Case 1850K Tier 3 Crawler Dozer Operator's Manual 84149237 - PDF DOWNLOAD

1850K (Tier 3) Crawler dozer

Operator's Manual

Print no. 84149237

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.

SUBJECT

TABLE OF CONTENTS

PAGE

SAFETY RULES ........................................................................................................................................ I-VIII Decommissioning the machine .................................................................................................................. VIII Dispose of wastes in an appropriate manner .............................................................................................. VIII FOREWORD ................................................................................................................................................... IX IDENTIFICATION DATA .................................................................................................................................. 2 COMFORT LEVELS ........................................................................................................................................ 4 GENERAL SPECIFICATIONS ......................................................................................................................... 5 Main dimensions 1850K BD .......................................................................................................................... 8 Main dimensions 1850K PAT ........................................................................................................................ 9 Stability ........................................................................................................................................................11 List and location of safety decals .................................................................................................................12 Preliminary instructions and break-in period ................................................................................................ 27 OPERATION RULES ......................................................................................................................................28 First operation decal .................................................................................................................................... 29 Installing Angledozer (HA) blade hoses ........................................................................................................30 Bulldozer equipement installation (BD) ......................................................................................................... 30 CONTROLS AND INSTRUMENTS .................................................................................................................. 32 OPERATION INSTRUCTIONS .......................................................................................................................49 General information ......................................................................................................................................49 Prior to starting ............................................................................................................................................49 Engine starting ............................................................................................................................................. 49 Stopping the machine .................................................................................................................................. 52 Stopping the engine ..................................................................................................................................... 53 Driver’s seat (depending upon the versions) ................................................................................................. 54 Fuel reservoir ...............................................................................................................................................55 Blade adjustment .........................................................................................................................................55 Cab tilting .....................................................................................................................................................56 Lowering the cab .......................................................................................................................................... 57 Oil refilling and bleeding of the cab tilting system ....................................................................................... 57 Brakes disengagement ................................................................................................................................58 Towing the machine ..................................................................................................................................... 60 Moving the machine with outside means ...................................................................................................... 61 Instructions for lowering the equipment to the ground with engine inoperative .............................................. 62 Transporting the machine .............................................................................................................................62 Long storage of the machine ........................................................................................................................ 63 Cold climate precautions .............................................................................................................................. 63 Starting the machine at low temperatures .................................................................................................... 64 Starting the machine with booster batteries ..................................................................................................65 MACHINE OPERATION ................................................................................................................................. 66 CAB ................................................................................................................................................................ 66

SUBJECT

TABLE OF CONTENTS

PAGE

MAINTENANCE .............................................................................................................................................. 83 Maintenance operations ...............................................................................................................................84 General maintenance and lubrication diagram .............................................................................................. 86 List of programmed maintenance .................................................................................................................87 Every 10 hours work .................................................................................................................................... 89 Every 100 hours work .................................................................................................................................. 91 Every 250 hours work .................................................................................................................................. 94 Every 500 hours work .................................................................................................................................. 95 Every 1000 hours work .............................................................................................................................. 100 Every 2000 hours work .............................................................................................................................. 108 Every 3000 hours work .............................................................................................................................. 112 As required ................................................................................................................................................ 113 ELECTRICAL SYSTEM ................................................................................................................................ 118 Electrical diagram of protection tree ........................................................................................................... 124 TABLE OF FLUIDS USED ........................................................................................................................... 125 GENERAL ELECTRICAL DIAGRAM ....................................................................................... Inside back cover

TO THE OWNER

1850-M0086

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 who know the best methods of repair and maintenance for your Crawler.

RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE

1

1850-2M0167

4

3

OPERATOR’S MANUAL SEAT

2

1850-M0045

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.

SAFETY RULES GENERALITIES

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.

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 unauthorized 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, jewelry, loose or hanging apparel, 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 minimize 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.

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.

Containers must be stored in fresh, well ventilated places, out of reach of unauthorized persons. Follow the instructions provided by the manufacturer.

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.

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

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

OPERATION 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. If 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.

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

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.

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 up, 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 slip 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 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 dangers.

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

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 unauthorized 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 authorized 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 characterized by the presence of all the perils and risks listed above. In these conditions, the danger represented by large tree limbs (possible falling on the machine), large roots (acting as a leverage under the machine when uprooted causing rollover of the unit, etc. is emphasized.

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 unauthorized personnel to perform any maintenance operations. Do not perform maintenance operation without prior authorization. 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.

Do not wear rings, wrist watches, jewelry, loose or hanging apparel, 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 remember to position the transmission drive control in neutral and engage the control lock to secure the machine.

The parking brake is automatically set.

NEVER LEAVE THE MACHINE UNATTENDED with the engine running.

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, 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 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.

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

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

See the relevant chapter in this manual.

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 minimize 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 maneuvers 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 stand 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 jewelry 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 is 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 sparks nearby 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 condition.

NEVER USE tools with mushroomed heads or frayed.

Always wear eye protection.

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 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 site. 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. Strictly follow 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 unauthorized 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 unauthorized 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 the instructions of this manual thoroughly.

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

OPERATOR PROTECTIVE STRUCTURE

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.

WARNING Your machine is equipped with an operator Protective Structure, such as: a Rollover Protective Structure (ROPS) or Falling Object Protective Structure (FOPS) or Cab with ROPS. A ROPS may be a cab frame or a two-posted or four-posted structure used for the protection of the operator to minimize the possibility of serious injury. The mounting structure and fasteners forming the mounting connection with the machine are part of the ROPS.

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.

The Protective Structure is a special safety component of your machine.

DO NOT attach any device to the Protective Structure for pulling purposes. DO NOT drill holes to the Protective Structure.

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

The Protective Structure and interconnecting components are a certified system. Any damage, fire, corrosion or modification will weaken the structure and reduce your protection. If this occurs, the Protective Structure MUST be replaced so that it will provide the same protection as a new Protective Structure. Contact your dealer for Protective Structure inspection and replacement.

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 sitting 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.

After an accident, fire, tip or roll over, the following MUST be performed by a qualified technician before returning the machine to field or job site operation:

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

• The Protective Structure MUST be replaced.

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

• The mounting or suspension for the Protective Structure, operator seat and suspension, seat belts and mounting components and wiring within the operator’s protective system MUST be carefully inspected for damage.

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

• All damaged parts MUST be replaced.

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

DO NOT WELD, DRILL HOLES, ATTEMPT TO STRAIGHTEN OR REPAIR THE PROTECTIVE STRUCTURE. MODIFICATION IN ANY WAY CAN REDUCE THE STRUCTURAL INTEGRITY OF THE STRUCTURE WHICH COULD CAUSE DEATH OR SERIOUS INJURY IN THE EVENT OF FIRE, TIP, ROLLOVER, COLLISION OR ACCIDENT.

VI

SAFETY RULES UNDERSTAND SIGNAL WORDS • In this manual you will find the following words: - DANGER; - WARNING; - CAUTION. referring to different hazard risks.

These words are always accompanied by the safety alert symbol.

DANGER WARNING CAUTION IMPORTANT NOTE DANGER: indicates an imminent hazardous situation which, if not avoided, will result in death or serious injury.

WARNING: indicates a potential hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION: indicates a potential hazardous situation which, if not avoided, may result in minor or moderate injury.

IMPORTANT: indicates a situation which, if not avoided, may cause damage to the machine.

NOTE: indicates an additional explanation for information purposes.

VII

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 authorized to perform this 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 all 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 centers, or from your dealer.

VIII

SAFETY RULES

FOREWORD This manual is designed to serve as 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 VIII. 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.

IX

SAFETY RULES

X

1850K

1

1850K (Tier 3) Crawler dozer

1850-M0086

WARNING The safety of the operator and bystanders depends on the operator's 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 become familiar 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.

Record the information below for quick reference in the case of necessity.

IMPORTANT ENGINE INFORMATION This engine conforms to 2003 U.S. EPA And California Tier 3 and EU Stage III regulations for heavy duty non-road compression ignition diesel cycle engines as applicable.

THIS ENGINE IS CERTIFIED TO OPERATE ON DIESEL FUEL

MODEL No. SERIAL No. DATE CODE

1850-M0044

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

1850K

3

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

Record the data of your machine below.

TECHNICAL TYPE/MODEL UNIT SERIAL No. YEAR

1850-M0191

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 (5 digits); - check letter "N"; - year of production "6" for 2006; - manufacturing plant H (Lecce Plant); - product line "C" (Dozer); - machine serial number (last 5 digits).

According to the machine configuration, the marking will be one of the following: MODEL

MARKING

1850K LT (Series 3)

★HHA185LTN6HCxxxxx★

1850K XLT (Series 3)

★HHA185XTN6HCxxxxx★

1850K LGP (Series 3)

★HHA185LPN6HCxxxxx★

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

1850-M0190

4

1850K

Machine manufactured by:

Series: 1850K Model

Address:

Zona Industriale Surbo 73100 LECCE (ITALY) Telephone: +39 08326881

This machine complies with the EEC Directives relative to safety of machines 98/37/CE; EN474-1:1994; EN 474-2:1996.

Technical type

1850K LT (Series 3)

535.110.185

1850K XLT (Series 3)

535.120.185

1850K LGP (Series 3)

535.130.185

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 Sound level pressure at the operator's seat

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 maneuvers; - when travelling, adjust the speed of the machine so as to minimize vibrations; - keep the work site in good conditions (remove stones and obstacles, fill ditches and holes, etc.).

Level of guaranteed noise power, determined in accordance with European Directive 2000/14/CE.

SERVICE

Standard machine LpA = 81 dB (A) Level of continuous equivalent weighted sound pressure A measured on an identical machine according to ISO 6396:1992.

Noise outside the machine

LEVEL OF VIBRATIONS 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 to or LOWER than........m/s2.

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

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. ?,??

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;

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 centers, 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.

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 A); - the part number (from the Spare Parts Catalog) of the part being ordered.

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

1850K

5

GENERAL SPECIFICATIONS ENGINE Engine "emissioned" Net flywheel power: 1850K Tier3 LT/XLT (196 Hp gross) kw

hp

Net power

rated @ 2000 rpm

rated @ 2000 rpm

DIN 6270

139

187

SAE J1349

137

184

ISO 9249

139

186

EEC 80/1269

139

187

1850K Tier3 LGP (211 Hp gross) kw

hp

Net power

rated @ 2000 rpm

rated @ 2000 rpm

DIN 6270

151

202

SAE J1349

148

199

ISO 9249

150

201

EEC 80/1269

151

202

Make and model .... IVECO 667TA/EB6-667TA/EB4 Type ................. turbocharged, air to air aftercooled, direct injection, 4-cycle diesel Number of cylinders .............................................. 6 Bore x stroke ............104 x 132 mm (4.10 x 5.20 in) Displacement ................................ 6702 cc (409 in3) Governed rpm .................. LT/XLT version 2000 rpm version LGP 2000 rpm Maximum torque ....... 860Nm (LT/XLT)-(634 LBF-FT) ................................... 952Nm(LGP)-(702 LBF-FT) at 1400 rpm Lubrication .................... full pressure by gear pump.

The machine may be operated up to 3048 m (10,000 ft) altitude without derating the engine.

Engine complies with TIER 3 97/68/CE, 2001/63/ CE, 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:

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.

Fuel system common-rail high pressure system electronic unit EDC 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, turbo charge type HOLSET HX35.

TRANSMISSION Hydraulic torque converter with max. stall torque ratio 2.28 : 1.

"Powershift" transmissions providing three forward and three reverse speeds, with ELECTRONIC sliding control. The transmission is disengaged when the joystick is moved to neutral.

AUTO KICK DOWN function button and AUTO SHIFT function button.

Safety lock lever preventing in "lock" position the FORWARD + REVERSE operation of the joystick 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 center of rear transmission housing.

Double reduction modular type final drives.

Reduction ratio: 1 : 12.286.

Oil sump capacity ............................ 16 L (4.2 USG)

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

6

1850K

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, a hydraulic motor and relevant controls, electro-hydraulically actuated.

BRAKES Oil-bath disk 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.

Variable displacement piston pump.

Total flow oil filtration: with safety by-pass valve in case of clogging, on oil return line to reservoir.

Four-spool and five-spool control valves are available.

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

An electric blade control is available also with the "Twist movement": by rotating the grip, on its own axes, in both directions, you can control the blade angling movement, when the pat blade option is installed. This is the PowerAngle -Tilt blade option with the interval C-Frame.

Two double-acting hydraulic cylinders incorporating stroke-end valves operate the blade.

An optional supplementary lever is available for the third spool (ripper).

A safety locking lever retains the equipment control and gearshifting controls in neutral to prevent accidental maneuvers.

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: .............. 610 mm (24 in) optional: .............. 560 mm (22 in) XLT - Number of bottom rollers: ................................... 8 - Number of shoes: ............................................. 45 - Width of standard shoes : .............. 610 mm (24 in) optional: .............. 560 mm (22 in) LGP - Number of bottom rollers: ................................... 8 - Number of shoes: ............................................. 45 - Width of standard shoes : .............. 915 mm (36 in) optional: .............. 762 mm (30 in) For LGP with PAT provision, the only shoe size available is 762 mm (30 in).

FRAME Load bearing with welded steel boxed structure on which the various groups are mounted.

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

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

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

1850K

7

ELECTRICAL SYSTEM

SPEEDS

Voltage 24 Volt.

Alternator BOSCH 65 Amp. Starter motor

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

ISKRA 7.8 kW Starter motor with automatic pinion engagement by solenoid.

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

660 CCA. Low maintenance type.

The machine complies with 89/336/EEC "electromagnetic compatibility"

Speeds

I

II

III

- forward - reverse

4.3 (2.7) 5.2 (3.2)

6.7 (4.1) 8.4 (5.2)

10.9 (6.8) 13.0 (8.1)

RIPPER (supplied on request) 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)

CAB

COLD STARTING (Optional)

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

A cold starting device is available, allowing the starting of the machine at particularly low temperatures.

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.

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 organization.

RIPPER (supplied on request) LT/XLT PD180

LGP RP14F

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

Parallelogram

Parallelogram

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

mm 540 (21.3 in)

mm 432 (17 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 503 (19.8 in)

mm 490 (19.29 in)

Clearance, under tool beam with ripper towered ...

mm 390 (15.3 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) 3.9 (137.7 ft3) 3385 (133.3 in) 1215 (47.8 in) 758 (29.9 in) ± 5° 481 (18.9 in) 1100 (43.3 in) 5440(214.1 in) 20300 (44753.8 lb)

LT BD 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 lb) Semi-U (HSU) 5.6 (197.8 ft3) 3460 (136.2 in) 1425 (56.1 in) 840 (33.1 in) ± 5° 481 (18.9 in) 1100 (43.3 in) 5487 (216 in) 20530 (45260.9 lb)

M

Semi-U (HSU) 5.6 (197.8 ft3) 3460 (136.2 in) 1425 (56.1 in) 840 (33.1 in) ± 5° 550 (21.6 in) 1190 (46.8 in) 5878 (231.4 in) 21630 (47686 lb)

Straight (HS) 3.9 (137.7 ft3) 3385 (133.3 in) 1215 (47.8 in) 758 (29.9 in) ± 5° 481 (18.9 in) 1100 (43.3 in) 5440(214.1 in) 21400 (47178.9 lb)

XLT BD 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)

Straight (HS) 3,7 (130.7 ft3) 3900 (153.5 in) 1110 (43.7 in) 836 (32.9 in) ± 5° 535 (21 in) 1160 (45.7 in) 5675 (223.4 in) 22730 (50111 lb)

F

E I

1850-2M0007

LGP BD 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) 19400 (42769 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

BLADE 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 length 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

A

MAIN DIMENSIONS 1850K BD

8 1850K

H F B

G

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

* ** ***

C

480 (18.9 in) 568 (22.4 in) 1900 (74.8 in) 560-610 (22-24 in) 100 (3.9 in) 184 (7.2 in) 388 (15.3 in) 614 (24.2 in) 822 (32.4 in) 25° 3610 (142.1 in) 4067 (160.1 in) 4195 (165.1 in) 20382 (44934.6 lb) 20518 (45234.6 lb)

XLT PAT 13.5 ft (162 in) – 3235 (127.4 in) 71.5 (2.8 in) 390 (15.3 in) 3205 (126.2 in) 5931 (233.5 in) 1260 (49.6 in) 800 (31.5 in) 1324 (52.1 in) 33.5 (1.3 in) 2460 (96.8 in) 2510 (98.8 in) – 20325 (44809 lb) 480 (18.9 in) 568 (22.4 in) 1900 (74.8 in) 560-610 (22-24 in) 100 (3.9 in) 184 (7.2 in) 388 (15.3 in) 614 (24.2 in) 822 (32.4 in) 25° 3610 (142.1 in) 4067 (160.1 in) 4340 (170.9 in) 21618 (47659.6 lb) 21754 (47959.6 lb)

568 (22.4 in) 2082 (82 in) 762 (30 in) 100 (3.9 in) 221 (8.7 in) 654 (25.7 in) 25° 4067 (160.1 in) 4340 (170.9 in) 22488 (49578 lb)

LGP PAT 13.5 ft (162 in) – 3235 (127.4 in) 71.5 (2.8 in) 390 (15.3 in) 3205 (126.2 in) 5931 (233.5 in) 1260 (49.6 in) 800 (31.5 in) 1324 (52.1 in) 33.5 (1.3 in) – – 2844 (112 in) 21059 (46427.1 lb)

Includes ROPS Cab, 610 mm (24 in) shoes (762 mm (30 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 (762 mm (30 in) for LGP), 10% fuel, blade lift cylinders, lubricants, coolant.

mm mm mm mm mm mm deg mm mm kg

M

12 ft (144 in)

T

M Blade tilt (7.6 DEG) N Gauge O Track shoes width P Minimum distance shoes-mainframe Q Cut reach R Cast reach S Blade angle T Blade width U Tractor length Operating weight with blade*

13.5 ft (162 in)

Q

– 3235 (127.4 in) 71.5 (2.8 in) 390 (15.3 in) 2700 (106.2 in) 5617 (221.1 in) 1133 (44.6 in) 766 (30.1 in) 1324 (52.1 in) 33.5 (1.3 in) 2460 (96.8 in) 2510 (98.8 in) – 19089 (42084 lb)

LT PAT

P

m3 mm mm mm mm mm mm mm mm mm mm mm mm kg

A

12 ft (144 in)

S

L N

TRACTOR DIMENSION Blade dimensions Blade capacity SAE J1265 A Height over cab B Shoe grouser height C Ground clearance D Length of track on ground E Overall length with blade F Max lift above ground G Digging depth H Height of blade I Cutting edge angle L Overall width with shoes 560 (22 in) Overall width with shoes 610 (24 in) Overall width with shoes 762 (30 in) Shipping weight w/blade***

E

R

I

D

O

U

MAIN DIMENSIONS 1850K PAT

1850-M0088

1850K 9

10

1850K 1850K PAT IMPLEMENT WEIGHT LT PAT

Blade weight (12 ft) Blade weight (13.5 ft) Cylinders & Others Short C-Frame weight Long C-Frame weight Total PAT implement weight

XLT PAT

LGP PAT

kg

lb

kg

lb

kg

lb

kg

lb

kg

lb

1293

2850

-

-

1293

2850

-

-

-

-

-

-

1429

3150

-

-

1429

3150

1429

3150

295

650

295

650

295

650

295

650

295

650

1225

2700

1225

2700

-

-

-

-

-

-

-

-

-

-

1361

3000

1361

3000

1361

3000

2812

6200

2948

6500

2948

6500

3084

6800

3084

6800

1850K PAT MACHINE WEIGHT LT PAT With 560 mm (22 in) shoes With 610 mm (24 in) shoes With 762 mm (30 in) shoes

XLT PAT

LGP PAT

kg

lb

kg

lb

kg

lb

kg

lb

kg

lb

20229

44597

20365

44897

21446

47280

21582

47580

-

-

20382

44935

20518

45235

21618

47660

21754

47960

-

-

-

-

-

-

-

-

-

-

22488

49578

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

1850K

11

STABILITY POSITION OF CENTER OF GRAVITY (BD) In transportation conditions.

Note: the center of gravity depends upon the position of the equipment.

For inches divide 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 means 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

12

1850K

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 five groups: Group A - danger decals Group B - warning decals Group C - general-purpose decals Group D - maneuver decals Group E - information decals The exact location on the machine is found in the figure here below.

LIST OF DECALS

A

B B

C

D

E

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

1E

DECAL LOW EMISSION

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

1850K

13

LOCATION OF SAFETY DECALS 1E

10B

3B 6B

2A

1A

7D

3A 4B

8D

2D 9B

1C

8B

10B

1B

5C

1850-M0192

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

14

1850K

3D

5B 1D

6D 2B

"A" 1850-2M0016

1850-M0145

2C 4D

1850-2M0013

7B 1850-2M0017

1850-2M0014

5D

1850-M0146

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

1850K

15

3C

4C

1850-2M0019

7D

1850-M0197

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

16

1850K

LIST OF SAFETY DECALS Group A - Danger decals 1A. The track release spring is assembled with a high compression load and non-compliance with the procedures described in the instruction manual for repairs may cause people lethal injuries.

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.

1850-2M0020

2A. The presence of this decal indicates that people are in danger of serious injuries because the fluid under pressure may be sufficiently forceful to perforate the skin.

DANGER 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. 1850-2M0021

3A. The presence of this decal indicates that only the operator can put the machine into operation, and only with the transmission lever in neutral so as to prevent involuntary movements from causing lethal injuries to people standing in proximity of the machine.

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

17

LIST OF SAFETY DECALS Group B - Warning decals 1B. The decal indicates that if the coolant reaches high temperatures it may cause serious burns to the operator. Unscrew the radiator cap slowly to release the pressure.

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

2B. The decal indicates that it is necessary to read the operator's manual carefully before starting any service operation on the machine and before putting it into operation so as to prevent damages to the machine or serious injuries to people.

WARNING

Service when cool Fasten seat belt No riders Keep others away 1850-2M0025

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

18

1850K

3B. Do not try to modify or repair the cab because this may damage its protective structure, with consequent risk of serious injuries to the operator.

WARNING Do not modify or repair ROPS or FOPS in any manner

1850-2M0026

4B. The decal gives instructions on how to tilt the cab.

Be careful that there are no people on the left side of the machine during the tilting operation.

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 - 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-M0144

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

1850K

19

5B. The decal indicates the need to put the main switch of the electric system in the OFF position before starting any service operation on the machine in order to prevent injuries to people. This precaution must also be taken when the machine is parked, in order to prevent any theft.

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

6B. The decal indicates the presence of acid in the batteries, which could cause serious injuries to people if it comes into contact with the skin and eyes. Consult the operator's manual with regard to the recharging and emergency starting procedure.

EXPLOSION HAZARD RUN OVER HAZARD Read procedure in Operator's Manual before jump start or service to avoid injury 1850-2M0029

7B. The decal indicates the presence of the fan and belt, which if in movement could cause amputations. Stop the engine before starting any service operation on the machine.

WARNING

ENTANGLEMENT HAZARD Keep clear or stop engine before servicing.

1850-2M0030

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

20

1850K

8B. The decal indicates that the machine must be secured with proper blocking device once the brakes have been disconnected. Pay attention during the brake disconnection operation because their highly loaded springs could cause serious injuries to people.

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. 1850-2M0032

9B. The decal indicates that the operator is not to jump off of the machine should it tip over because this could result in injury - even fatal - to the operator.

Always have the seat belt fastened when the machine is in operation.

AVOID CRUSHING DO NOT JUMP IF MACHINE TIPS OVER

USE SEAT BELT 1850-2M0031

10B. The decal indicates the machine parts that have reached high temperatures. Pay attention because contact could result in serious burns.

1850-2M0033

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

1850K

21

LIST OF SAFETY DECALS Group C - General purpose decals 1C. The decal indicates the periodic maintenance intervals to be complied with. Refer the part relative to maintenance described in this manual.

1850-2M208

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

22

1850K

2C. The decal indicates the refuelling point. Put in only automotive fuel in this point because other substances would cause serious damage to the machine.

FUEL

1850-2M0035

3C. The decal indicates the maintenance interval for replacing the clutch oil filter cartridge.

WARNING REPLACE THE CLUTCH OIL FILTER CARTRIDGE EVERY 500 HOURS.

1850-2M0036

4C. The decal indicates the maintenance interval for replacing the transmission oil filter cartridge.

WARNING REPLACE THE TRANSMISSION OIL FILTER CARTRIDGE EVERY 500 HOURS.

1850-2M0037

5C. The decal indicates the hydraulic oil filling point.

Put in only hydraulic oil in this point because other types of oils would cause serious damage to the machine.

1850-2M0022

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

1850K

23

LIST OF SAFETY DECALS Group D - Maneuver decals 1D. The decal indicates the various positions the implement can take.

1850-2M0038

2D. The decal indicates how the machine must be lifted. The cables or chains must be securely fastened in the relevant points in order to prevent them from breaking and causing serious injuries to people standing near the machine.

1850-2M0039

3D. The decal indicates the need to consult the use and maintenance manual before putting the machine into operation.

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

1850-2M0041

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

24

1850K

4D. The decal indicates the accelerator lever. Maximum acceleration is achieved by lowering the lever. Minimum acceleration is achieved by raising the lever.

1850-2M0040

5D. The decal indicates the need to put the lever in the locked position before leaving the operator's seat in order to prevent accidental operation of the transmission and implement.

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

1850-2M0042

6D. The decal indicates the ripper control lever.

The ripper is lowered by moving the lever forward.

The ripper is raised by moving the lever back.

1850-2M0043

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

1850K

25

7D. Turn the main switch key to the "0" position to cut out the batteries. Turn the key to the "1" position to enable batteries and start up the machine.

1850-M0189

8D. Carefully follow the instructions on this decal in order to prevent serious injuries to people.

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 INSTRUCTIONS.

1850-2M0045

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

26

1850K

LIST OF SAFETY DECALS Group E - Information Decals 1E. The plate indicates that the machine is equipped with a low polluting emission engine.

TH001418

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

1850K

27

PRELIMINARY INSTRUCTIONS AND BREAK-IN PERIOD PRELIMINARY INSTRUCTIONS

BREAK-IN PERIOD

When delivering the machine, 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 any leaks 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 be 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)

28

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 minimize 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 any 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-M0152

L

N

L

1850-M0151

DOWN

UP

To steer left, move the L control in “S” position, to steer right, move the L control in “D” position.

S

D

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

1850-2M0046

ON

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 to position “OFF”.

Main switch

1850-2M0053

9-

A

6-

1-9

3-

1850-2M0154

Starter switch

START

7

1850-M0150

D

3

1850-2M0054

6

2-5

1850-M0153

4-7

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

Warm-up the engine for at least 5 minutes.

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-M0148

B

A

To operate the machine: - Move the lever 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

FIRST OPERATION DECAL

5-

4-

n/m in

100 0

1

3

2

1850-2M0048

A

A

1850-M0148

1850-M0149

B

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

B

A

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

0

1850K 29

30

1850K

INSTALLING ANGLEDOZER (HA) BLADE HOSES

BULLDOZER EQUIPMENT INSTALLATION (BD)

If the Angledozer (HA) blade is to be installed, the tilt control hoses must be connected on the points shown in the figure. These connection points are closer together than the implement in order to prevent the pipes from becoming damaged.

When assembling the equipment, first of all consider the following instructions: - 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; - length 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 moulboard 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 be made 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. Length of diagonal tie-rod (3) connecting the push arms to the moulboard 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; - Use GR5 PLUS grease to lubricate all the hinging.

D180-2M068

Note - On reassembly grease the threaded ends of the tie rods (1) with GR5 PLUS grease.

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

1850K

31

h

f

b

Cl C2 t

m

S

g a

b

C3 d

d

C1

C1 e

e

3 a

L1

1

2

L2

T

3

g C2

f

h

m

D180-2M069

Push arms and bulldozer blade 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-f. Diagonal tie rod hinge (2 and 3) g. Blade control cylinder rod hinges h-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-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

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

32

1850K

CONTROLS AND INSTRUMENTS 9

17 16

21 18

19

14

15

1

8 8 2

10 13 12

3

11 20

5 6 4 7 8

8 1.

2.

3.

4.

5.

6.

Right safety lever and parking brake Blade control lever Ripper control lever Engine starter switch Ashtray 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 (Optional) 12. AUTO KICK DOWN "AL" function button 13. Steering control 14. Armrest adjustment lever

1850-M0035

15. Left safety lever and parking brake 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 4, 6, 7 are located on the dashboard, as indicated.

6

Note – The terms left and right used in this text are intended as referring to the operator sitting in his seat, facing forward.

4 7

1850-M0013

on ROPS

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

1850K 1.

33

RIGHT SAFETY LEVER AND PARKING BRAKE

WARNING Do not use the safety lever and parking brake as a service brake. The machine must be stopped by pressing on the brake pedal (service brake).

1

2

WARNING Always engage the parking brake when stopped or before exiting from the machine.

CONTROL BLOCK When this device is lifted as in the illustration to position (1) (vertical position), it blocks the EQUIPMENT CONTROL LEVER, the GEAR CONTROL BUTTONS and engages the parking brake.

This block is used to prevent unintentional movement of the levers (3-4) and buttons (11) which could cause dangerous manoeuvres.

- Lift the safety lever to a vertical position (1) to disable gear and equipment controls.

- Lower the safety lever to a horizontal position (2) to enable gear and equipment controls.

PARKING BRAKE This device blocks both driving wheels.

Engaging the parking brake - The parking brake must be engaged when the machine is stopped and after it has been switched off with the brake pedal.

- Lift the lever to a vertical position (1) to engage the parking brake.

- Lower the lever to a horizontal position (2) to release the parking brake.

Note - When the machine has been parked in a steep position, brief machine translation may take place after the parking brake has been engaged, due to the progressive intervention of the parking brake itself. Verify that the machine has been properly blocked before exiting.

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

1850-M0102

34 2.

1850K BLADE CONTROL LEVER (Bulldozer version)

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 cross tilting of the blade is obtained. The lever must be held until the blade reaches the desired tilting.

F

H

B

A D

D350M0159

Blade control lever A

2

1

F H N

n/min

0

1000

3

A

B D

1850-M0048

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

1850K

35

BLADE CONTROL LEVER (PAT version with 6-function blade)

1 Leftward angling

In the version arranged with "PAT" equipment, the equipment control lever has the same functions of the BD blade, and, on top of that, the following two control functions can be performed:

1 Blade leftward angling: leftward angling of the blade is obtained by turning the lever to the left on its vertical axis.

2 Blade rightward angling rightward angling of the blade is obtained by turning the lever to the right on its vertical axis.

Angle left

Angle right 2 Rightward angling

1850-M0135

3.

RIPPER CONTROL LEVER (optional)

- With lever forward in P = ripper lowering.

- With lever backward in R = ripper raising.

- Lever in N = neutral.

Ripper control lever

1850-M0051

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

36 4.

1850K ENGINE STARTING SWITCH WARNING

Prior to starting the engine, make sure that the joystick 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 (4): Starting switch

Positions:

1850-2M0063

OFF

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

ACC

- All functions related to electrical system services are activated.

ON

- All other functions of the electrical system are activated. The safety lever indicator lights and pre-heating indicator light comes ON. The indicator lights on the instrument panel (see instrument panel) come ON.

on CAB Pre-heating indicator

4

START - The functions relative to position "ACC" are cut off. Turn to this position to start the engine once the pre-heating indicator goes off. The switch returns automatically into position "ON" once the key is released.

Safety lever indicators 1850-M0014

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

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

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.

Note – For particularly low 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 arctic fuel and larger batteries (180 Amph - 770 Amp) is recommended.

OFF ACC. ON

START

Safety lever indicator lights

Starter key

WARNING Under forced starting conditions (i.e. low ambient temperatures) do not try beyond three attempts of 30 sec. max. each, intervalled by at least a 2-minute 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).

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

Pre-heater indicator light 1850-M0053

1850K

37

5.

ASHTRAY

6.

24V DC POWER OUTLET/CIGARETTE LIGHTER (OPTIONAL)

5

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.

7.

HORN

8.

VENTILATION DUCTS

9.

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

6

8 7

Starter key

1850-M0016

9

1850-M0193

10. TRANSMISSION CONTROL LEVER 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.

By moving the lever (3) forward to the FORWARD position, the machine moves forward after engaging the 1st speed.

To select 2nd or 3rd speed actuate the switch P in "(1)" position.

To downshift actuate again switch P in "(2)" position.

By moving the lever (3) back to the REVERSE position, the machine moves in reverse after engaging the 1st reverse speed. The gearshifting and the direction change can be made with machine in motion or standing.

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

1 FORWARD

NEUTRAL

2

3

REVERSE

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

1850-M0010 1850-M0130

38

1850K

Selecting forward speed ("F") 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 downshifted.

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

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") 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.

11-12. 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.

Auto mode description Safety levers AL

Automatically downshifts the transmission 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

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

1850K

39

AUTO SHIFT "AS" 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.

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.

AS

AL

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

" " "

1850-M0159

AUTO SHIFT "AS" button.

AUTO KICK DOWN "AL" button

1st F 1st F 1st F

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

The system is capable of downshifting 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.

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. 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).

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

40

1850K

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

2 D

L

1

Steering rightward To steer rightward move the (1) control in (2) 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 the stroke of the lever is, the greater the steering of the machine.

1850-M0131

Rightward steering Leftward steering To steer leftward, move the (1) control in (3) position.

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

3

1

1850-M0132

Leftward steering 14. ARMREST ADJUSTMENT LEVERS To adjust the position of the armrest, operate the related levers.

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

1850K

41

15. LEFT SAFETY LEVER WARNING Do not use the safety lever and parking brake as a service brake. The machine must be stopped by pressing on the brake pedal (service brake).

4

5

WARNING Always engage the parking brake when stopped or before exiting from the machine.

This device can have two positions.

The device, lifted as illustrated in the figure in position (4), (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 (2-3) and the lever (10-13) which could cause dangerous maneuvers. In this position, the parking brake is automatically applied.

Position (5): it activates the equipment control levers, the joystick switch and disengages the parking brake.

1850-M0105

Position 4 = neutral Position 5 = operating position

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

42

1850K

16. INSTRUMENT PANEL Indicator lights and instruments

L1

L2

L3

L4

L5

L6

L7

1

L8

L9

L10 L11

L12

2 n/min

DL1

DL2

S1

0

x 1000

3

S3

S2

S4 1850-M0001

L1.

L2.

L3.

L4.

L5.

L6.

L7.

L8.

L9.

Battery charge indicator Engine oil pressure indicator Engine air cleaner indicator Hydraulic oil filter indicator Transmission oil pressure indicator Transmission oil temperature indicator Brake failure indicator Optional red lamp General alarm indicator

L10.

L11.

L12.

DL1.

DL2.

S1.

S2.

S3.

S4.

Front work lights indicator Rear work lights indicator Headlights indicator + dashboard light Fuel reserve LED indicator Engine coolant temperature LED indicator Fuel level instrument Engine coolant temperature gauge Display Rev. counter.

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

1850K

43

L1. Battery charge indicator

L7. Brake failure indicator

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

L8. Optional red lamp 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.

L9. General alarm indicator It warns the operator with a dual signal (sound and flashing light) about possible 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 organization.

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

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.

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.

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.

Overheating of the oil must be avoided since it alters the specifications of the oil and jeopardizes 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.

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 in order 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)

44

1850K

INSTRUMENTS DL2

Coolant temperature This instrument indicates the temperature of the coolant.

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

S2

1850-2M0073

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

1

2 n/min

0

x 1000

3

S3

S4 1850-2M0074

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

1850-2M0075

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).

1850-2M0151

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

1850K

45

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

TABLE 1 Failed component

Trouble code

Failed component

Trouble code

Left proportional solenoid valve coil

E001

PWM output error on Tilt axle

b4

Right proportional solenoid valve coil

E002

Tilt sensor error

b5

Forward "F" speed solenoid

E004

PWM output error on angle axle

b6

Reverse "R" speed solenoid

E008

Angle sensor error

b7

1 speed solenoid

E016

PWM output error on ripper axle

r2

3 speed solenoid

E032

Ripper sensor error

r3

Left steering lever solenoid

E064

Blade priority functionality error

b8

Right steering lever solenoid

E128

Blade/Ripper Eeprom read data error

b0 or r0

PWM output error on blade axle

b2

Blade/Ripper Eeprom write data error

b1 or r1

Blade sensor error

b3

st

rd

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).

1850-2M0153

TABLE 2 Failed component

LH prop. sol. RH prop. sol. For. "F" Rev. "R" 1 st speed 3 rd LH steer.

RH steer.

Valve coil valve coil speed solen. speed solen. solen. speed solen. lever solen. lever solen.

Left prop. solenoid valve coil Right prop. solenoid valve coil Forward "F" speed solenoid Reverse "R" speed solenoid 1 st speed solenoid 3 rd speed solenoid Left steering lever solenoid Right steering lever solenoid

001

003 002

005 006 004

009 010 012 008

017 018 020 024 016

033 034 036 040 048 032

065 066 068 072 080 096 064

129 130 132 136 144 160 192 128

Reverse "R" speed solenoid trouble code Trouble code on display 1st speed solenoid trouble code 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 two.

Reverse "R" speed solenoid trouble code 1st speed solenoid trouble code

= 008 + = 016

Trouble code for both

= 024

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

46

1850K

17. SWITCH AND INDICATOR PANEL

on CAB 1

a. The front and rear windshield wipers of the machine turn on when the switch is pressed.

0

n /m in

2

x 1000

3

b. The front and rear windshield washers of the machine turn on when the switch is pressed. c. The side windshield washers turn on when the switch is pressed. d. The windshield wipers of the side doors turn on when the switch is pressed. a

b

c

d

e. The work lights and instruments of the machine turn on when the switch is pressed.

e

f

g h m

n

on ROPS

f. The rear work lights turn on when the switch is pressed.

e

f

g

h

m

n

a. Front/rear wiper 1 speed switch. b. Front/rear washer button. c. Side doors washer button. d. Side doors wiper 2 speed switch. e. Headlights and instruments switch. f. Rear work lights switch. g. Operator safety indicator lamp. h. Operator safety indicator lamp. m.Water in fuel pre-filter indicator lamp. n. Pre-heating indicator lamp.

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

1850-M0107

1850K

47

g-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 (X) (NEUTRAL).

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

When the implement safety lever (1) is lowered, the indicator lamp "g" turns off, whereas the "h" indicator lamp turns off when the transmission safety lever (2) is lowered.

X X

2

Y

1 Y

1850-M0109

Position X = neutral Position Y = operation position

m.

WATER IN FUEL PRE-FILTER INDICATOR LAMP

When the lamp turns on, this means there is water in the fuel pre-filter. Drain the water and sediment from the fuel pre-filter as described in operation 3 of the routine maintenance described in this manual.

n.

PRE-HEATING INDICATOR LIGHT

The indicator lights come ON during the engine preheating phase (starting key in position "ON") when the outside temperature is particularly low.

At the end of this phase, the indicator light goes OFF and the machine can started by turning the key in "START" further.

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

48

1850K

18. ENGINE THROTTLE LEVER When lowering the lever = maximum acceleration.

When raising the lever = minimum acceleration.

18

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

19

21

D180-M0036

20. ELECTRICAL SYSTEM MASTER SWITCH The electrical system master switch is found when opening the left panel (1), indicated in the figure. The key (20) of the electrical system master switch must be in position "1" when the system must be operational.

Turn the switch key into position "0" (same as moving direction of machine) when the machine is parked at the end of the work shift.

1 1850-M0194

21. BRAKE PEDALS (SERVICE BRAKE) Press this pedal to stop the machine.

20 1850-M0195

20 1850-M0196

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

1850K

49

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.

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 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.

Open the left cab side panel.

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

- 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.

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

D180-2M176

50

1850K

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

Prior to climbing onto 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.

1850-M0128

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.

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.

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

1850-M0156

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

1850K

51

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

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 to position "START".

Once the engine is started, release the key.

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

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

Motion direction ON

START

ACC. OFF

Starter key

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.

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

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

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.

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

1850-M0157

52

1850K

STOPPING THE MACHINE WARNING Always engage the parking brake when stopped or before exiting from the machine.

WARNING Do not use the safety lever and parking brake as a service brake. The machine must be stopped by pressing on the brake pedal (service brake).

WARNING Never park on a slope without blocking accurately 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.

1

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.

FORWARD

- Reduce the engine speed.

- Stop the machine using the brake pedal (21).

- Move the gearshifting control to neutral, pressing button (1) and engage the relevant safety lever into neutral position A.

REVERSE

Lower the equipment to the ground and engage the left and right equipment safety lever in neutral position A.

B

2

NEUTRAL

3

1850-M0130 1850-M0010

A A

Note - When the machine has been parked in a steep position, brief machine translation may take place after the parking brake has been engaged, due to the progressive intervention of the parking brake itself. Verify that the machine has been properly blocked before exiting.

B

1850-M0110

Position A = neutral Position B = operation position

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

1850K

53

STOPPING THE ENGINE Motion direction 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 varying from 3 to 5 minutes be observed, prior to stopping the engine. A sudden shut-off of the engine with the turbocharger at high speed and temperature will result in a transfer of heat to the bearing housing. Repeated hot shut-offs could damage the shaft bearings.

ON

START

ACC. OFF

Starter key 1850-M0158

With engine at low idle, move the engine starter key into position "0".

Prior to leaving the machine, in case this is going to be unmanned, move the ELECTRICAL SYSTEM MASTER SWITCH to "0".

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 4 (Starter switch).

D180-2M177

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

54

1850K

SEAT ADJUSTMENT (depending upon the versions)

On CAB

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

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

6

3

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

4

5

1

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

2 1850-M0133

1 2 3 4 5 6

-

Height adjustment (pneumatic).

Operator's weight correct setting indicator.

Backrest angle adjustment.

Front cushion 3-position angle setting.

Horizontal adjustment (sliderails).

Lumbar support adjustment, 5-position.

On ROPS

6

3 4 5

1

2 1850-M0134

1 2 3 4 5 6

-

Height adjustment (mechanical).

Operator's weight correct setting indicator.

Backrest angle adjustment.

Front cushion 3-position angle setting.

Horizontal adjustment (sliderails).

Lumbar support adjustment, 5-position.

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

1850K

55

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.

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 refuelling occurs at the end of each day's work; this will prevent condensation 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.

1850-M0198

BLADE ADJUSTMENT 1

Bulldozer version In the bulldozer version, with a blade tilt control rod on the left side, tighten or loosen sleeve (1) using bar (2) to move further.

2 1850-M0111

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

56

1850K

CAB TILTING

1

3 2

The cab is tiltable on the left side of the machine to provide easy accessibility for the maintenance of the main groups of the machine.

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

1850-M0155

WARNING Prior to tilting the cab, make sure that left panel (1) of the engine compartment and the left door (3) are closed, to prevent interference.

Also, make sure that left panel (2) under the cab is open to prevent interference with the frame during the tilting phase.

- Loosen the six screws (5) securing the cab on the right side of the machine.

The screws secure the two supports (6) of the cab to the base of the machine frame (three screws each side); 6

6

4

5 1850-M199

- turn diverter valve (4) into cab tilting "position

"; Diverter valve (4) in cab tilting position 1850-M0113

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

1850K

57

- actuate hand pump (4) using lever (1) inserted into hole (3) to tilt the cab, very slowly; 5

3 1

4 2

1850-M0200

1. Pump actuating lever - 2. Diverter valve - 3. Lever hole 4. Hand pump - 5. Hand pump oil plug.

Note – Once the center of gravity of the cab overcomes the dead point, it is not necessary to pump oil with lever (1), since the tilting continues naturally under the effect of gravity, to the position determined by the tension of safety cable (7).

Control the last tilting travel of the cab, by alternating diverter valve (2) from one position to the other .

7

6

LOWERING THE CAB To lower the cab, proceed as follows: - turn diverter valve (2) into lowering position ; - actuate hand pump (4) with lever (1) and constantly check that there is no interference with the parts below, such as wires or pipes.

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 (2) into "tilting position" ".

Tighten the six screws securing the cab to a torque of 51÷ 55 daNm (376 ÷ 405 lb ft).

1850-M0115

6. Hydraulic cylinder - 7. Safety cable

Diverter valve 2 in cab lowering position.

OIL REFILLING AND BLEEDING OF THE CAB TILTING SYSTEM Proceed as follows: - make sure that cylinder (6) as the rod fully retracted; - remove pump plug (5) and fill with prescribed oil; - perform two or three tilting and lowering maneuvers of the cab, to bleed the air from the system; - fill with oil through the plug, with the rod of cylinder (6) fully retracted; - close plug (5).

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

1850-M01116

58

1850K

BRAKES DISENGAGEMENT 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; - 2 brakes disengagement bolt (P/N 380001315).

Note – For special tools, please contact your CASE Authorised Service Centre.

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.

Disengaging brakes procedure 1) Remove guard (1) and stone guard (2) loosening securing screw (3) on both sides of machine.

2) Loosen plug (4) using a allen wrench from two sides of transmission. Tighten the disengagement screw (5) (PN 380001315) complete with washer and locknut (6) on piston (7).

2

1

3 3

4

1850-M0117

Brakes engaged position 7

6

5

4,5 mm (0.18 in) 1850-M0118

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

1850K

59

3) Open the panel of lower cab from right side of machine and access to diagnostic panel indicated.

D180-2M183

4) Connect hand pump to pressure pick-up point (1) indicated on diagnostic panel and actuate it until disengagement screw (2) protrudes, indicating the disengagement of piston (4) of 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.

1

D180-2M184

5) Tighten lock-nut (3) until it contacts the face of the transmission housing, so that piston (4) is prevented from returning.

Brakes disengaged position 4

3

4,5 mm (0.18 in)

6) Repeat the operation 5 for the apposite side.

-

2

1850-M0120

Brakes disengaged position

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

4

4,5 mm (0.18 in)

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

3

2

1850-M0121

60

1850K

TOWING THE MACHINE WARNING Keep exposed personnel clear of anchor points and cables or chains.

Do not pull unless operator’s compartment of machines involved are properly guarded against potential cable or chain backlash.

Prior to the towing, make sure that the cable or the towing bar are in good condition 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 hauling if if a longer distance becomes necessary.

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.

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, a larger machine or connecting other machines to the rear part could be necessary in order 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)

1850K

61

MOVING THE MACHINE WITH OUTSIDE MEANS Towing and recovering the machine Should the engine fail to start or when the machine must be towed, it is necessary to disengage the brakes manually, 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 condition and are free from defects or troubles.

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

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

The maximum allowable load on the front hook is 200 kN. (44.960 lbf).

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.

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

Max. 200 kN (44.960 lbf)

1850-2M0096

Lifting 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.

1850-M0012

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.

D350M0168

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

62

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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 SHUTTING 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 tires, 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 maneuvering, avoiding sudden starts or stops; - lower the equipment, apply the parking brake and follow the entire procedure recommended for stopping and leaving the machine.

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

1850-2M0097

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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 parts 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.

LONG STORAGE OF THE MACHINE 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.

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.

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

40% - 35 °C (-31 °F)1.

50%

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.

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STARTING THE MACHINE AT LOW TEMPERATURES The machine is equipped with an optional device for starting at particularly low temperatures. See page 33.

Temperature °C (°F) < 0 °C (32 °F)

Activation of engine pre-heating

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

Fuel

Engine oil

Antifreeze 50%

No

STD

15W-40

20%

0 to -14 °C (32 °F to 57 °F)

Yes

Arctic fuel

15W-40

30%

-15 to -24 °C (5 °F to -13 °F)

Yes

Arctic fuel

10W-30

40%

Yes

Arctic fuel

10W-30

50%

> -24 °C (-13 °F)

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65

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.

WARNING When connecting the jumper cables, make sure that the positive and negative terminals are not short-circuited; a shorted battery could explode.

Beware when connecting the jumper cables to the engine crankcase of the disabled machine with the possibility of generating sparks, in a position as far as possible from the battery.

1850-M0177

Use of jumper cables for a temporary performance of the battery

- The machine mounts two 12 Volt batteries, for a total of 24 Volt. Make sure that the corresponding batteries have the same voltage.

Operating machine

- Turn the starter switch of the operating unit and disabled unit into "OFF".

- Connect one end of the jump lead to the machine 12 volt batteries positive (+) terminal and the other to the auxiliary 12 volt batteries positive (+) terminal.

- Connect one end of the second jump lead to the auxiliary 12 volt batteries negative (-) terminal and the other end to the machine engine block: following this procedure will prevent sparks occurring near the batteries.

- Make sure that the four terminals are firmly secured, providing a good contact.

Disabled machine

Ground

- Start the engine of the disable vehicle.

- After starting the engine of the disabled vehicle, remove the cables with a reversed sequence.

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

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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 circumstances, keep head, body, limbs, feet, hands and fingers within the operator's compartment to minimize 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 using 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 attention when working near overhangs.

Always designate a flagman when the operators visibility of the working place, 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.

Working in the 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 become familiar 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.

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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.

Work 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 moulboard corner tilted.

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

Under these conditions the angle is good for the initial cutting, but during continued dozing the moulboard 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

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Power Steering 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 tracks) 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

OPERATING ANGLE Important: For safety reasons and for effective machine operation ensure that operating angles shown below are never exceeded.

1850-M0154

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69

Moving large rocks and boulders It could become necessary to move boulders with the dozer, during all kinds of work. 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 on 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

Moving boulders with the side of the blade

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

D350M0170

249

70

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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 center slot and continually cutting away the top. This method is always recommended when the pile is excessively high and it is the only possible way 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

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71

Center slot dozing of pile

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 start 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 damage 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 piles 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.

1850-2M0163

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 could cause the machine to tip over.

Chances of this occurring are lessened when the machine is dozing as it is moving along using the load as an additional stabilizer. Also, the machine is stabilized 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 center slot

247

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On the other hand, the machine overcomes steep downhill slopes safely. 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 overcomes steep downhill slopes safely, or three loads at the end of the cut, then push most of the pile down in a single pass.

Grading on side slopes If a slope must be notched (e.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 (1), so the dozer can start level cuttings, as in (2).

Start cutting 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.

1

2

1850-M0129

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

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73

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, build up 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, back up rapidly so that the uplifting roots will not catch under and tilt over the machine.

D350M0172

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

OPERATING TIPS Before beginning to doze, the moulboard 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 condition.

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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.

1850-M0160

For LT - XLT Version

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.

WARNING To make sharp turns, raise the ripper teeth off the ground to prevent damage. 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.

1850-M0161

For LGP Version

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

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

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.

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75

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 the breakage. Exceptions are stratified materials where large slabs are lifted when working with more than one tooth.

As regards the 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.

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.

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 irregularities.

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

The cab has two doors which can be opened 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 in all climatic conditions.

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

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

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.

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

Do not jump off the machine.

Do not climb or 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.

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

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77

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

1850-M0201

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

1850-M0202

During machine operation the doors can be kept open turning them until pin (1) enters into the appropriate receptacle (3).

2 1

3

D180-2M187

To release window, press button (4) inside and pull the door using handle (2).

4

D180-2M188

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Lubricate the door hinges through the grease fittings indicated.

1850-2M0102

REAR WINDOW WARNING If replacement of glass 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.

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 impairing transparency.

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CAB LIGHTING The roof lamp (1) is positioned on the roof panel of the cab and can be set at three different positions: - side 2 pressed: light remains on; - side 3 pressed: light remains off; - central position (neutral) light off.

1

2

3

D180-2M190

12 VOLT SUPPLEMENTARY RECEPTACLE (On cab only) Supplementary power receptacle (1), located in the rear left part of the cab, can be used to power a refrigerator, if any, to be located in the compartment behind the seat or to power a portable phone.

Phone holder (2) to be used to store a portable phone, during battery charging phase as well.

2 1

1850-M0125

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CAB INSIDE HEATING AND VENTILATION The climatisation of the cab is provided by actuating the controls located under the top of the cab in front of the operator.

The rotation of knob (4) activates and regulates the speed of the fan.

The rotation of knob (5) provides the intake of air taken from outside or inside into the cab.

The rotation of knob (6) counter clockwise makes cold air flow out the vents, whereas when the knob is rotated clockwise, the air is warm.

3

4

5

6

D180-2M191

AIR CONDITIONER (OPTIONAL) Use knob (3) to operate the air conditioner.

Knob (4) regulates the fan speed.

Knob (6) regulates the air temperature.

3 4 5 6

-

Air conditioning control Fan speed control Air recirculation control Temperature control

Note - The air conditioner is inoperative when the engine is not running, since it is driven by the engine.

Before engine start assure the knob (3) of conditioner command in "OFF" posizion Prior to cutting-off the engine, always cut-off the air conditioner using knob (3).

Keep doors and windows closed to obtain a correct air conditioning of the cab.

It is recommended to avoid attempting repairs on the air conditioning system by unskilled personnel.

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Demisting and defrosting For a fast demisting or defrosting of the front, side and rear windows, proceed as follows: - actuate the fan at maximum speed using knob (1).

- actuate knob (2) until maximum temperature is reached.

Suitably adjust directional outlets in the cab, directing the hot air to the windows.

1

2 D180-2M192

D180-2M169

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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 (1) from glass; - loosen screws (2) and remove the blade.

1

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

1850-M0126

If the spray pattern of nozzles (3) 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 impairing transparency.

2 3

1850-M0127

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

Important – When the ambient temperature decreases to 0 °C (32 °F) and below, always use an antifreeze type washer solution.

1850-M0203

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83

MAINTENANCE MAINTENANCE SAFETY WARNINGS Do not let unauthorized personnel perform any maintenance operations. Carefully study this manual before starting, operating, maintaining, fuelling or servicing the machine.

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

Never perform lubrication, repair or adjustment 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 fluids to clean parts. Use only 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 can be forceful enough 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 who might be performing repairs or who might be near the machine before starting the engine.

Keep hands, limbs and face away from loose connections of pipes when performing efficiency or leakage tests of injectors or systems. Also, wear protective 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 the lock position.

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

84

1850K

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

Use this list to coordinate maintenance scheduled at the same intervals.

Before proceeding with any service operations, 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.

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

Lubrication is an essential part of preventive maintenance as it extends 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 the instructions regarding types of lubricant and the frequency of their application be followed. Periodic lubrication of moving parts reduces the probability of mechanical failures to a minimum.

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

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

1850K

85

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 make a walk around inspection at the completion of each day, to check: 1. Side final drive oil leakages 2. Ineffective or broken instruments 3. Engine oil/coolant leakages

4. Hydraulic system leaks and damaged hoses 5. Caked dirt on radiator grill 6. Blade wear or damage 7. Track rollers and idler wheel oil leakages 8. Track tensioner grease leakages 9. Caked dirt and mud on track frames 10.Loose track shoe bolts

3

2

4

5 7 10

6

1

9

8 1850-M0114

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

86

1850K

GENERAL MAINTENANCE AND LUBRICATION DIAGRAM

D180-2M207

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

LIST OF SCHEDULED MAINTENANCE When required

41

37

Every 3000 hours 30

31 20 22

18 12

26 13

Every 1000 hours 17

39

32

35

40

29

28

25 12

15

27

23

21

19

24

27

18

Every 250 hours

11 6

34

Every 500 hours

16

38 36

Every 2000 hours

33

21

87

8

5

9 2

Every 100 hours Every 10 hours

7 4

1

6

10

3

D180-2M209

EVERY 10 HOURS WORK (daily) 1. Engine oil: check oil level.

2. Torque/converter: check oillevel.

3. Fuel pre-filter: drain condensation.

4. Radiator: check coolant level.

EVERY 100 HOURS WORK

EVERY 500 HOURS WORK

EVERY 1000 HOURS WORK

EVERY 2000 HOURS WORK

5. Bevel gear, steering and brakes: check oil level.

6. Final drives: check oil level.

7. Fuel reservoir: drain condensation.

8. Equipment hydraulic system: check oil level.

9. Blade cylinder linkage pivots: grease pivots.

10. Ripper linkage pivots: grease pivots.

12-13. Engine: oil and filter change.

14.

Operation not enabled.

15. Fuel filter: replace filter.

16.

Steering and brakes circuit delivery oil filter: replace cartridge.

17. Torque/converter: change oil and delivery filter cartridge.

18.

Cab air filters: replace filters.

19.

Doors grease fittings: grease pivot.

20. Engine: replace crankcase ventilation filter.

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

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

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

24. Batteries: check electrolyte level.

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

26. Fan-alternator belt: check condition and sagging of belt, replace.

27. Track frame body suspensions: grease the swinging crossbar linkages.

28. Engine: replacing the fuel pre-filter.

29. Radiator: change coolant.

30. Final drives: change oil.

31. Equipment hydraulic circuit: change oil, clean magnetic rod and suction filter.

32. Clogged engine air cleaner: replace cartridges.

33. Blade cylinder support linkage pivots: grease pivots.

34. Fuel injectors: calibrate setting of injectors.

35. Braking system: braking system check.

EVERY 250 HOURS WORK 11. Undercarriage: check sag of track chains.

EVERY 3000 HOURS WORK 36. Valve clearance: check valve clearance, with cold engine.

AS REQUIRED Operations to be performed when relevant indicators come ON: 37. Equipment hydraulic system return oil filter: replace cartridge.

38. Engine air cleaner: clean cartridges.

39. Braking system: indicator light check.

Other operations to be performed according to necessity: 40. Cab air filters: clean filters.

41. Radiator cores: clean.

88

1850K

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

1850K

89

EVERY 10 HOURS WORK 1.

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 (1) that the oil level is between the two notches indicated. If necessary, top off the oil through filler neck (2), paying attention not to exceed the corresponding notch.

2

1 WARNING Do not operate the engine with oil below the lower notch (MIN).

1850-M0024

1. Engine oil dipstick 2. Engine oil filler neck

The correct oil level must be maintained between the two marks, MIN and MAX.

MAX MIN

1

1850-M0038

1. Engine oil dipstick

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

90 2.

1850K TORQUE CONVERTER / TRANSMISSION Check oil level

Open the upper left engine compartment panel.

With engine inoperative for 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.

1

1850-M0204

1. Plug with dipstick.

3.

FUEL PRE-FILTER - Draining condensation

Open the upper left engine compartment panel and drain the water and sediments from the fuel filter (2) through the draining valve (3) indicated.

Remove the connector (4).

With engine inoperative, loosen the valve located below the filter about 4 full turns and move it downward about 2 cm (3/4 in).

Make flow out from drain pipe (5) the possible water and sediment. Until do not go out combustible clean only.

Move the valve upward and tighten it, without over tightening.

2

3 4 1850-M0070

Note – The draining interval can be increased or decreased, depending on the presence of water and the quantity of fuel.

5

3 1850-M0171

Water draining valve on fuel filter Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1850K 4.

91

RADIATOR - Check coolant level

Open the upper panel of the engine compartment and check the engine coolant level through sight gauge (1).

The coolant level must not drop below this gauge.

1

1850-M0167

If required, top up with liquid through the filler neck (2), with engine inoperative for at least 1 hour, to release residual pressure from the system.

It is recommended to fill system with a 50/50 mix of ethylene glycole (antifreeze) and water for maximun protection against: - freezing down to -35 °C (-31 °F); - the formation of scale; - boiling during hot periods up to + 110 °C ( 230 °F); - the corrosion of metal materials.

2 D180-2M047

EVERY 100 HOURS WORK 5.

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 (3), 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.

3

1850-M0205

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

92 6.

1850K FINAL DRIVES - Check oil level

1

Check that the level reaches plug (1) as indicated (one level plug on each final drive); top off as required through the plug hole.

1850-M0166

1. Final drive oil filler and level plug.

7.

FUEL RESERVOIR - Draining condensation

For access to draining condensation valve of fuel reservoir remove lower cover of this and fixed screws.

Drain any water and sediment that has deposited on the bottom of the reservoir in the well indicated, from the rear side of the machine.

1850-2M0117

For this purpose, loosen the valve indicated in the bottom figure and let the liquid 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 the outdoor temperature is above 0 °C (32 °F), drain before starting the engine; at a temperature below 0 °C (32 °F), drain at the end of the work shift, since water, when freezing, would not drain.

1850-2M0118

Fuel draining valve

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

1850K 8.

93

Equipment HYDRAULIC SYSTEM Check oil level WARNING

1 B A

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.

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.

9.

1850-M0206

BLADE CYLINDER LINKAGE PIVOTS Grease pivots

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.

1850-M0050

10. 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-M0168

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

94

1850K

EVERY 250 HOURS WORK 11. UNDER CARRIAGE - Check sag of track chains In sealed and lubricated track chains, strong phenomena of internal wear do not occur if the track chain is adjusted in a timely fashion, whenever required.

When the track chain is too tight, it is subject to useless and dangerous stress. The wear speed increases and drawbar traction power is lost. When it is too slack, the links are hitting the undercarriage, increasing the wear of all parts involved.

Keep in mind that a normal adjustment is proper for dry, stony or rocky terrains, whereas it is necessary to further slacken the track chains in muddy, very wet and clayey conditions, or when sand, gravel, snow or ice are present.

L = 30 to 40 mm (1.2 to 1.6 in)

SM9353

Track chain sag

Tightening the track chain C

In the event the track chain has become slack, it is necessary to increase the tension. Prior to any operation, measure the sagging of the track chains in section (L) between the support roller and the idler. If sagging (L) exceeds 30 to 40 mm (1.2 to 1.6 in) (regular sagging) pump grease into fitting (I) of valve (VR) of the adjustment cylinder, until the correct tension is obtained.

V

Loosening the track chain When disassembly operations must be performed or the track chain is excessively tensioned, the tension must be loosened. Prior to slackening the track chain, check that the sag on section (L) is lower than 30 to 40 mm (1.2 to 1.6 in). If loosening is required, proceed as follows:

Vs

- Remove access cover (C) on the track tensioner frame, removing retaining screws (V).

Vr I

With a 24 mm (0.9 in) wrench, slightly loosen adjustment valve (VR) and back up the machine a few yards, if required. Retighten the valve and check sag (L).

1850-M0163

WARNING Fluid under pressure. Do not loosen track tension by loosening pressure relief valve (VS). Do not remove the grease fitting (I) mounted on adjusting valve (VR).

Adjusting the track chain C. I. V. VR. VS.

Cover Grease fitting Securing screws Adjustment valve Pressure relief valve

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

1850K

95

EVERY 500 HOURS WORK 12-13. ENGINE - Oil and filter change Place a container of adequate capacity (23 l - 6 USG) under the oil sump.

Open the lower panel (3) of the engine compartment and drain the oil through lower plug (2), while it is warm, loosening it with a 12 mm (0.47 in) Allen wrench. To facilitate the draining, remove plug (4).

Open the right panel, upper and lower engine compartment.

Replace the engine oil filter (1), 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 seatingfaceontheengineblock,tightenwithanother3/4turn.

1 1850-M0026

The filter must be replaced at the prescribed intervals.

2

Reinstall draining plug (2) and pour new oil through filler neck (4), to the maximum level marked on dipstick (5); Refill with oil of the prescribed type and grade (see "FLUID CAPACITIES CHART").

- operate the engine at low idle; - stop the engine and top up at maximum level, after a few minutes.

3 1850-M0054

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.

4

5 1850-M0027

MAX MIN

5

1850-M0052

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

96

1850K

Note – If the fuel used has a sulfur content exceeding 0,5%, the engine oil change must be performed as indicated by "FLUID CAPACITIES CHART".

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

Note – In case of a lower classification of CH4 engine oil, the change must be done every 250 hours.

Note – Improper disposal of oil is a menace for the environment. Seek information about the appropriate way to recyle or dispose of oil from local authorities or waste management centres, or from your Dealer.

ENGINE: 15. FUEL FILTER - Replace filter Open the left side panel of the engine compartment.

WARNING Never use gasoline, solvent or other flammable fluids to clean parts. Use only qualified, 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 of personal injuries caused 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 filter (9) indicated in the figure.

Clean the support area in contact with the filter gaskets with a dry rag.

Replace gaskets. Apply a film of engine oil on the filter gasket, and tighten them against the support.

Then turn another 1/2 turn.

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

9

1850-M0028

1850K

97

16. STEERING/BRAKES CIRCUIT DELIVERY OIL FILTER - Replace cartridge

1

Open front panel (1) to access the steering/brakes oil filter by loosening the two fixing screws and tilting it forward.

1850-M0143

Remove filter (2) from the filter support. Replace it with a new one and tighten it to a torque of 3.5 ÷ 4 daNm (26 ÷ 29.50 lbft).

Replace the steering/brakes circuit delivery filter at the same time you replace the transmission/torque converter filter.

2

1850-M0055

17. TORQUE CONVERTER / TRANSMISSION Change oil and delivery filter cartridge Oil draining Remove plug (3) from the bottom of the machine, with the transmission oil warm, and let it drain into a container with a 40 liter (10 USG) capacity, at least.

3

D180-2M201

To facilitate the draining, open the right panel under the cab and loosen plug (4) from the transmission oil filler neck.

4

D180-2M196

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

98

1850K

Replacing the transmission/torque converter delivery filter.

1

WARNING Never use gasoline, solvent or other flammable fluids to clean parts. Use non-flammable, nontoxic commercial solvents. When using compressed air for cleaning parts, use safety glasses with side shields or goggles so as to reduce the danger of personal injuries caused by flying particles. Limit pressure to 2 bar (29 p.s.i.), in accordance with local and national regulations.

Open the front panel (1) to access the transmission oil filter by loosening the two fixing screws and tilting it forward.

Clean the area surrounding the filter.

Remove filter (2) and replace it with a new one.

Re-install the filter tightening it to 3.5 to 4 daNm (26 ÷ 29.50 lbft) maximum.

Oil refilling Re-install plug after cleaning it. 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 system, checking the dipstick on the plug.

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.

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

1850-M0143

2

1850-M0057

1850K

99

18. CAB AIR FILTERS - Replace filters 2 To reach the cab ventilation air filter (1), open the panel under the cab, on the left side of the machine. Loosen the knob (2) and replace the filter (1).

Note – Before re-installing the filter, clean the inside of the container.

1

1850-M0071

To reach the re-circulation air filter (3), rotate in forward the back rest of operator seat cab.

Loosen the knobs (4) and replace the filter (3).

4

3

1850-M0162

19. DOORS GREASE FITTINGS - Grease pivot Lubricate the door hinges through the grease fittings indicated.

1850-M0164

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

100

1850K

EVERY 1000 HOURS WORK 20. ENGINE - Replace crankcase ventilation filter

2

1

Park the machine on a flat surface.

Open the lower panel of the engine compartment.

Remove the pipe (1) from the 90° union.

Loosen the fixing screws (3) of the engine cover (4) and remove it.

Turn over the cover and set it on a workbench. Loosen the nut (2) together with the washer. Clean the inside of the cover (4) with a dry cloth.

Extract the filter (5) from the flexible pipe (6) and replace it with a new filter.

Replace the filter (8) by removing the screws (7).

Replace all the rubber gaskets with new ones when reassembling.

3 4

1850-M0029

7

8

6 5

WARNING Never remove filters while engine is running.

WARNING

4

Replace all covers or guards after servicing or cleaning the machine. NEVER operate the machine with covers or guards removed.

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

1850-M0108

1850K

101

21. BEVEL GEAR STEERING AND BRAKES Change oil and wash suction filter Drain oil

1

Place a container of at least 50 liter (13 USG) capacity under the transmission housing.

Remove plug (1) and let the oil drain completely.

Retighten plug (1) after washing it.

1850-M0169

1. Steering and brakes oil draining plug.

Wash the suction filter and magnetic rod Tilt the cab, clean the base of the filter and the surrounding area, remove plug (2) and pull out the mesh filter and the magnetic rod.

Wash both of them with solvent. Clean inside the body.

Re-install the filter, magnetic rod and cover (3).

Check and top off the oil after changing it.

3 2 1850-M0061

Oil filling Pour in oil up to the prescribed level, indicated by the mark on dipstick (4).

Start the engine and let it run at about 1000 rpm.

Actuate the steering levers a few times.

Stop the engine and after a few minutes check that the oil level reaches the upper mark on the dipstick. Top up, as required, through the plug hole.

4

1850-M0207

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

102

1850K

The correct oil level must be between the two marks MIN and MAX. WARNING Do not run the engine in closed areas without proper ventilation to remove deadly exhaust fumes.

MIN

MAX

1850-2M0135

22. TORQUE CONVERTER TRANSMISSION CIRCUIT Wash suction filter and magnetic rod Tilt the cab, clean the base of the filter and the surrounding area, remove plug (1) and pull out the mesh filter and the magnetic rod.

Wash both of them with solvent. Clean inside the body.

Re-install the filter, magnetic rod and cover (2). Check and top up the oil after changing it (as described in operation 2).

1 2

1850-M0062

23. TORQUE CONVERTER TO TRANSMISSION DRIVE SHAFT - Grease (U joints) Tilt the cab.

Pump grease (three or four strokes) into the appropriate fitting to lubricate the spiders.

Drive shaft

Note – Perform the operation more frequently when the machine operates in extremely dusty conditions.

D350M0117

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

1850K

103

24. BATTERIES - Check electrolyte level WARNING Batteries contain SULFURIC ACID. Protect eyes when working on batteries. In the event acid comes into contact 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 (1) on rear panel (2) indicated.

- Rotate the panel.

- Check that the elecrolyte reaches the reference mark on the side of the batteries (3).

- To restore level, top off with distilled water.

- Do not overfill.

1

2 CAUTION While closing the rear panel (2), pay attention that the safety cable does not cause interference.

3

CAUTION 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 stops, it is preferable to idle the engine rather than shut 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.

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

1850-M0179

104

1850K

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 -).

25. 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 with a new one.

The belt must deflect 15 to 20 mm (19/32 to 25/32 in) under as force of 110 N (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.

1850-M0037

Acceptable condition Belt to be replaced

D350M0178

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

1850K

105

26. 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 combined with longitudinal cracks, fraying, breakage points on the belt are not acceptable. In such a case, replace it.

Replacing a belt To replace the belt, actuate tensioner (2) with a lever (1) and pull it out.

To reinstall a new belt, rest it on the alternator and crankshaft pulleys, lift the tensioner and complete the belt turn, as ilustrated in the figure.

1 2

1850-M0039

27. TRACK SUSPENSION Lubricate the swing cross-member Remove the nut indicated in the figure and pump grease into the two lubricating fittings of the swing cross-member (one each side).

1850-M0165

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

106

1850K

28. ENGINE - Replacing the fuel pre-filter WARNING Extinguish all smoking materials or free flames before checking or refuelling the fuel tank, replacing filters or removing the condensation plug, due to the presence of flammable fumes.

WARNING Never use gasoline, solvents or any other flammable fluids to clean parts. Use approved non-toxic and non-flammable commercial solvents only.

Wear safety glasses with side panels when using compressed air to clean components, so as to reduce the danger of personal injuries caused by flying particles.

Limit the pressure to 2 bar in accordance with current local or national regulations.

Clean the base of the support and the surrounding area.

Loosen the filter (1) as indicated in the figure.

Clean the support area where the filter gasket is with a dry rag.

Apply a film of engine oil to the filter gasket, then tighten the filter until it touches the support.

Then tighten a further ½ turn.

Bleeding the air The entry of air into the fuel system occurs during prolonged periods of inactivity of the machine, when the filters and pipes are removed or when running out of fuel.

The presence of air makes the starting difficult; thus the system must be bled. The bleeding must be performed with the tank full, proceeding as follows: - loosen bleeding screw (2) on the fuel pre-filter a few turns and actuate button (3) until fuel free form air bubbles flows through the bleeding screw.

- then retighten the bleeding screw.

3 2

1

1850-M0064

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

1850K

107

29. RADIATOR - Change coolant 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 a hot engine.

Open the upper panels (1) indicated.

Replace the coolant proceeding as follows: - with engine cold, drain the engine coolant opening the valve (2) at the bottom of the radiator (to facilitate the drain, remove the filler cap and add a flex hose on valve); - 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.

1

1850-M0065

2

Note – If the engine cooling system is filled with water instead of coolant (having anti-oxidant, anti-scaling, anticorrosion properties), flush the system as described below.

- 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.

It is recommended to fill system with a 50/50 mix of ethylene glycole (antifreeze) and water for maximun protection against freezing down to -35 °C (-31 °F).

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

1850-M0072

108

1850K

EVERY 2000 HOURS WORK 30. FINAL DRIVES - Change oil 1

Remove lower plug (2) (one for each final drive) and let all oil drain out. After retightening the plug, refill with new oil through filler plug (1).

Repeat the operation on both sides.

2 1850-M0170

31. EQUIPMENT HYDRAULIC CIRCUIT Change oil

3 4

Drain oil Position the machine on level ground so that the equipment is resting on the ground.

Remove filler plug (3) and unscrew bottom plug (6) to drain the oil from the reservoir.

Wash plug (6) with solvent.

5

WARNING Never use gasoline or other flammable fluids to clean parts. Use only qualified, non-flammable, non-toxic commercial solvents.

6

Oil refilling Re-install plug (6).

Loosen breather cap (3) and pour oil into the filler neck of the tank, up to maximum level (4). Then retighten cap (3).

WARNING After every maintenance intervention on the tank requiring the total draining of the oil, it is necessary, when refilling, to remove cap (3) to provide the bleeding of air trapped inside the tank.

Start the engine. Have the blade as well as the ripper move 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 the maximum level indicator. 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.

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

1850-M0208

1850K

109

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.

32. CLOGGED ENGINE AIR CLEANER Replace cartridges

1

2

Open the engine left side panel.

Remove the cover (2) from canister (1) loosening the nut (3).

Remove the primary filter (4) from canister loosening the nut (5).

Remove the secondary filter (6) from canister loosening the nut (7).

Replace the primary and secondary filters.

Before installing new elements, clean inside canister (1).

3

Check the dust valve (8). Make sure there is no obstruction inside the valve.

1850-M0032

Note – If there is a large amount of dust inside the end cover, check dust valve (8) for proper operation.

4 WARNING When using compressed air for cleaning parts, use safety glasses with side shields or goggles so as to reduce the danger of personal injuries caused by flying particles. Limit pressure to 2 bar (29 p.s.i.), in accordance with local and national regulations.

5

Important – Keep spare elements of the prescribed type, available from the Sales Organization, on hand to reduce machine down-time.

1850-M0067

Note – Perform the operation more frequently when the machine operates in extremely dusty conditions.

6

7 8 1850-M0068

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

110

1850K

33. BLADE CYLINDER LINKAGE PIVOTS Grease pivots Pump grease into the lube fittings of the blade cylinder support.

The fitting indicated by the arrow is also installed on the opposite side of the machine.

1850-M0069

34. FUEL INJECTORS Calibrate setting of injectors DANGER 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.

Have the injectors checked by a specialized service shop.

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

1850K

111

35. BRAKING SYSTEM - Braking system check 1

Service brake efficiency check Follow the procedure described below for checking the efficiency of the braking system: -

Put the machine on level ground.

Start the engine and heat it up for at least 5 minutes.

Keep the brake pedal pressed.

Lower safety levers.

Slightly lift the blade off the ground.

Put the gear lever in 1, drive.

Run the engine at the maximum rpm.

The machine must remain still or crawl slowly in this condition.

Run the engine at the minimum rpm.

Put the gear lever in 2, drive.

Run the engine at the maximum rpm.

The machine should be locked in this condition.

If not, contact an authorized dealer for an inspection of the braking system.

Brake accumulator check If the brake accumulator low pressure pilot light (1) turns on, contact an authorized dealer for an inspection of the braking system and the brake accumulator charge (2).

1 0

n /m in

2

x 1000

3

1850-M0073

2

D180-2M200

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

112

1850K

EVERY 3000 HOURS WORK 36. VALVE CLEARANCE Check valve clearance, with engine cold Adjust the clearance of the rocker arms with respect to the valve stems considering the firing order: 1-5-34-2-6.

The valve clearance with cold engine is: – intake valve 0.25 ± 0.05 mm – exhaust valve 0.50 ± 0.05 mm.

Note – This operation must be performed by specialised personnel.

Consult an authorised workshop.

WARNING For this engine type with internal EGR (Exhaust Gas Recirculation) a standard valve lash setting procedure will lead to wrong valve clearances and serious engine damage.

Each cylinder must be checked by putting engine to TDC (Top Dead Center) firing for that cylinder and setting both valve clearances on that cylinder only.

NO SHORT CUTS INVOLVING THE SETTING OF VALVES ON ONE CYLINDER WHILE THE ENGINE IS AT T.D.C. OF ANOTHER CYLINDER ARE ALLOWED!

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

1850K

113

AS REQUIRED Operations to be performed when relevant indicators come ON:

37. EQUIPMENT HYDRAULIC SYSTEM RETURN OIL FILTER - Replace cartridge

1

WARNING FLUID UNDER PRESSURE; prior to removing the cap, turn it slowly to relieve the pressure.

Operation to be performed when indicator light 1 on the instrument panel comes ON, indicating that the oil filter is clogged.

1

2 n/min

1

0

x 1000

3

1850-M0075

Proceed with the replacement of the filter as follows: - remove cover (2), remove return filter (3) and replace it; - install a new gasket (5); - install cover (2); - check that the oil level is between max. level upper sight gauge and min. level lower gauge. 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 (4).

2 5

3

4

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.

1850-M0076

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

114

1850K

38. ENGINE AIR CLEANER - Clean cartridges Operation to be performed whenever indicator light (7), located on the instrument panel, indicates that the air cleaner is clogged.

When the air cleaner indicator light come ON, clean primary filter (4), and follow the instructions below.

Open the engine left side panel.

Remove the cover (2) from canister (1) loosening the nut (3).

Remove the primary filter (4) from canister loosening the nut (5).

Clean the primary filter (4).

Install the primary filter (4) and the cover (2).

Before installing the primary filter, clean inside canister.

Check the dust valve (6). Make sure there is no obstruction inside the valve.

7

D180-2M145

1

2 3

Note – If there is a large amount of dust inside the end cover, check dust valve (6) for proper operation.

Start the engine and check if the air cleaner indicator light (7) is ON. If YES, replace the primary and secondary air filters as described in operation 32.

1850-M0032

Important – After cleaning primary filter (4) three times, replace it.

Replace the element when the relevant gasket is damaged as well.

4

5 6 1850-M0082

Cleaning the Element Check the dirty element for damage and check the rubber seal on the end. Push the rubber seal with your finger. If the rubber seal feels hard and does not move back to original shape, discard the element.

- Wear face protection and remove the loose dirt with compressed air at 30 psi (207 kPa, 2.1 bar) maximum. Hold the nozzle at least 1 inch (25 mm) from the element.

1850-M0078

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

1850K

115

- Mix two tablespoons of detergent with two gallons (7.6 liters) of water, one cup for 16 gallons (60 liters) water.

- Soak the element in the soap solution for 15 to 20 minutes and then move the element up and down rapidly to loosen as much dirt as possible.

1850-M0079

- Use a water hose without a nozzle with pressure less than 40 psi (275 kPa, 2.8 bar) to remove all soap from the element.

1850-M0080

- Allow the element to air dry.

- Use a light and inspect the element for holes or splits in the pleats. Check for damage to the metal parts and rubber gasket. Replace the element if damaged.

Note – If the element is not to be used for some time, cover the element with paper for storage.

WARNING When using compressed air for cleaning parts, use safety glasses with side shields or goggles so as to reduce the danger of personal injuries caused 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.

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

1850-M0081

116

1850K

39. BRAKING SYSTEM - Indicator light check 1

If the brake accumulator low pressure pilot light (1) turns on, contact an authorized dealer for an inspection of the braking system and the brake accumulator pre-charge.

1 0

n /m in

2

x 1000

3

1850-M0073

Other operations to be performed as needed 40. CAB AIR FILTERS - Clean Filters

2

To reach the cab ventilation air filter (3), open the panel under the cab, on the left side of the machine. Loosen the knob (2) and extract the filter (3). Inspect the filter.

If it is clogged, clean it as described here below: - gently tap the filter on a flat surface, with the drilled face downward; - blow with clean and dry compressed air. The air jet must move back and forth along the pleats of the elements, until all dirt is eliminated; - re-install the filter.

3

1850-M0071

WARNING Keep the air jet at some distance from the filter.

Note – Before re-installing the filter, clean the inside of the container.

To reach the re-circulation air filter (4), rotate in forward the back rest of operator seat cab.

Loosen the knobs (5) and remove the filter (4).

In the event the filter is torn, replace it. If the filter is clogged, clean it using a water and detergent and dry it with compressed air.

5

WARNING When using compressed air for cleaning parts, use safety glasses with side shields or goggles so as to reduce the danger of 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)

4

1850-M0162

1850K

117

41. RADIATOR CORES - Clean Clean the engine radiator (1), aftercooler radiator (2), transmission oil heat exchanger (4) and hydraulic oil heat exchanger (5) following these directions: - Open the front radiator access door.

- Point a jet of low-pressure compressed air in the direction shown by the arrows in the figure.

If necessary, use a stiff, non-metallic bristle brush.

Be careful to not damage the radiator fins.

- Cleaning the aftercooler radiator (2), the transmission oil heat exchanger (4) and the hydraulic oil heat exchanger (5).

- Cleaning the engine radiator (1) after removing the fixing screws (3) with consequent turning of the transmission oil heat exchanger (4) forward by means of the slots (6). In this way air can be blown on the engine radiator.

2

1

- Clean the air condenser (7) using a jet of lowpressure compressed air pointed in the direction shown by the arrows in the figure.

3

3

4 5

6

1850-M0172

WARNING Keep the jet of compressed air at a certain distance from the radiator cores.

WARNING

7

When using compressed air for cleaning parts, use safety glasses with side shields or goggles so as to reduce the danger of personal injuries caused by flying particles. Limit pressure to 2 bar (29 p.s.i.), in accordance with local and national regulations.

1850-M0085

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

118

1850K

ELECTRICAL SYSTEM FUSES The fuses are located inside the respective boxes A and B in the cab.

Depending on the type of machine set-up, the position of the fuse boxes may change. In particular, in the case of the CAB version, the boxes are installed vertically on the left side of the instrument panel, whereas the two boxes are inside the glove compartment, in a horizontal position, for the ROPS version.

Remove the snap-on lids on boxes A and B to get to the fuses.

A

B 1850-M0136

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.

Note – If a fuse blows out, replace it at once. Look for the cause of the trouble. If the trouble reoccurs, have the system checked by specialized personnel.

A B 1850-M0137

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

1850K

119

The circuits that the fuses protect for versions CAB and ROPS, respectively, are shown below.

FUSES FOR CAB VERSION FUSE BOX A FUSE

DESCRIPTION

FUSE BOX A VALUE

F1A

Tractor Relay Solenoid; Cab Relay Solenoid

F2A

Operator Safety Proximity Switch

5 Amp.

F3A

Starting Relay Solenoid

5 Amp.

F4A

Buzzer; Monitor

5 Amp.

F5A

Steering Safety Solenoid Valve; Microcontroller (PIN 53) Implement Supply Solenoid

3 Amp.

F6A

Horn

7.5 Amp.

F7A

Microcontroller (PIN 1, 2, 33, 46)

7.5 Amp.

F8A

Microcontroller (PIN 52); AUTO-SHIFT; AUTO KICK/DOWN; Joystick Transmission

F9A

Cab Lights; Lighter; 24/12 Volt Converter; Radio (optional)

F10A

Empty

F11A

Rear Flood Lights (Side Beam)

5 Amp.

5 Amp.

7.5 Amp.

7.5 Amp.

FUSE BOX B FUSE

FUSE BOX A SIMBOLS

DESCRIPTION

1850-M0138

FUSE BOX B VALUE

F1B

Flood Lights (Front Beam); Switch Lamps

7.5 Amp.

F2B

CR Climate Control

F3B

Right Door Windshield Motor Pump

7.5 Amp.

F4B

Left Door Windshield Motor Pump; Side Windshield Washer Motor Pump

7.5 Amp.

F5B

Rear Windshield Wiper Motor I Speed

7.5 Amp.

F6B

Front and Rear Windshield Motor Pump; Front Windshield Wiper Motor I Speed

7.5 Amp.

F7B

CR Climate Control; Compressor solenoid (optional)

20 Amp.

F8B

Empty

F9B

Empty

F10B

Optional (Pneumatic Operator Seat)

F11B

Steering Solenoid Valve Cut-Off Relays

20 Amp.

FUSE BOX B SIMBOLS

7.5 Amp. 3 Amp.

1850-M0139

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

120

1850K

FUSES FOR ROPS VERSION FUSE BOX A FUSE

DESCRIPTION

FUSE BOX A VALUE

F1A

Tractor Relay Solenoid; Cab Relay Solenoid

F2A

Operator Safety Proximity Switch

5 Amp.

F3A

Starting Relay Solenoid

5 Amp.

F4A

Buzzer; Monitor

5 Amp.

F5A

Steering Safety Solenoid Valve; Microcontroller (PIN 53) Implement Supply Solenoid

3 Amp.

F6A

Horn

7.5 Amp.

F7A

Microcontroller (PIN 1, 2, 33, 46)

7.5 Amp.

F8A

Microcontroller (PIN 52); AUTO-SHIFT; AUTO KICK/DOWN; Joystick Transmission

F9A

Cab Lights; Lighter; 24/12 Volt Converter; Radio (optional)

F10A

Empty

F11A

Rear Flood Lights (Side Beam)

5 Amp.

5 Amp.

7.5 Amp.

7.5 Amp.

FUSE BOX B FUSE

FUSE BOX A SIMBOLS

DESCRIPTION

1850-M0138

FUSE BOX B VALUE

F1B

Flood Lights (Front Beam); Switch Lamps

7.5 Amp.

F2B

Empty

-

F3B

Empty

-

F4B

Empty

-

F5B

Empty

-

F6B

Empty

-

F7B

Empty

-

F8B

Empty

-

F9B

Empty

F10B

Optional (Pneumatic Operator Seat)

F11B

Steering Solenoid Valve Cut-Off Relays

FUSE BOX B SIMBOLS

7.5 Amp. 3 Amp.

1850-M0140

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

1850K

121

RELAY BOX FUSES The circuits protected by the fuses inside the relays boxes (1) located on the left rear side of the machine are shown below.

To get to the relay box, remove the fixing screws from the left rear panel (2) and then tilt the panel.

2

1 1850-M0180

12 11 10 9

7 6

8

5 4 3

16 15 14 13

22 21 20 19 18 17 1.

2.

3.

4.

5.

6.

1850-M0181

Boxes relays Rear panel Fuse engine control (Pin 40) (4 Amp.) Fuse joystick Ripper (5 Amp.) Fuse joystick Blade (7.5 Amp.) Steering/implement priority control transducer fuse Blade rapid descent control solenoid valve (5 Amp.) 7. Fuse diagnostic valve (3 Amp.) 8. Relay, engine controller safety 9. Relay, starter safety 10. Relay, operator’s safety 11. Relay, starter safety 12. Relay, steering solenoid valve 13. Relay, steering solenoid valve 14. Relay, gearshifting safety 15. Relay, gearshifting safety 16. Relay, conditioner compressor control 17. Diode, brakes safety solenoid valve Diode, pilot valves safety solenoid valve 18. Diode, back-up alarm 19. Diode, seat compressor 20. Diode, proximity sensor de-coupling 21. Diode, proximity sensor de-coupling 22. Diode, transmission engagement safety

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

122

1850K

To get the relay box (1) remove the fixing screws from the left rear panel (2) and then tilt the panel.

1

2

1850-M0182

3 13

14

15

16

5 6 7 8 9 10 11 12 4 1850-M0183

1. Box relays 2. Rear panel 3. Relay, cold starting control (150 Amp) (Optional) 4. Fuse, cold starting (150 Amp) (Optional) 5. Fuse, starting (60 Amp) 6. Fuse, engine controller (30 Amp) 7. Fuse, machine services (40 Amp) 8. Empty 9. Fuse, cab services (30 Amp) 10. Empty 11. Fuse, condenser (20 Amp) (Optional) 12. Empty 13. Relay, starting 14. Relay, machine services 15. Relay, cab services 16. Relay, condenser (Optional)

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

1850K

123

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 80 Amp. Fuse 2 protects the alternator 80 Amp.

2

1

1850-M0034

MASTER SWITCH-DIAGNOSTIC Open the left side door on the machine to access the grid (3).

1850-M0209

Note - By means of the diagnostic request switch (7) we can check engine control unit operating status and verify the presence of any active error codes. Refer to the engine Service Manual 1850K Tier3 section 1 for button (7) operating procedure.

4

5

6 7 8 3 D180-2M205

4. Diagnostic engine 5. Diagnostic joystick 6. Diagnostic lamp 7. Diagnostic request switch 8. Electrical master switch

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

F1A - 5A

F10B - 7.5A

F4A - 5A

F2A - 5A

F3A - 5A

F11B - 3A

F5A - 3A

FUS. 4A

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

CAB RELAY SOLENOID

TRACTOR RELAY SOLENOID

OPTIONAL - SEAT COMPRESSOR

MONITOR

BUZZER

STEERING S.V. CUR-OFF RELAYS

MICROCONTROLLER (PIN 53) IMPLEMENT SUPPLY SOLENOID

STEERING SAFETY SOLEN. VALVE

CONTROL UNIT (PIN 40)

OPERATOR SAFETY PROXIMITY SW

STARTING RELAY SOLENOID

KEY SWITCH

FUSE 80A

F7B - 20A

F9A - 7.5A

F6A - 7.5A

FUSE 30A

MOTOR DIAGNOSTIC (connector)

GRID HEATER

ALTERNATOR

COMPRESSOR SOLENOID-OPTIONAL

CR CLIMATE CONTROL

RADIO - OPTIONAL

POT. DIVIDER

LIGHTER

CAB LIGHTS

HORN

STARTER MOTOR CONTROL

CAB RELAY

TRACTOR RELAY

ENGINE CONTROL UNIT

FUSE 3A

FUSE 150A

FUSE 80A

F6B - 7.5A

F5B - 7.5A

F4B - 7.5A

F3B - 7.5A

F2B - 20A

FUSE 5A

F1B - 7.5A

F11A - 7.5A

F1B - 7.5A

F8A - 5A

F7A - 7.5A

FUSE 7.5A

FUSE 5A

ELECTRICAL DIAGRAM OF PROTECTION TREE

FRONT WINDSHIELD WIPER MOTOR I SPEED

FRONT AND REAR WINDSHIELD MOTOR PUMP

REAR WINDSHIELD WIPER MOTOR I SPEED

SIDE WINDSHIELD WASHER MOTOR PUMP

L-H DOOR WINDSHIELD MOTOR PUMP

R-H DOOR WINDSHIELD MOTOR PUMP

CR CLIMATE CONTROL

BLADE RAPID DESCENT CONTROL SOLENOID VALVE

STEERING/IMPLEMENT PRIORITY CONTROL TRANSDUCER FUSE

SWITCHES LAMPS

FLOOD LIGHTS (FRONT BEAM)

REAR FLOOD LIGHTS (SIDE BEAM)

FLOOD LIGHTS (FRONT BEAM)

MICROCONTROLLER (PIN 52) AUTO SHIFT - AUTO KICK/DOWN JOYSTICK TRANSMISSION

MICROCONTROLLER (PIN 1,2,33,46)

FUSE JOYSTICK BLADE

FUSE JOYSTICK RIPPER

STARTER MOTOR

1850-3R061

124 1850K

- 25 /20 °C (- 13 / 77 °F)

SAE 10W - 30

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

Notes: - Oil quantities indicated are those required for periodical changes.

- In case of a lower classification of CH4 engine oil, the change must be done every 250 hours.

- The change interval must be reduced when present sulfur in the fuel exceed to 0,5% or the ambient temperature exceed to 38 °C.

All season

All season

All season

All season

- 20 / 50 °C ( - 4 - 122 °F)

All season

ATF Type A Suffix A

–

API CH4 ACEA E5

API GL5 or MIL-L-2105 D

ISO VG-46 DIN 51524 PART 2 HVI

API CH4 ACEA E5

CNH MAT 3505 MS 1209

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% sulfur 0.5 to 1% up to 1%

If the content of sulfur of the fuel exceeds 0.5%, change the engine oil as follows:

SAE 10W

CNH MS 1209, Hy-Tran® Ultra

Cab tilting pump

0.5 (0.1)

Grade 251 H - EP, Spec B-27

CASE Molydisulfide Grease

Grease fittings

SAE 80W - 90

Grade NT

SAE 10W - 30

All season

- 15 / 40 °C ( -5 / 104 °F)

SAE 15W - 40

SAE 10W

–

Down to - 35 °C (-31 °F)

Outdoor temperatures of reference

–

–

VISCOSITY GRADE

SAE 10W - 30

AKCELA GEAR 135 HEP

AKCELA Hydraulic Excavator Fluid - MS 1230

AKCELA NO. 1 Engine Oil

AKCELA Hy-Tran® Ultra

AKCELA NO. 1 Engine Oil*

–

Premium Anti-Freeze MS 1710

Fluids and lubricants AKCELA

CASE NO. 1 Engine Oil

7 (1.8)

Idlers Rollers and track chains

70 (18.5)

Rear Transmission housing Planetary steering / brakes

33 (8.7)

48 (12.6)

Torque converter/Transmission (Front Transmission Housing)

Final drives (each)

19 (5)

Engine

116 (30.6) 121 (32)

400 (105.7)

Fuel reservoir

Equipment Hydraulic Reservoir 1850K POWER STEERING 1850K with RIPPER

25 (6.6)

QUANTITY (liters) USG

Cooling system

ITEM

1850K - Table of fluids used

1850K 125

126

1850K

NOTES

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