Case 580N User manual

Printedin U.S.A.
© 2015 CNH Industrial America LLC. All Rights Reserved.
Case is a trademark registered in the United States and many
other countries, owned by or licensed to CNH Industrial N.V.,
its subsidiaries or affiliates.
Part number 47860801
English
March 2015
SERVICE MANUAL
580N
580SN WT
580SN
590SN
Tier 3
Tractor Loader Backhoe

SERVICEMANUAL
580NFour-WheelDrive(4WD)TIER3,580NTwo-WheelDrive(2WD)TIER3,
580NTwo-WheelDrive(2WD)TIER3,580SNFour-WheelDrive(4WD)TIER
3,580SNFour-WheelDrive(4WD)TIER3,580SNTwo-WheelDrive(2WD)
TIER3,580SNTwo-WheelDrive(2WD)TIER3,580SNWTFour-WheelDrive
(4WD)TIER3,590SNFour-WheelDrive(4WD)TIER3,590SNTwo-Wheel
Drive(2WD)TIER3
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LinkProduct/Engine
ProductMarketProductEngine
580NTwo-WheelDrive(2WD)
TIER3
MiddleEastAfricaF4GE9454K*J603
580NTwo-WheelDrive(2WD)
TIER3
NorthAmericaF4GE9454K*J603
580NTwo-WheelDrive(2WD)
TIER3
LatinAmericaF4GE9454K*J603
580NTwo-WheelDrive(2WD)
TIER3
AustraliaNewZealandF4GE9454K*J603
580NTwo-WheelDrive(2WD)
TIER3
AsiaPacicF4GE9454K*J603
580NTwo-WheelDrive(2WD)
TIER3
AsiaPacicF4GE9454K*J603
580NTwo-WheelDrive(2WD)
TIER3
NorthAmericaF4GE9454K*J603
580NTwo-WheelDrive(2WD)
TIER3
AustraliaNewZealandF4GE9454K*J603
580NTwo-WheelDrive(2WD)
TIER3
MiddleEastAfricaF4GE9454K*J603
580NTwo-WheelDrive(2WD)
TIER3
LatinAmericaF4GE9454K*J603
580NFour-WheelDrive(4WD)
TIER3
MiddleEastAfricaF4GE9454K*J603
580NFour-WheelDrive(4WD)
TIER3
NorthAmericaF4GE9454K*J603
580NFour-WheelDrive(4WD)
TIER3
AsiaPacicF4GE9454K*J603
580NFour-WheelDrive(4WD)
TIER3
LatinAmericaF4GE9454K*J603
580NFour-WheelDrive(4WD)
TIER3
AustraliaNewZealandF4GE9454K*J603
580SNTwo-WheelDrive(2WD)
TIER3
AustraliaNewZealandF4HE0484G*J108
580SNTwo-WheelDrive(2WD)
TIER3
AsiaPacicF4HE0484G*J108
580SNTwo-WheelDrive(2WD)
TIER3
NorthAmericaF4HE0484G*J108
580SNTwo-WheelDrive(2WD)
TIER3
MiddleEastAfricaF4HE0484G*J108
580SNTwo-WheelDrive(2WD)
TIER3
LatinAmericaF4HE0484G*J108
580SNTwo-WheelDrive(2WD)
TIER3
NorthAmericaF4HE0484G*J108
580SNTwo-WheelDrive(2WD)
TIER3
AustraliaNewZealandF4HE0484G*J108
580SNTwo-WheelDrive(2WD)
TIER3
AsiaPacicF4HE0484G*J108
580SNTwo-WheelDrive(2WD)
TIER3
MiddleEastAfricaF4HE0484G*J108
580SNTwo-WheelDrive(2WD)
TIER3
LatinAmericaF4HE0484G*J108
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ProductMarketProductEngine
580SNFour-WheelDrive(4WD)
TIER3
MiddleEastAfricaF4HE0484G*J108
580SNFour-WheelDrive(4WD)
TIER3
NorthAmericaF4HE0484G*J108
580SNFour-WheelDrive(4WD)
TIER3
AsiaPacicF4HE0484G*J108
580SNFour-WheelDrive(4WD)
TIER3
LatinAmericaF4HE0484G*J108
580SNFour-WheelDrive(4WD)
TIER3
AustraliaNewZealandF4HE0484G*J108
580SNFour-WheelDrive(4WD)
TIER3
AsiaPacicF4HE0484G*J108
580SNFour-WheelDrive(4WD)
TIER3
MiddleEastAfricaF4HE0484G*J108
580SNFour-WheelDrive(4WD)
TIER3
NorthAmericaF4HE0484G*J108
580SNFour-WheelDrive(4WD)
TIER3
AustraliaNewZealandF4HE0484G*J108
580SNFour-WheelDrive(4WD)
TIER3
LatinAmericaF4HE0484G*J108
580SNWTFour-WheelDrive
(4WD)TIER3
NorthAmericaF4HE0484G*J108
580SNWTFour-WheelDrive
(4WD)TIER3
LatinAmericaF4HE0484G*J108
580SNWTFour-WheelDrive
(4WD)TIER3
AsiaPacicF4HE0484G*J108
580SNWTFour-WheelDrive
(4WD)TIER3
AustraliaNewZealandF4HE0484G*J108
580SNWTFour-WheelDrive
(4WD)TIER3
MiddleEastAfricaF4HE0484G*J108
590SNTwo-WheelDrive(2WD)
TIER3
LatinAmericaF4HE9484C*J106
590SNTwo-WheelDrive(2WD)
TIER3
NorthAmericaF4HE9484C*J106
590SNTwo-WheelDrive(2WD)
TIER3
AsiaPacicF4HE9484C*J106
590SNTwo-WheelDrive(2WD)
TIER3
AustraliaNewZealandF4HE9484C*J106
590SNTwo-WheelDrive(2WD)
TIER3
MiddleEastAfricaF4HE9484C*J106
590SNFour-WheelDrive(4WD)
TIER3
NorthAmericaF4HE9484C*J106
590SNFour-WheelDrive(4WD)
TIER3
LatinAmericaF4HE9484C*J106
590SNFour-WheelDrive(4WD)
TIER3
AustraliaNewZealandF4HE9484C*J106
590SNFour-WheelDrive(4WD)
TIER3
MiddleEastAfricaF4HE9484C*J106
590SNFour-WheelDrive(4WD)
TIER3
AsiaPacicF4HE9484C*J106
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Contents
INTRODUCTION
Engine.......................................................................................10
[10.001]Engineandcrankcase.............................................................10.1
[10.216]Fueltanks..........................................................................10.2
[10.218]Fuelinjectionsystem...............................................................10.3
[10.254]Intakeandexhaustmanifoldsandmufer.........................................10.4
[10.400]Enginecoolingsystem.............................................................10.5
Transmission..............................................................................21
[21.112]Powershuttletransmission.........................................................21.1
[21.113]Powershifttransmission............................................................21.2
[21.134]Powershuttletransmissionexternalcontrols......................................21.3
[21.135]Powershifttransmissionexternalcontrols..........................................21.4
[21.154]Powershuttletransmissioninternalcomponents..................................21.5
[21.155]Powershifttransmissioninternalcomponents......................................21.6
Frontaxlesystem.......................................................................25
[25.100]Poweredfrontaxle.................................................................25.1
[25.102]Frontbevelgearsetanddifferential...............................................25.2
[25.108]Finaldrivehub,steeringknuckles,andshafts.....................................25.3
[25.400]Non-poweredfrontaxle............................................................25.4
Rearaxlesystem........................................................................27
[27.100]Poweredrearaxle..................................................................27.1
[27.106]Rearbevelgearsetanddifferential................................................27.2
[27.120]Planetaryandnaldrives..........................................................27.3
Brakesandcontrols....................................................................33
[33.110]Parkingbrakeorparkinglock......................................................33.1
[33.202]Hydraulicservicebrakes...........................................................33.2
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Hydraulicsystems.......................................................................35
[35.000]Hydraulicsystems..................................................................35.1
[35.102]Pumpcontrolvalves................................................................35.2
[35.104]Fixeddisplacementpump..........................................................35.3
[35.106]Variabledisplacementpump.......................................................35.4
[35.204]Remotecontrolvalves.............................................................35.5
[35.300]Reservoir,cooler,andlters........................................................35.6
[35.350]Safetyandmainreliefvalves......................................................35.7
[35.359]Maincontrolvalve..................................................................35.8
[35.525]Auxiliaryhydraulicvalvesandlines................................................35.9
[35.703]Stabilizerhydraulicsystem.......................................................35.10
[35.723]Frontloaderbuckethydraulicsystem............................................35.11
[35.726]Excavatorandbackhoehydrauliccontrols.......................................35.12
[35.736]Boomhydraulicsystem..........................................................35.13
[35.737]Dipperhydraulicsystem..........................................................35.14
[35.738]Excavatorandbackhoebuckethydraulicsystem................................35.15
[35.739]Swingarmhydraulicsystem.....................................................35.16
[35.740]T elescopicarmhydraulicsystem.................................................35.17
Framesandballasting.................................................................39
[39.100]Frame..............................................................................39.1
[39.129]Stabilizers..........................................................................39.2
Steering.....................................................................................41
[41.101]Steeringcontrol....................................................................41.1
[41.200]Hydrauliccontrolcomponents......................................................41.2
[41.216]Cylinders...........................................................................41.3
Wheels......................................................................................44
[44.511]Frontwheels........................................................................44.1
[44.520]Rearwheels........................................................................44.2
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Cabclimatecontrol.....................................................................50
[50.200]Airconditioning.....................................................................50.1
Electricalsystems.......................................................................55
[55.024]Transmissioncontrolsystem.......................................................55.1
[55.100]Harnessesandconnectors.........................................................55.2
[55.201]Enginestartingsystem.............................................................55.3
[55.301]Alternator...........................................................................55.4
[55.302]Battery..............................................................................55.5
[55.408]Warningindicators,alarms,andinstruments......................................55.6
[55.525]Cabenginecontrols................................................................55.7
[55.991]T elematics..........................................................................55.8
[55.DTC]FAULTCODES....................................................................55.9
Frontloaderandbucket...............................................................82
[82.100]Arm.................................................................................82.1
[82.300]Bucket..............................................................................82.2
Booms,dippers,andbuckets.......................................................84
[84.100]Bucket..............................................................................84.1
[84.114]Boompivotingsupport.............................................................84.2
[84.910]Boom...............................................................................84.3
[84.912]Dipperarm.........................................................................84.4
Platform,cab,bodywork,anddecals.............................................90
[90.105]Machineshieldsandguards.......................................................90.1
[90.114]Operatorprotections...............................................................90.2
[90.124]Pneumatically-adjustedoperatorseat..............................................90.3
[90.150]Cab.................................................................................90.4
[90.151]Cabinterior.........................................................................90.5
[90.154]Cabdoorsandhatches............................................................90.6
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INTRODUCTION
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Contents
INTRODUCTION
Foreword-Importantnoticeregardingequipmentservicing....................................3
Safetyrules.....................................................................................4
Safetyrules.....................................................................................5
Safetyrules-Ductileiron.......................................................................6
Safetyrules-Ecologyandtheenvironment....................................................7
Basicinstructions-Shopandassembly........................................................8
Battery-Basicinstructions...................................................................10
Basicinstructions–Supportstrutforloaderliftarm..........................................12
BasicinstructionsHood.......................................................................14
Basicinstructions-Fuseandrelaylocations.................................................15
Basicinstructions-Fuse,relay,anddiodeicondenitions...................................19
Basicinstructions-Diagnosticservicetoolport..............................................26
Basicinstructions-Weldingonthemachine.................................................27
Cabheater-Basicinstructions...............................................................29
Torque-Minimumtighteningtorquesfornormalassembly...................................30
AbbreviationMeasurements..................................................................35
Capacities–580N............................................................................37
Capacities–580SN...........................................................................39
Capacities–580SNWT......................................................................41
Capacities–590SN...........................................................................43
Consumables.................................................................................45
Generalspecication-SevereColdWeatherPackage(SCWP)(optional)..................48
Hydrauliccontamination......................................................................49
Productoverview-Machineorientation......................................................50
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INTRODUCTION
Foreword-Importantnoticeregardingequipmentservicing
Allrepairandmaintenanceworklistedinthismanualmustbecarriedoutonlybyqualieddealershippersonnel,
strictlycomplyingwiththeinstructionsgiven,andusing,wheneverpossible,thespecialtools.
Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein
shallberesponsibleforanysubsequentdamages.
Themanufacturerandalltheorganizationsofitsdistributionchain,including-withoutlimitation-national,regional,or
localdealers,rejectanyresponsibilityfordamagescausedbypartsand/orcomponentsnotapprovedbythemanu-
facturer,includingthoseusedfortheservicingorrepairoftheproductmanufacturedormarketedbythemanufacturer.
Inanycase,nowarrantyisgivenorattributedontheproductmanufacturedormarketedbythemanufacturerincase
ofdamagescausedbypartsand/orcomponentsnotapprovedbythemanufacturer.
Themanufacturerreservestherighttomakeimprovementsindesignandchangesinspecicationsatanytimewithout
noticeandwithoutincurringanyobligationtoinstallthemonunitspreviouslysold.Specications,descriptions,and
illustrativematerialhereinareasaccurateasknownattimeofpublicationbutaresubjecttochangewithoutnotice.
Incaseofquestions,refertoyourCASECONSTRUCTIONSalesandServiceNetworks.
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INTRODUCTION
Safetyrules
Personalsafety
Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialpersonalinjuryhazards.Obeyall
safetymessagesthatfollowthissymboltoavoidpossibledeathorinjury.
ThroughoutthismanualyouwillndthesignalwordsDANGER,WARNING,andCAUTIONfollowedbyspecialin-
structions.Theseprecautionsareintendedforthepersonalsafetyofyouandthoseworkingwithyou.
Readandunderstandallthesafetymessagesinthismanualbeforeyouoperateorservicethemachine.
DANGERindicatesahazardoussituationthat,ifnotavoided,willresultindeathorseriousinjury.
WARNINGindicatesahazardoussituationthat,ifnotavoided,couldresultindeathorseriousinjury.
CAUTIONindicatesahazardoussituationthat,ifnotavoided,couldresultinminorormoderateinjury.
FAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT
INDEATHORSERIOUSINJURY .
Machinesafety
NOTICE:Noticeindicatesasituationthat,ifnotavoided,couldresultinmachineorpropertydamage.
ThroughoutthismanualyouwillndthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor
propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety.
Information
NOTE:Noteindicatesadditionalinformationthatclariessteps,procedures,orotherinformationinthismanual.
ThroughoutthismanualyouwillndthewordNotefollowedbyadditionalinformationaboutastep,procedure,or
otherinformationinthemanual.ThewordNoteisnotintendedtoaddresspersonalsafetyorpropertydamage.
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4

INTRODUCTION
Safetyrules
Unlessotherwiseinstructed,alwaysperformthesestepsbeforeyouservicethemachine:
1.Parkthemachineonaat,levelsurface.
2.Placethebackhoeinthetransportpositionwiththeswinglockpininstalledfortransport.
3.Placetheloaderbucketontheground,withthebottomoftheloaderbucketparalleltothesurface.
4.Placethedirectioncontrolleverandthetransmissioninneutral.
5.Ifyouneedtoopenthehoodtoperformservice,raisetheloaderarmsandinstallthesupportstrut.
6.Shutdowntheengine.
7.Placea'DoNotOperate'tagonthekeyswitchsothatitisvisibletootherworkersorremovethekey.
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INTRODUCTION
Safetyrules-Ductileiron
DANGER
Alteringcastductileironcancauseittoweakenorbreak.
Beforeyouweld,cut,ordrillholesonanypartofthismachine,makesurethatthepartisnotcast
ductileiron.
Failuretocomplywillresultindeathorseriousinjury.D0148A
Alteringcastductileironcancauseittoweakenorbreak.Unauthorizedmodicationstocastductileironpartscan
causedeathorseriousinjury.Donotweld,cut,drill,repair,orattachitemstocastductileironpartsonthismachine.
Beforeyouweld,cut,ordrillholesonanypartofthismachine,makesurethepartisnotcastductileiron.Seeyour
dealerifyoudonotknowifapartiscastductileiron.
Thefollowingitemsareexamplesofcastductileironparts.Theremayalsobeotherpartsmadeofcastductile
ironthatarenotonthelistbelow.
•two-wheeldrivesteeringlink
•dumplinks
•frontaxle
•stabilizers
•extend-a-hoe
•swingtower
•bucketlinkage
•Air-Conditioning(A/C)compressormountingbracket
Donotmakeanyunauthorizedmodications.Consultanauthorizeddealerbeforemakinganychanges,additions,
ormodicationstothismachine.
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6

INTRODUCTION
Safetyrules-Ecologyandtheenvironment
Soil,air,andwaterqualityisimportantforallindustriesandlifeingeneral.Whenlegislationdoesnotyetrulethe
treatmentofsomeofthesubstancesthatadvancedtechnologyrequires,soundjudgmentshouldgoverntheuseand
disposalofproductsofachemicalandpetrochemicalnature.
Familiarizeyourselfwiththerelativelegislationapplicabletoyourcountry,andmakesurethatyouunderstandthis
legislation.Wherenolegislationexists,obtaininformationfromsuppliersofoils,lters,batteries,fuels,anti-freeze,
cleaningagents,etc.,withregardtotheeffectofthesesubstancesonmanandnatureandhowtosafelystore,use,
anddisposeofthesesubstances.
Helpfulhints
•Avoidtheuseofcansorotherinappropriatepressurizedfueldeliverysystemstolltanks.Suchdeliverysystems
maycauseconsiderablespillage.
•Ingeneral,avoidskincontactwithallfuels,oils,acids,solvents,etc.Mostoftheseproductscontainsubstances
thatmaybeharmfultoyourhealth.
•Modernoilscontainadditives.Donotburncontaminatedfuelsandorwasteoilsinordinaryheatingsystems.
•Avoidspillagewhenyoudrainuidssuchasusedenginecoolantmixtures,engineoil,hydraulicuid,brakeuid,
etc.Donotmixdrainedbrakeuidsorfuelswithlubricants.Storealldraineduidssafelyuntilyoucandisposeof
theuidsinaproperwaythatcomplieswithalllocallegislationandavailableresources.
•Donotallowcoolantmixturestogetintothesoil.Collectanddisposeofcoolantmixturesproperly.
•Theair-conditioningsystemcontainsgasesthatshouldnotbereleasedintotheatmosphere.Consultanair-condi-
tioningspecialistoruseaspecialextractortorechargethesystemproperly.
•Repairanyleaksordefectsintheenginecoolingsystemorhydraulicsystemimmediately.
•Donotincreasethepressureinapressurizedcircuitasthismayleadtoacomponentfailure.
•Protecthosesduringwelding.Penetratingweldsplattermayburnaholeorweakenhoses,allowingthelossofoils,
coolant,etc.
Batteryrecycling
Batteriesandelectricaccumulatorscontainseveralsubstancesthatcanhaveaharmful
effectontheenvironmentifthebatteriesarenotproperlyrecycledafteruse.Improper
disposalofbatteriescancontaminatethesoil,groundwater,andwaterways.CASE
CONSTRUCTIONstronglyrecommendsthatyoureturnallusedbatteriestoaCASE
CONSTRUCTIONdealer,whowilldisposeoftheusedbatteriesorrecycletheused
batteriesproperly.Insomecountries,thisisalegalrequirement.
Mandatorybatteryrecycling
NOTE:ThefollowingrequirementsaremandatoryinBrazil.
Batteriesaremadeofleadplatesandasulfuricacidsolution.Becausebatteriescontainheavymetalssuchaslead,
CONAMAResolution401/2008requiresyoutoreturnallusedbatteriestothebatterydealerwhenyoureplaceany
batteries.Donotdisposeofbatteriesinyourhouseholdgarbage.
Pointsofsaleareobligedto:
•Acceptthereturnofyourusedbatteries
•Storethereturnedbatteriesinasuitablelocation
•Sendthereturnedbatteriestothebatterymanufacturerforrecycling
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7

INTRODUCTION
Basicinstructions-Shopandassembly
Shimming
Foreachadjustmentoperation,selectadjustingshimsandmeasuretheadjustingshimsindividuallyusingamicrom-
eter,thenadduptherecordedvalues.Donotrelyonmeasuringtheentireshimmingset,whichmaybeincorrect,or
theratedvalueshownoneachshim.
Rotatingshaftseals
Forcorrectrotatingshaftsealinstallation,proceedasfollows:
1.Beforeassembly,allowthesealtosoakintheoilitwillbesealingforatleastthirtyminutes.
2.Thoroughlycleantheshaftandcheckthattheworkingsurfaceontheshaftisnotdamaged.
3.Positionthesealinglipfacingtheuid.
NOTE:Withhydrodynamiclips,takeintoconsiderationtheshaftrotationdirectionandpositionthegroovessothat
theywillmovetheuidtowardstheinnersideoftheseal.
4.Coatthesealinglipwithathinlayeroflubricant(useoilratherthangrease).Fillthegapbetweenthesealinglip
andthedustlipondoublelipsealswithgrease.
5.Insertthesealinitsseatandpressdownusingaatpunchorsealinstallationtool.Donottapthesealwitha
hammerormallet.
6.Whileyouinserttheseal,checkthatthesealisperpendiculartotheseat.Whenthesealsettles,makesurethat
thesealmakescontactwiththethrustelement,ifrequired.
7.T opreventdamagetotheseallipontheshaft,positionaprotectiveguardduringinstallationoperations.
O-ringseals
LubricatetheO-ringsealsbeforeyouinsertthemintheseats.ThiswillpreventtheO-ringsealsfromoverturningand
twisting,whichwouldjeopardizesealingefciency.
Sealingcompounds
Applyasealingcompoundonthematingsurfaceswhenspeciedbytheprocedure.Beforeyouapplythesealing
compound,preparethesurfacesasdirectedbytheproductcontainer.
Spareparts
OnlyuseCNHOriginalPartsorCASECONSTRUCTIONOriginalParts.
Onlygenuinesparepartsguaranteethesamequality,duration,andsafetyasoriginalparts,astheyarethesame
partsthatareassembledduringstandardproduction.OnlyCNHOriginalPartsorCASECONSTRUCTIONOriginal
Partscanofferthisguarantee.
Whenorderingspareparts,alwaysprovidethefollowinginformation:
•Machinemodel(commercialname)andProductIdenticationNumber(PIN)
•Partnumberoftheorderedpart,whichcanbefoundinthepartscatalog
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8

INTRODUCTION
Protectingtheelectronicand/orelectricalsystemsduringchargingandwelding
Toavoiddamagetotheelectronicand/orelectricalsystems,alwaysobservethefollowingpractices:
1.Nevermakeorbreakanyofthechargingcircuitconnectionswhentheengineisrunning,includingthebattery
connections.
2.Nevershortanyofthechargingcomponentstoground.
3.Alwaysdisconnectthegroundcablefromthebatterybeforearcweldingonthemachineoronanymachine
attachment.
•Positiontheweldergroundclampasclosetotheweldingareaaspossible.
•Ifyouweldincloseproximitytoacomputermodule,thenyoushouldremovethemodulefromthemachine.
•Neverallowweldingcablestolieon,near,oracrossanyelectricalwiringorelectroniccomponentwhileyou
weld.
4.Alwaysdisconnectthenegativecablefromthebatterywhenchargingthebatteryinthemachinewithabattery
charger.
NOTICE:Ifyoumustweldontheunit,youmustdisconnectthebatterygroundcablefromthemachinebattery.
Theelectronicmonitoringsystemandchargingsystemwillbedamagedifthisisnotdone.
5.Removethebatterygroundcable.Reconnectthecablewhenyoucompletewelding.
WARNING
Batteryacidcausesburns.Batteriescontainsulfuricacid.
Avoidcontactwithskin,eyesorclothing.Antidote(external):Flushwithwater.Antidote(eyes):ush
withwaterfor15minutesandseekmedicalattentionimmediately.Antidote(internal):Drinklarge
quantitiesofwaterormilk.Donotinducevomiting.Seekmedicalattentionimmediately.
Failuretocomplycouldresultindeathorseriousinjury.W0111A
Specialtools
ThespecialtoolsthatCASECONSTRUCTIONsuggestsandillustrateinthismanualhavebeenspecicallyre-
searchedanddesignedforusewithCASECONSTRUCTIONmachines.Thespecialtoolsareessentialforreliable
repairoperations.Thespecialtoolsareaccuratelybuiltandrigorouslytestedtoofferefcientandlong-lastingoper-
ation.
Byusingthesetools,repairpersonnelwillbenetfrom:
•Operatinginoptimaltechnicalconditions
•Obtainingthebestresults
•Savingtimeandeffort
•Workinginsafeconditions
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9

INTRODUCTION
Battery-Basicinstructions
WARNING
Explosivegas!
Batteriesemitexplosivehydrogengasandotherfumeswhilecharging.Ventilatethechargingarea.
Keepthebatteryawayfromsparks,openames,andotherignitionsources.Neverchargeafrozen
battery.
Failuretocomplycouldresultindeathorseriousinjury.W0005A
WARNING
Hazardouschemicals!
Batteryelectrolytecontainssulfuricacid.Contactwithskinandeyescouldresultinsevereirritation
andburns.Alwayswearsplash-proofgogglesandprotectiveclothing(glovesandaprons).Wash
handsafterhandling.
Failuretocomplycouldresultindeathorseriousinjury.W0006A
•Donotruntheenginewiththealternatorwiresdisconnected.
•Beforeusinganelectricwelder,disconnectthealternatorwires,instrumentclusterandbatteries.Disconnectthe
EngineControlUnit(ECU)connectors.
•Donotuseasteamcleaneroracleaningsolventtocleanthealternator.
•Keepthebatteryventsclean.Ensurethebatteryventsarenotrestricted.
Disconnectbattery
1.Removethebatterycoverhardware.
RCPH11TLB001AAM1
2.Removethebatterycover.
RCPH11TLB002AAM2
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10

INTRODUCTION
3.Disconnectthenegativebatterycablefromthenega-
tivebatteryterminal.
RCPH11TLB003AAM3
Masterdisconnectswitch(ifequipped)
Enableordisableelectricalpowerfromthemachine
batteriestotheelectricalcomponentsusingthemaster
disconnectswitch,locatedontherighthandsideofthe
engine.
•(A)–Connectthebatterypower
•(B)–Disconnectthebatterypower
NOTICE:Waitatleast60secondsafterignitionkeyis
placedintheOFFpositionbeforeturningmasterdiscon-
nectswitchtoOFF .Thisallowsthemachinecontrollersto
shutdownproperly.
NOTICE:Somemachineserviceproceduresrequirean
actualterminaldisconnectofthebatteries.Donotusethe
masterdisconnectforthosetypesofprocedures,suchas
weldingonthemachine.
RAIL14TLB0409AA4
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INTRODUCTION
Basicinstructions–Supportstrutforloaderliftarm
WARNING
Crushinghazard!
Ifyouservicethemachinewiththeloaderliftarmsraised,alwaysusethesupportstrut.Removethe
retainingpinandplacethesupportstrutontothecylinderrod.Installtheretainingpinintothesupport
strut.Lowertheliftarmsontothesupportstrut.
Failuretocomplycouldresultindeathorseriousinjury.W0230A
Raiseandsupportloaderliftarms:
1.Emptytheloaderbucket.
2.Raisetheloaderliftarmstothemaximumheight.
3.Shutdowntheengine.
RCPH10TLB230AAF1
4.Removetheretainingpin.
5.Lowerthesupportstrutontothecylinderrod.
6.Installtheretainingpin.
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7.Starttheengine.
8.Slowlylowertheliftarmssothattheendofthesupport
strutrestsonthecylinder.
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INTRODUCTION
Lowersupportedloaderliftarms:
1.Raisetheliftarmssothattheendofthesupportstrut
nolongerrestsonthecylinder.
2.Shutdowntheengine.
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3.Removetheretainingpinfromthesupportstrut.
4.Raisethesupportstrutuptothestoragepositionand
securewiththeretainingpin,asshown.
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5.Starttheengine.
6.Lowertheloadertotheground.
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