Case 650L Crawler Dozer Operator's Manual 84247253 - PDF DOWNLOAD

OPERATOR’S MANUAL

CRAWLER DOZER 650L TIER 3

84247253 CNH AMERICA LLC 700 STATE STREET RACINE, WI 53404 U.S.A.

North American English Part Number 84247253 Printed in U.S.A. • Rac © 2009 CNH America LLC. All Rights Reserved.

Case is a registered trademark of CNH America

(Replaces 84152733)

Issued July 2009

650L CRAWLERS TIER 3 OPERATOR’S MANUAL

CASE CONSTRUCTION MANUALS Manuals are available from your Dealer for the operation, service, and repair of your machine. For prompt convenient service, contact your Dealer for assistance in obtaining the manuals for your machine.

Your Dealer can expedite your order for Operator’s Manuals, Parts Catalogs, Service Manuals, and Maintenance records.

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

NOTE: 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.

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

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

●

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

●

CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW.

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

The first panel indicates the nature of the hazard.

●

The second panel indicates the appropriate avoidance of the hazard.

●

Background color is YELLOW.

●

Prohibition symbols such as

and

STOP

if used, are RED.

IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR: ●

Is instructed in safe and proper use of the machine.

●

Reads and understands the Manual(s) pertaining to the machine.

●

Reads and understands ALL Safety Decals on the machine.

●

Clears the area of other persons.

●

Learns and practices safe use of machine controls in a safe, clear area before operating this machine on a job site.

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

WARNING_01_NA

TABLE OF CONTENTS CHAPTER 1 TO THE OWNER RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 IDENTIFICATION NUMBERS AND PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 MACHINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 CHAPTER 2 SAFETY AND DECALS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 CHAPTER 3 INSTRUMENTS AND CONTROLS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 DIRECTION CONTROL, HYDROSTATIC DRIVE CONTROL, HAND THROTTLE . . . . . . . . . . . . . . . . . 3-14 OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 CHAPTER 4 OPERATING INSTRUCTIONS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 OPERATING IN HOT WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 OPERATING IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 BOOSTER BATTERY CONNECTION TO MACHINE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 DOZER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 TRACK SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 CHAPTER 5 LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 AS REQUIRED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 EVERY 10 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 EVERY 50 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 EVERY 100 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 EVERY 250 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 EVERY 500 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 EVERY 1000 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 EVERY 2000 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 CHAPTER 6 MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 CHAPTER 7 ELECTRICAL TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

I

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

TRANSPORT DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

CHAPTER 9 INDEX

II

8-1 8-6 8-7 8-9 8-9

CHAPTER 1 - GENERAL INFORMATION

Chapter 1 TO THE OWNER

Figure 1

BD08H494

650L SERIES 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.

This Crawler, with standard equipment and authorized attachments, is intended to be used for above ground material handling. Use only approved accessories and attachments designed for your machine.

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. All persons who will be operating this machine shall possess a valid local vehicle operating permit and / or other applicable local age work permit.

The information in this manual is provided on the basis of information that was available at the time that the manual was written. Settings, procedures, part numbers, software, and other items can change. These changes can affect the service that is given to the machine. Ensure that you have complete and most current information from your Dealer before you start any machine operation.

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.

1-1

CHAPTER 1 - GENERAL INFORMATION This Operator’s Manual is to be stored in the manual compartment equipped on this machine. Make sure this manual is complete and in good condition.

Contact your dealer to obtain additional manuals.

Contact your dealer for any further information or assistance about your machine. Your dealer has approved service parts. Your dealer has technicians with special training that know the best methods of repair and maintenance for your Crawler.

BD06E039-01

Figure 2

OPERATOR’S MANUAL POUCH ATTACHED TO SEAT BACK

ATTENTION: The engine and fuel system on your machine is designed and built to government emissions standards. Tampering by dealers, customers, operators and users is strictly prohibited by law. Failure to comply could result in government fines, rework charges, invalid warranty, legal action and possible confiscation of the machine until rework to original condition is completed. Engine service and or repairs must be done by a certified technican only!

1-2

CHAPTER 1 - GENERAL INFORMATION

RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE

IDENTIFICATION NUMBERS AND PLATES W r i t e yo u r m a c h i n e m o d e l nu m b e r, P r o d u c t Identification Number (P.I.N.) and serial numbers on t h e l i n e s p r o v i d e d b e l ow. W r i t e t h e va r i o u s component number plates down also. Always, give these numbers to your dealer when you need parts or information for your machine.

FRONT

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.

RIGHT HAND

LEFT HAND

BD08D183

Figure 4

PRODUCT IDENTIFICATION NUMBER (P.I.N.) LOCATED ON THE LEFT FRONT RADIATOR SHROUD

REAR

MACHINE P.I.N. Figure 3

BS02K072X

BASIC MACHINE

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

BD08D187

Figure 5

ROPS (ROLL OVER PROTECTIVE STRUCTURE) PLATE IS LOCATED ON THE LEFT-HAND SIDE REAR POST

ROPS PLATE

1-3

CHAPTER 1 - GENERAL INFORMATION

BD08D190

Figure 6

650L ENGINE PLATE LOCATED ON THE TOP REAR VALVE COVER

ENGINE PLATE

BD99J147

Figure 7

DOZER BLADE PLATE

1-4

BD08D193

Figure 8

Figure 10

HYDROSTATIC PUMP PLATE LOCATED BEHIND BELLY PAN

HYDROSTATIC PUMP PLATE

FINAL DRIVE LOCATED AT INSIDE REAR OF FINAL DRIVE CASE

FINAL DRIVE PLATE

Figure 9

HYDROSTATIC MOTORS PLATE LOCATED BEHIND REAR BELLY PAN

HYDROSTATIC MOTOR PLATES

DOZER BLADE PLATE LOCATE AT LEFT REAR OF BLADE

BD08D188

BD08D192

CHAPTER 1 - GENERAL INFORMATION

MACHINE COMPONENTS

1

12

11

11 10

2

8 9

3 7

6 4

5

5

5

5

5 5 Figure 11

BD08H495

1.

4.

7.

10.

Operator ROPs Cab Final Drive Track Tip Out Radiator Shroud

2.

5.

8.

11.

Left Hand Rear Access Door Track Rollers Left Side Lift Cylinder Hand Holds

3.

6.

9.

12.

Ripper Attachment Idler Left Engine Door Handle Front Work Lights

1-5

CHAPTER 1 - GENERAL INFORMATION

4

5

6 3

7

2 1

8

9

Figure 12

BD08D181

1. Hydraulic Reservoir Fill Cap 4. Rear Work Lights 7. Blade Pitch Adjustment Bar

2. Cab Air Filter Access Panel 5. Upper Right Engine Panel 8. Track Adjustment Access

3. Fuel Fill Cap 6. Lower Right Engine Panel 9. Hitch Figure 13

1-6

CHAPTER 1 - GENERAL INFORMATION

2 1

Figure 14

BD02J032

RIPPER 1. 3 POSITION RIPPER SHANK

Figure 15

BD02M132

DRAWBAR

2. TOOTH

Figure 16

BD02J096

HITCH

1-7

CHAPTER 1 - GENERAL INFORMATION

NOTES

1-8

CHAPTER 2 - SAFETY AND DECALS

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

READ OPERATOR’S MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

READ REPAIR MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTRUCTIONAL DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-12 2-13 2-13 2-19

2-1

CHAPTER 2 - SAFETY AND DECALS

2-2

CHAPTER 2 - SAFETY INFORMATION

SAFETY INFORMATION SAFETY RULES This Chapter identifies general safety practices and precautions for the operator. This chapter also identifies where safety decals are located and gives a brief description of decal content. Before operating the crawler, walk around the machine and locate the Safety Decals. If you have any questions about the Safety Decals contact your Dealer.

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

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.

Decal part numbers are located on the decal. Take this par t number to your Dealer a nd re place damaged or illegible decals.

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

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.

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.

GENERAL AND SPECIFIC SAFETY INFORMATION

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

BD06E039-01

Figure 1

OPERATOR’S MANUAL STORAGE LOCATED IN POUCH BEHIND SEAT

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

2-3

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

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

• • • •

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

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

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

In U.S.A. and Canada call one of many One Call System Director services. If you do not know the l o c a l n u m b e r, c a l l t h e n a t i o n a l n u m b e r 1-888-258-0808. (U.S.A. and Canada only): This number will direct you to the state or regional utility that assists with excavation activity.

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

2-4

RH99G001

Figure 2

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION

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

Where applicable, 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

CHAPTER 2 - SAFETY INFORMATION OPERATOR PRECAUTIONS PERSONNEL PRECAUTIONS

PROPER ENTRY AND EXIT

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

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

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

• Certain protective equipment should be replaced and renewed upon age and wear. Old hard hats may not afford proper protection. Faded and soiled vest are no longer highly visible as intended. See the manufacturer recommendations.

• Do not rush. Walk, do not run.

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

who

has

the

OPERATOR - GENERAL

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

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

Figure 3

BD08M004

• Always face the machine and use the hand holds when getting on and off. Always use three points of support. Do not rush.

• Exit the machine slowly and use the hand holds.

Do not jump down.

WARNING Never exit the machine without first confirming the parking brake is set. Failure to follow these instructions may cause death or serious injury.

M1115

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

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

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

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

• Remove all loose objects stored in the machine.

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

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

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

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

Failure to follow these instructions may cause death or serious injury.

M1113

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

• Do not jump off the machine.

• Do not dismount while the machine is in motion.

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

2-5

CHAPTER 2 - SAFETY INFORMATION STARTING AND STOPPING PRECAUTIONS

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

Sound the horn, if equipped, before starting.

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

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

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

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

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

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

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

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

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

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

2-6

CHAPTER 2 - SAFETY INFORMATION OPERATING PRECAUTIONS

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

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

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

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

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

• Carry loads in recommended positions for maximum stability.

• Never lift loads in excess of capacity.

• Use the recommended machine ballast and counterweighting.

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

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

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

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

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

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

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

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

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

• Contact

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

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

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

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

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

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

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

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

• When roading a machine, know and use the

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

signaling devices required on the machine.

Provide an escort for roading where required.

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

• Use the recommended transport devices when roading the machine.

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

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

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

2-7

CHAPTER 2 - SAFETY INFORMATION

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

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

MAINTENANCE PRECAUTIONS

• Do not attempt repairs unless trained. Refer to manuals and experienced repair personnel for help.

• Never make repairs on pressurized components, fluid, gas or mechanical until the pressure has been relieved according to proper service procedures in the Repair Manual.

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

• Wear protective glasses and other required safety equipment machine.

when

servicing

or

repairing

the

• Wear gloves to protect hands when handling cable.

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

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

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

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

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

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

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

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

WARNING: In order to reduce the risk of fires due to the build-up of debris in the engine compartment and elsewhere on your Case Crawler Dozer. It is recommended that you clean all radiators, coolers and engine compartments, as necessary. Failure to comply could result in damage to the machine or serious injury to the operator.

2-8

CHAPTER 2 - SAFETY INFORMATION

• When absolutely necessary to tow the machine,

BURN PREVENTION

do not exceed the recommended towing speed. Be sure the towing machine has sufficient braking capacity to stop the towed load. If the towed machine cannot be braked, a tow bar must be used or two towing machines must be used. One in front pulling and one in the rear to act as a brake. Avoid towing over long distances. It is not recommended to tow this machine.

B ATTERY ACID C AUS ES SEV ER E BUR NS. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote:

• Observe proper maintenance procedures.

• Whenever servicing or replacing hardened pins,

INTERNAL - drink large quantities of water or milk.

DO NOT induce vomiting. Seek medical attention immediately.

etc., use a brass drift or other suitable material between the hammer and pin. Alternative: Use a brass hammer, drift or suitable material on the pin, etc.

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

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

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

FUEL HANDLING PRECAUTIONS

WARNING

EXTERNAL - flush with water.

BATTERIES PRODUCE EXPLOSIVE GASES. Keep sparks, flame, cigars and cigarettes away.

Ventilate when charging or using in enclosed area.

Always wear eye protection when working near batteries. Wash hands after handling. KEEP OUT OF REACH OF CHILDREN OR PETS. Failure to comply could result in death or serious injury.

• Do not smoke or permit open flames while fueling

M144C

or near fueling operations.

• Never remove the fuel cap or refuel gasoline engine powered machines with the engine running or hot. Never allow fuel to spill on hot machine components. Never allow fuel to spill on the environment.

• To avoid spilling fuel maintain control of the fuel filler nozzle when filling the tank.

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

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. Failure to comply could result in death, serious injury, or machine damage.

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

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

• Never use fuel for cleaning purposes.

• Use the correct fuel grade for the operating season.

SA031

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

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

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

before

attempting

service

2-9

CHAPTER 2 - SAFETY INFORMATION HAZARDOUS CHEMICAL PRECAUTIONS

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

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

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

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

dealer

for

correct

BS09A213

disposal

Figure 4

TRANSPORTING PRECAUTIONS

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

ROLL-OVER PROTECTIVE STRUCTURE

• Do NOT modify the ROPS in any manner.

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

FIRE EXTINGUISHER It is recommended that you have a fire extinguisher on your machine. Contact your Dealer for the type and location of a fire extinguisher on this machine.

SEAT BELT PRECAUTIONS The seat belt is an important part of the ROPS operator protection system. Always use the seat belt and check the seat belt and hardware on a routine basis to confirm that bolts are torqued properly and that the belt system is not damaged from wear or abrasion.

2-10

WARNING Before starting the engine ensure the seat belt is securely fastened. The seat belt can help insure your safety if it is used and properly maintained.

Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members. Failure to follow these instructions may result in death or serious injury.

M422B

CHAPTER 2 - SAFETY INFORMATION SPECIFIC PRECAUTIONS TO THIS MACHINE

TO FASTEN THE SEAT BELT

• Since the tracks are used as steps, always clear the tracks of debris, rocks, ice, moisture or any other item that might cause a fall, before entering or leaving the cab, for operation or service.

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

• Lower the blade and attachments to the ground before leaving the machine.

WARNING 2

1

Never exit the machine with the engine operating.

Failure to follow these instructions may cause death or serious injury.

M1114

Figure 5

BD99J183

1. RIGHT HAND BELT STRAP 2. LATCH MECHANISM

Insert the metal end of the right-hand belt strap (1) into the latch mechanism (2) on the left-hand side of the seat.

TO UNFASTEN THE SEAT BELT

3

Figure 6

BD99J184

3. RELEASE BUTTON

To release the seat belt, push the red release button (3) on the buckle, while holding the retractable end.

WARNING Securely fasten your seat belt. Your machine is equipped with a ROPS cab, ROPS canopy or ROPS frame for your protection. The seat belt can help insure your safety if it is used and maintained. Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members.

Failure to comply could result in death or serious injury.

M437

2-11

CHAPTER 2 - SAFETY INFORMATION

SAFETY DECALS WARNING Damaged, missing, or dirty safety decals can cause injury or death. Replace any missing or damaged safety decals and keep all safety decals clean. See your Dealer for new safety decals. Failure to comply could result in death, serious injury, or machine damage.

TEXT SAFETY DECAL PER ANSI STANDARD

84-170

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

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

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

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

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

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

• CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. This Caution message also alerts the Operator or Service Technican that machine damage may occur. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW.

2-12

332512A1

Figure 7

CHAPTER 2 - SAFETY INFORMATION I f S a fe t y D e c a l s o n t h i s m a c h i n e a r e , I S O (International Standards Organization) 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

ISO TWO PANEL DECAL

BS02N083

Figure 8

IMPORTANT: This IMPORTANT header is used for items that do not fall into a Safety issue, but rather needs to be called out as a detail that needs extra attention. These are also used for environmental issues.

NOTICE: This header is used where the operator may get a helpful hint where safety is not an issue.

2-13

CHAPTER 2 - SAFETY INFORMATION

2-14

CHAPTER 2 - SAFETY INFORMATION READ OPERATOR’S MANUAL Decals which display the Read Operator’s Manual symbol are intended to direct the operator to the Operator’s Manual for further information regarding safety, maintenance, adjustments and/or procedures for specific areas of the machine. When a decal displays the following symbol refer to the Operator’s Manual.

329044A1

Figure 11

The following safety decals have been placed on your machine in the areas indicated. Safety decals are intended for the personal safety of you and those working with you. Please take this manual, walk around your machine and note the content and location of these warning decals. Review these decals with all machine operators.

It is the Owner’s responsibility to keep the decals legible. If they are not, obtain replacements from your dealer. Part numbers are on the decal.

384270A1A

Figure 9

READ REPAIR MANUAL

Some decal locations may vary slightly between models and component configurations. If you have any questions about the decals or their replacement contact your Dealer.

When a decal displays the Read Repair Manual symbol, refer to the Repair Manual for fur ther infor mation concer ning the ser vice operation, maintenance or adjustment about to be performed.

Specific information concerning this procedure will be detailed in the Repair Manual.

BC00G075

Figure 10

One or both of these symbols may appear on a decal relating to safety, machine operation or service.

Below is a sample decal that directs the Machine Operator or Repair Technician to the Operator’s Manual for additional information concerning this procedure.

2-15

CHAPTER 2 - SAFETY INFORMATION

1 1 2

1

2

Figure 12 1. 383973A1, DECAL LOCATION IS ON RIGHT SIDE JUST BELOW STARTER AND ON LEFT SIDE NEXT TO BATTERY. DANGER: EXPLOSION AND RUN OVER HAZARD 2. 321-7040, DECAL LOCATION IS ON RIGHT SIDE JUST BELOW STARTER. DANGER: STARTING IN GEAR CAN CAUSE DEATH. START ONLY FROM OPERATOR SEAT.

BD08H497 / 383973A1 / BD08H498 / 321-7040

2-16

CHAPTER 2 - SAFETY INFORMATION

3 3

Figure 13 3. 87634107, DECAL LOCATIONS ON LEFT AND RIGHT SIDES, DANGER: BEFORE LEAVING THE OPERATOR’S SEAT MOVE THE LEVERS TO THE LOCKING POSITION. LOCKING POSITION IS DOWN TO DENY OPERATOR EXIT.

BD08D194 / 87634107

4 4

Figure 14 4. 384258A1, DECAL LOCATION IS ON THE UNDER SIDE OF THE RADIATOR CAP ACCESS COVER, WARNING: HOT LIQUID UNDER PRESSURE. SERVICE WHEN COOL.

BD08H518 / 384258A1

2-17

CHAPTER 2 - SAFETY INFORMATION

5

5

Figure 15 5. 383972A1, DECAL LOCATIONS ARE ON LEFT AND RIGHT SIDE OF THE CAB OR CANOPY. WARNING: DO NOT MODIFY OR REPAIR ROPS IN ANY MANNER.

BD08N010 / 383972A1

6

6

Figure 16 6. 332512A1, DECAL LOCATIONS ARE ON THE LEFT AND RIGHT SIDE OF THE RADIATOR SHROUD, WARNING: ENTANGLEMENT HAZARD. KEEP CLEAR OR STOP THE ENGINE BEFORE SERVICING.

BD08H496 / 332512A1

2-18

CHAPTER 2 - SAFETY INFORMATION

7 7

Figure 17 7. 383971A1, DECAL LOCATION IS BETWEEN BRAKE AND DECELERATOR PEDAL, WARNING: DEPRESS PEDAL SLOW, RELEASE FAST.

BD02K026 / 383971A1

2-19

CHAPTER 2 - SAFETY INFORMATION

8 8

9

9

Figure 18 8. 321-7030, DECAL LOCATION IS ON THE RIGHT SIDE CAB UPRIGHT POST, WARNING: DO NOT JUMP IF MACHINE TIPS. USE SEAT BELT. 9. 382622A1, DECAL LOCATION IS ON THE RIGHT SIDE CAB UPRIGHT POST, WARNING: READ OPERATORS MANUAL. FASTEN SEAT BELT. NO RIDERS. KEEP OTHERS AWAY.

BD02K012 / 321-7030 / 382622A1

2-20

CHAPTER 2 - SAFETY INFORMATION

10

10

Figure 19

BT08H403/ 8603092

10. 8603092, DECAL LOCATION IS ON THE HOOD, WARNING: DO NOT USE ETHER.

INSTRUCTIONAL DECALS The following instructional decals are located at controls and components on these machines. The decals are shown in the next Chapter with the appropriate control device or component.

12 11

13

831L92 / BC08N292 / 87748406

Figure 20

11. ENGINE THROTTLE INSTRUCTIONAL DECAL 12. RIPPER INSTRUCTIONAL DECAL 13. BLADE CONTROL DECAL

2-21

CHAPTER 2 - SAFETY INFORMATION

14

15

Figure 21

87403196 / 87403197

14. DIRECTION AND DRIVE CONTROL INSTRUCTIONAL DECAL 15. REVERSE FORWARD RATIO INSTRUCTIONAL DECAL

16 17

87550110 / 379422A2

16. INSTRUMENT LOCKUP INSTRUCTIONAL DECAL 17. MASTER DISCONNECT INSTRUCTIONAL DECAL

2-22

Figure 22

CHAPTER 3 - INSTRUMENTS AND CONTROLS

Chapter 3 INSTRUMENTS AND CONTROLS TABLE OF CONTENTS INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 LCD MULTI-FUNCTION DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 NAVIGATING THROUGH THE LCD MULTI-FUNCTION DISPLAY SCREENS . . . . . . . . . . . . . . . . . . . . . 3-9 USING ARROW UP AND DOWN KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 TO RESET THE TRIP INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 SERVICE SCREENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 HYDROSTATIC DRIVE SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 BRAKE, DECELERATOR AND FOOTREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 PARKING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 DIRECTION CONTROL, HYDROSTATIC DRIVE CONTROL, HAND THROTTLE . . . . . . . . . . . . . . . . . . . . . . 3-14 DOZER BLADE CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 BLADE CONTROL HANDLE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 RIPPER CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 SEAT CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 CAB FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 OPERATOR’S SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 TO FASTEN SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 TO RELEASE SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 CANOPY MODEL INSTRUMENT PANEL ANTI THEFT COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3-1

CHAPTER 3 - INSTRUMENTS AND CONTROLS

NOTES

3-2

CHAPTER 3 - INSTRUMENTS AND CONTROLS

INSTRUMENT PANEL

A

1

2

3

4

Figure 1

BD08N011

Turn the key switch to the ON position and check the condition of the warning lamps. This Power Up position will allow the AIC to perform the lamp, alarm check and initialize zero position of the gages. The warning lamps will illuminate for approximately three seconds.

1. FRONT WORK LIGHT SWITCH: 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.

BS96H046

3. FRONT AND REAR WINDSHIELD WIPERS: This switch has two positions, ON and OFF. To turn ON press the icon. The switch icon will illuminate when pressed.

0097

Figure 2

4. FRONT AND REAR WINDSHIELD WASHER: Push the momentary switch icon to activate the front and rear windshield washer. Release the switch to stop the front and rear windshield washers.

2. REAR WORK LIGHT SWITCH: This switch has two positions, ON and OFF. To turn ON press the icon. The switch icon will illuminate.

BS98M034

Figure 3

Figure 4

0099

Figure 5

3-3

CHAPTER 3 - INSTRUMENTS AND CONTROLS

10

6

5

7

8

9

Figure 6

BD08N011

5. RIGHT-HAND AND LEFT-HAND DOOR WINDSHIELD WIPERS: This switch has two positions, ON and OFF. To turn ON press the icon.

8. ESCAPE - SERVICE/ENTER: Use the upper or escape portion of this switch to return to the previous top menu or escape back to the main or driving screen.

Figure 7

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

BC00G12

6. LEFT-HAND AND RIGHT-HAND DOOR WINDSHIELD WASHERS: Push the momentary switch icon to activate the left and right door windshield washers. Release the switch to stop the left and right door windshield washers.

BS02M143 / BS02M144

9. HORN: Push the switch to activate the horn.

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

Figure 8

BC00B132

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

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

Figure 10

Figure 11

BS98M064

10. SPARE PLUG: Spare plug provided for options.

Figure 12 BS02M141 / BS02M142

3-4

Figure 9

CHAPTER 3 - INSTRUMENTS AND CONTROLS 11. KEY SWITCH: The key switch has four positions: 1. ACCESSORY POSITION: This position energizes the accessory switches.

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

3. 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.

4. 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 the ON position (3).

BS98M031/RB99J175/RB99J178/RB99J176

11

2 3 1

4

Figure 13

BD02M022 / 87412595

Figure 14

INSTRUCTIONAL DECAL FOR KEY SWITCH

3-5

CHAPTER 3 - INSTRUMENTS AND CONTROLS

12

13

14

15 16

B

17 Figure 15

BD08N013

12. HYDROSTATIC DRIVE FILTER WARNING LAMP: This warning lamp shows the condition of the transmission filter. If the warning lamp illuminates red 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 red 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.

BS96H049

13. CHARGE PRESSURE WARNING LAMP: This warning lamp illuminates red 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 red 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.

BS99J181

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

BS99J182

Figure 20

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

Figure 18 BS99J182

3-6

Figure 19

Figure 21

CHAPTER 3 - INSTRUMENTS AND CONTROLS

D 21 C

20 22

19

18 Figure 22

BD08N013

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

BS98M026

BS98M048

Figure 26

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

Figure 24

20. ENGINE PREHEATING SYSTEM LAMP: This lamp illuminates yellow when the incoming air needs to be preheated, due to cold temperatures. Wait until the indicator lamp goes off before turning the key switch to the start position.

BC02N191

21. HYDROSTATIC DRIVE OIL TEMPERATURE WARNING: This warning lamp will glow red and the warning buzzer will sound when the transmission operating temperature is too high. The temperature should be monitored by watching the gauge D. The transmission operating temperature is normal when the gauge needle is in the green area.

Figure 23

19. ENGINE COOLANT TEMPERATURE: This warning lamp illuminates red 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.

BS96H053

E

The operator may monitor the gauge (E) with the key switch on or the engine running.

BS99J185

Figure 27

Figure 25

3-7

CHAPTER 3 - INSTRUMENTS AND CONTROLS

23

24

Figure 28

BD08N013

23. CAUTION MASTER INDICATOR: This Caution Master indicator illuminates yellow to indicate there is a non-critical warning. When ON a change in operating method is required, a scheduled shutdown for maintenance is needed, or if the condition persists, contact your dealer.

BC00B291

3-8

Figure 29

24. STOP MASTER INDICATOR: When the Stop Master indicator illuminates the Operator must bring the machine safely to a stop and immediately turn OFF the engine. Failure to do so may result in injury and/or damage to the machine.

BC00B290

Figure 30

CHAPTER 3 - INSTRUMENTS AND CONTROLS LCD MULTI-FUNCTION DISPLAY

NAVIGATING THROUGH THE LCD MULTI-FUNCTION DISPLAY SCREENS

1

2

A

C

B

D

3 A

B Figure 32

BD06G112-01 BD06G111-01

Figure 31

The LCD Multi-Function Display is located in the center of the modular dashboard. On start up the cluster will flash the instructional lamps and the LCD Multi-Display will flash, CASE. Information is displayed in three zones on the LCD, as directed by the operator or machine. In most situations the operator or technican will be given specific information to follow if conditions are not correct.

The screen image above is the normal operating screen.

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

In the example, above, the machine hours are d i s p laye d . M a c h i n e h o u r s w i l l a l way s b e displayed briefly, on start up. After, the machine is started, the display will show engine rpm’s.

KEY PAD

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

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

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

C. Escape key: Use this key to exit and return to the driving screen. Use this key anytime you would like to start over and begin again. To escape out to the previous menu / escape adjusted value.

D. Enter key: Use this key to confirm, yes, this is what I want. Use this key to make a selection in a menu / save adjusted value.

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

3. Zone Three: This lower 1/3 of the display is in two sections. Zone A will show fault codes and Zone B will show additional and optional information, such as time.

3-9

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

From the driving screen push the down arrow.

BD06F169-01

Figure 36

After pushing the down button, the fourth time, from the driving screen, will display Trip 1.

If the operator chooses to use the Up button, from the driving screen, the previous sequences will be reversed.

TO RESET THE TRIP INFORMATION BD07H118-01

Figure 33

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

BD06F170-01

Figure 37

At the Trip screen you wish to re-set.

Press the enter button.

BD06F027-01

Figure 34

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

BD06F172-01

Figure 38

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

BD06F170-01

Figure 35

Press the down button again and the Trip 2 screen will display.

3-10

CHAPTER 3 - INSTRUMENTS AND CONTROLS SERVICE SCREENS The following menus are available for Operator modification: Preferences This menu allows the operator to select the following languages for display: Italian, French, German, Spanish, Por tuguese.

English is the default language.

Display T h i s m e nu a ll ow s t h e o p e ra t o r t o s e l e c t t h e brightness of the screen. The display increments allow the operator to adjust from a minimum brightness of 1 to a maximum brightness of 20.

Clock Allows the operator to change the clock time and select 12 or 24 hour clock.

Next Service Allows the operator to change the next service reminder. See page 5-4 in the Lubrication, Filters and Fluids Chapter for details.

Versions Identifies the software versions installed.

Settings Allows the operator to change the maximum speed, shuttle control and steering control.

Usage Data Allows the operator to see the total hours of machine usage in low and high speed. Hours can be reset.

Reset Allows the operator to reset factory settings and reset errors.

Active Error Screen Allows the operator to see an active error. A currently occurring error.

To access these screens push down and hold the ENTER key for more than 2 seconds. The key switch must be ON.

3-11

CHAPTER 3 - INSTRUMENTS AND CONTROLS HYDROSTATIC DRIVE SPEEDS

BRAKE, DECELERATOR AND FOOTREST

The Hydrostatic Drive speed is selected by the operator. The maximum speed is selectable in a range of 10 increments.The range is controlled by the Drive UP/DOWN buttons on the Direction Control Lever.

2 1

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

3

3

BD06G114-01

Figure 42

1. BRAKE PEDAL Push this pedal to slow or stop the machine.

Pushing the pedal all the way down will engage the parking brake. The Park Brake indicator on the cluster will illuminate. Releasing the pedal will release the brake.

BD06G113-01

Figure 39

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.

3. LEFT AND RIGHT FOOTREST

BD02M165-01

Figure 40

HYDROSTATIC DRIVE CONTROL BUTTONS

A

B

Figure 41 A. HYDROSTATIC DRIVE SPEED UP BUTTON (RABBIT SYMBOL) B. HYDROSTATIC DRIVE SPEED DOWN BUTTON (TURTLE SYMBOL)

BD02M166-01

3-12

CHAPTER 3 - INSTRUMENTS AND CONTROLS PARKING BRAKES

4

4 Figure 43

BD06G115-01

4. PARKING BRAKE LEVERS ENGAGED

5

5

Figure 44

BD06G116-01

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

5

BD06G118-01

5

Figure 45

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

3-13

CHAPTER 3 - INSTRUMENTS AND CONTROLS

DIRECTION CONTROL, HYDROSTATIC DRIVE CONTROL, HAND THROTTLE

1

2

3

4

Figure 46

BD06E060-01

1. DIRECTION CONTROL LEVER

2

This lever controls the forward speed, neutral or reverse speed, and turning.

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 47

BD06E061-01

A

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

2. HYDROSTATIC DRIVE SPEED UP/DOWN BUTTONS A. UP BUTTON (Drive speed increase) B. DOWN BUTTON (Drive speed decrease)

B

BD02M166-01

Figure 48

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 Hydrostatic Drive Speed Gauge.

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

3-14

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

3 3

4. REVERSE TO CONTROL

FORWARD

SPEED

RATIO

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

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

4

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

DECAL

BD06E062-01 / 8371L92

Figure 49

3-15

CHAPTER 3 - INSTRUMENTS AND CONTROLS DOZER BLADE CONTROL LEVER 1. THE DOZER BLADE CONTROL LEVER

BS99J212

1

Figure 50

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

Figure 51

B. LOWER: 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.

BS99J214

BD08N034-01

Figure 53

BD09A003-01

Figure 54

Figure 52

D. LIFT:

3-16

CHAPTER 3 - INSTRUMENTS AND CONTROLS

BS99J21

Figure 55

E. TILT LEFT

BS99J218

Figure 56

F. TILT RIGHT 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.

BS99J217

BD09A004-01

Figure 59

BD09A005-01

Figure 60

Figure 57

G. ANGLE LEFT Rotate the lever counter- clockwise to angle the blade left.

BS99J219

Figure 58

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

3-17

CHAPTER 3 - INSTRUMENTS AND CONTROLS BLADE CONTROL HANDLE POSITION

RIPPER CONTROL LEVER

1

B 1 C

D

BD02J034-01

Figure 62

1. RIPPER CONTROL LEVER BD08N034-01

Figure 61

B. LOWER:

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.

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

BS99J221

Figure 63

D. RAISE:

BS99J222

Figure 64

C. 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.

3-18

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR’S SEAT L Series Crawler Canopy machines are available with vinyl mechanical suspension seats or vinyl air suspension seats. Cab machines are equipped with cloth air suspension seats.

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

2 SEAT CONTROLS

Figure 67

BD02H120

1

2. FORWARD/REARWARD ADJUSTMENT LEVER 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.

Figure 65

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 68

3. OPERATOR COMFORT CONTROL MECHANICAL SUSPENSION SEAT

BD02K003

Figure 66

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 figure below.

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

3-19

CHAPTER 3 - INSTRUMENTS AND CONTROLS

4

Figure 69

BD02M170

Figure 72

BD02N037

CAB FEATURES

1

A

BD02H123

Figure 70

AIR SUSPENSION SEAT

Figure 73

BD02K015

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

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

1. CAB DOOR RELEASE AND LOCK: To open the cab door grip the handle and push the release button. The release button will lock the cab with the ignition key. The cab door may be opened and locked into the open position.

2

4

BD08N051

Figure 74

2. OUTSIDE CAB DOOR RELEASE: BD02H139

Figure 71

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.

3-20

The cab door may be released from the locked open position, from the outside, by pulling this lever down.

CHAPTER 3 - INSTRUMENTS AND CONTROLS

6

3

Figure 77

BD06H008

Figure 75

BD06G119

3. INTERIOR CAB DOOR RELEASE: Pull this knob to release the cab door from the locked open position.

6. CLIMATE CONTROL PANEL: This panel controls the temperature and fan functions for the cab.

7

4 5

BD08A447-01

Figure 78

7. 12 VOLT AUXILIARY POWER SUPPLY: BD06G120

Figure 76

4. DOME LIGHT: The dome light is located above the operator’s head.

5. CAB RADIO-CD PLAYER:

3-21

CHAPTER 3 - INSTRUMENTS AND CONTROLS

1

Figure 79

BD08N017

1. MASTER DISCONNECT SWITCH: Shown in OFF position.

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

Circle =OFF, Bar = ON.

O

379422A2

1

Figure 80

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.

3-22

CHAPTER 3 - INSTRUMENTS AND CONTROLS OPERATOR’S SEAT BELT The illustrations that follow show the correct procedure to fasten and release the belt.

WARNING You are protected by the ROPS (Roll-Over Protective Structure) system on this machine. The seat belt is an important part of that ROPS system.

Before you operate this machine, always fasten the seat belt. If the machine rolls over and you DO NOT have the seat belt fastened, you can be crushed by the ROPS or the machine.

Figure 83

BD02M168

RELEASE BAR

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

CANOPY MODEL INSTRUMENT PANEL ANTI THEFT COVER

Figure 81

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

BD08A024

Figure 84

An anti-theft cover is provided for canopy models.

Fold the plate up over the instrument panel and lock the sides with padlocks. See the instructions on the decal.

Figure 82

BD99J184

RELEASE BUTTON

3-23

CHAPTER 3 - INSTRUMENTS AND CONTROLS

NOTES

3-24

CHAPTER 4 - OPERATING INSTRUCTIONS

Chapter 4 OPERATING INSTRUCTIONS TABLE OF CONTENTS OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 INITIAL PROCEDURES AND RUN IN SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 BEFORE YOU START EACH DAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 DIRECTION CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 TURNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 STEERING GRADUAL TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 POWER TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 COUNTER - ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 ADJUSTING STEERING SENSITIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 HYDROSTATIC DRIVE SPEED CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 DECELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 CLIMATE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 MOVING A DISABLED CRAWLEr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 LIFTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 OPERATING IN HOT WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 OPERATING IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 BOOSTER BATTERY CONNECTION TO MACHINE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 DOZER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 ENGINE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 TRACK SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 UNDERCARRIAGE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 FACTORS CONTROLLING UNDERCARRIAGE WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 CONTROLLING TRACK WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Extending THE LIFE OF SEALED TRACK AND THE CASE LUBRICATED TRACK (CLT) . . . . . . . . . . . . . 4-19 CASE EXTENDED LIFE TRACK (CELT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4-1

CHAPTER 4 - OPERATING INSTRUCTIONS

NOTES

4-2

CHAPTER 4 - OPERATING INSTRUCTIONS

OPERATING INSTRUCTIONS This Chapter will explain the operation procedures for the machine and components. Run-In-Periods, Pre-Start Procedures, Hot and Cold Engine starting procedures and some work site operations.

If you have any questions about the operation of this machine, contact your Dealer before you begin operating.

WARNING Before you start the engine, always sit in the operator’s seat, fasten the seat belt, apply the parking brake, and make sure the direction control lever is in NEUTRAL. Give a warning to all persons around you that you are starting the engine. Failure to comply could result in death or serious injury.

INITIAL PROCEDURES AND RUN IN SERVICE Track Shoe bolts . . . . . . . . . . . . . 20 hrs / page 5-18 Brake Pedal Check the operation of the brake on a hard level surface when the machine is new.

DAILY WALK-AROUND INSPECTION 1. Check for leaks under the machine.

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

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

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

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

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

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

STARTING THE ENGINE 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.

ENGINE OPERATION

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

During the first 20 hours of operation, or if you rebuild the engine:

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

1. Operate the machine with normal loads for the first eight hours.

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.

2. Do not work the engine hard at stall speeds (tracks stopped and the engine running at full throttle).

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

operating

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

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

5. Turn the key switch to the ON position. Monitor the display panel for gauge and machine functions. Allow a few seconds for the machine to do a wake up and self-check.

3. Keep the engine temperature.

at

normal

WARNING Before starting engine, study operator’s manual safety messages. Read all safety signs on machine.

Clear the area of other persons. Learn and practice safe use of controls before operation. It is your responsibility to understand and follow manufacturer’s instructions on machine operation, service, and to observe pertinent laws and regulation. Failure to comply could result in death or serious injury.

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.

4-3

CHAPTER 4 - OPERATING INSTRUCTIONS 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.

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 operator’s compartment, always support or lower the equipment (backhoe, blade, boom, bucket, etc.) to the ground and stop the engine.

Failure to follow these instructions may result in death or serious injury.

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. Failure to comply could result in death or serious injury.

CRAWLER OPERATION The drive and steering on the L Series 3 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.

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.

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.

Failure to comply could result in death or serious injury.

4-4

WARNING You are protected by the ROPS (Roll-Over Protective Structure) system on this machine. The seat belt is an important part of that ROPS system.

Before you operate this machine, always fasten the seat belt. If the machine rolls over and you DO NOT have the seat belt fastened, you can be crushed by the ROPS or the machine. Failure to comply could result in death or serious injury.

CHAPTER 4 - OPERATING INSTRUCTIONS BEFORE YOU START EACH DAY

BD02H122

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.

Figure 4

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

5. Start the engine and allow proper warm up.

6. To start the machine in cold weather, -17°C (0°F) and below, see Operating in Cold Weather in this manual.

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

F

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

N

NOTICE: The Hydrostatic Drive Speed will default to the 60% speed each time the machine is shut off.

R

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

BD02K029

Figure 2

3. Place the Direction Control Lever in Neutral.

NOTE: N should be seen on the Digital Display.

BD06G113-01

Figure 3

4-5

CHAPTER 4 - OPERATING INSTRUCTIONS DIRECTION CONTROL LEVER

F 1 N

1

R BD02M033

Figure 5

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.

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

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

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

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 the machine in this section.

WORKING OPERATIONS 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.

1

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

BD06G113-01

Figure 7

1. NEUTRAL POSITION

Push the Direction Control Lever into the position you wish the crawler to go and verify the selection by reading the Digital Display.

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.

4-6

CHAPTER 4 - OPERATING INSTRUCTIONS TURNING

COUNTER - ROTATION

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

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

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

B911447JFX

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.

Figure 8

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.

4-7

CHAPTER 4 - OPERATING INSTRUCTIONS ADJUSTING STEERING SENSITIVITY The Direction Control Lever has three sensitivity settings.

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

D

• Smooth • Normal • Fast To change the sensitivity:

BD06G112-01

Figure 11

3. Select the SETTINGS menu by pressing the Service/Enter switch (D). The screen will show Settings at the top, followed by:

D

• Max Spd • Shuttle • Steer 4. Push the down arrow and go to Steer.

NOTICE: Normal is the setting from the factory.

5. Press the Service/Enter (D) switch until the desired choice is blinking.

BD06G112-01

Figure 9

1. Press and hold the Service/Enter switch (D) for 2 or 3 seconds until the screen shows SERVICE at the top.

6. Push the Service/Enter (D) switch again to confirm the chosen selection and store the choice.

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

The Shuttle choices are the same:

• Smooth • Normal • Fast After selecting desired value press the Service/Enter switch to confirm the selection and store the choice.

B BD06G112-01

ADJUSTING MAXIMUM HYDROSTATIC DRIVE SPEED PARAMETER Figure 10

2. Press the down (B) arrow until, (SETTINGS) is on the Digital Display.

To adjust the Maximum Drive speed follow the same steps as for Steering Sensitivity.

The drive speed choices will be 70%, 80%, 90% or 100%.

A f t e r s e l e c t i n g t h e d e s i r e d va l u e p r e s s t h e Service/Enter switch to confirm and store the choice.

4-8

CHAPTER 4 - OPERATING INSTRUCTIONS HYDROSTATIC DRIVE SPEED CONTROLS

3

1

4 2 BD04N011 BD02M166

Figure 12

1. HYDROSTATIC DRIVE SPEED UP BUTTON 2. HYDROSTATIC DRIVE SPEED DOWN BUTTON

The CASE L Series 3 Crawlers have infinitely variable speeds in Forward and Reverse from 0 to 9.7 km/h (0 to 5.5 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 drive speeds.

NOTE: The speed can only be increased to the maximum drive speed setting, which can be adjusted. See page 4-8. From the factory 90% is the highest speed.

Figure 13

3. HYDROSTATIC DRIVE SPEED GAUGE 4. DIGITAL DISPLAY

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

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

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

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

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

4-9

CHAPTER 4 - OPERATING INSTRUCTIONS DECELERATOR PEDAL

6 5

Figure 16 6. REVERSE TO FORWARD SPEED RATIO CONTROL

BD02M025-01 BD02K026-01

Figure 14

5. DECELERATOR PEDAL

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

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.

7

BD06H010-01

Figure 17

7. ENGINE HAND THROTTLE

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

383971A1

Figure 15

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.

4-10

CHAPTER 4 - OPERATING INSTRUCTIONS CLIMATE CONTROL SYSTEM

2 1

BD06H008-01

3

Figure 18

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

2. HEAT OR AIR CONDITION CONTROL KNOB This control knob has three position. Off, as shown, is the extreme left position. This position also turns the fan off. The second position, straight up, is for heat and the third position, snowflake icon, is for air-conditioning.

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

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

4-11

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.

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.

Figure 21

BD02M166

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

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

WARNING When moving the machine on or off of the trailer, drive slowly and keep the machine centered on the trailer and ramp. Failure to comply can result in death, serious injury, or machine damage.

B835873F-01

Figure 19

BLOCKS FOR TRAILER WHEELS

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

MOVING A DISABLED CRAWLER

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

Towing the crawler is not recommended. 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. Contact your dealer.

3. Lower the blade and ripper, if equipped, onto 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.

BD02M052-01

Figure 20

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.

4-12

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

Figure 22

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.

BS02N082

Figure 23

4-13

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.

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.

4-14

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

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

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

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

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

WARNING This machine is equipped with an engine pre-heating system. DO NOT use ether for cold weather starting. Failure to comply can cause death, serious injury, or machine damage.

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

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

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

4. Actuate the starter motor.

5. 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 warmed.

NOTE: 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.

CHAPTER 4 - OPERATING INSTRUCTIONS

BOOSTER BATTERY CONNECTION TO MACHINE BATTERY WARNING Batteries produce explosive gases. Keep sparks, flame, and cigarettes away. Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. Failure to comply can cause death or serious injury.

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

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

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

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

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

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

1 2

BD08H506

Figure 24

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

4-15

CHAPTER 4 - OPERATING INSTRUCTIONS

DOZER OPERATION 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.

WARNING

ENGINE SPEED 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.

DOZER BLADE PITCH

1

2

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.

WARNING BC00G049

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.

Figure 25

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

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

2. Blade will stay on top in soft ground.

3. Blade will not dig into ground.

WARNING DO NOT operate the machine while under the influence of alcohol or drugs. Failure to comply can result in death, serious injury, or machine damage.

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

4. Blade best used for fine grading.

Forward Position Advantages (2) 1. Load slides off the blade as the crawler travels in reverse.

2. Blade will dig into hard ground easier.

3. Less load spillage over top of blade.

4. Load slides off the blade easier when pushing up hill.

NOTE: See Blade Pitch Adjustment on page 6-9 in this manual for adjustment procedure.

BLADE LIFT EYE

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.

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.

4-16

BD99J147

Figure 26

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

CHAPTER 4 - OPERATING INSTRUCTIONS

TRACK SYSTEMS

3

2

1 4 8 6 7

5 Figure 27

BD08N019

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

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

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

2. CARRIER 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.

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

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

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

8. TRACK LINKS A number of track links make up the track chain assembly. Each link assembly consists of a right-hand and a left-hand link, the track pin is solid with sealed track chains and hollow with Case Lubricated Track (CLT) 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.

4-17

CHAPTER 4 - OPERATING INSTRUCTIONS

10

9

9

Figure 28

BD08N019

9. TRACK GUIDES - Front and Rear Track guides prevent rocks and other debris from entering between front roller, idler, and rear roller and sprocket.

10. ROCK GUARD - If Equipped Rock guards are optional extensions of the track guides. Used in rocky conditions, the rock guards help keep rocks and debris out of the track system to help minimize wear.

14

BD02H011

Figure 30

14. MASTER LINK

13 11

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

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

12

BD08N020

Figure 29

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

12. Track Shoe bolts - 4 per shoe 13. Track Shoe Grouser

4-18

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.

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

CHAPTER 4 - OPERATING INSTRUCTIONS CONTROLLING TRACK WEAR

CASE EXTENDED LIFE TRACK (CELT)

• Minimize the effects of packing by checking track

T h e C as e E x te n d ed L i fe Track (C E LT ) c h ai n incorporates a bushing that is free to rotate on the standard lubricated track bushing. This method allows wear to be distr ibuted over the 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.

sag frequently when working in mud, snow and wet sand. Packing can cause track jumping and banging.

• Severe

packing of materials undercarriage components causes increasing track tension.

between wear by

• 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 factors that you can not control, you can do something about the way you operate and maintain the machine.

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

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

• 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.

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

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

• 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

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 recommended in high abrasive/low impact applications where bushing wear is severe. The narrowest possible track shoe that will give adequate flotation should be used to obtain maximum life from the sealed and lubricated 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.

NOTICE: If the machine is not used 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.

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.

• 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.

EXTENDING THE LIFE OF SEALED TRACK AND THE CASE LUBRICATED TRACK (CLT)

• 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.

• Letting the pins and bushings run to destruction results in accelerated wear of other components.

Turn the pins and bushings to extend track life.

4-19

CHAPTER 4 - OPERATING INSTRUCTIONS Wear Factors 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.

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

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

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.

Packing 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.

4-20

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

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

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

Wear is then accelerated.

When a packing problem continues install relieved track sprockets.

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

EXTREME REVERSE LOADING - 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.

Operating and Maintenance 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.

Track Shoes 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.

CHAPTER 4 - OPERATING INSTRUCTIONS 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.

Other Wear Factors l

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.

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. During severe applications, the sprockets and track bushings wear much faster.

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.

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.

4-21

CHAPTER 4 - OPERATING INSTRUCTIONS 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.

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.

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 we a r o f t h e s p r o cke t s a n d bushings.

912287

912285

Figure 31

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.

912288

912286

4-22

Figure 32

Figure 33

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.

Figure 34

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.

CHAPTER 4 - OPERATING INSTRUCTIONS Track Sag Adjustment Chart 100 90% 75% 60% 45% 30% 15% 0% 912289

13 MM (0.5 INCH)

Figure 35

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.

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.

38 MM (1.5 INCH)

51 MM (2.0 INCH) Figure 36

912346

1. TRACK TENSION (PERCENT TIGHT)

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

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.

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

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.

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.

Figure 37

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

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

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

4-23

CHAPTER 4 - OPERATING INSTRUCTIONS

NOTES

4-24

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

Chapter 5 LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 ENGINE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 HYDROSTATIC DRIVE AND HYDRAULIC RESERVOIR REFILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 FINAL DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 GREASE FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 LUBRICATION AND SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 AS REQUIRED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 EVERY 10 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 EVERY 50 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 EVERY 100 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 EVERY 250 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 EVERY 500 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 EVERY 1000 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 EVERY 2000 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

5-1

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

NOTES

5-2

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

LUBRICATION, FILTERS, AND FLUIDS This chapter contains basic service and maintenance procedures to keep the machine operating under normal working conditions. This chapter does not replace the professional service that your dealer provides for the more complex procedures and service. Do not attempt to service or maintain this machine unless you understand the procedures completely. Contact your dealer If you have any questions about the service or repair of this machine.

WARNING All Service, Lubrication and Adjustment procedures in this manual should be performed with the machine on a firm level surface, with all attachments down on the surface, engine off, and key removed, unless otherwise specified.

Failure to follow these instructions and procedures may result in death or serious injury.

GENERAL SAFETY BEFORE YOU SERVICE

DANGER 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. Failure to follow these directions may result in death or serious injury.

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

Lubrication, maintenance and service intervals in this manual are based on normal working conditions. If the machine is working in extreme and adverse conditions, the service interval times should be shortened. If you have any questions about service intervals, contact your Dealer.

Before you ser vice the machine, put a Do Not Operate tag on the instrument panel. Confirm that the machine is clearly marked Out Of Operation.

One Do Not Operate tag is included with your machine. Additional tags are available from your Dealer. If you do not have the Do Not Operate tag that was included with the machine, make a tag so that the machine is clearly marked Out.

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

Failure to follow these directions may result in death or serious injury.

321-4614X

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

The information in this manual is provided on the basis of information that was available at the time that the manual was written. Settings, procedures, part numbers, software, and other items can change.

These changes can affect the service that is given to the machine. Ensure that you have complete and most current information from your Dealer before you start any machine operation.

Figure 1

Use the correct safety clothing and safety equipment.

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

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, diesel fuel thinners, etc., will cause discoloration, cracking or deformation of the part being cleaned.

5-3

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS ENGINE HOURMETER

To reach the Next Service Menu:

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

Turn the key switch to on.

BD06G223-01

Push and hold the enter button. This will bring the service screen up. Now use the arrow down key to get to the next service menu.

Figure 2

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.

The operator may use the AIC Service Menu to see when the next service is due and select choices for service reminders.

NEXT SERVICE MENU This menu:

• allows the operator to display how many hours until next service.

• allows the operator to acknowledge that service has been completed.

BT09A051-01

Figure 3

NEXT SERVICE SCREEN WITH NEXT SERVICE HOURS HIGHLIGHTED FOR SELECTION

The operator may select from the following choices: Next: Displays how many hours until next service.

Allows operator to reset hours for next service.

Mode: Allows switching between the following.

Auto: Allows the machine to automatically reset the service interval. A service reminder will appear at power up and power down.

Man: The operator must manually reset when service is due. A service reminder will appear at power up and power down.

Off: Service reminders are off.

Ser vice per iods are adjustable in 50 hour increments.

• allows the operator to reset the service hour clock.

• allows the operator to change the mode of operation.

BT09A052

Figure 4

When all infor mation is entered, the Ser vice Completed screen will appear. Press the confirm key to set.

5-4

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUIDS AND LUBRICANTS ENGINE CRANKCASE Capacity with Filter Change ...................................................................................................12.3 Liters (13.0 qts) Capacity with out Filter Change .............................................................................................11.5 Liters (12.2 qts) Specification ...............................................................................................................Case Akcela No. 1 10W-30 FUEL TANK Capacity ...............................................................................................................................154.4 Liters (40.8 gal) Specification ................................................................................................................................................Diesel NOTE: Biodiesel fuel may be used in these machines. See page 5-8 in this Chapter for important information.

COOLING SYSTEM Capacity .................................................................................................................................21.4 Liters (22.6 qts) Specification ........... Case HD Universal Low-Silicate Anti-Freeze/Coolant and Deionized water, 50%/50% mix.

NOTE: If the ambient temperature is lower than -37°C (-34°F), adjust the mixture according to the coolant manufacturer specifications.

HYDROSTATIC DRIVE AND HYDRAULIC RESERVOIR REFILL Capacity .................................................................................................................................72.7 Liters (16.5 gal) Specification ........................................................................................................... Hydrosyst AW 68 / MAT 3508 Cold Temperature Specification .................................................................. Akcela Excavator Fluid / MAT 3509 FINAL DRIVES Capacity - Each Side.................................................................................................................14.2 Liters (15 qts) Specification ......................................................................................................Case Hy-Tran® Ultra / MAT 3505 GREASE FITTINGS Quantity............................................................................................................................................. As Required Specification .............................................................................................................. Case Molydisulfide Grease

5-5

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART

As Required (AR)

Every 10 Hours

Initial 20 Hours Every 50 Hours Every 100 Hours Every 250 Hours

Every 500 Hours

Every 1000 Hours

5-12 5-12 5-13 5-13 5-13 5-14 5-15 5-15 5-16 5-16 6-3 5-18 5-19 5-20 5-21 5-24 5-25 5-26 5-27 5-28 5-28 5-29 5-30

See Dealer 5-31 5-32 Every 2000 Hours

5-33 5-33

5-6

Fan and Air Conditioning Drive Belt Dust Valve Dozer Blade Shaft Roller Clean Tracks And Check Track Shoe Bolts Track Chain Tension Cab Air Filters Engine Oil Coolant Reservoir Fluid Level Transmission and Hydraulic Fluid Level Equipment Pivot Points Initial Track Shoe Bolt Torque Check Fuel Filter for Water Radiator Fluid Level Final Drive Oil Level Engine Oil and Filter Fuel Filters Fuel System Battery Fluid Level Hydraulic Reservoir Breather Relief Valve Fuel Tank for Water Drive Shaft Slip Spline Fuel Tank Breather Final Drive Oil Change Engine Valve Clearance Engine Coolant Engine Air Filter System Hydraulic/Transmission Fluid and Filter Change Reservoir Suction Screens

REPLACE

LUBRICATE

DRAIN

CHANGE

CLEAN

CHECK

SERVICE POINTS

INITIAL

SERVICE INTERVAL

PAGE NUMBER

FREQUENCY IN HOURS

AR AR AR AR AR AR 10 10 10

AR AR

10 20 50 100 250 500 500 500 500 1000 1000 1000 1000 1000 1000 2000 2000 2000 2000 2000

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS LUBRICATION AND SERVICE PRODUCTS

Figure 5

BD08A523

For the very best protection of your investment, use the Case Family of Lubrication and Service Products. Contact your Dealer for these products and any questions you might have about your machine’s service and lubrication requirements.

SYSTEMGARD LUBRICATION ANALYSIS PROGRAM

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.

Systemgard Analysis Packages are available for Oil/Hydraulic, Diesel Fuel and Coolant Tests.

BP97H063

Figure 6

ENVIRONMENT Always consider the environment and dispose of all fluids and lubricants in accordance with local, regional and national standards.

Do not put oil or fluids into the ground or into containers that can leak.

Check with your local environmental or recycling center or your Case Dealer for correct disposal information.

5-7

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS BIODIESEL FUEL Fatty Acid Methyl Ester Biodiesel (Biodiesel Fuel) consists of a family of fuels derived from vegetable oils treated with methyl esters.

IMPORTANT: Biodiesel fuel blends are approved for your engine only if they comply with Specification Standards EN 14214 or ASTM D6751.

IMPORTANT: It is imperative that you check which blend is approved for your engine with your local dealer. Beware that the use of biodiesel fuel that does not comply with the Standards EN14214 or ASTM D6751 could lead to severe damage to the engine and fuel system of your machine. The use of fuels that are not approved may void warranty coverage.

Biodiesel Fuel Usage Conditions IMPORTANT: The biodiesel fuel must meet the fuel specifications mentioned above.

When handling biodiesel fuel, care must be taken not to allow water into the fuel supply. Biodiesel fuel will actually attract moisture from the atmosphere. Fuel tanks must be kept as full as possible to limit the amount of air and water vapors in them. It may be necessary to drain the fuel filter water tap more frequently.

Potential oxidation and stability could be a problem with the fuel stored in the machine.

Biodiesel fuel may degrade natural rubber gaskets and hoses, as it is more solvent than petro-diesel.

Check hoses and other engine components more frequently when using a biodiesel fuel.

BIODIESEL STORAGE IMPORTANT: DO NOT store machines for more than three months with biodiesel blends in the fuel system. DO NOT store biodiesel fuel in on-site storage tanks for more than three months.

Biodiesel fuel must be purchased from a trusted supplier that understands the product and maintains good fuel quality. Biodiesel fuel must be pre-blended by the supplier. Mixing biodiesel fuels on site can result in an incorrect mixture which can lead to problems with both engine and fuel system.

DO NOT allow water to collect in the fuel or storage tanks. Keep fuel tanks and storage tanks as full as possible to limit the amount of air and water vapors. It may be necessary to drain the machine fuel filters more frequently. Potential oxidation and stability could create a problem with fuel stored in the machine.

Engine perfor mance is effected by the use of biodiesel fuel. There may be up to 12 percent reduction in power or torque depending on the blend used.

If long periods of storage are required, run the machine for 20 hours using regular diesel fuel in order to flush the biodiesel fuel from the engine fuel system.

IMPORTANT: DO NOT modify the engine and/or fuel injection pump settings to recover reduced performance.

IMPORTANT: Biodiesel fuel must not be stored in on-site storage tanks for more than 3 months.

The reduced power must be accepted if using any biodiesel fuel blend.

Any spillage of biodiesel fuel must be cleaned up immediately before it can cause damage to the environment and/or the paint finish of the machine.

Some modification may be required to allow the engine to use biodiesel fuel. Consult your dealer for c o m p l e t e i n fo r m a t i o n r e g a r d i n g a p p r o v e d modifications.

Before using biodiesel fuel blends, you should consult with your dealer to receive full information about the approved blend for your machine and any detailed conditions of its usage.

Biodiesel has a higher cloud point than diesel fuel.

IMPORTANT: The use of high biodiesel fuel blends is not recommended in cold weather conditions.

With biodiesel fuels, it may be necessary to change engine oil, engine oil filters and fuel filter elements more frequently then with diesel fuel. Biodiesel can remove rust and other particles that adhere to the inside of the fuel tank. These particles are then trapped by the vehicle filters and may cause shortened filter life and/or filter blockages. In cold weather, this is more likely to occur. Consult your dealer for information on cold weather operation and proper maintenance inter vals when using any biodiesel fuel blend.

5-8

Be aware that not fulfilling the requirements and conditions of biodiesel fuel usage will void your machine’s warranty coverage.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS ACCESS DOORS AND PANELS

3

1 2

Figure 7

BD08M005

1. UPPER LEFT ENGINE ACCESS DOOR 2. LOWER LEFT ENGINE ACCESS PANEL 3. LEFT REAR ACCESS DOOR

Figure 10

BD08N014

UPPER LEFT ENGINE ACCESS DOOR AND LOWER LEFT ACCESS PANEL OPEN

Figure 11

BD08N055

Figure 8

BD08N053

Pull out on the bottom portion of the engine access door handle to open it.

Push up on this latch to open the left rear access door. Push down on the latch to open the right rear access door.

This door may be locked with a padlock.

This door may be locked with a padlock.

6 4

7

5

Figure 12

BD08D186 BD08N054

Figure 9

4. LEFT ENGINE ACCESS DOOR SUPPORT ROD

Lock the left engine access door open with the support rod. Make sure the rod sets into the bracket, as shown, before servicing the machine.

LEFT REAR ACCESS DOOR OPEN 5. BATTERY 6. FUSE AND RELAY LOCATION 7. MASTER DISCONNECT

After opening the left engine access door you may lift out the lower access panel.

5-9

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

9

8

10

Figure 13

BD08M006

8. RIGHT REAR ACCESS DOOR 9. UPPER RIGHT ENGINE ACCESS DOOR 10. LOWER RIGHT ENGINE ACCESS PANEL

C C

A Figure 14

To open the right side engine access panels it is necessary to remove four bolts and loosen two.

Remove the bottom three bolts (A) on the lower panel and remove it. Remove the center bolt (B) only on the upper panel.

Loosen the two outside bolts (C) on the upper panel.

Leave these bolts on the machine to hang the door when installing.

Lift the upper panel off.

Reverse this procedure to reinstall the panels.

Hang the upper panel first and then install the lower panel. Adjust the panels and start the four bolts that were removed before tightening all six bolts.

5-10

Figure 15

UPPER RIGHT ENGINE ACCESS DOOR AND LOWER RIGHT PANEL OPEN

B

BD08N056

BD08N015

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Access Doors And Panels - Continued

12 13 11 17

Figure 19

BD08M007

Figure 16

BD08D184

17. CAB EXTERIOR AIR FILTER ACCESS

RIGHT REAR ACCESS DOOR OPEN 11. WINDSHIELD WASHER BOTTLE 12. MAINTENANCE DECAL 13. HYDRAULIC/HYDROSTATIC DRIVE FILTERS/HYDRAULIC BREATHER

14

18

15

Figure 20

BD02J067

18. SERVICE TOOL PORT ACCESS

Figure 17

BD08M003

14. RADIATOR ACCESS DOOR 15. RADIATOR CAP ACCESS DOOR (SHOWN OPEN)

19 16

Figure 21 19. ENGINE OIL DRAIN ACCESS PANEL (LOOKING TOWARD THE FRONT OF MACHINE, FROM REAR)

BD08N002

Figure 18 16. RADIATOR CAP ACCESS DOOR (SHOWN WITH LOCK INSTALLED)

BD08M057

5-11

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

AS REQUIRED MAINTENANCE FAN AND AIR CONDITIONING DRIVE BELTS

Air filter dust valve

Check the condition of the belts as required by machine hours and working conditions. Check for cracking, deterioration and replace as necessary.

The fan belt uses an automatic belt tensioner and will not need tension checks.

Adjusting The Air Conditioning Belt: 1. Keep all non-authorized personnel clear of the area. Park the machine on firm, level ground, lower the attachment to the ground. Stop the engine and remove the key.

2. Turn the master disconnect to OFF. BD02J088-01

Figure 23

Under normal conditions the dust valve will clear itself. Certain working or environmental conditions, may make it necessary to remove the valve and wipe it clean. In extreme cold make sure it does not ice shut.

2

WINDSHIELD WASHER BOTTLE

1

BD08N018

Figure 22

1. PIVOT BOLT 2. ADJUSTMENT BOLT

3. Loosen the pivot bolt.

4. Loosen the adjustment bolt.

5. To tighten the belt, pull the compressor in the correct direction.

6. To loosen the belt, push the compressor in the correct direction.

7. Tighten the adjustment bolts.

8. Tighten the pivot bolts.

If adjustments were necessary, run the machine for a short period and check the belt again.

BD08D184

Figure 24

As necessary, add windshield washer fluid to the bottle. Do not activate the washers if the bottle is empty. Damage to the washer motor will occur.

COOLERS AND ENGINE COMPARTMENT CLEAR OF DEBRIS In cer tain wor king conditions it may become necessary to check the radiator, coolers and engine compartment for a build up of debris, dirt and foreign material that might impede cooling components.

1. Keep all non-authorized personnel clear of the area. Park the machine on firm, level ground, lower the attachment to the ground. Stop the engine and remove the key.

2. Turn the master disconnect to OFF. 3. Open the engine access and inspect for debris build up. Clean as necessary.

5-12

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS AS REQUIRED MAINTENANCE - continued

DOZER BLADE SHAFT ROLLER

TRACKS

Lubricate the dozer blade shaft roller grease fitting, as required.

Specification . . . . . . . . . Case Molydisulfide Grease

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

1

Check the track tension frequently when you operate.

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

Correct track adjustment is the most important factor that helps to control undercarriage wear. The correct track sag should always be maintained. See Chapter 6 Maintenance and Adjustm ents for information on adjusting track tension.

Figure 25

BD09A021

1. DOZER BLADE SHAFT ROLLER GREASE FITTING

The dozer blade shaft roller fitting is located behind the right rear access door. One fitting.

REAR ACCESS DOOR HINGES Lubricate the rear access door hinge fittings, as required.

Specification . . . . . . . . . Case Molydisulfide Grease

1

1

BD08D187

Figure 26

1. REAR ACCESS DOOR HINGE GREASE FITTINGS

Two fittings per door.

5-13

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS CAB AIR FILTERS The internal cab filter is located behind the seat.

1 3

4

4

Figure 29 3. EXTERNAL CAB FILTER COVER 4. EXTERNAL CAB FILTER COVER THUMBSCREWS

BD08N022

Figure 27

BD06G123-01

1. INTERNAL CAB FILTER

Check and clean the internal cab filter as required.

This filter may be cleaned with mild soap and water.

5

5

2 BD08N023

Figure 30

5. EXTERNAL CAB FILTER THUMBSCREWS

Remove the two thumbscrews that hold the paper filter in place and replace the filter.

BD08M007

Figure 28

2. EXTERNAL CAB FILTER PRIMARY COVER

The external cab filter is located behind the cab under the rear glass. Remove the exterior thumb screws to access the secondary filter cover.

5-14

Reverse the procedure after installing the new filter.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

EVERY 10 HOURS ENGINE OIL LEVEL

COOLANT RESERVOIR FLUID LEVEL

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

Specification . . . . . . . . .Case Akcela No. 1 10W-30

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.

Specification . . . . . Case HD Universal Low-Silicate Anti-Freeze Coolant and Deionized water 50%-50% mix.

To get an accurate measure of the engine oil level, make sure to push the engine oil level dipstick completely down before removing. If the engine was running recently, allow for oil to drain down to the pan before checking.

1 2

1

Figure 32

BD08M010

1. COOLANT RESERVOIR BD08M009

Figure 31

1. ENGINE OIL DIPSTICK 2. ENGINE OIL FILL TUBE

1. Keep all non-authorized personnel clear of the machine. Move the machine to firm level ground and place the attachment on the ground. Turn the engine off.

2. Pull engine dipstick out, clean it with a clean, dry, lint free cloth. Reinsert into engine. Pull out again to visually inspect the engine oil level on dipstick.

3. If necessary to add oil, remove oil filler cap and fill engine oil to proper level.

4. After adding oil, check oil level again, replace filler cap and dipstick and close engine cover.

See page 5-21 for proper Oil Viscosity / Temperature Range usage.

1. Keep all non-authorized personnel clear of the machine. Move the machine to firm level ground and place the attachment on the ground. Turn the engine off.

2. Proper coolant level is between FULL and LOW marks.

3. If necessary to add coolant, remove reservoir cap and fill to proper level with fresh coolant mixture.

4. If no coolant is shown in reservoir, check coolant level in radiator. Fill radiator with proper coolant mixture and replace cap. Then refill reservoir to proper level. Inspect hoses and connections for leaks.

WARNING WARNING: Never remove radiator cap when engine is hot. Allow engine to cool before removing radiator cap. Failure to comply could result in machine damage, injury or death.

It is recommended that ethylene glycol and water be used in the machine year round.

5-15

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 10 HOURS

GREASE EQUIPMENT PIVOT POINTS Specification . . . . . . . . Case Molydisulfide Grease

HYDRAULIC / HYDROSTATIC DRIVE FLUID LEVEL CHECK Specification . . . . . . . Hydrosyst AW 68 / MAT 3508 Check the fluid level every 10 hours of operation or each day, whichever occurs first.

2

WARNING WARNING: Release all hydraulic pressure before performing any work on the hydraulic system.

Hydraulic fluids are under extreme pressure. Failure to comply could result in machine damage, injury or death.

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.

1 3

Figure 35

BD02H017

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

4

1

Figure 36

BD02F026

4. Tilt cylinder, rod end . . . . . . . . . . . . . . . . . . . . . 1 Figure 33

BD06E031-01

1. HYDRAULIC / HYDROSTATIC DRIVE OIL RESERVOIR SIGHT GAUGE

The hydraulic / hydrostatic drive oil reservoir sight gauge is located behind the right-rear access door.

The oil level must be up to the FULL COLD mark.

6 5 2

BD09C026

Figure 37

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

BD06E032-01

2. HYDRAULIC RESERVOIR FILL TUBE

5-16

Figure 34

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 10 HOURS

7 7 7

BD09C001

Figure 38

BD06G225

Figure 41

10. Angle cylinder closed end . . . . . . . 2 (1 ea. side)

7. Blade pitch strut . . . . . . . . . . . . . . . . . . . . . . . . 2

8

Figure 39

BD08N025

8. C-frame pivot pin. . . . . . . . . . . . . . .2 (1 ea. side)

9

BD02J017

Figure 40

9. Ripper lift cylinder . . . . . . . . . . . . . .2 (1 ea. side)

5-17

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

EVERY 50 HOURS DRAINING WATER FROM FUEL FILTER Check the filter for water and sediment every 50 hours of operation. The filter is located on the left side of the engine.

4

Figure 44

BD09A022

2

4. FUEL TANK DRAIN PLUG

1

4. If water or sediment are found in the filter it will be necessary to drain any water and sediment from the fuel tank. See draining fuel tank in this chapter.

Figure 42

BD08H511

1. FUEL FILTER 2. PRIMING PLUNGER

WARNING

1. Keep all non-authorized personnel clear of the machine. Move the machine to firm level ground and place the attachment on the ground. Turn the engine off.

WARNING: Do not smoke or allow any open flame near by when draining fuel. Stop engine. Thoroughly clean up any spilled fuel. Failure to comply could result in machine damage, injury or death.

3 5

BD08H510

Figure 43

3. DRAIN VALVE AT BOTTOM OF FILTER

2. Remove the wire at the bottom of the fuel filter before draining.

3. Rotate the drain valve at the bottom of the filter to the left (counter-clockwise). Drain any water and sediment from the fuel filter. Tighten the valve ONLY finger tight.

5-18

BD09A023

Figure 45

5. ENVIRONMENTAL FUEL DRAIN (IF EQUIPPED)

A drain hose is supplied with machines so equipped.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

EVERY 100 HOURS RADIATOR COOLANT LEVEL Check the radiator coolant level at the sight gauge every 100 hours of operation when the coolant is cold and the engine is stopped. The coolant must be seen in the sight gauge.

Specification . . . . .Case HD Universal Low-Silicate Anti-Freeze/Coolant and Deionized water, 50%/50% mix 50% water and 50% anti-freeze/coolant is the mix for most conditions. See the manufacturer instructions on the container.

DO NOT remove the radiator cap for this check.

Figure 47

BD08N058

3. Lift up on the latch handle to open the access door. The sight gauge is located inside the access door.

4. Coolant must be visible in the sight gauge.

1

Figure 46

BD09A042

Check coolant level every 8 hours. Coolant should be changed at 1000 hours. The coolant reservoir tank is located on the left side of the engine compartment.

WARNING Never remove radiator cap when engine is hot. Allow engine to cool before removing radiator cap. Failure to comply could result in machine damage, injury or death.

1. Keep all non-authorized personnel clear of the machine. Move the machine to firm level ground and place the attachment on the ground. Turn the engine off.

2. Push down on the top portion of the latch of the access door. This will release the latch handle.

BD08M008

Figure 48

1. SIGHT GAUGE

5. If coolant is low, add the correct amount with ethylene glycol and water. DO NOT attempt to remove the radiator cap until all components of the engine and cooling system are cool to the touch.

When removing the radiator cap, always open it slowly to the first notch. Allow pressure to be released slowly and then open the cap completely.

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.

6. If necessary to add coolant, remove reservoir cap and fill to proper level with fresh coolant mixture.

5-19

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

EVERY 250 HOURS FINAL DRIVE OIL CHECK

BATTERY FLUID CHECK

Check the Final Dr ive oil ever y 250 hours of operation.

Specification . . . . Case Hy-Tran® Ultra / MAT 3505

See page 7-4 in the Electrical Chapter of this manual for complete battery instructions.

1. Keep all non-authorized personnel clear of the machine. Move the machine to firm level ground and place the attachment on the ground. Turn the engine off.

1

Figure 49

BD02M131

2. Remove the check plug (1) slowly to release the pressure. Oil should be to the top of this plug orifice on both sides.

2

BD02J069

Figure 50

3. If necessary, add oil to the final drive through the fill plug (2).

4. Install the fill plug.

Repeat steps 1 through 4 for the other final drive.

5-20

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

EVERY 500 HOURS ENGINE OIL AND FILTER CHANGE Change the engine oil and engine oil filter every 500 hours of operation. Change the engine oil more frequently than every 500 hours when the engine operating conditions are severe (frequent stopping and starting and high or low engine temperatures).

Specification . . . . . . . Case Akcela No. 1 - 10W-30 ENGINE LUBRICATION AND ENGINE OIL 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.

BP97H064-01

If Case Multi-Viscosity Engine Oil is not available, use only oil meeting API CI-4 engine oil service category.

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.

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

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.

Figure 51

OIL VISCOSITY/TEMPERATURE RANGES

BC07N452

Figure 52

5-21

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Oil Change and Filter Replacement

Changing Oil and Filter

Oil Capacity - With Filter Change

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

650L . . . . . . . . . . . . . . . . . . . . . 12.3 Liters (13.0 qts) Engine Oil Level 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.

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

Change the engine oil more frequently than every 500 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 suitable container that will hold the drained quantity.

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

2 1 1

Figure 54

BD08M002

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

Two bolts secure the plate.

BD08M009

Figure 53

1. 650L ENGINE OIL DIPSTICK 2. 650L ENGINE OIL FILL CAP

2

BD08H517

3. ENGINE OIL DRAIN PLUG

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

5-22

Figure 55

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

3

Figure 56

BD09C026

4. ENGINE OIL FILTER

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 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, turbocharger oil lines with oil.

prime

the

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.

5-23

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 500 HOURS FUEL FILTER REPLACEMENT Replace the in line and primary fuel filter every 500 hours of operation. For convenient maintenance, change both the fuel filter and the oil filter at the same time.

1

The fuel filter and lines must be primed with fuel after replacing the filter. See the following page for instructions on Priming the Fuel System.

Never allow fuel to spill or leak into the ground or the environment. Dispose of the used filters and fuel by fo l l o w i n g a l l l o c a l , r e g i o n a l a n d n a t i o n a l environmental guidelines and regulations.

1. Keep all non-authorized personnel clear of the machine. Move the machine to firm level ground and place the attachment on the ground. Turn the engine off.

2. Have a container ready to capture fuel that might spill or leak from the hoses and filters.

Figure 59

BD08M002

1. ENGINE BELLY PAN

5. Remove the belly pan to access the fuel filter.

Two bolts secure the plate. Remove the in line fuel filter. Notice the direction of fuel flow and how the filter is positioned.

2 2

BD08H508

Figure 60

2. PRIMARY FUEL FILTER BD08H508

Figure 57

3. Clean the area around the filter head and priming plunger to help reduce the risk of contamination.

6. Turn the primary filter counterclockwise and remove it from the filter head.

7. Apply a thin layer of clean oil to the gasket of the new primary filter.

8. Install the primary fuel filter. Use your hands to tighten the filter 3/4 turn after the filter makes contact with the filter head. Do not use a strap wrench.

9. Follow steps for bleeding air from the fuel system.

BD08H509-01

Figure 58

FUEL SHUTOFF VALVE IN OFF POSITION

4. Close the fuel shutoff valve. The shutoff valve will be positioned 90 degrees, in relation to the line.

5-24

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS REMOVING AIR FROM THE FUEL SYSTEM Air must be removed from the fuel system if one of more of the following conditions occur: A. Fuel filters have been replaced.

B. The engine stops because of no fuel in the system.

C. Components of the fuel system are serviced.

D. The machine has been in storage.

1. Fill the tank with fuel.

2. Confirm that the fuel line shutoff valve is in the ON position.

2

1 3

Figure 61

BD08H509

1. FUEL SHUT OFF (ON POSITION) 2. HAND PRIMER 3. AIR BLEED SCREW

3. Loosen the air bleed screw 1 or 2 turns.

4. Push the hand primer down and release, continuously, until fuel has filled the primary filter.

NOTICE: After a few pumps of the primer plunger you should hear fuel start to move into the primary filter. If not, it may be necessary to bump the starter switch to turn the engine over slightly.

5. Operate the hand primer until fuel with no air bubbles flows from around the air bleed screw.

6. Tighten the air bleed screw.

7. Start the engine and check for fuel leaks.

8. Make certain there are no leaks at connection and replace the engine belly pan.

WARNING WARNING: Do not smoke or allow any open flame near by when draining fuel. Stop engine. Thoroughly clean up any spilled fuel. Failure to comply could result in machine damage, injury or death.

5-25

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 500 HOURS BATTERY FLUID LEVEL

WARNING 4

Before you service a battery, always wear face protection, protective gloves and protective clothing.

Battery acid or battery explosion can cause serious injuries.

SA046

Check the fluid level of the batteries every 500 hours of operation.

Specification . . . . . . . . . . . . . . . . . . . . distilled water

Figure 64

BD08H515

4. CELL SPLIT RING

3. In extreme heat conditions, check battery fluid every 250 hours.

If the temperature is 32°F (0°C) or below and you have added water to the batteries, do the following; Connect a battery charger to the batteries or operate the machine for approximately two hours. This procedure is necessary to mix the water with the electrolyte.

1

WARNING Figure 62

BD08H505

1. SINGLE BATTERY CONFIGURATION LOCATION

The battery or batteries, depending on the machine configuration are located behind the left rear access door. Shown above is a single battery configuration.

If dual batteries were installed the additional battery would mount just to the left of the single battery.

3

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.

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

SB034

2 CLEANING THE BATTERIES

BD08H513

Figure 63

2. BATTERY CELL 3. BATTERY CELL CAP

1. Remove battery cell caps and visually inspect electrolyte (acid) level. Proper level is 10 ~ 15 mm (0.4” ~ 0.6”) above cell plates.

2. If the fluid level is low, add distilled water to each cell until the fluid level is at the split ring at the bottom of each cell opening.

5-26

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 a battery saver product. Follow the instructions on the container. These cleaner products do not need water.

2. Use baking soda or ammonia and flush the outside of the batteries with water. If you do not have a battery saver product, use other special cleaners to prevent corrosion on the battery terminals.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

EVERY 1000 HOURS HYDRAULIC RESERVOIR BREATHER Clean the hydraulic reservoir breather and relief valve every 1000 hours of operation. The breather is located behind the hydraulic and hydrostatic drive filters.

1. Keep all non-authorized personnel clear of the machine. Move the machine to firm level ground and place the attachment on the ground. Turn the engine off.

BD06E045-01

Figure 67

6. Clean the valve with a cleaning solvent.

7. Wear full coverage face protection and use compressed air to dry the valve.

8. Install the relief valve breather and close the access door.

Figure 65 HYDRAULIC RESERVOIR BREATHER AND RELIEF VALVE

BD09A041

2. Open the access door and secure it in the open position.

3. Clean the area around the breather and relief valve.

4. Remove the relief valve.

BD06E044-01

Figure 66

5. Remove the clamp that secures the cover.

5-27

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 1000 HOURS GREASE DRIVE SHAFT SLIP SPLINE Specification . . . . . . . . . . Case Molydisulfide Grease NOTICE: Universal Joints are Lubricated for life.

DRAIN WATER AND SEDIMENT FROM FUEL TANK Every 1000 hours of operation, or more frequently in some regions, drain the fuel tank to check for water and sediment.

1

BD08H499

Figure 68

SLIP SPLINE Figure 69

BD09A022

1. FUEL TANK DRAIN PLUG

1. Keep all non-authorized personnel clear of the machine. Move the machine to firm level ground and place the attachment on the ground. Turn the engine off.

2. Have a suitable container ready to capture fuel for inspection and slowly remove the drain plug.

3. Open the drain and allow water and/or fuel to flow. When pure fuel drains, close drain. if water is found in the fuel tank, fuel filters should also be checked.

WARNING WARNING: Do not smoke or allow any open flame near by when draining fuel. Stop engine. Thoroughly clean up any spilled fuel. Failure to comply could result in machine damage, injury or death.

5-28

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 1000 HOURS FUEL TANK BREATHER Clean the fuel tank breather every 1000 hours of operation or if the breather becomes covered with dirt and debris.

Figure 72

BD08H501

FUEL TANK BREATHER

4. Remove the breather.

BD08H500

Figure 70

REAR COVER

1. Keep all non-authorized personnel clear of the machine. Move the machine to firm level ground and place the attachment on the ground. Turn the engine off.

2. This procedure will require the removal of the rear cover and is a two person procedure.

Figure 73

BD08H503

FUEL TANK BREATHER COMPONENTS

5. Clean the fuel cap and breather with cleaning solvent.

6. Wear full face protection and use compressed air to dry.

7. Reverse the components.

BD08H502

procedure

to

reinstall

the

Figure 71

REAR WINDOW WASHER HOSE

3. On machines equipped with a rear window washer, carefully remove the fluid hose from the cover.

5-29

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 1000 HOURS Final Drive Oil Change If possible, drain the final drives when the oil is warm.

You will remove more contamination from the final drives with warm oil.

1

Figure 74

BD02J069

3

BD02H107

2

Figure 75

1. Keep all non-authorized personnel clear of the machine. Move the machine to firm level ground and place the attachment on the ground. Turn the engine off.

2. Clean the area around the fill (1), check (2) and drain plug (3) with cleaning solvent.

3. Remove the fill plug (1)slowly to relieve pressure.

4. Remove the drain plug (3) and drain the final drive oil into a container.

5. Install the drain plug (3) and put new oil in the final drive.

6. Fill until a small amount seeps from the check plug (2) orifice. Install the plug.

7. Install the fill plug (1).

8. Repeat steps 1 through 6 for the other final drive.

5-30

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

EVERY 2000 HOURS CLEANING COOLING SYSTEM Specifications . . . .Case HD Universal Low-Silicate Anti-Freeze/ Coolant and Deionized water 50%-50% mix.

Case XHD Heavy-Duty Anti-freeze/Coolant is also available. This anti-freeze/coolant is pre-charged with supplemental diesel additives.

Coolant Capacity . . . . . . . . . . . . . . .18.9 litres (5 gal) Drain, flush, and replace the engine coolant every 2000 hours of operation or each year whichever occurs first. Clean the system and replace the coolant if the coolant becomes dirty or has the color of rust.

Coolant Solution A mixture of 50% anti-freeze/coolant 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).

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.

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

BD08M003

Figure 76

RADIATOR CAP ACCESS DOOR (SHOWN OPEN)

1. Keep all non-authorized personnel clear of the machine. Move the machine to firm level ground and place the attachment on the ground. Turn the engine off.

2. Open the radiator door. Loosen and remove the radiator cap.

3. Place a container of suitable capacity under the drain valve and drain the radiator. The radiator drain is located under the right side of the radiator.

4. When coolant is completely drained, close the drain valve.

5. Use a system cleaning product to clean and flush the system.

6. After the system has been cleaned and flushed following the cleaning product instructions, close and secure the drain valve.

7. Fill with the proper mix of antifreeze/coolant and water for the system and for the prevailing weather conditions.

8. Check the hoses and water pump for leaks.

9. Make sure that the outside of the engine and radiator is clean.

10. 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.

5-31

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 2000 HOURS AIR FILTER SYSTEM Change the air filter elements every 2000 hours of operation or each year. Always replace both eleme nts if th e air restr iction indicator lamp illuminates and stays on after start up or during operation.

3

Figure 79

BD08N060

3. PRIMARY AIR FILTER ELEMENT

4. Carefully remove the primary (outer) element (3).

Figure 77 AIR FILTER RESTRICTION INDICATOR LAMP

BD06G224-01

The air filter indicator lamp should illuminate briefly on start up and then go out.

4

Replacing the Engine Air Filter Elements: 1. Keep all non-authorized personnel clear of the machine. Move the machine to firm level ground and place the attachment on the ground. Turn the engine off.

BD08A407

Figure 80

4. SECONDARY AIR FILTER ELEMENT

2. Open the left side access panel.

5. Remove the secondary element (4).

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

1

7. Install a new secondary element. Do not clean the secondary element. The secondary element must always be replaced when replacing primary element.

8. Install a new primary (outer) element. Make sure the element has full gasket contact.

2

9. Install the end cover.

BD08N059

Figure 78

1. ENGINE AIR FILTER COVER CLAMP 2. ENGINE AIR FILTER END COVER

3. Pull out on the cover clamp (1) of the air cleaner cover and rotate cover counter-clockwise.

Remove the end cover (2).

5-32

10. Make sure other persons are clear of the machine. Start the engine and check the air filter warning lamp.

IMPORTANT: Each time you service the air filter system make sure both filters are seated properly and the cover is secure.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 3. Rotate all control levers through their respective m ove m e n t s s eve ra l ti m e s t o h e l p r e l i eve pressure.

EVERY 2000 HOURS HYDRAULIC/HYDROSTATIC DRIVE SYSTEM FILTER AND FLUID CHANGE Every 2000 hours of operation the hydraulic / drive system must be serviced.

Specifications . . . . . . Hydrosyst AW 68 / MAT 3508 Cold Temperature Specification. Akcela Excavator Fluid / MAT 3509 Refill capacity with filters . . . . . . . .20 gal (75.7 litres) T h e fo l l o w i n g changed/cleaned.

components

should

4. Slowly loosen, but do not remove the hydraulic reservoir cap to help relieve pressure.

5. Open the right rear access door.

6. Clean the outside of the filters and filter heads with cleaning solvent.

be

• clean hydrostatic and equipment suction screens • change hydraulic and hydrostatic filters • change hydraulic/hydrostatic fluid

3 2

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.

It is best to perform this procedure with the oil warm, but not HOT. Allow the engine, hydraulic and cooling system components to cool before beginning the procedure.

2. HYDROSTATIC DRIVE FILTER 3. HYDRAULIC FILTER

7. Rotate the filters counter clockwise and remove.

Dispose of the used filters in accordance with local and state regulations.

4

1

BD06J139-01

Figure 82

BD09A041

Figure 81

1. HYDRAULIC FILTER INDICATOR LAMP

If machine is new or any part of the hydraulic or hydrostatic drive system has been serviced, replace the filter at 250 hours for the first and second filter change.

BD09A025

Figure 83

4. HYDRAULIC RESERVOIR DRAIN PLUG

8. Remove the drain plug on the hydraulic reservoir and drain the fluid into an acceptable container.

Hydraulic /Hydrostatic Drive Filter Change 1. Keep all non-authorized personnel clear of the machine. Move the machine to firm level ground and place the attachment on the ground. Turn the engine off.

2. Put a Do Not Operate tag on the instrument panel.

5-33

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Hydraulic / Hydrostatic Drive System Filter And Fluid Change - Continued

8

5

BD06E059-01

Figure 86

8. FILLER CAP

17. Remove the reservoir cap and fill with new fluid.

Figure 84

BD09A043

5. SEAT / FLOOR PLATE BOLTS

9. Remove the four bolts that secure the floor plate and raise the seat up to access the suction screens and hoses.

18. Put new Hydrosyst AW 68 fluid into the reservoir.

19. Install the filler cap.

20. Operate the hydraulic equipment and hydrostatic drive at 20% with no load. Check the oil level.

21. Add oil as required. Check for leaks.

6

7

BD08H512

Figure 85

6. HYDROSTATIC DRIVE SUCTION SCREEN 7. HYDRAULIC SUCTION SCREEN

10. Clean the area around the suction screen hoses.

11. Remove the fittings and pull the screens through and clean or replace as necessary.

12. Install the screens, hoses and clamps.

13. Clean the gasket surface on the filter heads with a clean cloth, make sure all dirt and gasket parts are removed.

14. Put clean oil on the gasket of the new filters.

15. Turn the filters clockwise until the gasket makes contact, then tighten an additional 3/4 turn.

16. Replace the hydraulic reservoir drain plug.

5-34

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Chapter 6 MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 INITIAL 20 HOUR TRACK SHOE BOLT TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 STEEL TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 REAR ATTACHMENT TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 ROLL-OVER PROTECTIVE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 DAMAGE TO THE ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 WELDING ON THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 FAN, AIR CONDITIONING DRIVE BELT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6-1

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

NOTES

6-2

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

MAINTENANCE AND ADJUSTMENTS TRACKS Service Specifications

1

3

Clean Tracks . . . . . . . . . . . . . . . . . . . . . As Required Check Tension . . . . . . . . . . . . . . . . . . . . . Periodically IMPORTANT: Always adjust the track tension more often when operating in mud, snow or adverse material. Debris will stick to the track parts and cause the tracks to become too tight.

4

2

INITIAL 20 HOUR TRACK SHOE BOLT TORQUE Check the torque of the track shoe bolts after the first 20 hours of operation and then as required, with a new machine or if the shoes have been removed.

Wide shoes may require more frequent checks.

Turning resistance, working conditions and other variables must be taken into consideration for checking shoe torque intervals. Contact your Dealer if you have any questions concerning shoe torque for your machine.

Do a random check of ten bolts on each side. If bolts are found with incorrect torque values, check all.

BD06E072-01

Figure 1

Tighten the bolts in the sequence shown for the standard track shoe.

Tighten the standard link bolts 190 to 230 pound feet (257 to 311 Nm).

Tighten the master link bolts 225 to 247 pound feet (305 to 334 Nm). Do not over tighten.

IMPORTANT: When track shoe bolts loosen, the holes in the track links and shoes become worn out at an accelerated rate and become extremely difficult to keep tight.

6-3

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TRACKS Clean the tracks and undercarriage as required or at the end of the work shift. Park the machine on a level surface to prevent distortion of the track seals. If the temperature is cold, park the machine on a surface that will not freeze to the track shoes.

Check the track tension frequently when you operate.

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

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

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

2. Move the machine backward 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.

Figure 3

BD06E024-01

4. Place a straightedge over the track, as shown and measure the track deflection midway between the top roller and the idler wheel. The correct adjustment is between 1.5 to 2 inches (38 to 51 mm).

To Tighten The Track:

1 2

Figure 4

See the instructional decal, above, located on the left side of the machine.

BD07G136-01

Figure 2

1. TRACK CHAIN PIN 2. CARRIER ROLLER

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

1

BD08N020

Figure 5

1. TRACK ADJUSTER GREASE FITTING

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

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

6-4

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS AS REQUIRED MAINTENANCE - continued 3. Check the deflection of the track again and adjust, if necessary.

4. Repeat the procedure for the other track.

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

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

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

3. When complete, re-torque the ball check to 44-55 pound feet (60 - 74 Nm).

4. Repeat the procedure for the other track.

6-5

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS STEEL TRACK

3. Install the cap on the track adjuster.

TO TIGHTEN THE STEEL TRACK

4. Move the machine backward and forward the length of the track. Do not use the brakes to stop.

Check the track tension again.

5. Adjust the other track.

Torque Track Shoe Bolts - Steel Track Check the torque of the track shoe bolts after the first 20 hours of operation and then as required, with a new machine or if the shoes have been removed.

BD02H015

Figure 6

1. Put grease into the adjuster grease fitting until deflection is between 38 to 51 mm (1-1/2 to 2 inches).

2. Install the cap on the track adjuster.

Wide shoes may require more frequent checks.

Turning resistance, working conditions and other variables must be taken into consideration for checking shoe torque intervals. Contact your Dealer if you have any questions concerning shoe torque for your machine.

Do a random check of ten bolts on each side. If bolts are found with incorrect torque values, check all.

3. Move the machine backward and forward the length of the track. Do not use the brakes to stop.

1

3

4. Check the deflection of the track again and adjust as required.

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

BD06E072-01

TO LOOSEN THE STEEL TRACK

2

Figure 8

Tighten the bolts in the sequence shown for the standard track shoe.

Tighten the standard link bolts 190 to 230 pound feet (257 to 311 Nm).

Tighten the master link bolts 225 to 247 pound feet (305 to 334 Nm). Do not over tighten.

IMPORTANT: When track shoe bolts loosen, the holes in the track links and shoes become worn out at an accelerated rate and become extremely difficult to keep tight.

BD02H016

Figure 7

1. Grease is under pressure. Wear full face protection. Use a deep socket and slowly 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).

2. Tighten the large adapter 60 to 51 Nm (45 to 55 lb ft).

6-6

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REAR ATTACHMENT TORQUE VALUES

Figure 9

BD02J032

Ripper ................................................................................................................... 1300 to 1160 Nm (855 to 960 ft lb)

BD02M132

Figure 10

Drawbar . . . . . . . . 1300 to 1160 Nm (855 to 960 ft lb)

BD02J096

Figure 11

Hitch . . . . . . . . . . . . 430 to 485 Nm (315 to 355 ft lb)

NOTE: The drawbar can be rotated to change the height of the pin. Position shown is the high position.

6-7

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ADJUSTING THE RIPPER SHANKS

BD02J015

Figure 12

1. Remove the retaining clip and washer.

2. Drive the pin out and adjust the shank to the position desired.

6-8

BD02J016

Figure 13

3. Replace the pin, washer and retaining clip.

The ripper shanks have three positions. Use the appropriate depth for the working condition.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS DOZER BLADE PITCH ADJUSTMENT

WARNING This procedure requires the blade to be lifted slightly in order to make the necessary pitch adjustment.

Raise the blade ONLY high enough to make the adjustment. Failure to follow these instructions may cause serious injury.

1. Raise dozer blade up approximately 100 mm (4 in).

BD02J078

Figure 16

2. Release the dozer blade control lever and shut the engine off.

6. The cover guard may be used as a tool to turn the turnbuckle.

3. Remove the ignition key and set the parking brakes.

7. Replace the cover guard and retaining bolt.

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

2

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 14

BD06G225

1. COVER GUARD 2. RETAINING BOLT

4. Remove the retaining bolt 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 the blade as the crawler travels in reverse.

2. Blade will dig into hard ground easier.

3. Less load spillage over top of blade.

4. Load slides off the blade easier when pushing up hill.

3

BD02J079

Figure 15

3. TURNBUCKLE

5. Adjust the turnbuckle clockwise or counter clockwise until the desired pitch angle is reached.

6-9

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 operator’s seat belt is correctly installed.

DO NOT ATTEMPT TO WELD OR STRAIGHTEN THE ROPS.

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

Maintenance and Inspection of ROPS 1. Check the torque of the ROPS mounting bolts. If necessary, tighten the bolts to the correct torque.

ROPS Mounting Bolts - Both Sides 203 to 237 Nm (150 to 175 lb ft) - both sides 2. 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.

3. Check the operator’s seat and the mounting parts for the seat belt. Tighten the bolts to the correct torque. See “Operator’s Seat” in this manual. Replace the parts that have wear or damage.

Torque Specifications

DAMAGE TO THE ROPS If the machine has rolled over or the ROPS has sustained damage (such as hitting an overhead object during transpor t), you must replace the damaged ROPS components to restore original level of protection.

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.

Before you operate the machine, replace all ROPS components that are damaged.

WARNING

Seat: 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

WARNING Improper ROPS inspection or maintenance can cause injury or death. Do the recommended ROPS inspection shown in this manual. If you must replace th e ROPS, ROPS par ts, or ROPS m oun ting hardware, use only the replacement parts shown in the Case parts catalog for this machine.Failure to comply could cause machine damage, injury or death.

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.

6-10

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.

Failure to comply could result in serious injury or death.

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.

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. Failure to comply could cause machine damage, injury or death.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS WELDING ON THE MACHINE

MACHINE CLEANING

Whenever carrying out a welding operation on the crawler as authorized by the manufacturer and in accordance with correct procedures:

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.

1. Disconnect the batteries.

2. Disconnect the alternator B+ and D+ terminal wires.

3. Disconnect the three deutsch connectors. See the Service manual or contact your Dealer.

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.

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. Failure to comply could cause machine damage, injury or death.

CM115

6-11

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) Type of Fire Extinguisher It is recommended that you have a fire extinguisher on your machine. The fire extinguisher shown below is available from your dealer and can be installed on the machine.

This dry chemical fire extinguisher has a 5 pound capacity and is approved for Class A, B and C type fires. The operating temperature is from - °54 to °49 C (- °65 to °120 F).

Inspection and Care EVERY MONTH - It is recommended that you inspect the fire extinguisher once each month for damage and to insure that the gauge is working correctly.

E 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 17

NOTICE: DO NOT mount the Fire Extinguisher on any part of the ROPS structure. DO NOT make any modifications to the ROPS structure.

6-12

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS FAN AND AIR CONDITIONING DRIVE BELT

FAN, AIR CONDITIONING DRIVE BELT REPLACEMENT

Service Interval

Check the condition of the belt as required by machine hours and working conditions. Check for cracking, deterioration and replace as necessary.

REPLACING THE DRIVE BELT: 1. Park the machine on a level surface and lower all attachments.

2. Turn the key switch off and remove the key.

3. Turn the master disconnect to OFF.

Check the tension of a new drive belt after the first 10 hours of operation.

Check tension. . . . . . . . . . . . . . . . . .Every 250 hours 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.

ENGINE VALVE CLEARANCE The engine valves should be checked by a service technician every 1000 hours.

BD06E068-01

Figure 18

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

5. Push the breaker bar forward just enough to release the tension on the drive belt.

6. Remove the drive belt from the water pump pulley first and then from the other pulleys.

7. Use the breaker bar and install the new belt around the pulleys.

6-13

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS MACHINE STORAGE

Removal From Storage

Storage Preparation

Do not start the engine until steps 1 through 12 have been done.

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.

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.

6. Check the final drives oil level.

4. Drain the fuel tank.

7. Lubricate the machine at all grease fittings.

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.

8. Use petroleum base solvent and remove the Case Rust and Corrosion Preventive from the hydraulic cylinder rods, equipment valve spools and hydrostatic drive valve spools.

6. Drain the flushing oil from the fuel tank.

7. Put 15 ml (one teaspoon) of Shell Oil Company VPI crystals in the fuel tank.

8. Move all hydraulic controls to relieve any pressure in the hydraulic circuits.

9. Change the engine oil and replace the oil filter.

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 hydrostatic drive 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.

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.

6-14

9. See Battery Service in this manual. Install the battery.

10. Fill the fuel tank.

11. Remove the air from the fuel system. See Removing Air from Fuel system in this manual.

12. If the machine is equipped with a turbocharger, you must prime the turbocharger oil lines with oil.

See Priming the Turbocharger in this manual.

13. Start the engine. It is important that you refer to the procedure on Starting the Engine in this manual.

CHAPTER 7 - ELECTRICAL

Chapter 7 ELECTRICAL TABLE OF CONTENTS BATTERY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 CLEANING THE BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7-1

CHAPTER 7 - ELECTRICAL

NOTES

7-2

CHAPTER 7 - ELECTRICAL

ELECTRICAL BATTERY LOCATION AND SERVICE

vent w

The battery or batteries are located behind the left rear access door. The electrical system in this machine is 12 volts negative ground.

2

1

Figure 3

BD08D186

2. SINGLE BATTERY CONFIGURATION

BATTERY SAFETY Figure 1

BD08M005

1. LEFT REAR ACCESS DOOR

WARNING

WARNING

BATTERY AC ID C AUS ES SEV ERE BUR NS. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote: EXTERNAL - flush with water.

INTERNAL - drink large quantities of water or milk.

DO NOT induce vomiting. Seek medical attention immediately.

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

BATTERIES PRODUCE EXPLOSIVE GASES. Keep sparks, flame, cigars and cigarettes away.

Ventilate when charging or using in enclosed area.

Always wear eye protection when working near batteries. Wash hands after handling. KEEP OUT OF REACH OF CHILDREN OR PETS. Failure to comply could result in death or serious injury.

M144C

Figure 2

When the machine is not in use, the batteries need a charge every six weeks to keep the specific gravity at or above 1250.

State of Charge Specific Gravity 100% charged 1.265 75% charged 1.239 50% charged 1.200 25% charged 1.170 Fully discharged 1.110

Before you service components of the electrical system, always turn the Master Disconnect to off and disconnect the NEGATIVE (-) battery cable.

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. Failure to follow these procedure may cause death or serious injury.

SA031

WARNING Before you service a battery, always wear face protection, protective gloves and protective clothing.

Battery acid or battery explosion can cause death or serious injury.

SA046

Figure 4

WARNING Do not reverse battery terminals. Connect positive cable ends to positive (+) terminals and negative cable ends to negative terminals (-). Failure to comply could result in death or serious injury.

M1111

7-3

CHAPTER 7 - ELECTRICAL BATTERY FLUID LEVEL Check the fluid level of the batteries every 250 hours of operation. If the fluid level is low, add clean or distilled water to each vent well until the fluid level is 3/16 inch from the vent well bottom. See the instructions on the battery.

5

In extreme heat conditions check battery fluid more often.

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.

Figure 7

BD08H515

5. VENT WELL SPLIT RING - FILL TO THIS LEVEL

WARNING

3

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.

M503

Keep the battery vent unobstructed and clean.

BD08H504

Figure 5

WARNING

3. VENT WELL CAP (6)

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.

M512 BD08H513

Figure 6

4. VENT WELL CAP OPEN

SERVICING BATTERIES All batteries require cleaning, as necessary, and checks to make sure the venting holes are not restricted.

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 container.

7-4

CHAPTER 7 - ELECTRICAL

WARNING 6

Disconnect the ground cable first when the battery cables are disconnected from the battery. Connect the ground cable last when the battery cables are connected to the battery.

47-55A

7 WELDING ON THE MACHINE Whenever carrying out a welding operation on the crawler as authorized by the manufacturer and in accordance with correct procedures: Figure 8

BD08H505

6. POSITIVE BATTERY CABLE (RED COVER) 7. NEGATIVE BATTERY CABLE (BLACK COVER)

1. Disconnect the batteries.

2. Disconnect the alternator B+ and D+ terminal wires.

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.

BOOSTER BATTERY PROCEDURE

3. Disconnect the deutsch connectors. See the Service manual or contact your Dealer.

4. Connect the welding apparatus ground cable to the component on which the welding operation is to be performed.

Welding in certain areas of the crawler may require that the controller itself be disconnected and grounded. Contact your Dealer.

8

9 BD08H506

Figure 9

8. POSITIVE BOOSTER CABLE 9. NEGATIVE BOOSTER CABLE

To use an auxiliary battery for starting: 1. Do not connect across terminals on starter.

2. Attach a booster battery by connecting the positive terminal of the booster battery to the “positive terminal” provided or to the positive terminal of the machine battery.

3. Connect the negative terminal of the booster battery to the “negative terminal” provided or to the chassis of the machine. Then use recommended star ting procedures from operators seat.

7-5

CHAPTER 7 - ELECTRICAL 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.

• Use Case Battery Saver and 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.

Figure 10

BS09A213

ACCESSORY OUTLET (12 VOLT, 10 AMP) Cab and ROPS models have one outlet on the lower, left side of the front console, shown below.

Figure 11

BD08A447-01

•

12 VOLT ACCESSORY CLUSTER CONSOLE

7-6

OUTLET

ON

INSTRUMENT

CHAPTER 7 - ELECTRICAL FUSES AND RELAYS

1 2

A B C D E F G H

ROPS MODEL

J K L M

CAB MODEL BD08D186 / 84164295 / 84153293

Figure 12

1. FUSES AND RELAYS ARE LOCATED BEHIND THE LEFT REAR ACCESS DOOR, SHOWN ABOVE. 2. FUSE AND RELAY DECALS ARE LOCATED ON THE LEFT REAR ACCESS DOOR.

7-7

CHAPTER 7 - ELECTRICAL

NOTES

7-8

CHAPTER 8 - SPECIFICATIONS

Chapter 8 SPECIFICATIONS TABLE OF CONTENTS ENGINE.................................................................................................................................................................... 3 PERFORMANCE DATA ............................................................................................................................................4 POWER TRAIN ........................................................................................................................................................4 HYDRAULIC SYSTEM .............................................................................................................................................4 ELECTRICAL SYSTEM ............................................................................................................................................4 TRACK DATA ............................................................................................................................................................ 5 TRANSPORT DIMENSIONS ....................................................................................................................................6 OPERATING DATA AND DIMENSIONS ................................................................................................................... 7 OPERATING DATA AND DIMENSIONS - RIPPER ..................................................................................................9 WEIGHTS .................................................................................................................................................................9 OPERATING WEIGHT .............................................................................................................................................9 ADDITIONAL WEIGHTS OF OPTIONAL EQUIPMENT ...........................................................................................9 CONVERSION TABLE ...........................................................................................................................................10 UNITS OF MEASURE ............................................................................................................................................11

8-1

CHAPTER 8 - SPECIFICATIONS

NOTES

8-2

CHAPTER 8 - SPECIFICATIONS

SPECIFICATIONS NOTE: All specifications are given according to SAE Standards or Recommended Practices where the specification applies.

ENGINE Make and Model 650L ............................................................................................................................................Case 445TA/EHA Firing Order 650L ............................................................................................................................................................ 1-3-4-2 Bore and Stroke 650L ............................................................................................................ 4.09 in x 5.20 in (104 mm x 132 mm) Displacement 650L ...........................................................................................................................................274.6 cu in (4.5 L) Compression Ratio 650L ............................................................................................................................................................ 17 to 1 Governor 650L ...............................................................................................................................................Mech. Flywheel Horsepower 650L Max. Rated Gross H.P................................................................ 80.5 H.P. @2000 rpm (60 kW @2000 rpm) 650L Max. Rated Net H.P.................................................................... 73.8 H.P. @2000 rpm (55 kW @2500 rpm) Maximum Peak Torque 650L Gross ........................................................................................ 295 lb/ft @1400 rpm (363 Nm @1400 rpm) 650L Net ........................................................................................... 289 lb/ft @ 1400 rpm (355 Nm @1400 rpm) Rated Speed 650L .........................................................................................................................................................2000 rpm 650L High Idle ................................................................................................................................. 2160 ± 50 rpm 650L Low Idle.................................................................................................................................... 900 ± 50 rpm

8-3

CHAPTER 8 - SPECIFICATIONS PERFORMANCE DATA TRAVEL SPEEDS Speeds Forward and Reverse - ..............................................Infinitely variable from 0 to 8.9 km/h (0 to 5.5 mph) Track Pull (Maximum / Both Tracks) ..................................................................................... 36 074 lb ft. (160 465 N) NOTE: Track Speed and Track Pull are with CLT chain. If machine is equipped with CELT, chain speed will be increased 4 per cent and track pull will be reduced 4 per cent.

Gradability (Maximum Operating Angle Without Losing Engine Oil Pressure) Fore and Aft........................................................................................................................................... 45 degrees Sideways ............................................................................................................................................... 45 degrees POWER TRAIN Transmission - Make .................................................................................................................................. Rexroth Transmission - Type.............................................................................................................. Dual Path Hydrostatic Pumps - Model ..........................................................................................................................................AA4VTG Pumps - Type ......................................................................................................................... Variable Axial Piston Pumps - Displacement ................................................................................................................................... 71 cc Motors - Model ............................................................................................................................................AA6VM Motors - Type .............................................................................................................................Variable Bent Axis Motors - Displacement ................................................................................................................................... 80 cc Transmission Filter - Type.................................................................................. 4 Micron At Beta 75 Replacement Steering Brakes..................................................................................................................................... Hydrostatic Parking Brakes ............................................................................. SAHR (Spring Applied Hydraulically Released) Final Drives - Type....................................................... 2 Helical Gear Reductions w/ Planetary Output Reduction Final Drives - Ratio....................................................................................................................................... 61.4: 1 HYDRAULIC SYSTEM Hydraulic Control System....... Mechanical, 3 spool Standard / 4 spool Optional Equipment Valve, Multi Function Joystick Control 650L Pump Capacity @ 2000 rpm.......................................20.3 gal/min @ 3000 psi (78.8 L/min @ 20 880 Kpa) ELECTRICAL SYSTEM Type of Ground..........................................................................................................................................Negative Battery Make ..................................................................................................................................................Exide Battery Type ...................................................................................................................... 12 Volt Storage SAE 31 CCA...................................................................................................................................................................700 System Voltage ............................................................................................................................................ 12 Volt Quantity...................................................................................................1 12 Volt Standard / 2 Batteries Optional Battery Capacity......................................................................................................................................650 Amps Alternator with attached Regulator Make/Type ................................................................ Denso / 12 Volt, 90 Amp Starter Motor Make/Type..................................................................................... Nippon Denso 7.5 Kw / Solenoid

8-4

CHAPTER 8 - SPECIFICATIONS TRACK DATA Type of Track Adjustment ......................................................................................................................... Hydraulic Type of Track Frame Suspension ....................................................................................................................Rigid Track Link Pitch .......................................................................................................................6.29 in (159.77 mm) Height of 1 Bar Track Shoe Grouser .........................................................................................2.059 in (52.3 mm) Track Pin Diameter ....................................................................................................................1.130 in (28.7 mm) CLT (Case Lubricated Track) Bushing Diameter .......................................................................2.125 in (54.0 mm) CELT (Case Extended Life Track) Bushing Diameter................................................................2.75 in (69.85 mm) CLT Number of Sprocket Teeth ...........................................................................................................................25 CELT Number of Sprocket Teeth .........................................................................................................................13 CLT Sprocket Pitch Diameter ................................................................................................25.213 in (640.4 mm) CELT ...................................................................................................................................26.200 in (665.47 mm) Track Frame Construction .............................Reinforced Boxed Sections with Replaceable Sloped Track Covers Number of Carrier Rollers Per Side.......................................................................................................................1 Number of Track Rollers Per Side .........................................................................................................................6 Track Shoe Width Options Long Track (LT).............................................................................................................................16.0 in (406 mm) Wide Track (WT).......................................................................................... 16.0 in (406 mm) or 20.0 in (508 mm) Low Ground Pressure (LGP)........................................................................................................27.0 in (686 mm) Length of Track on Ground (CLT) ....................................................................................................................... 84.3 in (2141.2 mm) on Ground (CELT)..................................................................................................................... 83.5 in (2120.9 mm) Track Gauge 650L LT ....................................................................................................................................56.47 in (1434 mm) 650L WT & LGP ....................................................................................................................... 68.0 in (1727 mm) Ground Pressure with CLT chain 650L LT (56” Gauge / 96” Pat Blade, 16” shoe .......................................................................42.60 kPa (6.18 psi) 650L WT (67” Gauge / 112” Pat Blade, 20” shoe....................................................................43.05 kPa (6.24 psi) 650L LGP (67” Gauge / 120” Pat Blade, 27 in shoe ...............................................................26.58 kPa (3.86 psi) NOTE: If machine is equipped with optional CELT chain ground pressure will be 0.7 kPa (0.1 psi) greater.

8-5

CHAPTER 8 - SPECIFICATIONS

TRANSPORT DIMENSIONS

Figure 1

BS02K072

TRANSPORT LENGTH AND WIDTH WITH BLADE FULLY ANGLED AT 25°

Blade width

(A) Transport width

(B) 650L w/o Drawbar

2286 mm (90 in)

2127.2 mm

83.7 in

4532.2 mm

178.4 in

2438.4 mm (96 in)

2265.3 mm

89.2 in

4500.2 mm

177.2 in

2844.8 mm (112 in)

2633.7 mm

103.7 in

4650.2 mm

183.1 in

3048 mm (120 in)

2817.8 mm

110.9 in

4693.2 mm

184.8 in

NOTE: Add 63 mm (2.5 in) for drawbar. If unit is equipped with ripper add 886 mm (34.9in).

8-6

CHAPTER 8 - SPECIFICATIONS

OPERATING DATA AND DIMENSIONS

BS02K102

Figure 2

A. Top of Exhaust Stack ............................................................................................................2619 mm (103.1 in) B. Blade Height ..............................................................................................................................843 mm (33.2 in) C. Ground Clearance at Belly Pans ...............................................................................................334 mm (13.1 in) D. Shank Height (Transport Position) .............................................................................................393 mm (15.5 in) E. Top of Seat Head Rest ............................................................................................................2125 mm (83.7 in) F. Height of Cab with Air Conditioning ...................................................................................... 2642 mm (104.0 in) F. ROPS Canopy Height...........................................................................................................2639 mm (103.9 in) Blade Blade Depth Below Ground ................................................................................................................ 531 mm (20.9) Blade Angle Each Direction ............................................................................................................. 0 to 25 Degrees Blade Pitch (adjustable) ..................................................................................................... 52 degrees to 60 degrees 650L LT 90 in. Blade Tilt (0 to 9 Degrees) .........................................................................................180 mm (7.1 in) 650L LT 96 in. Blade Tilt (0 to 9 Degrees) .........................................................................................193 mm (7.6 in) 650L WT 112 in. Blade Tilt (0 to 9 Degrees) .....................................................................................226 mm (8.9 in) 650L LGP 120 in. Blade Tilt (0 to 9 Degrees) ...................................................................................241 mm (9.5 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.

8-7

CHAPTER 8 - SPECIFICATIONS

BS02K101

Figure 3

A. Length, no blade, no rear equipment and CLT chain ............................................................................................................................................ 3114 mm (122.6 in) B. Overall Length, blade straight, no rear equipment .............................................................................................................................................4132 mm (162.7 in) C. Overall Length, blade straight, w/drawbar .............................................................................................................................................4149 mm (163.3 in) D. Overall Length, blade straight, w/ripper .............................................................................................................................................4973 mm (195.8 in) NOTE: Overall Length is with blade pitch at 55 degrees (factory setting).

8-8

CHAPTER 8 - SPECIFICATIONS

OPERATING DATA AND DIMENSIONS - RIPPER Overall Width (Maximum) ..............................................................................................................1839 mm (72.4 in) Width of Cut (Maximum) ................................................................................................................1781 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) ........................................................................ 1300 to 1160 Nm (855 to 960 lb ft)

WEIGHTS OPERATING WEIGHT Operating weights include ROPS full fuel and hydraulic tank, 77 kg (170 lb) operator, CLT chain, track guides, backup alarm, horn, lights, track shoe, C-frame, and blade width as noted.

650L LT- 56” gauge, 96” Pat blade, 16” shoe ............................................................................. 7370 kg (16 250 lbs) 650L WT - 67” gauge, 112” Pat blade, 20” shoe ........................................................................ 7619 kg (16 800 lbs) 650L LGP - 67” gauge,120” Pat blade, 27” shoe........................................................................ 7959 kg (17 550 lbs) ADDITIONAL WEIGHTS OF OPTIONAL EQUIPMENT APPROXIMATE ADD-ON WEIGHT Dual Batteries for ROPS or CAB ........................................................................................................... 29 kg (64 lbs) Rear Screen (For Cab) .......................................................................................................................... 25 kg (55 lbs) Center Rock guards 650L.................................................................................................................... 70 kg (154 lbs) ROPS Canopy or Cab Canopy Brush Guard....................................................................................... 50 kg (110 lbs) Forestry Side Screens ........................................................................................................................... 40 kg (88 lbs) Hydraulic Equipment Pump w/PTO ....................................................................................................... 24 kg (53 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) Tool Box ..................................................................................................................................................... 3 kg (7 lbs) Light Package (4 front / 2 rear) .................................................................................................................. 2 kg (4 lbs) ALLIED EQUIPMENT ADD-ON WEIGHT Winch (Cargo 30) ............................................................................................................................ 454 kg (1001 lbs) Winch (Hyster Model W3C) ............................................................................................................. 612 kg (1350 lbs) Log Arch (Hyster) .............................................................................................................................. 227 kg (500 lbs) Forestry Guards (Door screens and Front screen).............................................................................. 90 kg (198 lbs) Heater for ROPS Unit ............................................................................................................................ 32 kg (71 lbs) Radio ......................................................................................................................................................... 1 kg (2 lbs)

8-9

CHAPTER 8 - SPECIFICATIONS CONVERSION TABLE QUANTITY

TYPICAL APPLICATION

FROM OLD UNIT

TO METRIC UNIT

MULTIPLY BY

Flow, volume

Liquid flow, pump capacity

gal/min

L/min

3.785 412

Force, thrust , drag

Pedal, spring, belt, lever

lbf

N

4.48 222

Length or distance

Land distance, odometers

mile

Km

1.609 344

yd

M

0.914 4

ft

M

0.304 8

in

mm

25.4

lbf·in

N·m

0.112 984 8

Torque bending moment

Power

General, engine torque, fasteners

lbf·ft

N·m

1.355 818

kgf·cm

N·m

0.098 066 5

Btu/min

W

17.584 27

Btu/h

W

0.293 071 1

Motors

hp (electric)

kW

0.746

Air Conditioning, heating

Engine

hp (550 ft·lbf/s)

kW

0.745 699 9

Power quotient

Engine performance

lb/hp

kg/kW

0.608 032 7

Temp Scale

General Use

°F

°C

t°c = (t°f-32)/1.8

Velocity, linear

Vehicle

mi/h

km/h

1.609 344

Volume

Bucket capacity

yd³

m³

0.764 554 9

ft³

m³

0.028 316 85

bushel

m³

0.035 239 07

gal

L or dm³

3.785 412

qt

L or dm³

0.946 352 9

pt

L or dm³

0.473 176 5

Flow, volume

oz

mL

29.573 53

Flow, mass

psi

bar

.0689 655

psi

kPa

6.894 757

lb

kg

0.453 592

Liquid, fuel, lubricants

Figure 4

8-10

CHAPTER 8 - SPECIFICATIONS UNITS OF MEASURE ampere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V kilonewton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kN newton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N pound. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .lb ounce. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . oz newton per millimeter . . . . . . . . . . . . . . . . . . . N/mm pound per inch. . . . . . . . . . . . . . . . . . . . . . . . . . . lb/in revolution per minute . . . . . . . . . . . . . . . . . . . . . . rpm kilometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .km meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .m centimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .cm millimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm mile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mi foot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ft inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .in kilogram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg kilowatt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kW watt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hp Btu per hour. . . . . . . . . . . . . . . . . . . . . . . . . . . Btu/hr kiloPascal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kPa pound per square inch. . . . . . . . . . . . . . . . . . . . . . psi degrees Celsius. . . . . . . . . . . . . . . . . . . . . . . . . . . °C degrees Fahrenheit . . . . . . . . . . . . . . . . . . . . . . . . °F newton-meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . N·m pound foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lb ft pound inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lb in kilometer per hour . . . . . . . . . . . . . . . . . . . . . . . km/h mile per hour . . . . . . . . . . . . . . . . . . . . . . . . . . . .mph cubic meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . m³ cubic yard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .yd³ liter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L milliliter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ml cubic inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . in³ US gallon . . . . . . . . . . . . . . . . . . . . . . . . . . . . .US gal US quart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .US qt fluid ounce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . fl oz Glossary Of Terms Default - the position or setting that a device, control or instrument will initiate unless an alternative position is specified or selected.

Relieving Hydraulic Pressure - to release pressure from the hydraulic circuits Detent; Detent Position - the position that a control device will remain in when placed in position by the operator, usually due to the configuration or notch in the spool.

8-11

CHAPTER 8 - SPECIFICATIONS

NOTES

8-12

CHAPTER 9 - INDEX

Chapter 9

INDEX A

D

Access Doors ............................................. 5-9, 5-20 Air Filter Restriction Lamp ................................... 3-7 Air Filter System Warning Lamp ............................................... 5-32 Anti Theft Cover ................................................. 3-23

Decelerator Pedal ...............................................3-12 Decelerator Pedal Operating Instructions ..........4-10 Direction Control Lever ............................... 3-14, 4-6 Display-Service/Enter Switch ...............................3-4 Dozer Blade Control Lever .................................3-16 Angle Left .......................................................3-16 Angle Right ....................................................3-16 Float ...............................................................3-16 Hold ................................................................3-17 Lift ..................................................................3-16 Lower .............................................................3-16 Tilt Left ...........................................................3-16 Tilt Right .........................................................3-16 Dozer Operation .................................................4-16 Drive Sprocket ....................................................4-17

B Backrest Tilt Adjustment Lever .......................... 3-19 Battery Cleaning .......................................... 5-26, 7-4, 7-6 Fluid Level .............................................. 5-26, 7-4 Safety .............................................................. 7-3 Service ............................................................ 7-3 Before You Start Each Day ................................. 4-5 Blade Control Handle Position ........................... 3-18 Blade Lift Eye .................................................... 4-16 Bushing and Sprocket Wear Chart .................... 4-23

C Cab Door Release/Lock .................................... 3-20 Cab Vent ............................................................ 3-21 Carrier Roller ..................................................... 4-17 Case Extended Life Track (CELT) ..................... 4-19 Climate Control Operation ................................. 4-11 Climate Control Panel ........................................ 3-21 Components of the Undercarriage .................... 4-17 Carrier Roller ................................................. 4-17 Drive Sprocket ............................................... 4-17 Idler ............................................................... 4-17 Recoil Spring Housing ................................... 4-17 Track Adjuster (Steel Track) ......................... 4-17 Track Chain ................................................... 4-17 Track Frame .................................................. 4-17 Track Links .................................................... 4-18 Track Rollers ................................................. 4-17 Track Shoes .................................................. 4-18 Conversion Units ............................................... 8-10 Coolant Levels Coolant Reservoir ......................................... 5-15 Radiator ......................................................... 5-19 Coolant Reservoir .............................................. 5-15 Coolant Solution, Engine Cooling System 5-15, 5-31 Crawler Operation ............................................... 4-4 Before You Start Each Day ............................. 4-5 Direction Control Lever ................................... 4-6 Power Turn ...................................................... 4-7 Steering Gradual Turn ..................................... 4-7

E Electrical System ..................................................7-3 Engine Hourmeter ........................................................5-4 Specifications ...................................................8-3 Engine Air Filter Restriction ..................................3-7 Engine Coolant Heater .......................................4-15 Engine Cooling System Coolant Solution ................................... 5-15, 5-31 Engine Hand Throttle .........................................3-15 Engine Lubrication .................................... 5-21, 5-28 Engine Oil Selection .......................................5-21 Engine Oil Level ....................................... 5-15, 5-22 Engine Oil Selection ...........................................5-21 Engine Operation .................................................4-3 Engine Speed ..................................................4-4 Parking the Machine and Stopping the Engine 4-4 Starting the Engine ..........................................4-3 Engine Service Engine Oil Level ................................... 5-15, 5-22 Oil Change and Filter Replacement ...............5-22 Engine Speed .......................................................4-4 Engine Start Aids Engine Coolant Heater ...................................4-15 Engine Starting Aids ...........................................4-14 Intake Air Grid Heater ....................................4-14 Extinguisher Mounting, Fire ................................6-12

F Factors Controlling Undercarriage Wear ............4-18 Wear Factors You Can Control ......................4-20 Wear Factors You Can Not Control ...............4-20 Filter 9-1

CHAPTER 9 - INDEX Engine ........................................................... 5-22 Hydraulic ....................................................... 5-33 Final Drives Oil Change .................................................... 5-30 Fire Extinguisher Mounting ................................ 6-12 Fluid and Lubricants ............................................ 5-5 Fluid Level Check Hydraulic System .......................................... 5-33 Forward/Rearward Adjustment Lever ................ 3-19 Front Console Key/Ignition Switch .......................................... 3-5 Fuel Handling Precautions .................................. 2-9 Fuel Warning Lamp ............................................. 3-7

G General Safety ..................................................... 5-3

H Hazardous Chemical Precautions ..................... 2-10 Horn ..................................................................... 3-4 Hourmeter, Engine .............................................. 5-4 Hydraulic Filter ................................................... 5-33 Hydraulic Filter Warning Lamp ............................ 3-6 Hydraulic Fluid Change ..................................... 5-16 Hydraulic System ............................................... 5-33 Fluid Level Check .......................................... 5-33 Hydraulic Filter .............................................. 5-33 Hydraulic Fluid Change ................................. 5-16 Specifications .................................................. 8-4 Hydrostatic Drive Filter Warning Lamp ................ 3-6 Hydrostatic Drive Speed Gauge ........................ 3-12 Hydrostatic Drive Speed Parameter Adjustment . 4-8 Hydrostatic Drive Speed Up/Down Buttons ....... 3-14

I Identification Numbers Product Identification Number (P.I.N.) ............ 1-3 ROPS Canopy ................................................. 1-4 Idler .................................................................... 4-17 Instructions, General Safety ................................ 5-3 Instrument Panel ................................................. 3-3 Instrument Panel Lock Out ................................ 3-23 Instruments/Controls Dozer Blade Control Lever ............................ 3-16 Blade Control Handle Position .................. 3-18 Operators Seat .............................................. 3-19 Operators Seat Belt ....................................... 3-23 Ripper Control Lever ..................................... 3-18 Interior Cab Door Release ................................. 3-21

K Key Switch, Ignition ............................................. 3-5 9-2

L Lifting the Crawler ..............................................4-13 Lubrication Quick Reference Chart ......................5-6 Lubrication/Filters/Fluid Hydraulic System ...........................................5-33 Lubrication/Filters/Fluids Access Doors ......................................... 5-9, 5-20 Engine Lubrication ............................... 5-21, 5-28 Fluid and Lubricants .........................................5-5

M Machine Cleaning ...............................................6-11 Machine Components ..........................................1-5 Machine Storage ................................................6-14 Removal From ...............................................6-14 Storage Preparation .......................................6-14 Maintenance Precautions .....................................2-8 Maintenance Quick Reference Chart ...................5-6 Maintenance/Adjustments Machine Cleaning ..........................................6-11 Roll-Over Protective Structure .......................6-10 Seat Belt ........................................................6-10 Spark Arrester Muffler ....................................6-10 Torque Specifications for Seat and Seat Belt Mounting Bolts .......................................6-10 Master Disconnect Switch ..................................3-22 Menu Up/Down Switch .........................................3-4

O Oil Change Engine ............................................................5-22 Final Drives ....................................................5-30 Oil Viscosity/Temperature Ranges .....................5-21 Operating Data and Dimensions Long Track (LT) ...............................................8-7 Ripper ..............................................................8-9 Operating in Cold Weather .................................4-14 Engine Starting Aids ......................................4-14 Operating in Hot Weather ...................................4-14 Operating Instructions Crawler Operation ............................................4-4 Dozer Operation .............................................4-16 Operating in Cold Weather ............................4-14 Operating in Hot Weather ..............................4-14 Track Systems ...............................................4-17 Transporting the Machine ..............................4-12 Vandal Lockup ...............................................3-22 Operating Precautions ..........................................2-7 Operating Weight .................................................8-9 Operators Seat Belt ............................................3-23 Optional Equipment Weights ............................................................8-9 Outside Cab Door Release ................................3-20

CHAPTER 9 - INDEX

P Parking Brake Levers ........................................ 3-13 Parking the Machine and Stopping the Engine ... 4-4 Power Turn .......................................................... 4-7

R Radiator ............................................................. 5-19 Rear Attachment Torque Values ....................... 6-13 Recoil Spring Housing ....................................... 4-17 Reverse/Forward Speed Ratio Control .............. 3-15 Ripper Operating Data and Dimensions ..................... 8-9 Ripper Control Lever ......................................... 3-18 Hold ............................................................... 3-18 Lower ............................................................ 3-18 Raise ............................................................. 3-18 Ripper Shank Adjustment .................................... 6-8 Roll-Over Protective Structure ........................... 6-10 ROPS Damage To ................................................... 6-10 Maintenance and Inspection ......................... 6-10 RPM display ........................................................ 3-4

S Safety Decals .................................................... 2-12 Safety Instructions, General ................................ 5-3 Safety, Battery ..................................................... 7-3 Seat Belt ............................................................ 6-10 Torque Specifications .................................... 6-10 Seat Belt Precautions ........................................ 2-10 Seat Comfort Control ......................................... 3-19 Seat Lumbar Control ......................................... 3-20 Shoe Bolt Torque ................................................. 6-3 Shuttle Parameter Adjustment ............................. 4-8 Sides of the Machine Right-hand, Left-hand, Front, and Rear .......... 1-3 Spark Arrester Muffler ....................................... 6-10 Specific Machine Precautions ........................... 2-11 Specifications Engine Specifications ...................................... 8-3 Hydraulic System ............................................ 8-4 Operating Data and Dimensions .............. 8-7, 8-9 Track System .................................................. 8-5 Travel Speeds ................................................. 8-4 Weights ........................................................... 8-9 Standard Seat Controls Backrest Tilt Adjustment Lever ..................... 3-19 Forward/Rearward Adjustment Lever ........... 3-19 Starting and Stopping Precautions ...................... 2-6 Starting the Engine .............................................. 4-3 Steering Gradual Turn ......................................... 4-7 Steering Sensitivity Adjustment ........................... 4-8

Storage Machine Storage ............................................6-14 Preparation ....................................................6-14 Removal From ................................................6-14 Switch Key/Ignition ......................................................3-5

T Torque Specifications Seat Belt Mounting Bolts ................................6-10 Towing a Disabled Crawler Releasing the Brakes .....................................4-12 Track Adjuster (Steel Track) ...............................4-17 Track Chain ........................................................4-17 Track Frame .......................................................4-17 Track Links .........................................................4-18 Track Rollers ......................................................4-17 Track Shoe Bolts - Steel Track .............................6-6 Track Shoes .......................................................4-18 Track System Specifications ...................................................8-5 Track Systems ....................................................4-17 Blade Lift Eye .................................................4-16 Bushing and Sprocket Wear Chart .................4-23 Case Extended Life Track (CELT) .................4-19 Components of the Undercarriage .................4-17 Factors Controlling Undercarriage Wear ........4-18 Track Shoe Bolts - Steel Track ........................6-6 Transporting the Machine ...................................4-12 Travel Speeds Steel Track Crawler ..........................................8-4

U Utility Safety .........................................................2-4 Utility Safety Rules Message ................................2-4

V Vandal Lockup ....................................................3-22

W Walk-Around Inspection .......................................4-3 Warning Lamp for Air Filter Restriction ..............5-32 Weights ................................................................8-9 Operating Weight .............................................8-9 Optional Equipment ..........................................8-9 Welding on the Machine ............................. 6-11, 7-5

9-3

CHAPTER 9 - INDEX

9-4