Case 750L 850L Tier 3 Crawler Dozer Operator’s Manual - PDF DOWNLOAD

OPERATOR’S MANUAL CRAWLER DOZER

750L 850L TIER 3

READ, UNDERSTAND, AND FOLLOW ALL SAFETY PRECAUTIONS AND INSTRUCTIONS FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE. Bur • Issued 01Jan 08 Printed in U.S.A. • Book/Form Number 87479855 NA Copyright © 2007. CNH America, LLC. All Rights Reserved.

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

All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer This unit first became available 01-2008 REVISION HISTORY

Issue

Issue Date

Applicable Machines

Remarks

First Edition

01Jan 08

750L & 850L Tier 3 Crawler Dozer

87659149 NA

Revision 1

01Jan 08

750L & 850L Tier 3 Crawler Dozer

87479855 NA

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: ❷ Is instructed in safe and proper use of the machine. ❷ Reads and understands the Manual(s) pertaining to the machine. ❷ Reads and understands ALL Safety Decals on the machine. ❷ Clears the area of other persons. ❷ 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 instructions on machine operation and maintenance.

CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Battery post, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

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

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

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

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

TABLE OF CONTENTS CHAPTER 1 GENERAL INFORMATION TO THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 MACHINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 CHAPTER 2 SAFETY AND DECALS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 SAFETY AND SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 CHAPTER 3 INSTRUMENTS AND CONTROLS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 BRAKE, DECELERATOR AND FOOTREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 PARKING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 DIRECTION CONTROL, HYDROSTATIC DRIVE CONTROL, HAND THROTTLE . . . . . . . . . . . . . . . . . 3-15 CHAPTER 4 OPERATING INSTRUCTIONS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 RUN-IN PERIOD OF A NEW MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 CRAWLER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 MOVING A DISABLED CRAWLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 OPERATING IN HOT WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 OPERATING IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 BOOSTER BATTERY CONNECTION TO MACHINE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 TILTING THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 DOZER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 TRACK SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 FACTORS CONTROLLING UNDERCARRIAGE WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 CHAPTER 5 LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 LUBRICATION, FILTERS, AND FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 SYSTEMGARD LUBRICATION ANALYSIS PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 PLASTIC AND RESIN PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 ENGINE HOURMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 LUBRICATION AND MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 ACCESS DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 AS REQUIRED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 TRACK MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 EVERY 10 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 INITIAL 20 HOUR TRACK SHOE BOLT TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 EVERY 50 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 EVERY 250 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 EVERY 500 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 EVER 1000 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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EVERY 2000 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 CHAPTER 6 MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 ROLL-OVER PROTECTIVE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 MACHINE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 ADJUSTING THE RIPPER SHANKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 DOZER BLADE PITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 FAN AND AIR CONDITIONING DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 CHAPTER 7 ELECTRICAL TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 CHAPTER 8 SPECIFICATIONS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

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Chapter 1 GENERAL INFORMATION TO THE OWNER

Figure 1

BD04N036X

L 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.

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

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

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

Anyone making such unauthorized modifications is responsible for the consequences.

This 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.

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

A25808

Figure 2

OPERATOR’S MANUAL POUCH ATTACHED TO SEAT BACK

RIGHT HAND

LEFT HAND

REAR Figure 3

B830800J

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.

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

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

Machine ➤ Machine Model and Type

➤ Product Identification Number: P.I.N.

➤ Year of Build

Component Serial Numbers ➤

Figure 5

BD02J092

Engine serial number

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

➤ ROPS Cab or Canopy serial number

ENGINE

➤

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

Dozer Blade serial number

➤

Figure 6

BD99J147

DOZER BLADE

Figure 4

BD04N009X

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

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MACHINE COMPONENTS

1

11

10

2

8 9 3

5 4

7 6 Figure 7

BD04N003

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

5.

6.

7.

8.

CARRIER ROLLER TRACK ROLLER IDLER LEFT-HAND ENGINE ACCESS DOOR

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

4 3 5 1

2 Figure 8

BD04N033

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

1-4

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

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1

2

Figure 9

BD02J032

RIPPER 1. RIPPER SHANK

Figure 10

BD02M132

DRAWBAR

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Figure 11

BD02M171

HITCH

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Chapter 2 SAFETY AND DECALS TABLE OF CONTENTS SAFETY AND SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 GENERAL AND SPECIFIC SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 UTILITY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 OPERATOR PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Personnel Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Operator - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Proper Entry And Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Starting And Stopping Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Fuel Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Burn Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Hazardous Chemical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Transporting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Roll-over Protective Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Seat Belt Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 To Fasten The Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 To Unfasten The Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Specific Precautions To This Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 READ OPERATOR’S MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 READ REPAIR MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

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CHAPTER 2 - SAFETY AND DECALS

SAFETY AND SAFETY DECALS This Chapter will cover general safety practices and precautions for the operator. This chapter will also show where safety decals are located and provide the information needed to replace any damaged or illegible decals through your local Dealer.

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

Figure 1

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

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

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

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

• CAUTION: Indicates a potentially hazardous Figure 2

BD06E039-01

OPERATOR’S MANUAL STORAGE LOCATED IN POUCH BEHIND SEAT

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

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

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

• The first panel indicates the nature of the hazard.

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

• Background color is YELLOW. • Prohibition symbols such as

and

STOP

if

used, are RED.

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

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

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

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

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

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

• • • •

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

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

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

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

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

Figure 3

RH99G001

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION.

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

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CHAPTER 2 - SAFETY AND DECALS 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 the original users intention. Faded and soiled vest are no longer as highly visible as original intent.

See the manufacture’s recommendation.

• Do not rush. Walk, do not run.

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

who

has

the

BD07G142-01

Figure 4

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

• Exit the machine slowly and use the hand holds.

Do not jump down.

WARNING: Never exit the machine with the engine operating.

Figure 5

OPERATOR - GENERAL

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

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

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

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

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

• Make sure that all protective guards, canopies,

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

Figure 6

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

Figure 7

• 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.

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.

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CHAPTER 2 - SAFETY AND DECALS Starting And Stopping Precautions

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

Sound the horn, if equipped, before starting.

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

• Check that the parking device is applied, place the 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.

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• Use the recommended transport devices when

Operating Precautions

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

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

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

• Never transport a loaded bucket at full height.

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

roading the machine.

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

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

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

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

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

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

• Contact

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

• Operate and drive the machine with care and at

• Before you drive or operate in an area with high

speed compatible with conditions. Use extra caution when operating over rough ground, on slopes, and when turning.

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.

• 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.

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

be under or to reach through the machine and its equipment while operating.

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.

• Select a gear that will prevent excessive speed

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

• Watch for bystanders and never allow anyone to

when going downhill. Do not coast downhill.

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

Provide an escort for roading where required.

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

• You must make a judgment if weather, road, or earth conditions will permit safe operation on a hill, ramp, or rough ground.

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CHAPTER 2 - SAFETY AND DECALS

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

• Be alert and always know the location of all

Maintenance Precautions

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

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.

• Never make repairs on pressurized components,

• Develop fluid and smooth operating techniques

• Before you service the machine, put a DO NOT

and maintain the surface condition where the machine travels in order to control vibration transfer to the operator.

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

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

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CHAPTER 2 - SAFETY AND DECALS

• When absolutely necessary to tow the machine, do not exceed the recommended towing speed. Be sure the towing machine has sufficient braking capacity to stop the towed load. If the towed machine cannot be braked, a 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.

• Observe proper maintenance procedures.

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

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

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

FUEL HANDLING PRECAUTIONS

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

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

Antidote: EXTERNAL - Flush with water.

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

DO NOT induce vomiting. Seek medical attention immediately.

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

WARNING: BATTERIES PRODUCE EXPLOSIVE GASES. Keep sparks, flame, cigars and cigarettes away. Ventilate when charging or using in enclosed area. Always wear eye protection when working near batteries. Wash hands after handling. KEEP OUT OF REACH OF CHILDREN. Figure 8

• When the battery electrolyte is frozen, the battery

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

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

• To avoid spilling fuel maintain control of the fuel

• Hot coolant can spray out if the radiator cap is

• Never remove the fuel cap or refuel gasoline

filler nozzle when filling the tank.

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

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

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

• Never use fuel for cleaning purposes.

• Use the correct fuel grade for the operating season.

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

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

before

attempting

service

HAZARDOUS CHEMICAL PRECAUTIONS

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

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

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

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

dealer

for

correct

disposal

TRANSPORTING PRECAUTIONS

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

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CHAPTER 2 - SAFETY AND DECALS To Unfasten The Seat Belt

ROLL-OVER PROTECTIVE STRUCTURE

• Do NOT modify the ROPS in any manner.

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

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

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

WARNING: Securely fasten your seat belt.

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

Figure 11

SPECIFIC PRECAUTIONS TO THIS MACHINE

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.

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

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

Figure 9

TO FASTEN THE SEAT BELT

1

2

BD99J183-01

Figure 10

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

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

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CHAPTER 2 - SAFETY AND DECALS

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

SC002

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.

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

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

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

READ OPERATOR’S MANUAL 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.

BC00G075

Figure 13

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.

329044A1

Figure 12

384270A1A

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1

2

1

Figure 14

BD02J074

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

1

Figure 16

383973A1

2 BD02M045

Figure 15

Figure 17

321-7040

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3

5

3

5

Figure 18

329044A1 / BD02M133

3. 329044A1

4

Figure 19

383972A1

4. 383972A1 (2) ONE EACH SIDE

5

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

332512A1 / BD99M009

Figure 20

5. 332512A1 (2) ONE EACH SIDE

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6 6

7

7

Figure 21

321-7030

6. 382622A1 7. 321-7030

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8

8

Figure 22

383971A1

8. 383971A1

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

Chapter 3 INSTRUMENTS AND CONTROLS TABLE OF CONTENTS INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Navigating Through The Lcd Multi-function Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Using Arrow Up And Down Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 To Reset The Trip Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Hydrostatic Drive Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 BRAKE, DECELERATOR AND FOOTREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 PARKING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 DIRECTION CONTROL, HYDROSTATIC DRIVE CONTROL, HAND THROTTLE . . . . . . . . . . . . . . . . . . . . . . 3-15 DOZER BLADE CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 BLADE CONTROL HANDLE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 RIPPER CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 SEAT CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 CAB FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 OPERATOR’S SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 To Fasten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 To Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

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INSTRUMENT PANEL

A

1

2

3

4

Figure 1

BD08A447-02

NOTE: To check the condition of the warning lamps turn the key switch to on. 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.

Figure 2

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 on.

0097

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

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.

Figure 3

BS98M034

0099

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Figure 4

Figure 5

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

6

5

10

7

8

9

Figure 6

BD08A447-02

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/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.

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

Figure 10

BS02M143 / BS02M144 \

Figure 8

BC00B132

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

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.

BS02M141 / BS02M142

Figure 9

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

Figure 11

BS98M064

10. BLANK PLUG: Blank plug provided for options.

Figure 12

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

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

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

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

11

Figure 13

BS98M031/RB99J175/RB99J178/RB99J176

BD06G110-01 / 87412595

Figure 14

INSTRUCTIONAL DECAL FOR KEY SWITCH

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

13

14

12

15

B 16

17

Figure 15

BD07G222-01

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.

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.

Figure 20

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 19

BS96H049

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

Figure 21

BS99J182

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

D 20

21

E

C 22

19

18 Figure 22

BD07G222-01

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.

Figure 23

BS98M026

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.

BS98M048

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.

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.

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

Figure 24

BS96H053

BS99J185

Figure 27

Figure 25

BC02N191

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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.

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24

23

Figure 28

BD07G222-01

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

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.

Figure 30

BC00B290

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25

1

2

3 A

B

Figure 31

BD06G111-01

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

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

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

The screen image above is the 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.

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

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.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS Navigating Through The Lcd Multi-function Display Screens

A

C

B

D

Figure 32

BD06G112-01

KEY PAD

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

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

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

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

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS Using Arrow Up And Down Keys At any time, during operation or with the key switch on, the operator may scroll through 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.

Figure 33

BD07H118-01

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

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.

Trip 1 Trip 2 Info 2 Info1

Figure 34

BD06F027-01

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

Figure 35

BD06F170-01

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS To Reset The Trip Information

BD06F170-01

Figure 37

At the Trip screen you wish to re-set.

Press the enter button.

BD06F172-01

Figure 38

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS Hydrostatic Drive Speeds 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.

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

BD02M165-01

Figure 40

HYDROSTATIC DRIVE CONTROL BUTTONS

A

B

Figure 39

BD06G113-01

BD02M166-01

Figure 41

A. HYDROSTATIC DRIVE SPEED UP BUTTON B. HYDROSTATIC DRIVE SPEED DOWN BUTTON

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

BRAKE, DECELERATOR AND FOOTREST

PARKING BRAKES

2 1

3

4

3

4 Figure 43

BD06G115-01 BD06G114-01

Figure 42

4. PARKING BRAKE LEVERS ENGAGED

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

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

2. DECELERATOR PEDAL

5

5

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

Figure 44

BD06G116-01

3. LEFT AND RIGHT FOOTREST

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

5

Figure 45

BD06G118-01

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

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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, as well as 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 gauge.

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

B

Figure 48

BD02M166-01

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.

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

3 3

4. REVERSE TO CONTROL

FORWARD

SPEED

RATIO

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

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

4

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

4

BD06E062-01 / 8371L92

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

1

Figure 53

BD02J038

A Figure 50

BS99J212

B

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.

C

Figure 51

BS99J213

B. LOWER:

Figure 54

BD02J038

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

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

D Figure 52

BS99J214

D. LIFT:

BD02J038

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BS99J21

Figure 56

E. TILT LEFT

BS99J218

Figure 57

E

F. TILT RIGHT

F

C

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

Figure 60

BD02J038 BS99J217

Figure 58

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

H G BS99J219

Figure 59

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

Figure 61

BD02J038

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CHAPTER 3 - INSTRUMENTS AND CONTROLS BLADE CONTROL HANDLE POSITION

RIPPER CONTROL LEVER

1

1

3 2 Figure 62

BD02J038

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.

BD02J038

Figure 63

1. LOWER:

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

BS99J221

Figure 64

2. RAISE:

BS99J222

Figure 65

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS OPERATOR’S SEAT A vinyl mechanical suspension or vinyl air suspension seat may be ordered on a L Series 3 Crawler ROPS machine. Cab machines come standard with cloth air suspension seats.

SEAT CONTROLS

2

1

Figure 68

BD02120

2. FORWARD/REARWARD LEVER

ADJUSTMENT

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

Figure 66

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.

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

)

A

3

1

Figure 69

BD02K005

3. OPERATOR COMFORT CONTROL

BD02K003

Figure 67

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

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

Figure 70

BD02K006

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CHAPTER 3 - INSTRUMENTS AND CONTROLS CAB FEATURES

1

A

Figure 71

BD99J182

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

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

Figure 74

BD02K015

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.

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

2 4

Figure 75

BD02K014

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

Figure 72

BD02H139

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

3

4

BD06G119

Figure 76

3. INTERIOR CAB DOOR RELEASE: Figure 73

BD02N037

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Pull this knob to release the cab door from the locked open position.

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4 5 1 Figure 80

BD02F002

1. CAB TILT HYDRAULIC JACK: Figure 77

BD06G120

This jack is used to tilt the cab over for service access.

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

5. CAB RADIO-CD PLAYER:

6 2

Figure 81

BD02F028

2. CAB TILT JACK HANDLE: Storage for the jack handle is located on the underside of the left rear access door.

Figure 78

BD06H008

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

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

7

BD06G124

Figure 79

7. 12 VOLT AUXILIARY POWER SUPPLY:

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1

Figure 82

BD02F033

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

0 =OFF, 1 = ON.

1

O

Figure 83

379422A2

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS 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.

SA080

TO FASTEN

Figure 86

BD02M168

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

RELEASE BAR

Figure 84

BD02M167

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

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

Figure 85

BD99J184

RELEASE BUTTON

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NOTES

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

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

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

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

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

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

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

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

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

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

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

CRAWLER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Before You Start Each Day . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Direction Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Steering Gradual Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Power Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Counter - Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Adjusting Steering Sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Hydrostatic Drive Speed Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Decelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Climate Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 MOVING A DISABLED CRAWLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Opening The Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Releasing The Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Lifting The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 OPERATING IN HOT WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 OPERATING IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Engine Starting Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 BOOSTER BATTERY CONNECTION TO MACHINE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 TILTING THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Lowering The Rops Cab Or Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 DOZER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Dozer Blade Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 TRACK SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

4-24 4-24 4-25 4-25 4-26 4-26

FACTORS CONTROLLING UNDERCARRIAGE WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Bushing and Sprocket Wear Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

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CHAPTER 4 - OPERATING INSTRUCTIONS

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CHAPTER 4 - OPERATING INSTRUCTIONS

RUN-IN PERIOD OF A NEW MACHINE 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.

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

2. Keep the engine at normal operating temperature.

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

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

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

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

SB055

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

1. Check for leaks under the machine.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

WARNING: Raised equipment on the machine without an operator can cause injury or death. Before you leave the 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.

SA044

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

SA038

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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.

BEFORE YOU START EACH DAY

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

Be a careful operator, you can prevent accidents.

Read the following information.

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

Figure 1

BD99J183

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

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

SA015

F

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

N R

SA080

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

Figure 2

BD02K029

3. Place the Direction Control Lever in Neutral.

CM112

NOTE: N should be seen on the Digital Display.

Figure 3

BD06G113-01

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

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

WORKING OPERATIONS

Figure 4

BD02H122

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

5. Start the engine and allow proper warm up.

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

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

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

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

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

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

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

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

1

Figure 5

BD02H125

1. DECELERATOR PEDAL

10. Press the Decelerator Pedal all the way down.

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS DIRECTION CONTROL LEVER

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

F 1

STEERING GRADUAL TURN

N

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

R

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

BD02K029

Figure 6

1. DIRECTION CONTROL LEVER

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

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

Figure 8

B911447JFX

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

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

COUNTER - ROTATION BD06G113-01

Figure 7

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

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

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

4-8

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

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

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

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

• Smooth • Normal • Fast

D

To change the sensitivity:

BD06G112-01

D

Figure 11

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

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

Figure 9

BD06G112-01

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

NOTE: Normal is the setting from the factory.

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

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

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

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

B

The Shuttle choices are the same:

Figure 10

BD06G112-01

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

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

ADJUSTING MAXIMUM HYDROSTATIC DRIVE SPEED PARAMETER 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.

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CHAPTER 4 - OPERATING INSTRUCTIONS HYDROSTATIC DRIVE SPEED CONTROLS

1

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

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

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

2

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

Figure 12

BD02M166

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 4-9. From the factory 90% is the highest speed.

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

3

4

BD04N011

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.

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CHAPTER 4 - OPERATING INSTRUCTIONS DECELERATOR PEDAL

6 5

Figure 16 6. REVERSE TO FORWARD SPEED RATIO CONTROL

BD02M025-01

Figure 14

BD02K026-01

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.

Figure 15

383971A1

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS 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.

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

SÁ129

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

Figure 19

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

To move the machine you must: 1. Tilt the cab to access the service area. See tilting the cab in this section on page 4-20.

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

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

3. Release the brakes.

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

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

2

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

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

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

Figure 21 2. LOWER RELIEF VALVES FOR MOVING THE CRAWLER IN A FORWARD DIRECTION (SHOWN LOOKING TO THE REAR OF THE CRAWLER)

BD02M124

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

1

Figure 20

BD02M127

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

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Figure 22

5. Remove the relief valve plastic protective caps.

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CHAPTER 4 - OPERATING INSTRUCTIONS

BD02N036

Figure 23

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

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

1

Figure 27

BD02M125

CAP INSTALLED

Figure 24

BD02H050

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

2 BD02M126

Figure 28

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

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

Figure 25

BD02F009 / 4195

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

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

6. The machine is now ready to be moved.

7. After moving raise the cab back up all the way to over center by making sure the retaining cable is fully extended. See Cab Tilt procedure in this manual page 4-20.

2

8. Disconnect the hand pump.

Figure 26

BD02H057

2. Disconnect the fitting (2) at the brake solenoid and cap it, as shown in the following photo.

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

10. Remove the vacuum pump, if used.

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

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

SB042

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

Figure 31

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.

CM113

B835873F-01

Figure 29

1. BLOCKS FOR TRAILER WHEELS

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

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

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

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

5. Stop the engine and remove the key.

BD02M052-01

Figure 30

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

7. Put blocks at both ends of the tracks.

8. Remove the blocks from the trailer wheels.

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

Figure 32

BS02N080 / BS02N081

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

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

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

Figure 33

BS02N082

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

2. Test the radiator cap before hot weather starts.

Replace the cap as required.

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

4. Check the condition of the fan drive belt.

5. Use lubricants of the correct viscosity.

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

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

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

9. Clean dirt from the precleaner daily.

OPERATING IN COLD WEATHER Cold weather conditions cause special problems.

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

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

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

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

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

Inspect the battery cables and terminals.

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

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

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

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

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

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

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

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

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

Figure 34

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.

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CHAPTER 4 - OPERATING INSTRUCTIONS ENGINE COOLANT HEATER (If Equipped) The right side of the engine cylinder block is provided with a passage for installing a coolant heater. See your dealer for this option. Follow the heater manufacturer’s instructions for installing.

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

SA031

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

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

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

Figure 35

B830661M

1. COOLANT HEATER PASSAGE

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.

ENGINE OIL HEATER (IF EQUIPPED) The engine oil heater is installed on the right side of the engine oil pan. See your Dealer for this option.

Follow the heater manufacturer’s instructions for installation and operation.

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

1

2

BD02J063

Figure 36

B830662J

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Figure 37

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

M853

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

Figure 38

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

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

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

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

BD02F033

BD02F005

Figure 41

BD02M058

Figure 42

Figure 39

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

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

BD02F003

Figure 40

5. Remove the two bolts that attach the brush guard to the canopy, if equipped. (one each side) Figure 43

BD02F006

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

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Figure 44

BD02F008

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

Figure 47

BD02M120

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

Figure 45

BD02F021

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

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

Figure 48

BD02M164

RETAINING CABLE

Refilling and Bleeding the Tilt System

2

1

BD02F024

Figure 46

BD02F020

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

Figure 49

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

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

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS LOWERING THE ROPS CAB OR CANOPY

Figure 53

BD02F008 BD02F018

Figure 50

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

BD02F007

Figure 51

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

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

BD02F004

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

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

Figure 54

BD02F021

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

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

Figure 52

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

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

1

2

SA015

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

SA080

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

CM112

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

SA044

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

BC00G049

Figure 55

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

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

2. Blade will stay on top in soft ground.

3. Blade will not dig into ground.

4. Blade best used for fine grading.

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

2. Blade will dig into hard ground.

3. Less load spillage over top of blade.

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

BLADE LIFT EYE

SA038

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

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

SB013

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

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

ENGINE SPEED

BD99J147

Figure 56

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

TRACK SYSTEMS

2 1 8 3 7 4

5

6

Figure 57

BD04N032X

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

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

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

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

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

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

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

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

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

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS COMPONENTS OF THE UNDERCARRIAGE

9

10 10 Figure 58

BD04N032X

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

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

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

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

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

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

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

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

Operating techniques and maintenance also greatly affect undercarriage life. Unlike the other wear fa c t or s th a t yo u c an n ot c o nt ro l , yo u c an d o something about the way you operate and maintain the machine.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

FACTORS CONTROLLING UNDERCARRIAGE WEAR WEAR FACTORS YOU CAN NOT CONTROL

High Abrasiveness

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

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

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

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

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

Moderate Abrasiveness

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

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

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS Packing

Track Shoes

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

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

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

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

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

Wear is then accelerated.

When a packing problem continues install relieved track sprockets.

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

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

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

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

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

Check the track tension frequently when you operate.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Figure 59

912285

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

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

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

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

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Figure 60

912286

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CHAPTER 4 - OPERATING INSTRUCTIONS 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.

Figure 63

912289

Clean Tracks

Figure 61

912287

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

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.

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

Figure 62

912288

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

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

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

38 MM (1.5 INCH)

51 MM (2.0 INCH)

912346

Figure 64

1. TRACK TENSION (PERCENT TIGHT)

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

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

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

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

Figure 65

912347

PERCENT OF WEAR 1.

2.

3.

4.

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

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

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

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

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

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

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

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

Hydraulic Reservoir Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

LUBRICATION AND MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 ACCESS DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 AS REQUIRED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 TRACK MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 EVERY 10 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 INITIAL 20 HOUR TRACK SHOE BOLT TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 EVERY 50 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 EVERY 250 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 EVERY 500 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 EVER 1000 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 EVERY 2000 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

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

Figure 1

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

SC021

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

B770996R

Figure 3

321-4614

Figure 4

SA044

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

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.

Figure 2

B801147T

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

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

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

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

SYSTEMGARD LUBRICATION ANALYSIS PROGRAM

Figure 5

BP97H063

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

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

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

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

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

Figure 6

BD06G223-01

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

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

5-4

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

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

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUIDS AND LUBRICANTS ENGINE CRANKCASE Capacity with Filter Change, 750L ........................................................................................ 12.3 Liters (13.0 qts) Capacity w/o Filter, 750L........................................................................................................11.5 Liters (12.2 qts) Capacity with Filter Change, 850L .........................................................................................15.8 Liters (16.7 qts) Capacity w/o Filter Change, 850L ..........................................................................................15.0 Liters (15.8 qts) Specification ......................................................................................................................... CASE AKCELA No. 1 FUEL TANK Capacity ..................................................................................................................................189.3 Liters (50 gal) COOLING SYSTEM Capacity, 750L ............................................................................................................................22.5 Liters (6 gal) Capacity, 850L ............................................................................................................................26.5 Liters (7 gal) Specification ................................................................................................ 50% Water and 50% Ethylene Glycol NOTE: If the ambient temperature is lower than -37°C (-34°F), adjust the mixture according to the coolant manufacturer specifications.

HYDRAULIC RESERVOIR REFILL Capacity ....................................................................................................................................75.7 Liters (20 gal) Specification .....................................................................................................................Case AW 68 / MAT 3508 Specification - Alternate .....................................................................Case Hydraulic Excavator Fluid / MAT 3509 FINAL DRIVES Capacity - Each Side................................................................................................................ 14.2 Liters (15 qts) Specification .................................................................................................................. MS-1209, Hy-Tran® Ultra GREASE FITTINGS Quantity .............................................................................................................................................. As Required Specification ................................................................................................................ Case Molydisulfide Grease

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

LUBRICATION AND MAINTENANCE CHART

As Required (AR)

Every 10 Hours

Every 50 Hours Every 250 Hours Every 500 Hours

Every 1000 Hours

5-8 5-9 5-9 5-11 5-12 5-12 5-13 5-13 5-14 5-15 5-15 5-16 5-16 5-20 5-21 5-22 5-24 5-24 5-23 5-25

See Dealer

Every 2000 Hours

5-26 5-26 5-29 5-30

Fan and Air Conditioning Drive Belt Clean Tracks Track Chain Tension Cab Air Filters Engine Oil Coolant Reservoir Fluid Level Transmission and Hydraulic Fluid Level Equipment Pivot Points Initial Track Shoe Bolt Torque Radiator Fluid Level First Stage Fuel Filter for Water Final Drive Oil Level Engine Oil and Filter Battery Fluid Level Fuel Filters Hydraulic Reservoir Breather Relief Valve Fuel Cap Breather Fuel Tank for Water Drive Shaft Slip Spline Final Drive Oil Change Engine Valve Clearance Engine Coolant Engine Air Filter System Hydraulic/Transmission 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 10 10 10

AR

10 20 50 50 250 500 500 500 1000 1000 1000 1000 1000 1000 2000 2000 2000 Figure 7

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ACCESS DOORS

Figure 8

BD04N017X

RIGHT REAR COMPARTMENTS

Figure 9

BD04N033X

Figure 11

BD04N034X

LEFT REAR COMPARTMENT

Figure 12

BD02J018

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

ENGINE SIDE PANELS - RIGHT

Figure 10

BD02J081

RADIATOR

Figure 13

BD02J067

ENGINE SIDE PANELS - LEFT

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

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

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

2. Turn the master disconnect to OFF.

BD06E068-01

Figure 14

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

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

AIR FILTER DUST VALVE

BD02J088-01

Figure 15

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

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

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

Check the track tension frequently when you operate.

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

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

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

BD06E024-01

Figure 17

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).

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

1 2

Figure 16

BD07G136-01

1. TRACK CHAIN PIN 2. CARRIER ROLLER

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

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

AS REQUIRED MAINTENANCE To Tighten The Track

2

1

Figure 20

BD06E027-01

2. TRACK ADJUSTMENT BALL CHECK FITTING Figure 18

BD07G135-01

1. TRACK ADJUSTER GREASE FITTING

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

1. Use a 3/4 in deep socket and loosen the ball check fitting, SLOWLY, about two turns. DO NOT r e 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.

1

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

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

4. Repeat the procedure for the other track.

BD06E027-01

Figure 19

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

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

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

4. Repeat the procedure for the other track.

Figure 21

87542610

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Door hinges - As required

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

Figure 23

BD02H103

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

Figure 22

BD06G123-01

The internal cab filter is located behind the seat.

12

The external cab filter is located behind the cab under the rear glass (not shown).

BD02H102

Figure 24

2. Cab door hinges. . . . . . . . . . . . . . . 4 (2 ea. side)

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

EVERY 10 HOURS Engine Oil Level

Coolant Reservoir Fluid Level

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

Specification . . . . . . . . 10W30 Case No. 1 engine oil

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

To get an accurate measure of the engine oil level, make sure to push the engine oil level dipstick completely down before removing.

2

1 BD08A412

Figure 25

1. ENGINE OIL DIPSTICK 2. ENGINE OIL FILL TUBE

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

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

1

BD06E028-01

Figure 26

Follow the instructions on the dipstick and add oil if necessary.

Figure 27

BD02K017

1. COOLANT RESERVOIR

COOLERS AND ENGINE COMPARTMENT CLEAR OF DEBRIS Check the radiator, coolers and engine compartment for a build up of debris, dirt and foreign material that might impede the cooling components. Failure to comply could result in serious injury or death.

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

GREASE EQUIPMENT PIVOT POINTS

Hydraulic / Hydrostatic Drive Fluid Level Check Specification . . . . . . . . . . . MS-1209 Hy-Tran® Ultra

Use Case Molydisulfide Grease

Check the oil level every 10 hours of operation or each day, whichever occurs first.

NOTE: Check the oil level of the hydraulic reservoir only when the machine is level, front mounted equipment is on the ground, the ripper, (if equipped) is on the ground, and the engine is stopped.

2 1 3

Figure 30

BD02H017

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

1

4

Figure 28

BD06E031-01

1. HYDRAULIC / HYDROSTATIC DRIVE OIL RESERVOIR SIGHT GAUGE

5

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.

BD02F026

Figure 31

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

2

7 Figure 29

BD06E032-01

2. HYDRAULIC RESERVOIR FILL TUBE

6

BD02H019

Figure 32

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

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

INITIAL 20 HOUR TRACK SHOE BOLT TORQUE

EVERY 10 HOURS

Check the torque of the track shoe bolts after the first 20 hours of operation with a new machine or if the shoes have been removed.

8

3

1

8 2

4 Figure 33

BD06G225

8. Blade Pitch Strut . . . . . . . . . . . . . . . . . . . . . . . .2

9

Figure 36

BD06E072-01

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

Tighten the standard link bolts 300 to 330 lb. ft. (406 to 447 Nm) and 318 to 346 lb.ft. (430 to 470 Nm) for the master link bolts. Do not over tighten.

10

Figure 34

BD02H020

9. Angle cylinder closed end . . . . . . . 2 (1 ea. side) 10. C frame pivot pin . . . . . . . . . . . . . . 2 (1 ea. side) Use Case Molydisulfide Grease

13

BBD02J017

Figure 35

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

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

EVERY 50 HOURS

DRAINING WATER FROM FUEL FILTER

RADIATOR COOLANT LEVEL

Check the first stage fuel filter for water and sediment every 50 hours of operation.

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

DO NOT remove the radiator cap for this check.

1. Rotate the drain valve to the left (counter-clockwise) and drain any water and sediment from the fuel filter. Tighten the valve ONLY finger tight.

1

1

Figure 39

BD08A412

Figure 37

BD08A403

1. SIGHT GAUGE

1. FUEL FILTER 2. DRAIN VALVE (BOTTOM OF FILTER, NOT SHOWN)

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

3

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.

Figure 38

SA023

BD02K022-01

Figure 40

3. FUEL TANK DRAIN PLUG

2. If water or sediment are found in the filter it will be necessary to drain any water and sediment from the fuel tank.

WARNING: Be careful to not spill fuel into the environment. Follow all local and federal regulations in regard to disposal of waste fuel and oils.

Figure 41

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

EVERY 250 HOURS FINAL DRIVE OIL CHECK Check the Final Dr ive oil ever y 250 hours of operation.

Specification . . . . . . . . Case IH 135-H EP Gear Lube 1. Park the machine on a level surface. Stop the engine.

1

Figure 42

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 43

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.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

EVERY 500 HOURS ENGINE OIL AND FILTER 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).

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

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

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

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

Figure 44

BP97H064-01

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

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

Oil Viscosity/Temperature Ranges

Figure 45

BC07N452

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 500 HOURS ENGINE SERVICE SPECIFICATIONS Oil Level Check Interval....................................................................Every 10 hours of Operation or Once Each Day Oil Change and Filter Replacement Interval................................................................ Every 500 Hours of Operation Oil Type.....................................................................................................................................................CASE No. 1 Oil Capacity - with Filter Change 750L................................................................................................................................... 12.3 Liters (13.0 qts) 850L................................................................................................................................... 15.8 Liters (16.7 qts) Engine Oil Level

Oil Change and Filter Replacement

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

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

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

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

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

1

BD08A412

1. ENGINE OIL DIPSTICK 2. ENGINE OIL FILL TUBE

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 container that will hold the suitable quantity.

1

2

Figure 46

Figure 47

BD02K002

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

2

Figure 48

P320073

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

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Priming the Turbocharger Oil Lines with Oil In cold weather, after several weeks of storage, or after the engine oil filter has been replaced, prime the turbocharger oil lines with oil.

1. Disconnect the plug to the injection pump solenoid.

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

3

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

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

Figure 49

B4140898S

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

Discard the filter.

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

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

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

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

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

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

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

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

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

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

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 500 HOURS

CLEANING THE BATTERIES

BATTERY FLUID LEVEL

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.

WARNING: Before you service a battery, always wear face protection, protective gloves and protective clothing. Battery acid or battery explosion can cause serious injuries.

Figure 50

SA046

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

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

BD07G137-01

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.

WARNING: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote EXTERNAL: flush with water.

INTERNAL: drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately.

EYES: flush with water for 15 minutes and get prompt medical attention.

Figure 51

BATTERIES LOCATED BEHIND LEFT SIDE ACCESS DOOR

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

Figure 53

SB032

In extreme heat conditions check battery fluid every 250 hours.

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

WARNING: Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: 1. When you DISCONNECT the battery cables, always disconnect the negative (1) battery cable first.

2. When you CONNECT the battery cables, always connect the negative (-) cable last.

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

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

SB034

5-20

Figure 52

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 500 HOURS

REMOVING AIR FROM THE FUEL SYSTEM

FUEL FILTER REPLACEMENT

Air must be removed from the fuel system if one or more of the following conditions occurs:

Close the fuel shutoff valve (if equipped).

A. If the engine stops because of no fuel in the tank.

B. If the fuel filters are replaced.

C. If the fuel system is serviced.

D. If the machine has been in storage.

1. If necessary, fill the fuel tank.

2. Make sure the fuel tank shutoff valve is in the ON position.

3. Loosen the air bleed screw (1) on the filter head 1 or 2 turns.

Figure 54

BD08A412

2

1. Clean the filter head and the outside of the fuel filter.

2. Turn the filter counterclockwise and remove from the filter head.

1

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

4. Install the filter. Use your hands to tighten the filter 3/4 turn after the filter makes contact with the filter head.

5. Loosen the filter approximately one turn.

BD07G163-01

6. Tighten the filter until the filter is touching the filter head and then tighten 3/4 turn. Do not use a strap wrench.

7. Open the shutoff valve at the hand primer.

8. Remove the air from the fuel system. See removing air from the fuel system.

Figure 56

1. AIR BLEED FITTING 2. HAND PRIMER

4. Operate the hand primer (2) until fuel with no air bubbles flows from around the air bleed screw.

5. Tighten the air bleed screw.

6. Start the engine and check for fuel leaks.

In Line Filter Replacement Replace the in line filter after 500 hours of operation.

Figure 55

BD02M137

9. Make sure the filter is placed in line with the correct flow direction.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

EVER 1000 HOURS HYDRAULIC RESERVOIR BREATHER Clean the hydraulic reservoir breather and relief valve every 1000 hours of operation.

1. Park the machine on firm level ground and turn the engine off.

Figure 59

BD06E045-01

6. Clean the valve with a cleaning solvent.

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

8. Install the breather and close the access door.

BD07G137-01

Figure 57

1. HYDRAULIC RESERVOIR BREATHER AND RELIEF VALVE

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

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

4. Remove the valve.

BD06E044-01

Figure 58

5. Remove the clamp that secures the cover.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 1000 HOURS DRIVE SHAFT SLIP SPLINE The cab must be tilted to access the drive shaft spline.

Specification . . . . . . . . . .Case Molydisulfide Grease NOTE: Universal Joints are Lubricated for life.

1

BD02H004

Figure 61

1

Figure 60

B911749

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

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 1000 HOURS 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

BD02K022-01

Figure 62

1. FUEL TANK DRAIN PLUG

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

If water is found in the fuel tank the fuel filters should also be checked.

FUEL TANK BREATHER Clean the fuel cap breather every 1000 hours of operation or if the breather becomes covered with dirt and debris.

BD06E050-01

Figure 63

1. Remove the fuel cap.

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

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

4. Install the fuel cap.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 1000 HOURS Final Drive Oil Change Park the machine on a level surface. Stop the engine.

NOTE: If possible, drain the final drives when the oil is warm. You will remove more contamination from the final drives with warm oil.

1

Figure 64

BD02J069

2

3

Figure 65

BD02H107

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

2. Remove the fill plug slowly to relieve pressure.

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

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

5. Fill until a small amount leaves the check plug (2) orifice and install the plug.

6. Install the fill plug (1).

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

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

EVERY 2000 HOURS 1. Open the radiator door.

CLEANING COOLING SYSTEM Specifications . 50% ethylene glycol and 50% water Coolant Capacity . . . . . . . . . . . . . . 18.9 litres (5 gal) Drain, flush, and replace the engine coolant every 2000 hours of operation or each year whichever occurs first. Clean the system and replace the coolant if the coolant becomes dirty or has the color of rust.

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

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.

2. 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 left side of the radiator.

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

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

Follow the directions included with the cleaning solution.

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

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

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

9. Fill the cooling system slowly until the coolant level is up to the top of radiator opening.

NOTE: Allow the venting of entrapped air when filling the cooling system until you have the correct quantity of coolant in the system.

10. Install the radiator cap.

11. Fill the coolant reservoir up to the FULL mark on the reservoir.

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

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

SA023

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

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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 68

BD08A406

3. Carefully remove the primary (outer) element.

1

Figure 66

BD06G224-01

4

1. AIR FILTER RESTRICTION INDICATOR LAMP

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

Replacing the Engine Air Filter Elements: 1. Open the access panel.

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

BD08A407

Figure 69

4. Remove the secondary element.

1

2

Figure 67

BD08A405

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 2000 HOURS

BD08A408

Figure 70

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

6. Install a new secondary element.

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

8. Install the end cover.

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

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

TURBO PRE CLEANER (OPTIONAL) The optional turbo preclean requires no service.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 2000 HOURS HYDRAULIC/HYDROSTATIC DRIVE SYSTEM FILTER AND FLUID CHANGE

1

Every 2000 hours of operation the hydraulic / drive system must be serviced.

Specifications . . . . . . . . . . MS-1209, Hy-Tran® Ultra Refill capacity with filters . . . . . . . .20 gal (75.7 litres) T h e fo l l o w i n g changed/cleaned.

components

should

be

• clean hydrostatic and equipment suction screens • change hydraulic and hydrostatic filters • change hydraulic/hydrostatic fluid WARNING: Hydraulic fluid or grease injected into your skin can cause severe injury or death. Keep your hands and body away from any pressurized leak. If fluid is injected into your skin, see a doctor immediately and have the fluid removed.

Figure 71

SA024

2

BD07G139-01

Figure 73

1. HYDRAULIC FILTER 2. HYDROSTATIC DRIVE FILTER

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

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

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

Hydraulic / Transmission Fluid Change 1. Make sure the oil is warm.

1

2. Lower the equipment to the ground and stop the engine.

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

4. Have a suitable container that will hold the quantity of fluid.

5. Loosen hydraulic fill cap slowly.

Figure 72

BD06J139-01

1. HYDRAULIC FILTER INDICATOR LAMP

NOTE: 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.

Hydraulic /Hydrostatic Drive Filter Change 1. Open the side access door.

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

3. Rotate the filters counter-clockwise and remove them. Dispose of the used filters in accordance with local and state regulations.

BD02M047-01

Figure 74

6. Remove the drain plug and remove all fluid from the reservoir.

7. Replace the drain plug.

8. Tilt the cab and clean the reservoir suction screens.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Suction Screen Cleaning The Suction Screens are located at the front, right, bottom corner of the Hydraulic Fluid tank.

1

1

2 Figure 76

BD06E059-01

1. FILLER CAP

9. Remove the filler cap.

BD07H130-01

Figure 75

1. HYDROSTATIC DRIVE SUCTION SCREEN 2. HYDRAULIC SUCTION SCREEN

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

10. Put new MS-1209, Hy-Tran® Ultra fluid into the reservoir.

11. Install the filler cap.

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

13. Add oil as required. Check for leaks.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

NOTES

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Chapter 6 MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Procedure To Adjust Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Track Shoe Bolts - Steel Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Welding On The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3 6-3 6-3 6-4 6-5 6-5

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

Maintenance and Inspection of ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Damage to the ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6 6-6 6-6 6-6 6-7

MACHINE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 ADJUSTING THE RIPPER SHANKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 DOZER BLADE PITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Rearward Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Forward Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Type of Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Inspection and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 FAN AND AIR CONDITIONING DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Service Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storage Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal From Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear Attachment Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

TRACKS SERVICE SPECIFICATIONS Clean Tracks ............................................................................................................................................ As Required Check Tension ...........................................................................................................................................Periodically Check Track Shoe Bolt Torque ............... After The First 20 Hours Of Operation On New Machine And As Required Shoe Bolt Torque (standard link bolts)...................................................................... 406 to 447 Nm (300 to 330 lb ft) Shoe Bolt Torque (master link bolts)......................................................................... 430 to 470 Nm (318 to 346 lb ft) IMPORTANT: When the machine has been operating in mud, snow or adverse material, debris will stick to the track parts and cause the tracks to become too tight. Always adjust the track tension more often when operating in these conditions.

PROCEDURE TO ADJUST TRACK TENSION 1. Do not clean the tracks before adjustment.

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

1 B911469J

Figure 3

2

Figure 1

BD02H010

3. Stop the machine so that a pin (1) in the track chain is over the carrier roller (2).

4. Put a straightedge over the track.

Figure 2

BD02H013

5. Measure the track deflection midway between the top roller and the idler wheel. The correct adjustment is between 38 to 51 mm (1-1/2 to 2 inches).

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TO TIGHTEN THE STEEL TRACK

BD02H015

TO LOOSEN THE STEEL TRACK

Figure 4

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

Figure 5

BD02H016

2. Install the cap on the track adjuster.

1. Use a deep socket and loosen the large adapter two turns. DO NOT remove the large adapter. Let the grease come out until the track deflection is 38 to 51 mm (1-1/2 to 2 inches).

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

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

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

3. Install the cap on the track adjuster.

5. Adjust the other track.

NOTE: During the operation of the machine, material can build up in the root of the sprocket forcing the bushing out of the sprocket tooth. When the bushing gets high enough it will move over one sprocket tooth causing a loud noise.

This problem can be reduced by loosening the track or installing relieved sprockets.

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

Check the track tension again.

5. Adjust the other track.

TRACK SHOE BOLTS - STEEL TRACK Check the torque of the track shoe bolts after the first 20 hours of operation with a new machine. Then, if the machine is new or if the track shoes have been removed, check the torque of the track shoe bolts every 100 hours of operation until the track shoes remain tight.

Tighten the standard link bolts 406 to 447 Nm (300 to 330 lb ft) and 430 to 470 Nm (318 to 346 lb ft for the master link bolts.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ENGINE VALVE CLEARANCE The engine valves should be checked by a service technician every 1000 hours.

WELDING ON THE MACHINE Whenever carrying out a welding operation on the crawler as authorized by the manufacturer and in accordance with correct procedures: 1. Disconnect the batteries.

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

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.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

ROLL-OVER PROTECTIVE STRUCTURE Your machine has a roll-over protective structure (ROPS). A ROPS label shows the serial number of the ROPS, gross weight, approval, regulation, and model numbers of the machine. The label is on the left-hand side.

Before you operate this machine, always make sure that the ROPS and operator’s seat belt is correctly installed.

MAINTENANCE AND INSPECTION OF ROPS 1. Check the torque of the ROPS mounting bolts. If necessary, tighten the bolts to the correct torque.

See ROPS Torque Specifications in this manual.

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

3. Check for cracks, rust, or holes in the ROPS and ROPS parts. Age, weather, and accidents can cause damage to the ROPS and ROPS parts. If you have any doubt about the ROPS system, see your dealer.

SEAT BELT The seat belt is an important part of your ROPS. You must wear the seat belt at all times when you operate the machine.

Before you operate this machine, always make sure that the ROPS and operator’s seat belts are correctly installed.

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

SA080

DAMAGE TO THE ROPS

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

See the parts catalog or your dealer for components that can be replaced.

DO NOT TRY TO WELD OR STRAIGHTEN THE ROPS. WARNING: Do not modify ROPS in any manner. Unauthorized modifications such as welding, drilling, cutting or adding attachments can weaken the structure and reduce your protection. Replace ROPS if subjected to roll-over or damage. Do not attempt to repair.

SB026

WARNING: If you operate this machine without a ROPS and the machine rolls over, you can be injured or killed. Remove the ROPS only for service or replacement. Do not operate this machine with the ROPS removed.

SA027

WARNING: Adding additional weight (attachments, etc.) to the machine can cause injury or death. Do not exceed the gross weight printed on the ROPS label.

SA028

WARNING: Improper ROPS inspection or maintenance can cause injury or death. Do the recommended ROPS inspection shown in this manual. If you must replace the ROPS, ROPS parts, or ROPS mounting hardware, use only the replacement parts shown in the Case parts catalog for this machine.

SA029

WARNING: Before you start the engine, always sit in the 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.

If the machine has rolled over or the ROPS has been in some other type of accident (such as hitting an overhead object during transport), you must replace the damaged ROPS components to get as much protection as you had originally.

SB037

After an accident, check the following for damage.

A. ROPS canopy.

B. Lower ROPS frame.

C. Operator’s seat.

D. Seat belt mounting and seat belt.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TORQUE SPECIFICATIONS

MACHINE CLEANING

Seat

It is recommended that the complete machine be kept clean. Machine operation in water, mud, dust, landfill, land clearing or forestry will require complete machine clean up. Cleaning includes periodically removal of inspection covers and guards to gain access for cleaning and removal of dirt or debris.

Clean all dirt and foreign material from the front engine guard. Dirt will cause rust on the engine oil pan and the loss of engine oil.

33.9 to 47.4 Nm (25 to 35 lb ft) - 2 per side Seat Belt Mounting Bolts - Both Sides 46.7 to 54.2 Nm (34 to 40 lb ft) - both sides ROPS Mounting Bolts - Both Sides 203 to 237 Nm (150 to 175 lb ft) - both sides

After cleaning is complete, install ALL covers and guards.

DO NOT operate machine with covers or guards removed.

WARNING: Replace all covers or guards after servicing or cleaning the machine.

NEVER operate the machine with covers or guards removed.

CM115

ADJUSTING THE RIPPER SHANKS

1 2 BC02M137

Figure 6

1. Remove the retaining clip (1).

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

3. Replace the pin and retaining clip.

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

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

DOZER BLADE PITCH ADJUSTMENT 1. Raise dozer blade up approximately 100 mm (4 in).

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

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

7. Replace the cover guard and retaining pin.

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

WARNING: Be careful with this procedure and raise the blade only high enough to make the necessary adjustment.

REARWARD POSITION BLADE PITCHED REARWARD When dozer blade is pitched in the rearward position, the blade will be able to push a larger load. Blade will stay on top in soft ground.

REARWARD POSITION ADVANTAGES 1. Blade is able to push a larger load.

2. Blade will stay on top in soft ground.

3. Blade will not dig into the ground.

4. Blade best used for fine grading.

FORWARD POSITION BLADE PITCHED FORWARD

BD02J077

Figure 7

4. Remove the retaining pin to release the cover guard.

When dozer blade is pitched in the forward position, the load slides off of blade as crawler travels in reverse. Blade will dig into hard ground.

FORWARD POSITION ADVANTAGES 1. Load slides off of blade as the crawler travels in reverse.

2. Blade will dig into hard ground.

3. Less load spillage over top of blade.

BD02J079

Figure 8

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

BD02J078

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

FIRE EXTINGUISHER MOUNTING (IF EQUIPPED)

FAN AND AIR CONDITIONING DRIVE BELT

TYPE OF FIRE EXTINGUISHER

SERVICE INTERVAL

It is recommended that you have a fire extinguisher on your machine. The fire extinguisher shown below is available from your dealer and can be installed on the machine.

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

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

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

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

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

2. Turn the master disconnect to OFF. 3. Install a 1/2 inch breaker bar in the tension pulley bracket.

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

E V E RY 6 M O N T H S - H ave t h e d r y c h e m i c a l removed and refilled by a fire equipment technician.

ONCE EACH YEAR - Have the fire equipment technician inspect the fire extinguisher.

Figure 10

BD02M057

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

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

MACHINE STORAGE STORAGE PREPARATION

REMOVAL FROM STORAGE

If the machine is to be in storage for more than 30 days, park the machine inside a building. If a building is not available, park the machine in a dry area on planks and cover the machine with a waterproof covering.

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

1. Wash the machine.

2. Lubricate the machine at all grease fittings.

3. Paint any area where the paint has been damaged.

1. Change the fuel filters.

2. Put coolant in the engine cooling system.

3. Check the condition of the drive belt. Replace if required.

4. Check the engine oil level.

5. Check the hydraulic oil level.

4. Drain the fuel tank.

6. Check the final drives oil level.

5. Put approximately 8 liters (2 U.S. gallons) of diesel flushing oil in the fuel tank. Run the engine until the exhaust smoke is blue white.

7. Lubricate the machine at all grease fittings.

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. 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.

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

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

10. Fill the fuel tank.

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

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

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.

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.

13. Charge the battery. Remove the battery from the machine and put the battery on a wooden pallet in a cool dry area. If possible, keep the battery in a building where the temperature is above freezing 0°C (32°F). Make sure the battery is clean.

NOTE: Check the battery periodically for the correct electrolyte level. Test the electrolyte with a hydrometer. When the hydrometer reading is near 1.215, charge the battery.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REAR ATTACHMENT TORQUE VALUES

Figure 11

BD02J032

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

Figure 12

BD02M132

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

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Figure 13

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

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

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CHAPTER 7 - ELECTRICAL

Chapter 7 ELECTRICAL TABLE OF CONTENTS ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3 7-3 7-3 7-4 7-4 7-4

FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Accessory Outlet (12 volt, 10 amp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

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CHAPTER 7 - ELECTRICAL

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CHAPTER 7 - ELECTRICAL

ELECTRICAL SYSTEM BATTERY SAFETY

WARNING: Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: 1. When you DISCONNECT the battery cables, always disconnect the negative (1) battery cable first.

2. When you CONNECT the battery cables, always connect the negative (-) cable last.

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

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

WARNING: Batteries give off explosive gases. Keep all open flames, sparks and cigarettes away. Ensure adequate ventilation when charging batteries or when using in a confined place. Always protect your eyes when working near batteries.

SAFETY_ID_1C02

WARNING: Do not reverse battery terminals. Connect positive cable ends to positive (+) terminals and negative cable ends to negative terminals (-).

SAFETY_ID_1C02

SB034

WARNING: Before you service a battery, always wear face protection, protective gloves and protective clothing. Battery acid or battery explosion can cause serious injuries.

BATTERY SERVICE

SA046

WARNING: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote EXTERNAL: flush with water.

INTERNAL: drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately.

EYES: flush with water for 15 minutes and get prompt medical attention.

SB032

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

SA033

WARNING: Before any operation on the components of the electrical circuit, put the key switch in the shut down position. When disconnecting the battery cables, always disconnect the negative (-) cable first. When reconnecting the battery cables, always connect the negative (-) cable last.

SAFETY_ID_1C02

WARNING: Connecting auxiliary cables wrongly or short-circuiting batteries terminals can cause an accident. Connect auxiliary starting cables as per the following instructions.

1

BD06E047

2

Figure 1

1. NEGATIVE BATTERY CABLE 2. POSITIVE BATTERY CABLE

NOTE: The electrical system in this machine is 12 volts negative ground.

Before you service components of the electrical system, always disconnect the NEGATIVE (-) battery cable.

Dirt, moisture, and corrosion on the battery will discharge the battery. Clean the battery with Case Battery Saver and Cleaner. Follow the instructions on the can.

Disconnect the alternator wires if you must run the engine with the battery wires disconnected.

Before you use an electric welder, disconnect the alternator wires, instrument cluster, and turn the master disconnect switch to OFF. Do not use a steam cleaner or cleaning solvent to clean the alternator.

SAFETY_ID_1C02

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CHAPTER 7 - ELECTRICAL BATTERY FLUID LEVEL Check the fluid level of the batteries every 500 hours of operation. If the fluid level is low, add clean or distilled water to each cell until the fluid level is at the split ring at the bottom of each cell opening.

In extreme heat conditions check battery fluid every 250 hours.

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

BATTERY VENTS Keep the battery vents clean, make sure the vents are not restricted.

CLEANING THE BATTERIES Check the batteries and batter y compar tment regularly for dirt, corrosion and damage. Dirt mixed with electrolyte or moisture on the top of the batteries can cause a discharged condition in the batteries.

Use one of the following methods to clean the batteries.

• Use Case Battery Saver, Part Number M20376.

Follow the instructions on the container. This cleaner does not need water.

• Use baking soda or ammonia and flush the outside of the batteries with water. If you do not have Case Battery Saver, use other special cleaners to prevent corrosion on the battery terminals.

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CHAPTER 7 - ELECTRICAL

FUSES AND RELAYS

1

2

A B C D E F G H J K L M

Figure 2

BD06E047/87488059

1. FUSE AND RELAY LOCATION IS UNDER THE LEFT REAR ACCESS DOOR, SHOWN ABOVE. 2. FUSE AND RELAY DECALS ARE LOCATED UNDER THE LEFT REAR ACCESS DOOR, NOT SHOWN.

Figure 3

BS08C029

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Figure 4

7-5

CHAPTER 7 - ELECTRICAL ACCESSORY OUTLET (12 VOLT, 10 AMP) Cab and ROPS models have one outlet on the lower, left side of the front console, shown below.

BD08A447-01

Figure 5

1. 12 VOLT ACCESSORY OUTLET ON INSTRUMENT CLUSTER CONSOLE

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CHAPTER 8 - SPECIFICATIONS

Chapter 8 SPECIFICATIONS TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel Speeds 750L and 850L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3 8-3 8-3 8-3

TRACK SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 TRANSPORT DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 OPERATING DATA AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 OPERATING DATA AND DIMENSIONS - RIPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Additional Weights of Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

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CHAPTER 8 - SPECIFICATIONS

SPECIFICATIONS NOTE: All specifications are given according to SAE Standards or Recommended Practices where the specification applies.

ENGINE Make and Model 750L ............................................................................................................................................. NEF 445TA/E66 850L .............................................................................................................................................. NEF 667TA/E66 Firing Order 750L ........................................................................................................................................................... 1-3-4-2 850L ......................................................................................................................................................1-5-3-6-2-4 Bore and Stroke 750L ................................................................................................................... 104 x 132 mm (4.09 in x 5.20 in) 850L .................................................................................................................... 104 x 132 mm (4.09 in x 5.20 in) Displacement 750L ................................................................................................................................ (4) 4500 cm3 (274.6 in3) 850L ................................................................................................................................. (6) 6750 cm3 (411.9 in3) Compression Ratio 750L ......................................................................................................................................................... 17.5 to 1 850L ......................................................................................................................................................... 17.5 to 1 Horsepower, Max. Rated Gross @ 2000 rpm 750L .............................................................................................................................................. 67.1 kW (90 hp) 850L .............................................................................................................................................. 73.8 kW (99 hp) Engine Speeds 750L and 850L High Idle ..................................................................................................................................... 2170 to 2270 rpm Rated Speed ........................................................................................................................................... 2000 rpm Low Idle ........................................................................................................................................ 800 to 1050 rpm

HYDRAULIC SYSTEM System Relief Pressure.......................................................................... 20,340 to 21,370 kPa (2950 to 3100 psi) Pump Capacity ................................................................................ 20.3 gal/min @ 3000 psi @ 2000 engine rpm

TRAVEL SPEEDS 750L AND 850L Speeds Forward ......................................................................Infinitely variable from 0 to 9.7 km/h (0 to 5.5 mph) Speeds Reverse ......................................................................Infinitely variable from 0 to 9.7 km/h (0 to 5.5 mph) Track Pull (Maximum / Both Tracks ................................................................................... 176,976 N (39,786 lb ft) NOTE: Travel Speed and Track Pull are with CLT chain. If machine is equipped with CELT chain speed will be reduced 4% and track pull will be increased 4%.

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CHAPTER 8 - SPECIFICATIONS

TRACK SYSTEM Track Gauge 750L / 850L LT ..............................................................................................................................1575 mm (62 in) 750L / 850L WT & LGP .................................................................................................................1778 mm (70 in) Track Rollers Per Side 750L ...................................................................................................................................................................... 6 850L ...................................................................................................................................................................... 7 Length of Track on Ground (With Standard CASE Lubricated Track) 750L ...........................................................................................................................................2266 mm (89.2 in) 850L ...........................................................................................................................................2352 mm (92.6 in) Length of Track on Ground (With Optional CASE Extended Life Track) 750L ...........................................................................................................................................2288 mm (90.1 in) 850L ...........................................................................................................................................2373 mm (93.4 in) Number of Track Shoes Per Side 750L .................................................................................................................................................................... 39 850L .................................................................................................................................................................... 40 Number of Carrier Rollers Per Side All Models ................................................................................................... 1 Ground Pressure with CLT chain 750L LT (62 “ Gauge / 104 “ Blade w/ 457 mm (18 in) shoe ...................................................40.54 kPa (5.88 psi) 750L LT (62 “ Gauge / 104 “ Blade w/ 508 mm (20 in) shoe ...................................................36.96 kPa (5.36 psi) 750L WT (70 “ Gauge / 120 “ Blade w/ 610 mm (24 in) shoe .................................................31.78 kPa (4.61 psi) 750L LGP (70 “ Gauge / 124 “ Blade w/ 711 mm (28 in) shoe ................................................27.85 kPa (4.04 psi) 850L LT (62 “ Gauge / 104 “ Blade w/ 457 mm (18 in) shoe ...................................................40.13 kPa (5.82 psi) 850L LT (62 “ Gauge / 104 “ Blade w/ 508 mm (20 in) shoe ...................................................36.54 kPa (5.30 psi) 850L WT (70 “ Gauge / 120 “ Blade w/ 610 mm (24 in) shoe .................................................31.30 kPa (4.54 psi) 850L LGP (70 “ Gauge / 124 “ Blade w/ 711 mm (28 in) shoe ................................................27.58 kPa (4.00 psi) NOTE: If machine is equipped with optional CELT chain ground pressure will be 0.7 kPa (0.1 psi) greater.

CASE Lubricated Track (CLT)...................................................................................................................... Standard CASE Extended Life Track (CELT) ................................................................................................................ Optional LT = Long Track WT = Wide Track LGP = Low Ground Pressure

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CHAPTER 8 - SPECIFICATIONS

TRANSPORT DIMENSIONS

Figure 1

BS02K072

TRANSPORT LENGTH AND WIDTH WITH BLADE FULLY ANGLED AT 25°

Blade width

(A) Transport width

(B) 750L w/o Drawbar

(B) 850L w/o Drawbar

2642 mm (104 in)

2446 mm

96.3 in

4696 mm

184.9 in

4782 mm

188.3 in

2794 mm (110 in)

2585 mm

101.8 in

4728 mm

186.1 in

4814 mm

189.5 in

3048 mm (120 in)

2815 mm

110.8 in

4782 mm

188.3 in

4868 mm

191.7 in

3150 mm (124 in)

2907 mm

114.4 in

4803 mm

189.1 in

4889 mm

192.5 in

3302 mm (130 in)

3043 mm

119.8 in

4835 mm

190.4 in

4921 mm

193.7 in

NOTE: Add 150 mm (5.9 in) for drawbar. If unit is equipped with ripper add 975 mm (38.4 in).

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CHAPTER 8 - SPECIFICATIONS

OPERATING DATA AND DIMENSIONS

Figure 2

BS02K102

A. Top of Exhaust Stack 750L .........................................................................................................................................2624 mm (103.3 in) 850L .........................................................................................................................................2614 mm (102.9 in) B. Blade Height (750/850L) ...............................................................................................................914 mm (36 in) C. Ground Clearance at Belly Pans 750L .............................................................................................................................................366 mm (14.4 in) 850L .............................................................................................................................................369 mm (14.5 in) D. Shank Height (Transport Position) .............................................................................................440 mm (17.3 in) E. Top of Seat Head Rest .............................................................................................................2229 mm (87.8 in) F. Height of Cab w/o Air Conditioning ....................................................................................... 2773 mm (109.2 in) with Air Conditioning ............................................................................................................2788 mm (109.8 in) ROPS Height .......................................................................................................................2773 mm (109.2 in) Blade Blade Depth Below Ground ............................................................................................................ 483 mm (19.0 in) Blade Angle Each Direction ............................................................................................................. 0 to 25 Degrees Blade Pitch .................................................................... 55° Standard (52° to 60° with optional adjustable pitch link) 104 in. Blade Tilt (0 to 8.3 Degrees) ................................................................................................381 mm (15.0 in) 110 in. Blade Tilt (0 to 8.3 Degrees) ................................................................................................404 mm (15.9 in) 120in. Blade Tilt (0 to 8.3 Degrees) .................................................................................................439 mm (17.3 in) 124 in. Blade Tilt (0 to 8.3 Degrees) ................................................................................................455 mm (17.9 in) 130 in. Blade Tilt (0 to 8.3 Degrees) ................................................................................................478 mm (18.8 in) NOTE: Ground clearance and overall height dimensions are with the Grouser fully penetrated per SAE J1234.

Add 52.5 mm (2.06 in) if machine is on solid surface.

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CHAPTER 8 - SPECIFICATIONS

Figure 3

BS02K101

A. Length, no blade, no rear equipment and CLT chain 750L .................................................................................................................................... 3153 mm (124.1 in) 850L .................................................................................................................................... 3261 mm (128.4 in) B. Overall Length, blade straight, no rear equipment 750L .....................................................................................................................................4171 mm (164.2 in) 850L .....................................................................................................................................4258 mm (167.6 in) C. Overall Length, blade straight, w/drawbar 750L .....................................................................................................................................4322 mm (170.2 in) 850L .....................................................................................................................................4408 mm (173.5 in) D. Overall Length, blade straight, w/ripper 750L .....................................................................................................................................5147 mm (202.6 in) 850L .....................................................................................................................................5233 mm (206.0 in) NOTE: Overall Length is with blade pitch at 55 degrees (factory setting). If blade pitch is adjusted to 60 degrees length will decrease 15 mm (0.6 in) if equipped with optional adjustable pitch link.

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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, front and rear pull hooks, side shields, track guides.

750L LT w/18 in shoes and 104 in blade ................................................................................... 8569 kg (18,895 lbs) 750L LGP w/28 in shoes and 124 in blade................................................................................. 9157 kg (20,191 lbs) 850L LT w/20 in shoes and 104 in blade .................................................................................... 8902 kg (19,629 lbs) 850L LGP w/28 in shoes and 124 in blade................................................................................. 9399 kg (20,724 lbs) ADDITIONAL WEIGHTS OF OPTIONAL EQUIPMENT APPROXIMATE ADD-ON WEIGHT Dual Batteries for ROPS or CAB ........................................................................................................... 29 kg (64 lbs) Rear Screen (For Cab) .......................................................................................................................... 32 kg (71 lbs) Center Rock guards 750L.................................................................................................................. 100 kg (221 lbs) Center Rock guards 850L.................................................................................................................. 106 kg (234 lbs) ROPS Canopy or Cab Canopy Brush Guard....................................................................................... 47 kg (104 lbs) Forestry Side Screens ........................................................................................................................... 35 kg (77 lbs) Hydraulic Equipment Pump w/PTO ....................................................................................................... 24 kg (53 lbs) 4 Spool Valve w/Plugs (Mechanical Controls) ......................................................................................... 8 kg (18 lbs) Adjustable Blade Pitch Link ..................................................................................................................... 5 kg (11 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 for ROPS................................................................................................................................. 15 kg (33 lbs) Light Package (4 front / 2 rear) .................................................................................................................. 2 kg (4 lbs) ALLIED EQUIPMENT ADD-ON WEIGHT Winch (Carco Model 30B-PS) ......................................................................................................... 454 kg (1000 lbs) Winch (Hyster Model W3C) ............................................................................................................. 612 kg (1350 lbs) Log Arch (Hyster) .............................................................................................................................. 227 kg (500 lbs) Forestry Guards (Door screens and Front screen)............................................................................ 100 kg (220 lbs) Heater for ROPS Unit ............................................................................................................................ 32 kg (71 lbs) Radio ......................................................................................................................................................... 1 kg (2 lbs)

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CHAPTER 9 - INDEX

Chapter 9

INDEX A

Steering Gradual Turn ......................................4-8

Access Doors ............................................. 5-7, 5-16 Accessory Outlet ................................................. 7-6 Air Filter Restriction Lamp ................................... 3-7 Air Filter System Warning Lamp ............................................... 5-26

B Backrest Tilt Adjustment Lever .......................... 3-20 Battery Cleaning ................................................. 5-20, 7-4 Fluid Level .............................................. 5-20, 7-4 Safety .............................................................. 7-3 Service ............................................................ 7-3 Vents ............................................................... 7-4 Before You Start Each Day ................................. 4-6 Blade Control Handle Position ........................... 3-19 Blade Lift Eye .................................................... 4-23 Brake Release for Towing ................................. 4-15 Bushing and Sprocket Wear Chart .................... 4-30

C Cab Door Release/Lock .................................... 3-21 Cab Tilt Hydraulic Jack ...................................... 3-22 Cab Tilt System Oil ............................................ 4-21 Cab Vent ............................................................ 3-22 Carrier Roller ..................................................... 4-24 Case Extended Life Track (CELT) ..................... 4-26 Climate Control Operation ................................. 4-12 Climate Control Panel ........................................ 3-22 Components of the Undercarriage .................... 4-24 Carrier Roller ................................................. 4-24 Drive Sprocket ............................................... 4-24 Idler ............................................................... 4-24 Recoil Spring Housing ................................... 4-24 Track Adjuster (Steel Track) ......................... 4-24 Track Chain ................................................... 4-24 Track Frame .................................................. 4-24 Track Links .................................................... 4-25 Track Rollers ................................................. 4-24 Track Shoes .................................................. 4-25 Coolant Levels Coolant Reservoir ......................................... 5-12 Radiator ......................................................... 5-15 Coolant Reservoir .............................................. 5-12 Coolant Solution, Engine Cooling System 5-12, 5-26 Crawler Operation ............................................... 4-6 Before You Start Each Day ............................. 4-6 Direction Control Lever ................................... 4-8 Power Turn ...................................................... 4-8 87479855NA

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D Decelerator Pedal ...............................................3-14 Decelerator Pedal Operating Instructions ..........4-11 Direction Control Lever ............................... 3-15, 4-8 Display-Service/Enter Switch ...............................3-4 Dozer Blade Control Lever .................................3-17 Angle Left .......................................................3-17 Angle Right ....................................................3-17 Float ...............................................................3-17 Hold ................................................................3-18 Lift ..................................................................3-17 Lower .............................................................3-17 Tilt Left ...........................................................3-17 Tilt Right .........................................................3-17 Dozer Operation .................................................4-23 Drive Sprocket ....................................................4-24

E Electrical Service Accessory Outlet ..............................................7-6 Electrical System ..................................................7-3 Engine Hourmeter ........................................................5-4 Specifications ...................................................8-3 Engine Air Filter Restriction ..................................3-7 Engine Coolant Heater .......................................4-19 Engine Cooling System Coolant Solution ................................... 5-12, 5-26 Engine Hand Throttle .........................................3-16 Engine Lubrication .................................... 5-17, 5-23 Engine Oil Selection .......................................5-17 Engine Oil Level ....................................... 5-12, 5-18 Engine Oil Selection ...........................................5-17 Engine Operation ......................................... 4-3, 4-4 Engine Speed ..................................................4-4 Parking the Machine and Stopping the Engine 4-5 Starting the Engine ..........................................4-4 Engine Service Engine Oil Level ................................... 5-12, 5-18 Oil Change and Filter Replacement ...............5-18 Priming the Turbocharger Oil Lines with Oil ...5-19 Engine Speed .......................................................4-4 Engine Start Aids Engine Coolant Heater ...................................4-19 Engine Starting Aids ...........................................4-18 Intake Air Grid Heater ....................................4-18 Extinguisher Mounting, Fire ..................................6-9

9-1

CHAPTER 9 - INDEX

F Factors Controlling Undercarriage Wear ........... 4-25 Wear Factors You Can Control ..................... 4-27 Wear Factors You Can Not Control .............. 4-26 Factors Controlling Undercarriage Wear - Wear Factors You Can Not Control ...................... 4-26 Filter Engine ........................................................... 5-18 Hydraulic ....................................................... 5-29 Final Drives Oil Change .................................................... 5-25 Fire Extinguisher Mounting .................................. 6-9 Fluid and Lubricants ............................................ 5-5 Fluid Level Check Hydraulic System .......................................... 5-29 Forward/Rearward Adjustment Lever ................ 3-20 Front Console Key/Ignition Switch .......................................... 3-5 Fuel Gauge Monitor, No Power ........................... 3-4 Fuel Handling Precautions .................................. 2-9 Fuel Warning Lamp ............................................. 3-7

G General Information ............................................. 1-1 General Safety ..................................................... 5-3

H Hazardous Chemical Precautions ....................... 2-9 Horn ..................................................................... 3-4 Hourmeter, Engine .............................................. 5-4 How to Extend the Life of Sealed Track and the Case Lubricated Track (CLT) ............................... 4-26 Hydraulic Filter ................................................... 5-29 Hydraulic Filter Warning Lamp ............................ 3-6 Hydraulic Fluid Change ............................ 5-13, 5-29 Hydraulic System ............................................... 5-29 Fluid Level Check .......................................... 5-29 Hydraulic Filter .............................................. 5-29 Hydraulic Fluid Change ........................ 5-13, 5-29 Specifications .................................................. 8-3 Hydrostatic Drive Filter Warning Lamp ................ 3-6 Hydrostatic Drive Speed Gauge ........................ 3-13 Hydrostatic Drive Speed Parameter Adjustment . 4-9 Hydrostatic Drive Speed Up/Down Buttons ....... 3-15

I Identification Numbers Engine ............................................................. 1-3 Product Identification Number (P.I.N.) ............ 1-3 ROPS Canopy ................................................. 1-3 Idler .................................................................... 4-24 Instructions, General Safety ................................ 5-3 Instrument Panel ................................................. 3-3 9-2

Instruments/Controls Dozer Blade Control Lever .............................3-17 Blade Control Handle Position ...................3-19 Operators Seat ...............................................3-20 Operators Seat Belt .......................................3-24 Ripper Control Lever ......................................3-19 Interior Cab Door Release ..................................3-21

K Key Switch, Ignition ..............................................3-5

L Lifting the Crawler ..............................................4-17 Lowering the Cab ...............................................4-22 Lubrication/Filters/Fluid Hydraulic System ...........................................5-29 Lubrication/Filters/Fluids Access Doors ......................................... 5-7, 5-16 Engine Lubrication ............................... 5-17, 5-23 Fluid and Lubricants .........................................5-5

M Machine Cleaning .................................................6-7 Machine Components ..........................................1-4 Machine Storage ................................................6-10 Removal From ...............................................6-10 Storage Preparation .......................................6-10 Maintenance Precautions .....................................2-8 Maintenance/Adjustments Machine Cleaning ............................................6-7 Roll-Over Protective Structure .........................6-6 Seat Belt ..........................................................6-6 Spark Arrester Muffler ......................................6-7 Torque Specifications for Seat and Seat Belt Mounting Bolts .........................................6-7 Master Disconnect Switch ..................................3-23 Menu Up/Down Switch .........................................3-4

O Oil Change Engine ............................................................5-18 Final Drives ....................................................5-25 Oil Viscosity/Temperature Ranges .....................5-17 Operating Data and Dimensions Long Track (LT) ...............................................8-6 Ripper ..............................................................8-8 Operating in Cold Weather .................................4-18 Engine Starting Aids ......................................4-18 Operating in Hot Weather ...................................4-18 Operating Instructions ..........................................4-4 Crawler Operation ............................................4-6 Dozer Operation .............................................4-23 Operating in Cold Weather ............................4-18 Operating in Hot Weather ..............................4-18 Issued 01-08

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87479855NA

CHAPTER 9 - INDEX Run-In Period of a New Machine .................... 4-3 Track Systems .............................................. 4-24 Transporting the Machine ............................. 4-16 Vandal Lockup .............................................. 3-23 Operating Precautions ......................................... 2-7 Operating Weight ................................................. 8-8 Operators Seat Belt ........................................... 3-24 Optional Equipment Weights ........................................................... 8-8 Outside Cab Door Release ................................ 3-21 Owner, To The ..................................................... 1-1

P Parking Brake Levers ........................................ 3-14 Parking the Machine and Stopping the Engine ... 4-5 Plastic and Resin Parts ....................................... 5-4 Power Turn .......................................................... 4-8 Pressure Relief Valves ...................................... 4-13 Priming the Turbocharger Oil Lines with Oil ...... 5-19

R Radiator ............................................................. 5-15 Rear Attachment Torque Values ....................... 6-11 Recoil Spring Housing ....................................... 4-24 Reverse/Forward Speed Ratio Control .............. 3-16 Ripper Operating Data and Dimensions ..................... 8-8 Ripper Control Lever ......................................... 3-19 Hold ............................................................... 3-19 Lower ............................................................ 3-19 Raise ............................................................. 3-19 Ripper Shank Adjustment .................................... 6-7 Roll-Over Protective Structure ............................. 6-6 ROPS Damage To ..................................................... 6-6 Maintenance and Inspection ........................... 6-6 RPM display ........................................................ 3-4 Run-In Period of a New Machine ......................... 4-3 Track Shoe Bolts ............................................. 4-3

S Safety Decals .................................................... 2-11 Safety Instructions, General ................................ 5-3 Safety, Battery ..................................................... 7-3 Seat Belt .............................................................. 6-6 Torque Specifications ...................................... 6-7 Seat Belt Precautions ........................................ 2-10 Seat Comfort Control ......................................... 3-20 Seat Lumbar Control ......................................... 3-21 Shuttle Parameter Adjustment ............................. 4-9 Sides of the Machine Right-hand, Left-hand, Front, and Rear .......... 1-2 87479855NA

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Bur

Spark Arrester Muffler ..........................................6-7 Specific Machine Precautions ............................2-10 Specifications Engine Specifications .......................................8-3 Hydraulic System .............................................8-3 Operating Data and Dimensions .............. 8-6, 8-8 Track System ...................................................8-4 Travel Speeds ..................................................8-3 Weights ............................................................8-8 Standard Seat Controls Backrest Tilt Adjustment Lever ......................3-20 Forward/Rearward Adjustment Lever ............3-20 Starting and Stopping Precautions .......................2-6 Starting the Engine ...............................................4-4 Steering Gradual Turn ..........................................4-8 Steering Sensitivity Adjustment ............................4-9 Storage Machine Storage ............................................6-10 Preparation ....................................................6-10 Removal From ................................................6-10 Switch Key/Ignition ......................................................3-5

T Tilting the Cab ....................................................4-20 To the Owner ........................................................1-1 Torque Specifications Seat Belt Mounting Bolts ..................................6-7 Towing a Disabled Crawler Releasing the Brakes .....................................4-13 Track Adjuster (Steel Track) ...............................4-24 Track Chain ........................................................4-24 Track Frame .......................................................4-24 Track Links .........................................................4-25 Track Maintenance/Adjustments ..........................5-9 Track Rollers ......................................................4-24 Track Shoe Bolts ..................................................4-3 Track Shoe Bolts - Steel Track .............................6-4 Track Shoes .......................................................4-25 Track System Specifications ...................................................8-4 Track Systems ....................................................4-24 Blade Lift Eye .................................................4-23 Bushing and Sprocket Wear Chart .................4-30 Case Extended Life Track (CELT) .................4-26 Components of the Undercarriage .................4-24 Factors Controlling Undercarriage Wear ........4-25 Factors Controlling Undercarriage Wear - Wear Factors You Can Not Control ................4-26 How to Extend the Life of Sealed Track and the Case Lubricated Track (CLT) ................4-26 Track Shoe Bolts - Steel Track ........................6-4 Wear Factors You Can Control ......................4-25 Transporting the Machine ...................................4-16 9-3

CHAPTER 9 - INDEX Travel Speeds Steel Track Crawler ......................................... 8-3 Turbo Precleaner ............................................... 5-28

U Utility Safety ......................................................... 2-4 Utility Safety Rules Message ............................... 2-4

V Vandal Lockup ................................................... 3-23

W Walk-Around Inspection ...................................... 4-4 Warning Lamp for Air Filter Restriction .............. 5-26 Wear Factors You Can Control ......................... 4-25 Weights ................................................................ 8-8 Operating Weight ............................................ 8-8 Optional Equipment ......................................... 8-8 Welding on the Machine ...................................... 6-5

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Issued 01-08

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87479855NA