81808304-01

January 2012

Operation &
Maintenance
Manual
2021B Wheel Loader
L2Z06151-Up (Machine)
 Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations
before an accident occurs. A person must be alert to potential hazards. This person should also have the
necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are
not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”,
“WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings
in this publication and on the product are, therefore, not all inclusive. If a tool, procedure work method or
operating technique that is not specifically recommended by Caterpillar issued, you must satisfy your self
that it is safe for you and for others. You should also ensure that the product will not be damaged or be
made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that was available
at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments,
illustrations, and other items can change at anytime. These changes can affect the service that is given to the
product. Obtain the complete and most current information before you start any job. Cat dealers have the most
current information available.

When replacement parts are required for this

product Caterpillar recommends using
Cat replacement parts or parts with
equivalent specifications including, but not
limited to, physical dimensions, type, strength
and material.

Failure to heed this warning can lead to

premature failures, product damage, personal
injury or death.
 3
Table of Contents

Table of Contents Maintenance Section

Lubricant Viscosities and Refill Capacities ........46

Foreword .............................................................4
Machine Fluid Recommendations .....................47
Safety Section Maintenance Interval Schedule .........................48

Safety Signs and Labels .....................................5

General Hazard Information ................................8 Index Section
Crushing Prevention and Cutting Prevention ......9
Index ..................................................................71
Burn Prevention .................................................10
Fire Prevention and Explosion Prevention ........10
Electrical Storm Injury Prevention .....................12
Tire Information .................................................12
Mounting and Dismounting ................................12
Before Starting Engine ......................................13
Engine Starting .................................................13
Before Operation ...............................................13
Operation ...........................................................13
Parking ..............................................................14

Product Information Section

Specifications and Model Views ........................15

Machine General Information ............................15
Product Identification Information ......................19

Operation Section

Before Starting Inspection .................................20

After Starting Inspection ....................................22
Switches and Instruments .................................24
Machine Control ................................................27
Machine Operation ............................................31
Operating Techniques........................................33
Machine Parking ................................................42
Transportation Information ................................44
4
Foreword
Foreword
Literature Information
This manual should be stored in the operator’s
compartment.
This manual contains safety information, operation
instructions, transportation information, lubrication
information and maintenance information.
Some photographs or illustrations in this publication
show details or attachments that can be different
from your machine. Guards and covers might have
been removed for illustrative purposes.
Continuous improvement and advancement of
product design might have caused changes to your
machine which are not included in this publication.
Read, study and keep this manual with the machine.
Whenever a question arises regarding your
machine, or this publication, please consult
your Cat dealer for the latest available
information.
Safety
The safety section lists basic safety precautions. In
addition, this section identifies the text and locations
of warning signs and labels used on the machine.
Read and understand the basic precautions listed
in the safety section before operating or performing
lubrication, maintenance and repair on this machine.
Operation
The operation section is a reference for the new
operator and a refresher for the experienced
operator. This section includes a discussion of
gauges, switches, machine controls, attachment
controls, transportation and towing information.
Photographs and illustrations guide the operator
through correct procedures of checking, starting,
operating and stopping the machine.
Operating techniques outlined in this publication are
basic. Skill and techniques develop as the operator
gains knowledge of the machine and its capabilities.
Maintenance
The maintenance section is a guide to equipment
care. The Maintenance Interval Schedule (MIS)
lists the items to be maintained at a specific service
interval. Items without specific intervals are listed
under the “When Required” service interval. The
Maintenance Interval Schedule lists the page
number for the step-by-step instructions required
to accomplish the scheduled maintenance. Use
the Maintenance Interval Schedule as an index or
“one safe source” for all maintenance procedures.
Maintenance Intervals
Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hour
meter intervals if they provide more convenient
servicing schedules and approximate the indicated
service hour meter reading. Recommended service
should always be performed at the interval that
occurs first.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the maintenance intervals chart might
be necessary.
Perform service on items at multiples of the original
requirement. For example, at every 500 service
hours or 3 months, also service those items listed
under every 250 service hours or monthly and every
10 service hours or daily.
Warning
Diesel engine exhaust and some of its constituents
are known to cause cancer, birth defects, and
other reproductive harm.
Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands
after handling.
 5
Safety Section
Safety Signs and Labels

Safety Section
Safety Signs and Labels

There are several specific warning signs on this

machine. The exact location of the hazards and
the description of the hazards are reviewed in this
section. Please become familiarized with all warning
signs.

Make sure that all of the warning signs are legible.

Clean the warning signs or replace the warning
signs if you cannot read the words. Replace the
illustrations if the illustrations are not legible. When Illustration 2
you clean the warning signs, use a cloth, water
and soap. Do not use solvent, gasoline, or other
harsh chemicals to clean the safety signs. Solvents,
gasoline, or harsh chemicals could loosen the No clearance for man in this area when machine
adhesive that secures the warning sign. Loose turns. Severe injury or death from crushing could
adhesive will allow the warning sign to fall. occur.

Replace any safety sign that is damaged, or Connect steering frame lock link between front and
missing. If a safety sign is attached to a part that is rear frames before lifting machine, transporting
replaced, install a safety sign on the replacement machine on another vehicle, or performing service
part. Any Cat dealer can provide new safety signs. near center of machine.

Disconnect steering frame lock link and secure

to retaining plates before resuming operation or
Steering Frame Lock machine will not steer.

Brakes

Illustration 1

This warning label is located on the right side of the

operators compartment and side of the air tank.
Illustration 3

This warning label is located on the transmission shift

lever cover.
6
Safety Section
Safety Signs and Labels

Machine Before Service

Low air pressure or system defect sound horn.
Stop and investigate.

Air System

Illustration 6

Illustration 4

Illustration 7

This caution label is located on the left side of the

operators compartment and above the hydraulic

Machine Parking

Illustration 5

This caution label is located on the guard and assembly

of the air tank. The guard assembly located on right
side of the machine.

Illustration 8
 7
Safety Section
Safety Signs and Labels

Illustration 9

This caution label is located on the right side of the

operator seat.

Lower the bucket before stopping engine or

parking the unit.
8
Safety Section
General Hazard Information
General Hazard Information
lllustration 10
Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls before
you service the equipment or before you repair the
equipment.
Know the width of your equipment in order to maintain
proper clearance when you operate the equipment near
fences or near boundary obstacles.
Be aware of high voltage power lines and power cables
that are buried. If the machine comes in contact with
these hazards, serious injury or death may occur from
electrocution.
lllustration 11
Wear a hard hat, protective glasses, and other protective
equipment, as required.
Do not wear loose clothing or jewelry that can snag on
controls or on other parts of the equipment.
Make sure that all protective guards and all covers are
secured in place on the equipment.
Make sure that all protective guards and all covers are
secured in place on the equipment.
Keep the equipment free from foreign material. Remove
debris, oil, tools, and other items from the deck, from
walkways, and from steps.
Secure all loose items such as lunch boxes, tools,
and other items that are not a part of the equipment.
Know the appropriate work site hand signals and the
personnel that are authorized to give the hand signals.
Accept hand signals from one person only.
Never put maintenance fluids into glass containers.
Drain all liquids into a suitable container.
Obey all local regulations for the disposal of liquids.
Use all cleaning solutions with care. Report all
necessary repairs.
Do not allow unauthorized personnel on the
equipment.
Perform all maintenance unless otherwise specified
as follows.
• Park the machine on level ground.
• Move the transmission control to NEUTRAL
• Move all attachments controls to HOLD
• The engine stopped
• The engine start switch key OFF and the key
removed
• The parking/secondary brake engaged.
• Release the pressure in the system.
Pressure Air and Water
Pressurized air and/or water can cause debris and/or
hot water to be blown out. This could result in personal
injury.
When pressure air and/or pressure water is used for
cleaning, wear protective clothing, protective shoes,
and eye protection. Eye protection includes goggles
or a protective face shield.
The maximum air pressure for cleaning purposes
must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be below
275 kPa (40 psi).

Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped. The pressure
can cause hydraulic fluid or items such as pipe
plugs to escape rapidly if the pressure is not relieved
correctly.
Do not remove any hydraulic components or parts until
pressure has been relieved or personal injury may
occur. Do not disassemble any hydraulic components
or parts until pressure has been relieved or personal
injury may occur. Refer to the Service Manual for any
procedures that are required to relieve the hydraulic
Illustration 12
Always use a board or cardboard when you check for a
leak. Leaking fluid that is under pressure can penetrate
body tissue. Fluid penetration can cause serious injury
and possible death. A pin hole leak can cause severe
injury. If fluid is injected into your skin, you must get
treatment immediately. Seek treatment from a doctor
who is familiar with this type of injury.
Dispose of Waste Properly
Illustration 13
9
Safety Section
Crushing Prevention and Cutting Prevention
Care must be taken in order to ensure that fluids
are contained during performance of inspection,
maintenance, testing, adjusting and repair of the
equipment. Prepare to collect the fluid with suitable
containers before opening any compartment or
disassembling any component containing fluids.
• Tools that are suitable for collecting fluids and
equipment that is suitable for collecting fluids.
• Tools that are suitable for containing fluids and
equipment that is suitable for containing fluids.
Obey all local regulations for the disposal of liquids.
Crushing Prevention and
Cutting Prevention
Support the equipment properly before you perform
any work or maintenance beneath that equipment. Do
not depend on the hydraulic cylinders to hold up the
equipment. Equipment can fall if a control is moved,
or if a hydraulic line breaks.
Unless you are instructed otherwise, never attempt
adjustments while the machine is moving or while the
engine is running.
Whenever there are equipment control linkages the
clearance in the linkage area will change with the
movement of the equipment or the machine. Stay clear
of areas that may have a sudden change in clearance
with machine movement or equipment movement.
Stay clear of all rotating and moving parts.
If it is necessary to remove guards in order to perform
maintenance, always install the guards after the
maintenance is performed.
Keep objects away from moving fan blades. The fan
blade will throw objects or cut objects.
Do not use a kinked wire cable or a frayed wire cable.
Wear gloves when you handle wire cable. When you
strike a retainer pin with force, the retainer pin can
fly out. The loose retainer pin can injure personnel.
Make sure that the area is clear of people when you
strike a retainer pin. To avoid injury to your eyes, wear
protective glasses when you strike a retainer pin.
Chips or other debris can fly off an object when you
strike the object. Make sure that no one can be injured
by flying debris before striking any object.
10
Safety Section
Burn Prevention & Fire Prevention and Explosion Prevention

Burn Prevention Fire Prevention and Explosion

Do not touch any part of an operating engine. Allow the Prevention
engine to cool before any maintenance is performed
on the engine. Relieve all pressure in the air system,
oil system, lubrication system, fuel system and in the
cooling system before any lines, fittings or related items
are disconnected.

Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. Any contact with hot
coolant or with steam can cause severe burns. Allow
cooling system components to cool before the cooling
system is drained.
Illustration 14
Check the coolant level only after the engine has been
All fuels, most lubricants and some coolant mixtures
stopped.
are flammable.
Ensure that the filler cap is cool before removing the Flammable fluids that are leaking or spilled onto hot
filler cap. The filler cap must be cool enough to touch surfaces or onto electrical components can cause
with a bare hand. Remove the filler cap slowly in order a fire. Fire may cause personal injury and property
to relieve pressure. damage.

Cooling system conditioner contains alkali. Alkali can Remove all flammable materials such as fuel, oil, and
cause personal injury. Do not allow alkali to contact the debris from the machine. Do not allow any flammable
skin, the eyes, or the mouth. materials to accumulate on the machine.

Store all fuels and lubricants in properly marked

Oils
Hot oil and hot components can cause personal injury.
Do not allow hot oil to contact the skin. Also, do not
allow hot components to contact the skin.
Remove the hydraulic tank filler cap only after the
engine has been stopped. The filler cap must be
cool enough to touch with a bare hand. Follow the
standard procedure in this manual in order to remove
the hydraulic tank filler cap.
Batteries
Batteries give off flammable fumes which can explode.
Do not smoke when you observing the battery
electrolyte level.
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for servicing
batteries. Wash hands after touching the batteries and
connectors. Use of gloves is recommended.
containers and away from all unauthorized personnel.
Store oily rags and any flammable materials in
protective containers. Do not smoke in areas that are
used for storing flammable materials.
Do not operate the machine near any flame.
Do not weld on lines or on tanks that contain
flammable fluids. Do not flame cut lines or tanks
that contain flammable fluid. Clean any such lines or
tanks thoroughly with a nonflammable solvent prior to
welding or flame cutting.
Check all electrical wires daily. Repair any wires that
are loose or frayed before you operate the machine.
Clean all electrical connections and tighten all electrical
connections.
Dust that is generated from repairing nonmetallic
hoods or nonmetallic fenders can be flammable and/or
explosive. Repair such components in a well ventilated
area away from open flames or sparks.

Inspect all lines and hoses for wear or for deterioration.
The hoses must be properly routed. The lines and the
hoses must have adequate support and secure clamps.
Tighten all connections to the recommended torque.
Leaks can cause fires.
Illustration 15
Use caution when you are refueling a machine. Do not
smoke while you are refueling a machine. Do not refuel
a machine near open flames or sparks. Always stop the
engine before refueling. Fill the fuel tank outdoors.
Illustration 16
11
Safety Section
Fire Prevention and Explosion Prevention
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or
a hydrometer.
Improper jumper cable connections can cause an
explosion that can result in injury. Refer to the Operation
Section of this manual for specific instructions.
Do not charge a frozen battery. This may cause an
explosion
Lines, Tubes and Hoses
Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are bent
or damaged.
Repair any lines that are loose or damaged. Leaks can
cause fires. Consult your Cat dealer for repair or for
replacement parts.
Check lines, tubes and hoses carefully. Do not use
your bare hand to check for leaks. Use a board or
cardboard to check for leaks. Tighten all connections
to the recommended torque.
Replace the parts if any of the following conditions
are present:
• End fittings are damaged or leaking.
• Outer coverings are chafed or cut.
• Wires are exposed.
• Outer coverings are ballooning.
• Flexible part of the hoses are kinked.
• Outer covers have embedded armoring.
• End fittings are displaced.
Make sure that all clamps, guards, and heat shields are
installed correctly. During machine operation, this will
help to prevent vibration, rubbing against other parts,
and excessive heat.
12
Safety Section
Tire Information
Electrical Storm Injury
Prevention
When lightning is striking in the vicinity of the machine,
the operator should never attempt the following
procedures:
• Mount the machine.
• Dismount the machine.
If you are in the operator’s station during an electrical
storm, stay in the operator’s station. If you are on the
ground during an electrical storm, stay away from the
vicinity of the machine.
Tire Information
Explosions of air inflated tires have resulted from heat-
induced gas combustion inside the tires. Explosions
can be caused by heat that is generated by welding,
by heating rim components, by external fire, or by
excessive use of brakes.
A tire explosion is much more violent than a blowout.
The explosion can propel the tire, the rim components,
and the axle components as far as 500 m (1500 ft) or
more from the machine. Both the force of the explosion
and the flying debris can cause property damage,
personal injury, or death.
Illustration 17
(A) At least 15 m (50 ft)
(B) At least 500 m (1500 ft)
Do not approach a warm tire. Maintain a minimum
distance, as shown. Stay outside the shaded area in
Illustration 17.
Dry nitrogen gas is recommended for inflation of tires.
If the tires were originally inflated with air, nitrogen is
still preferred for adjusting the pressure. Nitrogen mixes
properly with air.
Nitrogen inflated tires reduce the potential of
a tire explosion because nitrogen does not aid
combustion. Nitrogen helps to prevent oxidation of
the rubber, deterioration of rubber, and corrosion of
rim components.
To avoid over inflation, proper nitrogen inflation
equipment and training in the usage of the equipment
are necessary. A tire blowout or a rim failure can
result from improper equipment or from misused
equipment.
When you inflate a tire, stand behind the tread and use
a self-attaching chuck.
Servicing tires and rims can be dangerous. Only trained
personnel that use proper tools and proper procedures
should perform this maintenance. If correct procedures
are not used for servicing tires and rims, the assemblies
could burst with explosive force. This explosive force
can cause serious personal injury or death. Carefully
obey the specific instructions from your tire dealer.
Mounting and Dismounting
Illustration 18
Mount the machine and dismount the machine only
at locations that have steps and/or handholds. Before
you mount the machine, clean the steps and the
handholds. Inspect the steps and handholds. Make
any necessary repairs.
Face the machine whenever you mount the machine
and whenever you dismount the machine.
Maintain a three-point contact with the steps and with
the handholds.
Note: Three-point contact can be two feet and one
hand. Three-point contact can also be one foot and
two hands.
Never mount a moving machine. Never dismount a
moving machine. Never jump off the machine.

Do not carry tools or supplies when you mount the
machine or when you dismount the machine. Use a
hand line to raise and lower tools or supplies.
Do not use any controls as handholds when you
enter the operator compartment or when you exit the
operator compartment.
Before Starting Engine
Start the engine only from the operator compartment.
Never short across the starter terminals or across the
batteries. Shorting could damage the electrical system
by bypassing the engine neutral start system.
Inspect the condition of the seat belt and of the
mounting hardware. Replace any parts that are worn
or damaged. Regardless of appearance, replace the
seat belt after three years of use. Do not use a seat
belt extension on a retractable seat belt.
Adjust the seat so that full pedal travel can be achieved
with the operator’s back against the back of the seat.
Make sure that the machine is equipped with a lighting
system that is adequate for the job conditions. Make
sure that all machine lights are working properly.
Before you start the engine and before you move the
machine, make sure that no one is underneath the
machine, around the machine, or on the machine.
Make sure that the area is free of personnel.
Engine Starting
If a warning tag is attached to the start switch or to the
controls, do not start the engine. Also, do not move
any controls.
Move all hydraulic controls to the HOLD position before
you start the engine.
Move the transmission direction control lever to the
NEUTRAL position.
Engage the parking brake.
Diesel engine exhaust contains products of combustion
which can be harmful to your health. Always operate
the engine in a well ventilated area. If you are in an
enclosed area, vent the exhaust to the outside.
13
Safety Section
Before Starting Engine
Before Operation
Clear all personnel from the machine and from the
area.
Clear all obstacles from the path of the machine.
Beware of hazards such as electrical wires, ditches,
etc.
Make sure that all windows are clean. Secure the
doors in the open position or in the shut position.
Secure the windows in the open position or in the
shut position.
For the best visibility of the area that is close to the
machine, adjust the rearview mirrors (if equipped).
Make sure that the machine horn, the backup alarm (if
equipped) and all other warning devices are working
properly.
Fasten the seat belt securely.
Operation
Only operate the machine while you are in a seat.
The seat belt must be fastened while you operate the
machine. Only operate the controls while the engine
is running.
While you operate the machine slowly in an open
area, check for proper operation of all controls and
all protective devices.
Before you move the machine, ensure that no one will
be endangered.
Do not allow riders on the machine unless the machine
has the following equipment:
• Additional seat
• Additional seat belt
• Rollover Protective Structure (ROPS)
Note any needed repairs during machine operation.
Report any needed repairs.
Carry work tools approximately 40 cm (15 inches)
above ground level. Do not go close to the edge of a
cliff, an excavation, or an overhang.
If the machine begins to sideslip downward on a grade,
immediately remove the load and turn the machine
downhill.
14
Safety Section
Parking

Avoid any conditions that can lead to tipping the

machine. The machine can tip when you work on hills,
on banks and on slopes. Also, the machine can tip
when you cross ditches, ridges or other unexpected
obstacles.

Avoid operating the machine across the slope. When

possible, operate the machine up the slopes and down
the slopes.

Maintain control of the machine. Do not overload the

machine beyond the machine capacity.

Be sure that the hitches and the towing devices are

adequate.

Only connect the trailing equipment to a drawbar or

to a hitch.

Never straddle a wire cable. Never allow other

personnel to straddle a wire cable.

Before you maneuver the machine, make sure that no

personnel are between the machine and the trailing
equipment. Block up the hitch of the trailing equipment
in order to align the hitch with the drawbar. Maneuver
the machine. Connect the machine to the trailing
equipment.

Know the maximum dimensions of your machine.

Always keep the Rollover Protective Structure (ROPS)

(If Equipped) installed during machine operation.

Parking
Park on a level surface. If you must park on a grade,
chock the machine.

Apply the service brake in order to stop the machine.

Move the transmission control lever to the NEUTRAL
position.

Engage the parking brake.

Lower all work tools to the ground.

Stop the engine using engine shut-off cable.

Turn the engine start switch to OFF position and

remove the key.
 15
Product Information Section
Specifications and Model Views

Product Information Machine General Information

Section Engine
Specifications and Model Table 1
Views 6R1080TA3, Bharat Stage III
Model
(CEV) Complaint Engine
Model View Illustrations
Make Kirloskar Oil Engines

Type 4 Stroke, 6 Cylinders

4
7 Bore & Stroke 105 mm X 125 mm

Displacement 6.495 Liter

3 1
Gross Power @ 2300 rpm 115 hp

Net Power @ 2300 rpm 102.5 hp

2 Max.Torque @ 1500 rpm 415 N.m

5 6 Turbo with Charged Air

Aspiration
Cooler
Illustration 19
Electrical System 24 V

Bucket (1), Engine (2), Battery (3),Operator’s

compartment (4), Air tank (5), Lift arm (6) &
Tilt cylinder (7)
Transmission
Twin turbine transmission with an integral torque
converter planetary gear box with single lever
powershift control. Shift from first turbine to second
9
8
10
turbine is automatic upon demand. Soft shift feature
for full powershift between forward and reverse. Two
`

stage, four element torque convertor.

Table 2

TRAVEL SPEEDS FOR 2021 WHEEL LOADER WITH

TWIN TURBINE TRANSMISSION

11 Low Turbine 3.2 Km/h 2.0 M/h

12
FORWARD - 1
Illustration 20 High Turbine 7.2 Km/h 4.4 M/h

Air cleaner (8), Pre cleaner (9), Radiator (10), Low Turbine 12.3 Km/h 7.7 M/h
Hydraulic tank (11) & Fuel tank (12) FORWARD - 2
High Turbine 25.8 Km/h 16.1 M/h

Low Turbine 4.5 Km/h 2.8 M/h

REVERSE - 1
High Turbine 9.3 Km/h 5.8 M/h
16
Product Information Section
Specification and Model Views

Drive Axles Parking Brake

1. Front axle Fixed Mechanically expanding shoe off transmission output

2. Rear Axle oscillates at ± 11°
3. Full Floating axle shafts – can be removed
independently off wheel and planetary.
4. Conventional heavy duty differential.
shaft, pedal operated.
Emergency Brake
Use service brakes. When air pressure drops below 45
psi, an audible warning horn sounds and the brakes
are applied automatically. Operator can also manually
apply the brakes.

Steering Tires
Pivot Steering
Rims are bolted directly to the wheels for positive non-
Full power steering through orbitrol valve to steering slip retention.
cylinders.
Standard Tire size ……………….14.00 X 25 – 20 PR
80° steering and 50° bucket swing.
Note: In certain applications (such as load-and-
carry work) the loader’s productive capabilities might
Steering Hydraulic System exceed the tires tones-KM/h (TKPH) capabilities. We
recommend that you consult a tire supplier to evaluate
1. Load sensing hydraulic system with priority valve all conditions before selecting a tire model.
to ensure regulated oil supply to steering.

2. Two double acting steering cylinders. Electrical System

3. Common gear pump for steering and hydraulic Negative ground fuse protected system for starting,
system. lighting and accessories. System includes 55A
alternator, automatic voltage regulator and two 12V,
150ampere hour batteries. Key operated electrical
Filters on-off switch with neutral start safety feature. All dash
gauges illuminated.
Table 3

Engine Oil Paper Element Filter

Fuel prefilter - Felt fine filter paper

Fuel System
plus water separator

Transmission Remote mounted full flow oil filter

Wire mesh strainer on the suction

Hydraulic System side and renewable filter on the
return side

Air Intake System Duel element filter with precleaner

Brakes
Service Brakes

Four Wheels air actuated brakes with separate circuit

for front & rear axles. In the event of air pressure loss in
either of the circuit, audible warning sounds. Automatic
trans-declutch on depression of brake pedals.
 17
Product Information Section
Specification and Model Views

Operating Data for Various Buckets

Note: All dimensions, specifications and ratings conform to or exceed SAE (Society of Automotive Engineers)
Specifications. J732C (Specifications definitions) & J742B (Bucket Rating) where applicable.

Table 4

General General
Unit Rock Coal
Purpose Purpose

Bucket Capacity (SAE Heaped) 2:1 cu.m/cu.yd 1.70/2.25 1.70/2.25 2.50/3.30 3.00/3.92

Pay Load Kg/lb 2722/6001 2722/6001 2722/6001 3300/7275

Bucket Struck Capacity cu.m/cu.yd 1.48/1.94 1.48/1.94 2.10/2.70 2.55/3.34

Bucket Width mm/inch 2550/100 2550/100 2550/100 2800/110

Bucket Weight kg/lb 700/1544 1100/2425 1018/2240 1039/2291

At Maximum Lift

Dump Clearance @ 45° mm/inch 2801/110 2640/104 2587/101 2569/101

Reach to Tyres @ 45° mm/inch 1074/42 1240/49 1288/51 1275/50

Overall Length on Ground mm/inch 6705/264 6939/273 7017/277 7062/278

Turning Radius Outside Bucket

mm/inch 5438/214 5523/217 5626/222 5670/223
Corner

Breakout Force @ 102mm (4in)

kg/lb 10875/23980 8737/19256 7966/17525 8703/19187
from Cutting Edge

Static Tipping Load

Straight Ahead kg/lb 7506/16550 7107/15670 7347/16198 7812/17222

Full Turn kg/lb 6353/14006 6010/13252 6229/13732 6620/14595

Operating Weight

Front kg/lb 5020/11064 5655/12463 5130/11310 5700/12566

Rear kg/lb 5920/13048 5685/12530 5880/12962 6260/13801

Total kg/lb 10940/24112 11300/24905 11010/24273 11960/26367

Note: For bucket equipped with teeth reduce dump clearance by 127 mm (5 inches)
18
Product Information Section
Specification and Model Views

Bucket Hydraulic System

The hydraulic system of the Wheel Loader contains
the followings.

• Tandem Gear pump.

• Two double acting Lift cylinders

• One double acting Tilt cylinder.

• Two spool Hydraulic control valve

• Adjustable lift arm kick out control valve

• Bucket leveling valve for automatic loading

position

• Lift arm control positions like Raise, Lower, Hold

and Float

• Hydraulic tank, filter and sump screen are

serviceable without draining tank.

• Pump flow @ 2300 rpm – 215 lpm

Hydraulic Cycle Time

Table 5

Raise 6.0 Seconds

Lower 3.0 Seconds

Tilt 1.0 Seconds

Shipping Information (Approximate)

Table 6

SHIPPING INFORMATION (Approximate)

Bucket General
Machine
Purpose
Including Lift
1.7 cu.m
Arm & Rims
(2.2 cu.yd)

5855 mm 2540 mm
Length
(19 ft 2 in) (8ft 4 in)

Height without 2550 mm

Cab (8 ft 1 in) 1016 mm
Height with 3022 mm (3ft 6 in)
Cab (9 ft 11 in)

2362 mm 1118 mm
Width
(7 ft 9 in) (3ft 8 in)

10940 Kg 700 Kg
Weight
(24112 lb) (1543 lb)
 19
Product Information Section
Product Identification Information

Product Identification
Information
Plate Locations and Film
Locations
262-9024
lllustration 23 (SIN)
The Product Identification Number (PIN) will be
used to identify a powered machine that is designed
for an operator to ride. Part Identification Number Plate (PIN)

Cat products such as Engines, Transmissions and Service Information Number Plate (SIN)
major attachments that are not designed for an
operator to ride are identified by Serial Numbers. Note: The PIN and SIN plates are located on the left
side of the operators compartment above the hydraulic
For quick reference, record the identification tank.
numbers in the spaces that are provided below the
illustration.

lllustration 24

lllustration 21 Engine number is stamped on a lable which is

fastened in left side of the engine. If you need parts,
service or information for your engine, you must give
engine type and CMO number.

lllustration 22 (PIN)
lllustration 25

Transmission Serial number plate.

20
Operation Section
Before Starting Inspection

Operation Section Engine Oil Level Check

Before Starting Inspection

Before starting the engine, the following inspection
should be performed to make sure that the loader
is ready to operate. The bucket or other attachment
should be completely lowered, and the parking brake
applied before making the inspection.

Daily Inspection
For a maximum service life of the machine, complete
a thorough daily inspection before you mount the lllustration 26
machine and before you start the engine.
Remove the engine crankcase dipstick, wipe it clean
Inspect the area around the machine and under the and reinsert it. Remove it and observe the indicated
machine. Look for loose bolts, trash buildup, oil, coolant crankcase oil level. Add oil if below the “MAX” MARK.
leakage, broken parts, or worn parts. Never operate the engine if the level is below the
“LOW” mark. Do not overfill the crankcase when adding
Note: Watch closely for leaks. If you observe a leak, oil, excess oil causes foaming and other problems.
find the source of the leak and correct the leak. If you
suspect a leak or you observe a leak, check the fluid
levels more frequently. Coolant Level Check
Inspect the condition of the equipment and of the
hydraulic components.

Check the condition of the tires. Adjust the inflation

pressure, if necessary.

Check all of the oil levels, all of the coolant levels, and
all of the fuel levels.

Remove any trash buildup and debris. Make all

necessary repairs before you operate the machine.

Make sure that all covers and guards are securely

attached.
lllustration 27
Adjust the mirrors (If Equipped) for the correct rear Remove the radiator cap and check for radiator coolant
view of the machine. ½” to ¾” above the top tank baffle plate. Add coolant if
needed. In sub-freezing temperature, make sure that
Grease all of the fittings that need to be serviced on
it contains sufficient permanent (ethylene glycol) type
a daily basis.
anti-freeze to prevent freezing.
 21
Operation Section
Before Starting Inspection

Fuel Level Check system, check for flow from Add plug (lower) (2). Make
sure to hold the rpm during this check. If the check is
made at a lower rpm, it may result in a low oil level
during normal operation.

Add oil, if necessary, to bring the level to the Add plug

(lower) (2). Note that the plug level is used for the
cold check. When the transmission reaches operating
temperature, thermal expansion will raise the oil level
to the Full plug (upper) (1).

Hydraulic Oil Level (Cold Check)

lllustration 28 2

Fill the fuel tank to capacity if it was not filled when

the unit was shut down. The fuel tank should be filled
at the end of the shift whenever possible to minimize 1
moisture condensation. Check fuel level, remove the
fuel tank dipstick, wipe it clean and reinsert , remove
it and observe the indicated fuel level. If necessary
add fuel.

Transmission Oil Level

(ColdCheck) lllustration 30

Open the hydraulic tank vent cock (1) to release any

pressure in the tank. Open the hydraulic tank cap (2)
and Check the oil level. Add oil, if necessary to the
1 bottom of the tank fill tube. Replace the cap (2) securely
and close the vent cock (1).

Air Cleaner

lllustration 29

The transmission oil level check plugs are located on

the front of the housing near the lower right side.

Before starting engine, remove the Full plug

(upper) (1). If oil flows from the plug opening, the
transmission has sufficient oil to permit safe starting of
the engine. If no oil flow is present, add sufficient oil to
cause a flow from the opening, and replace the plug.
lllustration 31

Shift the range selector to neutral and start the engine. Check the engine air cleaner dust valve to make sure
Accelerate to 1000 to 1500 rpm. Operate at this rpm for that it is not clogged or blocked. A finger flicked the
approximately one minute to charge the hydraulic rubber dust valve should release any obstruction.
22
Operation Section
After Starting Inspection

If not, remove the cup from the cleaner and shake any With the engine operating at a fast idle speed, check
excessive dust or obstruction in the cup and valve. for battery charging current on the ammeter and air
Replace the dust cup. tank pressure on the air pressure gauge.

Air Tank Check the engine, transmission, steering and hydraulic

system components for coolant / oil leakages. Tighten
leaking fluid check cocks or drain cocks to stop leakage
and or prevent subsequent loosening. Report leaks
that cannot be stopped to those responsible for unit
maintenance.

Transmission Oil Level

(Hot Check)

1
lllustration 32

Open the drain cocks to drain moisture and water

sediment. Close the drain cocks on the air tank.

Tires
Check the tire pressure with an accurate gauge. Inflate
the tires to the pressures specified. Inspect all tires
carefully for cuts, breaks, imbedded debries or other
damages. Report tire damage to those responsible for
vehicle maintenance.
Visual Inspection
Carefully check for oil, fuel, coolant or lubricant leaks.
Make sure all component fluid level check cocks
and drain cocks are tightened securely to prevent
subsequent loosening. Report any leakage that cannot
be stopped to the mechanic. Clean caked mud or other
materials from hydraulic and steering hoists. Take care
to avoid damaging of hoist piston rods.
After Starting Inspection
Before starting the engine to post-starting inspection,
be sure that all personnel are clear of the unit, the
transmission and hydraulic system controls are in
“Neutral” positions, and the parking brake is in fully
applied condition. Sound the horn.
2
lllustration 33
Shift range selector to neutral, and start the engine.
Operate the vehicle until the transmission reaches a
normal operating temperature. Then idle the engine
and apply the parking brake. Shift through all range
positions slowly to ensure that all areas of the system
are filled with oil.
Shift to neutral and set the engine speed at 1200 to
1500 rpm. Remove the Full plug (upper) (1). The oil
should be at or near the level of the plug opening. Add
or drain oil as necessary to bring it to the Full plug level.
(The transmission may be operated as long as the oil
level is above the ADD plug).
Note: Observe the type of flow from the plug opening.
Foaming or spurting may indicate a false level.

Start the engine (see “Starting the engine”), and

observe the instrument panel gauges. If the engine
lubricating oil pressure gauges does not register oil
pressure within 10 to 15 seconds, shut off the engine
to prevent any damage until the trouble is corrected.
 23
Operation Section
Steering Frame Lock

Hydraulic Oil Level (Hot Check) Connect steering frame lock (1) when the machine is
being lifted and being transported. Also connect the
steering frame lock if you are performing service work
near the articulation joint. Install pin (2) in order to
2
secure the steering frame lock.

Separate steering frame lock (1) before the machine

1
is operated.

Move the steering frame lock into the unlocked position

and install pin (2).

Illustration 34

Operate the hydraulic system lift and tilt levers several

times to warm the oil and make sure that all hoses
and components are charged and lower the bucket
completely to the ground. With the engine idling
carefully open the tank vent cock (1) to dissipate
any tank pressure. Then remove the tank filler tube
cap (2) and check hydraulic oil level. Add hydraulic
oil, if needed. Replace the cap (2) tightly and close
the vent cock (1) securely.

Steering Frame Lock

No clearance for person in this area when machine

turns. Severe injury or death from crushing could
occur.

The steering frame lock is located on the left side of

the machine.

lllustration 35
24
Operation Section
Switches and Instruments

Switches and Instruments Gauges

Engine Start Switch
3
2

3
1

Illustration 37

Illustration 36 Convertor Temperature Gauge (1) - Indicates the

(1) OFF
(2) ON
(3) START
OFF (1) – Insert the engine start switch key only while
the start switch is in the OFF position. Remove the
engine start switch key only while the start switch is in
the OFF position.
ON (2) – The engine start switch will
return to the ON position when the engine
start switch key is released from the START position.
transmission oil operating temperature. The needle
should stay within the GREEN range at all times. If it
goes into the RED range, shift the transmission control
lever to NEUTRAL position, allow the transmission oil to
cool. If the needle remains in the RED range indicates
that the transmission is in trouble and stop the engine
immediately.
Transmission Clutch Pressure Gauge (2) – The
gauge indicates the clutch apply pressure. In normal
operation, the needle will fluctuate during range shifts
and will drop below normal during inching and clutch
cutoff operation.

START (3) – Turn the engine start switch Air Pressure Gauge (3) - The gauge indicates the
key to the START position in order to pressure in air reservoir, brakes will not release until
start the engine. Release the engine start switch key the pressure exceeds 4.22 Kg/cm² (60 PSI).
after the engine starts.
4
The transmission control lever must be in the
NEUTRAL position and the hydraulic control levers
must be in the HOLD position before you turn the
engine start switch and before you start the engine.

Note: The engine may fail to start after the key is

turned to the start position. If this happens, the key
must be returned to the OFF position. Attempt to
start the engine again. Remove key when not
operating.

Illustration 38

Hour Meter (4) - This gauge indicates the total operating

hours of the engine. The hour meter should be used to
determine service hour maintenance intervals.
 25
Operation Section
Switches and Instruments

Light Switches
5

4
3
7 2
1
6

Illustration 39

Ammeter (5) - Indicates the operation of the Alternator Illustration 40

regulator circuit and state the amount of charge or
Directional Turn Signal Switch (1) – In order activate
discharge in the battery circuit. After starting the
the left turn signal to turn the switch to left side. In
engine, the ammeter should show a high rate of
order activate the right turn signal to turn the switch
charge, then tapper off.
to right side and move the switch to the centre in order
Water Temperature Gauge (6) - The gauge indicates to deactivate either turn signals.
the engine coolant temperature. The gauge needle
Head and Tail Light Switch (2) - Move the switch to
should be in WHITE range. If the needle is in the RED
down position in order to turn on the tail lights and
range stop the engine and inspect the cooling system
again move the switch to down, turn on the head lights.
for any leaks, obstruction or blockage and coolant in
radiator. Panel Switch (3) – This switch controls the panel
illumination.
Engine Oil Pressure Gauge (7) - The gauge indicates
the engine lube oil pressure. At normal speed, the Rear Flood Light (4) – Move the switch to ON
gauge should register to the right of the centre of the position in order to turn on the rear flood light.
dial. The RED bar on the gauge refers to pressure at
normal speed not at idling speed.

Illustration 41

Cab Light Switch (5) (IF Equipped) – The Switch is

located on the upper left side of the operators
compartment.
26
Operation Section
Switches and Instruments

Hazard Flasher Control

Illustration 42

Head Light Dipper Switch – The dipper switch is
located on front foot area in the operators compartment.
Press the dipper switch with foot in order to activate
the front head lights form high beam to low.
Front and Rear Wipers
(If Equipped)
Illustration 44
The hazard switch is located on the left hand side of
the front panel. To move the switch upward position, in
order to activate the hazard flashers. Both turn signal
lights will flash. Move the switch to downward position,
in order to deactivate the hazard flashers.
Horn

1 2
`

Illustration 45
Illustration 43

The Switch is located on the upper left side of the
operators compartment. In order to activated the front
window wiper turn on the wiper switch (1). Turn on the
wiper switch (2) to activate the rear wiper.
Horn switch is located on the right foot area (front)
of the operators compartment is shown in the above
picture. Press the switch with foot in order to sound
the horn. Use the horn for alerting personnel or for
signaling personnel.
 27
Operation Section
Machine Control

Backup Alarm Machine Control

Parking Brake Control
The parking brake pedal is located on the left side
foot area of the operators compartment. Mechanically
expanding shoe off transmission output shaft, pedal
operated.

Always stop the engine and engage the parking brake

before you get off the machine.

Illustration 46
1
The alarm will sound when the transmission shift
control lever in the REVERSE position. The alarm is
used to alert the people behind the machine that the
machine is backing up.

The backup alarm is mounted on the rear left side of

the machine.

Seat Belt
Always check the condition of the seat belt and
the condition of the mounting hardware before you
operate the machine.
Illustration 48
Parking Brake Engaged – Push the lever pedal (1)
to downward position in order to engage the parking
brake.

`
2

Illustration 47

Inspect the seat belt for webbing that is worn or Illustration 49

frayed.
Parking Brake Disengaged – Press the release pedal
Check the buckle for wear or for damage. If the seat
(2) in order to disengage the parking brake.
belt is worn or if the buckle is damaged, replace
the seat belt and/or the buckle. Secondary Brake – The parking brake serves as a
secondary brake. The secondary brake should be used
Inspect the belt mounting hardware. Replace any if the service brake fails to stop the machine.
hardware that is damaged or worn. Make sure that
28
Operation Section
Machine Control
Service Brake Control
Push the brake pedal downward in order to slow down
the machine or stop the machine. Use the brake pedal
while you are operating on a downgrade in order to
prevent the engine from over speed.
lllustration 50
The rear brake lights must come on when you apply the
brake. If the rear brake lights are not functioning, repair
the brake lights before you operate the machine.
Accelerator Control
lllustration 51
Accelerator Pedal – Push down the pedal in order
to increase travel speed. Release the pedal in order
to decrease travel speed. The accelerator pedal will
return to the low idle setting.
Use the pedal to reduce engine rpm for directional
shifts when you use the loader.
Transmission Direction
Control
lllustration 52
F O RWA R D ( 1 ) & ( 2 ) – M o v e t h e
transmission lever upward. The machine
will move forward.
NEUTRAL(3) – The machine should not
move when the transmission lever is in the
neutral position.
REVERSE(4) – Move the transmission
lever downward. The machine will move
in reverse.
Forward directional changes and reverse directional
changes are possible while the machine is
moving. However, reducing the engine speed
is recommended, when the directional changes are
being made. Reducing the machine ground speed
and/or braking is recommended, when directional
changes are being made. This permits operator
comfort and maximum service life of the power train
components.
To avoid an unstable machine, the machine should
be stopped before any directional changes are
made with a raised load.
The lever should be moved to the NEUTRAL
position when you are leaving the machine.
 29
Operation Section
Machine Controls

Steering Control Engine Shut Off Control

lllustration 53 lllustration 55

The steering wheel controls the directional steering Engine shut off control is located on right side of the
of the machine. The machine will turn in the same seat. Push in before staring engine. Pull up the engine
direction as the steering wheel is turned. shut off cable to stop the engine.

LEFT TURN – Move the steering wheel Emergency Brake Control

counter clockwise in order to steer the machine to
the left. Turn the steering wheel further in order to Valve (Push - Pull)
achieve a more acute turn.

RIGHT TURN – Move the steering wheel clockwise

in order to steer the machine to the right. Turn the
steering wheel further in order to achieve a more
acute turn.

Transmission Declutch Valve

lllustration 56

Emergency brake control is located on right side of the

seat. Push and pull the toggle type air control valve
associated with the brake control system.

Controls the inversion and relay emergency valves

for energizing the brake chambers, when the knob is
pulled outward and automatically operates to energize
lllustration 54
the brake chambers if the air pressure in the system
The declutch valve switch is located on left side of the falls to below 45 psi.
seat. The declutch valve is connected in the air line
between treadle valve and declutch cylinder. Move the
switch to ON position in order to direct the air pressure
to declutch cylinder, when the brakes are applied. If
the switch is in OFF position this feature of operation
is blocked.
30
Operation Section
Machine Controls

Battery Master Switch Loader Bucket Tilt Control

lllustration 57 lllustration 59

Battery Master Switch is located on left side of the
seat. Insert the battery master switch, to turn on the
switch in order to connect the batteries to electrical
system. Turn off the switch in order to disconnect the
batteries from the electrical system.
Loader Bucket Lift Control
Dump (1) – Move the lever forward to
position (1) in order to dump a load from the
bucket.
Hold (2) – Move the lever to position (2) in
order to stop movement of the loader bucket.
The bucket will remain in the selected
position.

Tilt Back (3) – Move the lever to position (3)

in order to tilt the bucket backward.

lllustration 58

Float (1) – Move the lever forward to

position (1).

Lower (2) – Move the lever to position (2) in

order to lower the loader bucket.

Hold (3) – Move the lever to position (3) in

order to stop movement of the loader bucket.
The bucket will remain in the selected
position.

Raise (4) - Move the lever to position (4) in

order to raise the loader bucket.

Machine Operation
Machine Operation Information
The machine must be under control at all times.
Do not place the transmission in NEUTRAL in order
to allow the machine to coast.
Select the gear speed that is necessary before you
start down a grade. Do not change the gears while
you are going down a hill.
When you go downgrade, use the same gear speed
that would be used to go upgrade.
Do not allow the engine to over speed when you go
downhill. Use the brake pedals in order to reduce
engine over speed when you are going downhill.
When the load is pushing the machine, put the
transmission lever in first speed before you start
downhill.
To avoid early brake wear or early brake damage,
do not use the brake pedals as foot rests.
1. Fasten the seat belt.
2. Raise all of the lowered work tools enough to clear
any unexpected obstacles.
lllustration 60
3. Push the brake pedals downward in order to stop
the machine from moving.
4. Release the parking brake.
31
Operation Section
Machine Operation
5. Release the brake pedals in order to move the
machine.
6. Move the accelerator pedal to the desired engine
speed.
7. Move the machine forward for best visibility and
for best control.
Changing Direction and Speed
Changing from low speed to high speed at full engine
speed is possible. Directional changes at full engine
speed are possible. However, if you are changing
direction, reducing the machine speed and/or braking
the machine is recommended. This will provide
operator comfort and the maximum service life for the
power train components. Keep the loaded bucket low
to the ground. Stop the machine in order to avoid an
unstable machine.
1. Lower the engine speed with the accelerator
pedal.
2. Push the brake pedals downward in order to slow
the machine. Push the brake pedals downward in
order to stop the machine.
3. Move the transmission direction control lever to
the desired speed and to the desired direction.
4. Release the brake pedals.
5. Increase the engine speed with the accelerator
pedal.
32
Operation Section
Machine Operation

Parking Brake
NOTICE
The parking brake must be engaged before the
operator leaves the seat.

Do not engage the parking brake while the machine

is moving unless the primary service brake fails. The
use of the parking brake as a service brake in regular
operation will cause severe damage to the brake
system.

Illustration 61

Switching the direction control lever from NEUTRAL

to either direction will not cause the machine to
move while the parking brake lever is engaged.
You must first disengage the parking brake. Then
move the direction control lever from the NEUTRAL
position in order for the machine to move. Always
apply the service brake before the parking brake is
disengaged.

NOTICE
Moving the machine with the parking brake engaged
can cause excessive wear or damage to the brake.
If necessary, have the brake repaired before
operating the machine.

Operating Techniques
Loader Operation
Illustration 62
Before starting the engine and operating the loader,
always follow the following safety pre-cautions.
1. Walk around the unit before mounting, to make
sure that no one is near the loader.
2. When mounting, do not use the steering wheel
as a hand hold if the loader has been shut down
for less than 10 minutes. Any undissipated
steering accumulator pressure will turn the front
wheels if the steering wheel is turned in this
manner.
3. Make sure that the transmission and hydraulic
system controls are in “NEUTRAL” position.
4. Apply the parking brake if released.
Engine Normal Starting
With the transmission range selector lever in ‘Neutral’
and the hydraulic system control levers in ‘Hold’ push
in the engine shut off lever.
Insert the key fully and press the starter button.
Release the button immediately when the engine
starts. Observe the engine oil pressure gauge. If no
pressure is indicated within 10 to 15 seconds shut off
the engine.
33
Operation Section
Operating Techniques
Never crank the engine longer than 30 seconds
continuously. Allow at least 2 minutes cooling time
between cranking periods to avoid overheating the
cranking motor.
Allow the engine to idle for several minutes to
warm the hydraulic system and circulate it through
all moving parts.
Do not release the parking brake until the air
pressure gauge registers 6.3 Kg/cm2.
Cold Weather Starting Aids
If a starting aid is required regularly to help starting
the engine under adverse conditions, installation of
the approved starting aids is suggested for safety and
best results.
Engine Operation
Engine Warm-up
With the transmission range selector lever in ‘Neutral’
and the hydraulic system control levers in ‘Hold’
position push in the engine shut off lever.
Insert the key fully and press the starter button.
Release the button immediately when the engine
starts. Observe the engine oil pressure gauge. If no
pressure is indicated within 10 to 15 seconds shut off
the engine.
Illustration 63
When an engine is started after being allowed to cool,
the lubrication oil is thick and cold, and the bearings
are partly dry. The lubrication oil pump requires as
short periods
34
Operation Section
Operating Techniques

to fully lubricate all engine working parts after starting.
If the engine is placed under load at full speed
immediately after starting, these partly exposed parts
are exposed to conditions that can cause excessive
wear. To avoid unnecessary wear, always allow the
engine to fully circulate lubricant and warm up
gradually before operating at full speed and full load.
Engine Proper Operation
“STALLING” the converter prevents the engine from
developing full speed and hence it cannot operate at
full efficiency. This practice also can result in rapid
converter or transmission failure. Get the best engine
efficiency by operating the engine at top governed
speed with the transmission in the correct range to
utilize full power, when maximum power is needed
for the load.

lllustration 64
lllustration 66

HINDUSTAN units are equipped with engines capable

One of the first indications that a diesel engine is not
of delivering more than enough power for the loads,
operating properly is a smoky may result from incorrect
for which they are designed. These engines are well
engine operation that allows the engine to run too cold.
proven on many jobs under all conditions for adequate
The engine, cooling system is equipped with
power. Although this power is available, it cannot be
thermostats to maintain operating temperature
fully utilized if the engine is not operated properly.
between 160° to 185° F, under normal operating
conditions (Full load). When an engine is allowed to
idle for extended periods, the thermostat cannot
function properly and allow the engine to run too cold.
Never idle the engine more than 5 minutes at a time,
shut it down.

Engine Cool and Hot

lllustration 65

Maximum engine power is available only at the top

governed speed. The engine should be operated at
top rated speed, when maximum power is needed for
the load. The proper transmission gear range must
also be used to utilize engine power. If the
transmission is in too high a gear range to utilize full
engine power, the transmission converter unit will be lllustration 67
in a full or partial “stall” conditions.
 35
Operation Section
Operating Techniques

After an engine has been operating under full load at Engine Stopping
or near full speed, a great deal of heat is stored up in
its iron mass. If stopped abruptly without allowing the
engine to cool evenly through circulation of its coolant
and lubricating oil, this heat will be dissipated unevenly,
which in extreme conditions, can crack or warp certain
parts. Remember coolant and lubricant circulation
stops when engine stops. A hot engine should not be
shut down quickly.

Cool a hot engine by operating at 1000 rpm and

slowly decelerating over a 5 minute period to idle
speed. Idle the engine for at least 2 minutes then shut
it off. ALWAYS COOL A HOT ENGINE GRADUALLY
BEFORE SHUTTING IT DOWN.
lllustration 69

Lower the bucket completely in a level position.

The bucket-control levers in ‘Hold‘ position.

The transmission shift lever in ‘Neutral’, apply the

parking brake securely.

lllustration 68

Almost all impending failures give some warning before

engine parts actually fail. By paying attention to engine
gauges, listening for unusual noises, and observing
performance on unexpected engine breakdown can
be avoided. When an engine gives its warning of
trouble ahead, shut it down and call a mechanic. A
few moments delay after the first warning can result lllustration 70
in a very costly breakdown.
Pull up the engine shut off cable located at the right
side just behind the operators seat to stop the fuel flow
to the engine.

Turn the steering wheel left and right until the

accumulator pressure has been released. The
power service brakes will operate for several brake
applications. Make sure the parking brake is applied
securely before shutting off the engine. Lower the
bucket completely.
36
Operation Section
Operating Techniques

Transmission Operation
The loader is equipped with a planetary gear type
hydraulically actuated transmission which does not
require a mechanically operated clutch to disengage the
gearing when shifting. This model have transmission
with two forward and one reverse gear ratio controlled
by a single lever. Operation for the transmission is
covered in the following section.
If the control lever is not positioned to move the control
valve spool to the full detent position, oil pressure
applied to the transmission clutch packs will be
inadequate. This causes clutch slippage and warps or
scores clutch plates. DO NOT feather the transmission
control levers while shifting, move directly into the full
detent position.
The following sketches illustrate do’s and don’ts of
transmission shifting. These practices shown are very
critical to both transmission life, and to loader operating
safety.

lllustration 71 lllustration 72

1. 1st FORWARD Do not shift repeatedly between forward and reverse to

bump shake, or rock unit to dislodge stuck or irregularly
2. 2nd FORWARD shaped material.
3. NEUTRAL
4. REVERSE

The forward, reverse, and neutral positions of the

lever, for the two speed transmissions are shown in
the illustration.

When operating the loader, start in 1st forward range.

Up shift to 2nd forward range if load and distance
conditions permit. The control lever must be lifted
towards the steering wheel to shift from 1st to 2nd range.
lllustration 73
The greatest torque is transmitted to the wheels, in 1st
forward position. Do not coast loader down grade in neutral and then
stop unit by shifting directional selector into gear. Keep
Transmission Shifting in gear at all times.
Precautions
When changing direction from forward to reverse,
always decelerate the engine and apply the service
brakes to come to a complete stop before shifting the
control lever. Shifting the lever into forward or reverse
while the loader is moving in the opposite direction,
even very slowly, places excessive stress on the power-
train particularly the transmission. Stop completely
before changing direction.

lllustration 74
Do not coast or freewheel loader down grade, either
forward or reverse, at any time.
lllustration 75
Do not use transmission to control gradual starts or
stops. Use brakes and accelerator pedal.
Brakes
Front and Rear axle service brakes are independent
of each other, but are controlled by one treadle valve.
Generally, when applying the brakes with the treadle
valve to slow or stop the vehicle, depress the pedal for
the degrees of braking required by the vehicle speed,
load and road conditions. Release the pedal as the
vehicle slows down, until, when stopped. The pedal is
depressed only enough to hold the vehicle stationary.
Do not fan the brakes by repeatedly depressing and
releasing the pedal. This practice needlessly depletes
the brake system air supply.
In loading operations, when the brake treadle is
depressed part way, air pressure is directed to apply
the brakes. When the treadle is fully depressed in a
brake application air pressure is also directed to a
declutch cylinder in the transmission control valve. The
transmission is disengaged in this manner to divert
full power to the loader hydraulic system for operating
the bucket or other attachment when the unit is held
stationary by the brakes.
37
Operation Section
Operating Techniques
The vehicles are equipped with a drum type parking on
the transmission output flange. This brake is applied
through mechanical linkage.
Emergency Brake
To charge the air systems after making an initial start-
up the Emergency Brake Control Valve must be pushed
down and held until the air gauge register pressure
in excess of 4.0 kg/cm² (47 PSI). Above this figure,
the valve will remain in the charging position. Service
brakes will not released until a pressure of over 4.22
kg/cm² (60 PSI), is developed in the system.
If the system pressure falls to 3.16 kg/cm² (45 PSI)
the plunger of the brake hand control valve will
automatically spring outwards to the emergency
position and apply the service brakes. An emergency
stop can be made by pulling the plunger out manually.
After an emergency stop, either automatically or
manually the control valve must be reset to charge
the complete system.
Hydraulic System Controls
` `
1
2
lllustration 76
Two levers control all operations of the bucket or other
optional attachments. The inner lever (1) controls
the forward and rearward bucket tilting, and optional
attachments. The outer lever (2) operates the bucket
lift hoists to raise and lower the bucket or other
attachments.
38
Operation Section
Operating Techniques
lllustration 77
The operating positions for the bucket tilt (inner) lever
are (from front to rear) Dump, Hold and Tilt back. The
bucket lift (outer) lever operating positions are (from
front to rear) Float, Lower, Hold and Raise. When
operating an optional front attachments such as a clam
type bucket, the tilt lever is moved side ways (left and
right) to control separate attachment functions such
as opening and closing the clam bucket.
For maximum bucket operating force, the service brake
treadle valve should be fully depressed to declutch
the transmission. This allows full engine power to be
applied to the bucket hydraulic power system.
Parking the Loader
Before parking the loader, fill fuel tank completely to
prevent moisture condensation in the tank while the
loader is shut down.
Park the loader on level ground. If it must be parked on
a grade, be sure to position the loader at right angles
to the grade.
Under the bucket to keep it slightly off the ground.
Completely lower the bucket or other front and / or
rear attachments to the ground. If the unit is to be
parked for an extended period, it is a good practice
to place planking or timbers. Shut off the engine by
pulling out the engine shut off control. Apply the parking
brake securely.
lllustration 78
Open the air drain cock and leave open while the unit
is parked. If sub-freezing temperatures are expected,
make sure that, the cooling system contains sufficient
antifreeze to prevent coolant freezing. If not the radiator
and engine block should be completely drained, are
refilled at the start of the next shift.
Clean dirt, mud or other materials from the bucket and
lift arms, particularly around the bucket tilt and lift hoists
and steering hoists.
Moving Disabled Loader
Should a failure or unusual noises indicating obvious
trouble in the power train or other loader system
develop, shut the unit down until the nature and
extent of the trouble is determined. If the loader cab
be moved to a service shop for repairs without danger
of subsequent damage enroute, remove the wheel
planetary flange covers from all four wheels and pull-
out the axle shafts to prevent of the drive train parts
while the loader is being towed. If it is towed by chain
or cable, start the engine and make sure sufficient air
pressure and steering system oil pressure is developed
for safe steering and braking before releasing the
parking brake and attempting to move the unit.
If the engine, steering, brake or hydraulic systems
cannot be operated other means of safely the loader
to the service area must be used, or repairs made at
the job site.

Loader Working
Standard Bucket Functions
lllustration 79
The work cycle for loaders equipped with the standard
bucket can be divided into four phases, Loading,
Carrying, Dumping and Returning. In all phases of
operations, safety should be the first consideration at
all times.
lllustration 80
The most common operation for loaders with standard
bucket is removing material from stock-piles and
loading it in hauling units. The hauling unit and the
loader should be positioned at the stockpile or bank
as shown in method I or II.
Loading
Raise the bucket about one foot of the ground. To
position the bucket for loading, pull the tilt control lever
all the way back and release it. The automatic bucket
leveler will position the bucket parallel to the ground
for loading. Shift the transmission into the first range.
Accelerate the engine. The bucket cutting edge should
39
Operation Section
Operating Techniques
enter the stock-pile or bank at a slight angle to the
loader on the side towards the hauling unit and about
12” to 15” above the gound
lllustration 81
As the bucket moves into the pile, pull the bucket lift
back into the “Raise” position and move the tilt lever
between “Hold” and “Tilt back” and the bucket back
intermittently until full. The lift arms will then be partly
raised when the bucket is filled.
In the case of low stock-pile particularly of free flowing
material, do not raise the bucket with the lift lever.
keep the bucket a foot or two off the ground, so that
the low stock-pile can provide back stop to get a full
bucket. The bucket loading operation should end with
the bucket behind the hauling until and tilted back
against the stops. Avoid excessive wheel spin while
loading to prevent rapid wear.
Carrying
Shift the transmission into reverse range and back
away with the steering wheel at the maximum turn
position. While decelerating prior to shifting from
reverse to forward start a full turn towards the hauling
unit. The turn should be completed during the change
of direction. Allow the lift arm to continue raising the
bucket arms so that when hauling unit is reached the
bucket is high enough to clear the top edge of the
body.
If the load must be carried some distance to be
dumped, carry the bucket at the height at which it
finished loading (Haul road and distance permitting).
If it must be carried for an extended distance, lower
the bucket to about 18" above ground for better
balance particularly on grades.
40
Operation Section
Operating Techniques
Dumping
lllustration 82
Move the tilt control lever forward to the ‘Dump’ position
to start dumping the bucket just before reaching the
dumping point so that the braking effect will throw
the load well into the dump body or bin. The dumping
should be done with the lift control lever in ‘Hold”.
Pumping the tilt control lever from ‘Dump’ to ‘Hold’
several times may help spread the load more evenly.
Maintain maximum engine speed for maximum dump
speed.
lllustration 83
After the load is dumped, pull the tilt control lever back
into the ‘Tilt Back’ detent position and release it. The
automatic bucket leveler will level the bucket with no
further attention. Back away from the dump spot and
move the lift control lever all the way forward to ‘Float’
while making a full turn. While decelerating to change
direction start a full turn toward the stockpile or bank.
When the rearward movement is complete, shift the
transmission from reverse to forward. The turn should
be completed during the change to drop to about one
foot above ground as another loading phase begins.
Digging
lllustration 84
The standard loader bucket can also be used for
digging out material below grade level. To dig or
excavate below ground level, lower the bucket and
position it with the tilt control lever to a slight digging
angle. Move the loader forward in first gear and push
the tilt control lever forward at the same time until the
bucket cutting edge has penetrated to the desired
depth. When this depth is reached, pull the tilt control
lever back to the ‘Hold’ position. Maintaining a level cut
by raising or lowering the bucket lift arms as required.
When full, tilt the bucket back with the tilt control lever
and place the lever in ‘Hold’. Raise the bucket with the
lift control lever to the required carry height and carry
the load to the dump spot.
lllustration 85
Should the engine stall while operating the loader
move the bucket control levers to the ‘Hold’
position. Hold the unit with the foot brakes and
apply the parking brake securely before attempting
to start the engine.
 41
Operation Section
Operating Techniques

Standard Bucket Operating

Hints
Minimum steering wheel movement means maximum
drive wheel power. Where possible load the bucket in a
full turn and maintain the turn in the reverse movement
of the travel phase.

Lift the bucket only high enough to clear the dumping

area. Carry the bucket at a height consistent with good
safety practices. The bucket should be carried low,
for extended distances, particularly on slopes for best
machine stability.

Maintain full engine power by depressing the brake

treadle to declutch the transmission as required while
loading hard-packed material, dumping sticky material,
or for slowly easing up to the dumping point.

After dumping and clearing the dump area, move the

lift control lever to ‘Float’ and immediately pull the tilt
control lever to ‘Tilt Back’ position and release. This
practice provides the fastest lift arm lowering time with
minimum hydraulic power requirement.

To maintain traction on soft or slippery footing ‘duck

walk’ the loader by turning from side to side while
moving forward or backward. This action provides a new
footing constantly to improve wheel traction.

For back leveling with the standard bucket, move the

lift control lever to ‘Float’ and the tilt control lever to
‘Dump’. DO NOT use this bucket position for ‘Dozing’
as excessive stress will be placed on the tilt hoists.

When attempting to use the loader lifting work by

welding a chain and hook to the bucket in the fully
dumped position. Lift objects only with the bucket
between the level and rolled back positions. Do not
attempt to lift weight in excess of the loaders capacity
by counter weighting thereby over-loading the unit.
42
Operation Section
Machine Parking

Machine Parking Stopping the Engine

Stopping the Machine NOTICE
Stopping the engine immediately after it has been
1. Reduce the engine speed slightly. working under load, can result in overheating and
accelerated wear of the engine components.

Refer to the following procedure, to allow the engine

to cool.

Note: Operate the engine for five minutes at low idle

with no load.

This allows hot areas in the engine to cool gradually.

This will extend the engine life.

lllustration 86

2. Apply the service brakes in order to stop the

machine.

3. Stop the machine on level ground, when

possible.

4. Move the transmission shift control to NEUTRAL.

lllustration 88

1. Pull-up the engine shut-off cable to stop position

in order to stop the engine.

Illustration 87

5. Engage the parking brake.

6. Lower all raised work tools to the ground and apply

slight downward pressure.

7. Move all hydraulic control levers into the HOLD

position.
 43
Operation Section
Machine Parking

Leaving the Machine

lllustration 89

1. Pull-up the engine shut-off cable to stop the

engine.

2. Move all hydraulic control levers back and forth in

order to relieve hydraulic pressure.

3. Move all hydraulic control levers into the HOLD

position.

4. Remove the engine start switch key.

This will prevent unauthorized persons from starting

the engine or from turning on the lights.

5. When you exit the machine, close the windows

and lock the cab doors, if equipped.

6. Use the steps and the handholds when you get

off the machine. Face the machine and use both
hands. Make sure that the steps are clear of debris
before you dismount.

7. Ensure that all lights are shut off.

44
Operation Section
Transportation Information
Transportation Information
Shipping the Machine
Before you load the machine, remove any slippery
material from the loading dock and from the truck bed.
Remove the slippery material in order to prevent the
slipping of the machine. This should also be done in
order to prevent a shift while the machine is moving
in transit.
NOTICE
Obey all state and local laws governing the weight,
width and length of a load.
Make sure the cooling system has proper antifreeze if
moving machine to a colder climate.
Observe all regulations governing wide loads.
lllustration 90
1. Chock the trailer wheels or the rail car wheels
before you load the machine.
2. After the machine is positioned, connected the
steering frame lock in order to hold the front frame
and the rear frame in place.
3. Lower the bucket or the work tool to the floor of
the transport vehicle.
4. Engage the parking brake.
5. Turn the engine start switch to the OFF position.
Remove the engine start switch key.
6. Move all of the control levers in order to relieve
any trapped pressure.
7. Turn the battery disconnect switch to the OFF
position. Remove the battery disconnect switch
key.
8. Lock the door and the access cover. Attach any
vandalism protection.
9. Secure the machine, any equipment, and any
tools with adequate tie-downs in order to prevent
movement during shipping.
10. Cover the exhaust opening. The turbocharger
(if equipped) should not rotate when the engine
is not operating. Damage to the turbocharger can
result.
Roading the Machine
Check with the proper officials in order to obtain the
required license and other similar items before roading
the machine.
Complete a through daily inspection before you mount
the machine and before you start the engine.
Reference: For more information, refer to Operation
and maintenance Manual, “Daily Inspection”
Carry the work tools as low to the ground as possible.
Disable the controls for the work tool when the machine
is roaded.
Inflate the tires to the correct pressure. Stand behind
the tire tread while you inflate the tires.
Reference: For more information, refer to the
Operation and Maintenance Manual, “Tire Inflation
information”.
Lifting and Tying Down the
Machine
Improper lifting and improper tie-downs can allow
the load to shift or fail and cause injury or damage.
Use only properly rated cables and slings with lift
and tie down points provided.
Follow the instructions in operation and
maintenance manual, “Lifting and Tying Down
the Machine” for the proper technique for securing
the machine. Refer Operation and Maintenance
Manual, “Specification and Model Views” for the
specific weight information..
 45
Operation Section
Transportation Information

NOTICE

Improper lifting and tie-downs can allow the load to shift

and cause injury or damage. Install the steering frame
lock link before lifting.

Use properly rated cables and properly rated slings to

lift the machine.

Position the crane or the lifting device in order to lift the

machine in a level position.

1. Engage the parking brake before you sling the

machine and before you secure the machine with
tie-downs.

2. Install the frame lock pin prior to lifting the

machine.

3. Attach two lifting cables to the rear of the machine.

There is one lifting eye on each side of the rear of
the machine.

4. Attach two lifting cables to the front of the machine.

There is one eye on each side of the front of the
machine. The lifting eyes are identified by a label
that shows a hook.

5. Connect the four lifting cables to the spreader

bars. The spreader bars must be centered over the
machine.

6. If equipped, secure any attachments.

7. Lift the machine. Move the machine to the desired

position.

8. When the machine is positioned, place the blocks

behind the tires.

9. Secure the machine at the tie-down positions.

Check all of the laws that govern the load characteristics

(height, weight, width, and length).

Reference: For shipping instructions, refer to Operation

and Maintenance Manual, “Shipping the Machine”.
46
Maintenance Section
Lubricant Viscosities and Refill Capacities

Maintenance Section
Lubricant Viscosities and
Refill Capacities

Lubricant Viscosities
Table 7

Lubricant Viscosities for Ambient Temperatures

°C °F
Oil Type and
Compartment or System Oil Viscosities
Classification
Min Max Min Max

Engine Crankcase K Oil Premium SAE 15W40 -15 50 5 122

Transmission Caterpillar TDTO SAE 30 0 50 32 122

Hydraulic & Steering EXXON MOBILE SPEC-

ISO VG 68 -20 40 -4 104
System ESSO NUTO H68

Differential and Final

Caterpillar GO (Gear Oil) SAE 90 -20 40 -4 104
Drives
 47
Maintenance Section
Lubricant Viscosities and Refill Capacities

Machine Fluid Recommendations

Factory Fill :

Table 8

LUBRICANT
COMPARTMENT OIL TYPE AMBIENT CHANGE
OIL CAPACITY
OR & TEMPERATURE(2) PERIOD
VISCOSITIES (LITERS)
SYSTEM CLASSIFICATION (HOURS)(1)
Min°C Max°C

First 50 &
Engine K Oil Premium SAE 15W40 -15 50 11.5
Every 500

Caterpillar
Transmission SAE 30 0 35 1000 35
TDTO

Hydraulic and EXXON MOBILE

ISO VG68 -20 40 1000 123
Steering System SPEC-ESSO NUTO H68

Differential and Caterpillar

SAE 90 -20 40 1000 28
Final Drives GO (Gear Oil)

Recommendations :
(1) The Oil Change Hours are given as a guidance for operating under normal conditions and may vary
depending upon site conditions.
(2) If the ambient temperatures are beyond the specified range, contact your CAT Dealers for additional
information on selecting oils.
48
Maintenance Section
Maintenance Interval Schedule

Maintenance Interval Schedule Steering Cylinder Pins - Lubricate ................... 55

Note: All safety information, warnings, and instructions
must be read and understood before you perform any
operation or any maintenance procedure.
Before each consecutive interval is performed, all of
the maintenance requirements from the previous
interval must also be performed.
When Required
Battery Electrolyte Level - Check ..................... 52
Battery or Battery Cable - Inspect/Replace ..... 52
Bucket Cutting Edges and Tooth -
Inspect/Replace ............................................... 53
Cab Interior - Clean .......................................... 54
Engine Air Filter ( Primary & Secondary) -
Clean/Replace ................................................. 49
Frame Support Structure and Lift Arm -
Inspect for Cracks ............................................ 51
Fuses - Replace ............................................... 63
Hydraulic System Oil Filter Screen - Clean ..... 65
Radiator Core - Clean ...................................... 68
Windows Wipers (Front & Rear) -
Inspect/Replace ............................................... 70
Every 10 Service Hours
Air Tank Water and Sediment - Drain .............. 67
Backup Alarm - Test ......................................... 54
Cooling System Coolant Level - Check ........... 54
Engine Air Cleaner - Inspect ........................... 51
Engine Oil Level - Check ................................. 61
Fuel Filter (Cum Water Separater) -
Water Drain ...................................................... 62
Fuel Level - Check ........................................... 63
Fuel Tank Water and Sediment - Drain ............ 63
Hydraulic System Oil Level - Check ................ 65
Loader Bucket, Cylinders, Linkage Pins -
Lubricate .......................................................... 57
Seat Belt - Inspect ............................................ 68
Tire Inflation - Check ........................................ 68
Transmission Oil Level - Check ....................... 67
Walk - Around Inspection ................................. 69
Windows - Clean .............................................. 70
Every 50 Service Hours
Support Pivot Pins - Lubricate ......................... 55
Every 100 Service Hours
Battery Electrolyte Level - Check/Refill ............ 52
Differential Oil Level (Front & Rear) - Check ... 59
Drive Line Universal Joints (Front & Rear) -
Lubricate .......................................................... 58
Drive Shaft spline (Front & Rear) - Lubricate ... 58
Final Drive Oil Level - Check ........................... 60
Every 200 Service Hours
Brake Cam Shafts - Lubricate .......................... 56
Brake Shoe Anchor Pins - Lubricate ................ 56
Belt - Inspect .................................................... 53
Slack Adjusters - Lubricate .............................. 56
Transmission Oil Filter - Change ..................... 66
Every 250 Service Hours
Breathers - Clean/Replace .............................. 55
Primary Fuel Filter Element - Replace ............. 62
Every 300 Service Hours
Hydraulic System Oil Filter - Change ............... 64
Hydraulic System Oil Filter Screen - Clean ..... 65
Every 500 Service Hours
Engine Air Filter (Primary Element) -
Clean/Replace ................................................. 49
Engine Oil and Filter - Change
(First 50 Hours & Every 500 Hours) ................. 61
Fuel Filter (Cum Water Separator) - Replace .. 62
Fuel Tank Filler Cap - Clean ............................ 62
Every 1000 Service Hours
Cooling System - Drain/Flush/Refill ................. 69
Differential Oil (Front & Rear) - Change ......... 59
Final Drive Oil - Change ................................... 60
Hydraulic System Oil - Change ........................ 64
Transmission Oil - Change .............................. 66

Axle Cradle Mounting Pins - Lubricate ............ 56

Engine Oil and Filter - Change
( First 50 Hours & Every 500 Hours) ................ 61
Hydraulic System Oil and Filter - Change
( First 50 Hours & Every 300 Hours) ................ 64
Hydraulic System Oil Filter Screen - Clean
( First 50 Hours & Every 300 Hours) ................ 65
 49
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace

Engine Air Filter (Primary Cleaning Primary Air Filter Elements

Element) - Clean / Replace
NOTICE
Never service the air cleaner when the engine is
running, to avoid engine damage.

lllustration 93

1. Remove the air cleaner housing cover (1).

2. Remove the primary filter element (2) from the

air cleaner housing.
lllustration 91

The air filter alert indicator is mounted on the air outlet

NOTICE
tube of the cleaner body. It shows at a glance, when
Do not clean the filter elements by bumping or tapping
the system airflow is being restricted, the red band them. Do not use filter elements with damaged pleats,
increases in the indicator. When the red band reaches gaskets or seals. Engine damage can result.
top of the indicator window. Service the air cleaner
filter and reset the indicator by pushing plunger to
3. Clean the primary filter element.
downward position. If it is not reset, need to service
the indicator or replace.

Service Pre Cleaner - Clean

lllustration 94

When you use pressure air, the maximum air

lllustration 92 pressure is 3.0 Kg/cm² (43 psi).

Remove the wing nut and lift off the top cover. Remove a. When you clean the inside pleats and the
the slotted plate. outside pleats, direct the air along the pleats.

Clean thoroughly the deflector base plate, bowl,

slotted plate and cover. After cleaning assemble the
service pre cleaner.
50
Maintenance Section
Engine Air Filter Secondary Element - Replace

b. Inspect the filter elements after you clean the
filter elements. Do not use a filter if the pleats,
the gaskets or the seals are damaged.
c. Cover the clean filter elements. Store the
elements in a clean, dry location.
Replace the primary element after two
cleaning interwals.
4. Install a clean filter element and install the cover.
Engine Air Filter Secondary
Element - Replace
NOTICE
Always replace the secondary filter element. Never
attempt to reuse it by cleaning.
The secondary filter element should be replaced at the
every change of the primary element.

5. Tighten the cover screws finger tight. Do not use

a tool to tighten the cover screws.

Inspecting the Primary Air Filter

Elements

lllustration 96

1. Remove the air cleaner housing cover (1).

2. Remove the primary filter element (2) from the air

cleaner housing.

Illustration 95

Inspect the clean, dry primary air filter element. Use a

bright light in a dark room or in a similar facility. Place
the light in the primary air filter element. Rotate the
primary air filter element. Inspect the primary air filter
element for tears and/or holes. Inspect the primary air
filter element for light that may show through the filter
material. If it is necessary in order to confirm the result,
compare the primary air filter element to a new primary
air filter element that has the same part number.
lllustration 97
Do not use a primary air filter element that has any
tears and/or holes in the filter material. Do not use 3. Remove the secondary filter element.
a primary air filter element with damaged pleats,
gaskets or seals. Discard damaged primary air filter 4. Cover the air inlet opening. Clean the inside of the
elements. air cleaner housing.

5. Inspect the gasket between the air inlet pipe and

the air cleaner housing. Replace the gasket if the
gasket is damaged.
 51
Maintenance Section
Engine Air Filter Secondary Element - Replace

Engine Air Cleaner - Inspect

` 2

` 1

lllustration 98

6. Uncover the air inlet opening. Install a new lllustration 100

secondary element.
Clean the dust cup (1) and check the pre cleaner (2)
7. Install the primary element and the air cleaner for dust collection.
housing cover. Fasten the clips in order to secure
the air cleaner housing cover.
Frame Support Structure and
Lift Arm - Inspect

Before doing any welding on the vehicle, disconnect

the battery cable to prevent damage of the battery
and electrical system.

Maintenance of the frame consists of periodic

inspection for cracks or breaks in the welds, and
fracture or bending of the frame structure. If any of the
Illustration 99 these faults are found it should be remedied at once.
8. Reset the filter element indicator. Check the lift arm and its components for cracks and
bends or any damages.
52
Maintenance Section
Battery Electrolyte Level - Check/Refill
Battery Electrolyte Level -
Check / Refill
lllustration 101
1. Open the battery access cover that is located on
the rear of the machine.
2. Clean the battery top surface with a clean cloth.
Keep the terminals clean and keep the terminals
coated with petroleum jelly.
3. Inspect the electrolyte level in each battery cell.
Maintain the electrolyte level to the bottom of the
filler opening. Use distilled water. If distilled water
is not available, use clean drinking water.
4. Close the battery access cover.
Battery or Battery Cable -
Inspect/Replace
1. Stop the engine using engine shut-off cable. Turn
all switches to the OFF position.
2. Disconnect the negative battery cable from the
frame.
Note: Do not allow the disconnected battery cable to
contact the frame of the machine.
3. Disconnect the negative battery cable at the
battery.
4. Perform the necessary repairs. Replace the cable
or the battery, as needed.
5. Connect the negative battery cable at the
battery.
6. Connect the battery cable to the frame of the
7. Install the engine start switch key.
Braking System - Test
Service Brake Holding Ability Test
Check the area around the machine. Make sure that the
machine is clear of personnel and clear of obstacles.
Test the brakes on a dry, level surface.
Fasten the seat belt before you test the brakes.
The following tests are used to determine if the service
brake is functional. These tests are not intended to
measure the maximum brake holding effort. The brake
holding effort that is required to sustain a machine at a
specific engine rpm varies depending on the machine.
The variations are the differences in the engine setting,
in the power train efficiency, and in the brake holding
ability, etc.
1. Start the engine. Raise the bucket slightly.
2. Apply the service brake. Release the parking
brake.
3. M o v e t h e t r a n s m i s s i o n c o n t r o l l e v e r t o
FORWARD.
4. Gradually increase the engine speed to high idle.
The machine should not move.
If the machine begins to move, reduce the engine
speed immediately and engage the parking
5. Reduce the engine speed to low idle. Move the
transmission to NEUTRAL. Engage the parking
brake. Lower the bucket to the ground. Stop the
engine.
Secondary Brake Holding Ability
Test
Check the area around the machine. Make sure that the
machine is clear of personnel and clear of obstacles.
Test the brakes on a dry, level surface.
Fasten the seat belt before you test the brakes.
The following tests are used to determine if the parking
brake is functional. These tests are not intended
to measure the maximum brake holding effort. The
 53
Maintenance Section
Bucket Cutting Edge and Tooth - Inspect/Replace

holding effort that is required to sustain a machine at a Bucket Cutting Edges and
specific engine rpm varies depending on the machine.
The variations are the differences in the engine setting, Tooth - Inspect / Replace
in the power train efficiency, and in the brake holding
ability, etc.

1. Start the engine. Raise the bucket slightly.

Personal injury or death can result from bucket
2. Engage the parking brake. falling.
3. M o v e t h e t r a n s m i s s i o n c o n t r o l l e v e r t o Block the bucket before changing bucket cutting
FORWARD. edges.
4. Gradually increase the engine speed to high idle.
The machine should not move.

If the machine begins to move, reduce the engine

speed immediately and engage the service

5. Reduce the engine speed to low idle. Move the

transmission to NEUTRAL. Lower the bucket to
the ground. Stop the engine.

Fan Belt - Inspect

lllustration 103

1. Check the area around the machine. Make sure

that the machine is clear of personnel and clear
of obstacles.

2. Test the brakes on a dry, level surface.

3. Raise the bucket. Place a block under the

bucket.

4. Lower the bucket to the blocking.

Do not block up the bucket too high. Block up the

lllustration 102
Stop the engine. Open the engine access door. The
single V-belt is located at the front of the engine.
Inspect the condition of the V-belt. If the V-belt is
cracked or frayed, replace the V-belt.
Check by pressing midway between the pulleys to
see whether the belt deflects by not more than 10 to
15 mm.
If necessary re-tension V-belt by loosening and re-
tightening the battery charging alternator.
bucket so that the bucket is high enough to remove
the cutting edges and the end bits.
5. Clean the contact surfaces.
6. The bucket being of welded construction, it cannot
be disassembled. Inspect cutting edge and tooth
for cracks and wear found. If necessary, It can be
repaired.
7. Raise the bucket. Remove the blocks.
8. Lower the bucket to the ground.
54
Maintenance Section
Cooling System Level - Check

Cooling System Coolant Cab Interior - Clean

Level - Check 1. Use high pressure air in order to clean the entire
cab and the main electrical box.

2. Wash off any remaining dirt and debris. Use

Pressurized system: Hot coolant can cause serious
burn. To open cap, stop engine, wait until radiator
is cool. Then loosen cap slowly to relieve
the pressure.
caution and minimize the water around electrical
connections and the cab roof.
3. Scrub the floor mat, the instrument panel, the
windows, and the mirrors. Wipe the cab dry.

Tire Inflation Pressure

The recommended tire inflation pressures that are
shown in the following table. The tire depends on the
correct inflation pressure.
Table 9

FRONT TIRE SHIPPING PRESSURE

Size Ply Rating Shipping

lllustration 104
14.00 X 25 20 345 Kpa (50 psi)
1. The radiator cap is located on the top of the
radiator on the rear side of the machine. Remove
the radiator cap slowly in order to relieve system Table 10
pressure.
REAR TIRE SHIPPING PRESSURE
2. Maintain the coolant level. If you need to add
coolant daily, check the cooling system for leaks. Size Ply Rating Shipping

14.00 X 25 20 276 Kpa (40 psi)

Backup Alarm - Test

Turn the engine start switch key to ON in order to
perform the test.

Apply the service brake. Move the transmission

direction control lever to REVERSE position.

The backup alarm should immediately sound.

lllustration 105 The backup alarm will continue to sound until the
transmission direction control lever is moved to the
3. Inspect the radiator cap. Replace the radiator cap NEUTRAL position or to the FORWARD position.
if the radiator cap is damaged.

4. Install the radiator cap. Close the access panel.

 55
Maintenance Section
Breathers - Clean/Replace

Differential Breathers - Steering Cylinder Pins -

Clean / Replace Lubricate

lllustration 106
1. Clean the area around the breather. Remove the
breather from the rear axle .
2. Wash the breather in clean nonflammable solvent.
Wipe the breather dry and check the breather for
any damage.
3. Install the clean breather back into the axle.
lllustration 108
Apply the lubricant to the grease fittings for the steering
cylinder both rod and base end mounting pins. Repeat
for other steering cylinder mountings pins.
Support Pivot Pins - Lubricate
1

`
Replace the breather if damaged/necessary.

Transmission Breather -
Clean / Replace `

lllustration 109

Apply the lubricant to the grease fitting (1) for the top
support pin.

Apply the lubricant to the grease fitting (2) for the top
support pin.

lllustration 107

Clean the area around the breather. Remove the

transmission breather from the top of the transmission
case.

Clean the breather in clean nonflammable solvent and

allow the breather to dry. Replace the breather.
56
Maintenance Section
Axle Cradle Mounting Pins - Lubricate

Axle Cradle Mounting Pins - Brake Cam Shafts - Lubricate

Lubricate

lllustration 110 Illustration 112

Apply the lubricant to the grease fittings for the rear Apply lubricant to the grease fittings for the brake cam
axle oscillation cradle mounting pins. shafts.

Slack Adjusters - Lubricate Brake Shoe Anchor Pins -

Lubricate

Illustration 111

Apply lubricant to the grease fittings for the slack Illustration 113
adjusters.
Apply lubricant to the grease fittings for the brake shoe
anchor pins.
 57
Maintenance Section
Loader Bucket, Cylinders and Linkage Pins - Lubricate

Loader Bucket, Cylinders and

Linkage Pins - Lubricate
5
7

6
1

Illustration 116

Apply the lubricant grease fittings (5) for the rod end
of the lift cylinder. There is a grease fittings for each
Illustration 114 side of the machine.

Apply lubricant to the grease fitting (1) for the bucket
mounting upper pivot pin.
Apply the lubricant grease fittings (2) for the lower
pivot pins. There is a grease fittings for each side of
the machine.
3
Apply the lubricant grease fittings (6) for the base end
of the lift cylinder. There is a grease fittings for each
side of the machine.
Apply the lubricant grease fittings (7) for the lift arm
mounting pin. There is a grease fittings for each side
of the machine.

Illustration 115 Illustration 117

Apply lubricant to the grease fittings (3) & (4) for the Apply the lubricant grease fittings (8) for the base end
dump lever mounting pins. of the tilt cylinder.
58
Maintenance Section
Drive Shafts Spline (Front & Rear) - Lubricate

Illustration 118 lllustration 121

Apply the lubricant grease fittings (9) for the rod end
Apply lubricant to the grease fitting for the drive
of the tilt cylinder.
shaft spline of the front and reardrive shafts.

Drive Shaft Spline Drive Line Universal Joints

(Front & Rear) - Lubricate (Front & Rear) - Lubricate

lllustration 119
lllustration 122

Access the grease fittings for the drive shaft spline

from the bottom of the machine.

lllustration 123

lllustration 120
Apply lubricant to the grease fitting for the front
and rear drive shafts Universal Joints (Both ends).
 59
Maintenance Section
Differential Oil (Front & Rear) - Change

Differential Oil (Front & Rear) - Differential Oil Level

Change (Front & Rear ) - Check

lllustration 124 lllustration 126

1. Remove the oil drain plug and drain the oil into a
1. Remove the oil plug in order to check the oil.
suitable container.
2. The oil level should be at the bottom of the plug
2. The plug is magnetic. Check the plug for metal.
threads.
Clean the drain plug and install the drain plug.
3. Clean the oil plug and install the oil plug.

lllustration 125

3. Remove the oil level/fill plug. Refer to Operation and

Maintenance Manual, “Lubricant Specifications”
and Operation and Maintenance Manual, “Refill
Capacities” for oil.

4. Add oil until the oil is level with the threads for the
filler plug.

Note: Allow time for the oil to flow through the axle
housing

5. Clean the filler plug and install the filler plug.

60
Maintenance Section
Final Drive Oil - Change & Check

Final Drive Oil - Change Final Drive Oil Level- Check

lllustration 127 lllustration 129

1. Position the oil fill/drain plug at the bottom. Remove 1. Position the plug hole. Use the oil level mark on
the oil fill/drain plug and drain the oil into a suitable the drive axle assembly as a reference.
container.
2. Remove the plug in order to check the oil level.

3. The oil should be level with the bottom of the plug

threads.

4. Clean the plug and install the plug.

5. Repeat the procedure for the other final drives.

lllustration 128

2. Position the plug hole. Use the oil level mark on

the drive axle assembly as a reference.

3. Add oil to the bottom of the filler plug.

4. Clean the plug and install the plug.

5. Repeat the procedure for the other final drives.

 61
Maintenance Section
Engine Oil level - Check

Engine Oil Level - Check Engine Oil and Filter - Change

Run the engine until it gets warm. Stop the engine and
NOTICE remove the battery connections.
Do not overfill the crankcase. Engine damage can
result. 1. Place the oil tray under the engine.

2. Unscrew oil drain plug on the end of drain pipe &

drain oil completely. Wait until last drop of oil.

lllustration 130

1. Open the engine access door on the right side of

the machine.
lllustration 132

3. Collect used oil in suitable receptacle ready

for proper disposal to prevent environmental
prevention.

4. Refit oil drain plug with new joint washer and

tighten firmly.

5. Fill in fresh lube oil and do not flush the lube system
with diesel or kerosene. Refer to Operation and
Maintenance Manual, “Refill Capacities”.

6. Replace “Spin-on” lube oil filter cartridge for every

oil change.
lllustration 131
7. Release lube oil filter cartridge with special tool
2. While the engine is stopped, maintain the oil level
and spin off.
between the “LOW” mark and the “MAX” mark on
the engine oil dipstick. 8. Clean sealing surface of filter carrier. Fit the filter
cartridge in dry condition. Do not fill oil in the filter
3. If necessary, add oil.
before assembly.
4. Close the access door.
9. Apply light film of oil to rubber seal of new cartridge.
Screw the cartridge into place by hand until seal
is evenly seated.

10. Tighten lube oil filter cartridge firmly by giving a

final half turn.

11. Check oil level and lube oil pressure. Check seal
of lube oil filter cartridge for leaks.
62
Maintenance Section
Fuel Filter - Replace

Fuel Filter (Cum Wtare Primary Fuel Filter Element -

Separater) - Replace Replace

lllustration 133
1. Keep the machine ready to perform the work.
2. Clean the filter assembly externally.
lllustration 134
1. Loosen the centre bolt and remove the bowls
and discard the elements.
2. Clean the filter bowl with cleaning cloth.

3. Remove the cartridge by rotating in anticlockwise
by hand.
4. Collect driping fuel in a tray.
5. Destroy the removed cartridge.
6. Clean the sealing surface of filter.
7. Apply light film of oil or diesel fuel to the rubber
gasket of the new fuel filter cartridge.
3. Install the new filter elements. Ensure that the
rubber gasket between the filter bowls and filter
head is in good condition.
4. Assemble the filters in the reverse order of
dismantling.
5. Tighten the centre bolts.
6. Prime the fuel system in order to fill the filter
elements with fuel.

8. Screw in the new cartridge finger tight against the Fuel Tank Filler Cap - Clean
gasket.

9. Tighten the fuel filter cartridge with a final half turn

using commercial tool. Open fuel stopcock and
check for leaks.

Note : Drain the water droplets daily or twice a day

(depends on hours of operation) from main fuel filter
cum water separator.

lllustration 135

Clean the filler cap in solvent and fix it. Clean the filler
neck screen.
 63
Maintenance Section
Fuel Tank Water and Sediment - Drain

Fuel Tank Water and Sediment Fuel Level - Check

- Drain

lllustration 138
lllustration 136
Check fuel level, remove the fuel tank dipstick, wipe it
1. Fuel tank is located on the rear side of the clean and reinsert. Remove it and observe the
machine near fan guard. indicated fuel level. If necessary add fuel.

2. Slowly remove the fuel tank cap (1) in order to

relieve pressure. Fuses - Replace
3. Clean the filler cap (1) and filler neck screen.
NOTICE
Replace the fuses with the same type and size only.
Otherwise, electrical damage can result.

If it is necessary to replace fuses frequently, an

electrical problem may exist. Contact your Caterpillar
dealer

lllustration 137

4. The fuel tank drain valve (2) is located on the

bottom of the fuel tank. Remove the fuel tank drain
plug. Allow the water and sediment to drain into a
suitable container. Install the fuel tank drain plug.
If necessary replace the drain plug.
lllustration 139

Fuses – Fuses protect the electrical system from

damage that is caused by overloaded circuits.
Replace the fuse if the element separates. If the
element of a new fuse separates, check the circuit.
Repair the circuit, if necessary.
64
Maintenance Section
Hydraulic system Oil - Change
Hydraulic System Oil - Change
`
2
1
`
lllustration 140
Operate the machine for a few minutes in order to warm
the hydraulic system oil.
The machine should be level. Lower the bucket to the
ground and apply slight downward pressure. Engage
the parking brake and stop the engine.
1. The hydraulic tank is located left side of the
machine. Open the hydraulic vent cock (1) to
release any pressure in the tank. Open hydraulic
tank filler cap (2).
2. The Hydraulic Tank drain plug (3) is located on the
bottom of the hydraulic tank. Remove the drain
plug (3) to drain the hydraulic oil into suitable
container. Install the hydraulic tank drain plug.
3. Fill the hydraulic system oil tank. Refer to Operation
and Maintenance Manual, “Lubricant Viscosities
and Refill Capacities” .
4. Maintain the oil level into bottom of the hydraulic
tank fill tube.
5. Inspect the gasket on the hydraulic tank filler cap
for damage. Replace the gasket, if necessary.
6. Install the hydraulic tank filler cap (2).
7. Close the hydraulic tank vent cock (1).
Hydraulic System Oil Filter -
Replace
`
1
5 4
2 3
lllustration 141
The oil filter element should be replaced periodically.
Refer Operation and Maintenance Manual “Maintenance
Interval Schedule”.
1. Lower the bucket completely to the ground.
2. Engage the parking brake and shut off the
engine.
3. Open the hydraulic tank vent cock (1) to release
any pressure in this tank.
4. Remove bolts (2), washers (3), cover (4) and
gasket (5).
5. Remove three wing nuts and valve assembly.
Note: Do not disassemble the valve assembly unless
it is damaged or not working.
6. Remove the filter element and inner gasket.
7. Install the new inner gasket and new filter
element.
8. Install valve assembly. Secure with wing nuts.
9. Install new cover gasket (5), cover (4), washers
and bolts (3) & (4).
10. If required fill the oil to the tank in proper level.
Close the hydraulic tank vent cock (1).

Hydraulic System Oil Filter
Screen - Clean
` 1
5 4
2 3
lllustration 142
The oil tank filter screen should be removed and
cleaned periodically. Refer Operation and Maintenance
Manual “Maintenance Interval Schedule”.
1. Lower the bucket completely to the ground.
2. Engage the parking brake and shut off the
engine.
3. Open the hydraulic tank vent cock (1) to release
any pressure in this tank.
4. Remove bolts (2), washers (3), cover (4) and
gasket (5).
5. Remove retainer and filter screen. Clean the
screen and install in to the hydraulic oil tank.
Secure the screen with retainer.
6. Install new cover gasket (5), cover (4), washers
and bolts (3) & (4).
7. If required fill the oil to the tank in proper level.
Close the hydraulic tank vent cock (1).
65
Maintenance Section
Hydraulic System Oil Filter Screen - Clean
Hydraulic System Oil Level -
Check
`
2
1
lllustration 143
Oil check needs to be done every day before starting
the machine.
Before checking the hydraulic oil level. Operate the
hydraulic system lift and tilt levers several times to
warm the oil and make sure that all the hydraulic lines
and components are fully charged. Lower the bucket
completely to the ground.
Engage the parking brake and have the engine idling.
The machine should be on fairly level ground.
Open the hydraulic tank vent cock (1) to release any
pressure in this tank. Open the hydraulic tank cap
(2) and Check the oil level. Add oil, if necessary to
the bottom of the tank fill neck. Replace the cap (2)
securely and close the vent cock (1).
66
Maintenance Section
Transmission Oil and Filter - Change
Transmission Oil and Filter -
Change
lllustration 144
The transmission should be at operating temperature
when the oil is drained.
1. Remove the drain plug from the transmission
housing and drain the oil with suitable container.
2. While the oil is draining, check for evidence of
contamination. Any accumulation of sludge or soft
dirt in the sump should be removed with flushing
oil.
lllustration 145
3. Remove the oil filter element from the remote-
mounted filter.
lllustration 146
4. Remove the oil strainer cover and strainer from
the transmission housing.
5. Clean the oil strainer by agitating it in mineral sprits
or solvent. Flush all residue and foreign particles
from the screen mesh. Dry the strainer with
compressed air – do not use linty shop towels.
6. Should it become necessary to use a different
transmission fluid, thoroughly flush the system
with the fluid to be used before refilling.
7. Install the drain plug, and tighten it sufficiently to
prevent leakage. Install a new filter element and
gasket in to the remote-mounted filter.
8. Install the oil strainer and gasket, slip the open
end of the strainer onto the suction tube with in
the housing, then rotate the strainer cover as
necessary to locate the strainer at its lowest point.
Install the six bolts.
9. Refill the transmission oil to the system. Refer
Operation and Manitenance Manual “ Lubricant
Viscosities and Refill Capacities”.
 67
Maintenance Section
Transmission Oil Level - Check

Transmission Oil Level - Air Tank Water and Sediment

Check - Drain

lllustration 147
lllustration 148

Keep the machine on level ground and open the Full

plug (1) (upper). If oil flows from the plug opening, the
transmission has sufficient oil to permit safe starting
of the engine. If no oil flow is present, add sufficient oil
to cause a flow from the opening, and close and tight
the plug securely.

Shift the range selector to neutral, and start the engine

accelerate to 1000 to 1500 rpm. Operate at this rpm
for approximately one minute to charge the hydraulic
system, then check for flow from Add plug (2) (lower).
Make sure to hold the rpm during this check. If the
check is made at a lower rpm, it may result in a low oil
level during normal operation.
lllustration 149
Add oil, if necessary to bring the level to Add plug (2)
(lower). Note that the Add plug level is used for the This maintenance should be performed daily
cold check. When the transmission reaches operating (or as necessary) to drain the water and sediment.
temperature, thermal expansion will raise the oil level
to the Full plug. Air tank is located on the left side of the machine. Drain
cocks is located side and bottom of the air tank.

Open the drain cocks to drain the water and

68
Maintenance Section
Radiator Core - Clean

Radiator Core - Clean Tire Inflation - Check

lllustration 150 lllustration 152

Measure the tire pressure on each tire. Consult

your dealer for the correct load rating and for
the correct operating pressures.

Inflate the tires, if necessary. Refer to Operation and

Maintenance Manual, “Tire Inflation Pressure”.

Seat Belt - Inspect

lllustration 151

NOTICE
Do not spray high pressure water into the radiator while
the engine is running.

You can use compressed air, high pressure water,

or steam to remove dust and other debris from the
radiator fins. However, the use of compressed air is
preferred. lllustration 153

Inspect the seat belt for webbing that is worn or

frayed. Replace the seat belt if the seat belt is worn
or frayed.

Check the buckle for wear or for damage. If the buckle

is worn or damaged, replace the seat belt and/or the
buckle.

Check the seat belt mounting hardware for wear or for

damage. If the seat belt mounting hardware is worn or
 69
Maintenance Section
Walk - Around Inspection

Walk - Around Inspection
NOTICE
Accumulated grease and oil on a machine is a fire
hazard. Remove this debris with steam cleaning or high
pressure water, at least every 1000 hours or each time
any significant quantity of oil is spilled on a machine.
Note: Inspect the machine for leaks. If leaks are
observed, find the source of the leak and correct the
leak. If leaks are suspected, check the fluid levels more
frequently than the recommended intervals. If leaks
are observed, check the fluid levels more frequently
than the recommended intervals.
Inspect the tires (8) for damage and for proper inflation.
Replace any missing valve caps. Tighten any loose
bolts.
Inspect the axles (9) for leaks. Inspect the front and
rear differential for leaks.
Inspect the engine air cleaner (10) for dirt buildup.
Remove the dirt from the engine air cleaner. Service
the air filter elements when enters the red zone on the
filter service indicator.
Inspect the steps and handholds (11). These objects
must be clean. Also, these objects must be in good
condition. Inspect the cab mountings for damage.
Notify your dealer for repairs, if necessary. Tighten any
loose bolts on mountings.

Make sure that the access covers and the guards are
10
5 7 secured. Inspect the access covers for damage and
12 the guards for damage.
2 Inspect the lights (12) for broken bulbs and for broken
1
lenses. Replace the bulbs or lenses, if necessary.
6
Inspect the operator’s compartment for cleanliness.
Keep the operator’s compartment clean.
` `
`
`

4
`

9 9
8 11 3 8
Cooling System - Drain/Flush/
lllustration 154
Refill
Inspect the bucket (1) for damage or for excessive
wear. Inspect the linkage (2) for damage or for
excessive wear. Repair the bucket or the linkage, if
necessary. Replace any bucket teeth, if necessary.

Inspect the transmission (3) for leaks. Correct any

leaks. Check the hoses around the transmission.

Inspect the hydraulic system for leaks. Inspect the

hydraulic tank (4), cylinder rod seals, hoses and tubes.
Also inspect plugs, couplings and fittings. Correct any
leaks.

Inspect the engine compartment (5) for trash buildup.

Remove any trash buildup that is in the engine
compartment. Clean the screens on the engine access
lllustration 155
doors.
Cooling system drain plug is located on the bottom
Inspect the belts for the engine attachments (6) for right side of the radiator. Drain, flush and refill the
worn belts, for cracked edges or for frayed edges. radiator.
Replace any damaged belts.

Inspect the cooling system for leaks, for faulty hoses,

and for trash buildup. Correct any leaks and remove
any trash buildup from the radiator (7).
70
Maintenance Section
Windows Wipers Front and Rear - Inspect/Replace

Window Wipers (Front & Rear)

- Inspect / Replace

lllustration 156

Inspect the condition of the wiper blades. Replace the

wiper blades if the wiper blades are worn or damaged
or if streaking occurs.

Windows - Clean
Use commercially available window cleaning solutions
in order to clean the windows. Clean the outside of
the windows from the ground, unless handholds are
available.

Illustration 157

Use a pole with a squeegee in order to reach the high

areas of the window.

Index
A D
Accelerator Control ........................................... 28
After Starting Inspection ................................... 22
Hydraulic Oil Level Check
(Hot Check) .................................................. 23
Transmission Oil Level Check
(Hot Check) .................................................. 22
Air Tank Water and Sediment - Drain ............... 67
Axle Cradle Mounting Pins - Lubricate ............. 56
B Electrical Storm Injury Prevention .................... 12
Backup Alarm ................................................... 27
Backup Alarm - Test.......................................... 54
Battery Electrolyte Level - Check/Refill ............ 52
Battery or Battery Cable - Inspect/Replace ...... 52
Before Operation .............................................. 13
Before Starting Engine ..................................... 13
Before Starting Inspection ................................ 20
Air Cleaner.................................................... 21
Air Tank ......................................................... 22
Coolant Level Check .................................... 20
Daily Inspection ............................................ 20
Engine Oil Level Check ................................ 20
Fuel Level Check .......................................... 21
Hydraulic Oil Level Check (Cold Check) ...... 21
Tires .............................................................. 22
Transmission Oil Level Check (Cold Check) 21
Visual Inspection........................................... 22
Brake Cam Shafts - Lubricate .......................... 56
Brake Shoe Anchor Pins - Lubricate................. 56
Brakes .............................................................. 37
Braking System - Test....................................... 52
Service Brake Holding Ability Test ................ 52
Secondary Brake Holding Ability Test ........... 52
Bucket Cutting Edges and Tooth -
Inspect/Replace ................................................ 53
Bucket Hydraulic System.................................. 18
Burn Prevention ................................................ 10
Batteries ....................................................... 10
Coolant ........................................................ 10
Oils ............................................................... 10
C Warning .......................................................... 4
Cab Interior - Clean .......................................... 54
Changing Direction and Speed......................... 31
Cold Weather Starting Aids .............................. 33
Cooling System - Drain/Flush/Refill .................. 69
Cooling System Coolant Level - Check ............ 54
71
Index Section
Crushing Prevention and Cutting Prevention ..... 9
Differential Breathers - Clean/Replace ............. 55
Differential Oil (Front & Rear) - Change .......... 59
Differential Oil Level (Front & Rear) - Check ... 59
Drive Shaft Spline (Front & Rear) -
Lubricate ........................................................... 58
Drive Line Universal Joints ( Front & Rear) ...... 58
E
Emergency Brake ............................................. 37
Emergency Brake Control valve (Push-Pull) .... 29
Engine Air Cleaner - Inspect ............................. 51
Engine Air Filter Primary Element -
Clean/Replace .................................................. 49
Engine Air Filter Secondary Element -
Replace ............................................................ 50
Engine Normal Starting .................................... 33
Engine Oil and Filter - Change ......................... 61
Engine Oil Level - Check .................................. 61
Engine Operation.............................................. 33
Engine Cool and Hot .................................... 34
Engine Proper Operation .............................. 34
Engine Stopping ........................................... 35
Engine Warm-up ........................................... 33
Engine Shut Off Control.................................... 29
Engine Start Switch .......................................... 24
Engine Starting ................................................. 13
F
Fan Belt - Inspect ............................................. 53
Final Drive Oil - Change ................................... 60
Final Drive Oil Level - Check ............................ 60
Fire Prevention and Explosion Prevention ....... 10
Lines, Tubes and Hoses ............................... 11
Foreword ............................................................ 4
Literature Information ..................................... 4
Maintenance ................................................... 4
Maintenance Intervals .................................... 4
Operation ........................................................ 4
Safety ............................................................. 4
Frame Support Structure and Lift Arm -
Inspect .............................................................. 51
Front and Rear Wipers (If Equipped)................ 26
Fuel Filter - (Cum Water Separator) Replace .. 62
Fuel Level - Check............................................ 63
72
Index Section
Fuel Tank Filler Cap - Clean ............................. 62
Fuel Tank Water and Sediment - Drain............. 63
Fuses - Replace ............................................... 63
G Stopping the Machine ................................... 42
Gauges ............................................................. 24
General Hazard Information ............................... 8
Dispose of Waste Properly ............................. 9
Fluid Penetration ............................................ 9
Pressure Air and water ................................... 8
H
Hazard Flasher Control .................................... 26
Horn .................................................................. 26
Hydraulic Cycle Time ........................................ 18
Hydraulic System Controls ............................... 37
Hydraulic System Oil - Change ........................ 64
Hydraulic System Oil Filter - Replace ............... 64
Hydraulic System Oil Filter Screen - Clean ...... 65
Hydraulic System Oil Level - Check ................. 65
L Parking the Loader ........................................... 38
Leaving the Machine ........................................ 43
Light Switches .................................................. 25
Loader Bucket Lift Control ................................ 30
Loader Bucket Tilt Control ................................ 30
Loader Bucket. Cylinders and Linkage Pins -
Lubricate ........................................................... 57
Loader Operation.............................................. 33
Loader Working ................................................ 39
Standard Bucket Functions .......................... 39
Carrying .................................................... 39
Digging...................................................... 40
Dumping ................................................... 40
Lubricant Viscosities and Refill Capacities ....... 46
M Machine Before Service.............................. 6
Machine Control ............................................... 27
Machine Fluid Recommendations .................... 47
Machine General Information ........................... 15
Brakes .......................................................... 16
Drive Axles .................................................... 16
Engine .......................................................... 15
Electrical System .......................................... 16
Filters ............................................................ 16
Steering ........................................................ 16
Steering Hydraulic System ........................... 16
Tires .............................................................. 16
Transmission ................................................ 15
Machine Operation ........................................... 31
Machine Operation Information ........................ 31
Machine Parking ............................................... 42
Stopping the Engine ..................................... 42
Maintenance Interval Schedule ........................ 48
Maintenance Section ........................................ 46
Model View Illustrations .................................... 15
Mounting and Dismounting ............................... 12
Moving Disabled Loader ................................... 38
O
Operating Data for Various Bucket ................... 17
Operating Techniques....................................... 33
Operation .......................................................... 13
Operation Section ............................................. 20
P
Parking ............................................................. 14
Parking Brake ................................................... 32
Parking Brake Control ...................................... 27
Primary Fuel Filter Element - Replace.............. 62
Product Identification Information ..................... 19
Plate Locations and Film Locations.............. 19
Product Information Section ............................. 15
R
Radiator Core - Clean....................................... 68
S
Safety Section .................................................... 5
Safety Signs and Labels................................. 5
Air System .................................................. 6
Brakes......................................................... 5
Machine Parking ......................................... 6
Steering Frame Lock .................................. 5
Seat Belt ........................................................... 27
Seat Belt - Inspect ............................................ 68
Service Brake Control....................................... 28
Shipping Information......................................... 18
Slack Adjusters - Lubricate ............................... 56
Specifications and Model Views ....................... 15
Standard Bucket Operating Hints ..................... 41
Steering Control................................................ 29
Steering Cylinder Pins - Lubricate .................... 55
Steering Frame Lock ........................................ 23
Support Pivot Pins - Lubricate .......................... 55
 73
Index Section

T
Tire Inflation - Check ........................................ 68
Tire Inflation Pressure ...................................... 54
Tire Information ................................................ 12
Transmission Breather - Clean/Replace ........... 55
Transmission Declutch Valve............................ 29
Transmission Direction Control ........................ 28
Transmission Oil and Filter - Change ............... 66
Transmission Oil Level - Check ........................ 67
Transmission Operation ................................... 36
Transmission Shifting Precautions ................... 36
Transportation Information ............................... 44
Lifting and Tying down the Machine ............. 44
Roading the Machine.................................... 44
Shipping The machine .................................. 44

W
Walk - Around Inspection .................................. 69
Windows - Clean .............................................. 70
Windows Wipers (Front and Rear) -
Inspect/Replace ................................................ 70
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