Case 650K 750K 850K Series 2 Crawler Operator's Manual 6-85641 - PDF DOWNLOAD

650K, 750K, 850K SERIES 2 CRAWLER

OPERATOR’S MANUAL 6-85641 NA Issued 12-2005

OPERATORS MANUAL CRAWLER DOZER

650K, 750K, 850K SERIES 2

Bur • Issued 12-2005 Printed in U.S.A. • Book/Form Number 6-85641 NA Copyright © 2005. CNH America, LLC. All Rights Reserved.

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

All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

REVISION HISTORY

Issue

Issue Date

Applicable Machines

Remarks

First Edition

12-2004

650K, 750K, 850K SERIES 2

6-85640

Revision 1

12-2005

650K, 750K, 850K SERIES 2

6-85641

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

TABLE OF CONTENTS CHAPTER 1 GENERAL INFORMATION TO THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 MACHINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 CHAPTER 2 SAFETY AND DECALS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BEFORE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERSONAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UTILITY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIRE EXTINGUISHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BURN PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HAZARDOUS CHEMICALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIRE OR EXPLOSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DUCTILE IRON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1 2-3 2-3 2-4 2-4 2-5 2-6 2-6 2-6 2-6 2-7 2-8 2-8 2-9

CHAPTER 3 INSTRUMENTS AND CONTROLS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 BRAKE, DECELERATOR AND FOOTREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 PARKING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 DIRECTION CONTROL LEVER,TRANSMISSION CONTROL, HAND THROTTLE . . . . . . . . . . . . . . . . 3-10 DOZER BLADE CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 CONTROL HANDLE POSITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 RIPPER CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 OPERATORS SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 OPERATORS SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 CHAPTER 4 OPERATING INSTRUCTIONS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 RUN-IN PERIOD OF A NEW MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 CRAWLER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 MOVING A DISABLED CRAWLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 OPERATING IN HOT WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 OPERATING IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 BOOSTER BATTERY CONNECTION TO MACHINE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 TILTING THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 DOZER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 TRACK SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 FACTORS CONTROLLING UNDERCARRIAGE WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

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CHAPTER 5 LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 GENERAL SAFETY BEFORE YOU SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 SYSTEMGARD LUBRICATION ANALYSIS PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 PLASTIC AND RESIN PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 ENGINE HOURMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 LUBRICATION AND MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 GREASE FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 ACCESS DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 AIR FILTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 FINAL DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 CHAPTER 6 MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 REVERSIBLE FAN POSITIONS (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 ROLL-OVER PROTECTIVE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 MACHINE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 ADJUSTING THE RIPPER SHANKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 DOZER BLADE PITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 FAN AND AIR CONDITIONING DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 CHAPTER 7 ELECTRICAL TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESSORY OUTLETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1 7-3 7-5 7-7 7-8

CHAPTER 8 SPECIFICATIONS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRAVEL SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRACK SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1 8-3 8-3 8-3 8-4 8-5 8-6 8-8 8-8

CHAPTER 9 INDEX

II

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CHAPTER 1 - GENERAL INFORMATION

Chapter 1 GENERAL INFORMATION TO THE OWNER

Figure 1

BD04N031

K SERIES 2 CRAWLER

This manual contains important information about the safe operation, adjustment and maintenance of your 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 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 approved service parts. Your dealer has technicians with special training that know the best methods of repair and maintenance for your Crawler.

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CHAPTER 1 - GENERAL INFORMATION

RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE 1

A25808

Figure 2

OPERATOR’S MANUAL POUCH ATTACHED TO SEAT BACK

4

3

2 Figure 3

B830800J

1. FRONT 2. REAR

3. RIGHT-HAND SIDE 4. LEFT-HAND SIDE BASIC MACHINE, DOZER AND RIPPER

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

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CHAPTER 1 - GENERAL INFORMATION

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

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

Machine ➤ Machine Model and Type

➤ Product Identification Number: P.I.N.

➤ Year of Build

Component Serial Numbers ➤

Figure 5

BD02J092

Engine serial number

CAB PLATE IS LOCATED ON THE RIGHT-HAND SIDE REAR POST

➤ Transmission and serial number

ENGINE

➤

ENGINE PLATE IS LOCATED ON THE LEFT REAR SIDE OF THE ENGINE (4 AND 6 CYLINDER)

ROPS cab or canopy serial number

➤ Dozer blade serial number

➤

Figure 4

BD04N009

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

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CHAPTER 1 - GENERAL INFORMATION

1 Figure 6

BD02H141

TRANSMISSION

1

Figure 7

BD02J108

1. ON THE HOUSING UNDER THE CAB

Figure 8

BD99J147

DOZER BLADE

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CHAPTER 1 - GENERAL INFORMATION

MACHINE COMPONENTS

1

11

10

2

8 9 3

5 4

7

6 Figure 9

BD04N003

1. ROPS 2. LEFT-HAND REAR ACCESS DOOR 3. SPROCKET 4. TRACK

5.

6.

7.

8.

CARRIER ROLLER TRACK ROLLER IDLER LEFT-HAND ENGINE ACCESS DOOR

9. BLADE 10. RADIATOR DOOR 11. HAND RAILS & HANDLES

4 3 5 1

2

Figure 10

BD04N033

1. RIGHT-HAND ACCESS DOOR 2. STEPS 3. HAND RAILS

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4. BLADE PITCH ADJUSTMENT 5. RIGHT-HAND ENGINE ACCESS DOOR

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CHAPTER 1 - GENERAL INFORMATION

1

2

Figure 11

BD02J032

RIPPER 1. RIPPER SHANK

Figure 12

BD02M132

DRAWBAR

1-6

2. TOOTH

Figure 13

BD02M171

HITCH

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CHAPTER 2 - SAFETY AND DECALS

Chapter 2 SAFETY AND DECALS TABLE OF CONTENTS SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 BEFORE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 PERSONAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 UTILITY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 FIRE EXTINGUISHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 BURN PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 HAZARDOUS CHEMICALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 FIRE OR EXPLOSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 DUCTILE IRON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

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SAFETY RULES • Different jobs will require different protective

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

M171C

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

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

Do not remove this manual or the safety manual from the machine. See your dealer for additional manuals.

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

equipment. Items such as hard hats, protective shoes, heavy gloves, reflector type vests, respirators, and ear protection can be required.

Know and use the equipment that is required before you start the job.

• Be prepared for emergencies. Always have a first aid kit and a fire extinguisher with you. Be sure that the fire extinguisher is properly maintained.

Be familiar with the correct use.

• Know the signals used on your job. Follow the instructions of the flagman, signs, etc.

• Check that all doors, guards, and covers are installed correctly and closed.

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

• Before you start each day, walk around the machine and check for oil or fluid leaks. Replace all broken or missing parts and do the required lubrication and maintenance as shown in this manual. Clean all trash and debris from the machine.

BD02J018

Figure 2

BD02J019

Figure 3

Figure 1

A25808

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

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

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

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

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

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CHAPTER 2 - SAFETY AND DECALS

• Remove all loose objects from the operators area and from the machine. Loose objects can jam controls and cause accidents.

• Before you start the engine, always fasten the seat belt, sound the horn and make sure all personnel are clear of the machine safety area.

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

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

PERSONAL SAFETY If Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows:

• The first panel indicates the nature of the hazard.

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

• Background color is YELLOW. Prohibition symbols such as used, are RED.

and

STOP

if

UTILITY SAFETY Safety precaution MUST be followed when working near buried Utility Lines.

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

• • • •

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

Before beginning any trenching, or other construction work it is your responsibility to be aware of all such utility lines buried in the area of your project and to avoid them.

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

In U.S.A. and Canada call one of many One Call System Director services. If you do not know the local number, call the national number (U.S.A. and Canada only): 1-888-258-0808.

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

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

• Do not permit other persons to ride on the machine. Other persons can fall or can cause an accident.

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

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

• Before you drive or operate in an area with high lines or cables, tell the power or utility company what you are going to do. You MUST HAVE THE POWER DISCONNECTED OR KEEP A SAFE WORKING DISTANCE from the lines or cables.

You must know the safe working distance from the high voltage power equipment and must know any federal, state/provincial or local safety codes or regulations that apply to the job site.

Figure 4

RH99G001

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION

Know the utility color code (U.S.A. and Canada): Electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Gas, Oil, or Petroleum . . . . . . . . . . . . . . . . . . . Yellow Communication, Telephone, Television . . . . . Orange Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue Sewer. . . . . . . . . . . . . . . . . . . . . . . . . . Green/Brown Proposed Excavation. . . . . . . . . . . . . . . . . . . . White Surveying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pink Reclaimed Water and Slurry . . . . . . . . . . . . . . Purple After locating the utility lines, carefully dig a hole by hand and/or automatic vacuum equipment to the utility line to verify the location and depth of the line.

• When the machine is in reverse an alarm will sound.

• Electrical cables, gas pipes, water pipes, sewers, or other underground objects can cause injury or death. Learn the location of underground hazards before you operate your machine in a new area.

•

If this machine rolls over you can be injured or killed. You must make a judgment if weather, road, or earth conditions will permit safe operation on a hill, ramp, or rough ground. Always fasten the seat belt.

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

•

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

• Operate the machine controls from the operators seat only. Always fasten the seat belt.

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PARKING THE MACHINE 1. When the work day is finished, make sure the machine is parked on level ground.

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

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

3. Shift the direction controls to NEUTRAL.

FIRE EXTINGUISHER It is recommended that the fire extinguisher be maintained on the crawler when it is in operation to aid in event of a fire. See your dealer for further information.

!

WARNING: It is good practice to carry a fire extinguisher on the machine. Be sure that the extinguisher is properly maintained and be familiar with its proper use.

M103B

4. Pull both parking brake levers back into the applied position.

5. Run the engine for a few minutes with no load.

This decreases the temperature of the engine parts evenly.

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

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

8. Always face the machine and use the hand rails when leaving the machine. Do not rush and do not jump from the machine.

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

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

Figure 5

72L95

BURN PREVENTION • Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote - EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call a doctor immediately. EYES: Flush with water for 15 minutes and get prompt medical attention.

• When the battery electrolyte is frozen, the battery can explode if, (1) you try to charge the battery, or (2) you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.

• Hot coolant can spray out if the radiator cap is removed. To remove the radiator cap, let the cooling system cool, turn the radiator cap to the first notch, wait until the pressure is released, then remove the radiator cap.

HAZARDOUS CHEMICALS • If you are exposed to or come in contact with hazardous chemicals you can be seriously injured. The fluids, lubricants, paints, adhesives, coolants, etc., used with your machine can be hazardous.

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• Material Safety Data Sheets (MSDS) provide

• A fire can cause injury or death. Always have a fire

information about the chemical substances within a product, safe handling procedures, first aid measures and procedures to be taken when the product is accidentally spilled or released. MSDS are available from your dealer.

extinguisher near or on the machine. Make sure the fire extinguisher is serviced according to the manufacturers instructions.

• If a fire extinguisher has been used, always recharge or replace the fire extinguisher before operating the machine.

• Before you service the machine, check the MSDS for each fluid, lubricant, etc., used in your machine. This information indicates what the risks are and how to service the machine safely. Follow this information when servicing the machine.

• Remove all trash or debris from the machine each

• Before you service this machine and before you

If the machine has an oil, fuel, or hydraulic leak, always repair the leak and clean the area before operating.

day. Especially check the engine area and exhaust system.

•

dispose of the old fluids and lubricants, always remember the environment. DO NOT put oil or fluids into the ground or into containers that can leak.

• Keep the cooling system clean and maintain the

• Check with your local environmental or recycling

• Make sure that you do not store oily rags or other

center or your dealer for correct disposal information.

• Fluids such as Gasoline, Kerosene, Diesel Fuel, Hydraulic Oil, etc. contain chemicals that can be dangerous to your health and can cause cancer and/or birth defects. Contact either internally or externally can cause infection or other injury. If any internal or external contact occurs, see your local Poison Control Center or doctor IMMEDIATELY.

FIRE OR EXPLOSION PREVENTION • Sparks or flame can cause the hydrogen gas in a

correct coolant level. flammable materials on the machine.

• If you weld, grind, or use a cutting torch on this machine.

1. Disconnect or isolate the drive train controller.

2. Keep the ground cable from the welder as near the work area as possible.

3. Before welding or using a torch on the machine, clean the area to be repaired.

• Check the electrical system for loose connections or frayed insulation. Repair or replace the loose or damaged parts.

battery to explode. To prevent an explosion, do the following: 1. Connect the negative (-) cable last.

2. When connecting jumper cables to start the engine, use the procedure shown in this manual on. See Booster Battery Connection in this manual.

3. Do not short circuit the battery posts with metal items.

4. Do not weld, grind, or smoke near a battery.

• Sparks from the electrical system or engine exhaust can cause an explosion and fire. Before you operate this machine in an area with flammable dust or vapors, use good ventilation to remove the flammable dust or vapors before you start.

•

Engine fuel can cause an explosion or fire. Do not fill the fuel tank with the engine running, if you are near an open fire, or if you are welding, smoking, etc.

• Use nonflammable cleaning solvent to clean parts.

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MAINTENANCE • Before you service the machine, put a Do Not Operate tag on the instrument panel.

• Improper service or repair can cause injury or death. If you do not understand a service or adjustment procedure, see the service manual for this machine or see your dealer.

• Know and understand how to release hydraulic pressure before servicing the crawler.

• Unauthorized modifications to this machine can cause injury or death. Do not make unauthorized modifications to this machine.

• If you must service this machine with the engine running, have another person help you. Follow the instructions in this manual or the service manual.

Do not leave the operators seat with the engine running.

• Metal chips or debris can cause eye injury. Always wear eye or face protection when you use a hammer on this machine. Use a hammer with a soft face, such as brass, to drive hardened pins.

• Hydraulic fluid or grease injected into your skin can cause severe injury or death. Keep your hands and body away from any pressurized leak.

If fluid is injected into your skin, see a doctor immediately and have the fluid removed.

• When you service this machine, always wear face or eye protection, safety shoes, and other protective items as required.

DUCTILE IRON • Before you weld, cut or drill holes in a part on this machine, make sure the part is not cast ductile iron. See your dealer if you do not know if a part is cast ductile iron.

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SAFETY DECALS WARNING: Injury or death can result if you cannot read a safety decal or if a safety decal is missing. Replace any missing or damaged safety decal and keep all safety decals clean.

See your dealer for new safety decals.

1

SC002

Make sure that you read all the safety decals and all instructional decals. Check these decals every day before you start. Clean these decals if you cannot read the words.

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

You must replace a decal if the decal is damaged, missing, or cannot be read. If a decal is on a part that is replaced, make sure the decal is on the new part.

See your dealer for new decals.

383973A1

2

2

1

Figure 8

Figure 6

BD02J074

1. 383973A1 2. 321-7040 (2)

1

321-7040

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3

5

3

329044A1 / BD02M133

5

Figure 10

3. 329044A1

4

383972A1

Figure 11

4. 383972A1 (2) ONE EACH SIDE

5

These decals are located on the left and right side of the ROPS facing away from the operator and warns that no modification may be made.

Figure 12

332512A1 / BD99M009

5. 332512A1 (2) ONE EACH SIDE

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6 6

7

7

Figure 13

321-7030

6. 382622A1 7. 321-7030

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8

8

383971A1

Figure 14

8. 383971A1

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Chapter 3 INSTRUMENTS AND CONTROLS TABLE OF CONTENTS INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 BRAKE, DECELERATOR AND FOOTREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 PARKING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 DIRECTION CONTROL LEVER, TRANSMISSION CONTROL, HAND THROTTLE . . . . . . . . . . . . . . . . . . . . 3-10 DOZER BLADE CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 CONTROL HANDLE POSITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 RIPPER CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 OPERATORS SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 SEAT CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 OPERATORS SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 To Fasten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 To Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

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INSTRUMENT PANEL

A

1

2

3

4

5 Figure 1

BD04N010

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

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

NOTE: See Operating Instructions in this Manual for programming.

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

BS98M034

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

Figure 2

BC00G075

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

0097

0099

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Figure 5

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

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

Figure 3

BS98M034

Figure 4

Figure 6

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

7

6

8

10

9

Figure 7

BD04N010

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

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

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

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

Figure 8

BC00G12

7. LEFT-HAND AND RIGHT-HAND DOOR WINDSHIELD WASHERS (IF EQUIPPED) Push the rocker switch icon to activate the left and right door windshield washers. Release the rocker switch to stop the left and right door windshield washer.

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

10. HORN Push the switch to activate the horn.

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

Figure 9

BC00B132

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

Figure 11

BS02M143 / BS02M144

Figure 12

BS98M064

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

BS02M141 / BS02M142

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CHAPTER 3 - INSTRUMENTS AND CONTROLS 11. KEY SWITCH The key switch has four positions: ACCESSORY POSITION This position energizes the drivetrain controller, accessory switches and instrument cluster.

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

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

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

11

Figure 13

BS98M031/RB99J175/RB99J178/RB99J176

BD04N012/ 87412595

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Figure 14

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

13

14

15

16

17

18

12 B

Figure 15

BC02J064

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

BS99J182

Figure 16

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

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

BS98M032

Figure 17

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

Figure 20

BS99J181

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

BS99J182

Figure 19

BS96H049

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

Figure 18

Figure 21

BS99J182

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

Figure 22

BS99J183

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19 D

20

21 E

C

E e 22 E e 23

Figure 23

BC02J064

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

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

22. GRID HEATER LAMP Turn the key switch to on. When the incoming engine air needs to be preheated, due to cold temperatures, the lamp will illuminate. Wait until the indicator lamp goes off before turning the key switch to the start position.

BS99J185

Figure 27

Figure 24

BS96H053

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

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

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

NOTE: Contact your dealer if this lamp illuminates.

Figure 25

TRAN_FLT

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

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

BS99J185

Figure 28

Figure 26

BS98M048

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

25 24

Figure 29

BD99K104

24. DIGITAL DISPLAY This display is used to monitor engine and transmission control information. The Direction Control Lever position, (FNR) will be displayed on the left side of the display. Machine hours or operating RPMs will be displayed on the right side of the display.

Ser vice messages and infor mation will be displayed across the center por tion of the display.

25. TRANSMISSION SPEED GAUGE This gauge shows the transmission speed selected by the operator. The maximum speed is selectable in a range of 10 increments.The r a n g e i s c o n t r o l l e d by t h e Tr a n s m i s s i o n UP/DOWN buttons on the Direction Control Lever.

Figure 31

BD02M165

TRANSMISSION CONTROL BUTTONS

A

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

B

Figure 32

BD02M166

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

BD04N011

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Figure 30

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

BRAKE, DECELERATOR AND FOOTREST

PARKING BRAKES

2 1

4

3

3 Figure 34

BD02H120

Figure 33

BD99J224

1. BRAKE PEDAL

4. PARKING BRAKE LEVERS (ONE EACH SIDE)

Push this pedal to slow or stop the machine.

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

2. DECELERATOR PEDAL Push this pedal down to reduce the machine speed. This command can reduce the speed all the way to zero by destroking the drive pumps along with decreasing engine RPM. NOTE: A good way to control the dozer for precision work is to use the decelerator like the brake pedal on a car with an automatic transmission.

Figure 35

BD02H121

PARKING BRAKE ENGAGED

3. LEFT AND RIGHT FOOTREST

BD02H122

Figure 36

PARKING BRAKE DISENGAGED (WORK POSITION)

Both parking brake levers need to be down for the machine to operate. These brakes are spring applied hydraulic released (SAHR).

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

DIRECTION CONTROL LEVER,TRANSMISSION CONTROL, HAND THROTTLE 1 4

2

3

Figure 37

BD02K029

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

2

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

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

Figure 38

BD02J061

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

2. TRANSMISSION SPEED UP/DOWN BUTTONS

A

A. UP BUTTON (transmission speed increase) B. DOWN BUTTON decrease)

B BD02M166

Figure 39

(transmission

speed

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

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS 3. ENGINE HAND THROTTLE Pull the throttle lever BACK to increase the engine speed. Push the throttle lever FORWARD to decrease the engine speed.

3

3

4. REVERSE TO CONTROL

FORWARD

SPEED

RATIO

This control knob allows the operator to control the reverse speed in relation to the forward speed. Rotate the knob clockwise to increase the speed of reverse faster than forward. The knob will stay in the desired position.

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

Figure 40

BD02H134 / 8371L92

4

Figure 41

87403197

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

DOZER BLADE CONTROL LEVER 1. THE DOZER BLADE CONTROL LEVER

1

Figure 45

BD02J038

A BS99J212

B

Figure 42

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

BS99J213

C

Figure 43

B. LOWER:

Figure 46

BD02J038

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

W h e n r e l e a s e d , t h e c o n t r o l leve r w i ll r e t u r n automatically to the HOLD position.You must manually move the control lever from the FLOAT position to the HOLD position.

D BS99J214

Figure 44

D. LIFT:

Figure 47

BD02J038

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

Figure 48

BS99J21

E. TILT LEFT

Figure 49

BS99J218

E

F. TILT RIGHT

F

C

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

Figure 50

BS99J217

G. ANGLE LEFT

Figure 52

BD02J038

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

H G Figure 51

BS99J219

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

BD02J038

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Figure 53

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

CONTROL HANDLE POSITIONS

RIPPER CONTROL LEVER

1

1

3 2 BD02J038

Figure 54

1. Jam Nut The position of the control handle can be adjusted to a suitable operator’s position. Loosen jam (1) nut on the control lever. Adjust the handle to a suitable position. Tighten jam nut on the control lever.

Figure 55

BD02J038

1. LOWER:

The position of the handle may be adjusted Up, Down, or Angled Side to Side for operator comfort.

Figure 56

BS99J221

2. RAISE:

Figure 57

BS99J222

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATORS SEAT A vinyl mechanical suspension or vinyl air suspension seat may be ordered on a K Series 2 crawler ROPS machine. Cab machines come standard with cloth air suspension seats.

SEAT CONTROLS

1

2

Figure 60

BD02120

Figure 58

BD02H137

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

3

A

1

BD02K005

Figure 61

3. OPERATOR COMFORT CONTROL

Figure 59

BD02K003

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

2. FORWARD/REARWARD LEVER

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

ADJUSTMENT

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

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

BD02K006

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Figure 62

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

CAB

1

A

Figure 63

BD99J182

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

Figure 66

BD02K015

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

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

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

2

4 Figure 67

BD02K014

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

Figure 64

BD02H139

3

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

Figure 68

BD02K013

4

3. INTERIOR CAB DOOR RELEASE The cab door may be released from the locked open position by pushing the knob back and away from the operator.

BD02N037

3-16

Figure 65

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4

8

Figure 69

BD02M064

4. COAT HANGER

6 5

8 Figure 72

BD02H110 / BD02H112

8. RETRACTABLE SUN VISOR, FRONT Figure 70

BD02H131

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

6. CAB VENT One of six louvered vents for operator comfort.

9

7 BD02H113

Figure 73

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

B

C A Figure 71

BD02H108

7. ADJUSTABLE SPOT OR DOME LIGHT By using the switch (A) the operator may select the adjustable spot light (B) or the Full dome light (C).

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

10

Figure 74

BD02M134

10. RETRACTABLE EQUIPPED)

SUN

VISOR,

REAR

(IF

11

Figure 75

BD02M135

11. RETRACT CORD FOR REAR SUN VISOR (IF EQUIPPED) Pull the cord down and fold the sun visor back up carefully.

12

BD02H111

Figure 76

12. ADJUSTABLE REAR VIEW MIRROR

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13

13 14 15

Figure 77

BD021H130

13. OPERATOR COMFORT VENTS 14. 12V AUX POWER SUPPLY (2) 15. LEFT REAR SPEAKER (One each side)

17

BD02H109

Figure 79

17. SLIDING WINDOW ADJUSTMENT AND LOCK (IF EQUIPPED) Figure 78

BD02H129

16. STORAGE AREA AND TIE DOWN STRAPS (IF EQUIPPED

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Press the lock in to adjust the window up and down. Release the lock and the window will stay in this position. Make sure the window is locked into the slot before moving.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

2 1 BD02F002

Figure 80

1. CAB TILT HYDRAULIC JACK: Figure 82

BD02F033

This jack is used to tilt the cab off for service access. The handle for the jack is located under the access door on the left-hand side. (Fig. 81)

2. MASTER DISCONNECT SWITCH: This switch allows the operator or ser vice technican to stop all power from the battery.

0 =OFF, 1 = ON.

1

O

BD02F028

Figure 81

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

Figure 83

379422A2

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

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

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

SA080

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

Figure 86

BD02M168

RELEASE BAR

Figure 84

BD02M167

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

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

Figure 85

BD99J184

RELEASE BUTTON

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NOTES

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

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

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

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

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

ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Walk-Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Extreme engine conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking the Machine and Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4 4-4 4-4 4-4 4-4 4-5

CRAWLER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Before You Start Each Day . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Direction Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Steering Gradual Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Power Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Counter-rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Adjusting steering sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Transmission speed controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Decelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Onboard diagnostics and computer operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Digital display and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Display menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Activating the service reminder to (AUTO): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Activating the service reminder to (Man): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Setting the next service to (NONE): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Climate control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 MOVING A DISABLED CRAWLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Opening the pressure relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Releasing The Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Lifting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 OPERATING IN HOT WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 OPERATING IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Starting Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

4-22 4-22 4-23 4-23 4-24

BOOSTER BATTERY CONNECTION TO MACHINE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 TILTING THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Lowering the rops cab or canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 DOZER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Blade Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 TRACK SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

CHAPTER 4 - OPERATING INSTRUCTIONS Wear Factors You Can Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30 How to Extend the Life of Sealed Track and the Case Lubricated Track (CLT) . . . . . . . . . . . . . . . . . . . . . . .4-31 Case Extended Life Track (CELT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31 FACTORS CONTROLLING UNDERCARRIAGE WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 Bushing and Sprocket Wear Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35

4-2

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

2. Keep the engine at normal operating temperature.

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

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

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

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

SB055

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4-3

CHAPTER 4 - OPERATING INSTRUCTIONS

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

1. Check for leaks under the machine.

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

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

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

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

6. Clean the steps, hand rails, and operators compartment. Remove any loose items in the operators compartment.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

3. Place the Direction Control Lever to NEUTRAL. 4. Engage the parking levers by pulling them all the way back to the engaged position.

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

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

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

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

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

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

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

SA044

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

SA038

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CHAPTER 4 - OPERATING INSTRUCTIONS

CRAWLER OPERATION The drive and steering on the K Series 2 crawlers are controlled by a microprocessor. The Direction Control Lever sends an electronic signal to the controller.

There is no mechanical linkage and therefore an entirely different “feel” and sensitivity will be noticed by the operator.

BEFORE YOU START EACH DAY

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

Be a careful operator, you can prevent accidents.

Read the following information.

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

Figure 1

BD99J183

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

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

SA015

F

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

N R

SA080

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

Figure 2

BD02K029

3. Place the Direction Control Lever in Neutral.

CM112

NOTE: N should be seen on the Digital Display.

Figure 3

BD04N011

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CHAPTER 4 - OPERATING INSTRUCTIONS 12. Test the foot brake by operating the crawler forward and pushing the brake pedal. The crawler must stop in a straight line.

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

WORKING OPERATIONS

Figure 4

BD02H122

4. Sound the horn to alert those around that you are starting the machine.

5. Start the engine and allow proper warm up.

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

This crawler is designed to operate efficiently with the hydrostatic pumps running at full engine rpm’s.

This provides optimum power and cooling of the hydrostatic components. Use of the bump up and down buttons is recommended for reduction of machine speed. Operation with low engine speeds m ay c a u s e ex c e s s i ve h e a t i n g o f hy d r o s t a t i c components.

For continuous roading situations, it is recommended not to bump the machine speed above 8.

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

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

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

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

1

Figure 5

BD02H125

1. DECELERATOR PEDAL

10. Press the Decelerator Pedal all the way down.

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS DIRECTION CONTROL LEVER

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

F 1

STEERING GRADUAL TURN

N

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

R

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

BD02K029

Figure 6

1. DIRECTION CONTROL LEVER

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

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

Figure 8

B911447JFX

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

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

COUNTER-ROTATION BD04N011

Figure 7

Push the Direction Control Lever into the position you wish the crawler to go and verify the selection by reading the Digital Display. See Figure 7 above (Neutral shown).

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

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

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

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

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

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

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

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

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

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

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

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

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

1

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

Figure 9

BC02M138

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

SETTINGS

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

After selecting desired value press the Service/Enter switch.

2

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

At step 5: Figure 10

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

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

After selecting desired value press the Service/Enter switch.

BC02M138

STEER 2

3

Figure 11

BC02M138

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

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CHAPTER 4 - OPERATING INSTRUCTIONS TRANSMISSION SPEED CONTROLS

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

1

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

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

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

2

Figure 12

BD02M166

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

The CASE K Series 2 Crawlers have infinitely variable speeds in Forward and Reverse from 0 to 9.7 km/h (0 to 6.7 mph). The maximum speed is selectable in a range of 10 increments. To move from one speed to another press the UP (1) or DOWN (2) button. The operator may increment up one touch at a time or hold the button to move through the transmission speeds.

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

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

3

4 BD04N011

Figure 13

3. TRANSMISSION SPEED GAUGE 4. DIGITAL DISPLAY

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

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CHAPTER 4 - OPERATING INSTRUCTIONS DECELERATOR PEDAL

5

Figure 14

BD02H125

5. DECELERATOR PEDAL Figure 16

383971A1

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

7

6

BD02K029

Figure 17

7. ENGINE HAND THROTTLE

Figure 15 6. REVERSE TO FORWARD SPEED RATIO CONTROL

BD02M025

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

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

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

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

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

4-11

CHAPTER 4 - OPERATING INSTRUCTIONS ONBOARD DIAGNOSTICS AND COMPUTER OPERATION

3

2

1

Figure 18

BD04N010

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

DISPLAY MENUS To access the Display Menus:

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

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

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

2

3 BC02M13

Figure 19

1. Press the Display-Service / Enter Switch (3).

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS When the Service Reminder has been activated and set to (AUTO): 1. The operator will be notified when the crawler reaches within 10 hours of the “Next Service” (NS).

1 Figure 20

BD04N010

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

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

NOTE: The service reminder message may be custom tailored to your work environment or turned off, if desired. From the factory the service reminder will be NONE. NOTE: Viewing any service menu for more than 30 seconds without pressing a button will cause the display to default back to the driving display.

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CHAPTER 4 - OPERATING INSTRUCTIONS When the Service Reminder has been activated and set to (MAN):

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

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

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

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

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

3. When the crawler is at, or goes past NS the Service Soon lamp will remain illuminated and the Digital Display will show negative (-) in front of the hours until the operator or ser vice technican manually resets the interval.

1 2

3 BC02M138

Figure 21

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2

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

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

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

3 BC02M138

Figure 22

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

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

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

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

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

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

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

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

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

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS CLIMATE CONTROL SYSTEM

1 2 4

3 Figure 23

BD02K025

1. AIR CONDITION CONTROL KNOB - Turn the knob to the snowflake icon to activate the air conditioner.

WATER SHUTOFF VALVE

Turn the water shutoff valve off or clockwise all the way to maximize the air conditioning.

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

3. AIR RECIRCULATION - This control allows the operator to choose, outside air or cab only circulation.

A. Turn the knob all the way counter clockwise for cab only recirculation.

B. Turn the knob all the way clockwise for outside air to be recirculated in the cab.

4. FAN - Set the 3-speed fan at desired comfort setting.

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

SÁ129

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

Figure 24

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

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

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

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

3. Release the brakes.

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

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

2

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

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

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

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

BD02M124

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

1

Figure 25

BD02M127

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

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BD02N033

Figure 27

5. Remove the relief valve plastic protective caps.

4-17

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

1

BD02N036

Figure 28

6. Use a 4 mm allen wrench and turn the engagement screw out three turns on each relief valve.

Figure 29

BD02H050

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

2

Figure 30

BD02F009 / 4195

2. Disconnect the fitting (2) at the brake solenoid and cap it as shown in Fig 33.

2

Figure 31

BD02H057

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CHAPTER 4 - OPERATING INSTRUCTIONS

Figure 32

BD02M125

CAP INSTALLED

Figure 33

BD02M126

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

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

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

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

6. The machine is now ready to be moved.

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

8. Disconnect the hand pump.

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

10. Remove the vacuum pump, if used.

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

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

SB042

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

1

Figure 36

BD02M166

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

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

1

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

CM113

B835873F

Figure 34

1. BLOCKS FOR TRAILER WHEELS

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

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

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

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

5. Stop the engine and remove the key.

BD02M052

Figure 35

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

7. Put blocks at both ends of the tracks.

8. Remove the blocks from the trailer wheels.

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

Figure 37

BS02N080 / BS02N081

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

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

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

Figure 38

BS02N082

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

2. Test the radiator cap before hot weather starts.

Replace the cap as required.

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

4. Check the condition of the fan drive belt.

5. Use lubricants of the correct viscosity.

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

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

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

9. Clean dirt from the precleaner daily.

OPERATING IN COLD WEATHER Cold weather conditions cause special problems.

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

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

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

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

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

Inspect the battery cables and terminals.

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

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

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

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

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

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

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

ENGINE STARTING AIDS GRID HEATER (IF EQUIPPED) This machine is equipped with an manifold grid heater cold weather starting aid which is effective in temperatures down to -18°C (0°F). The manifold grid heater heats indrawn air, prior to it entering the combustion chamber.

WARNING: Ether must not be used.

To use the grid heater in temperatures below 4°C (40°F) open the throttle fully. Turn the key switch to the ON position and check the instrument cluster.

Wait for the cold start indicator light to go OFF before turning the key switch to the START position. Turn the key switch the START position until the engine starts, then release the key.

If the engine fails to start after a maximum of 60 seconds of cranking repeat the starting procedure.

Do not operate the starting motor for more than 60 seconds.

NOTE: If the operator does not crank the engine within 30 seconds after the grid heater lamp has gone out the process must be started over.

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

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CHAPTER 4 - OPERATING INSTRUCTIONS ENGINE COOLANT HEATER (IF EQUIPPED)

ENGINE OIL HEATER (IF EQUIPPED)

The right side of the engine cylinder block is provided with a passage for installing a coolant heater. See your dealer for this option. Follow the heater manufacturers instructions for installing.

The engine oil heater is installed on the right side of the engine oil pan. See your dealer for this option.

Follow the heater manufacturers instructions for installing.

1. ENGINE OIL HEATER LOCATION

1

Figure 39

BD99J214

1. COOLANT HEATER PASSAGE

B830661M

Figure 40

B830661M

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Figure 41

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CHAPTER 4 - OPERATING INSTRUCTIONS

BOOSTER BATTERY CONNECTION TO MACHINE BATTERY

1

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

2

SA031

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

1. Sit in the operators seat and have the other person make the connections. Make sure the booster battery is 12 volts.

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

Figure 42

BD02J063

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

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

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

M853

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

Figure 43

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

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

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

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

BD02F005

Figure 46

BD02M058

Figure 47

Figure 44

BD02F033

4. Turn the master disconnect switch to the “power off” position as shown.

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

Figure 45

BD02F003

5. Remove the two bolts that attach the brush guard to the canopy, if equipped. (one each side) BD02F006

Figure 48

7. Remove the six support mount bolts on the right side of the cab.

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CHAPTER 4 - OPERATING INSTRUCTIONS

Figure 49

BD02F008

8. Remove the clevis pins from the control valve behind the right-hand middle access door.

Figure 52

BD02M120

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

Figure 50

BD02F021

9. Open the left engine compartment panel and disconnect the throttle linkage quick disconnect.

Pull the outer collar toward you and slip the coupler off of the pivot ball.

Figure 53

BD02M164

RETAINING CABLE

Refilling and Bleeding the Tilt System

2

1

Figure 54

BD02F024 BD02F020

Figure 51

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

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

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

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS LOWERING THE ROPS CAB OR CANOPY

BD02F008

Figure 55

BD02F018

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

Figure 56

BD02F007

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

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

Figure 58

5. Connect the control rods to the hydraulic control valve.

NOTE: Align the spool in the direction of linkage travel.

BD02F021

Figure 59

6. Open the left engine compartment panel and connect the throttle linkage quick disconnect.

Pull the outer collar towards you and slip the coupler over the pivot ball.

Figure 57

BD02F004

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

2

1

SA015

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

SA080

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

CM112

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

SA044

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

Figure 60

BC00G049

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

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

2. Blade will stay on top in soft ground.

3. Blade will not dig into ground.

4. Blade best used for fine grading.

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

2. Blade will dig into hard ground.

3. Less load spillage over top of blade.

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

BLADE LIFT EYE

SA038

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

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

SB013

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

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

ENGINE SPEED

Figure 61

BD99J147

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

TRACK SYSTEMS

2 1

8

3 7 4 5

6 Figure 62

BD04N014

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

6. TRACK ADJUSTER GREASE FITTING

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

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

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

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

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

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

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The track adjuster is a grease filled hydraulic cylinder used to maintain or adjust track tension.

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

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS COMPONENTS OF THE UNDERCARRIAGE

9

10

10 Figure 63

BD99J230

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

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

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

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

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

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

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

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

Operating techniques and maintenance also greatly affect undercarriage life. Unlike the other wear fa ctor s that yo u can not control, yo u can do something about the way you operate and maintain the machine.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

HOW TO EXTEND THE LIFE OF SEALED TRACK AND THE CASE LUBRICATED TRACK (CLT) NOTE: Turn the pins and bushings at the 100% wear limit. Operating past the 100% wear limit can cause the bushings to crack or to wear completely through to the pin.

NOTE: Letting the pins and bushings run to destruction results in accelerated wear of other components. Turn the pins and bushings to extend track life.

CASE EXTENDED LIFE TRACK (CELT) T he C a s e E x te n de d Li fe Tra ck (CE LT ) c h ain incorporates a bushing that is free to rotate on the standard lubricated track bushing. This method allows wear to be distr ibuted over the entire circumference of the bushing and because the bushing is free to rotate it does not create the scrubbing action between the sprocket and the bushing as the conventional crawler track chain does.

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

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

Recommended Application T h e C a s e E x t e n d e d L i fe Tr a c k ( C E LT ) i s r e c o m m e n d e d i n h i g h a b r a s i ve / l ow i m p a c t applications where bushing wear is severe. The narrowest possible track shoe th at will give a d e q u a te fl o ta t i o n s h o u l d b e u s e d to o b ta i n maximum life from the sealed and lubr icated standard pin and bushing joint. Field testing in abrasive conditions has proven the CELT bushing will obtain up to twice the wear life as the conventional lubricated track bushings.

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

FACTORS CONTROLLING UNDERCARRIAGE WEAR WEAR FACTORS YOU CAN NOT CONTROL

High Abrasiveness

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

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

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

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

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

Moderate Abrasiveness

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

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

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS Packing

Track Shoes

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

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

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

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

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

Wear is then accelerated.

When a packing problem continues install relieved track sprockets.

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

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

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

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

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

Check the track tension frequently when you operate.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

912285

Figure 64

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

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

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

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

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912286

Figure 65

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

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

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

912287

Figure 66

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

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

Track Sag Adjustment Chart 100 90% 75% 60% 45% 30% 15% 0%

912288

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

912289

13 MM (0.5 INCH)

Figure 67

38 MM (1.5 INCH)

51 MM (2.0 INCH) Figure 69

912346

1. TRACK TENSION (PERCENT TIGHT)

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

Figure 68

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

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

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

NOTE: It is recommended that you turn the pins and bushings at the 100% wear limit.

Figure 70

912347

PERCENT OF WEAR 1.

2.

3.

4.

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

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

NOTES

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

Chapter 5 LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS GENERAL SAFETY BEFORE YOU SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 SYSTEMGARD LUBRICATION ANALYSIS PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 PLASTIC AND RESIN PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 ENGINE HOURMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Reservoir/Transmission Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Grease Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5 5-5 5-5 5-5 5-5 5-5 5-5

LUBRICATION AND MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 GREASE FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Ripper - 50 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Drive Shaft slip spline- 1000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 ACCESS DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Engine Oil Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Oil Viscosity/Temperature Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Change and Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Priming the Turbocharger Oil Lines with Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-11 5-11 5-11 5-11 5-12

AIR FILTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning Lamp for Air Filter Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Primary (Outer) Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Secondary (Inner) Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turbo Precleaner (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Primary (Outer) Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-13 5-13 5-13 5-13 5-14 5-14 5-14 5-15 5-16

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-17 5-17 5-17 5-18

DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Line Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Draining Water and Sediment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

First and second stage filter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

In line filter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing Air From the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Tank Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-19 5-19 5-19 5-19 5-19 5-20 5-21 5-21 5-22

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Issued 12-05

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5-1

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23 Fluid Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23 Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23 Hydraulic and Transmission Fluid Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24 Suction screen cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24 Hydraulic Reservoir Breather and Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25 Fluid Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25 Transmission Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25 Transmission and Hydraulic Fluid Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26 Suction screen cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26 FINAL DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27 Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27 Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27

5-2

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

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

Figure 1

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

SC021

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

B770996R

Figure 3

321-4614

Figure 4

SA044

Read the safety decals and information decals on the machine. Read the operators manual and safety manual. Understand the operation of the machine before you start servicing.

Figure 2

B801147T

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

Use the correct safety clothing and safety equipment.

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

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5-3

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

SYSTEMGARD LUBRICATION ANALYSIS PROGRAM

Figure 5

BP97H063

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

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

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

The normal engine oil change interval is every 250 hours of operation. Operating conditions, quality of the engine oil and sulphur content of the fuel can change this interval. It is recommended that you use the Systemgard Lubricant Analysis program. See your dealer.

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

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

5-4

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

Figure 6

BD02N037

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

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

Issued 12-05

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6-85641NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUIDS AND LUBRICANTS ENGINE CRANKCASE Capacity with Filter Change, 650K Series 2, 750K Series 2................................................ 13.6 Liters (14.4 qts) Capacity w/o Filter, 650K Series 2, 750K Series 2 ...............................................................12.8 Liters (13.5 qts) Capacity with Filter Change, 850K Series 2 ..........................................................................14.9 Liters (15.8 qts) Capacity w/o Filter Change, 850K Series 2...........................................................................14.2 Liters (15.0 qts) Specifications ...................................................................................................................... CASE AKCELA No. 1 FUEL TANK Capacity .................................................................................................................................189.3 Liters (50 gal) COOLING SYSTEM Capacity .....................................................................................................................................18.9 Liters (5 gal) Specifications ............................................................................................. 50% Water and 50% Ethylene Glycol NOTE: If the ambient temperature is lower than -37°C (-34°F), adjust the mixture according to the coolant manufacturer specifications.

HYDRAULIC RESERVOIR/TRANSMISSION REFILL Capacity ...................................................................................................................................75.7 Liters (20 gal) Specifications ................................................................................................................ MS-1209, Hy-Tran® Ultra FINAL DRIVES Capacity - Each Side ............................................................................................................... 14.2 Liters (15 qts) Specifications ............................................................................................................... MS-1209, Hy-Tran® Ultra GREASE FITTINGS Quantity ............................................................................................................................................. As Required Specifications ............................................................................................................. Case Molydisulfide Grease

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5-5

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

LUBRICATION AND MAINTENANCE CHART

As Required (AR)

Every 10 Hours.

See Note 3

Every 50 Hours

Every 250 Hours

Every 500 Hours

Every 1000 Hours

Every 2000 Hours

6-10 5-13 5-24 5-22 6-3 6-3 6-3 5-20 5-16 5-11 5-22 5-7 5-17 5-8 5-14 5-17 5-19 5-11 5-11 5-26 67-4 5-19 5-20 5-23 5-21 6-5 5-19 5-8 5-26 5-23 5-23 5-22 5-25 5-24 5-18 5-13

Fan and Air Conditioning Drive Belt Air Filter (See Notes 1) Transmission Filter (See Notes 2) Hydraulic Filter (See Note 2) Steel Track Shoe Bolt Torque (See Note 5) Clean Tracks Track Chain Tension (See Note 5) In Line Fuel Filter Cab Filters (If Equipped Engine Oil Level Transmission and Hydraulic Fluid Level Equipment Pivot Points Coolant Reservoir Fluid Level Ripper Grease Points (If Equipped) Air Filter Dust Valve Radiator Fluid Level First Stage Fuel Filter for Water Engine Oil Engine Oil Filter Final Drive Oil Level Drive Belt Battery Fluid Level Fuel Filters In Line Fuel Filter Hydraulic Reservoir Breather Relief Valve Fuel Cap Breather Engine Valve Clearance Fuel Tank for Water Drive Shaft Slip Spline Final Drive Oil Transmission Suction Screen Hydraulic Suction Screen Hydraulic Oil Filter Transmission and Hydraulic Fluid Transmission Filter (See Note 6) Engine Coolant (See Note 7) Air Filter Elements (See Note 7)

REPLACE

LUBRICATE

DRAIN

CHANGE

CLEAN

CHECK

SERVICE POINTS

NUMBER OF POINTS

SERVICE INTERVAL

PAGE NUMBER

FREQUENCY IN HOURS

AR AR AR AR AR AR AR AR AR 10 10 14

10 10 10 50 50 50 250 250 250 250 500 500 500 1000 1000 1000 1000

1

1000 1000 2000 2000 2000 2000 2000 2000 2000

NOTE NOTE NOTE NOTE

1: Service the air filter elements if the air filter warning lamp illuminates.

2: Replace the transmission filter or hydraulic filter if the filter restriction warning lamp illuminates or at 2000 hours.

3: Every 10 hours of operation or once each day, whichever comes first.

4: If the machine is new or if the track shoes have been removed, check the torque of the steel track shoe bolts after the first 20 hours of operation and then every 100 hours of operation until the track shoe bolts remain tight.

NOTE 5: For increased track life, always keep the track tension correct. Adjust the tracks for 38 to 51 mm (1.5 to 2 Inches) of track sag.

NOTE 6: If the machine is new or the transmission has been overhauled, replace the filter at 250 hours for the first and second filter change.

NOTE 7: Every 2000 hours of operation or each year, whichever occurs first.

5-6

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

GREASE FITTINGS DOZER - 10 HOURS Use Case Molydisulfide Grease

8

9 2 1 3 Figure 10

BD02H020

Figure 7

BD02H017

1. Tilt cylinder, closed end. . . . . . . . . . . . . . . . . . . 1 2. Angle cylinder, rod end . . . . . . . . . .2 (1 ea. side) 3. Trunnion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8. Angle cylinder closed end . . . . . . . 2 (1 ea. side) 9. C frame pivot pin . . . . . . . . . . . . . . 2 (1 ea. side) DOOR HINGES - AS REQUIRED

4 10

5

Figure 11

BD02J017

10. Access door hinges . . . . . . . . . . . . 2 per door (6) Figure 8

BD02F026

4. Tilt cylinder, rod end . . . . . . . . . . . . . . . . . . . . . 1 5. Center pivot. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 7

6 BD02H102

Figure 12

11. Cab door hinges. . . . . . . . . . . . . . . 4 (2 ea. side) Figure 9

BD02H019

6. Lift cylinder, rod end . . . . . . . . . . . .2 (1 ea. side) 7. Lift cylinder, closed end. . . . . . . . . .2 (1 ea. side)

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5-7

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS RIPPER - 50 HOURS Use Case Molydisulfide Grease

12

1 Figure 13

BBD02J017

12. Ripper lift cylinder . . . . . . . . . . . . . 2 (1 ea. side) DRIVE SHAFT SLIP SPLINE- 1000 HOURS NOTE: Universal Joints are Lubricated for life.

Figure 15

BD02H004

Use Case Molydisulfide Grease

NOTE: The cab must be tilted to access the drive shaft spline.

1

B911749

Figure 14

1. SLIP SPLINE . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5-8

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

ACCESS DOORS

Figure 16

BD02J033

RIGHT REAR COMPARTMENTS

Figure 17

BD02H097

Figure 19

BD99J173

LEFT REAR COMPARTMENT

Figure 20

BD02H098

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

ENGINE SIDE PANEL - RIGHT

Figure 18

BD02J081

RADIATOR Figure 21

BD02J067

ENGINE SIDE PANEL - LEFT

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Bur

5-9

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

ENGINE LUBRICATION ENGINE OIL SELECTION Case No. 1 Engine Oil is recommended for use in your Case Engine. Case Engine Oil will lubricate your engine correctly under all operating conditions.

If Case Multi-Viscosity Engine Oil is not available, use only oil meeting API engine oil service category CE.

RH99K130

Figure 22

BP97H064

Figure 23

See the chart below for recommended viscosity at ambient air temperature ranges.

NOTE: Do not put Performance Additives or other oil additive products in the engine crankcase. The oil change intervals given in this manual are according to tests with Case lubricants.

NOTE: Use of an engine oil pan heater or an engine coolant heater may be required when operating temperatures are in Winter or Arctic conditions.

NOTE: The use of low viscosity oils, such as 10W-30 can be used to aid in starting the engine and in providing sufficient oil flow at ambient temperatures below -5°C (23°F). The continuous use of low viscosity oils can decrease engine life due to wear.

See the chart above for the correct oil for ambient temperatures.

OIL VISCOSITY/TEMPERATURE RANGES

Figure 24

BC02N250

NOTE: Use of an engine oil pan heater or an engine coolant heater may be required when operating temperatures are in Winter or Arctic conditions.

NOTE: The use of low viscosity oils, such as 10W-30 can be used to aid in starting the engine and in providing sufficient oil flow at ambient temperatures below -5°C (23°F). The continuos use of low viscosity oils can decrease engine life due to wear. See chart above for the correct oil for ambient temperatures.

5-10

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

ENGINE SERVICE ENGINE SERVICE SPECIFICATIONS Oil Level Check Interval ....................................................................Every 10 hours of Operation or Once Each Day Oil Change and Filter Replacement Interval................................................................ Every 250 Hours of Operation Oil Type.....................................................................................................................................................CASE No. 1 Oil Capacity - with Filter Change 650K Series 2, 750K Series 2 ..........................................................................................13.6 Liters (14.4 qts) 850K Series 2....................................................................................................................14.9 Liters (15.8 qts) ENGINE OIL LEVEL

OIL CHANGE AND FILTER REPLACEMENT

Check the engine oil level before you start the engine each day or before the start of each 10 hour shift.

Always check the oil level with the engine stopped and when the machine is on level ground.

NOTE: For more complete removal of foreign material, change the engine oil while the engine is still warm from operation.

Push the engine oil level dipstick completely down and pull out before you check the oil level.

If the oil level is below the ADD mark, add oil to raise the oil level up to the FULL mark.

IMPORTANT: You must shorten the oil change interval if you use diesel fuel with a sulphur content of more than 0.5%.

Change the engine oil more frequently than every 250 hours when the engine operating conditions are severe (frequent stopping and starting and high or low engine temperatures).

1. Before draining the oil, have a container that will hold the suitable quantity.

2

1

1

Figure 25

BD02J026

1. ENGINE OIL DIPSTICK 2. ENGINE OIL FILL TUBE Figure 26

BD02K002

2. Remove this plate (1) to access the oil pan.

2

P320073

Figure 27

3. Remove the engine oil drain plug (2).

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Bur

5-11

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS PRIMING THE TURBOCHARGER OIL LINES WITH OIL ENGINES WITH TURBOCHARGER: In cold weather, after several weeks of storage, or after the engine oil filter has been replaced, prime the turbocharger oil lines with oil.

1. Disconnect the plug to the injection pump solenoid.

3

2. Actuate the starter motor for 10 to 20 seconds.

3. Connect the wire to the injection pump solenoid and start the engine.

B4140898S

Figure 28

4. Run the engine at idle speed for a few minutes.

4. Turn the oil filter (3) counterclockwise to remove.

Discard the filter.

5. Use a clean cloth and wipe the sealing surface of the oil filter base to remove all dirt or gasket material.

6. Apply a thin layer of clean grease or oil to the gasket of the new oil filter.

7. Turn the new oil filter onto the base until the gasket makes contact with the base. Continue to tighten the filter for 3/4 turn with your hand.

IMPORTANT: Do not use a filter strap wrench to install the oil filter. An oil filter strap wrench can cause a leak if the filter is dented.

IMPORTANT: Clean all dirt and foreign material from the front engine guard a minimum of every thirty days. Dirt will cause rust on the engine oil pan and a loss of engine oil.

8. Install the drain plug. Tighten the drain plug to a torque of 68 to 82 Nm (50 to 60 lb ft).

Overtightening can damage the oil pan. Install the guard plate.

9. Put new oil into the engine oil fill tube.

10. Before you start the engine, prime the turbocharger oil lines with oil. See the following topic.

11. Start the engine and run at idle speed. Check the engine oil filter for leaks. After two minutes, stop the engine, wait for 2 or 3 minutes, and check the engine oil level with the dipstick.

5-12

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Bur

6-85641NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

AIR FILTER SYSTEM SERVICE SPECIFICATIONS Air Filter Dust Valve ................................................................................................................. Check Every 50 Hours Air Filter Element Replacement....................................................................... Every 2000 Hours or Once Each Year NOTE: Service the elements if the warning lamp for the air filter restriction illuminates.

1. Do not install a new element that is more than five years old. The date of manufacture is on the end cap of the element.

2. Replace both elements after one year in the machine.

3. Do not remove the elements from the machine to c h e c k fo r r e s t r i c t i o n . A l w ay s fo l l o w t h e recommended ser vice instr uctions in this section.

PRIMARY (OUTER) ELEMENT Replace the primary (outer) element after three washings or after the element has been in the machine for one year. See cleaning the primary (outer) element. To service: 1. Open the access panel.

2. Pull the cover clamp (1) of the air cleaner cover out and rotate counter clockwise. Remove the end cover.

4. Each time you service the air cleaner system, make sure all hose connections and flanges are air tight. Replace all damaged parts.

1

WARNING LAMP FOR AIR FILTER RESTRICTION

2

1 Figure 30

BD04N021

1. CLAMP 2. END COVER

3. Carefully remove the primary (outer) element.

Figure 29

BC02J064

1. AIR FILTER INDICATOR LAMP

You must service the air filter if the air filter warning lamp illuminates when the engine is running. After the shift or at the end of the day, service the air cleaner. Make sure you check the condition of the warning lamp bulb each day before you operate the machine.

3

BD04N022

Figure 31

3. PRIMARY (OUTER) ELEMENT

4. Use a clean damp cloth and clean inside of the filter body.

5. Install a clean or new primary (outer) element.

Make sure the element has full gasket contact.

6. Install the end cover.

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Issued 12-05

Bur

5-13

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 7. Make sure other persons are clear of the machine. Start the engine and check the air filter warning lamp. If the lamp is still illuminated, replace the secondary (inner) element.

DUST VALVE

SECONDARY (INNER) ELEMENT Replace the secondary (inner) element (1) after the primary (outer) element has been cleaned three times, (2) after one year in the machine, or (3) after the primary (outer) element has been cleaned or replaced and the air filter warning lamp is still illuminated with the engine running. DO NOT clean the secondary element.

1. Open the access panel. Remove the end cover and remove the primary (outer) element.

2. Remove and discard the secondary (inner) element.

Figure 33

BD02J088

The Dust Valve should be checked every 50 hours of machine operation or more often if work is being performed in severe environments.

1. Remove the valve and wipe it clean.

TURBO PRECLEANER (OPTIONAL) The optional turbo precleaner requires no service.

1

BD04N023

Figure 32

1. SECONDARY (INNER) ELEMENT

3. Use a clean damp cloth and clean the inside of the filter body.

4. Install a new secondary (inner) element. Make sure the gasket is making full contact.

5. Install the primary (outer) element and the end cover.

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6-85641NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS CLEANING THE PRIMARY (OUTER) 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.

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

CA5002J

Figure 36

5. Allow the element to air dry. If you use a drier, do not exceed 71°C (160°F) and make sure the air is circulating in the drier.

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

Figure 34

CA5000J

2. Mix two tablespoons of D1400 detergent (Case par t number A40910) with 7.5 Liters (two gallons) of water, one cup for 60 Liters (16 gallons) of water.

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

CA5003J

Figure 37

Figure 35

CA5001J

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

6-85641NA

Issued 12-05

Bur

5-15

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS CAB FILTERS There are two cab air filters that require service.

BD02K024

Figure 38

The internal cab filter is located between the seat and left side console. Remove the two thumbscrews, the cover screen and clean or replace as required.

BD02K019

Figure 39

The external cab filter is located behind the battery and the left rear access door.

BD02K020

Figure 40

Remove the four thumb screws and the frame that holds the external filter in place. Clean or replace the filter as required.

5-16

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Bur

6-85641NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

ENGINE COOLING SYSTEM SERVICE SPECIFICATIONS Coolant Reservoir Level Check Interval ....................................................................... Every 10 Hours Of Operation Radiator Coolant Level Check Interval ......................................................................... Every 50 Hours Of Operation Check and Tighten Coolant Hose Clamps .............................................................................................. As Required Coolant System Change Interval ................................................ Every 2000 hours of operation or once every year.

Coolant Capacity .............................................................................................................................18.9 Liters (5 gal) COOLANT SOLUTION A mixture of 50% ethylene glycol and 50% water must be used in this machine. This mixture is used if the lowest ambient temperature is above -37° C (-34° F). If the ambient temperature is lower, adjust the mixture to attain a lower freeze point using the freeze point-concentration chart on the label of your antifreeze concentrate. Never use a coolant solution containing more than 60% glycol. It is recommended that ethylene glycol and water be used in your machine all year.

IMPORTANT: After you fill the cooling system, mix the ethylene glycol and water completely by running the engine at operating temperature for approximately five minutes. This procedure must be done when the machine is in temperatures below 0° C (32° F).

COOLANT RESERVOIR FLUID LEVEL Check the coolant reservoir fluid level every 10 hours of operation, when the coolant is cold and the engine is stopped. Do not remove the radiator cap during this check. The coolant level must be between the FULL and ADD marks on the reservoir. Add coolant as required to the coolant reservoir.

1

Figure 42

BD02J084

1. SIGHT GAUGE

NOTE: If the radiator coolant level is low and the coolant reservoir level is at the FULL mark, check for air leaks in the hose between the radiator and coolant reservoir.

WARNING: Hot coolant can spray out if radiator cap is removed. To remove radiator cap: Let system cool, turn to first notch, then wait until all pressure is released. Scalding can result from fast removal of radiator cap.

Check and service engine cooling system according to maintenance instructions.

SA023

1

Figure 41

BD02K017

1. COOLANT RESERVOIR

RADIATOR COOLANT LEVEL Check the radiator coolant level at the sight gauge every 50 hours of operation when the coolant is cold and the engine is stopped. The coolant level must be in the sight gauge.

6-85641NA

Issued 12-05

Bur

5-17

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS CLEANING COOLING SYSTEM Drain, flush, and replace the engine coolant every 2000 hours of operation or each year whichever occurs first. Clean the system and replace the coolant if the coolant becomes dirty or has the color of rust.

12. Make sure all persons are clear of the machine.

Start the engine and increase the temperature of the engine coolant. When the coolant is at operating temperature, stop the engine and allow to cool. Check the coolant level at the coolant reservoir only. Do not remove the radiator cap.

If possible, drain the cooling system when the coolant is warm. DO NOT remove the radiator cap if the coolant is hot.

1. Open the radiator door.

1

BD99J218

Figure 43

1. RADIATOR DOOR

2. Loosen and remove the radiator cap.

3. Place a container of suitable capacity under the drain valve and drain the radiator.

4. After all the coolant is removed, close the drain valve.

5. Add a cleaning solution to the cooling system and fill the cooling system with clean water.

Follow the directions included with the cleaning solution.

6. After you drain the cleaning solution, flush with clean water.

7. Check the hoses, elbow, and water pump for leaks.

8. Make sure that the outside of the engine and radiator is clean.

9. Fill the cooling system slowly until the coolant level is up to the top of radiator opening.

NOTE: Allow the venting of entrapped air when filling the cooling system until you have the correct quantity of coolant in the system.

10. Install the radiator cap.

11. Fill the coolant reservoir up to the FULL mark on the reservoir.

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6-85641NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

DIESEL FUEL SYSTEM SERVICE SPECIFICATIONS Drain First Stage Fuel Filter.......................................................................................................................... 50 Hours Replacing the Fuel Filter............................................................................................................................. 500 Hours Draining Water From The Fuel Tank......................................................................................................... 1000 Hours Clean Fill Cap Breather ............................................................................................................................ 1000 Hours Fuel Tank Capacity .......................................................................................................... 189.3 Liters (50.0 U.S. Gal) FUEL LINE SHUTOFF VALVE

DRAINING WATER AND SEDIMENT

Close the shutoff valve at the hand primer when the fuel filter is replaced or the fuel system is serviced.

Check the first stage fuel filter for water and sediment every 50 hours of operation.

NOTE: If the fuel filter has any water and sediment, go to step 2 and drain any water and sediment from the fuel tank.

FUEL GAUGE

1

Figure 44

BD99J195

BD02J026

Figure 45

1. FUEL FILTER

1. Open the drain plug at the bottom of the fuel tank to drain water and sediment from the fuel tank.

BD02K022

6-85641NA

Issued 12-05

Bur

Figure 46

5-19

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS FUEL FILTER REPLACEMENT

REMOVING AIR FROM THE FUEL SYSTEM

Replace the fuel filter after every 500 hours of operation.

Air must be removed from the fuel system if one or more of the following conditions occurs: A. If the engine stops because of no fuel in the tank.

B. If the fuel filters are replaced.

C. If the fuel system is serviced.

D. If the machine has been in storage.

1. If necessary, fill the fuel tank.

2. Make sure the fuel tank shutoff valve is in the ON position.

3. Loosen the air bleed screw (1) on the filter head 1 or 2 turns.

BD02J026

Figure 47

2. Clean the filter head and the outside of the fuel filter.

1

3. Turn the filter counterclockwise and remove from the filter head.

4. Apply a thin layer of clean oil to the gasket of the new filter.

5. Install the filter. Use your hands to tighten the filters 1/2 turn after the filter makes contact with the filter head.

6. Loosen the filter approximately one turn.

7. Tighten the filter until the filter is touching the filter head and then tighten 1/2 to 3/4 turn. Do not use a strap wrench.

Figure 49

BD02J026

1. AIR BLEED SCREW

8. Open the shutoff valve at the hand primer.

4. Operate the hand primer until fuel with no air bubbles flows from around the air bleed screw.

9. Remove the air from the fuel system. See removing air from the fuel system.

5. Tighten the air bleed screw.

6. Start the engine and check for fuel leaks.

IN LINE FILTER REPLACEMENT Replace the in line filter after 500 hours of operation.

BD02M137

Figure 48

Make sure the filter is placed in line with the correct flow direction.

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6-85641NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS FUEL TANK BREATHER Clean the fuel cap breather every 1000 hours of operation or if the breather is coated with dirt.

1. Remove the fuel cap.

2. Clean the fuel cap and breather with cleaning solvent.

3. Dry the fuel cap and breather with compressed air.

4. Install the fuel cap.

1

2 3 Figure 50

BD02H106

1. FUEL TANK BREATHER 2. FUEL TANK CAP 3. LOCKING HARDWARE

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Bur

5-21

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

HYDRAULIC SYSTEM SERVICE SPECIFICATIONS Fluid Level Check ......................................................................................................... Every 10 Hours Of Operation Filter Change .............. Every 2000 hours of operation or when the respective warning lamp for the filter illuminates Clean Hydraulic Reservoir Breather ........................................................................ Every 1000 Hours Of Operation Clean Suction Screen............................................................................................... Every 2000 Hours Of Operation Change Hydraulic Fluid ........................................................................................... Every 2000 Hours Of Operation Type of Fluid ........................................................................................................................MS-1209, Hy-Tran® Ultra Reservoir Refill Capacity With Filter Change ............................................................................... 75.7 Liters (20 gal) WARNING: Hydraulic fluid or grease injected into your skin can cause severe injury or death. Keep your hands and body away from any pressurized leak. If fluid is injected into your skin, see a doctor immediately and have the fluid removed.

1

SA024

FLUID LEVEL CHECK Check the oil level every 10 hours of operation or each day, whichever occurs first.

NOTE: Check the oil level of the hydraulic reservoir only when the machine is level, front mounted equipment is on the ground, the ripper, (if equipped) is on the ground, and the engine is stopped.

Check the oil level at the sight gauge on the hydraulic reservoir. The oil level must be between the RED (full) and BLACK (add) marks on the gauge. If the oil level is below the BLACK (add) mark, add oil to raise the level up to the RED (full) mark.

Figure 52

BC02J064

1. HYDRAULIC FILTER INDICATOR LAMP

NOTE: If machine is new or any part of the hydraulic or transmission system has been serviced, replace the filter at 250 hours for the first and second filter change.

1. Open the side access door.

2. Clean the outside of the filter and filter head with cleaning solvent.

3. Rotate the filter counterclockwise and remove the filter. Discard the old filter.

1 1

2

BD02H105

Figure 51

1. HYDRAULIC RESERVOIR FILL TUBE 2. OIL LEVEL SIGHT GAUGE

HYDRAULIC FILTER Replace the filter every 2000 hours of operation or if the hydraulic filter warning lamp illuminates.

Figure 53

BD02J102

1. HYDRAULIC FILTER

4. Clean the gasket surface on the filter head with a clean cloth, make sure all dirt and gasket parts are removed.

5. Put clean oil on gasket of the new filter.

6. Turn the filter clockwise until the gasket makes contact, then tighten an additional 1/2 turn.

7. Start engine and check for oil leaks.

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6-85641NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS HYDRAULIC AND TRANSMISSION FLUID CHANGE

SUCTION SCREEN CLEANING

1. Make sure the oil is warm.

1

2

2. Lower the equipment to the ground and stop the engine.

3. Put a Do Not Operate tag on the instrument panel.

4. Have a suitable container that will hold the quantity of fluid.

5. Loosen hydraulic fill cap slowly.

Figure 56

BD02J108

1. TRANSMISSION SUCTION SCREEN 2. HYDRAULIC SUCTION SCREEN

To access the suction screens it will be necessary to tilt the cab over.

Remove the fittings and pull the screens through and service or replace as necessary.

Figure 54

BD02M047

HYDRAULIC RESERVOIR BREATHER AND RELIEF VALVE

6. Remove the drain plug and remove all fluid from the reservoir.

1. Open the side access door and clean the area around the breather and relief valve.

7. Change the hydraulic filter.

2. Remove the breather and relief valve.

8. Install the drain plug.

1

1

BD02H050

Figure 55

BD02H105

Figure 57

1. BREATHER AND RELIEF VALVE

3. Clean the valve with cleaning solvent and dry with compressed air.

1. FILLER CAP

9. Remove the filler cap.

10. Put new MS-1209, Hy-Tran® Ultra fluid into the reservoir.

4. Install the breather and close the access door.

11. Install the filler cap.

12. Operate the hydraulic equipment and transmission at 20% with no load and then check the oil level.

13. Add oil as required. Check for leaks.

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Issued 12-05

Bur

5-23

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

TRANSMISSION SERVICE SPECIFICATIONS Fluid Level Check ......................................................................................................... Every 10 Hours Of Operation Filter Change ...................................................Every 2000 Hours Of Operation Or If The Warning Lamp Illuminates Clean Hydraulic Reservoir Breather ........................................................................ Every 1000 Hours Of Operation Clean Suction Screen............................................................................................... Every 2000 Hours Of Operation Change Transmission Fluid ...................................................................................... Every 2000 Hours Of Operation Type of Fluid ........................................................................................................................MS-1209, Hy-Tran® Ultra Refill Capacity With Filter Change................................................................................................. 75.7 Liters (20 gal)

WARNING: Hydraulic fluid or grease injected into your skin can cause severe injury or death. Keep your hands and body away from any pressurized leak. If fluid is injected into your skin, see a doctor immediately and have the fluid removed.

1

SA024

FLUID LEVEL CHECK Check the oil level every 10 hours of operation or each day, whichever occurs first.

NOTE: Check the oil level of the hydraulic reservoir only when the machine is level, front mounted equipment is on the ground, the ripper is on the ground, and the engine is stopped.

Check the oil level at the sight gauge on the hydraulic reservoir. The oil level must be between the RED (full) and BLACK (add) marks on the gauge. If the oil level is below the BLACK (add) mark, add oil to raise the level up to the RED (full) mark.

Figure 59

BC02J064

1. TRANSMISSION FILTER WARNING LIGHT

NOTE: If machine is new or any part of the hydraulic system has been serviced, replace the filter at 250 hours for the first and second filter change.

1. Open the access door.

2. Clean the outside of the filter and filter head with cleaning solvent.

3. Rotate the filter counterclockwise and remove the filter. Discard the filter.

1

2

2 BD02H105

Figure 58

1. HYDRAULIC RESERVOIR FILL TUBE 2. OIL LEVEL SIGHT GAUGE

TRANSMISSION FILTER Replace the filter every 2000 hours of operation or if the transmission filter warning lamp illuminates.

1 Figure 60

BD02J102

1. TRANSMISSION FILTER

4. Clean the gasket surface on the filter head with a clean cloth, make sure all dirt and gasket parts are removed.

5. Put clean oil on gasket of the new filter.

6. Turn the filter clockwise until the gasket makes contact, then tighten an additional 1/2 turn.

7. Start the engine and check for oil leaks.

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6-85641NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS TRANSMISSION AND HYDRAULIC FLUID CHANGE

SUCTION SCREEN CLEANING

1. Make sure the oil is warm.

1

2. .Lower the equipment to the ground and stop the engine.

2

3. Put a Do Not Operate tag on the instrument panel.

4. Have a suitable container that will hold the quantity of fluid.

5. Loosen hydraulic fill cap.

6. Remove the drain plug and remove all fluid from the reservoir.

BD02J108

7. Change the transmission filter.

Figure 62

1. TRANSMISSION SUCTION SCREEN 2. HYDRAULIC SUCTION SCREEN

8. Install the drain plug.

To access the suction screens it will be necessary to tilt the cab over. See Tilting the Cab in the Operating Instructions Section.

1

Remove the fittings and pull the screens through and service or replace as necessary.

Figure 61

BD02H105

1. FILLER CAP

9. Remove the filler cap.

10. Put new MS-1209, Hy-Tran® Ultra fluid into the reservoir.

11. Install the filler cap.

12. Operate the hydraulic equipment and then check the oil level.

13. Add oil as required. Check for leaks.

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Bur

5-25

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FINAL DRIVES SERVICE SPECIFICATIONS OIl Level Check Interval.............................................................................................. Every 250 Hours Of Operation OiL Change Interval.................................................................................................. Every 1000 Hours Of Operation Type Of Oil...........................................................................................................................MS-1209, Hy-Tran® Ultra Capacity (each side)...................................................................................................................... 14.2 Liters (15 qts) OIL LEVEL CHECK

OIL CHANGE

Park the machine on a level surface. Stop the engine.

Park the machine on a level surface. Stop the engine.

NOTE: If possible, drain the final drives when the oil is warm. You will remove more contamination from the final drives with warm oil.

1 3

Figure 63

BD02M131

1. Remove the check plug (1) slowly to release the pressure. Oil should be to the top of this plug orfice.

Figure 65

BD02H107

1. Clean the area around the fill (2), check (1) and drain plug (3)with cleaning solvent.

2

2. Remove the fill plug slowly to relieve pressure.

3. Remove the drain plug (3) and drain the final drive oil into a container.

4. Install the drain plug (3) and put new oil in the final drive.

5. Fill until a small amount leaves the check plug (1) orfice and install the plug.

6. Install the fill plug.

BD02J069

Figure 64

7. Repeat steps 1 through 6 for the other final drive.

2. If necessary, add oil to the final drive through the fill plug (2).

3. Install the fill plug.

4. Repeat steps 1 through 4 for the other final drive.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Chapter 6 MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure to adjust track tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Track Shoe Bolts - Steel Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Welding on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3 6-3 6-3 6-4 6-5 6-5 6-5

REVERSIBLE FAN POSITIONS (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 ROLL-OVER PROTECTIVE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance and Inspection of ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Damage to the ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-7 6-7 6-7 6-7 6-8

MACHINE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 ADJUSTING THE RIPPER SHANKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 DOZER BLADE PITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Rearward Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Forward Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Type of Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Inspection and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 FAN AND AIR CONDITIONING DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Service Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Storage Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Removal From Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

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6-1

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

NOTES

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

TRACKS SERVICE SPECIFICATIONS Clean Tracks ............................................................................................................................................ As Required Check Tension ...........................................................................................................................................Periodically Check Track Shoe Bolt Torque ............... After The First 20 Hours Of Operation On New Machine And As Required Shoe Bolt Torque (standard link bolts)...................................................................... 406 to 447 Nm (300 to 330 lb ft) Shoe Bolt Torque (master link bolts)......................................................................... 430 to 470 Nm (318 to 346 lb ft) IMPORTANT: When the machine has been operating in mud, snow or adverse material, debris will stick to the track parts and cause the tracks to become too tight. Always adjust the track tension more often when operating in these conditions.

PROCEDURE TO ADJUST TRACK TENSION 1. Do not clean the tracks before adjustment.

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

1 B911469J

Figure 3

2

Figure 1

BD02H010

3. Stop the machine so that a pin (1) in the track chain is over the carrier roller (2).

4. Put a straightedge over the track.

Figure 2

BD02H013

5. Measure the track deflection midway between the top roller and the idler wheel. The correct adjustment is between 38 to 51 mm (1-1/2 to 2 inches).

6-85641NA

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Bur

6-3

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TO TIGHTEN THE STEEL TRACK

BD02H015

TO LOOSEN THE STEEL TRACK

Figure 4

1. Put grease into the adjuster grease fitting until deflection is between 38 to 51 mm (1-1/2 to 2 inches).

Figure 5

BD02H016

2. Install the cap on the track adjuster.

1. Use a deep socket and loosen the large adapter two turns. DO NOT remove the large adapter. Let the grease come out until the track deflection is 38 to 51 mm (1-1/2 to 2 inches).

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

2. Tighten the large adapter 60 to 51 Nm (45 to 55 pound-feet).

4. Check the deflection of the track again and adjust as required.

3. Install the cap on the track adjuster.

5. Adjust the other track.

NOTE: During the operation of the machine, material can build up in the root of the sprocket forcing the bushing out of the sprocket tooth. When the bushing gets high enough it will move over one sprocket tooth causing a loud noise.

This problem can be reduced by loosening the track or installing relieved sprockets.

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

Check the track tension again.

5. Adjust the other track.

TRACK SHOE BOLTS - STEEL TRACK Check the torque of the track shoe bolts after the first 20 hours of operation with a new machine. Then, if the machine is new or if the track shoes have been removed, check the torque of the track shoe bolts every 100 hours of operation until the track shoes remain tight.

Tighten the standard link bolts 406 to 447 Nm (300 to 330 pound-feet) and 430 to 470 Nm (318 to 346 lb ft for the master link bolts.

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6-85641NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ENGINE VALVE CLEARANCE The engine valves should be checked by a service technician every 1000 hours.

WELDING ON THE MACHINE Whenever carrying out a welding operation on the crawler as authorized by the manufacturer and in accordance with correct procedures: 1. Disconnect the batteries.

2. Disconnect the alternator B+ and D+ terminal wires.

BD02M046

Figure 6

3. Disconnect the three deutsch connectors located to the right and above the battery behind the left rear access door. ROPS model shown.

NOTE: Cab models have the deutch connectors located slightly higher than the ROPS machines.

4. Connect the welding apparatus ground cable to the component on which the welding operation is to be performed.

IMPORTANT: Welding in certain areas of the crawler may require that the controller itself be disconnected and grounded. Contact your dealer.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

REVERSIBLE FAN POSITIONS (IF EQUIPPED) This fan has two positions, PUSHER and SUCTION. The fan blades can be rotated manually.

1. Stop the engine and put a Do Not Operate tag on the instrument panel.

7. Release the belt tensioner and install the right front side panel.

8. Remove the Do Not Operate tag.

2. Pull both parking brake levers back to the engaged position.

3. Turn the master disconnect to off.

4. Remove the left front engine side panel.

5. To rotate the fan as you change each blade, install a 1/2 inch breaker bar in the automatic belt tensioner. Lift up to release the belt tension.

6. Push in each fan blade, rotate to the required position, and release. Make sure each blade is in the LOCKED position.

IMPORTANT: Make sure all six blades are rotated to the same position before you start the engine.

Figure 8

BD02J086

Make sure all blades are rotated to the same position.

1

2

1

3

B911784J

Figure 7

1. AIR FLOW 2. SUCTION POSITION 3. PUSHER POSITION

NOTE: Spray a small amount of penetrating oil on the shaft of each blade at least five or six times a year. This action will help blade rotation.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

ROLL-OVER PROTECTIVE STRUCTURE Your machine has a roll-over protective structure (ROPS). A ROPS label shows the serial number of the ROPS, gross weight, approval, regulation, and model numbers of the machine. The label is on the left-hand side.

Before you operate this machine, always make sure that the ROPS and operators seat belt is correctly installed.

MAINTENANCE AND INSPECTION OF ROPS 1. Check the torque of the ROPS mounting bolts. If necessary, tighten the bolts to the correct torque.

See ROPS Torque Specifications in this manual.

2. Check the operators seat and the mounting parts for the seat belt. Tighten the bolts to the correct torque. See “Operators Seat” in this manual.

Replace the parts that have wear or damage.

3. Check for cracks, rust, or holes in the ROPS and ROPS parts. Age, weather, and accidents can cause damage to the ROPS and ROPS parts. If you have any doubt about the ROPS system, see your dealer.

SEAT BELT The seat belt is an important part of your ROPS. You must wear the seat belt at all times when you operate the machine.

Before you operate this machine, always make sure that the ROPS and operator’s seat belts are correctly installed.

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

SA080

DAMAGE TO THE ROPS If the machine has rolled over or the ROPS has been in some other type of accident (such as hitting an overhead object during transport), you must replace the damaged ROPS components to get as much protection as you had originally.

Before you operate the machine, replace all ROPS components that are damaged.

See the parts catalog or your dealer for components that can be replaced.

DO NOT TRY TO WELD OR STRAIGHTEN THE ROPS. WARNING: Do not modify ROPS in any manner. Unauthorized modifications such as welding, drilling, cutting or adding attachments can weaken the structure and reduce your protection. Replace ROPS if subjected to roll-over or damage. Do not attempt to repair.

SB026

WARNING: If you operate this machine without a ROPS and the machine rolls over, you can be injured or killed. Remove the ROPS only for service or replacement. Do not operate this machine with the ROPS removed.

SA027

WARNING: Adding additional weight (attachments, etc). to the machine can cause injury or death. Do not exceed the gross weight printed on the ROPS label.

SA028

WARNING: Improper ROPS inspection or maintenance can cause injury or death. Do the recommended ROPS inspection shown in this manual. If you must replace the ROPS, ROPS parts, or ROPS mounting hardware, use only the replacement parts shown in the Case parts catalog for this machine.

SA029

WARNING: Before you start the engine, always sit in the operators seat, fasten the seat belt, apply the parking brake, and make sure the transmission direction control is in NEUTRAL. Give a warning to all persons around you that you are starting the engine.

SB037

After an accident, check the following for damage.

A. ROPS canopy.

B. Lower ROPS frame.

C. Operator’ s seat.

D. Seat belt mounting and seat belt.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TORQUE SPECIFICATIONS

MACHINE CLEANING

Seat

It is recommended that the complete machine be kept clean. Machine operation in water, mud, dust, landfill, land clearing or forestry will require complete machine clean up. Cleaning includes periodically removal of inspection covers and guards to gain access for cleaning and removal of dirt or debris.

Clean all dirt and foreign material from the front engine guard. Dirt will cause rust on the engine oil pan and the loss of engine oil.

33.9 to 47.4 Nm (25 to 35 lb ft) - 2 per side Seat Belt Mounting Bolts - Both Sides 46.7 to 54.2 Nm (34 to 40 lb ft) - both sides ROPS Mounting Bolts - Both Sides 203 to 237 Nm (150 to 175 lb ft) - both sides

After cleaning is complete, install ALL covers and guards.

DO NOT operate machine with covers or guards removed.

WARNING: Replace all covers or guards after servicing or cleaning the machine.

NEVER operate the machine with covers or guards removed.

CM115

ADJUSTING THE RIPPER SHANKS

1 2 Figure 9

BC02M137

1. Remove the retaining clip (1).

2. Drive the pin (2) out and adjust the shank to the position desired.

3. Replace the pin and retaining clip.

The ripper shanks have three positions. Use the appropriate depth for the working condition.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

DOZER BLADE PITCH ADJUSTMENT 1. Raise dozer blade up approximately 100 mm (4 in).

6. The cover guard may be used as a tool to turn the turnbuckle.

2. Release the dozer blade control lever and shut the engine off.

7. Replace the cover guard and retaining pin.

3. Remove the ignition key and set the parking brakes.

WARNING: Be careful with this procedure and raise the blade only high enough to make the necessary adjustment.

REARWARD POSITION BLADE PITCHED REARWARD When dozer blade is pitched in the rearward position, the blade will be able to push a larger load. Blade will stay on top in soft ground.

REARWARD POSITION ADVANTAGES 1. Blade is able to push a larger load.

2. Blade will stay on top in soft ground.

3. Blade will not dig into the ground.

4. Blade best used for fine grading.

FORWARD POSITION BLADE PITCHED FORWARD

Figure 10

BD02J077

4. Remove the retaining pin to release the cover guard.

When dozer blade is pitched in the forward position, the load slides off of blade as crawler travels in reverse. Blade will dig into hard ground.

FORWARD POSITION ADVANTAGES 1. Load slides off of blade as the crawler travels in reverse.

2. Blade will dig into hard ground.

3. Less load spillage over top of blade.

Figure 11

BD02J079

5. Adjust the turnbuckle clockwise or counter clockwise until the desired pitch angle is reached.

Figure 12

BD02J078

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

FIRE EXTINGUISHER MOUNTING (IF EQUIPPED)

FAN AND AIR CONDITIONING DRIVE BELT

TYPE OF FIRE EXTINGUISHER

SERVICE INTERVAL

It is recommended that you have a fire extinguisher on your machine. The fire extinguisher shown below is available from your dealer and can be installed on the machine.

Check the tension of a new drive belt after the first 10 hours of operation.

Check tension . . . . . . . . . . . . . . . . . Every 250 hours

This dry chemical fire extinguisher has a 5 pound capacity and is approved for Class A, B and C type fires. The operating temperature is from -54° to 49°C (-65° to 120°F).

INSPECTION AND CARE EVERY MONTH - It is recommended that you inspect the fire extinguisher once each month for damage and to insure that the gauge is working correctly.

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

2. Turn the master disconnect to OFF. 3. Install a 1/2 inch breaker bar in the tension pulley bracket.

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

E V E RY 6 M O N T H S - H ave t h e d r y c h e m i c a l removed and refilled by a fire equipment technician.

ONCE EACH YEAR - Have the fire equipment technician inspect the fire extinguisher.

BD02M057

Figure 13

4. DO NOT mount the Fire Extinguisher on any part of the ROPS structure. DO NOT make any modifications to the ROPS structure.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

MACHINE STORAGE STORAGE PREPARATION

REMOVAL FROM STORAGE

If the machine is to be in storage for more than 30 days, park the machine inside a building. If a building is not available, park the machine in a dry area on planks and cover the machine with a waterproof covering.

Do not start the engine until steps 1 through 13 have been done.

1. Wash the machine.

2. Lubricate the machine at all grease fittings.

3. Paint any area where the paint has been damaged.

1. Change the fuel filters.

2. Put coolant in the engine cooling system.

3. Check the condition of the drive belt. Replace if required.

4. Check the engine oil level.

5. Check the hydraulic oil level.

4. Drain the fuel tank.

6. Check the transmission oil level.

5. Put approximately 8 liters (2 U.S. gallons) of diesel flushing oil in the fuel tank. Run the engine until the exhaust smoke is blue white.

7. Check the final drives oil level.

8. Lubricate the machine at all grease fittings.

7. Put 15 ml (one teaspoon) of Shell Oil Company VPI crystals in the fuel tank.

9. Use petroleum base solvent and remove the Case Rust and Corrosion Preventive from the hydraulic cylinder rods, equipment valve spools and transmission valve spools.

8. Move all hydraulic controls to relieve any pressure in the hydraulic circuits.

10. See Battery Service in this manual. Install the battery.

9. Change the engine oil and replace the oil filter.

11. Fill the fuel tank.

6. Drain the flushing oil from the fuel tank.

10. Drain the cooling system. Leave the drain valves open and do not tighten the radiator cap. Put a Do Not Operate tag on the instrument panel.

11. Clean the primary element for the air filter.

12. Cover the exposed cylinder rods, equipment valve spools, and transmission valve spools with Case Rust and Corrosion Preventive.

13. Charge the battery. Remove the battery from the machine and put the battery on a wooden pallet in a cool dry area. If possible, keep the battery in a building where the temperature is above freezing 0°C (32°F). Make sure the battery is clean.

12. Remove the air from the fuel system. See Removing Air from Fuel system in this manual.

13. If the machine is equipped with a turbocharger, you must prime the turbocharger oil lines with oil.

See Priming the Turbocharger in this manual.

14. Start the engine. It is important that you refer to the procedure on Starting the Engine in this manual.

NOTE: Check the battery periodically for the correct electrolyte level. Test the electrolyte with a hydrometer. When the hydrometer reading is near 1.215, charge the battery.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REAR ATTACHMENT TORQUE VALUES

Figure 14

BD02J032

Ripper ................................................................................................................. 1 300 to 1 160 Nm (855 to 960 ft lb)

BD02M132

Figure 15

Drawbar . . . . . . 1 300 to 1 160 Nm (855 to 960 ft lb)

6-12

Figure 16

BD02M171

Hitch . . . . . . . . . . . . 430 to 485 Nm (315 to 355 ft lb)

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CHAPTER 7 - ELECTRICAL

Chapter 7 ELECTRICAL TABLE OF CONTENTS ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3 7-3 7-3 7-4 7-4 7-4

FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Additional Fuse Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal of the instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation of the instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing a bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-7 7-7 7-7 7-7

ACCESSORY OUTLETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

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CHAPTER 7 - ELECTRICAL

NOTES

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CHAPTER 7 - ELECTRICAL

ELECTRICAL SYSTEM BATTERY SAFETY

WARNING: Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: 1. When you DISCONNECT the battery cables, always disconnect the negative (1) battery cable first.

2. When you CONNECT the battery cables, always connect the negative (-) cable last.

3. Do not short circuit the battery posts with metal items.

4. Do not weld, grind, or smoke near a battery.

WARNING: Batteries give off explosive gases. Keep all open flames, sparks and cigarettes away. Ensure adequate ventilation when charging batteries or when using in a confined place. Always protect your eyes when working near batteries.

SAFETY_ID_1C02

WARNING: Do not reverse battery terminals. Connect positive cable ends to positive (+) terminals and negative cable ends to negative terminals (-).

SAFETY_ID_1C02

SB034

WARNING: Before you service a battery, always wear face protection, protective gloves and protective clothing. Battery acid or battery explosion can cause serious injuries.

BATTERY SERVICE

SA046

WARNING: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote EXTERNAL: flush with water.

INTERNAL: drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately.

EYES: flush with water for 15 minutes and get prompt medical attention.

SB032

WARNING: When the battery electrolyte is frozen, the battery can explode if, (1) you try to charge the battery, or (2) you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.

SA033

WARNING: Before any operation on the components of the electrical circuit, put the key switch in the shut down position. When disconnecting the battery cables, always disconnect the negative (-) cable first. When reconnecting the battery cables, always connect the negative (-) cable last.

SAFETY_ID_1C02

WARNING: Connecting auxiliary cables wrongly or short-circuiting batteries terminals can cause an accident. Connect auxiliary starting cables as per the following instructions.

1

BD02J017

2

Figure 1

1. NEGATIVE BATTERY CABLE 2. POSITIVE BATTERY CABLE

NOTE: The electrical system in this machine is 12 volts negative ground.

Before you service components of the electrical system, always disconnect the NEGATIVE (-) battery cable.

Dirt, moisture, and corrosion on the battery will discharge the battery. Clean the battery with Case Battery Saver and Cleaner. Follow the instructions on the can.

Disconnect the alternator wires if you must run the engine with the battery wires disconnected.

Before you use an electric welder, disconnect the alternator wires, instrument cluster, and turn the master disconnect switch to OFF. Do not use a steam cleaner or cleaning solvent to clean the alternator.

SAFETY_ID_1C02

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CHAPTER 7 - ELECTRICAL BATTERY FLUID LEVEL Check the fluid level of the batteries every 500 hours of operation. If the fluid level is low, add clean or distilled water to each cell until the fluid level is at the split ring at the bottom of each cell opening.

In extreme heat conditions check battery fluid every 250 hours.

IMPORTANT: If the temperature is 0°C (32°F) or below and you have added water to the batteries, do the following; Connect a battery charger to the batteries or operate the machine for approximately two hours. This procedure is necessary to mix the water with the electrolyte.

BATTERY VENTS Keep the battery vents clean, make sure the vents are not restricted.

CLEANING THE BATTERIES Check the batteries and batter y compar tment regularly for dirt, corrosion and damage. Dirt mixed with electrolyte or moisture on the top of the batteries can cause a discharged condition in the batteries.

Use one of the following methods to clean the batteries.

1. Use Case Battery Saver, Part Number M20376.

Follow the instructions on the container. This cleaner does not need water.

Use baking soda or ammonia and flush the outside of the batteries with water. If you do not have Case Battery Saver, use other special cleaners to prevent corrosion on the battery terminals.

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CHAPTER 7 - ELECTRICAL

FUSES AND RELAYS

3

4

5

6

7

8

9

10

11

12

13

1

2

A B C D E F G H J K L M

Figure 2

BD02J104 / BD99M013

1.

2.

3.

4.

5.

6.

7.

INJECTION PUMP RELAY STARTER RELAY HEATER/SEAT BACK UP ALARM FLEET MANAGEMENT BRAKE FNR (FORWARD,NEUTRAL,REVERSE)

8.

9.

10.

11.

12.

13.

NEUTRAL OK AC TRACTOR SAFETY CAB DRIVETRAIN CONTROLLER

A. Not Used

G. Drivetrain Controller 1 amp

B. Cab Unswitched Power 30 amp

H. Safety Relay 25 amp

C. Not Used

J. Tractor Relay 30 amp

D.Heater/Seat Relay 30 amp

K. 30 amp

E. Brake/Back Up Relay 10 amp

L. Cab Relay 10 amp

F. FNR DirectionControl 1 amp

M. Ignition Switch 10 amp

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CHAPTER 7 - ELECTRICAL ADDITIONAL FUSE LOCATIONS

BD02K011

Figure 3

Figure 4

BD02K010

Additional fuses are located on the left-hand side of the front console. Remove the cover for access.

Figure 5

FSETIF

F1B - Front Lights Switch ................................................................................................................................. 10A F2B - Blower & AC Switch................................................................................................................................ 20A F3B - Right- Hand Door Wiper Switch, Motor ................................................................................................. 7.5A F4B - Left- Hand Door Wiper Switch, Motor, Washer Switch and Motor......................................................... 7.5A F5B - Rear Wiper Switch, Motor ..................................................................................................................... 7.5A F6B - Front Wiper Switch, Motor, Front/Rear Washer Switch, Motor .............................................................. 7.5A F7B - AC Relay for Condenser Fans, AC Clutch .............................................................................................. 20A F8B - ......................................................................................................................................................... optional F9B - Heater Control Module ............................................................................................................................. 3A F10B - ....................................................................................................................................................... optional F11B - ...................................................................................................................................................... not used F1A - Microcontroller, Heater, Seat, Cab Relay ................................................................................................. 5A F2A - Proximity Switches, Injector Pump, Hold Relay ........................................................................................ 5A F3A - Start/Injector Relays ................................................................................................................................. 5A F4A - Instrument Cluster Power, Buzzer ............................................................................................................ 5A F5A - Lighter/Radio (Cab) ................................................................................................................................ 15A F6A - Horn Switch + Unswitched Battery Power to Instrument Cluster........................................................... 7.5A F7A - ........................................................................................................................................................ not used F8A - ........................................................................................................................................................ not used F9A - Lighter/12v Jack, Radio Memory, Interior Lights ...................................................................................... 7.5 F10A.......................................................................................................................................................... not used F11A - Rear Light Switch ................................................................................................................................. 10A

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CHAPTER 7 - ELECTRICAL

INSTRUMENT CLUSTER REMOVAL OF THE INSTRUMENT CLUSTER 1. Turn the master disconnect off.

2. Loosen and remove the 2 screws that fasten the instrument cluster in the console.

4

3. Pull the instrument cluster out of the console far enough to disconnect the electrical connector from the rear of the instrument cluster.

4. Disconnect the electrical connector from the socket on the rear of the instrument cluster and remove the instrument cluster from the console.

INSTALLATION OF THE INSTRUMENT CLUSTER 1. Reverse the removal instructions to re-install the cluster.

REPLACING A BULB

BD00H150

Figure 8

4. Turn the socket assembly (4) counter clockwise to remove. The bulb and the socket assembly (4) are ser viced together. Replace the socket assembly (4) as required.

1. Remove the instrument cluster from the console.

Figure 6

BD00H152

2. Remove the 2 screws that fasten the rear cover to the frame.

1 2 3

Figure 7

BD00H151

3. Remove the rear cover (1) from the frame (2).

NOTE: Make sure the O-ring (3) is in the correct position on the rear cover (1) before the rear cover (1) is installed onto the frame (2).

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CHAPTER 7 - ELECTRICAL

ACCESSORY OUTLETS There is one 12 volt accessory outlet behind the seat on ROPS models.

Cab models have two outlets, one behind and to the left of the operator, shown below, and one near the right arm of the operator, not shown.

BDO2H130

Figure 9

1. 12 VOLT ACCESSORY OUTLET BEHIND OPERATOR IN CAB

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CHAPTER 8 - SPECIFICATIONS

Chapter 8 SPECIFICATIONS TABLE OF CONTENTS ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 TRAVEL SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 TRACK SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 TRANSPORT LENGTH AND WIDTH WITH BLADE FULLY ANGLED 25 DEGREES . . . . . . . . . . . . . . . . . . . . 8-5 OPERATING DATA AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 OPERATING DATA AND DIMENSIONS - RIPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Additional Weights of Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

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CHAPTER 8 - SPECIFICATIONS

ENGINE SPECIFICATIONS NOTE: All specifications are given according to SAE Standards or Recommended Practices where the specification applies.

Make and Model 650K Series 2 / 750K Series 2.......................................................................................... 445T/M2 850K Series 2 .......................................................................................................................................668T/M2 Firing Order 650K Series 2 / 750K Series 2 ................................................................................................... 1-3-4-2 850K Series 2 ...................................................................................................................................1-5-3-6-2-4 Bore and Stroke 650K Series 2 / 750K Series 2 .................................................... 104 x 132 mm (4.09 in x 5.20 in) 850K Series 2 ................................................................................................. 104 x 132 mm (4.09 in x 5.20 in) Displacement 650K Series 2 / 750K Series 2......................................................... 4.5 L, 4 485 cm3 (274 cubic inch) 850K Series 2 ................................................................................................ 6.8 L, 6 729 cm3 (411 cubic inch) Compression Ratio 650K Series 2 / 750K Series 2...................................................................................... 17.0 to 1 850K Series 2 ...................................................................................................................................... 17.0 to 1 Horsepower, Max. Rated Gross @ 2 000 rpm 650K Series 2 .......................................................................................................................... 60.0 kW (80 hp) 750K Series 2 ........................................................................................................................... 67.1 kW (90 hp) 850K Series 2 ........................................................................................................................... 73.8 kW (99 hp) Engine Speeds High Idle All Models ................................................................................................................. 2 170 to 2 270 rpm Rated Speed All Models......................................................................................................................... 2 000 rpm Low Idle All Models ..................................................................................................................... 800 to 1 050 rpm NOTE: All specifications were reached using Number 2 diesel fuel.

HYDRAULIC SYSTEM System Relief Pressure ............................................................................ 20 340 to 21 370 kPa (2 950 to 3 100 psi) Pump Capacity .................................................................................. 20.3 gal/min @ 3 000 psi @ 2 000 engine rpm

TRAVEL SPEEDS Speeds Forward ..........................................................................Infinitely variable from 0 to 9.7 km/h (0 to 6.0 mph) Speeds Reverse ..........................................................................Infinitely variable from 0 to 9.7 km/h (0 to 6.0 mph) Track Pull (Maximum / Both Tracks....................................................................................... 186 824 N (42 000 LBF) NOTE: Track speed and track pull are with CLT chain. If machine is equipped with CELT chain speed will be reduced 4% and track pull will be increased 4%.

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TRACK SYSTEM Track Gauge 650K Series 2 LT ........................................................................................................................ 1 448 mm (57 in) 650K Series 2 WT & LGP ............................................................................................................1 702 mm (67 in) 750K Series 2 / 850K Series 2 LT ................................................................................................1 575 mm (62 in) 750K Series 2 / 850K Series 2 WT & LGP...................................................................................1 778 mm (70 in) Track Rollers Per Side 650K Series 2 / 750K Series 2 .............................................................................................................................. 6 850K Series 2........................................................................................................................................................ 7 Length of Track on Ground (With Standard CASE Lubricated Track) 650K Series 2............................................................................................................................2 230 mm (87.8 in) 750K Series 2............................................................................................................................2 266 mm (89.2 in) 850K Series 2............................................................................................................................2 352 mm (92.6 in) Length of Track on Ground (With Optional CASE Extended Life Track) 650K Series 2............................................................................................................................2 251 mm (88.6 in) 750K Series 2............................................................................................................................2 288 mm (90.1 in) 850K Series 2............................................................................................................................2 373 mm (93.4 in) Number of Track Shoes Per Side 650K Series 2...................................................................................................................................................... 38 750K Series 2...................................................................................................................................................... 39 850K Series 2...................................................................................................................................................... 40 Number of Carrier Rollers Per Side All Models ........................................................................................................ 1 Ground Pressure with CLT chain 650K Series 2 LT (57 “ Gauge / 98 “ Blade w/ 406 mm (16 in) shoe) .................................... 44.61 kPa (6.47 psi) 650K Series 2 WT (67 “ Gauge / 110 “ Blade w/ 559 mm (22 in) shoe)..................................33.99 kPa (4.93 psi) 650K Series 2 LGP (67 “ Gauge / 120 “ Blade w/ 635 mm (25 in) shoe .................................30.54 kPa (4.43 psi) 750K Series 2 LT (62 “ Gauge / 104 “ Blade w/ 457 mm (18 in) shoe.....................................40.54 kPa (5.88 psi) 750K Series 2 LT (62 “ Gauge / 104 “ Blade w/ 508 mm (20 in) shoe.....................................39.96 kPa (5.36 psi) 750K Series 2 WT (70 “ Gauge / 120 “ Blade w/ 610 mm (24 in) shoe...................................31.78 kPa (4.61 psi) 750K Series 2 LGP (70 “ Gauge / 124 “ Blade w/ 711 mm (28 in) shoe .................................27.85 kPa (4.04 psi) 850K Series 2 LT (62 “ Gauge / 104 “ Blade w/ 457 mm (18 in) shoe.....................................40.13 kPa (5.82 psi) 850K Series 2 LT (62 “ Gauge / 104 “ Blade w/ 508 mm (20 in) shoe.....................................36.54 kPa (5.30 psi) 850K Series 2 WT (70 “ Gauge / 120 “ Blade w/ 610 mm (24 in) shoe...................................31.30 kPa (4.54 psi) 850K Series 2 LGP (70 “ Gauge / 124 “ Blade w/ 711 mm (28 in) shoe .................................27.58 kPa (4.00 psi) NOTE: If machine is equipped with optional CELT chain ground pressure will be 0.7 kPa (0.1 psi) greater.

CASE Lubricated Track (CLT)...................................................................................................................... Standard CASE Extended Life Track (CELT) ................................................................................................................ Optional LT = Long Track WT = Wide Track LGP = Low Ground Pressure

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TRANSPORT LENGTH AND WIDTH WITH BLADE FULLY ANGLED 25 DEGREES

Figure 1

BS02K072

Blade width

A Transport width

B 650K Series 2 w/o Drawbar

B 750K Series 2 w/o Drawbar

B 850K Series 2 w/o Drawbar

2 489 mm (98 in)

2 308 mm

90.9 in

4 618 mm

181.8 in

2 642 mm (104 in)

2 446 mm

96.3 in

4 649 mm

183.0 in

4 696 mm

184.9 in

4 782 mm

188.3 in

2 794 mm (110 in)

2 585 mm

101.8 in

4 682 mm

184.3 in

4 728 mm

186.1 in

4 814 mm

189.5 in

3 048 mm (120 in)

2 815 mm

110.8 in

4 736 mm

186.5 in

4 782 mm

188.3 in

4 868 mm

191.7 in

3 150 mm (124 in)

2 907 mm

114.4 in

4 757 mm

187.3 in

3 302 mm (130 in)

3 043 mm

119.8 in

4 803 mm

189.1 in

4 889 mm

192.5 in

4 835 mm

190.4 in

4 921 mm

193.7 in

NOTE: Add 150 mm (5.9 in) for drawbar.

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OPERATING DATA AND DIMENSIONS

Figure 2

BS02K102

A. Top of Exhaust Stack 650K Series 2 / 750K Series 2 ...........................................................2 624 mm (103.3 in) 850K Series 2 .....................................................................................................................2 614 mm (102.9 in) B. Blade Height .................................................................................................................................914 mm (36 in) C. Ground Clearance at Belly Pans 650K Series 2 ........................................................................383 mm (15.1 in) 750K Series 2 / 850K Series 2.................................................................................................379 mm (14.9 in) D. Shank Height (Transport Position) .............................................................................................450 mm (17.3 in) E. Top of Seat Head Rest ............................................................................................................2 229 mm (87.8 in) F. Height of Cab w/o Air Conditioning ...................................................................................... 2 773 mm (109.2 in) with Air Conditioning ...........................................................................................................2 788 mm (109.8 in) ROPS Height ......................................................................................................................2 773 mm (109.2 in) G. Blade Depth Below Ground ...................................................................................................... 495 mm (19.5 in) Blade Angle Both Directions ................................................................................................... 0 to 25 Degrees Blade Tilt, Each End (0 to 8.3 Degrees) ....................................................................................356 mm (14 in) NOTE: Ground clearance and overall height dimensions are with the Grouser fully penetrated per SAE J1234.

Add 52.5 mm (2.06 in) if machine is on solid surface.

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Figure 3

BS02K101

A. Length, no blade, no rear equipment and CLT chain 650K Series 2 .....................................................................................................................3 076 mm (121.1 in) 750K Series 2 .................................................................................................................... 3 153 mm (124.1 in) 850K Series 2 .................................................................................................................... 3 261 mm (128.4 in) Width - Blade Angled ...........................................................................................................2 530 mm (99.7 in) B. Overall Length, blade straight, no rear equipment 650K Series 2 .....................................................................................................................4 126 mm (162.4 in) 750K Series 2 .....................................................................................................................4 171 mm (164.2 in) 850K Series 2 .....................................................................................................................4 258 mm (167.6 in) C. Overall Length, blade straight, w/drawbar 650K Series 2 .....................................................................................................................4 276 mm (168.3 in) 750K Series 2 .....................................................................................................................4 322 mm (170.2 in) 850K Series 2 .....................................................................................................................4 408 mm (173.5 in) D. Overall Length, blade straight, w/ripper 650K Series 2 .....................................................................................................................5 101 mm (200.8 in) 750K Series 2 .....................................................................................................................5 147 mm (202.6 in) 850K Series 2 .....................................................................................................................5 233 mm (206.0 in) NOTE: Overall Length is with blade pitch at 55 degrees (factory setting). If blade pitch is adjusted to 60 degrees length will decrease 15 mm (0.6 in).

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CHAPTER 8 - SPECIFICATIONS

OPERATING DATA AND DIMENSIONS - RIPPER Overall Width (Maximum) .............................................................................................................1 839 mm (72.4 in) Width of Cut (Maximum) ...............................................................................................................1 781 mm (70.1 in) Dig Depth (Maximum) ......................................................................................................................363 mm (14.3 in) Ground Clearance (lowest position transport) ..................................................................................302 mm (11.9 in) Number of Teeth (Standard) ...................................................................................................................................... 3 Number of Teeth (Maximum) ................................................................................................................................... 5 Torque (rear mounted equipment) ...................................................................... 1 300 to 1 160 Nm (855 to 960 ft lb)

WEIGHTS OPERATING WEIGHT Operating weights include ROPS full fuel and hydraulic tank, 77 kg (170 lb) operator, CLT chain, front and rear pull hooks, side shields, track guides.

650K Series 2 LT w/16 in shoes and 98 in blade...................................................................... 8 244 kg (18 177 lbs) 650K Series 2 LGP w/25 in shoes and 120 in blade ................................................................ 8 813 kg (19 433 lbs) 750K Series 2 LT w/18 in shoes and 104 in blade.................................................................... 8 569 kg (18 895 lbs) 750K Series 2 LGP w/28 in shoes and 124 in blade ................................................................. 9 157 kg (20 191 lbs) 850K Series 2 LT w/20 in shoes and 104 in blade..................................................................... 8 902 kg (19 629 lbs) 850K Series 2 LGP w/28 in shoes and 124 in blade ................................................................. 9 399 kg (20 724 lbs) ADDITIONAL WEIGHTS OF OPTIONAL EQUIPMENT Approximate Add-On Weight Dual Batteries for ROPS or CAB ........................................................................................................... 29 kg (64 lbs) Rear Screen (For Cab) .......................................................................................................................... 32 kg (71 lbs) Center Rockguards 650K Series 2 ...................................................................................................... 72 kg (159 lbs) Center Rockguards 750K Series 2 .................................................................................................... 100 kg (221 lbs) Center Rockguards 850K Series 2 .................................................................................................... 106 kg (234 lbs) ROPS Canopy or Cab Canopy Brush Guard....................................................................................... 47 kg (104 lbs) Forestry Side Screens ........................................................................................................................... 35 kg (77 lbs) Hydraulic Equipment Pump w/PTO ....................................................................................................... 24 kg (53 lbs) Heater for ROPS Unit ............................................................................................................................ 32 kg (71 lbs) 4 Spool Valve w/Plugs (Mechanical Controls) ......................................................................................... 8 kg (18 lbs) Tractor Lift Hooks..................................................................................................................................... 5 kg (11 lbs) Front Counterweight w/Pull Hook ...................................................................................................... 399 kg (880 lbs) Radiator Brush Screen ............................................................................................................................ 8 kg (18 lbs) Allied Equipment Add-On Weight Winch (Carco Model 30B-PS.......................................................................................................... 454 kg (1 000 lbs) Winch (Hyster Model W3C ............................................................................................................. 612 kg (1 350 lbs) Log Arch (Hyster) .............................................................................................................................. 227 kg (500 lbs)

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CHAPTER 9 - INDEX

Chapter 9

INDEX A Access Doors ...................................................... 5-9 Accessory Outlet ................................................. 7-8 Adjustable Cab Dome Light ............................... 3-17 Air Filter System ................................................ 5-13 Cleaning the Primary (Outer) Element .......... 5-15 Primary (Outer) Element ............................... 5-13 Secondary (Inner) Element ........................... 5-14 Service Specifications ................................... 5-13 Warning Lamp ............................................... 5-13

B Backrest Tilt Adjustment Lever .......................... 3-15 Battery Cleaning .......................................................... 7-4 Fluid Level ....................................................... 7-4 Safety .............................................................. 7-3 Service ............................................................ 7-3 Vents ............................................................... 7-4 Before Operation Safety ...................................... 2-3 Before You Start Each Day ................................. 4-6 Blade Lift Eye .................................................... 4-28 Booster Battery Connection to Machine Battery 4-24 Brake Release for Towing ................................. 4-18 Burn Prevention Safety ........................................ 2-6 Bushing and Sprocket Wear Chart .................... 4-35

C Cab Door Release/Lock .................................... 3-16 Cab Tilt Hydraulic Jack ...................................... 3-20 Cab Tilt System Oil ............................................ 4-26 Cab Vent ............................................................ 3-17 Carrier Roller ..................................................... 4-29 Case Extended Life Track (CELT) ..................... 4-31 Cleaning Cooling System .................................. 5-18 Cleaning the Primary (Outer) Element .............. 5-15 Climate Control Operation ................................. 4-16 Climate Control Panel ........................................ 3-17 Coat Hanger ...................................................... 3-17 Components of the Undercarriage .................... 4-29 Carrier Roller ................................................. 4-29 Drive Sprocket ............................................... 4-29 Idler ............................................................... 4-29 Recoil Spring Housing ................................... 4-29 Track Adjuster (Steel Track) ......................... 4-29 Track Chain ................................................... 4-29 Track Frame .................................................. 4-29 Track Links .................................................... 4-30 Track Rollers ................................................. 4-29 Track Shoes .................................................. 4-30 6-85641NA

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Control Handle Positions ....................................3-14 Coolant Levels Coolant Reservoir ..........................................5-17 Radiator .........................................................5-17 Coolant Reservoir ...............................................5-17 Coolant Solution, Engine Cooling System ..........5-17 Crawler Operation ................................................4-6 Before You Start Each Day ..............................4-6 Power Turn .......................................................4-8 Steering Gradual Turn ......................................4-8 Transmission Control Levers ...........................4-8

D Decelerator Pedal .................................................3-9 Decelerator Pedal Operating Instructions ..........4-11 Diagnostics/Computer Operation .......................4-12 Diesel Fuel System ............................................5-19 Draining Water and Sediment ........................5-19 Fuel Line Shutoff Valve ..................................5-19 Fuel Tank Breather ........................................5-21 Removing Air From the Fuel System .............5-20 Service Specifications ....................................5-19 Digital Display .......................................................3-8 Direction Control Lever .......................................3-10 Display-Service/Enter Switch ...............................3-4 Dozer Blade Control Lever .................................3-12 Angle Left .......................................................3-12 Angle Right ....................................................3-12 Float ...............................................................3-12 Hold ................................................................3-13 Lift ..................................................................3-12 Lower .............................................................3-12 Tilt Left ...........................................................3-12 Tilt Right .........................................................3-12 Dozer Operation .................................................4-28 Draining Water and Sediment ............................5-19 Drive Sprocket ....................................................4-29 Ductile Iron Safety ................................................2-8

E Electrical Service Accessory Outlet ..............................................7-8 Electrical System ..................................................7-3 Engine Hourmeter ........................................................5-4 Specifications ...................................................8-3 Engine Coolant Heater .......................................4-23 Engine Cooling System ......................................5-17 Cleaning Cooling System ...............................5-18 Coolant Solution .............................................5-17 9-1

CHAPTER 9 - INDEX Service Specifications ................................... 5-17 Engine Hand Throttle ......................................... 3-11 Engine Lubrication ............................................. 5-10 Engine Oil Selection ...................................... 5-10 Engine Oil Heater .............................................. 4-23 Engine Oil Level ................................................ 5-11 Engine Oil Selection .......................................... 5-10 Engine Operation .......................................... 4-3, 4-4 Engine Speed .................................................. 4-4 Parking the Machine and Stopping the Engine 4-5 Starting the Engine .......................................... 4-4 Engine Service .................................................. 5-11 Engine Oil Level ............................................ 5-11 Engine Service Specifications ....................... 5-11 Oil Change and Filter Replacement .............. 5-11 Priming the Turbocharger Oil Lines with Oil .. 5-12 Engine Service Specifications ........................... 5-11 Engine Speed ...................................................... 4-4 Engine Starting Aids .......................................... 4-22 Ether Start Aid Engine Coolant Heater .................................. 4-23 Engine Oil Heater .......................................... 4-23 Ether Starting Fluid .............................................. 6-4 Extinguisher Mounting, Fire ............................... 6-10

F Factors Controlling Undercarriage Wear ........... 4-30 Wear Factors You Can Control ..................... 4-32 Wear Factors You Can Not Control .............. 4-31 Factors Controlling Undercarriage Wear - Wear Factors You Can Not Control ...................... 4-31 Filter Engine ........................................................... 5-11 Hydraulic ....................................................... 5-22 Transmission ................................................. 5-24 Final Drives ........................................................ 5-26 Oil Change .................................................... 5-26 Oil Level Check ............................................. 5-26 Service Specifications ................................... 5-26 Fire and Explosion Prevention Safety ................. 2-7 Fire Extinguisher Mounting ................................ 6-10 Fire Extinguisher Safety ...................................... 2-6 Fluid and Lubricants ............................................ 5-5 Fluid Level Check Hydraulic System .......................................... 5-22 Transmission ................................................. 5-24 Forward/Rearward Adjustment Lever ................ 3-15 Front Console Key/Ignition Switch .......................................... 3-5 Fuel guage monitor, no power ............................. 3-4 Fuel Line Shutoff Valve ..................................... 5-19 Fuel Tank Breather ............................................ 5-21 Fuel Warning Lamp ............................................. 3-7 9-2

G General Information ..............................................1-1 General Safety .....................................................5-3

H Hazardous Chemicals Safety ...............................2-6 Horn ......................................................................3-4 Hourmeter, Engine ...............................................5-4 How to Extend the Life of Sealed Track and the Case Lubricated Track (CLT) ................................4-31 Hydraulic Filter ...................................................5-22 Hydraulic Fluid Change ............................ 5-23, 5-25 Hydraulic System ...............................................5-22 Fluid Level Check ..........................................5-22 Hydraulic Filter ...............................................5-22 Hydraulic Fluid Change ........................ 5-23, 5-25 Relief and Check Valves Service ...................5-23 Service Specifications ....................................5-22 Specifications ...................................................8-3

I Identification Numbers Engine ..............................................................1-3 Product Identification Number (P.I.N.) .............1-3 ROPS Canopy .................................................1-4 Transmission ....................................................1-4 Idler ....................................................................4-29 Instructions, General Safety .................................5-3 Instrument Panel ..................................................3-3 Water Temperature Gauge ..............................3-7 Instruments/Controls Dozer Blade Control Lever .............................3-12 Control Handle Positions ...........................3-14 Operators Seat ...............................................3-15 Operators Seat Belt .......................................3-21 Ripper Control Lever ......................................3-14 Interior Cab Door Release ..................................3-16

K Key Switch, Ignition ..............................................3-5

L Lifting the crawler ...............................................4-21 Lowering the cab ................................................4-27 Lubrication/Filters/Fluid Air Filter System .............................................5-13 Engine Cooling System ..................................5-17 Engine Service ...............................................5-11 Final Drives ....................................................5-26 Hydraulic System ...........................................5-22 Transmission ..................................................5-24 Lubrication/Filters/Fluids Access Doors ...................................................5-9 Diesel Fuel System ........................................5-19 Issued 12-05

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CHAPTER 9 - INDEX Engine Lubrication ........................................ 5-10 Fluid and Lubricants ........................................ 5-5 Transmission ................................................. 5-24

P

M Machine Cleaning ................................................ 6-8 Machine Components .......................................... 1-5 Machine Operation Safety ................................... 2-5 Machine Storage ............................................... 6-11 Removal From ............................................... 6-11 Storage Preparation ...................................... 6-11 Maintenance Safety ............................................. 2-8 Maintenance/Adjustments Ether Starting Fluid ......................................... 6-4 Machine Cleaning ........................................... 6-8 Reversible Fan Positions ................................ 6-6 Roll-Over Protective Structure ........................ 6-7 Seat Belt .......................................................... 6-7 Spark Arrester Muffler ..................................... 6-8 Torque Specifications for Seat and Seat Belt Mounting Bolts ........................................ 6-8 Master disconnect switch .................................. 3-20 Menu Up/Down Switch ........................................ 3-4

N Next Service to (NONE) .................................... 4-15

O Oil Change Engine ........................................................... 5-11 Final Drives ................................................... 5-26 Oil Level Check Final Drives ................................................... 5-26 Oil Viscosity/Temperature Ranges .................... 5-10 Operating Data and Dimensions Long Track (LT) and Rubber Track Crawlers .. 8-6 Ripper .............................................................. 8-8 Operating in Cold Weather ................................ 4-22 Engine Starting Aids ...................................... 4-22 Operating in Hot Weather .................................. 4-22 Operating Instructions ......................................... 4-4 Booster Battery Connection to Machine Battery ...

4-24 Crawler Operation ........................................... 4-6 Dozer Operation ............................................ 4-28 Operating in Cold Weather ............................ 4-22 Operating in Hot Weather ............................. 4-22 Run-In Period of a New Machine .................... 4-3 Track Systems .............................................. 4-29 Transporting the Machine ............................. 4-20 Vandal Lockup .............................................. 3-20 Operating Weight ................................................. 8-8 Operators Seat Belt ........................................... 3-21 Optional Equipment Weights ........................................................... 8-8 6-85641NA

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Parking Brake Levers ...........................................3-9 Parking the Machine and Stopping the Engine ....4-5 Parking The Machine Safety ................................2-6 Personal Safety ....................................................2-4 Plastic and Resin Parts ........................................5-4 Power Turn ...........................................................4-8 Pressure Relief Valves .......................................4-17 Primary (Outer) Element ....................................5-13 Priming the Turbocharger Oil Lines with Oil .......5-12

R Radiator ..............................................................5-17 Rear Attachment Torque Values ........................6-12 Recoil Spring Housing ........................................4-29 Relief and Check Valves Service .......................5-23 Removing Air From the Fuel System .................5-20 Reverse/Forward Speed Ratio Control ..............3-11 Reversible Fan Positions ......................................6-6 Ripper Operating Data and Dimensions ......................8-8 Ripper Control Lever ..........................................3-14 Hold ................................................................3-14 Lower .............................................................3-14 Raise ..............................................................3-14 Ripper Shank Adjustment .....................................6-8 Roll-Over Protective Structure ..............................6-7 ROPS Damage To ......................................................6-7 Maintenance and Inspection ............................6-7 RPM display .........................................................3-4 Run-In Period of a New Machine .........................4-3 Track Shoe Bolts ..............................................4-3

S Safety Decals .......................................................2-9 Safety Instructions, General .................................5-3 Safety, Battery ......................................................7-3 Safety, Decals, and Hand Signals Personal Safety ................................................2-4 Safety Rules .....................................................2-3 Utility Safety .....................................................2-4 Safety/Decals/Hand Signals Before Operation ..............................................2-3 Burn Prevention ...............................................2-6 Ductile Iron .......................................................2-8 Fire and Explosion Prevention .........................2-7 Fire Extinguisher ..............................................2-6 Hazardous Chemicals ......................................2-6 Machine Operation ...........................................2-5 9-3

CHAPTER 9 - INDEX Maintenance .................................................... 2-8 Parking The Machine ...................................... 2-6 Safety Decals .................................................. 2-9 Seat Belt .............................................................. 6-7 Torque Specifications ...................................... 6-8 Seat Comfort Control ......................................... 3-15 Seat Lumbar Control ......................................... 3-16 Secondary (Inner) Element ................................ 5-14 Service Interval Change .................................... 4-14 Service Reminder (AUTO) ................................. 4-13 Service Reminder (MAN) ................................... 4-14 Service Reminder Activation to (AUTO) ............ 4-15 Service Reminder Activation to (MAN) .............. 4-15 Service Reminder Reset .................................... 4-14 Service Soon Lamp ............................................. 3-3 Service Specifications ....................................... 5-13 Diesel Fuel System ....................................... 5-19 Engine Cooling System ................................. 5-17 Final Drives ................................................... 5-26 Hydraulic System .......................................... 5-22 Transmission ................................................. 5-24 Shuttle Parameter Adjustment ............................. 4-9 Sides of the machine Right-hand, left-hand, front, and rear .............. 1-2 Spark Arrester Muffler ......................................... 6-8 Specifications Engine Specifications ...................................... 8-3 Hydraulic System ............................................ 8-3 Operating Data and Dimensions .............. 8-6, 8-8 Track System .................................................. 8-4 Travel Speeds ................................................. 8-3 Weights ........................................................... 8-8 Standard Seat Controls Backrest Tilt Adjustment Lever ..................... 3-15 Forward/Rearward Adjustment Lever ........... 3-15 Starting the Engine .............................................. 4-4 Steering Gradual Turn ......................................... 4-8 Steering Sensitivity Adjustment ........................... 4-9 Storage Machine Storage ........................................... 6-11 Preperation .................................................... 6-11 Removal From ............................................... 6-11 Sun Visor, Front ................................................. 3-17 Sun Visor, Rear ................................................. 3-18 Switch Key/Ignition ..................................................... 3-5

T Tilting the cab .................................................... 4-25 To the Owner ....................................................... 1-1 Torque Specifications Seat Belt Mounting Bolts ................................. 6-8 Towing a Disabled Crawler 9-4

Releasing the Brakes .....................................4-17 Track Adjuster (Steel Track) ...............................4-29 Track Chain ........................................................4-29 Track Frame .......................................................4-29 Track Links .........................................................4-30 Track Rollers ......................................................4-29 Track Shoe Bolts ..................................................4-3 Track Shoe Bolts - Steel Track .............................6-4 Track Shoes .......................................................4-30 Track System Specifications ...................................................8-4 Track Systems ....................................................4-29 Blade Lift Eye .................................................4-28 Bushing and Sprocket Wear Chart ................4-35 Case Extended Life Track (CELT) .................4-31 Components of the Undercarriage .................4-29 Factors Controlling Undercarriage Wear .......4-30 Factors Controlling Undercarriage Wear - Wear Factors You Can Not Control ................4-31 How to Extend the Life of Sealed Track and the Case Lubricated Track (CLT) ................4-31 Track Shoe Bolts - Steel Track ........................6-4 Wear Factors You Can Control ......................4-30 Transmission ......................................................5-24 Fluid Level Check ..........................................5-24 Service Specifications ....................................5-24 Transmission Filter .........................................5-24 Transmission Control Levers ................................4-8 Transmission Filter .............................................5-24 Transmission Speed Gauge .................................3-8 Transmission Speed Parameter Adjustment ........4-9 Transmission Speed Up/Down Buttons ..............3-10 Transporting the Machine ...................................4-20 Travel Speeds 8-3 Steel Track Crawler .........................................8-3 Turbo Precleaner ................................................5-14

U Utility Safety Rules Message ................................2-4

V Vandal Lockup ....................................................3-20

W Walk-Around Inspecion ........................................4-4 Warning Lamp for Air Filter Restriction ..............5-13 Water Shutoff .....................................................4-16 Water Temperature Gauge ..................................3-7 Wear Factors You Can Control ..........................4-30 WEIGHTS .............................................................8-8 Weights ................................................................8-8 Operating Weight .............................................8-8 Issued 12-05

Bur

6-85641NA

CHAPTER 9 - INDEX Optional Equipment ......................................... 8-8 Welding on the Machine ...................................... 6-5

6-85641NA

Issued 12-05

Bur

9-5

CHAPTER 9 - INDEX

9-6

Issued 12-05

Bur

6-85641NA