Case 1150K TIER 3 Crawler Dozer Operator’s Manual 84272799 - PDF DOWNLOAD

1150K TIER 3 Crawler Dozer

Operator’s Manual

Print No. 84272799 English 11/09 Replaces p/n 84146927

ORIGINAL INSTRUCTIONS - according to Directive 2006/42/EC, Annex I 1.7.4.1

1150K Tier 3 Crawler Dozer

Operator’s Manual

Print No. 84272799 English 11/09 Replaces p/n. 84146927

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

All data given in this publication is subject to production variations. Dimensions and weights are only approximate.

Illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer.

REVISION HISTORY Issue

Issue date

Applicable Machines

Remarks

First Edition

01Mar 08

1150K Series 3 Crawler Dozer

87728511 EUR

Revision 1

01Aug 08

1150K Series 3 Crawler Dozer

84146927 EUR

Revision 2

01Nov 09

1150K Series 3 Crawler Dozer

Updated manual with European Declaration of Conformity information.

Manual part number 84272799.

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF DEATH OR SERIOUS INJURY

Safety Decals on this machine use the words Danger, Warning, or Caution, which are defined as follows: ●

DANGER: Indicates an immediate hazardous situation that, if not avoided, will result in death or serious injury. The color associated with Danger is RED.

● WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. The

color associated with Warning is ORANGE. ● CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It

may also be used to alert against unsafe practices. The color associated with Caution is YELLOW.

If Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows: ● The first panel indicates the nature of the hazard. ● The second panel indicates the appropriate avoidance of the hazard. ● Background color is YELLOW. ● Prohibition symbols such as

and

STOP

if used, are RED.

IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR: ● Is instructed in safe and proper use of the machine. ● Reads and understands the Manual(s) pertaining to the machine. ● Reads and understands ALL Safety Decals on the machine. ● Clears the area of other persons. ● Learns and practices safe use of machine controls in a safe, clear area before operating this machine on a job site.

It is your responsibility to observe pertinent laws and regulations and follow Case Construction instructions on machine operation and maintenance.

TECHNICAL MANUALS Manuals are available from your Dealer for the operation, service, and repair of your machine.

Contact your Dealer for assistance in obtaining the manuals for your machine. Your Dealer can expedite your order for Operator’s Manuals, Parts Catalogs, Service Manuals, and maintenance records.

Always give the Machine Name, Model, and P.I.N. (Product Identification Number) or S.N. (Serial Number) of your machine so your Dealer can provide the correct manuals for your machine.

Any use of editorial or pictorial content is strictly prohibited without express written permission from CNH America, LLC. Racine, WI 53403 U.S.A.

TABLE OF CONTENTS CHAPTER 1 GENERAL INFORMATION TO THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 "EC" DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 OFFICIAL DOCUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 MACHINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 CHAPTER 2 SAFETY AND SAFETY DECALS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 SAFETY AND SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 CHAPTER 3 INSTRUMENTS AND CONTROLS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 BRAKE, DECELERATOR AND FOOTREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 PARKING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 DIRECTION CONTROL LEVER,TRANSMISSION CONTROL, HAND THROTTLE . . . . . . . . . . . . . . . . . 3-14 DOZER BLADE CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 RIPPER CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 OPERATOR’S SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 CHAPTER 4 OPERATING INSTRUCTIONS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 RUN-IN PERIOD OF A NEW MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 CRAWLER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 MOVING A DISABLED CRAWLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 OPERATING IN HOT WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 OPERATING IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 BOOSTER BATTERY CONNECTION TO MACHINE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 TILTING THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 DOZER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 TRACK SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 FACTORS CONTROLLING UNDERCARRIAGE WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 CHAPTER 5 LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 GENERAL SAFETY BEFORE YOU SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 SYSTEMGARD LUBRICATION ANALYSIS PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 PLASTIC AND RESIN PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 ENGINE HOURMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 ACCESS DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 AS REQUIRED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 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EVERY 10 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INITIAL 20 HOUR TRACK SHOE BOLT TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EVERY 50 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EVERY 250 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EVERY 500 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EVERY 1000 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EVERY 2000 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 6 MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE AND ADJUSTMENT WELDING ON THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ROLL-OVER PROTECTIVE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MACHINE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE RIPPER SHANKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DOZER BLADE PITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR ATTACHMENT TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-14 5-16 5-17 5-19 5-22 5-25 5-28

6-1 6-3 6-4 6-5 6-5 6-6 6-7 6-8 6-9

CHAPTER 7 ELECTRICAL TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 CHAPTER 8 SPECIFICATIONS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSPORT LENGTH AND WIDTH WITH BLADE FULLY ANGLED 25 DEGREES . . . . . . . . . . . . . . .

OPERATING DATA AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATING DATA AND DIMENSIONS - RIPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1 8-3 8-5 8-6 8-8

CHAPTER 9 INDEX CHAPTER 10 AFTER DELIVERY CHECK - DEALER COPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 AFTER DELIVERY CHECK - OWNERS COPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

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CHAPTER 1 - GENERAL INFORMATION

Chapter 1 GENERAL INFORMATION TO THE OWNER

Figure 1

BD06G104

K SERIES CRAWLER

CNH AMERICA LLC 501 Richardson Rd. Calhoun, Georgia 30701 DEALER’S STAMP

Figure 2

This manual contains important information about the safe operation, adjustment and maintenance of your Case Crawler. Refer to the Detail Index at the end of this manual for locating specific items about your machine. The Crawler conforms to current safety regulations.

Use this manual as a guide. Your Crawler will remain a reliable working tool as long as it is kept in good working condition and serviced properly.

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"EC" DECLARATION OF CONFORMITY On page 1-3 is provided copy of the “EC” Declaration of Conformity (EC DoC). The EC DoC is the manufacturer’s declaration about equipment compliance to relevant EU provisions.

Please keep the original document in a safe place. Local authorities may require you to show this document in order to assure compliance of your equipment.

Translation of this declaration in your own country language is provided on the reverse page of the original document. For your better and easier understanding of the document hereafter you’ll find some explanatory notes.

Under section 1.2 are listed those options or variants which have safety related functions. Some of them

1 are standard provided, like FOPS or ROPS (please refer to page 6-4 for other detail).

2

Under point 2 are listed all information required by EU “Outdoor Noise” Directive 2000/14/EC. Please refer your own original EC DoC for specific equipment information. Other information about equipment guaranteed sound power level (Lwa) can be found on page 1-4. On the same page are indicated information about operator’s station noise level (LpA) which is not matter of above mentioned EU Directive and therefore not indicated on it.

Generic serial number for this equipment type. Sequence of letters and numbers may vary depending on

3 equipment configuration.

4

EC DoC serial number. Please make reference to this number when requiring information or support to Case about EC DoC.

5 Signature of a person authorised to sign the document on behalf of the company.

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1

2

3 4 5

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CHAPTER 1 - GENERAL INFORMATION

OFFICIAL DOCUMENTS Information concerning airborne noise emission Sound power level Lwa =109 dB (A) Guaranteed sound power level (1) determined according to European Directive 2000/14/EC. Sound pressure level at operator’s station LpA = 77 dB (A) Equivalent continuous A-weighted emission sound pressure level at the operator’s station measured with cab door and windows closed and the heating/air conditioning fan in operation at 2nd speed, measured on identical machine according to ISO 6396:2008.

Information concerning hand-arm and whole body vibration emission The level of vibrations transmitted to the operator depends mainly upon the conditions of the ground on which operations take place, the mode of operation of the machine and its equipment. The exposure to vibrations can be considerably reduced when the following recommendations are complied with:

• Use equipment compatible with the machine and the type of work to be done.

• Adjust and lock the seat in the correct position; also regularly inspect the suspension of the seat, performing the adjustments and repairs as required.

• Regularly perform the current maintenance operations of the machine at the prescribed intervals.

• Operate the equipment in a uniform manner, avoiding sharp movements or excessive loads.

• When travelling, avoid very rough terrain or driving over obstacles such as large rocks.

This machine is equipped with an operator’s seat which meets the criteria of EN ISO 7096:2000 representing vertical vibration input under severe but typical operating conditions.

The intent is to limit the machine operator’s exposure to vibrations. The exposure is dependant on basic machine operating techniques which can be controlled by following the instructions described in this manual.

• The weighted root mean square acceleration emission of the machine to which the operator’s arms are subjected does not exceed 25 m/s2.

• The weighted root mean square acceleration of the machine to which the body is subjected does not exceed 0.5 m/s2.

These results were obtained using an acceleration gauge while stock-piling on a level surface.

NOTE: Whole body emission value is determined under particular operating and terrain conditions and is therefore not representative for the various conditions in accordance with the intended use of the machine. Consequently this single whole–body vibration emission value is not intended to determine the whole–body vibration exposure as required by European Directive 2002/44/EC. For this purpose it’s recommended to carry out a real working condition measurement. If a real working condition measurement is not feasible, use the below reported indicated values for dozers only, according to ISO/TR 25398.

In compliance with EU standards, 78/764/EEC the vibration levels measured on seat for machines described in this manual are as specified below.

Average Typical operating condition

Standard deviation(s)

1.4*aw,eqx

1.4*aw,eqy

aw,eqz

1.4*Sx

1.4*Sy

Sz

[m/s2]

[m/s2]

[m/s2]

[m/s2]

[m/s2]

[m/s2]

Dozing

0.74

0.58

0.70

0.31

0.25

0.31

Tear up by scarifier

1.25

1.19

1.02

0.40

0.41

0.28

Transfer movement

0.87

0.80

0.97

0.43

0.40

0.34

* ISO/TR 25398:2006 Mechanical vibration – Guideline for the assessment of exposure to whole–body vibration of ride on operated earthmoving machines – Using harmonized data measured by international institutes, organizations and manufacturers.

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CHAPTER 1 - GENERAL INFORMATION Do Not operate or permit anyone to operate or service this machine until you or the other persons have read and understand the safety, operation and maintenance instructions in this manual. Use only trained operators who have demonstrated the ability to operate and service this machine correctly and safely.

This Crawler, with standard equipment and authorized attachments, is intended to be used for above ground material handling.

Do Not use this machine for any application or purpose other than those described in this manual. Consult an authorized dealer of the Case Construction on changes, additions or modifications that can be required for this machine to comply with various country regulations and safety requirements. Unauthorized modifications will cause serious injury or death. Anyone making such unauthorized modifications is responsible for the consequences.

This Operator’s Manual is to be stored in the manual compartment equipped on this machine, Make sure this manual is complete and in good condition. Contact your dealer to obtain additional manuals. Contact your dealer for any further information or assistance about your machine. Your dealer has Case Construction approved service parts. Your dealer has technicians with special training that know the best methods of repair and maintenance for your Crawler.

RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE FRONT

Figure 3

BD06E039

OPERATOR’S MANUAL POUCH ATTACHED TO SEAT BACK

RIGHT HAND

LEFT HAND

OFFICIAL DOCUMENTS An "EC" declaration of conformity.

NOTE: An original of this "CE" declaration is supplied with each machine and must be kept carefully by the owner.

NOTE: The official documents supplied with the machine must be kept by the owner so as to be able to present them to any inspecting authority which may request them.

REAR Figure 4

BS06D299

BASIC MACHINE

The terms Right-hand, Left-hand, Front, and Rear are used in this manual to indicate the sides as they are seen from the operator's seat.

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IDENTIFICATION NUMBERS Write your machine model number, Product Identification Number (P.I.N.) and serial numbers on the lines provided below. Always give these numbers to your dealer when you need parts or information for your machine.

Make a record of the numbers. Keep the record and your Manufacturer’s Statement of Origin in a safe place. If the machine is stolen, report the numbers to your local law enforcement agency.

Machine ➤ Machine Model and Type

➤ Product Identification Number: P.I.N.

➤ Year of Build

Component Serial Numbers ➤ Engine serial number Figure 6

BD06K002

➤

ENGINE Transmission and serial number

➤ ROPS cab or canopy serial number

➤ Dozer blade serial number

1

➤

Figure 7

BD02J108

TRANSMISSION 1. ON THE HOUSING UNDER THE CAB

BD02K018/87477990

Figure 5

PRODUCT IDENTIFICATION NUMBER (P.I.N.) ROPS CANOPY PLATE IS LOCATED ON THE LEFT-HAND UPPER SIDE CAB PLATE IS LOCATED ON THE RIGHT-HAND SIDE REAR POST

Figure 8

BD99J147

DOZER BLADE

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MACHINE COMPONENTS 1

2 12

11

12 3 9

4

6

6 8

5

10 7 Figure 9

BD06G105

1. Cab

5. Track

2. Right-hand Rear Access Door 3. Right-hand Center Access Door 4. Sprocket

6. Carrier Rollers 7. Track Roller 8. Idler

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9. Right-hand Engine Access Door and Side Shield Panel 10. Blade 11. Radiator Door 12. Hand Holds

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CHAPTER 1 - GENERAL INFORMATION

6

1 2 4

4 5

4

3

Figure 10

BD06G106

1. Left-hand Engine Access Door and Side Shield Panel 2. Blade Pitch Adjuster

1-8

3. Step 4. Hand Holds

5. Left-Rear Access Door 6. Fuel Fill

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1

2

Figure 11

BD02J032

RIPPER

1. Ripper Shank

Figure 12

BD02M132

DRAWBAR

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Figure 13

BD02M171

HITCH

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CHAPTER 1 - GENERAL INFORMATION

NOTES

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CHAPTER 2 - SAFETY AND SAFETY DECALS

Chapter 2 SAFETY AND SAFETY DECALS TABLE OF CONTENTS SAFETY AND SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 GENERAL AND SPECIFIC SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 UTILITY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 OPERATOR PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 PERSONNEL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 OPERATOR - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 PROPER ENTRY AND EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 STARTING AND STOPPING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 OPERATING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 MAINTENANCE PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 FUEL HANDLING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 BURN PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 HAZARDOUS CHEMICAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 TRANSPORTING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 ROLL-OVER PROTECTIVE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 SEAT BELT PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 TO FASTEN THE SEAT BELT: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 TO UNFASTEN THE SEAT BELT: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 FIRE EXTINGUISHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 SPECIFIC PRECAUTIONS TO THIS MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 READ OPERATOR’S MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 READ SERVICE MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

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SAFETY AND SAFETY DECALS GENERAL AND SPECIFIC SAFETY INFORMATION WARNING: This safety alert symbol indicates important safety messages in this manual. When you see this symbol, carefully read the message that follows and be alert to the possibility of death or serious injury.

Figure 1

Most accidents involving machine operation and maintenance can be avoided by following basic safety rules and precautions. Read and understand all the safety messages in this manual, the safety manual, and the safety decals on the machine before you operate or service the machine. See your dealer if you have any questions.

Safety Decals on this machine use the words, Danger, Warning or Caution, which are defined as follows:

• DANGER: Indicates an immediate hazardous situation which, if not avoided, will result in death or serious injury. The color associated with Danger is RED.

• WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. The color associated with Warning is ORANGE.

• CAUTION: Indicates a potentially hazardous Figure 2 OPERATOR’S MANUAL STORAGE LOCATED IN POUCH BEHIND SEAT

READ THIS MANUAL COMPLETELY and make sure you understand the controls. All equipment has a limit. Make sure you understand the speed, brakes, steering, stability and load characteristics of this machine before you start to operate.

DO NOT remove this manual or the safety manual from the machine. See your dealer for additional manuals. Also see the manual information on the Title pages (first and second pages in front of the Table of Contents) of this manual.

situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW. ISO two panel pictorial symbol decals are defined as follows:

• The first panel indicates the nature of the hazard.

• The second panel indicates the appropriate avoidance of the hazard.

• Background color is YELLOW. • Prohibition symbols such as

and

STOP

if

used, are RED.

The safety information given in this manual does not replace safety codes, insurance needs or, federal, state, and local laws. Make sure your machine has the correct equipment according to these rules or laws.

Additional safety messages are used in the text of the manual to show specific safety hazards.

IMPORTANT: Safety messages in this section point out situations which can be encountered during the normal operation and maintenance of your machine.

These safety messages also give possible ways of dealing with these conditions.

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CHAPTER 2 - SAFETY AND SAFETY DECALS UTILITY SAFETY Safety precaution MUST be followed when working near buried and overhead Utility Lines.

During operation it is likely that you will be working around or near buried or overhead utility lines which may include, but are not limited to:

• • • •

Electrical Power Line Gas Line Water Line Communication Line - Telephone or Cable Television

• Sewer Line IMPORTANT: Before beginning any machine operation, it is your responsibility to be aware of all such utility lines buried and overhead in the area of your project and to avoid them.

ALWAYS have all local utility companies mark the location of their lines.

IMPORTANT: Check with local authorities for laws, regulations and/or strict penalties requiring you to locate and avoid existing utilities.

Call All Local Utility Companies Before You perform any machine operation.

After locating any buried utility lines, carefully dig a hole by hand and/or automatic vacuum equipment to the utility line to verify the location and depth of the line.

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CHAPTER 2 - SAFETY AND SAFETY DECALS OPERATOR PRECAUTIONS PROPER ENTRY AND EXIT

PERSONNEL PRECAUTIONS

• Be prepared for emergencies. Always have a first aid kit and a working fire extinguisher with you and know how to use each.

• Avoid loose fitting clothing, loose or uncovered long hair, jewelry and loose personal articles.

• Know and use the protective equipment that is to be worn when operating this machine. Hard hats, protective glasses, protective shoes, gloves, reflector type vests, respirators and ear protection are examples of equipment that may be required.

• Certain protective equipment should be replaced and renewed upon age and wear. Old hard hats may not afford the original users intention. Faded and soiled vest are no longer as highly visible as original intent.

See the manufacture’s recommendation.

• Do not rush. Walk, do not run.

• Know and use the hand signals required for particular jobs and know responsibility for signaling.

who

has

the

OPERATOR - GENERAL

• It is the responsibility of the operator to read and understand the Operator’s Manual and other information provided and use the correct operating procedure. Machines should be operated only by qualified operators.

• Do not operate this machine or perform maintenance work if you have not had appropriate training and read and fully understand the instructions and warnings in this manual.

• Wear the seat belt to maximize the protection capability of the ROPS (Roll Over Protective Structure).

• Inspect the ROPS and seat belt mounting bolts on a daily basis to ensure their integrity.

• Do not permit riders on the machine if there is no manufacturer’s designated place for a rider.

• Make sure that all protective guards, canopies, doors, etc. are in place and secure before starting and operating the machine.

• Remove all loose objects stored in the machine.

Remove all objects which do not belong in or on the machine and its equipment.

• After service has been performed, make certain all tools, parts and equipment have been cleared from the machine area.

BD06G108

Figure 3

• Always face the machine and use the hand holds when getting on. Do not rush.

• Exit the machine slowly and use the hand holds.

Do not jump down.

WARNING: Never exit the machine with the engine operating.

Figure 4

WARNING: Never exit the machine without first confirming the parking brake is set.

Figure 5

WARNING: Never exit the machine unless the blade and attachment or tools are down resting on the ground.

Figure 6

• Use the recommended hand holds and steps with at least three points of support when getting on and off the machine. Keep steps and platform clean.

• Do not jump off the machine.

• Do not dismount while the machine is in motion.

• Foreign material or grease on the steps and hand holds can cause an accident. Keep the steps and hand holds clean.

• Do not lift personnel or allow personnel to work while standing in the bucket or on other attachments. This machine is not a man-lift.

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CHAPTER 2 - SAFETY AND SAFETY DECALS STARTING AND STOPPING PRECAUTIONS

• Walk around the machine and warn all personnel who may be servicing the machine or are in the machine path prior to starting. Do not start until all personnel are clearly away from the machine.

Sound the horn, if equipped, before starting.

• Walk around the machines tool, attachment, or furthermost contact point to view operation danger area from the work site personnel view and angle.

• Check that the parking device is applied, place the transmission in neutral or park as specified by the manufacturer, before starting the machine.

• Adjust, secure and latch the seat and fasten the seat belt before starting the machine.

• Start and operate the machine only from the operator’s station.

• Use jumper cables only in the recommended manner. Improper use can result in battery explosion or unexpected machine motion.

Ventilate the battery area before using jumper cables. Make sure that using jumper cables will not interfere or harm electronic processing or computer devices.

• Do not operate the engine in an enclosed area without adequate ventilation.

• Park the machine on level ground whenever possible and apply the parking brake. On grades, park the machine with the wheels or track securely blocked.

• Before leaving the operator station lower the equipment to the ground and shut off the engine.

• Remove the starter key or disconnect switch when leaving the machine parked or unattended.

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CHAPTER 2 - SAFETY AND SAFETY DECALS OPERATING PRECAUTIONS

• Check brakes, steering and other machine control devices in accordance with the manufacturer’s instructions prior to starting operation. Observe all gauges or warning instruments for proper operation. Operate all controls to insure proper operation. If any malfunctions are found, remove the starter key. Place a DO NOT OPERATE TAG on the machine until the malfunction is corrected.

• If a failure that causes loss of control such as steering, service brakes or engine occurs, stop the machine motion as quickly as possible, remove the starter key or disconnect switch key. Place a DO NOT OPERATE TAG on the machine and keep it securely parked until the malfunction is corrected or the machine can be safely moved.

• Understand the machine limitations and keep the machine under control.

• Never transport a loaded bucket at full height.

Operate the machine with the load as low as possible until it becomes necessary to raise the boom to discharge the load into a truck, container, etc.

• Never transport a loaded bucket at full height.

Operate the machine with the load as low as possible until it becomes necessary to raise the boom to discharge the load into a truck, container, etc.

• Operate and drive the machine with care and at speed compatible with conditions. Use extra caution when operating over rough ground, on slopes, and when turning.

• Note and avoid all hazards and obstructions such as ditches, underground lines, trees, cliffs, overhead electrical wires or areas where there is danger of a slide.

• Carry loads in recommended positions for maximum stability.

• Never lift loads in excess of capacity.

• Use the recommended machine ballast and counterweighting.

• Know and understand the job site traffic flow patterns and obey signalmen, road signs and flagmen.

• Know and understand that job site conditions may change on an hourly basis. Hills of dirt, debris or obstructions may grow and change from the time you began the day. It is your responsibility to monitor the changes and keep the machine, tools and attachments, etc. a safe distance.

• Watch for bystanders and never allow anyone to be under or to reach through the machine and its equipment while operating.

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• Select a gear that will prevent excessive speed when going downhill. Do not coast downhill.

• When roading a machine, know and use the signaling devices required on the machine.

Provide an escort for roading where required.

• Use the recommended transport devices when roading the machine.

• Before you operate at night, check that all lamps illuminate.

• If your machine has a cab make sure that all windows are clean and that the windshield wipers work correctly.

• Engine exhaust fumes can cause death. If you operate this machine in an enclosed area, make sure there is ventilation to replace the exhaust fumes with fresh air.

• Check all controls in a clear area and make sure the machine is operating correctly.

• Confirm that the attachment is properly mounted to the mounting mechanism as specified by the manufacturer.

• Dust, fog, smoke, etc., can decrease your vision and cause an accident. Stop the machine or decrease the speed until you can see.

• Contact

with high voltage power lines, underground cables, etc., can cause serious injury or death from electrocution.

• Before you drive or operate in an area with high voltage lines, cables, or a power station, tell the power or utility company what you are going to do.

You MUST HAVE THE POWER DISCONNECTED OR KEEP A SAFE WORKING DISTANCE from the lines, cables, or power station. Keep all parts of the machine a safe distance away from the power source. You must also know any federal, state/provincial, or local safety codes or regulations that apply to the job site.

If a part of the machine touches high voltage power: 1. Warn other workers NOT TO TOUCH THE MACHINE and to stay away from the machine.

2. If you can break contact, reverse the operation that caused contact with the high voltage power, and move the machine away from the danger area. If you cannot break contact stay in the machine until the utility company de-energizes the line and tells you that the power is off.

• If you have extreme conditions, such as a fire, or contact with power lines, etc. and you are forced to leave the machine, do not step off the machine.

Jump as far from the machine as possible with your feet together and do not touch the ground with your hands.

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CHAPTER 2 - SAFETY AND SAFETY DECALS

• Do not operate the machine if you do not feel well.

This can be dangerous for you and for the people around you.

MAINTENANCE PRECAUTIONS

• Do not attempt repairs unless trained. Refer to

• You must make a judgment if weather, road, or

manuals and experienced repair personnel for help.

earth conditions will permit safe operation on a hill, ramp, or rough ground.

• Never make repairs on pressurized components,

• Stay away from hazardous areas such as ditches, overhangs, etc. Walk around the work area before you start and look for hazards.

• Be alert and always know the location of all workers in your area. Keep all other persons completely away from your machine. Injury or death can result if you do not follow these instructions.

• Develop fluid and smooth operating techniques and maintain the surface condition where the machine travels in order to control vibration transfer to the operator.

fluid, gas or mechanical until the pressure has been relieved according to proper service procedures in the service manual.

• Before you service the machine, put a DO NOT OPERATE TAG on the key switch. Make sure that the machine is clearly “tagged out”.

• Wear protective glasses and other required safety equipment machine.

when

servicing

or

repairing

the

• Wear gloves to protect hands when handling cable.

• Disconnect the battery before working on the electrical system. Know the consequences of disconnecting any electronic or computer devices.

• Avoid lubrication or mechanical adjustments with the machine in motion or the engine operating. If the engine must be in operation to make certain adjustments, place the transmission in neutral, apply the parking device, place the equipment in a safe position, securely block the wheels and use extreme caution.

• Securely block the machine or any component that may fall before working on the machine or component. If possible, use a back up or secondary blocking device, also.

• To prevent unexpected movement, securely block working elements when repairing or changing working tool parts such as cutting edges.

• Use extreme caution when removing radiator caps, drain plugs, grease fittings or pressure taps.

Park the machine and let it cool down before opening a pressurized tank.

• Release all pressure before working on systems which have an accumulator.

• Use a piece of cardboard, newspaper, or wood to check for pressurized leaks to prevent fluid penetrating the skin. Pressurize accumulators with the proper gas according to the manufacturer’s recommendations.

• When inflating tires, use a self-attaching inflation chuck with remote shutoff and stand clear of the tire. Position yourself beside the tire and not beside the rim.

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• When absolutely necessary to tow the machine, do not exceed the recommended towing speed. Be sure the towing machine has sufficient braking capacity to stop the towed load. If the towed machine cannot be braked, a towbar must be used or two towing machines must be used. - one in front pulling and one in the rear to act as a brake.

Avoid towing over long distances. It is not recommended to tow this machine.

• Observe proper maintenance procedures.

• Whenever servicing or replacing hardened pins, etc., use a brass drift or other suitable material between the hammer and pin. Alternative: Use a brass hammer, drift or suitable material on the pin, etc.

• Keep the brakes and steering systems in good operating condition.

• Replace all missing, illegible or damaged safety signs. Keep all safety signs clean.

FUEL HANDLING PRECAUTIONS

• Do not smoke or permit open flames while fueling or near fueling operations.

BURN PREVENTION WARNING: BATTERY ACID CAUSES SEVERE BURNS. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing.

Antidote: EXTERNAL - Flush with water.

Antidote: INTERNAL - Drink large quantities of water or milk.

DO NOT induce vomiting. Seek medical attention immediately.

EYES - Flush with water for 15 minutes and seek medical attention immediately.

WARNING: BATTERIES PRODUCE EXPLOSIVE GASES. Keep sparks, flame, cigars and cigarettes away. Ventilate when charging or using in enclosed area. Always wear eye protection when working near batteries. Wash hands after handling. KEEP OUT OF REACH OF CHILDREN. Figure 7

• When the battery electrolyte is frozen, the battery

engine powered machines with the engine running or hot. Never allow fuel to spill on hot machine components. Never allow fuel to spill on the environment.

can explode if, you try to charge the battery, or you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured

• To avoid spilling fuel maintain control of the fuel

• Hot coolant can spray out if the radiator cap is

• Never remove the fuel cap or refuel gasoline

filler nozzle when filling the tank.

• Do not fill the fuel tank completely to the top. Allow room for expansion.

• Clean up spilled fuel immediately and dispose of contaminated material in an environmentally correct manner.

• Tighten the fuel tank cap securely. Should the fuel cap be lost, replace it only with the original manufacturer’s approved cap. Use of a non-approved cap without proper venting may result in pressurization of the tank.

• Never use fuel for cleaning purposes.

• Use the correct fuel grade for the operating season.

removed. To remove the radiator cap, let the cooling system cool, turn to the first notch, wait until the pressure is released, then remove the radiator cap.

• Confirm that all components, hydraulic, engine, etc., are cool procedures.

before

attempting

service

HAZARDOUS CHEMICAL PRECAUTIONS

• If you are exposed to or come in contact with hazardous chemicals you can be seriously injured.

The fluids, lubricants, paints, adhesives, coolants, etc., used with your machine can be hazardous.

• Before you service this machine and before you dispose of the old fluids and lubricants, always remember the environment. DO NOT put oil or fluids into the ground or into containers that can leak.

• Check with your local environmental or recycling center or your information.

dealer

for

correct

disposal

TRANSPORTING PRECAUTIONS

• Know the rules, laws, and safety equipment necessary for transporting this machine on a road or highway.

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CHAPTER 2 - SAFETY AND SAFETY DECALS TO UNFASTEN THE SEAT BELT:

ROLL-OVER PROTECTIVE STRUCTURE

• Do NOT modify the ROPS in any manner.

Unauthorized modifications such as welding, drilling, cutting, or adding attachments can weaken the structure and reduce your protection. Replace ROPS if it is subjected to roll-over or damage. Do not attempt to repair.

• The ROPS also serves as a certified Falling Objects Protective Structure (F.O.P.S.). The FOPS provides cab protection from objects falling onto the machine or during forestry work. Avoid hazardous work environments.

To release the seat belt, push the red bar or button on the buckle, while holding the retractable end.

WARNING: Securely fasten your seat belt.

Your machine is equipped with a ROPS cab, ROPS canopy or ROPS frame for your protection. The seat belt can help insure your safety if it is used and maintained. Failure to follow these instructions may result in death or serious injury.

Figure 10

SPECIFIC PRECAUTIONS TO THIS MACHINE

SEAT BELT PRECAUTIONS WARNING: Before starting the engine ensure the seat belt is securely fastened. The seat belt can help insure your safety if it is used and properly maintained. Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members. Failure to follow these instructions may result in death or serious injury.

Figure 8

TO FASTEN THE SEAT BELT:

• Since the tracks are used as steps, always clear debris and dangerous conditions off, before entering or leaving the cab, for operation or service.

• Welding in certain areas of the crawler may require the controller be disconnected and grounded. Contact your Dealer before you weld.

FIRE EXTINGUISHER It is recommended that you have a fire extinguisher on you r ma c hi ne. Fo l low the ma nufa ct ur e r ’s recommendation on the operation and maintenance of the fire extinguisher. The operator shall be familiar with the fire extinguisher’s operation.

Refer to page 6-7 for details on the mounting and type of fire extinguisher.

1 2 BD99J183

Figure 9

1. RETRACTABLE HALF OF THE SEAT BELT 2. BUCKLE HALF OF THE SEAT BELT

Pull the seat belt retractable half (1) across the operator and buckle securely with the buckle half (2).

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SAFETY DECALS WARNING: Replace any missing or damaged safety decals and keep all safety decals clean. See your Case dealer for new safety decals. If you can not read a decal or if a decal is missing, the result can be serious injury or death.

Figure 11

ISO two panel pictorial symbol decals are defined as follows:

• The first panel indicates the nature of the hazard.

• The second panel indicates the appropriate avoidance of the hazard.

• Background color is YELLOW. Prohibition symbols such as

and

STOP

if used, are RED.

Make sure that you read all the safety decals and all instructional decals. Check these decals every day before you start. Clean these decals if they are not legible.

NOTE: When you clean the decals, use only a cloth, water, and soap. Do not use solvent, gasoline, etc.

You must replace a decal if the decal is damaged, missing, or can not be read. If a decal is on a part that is replaced, make sure the decal is on the new part. See your Case dealer for new decals. Part numbers are on the decal.

READ OPERATOR’S MANUAL

READ SERVICE MANUAL

1

2

BC00G075 Figure 12 1. READ THE APPROPRIATE INFORMATION IN THE OPERATOR’S MANUAL 2. READ THE APPROPRIATE INFORMATION IN THE SERVICE MANUAL

384270A1

Figure 13

Figure 14

87706393

These symbols may occupy only a small portion of the main decal, as shown above. If you have any questions regarding operation or service, contact your Dealer.

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1 1

2

2 2

Figure 15 1. 87706390, WARNING: READ OPERATOR’S MANUAL, EXPLOSION HAZARD - RUN OVER HAZARD. 2. 87706393, WARNING: READ OPERATOR’S MANUAL, START ONLY FROM OPERATOR SEAT - RUN OVER HAZARD. (2 LOCATIONS)

BD07K088 / 87706390 / BD07K084 / 87706393

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3 3 4

4

Figure 16

BD07K083 / 87706392 / 87695709

3. 87695709, WARNING: HOT SURFACE, STAND CLEAR. 4. 87706392, WARNING: READ OPERATOR’S MANUAL, FLUID UNDER PRESSURE.

Decals 3 and 4 are located on the front, top of the hood.

5

Figure 17

87715063

5. 87715063, WARNING: DO NOT MODIFY OR REPAIR THE ROPS - READ THE OPERATOR’S MANUAL.

Decals 5 are located on the left and right side of the ROPS, facing away from the operator.

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6

6

6

BD07K101 / 332511A1 / BD07K126

Figure 18

6. 332511A1, WARNING: ENTANGLEMENT HAZARD. 2 DECALS, ONE ON EACH SIDE OF THE ENGINE FAN SHROUD.

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7

7

8

8

Figure 19

BD07K078 / 87706391 / 87706389

7. 87706391, WARNING: READ THE OPERATOR’S MANUAL, ROLLOVER HAZARD - DO NOT JUMP - BUCKLE SAFETY BELT. 8. 87706389, WARNING: READ THE OPERATOR’S MANUAL.

Decals 7 and 8 are located on the front, right side, upper door post.

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9

9

Figure 20

BD07K090 / 877063595

9. 87706395, WARNING: READ THE OPERATOR’S MANUAL, ENGINE RPM CHANGE.

Decal 9 is located just left and above the decelerator pedal.

10 10

Figure 21

BD06K002 / 87347223

10. 87347223, WARNING: PRESSURIZED SYSTEM, READ THE OPERATOR’S MANUAL.

Decal 10 is found on the top of the engine valve cover.

11 11

Figure 22

BD07J115 / 328903A1

11. 328903A1, WARNING: PRESSURIZED SYSTEM, READ THE SERVICE MANUAL.

Decal 11 is located under the right side, front access door just to the rear of the right cab door.

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13

12

12

13

Figure 23

BD07K085 / 87719507 / 87695709

12. 87719507, WARNING: RUN OVER HAZARD, STAND CLEAR. 2 DECALS, ONE EACH SIDE. 13. 87695709, WARNING: HOT SURFACE, STAND CLEAR. 2 DECALS, ONE EACH SIDE.

Decals 12 and 13 are found at the bottom, rear corner of the engine access doors.

14 14

Figure 24

BD07K087 / 71433088

14. 71433088, WARNING: PINCH HAZARD, READ THE SERVICE AND OPERATOR’S MANUAL.

Decals 14 are found below and between the two carrier rollers on the track frame.

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CHAPTER 2 - SAFETY AND SAFETY DECALS

15 15

Figure 25

BD07K086 / 87706396

15. 87706396, WARNING: READ THE OPERATOR’S AND SERVICE MANUAL FOR ADJUSTMENT PROCEDURE.

Decal 15 is found on the left side, threshold of the cab entry.

16

#/$%

Figure 26

87473257

16. 87473257, WARNING: GUARANTEED SOUND POWER LEVEL

Decal 16 is found on the left side, threshold of the cab entry.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

Chapter 3 INSTRUMENTS AND CONTROLS TABLE OF CONTENTS INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 NAVIGATING THROUGH THE LCD MULTI-FUNCTION DISPLAY SCREENS . . . . . . . . . . . . . . . . . . . . . . . 3-9 USING ARROW UP AND DOWN KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 TO RESET THE TRIP INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 BRAKE, DECELERATOR AND FOOTREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 PARKING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 DIRECTION CONTROL LEVER, TRANSMISSION CONTROL, HAND THROTTLE . . . . . . . . . . . . . . . . . . . . 3-14 DOZER BLADE CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 RIPPER CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 SEAT CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 OPERATOR’S SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 TO FASTEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 TO RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

INSTRUMENT PANEL

1

A

2

3

4

5 Figure 1

BD06G109

NOTE: To check the condition of the warning lamps turn the key switch to on. The warning lamps will illuminate for approximately three seconds. If the lamp does not illuminate, replace the bulb.

1. SERVICE SOON LAMP This lamp will illuminate when the machine has been programed to notify the operator of service intervals.The lamp will illuminate and the service message can be read on the digital display.

NOTE: See Operating Instructions in this Manual for programming.

3. REAR WORK LIGHT SWITCH (IF EQUIPPED) This switch has two positions, ON and OFF. To turn ON press the icon. The switch icon will illuminate.

BS98M034

4. FRONT AND REAR WINDSHIELD WIPERS (IF EQUIPPED) This switch has two positions, ON and OFF. To turn ON press the icon.

Figure 2

BC00G075

2. FRONT WORK LIGHT SWITCH (IF EQUIPPED) This switch has two positions, ON and OFF. To turn ON press the icon. Turning the switch on illuminates the instrument face and is confirmed by the illuminated symbol (A). The switch icon will illuminate. Figure 1

0097

0099

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Figure 5

5. FRONT AND REAR WINDSHIELD WASHER (IF EQUIPPED) Push the rocker switch icon to activate the front and rear windshield washer.

Release the rocker switch to stop the front and rear windshield washer.

Figure 3

BS98M034

Figure 4

Figure 6

3-3

CHAPTER 3 - INSTRUMENTS AND CONTROLS

7

6

8

9

10

BD06G109

11 Figure 7

6. RIGHT-HAND AND LEFT-HAND DOOR WINDSHIELD WIPERS (IF EQUIPPED) This switch has two positions, ON and OFF. To turn ON press the icon.

9. DISPLAY - SERVICE/ENTER Use this switch to select between display and service menus or enter selections.

The Diamond icon, or top portion of the switch, is used to select displays.

The 90 Degree Arrow icon, or bottom portion of the switch, is used to enter selected choices.

Figure 8

BC00G12

7. LEFT - HAND/RIGHT-HAND DOOR W I N D S H I E L D WA S H E R S ( I F EQUIPPED) Push the rocker switch icon to activate the left and right door windshield washers. Release the rocker switch to stop the left and right door windshield washer.

Figure 9

BC00B132

8. MENU UP/DOWN Use this UP / DOWN switch to scroll through the menus.

NOTE: Pressing the Service/Enter portion of the switch with the key switch OFF will allow the operator or service technican to monitor the fuel gauge without powering up.

BS02M143 / BS02M144

Figure 11

\

10. HORN Push the switch to activate the horn.

NOTE: The horn has constant power and may be used with the key switch in OFF. Figure 12

BS98M064

11. BLANK PLUG Blank plug provided for options.

Figure 13

NOTE: Push the UP arrow at start up to display engine rpms on the digital display.

BS02M141 / BS02M142

3-4

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CHAPTER 3 - INSTRUMENTS AND CONTROLS 12. KEY SWITCH The key switch has four positions: ACCESSORY POSITION This position energizes the drivetrain controller, accessory switches and instrument cluster.

ENGINE STOP (OFF POSITION) To stop the engine, turn the key to STOP. After the engine has stopped, remove the key.

ENGINE ON (ON POSITION) Turn the key clockwise to ON and check the warning lamps. This is the normal position of the key switch when the engine is running.

ENGINE START (START POSITION) Turn the key completely clockwise to the START position to actuate the starter motor. After the engine starts, release the key. The key will return automatically to ON. BS98M031/RB99J175/RB99J178/RB99J176

12

Figure 14

BD06G110 / 87412595

Figure 15

INSTRUCTIONAL DECAL FOR KEY SWITCH

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

14

15

13

16 17

B

18

Figure 16

BD06G107

13. TRANSMISSION FILTER WARNING LAMP This warning lamp shows the condition of the transmission filter. If the warning lamp illuminates during normal operation, (transmission oil at operating temperature and engine at full throttle), stop the engine and replace the filter.

BS99J182

Figure 17

16. PARKING BRAKE ENGAGED This lamp illuminates when one or both the parking brake levers are pulled ON. The parking brake can be set by pulling either brake handle into the ON position, depressing the brake pedal completely, or letting the machine set in neutral for 30 seconds.

14. CHARGE PRESSURE WARNING LAMP This warning lamp illuminates and warning buzzer will sound if, (1) the engine is stopped and the key switch is on, or (2) there is no or low oil pressure in the transmission. Do not run the machine if the warning lamp illuminates.

BS98M032

Figure 18

17. ALTERNATOR This lamp illuminates when the battery condition drops below proper operating voltage. This lamp illuminates with the key switch in the ON position but should go OUT with the engine running. The gauge (B) should be monitored by the operator.

Figure 21

BS99J181

15. LOW ENGINE OIL PRESSURE This warning lamp illuminates and warning buzzer will sound when the engine is stopped and the key switch is on, or there is no or low oil pressure in the engine. Do not run the engine if the warning lamp illuminates.

BS99J182

Figure 20

BS96H049

18. HYDRAULIC FILTER WARNING LAMP This warning lamp shows the condition of the hydraulic filter. If the warning lamp illuminates during normal operation, (hydraulic oil at operating temperature and engine at full throttle), stop the engine and replace the filter.

Figure 19

Figure 22

BS99J182

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

D 21 22

E

C

23

20

19

Figure 23

BC02J064

19. ENGINE AIR FILTER RESTRICTION This warning lamp illuminates when, the key switch is in the START position or, when the engine air filter element requires service.

22. TRANSMISSION OIL TEMPERATURE WARNING This warning lamp will glow and the warning buzzer will sound when the transmission operating temperature is too high. The temperature should be monitored by watching the gauge (D).

The transmission operating temperature is normal when the gauge needle is in the green area.

Figure 24

20. ENGINE COOLANT TEMPERATURE This warning lamp illuminates and the warning buzzer sounds when the engine coolant temperature is too high. The temperature should be monitored by watching the gauge (C).

The temperature of the coolant is normal when the gauge needle is in the green area.

BS98M048

23. FUEL WARNING LAMP This warning lamp will glow and the warning buzzer will sound for a few moments when the machine is low on fuel.

E.The operator may monitor the gauge with the key switch on, the engine running or by pushing the Service/Enter button with the key switch off. (90 degree arrow icon)

Figure 25

BS96H053

21. TRANSMISSION FAULT This warning lamp illuminates when the transmission controller encounters an error.

Figure 27

BS99J185

Figure 28

NOTE: Contact your dealer if this lamp illuminates.

Figure 26

TRAN_FLT

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

24

1 2

3 A

B

Figure 29

BD99K104

24. LCD MULTI-FUNCTION DISPLAY The LCD Multi-Function Display is located in the center of the modular dashboard. On start up the cluster will flash the instructional lamps and the LCD Multi-Display will flash, CASE, with the machine model.

3. Zone Three: This lower 1/3 of the display is in two sections. Zone A will show fault codes and Zone B wil l s how ad ditio nal and op tional information.

Information will be displayed in three zones on the LCD, as directed by the operator or machine. In most situations the operator or technican will be given specific information to follow if conditions are not correct.

The screen image above is the nor mal driving screen.

1. Zone One: This top 1/3 portion of the display will show the operator messages.

In the example, above, the machine hours are di s p l ayed . Ma c h i n e h o ur s w i l l al way s b e displayed briefly, on start up. After, the machine is started, the display will show engine rpm’s.

After, beginning travel, the machine will display travel speed.

2. Zone Two: This middle 1/3 of the display is dedicated to transmission signals. The example, above, shows the Direction Control Lever in Neutral with the transmission at 60%. 60% is the default speed. When the key switch has been shut off it will default the transmission to this setting.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS NAVIGATING THROUGH THE LCD MULTI-FUNCTION DISPLAY SCREENS

A

C

B

D

Figure 30

BD06F186

KEY PAD

Located on the front console, just to the left of the Horn Switch, is the key pad. Use this key pad to move from one screen to another, choose various selections, monitor the machine functions, and retrieve information.

A. Up arrow key: Use this key to scroll up to selections.

B. Down arrow key: Use this key to scroll down to selections.

C. Escape key: Use this key to exit and return to the driving screen. Use this key anytime you would like to start over and begin again.

D. Enter key: Use this key to confirm, yes, this is what I want.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS USING ARROW UP AND DOWN KEYS At any time, during operation or with the key switch on, the operator may scroll through three information screens and two trip screens by using the arrow keys. These five screens are in a circular loop and may be reached by pressing the up or down key. The following sequence is using the down key only.

From the driving screen push the down arrow.

Figure 33

BD06F184 BD06F183

Figure 31

Info 1 is the first information screen using the down arrow from the driving screen.

Push the down button again and the Info 3 screen will display.

BD06F169

Figure 34

Press the down button again and the Trip 1 screen will display.

BD06F027

Figure 32

Info 2 is the second screen down from the driving screen.

BD06F170

Figure 35

After pushing the down button, the fifth time from the driving screen, will display Trip 2.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS If the operator chooses to use the Up button, from the driving screen, the previous sequences will be reversed.

TO RESET THE TRIP INFORMATION

Trip 2 Trip 1 Info 3 Info 2 Info1

BD06F170

Figure 36

At the Trip screen you wish to re-set.

Press the enter button.

BD06F172

Figure 37

At this screen, press confirm, to clear the numbers and reset the date information.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS 4. TRANSMISSION SPEEDS The transmission speed is selected by the operator. The maximum speed is selectable in a range of 10 increments.The range is controlled by the Transmission UP/DOWN buttons on the Direction Control Lever.

Once the key switch has been shut off it will default the Transmission Speed to 60% as shown below on start up.

Figure 39

BD02M165

TRANSMISSION CONTROL BUTTONS

A

B

Figure 40

BD02M166 BD06G113

3-12

Figure 38

A. TRANSMISSION SPEED UP BUTTON B. TRANSMISSION SPEED DOWN BUTTON

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

BRAKE, DECELERATOR AND FOOTREST

PARKING BRAKES

2 1

3

3 4

4

Figure 42

BD06G115

Figure 41

BD06G114

1. BRAKE PEDAL

4. PARKING BRAKE LEVERS ENGAGED

Push this pedal to slow or stop the machine.

Pushing the pedal all the way down will engage the parking brake.

2. DECELERATOR PEDAL Push this pedal down to reduce the machine speed. This command can reduce the speed all the way to zero by destroking the drive pumps along with decreasing engine RPM.

5

5

NOTE: A good way to control the dozer for precision work is to use the decelerator like the brake pedal on a car with an automatic transmission.

3. LEFT AND RIGHT FOOTREST BD06G116

Figure 43

5. PARKING BRAKE LEVERS DISENGAGED THE MACHINE MAY TRAVEL Both parking brake levers need to be down for the machine to operate. These brakes are spring applied hydraulic released (SAHR).

5

BD06G118

5

Figure 44

NOTE: Any time the crawler is not moving for 30 seconds or more the SAHR brake applies.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

DIRECTION CONTROL LEVER,TRANSMISSION CONTROL, HAND THROTTLE

1 2 3

4

Figure 45

BD06E060

1. DIRECTION CONTROL LEVER This lever controls the forward speed, neutral or reverse speed, as well as turning.

2

To turn, push or pull the lever to the direction you want the crawler to go, in forward or reverse. The crawler will not move unless engine rpms are 1000 or higher.

This lever has detent positions in forward and reverse. The lever will stay in the forward or reverse position until the operator pulls it out. At start up the crawler must be in Neutral for several seconds before it will move.

The Direction Control Lever position will be displayed on the instrument gauge.

2. TRANSMISSION SPEED UP/DOWN BUTTONS Figure 46

BD06E061

B. DOWN BUTTON decrease)

A

B BD02M166

A. UP BUTTON (transmission speed increase)

Figure 47

(transmission

speed

These two buttons change the speed of the crawler from low to high. The maximum speed is selectable in a range of 10 increments. To increase track speed push the upper button. To decrease track speed push the lower button. The operator may choose to hold the appropriate button in the DOWN or UP position to allow the speed to increment. The speed range will be indicated by the needle on the Transmission Speed Gauge.

NOTE: Top speed is limited to 90% from the factory.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS 3. ENGINE HAND THROTTLE Pull the throttle lever BACK to increase the engine speed. Push the throttle lever FORWARD to decrease the engine speed. See the instructional decal located to the right of the throttle.

3 3

4. REVERSE TO CONTROL

FORWARD

SPEED

RATIO

This control dial allows the operator to control the reverse speed in relation to the forward speed.

Rotate the knob clockwise to increase the speed of reverse faster than forward. The knob will stay in the desired position. See the instructional decal located just behind the dial.

4

NOTE: Maximum reverse speed is limited to maximum machine speed. The speed ranges are: 80%, 100%, 115%, and 130% of forward speed.

4

Figure 48

BD02H134 / 8371L92

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

DOZER BLADE CONTROL LEVER 1. THE DOZER BLADE CONTROL LEVER The dozer blade control lever is located on the righthand console. Position A, FLOAT is the only position that the lever will remain in, without the operator holding the lever. In any other position, if the lever is released, the blade will stop and the lever will return to neutral or HOLD.

1

BD06G117

Figure 52

A B BS99J212

Figure 49

A. FLOAT: Float (Detent): This is a detent position. When in the FLOAT (Detent) position, the blade can follow the level of the ground without movement of the control lever.

BS99J213

C

Figure 50 Figure 53

BD06G117

B. LOWER: C. HOLD: The blade will stop moving in the HOLD position.

W he n r el e a s ed , t h e c o n tr o l l ever w i l l r e t ur n automatically to the HOLD position.You must manually move the control lever from the FLOAT position to the HOLD position.

BS99J214

D

Figure 51

D. LIFT:

Figure 54

BD06G117

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

Figure 55

BS99J21

E. TILT LEFT

F

Figure 56

BS99J218

C

F. TILT RIGHT

E

C. HOLD The blade will stop moving when the control lever is in the HOLD position. When released, the control lever will return automatically to the HOLD position.

Figure 57

BS99J217

G. ANGLE LEFT

Figure 59

BD06G117

Rotate the lever counter- clockwise to angle the blade left.

H G Figure 58

BS99J219

H. ANGLE RIGHT Rotate the lever clockwise to angle the blade right.

BD06G117

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Figure 60

3-17

CHAPTER 3 - INSTRUMENTS AND CONTROLS

RIPPER CONTROL LEVER 1

3

2

BD06K001

Figure 61

1. LOWER:

BS99J221

Figure 62

2. RAISE:

BS99J222

Figure 63

3. HOLD: The ripper will stop moving when the control lever is in the HOLD position. When released, the control lever will return to the HOLD position automatically.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR’S SEAT A cloth mechanical seat is standard with a cloth air suspension seat as optional SEAT CONTROLS

1

2

Figure 66

BD02120

Figure 64

BD02H137

1. BACKREST TILT ADJUSTMENT LEVER Located between the left-hand console and the seat on the air suspension and slightly further back for the mechanical suspension seat, see photo below. )

3

A

1

BD02K005

Figure 67

3. OPERATOR COMFORT CONTROL

BD02K003

Figure 65

On the mechanical suspension seat use the control knob/crank (3) and follow the directions on the decal (A). Sit in the seat and adjust the knob/crank until the yellow pointer reaches the end of the adjustment barrel. See photo below.

Lift up the lever, move the backrest forward or rearward, and release the lever. The backrest is locked in that position.

2. FORWARD/REARWARD LEVER

ADJUSTMENT

This bar is located in the same position for both seats.

Pull this bar up and adjust the seat forward or rearward as required. Release the bar to lock the seat in that position.

BD02K006

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Figure 68

3-19

CHAPTER 3 - INSTRUMENTS AND CONTROLS 5. ARM REST CONTOL: Use a 5/8 or 16 mm wrench to adjust the left or right arm rest.

A

Figure 69

BD99J182

On the air suspension seat pull the control knob (A) out to lower the seat. Push in to raise. The key switch must be in the ON position to activate the compressor.

NOTE: Over time there will be some air loss and the operator should re-adjust at the beginning of the work day.

NOTE: Adjust the seat so that you can apply the foot brake when your back is against the seat backrest.

4

Figure 70

BD02H139

4. LUMBAR ADJUSTMENT CONTROL This adjustment is on the left-hand shoulder side for the air suspension seat and on the lower left-hand rear side for the mechanical suspension seat

4

BD02N037

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Figure 71

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

CAB 4

1

Figure 72

BD02K015

Figure 75

BD06G120

1. CAB DOOR RELEASE AND LOCK The cab door may be opened and locked into position.

4. DOME LAMP

5 6

2

Figure 73

BD02K014

Figure 76

BD02H131

5. CLIMATE CONTROL PANEL

2. OUTSIDE CAB DOOR RELEASE The cab door may be released from the locked open position by pulling the lever toward the operator.

This panel controls the temperature and fan functions for the cab. See Operating Instructions in this Manual for specific instructions.

IMPORTANT: Do not operate the heat or air system with the cab vents all closed. Open at least two of the cab vents to operate the heat or air.

6. CAB RADIO-CD PLAYER

3

7. RETRACTABLE SUN VISOR, FRONT

Figure 74

BD06G119

3. INTERIOR CAB DOOR EACH SIDE)

RELEASES

8

(ONE

The cab doors may be released from the locked open position by pulling the knob.

BD02H113

Figure 77

8. RETRACT LEVER FOR SUN VISOR Hold the lever to the right and fold the sun visor back up carefully.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

12

9

11

1

10 Figure 79

BD02F002

1. CAB TILT HYDRAULIC JACK: BD06G124

Figure 78

9. OPERATOR COMFORT VENTS IMPORTANT: Never operate the heat or air system with all vents closed. Open at least 2 vents before operating.

This jack is used to tilt the cab off for service access. The handle for the jack is located under the access door on the left-hand side.

10. 12V AUX POWER SUPPLY 11. CUP HOLDERS 12. ACCESSORY STORAGE (2) ONE EACH SIDE

Figure 80

BD02F028

NOTE: See the Operating Instructions in this Manual for Cab Tilt procedures.

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BD06E064

Figure 81 MASTER DISCONNECT SWITCH LOCATION

The master disconnect switch is located behind the right side access panel.

BD06E063

Figure 84

MASTER DISCONNECT SWITCH IN ON POSITION

WARNING: Batteries produce explosive gases. Keep sparks, flame, and cigarettes away. Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries.

Figure 82

D38-14A

VANDAL LOCKUP ROPS MODEL (Not Shown) Pull the locking plate from its storage position and lock it over the instrument panel to lock the machine from operation.

Figure 83

BD06E065

MASTER DISCONNECT SWITCH IN OFF POSITION

This switch allows the operator or service technican to stop all power from the battery.

0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OFF 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ON

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR’S SEAT BELT The illustrations that follow show the correct procedure to fasten and release the belt.

WARNING: You are protected by the ROPS (Roll-Over Protective Structure) system on this machine. The seat belt is an important part of that ROPS system. Before you operate this machine, always fasten the seat belt. If the machine rolls over and you DO NOT have the seat belt fastened, you can be crushed by the ROPS or the machine. Failure to follow these instructions may result in death or serious injury.

SA080

TO FASTEN Pull the right-hand belt from holder. Fasten the belt end into the left-hand buckle.

Figure 87

BD02M168

RELEASE BAR

Figure 85

BD02M167

Make sure the belt end and buckle are securely fastened. The left-hand receiving end of the belt (buckle) will not pull out.

TO RELEASE There are two releases on the belt.To release the seat belt, push the red button or the red bar on the buckle.

Figure 86

BD99J184

RELEASE BUTTON

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CHAPTER 4 - OPERATING INSTRUCTIONS

Chapter 4 OPERATING INSTRUCTIONS TABLE OF CONTENTS RUN-IN PERIOD OF A NEW MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Track Shoe Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3 4-3 4-3 4-3

ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Walk-Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Parking the Machine and Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 CRAWLER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Before You Start Each Day . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Direction Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Steering Gradual Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Power Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Counter - Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Adjusting Steering Sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Transmission Speed Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Decelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Onboard Diagnostics And Computer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Digital Display And Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Display Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Activating The Service Reminder To (AUTO): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Activating The Service Reminder To (MAN): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Setting The Next Service To (NONE): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Climate Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 MOVING A DISABLED CRAWLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Opening The Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Releasing The Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Lifting The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 OPERATING IN HOT WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 OPERATING IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Coolant Heater (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil Heater (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-22 4-22 4-22 4-23

BOOSTER BATTERY CONNECTION TO MACHINE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 TILTING THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 DOZER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 Blade Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 TRACK SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Components of the Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Components of the Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Factors Controlling Undercarriage Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wear Factors You Can Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Extend the Life of Sealed Track and the Case Lubricated Track (CLT) . . . . . . . . . . . . . . . . . . . . . . .

Case Extended Life Track (CELT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4-28 4-28 4-29 4-29 4-29 4-30 4-30 4-1

CHAPTER 4 - OPERATING INSTRUCTIONS FACTORS CONTROLLING UNDERCARRIAGE WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 Bushing and Sprocket Wear Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34

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CHAPTER 4 - OPERATING INSTRUCTIONS

RUN-IN PERIOD OF A NEW MACHINE ENGINE OPERATION During the first 20 hours of operation, or if you rebuild the engine, make sure you do the following: 1. Operate the machine with normal loads for the first eight hours. Do not work the engine hard at stall speeds (tracks stopped and the engine running at full throttle).

2. Keep the engine at normal operating temperature.

3. Do not run the engine at idle speeds for long periods of time.

BRAKE PEDAL Check the operation of the brake on a hard level surface when the machine is new.

TRACK SHOE BOLTS When the machine is new or if the track shoes have been removed, check the track shoe bolt torque after the first 20 hours of operation with a new machine or if the shoes are removed. Then, check the track shoe bolt torque every 100 hours of operation until the track shoe bolts remain tight. Tighten to a torque of 406 to 447 Nm (300 to 330 lb ft) for the standard link bolts and 430 to 470 Nm (318 to 346 lb ft) for the master link bolts. Do not over tighten the track shoe bolts.

WARNING: Before starting engine, study Operator’s Manual safety messages. Read all safety signs on machine. Clear the area of other persons. Learn and practice safe use of controls before operation. It is your responsibility to understand and follow manufacturers instructions on machine operation, service, and to observe pertinent laws and regulation. Operator’s and service manuals can be obtained from your dealer.

SB055

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4-3

CHAPTER 4 - OPERATING INSTRUCTIONS

ENGINE OPERATION WALK-AROUND INSPECTION Do the following items each day before you start the engine.

1. Check for leaks under the machine.

2. Check track tension and check for loose, missing, or broken parts.

3. Check the machine and equipment (dozer, ripper, etc.) for wear, damage, missing, or broken parts.

4. Check the machine for debris, especially around the engine area and radiator. Make sure these areas are clean.

5. Clean or replace any safety or instructional decals that cannot be read.

6. Clean the steps, hand rails, and operator’s compartment. Remove any loose items in the operator’s compartment.

7. See the Lubrication/Maintenance Chart in this manual and do the items under 10 Hours.

STARTING THE ENGINE NOTE: If the weather is cold, if the machine has not been run for several weeks, or if the engine oil filter has been replaced, see Priming the Turbocharger Lines with Oil in this manual.

6. Turn the key switch to the START position. If the engine star ts and stops, do not engage the starter motor again until the starter motor stops turning.

NOTE: Do not operate the starter motor more than 30 seconds at one time. Let the starter motor cool for three minutes before you engage the starter motor again. While the starter motor is engaged, white or black smoke must be seen at the exhaust pipe. If no smoke is seen, check the fuel supply.

7. After the engine starts, check the instruments to make sure the gauge indications are correct.

Run the engine at 1000 rpm until the coolant temperature is warm.

ENGINE SPEED Do not run the engine at idle speed for long periods.

This can cause a low operating temperature, which can cause acids and deposits in the engine oil. It is recommended that you run the engine at full throttle when operating conditions permit and when safe.

IMPORTANT: Turbocharged Engines: If the engine stalls during normal operation, start the engine immediately. This will prevent damage to the turbocharger.

1. Adjust the seat and fasten your seat belt. Make sure you can push the brake pedal completely down with your back against the seat cushion.

2. Make sure the parking brakes are engaged by pulling both levers all the way back.

3. Make sure the equipment control levers are in NEUTRAL with the equipment on the ground.

NOTE: The Direction Control Lever must be in Neutral or the engine will not crank. N will be displayed on the left side of the Digital Display.

4. Sound the horn to alert those around the machine that you intend to start.

NOTE: See Operating in Cold Weather in this manual for starting the engine during cold weather.

5. Turn the key switch to the ON position. Monitor the display panel for gauge and machi ne functions.

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CHAPTER 4 - OPERATING INSTRUCTIONS PARKING THE MACHINE AND STOPPING THE ENGINE 1. When the work day is finished, make sure the machine is parked on level ground.

6. Make sure the engine is at its lowest idle.

7. Turn the key switch to OFF to stop the engine.

IMPORTANT: If you must temporarily park the machine on a hillside, put the front of the machine toward the bottom of the hill. Make sure the machine is behind an object that will not move.

8. When you park the machine, make sure the track system is clean. In cold weather place the machine on planks. This will prevent the tracks from freezing to the ground.

2. Lower the dozer blade and ripper (if equipped) to the ground.

If your machine is frozen to the ground, do not try to drive the machine. This will cause damage to the power train.

WARNING: Raised equipment on the machine without an operator can cause injury or death. Before you leave the operator’s compartment, always support or lower the equipment (backhoe, blade, boom, bucket, etc.) to the ground and stop the engine.

F N

SA044

R

WARNING: Jumping on or off the machine can cause an injury. Always face the machine, use the hand rails and steps, and get on or off the machine slowly.

SA038

Figure 1

BD06E061

3. Place the Direction Control Lever to N (Neutral).

Figure 2

BD06H010

4. Engage the parking levers by pulling them all the way back to the engaged position.

5. Run the engine at low idle speed for a few minutes if the engine has been working with a heavy load. This decreases the temperature of the engine parts evenly.

IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down.

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4-5

CHAPTER 4 - OPERATING INSTRUCTIONS

CRAWLER OPERATION T h e d r i ve a n d s t e e r i n g a r e c o n t r o l l e d by a microprocessor. The Direction Control Lever sends an electronic signal to the controller. There is no mechanical linkage and therefore an entirely different “feel” and sensitivity will be noticed by the operator.

BEFORE YOU START EACH DAY

Onboard diagnostics allow the operator to monitor the service inter vals and custom tailor Service Messages to the work environment. The operator may also adjust the sensitivity of the machine control by selecting one of three settings through the onboard computer.

Be a careful operator, you can prevent accidents.

Read the following information.

WARNING: Always know the location of all workers in your area. Warn them before you start working the machine. Always keep all other persons away from your area. Serious injury or death can result if you do not follow these instructions.

Figure 3

BD99J183

1. Adjust the seat and fasten your seat belt. Make sure you can push the brake pedal completely down with your back against the seat cushion.

2. Turn the ignition switch to ON and monitor the display gauges.

SA015

F

WARNING: You are protected by the ROPS (Roll-Over Protective Structure) system on this machine. The seat belt is an important part of that ROPS system. Before you operate this machine, always fasten the seat belt. If the machine rolls over and you DO NOT have the seat belt fastened, you can be crushed by the ROPS or the machine.

N R

SA080

WARNING: DO NOT operate the machine while under the influence of alcohol or drugs.

CM112

Figure 4

BD06E061

3. Place the Direction Control Lever in Neutral.

NOTE: N should be seen on the Digital Display.

Figure 5

BD06G113

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CHAPTER 4 - OPERATING INSTRUCTIONS 4. Sound the horn to alert those around that you are starting the machine.

5. Turn the key switch to ON and watch for the engine pre-heat indicator. If the engine pre-heat lamp is ON, wait for it to go out before starting the engine.

6. When the temperature is cold, 0°F (-17°C) and below, see Operating in Cold Weather in this manual.

10. Press the Decelerator Pedal all the way down.

11. Place the Direction Control Lever in F (Forward) and slowly release pressure on the Decelerator Pedal.

NOTE: The crawler will not move if the engine rpm is below 1000.

12. Test the foot brake by operating the crawler forward and pushing the brake pedal. The crawler must stop in a straight line.

NOTE: Pressing the brake pedal all the way down will engage the parking brake.

Figure 6

BD06G118

7. Push the Parking Brake Levers Down into the Disengaged position. Both the right and left levers must be down.

8. Use the Transmission Speed Down Button to place the machine i n a lower speed. The Transmission Speed Gauge will reflect the speed selected.

NOTE: The Transmission Speed will default to the 60% speed each time the machine is shut off.

9. Raise the blade above the ground and make sure the ripper, if equipped, is in the TRANSPORT position.

1

Figure 7

BD02H125

1. DECELERATOR PEDAL 84272799

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4-7

CHAPTER 4 - OPERATING INSTRUCTIONS DIRECTION CONTROL LEVER

F

1

N

R

Figure 9

BD02M019

BD06E061

Figure 8

1. DIRECTION CONTROL LEVER

T h e d r i ve a n d s t e e r i n g a r e c o n t r o l l e d by a microprocessor. The Direction Control Lever sends an electronic signal to the controller. There is no mechanical linkage and therefore the “feel” and “sensitivity” may be significantly different from conventional crawlers.

The Direction Control Lever will detent into Forward or Reverse. The operator must pull the Direction Control Lever out of these positions. See Turning on the this page.

4-8

Push the Direction Control Lever into the position you wish the crawler to go and verify the selection by reading the Digital Display. See Figure 9 above (Neutral shown).

NOTE: The crawler will not move unless engine rpm is above 1000.

To turn the crawler push the Direction Control Lever toward the direction desired. Turning must always be commanded through Forward or Reverse.

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CHAPTER 4 - OPERATING INSTRUCTIONS TURNING Fo r w a r d o r r eve r s e m o t i o n m u s t a l w ay s b e commanded in conjunction with turning. Moving the direction control lever only left or right will result in no motion. Turns must be taken through forward or reverse.

STEERING GRADUAL TURN 1. To turn the crawler to the left push the Direction Control Lever forward and to the eleven o clock position. The crawler will gradually turn to the left.

2. To turn the crawler to the right, push the Direction Control Lever forward and to the one o clock position. The crawler will gradually turn to the right.

Figure 10

B911447JFX

POWER TURN 1. By pushing the Direction Control Lever toward the ten o clock position the crawler will turn sharper to the left with appropriate power to each track.

2. By pushing the Direction Control Lever toward the two o clock position the crawler will turn sharper to the right with appropriate power to each track.

COUNTER - ROTATION 1. To counter-rotate the crawler to the left, push the Decelerator Pedal all the way down, push the Direction Control Lever forward and then straight left to the nine o clock position. Slowly release the Decelerator Pedal.

2. To counter-rotate the crawler to the right, push the Decelerator Pedal all the way down, push the Direction Control Lever forward and then straight right to the three o clock position. Slowly release the Decelerator Pedal.

NOTE: The Steering sensitivity has three settings and may be adjusted for operator or work preference.

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4-9

CHAPTER 4 - OPERATING INSTRUCTIONS ADJUSTING STEERING SENSITIVITY The Direction Control Lever has three sensitivity settings (1,2,3) and will be set at 2 from the factory.

STEER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . Smooth STEER 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normal STEER 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fast To change the sensitivity:

4. Toggle through the setting menu by using the Up or Down arrows (2) until (STEER 2) is shown on the Digital Display.

NOTE: (STEER 2), Normal is the setting from the factory.

5. When, (STEER_#) is on the Digital Display screen press the Service/Enter button (3). The # will blink.

6. Change the # by using the Up or Down arrow (2).

7. After selecting the sensitivity desired press the Ser vice/Enter switch (3) again to store the information.

NOTE: The Settings Menu may be hidden entirely by contacting your Dealer.

1

ADJUSTING SHUTTLE PARAMETER To adjust the Shuttle parameter follow the same steps as for Steering Sensitivity.

Figure 11

BC02M138

1. Press and release the Service/Enter switch (1).

SETTINGS

At step 5: (SHUTTLE _#) At this display where the # is located the value can be 1, 2 or 3. 1 being smooth and 3 being fast.

After selecting desired value press the Service/Enter switch.

2

ADJUSTING MAXIMUM TRANSMISSION SPEED PARAMETER To adjust the Maximum Transmission speed follow the same steps as for Steering Sensitivity.

At step 5: Figure 12

(MAX_SP###) At this display where the ### are located the value can be 70,80,90 or 100.

2. Use the up or down arrow to display the settings menu, (SETTINGS) on the Digital Display.

After selecting desired value press the Service/Enter switch.

BC02M138

STEER 2

3

BC02M138

Figure 13

3. Select the SETTINGS menu by pressing the Service/Enter switch (3).

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CHAPTER 4 - OPERATING INSTRUCTIONS The Digital Display (4) will reflect the position of the Direction Control Lever as Forward, Neutral or Reverse.

TRANSMISSION SPEED CONTROLS

1

NOTE: The crawler will not move unless the engine rpm is above 1000.

NOTE: A flashing F or R indicates the directional control lever must be returned to neutral before movement is allowed.

WARNING: The Direction Control Lever has three sensitivity settings. Be familiar with the setting that best suits the work and operator requirements.

2

Figure 14

BD02M166

1. TRANSMISSION SPEED UP BUTTON 2. TRANSMISSION SPEED DOWN BUTTON

The CASE K Series Crawlers have infinitely variable speeds in Forward and Reverse from 0 to 9.7 km/h (0 to 6.0 mph). The maximum speed is selectable in a range of 10 increments. To move from one speed to another press the UP (1) or DOWN (2) button. The operator may increment up one touch at a time or hold the button to move through the transmission speeds.

NOTE: The speed can only be increased to the maximum transmission speed setting, which can be adjusted. See page 4-9. From the factory 90% is the highest speed.

NOTE: When the crawler engine is shut off the Transmission Speed will default to 60%.

3

4 BD02M019

Figure 15

3. TRANSMISSION SPEED GAUGE 4. DIGITAL DISPLAY

The Transmission Speed Gauge (3) will allow the operator to know which Speed is selected. When the crawler engine is shut off the Transmission Speed will default to 60%, as shown above.

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4-11

CHAPTER 4 - OPERATING INSTRUCTIONS DECELERATOR PEDAL

5

Figure 16

BD02H125

5. DECELERATOR PEDAL

The Decelerator Pedal can be used by the operator to slow or stop the vehicle. It reduces the throttle setting as it is depressed. The decelerator works in any direction, forward or reverse.

Figure 18

383971A1

8

6

9

7 Figure 19

BD06H010

Figure 17 6. REVERSE TO FORWARD SPEED RATIO CONTROL 7. R TO F SPEED RATION CONTROL INSTRUCTIONAL DECAL

BD02M025

This control knob allows the operator to control the reverse speed in relation to the forward speed.

Rotate the knob clockwise to increase the speed of reverse faster than forward. The knob will stay in the desired position.

4-12

8. ENGINE HAND THROTTLE 9. HAND THROTTLE INSTRUCTION DECAL

1. Pull the Throttle Lever back to increase the engine speed.

2. Push the Throttle Lever forward to decrease the engine speed.

NOTE: Always shut the engine down with the throttle at its lowest setting to keep from damaging the turbocharger.

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CHAPTER 4 - OPERATING INSTRUCTIONS ONBOARD DIAGNOSTICS AND COMPUTER OPERATION

1 3 2

Figure 20

BD02M056

DIGITAL DISPLAY AND CONTROL The Digital Display (1) may be used to view Service and Operating Information. By using the Menu Up/Down Arr ow S witc h (2) and the Display Service/Enter Switch (3) the operator or service technician may display fault codes, monitor service schedules or change operating parameters.

DISPLAY MENUS To access the Display Menus:

3. The engine r/min (rpm) display will show, engine r/min (rpm) on the right hand side of the Digital Display, if selected. FNR will show on the left hand side.

4. The Next Service display will show NS on the left hand side of the Digital Display. The right hand side of the Digital Display will show the engine hours until the next service is due. If the service interval has passed the display will show service interval hours in negative numbers -##.#. See example below.

NOTE: A flashing F or R indicates the Direction Control Lever must be returned to neutral before movement is allowed.

1

When The Service Reminder Has Been Activated And Set To (AUTO):

2

1. The operator will be notified when the crawler reaches within 10 hours of the “Next Service” (NS).

2. The Service Soon lamp (1) will illuminate for 5 seconds and the exact information will be on the Digital Display.

3 Figure 21

BC02M13

1. .Press the Up or Down arrow (2) to select the desired display.

2. The driving display will show hour meter reading or engine RPM on the right hand side of the Digital Display. The left side of the display will show the transmission FNR selection.

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3. When the crawler is at NS the service reminder will automatically reset to the next service due.

NOTE: The service reminder message may be custom tailored to your work environment or turned off, if desired. From the factory the service reminder will be NONE.

4-13

CHAPTER 4 - OPERATING INSTRUCTIONS When The Service Reminder Has Been Activated And Set To (MAN):

6. Press the Service/Enter switch (3) to store the information.

1. The operator will be notified when the crawler reaches within 10 hours of the “Next Service” (NS).

NOTE: After changing the Service Interval, the Service Reminder feature must be reset before Next Service (NS) will be updated.

2. The Service Soon lamp (1) will illuminate for 5 seconds and the exact information will be on the Digital Display.

NOTE: Factory default for Service Interval (SI) is 250 hours.

3. When the crawler is at, or goes past NS the Service Soon lamp will remain illuminated and the Digital Display will show negative (-) in front of the hour s unti l the operator or ser vic e technican manually resets the interval.

1 2

3 BC02M138

Figure 22

Resetting The Service Reminder: This procedure will allow the operator or service technican to reset the next service due (NS).

1. Press and release the Service/Enter switch (3).

2. Use the Up/Down arrows (2) to display the service reminder menu, (SERV_RMDR).

3. Select the service reminder menu by pressing the Service/Enter switch (3).

4. The Digital Display will read (RESET?_).

5. Press the Service/Enter switch (3).

The computer will automatically calculate when the next service (NS) is due, based on the Service Interval (SI).

Changing the Service Interval: This procedure will allow the operator or service technican to customize the service intervals.

1. Press and release the Service/Enter switch (3).

2. Use the Up/Down arrows (2) to display the service reminder menu, (SERV_RMDR).

3. Select the service reminder menu by pressing the Service/Enter switch (3).

4. The Digital Display will read (RESET?_).

5. Use the Up/Down arrows (2) to change the intervals, I.E., 50 to 100.

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CHAPTER 4 - OPERATING INSTRUCTIONS ACTIVATING THE SERVICE REMINDER TO (AUTO): 1. Press and release the Service/Enter switch (3) to enter to service menus.

1

2. Use the Up or Down arrow switch (2) to display the service reminder menu, (SERV_RMDR).

2

3. Select the service reminder menu by depressing the Service/Enter (3) switch.

4. Use the Up or Down arrows (2) until (AUTO) is displayed.

5. Press and release the Service/Enter switch (3) and the setting is changed.

3 BC02M138

Figure 23

ACTIVATING THE SERVICE REMINDER TO (MAN): 1. Press and release the Service/Enter switch (3) to enter to service menus.

2. Use the Up or Down arrow switch (2) to display the service reminder menu, (SERV_RMDR).

3. Select the service reminder menu by depressing the Service/Enter switch (3).

4. Use the Up or Down arrows (2) until (MAN) is displayed.

5. Press and release the Service/Enter switch (3) and the setting is changed.

SETTING THE NEXT SERVICE TO (NONE): 1. Press and release the Service/Enter switch (3) to enter to service menus.

2. Use the Up or Down arrow switch (2) to display the service reminder menu, (SERV_RMDR).

Press the Service/Enter switch (3) to select it.

3. Use the Up or Down arrows (2) to display the service interval parameter (SI). Select it by pressing the Service/Enter Switch (3).

4. Use the Up or Down arrow switch (2) to display the “NONE” selection. Press Service/Enter switch (3) to select it.

5. Reset the service reminder using the procedure described above to update NS.

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4-15

CHAPTER 4 - OPERATING INSTRUCTIONS CLIMATE CONTROL PANEL Before activating the heat or air system you must open at least two of the cab vents. Operating the system with vents closed may cause a system malfunction.

1 4 2

BD02K025

3

Figure 24

1. CLIMATE CONTROL PANEL - The Climate Control Panel is located to the left of the radio above the Operator’s head, when sitting in the seat.

2. FAN CONTROL KNOB - Set the 4-speed fan at desired comfort setting. Straight up, as shown, is off. Tur n the fan control knob in one step increments to the right or clockwise to increase fan speed.

3. HEAT - AIR - This control knob has three positions. Off, as shown, is the left most position.

The second position, straight up, is for heat and the third position to the extreme right is for air-conditioning.

4. TEMPERATURE CONTROL - Adjust this knob to control the cab temperature. Red zone is warmer and Blue zone cooler.

IMPORTANT: If your machine is equipped with a water shut-off valve it should be left ON for all temperature operating conditions.

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MOVING A DISABLED CRAWLER WARNING: Personal injury or death can result if you move this crawler incorrectly. Attach a towing machine or block the tracks of the disabled crawler to prevent movement before you release the brakes or relieve pressure. The machine can move out of control if you do not block the tracks. The following instructions are for moving the machine a short distance only.

SÁ129

WARNING: Tow option bypasses high pressure relief valves. Catastrophic hydrostatic motor damage can occur if hydraulic circuit empties or overheats.

If your machine is disabled, you must make a judgment if the machine can be moved without more damage. If possible, repair the machine at the job site. If necessary, contact your dealer.

To move the machine you must: 1. Tilt the cab to access the service area. See tilting the cab in this section on page 4-25.

IMPORTANT: The cab may only be tilted on a hard and level surface.

2. Open pressure relief valves to bypass the hydrostatic motors. (two upper valves for forward movement and two lower valves for rearward movement.

3. Release the brakes.

OPENING THE PRESSURE RELIEF VALVES This instruction is for moving the machine a few feet and no faster than 1.6 km/hr (1 mph). Park the haul trailer as close as possible to the machine.

1. Make sure the machine used for moving the disabled one has the braking capacity, weight, and power to control both machines.

2

2. The towing machine must be equipped with a rear shield to protect the operator if the cable or tow bar disengages. Do not use chain to tow this machine.

3. If required, attach a second machine behind the disabled machine to assist with additional control or braking.

4. Attach a rigid drawbar or cables to the disabled machine.

Figure 26 2. LOWER RELIEF VALVES FOR MOVING THE CRAWLER IN A REARWARD DIRECTION (SHOWN LOOKING TO THE REAR OF THE CRAWLER)

BD02M124

NOTE: The belly pan will have to be removed to access the lower relief valves.

1

Figure 25

BD02M127

1. TOP OR UPPER RELIEF VALVES FOR MOVING THE CRAWLER FORWARD

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BD02N033

Figure 27

5. Remove the relief valve plastic protective caps.

4-17

CHAPTER 4 - OPERATING INSTRUCTIONS RELEASING THE BRAKES This machine is equipped with SAHR (spring applied hydraulically released) parking brakes. Hydraulic pressure must release the brakes. If the engine will not run, you MUST use a hand pump to release the brakes.

1

BD02N036

Figure 28

6. Use a 5 mm allen wrench and turn the engagement screw out three turns on each relief valve.

Figure 29

BD02H050

1. Connect a vacuum pump, if available, to the hydraulic reservoir and hold a vacuum to keep from losing fluid.

2

Figure 30

BD02F009 / 4195

2. Use a 17mm wrench to disconnect the fitting (2) at the brake solenoid and cap it as shown.

2

Figure 31

BD02H057

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Figure 32

BD02M125

CAP INSTALLED

Figure 33

BD02M126

3. Connect a hand pump with the capacity to reach and maintain 2275 kPa, 22.7 bar (330 ±20 psi).

4. Operate the pump until the correct pressure is reached and the brakes are now released.

IMPORTANT: Check and maintain 2275 kPa, 22.7 bar (330 ± 20 psi) maximum in the brake line when moving the machine. Damage to the brake system can result if the pressure is reduced.

5. Remove tools and equipment from the service area and slowly lower the cab to the operating position.

6. The machine is now ready to be moved.

7. After moving raise the cab back up all the way to over center by making sure the retaining cable is fully extended. See Cab Tilt procedure in this manual.

8. Disconnect the hand pump.

9. Remove the plug and reconnect the line to the brake solenoid.

10. Remove the vacuum pump, if used.

11. Tighten the relief valve engagement screws back in carefully until it stops.

12. Install the belly pan if the lower relief valves were used.

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CHAPTER 4 - OPERATING INSTRUCTIONS

TRANSPORTING THE MACHINE WARNING: The machine can slip and fall from a trailer or ramp and cause injury or death. Make sure the trailer and ramp is not slippery. Remove all oil, grease, ice, etc.

Carefully move the machine off or onto the trailer with the machine centered on the trailer and ramp.

SB042

You must know the rules or laws for safety that are used in each area that you will be in. Make sure that your truck and crawler are equipped with the correct safety equipment.

1

Figure 36

BD02M166

9. When moving the crawler off of the trailer, select a slower drive speed by using the Transmission Speed Down button on the Direction Control Lever.

10. Drive slowly and keep the machine centered on the trailer and ramp.

1

WARNING: When moving the machine on or off of the trailer, drive slowly and keep the machine centered on the trailer and ramp.

CM113

B835873F

Figure 34

1. BLOCKS FOR TRAILER WHEELS

1. Put a block on both sides of the trailer wheels.

2. Be careful. Move the crawler slowly onto the trailer. Place the Direction Control Lever in the neutral position.

3. Lower the blade and ripper, if equipped, to the trailer.

4. Put the parking brakes into the engaged position by pulling both levers all the way back.

5. Stop the engine and remove the key.

BD02M052

Figure 35

6. Use chains to fasten the crawler to the trailer.

7. Put blocks at both ends of the tracks.

8. Remove the blocks from the trailer wheels.

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CHAPTER 4 - OPERATING INSTRUCTIONS LIFTING THE MACHINE IMPORTANT: Only personnel with heavy machine lifting experience should attempt lifting the crawler. Contact your Dealer.

Figure 37

BS02N080 / BS02N081

Lifting equipment must be passed around the track evenly front and rear, right and left sides.

IMPORTANT: Lifting equipment and rigging must have a capacity rating sufficient to handle the weight of the machine.

IMPORTANT: All personnel should be clear of the general area before lifting the crawler.

Figure 38

BS02N082

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CHAPTER 4 - OPERATING INSTRUCTIONS

OPERATING IN HOT WEATHER To prevent damage to the machine, do the following: 1. Keep the coolant at the correct level in the coolant reservoir and in the radiator.

2. Test the radiator cap before hot weather starts.

Replace the cap as required.

3. Clean all dirt and debris from the radiator and engine area daily.

4. Check the condition of the fan drive belt.

5. Use lubricants of the correct viscosity.

6. Use the correct solution of ethylene glycol and water in the cooling system.

7. Check the dust valve for the air cleaner more frequently during extreme dust conditions.

8. Check the battery at 250 hours when conditions require.

9. Clean dirt from the precleaner daily.

OPERATING IN COLD WEATHER Cold weather conditions cause special problems.

During these conditions, your machine will require special attention to prevent serious damage. Cold weather maintenance will extend the service life of your machine.

1. BATTERY AND ELECTRICAL SYSTEM: Clean the battery and make sure the battery is at full charge.

NOTE: A fully charged battery at -17°C (0°F) has only 40 percent of the normal starting power.

Then, when the temperature decreases to -29°C (-20°F), the battery has only 18 percent of the power remaining.

If you add water to the battery and the temperature is below 0°C (32°F), make sure you charge the battery or run the engine for approximately two hours. This procedure will prevent battery freezing.

Inspect the battery cables and terminals.

2. LUBRICANTS: Use the correct viscosity oil in each component. As an example: SAE 30 engine oil at 0°C (32°F) increases the starting load by about 250 percent. Make sure you follow the recommended oil and filter service as shown in this manual.

3. FUEL SYSTEM: Check with your fuel supplier for the correct cold weather fuel. Engine power will be reduced if wax particles are in the fuel filters.

4. COOLING SYSTEM: Check the coolant mixture before you operate in cold temperatures. A mixture of 50% ethylene glycol and 50% water must be used in this machine. This mixture is used if the lowest ambient temperature is above -37°C (-34°F). If the ambient temperature is lower, adjust the mixture to 60% ethylene glycol and 40% water. It is recommended that ethylene glycol and water be used in your machine all year.

5. COLD TEMPERATURE STARTING AIDS: See your dealer for extra starting aids such as battery heater, coolant heater, engine oil heaters, etc.

6. GENERAL: Before you operate, move the machine slowly in LOW gear and actuate each hydraulic control for about ten minutes.

When you park the machine, make sure the track system is clean. In cold weather place the machine on planks. This will prevent the tracks from freezing to the ground.

If your machine is frozen to the ground, do not try to drive the machine. This will cause damage to the power train.

WARNING: This machine is equipped with an engine pre-heating system. DO NOT use ether for cold weather starting.

Figure 39

STARTING THE ENGINE 1. See Starting the Engine in this manual and use the correct procedure to start the engine.

2. Turn the key switch to ON and watch the instrument cluster. If the temperature is too low, and engine pre-heating is required the engine pre-heating lamp will illuminate. If the lamp does illuminate, wait until it goes out, before cranking the engine.

3. Place the hand throttle at the 1/2 throttle position and hold until engine starts.

4. Actuate the starter motor.

ENGINE COOLANT HEATER (IF EQUIPPED) The right side of the engine cylinder block is provided with a passage for installing a coolant heater. See your dealer for this option. Follow the heater manufacturers instructions for installing.

Make sure to check for water in the fuel system. Cold temperatures can cause water to collect in the fuel tank. Check the first stage fuel filter for water. If no water is found, extend the interval.

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CHAPTER 4 - OPERATING INSTRUCTIONS ENGINE OIL HEATER (IF EQUIPPED) The engine oil heater is installed on the right side of the engine oil pan. See your dealer for this option.

Follow the heater manufacturers instructions for installing.

1. ENGINE OIL HEATER LOCATION

B830661M

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Figure 40

4-23

CHAPTER 4 - OPERATING INSTRUCTIONS

BOOSTER BATTERY CONNECTION TO MACHINE BATTERY WARNING: Batteries produce explosive gases. Keep sparks, flame, and cigarettes away. Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries.

SA031

Two persons are required for this procedure. Make sure the person making the connection is wearing face protection.

1. Sit in the operator’s seat and have the other person make the connections. Make sure the booster battery is 24 volts.

2. If using another machine for power, make sure the two machines do not touch.

3. Connect the positive (+) jumper cable to the positive (+) battery terminal.

4. Connect the negative (-) jumper cable to a good frame ground away from the battery.

5. See Starting the Engine in this manual and use the correct procedure to start the engine. Have the other person disconnect the negative (-) jumper cable first and the positive (+) jumper cable last.

1

2

BD02J063

Figure 41

1. POSITIVE (+) JUMPER CABLE 2. NEGATIVE (-) JUMPER CABLE

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TILTING THE CAB WARNING: Make sure there are no loose objects in the cab or canopy prior to tilting. Falling objects could cause death and serious injury.

M853

WARNING: The cab may only be tilted when the crawler is on a level and firm surface.

IMPORTANT: The left and right hand ROPS side panels must be OPEN to prevent interference with frame components. The left and right engine compartment panels and cab doors must be CLOSED. 1. Park the machine on a level, and hard surface.

WARNING: Use additional support to hold the cab over if the machine is not on level ground. The operator or service technican must make a judgement if conditions are safe to lilt the cab.

5. Remove the two bolts that attach the brush guard to the canopy, if equipped. (one each side)

2. Engage the parking brakes by pulling both levers all the way back.

3. Open the right and left side panels under the cab.

Figure 42

BD02F033

4. Turn the master disconnect switch to the power off position as shown. (Fig. 20)

Figure 43

BD02F003

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BD02F005

Figure 44

BD02M058

Figure 45

6. Tip the brush guard back and block with suitable hardware to keep it from coming back down into contact with the canopy.

BD02F006

Figure 46

4-25

CHAPTER 4 - OPERATING INSTRUCTIONS 7. Remove the six support mount bolts on the right side of the cab.

Refilling and Bleeding the Tilt System

2

1

Figure 50

BD02F024

Figure 47

BD02F020

8. Turn the pump diverter valve (1) into the cab tilt position. (long portion of the handle to the left of center) Actuate the hand pump and tilt the cab slowly.

1. Make sure that the cylinder rod is fully retracted.

2. Remove the fill check plug (2) and fill with MS-1209 Hy Tran.

3. Tilt and lower the cab two to three times to remove air from the system.

4. If necessary top off with oil and install the fill check plug.

Lowering The Rops Cab Or Canopy

Figure 48

BD02M120

IMPORTANT: Be certain that the cab is tilted clear over to the maximum over center degree and that the retaining cable is tight.

Figure 51

BD02F018

1. Turn the diverter valve to the lower position. (long portion of the handle to five o clock) Actuate the hand pump and lower the cab slowly.

2. Install the six support mount bolts and torque to 550 - 623 Nm (406 - 460 ft lb).

3. If equipped with a brush guard, lower the brush guard into alignment with the cab.

4. Install the bolts and torque to 570 to 730 Nm (420 to 540 ft lb).

Figure 49

BD02M164

RETAINING CABLE

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DOZER OPERATION BLADE PITCH WARNING: Always know the location of all workers in your area. Warn them before you start working the machine. Always keep all other persons away from your area. Serious injury or death can result if you do not follow these instructions.

1

2

SA015

WARNING: You are protected by the ROPS (Roll-Over Protective Structure) system on this machine. The seat belt is an important part of that ROPS system. Before you operate this machine, always fasten the seat belt. If the machine rolls over and you DO NOT have the seat belt fastened, you can be crushed by the ROPS or the machine.

SA080

WARNING: DO NOT operate the machine while under the influence of alcohol or drugs.

CM112

WARNING: Raised equipment on the machine without an operator can cause injury or death. Before you leave the operator’s compartment, always support or lower the equipment (backhoe, blade, boom, bucket, etc.) to the ground and stop the engine.

SA044

WARNING: Jumping on or off the machine can cause an injury. Always face the machine, use the hand rails and steps, and get on or off the machine slowly.

BC00G049

Figure 52

1. REARWARD POSITION (52 DEGREE PITCH) 2. FORWARD PITCH (60 DEGREE PITCH)

Rearward Position Advantages 1. Blade is able to push larger load.

2. Blade will stay on top in soft ground.

3. Blade will not dig into ground.

4. Blade best used for fine grading.

Forward Position Advantages 1. Load slides off the blade as the crawler travels in reverse.

2. Blade will dig into hard ground.

3. Less load spillage over top of blade.

NOTE: See Blade Pitch Adjustment in this manual for adjustment procedure.

BLADE LIFT EYE

SA038

WARNING: Hillside operations can be dangerous. Rain, snow, ice, loose gravel, soft ground, etc., change the ground conditions.

You must make a judgment if your machine can be safely operated on any hillside or ramp.

SB013

The operating tips given in this section do not include all possible conditions. This is basic information that can help you move more material in less time.

If you are a new operator, always operate the machine in an open area at decreased speed until you know the function of each control.

ENGINE SPEED

BD99J147

Figure 53

Do not pull, tow, or lift the machine using the blade lift eye.

Run the engine at full throttle when safe. The ground condition and type of job will control the track speed and range position that you use.

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CHAPTER 4 - OPERATING INSTRUCTIONS

TRACK SYSTEMS

2

3

2

1

4

6

8 7

5 Figure 54

BD06E014

COMPONENTS OF THE UNDERCARRIAGE To fully understand the undercarriage, it is important to understand the purpose of each component. It is also very important to know how the component functions with the other components in the system.

1. IDLER The idler carries the track chain around the front of the track frame. This assembly can slide forward or rearward on the track frame against the recoil spring to absorb any shock loads.

These shock loads can be from changes in the terrain or temporary material buildup on the tracks.

2. CARRIER ROLLERs The roller is mounted on the top of the track frame to support the track chain between the drive sprocket and idler. This roller also helps to maintain alignment of the chain between the idler and drive sprocket.

3. TRACK CHAIN The track chain includes a number of link assemblies that are connected together to form a complete chain. Shoes are bolted to the track chain to provide traction for the machine. The drive sprocket rotates the track chain around the undercarriage assembly.

4. DRIVE SPROCKET The drive sprockets transmit engine power to the tracks. The drive sprockets do not support the weight of the machine.

5. TRACK ROLLERS The track rollers are mounted to the bottom of the track frame. These rollers carry the weight of the machine on the track chain.

4-28

6. TRACK ADJUSTER GREASE FITTING The track adjuster is a grease filled hydraulic cylinder used to maintain or adjust track tension.

To change track tension, add grease or remove grease from the track adjuster.

7. TRACK FRAME The track frames are attached to the machine chassis on each side. All of the track components, except the drive sprockets are attached to the track frames.

8. TRACK LINKS A number of track links make up the track chain assembly. Each link assembly consists of a right-hand and a left-hand link, the track pin is solid with sealed track chains and hollow with (Case Lubricated Track) chains, bushings and seals. Each link assembly is bored at both ends to hold the pins and bushing that connect the two links. The bushing is pressed into each link. A pin is inserted through the bushing and the next set of links is pressed onto the pin. It is important to understand the construction of the track chain. The pins and bushings of the sealed track are generally the first items of the undercarriage to wear. This wear will affect the rest of the components in the system.Wear par ts are not covered under machine warranty.

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9

10 10

Figure 55

BD06E014

9. TRACK SHOES The track shoes are installed on the track chain to give traction and flotation to the machine.

10. TRACK GUIDES To prevent rocks and debris from entering between front roller, idler, and rear roller and sprocket.

FACTORS CONTROLLING UNDERCARRIAGE WEAR Undercarriage wear is an inevitable part of owning a track machine. Sooner or later, even the best undercarriage will need to be replaced.

You can prolong undercarriage life by understanding factors that contribute to wear.

Soil conditions are a major factor in determining the amount of life you can expect from an undercarriage.

Nonabrasive soils, such as silt and clay, cause the least amount of wear. Wet, sandy soils are the most abrasive and cause the most wear.

Severe packing of materials between undercarriage components causes wear by increasing track tension.

NOTE: Running tracks that are too tight reduces bushing and sprocket life 2.5 to 3 times.

Operating techniques and maintenance also greatly affect undercarriage life. Unlike the other wear fac tor s tha t yo u ca n n ot co ntr ol , yo u can d o something about the way you operate and maintain the machine.

NOTE: Avoid spinning the tracks as much as possible, especially in abrasive soil conditions.

NOTE: Avoid long runs at high speed and limit the amount of reverse travel.

NOTE: Avoid frequent reverse operation. If necessary to work in reverse, keep travel speed to a minimum.

Speed impact, turning and direction of operation greatly affect wear.

Working in rocky conditions and other surfaces, where the grousebars do not penetrate, causes high impact and twisting loads on the track chains.

NOTE: When possible, work up and down a slope instead of across it. This decreases wear on roller flanges and link side rails.

Now that you know the major factors contributing to track wear and you are serious about reducing the maintenance and repair of your undercarriage, here are a few operating and maintenance tips to help you get the most life from your machine’s undercarriage.

Check track tension and clean the undercarriage more frequently when working in high packing conditions.

WEAR FACTORS YOU CAN CONTROL NOTE: Minimize the effects of packing by checking track sag frequently when working in mud, snow and wet sand. Packing can cause track jumping and banging.

NOTE: Tracks that are too tight rob power and cause early bushing and sprocket wear. Periodically check tracks for correct tension.

Constantly turning the crawler in the same direction will cause uneven wear.

Use the smallest track shoes possible to minimize track chain twisting. Limit the use of wide track shoes to flotation applications.

Park the machine on level ground to prevent seal distortion (Case Lubricated Track).

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4-29

CHAPTER 4 - OPERATING INSTRUCTIONS Clean the undercarriage more often when operating in freezing conditions and park the machine on planks or a surface that the machine will not freeze to.

HOW TO EXTEND THE LIFE OF SEALED TRACK AND THE CASE LUBRICATED TRACK (CLT) NOTE: Do not turn the pins and bushings at the 100 per cent limit, as on smaller machines.

NOTE: Letting the pins and bushings run to destruction results in accelerated wear of other components. The pins and bushings should be flipped, end to end, with the lube hole remaining DOWN, for proper lubrication. Contact your Dealer or see the Service Manual for this procedure.

CASE EXTENDED LIFE TRACK (CELT) The Cas e E xte nd ed Li fe Track (C ELT) ch ai n incorporates a bushing that is free to rotate on the standard lubricated track bushing. This method allows wear to be distr ibuted over the entir e circumference of the bushing and because the bushing is free to rotate it does not create the scrubbing action between the sprocket and the bushing as the conventional crawler track chain does.

The major reduction in wear on the CELT chain is the exter nal bushing wear caused by the sprocket contact. The CELT bushing rotates with the sprocket.

The wear point is primarily between the outer and inner bushing, and therefore as the chain wears it may become somewhat more “noisy” under certain transporting conditions due to the wear between the inner and outer bushings. This is normal.

Recommended Application T h e C a s e E x t e n d e d L i fe Tr a c k ( C E LT ) i s r e c o m m e n d e d i n h i g h a b r a s i ve / l ow i m p a c t applications where bushing wear is severe. The narrowest pos si ble track shoe that will give ad eq ua te f lo ta ti on s ho ul d b e us e d to o bta i n maximum life from the sealed and lubr icated standard pin and bushing joint. Field testing in abrasive conditions has proven the CELT bushing will obtain up to twice the wear life as the conventional lubricated track bushings.

NOTE: If the machine has sat for extended periods of time or is working in corrosive environmental applications, it is recommended that the bushings be checked before operating the machine. If the bushings will not rotate, they should be loosened using an acceptable tool. This is especially necessary on new chains where the clearance between bushings is minimal.

FACTORS CONTROLLING UNDERCARRIAGE WEAR WEAR FACTORS YOU CAN NOT CONTROL

High Abrasiveness

You can not stop normal undercarriage wear - even if you have the best design and top quality parts. You can however, increase the undercarriage life if you understand the causes of wear. Soil and underfoot conditions can not be controlled. These include abrasive soils, impact, packing and moisture.

These soils contain a high amount of sharp, irregular shaped sand particles.

Abrasive Soils Each type of soil a machine works in has a different level of abrasiveness. Generally, the higher the abrasiveness, the higher the wear rate.

Moisture also plays a major roll in the abrasiveness of soils. A sand slurry will be less abrasive than a damp sand, especially if the sand is packing the sprocket roots and around the bushings. Wet abrasives act like grinding compounds.

Low Abrasiveness Silts and clays are in this category. When wet, this type soil feels slick and can be easily molded.

Moderate Abrasiveness

Impact Impact is best described as the amount of grouser penetration in the ground. The effect of high impact loads can be reduced by reducing the machine speed and by using the smallest track shoes possible.

Low Impact Track shoe grousers will completely penetrate the ground surface with little or no rock or other irregularities.

High Impact Track shoe grousers will not penetrate the ground surface. Large rock or large irregularities cause high impact loads on the undercarriage system. Rocky terrain causes bending, breaking and chipping of the components. Reduce the machine speed and use the smallest track shoes possible.

Silts or clays that contain a low amount of rounded sand particles and enough moisture to stick together, are in this category.

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Track Shoes

Packing materials are any material that sticks to or packs around the moving components. To maintain correct track tension, the tracks must be adjusted as often as required when working in this type of soil condition.

The shoes must provide adequate traction and flotation but must be no wider than absolutely necessary. Flotation is the ability to stay on the surface of soft ground or mud. Correct flotation occurs when the grousers penetrate fully into the ground without letting the track shoes go below the surface.

Packing materials cause a mismatch between components, particularly between the chain and sprocket. The packing materials tighten the chain causing increased stress and strain on links, pins, bushings and the contact surfaces between mating par ts. For example, as mismatch occurs due to packing in the sprocket root, each track bushing rides higher in the sprocket. This condition causes rapid and severe, forward and reverse wear and chain to sprocket “jumping” that is indicated by a loud “banging” noise. This results in high impact loads that causes additional wear and cracking.

This packing condition can also stop rollers from turning. When this happens, the track chain slides over that spot on the roller causing a flat spot.

Packing materials increase the abrasive effect of most material by not allowing the material to escape.

Wear is then accelerated.

When a packing problem continues install relieved track sprockets.

INTERMITTENT PACKING - Packing can also occur between some of the sprocket teeth. When this happens, the track is tightened and released rapidly causing the recoil spring to compress and release. A loud “banging” noise will result.

EXTREME REVERSE LOADING - Dur ing this operation the machine is backing up a hill and the top of both track chains are tight, compressing the recoil springs. You suddenly drive the machine forward.

The loud “banging” noise that you hear can be from one or both recoil springs releasing.

WEAR FACTORS YOU CAN CONTROL Good operating techniques and a good maintenance program will help you to get the longest life from your undercarriage.

Track Tension NOTE: Running tracks that are too tight reduces bushing and sprocket life 2.5 to 3 times.

Check the track tension frequently when you operate.

When wor king in mud, snow and some sandy conditions, check the track tension more often.

Material will pack on the undercarriage parts and cause the tracks to become too tight. Always maintain the correct track tension and always clean the undercarriage when you are done for the day.

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Track shoes that are too wide can have a damaging effect on many of the under- carriage components.

Because the middle of the track shoe is fastened to the track links, the links act as a fulcrum and must absorb or transmit any leverage or twisting forces that occur as the machine moves over uneven or rocky terrain. All of the other components (sprockets, track rollers and idlers) resist and restrict the twisting forces of the links. As a result, most of the wear and damage caused by this twisting action affects the links, pins, bushings and track plate mounting hardware. Listed below are some of the effects of wide track shoes: 1. Resistance to turning - results in wear on the shoe corners and twists the track chain.

2. Bending, cracking or breaking the track shoes, shoe hardware and links.

3. Constant problems with loose shoe hardware that makes the bolt holes larger.

4. Increased wear on links, roller flanges and idler flanges caused by a constant twisting of the track chain.

5. Decreased pin and bushing life or decreased link life due to elongated pin and bushing bores. This is a result of the twisted links.

6. Possible loss of lubricant in the Case Lubricated Track pins. This will result in early pin and bushing wear.

WEAR FACTORS YOU CAN PARTIALLY CONTROL Speed Unnecessary speed directly affects the wear rate on pins, bushings and sprockets. The faster the speed, the faster the wear rate. High s peed rever se accelerates bushing and sprocket wear. Reverse speeds are faster than forward speeds. Wear rate is a function of speed and distance traveled, not just hours worked.

Impact High speed will increase impact loading when there is low grouser penetration on hard surfaces or when working in rock.

4-31

CHAPTER 4 - OPERATING INSTRUCTIONS Impact can cause structural problems such as bending, cracking or breakage of components. This can also affect pin and bushing retention and bushing cracking. And, if a chain is worn, can cause fractures.

Turning Wear rate increases with increased turning. Turning increases interference loads between moving components. Turning in reverse accelerates bushing and sprocket wear due to increased loads transferred from the rotation of the bushings against the sprocket in reverse.

Terrain Changes in the terrain changes the attitude of your machine the same way as the varying machine applications. This condition shifts the center of gravity and increases the weight of the machine on different parts of the undercarriage.

1. Working Uphill - This condition moves the we i g h t o f t h e m a c h i n e r e a r wa r d c au s i n g increased wear of the rear rollers and increases fo r wa r d d r i ve w e a r o f t h e s p r o cke t s a n d bushings.

Track Slip Wear rate on all components increase when tracks are slipping. Track shoe grousers are affected due to increased sliding between the grouser and the ground.

Favored Side Operation Wear rates will increase on all components when only one side of the machine is favored. Wear increases as more power is applied to the favored side. Also, more packing and slippage will occur on the favored side that results in an increased wear rate.

Reverse Operation Avoid excessive use of reverse operation. This is not only nonproductive use of the machine but it also accelerates bushing and sprocket wear. Most speeds are faster in reverse than forward.

Figure 56

912285

2. Working Downhill - The machine weight is moved forward causing increased wear of the front rollers. However, due to the design of the track system, working downhill reduces the wear of the sprockets and bushings.

Applications Application is often used to describe underfoot conditions. In this section application will describe what the machine is doing, without regarding the under foot conditions.

Dozing - This operation shifts the machine weight to the front causing a faster wear rate on the front rollers and idlers.

Ripping - This operation will shift the machine weight toward the rear causing a faster wear rate on the rear rollers. Then, dur ing severe applications, the sprockets and track bushings wear much faster.

4-32

Figure 57

912286

3. Working on the Side of the Hill - This moves the weight of the machine toward the downhill side of the machine. Wear is increased on the rail sides, roller and idler flanges, bushing ends and track shoe ends that are on the downside of the hill.

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CHAPTER 4 - OPERATING INSTRUCTIONS Correct Tension CORRECT TRACK ADJUSTMENT IS THE MOST IMPORTANT FACTOR THAT HELPS TO CONTROL UNDERCARRIAGE WEAR. Track sag of 38 to 51 mm (1-1/2 to 2 inches) must be maintained for all Case crawlers.

IMPORTANT: When operating in packing conditions (mud, snow, etc.) material will stick to the track parts and cause the track tension to be too tight. Check and adjust the track tension often during these conditions.

Figure 58

912287

4. Working on a Crown - The inner components carry the heaviest load. The wear is increased on the inner links, roller treads, idler treads and track plate ends. In extreme situations, the inner sprocket/bushing wear is greatly increased.

The following char t shows track tension (% of tightness). A tight track requires more horsepower to move the machine, increases fuel consumption, and can reduce bushing and sprocket life up to 2.5 to 3 times.

Track Sag Adjustment Chart 100 90% 75% 60% 45% 30% 15% 0% 13 MM (0.5 INCH)

Figure 59

912288

5. Working in a Depression - The outer components carry the heaviest load. The wear is increased on the outer links, roller treads, idler tr e a ds, an d t ra ck p l at e e n ds. I n ex tr e m e situations, the outer sprocket/bushing wear is greatly increased.

912289

38 MM (1.5 INCH)

51 MM (2.0 INCH)

912346

Figure 61

1. TRACK TENSION (PERCENT TIGHT)

High speed reverse operation or long periods of reverse operation also increases track wear.

Figure 60

Clean Tracks W h e n t h e d ay i s f i n i s h e d , a l way s c l e a n t h e undercarriage. Park the machine on a level surface to prevent distortion of the track seals (Case Lubricated Track). If the temperature is cold, park the machine on a surface that will not freeze to the track shoes.

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4-33

CHAPTER 4 - OPERATING INSTRUCTIONS BUSHING AND SPROCKET WEAR CHART The tighter you have the tracks, the faster the wear.

The following char t illustrates the relationship between wear rate and track sag.

NOTE: It is recommended that you flip the pins and bushings at the 100% wear limit. The lubrication hole must be down for proper lubrication. Contact your Dealer or see the Service Manual for this procedure and the Wear Charts.

Figure 62

912347

PERCENT OF WEAR 1.

2.

3.

4.

38 TO 51 MM (1.5 TO 2 INCH) TRACK SAG 25 MM (1 INCH) TRACK SAG 13 MM (0.5 INCH) TRACK SAG HOURS OF USEFUL TRACK LIFE

NOTE: 120% Wear is Running the Track to Destruction.

NOTE: The chart indicates how many less hours of track wear when tracks are operated to tight.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

Chapter 5 LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS GENERAL SAFETY BEFORE YOU SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 SYSTEMGARD LUBRICATION ANALYSIS PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 PLASTIC AND RESIN PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 ENGINE HOURMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 ACCESS DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 AS REQUIRED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 TRACK MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 EVERY 10 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 INITIAL 20 HOUR TRACK SHOE BOLT TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 EVERY 50 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 EVERY 250 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 EVERY 500 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 EVERY 1000 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 EVERY 2000 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

LUBRICATION, FILTERS, AND FLUIDS GENERAL SAFETY BEFORE YOU SERVICE WARNING: Before you begin any service or repair work you must know and understand how to relieve hydraulic pressure properly. Always have tools and attachments down in safe positions.

Figure 1

WARNING: Unless otherwise specified, all machine service should be performed after the machine has been parked safely on firm level ground with all tools and attachments in the safest possible position and the engine shut off.

WARNING: Improper service or repair can cause injury or death. If you do not understand the service procedures for this machine, see your Dealer or the service manual for this machine.

Figure 2

WARNING: Raised equipment on the machine without an operator can cause injury or death. Before you leave the operator’s compartment, always support or lower the equipment (ripper, blade, bucket, etc.) to the ground and stop the engine.

Figure 3

Read the safety decals and information decals on the machine. Read the Operator’s Manual and safety manual. Understand the operation of the machine before you start servicing.

Before you ser vice the machine, put a Do Not Operate tag on the instrument panel. One Do Not Operate tag is included with your machine. Additional tags are available from your dealer.

Lubrication, Maintenance and Service Intervals in this manual are for normal working conditions. If the m ac hi n e i s wor k i n g i n ex t r e m e an d a d ver s e conditions the Service Interval times should be shortened. If you have any question about service intervals contact your Dealer.

Unless otherwise specified, Use the correct safety clothing and safety equipment.

Understand how to use a fire extinguisher and first aid kit.

WARNING: Never open High Pressure Fuel lines.

Figure 4 BD06E067

Figure 6

This accumulator should only be serviced by your Dealer Technician.

Figure 5

321-4614

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

SYSTEMGARD LUBRICATION ANALYSIS PROGRAM

Figure 7

BP97H063

Ask your dealer about our lubr icant analysis program, Systemgard. Through this service, your lubricants are tested in an independent laboratory.

You simply remove a sample of lubricant from your machine and send the sample to the independent S y s t e m g a r d l a b o r a t o r y. A f t e r t h e s a m p l e i s processed, the laboratory will report back to you and guide you with maintenance requirements.

Systemgard can help support your equipment up time and provide you with a service that can pay back dividends when you trade for another piece of Case equipment.

ENGINE HOURMETER Service your machine at the intervals and locations given in the Lubrication/Maintenance Chart. When you service your machine, use only high quality lubricants.

The normal engine oil change interval is every 250 hours of operation. Operating conditions, quality of the engine oil and fuel quality can change this inter val. It is r ecommended that you us e the Systemgard Lubricant Analysis program. See your Dealer.

PLASTIC AND RESIN PARTS Avoid using gasoline, kerosene, paint thinner, etc., when cleaning plastic windows, console, instrument cluster, monitor, gauges, etc. Use ONLY water, mild soap and a soft cloth when you clean these parts.

Using gasoline, kerosene, thinners, etc., will cause discoloration, cracking or deformation of the part being cleaned.

Figure 8

BD02M015

The engine hourmeter shows the amount of actual hours the engine has run. The first number to the right displays tenths of an hour and the remaining numbers to the left display hours. Use the engine hourmeter along with the Lubrication/Maintenance Chart to service your machine at the correct time periods.

Engine hours are displayed with the key switch off or with the engine running, if the operator chooses.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUIDS AND LUBRICANTS Engine Crankcase Capacity with Filter Change .......................................................................................................... 16.5 qt (15.6 L) Capacity w/o Filter.......................................................................................................................... 17.3 qt (16.4 L) Specifications .......................................................................................................... CASE No. 1 API Service CI-4 Fuel Tank Capacity ..................................................................................................................................... 65 gal (246 litres) Cooling System Capacity .........................................................................................................................................8.6 gal (32.5 L) Specifications ............................................................................................. 50% Water and 50% Ethylene Glycol NOTE: If the ambient temperature is lower than -37°C (-34°F), adjust the mixture according to the coolant manufacturer specifications.

Hydraulic Reservoir/Transmission Refill Capacity ..........................................................................................................................................26 gal (98.4 L) Specifications ................................................................................................................ MS-1209, Hy-Tran® Ultra Final Drives Capacity - Each Side ...................................................................................................................... 15 qts (14.2 L) Specifications ........................................................................................................ Case IH 135-H EP Gear Lube Track Roller Capacity - Each Side...................................................................................................................... 0.48 qt (0.45 L) Front Idler Capacity - Each Side...................................................................................................................... 0.49 qt (0.46 L) Carrier Roller Capacity - Each Side...................................................................................................................... 0.31 qt (0.29 L) CLT and CELT Tracks Capacity - Each Pin......................................................................................................................0.95 oz (28.1 ml) Grease Fittings Quantity ............................................................................................................................................. As Required Specifications ............................................................................................................. Case Molydisulfide Grease

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5-5

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART

As Required (AR)

Every 10 Hours

Initial 20 Hours Every 50 Hours

Every 250 Hours

Every 500 Hours

Every 1000 Hours

5-10 5-11 5-11 5-13 5-14 5-14 5-15 5-15 5-16 5-17 5-17 5-18 5-19 5-21 5-22 5-23 5-24 5-25 5-26 5-26 5-26 5-27

See Dealer

Every 2000 Hours

5-28 5-29 5-31 5-31 5-32

Fan and Air Conditioning Drive Belt Clean Tracks Track Chain Tension Cab Air Filters Engine Oil Coolant Reservoir Fluid Level Transmission and Hydraulic Fluid Level Equipment Pivot Points Initial Track Shoe Bolt Torque Radiator Fluid Level First Stage Fuel Filter for Water Equalizer Beam Pivots Engine Oil and Filter Final Drive Oil Level Battery Fluid Level Fuel Filters Crankcase Ventilation Filters Hydraulic Reservoir Breather Relief Valve Fuel Cap Breather Fuel Tank for Water Drive Shaft Slip Spline Final Drive Oil Change Engine Valve Clearance Engine Coolant Engine Air Filter System Hydraulic /Transmission Fluid Change Hydraulic/Transmission Filter Change Reservoir Suction Screen

REPLACE

LUBRICATE

DRAIN

CHANGE

CLEAN

CHECK

SERVICE POINTS

INITIAL

SERVICE INTERVAL

PAGE NUMBER

FREQUENCY IN HOURS

AR AR AR AR 10 10 10

AR

10 20 50 50 50 250 250 500 500 500 1000 1000 1000 1000 1000 1000 2000 2000 2000 2000 Figure 9

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

ACCESS DOORS

1

Figure 12

BD06E015

Figure 10

BD06E016

LEFT REAR COMPARTMENT ACCESS HANDLE

The left and right access doors and left and right engine side panels open by pulling on the handle, as shown.

1. LEFT ACCESS DOOR SUPPORT STRUT

The left and right side access doors are held open by a support strut.

2

Figure 13 2. LEFT UPPER ENGINE ACCESS PANEL SUPPORT ROD

BD06E018

The left and right side engine side panels are held open with a support rod.

Figure 11

BD06E017

The left and right access doors and left and right engine side panels may be locked, as shown.

BD06E019

Figure 14

Make sure that the rod is locked into the position shown before servicing.

To close the upper engine side panels, lift the rod end out of the lock position and close the panel.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

BD06G227

Figure 15

After securing the upper engine side panels open the operator or technician may lift the lower panels up and out for more access.

Figure 18

BD99J173

RIGHT REAR COMPARTMENTS

Figure 19

BD02H098

BD06E020

Figure 16

To access the radiator use a 5/8 or 16mm wrench and remove the two bolts shown.

BD06E021

Figure 17

After removing the two bolts the radiator shroud may be tipped out, as shown.

5-8

IMPORTANT: The right rear access door must be locked into the up position with the support strut, as shown.

Figure 20

BD06G226

Before closing the right rear access door place the support strut into the storage retainer.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

1

Figure 21

BD06E022

1. ENGINE OIL DRAIN PLUG

Use a 21 mm wrench to remove the four bolts that hold the access plate under the engine oil pan.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

AS REQUIRED MAINTENANCE FAN AND AIR CONDITIONING DRIVE BELT Check the condition of the belt as required by machine hours and working conditions. Check for cracking, deterioration and replace as necessary.

1. Park the machine on a level surface and apply the parking brake.

2. Turn the master disconnect to OFF.

BD06E068

Figure 22

3. Install a 1/2 inch breaker bar in the tension pulley bracket.

Push the breaker bar forward just enough to release the tension on the drive belt. Remove the drive belt from the water pump pulley first and then from the other pulleys.

AIR FILTER DUST VALVE

BD02J088

Figure 23

Under normal conditions the dust valve will clear itself. Under certain conditions, it may be necessary to remove the valve and wipe it clean.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS TRACK MAINTENANCE Clean the tracks and undercarriage as required or at the end of the work shift. Park the machine on a level surface to prevent distortion of the track seals. If the temperature is cold, park the machine on a surface that will not freeze to the track shoes.

Check the track tension frequently when you operate.

Check the track tension more often when working in extreme conditions. When material packs and collects on the undercarriage parts the tracks may become too tight.

Correct track adjustment is the most important factor that helps to control undercarriage wear. The correct track sag should always be maintained.

Procedure To Adjust Track Tension 1. Do not clean the tracks before adjustment.

2. Move the machine rearward and forward the length of the track. This will make the bottom of the track tight. Do not use the brakes to stop the machine.

BD06E024

Figure 25

4. Place a straightedge over the track, as shown and measure the track deflection midway between the top roller and the idler wheel. The correct adjustment is between 1 and1/2 to 2 inches (38 to 51 mm).

1

2

Figure 24

BD06E023

1. TRACK CHAIN PIN 2. CARRIER ROLLER

3. Stop the machine so that a pin in the track chain is over the carrier roller.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS To Loosen The Track:

AS REQUIRED MAINTENANCE To Tighten The Track

2

1 Figure 28 2. TRACK ADJUSTMENT BALL CHECK FITTING

Figure 26

BD06E026

1. TRACK ADJUSTER GREASE FITTING

The grease is under extreme pressure. Be careful to back the ball check adjustment off SLOWLY. Wear full coverage face protection before proceeding.

1. Use a 3/4 in deep socket and loosen the ball check fitting, SLOWLY, about two turns. DO NOT r e move t h e a d ap t er. A l low t h e gr e as e t o evacuate until the track deflection is within the proper range.

1

2. Move the machine rearward and forward the length of the track. Do not use the brakes to stop.

3. When complete, re-torque the ball check to 44-55 pound feet.

4. Repeat the procedure for the other track.

BD06E027

Figure 27

1. Put grease into the fitting until deflection is correct.

2. Move the machine rearward and forward the length of the track. Do not use the brakes to stop.

3. Check the deflection of the track again and adjust, if necessary.

4. Repeat the procedure for the other track.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS DOOR HINGES - AS REQUIRED

AS REQUIRED MAINTENANCE Cab Air Filters Check the inter nal and exter nal cab filters as required. Clean or replaced as necessary.

BD06E015

Figure 31

1. Access door hinges . . . . . . . . . . . . 2 per door (6) Figure 29

BD06G123

The internal cab filter is located behind the seat.

Figure 30

BD06G122

The external cab filter is located behind the cab under the rear glass.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

EVERY 10 HOURS Engine Oil Level

Coolant Reservoir Fluid Level

Check the engine oil level ever y 10 hour s of operation or once each day. Always check the oil level with the engine stopped and the machine on level ground.

Specification . . . . . . . . 10W30 Case No. 1 engine oil

Check the coolant reservoir fluid level every 10 hours of operation, when the coolant is cold and the engine is stopped. Do not remove the radiator cap during this check. The coolant level must be between the FULL and ADD marks on the reservoir. Add coolant as required to the coolant reservoir.

To get an accurate measure of the engine oil level, make sure to push the engine oil level dipstick completely down before removing.

2

A mixture of 50% ethylene glycol and 50% water must be used in this machine. This mixture is used if the lowest ambient temperature is above -37° C (-34° F). If the ambient temperature is lower, adjust the mixture to attain a lower freeze point using the freeze point-concentration chart on the label of your antifreeze concentrate. Never use a coolant solution containing more than 60% glycol. It is recommended that ethylene glycol and water be used in your machine all year.

IMPORTANT: After you fill the cooling system, mix the ethylene glycol and water completely by running the engine at operating temperature for approximately five minutes. This procedure must be done when the machine is in temperatures below 0° C (32° F).

1

BD06E029

Coolant Solution

Figure 32

1. ENGINE OIL DIPSTICK 2. ENGINE OIL FILL TUBE

1

BD06E028

Figure 33

Follow the instructions on the dipstick and add oil if necessary.

Figure 34

BD06E030

1. COOLANT RESERVOIR

Extreme engine conditions When continual 40 degree plus, downhill operation, is performed the engine will require 1.0 qt. (0.9 liter) of additional oil added to the crankcase.

Returning to normal 40 degree and less severe applications will require the additional 1.0 qt. (0.9 liter) of oil to be drained off.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 10 HOURS

GREASE EQUIPMENT PIVOT POINTS

Hydraulic / Transmission Fluid Level Check Specification . . . . . . . . . . . MS-1209 Hy-Tran® Ultra

Dozer Specification . . . . . . . . . . Case Molydisulfide Grease

Check the oil level every 10 hours of operation or each day, whichever occurs first.

NOTE: Check the oil level of the hydraulic reservoir only when the machine is level, front mounted equipment is on the ground, the ripper, (if equipped) is on the ground, and the engine is stopped.

3

1

2

1 4

Figure 38

BD06E033

1.

2.

3.

4.

Angle cylinder, closed end . . . . . . . 2 (1 ea. side) Angle cylinder, rod end . . . . . . . . . 2 (1 ea. side) Tilt cylinder. . . . . . . . . . . . . . . . . . . 2 (1 ea. end) Center pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Figure 35

BD06E031

1. HYDRAULIC / TRANSMISSION OIL RESERVOIR SIGHT GAUGE

The hydraulic / transmission oil reservoir sight gauge is located behind the right-rear access door.

5

The oil level must be up to the FULL COLD mark.

Figure 36

5

6 7

8

2 BD02F026

5.

6.

7.

8.

Figure 39

Lift cylinder, rod end. . . . . . . . . . . . 2 (1 ea. side) Lift cylinder, closed end . . . . . . . . . 2 (1 ea. side) C-Frame Pivot . . . . . . . . . . . . . . . . 2 (1 ea. side) Equalizer beam pivot . . . . . . . . . . . . . . . . . . . . .1

Figure 37

BD06E032

2. HYDRAULIC RESERVOIR FILL TUBE

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

INITIAL 20 HOUR TRACK SHOE BOLT TORQUE

EVERY 10 HOURS

Check the torque of the track shoe bolts after the first 20 hours of operation with a new machine or if the shoes have been removed.

9 3

1

2

4 Figure 40

BD06E035

9. C - Frame pin . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Front fitting only.

10 Figure 43

BD06E072

Tighten the bolts in the sequence shown for the standard track shoe.

Tighten the standard link bolts 300 to 330 pound-feet (406 to 447 Nm) and 318 to 346 pound-feet (430 to 470 Nm) for the master link bolts. Do not over tighten.

Figure 41

BD02J017

10. Ripper lift cylinder . . . . . . . . . . . . . 2 (1 ea. side)

11

BD06G225

Figure 42

11. Pivot beam adjuster . . . . . . . . . . . . . . . . . . . . . .2

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

EVERY 50 HOURS RADIATOR COOLANT LEVEL

DRAINING WATER FROM FUEL FILTER

Check the radiator coolant level at the sight gauge every 50 hours of operation when the coolant is cold and the engine is stopped. The coolant must be seen in the sight gauge.

Check the first stage fuel filter for water and sediment every 50 hours of operation.

DO NOT remove the radiator cap for this check.

1. Rotate the drain valve to the left (counterclockwise) and drain any water and sediment from the first stage fuel filter. Tighten the valve.

1

1

2

Figure 44

BD06E036

Figure 46

1. SIGHT GAUGE

NOTE: If the radiator coolant level is low and the coolant reservoir level is at the FULL mark, check for air leaks in the hose between the radiator and coolant reservoir.

1. FUEL FILTER 2. DRAIN VALVE

WARNING: Hot coolant can spray out if radiator cap is removed. To remove radiator cap: Let system cool, turn to first notch, then wait until all pressure is released. Scalding can result from fast removal of radiator cap.

Check and service engine cooling system according to maintenance instructions.

SA023

3

Figure 45

Figure 47

BD02K022

3. FUEL TANK DRAIN PLUG

2. If water or sediment are found in the filter it will be necessary to drain any water and sediment from the fuel tank.

WARNING: Be careful to not spill fuel into the environment. Follow all local and federal regulations in regard to disposal of waste fuel and oils.

Figure 48

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5-17

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 50 HOURS EQUALIZER BEAM LUBRICATION

BD06E035

Figure 49

Every 50 hours of operation grease the equalizer beam end bushings. 2 fittings (1 ea. side)

BD06E066

Figure 50

Every 50 hours of operation grease the center equalizer beam bushing. 1 fitting, shown above.

Rear fitting only.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

EVERY 250 HOURS ENGINE OIL AND FILTER Change the engine oil and engine oil filter every 250 hours of operation. Change the engine oil more frequently than every 250 hours when the engine operating conditions are severe (frequent stopping and starting and high or low engine temperatures).

Specification ............................................................................................................................ Case No. 1 Engine Oil ENGINE LUBRICATION AND ENGINE OIL SELECTION Case No. 1 Engine Oil is recommended for use in your Case Engine. Case Engine Oil will lubricate your engine correctly under all operating conditions.

If Case Multi-Viscosity Engine Oil is not available, use only oil meeting API CI-4 engine oil service category.

NOTE: Do not put Performance Additives or other oil additive products in the engine crankcase. The oil change intervals given in this manual are according to tests with Case lubricants.

NOTE: Use of an engine oil pan heater or an engine coolant heater may be required when operating temperatures are in Winter or Arctic conditions.

NOTE: The use of low viscosity oils, such as 10W-30 can be used to aid in starting the engine and in providing sufficient oil flow at ambient temperatures below - 5°C (23°F). The continuous use of low viscosity oils can decrease engine life due to wear.

See the chart below for recommended viscosity at ambient air temperature ranges.

Figure 51

BP97H064

Oil Viscosity/Temperature Ranges

Figure 52

BS99N019

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 5. Apply a thin layer of clean grease or oil to the gasket of the new oil filter.

EVERY 250 HOURS Oil Change and Filter Replacement NOTE: For more complete removal of foreign material, change the engine oil while the engine is still warm from operation.

Park the machine of firm, level ground. The old oil and contaminants will drain better if the engine is slightly warm.

Use a 21 mm wrench and remove the four bolts that secure the engine oil access plate under the engine.

1. Before draining the oil, have a container that will hold the suitable quantity.

Figure 53

BD02K002

6. Turn the new oil filter onto the base until the gasket makes contact with the base. Continue to tighten the filter for 3/4 turn with your hand.

IMPORTANT: Do not use a filter strap wrench to install the oil filter. An oil filter strap wrench can cause a leak if the filter is dented.

IMPORTANT: Clean all dirt and foreign material from the front engine guard a minimum of every thirty days. Dirt will cause rust on the engine oil pan and a loss of engine oil.

7. Install the drain plug. Tighten the drain plug to a torque of 68 to 82 Nm (50 to 60 lb ft).

Overtightening can damage the oil pan. Install the guard plate.

8. Put new oil into the engine oil fill tube.

9. Before you start the engine, prime the turbocharger oil lines with oil. See the following topic.

1

10. Start the engine and run at idle speed. Check the engine oil filter for leaks. After two minutes, stop the engine, wait for 2 or 3 minutes, and check the engine oil level with the dipstick

BD06E022

Figure 54

2. Remove the engine oil drain plug (1).

3

BD06G228

Figure 55

3. Turn the oil filter (3) counterclockwise to remove.

Discard the filter.

4. Use a clean cloth and wipe the sealing surface of the oil filter base to remove all dirt or gasket material.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Planetary Drive Ends

EVERY 250 HOURS FINAL DRIVE OIL CHECK Check the Final Dr ive oil ever y 250 hours of operation.

Specification . . . . . . . Case IH 135-H EP Gear Lube

2

Park the machine on a level surface. Stop the engine.

1

BD06E071

Figure 57

2. PLANETARY FILL AND CHECK PLUG

Check the fluid in each planetary. Oil should just run out of the plug, when removed for inspection. If necessary, add fluid.

BD06E046

Figure 56

1. FILL AND CHECK PLUG

1. Remove the check plug (1) slowly to release the pressure. Oil should be to the top of this plug orifice on both sides.

2. If necessary, add oil to the final drive through the fill plug (1).

3. Install the fill plug.

Repeat steps 1 through 4 for the other final drive.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

EVERY 500 HOURS BATTERY FLUID LEVEL

CLEANING THE BATTERIES

WARNING: Before you service a battery, always wear face protection, protective gloves and protective clothing. Battery acid or battery explosion can cause serious injuries.

SA046

Figure 58

Check the fluid level of the batteries every 500 hours of operation.

Specification . . . . . . . . . . . . . . . . . . . . . distilled water

Check the batter ies and batter y compar tment regularly for dirt, corrosion and damage. Dirt mixed with electrolyte or moisture on the top of the batteries can cause a discharged condition in the batteries.

Use one of the following methods to clean the batteries.

1. Use Case Battery Saver, Part Number M20376.

Follow the instructions on the container. This cleaner does not need water.

Use baking soda or ammonia and flush the outside of the batteries with water. If you do not have Case Battery Saver, use other special cleaners to prevent corrosion on the battery terminals.

WARNING: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote EXTERNAL: flush with water.

INTERNAL: drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately.

EYES: flush with water for 15 minutes and get prompt medical attention.

BD06E047

Figure 59

Figure 61

SB032

BATTERIES LOCATED BEHIND LEFT ACCESS DOOR

If the fluid level is low, add clean or distilled water to each cell until the fluid level is at the split ring at the bottom of each cell opening.

In extreme heat conditions check battery fluid every 250 hours.

If the temperature is 32°F (0°C) or below and you have added water to the batteries, do the following; Connect a battery charger to the batteries or operate the machine for approximately two hours. This procedure is necessary to mix the water with the electrolyte.

WARNING: Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: 1. When you DISCONNECT the battery cables, always disconnect the negative (1) battery cable first.

2. When you CONNECT the battery cables, always connect the negative (-) cable last.

3. Do not short circuit the battery posts with metal items.

4. Do not weld, grind, or smoke near a battery.

SB034

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 500 HOURS

7. Open the shutoff valve.

FUEL FILTER REPLACEMENT

8. Remove the air from the fuel system.

Replace the fuel filters every 500 hours of operation.

REMOVING AIR FROM THE FUEL SYSTEM Air must be removed from the fuel system if one or more of the following conditions occurs: A. If the engine stops because of no fuel in the tank.

B. If the fuel filters are replaced.

C. If the fuel system is serviced.

D. If the machine has been in storage.

1. If necessary, fill the fuel tank.

2. Make sure the fuel tank shutoff valve is in the ON position.

Figure 62

BD06E040

1. Close the fuel shutoff valve. (shown in open or flow position).

3. Loosen the air bleed screw (1) on the filter head 1 or 2 turns.

2 1 Figure 63

BD06E029

2. Clean the filter heads and the outside area around the fuel filters.

Figure 65

BD06E041

1. AIR BLEED FITTING 2. HAND PRIMER

2 1 1 Figure 64

BD06E037

3. Loosen the drain valve (1) and drain the first stage filter.

4. Remove both the first and second stage filters.

5. Apply a thin layer of clean oil to the gasket of each new filter.

6. Install the new filters. Use your hands to tighten the filters 1/2 turn after the filter makes contact with the filter head.

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Figure 66

4. Operate the hand primer until fuel with no air bubbles flows from around the air bleed screw.

5. Tighten the air bleed screw.

6. Start the engine and check for fuel leaks.

5-23

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 500 HOURS IN LINE FILTER REPLACEMENT Replace the in line filter after 500 hours of operation.

BD06E042

Figure 67

Place the new filter in the correct direction for fuel flow.

CRANKCASE BREATHER FILTERS

BD06J138

Figure 68

The crankcase breather is located at the left rear top of the engine.

Clean the area around the breather box and remove the cover to access the two filters.

Replace the filters every 500 hours of operation.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

EVERY 1000 HOURS HYDRAULIC RESERVOIR BREATHER Clean the hydraulic reservoir breather and relief valve every 1000 hours of operation.

1. Park the machine on firm level ground and turn the engine off.

BD06E045

Figure 71

6. Clean the valve with a cleaning solvent.

7. Wear full coverage face protection and use compressed air, to dry the valve 8. Install the breather and close the access door.

Figure 69

BD06E043

1. HYDRAULIC RESERVOIR BREATHER AND RELIEF VALVE

2. Open the access door and secure it in the open position.

3. Clean the area around the breather and relief valve.

4. Remove the valve.

Figure 70

BD06E044

5. Remove the clamp that secures the cover.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 1000 HOURS

FUEL TANK BREATHER

DRIVE SHAFT SLIP SPLINE

Clean the fuel cap breather every 1000 hours of operation or if the breather becomes covered with dirt and debris.

Grease the drive shaft slip spline every 1000 hours of operation. The cab must be tilted to access the drive shaft spline.

Specification . . . . . . . . . . Case Molydisulfide Grease NOTE: Universal Joints are Lubricated for life.

1. SLIP SPLINE . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1

BD06E050

Figure 74

1. Remove the fuel cap.

2. Clean the fuel cap and breather with cleaning solvent.

BD06E048

Figure 72

DRAIN WATER AND SEDIMENT FROM FUEL TANK

3. Wear full face protection and use compressed air to dry.

4. Install the fuel cap.

Every 1000 hours of operation, or more frequently in some regions, drain the fuel tank to check for water and sediment.

1

BD02K022

Figure 73

1. FUEL TANK DRAIN PLUG

Have a suitable container ready to capture fuel for inspection and slowly remove the drain plug.

If water is found in the fuel tank the fuel filters should also be checked.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 5. Fill the final drive with new oil until it just begins to run from the check plug. Install the plug.

EVERY 1000 HOURS FINAL DRIVE OIL CHANGE Change the oil in the final drives every 1000 hours of operation.

Specifications . . . . . Case IH 135-H EP Gear Lube

6. Install the fill plug and repeat the procedure for the other side.

PLANETARY DRIVE ENDS

Park the machine on a firm level surface and stop the engine. If possible, drain the final drives when the oil is warm to help remove contaminants.

1

1

2

BD06E071

2

Figure 77

1. FILL / CHECK PLUG 2. DRAIN PLUG Figure 75

BD06E046

1. FILL / CHECK PLUG 2. FINAL DRIVE DRAIN PLUG

1. Clean the areas around the fill /check and drain plugs. The drain plugs are located under the housing.

2. Remove the fill/check plug (1) slowly.

1. Clean the areas around the fill / check and drain plugs.

2. Slowly remove the drain plug and drain into a suitable container.

3. After draining replace the drain plug and fill with oil until it just begins running out of the fill / check orifice.

4. Repeat the procedure for the other side.

3

Figure 76

XXXX

3. FINAL DRIVE DRAIN PLUG (ONE EACH SIDE)

3. Have a suitable container ready and slowly remove the drain plug. Drain the oil completely.

4. Replace the drain plug.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

EVERY 2000 HOURS CLEANING COOLING SYSTEM Specifications . 50% ethylene glycol and 50% water Coolant Capacity . . . . . . . . . . . . . . 18.9 litres (5 gal) Drain, flush, and replace the engine coolant every 2000 hours of operation or each year whichever occurs first. Clean the system and replace the coolant if the coolant becomes dirty or has the color of rust.

Coolant Solution A mixture of 50% ethylene glycol and 50% water must be used in this machine. This mixture is used if the lowest ambient temperature is above -37° C (-34° F). If the ambient temperature is lower, adjust the mixture to attain a lower freeze point using the freeze point-concentration chart on the label of your antifreeze concentrate. Never use a coolant solution containing more than 60% glycol. It is recommended that ethylene glycol and water be used in your machine all year.

Figure 78

BD06E020

1. Remove the two bolts that secure the door and tip it out, as shown below.

IMPORTANT: After you fill the cooling system, mix the ethylene glycol and water completely by running the engine at operating temperature for approximately five minutes. This procedure must be done when the machine is in temperatures below 0° C (32° F).

WARNING: Hot coolant can spray out if radiator cap is removed. To remove radiator cap: Let system cool, turn to first notch, then wait until all pressure is released. Scalding can result from fast removal of radiator cap.

Check and service engine cooling system according to maintenance instructions.

1

Figure 79

BD99J218

1. RADIATOR DOOR

SA023

If possible, drain the cooling system when the coolant is warm. DO NOT remove the radiator cap if the coolant is hot.

Figure 80

BD06E051

2. Loosen and remove the radiator cap.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS AIR FILTER SYSTEM

EVERY 2000 HOURS

Change the air filter elements every 2000 hours of operation or each year. Always replace both elem ents if the air r estr ic tion indic ator lam p illuminates and stays on after start up or during operation.

2

1 Figure 81

BD06E053

2. RADIATOR DRAIN VALVE

3. Place a container of suitable capacity under the drain valve and drain the radiator. The radiator drain is located under the left side of the radiator.

4. After all the coolant is removed, close the drain valve.

Figure 82

BD06G224

1. AIR FILTER RESTRICTION INDICATOR LAMP

5. Add a cleaning solution to the cooling system and fill the cooling system with clean water.

Follow the directions included with the cleaning solution.

The air filter indicator lamp should illuminate briefly on start up and then should go out.

6. After you drain the cleaning solution, flush with clean water.

2. Pull the cover clamp (1) of the air cleaner cover out and rotate counter clockwise. Remove the end cover.

7. Check the hoses, elbow, and water pump for leaks.

Replacing the Engine Air Filter Elements: 1. Open the access panel.

8. Make sure that the outside of the engine and radiator is clean.

9. Fill the cooling system slowly until the coolant level is up to the top of radiator opening.

1

NOTE: Allow the venting of entrapped air when filling the cooling system until you have the correct quantity of coolant in the system.

10. Install the radiator cap.

2

11. Fill the coolant reservoir up to the FULL mark on the reservoir.

12. Make sure all persons are clear of the machine.

Start the engine and increase the temperature of the engine coolant. When the coolant is at operating temperature, stop the engine and allow to cool. Check the coolant level at the coolant reservoir only. Do not remove the radiator cap.

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BD06E055

Figure 83

1. CLAMP 2. END COVER

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 6. Install a new secondary element.

EVERY 2000 HOURS

7. Install a new primary (outer) element. Make sure the element has full gasket contact.

8. Install the end cover.

9. Make sure other persons are clear of the machine. Start the engine and check the air filter warning lamp.

3

IMPORTANT: Each time you service the air filter system make sure both filters are seated properly and the cover is secure.

TURBO PRECLEANER (OPTIONAL) The optional turbo precleaner requires no service.

Figure 84

BD06E056

3. PRIMARY (OUTER) ELEMENT

3. Carefully remove the primary (outer) element.

4

BD06E057

Figure 85

4. SECONDARY (INNER) ELEMENT

4. Remove the secondary element.

BD06E058

Figure 86

5. Use a clean damp cloth and clean inside of the filter body.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 2000 HOURS

1

HYDRAULIC/TRANSMISSION SYSTEM FILTER AND FLUID CHANGE Ever y 2000 hours of operation the hydraulic / transmission system must be serviced.

Specifications . . . . . . . . . . MS-1209, Hy-Tran® Ultra Refill capacity with filters . . . . . . . .20 gal (75.7 litres) T h e fo l l o w i n g changed/cleaned.

components

should

be

• clean hydrostatic and equipment suction screens • change hydraulic and transmission filters • change hydraulic/transmission fluid WARNING: Hydraulic fluid or grease injected into your skin can cause severe injury or death. Keep your hands and body away from any pressurized leak. If fluid is injected into your skin, see a doctor immediately and have the fluid removed.

Figure 87

SA024

2

BD02J102

Figure 89

1. HYDRAULIC FILTER 2. TRANSMISSION FILTER

4. Clean the gasket surface on the filter heads with a clean cloth, make sure all dirt and gasket parts are removed.

5. Put clean oil on gasket of the new filters.

6. Turn the filters clockwise until the gasket makes contact, then tighten an additional 1/2 turn.

Hydraulic / Transmission Fluid Change 1. Make sure the oil is warm.

2. Lower the equipment to the ground and stop the engine.

1

3. Put a Do Not Operate tag on the instrument panel.

4. Have a suitable container that will hold the quantity of fluid.

5. Loosen hydraulic fill cap slowly.

Figure 88

BD06J139

1. HYDRAULIC FILTER INDICATOR LAMP

NOTE: If machine is new or any part of the hydraulic or transmission system has been serviced, replace the filter at 250 hours for the first and second filter change.

Hydraulic / Transmission Filter Change 1. Open the side access door.

2. Clean the outside of the filters and filter heads with cleaning solvent.

3. Rotate the filters counterclockwise and remove them. Dispose of the used filters in accordance with local and state regulations.

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BD02M047

Figure 90

6. Remove the drain plug and remove all fluid from the reservoir.

7. Replace the drain plug.

8. Tilt the cab and clean the reservoir suction screens.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Suction Screen Cleaning

1 1

Figure 93

BD06E059

Figure 91

BD06E053

9. Remove the filler cap.

1. SUCTION SCREENS

1

1. FILLER CAP

10. Put new MS-1209, Hy-Tran® Ultra fluid into the reservoir.

2

11. Install the filler cap.

3

12. Operate the hydraulic equipment and transmission at 20% with no load and then check the oil level.

13. Add oil as required. Check for leaks.

BD06E052

Figure 92

1. FRONT HYDROSTATIC CHARGE SUCTION SCREEN 2. REAR HYDROSTATIC CHARGE SUCTION SCREEN 3. EQUIPMENT HYDRAULIC SUCTION SCREEN

Remove the fittings and pull the screens through and service or replace as necessary.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Chapter 6 MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS WELDING ON THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 ROLL-OVER PROTECTIVE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Maintenance and Inspection of ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Damage to the ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 MACHINE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 ADJUSTING THE RIPPER SHANKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 DOZER BLADE PITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Rearward Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Forward Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Type of Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Inspection and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Storage Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Removal From Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 REAR ATTACHMENT TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

MAINTENANCE AND ADJUSTMENT WELDING ON THE MACHINE Whenever carrying out a welding operation on the crawler as authorized by the manufacturer and in accordance with correct procedures: 1. Disconnect the batteries.

2. Disconnect the alternator B+ and D+ terminal wires.

3. Disconnect the following connectors.

BD06E073

Figure 3

1. REMOVE THE FOUR SCREWS AND EXPOSE THE CONTROLLER MODULE

1

Figure 1

BD02M046

4. This connector is located under the left access panel just under the left fuse block.

PICT1224

Figure 4

6. Remove the ether continuator, if installed.

NOTE: Cab models have the deutch connectors located slightly higher than the ROPS machines.

2

7. Connect the welding apparatus ground cable to the component on which the welding operation is to be performed.

IMPORTANT: Welding in certain areas of the crawler may require that the controller itself be disconnected and grounded. Contact your dealer.

Figure 2

BD06E075

5. This connector is located under the left access panel in the upper right corner, just above the cab retaining cable.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

ROLL-OVER PROTECTIVE STRUCTURE Your machine is equipped with an operator Protective Structure, such as: a Rollover Protective Structure (ROPS) or Falling Object Protective Structure (FOPS) or Cab with ROPS. A ROPS may be a cab frame or a two-posted or four-posted structure used for the protection of the operator to minimize the possibility of serious injury. The mounting structure and fasteners forming the mounting connection with the machine are part of the ROPS. Th e P r o t ec t i ve S t r u c t ur e i s a s p e c i al s a fe ty component of your machine.

DO NOT atta ch any devic e to the Pr otec tive Structure for pulling purposed DO NOT drill holes to the Protective Structure.

The Protective Str ucture and interconnecting components are a certified system. Any damage, fire, corrosion or modification will weaker the structure and reduce your protection. If this occurs, the Protective Structure MUST be replaced so that it wi ll p r ovi de t he sa me p ro tec ti on as a new Protective Str ucture. Contact your Dealer for Protective Structure inspection and replacement.

Before you operate this machine, always make sure that the ROPS and operator’s seat belts are correctly installed.

WARNING: You are protected by the ROPS (Roll-Over Protective Structure) system on this machine. The seat belt is an important part of that ROPS system. Before you operate this machine, always fasten the seat belt. If the machine rolls over and you DO NOT have the seat belt fastened, you can be crushed by the ROPS or the machine.

SA080

DAMAGE TO THE ROPS After an accident, fire, tip or roll over, the following MUST be performed by a qualified technician before returning the machine to field or job site.

• The Protective Structure MUST be replaced.

• The mounting or suspension for the Protective Structure, operator seat and suspension, seat belts and mounting components and wiring within the operator’s protective system MUST be carefully inspected for damage.

• All damaged parts MUST be replaced.

321-6931

Figure 5

Before you operate this machine, always make sure that the ROPS and operator’s seat belt is correctly installed.

MAINTENANCE AND INSPECTION OF ROPS 1. Check the torque of the ROPS mounting bolts. If necessary, tighten the bolts to the correct torque.

See ROPS Torque Specifications in this manual.

2. Check the operator’s seat and the mounting parts for the seat belt. Tighten the bolts to the correct torque. See “OPERATOR’S Seat” in this manual. Replace the parts that have wear or damage.

3. Check for cracks, rust, or holes in the ROPS and ROPS parts. Age, weather, and accidents can cause damage to the ROPS and ROPS parts. If you have any doubt about the ROPS system, see your Case dealer.

SEAT BELT The seat belt is an important part of your ROPS. You must wear the seat belt at all times when you operate the machine.

6-4

DO NOT WELD, DRILL HOLES, ATTEMPT TO STRAIGHTEN OR REPAIR THE PROTECTIVE STRUCTURE. MODIFICATION IN ANY WAY CAN REDUCE THE STRUCTURAL INTEGRITY OF THE STRUCTURE WHICH COULD CAUSE DEATH OR SERIOUS INJURY IN THE EVENT OF FIRE, TIP, ROLLOVER, COLLISION OR ACCIDENT. WARNING: Do not modify ROPS in any manner. Unauthorized modifications such as welding, drilling, cutting or adding attachments can weaken the structure and reduce your protection. Replace ROPS if subjected to roll-over or damage. Do not attempt to repair.

SB026

WARNING: If you operate this machine without a ROPS and the machine rolls over, you can be injured or killed. Remove the ROPS only for service or replacement. Do not operate this machine with the ROPS removed.

SA027

WARNING: Adding additional weight (attachments, etc). to the machine can cause injury or death. Do not exceed the gross weight printed on the ROPS label.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS WARNING: Improper ROPS inspection or maintenance can cause injury or death. Do the recommended ROPS inspection shown in this manual. If you must replace the ROPS, ROPS parts, or ROPS mounting hardware, use only the replacement parts shown in the Case parts catalog for this machine.

SA029

WARNING: Before you start the engine, always sit in the operator’s seat, fasten the seat belt, apply the parking brake, and make sure the transmission direction control is in NEUTRAL. Give a warning to all persons around you that you are starting the engine.

MACHINE CLEANING It is recommended that the complete machine be kept clean. Machine operation in water, mud, dust, landfill, land clearing or forestry will require complete machine clean up. Cleaning includes periodically removal of inspection covers and guards to gain access for cleaning and removal of dirt or debris.

Clean all dirt and foreign material from the front engine guard. Dirt will cause rust on the engine oil pan and the loss of engine oil.

After cleaning is complete, install ALL covers and guards.

DO NOT operate machine with covers or guards removed.

WARNING: Replace all covers or guards after servicing or cleaning the machine.

NEVER operate the machine with covers or guards removed.

SB037

TORQUE SPECIFICATIONS

CM115

Seat 33.9 to 47.4 Nm (25 to 35 lb ft) - 2 per side

ADJUSTING THE RIPPER SHANKS

Seat Belt Mounting Bolts - Both Sides 46.7 to 54.2 Nm (34 to 40 lb ft) - both sides ROPS Mounting Bolts - Both Sides 203 to 237 Nm (150 to 175 lb ft) - both sides

1 2 BC02M137

Figure 6

1. Remove the retaining clip (1).

2. Drive the pin (2) out and adjust the shank to the position desired.

3. Replace the pin and retaining clip.

The ripper shanks have three positions. Use the appropriate depth for the working condition.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

DOZER BLADE PITCH ADJUSTMENT 1. Raise dozer blade up approximately 100 mm (4 in).

6. The cover guard may be used as a tool to turn the turnbuckle.

2. Release the dozer blade control lever and shut the engine off.

7. Replace the cover guard and retaining pin.

3. Remove the ignition key and set the parking brakes.

WARNING: Be careful with this procedure and raise the blade only high enough to make the necessary adjustment.

REARWARD POSITION BLADE PITCHED REARWARD When dozer blade is pitched in the rearward position, the blade will be able to push a larger load. Blade will stay on top in soft ground.

REARWARD POSITION ADVANTAGES 1. Blade is able to push a larger load.

2. Blade will stay on top in soft ground.

3. Blade will not dig into the ground.

4. Blade best used for fine grading.

FORWARD POSITION BLADE PITCHED FORWARD

BD02J077

Figure 7

4. Remove the retaining pin to release the cover guard.

When dozer blade is pitched in the forward position, the load slides off of blade as crawler travels in reverse. Blade will dig into hard ground.

FORWARD POSITION ADVANTAGES 1. Load slides off of blade as the crawler travels in reverse.

2. Blade will dig into hard ground.

3. Less load spillage over top of blade.

BD02J079

Figure 8

5. Adjust the turnbuckle clockwise or counter clockwise until the desir ed pitch angle is reached.

BD02J078

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) TYPE OF FIRE EXTINGUISHER It is recommended that you have a fire extinguisher on your machine. The fire extinguisher shown below is available from your dealer and can be installed on the machine.

This dry chemical fire extinguisher has a 5 pound capacity and is approved for Class A, B and C type fires. The operating temperature is from -54° to 49°C (-65° to 120°F).

DO NOT mount the Fire Extinguisher on any part of the ROPS or FOPS structure. DO NOT make any modifications to the ROPS or FOPS structure.

INSPECTION AND CARE EVERY MONTH - It is recommended that you inspect the fire extinguisher once each month for damage and to insure that the gauge is working correctly.

E VE RY 6 M O NTH S - H ave th e dr y c h e mi c al removed and refilled by a fire equipment technician.

ONCE EACH YEAR - Have the fire equipment technician inspect the fire extinguisher.

Figure 10

BD02M057

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

MACHINE STORAGE STORAGE PREPARATION

REMOVAL FROM STORAGE

If the machine is to be in storage for more than 30 days, park the machine inside a building. If a building is not available, park the machine in a dry area on planks and cover the machine with a waterproof covering.

Do not start the engine until steps 1 through 13 have been done.

1. Wash the machine.

2. Lubricate the machine at all grease fittings.

3. Paint any area where the paint has been damaged.

1. Change the fuel filters.

2. Put coolant in the engine cooling system.

3. Check the condition of the drive belt. Replace if required.

4. Check the engine oil level.

5. Check the hydraulic oil level.

4. Drain the fuel tank.

6. Check the transmission oil level.

5. Put approximately 8 litres (2 U.S. gallons) of diesel flushing oil in the fuel tank. Run the engine until the exhaust smoke is blue white.

7. Check the final drives oil level.

8. Lubricate the machine at all grease fittings.

7. Put 15 ml (one teaspoon) of Shell Oil Company VPI crystals in the fuel tank.

9. Use petroleum base solvent and remove the Case Rust and Corrosion Preventive from the hydraulic cylinder rods, equipment valve spools and transmission valve spools.

8. Move all hydraulic controls to relieve any pressure in the hydraulic circuits.

10. See Battery Service in this manual. Install the battery.

9. Change the engine oil and replace the oil filter.

11. Fill the fuel tank.

6. Drain the flushing oil from the fuel tank.

10. Drain the cooling system. Leave the drain valves open and do not tighten the radiator cap. Put a Do Not Operate tag on the instrument panel.

11. Clean the primary element for the air filter.

12. Cover the exposed cylinder rods, equipment valve spools, and transmission valve spools with Case Rust and Corrosion Preventive (Par t Number B17510).

12. Remove the air from the fuel system. See Removing Air from Fuel system in this manual.

13. If the machine is equipped with a turbocharger, you must prime the turbocharger oil lines with oil.

See Priming the Turbocharger in this manual.

14. Start the engine. It is important that you refer to the procedure on Starting the Engine in this manual.

13. Charge the battery. Remove the battery from the machine and put the battery on a wooden pallet in a cool dry area. If possible, keep the battery in a building where the temperature is above freezing 0°C (32 F). Make sure the battery is clean.

NOTE: Check the battery periodically for the correct electrolyte level. Test the electrolyte with a hydrometer. When the hydrometer reading is near 1.215, charge the battery.

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REAR ATTACHMENT TORQUE VALUES

Figure 11

BD02J032

Ripper ........................................................................................................................705 to 1265 Nm (520 -930 ft lb)

Figure 12

BD02M132

Drawbar . . . . . . . . . . 705 to 1265 Nm (520 -930 ft lb)

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BD02M171

Figure 13

Hitch . . . . . . . . . . . . 430 to 485 Nm (315 to 355 ft lb)

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

NOTES

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CHAPTER 7 - ELECTRICAL

Chapter 7 ELECTRICAL TABLE OF CONTENTS ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessory Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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ELECTRICAL SYSTEM BATTERY SAFETY

BATTERY SERVICE

WARNING: Batteries give off explosive gases. Keep all open flames, sparks and cigarettes away. Ensure adequate ventilation when charging batteries or when using in a confined place. Always protect your eyes when working near batteries.

2 1

SAFETY_ID_1C02

WARNING: Do not reverse battery terminals. Connect positive cable ends to positive (+) terminals and negative cable ends to negative terminals (-).

SAFETY_ID_1C02

WARNING: When the battery electrolyte is frozen, the battery can explode if, (1) you try to charge the battery, or (2) you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.

SA033

WARNING: Before any operation on the components of the electrical circuit, put the key switch in the shut down position. When disconnecting the battery cables, always disconnect the negative (-) cable first. When reconnecting the battery cables, always connect the negative (-) cable last.

SAFETY_ID_1C02

WARNING: Connecting auxiliary cables wrongly or short-circuiting batteries terminals can cause an accident. Connect auxiliary starting cables as per the following instructions.

SAFETY_ID_1C02 SB034

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BD06E047

Figure 1

1. NEGATIVE BATTERY CABLE 2. POSITIVE BATTERY CABLE

NOTE: The electrical system in this machine is 24 volts negative ground.

Before you service components of the electrical system, always disconnect the NEGATIVE (-) battery cable.

Dir t, moisture, and corrosion on the battery will discharge the battery. Clean the battery with Case Battery Saver and Cleaner. Follow the instructions on the can.

Disconnect the alternator wires if you must run the engine with the battery wires disconnected.

Before you use an electric welder, disconnect the alternator wires, instrument cluster, and turn the master disconnect switch to OFF. Do not use a steam cleaner or cleaning solvent to clean the alternator.

BATTERY VENTS Keep the battery vents clean, make sure the vents are not restricted.

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CHAPTER 7 - ELECTRICAL

FUSES AND RELAYS

Figure 2

The fuses and relays are located behind the left rear access panel. To remove the fuse covers press on both sides at the release clip and pull the cover off.

87580675

Figure 3

See the fuse decal located under the access door.

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CHAPTER 7 - ELECTRICAL ACCESSORY OUTLETS There is one 12 volt accessory outlet behind the seat, on the right-hand side of the machine.

Figure 4

BD06G124

1. 12 VOLT ACCESSORY OUTLET BEHIND OPERATOR IN CAB

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CHAPTER 7 - ELECTRICAL

NOTES

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CHAPTER 8 - SPECIFICATIONS

Chapter 8 SPECIFICATIONS TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Power Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Track System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Tractor Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Tractor Shipping Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 TRANSPORT LENGTH AND WIDTH WITH BLADE FULLY ANGLED 25 DEGREES . . . . . . . . . . . . . . . . . . . . 8-5 OPERATING DATA AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 OPERATING DATA AND DIMENSIONS - RIPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

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SPECIFICATIONS ENGINE NOTE: All specifications are given according to SAE Standards or Recommended Practices where the specification applies.

Make and Model .............................................................................................................................Case, 667TA/EDJ Firing Order ..............................................................................................................................................1-5-3-6-2-4 Bore and Stroke ..................................................................................................... 4.09 in x 5.20 in (104 x 132 mm) Displacement ...................................................................................................................................... 409 in³ (6.7 L) Compression Ratio ............................................................................................................................................ 17: 1 Horsepower, Max. Rated Gross @ 2200 rpm...................................................................................... 130 hp (97 kw) Torque, Max. Peak Gross@ 1400 rpm ........................................................................................... 434 lb ft (589 Nm) Engine Speeds High Idle ........................................................................................................................................ 2350 ± 50 rpm Rated Speed .......................................................................................................................................... 2200 rpm Low Idle ....................................................................................................................................... 900 to 1100 rpm Engine Gradability ...................................................................................................................... 45 degree maximum HYDRAULIC SYSTEM Main Relief Pressure ................................................................................................................ 2974 psi (20500 kPa) Load sense Relief......................................................................................................................2364 psi (16300 kPa) The pressure seen at the diagnostic port is load sense Relief.

Pump Capacity .................................................................................... 20.3 gal/min @ 3000 psi @ 2000 engine rpm TRAVEL SPEEDS Speeds Forward ..........................................................................Infinitely variable from 0 to 9.6 km/h (0 to 6.0 mph) Speeds Reverse ..........................................................................Infinitely variable from 0 to 9.6 km/h (0 to 6.0 mph) Track Pull (Maximum / Both Tracks....................................................................................... 213,514 N (48,000 LBF) POWER TRAIN Transmission - Make....................................................................................................................................... Rexroth Transmission - Type .................................................................................................................. Dual Path Hydrostatic Pumps - Model ..............................................................................................................................................AA4VTG Pumps - Type.............................................................................................................................. Variable Axial Piston Pumps - Displacement ....................................................................................................................................... 90 cc Motors - Model.................................................................................................................................................AA6VM Motors - Type..................................................................................................................................Variable Bent Axis Motors - Displacement...................................................................................................................................... 107 cc Transmission Filter - Type ............................................................ 2 micro replaceable with 100 mesh suction screen Steering Brakes ........................................................................................................................................Hydrostatic Parking Brakes ...............................................................................................Spring Applied Hydraulically Released Final Drives................................................................... 2 Helical Gear Reductions with Planetary Output Reduction NOTE: Track speed and track pull are with CLT chain. If machine is equipped with CELT chain speed will be reduced 4% and track pull will be increased 4%.

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CHAPTER 8 - SPECIFICATIONS TRACK SYSTEM Track Adjustment .......................................................................................................................................... Hydraulic Track Frame Suspension .........................................................................Pivot Shaft and Oscillating Equalizer Beam Height of Track Shoe Grouser .........................................................................................................52.5 mm (2.07 in) Track Gauge XLT .............................................................................................................................................. 1778 mm (70 in) WT & LGP ..................................................................................................................................1981.2 mm (78 in) Track Rollers Per Side ............................................................................................................................................... 7 Length of Track on Ground (With Standard CASE Lubricated Track)........................................2590.8 mm (102.0 in) Length of Track on Ground (With Optional CASE Extended Life Track) ....................................2570.5 mm (101.2 in) Number of Track Shoes Per Side ............................................................................................................................43 Number of Carrier Rollers Per Side All Models ........................................................................................................ 2 Ground Pressure with CLT chain XLT (70 “Gauge / 120 “Blade w/ 508 mm (20 in) shoe)............................................................ 46.9 kPa (6.80 psi) XLT (70 “Gauge / 120 “Blade w/ 610 mm (24 in) shoe).............................................................39.7 kPa (5.76 psi) XLT (70 “Gauge / 132 “Blade w/ 508 mm (20 in) shoe).............................................................47.2 kPa (6.84 psi) XLT (70 “Gauge / 132 “Blade w/ 610 mm (24 in) shoe).............................................................40.0 kPa (5.80 psi) WT (78 “Gauge / 120 “Blade w/ 508 mm (20 in) shoe ..............................................................46.2 kPa (6.70 psi) WT (78 “Gauge / 120 “Blade w/ 610 mm (24 in) shoe) .............................................................39.4 kPa (5.72 psi) WT (78 “Gauge / 132 “Blade w/ 508 mm (20 in) shoe ..............................................................46.5 kPa (6.75 psi) WT (78 “Gauge / 132 “Blade w/ 610 mm (24 in) shoe) .............................................................39.7 kPa (5.76 psi) WT (78 “Gauge / 132 “Blade w/ 762 mm (30 in) shoe) .............................................................32.5 kPa (4.72 psi) LGP (78 “Gauge / 132 “Blade w/ 864 mm (34 in) shoe .............................................................29.2 kPa (4.23 psi) NOTE: If machine is equipped with optional CELT chain ground pressure will be 0.7 kPa (0.1 psi) greater.

CASE Lubricated Track (CLT)...................................................................................................................... Standard CASE Extended Life Track (CELT) ................................................................................................................ Optional XLT = Long Track WT = Wide Track LGP = Low Ground Pressure TRACTOR OPERATING WEIGHT Operating weight includes ROPS, full fuel and hydraulic tanks, 170 lb (77 kg) operator, CLT chain, front pull hook, rear retrieval hitch, track guides, backup alarm, horn and lights on cab, not ROPS. Track shoe and blade width as shown.

1150K LT 20 in shoes 120 in blade

1150K WT 30 in shoes 132 in blade

1150K LGP 34 in shoes 132 in blade

Lbs

27 735

28 902

29 365

Kg

12 578

13 107

13 317 Figure 1

TRACTOR SHIPPING WEIGHT Shipping weight includes base unit weight w/o ROPS, 15 gallons fuel, full hydraulic system, front pull hook, retrieval hitch, side shields, backup alarm, horn, and lights on cab, not ROPS. Base Unit

1150K LT 70 in gauge

1150K WT 78 in gauge

1150K LGP 78 in gauge

Lbs

19 405

19 700

19 700

Kg

8 908

8 934

8 934 Figure 2

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CHAPTER 8 - SPECIFICATIONS

TRANSPORT LENGTH AND WIDTH WITH BLADE FULLY ANGLED 25 DEGREES

BS02K072

Figure 3

Blade width

A Transport width

B 650K w/o Drawbar

120 in (2489 mm)

111.0 in

2815 mm

211.9 in

5382 mm

132 in (2642 mm)

121.9 in

3096 mm

214.6 in

5452 mm Figure 4

NOTE: Add 9.4 in (240 mm) for drawbar. Add 46.8 in (1188 mm) for ripper.

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CHAPTER 8 - SPECIFICATIONS

OPERATING DATA AND DIMENSIONS

Figure 5

BS06C239

A. Top of Exhaust Stack ...............................................................................................................112.1 in (2849 mm) B. Blade Height ..............................................................................................................................44.1 in (1119 mm) C 1. Ground Clearance at Belly Pans ..............................................................................................14.9 in (379 mm) C 2. Ground Clearance at Drawbar..............................................................................................17.6 in (448 mm) C 3. Center line of Drawbar Opening.......................................................................................20.6 in (524 mm) D. Shank Height (Transport Position) ...............................................................................................13.5 in (343 mm) E. Top of Seat Head Rest ...............................................................................................................94.7 in (2045 mm) F 1. Height of Cab with Air Conditioning.....................................................................................111.38 in (2829 mm) F 2. ROPS Height.....................................................................................................................111.0 in (2822 mm) NOTE: Ground clearance and overall height dimensions are with the Grouser fully penetrated per SAE J1234.

Add 52.5 mm (2.06 in) if machine is on solid surface.

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CHAPTER 8 - SPECIFICATIONS

A B C D Figure 6

BS02K101

A. Length, no blade, no rear equipment and CLT chain ...........................................................142.2 in (3 611.5 mm) B. Overall Length, blade straight, no rear equipment ..................................................................188.4 in (4 786 mm) C. Overall Length, blade straight, w/drawbar........................................................................... 197.9 in (5 025.8 mm) D. Overall Length, blade straight, w/ripper...................................................................................235.2 in (5 973 mm) NOTE: Overall Length is with blade pitch at 57.5 degrees. If blade pitch is adjusted to 55 degrees, length will decrease 12 mm (0.47 in).

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CHAPTER 8 - SPECIFICATIONS

OPERATING DATA AND DIMENSIONS - RIPPER Overall Width (Maximum) ................................................................................................................................ 67.4 in Width of Cut (Maximum) .................................................................................................................................. 64.4 in Dig Depth (Maximum) ...................................................................................................................................... 18.8 in Ground Clearance (lowest position transport) .................................................................................................. 11.9 in Number of Teeth (Standard) ...................................................................................................................................... 3 Number of Teeth (Maximum) .................................................................................................................................... 3 Torque (rear mounted equipment) ............................................................................. 705 to 1265 Nm (520 -930 ft lb)

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CHAPTER 9 - INDEX

Chapter 9

INDEX A Access Doors ............................................. 5-7, 5-19 Accessory Outlet ................................................. 7-5 Adjustable Cab Dome Light ............................... 3-21 After Delivery Check ................................. 10-1, 10-3 Air Filter Restriction Lamp ................................... 3-7 Air Filter System Warning Lamp ............................................... 5-29

B Backrest Tilt Adjustment Lever .......................... 3-19 Battery Cleaning ........................................................ 5-22 Fluid Level ..................................................... 5-22 Safety .............................................................. 7-3 Service ............................................................ 7-3 Vents ............................................................... 7-3 Before You Start Each Day ................................. 4-6 Blade Lift Eye .................................................... 4-27 Booster Battery Connection to Machine Battery 4-24 Brake Release for Towing ................................. 4-18 Bushing and Sprocket Wear Chart .................... 4-34

Crawler Operation ................................................4-6 Before You Start Each Day ..............................4-6 Power Turn .......................................................4-9 Steering Gradual Turn ......................................4-9 Transmission Control Levers ...........................4-8

D Decelerator Pedal ...............................................3-13 Decelerator Pedal Operating Instructions ..........4-12 Diagnostics/Computer Operation .......................4-13 Direction Control Lever .......................................3-14 Display Menus ....................................................4-13 Display-Service/Enter Switch ...............................3-4 Dozer Blade Control Lever .................................3-16 Angle Left .......................................................3-16 Angle Right ....................................................3-16 Float ...............................................................3-16 Hold ................................................................3-17 Lift ..................................................................3-16 Lower .............................................................3-16 Tilt Left ...........................................................3-16 Tilt Right .........................................................3-16 Dozer Operation .................................................4-27 Drive Sprocket ....................................................4-28

C Cab Door Release/Lock .................................... 3-21 Cab Tilt Hydraulic Jack ...................................... 3-22 Cab Tilt System Oil ............................................ 4-26 Cab Vent ............................................................ 3-21 Carrier Roller ..................................................... 4-28 Case Extended Life Track (CELT) ..................... 4-30 Climate Control Operation ................................. 4-16 Climate Control Panel ........................................ 3-21 Coat Hanger ...................................................... 3-21 Components of the Undercarriage .................... 4-28 Carrier Roller ................................................. 4-28 Drive Sprocket ............................................... 4-28 Idler ............................................................... 4-28 Recoil Spring Housing ................................... 4-28 Track Adjuster (Steel Track) ......................... 4-28 Track Chain ................................................... 4-28 Track Frame .................................................. 4-28 Track Links .................................................... 4-29 Track Rollers ................................................. 4-28 Track Shoes .................................................. 4-29 Coolant Levels Coolant Reservoir ......................................... 5-14 Radiator ......................................................... 5-17 Coolant Reservoir .............................................. 5-14 Coolant Solution, Engine Cooling System 5-14, 5-28 84272799

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E Electrical Service Accessory Outlet ..............................................7-5 Electrical System ..................................................7-3 Engine Hourmeter ........................................................5-4 Specifications ...................................................8-3 Engine Air Filter Restriction ..................................3-7 Engine Coolant Heater .......................................4-22 Engine Cooling System Coolant Solution ................................... 5-14, 5-28 Engine Hand Throttle .........................................3-15 Engine Lubrication ..............................................5-19 Engine Oil Selection .......................................5-19 Engine Oil Heater ...............................................4-23 Engine Oil Level .................................................5-14 Engine Oil Selection ...........................................5-19 Engine Operation ......................................... 4-3, 4-4 Engine Speed ..................................................4-4 Parking the Machine and Stopping the Engine 4-5 Starting the Engine ..........................................4-4 Engine Service Engine Oil Level .............................................5-14 Oil Change and Filter Replacement ...............5-20 Engine Speed .......................................................4-4 9-1

CHAPTER 9 - INDEX Engine Starting Aids Engine Coolant Heater .................................. 4-22 Engine Oil Heater .......................................... 4-23 Starting the Engine ........................................ 4-22 Extinguisher Mounting, Fire ................................. 6-7

Operator’s Seat ..............................................3-19 Operator’s Seat Belt .......................................3-24 Ripper Control Lever ......................................3-18 Interior Cab Door Release ..................................3-21

K F Factors Controlling Undercarriage Wear ........... 4-29 Wear Factors You Can Not Control .............. 4-30 Wear Factors You Can Control ..................... 4-31 Wear Factors You Can Partially Control ....... 4-31 Filter Engine ........................................................... 5-20 Hydraulic ....................................................... 5-31 Fire Extinguisher Mounting .................................. 6-7 Fluid and Lubricants ............................................ 5-5 Fluid Level Check Hydraulic System .......................................... 5-31 Forward/Rearward Adjustment Lever ................ 3-19 Front Console Key/Ignition Switch .......................................... 3-5 Fuel gauge monitor, no power ............................. 3-4 Fuel Handling Precautions .................................. 2-9 Fuel Warning Lamp ............................................. 3-7

G General Information ............................................. 1-1

H Hazardous Chemical Precautions ....................... 2-9 Horn ..................................................................... 3-4 Hourmeter, Engine .............................................. 5-4 How to Extend the Life of Sealed Track and the Case Lubricated Track (CLT) ............................... 4-30 Hydraulic Filter ................................................... 5-31 Hydraulic Filter Warning Lamp ............................ 3-6 Hydraulic Fluid Change ............................ 5-15, 5-31 Hydraulic System ............................................... 5-31 Fluid Level Check .......................................... 5-31 Hydraulic Filter .............................................. 5-31 Hydraulic Fluid Change ........................ 5-15, 5-31 Specifications .................................................. 8-3

I Identification Numbers Engine ............................................................. 1-6 Product Identification Number (P.I.N.) ............ 1-6 ROPS Canopy ................................................. 1-6 Transmission ................................................... 1-6 Idler .................................................................... 4-28 Instrument Panel ................................................. 3-3 Water Temperature Gauge ............................. 3-7 Instruments/Controls Dozer Blade Control Lever ............................ 3-16 9-2

Key Switch, Ignition ..............................................3-5

L Lifting the crawler ...............................................4-21 Lowering the cab ................................................4-26 Lubrication/Filters/Fluid Hydraulic System ...........................................5-31 Lubrication/Filters/Fluids Access Doors ......................................... 5-7, 5-19 Engine Lubrication .........................................5-19 Fluid and Lubricants .........................................5-5

M Machine Cleaning .................................................6-5 Machine Components ..........................................1-7 Machine Storage ..................................................6-8 Removal From .................................................6-8 Storage Preparation .........................................6-8 Maintenance Precautions .....................................2-8 Maintenance/Adjustments Machine Cleaning ............................................6-5 Roll-Over Protective Structure .........................6-4 Seat Belt ..........................................................6-4 Spark Arrester Muffler ......................................6-5 Torque Specifications for Seat and Seat Belt Mounting Bolts .........................................6-5 Menu Up/Down Switch .........................................3-4

N Next Service to (NONE) .....................................4-15

O Oil Change Engine ............................................................5-20 Oil Viscosity/Temperature Ranges .....................5-19 Operating Data and Dimensions Long Track (LT) and Rubber Track Crawlers ..8-6 Ripper ..............................................................8-8 Operating in Cold Weather .................................4-22 Operating in Hot Weather ...................................4-22 Operating Instructions ..........................................4-4 Booster Battery Connection to Machine Battery ...

4-24 Crawler Operation ............................................4-6 Dozer Operation .............................................4-27 Operating in Cold Weather ............................4-22 Operating in Hot Weather ..............................4-22 Run-In Period of a New Machine .....................4-3 Issued 11-09

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CHAPTER 9 - INDEX Track Systems .............................................. 4-28 Transporting the Machine ............................. 4-20 Vandal Lockup .............................................. 3-23 Operating Precautions ......................................... 2-7 Operator’s Seat Belt .......................................... 3-24 Outside Cab Door Release ................................ 3-21 Owner, To The ..................................................... 1-1

P Parking Brake Levers ........................................ 3-13 Parking the Machine and Stopping the Engine ... 4-5 Plastic and Resin Parts ....................................... 5-4 Power Turn .......................................................... 4-9 Pressure Relief Valves ...................................... 4-17

R Radiator ............................................................. 5-17 Rear Attachment Torque Values ......................... 6-9 Recoil Spring Housing ....................................... 4-28 Reverse/Forward Speed Ratio Control .............. 3-15 Ripper Operating Data and Dimensions ..................... 8-8 Ripper Control Lever ......................................... 3-18 Hold ............................................................... 3-18 Lower ............................................................ 3-18 Raise ............................................................. 3-18 Ripper Shank Adjustment .................................... 6-5 Roll-Over Protective Structure ............................. 6-4 ROPS Damage To ..................................................... 6-4 Maintenance and Inspection ........................... 6-4 RPM display ........................................................ 3-4 Run-In Period of a New Machine ......................... 4-3 Track Shoe Bolts ............................................. 4-3

S Safety Decals .................................................... 2-11 Safety, Battery ..................................................... 7-3 Safety/Decals/Hand Signals Safety Decals ................................................ 2-11 Seat Belt .............................................................. 6-4 Torque Specifications ...................................... 6-5 Seat Belt Precautions ........................................ 2-10 Seat Comfort Control ......................................... 3-19 Seat Lumbar Control ......................................... 3-20 Service Interval Change .................................... 4-14 Service Reminder (AUTO) ................................. 4-13 Service Reminder (MAN) ................................... 4-14 Service Reminder Activation to (AUTO) ............ 4-15 Service Reminder Activation to (MAN) .............. 4-15 Service Reminder Reset .................................... 4-14 Service Soon Lamp ............................................. 3-3 84272799

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Shuttle Parameter Adjustment ...........................4-10 Sides of the machine Right-hand, left-hand, front, and rear ...............1-5 Spark Arrester Muffler ..........................................6-5 Specific machine precautions .............................2-10 Specifications Engine Specifications .......................................8-3 Hydraulic System .............................................8-3 Operating Data and Dimensions .............. 8-6, 8-8 Track System ...................................................8-4 Travel Speeds ..................................................8-3 Standard Seat Controls Backrest Tilt Adjustment Lever ......................3-19 Forward/Rearward Adjustment Lever ............3-19 Starting and Stopping Precautions .......................2-6 Starting the Engine ..................................... 4-4, 4-22 Steering Gradual Turn ..........................................4-9 Steering Sensitivity Adjustment ..........................4-10 Storage Machine Storage ..............................................6-8 Preparation ......................................................6-8 Removal From ..................................................6-8 Sun Visor, Front .................................................3-21 Switch Key/Ignition ......................................................3-5

T Tilting the cab .....................................................4-25 To the Owner ........................................................1-1 Torque Specifications Seat Belt Mounting Bolts ..................................6-5 Towing a Disabled Crawler Releasing the Brakes .....................................4-17 Track Adjuster (Steel Track) ...............................4-28 Track Chain ........................................................4-28 Track Frame .......................................................4-28 Track Links .........................................................4-29 Track Rollers ......................................................4-28 Track Shoe Bolts ..................................................4-3 Track Shoes .......................................................4-29 Track System Specifications ...................................................8-4 Track Systems ....................................................4-28 Bushing and Sprocket Wear Chart .................4-34 Case Extended Life Track (CELT) .................4-30 Components of the Undercarriage .................4-28 Factors Controlling Undercarriage Wear ........4-29 Factors Controlling Undercarriage Wear - Wear Factors You Can Not Control ................4-30 How to Extend the Life of Sealed Track and the Case Lubricated Track (CLT) ................4-30 Wear Factors You Can Control ......................4-29 Transmission Control Levers ................................4-8 Transmission Filter Warning Lamp .......................3-6 9-3

CHAPTER 9 - INDEX Transmission Speed Gauge .............................. 3-12 Transmission Speed Parameter Adjustment ..... 4-10 Transmission Speed Up/Down Buttons ............. 3-14 Transporting the Machine .................................. 4-20 Travel Speeds Steel Track Crawler ......................................... 8-3 Turbo Precleaner ............................................... 5-30

U Utility Safety ......................................................... 2-4 Utility Safety Rules Message ............................... 2-4

V Vandal Lockup ................................................... 3-23

W Walk-Around Inspection ...................................... 4-4 Warning Lamp for Air Filter Restriction .............. 5-29 Water Temperature Gauge .................................. 3-7 Wear Factors You Can Control ......................... 4-29 Welding on the Machine ...................................... 6-3

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CHAPTER 10 - AFTER DELIVERY CHECK

Chapter 10 AFTER DELIVERY CHECK - DEALER COPY AFTER FIRST 100 HOURS OF OPERATION OF NEW MACHINE

Owners Name: Address: Dealers Name: Address: Machine Model Number:

Hourmeter Indication:

Machine Product Identification Number (P.I.N.):

COOLING SYSTEM

HYDRAULIC SYSTEM

Check the coolant levels.

Check the oil level.

Check for leaks.

Check the pressure setting of the main relief valve.

FUEL SYSTEM GENERAL

Check for leaks.

Drain water and sediment from the fuel tanks.

Look for oil leaks and loose parts.

Tighten all hose clamps.

Check drive chain tension

ELECTRICAL SYSTEM Check battery.

Check track shoe torque.

Check operation of starter, alternator, and instruments.

Check brake operation.

Check operation of all lamps.

Check the control levers for correct operation.

Check the operator’s seat for correct operation.

LUBRICATION SAFETY

Lubricate all pivot points.

Inspect the ROPS. Check the safety decals and replace if necessary.

ENGINE Check condition of drive belt.

Check the operator restraint system.

Check engine oil level.

Make sure the machine has the Operator’s Manual in the manual storage box.

Check engine speed at idle and at full throttle.

Service air cleaner.

DEALER: Make sure the owner and/or operator understands all the safety and information decals, the service information, and the service procedures in this manual.

Technician Signature: Dealer Signature: Owner Signature:

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CHAPTER 10 - AFTER DELIVERY CHECK

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CHAPTER 10 - AFTER DELIVERY CHECK

AFTER DELIVERY CHECK - OWNERS COPY AFTER FIRST 100 HOURS OF OPERATION OF NEW MACHINE

Owners Name: Address: Dealers Name: Address: Machine Model Number:

Hourmeter Indication:

Machine Product Identification Number (P.I.N.):

COOLING SYSTEM

HYDRAULIC SYSTEM

Check the coolant levels.

Check the oil level.

Check for leaks.

Check the pressure setting of the main relief valve.

FUEL SYSTEM GENERAL

Check for leaks.

Drain water and sediment from the fuel tanks.

Look for oil leaks and loose parts.

Check tire pressure.

Tighten all hose clamps.

ELECTRICAL SYSTEM Check battery.

Check track shoe bolt torque.

Check operation of starter, alternator, and instruments.

Check brake operation.

Check operation of all lamps.

Check the control levers for correct operation.

Check the operator’s seat for correct operation.

LUBRICATION SAFETY

Lubricate all pivot points.

Inspect the ROPS. Check the safety decals and replace if necessary.

ENGINE Check condition of drive belt.

Check the operator restraint system.

Check engine oil level.

Make sure the machine has the Operator’s Manual in the manual storage box.

Check engine speed at idle and at full throttle.

Service air cleaner.

DEALER: Make sure the owner and/or operator understands all the safety and information decals, the service information, and the service procedures in this manual.

Technician Signature: Dealer Signature: Owner Signature:

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