OPERATORSINSTRUCTION

MANUAL 3695

miCHIGAn', .• mi VME GroupVOLVOBM

EUCLID

miCHIGAn L140OPERATORSINSTRUCTION

MANUAL

PUBLICATIONNO. 3695

DISTRIBUTOR.ADDRESS ...

DLR/BRCH.ADDRESS ..

\ .....• >' • "_ •. fI/" , ...-!..

. ;.~,-.:''i' :•.• ~i.iwll •••dOX "I

'~ON''t:NO.SERVICE PHONt:. rn.J...

SPARE PARTS PHONE NO ..

MACHINE:SERIAL NO..ENGINE TYPE/NO ...HYDRAULIC TRANSM. TYPE/NO ...

STARTING KEY NO ..CAB KEY NO..

Printed in U.S.A.

FOREWORD

The purpose of this manual is to serve as a guide to theproper operation and maintenance of your machine.Study this manual carefully before starting, operatingthe machine or performing any preventive maintenanceprocedures. Many hours have been spent in designingand producing the safest and most efficient machinepossible. All this time may be wasted if you do not readthe safety instructions and follow them. Become familiarwith all controls and instructions and keep this manualin the machine for handy reference. Machines usuallydo not cause accidents, people do. A safety consciousperson and a well maintained machine make a safe,efficient and profitable combination.

Operational instructions for many options are given inthis manual. Please disregard any instructions that donot apply to your machine. Illustrations in this manualmay show optional equipment.

It is our policy to constantly strive to improve ourproducts. The right therefore is reserved to makechanges in design and improvements whenever it isbelieved the efficiency of the product will be improved,without incurring any obligation to incorporate suchimprovements in any product which has been shippedor is in service.

SAFETY REGULATIONS

Each country has its own safety legislation. It is in theoperator's own interest to be conversant with theseregulations and to comply with them in full. This alsoapplies to local bylaws and regulations in force on aparticular worksite.Should the recommendations in this manual deviatefrom those of the user's country, the nationalregulations should be followed.

SAFETY ALERT SYMBOL

The symbol shown above will appear at various pointsin this manual in conjunction with warning statements.Its appearance means: "WARNING! BEALERT! YOURSAFETY IS INVOLVED!"

Note: Make sure that the warning Decals are read-able, otherwise accidents may occur.

KNOW THE CAPACITY AND LIMITS OF YOURMACHINE!

~C_O_N_T_E_N_T_S ~:>

'--P_R_E_s_E_N_T_A_TI_o_N ~)

'--I_N_S_TR_U_M_E_N_T__ PA__NE_L ~:>

~O_T_H_E_R_C_O_N_T_R_O_L_S ______':>

'--O_P_E_R_A_T_IN_G ~~:>

PREVENTIVE )~M_A_I_N_T_E_NA__NC_E ~

'--S_P_E_C_IF_IC_A_T_I_O_N_S ~:>

,--A_L_P_H_A_B_E_T_IC_A_L_I_N_D_EX__ ~)

UNAUTHORIZED MODIFICATION OF ROLLOVER PROTECTIVE STRUCTURE (ROPS)

Do not make unauthorized modifications or alterations to the ROPS such as: welding on fire extinguisherbrackets, CB antenna brackets, or fire suppression systems. Unauthorized modifications will affect thestructural limits of the ROPS and will void the certification.

The Rollover Protective Structures (ROPS) have been certified to meet specified test requirements. Thesecertifications are required by the U.S. Department of Labor under OSHA Regulation 1926.1000.

Any planned modification or change must be reviewed in advance by the Engineering Department todetermine if the modification or change can be made within the limits of the certifying tests.

It is important that each person in your organization, including management, be made fully aware of theserules involving the ROPS.

Whenever anyone sees a machine ROPS with unauthorized modifications or changes, both the customerand manufacture should be notified in writing.

SPARK ARRESTER MAY BE REQUIRED

Many states and other governmental entities have adopted laws and regulations which require sparkarresters on machines operating on or near forests, brush or grass covered lands within their jurisdiction.The Federal government also has regulations (Forest Services) which require spark arresters on machinesoperating on National lands.

Use of machines without spark arresters in areas where such use is prohibited by law or regulation cansubject the owner or operator of the machine to penal fines or civil damages, including the costs of firesuppression.

Spark arresting equipment complying with the applicable laws and regulations must be installed on anymachines which are likely to be operated in such areas. All machines which are converted for woodland use(loggers, harvesters, etc.) should be equipped with approved spark arresting equipment.

Machines with turbo charged engines do not require additional spark arresting equipment to comply withcurrently known laws and regulations.

TABLE OF CONTENTS

PRESENTATION 1Maintenance and Inspections 3Nameplates and Decals 4Product Identification 9INSTRUMENT PANEL 12Left Hand Instrument Panel 12Right Hand Instrument Panel 18Overhead Panel 22OTHER CONTROLS 25OPERATING 32Prepare to Operate 32Procedure Before Starting 32Run In Instructions 34Starting Engine 35Before Operating 36Operating·the Machine 37General Information 37Application 38

PARKING MACHINE 43Short Term 43Long Term 44TRANSPORTING 46TOWING 46DELIVERY AND SITE TO SITE INFORMATION 46PREVENTIVE MAINTENANCE 47Service Position 47A Few Simple Rules When Servicing 48Maintenance Intervals 51Basic Maintenance Procedures 53SPECIFICATIONS 87ALPHABETICAL INDEX 93

NOTES

TS40115

PRESENTATION

The L140 is a wheel loader with articulated frame steering and four wheel drive. It weighs approximately

19,151 kg (42220 Ibs.)

ENGINE

The engine is a six cylinder, in line 4 cycle turbocharged Cummins LT-10-C250 diesel engine.

DRIVE TRAIN

The drivetrain includes a high efficiency, single-stage single phase torque converter and a countershaft type,powershift with directional clutch modulation transmission.

The fixed front and oscillating rear axles utilize full floating axle shafts with planetary type hub reductions ineach wheel. Limited slip differentials are included in both the front and rear axles.

BRAKES

The brake system is a dual circuit, fully hydraulic, outboard mounted dry disc brake system. One brakecircuit is for the front axle and one for the rear axle with one brake caliper per wheel. Application of the leftpedal neutralizes the transmission as well as applying the brakes.

The machine is equipped with a spring applied, hydraulically released dry disc parking brake mounted on thefront axle input flange.

STEERING

The articulated frame machine is equipped with a fully hydraulic steering system with a separate pump andtwo double acting cylinders.

CAB

The machine is equipped with a cab that has been RaPS/FOPS tested and approved in accordance withSAE J1040C and SAE J231. The cab is equipped with a filtered fresh air heater and pressurizing system.The cab has two exits; one through the left hand door and the other, the right hand door.

HYDRAULICS

The hydraulic system is closed and pressurized. Oil is pumped through a gear pump mounted on the torqueconverter to supply oil for the two double acting lifting cylinders and the two bucket cylinders.

2

TS40011

MAINTENANCE AND INSPECTIONS

MAINTENANCE

If the machine is to work as economically as possible,thorough maintenance is necessary. The recommended inter-vals for maintenance and lubrication refer to normal workingand environmental conditions. The maintenance work de-scribed in this manual can be carried out by the operatorhimself. Further adjustments and repairs to the the machineshould be performed by an authorized dealer.

INSPECTIONS

Delivery Inspections

Before the machine left the factory it was tested and adjusted.In addition to this, your dealer has carried out a further check,the "Delivery Inspection", according to our instructions beforethe machine was delivered to you.

Follow-Up Inspections

It is important that the machine receive further checks.Retightening of bolts, checking adjustments and other minormeasures have to be carried out. You are entitled to twoservice inspections free of charge. The first must be carriedout within the first 30 days or 100 hours of operation. Thesecond is to be completed within 6 months, but not more than1000 hours of operation.

The points in time at which these services should be carriedout may be changed without prior notice.

Maintenance Inspections

In addition to the maintenance listed in this manual, authorizeddealers offer maintenance programs which give an indicationof the general condition of the machine.

Further information about these programs can be obtainedfrom the nearest authorized dealer.

3

NAMEPLATES AND WARNING DECALS

6

1

.'_""_"'--'_'_-_ ..._ ...-...... '.._._, ....._ ..12 11

15

14T840117

The numbers on the illustration refer to the machine plates, warning and information decals which areinstalled on the machine. It is the responsibility of the operator to make sure that the yellow and blackwarning decals are readable, otherwise accidents may occur. If the decals are no longer readable, new onesshould be ordered and installed.

4

NAMEPLATES AND WARNING DECALS - Left Side

1. Heater Control- In cab on left side below panel.

2. Important- Release Parking Brake - Located above the heater control knob.

3. Gear Indicator- On plate below steering wheel; left side.

4. Bucket and Boom Operation- In cab on Boom/Bucket lever tower next to operator seat.

5. WARNING- Brake System - Located in cab on left side below panel.

6. Canopy Serial Number Plate- Located at upper right rear of cab.

7. WARNING- ROPS - Located at upper right rear of cab.

8. MICHIGAN- Model designation. (both sides)

9. L 140- Model designation. (both sides)

10. WARNING- Jump start - Radiator cowling above the battery box. (both sides)

11. WARNING- Side Panel. - On engine compartment hoodsides.

12. WARNING- Articulated Warning - (2) Located on front side of fuel tank and front side of hydraulictank.

13. Transmission oil level- Front of rear frame on left side behind fuel tank.

14. Pressure check- Front of rear frame on left side.

16. Filter Replacements- Located on left side rear of the front frame.

17. Lubrication Instructions- Located on rear left side of front frame.

5

NAMEPLATES AND WARNING DECALS

10

TS40116

The numbers on the illustration refer to the machine plates, warning and information decals which areinstalled on the machine. It is the responsibility of the operator to make sure that the yellow and blackwarning decals are readable, otherwise accidents may occur. If the decals are no longer readable, new onesshould be ordered and installed.

6

NAMEPLATES AND WARNING DECALS - Right Side

1. L 140- Model designation. (both sides)

2. MICHIGAN- Model designation.(both sides)

3. Serial Number Plate- Outside front of engine compartment behind cab.

4. Patent Decal- Outside front of engine compartment behind cab.

5. WARNING- Hydraulic Brake Pressure - Outside front of engine compartment behind cab.

6. Important- Engine Oil Change - On plate below right hand panel.

7. WARNING TAG- On steering wheel when servicing machine.

8. Hydraulic Oil Level- On side of the hydraulic tank next to sight gage ports.

9. WARNING- Articulated Warning - (2) Located on the front side of the Hydraulic tank and the frontside of the fuel tank.

10. Hydraulic Oil Filter- Located on the top front of the hydraulic tank.

11. WARNING- Hydraulic PressureWarning - On top front of hydraulic tank.

12. Important- Pressure Relief Element - Located on the hydraulic tank between the ladder mounts.

13. Transmission Drain- Bottom of transmission.

14. Transmission Oil Filter- Inside of the right rear frame.

15. Cooler in/Cooler out- On bracket inside engine compartment; left side.

16. WARNING- Battery Disconnect Switch - On rear right frame inside the engine compartment.

17. WARNING- Side Panel - On engine compartment hoodsides.

18. Lifting and Tie Down- Back side of battery box.

19. VME Nameplate- Lower right side on radiator guard.

7

NOTES

8

TS40127

TS19985

PRODUCT IDENTIFICATION NUMBER

VME AMERICAS INC. is a worldwide company withmanufacturing facilities in many countries. To aid in productionscheduling, certain machine models are produced in only oneplant and other machine models are built in several plants andexported to meet our world market requirements.

At the time of manufacture, every machine is assigned aproduct identification (serial) number to identify that machinefrom all others built by the VME Group.

The following breakdown explains the product identification(serial) numbering system.

000 X or XXXL4. Plant of Manufacture (1 to 3 letters)3. Production Sequence Number

,-----2. Production Lot Letter

L...-----1. Model, Engine & Version (3 or 4 digits)

Always use the complete product identification (serial) numberon all Delivery & Inspection Reports, parts orders, warrantyrequests, correspondence, service reports and literatureorders.

9

TS40287

TS19605

TS40137

PRODUCT IDENTIFICATION NUMBER (Serial Number)LOCATIONS

Rear frame--Iocated on the RH frame assembly to the rear ofthe battery box.

Front frame--Iocated on the RH rear of the front frameassembly.

Axle serial number.

10

TS40288

TS17959

TS40139

Engine serial number.

Torque Converter serial number.

Transmission serial number.

11

INSTRUMENT PANEL

BLOWER

• • •LOW MED HI

TS19964

j TEMPERATURE• • •COOL OFF WARM

TS19965

19TS40273

Note: Before operating the machine, the operator mustknow the location and proper operation of all controls.Read this manual carefully .

Observe the gauges and warning lights while working themachine. Do not operate the machine when gauges andwarning lights are not working properly.

1. BLOWER SWITCH:

With the temperature switch to heat or cool, this switchcontrols the blower fan speed in three positions. Push therocker switch to the left for low blower fan speed, push therocker switch to the middle position for medium blower fanspeed. Push the rocker switch to the right for high blower fanspeed.

2. TEMPERATURE SWITCH:

Controls the cab air temperature. Push the rocker switch tothe left to turn on the air conditioner. Push the rocker switch tothe right to turn on the heater. Push the rocker switch to themiddle position to turn the air conditioner, the heater and theblower off.

Note: Defroster Operation - The defroster function isactivated at the same time the temperature switch ispushed to the WARM position. The blower switch controlsthe force of air for the defroster.Turn the heater control knob counterclockwise all of theway if using the air conditioner.

12

~ WORK LIGHTS

-D· • •'/ FRONT OFF FRONT8 REAR

TS19966

TEST• •SEC.STEER

LAMPS

TS19967

COLDSTART

TS19968

3. WORKLIGHTSWITCH:

Push the switch to the left for front. Push the switch to theright for front,side and rear lights.

4. SECONDARYSTEER AND BULB TEST SWITCH(Optional):

Push the switch to the left with the engine running to checkthe secondarysteering system.The secondarysteeringsystemwarning light must flash. The audio alarm and the secondarysteeringmotor and pumpmust operate. (Listen to the sound ofthe pump motor.) If the system does not operate correctly,report any needed repairs before operating the machine. Pushthe switch to the right to test the warning lights for properoperation.

5. COLDSTARTSWITCH:

In ambient temperatures of 10'G (50'F) or below, it may benecessary to engage the cold start switch. Turn the ignitionswitch key to the START position and begin to crank theengine. Push the cold start switch and release. Do not holdthe cold start switch in. If the engine does not start, push thecold start switch again and release while continuing to crankthe engine.

Note: The cold start switch will not activate unless theignition switch key is in the STARTposition.

13

T819969

e \0 ::~E~ .t:!l. =~~~EIDIFF.~ .(0). ~~~~~

~.(O). REARBRAKE

T819970

19T840273

6. HOURMETER:

Indicates total hours of engine operation. The hourmeterprovides a record of operating hours for preventive mainte-nance scheduling.

7. PARKING BRAKE WARNING LIGHT AND AUDIBLEALARM:

The parking brake has two indications:

• Parking Brake Engaged -- Solid amber light.

• Parking Brake Engaged, transmission in gear -- solidamber light and warning buzzer.

8. BRAKE PUMP/DIFFERENTIAL WARNING LIGHT:Two indications.

• Brake pump failure -- solid red light and warning buzzer.

• Pressure differential between front and rear brake systems-- flashing red light.

9. FRONT BRAKE WARNING LIGHT:

Flashing red light indicates low front brake accumulatorpressure.

10. REAR BRAKE WARNING LIGHT:

Flashing red light indicates low rear brake accumulatorpressure.

14

~.~ .. tb~DITIONW \&I PRESSURE~ ~ SECONDARY~ 1:1..6 STEERING

~ ® TRANSMISSION~WFILTER

TS19971

ENGINE OILPRESSURE

COOLANTLEVEUTEMPERATURE

((90 ALTERNATORQ~ ~~LEVEL

TS40274

11. AIR CONDITIONERWARNINGLIGHT: (Optional)

System malfunction -- solid red light.

12. SECONDARYSTEERING SYSTEM WARNING LIGHT(OPTIONAL):

The secondary steering system is in effect when red lightflashes and audio alarm activates. When the steering systemis activated, safely stop and shut down the machine.

13. TRANSMISSIONFILTERWARNING LIGHT:

Solid red light that warns when transmission fluid is at filterbypass pressure (transmission filter requiring immediateservicing).

14. LUBE FAULT WARNINGLIGHT (Optional):

Solid red light when automatic lube system has eithercondition:

• High lube pressure.

• Low lube level.

15. ENGINEOIL PRESSURE(Optional):

Flashing red light indicates low engine oil pressure.

16. COOLANT LEVEL/TEMPERATURE(Optional):

• Coolant level drop -- solid red light and warning buzzer.• Coolant temperature too high -- solid red light.

17. ALTERNATOR(Optional):

Solid red light indicates low alternator output.

18. FUEL LOW LEVEL (Optional):

• Solid red light indicates low fuel level.

15

2 430 CLIMATE

CONTROL-V.IC'"_.,,,_$1"-·"DJU$''''o-..SfHItOG'OOIOI_IO"·"OW

IMPORTANT'U'_OO_'OIIaCI~"'1'I"~W",M""'_'_D._._ .....-.,...._-

0

1 2

~15\::I_r--~-u;,,;;--16

E? COOl .... r~. U'lEu.,... lfllHU,TUM 17GE:!I"llf"'-"'T~~18

19

ffi!Cwx

0-W..

o:§lUlOIDz!::io:zo000X::tID

z°;::iii\2

000 0000

16

o

T840273

T840275

19. CIRCUIT BREAKERS:

Circuit breakers provide protection for the various electrical circuits. To reset circuit breakers, wait 30seconds and push in. Circuit breaker protection is provided as follows:Option:Rear Lights 15 AmpHeater 15 AmpHorn/Monitor/Boom/BucketiLube 15 AmpSide Lights 15 AmpFront Lights 15 AmpBrake Lights 15 AmpIgnition 15 Amp

Other Circuit Breakers

Main (located in engine compartment) 100 AmpPark release -(Optional)

(located in engine compartment) 100 Amp

If any circuit breaker is repeatedly activated, troubleshoot the portion of the electrical system protected bythat circuit breaker without delay.

17

RIGHT HAND INSTRUMENT PANEL

o

o

2 4

0('5

8Ii !Ol"T!O!!P ..... .,a .. c:owr....C»8WIOII-..._~ ...-..CUtOUf ....-.utOII-... ..... _~.

7

1. FUEL GAUGE:

o

TS40276

Indicates the amount of fuel in the fuel tank with the ignitionswitch in the "ON" position.

TS19620

2. TRANSMISSION OIL TEMPERATURE GAUGE:

Indicates temperature of the fluid in the converter andtransmission. Normal operating temperature is 82,2-104,4"C(180-220°F).When the needle is at the 121°C(250°F)area ofthe gauge, do not operate the machine and determine thecause.

TS17806

18

TS40277

AUXILIARY.(0).PARKING BRAKERELEASE

DISENGAGEPARKINGBRAKETURN IGNITIONSWITCHTO·ON·POSITIONPRESSAUXILIARY RELEASESWITCH AND HOLDUNTILYELLOWPARKING BRAKELIGHT GOESOUT

TS19973

ENGINESHUT-DOWNCHECK OIL/COOLANT

TS19974

3. ENGINE OIL PRESSUREGAUGE (Mechanical):

Indicates oil pressure in the engine lubricating system. Areading of 205-275 kPa (30-40 psi) at low idle and 310-345kPa (45-50 psi) at high idle rpm indicates normal oil pressure.A lower reading indicates low oil pressure and is a warning totroubleshoot immediately. If the gauge does not register within10 to 15 seconds after engine is started, shut down engineimmediately and determine cause.

4. AUXILIARY PARKING BRAKE RELEASE(OPTIONAL):

In the event of a dead engine the parking brake release willactivate a motor, charging one of the brake accumulators andsupplying release pressure to the parking brake.

• Disengage the parking brake.

• Turn the ignition switch key to the" ON" position.

• Press the auxiliary release switch and hold until the yellowparking brake light goes out.

5. ENGINE SHUT-DOWN CHECK OIL/COOLANTLIGHT(OPTIONAL):

Indicates engine has been shut down because of low engineoil or engine coolant levels.

19

o

o

)~-.-~oo.o.... '",.....__ ..COI.O._'..._-"---..........n_·

o

8".'''S!!W!I!!!L'f

[~~-•o6

EB 8

12 VOLT POWER SUPPLY2 AMP CONTINUOUS OPERATIONUNIT IS THERMO PROTECTED ANDWILL CUTOUT WHEN OVER HEATED.OPERATION WILL RESUME WHEN COOLED.

o 0TS19975

TS17807

TS40276

6. DC POWER SUPPLY (Optional):

Two terminals are provided for electrical attachments requiringa 12 volt power source, such as radios, CBs or otherattachments.

7. WATER TEMPERATURE GAUGE:

Indicates the temperature of the engine coolant. Under normaloperating conditions, the gauge will read 71, 1-83,3°C(180-200°F). If the gauge reads above 93,3°C (200°F), stopwork, and idle the engine. Determine the cause of the highengine coolant temperature.

WARNING: Do not remove the radiator cap ifthe machine is hot. Loosen the cap slowly tolet the pressure out of the system.

20

TS19619

)~ IGNITION

OFF

ACC @ ON

~~~

COLD WEATHERSTARTINGPUSH a RELEASECOLD STARTBUTTON WHENCRANKING ENGINEREPEAT IFNECESSARY

TS19976

8. BATTERYGAUGE:

Indicates the condition of the batteries. With the ignition switchin the "ON" position, the battery gauge will indicate the voltageavailable from the batteries. When the needle is below 24volts, the batteries are low. When the needle is between 24and 28 volts, the batteries are fully charged. When the needleis in the red area with the engine running, check the chargingsystem.

9. IGNITIONSWITCH:

Energizes all gauges, warning lights, warning buzzer, switchesand starting motor. Actuates starting motor only when turnedall the way to the right. Shuts engine down when in the "OFF"position.

21

OVERHEAD INSTRUMENT PANEL

8

°0 0"'" on °0o ~~ sbJ 0

CJ] I[q) I WASHER1

0 1[91FRONT 1WIPERTS19977

~ i I]If L5. I DOME 1-, I ,- LIGHTS

0 [91~~~:R )TS19978

7 9

Pull the knob out to the first position for moderate wiperspeed. Pull the knob out further to the second position for fastwiper speed.

2. WINDSHIELD WASHER SWITCH:

Push the switch to activate the washer.

3. REAR WIPER SWITCH:

Pull the knob out to the first position for moderate wiperspeed. Pull the knob out further to the second position for fastwiper speed.

4. DOME LIGHTS SWITCH:

Push the switch to either rocker position to activate the cleardome light or the red dome light.

22

DD] II 01FRONT 1///11 FLOODS

TS40278

DTS19980

5. FRONT CAB LIGHTS SWITCH:

Push the switch to the "ON" position to energize the frontfloodlights on the ROPS canopy.

6. WARNING BEACON SWITCH (OPTIONAL):

Push the switch to the "ON" position to energize the beaconon the ROPS canopy.

23

8

°0 0'""'o ~~ :07 9

T540279

Circuit breakers are provided for protection of the overheadinstrument panel circuits. Circuit breaker protection is providedas follows:

WIPER/WASHER

FRONTFLOODS

T540286

24

TS19992

INDICATORLIGHT

TURNSIGNALLEVER

HAZARD WARNINGFlASHER LIGHT

~TS19612

TS17793

OTHER CONTROLS

PARKING BRAKE:

The parking brake has two manual positions, ENGAGE andRELEASE, and one automatic position, AUXILIARY. If theparking brake is engaged and the machine is in FORWARD orREVERSE, the parking brake knob automatically moves intothe AUXILIARY position. In this position, the service brakesare applied preventing "drive thru" damage to the parkingbrake.

Pull the parking brake knob out to engage the parking brakeand push the knob in to release the parking brake.

TURN SIGNAL/EMERGENCY FLASHER SWITCH:

To signal for a left turn, push the lever upward. To signal for aright turn, pull the turn signal lever down. To activate theemergency flashers, pull the switch outward. Push in todeactivate. The red light on the switch housing indicates whenthe signals or flashers are activated.

HEATER CONTROL KNOB:

Variable heater control for operator comfort. Turn the knobclockwise for more heat or counterclockwise for less heat.Turn the heater control knob counterclockwise completelywhen operating the air conditioner.

25

BUCKET BOOMDUMP FLOAT

fTLOWER --

HOLD ,:.,__HOLD,__

ROLLBACK RAISE...~=,

TS16422

2

TS40135

BOOM AND BUCKET CONTROL LEVERS

Boom Lever:

Pull the lever (1) all the way back to RAISE the boom.

Push the lever forward to the next position to reach the HOLDposition.

Hold the lever between FLOAT and HOLD for the LOWERposition.

Push the lever all the way forward to reach the FLOATposition.

Note: All boom lever positions are detent positionsexcept the LOWER position .

Bucket Lever:

Pull the lever (2) all the way back for the ROLLBACK position.

Push the lever forward to the next position to reach the HOLDposition.

Push the lever all the way forward to reach the DUMPposition.

Note: If the bucket is in the DUMP position, you can usethe bucket leveler to return the bucket to a level diggingposition. Pull the lever all the way back to theROLLBACK position and release the lever. When thebucket reaches a level digging position, the lever willreturn to the HOLD position automatically.

26

GEAR DIRECTION

TS16548

TS19613

TRANSMISSION CONTROLS

DIRECTION CONTROL

Neutral

Neutral is in the center position.

Forward

Push the control lever all the way forward for the FORWARDdirection.

Reverse

Pull the control lever all the way back for the REVERSEdirection.

GEAR CONTROL

First Gear Range

Push the Gear control lever forward (away from the operator)until the red shift indicator is in the "1" position.

Second Gear Range

Pull the gear control lever towards the operator so the shiftindicator is in the "2" position.

Third Gear Range

Pull the gear control lever towards the operator so the shiftindicator is in the "3" position.

Fourth Gear Range

Pull the gear control lever towards the operator so the shiftindicator is in the "4" position.

Note: Pulling the gear control lever toward the operatorwill upshift the transmission. Pushing the lever forwardwill downshift the transmission.

27

ACCELERATORPEDAL

TS40280

BRAKEPEDAL

TS40281

TS40282

ACCELERATOR PEDAL

The accelerator pedal controls engine rpm.

1. When the pedal is released, the engine is at low idle.

2. Push on the pedal to increase engine speed.

SERVICE BRAKES

7The service brakes are located to the left and to the right ofthe steering column. The following describes each brake pedalfunction:

Right Brake Pedal

1. Activates the service brakes.

2. Provides warning for loss of pressure in both the frontand rear brake systems.

3. provides brake light illuminations.

Left Brake Pedal

1. Sends pilot pressure to the right brake pedal which inturn activates the service brakes, when applied.

2. Provides hydraulic signal for declutching transmission.

HORN

The horn button is located in the center of the steering wheel.Push the button to activate the horn.

28

TS17961-4

TS17961-3

TS17961-2

OPERATORS SEAT

Adjust the operator's seat to a comfortable position.

WARNING: Do not attempt to make seatadjustments while machine is in motion.

Adjustment of the Weight Control Knob

Turn knob (1) so that the number on the dial corresponds tothe weight of the operator-

Note: This adjustment is to be made prior to the operatorsitting on the seat.

Turn knob (1) clockwise to increase weight settinq,

Turn knob (1) counterclockwise to decrease weight settinq,

Adjustment of the Seat Base Height and Tilt

To raise front of seat, pull lever (1) up while leaning backward.When desired position is reached, release lever-

To lower front of seat, pull lever (1) up while leaning forward,When desired position is reached, release lever-

Adjustment of the Seat Base Height and Tilt

To raise rear of seat, pull lever (2) up while leaning forward.When desired position is reached, release lever-

To lower rear of seat, pull lever (2) up while leaning backward.When desired position is reached, release lever-

29

TS17961-5

TS17965

TS17961-1

Adjustment of the Seat Back Rest

To recline the back rest, pull lever (1) upward and gently leanbackward. When desired position is reached, release lever.

To return to original position, lean forward and pull lever (1)upward. -

Adjustment of the Armrest Angl'e

To raise the armrest up, lift armrest and turn adjusting knob (1)clockwise. Lower and check adjustment.

Turn knob (1) clockwise to increase armrest height.

Seat Base Slide Adjustment

To move the seat forward, pull lever (1) upward and slowlymove the seat forward.

To move the seat backward, pull lever (1) upward and pushthe seat back slowly.

30

~~.KEY OFF.

(

TS40132

TS17841

TS17842

BATTERY DISCONNECT SWITCH

The switch is located in the engine compartment on the rightframe rail.

To turn the Battery Disconnect Switch "ON":

IThe battery disconnect switch handle must be in one of twopositions for the key to unlock the disconnect switch. Thesepositions are shown above. A light lock can be felt when thedisconnect switch is turned to one of these positions.Open the protective cap on the key slot of the batterydisconnect switch. Insert the key. Turn the key clockwise 1/4turn until it stops. The key is in the "ON" position.Turn the battery disconnect switch clockwise 1/4 turn until itstops. In this position the battery disconnect switch is "ON".This suppliescurrent to the ignitionswitch.

To Turn the Battery Disconnect Switch "OFF" (This can bedone two ways):

A. Turn the battery disconnect switch counterclockwise1/4 turn until it stops, then turn the key 1/4 turncounterclockwiseuntil it stops. Remove the key. Thebattery disconnect switch is "OFF" and locked. Closethe protective cap on the key slot.

Note: With the battery disconnect switch off and lockedit will spin freely in either direction.

B. Remove the key in the "ON" position. Close theprotective cap on the key slot.

Note: This will allow the battery disconnect switch to beturned on and off without the key. It also will not lock.

31

V50385

EL13914

OPERATINGPREPARE TO OPERATE

Before you operate the machine, read and understand thismanual.

Never operate the machine while under the influence ofalcohol, medicine or other drugs.

The cab has two exits; The left hand door and the right handdoor.

The cab is for the protection of the operator. It meets therequirements for R.O.P.S.lF.O.P.S. protection according to theS.A.E. and I.S.0. Standards.

Wear suitable clothing.

Know the area and the company rules.

PROCEDURE BEFORE STARTING

1. A walk around inspection should be carefully per-.~ formed looking for leaks, loose, missing or damaged

parts. Defects should be corrected prior to starting theengine.

2. Daily maintenance checks should be completed./'

Note: Perform maintenance checks in a sequence toavoid repeatedly mounting and dismounting the machine.

A WARNING: When mounting and dismountingthe machine, use three point mount (i.e. Twohands and one foot/one hand and two feet).Don't Jump!In addition to the walk around inspection and daily mainte-nance check, the following checks should be made:

• Frame Locking Link is in the stored position.• Wheels blocks removed.• Battery disconnect switch is in the "On" position.• Windows are clean.• Mirrors adjusted for visibility.• Park brake is applied.• Gear selector is in the "Neutral" position.• Boom and bucket levers in "Hold" position with bucket on

ground.• Seat is adjusted and the seat belt fastened.

32

IMPORTANT 0 ~ 0 AIR eTESTING OF MONITOR PARK -@- CONDITION .(;). ENGINE OILSYSTEM BRAKE PRESSURE PRESSUREACTUATE TEST SWITCHALL LAMPS SHOULD (!)~ 0£ 0$ COOLANTLIGHT AND ALARM BRAKE SECONDARYSHOULD SOUND PUMP/DIFF STEERING LEVEUWITH ENGINE RUNNING TEMPATURE• IF ANY REO LAMP Q Q~

.....LIGHTS MAINTENANCE * FRONT TRANSMISSION GE:!J ALTERNATORISREOUIRED BRAKE FILTERI• IF ANY LAMP FLASHES TEMPERATUREOPERATION MAYPROCEED WITH CAUTION G G-e- 0-'• IF ANY LAMP LIGHTS ~ -Q- REAR LUBE FUELAND ALARM SOUNDS BRAKE FAULT LOW LEVELSTOP MACHINE

TS40283

RED:

TEST

• •Test control lamps before starting the machine by turning thekey switch to the "On" or "Acc" position and depressing thetest switch on the dash.

SEC.STEER

LAMPS

• Brake Pump/Differential Warning Light

• Rear Brake Warning Light I• Front Brake Warning LightTS40009

• Air Conditioner Warning Light

• Secondary Steering System Warning Light (Optional)

• Transmission Filter Warning Light

• Lube Fault Warning Light (Optional)

• Engine Oil Pressure (Optional)

• Coolant Level/Temperature (Optional)

• Alternator (Optional)

• Fuel Low Level (Optional)

YELLOW:

• Park Brake Warning Light

Note: If a light fails to illuminate when the switch isdepressed or fails to go out when the test switch isreleased, the machine should not be operated until thesourceof the problemis identifiedandcorrected.

33

RUN IN INSTRUCTIONS

During the first 100 hour run in period, the machine must be operated with a certain amount of care.

ENGINE

The engine may be put to work, but the operator has an opportunity to establish conditions for optimumservice life by:

1. Operating as much as possible at three-quarter throttle load range.

2. Avoiding operation for long periods at engine idle speeds, or at the maximum horsepower levels inexcess of five minutes.

3. Developing the habit of watching the engine instruments closely during operation and letting up onthe throttle if the coolant temperature exceeds 200°F (93°C).

4. Operating with a power requirement that allows acceleration to governed speed when conditionsrequire more power.

5. Checking the oil level every 8 to 10 hours during the run in period.

HYDRAULIC TRANSMISSION

The transmission filter and strainer must be changed after the first 50 and 100 hours and every 500 hoursthereafter.

HYDRAULIC SYSTEM

The hydraulic filter elements must be changed after the first 50 hours of operation and every 1000 hoursthereafter.Check the oil pressure and the temperature frequently.

34

)~ IGNITION

COLD WEATHERSTARTINGPUSH 8 RELEASECOLD STARTBUTTON WHENCRANKING ENGINEREPEAT IFNECESSARY

OFF

ACC @ ON

~'~'

TS40012

COLDSTART

I II I

TS40013

STARTING ENGINE

1. Make sure the area around the machine is clearbefore starting.

2. Sound the horn.

Note: Check your company safety rules for specialprocedures that may be used, for alerting personnelaround you of your intentions to start the machine.

Starting a warm engine or in warm weather.

1. Make sure the accelerator pedal is released.

2. Turn the ignition switch key all the way clockwise tothe "START" position.

Note: DO NOT operate the starter for more than 30seconds at one time. I3. Release the key.Starting Engine in Cold Weather.

1. Make sure accelerator pedal is released.2. Turn the Ignition key switch to the "START" Position.3. With the Ignition switch key in the "START" position,

depress the cold start switch for approximately onesecond and release.

Note: Do not operate the starter for more than 30seconds at one time.

4. Repeat the procedure if necessary.

35

If Engine does not Start

1. Wait until engine flywheel comes to a complete stop.

2. Turn the ignition key to the "OFF" position before trying to start the engine again.

3. Repeat the procedure for starting the engine.

Note: If auxiliary batteries are to be utilized for starting in cold weather, be sure to refer to theelectrical section in the maintenance section of the manual.

BEFORE OPERATING

1. Keep the engine at low idle rpm for about 2 minutes after starting.

2. As engine temperature increases to normal operating temperature, check gauges to determine thatsystems are operating properly.

Note: Protect the turbo-charger during start up by not accelerating above 1000 rpm until the oil hashad time to circulate through the system.

If the engine oil pressure gauge does not show pressure within 1 to 2 seconds, stop the engineand determine the cause.

3. Observe the indicator lights.

WARNING: Do not operate machine until red indicator lights are extinguished. If lightsdo not go out, have problem identified and corrected. Lights will glow slightly at night.

4. Check operation of all the switches.

5. Make a functional check of the operating controls for proper operation.

a. Transmission control levers.

b. Steering.

c. Boom and Bucket control levers.

d. Brakes.

WARNING: Make sure your seat belt is fastened.

7. Unusual noises may indicate a problem. Check out prior to operating.

36

OPERATING THE MACHINE

General Information

Note: Do not try to work too fast. Know your capability and that of the machine.

Make sure the path of operation is clear of large rocks or other large debris. Failure to do so mayresult in damage to the machine.

1. The machine can be moved from job to job under its own power.

2. Put the gear control lever in the correct speed range for operating conditions.

3. Move the boom control lever to the "RAISE" position to raise the bucket approximately 46 - 61 cm(18-24 in) above the ground. Move the bucket to the ROLLBACK position.

4. Disengage the parking brake.

WARNING: Sound the horn before moving the machine.

5. Put the directional control lever in the FORWARD position.

WARNING: Operate the machine only when seated. Do not allow riders! I6. Use the accelerator foot pedal to control the speed of the machine.

WARNING: Watch where you are going. Stay away from people, the edge of cliffs,slide areas, other machines and vehicles; etc.

7. Do not brake hard when carrying a load.

Note: When applying the left brake pedal, the declutch switch will be activated and the transmissionwill disengage.

37

T519932

T519933

APPLICATION

Bucket Operation

Here are a few important points to improve efficiency:

1. Level work area.2. Control engine speed to avoid wheel spin.3. The machine should be straight when approaching the

material.4. High front wheel ground pressure.

To increase front wheel ground pressure, raise the bucketslightly after it has entered the material. Wheel spin is reducedas pressure on the front wheels is increased. For greaterpenetration, crowd the pile with the machine as straight aspossible.

Filling The Bucket

• Move towards the material to be loaded with the buckettilted down slightly.

• Shift the transmission lever to first gear.

Note: Always downshift the transmtsslon in sequence:FOURTH to THIRD, THIRD to SE

TS19934

TS19935

Backing Out of a Pile

A WARNING: Always look behind and to bothsides when you reverse directions.• Shift the transmission lever into reverse and lower the

boom to the carry position.• Press accelerator pedal to maximum position if conditions

permit and begin turning the machine.• As soon as possible, while the machine is still moving in

reverse, shift the transmission to forward and move thegear control lever to second range position.

• Move the gear range lever to third or fourth speed rangesonly if travel surfaces and conditions permit.

Operating with a Load IWhen operating with a load, do not raise the bucket higherthan necessary approximately 45 - 60 cm (18 . 24 in) with thebucket in the rollback position. This is called the carry position.

Note: Load and carry operations should be kept to 150 m(500 ft.) maximum for one way travel.

As machine approaches dump area, release pressure onaccelerator pedal and downshift the transmission through thegears to second gear range. Then use accelerator/brake tocontrol machine speed and rimpull.

Note: Always downshift the transmission in sequence:FOURTH to THIRD, THIRD to SECOND, SECOND to FIRST.Do not skip gears. Downshiftin into a gear when themachine is traveling faster ated speed for thatgear may damage the drivetrain. See the specificationsection of this manual for travel speeds.

TS19936

TS19937

Dumping a load over Bank

• If conditions permit, move boom control lever to detentRAISE position to lift bucket to desired dump height duringthe last 15 to 30 m (50 to 100 ft.) before dump area.

Note: The boom will continue to raise while the lever is indetent RAISE position. A boom kickout can be set at apredetermined dump height to automatically release theboom lever from the RAISE detent and return the boomlever to the HOLD position.

• If approach to dumpsite is on an uphill grade, the machinecan be slowed down be reducing pressure on acceleratorfoot pedal. If approach to dumpsite is on a downhill grade,use service brakes to slow machine.

WARNING: Always use the service brakeswhen dumping over the edge of a spoil area.

• Move bucket control lever to DUMP position.

• When bucket is empty, move bucket control lever toROLLBACK position. Hold lever until bucket is in the fullROLLBACK position.

• Move transmission direction control lever to REVERSEand back away from the dump area.

WARNING: Always look behind and to bothsides when reversing directions.

40

TS40122

TS40123

TS40124

Loading a Hauler

The hauler to be loaded should be positioned close to theloader.When dumping the load into the hauler body, do not raise thebucket more than necessary and avoid hard brake application.

Note: It is not recommended that a hauler be loaded fromthe blind side. If blind side loading is necessary, makesure you know the location of the hauler operator.

• When dumping, keep the bucket as low as possible to thehauler, this will lessen the impact and make it easier toposition the load. If the work site is sloped, try to approachtraveling uphill.

• When loading rock, try to fill the first bucket with smallmaterial, in order to soften the impact of larger pieces.

Note: If you are handling sticky material, shake thebucket against its mechanical stop repeatedly. I• When the bucket is empty, move the bucket control lever

to the ROLLBACK detent position and release. The bucketwill return to the level position automatically and thebucket control lever will return to the HOLD position.

• Move transmission lever to REVERSE position. Press onaccelerator to begin backing away from the hauler. Beginturning the machine in order to return to the pile in theshortest distance.

WARNING: Always look behind and to bothsides when you reverse directions. Make sureyou check the area around the machine oftenfor other workers, machines, etc., that may bein your way.·

41

------ -- - - -

TS19941

TS19942

Excavating

When excavating and stripping top soil start by angling thebucket down 2° - 3°. Always operate in first gear and at lowengine speed. Gradually increase engine speed and raise thebucket slightly. A straight edge bucket with teeth is best forthis type of operation.

Levelling

1. When levelling keep the bottom of the bucket levelwith the ground and try to keep sufficient material inor in front so that hollows in the ground are filled.

2. To finish leveling work, keep the edge of the bucketslightly downward and reverse with slight bucket downpressure.

3. A final touch can be done by reversing with the bucketflat against the ground and the boom lever in floatposition.

A straight edged bucket is best for this type of operation.

42

Stopping

The machine can be stopped regardless of the gear selector control position.

Stop the Machine as Follows:

• Reduce engine speed.• Apply service brakes and, after the machine has come to a complete stop, move the transmission gear

selector to the desired gear range to either continue operation or to neutral for parking.

PARKING MACHINE

Short Term

1. Move the machine to a safe area for parking.

2. Set the park brake.

3. Put the transmission gear selector in the "NEUTRAL" position.

4. Lower the boom and bucket to the ground and make sure the levers are in the "HOLD" position.

5. Let the engine run at low idle rpm for approximately 5 minutes to allow the engine to cool down.

7. Turn the ignition switch key to the "OFF" position. I6. Check that all switches and controls are in the "OFF" position.8. When leaving the machine unattended, remove the ignition switch key. Lock all doors and vandalism

guards to prevent theft or damage. Turn the battery disconnect switch key to the "OFF" position.Remove the key.

A WARNING: When mounting and dismounting the machine, use three point mount (i.e.Two hands and one foot/one hand and two feet.) DON'T JUMP!Note: If necessary, secure the frame locking link and block the wheels.

43

;7 .·.·R~J.....;;; ,:;;;; .;i-- -if-r

Long Term

1. Thoroughly clean machine. Touch-up paint where necessary to prevent rust.

2. Cover exhaust pipe openings.

3. CHECK ALL FLUID LEVELS: Hydraulic, transmission, axles, engine oil, radiator (check for proper"anti-freeze protection).

4. Fill fuel tank and hydraulic reservoir.5. Set parking brake.

6. GREASE UNPAINTED PARTS FOR PROTECTION: Cylinder rods, driveshaft splines, hydraulicvalve spools and transmission linkage.

7. Apply anti-corrosion spray to exposed pin ends and lock plates.

8. The battery disconnect switch should be in the off position and locked. For additional protection,remove ground cables from batteries.

9. Check tire pressures.

10. Check for signs of oil or water leaks.

11. Check air filter and piping.

12. Check fans and all belts.

13. Grease machine thoroughly.

14. Install side panels if parked outside.

15. Cab doors should be closed tightly. If no cab is used, cover cockpit with waterproof cover.

16. Remove all keys.

17. Store the machine in a position to allow forward and reverse motion. (for scheduled maintenance ofstored machines.)

Start and Operate Machine Every 30 Days (sooner if conditions warrant.)

1. CHECK ALL FLUID LEVELS: Hydraulic, transmission, axles, engine oil, coolant (check for properanti-freeze protection) and battery electrolyte level. Refill as required.

44

2. Check air filter and piping.

3. Check tire pressure.

4. Check condition of the fans and belts.

5. Turn battery disconnect switch to "ON" position.

6. Remove any hardened grease on the cylinder rods.

7. Start engine - keep at low idle.

8. Check all instrument panel gauges - pressure, temperature, warning lights and circuit breakers.

9. Operate engines at low idle for at least 15 minutes.

10. Release parking brake.

11. Check the brakes. (service and secondary).

12. Actuate the transmission through all gears (forward and reverse) at half-high RPM.

13. Move the machine forward and backward at half-high RPM. (Axle to be rotated to assure properlubrication)

14. All hydraulic components to be cycled to assure oil flow through the complete system.

16. Set the parking brake. I15. Reposition machine with boom lowered.17. Stop the engine.

18. Reinstall waterproof covering over entire cockpit (if machine is not equipped with enclosed cab.)

19. Grease all exposed cylinder rods or any other rod that cannot be retracted.

20. Battery disconnect switch to be off and locked.

21. Check for leaks on the machine.

22. Fill out the machine card: Date, operator's name. Note the conditions to be repaired as well as anydiscrepancy (rust not noticed the previous month, etc.)

23. Advise of any discrepancy to the foreman for immediate rework.

45

TRANSPORTING

1. Always load and unload on a level surface.2. Due to the size and weight of the machine, it may be disassembled to conform to the following:

A. Capacity of the transporting truck.B. Local weight limitations of roadways.C. Necessity of road permits for transporting.

3. Use adequate chains, blocks, cables, etc., to secure to trailer floor.4. Measure overall height and width of the machine on the trailer.

Note: It is important that you know the overall height, width, and weight when transporting themachine.

5. Transporting in foggy, dusty or stormy weather conditions requires additional care.6. The transporting of wheel loaders from a port or jobsite to another jobsite is becoming more and

more common. Special precautions are necessary to reduce the possibility of damage to tires andother components of the machine.

Note: Tire inflation pressure requirements on roaded machines vary from tire inflation pressurerequirements on working machines. Roading a machine with the wrong tire inflation pressure couldresult in damage to the tires. If a machine is to be roaded between jobs, it is important to consultyour tire distributor for the recommended roading pressure.

TOWING

WARNING: When the machine is being towed, the engine should be running or theoptional supplemental steering system should be operating. DO NOT attempt to startthe engine by towing the machine. If these conditions are not met, the steer lines mustbe connected such that the steer point is free to move or towing should be performedwith an axle off the ground.

The machine may be towed providing a drawbar is used, a maximum speed of 10 km/h (6 mph), the towingdistance does not exceed 10 km (6 miles) and the selector controls are in 4th gear and neutral. Towinglonger distances at higher speeds may damage the hydraulic transmission. To tow longer distances, thefront and rear driveshafts must be removed.

• Prior to towing, the parking brake must be released. If Hydraulic pressure is not available, lower theboom and bucket to the ground and block the wheels.

• Turn the parking brake caging nut on the caging stud clockwise until the parking brake is released.• Using an appropriate lifting device, with the boom lever in the "FLOAT" position, raise the boom and

block securely.• Secure the drawbar, remove the blocks and proceed with care.

WARNING: If the machine is not connected to the towing machine and the parkingbrake is manually released, the tires must be blocked.

Note: After towing a machine with the parking brake manually released, the parking brake willrequire a readjustment prior to returning to operation.

46

PREVENTIVE MAINTENANCE

SERVICE POSITION

Before working on the machine, park it on a level surface and put in the SERVICE POSITION:

5

TS19695A I11. Frame locking link connected.2. Bucket on the ground.3. Parking brake applied.4. Engine stopped, key removed exceptwhen service requires engine operating.

5. Do not operate tag or Redwarning flag on steering wheel.6. The wheels blocked.7. Let machine cool. *8. Pressure released from alllines,tanks and accumulators.

WARNING: * If work must be done on a warm machine, beware of hot fluids andcomponents.

47

V50385

EL 13914

V50389A

. W.·.'. .'3... ;"

A FEW SIMPLE RULES WHEN SERVICING

• Do not perform any work on the machine unless you areauthorized to do so.

• Maintenance can be dangerous unless performed properly.Be satisfied that you have the necessary skill andinformation, correct tools and equipment to do the jobcorrectly.

• Standard maintenance procedures should always beobserved. Read the manufacturer's manual or findassistance if you do not understand what you are doing.

• Keep the work place clean. Oil or water on the floormakes it slippery and also dangerous in connection withelectrical equipment or electrically powered tools. Oilyclothes are a serious fire hazard.

• When running a machine indoors, be sure the building isproperly ventilated

• Do not wear loose fitting clothing or jewelry when workingon a machine.

• Always wear a hard hat, safety glasses, gloves, shoes, orother protective articles as the job requires.

• Keep the machine and all equipment free of dirt and oil.This will decrease possible fire hazards and make it easierto find loose or defective parts. This is especially importantwhen working with combustible materials.

• Machines should be clean of debris particularly around theengine, exhaust, and drive line components.

• Fire prevention features provided by the manufacturershould be maintained in operational condition and shouldbe used to supplement the operator's fire preventionefforts. In no case should the features be used orassumed as replacement for diligent operator efforts atpreventing fires.

• Prior to welding or brazing on any part of the machine, thepart and the surrounding area should be cleaned and a fireextinguisher should be made readily available.

• There is always a risk of fire. Find out which type of fireextinguisher to use, where it is and how to use it.

• In case of fire be prepared to run for safety, but if timepermits first:Stop the engine.Turn off the battery disconnect switch.Start combating the fire and/or call for help.

• Gasoline is highly flammable and should never be used asa cleaning fluid. Use an approved solvent for cleaning.

• Some solvents can cause skin rashes and or fire dangers.Do not inhale solvent vapors.

• Store flammable starting aids in a cool, well ventilatedlocation.

• Smoking, open flames, etc., should not be permittedaround any machine during fueling operations and/or whenthe fuel system is open to the atmosphere.

48

V50387A

TS21481

•••

••

••

EL13917

• Always be sure the frame locking link is connected whenworking in the center hinge area.

• When lifting or supporting components, use equipmentwith a weight capacity as great as or greater than theweight of the component.

• Use the correct tool(s) for the job. Repair or replace anybroken or defective equipmentor tools.

• make sure that no tool(s) or other object(s) are left insidethe machinewhere they may cause damage.

• Check that there is no damage to electric wires andhoses.

• Release all system pressure slowly before working on anypart of the hydraulicsystem.

• Removeall pressurecaps carefully.• Be careful of hot fluid when changing oil in the engine,

hydraulicsystem, transmission,etc.• Before you work on the machine always lower the

attachment or body. If you must work on the machinewiththe attachment or body raised, always securely supportthe attachment or body.

• Be sure the machine is in the SERVICEPOSITIONbeforelifting the machine. Always support an elevated machineusing the proper blocks and/or cribbing before beginningwork on it.

To find leakage, use cardboard or wood, not your hand.Never adjust a pressure relief valve above the manu-facturer's recommendations.Hydraulicfluid is flammable.Do not weld on pipes or tubesthat are filled with fluid. Be careful when welding next tofilled pipes or tubes.Always inspect the cooling system with the enginestopped.Read all nameplates and decals before you operate themachine. Each nameplate and decal has importantinformationabout operation or service.Always stop the engine before removing inspectioncovers.Do not let tools or parts fall into the opening.Stand away from the rear area when the engine is running.

49

NOTES

--------------------------------------------------------------------------------

;-.'~...4,...."" 0,'

50

Put the machine in the SERVICE POSITION.

Daily First First YearlyPage or 50 Every 100 Every Every Every Every EveryOr As

No. Every Only 50 Only 100 250 500 1000 2000 EveryReq'd.

10 2500

GENERALLeaks •Loose Bolts and Fittings •

LUBRICATION 86 SEE LUBRICATION CHARTENGINE

Check Engine Oil Level 54 •Change Engine Oil 54 •Change Oil Filters 55 •Check Air Cleaner Service Indicator 56 •Service Air Cleaner 56 • •Check Air Intake Lines and Clamps 57 •Drain Sediment From Fuel Tank 57 •Change Fuel Filter Element 58 •Change Fuel Water Seperator 58 •Check Coolant Level 59 •Change Coolant, Flush System, and Check 60 •Coolant ProtectionClean Radiator 60 • •Check Cold Start System 61 •Check Belt Tension 62 •

ELECTRICAL SYSTEMCheck Battery Condition 63 •Check Battery Cables and Connections 63 •Charging Batteries 64 •Starting with Auxiliary Batteries 64 •Check Exterior Lights 64 •Check Neutral Start Switch 64 •Check Horn 64 •

POWER TRANSMISSIONCheck Transmission Fluid Level 66 •Change Transmission Fluid 66 •Clean Transmission Breather 67 •Clean Torque Converter Breather 67 •Change Transmission Filter Elements 67 • • •Clean Transmission Sump Screen 68 •Check Lubricant Level in Mid·Mount Bearing 69 •Change Lubricant in Mid-Mount Bearing 69 •Clean Mid-Mount Bearing Breather 70 •Check Lubricant Level in Differentials 70 •Check Lubricant Level in Planetary Hubs 70 •Change Lubricant in Axles 71 •Clean Axle Breathers 71 •

BRAKESCheck Brake Operation 72 •

MAINTENANCE INTERVALS OPERATING HOURS

I

51

------------------------------------------ ----

Put the machine in the SERVICE POSITION.

MAINTENANCE INTERVALS OPERATING HOURSDaily First First YearlyPage or 50 Every 100 Every Every Every Every Every Or AsNo. Every Only 50 Only 100 250 500 1000 2000 Every Req'd.10 2500

WHEEL SUSPENSIONand STEERINGCheck Secondary Steer System 72 •

FRAME, SPRINGS and WHEELSCheck Rollover Protection System 73 •Check Wheels 73 •Check and Tighten Wheel Bolts (After Wheel

Removal, Check Torque of Bolts at 5 and 10 73 •Hours of Operation)Check Tire Condition 74 •Check Tire Inflation 74 •

CABCheck and Clean Cab Air Filter 75 •Check Wiper Blade Condition 76 •Check Windshield Washer Fluid Level 76 •Check Seat Belt and Mounting 76 •Check Heater and Defroster 77 •Check Air Conditioner 77 •

HYDRAULIC SYSTEM and OTHERFUNCTIONS

Check Hydraulic Fluid Level 78 •Change Hydraulic Fluid 79 •Change Hydraulic Return Filter Elements 80 • •Change"Hydraulic Reservoir Breather 81 •Check Backup Alarm 81 •Clean and Check Lines and Hoses 82 •Adjustment of Boom Kickout Switch 83 •Adjustment of Bucket Leveller 84 •

52

Put the machine in the SERVICE POSITION.

AWARNINGNO ROOM FOR A MAN IN THISAREA WHEN MACHINE IS TURNED.

DO NOT STAND OR WORK IN THISAREA WHEN ENGINE IS RUNNING.

USE STEERINGFRAME LOCK WHENSERVICING.

TS16350

ENGINEMOUNTS

TS40140

ENGINEMOUNTS

TS40141

GENERAL

The most important care is the preventive maintenance thatyou perform, which comprises of lubrication and variouschecks and adjustments. Most of these service measures aresimple to perform and require no detailed explanation. In somecases, more detailed instructions are required and these areprovided on the following pages.

WARNING: When working under raised boomor by the center hinge, the boom or thecenter hinge must be secured.

Checking fluid levels-General

When checking fluid levels, the machine should be on levelground.

The levels should be checked in the morning when the fluidsare cold and have drained to the bottom of each component.This does not apply to the hydraulic transmission and thehydraulic tank.

Schedule servicing to avoid damage to the machine. Keepgood records. Read the machine manuals. IMake complete visual inspection.

Check for loose bolts and capscrews, leaks and worn parts.Report everything that needs attention.

53

Put the machine in the SERVICE POSITION.

TS19659

TS40156

ENGINE

Check Engine Oil Level

Check the engine oil level. Look for contaminants in the oil.Add oil as needed.

Note: Never operate the engine with the oil level belowthe "L" (Low) or the "H" (High) mark. Wait at least 5minutes after shutting off the engine to check the oil.

The engine must be level when checking the oil level.

Change Engine Oil

Changeengine oil every 250 hours of operation.

Note: Whenever oil is changed, filters should also bechanged.

There may exist applications or severe operating condi-tions where 250 hour oil change intervals are notadequate; if such a situation exists, the oil should bechanged ever 125 hours, or even more often if conditionsdictate.

1. Bring engine to operating temperature, shut downengine, remove drain plugs from bottom of oil pan,and drain oil.

2. Install drain plugs in oil pan. Tighten plug to 81 - 95Nm (60-70 ft-Ibs).

3. Remove and replace the oil filters. Refer to section"Change Oil Filters."

4. Fill the crankcase to "H" (high level) mark on thedipstick.

5. Start the engine and visuallycheck for oil leaks.

6. Shut down the engine; allow 15 minutesfor oil to drainback into the pan; recheck the oil level with thedipstick.Add oil as required.

Note: Refer to the recommended lubrication chart in thespecification section of this manual.

A WARNING: Hot oil can cause severe burns.54

Change Engine Oil Filters

Put the machine in the SERVICE POSITION.

TS40157

TS40158

1. Clean the area around the lubricatingoil filter head.

2. Unscrew the Full Flow Filter (1) and Bypass Filter (2)and discard.

Note: The o-ring can stick on the filter head. Make sure itis removed.

3. Fill the filter with lubricatingoil. Apply a light even coatof lubricatingoil to the gasket sealing surface prior toinstalling the filter.

Note: When the filters are not filled with oil, the lack oflubrication during the delay until the filters are pumpedfull of oil is harmful to the engine.

4. Position the element to the filter head. Tighten byhand until the seal touches the filter head, tighten aadditionalone-half to three-fourthsturn.

Note: Mechanical overtightening can distort the threadsor damage the filter element seal.

5. Operate the engine at idle speed to inspect for leaksat the filters and the drain plug.

6. Shut off the engine. Wait approximately5 minutes to Ilet the oil drain from the upper parts of the engine.Recheck engine oil level; add oil as necessary tobring the oil level to "H" mark on the dipstick.

Note: Always allow oil to drain back to the oil pan beforechecking the level. This may require 15 minutes.

55

Put the machine in the SERVICE POSITION.

T840159

2

T817587

Check Air Cleaner Service Indicator

Check the air cleaner service indicator. When the yellowindicator reaches 500 mm (20 in.) H20 vacuum, service the airfilter elements. Push the button to reset the service indicatorafter the elements are serviced.

Service Air Cleaner

Attention: The vacuator valve (7) should be cleaned daily.Tap the rubber valve to remove the accumulation of dirtin the valve.

1. Remove the air cleaner cap (6) from the housing (8).Clean the cap (6).

2. Remove the wing nut (1) from the air cleaner housing(8). Remove the cover (2).

3. Remove the vacuator valve (7) from the housing (8).Clean the cover (2) and the valve (7).

4. Remove the primary element (3) from the air cleanerhousing (8).

5. Clean the primary element (3) if it is not to bereplaced.

• Use low pressure air to clean the dirty element. Apply airfrom the inside out.

• You can clean a very dirty element in warm water with anon-sudsing type detergent. Put the element into thedetergent solution. Leave the element in the solution untilthe dirt particles are loosened. Remove the dirt particleswith a non-metalic brush or by moving the element upand down in the water. Remove the soap with cleanwater. Let the element become dry in the open air.

• Check the gasket of the element for damage. Use a brightlight to check the filter for damage. DISCARD ANYDAMAGED ELEMENT.

56

Put the machine in the SERVICE POSITION.

TS17587

TS19782

6. Remove the nut (4) from the rod securing thesecondaryair cleaner element (5).

7. Remove the secondary element (5) from the aircleaner housing (8). Replace the secondary element(5) if it is dirty or damaged. Clean the air cleanerhousing.

Note: DO NOT clean the secondary element. Thesecondary element must be replaced when dirty.

8. Install the secondary air cleaner element (5) in the aircleaner housing (8).

9. Install the nut (4) and tighten.

10. Install the primary element (3) in the air cleanerhousing (8).

11. Install the vacuator valve (7) to the housing (8).

12. Install the cover (2) to the air cleaner housing (8).Install the wing nut (1) and tighten.

13. Install the air cleaner cap (6) on the housing (8).

Check Air Intake Lines and Clamps

Tighten all clamps and hoses as needed. Replace the hosesand clamps as needed.

Drain Sediment from Fuel Tank IWhen the fuel tank is almost empty, remove the drain plugfrom the bottom of the tank. Remove any sediment from thetank. Clean and install the drain plug. Check fuel tankmounting bolts. Tighten as required. Fill the tank with cleanfuel.

57

Put the machine in the SERVICE POSITION.

TS40160

TS40161

TS40162

Change Fuel Filter Element

1. Clean the area around the fuel filter head.

2. Unscrew the element and discard the element. Cleanthe gasket surface of the filter head.

3. Fill the new filter with clean fuel and apply a light evencoat of lubricating oil to the gasket sealing surfaceprior to installingthe filter.

4. Install the filter; tighten by hand until the seal touchesthe filter head. Tighten an additional one-half tothree-fourthsturn.

Note: Mechanical overtightening can distort the threads ordamage the filter element seal.

Drain the Fuel-Water Separator

The fuel-water separatorshould be draineddaily.1. Shut off the engine.

2. Use your hand to open the drain valve. Turn the valvecounterclockwiseapproximately 1 112 to 2 turns untildraining occurs. Drain the filter sump of water untilclear fuel is visible.

3. Turn the valve clockwise approximately 1 112 to 2turns to close the drain valve.

Note: Do not overtighten the valve. Overtightening candamage the threads.

58

Put the machine in the SERVICE POSITION.

TS19664

TS40219

TS40165

Check Coolant Level

WARNING: Loosen the radiator cap slowly.Let the pressure out of the system.

WARNING: DO NOT remove the racliator cap ifthe machine is hot. HOT COOLANT can causeburns.

Check the radiator coolant level. Look for leakage. Replacehoses and clamps and tighten clamps as needed. Check thecondition of the coolant. Add coolant as needed. Replace thecap.

Change the Coolant Filter

1. Close the shut-off valves on the inlet and drain lines ifso equipped.

2. Unscrew the element and discard. Clean the gasketsurface.

3. Apply a light even coat of lubricating oil to the gasketsealing surface prior to installing the filter. I

4. Install a new element, hand tighten until the sealtouches the filter head. Tighten an additional one-halfto three-fourths turn. Open the shut-off valves.

Note: Mechanical tightening will distort or crack the filterhead.

59

Put the machine in the SERVICE POSITION.

TS19666

RADIATORCAP

RADIATOR

TS40142

Change Coolant, Flush System and Check Coolant Prot-ection

1. Open the petcock located in the bottom of theradiator.Drain the coolant. Replace the plug.

2. Remove the drain plugs from the cylinder block.Remove the coolant from the block and head. Cleanthe drain plugs. Install and tighten the drain plugs inthe cylinder block.

Note: See engine manufacturer's manual for correctcooling system cleaning procedures and plug locations.

3. Clean and flush the cooling system.

4. Remove the radiator cap and add clean coolant withcorrect anti-freeze mixture until level is at the fillerneck. Replace the cap.

5. Start the engine and check for leakage. When theengine is at operatingtemperature,stop the engine.

6. Check the coolant level. Check the freezing point ofthe coolant. Add coolant or anti-freeze as needed.Install the cap.

Clean Radiator

Removethe grille and clean the radiator using steam,water orregulatedcompressedair. Install the grille.

60

Check Cold Start System

Put the machine in the SERVICE POSITION.

TS21 080

Note: The weight of a full ether cylinder (5) is 1,0 kg (35oz.). The weight of an empty cylinder is 0 5 kg (17 oz.).

Connect or install an ether cylinder (5) as needed.

1. Disconnect the line (1) from the relief valve (3) on theether cylinder (5).

2. Loosen the clamp (4) on the ether cylinder (5).

3. Unscrew the ether cylinder (5) from the valve (2) andremove the cylinder from the clamp (4).

4. Remove the gasket (6) from the valve (2). Inspect andreplace the gasket as needed. Install the gasket inthe valve.

5. Remove the cap from the end of a new cylinder (5).Install the full cylinder through the clamp (4) andscrew the cylinder into the valve (2).

6. Tighten the clamp (4) on the cylinder (5).

7. Connect the line (1) on the cylinder relief valve(3).Check all the connections and lines for leaks ordamage. Make repairs as needed. Check and tightenall mountingbolts and nuts.

I

61

Put the machine in the SERVICE POSITION.

BELT TENSION CHART (Pou-)

Be" _Be"·u__

Width - Tenalon In.. I....k»n TensionInch" Gouge Min.-MIx. Min.-MIx ..380 ST-1274 130-150 80-120.440 130-150 80-120112 130-150 80-12011/16 130-150 80-1203/' ST-l138 130-150 80-1207/8 130-150 80-12050r6Rib ST-1293 14()..160 90-1208 Rib 51'1293 190-210 155-165

• Adjust used belts to the values in this column. If below minimum.re-tenson to maximum.

NOTE: A belt is considered used if it has been in operation for at least10minutes.

EL14032

T540166

Check Belt Tension

Visually check belts daily for cracks, fraying and looseness.Adjust belts that have a glazed or shiny surface whichindicates belt slippage. Correctly installed and tensioned beltswill show even pulley and belt wear.Belt damage can be caused by:

• Incorrect tension• Incorrect size or length• Pulley misalignment• Incorrect installation• Severe operating environment• Oil or grease on the belts

Using an appropriate belt tension gauge, check tension at apoint midway between the pulleys. If the belt tension is lessthan that shown in the chart, the belt must be adjusted.An alternate method (deflection method) can be used to checkbelt tension by applying 110 N (25 Ib) force between thepulleys on v-belts. If the deflection is more than one (1) beltthickness per foot of pulley center distance, the belt tensionmust be adjusted. Refer to the chart for proper tension.For further information relating to belt tension, refer to theengine manual.

62

Put the machine in the SERVICE POSITION.

INSTRUMENTPANEL

BATTERIES

TS40143

BATTERIES

TS40144

TS19669

ELECTRICAL SYSTEM

ATTENTION:When performing any welding operation on amachine, shut off the battery disconnect switch and disconnectpositive (+) and negative (-) wiring connections at the battery.

Check Battery Condition

WARNING: All lead-acid batteries generatehydrogen gas which is highly flammable. Ifignited by a spark or flame, the gas mayexplode violently, causing spraying of acid,fragmentation of the battery, and possiblesevere personal injuries. Wear safety glasseswhen working near batteries. In case ofcontact with acid, flush immediately withwater.

Check for obvious damage such as cracked or broken case orterminal damage. Replace any damaged batteries.

Check Battery Cables and Connections ICheck the battery cables and connections for damage,looseness, and corrosion. Replace damaged cables asneeded. Clean and tighten connections as needed.

63

Put the machine in the SERVICEPOSITION.

TS20788

A WARNINGDO NOT CONNECT JUMPER CABLES TO THEBATTERY TERMINALS.USE SYSTEM VOLTAGE TO JUMP START.CONNECT THE POSITIVE CABLE FIRST TO THEPOSITIVE STARTER CABLE. CONNECT THENEGATIVE CABLE TO THE MACHINE FRAME.FAIWRE TO FOLLOW THIS PROCEDURE COULDRESULT IN PERSONAL INJURY OR DAMAGE TOTHE ELECTRICAL SYSTEM.

TS17403

Charging Batteries

WARNING:When batteries are being charged,explosive gasses are formed. A short circuit,open flame or spark near the battery cancause a serious explosion. Always turn thebattery charger off before disconnecting orconnecting the leads to the battery. Providegood ventilation, especially if the battery isbeing charged in an enclosed area.

WARNING: Always use a voltmeter orhydrometer to check the battery charge.Never use a metal object across the posts totest a battery. Sparks may cause anexplosion.

WARNING:Never let the fluid be pushed outof the battery or the temperature go above125°F (51.7°C). If the battery case feels hot,stop charging for 20 minutes then start thecharger at a lower amperage rate. Hightemperature will prevent the battery fromholding the charge. Makesure the battery is aminimumof 60°F (15.6°C) before charging.

Starting with Auxiliary Batteries

If the machine is jump started utilizing auxiliary batteries, referto the decals on the radiator cowling for instructions.

Check Exterior Lights

Check that all exterior lights are in proper operating conditionand adjusted properly. Replace and/or adjust as required.

Check Neutral Start Switch

If the starter turns the engine over with the transmission ineither "Forward" or "Reverse", the neutral start switch shouldbe replaced.

Check Horn

Check the horn button and make sure the horn operatescorrectly. Repair as needed.

64

Put the machine in the SERVICE POSITION.

TRANSMISSIONMOUNTS

FLUID LEVELSIGHT GLASS

CONVERTERMOUNTINGBOLTS

T840145

TRANSMISSIONMOUNTS

COOLERPRESSUREPORTS

TRANSMISSIONDRAIN

T840146

POWER TRANSMISSION

Illustrated are the locations of the transmission fill cap,mounts, pressure ports, fluid level sight glass,convertermounting bolts, cooler pressure ports and the transmissiondrain.

The transmission lines are illustrated in the figure below.

RADIATOR

DOWNSTREAMPRESSURE

REGULATINGVALVE

I

T840134

65

Put the machine in the SERVICE POSITION.

TS19956

TS40284

Check Transmission Fluid Level

Check the transmission fluid level before starting the engine. Ifthe sight glass is empty, add fluid as needed. If there is fluid inthe sight glass, start the engine. Check the fluid level again. Ifthere is fluid in the sight glass follow these steps to check forcorrect level.

c- 1. The fluid temperature must be 82'2-9330C~~

t// Run engine for three minutes. During this time, puttransmission in each speed range and both directionstwo times.

l·{ The engine must be running at low idle.

4. The transmission must be in the "NEUTRAL" position.

5. Check the transmission fluid level.- . . --. ------~ok for contamination in the fluid. /( --_=-: _---------------------

7. Add fluid as needed until fluid is at the FULL mark.

8. Look for fluid leakage. Repair any leaks as needed.

Change Transmission Fluid

1. Remove the transmission drain plug and drain the fluidfrom the transmission and torque converter. Clean thedrain plug. Install the drain plug.

2. Remove the transmission fill cap. Add clean fluid asneeded, until the level is at the "FULL" mark on thesight gauge.

Refer to "Check Transmission Fluid Level" in this section ofthis manual.

66

Put the machine in the SERVICE POSITION.

BRAKEACCUMULATORS

TS40168

TS40285

TS16794

Clean Transmission Breather

The transmission breather is mounted on the inside of theengine compartment next to the brake converters. Remove thebreather. Clean, dry and re-install the clean breather.

Clean Torque Converter Breather

Remove the torque converter breather from the top of theconverter. Clean and dry the breather. Install the cleanbreather.

Change Transmission Filter Element

1. Remove and discard the old spin-on filter element.

2. Lubricate the rubber seal on the end of the new filterelement with clean transmission fluid.

3. Install the new filter element into the filter head.

4. Tighten the filter element until the gasket touches thehousing. Tighten the filter element two-thirds of a turn(240°)more.

5. Run the engine for 5 minutes at 1500 rpm. Check forleakage. Check the transmission fluid level. Add fluidas needed

67

Put the machine in the SERVICE POSITION.

TS17590

Clean Transmission Sump Screen

WARNING: Be careful of hot fluid when work-ing with hydraulic lines.

1. Remove the transmission drain plug. Remove the fluidfrom the transmission and torque converter. Clean thedrain plug.

2. Remove the split flange bolts (6)and flange halves (4)from the sump screen (2) and hose (5). Remove thehose.

3. Remove the discard the hydraulic hose O-ring (3).

4. Remove the sump screen (2) from the transmission.

5. Clean the sump screen (2).

6. Remove the gasket (1). Install a new gasket on thesump screen. Install the sump screen.

7. Install a new O-ring (3) on the hose (5). Install the splitflange halves (4) and bolts (6).

8. Tighten the split flange bolts to a torque of 62,4- 78,6Nm (46-58 Ibf ft).

9. Remove the transmission fill cap. Add clean fluid asneeded, until the level is at the FULL mark on thesight gauge.

10. Install the transmission fill cap.

Note: See "Check Transmission Fluid Level" in this sectionof this manual.

68

Lubricant Check Points

Put the machine in the SERVICE POSITION.

PUNETARYLEVElJDRAIN, PLUG

TORQUECONV!AT£RTO TRANIMII8ION

rI,mIL .,

I..J

PUNETARYLEVEUDRAIN

Pl.UG

PLANETARYLEVl:LlDRA ..

PLUG

TS19683

TS19684

PLANETARYlEVEUDIWN

PLUG

TS17314

Check Lubricant Level In Mid-mount Bearing

Clean the surface around the level plug in the mid-mountbearing. Remove the plug and check lubricant level. Addlubricant as needed until the lubricant level is at the plugopening.Clean and install the level plug.

Change Lubricant in Mid-mount Bearing

1. Remove the drain plug from the mid-mount bearing.Remove the lubricant from the bearing. Clean andinstall the drain plug.

2. Remove the level plug from the mid-mount bearing.Add clean lubricant until lubricant is level with the plugopening.Clean and install the level plug.

69

Put the machine in the SERVICE POSITION.

TS19685

TS19680

TS18033

Clean Mid-mount Bearing Breather

Clean the area around the mid-mount breather. Remove thebreather. Clean the breather in clean solvent.

Dry and install the clean breather.

Check Lubricant Level in Differentials

Check the lubricant level in both differentials.

Clean the surface around the level plug. Remove the plug andcheck lubricant level. Add lubricant as needed until thelubricant level is at the plug opening. Clean and install thelevel plug.

Check Lubricant Level in Planetary Hubs

Check the lubricant level in all four planetary hubs.

Make sure the arrow on the cover is down. Clean the surfacearound the level plug. Remove the plug and check lubricantlevel. Add lubricant as needed until the lubricant level is at theplug opening. Clean and install the level plug.

70

Put the machine in the SERVICE POSITION.

TS18034

TS19681

TS19682

Change Lubricant in Axles

Change the lubricant in the front and rear axles.

WARNING: Protect eyes (safety glasses) andskin against contact with lubricant. Containsstrong corrosive substance. Flush exposedareas with clean water and get medicalattention.

1. Remove the drain plug from each planetary, with thedrain plug down.

2. Remove the lubricant from each planetary. Clean thedrain plugs. Install the drain plugs.

3. Remove the differential drain plugs from both axlehousings. Remove the lubricant. Clean and install thedrain plugs.

4. Remove the planetary level plug from each planetarywith the arrow on the cover down. Add clean lubricantto each planetary until the lubricant level is at the plugopening. Install the level plug.

5. Remove the differential level plug from both axlehousings. Add clean lubricant to each differential untilthe lubricant level is at the plug opening. Install thelevel plug.

Clean Axle Breathers

Clean the breathers in both axles.

Clean the area around the axle breather. Remove the breather(arrow). Clean the breather in clean solvent.

Dry the breather. Install the clean breather.

71

BRAKE PRESSURETEST PORT

Put th machine in the SERVICE POSITION.

TS40 47

BRAKES

Check the Brake Operation

Check the service brakes for correct operation. Repair oradjust as required.

1. If the service brakes are operating correctly, they willhold the machine in the "FORWARD", travel rangeposition, "SECOND" gear range with the engine at highidle rpm and the machine on level ground.

2. Check the parking brake for correct operation: Theparking brake must hold the machine on a 20 to 30%slope for one minute, with the machine running inneutral and with the parking brake applied (red knobpulled out).

Alternate method for checking parking brake: The parkingbrake must hold the machine with a 71 to 84 kn (16,000 to19,000 lb.) drawbar pull.

Note: Do not check the parking brake with transmission inFORWARD or REVERSE and the engine running. This willautomatically apply the service brakes. Checking theparking brake can be done with the transmission inNEUTRAL ONLY.

WHEEL SUSPENSIONAND STEERINGCheck Secondary Steering System (Optional Equipment)

To check the secondary steering system, push the test switchwith the engine running. The secondary steering light mustilluminate. The buzzer and the secondary steering motor andpump must operate. Listen for the sound of the pump motor. Ifthe system does not operate correctly, repair as needed.

72

Put the machine in the SERVICE POSITION.

FRAME, SPRINGS AND WHEELS

Check Wheels

Check wheels for damage, looseness and missing studs. Replace or tighten as needed.

Check and Tighten Wheel Nuts

1. Replace any missing or damaged wheel nuts.

2. Tighten all wheel Nuts as needed to a torque of 394,0 - 516,0 Nm (290 - 380 Ibf-ft).

Note: After wheel removal, wheel nut torque must be checked again at five and ten hours ofoperation.

Check Rollover Protection System (ROPS)

Rollover Protective Structures are for the protection of the operator if a machine rolls over. As eachmachine continues in service, it is possible that fatigue cracks can develop in the ROPS. If this condition isundetected, it could cause failure of the ROPS in the event of a rollover. To detect an early change incondition of the ROPS, make a visual inspection of the ROPS structure every 1000 operating hours. If arollover occurs, replace the entire ROPS before you put the machine back into service. Use the followingprocedure when you make a visual inspection.

1. Check for bent, deformed or broken ROPS legs or mounting brackets. Damage in these areascannot be repaired. Replace ROPS or mounting brackets in this condition.

2. Check for loose or missing bolts. Replace missing bolts with grade 8 bolts. Tighten loose bolts tothe specified torque. Replace all bolts in the ROPS mounting group as well as the ROPS structure ifthe machine has been in a rollover accident.

3. Check the rubber vibration dampeners for wear and damage. If the ROPS structure makes a rattlingnoise when you operate the machine, replace the vibration dampeners.

4. If the ROPS was in a fire, replace the entire ROPS, including mounts, brackets, bolts and vibrationdampeners.

A WARNING: DO NOT weld or drill on any part of the ROPS. Any unauthorized changes tothe ROPS could decrease the ability of the structure to protect the operator in theevent of a rollover. Any unauthorized repairs or modifications could void the ROPScertification.5. Check for cracks in the metal structure of the ROPS. Some cracks can be repaired. Take

photographs of any cracks and check with VME Americasbefore attempting any repair.

73

Put machine in the SERVICEPOSITION.

TRAJECTORY PATHS

_WARNING_ALWAYSSTAYOUTOF THETRAJECTORYPATHAS

INDICATEDBYSHADEDAREA

CheckTire pressure

With the machine empty, check the pressure in all four