Case 621E Operators Manual

Wheel Loader OPERATOR’S MANUAL Part number 51486471 1 st edition English September 2018 621E

Contents 1 GENERAL INFORMATION Note to the owner........................................................................... 1-1 Read the operator's manual ................................................................ 1-4 Product identification (Sides of the machine) .............................................. 1-6 Product overview – (Machine Components) ............................................... 1-7 Part identification – (Identification plates) .................................................. 1-9 Safety rules – (Ecology and the environment) ............................................ 1-12 Biodiesel - Biodiesel fuel .................................................................. 1-13 International symbols ...................................................................... 1-15 Service instructions (Availability and access to the parts catalog) ........................ 1-17 2 SAFETY INFORMATION Safety rules ................................................................................. 2-1 Safety rules (Signal word definitions) ...................................................... 2-2 Safety rules (Personnel) ................................................................... 2-3 Operating precautions (Starting the machine) ............................................. 2-8 Operating precautions (Machine operation) .............................................. 2-10 Basic operating safety rules ............................................................... 2-14 Safty Precautions (Weld works) .......................................................... 2-21 Safty Precautions – Fuel handling ........................................................ 2-23 Fire and explosion prevention ............................................................. 2-24 General safety and precautions ........................................................... 2-26 Safety (Utility lines) ....................................................................... 2-27 Safty Precautions (Machine transport) .................................................... 2-28 Operating precautions (Stopping the machine) ........................................... 2-29 Safty Precautions – (Machine service) ................................................... 2-30 Roll - over protective structure (ROPS) ................................................... 2-38 Seat belt precautions ...................................................................... 2-40 Tires and wheels – (Safety precautions) .................................................. 2-41 Safety Decals .............................................................................. 2-43 Hand signals ............................................................................... 2-68 3 CONTROLS AND INSTRUMENTS OPERATOR'S SEAT Operator seat (Standard) .............................................................. 3-1 Operator Seat (Optional – With air suspension) ....................................... 3-4 Shoulder belt ........................................................................... 3-7 FORWARD CONTROLS Front console ........................................................................... 3-8 Parking brake ........................................................................... 3-9 Steering column controls .............................................................. 3-10 Key start switch ........................................................................ 3-12 Foot pedals (Service brake and Throttle) ............................................. 3-13

Cab Internal Ventilation ................................................................ 3-14 LEFT-HAND SIDE CONTROLS Cab door (Door latch) ................................................................. 3-17 Drive – (Control through the lever on the steering column) ........................... 3-18 RIGHT-HAND SIDE CONTROLS Right console .......................................................................... 3-19 Drive – (Control through the loader lever) ............................................ 3-25 Control levers .......................................................................... 3-26 Window latches ........................................................................ 3-30 Cab (Emergency exits) ............................................................... 3-31 Cab (Cradle for auxiliary equipment) ................................................. 3-32 REARWARD CONTROLS Cab (Air recirculation louvers) ........................................................ 3-33 INSTRUMENT CLUSTER Dashboard ............................................................................. 3-34 Keypad – LCD monitor control ........................................................ 3-44 LCD Display – (General description) ................................................. 3-45 LCD Display – (Menu screens) ....................................................... 3-47 LCD Display – (Trip screens) ......................................................... 3-49 LCD Display – (Selection screens) ................................................... 3-51 LCD Display – (Service screens) ..................................................... 3-52 EXTERIOR CONTROLS Electrical (Master switch) ............................................................. 3-59 4 OPERATING INSTRUCTIONS COMMISSIONING THE UNIT Run-in period of a new machine ........................................................ 4-1 Before starting the engine .............................................................. 4-2 STARTING THE UNIT Starting the engine ..................................................................... 4-4 Machine operation (In cold environments) ............................................. 4-6 Machine operation (In hot environments) .............................................. 4-8 PARKING THE UNIT Stopping the machine .................................................................. 4-9 5 TRANSPORT OPERATIONS SHIPPING TRANSPORT Machine transport ...................................................................... 5-1

RECOVERY TRANSPORT Tow procedure .......................................................................... 5-5 6 WORKING OPERATIONS GENERAL INFORMATION Operating Instructions .................................................................. 6-1 TRANSMISSION Transmission operation ............................................................. 6-5 LOADER OPERATIONS Control levers (One lever/two spools) ............................................. 6-6 Control levers (Two levers/three spools) ........................................... 6-7 Control levers (Three levers/three spools) ......................................... 6-8 Control levers (Three levers/four spools) .......................................... 6-9 Loader functions ................................................................... 6-10 Bucket (Level indicator) ........................................................... 6-14 Hydraulic connections – Auxiliary (if equipped) ................................... 6-15 Operating the machine – (Transmission clutch) .................................. 6-16 Machine operation (Ride Control) (if equipped) .................................. 6-17 7 MAINTENANCE GENERAL INFORMATION Maintenance and adjustments ......................................................... 7-1 Part identification (Security lock, transport and service) ............................... 7-7 Part identification – (Cradle for locking the loader arms) .............................. 7-8 Part identification (Access doors and filling points) .................................... 7-9 Basic instructions (Daily inspection) .................................................. 7-12 Fuel system............................................................................ 7-13 Engine lubrication system ............................................................. 7-16 Engine coolant system ................................................................ 7-17 Engine air filter system ................................................................ 7-18 Hydraulic system ...................................................................... 7-19 Drive ................................................................................... 7-20 Front axle / Rear axle ................................................................. 7-21 Brake system .......................................................................... 7-22 Wheels and tires ...................................................................... 7-23 Lubrication analysis program .......................................................... 7-24 Auxiliary electrical outlet / Service connector (if equipped) ........................... 7-25 Machine operation – in harsh environments (Corrosion protection) .................. 7-26 MAINTENANCE CHART Maintenance chart ..................................................................... 7-28 AS REQUIRED Engine air filter (Replacement) ....................................................... 7-30

Cab (Checking) ....................................................................... 7-32 Air conditioner (Compressor seal lubrication) ........................................ 7-33 Air conditioner (Checking) ............................................................ 7-34 Drive belt – (Engine accessories and air-conditioning compressor) (Replacement) . 7-36 Tires (Calibration and pressure check) ............................................... 7-38 Wheels (Verification of the nut torque) ................................................ 7-39 Hydraulic fluid filter (Checking) ....................................................... 7-40 Windscreen washer reservoir (Filling) ................................................ 7-41 Loader control (Height control and adjustment of the return-to-movement) .......... 7-42 Loader control (Adjustment of the return-to-digging mechanism) .................... 7-44 Loader control (Fine adjustment of bucket height) .................................... 7-46 WHEN THE WARNING LAMP LIGHTS Warning lights (Check) ................................................................ 7-47 EVERY 10 HOURS Engine oil (Checking the level) ....................................................... 7-48 Engine coolant (Checking the level) .................................................. 7-50 Air filter dust valve (Verification and cleaning) ........................................ 7-52 INITIAL 20 HOURS Roll Over Protection Structure – (ROPS) (Check of the torque of the bolts in the initial period) ................................................................................ 7-53 Seat belts – (Check of the torque of the bolts in the initial period) .................... 7-53 EVERY 50 HOURS Transmission fluid (Checking the level) ............................................... 7-54 Hydraulic fluid (Checking the level) ................................................... 7-56 Fuel filter (Draining) ................................................................... 7-58 Grease points.......................................................................... 7-59 Initial 100 hours Transmission fluid and filter (Replacement in initial period) .......................... 7-61 Front and rear axles oil (Change in initial period) ..................................... 7-61 EVERY 100 HOURS Brake accumulator (Checking) ........................................................ 7-62 Lubrication points ...................................................................... 7-63 EVERY 250 HOURS Engine air filter (Restriction sensor) (Check) ......................................... 7-67 Cab air filter (Verification and cleaning) ............................................... 7-69 Drive belt – (Belt for the engine accessories and for the air-conditioning compressor) (Checking) ............................................................................ 7-72 Parking brake (Checking) ............................................................. 7-73

Secondary steering (Checking) ....................................................... 7-74 EVERY 500 HOURS Engine oil and filter (Replacement) ................................................... 7-76 Blow-by filter (Engine breather) (Replacement) ...................................... 7-78 Fuel filter –/Water separator filter (Replacement) ..................................... 7-79 Fuel reservoir (Draining) .............................................................. 7-81 Air intake lines (Verification of the hoses) ............................................ 7-82 Roll over protective structure (ROPS) (Check) ....................................... 7-84 Operator’s seat (Checking) ........................................................... 7-86 Seat belts (Checking the torque of the bolts) ......................................... 7-88 Front and rear axles oil (Checking the level) ......................................... 7-89 Every 1000 hours Hydraulic fluid filter –/Brake fluid (Replacement) ..................................... 7-90 Transmission fluid and filter (Replacement) .......................................... 7-93 Front and rear axles oil (Changing) ................................................... 7-96 Lubrication points ...................................................................... 7-99 EVERY 2000 HOURS Hydraulic fluid / Brake fluid (Change) ................................................ 7-101 Drive (Calibration) ................................................................... 7-103 Parking brake – (Test) ............................................................... 7-105 EVERY 4000 HOURS Engine coolant (Changing) .......................................................... 7-108 Fuel injectors (Calibration) ........................................................... 7-111 Storage Preparing for storage ................................................................. 7-112 Removal from storage ................................................................ 7-115 Electrical Starting with auxiliary batteries ....................................................... 7-117 Batteries (Checking) ................................................................. 7-119 Lamps Spare ......................................................................... 7-123 Miscellaneous fuses (Replacement) ................................................. 7-124 8 SPECIFICATIONS Lubrication, Filters and Fluids ............................................................. 8-1 General specification ....................................................................... 8-2 Overall dimensions ......................................................................... 8-7 Operating weights ......................................................................... 8-13 Standard torque data ...................................................................... 8-17

9 ACCESSORIES Radio (Optional) ........................................................................... 9-1

1 - GENERAL INFORMATION 1 - GENERAL INFORMATION###_1_### Note to the owner Introduction This manual has been developed as a guide for the safe and proper use of the machine, as well as for its maintenance. Always follow the recommendations in this manual to ensure the best performance, cost-effective operation and long service life of your machine. The manual is in sections. For a list of sections, see the table of contents. Refer to the index at the back of this manual for locating specific items about your machine. This manual contains all of the information related to daily maintenance, periodic maintenance, correct use and procedures for safe operation and maintenance of the machine. Some maintenance services require technical skills and appropriate tools for execution. Allow only trained technicians to perform such maintenance services on the machine. The recommendations in this manual also allow you to prevent the most common causes of accidents that might occur during work or maintenance operations of the machine. If you are in any doubt, consult your Authorized CASE CONSTRUCTION Dealer. Read and fully understand all of the instructions and warnings in this manual before you start the engine or operate the machine. Pay special attention to the instructions related to safety, operation and maintenance to avoid unnecessary risks or injuries when you use or perform maintenance operations on the machine. Do not operate this machine or perform maintenance work if you have not had appropriate training. Have all operators read this manual carefully. The information in this manual is provided on the basis of information that was available at the time the manual was written. Settings, procedures, part numbers, software and other items can change. These changes can affect the maintenance performed on the machine. Make sure that your Authorized CASE CONSTRUCTION Dealer has provided complete and current information before you start to operate any machine. Do NOT remove this manual from the machine. It should be stored and kept in the appropriate compartment in the cab. Make sure this manual is complete and in good condition. Contact an Authorized CASE CONSTRUCTION Dealer if you need additional manuals or manuals in other languages. Always keep the manual in its compartment. Your machine was designed and manufactured in accordance with the strictest quality standards. It complies with the current safety regulations. Never use the machine for applications that are not included in this manual. Modifications made without authorization could result in serious or fatal accidents. Anyone making such unauthorized modifications shall be accountable for the consequences. The engine and fuel system of the machine are designed and manufactured in accordance with government emissions regulations. Tampering by dealers, customers and operators is strictly prohibited by law. Failure to comply with this recommendation could result in government fines, rework costs, voided warranty, lawsuits, and possible confiscation of the machine until it is returned to its original design. Technical assistance to the engine and repairs must be done by a certified technician only. Your Authorized CASE CONSTRUCTION Dealer will provide assistance with technicians specially trained and able to use the best methods in carrying out maintenance and repair services on your machine, using genuine CASE CONSTRUCTION-approved parts. The dealer can also provide additional information, as well as after-sales service that involves the acquisition of genuine parts, quality assurance and total reliability. For additional information, see your Authorized CASE CONSTRUCTION Dealer. 1-1

1 - GENERAL INFORMATION Basic information COIL16WEL0228FB 1 Your loader was designed for heavy work conditions. Your loader stands out for its sturdiness, large load capacity, and ease of operation. Your loader has a spacious cab, with ROPS/FOPS certification. Your loader provides broad visibility and more comfort for the operator, with air conditioning, heating, and simple, smooth controls. The engine offers high torque, high performance, reliability, and low consumption. The engine also has fewer moving parts, which means less wear and lower maintenance cost, as well as integrated components that facilitate access. The innovative “Cooling Box” cooling module, mounted in the center of the machine, eliminates the overlaid heat exchangers and allows full access to fresh, clean air. This means a more efficient cooling, extension of service life of the components, and greater durability of the coolant. The location of the cooling system, behind the cab, made it possible to install the engine behind the rear axle. This provides better balance, stability, and weight transfer. Even the hydraulic fluid tank plays an important role in the cooling system. At the same time as the tank helps to direct the air flow, it also is cooled by the air clean in circulation. The large hydraulic fan operates independently of the motor, at a low speed. The fan produces less noise, even though it moves a 10% greater volume of air (at a higher engine rpm of 2000 RPM) than conventional cooling systems. This is possible because the hydraulic fan captures the air in three directions. In addition, there no impact from small abrasive particles in the heat exchangers. This eliminates the need for reinforced radiators. In working environments with high levels of dust or debris in the air, the reversible fan (optional) is a solution that saves time when you clean the cooling module. The operator can use a switch in the cab to quickly reverse the fan and remove dust and debris from the cooling module. This saves time and improves productivity. The transmission is “Powershift” type with proportional shifting. It uses electronic control module to make the gear changes smooth and precise. In addition to the automatic or manual shift options, you can set a customized program of shifting sequences, to obtain greater productivity and reduce operator fatigue. For excellent lift capacity, uncoupling of the “Declutch” transmission is standard. Simply activate the brake pedal to instantly transmit more engine power. This way you are able to obtain fast lift cycles with the bucket full. The shafts are “Limited Slip” type, on both the front axle and the rear axle. When you stack material or push material on slippery ground, both axles minimize wheel slip. This maintains power and reduces tire wear. Outer planetaries and disc brakes in oil bath ensure an exceptional performance and reliability. 1-2

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