-N-R Switch may beenabled by pushing down on the top ofthe switch (4). The indicator light on thebottom of the switch will illuminate.The Auxiliary F-N-R Switch will beDEACTIVATED and F-N-R control willdefault back to the TransmissionControl Lever if:

1. The engine is stopped.2. The parking brake is applied.3. The transmission control lever is

taken out of the neutral position.

NOTE: SeeTransmission Operation/initial machine movement for moving themachine after engine start up.

1

B

C

A

2

3

4

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Two Spool - Two Levers

BC01E133/BS00B354

4. BUCKET CONTROLA. DUMPB. ROLLBACKC. HOLD: The bucket will not move when the control lever is in the HOLD

position. When released, the control lever will automatically return to theHOLD position.

5. LIFT ARM CONTROLD. FLOAT (Detent): This is a detent position. When in the FLOAT (Detent)


E. LOWERF. HOLD: The loader arms will not move when the control lever is in the

HOLD position. When released, the control lever will automatically return tothe HOLD position. You must manually move the control lever from theFLOAT position to the HOLD position.

G. RAISE

B

C

G

FED

A

4

5

4

5

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Two Spool - Two Levers (Continued)

BC01E133

6. Kickdown Button (Downshift Transmission)

7. FNR Switch

A. Forward (Transmission)

B. Neutral (Transmission)

C. Reverse (Transmission)

6

7

A

B

C

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

BC01E133

1. AUXILIARY F-N-R SWITCHA. FORWARDB. NEUTRALC. REVERSE

To actuate the Auxiliary F-N-R switchthe following conditions MUST be met:

1. The machine must be stopped.2. The engine must be running.3. The Auxiliary F-N-R Switch (1)

must be in Neutral (B).

RD98K322

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

RD98K313

5. The parking brake (3) must bereleased.

BD01E113

When steps 1 through 5 have been metthe Auxiliary F-N-R Switch may beenabled by pushing down on the top ofthe switch (4). The indicator light on thebottom of the switch will illuminate.

The Auxiliary F-N-R Switch will beDEACTIVATED and F-N-R control willdefault back to the TransmissionControl Lever if:

1. The engine is stopped.2. The parking brake is applied.3. The transmission control lever is

taken out of the neutral position.

NOTE: SeeTransmission Operation/initial machine movement for moving themachine after engine start up.

1

A

C

B

2

3

4

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Three Spool - Two Levers

BC01E130/BS00B355

8. BUCKET AND LIFT ARM CONTROLA. DUMPB. ROLLBACKC. HOLD: The loader arms and bucket will not move when the control lever is


D. FLOAT (Detent): This is a detent position. When in the FLOAT (Detent)position, the loader bucket can follow the level of the ground withoutmovement of the control lever.

E. LOWERF. RAISE

9. AUXILIARY CONTROL (IF EQUIPPED)

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

G. ________________________________________H. ________________________________________I. HOLD: There will not be any auxiliary function with the control lever in this


9

8

EA

B

G

C

D

F H

8 9 I

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Three Spool - Two Levers (continued)

BC01E130/BC01E131

10. KICKDOWN BUTTON (Downshift Transmission)

11. F-N-R SWITCHA. FORWARD (Transmission)B. NEUTRAL ( Transmission)C. REVERSE (Transmission)

NOTE: See page 70 of this manual for the correct procedure to enable the F-N-Rfunction for the loader control lever.

10

1011

11

BA

C

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Three Spool - Three Levers

BC01E132/376629A1

12. BUCKET CONTROLA. DUMPB. ROLLBACKC. HOLD: The bucket will not move when the control lever is in the HOLD


13. LIFT ARM CONTROLD. FLOAT (Detent): This is a detent position. When in the FLOAT (Detent)


E. LOWERF. HOLD: The loader arms will not move when the control lever is in the

HOLD position. When released, the control lever will automatically return tothe HOLD position. You must manually move the control lever from theFLOAT position to the HOLD position.

G. RAISE

14. AUXILIARY CONTROL (IF EQUIPPED)

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

H. ________________________________________I. ________________________________________J. HOLD: There will not be any auxiliary function with the control lever in this


D

E

F

GBI

14

A

C

H 12

1213

14 J

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Three Spool - Three Levers (continued)

BC01E132

15. Kickdown Button (Downshift Transmission).

16. FNR Switch

A. Forward (Transmission)

B. Neutral (Transmission)

C. Reverse (Transmission)

NOTE: See page 73 of this manual for the correct procedures to enable the F-N-Rfunction on the side panel.

15

16

A

B

C

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Four Spool - Two Levers

BC01E130/BS00B357

17. BUCKET AND LIFT ARM CONTROLA. DUMPB. ROLLBACKC. HOLD: The loader arms and bucket will not move when the control lever is


D. FLOAT (Detent): This is a detent position. When in the FLOAT (Detent)position, the loader bucket can follow the level of the ground withoutmovement of the control lever.

E. LOWERF. RAISE

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

G. ________________________________________H. ________________________________________I. ________________________________________J. ________________________________________K. HOLD: There will not be any auxiliary function with the control lever in this


18

E A

B C FH

K G

J

I

17

D17

18

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Four Spool - Two Levers (continued)

BC01E130/BC01E131

19. KICKDOWN BUTTON (Downshift Transmission)

20. F-N-R SWITCHA. FORWARD (Transmission)B. NEUTRAL (Transmission)C. REVERSE (Transmission)

NOTE: See page 70 of this manual for the correct procedure to enable the F-N-Rfunction on the Loader Control Lever.

19

1920

20

BA

C

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SIDE CONSOLE

BD02B021

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

To activate the F-N-R function all of the following conditions must be met:A. The machine must NOT be moving.B. The engine must be running.C. The Transmission Control Lever and the F-N-R switch both have to be in

the NEUTRAL position.D. The parking brake must be released.

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

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

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

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SIDE CONSOLE

BD02B022

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

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

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

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

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

2

3

4

5

BC00B128

BC00B127

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SIDE CONSOLE

BD02B022

6. WIPER/WASHER SWITCH (IFEQUIPPED):The wiper/washer switch has f ivepositions.A.OFF - Turn the switch completelycounterclockwise for OFF.B.INTERMITTENT - Rotate the switchclockwise to the f i rs t posi t ion forintermittent wiper speed.C.LOW - Rotate the switch clockwise tothe second position for low wiper speed.D.HIGH - Rotate the switch clockwise tothe third position for high wiper speed.E.WASH - Push down on the switch forwasher fluid.

6

BC00B131

A

B

C

D

E

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SIDE CONSOLE

BD02B022

7. LAMP SWITCH:The lamp switch has five positions:A.OFF - Turn the switch completelycounterclockwise for OFF.B.PARK - Turn the switch to thisposition to illuminate the marker andtail lamps.C.DRIVE - Turn the switch to thisposit ion to i l luminate the consolelamps, driving lamps, marker lampsand tail lamps.D.ALL - Turn the switch to this positionto illuminate the console lamps, drivinglamps and flood lamps.

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

7

BC00B133

E

D

C

B A

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SIDE CONSOLE

BD02B022

8. AIR CONDITIONING TEMPERATURE CONTROL (IFEQUIPPED):Turn the control clockwise for ON. Adjust the control to the neededtemperature. Turn the control counterclockwise for OFF (seeRecirculation Louvers in this manual). Select the desired fan speed.

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

9. DECLUTCH SWITCH:The declutch disengages the transmission when maximum power isneeded for the loader (the foot pressure required to disengage thetransmission is adjustable, see Declutch Adjustment on page 195 ofthis manual). Push down on the top of the declutch switch and pushon either brake pedal to operate the machine with the declutch.

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

11. RETURN-TO-TRAVEL SWITCH:The Return-To-Dig switch is used to automatically return the loaderbucket to the dig position after you have dumped the loader bucket.Push down on the top of the Return-To-Travel switch to engage alldetents. Push the bottom of the switch for the OFF position.

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BS98M034

BC00B098

BC00B097

BC00B086

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SIDE CONSOLE

BD02B022

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

operation).

13. RIDE CONTROL SWITCH:Push down on the top of the Ride Control switch and pull back on theLoader Lift Control Lever to raise the lift arms until the Green light inthe Ride Control Switch intensifies for the ON position. Push thebottom of the switch for the OFF position. Ride Control is OFF whenkey switch is OFF. Ride Control Must be reset once the engine is

started again. (see Ride Control Operation in this manual for operation).

14. REAR WIPER/WASHER SWITCH (IF EQUIPPED):The rear wiper/washer switch has three positions.A.OFF - The switch completely off when the bottom of the switch ispushed down.ON - Push down on the top of the switch for the ON position

WASH - Push down on the top of the switch and hold, washer fluid will continue toflow as long as the switch is held down.

1213

14

BC00B081

BC00B094

BC00B083

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SIDE CONSOLE

BD02B022

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

16. BACKUP ALARM CANCELLATION SWITCH (IF EQUIPPED): Push down on the top of the backup alarm ON/OFF switch to turn theaudible sound OFF for the backup alarm. The symbol on the switchwill illuminate when the backup alarm is in the OFF position.Push down on the bottom of the backup alarm ON/OFF switch to turnthe audible sound ON for the backup alarm.

M564

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

15 16

BS98M034

BCOOBO79

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SIDE CONSOLE

BD02B055

17. COUPLER PIN ENGAGE SWITCH ( IF EQUIPPED):Slide the locking plate towards the center of the switch, push down onthe top of the switch to RETRACT the pins. The switch lamp willilluminate when the pins are retracted. The switch will lock in the PINEXTENDED position after the bottom of the switch has been pressedand the PINS EXTENDED.

18. ENGINE ECONOMY SWITCH

Push the top of the switch to have the engine change to the economy mode. Theswitch lamp will illuminate when in the economy mode. Depending on workingconditions and operator use of the machine, fuel economy can be realized in thismode.

1718

BC00B099

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MASTER DISCONNECT SWITCH

BD02B030

1 . MASTERDISCONNECT SWITCHThe Master DisconnectSwitch has two positions:ON and OFF.

ON - Th is pos i t ionenerg i zes the en t i r eelectrical system. Whenthe master Disconnectswitch is ON and the keysw i t ch is OFF, t he

following electrical components havepower: dome lamp, horn, stop lamps,four-way flashers and the rotary lightswitch.

OFF - Th is pos i t iondisconnects all power tothe machine.

IMPORTANT: DO NOT use the masterDisconnect Switch to stop the engine.

1

BS00A018

BS00A203

BS00A017

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Recirculation Air LouversThe recirculation air louvers are behindthe operators seat next to the floor.When open, air is recirculated in thecab. To open the louvers turn the knobclockwise. To close the louvers turn theknob counterclockwise.NOTE: Always have these louversopen for maximum cooling with the airconditioning or maximum heat with theheater.

Main Air LouversThe louvers on the RH and LH side infront of the console direct air flow backto the operator.The lower front louvers direct air flowback to the operator.

RD98K3231. MAIN LOUVERS

BD00B0051. KNOB- LOOSEN AND SLIDE KNOB AS

REQUIRED TO OPEN OR CLOSE LOUVERS

2. RECIRCULATION LOUVERS (BEHIND FILTER)

RD98K3031. MAIN LOUVERS

RD97F1941. MAIN LOUVERS

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Defrost Air LouversThe upper louvers under the frontwindshield and the louver under therear window direct the air f low todefrost the windows. To get maximumair flow on the windows, close all otherlouvers and turn the blower fan to thefastest speed.

If a fogging condition occurs make surethe rec i rcu lat ion a i r louvers areCLOSED. I f equ ipped w i th A i rConditioning, turn the Air ConditioningON and tu rn the Hea t Con t ro lcompletely clockwise.

RD97F1941. DEFROST LOUVERS

RD98K3031. DEFROST LOUVERS

RD98K3231. DEFROST LOUVERS

Radio (If Equipped)

RD97F215

A radio (if equipped) is available for thismachine from your dealer. Refer to theradio manufacturers instructions forcorrect operation.

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Door Latch

RD97F2181. PUSH TO OPEN DOOR

Window Latch

RD98K3011. LIFT TO OPEN

RD98K3021. LATCH PIN2. HOLD LATCH

The window can be kept partially openby lifting the Hold Latch and sliding itback on the Latch Pin until the HoldLatch locks in the Latch Pin.The window may be opened andlocked against the side of the cab. Todo this pull the hold latch toward therear of the cab when the window ispartially open. This will unlatch thewindow and allow the window to swingback against the cab and lock.To release the window from the fullopen posit ion, pull on the windowrelease in the right hand rear corner ofthe cab.

Window Retainer Latch

RD97F1731. PULL TO RELEASE WINDOW

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OPERATORS SEAT

Standard Seat

RD98K267

1. LUMBAR ADJUSTMENT KNOB:Turn the knob clockwise to increase thelumbar suppor t , t u rn the knobcounterclockwise to decrease thelumbar support.

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

NOTE: Each armrest will pivot to the upposition.

RD98K266

3. RECLINER ADJUSTMENT HANDLE: L i f t up on the hand le , move thebackrest to the desi red posit ion,release the handle to lock the backrestin position.

RD98K266

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

5. WEIGHT ADJUSTMENT KNOB: To adjust the seat for your weight youmust pull the release lever out of theknob, Use the release lever to turn theknob clockwise to increase the weightres i s tance. Tu rn the knobcounterclockwise to decrease theweight resistance.

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

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Optional Air Ride Seat

RD98K267

1. LUMBAR ADJUSTMENT KNOB:Turn the knob clockwise to increase thelumbar suppor t , t u rn the knobcounterclockwise to decrease thelumbar support.

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

NOTE: Each armrest will pivot to the upposition.

RD98K268

3. RECLINER ADJUSTMENT HANDLE: L i f t up on the hand le , move thebackrest to the desired posit ion,release the handle to lock the backrestin position.

RD98K268

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

NOTE: When adjusting the seat heightfor the first time or for a differentoperator. Sit in the operators seat, liftup momentarily on the heightadjustment handle. The seat willautomatically adjust to the operatorsweight. See height adjustment handlefor final adjustments.

5. HEIGHT ADJUSTMENT HANDLE: A. (Automatic Adjustment): With

the operator sitting in the seat.Lift the handle UP and release.The seat wi l l automatical lyadjust UP and then bleed off airpressure to the optimum airpressure for the weight of theoperator.

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B. (Manual Adjustment): The seatcan be raised or lowered byincreasing or decreasing the airpressure in the seat. Lift thehandle UP to increase the airpressure. Push the hand leDOWN to decrease the a i rpressure and lower the seat.

RD98K268

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

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

BD00B010

8. DAMPENING ADJUSTMENT LEVER:The dampening adjustment lever hasfour positions from soft to hard. Thefirst adjustment is with the small end ofthe adjustment lever pointing towardthe front of the seat, as shown. Theother th ree ad jus tments can beobtained by rotating the small end ofthe adjustment lever out away from theseat. Each of the adjustments has aslight detent. The suspension can bead jus ted to va r ious opera t i ngconditions.

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SEAT BELT

RD97F225

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

NOTE: Make sure the belt end andbuckle are securely fastened. Do notpull out the right-hand buckle.

RD97F225

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

M437

Inspection and Care1. Keep sharp edges and items that can cause damage, away from the belts.

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

3. Replace all parts that have damage or wear.

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

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

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

7. Keep seat belts clean and dry.

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

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

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

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Emergency Exit

BD02B0641. EMERGENCY EXIT

RD98K3011. PIN2. LATCH

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

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OPERATING INSTRUCTIONS

BEFORE STARTING THE ENGINE1. Do a daily walk around, visual

inspection of the machine. Checkfor such items as hoses rubbingagainst other components, oi lleaks, debris or trash buildup, loosebolts, damaged, or missing partsthat would effect the normal andsafe operation of the machine.Make any necessary correctionsbefore operating the machine.

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

3. Check that the machine fuel tank isfilled with clean fuel that has thespecification given in this manual.

CM112

RUN-IN PROCEDUREI t i s impor tan t t ha t the run- ininstruct ions for a new engine befollowed. Proper run-in will increaseengine power and service life. If theengine is not run-in properly, the pistonr ings and cy l i nde r bore can bedamaged.

During the first 100 hours of operation,operate the machine as follows:

1. Do not run the engine at idle speedfor long periods of time.

2. Operate the machine with normalloads as much as possible.

3. Monitor the engine instrumentsf r equen t l y du r ing opera t i on .Reduce throttle and/or load if thecoolant temperature exceeds safeoperating limits.

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

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

AFTER FIRST 100 HOURS OF OPERATIONHave your dealer do the After Delivery Check ...........................See After Delivery

Check in this manual

AFTER FIRST 100 HOURS OF OPERATIONChange the front and rear axle differential and planetary oil when the axles are new or repaired .................... See Axle Planetary

in this manualChange the transmission oil and filter when the transmission is new or repaired ...........................See Transmission Specifications

in this manual

Check all hose clamps, tighten as required.

SEAT BELTAlways securely fasten your seat belt before operating the machine. From time totime, carefully inspect the seat belts for worn areas and replace belts whenneeded.

SA121

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

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STARTING THE ENGINE

SC037

NOTE: If the weather is cold, if the machine has not been run for several weeks orif the engine oil filter has been replaced, see Priming the Turbocharger lines withOil in the manual.

NOTE: For cold weather starting and operating procedures see Cold WeatherStarting and Operating in Cold Weather in this manual.

1. Turn the master disconnect switchto The ON position.

2. Adjust the seat and fasten yourseat belt. Make sure you can pushthe foot pedals completely downwith your back against the seatcushion.

3. Make sure the transmissiondirection control is in NEUTRALand the parking brake is applied.

4. Turn the key switch to the ONposition and check the instrumentcluster.

NOTE: If the weather is cold, See ColdWeather Starting in this manual. If theengine has not been started for 3 ormore days or if the engine oil filter hasbeen replaced, See Priming theTurbocharger in this manual.

5. Turn the key switch to the STARTposition until the engine starts, thenrelease the key.

NOTE: If the engine starts and thenstops, do not engage the starter motoragain until the starter motor stopsturning. DO NOT operate the startermotor more than 30 seconds at onetime. Let the starter motor cool for atleast two minutes before you actuatethe starter motor again.

6. After the engine starts, check theinstruments to make sure theindications are correct. Run theengine at approximately 1200 RPMwith the transmission in neutralun t i l t he eng ine coo lan ttemperature is warm.

NOTE: Operate the machine atreduced loads until all systems reachoperating temperature. This is veryimportant during extremely coldweather operation to protect both theengine and hydraulic systems. SeeOperating in Cold Weather in thismanual.

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

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Priming the TurbochargerLines with Oil

BD02B057

1. Disconnect the wire from the fuelinjection pump solenoid.

2. Actuate the starter motor for about15 to 20 seconds until there is oil inthe lines.

3. Connect the wire to the fuelinjection pump solenoid.

Engine SpeedDo not operate the engine at idle speedfor long periods. This can cause a lowoperating temperature. A low operatingtemperature can cause acids anddeposits in the engine oil.

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STOPPING THE ENGINE AND PARKING THE MACHINE

SA038

1. Before you leave the machine,make sure the machine is parkedon level ground. The machine mustbe on level ground before you doscheduled maintenance.

IMPORTANT: If you must temporarilypark the machine on a hillside, put thefront of the machine toward the bottomof the hill. Make sure the machine isbehind an object that will not move.

2. Lower the loader to the ground.

3. Shift the transmission directioncontrol to NEUTRAL and apply theparking brake.

4. Run the engine at idle speed forthree to five minutes to decreasethe temperature of the engine andturbocharger.

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

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

7. Turn the master disconnect switchto the OFF position.

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

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Engine Coolant HeaterAn electric engine coolant heater isavailable for your machine. The heaterwill keep the engine coolant at a warmtempera tu re fo r improved co ldtemperature starting. The heater ratingis 1500 watts at 115 volts. Connect theheater to a 120 volt grounded outlet. Aheavy duty three wire extension cord isrequired.

BD02B079

The heater is installed in the heaterhousing on the front left side of theengine. Do the following to install theheater:

1. When engine is cool remove somecoolant from the engine.

2. Remove the threaded plug from thehousing.

3. Install the heater assembly.

4. Install the connector onto theheater assembly.

5. Refill engine coolant to properlevel.

BD02B0781. CONNECTOR2. HEATER ASSEMBLY

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Booster Battery Connections to Machine Jumper Stud and Ground (Jump Start)

SA006

M146B

NOTE: Two persons are required forthis procedure. Make sure the personmaking the connections is wearing faceprotection.

1. Open the side door.

2. Sit in the operators seat and havethe o the r pe rson make theconnections.

3. If using jumper batteries, makesure the jumper batteries are 24volts.

4. If using another machine for power,make sure the two machines, DONOT touch.

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

5. Connect the positive (+) jumpercable to the positive (+) batteryterminal on the jumper batteries orthe other machine. Connect theother end to the positive jumperstud.

6. Connect the negative (-) jumpercable to the negative (-) terminal onthe jumper batteries or the othermachine. Connect the other end ofthe negative (-) jumper cable to agood frame ground away from thebatteries.

7. Start the engine according to theinstructions in this manual. SeeStarting the Engine in this manual.

8. Have the other person disconnectthe jumper cables in the reverseorder that the jumper cables wereconnected in.

9. Close the side door.

BD02B0301. CONNECT POSITIVE JUMPER CABLE

HERE

WARNING: Batteries contain acid and explosive gas. Explosion canresult from sparks, flames or wrong cable connections. To connect thejumper cables correctly to the battery of this machine, see the correctmethod shown on this page. Failure to follow these instructions can causeserious injury or death.

WARNING: Battery explosion and/or damage to electrical componentscan result from improper connection of booster batteries or charger.Connect positive to positive and negative to negative. Externally, batteryacid can cause burns and blindness, and taken internally it is poison.

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MACHINE OPERATION

SA040

Before You Operate the MachineBefore you operate the machine each day or before shift test the machine forcorrect operation.

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

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

3. Fasten and adjust the seat belt.

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

5. Check the loader controls for correct operation.

6. Periodically test the parking brake neutral interlock function:A. Apply the parking brake by pushing down on the top side of the switch.B. Enable the pilot control levers by pushing down on the right side of the

switch.C. Push down and hold your foot against the brake pedal.D. Raise the loader bucket above the ground.E. Shift the transmission into first gear forward.F. Take your foot off the brake pedal.G. Increase the engine speed to 1/2 throttle. The machine must not move. If

the machine moves, see the service manual or see your authorized dealerand correct the problem. When the parking brake is applied, thetransmission is automatically shifted into Neutral.

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

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7. Test the parking brakes at a maximum of 250 hour intervals:A. Apply the parking brake by pushing down on the top of the switch.B. Shift the transmission into 3rd gear NEUTRAL.C. Press the program switch.D. Press the up count switch until the Display Center reads 011.E. Return the program/reset switch to the off (center) position.F. Press the up count switch until the 01 is shown in the Display Center.G. Push down and hold your foot against the brake pedal.H. Enable the pilot control levers by pushing down on the right hand side of

the pilot control switch.I. Raise the loader bucket above the ground.J. Shift the transmission to FORWARD and increase the engine speed to full

throttle. The machine must not move. If the machine does move, see theservice manual or see your dealer and correct the problem.

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

L. Shift the transmission to the NEUTRAL position.M.Press the reset switch momentarily to return to normal operation.

CM112

M142A

M122B

SB013

8. Release the parking brake.

9. Test the foot brakes for correct operation at a maximum of 250 hour intervals.A. Push down and hold your foot against the brake pedal.B. Raise the loader bucket just above the ground.

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

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

WARNING: Operate the machine with the door closed to provide properROPS protection and to properly utilize the heating, ventilating or coolingsystems.

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

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C. Place the transmission in the manual mode.D. Shift the transmission into 2nd gear forward.E. Release the parking brake.F. Increase the engine speed to full throttle. the machine must not nove. If the

machine does move, decrease engine speed to low idle. See your Servicemanual or your dealer for repairs.

G. Reset the parking brake.

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

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

The transmission can be operated in Automatic or manual mode.

Initial Machine Movement1. Hold the foot brake on.

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

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

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

5. Release the foot brake.

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

Manual Mode OperationTo put the transmission in the Manual mode press the bottom of the Autoshiftswitch.

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

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

Down-Shift Button, Manual ModeThe down-shift button is used to shift the transmission from 2nd gear to 1st. Thetransmission will shift back to 2nd gear if (1) the down-shift button is pressedagain or (2) if the transmission control lever is moved to NEUTRAL and then toFORWARD or REVERSE.

Automatic Mode OperationTo put the transmission in the automatic mode press the top of the Autoshiftswitch.

Shifting, Automatic ModeWhen the transmission is in the automatic mode, the transmission will start tomove in 1st gear (when the machine is stopped) and automatically up-shift untilthe gear selected has been reached. The transmission will also down-shiftautomatically as the speed decreases.

Down-shift Button, Automatic ModeThe down-shift button is used to shift down through the gears in single steps.Each time the switch is pressed down the transmission will shift down one gearrange until 1st gear is reached. Once the down-shift button has been presseddown the transmission is taken out of the automatic mode. The transmission willremain in the gear that was selected by the down-shift button. It will return to theautomatic mode when (1) the transmission control lever gear changes, or (2) thetransmission control lever is moved to NEUTRAL and then to FORWARD or toREVERSE.

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LOADER CONTROL LEVERS

Two Spool Valve - Two Control Levers

BC01E133

NOTE: This page shows the basicloader control lever positions. TheDetent Switch is in the OFF position.

See Loader Function Switches in thismanua l f o r RETURN-TO-DIG,BUCKET HEIGHT CONTROL andRETURN-TO-TRAVEL/FLOATswitches.

B1119A88J

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

automatically.

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1

1. DUMP 2. ROLLBACK 3. LOWER 4. RAISE

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Two Spool Valve - One Control Lever

BC01E131

NOTE: This page shows the basicloader control lever positions. TheDetent Switch for the loader functionsis in the OFF position.


B1119A88J

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

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5

1. DUMP 2. ROLLBACK 3. LOWER 4. RAISE

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Three Spool Valve - Three Control Levers

BC01E132



BS00C008

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

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2

1. CLAM OPEN (IF EQUIPPED 3. DUMP 5. LOWER2. CLAM CLOSED (IF EQUIPPED) 4. ROLLBACK 6. RAISE

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Three Spool Valve - Two Control Levers

BC01E130



B1120A88J

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

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1. DUMP 3. LOWER 5. CLAM OPEN2. ROLLBACK 4. RAISE 6. CLAM CLOSED

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Four Spool Valve - Two Control Levers

BC01E130

B1238A88J

B1239A88J

B1239A88J


See Next Page for RETURN-TO-DIG,BUCKET HEIGHT CONTROL andRETURN-TO-TRAVEL/FLOATswitches.

B1121A88J

IMPORTANT: If your machine isequipped with an auxiliary attachment,write the control lever positions next tothe numbers below.

HOLD: The loader arms, bucket,and auxiliary attachment will not

move when the control levers are inHOLD. When released, the controll evers w i l l r e tu rn to HOLDautomatically.

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LOADER FUNCTION SWITCHESPush down on the top of the detentswitch to engage all detents. Push onthe bottom of switch for the OFFposition.

The Return-To-Dig function is used tomove the loader bucket for another digcycle after you have dumped the load.

BD02B0551. DETENT ON/OFF SWITCH2. RETURN-TO-TRAVEL/ FLOAT SWITCH

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

BC01E1331. FLOAT2. ROLLBACK DETENT

BC01E1311. 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 loaderreaches the Return-To-Dig position. See Loader Adjustments in this manual forReturn-To-Dig Adjustment.

B1125A88J

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

BC01E1331. RAISE

BC01E1311. RAISE

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

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

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

BC01E1331. ROLLBACK DETENT2. FLOAT

BC01E1311. 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 loaderreaches the Return-To-Travel position. See for Return-To-Travel Adjustment inthis manual.

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

B1128A88J

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

BC01E1311. FLOAT

BC01E1331. FLOAT

LOADER CONTROLThe loader cont ro l l evers areconnected to a hydraulic accumulatorthrough a pressure reducing valve. Thepurpose of the reducing valve andaccumulator combination is to: (1)allow the operator to lower the loaderarms if the engine stops with the loaderarms raised, or (2) give the conrolsystem hydraulic presusre assistancewhen operating the machine at low idlespeed.

1. Start the engine.

2. Raise the loader bucket.3. Stop the engine.4. Move the lift arm control to

LOWER. The loader bucket mustlower to the ground. If the bucketdoes not lower to the ground, seethe Serv i ce Manua l f o r t h i smachine or see your dealer.

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BRAKE ACCUMULATORSTwo hydraul ic accumula tors areconnected in the brake system. Thepurpose of the accumulators is toprovide the brake modulating valvewith a positive supply of pressurizedhydraulic fluid.

Periodically test the accumulators forcorrect operation.

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

seconds.3. Stop the engine.

4. Without starting the engine, turnthe key to the ON position. Afterthe instrument cluster completesthe diagnostic check, confirm thatthe brake pressure light is not on.

5. Repeatedly pump the brake pedaluntil the brake pressure lamp isilluminated.

6. After the lamp illuminates, continueto pump the brake pedal and countthe number of full applications.

If you can complete six (6) full brakeapplications after the indicator lampil luminates, the accumulators areworking correct ly. I f you can notcomplete six (6) applications, see theService Manual for this machine or seeyour dealer.

DECLUTCHThe Declutch function is used to allowthe engine to increase speed andsupply the loader with more hydraulicoil for greater loader power and fastercontrol function. When the declutchswitch is in the ON position, and youpush down on the brake pedal, thetransmission is disengaged from thedrive wheels. Realease the brake pedalto engage the transmission power. Themach ine can ro l l f ree when thedeclutch switch is pushed. If required,use the brake to stop the machine. TheDeclutch Switch is adjustable. SeeDeclutch Adjustment on page 195 ofthis manual.

BD02B0551. DECLUTCH SWITCH

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RIDE CONTROLRide Control is a feature that increases the ride comfort of the WheelLoader over all types of terrain with either an empty or loaded bucket.Ride Control will reduce Fore and Aft pitching motion during travel toallow faster speeds in load and carry applications for increasedproductivity and operator comfort. It will also reduce shock loads tothe Wheel Loader for reduced tire flex, structural fatigue and

vibration, resulting in longer component life and reduced costs.

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

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

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

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

BUCKET LEVEL INDICATORThe bottom of the bucket is parallelwith the ground when the mark on thebucket linkage is even with the mark onthe cylinder rod eye.

B4065588T

BC00B094

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AUXILIARY HYDRAULIC CONNECTION (IF EQUIPPED)Your Wheel Loader is equipped with an Auxiliary Hydraulic System. A controllever on the console controls flow to the auxiliary hydraulic connection points onthe lift arms.

BD02B056 FAR1048

Auxiliary Hydraulic System Specifications921C Wheel LoaderMaximum System Pressure ................................................... 2 850 PSI (196 bar)Maximum Capacity at 2 100 Engine RPM .............................................. 106 GPM (401 L/Min)

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

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QUICK ATTACH COUPLER (If Equipped)

Hydraulic Control Lever on the CouplerConnecting Attachments to the Coupler

1. Put the bucket or other attachmenton a level surface.

2. Apply the parking brake. Stop theengine.

3. Open the coupler hydraulic cylinderlocking valve by rotating the redcontrol handle down to a verticalposition.

FAR1049

4. Start the engine.5. Push the auxiliary hydraulics

control lever forward to retract thelockig pins (1) and indicator tabs(2).

FAR10501. LOCKING PINS2. INDICATOR TABS

6. Close the coupler hydrauliccylinder loakcing valve by rotatingthe red control handle up to ahorizontal position..

FAR1050

7. Connect the attachment to thehydraulic couplers, if required.

FAR1055

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Disconnecting Attachments to the Coupler1. Lower the bucket or other

attachment onto a level surface.Tilt the bucket or attachment sothat it is flat on the surface.

2. Apply the parking brake. Stop theengine.

3. Disconect the attachment hydraulichoses from the auxiliary couplers, ifconnected.

4. Open the coupler hydraulic cylinderlocking valve by rotating the redcontrol handle down to a verticalposition..

FAR1056

5. Start the engine.6. Push the auxiliary hydraulics

control lever froward to retract thelocking pins and indicator tabs..

BD02B056AUXILIARY HYDRAULICS CONTROL LEVER

7. Lower the lift arms and back awayf rom the bucke t o r o the rattachment.

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COUPLER PIN ENGAGEMENT (IF EQUIPPED)Use the factory/field installed couplersystem to change attachments quickly.A control switch for the system islocated on the RH console.

To connect an attachment, position thefront coupler into the attachment, pushand hold on the top of the COUPLERswitch to RETRACT the PINS andrelease the switch (PINS ENGAGED).Make sure the Coup ler Pins areengaged before you use the machine.

BD02B055

Slide the locking plate towards the center of the switch, push down onthe top of the switch to RETRACT the pins. The switch lamp willilluminate when the pins are retracted. The switch will lock in the PINEXTENDED position after the bottom of the switch has been pressedand the PINS EXTENDED.

M781

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

BC00B099

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

BD02B055

Transport PositionTo adjust the rotating beacon lamp tothe TRANSPORT poisiton, rotate thelamp assembly and mounting bardownward unti l the spring loadeddetents hold the lamp assembly andmounting bar in the transport positionas shown in the following photo.

BD02B077

Operating PositionTo adjust the rotating beacon lamp tothe OPERATING poisiton, rotate thelamp assembly and mounting barupward until the spring loaded detentshold the lamp assembly and mountingbar in the operating position as shownin the following photo.

BD02B080

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LOADER OPERATING TIPSThis Wheel Loader, with standard equipment and authorized attachments, isintended to be used for above ground level digging and general earthmovingpurpose such as land leveling, truck loading, material rehandling and ditchcleaning. If the machine is to be used for lifting objects, make sure that themachine is properly equipped and follow the instructions and safety precautions inthis manual.

Leveling OperationAlways operate the machine in reversewhen leveling the surface.

Pushing OperationWhen pushing material do not set thebucket dumping angle more than 20degrees.

IMPORTANT: The bucket MUST NOTbe in the FULL DUMP position duringthe pushing operation.

Scraping OperationWhen scraping hard or frozen surfacesthe bucket must be level and flat to thesurface. Operate the machine at a slowspeed.

163L96

164L96

163L96

M465

WARNING: Impact Hazard - Bucket edge or teeth can catch on frozensurface or buried object during surface scraping operations. Beforeoperation inspect the area for objects the bucket can catch on and markthem. During operation make sure the bottom of the bucket is level with thesurface to be scraped. Operate the machine around the objects and atslow speed. Injury to the operator and damage to the machine can resultif these precautions are not followed.

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Transport and Carry OperationThe bucket must be in the roll backposition and the bottom of the bucketmust not be more than 305 to 457 mm(12 to 18 inches) off the surface.

165L96

SA041

Operating on a HillBefore you operate this machine on a hill, always put the transmission in a lowerrange and test the brakes. DO NOT let the machine move down a hill with thetransmission in NEUTRAL. The transmission is in NEUTRAL when the left brakepedal is pushed down and the left side of the declutch switch is pushed down.

Loader ControlThe loader cont ro l l evers areconnected to a hydraulic accumulatorthrough a pressure reducing valve. Thepurpose of the reducing valve andaccumulator combination is to: (1)allow the operator to lower the loaderarms if the engine stops with the loaderarms raised, or (2) give the controlsystem hydraulic pressure assistancewhen operating the machine at low idlespeed . To tes t accumu la to rperformance, perform steps 1 through5.


2. Raise the loader bucket.

3. Stop the engine.

4. Turn the key to RUN.

5. Move the lift arm control toLOWER. The loader bucket mustlower to the ground. If the bucketdoes not lower to the ground, seethe Serv i ce Manua l f o r t h i smachine or see your dealer.

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

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LIFTING THE MACHINEFour lifting attachment points, identifiedby the symbol below, are provided atthe front and rear of the machine.

139729A1

Always put the transport and servicelink in the LOCKED position beforelifting the machine (see Page 99).

Always use lifting equipment of anappropriate type and capacity to lift themach ine. re fe r to the P roduc tIdentification Number (P.I.N.) plate forthe weight of a basic machine. Theweight of your machine can vary fromthe basic machine weight dependingon the options and attachments that yuhave selected for your machine. Youmust weigh your machine to determineits exact weight.

.

BD00B12

.

BD00B017

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TOWING THE MACHINEIf your machine is disabled, you must make a judgment if the machine can bemoved 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 transporttrailer, park the trailer as close as possible to the machine (see Transporting theMachine in this manual).

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

NEVER TOW MACHINE FROM THE FRONT.

1. Attach a rigid drawbar to a pin inthe rear counterweight.

BD02B048

2. If the machine cannot be started torelease the parking brake, do thefollowing:A. Put blocks in front of and behind

each tire.B. Remove the Parking brake

cover (1).C. Loosen the lock nut (2).D. Turn the adjusting screw

counterc lockwise unt i l theparking brake is released (3).

3. If the machine is to be towed morethan 1/2 mile (0.8 km) you mustdisconnect the front and rear driveshafts.

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

300372A1

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TRANSPORTING THE MACHINE

SB042

46-76C

84-13A

You must know the rules or laws fortransportation and safety that are usedin each area that you will be in. Makesure that the truck and machine areequipped wi th the correct safetyequipment.

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

2. Be Careful, move the machineSLOWLY onto the trailer.

3. Lower the loader bucket onto thetrailer.

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

BD00B021

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

6. Make sure the transmission controlis in the NEUTRAL position andloader controls are in the HOLDposition.

7. Turn the battery master disconnectswitch to the OFF position.

8. Put blocks at the FRONT andREAR of each tire of the machine.

9. Use chains to fasten the machineto the trailer. See the Next Page fortie down locations of the machine.

10. Put a cover over the exhaust pipe. 11. Rotate the beacon to the

TRANSPORT pos i t i on . Seebeacon in this manual.

12. Measure from the ground to thehighest point of the machine. Youmust know the clearance height ofthe machine..

94F25TIE DOWN DECAL

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

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

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

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Transporting the Machine on a TrailerMachine Tie Down Locations

BD00B013CHAINS MUST BE SECURELY FASTENED TO THE TIE DOWN SLOT. OPTIONAL TIE DOWN LOCATION.

BD00B014CHAINS MUST BE SECURELY FASTENED TO THE TIE DOWN SLOT. OPTIONAL TIE DOWN LOCATION.

FAR1069CHAINS MUST BE SECURELY FASTENED. FRONT TIE DOWN LOCATION.

BK00D002CHAINS MUST BE SECURELY FASTENED AROUND LOADER FRAME. MIDDLE TIE DOWN LOCATION.

BD00B012CHAINS MUST BE SECURELY FASTENED TO TIE DOWN EYE (1) OR SLOTS (2). REAR TIE DOWN LOCATION.

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OPERATING IN COLD WEATHERCold weather conditions cause special problems. During these conditions yourmachine will require special start up, and warm up, and maintenance proceduresfor the best performance. Proper cold weather maintenance will extend theservice life of your machine.

1. BATTERIES/ELECTRICALSYSTEM - Clean the batteries andmake sure the batteries are at fullcharge.

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

Inspect the battery cables andterminals. Clean the terminals andapply electrical terminal sealers(see your dea ler ) to preven tcorrosion.

If you add water to the batteriesand the temperature is below 32°F(0°C), make sure you charge thebatteries or run the engine forapproximately two (2) hours. Thisprocedure wil l prevent batteryfreezing (see Batteries and BoosterBat te ry Connec t ions i n th i smanual.

Inspect the battery cables andterminals. Clean the terminals andapply electrical terminal sealer (seeyour dealer) to prevent corrosion.

2. LUBRICANTS - Make sure youfollow the recommended oil andfilter service for the engine and thehydraulic system as shown in thismanual. Use the correct viscosityoi l in each component for theambient temperatures the machineis operated in (see Lubrication inthis manual).

3. FUEL SYSTEM - Check with yourfuel supplier for the correct coldweather fuel. Engine power will bereduced if wax particles are in thefuel filters.

Check for water in the fuel system.Cold temperatures can causecondensation to form in the fueltank. Check the first stage fuel filterfor water. If no water is found,extend the interval (see Diesel FuelSystem in this manual).

4. COOLING SYSTEM - Check thecoolant mixture before you operatein cold temperatures. A mixture of50% ethylene glycol and 50%water mus t be used in th i smachine. This mixture is used if thelowest ambient temperature isabove -34°F (-37°C). If the ambienttemperature is lower, adjust themixture. It is recommended thatethylene glycol and water be usedin your machine al l year (SeeEngine Cooling System in thismanual).

5. COLD TEMPERATURE STARTINGAIDS See your dealer for extrastarting aids (see Cold WeatherStarting in this manual).

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6. MACHINE WARM-UP - Once theengine has started, run the engineat half throttle (1100 to 1300 RPM)for a minimum of 10 minutes underno load. This will help warm thehydraulic oil and the transmissionoil.

After engine warm-up, enable thepilot controls by pushing down onthe right hand side of the switch onthe instrument control panel. Applyand hold the foot brake, and cycleall hydraulic functions severalt imes. In severe cold weatherconditions, the hydraulic functionsmay be slow to respond. Cycling allthe hydraulic system functionssevera l t imes w i l l wa rm thehydraulic oil and the hydraulicsystem components.

The hydraulic steering can becomes low in severe co ld weatherconditions. Cycle the steering fromfull right to left a minimum of 3 to 5t imes befo re you d r i ve themachine.

NOTE: Make sure there is clearancearound the machine before steering themachine from right to left.

In severe cold weather conditionsthe brakes response can be slow.The use o f cor rec t o i l in thehydraulic/brake system is required.Even with the correct oil in thehydraulic/brake system the first fewtimes the brakes are actuated theremay be some delay before thebrakes are applied. The operatormust actuate the brake pedal aminimum of 8 to 10 times beforethe machine is moved.

When the mach ine has beencorrectly warmed up, apply the footb rake and ho ld , sh i f t t hetransmission to forward push thepark brake to the Off position andrelease the foot brake. Operate themachine in a clear safe area.Check the full operation of themachine. DO NOT operate themachine in third or fourth gear untilthe transmission oil and axle oilhave been warmed up and themachine moves freely.

IMPORTANT: DO NOT operate themachine in a closed in area.

IMPORTANT: DO NOT operate themachine on the road until thetransmission oil and axle oil have beencorrectly warmed up. Operate themachine in a clear safe area beforeroad operation.

7. If the machine has been left idlingin cold temperature, the engine willstay warm. But the hydraulic/brakeoil and the axle oil will not staywarm. The oil and components canbecome cold and s low brakefunction response time. If thisshould happen you MUST gothrough the complete machinewarm-up procedure.

8. The transmission is equipped withinternal protection that does notallow the transmission to engagebe low -12°C (10°F) . I f t hetransmission does not engagebelow these temperatures, allow 2to 4 minutes of running in neutral( th i s t ime w i l l var y w i thtemperature), then try again.

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OPERATING IN HOT WEATHERTo prevent damage to the machine, dothe following:

1. Keep the coolant at the correctlevel in the radiator.

2. Use the correct solution of ethyleneglycol and water in the coolingsystem.

3. Test the radiator cap before hotweather starts. Replace the cap asrequired. See your dealer.

4. Clean all dirt and debris from theradiator and engine area.

5. Check the condition of the drivebelts.

6. Use lubricants of the correctviscosity.

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NOTES

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WHEELS/TIRES/BALLAST

BALLASTIt is the recommendation of the CaseCorporation NOT to add Ballast to thetires of your machine.

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

WHEELS AND TIRES

SD020

84-113

SB134

Tire PressureDO NOT inf late the t i res more than the recommneded pressure. Forrecommended tire size air pressure, see Tire Pressure Chart in this manual.

WARNING: Exploding tires and/or rim parts can cause injury or death.Keep yourself and others out of the DANGER AREA. Stand on the treadside of the tire. Always use the correct air pressure and follow theinstructions in this manual for adding air or servicing the tires.

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

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

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B910410J

The above illustration show danger areas caused by exploding tires and/or rimparts. KEEP YOURSELF AND OTHERS OUT OF THESE DANGER AREAS.

The next page shows the correct methods that you MUST use when adding air orservicing a tire.

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Adding Air to the TiresThis procedure is only for adding air tothe tire. If the tire has lost most or all ofthe air, do the following.

1. Before you add air, have the wheelcorrectly installed on the machineor put the wheel in a restrainingdevice (tire inflation cage).

B790490R

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

3. Stand BEHIND the tread of the tireand make sure ALL persons areaway from the side of the t irebefore you start to add air.

B4039288T

4. Inflate the tire to the recommendedair pressure. DO NOT inflate thetire more than the recommendedpressure given on the followingpage.

Tire or Rim ServiceAlways have a qualified tire mechanicservice the tires and r ims for thismachine. It is recommended that youhave this mechanic inflate the tires. Toprevent accidents, use a restrainingdevice (tire inflation cage), correctequipment, and correct procedure.Explosive separation of the tire (singlepiece rim) or the tire and/or rim parts(multi-piece rim) can cause seriousinjury or death.

Tire Tread DirectionWhen the tire is installed on the wheelmake sure the t i re tread is in thedirection shown.

B770164R

FORWARD

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Wheel Nut TorqueCheck the torque of the wheel nutsafter every 20 hours of operation untilthe wheel nuts stay tight, if the machineis new or if a wheel has been removedand installed.

If a wheel is removed from the machineand installed, tighten the nuts using thesequence shown. First tighten the nutsto 203 Nm (150 pound-feet), then to afinal torque of 515 to 569 Nm (380 to420 pound-feet) in the same sequence.

B910920J

Tire Pressure Chart

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

24

TIRE PLY TREAD TIRE PRESSURE

SIZE RATING TYPE kPa (PSI) (bar)

26.5 X 25 F & R 20 L2 345 50 3.4

26.5 X 25 F & R 20 L3 345 50 3.4

26.5 X 25 F & R 20 L4 380 55 3.8

26.5 X 25 FRONT 20 L5 380 55 3.8

REAR 20 L5 276 40 2.8

26.5 R 25 FRONT XHA TL* 414 60 4.1

REAR XHA TL* 207 30 2.1

26.5 R 25 FRONT XRD IA 414 60 4.1

REAR XRD IA 207 30 2.1

750/65R25 FRONT XLD L3 414 60 4.1

REAR XLD L3 207 30 2.1

26.5 R 25 FRONT VMT L3 414 60 4.1

REAR VMT L3 310 45 3.1

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LUBRICATION/FILTERS/FLUIDS

GENERAL SAFETY BEFORE YOU SERVICE

SC021

SA044

Read the safety decals and informationdecals on the machine. Read theoperators manual and safety manual.Understand the operat ion of themachine before you start servicing

B801147T

Before you service the machine, put aDo Not Operate tag on the instrumentpanel. One Do Not Operate tag isincluded with your machine. Additionaltags are available from your dealer.

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

B770996R

B901248J

WARNING: Improper service or repair can cause injury or death. If you donot understand the service procedures for this machine, see your dealeror the service manual for this machine.

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

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

B830752T

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

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

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

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

TRANSPORT/SERVICE LINK

SA069

BK00D004LOCKED POSITION

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

BK00D003OPERATING POSITION

After servicing and before you movethe machine, return the Transport/Serv ice l i nk in the OPERATINGposition.

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

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ENGINE HOURMETERService your machine at the intervals and locations given in the Lubrication/Maintenance Chart. When you service your machine, use only high qualitylubricants.

RD97F198

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

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FLUIDS AND LUBRICANTSEngine Crankcase

Oil Capacity - with filter change .............................................. 36.9 litres (39 U.S. Quarts)Specifications............................................See Engine Lubrication in this manual

Cooling SystemCapacity ........................................................................ 57 litres (60 U.S. Quarts)Specifications.............................................. 50% water and 50% Ethylene Glycol

Fuel TankCapacity .................................................................... 394 litres (104 U.S. GallonsSpecifications...........................................See Diesel Fuel System in this manual

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

TransmissionRefill Capacity - with filter change ...............................27.4 litres (29 U.S. Quarts)Total System Capacity....................................................46 litres (49 U.S. Quarts)Specifications...............................................................Case No. 1 SAE 15W - 40Capacity

(ZF Axle)Front Axle Capacity .............................................45.4 litres (48.0 U.S. Quarts)Rear Axle Capacity ..............................................48.3 litres (51.0 U.S. Quarts)

Specifications...................................................................... Case Transaxle FluidGrease Fittings

Quantity..............................................................................................As RequiredSpecifications............................................................. Case Molydisulfide Grease

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LUBRICATION/MAINTENANCE CHART

NOTE 1:Service the air filter elements if the air filter warning lamp illuminates.NOTE 2:Service the hydraulic filters if the hydraulic filter lamp illuminates.NOTE 3:Every 10 hours of operation or once each day, whichever comes first.NOTE 4:Check the dearation tank coolant level if the cooling level warning lamp illuminates.NOTE 5:Service transmission filter if the transmission filter restriction warning lamp illuminates or

every 1000 hours (whichever comes first).❉ - As Needed

PAGE

NO.

SERVICE POINTS

NO.OF

POINTS

FREQUENCY IN HOURS

CHECK

CLEAN

LUBRICATE

DRAIN

WATER

156 Air Cleaner (See Note 1) ❉

167 Hydraulic Filter (See Note 2 ❉

203 Alternator Drive Belt ❉

204 Air Conditioning Compressor Belt Tension (If Equipped) ❉

173 Transmission Filter (See Note 5) ❉

153 Engine Oil Level (See Note 3) 10

174 Transmission Oil Level (engine running oil warm) 50

161 Dearation Tank Coolant Level (See Note 4) 50

146 Rear Axle Trunnion Pivots 2 50

174 Hydraulic Reservoir Fluid Level 50

146 Front Drive Shaft Support Bearing 50

146 Bucket Pivots 3 50

146 Steering Cylinder Pivots - Rod End 2 100

146 Steering Cylinder Pivots - Closed End 2 100

146 Loader Lift Arm and Cylinder Pivots 10 100

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NOTE 1:Use Case Filter A77659NOTE 2:Reduce to 250 hours or less if Case No. 1 Engine Oil is not used.

PAGE

NO. SERVICE POINTS

N‘O.OF

POINTS

FREQUENCY IN HOURS

CHECK

CHANGE

REPLACE

LUBRICATE

CLEAN

DRAIN

WATER

146 Center Drive Shaft Slip Joint 250

146 Rear Drive Shaft Slip Joint 250

204 Air Conditioning Compressor Belt Tension (If Equipped) 250

203 Alternator Drive Belt Tension 250

133 Tire Condition and Air Pressure 4 250

208 Battery Fluid Level 2 250

161 Engine Cooling System Filter (See Note 1) 250

179 Cab Air Filter (If Equipped) 250

165 Fuel Filter 250

200 ROPS and Seat Belt Mounting Bolts 500

165 Fuel Tank 500

154 Engine Oil (See Note 2) 500

154 Engine Oil Filter(See Note 2) 500

168 Hydraulic Filters 1000

174 Transmission Breather 1000

174 Transmission Oil 1000

186 Front Axle Differential and Planetary Oil 1000

147 Upper and Lower Chassis Pivots 2 1000

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

NOTE 2:Contact your dealer.NOTE 3:Or when ambient operating temperatures require.SM - See Service Manual.

PAGE

NO. SERVICE POINTS

N‘O.OF

POINTS

FREQUENCY IN HOURS

CHECK

CHANGE

REPLACE

ADJUST

CLEAN

187 Rear Axle Differential Oil and Planetary Oil 1000

SM Turbocharger Mounting Bolt Torque 2000

169 Hydraulic Oil (See Note 3) 2000

162 Engine Coolant (See Note 1) 2000

157 Air Filter Elements 2000

SM Engine Injectors (See Note 2) 6000 6000

SM Fuel Pump (See Note 2) 6000 6000

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ACCESS DOORS

BD02B034 BD02B035

BD02B060

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GREASE FITTINGS - 50 HOURSUse Case Molydisulfide Grease

B910922J1. Bucket pivot points ....................................................................................... 32. Rear axle trunnion (remote fitting) .............................................................................. 23. Front drive shaft support bearing.................................................................... 1


B910922J1. Steering cylinder - closed end and rod end ............................. 4 (2 each side)2. Loader pivot points - remote grease fittings ................................................. 43. Loader pivot points ................................................................................................. 6

11

12

23

12 3 3

2 3

3321

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BS02B1771. Center drive shaft slip joint ........................................................................... 12. Rear drive shaft slip joint .............................................................................................. 1


BS02B1771. Upper and lower chassis pivot ............................................................ 2 (one each pivot)

2 1

1

1

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148

FLUID LEVELS

10 Hours

BD02B0301. ENGINE OIL

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

RD98K3172. RADIATOR COOLANT LEVEL

ETHYLENE GLYCOL AND WATER

B910922J

1

2

1

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50 Hours

BD02B076HYDRAULIC RESERVOIRMS-1209 HY-TRAN ULTRA

RD97F167TRANSMISSION

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

B910922J

BD02B067DEAERATION TANK

ETHYLENE GLYCOL AND WATER

BD02B063DEAERATION TANK

1. SIGHT GLASSWhenever the hood is opened tope form ma in tenance, check thecoolalnt level in the deaeration tank.The coolant must be above the level ofthe sight glass (1) when the engine isstopped and cool. If coolant is belowthe sight glass, remove the cap and fillto the neck with the specified coolant.

3 4

3 4

5

5

1

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250 Hours

BD02B037BATTERIES

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

BS02B177

1

1

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ENGINE LUBRICATION

Engine Oil SelectionCase No. 1 Engine Oil is recommended for use in your Case Engine. CaseEngine Oil will lubricate your engine correctly under all operating conditions.If Case Multi-Viscosity Engine Oil is notavailable, use only oil meeting APIengine oi l service category CH-4(preferred) or CG-4

RH99K130 BP97H064

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

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

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Oil Viscosity/Temperature Ranges

BS99M162

NOTE: Use of an engine oil pan heater or an engine coolant heater may berequired 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 instarting the engine and in providing sufficient oil flow at ambient temperaturesbelow - 5°C (23°F). The continuous use of low viscosity oils can decrease enginelife due to wear. See the chart above for the correct oil for ambient temperatures.

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Engine Service SpecificationsOil Level check interval ................................ Every 10 hours of operation or each

day, whichever occurs first.Oil Change interval (See Note) ................................ Every 500 hours of operationOil filter change interval (See Note) ......................... Every 500 hours of operation

or once a year whichever occurs first.Oil type ....................................................... Case No. 1 Engine Oil (SAE 15W-40)Oil Capacity - with filter change ...................................................... 36.9 litres39 (U.S. Quarts)

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

Engine Oil LevelTo check the engine oil level put themachine on a level surface and stopthe engine. Remove engine oil dipstickand wipe clean with a cloth. Replacedipstick in tube and push the engine oildipstick completely DOWN and thenremove. If the oil level is below theADD mark, add oil to raise the oil levelto the FULL mark. It takes 4 quarts(3.78 litres) to raise the oil level fromthe ADD mark to the FULL mark.

BD02B030

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Engine Oil Change and Filter ReplacementChange the engine oil and replace thefilter after every 500 hours of operationor once a year whichever occurs first.

NOTE: Reduce oil and filter changeintervals to 250 hours if Case No. 1Engine Oil is not used. See EngineService Specification in this manual.

NOTE: For more complete removal offoreign material, change the engine oilwhile the engine is still warm fromoperation.

IMPORTANT: You must shorten the oilchange interval if you use diesel fuelwith a sulphur content of more than0.5%.

Change the engine oil more frequentlywhen the engine operating conditionsare severe (frequent stopping ands tar t ing and h igh or low eng inetemperatures).

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

2. Remove the engine oil drain plug.

3. Open the rear engine accessdoors.

BD02B061

4. Turn the oil filter counterclockwiseto remove. Discard the oil filter.

5. Use a clean cloth and wipe thesealing surface of the oil filter baseto remove all dirt.

6. Apply a thin layer of clean greaseor oil to the gasket of the new oilfilter.

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

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

8. Install the drain plug.

9. See Engine Lubrication in thismanual for the correct type andquantity of oil. Put new oil into theengine.

BD02B062

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BD02B057

10. Fill the turbocharger oil lines withoil.

A. Disconnect the wire (Shown)f r om the in jec t i on pumpsolenoid. This will prevent theengine from starting.

B. Turn the key switch to theSTART and actuate the starterfor 10 to 30 seconds.

C. Connect the wire to the injectionpump solenoid.

11. Start the engine and run at idlespeed. Check the engine oil filterfor leaks. After two minutes, stopthe engine, wait for 2 or 3 minutes,and check the engine oil level withthe dipstick.

12. Close the engine access doors.

Systemgard Lubrication Analysis ProgramThe normal engine oil change intervalis every 500 hours of operation or oncea year wh ichever occurs f i r s t .Operating conditions, quality of theengine oil and sulphur content of thefuel can change this interval. It isrecommended to use the SystemgardLubrication Analysis Program. Seeyour dealer.

NOTE: Reduce oil and filter changeintervals to 250 hours if Case No. 1Engine Oil is not used. See EngineService Specification in this manual.

CM107

CM115

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

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

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AIR FILTER SYSTEM

Service SpecificationsAir cleaner cap interval .............................................................................. As requiredAir filter element service intervalPrimary (Outer) Element ......Service the element if the air filter indicator lamp

illuminates. Replace the element after threewashings. Also, replace the element after 2000

hours of operation or each year, whicheveroccurs first.

Secondary (Inner) Element ............ Replace the element after the primary (outer)element has been cleaned three times, or after

the primary element has been cleaned orreplaced and the air filter indicator lamp is still

illuminated with the engine running. Also,replace the element every 2000 hours or each

year, whichever occurs first.

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

Cap for the Air CleanerThis cap removes coarse particles fromthe air entering the air intake pipe.

RD97F158

Wear face protection and clean thedus t and d i r t f rom the cap w i thcompressed a ir. To c lean oi l andgrease from the cap, wash the cap inhot water with a smal l amount ofdetergent.

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Primary (Outer) Element1. Open the RIGHT engine access

door. Lift the spring clamps andremove the end cover.

NOTE: If there is a large amount ofdust inside the end cover, checkaspirator check valve for properoperation

RD97D078

2. Carefully remove the primary(outer) element.

RD97D079

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

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

5. Install the end cover and push thespr ing clamps into the lockedposition.

6. Close the access door.

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

Secondary (Inner) Element

1. Remove the primary (outer)element.

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

RD97D080

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

RD97D081

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

5. Install the primary (outer) elementand end cover.

NOTE: Make sure the end cover is inplace and each spring clamp is closedtight.

6. Close the access door.

CM115


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Cleaning the ElementCheck the dirty element for damageand check the rubber seal on the end.Push the rubber seal with your finger. Ifthe rubber seal feels hard and does notmove back to original shape, discardthe element.

1. Wear face protection and removethe loose dirt with compressed aira t 30 ps i ( 207 kPa , 2 .1 ba r )maximum. Hold the nozzle at least1 inch (25 mm) from the element.

777L94

2. Mix two tablespoons of D1400detergent (Case Part NumberA40910) with two gallons (7.6litres) of water, one cup for 16gallons (60 litres) water.

3. Soak the element in the soapsolution for 15 to 20 minutes andthen move the element up anddown rapidly to loosen as much dirtas possible.

780L94

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

778L94

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

6. Use a light and inspect the elementfor holes or splits in the pleats.Check for damage to the metalparts and rubber gasket. Replacethe element if damaged.

779L94

NOTE: If the element is not to be usedfor some time, cover the element withpaper for storage.

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ENGINE COOLING SYSTEM

Service SpecificationsCooling System Capacity .................................................57 litres (60 U.S. Quarts)Cooling system drain, flush, and refill interval ....... Every 2000 hours of operation

or each year, whichever occurs first.Cooling system filter replacement interval .............. Every 250 hours of operation

with Case filter A77659, every time youdrain, flush, and refill the cooling system.

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

ThermostatStarts to open ................................................................................... 82°C (180°F)Completely open ....................................................................... 94°C (94°C202°F)Radiator cap ........................................................... 103.4 kPa, 1 bar (15 psi)

Coolant MixtureA mixture of 50% Ethylene Glycol and 50% water must be used in this machine.This mixture is used if the lowest ambient temperature is above -37°C (-34°F). Ifthe ambient temperature is lower, adjust the mixture to 60% Ethylene Glycol and40% water. It is recommended that Ethylene Glycol and water be used in yourmachine all year.

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

SA023

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

Scalding can result from fast removal of deaeration tank cap. Check and service engine cooling system according to maintenanceinstructions.

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Radiator Fluid LevelThe coolant fluid level is monitored atthe instrument cluster. When thecoolant level indicator illuminates, addcoolant to the deaeration tank asrequired.

RD98K316

NOTE: Cooling System is underpressure. Before adding coolant, allowradiator to cool and remove radiatorcap SLOWLY.

BD02B067

Replacing the Coolant FilterReplace the Coolant Filter every 250hours of operation. Drain and flush theEngine Cooling System every 2000hours. Replace the Coolant Filter afterevery draining and flushing of theEngine Cooling System.

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

RD97F1421. SHUTOFF VALVE SHOWN IN THE ON

POSITION

2. Turn the coolant filtercounterclockwise to remove the oldfilter. Discard the filter.

3. Use a clean cloth and clean thecoolant filter mounting area on theengine.

4. Apply a thin layer of clean greaseor oil to the gasket of the newcoolant filter.

5. Turn the new coolant filterclockwise until the gasket comes incontact with the filter head. Tightenthe coolant filter 1/2 to 3/4 of a turnby hand.

IMPORTANT: Do not use a filter strapwrench to install the coolant filter.When the coolant filter is too tight youcan cause damage to the gasket andcoolant filter.

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

1

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Cleaning the Cooling SystemDrain, flush, and replace the enginecoolant every 2000 hours of operationor each year, whichever occurs first.Clean the system and replace thecoolant if the coolant becomes dirty orhas the color of rust.

DO NOT remove the deaeration tankcap if the coolant is hot.

1. Open the cooling system drainvalve and remove the deaerationtank cap. The drain valve is locatedat the lower left steel tube betweenthe engine and the radiator.

2. After all coolant is removed. Closethe drain valve.

3. Add cleaning solution to the coolingsystem and fill the cooling systemwi th c lean wa ter. Fo l low thed i r ec t i ons i nc luded w i th thecleaning solution.

4. After you drain the cleaningsolution flush with clean water anddrain the water.

5. Replace the coolant filter with anA77659 coolant filter.

6. Put a 50% mixture of EthyleneGlycol and water in the deaerationtank. See Coolant Mixture in thismanual.

7. Start the engine and run at idlespeed unt i l t he eng ine i s a toperating temperature. Check theinstrument cluster monitor, if themonitor illuminates. Add coolant asrequired.

8. Install the deaeration tank cap, ifremoved.

Cleaning the Screens and Coolers1. Clean the screens and coolers as

necessary.2. Use a pressure washer to clean the

screens from the radiator rear.

IMPORTANT: Be careful not to bend ordamage the fins during cleaning. DONOT exceed 6890kPa (1000 PSI)nozzle pressure when cleaning.

BD02B044

3. Open the left and right hand sidedoors to clean the front side of theradiator, back/front side of thehydraulic/transmission oil cooler,back/front side of the air to aircooler and back/front side of thefuel cooler.

BD02B045

NOTE: After cleaning the coolers washall trash from the top of the fuel tank.

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DIESEL FUEL SYSTEM

Service SpecificationsFuel Tank Capacity ................................................... 394 litres (104 U.S. Gallons)Interval for draining water from the fuel filter ....................... 50 hours of operationFuel filter replacement interval .......................................... 250 hours of operation

or once each year, whichever occurs firstAdjust fuel injector ....................................................... 1500 hours of operation or

or once each year, whichever occurs firstClean and calibrate fuel injectors and fuel pump ........ 6000 hours of operation or

every 3 years, whichever occurs first.

Fuel ConditionerDiesel fuel conditioner is available fromyour dealer. Follow the instructions onthe can.

The conditioner will:

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

2. Disperse insoluble gummydeposits that can form in the fuelsystem.

3. Separate moisture from the fuel.

4. Stabilize the fuel in storage.

SA022

M139C

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

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

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Diesel FuelUse No. 2 diesel fuel in the engine ofthis machine. The use of other fuelscan cause the loss of engine powerand high fuel consumption.

In very cold temperatures, a mixture ofNo . 1 and No . 2 d iese l f ue ls i stemporar i l y pe rm i t ted . See thefollowing Note.

NOTE: See your fuel dealer for winterfuel requirements in your area. If thetemperature of the fuel lowers belowthe cloud point (wax appearance point),wax crystals in the fuel will cause theengine to lose power or not start.

The diesel fuel used in this machinemust meet the specifications in thechart below or Specification D975-81 ofthe American Society for Testing andMaterials.

Fuel StorageIf you keep fuel in storage for a periodof time, you can get foreign material orwater in the fuel storage tank. Manyengine problems are caused by waterin the fuel.

Keep the fuel storage tank outside andkeep the fuel as cool as possible.Remove water f rom the s to ragecontainer at regular periods of time.

Fill the fuel tank at the end of the day toprevent condensation in the fuel tank.

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

Specifications for Acceptable No. 2 Diesel FuelAPI Gravity, Minimum API Gravity, Minimum .................................................... 34Flash Point, Minimum ...................................................................... 60°C (140°F)Cloud Point (wax appearance point), Maximum ..... -20°C (-5°F) See Note AbovePour Point, Maximum ............................................ -26°C (-15°F) See Note AboveDistillation Temperature, 90% Point ........................... 282 to 338°C (540 to 640F)Viscosity, at 38°C (100°F)

Centistokes .......................................................................................... 2.0 to 4.3Cetane Number, Minimum ...................... 43 (45 to 55 for winter or high altitudes)Water and Sediment, by Volume, Maximum ............................................... 0.05%

SA022

M139C

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

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

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Removing Water and Sediment from the Fuel SystemDrain the water for the fuel filter afterevery 50 hours of operation. Drain thewater and sediment from the fuel tankafter every 500 hours of operation.

1. Turn the drain valve on the fuelfilter counterclockwise 2 or 3 turnsand drain the water from the fuelfilter.

BD02B039

2. Close the drain valve.

3. Use a large enough container anddrain water and sediment from thefuel tank. Dispose of water andsediment properly.

B4029591T

Fuel FilterReplace the fuel filter after every 250hours of operation.

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

BD02B039

2. Turn the filter counterclockwiseand remove the filter. Discard thefilter.

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

4. Install the filter. Use your hands totighten the filter 1/2 to 3/4 turn afterthe filter makes contact with thefilter head.

IMPORTANT: Do not use a filterwrench when installing a new filter.

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HYDRAULIC/BRAKE SYSTEM

Service SpecificationsHydraulic/Brake System Fluid ChartHydraulic Reservoir Refill Capacity.............................121 Litres (128 U.S. Quarts)Total System Capacity.................................................242 Litres (256 U.S. Quarts)Type of Fluid ................................................................... MS-1209, Hy-Tran Ultra®

Hydraulic Reservoir Fluid Level Check Interval ..............................Every 50 HoursFilter Replacement Interval ................................Every 1000 Hours of Operation or

if the Hydraulic Filter WarningLamp Illuminates

Suction Screen Cleaning Interval................................................Every 2000 HoursHydraulic Fluid Change Interval ..................................................Every 2000 Hours

or once each year, whichever occurs first.

SA047

WARNING: Pressurized hydraulic system. Before you replace thehydraulic filter or service the hydraulic system, wear face protection andslowly loosen the hydraulic reservoir fill cap to relieve the air pressure. Ifyou do not follow these instructions, you can be injured.

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Hydraulic Oil Level

BD02B0761. SIGHT GAUGE2. FILLER CAP

Check the oil level of the hydraulicreservo i r eve ry 50 hours o foperation.

To check the oil level in the hydraulicreservoir do the following:

1. Park the machine on a levelsur face and lower the loaderbucket to the ground. Apply theparking brake.

2. Stop the engine.

3. Check the oil level in the sightgauge. If the oil is cold, the level iscorrect when you see oil in thelower 1/4 of the sight gauge. If theoil is at operating temperature,50°C (120°F), the oil level must bein the upper 1/4 of the sight gauge.DO NOT over fill. See HydraulicSystem in this manual for thecorrect oil.

To add oil to the hydraulic reservoir dothe following:

1. Clean the area around the fillercap.

2. Slowly loosen the filler cap on thehydraul ic reservoi r. Th is wi l lrelease the air pressure in thehydraulic reservoir. Remove thef i l l e r cap f rom the hyd rau l i creservoir.

3. After oil has been added to thehydraulic reservoir, inspect the sealon the filler cap. Replace the sealas required.

4. Install the filler cap and handtighten.

Hydraulic FiltersReplace the two hydraulic filters every1000 hours of operat ion or i f thehydraulic oil filter LAMP illuminates.

Hydraulic Filter TestTo check the condition of the hydraulicfilters do the following.

1. Start the engine. If the hydraulic oilis not at operating temperature orapproximately 50°C (120°F) do thefollowing.

A. Hold the loader control lever inthe ROLLBACK position until theloader bucket is against thestops, cont inue to hold thecontrol lever in the ROLLBACKposition for 15 seconds.

B. After 15 seconds, move thecont ro l l ever to the HOLDposition.

C. Repeat steps a and b until theside of the hydraulic reservoirfeels very warm.

1

2

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2. Increase the engine speed to fullthrottle. If the indicator lamp for thehydraulic oil filters i lluminates,replace both filters.

RD98K3171. HYDRAULIC OIL FILTER INDICATOR

LAMP

Hydraulic Filter ReplacementIMPORTANT: Always replace bothhydraulic filters at the same time.

1. Park the machine on a levelsurface. Lower the loader bucket tothe ground and stop the engine.Apply the parking brake.

2. Slowly loosen the filler cap on thehydraul ic reservoi r. Th is wi l lrelease the air pressure in thehydraulic reservoir.

3. Remove the access cover.

4. Use a strap wrench to remove theo ld f i l t e r s . Tu rn the f i l te rscounterclockwise to remove.

BD02B075

5. Lubricate the gasket on each newfilter with MS-1209, Hy-Tran Ultra®

fluid. Turn the filter clockwise untilthe filter contacts the head of thefilter assembly. Continue to tightenthe filter 1/2 to 3/4 turn by hand.

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

6. Tighten the filler cap.

7. Start and run the engine atapproximately 1000 rpm. Check foroil leaks around each filter.

8. Stop the engine and check thehydraul ic o i l level. Add oi l asrequired. See Hydraulic System inth is manua l fo r co r rec tspecifications.

9. Install the access cover.

SA047

SA047

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Hydraulic/Brake Oil Change

64L951. FILLER CAP 4. DRAIN VALVE2. SUCTION SCREEN 5. ACCESS COVER3. RESERVOIR FILTER 6. SEAL

1

2

3

4

5

6

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Change the hydraulic/brake oil every2000 hours of operation or one timeeach year, or when ambient operatingtemperatures require, whicheveroccurs f i rs t . When chang ing thehydraulic oil also replace both hydraulicoil filters and clean the suction screen.

1. Make sure the hydraulic oil is atoperating temperature.

2. Park the machine on a levelsurface. Lower the loader bucket tothe ground and apply the parkingbrake.

3. Stop the engine. Put a DO NOTOPERATE tag on the steeringwheel.

4. Make sure the accumulators arecompletely discharged. Push downand re lease one of the brakepedals a minimum of 30 times.

5. Clean the area around the filler capand access cover. Slowly removethe filler cap of the reservoir. Thiswill remove the air pressure fromthe reservoir.

6. Remove the plug from the drainvalve and install a hose on thedrain valve.

7. Put the other end of the drain hoseinto a container that will hold 32gallons (121 litres).

8. Open the drain valve.

9. Replace the hydraulic oil filters.

10. Remove the access cover from thehydraulic reservoir and remove thesuction screen. Turn the suctionsc reen coun terc lockw ise toremove.

11. Clean the inside of the hydraulicreservoir with clean cloths.

12. Clean the suction screen in solventand dry the suction screen withcompressed air. Install the suctionscreen.

13. Turn the reservoir drain valve toOFF. Remove the drain hose andinstall the plug in the drain valve.

14. Install the access cover with a newseal and tighten the mounting bolt.

15. See Hydraulic System in thismanual for the correct type andquantity of hydraulic oil. Put new oilinto the reservoir.

16. Install the reservoir filler cap.

17. Start the engine and run at 1000rpm. Check for oil leaks around thefilters, access cover and the drainplug. When the balance pressurewarning buzzer stops makingnoise, run the engine at 1500 rpm.

18. Bleed the brake system to removeold oil from the system. Remove aminimum of 1 Liter of oil from eachbleed screw to make sure all old oilis removed from the system (SeeBleeding the brake system in thismanual).

19. Operate the loader controls severaltimes to remove any air in the lines.

20. Lower the loader bucket to theground and stop the engine. Checkthe hydraulic oil level.

21. Add oil as required.

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Bleeding the Brake System

1. Park the machine on a levelsu r face . B lock the whee ls .Completely raise the loader frame,connec t accep tab le l i f t i ngequipment to the loader arms thatwill hold the loader arms in place.Apply the parking brake. Stop theengine. Put a DO NOT OPERATEtag on the steering wheel.

2. Loosen the bleed screw on theaccumulator charge valve a smallamount. If possible attach a hoseto the bleed screw to help preventoil spillage.

BD00C0051. BLEED SCREW ON ACCUMULATOR

CHARGE VALVE

3. Start and run the engine at idle.

NOTE: Oil will begin to flow from thebleed screw when engine is started.

4. When there are no air bubbles inthe oil that is flowing from the bleedscrew, close the bleed screw.

5. Continue to run the engine at idleuntil the low brake pressure lamp isno longer i lluminated and bothaccumulators are fully charged.

6. Stop the engine.

7. Do procedure A or B to fullydischarge the two accumulatorpistons.A. Push down and then release the

brake pedal 15 to 20 times untilthere is no hydraulic pressure inthe brake system.

B. See Step 9 of this procedure forlocation of the bleed screw onthe axle. Loosen the b leedscrew on the front axle, pushdown on the brake pedal untilthere is no forced flow from theopen bleed screw. Tighten thebleed screw.

8. Start and run the engine at idle.Apply the parking brake.

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9. Open the left bleed screw on thefront axle.

BD00B0271. BLEED SCREW ON FRONT AXLE

10. Slowly push down on the brakepedal until oil begins to flow fromthe bleed screw. Hold the brakepedal in position until 1 liter of oilhas been bled and/or there is no airbubbles in the oil flowing from thebleed screw. Close the bleed screwand release the brake pedal.

NOTE: DO NOT push the brake pedalfarther than necessary to cause the oilto flow from the bleed screw. Thefarther you push the pedal the higherthe pressure in the brake circuit. Highpressure can cause injury or damage.

11. Open the right bleed screw on thefront axle. Repeat Step 10

12. Start and run the engine at idle for2 minute.

13. Stop the engine. Open the leftbleed screw on the rear axle.Repeat Step 10.

14. Open the right bleed screw on therear axle. Repeat Step 10.

15. Check the brake system for correctoperation. If the brake system isnot operating properly see theService Manual or your CaseDealer.

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TRANSMISSION

Service SpecificationsTransmission refill capacity with filters ........................ 27.4 litres (29 U.S. Quarts)Total system capacity ..................................................... 46 litres (49 U.S. Quarts)Type of oil ................................................. Case No. 1 Engine Oil (SAE 15W - 40)Oil lever check interval ............................................................................ 50 hoursFilter replacement interval ............................ After the first 100 hours of operation

and then every 1000 hours there after.Breather cleaning interval ................................................................... 1000 hoursOil change interval ................................................. After the first 100 hours of operation

and then every 1000 hours there after.

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

CM107

IMPORTANT: Change the transmission oil and replace the filter after the first 100hours of operation.


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Transmission Oil LevelSee this page for the two methods tocheck the transmission oil level.

B910924J

RD97F1671. SIGHT GAUGE

Cold Oil Level CheckBefore you start the engine, check thetransmission oil level in the sightgauge. If the oil level is below thearrow, add oil to raise the oil level up tothe arrow. See Transmission ServiceSpecifications in this manual for thecorrect type of oil.

Warm Oil Level CheckCheck the transmission oil level every50 hours of operation when the oil is atope ra t i ng tempera tu re . Do thefollowing.

1. Park the machine on a levelsurface.

2. Apply the parking brake.

3. Shift the transmission toNEUTRAL.

4. Run the engine at idle speed.

5. If the oil level is at or below theADD mark , put the t ransport /se rv i ce l i nk i n the LOCKEDposition and add oil to raise the oillevel up to the FULL mark. SeeTransmiss ion Serv i ceSpecifications in this manual for thecorrect oil.

Oil Change, Filter Replacement, and Breather CleaningChange the t ransmission o i l andreplace the filter after the first 100hours of operation with a new machineor i f t he t ransmiss ion has beenreplaced or rebuilt. Then, do the aboveservice and clean the breather every1000 hours or operation.

If possible, drain the oil when the oil isa t ope ra t ing tempera ture . Morecontamination is removed when the oilis at operating temperature.

1. Put the transport/service link in theLOCKED pos i t ion , app ly theparking brake, and stop the engine.

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

3. Have a container that will holdapproximately 29 U.S. Quarts (27.4litres).

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4. Remove the filler tube plug.

B4028891T

5. Remove the drain plug and drain the oilfrom the transmission.

RB97G074J

6. Remove the transmission filters.Discard the old transmission filters.

BD02B081

7. Install the filter as shown. Makesure the filter is SEATED againstthe filter base.

8. Remove the breather. Clean thebreather with solvent and dry withcompressed air. Be sure to wearface p ro tec t ion when us ingcompressed air.

RD98M046

9. Install the breather.

10. Install the drain plug. Put new oili n to the t ransmiss ion . SeeTransmiss ion Serv i ceSpecifications in this manual.

11. Check the oil level in the sightgauge.

12. Start the engine and check for oilleaks around the filters and drainplug.

13. Increase the transmission oiltempera tu re to opera t i ngtemperature and check the oil levelagain.

14. Stop the engine and return thet ranspor t / se rv i ce l i nk to theOPERATING position.

1. DRAIN PLUG 2. O-RING

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AXLESZF

Service SpecificationsFront axle capacity ................................................... 45.4 litres (48.0 U.S. Quarts)Rear axle capacity ....................................................... 48.3 litres (51 U.S. Quarts)Type of oil ............................................................................. Case Transaxle FluidAlternate oil ............................................................................................. See noteOil change interval ................................... After the first 100 hours of operation

and then every 1000 hours there after.

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

Axle Oil LevelTo check the oil level, do the following procedure.

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

1. Park the machine on a levelsurface. Apply the parking brakeand stop the engine.

2. Remove the oil level and filler plugfrom the center bowl of the axle.The oil level must be level with thebottom of the oil level and filler plughole.

BD02B0741. OIL LEVEL AND FILLER PLUG

3. Add oil as required. See AxleService Speci f icat ions in th ismanual.

4. Clean and install the filler plug.

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Front Axle Oil ChangeAfter the first 100 hours of operationand then every 1000 hours there after.


2. Have a container that will holdapproximately 42.3 litres (45 U.S.Quarts) for the front axle and aconta ine r tha t w i l l ho ldapproximately 45.5 litres (48 U.S.Quarts) for the rear axle.

3. With the oil warm from operation,remove the oil level and filler plugand the drain plug from center bowlof the axle. Drain the oil from theaxle.

BD02B0741. OIL LEVEL AND FILLER PLUG2. DRAIN PLUG

4. Remove the the drain plugs fromthe planetary ends of the axle.Drain the oil from both planetaryends of the axle. The drain plugcan be located in either location,see the following photo.

BD00C0071. DRAIN PLUG2. DRAIN PLUG

5. Clean the oil level and oil fillerplugs.

6. After all oil has been removed,install and tighten the drain plugs.

7. Install the exact amount of oil in thecenter bowl of the axle. See AxleService Specifications on 176 inthis manual.

8. Install the oil level and filler plug inthe center bowl of the axle.

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Rear Axle Oil ChangeAfter the first 100 hours of operationand then every 1000 hours there after.


2. Have a container that will holdapproximately 42.5 litres (45 U.S.Quarts) for the front axle and aconta ine r tha t w i l l ho ldapproximately 45.4 litres (48 U.S.Quarts) for the rear axle.

3. With the oil warm from operation,remove the oil level and filler plugfrom the beam of the axle and thedrain plugs from the planetary endsof the axle. Drain the oil from theplanetary ends of the axle.

BD00C010

BD00C0071. OIL LEVEL AND FILLER PLUG2. DRAIN PLUG FOR PLANETARY

4. Remove the drain plug from centersection of the axle. Drain the oilfrom the center section of the axle.

BD00B0023. DRAIN PLUG FOR AXLE CENTER

SECTION

5. Clean the oil level and oil filler plugand the drain plugs.

6. After all oil has been removed,install and tighten the drain plugs.

7. Install the exact amount of oil in theax le . See Ax le Serv i ceSpeci f icat ions on 176 in th ismanual.

BD00B0021. OIL LEVEL AND FILLER PLUG

8. Install the oil level and filler plug inthe beam of the axle.

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CAB AIR FILTERClean or replace the cab air filters (ifequipped) every 250 hours of operationor if the air flow in the cab is reduced.

NOTE: If your machine is new, makesure the plastic cover is removed fromthe filters.

Removal and Installation1. Turn the handle and open the

access door.

RD97F156

2. Pull the air filter out.

RD98K285

3. Install a filter that has been cleanedor a new filter.

RD98K285

4. Close the access door and turn thehandle to the locked position.

RD97F156

Circulation Cover 1. Remove the air circulation filter.

RD97F222

2. Install a filter that has been cleanedor a new filter.

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Cleaning the FilterCheck the dirty element for damageand check the rubber seal on the end.Push the rubber seal with your finger. Ifthe rubber feels hard and does notmove back to original shape, discardthe element.

1. Remove the loose dirt withcompressed air, 30 psi (207 kPa, 2bar) maximum. Hold the nozzle atleast one inch (25 mm) from theelement. Make sure you wear faceprotection when using compressedair.

786L94

2. Mix two tablespoons of D1400detergent (Case part numberA40910) with two gallons (7.6litres) of water, one cup for 16gallons (60 litres) of water.

3. Soak the element in the soapsolution for 15 to 20 minutes andthen shake the element up anddown rapidly to loosen as much dirtas possible.

787L94

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

788L94

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

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6. Use a light and inspect the elementfor holes or splits in the pleats.Check for damage to the metalparts and rubber gasket.

789L94

NOTE: If the element is not to be usedfor some time, wrap the element withpaper for storage.

WINDSHIELD WASHER RESERVOIR (If Equipped)

RD98K286

The windshield washer reservoir is located on the frame below the cab on theRight Hand side. To add washer fluid, pull the cap up.

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

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NOTES

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MAINTENANCE/ADJUSTMENT

CAB SERVICE

Air ConditioningThe components of the operators cab, including the components of the airconditioning system, require service at different intervals. Service the followingitems as required to maintain maximum operating efficiency.

SA048

Lubrication of the Air Conditioning Compressor SealsOperate the air conditioning once every250 hours to lubricate the compressorseals. Turn the air conditioning controlto MAXIMUM for at least 15 minutes. Intemperatures below 32°F (0°C) put acover ove r the a i r cond i t ion ingcondenser. This will make sure therefrigerant and lubricants in the systemwill be at operating temperature.

Condenser

RD97F158

Keep the air conditioning condensercore clean. Use compressed air (wearface protection) or a rigid brush toclean the condenser. Also check andclean the grille screen.

IMPORTANT: Because the condenserfins bend easily, be careful when youclean the condenser.

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

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10 Ampere Circuit Breakers for Condenser Blower Fans

RD97F158

If one of the fans stop, remove the plugon that side and push the Reset Buttonon the circuit breaker. Install the plug. Iffan still will not operate properly, seeyour dealer.

Cab HeadlinerThe foam head l ine r in your cabdecreases noise. To keep the headlinerin good operating condition, removedust with a vacuum cleaner.

IMPORTANT: DO NOT wash theheadliner with water because watercan cause damage to the headliner andlower the noise control capacity of theheadliner.

RD97F2151. CAB HEADLINER

Door HingesUse graphite to lubricate the cab doorhinges. DO NOT use oil.

Hoses and WiringCheck all hoses and wiring for damage.If damage occurred, see your dealer forrepair or replacement.

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Operators SeatRemove dust and dirt from the seat with a vacuum cleaner or soft brush. Cleanstains with the correct use of a material cleaner.

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

SA049

CLEANER FLUID - This type of cleaner can be used for grease or oil stains.Carefully remove the item that caused the stain with a scraper or a knife that is notsharp. Use very little cleaner, no pressure, and clean cloths. Move the cloth fromthe outside of the stain toward the center of the stain and constantly change to aclean section of cloth.

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

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

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

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LOADER ADJUSTMENTS

Return-To-Dig Adjustment

1. Park the machine on a levelsurface.

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

RP98N357

3. Apply the parking brake and stopthe engine.

4. Make sure the switch is even withthe edge of the shield. Adjust theshield and actuator to get 1/8 to 3/16 inch (3.2 to 5.0 mm) clearancebetween the sw i t ch and theactuator. Make sure the actuator isparallel to the shield so that the 1/8to 3 /16 inch (3 .2 to 5 .0 mm)clearance is maintained throughthe full stroke of the cylinder.

B4037588T1. SWITCH2. SHIELD

5. Loosen the cap screws that fastenthe actuator.

B4037088T1. SWITCH

6. Move the actuator all the way to therear.

B4037288T

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7. Turn the key switch to the ONposition but do not start the engine.

RD98K312

8. Push down on the top side of thedetent function switch.

BD02B0551. DETENT OFF/ON SWITCH

9. Have another person help you atthis time. Slowly move the actuatorforward until the bucket controllever returns to NEUTRAL.

B4037188T

10. Tighten the cap screws that fastenthe actuator. Make sure the 1/8 to3/16 inch (3.2 to 5.0 mm) clearanceis maintained through the ful lstroke of the cylinder.

B4037088T

11. Start the engine. Raise the loaderframe all the way and dump thebucket completely. Increase theengine speed to full throttle. Pullback the bucket control lever to theROLLBACK position. The bucketwill roll back automatically.

12. Lower the bucket to the floor andstop the engine.

13. If the bucket is not in the correctposition, adjust the actuator asrequired.

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Return-To-Travel Minor Adjustment

1. Lower the loader bucket to theground.

2. Park the machine on a levelsurface and apply the parkingbrake.

3. Stop the engine.

4. Loosen the front actuator.

B4063388T

5. To increase the carry height, movethe actuator down in the slot. Todecrease the carry height, movethe actuator up in the slot.

6. Tighten the actuator and check theadjustment.

Return-To-Travel Adjustment

1. Park the machine on a levelsurface and apply the parkingbrake.

2. Raise the loader until the frontactuator is even with the Return-To-Travel switch. Make sure theclearance is 1/8 to 3/16 inch (3.2 to5.0 mm).

B4196789T1. FRONT ACTUATOR2. RETURN-TO-TRAVEL SWITCH

3. Stop the engine.

4. Loosen and remove the screwsand hardened washers that fastenthe cover.

B4196689T

2

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5. Remove the cover.

B4196589T

6. Check the clearance between theactuator and the swi tch. Thisclearance is 1/8 to 3/16 inch (3.2 to5.0 mm). If the clearance is notcorrect, loosen the nuts for theswitch and adjust the nuts so thereis 1/8 to 3/16 inch (3.2 to 5.0 mm)clearance between the switch andthe actuator. Hold the switch inposition and tighten the nuts.

B4196489T

7. Have another person help you atthis time. Start the engine andlower the loader frame until thebucket is at the desired heightabove the floor. Put a sufficientsupport under each end of thebucket and stop the engine.

8. Loosen the actuator.

B4196289T

9. Move the actuator up in the slotand hand tighten the actuator.

B4196189T

10. Turn the key switch to ON but donot start the engine.

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11. Push down on the top of theReturn-To-Travel detent switch.Move the lift control lever from theHOLD pos i t i on to the RAISEposition several times to relieve allof the pressure in the accumulator.Turn the key switch to the ONposition. Move the lift control leverto the FLOAT position. The l iftcontrol lever will remain in thisposition and the loader frame willnot move.

BD02B0551. RETURN-TO-TRAVEL SWITCH

12. Loosen the actuator and slowlymove the actuator down the slotuntil the lift control lever returns toHOLD.

B4196089T

13. Tighten the actuator. Move the liftcontrol lever to the FLOAT position.The loader frame will lower andstop at the adjusted height abovethe floor.

B4196289T

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

B4196589T

15. Install the screws and hardenedwashers and tighten the screws.

B4196689T

16. Remove each support from underthe bucket and lower the bucket tothe floor.

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Bucket Height Control Minor Adjustment

1. Park the machine on a levelsurface. Lower the loader bucket tothe floor.


3. Loosen the rear actuator.

B4063488T

4. To increase the dump height, movethe actuator down in the slot. Todecrease the dump height, movethe actuator up.

5. Tighten the actuator.

6. Start the engine and pull the liftcontrol lever to the RAISE detentposition. When the loader armsstop moving, check the dumpheight.

Bucket Height Control Adjustment

1. Park the machine on a levelsurface and lower the loader frameso the bucket is flat on the floor.

RP98N357

2. Stop the engine and apply theparking brake.

3. Loosen and remove the screwsand hardened washers that fastenthe cover.

B4196689T

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4. Remove the cover.

B4196589T

5. Start the engine and raise theloader frame until the rear actuatoris even with the Bucket HeightControl switch. Stop the engine.Connec t acceptab le l i f t i ngequipment to the loader arms thatwill hold the loader in place.

B4195489T

6. Loosen the nuts of the switch andadjust the nuts so there is 1/8 to 3/16 inch (3.2 to 5.0 mm) clearancebetween the sw i t ch and theactuator. Hold the switch in positionand tighten the nuts.

B4195989T

7. Disconnect the lifting equipment.Start the engine. Dump the bucketcompletely and raise or lower theloader frame for the bucket heightrequired. Stop the engine. Connectthe l i f t i ng equ ipment to thecrossmember of the loader.

8. Loosen the actuator.

B4195789T

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9. Move the actuator down in the slot.

B4195689T

10. Turn the key switch to ON but donot start the engine.

11. Push in the left side of the BucketHe ight Contro l sw i tch on theinstrument panel. Move the lif tcontrol lever to the RAISE position.The lift control lever will remain inthis position and the loader framewill not move.

B4063488T

12. Slowly move the actuator up theslot until the lift control lever returnsto HOLD.

13. Tighten the actuator.

B4195789T14. Disconnect the lifting equipment

f rom the crossmember of theloader frame. Start the engine andlower the loader frame so thebucket is flat on the floor.

15. Put the lift control lever in theRAISE position. The loader framewill raise and stop at the adjustedbucket height.

16. Lower the loader frame so that thebucket is flat on the floor. Stop theengine.

17. Install the cover.

B4196589T18. Install the screws and hardened

washers and tighten the screws.

CM115


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TRANSMISSION CLUTCH CALIBRATIONTransmiss ion c lu t ch ca l i b ra t i onensures opt imum shi f t ing o f thet ransmiss ion . Make su re o f t hefo l lowing before proceeding withtransmission clutch calibration.

A. The parking brake has beentested.

B. The transmission oil is warm.C. The engine idle speed is correct.D. The transmission is in neutral.E. The parking brake is applied.

Do the following procedure to calibratethe transmission clutches:

1. Put the transmission in themachine shift mode and the gearselector in 3rd gear neutral.

2. Press the program switch.

3. Press the up-count switch until thedisplay reads 011.

4. Return the program switch to thecenter position.

5. Press the up-count switch twice sothe display reads 02.

At this time, 2 00 00 will begin flashingin the display center.● After one second, the Clutch

Calibration Main Code status will bedisplayed in the 3rd and 4th spaces(2 XX 00 - the XX represents the 3rdand 4th spaces).

● The Modulation Cycle Number willbe displayed in the 1st and 2ndspaces (2 00 XX - the XX representsthe 1st and 2nd spaces).

● During Clutch Calibration, the ClutchCalibration Main Code will changefrom 01 to 07 as the process iscompleted. The code 07 will indicatethat the process is complete and theInformation Center will return tonormal working status.

● If any of the Clutch Calibrationparameters are incorrect, the displaycenter will stop flashing and displaythe Clutch Calibration Main Code inthe 1st, 2nd, 3rd, and 4th spaces.

In the event, the code in the 3rd and4th spaces will be 09 to 14 and willindicate the process that the calibrationwas in when it was aborted.

The 1st and 2nd spaces will producethe Clutch Calibration Sub-Code, whichis the code that will inform the operatorof the reason process was aborted.

6. After completing the clutchcalibration procedure, turn theengine off for 15 seconds to set thecalibration in the controller.

NOTE: See Clutch Calibration MainCode and Clutch Calibration Sub-Codeon the following page.

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DECLUTCH ADJUSTMENT1. Park the machine on a level

surface.

2. Lower the loader bucket to thefloor.


NOTE: The following photo shows thebrake pedal/valve assembly removedfor clarity. Do not remove the brakepedal/valve assembly from themachine.

BD00C0061. PLUG2. ADJUSTMENT SCREW

4. Remove the plug (1) from the baseof the left hand brake pedal/valveassembly.

Clutch Calibration Main Codes

CLUTCH CALIBRATIO

N MAIN CODE

MEANING

00Clutch Calibration Mode was not

initiated because one of the requirements was not met.

01 Adjusting 1st gear02 Adjusting 2nd gear03 Adjusting 3rd gear04 Adjusting 4th gear05 Adjusting Forward gear06 Adjusting Reverse gear07 Clutch Calibration Completed08 Operator aborted calibration

procedure.09 Aborted while adjusting 1st gear10 Aborted while adjusting 2nd gear11 Aborted while adjusting 3rd gear12 Aborted while adjusting 4th gear13 Aborted while adjusting Forward gear14 Aborted while adjusting Reverse gear

Clutch Calibration Sub- Codes

CLUTCH CALIBRATION SUB-CODE

MEANING

00Calibration in process

01 Fault present02 Shift lever not in neutral03 Park brake not applied04 Output speed not 0 kph/mph05 Low transmission oil temperature06 High transmission oil temperature07 Low engine RPM08 High engine RPM

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5. Turn the adjustment screw (2) in orout as requ i red to adjus t thedec lu tch po in t . Tu rn ing thead jus tmen t sc rew c lockw iseincreases the brake force at thedeclutch. Turning the adjustmentscrew counterclockwise decreasesthe brake force at the declutch.

NOTE: The declutch is set the at thefactory at approximately 30 percent offull brake system pressure. Do notincrease this setting more that 1 turnclockwise (approximately +325 psi) Donot reduce this setting more than 1/2turn counterclockwise (approximately -75 psi).

6. Install the plug (1) in the base ofthe left hand brake pedal/valveassembly.

7. If the declutch is not operatingproperly see the Service Manual oryour Case Dealer

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SECONDARY STEERING CHECKNOTE: Test the secondary steering at a maximum of 250 hours.

The secondary steering system is electrically powered which allows you to steerthe machine if the primary steering system stops working. Always maintain thebatteries.

RD98K316

1. Park the machine on a hard, levelsurface with enough clearancearound the machine to allow you tocompletely steer from side to side.


3. Raise the bucket approximately500 mm (20 inches) above theground.

4. With the machine at low idle andsteering straight ahead, turn thesteering wheel either left or right.DO NOT TURN THE STEERINGWHEEL TO THE STEERINGSTOP. While steering, turn the keyswitch to the OFF position to stopthe engine and then immediatelyback to the ON position (not theSTART posi t ion. Release thesteering wheel. The secondarysteering pump/motor should startrunning immediately.

IMPORTANT: DO NOT turn the keyswitch to the OFF position if themachine is steered against either theright hand or left hand steering stop.The steering wheel may kick back.

NOTE: The secondary steering systemwill only function as long as there issufficient battery capacity.

5. Steer the machine left and right toconfirm that the secondary steeringpump is working. The secondarypump/motor should not be runcontinuously for more than 20seconds at a t ime without a 2minute cool down.

NOTE: Operating the secondary pump/motor for long periods of time canresult in very hot conditions andshortened secondary pump/motor life.

6. Look at the instrument cluster toverify that the secondary steeringlight comes on.

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7. Turn the key switch to the OFFposition. The secondary steeringmotor should stop.

8. If Steps 2 through 6 functionproperly, the secondary steeringsystem is operat ing correct ly.Repair the secondary steeringsystem if the secondary steeringsystem does not operate correctly.

9. Restart the engine and allow thebat te r i es to recharge fo r aminimum of 10 minutes.

PARKING BRAKE CHECKNOTE: Test the parking brake at a maximum of 250 hours.

Before you operate the machine periodically test the parking brake functions.

RD98K316

1. To release the park brake, all thefollowing are required:

A. Push the Park Brake switch tothe release position.

B. Service brake depressedindicating brake lights.

C. Transmission shifter positionedfrom N to F or R for a second,and back to N.

D. Adequate service brakepressure to stop the machine.

2. To engage the park brake, any ofthe following is required:

A. Loss of service brake pressurein both axles.

B. Loss of system electrical power(key OFF).

C. Park Brake switch in engagedposition.

3. To test these functions:

A. Start on a clear level surface.

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B. With Step 1, A through Ccomple te , s ta r t the eng inerelease the park brake, redwarning light out.

C. Shutdown the engine turn thekey switch to the ON position,engine off the Park Brake lightshould come ON.

D. Release the park Brake using Band C in Step 1. Make sure thepark brake light is out.

E. Pump the service brakes, thered warning light should comeON first. Continue to pump theservice brakes. Pump until thebrake light comes ON, pump thebrakes three more times, it couldrequire as many as forty pumpstotal.

F. Start the engine and allow thebrake pressure to build until thewarning light goes out.

G. Depress the service brake andrelease. The light must stay ON.

H. Put the transmission in F or Rand back to N the brake lightmust stay ON.

I. Put the park brake switch in theengaged position, attempt B andC in Step 1. The park brake lightmust stay ON.

4. Put the park brake switch in therelease position, attempt B and Cin Step 1. The park brake light mustturn OFF,

A. Allow the machine to roll slowlyforward with the transmission inF put the park switch to engage.The machine must come to astop immediately. Park light ON.Transmission disengages.

If all steps are working positive thesystem works correct. If there was aproblem with the test contact yourdealer.

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ROLL-OVER PROTECTIVE STRUCTUREYour mach ine has a Ro l l -OverProtective Structure (ROPS). A ROPSlabel shows the serial number of theROPS, g ross we igh t , app rova l ,regulation, and model numbers of themachine. See Identification Numbers inthis manual.

Before you operate this machine,always make sure that the ROPS andoperator �s seat belts are correctlyinstalled.

Seat BeltThe seat belt is an important part ofyour ROPS. You must wear the seatbelt at all times when you operate themachine.

1. Keep the seat belts away fromobjects that can damage the seatbelts.

2. Check the seat belts for damage.Rep lace a l l par ts t ha t a redamaged.

3. Make sure that the mounting boltsof the seat belts are tight. SeeTorque Specifications for Seat inthis manual.

4. Keep the seat belts clean. Washthe seat belts only in soap andwater.

5. Do not put the seat belts in bleachor dye. You will make the seat beltsweak.

Maintenance and Inspection of ROPSAfter the first 20 hours of operation andafter every 500 hours of operation, dothe following:

1. Check the torque of the ROPSmounting bol ts. I f necessary,tighten the bolts to the correcttorque. See torque specificationson this page.

2. Check the operators seat and themounting parts for the seat belt.Tighten the bolts to the correcttorque. See Torque Specificationsin this manual. Replace parts thathave wear or damage.

3. Check for cracks, rust, or holes inthe ROPS and ROPS parts. Age,weather, and accidents can causedamage to the ROPS and ROPSparts. If you have any doubt aboutthe ROPS system, see your dealer.

Torque Specifications for ROPS Cab and ROPS Canopy

RD97F234ROPS CAB AND ROPS CANOPY MOUNTING

BOLTS (BOTH SIDES), TIGHTEN TO 786 TO 840 Nm (580 TO 62POUND-FEET)

NOTE: Torque specifications are forclean, dry threads.

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Damage to the ROPSIf the machine has rolled over or theROPS has been in some other type ofaccident (such as hitting an overheadobject during transport), you mustrep lace the damaged ROPScomponents to get as much protectionas you had originally.

After an accident, check the followingfor damage.

A. ROPS canopy or cab.

B. Operators seat.

C. Seat belt mounting bolts andseat belt.

Before you operate the machine,replace all ROPS components that aredamaged.

See the Parts Catalog or your dealerfor components that are replaceable.

DO NOT TRY TO WELD ORSTRAIGHTEN THE ROPS.

SA029

SB026

SA027

SA028

SA036

WARNING: Improper ROPS inspection or maintenance can cause injuryor death. Do the recommended ROPS inspection shown in this manual. Ifyou must replace the ROPS, ROPS parts, or ROPS mounting hardware,use only the replacement parts shown in the Case parts catalog for thismachine

WARNING: Do not modify ROPS in any manner. Unauthorizedmodifications such as welding, drilling, cutting or adding attachments canweaken the structure and reduce your protection. Replace ROPS ifsubjected to roll-over or damage. Do not attempt to repair.

WARNING: If you operate this machine without a ROPS and the machinerolls over, you can be injured or killed. Remove the ROPS only for serviceor replacement. Do not operate this machine with the ROPS removed.

WARNING: Adding additional weight (attachments, etc.) to the machinecan cause injury or death. Do not exceed the gross weight printed on theROPS label

WARNING: Always fasten the seat belt securely before starting theengine

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TORQUE SPECIFICATIONS FOR SEAT AND SEAT BELTS

63971. 73 TO 87 Nm

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ALTERNATOR BELT AND AIR CONDITIONING COMPRESSOR BELT

Service IntervalAlternator belt service interval ............................................ Check every 250 hoursAir conditioning compressor belt service interval ............... Check every 250 hours

Alternator BeltInspection and Adjustment

1. Check the alternator belt for thecorrect tension with a belt tensiongauge as shown in the illustration.

B910927

2. The correct tension for a new beltis 140 to 160 pound force (623 to712 Newtons) for a used belt is 90to 120 pound force (400 to 534Newtons).

3. If the tension for the alternator beltis not correct, loosen the strap boltand the p i vo t bo l t . Tu rn theadjusting bolt counterclockwise toloosen or clockwise to tighten thealternator belt.

BD02B040

1. PIVOT BOLT 3. STRAP BOLT2. ADJUSTING BOLT

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Removal and Installation1. Loosen the strap bolt and the pivot

bo l t . Turn the ad jus t i ng bo l tcounterclockwise until the belt isloose. Remove and discard thealternator belt.

BD02B040

2. Install a new alternator belt. SeeAlternator Belt Inspection andAd jus tmen t and ad jus t t hea l te rnator be l t to the cor rec ttension.

NOTE: The illustration is shown withthe removal of the alternator shield toshow service points. NEVER operatethe machine without the shield in place.

Air Conditioning Compressor BeltInspection and Adjustment

1. Check the air conditionercompressor belt for the correcttension with a belt tension gaugeas shown in the illustration.

B910928J

2. The correct tension for a new beltis 130 to 150 pound force (578 to667 Newtons) for a used belt is 80to 120 pound force (356 to 534Newtons).

CM115

1. PIVOT BOLT 3. STRAP BOLT2. ADJUSTING BOLT

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3. If the tension for the airconditioning compressor belt is notcorrect, loosen the pivot bolt .Loosen the strap bolt and nut,move the a i r cond i t ion ingcompressor as required to loosenor t ighten the air condit ioningcompressor belt.

BD02B0411. PIVOT BOLT2. STRAP BOLT

Removal and Installation1. Loosen the pivot bolt. Loosen the

s t rap bo l t and move the a i rconditioning compressor down untilthe belt is loose. Remove andd iscard the a i r cond i t ion ingcompressor belt.

BD02B0411. PIVOT BOLT2. STRAP BOLT

2. Install a new air conditioningcompressor be l t . See A i rCondit ioning Compressor BeltInspection and Adjustment andad jus t t he a i r cond i t ion ingcompressor belt to the correcttension.

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FIRE EXTINGUISHER MOUNTING (If Equipped)

Type of Fire ExtinguisherIt is recommended that you have a fireextinguisher on your machine. The fireextinguisher shown below is availablefrom your dealer and can be installedon the machine.

This dry chemical fire extinguisher hasa 5 pound capacity and is approved forClass A, B and C type f i res. Theoperating temperature is from -65° to120°F (-54° to 49°C).

Inspection and CareEVERY MONTH - It is recommendedthat you inspect the fire extinguisheronce each month for damage and toinsure that the gauge is workingcorrectly.

EVERY 6 MONTHS - Have the drychemical removed and refilled by a fireequipment technician.

ONCE EACH YEAR - Have the fireequipment technician inspect the fireextinguisher.

153L95

IMPORTANT: DO NOT mount the Fire Extinguisher on any part of the ROPS orFOPS structure. DO NOT make any modifications to the ROPS or FOPSstructure.

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ELECTRICAL SYSTEMBattery Safety

SA046

SB032

SA033

SB034

BATTERY SERVICENOTE: The electrical system in thismachine is 24 volts. Each battery is 12volts.

Before you service components of theelectrical system, always disconnectthe NEGATIVE (-) battery cable.

Do not run the engine with the batterycab les d isconnected or w i th thealternator wires disconnected.

Before you use an electric welder,d isconnect the a l te rnator wi res ,instrument cluster, and turn the masterdisconnect switch to OFF.

Do not use a steam cleaner or cleaningsolvent to clean the alternator.

WARNING: Before you service a battery, always wear face protection,protective gloves and protective clothing. Battery acid or battery explosioncan cause serious injuries.

WARNING: Battery acid causes severe burns. Batteries contain sulfuricacid. Avoid contact with skin, eyes or clothing. Antidote - EXTERNAL: flushwith water. INTERNAL: drink large quantities of water or milk. Follow withmilk of magnesia, beaten egg or vegetable oil. Call physician immediately.EYES: flush with water for 15 minutes and get prompt medical attention.

WARNING: When the battery electrolyte is frozen, the battery canexplode if, (1) you try to charge the battery, or (2) you try to jump start andrun the engine. To prevent the battery electrolyte from freezing, try to keepthe battery at full charge. If you do not follow these instructions, you orothers in the area can be injured.

WARNING: Sparks or flame can cause hydrogen gas in a battery toexplode. To prevent an explosion, do the following:1. When you disconnect the battery cables, always disconnect thenegative (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.

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ELECTRICAL SYSTEM

Battery Fluid LevelCheck the fluid level of the batteriesevery 250 hours of operation. If thefluid level is low, add clean or distilledwater to each cell until the fluid level isat the split ring at the bottom of eachcell opening.

IMPORTANT: If the temperature is32°F (0°C) or below and you haveadded water to the batteries, do thefollowing; Connect a battery charger tothe batteries or operate the machine forapproximately two hours. Thisprocedure is necessary to mix thewater with the electrolyte.

Battery VentsKeep the battery vents clean, makesure the vents are not restricted.

Cleaning the BatteriesCheck the batteries regularly for dirt,corrosion and damage. Dirt mixed withelectrolyte or moisture on the top of thebatteries can cause a dischargedcondition in the batteries. Use one ofthe following methods to clean thebatteries.

1. Use Case Battery Saver, PartNumber M20376. Fo l l ow theinstructions on the container. Thiscleaner does not need water.

2. Use baking soda or ammonia andflush the outside of the batterieswith water. If you do not have CaseBattery Saver, use other specialcleaners to prevent corrosion onthe battery terminals.

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ELECTRICAL SYSTEM

FUSES

RD97F154

The fuses in this machine are bladetype. To replace, pull the old fusestraight out and push the new fusestraight in. The amperage for each fuseis stamped on the fuse. Refer to thefuse panel decal for correct location ofeach fuse.

449770A1/315096A1

SERVICE ELECTRICAL CONNECTOR (IF EQUIPPED)The cigar lighter socket (24 volt) canbe used for the connection of a lightingdev ice to he lp w i th serv i ce andmaintenance procedures.

NOTE: This is a 24 volt outlet.

BD00B030

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ELECTRICAL SYSTEM

AUXILIARY POWER OUTLET (IF EQUIPPED)The Auxiliary Power Outlet socket (12volt) can be used for the connection ofa lighting device to help with serviceand maintenance procedures.

NOTE: This is a 12 volt outlet.

BD00B003

AUXILIARY POWER EQUIPMENT MOUNTING BRACKET LOCATION

The aux i l ia ry power equ ipmen tmounting brackets are located behindthe right and left ROPS post covers.These brackets are for mount ingradios, phones, etc.

To locate the bottom of the mountingbracket measure 300 mm (11.8 inches)from the bottom edge of the plasticpane l . To l oca te the top o f t hemounting bracket measure 420 mm(16.5 inches) from the bottom edge ofthe plastic panel. The mounting bracketis approximately 70 mm (2.75 inches)wide.

BD00B0091. RIGHT ROPS POST COVER

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ELECTRICAL SYSTEM

REPLACEMENT BULBS

* DO NOT touch the new halogen bulb with your fingers. Use gloves or use atissue to hold the bulb.

CASE PART NUMBER

Dome Lamp 395185A1

Engine Compartment E136074

Front Position Lamp E100139

Front Turn Signal E116591

Maximum Width Marker Lamp E136074

Number Plate Lamp E136704

*Road Lamp E133014 (Halogen)

Rear Position Lamp E100139

Rear Turn Signal E116591

*Rotating Beacon A187543 (Halogen)

Stop Lamp E116591

Work Lamp 103653A1

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ELECTRICAL SYSTEM

NOTES

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MACHINE STORAGEStorage PreparationIf the machine is to be in storage formore than 30 days, park the machineinside a building. If a building is notavailable, park the machine in a dryarea on planks and cover the machinewith a waterproof covering.

1. Wash the machine.

2. Lubricate the machine at all greasefittings.

3. Paint any areas where the painthas been damaged.

4. Move all hydraulic controls tore l ieve any p ressure in thehydraulic circuits.

5. Drain the fuel tank.

6. Put approximately 8 litres (2 U.S.Gallons) of diesel flushing oil in thefuel tank. Run the engine until theexhaust smoke is blue-white.

7. Drain the flushing oil from the fueltank.

8. Put 15 ml (one tablespoon) of ShellOil Company VPI crystals in thefuel tank.

9. Change the engine oil and replacethe oil filter.

10. Drain the cooling system. Leavethe drain open and do not tightenthe radiator cap. Put a Do NotOperate tag in the cab.

11. Clean or replace the primaryelement for the air filter.

12. Cover the exposed steeringcylinder rods, equipment valvespoo ls w i th Case Rus t andCorrosion Preventat ive (Par tNumber B17510).

13. Charge the batteries. Remove thebatteries from the machine and putthe batteries on a wooden pallet ina cool dry area. If possible, keepthe batteries in a building wherethe temperature is above freezing(0°C [32°F ] ) . Make sure thebatteries are clean.

NOTE: Always wear face protectionwhen checking batteries. Check thebatteries periodically for the correctelectrolyte level. Test the electrolytewith a hydrometer. When thehydrometer reading is near 1.215,charge the batteries.

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MACHINE STORAGE

Removal from StorageDo not start the engine until steps 1through 10 have been done.

1. Change the fuel filter.

2. Put coolant in the engine coolingsystem.

3. Check the condition of the drivebelts. Replace if required.

4. Check the engine oil level.

5. Check the hydraulic oil level.

6. Check the transmission oil level.

7. Check the oil level of both axles.

8. Lubricate the machine at all greasefittings.

9. Use petroleum base solvent andremove the Case Rus t andCorrosion Preventive from thehydraulic cylinder rods.

10. See Battery Service in this manualand install the batteries.

11. Fill the fuel tank.

12. Prime the turbocharger with cleaneng ine o i l . See your Serv iceManual or your dealer.

13. Start the engine. It is important thatyou use the Starting the Engineprocedure in th is manual fo rpriming the turbocharger lines withoil.

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SPECIFICATIONS

ENGINE DATANOTE: All specifications are given according to SAE Standards orRecommmended Practices where the specification applies.Make and model .................................................................. Cummins QSM11 - CType ........................................................................ six cylinder, four stroke cycle,

turbocharger aftercooled Air to AirFiring order ........................................................................................... 1-5-3-6-2-4Bore and stroke .................................................. 125 x 147 mm (4.92 x 5.79 inch)Displacement ...................................................................................... 661 cu inchCompression ratio ..................................................................................... 16.3 to 1Horsepower

SAE gross .................................... 216.3 kW at 2 100 r/min (290 at 2100 rpm)Engine speeds

Full throttle - no load ......................................................................... 2280 rpmIdle speed ........................................................................................... 970 rpmHydraulic stall ...................................................................... 2110 to 2250 rpmConverter stall ..................................................................... 2040 to 2240 rpmCombined hydraulic and converter stall .............................. 1490 to 1720 rpm

Valve clearance - engine coldIntake valves .................................................................. 0.35 mm (0.014 inch)Exhaust valves .............................................................. 0.68 mm (0.027 inch)

Lubrication SystemOil pressure at idle speed (minimum) ...................................... 70 kPa (10 psi)Oil pressure at 1 300 rpm ................................. 240 to 310 kPa (35 to 40 PSI)Type of system ............................................................ pressure and spray

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SPECIFICATIONS

BUCKET

TRAVEL SPEEDS (with 26.5 x 25 Tires)

DESCRIPTION WIDTH CAPACITIES WEIGHTSAE Heaped Struck kg pounds

m3 yd3 m3 yd3

4.75 GP 3 048 mm (120 in) 3.60 (4.75) 2.91 (3.81) 1.604 (3 537)4.75 GP W/S Segment

Edges and Teeth3 1 06 mm (122.3 in) 3.82 (5.00) 3.07 (4.02) 1 966 (4 335)

5.00 GP 3 048 mm (120 in) 3.82 (5.00) 3.35 (4.38) 1 677 (3 698)

FIRST SECOND THIRD FOURTHkm/h (mph) km/h (mph) km/h (mph) km/h (mph)

Forward 8.2 (5.1) 14.5 (9.0) 26.7 (16.6) 38.8 (24.1)Reverse 8.2 (5.1) 14.5 (9.0) 26.7 (16.6) -----

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SPECIFICATIONS

OPERATING DATA AND DIMENSIONS 921CSpecifications taken with 26.5 x 25, 20 PR, L3 tires, ROPS cab with heater, 2450kg (5,400 pound) rear counterweight, fenders, lights, full fuel, and a 80 kg (175pound) operator. Specifications per SAE J732, J1234, J742, and J818.

BS02B176

Machines with 3.63 m3 (4.75 yd3) General Purpose BucketTipping load, machine straight ............................. 19 643 kg (43 305 pounds)Tipping load, 40 degree turn ................................ 15 675 kg (34 558 pounds)

A. Overall operating height, fully raised .................. 5 635 mm (18 foot 5.9 inch)B. Height to bucket hinge pin, fully raised ............... 4 284 mm (14 foot 0.7 inch)C. Dump height, 45 degree dump, full height .......... 3 146 mm (10 foot 3.9 inch)D. Bucket reach, 45 degree dump, full height ........... 1 096 mm (3 foot 7.2 inch)E. Bucket reach, 45 degree dump, 7 foot

(2134 mm) dump height ....................................... 1 747 mm (5 foot 8.8 inch)Dump angle at full height ................................................................ 50 degree

F. Bucket rollback at ground line ......................................................... 39 degreeG. Digging Depth, bucket flat .................................................... 30 mm (1.2 inch)H. Wheel Base ................................................................... 3 404 mm (134 inch)

Tread width ...................................................................... 2 210 mm (87 inch)J. Overall length (without bucket teeth) .................. 8 612 mm (28 foot 3.0 inch)K. Overall height to top of ROPS cab ....................... 3 571 mm (11 foot 8.6 inch)L. Height to top of exhaust pipe ............................... 3 526 mm (11 foot 6.8 inch)M. Height to top of steering wheel ............................. 2 837 mm (9 foot 3.7 inch)

Operating weight .................................................. 22 961 kg (50 621 pounds)Turning angle from center ........................................................ 40 degree

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BS02B176

Machines with 3.63 m3 (4.75 yd3) General Purpose Bucket with Teeth and Bolt on Edges

Tipping load, machine straight .............................. 19 177 kg (42 278 pounds)Tipping load, 40 degree turn ................................ 15 215 kg (33 544 pounds)

A. Overall operating height, fully raised ................... 5 634 mm (18 foot 5.8 inch)B. Height to bucket hinge pin, fully raised ................ 4 283 mm (14 foot 0.6 inch)C. Dump height, 45 degree dump, full height ............. 2 939 mm (9 foot 7.7 inch)D. Bucket reach, 45 degree dump, full height ............ 1 245 mm (4 foot 1.0 inch)E. Bucket reach, 45 degree dump, 7 foot

(2134 mm) dump height ...................................... 1 806 mm (5 foot 11.1 inch)Dump angle at full height ................................................................ 50 degree

F. Bucket rollback at ground line ........................................................ 40 degreeG. Digging Depth, bucket flat .................................................... 71 mm (2.8 inch)H. Wheel Base .................................................................... 3 404 mm (134 inch)

Tread width ....................................................................... 2 210 mm (87 inch)J. Overall length ...................................................... 8 895 mm (29 foot 2.2 inch)K. Overall height to top of ROPS cab ...................... 3 571 mm (11 foot 8.6 inch)L. Height to top of exhaust pipe ............................... 3 526 mm (11 foot 6.8 inch)M. Height to top of steering wheel .............................. 2 837 mm (9 foot 3.7 inch)

Operating weight ................................................. 23 323 kg (51 418 pounds)Turning angle from center ........................................................ 40 degree

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BS02B176

Machines with 3.82 m3(5.0 yd3 ) General Purpose Bucket

Tipping load, machine straight ...........................19 727 kg (43 491 pounds)Tipping load, 40 degree turn ............................... 15 708 kg (34 631 pounds)

A. Overall operating height, fully raised ................ 5 857 mm (19 foot 2.6 inch)B. Height to bucket hinge pin, fully raised ............. 4 284 mm (14 foot 0.7 inch)C. Dump height, 45 degree dump, full height ........ 3 129 mm (10 foot 3.2 inch)D. Bucket reach, 45 degree dump, full height .......... 1 114 mm (3 foot 7.9 inch)

Dump angle at full height ................................................................ 50 degreeE. Bucket reach, 45 degree dump, 7 foot

(2134 mm) dump height ..................................... 1 758 mm (5 foot 9.2 inch)F. Bucket rollback at ground line ......................................................... 39 degreeG. Digging Depth, bucket flat .................................................... 30 mm (1.2 inch)H. Wheel Base ................................................................... 3 404 mm (134 inch)

Tread width ...................................................................... 2 210 mm (87 inch)J. Overall length ...................................................... 8 637 mm (28 foot 4.0 inch)K. Overall height to top of ROPS cab ....................... 3 571 mm (11 foot 8.6 inch)L. Height to top of exhaust pipe ............................... 3 526 mm (11 foot 6.8 inch)M. Height to top of steering wheel ............................. 2 837 mm (9 foot 3.7 inch)


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SPECIFICATIONS

OPERATING DATA AND DIMENSIONS 921C XRSpecifications taken with 26.5 x 25, 20 PR, L3 tires, ROPS cab with heater, 2450kg (5400 pound) rear counterweight, fenders, lights, full fuel, and a 80 kg (175pound) operator. Specifications per SAE J732, J1234, J742, and J818.

BS02B176

XR Machines with 3.63 m3 (4.75 yd3) General Purpose Bucket

Tipping load, machine straight ............................. 15 375 kg (33 896 pounds)Tipping load, 40 degree turn ................................ 12 358 kg (27 245 pounds)

A. Overall operating height, fully raised ................... 6 186 mm (20 foot 3.6 inch)B. Height to bucket hinge pin, fully raised .............. 4 835 mm (15 foot 10.4 inch)C. Dump height, 45 degree dump, full height ........... 3 698 mm (12 foot 1.6 inch)D. Bucket reach, 45 degree dump, full height .......... 1 174 mm (3 foot 10.2 inch)E. Bucket reach, 45 degree dump, 7 foot

(2134 mm) dump height ........................................ 2 232 mm (7 foot 3.9 inch)Dump angle at full height ................................................................ 45 degree

F. Bucket rollback at ground line ........................................................ 39 degreeG. Digging Depth, bucket flat .................................................... 44 mm (1.7 inch)H. Wheel Base .................................................................... 3 404 mm (134 inch)

Tread width ....................................................................... 2 210 mm (87 inch)J. Overall length (without bucket teeth) ................... 9 173 mm (30 foot 1.1 inch)K. Overall height to top of ROPS cab ...................... 3 571 mm (11 foot 8.6 inch)L. Height to top of exhaust pipe ............................... 3 526 mm (11 foot 6.8 inch)M. Height to top of steering wheel .............................. 2 837 mm (9 foot 3.7 inch)


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BS02B176

XR Machines with 3.63 m3 (4.75 yd3) General Purpose Bucket with Teeth and Bolt on Edges

Tipping load, machine straight .............................. 14 927 kg (32 908 pounds)Tipping load, 40 degree turn ................................. 11 914 kg (26 265 pounds)

A. Overall operating height, fully raised .................. 6 186 mm (20 foot 3.5 inch)B. Height to bucket hinge pin, fully raised ............. 4 834 mm (15 foot 10.3 inch)C. Dump height, 45 degree dump, full height ........... 3 491 mm (11 foot 5.4 inch)D. Bucket reach, 45 degree dump, full height ........... 1 323 mm (4 foot 4.1 inch)E. Bucket reach, 45 degree dump, 7 foot

(2134 mm) dump height ....................................... 2 305 mm (7 foot 6.7 inch)Dump angle at full height ................................................................ 45 degree

F. Bucket rollback at ground line ......................................................... 40 degreeG. Digging Depth, bucket flat .................................................... 84 mm (3.3 inch)H. Wheel Base ................................................................... 3 404 mm (134 inch)

Tread width ...................................................................... 2 210 mm (87 inch)J. Overall length ......................................................... 9 451 mm (31 foot 0 inch)K. Overall height to top of ROPS cab ....................... 3 571 mm (11 foot 8.6 inch)L. Height to top of exhaust pipe ............................... 3 526 mm (11 foot 6.8 inch)M. Height to top of steering wheel ............................. 2 837 mm (9 foot 3.7 inch)


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SPECIFICATIONS

BS02B176

XR Machines with 3.82 m3 (5.0 yd3) General Purpose Bucket

Tipping load, machine straight .............................. 15 393 kg (33 937 pounds)Tipping load, 40 degree turn ................................. 12 359 kg (27 247 pounds)

A. Overall operating height, fully raised ................... 6 408 mm (21 foot 0.3 inch)B. Height to bucket hinge pin, fully raised .............. 4 835 mm (15 foot 10.3 inch)C. Dump height, 45 degree dump, full height ........... 3 679 mm (12 foot 0.9 inch)D. Bucket reach, 45 degree dump, full height .......... 1 192 mm (3 foot 10.9 inch)

Dump angle at full height ................................................................ 45 degreeE. Bucket reach, 45 degree dump, 7 foot

(2 134 mm) dump height ....................................... 2 243 mm (7 foot 4.3 inch)F. Bucket rollback at ground line ........................................................ 39 degreeG. Digging Depth, bucket flat .................................................... 44 mm (1.7 inch)H. Wheel Base .................................................................... 3 404 mm (134 inch)

Tread width ....................................................................... 2 210 mm (87 inch)J. Overall length (without bucket teeth) ................... 9 199 mm (30 foot 2.2 inch)K. Overall height to top of ROPS cab ...................... 3 571 mm (11 foot 8.6 inch)L. Height to top of exhaust pipe ............................... 3 526 mm (11 foot 6.8 inch)M. Height to top of steering wheel .............................. 2 837 mm (9 foot 3.7 inch)


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SPECIFICATIONS

OPERATING WEIGHT ADJUSTMENTS

Optional Equipment

Tire Weight Adjustments

NOTE: It is Case Corporation�s recommendation NOT to add ballast to the tires ofyour machine. Keep tires inflated to the correct pressure. See Tire Pressure Chartin this manual.

VERTICAL HEIGHT ADJUSTMENT

Item (kg) Pounds2100lb Counterweight - 1500 - 3 307ROPS Canopy -134 -295

Item (kg) Pounds26.5 R 25, XHA TL★ + 208 + 46026.5 x 25, 20 PR, L2 - 205 - 45226.5 x 25, 20 PR, L3 0 026.5 x 25, 20 PR, L4 + 528 + 1 16426.5 x 25, 20 PR, L5 + 722 + 1 59226.5 R 25, XLDD1A TL★ + 1 495 + 3 296

Item mm Inch

26.5 x 25, 20 PR, L3 + 45.7 + 1.8

26.5 x 25, 20 PR, L4 + 45.7 + 1.8

26.5 R 25 XHA TL★ + 45.7 + 1.8

26.5 R 25 XRDD1A TL★ + 45.7 + 1.8

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SPECIFICATIONS

SPECIAL BOLT TORQUESNm POUND-FOOT

Cover plate to rear trunnion bar ...........................108 to 122 (80 to 90)Trunnion rear inner plate to axle ..........................285 to 319 (210 to 235)Trunnion casting mounting...................................658 to 739 (485 to 545)Engine support bracket to rear chassis................386 to 434 (285 to 320)Transmission mounting to transmission........... 1125 to 1274 (830 to 940)Drive line mounting bolts......................................136 to 149 (100 to 110)Transmission to flywheel housing ............................54 to 60 (40 to 44)Fan mounting nut .................................................108 to 122 (80 to 90)Wheel mounting nuts ...........................................515 to 569 (380 to 420)Carrier bearing bolt ..............................................149 to 163 (110 to 120)Hydraulic pump to transmission ...........................237 to 258 (175 to 190)Engine and transmission shock mount nuts.......929 to 1044 (685 to 770)Cab and canopy mounting bolts...........................786 to 841 (580 to 620)Counterweight bolts ......................................... 1125 to 1261 (830 to 930)Hydraulic tank cover bolt..........................................20 to 27 (15 to 20)Flex plate to flywheel ...............................................32 to 41 (24 to 30)Hydraulic oil filter head to mounting bracket ............20 to 27 (15 to 20)Engine shock mount nuts.....................................397 to 447 (293 to 330)Steering wheel retaining nut.....................................41 to 47 (30 to 35)Loader linkage pin keeper....................................386 to 434 (285 to 320)Front axle mounting bolts.................................1871 to 1979 (1380 to 1460)Muffler clamp to elbow .............................................62 to 73 (46 to 54)Muffler clamp at turbo ..............................................16 to 19 (12 to 14)Front steering pin bolt ..........................................664 to 691 (490 to 510)Articulation pivot mounting ...................................205 to 235 (151 to 173)Articulation mounting pin keeper..........................488 to 515 (360 to 380)Upper articulation pin keeper bolt ........................386 to 434 (285 to 320)Brake pump bolts ................................................... 88 to 100 (65 to 74)Brake pump gear nut ...........................................108 to 122 (80 to 90)Brake pump suction line clamps .............................. 10 to 11 (7.5 to 8.3)Muffler to bracket .....................................................66 to 85 (49 to 63)Muffler bracket to engine..........................................60 to 76 (44 to 56)Charge air cooler bolts .............................................28 to 34 (20.6 to 25.2)Charge air hose clamps .............................................9 to 10 (6.7 to 7.5)Exhaust stack to hood..............................................27 to 30 (19.8 to 22.3)Cooler frame mounting bolts ................................ 118 to 149 (87 to 110)

NOTE: All torques are listed with dry threads.

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INDEXA

Access Doors ................................ 147Adding Air To The Tires ................ 137Adding Ballast Weight To

Machine .................................... 135Adjustment Knob for Wrist Rest ...... 81After Delivery Check ............. 235, 237Air Cleaner .................................... 158Air Cleaner Cap ............................. 158Air Conditioning ............................. 185

Circuit Breakers for Condenser Blower Fans ..................... 186

Lubrication of the Air Conditioning Compressor Seals ............ 185

Temperature Control ................... 84Air Conditioning Compressor ........ 185Air Conditioning Compressor

Belt ............................................ 205Air Conditioning Condenser .......... 185Air Conditioning Indicator ................ 44Air Filter - Cab ............................... 181Air Filter Indicator ............................ 45Air Filter Primary Element ............. 159Air Filter Secondary Element ........ 159Air Filter Service Specifications ..... 158Air Filter System ............................ 158Air Filter, Cleaning ......................... 161Air Louvers, Cab ............................. 89Alternator Belt ............................... 205

Removal and Installation ........... 206Autoshift Switch ......................... 85, 86Auxiliary Hydraulic Connection ..... 120Auxiliary Hydraulic System

Specifications .......................... 120Auxiliary Power Equipment Mounting

Bracket .................................... 212Auxiliary Power Outlet ................... 212Axle ZF

Oil Change, Front Axle .............. 179Axle Oil Change, Front .................. 179Axle Oil Change, Rear .................. 180Axle Oil Level ................................ 178Axle Service Specifications ........... 178

Axle, ZFOil Change, Rear Axle .............. 180

Axles ZF ................................ 178, 179

BBallast, Wheel ............................... 135Batteries

Cold Weather Operations ......... 131Battery ........................................... 210

Fluid Level ................................. 210Safety ........................................ 209Service ...................................... 209Vents ......................................... 210

Battery Cleaning ............................ 210Battery Connection - Booster ........ 105Battery Fluid Level ........................ 210Battery Safety ................................ 209Battery Service .............................. 209Battery Vents ................................. 210Beacon Indicator ............................. 38Before Starting The Engine ............. 99Belt

Alternator, Removal andInstallation ........................ 206

Belt - Air ConditioningCompressor .............................. 205

Belt - Alternator ............................. 205Belt, Seat ....................................... 202Belts

Seat ........................................... 100Belts, Seat ....................................... 96Bleeding the Brake System ........... 173Blower Fan Switch .......................... 81Bolt Torques, Special .................... 226Booster Battery Connection .......... 105Brake

Park, Switch ................................ 36Parking, Check .......................... 200

Brake Pressure Indicator ................. 39Brake System

Bleeding .................................... 173Brakes

Pedals ......................................... 68

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226

BucketHeight Control Adjustment .........193Height Control Minor

Adjustment ........................193Bucket Height Contro

l Adjustment ...............................193Bucket Height Control Function .....116Bucket Height Control Minor

Adjustment ...............................193Bucket Level Indicator ....................119Bulbs, Replacement .......................213

CCab

Cab Headliner ............................186Door Hinges ...............................186Hoses and Wiring ......................186Operators Seat ..........................187

Cab Air Filter ..................................181Circulation Cover ........................181Cleaning .....................................182Removal and Installation ...........181

Cab Headliner ................................186Cab Service ...................................185Cap, Air Cleaner ............................158Caution Master Indicator ..................42Chart - Tire Pressure .....................138Chart, Lubrication ...........144, 145, 146Chart, Maintenance ........144, 145, 146Charts

Hydraulic System Fluid ..............168Chemicals, Hazardous .....................16Cleaning The Air Filter ...................161Cleaning the Batteries ....................210Cleaning The Battery .....................210Cleaning The Cooling System .......164Clutch Calibration

Main Codes ................................197Sub-Codes .................................197Transmission .............................196

Conditioner, Fuel ............................165Console

Front ............................................33Identification Front .....33, 35, 36, 37

Console Front ......................35, 36, 37Control

Steering Wheel Tilt ......................35

Control LeversFour Spool Valve - Two Control

Levers .............................. 114Three Spool Valve - Three Control

Levers - ............................. 112Three Spool Valve - Two Control

Levers .............................. 113Two Spool Valve - One Control Lever

111Two Spool Valve - Two Control

Levers .............................. 110Control Levers - Loader ................ 110Controls

Air Conditioning Temperature ..... 84Blower Fan .................................. 81Hand ......................... 33, 35, 36, 37Heat, Cab .................................... 81Lamp Switch ............................... 83Wiper/Washer Switch ................. 82

Coolant Filter, Engine .................... 163Cooling System

Cold Weather Operations ......... 131Coupler Pin Engage Switch ............ 87Coupler Pin Engagement .............. 123

DDecals, Safety ................................. 17Declutch Switch ............................... 84Defrost Air Louvers ......................... 90Detent On/Off Switch ...................... 84Diesel Fuel System ....................... 165Disabled Machine Towing ............. 128Display Center

Transmission .................. 65, 66, 67Displays Warning

Non - Critical Warning Displays .. 42Door Hinges .................................. 186Door Hinges Maintenance ............. 186Door Latch ....................................... 91Door, Access ................................. 147

EElectrical

Service Connector .................... 211Electrical System ........................... 209Emergency Exit ............................... 97

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EngineData .......................................... 217Ether Starting of ........................ 104Specifications ............................ 217

Engine CoolantCleaning the Cooling System .... 164Fluid Level ................................. 163

Engine Coolant Heater .................. 104Engine Coolant Mixture ................. 162Engine Coolant Temperature

Gauge ......................................... 51Engine Cooling System

Coolant Mixture ......................... 162Service Specifications ............... 162Thermostat ................................ 162

Engine Cooling SystemSpecifications ............................ 162

Engine Hourmeter ......................... 142Engine Lubrication ........................ 153Engine Oil Change ........................ 156Engine Oil Filter ............................. 156Engine Oil Level ............................ 155Engine Oil Pressure Gauge ............. 50Engine Oil Selection ...................... 153Engine Service Specification ......... 155Engine Speed ................................ 102Environment .................................. 141Exit

Emergency .................................. 97Extinguisher Mounting, Fire .......... 208

FFact Attachment ............................ 123Filter

Air .............................................. 159Cab Air ...................................... 181Coolant ...................................... 163Engine Coolant ......................... 163Engine Oil ................................. 156Fuel ........................................... 167Hydraulic Oil .............................. 170Transmission Oil ....................... 176

Filter Replacement, Air .................. 159Filter Replacement, Engine

Coolant ...................................... 163Filter Replacement, Engine Oil ..... 156

Filter Replacement, Hydraulic Oil .. 170Filter Replacement, Transmission

Oil .............................................. 176Fire Extinguisher Mounting ............ 208Fire Prevention Information ............. 14First Service Intervals .................... 100Fittings, Grease

100 Hours ................................. 148250 Hours .................................. 1491000 Hours ............................... 14950 Hours ................................... 148

Float .............................................. 117Fluid and Lubricants ...................... 143Fluid and Lubricants, Capacities ... 143Fluid Level ..................................... 163Fluid Levels ................................... 150

10 Hours ................................... 150250 Hours ................................. 15250 Hours ................................... 151

Foot PedalsBrake Pedals ............................... 68Foot Throttle ................................ 68

Four-Way Flasher Lamp .................. 38Four-Way Flasher Switch ................ 33Front Console ................ 33, 35, 36, 37

Four-Way Flasher ....................... 33Pilot Control Switch ..................... 33Program/Reset Switch ................ 34Up/Down Count Switch ............... 34

Fuel Conditioner ............................ 165Fuel Filter ...................................... 167Fuel Level Gauge ............................ 49Fuel Storage .................................. 166Fuel System

Cold Weather Operations ......... 131Diesel Fuel Specifications ......... 166Fuel Conditioner ........................ 165Fuel Filter .................................. 167Fuel Storage ............................. 166Removing Water From The Fuel

System ............................. 167Fuel System Service

Specifications ............................ 165Function Switches - Loader ........... 115Fuse Panel .................................... 211Fuses ............................................ 211

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GGauge

Engine Coolant Temperature .......51Engine Oil Pressure......................50Fuel Level ....................................49Hydraulic Oil Temperature ...........47Transmission Oil Temperature ....46Volt Meter ....................................48

General Safety ...............................139Grease Fittings

1000 Hours ................................149250 Hours ...................................149100 Hours ...................................14850 Hours ....................................148

HHand Signals ....................................29Heat Control, Cab ............................81Horn .................................................36Hoses and Wiring ...........................186Hot Weather Operation ..................133Hourmeter, Engine .........................142Hydraulic Connection - Auxiliary ....120Hydraulic Filter Test .......................169Hydraulic Oil Filter ..........................170Hydraulic Oil Filter Indicator .............45Hydraulic Oil Temperature Gauge ...47Hydraulic System

Filter Replacement .....................170Fluid Chart .................................168Hydraluic Filter Test ...................169Hydraulic/Brake Oil Change ......171

Hydraulic System Service Specifications ..........................168

Hydraulic/Brake Oil Change ...........171

IIdentification Numbers .......................4Indicator

Air Conditioning ...........................44Air Filter .......................................45Beacon .........................................38Brake Pressure ............................39Caution Master ............................42Hydraulic Oil Filter .......................45Lamp ............................................39

Low Coolant ................................ 39Parking Brake ............................. 44Pilot Lockout ............................... 39Secondary Steering .................... 44Stop Master ................................ 40Transmission Oil Filter ................ 45

Indicator Lamps, Instrument Panel ............ 38, 39, 40, 42, 44, 45,

46, 47, 48, 49, 50, 51Information Center .......................... 52

Programming ........................ 53, 59Instructions, General Safety .......... 139Instrument Cluster .............. 38, 39, 40,

42, 44, 45, 46, 47, 48, 49, 50, 51Instrument Panel Indicator

Lamps ................ 38, 39, 40, 42, 44, 45, 46, 47, 48, 49, 50, 51

JJump Start ..................................... 105

KKey Switch, Ignition ......................... 37

LLamp Indicator ................................ 39Lamp Switch, Cab ........................... 83Lamps

Four-Way Flasher ....................... 38Turn Signal ................................. 38

LatchDoor ............................................ 91Window ....................................... 91Window Retainer ........................ 92

LeverTransmission Control .................. 35Turn Signal ................................. 36

LeversLoader Control ............................ 69

Link, Safety ................................... 141Link, Transport .............................. 141Loader

Bucket Height Control Adjustment ....................... 193

Bucket Height Control Minor Adjustment ....................... 193

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Return-To- Travel MinorAdjustment ....................... 190

Return-To-Dig Adjustment ........ 188Loader Adjustments ...................... 188Loader Control Levers ............. 69, 110

Four Spool - Two Levers ............. 78Three Spool - Two Levers ........... 74Two Spool - One Lever ............... 69Two Spool - Two Levers ............. 71

Loader Function Switches ............. 115Bucket Height Control ............... 116Float .......................................... 117Return-To-Travel ....................... 116

Loader Operating Tips .................. 125Leveling Operation .................... 125Pushing Operation .................... 125Scraping Operation ................... 125Transport and Carry

Operation ......................... 126Loader Operations

Cold Weather ............................ 131Louvers

Defrost Air ................................... 90Main ............................................ 89Recirculation ............................... 89

Low Coolant Indicator ..................... 39Lubrication Analysis,

Systemgard ....................... 140, 157Lubrication Chart ........... 144, 145, 146Lubrication, Engine ....................... 153

MMachine Components ....................... 7Machine Operation ........................ 106

Before Operating ....................... 106Transmission Operation ............ 108

Machine Storage ........................... 215Removal From .......................... 216Storage Preparaton ................... 215

Machine Storage Removal ............ 216Machine Tie Down Locations ........ 130Main Air Louvers ............................. 89Maintenance and Inspection of

ROPS ........................................ 202

Maintenance Chart ........ 144, 145, 146Master Disconnect Switch ............... 88

OOil Change, Engine ....................... 156Oil Level

Axle ........................................... 178Engine ....................................... 155Transmission ............................. 176

Oil Level, Transmission ................. 176Oil Selection, Engine ..................... 153Oil Viscosity/Temperature

Ranges ...................................... 154Operating Data Specifications

921C ......................................... 219Operating Data Specifications

921C -XR .................................. 222Operating Dimensions

Specifications .................... 219, 222Operating In Hot Weather ............. 133Operating Instructions ..................... 99

Before Starting The Engine ......... 99Operating The Machine ................. 106Operating Tips - Loader ................ 125Operating Weight Adjustments ...... 225Operator Manual Storage

Compartment ................................ 3Operators Seat ........................ 92, 187Optional Equipment ....................... 225Owner, To The .................................. 1

PPark Brake Switch ........................... 36Parking Brake Check .................... 200Parking Brake Indicator ................... 44Parking The Machine .................... 103Pedals, Foot .................................... 68Pilot Control Switch ......................... 33Pilot Lockout Indicator ..................... 39Plastic and Resin Parts ................. 141Power Outlet, Auxiliary .................. 212Pressure, Tire ................................ 135Primary Element, Air Filter ............ 159Priming the Turbocharger Lines

with Oil ...................................... 102

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Product Identification Number ............4Program/Reset Switch .....................34Programming

Gauge Displays ...........................58Information Center .................53, 59Setting Display Center Lamp .......63

RRadiator

Fluid Level .................................163Radio ................................................91Rear Wiper/Washer Switch ..............85Remove From Storage ...................216Removing Water From The Fuel

System .....................................167Reservoir, Windshield Washer .......183Return-To-Dig Adjustment .............188Return-To-Dig Function .................115Return-To-Travel ............................116Return-To-Travel Minor

Adjustment .................................190Return-To-Travel Switch ..................84Ride Control ...................................119Ride Control Switch .........................85Roll-Over Protective Structure .......202ROPS .............................................202

Cab Torque ................................202Canopy Torque ..........................202Damage to .................................203Maintenance and

Inspection of ......................202Seat and Seat Belt, Torque

Specifications ....................204Seat Belt ....................................202

ROPS Cab TorqueSpecifications .............................202

ROPS Canopy TorqueSpecifications .............................202

ROPS Damage Information ...........203Rotating Beacon ............................124Rotating Beacon Switch ...................86Run-In Procedure .............................99

SSafety

Decals ..........................................17

Hand Signals .............................. 29Hazardous Chemicals ................. 16Utility ........................................... 10

Safety Instructions, General .......... 139Safety Link, Service ...................... 141Safety Rules ...................................... 9

Before Operation ........................ 11Burn Prevention .......................... 14Fire/Explosion Prevention ........... 14Machine Operation ..................... 12Maintenance ............................... 13Parking the Machine ................... 12Wheels and Tires ........................ 15

Safety, Battery ............................... 209Safety/Decals/Hand Signals .............. 9Seat

Operators .................................... 92Optional Air Ride ......................... 93Standard ..................................... 92

Seat Belt ........................................ 202Seat Belts ................................ 96, 100

Inspection and Care .................... 96Seat Torque Specifications ........... 204Seat, Operators ............................. 187Secondary Element, Air Filter ....... 159Secondary Steering Indicator .......... 44Sediment Removal, Fuel System .. 167Serial Numbers ................................. 4Service Electrical Connector ......... 211Service Intervals - First ................. 100Service Safety Link ....................... 141Setting Display Center Lamp .......... 63Special Bolt Torques ..................... 226Specifications

Air Filter .................................... 158Auxiliary Hydraulic System ....... 120Axle ........................................... 178Bucket ....................................... 218Cooling System, Engine ........... 162Diesel Fuel System ................... 165Engine Cooling System ............ 162Engine Service .......................... 155Fuel System .............................. 165Hydraulic System ...................... 168Machine ............................ 219, 222

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Machines with 4.75 yd3 (3.63 m3) General Purpose Bucket with Teeth and Bolton Edges .......................... 220

Machines with 5.0 yd3 (3.82 m3) General PurposeBucket .............................. 221

ROPS Torque ........................... 202Seat Torque .............................. 204Special Bolt Torques ................. 226Thermostat ................................ 162Tire Weight ................................ 225Transmission ............................. 175Travel Speeds ........................... 218Vertical Height Adjustment ........ 225Weight Adjustments .................. 225XR Machines with 4.75 yd3 (3.63

m3) General PurposeBucket .............................. 222

XR Machines with 4.75 yd3 (3.63 m3) General Purpose Bucket with Teeth and Bolt on Edges .......................... 223

XR Machines with 5.0 yd3 (3.82 m3) General PurposeBucket .............................. 224

Specifications, Engine Data .......... 217Starting The Engine ...................... 101Steering Wheel Tilt Control ............. 35Steering, Secondary ...................... 199Stop Master Indicator ...................... 40Stopping The Engine ..................... 103Storage Compartment

Operator Manual ........................... 3Storage Removal, Machine ........... 216Storage, Fuel ................................. 166Switch

Autoshift ...................................... 85Blower Fan .................................. 81Coupler Pin Engage .................... 87Declutch ...................................... 84Detent On/Off .............................. 84Four-Way Flasher ....................... 33Key/Ignition ................................. 37

Lamp ........................................... 83Master Disconnect ...................... 88Park Brake .................................. 36Pilot Control ................................ 33Program/Reset ............................ 34Rear Wiper/Washer .................... 85Return-To-Travel ......................... 84Ride Control ................................ 85Rotating Beacon ......................... 86Up/Down Count ........................... 34Wiper/Washer ............................. 82

Systemgard Analysis ............. 140, 157

TThermostat Specifications ............. 162Throttle, Foot ................................... 68Tire Or Rim Service ....................... 137Tire Pressure ................................. 135Tire Pressure Chart ....................... 138Tire Tread Direction ....................... 137Tire Weight Adjustments ............... 225Torque - Wheel Nut ....................... 138Towing The Machine ..................... 128Towing, Machine ........................... 128Transmission

Breather Cleaning ..................... 176Clutch Calibration ...................... 196Clutch Calibration Main

Codes ............................... 197Clutch Calibration

Sub-Codes ....................... 197Cold Oil Level Check ................ 176Control Lever .............................. 35Filter Replacement .................... 176Oil Change ................................ 176Oil Level .................................... 176Operation of .............................. 108Warm Oil Level Check .............. 176

Transmission BreatherCleaning .................................... 176

Transmission Clutch Calibration ................................. 196

Transmission DisplayCenter ............................. 65, 66, 67

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Transmission Oil Filter ...................176Transmission Oil Filter Indicator .......45Transmission Oil Level ...................176Transmission Oil Level Check ........176Transmission Oil Temperature

Gauge ..........................................46Transmission Operation

Automatic Mode Operation ........109Down-shift Button, Automatic

Mode .................................109Down-Shift Button, Manual

Mode .................................109Down-Shifts Manual Mode .........109Manual Mode Operation ............108Shifting, Automatic Mode ...........109Up-Shifts Manual Mode .............108

Transmission ServiceSpecifications .............................175

Transport Link ................................141Transporting The Machine .............129Transporting The Machine

On A Trailer ...............................130Turbocharger

Priming the Lines with Oil ..........102Turn Signal Lever .............................36

UUp/Down Count Switch ....................34Utility Safety .....................................10

VVertical Height Adjustment .............225Volt Meter Gauge .............................48

WWarm Oil Level Check ...................176Warning Displays

Non - Critical Warning Displays ...............................42

Water Removal, Fuel System ........167

Weight AdjustmentsOptional Equipment .................. 225Tire Weight ............................... 225

Weight Adjustments - Operating ... 225Wheel And Tires ............................ 135Wheel Ballast ................................ 135Wheel Nut Torque ......................... 138Window Latch .................................. 91Window Retainer Latch ................... 92Windshield Washer Reservoir ....... 183Wiper/Washer Switch ...................... 82Wrist Rest ........................................ 81

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AFTER DELIVERY CHECKAFTER FIRST 100 HOURS OF OPERATION OF NEW MACHINE

Owners Name:

Address:

Dealers Name:

Address:

Machine Model Number: Hourmeter Indication:

Machine Product Identification Number (P.I.N.):

COOLING SYSTEMCheck the coolant levels.

Check for leaks.

FUEL SYSTEMCheck for leaks.

Drain water and sediment from the fuel tanks.

ELECTRICAL SYSTEMCheck battery.

Check operation of starter, alternator, and instruments.

Check operation of all lamps.

LUBRICATIONLubricate all pivot points.

Check the tansmission and axle oil level.

EngineCheck condition of drive belt.

Check engine oil level.

Check engine speed at idle and at full throttle.

Service air cleaner.

HYDRAULIC SYSTEMCheck the oil level.

Check the pressure setting of the main relief valve.

Replace the hydraulic oil filter.

GENERALLook for oil leaks and loose parts.

Check tire pressure.

Tighten all hose clamps.

Check drive chain tension..

Check wheel nut torque.

Check brake operation.

Check the control levers for correct operation.

Check the operators seat bar for correct operation.

SAFETYInspect the ROPS.

Check the safety decals and replace if necessary.

Check the operator restraint system.

Make sure the machine has the operators manual in the manual storage box.

DEALER: Make sure the owner and/or operator understands all the safety and information decals, the service information, and the service procedures in this manual.

Technician Signature:

Dealer Signature:

Owner Signature:

Owner Copy

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AFTER DELIVERY CHECKAFTER FIRST 100 HOURS OF OPERATION OF NEW MACHINE

Owners Name:

Address:

Dealers Name:

Address:

Machine Model Number: Hourmeter Indication:

Machine Product Identification Number (P.I.N.):

COOLING SYSTEMCheck the coolant levels.

Check for leaks.

FUEL SYSTEMCheck for leaks.

Drain water and sediment from the fuel tanks.

ELECTRICAL SYSTEMCheck battery.

Check operation of starter, alternator, and instruments.

Check operation of all lamps.

LUBRICATIONLubricate all pivot points.

Check the tansmission and axle oil level.

EngineCheck condition of drive belt.

Check engine oil level.

Check engine speed at idle and at full throttle.

Service air cleaner.

HYDRAULIC SYSTEMCheck the oil level.

Check the pressure setting of the main relief valve.

Replace the hydraulic oil filter.

GENERALLook for oil leaks and loose parts.

Check tire pressure.

Tighten all hose clamps.

Check drive chain tension..

Check wheel nut torque.

Check brake operation.

Check the control levers for correct operation.

Check the operators seat bar for correct operation.

SAFETYInspect the ROPS.

Check the safety decals and replace if necessary.

Check the operator restraint system.

Make sure the machine has the operators manual in the manual storage box.

DEALER: Make sure the owner and/or operator understands all the safety and information decals, the service information, and the service procedures in this manual.

Technician Signature:

Dealer Signature:

Owner Signature:

Dealer Copy

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CASE TECHNICAL MANUALSManuals are available from your Dealer for the operation, service and repair ofyour machine. For prompt convenient service, contact your Dealer for assistancein obtaining the manuals for your machine.

Your Dealer can expedite your order for operators manuals, parts catalogs,service 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 correctmanuals for your machine.

NOTE: Case, LLC. reserves the right to make improvements in design orchanges in specifications at any time without incurring any obligation to installthem on units previously sold.

CASE, LLC.700 STATE STREET

Printed in France RACINE, WI 53404 U.S.A.

Case 921 C Wheel Loader operating manual

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Transcript of Case 921 C Wheel Loader operating manual