Case 1850K Crawler Dozer Tier II Engine Operator’s Manual - PDF DOWNLOAD

1850K Crawler Dozer Tier II Engine

Operator’s Manual Bur 6-36840GB

1850K (Tier 2) Crawler dozer

Operator's Manual

Print no. 6-36840

WARNING STUDY THIS MANUAL BEFORE STARTING, OPERATING, MAINTAINING, FUELING OR SERVICING THE MACHINE.

This alert symbol signals important messages involving your safety. It means: WARNING! BE ALERT! IT INVOLVES YOUR SAFETY.

Read and heed carefully all safety instructions identified by the key words WARNING and DANGER.

The safety plates applied to this machine are color coded yellow with black edges and wording for the points to which ATTENTION must be paid and red colored with white edges and wording for DANGER points.

Issued November, 2004 • 6-36840GB • Bur Copyright © 2004 CNH America LLC. All Rights Reserved.

TO THE OWNER

1850-2M0001

K SERIES CRAWLER 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.

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 Corporation 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 Operators 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 Corporation 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

1850-2M0167

OPERATOR’S MANUAL SEAT

B830800J

1. FRONT 2. REAR

3. RIGHT-HAND SIDE 4. LEFT-HAND SIDE

BASIC MACHINE, DOZER AND RIPPER 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.

TABLE OF CONTENTS SUBJECT

PAGE

SAFETY RULES .......................................................................................................................................... I-VII Decommissioning the machine ................................................................................................................... VII Dispose of wastes in an appropriate manner ............................................................................................... VII FOREWORD ................................................................................................................................................. VIII IDENTIFICATION DATA .................................................................................................................................. 2 COMFORT LEVELS ........................................................................................................................................ 3 GENERAL SPECIFICATIONS ......................................................................................................................... 4 Main dimensions ........................................................................................................................................... 7 Stability ......................................................................................................................................................... 8 List and location of safety decals .................................................................................................................. 9 Preliminary instructions and break-in period ................................................................................................ 17 OPERATION RULES ......................................................................................................................................18 First operation decal .................................................................................................................................... 19 Equipment installation decal ........................................................................................................................ 20 CONTROLS AND INSTRUMENTS .................................................................................................................. 21 OPERATION INSTRUCTIONS .......................................................................................................................33 General information ......................................................................................................................................33 Prior to starting ............................................................................................................................................33 Engine starting ............................................................................................................................................. 33 Stopping the machine .................................................................................................................................. 35 Stopping the engine ..................................................................................................................................... 36 Operator's seat adjustment ..........................................................................................................................36 Fuel reservoir ...............................................................................................................................................37 Blade adjustment .........................................................................................................................................37 Cab tilting .....................................................................................................................................................38 Lowering the cab .......................................................................................................................................... 39 Oil refilling and bleeding of the cab tilting system ....................................................................................... 39 Brakes disengagement ................................................................................................................................40 Towing the machine ..................................................................................................................................... 41 Moving the machine with outside means ...................................................................................................... 42 Instructions for lowering the equipment to the ground with engine inoperative .............................................. 43 Transporting the machine .............................................................................................................................43 Long storage of the machine ........................................................................................................................ 44 Cold climate precautions .............................................................................................................................. 44 Starting the machine at low temperatures .................................................................................................... 45 Starting the machine with booster batteries ..................................................................................................45 MACHINE OPERATION ................................................................................................................................. 46 CAB ................................................................................................................................................................ 55 MAINTENANCE .............................................................................................................................................. 59 Maintenance operations ............................................................................................................................... 60 Walk around inspection ................................................................................................................................60 List of programmed maintenance .................................................................................................................61 Every 10 hours work .................................................................................................................................... 63 Every 100 hours work .................................................................................................................................. 65 Every 250 hours work .................................................................................................................................. 68 Every 500 hours work .................................................................................................................................. 70 Every 1000 hours work ................................................................................................................................73 Every 2000 hours work ................................................................................................................................78 When required .............................................................................................................................................. 81 ELECTRICAL SYSTEM .................................................................................................................................. 85 Electrical diagram of protection tree ............................................................................................................. 87 TABLE OF FLUIDS USED .............................................................................................................................88 GENERAL ELECTRICAL DIAGRAM ....................................................................................... Inside back cover

SAFETY RULES Be sure exposed personnel in the area of operation are clear of the machine before moving it or its attachments.

WALK COMPLETELY AROUND the machine before mounting. Sound horn.

GENERALITIES Carefully study this manual before starting, operating, maintaining, fuelling or servicing the machine.

Read and heed all safety rules before any intervention.

Before starting machine, check, adjust and lock the operator's seat for maximum comfort and control of the machine.

Do not allow unauthorised personnel to operate service or maintain this machine.

Do not operate the machine if not feeling well or fatiqued.

Fasten your seat belt.

Do not wear rings, wrist watches, jewellery, loose or hanging apparels, such as ties, torn clothing, scarves, unbuttoned or unzipped jackets that can catch on moving parts. Wear proper safety equipment as recommended for the job. Examples: hard hat, heavy gloves, ear protection, safety glasses or goggles, reflector vests, respirator.

Consult your employer for specific safety equipment requirements.

Obey all flag signals and signs.

Due to the presence of flammable fluids, on the machine never check or fill fuel reservoirs or batteries near open flames, smoking materials or sparks.

REMEMBER THAT STARTING FLUID IS FLAMMABLE. Follow the recommendations printed on containers and in the Operation and Maintenance Manual.

Keep operator's compartment, stepping points, grab-rails and handles clear of foreign objects, oil, grease, mud or snow accumulation to minimise the danger of slipping or stumbling. Clean mud or grease from shoes before attempting to mount or operate the machine.

DO NOT PUNCTURE OR BURN CONTAINERS. Containers must be stored in fresh, well ventilated places, out of reach of unauthorised persons. Follow the instructions provided by the Manufacturer.

Do not jump on or off the machine. Keep two hands and one foot, or two feet and one hand in contact with step, grab rails and handles at all times.

Never use these products near open flames, smoking materials or sparks

Do not use controls or hoses as hand holds when climbing on or off machine. Hoses and controls are movable and do not provide a solid support. Also, controls may be inadvertently moved causing accidental machine or equipment movement.

OPERATION

Never attempt to operate the machine or its tools from any position other than seated in the operator's seat.

Do not run the engine in closed areas without proper ventilation to remove deadly exhaust gases.

Keep head, body, limbs, hands and feet inside operator's compartment at all times, to reduce exposure to hazards outside the operator's compartment.

Roll Over Protective Structures are required on loaders, dozers, graders, excavators. NEVER OPERATE machines without ROPS.

Be careful of slippery conditions on stepping points, hand rails, and on the ground. Wear safety boots or shoes that have a high slip resistant sole material.

Make sure the Operator's compartment is free of foreign objects, especially if not firmly secured. Never use the machine to transport objects, unless proper securing points are provided.

Do not leave the machine until it is completely stopped.

Check the seat safety belt at least twice a year. If there are signs of wear or fraying or other signs of weakness that could lead to failure, replace it.

Check monitoring instruments at start-up and frequently during operations. The brake pressure gauge shows a pressure lower than the minimum operating pressure, stop the machine immediately.

DO NOT CARRY RIDERS ON MACHINE.

STARTING

Study and familiarize with escape routes alternate to normal exit routes.

NEVER START OR OPERATE AN UNSAFE MACHINE. Before operating a machine, always ensure that any unsafe condition has been repaired.

Seat belts are required by current regulations to be provided with Roll Over Protection Structures or cabs.

Keep safety belts fastened around you during operation.

Check brakes, steering and attachment controls before moving. Advise the proper maintenance authority of any malfunctioning part or system.

For your personal protection, do not climb on or off machine while machine is running.

Make sure that exposed persons in the area of operation are clear of the machine, before starting the engine and operating the equipment. Sound horn. Obey all indications provided by flags and signals.

Be sure all protective guards or panels are in place, and all safety devices provided are in place and in good operating conditions.

I

SAFETY RULES Operators must thoroughly know the performances of the machine they are operating. When working on slopes or near sudden level drops of the terrain, avoid areas where ground is loose or soft since rolling-over or loss of control of machine could result.

NEVER COAST the machine down grades and slopes with the transmission in neutral or neutralized.

Choose and shift into the most appropriate gear to keep the speed required, thus preventing any loss of control.

Do not operate machinery in a condition of extreme fatigue or illness. Be especially careful towards the end of working shift.

Where noise exposure exceeds 90 dBA for 8 hours, wear approved ear protection.

Do not operate machine with brakes out of adjustment.

When counterweights are provided, do not work machine if they have been removed.

Operate the machine at speeds slow enough to ensure complete control at all times.

Overtaking maneuver must be performed only when absolutely necessary and unavoidable. Beware of possible uneven terrains, poor visibility conditions, the presence of other machinery or persons out of sight.

Travel slowly over rough terrain, on slopes or near dropoffs, in congested areas or on ice or slippery surfaces.

Operate the machine at a speed adequate to the working conditions in the site and slow enough to ensure complete control at all times.

When backing, always look to where the machine is to be moved. Be alert to the position of exposed personnel. DO NOT OPERATE if exposed personnel enter the immediate work area. STOP THE MACHINE.

Never use the machine as a work platform or scaffolding, nor other inappropriate operations (i.e. pushing railway cars, trucks or other machines).

Maintain a safe distance from other machines. Provide sufficient clearance for ground and visibility conditions.

Yield right-of-way to loaded machines.

Be alert of people in the operating area of the machine.

Maintain clear vision of areas of travel or work. Keep cab windows clean and repaired.

When operating a machine, know in advance what clearances will be encountered, overhead doors, cables, pipes, bearing load limitations of ground, bridges, floors or ramps.

When pulling or towing through a cable or chain, do not start suddenly at full throttle; take-up slack carefully.

When roading, find-out what conditions are likely to be encountered, clearances, traffic congestion, type of road surfacing, etc. Beware of fog, smoke or dust elements that obscure visibility.

Inspect carefully for flaws or troubles before using.

Avoid kinking chains or cables. Do not pull through a kinked chain or cable to the high stresses and possibility of failure of the kinked area. Always wear heavy gloves when handling chains or cables.

When crossing gullies or ditches, move at an angle with reduced speed after ensuring ground conditions will permit a safe traverse.

Be sure chains and cables are anchored and the anchor points are strong enough to handle the expected load.

Keep exposed personnel clear of anchor points and cables or chains.

Explore the working area to identify potential risks such as: slopes, overhangs, pits, demolition rubble, fires, ravines, ditches, soft terrain, heavy traffic, crowded parking areas, closed ambients. In such conditions, proceed with extreme care.

DO NOT PULL UNLESS OPERATOR'S COMPARTMENT OF MACHINES INVOLVED ARE PROPERLY GUARDED AGAINST POTENTIAL CABLE OR CHAIN BACKLASH.

Whenever possible, avoid going over obstacles such as rough terrain, rocks, logs highly irregular ground, steps, ditches, railroad tracks. When obstructions must be crossed, do so with extreme care at an angle, if possible.

Reduce speed, shift-down. Ease up to the break over point, pass the balance point slowly on the obstruction and ease down on the other side.

Be alert to soft ground conditions close to newly constructed walls. The fill material and weight of the machine may cause the wall to collapse under the machine.

In darkness, check area of operation carefully before moving in with machine. Use all lights provided. Do not move into area of restricted visibility.

In steep down-hill operation, do not allow engine to overspeed. Select proper gear before starting down grade.

If engine has a tendency to stall for any reason under load or idle, report this for adjustment to proper maintenance authority immediately. Do not continue to operate machine, until condition has been corrected.

Avoid side hill travel, whenever possible. Drive up and down the slope. Should the machine slipping sideways, turn it immediately downhill.

On machines supplied with suction radiator fans, be sure to periodically check engine exhaust parts for leaks, as exhaust fumes are dangerous to the operator.

The grade of slope you should attempt will be limited by factors such as condition of the ground, load being handled, type of machine, speed of machine and visibility.

In case of closed type cabs, always keep an opening with the outside, to ensure a constant air circulation.

There is no substitute for good judgement when working on slopes.

II

SAFETY RULES Keep head, body, limbs, feet, fingers or hands away from bucket, blade or ripper when in raised position.

Avoid operating equipment too close to an overhang or high wall, either above or below the machine. Be on the look-out for caving edges, falling objects and slides.

Beware of concealment by brush and undergrowth of these danger.

Always disconnect the master switch before any intervention (i.e. cleaning, repairing, maintaining, refuelling etc.). Do the same when parking for prolonged periods of time to avoid accidental or unauthorised starting.

When pushing-over trees, the machine must be equipped with proper overhead guarding. Never allow a machine to climb up on the root structure particularly while the tree is being felled. Use extreme care when pushing over any tree with dead branches.

Never lower attachments or tools other than seated in operator's seat. Sound horn. Make sure area near the attachment is clear. Lower the attachment slowly. DO NOT USE FLOAT POSITION of hydraulic system.

When pushing trees with dead limbs, proceed with extreme care. Avoid brush piles, logs or rocks.

Place master switch in OFF, securely block the machine and lock it every time you leave it unattended. Return keys to authorised security. Heed all shut-down operations of the Operation and Maintenance Instruction Manual are followed.

NEVER DRIVE OVER THEM or other surface irregularities that brake traction with the ground, especially when on slopes or near drop-offs.

Be alert to avoid changes in traction conditions that could cause loss of control. DO NOT DRIVE on ice or frozen ground conditions when working the machine on steep slopes or near drop-offs.

MAINTENANCE GENERALITIES

Working in virgin and rough terrains is characterised by the presence of all the perils and risks listed above. In these conditions, it is emphasised the danger represented by large tree limbs (possibly falling on the machine), large roots (acting as a leverage under the machine when uprooted causing roll-over of the unit) etc...

Before operating or performing any intervention on the machine: - read carefully all the rules contained by this Manual, - read and obey all safety related plates and instructions located on the machine.

Do not allow unauthorised personnel to perform any maintenance operation. Do not perform maintenance operation without prior authorisation. Follow all recommended maintenance and service procedures.

STOPPING When the machine is stopped for whatever reason, follow the instructions of chapters "Stopping the machine" and "Stopping the engine" of the Operation and Maintenance Instruction Manual.

Keep operator's compartment free of all loose objects.

NEVER LEAVE THE MACHINE UNATTENDED with the engine running.

Do not wear rings, wrist watches, jewellery, loose or hanging apparels, such as ties, torn clothing, scarves, unbuttoned or unzipped jackets that can catch on moving parts. Wear proper safety equipment as recommended for the job. Examples: hard hat, heavy gloves, ear protection, safety glasses or goggles, reflector vests, respirator.

Consult your employer for specific safety equipment requirements.

Always, before leaving the operator's seat and after making sure all people are clear of the machine, slowly lower the attachments or tools flat to the ground in a positive ground support position.

Do not use controls or hoses as hand holds when climbing on or off machine. Hoses and controls are movable and do not provide a solid support. Also, controls may be inadvertently moved causing accidental machine or equipment movement.

Always remember to position the transmission drive control in neutral and engage the control lock to secure the machine.

The parking brake is automatically set.

Return the controls to rest position. Place the gearshift lever in neutral. Turn the start switch to off and extract the key.

Do not jump on or off the machine. Keep two hands and one foot, or two feet and one hand in contact with step grab rails and handles at all times.

See the relevant chapter in this Manual.

Do not perform any service operation on the machine with a person seated in the operator's compartment, unless he is an authorised operator co-operating in the operation to be performed.

Park in a non- operating and no-traffic area or as instructed.

Park on firm level ground if possible. Where not possible, position machine at a right angle to the slope, making sure there is no danger of uncontrolled sliding movements.

Keep operator's compartment, stepping points, grab-rails and handles clear of foreign objects, oil, grease, mud or snow accumulation to minimise the danger of slipping or stumbling. Clean mud or grease from shoes before attempting to mount or operate the machine.

If parking in traffic lanes cannot be avoided, provide appropriate flags, barriers, flares and signals as required.

Also provide advance warning signals in the traffic lane of approaching traffic.

III

SAFETY RULES To load/unload a machine from transporter, choose a level surface ensuring firm support to the wheels of truck or trailer. Use strong access ramps, with adequate height and angle. Keep surface free of mud, oil or slippery materials.

Keep shoes free of mud or grease before climbing or driving the machine.

Never attempt to operate the machine or its tools from any position other than seated in the operator's seat.

Anchor the machine securely to the bed of truck or trailer and block wheels or tracks with appropriate wedges.

When maintenance operations require moving hydraulically operated attachments by means of machine's hydraulic system remember that all manoeuvres must be made only when seated in the operator's seat. Before starting machine or moving attachment or tools, set brakes , sound horn and call for an all clear. Raise attachment slowly.

Never align holes with fingers or hands; always use appropriate aligning tools.

Eliminate all sharp edges and burrs from re-worked parts.

Use only approved grounded auxiliary power sources for heaters, chargers, pumps and similar equipment to reduce the hazards of electrical shocks.

Always block booms or parts of the machine which must be raised to perform interventions under them with external devices. Do not allow persons to move into the vicinities nor standing under equipment not being blocked. Unless you are totally sure about your safety, avoid staying under raised equipment, even in case it is blocked.

Lift and handle heavy parts with a lifting device of proper capacity. Be sure parts are supported by proper slings and hooks. Use lifting eyes if provided. Watch-out for people in the vicinity.

Never pour gasoline or diesel fuel into open, wide and low containers. Never use gasoline, solvent or other flammable fluid to clean parts. Use exclusively qualified, non-flammable, non-toxic commercial solvents.

Do not place the body, limbs or fingers into sharp articulation uncontrolled openings of the machine and without proper protections, unless they are blocked in a safe manner.

When using compressed air for cleaning parts, use safety glasses with side shields or goggles. Limit pressure to 2 bar, in accordance with local and national regulations.

Never perform interventions with engine running, except as called for in a Manual. Do not wear loose clothing or jewellery near moving parts.

Do not run the engine in closed areas without proper ventilation to remove deadly exhaust fumes.

When servicing or maintenance require access to areas that cannot be reached from the ground, use a ladder or step platform that meet local and national regulations, to reach the service point. If such ladder or platform are not available, use the machine hand holds and steps as provided. Perform all service or maintenance carefully.

Do not smoke or permit any open flames or spark near when re-fuelling or handling flammable materials.

Do not use an open flame as a light source to look for leaks or for inspection anywhere on the machine.

Make sure that all mechanic's tools are in good conditions.

NEVER USE tools with mushroomed heads or frayed.

Always wear eye protections.

Shop and/or field service platforms or ladders must be constructed and maintained in accordance with local and national regulations.

Move with extreme care when working under the machine, its attachments and or on or near them. Always wear protective safety equipment as required, such as hard hat, goggles, safety shoes, ear plugs.

Disconnect batteries and tag all controls according to current regulations to warn that work is in progress. Block machine and all attachments that must be raised according to current regulations.

When performing operations requiring running of the engine, have a qualified operator in the operator's seat at all times with the mechanic on sight. Place the transmission in neutral and set the brakes and safety lock.

Due to the presence of flammable fluids, never check or fill fuel tanks, batteries, nor use starting fluid near lighted smoking materials or open flames.

KEEP HANDS AND CLOTHING AWAY FROM MOVING PARTS.

BRAKES ARE INOPERATIVE when manually released for servicing. Provisions must be made to maintain control of the machine by blocking or other means.

For field service, move machine to level ground, if possible, and block it. If work on an incline is absolutely necessary, first block machine and its attachments securely, than move it to level ground as soon as possible.

The fuel filling nose must be kept constantly inside the filling neck. Keep this contact from the beginning to the end of the fuelling operation to avoid the possibility that sparks due to static electricity are generated.

Do not trust worn and /or kinked chains and cables: do not use them for lifting or pulling operations. To handle them, always use heavy gloves.

Use only designated towing or attaching points. Use care in making attachments. Make sure pins and/or locks are secure before pulling. Stay clear of drawbars, cables or chains under load.

Be sure chains and cables are anchored and the anchor points are strong enough to handle the expected load.

Keep exposed personnel clear of anchor points and cables or chains.

To move a disabled machine, use a trailer or a low-boy, if available. In case towing is needed, use all necessary signals required by local and national regulations, and follow the directions provided in this Manual.

No bystanders are allowed near the hooking points, chains or cables.

IV

SAFETY RULES DO NOT PULL UNLESS OPERATOR's COMPARTMENT OF MACHINES INVOLVED ARE PROPERLY GUARDED AGAINST POTENTIAL CABLE OR CHAIN BACKLASH.

STARTING

Keep the area where maintenance operations are performed CLEAN and DRY. Immediately clean all fluid spillages.

Do not place head, body, limbs, feet, hands or fingers, near rotating fans or belts. Be especially alert near pusher fans.

Do not run the engine in closed areas without proper ventilation to remove deadly exhaust fumes.

STARTING FLUID IS HIGHLY FLAMMABLE. Follow strictly the recommendations printed on containers and in the Operation and Maintenance Manual. Containers must be stored in fresh, well ventilated places, out of reach of unauthorised persons. DO NOT PUNCTURE OR BURN CONTAINERS.

Do not pile oily or greasy rags; they represent a fire hazard.

Store in closed metal container.

Before starting machine, check, adjust and lock the operator's seat for maximum comfort and control of the machine. Be sure exposed personnel in the area of operation are clear of the machine before moving it or its attachments. Sound horn.

ENGINE Loosen the radiator cap very slowly, to release pressure from the system, before removing it. All coolant level topups must be performed with engine OFF.

Rust inhibitors are volatile and flammable Use only in well ventilated areas. Keep open flames away - DO NOT SMOKE - Store containers in a cool well ventilated place, secure against unauthorised personnel.

Do not run engine when refuelling and use care if the engine is hot due to the increased possibility of a fire if fuel is spilled.

Do not carry loose objects in pockets that might fall unnoticed into open compartments.

Never attempt to check or adjust fan belts when engine is running.

Do not adjust engine fuel pump when machine is moving.

Wear proper protective equipment such as safety goggles or safety glasses with side shields, hard hat, safety shoes, heavy gloves when metal or other particles are apt to fly or fall.

Do not lubricate the machine with engine running.

Do not run the engine with air intakes, door or protections open.

Wear welders protective equipment such as dark safety glasses, helmets, protective clothing, gloves and safety shoes, when welding or burning. Wear dark safety glasses near welding zones. DO NOT LOOK AT ARC WITHOUT PROPER EYE PROTECTION.

ELECTRICAL SYSTEM Always disconnect batteries prior to any intervention on machine or electrical system (cleaning, repair, maintenance).

Know your jacking equipment and its capacity. Be sure the jacking point used on the machine is appropriate for the load to be applied. Be sure the support of the jack at the machine and under jack is appropriate and stable.

Should booster batteries be used, remember to connect both ends of the booster cables in the proper manner (+) with (+) and (-) with (-). Avoid short-circuits of the terminals.

Follow thoroughly the instructions of this Manual.

The load lifted by jacks is always dangerous: it is necessary to transfer loads to appropriate blocking as a safety measure, before proceeding with service or maintenance work, according to local or national regulations.

Before any intervention, make sure that the main switch is OFF. BATTERY GAS IS HIGHLY FLAMMABLE. Leave battery box open to improve ventilation when recharging batteries.

Never check charge by placing metal objects across the posts. Keep sparks or open flames away from batteries. Do not smoke near battery to guard against the possibility of causing an explosion.

Steel cables are frayed after prolonged use; always wear appropriate protections (heavy gloves, goggles etc.).

Handle all parts carefully. Keep hands and fingers away from structures, gears or moving parts.

Before any intervention, make sure that there are no fuel or electrolyte leakages; eliminate them before proceeding with further work. When recharging batteries in closed ambients, make sure that there is appropriate ventilation to prevent possible accidental explosions due to the accumulation of gases generated during the recharge.

Compressed air systems can have water deposits created by moisture condensation due to changes of atmospheric conditions. If required, discharge deposits, as instructed.

V

SAFETY RULES HYDRAULIC SYSTEM Fluid escaping under pressure from a very small hole can be almost invisible and can have sufficient force to penetrate the skin. Use a piece of cardboard or wood to search for suspected pressure leaks. DO NOT USE HANDS. If injured by escaping fluid, see a doctor at once.

Serious infection or reaction can develop if proper medical treatment is not administered immediately.

Stop the engine and release all pressures in the system before removing panels, housings, plugs or covers.

In case pressures must be measured, use instruments of adequate capacity. Always follow the recommended procedures.

EQUIPMENT Keep head, body, limbs, feet, fingers or hands away from bucket, blade or ripper when in raised position.

Prior to any intervention, install all safety devices according to current rules and regulations.

In case equipment on the machine must be operated by hydraulic systems, remember to proceed only after seating in the operator's compartment. Make sure that there are no persons in the operating area of the machine. Alert people before operating using the horn and by voice. Move the equipment very carefully.

Do not use machine to transport loose objects, unless proper devices for this purpose are provided.

Clutches and brakes of this machine and eventual auxiliary equipment and attachments (such as operating cylinder or winches control valves) must always be properly adjusted in accordance with the instructions provided by the Manuals of the Manufacturer.

Never perform adjustments with engine running, except when called for by the above instructions.

When changing work shift, check that wheel or rim securing screws and brackets are not loosen; if necessary, retighten to the prescribed torque.

VI

SAFETY RULES

WARNING On machines having hydraulically, mechanically, and/or cable controlled equipment (such as shovels, loaders, dozers, excavators etc.) be certain the equipment is lowered to the ground before servicing, adjusting and/or repairing. If it is necessary to have the hydraulically, mechanically, and/or cable controlled equipment partially or fully raised to gain access to certain items, be sure the equipment is suitably supported by means other than the hydraulic lift cylinders, cable and/or mechanical devices used for controlling the equipment.

DECOMMISSIONING THE MACHINE

WARNING • The decommissioning of the machine must be performed exclusively by personnel trained, qualified and authorised to perform such operation.

For the decommissioning of the machine, the availability of particular tooling (hoists, hydraulic presses. containers for liquids etc.) is required as well as specific tools listed in the Repair Manuals, available from CASE Dealers.

This has the purpose of avoiding that during disassembly operations, dangerous situations may arise both for the personnel involved and the environment.

• Start the disassembly of hydraulic components only after, the hydraulic oil and lubricants have fully cooled-off and after all residual pressures have been released, as described by the Repair Instruction Manual.

In the machine are present: • Fluids under pressure (hydraulic system, cooling system etc.)

• Gases (air conditioning system and accumulator, if installed) • Mechanical devices mounted under pressure (track tensioner etc.)

• Acid (battery) • Heavy machine components (frames, blades, buckets etc.)

• Prior to proceeding with disassembly operations, comply with the GENERAL SAFETY RULES and drain each components of the machine filled with fluids, both in the reservoirs and the relevant systems.

DISPOSE OF WASTES IN AN APPROPRIATE MANNER • The improper disposal of waste is a menace for the environment. Potentially dangerous wastes used on CASE machines include lubricants, coolant, fuel, filters and batteries.

- Use sealed containers when draining fluids; do not use containers for food or drinks which could be erroneously used for drinking.

- Recycle all waste.

- Seek information about the appropriate manners of re-cycling or disposing of waste from local authorities or waste management centres, or from your Dealer.

VII

SAFETY RULES

FOREWORD This manual is designed to serve as a guidance for correct and safe operation of the machine and its system servicing.

The continued observance of the instructions provided herein will ensure the best possible performance, operation economy and long life of the machine and will avoid the most common causes of accidents which may occur during work or maintenance operations.

As regards safety in particular, carefully read the general rules given on pages I through VII. The repair procedures for this machine are described in separate service publications obtainable from the Manufacturer's Organization.

Each machine is supplied with a copy of this manual. The descriptions and illustrations appearing in this manual are not binding; thus CASE reserves the right, while retaining the basic features of the model herein described and illustrated, to make at any time, and without necessarily bringing this manual up-to-date, any alteration to units, parts, accessories or their supply, deemed necessary for improvement or for any manufacturing or commercial reason. For any clarification, refer to your Dealer who will provide any information you may need.

The information provided by this Manual is valid at the time of publication. Since CASE is constantly improving its products, some information may not be up-to date. In the event discrepancies are experienced, consult the Sales and Service Organization.

VIII

1850K

1

1850K (Tier 2) Crawler dozer

1850-2M0001

WARNING The safety of the operator and bystanders depends upon its judgement capacity and prudence in operating the machine. Thus it is necessary to be knowledgeable of the position and function of all controls. Each machine has limitations: prior to operate it is necessary to familiarize with its capabilities and speed, braking, steering, stability and working features.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2

1850K

IDENTIFICATION DATA A. Engine data plate The engine data plate is visible by opening the engine left side panel and it includes all the identification data and other important information related to the engine.

1. Engine serial number (E.S.N. Engine Serial Number Cummins) 1 s in m m Cu

CID / L Cummins Engine Company, Inc. Columbus. Indiana 47202 - 3005

CPL

Family

Engine Serial No.

FEL

Cust. Spec.

NOx

µModel

e WARNING: Injury may result and is voided if fuel rate, rpm or altitudes exceed published maximum values for this model and appliication.

Date od MFG (SEE TAB) Cummins Engine Co.Lfd.

Valve lash cold

Inch

Int.

Exh.

Timing - TDC

MM

Int.

Exh.

Fuel rate at rate HP

Firing Order Rated HP/kW

PM

3 mm / st Low ldie RPM

FR at

EPA

RPM

1850-2M0002

IMPORTANT ENGINE INFORMATION This engine conforms to 2003 U.S. EPA And California Tier 2 and EU Stage II regulations for heavy duty non-road compression ignition diesel cycle engines as applicable.

THIS ENGINE IS CERTIFIED TO OPERATE ON DIESEL FUEL

1850-2M0003

B. Machine identification plate The identification plate includes the main data of the machine and it is visible under the operator's seat.

1850-2M0005 1850-2M0004

C. Marking and serial number On the right side of the transmission housing it is possible to read the MARKING of the machine, composed of: In the lower part: - manufacturer code (the first three digits) HHA; - machine code 01850S; - machine serial number (last eight digits) 00000000 According to the machine configuration, the marking will be one of the following: MODEL 1850K LT T2

MARKING

(Power Steering) ★HHA01850Sxxxxxxxx★

1850K XLT T2 (Power Steering) ★HHA1850STxxxxxxxx★ 1850K LGP T2 (Power Steering) ★HHA1850SPxxxxxxxx★ 1850-2M0006

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

3

Machine manufactured by:

Series: 1850K Model

Address:

Zona Industriale Surbo 73100 LECCE (LE) Telephone: (0832) 6881

This machine complies with the EEC Directives relative to safety of machines (Directives 89/392, 91/368, 93/44 and 93/68)

Technical type

1850K LT (Power Steering)

535.100.053

1850K XLT (Power Steering)

535.100.054

1850K LGP (Power Steering)

535.100.055

LT/XLT/LGP versions show the undercarriages of the machine: LT = 7 rollers undercarriage XLT = 8 rollers undercarriage LGP = 8 rollers undercarriage (Low ground pressure)

COMFORT LEVELS Noise at operator's seat (with sound suppression option) Evaluated on identical machines, in accordance with EEC Directive 95/27 ISO 6396 Standard machine LpA = 81 dB (A) Noise outside the machine Level of guaranteed noise power, determined in accordance with European Directive 2000/14/CE Standard machine LWA = 111 dB (A)

- the machine must be equipped with a seat complying with the comfort criteria prescribed by EN ISO 7096: 2000;the same must be adjusted in accordance with personal requirements; - ensure that the machine is maintained in efficient conditions; - steer, brake, accelerate, shift gear and move the equipment without sharp manoeuvres; - when travelling, adjust the speed of the machine so as to minimise vibrations; - keep the work site in good conditions (remove stones and obstacles, fill ditches and holes etc.)

LEVEL OF VIBRATIONS

SERVICE

Level of vibrations on hands and arms: from investigations conducted on machines identical to this one, under travel and digging conditions over cycles of different lengths, it is assumed that the level of vibrations is EQUAL or LOWER than ?,?? m/s2.

The value must be considered weighted rms with the "wide band" method and weighting complying with ISO 2631-1.

For the service operations not easily performed with the means available to the User. it is recommended that you contact the Sales Organization or the Service Centres, which have available skilled personnel, adequate tooling and genuine spare parts. The entire Organization is at the disposal of Customers to provide clarifications and recommendations or to intervene with its skilled personnel, whenever an irregular operation is experienced on your machine.

Level of vertical vibrations on the operator's seat: from investigations conducted on machines identical to this one, under travel and digging conditions over cycles of different lengths, it is assumed that the level of vibrations is EQUAL or LOWER than ?,?? m/s2 LTS "ON" ?,?? m/s2 LTS "OFF" The value must be considered rms weighted with the "wide band" method and weighting in compliance with ISO 7096 and ISO 2631-1.

The exposure to vibrations by the operator can be reduced when the following recommendations are considered: - always use the most appropriate equipment for the type of work to be performed;

SPARE PARTS To ensure a perfect performance of the machine, you are reminded that parts must be replaced exclusively with genuine spares.

To order them it is necessary to specify: - type and serial number of the machine (plate B); - type and serial number of the engine (plate C); - the part number (from the Spare Parts Catalogue) of the part being ordered.

Spare Parts Catalogue 1850K Print No. 7-8610

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

4

1850K

GENERAL SPECIFICATIONS ENGINE Engine "emissioned" Net flywheel power: 1850K Tier2 LT/XLT (190 Hp gross) kw Net power

rated @ 2000 rpm

hp

peak @ 1700 rpm

rated @ 2000 rpm

peak @ 1700 rpm

DIN 6270

136

142

182

190

SAE J1349

134

140

180

187

ISO 9249

135

141

182

189

EEC 80/1269

136

142

182

190

1850K Tier2 LGP (207 Hp gross) Net power

kw

hp

rated @ 2000 rpm

peak @ 2000 rpm

DIN 6270

147

197

SAE J1349

145

194

ISO 9249

146

196

EEC 80/1269

147

197

Make and model ................... CUMMINS 6CTAA8.3 Type ...... turbocharged, aftercooled, direct injection, 4-cycle diesel Number of cylinders .............................................. 6 Bore x stroke ............ 114 x 135 mm (4.49 x 5.31 in) Displacement ................................ 8267 cc (504 in3) Governed rpm ............... STD/XLT version 2000 rpm version LGP 2000 rpm Maximum torque .... 84.2 daNm (621 lb ft) at 1500 rpm Lubrication ..................... full pressure by gear pump The machine may be operated up to 2500 m (8202 ft) altitude without derating the engine.

Engine complies with TIER 2 CE 97/68, and with U.S. standards CARB & EPA. Lubrication Combined replaceable oil filter; the upper section includes the total flow filtering element, whereas the lower section contains the by-pass element.

Minimum permissible lube pressure: - At low idle .................................. 0.69 bar (10 Psi) - At nominal rpm ........................... 2.07 bar (30 Psi) Oil sump capacity ............................... 19 L (5 USG)

Cooling system Circulated water by centrifugal pump, integrally mounted. The coolant flows from the oil heat exchanger into the cylinder block, then passes through the cylinder head.

Radiator equipped with seven blade blowing fan.

Water circulation from engine to radiator regulated by thermostat.

Setting of thermostat ......... 81 to 83 °C (178 to 181 °F) Max. opening ...................................... 95 °C (203 °F) Upper tank temperature Max. allowed .................................... 100 °C (212 °F) Max. recommended ............................ 70 °C (158 °F) Fuel system In-line BOSCH type PES.MW injection pump, with RSV governor.

BOSCH drilled injectors, set at 260 + 10 bar (3771 + 145 psi).

A mechanical fuel pump pulling the fuel from the reservoir. The fuel flows through a pre-filter between reservoir and fuel pump. Two replaceable cartridge filters, one with water separator and one filtering the particles in the fuel.

Air intake Dry air cleaner with replaceable cartridges, turbocharger, equipped with WASTEGATE valve.

TRANSMISSION Hydraulic torque converter with max. stall torque ratio 2.280 : 1.

"Powershift" transmissions providing three forward and three reverse speeds, with ELECTRONIC sliding control. Moving the joy-stick to neutral the transmission is disengaged.

AUTO KICK DOWN function button and AUTO SHIFT function button.

Safety lock lever preventing in "lock" position the FORWARD + REVERSE operation of the joy-stick and automatically engaging the service brakes.

Torque converter/transmission oil cooling by a radiator, side by side to the water radiator.

Transmission oil filtered by two total flow filters; one metal mesh on suction line, the other cartridge type with by-pass valve on delivery line.

Final drives Central bevel gear type reduction in the centre of rear transmission housing.

Double reduction modular type final drives.

Reduction ratio: 1 : 12.286.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

5

STEERING DIFFERENTIAL Power Steering The steering differential allows steering without ever locking the track, transferring power with continuity to both tracks, during the steering phase, with tight turns, as well. With the two tracks constantly under traction, it is possible to push greater loads also at maximum speed.

The steering occurs by increasing the speed of one track and slowing-down the other, in an equal manner; the speed difference makes the machine steering. The steering system operates as a differential and it is composed of: a pump, an hydraulic motor and relevant controls, joy-stick actuated.

BRAKES Oil-bath disc brakes, spring applied pressure release The single pedal actuates, simultaneously, the brakes of both tracks, both as service and emergency devices. The machine is prevented from moving with parking brakes engaged. A manual system allows the disengagement of the brakes, without hydraulic pressure, to tow the machine, in the event of a failure.

Parking brake: automatically actuated, by the transmission safety lever or with engine inoperative.

EQUIPMENT HYDRAULIC SYSTEM Hydraulic oil reservoir, equipped with level indicators, located in the back of the machine.

Gear type feeding pump.

Oil filtration by means of two total-flow filters: one metal mesh on pump suction line; one replaceable, with safety by-pass valve in case of clogging, on oil return line to reservoir.

Three-spool, monoblock control valve.

Single lever control for the first two spools of the control valve for: • raising/lowering/floating of blade; • blade tilting.

Two double-acting hydraulic cylinders incorporating stroke-end and quick dropping valves in the upper sleeve, operate the blade.

An optional supplementary lever is available for the third spool.

A safety locking lever, retains the equipment control and gearshifting controls in neutral, to avoid accidental maneuver.

Power Steering The hydraulic system load-sensing, controls the hydraulic power required by the steering/equipment circuits, with maximum efficiency.

The flow of the steering system is prioritized, when power is required by the equipment controls, at the same time. The circuit is composed of a variable displacement piston pump and an hydraulic motor distributing adequate power to each track, during the steering phase.

UNDERCARRIAGE Includes two welded box structure type track frames.

The track frames are connected, in the front, by an oscillating cross-bar and are hinged, in the rear, on the PIVOT SHAFTS. Lubricated track chains.

Two support rollers per side, permanently lubricated.

Sprockets with replaceable toothed sectors.

Idler wheels permanently lubricated, and hydraulic tension adjuster.

LT - Number of bottom rollers .................................... 7 - Quantity of shoes per track chain: ................... 40 - Width of standard shoes: .............. 560 mm (22 in) optional: .............. 610 mm (24 in) XLT - Number of bottom rollers: ................................... 8 - Number of shoes: ............................................. 45 - Width of shoes : ............................ 560 mm (22 in) optional: .............. 610 mm (24 in) LGP - Number of bottom rollers: ................................... 8 - Number of shoes: ............................................. 45 - Width of shoes : ............................ 915 mm (36 in) optional: .............. 760 mm (30 in) FRAME Load bearing with welded steel boxed structure on which the various groups are mounted.

Mounted frontally on the oscillating cross-bar and to the track frames in the rear.

ELECTRICAL SYSTEM Voltage 24 Volt.

Alternator DELCO REMY 70 Amp. Starter motor DELCO REMY 7.8 kW Starter motor with automatic pinion engagement by solenoid.

Batteries Twin 12 Volt, series connected batteries, 155 Amph.

Low maintenance type.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

6

1850K

CAB

RIPPER (supplied on request)

Modular type, elastically suspended by elastic blocks, integrated in the safety structure.

Parallelogram type with welded box steel elements frame. Three position tool bar with three semi-curved shanks with replaceable tips.

Controlled by two double stroke hydraulic cylinders.

Weight: ...................................... 2010 kg (4431 lbs)

The cab offers maximum visibility of the blade and rear equipment for maximum productivity.

Also, the cab provides maximum comfort to the operator, in all weather conditions.

COLD STARTING (Optional) A cold starting device is available, allowing the starting of the machine at particularly low temperatures.

SPEEDS MAX. SPEEDS (forward - reverse) in km/hr (mph): Speeds

I

II

III

- forward - reverse

4.1 (2.55) 5.0 (3.11)

6.8 (4.22) 8.3 (5.15)

10.6 (6.58) 12.7 (7.88)

AUXILIARY APPLICATIONS Some equipment described and illustrated in this Manual are provided to specific markets to satisfy specific requirements.

Other devices and special applications can be supplied, upon request, in agreement with the Sales Organisation.

RIPPER (supplied on request) LT/XLT PD180

LGP RP14F

Type ...................................................................

Parallelogram

Parallelogram

Ripping depth ......................................................

mm 540 (21.26 in)

mm 440 (17.32 in)

Ripping width ......................................................

mm 1900 (74.8 in)

mm 1800 (70.87 in)

Shanks ...............................................................

3

3

Shank holders .....................................................

3

3

Clearance, under tooth with ripper raised .............

mm 455 (17.91 in)

mm 490 (19.29 in)

Clearance, under tool beam with ripper towered ...

mm 235 (9.25 in)

mm 235 (9.25 in)

Hydraulic cylinders rod x bore x stroke ...............

mm 100 x 480 (2) (3.93 x 18.90 in)

mm 140 x 380 (1) (5.51 x 14.96 in)

Overall width .......................................................

mm 2130 (83.86 in)

mm 2030 (79.92 in)

Weight (with three shanks) ..................................

kg 2010 (4431 lb)

kg 1430 (3152 lb)

MODEL

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

O

Q

B

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

* ** ***

G

N L

Straight (HS) – 3385 (133.3 in) 1215 (47.8 in) 758 (29.9 in) 10° 472 (18.5 in) 1100 (43.3 in) 5440(214.1 in) 20300 (44753.8 lb)

LT 3235 (127.4 in) 3195 (125.8 in) 4195 (165.1 in) 2700 (106.2 in) 1900 (74.8 in) 560-610 (22-24 in) 71,5 (2.8 in) 390 (15.3 in) 2460 (96.8 in 2510 (98.8 in) – – 17290 (38117.9 lb) Semi-U (HSU) 5,6 (197.8 ft3) 3460 (136.2 in) 1425 (56.1 in) 850 (33.5 in) 10° 472 (18.5 in) 1100 (43.3 in) 5487 (216 in) 20530 (45260.9 lb)

M

Straight (HS) – 3385 (133.3 in) 1215 (47.8 in) 758 (29.9 in) 10° 472 (18.5 in) 1100 (43.3 in) 5440(214.1 in) 21400 (47178.9 lb)

XLT 3235 (127.4 in) 3195 (125.8 in) 4340 (170.9 in) 3205 (126.2 in) 1900 (74.8 in) 560-610 (22-24 in) 71,5 (2.8 in) 390 (15.3 in) 2460 (96.8 in) 2510 (98.8 in) – – 18390 (40543 lb) Semi-U (HSU) 5,6 (197.8 ft3) 3460 (136.2 in) 1425 (56.1 in) 850 (33.5 in) 10° – – – 21630 (47686 lb)

A

Straight (HS) 3,7 (130.7 ft3) 3900 (153.5 in) 1110 (43.7 in) 836 (32.9 in) 10° 535 (21 in) 1160 (45.7 in) 5675 (223.4 in) 22730 (50111 lb)

F

E I

1850-2M0007

LGP 3235 (127.4 in) 3195 (125.8 in) 4340 (170.9 in) 3205 (126.2 in) 2082 (82 in) 762-915 (30-36 in) 71,5 (2.8 in) 390 (15.3 in) – – 2844 (111.9 in) 2997 (118 in) 19410 (42791.7 lb)

Includes ROPS Cab, 610 mm (24 in) shoes (915 mm (36 in) for LGP), fuel oil and operator, for unit with ROPS canopy deduct 300 kg (661.4 lb).

With ripper raised, add 935 mm (36.8 in) to dozer length.

Includes ROPS Cab, 610 mm (24 in) shoes (915 mm (36 in) for LGP), 10% fuel, blade lift cylinders, lubricants, coolant.

m3 mm mm mm deg mm mm mm kg

BLADES DIMENSIONS Blade capacity SAE J1265 L Width of blade M Height of blade N Max. tilt O Max. pitch P Digging depth Q Max. lift above ground R Overall legth with blade** Operating weight with blade*

D

mm mm mm mm mm mm mm mm mm mm mm mm kg

R

C

TRACTOR DIMENSION A Height over cab B Height over muffler C Tractor length D Length of track on ground E Gauge F Track shoes width G Shoe grouser height H Ground clearance I Overall width with shoes 560 (22 in) Overall width with shoes 610 (24 in) Overall width with shoes 760 (30 in) Overall width with shoes 915 (36 in) Shipping weight w blade***

P

H

MAIN DIMENSIONS

1850K 7

8

1850K

STABILITY POSITION OF CENTER OF GRAVITY In transportation conditions Note: the centre of gravity depends upon the position of the equipment.

For inches device by 25.4

MACHINE W/ BLADE & RIPPER

X

Z

1285 mm 835 mm W/ blade and ripper on the ground 50.59 in 32.87 in W/ blade on ground and ripper at max. height

1320 mm 880 mm 51.96 in 34.64 in

W/ blade at max. height and ripper 1270 mm 930 mm on ground 50 in 36.61 in

Z X

W/blade at max. height and ripper 1310 mm 980 mm at max. height 51.57 in 38.58 in

MACHINE W/ BLADE ONLY

X

1850-2M0008

Z

Blade on the ground

1575 mm 780 mm 62 in 30.70 in

Blade at max. height

1565 mm 935 mm 61.61 in 36.81 in Z X 1850-2M0009

X MACHINE W/OUT BLADE AND W/OUT RIPPER

Z

1230 mm 910 mm 48.42 in 35.82 in

Z WARNING

X

The machine, as delivered by the plant, is not intended for any other application and, in particular, should not be considered for use as a mean for hooking, lifting or moving suspended loads.

Any different usage, therefore, MUST BE AVOIDED, unless the machine has been originally provided, by the manufacturer, with special equipment and particular instructions for specific applications.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850-2M0010

1850K

9

LIST AND LOCATION OF SAFETY DECALS All the safety plates applied on the machine to provide maximum operational safety against unavoidable risks, are listed here below: They have been divided into four groups: Group A - danger decals Group B - warning decals Group C - general-purpose decals Group D - maneuver decals The exact location on the machine is found in the figure here below.

LIST OF DECALS

A

B B

C

D

1A

TRACK TENSIONER SPRING DECAL

2A

TRACK TENSIONER SAFETY DECAL

3A

ENGINE STARTING DANGER DECAL

1B

FLUIDS UNDER PRESSURE DECAL

2B

OPERATION SAFETY DECAL

3B

SAFETY WARNING DECAL

4B

CAB TILTING SAFETY DECAL

5B

SWITCH DECAL

6B

BATTERY SAFETY DECAL

7B

ENGINE BELTS DECAL

8B

BRAKES SAFETY DECAL

9B

MANEUVER SAFETY DECAL

10B

HOT ZONE WARNING DECAL

1C

MAINTENANCE DECAL

2C

FUEL DECAL

3C

BRAKES/STEERING OIL CARTRIDGE REPLACEMENT DECAL

4C

TRANSM. OIL CARTRIDGE REPLACEMENT DECAL

5C

HYDRAULIC OIL DECAL

1D

EQUIPMENT OPERATION DECAL

2D

MACHINE LIFTING DECAL

3D

CONTROLS WARNING DECAL

4D

THROTTLE CONTROL DECAL

5D

EQUIP./TRANSM. CONTROL WARNING DEC.

6D

RIPPER CONTROL DECAL

7D

MASTER SWITCH DECAL

8D

STEERING SAFETY DECAL

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

10

1850K

LOCATION OF SAFETY DECALS 3B

10B

6B

2A

1A

3A 4B

8D

2D 9B

1C

8B

10B

1B

5C

1850-2M0011

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

11

3D

5B 1D

6D 2B

"A" 1850-2M0016

1850-2M0012

2C 4D

1850-2M0013

7B 1850-2M0017

7D

DET. "A"

1850-2M0014

1850-2M0018

5D 3C

4C

1850-2M0015

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850-2M0019

12

1850K

LIST OF SAFETY DECALS Group A - Danger decals

1A

2A

DANGER

DANGER

TRACK RELEASE SPRING IS ASSEMBLED INTO MACHINE WITH HIGH COMPRESSIVE LOAD. FOLLOW PROCEDURES RECOMMENDED IN UNDERCARRIAGE SERVICE MANUAL WHEN ASSEMBLING OR DISASSEMBLING THIS PART.

FLUID UNDER PRESSURE DO NOT LOOSEN TRACK TENSION BY UNSCREWING OVERLOAD RELIEF VALVE. DO NOT REMOVE THE LUBE FITTING LOCATED ON TOP OF THE BALL CHECK ASSEMBLY. FOLLOW PROCEDURES RECOMMENDED IN THE UNDERCARRIAGE SERVICE MANUAL.

1850-2M0020

1850-2M0021

3A

Starting in gear can cause death. Start engine only from operator seat with transmission control (s) in NEUTRAL 1850-2M0023

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

13

LIST OF SAFETY DECALS Group B - Warning decals

1B

2B

WARNING

WARNING HOT LIQUID UNDER PRESSURE Service when cool 1850-2M0024

Service when cool Fasten seat belt No riders Keep others away

3B

1850-2M0025

WARNING Do not modify or repair ROPS or FOPS in any manner 1850-2M0026

4B

IMPORTANT TO TILT THE CAB PROCEED AS FOLLOWS: - PLACE THE MACHINE ON FLAT GROUND, WITH THE DOORS CLOSED - OPEN BOTH CAB SIDE PANELS - REMOVE THE SIX CAP SCREWS SECURING THE RIGHT SUSPENSION SUPPORTS TO THE FRAME - DISCONNECT THE THROTTLE LINK FROM QUICK RELEASE JOINTS - ACTUATE THE CAB TILT PUMP LEVER WITH DIVERTER IN POSITION METERING THE FINAL TILTING STROKE BY ACTUATING THE DIVERTER

TO LOWER THE CAB, OPERATE CAREFULLY TO AVOID DAMAGING THE PARTS UNDER THE CAB AS FOLLOWS: - ACTUATE THE CAB TILT PUMP LEVER WITH DIVERTER IN POSITION REFER TO THE OPERATION AND MAINTENANCE MANUAL 1850-2M0027

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

14

1850K

5B

WARNING 9B

ALWAYS TURN THE MASTER SWITCH TO THE OFF POSITION BEFORE CLEANING, REPAIRING OR SERVICING, AND AFTER PARKING MACHINE. 1850-2M0028

6B

7B

WARNING AVOID CRUSHING DO NOT JUMP IF MACHINE TIPS

ENTANGLEMENT HAZARD EXPLOSION HAZARD RUN OVER HAZARD Read procedure in Operator's Manual before jump start or service to avoid injury

Keep clear or stop engine before servicing

1850-2M0029

1850-2M0030

USE SEAT BELT

1850-2M0031

8B

WARNING THE BRAKES ARE INOPERATIVE WHEN MANUALLY DISCONNECTED. THE MACHINE MUST BE SECURED BY APPROPRIATE BLOCKING DEVICES. THE BRAKES ARE EQUIPPED WITH STRONGLY LOADED SPRINGS. WHEN ASSEMBLING OR DISASSEMBLING THE BRAKES ALWAYS COMPLY WITH THE PROCEDURES RECOMMENDED IN THE WORKSHOP MANUAL.

10B

1850-2M0032

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850-2M0033

1850K

15

LIST OF SAFETY DECALS Group C - General purpose decals

2C

1C

FUEL

1850-2M0035

3C

WARNING REPLACE THE CLUTCH OIL FILTER CARTRIDGE EVERY 500 HOURS. 1850-2M0036

4C

WARNING REPLACE THE TRANSMISSION OIL FILTER CARTRIDGE EVERY 500 HOURS. 1850-2M0037

5C

1850-2M0034

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850-2M0022

16

1850K

LIST OF SAFETY DECALS Group D - Maneuver decals

1D

2D

4D

1850-2M0038

1850-2M0039

1850-2M0040

3D

WARNING

5D

PRIOR TO STARTING OR OPERATING THE MACHINE READ THE "OPERATION AND MAINTENANCE" MANUAL.

WARNING BEFORE LEAVING THE OPERATOR'S SEAT, MOVE THE LEVER TO LOCK POSITION

1850-2M0041

6D

1850-2M0042

8D

7D

1850-2M0043

NOTICE MACHINE WILL TURN IF THE ENGINE IS RUNNING, WHEN THE STEERING LEVER IS MOVED WITH THE TRANSMISSION IN NEUTRAL OR IN GEAR. ENGAGE THE STEERING CONTROL LOCK BY APPLYING THE PARKING BRAKE. SEE THE OPERATION MANUAL FOR FURTHER INSTRUCTION

1850-2M0044

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850-2M0045

1850K

17

PRELIMINARY INSTRUCTIONS AND BREAK-IN PERIOD PRELIMINARY INSTRUCTIONS

BREAK-IN PERIOD

When delivering the machine, the Sales Organization personnel provides the main instructions regarding its operation and maintenance to the Customer.

These instructions are summarized in the list here below: - Decantation of fuel.

- Check of capacities: coolant, fuel and lubricants.

- Draining of deposits from the fuel reservoir.

- Air bleeding of fuel system.

- Starting and stopping the engine.

- Rules for a safe conduct at work.

- First period of operation.

- Operation of the machine and of the equipment.

- Lubrication and lubricants.

- Maintenance of the air cleaner.

- Maintenance of filters: fuel, engine oil and hydraulic oil.

- Maintenance of the engine cooling system (the system is provided with a water/antifreeze mixture of a glycol type).

- Maintenance of the hydraulic systems: torque converter/transmission, steering, equipment.

- Checking the on-board Diagnosis.

A break-in period of at least 60 hours, is required, following the directions listed here below: - after each cold steering, operate the engine a few minutes at idle speed; - do not operate the engine at maximum power for prolonged time; - check frequently, if there are oil or coolant leakages.

Start the engine. Monitor all instruments and indicator lights; actuate the controls of the machine to check their operation. Cut-off the engine and check if there are eventual leakages from sleeves, pipes and connections.

WARNING Never perform interventions with engine running, except as called for in this Manual.

Before operating or performing any intervention on the machine, read carefully all the rules listed in this Manual.

During the first period of operation of the machine, besides the normal maintenance operations listed in the relevant chapter, it is recommended that supplementary operations are performed, which, at a later stage, are carried-out at longer intervals, as listed here below: Within the first 100 hours work: - change the fuel filter; - change the torque converter/transmission oil and relevant filter; - change the filter on the hydraulic system oil return to the reservoir.

Within the first 1000 hours: - check the fuel injection system and the engine valve clearance.

The above directions must be followed after overhauls, as well.

WARNING Do not run the engine of this machine in closed areas without proper ventilation to remove deadly exhaust gases.

Be sure exposed personnel in the area of operation are clear of the machine before moving it or its attachments.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

18

1850K

OPERATION RULES WARNING Carefully study this Manual before starting, operating, maintaining, fuelling or servicing the machine.

This alert symbol signals important messages involving your safety. It means: WARNING! BE ALERT! IT INVOLVES YOUR SAFETY. Read and heed carefully all safety instructions identified by the key words WARNING and DANGER. Do not operate machinery in a condition of extreme fatigue or illness; do not jump on or off the machine; use the appropriate handrails and steps which must always be kept clean. Also keep the operator's compartment clean; all tools and/or personal belongings not required on the machine must be removed or be secured.

This machine and its equipment must be operated exclusively by qualified personnel, sitting in the operator's seat.

Your safety and the safety of bystanders depends upon your prudence and common sense in operating this machine.

It is necessary to be acquainted with the location and function of all controls and with stability features of the machine before starting to operate.

Before starting machine, check, adjust and lock the operator's seat for maximum comfort and control of the machine.

Never attempt to operate the machine or its tools from any position other than seated in the operator's seat. Under all circumstances, keep head, body, limbs, arms and feet inside the operator's compartment to minimise the possibility of exposure to external dangers.

Make sure that the portion of the engine exhaust system under the hood is sealed.

In darkness, check area of operation carefully before moving in with machine. Use all lights provided. Check, during daylight as well, that all lights are operating. Replace burnt bulbs at once.

NEVER LEAVE THE MACHINE UNATTENDED with the engine running. The equipment can be lowered moving the control lever with engine running or inoperative.

Always, before leaving the operator's seat and after making sure all people are clear of the machine, slowly lower the attachments or tools flat to the ground in a positive ground support position.

Move eventual supplementary equipment to closed and safe position.

Return all controls to rest position.

Place engine controls on cut-off position Lock all controls and disconnect the starter switch.

Do not park the machine on a slope, without blocking it accurately, to prevent any movement.

Always engage the parking brake, before leaving the machine.

Be sure exposed personnel in the area of operation are clear of the machine before moving it or its attachments. WALK COMPLETELY AROUND the machine before mounting. Sound horn.

Keep all persons away form equipment being raised to avoid possible injuries.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850-2M0049

L

N

R

F

L UP

1850-2M0052

DOWN

P

To steer leftward, move the L control in “S” position, to steer rightward move the L control in “D” position.

S

D

Open the external panel and turn the main switch into position “ON”.

1850-2M0046

1850-2M0050

B

A

At the end of the operations: cut-off the engine with the starter switch, open the external left panel and turn the main switch into position “OFF”.

1850-2M0053

9-

Main switch

ON

6-

1-9

3-

1850-2M0154

Starter switch

START

7

D350M0156

D

3

1850-2M0054

6

2-5

1850-2M0051

4-7

Insert the key into the starter switch, push it in and turn it into position “START”.

Warm-up the engine for at least 5 minutes.

H

OFF

ACC

ON

Raise the equipment moving the blade control lever into position “D”.

7-8

2-5

1850-2M0055

B

Make sure that the transmission and implement control safety device are in position “A”.

OFF

2-

1850-2M0047

B

A

To operate the machine: - Move the L control in “F” position (forward speed), “R” position (reverse speed) in “N” position (neutral) - Accelerate using the lever “A” on dashboard.

- To brake, use the pedal “B”.

7-

8-

1-

Main switch

OFF

ON

A

FIRST OPERATION DECAL

5-

n/m in

100 0

1

3

2

1850-2M0048

A

A

1850-2M0047

1850-2M0055

B

Unlock the transmission and implement control safety devices, moving the levers from position “A”.

A

Adjust the engine speed, operating on the lever “A” (throttle control) and the throttle pedal.

B

4-

0

1850K 19

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

- Use MRM2 grease to lubricate all the hinging.

Lenght of diagonal tie-rod (3) connecting the push arms to the mouldboard can be adjusted to allow quadrature of the push arms with the machine. Finally, at the end of the assembly, when checking sizes (L1 and L2), should (L1) appear to be greater than (L2), it is necessary to lengthen the tie-rod (3): or otherwise shorten it.

- Ball and socket joints (b) for hinging the adjustable tie-rod (1) and the tilt cylinder (T) to the moulboard must be adjusted by means of shims (s) in order to allow the ball freedom of movement with an axial backlash of 0.3-0.6 mm; - Lenght of adjustable diagonal tie-rod (3) must be the same as that of the fixed tie-rod (2). Once this is performed, proceed with assembling the complete equipment. After hinging the boom to the track, pay attention to lay the mouldboard, on a wooden support, by means of the central leverage support so that the rear wall is vertical and the booms are symmetrical as compared with the machine, by measuring sizes L1-L2 between boom and track.

- Use fulcrum in (d), to oscillate crosswise first the tie-rod and then the cylinder to check their alignment with the respective seats on the moulboard.

- If it appears, upon checking, that connection can take place without forcing, proceed with fastening, paying attention to guarantee a backlash of 0.3-0.6 on the ball, previously set by means of shims (s).

- Otherwise, move the push arms by means a lever, until detecting a free connection of the tie-rod and the cylinder, then shim at point (a) by distributing the shims according to the obtained space.

At equipment assembly stage, first of all consider following instruction:

1850K BULLDOZER EQUIPMENT INSTALLATION

e

m

g

C3 C1

d e

L2

L1

3 a

Push arms and bulldozer blade

h

C2

C1

b

m

f

T

1

b

3

2

SM959

g

t

Note – On reassembly grease the threaded ends of the tie rods (1) with Fiat grease MRM2.

a. Hinge front push arms - b. Front ball hinge side tie rod (1) and cylinder (T) - d. Rear hinge side tie rod (1) and cylinder (T) - e. and f. Diagonal tie rod hinge (2 and 3) - g. Blade control cylinder rod hinges - h. and m. Hinges central blade leverage - Cl. Blade control cylinder - C1. Fixing screws hinge pin plate (e-g), tightening torque 17 ÷ 19 daNm (125 ÷ 140 lb ft) - C2. Fixing screws hinge pin flange (a-f-h), tightening torque 22 ÷ 24 daNm (162 ÷ 177 lb ft) - C3. Fixing screws ball hinge seat (b), tightening torque 22 ÷ 24 daNm (162 ÷ 177 lb ft) - L. = 1206 ÷ 1208 mm (47.48 ÷ 47.55 in). Length of the tie rods (1) to be measured as shown in the illustration - L1. and L2. Check values on reassembly (maximum tolerance 10 mm) - S. Regulator plates ball joint - T. Hydraulic tilt control cylinder - 1. Left hand lateral tie rod for adjusting cutting position and sideways tilting of the blade - 2. Left hand diagonal tie rod connecting blade to push arms - 3. Right hand diagonal tie rod connecting blade to push arms.

f

d

a

S

C2

Cl

h

20 1850K

EQUIPMENT INSTALLATION DECAL "SEE INSTALLATION INSTRUCTION (BUR6-49110)"

1850K

21

CONTROLS AND INSTRUMENTS 17 16

9

21 18

19

14

15

1

8 8 2

10-13 11

3

12 22

5 6

4 7 8

8

1. Safety lever (equipment control and gearshifting lever locking) - 2. Blade control lever - 3. Ripper control lever - 4.

Engine starter switch - 5. Ashtray - 6. Cigarette lighter - 24V DC Power Outlet - 7. Horn - 8. Air inlet ducts - 9. Cab heating and ventilation controls (on cab roof) - 10. Transmission control lever - 11. AUTO SHIFTING "AS" function button

7 A

n/min

0

1000

(Optional) - 12. AUTO KICK DOWN "AL" function button 13. Steering control - 14. Armrest adjustment lever 15. Transmission safety lever (Gearshifting lock) - 16. Instrument panel - 17. Switch and indicator panel - 18. Engine throttle lever - 19. Engine decelerator control pedal 20. Electrical system master switch - 21. Brake pedal.

For the version equipped with ROPS structure, components 5, 7, 8 are located on the dashboard, as indicated.

5

2

1

1850-2M0056

3

Note – The terms left and right used in this text, are intended as referred to the operator seating in its seat facing forward.

8

1850-2M0057

on ROPS

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

22

1.

1850K SAFETY LEVER (Equipment control and gearshifting lever lock) F

The device, lifted as illustrated in the figure in position A (vertically) blocks the EQUIPMENT CONTROL LEVERS AND THE FWD-REV JOYSTICK in neutral position. Allows starting of engine.

This is to avoid unwanted movements of levers (3-4) and buttons (11) which could cause dangerous manoeuvres. In this position, the parking brake is automatically applied.

Position B: it activates the equipment control levers, the joystick switch and disengages the parking brake.

H

B

A D

D350M0159

A

F

2

1

A

n/min

3

1000

0

H N

A

B

D

B Blade control lever

1850-2M0059

1850-2M0058

Position A = neutral Position B = operation position

2.

3.

RIPPER CONTROL LEVER (upon request)

- With lever forward in P = ripper lowering - With lever backward in R = ripper raising - Lever in N = neutral

BLADE CONTROL LEVER

The lever controls the raising, lowering and tilting of the blade.

To raise or to lower the blade, move the lever backward to position D or forward to position H, respectively.

To stop the blade in the desired position, in both cases, release the lever which is automatically returned to neutral N. To float the blade, meaning bearing on the ground exclusively under its own weight, push the lever to stroke-end forward, into position F, where it engages an appropriate detent.

The float condition is terminated when the lever is returned into neutral position N. Moving the lever leftward into position A or rightward into position B, the tilting of the blade is obtained. The lever must be held until the blade reaches the desired tilting.

1850-2M0060

Ripper control lever

A

2

1 n/min

0

1000

3

P N R 1850-2M0062

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

4.

23

ENGINE STARTING SWITCH WARNING Do not pre-heat the engine more than 30 seconds, to avoid possible damages to the glow plug.

Starting switch ON

START

1850-2M0063 ACC.

on CAB

Safety lever indicator lights

OFF

Pre-heater indicator light

H

A

2

1 n/min

0

1000

3

Pre-heating indicator Safety lever indicator

Starter key

1850-2M0064

on CAB

Table A

5

Temperature

Pre-heating time

Below -15 °C (5 °F)

20 sec.

Below -24 °C (-11 °F)

30 sec.

1850-2M0061

on ROPS WARNING Prior to starting the engine, make sure that the Joy-stick is in neutral position and that the parking brake is engaged.

The starter switch starts and shuts-off the engine.

To actuate it, turn the key: Position H: Operation to be perfomed only on machines equipped with cold starting device.

Arrange the machine as described at point (STARTING THE MACHINE AT COLD TEMPERATURES)

Engine pre-heating position Place the starter key onto "H" position when the temperature is particularly low (less than - 15 °C (5 °F).

Keep the key in this position for a time sufficient to allow the pre-heating. The time changes depending upon the ambient temperature. see Table A. In this position, for the entire duration of the pre-heater, the pre-heater indicator light is ON.

At the end of this phase, the engine pre-heating indicator light (see figure) goes OFF and the machine can be started, turning further the key into "START".

This operation is not required when the engine is hot or the ambient temperature above 30 °F, thus the key can be turned from "OFF" to "START".

Positions: OFF

- Position allowing the insertion and removal of the starter key. Engine inoperative.

ACC

- All functions related to electrical system services are activated. The indicator lights onthe instrument panel (see Instrument panel) come ON.

ON

- All other functions of the electrical system are activated and the safety lever indicator lights come ON

D350M0160

Safety lever indicator lights

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

24

1850K

START - The functions relative to position "ACC" are cut-off. Starting of the engine. The switch returns automatically to position "ON" when the key is released.

9.

CAB HEATING AND VENTILATION CONTROLS (For the setting of the controls, refer to the cab)

In the event the engine fails to start, wait for 30 seconds before a new attempt; this is to protect the batteries and the starter motor from overheating.

AUTO

Note – For particularly frigid temperatures (down to -15 °C (5 °F) use an engine oil with appropriate viscosity and fuel with low temperature additives.

Down to - 20 °C (- 4 °F) the use of artic fuel and larger batteries (180 Amph - 770 Amp) is recommended.

WARNING

1

STOP

ECOM

2

D150-2M042

10. TRANSMISSION CONTROL LEVER

Under forced starting conditions (i.e. low ambient temperatures) do not try beyond three attempts of 30 sec.s max. each, intervalled by at least a 2 minutes pause, to avoid thermal overheating damaging electrical components. After the third attempt, let the starter solenoid to cool-off to a temperature of 25 °C (77 °F).

5.

ASHTRAY

6.

24V DC POWER OUTLET/CIGARETTE LIGHTER

The power outlet is equipped with cigarette lighter (on the option with cab) and can be used to feed 24V DC power supply to a trouble lamp or a fuel transfer pump.

The machine is equipped with three forward and three reverse speeds. The controls are electrically actuated by the following switch, located in the left side of the cab.

When the lever L into position F the transmission is arranged for Forward motion, 1st speed.

To select 2nd or 3rd speed actuate the switch P in "UP" position.

To downshift actuate again switch P in "DOWN" position.

F

P L

UP

N

DOWN

7.

HORN

8.

VENTILATION DUCTS R

6

C F

3

9

7

1850-2M0067

F. Forward speed - L. Transmission control lever. - N. Neutral - R. Reverse speed - P. Speed upshifting/ downshifting button.

8

When moving the lever into position R the transmission is shifted into 1st REVERSE. The gearshifting and the direction change can be made with machine in motion or standing.

When pressing switch P, the most appropriate speed from 1st through 3rd can be selected.

Starter key

1850-2M0065

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

25

Selecting forward speed ("F")

11. AUTO SHIFT "AS"

When lever L is pushed forward into position ("F") the machine is set in 1st forward.

When pressing, switch P in “UP” position, the speeds are upshifted.

When pressing switch P into position "DOWN" the speed is down-shifted.

The display on the dashboard indicates the speed engaged and possible options (Auto-Shift, Auto-Low).

Button AS is selected when the operating cycle requires frequent FORWARD - REVERSE shifting.

The system selects 1st forward for the work phase and 2nd reverse for back-up travel.

1850-2M0150

Display on the dashboard

Selecting reverse speed ("R") When pulling lever L backward into position ("R") the machine shifts into REVERSE and provides the rearward motion only, with the possibility of choosing among 1st, 2nd and 3rd speed, by actuating switch P. The change of direction is always possible, irrespective of the speed in which it stands.

As an example, while one operates with 2nd speed engaged and the direction is reversed by the gearshifting lever to position "R", the shifting from second forward to second reverse occurs automatically.

Speed upshifting ("UP") Speed downshifting ("DOWN") Switch the transmission speeds are upshifted every time switch P is pressed into position UP, selecting the most appropriate operational speed, up to 3rd.

To downshift, press switch P in "DOWN" position.

AUTO KICK DOWN AND AUTO SHIFT FUNCTIONS When pressing buttons AS - AL the two operating modes are selected. The selection of one excludes the function of the other.

Safety levers Auto mode description Automatically downshifts the transAL mission when the engine lugs down to a predetermined RPM level AS

Allows the operator to pre-select the 1st speed for forward and 2nd speed for reverse at directional change

1850-2M0068

AUTO SHIFT "AS" button.

AUTO KICK DOWN "AL" button When pressing the AUTO SHIFT button once, the option is activated and the display shows symbol AS. The option is cut-off by pressing the button a second time.

The gears are shifted in accordance with the following inversion logic.

INVERSION LOGIC (with "AS" function activated) If you are in1st F by pushing R shifts into 2nd R " 2nd F " R " 2nd R rd " 3 F " R " 3rd R " " "

1st R 2nd R 3rd R

" " "

F F F

" " "

1st F 1st F 1st F

12. AUTO KICK DOWN "AL" When button AL is pressed, a semi automatic gearshifting is selected.

The system is capable of down shifting automatically to the nearest speed, when the machine changes from a travel to a digging phase, gradually arranging the most appropriate speed, depending upon the resistance encountered during the pushing phase.

Operation of AUTO KICK DOWN option : AL

Activation of option The "Auto kick-down" option is activated by pressing button AL. When the option is engaged, symbol "AL" appears on the monitor display.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

26

1850K

Deactivation of the option The "Auto kick-down" option is disengaged by pressing (a second time) button AL. When the option is deactivated, symbol "AL" on the monitor display goes OFF.

Leftward steering To steer leftward, move the L control in "S" position.

The right one increases the speed, whereas the left one slows down in the same amount.

Logic of the Auto kick-down The logic of the "Auto kick-down" is managed by the electronic controller unit. The Auto kick-down provides the automatic downshifting of the gear engaged (from 3rd to 2nd or 2nd to 1st) when the engine speed decreases below the pre-arranged threshold. With the option activated, by pressing the brake pedal or the decelerator pedal, the automatic downshifting is only temporarily cut-off.

The option does not operate in reverse.

Note – When the machine operates at an engine speed below the pre-arranged threshold and the option is engaged, the machine operates in 1st only and the system does not allow shifting into 2nd or 3rd (this limitation applies to "Forward" direction only).

S

L

1850-2M0070

Leftward steering

14. ARMREST ADJUSTMENT LEVERS To adjust the position of arm rest, operate the related levers.

13. STEERING CONTROL This device provides steering without locking the track chain.

Steering rightward To steer rightward move the L control in "D" position, the right track chain slows-down, whereas the left track chain accelerates in the same amount; the speed differential steers the machine.

The greater is the stroke of the lever, the greater is the steering of the machine.

15. TRANSMISSION SAFETY LEVER This device can have two positions.

Position A (vertical): in this position, the machine can be started.

When parking with engine running, the joy stick are neutralized. This is to avoid that an unwanted movement could occur. In this position, the parking brake is engaged.

Position B (lowered): the lever allows the shifting of gears and releases the parking brake.

A

L

D

B

1850-2M0069

Rightward steering

1850-2M0071

Position A = neutral Position B = in operating position

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

27

16. INSTRUMENT PANEL Indicator lights and instruments

L1

L2

L3

L4

L5

L6

L8

L7

1

L9

L10

L11

L12

2 n/min

DL1 S1

DL2

0

x 1000

S3

3

S2

S4 1850-2M0072

Indicator lights and instruments

L1. Battery charge indicator - L2. Engine oil pressure indicator - L3. Engine air cleaner indicator - L4. Hydraulic oil filter indicator - L5. Transmission oil pressure indicator - L6. Transmission oil temperature indicator - L7. Brake lube system failure indicator - L8. Brake failure indicator L9. General alarm indicator - L10. Front work lights indica-

tor - L11. Rear work lights indicator - L12. Headlights indicator + dashboard light - DL1. Fuel reserve LED indicator - DL2. Engine coolant temperature LED indicator - S1. Fuel level instrument - S2. Engine coolant temperature gauge - S3. Display - S4. Rev. Counter.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

28

1850K

L1. Battery charge indicator

L7. Brake lube system failure indicator

The indicator light comes ON when the charging of the batteries is insufficient.

L8. Brake failure indicator L2. Engine oil pressure indicator The indicator light is activated when the pressure of the engine lube oil drops below a defined value. Also, it comes ON when the engine oil filter is clogged.

L3. Engine air cleaner indicator The constant glowing of the indicator signals the clogging of the air cleaner cartridges, requiring cleaning or replacement.

L4. Hydraulic oil filter indicator The activation of the indicator signals the clogging of the oil filters, which require to be replaced.

L9. General alarm indicator It warns the operator with a dual signal (sound and flashing light) about eventual functional troubles signalled by the indicators.

When the general signal operates, it is necessary: - to stop the machine and cut-off the engine; - to disengage the electrical system master switch; - to take the measures required to eliminate the cause of the trouble. If the trouble persists, contact the Service Organisation.

L10. Front work lights indicator The indicator light comes ON when the switch is engaged.

L5. Transmission oil pressure indicator The activation of the indicator signals an insufficient pressure, which could be caused by: - clogged oil filters; - use of oil with a viscosity not appropriate for the ambient temperature; - abnormal operation of the system.

If required, perform appropriate inspections taking the necessary corrective actions; if the trouble persists, contact the Service Organization.

L6. Transmission oil temperature indicator The activation of the indicator signals an excessively high temperature of the oil; trouble which could be caused by: - clogged oil suction filter; - prolonged operation of the machine under irregular conditions; - abnormal operation of the hydraulic system.

The overheating of the oil must be avoided since it alters the specifications of the oil and causes prejudice to the operation of the components.

Operating with oil at temperatures relatively high is permitted for short periods, provided that the engine coolant, circulating in the heat exchanger and cooling the oil, does not reach excessive temperatures.

L11. Rear work lights indicator The indicator light comes ON when the switch is engaged.

L12. Headlights indicator + dashboard light The indicator light comes ON when the switch is engaged.

DL1. Fuel reserve LED indicator The activation of the indicator light signals that it is necessary to refuel.

DL2. Engine coolant temperature LED indicator It comes ON when the temperature of the coolant in the radiator is too high.

Notice – In any case, keep in mind that, to obtain maximum performance by the torque converter, the speed engaged must be appropriate for the work to be done.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

29

INSTRUMENTS Coolant temperature This instrument indicates the temperature of the coolant.

When the temperature is too high (red zone) indicator light (DL2, indicator lights figure) comes ON, signalling that the engine is overheating. Run engin with no load until temperature drops.

Fuel level It indicates the level of the fuel in the reservoir. When the pointer is near the red zone, indicator light (DL1) comes ON, signalling an "empty reservoir". Refuel as soon as possible.

DL1 S1

DL2 S2 1850-2M0075

1850-2M0073

Display S3 The display shows three functions: A) - Digital hourmeter, indicating the total work hours and it is automatically activated when the ignition switch is turned on (four, five and six digit) B) - Speed engaged one (five and six for AL/AS functions) digit C) - Error codes, one (with 0) and three, four, five and six digit (for example 0 E016)

Tachometer (rpm's x 1000) It indicates the engine rpm's.

1

2 n/min

0

x 1000

S3

3

S4 1850-2M0074

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850-2M0151

30

1850K

When the failed component is one only, the display shows a code listed in TABLE 1.

For each trouble code, find the corresponding component.

Ex: 0 E016

1850-2M0152

TABLE 1 Failed component

Trouble code

Forward "F" speed solenoid

004

Reverse "R" speed solenoid

008

1st speed solenoid

016

3rd speed solenoid

032

When the failed components are two, the display shows a trouble code listed in TABLE 2, given by the addition of two single codes listed in TABLE 1. As an example, code 024 indicates that two parts are in trouble. On the top, the column identifies, in correspondence with the "1st speed" solenoid (first failed component).

Whereas, on the left, it identifies the reverse speed "R". The crossing of the two components determines the trouble code, given by the addition of the twos.

1850-2M0153

TABLE 2 Failed component

LH prop. sol. valve coll

Forward "F" speed solenoid Reverse "R" speed solenoid 1st speed solenoid

RH prop. sol. valve coll

For. "F" speed solenoid

Rev. "R" speed solenoid

1st speed solenoid

3rd speed solenoid

004

012

020

036

008

024

040

016

048

3rd speed solenoid

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

032

1850K

31

17. SWITCH AND INDICATOR PANEL 1

2

g.

REAR WORK LIGHT ACTIVATION SWITCH

h.

SAFETY LEVER INDICATOR The indicator lights come ON when the machine is started and the equipment control safety lever (1) and gearshifting safety lever (2) are in raised position (A) (NEUTRAL).

The indicator lights go OFF, when the levers are lowered to operate the machine (Position B).

n/min

0

a

b

c

d

x 1000

e

3

f

g

h

i 1850-2M0076

on CAB

D350M0160

A

2

A

A

B

2

1 n/min

0

1000

1

3

B

g i h e f 1850-2M0078

1850-2M0077

on ROPS a. FRONT/REAR WIPER 1 speed SWITCH (with cab only) b. FRONT/REAR WASHER BUTTON (with cab only) c. SIDE DOORS WASHER BUTTON - d. SIDE DOORS WIPER 2 speed SWITCH - e. LIGHT SWITCH - f. FRONT WORK LIGHT ACTIVATION SWITCH - g. Rear work light activation switch - h. Safety lever indicator - i. Pre-heating indicator light.

Position A = NEUTRAL Position B = operation position

i.

PRE-HEATING INDICATOR LIGHT

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

32

1850K

18. ENGINE THROTTLE LEVER

20. ELECTRICAL SYSTEM MASTER SWITCH

Forward = maximum acceleration.

Backward = minimum acceleration.

The electrical system master switch is found when opening the left panel, indicated in the figure. The key of the electrical system master switch must be in position ON when the system must be operational.

Turn the switch key into position OFF (same as moving direction of machine) when the machine is parked at the end of the work shift, then extract the key.

19. ENGINE DECELERATION CONTROL PEDAL When pressing the pedal, the engine rpm's are, momentarily, reduced to slow idle.

Moving direction

ON

1 n/m

2

in

0 1000

3

OFF

19 1850-2M0080

21. BRAKE PEDAL 22 20

1850-2M0079

When the pedal is pressed, both track chains are braked.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

33

OPERATING INSTRUCTIONS GENERAL INFORMATION Before placing the machine in motion, be certain it has been properly prepared for use and has been properly serviced since the last operating period. Refer to the chapter "PRELIMINARY INSTRUCTIONS AND BREAK-IN PERIOD" for detailed information.

If repairs have been made during the last period of inactivity of the machine, ensure that all bolts and nuts of the components involved are properly tightened and that all necessary adjustments are made.

PRIOR TO STARTING (DAILY) By reacting promptly as soon as troubles develop it is possible to reduce maintenance costs and machine downtime. Thus, it is recommended that, every day, prior to starting or at the end of the day, a walk-around inspection is done, performing the following operations: - remove dirt, mud, oil and snow from the machine; - check if there are oil leakages.

- Check the hydraulic oil level.

- Check the torque converter/transmission oil level.

- Check the operation of the throttle pedal, the color of exhaust fumes and the exhaust noise.

- Check the ROPS cab, safety belt for damages and the loosening of securing fixtures.

- Prior to operating the machine, warm-up the various components, without considering the season.

- Do not operate the engine at high speed without load, especially when cold.

ENGINE STARTING

WARNING Warn all people who may be servicing or working around the machine before starting.

Do not run the engine of this machine in closed areas without proper ventilation to remove deadly exhaust gases.

Observe all start-up procedures and WARNINGS listed in this Manual.

DANGER In case it is difficult to identify the cause of leakage due to the presence of dirt, clean the component to be inspected.

Start the engine to identify coolant or oil leakages.

Oil leakages under pressure are dangerous since hydraulic oil could penetrate the skin.

Do not try to locate leakages from the hydraulic system using bare hands. Use a piece of cardboard.

- Check for damaged hoses and pipes in the hydraulic system.

- Check the engine oil level and the presence of contaminants in the oil.

- Check fuel level in the tank.

- Drain water from the sedimentation filter.

- Check the coolant level and the presence of dirt on the radiator fins.

- Check the engine air cleaner restrictor indicator.

- Check the operation of instruments and indicator lights on the dashboard, lights, horn.

Open the left cab side panel.

Turn ON the ELECTRICAL MASTER SWITCH located inside the left side panel of the cab indicated in the figure.

Moving direction

ON

OFF

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850-2M0080

34

1850K

Climb on the machine using only points where handrails and steps are provided.

Prior to climbing on the machine, clean and inspect steps and handrails.

Climb and descend the machine facing it.

Keep three contact points with handrails and steps.

Note – The three contact points can be two feet and one hand or two hands and one foot.

Do not climb or leave the machine while it is in motion.

Do not jump off the machine.

Do not attempt climbing or leaving a machine while transporting equipment or other materials.

When entering or leaving the operator's compartment, do not use any control as a grabbing point.

D350M0087

Make sure that the GEARSHIFTING and BLADE CONTROL safety levers are in neutral position (raised).

Insert the key into the starter switch, pressing it slightly and turn it clockwise into position "ON", fig. starter key.

Motion direction ON

START

ACC. OFF 1850-2M0081

H

Starter key 1850-2M0082

Secure the safety belt before placing the machine in motion. Adjust it while seated.

Adjust and block the seat in the most convenient and comfortable position.

Monitor the instrument panel and the indicator lights that there are no troubles on the machine.

Press the engine starter switch key and turn it into position "START".

Once the engine is started, release the key.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

35

Do not keep the starter key in position START more than 10 seconds at each attempt; otherwise, the starter motor is damaged.

Warm-up the engine for at least 5 minutes, without considering ambient conditions.

Reduce the engine speed.

Move the joy-stick control to neutral, and engage the relevant safety lever into neutral position A. F

P L UP

Notice – If the engine has been inoperative for a long time or with low ambient temperature, increment the circulation of fuel with a few strokes of the primer pump.

N

DOWN

Notice – Do not operate the starter motor for more than 10 seconds.

If necessary, wait for a few minutes to facilitate the cooling-off of the starter motor. Avoid pointless starting attempts, since there is the risk of exhausting the batteries. Search for cause of failed starting.

R 1850-2M0067

A B

A

Note – The most frequent causes of starting failure may be: presence of air in the fuel system, low battery charge, defective operation of the starter motor or faults in the electrical system.

B

1850-2M0083

STOPPING THE MACHINE WARNING

Position A = neutral Position B = operation position

Lower the equipment to the ground and engage the equipment safety lever into neutral position A.

Never park on a slope without blocking the machine to prevent any movement.

Every time the operation of the machine is interrupted, for whatever reason, check that all controls are in neutral position and that the equipment control lever locking device is in lock position.

WARNING Always, before leaving the operator's seat and after making sure all people are clear of the machine, slowly lower the attachments or tools flat to the ground in a positive ground support position.

Move eventual supplementary equipment to closed and safe position.

Return all controls to rest position.

Place engine controls on cut-off position.

Lock all controls and disconnect the starter switch.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

36

1850K

STOPPING THE ENGINE

OPERATOR'S SEAT ADJUSTMENT

WARNING - NOTICE At the end of each operation period of the machine, do not shut-off the engine suddenly, but it is recommended that a cooling-off period variable from 3 to 5 minutes is observed, prior to stopping the engine. A sudden shut-off of the engine with the turbo-charger at high speed and temperature will result in a transfer of heat to the bearing housing. Repeated hot shut-off could damage the shaft bearings.

With engine at low idle, move the engine starter key into position OFF and remove the key.

The seat is provided with devices allowing the adjustment of the inclination of back rake, of the distance to reach the controls and of the height.

Further a lever to control the seat rotation and a knob to adjust the lumbar section support are provided.

WARNING Before starting the machine, adjust and lock the seat for maximum comfort and control of the machine.

Inspect periodically the seat belt. No traces of fraying, wear or other weaknesses that could lead to failure must be found.

Motion direction ON

START

ACC. OFF H

e Starter key d

1850-2M0084

a

Prior to leaving the machine, in case this is going to be unmanned, move the ELECTRICAL SYSTEM MASTER SWITCH into OFF and remove the key.

b

Moving direction

c 1850-2M0165

a b c d e

ON

-

Fore & aft adjustment control.

Seat height/weight adjustment control.

Swivel operation control.

Seat back adjustment control.

Lumbar section support adjustment control.

OFF

1850-2M0080

If outdoor temperature is low, it could be difficult starting the engine. It is appropriate to pre-heat the engine; please refer the relevant instructions at item 5 (Starter switch) page 23.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

37

e d a

1850-2M0085

b

Fuel filter cap c 1850-2M0166

On ROPS

FUEL RESERVOIR DANGER Extinguish all smoking materials and open flames before checking and filling fuel reservoirs.

Never refuel with engine in operation.

Never use matches, cigarette lighters or torches as a source of light near flammables.

BLADE ADJUSTMENT Bulldozer version In the bulldozer version, with a blade tilt control rod on the left side, tighten or loosen sleeve E using bar T to move further.

E

Always use fuel that has settled. When transferring fuel from the settling vessel to the machine reservoir, use a pump equipped with a filter.

It is recommended that the refuelling occurs at the end of each day's work; this will prevent condensations during overnight parking. Do not run-out of fuel; this will cause the entry of air into the fuel system with consequent need for a bleeding operation.

T D350M0091

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

38

1850K

CAB TILTING WARNING The cab is tiltable on the left side of the machine to allow an easy accessibility for the maintenance of the main groups of the machine.

To tilt the cab using an hydraulic cylinder and an hand pump, proceed as follows: - place the machine on a flat surface and open right and left side panels (2) under the cab;

Prior to tilting the cab, make sure that left panel (1) of the engine compartment is closed, to prevent interferance, in open position, with front central window (4) of the cab.

Also, make sure that right and left panel (2) under the cab are open to prevent interfance with the frame during the tilting phase.

4

1 2

3

1 2

1850-2M0164

1850-2M0086

- open upper left panel (1) of the engine compartment and lower side panel (3); - disconnect the engine throttle lever quick release coupling G.

- Return to the right side and loosen the six screws V securing the cab.

The screws secure the two supports S of the cab to the base of the machine frame (three screws each side);

G S V

1850-2M0087

G. Throttle lever quick release coupling.

- close lower panel (3) and upper panel (1).

1850-2M0088

- turn diverter valve B into "cab tilting" position

";

Diverter valve B in cab tilting position 1850-2M0089

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

39

- actuate hand pump P using lever A inserted into hole C to tilt the cab, very slowly;

LOWERING THE CAB To lower the cab, proceed as follows: - turn diverter valve B into lowering position

A

C

;

Diverter valve B in cab lowering position.

1850-2M0092

- actuate hand pump P with lever A and constantly check that there is no interference with the parts below, such as wires or pipes.

T

B

P

1850-2M0090

A. Pump actuating lever - B. Diverter valve - C. Lever hole - P. Hand pump - T. Hand pump oil plug.

Note – Once the centre of gravity of the cab overcomes the dead point, it is not necessary to pump oil with lever A, since the tilting continues naturally under the effect of gravity, to the position determined by the tension of safety cable F. Control the last tilting travel of the cab, by alternating diverter valve B from one position to the other .

Note – During the final portion of the travel, the lowering of the cab occurs under the effect of gravity which must be controlled by moving gradually diverter valve B into "tilting position" .

Re-connect quick release joint G of the engine throttle linkage and tighten the six screws V securing the cab, to a torque of 51÷ 55 daNm (376 ÷ 405 lb ft).

OIL REFILLING AND BLEEDING OF THE CAB TILTING SYSTEM E

F

Proceed as follows: - make sure that cylinder E as the rod fully retracted; - remove pump plug T and fill with prescribed oil; - perform two or three tilting and lowering maneuver of the cab, to bleed the air from the system; - fill with oil through the plug, with the rod of cylinder E fully retracted; - close plug T.

1850-2M0091

E. Hydraulic cylinder - F. Safety cable

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

40

1850K

BRAKES DISENGAGEMENT

Brakes engaged position

In the event the engine is inoperative and the machine must be moved, it is necessary to manually disengage the brakes, proceeding as follows: Tooling required: - wrench, 19 mm and 22 mm (0.74 and 0.87 in); - allen wrench 8 mm (0.31 in); - hand pump (*P/N 75295017); - 2 brakes disengagement bolt (* P/N 380001315)

S

C

A

B

4,5 mm (0.18 in)

D350M0164

WARNING

WARNING

Brakes mechanically disengaged are inoperative.

Prior to beginning the operations for the disengagement of the brakes, implement all the precautions required to block the machine.

Brakes mechanically disengaged are inoperative.

Prior to beginning the brake disengagement operations, implement all necessary cautions to secure the machine.

3) Loosen plug (T) on connection (R) as indicated, on the transmission housing.

Disengaging the brakes

R

T

Tilt the cab.

1) Remove guards (R, fig A) and stone guard (P) loosening securing screws (V) on both sides.

2) Remove plug (T) using an Allen wrench and tighten disengagement screw (A, fig. B 380001315) complete with washer and locknut (C) on piston (S).

R

P V

V

1850-2M0094

T

Connect hand pump (75295017) and actuate until disengagement screw (A, fig. E) indicating the unlocking of piston (S) (about 4.5 mm) (0.18 in).

Note – The hand pump must have a delivery of at least 100 cu cm per stroke and a head of at least 20 bar (290 p.s.i.). The cab-lifting pump is not sufficient to disengage the brakes.

A 1850-2M0093

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

41

TOWING THE MACHINE

Brakes disengaged position S

C

A

E

4,5 mm (0.18 in)

D350M0165

(*) For special tools, please contact your CASE Authorised Service Centre.

4) Tighten locknut (C, fig. F) until it touches the face of the transmission housing, so that piston (S) is prevented from going back. Under this condition the machine is not braked on one side only.

Repeat the operation from 2 through 4 on the opposite side, as well.

C

A

F 4,5 mm (0.18 in)

-

Do not use chains for towing. A link of the chain could snap, causing personal injuries. Use a steel cable with eyes at the ends. Place a flagman in a safe position to stop the towing operation in the event the cable starts breaking or fraying.

Keep the angle of the towing cable at a minimum.

Do not exceed a deviation angle of 30 ° from a straight position.

A sudden movement of the machine could overload the cable or the towing bar. causing its failure. For better working conditions, move gradually and smoothly.

Brakes disengaged position S

Prior to the towing, make sure that the cable or the towing bar are in good conditions and are strong enough for the towing. Use a cable or a towing bar having a capacity of at least 1.5 times the gross mass of the pulling machine, in the event a disabled machine stuck in mud must be recovered or must be towed on a slope.

When towing, connect the towing cable to the prescribed points on the fame only, if installed.

These towing instructions are intended to move a machine incapable of moving on its own a short distance at slow speed. Pull the machine at a speed of 2 kmph (1.25 mph) or lower toward a place suitable for the repair operation.

Always transport the machine by hauling, if a longer distance becomes necessary.

D350M0166

Once both brakes are disengaged, the machine can be towed.

Normally, the towing machine must have the same characteristics of the machine on-tow. Check that the towing machine has a sufficient mass and power, capable of controlling both machines in relation to the slope and distance to be travelled.

To allow a sufficient control and braking, when moving a machine down a slope, it could be necessary a larger machine or connecting other machines to the rear part, to avoid uncontrolled movements.

It is not possible to provide instructions for different situations. The minimum capacity of the towing machine is sufficient for flat surfaces whereas the maximum one is required on gradients or rough terrain.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

42

1850K

MOVING THE MACHINE WITH OUTSIDE MEANS Towing and recovering the machine

Lifting

Should the engine fail to start or when the machine must be towed, it is necessary to disengage manually the brakes, as described in chapter "TOWING THE MACHINE" in the Instruction Manual.

For this operation, use equipment or vehicles appropriate for this purpose.

When using cables for towing or recovery, make sure that all parts are in good conditions and are free from defects or troubles.

The maximum allowable load on the rear towing hook is 300 kN (67.442 lbf).

The same recommendations seen in the preceding point for the use of cables apply.

Always handle tractor and equipment separately.

For the tractor, a slinging as illustrated in the figure is recommended.

For the front equipment it is recommended that the two end eyes of the blade and the tips of the blade are hooked, as illustrated in the figure.

Max. 300 kN (67.442 lbf) 1850-2M0095

The maximum allowable load on the front hook is 140 kN. (31.473 lbf)

D350M0167

Prior to lifting, check that: - the parking brake is applied; - all cab doors, panels and mobile parts are secured; - all actuating cylinders are secured by the appropriate pins.

Max. 140 kN (31.473 lbf) 1850-2M0096

Cables must be firmly secured; make sure that they are attached to a point strong enough in relation to the effort to be made, which, in any case, must not exceed the maximum allowed value for the towing hook involved.

Operating mass kg (lbs)

LT

XLT

LGP

1850K Power Steering

20380

21130

22330

(44930 lb) (46583 lb) (49229 lb)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D350M0168

1850K

43

INSTRUCTIONS FOR LOWERING THE EQUIPMENT TO THE GROUND WITH ENGINE INOPERATIVE WARNING Obey all procedures and WARNINGS relative to the instructions for STOPPING THE MACHINE and SHUT-OFF THE ENGINE listed in this Manual.

The equipment can be lowered with appropriate movements of the control levers, with engine running or inoperative.

Move slowly FORWARD the specific control lever (blade or ripper) causing the lowering of the equipment involved.

When the blade is firmly bearing on the ground, move the lever alternatively FORE and BACK to stroke-end, a couple of times.

With this maneuver the equipment is bearing firmly on the ground and the residual pressures in the hydraulic system are released as well.

TRANSPORTING THE MACHINE When moving the machine on vehicles requiring the removal of the blade, secure the cylinders to the blocking plate inserting the appropriate welded pin on the plate shown into the holes of cylinders, then lock with a retaining nut.

Loading Before proceeding with the loading operation, make sure the ramps and carrier platform are lined with suitable non-skid material (wood, rubber etc.) securely fixed to the above parts (avoid using wood planks, old tyres etc.). Proceed as follows: - apply the trailer and tractor parking brakes; - lower the rear stabilizers of the trailer; - align the machine tracks properly with the ramps for correct climbing; - seek the help of a flagman standing in a position from which he can easily keep in sight the ramps, loading platform, machine and operator; - raise the equipment from the ground only as high as will not interfere with the loading operation, - climb up very slowly keeping the blade or frame close to the trailer platform; do not steer or change direction on the ramps; - position the machine on the platform so as to ensure an optimum load distribution with soft maneuver, avoiding sudden starts or stops; - lower the equipment, apply the parking brake and follow the entire procedure recommended for stopping and leaving the machine.

Transportation Before moving, it is necessary to perform the following operations: - apply and bolt, wooden chocks to platform, at the ends of the track chains; safety links or chains on the sides and along the machine to avoid movements during the transport; - check that cab door panels and other mobile port are correctly closed; - apply the signals prescribed by road traffic regulations in the event the dimensions of the machine exceed admissible values.

Unloading The operations and precautions to be followed during the unloading phase are practically similar to those applicable for the loading phase. During the descent it is necessary to keep the equipment as near the ground as practical to prevent slipping or wavering of the machine.

1850-2M0097

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

44

1850K

LONG STORAGE OF THE MACHINE

COLD CLIMATE PRECAUTIONS

If the unit is going to be inoperative for a long time, comply with the following rules: - Clean the machine completely and lubricate all components equipped with grease fittings.

- Drain the water from the cooling system. If the system is filled with an antifreeze mixture, this operation is not necessary.

- To avoid rusting, it is necessary to refill completely the fuel reservoir.

- Remove the injectors and inject, through the injector holes, some engine oil (the operation should be performed using a syringe, after moving each piston to B.D.C.).

- After injecting the oil, crank the engine a few turns using the starter motor, so as to spread a protective film of oil on the sleeve walls. Then reinstall the injectors.

- If possible, store the batteries in a place where there is no danger of freezing. Recharge them monthly.

When ambient temperatures are near 0 °C (32 °F) make sure that the cooling system is filled with an antifreeze mixture, to prevent the danger of freezing, otherwise, replace the water in the system with such a mixture.

Flush the cooling system before adding the antifreeze mixture. Use appropriate specific products for this operation, following the instructions on the container.

WARNING Remove the radiator cap only after the engine has sufficiently cooled-off. With engine inoperative, turn the cap slowly so that residual pressure is released before removing it completely.

The use of CASE coolant is recommended. Please find in the table below the percentages of the mixture related to ambient temperatures:

WARNING To recharge the batteries, a slow charge is preferable.

Should booster batteries be used, remember to connect both ends of the booster cables in the proper manner (+) with (+) and (-) with (-). Avoid short-circuits of the terminals.

Place the machine in a protected place or cover it with a tarpaulin.

To ensure an adequate protection of the transmission components, at least once a month, the machine should be moved for short distances, so that a film of oil is renewed on the parts.

AMBIENT ANTIFREEZE TEMPERATURES Down to: 20% - 18 °C (17.6 °F) 30% - 15 °C (5 °F).11 - 25 °C (-13 °F)1.

40% 50% - 35 °C (-31 °F)1.

WATER

80% 70% 60% 50%

Run the engine for some time after adding the fluid, to obtain a correct mixing.

WARNING Do not run the engine of this machine in closed areas without proper ventilation to remove deadly exhaust gases.

Also, use lube oils with a proper viscosity for temperature conditions, as indicated in the lube capacity.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

45

STARTING THE MACHINE AT LOW TEMPERATURES The engine starts regularly down to a temperature of 15 °C (5 °F) with the help of Arctic fuel, 50% anti-freeze in the cooling system, 10W-30 engine oil and fully efficient batteries.

To start at temperatures near or below - 15 °C (5 °F) it

is necessary to activate the cold starting device (optional).

To activate the cold starting device, please refer to item 5 page 23 (engine starting switch - position H)

Temperature °C (°F)

Activation of engine pre-heating

Fuel

Engine oil

Antifreeze 50%

> 0 °C (32 °F)

No

STD

15W-40

20%

0 to 14 °C (32 °F to 57 °F)

No

Artic fuel

15W-40

30%

-15 to -24 °C (5 °F to -13 °F)

Yes, for 20 sec.s

Artic fuel

10W-30

40%

Yes, for 30 sec.s

Artic fuel

10W-30 (*)

50%

< -24 °C (-13 °F)

(*) For temperatures below - 24° C (- 13° F) a pre-heating device of the sump oil is available.

STARTING THE MACHINE WITH BOOSTER BATTERIES In the event the batteries are partially exhausted, it is possible to start the engine using booster batteries. The batteries are easily accessible from the left side of the machine, after removing the panel indicated.

Proceed as follows: - Connect the exhausted batteries to the booster batteries or to the batteries of another machine;

Moving direction

ON

OFF WARNING Should booster batteries be used, remember to connect both ends of the booster cables in the proper manner (+) with (+) and (-) with (-). Avoid short-circuits of the terminals.

- Switch on the electrical system master switch.

- Start normally the engine with the engine starter switch (posit. start).

- Once the engine has started, remove the jumper cables form the machine.

1850-2M0080

Note – Do not start the engine without batteries, since there is the possibility of damaging the electronics equipping the machine.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

46

1850K

MACHINE OPERATION WARNING Never attempt to operate the machine or its equipment from any position other than seated in the operator's seat. In all circumstance, keep head, body, limbs, feet, hands and fingers within the operator's compartment to minimise the possibility of exposure to external dangers.

Keep all equipment low or in a position ensuring maximum visibility and the control of the machine.

Never use the equipment as a platform to lift personnel nor to carry riders on the machine.

When pulling or towing through a cable, do not start suddenly at full throttle; take-up slack carefully.

Use only designated anchoring points when pulling or towing. Take extreme care when hooking.

Make sure that pins and locks are properly secured before pulling.

Keep exposed personnel clear of the equipment (or supplementary attachments) when raised, to avoid possible injuries.

NEVER COAST the machine down grades and slopes with the transmission in neutral or neutralized.

Explore the working area to identify potential risks such as: slopes, overhangs, pits, demolition rubble, fires, ravines, ditches, soft terrain, heavy traffic, crowded parking areas, closed ambients. In such conditions, proceed with extreme care.

Working on slopes is dangerous.

Pay special attentions when working near overhangs.

Always designate a flagman when visibility of the working place, by the operator, is limited. The flagman must be capable of communicating directly with the operator and the latter must obey the signals.

Be aware of falling walls, falling objects and landslides. Always remember that these dangers could be concealed by brushes, undergrowth etc.

When working in ditches or near high embankments, make sure that the walls are adequately supported, so as to prevent landslides.

Before working in the vicinity of gas lines or other utility lines always contact the nearest utility office before beginning work.

You and the utility representative must jointly determine what specific precautions must be taken to insure safety.

Work in proximity of overhead or underground power lines involves serious body injuries and death hazards, thus special precautions must be taken according to national and local safety regulations.

For the purposes of this Manual you are considered to be working in the proximity of power lines when the attachment or the load raised by machine, in any position, can reach to within the minimum distances specified by local and national safety regulations.

Slow down working speeds. Reaction times could be too slow and distances could be erroneously evaluated.

PRACTICAL OPERATION TIPS It is good practice, when the operator first gets on the machine, to familiarize with its controls.

The operator must perform all the operations the equipment is capable of doing, to develop sufficient "feeling" with the controls and their reaction.

Remember that, when the control levers are in neutral position, the equipment is solid with the machine: this means that it will follow along any movement of the machine.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

47

A

B Blade pitch A. Loose soil.

B. Hard soil.

243

Dozing When working on grades, it is best to move downhill for better traction. Gradually lower the blade at the beginning of each pass and accelerate the engine fully. The dozing depth should be such as to allow a load within a short distance (5-6 m /15-18 ft); the full load should, then, just be pushed to the unloading area.

When the ground is hard, getting a full load in a short distance becomes difficult. Under these conditions, instead of pushing a half empty blade towards the unloading area, it is better to return to the starting point and doze more. The load of the second pass is added to the first one and will result in more effective dozing, especially when the unloading distance is considerable.

Working is often made more difficult when large rocks are present and are caught under the blade and pushed forward or lifting the front of the machine, making uneven cuts. This humped effect can be avoided by backing-up with the blade at a lower depth capable of dislodging the rock. If necessary, operate with the moldboard corner tilted.

When dozing in hard terrain and the blade is unable to cut the material, it is advisable to increase the moldboard's draft.

Under these conditions the angle is good for the initial cutting, but during continued dozing the moldboard will pick-up more resistance as the load will push the blade upward. Also, a high pitch reduces the rolling of the material on the blade, increasing the resistance. In hard and rough dozing, the operation might be easier if the blade is tilted; if the work to be done is over a considerable area, first use the ripper to break-up the soil.

Road and ditch cutting When cutting steep slopes (for roads or ditches) dozing should begin by cutting the depth of the ditch and tilting the blade to cut the sides with the desired angle.

Care must be taken in monitoring that the profile of the slope is regular, as any correction would be most difficult or, in some cases, even impossible.

Pushing loads When materials have the tendency to spill out the sides of the blade. This problem can be reduced by working repeatedly, when possible, following the same path on successive trips so that the spills forming windrows on both sides prevent a further loss of material from the blade. When pushing loads on a level terrain, keep the blade just touching the ground or at a depth deep enough to skim the surface. However, if the terrain is uneven it is appropriate to cut a little deeper to compensate the dirt which falls out the sides or in the hollows.

Pushing loads on turns

254

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

48

1850K

Power Steering The Power Steering solves the steering problems, especially when pushing a load, since it provides constant power on both tracks under all conditions, steering the machine in a natural manner.

Thus traction is increased facilitating the maneuver by the operator, providing a smoother ground surface (not damaged by the blocking of the tacks) limiting also the losses of material previously piled-up.

Pushing loads on turns with Power Steering

Spreading When spreading materials, hold the blade slightly above the ground, so that it can slide under the cutting edge, creating an even layer.

If the layer to be spread is of a considerable height, let the blade rest at a height just above the desired layer, since the compactation occurring later will lower the layer, especially when loose materials are involved.

Grading After the ground has been dozed, the surface might be rough due to small windrows, ground lifted by the tracks or small piles left around turning points. These terrain irregularities must be smoothed over by operating the dozer in reverse and letting the blade float.

Under these conditions, the blade operates as a harrow, topping off high spots and filling voids, without altering the level.

Grading is often made difficult, and sometimes impossible, because of boulders or other debris, which have to be removed first.

D350M0169

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

49

Moving large rocks and boulders It could become necessary to move boulders with the dozer, during all kinds of works. There are several procedures. In fact a fully loaded blade may be used or the boulder can be pushed directly by the blade by the forward or reverse action of the machine.

The choice of procedures used depends upon several factors: the dimensions and shape of the boulder,

space available, type of work being performed. With tractor in forward and fully loaded blade the boulder can be moved by glancing it off the load; in this manner the rock will roll-off to the nearest side of the machine.

Repeating this type of maneuver will eventually edge the boulder from the working area.

Moving boulders with full blade D350M0170

Moving boulders with the side of the blade 249

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

50

1850K

Piling To pile materials, two well accepted methods are recommended: Form a pile of material on the first pass, then, with successive passes, accumulate material in front of the established pile.

After forming an initial pile on the first pass push material on successive passes to the top of the established pile and make it fall over the opposite side.

Sometimes, instead of piling it, the material is pushed to fill a ditch. In this case, since the filling material tends to let the machine sink it is appropriate to build a small step before reaching the edge of the ditch, raising slightly the blade.

This step improves safety since, proceeding with subsequent passes, the front of the tracks shall allow, in steps, to protrude over the original edge.

Pile levelling If the pile is not too bulky or hard, it can be levelled by dozing the blade into it, than it can be spread or re-piled somewhere else.

If the pile is too large or too hard to be spread with a single pass, or it must be spread in different directions, the first pass may be made grading one side to ground level, repeating the cuts, as required from different angles, on the remaining pile. If the dozing leaves high walls which could fall on the machine, turn the blade from time to time toward the wall and with it raised, push the mound down.

If the dozer is unable to cut a pile because of its steep sides, a ramp can be built by pushing into one side with the blade raised and then backblading with a down pressure.

The levelling of a pile can also be made by dozing a centre slot and continually cut away the top. This method is always recommended when the pile is excessively high and it is the only possible when there no access to the side of the pile.

The center slot width must be greater than the width of the blade, thus allowing a protective border to be built preventing the dozer from getting trapped, once the digging reaches a certain depth or boulders and earth or the walls collapse on the machine.

Also, a narrow cut does not allow the machine to properly maneuver and dispose of rocks or roots encountered while dozing.

Piling

Cutting a pile with side cuts

A

B

251

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

253

1850K

51

Centre slot dozing of pile 1850-2M0163

Going over obstacles Any obstacle (logs, roots, ridges etc.) must be removed, if possible, or avoided. If this is impossible, crossing must be done very slowly and at an angle so that one track will reach the top and starts to descend on the other side, while the track is still climbing. This method of operation slows down the dropping and decreases the shock against the ground, which could cause damages to the machine and the operator.

If the obstacle is made of soft material it is good practice to sharply turn the machine while crossing, so that the track edges will help cut the material down.

When the dozer is operating in heavy work, the tracks often spin, forming small pile of earth near their rear end. Under these circumstances, when reversing direction, it is good practice to move sideways as much as required, to avoid the tracks hitting these windrows.

A ditch may be crossed without danger only if its width is not greater than 1/3 the track length and if the track movement will not collapse the banks.

Hill work Dozing on side slopes requires special care. Even when the dozer appears to have sufficient margin of safety, the sudden running over an unseen obstacle by the upper track or the lower track moving into a hollow, the machine could tip over.

Chances of this occurring are lessened when the machine is dozing as it is moving along using the load as an additional stabiliser. Also, the machine is stabilised by the low windrow.

Dozing on frozen slopes is hazardous as the grousers act as skates causing the machine to slide uncontrolled downhill. There is a danger of tipping over rocky slopes as well, especially shale with beds parallel to the surface and on soft fills where the lower track sinks deeper than the upper one.

If the machine starts to slowly roll over, sometimes it is possible to prevent the trouble by quickly turning downhill, lowering the blade at the same time.

Slopes too steep to be safely worked sideways, sometimes, may, be dozed by operating the machine along it diagonally.

Cutting a pile with centre slot

247

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

52

1850K

On the other hand, the machine overcomes safely steep slopes downhill. Steering is apt to be tricky on steep slopes, whether up or down.

Digging and pushing should be done downhill to obtain a better pushing effort. This is particularly advantageous when the ground is very tough, even if the soil must be pushed up the hill. When digging is limited to a given area on the slope and material must then be pushed downhill, it is a good technique to drop to or three loads at the end of the cut, then pushing most of the pile down in a single pass.

A

B

Grading on side slopes If a slope must be notched (i.g. road cuts in hillsides) it will be necessary to first build a shelf. Set the blade in tilt position opposite to the slope so the dirt moved will slide downhill and help in building up the shelf. If the slope is too steep to work effectively with tilted blade, proceed in one of the following ways: Push the material downhill to form a shelf as in (A), so the dozer can start level cuttings, as in (B).

Start cut transversally to the slope, then turn at the same time to unload downhill. This will provide a more level shelf, which can than be enlarged or graded off as required.

Dig a strip transversally to the slope, then proceed with a series of parallel cuts, always operating the higher track in the previous strip.

In each case the best possible advantage should be taken with the soil configuration. When natural aids are not available, the machine can be moved onto boards or other lifts to start the cut at the desired slope.

1850-2M0162

Notching a shelf on side slopes, travelling and unloading downhill

252

Notching a shelf on side slopes, travelling across the slope, steering and unloading downhill

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

53

Clearing In land clearing of brush and small trees, clearing can be accomplished in one pass, with the blade cutting slightly below the ground. This will allow the blade to shear the roots. It may be necessary to back up occasionally to clear the roots from the cutting edge.

Roots under the edge cause the blade to ride up and waste machine power.

When uprooting a tree, first place the blade fully raised against the trunk, then engage first gear forward and push with the engine fully accelerated. If the tree resists, shift the transmission to neutral then into first forward again; repeat a few times. If the tree does not fall quickly, make a few passes to cut some of the outlaying root structure. To improve the pushing, buildup an earth ramp opposite the direction the tree is to be felled, so that the blade can touch the tree in a higher position. Remember, when the tree begins to fall, to back-up rapidly, so that the uplifting roots will not catch under and tilt over the machine.

OPERATING TIPS Before beginning to doze, the moldboard should have proper tilt and pitch for the work to be done. While dozing, always use a speed adequate to obtain best results from the machine.

To get smooth cuts, (meaning regular surfaces) the operator should closely watch the ground pattern and when the machine noses down or up, he must react swiftly with the control lever to raise or lower the blade, as required.

Note – Keep the cutting edges in good conditions.

RIPPER The ripper is supplied as an optional.

To raise or lower the ripper, move the control lever backward or forward, respectively. To stop the ripper in the desired position, release the control lever which will return to hold position in neutral.

The ripper is equipped with shanks/teeth removable from the relevant frame, as required. Thus it is possible to work with all the teeth or, in particularly heavy conditions, with the central one only.

Engage FIRST gear for all ripping operations. Use more shanks rather than increasing travel speed.

To obtain the best results, the following considerations should be kept in mind:

D350M0172

Breakage. The soil can be broken in fine or coarse pieces, as required. It depends on work depth, number and shape of the shanks and pass spacing.

Breakage must be established on the basis of the subsequent use of the ripped material. As an example, if the material must be spread and back bladed, a finer breakage is required than when it must be dozed away.

Dozing a shelf on side slopes by successive cuts across the slope

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54

1850K

Work depth. It is good practice to work to maximum depth permitted by the available power and traction of the machine, taking into account the breakage desired.

Note that: - With strongly cohesive materials, such as clay, tuff, marl, gypsum, sandstone, calcite and other compact soils, the greater the depth the coarser the breakage; - With stratified materials, such as limestone, schist, gneiss, travertine etc., the greater the depth the finer the breakage.

Number and shape of teeth. The number of teeth depends on the power required of the machine in relation to the desired breakage. Generally, the greater the number of teeth, the finer is the breakage. Exceptions are stratified materials where large slabs are lifted when working with more than one tooth.

As regard tooth shape, the partially curved type can be considered a universal standard. Curved teeth facilitate the lifting and to some extent, also the turning over of the material.

WARNING To make sharp turns, raise the ripper teeth off the ground, to prevent damages. Only wide turns or small directional corrections are permissible when the ripper is sunk-in.

With surfaces with deep depressions, first make passes to level the ground, prior to ripping, to avoid breaking the shanks.

WARNING When not in use, always carry the ripper in full raise position during operation and lowered to the ground when parked.

Spacing between passes. It must be such as to complete the breakage of the previous pass, always in relation to the desired fineness. Generally, spacing must be less than work depth.

In plastic soils, e.g. gypsum (in which the implement makes just a cut) or in hard soil (in which the working depth must be reduced) criss-cross passes may be required.

Speed and direction. It is good practice not to exceed 1.5 to 2 kmph (1 to 1.2 mph) to prevent harmful shocks to the implement and excessive wear. When working on soft material, it is preferable to increase the depth rather than the speed. In the case of stratified materials, work crosswise and against the vein; on the contrary, if the material is landslipping. work in the direction of the landslide.

1850-2M0098

Notice – Do not reverse or steer while the teeth are into the ground. Torsional forces could breake the teeth.

Material heaping. Generally it is convenient to heap material crosswise to the ripping direction in order to keep the transport distance to a minimum and to smooth out any irregularity.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

55

CAB Do not climb or leave a machine while it is running.

Do not jump off the machine.

SAFETY CAB Safety cab with roll-over protection structure (ROPS) and against falling objects (FOPS) safegarding the operator.

The cab has two doors which can be open 90° (to be used only to enter the cab) assisted by gas filled cylinders and two hinged side panels, with lock in maximum open position, providing enough ventilation and reducing the inlet of dust. It is amply glazed and provides maximum operator comfort under whatever climatic condition.

Do not climb nor leave the machine while transporting equipment or other materials.

When climbing or leaving the operator's compartment, do not use any control as a grabbing point.

Note – The key provided with the machine is universal, i.e. it operates the cab door locks, the side panels and the engine starting switch.

WARNING The protection offered by ROPS may be prejudiced by any damage or structural change.

Inspect your seat belt periodically for signs of fraying, wear or other weaknesses leading to failure.

DOOR The door is open by the handle indicated in the figure, after opening its locks (incorporated in the handle itself) with the appropriate key.

1850-2M0081

Enter and exit the operator's compartment using the appropriate grab handles and stepping points.

Before climbing the machine, clean and inspect steps and handrails.

Climb and leave the machine facing it.

Keep three contact points with steps and handrails.

Note – The three points can be two feet and one hand or two hands and one foot.

1850-2M0099

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56

1850K

To open from inside, push handle as indicated in the figure.

Lubricate the door hinges through the grease fittings indicated.

D350M0174

1850-2M0102

REAR WINDOW

WARNING If replacement of glass is necessary, be sure to use safety glass as spare.

Do not strike the glass to remove it from cab parts.

Glass may shatter and cause personal injuries.

M

1850-2M0100

To release window, press button P inside and pull the door using handle M.

Note – Windows must always be kept clean to ensure good visibility.

It is recommended to use specific window cleaners and dust free cloth to avoid scratching the glass and impair transparency.

P

1850-2M0101

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

57

CAB LIGHTING

CAB INSIDE HEATING AND VENTILATION

The ceiling lights are located on the top of the cab.

Switch M in raised position activates fixed light L, in lowered position it actuates movable light P. In central position both lights are OFF.

The climatisation of the cab is provided by actuating the controls located under the top of the cab in front of the operator.

1

M

2

3

4 5 6

7

L P AUTO

13

12

STOP

ECOM

3

1

2

8

9 10

C F

11 D150-2M076

1850-2M0103

1. Decrease of inside temperature - 2. Increase of inside temperature - 3. Automatic function - 4. Compressor switch OFF - 5. Re-circle - 6. Outside temperature - 7. Switching OFF - 8. 1st fan speed - 9. 2nd fan speed - 10. 3rd fan speed - 11. Change from °C to °F and viceversa - 12. Established degrees monitor - 13. Cab inside temperature sensor.

12 VOLT SUPPLEMENTARY RECEPTACLE (On cab only) Supplementary power receptacle P, located in the rear left part of the cab, can be used to power a refrigerator to be located in the compartment behind the seat or to power a portable phone.

Demisting and defrosting To obtain a fast demisting or defrosting of the front, side and rear windows, proceed as follows: - activate through button 10, the fan at max. speed; - actuate button 2 until max. temperature is obtained.

Open the cab vents directing the air flow toward the windows.

T

P D150-2M075

Phone holder (T) to be used to store a portable phone, during battery charging phase as well.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D150-2M077

58

1850K

WIPER Should visibility be unsatisfactory as a result of faulty wiper blade operation, clean rubber blades using a specific detergent or alcohol. Should faulty operation persist, change the blades.

For the front wiper proceed as follows: - tilt out complete arm C from glass; - loosen screws D and remove the blade.

If the spray pattern of nozzles S is defective, clean the holes with a needle.

If necessary, re-adjust the spray nozzle orientation so that the fluid will strike the windshield uniformly.

Note – Always keep windows clean to ensure good visibility.

It is recommended to use specific window cleaners and dust free cloth to avoid scratching the glass and impair transparency.

Check and fill as required, the level of the windshield washer fluid in its reservoir, reached by opening the rear left panel in the battery compartment.

C

D350M0096

To replace the side and rear window blades, proceed as for the front wiper.

D 1850-2M0104

S

Note – Use DP1 detergent diluted with water, in relation to ambient temperatures. A 50/50 mixture of detergent and water is not freezing down to - 10 °C (15 ° F). Below this temperature, use pure windshild washer fluid.

D350M0097

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

59

MAINTENANCE MAINTENANCE SAFETY WARNINGS Do not allow unauthorised personnel to perform any maintenance operation. Study carefully this Manual before starting, operating, maintaining, fuelling or servicing the machine.

Always place the starter switch in lock position prior to perform cleaning, repair or any other intervention on the machine and after parking it, to prevent personal injuries.

Never perform lubrication, repair or adjusting operations with engine running, except as specifically called for in this Manual, to avoid being caught by moving parts or being crushed by the machine.

Never use gasoline, solvent or other flammable fluid to clean parts. Use exclusively qualified, nonflammable, non-toxic commercial solvents.

Follow the instructions of chapters "Stopping the machine" and "Stopping the engine" of the Operation and Maintenance Instruction Manual, before lubricating or performing any other intervention.

Always lower the equipment to the ground and release pressure from all systems prior to proceeding with any maintenance or repair work.

The equipment and attachments can be lowered by moving the control lever with engine running or inoperative.

Every time components and groups of the machine must be removed, be sure the jacking point used on the machine is appropriate for the load to be applied. Be sure the support of the jack at the machine and under jack is appropriate and stable.

Transfer load to appropriate blocking as a safety measure, before proceeding with service or maintenance work.

Never work over or under a machine or its components being supported only by jacks or other lifting devices, in accordance with current national and/or local regulations.

Never work under or near the equipment of a machine or its components adequately supported and blocked.

DO NOT USE HANDS to search for suspected pressure leaks. Fluid escaping under pressure nd can have sufficient force to penetrate the skin. Use a piece of cardboard or wood When servicing or maintenance require access to areas that cannot be reached from the ground, use a ladder or step platform that meet local and national regulations, to reach the service point. If such ladder or platform are not available, use the machine hand holds and steps as provided. Perform all service or maintenance carefully.

Use only grounded auxiliary equipment to power heaters, battery charges, pumps or similar equipment, to reduce the risk of electrocution.

Warn all personnel which could be performing repairs or in the vicinity of the machine prior to starting the engine.

Keep hands, limbs and face away from loosen connections of pipes when performing efficiency or leakage tests of injectors or systems. Also, wear prptective glasses with side shields.

NEVER ALIGN HOLES WITH FINGERS OR HANDS; always use appropriate aligning tools.

Do not use an open flame as a light source to look for leaks or for inspection anywhere on the machine, due to the presence of flammable fluids.

Always place the safety lever in lock position.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

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1850K

MAINTENANCE OPERATIONS The service intervals indicated herein refer to normal operating conditions; during the initial break-in period and under particularly severe conditions, other intervals may be needed.

Use this list to co-ordinate maintenance scheduled at the same intervals.

Before proceeding with any service operation, lower the equipment to the ground and shut-off the engine.

It is advisable to change oil immediately after stopping the machine as warm oil will drain out more easily, along with any suspended deposit or scale.

Before and after lubrication operations, accurately clean all fittings, covers, plugs to prevent dirt from entering the system.

Lubrication is an essential part of preventive maintenance, controlling to a great extent, the useful life of the unit. Different components require different lubricants, and some components in the unit require more frequent lubrication than others. It is important that the instructions regarding types of lubricant, and the frequency of their application, be followed. periodic lubrication of moving parts reduces to a minimum, the probability of mechanical failures.

Note – Do not tamper with the fuel injection equipment setting, otherwise CASE will void all warranties.

WALK AROUND INSPECTION (to be performed daily) By quickly responding to initial troubles, required maintenance and downtime will be reduced. It is recommended to check the machine each day, before beginning work or to make a walk around inspection at the completion of each day to check: A. Side final drive oil leakages B. Ineffective or broken instruments C. Engine oil/coolant leakages

D. Hydraulic system leaks and damaged hoses E. Caked dirt on radiator grill F. Blade wear or damage H. Track rollers and idler wheel oil leakages I. Track tensioner grease leakages L. Caked dirt and mud on track frames M. Loosen track shoe fasteners

C

B

D

E H M

F

A

L

I 1850-2M0105

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

LIST OF PROGRAMMED MAINTENANCE 38

34 29

33 24

14 7

Every 2000 hours

28 17

19

6

17

36

37

32 27

21

29

22

25 15

Every 500 hours

16

23

20

18

8

Every 100 hours Every 10 hours

26

12

Every 250 hours 10

3

31

Every 1000 hours

12 13 9

35

When required

30 23

61

5

2

4

7

11

1

1850-2M0106

EVERY 10 HOURS WORK (daily)

EVERY 100 HOURS WORK

EVERY 500 HOURS WORK

EVERY 1000 HOURS WORK

Bevel gear, steering and brakes: check oil level.

7. Final drives: check oil level.

8. Fuel reservoir: drain condensation.

9. Equipment hydraulic system: check oil level.

10. Blade cylinder linkage pivots: grease pivots.

11. Ripper linkage pivots: grease pivots.

15. Fuel filters: replace filters.

16. Steering and brakes circuit delivery oil filter: replace cartridge.

17. Torque convertertransmission hydraulic system: change oil and delivery filter cartridge.

18. Cab ventilation air filter: replace filter.

19. Engine coolant filter: replace cartridge.

20. Doors grease fittings: grease pivot.

21. Fuel injectors: calibrate setting of injectors.

22. Valve clearance: check valve clearance, with cold engine.

23. Bevel gear, steering and brakes: change oil and wash suction filter.

24. Torque converter-transmission circuit: wash suction filter and magnetic rod.

25. Torque converter to transmission prop shaft: grease spiders (two fittings).

26. Batteries: check electrolyte level.

27. Air conditioner compressor: check condition of belt and adjust sag.

28. Fan-alternator belt: check condition and sagging of belt, replace.

6.

1.

2.

3.

4.

5.

Braking system: indicator light check Engine oil: check oil level.

Torque converter/transmission hydraulic system: check oil level.

Fuel filters: drain condensation.

Radiator: check coolant level

EVERY 250 HOURS WORK 12. Engine sump: change oil.

13. Engine oil filter: change filtering cartridge.

14. Undercarriage: check sag of track chains.

EVERY 2000 HOURS WORK 29. Final drives: change oil.

30. Equipment hydraulic circuit: change oil, clean magnetic rod and suction filter.

31. Radiator: change coolant.

32. Clogged engine air cleaner: Replace cartridges.

33. Blade cylinder linkage pivots: grease pivots.

AS REQUIRED Operations to be performed when relevant indicators come ON: 34. Equipment hydraulic system return oil filter: replace cartridge.

35. Engine air cleaner: clean cartridges.

Other operations to be performed according to necessity: 36. Cab ventilation air filter: clean filter.

37. Glass fuel filter: clean mesh filter.

38. After cooler radiator: clean.

_______________________________________________________

NOTES

_______________________________________________________

_______________________________________________________

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63

EVERY 10 HOURS WORK 1.

BRAKING SYSTEM - Indicator lights check

MAX MIN

Check the L8 indicator light does not show operating system failures.

L8

D350M0176

Oil dipstick (A) The correct oil level must be maintained between the two marks.

1

2 n/min

0

x 1000

3.

3

1850-2M0159

L8. Braking system failures.

2.

TORQUE CONVERTER / TRANSMISSION HYDRAULIC SYSTEM - Check oil level

Open the upper left engine compartment panel.

With engine inoperative since at least 15 minutes and machine on flat ground, check that the oil level is near the upper notch of the dipstick of cap 1.

If necessary, top-off through the filler neck, checking the level after running the engine at idle speed for a few minutes and shifting the transmission a few times.

ENGINE OIL - Check oil level

Open the upper left engine compartment panel.

With the machine on flat ground and the engine inoperative at least 5 minutes, check on the appropriate dipstick A that the oil level is between the two nothes indicated. If necessary, top-off the oil through filler neck B payng attention not to exceed the corresponding notch.

WARNING Do not operate the engine with oil below the lower notch (MIN.).

A

1

B

C

1850-2M0107

A. Engine oil dipstick - B. Engine oil filler neck - C. Fuel filter.

1850-2M0108

1. Plug with dipstick.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

64

4.

1850K FUEL FILTERS - Draining condensation

Open the upper left engine compartment panel, drain the water and sediments from the fuel filter through the draining valve indicated.

With engine inoperative, loosen the valve located below the filter about 4 full turns and move it downward about 2 cm (3/4 in).

Drain water and sediments until clean fuel only, flowsout.

Move the valve upward and tighten it, without over tightenin.

5.

RADIATOR - Check coolant level

Open the upper panel of the engine compartment and check the engine coolant level through sight gauge A. The coolant level must not get below this gauge.

If required, top-up with liquid through the filler neck, with engine inoperative since at least 1 hour, to release residual pressure from the system.

Note – The draining interval can be increased or decreased, as a function of the presence of water and the quantity of fuel.

A 1850-2M0112

1850-2M0109

It is recommended to fill the system with antifreeze liquid diluted 50% with water, for maximum protection against: - antifreeze action down to - 40 °C (- 40 °F); - the formation of scale; - boiling during hot periods up to + 110 °C ( 230 °F); - the corrosion of metal materials.

Water draining valve on fulel filter C

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

65

EVERY 100 HOURS WORK

7.

6.

Check that the level reaches plug A as indicated (one level plug on each final drive); top-off as required through the plug hole.

BEVEL GEAR, STEERING AND BRAKES Checking the oil level

Check the oil level with the machine on a flat surface and the engine inoperative for at least 5 minutes. To reach the oil dipstick, open the panel indicated under the cab, on the right side of the machine. Loosen plug 2, pull out the dipstick underneath and check that the oil level is between mark MIN and mark MAX etched on the dipstick. Top-off with oil, as required, through the dipstick tube.

FINAL DRIVES - Check oil level

A

1850-2M0116

A. Final drive oil filler and level plug.

2

8.

FUEL RESERVOIR - Draining condensation

Drain any water and sediment deposited at the bottom of the reservoir in the well indicated, from the rear side of the machine.

1850-2M0115

The correct oil level must be between the two marks.

1850-2M0117

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66

1850K

For this purpose, loosen the valve indicated in the bottom figure and let the liquid to flow from the pipe into a container, until clean fuel flows. Drain more frequently when the machine operates in damp environments, cold climate or marked temperature changes.

When outdoor temperature is above 0 °C (32 °F) perform the draining before starting the engine; at temperature below 0 °C (32 °F) the draining must be performed at the end of the work shift, since water, when freezing, would not drain.

If the level shows through lower indicator A, remove the filling cap, opening the right side panel indicated. then, top-off the level through filler neck 1 until it shows through upper indicator B.

1

1850-2M0111

1850-2M0118

10. BLADE CYLINDER LINKAGE PIVOTS Grease pivots

Fuel draining valve

9.

Pump grease into the lube fittings of the blade cylinder support. The fitting indicated by arrows is also installed on the opposite side of the machine.

Equipment HYDRAULIC SYSTEM Check oil level WARNING

Fluid under pressure; prior to removing the cap, turn it slowly to relieve the pressure.

Check that the oil level reaches between sight gauges B max. level and A min. level. This check must be performed with machine level, equipment resting on the ground, cold oil and engine running at low idle.

B A

Max. Min.

1850-2M0113

1850-2M0110

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

67

11. RIPPER LINKAGE PIVOTS - Grease pivots Pump grease into the fittings of the ripper linkage.

The black arrows indicate that the same fittings are located on the opposite side as well.

1850-2M0161

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1850K

EVERY 250 HOURS WORK WARNING 12. ENGINE SUMP - Change oil Open the left front panel of the engine compartment indicated and drain the oil through lower plug T, while it is warm, loosening it with an 8 mm (0.31 in) Allen wrench. To facilitate the draining, remove plug B. When the oil stops flowing, refill with fresh oil of the prescribed type and grade (see "FLUID CAPACITIES CHART") as follows: - re-install draining plug T and pour new oil through filler neck B, to the maximum level marked on dipstick A; - operate the engine at low idle; - stop the engine and top-up at maximum level, after a few minutes.

Do not run the engine in closed areas without proper ventilation to remove deadly exhaust fumes.

Be sure exposed personnel in the area of operation are clear of the machine before moving it or its attachments. Walk completely around the machine before mounting. Sound horn.

Note – If the fuel used has a sulphur content exceeding 1%, change the engine oil every 150 hours work.

WARNING Never use gasoline, solvent or other flammable fluid to clean parts. Use exclusively qualified, nonflammable, non-toxic commercial solvents.

13. ENGINE OIL FILTER Change filtering cartridge

T

1850-2M0119

Open the right panel, upper and lower engine compartment.

The replacement of the filter must be performed at the prescribed interval.

Replace the filter, proceeding as follows: - clean the filter supporting area and loosen it; - fill the new filter with fresh oil and lubricate the relevant gasket; - tighten the filter manually. After the gasket contacts its seating face on the engine block, tighten further 3/4 turn.

T. Engine oil draining plug.

A B

1850-2M0121

1850-2M0120

A. Oil dipstick - B. Filler neck.

Engine oil filter

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

69

14. UNDER CARRIAGE - Check sag of track chains

Note – Track tension must be somewhat loose when working in muddy, very wet terrains and when sand, gravel, snow or ice are present.

WARNING Fluid under pressure: to loosen the track tension, follow the procedure recommended by this "Operation and Maintenance Manual".

The idler wheel return spring is mounted with a high compression load. To assemble or disassemble this component follow the procedures recommended by the "Repair Instruction Manual".

I

Vr Vs

If the sagging of the chains in section L included between the support roller and the idler exceeds 30 40 mm (1.18 in - 1.57 in) (normal tension), pump grease into fitting I indicated in valve VR of the adjustment cylinder, until the track chain tension is normal.

If the track is too tight, discharge grease from the cylinder by slowly loosening adjusting valve VR, and if necessary, backing-up, the machine a few yards.

Re-tighten the valve.

DANGER Fluid under pressure. Do not loosen track tension by loosening pressure relief valve VS. Do not remove the grease fitting mounted on adjusting valve VR. L 30 ÷ 40 mm

1850-2M0144

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850-2M0145

70

1850K 16. STEERING/BRAKES CIRCUIT DELIVERY OIL FILTERS Replace cartridge

EVERY 500 HOURS WORK ENGINE: 15. FUEL FILTERS - Replace filters Open the left side panel of the engine compartment.

Remove the front panel and remove filters F1 from the filter support. Replace them with a new one and tighten it to a torque of 3.5 ÷ 4 daNm (26 ÷ 29.50 lbft).

WARNING Never use gasoline, solvent or other flammable fluid to clean parts. Use exclusively qualified, nonflammable, non-toxic commercial solvents.

When using compressed air for cleaning parts, use safety glasses with side shields or goggles, so as to reduce the danger for personal injuries cause by flying particles. Limit pressure to 2 bar (29 p.s.i.), in accordance with local and national regulations.

Clean the base of the support and the surrounding area.

Loosen the filters indicated in the figure.

Clean with a dry rag the support area contacting the filter gaskets.

Replace gaskets "1" fill the new filters with fresh fuel and apply a film of engine oil on the gasket, and tighten them against the support.

Then, turn 1/2 turn further.

F1

1850-2M0127

F1. Steering/brakes and transmission oil filters.

Replace at same time as trans/torque converter filter.

17. TORQUE CONVERTER / TRANSMISSION HYDRAULIC SYSTEM Change oil and delivery filter cartridge Oil draining Remove plugs A from the bottom of the machine, with warm transmission oil and let it drain into a container with a 40 liter (10 USG) capacity, at least.

1850-2M0126

Fuel filters

1

A 1850-2M0128 D350M0113

A. Draining plugs (see page 61).

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

71

To facilitate the draining, open the right panel under the cab and loosen plug 1 from the transmission oil filler neck.

F2

1850-2M0129

F2. Transmission/torque converter oil filter

Clean the area surrounding the filter.

Remove filter F2 and replace it with a new one.

Re-install the filter tightening it to 3.5 to 4 daNm (26 ÷ 29.50 lbft) maximum.

1

1850-2M0108

Replacing the transmission/torque converter delivery filter

WARNING Never use gasoline, solvent or other flammable fluid to clean parts. Use non-flammable, non-toxic commercial solvents.

When using compressed air for cleaning parts, use safety glasses with side shields or goggles, so as to reduce the danger for personal injuries cause by flying particles. Limit pressure to 2 bar (29 p.s.i.), in accordance with local and national regulations.

Oil refilling Re-install plugs A, after cleaning them pour oil through filler neck up to the level of the upper mark, etched on the oil level dipstick.

Start the engine and run it at low idle for a few minutes; actuate the gearshift lever a few times.

Shut-off the engine and, after a few minutes, top-off the oil in the systyem, checking the dipstick on the plug 1.

WARNING Do not run the engine in closed areas without proper ventilation to remove deadly exhaust fumes.

Be sure exposed personnel in the area of operation are clear of the machine before moving it or its attachments. Walk completely around the machine before mounting. Sound horn.

18. CAB VENTILATION AIR FILTER - Replace filter Remove the filter as indicated at page 83 item 36 and replace it.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

72

1850K

19. ENGINE COOLANT FILTER - Replace cartridge Open the engine compartment upper panel.

DANGER FLUID UNDER PRESSURE; prior to removing the cap, turn it slowly to relieve the pressure.

To avoid burns, do not loosen the radiator cap with an hot engine.

Loosen the filter F, paying attention to possible spillages of liquid. Prior to installing a new filter, clean the zone of the support facing the gasket.

Apply a film of oil on a new filter gasket.

Spin on until it touches the support.

Tighten ½ turn furtner.

Turn the filter valve to "ON".

Start the engine and check that there are no leakages.

Shut-off the engine and check the coolant level.

WARNING Do not run the engine in closed areas without proper ventilation to remove deadly exhaust fumes.

Loosen slowly the radiator cap, with the engine inoperative since at least 1 hour, to relieve the residual pressure in the system.

20. DOORS GREASE FITTINGS - Grease pivot Lubricate the door hinges through the grease fittings indicated.

1850-2M0156

Remove dirt or caking accumulated between the support and filter. Close the valve V on the filter support.

V

F

1850-2M0131

F. Coolant filter with DCA4 additive.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850-2M0102

1850K

73

EVERY 1000 HOURS WORK

23. BEVEL GEAR STEERING AND BRAKES Change oil and wash suction filter

ENGINE:

Drain oil

21. FUEL INJECTORS Calibrate setting of injectors

Place a container of at least 50 liter (13 USG) capacity under the transmission housing.

Remove plug A and let the oil drain completely.

DANGER

Retighten plug A after washing it.

Keep hands away from the tip of injectors, when checking efficiency. Fine sprayed fuel under pressure could penetrate the skin and cause blood poisoning. Also, when checking the efficiency of injectors, wear safety glasses with side shields.

A

Have the injectors checked by a Service specialized shop.

22. VALVE CLEARANCE Check valve clearance, with cold engine Have the clearance between engine valves and rocker arms checked by specialized personnel.

The adjustment of the valve clearance must be done with cold engine.

Valve clearance - Intake ..................................... 0.30 mm (0.012 in) - Exhaust .................................. 0.60 mm (0.024 in)

1850-2M0133

A. Steering and brakes oil draining plug.

Wash the suction filter and magnetic rod Tilt the cab, remove plug 1 and pull-out the mesh filter indicated in the figure and the magnetic rod 5.

Wash both of them with solvent. Clean inside the body.

Re-install the filter, magnetic rod and cover.

Check and top-off the oil after changing it.

1 2

4

3 5 F 1850-2M0132

Valve clearance check 1850-2M0134

F. Transmission/torque converter suction filter - 1. Nut 2. Cover - 3. Gasket - 4. Mesh filter - 5. Magnetic rod.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

74

1850K

Oil filling Pour in oil up to the prescribed level, indicated by the mark on dipstick 2.

24. TORQUE CONVERTER TRANSMISSION CIRCUIT Wash sunction filter and magnetic rod

Start the engine and let it run at about 1000 rpm.

Actuate the steering levers a few times.

Tilt the cab, remove plug 1 and pull-out the mesh filter indicated in the figure and the magnetic rod.

Stop the engine and after a few minutes check that the oil level reaches the upper mark on the dipstick. Topup, as required, through the plug hole.

Wash both of them with solvent. Clean inside the body.

Re-install the filter, magnetic rod and cover. Check and top-up the oil after changing it (as described in item 3).

1 2 3

4 5 F

1850-2M0136

2

F. Transmission/torque converter suction filter - 1. Nut 2. Cover - 3. Gasket - 4. Mesh filter - 5. Magnetic rod

25. TORQUE CONVERTER TO TRANSMISSION PROP SHAFT - Grease (U joints) 1850-2M0115

Tilt the cab.

Pump grease (three or four strokes) into the appropriate fitting to lubricate the spiders.

Note – Perform the operation more frequently when the machine operates in extreme dusty conditions.

MAX MIN

1850-2M0135

Propeller shaft

Dipstick A The correct oil level must be between the two marks.

WARNING Do not run the engine in closed areas without proper ventilation to remove deadly exhaust fumes.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D350M0117

1850K

75

26. BATTERIES - Check electrolyte level

CAUTION WARNING Batteries contain SULPHURIC ACID. Protect eyes when working on batteries. In the event acid contacts skin, eyes or clothing, WASH IMMEDIATLEY WITH WATER FOR AT LEAST TEN MINUTES.Seek medical help.

Should booster batteries be used, remember to connect both ends of the booster cables in the proper manner (+) with (+) and (-) with (-). Avoid short-circuits of the terminals.

FUMES ARE FLAMMABLE. Estinguish all smoking materials and free flames, before checking, topping-up or charging batteries. Do not check batteries by shorting.

- Remove the three screws S on rear panel P indicated.

- Rotate the panel.

- Check that the elecrolyte reaches the reference mark, on the side of the batteries B. - To restore level, top-off with distilled water.

- Do not overfill.

S

To maintain batteries in efficient conditions, follow these instructions: - do not leave lights on for extended periods when engine is off or idling; - for short stoppages, it is preferable idling the engine rarther than shutting it off, since each starting can run down the batteries; - make sure the cable terminals are properly secured to battery posts and are covered with a thin layer of petroleum jelly; - keep batteries clean, especially the top; - disconnect the ground cable before touching the terminals.

CAUTION To avoid possible damages to the electrical system: - do not mismatch the terminal connection on batteries; - do not let the engine run when batteries are disconnected; - if batteries are partially discharged and auxiliary batteries are used to start the engine, or in the event of battery charging through external systems, connect terminals of the same sign, (+ to + and - to -).

P

1850-2M0137

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

76

1850K

27. AIR CONDITIONER COMPRESSOR Check condition of belt and adjust sag Open the access panel on the left side of the machine.

1. Check the conditions of the compressor belt. In the event the belt is worn or damaged, replace it wit a new one.

The belt must deflect 15 to 20 mm (19/32 to 25/32 in)under as force of 110N (25 lbs).

2. Loosen the compressor mounting bolt and the bracket adjusting screw.

3. To obtain a correct belt adjustment, move the compressor outward. Tighten the compressor mounting bolt and the bracket adjusting screw.

4. If necessary, repeat phases 2 and 3.

28. FAN-ALTERNATOR BELT Check condition and sagging of belt, replace WARNING Do not inspect the tension or adjust belts with the engine running. Be particularly aware of fans.

Do not place the head, body, limbs, feet or hands near belts or moving fans. Be particularly aware of blowing fans.

Open the right and left engine panels and inspect the belt. Crosswise cracks on the belt are acceptable.

Crosswise cracks combind with longitudinal cracks, fraying, breakage points on the belt are not acceptable. In such a case, replace it.

Acceptable condition Belt to be replaced

D350M0178

1850-2M0138

Measure the belt sag on the long span of the belt that under a pressure of a finger deflects a minimum of 9.5 mm (3/8 in) and a maximum of 12.7 mm (1/2 in).

A more accurate inspection can be done using a belt dynamometer located in the middle of the longest span of the belt.

Under these circumstances, the tension limits must be included between a minimum of 36 daNm (265 lbft) and a maximum of 49 daNm (361 lbft).

1850-2M0122

Inspection of belt tension

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

77

Replacing a belt Actuate the tensioner with a leverage and remove the belt. To install a new belt, place it on the fan and crankshaft pulleys, raise the tensioner and complete the turning of the belt, as illustrated. Also, check that the tensioner securing nut is tightened to a torque of 4.3 daNm (31.7 lbft).

1850-2M0123

Removing the belt

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

78

1850K

Wash plug T with solvent.

EVERY 2000 HOURS WORK 29. FINAL DRIVES - Change oil Remove lower plug B (one for each final drive) and let all oil drain out. After retightening the plug, refill with new oil through filler plug A. Repeat the operation on both sides.

Max Min

B A

A T

1850-2M0141

WARNING

B

Never use gasoline, other flammable fluid to clean parts. Use exclusively qualified, non-flammable, non-toxic commercial solvents.

1850-2M0139

Final drive

Loosen the screws on cover C and remove it. Remove filter Fa unscrewing it. Wash and clean accurately.

The filter must be cleaned and inspected at each oil change. If the filter, during the various inspections, results to be damaged, replace it with a new one.

30. EQUIPMENT HYDRAULIC CIRCUIT Change oil and suction filter Drain oil - Position the machine on level ground so that the equipment is resting on the ground; - open the right side panel of the hydraulic oil reservoir; - remove filler plug D and unscrew bottom plug T to drain the oil from the reservoir.

Oil refilling Re-install plug T. Loosen breather cap D and pour oil into the filler neck of the tank, up to maximum level B. Then retighten cap D.

WARNING D

After every maintenance intervention on the tank requiring the total draining of the oil, it is necessary, when refilling, to remove cap P to provide the bleeding of air trapped inside the tank.

Fa C V

Hydraulic oil reservoir 1850-2M0140

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

79

Start the engine, have the blade, as well as the ripper, moving a few times, to fill the pipes and cylinders and top-off with oil as required.

Check that the oil level is in the middle of maximum level indicator B. This check must be performed with the machine on a flat surface, the equipment resting on the ground, cold oil and the engine running at low idle.

WARNING Do not run the engine in closed areas without proper ventilation to remove deadly exhaust fumes.

Be sure exposed personnel in the area of operation are clear of the machine before moving it or its attachments. Walk completely around the machine before mounting. Sound horn.

31. RADIATOR - Change coolant

Note – If the engine cooling system is filled with water instead of coolant (having anti-oxidant, anti-scaling, anti-corrosion properties) flush the system as described here after.

- Dilute "Radiator flushing de-scaling product" or an equivalent product in water, following the dosage indicated on the container. Pour the solution into the radiator when the engine is cold.

- Operate the machine with engine at high speed, until it warms-up completely.

- Drain the solution. Wait for the engine to cool-off a little, then run water through the radiator filler neck letting it flush through the lower side of the radiator.

Use Antifreeze mixed with water at 50% for operation down to - 35 °C (- 31 °F).

32. CLOGGED ENGINE AIR CLEANER Replace cartridges

DANGER FLUID UNDER PRESSURE; prior to removing the cap, turn it slowly to relieve the pressure.

To avoid burns, do not loosen the radiator cap with an hot engine.

Open the upper panels S indicated.

Replace the coolant proceeding as follows: - with engine cold, drain the engine coolant unscrewing the plug at the bottrom of the radiator (to facilitate the flow, remove the filler cap as well); - refit the plug; - pour coolant slowly into the radiator filler neck up to overflowing it; - tighten the radiator cap; - start the engine and let it run for a few minutes; - let the engine cool-off, then top-up coolant level through the radiator filler neck.

Open the engine left side panel.

Remove the cover C from canister loosening the screw V. Remove the two filtering elements: one inner B, the other outer A and replace them.

Before installing new elements, clean inside canister C. C

V

S

1850-2M0142

1850-2M0157

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

80

1850K

A

B

D350M0182

WARNING When using compressed air for cleaning parts, use safety glasses with side shields or goggles, so as to reduce the danger for personal injuries cause by flying particles. Limit pressure to 2 bar (29 p.s.i.), in accordance with local and national regulations.

Important – Keep spare elements of the prescribed type, available from the Sales Organization, on hand to reduce machine down-time.

33. BLADE CYLINDER LINKAGE PIVOTS Grease pivots Pump grease into the lube fittings of the blade cylinder support.

The fitting indicated by arrow is also installated on the opposite side of the machine.

1850-2M0113

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

81

AS REQUIRED D

F

Operations to be performed when relevant indicators come ON: L

L3. Clogged air cleaner L4. Clogged hydraulic oil filter L3 L4

1

2

Hydraulic oil reservoir

n/min

0

x 1000

3

1850-2M0143

34. EQUIPMENT HYDRAULIC SYSTEM RETURN OIL FILTER - Replace cartridge

1850-2M0130

B A

Max. Min.

WARNING FLUID UNDER PRESSURE; prior to removing the cap, turn it slowly to relieve the pressure.

Operation to be performed when indicator light L4 on the instrument panel comes ON, indicating that the oil filter is clogged.

1850-2M0110

Proceed with the replacement of the filter as follows: - remove cover L, remove return filter F and replace it; - install cover L; - check that the oil level is between max. level upper sight gauge B and min. level lower gauge A. This check must be performed with machine on level ground, equipment resting on the ground and engine running at low idle; - top-up oil level, as required, through filler neck D.

WARNING Do not run the engine in closed areas without proper ventilation to remove deadly exhaust fumes.

Warn all exposed personnel repairing or maintaining the machine before starting it.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

82

1850K

35. ENGINE AIR CLEANER - Clean cartridges Operation to be performed whenever indicator light L3, located on the instrument panel, indicates that the air cleaner is clogged.

Air cleaner consists of two coaxial elements: one inner B and one outer A. When the air cleaner indicator light comes ON, clean outer element A. If, after re-installation of the outer element, the indicator stays ON, replace also inner element B. Clean the air cleaner canister and the surrounding area.

Remove the filter cover and pull outer element A first, then inner element B.

1850-2M0155

B

A

D350M0182

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

83 36. CAB VENTILATION AIR CLEANER Clean Filter

Other operations to be performed according to necessity

To reach the air cleaner, open the panel under the cab, on the left side of the machine. Remove the retaining device and extract the filter E using the appropriate handles.

Inspect the filter. If it is clogged, clean it as described here below: - tap slightly the filter on a flat surface, with the drilled face downward; - blow with clean and drycompressed air. The air jet must move fore and back along the plears of the elements, until all dirt is eliminated; - re-install the filter.

WARNING L.039

WARNING

Keep the air jet at some distance from the filter.

Note – Before re-installing the filter, clean the inside of the container.

When using compressed air for cleaning parts, use safety glasses with side shields or goggles, so as to reduce the danger for personal injuries cause by flying particles. Limit pressure to 2 bar (29 p.s.i.), in accordance with local and national regulations.

E

Clean outer element A, directing a jet of dry and clean compressed air, at a pressure of about 2 bar (29 p.s.i.), along the pleats, inside the cartridge, until dust is completely eliminated.

After cleaning the cartridge, check it for ruptures or holes by placing a light bulb inside the element: Light will shine through any holes or tears, making them visible, thus the element must be replaced. Replace the element when the relevant gasket is damaged, as well.

DC180-BM049

WARNING Important – Keep spare elements of the prescribed types, available from the Sales Organisation, on hand to reduce machine downtime.

When using compressed air for cleaning parts, use safety glasses with side shields or goggles, so as to reduce the danger for personal injuries caused by flying particles. Limit pressure to 2 bar (29 p.s.i.), in accordance with local and national regulations.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

84

1850K

37. GLASS FUEL FILTER - Clean mesh filter

WARNING Never use gasoline, solvent or other flammable fluid to clean parts. Use non-flammable, non-toxic commercial solvents.

B Remove the guard under the fuel reservoir in the rear part of the machine and close fuel cut-off valve R. Open the left side panels of the engine compartment and loosen ringnut A, remove the mesh filter from glass B and clean it.

After reinstalling the filter, open valve R and actuate manually the primer pump, a few times, to refill the glass.

A 1850-2M0125

38. AFTER COOLER RADIATOR - Clean

R

1850-2M0124

1850-2M0160

After cooler radiator

1850-2M0158

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K

85

ELECTRICAL SYSTEM FUSES Fuses are located on the left side of the dashboard for the cab version and inside the front pocket (as indicated in the figure).

Remove the pressure fitted covers on fuse boxes A and B.

A

The fuses protect: FUSE BOX A (upper mounted) 1 = Machine services relay/cab services - 5 Amp 2 = Electric cut-off (hold) - Oper. safety levers Timer - 5 Amp 3 = Start safety - Eng. stop electr. relay solen. 5 Amp 4 = Buzzer-Monitor - 6 W/B solenoid valve Resistance - Control valve linkage - 5 Amp 5 = Operator safety relay - Steering safety solen. valve - F/R direction gearshift holding sol. 5 Amp 6 = Horn - 7.5 Amp 7 = Micro controller - 7.5 Amp 8 = Micro controller - 5 Amp 9 = Cab lights - Cigarette lighter - Voltage reduction Radio - 7.5 Amp 10 = Empty - 7.5 Amp 11 = Rear work lights - 7.5 Amp

B

A B 1850-2M0147

on ROPS

on CAB Fuse box A

Fuse box B

FUSE BOX B (lower mounted) 1 = Front lights - Symbol lighting - 7.5 Amp 2 = CR climate control - 20 Amp 3 = RH door wiper - 7.5 Amp 4 = LH door wiper - Door washer pump - 7.5 Amp 5 = Rear wipers - 7.5 Amp 6 = Front wipers - Front and rear washer pump 7.5 Amp 7 = CR climate control - 20 Amp 8 = Pre-heating relay - pre-heating indicator light 5 Amp 10 = Optional - 7.5 Amp 11 = Not used - 5 Amp

WARNING Always disconnect the battery grounding cable prior to cleaning, repairing, connecting or disconnecting any wire of the electrical system, to prevent personal injuries.

Always keep all lights mounted on the machine in working conditions. Replace all burnt-out bulbs as soon as possible.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

D350M0183

86

1850K

LINK FUSES "Link" fuses are reached by opening the left side engine cowling. They are located on the inner side of the frame beam.

Fuse 1 protects the machine 50 Amp. Fuse 2 protects the alternator 80 Amp.

2 1

1850-2M0148

1-2 LINK fuses

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

F11B - 5A

F5A - 5A

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

F8B - 5A

F1A - 5A

F10B - 7.5A

F4A - 5A

F2A - 5A

F3A - 5A

ST M ACC G2 G1 B

START ON ACC OFF H

F7B - 20A

F9A - 7.5A

COLD START. INDICATOR LAMP

ALTERNATOR

MEGA

FUSE 150A

CR CLIMATE CONTROL

RADIO - OPTIONAL

POT. DRIVER

LIGHTER

CAB LIGHTS

HORN

STARTER MOTOR CONTROL

ENG. STOP ELECTR. PULL SOLENOID

CAB RELAY

TRACTOR RELAY

LINK

FUSE 80A

F6A - 7.5A

COLD STARTING RELAY SOLENOID

CAB RELAY SOLENOID

TRACTOR RELAY SOLENOID

OPTIONAL

CONTROL VALVE LINKAGE

RESISTANCE

6-WAY BLADE SOLENOID VALVE

MONITOR - MULTIPLE

BUZZER

EMPTY

FWD/REV. DIRECTION GEARSHIFT HOLDING SOLEN.

I.R.C. BLOCK SUPPLY SOLEN. VALVE

STEERING SAFETY SOLEN. VALVE

TIMER

ENGINE STOP ELECT. HOLD SOL.

ENGINE STOP ELECTR. RELAY SOLENOID OPERATOR SAFETY PROXIMITY SW. PROXIMITY SW.

STARTING RELAY SOLENOID

KEY IGNITION

LINK

FUSE 50A

F6B - 7.5A

F5B - 7.5A

F4B - 7.5A

F3B - 7.5A

F2B - 20A

F1B - 7.5A

F11A - 7.5A

F10A - 7.5A

F8A - 5A

STARTER MOTOR

1850-2M0149

FRONT WINDSHIELD WIPER MOTOR I SPEED

L-H DOOR WINDSHIELD MOTOR PUMP SIDE WINDSHIELD WASHER MOTOR PUMP REAR WINDSHIELD WIPER MOTOR I SPEED FRONT AND REAR WINDSHIELD MOTOR PUMP

R.H. DOOR WINDSHIELD MOTOR PUMP

CR CLIMATE CONTROL

SWITCHES LAMPS

FLOOD LIGHTS (FRONT BEAM)

REAR FLOOD LIGHTS (SIDE BEAM)

MICROCONTROLLER (PIN 1,2,33,46) MICROCONTROLLER (PIN 12,13,14,24,39,41,43,52) EMPTY

GRID HEATER

F7A - 7.5A

ELECTRICAL DIAGRAM OF PROTECTION TREE

1850K 87

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Note:

SAE 80W - 90

Oil quantities indicated are those required for periodical changes. { } First fill quantity. * In case of use of engine oil classified "CH4" the change interval can be extended to 500 hours providing that the ambient temperature does not exceed 38 °C (100 °F) and the fuel sulphur content does not exceed 0.5%.

0.5

All season

All season

All season

All season

- 20 / 50 °C ( - 4 - 122 °F)

All season

All season

ATF Type A Suffix A

–

API CF-4

API GL5 or MIL-L-2105 D

DIN 51524 PART-1 DIN 51524 PART-2 ISO VG-46

API CF-4

ATF Type A Suffix A

API CH4 and ACEA E5

DIESEL FUEL ASTM No. 2D Grade TT of reputable quality and make

Mixture of water and antifreeze at 50%. The mixture provides oxidation, foaming, corrosion, scaling and freezing protection properties down to - 35 °C (- 31 °F).

International Classification

Normal Service interval Half normal interval One quarter normal interval

as 0.5% sulphur 0.5 to 1% up to 1%

If the content of sulphur of the fuel exceeds 0.5%, change the engine oil as follows:

SAE 10W

7

Idlers Rollers and track chains

CASE GEAR 135 HEP

CNH MS 1209, Hy-Tran® Ultra

18

Final drives (each)

Grade NT

CASE Hydraulic Excavator Fluid - MS 1230

Cab tilting pump

110 (130)

Equipment Hydraulic Reservoir

SAE 10W - 30

CASE NO. 1 Engine Oil

SAE 10W

- 25 /25 °C (- 13 / 77 °F)

SAE 10W - 30

Grade 251 H - EP, Spec B-27

46 (60)

Rear Transmission housing Planetary steering / brakes

CNH MS1209 Hy-Tran® Ultra

- 15 / 40 °C ( -5 / 104 °F)

SAE 15W - 40

CASE Molydisulfide Grease

31 (40)

Torque converter/Transmission (Front Transmission Housing)

CASE NO. 1 Engine Oil*

–

–

Down to - 35 °C (-31 °F)

Agriflú mixed with 50% water protect down to - 35 °C (- 31°F)

Grease fittings

16 (19)

Engine

–

Outdoor temperatures of reference

VISCOSITY GRADE

SAE 10W - 30

400

Fuel reservoir

Premium Anti-Freeze MS 1710

Fluids and lubrificants AKCELA

CASE NO. 1 Engine Oil

28 (30)

QUANTITY (litres)

Cooling system

ITEM

1850 K -Table of fluids used

88 1850K