Case 21D 121D 221D Wheel Loaders Operator’s Manual 6-27772 – PDF DOWNLOAD

Description

Case 21D 121D 221D Wheel Loaders Operator’s Manual 6-27772 – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Case 21D 121D 221D Wheel Loaders Operator’s Manual 6-27772 – PDF DOWNLOAD

PREFACE :

These operator’s manual are designed to familiarize the operator with the machine and its designated use. The instruction manual contains important information on how to operate the machine safely, properly and with maximum efficiency.

• Observing these instructions helps to prevent hazardous situations, to reduce repair costs and downtimes and to increase the reliability and service life of the machine.
• The instruction manual must be supplemented by the respective national rules and regulations for accident prevention and environmental protection. The operator’s manual must always be available in the operator’s cab of the machine.

The operator’s manual must be read and put into practice by any person in charge of carrying out work with or on the machine, such as
– operation, including setting-up, troubleshooting in the course of work, care, evacuation of production waste and disposal of fuels and consumables.
– maintenance (inspection, servicing, repair) and / or
– transport.

• In addition to the operator’s manual and the mandatory rules and regulations for accident prevention and environmental protection in the user’s country and at place where the machine is to be used, the generally recognized technical rules for safe and proper working must be observed.
• The operator’s manual are directed to the construction- machine specialist. They cannot provide basic know-how. This can be acquired, for example, in several days’ instruction by one of our qualified mechanics or by attending our training course for operators or maintenance personnel.

TABLE OF CONTENTS:

Case 21D 121D 221D Wheel Loaders Operator’s Manual 6-27772 – PDF DOWNLOAD

PART 1 – INTRODUCTION
PREFACE
After-Sales-Service 3
FUNDAMENTAL SAFETY INSTRUCTIONS 4
Warnings and symbols 4
Designated use 4
Organizational measures 5
Selection and qualification of personnel 6
OPERATING, SAFETY INSTRUCTIONS
Standard operation 6
MAINTENANCE, SAFETY INSTRUCTIONS 7
WARNING OF SPECIAL DANGERS
Electric energy 8
Gas, dust, steam and smoke 8
Hydraulic and pneumatic equipment 9
Noise 9
Oil, grease and other chemical substances 9
TRANSPORTING AND TOWING – RECOMMISSIONING 9
PART 2 – OPERATION
OPERATION – SAFETY INSTRUCTIONS 13
DESCRIPTION OF THE MACHINE
Layout of the machine 15
Basic unit 16
Chassis 16
Drive unit 16
Axles 16
Brakes 16
Hydraulic system 16
Electrical system 16
Working equipment 16
TECHNICAL DATA 17
Wheel loader 21D 17
TECHNICAL DATA 21
Wheel loader 121D 21
TECHNICAL DATA 25
Wheel loader 221D 25
Noise emissions
Outside the machine 29
Inside the machine 29
Vibration levels
Vertical vibration level at the operator’s seat 29
Vibration level at hands and arms 29
CE Mark 30
STABILITY
Centre of gravity position during transport 31
Rated load at stability limit 32
Warning and instruction signs
Machine number 35
Engine number 35
Axle number 35
Travel pump number 35
Travel motor number 35
Attachments 35
DRIVER’S CAB
Entering and leaving the machine – Safety instructions 36
Driver’s cab door
Opening the door 37
Closing the door 37
Fold-down window 37
Emergency exit 38
Documentation 38
Cab interior lighting 39
Roller blind 39
Adjusting the operator’s seat
Adjusting the weight-oriented suspension 40
Weight adjustment 40
Height adjustment 40
Fore-and-aft adjustment 41
Backrest adjustment 41
Adjusting the right armrest 42
Height adjustment 42
Fore-and-aft adjustment 42
WARNING, MONITORING AND CONTROL ELEMENTS 43
Driver’s stand, overall layout 44
Warning and control lamps 45
Switches and pushbuttons 49
PUTTING THE MACHINE INTO OPERATION 53
Refuelling
Refuelling – Safety instructions 53
Refuelling 53
Electrical system ON / OFF
Battery main switch 54
Immobilizer 54
Electrical system key-switch
Starting and stopping the engine 55
Starting 55
Engine does not start 56
Stopping the engine 56
Ventilation and heating
Ventilation 57
Heating 58
Fan 58
Horn, travel direction indicator, main beam and windscreen wiper / -washer 59
Lighting 61
Rear screen wiper / washer 62
Cigarette lighter / Socket outlet 62
DRIVING 63
Driving – Safety instructions 63
Adjustment of steering column
Steering column – Safety instructions 63
Adjusting the steering column 64
Seat belt
Seat belt – Safety instructions 64
Control lever – Travelling / Working 65
Driving
Warming up the machine 66
Engine 66
Steering and working hydraulics 66
Front and rear axle 66
Braking and stopping 66
Start 67
Travel direction and gears 67
Fast-speed variant (optional equipment)
Activating fast speed 68
Disengaging fast speed 68
Monitoring the indicators
Hydraulic oil temperature 69
Engine oil pressure 70
Alternator 70
Air filter 70
Coolant temperature 71
Braking pressure 71
Driving on public roads 72
Recovering / towing of the machine
Recovery and towing, safety instructions 74
Towing lug 74
Towing 75
Transport
Transport – Important information 76
Loading by crane 76
Blocking the articulated joint 77
WORKING OPERATION
Working operation – Safety instructions 78
Driving on public road 84
Road transfer 84
STANDARD EQUIPMENT 85
Control lever for bucket equipment
Floating position of the bucket equipment 86
Combined functions 86
Control lever – 3rd/4th function 87
Quick-change device 87
Control lever locking 87
Locking the control levers 87
Unlocking the control levers 87
OPTIONAL EQUIPMENT
Bottom-dum bucket 88
Sweeper 88
After daily operation
Securing the machine 89
Cleaning and refuelling of machine 89
Carry out visual inspection 89
Chock 89
WORKING EQUIPMENT 90
Assembling working equipment – safety instructions 90
ATTACHMENTS 92
Quick-change device 92
Bucket
Attaching the bucket 92
Checking the bucket locking 93
Detaching the bucket 93
Four-in-one bucket
Attaching the four-in-one bucket 94
Detaching the four-in-one bucket (bottom-dump bucket) 95
Equipment carrier with lifting forks
Attaching the equipment carrier 96
Removing the equipment carrier 96
Lifting forks 96
Working with lifting forks 97
Taking up loads 97
Transporting loads 97
Setting down loads 97
Floodlamps, front 98
Floodlamps, rear 98
Rotary beacon 98
Acoustic reversing signal (Back-up alarm) 99
Pipe-break safety system
Without shut-off possibility 100
PART 3 – INSPECTION AND SERVICING
INSPECTION AND SERVICING – SAFETY INSTRUCTIONS 103
MAINTENANCE WORK
Securing the machine 107
Opening the engine hood 107
SERVICING
Draining hose for oil changes 108
Operating-hours meter 108
Inspection and servicing plans – instructions
Intervals 109
Change of engine oil 109
Oil / Greases 109
Cleaning jobs 109
Servicing material 109
Plan V – once prior to initial commissioning 110
Plan N – After initial commissioning 111
Plan T – All 10 HOURS or each working shift 112
Plan W – All 50 HOURS or weekly 112
Plan B – after every 500 HOURS 114
Plan C – after every 1000 HOURS 114
Plan D – after every 3000 HOURS 114
LUBRICATING CHART – GREASE
Lubricating chart – grease 117
Joints and hinges 117
OIL INSPECTION PLAN
Oil inspection plan 119
Refilling quantities – Oil 119
Refilling quantities – Other 119
LUBRICANTS 120
Oils for internal combustion engines 120
Oils for hydraulic system, mineral 121
Oils for axles and gearboxes (selection) 122
Greases for bearing points and slewing rings 123
ENGINE
Safety instructions for inspection and servicing 124
Checking the engine oil level / Topping up oil 124
Changing the engine oil 125
Replacing the engine oil filter 126
Crankcase ventilation 126
Valve clearance 127
COOLING SYSTEM
Checking the cooling liquid level 128
Changing the cooling liquid 128
AIR-INTAKE SYSTEM
Dust-discharge valve 129
Removing, checking and cleaning the main filter element 130
Cleaning the main filter element 131
Checking / replacing safety filter 131
Checking air-intake lines 132
FUEL SYSTEM
Fuel filter 133
Water pre-separator 134
Draining off water 134
Cleaning the water pre-separator 134
Cleaning the fuel tank 134
Injection nozzles 135
ELECTRICAL SYSTEM
Safety instructions 136
Alternator, instructions 136
Battery main switch 137
Battery
Battery – checking the fluid level 138
Battery – checking the charge 138
Removing and installing the battery 139
HYDRAULIC SYSTEM
Checking the hydraulic oil level 140
Return flow filter 140
Replacing the filter 140
Breather filter 141
Hydraulic reservoir
Changing the hydraulic oil 142
Filling the hydraulic reservoir with oil 142
Bleeding the hydraulic working and steering systems
Working hydraulic system 142
Steering hydraulic system 142
OPTIONAL EQUIPMENT 143
Environmentally compatible hydraulic fluid (biodegradability)
Environmentally compatible hydraulic fluid, operating instructions 143
Environmentally compatible hydraulic fluid, conversion 143
Environmentally compatible hydraulic fluid, sampling 144
Oils for hydraulic system, synthetic (biodegradability) 145
AXLES 146
Safety instructions 146
Front axle 146
Rear axle 147
Transfer gearbox 147
Planetary gears 148
BRAKES
Working on brakes, safety instructions 149
Parking brake 149
Reducing braking pressure 149
Checking the brake disks 149
Bleeding the braking system
Bleeding 151
TYRES AND WHEELS
Tyres and wheels – Safety instructions 152
Tyre pressure – Safety instructions 153
Checking the tyre pressure – Reinflating the tyre 154
Tyre pressure 155
Changing a wheel 156
Fastening of wheels 156
Tyre tread position 156
LUBRICATING THE GREASING POINTS 157
DRIVER’S CAB VENTILATION
Filter 157
PUTTING THE LOADER OUT OF OPERATION
Preserving the engine 158
Battery storage 158
RECOMMISSIONING
Removal of engine preserving agents 159
PART 4 – REPAIR WORK
REPAIR WORK – SAFETY INSTRUCTIONS 163
ENGINE 164
Engine – repair instructions
Replacing V-belts 164
Replacing alternator / coolant pump V-belts 164
Assisted starting (jump-starting) – Safety instructions
Assisted starting (jump-starting) 166
Prior to assisted starting 166
Connecting the jumper cables 166
Starting the engines 166
ELECTRICAL SYSTEM
Fuses 167
Replacing fuses 168
Replacing bulbs 168
Lighting
Headlamp 169
Turn signal lamp 170
Tail/brake signal lamp 170
Cab interior lamp 171
Floodlamp 171
Rotary beacon 172
Replacing the lamp 172
WELDING OPERATIONS
Welding operations – safety instructions 173
HYDRAULIC SYSTEM
Replacing hydraulic hoses – Safety instructions 174
Lifting cylinder – installation 174
BRAKES
Safety instructions 175
Checking the braking pressure 176
Replacing the brake disks 176
Checking the accumulator pressure 177
Checking the preloading pressure 177
ACCUMULATORS 178
Safety instructions 178
WORKING EQUIPMENT
Bucket 179
Replacing of teeth 179
Bucket limit stops 180
Upper dumping position 180
Rearward tilt position 180
Lifting forks
Checking of fork prongs 181
PART 5 – ANNEX
TROUBLESHOOTING 185
Instructions on troubleshooting 185
Layout of fault table
Fault 185
Possible causes 185
Measure 185
Section 185
Engine 186
Combustion engine start / stop 187
Steering system 188
Working equipment 189
Transmission 190
Brake system 192
ABBREVIATIONS 193

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• This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
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