Case 836C 856C 836C AWD 856C AWD Tier 4 Motor Grader Operator's Manual 47894596 - PDF DOWNLOAD

ORIGINAL INSTRUCTIONS

- according to Directive 2006/42/EC, Annex I, 1.7.4.1

836C 856C 836C AWD 856C AWD Tier 4 Motor Grader

OPERATOR’S MANUAL

Part number 47894596 1st edition English October 2015

Contents 1 GENERAL INFORMATION Note to the owner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Electro-Magnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Manual scope and required training level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Metric and imperial units abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Identification plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Driver´s cab ROPS and FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 Operator's manual storage on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 Machine orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 Machine components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 CE declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

2 SAFETY INFORMATION Safety rules and signal word definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 First-aid box storage compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 Warning triangle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 Noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 Vibration levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 Safety and informational signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

3 CONTROLS AND INSTRUMENTS Access to operator's platform Access doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Proper entry and exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjust the mirrors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab interior light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storage compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sun protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intake openings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tool kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12V DC socket outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Operator's seat Pneumatic suspension seat (Comfort seat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Forward controls Front console controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starter Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Windshield wiper and washer controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-13 3-15 3-16 3-17 3-18

Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Horn, turn signal, high beam and headlamp flasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Right-hand side controls Right-hand side controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ventilation and heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Floodlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearshift lever - powershift transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake-pressure-dependent transmission cutout/inching (option). . . . . . . . . . . . . . . . . . . . . .

3-23 3-25 3-27 3-29 3-31 3-37 3-41

Display Instrument panel - Warning and monitoring elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation of the multi-functional LCD display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Calling up the main menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Calling up the settings menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Calling up the display menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Calling up the diagnostics menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Calling up the service menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instrument panel/indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission oil temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic fluid temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel reserve indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selective Catalytic Reduction (SCR) system instrumentation warning. . . . . . . . . . . . . . . .

3-42 3-44 3-45 3-49 3-52 3-55 3-59 3-62 3-67 3-68 3-69 3-70 3-71 3-72

4 OPERATING INSTRUCTIONS Commissioning the unit Filling the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Filling the DEF/AdBlue® tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Refueling using the refueling station (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Starting the unit Before putting the machine into operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Warming up the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Machine movement start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Stopping the unit Stopping the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Shut off the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Moving the unit Foot throttle pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hand throttle lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Articulation joint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Driving on public roads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check during driving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Downhill driving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-14 4-14 4-15 4-16 4-19 4-19

5 TRANSPORT OPERATIONS Preparing for road transport Transporting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Crane loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

6 WORKING OPERATIONS General information Grader use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Working attachments Working attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Control levers for working attachments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Increasing the working speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Swivel arm adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Wheel lean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Floating position (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Dozer blade (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Rear ripper (option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Moldboard ripper (option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Emergency lowering of the working equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

After daily use After daily use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

7 MAINTENANCE General information Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Torque charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Securing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Engine hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Biodiesel - Biodiesel fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Lubrication plan - Front axle, Tandem axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Lubrication plan - Moldboard, Articulation frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Inspection plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26 Draining hose for oil changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

Selective Catalytic Reduction (SCR) - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28 Selective Catalytic Reduction (SCR) system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

Maintenance planning Maintenance planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

Once before initial commissioning Maintenance - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39 Maintenance - Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

When the warning lamp lights Change the main filter element - air intake system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41

Every 10 hours or daily service Check machine and units visually for defects, leaks and loss of consumables . . . . . . .

Check the engine oil level/topping up oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the Organic Acid Technology (OAT) coolant level/topping up coolant . . . . . . . . .

Check and clean the combined radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check and clean the AC condenser (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the air intake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the lighting function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the monitoring, warning and control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the hydraulic system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the service brake function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the parking brake function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the wheel condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the windshield washer fluid reservoir/topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the DEF/AdBlue® tank level/topping up fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-42 7-43 7-45 7-47 7-48 7-49 7-50 7-51 7-52 7-53 7-54 7-58 7-59 7-60 7-61 7-63 7-64

Every 50 hours or weekly Check the hydraulic oil level/topping up oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the tire pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the wheel nuts for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the blade slewing gear oil level/topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clean the grader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the powershift transmission oil level/topping up oil . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-65 7-66 7-67 7-68 7-69 7-71

Once after 250 hours Maintenance - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance - Change fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance - Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance - Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance - Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-73 7-74 7-75 7-76 7-77 7-78

Every 250 hours Check the rear axle oil levels/topping up oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check all lines, fittings and connections for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricate all articulated joints and hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the drive belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the battery and cable connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Grease the battery terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-79 7-81 7-83 7-84 7-85 7-86 7-87 7-88

Every 500 hours Bleed the fuel system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the service brake discs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clean/change the fresh air filter on the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the heating for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the driver´s cab mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the engine bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-89 7-91 7-92 7-95 7-97 7-98 7-99

Every 500 hours or yearly Change the engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-100 Change the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-102 Change the fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-104 Change the DEF/AdBlue® tank vent filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-105 Clean the DEF/AdBlue® supply module pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-106

Every 500 hours or 2-yearly Change the fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-107

Every 1000 hours Change the blade slewing gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-108 Change the powershift transmission oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-109 Change the powershift transmission oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-111 Check the compressor drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-112 Change the tandem box swing unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-113 Drain off water and deposits from the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-114 Change the drive belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-115 Change the hydraulic return flow filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-116 Change the front-wheel drive oil filter (Only all-wheel version). . . . . . . . . . . . . . . . . . . . . . . 7-118

Every 1000 hours or yearly Change the main filter element - air intake system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-119 Check the heating/air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-121 Compressor drive belt - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-122

Every 1500 hours Change the CCV/engine breather filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-123 Calibrating the gear box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-124

Every 2000 hours Change the differential/side reducer gear oil on rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-126 Check valve setting on engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-127

Every 3000 hours Clean the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-128 Check and adjust the hydraulic pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-129 Depressurising the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-130 Depressurising the hydraulic reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-132 Change the hydraulic reservoir breather valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-133 Clean the hydraulic reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-134 Change the environment friendly hydraulic fluid (if used) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-135 Hydraulic fluid analyze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-136

Every 3000 hours or every 3 years Change the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-137 Change the safety filter - air intake system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-139

Every 4000 hours or 2-yearly Change the DEF/AdBlue® supply module main filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-141

Every 4000 hours or every 4 years Change the Organic Acid Technology (OAT) coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-142

As required maintenance Clean the DEF/AdBlue® tank neck filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-144

Battery Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-145 Recharging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-147 Assisted starting (Jump-starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-148

Diagnosis sockets Diagnosis sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-150

Lighting system Replacing bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-151

Wheels Changing a wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-159

Equipment Replacing the blade cutting edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-160

Welding operations Protection of the electronic modules during welding operations . . . . . . . . . . . . . . . . . . . . . 7-161

Fuse and relay locations Checking/replacing fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-164

Storage Decommissioning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-170 Periodic checks during decommissioned period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-172 Recommissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-173

8 SPECIFICATIONS Main dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Noise level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 Front drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Dozer blade (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Rear ripper (option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17 Tire pressure - admissible tire size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

9 ACCESSORIES Radio (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotary beacon (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear view camera (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Towing attachments (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Telematics (option) - General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Telematics (option) - Location overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Telematics (option) - LED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

1 - GENERAL INFORMATION

1 - GENERAL INFORMATION###_1_### Note to the owner These operating instructions are designed to familiarize the operator with the machine and its designated use.

The instruction manual contains important information about how to operate the machine safely, properly, and economically. Observing these instructions helps to prevent hazardous situations, to reduce repair costs and downtimes and to increase the reliability and service life of the machine.

The instruction manual must be supplemented by the respective national rules and regulations for accident prevention and environmental protection.

NOTE: The operating instructions must always be available in the machine’s driver’s cab.

The operating instructions must be read and used by any person in charge of carrying out work with or on the machine, such as: • Operation, including setting-up, troubleshooting in the course of work, care, disposal of operation materials and consumables • Maintenance (inspection, servicing, repair work) and/or • Transport In addition to the operating instructions and the mandatory rules and regulations for accident prevention and environmental protection in the user’s country and at the place where the machine is to be used, the generally recognized technical rules for safe and proper work must be observed (Complies with the VDMA recommendation “Operating Instructions”).

The operating instructions are intended for construction machinery specialists. They cannot provide basic knowledge.

This can be acquired, for example, in several days’ instruction by one of our qualified mechanics or by attending one of our training courses for operators or maintenance personnel.

Your authorized dealer will be pleased to answer any questions you might have after reading the operating instructions.

All our operating manuals are issued in English and then translated. Even a good translation may give rise to questions which we will be pleased to answer.

The operating instructions are not work instructions for carrying out major repairs. Your authorized dealer will be glad to perform this work for you.

The documentation relating to the machine is listed by scope, quantity, and language in the shipping note of the machine or in the covering letter if supplied separately. The operating instructions and spare-parts list are marked with the machine’s number.

Upon receipt of the consignment, please check that the documentation is complete and in the language you requested.

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

1-1

1 - GENERAL INFORMATION

Warranty One of the manufacturer’s preconditions for the acceptance of the warranty is that the following compulsory inspection, maintenance and repair works must be carried out in compliance with the Maintenance Instructions and relaying on the manufacturer’s original spare parts.

The daily and weekly maintenance work can be performed by the machine operator. During the warranty period, all inspection, maintenance and repair work, except for the daily and weekly inspections and servicing, must be performed by your authorized dealer.

The inspection, maintenance and repair work which is carried out must be entered in the “Instructions for customers” booklet which is enclosed with the machine documentation.

Safety The pages in Section 2 list the precautions to be observed to ensure your safety and the safety of others. Read the safety precautions and follow the advice offered before operating the machine.

This manual contains information concerning the adjustment and maintenance of your new equipment. You have purchased a dependable machine, but only by proper care and operation can you expect to receive the performance and long service built into this equipment. Please have all operators read this manual carefully and keep it available for ready reference.

Your authorized dealer will instruct you in the general operation of your new equipment. Your dealer's staff of factory-trained service technicians will be glad to answer any questions that may arise regarding the operation of your machine.

Your authorized dealer carries a complete line of genuine service parts. These parts are manufactured and carefully inspected to insure high quality and accurate fitting of any necessary replacement parts. Be prepared to give your dealer the model and product identification number of your new equipment when ordering parts. Locate these numbers now and record them below. Refer to the 'General Information' section of this manual for the location of the model and product identification numbers of your machine.

PLEASE RECORD THE FOLLOWING INFORMATION

Model Product Identification Number (PIN)

1-2

1 - GENERAL INFORMATION

Intended use Intended use WARNING Avoid injury!

Using the machine for purposes other than or beyond the intended use is not allowed; for example: - for the transportation of persons, - as a working platform, - for pulling attached loads, - for pulling or transporting loads without the intended working equipment.

Failure to comply could result in death or serious injury.

W1142B

The machine has been built with state of the art technology and in accordance with accepted safety regulations.

Nevertheless, its use could lead to a risk to life and limb for the operator or third parties, or cause damage to the machine and other property.

The machine may only be used in technically excellent condition and in accordance with its intended use and in observance of the operating instructions. Important notices are to be found at the beginning of the chapters. Especially those malfunctions which affect safety must be rectified immediately.

The grader is primarily intended for: • Creating fine-graded surfaces • Clearing away top soil • Tearing up old road surfaces • Cutting slopes • Clearing away ice and snow • Gathering, spreading, mixing, and compacting materials.

The grader can also be used with other working equipment for special purposes. The technical data offer clear instructions in this respect.

Only equipment that has been approved by CASE CONSTRUCTION may be used.

No extensions or conversions may be made to units supplied.

Intended use includes following the operating instructions and fulfilling the inspection and maintenance conditions.

The manufacturer/supplier is not liable for any damage arising out of improper use. The risk is borne entirely by the user.

General description The grader, also called leveller, is a construction machine that is used to create large even areas. Graders are typically used in roadworks, where an even roadbed is required for the asphalt.

Major components of the grader The basic machine comprises the following major components: • Frame • Drive train • Driver’s Cab • Equipment

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1 - GENERAL INFORMATION

Frame The frame consists of a front and a rear frame. These are interconnected with bearings and bolts and can be pivoted about a vertical axis.

Drive train The drive train is provided by a water-cooled diesel engine driving the four rear wheels via a torque converter, 6-speed powershift transmission, cardan shaft, tandem chain drive on the four rear wheels.

All-wheel drive (optional) In addition to the rear-wheel drive, a hydrostatic electronically controlled front-wheel drive can be switched on.

Rear axle, tandem drive Axle gear with automatic No-Spin-differential. Floating tandem chain cases with roller chains for power transmission to the wheel hubs.

Front axle Swing axle with king-pin steering and hydraulic wheel camber adjustment.

Brakes The service brake is a hydraulic dual-circuit accumulator brake with four submerged multiple-disk brakes acting on the rear axle.

An electrically/hydraulically operated disk brake on the powershift transmission output shaft serves as a parking brake.

Steering Hydrostatic front-wheel steering with emergency steering.

Hydraulic system The working hydraulic system is a load-sensing system. The oil is supplied by a variable displacement pump which is controlled as required (load sensing) via directly operated control blocks. Two hydraulic functions can be carried out simultaneously without either affecting the other.

The hydraulic system is protected against over-loading by means of pressure relief valves.

Electrical system The electrical system has an operation voltage of 24 V.

Equipment Middle blade with hydraulic adjustment of all functions and sealed ball-bearing slewing ring. The following equipment is available as options: front grading blade, rear ripper, and blade ripper.

Spare parts Please use only OEM spare parts to maintain the machine’s operation integrity.

When ordering spare parts, please provide the following information: • Machine type • Serial number of machine and the engine • Parts number from the spare parts catalogue

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1 - GENERAL INFORMATION

Electro-Magnetic Compatibility (EMC) This machine complies strictly with the European Regulations on electro‐magnetic emissions. However, interference may arise as a result of add‐on equipment which may not necessarily meet the required standards. As such interference can result in serious malfunction of the unit and/or create unsafe situations, you must observe the following: • Ensure that each piece of non‐ CASE CONSTRUCTION equipment fitted to the machine bears the CE mark.

• The maximum power of emission equipment (radio, telephones, etc.) must not exceed the limits imposed by the national authorities of the country where you use the machine.

• The electro‐magnetic field generated by the add‐on system should not exceed 24 V/m at any time and at any location in the proximity of electronic components.

Failure to comply with these rules will render the CASE CONSTRUCTION warranty null and void.

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1 - GENERAL INFORMATION

Manual scope and required training level Introduction to this Manual This manual gives information for use of your CASE CONSTRUCTION machine, as intended and under the conditions foreseen by the manufacturer during normal operation and routine service and maintenance. This manual does not contain all the information related to periodical service, converting and repairs to be carried out by professional service personnel. For some of the latter activities, there may be a need for appropriate facilities, technical skills, and/or tools which are not supplied with the machine.

The manual is divided into sections as outlined in the General Table of Contents Page(s). Refer to the Detail Index at the end of this manual for locating specific items about your CASE CONSTRUCTION machine.

Scope and Required Training Level This manual gives information for use of your CASE CONSTRUCTION machine, as intended and under the conditions foreseen by the manufacturer during normal operation and routine service and maintenance.

This manual does not contain all the information related to periodical service, converting and repairs to be carried out by CASE CONSTRUCTION professional service personnel. For some of the latter activities, there may be a need for appropriate facilities, technical skills, and/or tools which are not supplied with the CASE CONSTRUCTION machine.

Periodical service consists of activities that must be done at defined intervals: • By trained personnel familiar with the CASE CONSTRUCTION machine characteristics.

• By trained personnel complying with the information for periodical service and safe practices, as partly specified by the manufacturer in this manual and in other company literature.

• In order to maintain the expected life time of the CASE CONSTRUCTION machine. Periodical service includes activities such as changing oil from the engine, hydraulic circuits or transmission, or other substances or components that need periodical exchange.

Converting consists of activities that must be done: • By professional service personnel familiar with the CASE CONSTRUCTION machine characteristics

Normal operation consists of use of the CASE CONSTRUCTION machine for the purpose intended by the manufacturer by an operator that is: • Familiar with the CASE CONSTRUCTION machine and the mounted or towed equipment.

• Complying with the information for operation and safe practices, as specified by the manufacturer in this manual and by the signs on the machine.

Normal operation includes: • The preparation and storage of the CASE CONSTRUCTION machine • Swinging components into work position and vice versa • Adding or removing ballast • Picking up and setting off mounted or towed equipment • The adjustment and setting of the CASE CONSTRUCTION machine and equipment for the specific condition of the field and/or the crop.

Routine service and maintenance consists of activities that must be done daily in order to maintain its proper function by an operator that is • Familiar with CASE CONSTRUCTION machine characteristics • Complying with the information for routine service and safe practices, as specified by the manufacturer in this manual and by the signs on the CASE CONSTRUCTION machine. Routine service includes activities such as fueling, cleaning, washing, topping up fluid levels, greasing, and replacing consumable articles such as lamp bulbs.

• Complying with the information for converting, as partly specified by the manufacturer in this manual, in assembly instructions, or in other company literature • In order to rebuild the CASE CONSTRUCTION machine in a configuration which is appropriate for a specific crop or soil condition (e.g., installation of dual wheels etc.)

Repair (and dismantling) consists of activities that must be done: • By professional service personnel familiar with the CASE CONSTRUCTION machine characteristics • Complying with the information for repair, as specified by the manufacturer in the CASE CONSTRUCTION dealer’s service manual.

• In order to restore the proper function of the CASE CONSTRUCTION machine after a failure or degradation of performance when scrapping or dismantling the CASE CONSTRUCTION machine.

Read this manual before you start the engine or operate this CASE CONSTRUCTION machine. If any information in this manual is not understood, or if you need more information or assistance, contact your CASE CONSTRUCTION dealer.

All persons training to operate, or who will be operating this CASE CONSTRUCTION machine, should be old enough to possess a valid local vehicle operating permit (or other applicable local age requirement) and must have

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1 - GENERAL INFORMATION

demonstrated the ability to operate and service the CASE CONSTRUCTION machine correctly and safely.

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1 - GENERAL INFORMATION

Metric and imperial units abbreviations Typical applications

Metric unit Name

Symbol

Imperial unit Name

Symbol

Area (Land area)

mm²

acre square foot square inch square inch

ac ft² in² in²

milliampere ampere ampere–hours volt microfarad ohm

mA A A*h V µF Ω

milliampere ampere ampere–hours volt microfarad ohm

mA A A*h V µF Ω

kilonewton newton

kN N

pound

lb

newton per meter

N/m

pound per foot pound per inch

lb/ft lb/in

megahertz kilohertz hertz

MHz kHz Hz

megahertz kilohertz hertz

MHz kHz Hz

revolutions per minute

r/min rpm

revolutions per minute

r/min ª rpm

kilometer meter centimeter millimeter micrometer

km m cm mm µm

mile foot inch

mi ft in

metric ton kilogram gram milligram

t kg g mg

pound

lb

ounce

oz

milligram per kilogram

mg/ kg

kilowatt watt

kW W

horsepower Btu per hour Btu per minute

Hp Btu/hr Btu/min

kilopascal

kPa

pascal megapascal

Pa MPa

pound per square inch inch of mercury inch of water pound per square inch

psi inHg inH2O psi

hectare square meter

ha m²

square millimeter Electricity

Force

Force per length

Frequency

Frequency − Rotational

Length

Mass

Mass per Mass Power

Pressure or stress (Force per area)

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1 - GENERAL INFORMATION

Typical applications

Metric unit Name

Symbol

Imperial unit Name

Temperature (other than Thermodynamic) degrees Fahrenheit degrees Celsius °C Time hour h hour minute min minute s second second Torque (includes Bending moment, Moment of force, and Moment of a couple) newton meter Nm pound foot pound inch Velocity kilometer per hour mile per hour km/h meter per second m/s foot per second millimeter per second inch per second mm/s meter per minute m/min foot per minute Volume (includes Capacity) cubic meter cubic yard m³ liter liter

1-9

°F h min s lb ft lb in mph ft/s in/s ft/min

ml

cubic inch US gallon UK gallon US quart UK quart fluid ounce

yd³ cu yd in³ US gal UK gal US qt UK qt fl oz

m³/min l/min ml/min

cubic foot per minute US gallon per minute UK gallon per minute

ft³/min US gal/min UK gal/min

dB

decibel

dB

l l

milliliter Volume per time (includes Discharge and Flow rate) cubic meter per minute liter per minute milliliter per minute Sound power level and Sound pressure level decibel

Symbol

1 - GENERAL INFORMATION

Glossary Acronym AIC ADC API ASTM CAN CE CU DIN DTC ECU ECM EDC EDCV EEC EM EN EST FMI FOPS FWD HFRR ISO LDA LED LpA LS LwA OEM OH PCS ppm PTO ROPS SAE TCU TPU UCM VDMA

Definition Advanced Instrument Cluster Analogue Digital Converter American Petroleum Institute American Society for Testing and Material Controller Area Network European Community Central Unit German Industrial Standard Institute Diagnostic Trouble Code Electronic Control Unit Electronic Control Module Electronic Diesel Control Electronic Drive Control Electric Engine Controller Earth Mover Tire Moulds European standard Electronic Service Tool Failure Mode Indicator Falling Objects Protective Structures Front Wheel Drive High Frequency Reciprocating Rig International Standardisation Organisation Load pressure dependent full-load limit stop Light Emitting Diode Sound pressure level in the workplace Limited Slip, (Additive to axle oils) Sound pressure level of the machine when stationary Original Equipment Manufacturer Operating Hour Power Control System Parts Per Million Power Take-Off Roll Over Protective Structures Society of Automotive Engineers (USA) Transmission Controller Unit Timer Processing Unit Universal Control Module Verband Deutscher Maschinen- und Anlagenbau e.V.

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1 - GENERAL INFORMATION

Identification plates Record the machine and part identification numbers. When ordering parts, obtaining information or assistance, always supply your dealer with the type and serial number of your machine or accessories. Keep a record of these numbers 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.

SS14C118

Pos. Designation 1 Model plate of the machine 2 Model plate of the engine

1

Pos. Designation 3 Model plate of the cab

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1 - GENERAL INFORMATION

Model plate of the machine Type/model PIN Model year

The machine model plate is affixed to the frame on the right side under the offset cylinder. In addition, the serial number is stamped onto the front frame.

SS14K156

Pos. 1 2 3 4 5 6 7

Designation Name of the manufacturer Type / Model & Designation Type approval number Product Identification Number (PIN) Total Permissible mass Permissible axle 1 load Permissible axle 2 load

2

Pos. 8 9 10 11 12 13 14

1-12

Designation Permissible axle 3 load Manufacturer's address Designation Year of construction Model Year Unladen mass Engine Max Net Power (ISO 14396/ECE R120)

1 - GENERAL INFORMATION

Model plate of the engine Manufacturer Engine type number Engine serial number

The plates are affixed to the cylinder head cover at the top next to the oil filler hole.

SS14J033

Pos. Designation 1 Name of the manufacturer 2 Month and year of production 3 CNH part number

3

Pos. Designation 4 FPT part number 5 Serial number

1-13

1 - GENERAL INFORMATION

Pos. 6 Engine type 7 Serial number 8 Engine family

Designation

SS14J034

4

SS14J028

5

County of origin label

1-14

1 - GENERAL INFORMATION

Model plate of the cab Type Serial number

The cab model plate is affixed to the inside of the cab centered behind the steering column.

Pos. 1 2 3 4 5 6

Designation Machine manufacturer Type Applicable models Serial number Total permissible mass Approval standards

SS14A128

6

SS11K196

7

CE mark The CE mark that is located on the machine model plate (see figure 2) certifies that the machine has been built in accordance with the CE directives 2006/42/EC. CE stands for “Communauté Européenne” (European Community).

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1 - GENERAL INFORMATION

Machine number

The model plate with the machine number is attached below the right cab door.

SS14K158

8

SS11H038

9

The number is moreover marked on the front frame.

Powershift transmission number

The model plate with the powershift transmission number is attached on the transmission housing.

SS11K216

Component numbers Identification plates with the serial number can also be found on other bigger units. Steel components can have the parts number or the factory number engraved in the metal where they are easily visible.

1-16

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1 - GENERAL INFORMATION

Driver´s cab ROPS and FOPS DANGER Crushing hazard!

Do not change the Roll Over Protective Structure (ROPS) in any way. Unauthorized changes such as welding, drilling, or cutting will weaken the ROPS and decrease your protection. Have an authorized dealer replace the ROPS if damage of any kind occurs. DO NOT TRY TO REPAIR THE ROPS. Failure to comply will result in death or serious injury.

D0037A

WARNING Roll-over hazard!

After an accident, fire, tip over, or roll over, a qualified technician MUST replace the Roll-Over Protective Structure (ROPS) before returning the machine to the field or job site operation.

Failure to comply could result in death or serious injury.

W0134A

The cab is equipped with an integrated ROPS/ FOPS safety component.

ROPS (Roll-Over Protective Structure) offers protection in the event of machine roll-over.

FOPS (Falling-Object Protective Structure) offers protection against objects falling from above.

Exact specifications about the cab are stamped on the plate. It is attached inside the cab in the center behind the steering column.

The safety components (ROPS/FOPS) of the cab are based on standard ISO 3471- SAE 1040C for ROPS and standard ISO 3449-J231-OSHA for FOPS. According to the EC Machine Directive, the ROPS/FOPS safety components must fulfill very high technical requirements. In the case of modifications or repairs of the cab it is therefore necessary to contact the cab manufacturer with regard to warranty issues.

1-17

SS14A128

Pos. 1 2 3 4 5 6

1

Designation Machine manufacturer Type Applicable models Serial number Total permissible mass Approval standards

1 - GENERAL INFORMATION

Operator's manual storage on the machine On the right side of the cab there is a pocket for storing the operator’s manual.

SS14D035

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1

1 - GENERAL INFORMATION

Machine orientation As used in this manual, the terms “right”, “left”, “front”, and “rear” indicate the sides of the machine as seen from the operator’s seat.

SS14C119

Pos. A Front B Rear

Designation

1

Pos. C Left D Right

1-19

Designation

1 - GENERAL INFORMATION

Machine components

SS14H041

Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Designation Steering cylinder Front frame Moldboard swing cylinder Blade-lifting cylinder Control block Steering, hydrostatic Driver’s cab Driver’s seat Engine air filter Diesel engine and transmission Hydraulic reservoir Radiator for transmission oil/hydraulic fluid/coolant/charge air Shift transmission, 6 gears Torque converter Rear ripper cylinder (option) Diesel Exhaust Fluid (DEF)/AdBlue® tank Rear ripper (option) Cardan shaft, powershift transmission, rear axle Parking brake (disk brake) Wheel hub Rear wheels

1

Pos. 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

1-20

Designation Service brake Rear axle gear Tandem case Rear frame Fuel tank Articulation joint Offset cylinder Pitch adjustment cylinder Blade carrier Blade ripper (option) Blade Moldboard extend cylinder Swivel arm, 5 adjustable positions Blade-slewing ring Blade-slewing gear Front wheels Front axle Wheel lean cylinder Dozer blade cylinder (option) Dozer blade (option)

1 - GENERAL INFORMATION

CE declaration of conformity On the following page you will find a copy of the “EC” Declaration of Conformity (EC DoC). The EC DoC is the manufacturer’s declaration that the equipment is in compliance to relevant EU provisions. Please keep the original document in a safe place. Local authorities may require you to show this document in order to assure compliance of your equipment.

You can find the translation of this description in your country’s language on the back of the original document. To better and more easily understand this document, you will find some explanatory notes below.

1. Those options or variants are listed at section 1.2 (see figure 1) which have safety related functions. Some of them are provided as standard, like FOPS or ROPS. See 1-17.

2. All information which is required by EU Directive 2000/14/EC “Noise for Outdoor Equipment” is listed in section 2. Please refer your own original EC DoC for more specific equipment information. For more information about equipment guaranteed sound power level (LWA) see 2-31. On the same page has specifications about station noise level (LpA) which are not dealt with in the above-mentioned EU Directive and therefore not indicated on it.

3. General serial number for this equipment type. The sequence of letters and numbers may vary depending on equipment configuration.

4. Signature of a person authorized to sign the document on behalf of the company.

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1 - GENERAL INFORMATION

Sample of “EC” Declaration of Conformity

SS14K168

1-22

1

2 - SAFETY INFORMATION

2 - SAFETY INFORMATION###_2_### Safety rules and signal word definitions Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury.

Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special instructions. These precautions are intended for the personal safety of you and those working with you.

Read and understand all the safety messages in this manual before you operate or service the machine.

DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.

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

CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY. Machine safety NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage.

Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or property damage. The word Notice is used to address practices not related to personal safety.

Information NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual.

Throughout this manual you will find the word Note followed by additional information about a step, procedure, or other information in the manual. The word Note is not intended to address personal safety or property damage.

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2 - SAFETY INFORMATION

Safety rules General safety rules Due to the machine mass being outside the ISO 5006 requirements there are certain sectors of the machine which will require the operator to take extra precautions to prevent contact with persons in the following areas: Areas in front of the Grader 856C blade. Areas behind the Grader 856C. A person or pet within the operating area of a machine can be struck or crushed by the machine or its equipment. DO NOT allow anyone to enter the work area.

Always know the location of all workers in your area.

Warn them before you start working on the machine.

Always keep all unauthorized bystanders clear of the area.

Always sound the horn before starting the machine. Make sure the work area is clear of other persons, domestic animals, tools, etc. before you operate the machine. Never allow anyone in the work area during machine operation.

Failure to comply could result in death or serious injury.

The operating instructions must always be available at the machine (in the driver’s cab).

Poor visibility may result in accidents. Always clean the windows and the glass covers of all lights before operating the machine. In conditions of poor visibility and after dark, always switch on the lighting system.

Always use approved attachments. Make sure that the attachment is compatible with the machine mounting system. The technical data offer clear instructions.

Use caution when you operate the machine on slopes.

Raised equipment, full tanks and other loads will change the center of gravity of the machine. The machine can tip or roll over when near ditches and embankments or uneven surfaces.

Never permit anyone other than the operator to ride on the machine. The cab is designed to provide a safe work envelope for only one person.

Never operate the machine under the influence of alcohol or drugs, or while you are otherwise impaired.

Model 836C is conform to revised ISO 5006.

Model 856C is not conform to revised ISO 5006.

Never operate the machine before having read and understood the operating instructions.

When digging or using ground-engaging attachments, be aware of buried cables. Contact local utilities to determine the locations of services.

Familiarize yourself with the layout, the functioning, and the activating devices of the control elements prior to putting the machine into operation.

Pay attention to overhead power lines and hanging obstacles. High voltage lines may require significant clearance for safety.

Inhalation/asphyxiation hazard! Never operate the engine in a closed building or area. Proper ventilation is required under all circumstances.

Hydraulic oil or diesel fuel leaking under pressure can penetrate the skin, causing serious injury or infection.

Operating personnel must have the knowledge about the operation and the functionality of this or comparable machines.

Only activate the control elements from the driver’s seat.

For start-up and shut-down procedures, always observe the indicators in accordance with the operating instructions.

Before setting the machine in motion, always check that the accessories have been safely stored.

Operate the machine only in a safe state and only in accordance with its intended use. Always observe all the safety instructions.

Before starting work or driving with the machine, check that the braking, steering, signaling and lighting systems are fully functional.

• DO NOT use your hand to check for leaks. Use a piece of cardboard or paper.

• Stop the engine, remove the key, and relieve the pressure before you connect or disconnect fluid lines.

• Make sure that all components are in good condition.

Tighten all connections before you start the engine or pressurize the system.

• If hydraulic fluid or diesel fuel penetrates the skin, seek medical attention immediately.

• Continuous long term contact with hydraulic fluid may cause skin cancer. Avoid long term contact and wash the skin promptly with soap and water.

Before starting maintenance work or repair, depressurize piping and hoses, cylinders, radiator, hydraulic reservoir, airbrake reservoir, and other systems or units to be removed in accordance with the specific instructions for that particular unit.

2-2

2 - SAFETY INFORMATION

Hydraulic and compressed air lines must be laid and fitted properly. Ensure that no connections are interchanged.

The fittings, lengths, and quality of the hoses must comply with the technical requirements.

Keep clear of moving parts. Loose clothing, jewelry, watches, long hair, and other loose or hanging items can become entangled in moving parts.

Before you leave the machine: 1. Park the machine on a firm, level surface.

2. Lower all hydraulic equipment — Implements, header, etc.

3. Move controls to release residual pressure.

4. Put all controls in neutral or park lock position.

5. Lock blade control levers with knobs on side of steering column (see also 4-16 and following).

Wear protective equipment when appropriate.

DO NOT attempt to remove material from any part of the machine while it is being operated or while components are in motion.

6. Turn off the engine and remove the key.

Make sure that all guards and shields are in good condition and properly installed before you operate the machine. Never operate the machine with shields removed.

Always close access doors or panels before you operate the machine.

8. Push the right-hand side console to the rear.

Dirty or slippery steps, ladders, walkways, and platforms can cause falls. Make sure these surfaces remain clean and clear of debris.

A person or pet within the operating area of a machine can be struck or crushed by the machine or its equipment. DO NOT allow anyone to enter the work area.

7. Engage the parking brake. Use wheel chocks if required.

When, due to exceptional circumstances, you would decide to keep the engine running after you leave the operator’s station, then you must follow these precautions: 1. Bring the engine to low idle speed.

2. Disengage all drive systems. Lower the blades and ripper and lock the controls of blades and ripper (see also 4-16 and following).

3.

Some components may continue to run down after disengaging drive systems.

Make sure all drive systems are fully disengaged.

Failure to comply could result in death or serious injury.

Raised equipment and/or loads can fall unexpectedly and crush persons underneath. Never allow anyone to enter the area underneath raised equipment during operation.

Never operate the engine in enclosed spaces as harmful exhaust gases may build up. Diesel exhaust contains dangerous compounds. Proper ventilation is required under all circumstances.

Before you start the machine, be sure that all controls are in neutral or park lock position.

Start the engine only from the operator’s seat. If you bypass the safety start switch, the engine can start with the transmission in gear. Do not connect or short across terminals on the starter solenoid. Attach jumper cables as described in the manual. Starting in gear may cause death or serious injury.

Always keep windows, mirrors, all lighting, and Slow Moving Vehicle (SMV) emblem clean to provide the best possible visibility while you operate the machine.

Operate controls only when seated in the operator’s seat, except for those controls expressly intended for use from other locations.

WARNING

W0113A

Shift the transmission into neutral.

4. Apply the parking brake.

Any work on or with the machine may be performed only by reliable personnel. Observe all legislated minimum age limits.

Define the machine operator’s responsibilities: • with regard to observing traffic regulations • giving the operator the authority to refuse instructions given by third parties that are contrary to known safe practices.

Observe all fire warnings and fire-fighting procedures.

Emergency exit NOTICE: The right cab door is marked as Emergency exit. Before leaving the cab, the right side console is to be pushed to the rear.

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2 - SAFETY INFORMATION

General maintenance safety Always carry out (or have carried out) inspection and servicing work on schedule.

Repair work on the electrical system may only be carried out by a qualified electrician.

Inspection and servicing personnel must have the relevant know-how for the inspection and servicing of this or comparable machines.

Stop the engine and remove the key before you connect or disconnect electrical connections.

Give a briefing to operating personnel before beginning special tasks and repair work, and appoint a person to supervise the activities.

Keep the area used for servicing the machine clean and dry. Clean up spilled fluids.

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions. Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Disconnect the battery prior to any work on the electrical system of the emergency flasher, diagnostic connector, telematic module (option), or blade control (option). Disconnect the negative terminal first and then the positive terminal. On completion of work, connect the positive terminal first and then the negative terminal. Take care not to interchange the cables when connecting the batteries (observe polarity).

NOTE: If you have any doubt regarding the electrical system you are working on, it is recommended to disconnect the battery.

Install guards and shields after you service the machine.

Take care when opening filler caps while the system is hot. Before removing the cap: completely cover the cap using a thick cloth, and slowly open the filler cap to allow the pressure to escape. Do not add cold water to a hot coolant reservoir.

Close all access doors and install all panels after servicing the machine.

Replace damaged or worn tubes, hoses, electrical wiring, etc.

Do not attempt to clean, lubricate, clear obstructions, or make adjustments to the machine while it is in motion or while the engine is running.

Check fastening and securing elements, e.g. bolts, nuts, washers, before using them again. Replace any damaged parts.

Never start up the driving engine while work is being done on the machine.

The engine, transmission, exhaust components, and hydraulic lines may become hot during operation. Take care when you service such components. Allow surfaces to cool before you handle or disconnect hot components.

Wear protective equipment when appropriate.

Service the machine on a firm, level surface.

Always make sure that working area is clear of tools, parts, other persons and pets before you start operating the machine.

Unsupported hydraulic cylinders can lose pressure and drop the equipment, causing a crushing hazard. Do not leave equipment in a raised position while parked or during service, unless the equipment is securely blocked against movement.

Jack or lift the machine only at jack or lift points indicated in this manual.

Incorrect towing procedures can cause accidents. When you tow a disabled machine follow the procedure in this manual. Use only rigid tow bars.

Fully open and latch engine compartment hood prior to performing work under the hood.

Stop the engine, remove the key, and relieve pressure before you connect or disconnect fluid lines.

Shut off the engine before you open the engine hood.

Wait for all movement to stop and allow the engine to cool before servicing.

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49.0 °C (120.2 °F). Allow fluids to cool before proceeding.

When welding, follow the instructions in the manual. Always disconnect the battery before you weld on the machine. Always wash your hands after you handle battery components.

Carry out welding, flame-cutting, and grinding work on the machine only if this has been expressly authorized, as there may be a risk of explosion and fire.

Prevent explosions. Before carrying out welding, flamecutting, and grinding operations, clean the machine and its surroundings to remove dust and other flammable substances. Make sure that the premises are adequately ventilated.

Wear closely fitting work clothes when operating the machine. Loose, wide work clothes can catch in machine parts and cause injury.

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Wear a safety helmet, safety shoes, gloves, and, in the event of hazardous levels of noise, ear protection.

Tighten leaking screw plugs only when the system is depressurized.

Wear eye protection and protective clothing during the cleaning process. Clear the area of bystanders.

In some cases, spare parts could contain asbestos. Do not machine spare parts containing asbestos. Inhaling asbestos is dangerous for the health.

Put all working equipment down on the ground so that no movements can occur if mechanical or hydraulic connections become detached.

When working in area near the centered articulated joint or all other joints, lock the joints. Remove the blocks when work is finished.

Do not inhale abraded particles from brake linings and be sure to wear a breathing mask.

The fastening of loads and the direction of crane operators should only be entrusted to experienced persons.

The banksman (reversing assistant) must remain in visual or verbal contact with the operator.

Before working on the hydraulic of the camber, drive the camber right or left to stop. For the case that the hydraulics can not be put into operation, secure the Front axle with wedges against oscillation and jack up.

When carrying out overhead assembly work, always use specially designed or otherwise safe climbing aids and working platforms. Never climb on machine parts.

If the machine has to be jacked up, wedge the front axle in place first to prevent it from moving.

Always tighten any screwed connections that have been loosened during service and repair work.

Secure any equipment or components which are to be attached or detached or whose position is to be altered, with hoists or suitable slinging/supporting devices to prevent them from moving, slipping, or falling.

Any safety devices removed for set-up, maintenance, or repair purposes must be refitted and checked immediately upon completion of the service and repair work.

Use only fully functional, reliable tools. Select the right tool for the job. Wrenches of the wrong size, for example, may slip and cause injury.

The operating instructions must be supplemented by instructions covering the duties involved in supervising and notifying special organizational features, such as job organization, working procedures, or the personnel entrusted with the work.

Handling oils and greases: • Hot lubricant or hydraulic oil emerging uncontrolled from the system may result in severe burns. Cool any burns immediately with running water and apply a dry dressing.

• Observe all product-related safety regulations.

• Do not use bare hands to check for leaks.

• Never get within range of an emerging oil jet.

• Avoid contact with the skin. Wear appropriate PPE, such as eye protection and gloves. Skin contact with old oils is a health hazard.

• Clean soiled skin thoroughly with warm soapy water and apply a protective cream.

This also applies to the installation and adjustment of safety devices and valves as well as to welding work on load-bearing elements.

Replace hydraulic hoses within the stipulated and appropriate intervals, even if no safety-relevant defects have been detected.

When carrying out maintenance work, tools and workshop equipment adapted to the task at hand are absolutely indispensable.

Repair work

• Never use fuels or solvents for cleaning the skin.

Never carry out repair work without having first read and understood the operating instructions.

• If you have swallowed any oil, avoid vomiting but consult a doctor or a hospital immediately.

The descriptions of job sequences provide only experienced personnel with the necessary instructions.

Only depressurized hydraulic systems may be opened.

Even when a machine is parked on a horizontal surface with its attachments supported on the ground and its driving motor switched off, there may still be substantial residual pressure in parts of the hydraulic system, e.g. primary pressure from the last hydraulic movements prior to stopping the machine.

The operating manual must be kept with the machine at all times.

Repair personnel must have know-how and experience relevant to repairing this or comparable machines.

In the absence of such know-how, meticulous training must be provided by experienced repair personnel.

Never repair damaged pipes; always replace them.

Replace hydraulic hoses immediately if you detect any damage or moist areas.

Use the recommended hand holds, steps, and work platforms with at least three points of contact when working

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at elevated locations and when accessing or exiting the machine.

Never open defective prestressed units but replace them as a single unit.

When carrying out repair work near to the centered articulated joint or other joints, block the joints. Remove the block after completing work.

In exceptional cases, open only when the system and the operating sequence are precisely known and any special tools required are available.

If the machine has to be jacked up, the front/rear axle must first be wedged in place to prevent it from moving.

When work is completed, lower machine and remove wedges.

The operating manual contains no information on this topic.

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Wheels and tires NOTE: Tires with ballast should not be used on machines traveling from one working site to another.

After 80.0 km (50.0 miles) drive or 2 h of continuous driving (neither limit should be surpassed) it is necessary to stop at least for 30 min to let the tires cool off. After 4 h of travel it will be necessary to stop for at least 1 h for the same reason.

Make sure that tires are correctly inflated. Do not exceed any recommended load or pressure. Follow the instructions in the manual for proper tire inflation.

Check the tire inflation pressure only when the tires are cold because the pressures indicated are higher than usual after warming up.

• Use filling equipment with a long filling hose, self-fixing nozzle, and pressure gauge.

• Inflate the tires only with compressed ambient air.

Never use flammable gases to avoid a risk of explosion.

• During tire inflation, avoid facing the sidewall of the tire, stand to the side facing the tire tread. It is safer there than at the sidewall or bead of the tire and rim of the wheel due to explosion.

will NOT eliminate the hazard. This condition can exist whether tires are inflated or deflated. The tire MUST be completely removed from the wheel or rim prior to welding the wheel or rim.

Always have a qualified tire technician service the tires and wheels. If a tire has lost all pressure, take the tire and wheel to a tire shop or your dealer for service. Explosive separation of the tire can cause serious injury.

Gas deflagration caused by heat in the tires can cause explosions in air-filled tires. This heat can be generated by frequent use of the brakes or by welding operations performed on the machine. It can throw tire and rim pieces over a distance of several hundred meters (feet). Tires and expelled tire or rim parts can cause severe injuries and even death.

Therefore: • If you suspect that there is an overheated tire, secure the machine and wait at a safe distance until the tire has cooled down again.

• Check the tires, rims, and rim components for damage, penetrating foreign bodies, and tight fit before inflating a tire.

• Constantly watch the tire and the pressure gauge of the filling equipment during inflation, and never exceed the prescribed tire pressures.

• Always have damaged tires repaired by a specialized workshop.

• Always place a safety cage around removed wheels.

• If in doubt about the safe condition of tires, rims, and rim parts, have the complete wheel removed from the machine in a qualified workshop.

• Make sure that nobody is standing near the tire while it is being inflated.

• Excessive tire pressure results in poor off-road driving performance and a danger of tires bursting.

• Insufficient tire pressure results in premature wear of the tire and poor machine stability.

Tires are heavy. Handling tires without proper equipment could cause death or serious injury.

Never weld on a wheel with a tire installed. Always remove the tire completely from the wheel prior to welding.

Inflated tires can generate a gas mixture with the air that can be ignited by high temperatures from welding procedures performed on the wheel or rim. Removing the air or loosening the tire on the rim (breaking the bead)

Always tighten the wheel nuts with a torque wrench. After several hours of operation, recheck the tightness of the wheel nuts with a torque wrench. For reasons of safety use only spare parts from the original equipment dealer.

Rims must be easy to identify (see ISO/DIS 4250-3).

Wheels must not be equipped with split rims joined by spot welding or by countersunk screws.

For reasons of safety use only spare parts from the original equipment manufacturer.

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Driving on public roads and general transportation safety Before operating the machine, check for correct operation of steering, brakes, hydraulic controls, instruments, and safety equipment. Make sure that the transmission control lever is in the neutral position. Make all adjustments before operating the machine.

Never allow the machine to roll with the gearshift lever in neutral.

When driving on public roads observe the maximum tread wear limits and the correct tire pressure.

Make sure both axles are equipped with tires of the same size and degree of wear.

Different tire diameters may cause damage to the differential gears.

Be aware of overhead structures or power lines and make sure that the machine and/or attachments can pass safely under.

Travel speed should be such that you maintain complete control and machine stability at all times.

Slow down and signal before turning.

Pull over to allow faster traffic to pass.

Machines parked on sloping terrain may start moving inadvertently. To reduce this risk, park the machine on a level surface and lower the working equipment to the ground.

The blade must not interfere with the steering range of the front wheels or with the steering linkage.

To avoid excessive tire wear: • Inflate the tire with the correct pressure, • Avoid abrupt starting or braking, • Do not take corners too fast. Clean the tires and the spaces between the tires before driving on public roads. This helps to avoid endangering other road users by soiled road surfaces or by ejected lumps of soil or stones.

Apply the parking brake only when the machine is stationary. While driving, apply the parking brake only in an emergency. The braking action is abrupt.

Comply with local laws and regulations.

Use appropriate lighting to meet local regulations.

Do not tow trailers. The machine is not suited for towing trailers or other vehicles. There is a risk of damage to gearboxes and axles. The tow-bar coupling is provided only for towing or recovering the machine out of hazard zones or for fastening of the machine onto transport vehicles.

Do not start the machine when the central warning light is flashing. Locate the cause of the fault and correct it before operating. If the main warning light comes on and the warning system sounds, immediately stop the machine and shut off the engine. Lower the working equipment and follow the instructions on the display to locate the cause of the problem.

Securely fasten the seat belt. Your machine is equipped with a Roll Over Protective Structure (ROPS) can, ROPS canopy, or ROPS frame for your protection. The seat belt can help ensure your safety if it is properly used and maintained. Never wear a seat belt loosely or with slack in the belt system.

DO NOT make seat adjustments while the machine is in motion. All seat adjustments should be made with the machine stationary and the parking brake applied.

When driving on public roads: • Observe the requirements of the machine’s general operating permit.

• Close the cab door.

Use safety chains for trailed equipment when safety chains are provided with machine or equipment.

• Carry a first-aid kit, warning triangle, and warning lamp on board.

Lift implements and attachments high enough above ground to prevent accidental contact with road.

• Check that the contents of the first aid kit is complete, and replace missing or old parts.

When you transport equipment or a machine on a transport trailer, make sure that it is properly secured. Be sure the Slow Moving Vehicle (SMV) emblem on the equipment or machine is covered while being transported on a trailer.

• When making short left/right turns, the steering wheel must move easily and the steering must react.

After driving a short distance, the braking effect of the service brake must be tested.

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Recovery and towing The machine may only be towed, loaded, and transported in accordance with the operating instructions.

After the recovery, the machine must be secured against inadvertent movements and unauthorized starting.

For towing of the machine, use only tow bars or towing ropes of adequate load-bearing capacity.

The towing speed must not exceed 8 km/h (5.0 mph).

The tow bar or the towing rope must be free from damage.

They must be designed in such a way that their calculated breaking load is equal to three times the tractive power of the towing vehicle.

The towing vehicle must have adequate tractive power.

Drive slowly and carefully.

Nobody may be in the hazard zone of the tow bar or of the towing rope.

Tow the machine only if the brakes and the steering of the machine are fully operational and if the machine cannot be transported by any other means.

Non-operational machines may only be towed over such a distance as required for the recovery of the machine from the hazard zone.

When towing the machine, observe the prescribed transport position and itinerary.

The recommissioning procedure must be strictly in accordance with the instructions and precautions in the operator’s manual.

Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure that the work area is clear of all bystanders.

Shut off the engine before removing or installing the articulated joint lock.

Before starting the emergency lowering operation, make sure that no persons are present around the blade.

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Fire and explosion prevention Fuel or oil that is leaked or spilled on hot surfaces or electrical components can cause a fire.

Crop materials, trash, debris, bird nests, or flammable material can ignite on hot surfaces.

belts, gears, cleaning fans, etc. More frequent cleaning of your machine may be necessary depending on the operating environment and conditions.

Always have a fire extinguisher on or near the machine.

Inspect the electrical system for loose connections and frayed insulation. Repair or replace loose or damaged parts.

Make sure that the fire extinguisher(s) is maintained and serviced according to the manufacturer’s instructions.

Do not store oily rags or other flammable material on the machine.

At least once each day and at the end of the day, remove all trash and debris from the machine especially around hot components such as the engine, transmission, exhaust, battery, etc. More frequent cleaning of your machine may be necessary depending on the operating environment and conditions.

Do not weld or flame cut any items that contain flammable material. Clean items thoroughly with non-flammable solvents before welding or flame-cutting.

At least once each day, remove debris accumulation around moving components such as bearings, pulleys,

Promptly investigate any unusual smells or odors that may occur during operation of the machine.

Do not expose the machine to flames, burning brush, or explosives.

Fire extinguisher (not supplied) The fire extinguisher ( 3 kg (6.6 lb) powder extinguisher) is attached on internal rear wall inside the cab. It is intended to enable the driver to safely leave the cab in the event of a fire. Have the fire extinguisher checked at the specified times by an authorized workshop.

The fire extinguisher equipping the machine must comply with local regulations.

Make sure that it is constantly kept in perfect working conditions and that the operating instructions provided by the manufacturer on the fire extinguisher itself have been properly understood.

To use the fire extinguisher in the event of fire: • Remove the fire extinguisher from its support.

• Remove the safety pin.

• Press the control lever full stroke and direct the jet toward the base of the fire.

NOTE: Recharge after use, even if partial.

Maintenance specification Every month Examine the fire extinguisher and make sure it is not damaged.

SS11K245

Every six months Have an approved specialist empty, and refill the powder in the fire extinguisher.

Every year Have an approved specialist examine the fire extinguisher.

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General battery safety Always wear eye protection when you work with batteries.

Batteries emit explosive hydrogen gas and other fumes while charging. Ventilate the charging area. Keep the battery away from sparks, open flames, and other ignition sources. Never charge a frozen battery.

Do not create sparks or have open flame near a battery.

Ventilate the area when you charge a battery or use a battery in an enclosed area.

Disconnect the negative (-) terminal first and reconnect the negative (-) terminal last.

When you weld on the machine, disconnect both terminals of the battery.

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

Avoid creating sparks when handling cables and electrical equipment. Avoid short circuits.

Never put tools on the battery. A short circuit may result, destroying the battery and causing injury.

Never wear necklaces, bracelets, or watch straps made of metal when working on the battery. The metal parts may induce a short circuit, resulting in burns.

When you use auxiliary batteries or connect jumper cables to start the engine, use the procedure shown in the operator’s manual. Do not short across terminals.

Never lean over the batteries when starting the machine from another vehicle.

Follow manufacturer’s instructions when storing and handling batteries.

Never use assisted starting if the batteries are defective or frozen.

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

This is a California Proposition 65 warning.

Battery acid causes burns. Batteries contain sulfuric acid.

Avoid contact with skin, eyes, or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 min and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.

Do not tilt the battery to prevent acid from flowing out of the vents.

Keep out of reach of children and other unauthorized persons.

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Assisted starting (Jump-starting) Batteries emit explosive hydrogen gas and other fumes while charging. Ventilate the charging area. Keep the battery away from sparks, open flames, and other ignition sources. Never charge a frozen battery.

Keep potential ignition sources such as unshielded lights or burning cigarettes away from the batteries.

Battery gases are highly flammable.

Use only tested jumper cables with insulated terminal clips and an adequate cable cross section.

Ensure that the bodywork of the supplying and receiving vehicles do not contact each other. Otherwise a current flow could result from connecting the positive poles. Risk of short-circuits.

Never use assisted starting with overvoltage, e.g. three or four batteries connected in series or auxiliary devices generating higher voltages than 24 V.

Wear goggles.

Never lean over the batteries when starting the machine from another vehicle. Risk of injury from acid splashes and battery gases.

Never use welding generators or welding transformers as a source of current.

Never use assisted starting if the batteries are defective or frozen.

Position the jumper cables in such a way that they cannot be caught by rotating engine components.

Never connect batteries (battery assemblies) unless they have the same voltage.

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Reflectors and warning lights Flashing amber warning lights must be used when operating on public roads (depending on local rules and regulations).

SS14C120

Pos. 1 2 3 4 5 6

2

Designation Rotary beacon (Option) Rear reflector Rear reflector (included into the lamp) Reflector on the back side of the rear ripper (Option) Reflector on the side of the rear ripper (Option) Side reflector

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Seat belts For machines with a seat belt for operating personnel: • Check the seat belt attached to the driver’s seat.

• In the event of damage or after an accident, have it replaced immediately.

• Seat belts must be worn at all times.

Seat belt inspection and maintenance: • Keep seat belts in good condition.

• Keep sharp edges and items than can cause damage away from the belts.

• Periodically check belts, buckles, retractors, tethers, slack take-up system, and mounting bolts for damage and wear.

• Replace all parts that have damage or wear.

• Replace belts that have cuts that can make the belt weak.

• Check that bolts are tight on the seat bracket or mounting.

• If the belt is attached to the seat, make sure that the seat or seat brackets are mounted securely.

• Keep seat belts clean and dry.

• Clean belts only with soap solution and warm water.

• Do not use bleach or dye on the belts because this can make the belts weak.

The driver’s seat is equipped with a lap seat belt with retractor (1). The automatic retractor/belt-tightener is installed on the left side of the seat.

Putting on the seat belt Slide the tongue (2) into the belt buckle (3). Check by pulling on the belt that the tongue has properly engaged.

The seat belt must not be blocked or twisted.

SS11K230

3

SS14H042

4

Removing the seat belt Depress the buckle interlock (4) and pull out the belt tongue.

The seat belt is retracted automatically.

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

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

The protective structure is a special safety component of your machine.

• All damaged parts MUST BE REPLACED.

DO NOT attach any device to the protective structure for pulling purposes. DO NOT drill holes in the protective structure.

The protective structure and interconnecting components are a certified system. Any damage, fire, corrosion, or modification will weaken the structure and reduce your protection. If this occurs, THE PROTECTIVE STRUCTURE MUST BE REPLACED so that it will provide the same protection as a new protective structure. Contact your dealer for protective structure inspection and replacement.

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

DO NOT WELD, DRILL HOLES, ATTEMPT TO STRAIGHTEN, OR REPAIR THE PROTECTIVE STRUCTURE. MODIFICATION IN ANY WAY CAN REDUCE THE STRUCTURAL INTEGRITY OF THE STRUCTURE, WHICH COULD CAUSE DEATH OR SERIOUS IN JURY IN THE EVENT OF FIRE, TIP, ROLL OVER, COLLISION, OR ACCIDENT. Seat belts are part of your protective system and must be worn at all times. The operator must be held to the seat inside the frame in order for the protective system to work.

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Air-conditioning system Inspection and servicing work that can be carried out by the machine operator is described in this section.

More detailed work on the air conditioning system requires special know-how and special tools; it must therefore be carried out only by trained specialists.

In such cases, have the work performed by a workshop specializing in air conditioning systems.

The air-conditioning system is under high pressure. Do not disconnect any lines. The release of high pressure can cause serious injury.

The air conditioning system contains gases that are harmful to the environment when released into the atmosphere. Do not attempt to service or repair the system.

In the interests of your own safety, observe the following instructions: • Never reach into the system or insert any objects into it.

• Shut off the engine and wait until it has cooled down before carrying out any servicing work.

• Disconnect the blower from the power supply to ensure that the blower cannot inadvertently start.

• Some air conditioning system components (e.g. heat exchanger and resistor at blower) may still be hot after being switched off and thus present a risk of burns.

Wait for these components to cool down before working on them with the system opened.

non-explosive, nontoxic, non-irritating, and free of smell and taste. However, R 134a will displace oxygen and can result in asphyxiation in confined spaces.

The following points must nonetheless be observed: • Avoid any contact with liquid refrigerant.

• Wear goggles to protect your eyes. If refrigerant gets into your eyes, seek medical advice immediately.

• Before any repairs are carried out on the air conditioning system It must be emptied. Be sure not to let the refrigerant dissipate into the environment. Use only an approved suction units to collect it.

• Welding is not permissible on parts of the closed system or in close proximity to them. Whether or not the system is filled with refrigerant, the resulting heat build-up may cause a very strong excess pressure that may result in damage to the system or even an explosion.

• Refrigerant cylinders must not be thrown and, when full, must not be exposed to sustained sunshine or other sources of heat. The maximum permissible temperature of a filled refrigerant cylinder is 45 °C (113 °F).

• It is crucial that the cooling system should be kept free of chlorine and chlorine-containing substances as well as of oils and greases.

• Evacuation systems and filling systems should be used only for R 134a.

• Work on air conditioning system in well ventilated locations.

When working on the refrigerant circuit (specialists) The R 134a refrigerant used is classified as a safety refrigerant. This means that the coolant is noncombustible,

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Personal Protective Equipment (PPE) Wear Personal Protective Equipment (PPE) such as hard hat, eye protection, heavy gloves, hearing protection, protective clothing, etc.

Wear closely fitting work clothes when operating the machine. Loose, wide garments may result in the control lever being inadvertently activated.

Wear working footwear with non-slip soles. Smooth soles may slip from steps and pedals resulting in injury or incorrect operation.

Do Not Operate tag Before you start servicing the machine, attach a ‘Do Not Operate’ warning tag to the machine in an area that will be visible.

SS12C522

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Hazardous chemicals If you are exposed to or come in contact with hazardous chemicals, you can be seriously injured. The fluids, lubricants, paints, adhesives, coolant, etc. required for the function of your machine can be hazardous. They may be attractive and harmful to domestic animals as well as humans.

Dispose of all fluids, filters, and containers in an environmentally safe manner according to local laws and regulations. Check with local environmental and recycling centers or your dealer for correct disposal information.

Store fluids and filters in accordance with local laws and regulations. Use only appropriate containers for the storage of chemicals or petrochemical substances.

Keep out of reach of children or other unauthorized persons.

Additional precautions are required for applied chemicals. Obtain complete information from the manufacturer or distributor of the chemicals before using them.

Utility safety When digging or using ground-engaging equipment, be aware of buried cables and other services. Contact your local utilities or authorities, as appropriate, to determine the locations of services.

Make sure that the machine has sufficient clearance to pass in all directions. Pay special attention to overhead power lines and hanging obstacles. High voltage lines may require significant clearance for safety. Contact local authorities or utilities to obtain safe clearance distances from high voltage power lines.

Retract raised or extended components, if necessary.

Remove or lower radio antennas or other accessories.

Should a contact between the machine and an electric power source occur, the following precautions must be taken:

If this is not possible try following: • Stop the machine movement immediately.

• Apply the parking brake, stop the engine, and remove the key.

• Remain in the cab and call for assistance. There is a risk of electrocution through contact with the ground surrounding the vehicle until the power line being contacted is de-energized. If a fire or other circumstance requires you to leave the vehicle, jump clear of the vehicle landing with your feet together while avoiding contact with the machine. Keep your feet together, and hop away from the vehicle.

• Do not permit anyone to touch the machine until power has been shut off to the power lines.

• Attempt to disengage contact from the electrical source.

Electrical storm safety Do not operate machine during an electrical storm.

If you are on the ground during an electrical storm, stay away from machinery and equipment. Seek shelter in a permanent, protected structure.

If an electrical storm should strike during operation, remain in the cab. Do not leave the cab or operator’s platform. Do not make contact with the ground or objects outside the machine.

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Mounting and dismounting Mount and dismount the machine only at designated locations that have handholds, steps, and/or or ladders.

Maintain a three-point contact with steps, ladders, and handholds.

Do not jump off of the machine.

Never mount or dismount from a moving machine.

Make sure that steps, ladders, and platforms remain clean and clear of debris and foreign substances. Injury may result from slippery surfaces.

Do not use the steering wheel or other controls or accessories as handholds when you enter or exit the cab or operator’s platform.

Face the machine when you mount and dismount the machine.

Remove oil, grease, soil, mud, snow, ice, and other material from the machine wheels as well as ramps and loading platforms on the transport vehicle.

Working at heights When the normal use and maintenance of the machine requires you to work at heights:

Do not use the machine as a lift, ladder, or platform for working at heights.

• Correctly use installed steps, ladders, and railings.

• Never use ladders, steps, or railings while the machine is moving.

• Do not stand on surfaces that are not designated as steps or platforms.

Use the recommended hand holds, steps, and work platforms with at least three points of contact when working at elevated locations and when accessing or exiting the machine.

Tools and equipment Tools, lifting equipment, slings, chocks, and other equipment must be in safe operating and working condition.

mandrel should be used and protective goggles must be worn.

Metal splinters can cause injury when accessory bolts are being driven in and out. Therefore, a brass or copper

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Welding operations Never perform welding operations unless you are qualified to do so.

Observe the accident prevention regulations.

Any work on receptacles that contain or have contained substances, • that are combustible or encourage combustion, • that are susceptible to explosion, or • that may develop health-hazardous gases, vapors, mist, or dust during welding operations, must be carried out only under expert supervision and only by experienced persons authorized to do such work.

Depressurize systems and assemblies (e.g. piping, radiator, hydraulic tank) prior to opening them.

Should you have any problems or queries, contact your authorized dealer.

• Detach corresponding terminals and plugs from the electronic control units (read and observe 7-161).

• Protect disconnected terminals and plugs from shortcircuiting and soiling by covering them with foil or adhesive tape.

Attach the welding-current pincers in the immediate vicinity of the welding zone.

Never connect the grounding terminal of the welding equipment to electronic components or to the attachment points of these components.

It is not advisable to carry out welding operations on the engine or on components mounted on the engine, as this may damage the components.

The welding current must not flow via the ball-bearing slewing ring or via pin couplings, articulated joints or hydraulic cylinders.

On completion of the welding operations, restore all electrical connections.

Prior to any welding operations on the machine: • Disconnect battery by disconnecting first the negative pole terminal, then the positive pole terminal.

• Disconnect positive pole terminal at three-phase alternator (alternator).

When reconnecting the battery, connect first the positive pole terminal, then the negative pole terminal.

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Engine maintenance Rotating fan blades and moving V-belts can cause injury.

Shut off the engine before opening the engine compartment. Wait for all movement to stop.

Open the engine compartment hood to the full open - service position (see also Engine hood - Advice).

Hot engine, exhaust and radiator components can cause burns. Wait until the engine, exhaust, and radiator have cooled down before starting work.

Hot engine oil or coolant can scald.

• Ensure safety latch is engaged prior to working in the engine compartment.

• Check at regular intervals that the gas-filled springs are in good working order. Have defective springs replaced immediately.

Read and observe the Operator’s Manual of the engine before beginning any work on the engine.

Risk of injury from rotating or hot parts of the engine.

Shut off the engine and let it cool down.

Used engine oil is classified as a potential carcinogen and genetic risk factor. DO NOT swallow any oil or inhale oil vapors. Avoid prolonged skin contact.

Do not carry out repair work unless the machine has been secured (see also 7-5).

Wear protective gloves.

Check and replace V-belts only when the engine is stationary.

When carrying out work in the engine compartment outdoors during windy weather, the hood may be slammed down by a gust of wind, especially if the gas-filled springs are defective.

Therefore:

Qualified repair work on the engine requires extensive knowledge and special tools.

In case of doubt, have repair work performed by a specialized workshop.

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Fuel system maintenance quirements. Diesel Exhaust Fluid (DEF)/AdBlue® is a non-toxic aqueous urea solution. It chemically reduces NOx emissions from heavy duty diesel powered machines. It is not explosive or considered harmful to the environment and is classified under the minimum risk category of transportable fluids.

If you have to work on the fuel system: • Switch off the engine and auxiliary heating.

• Secure the machine (see also 7-5).

• Avoid open flames.

• Do not eat, drink, or smoke while working.

Diesel fuel and any drained water/fuel mixture are potential health hazards. Never swallow these fluids. Avoid prolonged skin contact.

Avoid inhaling the vapors.

Wear PPE such as protective gloves, barrier cream, eye protection, etc.

• Personal Protection Equipment (PPE) is not required under normal conditions. If splashing is likely, wear eye protection.

• For prolonged or repeated contact, impervious gloves are recommended.

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

• Follow the precautions listed in this safety information chapter when handling any service fluid.

Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately.

• DEF/AdBlue® must be stored in clean, sealed containers.

Handling Diesel Exhaust Fluid (DEF)/AdBlue®

• Make sure that no debris enters the machine DEF/AdBlue® tank. Clean the DEF/AdBlue® tank cap and the surrounding area before opening.

• Your machine is equipped with additional components to comply with national and local exhaust emissions re-

• Fill the DEF/AdBlue® tank using clean filling equipment with the correct length and diameter nozzle.

2-22

2 - SAFETY INFORMATION

Electrical system general maintenance Switch off the machine immediately if trouble occurs in the electrical system.

Repair work on the electrical system may only be carried out by a qualified electrician.

cover is removed and the protective cap on the relay has slipped out of position, then a danger exists of the cover plate touching the relay contact and the machine ground at the same time.

Use only original fuses with the specified rating.

Observe also the safety instructions in chapter “General battery safety”.

Wear goggles, working gloves, and sturdy working clothing.

Risk of injury from battery acid and gases.

Before working on electrical equipment: • Shut off the engine.

• Prior to any work on the electrical system where tools, spare parts etc. might come into contact with electric cables or contacts, switch the key switch of the electrical system to 0, withdraw the key and disconnect the batteries.

• Disconnect the negative pole terminal first and then the positive pole terminal.

On completion of work: • Connect the positive pole terminal first and then the negative pole terminal.

Carry out voltage and continuity checks with a measuring instrument only.

When working with the machine, maintain distance from overhead electric lines. If work is to be carried out close to overhead lines, the equipment must be kept well away from the lines. Contact with overhead electrical lines could cause death or serious injury. Check out the prescribed distances.

Should a contact between the machine and an electric power source occur, the following precautions must be taken: • Attempt to disengage contact from the electrical source.

If this is not possible try following: • Stop the machine movement immediately.

• Apply the parking brake, stop the engine, and remove the key.

• Check if you can safely leave the cab or your actual position without contact with electrical wires. If not, stay in your position and call for help. If you can leave your position without touching lines, jump clear of the machine to make sure that you do not make contact with the ground and the machine at the same time.

• Do not permit anyone to touch the machine until power has been shut off to the power lines.

Do not use a test lamp.

Do not check by “touching ground” with a bare wire.

The resulting short circuit can damage the alternator or the electronic control units.

For reasons of safety, disconnect the positive terminal of the battery before removing the relay cover. When the

The electrical equipment of a machine should be inspected and checked at regular intervals. Defects, such as loose connections or cables, must be corrected immediately.

2-23

2 - SAFETY INFORMATION

Accumulators Accumulators are installed in the hydraulic system.

These accumulators contain nitrogen under high pressure. Even when the hydraulic pressure in the system is reduced, the nitrogen remains in the accumulator.

The accumulators are completely safe in operation. However, there is a risk of explosion if incorrectly handled.

Therefore: • Never mechanically handle the accumulator, and never weld or solder it.

• Testing and servicing work must be carried out by experts only.

• Always wear goggles and working gloves when removing the accumulator.

• Accumulators are to be filled with nitrogen only.

Never remove or paint over warning and information plates, rating plates, or type identification markings.

NOTICE: Never fill with compressed air or oxygen.

– Immediately report any defects or damage to the machine owner.

– Prior to recommissioning, an inspection by a specialist or expert is essential if the accumulator was damaged or if the admissible operating temperature or operating pressure was exceeded.

• Depressurize the hydraulic part of the system prior to any testing and servicing work.

Alternator Never disconnect cables from the alternator, regulator, and battery while the engine is running. This will damage the alternator and regulator.

Take care not to interchange the cables when connecting the batteries (observe polarity).

Carry out voltage and continuity checks with a measuring instrument only.

The circuit is an integral part of the central electronic system in the control console.

An LED in the control console (charging monitor) indicates that the alternator is functioning correctly.

This LED must light up when the key switch is switched on; it goes out when the engine is running.

If this is not the case, there is a fault in the alternator circuit or in the control console.

Do not use a test lamp.

Do not check by “touching ground” with a bare wire.

The resulting short circuit will damage the alternator or the electronic control units.

To prevent further damage, the cause of the malfunction must be traced and eliminated as quickly as possible.

Contact your authorized dealer for this.

When starting the engine, the alternator is controlled (preexcited) by an electronic circuit. This ensures that the alternator can deliver power.

2-24

2 - SAFETY INFORMATION

Cleaning the machine Select suitable cleaning agents for the materials in the parts to be cleaned.

Use lint-free cleaning rags when working on the hydraulic system or the engine. Cleaning agents and solvents may give off harmful, readily flammable vapors. Never work with such agents except in well-ventilated premises; never inhale the vapors and never smoke.

Prevent solvents and cleaning agents from coming into contact with the skin.

Wear solvent-resistant gloves. Observe the instructions on the packaging.

Before cleaning the machine with water or a high-pressure cleaner, or other cleaners, cover or tape up all openings which – for safety and functional reasons – no water, steam, or cleaning agents may enter. Special care must be taken with electric motors and switchgear cabinets.

After cleaning, remove any covers and tape applied before you started cleaning.

After cleaning, examine all fuel, motor oil and hydraulicfluid lines for leaks, loose connections, chafe marks, and damage. Any defects you find must be corrected immediately.

2-25

2 - SAFETY INFORMATION

Refueling Diesel fuel

Secure the machine against unauthorized starting during refueling:

Only use diesel fuel that conforms to European standard EN 590 or equivalent in your engine. Do not use any other low grade diesel fuel.

• Park the machine on firm, level ground.

• Lower the working equipment to the ground.

NOTICE: Use of other low grade diesel fuels will result in loss of engine power, high fuel consumption, and damage to the exhaust aftertreatment system (if equipped).

• Switch off any fuel-operated auxiliary heaters and air conditioners.

NOTE: When operating the machine in very cold climates, the use of winter blended fuel is permitted for a short period of time. See your fuel supplier for winter fuel requirements in your area.

• Apply the parking brake.

Fuel conditioner Diesel fuel conditioner is available from your CASE CONSTRUCTION dealer. Instructions for the use of the fuel conditioner is on the container.

• Shut off the engine.

• Remove the key from electrical system key switch.

• Refueling must always be performed from the ground in standing operator position (if not possible, a stable position on the rear wheel cover is necessary).

Refueling station (optional): • For correct operation of the refueling station see also 4-4.

• Park the machine on firm, level ground.

The use of diesel fuel conditioner will: • Clean fuel injectors, valves, and manifolds for increased service life

• Do not smoke or use open flames. Fuels and fuel vapors are flammable. Switch off fuel-operated auxiliary heating systems and air conditioners.

• Disperse insoluble gummy deposits that form in the fuel system

• Fuel may harm the skin, so wear protective gloves or use a protective cream.

• Separate moisture from the fuel

• Do not spill fuel or allow it to seep into the ground to avoid an environment hazard.

• Stabilize fuel in storage NOTICE: Use only CASE CONSTRUCTION approved biocide additives to prevent damage to the exhaust aftertreatment system (if equipped).

• Soak up any overflowing fuel immediately with cleaning rags or binding agents and discard without polluting the environment. Report fuel accidents immediately to the owner of the machine or to their representative.

Fuels and fuel vapors are highly flammable and could explode. Avoid the formation of sparks and do not use open flames such as lighters or matches.

• Secure the machine against unauthorized starting during refueling: Lower the working equipment to the ground. Shut off the engine. Remove the key from the electrical system key switch.

Diesel fuel and fuel vapors are a health hazard. Fuels must not be swallowed. Avoid prolonged contact with skin. Do not inhale the fumes. Wear protective gloves or use a protective cream. Do not eat, drink, or smoke during refueling.

NOTICE: Fill up the machine only with diesel fuel made from mineral oils in accordance with the EN 590 standard.

Refueling from cans

If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will cause power loss or will prevent the engine from starting.

If the machine is refueled often or regularly with fuel from cans or barrels, there is an increased risk of matter and water getting into the fuel system.

In cold weather, fill the fuel tank at the end of the day’s work in order to prevent the formation of condensation.

In this case:

NOTICE: Avoid spilling fuel. Do not let fuel get into the ground; it pollutes the environment. Soak up any overflowing fuel immediately with cleaning rags or binding agents and discard without polluting the environment.

Report fuel accidents immediately to the owner of the machine or to their representative.

• Drain off water from the fuel filter more often than specified in the maintenance schedule;

• Always fill fuel through a fine mesh;

• Drain off water and deposits from the fuel tank at shorter intervals; • Replace all fuel filters at shorter intervals.

2-26

2 - SAFETY INFORMATION

Operating safety Always face the machine when entering and leaving.

Avoid any kind of work method that might be detrimental to safety.

Before beginning work, familiarize yourself with the surroundings and conditions within the site, such as obstacles in the working and traveling area, the soil-bearing capacity, and any necessary barriers separating the construction site from public roads.

Take the necessary precautions to ensure that the machine is used only when in a safe and reliable state.

Operate the machine only if all protective and safety-oriented devices, such as removable safety devices, emergency shutoff equipment, soundproofing elements and exhausters, are in place and fully functional.

Check the machine at least once per working shift for obvious damage and defects. Report any changes (including changes in the machine’s working behavior) to the authority/person responsible immediately. If necessary, stop the machine immediately and secure it.

In the event of a malfunction, stop the machine immediately and secure it. Have any defects corrected immediately.

Operate internal combustion engines and fuel-operated heating systems only in adequately ventilated rooms. Before starting the machine in enclosed rooms, make sure that there is sufficient ventilation.

Observe the regulations in force at the respective site.

Before driving: • Clean off any earth, mud, snow, ice, grease, and oil adhering to your work footwear before operating the machine. Otherwise there is a risk of slipping off the pedals and initiating inadvertent movements.

• Adjust the driver’s seat, steering column, and mirrors and fasten the seat belt before setting off.

Never travel across slopes; always keep the working equipment and the load close to the ground, especially when traveling downhill.

On sloping terrain always adapt your traveling speed to the prevailing conditions. Always shift into a lower gear BEFORE approaching a slope. Never change into a lower gear on a slope.

Never allow the machine to roll with the gear lever in neutral position, e.g. when driving downhill.

When crossing underpasses, bridges, and tunnels or when passing under overhead lines, always make sure that there is sufficient clearance.

Reversing: During reversing operations, your view of the hazard zone is restricted. For this reason, allow experienced banksman (reversing assistant) to assist you. Review the signals with the banksman (reversing assistant) to ensure the signals are correctly understood. Inspect the site for underground gas, power and water lines before starting work. Any damage to such lines is a lifethreatening risk.

NOTE: The rear view camera is not referred as a reversing aid.

The door must be completely open and latched in order to enter the cab or operate the machine with the door open.

When the door is unlatched, it is free to move.

Use the horn to warn persons in the immediate vicinity of the machine before you operate the machine.

Stop work if anyone is in the hazard zone of the machine.

Continue working only after such persons have left the hazard zone.

NOTE: The hazard zone is that zone around the machine in which persons are within range of falling loads or working equipment due to operational movements by the machine, to its equipment and attachments or to swinging loads.

• Do not let other persons accompany you on the machine.

Always use and operate the machine in such a way as to guarantee its stability.

• Warn anyone in the vicinity with the horn before setting off.

Trenches and building pits may cave in. Keep well clear of them.

Driving on slopes: Make sure the wheels have sufficient grip; only then are the machine’s full steering and braking capabilities available. Do not drive across slopes. Never turn on slopes. Never steer with the articulated-frame steering on slopes.

Banksman The banksman must stay outside the hazard zone.

Let the banksman assist you:

Always keep at a sufficient distance from the edges of building pits and slopes.

• When you have no clear overview over the machine’s hazard zone

Avoid any work operation that might be detrimental to the safety of the machine.

• When reversing • When shunting

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2 - SAFETY INFORMATION

Use only those communication signals which you and the banksman understand, or use aids for communication (e.g. walkie-talkie/ camera). Calls cannot be understood by the banksman because of the noise by the machine during operation.

Keep constant contact with the banksman.

Stop the machine immediately if you lose contact with the banksman.

2-28

2 - SAFETY INFORMATION

Ecology and the environment When legislation does not yet rule the treatment of some of the substances required by advanced technology, sound judgment should govern the use and disposal of products of a chemical and petrochemical nature.

NOTE: The following are recommendations that may be of assistance: • Become acquainted with and ensure that you understand the relative legislation applicable to your country.

• Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, antifreeze, cleaning agents, etc., with regard to their effect on man and nature and how to safely store, use, and dispose of these substances.

Helpful hints • Avoid filling tanks using cans or inappropriate pressurized fuel delivery systems that may cause considerable spillage.

• In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them contain substances that may be harmful to your health.

• Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems.

• Avoid spillage when draining off used engine coolant mixtures, engine, gearbox and hydraulic oils, brake fluids, etc.

Do not mix drained brake fluids or fuels with lubricants. Store them safely until they can be disposed of in a proper way to comply with local legislation and available resources.

• Modern coolant mixtures, i.e. antifreeze and other additives, should not be allowed to get into the soil, but should be collected and disposed of properly.

• Do not open the air-conditioning system yourself. It contains gases that should not be released into the atmosphere.

Your CASE CONSTRUCTION dealer or air conditioning specialist has a special extractor for this purpose and will have to recharge the system properly.

• Repair any leaks or defects in the engine cooling or hydraulic system immediately.

• Do not increase the pressure in a pressurized circuit as this may lead to a component failure.

• Protect hoses during welding as penetrating weld splatter may burn a hole or weaken them, allowing the loss of oils, coolant, etc.

2-29

2 - SAFETY INFORMATION

First-aid box storage compartment The first-aid box can be stored in the shelf to the left of the driver’s seat.

SS14D036

1

SS14D037

1

Warning triangle The warning triangle can be stored in the shelf to the left of the driver’s seat.

2-30

2 - SAFETY INFORMATION

Noise emission Outside the machine In operation the sound power level LWA is: Machine 836C/836C AWD 856C/856C AWD

dB (A) 102 101

NOTE: sound power level is measured according to ISO 6395.

Evaluated on identical machines in accordance with directive 2000/14/EC. SS14K157

Inside the cab The emitted sound pressure level LpA in the cab is: Machine 836C/836C AWD 856C/856C AWD

dB (A) 77 78

NOTE: sound pressure level is measured according to ISO 6396.

The noise emissions listed apply to machines with standard settings.

For machines with e.g. increased cooling capacity, the sound pressure level and sound power level can be higher.

NOTICE: in case of operation with open cab door or window for long term or high noise level might be necessary to use ear protection.

2-31

1

2 - SAFETY INFORMATION

Vibration levels Preventing risks caused by vibrations The machine’s vibration negatively affects the comfort and in some cases the health and safety of the operator.

To reduce vibration risks to a minimum: • Make sure that the machine, the equipment, and the tools are suitable for the work to be carried out.

• Make sure that the machine is in good condition and that the servicing schedule is followed.

• Check the play in the equipment linkages.

• Make sure that the operator seat and its adjustment controls are in good condition. The operator seat is to be adjusted to the operator’s size and weight.

The operator seat complies with the ISO 7096:2008 standard, EM 4 class < 1,1 as shown on ISO 7096:2008 table 1.

For work: • Operate the controls through all stages to ensure smooth operation of the machine.

• Modify the machine’s operation to suit the working conditions.

• During travel, adjust the machine’s speed, reducing it if necessary.

• Make sure that the machine’s operating radius is in good condition and free of obstacles and holes.

Vibration level inside the cab The vibration level to which the operator’s hand arm system is exposed is less than 2.5 m/s² (8.20 ft/s²).

The vibration level to which the operator’s body is exposed is less than 0.5 m/s² (1.64 ft/s²).

These results are obtained using an acceleration gauge with the machine in final processing with the blade.

NOTE: The vibration levels vary according to working conditions and the type of terrain. They are not therefore representative for the different conditions of use, but rather correspond to the normal operating conditions defined in this manual.

Consequently, these values cannot be used to determine the operator’s exposure to vibrations as per the European Directive 2002/44/EC. For this reason, it is recommended that you measure the vibration levels in actual working conditions. If this is not possible, use the table below. This table is an extract from information sheet ISO/TR 25398:2006. (ISO/TR/25398; Earthmoving machinery – Guidelines for assessment of exposure to whole-body vibration of ride-on machines – Use of harmonized data measured by international institutes, organizations, and manufacturers).

Typical operating condition Finish grading Hard grading Transfer movement

1.4*aw,eqx [m/s2 (ft/s2)]

Average 1.4*aw,eqy [m/s2 (ft/s2)]

aw,eqz [m/s2 (ft/s2)]

1.4*Sx [m/s2 (ft/s2)]

0.41 (1.35)

0.48 (1.57)

0.38 (1.25)

0.22 (0.72)

0.26 (0.85)

0.14 (0.46)

0.61 (2.00)

0.64 (2.10)

0.78 (2.56)

0.21 (0.69)

0.21 (0.69)

0.30 (0.98)

0.39 (1.28)

0.36 (1.18)

0.58 (1.90)

0.25 (0.82)

0.25 (0.82)

0.34 (1.12)

2-32

Standard deviation(s) 1.4*Sy Sz [m/s2 (ft/s2)] [m/s2 (ft/s2)]

2 - SAFETY INFORMATION

Safety and informational signs The following safety signs and information related signs are placed on your machine as a guide for your safety and for those working with you. Walk around the machine and note the content and location of these safety and informational signs before operating your machine. Keep safety and informational signs clean and legible. Clean safety and informational signs with a soft cloth, water, and a gentle detergent. Do not use solvent, gasoline, or other harsh chemicals. Solvents, gasoline, and other harsh chemicals may damage or remove safety or informational signs. Replace all safety and informational signs that are damaged, missing, painted over, or illegible. If a safety or informational sign is on a part that is replaced, make sure the safety or informational sign is installed on the new part. See your dealer for replacement safety and informational signs.

Safety signs that display the “Read Operator’s Manual” symbol are intended to direct the operator to the operator’s manual for further information regarding maintenance, adjustments, or procedures for particular areas of the machine.

SS14F062

2-33

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2 - SAFETY INFORMATION

SS14F063

2-34

2

2 - SAFETY INFORMATION

1. Location: Frame – left/right, Dozer (or front counterweight if machine without dozer), Hood WARNING Crushing hazard!

Do not put the machine into operation when persons are standing in the area of the ARTICULATED JOINT between the machine and an adjacent obstacle.

Failure to comply could result in death or serious injury.

SS11M074

3

SS11M065

4

SS11M066

5

SS11M067

6

SS11M068

7

P/N: 4573751 2. Location: Steering column – left/right WARNING Avoid injury!

The EQUIPMENT should be SECURED against inadvertent operation through use of this knob prior to driving on public roads or when exiting the cab. See also 4-16 and following.

Failure to comply could result in death or serious injury.

P/N: 4572518 3. Location: Steering column – left-hand side WARNING Avoid injury!

Read and understand all the warning notes printed in the OPERATOR’S MANUAL. In particular, read the General Information and Safety Information chapters in the Operator’s Manual.

Failure to comply could result in death or serious injury.

P/N: 4572514

4. Location: Steering column WARNING Avoid injury!

Never JUMP OFF the machine. Always wear the SEAT BELT. Failure to comply could result in death or serious injury.

P/N: 76082781

5. Location: Side window – left/right Noise emission plate LWA indicates the LEVEL OF NOISE EMISSION in dB (A) (in accordance with standard 2000/14/EC).

P/N: 6557861

2-35

2 - SAFETY INFORMATION

6. Location: Engine compartment – front area left/right WARNING Moving Parts!

Risk of injury from ROTATING belt in the engine compartment. Turn off the engine prior to opening engine compartment. Keep hands away from rotating equipment.

Failure to comply could result in death or serious injury.

SS14E216

8

SS14E218

9

P/N: 76082844 7. Location: Radiator – left/right, Mounting bracket in engine compartment – left/right WARNING Burn hazard!

Surfaces within the engine compartment will be very hot following engine vehicle operation. Allow the system to cool and avoid surfaces likely to be hot or wear appropriate PPE. Failure to comply could result in death or serious injury.

P/N: 87350366 8. Location: Hood – left-hand side Fuel tank– fill here with diesel fuel.

P/N: 4572111

SS11M001

10

SS11M073

11

SS11M077

12

SS11M071

13

9. Location: Hood – left/right WARNING Pinch and Crush points!

Risk of injury caused by ROTATING COMPONENTS. Before working on the machine shut off the engine and withdraw the key. Follow instructions provided in Safety rules and following.

Failure to comply could result in death or serious injury.

P/N: 4572109 10. Location: Engine compartment – left-hand side Close engine hood by releasing the safety bar with your foot. See also Engine hood - Advice before carrying out repairs and servicing tasks.

P/N: 4577464 11. Location: Frame – front/middle/rear – left/right Identifies the permitted TIE-DOWN POINTS for loading.

P/N: 1288796

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2 - SAFETY INFORMATION

12. Location: Engine compartment – rear area, Coolant tank WARNING Burn hazard!

Take care if removing the filler cap while the system is hot. Before removing the cap: completely cover the cap using a thick cloth, and slowly open the filler cap to allow the pressure to escape. Do not add cold water to a hot coolant reservoir.

Failure to comply could result in death or serious injury.

P/N: 84269938 SS14E099

14

SS14E217

15

SS11M075

16

SS14E202

17

13. Location: Accumulators DANGER Pressurized components!

Accumulators under pressure at all times. See safety instructions in the accumulators section (see Safety rules and following).

Failure to comply will result in death or serious injury.

P/N: 74625754 14. Location: Frame – left/right, Rear windscreen left top corner This sign indicates the HIGHEST SPEED allowed for driving on public roads. The maximum permitted speed is limited to 20.0 km/h (12.4 mph) or 25.0 km/h (15.5 mph) for machines with speed limitation (option).

P/N: 4506973 (for 40.0 km/h (24.9 mph))

15. Location: Blade lifting cylinder – left/right WARNING Pressurized system hazard!

Relieve pressure before maintenance. See depressurizing the hydraulic system (see 7-130).

Failure to comply could result in death or serious injury.

P/N: 76084616

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2 - SAFETY INFORMATION

16. Location: Frame – right-hand side The CE sign indicates that this machine was built in observance of the European directives for the safety of machines.

It is located on the model plate of the machine.

P/N: 47668013

SS14K159

18

SS11M079

19

SS11K304

20

SS14H024

21

17. Location: Side window – right-hand side Indicates the EMERGENCY EXIT. P/N: 3805234

18. Location: Windshield washer fluid tank Windshield washer water can be filled into the windshield washer here.

P/N: 4572112

19. Location: Coolant tank P/N: 47757330

2-38

2 - SAFETY INFORMATION

20. Location: Fuel tank filler neck Only use low sulphur diesel.

P/N: 84319035

SS14E096

22

SS14E097

23

SS11M070

24

SS14E094

25

21. Location: Battery WARNING Battery acid causes burns.

Batteries contain sulfuric acid. Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation and burns. Always wear splashproof goggles and protective clothing (gloves and aprons).

Wash hands after handling.

Failure to comply could result in death or serious injury.

P/N: 84404565

22. Location: Frame – left/right (in front of the swivel arm for 836C and 836C AWD or behind the swivel arm for 856C and 856C AWD), Ripper – left/right (or on rear counterweight left/right if machine without ripper) Identifies the permitted LIFTING POINTS for loading.

P/N: 1288795 23. Location: Front – left/right, Rear – left/right WARNING Crush hazard!

Attachment may unexpectedly drop. Place attachment on ground and release hydraulic pressure prior to working on or around.

Failure to comply could result in death or serious injury.

P/N: 47627052

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2 - SAFETY INFORMATION

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3 - CONTROLS AND INSTRUMENTS

3 - CONTROLS AND INSTRUMENTS###_3_### Access to operator's platform

Access doors WARNING Fall hazard!

Close the cab doors before driving on public roads.

Failure to comply could result in death or serious injury.

W1037A

Opening the door Unlock the door with the key (1).

Pull the door open with the handle (2) and swing it open into the stop position until the engagement hook (3) engages the latch.

NOTICE: The cab door key is identical to the ignition key (1).

SS14H043

1

SS11M102

2

SS11H041

3

WARNING Fall hazard!

The door must be completely open and latched in order to enter the cab or operate the machine with the door open. When the door is unlatched, it is free to move.

Failure to comply could result in death or serious injury.

W1027A

Closing the door Unlock the latched open door with the pull handle (5) and swing it until it is closed and interlocked in the lock.

Lock the door with the key (1) (see figure 1).

After unlocking or locking the door latch (6) (see figure 2), each facing door can be opened or closed from inside even when the door is locked.

Emergency exit NOTICE: The right cab door is marked as Emergency exit. Before leaving the cab, the right side console is to be pushed to the rear.

3-1

3 - CONTROLS AND INSTRUMENTS

Proper entry and exit WARNING Fall hazard!

Jumping on or off the machine could cause an injury. Always face the machine, use the handrails and steps, and get on or off slowly.

Maintain a three-point contact to avoid falling: both hands on the handrails and one foot on the step, or one hand on the handrail and both feet on the steps.

Failure to comply could result in death or serious injury.

W0141A

SS14C123

1

SS11H045

2

WARNING Crushing hazard!

Prevent unexpected blade movement. Before you exit the cab, block all functions of the working equipment via the two locking knobs.

Failure to comply could result in death or serious injury.

W1311A

NOTE: For more details see also 4-16 and following.

WARNING Fall hazard!

Clean the steps and access handles to remove all traces of grease, oil, mud, and ice (in winter).

Failure to comply could result in death or serious injury.

W0139A

3-2

3 - CONTROLS AND INSTRUMENTS

Adjust the mirrors The two exterior mirrors at the driver’s cab must be adjusted in such a way that the driver can see the greatest possible part of the working area from the cab.

The additional third, lower rear mirror on the left side of the cab is to be set so that there is no blind angle and that range (A) can be seen. The dimensions apply that are measured from the end plate to the rear and from the tire to the side.

Pos. a b c d

5.1 m 4.6 m 8.2 m 7.8 m

Measurement (16.7 ft) (15.1 ft) (26.9 ft) (25.6 ft)

SS13F336

1

SS14E230

2

B-post mirror (Only for Low Profile Cab) The B-post mirror must be adjusted as follows: 1. Mark a rectangular boundary area around the machine with the dimensions (A) and (B).

2. Adjust the B-post mirror so that the driver can see the complete area of dimension (C).

Pos. (A) (B) (C)

Designation 1000.0 mm (39.4 in) 2000.0 mm (78.7 in) 2900.0 mm (114.2 in)

3-3

3 - CONTROLS AND INSTRUMENTS

Cab interior light The interior lighting (1) is switched on and off with the built-in switch.

The interior lighting is supplied with electric power when the key is in position I. After the ignition is turned OFF the interior lighting will fade within 30 s.

SS11H042

3-4

1

3 - CONTROLS AND INSTRUMENTS

Storage compartment The storage compartment is located to the left side of the driver’s seat.

SS14D037

1

SS11H043

1

Sun protection The sun protection roller blind is installed above the front and rear window.

Lowering the roller blind By pulling the tab (1) the roller blind can be lowered into any desired position.

Raising the roller blind The roller blind raises after the lever (2) is pulled downwards.

3-5

3 - CONTROLS AND INSTRUMENTS

Intake openings The fresh air intake opening is located on the outside in the upper part of the driver’s cab.

SS11H048

1

SS14D033

2

The recirculated air intake openings are located in the cab behind the driver’s seat.

The intake openings (see figures 1 and 2) for fresh and recirculated air must always be free from obstructions.

3-6

3 - CONTROLS AND INSTRUMENTS

Tool kit A tool kit can be stored at the right-hand side console.

SS14C016

3-7

1

3 - CONTROLS AND INSTRUMENTS

12V DC socket outlet The 12 V DC socket outlet is located beside the left-hand side storage.

• Maximal electric power outlet: 60 W • Maximal current rating/amperage: 5 A

SS13G150

3-8

1

3 - CONTROLS AND INSTRUMENTS

Operator's seat

Pneumatic suspension seat (Comfort seat) WARNING Loss of control hazard!

DO NOT make seat adjustments while the machine is in motion. All seat adjustment should be made with the machine stationary and the parking brake applied.

Failure to comply could result in death or serious injury.

W0293A

NOTICE: – Engage the locking levers in the required position.

– After locking, the driver’s seat and the backrest can no longer be moved into other positions.

An electrically operated compressor built into the seat supplies the suspension of the seat and the air cushions in the backrest with compressed air. The necessary valves are incorporated in the seat.

Adjusting the weight-dependent suspension CAUTION Avoid injury!

Before operating the machine, and whenever a new operator takes over, adjust the seat suspension to suit the operator’s specific weight.

Failure to comply could result in minor or moderate injury.

C0093A

Adjustment of dampening Adjustment of harder or softer dampening behaviour (1).

Adjusting the suspension/height of the seat SUSPENSION The driver’s weight should be adjusted when the machine is stationary and the driver’s seat loaded by pulling up the handle (4) briefly. The suspension is to be manually adapted to the body weight of the driver.

SEAT HEIGHT

SS11H117

1

SS11H118

2

Move handle (4) up or down until the seat is at the desired height. Release handle (4).

Adjusting the horizontal fore-aft suspension OPEN: Lever to the front.

BLOCKED: Lever towards the back.

3-9

3 - CONTROLS AND INSTRUMENTS

Fore-and-aft adjustment The fore-and-aft adjustment is enabled with the locking lever.

Lift locking lever upwards, move seat to desired position and release lever. The locking lever must engage in the required position. Once locked, the driver’s seat must no longer be movable into another position.

SS11H119

3

SS11H120

4

SS11H121

5

SS11H122

6

Seat depth adjustment The seat depth can be adjusted to individual requirements.

To adjust the seat depth, raise the handle on the right.

Adjust the desired position by pushing the seat forwards and backwards.

Backrest adjustment The backrest adjustment can be made with the locking lever.

Sit on seat and lean back lightly against backrest.

Pull locking lever upwards.

Adjust backrest by leaning back or forward, and release lever when backrest is in required position.

Seat inclination adjustment The fore-and-aft inclination of the seat can be adjusted to individual requirements.

To adjust the seat inclination, raise the handle on the left.

Adjust the desired seat inclination by position by loading and unloading the seat accordingly.

3-10

3 - CONTROLS AND INSTRUMENTS

Heated seat Switch controls for the optional heated seat are located along the left side of the backrest. The rocker switch has on/off positions. Use the switch for cold weather comfort.

RCPH10WHL074AAH

3-11

7

3 - CONTROLS AND INSTRUMENTS

Seat belt WARNING Roll-over hazard!

Securely fasten the seat belt. Your machine is equipped with a Roll-Over Protective Structure (ROPS) cab, ROPS canopy, or ROPS frame for your protection. The seat belt can help ensure your safety if it is properly used and maintained. Never wear a seat belt loosely or with slack in the belt system.

Failure to comply could result in death or serious injury.

W0143A

WARNING Equipment failure could cause accident or injury!

Always fasten seat belt securely before operating the machine. Inspect seat belt parts for wear and/or damage. To ensure operator safety, replace any and all worn or damaged parts of the seat belt prior to operation.

Failure to comply could result in death or serious injury.

W0046B

The driver’s seat is equipped with a lap seat belt with retractor (1). The automatic retractor/belt-tightener is installed on the left side of the seat.

Putting on the seat belt Slide the tongue (2) into the belt buckle (3). Check by pulling on the belt that the tongue has properly engaged.

The seat belt must not be blocked or twisted.

SS11K230

1

SS14H042

2

Removing the seat belt Depress the buckle interlock (4) and pull out the belt tongue.

The seat belt is retracted automatically.

3-12

3 - CONTROLS AND INSTRUMENTS

Forward controls

Front console controls

SS14D039

Pos. 16 Keypad

1

Designation

Function Navigation keys for multi-function display

31

Switch

Windshield wiper, front window

35

Pushbutton

Windshield washer, front window

39

Switch

Windshield wiper, rear window

43

Pushbutton

Windshield washer, rear window

47

Switch

Hazard warning system

69

Steering-column lever switch Lighting

Turn signal, horn, headlamp flasher, high beam

3-13

Symbol

3 - CONTROLS AND INSTRUMENTS

Pos. 87 Switch

103 107 Pull-switch

Designation Parking brake

Function

not used Activation of floating position function

3-14

Symbol

3 - CONTROLS AND INSTRUMENTS

Starter Switch The key-operated starter switch is used for activating the following functions: 0 = Electrical system OFF All electrical consumers – except for side-marker lamps and warning lights – without power, engine off.

I = Electrical system ON/self-test All indicating lamps, warning lamps, and LED indicators are on for about 3 s and a buzzer sounds for about 3 s.

II = Start the engine SS11H034

1

SS11H035

2

All warning and indicating lamps must go out when the engine is running. Indicator lamp (10) lights up when the parking brake is applied. See also Instrument cluster Analog-Digital Instrument Cluster (ADIC) - Check and following.

NOTE: Wait 30 s, or till the lights on the display expire between switching OFF and ON again.

3-15

3 - CONTROLS AND INSTRUMENTS

Windshield wiper and washer controls The front windshield wiper can be switched to continuous and to intermittent wiping. The windshield wiper is operated using the button (31).

• Press the button (31) once: intermittent wiping ON. • Press the button (31) twice: windshield wiper continuous wiping.

The windshield washer for the front window is activated with the button (35).

• Press the button (35) once: front windshield washer ON. SS14D040

The rear window wiper is activated with the button (39).

• Press the button (39) once: intermittent wiping ON. • Press the button (39) twice: rear windshield wiper continuous wiping.

The windshield washer for the rear window is activated with the button (43).

• Press the button (43) once: rear windshield washer ON.

3-16

1

3 - CONTROLS AND INSTRUMENTS

Service brake The four brakes on the rear axle are used as service brakes. The service brake is actuated hydraulically with pedal (79). The braking force depends on the pressure exerted on the pedal.

SS11K204

1

SS12M150

2

If the operating pressure in the braking system is too low, warning lamp (1) lights up.

WARNING Avoid injury!

Immediately park the machine. Locate the cause of the fault and fix it before driving the machine again.

Failure to comply could result in death or serious injury.

W1026A

3-17

3 - CONTROLS AND INSTRUMENTS

Parking brake WARNING Driving hazard!

Apply the parking brake only when the machine is stationary. While driving, apply the parking brake only in an emergency. The braking action is abrupt.

Failure to comply could result in death or serious injury.

W1028A

The parking brake is a disk brake flange-mounted on the powershift transmission. It is operated electrically.

The parking brake is automatically applied when the key switch is positioned from I to 0.

When the key switch is set from 0 to I, the parking brake must be released before driving.

Applying the parking brake The parking brake is applied via the rocker switch (87).

Push the locking slide in the direction of the arrow and press down the pushbutton. The indicator lamp (10) lights up.

SS14D041

1

SS11H063

2

The transmission is set to neutral.

Releasing the parking brake Releasing the automatically applied parking brake: 1. Push the locking slide in the direction of the arrow and press down the pushbutton. The indicator lamp (10) lights up.

2. Press down the pushbutton to release the rocker switch (87). The parking brake is released and the indicator lamp (10) goes out.

Releasing the manually applied parking brake: • To release the rocker switch (87) press down the pushbutton. The parking brake is released and the indicator lamp (10) goes out.

3-18

3 - CONTROLS AND INSTRUMENTS

Steering column WARNING Driving hazard!

Do not adjust the steering column while driving.

Before adjusting the steering column: - stop the machine, - put the gearshift lever in neutral, and - apply the parking brake.

Failure to comply could result in death or serious injury.

W1032A

The inclination of the steering column can be adjusted to four different positions for adaptation to the driver’s size and posture: • Push the lever (107) forwards with your foot to unlock the steering column.

• Tilt the steering column to the desired position.

• Release the lever (107) to relock the steering column.

• Make sure the steering column is locked.

3-19

SS14D042

1

3 - CONTROLS AND INSTRUMENTS

Steering The machine is equipped with a hydrostatic front-wheel steering which is operated by steering wheel (68).

Emergency steering In the event of steering pump or engine failure, the machine can still be steered as long as it is in motion. Steering under these circumstances requires, however, greater effort to turn the steering wheel.

The emergency steering can be used: • For driving the machine out of the hazard area.

• For towing the machine on a low-bed trailer.

SS14D045

1

SS14D046

2

SS11K287

3

The emergency steering cannot be used for working operations.

Articulated-frame steering The articulated-frame steering permits substantial reduction of the machine´s turning circle.

The articulated-frame steering is operated by control lever (66): Position (17) = articulated-frame steering to the left Position (18) = articulated joint steering to the right

The position of the articulated frame is indicated by markings on the articulated-frame steering cylinders.

3-20

3 - CONTROLS AND INSTRUMENTS

Horn, turn signal, high beam and headlamp flasher Pos. 2

Function

Symbol

High beam

Comment Shift lever forwards – indicator light (2) (see figure 2) lights up in blue.

High beam when low beam is on.

2

Headlight flasher

Pull lever backwards towards the driver and release.

11

Turn signal indicator lamp right

Shift lever to position (11) (see figure 1).

Indicator light (11) (see figure 2) lights up.

15

Turn signal indicator lamp left

Shift lever to position (15) (see figure 1).

Indicator light (15) (see figure 2) lights up.

B

Horn

Press lever button (B) (see figure 1).

3-21

SS14D047

1

SS11H057

2

3 - CONTROLS AND INSTRUMENTS

Switching on the lighting The lighting is switched on with the switch (30).

Switch (30) has three positions: • Position 0: lighting OFF • Position 1: Side lights ON • Position 2: Low beam ON

SS14C017

3-22

3

3 - CONTROLS AND INSTRUMENTS

Right-hand side controls

Right-hand side controls

SS14C018

Pos. 30

Switch

38

Switch

Floating position Option

40

Switch

Rotary beacon Option

42

Switch, 3–step

Floodlamps

Driver´s cab, front/rear

43

Switch

Floodlamps Option

Cab base, in front below

44

Switch

Floodlamps Option

Rear

45

Switch

Reversing signal Option

49 51

Designation Lighting

1

Function Side-marker lamps and low beam

Activate

Reserve Reserve 3-23

Symbol

3 - CONTROLS AND INSTRUMENTS

Pos. 53 65 82

Designation Reserve Blower

Function

83

Lever

Accelerator

84

Encoder

FWD/CM Encoder

86

Switch

Inching Option

Heating Selection of the 6 forward and 3 reverse gears Forwards/max speed Backwards/ idling speed All-wheel drive / Creep mode Option Brake-pressure-dependent transmission cutout

88

Switch

Transmission

Manual/automatic

91

Switch

Air conditioning system Option

92

Switch

Refuelling station Option

99 100

Rotary knob Switch

111

Switch

Heating Stepless heating adjustment Fresh air/recirculated air Switching from fresh air to recirculated air Rear window heating

Switch Gearshift lever

External

3-24

Symbol

3 - CONTROLS AND INSTRUMENTS

Ventilation and heating The cab can be ventilated through two hinged front windows and by an electrically operated blower. The cab is heated with warm water coming from the engine.

Coolant is circulated through the heat exchanger of the heating system. For this reason, the heating performance is dependent on the temperature of the engine. Full heating performance is therefore available only after the engine has reached its operating temperature.

Ventilation • When the engine is not running, set the key switch (73) to position 1.

SS11H037

1

SS14C019

2

• Turn the rotary knob (99) of the heating system clockwise to the limit stop. The heating is off.

Blower The rotary switch (65) can be used to select the following blower stages: • 0 = Blower OFF • 1 = Blower low • 2 = Blower middle • 3 = Blower high

Fresh air/recirculated air The mixing ratio of fresh air and recirculated air can be steplessly adjusted with the switch (100).

Fresh air: • Switch (100) not actuated.

Recirculated air: • Switch (100) actuated. Indicator lamp under the symbol lights up.

3-25

3 - CONTROLS AND INSTRUMENTS

Heating To activate the heating, the blower switch (65) must be at least in position 1. The heating rotary knob (99) serves to adjust the heating performance steplessly between cold and warm.

Maximum heating performance = turn the rotary knob (99) anti-clockwise to the limit stop.

No heating performance = turn the rotary knob (99) clockwise to the limit stop.

NOTICE: Let the heating run at least once every week for about 5 min at maximum heating performance to mix the water in the heat exchanger of the heating and in the engine.

SS14C019

3

SS11H050

4

SS11H051

5

Outlet nozzles The air is blown into the cab through the outlet nozzles (see figures 4 and 5). All nozzles can be tilted and closed.

3-26

3 - CONTROLS AND INSTRUMENTS

Air conditioning system (option) The machine can be equipped with an integrated air conditioner as an option.

Switching on the air conditioning system • Start the engine. See also 4-8.

• To switch on the air conditioner, the pushbutton (91) must be on and the rotary knob (65) must be in position 1, 2, or 3.

• Switch on the air conditioner by pressing the pushbutton (91). The indicator lamp under the symbol lights up.

• If a greater amount of air is desired, turn the rotary switch to level 2 or 3.

SS14C020

1

SS14C019

2

Adjusting the air temperature The temperature of the air blown into the cab can be adjusted with the heating rotary knob (99).

Settings: • Rotary knob to the right (min) = cooled air blown into the cab.

• Rotary knob to the left (max) = heated air blown into the cab.

• Between these limits, the desired temperature is steplessly variable.

• For better cooling performance, the blower can be set to levels 2 and 3 with the rotary knob (65).

Pre-conditions for a good cooling performance: • The fresh air suction openings at the rear of the cab must not be covered up or contaminated.

• The filter mat and the fins of the evaporator must be clean.

• The door and the windows of the cab must be closed.

• Set the cooling fan to 100 % (maximum) to assure the maximum cooling performance.

NOTE: For more information see also 3-25.

Switching off the air conditioning system • Switch off the air conditioner by pressing the pushbutton (91) (see figure 1).

3-27

3 - CONTROLS AND INSTRUMENTS

Outlet nozzles The integrated air conditioner has additional outlet nozzles on the left-hand side and on the right-hand side that can be rotated and closed.

SS11H053

3-28

3

3 - CONTROLS AND INSTRUMENTS

Floodlight The floodlights are activated and deactivated with the switches (42), (43), and (44) (see figure 2).

NOTICE: The floodlight can only be used when the headlight are on low beam or when the side-marker lights are on.

SS14C124

1

SS14C021

2

SS14C125

3

SS14C126

4

Floodlight drivers cab (see figure 3) – front/ rear – switch on Front floodlight ON: • Press the pushbutton (42) with the symbol once, the symbol lights up.

Front and Rear floodlight ON: • Press the pushbutton (42) with the symbol twice, the symbol lights up.

Floodlight drivers cab – front/rear – switch off • Press the pushbutton (42) without the symbol, the symbol goes off.

Floodlight cab floor (option) (see figure 4) – front – switch on • Press the pushbutton (44) (see figure 2) with the symbol, the symbol lights up.

Floodlight cab floor (option) – front – switch off • Press the pushbutton (44) (see figure 2) without the symbol, the symbol goes off.

3-29

3 - CONTROLS AND INSTRUMENTS

Floodlight (see figure 5) – rear (option) – switch on (End cover/additional weight) • Press the pushbutton (43) (see figure 2) with the symbol, the symbol lights up.

Floodlight – rear (option) – switch off • Press the pushbutton (43) (see figure 2) without the symbol, the symbol goes off.

SS14D048

3-30

5

3 - CONTROLS AND INSTRUMENTS

Drive Front-Wheel Drive (FWD) / Creep Mode (CM)–Encoder The encoder push buttons (1) and (2) are used for activating and deactivating the front-wheel drive (FWD) and the creep mode (CM) functions. The rotary knob (3) is used for the front-wheel drive aggressiveness selector and the creep mode speed selector depending on the selected function.

SS14E092

1

SS14E205

2

All-wheel drive (option) The grader is equipped with a drive acting on all four wheels of the rear axle (tandem axle).

Front-wheel drive can be switched on in addition to the rear-wheel drive.

The aggressiveness of the front-wheel drive system shall be adjustable via the rotary knob (3) (see figure 1).

The operator can adjust the aggressiveness by turning the encoder to the desired position when front-wheel drive is request or enabled.

There are 16 different positions: 1 to 5: The front wheel drive speed shall be lower than the rear wheel speed in every gear stage and direction.

6: The front wheel drive speed shall be equal to the rear wheel speed in every gear stage and direction.

7 to 16: The front wheel drive speed shall be higher than the rear wheel speed in every gear stage and direction.

The sixth detent of front-wheel drive (FWD) aggressiveness selector shall identify the neutral aggressiveness position and shall be the default value.

3-31

3 - CONTROLS AND INSTRUMENTS

Turning the encoder counter-clockwise from neutral aggressiveness position, the encoder led shall be lighted up from selected position to sixth detent.

SS14E206

3

SS14E207

4

SS14E092

5

Turning the encoder clockwise from neutral aggressiveness position, the encoder led shall be lighted up from sixth detent to position selected.

Activating the all-wheel drive Press the pushbutton (2) with the symbol and the symbol begins to flash. It is possible to select the aggressiveness with the rotary knob. To activate the all-wheel drive function it is necessary to drive faster than 2.0 km/h (1.2 mph). The symbol is stable and you can select the aggressiveness with the rotary knob.

NOTE: If the machine is not driving, the symbol is flashing.

Deactivating the all-wheel drive After pre-selection: 1. Press the pushbutton after pre-selection (machine is not driving and symbol is flashing) all LED’s will light off.

2. The all-wheel drive function is off.

All-wheel drive is active: 1. Press the pushbutton if the all-wheel drive is active (symbol is stable and machine is driving faster than 2.0 km/h (1.2 mph)) to pre-select the deactivation.

The symbol is flashing but the all-wheel drive is not deactivated.

2. The all-wheel drive will be deactivated below 2.0 km/h (1.2 mph)).

3-32

3 - CONTROLS AND INSTRUMENTS

Creep Mode (option) Creep Mode shall be a mode to drive the vehicle by front wheels only. The driver can use the creep mode to achieve a very low machine speed level at a certain engine speed.

The maximum speed in creep mode shall be limited to 5.0 km/h (3.1 mph).

Different max speeds shall be selectable via 16–detents rotary knob: possible min. to possible max. (target 0.5 5.0 km/h (1.6 - 3.1 mph)) Different ratios between accelerator pedal position and machine speed shall be selectable via rotary knob (e.g.: detent 16: max speed 5.0 km/h (3.1 mph) and accelerator position approximately 60 %).

There are 16 different positions: 1 to 10: maximum achievable speed increases as detents increase and it is reached at accelerator pedal position equal to 100 % (no saturation is performed).

11 to 16: maximum achievable speed remains constant as detents increase but the accelerator pedal position at which the maximum speed is reached decreases as detents increasing (saturation is performed).

Activating the creep mode Press the pushbutton (1) with the symbol; the symbol flash. After a few moments the symbol is stable and you can pre-select the maximum CM speed with the rotary in combination to requested engine speed by usage of accelerator pedal or hand throttle. If CM is activated, the main screen on AIC will change to indication of CM driving screen.

Creep Mode shall be activated if all the following condition are satisfied: • Creep Mode key pressed SS14E092

• Park brake disengaged • Error code 9170 not active • Gear direction neutral • Correct oil temperature (warming up the machine, if necessary) • Accelerator pedal not pressed / Hand throttle in low idle position Also be aware of following: • No system failure • TCU operates correctly (e.g. not in calibration mode) • FWD calibration performed

3-33

6

3 - CONTROLS AND INSTRUMENTS

Deactivating the creep mode Press the pushbutton (1) (see figure 6) with the symbol again; the symbol lights off and AIC screen change back to normal driving screen.

The Creep Mode shall be deactivated temporary (as long as persists the deactivation condition) if at least one of the following condition is satisfied: • Service brake engaged • Accelerator pedal < 7 % The Creep Mode shall be deactivated permanently if at least one of the following condition occurs: • Creep mode key pressed • Park brake engaged • Error code 9170 active • Gear direction not neutral • System failure • Oil temperature out of range • TCU severe failure or not in normal operation mode • FWD calibration not performed

Activating CM while FWD is enabled 1. The FWD (2) is enabled, the FWD button (1) lights stable and the aggressiveness is selectable.

2. Press the CM button (3) (CM conditions not satisfied).

SS14E214

7

SS14E211

8

3. The FWD button (2) lights stable, the CM button (3) flashes and the aggressiveness (1) is still selectable.

3-34

3 - CONTROLS AND INSTRUMENTS

4. After a while, when the CM conditions are satisfied, the FWD button (2) is off, the CM button (3) lights stable and the CM speed (1) is selectable.

SS14E215

9

Activating FWD while CM is enabled 1. The CM is enabled, the CM button (3) lights stable and the CM speed (1) is selectable.

2. Press the FWD button (2) (FWD conditions not satisfied).

SS14E215

10

SS14E213

11

SS14E214

12

3. The CM button (3) lights stable, the FWD button (2) flashes and the CM speed (1) is still selectable.

4. Press the CM button (3) (CM conditions not satisfied).

5. The CM button (3) is off, the FWD button (2) lights stable and the aggressiveness (1) is selectable.

3-35

3 - CONTROLS AND INSTRUMENTS

Activating FWD to FWD Zero Aggressiveness 1. The FWD is enabled, the FWD button (2) lights stable and the aggressiveness (1) is selectable.

2. Select the 4th gear.

3. The 6th detent flashes, the FWD button (2) light is stable and the aggressiveness (1) is selectable, but not active.

SS14E210

3-36

13

3 - CONTROLS AND INSTRUMENTS

Gearshift lever - powershift transmission WARNING Driving hazard!

Never allow the machine to roll with the gearshift lever in neutral.

Failure to comply could result in death or serious injury.

W1053A

Forward and reverse travel and the 6 forward and 3 reverse gears are selected with the gearshift lever (82).

All gears can be shifted under load.

The electronic transmission only shifts within the speed ranges of the individual gears.

SS14D049

3-37

1

3 - CONTROLS AND INSTRUMENTS

The control can be switched with rocker switch (88) into the manual or into the automatic mode.

Automatic mode Set rocker switch (88) to automatic mode.

After starting of the engine, the transmission is in the automatic-mode neutral position.

Preselection of gears: • Engine speed has to be below 1500 RPM. It’s possible to set the automatic mode over 1500 RPM, but the machine won’t drive.

•

WARNING Unexpected machine movement!

If you activate automatic mode or manual mode at speeds above 1500 RPM, be aware that the machine will start to drive if your speed then drops below approximately 1500 RPM. Make sure that all persons and obstacles are clear of the machine.

Failure to comply could result in death or serious injury.

W1283A

• Releasing the parking brake.

• Press the button on the gearshift lever (82) (see figure 1) and shift the lever forwards into forward gear or backwards into reverse gear.

Release the button.

• The automatic transmission now shifts into 2nd forward or 1st reverse gear.

Only if required by the driving situation, for instance setting off under load, will the gear control automatically shift down into 1st gear.

• Depending on the speed range, the automatic transmission then either shifts up into 6th forward gear (or up into 5th forward gear with activated all-wheel drive) or down into 3rd reverse gear.

3-38

SS14C023

2

3 - CONTROLS AND INSTRUMENTS

Ending automatic mode and shifting manually The automatic mode is ended by setting rocker switch (88) to manual position. The transmission retains the gear actually fixed by the automatic gearshift.

The automatic mode can also be ended by moving the gearshift slightly sideways. The transmission shifts into the next higher or lower gear.

Manual mode The machine can be shifted manually down into next lower gears by moving the gearshift lever slightly to the left.

By moving the gearshift lever slightly to the right, the machine can be shifted into the next higher gear.

The gearbox returns to the automatic mode if either the button on the gearshift lever is pressed briefly or the gearshift lever is moved through the N position (only when the rocker switch is on automatic mode).

Preselection of gears: • Engine speed has to be below 1500 RPM. It’s possible to set the manual mode over 1500 RPM, but the machine won’t drive.

•

WARNING Unexpected machine movement!

If you activate automatic mode or manual mode at speeds above 1500 RPM, be aware that the machine will start to drive if your speed then drops below approximately 1500 RPM. Make sure that all persons and obstacles are clear of the machine.

Failure to comply could result in death or serious injury.

W1283A

• Releasing the parking brake.

• Press the button on the gearshift lever (82) (see figure 1) and shift the lever forwards into forward gear or backwards into reverse gear.

Release the button.

3-39

SS14C023

3

3 - CONTROLS AND INSTRUMENTS

Forwards–reverse shifting WARNING Driving hazard!

Reduce the engine speed before reversing the travel direction.

Failure to comply could result in death or serious injury.

W1054A

Shifting from forward gears into reverse gears (reversing) is also possible while moving.

The machine is braked smoothly and, after stopping, sets off again in opposite direction.

• Reduce the engine speed before reversing the travel direction.

• Shift into the opposite travel direction.

Reversing signal NOTE: Comply with local laws and regulations.

• The reverse signal is optional.

• The switch in the cabin activates and deactivates the reverse signal.

• When activated, the reverse signal sounds with selected reverse gear.

• When deactivated, the reverse signal doesn’t sound with selected reverse gear.

3-40

3 - CONTROLS AND INSTRUMENTS

Brake-pressure-dependent transmission cutout/inching (option) The grader can be equipped with a brake-pressure-dependent transmission cutout function which is activated at a brake pressure of 25 bar (362.5 psi).

This function can be switched on and off.

The brake-pressure-dependent transmission cutout is activated only in 1st, 2nd and 3rd forward gear and in 1st reverse gear.

The brake-pressure-dependent transmission cutout is switched on with the pushbutton (86).

Brake-pressure-dependent transmission cutout ON: • Press the pushbutton (86) with the symbol; the symbol lights up.

Brake-pressure-dependent transmission cutout OFF: • Press the pushbutton (86) without the symbol; the symbol goes off.

3-41

SS14E221

1

3 - CONTROLS AND INSTRUMENTS

Display

Instrument panel - Warning and monitoring elements

SS11H003

Pos. Designation 1 Brake pressure warning lamp 2 3 4 5 6 7 8

Main beam indicator lamp Transmission oil temperature indicator Main warning indicator (YELLOW) Multi-function LCD display Main warning indicator STOP (RED) Hydraulic fluid temperature indicator Preheating monitoring lamp

1

Pos. Designation 9 Steering pressure/emergency steering pressure warning lamp 10 Parking brake indicator lamp 11 Turn signal monitoring lamp – right 12 Fuel gauge 13 Fuel tank warning lamp 14 Engine coolant 15 Turn signal monitoring lamp – left

3-42

3 - CONTROLS AND INSTRUMENTS

The combination instrument monitors numerous functions and can be adapted to the respective requirements of the driver. It not only monitors vehicle functions, but it also attracts the driver’s attention to potential malfunctions and indicates the necessity of taking appropriate measures after the occurrence of possibly critical malfunctions. After the ignition is turned on, the combination instrument performs the following self-test: 1.

Set the ignition switch to position I.

2.

The combination instrument automatically checks all monitored systems.

3.

All light-emitting diodes (LEDs) light up for 2 - 3 s.

4.

The four analogue instruments are initialized and are switched on for 2 - 3 s.

5.

The warning tone sounds for 2 - 3 s.

6.

If no faults are detected during the test, all monitored systems reset to their normal function.

7.

If only some of the LEDs light up, the combination instrument must be replaced.

8.

If the LEDs light up without a warning tone being sounded, the combination instrument must be replaced.

9.

If a warning is sounded without the LEDs being lit up and if the power supply to the acoustic warning system is not in order, the combination instrument must be replaced. If the power supply of the acoustic warning system is in order, the warning system is defective and must be replaced.

10. If no warning is sounded and if the LEDs in the combination instrument do not light up, the power supply must be checked.

3-43

3 - CONTROLS AND INSTRUMENTS

Operation of the multi-functional LCD display Switching between individual screens of the multi-function LCD display There is a keypad below the steering column.

The keypad can be used by the driver to proceed from one screen to the next, to select different items, to monitor the vehicle functions, and to recall info texts. All functions can be accessed in the same way.

Pos. Designation A Interrupt key/Escape: With this key, the driver can exit a submenu screen and go back to the travel information screen, discard changes made, and recall active fault codes.

B Entry key/Enter: This key confirms the selection of a specific function and stores the entry.

C Up key: This key is used for scrolling up through the screen selection.

D Down key: This key is used for scrolling down through the screen selection.

NOTE: The scrolling direction (up or down) from the current position is indicated by arrows on the screen.

3-44

SS11H004

1

3 - CONTROLS AND INSTRUMENTS

Calling up the main menu NOTE: The shown values are examples and no constant values.

Using the arrow keys During operation or when the ignition is on, the driver can use the arrow keys (C) and (D) to select between different screens.

For the screen sequence only the DOWN key (D) is used.

NOTE: Pressing the interrupt key (A) switches the LCD display back to normal main screen.

SS14D043

1

SS14C054

2

SS14D044

3

The multi-function LCD display is located in the center of the instrument panel. When the ignition is turned on, the warning indicator lamps are activated and the text CASE accompanied by the machine designation flashes on the multi-function display.

Main screen: These settings can also be changed by the driver.

Sector 1

2

3 4 5 6

Designation The number of operating hours is displayed briefly after the ignition is turned on. After the engine is started, the engine speed is displayed. After setting off, the traveling speed is displayed.

Indicates the transmission operating mode.

A = Automatic mode M = Manual mode L = Limp Home mode Time-of-day display format ( 12 h or 24 h).

Diesel Exhaust Fluid (DEF)/AdBlue® fluid level.

Gear information: Actual gear engaged by transmission (1...6).

Travel direction display Forwards (F), Reverse (R), and Neutral (N).

Press the DOWN key (D) while in this main screen (see figure 2).

3-45

3 - CONTROLS AND INSTRUMENTS

The first data screen Info 1 is displayed which is selected from the main screen with the DOWN key. This screen shows the engine speed, the traveling speed, the fuel reserve and the DEF/AdBlue® fluid level.

NOTE: Pressing the interrupt key switches the LCD display back to normal main screen.

Pos. 1 2 3 4

Designation Engine speed Traveling speed Fuel reserve DEF/AdBlue® fluid level

Dimension RPM km/h-mph % % SS14C050

4

SS14C051

5

SS14C052

6

SS14C053

7

Press the DOWN key (D) (see figure 3) while in this data screen.

Data screen INFO 2 is displayed.

Pos. Designation 1 Coolant temperature (in front of the fan) 2 Engine oil temperature 3 Engine oil pressure 4 DEF/AdBlue® fluid level

Dimension °C or °F °C or °F bar or psi %

After pressing the DOWN key (D) (see figure 3) once again, data screen INFO 3 is displayed.

Pos. Designation 1 Transmission oil temperature 2 Transmission oil sump temperature 3 Hydraulic fluid temperature 4 DEF/AdBlue® fluid level

Dimension °C or °F °C or °F °C or °F %

After pressing the DOWN key (D) (see figure 3) once again, data screen INFO 4 is displayed.

Pos. 1 2 3 4

Designation Boost air temperature System voltage Front Wheel Drive (FWD) mode DEF/AdBlue® fluid level

Dimension °C or °F V Detent number %

3-46

3 - CONTROLS AND INSTRUMENTS

NOTE: The trip screens are blocked while driving the unit.

After pressing the DOWN key (D) (see figure 3) once again, travel information screen 1/TRIP 1 is displayed.

Pos. 1 2 3 4

Designation Date of last reset Operating hours Total fuel consumption Fuel consumption per hour

Dimension h l l/h

Both travel information screens display two operating hours counters. They show the total number of operating hours after the last reset, the total fuel consumption, and the average fuel consumption per hour.

SS14C115

8

SS14C116

9

Scrolling further down displays travel information screen 2/TRIP 2.

Pos. 1 2 3 4

Designation Date of last reset Operating hours Total fuel consumption Fuel consumption per hour

Dimension h l l/h

Travel information screens 1 and 2 can be reset independently.

Pressing the UP key displays the previous screen again.

Resetting the traveling data Example: Travel information screen 2

SS14C116

10

SS14D043

11

Call up the relevant travel information screen.

Press entry key/ENTER (B), the reset message is indicated on the travel information screen.

3-47

3 - CONTROLS AND INSTRUMENTS

Pos. 1 Confirm

Designation

The travel information screen displays a reset message.

Press the entry key/ENTER (B) (see figure 11) in this screen to delete the numbers and to reset the traveling data. The current date and time-of-day are displayed automatically. Operating hours, total fuel consumption, and average fuel consumption per hour are set back to zero.

Travel information screen 1 (see figure 8 ) can also be reset in the same way as travel information screen 2.

SS14D057

12

SS14D043

13

SS14C056

14

Calling up the service screens After engine startup or ignition shut-on, the driver or the service technician can make use of the service menu for adapting the machine configuration to the respective working conditions, for recalling possible malfunctions or also for selecting different settings.

NOTICE: All settings are saved after they have been selected. After an abrupt disconnection of the battery, stored data can be lost, meaning that the multifunction LCD display must be reprogrammed.

In every menu in which changes can be made, the active line or value to be changed is marked with a black bar. After pressing the ENTER key (B), the line/value to be changed starts flashing. By pressing the arrow keys UP (C) and DOWN (D), the settings can be selected and confirmed with the ENTER key (B). The change is saved.

The marked line or value stops flashing. If a change is to be discarded, this can be done by pressing the break key ESCAPE (A) while the line is flashing.

After appearance of the main menu, press ENTER (B) for 2 s to activate the service screen (see figure 14). Press the DOWN key (D) to browse through the submenus.

Pos. 1 2 3 4

Designation Settings Display Diagnostics Service

The main menu can just be executed/displayed when the ground speed is lower than 1.5 km/h (0.9 mph). If the operator is trying to jump into the menu during driving, a warning message “Not allowed while driving” shall come up.

3-48

3 - CONTROLS AND INSTRUMENTS

Calling up the settings menu NOTE: The shown values are examples and no constant values.

If the Settings menu is selected with the ENTER key (B), 2 submenus will be displayed.

SS14D043

1

SS14D060

2

SS14C058

3

Settings menu screen Pos. 1 Engine 2 Fan

Designation

Engine screen (1) Pos. 1 Idle Auto 2 Low Idle 3 Factory Set

Designation

3-49

3 - CONTROLS AND INSTRUMENTS

Idle Auto screen • Off (Auto idle not selected) Idle is constant at normal idle or customized idle.

• On (Auto idle selected) – If engine is not running, set fixed speed of Normal idle (i.e. start up condition).

– If engine is running, operation use normal idle 800 RPM, AEB idle 900 RPM or accelerate idle 1200 RPM. NOTE: Accelerated idle is used when weather is cold and machine is not warm enough, to accelerate warming up of hydraulics and wet stake of the exhaust by condensation.

SS14C059

4

SS14D080

5

SS14C060

6

NOTE: The AEB Idle Speed will be used during transmission clutch calibration mode. Activation of AEB speed is independent of Auto Idle selection. That means, AEB_Idle Speed can be set when “Auto Idle” is enabled or disabled.

Low Idle screen The number of revolutions at idling can be changed from the standard value to another fixed value. The fixed standard idling speed is set to 800 RPM. This value can be changed with the arrow keys (C) and (D) and saved with the ENTER key (B) (see figure 1).

Displayed in the AIC +50 +100 +150 +200 +250 +300

Actual engine speed (rpm) 850 900 950 1000 1050 1100

Factory Set screen You can set the machine parameter back to the factory set parameter.

3-50

3 - CONTROLS AND INSTRUMENTS

Fan screen (2) Pos. 1 AC Fan Set 2 Fan Mode

Designation

SS14D061

7

SS14C062

8

SS14C063

9

AC Fan Set screen The A/C fan set screen (1) (see figure 7) is selected and called up with the ENTER key (B) (see figure 1).

You can select between ON, OFF, and AUTO.

Fan Mode screen Allows the selection of Fan Mode.

The following options are available: • ON (Default) • OFF NOTE: if fan mode is selected to “ON”, fan speed is controlled by interpretation of different temperatures (hydraulic oil, engine coolant, transmission oil, engine air intake).

If fan mode is selected to “OFF”, fan speed is set to 100% constantly. The temperature control is OFF.

3-51

3 - CONTROLS AND INSTRUMENTS

Calling up the display menu NOTE: The shown values are examples and no constant values.

If the Display menu is selected with the ENTER key (B), 6 submenus will be displayed.

SS14D043

1

SS14C064

2

SS14C065

3

Display menu screen Pos. 1 2 3 4 5 6

Designation Options Language Units Clock Backlight Factory Set

Options menu (1) Engine Speed (1): Allows the operator to select what is displayed on the main menu screen.

• ON (Default) • OFF Ground Speed (2): Allows the operator to select what is displayed on the main menu screen.

• ON (Default) • OFF

3-52

3 - CONTROLS AND INSTRUMENTS

Language menu (2) To open the language menu, place the cursor on “Language” and confirm the selection with the ENTER key (B) (see figure 1), whereupon the line “Language” starts flashing. Select the language desired with the arrow keys (C), (D) (see figure 1) and confirm and save the selection by pressing the ENTER key (B) (see figure 1).

• English • German • French • Italian

SS14C083

4

SS14C084

5

SS14C085

6

SS14C086

7

• Spanish • Portuguese

Units menu (3) • Metric • English • Imperial

Clock menu (4) • Format ( 12 h or 24 h) • Hour • Minute • Day • Month • Year

Backlight menu (5) The screen can be independently adapted to daytime and nighttime working conditions.

Pos. 1 2 3 4

Designation Daytime screen Daytime LED Nighttime screen Nighttime LED

The value to be changed is a percentage value.

3-53

3 - CONTROLS AND INSTRUMENTS

Factory Set screen (6) Set the machine parameter back to the factory set parameter.

SS14C087

3-54

8

3 - CONTROLS AND INSTRUMENTS

Calling up the diagnostics menu NOTE: The shown values are examples and no constant values.

If the Diagnostics menu is selected with the ENTER key (B), 4 submenus will be displayed.

SS14D043

1

SS14C089

2

SS14C090

3

Show Errors (1) Pos. 1 2 3 4

Designation RED = current critical warning YELLOW = current non-critical warning WHITE = faults not relevant to operation Fault memory

“Red faults” have priority over “yellow faults” and are therefore always displayed in first place.

Red, yellow and white faults are saved in the fault memory when no longer active.

Red warnings • In the case of active red faults, the warning tone is sounded continuously.

• The driver can confirm this message by pressing ENTER key (B) (see figure 1).

• After confirming in the main screen, the continuous tone changes to an intermittent signal and another instruction (e.g., STOP MOTOR) appears on the display.

• The red main warning lamp remains lit. The fault remains in the active list until the list is updated with the new status (i.e., fault no longer exists).

3-55

3 - CONTROLS AND INSTRUMENTS

Yellow warnings • In the case of yellow warnings, the warning tone is sounded every 2 s.

• The driver can confirm this message by pressing ENTER key (B) (see figure 1).

• The fault message disappears.

• The warning tone is stopped.

• The yellow main warning lamp remains on.

• The fault remains in the active list until the list is updated with the new status (i.e., fault no longer exists).

Fault code classification 1000–1999 3000–3999 4000–4999 5000–5999 9000–9999 19000–19999

Vehicle malfunction Engine malfunction Transmission malfunction Electro-hydraulic system malfunction Internal AIC malfunction Selective Catalytic Reduction (SCR) system malfunction

AIC Info screen (2) Pos. 1 Cluster H/W 2 Cluster S/W

Designation

SS14C091

4

SS14C094

5

Hardware screen This screen is a great help for ordering hardware.

Pos. 1 2 3 4

Designation CNH part number Serial number Hardware ID Hardware version

Press the ESCAPE key (A) (see figure 1) to display the AIC Info screen again.

3-56

3 - CONTROLS AND INSTRUMENTS

Software screen This screen is a great help for ordering the corresponding software.

Pos. 1 2 3 4

Designation CNH part number Bootloader version Software ID Software version

Press the ESCAPE key (A) (see figure 1) to display the AIC Info screen again.

SS14C095

6

SS14C092

7

SS14C096

8

SS14C097

9

UCM Info screen (3) Pos. 1 UCM HW Info 2 UCM SW Info

Designation

UCM HW Info screen • P/N: The UCM hardware part number • Ver: The UCM version number

UCM SW Info screen • P/N: The UCM software part number • Ver: The UCM version number

3-57

3 - CONTROLS AND INSTRUMENTS

TCU Info screen (4) Pos. Designation 1 TCU hardware part number 2 TCU hardware number 3 TCU software number

SS14C093

10

SS14H030

11

Engine Info screen (5) Pos. Designation 1 Hardware part number 2 Bootloader version 3 Software version number

3-58

3 - CONTROLS AND INSTRUMENTS

Calling up the service menu NOTE: The shown values are examples and no constant values.

If the Service menu is selected with the ENTER key (B), 2 submenus will be displayed.

SS14D043

1

SS14H031

2

SS14C105

3

Service menu screen Pos. 1 Calibration 2 Select Tires

Designation

Calibration menu (1) Pos. Designation 1 Transmission calibration 2 Fan Test

3-59

3 - CONTROLS AND INSTRUMENTS

Be aware the following information to execute the calibration: 1. Follow the instructions on the display screens.

2. Error code 9170 not active.

3. Warm-up the machine to reach the necessary minimum transmission sump temperature of 65.0 °C (149.0 °F).

4. The engine speed is set automatically to 900 RPM. 5. During the calibration process the fan speed is lowered and set automatically to “minimum”.

6. The calibration process will stop automatically if: • Park brake disengaged • Transmission sump temperature too high • Gearshift lever not in neutral • Vehicle moving 7. To interrupt the calibration process manually: • Press the ESCAPE key • Switch the ignition key to position OFF (only in emergency)

Transmission calibration screen The transmission calibration screen (1) (see figure 3) is selected and called up with the ENTER key (B) (see figure 1).

The prompt “Confirm Please” will be displayed and the following options given: • Continue • Cancel After the calibration, the prompt “Change OK Now, Turn Key OFF” will be displayed.

SS14C106

4

SS14C107

5

If the process could not be successfully carried out, leave the menu with the ESCAPE key (A) (see figure 1).

3-60

3 - CONTROLS AND INSTRUMENTS

Fan test screen The fan test screen (2) (see figure 3) is selected and called up with the ENTER key (B) (see figure 1).

NOTE: Adjustments by the operator are blocked.

SS14C108

6

SS14C113

7

Tires screen (2) Pos. 1 Tire selection

Designation

3-61

3 - CONTROLS AND INSTRUMENTS

Instrument panel/indicator lamps WARNING Avoid injury and/or machine damage!

If the main warning light comes on and the warning system sounds, immediately stop the machine and shut off the engine. Lower the working equipment and follow the instructions on the display to locate the cause of the problem.

Failure to comply could result in death or serious injury.

W1025B

When the ignition switch is turned to ON, all systems in the instrument panel are tested with self-test routines. All LEDs (LED = light-emitting diode) light up and a warning tone is heard for 3 s. At the end of this test, all systems return to the normal mode of operation. In the case of an open circuit condition in the cable between a sensor and the instrument panel, the LED blinks and the warning tone can be heard for 5 s.

Brake pressure indicator lamp (1): This indicator lamp lights up when the pressure in the brake system is too low. The alarm sounds continuously and the main warning lamp lights up accompanied by the following message on the screen: PARK THE MACHINE AND RECTIFY THE FAULT.

WARNING Avoid injury!

Immediately park the machine. Locate the cause of the fault and fix it before driving the machine again.

Failure to comply could result in death or serious injury.

SS13A377

W1026A

Lighting indicator lamp (2): This indicator lamp lights up when the headlights are on high beam.

Preheating system indicator lamp (grid heating) (8): Activate the heating by turning the ignition switch to ON. This indicator lamp lights up when the engine preheating system is on. Wait until the indicator lamp is OFF before turning the ignition switch to the START position to start up the engine. The indicator lamp may light up once again during the starting procedure and shortly after the engine starts up to postheat the air.

3-62

1

3 - CONTROLS AND INSTRUMENTS

Steering pressure/emergency steering pressure indicator lamp (9): The lamp indicates if the hydraulic pressure of steering system meets normal conditions. This indicator lamp is used for Main Steering Pressure and Secondary Steering Pressure.

Main Steering pressure failure will be indicated by constant lighted LED. Secondary Steering pressure failure will be indicated by flash lighted LED. Monitor Priority is set to Main Steering pressure. That means, in case both pressures are failed at the same time, the pressure failure LED will be ON permanently.

WARNING Avoid injury!

Immediately park the machine. Locate the cause of the fault and fix it before driving the machine again.

Failure to comply could result in death or serious injury.

W1026A

Parking brake indicator lamp (10): This indicator lamp lights up when the parking brake is locked. If the transmission is shifted into FORWARD or REVERSE GEAR while the parking brake is locked, the warning tone sounds.

Hazard warning system and turn signal – right indicator lamp (11): This green indicator lamp flash when the turn signal indicator (right) or the hazard warning system is on in ignition switch position I.

Hazard warning system and turn signal – left indicator lamp (15): This green indicator lamp flash when the turn signal indicator (left) or the hazard warning system is on in ignition switch position I.

3-63

SS13A377

2

3 - CONTROLS AND INSTRUMENTS

Main warning lamp “STOP” (red, critical) (6) Main warning lamp STOP is a CRITICAL warning indicator.

WARNING Avoid injury and/or machine damage!

If the main warning light comes on and the warning system sounds, immediately stop the machine and shut off the engine. Lower the working equipment and follow the instructions on the display to locate the cause of the problem.

Failure to comply could result in death or serious injury.

SS11H021

3

W1025B

The following table contains the critical symbols/warnings which may be displayed on the screen of the instrument panel and the measures that must be taken to remedy the situation. If a fault occurs, a warning is sounded and the main warning lamp lights up RED. The indicators on the instrument panel signal a warning.

Critical warnings Display message Engine oil pressure Brake pressure Steering pressure (with servo steering) Coolant temperature

Hydraulic fluid temperature Transmission oil temperature DEF/AdBlue® Level Tank EMPTY Power Limited DEF/AdBlue® Level Tank EMPTY Ext. Power Lim Poor DEF/AdBlue® Quality Detected Power Limited Poor DEF/AdBlue® Quality Detected Ext. Power Lim DEF/AdBlue® Injection Failed Power Limited

DEF/AdBlue® Injection Failed Ext. Power Lim

Description Low engine oil pressure below 0.7 bar (10.2 psi) Brake pressure too low Low main steering pressure Low secondary steering pressure Engine coolant temperature too high

Remedy Bring the machine safely to a halt and SHUT OFF the engine immediately.

Contact your authorized dealer.

DEF/AdBlue® level is too low

Refill DEF/AdBlue® immediately.

Bring the machine safely to a halt and SHUT OFF the engine immediately.

Check the coolant levels when the engine and the coolant are cold.

Contact your authorized dealer.

Hydraulic fluid temperature too high Bring the machine safely to a halt and Transmission oil temperature too high SHUT OFF the engine immediately.

Contact your authorized dealer.

DEF/AdBlue® level is too low Refill DEF/AdBlue® immediately.

DEF/AdBlue® quality is questionable Drain the tank and discard the DEF/AdBlue®. Fill with new DEF/AdBlue®.

DEF/AdBlue® quality is questionable Drain the tank and discard the DEF/AdBlue®. Fill with new DEF/AdBlue®.

Injection failure detected Check the DEF/AdBlue® tank level.

Drain the tank and discard the DEF/AdBlue®. Fill with new DEF/AdBlue®.

Contact your authorized dealer.

Injection failure detected Check the DEF/AdBlue® tank level.

Drain the tank and discard the DEF/AdBlue®. Fill with new DEF/AdBlue®.

Contact your authorized dealer.

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3 - CONTROLS AND INSTRUMENTS

Main warning lamp “CAUTION” (yellow, noncritical) (4) Main warning lamp CAUTION is a NONCRITICAL warning indicator.

NOTICE: “Caution” (yellow, noncritical). These faults can possibly be corrected by the driver himself.

When main warning lamp CAUTION lights up and an intermittent alarm is heard, change the mode of operation, plan an immobilization for servicing purposes, and – if the problem cannot be solved – contact the authorized dealer of your machine. The following table contains the noncritical symbols/warnings which may be displayed on the screen of the instrument panel and the measures that must be taken to remedy the situation.

SS11H022

4

Noncritical warning indicators Display message Coolant temperature

Description High engine coolant temperature above normal

Remedy 1. Run the engine in idle and monitor the temperature.

2. Clean the radiator.

3. Check the coolant level and top up, if necessary.

4. If this message continues to remain active, contact your authorized dealer.

Hydraulic fluid temperature

High hydraulic fluid temperature above normal

1. Let engine run at idle and watch the temperature.

2. Clean hydraulic fluid cooler.

3. Check the hydraulic fluid level.

4. If this message continues to remain active, contact your authorized dealer.

Transmission oil temperature

High transmission oil temperature above normal

1. Let engine run at idle and watch the temperature.

2. Clean transmission fluid cooler.

3. Shift into a lower gear.

4. If this message continues to remain active, contact your authorized dealer.

Air filter

Air filter highly contaminated 1. Clean the air filter.

2. Clean the primary and the secondary filter.

3. If this message continues to remain active, contact your authorized dealer.

3-65

3 - CONTROLS AND INSTRUMENTS

Display message Transmission oil filter

Description Transmission oil filter clogged up

Remedy 1. Replace the transmission oil filter.

2. If this message continues to remain active, contact your authorized dealer.

Hydraulic filter

Hydraulic oil filter restriction 1. Replace hydraulic oil filter.

2. If condition persists, contact your authorized dealer.

System voltage

Alternator malfunction Battery voltage too low 1. Check the electrical system.

2. Voltage levels are beyond the specified limits (min/max) 3. If this message continues to remain active, contact your authorized dealer.

DEF/AdBlue® Level LOW

DEF/AdBlue® level is too low

Poor DEF/AdBlue® Quality Detected

DEF/AdBlue® quality is questionable

DEF/AdBlue® Injection Failed Power Limited

Injection failure detected

1. Refill DEF/AdBlue® immediately.

1. Drain the tank and discard the DEF/AdBlue®.

2. Fill with new DEF/AdBlue®.

1. Check the DEF/AdBlue® tank level.

2. Drain the tank and discard the DEF/AdBlue®. Fill with new DEF/AdBlue®.

3. Contact your authorized dealer.

3-66

3 - CONTROLS AND INSTRUMENTS

Transmission oil temperature Transmission oil temperature (3) The transmission oil temperature instrument indicates the temperature of the oil in the transmission. Under normal operating temperature conditions, the instrument needle is in range (B) . If the temperature continues to rise into range (C) , an oscillating tone is heard, the main warning lamp CAUTION lights up yellow, and a message is displayed on the screen (see table 1). If the transmission oil temperature continues to rise further and if the needle of the instrument reaches range (D) , a continuous acoustic warning is sounded. The main warning indicator lights up red. Do NOT use the machine when the temperature has reached this range.

SS11H023

1

SS13A385

2

NOTICE: Attention Instrument range (A). See also 4-10.

Transmission oil temperature display Table

Instrument display 20 °C (68.0 °F) and below

1

Condition Oil temperature very low

Main warning lamp Caution (yellow)

20 - 120 °C (68.0 - 248.0 °F) Oil temperature normal 120.0 - 124.0 °C (248.0 255.2 °F)

Oil temperature above normal

Caution (yellow)

From 125 °C (257.0 °F)

Oil temperature very high

STOP (red)

Display message Low Perf of GR Warming Up Trans Oil Temp Full Perf of Grader allowed * Trans Oil Temp Above Normal Press Return Trans Oil Temp Too High Press Return Limit usage (blinking)

* The display message “Full Perf of Grader allowed” will only appear when the Hydraulic Oil Temperature and the Transmission Oil Temperature are in range.

NOTICE: Do not use the machine when the indicator lamp is lit up red and if the alarm sounds. Stop the machine, shift the transmission into NEUTRAL, and let the engine idle to prevent transmission damage. If this is not sufficient to cool the transmission oil down to operating temperature, check the transmission oil level. Correct the fault before putting the machine back into operation again.

3-67

3 - CONTROLS AND INSTRUMENTS

Hydraulic fluid temperature Hydraulic fluid temperature display (7) When the temperature is in the (A) range, move the hydraulic cylinders until the yellow main warning lamp goes off.

Under normal operating temperature conditions, the instrument needle is in range (B). If the temperature continues to rise into range (C), an oscillating tone is heard, the main warning lamp CAUTION lights up yellow, and a message is displayed on the screen (see table 1). If the temperature continues to rise further and if the needle of the instrument reaches range (D), a continuous acoustic warning is sounded and the main warning lamp STOP lights up red.

SS11H025

1

SS13A378

2

NOTICE: Attention Instrument range (A). See also 4-10.

Hydraulic fluid temperature indication Table

Instrument display 20 °C (68.0 °F) and below 20.0 - 90.0 °C (68.0 194.0 °F) 90.0 - 94.0 °C (194.0 - 201.2 °F) 95.0 °C (203.0 °F) and above

1

Pos. Main warning lamp Condition A Hydraulic fluid temperature Caution (yellow) too low B C

D

Hydraulic fluid temperature normal Hydraulic fluid temperature Caution (yellow) is high Hydraulic fluid temperature STOP (red) is very high

Display message Low Perf of GR Warming up Hyd Oil Temp Full Perf of Grader allowed * Hyd Oil Temp Above Normal Press Return Hyd Oil Temp Too High Press Return Limit usage (blinking)

*

The display message “Full Perf of Grader allowed” will only appear when the Hydraulic Oil Temperature and the Transmission Oil Temperature are in range.

NOTICE: Do not use the machine when the indicator lamp is lit up red and if the alarm sounds. Stop the machine and rectify the fault. Let the engine continue to idle.

3-68

3 - CONTROLS AND INSTRUMENTS

Fuel reserve indicator Fuel reserve indicator (12) This indicator shows the remaining fuel reserve.

SS11H027

1

SS13A379

2

During normal operating conditions, the display is in range (B). When the tank is almost empty, the needle is in range (A) and the main warning lamp lights up YELLOW. The remaining fuel reserve is approximately 18 % of the tank volume (see also 7-26).

NOTICE: Do not run the tank dry.

Fuel reserve indicator Instrument display Lower 18 % From 18 %

Pos. Condition A Fuel reserve low B Fuel reserve normal

Main warning lamp Caution (yellow)

3-69

Display status Lit up

3 - CONTROLS AND INSTRUMENTS

Engine coolant temperature Engine coolant temperature display (14) Under normal operating temperature conditions, the needle of the instrument is in range (B). If the coolant temperature continues to rise into range (C), an oscillating tone is heard, the CAUTION main warning lamp lights up yellow, and a message is displayed on the screen (see table 1). If the temperature continues to rise further and if the needle of the instrument reaches range (D), a continuous acoustic warning is sounded and the main warning lamp STOP lights up red.

SS11H029

1

SS13A380

2

Engine coolant temperature display Table

Instrument display 20 °C (68.0 °F) and below 20 - 105 °C (68.0 221.0 °F) 105.0 - 109.0 °C (221.0 - 228.2 °F) From 110 °C (230.0 °F)

1

Pos. Main warning lamp Condition A Coolant temperature too low B Coolant temperature is normal C Coolant temperature is high Caution (yellow)

D

Coolant temperature is very STOP (red) high

Display message

Eng Cool Temp Above Normal Press Return Eng Cool Temp Too High Press Return Limit usage (blinking)

NOTICE: Do not use the machine when the indicator lamp is lit up red and if the alarm sounds. Stop the machine, shut off engine, and rectify the fault.

3-70

3 - CONTROLS AND INSTRUMENTS

Warning lamps WARNING Avoid injury and/or machine damage!

If the main warning light comes on and the warning system sounds, immediately stop the machine and shut off the engine. Lower the working equipment and follow the instructions on the display to locate the cause of the problem.

Failure to comply could result in death or serious injury.

W1025B

Keep an eye on the warning lamps during driving. As long as none of the warning lamps lights up and no acoustic warning is sounded and if warning lamps (4) or (6) do not indicate any malfunction codes, the grader is working without problems.

SS11H078

1

SS11H079

2

SS11H080

3

Main warning indicator STOP (red) (6) This indicates to the operator there is a serious error and the machine should stop immediately to prevent damage to the machine.

Feature enable: • Key in ON position • Fault recording system active – if one or more active faults are in Red fault list

Main warning indicator (yellow) (4) This indicates to the operator there is a serious error but the machine can continue to operate.

Feature enable: • Key in ON position • Fault recording system active – if one or more active faults are in Yellow fault list • If CAN communication with the engine is lost (i.e. timed out) the lamp alternates between ON/OFF every 100 ms. This has priority over any other warning.

3-71

3 - CONTROLS AND INSTRUMENTS

Selective Catalytic Reduction (SCR) system instrumentation warning Diesel Exhaust Fluid (DEF)/AdBlue® instrumentation warning ATTENTION: The fuel system, exhaust after-treatment system, and engine on your machine are designed and built to government emissions standards. Tampering by dealers, customers, operators, and users is strictly prohibited by law. Failure to comply could result in government fines, rework charges, invalid warranty, legal action, and possible confiscation of the machine until rework to original condition is completed. Engine service and/or repairs must be done by a certified technician only!

Your machine is equipped with a warning system to inform the operator of the DEF/AdBlue® level, system malfunctions, and engine power loss that may result from the SCR system for reducing exhaust emissions.

During normal operation of your machine, the instrument cluster displays the DEF/AdBlue® fluid level (1) at all times.

Warning lights and indicators will be illuminated with a warning on the visual display. The display changes automatically to allow the operator to view the warning indicator and display message.

The DEF/AdBlue® level bar gauge (1) indicates the level of diesel exhaust fluid in the DEF/AdBlue® tank. When all bars are illuminated, the tank is full. Illuminated bars indicate the level of fluid remaining in the DEF/AdBlue® tank. When the tank is at 5 - 10 % of tank volume, the warning system will flash and/or will flash and sound an audible alarm dependent upon DEF/AdBlue® levels.

Gauge indication 6 - 10 % 5 % and below Empty

DEF/AdBlue® level gauge Master indicator Condition No engine power loss Caution (yellow) Moderate engine power Stop (red) loss Severe engine power loss – Stop (red) engine will not shut down

3-72

SS14E234

1

Alarm status None Continuous Continuous

3 - CONTROLS AND INSTRUMENTS

DEF/AdBlue® level displays Mild warning: Level is low

SS14C026

2

SS14C028

3

SS14H032

4

Severe warning: Tank is empty – Power limited

Strong warning: Tank is empty – Extreme Power Limitation

3-73

3 - CONTROLS AND INSTRUMENTS

DEF/AdBlue® quality displays Mild warning: Poor quality detected

SS14H033

5

SS14C033

6

SS14H034

7

Severe warning: Poor quality detected – Power limited

Strong warning: Poor quality detected – Extreme Power Limitation

3-74

3 - CONTROLS AND INSTRUMENTS

SCR failure displays Moderate warning: Injection failed – Power limited

SS14H035

8

SS14C036

9

Severe warning: Injection failed – Power limited

Strong warning: Injection failed – Extreme Power Limitation

SS14H036

3-75

10

3 - CONTROLS AND INSTRUMENTS

DEF/AdBlue® level faults, failures, and engine power loss levels

NHPH14ENG0028HA

3-76

11

3 - CONTROLS AND INSTRUMENTS

DEF/AdBlue® quality faults, failures, and engine power loss levels

NHPH14ENG0031HA

3-77

12

3 - CONTROLS AND INSTRUMENTS

SCR system technical faults, failures, and engine power loss levels

NHPH14ENG0030HA

3-78

13

3 - CONTROLS AND INSTRUMENTS

Resetting the Selective Catalytic Reduction (SCR) system After a failure or warning has been set, the SCR system must perform automatic tests to determine if failures or warnings have been resolved. The system must perform the following actions in order to recognize the resolved failures or warnings and reset itself.

• For DEF/AdBlue® level warnings: • Key switch must be cycled OFF then ON. • For poor DEF/AdBlue® quality warnings: • Machine must be operated for approximately 20 min at a minimum of 50 % load.

• For SCR system warnings, one of the following conditions must occur, depending on the exact cause of the warning: • Requires the machine to be operated for approximately 20 min at a minimum of 50 % load to operate the SCR system.

• Requires starting and running the engine, but does not require the SCR system to operate.

• Requires the key switch to be cycled OFF then ON.

Validation re-starts Validation re-starts allow operation of the machine for up to 30 min without power loss after a poor DEF/AdBlue® level/quality or SCR system fault has been detected. Up to three re-starts are permitted. Re-starts are counted if either of the following conditions are met: • Engine speed exceeds 1000 RPM. • Engine running time exceeds 5 min.

Normal operation will resume if a reset is detected within the 30 min window.

If a reset is not detected within 30 min, power loss will occur as described in the table above.

If all three validation re-starts have been used and the system has not been reset, see your local authorized dealer for repair.

3-79

3 - CONTROLS AND INSTRUMENTS

3-80

4 - OPERATING INSTRUCTIONS

4 - OPERATING INSTRUCTIONS###_4_### Commissioning the unit

Filling the fuel tank NOTE: Read and observe Safety rules and following before filling in fuel.

NOTE: If rear ripper is mounted, close the teeth protection and lower the rear ripper otherwise the engine hood can be damaged.

1. Open and latch the engine hood in the fully open position (see also Engine hood - Advice).

The filler neck is accessible after the engine hood is opened.

SS14F032

1

SS14D031

2

2. Unscrew the cap (3) of the filler neck.

The filler neck is located in the engine compartment.

NOTE: Replace the fuel filler cap, should it become lost or damaged always with one of the same type.

Consult your authorised dealer.

3. Fill fuel.

4-1

4 - OPERATING INSTRUCTIONS

Filling the DEF/AdBlue® tank Requirements The operator must maintain appropriate Diesel Exhaust Fluid (DEF)/AdBlue® levels at all times. No additional maintenance is required.

NOTICE: Prolonged idling of the machine with no load for more than 6 h will cause damage to the SCR catalyst. During periods of extended engine idle, especially in cold ambient conditions, the engine rpm may increase automatically to maintain proper exhaust temperatures.

NOTE: See your CASE CONSTRUCTION dealer for replacement components and cleaning agents.

See 7-8 for details on biodiesel fuel usage in your CASE CONSTRUCTION machine.

NOTICE: While any company can perform necessary maintenance or repairs on your equipment, CASE CONSTRUCTION strongly recommends that you use only authorized CASE CONSTRUCTION dealers and products that meet the given specifications. Improperly or incorrectly performed maintenance and repair voids the equipment warranty and may affect service intervals.

The DEF/AdBlue® tank is located on the left- hand side of the machine, next to the diesel filling port.

The DEF/AdBlue® tank cap (1) can be identified by the “blue” color of the cap. A fitting under the cap prevents the insertion of a diesel fill nozzle.

NOTICE: If any DEF/AdBlue® spills or contacts any surface other than the storage tanks, immediately clean the affected surface with clear water. DEF/AdBlue® will cause corrosion on painted and unpainted metallic surfaces, and may distort some plastic and rubber components.

SS14F033

1

It is recommended that DEF/AdBlue® filling equipment should have a fill nozzle/ pump with the correct length and diameter, triggered by the magnet in the tank filler neck and with overfill flow cut out.

This will ensure that: • The screen in the filler neck will not be damaged.

• Impurities are not entering the DEF/AdBlue® tank. The standardized DEF/AdBlue® nozzle matches the filler neck diameter.

• The DEF/AdBlue® tank is not overfilled, as the DEF/AdBlue® pump will stop when the DEF/AdBlue® tank is full.

• DEF/AdBlue® is not pumped in the fuel tank, as the DEF/AdBlue® nozzle cannot pump when the magnet is not sensed.

NOTICE: If a warning light has been triggered for low or empty DEF/AdBlue®, the system must be reset by cycling the ignition key OFF then ON after refilling the DEF/AdBlue® tank.

NOTICE: Refilling with a funnel is not recommended as this may lead to damage of the screen in the filler neck.

NOTE: The information above has been provided by the International Organization for Standardization (ISO), Document number ISO 22241-4 Diesel engines - NOx reduction agent AUS 32 - Part 4: Refilling interface.

Diesel Exhaust Fluid (DEF)/AdBlue® consumption NOTE: DEF/AdBlue® consumption is highly dependent on engine loads, humidity levels, DEF/AdBlue® fluid concentration, and engine speed. The “typical” consumption is only a guideline to verify proper function of the SCR system. CNH recommends to fill the DEF/AdBlue® tanks at every fuel refilling interval.

Diesel Exhaust Fluid (DEF)/AdBlue® filler cap Replace the DEF/AdBlue® filler cap, should it become lost or damaged always with one of the same type. Consult your authorised dealer.

4-2

4 - OPERATING INSTRUCTIONS

Internal filling neck filter A internal coarse filter is located in the filling neck of the DEF/AdBlue® storage tank. This filter collects large debris from refilling the storage tank and can be removed for cleaning by the customer.

4-3

4 - OPERATING INSTRUCTIONS

Refueling using the refueling station (Option) NOTE: Read and observe Safety rules and following before using the refueling station.

The grader can be equipped with a refueling station as an option.

The refueling station can be used to pump fuel from a bulk storage tank into the fuel tank of the machine.

The refueling station is installed in the middle on the firewall in the engine compartment.

The refueling station includes the intake hose (3), the electrically driven fuel pump (2), and the filler hose to the fuel tank of the grader (1).

SS14E077

1

SS14E204

2

Open and latch the engine hood in the fully open position (see also Engine hood - Advice).

NOTICE: Open the tank cap (3) (see figure 3). Before refueling, the tank cap must be opened to prevent overpressure in the tank. Otherwise the tank and pump could leak.

NOTICE: The pump can be irreparably damaged when allowed to run dry for prolonged periods.

The pump must therefore not be switched on unless it is to be used for refueling.

1. Prevent vehicle from moving.

2. Connect the suction hose to the bulk storage tank.

3. Open the fuel cap.

4. Turn key-switch to position “I”.

5. Don’t start the engine.

6. Battery voltage must be min. 19 V. 7. Press and hold the pushbutton (92) for min. 3 s. The buzzer sounds for 1 s. Release the pushbutton (92).

8. The main warning lamp lights up yellow.

NOTE: If the message “Restart Refuel” appears on the AIC-screen instead the main warning lamp in yellow, proceed as follows: –) Turn the key-switch to position “0”.

–) Repeat the procedure beginning at step 4.

9.

Following message appears on the AIC-screen: ”Please open fuel cap before!”

10. Press Enter = OK or ESC = Exit.

11. If you press OK, then the pump will switch ON. 12. The info screen 1 displays the tank level in %.

4-4

4 - OPERATING INSTRUCTIONS

13. The pump will switch off: • Automatically when the fuel tank is full (≥ 95 %).

• When pressing the pushbutton (92).

• When the key-switch is turned to position “0”.

• When the battery voltage is ≤ 18 V. • If the engine is started.

14. Turn key-switch to position “0”.

15. Disconnect the section hose from the bulk storage tank.

16. Close the tank cap.

SS14D031

NOTICE: The activated fuel pump will be AUTO OFF after a predefined time (Standard are 5 min). AUTO OFF is set up within the Engineering Service Tool. For more information, please contact your authorized dealer or the field service.

4-5

3

4 - OPERATING INSTRUCTIONS

Starting the unit

Before putting the machine into operation Putting into daily operation WARNING Equipment failure could cause accident or injury!

Before operating the machine, check for correct operation of steering, brakes, hydraulic controls, instruments, and safety equipment. Make sure the transmission control lever is in the neutral position.

Make all adjustments before operating the machine.

Failure to comply could result in death or serious injury.

W0204A

Before putting the machine into operation, the following checks must be performed: 1.

Open and latch the engine hood in the fully open position (see also Engine hood - Advice).

2.

Check the level of all fluids in the machine (engine oil, hydraulic fluid, and coolant) and make sure all oils and coolants are suited to the respective operating conditions.

3.

Carry out the daily servicing tasks.

4.

Inspect the machine, look for signs of possible leaks, and check the hoses. Retighten and replace, if needed.

5.

Check the tires for visible damage. Replace or repair as needed. Check the tire inflation pressure and correct it, if necessary (read and observe Safety rules and following).

6.

Clean the steps and handrails. Grease, oil, mud, or ice (in winter) on the steps and handrails may cause accidents. Make sure that steps and handrails are always clean.

7.

Clean the safety signs and replace those that have become illegible.

8.

Make sure that the engine access panels and all doors are closed and locked.

9.

Secure the cab door in completely closed or open position.

10. Remove all obstacles which might reduce your field of vision. Clean the windscreen, the windows, and the rearview mirrors.

11. Make sure no tools or other objects have been left behind on the machine or in the cab.

12. Make sure nobody is under or on the machine. Only the driver is allowed to stay on the machine.

13. Make sure no other persons are within the working range of the machine.

14. Familiarize yourself with the safety measures applied at the place of work.

15. Establish an escape route from the machine (emergency exit through the 2nd door, the hinged windows) in case a cab door is blocked or the machine topples over.

16. Before driving or working in the dark, make sure all lighting and signaling systems are fully operational.

17. Adjust the seat so that you can use the brake pedal without having to move your back off the backrest.

18. Put on the seatbelt and adjust it.

19. Check whether all the instruments on the control panel work properly while the engine is running and after operating temperature has been reached.

20. Check whether the grader control elements are operating perfectly.

21. Check and make certain the DEF/AdBlue® tank is properly filled. Low volume in the tank can cause loss of power and torque. The tank will need to be filled after approximately 1.5 fuel fills. Do not allow the DEF/AdBlue® tank to drop below 10 % volume for the best engine performance.

4-6

4 - OPERATING INSTRUCTIONS

Prior to start the engine WARNING Avoid injury!

Do not operate the machine while under the influence of alcohol or drugs.

Failure to comply could result in death or serious injury.

W0160A

Check the machine visually every day. Pay special attention to conditions that might affect the normal and safe operation of the machine: loose connections, defective hoses, oil leaks, accumulated dust and dirt, loose screws, and damaged or missing parts. Take the required corrective action before putting the machine back in operation.

Starting the engine WARNING Run-over hazard!

When attempting to start the engine, always sit in the operator's seat with the parking brake engaged and all control elements in neutral. Never attempt to start the engine from outside the cab.

Failure to comply could result in death or serious injury.

W1301A

WARNING Toxic gas and asphyxiation hazard!

Diesel exhaust contains dangerous compounds. Never operate the engine in a closed building or area. Proper ventilation is required under all circumstances.

Failure to comply could result in death or serious injury.

W1302A

Before starting the machine, the following points must be checked: 1. Open and latch the engine hood in the fully open position (see also Engine hood - Advice).

2. Check the oil levels in the engine crankcase and in the transmission.

3. Check the Organic Acid Technology (OAT) coolant level.

4. Check the electrolyte level in the batteries (if they are not maintenance-free).

5. Check the fuel system, the cooling system, and the machine surroundings for engine oil leaks.

6. Check the V-belt of the alternator.

7. Check the tires for proper inflation. See also 8-18.

Run-in period Your machine will give you a longer service life and better economic performance if you pay special attention to the engine during the first 100 h of operation.

During this period • Allow the engine to warm up before operating it under load.

• Do not run the engine for prolonged periods at full throttle.

• Do not run the engine in idle for prolonged period of time.

• Check the displays on the instrument panel regularly.

• Check the oil level and the coolant level frequently.

4-7

4 - OPERATING INSTRUCTIONS

Starting the engine WARNING Toxic gas and asphyxiation hazard!

Diesel exhaust contains dangerous compounds. Never operate the engine in a closed building or area. Proper ventilation is required under all circumstances.

Failure to comply could result in death or serious injury.

W1302A

NOTICE: Running the engine at idle for an extended time (6 hours maximum) is not recommended. Damage to the SCR muffler may occur. After an extended time period, operate the machine under load for a minimum of 30 minutes. During periods of extended engine idle, especially in cold ambient conditions, the engine rpm may increase automatically to maintain proper exhaust temperatures.

1. Turn the key switch (73) to position I. All systems with test indicators on the instrument panel are tested. All LEDs (LED = light-emitting diode) light up and a warning tone is heard for 3 s. At the end of this test, all systems return to the normal mode of operation. In the case of an open-circuit condition in the cable between a sensor and the instrument panel, the LED blinks and the warning tone can be heard for 5 s.

SS11H037

1

SS13F258

2

SS14C024

3

2. The warning lamps (1), (2), (8), and (9) go out.

3. Set the gearshift lever (82) to neutral (see also 3-37).

Set the pedal (80) or the lever (83) to low idling position.

4-8

4 - OPERATING INSTRUCTIONS

4. Turn the key in the key-switch (73) to position II. The engine starts.

NOTICE: Do not turn the key switch to position II while the engine is running, since this could damage the starter.

5. Release the key. It returns to position I. Let the cold engine idle for 3 - 5 min at about 1000 RPM before using it under load.

NOTICE: If the main warning lamp (on the front console), see figure 2, blinks in operation and if the acoustic warning system sounds a continuous tone, stop the engine and shut it off to locate and rectify the cause of this problem.

NOTICE: If the warning lamps, see figure 2, do not go out when the engine is running, shut off the engine immediately. Locate and rectify the cause of the malfunction before restarting the engine.

SS11H037

4

SS11H037

5

Engine fails to start If the engine fails to start, turn key-switch (73) to position 0 and repeat the starting procedure.

NOTICE: Never keep the starter switch in the starting position for more than 20 s without interruption.

Wait 2 min between the attempts to start.

NOTICE: The engine cannot be started by towing the machine.

Any attempt to start the engine by towing can cause transmission damage.

4-9

4 - OPERATING INSTRUCTIONS

Warming up the machine Warming up the engine and the powershift transmission Start the engine (see also 4-8).

1. Check that the parking brake is applied.

2. Set the gearshift lever to position N. 3. Start the engine.

4. Let the engine run at about 1000 RPM for 3 - 5 min before operating the engine under load.

5. Increase the engine speed up to 1500 RPM, put in the fourth gear and move off against the brake.

Transmission temperatures below -12 °C (10.4 °F) Warm up the transmission in position N at engine idle until the electronic system enables the transmission.

Transmission temperatures above -12 °C (10.4 °F) In this case, the transmission is enabled by the electronic system.

Warming up the working hydraulics During engine and powershift transmission warm-up, the working hydraulics is brought to operating temperature by retracting and extending all hydraulic cylinders.

Diesel Exhaust Fluid (DEF)/AdBlue® During cold weather conditions, it is normal for the DEF/AdBlue® to freeze inside the tank. Your machine is equipped with an internal tank heater to thaw frozen DEF/AdBlue®. Your machine will still function until the DEF/AdBlue® begins to flow. The SCR system will then function normally, however the DEF/AdBlue® level gauge may not display an accurate level until tank is completely thawed.

NOTICE: Do not use an anti-gelling or freeze point improver in your DEF/AdBlue®. The 32.5 % solution is specifically designed to provide the optimum NOx reduction properties. Any further blending or adjusting of the DEF/AdBlue® mixture will lessen its ability to perform correctly any may cause damage to the SCR components.

4-10

SS11H073

1

4 - OPERATING INSTRUCTIONS

Machine movement start-up NOTE: Prior to machine movement: Adjust the seat (see also 3-9).

Adjust the steering column (see also 3-19).

Fasten the seat belt (see also 3-12).

1. Release the parking brake. See also 3-18.

2. Hold the machine with the service brake.

3. The engine speed must be below 1500 RPM. 4. Set gearshift lever (82) to forward or reverse travel.

Do not use a higher gear for setting off. A higher gear results in an unnecessary increase of fuel consumption and oil temperature in the powershift transmission.

SS14D049

1

SS11K202

2

SS14C050

3

5. Increase the engine speed with pedal (80) to set the machine in motion.

The Info 1 screen displays the engine speed, the traveling speed, the fuel reserve, and the DEF/AdBlue® fluid level.

See also 3-45.

4-11

4 - OPERATING INSTRUCTIONS

Stopping the unit

Stopping the machine 1. Reduce the engine speed.

2. Activate the service brake until the machine has stopped.

3. Set the gearshift lever to neutral.

4. Apply the parking brake.

4-12

4 - OPERATING INSTRUCTIONS

Shut off the engine NOTICE: Do not shut off the engine at full load, but rather let it run at idle for another 3 min to reduce the temperature.

1. Reduce the engine speed.

2. Activate the service brake until the machine has stopped.

3. Set the gearshift lever (82) to neutral.

4. Lower the working equipment to the ground.

SS14C024

1

SS14D051

2

SS11H037

3

5. Apply the parking brake with the switch (87).

6. Turn the key-switch (73) to 0.

The engine is shut off.

7. Withdraw the key.

4-13

4 - OPERATING INSTRUCTIONS

Moving the unit

Foot throttle pedal The engine speed can be adjusted continuously with pedal (80).

SS14E223

1

SS14E223

1

Hand throttle lever With the hand throttle (83), the engine speed can be adjusted to a fixed level.

Hand throttle pushed fully forward = maximum engine speed Hand throttle pushed fully back = idling speed

4-14

4 - OPERATING INSTRUCTIONS

Articulation joint WARNING Unexpected machine movement!

Shut off the engine before removing or installing the articulated joint lock.

Failure to comply could result in death or serious injury.

W1033A

The articulation joint between front and rear frame can be locked mechanically on both sides if the machine is to be driven on public roads or transported on a low-bed trailer.

Locking the articulation joint SS11H074

1

SS11H075

2

1. Position the grader in such a way that the front and the rear frames are in alignment.

2. Shut off the engine.

3. Apply the parking brake.

4. Secure the machine (see also 7-5).

5. Release the retaining rods (see figure 1) from the rear shackle of the rear frame, swing forwards, and attach the retaining rods to the front frame shackle and secure it (see figure 2).

Releasing the articulation joint lock Bring the retaining rods (see figure 2) on both sides of the machine back to initial position (see figure 1).

4-15

4 - OPERATING INSTRUCTIONS

Driving on public roads WARNING Transport hazard!

Observe the local government regulations when driving on public roads.

Failure to comply could result in death or serious injury.

W1019A

NOTE: Read and observe Safety rules and following.

Take the following steps before driving on public roads: 1. Clean the machine to remove dirt.

2. Make sure both axles are equipped with tires of the same size and degree of wear.

3. Lock the articulation joint.

4. Check the brakes, steering, tires, and the lighting system.

5. Switch off the floodlights.

6. Lower the splash-guards on the front wheels.

SS11K286

1

SS14D052

2

SS14D053

3

6. Bring the blade into driving position such that the blade does not protrude over the dotted line. For the purpose of easier adjustment, marking lines (1) have been put on the slewing ring and on the blade.

7. For driving on public roads, the brake-pressure-dependent gearbox cutout function must be off (see also 3-41).

8. Check the wheel lean hydraulic cylinder for proper operation. For checking, move the control lever (72) several times from limit stop to limit stop.

4-16

4 - OPERATING INSTRUCTIONS

With the front grading blade attached: 9. Raise the front grading blade with the control lever (71) to position (10) (see figure 3), until the grading blade position pointer is in alignment with the yellow road travel marking.

SS11K236

4

SS11K197

5

SS11H077

6

SS14D054

7

10. Set the shutoff valve for the dozer cylinder to position (0).

With the rear ripper (1) attached: 11. Bring the teeth (6) into transport position. Lower the teeth protection (2) down on the end of the teeth.

12. Move the rear ripper up against the limit stop using the control lever (64).

4-17

4 - OPERATING INSTRUCTIONS

13. Set the lever (4) on the ripper cylinders (5) to position (B) in order to secure the rear ripper against inadvertent movements.

SS11H212

8

SS14D055

9

14. Finally block all functions of the working equipment.

To do so, turn the two locking knobs (60) and (78) in the opposite direction.

Check that the control levers are locked up.

4-18

4 - OPERATING INSTRUCTIONS

Check during driving During driving keep an eye on • The side and level indication of the moldboard and • The dozer blade level indication when the front grading blade is attached.

If the working equipment is found to be dropping, the blade, front grading blade, or the rear ripper must be brought back to the required transport position with the corresponding control levers.

Downhill driving Friction losses in the transmission produce a braking action in 1st and 2nd gear (permanent brake). Shift into 2nd gear when descending a slope with slight to medium gradient and into 1st gear for steeper gradients.

Reduced engine speed results in better braking action, but also in higher oil temperatures in the powershift transmission.

Depressing the accelerator by an appropriate amount permits optimal braking efficiency with acceptable oil temperatures.

Under these circumstances, the service brake needs to be operated only from time to time to maintain the desired road speed.

4-19

4 - OPERATING INSTRUCTIONS

4-20

5 - TRANSPORT OPERATIONS

5 - TRANSPORT OPERATIONS###_5_### Preparing for road transport

Transporting the machine WARNING Avoid injury!

Know all rules, regulations, laws, and required safety equipment for transporting or operating this machine on a road or highway. See your dealer to obtain a rotating beacon, backup alarm, and other safety equipment.

Failure to comply could result in death or serious injury.

W1063A

WARNING Avoid injury!

Remove oil, grease, soil, mud, snow, ice, and other materials from the machine wheels as well as ramps and loading platforms on the transport vehicle.

Failure to comply could result in death or serious injury.

W1055A

NOTICE: The responsibility for securing the load in commercial goods transport lies with the: 1. Forwarder 2. Owner of the vehicle 3. Driver 4. Sender Familiarize yourself with all applicable laws and regulations of the country concerned. Make sure the tractor vehicle, the low-bed trailer, and the machine itself are equipped with the prescribed safety devices.

1.

Place chocks in front of and behind the wheels of the low-bed trailer.

2.

Lock the articulation joint.

3.

Drive the machine slowly and carefully onto the lowbed trailer.

4.

Lower the working equipment to the low-bed trailer platform.

5.

Apply the parking brake.

6.

Shut off the engine.

7.

Withdraw the ignition key.

8.

Close the stopcock (if the ripper is installed).

9.

Set the gearshift lever (82) to position N.

SS14C127

1

SS14D049

2

10. Fasten the machine on the low-bed trailer with appropriate lashing materials at the tie-down points (see figures 3, 4, and 5) provided for this purpose.

11. Measure the height of the machine between the highest machine part and the ground. The low-bed trailer must be set for “road transport”.

NOTICE: Unlock the articulation joint lock before unloading the machine.

5-1

5 - TRANSPORT OPERATIONS

Tie-down point at the rear

SS11H214

3

SS11H084

4

SS11H085

5

Tie-down point in the middle

Tie down point in front

5-2

5 - TRANSPORT OPERATIONS

Crane loading DANGER Heavy objects!

Lift and handle all heavy components using lifting equipment with adequate capacity.

Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.

Failure to comply will result in death or serious injury.

D0076A

NOTICE: Lock the articulation joint if the machine is to be loaded with a crane.

SS14C128

1

SS14C129

2

Loading by crane requires a lifting tackle.

The lifting gear fastening points are indicated by marks on the machine.

Make sure the fastening ropes between traverse and machine are perpendicular.

5-3

5 - TRANSPORT OPERATIONS

5-4

6 - WORKING OPERATIONS

6 - WORKING OPERATIONS###_6_### General information

Grader use NOTE: Read and observe Safety rules and following.

The flexibility of the grader and the diversity of materials that can be handled open up many possible applications and working methods for the machine.

We therefore recommend that the driver attend an instruction course given by an authorized dealer.

NOTICE: Do not exceed the admissible inclination limits of the machine in longitudinal and transverse direction.

That reduces or interrupts the lubrication of the engine.

The admissible engine inclination angles are: Transverse inclination: left = 35 °, right = 35 ° Longitudinal inclination: downwards = 35 °, upwards = 35 °

6-1

6 - WORKING OPERATIONS

Working attachments

Working attachments The positions of the working attachments are adjusted hydraulically by means of the hydraulic components.

SS14C130

Pos. 1 2 3 4 5 6

Designation Wheel lean cylinder Moldboard extend cylinder Hydraulic motor of blade rotation mechanism Moldboard swing cylinder Saddle lock pin cylinder Blade-lifting cylinder, right

1

Pos. 7 8 9 10 11

6-2

Designation Blade-lifting cylinder, left Pitch adjustment cylinder Articulated-frame-steering cylinder Rear ripper cylinder (option) Dozer blade cylinder (option)

6 - WORKING OPERATIONS

Control levers for working attachments

1

SS14D056

Designation Control lever 61 Blade pitch adjustment

Position 5 6

Function Blade pitch steeper Blade pitch flatter

62

Blade slewing

3 4

Blade slewing to the right Blade slewing to the left

63

Extend blade

1 2

Blade extending to the right Blade extending to the left

64

Rear ripper (Option)

7 8

Lower rear ripper Raise rear ripper

66

Articulated joint

17 18

Articulated joint to the left Articulated joint to the right

71

Dozer blade (Option)

9 10

Lower dozer blade Raise dozer blade

6-3

Symbol

6 - WORKING OPERATIONS

Designation Control lever 72 Wheel lean

Position 19 20

Function Wheel lean to the left Wheel lean to the right

74

Swivel blade

11 12

Swivel blade out to the right Swivel blade out to the left

75

Raise blade – lower right

15 16

Lower right blade side Raise right blade side

76

Raise blade – lower left

13 14

Lower left blade side Raise left blade side

6-4

Symbol

6 - WORKING OPERATIONS

Increasing the working speed Depress button (105). As long as button (105) is kept depressed, the respective attachments work at a higher speed.

SS11H089

The working speed of the attachments can be increased by switching to a fast gear.

The fast gear function achieves its full effect only at higher engine speeds.

Blades WARNING Avoid injury and/or machine damage!

Before rotating the blade, make sure no bystanders are in the operating area. While rotating, make sure the blade does not hit the chassis, wheels, or track rods.

Failure to comply could result in death or serious injury.

W1057A

NOTE: For a description of the different levers for the blade see also 6-3.

The blade: • Has good ground clearance.

• Can be extended far out to both sides.

• Can be rotated continuously through 360 °.

• Has an adjustable pitch.

• See the control layout for a description of the functions.

6-5

1

6 - WORKING OPERATIONS

Swivel arm adjustment Swivel arm lock The swivel arm for the drawbar can be moved to five different positions and locked there.

The locking pin is disengaged hydraulically and locked by spring force.

SS11H090

1

SS11H091

2

SS11H092

3

SS14D058

4

Disengaging the swivel arm lock: 1. Let the blade sink to the ground.

2. Depress button (104) and hold. The locking pin is disengaged by means of a hydraulic cylinder.

Engaging the swivel arm lock: 1. Release button (104) shortly before reaching the desired swivel arm position. The locking pin engages by spring force in the corresponding detent.

Re-adjusting the swivel arm The swivel arm is locked in position (4) when the blade is in horizontal position.

Re-adjusting the swivel arm to the right: 1. Completely retract the blade swivel cylinder with the control lever (74). Then set the blade with the control levers (75) and (76) on the ground to relieve the hydraulic system.

Disengaging the swivel arm lock: 2. Depress button (104) (see figure 2) and hold; the locking pin disengages from the swivel arm.

3. Put the swivel arm into the desired position (1), (2), or (3) with the control levers (74), (75), and (76). Release button (104) (see figure 2) shortly before reaching the desired position. The locking pin engages by spring force.

6-6

6 - WORKING OPERATIONS

Re-adjusting the swivel arm to the left 1. Completely extract the blade swivel cylinder with the control lever (74). Then set the blade with the control levers (75) and (76) on the ground to relieve the hydraulic system.

Disengaging the swivel arm lock: 2. Depress button (104) (see figure 2) and hold. The locking pin disengages from the swivel arm.

3. Put the swivel arm into position (5) using the control levers (74), (75), and (76).

4. Release button (104) (see figure 2) shortly before reaching position (5). The locking pin engages by spring force.

6-7

SS14D059

5

6 - WORKING OPERATIONS

Wheel lean Model 836C/836C AWD 856C/856C AWD

A ± 14 ° 24 ' ± 12 °

The wheel lean can be hydraulically adjusted with the control lever (72) (see figure 2): Position (19) (see figure 2) = adjust wheel lean to the left Position (20) (see figure 2) = adjust wheel lean to the right

SS12N499

1

SS14D062

2

The wheel lean adjustment: • Reduces the machine’s turning circle • Compensates lateral thrust during scraping • Gives better grip on the ground If the wheel lean is adjusted when the steering is at either of the limit stops, the steering wheel turns back by a slight amount.

6-8

6 - WORKING OPERATIONS

Floating position (option) The grader can be supplied with a floating position function as an option. This floating position makes it easier to work with the machine when, for instance, the machine is used as a snow-plow with main blade following the irregularities of the ground in the floating position.

NOTICE: Never switch the machine to the floating position mode with the working equipment in a raised position, since this can cause the working equipment to drop too quickly.

NOTICE: Activate the floating position only if the tilting arm is locked in horizontal position and if the blade is in horizontal position. Disregarding this warning results in breakage of the blade-swiveling cylinders.

NOTICE: Set the main blade firmly on the ground.

Press button (38) – the floating position is activated.

Press switch (107) – the main blade is free to move over the ground, loaded only by its own weight.

Press switch (107) once again – the floating position is canceled.

Press button (38) – the floating position is deactivated.

6-9

SS14C117

1

SS14H040

2

6 - WORKING OPERATIONS

Dozer blade (option) The front grading blade is raised and lowered with the control lever (71).

Position (9) = lower the front grading blade Position (10) = raise the front grading blade

SS14D064

1

SS11K197

2

SS11K235

3

The shut-off valve must be open, i.e., the lever must be in position (1).

The position of the front grading blade is indicated visually.

Position (1) = blade completely raised Position (2) = for road travel (yellow) Position (3) = blade resting on the ground Position (4) = maximum scraping depth

6-10

6 - WORKING OPERATIONS

Rear ripper (option) NOTE: Read and observe Safety rules and following.

The rear ripper is equipped with up to five ripper teeth and can be used for heavy-duty ripping work.

Rear ripper, working position NOTICE: Use the ripping teeth only in symmetrical arrangement.

NOTICE: Before lowering the rear ripper, set the ballcock (4) (see figure 6) to position (A).

1. Tilt the teeth protection (2) backwards (see figure 3).

It is held in this position by springs.

SS11H108

1

SS14H039

2

SS11H109

3

2. Withdraw the cotter pins (4) and remove the retaining pin (3).

6-11

6 - WORKING OPERATIONS

3. Move a tooth into working position (see figure 4) and fasten with the retaining pin (3). Secure the retaining pin with the cotter pin (4) (see figure 3) and the safety ring (5) (see figure 3).

SS11K205

4

SS14D065

5

SS11H076

6

Rear ripper, working operation NOTICE: Pull the ripper out of the soil before turning or before reversing the grader.

The rear ripper is controlled with the control lever (64).

• To lower the rear ripper – set the control lever (64) to position (7).

• To raise the rear ripper – set the control lever (64) to position (8).

The number of teeth used, the ripping depth, and the driving speed depend on the nature of the material to be loosened.

For ripping, set off with the grader pressing the ripper into the ground.

Rear ripper, road travel The position of the rear ripper is adjusted with the control lever (64) (see figure 5). Raise the rear ripper up to the limit stop to reach the transport position.

1. Set the lever (4) on the rear ripper cylinders to position (B).

2. Bring the teeth back into transport position as described under “Rear ripper, working position” by proceeding in reverse order.

3. Lower the teeth protection (2) (see figure 1).

6-12

6 - WORKING OPERATIONS

Moldboard ripper (option) NOTE: Read and observe Safety rules and following.

Blade ripper, working position For ripping, optional teeth (3) can be brought into ripping position.

Model 836C/836C AWD 856C/856C AWD

Teeth 4 6

Turning the slewing rim by 180 ° permits carrying out ripping work in forwards and reverse direction.

1. Withdraw the cotter pin (1).

2. Remove the spacer (2).

SS13A386

3. Slide ripper teeth (3) outwards over the retaining bar (4), lower and place them into the guiding grooves (5).

4. Refit the spacer (2) and secure with cotter pin (1).

Blade ripper, working operation Set off with the machine pressing the blade ripper into the soil by extending the lifting cylinders.

The number of teeth used, the ripping depth, and the driving speed depend on the nature of the material to be loosened.

6-13

1

6 - WORKING OPERATIONS

Emergency lowering of the working equipment WARNING Crushing hazard!

Before starting the emergency lowering operation, make sure that no persons are present around the blade.

Failure to comply could result in death or serious injury.

W1303C

The machine must be equipped with a means permitting to lower or to raise the working equipment even in the event of engine or control system failure.

Emergency lowering of the blade In an emergency, the blade can be lowered by the valves (3) and (4) installed on the blade lifting cylinders (1) and (2).

SS14C131

1

SS13A868

2

SS13A867

3

Lower the left-hand side of the blade To lower the blade, loosen the lock nut (10) and turn out the setscrew (11) with the Allen key (included in the tool kit).

Lower the right-hand side of the blade For lowering the blade, loosen the lock nut (12) and turn out the setscrew (13) with the Allen key (included in the tool kit).

Emergency lowering of the blade out of floating position In an emergency, the blade can be lowered by actuating the valves (3) and (4) (see figure 1) installed on the bladelifting cylinders (1) and (2) (see figure 1).

6-14

6 - WORKING OPERATIONS

Lower the left-hand side of the blade The left side of the blade is lowered by the valve (3) (see figure 1) on the left-hand blade-lifting cylinder (2).

SS11H101

4

SS11H102

5

SS11H103

6

SS14D054

7

For lowering, unscrew the protective cap (5) (see figure 4).

When doing this, hold the solenoid body (6) (see figure 4) in its place. Lower the blade by pulling the red valve shaft (7).

Lower the right-hand side of the blade The right side of the blade is lowered by the valve (4) (see figure 1) on the right-hand blade-lifting cylinder (1) .

For lowering, unscrew the protective cap (9). When doing this, hold the solenoid body in its place. Lower the blade by pulling the red valve shaft (7) (see figure 5).

Emergency lowering of front grading blade/ rear ripper In machines equipped with a front grading blade and/or a rear ripper, these attachments can be lowered in an emergency with the control levers (71) or (64).

6-15

6 - WORKING OPERATIONS

After daily use

After daily use 1. Park the machine on firm, level ground.

2. Place all attachments on a jig or on the ground.

If the machine has to be parked on a slope: 3. Park the machine facing downhill and press the equipment into the ground.

NOTICE: To prevent damage to the cylinders, set the working equipment slowly down on the ground.

NOTICE: Do not shut off the engine out of full load, but rather let it run at idle for another 3 - 5 min to reduce the temperature.

4. Shut off the engine.

5. Apply the parking brake.

6. Turn the key switch of the electrical system to position I (ignition ON).

7. Move the control levers in all directions to depressurize the hydraulic cylinders.

8. Set the control and gearshift levers to neutral (N).

NOTICE: Wait 20 s after ignition shutoff before withdrawing the key from the key-switch to prevent loss of data in the electronic system.

9.

Turn the key switch of the electrical system to position 0 (ignition OFF) and remove the key.

10. Close the cab window.

11. Prior to exiting cab, block all functions of the working equipment via the two locking knobs (see also 4-16 and following).

12. Secure the machine by placing chocks under the wheels (Wheel chocks are supplied with the machine only in the on road version.).

13. Clean the machine to remove dirt.

14. Refill the fuel tank.

15. Visually inspect the engine, hydraulic system, axles, and transmissions for leaks.

NOTICE: Escaping oil pollutes the environment.

Repair leaks (or have them repaired) immediately.

Oil accidents must be reported to the owner of the machine.

15. Lock up the cab door and all key-equipped flaps and shrouds of the machine.

16. Check the machine and the working equipment for damage and all structural steel components for cracks or fractures.

If you find any damage: 17. Report any damage immediately to the owner.

6-16

7 - MAINTENANCE

7 - MAINTENANCE###_7_### General information

Instructions WARNING Improper operation or service of this machine can result in an accident.

Read and understand the SAFETY INFORMATION Section before you perform any maintenance, service, or repairs. Read and understand the specific service procedures for the components you plan to work with before you start servicing the machine.

Failure to comply could result in death or serious injury.

W0138A

WARNING Personal Protective Equipment (PPE) required.

When assembling, operating, or servicing the machine, wear protective clothing and PPE necessary for the particular procedure. Some PPE that may be necessary includes protective shoes, eye and/or face protection, hard hat, heavy gloves, filter mask, and hearing protection.

Failure to comply could result in death or serious injury.

W0353A

CAUTION Burn hazard!

Wait for all components to cool before performing any operation.

Failure to comply could result in minor or moderate injury.

C0053A

This section gives full details of the service procedures necessary to maintain your machine at peak efficiency.

NOTICE: Clearly mark the connectors before unplugging.

Clean the pipe and the connector before disassembly.

Presence of DEF/AdBlue® crystallization on the pipe or on the cover of the filter is not allowed.

DEF/AdBlue® crystallization has to be removed with water and a brush.

Usage of hammer or pliers are not allowed for the disassembly of the connector.

Follow the maintenance intervals by checking the hour meter every day. Before starting maintenance, park the machine on flat, firm ground, away from any obstacles, with the attachment on the ground. Keep all unauthorized personnel clear of the area. Unless otherwise specified, all maintenance operations should be carried out with: • the engine stopped • the machine parked on a firm, level surface • the transport/service link locked into position to stop the machine from unexpected articulation • the parking brake engaged • the key removed from the key switch • a "DO NOT OPERATE" tag on the key switch • wheel chocks blocking the wheels • all circuits cooled down prior to starting work • all hydraulic pressure released • any accumulator pressure released for the appropriate circuit Clean the grease fittings before lubrication. Clean around plugs and filler holes before adding fluid. No dust or dirt may enter the components or the circuits. Wear suitable clothing and remember to use the necessary safety equipment.

When performing service work on the machine, place a Do Not Operate tag on the instrument panel or key switch.

Turn off engine and remove key before leaving operator's compartment.

7-1

7 - MAINTENANCE

Any modification to this machine without prior authorization could cause serious injury. Do not make any modifications without authorization. Consult your dealer.

The service intervals in this chapter refer to normal operating conditions.

NOTICE: Take particular care to replace all filters regularly. Clean filters mean longer engine running life.

NOTICE: Oils and fluids must be disposed of properly.

Safety precautions NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

Disassembly, decommissioning, or scrapping the machine When the machine is taken out of service because it is damaged beyond repair or has reached the end of its useful life, disassembly, scrapping and/or recycling of components, fluids, etc. must be performed only by a qualified technician using service instructions and in compliance with local laws and regulations.

Preventing system contamination To prevent contamination when changing oils, filters, etc., always clean the area around filler caps, level and drain plugs, dipsticks, and filters prior to removal. Before connecting remote cylinders, ensure that oil contained within them is clean, has not degenerated due to long storage, and is of the correct grade.

To prevent dirt entry during greasing, wipe dirt from the grease fittings before greasing. Wipe excess grease from the fitting after greasing.

Flexibility of maintenance intervals The intervals listed in the lubrication and maintenance chart are guidelines to be used when operating in normal working conditions.

Adjust the intervals for environmental and working conditions. Intervals should be shortened under adverse (wet, muddy, sandy, extremely dusty) working conditions.

Lubrication and maintenance chart On page 7-36 and following you can find a list with the intervals when routine checks, lubrication, service, and/or adjustments should be performed. Use the chart as a quick-reference guide when servicing the machine. The operations follow the chart.

Warranty One of the preconditions for warranty is that the following compulsory servicing work has been performed by your authorized dealer or authorized workshop: 1. Compulsory servicing at 250 operating hours after commissioning.

2. Compulsory servicing at 500 operating hours after commissioning.

The proper execution of the compulsory servicing works must be documented on the service checklists.

7-2

7 - MAINTENANCE

Engine oil changing The intervals for engine oil change are valid for fuels with a sulphur content of <= 0,5 % and a permanent ambient temperature down to -10 °C (14.0 °F).

Shorter intervals must be observed for higher sulphur contents and/or permanent ambient temperatures below -10 °C (14.0 °F) (see engine operating manual).

If the engine oil change intervals are not reached within one year, the oil must be changed at least once a year.

Organic Acid Technology (OAT) coolant change If the coolant change intervals are not reached within four years, the coolant must be changed at least every four years.

Oils/Greases The specification of the oils and greases to be used are set out under 7-16.

Regular oil analyses Oil change intervals can be prolonged and wear of components detected at an early stage if regular oil analyses is performed.

Servicing material The servicing material required for regular servicing tasks is summarized in the spare parts list.

Further servicing tasks Optional equipment may require the supplementary inspections and servicing tasks prescribed by the manufacturer of the respective equipment. They can then be found under the corresponding keyword in the table of contents or in an appended brochure.

Do not operate tag Before you start servicing the machine, attach a “Do Not Operate” warning tag to the machine in an area that will be visible.

7-3

7 - MAINTENANCE

Torque charts Use the torques in this chart when special torques are not given. These torques apply to plain and zinc-dichromate fasteners as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphite lubricants, Molydisulfide greases, or other extreme pressure lubricants are used. A torque range of ± 10 % is acceptable.

Grade 8.8 bolts, nuts, and studs Size 4 mm 5 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 18 mm 20 mm 22 mm 24 mm 27 mm 30 mm 36 mm

Nm 4 N·m 7 N·m 12 N·m 29 N·m 57 N·m 100 N·m 159 N·m 248 N·m 352 N·m 500 N·m 681 N·m 865 N·m 1262 N·m 1719 N·m 2999 N·m

lb ft 3 lb ft 5 lb ft 9 lb ft 21 lb ft 42 lb ft 74 lb ft 117 lb ft 183 lb ft 260 lb ft 369 lb ft 502 lb ft 638 lb ft 931 lb ft 1268 lb ft 2212 lb ft

Markings for Grade 8.8 hardware

Grade 10.9 bolts, nuts and studs Size 4 mm 5 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 18 mm 20 mm 22 mm 24 mm 27 mm 30 mm 36 mm

Nm 5 N·m 10 N·m 17 N·m 41 N·m 82 N·m 143 N·m 227 N·m 354 N·m 487 N·m 690 N·m 942 N·m 1195 N·m 1749 N·m 2377 N·m 4149 N·m

lb ft 4 lb ft 7 lb ft 13 lb ft 31 lb ft 60 lb ft 105 lb ft 168 lb ft 261 lb ft 359 lb ft 509 lb ft 695 lb ft 882 lb ft 1290 lb ft 1753 lb ft 3061 lb ft

Markings for Grade 10.9 hardware

Grade 12.9 bolts, nuts, and studs Torque values specified for grade 10.9 hardware can be used for grade 12.9 hardware.

Markings for Grade 12.9 hardware

7-4

7 - MAINTENANCE

Securing the machine WARNING Avoid injury and/or machine damage!

Secure the machine so that unauthorized persons cannot start it.

Failure to comply could result in death or serious injury.

W1045B

WARNING Crushing hazard!

Always use approved attachments. Make sure the attachment is compatible with the machine mounting system.

Failure to comply could result in death or serious injury.

W0183A

NOTICE: The machine can be fitted with a variety of working equipment. The working equipment components are assembled with hydraulic cylinders and connectors. The components can be combined in a variety of ways so that the working equipment can be best adapted to the specific task.

NOTICE: Only install and operate equipment from other manufacturers which falls under 2006/42/EC if the following are available: - Manufacturer’s declaration of conformity - Declaration of compatibility for the machine NOTE: Read and observe Safety rules and following.

Secure the machine as described below: • Before carrying out any service or repair work on the machine.

• Before fitting or changing the working equipment.

Securing the machine: 1. Park the machine on firm and level ground.

2. Lower the working equipment to the ground.

3. Apply the parking brake.

NOTICE: Do not shut off the engine out of full load, but rather let it run at idle for another 3 - 5 min to reduce the temperature.

4. Shut off the engine.

NOTICE: Wait 20 s after ignition shutoff before withdrawing the key from the key-switch to prevent loss of data in the electronic system.

5.

Withdraw the key from the key switch of the electrical system.

6.

Prior to exiting cab, block all functions of the working equipment via the two locking knobs (see also 4-16 and following).

7.

Secure the machine from rolling away by placing chocks under the wheels.

8.

Depressurize the hydraulic system (see also 7-130).

9.

Lock the articulation joint.

10. Fully open and latch hood (see also Engine hood - Advice).

11. Disconnect the batteries before working on the electrical system.

12. When doing welding work on the machine, pay special attention to the section “Welding operations”, see also Safety rules and following.

7-5

7 - MAINTENANCE

Engine hood WARNING Heavy parts!

Keep your hands and body and all personnel clear of the machine hood as it closes.

Failure to comply could result in death or serious injury.

W1068A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

Opening the engine hood NOTE: If rear ripper is mounted, close the teeth protection and lower the rear ripper otherwise the engine hood can be damaged.

The engine hood has 2 opening positions: the first is a safety detent and the second is the service position. The closed engine hood can be unlocked from the driver’s cab by means of the locking handle (101).

SS14J017

1

SS14D067

2

SS14D068

3

Position 1: Safety detent To open the engine hood to position 1, pull locking handle (101) (see figure 1) upwards. The engine hood is released to detent position.

NOTE: The handles on the hood are intended to open and close the hood and should not be used for service activities. Open the hood completely, to the service position prior to performing activities within the engine compartment.

Service position WARNING Impact and crushing hazard!

Before performing any maintenance, park the machine on a firm, level surface. Lower the bucket or attachment to the ground. Relieve all hydraulic pressure. Place the service link in the locked position to prevent unexpected machine articulation. Keep the area clear of unauthorized bystanders.

Failure to comply could result in death or serious injury.

W1304A

Open engine hood further out of service position until the safety latch (see figure 4) engages in the lock position.

Verify that the safety latch has engaged by pulling down on the hood handle.

7-6

7 - MAINTENANCE

Closing the engine hood 1. Push the engine hood slightly in the direction against the arrow (see figure 3).

2. Hold the hood and with your foot press down on the safety latch to release. Pull the hood down into the detent position. Press the hood down to close and engage hood latch.

NOTICE: save the hood latch from pressurized water because may strip lubrication from the latch. Once the temperature drops to 0 °C, freezing becomes a problem.

Parts of hood latch should be kept lubricated.

SS14E247

4

LEIL15GRD0111AB

7-7

5

7 - MAINTENANCE

Biodiesel - Biodiesel fuels Biodiesel usage in CASE CONSTRUCTION products Introduction to Fatty Acid Methyl Ester (FAME) biodiesel FAME biodiesel, called biodiesel fuel in the following section, consists of a family of fuels derived from vegetable oils treated with methyl esters.

There are two main biodiesel fuel types: Rapeseed Methyl Ester (RME) and Soybean Methyl Ester (SME).

RME is a blend of rapeseed and sunflower methyl ester, and is the preferred crop in Europe. SME is the preferred crop in the United States.

Biodiesel fuel is a renewable alternative fuel source. Its use and development is promoted worldwide, especially in Europe and in the United States.

NOTICE: Your emissions control system is compatible with up to 7 % biodiesel fuel (B7). Be aware that the use of biodiesel fuel that does not comply with the standards mentioned in this section could lead to severe damage to the engine, fuel system or aftertreatment system of your machine. The use of non-approved fuels may void CASE CONSTRUCTION Warranty coverage.

Biodiesel can be used to run Tier 4b diesel engines only when blended with standard diesel fuel: • B7: indicates the blend of 7 % biodiesel and 93 % diesel fuels.

• B20: indicates the blend of 20 % biodiesel and 80 % diesel fuels. Do not use.

Biodiesel fuel has several positive features in comparison with diesel fuel: • Biodiesel adds lubricity to the fuel, which is beneficial in many circumstances, particularly as sulfur and aromatics are removed from the fuel.

• Biodiesel has a greater cetane number and burns cleaner.

allowed to use up to 7 % biodiesel fuel (B7) to supply the network.

Pure biodiesel blend stock (B100) specification is covered by the following requirements: • Europe: EN14214 - Automotive fuels. Fatty Acid Methyl Ester (FAME) for diesel engines. Requirements and test methods.

• DIN V 51606 - German standard for biodiesel.

Before raw oil can be converted into usable biodiesel fuel, it must undergo transesterification to remove glycerides. During the transesterification process, the oil reacts with an alcohol to separate the glycerine from the fat or vegetable oil. This process leaves behind two products: methyl ester (the chemical name for biodiesel) and glycerine (a byproduct usually sold for use in soaps or other products).

NOTICE: Biodiesel fuels approved for use in the CASE CONSTRUCTION equipment must be transesterified and comply with the European Standard EN14214 or the German standard DIN V 51606.

NOTICE: Cold Pressed Biodiesel, Cold Pressed Oil, Straight Vegetable Oil (SVO), or more generally unrefined vegetable oils used as motor fuel, are fuels that are normally made from Rapeseed oil or similar high oil content crops. These kinds of fuel are not transesterified, so they do not fulfil the EN14214 requirements. There is no recognized quality standard available for these types of fuel. Therefore the use of Cold Pressed Biodiesel, Cold Pressed Oil, Straight Vegetable Oil (SVO), or more generally unrefined vegetable oils used as motor fuel are NOT APPROVED at any blend in any CASE CONSTRUCTION product.

NOTICE: Any engine and fuel injection equipment fitted to a CASE CONSTRUCTION vehicle found to have run with any blend of NON-APPROVED fuel (fuel not fulfilling the specification described in the requirement EN14214) will no longer be covered for Warranty by CASE CONSTRUCTION.

• Biodiesel produces less particulate matter and reduces smoke emissions.

Biodiesel fuel usage conditions

• Biodiesel is fully biodegradable and non-toxic.

You must stringently follow the biodiesel fuel usage conditions. Incorrect application of the biodiesel fuel usage conditions could lead to severe damage to the engine, fuel injection equipment and aftertreatment system.

Diesel and biodiesel fuel specifications Tier 4b diesel fuel specifications are covered by the following:

The main concerns related to operation with biodiesel fuels are:

• EN 590 - Specification of Diesel fuel. (10 ppm sulfur maximum.)

Biodiesel blends are covered by: • European Diesel Fuel Specification EN 590 allows up to 7 % biodiesel since 2009. European fuel suppliers are

• Filters and injector blockage caused by poor fuel quality.

• Wear and corrosion of internal components due to water content, which affects lubricity.

• Deterioration of some rubber sealing compounds in the fuel system.

7-8

7 - MAINTENANCE

• Biodiesel oxidation, which can lead to the formation of deposits that can harm the fuel injection system.

NOTICE: Any problem in the engine fuel injection equipment associated with non-compliance to the following conditions for biodiesel fuel handling and maintenance will not be covered for Warranty by CASE CONSTRUCTION. Purchase biodiesel fuel from a trusted supplier who understands the product and maintains acceptable fuel quality.

The use of biodiesel blends up to B7 will not void the CASE CONSTRUCTION warranty as long as the following conditions for biodiesel fuel handling and maintenance are stringently followed: Biodiesel fuel must be pre-blended by the supplier. Mixing biodiesel fuels on-site can result in an incorrect mixture that could damage the engine and/or fuel system.

NOTICE: CASE CONSTRUCTION may void your warranty if the problem is associated with poor fuel quality due to improper blending. It is the responsibility of the fuel supplier and/or yourself to ensure the right type of fuel and blend is delivered and used.

Storage The machine should not be stored for more than 6 months with biodiesel in the fuel system. For longer storage time, it is strongly suggested that only regular EN 590 or #2 diesel fuel is used.

NOTE: If storage for longer than 6 months is necessary, the engine must be run on regular EN 590 or #2 diesel for a minimum of 20 hours to flush the biodiesel fuel out of the fuel system prior to storage.

Biodiesel is highly hygroscopic and tends to collect water more than diesel fuel. This increases the risk of algae and bacteria growth which can cause severe damage to the fuel injection system. Keep the machine fuel tanks and on-site storage tanks as full as possible to limit the amount of air and water vapors inside the tank. Drain water from the tanks at least once a week.

NOTICE: Use only CASE CONSTRUCTION approved biocide additives on Tier 4b engines with an exhaust aftertreatment system.

7-9

7 - MAINTENANCE

Lubrication plan - Front axle, Tandem axle

SS14J016

7-10

1

7 - MAINTENANCE

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

NOTE: If the machine is equipped with a lubrication system (option), then all lubricating nipples are connected by lubrication lines to the lubrication system. The illustration and the table only provide an overview about which bearing points are lubricated.

Pos. 1 2 3 4 5 6 7 8

Lubricating points 2 2 2 2 2 2 2 2

Steering cylinder Axle bearing Wheel lean cylinder bearing Wheel lean bar Wheel lean joint Wheel-hub carrier Wheel-hub carrier bolt Tandem/differential gear assembly

For correct oils see also 7-16.

7-11

Quantity x1 x1 x1 x1 x1 x1 x1 x2

7 - MAINTENANCE

Lubrication plan - Moldboard, Articulation frame

SS14K160

7-12

1

7 - MAINTENANCE

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

NOTE: If the machine is equipped with a lubrication system (option), then all lubricating nipples are connected by lubrication lines to the lubrication system. The illustration and the table only provide an overview about which bearing points are lubricated.

Pos. Lubricating points 9 Articulation frame steering cylinders 10 Saddle lock pin 11 Moldboard swing arm bearing

12 13 14 15 16 17 18 19

Moldboard swing cylinder bearing Articulation joint Blade-lifting cylinder bearing Blade-lifting cylinder mount Pitch adjustment cylinder bearing Blade-slewing ring Pitch adjuster bearing Rotary oil feed rotor

For correct oils see also 7-16.

7-13

Quantity 2x2 1 2 (836C/ 836C AWD) 3 (856C/ 856C AWD) 4 2x1 2x3 2x1 2 3 2x1 1

7 - MAINTENANCE

Inspection plan

SS14H049

7-14

1

7 - MAINTENANCE

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

Pos.

1 2 3 4 5 6

Lubricant property¹)

Component

Engine Hydraulic system Powershift transmission Differential gear on rear axle Tandem box on rear axle Blade slewing gear

I II III IV A IV B IV C

For correct oils see also 7-16.

7-15

Check oil level every ...OH 10 50 50 250 250 50

Change oil every ...OH 500 3000 1000 2000 1000 1000

7 - MAINTENANCE

Consumables I. Oils for internal combustion engines (change interval 500 OH) Standard

(H) (H)

0W-40 CJ-4 UNITEK to CNH MAT3521 API CJ-4 0W-40* (H)

5W-30 ACEA E6 (H) (H)

10W-40 CJ-4 UNITEK to CNH MAT3521 API CJ-4 10W-40* (H) (H)

-40 °C -40 °F

-30 °C -22 °F

-20 °C -4 °F

-10 °C 14 °F

15W-40 CJ-4 to CNH MAT3522* API CJ-4 15W-40* 0 °C 32 °F

10 °C 50 °F

(H) Engine oil pan or coolant block heater recommended in this range * Requires a 50 % reduction in oil change interval

7-16

20 °C 68 °F

30 °C 86 °F

40 °C 104 °F

50 °C 122 °F

7 - MAINTENANCE

II. Oils for hydraulic systems, mineral

SS13K038

1

Specification: • DIN 51524 HVLP

Oils (A) • ISO VG 46 (MS 1230) e.g.: AKCELA HYDRAULIC EXCAVATOR FLUID (B) • ISO VG 68 (MS 1216) e.g.: AKCELA AW HYDRAULIC FLUID 68 HV The hydraulic system must be warmed up before commencing work. Warm up the hydraulic system for approx. 10 min, with the engine at half-speed and repeated actuation of all control valves.

7-17

7 - MAINTENANCE

II. Oils for hydraulic systems, biodegradable

SS13K040

2

Specification: • DIN 51524 HVLP

Oils ISO VG 46 (MS 1230) e.g.: AKCELA HYDRAULIC EXCAVATOR FLUID BIO The hydraulic system must be warmed up before commencing work. Warm up the hydraulic system for approx. 10 min, with the engine at half-speed and repeated actuation of all control valves.

7-18

7 - MAINTENANCE

III. Oils for powershift transmissions with Ergopower

SS13K039

3

Specification: • API: CI-4 • ACEA: E7 API: American Petroleum Institute ACEA: Association des Constructeurs Européen d´Automobiles g.i.e.

Oils SAE 15W-40 (MS 1121) e.g.: AKCELA No. 1 ENGINE OIL 15W-40

Automatic powershift transmission-preheating.

7-19

7 - MAINTENANCE

IV.A. Oils for differential gear on rear axle

SS13K061

4

NOTICE: Axles and gearboxes may be damaged by low-grade oils.

Specification: • API: GL 5 LS additive API: American Petroleum Institute LS: Limited slip

Oils SAE 80W-90 e.g.: AKCELA GEAR 135H EP 80W-90

7-20

7 - MAINTENANCE

IV.B. Oils for tandem box on rear axle

SS13K035

5

NOTICE: Axles and gearboxes may be damaged by low-grade oils.

Specification: • API: GL 4 API: American Petroleum Institute

Oils SAE 20W-40 (MS 1317) e.g.: AKCELA TRANSAXLE FLUID 20W-40 Titan Utto ZF 20W-40 LS-additive: 0 - 0.1 % S: 0 % P: 0.15 % P+S: Phosphor and sulphur alloy corresponding to delivery specification: 2293219

7-21

7 - MAINTENANCE

IV.C. Oils for blade slewing gear

SS13K062

6

NOTICE: Axles and gearboxes may be damaged by low-grade oils.

Specification: • API: GL 5 API: American Petroleum Institute

Oils HYPOIDE SAE 80W-90 (MS 1316) e.g.: AKCELA GEAR 135 H EP 80W-90

7-22

7 - MAINTENANCE

V. Greases for bearing points and slewing rings

SS13K063

7

Specification: • NLGI 2

Oils Multipurpose Grease e.g.: AKCELA MULTI-PURPOSE GREASE 251H EP

For central lubricating systems and tensioning systems.

7-23

7 - MAINTENANCE

Environment friendly hydraulic fluid The hydraulic system of this machine can be filled ex factory with environmentally friendly, biodegradable hydraulic fluid (nonstandard). Stickers with corresponding instructions are then attached to the machine.

For the initial filling, we use only: PANOLIN HLP SYNTH VG 46 This synthetic hydraulic fluid has been tested by us and approved for use in our machines. A changeover from mineral hydraulic fluid to this biodegradable hydraulic fluid can, however, be made at a later date.

Environmentally friendly, biodegradable hydraulic fluid, may also not be simply poured away. They have to be disposed of in the same way that used oil is disposed of.

If hydraulic fluid seeps into the ground, the machine owner and the authorities responsible must be informed.

PANOLIN HLP SYNTH VG 46 is suitable only for use in hydraulic systems.

As PANOLIN HLP SYNTH VG 46 is not soluble in water, condensed water may be deposited in the hydraulic fluid tank.

Condensed water must therefore be drained off at regular intervals and after lengthy downtimes, then disposed of in the same way as used oil.

Use only PANOLIN HLP SYNTH VG 46 for changing or topping up the hydraulic fluid.

The hydraulic fluid may not be mixed with hydraulic fluids or hydraulic fluids from other manufacturers, as this reduces its biodegradability.

Operating equipment and attachments operated with mineral hydraulic fluid must not be mounted until thoroughly emptied, cleaned, and flushed.

Analysis will show whether the hydraulic fluid can be used beyond the standard changing intervals.

See also 7-136.

7-24

7 - MAINTENANCE

Organic Acid Technology (OAT) coolant A coolant that relies on inhibitors such as organic acid salts for corrosion and cavitation protection.

CASE CONSTRUCTION requires the use of a fully formulated Organic Acid Technology (OAT) -based coolant.

CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT is preferred. The coolant must meet the specifications outlined in the CNH material specification MAT3624. Use of coolant not meeting this specification is not allowed. Mixing of different coolant brands is not recommended.

NOTICE: OAT coolant is mandatory for all FPT engines compliant to Tier 4b emissions using Selective Catalytic Reduction (SCR). NEVER mix OAT coolant with conventional coolant and with conventional cooling system additives.

NOTICE: Issues as a result of failing to follow the above guidelines will not be covered under warranty.

In the case that the customer may have topped off an OAT coolant system with conventional coolant, check the OAT anti-freeze with conventional anti-freeze test strips to see if nitriles are present at a level higher than 20 PPM (parts per million).

If the nitrile level is excessive, follow the procedure below: 1. Empty the engine cooling system and drain the existing coolant into a suitable container.

2. Fill the system with clean water.

3. Start and run the engine for at least 30 minutes.

NOTE: Ensure to activate the heating system (if equipped) to circulate fluid through the heater core.

4. Repeat the steps from 1 to 3 twice 5. Fill the system with OAT coolant The decal shown (CNH part number 47757330) is located near the fill point of the cooling system whenever CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT is filled at the factory. It can also be identified by its yellow color.

The optimum coolant/water concentration is 50/50. This concentration will protect the cooling system to -37 °C (-35 °F).

If a premixed coolant is not available, mix the concentrate with 50 % of water.

The coolant concentration in the coolant/water mixture can be determined with a refractometer designed to measure ethylene glycol content.

Distilled water or deionized water is recommended for the use in the engine cooling systems.

DO NOT use hard water, sea water and softened sea that has been conditioned with salt. The minerals and salts present in potable water can cause corrosion and deposits resulting in shortened engine life.

7-25

SS14H024

8

7 - MAINTENANCE

Capacities Component Engine with engine oil filter

Hydraulic system

836C AWD about 12.5 l (3.3 US gal) about 185 l (48.9 US gal) about 70 l (18.5 US gal) about 27 l (7.1 US gal) about 21 l (5.5 US gal) about 31 l (8.2 US gal) about 31 2 x about 2 x about 60 l 60 l (15.9 US (15.9 US gal) gal) about about 2 l (0.5 US 2 l (0.5 US gal) gal)

Initial filling

For oil change

Powershift transmission

Initial filling

For oil change

Differential gear Side reducer gear

Tandem (chain case) Swing unit

Blade slewing gear

Cooling system with heating (OAT EG2 50-50 Premix)

The coolant is a 50:50 mixture with water

Fuel tank

Diesel Exhaust Fluid (DEF)/AdBlue® tank Windshield washer tank

Refrigerant R134a

7-26

836C about 12.5 l (3.3 US gal) about 170 l (44.9 US gal) about 70 l (18.5 US gal) about 27 l (7.1 US gal) about 21 l (5.5 US gal) about 31 l (8.2 US gal)

856C about 12.5 l (3.3 US gal) about 185 l (48.9 US gal) about 90 l (23.8 US gal) about 27 l (7.1 US gal) about 21 l (5.5 US gal) about 36 l (9.5 US gal)

about 32.0 L (8.5 US gal) about 278.0 L (73.4 US gal) 54.0 L (11.9 UK gal) 2.0 L (0.4 UK gal) 1.2 kg (2.6 lb)

2 x about 64 l (16.9 US gal) about 2.5 l (0.7 US gal) about 32.0 L (8.5 US gal) about 278.0 L (73.4 US gal) 54.0 L (11.9 UK gal) 2.0 L (0.4 UK gal) 1.2 kg (2.6 lb)

about 32.0 L (8.5 US gal) about 278.0 L (73.4 US gal) 54.0 L (11.9 UK gal) 2.0 L (0.4 UK gal) 1.2 kg (2.6 lb)

856C AWD about 12.5 l (3.3 US gal) about 200 l (52.8 US gal) about 90 l (23.8 US gal) about 27 l (7.1 US gal) about 21 l (5.5 US gal) about 36 l (9.5 US gal) about 36 2 x about 64 l (16.9 US gal) about 2.5 l (0.7 US gal) about 32.0 L (8.5 US gal) about 278.0 L (73.4 US gal) 54.0 L (11.9 UK gal) 2.0 L (0.4 UK gal) 1.2 kg (2.6 lb)

7 - MAINTENANCE

Draining hose for oil changes WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

W0251A

NOTE: The draining hose is an option.

NOTICE: – Collect escaping oil and dispose of it without polluting the environment.

– Carry out oil changes with the engine at operating temperature; warm oil drains away more easily.

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

– Depressurize the hydraulic system: see 7-130.

Some machine components, e.g. the hydraulic-oil reservoir, fuel tank and engine, are equipped with special oil drain valves (1). These allow oil changes to be made in a clean and non-polluting way.

Carry out oil changes as follows: 1. Place a receptacle for waste oil under the drain opening. See 7-26 for the capacity.

2. Choose the proper drain hose from the tool kit.

3. Unscrew the protective cap from the oil drain valve.

4. Screw on drain hose (2); the valve opens and the oil drains away.

5. After the oil has drained away, unscrew drain hose; the valve closes automatically.

6. Screw the protective cap back in place.

7-27

SS11H017

1

7 - MAINTENANCE

Selective Catalytic Reduction (SCR) - Overview Diesel Exhaust Fluid (DEF)/AdBlue® instrumentation warning NOTICE: The fuel system, exhaust after-treatment system, and engine on your machine are designed and built to government emissions standards. Tampering by dealers, customers, operators, and users is strictly prohibited by law. Failure to comply could result in government fines, rework charges, invalid warranty, legal action, and possible confiscation of the machine until rework to original condition is completed. Engine service and/or repairs must be done by a certified technician only!

Your machine is equipped with a warning system to inform the operator of the DEF/AdBlue® level, system malfunctions, and engine power loss that may result from the SCR system for reducing exhaust emissions.

During normal operation of your machine, the instrument cluster displays the DEF/AdBlue® fluid level (1) at all times.

Warning lights and indicators will be illuminated with a warning on the visual display. The display changes automatically to allow the operator to view the warning indicator and display message.

The DEF/AdBlue® level bar gauge indicates the level of diesel exhaust fluid in the DEF/AdBlue® tank. When all bars are illuminated, the tank is full. Illuminated bars indicate the level of fluid remaining in the DEF/AdBlue® tank. When the tank is at 5 - 10 % of tank volume, the warning system will flash and/or will flash and sound an audible alarm dependent upon DEF/AdBlue® levels.

SS14E234

DEF/AdBlue® level gauge Master indicator Condition No engine power loss Caution (yellow) Moderate engine power Stop (red) loss Severe engine power loss – Stop (red) engine will not shut down

Gauge indication 6 - 10 % 5 % and below Empty

1

Alarm status None Continuous Continuous

Critical Warnings The Stop Master Indicator is a critical warning display. See Critical Warning Displays.

When the Stop Master indicator illuminates, IMMEDIATELY bring the machine safely to a stop, and turn the engine OFF. Display message DEF/AdBlue® Level Tank EMPTY Power Limited DEF/AdBlue® Level Tank EMPTY Ext. Power Lim Poor DEF/AdBlue® Quality Detected Power Limited Poor DEF/AdBlue® Quality Detected Ext. Power Lim

Description DEF/AdBlue® level is too low

Remedy Refill DEF/AdBlue® immediately.

DEF/AdBlue® level is too low

Refill DEF/AdBlue® immediately.

DEF/AdBlue® quality is questionable Drain the tank and discard the DEF/AdBlue®. Fill with new DEF/AdBlue®.

DEF/AdBlue® quality is questionable Drain the tank and discard the DEF/AdBlue®. Fill with new DEF/AdBlue®.

7-28

7 - MAINTENANCE

Display message DEF/AdBlue® Injection Failed Power Limited

Description Injection failure detected

DEF/AdBlue® Injection Failed Ext. Power Lim

Injection failure detected

Remedy Check the DEF/AdBlue® tank level.

Drain the tank and discard the DEF/AdBlue®. Fill with new DEF/AdBlue®.

Contact your authorized dealer.

Check the DEF/AdBlue® tank level.

Drain the tank and discard the DEF/AdBlue®. Fill with new DEF/AdBlue®.

Contact your authorized dealer.

Non-critical warnings The caution master indicator is a non-critical warning display. See the non critical warning chart. When the caution master indicator is ON, change the operating method, schedule a shutdown for maintenance, or if the condition persists, contact your dealer. The non-critical warning table lists warning displays that may appear on the instrument cluster and the corrective action required.

NOTICE: When a fault occurs, an audible alarm may sound and the Caution Master Indicator will be yellow. The caution message will be displayed in the message area. If this occurs, return the machine to a service position, and turn the engine off, and take corrective action to help avoid expensive repairs.

Non-critical warnings Display message DEF/AdBlue® Level LOW

Description DEF/AdBlue® level is too low

Poor DEF/AdBlue® Quality Detected

DEF/AdBlue® quality is questionable

Remedy 1. Refill DEF/AdBlue® immediately.

1. Drain the tank and discard the DEF/AdBlue®.

2. Fill with new DEF/AdBlue®.

DEF/AdBlue® Injection Failed Power Limited

Injection failure detected 1. Check the DEF/AdBlue® tank level.

2. Drain the tank and discard the DEF/AdBlue®. Fill with new DEF/AdBlue®.

3. Contact your authorized dealer.

7-29

7 - MAINTENANCE

Resetting the Selective Catalytic Reduction (SCR) system After a failure or warning has been set, the SCR system must perform automatic tests to determine if failures or warnings have been resolved. The system must perform the following actions in order to recognize the resolved failures or warnings and reset itself.

• For DEF/AdBlue® level warnings: • Key switch must be cycled OFF then ON. • For poor DEF/AdBlue® quality warnings: • Machine must be operated for approximately 20 min at a minimum of 50 % load.

• For SCR system warnings, one of the following conditions must occur, depending on the exact cause of the warning: • Requires the machine to be operated for approximately 20 min at a minimum of 50 % load to operate the SCR system.

• Requires starting and running the engine, but does not require the SCR system to operate.

• Requires the key switch to be cycled OFF then ON.

Validation re-starts Validation re-starts allow operation of the machine for up to 30 min without power loss after a poor DEF/AdBlue® level/quality or SCR system fault has been detected. Up to three re-starts are permitted. Re-starts are counted if either of the following conditions are met: • Engine speed exceeds 1000 RPM. • Engine running time exceeds 5 min.

Normal operation will resume if a reset is detected within the 30 min window.

If a reset is not detected within 30 min, power loss will occur as described in the table above.

If all three validation re-starts have been used and the system has not been reset, see your local authorized dealer for repair.

7-30

7 - MAINTENANCE

Selective Catalytic Reduction (SCR) system What is Selective Catalytic Reduction (SCR)?

Your machine is equipped with additional components to comply with national and local exhaust emissions requirements. The main components of the SCR system include the SCR catalyst, the Diesel Exhaust Fluid (DEF)/AdBlue® injection unit, the DEF/AdBlue® tank, the Supply Module (SM), the Diesel Oxidation Catalyst (DOC), the Clean Up Catalyst (CUC) and the exhaust flap.

How does Selective Catalytic Reduction (SCR) work?

During combustion, harmful Nitrogen Oxide (NOx) molecules are formed in the exhaust. By injecting a DEF/AdBlue® solution into the exhaust prior to a catalyst, the NOx can be converted to harmless elemental Nitrogen and water. This happens when the NOx molecules react inside the catalyst with the heat generated by the engine and the ammonia in the DEF/AdBlue® solution.

During cold engine operation at low engine coolant and ambient air temperatures, water vapor will be visible from the exhaust when the engine operates. This water vapor will resemble steam or light white smoke and will dissipate as the engine and machine components warm and is considered normal.

NOTE: After engine shutdown, the SCR system will perform a purge cycle, which permits the supply module to continue to run for up to 90 seconds. This is to be considered normal and requires no action from the operator.

What is Diesel Exhaust Fluid (DEF)/AdBlue®?

DEF/AdBlue® is a clear, colorless, non-toxic, aqueous urea solution ( 32.5 %) with a slight ammonia odor. It is used to chemically reduce NOx emissions from heavy-duty diesel-powered vehicles. DEF/AdBlue® is neither explosive nor harmful to the environment. DEF/AdBlue® is classified under the minimum-risk category of transportable fluids.

International standard ISO 22241-1 defines DEF/AdBlue® quality.

Finding Diesel Exhaust Fluid (DEF)/AdBlue® Your authorized equipment dealer is fully equipped to accommodate all your DEF/AdBlue® needs.

7-31

7 - MAINTENANCE

Selective Catalytic Reduction (SCR) main components Supply Module (SM) The Supply Module (SM) (1) contains a pump which withdraws the DEF/AdBlue® fluid from the DEF/AdBlue® tank (2). The DEF/AdBlue® fluid is then directed to the dosing module connected to the Diesel Oxidation Catalyst (DOC).

SS14F029

1

SS14E250

2

SS14F018

3

Diesel Oxidation Catalyst (DOC) The Diesel Oxidation Catalyst (DOC) (1) converts part of the NO to NO2. The DOC is required to achieve as close as possible 50 %/ 50 % NO2/NOx ratio before the SCR. The presence of NO2 increases the NOx conversion efficiency of the SCR catalyst. The DEF/AdBlue® fluid is injected in the DOC by the dosing module (2) connected to the DOC.

Selective Catalytic Reduction (SCR) catalyst The main reaction involved in the SCR catalyst is the conversion of the NOx to N2 and water (H2O). An average NO2/NOx ratio around 50 % is required to give the optimum NOx reduction efficiency in the exhaust system.

Excess of ammonia (NH3) is often used to facilitate the NOx reduction to nitrogen (N2), resulting in NH3 slip. This ammonia must be removed by a secondary step in the Clean Up Catalyst (CUC).

7-32

7 - MAINTENANCE

Clean Up Catalyst (CUC) The Clean Up Catalyst (CUC) is located at the end of the SCR catalyst. The CUC converts the ammonia (NH3) slip to nitrogen (N2) and hydrogen (H2). The CUC ensures that the ammonia slip to ambient is minimal.

SS14F019

4

SS14F030

5

Exhaust flap The exhaust flap is a device located between the turbine and the exhaust system. The exhaust flap is equipped with a throttle valve which manages the rate and the “light off” temperature of the exhaust gas.

The “light off” temperature indicates the temperature at which the catalytic process is initiated.

7-33

7 - MAINTENANCE

Storage, handling, and transport NOTICE: Storage temperatures above 30 °C (86 °F) greatly reduce the shelf life of DEF/AdBlue®.

DEF/AdBlue® has a typical shelf life of 6-12 months. Refer to the SHELF LIFE table below. In order for DEF/AdBlue® to remain in a useable condition, storage requirements must be met.

• Store between -11 °C (12 °F) and 30 °C (86 °F).

• Use only an approved DEF/AdBlue® container. Contact your dealer to obtain proper storage container(s).

• Keep container tightly closed.

• Keep container in a cool, well-ventilated area.

• Keep away from heat and direct sunlight.

If the machine will exceed a four month shut down period: 1. Key OFF. NOTE: wait for completion of purging of DEF/AdBlue®. Pay attention of noises coming from pump after turning key off.

2. Drain the DEF/AdBlue® tank.

3. Flush the tank with deionized water.

4. Drain the deionized water NOTICE: Do not disconnect any electrical connections from the DEF/AdBlue® system.

Machine start-up after extended shutdown: 1. Fill the DEF/AdBlue® tank.

2. Replace the main filter in the supply module.

3. Start the machine.

Thawing • Your CASE CONSTRUCTION machine is equipped with an internal tank heater to thaw frozen DEF/AdBlue®. Your machine will still function until the DEF/AdBlue® begins to flow. The SCR system will then function normally.

NOTE: You may notice a slight reduction in engine torque in high demand situations until the DEF/AdBlue® is fully thawed.

• Do not heat DEF/AdBlue® for long periods of time at temperatures above 30 °C (86 °F). This causes the solution to decompose, which very slowly decreases the expected shelf life.

NOTICE: Do not use an anti-gelling or freeze point improver in your DEF/AdBlue®. The 32.5 % solution is specifically designed to provide the optimum NOx reduction properties. Any further blending or adjusting of the DEF/AdBlue® mixture will lessen its ability to perform correctly and may cause damage to the SCR components.

Handling and supply of additives, if any.

• Personal Protective Equipment (PPE) is not required under normal conditions. If splashing is likely, wear eye protection. For prolonged or repeated contact, impervious gloves are recommended. Follow the precautions listed in the SAFETY INFORMATION chapter when handling any service fluid.

• No additives are required.

NOTICE: Contaminated DEF/AdBlue® can affect the performance of your machine. Follow all instructions in this manual when handling DEF/AdBlue®.

Shelf life Constant ambient storage temperature Less than or equal to 10 °C (50 °F) Less than or equal to 25 °C (77 °F) ¹ Less than or equal to 30 °C (86 °F) Less than or equal to 35 °C (95 °F) Greater than 35 °C (95 °F)

Minimum shelf life 36 months 18 months 12 months 6 months -² 7-34

7 - MAINTENANCE

Constant ambient storage temperature Minimum shelf life ¹ To prevent decomposition of DEF/AdBlue®, prolonged transportation or storage above 25 °C (77 °F) should be avoided. ² Significant loss of shelf life: check every batch before use. See your CASE CONSTRUCTION dealer for more information on testing.

NOTE: The main factors taken into account to define the shelf life in the table above are the ambient storage temperature and the initial alkalinity of DEF/AdBlue®. The difference in evaporation between vented and non-vented storage containers is an additional factor.

NOTE: The information in this table is for reference only and has been provided by the International Organization for Standardization, Document number ISO 22241-3 Diesel engines - NOx reduction agent AUS 32 - Part 3: Handling, transportation and storage.

NOTE: DEF/AdBlue® that remains in the tank of the machine after the season does not require any special precautions unless storage exceeds the shelf life table above.

Disposal • Dispose of DEF/AdBlue® and any filter accumulations in accordance with all applicable Federal, State, and local laws governing waste disposal.

7-35

7 - MAINTENANCE

Maintenance planning

Maintenance planning Adjust Change fluid Cleaning Replace Grease Check

Lubricate Bleed Drain fluid Calibrate Charging

Maintenance action

Page no.

Once before initial commissioning x Maintenance - Check x Maintenance - Grease When the warning lamp lights x Change the main filter element - air intake system Every 10 hours or daily service Check machine and units visually for defects, leaks x and loss of consumables x Check the engine oil level/topping up oil Check the Organic Acid Technology (OAT) coolant x level/topping up coolant x Check and clean the combined radiator x Check and clean the AC condenser (option) x Check the air intake system x Check the lighting function Check the monitoring, warning and control elements x x Check the hydraulic system for leaks x Check the service brake function x Check the parking brake function x Check the wheel condition x Check the steering x Check the electrical system x Check the drive belt Check the windshield washer fluid reservoir/topping x up Check the DEF/AdBlue® tank level/topping up fluid x Every 50 hours or weekly x Check the hydraulic oil level/topping up oil x Check the tire pressure x Check the wheel nuts for tightness x Check the blade slewing gear oil level/topping up x Clean the grader Check the powershift transmission oil level/topping x up oil Once after 250 hours x Maintenance - Check x Maintenance - Replace x Maintenance - Change fluid x Maintenance - Grease x Maintenance - Calibrate x Maintenance - Clean Every 250 hours x Check the rear axle oil levels/topping up oil x Air conditioning - Check x Check the cooling system 7-36

7-39 7-40 7-41 7-42 7-43 7-45 7-47 7-48 7-49 7-50 7-51 7-52 7-53 7-54 7-58 7-59 7-60 7-61 7-63 7-64 7-65 7-66 7-67 7-68 7-69 7-71

7-73 7-74 7-75 7-76 7-77 7-78 7-79 7-81 7-83

7 - MAINTENANCE

Adjust Change fluid Cleaning Replace Grease Check Maintenance action Check all lines, fittings and connections for leaks Lubricate all articulated joints and hinges Check the drive belt tension Check the battery and cable connection Grease the battery terminals Bleed the fuel system Check the service brake discs Check the chain tension Clean/change the fresh air filter on the cab Check the heating for leaks Check the driver´s cab mounting bolts Check the engine bearing

Lubricate Bleed Drain fluid Calibrate Charging Page no.

x

7-84 7-85 7-86 7-87 7-88

x x x x Every 500 hours x x x

x x x x Every 500 hours or yearly x Change the engine oil x Change the oil filter x Change the fuel filter x Change the DEF/AdBlue® tank vent filter x Clean the DEF/AdBlue® supply module pre-filter Every 500 hours or 2-yearly x Change the fuel pre-filter Every 1000 hours x Change the blade slewing gear oil x Change the powershift transmission oil x Change the powershift transmission oil filter x Check the compressor drive belt x Change the tandem box swing unit oil x Drain off water and deposits from the fuel tank x Change the drive belt x Change the hydraulic return flow filter x Change the front-wheel drive oil filter (Only all-wheel version) Every 1000 hours or yearly x Change the main filter element - air intake system x Check the heating/air conditioning x Check the compressor drive belt Every 1500 hours x Change the CCV/engine breather filter x Calibrating the gear box Every 2000 hours x Change the differential/side reducer gear oil on rear axle x Check valve setting on engine Every 3000 hours x Clean the fuel tank x Check and adjust the hydraulic pressure x Depressurising the hydraulic system x Depressurising the hydraulic reservoir x Change the hydraulic reservoir breather valve 7-37

7-89 7-91 7-92 7-95 7-97 7-98 7-99 7-100 7-102 7-104 7-105 7-106 7-107 7-108 7-109 7-111 7-112 7-113 7-114 7-115 7-116 7-118

7-119 7-121 7-112 7-123 7-124 7-126 7-127 7-128 7-129 7-130 7-132 7-133

7 - MAINTENANCE

Adjust Change fluid Cleaning Replace Grease Check

Lubricate Bleed Drain fluid Calibrate Charging

Maintenance action x Clean the hydraulic reservoir x Change the environment friendly hydraulic fluid (if used) x Hydraulic fluid analyze Every 3000 hours or every 3 years x Change the hydraulic oil x Change the safety filter - air intake system Every 4000 hours or 2-yearly x Change the DEF/AdBlue® supply module main filter Every 4000 hours or every 4 years x Change the Organic Acid Technology (OAT) coolant As required maintenance x Clean the DEF/AdBlue® tank neck filter Battery x Battery x Recharging the battery x Assisted starting (Jump-starting) Diagnosis sockets x Diagnosis sockets Lighting system x Replacing bulbs Wheels x Changing a wheel Equipment x Replacing the blade cutting edges Welding operations Protection of the electronic modules during welding x operations

7-38

Page no.

7-134 7-135 7-136 7-137 7-139 7-141 7-142 7-144 7-145 7-147 7-148 7-150 7-151 7-159 7-160 7-161

7 - MAINTENANCE

Once before initial commissioning

Maintenance - Check 1. Level check • Engine oil • Coolant • Hydraulic oil • Rear axle oil • Blade slewing gear oil • Powershift transmission oil 2. Functionality and integrity • Lighting • Monitoring, warning, and control elements • Hydraulic system • Service brake • Parking brake • All lines, fittings, and connections for leaks 3. Pressure • Hydraulic system operating pressure • Tire pressure/refill 4. Tightness • Wheel nuts

7-39

7 - MAINTENANCE

Maintenance - Grease 1. Grease • All lubrication service points • All articulated joints and hinges

7-40

7 - MAINTENANCE

When the warning lamp lights

Change the main filter element - air intake system 1. For detailed information, see 7-119.

7-41

7 - MAINTENANCE

Every 10 hours or daily service

Check machine and units visually for defects, leaks and loss of consumables WARNING Falling object hazard!

Risk of injury from FALLING ENGINE HOOD. Latch the hood in the fully open position prior to working within the engine compartment.

Failure to comply could result in death or serious injury.

W1090B

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

NOTE: Do not start the engine before performing the checks.

1. Open the engine hood and check visually all easy accessible tubes and fittings. Check for any defects, leaks or loss of consumable. Use a torch light if necessary.

2. Go around the machine and check visually all easy accessible tubes and fittings. Check for any defects, leaks or loss of consumable.

7-42

7 - MAINTENANCE

Check the engine oil level/topping up oil WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

W0251A

WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

WARNING Rotating parts!

Shut off the engine before opening the engine hood.

Failure to comply could result in death or serious injury.

W1059A

WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

1. After shutting off the engine, wait about five minutes before checking the oil level. During this time the oil can flow back into the reservoir.

2. Pull out the oil dipstick and wipe it with a clean, lint-free cleaning rag before inserting it again.

3. Withdraw the dipstick again.

SS14J032

7-43

1

7 - MAINTENANCE

4. Check the oil level, then top up through the filler opening as far as the “max” mark (see figure 3). (For oil quality see 7-16 and for oil quantity see 7-26).

SS14J030

2

SS14J029

3

5. If the oil level is only just above the “min” mark, it must be topped up.

3 l (0.8 US gal) can be filled in between the “min” and “max” marks.

NOTICE: The oil level must not be allowed to fall below the “min” mark or rise above the “max” mark.

7-44

7 - MAINTENANCE

Check the Organic Acid Technology (OAT) coolant level/topping up coolant WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

WARNING Burn hazard!

Take care if removing the filler cap while the system is hot. Before removing the cap: completely cover the cap using a thick cloth, and slowly open the filler cap to allow the pressure to escape. Do not add cold water to a hot coolant reservoir.

Failure to comply could result in death or serious injury.

W1305A

WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

NOTICE: Never mix sealing additives into the coolant when leaks are detected. The additives can clog the cooling system. The reduced flow of coolant in this situation can cause overheating of the engine.

NOTICE: Have the cooling system repaired immediately.

NOTE: If rear ripper is mounted, close the teeth protection and lower the rear ripper otherwise the engine hood can be damaged.

The coolant must be checked at least once a day to ensure that coolant losses are detected without delay and damage is thus avoided.

1. Open the engine hood fully until safety latch engages.

– When the engine is cold, the coolant level must be at the “Cold Fill” mark.

– When the coolant level has fallen below the “Cold Fill” mark, more coolant must be added.

2. Unscrew the cap carefully by approx. half a turn.

Any excessive pressure is discharged.

3. Unscrew the cap completely.

4. Top up the coolant only to the “Cold Fill” mark.

5. Screw the cap back in place.

6. If the loss of coolant is excessive search for the defect and repair it.

7. Close the engine hood.

7-45

SS14D070

1

7 - MAINTENANCE

Topping up coolant • The optimum coolant/water concentration is 50/50.

This concentration will protect the cooling system to -37 °C (-35 °F).

If a premixed coolant is not available, mix the concentrate with 50 % of water. (for refilling quantity see 7-26).

• The coolant concentration in the coolant/water mixture can be determined with a refractometer designed to measure ethylene glycol content.

• Distilled water or deionized water is recommended for the use in the engine cooling systems.

DO NOT use hard water, sea water and softened sea that has been conditioned with salt. The minerals and salts present in potable water can cause corrosion and deposits resulting in shortened engine life.

7-46

7 - MAINTENANCE

Check and clean the combined radiator WARNING Rotating parts!

Shut off the engine before opening the engine hood.

Failure to comply could result in death or serious injury.

W1059A

WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

W0251A

CAUTION Flying debris!

Wear eye protection and protective clothing during the cleaning process. Clear the area of bystanders.

Failure to comply could result in minor or moderate injury.

C0150A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

NOTE: If the machine is used on sites with heavily contaminated ambient air, the multi–purpose radiator must be cleaned more often than indicated in the maintenance plans.

NOTICE: Do not use pointed or hard tools such as wire brushes or screwdrivers for cleaning. Such tools may damage the radiator fins.

NOTE: If rear ripper is mounted, close the teeth protection and lower the rear ripper otherwise the engine hood can be damaged.

The multi-purpose radiator contains – from back to front of the machine – cooling sections for hydraulic oil and gearbox oil, for engine coolant and for engine charge air.

1. Open the engine hood fully until safety latch engages (see also Engine hood - Advice).

2. Swing up the air duct (13).

3. If necessary, brush and suck off dirt from the radiator fins.

4. Remove firmly adhering dirt with compressed air or a water jet.

5. Clean the radiator working from top to bottom, removing detached dirt.

NOTICE: When water is used, the batteries must be covered up watertight or removed altogether, otherwise there is a risk of short-circuits.

7-47

SS14D071

1

7 - MAINTENANCE

Check and clean the AC condenser (option) WARNING Rotating parts!

Shut off the engine before opening the engine hood.

Failure to comply could result in death or serious injury.

W1059A

WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

W0251A

CAUTION Flying debris!

Wear eye protection and protective clothing during the cleaning process. Clear the area of bystanders.

Failure to comply could result in minor or moderate injury.

C0150A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

NOTE: If the machine is used on sites with heavily contaminated ambient air, the condenser must be cleaned more often than indicated in the maintenance plans.

NOTICE: Do not use pointed or hard tools such as wire brushes or screwdrivers for cleaning. Such tools may damage the condenser.

NOTE: If rear ripper is mounted, close the teeth protection and lower the rear ripper otherwise the engine hood can be damaged.

1. Open the engine hood fully until safety latch engages (see also Engine hood - Advice).

2. If necessary, brush and suck off dirt from the condenser.

3. Remove firmly adhering dirt with compressed air or a water jet.

NOTICE: When water is used, the batteries must be covered up watertight or removed altogether, otherwise there is a risk of short-circuits.

SS14H023

7-48

1

7 - MAINTENANCE

Check the air intake system WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

W0251A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

NOTICE: Never start the engine when parts of the air intake system have been removed.

Risk of damage to the engine if unfiltered air enters the engine.

Check the air intake line Make sure no unfiltered air gets into the engine, therefore: 1. Visual examination of the inlet duct between filter and engine for leaks and tightness. The intake duct must be free from apparent external damage.

2. Check the connecting hoses between filter and intake line for tightness and integrity.

7-49

7 - MAINTENANCE

Check the lighting function 1. Check function of complete lighting system.

2. If necessary replace defective bulbs.

7-50

7 - MAINTENANCE

Check the monitoring, warning and control elements 1. Turn the ignition switch to position ON. 2. All light-emitting diodes (LED) light up and a warning tone is heard for 3 s.

3. At the end of this test, all systems return to the normal mode of operation.

4. If the LEDs don’t light up, check the instrument panel.

5. If necessary, replace the instrument panel.

7-51

7 - MAINTENANCE

Check the hydraulic system for leaks NOTE: Read and observe Safety rules and following.

1. Go around the machine and check visually all easy accessible hydraulic tubes and fittings. Check for any defects, leaks or loss of consumable.

7-52

7 - MAINTENANCE

Check the service brake function NOTE: Concerning further information and instructions, see also Safety rules and following.

The submerged multiple-disk brakes installed in the wheel-hubs are low-wear brakes and largely maintenance-free.

Nevertheless, the following points must be observed: 1. Abnormal noise from the wheel-hubs during braking may be a sign of damaged brake discs.

– In this case, have the brakes checked by your authorized dealer.

7-53

7 - MAINTENANCE

Check the parking brake function The brake lining pads are basically maintenance-free and should only be checked for damage and for free movement of the brake disc. The lining thickness must be visually inspected.

The lining must be replaced when the minimum remaining thickness of 1.00 - 1.50 mm (0.04 - 0.06 in) per brake lining pad is reached.

The readjustment of the brakes is necessary after the installation of new brake lining pads or of a new brake disc and also during all other repair stages and in the case of insufficient braking performance.

1. For checking the parking brake, unscrew the screws (2) and remove the protective hood (1).

SS11H180

1

Replacement of the brake lining pads WARNING Unexpected machine movement!

Make sure that you secure the machine with wheel chocks before you perform this procedure.

Failure to comply could result in death or serious injury.

W1221A

1. Park the machine on level ground and secure it against inadvertent movement.

2. Release the parking brake by applying the required release pressure (min. 130.0 bar (1885.0 psi)).

3. Loosen the screw cap by turning anti-clockwise, and remove it.

4. Loosen the locknut (1) of the adjusting screw (2).

5. Turn the adjusting screw (2) anti-clockwise until the thrust pin (3) can be pressed fully into the piston.

6. Using a suitable screwdriver (S1), turn (or lever) the thrust pin (3) back up to the position at the piston (4).

SS14H044

7-54

2

7 - MAINTENANCE

7. Loosen the locknut (1) and turn the setting screw (2) out of the brake housing.

NOTE: The lining spring (5) is pre-loaded. The lining spring must be held in position with a suitable tool during the removal of the setting screw.

8. Remove the lining spring (5).

9. Take the two brake lining carriers (3) and (4) out of the lining groove in the brake housing.

NOTE: If it is not possible to change the brake lining carriers (3) and (4) by this method (insufficient room), the brake must be removed completely.

SS12J179

10. Change the brake lining carrier (3) and (4).

11. Press the lining spring (5) in position with a suitable tool while screwing in the setting screw (2).

7-55

3

7 - MAINTENANCE

Installing the brakes WARNING Unexpected machine movement!

Make sure that you secure the machine with wheel chocks before you perform this procedure.

Failure to comply could result in death or serious injury.

W1221A

1. Park the machine on level ground and secure it against inadvertent movement.

2. Turn the screw cap (5) anti-clockwise and remove it.

3. Loosen the locknut (1) and turn the adjusting screw (2) anti-clockwise until the plane surface of the thrust pin (6) is against the piston (9).

In this way, you are pushing the brake across the brake disc.

4. Screw the two guide pins (7) into the transmission housing, according to the assembly instructions of the manufacturer of the transmission.

5. Make the pressure connection.

6. Apply the required release pressure to the brake (min.

130.0 bar (1885.0 psi)), in order to preload the disk spring pack (10) fully at the end stop.

7. Vent the brake using the bleed valve (8).

7-56

SS14H045

4

7 - MAINTENANCE

Emergency release of the parking brake WARNING Unexpected machine movement!

Make sure that you secure the machine with wheel chocks before you perform this procedure.

Failure to comply could result in death or serious injury.

W1221A

NOTE: If the pressure supply fails, the parking brake can be released mechanically.

1. Secure the machine against inadvertent movement.

2. Loosen the screw cap by turning anti-clockwise, and remove it.

3. Loosen the locknut (1) and unscrew it till it reaches the end of the adjusting screw (2).

4. Turn the adjusting screw (2) anti-clockwise until the brake disk is completely free.

NOTE: For emergency release, a minimum torque of 70.0 N·m (51.6 lb ft) must be applied to the adjusting screw (2).

5. Screw in the locknut (1) up to the piston position and slightly tighten with the adjusting screw (2).

6. Turn the screw cap clockwise by several thread turns (to protect from dirt).

SS14H046

7-57

5

7 - MAINTENANCE

Check the wheel condition NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

1. Check the surface of the tires for dents, cuts and other damage.

2. Check the tread depth of tires.

3. Check for jammed objects between rim and tire. When removing the objects it is necessary to deflate the tire.

7-58

7 - MAINTENANCE

Check the steering 1. Warming up the machine, see 4-10.

2. Turn the steering completely to the left until the stop.

3. Turn the steering completely to the right until the stop.

7-59

7 - MAINTENANCE

Check the electrical system WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

W0251A

WARNING Rotating parts!

Shut off the engine before opening the engine hood.

Failure to comply could result in death or serious injury.

W1059A

WARNING Falling object hazard!

Risk of injury from FALLING ENGINE HOOD. Latch the hood in the fully open position prior to working within the engine compartment.

Failure to comply could result in death or serious injury.

W1090B

1. Open the hood, see Engine hood - Advice.

2. Check the machine, particularly the engine compartment, for disconnected or loosened connectors.

7-60

7 - MAINTENANCE

Check the drive belt WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

W0251A

WARNING Rotating parts!

Shut off the engine before opening the engine hood.

Failure to comply could result in death or serious injury.

W1059A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

Visual inspection NOTICE: If an air conditioner is installed, the compressor must be loosened and the belt removed.

1. Unlock the engine hood with lever (101) and open it (see also Engine hood - Advice).

SS14J017

7-61

1

7 - MAINTENANCE

2. Check the drive belt visually for cracks and damage.

The belt must be replaced, if: • Longitudinal cracks and transverse cracks intersect ( (1) replacement not necessary; (2) replacement necessary.)

• The belt is frayed at the edges.

• Parts of the belt material are missing.

• If shining or chafed areas are visible. The automatic belt tensioner (3) must be checked and replaced, if necessary.

7-62

SS11K189

2

SS13A389

3

7 - MAINTENANCE

Check the windshield washer fluid reservoir/topping up WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

W0251A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

1. Check that the reservoir is always filled with water and window cleaning agent and refill if necessary. In winter, add antifreeze to the wash fluid.

SS14D072

7-63

1

7 - MAINTENANCE

Check the DEF/AdBlue® tank level/topping up fluid NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

1. Turn the ignition on.

2. Check the Diesel Exhaust Fluid (DEF)/AdBlue® fluid level (4) on the main screen display.

SS14C054

1

SS14F033

2

3. If necessary, refill as following: A. Remove the Diesel Exhaust Fluid (DEF)/AdBlue® cap (1).

B. Fill in the tank.

C. Install the cap.

4. After refilling, check the Diesel Exhaust Fluid (DEF)/ AdBlue® fluid level (4), see figure 1, again.

7-64

7 - MAINTENANCE

Every 50 hours or weekly

Check the hydraulic oil level/topping up oil WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

W0251A

WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

The oil level must be visible around the mark in the middle of the inspection glass.

Top up with hydraulic oil if necessary.

If the loss of oil is excessive search for the defect and repair it.

When checking the hydraulic oil: 1. The working attachments must be lowered to the ground.

2. The engine must be off.

3. The hydraulic oil must be cold.

SS11K217

7-65

1

7 - MAINTENANCE

Check the tire pressure WARNING Explosion hazard!

When inflating tires, use a clip-on air chuck with a gauge, remote valve, and hose long enough to allow you to stand to one side and NOT in front of or over the wheel assembly. Keep others out of the DANGER AREA. Never inflate a tire beyond the maximum allowable pressure printed on the tire.

Failure to comply could result in death or serious injury.

W0059A

WARNING Explosion hazard!

Always maintain correct tire pressure as indicated in this manual. DO NOT inflate tires above the recommended pressure. Excessive pressure could result in tire failure.

Failure to comply could result in death or serious injury.

W0109A

NOTE: Read and observe Safety rules and following.

1. Park the machine on firm and level ground.

Stand the working equipment on the ground.

2. Apply the parking brake.

3. The working attachments and the blade must be lowered to the ground.

4. Shut off the engine.

5. Before inflating the tire, the wheel must be installed correctly on the machine or placed into an inflation cage.

SS11H181

1

SS11H182

2

6. Attach a pressure hose with remote trigger and selflocking nozzle (3) and pressure gauge (2) to the tire filling valve (1).

7. The prescribed inflation pressure (see 8-18) can be read at the pressure gauge (2) and corrected, if required.

Inflating tires 1. Make sure nobody is standing beside the tire and that all other persons remain out of the hazard zone.

2. It is absolutely necessary to use a pressure hose with remote trigger and self-locking filling nozzle.

3. Keep on the side of the tread pattern when inflating the tire.

4. Inflate the tire to the prescribed pressure. Do not inflate the tires to a higher pressure than specified.

7-66

7 - MAINTENANCE

Check the wheel nuts for tightness Check the wheel nuts for tightness.

Use a torque wrench.

Tightening torques With lock washer With pressure plate

836C/836C AWD 450 N·m (331.9 lb ft) 500 N·m (368.8 lb ft)

7-67

856C/856C AWD 550 N·m (406 lb ft) 600 N·m (442.5 lb ft)

7 - MAINTENANCE

Check the blade slewing gear oil level/topping up WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

NOTE: Read and observe Safety rules and following.

1. Secure the machine as described under 7-5.

2. Check that the blade-slewing gear is horizontal (level).

3. Check the oil level. It must reach the center of the sight glass (3).

4. Fill up with gearbox oil if necessary. To do this, unscrew the plug (2) and pour gearbox oil into the hole. (For oil quality see 7-16 and for oil quantity see 7-26).

5. If the loss of oil is excessive search for the defect and repair it.

6. Screw the plug (2) back in, with a new sealing ring.

SS13A390

7-68

1

7 - MAINTENANCE

Clean the grader Inspecting and cleaning the machine WARNING Moving parts!

Install all covers, panels, and guards after servicing or cleaning the machine. Never operate the machine with covers, panels, or guards removed.

Failure to comply could result in death or serious injury.

W0135A

Clean immediately if oil or grease has been spilled on the machine. Clean with steam or a high pressure water jet.

Look for any leaks, and check the condition of all pipes and hoses.

Take the opportunity during this operation to make a visual check of all the welded components (in case of appearance of cracks).

Cab headliner The foam headliner in your cab decreases noise. To keep the headliner in good operating condition, remove dust with a vacuum cleaner.

NOTICE: DO NOT wash the headliner with water. Water can cause damage to the headliner and lower the noise control capacity of the headliner.

Operator's seat WARNING Chemical hazard!

Always wear protective clothing and goggles when cleaning with solvents, acids, or alkaline chemical agents. Always follow the chemical manufacturer's instructions.

Failure to comply could result in death or serious injury.

W0180A

Remove dust and dirt from the seat with a vacuum cleaner or soft brush. Clean stains with the correct material cleaner.

Before removing stains, try to find what type and how old the stains are. Some stains can be removed with water or soap solution.

Cleaning Fluid - This type of cleaner can be used for grease or oil stains. Carefully remove the item that caused the stain with a scraper or a dull knife.

Use a minimum amount of cleaner and a clean cloth.

Move the cloth from the outside of the stain towards the center. When the stain is removed, use a clean cloth to dry the area to prevent a cleaning fluid pattern.

7-69

7 - MAINTENANCE

Plastic and resin parts When cleaning plastic parts, the console, the instrument panel, the indicators, etc. do not use gasoline, kerosene, paint solvents, etc. Only use water, soap and a soft cloth.

The use of gasoline, kerosene, paint solvents, etc. will cause discoloration, cracks or deformation of these parts.

7-70

7 - MAINTENANCE

Check the powershift transmission oil level/topping up oil WARNING Rotating parts!

The engine is running. Keep clear of rotating fans and belts.

Failure to comply could result in death or serious injury.

W0275A

WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

W0251A

WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

NOTICE: Since the torque converter of the powershift transmission discharges into the gearbox when the engine is stationary, oil level checking must be performed while the engine is running.

1. Check that the powershift transmission has been set to neutral.

2. Start the engine and let it run at idling speed.

3. Warm up the powershift transmission until the oil temperature is approx. 80 °C (176.0 °F), (see also 4-10).

4. Set the gearbox back to neutral and let the engine run at 1000 RPM.

SS13A393

1

SS14F041

2

5. Fully open the engine hood and latch (see also Engine hood - Advice).

NOTE: If rear ripper is mounted, close the teeth protection and lower the rear ripper otherwise the engine hood can be damaged.

6. Clean the dipstick and the filler neck.

7. Loosen the dipstick (1) by turning the handle to the left, pull out the dipstick and wipe clean with a lint-free cloth.

8. For checking, slide the oil dipstick into the filler neck (2) down to the stop.

7-71

7 - MAINTENANCE

9. Withdraw the dipstick, the oil must reach the top marking “hot max.”.

10. If necessary, top up with oil. (For oil quality see 7-16 and for oil quantity see 7-26).

11. The space between the “min” and “max” markings corresponds to 1 l (0.2 UK gal) of oil.

12. If the loss of oil is excessive search for the defect and repair it.

13. After checking, slide the dipstick down into the tube and fix it by turning the tee handle to the right.

SS11K198

7-72

3

7 - MAINTENANCE

Once after 250 hours

Maintenance - Check 1. Functionality and integrity • Hydraulic system • All lines, fittings, and connections for leaks • Steering 2. Pressure • Hydraulic system operating pressure 3. Tension • Chain 4. Tightness • Hydraulic oil tank mounting bolts • Fuel tank mounting bolts • Diesel Exhaust Fluid (DEF)/AdBlue® tank mounting bolts • Swing bearing • Engine hood mounting bolts • Tire bolts • Fender • All hydraulic cylinders • Steps

7-73

7 - MAINTENANCE

Maintenance - Replace 1. Replace • Fuel filter • Hydraulic return flow filter • Front-wheel drive oil filter (Only all-wheel version) • Powershift transmission oil filter

7-74

7 - MAINTENANCE

Maintenance - Change fluid 1. Change • Rear axle oil • Blade slewing gear oil • Powershift transmission oil

7-75

7 - MAINTENANCE

Maintenance - Grease 1. Grease all lubrication service points.

7-76

7 - MAINTENANCE

Maintenance - Calibrate 1. Calibrate • Gear box

7-77

7 - MAINTENANCE

Maintenance - Clean 1. Clean • Diesel Exhaust Fluid (DEF)/AdBlue® supply module pre-filter

7-78

7 - MAINTENANCE

Every 250 hours

Check the rear axle oil levels/topping up oil WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

Differential/side reducer gears 1. Check the oil level. Screw out the check plug (1) for this. The oil level must reach the lower edge of the hole.

2. If necessary, top up with gearbox oil through the hole.

(For oil quality see 7-16 and for oil quantity see 7-26).

3. If the loss of oil is excessive search for the defect and repair it.

4. Screw the check plug (1) back in place with a new sealing ring.

SS11H177

7-79

1

7 - MAINTENANCE

Tandem (chain case) 1. Check the oil level in the oil gauge glass (1).

SS14F060

2

SS14F064

3

2. If the level is not sufficient, top up with gearbox oil. For topping up, unscrew the oil filling plug (3) and pour new gearbox oil into the hole. (For oil quality see 7-16 and for oil quantity see 7-26).

3. If the loss of oil is excessive search for the defect and repair it.

4. Check the oil level in the oil gauge glass (1) again.

7-80

7 - MAINTENANCE

Air conditioning - Check WARNING Flying debris!

Wear eye protection and protective clothing during the cleaning process. Clear the area of bystanders.

Failure to comply could result in death or serious injury.

W0364A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

The filters should be changed every 250 hours or more frequently when operating conditions are severe.

Location of components inside the machine The heater/air conditioner is installed in the driver’s cab underneath the driver’s seat.

The components are accessible after removal of the seat and the cover. The heat exchanger, the evaporator, and the blower require no servicing.

• Blower (1) • Heat exchanger (2) • Evaporator (3) • Filter recirculation (4) • Heating valve (5) SS11H184

• The air conditioner should moreover be switched on once a month for 10 - 15 min. This prevents drying out and embrittlement of the shaft seal in the compressor. Otherwise there is a risk of refrigerant leaking out of the unit. This also ensures regular lubrication of the compressor components.

If performance is reduced or unsatisfying check evaporator (3) (see figure 1) soiled or cooling fins deformed?

• Blow out dirt and remove it by suction. Straighten the cooling fins.

Antifreeze protection sensor on evaporator kinked or leaking?

• Have the sensor repaired.

Filter mat (4) (see figure 1) soiled?

7-81

1

7 - MAINTENANCE

• Depending on the conditions of use, the filter mat must also be checked more often and cleaned by blowing out or by beating.

• To access the filter (4) remove the bolt (6), the spring washer (7) and the washer M6 (8).

• Remove the cover filter (9).

LEIL15GRD0108BB

2

SS14H047

3

Temperature control knob (99) difficult to move?

• If sluggish, check the Bowden cable for kinking or corrosion and replace it if necessary.

7-82

7 - MAINTENANCE

Check the cooling system NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

1. Check the screws of the radiator.

2. Check if the radiator is clogged and clean the radiator, if necessary.

7-83

7 - MAINTENANCE

Check all lines, fittings and connections for leaks WARNING Rotating parts!

Shut off the engine before opening the engine hood.

Failure to comply could result in death or serious injury.

W1059A

WARNING Falling object hazard!

Risk of injury from FALLING ENGINE HOOD. Latch the hood in the fully open position prior to working within the engine compartment.

Failure to comply could result in death or serious injury.

W1090B

1. Open the hood, see Engine hood - Advice.

2. Go around the machine and check visually all easy accessible tubes and fittings. Check for any defects, leaks or loss of consumable.

7-84

7 - MAINTENANCE

Lubricate all articulated joints and hinges 1. Lubricate all articulated joints and hinges.

7-85

7 - MAINTENANCE

Check the drive belt tension 1. Check the drive belt tension.

NOTE: Concerning further information and instructions, please refer to page 7-61 in this Manual.

7-86

7 - MAINTENANCE

Check the battery and cable connection 1. Check the battery and cable connection.

7-87

7 - MAINTENANCE

Grease the battery terminals NOTE: Read and observe Safety rules and following.

1. Grease the battery terminals.

7-88

7 - MAINTENANCE

Every 500 hours

Bleed the fuel system WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

High-Pressure fuel system After removal or replacement of the high-pressure fuel lines it is not necessary to perform external bleeding in order to start the engine. The fuel pump produces a high fuel pressure during starting and discharges the air at the high-pressure side through the injection nozzles.

1. Turn the key switch of the electrical system to position I but do not start the engine.

2. The electrical fuel pump now runs for about 30 s and vents the system (the running noise of the pump can be heard).

3. After this, start the engine.

4. If the engine does not start, then turn the key switch back to position 0 for about 30 s.

5. During this time the engine electronics performs a reset.

6. Then repeat the venting procedure.

7. If the engine now starts, then the system has been vented.

7-89

7 - MAINTENANCE

Bleeding the fuel system NOTICE: The fuel hose (6) must be resistant to fuels and transparent.

After repairs on the fuel system or after cleaning of the fuel tank, the system must be bled.

1. Slide the hose (6) over the bleeding valve (3).

2. Insert the bleeding hose (6) into a collecting receptacle (7).

3. Open the bleeding valve (3) with an open-end spanner (turning counterclockwise).

4. Press the button (2) of the hand pump repeatedly until there are no more air bubbles to be seen in the hose (6).

5. Close the bleeding valve (3) with an open-end spanner (turning clockwise).

6. Withdraw the hose (6) with the collecting recipient (7) from the bleeding valve (3) and dispose of the collected fuel in compliance with state-of-the-art techniques in closed containers.

7. Check all lines and connections and the fuel filter assembly for leaks.

7-90

SS14H048

1

7 - MAINTENANCE

Check the service brake discs NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

The submerged multiple-disk brakes installed in the wheel-hubs are low-wear brakes and largely maintenance-free.

Nevertheless, the following point must be observed: • Abnormal noise from the wheel-hubs during braking may be a sign of damaged brake disks.

In this case, have the brakes checked by your authorized dealer.

Bleeding the service brake When air has penetrated into the brake system, e.g. by detaching the brake lines, the braking system must be bled.

Have the brake system bled by your authorized dealer.

Check the thickness of the brake disks • Check the lining thickness of the brake disks as per the maintenance chart.

• Have the lining thickness of the brake disks checked by your authorized dealer.

Replacing the brake disks • Have the brake disks replaced by your authorized dealer.

7-91

7 - MAINTENANCE

Check the chain tension NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

NOTE: Check the chain tension on all four chains.

NOTE: It is recommended to remove the wheels to gain better access.

1. Remove the covers on top and on the side. This makes it easier to read the correct value on the measuring rod.

2. Raise the rear axle until the rear wheels are clear of the ground.

3. Place squared timber under the axle to prevent it from lowering.

SS13A860

4. A straight rigid rod of length about 840 mm (33.1 in) is required, in order to provide a reference point for the measurement.

5. Pass the rod into the tandem housing and place it on the highest tooth on the two related sprocket.

SS12J210

7-92

2

1

7 - MAINTENANCE

6. Place an angle piece on the top of the tandem housing in order to ensure that the measurement is taken at the correct angle.

SS13A859

SS12J212

4

7. Now pass the rod through the top opening along the angle piece in the tandem housing until it is resting on the chain.

SS12J213

7-93

5

3

7 - MAINTENANCE

8. Now read dimension (B) at side opening (A) (see figure 4) in the tandem housing.

9. The initial sag with a new chain/machine is indicated by dimension (B).

10. The maximum sag is the maximum permitted value of dimension (B) as shown in the following table. If the sag is greater than the maximum allowed value, then the chain must be replaced, refer to the service manual.

Initial sag (new chain) Maximum allowed sag

836C/836C AWD 0 - 10 mm (0.0 - 0.4 in) 60 - 65 mm (2.4 - 2.6 in)

856C/856C AWD 0 - 10 mm (0.0 - 0.4 in) 70 - 75 mm (2.8 - 3.0 in)

NOTE: This calculation is based on the maximum elongation of about 1% on a new chain.

7-94

7 - MAINTENANCE

Clean/change the fresh air filter on the cab WARNING Flying debris!

Wear eye protection and protective clothing during the cleaning process. Clear the area of bystanders.

Failure to comply could result in death or serious injury.

W0364A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

NOTICE: In very dusty working conditions the filter element and the filter mat must be cleaned more frequently.

Cleaning the fresh-air filter element 1. Loosen the screw (1) and lift the flap (2).

SS11K187

1

SS11K246

2

2. Remove the filter element (3).

Dry cleaning 1. Clean the filter element with compressed air. The pressure at the blowing nozzle must not exceed 5 bar (72.5 psi).

NOTICE: Excessive pressure will damage the filter element.

Wet cleaning 1. Clean the filter element with clear water (without detergents).

2. Dry the filter element before re-installation.

NOTICE: Replace the filter element after 5 cleaning cycles.

7-95

7 - MAINTENANCE

Re-install the filter element 1. Insert the filter element (3) (see figure 2).

2. Close the flap (2) (see figure 1) and tighten the screw (1) (see figure 1).

Cleaning the recirculated-air filter mat 1. Loosen the T-screw (1) and raise the protective grid (2) slightly.

2. Remove the filter mat.

3. Clean the filter mat with compressed air or with water.

SS11H114

7-96

3

7 - MAINTENANCE

Check the heating for leaks NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

1. Go around the machine and check visually all easy accessible heating tubes and fittings. Check for any defects, leaks or loss of consumable.

7-97

7 - MAINTENANCE

Check the driver´s cab mounting bolts 1. Check the driver´s cab/mounting bolts.

7-98

7 - MAINTENANCE

Check the engine bearing 1. Check the tightening torque of the rubber dampers.

2. If necessary, tighten with 248.0 N·m (182.9 lb ft).

SS14F051

7-99

1

7 - MAINTENANCE

Every 500 hours or yearly

Change the engine oil WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

NOTE: Collect escaping oil and dispose of it without polluting the environment.

1. Bring the engine oil to operating temperature.

2. Park the machine on a horizontal surface and secure it against inadvertent movement.

3. Shut off the engine.

4. Drain off the engine oil at the drain plug. Use the oildrainage hose for this. See also 7-27.

SS11K200

7-100

1

7 - MAINTENANCE

Once the engine oil has been drained off: 1. Unscrew the oil-drainage hose, screw the protective cap back onto oil drain plug.

2. Replace the engine oil filter (see also 7-102).

3. Fill the engine oil in through the filler opening until the oil level reaches the “max” mark on the dipstick. (For oil quality see 7-16 and for oil quantity see 7-26).

4. After running the engine briefly, check the oil level (see also 7-43).

7-101

SS14J030

2

SS14J029

3

7 - MAINTENANCE

Change the oil filter WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

NOTE: Collect escaping oil and dispose of it without polluting the environment.

1. Unscrew the filter cartridge (4).

2. Clean sealing surface on engine.

3. Fill the filter cartridge with engine oil.

4. Lightly oil the rubber seal of the new filter cartridge.

5. Screw the filter cartridge in place until the rubber seal is in contact, then tighten it by hand.

SS14D076

7-102

1

7 - MAINTENANCE

6. Fill engine oil in through the filler opening until the oil level reaches the “max” mark on the dipstick.

7. Start up the engine and check that the cartridge/engine connection is oil-tight.

8. Check the oil level (see also 7-43).

7-103

SS14J030

2

SS14J029

3

7 - MAINTENANCE

Change the fuel filter WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

WARNING Fuel vapors are explosive and flammable.

Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately.

Failure to comply could result in death or serious injury.

W0904A

NOTE: Read and observe Safety rules and following.

1. Secure the machine as described under 7-5.

2. Unscrew the fuel filter cartridge (1) and dispose of it without polluting the environment.

3. Clean the sealing surface of the filter head.

4. Fill the new fuel filter cartridge with fuel.

5. Apply a thin layer of oil on the gasket of the new fuel filter cartridge.

6. Screw the fuel filter onto the filter head until the gasket is in contact with the sealing surface and tighten it by hand.

7. Check after some time that the sealing surface between filter head and fuel filter is not leaking.

8. Bleed the system, see also 7-89.

NOTICE: Tightening the filter with too much force can damage the thread or the gasket.

7-104

SS14J031

1

7 - MAINTENANCE

Change the DEF/AdBlue® tank vent filter NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

1. Open the hood, see page Engine hood - Advice. The Diesel Exhaust Fluid (DEF)/AdBlue® tank vent filter is located on the left-hand side of the machine above the DEF/AdBlue® tank.

2. Loosen the clamps and remove the tank vent filter (1) from the hose.

3. Install a new filter to the hose and reinstall the filter with the clamp.

SS14F046

7-105

1

7 - MAINTENANCE

Clean the DEF/AdBlue® supply module pre-filter NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

1. Open the hood, see page Engine hood - Advice. The supply module pre-filter is located on the left-hand side of the machine above the supply module.

2. Use a suitable container to catch any fluid that is discharged during hose and filter disassembly. Clean the area before disassembly. Disconnect the inlet line from the supply module.

3. Disconnect the pre-filter from the inlet line.

4. Clean the filter. Replace the filter, if necessary.

5. Reinstall the pre-filter to the inlet line and connect the inlet line to the supply module.

SS14F053

6. Start the engine at idle speed and check for leaks.

7-106

1

7 - MAINTENANCE

Every 500 hours or 2-yearly

Change the fuel pre-filter WARNING Fuel vapors are explosive and flammable.

Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately.

Failure to comply could result in death or serious injury.

W0904A

WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

NOTE: Read and observe Safety rules and following.

1. Secure the machine as described under 7-5.

2. Remove the connector (1) from the sensor (2) by pressing the safety clip.

3. Unscrew the filter cartridge (3) and the sensor from the hand pump.

4. Unscrew the sensor from the filter cartridge.

5. Dispose of the filter cartridge and the fuel/water mixture.

6. Clean the sealing surface of the filter head.

7. Screw the sensor into the new filter cartridge and fill the cartridge with fuel.

8. Apply a thin layer of oil on the gasket of the fuel filter.

9. Screw the sensor into the filter cartridge.

10. Fill the filter cartridge with fuel and screw it onto the filter head until the gasket is in contact with the sealing surface, then tighten the filter cartridge by hand.

11. Plug the connector into the sensor.

12. Check after some time that the sealing surface between filter head and fuel filter is not leaking.

13. Bleed the system, see also 7-89.

7-107

SS14D078

1

7 - MAINTENANCE

Every 1000 hours

Change the blade slewing gear oil WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

NOTE: Read and observe Safety rules and following.

NOTE: Collect escaping oil and dispose of it without polluting the environment.

1. Secure the machine as described under 7-5.

2. Provide a collecting vessel for waste oil. For the required capacity of this vessel, see 7-26.

3. Unscrew the drain plug (1) and the oil flows out. Screw drain plug back in place with a new sealing ring.

4. Fill with new gearbox oil as described under 7-68. (For oil quality see 7-16 and for oil quantity see 7-26).

SS14J025

7-108

1

7 - MAINTENANCE

Change the powershift transmission oil WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

NOTE: Read and observe Safety rules and following.

NOTE: Collect escaping oil and dispose of it without polluting the environment.

NOTICE: Each time the oil has been changed, the gearbox must be reset with an AEB starter. Contact your authorized dealer for this.

1. Secure the machine as described under 7-5.

2. Prepare a collecting vessel for waste oil. For the required capacity of this vessel, see 7-26.

3. Thoroughly clean the powershift transmission around the oil drain plug (4), the oil dipstick (1) and (2), and the oil filter (3) and (5) (see figure 3).

4. Unlock the dipstick handle (1) by turning it counterclockwise and withdraw the dipstick from the filling pipe (2).

5. Drain off the gearbox oil through the drain plug (4).

7-109

SS14F041

1

SS11K228

2

7 - MAINTENANCE

After draining off the gearbox oil: 1. Unscrew the oil-drainage hose, screw the protective cap back onto the oil drain plug.

2. Replace the gearbox oil filter as detailed under 7-111.

3. Pour fresh gearbox oil into the filling pipe (2) (see figure 1) up to the lower mark “cold min.”. (For oil quality see 7-16 and for oil quantity see 7-26).

4. Check that the powershift transmission has been set to neutral.

5. Start the engine and let it run at idling speed.

6. After running the engine for some minutes, top up with gearbox oil to the lower dipstick “cold min.” mark.

7. Warm up the powershift transmission until the oil temperature is approx. 80 °C (176.0 °F), see also 4-10.

8. Move the gearshift back to neutral, bring the engine to idling speed.

9. Check the oil level. If necessary, top up again with gearbox oil to the top “hot max.” mark of the dipstick.

7-110

SS11K229

3

7 - MAINTENANCE

Change the powershift transmission oil filter WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

NOTICE: The oil filter must also be replaced each time the gearbox oil is changed.

1. Loosen the oil filter (3) with a releasing wrench, unscrew it by hand, and discard it in accordance with local environmental regulations.

2. Clean the sealing surface at the filter head (5).

3. Apply a light coating of oil to the seal of the new oil filter.

4. Fill the oil filter with oil. (For oil quality see 7-16 and for oil quantity see 7-26).

5. Carefully screw the oil filter on and tighten it by hand.

6. Check for leaks during the trial run.

SS11K229

7-111

1

7 - MAINTENANCE

Check the compressor drive belt WARNING Rotating parts!

Shut off the engine before opening the engine hood.

Failure to comply could result in death or serious injury.

W1059A

WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

W0251A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

NOTICE: Incorrect tension of the V-belt affects the performance of the compressor. It can also cause damage to the belt and/or the compressor.

The compressor (11) is flange-mounted on the engine block. The tension of the V-belt can be checked on the left-hand side of the engine.

1. Open the engine compartment.

2. Check that the retaining screws holding the compressor on the supporting bracket and those holding the supporting bracket on the engine block are properly tightened and retighten, if necessary.

3. Check the V-belt and replace if damaged.

4. Depress the V-belt in the middle between the pulleys with your thumb. If the tension is correct, the belt can be depressed by approx. 10 mm (0.4 in). If the tension of the belt deviates from this value, the belt must be retensioned or slackened by doing the following: 5. Loosen the tensioning screw (13) and tension the V-belt.

6. Tighten the tensioning screw.

7. Check all retaining screws and retighten to the correct torque.

7-112

SS11H186

1

7 - MAINTENANCE

Change the tandem box swing unit oil WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

– Place receptacles for waste oil under the drain plugs. For the required capacity of this vessel, see 7-26.

– Collect escaping oil and dispose of it without polluting the environment.

1. Unscrew both drain plugs (6); the oil flows out.

2. Screw drain plugs back in place with a new sealing ring.

3. Fill in new gearbox oil as described under 7-79. (For oil quality see 7-16 and for oil quantity see 7-26).

SS14G142

7-113

1

7 - MAINTENANCE

Drain off water and deposits from the fuel tank WARNING Fuel vapors are explosive and flammable.

Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately.

Failure to comply could result in death or serious injury.

W0904A

WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

Impurities and water settle on the bottom of the fuel tank. This is the case especially if the machine is filled up frequently or regularly with fuel from cans or drums or when the machine is used on sites with strong fluctuations of daytime/nighttime temperatures.

The result is the formation of condensed water, especially if the tank is not full.

At temperatures below 0 °C (32.0 °F), this water freezes and can no longer be drained off via the drain plug.

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

For this reason, water and deposits must be drained off at the end of the workshift and the tank subsequently filled.

1. Place a receptacle under the drain plug. The drain plug opens when the draining hose is screwed onto the valve.

2. Drain off water and deposits and dispose without polluting the environment.

3. Unscrew the draining hose.

4. The drain plug closes automatically.

5. Fill fuel through the strainer in the filler tube. Wash the strainer in paraffin oil before filling.

7-114

SS13A866

1

7 - MAINTENANCE

Change the drive belt WARNING Avoid injury!

Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear.

Failure to comply could result in death or serious injury.

W0208A

WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

W0251A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

NOTICE: If an air conditioner is installed, the compressor must be loosened and the belt removed.

1. Tilt the automatic belt tensioner (3) backwards using a special flex head square spanner (5) and remove the used belt (4) from alternator (1), water pump (2), deflection pulleys, and belt pulley.

2. Place the new belt (4) in correct position over belt pulley, water pump (2), alternator (1), and deflection pulleys.

3. Set the automatic belt tensioner (3) back to its tensioning position.

4. No other adjustments are necessary.

SS11H164

7-115

1

7 - MAINTENANCE

Change the hydraulic return flow filter WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

W0251A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

The return-flow filter must be replaced: – During servicing as per with the servicing schedule.

– After repairs to the hydraulic system.

1. Clean the reservoir surface and structures.

2. Release the reservoir charging pressure, as described in the section 7-132.

3. Unscrew the cap (3) and remove.

SS14G141

1

SS11K225

2

4. Lift out the return-flow filter (4).

7-116

7 - MAINTENANCE

5. Carefully insert the new filter cartridge (4) into the hydraulic reservoir.

6. Check the gasket (6) and the spring (5) of the cap (3) for damage and replace it if necessary (see figure 2).

7. Put the cap (3) (see figure 1) back in place and tighten it.

SS11K226

7-117

3

7 - MAINTENANCE

Change the front-wheel drive oil filter (Only all-wheel version) WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

NOTE: If rear ripper is mounted, close the teeth protection and lower the rear ripper otherwise the engine hood can be damaged.

The oil filter for the front-wheel drive is accessible after opening the engine hood. It is located on the left side of the engine.

1. Clean the filter head and the housing.

2. Unscrew the filter housing (1), taking care not to spill hydraulic oil.

3. Withdraw the filter element from the filter head (2) and dispose of it without polluting the environment.

4. Clean the filter housing and sealing surfaces on the filter head.

5. Press the new filter element with one turn onto the filter head.

6. Fill the filter housing with hydraulic oil.

7. Screw the filter housing back.

8. After putting the hydraulic system into operation, check the filter housing for leaks.

7-118

SS14D073

1

7 - MAINTENANCE

Every 1000 hours or yearly

Change the main filter element - air intake system WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

W0251A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

NOTICE: Never start the engine when parts of the air intake system have been removed.

Risk of damage to the engine if unfiltered air enters the engine.

NOTE: If rear ripper is mounted, close the teeth protection and lower the rear ripper otherwise the engine hood can be damaged.

• The grader has a dry air filter with one main filter element and one safety filter element.

• The dry air filter is located under the engine hood behind the driver’s cab. The filter is accessible on the left-hand side of the machine after opening the hood.

Factors to consider before you decide whether cleaning or washing of air filters is appropriate for your machine: • Heavy-duty air filter manufacturers do not recommend any type of cleaning process be used on their products. The heavy-duty air filter manufacturers does not warrant the air filter once it has been cleaned.

• Damaged filters should not be cleaned or reused.

If the filter is damaged in service, investigate the source of damage and make corrections to avoid future damage.

• It is recommended, when the warning lamp lights, to follow the service procedures and to replace the used filter with a new one. Dispose of the used filter in a responsible manner.

NOTE: Filter dirt holding capacity is reduced 20 40 % with each cleaning.

There is a risk of dirt reaching the clean side of the filter while cleaning, plus possible filter damage from high pressure water or compressed air, makes cleaning or washing a gamble. Add the cost of cleaning to the danger of filter damage when determining the risk versus the value of filter cleaning process.

Reuse of cleaned heavy-duty filters increases the likelihood of improper air cleaner servicing because of the shortened service life. Each time the air intake system is serviced, it is exposed to the possibility of contamination.

7-119

7 - MAINTENANCE

1. Detach the clips (2), remove the cap (4), and clean it.

SS14F052

1

SS14E084

2

2. Loosen the filter gasket seal. Use the handle to push down on the filter to loosen the seal, which will tilt the filter to approximately a 5 ° angle.

3. Carefully remove the main filter element (6).

NOTE: The safety filter element remains in place.

4. Before installing a new main filter element visually check for cuts, tears, or indentations on the sealing surfaces.

5. Slide the main filter element down at approximately a 5 ° angle until it hits the end of the housing. Rotate the filter toward the outlet section to complete the seal.

6. Install the cap and fasten the clips.

NOTE: If the cap doesn't’ seat, remove and re-check the filter position. The cap will be difficult to install if the filter isn’t installed correctly.

7. Check visually the inlet and outlet connections.

General maintenance tips 1.

Don’t remove filter for inspection.

2.

Never rap a filter to clean it.

3.

Never judge the filters life by looking at it. Measure the airflow restriction.

4.

Never leave an air cleaner open longer than necessary.

5.

Don’t ignore a worn or damaged gasket in the housing.

6.

Don’t use a damaged or bunched filter.

7.

Replace missing or damaged parts.

8.

Never substitute an incorrect filter model number.

7-120

7 - MAINTENANCE

Check the heating/air conditioning Heating 1. To turn on the heating, turn the fan knob (1), in position 1.

2. The heating rotary knob (2) serves to adjust the heating, performance steplessly between cold and warm.

3. Turn the knob (2) counterclockwise to increase the air temperature.

4. Turn the knob (2) clockwise to decrease the air temperature.

LEIL15GRD0109AB

1

LEIL15GRD0110AB

2

Air Conditioning 5. Start the engine.

6. To switch on the air conditioner, the pushbutton (3) must be on and the rotary knob (1) must be in position 1, 2 or 3.

7. Switch on the air conditioner by pressing the pushbutton (3). The indicator lamp under the symbol lights up.

8. If a greater amount of air is desired, turn the rotary switch to level 2 or 3.

7-121

7 - MAINTENANCE

Compressor drive belt - Check WARNING Rotating parts!

Shut off the engine before opening the engine hood.

Failure to comply could result in death or serious injury.

W1059A

WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

W0251A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

NOTICE: Incorrect tension of the V-belt affects the performance of the compressor. It can also cause damage to the belt and/or the compressor.

The compressor (11) is flange-mounted on the engine block. The tension of the V-belt can be checked on the left-hand side of the engine.

1. Open the engine compartment.

2. Check that the retaining screws holding the compressor on the supporting bracket and those holding the supporting bracket on the engine block are properly tightened and retighten, if necessary.

3. Check the V-belt and replace if damaged.

4. Depress the V-belt in the middle between the pulleys with your thumb. If the tension is correct, the belt can be depressed by approx. 10 mm (0.4 in). If the tension of the belt deviates from this value, the belt must be retensioned or slackened by doing the following: 5. Loosen the tensioning screw (13) and tension the V-belt.

6. Tighten the tensioning screw.

7. Check all retaining screws and retighten to the correct torque.

7-122

SS11H186

1

7 - MAINTENANCE

Every 1500 hours

Change the CCV/engine breather filter NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

The filter should be changed more frequently when operating conditions are severe.

The breather is located on the rear left-hand side on the engine (in travel direction).

1. Remove the screws on the filter housing. The housing will contain two filters.

2. Replace the two filters, taking care to fit back into housing correctly. Install the cover and tighten the screws.

SS13K052

7-123

1

7 - MAINTENANCE

Calibrating the gear box WARNING Hazard to bystanders!

Make sure the area surrounding the machine is clear of all persons before starting the engine.

Failure to comply could result in death or serious injury.

W0090A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

1. Check that the parking brake is applied.

2. Place the transmission control lever in neutral.

3. Start the engine.

4. With the engine running at idle, enter the service screen menu and scroll to calibration screen.

SS14H031

1

SS14C105

2

5. Press the confirm key.

6. Use the down arrow button to scroll to clutch calibration.

Highlight clutch calibration and press the confirm key.

Always follow the prompts on the screen.

NOTE: You can use the escape key to leave the calibration procedure at any time.

7. If the transmission oil temperature is too low, the message “Please wait for Sump Temp” appears on the screen and the machine must be warm-up before the calibration can be executed. The message is active as long as the oil temperature has reached the necessary temperature.

NOTE: To execute the calibration procedure the transmission oil temperature must be 70.0 - 95.0 °C (158.0 203.0 °F).

8. Warm-up procedure: 1.

Press and hold the travel brake.

2.

Engage the 3rd gear in manual mode.

3.

Set up the engine to high idle and change from 3rd gear into neutral from time to time to speed up the process.

7-124

7 - MAINTENANCE

9. If the oil temperature is in range to start the calibration process, follow the prompts on the screen to finish the process.

The screen will show a confirm prompt. If you doubt your ability to perform this operation, press the escape key and call your dealer.

If machine conditions are incorrect, an error message will appear. The calibration procedure will not complete.

Follow the prompts to aid in correcting any machine conditions.

The screen may display the following prompts to guide the user to correct machine conditions: • Not in neutral • Parking brake OFF • Machine moving

SS14C106

• Oil temp too low • Oil temp too high • Engine RPM low • Engine RPM high If conditions are correct, the user will see six calibration screens displayed. They will appear in the following order: • Adjust K1 • Adjust K2 • Adjust K3 • Adjust K4 • Adjust KV • Adjust KR • Adjust KW (5-speed only) Once the calibration process is complete, the user will be prompted to turn the engine Off and restart the machine.

If the process is not completed, the screen will prompt the user to escape.

7-125

3

7 - MAINTENANCE

Every 2000 hours

Change the differential/side reducer gear oil on rear axle WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

– Place receptacles for waste oil under the drain plugs. For the required capacity of this vessel, see 7-26.

– Collect escaping oil and dispose of it without polluting the environment.

1. Unscrew the drain plug (2); the oil flows out.

2. Screw drain plug back in place with a new sealing ring.

3. Fill in new gearbox oil as described under 7-79. (For oil quality see 7-16 and for oil quantity see 7-26).

SS11H218

7-126

1

7 - MAINTENANCE

Check valve setting on engine 1. For detailed information contact your authorized dealer.

7-127

7 - MAINTENANCE

Every 3000 hours

Clean the fuel tank WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

NOTICE: – Use only diesel fuel or a special-purpose cleaning oil to clean the tank. Observe the instructions issued by the manufacturer of the cleaning oil.

– Be sure to prevent fuel and cleaning oil from seeping into the ground.

– Keep for reuse or dispose in accordance with local environmental regulations.

1. Run the machine until the fuel tank is almost empty.

2. Check how much fuel is left in the tank and place an adequately large receptacle below the drain plug of the tank.

3. Drain off the diesel fuel at the drain plug. Use the oildrainage hose for this (see also 7-27).

4. Place a receptacle below the plug to catch the cleaning fluid.

SS13A866

1

SS14D031

2

5. Unscrew the tank cap (3).

6. Clean the tank cap (3) and the filler strainer thoroughly with diesel fuel.

7. Clean and flush the tank with a cleaning device.

8. When the cleaning fluid has drained off: – Unscrew the oil draining hose and screw a protective cap onto the drain plug.

9. Fill fuel through the filler strainer in the filler tube.

7-128

7 - MAINTENANCE

Check and adjust the hydraulic pressure • All pressure relief valves in the hydraulic system have been set at the factory to the prescribed operating pressure and have an anti-tampering protection.

• Have the operating pressures checked and readjusted by your authorized dealer.

7-129

7 - MAINTENANCE

Depressurising the hydraulic system WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries.

Hydraulic fluid is under extreme pressure. Rest the bucket or attachment on the ground. Shut the engine off, turn the key on, and move the hydraulic control lever through all movements several times to relieve residual pressure in the system.

Failure to comply could result in death or serious injury.

W0161A

WARNING Escaping fluid!

Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately.

Failure to comply could result in death or serious injury.

W0178A

WARNING Escaping fluid!

Do not connect or disconnect hydraulic quick coupler under pressurized conditions. Make sure all hydraulic pressure is removed from the system before connecting or disconnecting hydraulic quick coupler.

Failure to comply could result in death or serious injury.

W0095B

WARNING Burn hazard!

Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid temperature should not exceed 40 °C (104 °F).

Failure to comply could result in death or serious injury.

W0241A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

Depressurize the hydraulic system before starting work: 1. Apply the parking brake, set the powershift transmission to the neutral position.

2. Completely retract the blade pitch adjustment cylinder.

3. Lower the blade to the ground.

4. Tilt the wheel rake on one side to the limit stop.

5. If the machine is fitted with a front grading blade and/or a rear ripper, set it/them down onto the ground.

6. Shut off the engine and secure the machine as described in the section 7-5.

7-130

7 - MAINTENANCE

7. Move the control levers several times from limit to limit stop for the following functions: • Blade rotation • Blade shift • Articulated-joint steering • Front grading blade (option) • Rear ripper (option) 8. Depressurize the hydraulic reservoir (see also 7-132).

This depressurizes the aforementioned systems (cylinders and lines).

The lines between the control block and the lowering brake valves flange-mounted on the cylinders are then depressurized.

NOTICE: However, pressure remains in the blade lifting cylinders and the lowering brake valves flange-mounted on these.

Depressurize the blade lifting cylinder as described under 6-14.

Pressure also remains in the system sections wheel camber, blade rotation gear, and blade pitch adjustment. This pressure is released by careful loosening of the threaded line connections.

7-131

7 - MAINTENANCE

Depressurising the hydraulic reservoir WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

W0251A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

NOTE: If rear ripper is mounted, close the teeth protection and lower the rear ripper otherwise the engine hood can be damaged.

The hydraulic reservoir (1) is pressurized with a light precharging pressure of max. 0.7 bar (10.1 psi). This pressure must be released before opening the tank.

1. Open the hood.

2. Open the breather valve (2) by approx. 1/2 turn to let the air escape.

3. Close the breather valve again after the air has escaped.

SS14G143

7-132

1

7 - MAINTENANCE

Change the hydraulic reservoir breather valve WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

W0251A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

NOTE: Depressurize the hydraulic system, see also 7-130.

The breather valve (2) ensures the aeration and deaeration of the hydraulic reservoir in the event of hydraulic fluid level fluctuations.

• The valve maintains a reservoir precharging pressure of approx. 0.7 bar (10.1 psi).

• The breather valve is equipped with a filter element.

This filter element cannot be replaced or cleaned.

• The breather valve must therefore be replaced as a complete unit.

SS14J024

7-133

1

7 - MAINTENANCE

Clean the hydraulic reservoir WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

CAUTION Hazardous chemicals!

Never clean with gasoline, naphtha, or any other volatile materials. These materials are toxic and/or flammable.

Failure to comply could result in minor or moderate injury.

C0061A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

NOTICE: Use only hydraulic oil or a special cleaning agent for cleaning and flushing the reservoir.

1. Drain off hydraulic oil, see also 7-137.

2. Unscrew the breather filter (2) and remove the returnflow filter, see also Oil return filter - Replace.

3. Place a collecting vessel for flushing oil under the hydraulic reservoir.

4. Clean the inside of the reservoir with hydraulic oil or with flushing oil. Thoroughly remove all deposits and cleaning-agent residue.

5. Replace the O-ring seal underneath the cap (2).

6. Put the cap back in place.

SS14J024

7. Refit the cover plate below the hydraulic reservoir.

8. Fill with hydraulic oil.

7-134

1

7 - MAINTENANCE

Change the environment friendly hydraulic fluid (if used) WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

1. Bring hydraulic system to operating temperature.

2. Retract all hydraulic cylinders.

3. Drain off hydraulic fluid, see also 7-137.

4. Fill hydraulic fluid tank with ISO VG 46 up to halfway mark.

5. Activate all hydraulic functions including travelling for about 30 min. The hydraulic system is flushed.

6. Then drain off the hydraulic fluid after this time.

– It must be properly disposed of. A disposal expert must be consulted in this case, as this is a mixture of biodegradable hydraulic fluid and mineral hydraulic fluid.

7. Change the return flow filter, see also Oil return filter - Replace.

8. Change the oil filter for the front-wheel drive, see also Front-Wheel Drive (FWD) - Replace (only for 836C AWD and 856C AWD).

9. Fill the hydraulic fluid tank with new ISO VG 46.

Fix one instruction sticker: 1. In the cab.

2. On the hydraulic fluid tank.

3. On the equipment.

4. Put the machine into operation. Check level in hydraulic tank.

5. The hydraulic fluid may dissolve deposits in the hydraulic system.

– Therefore change all filters 30 to 50 operating hours after making the change.

– Make further filter changes according to the maintenance plan.

6. Sample the hydraulic fluid after 30 - 50 h operating hours and send in for analysis. See also 7-136.

7-135

SS11H116

1

7 - MAINTENANCE

Hydraulic fluid analyze Special analysis sets are compiled for taking samples.

They contain all necessary parts.

1. Analysis sets are available from our spare-parts service.

2. After 30 to 50 operating hours with environmentally friendly hydraulic fluid, take the first sample.

– Send this sample in for analysis.

3. After this, we recommend sending in a sample for analysis every 1000 operating hours or once a year.

4. It is essential that the hydraulic fluid should be analyzed not later than after 3000 operating hours.

– The results of the analysis show whether the hydraulic fluid is still serviceable and the changing intervals can be extended.

– In case of questions ask your authorized dealer.

7-136

7 - MAINTENANCE

Every 3000 hours or every 3 years

Change the hydraulic oil WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries.

Hydraulic fluid can also infect a minor cut or opening in the skin. Serious infection or reaction can result without immediate medical treatment. If injured by leaking fluid, see your doctor immediately.

Failure to comply could result in death or serious injury.

W0358A

WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

NOTICE: Do not start the drive engine when the hydraulic oil tank is empty.

The hydraulic pumps can be irreparably damaged by dry running.

Draining off the hydraulic oil 1. Place all working attachments on the ground.

2. Shut off the engine.

3. Release the reservoir charging pressure, as described under 7-132.

4. Place a collecting vessel under the drain plug of the hydraulic reservoir (8). For the required capacity of this vessel, see 7-26.

5. Drain off the hydraulic oil with the oil draining hose. Use of the oil draining hose is described under 7-27.

6. When the oil has drained off, unscrew the draining hose.

7. Screw the drain plug protective cap back in place.

7-137

SS11H174

1

7 - MAINTENANCE

Filling with hydraulic oil NOTE: For oil quality see 7-16 and for oil quantity see 7-26.

1. Place all working attachments on the ground.

2. Shut off the engine.

3. Clean the reservoir surface and structures.

4. Depressurize the reservoir precharging pressure as described under 7-132.

5. Unscrew the caps of the filler tube (3) and breather valve (2).

6. Fill in hydraulic oil through the strainer until the oil level reaches the mark in the middle of the inspection glass.

7. Screw caps back in place.

SS14J023

8. Start the engine and actuate the control levers of all attachments several times from limit stop to limit stop.

These movements help to fill and vent the hydraulic system.

9. Stand working attachments back on the ground and shut off the engine.

7-138

2

7 - MAINTENANCE

Change the safety filter - air intake system WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

W0251A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

NOTICE: – Never attempt to clean the safety filter element.

– Do not start the engine when the filter element has been detached. The engine sucks in unfiltered air and can thus be damaged.

– After three changes of the main filter element the safety filter must be replaced by a new one, but always after three years at the latest.

1. Detach the clips (2), remove the cap (4), and clean it.

SS14F052

1

SS14E084

2

SS14J026

3

2. Loosen the filter gasket seal. Use the handle to push down on the filter to loosen the seal, which will tilt the filter to approximately a 5 ° angle.

3. Carefully remove the main filter element (6).

4. Use the plastic handle on the safety filter to pull the filter toward the center of the housing and remove the safety filter.

5. Before installing a new safety filter element visually check for cuts, tears, or indentations on the sealing surfaces.

6. Use the plastic handle on the safety filter to put the safety filter into the positioning slot and then push the filter in place until the filter seats firmly and evenly within the housing.

7-139

7 - MAINTENANCE

7. Slide the main filter element down at approximately a 5 ° angle until it hits the end of the housing. Rotate the filter toward the outlet section to complete the seal.

8. Install the cap and fasten the clips.

NOTE: If the cap doesn't’ seat, remove and re-check the filter position. The cap will be difficult to install if the filter isn’t installed correctly.

9. Check visually the inlet and outlet connections.

7-140

7 - MAINTENANCE

Every 4000 hours or 2-yearly

Change the DEF/AdBlue® supply module main filter NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

1. Open the hood, see page Engine hood - Advice. The supply module main filter is located on the left-hand side of the machine directly below the supply module.

2. Use a suitable container to catch any fluid that is discharged during hose and filter disassembly. Thoroughly clean the underside of the supply module using compressed air. Remove the filter cover by turning counterclockwise.

3. Remove the equalizing element from the center of the filter. Discard the equalizing element following local environmental and waste regulations.

SS14F050

1

SS14G145

2

NOTICE: Contamination or damage of the sealing surface on the housing must be prevented.

4. Observe the color of the filter (gray or black). Insert the corresponding marked end of the filter removal tool, until a click is felt or heard, indicating that the tool is completely inserted.

5. Pull the filter and the filter removal tool out by hand. If necessary, insert a tool in the filter removal tool’s slot for additional leverage. Discard the filter, following local environmental and waste regulations.

NOTICE: Protect the filter chamber from contamination and particles.

6. Clean the supply module’s thread surfaces and the internal filter housing surface with water.

7. Oil the O-rings of the new filter and insert them into the supply module housing.

8. Insert the new equalizing element.

9. Clean the filter cover with water and reinstall.

10. Start the engine and rune at idle speed. Check for leaks.

NOTICE: Never use a filter wrench to install a new filter.

7-141

7 - MAINTENANCE

Every 4000 hours or every 4 years

Change the Organic Acid Technology (OAT) coolant WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

W0251A

NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

1. Open the hood, see page Engine hood - Advice. The Organic Acid Technology (OAT) tank is located on the right side of the machine.

SS14F048

1

SS14J037

2

2. Unplug the hose and drain the coolant into a suitable container.

3. Reinstall the hose.

7-142

7 - MAINTENANCE

4. Open the cap (1).

5. Fill the tank till the “Cold Fill” mark on the tank is reached.

6. Close the cap (1).

SS14F047

7-143

3

7 - MAINTENANCE

As required maintenance

Clean the DEF/AdBlue® tank neck filter NOTE: – Read and observe Safety rules and following.

– Secure the machine as described under 7-5.

1. Open the hood, see page Engine hood - Advice. The Diesel Exhaust Fluid (DEF)/AdBlue® tank is located on the left side of the machine. The mesh filter is located within the neck of the Diesel Exhaust Fluid (DEF)/AdBlue® fill tube.

2. Clean the area to be serviced in order to keep contamination from the Diesel Exhaust Fluid (DEF)/AdBlue® tank.

SS14F045

1

SS14F033

2

SS14F054

3

3. Remove the Diesel Exhaust Fluid (DEF)/AdBlue® cap (1).

4. Remove the filter assembly from the Diesel Exhaust Fluid (DEF)/AdBlue® tank neck.

5. Clean the filter with water, or if necessary replace the filter.

6. Reinstall the filter assembly.

7-144

7 - MAINTENANCE

Battery

Battery WARNING Battery gas can explode!

To prevent an explosion: 1. Always disconnect the negative (-) battery cable first. 2. Always connect the negative (-) battery cable last. 3. Do not short circuit the battery posts with metal objects. 4. Do not weld, grind, or smoke near a battery.

Failure to comply could result in death or serious injury.

W0011A

NOTE: If rear ripper is mounted, close the teeth protection and lower the rear ripper otherwise the engine hood can be damaged.

Battery location The batteries are located on the right-hand side of the engine.

The batteries are accessible after opening the engine hood and removing the step.

The system voltage of 24 V is supplied by two 12 V batteries connected in series.

SS11H152

1

SS11H153

2

Battery removal 1. Turn the key-switch to position "0" and withdraw the key. Wait for complete shutdown. Wait for completion of purging of DEF/AdBlue®. Pay attention of noises coming from pump after turning key OFF. 2. Disconnect the negative terminal (see figure 1) of the battery.

3. Remove the jumper cable between the batteries.

4. Disconnect the positive terminal of the battery.

5. Insulate the battery terminals.

6. Unscrew the battery holders (A) and (B).

7. The batteries can now be removed from the baseplate.

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7 - MAINTENANCE

Battery installation Before installing the battery, clean the battery posts and the pole terminals down to the bright metal.

1. Install the new battery.

2. Refit the battery holder (A) and (B) (see figure 2) and tighten the screws.

3. Connect the pole terminal to the positive post (see figure 1) of the battery and tighten the screw.

4. Re-install the jumper cable between the batteries and screw tight.

5. Connect the pole terminal to the negative post of the battery and screw tight.

6. Apply a special grease or acid-free vaseline to the battery posts and the pole terminals.

NOTICE: – To prevent damage, do not use force when tightening the screws of the pole terminals.

– Loose or corroded pole terminals will cause overloading of the alternator and the regulator.

Battery storage For extended outage periods, remove battery/batteries and store in a dry, well-ventilated place at ca. 20 °C (68.0 °F). Observe the following maintenance points: • Clean the battery/batteries.

• Check acid density and battery fluid level every 2 weeks.

• Charge the batteries when the acid density has fallen to 1.23 kg/dm³ at the latest.

• Keep battery/batteries clean and dry externally.

Winter operation In winter, batteries are subject to particularly harsh operating conditions. At low temperatures their starting power is much lower than their capacity at normal temperatures.

A discharged battery can freeze when the temperatures are just a few degrees below zero.

We therefore recommend having the batteries checked and, if necessary, recharged by your authorized dealer before the cold season begins.

7-146

7 - MAINTENANCE

Recharging the battery WARNING Avoid injury!

Use Personal Protective Equipment (PPE), including protective goggles, gloves, and safety footwear.

Failure to comply could result in death or serious injury.

W1036A

WARNING Explosive gas!

Batteries emit explosive hydrogen gas and other fumes while charging. Ventilate the charging area.

Keep the battery away from sparks, open flames, and other ignition sources. Never charge a frozen battery.

Failure to comply could result in death or serious injury.

W0005A

WARNING Battery acid causes burns. Batteries contain sulfuric acid.

Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.

Failure to comply could result in death or serious injury.

W0111A

Trickle charge/booster charge • When charging with weak currents (trickle charge with small charger), it is not necessary to disconnect the connecting leads to the electrical system. The instructions of the charger manufacturer must always be observed. When the batteries are not removed from the machine, use a charger with a charging voltage of 24 V (batteries connected in series).

NOTICE: When boost-charging the battery, the maximum charge current must not exceed 10 % of the nominal battery capacity. Maximum charging duration is 30 h for a completely discharged battery.

Fast charge 1. Observe the instructions of the charger manufacturer.

2. Before fast charging, i.e. charging with high currents, both connecting leads must be disconnected and the batteries removed (see also Safety rules and following and Battery - Replace).

3. Before charging, open the battery plugs to such an extent that the gas can escape from all cells.

4. A discharged battery can freeze at a temperature of - 10 °C (14.0 °F). It is essential to thaw out a frozen battery before fast charging or it may explode.

5. Plug the power cord of the charger into the socket only after the terminal clamps of the charger have been correctly fastened on the battery terminal posts.

– Red = Plus – Black = Minus 6. After charging, reinstall the battery and reconnect in the correct order (first the positive, then the negative lead).

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Assisted starting (Jump-starting) Prior to assisted starting NOTE: Read and observe Safety rules and following.

• Secure the supplying and receiving machines if necessary (warning triangle, accident prevention, traffic safety).

• Note the maximum capacity of the jumper cables.

• The engine output of the receiving machine must not be greater than that of the supplying machine.

• Switch off all consumers at the receiving machine (empty batteries) and switch the keyswitch to 0.

• Switch off all consumers at the supplying machine (charged batteries) and switch off the engine.

• The capacity of the supplying batteries must not be smaller than that of the discharged batteries.

NOTICE: A discharged battery can freeze at a temperature of -10 °C (14.0 °F). Before connecting the jumper cable, it is absolutely necessary to thaw the battery or it might explode.

Connecting the jumper cables 1. Connect the red jumper cable first to the positive pole of the empty battery (1), then to the positive pole of the charged battery (2).

2. Connect the black jumper cable first to the negative pole of the charged battery (3), then to a bare-metal part of the machine to be charged (4).

SS13A392

7-148

1

7 - MAINTENANCE

Starting up the engines 1. Start up the engine of the supplying machine and run it at high speed.

2. Start the engine of the receiving machine. If the engine fails to start after 15 s, wait for 1 min, then start again.

When the engine has started proceed as follows: 3. Switch on several consumers with high current consumption, e.g. the complete lighting system, the blower at stage 3 and possibly also the air conditioner. This prevents voltage peaks being produced when detaching the jumper cable that could damage electronic assemblies.

4. Disconnect the jumper cables in the following order: – Negative pole at receiving machine (4) (see figure 1) – Negative pole at supplying machine (3) (see figure 1) – Positive pole at supplying machine (2) (see figure 1) – Positive pole at receiving machine (1) (see figure 1) 5. Remove the jumper cables from the NATO connectors and store them.

6. Switch the high-current consumers off again.

7. Run the engine for about half an hour at medium speed.

The batteries are partially charged.

NOTICE: Have the electrical system of the machine checked. This can determine why the batteries were discharged.

7-149

7 - MAINTENANCE

Diagnosis sockets

Diagnosis sockets The diagnosis sockets are located to the left of the operator seat.

SS14E083

Pos. Designation 1 CAN diagnosis socket (all controllers CAN1 and CAN2) 2 ZF transmission diagnostic interface

7-150

1

7 - MAINTENANCE

Lighting system

Replacing bulbs

SS14D027

Pos. 1 Headlight 2 Turn signal light

Designation

3

Taillight/Stoplight/Turn signal light

4 5

Reversing light Number plate light (option)

1

Pos. Designation 6 Turn signal light/Sidemarker light 7 Driver’s cab – additional floodlights – on top in front (option) – on top at the rear (option) 8 Additional floodlights – in front at the bottom (option) – at the rear at the bottom (option) 9 Rotary beacon (Option)

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7 - MAINTENANCE

Replacing bulbs NOTICE: – Shut off the engine and set the key switch to “0” before replacing any bulbs.

– Replace defective bulbs only with bulbs with the same ratings.

– Never touch new bulbs with bare fingers. Finger sweat and dirt will burn into place when the bulb is hot and may reduce the service life of the bulb.

Before installing a new bulb: – Remove all traces of corrosion from the holder and the electrical contacts.

– This helps avoid contact problems and high contact resistances.

Bulbs – table Headlight Parking light Floodlight Turn signal light Brake light Tail light Cab interior light Rotary beacon light

55/50 W / 24 V 4 W / 24 V 70 W / 24 V 21 W / 24 V 21 W / 24 V 10 W / 24 V 10 W / 24 V 55 W / 24 V

7-152

7 - MAINTENANCE

Headlight – Driving light/Parking light 1. Loosen the screw (9) and carefully remove the headlight insert (10).

SS14J018

2

SS11K212

3

SS14J019

4

2. Turn the bulb carrier (11) to the left and withdraw it from the headlight insert (10).

Driving light 1. Remove the bulb (12) from the socket (13) and replace it with a new one.

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7 - MAINTENANCE

Parking light 1. Remove the socket (14) from the headlight insert (10) and replace the bulb (15) with a new one.

2. Install the bulb carrier (11) on the headlight insert and lock it in place by turning it clockwise.

SS14J020

5

SS11K214

6

SS11K207

7

3. Engage the headlight insert (10) with the clip (16) in the headlight housing (17), press the headlight insert (10) into the housing, and fasten it with the screw.

Turn signal light 1. Remove the screw (18) and unhook the housing (19).

2. Replace the defective bulb.

3. Reassemble in reverse order.

7-154

7 - MAINTENANCE

Rear light/Reversing light 1. Loosen the screws (5) and remove the glass (6) carefully from the housing.

SS11H189

8

SS11H190

9

2. Replace defective bulbs.

(1) – Bulb for reversing light (2) – Bulb for brake light (3) – Bulb for turn signal light (4) – Bulb for tail light 3. Reassemble in reverse order.

Number plate light 1. Loosen the screw (32) and withdraw the light housings (33).

2. Replace the defective bulb (34).

3. Reassemble in reverse order.

7-155

SS11H187

10

SS11H188

11

7 - MAINTENANCE

Sidemarker light/Turn signal light 1. Loosen the screw (36) and withdraw the light housings (37).

SS11K209

12

SS11K210

13

SS11K208

14

SS11K215

15

2. Replace defective bulbs.

(38) – Bulb for turn signal lights (39) – Bulb for sidemarker lights 3. Reassemble in reverse order.

Floodlights 1. Loosen the screw (40) and carefully remove the headlights insert (41) from the housing.

2. Slide the spring clamp (42) in the direction of the arrow and fold it up.

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7 - MAINTENANCE

3. Remove the bulb (43) from the headlight insert (41) and replace it with a new one.

4. Slide the bulb into the headlight insert (41) and engage the spring clamp (42) in the headlight insert.

5. Place the headlight insert (41) back on the housing and fasten it with the screws.

SS11K213

16

SS11K193

17

SS11K194

18

SS11K195

19

Rotary beacon (option) 1. Press the lever (21) and remove the cover (22).

2. Remove the lamp (23) and replace it with a new one.

3. Replace the cover (22) (see figure 17). Press the lever (21) (see figure 17) and snap on the cover (22) (see figure 17) until it audibly engages.

Rotary beacon, replacing the reflector 1. Remove the cover (22) (see figure 17).

2. Remove the hook (24) with the help of small pliers.

3. The reflector and the motor (25) can now be removed completely.

4. Install a new reflector with motor (25). Refit the hook (24) and put the cover (22) (see figure 17) back in place.

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7 - MAINTENANCE

Retrofitting a rotary beacon 1. The rotary beacon is fixed with 4 screws (1) at the rear of the cab roof on the right.

2. The beacon is connected to the power supply by means of the prefabricated cable with connector (2).

SS11H200

7-158

20

7 - MAINTENANCE

Wheels

Changing a wheel 1. Secure the machine as described under 7-5.

2. Loosen the wheel nuts on the wheel to be replaced by about 1 turn.

3. If a rear wheel is damaged, raise the relevant side of the machine with the blade. Turn the blade so that one end of the blade is in front of the damaged wheel. Then raise the machine with the appropriate lifting cylinder.

4. If a front wheel is damaged, raise the machine with the blade or with the front grading blade (optional equipment).

5. Prop up the raised axle with squared timber so that it cannot sink back down.

6. Deflate the tires.

7. Unscrew the wheel nuts and take off the wheel.

8. Take care not to damage the threads of the wheel nuts.

9. Do not lose the centring rings, spring washers, and wheel-nuts and reuse them when refitting the wheel.

10. Fitting the new wheel: – Inflate the tires to a pressure of approx. 1 bar (14.5 psi).

– Observe the instructions under page 7-67.

– Be sure not to damage the threads of the wheel studs.

11. Tighten the wheel nuts by hand.

12. Remove the supports under the lifted axle and lower the axle.

13. Tighten the wheel nuts crosswise with the prescribed torque.

14. Inflate the tires to the correct pressure. See also Safety rules and following and 8-18.

15. Check the wheel nuts after 5 operating hours with a torque wrench for tightness.

Tire tread position • When fitting wheels with tread direction dependent tires, pay attention to the direction of the tire tread.

• We recommend fitting the four rear wheels as shown.

This tire tread position yields the highest traction performance for forward travel.

• Fit the free wheeling front wheels with the tread against the tread direction of the rear wheels.

• For all-wheel driven machines, set the front-wheel tire tread pattern facing in the same direction as that of the rear wheels.

SS11H183

7-159

1

7 - MAINTENANCE

Equipment

Replacing the blade cutting edges NOTE: Read and observe Safety rules and following.

1. Raise the blade and prop it up with wood, so that the side blades (2) and the scraping blades (5) can be replaced.

2. Unscrew the countersunk bolts (4) and remove the blades.

3. Attach the new blades and secure them with countersunk bolts (4).

NOTE: Tighten the bolts with 250.0 N·m (184.4 lb ft).

7-160

SS14J021

1

SS11H202

2

7 - MAINTENANCE

Welding operations

Protection of the electronic modules during welding operations NOTE: Read and observe Safety rules and following.

NOTICE: The following procedure must be followed when performing welding operations to avoid damage to electronic assemblies (e.g. instrument panel, keypad, engine, ...): 1. Shut off the engine.

2. Turn the key switch of the electrical system to position “0” (ignition OFF) and remove the key.

3. Disconnect the negative and the positive leads from the battery. See also Battery - Replace.

Unplug electronic module connectors At several places, the connectors of electronic components must be unplugged.

• Gearbox control unit “EST37A” (XA1) • Universal control module “UCM” • Instrument panel connections • Engine control unit • Connectors in the driver’s cab • Alternator connector

1. Gearbox control unit “EST37A” (XA1) 1. The gearbox control unit is located in the right hand console in the cab.

2. Remove the panel. Loosen the screws and store them in a safe place.

SS14G146

1

SS14G147

2

3. Draw back the retaining clamp (1) and unplug the connector (2) from the EST unit (A) by pulling it upwards.

Do not forget to disengage the lug at the front end of the connector.

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7 - MAINTENANCE

2. Universal control module “UCM” 1. The UCM is located behind the seat.

2. Remove the cover behind the seat and also on the right-hand side armrest.

3. Loosen all connectors from the UCM.

SS14G149

3

SS11H205

4

SS11H206

5

3. Instrument panel connections 1. The instrument panel is located under the trimming behind the steering wheel. The trimming is fixed to the steering column by 4 screws.

2. Unplug the connectors (1) and (2) from the AIC.

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7 - MAINTENANCE

4. Engine control unit 1. The connectors of the engine control unit are located on the left side of the engine under the hood.

2. Open the engine hood. See also Engine hood - Advice.

3. Unplug the connectors of the engine control unit.

SS14G148

6

SS14E089

7

SS11H210

8

5. Connectors in the driver´s cab 1. The connectors (A) and (B) are located at the right rear under the floor plate of the driver’s cab.

2. Open the engine hood and engage it in service position II. See also Engine hood - Advice.

3. Unlock and withdraw the connectors (A) and (B).

6. Alternator connector 1. The alternator connector is located under the hood on the right side of engine.

2. Unlock the hooks (1) and pull out the alternator plug (2).

After all these steps have been completed, welding operations on the machine can begin (read and observe chapter “Welding operations” in Safety rules and following).

When welding operations are finished, restore all connections to the electronic components. Do this by following the steps described above in reverse order.

NOTICE: Failure to follow this procedure will invalidate all liability and warranty claims for any damage caused.

7-163

7 - MAINTENANCE

Fuse and relay locations

Checking/replacing fuses and relays NOTICE: – Shut off the engine and turn the key switch of the electrical system to 0 before removing fuses.

– Replace defective fuses only with fuses of the same current rating.

In the event of an electrical-function failing, check first the corresponding fuse: 1. Withdraw the fuse from the holder.

2. Check the fuse. In most cases, the melted wire of a defective fuse is visible to the naked eye. In case of doubt, check the fuse with an ohmmeter or immediately replace it with a new one.

3. If the fuse is defective, install a fuse with the same current rating in the holder.

4. If the fuse is not defective, check the electric assembly, the connector, and the cables (or have them checked).

SS11H197

1

SS14E078

2

SS11H199

3

The fuses and the relays are located to the right of the operator seat and behind the operator seat and are housed in 5 boxes.

Pos. 1F/1K 2F/2K 3F/3K 4F/4K 5F/5K

Designation Fuse/relay Fuse/relay Fuse/relay Fuse/relay UCM

box box box box

1 2 3 4

Opening the fuse cover 1. To remove the fuse cover, press the cover together where indicated by the arrows (A) and withdraw the cover in direction (B).

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7 - MAINTENANCE

Fuse/relay box 1F/1K

SS14J022

Fuse/relay designation 1F1 1F2 1F3 1F4 1F5 1F6 1F7 1F8 1F9 1F10 1K AR IGN PWR 1KAUX 1K17 1KCC 1K20.3

Amperes

10 A 30 A 5A 2A 20 A 15 A 7.5 A 7.5 A 5A 5A

Color code

Red Green Beige Beige Yellow Red Brown Brown Beige Beige

4

Consumer

AIC power supply EDC power supply Starter switch S1 to EDC Power Relay K10.1, UCM Ignition ON Filter heater Voltage transformer, radio, power outlet Interior cab light, Power supply rear camera Starter switch S1, starter relay K1.5, Crank signal UCM Alternator Diagnosis socket X123, relay 3K116 After Run Ignition Power Auxiliary relay EDC Relay Defrost Relay start control Relay filter heater

7-165

7 - MAINTENANCE

Fuse/relay box 2F/2K

SS14F039

Fuse/relay designation 2F11 2F12 2F13 2F14 2F15 2F16 2F17 2F18 2F19 2F20 2Kxx 2K14 2K19 2K42 2K115

Amperes

5A 2A 10 A 5A 10 A 7.5 A 7.5 A 10 A 10 A 20 A

Color code

Beige Red Beige Red Brown Brown Red Violet

5

Consumer

Parking brake etc.

Power supply, fuel level switch of fuelling system Relay stop light 2K19, stop light left/right Relay 2K42 floating position Floating position solenoid valves Hazard warning system Turn signal lights Horn, low beam, high beam, headlamp flasher Sidemarker lights, parking light, tail light Sensor SCR system Reserve Relay horn Relay stop light Relay floating position Relay parking brake

7-166

7 - MAINTENANCE

Fuse/relay box 3F/3K

SS14E081

Fuse/Relay designation 3F21 3F22 3F23 3F24 3F25 3F26 3F27 3F28 3F29 3F30 3K116 3K117 3K118 3Kxx 3K81.2

Amperes

7.5 A 7.5 A 15 A 15 A 5A 25 A 10 A 15 A 7.5 A 30 A

Color code

Brown Brown Blue Blue Beige Grey Red Blue Brown Green

6

Consumer

Low beam High beam (left, right) Floodlamp cab roof (front, rear) Floodlamp cab floor (bottom front, rear) Reversing alarm, reversing headlights Power supply NOx sensor, Urea quality, Exhaust flap Connector, operator seat Wiper/washer system, rear, front Rotary beacon Telematic modul & guidance control — unswitched power Relay AIC power delay Relay low beam Relay high beam Reserve Relay reversing

7-167

7 - MAINTENANCE

Fuse/relay box 4F/4K

SS14E082

Fuse/relay designation 4F31 4F32 4F33 4F34 4F35 4F36 4F37 4F38 4F39 4F40 4K111 4K67 4K67.1 4K10 4K12

Amperes

15 A 7.5 A 7.5 A 5A 5A 20 A 15 A 15 A 5A 5A

Color code

Blue Brown Brown Beige Beige Yellow

7

Consumer

Blower for heating air conditioner Gearbox control system EST37A Driving switch, speed sensor/gearbox, EST37A, Power supply Telematic modul & guidance control — switched power Arrestor bolts fast gear working hydraulics Refueling system Heater pre-fuel filter Defrost rear windowscreen License plate light, tail lamp left, parking light left Side-marker front, tail lamp right, parking light right Relay gear control neutral Relay refueling Relay refueling Relay floodlight driver’s cab Relay floodlight driver’s cab floor

7-168

7 - MAINTENANCE

Fuse/relay box 5F/5K

SS14F040

Fuse/relay designation 5F1 5F2 5F3 5F4 5F5 5F6 5F7 5F8 5F9 5F10 5k1 5k2 5k3 5k4 5k5

Amperes

10 A 10 A 7.5 A 7.5 A 7.5 A 7.5 A

Color code

Red Red Brown Brown Brown Brown

8

Consumer

UCM – Power supply 1 switched voltage – power delay UCM – Power supply 2 switched voltage – power delay UCM – Power supply – VF3 UCM – Power supply – VS1 UCM – Power supply – VF4 UCM – Power supply – VF6 Reserve Reserve Reserve Reserve Reserve Reserve Reserve Reserve Reserve

7-169

7 - MAINTENANCE

Storage

Decommissioning procedure If the machine is to be decommissioned for longer than 1 month, the following activities are to be carried out: 1. Place the machine on an even surface in a building or, if this is not possible, in the open under a tarpaulin.

2. The machine should be jacked up to protect the tires.

Once the machine has been jacked up, then the tire pressure should be reduced to 0.7 bar (10.2 psi) or less.

3. If the machine is stored outside, then it must be completely covered with a tarpaulin that also covers the tires to protect the machine from the effects of weather, sunshine, and rain.

Prior to decommissioning, the following activities are to be carried out: 1. Clean the machine.

2. Check the machine for damage and missing parts. Replace parts if necessary.

3. Block the articulated joint.

4. Lower work implements to the ground.

5. Grease the machine thoroughly. Grease the exposed piston rods or brush them with a preserving agent.

Contact your authorized dealer.

NOTICE: When the machine is recommissioned, the protective film will automatically disappear but grease must be removed.

6. Check the oil level and top up as necessary.

7. Clean or replace the air filter element.

8. Check the coolant level. If you had planned to change the coolant in the next 100 operating hours, change the coolant now.

9. Remove the key. Remove the batteries and clean the battery compartment. Ensure that no traces of acid remain. Store the batteries in a cool and dry room where the temperature is above 0 °C (32.0 °F) or remove the battery cable from the minus pole.

10. Touch up paint work where necessary.

11. Close off the air filter inlet and the exhaust pipe.

12. Remove the key and hang a sign saying “Do not operate” on it.

13. Close the engine hood and cab doors.

NOTE: Drain the DEF/AdBlue® system if the machine will be in storage longer than 90 days. The urea quality sensor on the bottom of the DEF/AdBlue® tank can be removed to drain fluid as necessary.

7-170

7 - MAINTENANCE

Preserving the engine 1. Clean the engine with a high-pressure cleaner.

2. Run engine warm and shut off.

3. Drain off engine oil.

4. Fill engine with rust-proofing oil (see engine operating instructions).

5. Drain fuel from fuel tank.

6. Mix a fluid consisting of 90 % diesel fuel and 10 % rustproofing oil and fill into the tank.

7. Allow engine to run for approx. 10 min.

8. Shut off the engine.

9. Turn engine several times by hand to allow preservation fluid to enter the cylinders and combustion chambers.

10. Take off V-belt and store it well-packed.

11. Spray corrosion inhibitor into the grooves of the V-belt pulley.

12. Close suction and exhaust openings.

7-171

7 - MAINTENANCE

Periodic checks during decommissioned period Check monthly: 1. Battery charge level. Charge batteries if necessary.

2. Oil and coolant levels. Top up if necessary.

3. Condition of the cables, connectors, and terminals for rust. Grease if necessary.

4. Condition of the paint work. where necessary.

Apply anti-rust agent

5. Open the air filter inlet and the exhaust pipe.

6. Remove grease from piston rods in hydraulic cylinders.

7. Install the batteries and connect them.

8. Check the tire pressures and pump the tires up to the prescribed pressure if necessary.

9. Remove jacks from under the machine if the machine is jacked up.

10. Release the articulated-joint lock.

WARNING Toxic gas and asphyxiation hazard!

Diesel exhaust contains dangerous compounds. Never operate the engine in a closed building or area. Proper ventilation is required under all circumstances.

Failure to comply could result in death or serious injury.

W1302A

11. Start the engine and keep the machine in operation for 2 h. Actuate all hydraulic cylinders one after another.

NOTICE: Park the machine so that it comes to a stop at a new position on the tires.

12. If necessary, jack up the machine, reduce the tire pressure, and cover the machine with a tarpaulin.

13. Steps 3, 4, 5, 11, and 12 as with decommissioning – Follow the steps described.

7-172

7 - MAINTENANCE

Recommissioning After an immobilization of approx. 1 year, 1. the oil must be changed in the: • Hydraulic system • Power shift transmission • Rear axle • Blade-slewing gear 2. and a functional test must be performed to check for leaks After an immobilization period of less than 1 year, all oil levels must be checked.

• Check the acid density and the levels of the battery fluid.

• Check the charge state of the batteries. Recharge the batteries if necessary.

• Install and connect the batteries.

• Check the tire pressures and pump the tires up to the prescribed pressure if necessary.

• Remove jacks from under machine if the machine is jacked up.

• Remove grease from piston rods in hydraulic cylinders.

• Open the air filter inlet and the exhaust pipe.

• Check the operation of the electrical system.

• Release the articulated-joint lock.

• Check the performance of braking and steering systems.

• Bring the machine into driving position and apply the parking brake.

• Bleed the hydraulic system.

• Carry out service work as per maintenance chart.

NOTE: If the DEF/AdBlue® tank was drained for long term storage (90 days or more), refill the tank with fresh fluid.

Remove the engine preservation agent NOTE: See also engine operating instructions.

1. Remove corrosion inhibitor from V-belt pulley grooves.

2. Install the V-belt and retighten it after a short period of operation.

3. Remove plugs from suction and exhaust openings.

4. Put the engine into operation.

7-173

7 - MAINTENANCE

7-174

8 - SPECIFICATIONS

8 - SPECIFICATIONS###_9_### Main dimensions Main dimensions 836C/836C AWD

SS14F056

1

NOTE: The height with Low Profile Cab (LPC) is less 180.0 mm (7.1 in).

8-1

8 - SPECIFICATIONS

Pos. A

Pos. L

Designation 136.0 mm (5.4 in)

M

10.0 mm (0.4 in)

C D E F G H I

Designation Front plate and rear scarifier 9085.0 mm (357.7 in) Front plate and rear weight 8425.0 mm (331.7 in) 2245.0 mm (88.4 in) 1585.0 mm (62.4 in) 310.0 mm (12.2 in) 1241.0 mm (48.9 in) 8996.0 mm (354.2 in) 5351.0 mm (210.7 in) 1981.0 mm (78.0 in)

N O P Q R S T

J

1427.0 mm (56.2 in)

U

101.0 mm (4.0 in) 661.0 mm (26.0 in) 1489.0 mm (58.6 in) 3586.0 mm (141.2 in) 3240.0 mm (127.6 in) 3355.0 mm (132.1 in) 836C AWD: 2326.0 mm (91.6 in) 836C: 2303.0 mm (90.7 in) 836C AWD: 1923.0 mm (75.7 in) 836C: 1900.0 mm (74.8 in)

K

487.0 mm (19.2 in)

B

The Grader 836C AWD with standard tyres 405/70 R20 SPT9 is shown. The dimensions that are influenced by tyres change when other tyres are used.

Tyres 836C/836C AWD 405/70 R20 SPT9 Dunlop 420/75 R20 XMCL Michelin 455/70 R20 SPT9 Dunlop 405/70 R24 SPT9 Dunlop

Height

Tread

Width across tyres

LPC Height

0.0 mm (0.0 in)

0.0 mm (0.0 in)

0.0 mm (0.0 in)

-180.0 mm (-7.1 in)

+21.0 mm (+0.8 in)

0.0 mm (0.0 in)

+16.6 mm (+0.7 in)

-158.0 mm (-6.2 in)

+29.0 mm (+1.1 in)

+60.0 mm (+2.4 in)

+100.6 mm (+4.0 in)

-151.0 mm (-5.9 in)

+51.0 mm (+2.0 in)

+2.0 mm (+0.1 in)

+2.0 mm (+0.1 in)

-132.0 mm (-5.2 in)

8-2

8 - SPECIFICATIONS

Main dimensions 856C/856C AWD

SS14F056

2

NOTE: The height with Low Profile Cab (LPC) is less 180.0 mm (7.1 in).

8-3

8 - SPECIFICATIONS

Pos. A

Pos. L

Designation 183.0 mm (7.2 in)

M

38.0 mm (1.5 in)

C D E F G H I

Designation Front plate and rear scarifier 10183.0 mm (400.9 in) Front plate and rear weight 9427.0 mm (371.1 in) 2541.0 mm (100.0 in) 1785.0 mm (70.3 in) 371.0 mm (14.6 in) 1573.0 mm (61.9 in) 10055.0 mm (395.9 in) 6023.0 mm (237.1 in) 2504.0 mm (98.6 in)

N O P Q R S T

J

1532.0 mm (60.3 in)

U

110.0 mm (4.3 in) 694.0 mm (27.3 in) 1619.0 mm (63.7 in) 3674.0 mm (144.6 in) 3330.0 mm (131.1 in) 3660.0 mm (144.1 in) 856C AWD: 2555.0 mm (100.6 in) 856C: 2549.0 mm (100.4 in) 856C AWD: 2100.0 mm (82.7 in) 856C: 2094.0 mm (82.4 in)

K

584.0 mm (23.0 in)

B

The Grader 856C AWD with standard tyres 17.5-25 EM SGL Goodyear is shown. The dimensions that are influenced by tyres change when other tyres are used.

Tyres 856C/856C AWD 17.5–25 EM SGL Goodyear 17.5–R25 EM XHA Michelin 17.5–R25 EM XTLA Michelin 17.5–R25 RM94 Pirelli

Height

Tread

Width across tyres

LPC Height

0.0 mm (0.0 in)

0.0 mm (0.0 in)

0.0 mm (0.0 in)

-180.0 mm (-7.1 in)

+2.0 mm (+0.1 in)

0.0 mm (0.0 in)

-7.0 mm (-0.3 in)

-178.0 mm (-7.0 in)

-9.0 mm (-0.4 in)

0.0 mm (0.0 in)

+4.0 mm (+0.2 in)

-189.0 mm (-7.4 in)

+31.0 mm (+1.2 in)

0.0 mm (0.0 in)

-23.0 mm (-0.9 in)

-141.0 mm (-5.6 in)

NOTE: Tires with ballast should not be used on machines traveling from one working site to another.

After 80.0 km (50.0 miles) drive or 2 h of continuous driving (neither limit should be surpassed) it is necessary to stop at least for 30 min to let the tires cool off. After 4 h of travel it will be necessary to stop for at least 1 h for the same reason.

8-4

8 - SPECIFICATIONS

Weights NOTE: Weights including operator 80.0 kg (176.4 lb) and full fuel tank 236.0 kg (520.3 lb).

Types Basic machine without equipment and additional weights Front axle weight

836C 10906.0 kg (24043.6 lb)

2336 kg (5150 lb) Rear axle weight 8570.0 kg (18893.6 lb) Basic machine with 11805.0 kg dozer and rear weight (26025.6 lb) Front axle weight 3043.0 kg (6708.7 lb) Rear axle weight 8762.0 kg (19316.9 lb) Basic machine with 12109.0 kg dozer and rear ripper, (26695.8 lb) 5 teeth with protector Front axle weight 2948.0 kg (6499.2 lb) Rear axle weight 9161.0 kg (20196.5 lb) Basic machine with 11701.0 kg front weight and rear (25796.3 lb) weight Front axle weight 2919.0 kg (6435.3 lb) Rear axle weight 8782.0 kg (19361.0 lb) Basic machine with 12005.0 kg front weight and rear (26466.5 lb) ripper, 5 teeth with fender Front axle weight 2824.0 kg (6225.9 lb) Rear axle weight 9181.0 kg (20240.6 lb) Max. operating 12500.0 kg weight total (27557.8 lb) Max. operating 3200.0 kg weight front axle (7054.8 lb) Max. operating 9300.0 kg weight rear axle (20503.0 lb)

836C AWD 11206.0 kg (24705.0 lb)

856C 13960.0 kg (30776.5 lb)

856C AWD 14360.0 kg (31658.4 lb)

2436.0 kg (5370.5 lb) 8770.0 kg (19334.5 lb) 12105.0 kg (26687.0 lb) 3143.0 kg (6929.1 lb) 8962.0 kg (19757.8 lb) 12409.0 kg (27357.2 lb)

3488.0 kg (7689.7 lb) 10473.0 kg (23089.0 lb) 15140.0 kg (33378.0 lb) 4506.0 kg (9934.0 lb) 10634.0 kg (23444.0 lb) 15571.0 kg (34328.2 lb)

3588.0 kg (7910.2 lb) 10773.0 kg (23750.4 lb) 15540.0 kg (34259.8 lb) 4606.0 kg (10154.5 lb) 10934.0 kg (24105.3 lb) 15971.0 kg (35210.0 lb)

3048.0 kg (6719.7 lb) 9361.0 kg (20637.5 lb) 12001.0 kg (26457.7 lb)

4360.0 kg (9612.2 lb) 11211.0 kg (24716.0 lb) 14976.0 kg (33016.4 lb)

4460.0 kg (9832.6 lb) 11511.0 kg (25377.4 lb) 15376.0 kg (33898.3 lb)

3019.0 kg (6655.8 lb) 8982.0 kg (19801.9 lb) 12305.0 kg (27127.9 lb)

4313.0 kg (9508.5 lb) 10663.0 kg (23507.9 lb) 15407.0 kg (33966.6 lb)

4413.0 kg (9729.0 lb) 10963.0 kg (24169.3 lb) 15807.0 kg (34848.5 lb)

2924.0 kg (6446.3 lb) 9381.0 kg (20681.6 lb) 12800.0 kg (28219.2 lb) 3400.0 kg (7495.7 lb) 9500.0 kg (20943.9 lb)

4167.0 kg (9186.7 lb) 11240.0 kg (24780.0 lb) 16250.0 kg (35825.1 lb) 5100.0 kg (11243.6 lb) 11600.0 kg (25573.6 lb)

4267.0 kg (9407.1 lb) 11540.0 kg (25441.3 lb) 16650.0 kg (36707.0 lb) 5200.0 kg (11464.0 lb) 11900.0 kg (26235.0 lb)

8-5

8 - SPECIFICATIONS

Noise level Types L-WA (at 70%) L-PA

836C 101.7 dB 77.3 dB

836C AWD 101.7 dB 77.3 dB

8-6

856C 101.2 dB 78.4 dB

856C AWD 101.2 dB 78.4 dB

8 - SPECIFICATIONS

Engine Type Manufacturer Name Model/Code Turbo-charging Cooling Charge air cooling Injection Cylinder Displacement Power output Torque Nominal speed

836C FPT NEF 6Cyl 115 kW 4Valve TAA F4HFE6133*B003 yes Charge air/water Turbocharged Common rail 6 6700 cm³ (409 in³) 115 kW (156 Hp) 725 N·m (535 lb ft) / 1400 RPM 2100 RPM

836C AWD FPT NEF 6Cyl 115 kW 4Valve TAA F4HFE6133*B003 yes Charge air/water Turbocharged Common rail 6 6700 cm³ (409 in³) 115 kW (156 Hp) 725 N·m (535 lb ft) / 1400 RPM 2100 RPM

8-7

856C FPT NEF 6Cyl 142 kW 4Valve TAA F4HFE6139*B003 yes Charge air/water Turbocharged Common rail 6 6700 cm³ (409 in³) 142 kW (193 Hp) 850 N·m (627 lb ft) / 1400 RPM 2100 RPM

856C AWD FPT NEF 6Cyl 142 kW 4Valve TAA F4HFE6139*B003 yes Charge air/water Turbocharged Common rail 6 6700 cm³ (409 in³) 142 kW (193 Hp) 850 N·m (627 lb ft) / 1400 RPM 2100 RPM

8 - SPECIFICATIONS

Electrical installation Types Operating voltage Battery number Battery voltage Alternator

836C 24 V 2 12 V 90 A

836C AWD 24 V 2 12 V 90 A

856C 24 V 2 12 V 90 A

8-8

856C AWD 24 V 2 12 V 90 A

8 - SPECIFICATIONS

Capacities Component Engine with engine oil filter

Hydraulic system

836C AWD about 12.5 l (3.3 US gal) about 185 l (48.9 US gal) about 70 l (18.5 US gal) about 27 l (7.1 US gal) about 21 l (5.5 US gal) about 31 l (8.2 US gal) about 31 2 x about 2 x about 60 l 60 l (15.9 US (15.9 US gal) gal) about about 2 l (0.5 US 2 l (0.5 US gal) gal)

Initial filling

For oil change

Powershift transmission

Initial filling

For oil change

Differential gear Side reducer gear

Tandem (chain case) Swing unit

Blade slewing gear

Cooling system with heating (OAT EG2 50-50 Premix)

The coolant is a 50:50 mixture with water

Fuel tank

Diesel Exhaust Fluid (DEF)/AdBlue® tank Windshield washer tank

Refrigerant R134a

8-9

836C about 12.5 l (3.3 US gal) about 170 l (44.9 US gal) about 70 l (18.5 US gal) about 27 l (7.1 US gal) about 21 l (5.5 US gal) about 31 l (8.2 US gal)

856C about 12.5 l (3.3 US gal) about 185 l (48.9 US gal) about 90 l (23.8 US gal) about 27 l (7.1 US gal) about 21 l (5.5 US gal) about 36 l (9.5 US gal)

about 32.0 L (8.5 US gal) about 278.0 L (73.4 US gal) 54.0 L (11.9 UK gal) 2.0 L (0.4 UK gal) 1.2 kg (2.6 lb)

2 x about 64 l (16.9 US gal) about 2.5 l (0.7 US gal) about 32.0 L (8.5 US gal) about 278.0 L (73.4 US gal) 54.0 L (11.9 UK gal) 2.0 L (0.4 UK gal) 1.2 kg (2.6 lb)

about 32.0 L (8.5 US gal) about 278.0 L (73.4 US gal) 54.0 L (11.9 UK gal) 2.0 L (0.4 UK gal) 1.2 kg (2.6 lb)

856C AWD about 12.5 l (3.3 US gal) about 200 l (52.8 US gal) about 90 l (23.8 US gal) about 27 l (7.1 US gal) about 21 l (5.5 US gal) about 36 l (9.5 US gal) about 36 2 x about 64 l (16.9 US gal) about 2.5 l (0.7 US gal) about 32.0 L (8.5 US gal) about 278.0 L (73.4 US gal) 54.0 L (11.9 UK gal) 2.0 L (0.4 UK gal) 1.2 kg (2.6 lb)

8 - SPECIFICATIONS

Brakes Types Brake assembly Type Brake operation Braking pressure Brake pump Parking brake

Brake release pressure

836C 2-circuit Wet multi disc hydraulic 40 bar (580 psi) 19.0 cm³ (1.2 in³) Disc brake, spring-loaded, hydraulically released 130 - 150 bar (1885 2175 psi)

836C AWD 2-circuit Wet multi disc hydraulic 40 bar (580 psi) 19.0 cm³ (1.2 in³) Disc brake, spring-loaded, hydraulically released 130 - 150 bar (1885 2175 psi)

8-10

856C 2-circuit Wet multi disc hydraulic 60 bar (870 psi) 23.0 cm³ (1.4 in³) Disc brake, spring-loaded, hydraulically released 130 - 150 bar (1885 2175 psi)

856C AWD 2-circuit Wet multi disc hydraulic 60 bar (870 psi) 23.0 cm³ (1.4 in³) Disc brake, spring-loaded, hydraulically released 130 - 150 bar (1885 2175 psi)

8 - SPECIFICATIONS

Axle Types Front axle Manufacturer Oscillation Wheel lean adjustment Effective wheel lean Angle of steering lock left/right Spreading Lag Toe-in Ground clearance to ISO 7134 Flange to Flange distance Rear axle Manufacturer Oscillation Dimensions tandem box Height Width Wall thickness Tyre base Flange to flange Chain tensioner adjustment

836C

836C AWD

856C

856C AWD

CASE CONSTRUCTION ± 15 ° ± 21 ° 45 '

CASE CONSTRUCTION ± 15 ° ± 21 ° 45 '

CASE CONSTRUCTION ± 15 ° ± 20 ° 30 '

CASE CONSTRUCTION ± 15 ° ± 20 ° 30 '

± 14 ° 24 ' 32 °/ 40 °

± 14 ° 24 ' 32 °/ 40 °

± 12 ° 35 ° 30 '/ 42 ° 30 '

± 12 ° 35 ° 30 '/ 42 ° 30 '

8° 0° 3.0 - 6.0 mm (0.1 0.2 in) 485.0 mm (19.1 in)

8° 0° 3.0 - 6.0 mm (0.1 0.2 in) 485.0 mm (19.1 in)

0° 0° 3.0 - 6.0 mm (0.1 0.2 in) 554.0 mm (21.8 in)

0° 0° 3.0 - 6.0 mm (0.1 0.2 in) 554.0 mm (21.8 in)

2040.0 mm (80.3 in)

2062.0 mm (81.2 in)

2064.0 mm (81.3 in)

2070.0 mm (81.5 in)

Graziano ± 15 °

Graziano ± 15 °

Graziano ± 15 °

Graziano ± 15 °

599.0 mm (23.6 in) 201.0 mm (7.9 in) 20.0 mm (0.8 in) 1241.0 mm (48.9 in) 2040.0 mm (80.3 in) -5.5 - 5.5 mm (-0.2 0.2 in)

599.0 mm (23.6 in) 201.0 mm (7.9 in) 20.0 mm (0.8 in) 1241.0 mm (48.9 in) 2040.0 mm (80.3 in) -5.5 - 5.5 mm (-0.2 0.2 in)

590.0 mm (23.2 in) 199.0 mm (7.8 in) 20.0 mm (0.8 in) 1572.6 mm (61.9 in) 2070.0 mm (81.5 in) -4.5 - 4.5 mm (-0.2 0.2 in)

590.0 mm (23.2 in) 199.0 mm (7.8 in) 20.0 mm (0.8 in) 1572.6 mm (61.9 in) 2070.0 mm (81.5 in) -4.5 - 4.5 mm (-0.2 0.2 in)

8-11

8 - SPECIFICATIONS

Front drive axle Types Front drive Manufacturer Name

Charge pressure

836C AWD 856C with without Hydromatik A4VG 56 EP4D1/ 32R-NSC02F043DH CW NBR ANSI B92.1a-1976 1 1/4" 14T 12/24DP SAE J744 127-2 (C) 410 - 430 bar (5945 6235 psi) 25 bar (362 psi)

Charge pump

11.6 cm³ (0.7 in³)

Direction of rotating Seal Shaft end Mounting flange Pressure cut [bar]

836C without

8-12

856C AWD with Hydromatik A4VG 71 EP4D1/ 32R-NSF041DH CW NBR ANSI B92.1a-1976 1 1/4" 14T 12/24DP SAE J744 127-2 (C) 410 - 430 bar (5945 6235 psi) 29 - 31 bar (420 450 psi) 19.6 cm³ (1.2 in³)

8 - SPECIFICATIONS

Transmission Types Manufacturer Name Type Gears forward/ backward

836C ZF 6WG 115 Ergo-Powershift 6/3

836C AWD ZF 6WG 115 Ergo-Powershift 6/3

8-13

856C ZF 6WG 160 Ergo-Powershift 6/3

856C AWD ZF 6WG 160 Ergo-Powershift 6/3

8 - SPECIFICATIONS

Dozer blade (option) Types Ground clearance Scraping depth

836C 512.0 mm (20.2 in) 124.0 mm (4.9 in)

836C AWD 512.0 mm (20.2 in) 124.0 mm (4.9 in)

8-14

856C 579.0 mm (22.8 in) 141.0 mm (5.6 in)

856C AWD 579.0 mm (22.8 in) 141.0 mm (5.6 in)

8 - SPECIFICATIONS

Rear ripper (option) Types Width Ground clearance tooth lifted up Ripping depth Ripping width, tooth centre - tooth centre Penetration force type equipment Penetration force max. equipment Brake out force type equipment Brake out force max. equipment

836C 2085.0 mm (82.1 in) 504.0 mm (19.8 in)

836C AWD 2085.0 mm (82.1 in) 504.0 mm (19.8 in)

856C 2305.0 mm (90.7 in) 579.0 mm (22.8 in)

856C AWD 2305.0 mm (90.7 in) 579.0 mm (22.8 in)

307.0 mm (12.1 in) 2000.0 mm (78.7 in)

307.0 mm (12.1 in) 2000.0 mm (78.7 in)

328.0 mm (12.9 in) 2220.0 mm (87.4 in)

328.0 mm (12.9 in) 2220.0 mm (87.4 in)

56347 N (12667 lb)

75893 N (17061 lb)

62215 N (13986 lb)

81484 N (18318 lb)

37943 N (8530 lb)

56920 N (12796 lb)

41900 N (9419 lb)

61113 N (13739 lb)

8-15

8 - SPECIFICATIONS

Blade Types Standard Blade height Blade thickness Scraper blade thickness Edge blade width Edge blade thickness Screw diameter

836C 3355.0 mm (132.1 in) 526.0 mm (20.7 in) 15.0 mm (0.6 in) 16.0 mm (0.6 in)

836C AWD 3355.0 mm (132.1 in) 526.0 mm (20.7 in) 15.0 mm (0.6 in) 16.0 mm (0.6 in)

856C 3660.0 mm (144.1 in) 603.0 mm (23.7 in) 20.0 mm (0.8 in) 16.0 mm (0.6 in)

856C AWD 3660.0 mm (144.1 in) 603.0 mm (23.7 in) 20.0 mm (0.8 in) 16.0 mm (0.6 in)

152.0 mm (6.0 in) 19.0 mm (0.7 in) 16.0 mm (0.6 in)

152.0 mm (6.0 in) 19.0 mm (0.7 in) 16.0 mm (0.6 in)

152.0 mm (6.0 in) 19.0 mm (0.7 in) 16.0 mm (0.6 in)

152.0 mm (6.0 in) 19.0 mm (0.7 in) 16.0 mm (0.6 in)

8-16

8 - SPECIFICATIONS

Steering Types Servo stat Supplier Steering pressure Steering turning left/right Turns from left to right Steering wheel diameter

836C LAGC 100 Rexroth 150 bar (2175 psi) 40 °

836C AWD LAGC 100 Rexroth 150 bar (2175 psi) 40 °

856C LAGC 160 Rexroth 150 bar (2175 psi) 42.5 °

856C AWD LAGC 160 Rexroth 150 bar (2175 psi) 42.5 °

7 407.0 mm (16.0 in)

7 407.0 mm (16.0 in)

10 407.0 mm (16.0 in)

10 407.0 mm (16.0 in)

8-17

8 - SPECIFICATIONS

Tire pressure - admissible tire size The machine can be equipped with different tires from various manufacturers.

Permitted tires for 836C/836C AWD Designation 405/70 R20 EM 455/70 R20 EM 420/75 R20 405/70 R24

Tread

Manufacturer Dunlop Dunlop Michelin Dunlop

SPT9 SPT9 XMCL SPT9

Air pressure Front Rear 3 bar (43.5 psi) 3.5 bar (50.8 psi) 2.5 bar (36.3 psi) 2.5 bar (36.3 psi) 2 bar (29.0 psi) 2 bar (29.0 psi) 2.5 bar (36.2 psi) 3.25 bar (47.12 psi)

Permitted tires for 856C/856C AWD Designation

Tread

Manufacturer

Air pressure Front

17.5–25 EM

Goodyear

SGL

17.5 R25 EM 17.5 R25 EM 17.5 R25

Michelin Michelin Pirelli

XHA XTLA RM94

2 bar (29.0 psi) 2 bar (29.0 psi) 2 bar (29.0 psi) 2.4 bar (34.8 psi)

Rear 2.35 bar (34.08 psi) 2.1 bar (30.5 psi) 2.1 bar (30.5 psi) 2.4 bar (34.8 psi)

NOTE: Tires with ballast should not be used on machines traveling from one working site to another.

After 80.0 km (50.0 miles) drive or 2 h of continuous driving (neither limit should be surpassed) it is necessary to stop at least for 30 min to let the tires cool off. After 4 h of travel it will be necessary to stop for at least 1 h for the same reason.

The tire pressures are valid for graders equipped with one of the above tire sizes, equipment attached, fuel tank full, and weights.

8-18

8 - SPECIFICATIONS

Consumables I. Oils for internal combustion engines (change interval 500 OH) Standard

(H) (H)

0W-40 CJ-4 UNITEK to CNH MAT3521 API CJ-4 0W-40* (H)

5W-30 ACEA E6 (H) (H)

10W-40 CJ-4 UNITEK to CNH MAT3521 API CJ-4 10W-40* (H) (H)

-40 °C -40 °F

-30 °C -22 °F

-20 °C -4 °F

-10 °C 14 °F

15W-40 CJ-4 to CNH MAT3522* API CJ-4 15W-40* 0 °C 32 °F

10 °C 50 °F

(H) Engine oil pan or coolant block heater recommended in this range * Requires a 50 % reduction in oil change interval

8-19

20 °C 68 °F

30 °C 86 °F

40 °C 104 °F

50 °C 122 °F

8 - SPECIFICATIONS

II. Oils for hydraulic systems, mineral

SS13K038

1

Specification: • DIN 51524 HVLP

Oils (A) • ISO VG 46 (MS 1230) e.g.: AKCELA HYDRAULIC EXCAVATOR FLUID (B) • ISO VG 68 (MS 1216) e.g.: AKCELA AW HYDRAULIC FLUID 68 HV The hydraulic system must be warmed up before commencing work. Warm up the hydraulic system for approx. 10 min, with the engine at half-speed and repeated actuation of all control valves.

8-20

8 - SPECIFICATIONS

II. Oils for hydraulic systems, biodegradable

SS13K040

2

Specification: • DIN 51524 HVLP

Oils ISO VG 46 (MS 1230) e.g.: AKCELA HYDRAULIC EXCAVATOR FLUID BIO The hydraulic system must be warmed up before commencing work. Warm up the hydraulic system for approx. 10 min, with the engine at half-speed and repeated actuation of all control valves.

8-21

8 - SPECIFICATIONS

III. Oils for powershift transmissions with Ergopower

SS13K039

3

Specification: • API: CI-4 • ACEA: E7 API: American Petroleum Institute ACEA: Association des Constructeurs Européen d´Automobiles g.i.e.

Oils SAE 15W-40 (MS 1121) e.g.: AKCELA No. 1 ENGINE OIL 15W-40

Automatic powershift transmission-preheating.

8-22

8 - SPECIFICATIONS

IV.A. Oils for differential gear on rear axle

SS13K061

4

NOTICE: Axles and gearboxes may be damaged by low-grade oils.

Specification: • API: GL 5 LS additive API: American Petroleum Institute LS: Limited slip

Oils SAE 80W-90 e.g.: AKCELA AXLEPOWER 80W-90

8-23

8 - SPECIFICATIONS

IV.B. Oils for tandem box on rear axle

SS13K035

5

NOTICE: Axles and gearboxes may be damaged by low-grade oils.

Specification: • API: GL 4 API: American Petroleum Institute

Oils SAE 20W-40 (MS 1317) e.g.: AKCELA TRANSAXLE FLUID 20W-40 Titan Utto ZF 20W-40 LS-additive: 0 - 0.1 % S: 0 % P: 0.15 % P+S: Phosphor and sulphur alloy corresponding to delivery specification: 2293219

8-24

8 - SPECIFICATIONS

IV.C. Oils for blade slewing gear

SS13K062

6

NOTICE: Axles and gearboxes may be damaged by low-grade oils.

Specification: • API: GL 5 API: American Petroleum Institute

Oils HYPOIDE SAE 80W-90 (MS 1316) e.g.: AKCELA GEAR 135 H EP 80W-90

8-25

8 - SPECIFICATIONS

V. Greases for bearing points and slewing rings

SS13K063

7

Specification: • NLGI 2

Oils Multipurpose Grease e.g.: AKCELA MULTI-PURPOSE GREASE 251H EP

For central lubricating systems and tensioning systems.

8-26

8 - SPECIFICATIONS

Environment friendly hydraulic fluid The hydraulic system of this machine can be filled ex factory with environmentally friendly, biodegradable hydraulic fluid (nonstandard). Stickers with corresponding instructions are then attached to the machine.

For the initial filling, we use only: ISO VG 46 This synthetic hydraulic fluid has been tested by us and approved for use in our machines. A changeover from mineral hydraulic fluid to this biodegradable hydraulic fluid can, however, be made at a later date.

Environmentally friendly, biodegradable hydraulic fluid, may also not be simply poured away. They have to be disposed of in the same way that used oil is disposed of.

If hydraulic fluid seeps into the ground, the machine owner and the authorities responsible must be informed.

ISO VG 46 is suitable only for use in hydraulic systems.

As ISO VG 46 is not soluble in water, condensed water may be deposited in the hydraulic fluid tank.

Condensed water must therefore be drained off at regular intervals and after lengthy downtimes, then disposed of in the same way as used oil.

Use only ISO VG 46 for changing or topping up the hydraulic fluid.

The hydraulic fluid may not be mixed with hydraulic fluids or hydraulic fluids from other manufacturers, as this reduces its biodegradability.

Operating equipment and attachments operated with mineral hydraulic fluid must not be mounted until thoroughly emptied, cleaned, and flushed.

Analysis will show whether the hydraulic fluid can be used beyond the standard changing intervals.

See also 7-136.

8-27

8 - SPECIFICATIONS

Organic Acid Technology (OAT) coolant A coolant that relies on inhibitors such as organic acid salts for corrosion and cavitation protection.

CASE CONSTRUCTION requires the use of a fully formulated Organic Acid Technology (OAT) -based coolant.

CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT is preferred. The coolant must meet the specifications outlined in the CNH material specification MAT3624. Use of coolant not meeting this specification is not allowed. Mixing of different coolant brands is not recommended.

NOTICE: OAT coolant is mandatory for all FPT engines compliant to Tier 4b emissions using Selective Catalytic Reduction (SCR). NEVER mix OAT coolant with conventional coolant and with conventional cooling system additives.

NOTICE: Issues as a result of failing to follow the above guidelines will not be covered under warranty.

In the case that the customer may have topped off an OAT coolant system with conventional coolant, check the OAT anti-freeze with conventional anti-freeze test strips to see if nitriles are present at a level higher than 20 PPM (parts per million).

If the nitrile level is excessive, follow the procedure below: 1. Empty the engine cooling system and drain the existing coolant into a suitable container.

2. Fill the system with clean water.

3. Start and run the engine for at least 30 minutes.

NOTE: Ensure to activate the heating system (if equipped) to circulate fluid through the heater core.

4. Repeat the steps from 1 to 3 twice 5. Fill the system with OAT coolant The decal shown (CNH part number 47757330) is located near the fill point of the cooling system whenever CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT is filled at the factory. It can also be identified by its yellow color.

The optimum coolant/water concentration is 50/50. This concentration will protect the cooling system to -37 °C (-35 °F).

If a premixed coolant is not available, mix the concentrate with 50 % of water.

The coolant concentration in the coolant/water mixture can be determined with a refractometer designed to measure ethylene glycol content.

Distilled water or deionized water is recommended for the use in the engine cooling systems.

DO NOT use hard water, sea water and softened sea that has been conditioned with salt. The minerals and salts present in potable water can cause corrosion and deposits resulting in shortened engine life.

8-28

SS14H024

8

9 - ACCESSORIES

9 - ACCESSORIES###_10_### Radio (option) NOTICE: The radio is connected to the electrical system when the ignition key is in position I. The radio (110) is located on the cab roof, in the upper right.

Different types of radios can be installed. Operating instructions are provided with the respective radio.

The 24 V vehicle voltage is reduced by a voltage transformer to 12 V radio operational voltage.

SS11H115

9-1

1

9 - ACCESSORIES

Rotary beacon (option) The rotary beacon can be adjusted in its height and position by turning the two spring bearings.

The rotary beacon can be switched on only when the key switch of the electrical system is set to position I (ignition ON).

SS11H112

1

SS14C025

2

Rotary beacon ON: • Press the pushbutton (40) with the symbol; the symbol lights up.

Rotary beacon OFF: • Press the pushbutton (40) without the symbol; the symbol goes off.

9-2

9 - ACCESSORIES

Rear view camera (option) NOTE: The rear view camera is not referred as a reversing aid (see also Safety rules and following; section “Operating safety, Banksman”). During reversing operations, your view of the hazard zone is restricted. For this reason, allow experienced banksman (reversing assistant) to assist you. Review the signals with the banksman (reversing assistant) to ensure the signals are correctly understood. Inspect the site for underground gas, power and water lines before starting work. Any damage to such lines is a life-threatening risk.

The rear view back-up camera reduces vehicle blind spots during reversing operations. It assists the operator when reversing and offers a view of other equipment, obstacles, and/or personnel in the work area.

The camera monitor is mounted in the cab.

For details refer to the camera manufacturer’s user guide for correct operation of the camera monitor.

SS14F036

1

SS14F035

2

The camera eye is mounted on the hood at the rear of the machine.

The camera eye has built-in moisture resistance for equipment that requires power washing and/or equipment that operates in harsh environments.

NOTICE: The standard position (setting) from plant is to see the rear ripper in the travel position only.

9-3

9 - ACCESSORIES

Towing attachments (option) NOTE: Read and observe Safety rules and following.

NOTICE: The towing attachments must not be used for pulling trailers.

NOTE: In case of emergency release of the parking brake, see also 3-18.

Option between: Front grading plate with towing attachment OR Front counterweight with towing attachment

SS11H213

1

SS11K203

2

SS14E090

3

Towing attachment at the rear counterweight (Option) Only available with attached rear counterweight (option).

9-4

9 - ACCESSORIES

Telematics (option) - General description This machine can be equipped with a telematics system.

This is an asset-monitoring system that combines internet, cellular, and GPS technologies. A transponder unit is mounted on the equipment that wirelessly communicates with a web-based user interface.

Using cellular technology, the transponder can send equipment data, including location, on/off status, usage and production metrics, diagnostic data, movement alarms, and unauthorized usage to the interface.

The system will help cut costs and keep accurate records.

See the furnished guide for operating your telematics system.

9-5

9 - ACCESSORIES

Telematics (option) - Location overview The telematics unit is located inside the right-hand side console.

SS14F042

1

SS14F034

2

SS14F044

3

SS14F043

4

The antenna is located on the cab roof.

Fuse/relay box 3F/3K Amperes Fuse/relay designation 3F30 5A

Color code Beige

Consumer Telematic module AM50 unswitched power

Fuse/relay box 4F/4K Amperes Fuse/relay designation 4F34 2A

Color code Grey

Consumer Telematic module AM50 switched power

9-6

9 - ACCESSORIES

Telematics (option) - LED display Additional information on the LED display The LED display panel is the controller’s minimum interface used to display and control data input and output.

(1A) The GSM/GPRS LED (red) displays the GSM/GPRS status: • Off – No GSM or GPRS coverage or the device is in “stand-by” mode.

• Slowly blinking – GSM coverage only. The system can receive SMS, but the connection with the website is not available.

• Blinking fast – GPRS coverage, but the website connection is not available for any reason.

SS13A858

• On – GPRS coverage and server connection.

1

(1B) The CAN LED (red) displays the CAN status: • Off – The CAN is not available or the device is in “standby” mode.

• Blinking – CAN messages on the BUS. (1C) The GPS LED (red) displays the GPS status: • Off – Before the GPS initialization or the device is in “stand-by” mode.

• Blinking – Searching for GPS signal.

• On – GPS fix 2D or 3D. (1D) The power LED (green) displays the power status: • Off – No power supply.

• Blinking – Downloading files or firmware from the server or waiting for the application firmware.

• On – Power supply and standard work or the device is in “stand-by” mode.

• Green (fixed) – Indicates that power supply is on.

Special LED configuration NOTE: Four LEDs on indicates both the loader and the firmware are not presently on board. The board is waiting for the download of the loader.

NOTE: Power LED (green) on and the three red LEDs blinking indicate problems with the GPRS modem (no SIM or modem initialization failed).

9-7

9 - ACCESSORIES

9-8

Index ###_Index_###

1 12V DC socket outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Access doors . . . . . . . .

Adjust the mirrors . . . . . . .

Air conditioning - Check . . . .

Air conditioning system (option).

Articulation joint . . . . . . .

Assisted starting (Jump-starting) Axle. . . . . . . . . . . . .

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A . . . . . . . . . . . . . .

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3-8

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. 3-1 . 3-3 . 7-81 . 3-27 . 4-15 7-148 . 8-11

B Before putting the machine into operation . . . . . . . . . .

Biodiesel - Biodiesel fuels . . . . . . . . . . . . . . . . .

Blade . . . . . . . . . . . . . . . . . . . . . . . . . .

Blades . . . . . . . . . . . . . . . . . . . . . . . . .

Bleed the fuel system . . . . . . . . . . . . . . . . . . .

Brake-pressure-dependent transmission cutout/inching (option) .

Brakes . . . . . . . . . . . . . . . . . . . . . . . . .

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C Cab interior light . . . . . . . . . . . . . . . . . . . .

Calibrating the gear box . . . . . . . . . . . . . . . . .

Calling up the diagnostics menu . . . . . . . . . . . . .

Calling up the display menu . . . . . . . . . . . . . . .

Calling up the main menu . . . . . . . . . . . . . . . .

Calling up the service menu . . . . . . . . . . . . . . .

Calling up the settings menu . . . . . . . . . . . . . . .

Capacities . . . . . . . . . . . . . . . . . . . . . . .

CE declaration of conformity . . . . . . . . . . . . . . .

Change the blade slewing gear oil . . . . . . . . . . . .

Change the CCV/engine breather filter . . . . . . . . . .

Change the DEF/AdBlue® supply module main filter . . . .

Change the DEF/AdBlue® tank vent filter . . . . . . . . .

Change the differential/side reducer gear oil on rear axle. . .

Change the drive belt . . . . . . . . . . . . . . . . . .

Change the engine oil . . . . . . . . . . . . . . . . . .

Change the environment friendly hydraulic fluid (if used) . . .

Change the front-wheel drive oil filter (Only all-wheel version) Change the fuel filter . . . . . . . . . . . . . . . . . .

Change the fuel pre-filter . . . . . . . . . . . . . . . .

Change the hydraulic oil . . . . . . . . . . . . . . . . .

Change the hydraulic reservoir breather valve . . . . . . .

Change the hydraulic return flow filter . . . . . . . . . . .

Change the main filter element - air intake system . . . . .

Change the oil filter . . . . . . . . . . . . . . . . . . .

Change the Organic Acid Technology (OAT) coolant. . . . .

Change the powershift transmission oil . . . . . . . . . .

Change the powershift transmission oil filter . . . . . . . .

Change the safety filter - air intake system . . . . . . . . .

Change the tandem box swing unit oil . . . . . . . . . . .

Changing a wheel . . . . . . . . . . . . . . . . . . .

Check all lines, fittings and connections for leaks . . . . . .

Check and adjust the hydraulic pressure . . . . . . . . . .

Check and clean the AC condenser (option) . . . . . . . .

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. . . 3-4 . . 7-124 . . . 3-55 . . . 3-52 . . . 3-45 . . . 3-59 . . . 3-49 . 7-26, 8-9 . . . 1-21 . . 7-108 . . 7-123 . . 7-141 . . 7-105 . . 7-126 . . 7-115 . . 7-100 . . 7-135 . . 7-118 . . 7-104 . . 7-107 . . 7-137 . . 7-133 . . 7-116 7-41, 7-119 . . 7-102 . . 7-142 . . 7-109 . .

7-111 . . 7-139 . . 7-113 . . 7-159 . . . 7-84 . . 7-129 . . . 7-48

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4-6 7-8 8-16 6-5 7-89 3-41 8-10

Check and clean the combined radiator . . . . . . . . . . . . . . . . .

Check during driving . . . . . . . . . . . . . . . . . . . . . . . . .

Checking/replacing fuses and relays . . . . . . . . . . . . . . . . . .

Check machine and units visually for defects, leaks and loss of consumables.

Check the air intake system . . . . . . . . . . . . . . . . . . . . . .

Check the battery and cable connection . . . . . . . . . . . . . . . . .

Check the blade slewing gear oil level/topping up . . . . . . . . . . . . .

Check the chain tension . . . . . . . . . . . . . . . . . . . . . . . .

Check the compressor drive belt . . . . . . . . . . . . . . . . . . . .

Check the cooling system . . . . . . . . . . . . . . . . . . . . . . .

Check the DEF/AdBlue® tank level/topping up fluid . . . . . . . . . . . .

Check the drive belt . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the drive belt tension . . . . . . . . . . . . . . . . . . . . . .

Check the driver´s cab mounting bolts . . . . . . . . . . . . . . . . . .

Check the electrical system . . . . . . . . . . . . . . . . . . . . . .

Check the engine bearing . . . . . . . . . . . . . . . . . . . . . . .

Check the engine oil level/topping up oil . . . . . . . . . . . . . . . . .

Check the heating/air conditioning . . . . . . . . . . . . . . . . . . .

Check the heating for leaks . . . . . . . . . . . . . . . . . . . . . .

Check the hydraulic oil level/topping up oil . . . . . . . . . . . . . . . .

Check the hydraulic system for leaks . . . . . . . . . . . . . . . . . .

Check the lighting function . . . . . . . . . . . . . . . . . . . . . . .

Check the monitoring, warning and control elements . . . . . . . . . . .

Check the Organic Acid Technology (OAT) coolant level/topping up coolant .

Check the parking brake function . . . . . . . . . . . . . . . . . . . .

Check the powershift transmission oil level/topping up oil . . . . . . . . .

Check the rear axle oil levels/topping up oil . . . . . . . . . . . . . . .

Check the service brake discs . . . . . . . . . . . . . . . . . . . . .

Check the service brake function . . . . . . . . . . . . . . . . . . . .

Check the steering . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the tire pressure . . . . . . . . . . . . . . . . . . . . . . . .

Check the wheel condition . . . . . . . . . . . . . . . . . . . . . . .

Check the wheel nuts for tightness . . . . . . . . . . . . . . . . . . .

Check the windshield washer fluid reservoir/topping up . . . . . . . . . .

Check valve setting on engine . . . . . . . . . . . . . . . . . . . . .

Clean/change the fresh air filter on the cab . . . . . . . . . . . . . . . .

Clean the DEF/AdBlue® supply module pre-filter . . . . . . . . . . . . .

Clean the DEF/AdBlue® tank neck filter . . . . . . . . . . . . . . . . .

Clean the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . .

Clean the grader . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clean the hydraulic reservoir . . . . . . . . . . . . . . . . . . . . . .

Compressor drive belt - Check . . . . . . . . . . . . . . . . . . . . .

Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control levers for working attachments . . . . . . . . . . . . . . . . .

Crane loading . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . 7-47 . . 4-19 . 7-164 . . 7-42 . . 7-49 . . 7-87 . . 7-68 . . 7-92 . 7-112 . . 7-83 . . 7-64 . . 7-61 . . 7-86 . . 7-98 . . 7-60 . . 7-99 . . 7-43 . 7-121 . . 7-97 . . 7-65 . . 7-52 . . 7-50 . . 7-51 . . 7-45 . . 7-54 . . 7-71 . . 7-79 . . 7-91 . . 7-53 . . 7-59 . . 7-66 . . 7-58 . . 7-67 . . 7-63 . 7-127 . . 7-95 . 7-106 . 7-144 . 7-128 . . 7-69 . 7-134 . 7-122 7-16, 8-19 . . . 6-3 . . . 5-3 . . . .

Decommissioning procedure . . . . . . . .

Depressurising the hydraulic reservoir . . . .

Depressurising the hydraulic system . . . .

Downhill driving . . . . . . . . . . . . .

Dozer blade (option) . . . . . . . . . . .

Draining hose for oil changes. . . . . . . .

Drain off water and deposits from the fuel tank Drive . . . . . . . . . . . . . . . . . .

Driver´s cab ROPS and FOPS . . . . . . .

Driving on public roads . . . . . . . . . .

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Ecology and the environment. . . . . . . .

Electrical installation . . . . . . . . . . .

Electro-Magnetic Compatibility (EMC) . . . .

Emergency lowering of the working equipment Engine . . . . . . . . . . . . . . . . .

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E . . . . . . . . . .

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. 7-170 . 7-132 . 7-130 . . 4-19 6-10, 8-14 . . 7-27 . 7-114 . . 3-31 . . 1-17 . . 4-16 . . . . .

. 2-29 . 8-8 . 1-5 . 6-14 . 8-7

Engine coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70 Engine hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 F Filling the DEF/AdBlue® tank. . .

Filling the fuel tank . . . . . . .

First-aid box storage compartment Floating position (option). . . . .

Floodlight . . . . . . . . . . .

Foot throttle pedal . . . . . . .

Front console controls . . . . . .

Front drive axle . . . . . . . . .

Fuel reserve indicator . . . . . .

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4-2 4-1 2-30 6-9 3-29 4-14 3-13 8-12 3-69

G Gearshift lever - powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 Grader use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Grease the battery terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88 . . . .

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H . . . . . . . .

Identification plates . . . . . . . . . . . . . . .

Increasing the working speed . . . . . . . . . .

Inspection plan . . . . . . . . . . . . . . . . .

Instructions . . . . . . . . . . . . . . . . . .

Instrument panel/indicator lamps . . . . . . . . .

Instrument panel - Warning and monitoring elements Intake openings . . . . . . . . . . . . . . . .

Intended use . . . . . . . . . . . . . . . . . .

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Hand throttle lever . . . . . . . . . . . . . .

Horn, turn signal, high beam and headlamp flasher Hydraulic fluid analyze . . . . . . . . . . . .

Hydraulic fluid temperature. . . . . . . . . . .

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. . 4-14 . . 3-21 . 7-136 . . 3-68

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. 1-11 . 6-5 . 7-14 . 7-1 . 3-62 . 3-42 . 3-6 . 1-3

L Lubricate all articulated joints and hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85 Lubrication plan - Front axle, Tandem axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Lubrication plan - Moldboard, Articulation frame . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Machine components . . . . . . . . .

Machine movement start-up . . . . . .

Machine orientation . . . . . . . . . .

Main dimensions . . . . . . . . . . .

Maintenance - Calibrate . . . . . . . .

Maintenance - Change fluid . . . . . .

Maintenance - Check . . . . . . . . .

Maintenance - Clean . . . . . . . . .

Maintenance - Grease . . . . . . . . .

Maintenance - Replace . . . . . . . .

Manual scope and required training level Metric and imperial units abbreviations .

Moldboard ripper (option) . . . . . . .

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. . 1-20 . . 4-11 . . 1-19 . . 8-1 . . 7-77 . . 7-75 7-39, 7-73 . . 7-78 7-40, 7-76 . . 7-74 . . 1-6 . . 1-8 . . 6-13

N Noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 Noise level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Note to the owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 O Operation of the multi-functional LCD display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 Operator's manual storage on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

P Parking brake . . . . . . . . . . . . . . . . . . . . .

Periodic checks during decommissioned period . . . . . . .

Pneumatic suspension seat (Comfort seat) . . . . . . . . .

Proper entry and exit . . . . . . . . . . . . . . . . . .

Protection of the electronic modules during welding operations

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. . . 9-1 6-11, 8-15 . . . 9-3 . . 7-147 . . 7-173 . . . 4-4 . . 7-151 . . 7-160 . . . 9-2

S Safety and informational signs . . . . . . . . . . . . . . . . .

Safety rules . . . . . . . . . . . . . . . . . . . . . . . . .

Safety rules and signal word definitions . . . . . . . . . . . . .

Seat belt. . . . . . . . . . . . . . . . . . . . . . . . . . .

Securing the machine . . . . . . . . . . . . . . . . . . . . .

Selective Catalytic Reduction (SCR) - Overview . . . . . . . . .

Selective Catalytic Reduction (SCR) system . . . . . . . . . . .

Selective Catalytic Reduction (SCR) system instrumentation warning Service brake . . . . . . . . . . . . . . . . . . . . . . . .

Shut off the engine . . . . . . . . . . . . . . . . . . . . . .

Starter Switch . . . . . . . . . . . . . . . . . . . . . . . .

Starting the engine . . . . . . . . . . . . . . . . . . . . . .

Steering . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering column . . . . . . . . . . . . . . . . . . . . . . .

Stopping the machine . . . . . . . . . . . . . . . . . . . . .

Storage compartment . . . . . . . . . . . . . . . . . . . . .

Sun protection . . . . . . . . . . . . . . . . . . . . . . . .

Swivel arm adjustment . . . . . . . . . . . . . . . . . . . .

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Radio (option) . . . . . . . . . . . . . .

Rear ripper (option) . . . . . . . . . . . .

Rear view camera (option) . . . . . . . . .

Recharging the battery . . . . . . . . . .

Recommissioning . . . . . . . . . . . . .

Refueling using the refueling station (Option) .

Replacing bulbs . . . . . . . . . . . . .

Replacing the blade cutting edges . . . . .

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. . 3-18 . 7-172 . . 3-9 . . 3-2 . 7-161

. . 2-33 . . 2-2 . . 2-1 . . 3-12 . . 7-5 . . 7-28 . . 7-31 . . 3-72 . . 3-17 . . 4-13 . . 3-15 . . 4-8 3-20, 8-17 . . 3-19 . . 4-12 . . 3-5 . . 3-5 . . 6-6

T Telematics (option) - General description.

Telematics (option) - LED display . . . .

Telematics (option) - Location overview .

Tire pressure - admissible tire size . . .

Tool kit . . . . . . . . . . . . . . .

Torque charts . . . . . . . . . . . .

Towing attachments (option) . . . . . .

Transmission. . . . . . . . . . . . .

Transmission oil temperature . . . . . .

Transporting the machine . . . . . . .

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. 9-5 . 9-7 . 9-6 . 8-18 . 3-7 . 7-4 . 9-4 . 8-13 . 3-67 . 5-1

V Ventilation and heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Vibration levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 Warming up the machine . . . . . .

Warning lamps . . . . . . . . . . .

Warning triangle . . . . . . . . . .

Weights . . . . . . . . . . . . . .

Wheel lean . . . . . . . . . . . .

Windshield wiper and washer controls .

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4-10 3-71 2-30 8-5 6-8 3-16

Dealer’s stamp

CNH Industrial Italia S.p.A. reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold.

Specifications, descriptions, and illustrative material herein are as accurate as known at time of publication, but are subject to change without notice.

Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your Case dealer.

© 2015 CNH Industrial Italia S.p.A. All Rights Reserved.

Case is a trademark registered in the United States and many other countries, owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates.

Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.