Case 865 DHP Grader Electronic Engine Operator's Manual 6-84181 - PDF DOWNLOAD

865 DHP Grader Electronic Engine

Operator’s Manual Revision Date: 03/2005

Brz 6-84181NA

!

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBI LITY OF DEATH OR SERIOUS INJURY. M171C

Safety Decals on this machine use the words Danger, Warning or Caution, which are defined as follows: DANGER: Indicates an immediate hazardous situation which, if not avoided, will result in deat h or serious injury. The color associated with Danger is RED. WARNING: Indicates a potentially hazardous situation which, if not avoided will result in serious injury. The color associated with Warning is ORANGE. CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in mino r or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW.

! WARNING IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR: Is instructed in safe and proper use of the machine.

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

Reads and understands ALL Safety Decals on the machine.

Clears the area of other persons.

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

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

Copyright © 2005 CNH America LLC All Rights Reserved CASE is a registered trademark of CNH America LLC.

Bur 6-84181NA April 2005

TABLE OF CONTENTS

TABLE OF CONTENTS TO THE OWNER .................................................................................................................................. 1 OPERATOR MANUAL STORAGE COMPARTMENT ..................................................................... 3 AFTER DELIVERY CHECK ............................................................................................................ 4 RIGHT, LEFT, FRONT AND REAR SIDES ..................................................................................... 4 OF THE MACHINE ......................................................................................................................... 4 IDENTIFICATION NUMBERS ........................................................................................................ 5 PRODUCT IDENTIFICATION NUMBER - P.I.N. ............................................................................ 5 ENGINE .......................................................................................................................................... 5 TRANSMISSION ............................................................................................................................ 6 REAR AXLE (GRAZIANO) ............................................................................................................. 6 ROPS CAB AND CANOPY ............................................................................................................ 6 REAR AXLE (CLARK-OPTIONAL) ................................................................................................. 6 MACHINE COMPONENTS ............................................................................................................ 7 DAFETY/DECALS/HAND SIGNALS ................................................................................................... 9 SAFETY RULES ............................................................................................................................. 9 UTILITY SAFETY ......................................................................................................................... 10 PERSONAL SAFETY ................................................................................................................... 11 BEFORE OPERATION ................................................................................................................. 12 MACHINE OPERATION ............................................................................................................... 13 START UP .................................................................................................................................... 14 OPERATING ................................................................................................................................. 14 SHUT DOWN ................................................................................................................................ 14 ADDITIONAL SAFETY RULES .................................................................................................... 15 NEUTRAL START AND REVERSE WARNING CHECKS ............................................................ 15 PARKING THE MACHINE ............................................................................................................ 17 BURN PREVENTION ................................................................................................................... 17 FIRE EXTINGUISHER ................................................................................................................. 18 FIRE OR EXPLOSION PREVENTION ......................................................................................... 18 MAINTENANCE ........................................................................................................................... 19 WHEEL AND TIRE MAINTENANCE ............................................................................................ 20 ROLL-OVER PROTECTIVE STRUCTURE .................................................................................. 20 READ OPERATORS MANUAL .................................................................................................... 21 SAFETY DECALS ........................................................................................................................ 21 SYMBOLS .................................................................................................................................... 22 MAIN SYMBOLS USED IN THIS MANUAL .................................................................................. 22 SAFETY RULES ........................................................................................................................... 24 DECALS ....................................................................................................................................... 25 HAND SIGNALS ........................................................................................................................... 30 INSTRUMENTS/CONTROLS ............................................................................................................. 33 OPERATOR’S COMPARTMENT .................................................................................................. 33 FRONT CONSOLE ....................................................................................................................... 34 INSTRUMENT PANEL INDICATORS ........................................................................................... 38 AIR CONDITIONER ..................................................................................................................... 47 OPERATORS SEAT ..................................................................................................................... 49 STANDARD SEAT ........................................................................................................................ 49 OPTIONAL AIR RIDE SEAT ......................................................................................................... 50 SEAT BELT ................................................................................................................................... 51 PARKING BRAKE ......................................................................................................................... 52 OPERATING INSTRUCTIONS ........................................................................................................... 55 BEFORE STARTING THE ENGINE ............................................................................................. 55 FIRST SERVICE INTERVALS ...................................................................................................... 57 AFTER FIRST 100 HOURS OF OPERATION .............................................................................. 57 SEAT BELT ................................................................................................................................... 57

I

TABLE OF CONTENTS

RUN-IN ......................................................................................................................................... 58 BOOSTER BATTERY CONNECTIONS TO MACHINE BATTERIES (JUMP START) ................. 59 OPERATING INSTRUCTIONS ..................................................................................................... 60 OPERATING TIPS ........................................................................................................................ 66 TYPICAL OPERATION ................................................................................................................. 67 WHEELS/TIRES ................................................................................................................................. 71 ADDING AIR TO THE TIRES ....................................................................................................... 73 TIRE OR RIM SERVICE ............................................................................................................... 73 TIRE TREAD DIRECTION ............................................................................................................ 73 WHEEL NUTS TORQUE AND TIRE PRESSURE ........................................................................ 74 TANDEM WHEEL LUG NUTS ...................................................................................................... 74 TIRE PRESSURE CHECK ........................................................................................................... 74 LUBRICATION/FILTERS/FLUIDS ...................................................................................................... 77 GENERAL SAFETY BEFORE YOU SERVICE ............................................................................ 77 ENGINE HOURMETER ................................................................................................................ 78 TRANSPORT/SERVICE PIN ........................................................................................................ 79 ENVIRONMENT ........................................................................................................................... 79 SYSTEMGARD LUBRICATION ANALYSIS PROGRAM .............................................................. 80 PLASTIC AND RESIN PARTS ...................................................................................................... 80 ENGINE HOOD ............................................................................................................................ 81 MAINTENANCE ........................................................................................................................... 82 GENERAL .................................................................................................................................... 82 FLUIDS AND LUBRICANTS ......................................................................................................... 83 LUBRICATION & MAINTENANCE CHART .................................................................................. 84 ACCESS DOORS ......................................................................................................................... 87 FLUID LEVELS ............................................................................................................................. 88 EACH 10 HOURS OR DAILY SERVICES .................................................................................... 88 EACH 50 HOURS SERVICES ...................................................................................................... 90 GREASE FITTINGS ..................................................................................................................... 91 EACH 100 HOURS SERVICES .................................................................................................... 91 EACH 250 HOURS SERVICES .................................................................................................... 93 EACH 500 HOURS SERVICES .................................................................................................... 95 ENGINE LUBRICATION ............................................................................................................... 96 ENGINE OIL SELECTION ............................................................................................................ 96 OIL VISCOSITY AND TEMPERATURE RANGES ....................................................................... 97 ENGINE SERVICE SPECIFICATIONS ........................................................................................ 98 ENGINE OIL LEVEL ..................................................................................................................... 98 ENGINE OIL CHANGE AND FILTER REPLACEMENT ............................................................... 98 SYSTEMGARD LUBRICATION ANALYSIS PROGRAM .............................................................. 99 AIR FILTER SYSTEM ................................................................................................................. 100 SERVICE SPECIFICATIONS ..................................................................................................... 100 CLEANING THE AIR FILTER ELEMENT ................................................................................... 100 ENGINE COOLING SYSTEM .................................................................................................... 102 SERVICE SPECIFICATIONS ..................................................................................................... 102 THERMOSTAT ........................................................................................................................... 102 COOLANT MIXTURE ................................................................................................................. 102 DRAINING AND FLUSHING THE COOLING SYSTEM ............................................................. 103 RADIATOR CLEANING .............................................................................................................. 103 DIESEL FUEL SYSTEM ............................................................................................................. 105 SERVICE SPECIFICATIONS ..................................................................................................... 105 FUEL CONDITIONER ................................................................................................................ 105 FUEL FILLER CAP ..................................................................................................................... 105 DIESEL FUEL ............................................................................................................................. 106 FUEL STORAGE ........................................................................................................................ 106 SPECIFICATIONS FOR ACCEPTABLE NO. 2 DIESEL FUEL ................................................... 106 FUEL TANK DRAIN COCK CLEAN ........................................................................................... 107

II

TABLE OF CONTENTS

CHANGING THE FUEL FILTERS ............................................................................................... 107 CHECKING THE FUEL INJECTOR NOZZLES .......................................................................... 108 ADJUSTING ENGINE VALVES .................................................................................................. 108 HYDRAULIC/BRAKE SYSTEM .................................................................................................. 109 SERVICE SPECIFICATIONS ..................................................................................................... 109 HYDRAULIC/BRAKE SYSTEM FLUID CHART ......................................................................... 109 HYDRAULIC SYSTEM OIL FILTER ........................................................................................... 110 CLEANING THE SUCTION LINE FILTER .................................................................................. 110 HYDRAULIC/BRAKE OIL CHANGE ............................................................................................ 111 TRANSMISSION ........................................................................................................................ 112 SERVICE SPECIFICATIONS ..................................................................................................... 112 TRANSMISSION OIL LEVEL CHECK ........................................................................................ 112 TRANSMISSION OIL FILTER CHANGE .................................................................................... 113 TRANSMISSION OIL CHANGE AND SCREEN CLEANING ..................................................... 113 REAR AXLE ................................................................................................................................ 114 SERVICE SPECIFICATIONS ..................................................................................................... 114 AXLE OIL LEVEL ........................................................................................................................ 114 REAR AXLE OIL CHANGE ......................................................................................................... 114 REAR AXLE END COMPARTMENT OIL LEVEL (OPCIONAL) .................................................. 115 SWING/CIRCLE TURN GEAR BOX ........................................................................................... 116 SERVICE SPECIFICATIONS ..................................................................................................... 116 CHECKING CIRCLE TURN GEAR BOX OIL ............................................................................. 116 TANDEM .................................................................................................................................... 117 SERVICE SPECIFICATIONS ..................................................................................................... 117 TANDEM DRIVE CASE OIL LEVEL CHECK ............................................................................. 117 TANDEM DRIVE CASE OIL CHANGE ....................................................................................... 117 TANDEM WHEEL NUT .............................................................................................................. 117 WINDSHIELD WASHER RESERVOIR (IF EQUIPPED) ............................................................ 118 MAINTENANCE/ADJUSTMENT ...................................................................................................... 119 PARKING BRAKE CHECK ......................................................................................................... 119 ROLL-OVER PROTECTIVE STRUCTURE ................................................................................ 119 SEAT BELT ................................................................................................................................. 119 MAINTENANCE AND INSPECTION OF ROPS ......................................................................... 120 TORQUE SPECIFICATIONS FOR ROPS CAB AND ROPS ...................................................... 120 DAMAGE TO THE ROPS ........................................................................................................... 121 TORQUE SPECIFICATIONS FOR SEAT AND SEAT BELTS .................................................... 122 OPERATORS SEAT ................................................................................................................... 122 CAB HEADLINER ....................................................................................................................... 123 DOORS HINGES ........................................................................................................................ 123 HOSES AND WIRING ................................................................................................................ 123 FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) ................................................................. 123 TYPE OF FIRE EXTINGUISHER ............................................................................................... 123 ALTERNATOR BELT AND AIR CONDITIONING COMPRESSOR BELT ................................... 124 ALTERNATOR BELT AND TENSIONER .................................................................................... 124 DRIVE BELT AND TENSIONER INSPECTION .......................................................................... 125 DRIVE BELT TENSIONER ......................................................................................................... 125 REINSTALLING THE DRIVE BELT ............................................................................................ 125 CIRCLE GUIDES CHECK AND ADJUST ................................................................................... 125 WEAR PLATE ADJUSTMENT .................................................................................................... 125 DRAWBAR ................................................................................................................................. 126 HYDRAULIC DIAGNOSTIC PANEL CHECK ............................................................................. 127 ELECTRICAL SYSTEM .................................................................................................................... 129 ELECTRICAL SYSTEM .............................................................................................................. 129 BATTERY SAFETY .................................................................................................................... 129 BATTERY SERVICE ................................................................................................................... 130 BATTERY FLUID LEVEL ............................................................................................................ 130

III

TABLE OF CONTENTS

BATTERY VENTS ...................................................................................................................... 130 CLEANING THE BATTERIES .................................................................................................... 130 LIMP-HOME ............................................................................................................................... 131 TRANSMISSION AUXILIARY SYSTEM ..................................................................................... 131 WELDING SERVICE ON THE MACHINE .................................................................................. 131 FUSE BOX ................................................................................................................................. 132 FUSE AND RELAY LIST ............................................................................................................. 132 MACHINE STORAGE ....................................................................................................................... 133 STORAGE PREPARATION ........................................................................................................ 133 REMOVAL FROM STORAGE .................................................................................................... 134 SPECIFICATION ............................................................................................................................... 135 ENGINE ...................................................................................................................................... 135 FAN ............................................................................................................................................ 135 RADIATOR ................................................................................................................................. 135 CHARGE AIR COOLER ............................................................................................................. 135 TRANSMISSION ........................................................................................................................ 136 TANDEM .................................................................................................................................... 136 FRONT AXLE ............................................................................................................................. 136 REAR AXLE ................................................................................................................................ 136 TIRES ......................................................................................................................................... 136 BRAKES ..................................................................................................................................... 136 STEERING ................................................................................................................................. 137 FLUID CAPACITIES ................................................................................................................... 137 ELECTRICAL SYSTEM .............................................................................................................. 137 OPERATION WEIGHTS ............................................................................................................. 138 CIRCLE ...................................................................................................................................... 139 MOLDBOARD ............................................................................................................................ 139 DRAWBAR ................................................................................................................................. 140 HYDRAULIC SYSTEM ............................................................................................................... 140 ACCESSORIES .......................................................................................................................... 140 OPERATING DATA AND DIMENSIONS ..................................................................................... 142 ALPHABETICAL INDEX .................................................................................................................. 145 AFTER DELIVERY CHECK ............................................................................................................. 149

IV

To the owner TO THE OWNER

TO THE OWNER 865 DHP GRADER ELECTRONIC ENGINE

Read this manual before you start the engine or operate the machine. If you need more information, see your dealer.

Your dealer can give you help with Case Corporation approved service parts. Your dealer has specially trained technicians who know the best methods of repair and maintenance for your machine.

Use this manual as a guide. Your Grader will remain a reliable working tool as long as it is kept in working condition and serviced properly.

1

TO THE OWNER

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

This Grader, with standard equipment and attachments, is intended to be used for above ground level general earth moving purpose such as land leveling and material rehandling.

DO NOT use this machine for any application or purpose other than those described in this manual. If the Grader is to be used in an application that involves special attachments or equipment, such as forestry, etc., consult an authorized dealer or the Case Corporation. Consult an authorized dealer or Case Corporation on changes, additions or modifications that can be required for this machine to comply with various country regulations and safety requirements.

Unauthorized modifications can cause serious injury or death. Anyone making such unauthorized modifications is responsible for the consequences.

This Operators Manual is to be stored in the manual compartment equipped on this machine. Make sure this manual is complete and in good condition. Contact you dealer to obtain additional manuals.

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

Before permitting a new operator on this machine, make sure: 1. That the operator has received the necessary training on how to operate the machine correctly and safely in one of our training centers or from an approved organization.

2. That the operator has read and understood the instructions given in this manual.

Call your dealer if you need any assistance or information.

2

TO THE OWNER

OPERATOR MANUAL STORAGE COMPARTMENT READ THIS MANUAL COMPLETELY and make sure you understand the controls. All equipment has a limit.

Make sure you understand the speed, brakes, steering, stability and other characteristics of this machine before you start to operate.

1

DO NOT remove this manual or the safety manual from the machine. See your dealer for additional manuals.

1. OPERATORS MANUAL STORAGE COMPARTMENT

Also see the manual information on the inside of the rear cover of this manual.

3

TO THE OWNER

AFTER DELIVERY CHECK Two copies of the After Delivery Check are in the back of this manual. One copy is for you and one copy is for the dealer. Make sure that your dealer does the After Delivery Check after the first 100 hours of machine operation.

NOTE: Your cost for this check will be for filters, oil or other accessories. If the dealer comes to your machine, there can also be a cost for the time and distance.

RIGHT, LEFT, FRONT AND REAR SIDES OF THE MACHINE Right-hand and left-hand, when used in this manual, indicate the right and left sides of the machine as seen from the operators seat.

RIGHT SIDE

FRONT

LEFT SIDE

4

REAR

TO THE OWNER

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

Make a record of the numbers. Keep the record in a safe place. If the machine is stolen, report the numbers to your local law enforcement agency.

MACHINE MODEL NUMBER PRODUCT IDENTIFICATION NUMBER ENGINE SERIAL NUMBER TRANSMISSION MODEL AND SERIAL NUMBER ROPS CAB OR CANOPY SERIAL NUMBER FRONT AXLE MODEL AND SERIAL NUMBER REAR AXLE MODEL AND SERIAL NUMBER

Product Identification Number - P.I.N.

Engine

CASE CORPORATION RACINE WISCONSIN 53404 USA MADE IN BRAZIL

MODEL

PRODUCT IDENTIFICATION NUMBER - PIN

149841A1

5

TO THE OWNER

Transmission

ROPS Cab and Canopy

Rear Axle (Graziano)

Rear Axle (Clark-Optional)

6

TO THE OWNER

MACHINE COMPONENTS 2

3

7

1 4

5

6

1. HAND RAILS

5. ARTICULATION CYLINDER

2. ROPS CAB

6. STEPS

3. BLADE LIFT CYLINDER

7. ENGINE ACCESS HOOD

4. BLADE CIRCLE

8

9 12

10

11

12. TRANSPORT SERVICE PIN

8. BLADE LIFT CYLINDERS 9. CIRCLE SIDE SHIFT CYLINDER 10. BLADE PITCH CYLINDER 11. BLADE SIDE SHIFT CYLINDER

7

TO THE OWNER

1

5 2 6

4 3

1. ENGINE ACCESS HOOD

4. LIFT AND TIE EYES

2. HAND RAILS

5. RADIATOR AND FAN

3. REAR RIPPER

6. DRAWBAR CIRCLE AND BLADE

8

7

8. HYDRAULIC FILTER

7. A/C CONDENSER

8

Dafety/Decals/Hand Signals

SAFETY/DECALS/HAND SIGNALS

! SAFETY RULES !

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

READ THIS MANUAL COMPLETELY and make sure you understand the controls. All equipment has a limit.

Make sure you understand the speed, brakes, steering, stability and other characteristics of this machine before you start to operate.

1

DO NOT remove this from the machine. See your dealer for additional manuals.

Also see the manual information on the inside of the rear cover of this manual.

1. OPERATORS MANUAL STORAGE BOX

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

IMPORTANT: Safety messages in this section point out situations which can happen during the normal operation and maintenance of your machine. These safety messages also give possible ways of dealing with these conditions.

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

!

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH.

9

SAFETY/DECALS/HAND SIGNALS

! UTILITY SAFETY !

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

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

Electrical Power Line

•

Gas Line

•

Water Line

•

Communication Line - Telephone or Cable Television

•

Sewer Line

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

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU TRENCH/DRILL Know the utility color code (U.S.A. and Canada):

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

1. Electric ................................................... Red

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

3. Communication, Telephone,

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

5. Sewer ...................................... Green/Brown

2. Gas, Oil or Petroleum ......................... Yellow Television .......................................... Orange 4. Water ..................................................... Blue 6. Proposed Excavation .......................... White 7. Surveying .............................................. Pink 8. Reclaimed Water, Slurry ..................... Purple After locating the utility lines, carefully dig a hole by hand and/or automatic vacuum equipment to the utility line to verify the location and depth of the line.

10

SAFETY/DECALS/HAND SIGNALS

!

PERSONAL SAFETY !

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

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

•

WARNING: Indicates a potentially hazardous situation which, if not avoided may result in serious injury. The color associated with Warning is ORANGE.

•

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

ISO two panel pictorial symbol decals are defined as follows: •

The first panel indicates the nature of the hazard.

•

The second panel indicates the appropriate avoidance of the hazard.

•

Background color is YELLOW.

•

Prohibition symbols such as

,

and

11

STOP

if used are RED.

SAFETY/DECALS/HAND SIGNALS

! BEFORE OPERATION !

•

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

•

Remove all loose objects from the cab. Loose objects can jam controls and cause accidents.

•

Different jobs will require different protective equipment. Items such as hard hats, protective shoes, heavy gloves, reflector type vests, respirators, ear protection, and eye protection can be required. Before you start the job, determine what protective equipment is required. Use this equipment at all times.

•

Before you start each day, walk around the machine and check for oil or fluid leaks.

Replace all broken or missing parts and do the required lubrication and maintenance as shown in this manual. Clean all trash and debris from the machine, especially from the engine area.

•

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

•

Make sure all persons are away from the machine before you start the engine.

•

•

Know the hand signals used on your job.

Follow the instructions of the flagman, signs, etc. See Hand Signals for more information.

Before you start the engine, always fasten the seat belt.

•

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

•

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

•

•

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

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

•

•

To avoid falling, always face the machine and use the hand rails and steps when getting on or getting off. Do not rush.

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

•

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

1

2

1

1. HAND RAILS 2. STEPS

12

SAFETY/DECALS/HAND SIGNALS

! MACHINE OPERATION !

•

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

•

Do not allow other persons to ride on the machine. Other persons can fall or can cause an accident. This is a one person machine with one operator’s seat.

•

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

Make sure the machine lamps are ON.

•

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

•

Before you drive or operate in an area with high voltage lines, cables, or a power station, tell the power or utility company what you are going to do. You MUST HAVE THE POWER DISCONNECTED OR KEEP A SAFE WORKING DISTANCE from the lines, cables, or power station. Keep all parts of the machine at least 5 m (15 feet) away from the power source. You must also know any federal, state/provincial, or local safety codes or regulations that apply to the job site.

•

If you have extreme conditions, such as a fire, etc., and you are forced to leave the machine, do not step off the machine. Jump as far from the machine as possible with your feet together and do not touch the ground with your hands.

•

Then, hop away with your feet together until you are a safe distance from the machine and the electrical current. Do not take large steps.

Because of the voltage differential across the ground, one foot can be in a higher voltage area than the other foot. This difference can kill you.

•

Do not operate the machine if you do not feel well. This can be dangerous for you and for the people around you.

•

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

•

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

•

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

•

If a part of the machine touches high voltage power:

•

Warn other workers NOT TO TOUCH THE MACHINE and to stay away from the machine.

•

Operate the machine within the specified capacities and limits. See Specifications section of this manual.

•

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

•

Operate the machine controls from the operators seat only.

•

Digging through underground cables, pipes, lines, etc., can cause injury or death. Learn the location of all underground hazards before you operate your machine in any area.

13

SAFETY/DECALS/HAND SIGNALS

•

When working in areas where traffic is heavy always have a person direct the traffic and direct other persons for you. Have guard rails, warning signs, etc., as required for your job.

Observe and know the mechanics of alternate exit routes.

•

Stop operating the machine if a malfunction occurs. Watch the indicator and warning lamps in the machine. Listen and smell for things that are not normal on your machine.

•

Drive around large objects such as large rocks or trees.

When operating always look at the direction of the movement of the machine. Be sure exposed personnel in the area of operation are clear of the unit before moving the machine or its attachments, mainly children. If someone arrives in operation area, stop the machine immediately.

Do not attempt to climb on or off machine while it is in motion.

Maintain a safe distance from other machines.

Provide sufficient clearance for ground and visibility conditions.

Start Up Do not start or operate an unsafe machine. Before working the machine, be sure that any unsafe condition has been satisfactorily remedied.

Yield right-of-way to loaded machines.

Shut Down

Check brakes and steering and attachment controls before moving. Advise the proper maintenance authority of any malfunction part or system.

Never leave the machine unattended with the engine running.

Always before leaving the operator’s seat and after making certain all people are clear of the machine, slowly lower attachments or tools flat to the ground in a positive ground support position.

Move any multipurpose tool or attachment to positive closed position. Return the controls to hold. Place transmission control in neutral and move engine controls to off position. Engage all control locks, set parking brake, and open and lock the master (key) switch.

Before starting machine, check, adjust and lock the operator’s seat for maximum comfort and control of the machine.

Be sure all people in the area are clear of the unit before releasing the parking brake or moving the machine or its attachments. Walk completely around machine before mounting. Sound horn.

Obey flagman, safety signals and signs.

Due to the presence of flammable fluid, never check or fill fuel tanks, storage batteries, or use starter fluid near lighted smoking materials or open flame or sparks.

Park in a nonoperating and non-traffic area or as instructed. Park on firm level ground if possible.

Where not possible, position machine at a right angle to the slope, making sure there is no danger of uncontrolled sliding movement. Set the parking brake. If parking in traffic lanes cannot be avoided, provide appropriate flags, barriers, flares and warning signals in the traffic lane for approaching traffic.

Operating Do not run the engine of this machine in closed area without proper ventilation to remove deadly exhaust gases.

Do not use machine to carry loose objects by means other than attachments designed for such objects.

Never lower attachments or tools from any position other than seated in operator’s seat.

Do not carry riders unless the machine is equipped for carrying people to reduce personal exposure to being thrown off.

14

SAFETY/DECALS/HAND SIGNALS

ADDITIONAL SAFETY RULES NEUTRAL START AND REVERSE WARNING CHECKS IMPORTANT: Perform these checks before operating machine

3. Move the transmission control lever to the forward position.

NEUTRAL START CIRCUIT CHECK:

•

Engage the parking brake.

•

Be sure the area around machine is clear of personnel.

•

Turn the key switch to START.

•

LISTEN: The starting motor should run

•

Disengage the parking brake.

REVERSE WARNING ALARM CHECK:

•

Completely depress the inching control pedal.

•

•

Move transmission control lever to the forward position.

Be sure area around machine is clear of personnel.

•

Engage the parking brake.

•

Turn the key switch to START.

•

Completely depress the inching control pedal.

•

LISTEN: The starting motor must not run.

•

•

Move the transmission control lever to the reverse position.

Move transmission control lever to 1st gear in Reverse.

•

•

Turn the key switch to START.

LISTEN: The reverse warning alarm must sound.

•

LISTEN: The starting motor must not run.

For more information, see inching control pedal, transmission control lever, ignition switch, in the section Instruments and controls.

IMPORTANT: 1. Move the transmission control lever to the reverse position.

•

Engage the parking brake.

•

Turn the key switch to START.

•

LISTEN: The starting motor should run

2. Move the transmission control lever to the neutral position.

•

Engage the parking brake.

•

Turn the key switch to START.

•

LISTEN: The starting motor should run

15

SAFETY/DECALS/HAND SIGNALS

TRANSMISSION OPERATING INSTRUCTIONS Starting engine

Transmission must be in neutral before engine can be started.

Parking brake

Transmission will not engage a gear with park brake on.

Starting machine

Move gear selector to desired gear which will be indicated on display and drive away. Inching pedal can be used also in a manner similar to a mechanical clutch. Most operators will find this to be a very natural operation.

Inching pedal

Use when starting or stopping. Use for grader finishing work requiring “ Creeper gear” or very slow speeds. Use for very slow ground speed work to increase engine speed for hydraulic performance (This should rarely be necessary because of the wide range performance of the hydraulic system). WARNING: Do not abruptly depress and release inching pedal to start a heavy load or free a stuck machine.

Upshifting

Upshift normally as speed, grade, and traction conditions permit.

Power shift, do not use inching pedal.

Downshifting

Downshift one range at a time. Do not lug down the engine below 1700 RPM. Watch tachometer. Power shift, do not use inching pedal.

Shifting while descending steep grades

During transport while descending short, steep grades, the engine may be driven from the ground by the wheels. In order to maintain a higher speed it could be necessary to upshift to protect the engine while using brakes for retardation. Normally the safe and recommended procedure is to descend slowly using a lower gear together with the brakes, particularly for longer distances.

Shifting forward to reverse and reverse to forward

Operator can make these shifts as required by normal working conditions. The transmission will automatically select the appropriate gear in the opposite direction and has built in shock protection.

Lugging engine down under heavy blade or ripper load

Do not repeatedly depress and release inching pedal to force movement of machine.

Stopping and starting with display indicating a gear higher than 3.

When moving and then stopping with the inching pedal depressed, the machine will always select 3rd gear to start. On level terrain or moderate grades start in 4th and upshift as conditions permit. On steep grades or when under load shift to lower gear and drive away.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel.

16

SAFETY/DECALS/HAND SIGNALS

! PARKING THE MACHINE !

•

When you park the machine and before you leave the operators area, always support or lower all attachments to the ground, apply the parking brake, stop the engine, and remove the key.

•

If you must temporarily park the machine on a hillside, place machine at a right angle in relation to the bottom of the hill. Make sure the machine is behind an object that will not move. Put blocks in front of each wheel on the downhill side.

•

Always face the machine and use the hand rails and steps when getting off. Do not rush and do not jump from the machine.

! BURN PREVENTION !

•

Batteries contain sulfuric acid which can cause severe burns. Avoid contact with skin, eyes, or clothing. Antidote - EXTERNAL Flush with water. INTERNAL - Drink large quantities of water or milk. DO NOT induce vomiting. Seek medical attention immediately.

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

BATTERIES PRODUCE EXPLOSIVE GASES. Keep sparks, flame, cigars and cigarettes away. Ventilate when charging or using in enclosed area. Always wear eye protection when working with the batteries.

Wash hands after handling. KEEP OUT OF REACH OF CHILDREN.

17

•

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

•

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

SAFETY/DECALS/HAND SIGNALS

! FIRE EXTINGUISHER !

It is recommended that you have a fire extinguisher on your machine. See your Case dealer for availability.

A dry chemical fire extinguisher is approved for Class A, B, and C fires.

! FIRE OR EXPLOSION PREVENTION !

•

Sparks or flame can cause the hydrogen gas in a battery to explode. To prevent an explosion, do the following:

•

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

1. When disconnecting the battery cables, disconnect the negative (-) cable first; when connecting the battery cables, connect the negative (-) cable last.

•

Remove all trash or debris from the machine as required. Especially check the engine area and exhaust system.

•

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

•

Keep the cooling system clean and maintain the correct coolant level.

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

•

Make sure you do not store oily rags or other flammable materials on the machine.

4. Do not weld, grind, or smoke near a battery. Keep open flame away from the battery.

•

Starting fluid (ether) can explode and cause injury or death. Do not breathe starting fluid vapors. Wear face protection when you remove or install a starting fluid container or when you use an aerosol spray starting fluid.

Use starting fluid according to the instructions in this manual.

•

If you weld, grind, or use a cutting torch on the machine, always remove the starting fluid container from the machine. Use compressed air to remove any ether fumes from the area.

•

Before welding on this machine, disconnect the battery ground (-).

•

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

2. When connecting jumper cables to start the engine, use the procedure as shown in Booster Battery Connection on section Operating Instructions.

•

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

•

Engine fuel can cause an explosion or fire.

Do not fill the fuel tank while the engine is running.

•

DO NOT smoke while refueling the machine.

•

Use nonflammable cleaning solvent to clean parts.

•

A fire can cause injury or death. Always have a fire extinguisher near or on the machine.

Make sure the fire extinguisher is serviced according to the manufacturer’s instructions.

18

SAFETY/DECALS/HAND SIGNALS

! MAINTENANCE !

•

•

Before you service the machine, put a Do Not Operate tag on the steering wheel. One Do Not Operate tag is included with your new machine. Additional tags, part number 3214614, are available from your Case dealer.

product, (2) safe handling procedures, (3) first aid measures, and (4) procedures to be taken when the product is accidentally spilled or released. Material Safety Data Sheets (MSDS) are available from your Case dealer.

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

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

•

Before you service this machine and before you dispose of the old fluids and lubricants, always remember the environment. Do not put oil or fluids into the ground or into containers that can leak. Check with your local environmental or recycling center or your Case dealer for correct disposal information.

•

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

•

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

Always see your Case dealer before you weld, cut, or drill holes in your machine.

•

Metal chips or debris can cause eye injury.

Always wear eye or face protection when you use a hammer on this machine. Use a hammer with a soft face, such as brass, to drive hardened pins.

•

If you must service this machine with the engine running, have another person help you. Follow the instructions in this manual or the service manual. Do not leave the operator’s seat while the engine is running.

•

Clean the machine regularly. A buildup of grease, dirt, and debris can cause possible injury or machine damage. Keep your work shop clean.

•

Before welding on this machine, disconnect the battery ground (-).

•

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

• •

Disconnect the batteries before working on the electrical system.

If you are exposed to or come in contact with hazardous chemicals you can be seriously injured. The fluids, lubricants, paints, adhesives, coolants, etc., used with your machine can be hazardous. Material Safety Data Sheets (MSDS) provide (1) information about the chemical substances within a 19

SAFETY/DECALS/HAND SIGNALS

! WHEEL AND TIRE MAINTENANCE !

•

Do NOT weld to wheel or rim when a tire is installed. Welding may cause an explosive air/ gas mixture that will be ignited with high temperatures. This can happen to tires inflated or deflated. Removing air or breaking bead is not adequate. Tire MUST be completely removed from the rim prior to welding.

•

Explosive separation of the tire and/or rim parts can cause injury or death. When tire service is necessary, have a qualified tire mechanic service the tire.

! ROLL-OVER PROTECTIVE STRUCTURE !

•

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

20

SAFETY/DECALS/HAND SIGNALS

! READ OPERATORS MANUAL !

Decals which display the “Read Operators Manual” symbol are intended to direct the operator to the Operators Manual for further information regarding safety, maintenance, adjustments and/or procedures for specific areas of the machine. When a decal displays the following symbol refer to the Operators Manual.

When a decal displays the symbol shown below, refer to the appropriate page of the Service Manual.

READ SERVICE MANUAL

READ OPERATORS MANUAL

! SAFETY DECALS !

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

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

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

!

WARNING: Injury or death can result if you cannot read a safety decal or if a safety decal is missing. Replace any missing or damaged safety decal and keep all safety decals clean. See your Case dealer for new safety decals.

21

SAFETY/DECALS/HAND SIGNALS

! SYMBOLS

!

MAIN SYMBOLS USED IN THIS MANUAL

!

!

WARNING - (Warning signal)

LIGHTS

FUELING

LOW TRANSMISSION HYDRAULIC OIL PRESSURE

AIR CLEANER RESTRICTION

LOW ENGINE OIL PRESSURE

PARKING BRAKE

DIFFERENTIAL LOCK

HYDRAULIC OIL FILTER RESTRICTION

HOURMETER

TRANSMISSION OIL FILTER RESTRICTION

OPERATOR’S SEAT ADJUSTMENT

BATTERY

LOCKED

BRAKE OIL - LOW PRESSURE

UNLOCKED

ENGINE WATER TEMPERATURE

BLADE FLOATATION - (Right cylinder)

ELECTRICAL SYSTEM

BLADE FLOATATION - (Left cylinder)

HYDRAULIC OIL TEMPERATURE

FRONT BLADE FLOATATION

TRANSMISSION OIL TEMPERATURE

RIPPER

HAZARD WARNING LIGHTS

SCARIFIER

SUPPLEMENTAL STEERING

SADDLE LOCK

22

SAFETY/DECALS/HAND SIGNALS

HORN

STROBE LIGHT (OPTIONAL)

RIGHT TURN SIGNAL

POSITION LIGHTS

LEFT TURN SIGNAL

HEADLIGHTS - HIGH BEAM

SHIFT DOWN

BLADE ANTI-SHOCK SYSTEM

SHIFT UP

COLD STARTING (OPTIONAL)

FRONT WINDSHIELD WIPER (OPTIONAL)

WARNING (Fluid under pressure)

WIPER / LOWER FRONT WINDSHIELD WASHER - LEFT AND RIGHT (OPTIONAL)

WARNING (Toxic gas)

FRONT WINDSHIELD WASHER (OPTIONAL)

WARNING (Electrical shock)

FAN / HEATER (OPTIONAL)

WARNING (Tire pressure)

WINDSHIELD - DEFROSTER

WARNING (Blood poisoning)

REAR LIGHT

WARNING (Radiator heat)

CAB LIGHT

DANGEROUS (Your safety is involved)

BLADE LIGHT

ARTICULATION

REAR WINDOW - WASHER AND WIPER (OPTIONAL)

23

SAFETY/DECALS/HAND SIGNALS

! SAFETY RULES !

!

This symbol is your safety alert sign. It means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

MOST ACCIDENTS ARE CAUSED BY FAILURE OF SOME INDIVIDUAL TO FOLLOW SIMPLE AND FUNDAMENTAL SAFETY RULES. FOR THIS REASON MOST ACCIDENTS CAN BE PREVENTED BY RECOGNIZING THE REAL CAUSE AND DOING SOMETHING ABOUT IT BEFORE ACCIDENT OCCURS. REGARDLESS OF THE CARE USED IN THE DESIGN AND CONSTRUCTION OF ANY TYPE OF EQUIPMENT THERE ARE MANY CONDITIONS THAT CAN’T BE COMPLETELY SAFEGUARDED AGAINST WITHOUT INTERFERING WITH REASONABLE ACCESSIBILITY AND EFFICIENT OPERATION.

Read and heed all safety instructions carrying the signal words WARNING and DANGER. BEFORE STARTING, OPERATING, MAINTAINING, FUELING OR SERVICING THIS MACHINE. Machine mounted safety signs have been color coded yellow with black borders and lettering for warning and red with white borders and lettering for danger points.

24

SAFETY/DECALS/HAND SIGNALS

DECALS ENGINE

S TA R T I N G

INSTRUCTIONS

F12

F11

F10

F9

F8

F7

F6

F5

F4

F3

F2

F1 BOX 1

DUAL POWER

PLACE FUEL SHUT-OFF IN RUN POSITION AND TURN KEY SWITCH UNTIL ENGINE STARTS. IF ENGINE DOES NOT START IN 30 SECONDS. ALLOW STARTER TO COOL FOR 2 MINUTES B E F O R E A N O T H E R S TA RT I N G AT T E M P T.

E. D. M.

15.0 AMP.

10.0 7.5 10.0 10.0 10.0 7.5 5.0 15.0 7.5 3.0 15.0 AMP. AMP. AMP. AMP. AMP. AMP. AMP. AMP. AMP. AMP. AMP.

F16

F14

F15

10.0 AMP. F12

F11

F10

10.0 AMP. F9

F8

STOP

C

COLD ENGINE

24V

F13

7.5 AMP.

F7

F6

7.5 AMP. F5

F4

F3

3.0 7.5 7.5 10.0 3.0 3.0 3.0 10.0 3.0 AMP. AMP. AMP. AMP. AMP. AMP. AMP. AMP. AMP. F14 F16 7.5 F15 3.0 10.0 AMP. AMP. AMP.

START ENGINE AT LOW IDLE OR ONE-FOURTH THROTTLE. INCREASE ENGINE SPEED TO ONEHALF THROTTLE UNTILL COOLANT TEMPERATURE GAUGE NEEDLE MOVES FROM ITS MINIMUM POSITION. WORK ENGINE WITH NO MORE THAN ONE-HALF LOAD UNTIL NORMAL COOLANT TEMPERATURE IS REACHED.

F2

F1 BOX 2

STOP

10.0 10.0 AMP. AMP. F13

20.0 AMP. 7.5 AMP.

DUAL POWER

R 8

R 9

R 7

R 6

R 10

R 11

R 12

R 5

R 4

R 3

R 13

R 14

R 2

R 1

WARN ENGINE START ENGINE WITH APPROXIMATELY ONEFOURTH THROTLE.

R RUN

E N G I N E S H U T- D O W N I N S T R U C T I O N S ALLOW TO RUN FOR 3 TO 4 MINUTES AT ONEFOURTH THOTTLE BEFORE SHUTTING OFF FUEL.

73152851

!

WARNING START UP

!

THIS MACHINE AND ITS ATTACHMENTS ARE TO BE OPERATED ONLY BY A QUALIFIED OPERATOR STATIONED AT THE OPERATOR’S

! WARNING MISUSE HAZARD Read Operator’s Manual.

Use proper safety equipment.

Keep others away.

393538A1

CONTROLS EITHER SEATED OR STANDING AS CONDITIONS REQUIRE.

!

BE SURE ALL PEOPLE IN THE AREA ARE CLEAR OF THE UNIT BEFORE RELEASING THE PARKING BRAKE OR MOVING THE MACHINE OR ITS ATTACHMENTS.

!

DO NOT RUN THE ENGINE OF THIS MACHINE IN CLOSED AREAS WITHOUT PROPER VENTILATION TO REMOVE DEADLY EXHAUST GASES.

!

OBEY FLAGMAN, SAFETY SIGNALS AND SIGNS.

SHUT DOWN !

393538A1

ALWAYS BEFORE LEAVING THE OPERATOR’S SEAT AND AFTER MAKING CERTAIN ALL PEOPLE ARE CLEAR OF THE MACHINE:

!

SLOWLY LOWER THE ATTACHMENTS OR TOOLS FLAT TO THE GROUND IN A POSITIVE GROUND SUPPORT POSITION. MOVE ANY MULTIPURPOSE TOOL TO POSITIVE CLOSED POSITION. RETURN THE CONTROLS TO HOLD AND ENGATE LOCK.

!

PLACE TRANSMISSION CONTROL IN NEUTRAL

!

MOVE ENGINE CONTROLS TO OFF POSITION AND REMOVE KEY FROM SWITCH.

! !

SET PARKING BRAKE. DISCONNECT AND LOCK THE MASTER SWITCH.

!

DO NOT PARK IN OR NEAR TRAFFIC LANES. IF MACHINE MUST BE LEFT IN OR NEAR TRAFFIC LANES, PROVIDE TRAFFIC WARNING DEVICES. 73152838-01 DL

73152838

25

!

WARNING

ALWAYS TURN THE MASTER SWITCH TO THE OFF POSITION BEFORE CLEANING, REPAIRING OR SERVICING, AND AFTER PARKING MACHINE. 73107891

73107891

SAFETY/DECALS/HAND SIGNALS

MASSA / MASS - MAX.

ESTRUTURA DE PROTEÇÃO PARA O OPERADOR OPERATORS PROTECTIVE STRUCUTURE

20.000 kg 44.050 lbs

MODELOS / MODELS 845 / 865 / 885 APROVAÇÃO STANDARDS

Nº SÉRIE / SERIAL P/N

ISO 3471 / 3449 - SAE J1040D/J231 - OSHA FG-AD51

75320349 - Clark 75320383 - Graziano

! WARNING

HAZARDOUS AREA Keep clear 283606A1

283606A1

!

WARNING

REMOVE FRONT WHEEL LEAN SHIPPING ANCHOR BOLT BEFORE OPERATING MACHINE.

26

SAFETY/DECALS/HAND SIGNALS

! WARNING COME-HOME MODO DE EMERGÊNCIA DA TRANSMISSÃO Come-home is a hardware function which allows limited machine operation in the event of transmission components failure. If it is not possible to replace the Transmission Control Module in the field, disconnect the gray connectors, 1 from 2 and 3 from 4. Then, connect connectors 2 and 3. This procedure will allow limited transmission operation to drive the machine to the workshop for repair.

Come-home é uma função de emergência para que a máquina possa ser conduzida no caso de falha de algum componente da transmissão. Caso a substituição do Módulo de Controle da Transmissão não seja possível, desconecte os conectores 1 de 2 e 3 de 4. Conecte então os conectores 2 e 3. Este procedimento permitirá uma operação limitada da transmissão, para conduzir a máquina a uma oficina para reparo.

For more details on operating this system, see the operators manual.

Para mais detalhes sobre a operação deste sistema, veja o manual do operador.

GRAY CINZA

1

3

GRAY CINZA

GRAY CINZA

2

4

GRAY CINZA

WELDING SERVICE SERVIÇO DE SOLDAGEM

BLACK PRETO

When welding operations are required, disconnect the black connector before welding.

Quando forem necessários serviços de soldagem, desconecte o conector preto.

! WARNING

! WARNING

PRESSURIZED SYSTEM HAZARD

PRESSURIZED SYSTEM HAZARD Relieve pressure before maintenance.

Relive pressure before maintenance.

335889A1

335889A1

328904A1

328904A1

IMPORTANT COOLING SYSTEM IS PROTECTED WITH 50 - 60 SOLUTION OF ETHYLENE GLYCOL AND WATER FOR PROTECTION TO -38°C (-34°F) DO NOT USE SOLUBLE OIL ADDITIVES. PRINTED IN USA

! DANGER

! WARNING

EXPLOSION HAZARD

HOT LIQUID UNDER PRESSURE HAZARD

Read procedure in Operator’s Manual before jump start or service to avoid injury.

Service when cool.

412471A1

412471A1

329044A1

329044A1

27

SAFETY/DECALS/HAND SIGNALS

! WARNING

CRUSH HAZARD Keep clear 323694A1

323694A1

! WARNING

! WARNING

PINCH POINT HAZARD

PINCH POINT HAZARD

Keep clear

Keep clear 283609A1

283609A1

283609A1

283609A1

! WARNING

! WARNING

PINCH POINT HAZARD

PINCH POINT HAZARD

Keep clear

Keep clear 283609A1

283609A1

283609A1

283609A1

! WARNING

CRUSH HAZARD Keep clear

! WARNING

323694A1

ENTANGLEMENT HAZARD Keep clear or stop engine before servicing.

323694A1

384267A1

384267A1

28

SAFETY/DECALS/HAND SIGNALS

ENGINE

S TA R T I N G

INSTRUCTIONS

! WARNING

PLACE FUEL SHUT-OFF IN RUN POSITION AND TURN KEY SWITCH UNTIL ENGINE STARTS. IF ENGINE DOES NOT START IN 30 SECONDS. ALLOW STARTER TO COOL FOR 2 MINUTES B E F O R E A N O T H E R S TA R T I N G AT T E M P T.

HOT LIQUID UNDER PRESSURE HAZARD

COLD ENGINE START ENGINE AT LOW IDLE OR ONE-FOURTH THROTTLE. INCREASE ENGINE SPEED TO ONEHALF THROTTLE UNTILL COOLANT TEMPERATURE GAUGE NEEDLE MOVES FROM ITS MINIMUM POSITION. WORK ENGINE WITH NO MORE THAN ONE-HALF LOAD UNTIL NORMAL COOLANT TEMPERATURE IS REACHED.

Service when cool.

329044A1

329044A1

WARN ENGINE

! DANGER

START ENGINE WITH APPROXIMATELY ONEFOURTH THROTLE.

EXPLOSION HAZARD

E N G I N E S H U T- D O W N I N S T R U C T I O N S

Read procedure in Operator’s Manual before jump start or service to avoid injury.

ALLOW TO RUN FOR 3 TO 4 MINUTES AT ONEFOURTH THOTTLE BEFORE SHUTTING OFF FUEL.

73152851

412471A1

412471A1

! WARNING

! WARNING

! WARNING

CRUSH HAZARD Keep clear

PINCH POINT HAZARD

HAZARDOUS AREA

Keep clear

Keep clear

323694A1

283606A1

283609A1

323694A1

283609A1

283606A1

IMPORTANT COOLING SYSTEM IS PROTECTED WITH 50 - 60 SOLUTION OF ETHYLENE GLYCOL AND WATER FOR PROTECTION TO -38°C (-34°F) DO NOT USE SOLUBLE OIL ADDITIVES.

F12

F11

F10

F9

F8

F6

F5

F4

F3

F2

F1 BOX 1

DUAL POWER

E. D. M.

PRINTED IN USA

15.0 AMP.

F14

F15

10.0 AMP. F12

F11

F10

WARNING

7.5 7.5 10.0 AMP. AMP. AMP. F16

10.0 AMP. F9

F8

STOP

C

ALWAYS TURN THE MASTER SWITCH TO THE OFF POSITION BEFORE CLEANING, REPAIRING OR SERVICING, AND AFTER PARKING MACHINE.

24V

10.0 7.5 10.0 10.0 10.0 7.5 5.0 15.0 7.5 3.0 15.0 AMP. AMP. AMP. AMP. AMP. AMP. AMP. AMP. AMP. AMP. AMP.

F16

!

F7

7.5 AMP.

F13

7.5 AMP.

F7

F6

7.5 AMP. F5

F4

F3

F2

F1 BOX 2

STOP

3.0 3.0 3.0 3.0 10.0 3.0 AMP. AMP. AMP. AMP. AMP. AMP. F15

3.0 AMP.

F14

10.0 AMP.

10.0 10.0 AMP. AMP. F13

20.0 AMP. 7.5 AMP.

73107891

283606A1

DUAL POWER

R 8

R 9

R 10

R 11

R 12

R 5

R 4

R 3

R 13

R 14

R 2

R 1

! WARNING MISUSE HAZARD Read Operator’s Manual.

Use proper safety equipment.

Keep others away.

R RUN

R 7

393538A1

393538A1

29

R 6

SAFETY/DECALS/HAND SIGNALS

HAND SIGNALS It is recommended that you and the flagman on the job use hand signals for communications. Before you start, make sure that you both understand the signals that will be used.

START ENGINE

STOP ENGINE

COME TO ME

ALL STOP AND HOLD

Move hands forward and rearward (palms in)

Move hands forward and rearward (palms out).

30

SAFETY/DECALS/HAND SIGNALS

GO THIS FAR

ALL STOP AND HOLD

STOP

EMERGENCY STOP

Move one hand back and forth.

RAISE EQUIPMENT

LOWER EQUIPMENT

31

SAFETY/DECALS/HAND SIGNALS

RAISE EQUIPMENT SLOWLY

LOWER EQUIPMENT SLOWLY

TURN MACHINE LEFT

TURN MACHINE RIGHT

SWING BLADE LEFT

SWING BLADE RIGHT

To stop movement, stop moving hand and make a fist.

To stop movement, stop moving hand and make a fist.

32

Instruments/Controls INSTRUMENTS/CONTROLS

OPERATOR’S COMPARTMENT WARNING: When the terms right and left are used in this manual, the reference point is the operator`s post (seat) in driving position, looking toward the front part of the machine.

Some of the following descriptions and instructions refer to optional items. Consult your CASE dealer with respect to the optional equipment available for your machine.

To facilitate reading and learning about the instruments and controls of this machine, it has been separated in 6 groups, as shown in the figure.

GROUP 1 Implement control levers (left side).

Implement control levers (right side).

GROUP 2 Steering wheel, console, pedals and hourmeter.

GROUP 3 Dashboard, transmission control lever, throttle control lever, fuse box and master switch.

GROUP 4 Operator’s seat and parking brake.

GROUP 5 Cab

33

INSTRUMENTS/CONTROLS

FRONT CONSOLE GROUP 1

4. BLADE PITCH LEVER

Implement control levers (left side)

This lever allows the change of the blade pitch angle.

Push the control lever forward (increase) or pull it rearward (decrease) until the desired pitch angle is achieved.

1

2

Release the lever to return it the neutral position.

4

5. CIRCLE TURN LEVER 5

This lever is used to return the circle in clockwise or counterclockwise rotations.

3

Push the lever forward to rotate counterclockwise or pull it rearward to rotate the circle clockwise.

1. BLADE LIFT LEVER (LEFT END)

After moving the circle to the desired position, release the lever to return it the desired position.

This lever is used to lower or raise the left end of the blade.

Implement control levers (right side)

Move the lever forward to lower or rearward to raise the blade. After reaching the desired height, release the lever to return it the neutral position.

7

8

2. FRONT SCARIFIER/BLADE OR RIPPER LEVER

9

6

This lever is used to lower or raise the front scarifier/blade or ripper.

Move the lever forward to lower or rearward to raise. After reaching the desired height, release the lever to return it the neutral position.

6. CIRCLE SIDE SHIFT LEVER

3. BLADE SIDE SHIFT LEVER

This lever is used to move the circle to the right or to the left. Move the lever forward to shift the circle to the left or rearward to shift the circle to the right. After moving the circle to the desired position, release the lever to return it to the neutral position.

This lever shifts the blade to the right or left. Push the lever forward to shift the blade to the left or pull it rearward to move the blade to the right.

After shifting the blade to the desired position, release the lever to return it the neutral position.

7. ARTICULATION LEVER Move the lever forward for left articulation or rearward for right articulation until the desired articulation angle is achieved. Release the lever to return it to the neutral position.

34

INSTRUMENTS/CONTROLS

8. FRONT WHEEL LEAN LEVER

GROUP 2

The front wheel lean lever leans the front wheels to the left or to the right to maintain stability when grading or ditching and to reduce turning radius.

Steering wheel, console and pedals 1

4

Move the lever forward to lean the wheels to the left or rearward to lean the wheels to the right.

After reaching the desired position, release the lever to return it to the neutral position.

7

5 3

9. BLADE LIFT LEVER This lever is used to lower or raise the right end of the blade. Move the lever forward to lower or rearward to raise the blade. After reaching the desired height, release the lever to return it to the neutral position.

2

6

1. FLOODLIGHTS, HEADLIGHTS LOW AND HIGH BEAM, DIRECTIONAL LIGHTS AND HORN LEVER 2. STEERING WHEEL 3. ELECTRONIC MONITOR, SPEEDOMETER, HOURMETER AND ENGINE RPM DIGITAL DISPLAYS 4. DIFFERENTIAL LOCK (OPTIONAL) 5. GEAR/ERROR DISPLAY 6. STEERING WHEEL TILT LEVER 7. HOURMETER

10. WARNING FLASHER 10

To activate the warning flasher press the button located on the right side of the front plastic console. To turn it off, press it once again.

8

9

10

11

8. INCHING PEDAL 9. CONSOLE TILT PEDAL 10. BRAKE PEDAL 11.ACCELERATOR/DECELERATOR PEDAL

35

INSTRUMENTS/CONTROLS

To sound the horn: push in on the end of the directional signal lever.

1. FLOODLIGHTS, HEADLIGHTS LOW AND HIGH BEAM, TURNING SIGNALS AND HORN LEVER

To activate the right directional signal, push the directional signal lever away from the operator seat.

To activate the left directional signal, pull the directional signal lever towards the operator seat.

2. STEERING WHEEL The steering wheel is attached to an orbitrol steering control unit. The orbitrol is a combination valve and oil pump which is responsible for the supply of oil to the steering cylinder.

To turn on the Parking Lights: rotate the light switch on the end of the directional signal lever one position.

The steering wheel may be tilted to achieve a better operator’s working position using steering wheel tilt lever.

To turn on the Driving Lights: rotate the light switch on the end of the directional signal lever two positions.

To Operate the High and Low Beams: Move the lever up (vertically) one position (with the light switch rotated to the “ON” position) and the hibeam lights come on.

Move the lever up (vertically) two positions (with the light switch rotated to the “ON” position) and the low-beam lights come on.

Move the lever up (vertically) to the top momentary position and release the lever (with the light switch rotated to the “ON” position) and the hi-beam lights will flash and return to the lowbeam position.

36

INSTRUMENTS/CONTROLS

3. ELECTRONIC MONITOR, SPEEDOMETER, HOURMETER AND ENGINE RPM DISPLAY DIGITALS

The control panel indicates any problem in machine function.

2. After the test phase the following indicators will be turned off until the engine is kept turned off:

For easy identification the signals are transmitted by activating a light emitting diode - LED.

• Low battery charge, E; • Low transmission oil pressure, F; • Low engine oil pressure, G; • Low brake oil pressure, H; • Parking brake, when the lever is pulled up, D.

This electronic monitor permits the operator to monitor all the machine functions from the work station.

FUNCTIONAL DESCRIPTION

All the LED’s indicators listed above will turn off except parking brake D (when activeted), and brake pressure H.

Electronic monitor check: 1. With engine shut-off and ignition key switch in the RUN position all the circuits are turned on.

3. If any faults occur (for the functions described on this monitor), the corresponding LED light and the red warning light will flash followed by an audible warning (see item 4).

The LED indicator lights flash in all functions for few seconds (test phase).

IMPORTANT: When starting the engine and the key goes to START position the electronic monitor will turn OFF. Only the parking brake light will stay ON if activated. When the ignition key goes to run position the electronic monitor will do the check again.

37

INSTRUMENTS/CONTROLS

4. The following LED’s indicators do not activate the audible warning:

6. Q - Speedometer registers the travel speed.

R - Indicates the engine RPM during operation.

• Parking brake, D; • Steering secondary (optional), P; • Differential lock , T; • General warning light, L; • High beam, N; • Turn signals, O and M.

S - Not available.

5. Differential lock functions only with the parking brake disengaged and only in 1st to 7th gears.

INSTRUMENT PANEL INDICATORS A. ENGINE WATER TEMPERATURE

E. LOW BATTERY CHARGE

When the light is ON, it means that the engine coolant has overheated which could be caused by:

When this light is ON, with the engine running, indicates defects in the charging system, caused by:

•

Lack of coolant in the system

•

Defective alternator

•

Radiator cooling fins clogged

•

Charging resistor damaged

•

Radiator circuit clogged

F. LOW TRANSMISSION OIL PRESSURE

•

Fan hydraulic drive system malfunction

•

Defective thermostat.

When the light is ON, this indicates insufficient oil pressure that may be caused by:

B. HYDRAULIC OIL TEMPERATURE

•

Use of oil with improper viscosity

When the light is ON, it means that the oil is overheated which could be caused by:

•

Low transmission oil level

•

Defective switch and/or defective panel.

•

Use of oil with improper viscosity

G. LOW ENGINE OIL PRESSURE

•

Low oil level.

When the light is ON, this indicates insufficient oil pressure that may be caused by:

C. TRANSMISSION OIL TEMPERATURE When the light is ON, it means that the oil is overheated and its probable causes are:

•

Use of oil with improper viscosity

•

Low engine oil level

•

Suction line filter clogged

•

Engine oil leak

•

Low oil level

•

Defective pressure switch

•

High oil level

•

Transmission hydraulic oil circuit troubles.

D. PARKING BRAKE When the light is ON, it means that the brake is actuated.

38

INSTRUMENTS/CONTROLS

H. LOW BRAKE OIL PRESSURE

IMPORTANT: Do not turn off the differential lock system when the grader is operating.

When the light is ON, this indicates insufficient oil pressure that may be caused by: • • •

Pump abnormalities Air in the brake system Oil leak on brake lines

•

Defective pressure switch.

5. GEAR AND ERROR CODE DISPLAY This display shows the actual neutral, forward or reverse transmission gear selected.

When an error occurs the display will flash an error code indicating that a problem has been detected in the system.

I. AIR FILTER RESTRICTION When the indicator remains on constantly, the air filter element is clogged and it will be necessary to clean or replace it.

•

When the ignition key is first turned on, the display will show three sets of double letters (TD DC ER) at the top and three 8’s. The first 8 will have a diagonal line through it. This is a system light check.

Defective switch and/or defective panel.

J. HYDRAULIC OIL FILTER RESTRICTION

If the key is left in this position without starting the engine, the display will next flash ER100 few times. This designates the revision version of the transmission’s computer software.

When the indicator remains on constantly, the oil filter element is clogged and it will be necessary to replace it.

K. TRANSMISSION RESTRICTION

OIL

FILTER

There is also an error code ER100 but this error code only appears during recalibration.

When the indicator remains on constantly, the oil filter element is clogged and it will be necessary to replace it.

The revision code may change. The next code will be ER101, ER102, etc.

L. WARNING FLASHER

6. STEERING WHEEL TILT LEVER

This indicator flashes when the button located on the right console is pressed in.

M. RIGHT TURN SIGNAL

Loosen the lever and adjust the steering wheel position to obtain more comfortable operating position. Tighten lever again to assure the steering wheel does not move.

N. HIGH BEAM

7. HOURMETER

O. LEFT TURN SIGNAL P. SECONDARY (OPTIONAL)

STEERING

The hourmeter indicates operating hours with the engine off and key switch in the RUN position.

LIGHT

Not available.

4. DIFFERENTIAL LOCK SWITCH OPTIONAL This switch is used to lock or unlock the differential when it is necessary. Use the differential lock switch only in straight line operation. To steer or articulate the machine the operator must turn off the differential lock switch.

39

INSTRUMENTS/CONTROLS

8. “INCHING” PEDAL

10. BRAKE PEDAL

The “inching control pedal” is helpful under the following conditions:

This pedal actuates the service brakes. To stop the grader press down on brake pedal.

•

When starting or stopping

•

For grader finishing work requiring “creeper gear” or very slow speeds

•

For very slow ground speed work to increase engine speed for hydraulic performance (this should rarely be necessary because of the wide range performance of the hydraulic system).

NOTE: Do not descend steep slope using only the service brake. Reduce the speed and apply the brakes. Select an appropriate speed, allowing total machine control. This will avoid brake heating, and will increase the life of the components.

11. ACCELERATOR/DECELERATOR PEDAL The accelerator/decelerator pedal is connected to the engine throttle controls. To accelerate the engine, press down on the front part of the pedal and to decelerate press down on the rear of the pedal. When the pedal is released, the engine speed will return to the hand throttle setting.

CAUTION: Do not abruptly depress and release inching pedal to start a heavy load or free a stuck machine.

9. CONSOLE TILT PEDAL

The console may be adjusted to improve operator comfort. Push the pedal to free the console.

Position the console in the desired position and then release the pedal to lock the console again.

40

INSTRUMENTS/CONTROLS

2. THROTTLE CONTROL LEVER

GROUP 3 Dashboard, transmission control lever, throttle control lever, fuse box and master switch.

2

3

5

6 1

7

4

The engine will remain at low idle with the throttle control lever all the way forward and engine speed will increase as the lever is pulled back.

8

3. TRANSMISSION CONTROL LEVER 1.

2.

3.

4.

5.

6.

7.

8.

FUSE BOX THROTTLE CONTROL LEVER TRANSMISSION CONTROL LEVER TOGGLE/ROCKER SWITCH PANEL GAUGE PANEL IGNITION SWITCH MASTER SWITCH POWER TAKE OFF

1. FUSE BOX

SHIFT PATTERN: R • REVERSE F • FORWARD N • NEUTRAL DS • DOWN SHIFT UP • UP SHIFT

In the fuse box are installed all the grader fuses.

For the identification of the fuses, refer to the electrical diagram.

41

INSTRUMENTS/CONTROLS

The transmission control lever is used to select the desired forward or rearward speeds.

NEUTRAL LOCK

These machines are equipped with a 8 speed forward and 4 speed reverse transmission.

The gear speed change is done using a shift lever.

To obtain forward speeds place this lever to the front. To obtain reverse speeds place this lever to the rear.

By using this lever the proper speed (1st, 2nd, etc.) can be selected. Observe the gear display readout for confirmation of the gear selected. If the display shows an “error code” it means that some fault has occurred in the transmission system. Therefore it is necessary to contact a Case dealer.

To move the shift lever out of neutral position, release the “Neutral Lock” by raising the release ring located under the shift handle knob.

When the machine is stopped, any gear lower than F3 or R2 may be selected to start again.

A single speed change is done with a single push and release of shift lever.

If the shift control lever is pushed and held to the right or left the gear speeds will change automatically.

42

INSTRUMENTS/CONTROLS

4. TOGGLE SWITCH PANEL

1. SADDLE LOCK PIN SWITCH

4. MOLDBOARD FLOAT SWITCH - RIGHT SIDE

The saddle lock pin switch activates a solenoid valve which sends hydraulic fluid for cylinder rod movements to release and engage the saddle pins.

This switch activates or deactivates the moldboard float function for the Right side of the blade. To activate the float function, push the toggle switch away from the operator’s seat. To deactivate the float function, push the toggle switch towards the operator’s seat.

With the toggle switch pushed away from the operator’s seat, the pins remain retracted from the saddle and with the toggle switch pushed towards the operator’s seat, the pins will extend and engage the locator hole in the saddle.

5. FRONT BLADE FLOAT SWITCH This switch activates or deactivates the front blade float function. To activate the float function, push the toggle switch away from the operator’s seat.

To deactivate the float function, push the toggle switch towards the operator’s seat.

Use the blade lift cylinders to assist movement of the saddle lock pins.

2. RIPPER / SCARIFIER SWITCH The ripper / scarifier switch activates a solenoid valve which sends hydraulic fluid to the rear ripper or the front scarifier cylinders.

6. MOLDBOARD ANTISHOCK FUNCTION SWITCH This switch activates and deactivates the moldboard cylinders antishock function. To activate the antishock function, push the toggle switch away from the operator’s seat. To deactivate the antishock function, push the toggle switch towards the operator’s seat.

To move the rear ripper, push the toggle switch away from the operator’s seat. To move the front scarifier, push the toggle switch towards the operator’s seat.

3. MOLDBOARD FLOAT SWITCH - LEFT SIDE This switch activates or deactivates the moldboard float function for the left side of the blade. To activate the float function, push the toggle switch away from the operator’s seat. To deactivate the float function, push the toggle switch towards the operator’s seat.

7. COLD START SWITCH This rocker switch is used to activate the cold weather starting aid.

43

INSTRUMENTS/CONTROLS

8. LIMP-HOME SWITCH

15. WORK LIGHTS SWITCH

This switch is used to move the machine in the event of a transmission electronic control unit problem. The rocker switch has three positions: Forward, Neutral and Reverse.

This switch activates the work lights above the moldboard and below the cab.

The work lights switch is a three-position switch.

The first position turns the lights OFF.

The switch must be in the Neutral position with the park brake applied to start the machine, when the limp-home mode is activated.

To turn on the lights above the moldboard, push the symbol side of the rocker switch to the second position.

The transmission shifter and the inching pedal are bypassed when in the limp-home mode.

See the Maintenance Section for more details on how to activate the limp-home mode.

To turn on the lights under the cab, push the symbol side of the rocker switch to the third position. The lights above the moldboard will stay on with the switch in the third position.

9. FRONT WINDSHIELD WIPER SWITCH

16. REAR FLOODLIGHT SWITCH

This switch is used to activate the front windshield wiper.

This switch activates the rear floodlights.

To turn on the rear floodlights, push the symbol side of the rocker switch.

The rocker switch has three positions: OFF, Low and High.

17. FRONT FLOODLIGHT SWITCH

10. FRONT WINDSHIELD WASHER SWITCH

This switch activates the front floodlights.

This switch is used to activate the front windshield washer.

To turn on the front floodlights, push the symbol side of the rocker switch.

11. REAR WINDOW WIPER SWITCH This switch is used to activate the rear window wiper.

The rocker switch has three positions: OFF, Low and High.

12. REAR WINDOW WASHER SWITCH This switch is used to activate the rear window washer.

13. AIR CONDITIONER SWITCH This switch activates the cab air conditioner.

To turn the air conditioner on, push on the symbol side of the rocker switch.

14. CAB AIR RECIRCULATION SWITCH This switch closes the cab recirculation door to prevent outside air from coming into the cab.

To close the reciruclation door to recirculate the cab air, push on the symbol side of the rocker switch.

44

INSTRUMENTS/CONTROLS

5. GAUGE PANEL

A. ENGINE OIL PRESSURE GAUGE The engine oil gauge indicates the pressure at which the engine oil is circulating through the engine.

1. CAB HEAT CONTROL

The red area means insufficient pressure.

To increase the temperature in the cab, turn the cab temperature control knob clockwise. To decrease the temperature in the cab, turn the cab temperature control knob counterclockwise.

The green area means normal operating pressure, and the yellow area, excessive engine oil pressure.

B. ENGINE COOLANT TEMPERATURE GAUGE

2. BLOWER FAN SPEED SWITCH To increase the cab blower fan speed, turn the cab blower fan control counterclockwise until the desired fan speed is obtained.

•

The marker in the GREEN area indicates the normal operating temperature range 80 to 95°C (176 - 203°F)

The blower fan speed switch has four positions: 1. OFF 2. Low 3. Medium 4. High

•

The WHITE area indicates low temperature.

•

The RED area indicates high temperature.

If during the work cycle, the coolant temperature stays either in the WHITE or RED area, stop the engine to check the cause of the problem.

C. FUEL LEVEL INDICATOR GAUGE The green area indicates the normal operating level.

Refill the tank using filtered fuel as recommended.

Refill the tank at the end of each work day, to avoid water condensation.

Never let the fuel tank run-dry, this will cause air to enter the fuel system.

Never refill the fuel tank with the engine running.

45

INSTRUMENTS/CONTROLS

D. TRANSMISSION OIL PRESSURE GAUGE

8. IGNITION SWITCH

The marker of the transmission oil pressure gauge must stay within the green area which indicates normal operating pressure. If the marker enters the red area, it is a signal that the oil pressure is too low.

This switch is a rotary type and is activated with a key.

It has four positions: OFF

Do not operate the machine with low transmission oil pressure. Stop and check the cause of the problem.

ACC

E. TRANSMISSION OIL TEMPERATURE GAUGE

RUN

START

The marker must register in the green area. Do not operate the machine when the gauge is in the red area.

Stop the machine and determine the cause of high temperature.

ACC - Acessories

6. MASTER SWITCH

In this position some circuits such as the wipers and lights, are energized for use.

OFF

The machine electrical functions can only be actuated if the rotary master switch is activated.

In this position all key activated electrical circuits are off. The key can be removed.

The master switch is activated by the starting switch in the “ON” position.

RUN In this position all key activated electrical circuits are “ON”.

7. AUXILIARY ELECTRICAL CURRENT RECEPTACLE

START In this position, the starting circuits are energized.

The switch is spring controlled for start and will return to the “RUN” position when the key is released.

CAUTION: Never leave the key in the “ON” position when the engine is not running.

The machine is equipped with a 24V auxiliary electrical power supply.

46

INSTRUMENTS/CONTROLS

AIR CONDITIONER B3 - AIR CIRCULATION SWITCH

1- A/C OPERATION The air conditioning control panel in the cab is on the right-hand side of the operator’s console.

ON/OFF push-button for start/stop system operation for air recirculation or outside ventilation.

B4 - AIR CONDITIONING SWITCH ON/OFF push-button conditioning compressor.

for

air

To operate the air conditioning, air recirculation or heater systems, follow the sequence below: 1- Start the engine. This will energize the machine’s basic functions.

2- Turn the cab fan switch (1) to desired speed position (3).

A - IGNITION SWITCH

B1 - CAB FAN SWITCH

3- Select either heat B2, fresh air B3, or cool air B4.

It is a rotatory button switch, with four positions:

2- A/C MAINTENANCE 1 - LOW SPEED

The air conditioning/heating system maintenance is limited to three items.

2 - MEDIUM SPEED

A- Air filter in evaporator case.

3 - HIGH SPEED

B- Air compressor

B2 - CAB HEATER SWITCH

C- Condenser

0 - OFF

The machine is equipped with a system that utilizes heat taken from the engine coolant.

1 This switch can be operated only if the engine coolant tap is open. The coolant flow through the cab heater motor is controled by a solenoid valve operated by the cab heater switch.

ON/OFF push-button for start/stop heating system and front/rear windshield heater operation.

1- THE AIR FILTER IN EVAPORATOR BOX MUST BE CLEANED WHEN NEEDED OR EACH 250 HOURS.

47

INSTRUMENTS/CONTROLS

2.2- RECOMMENDATIONS 1. Turn on A/C only when ventilation is turned on.

2. Make sure the evaporator inlet is not blocked.

1

3. Should the system performance fall below specification, inspect: • System refrigerant pressure; • Operation of fan unit.

• Evaporator for obstructions.

1- AIR CONDITIONER COMPRESSOR

4. Operate A/C at least 10 minutes per week.

2.1- A/C REFRIGERANT CHARGE

5. When engine is at high speed operate fan at maximum speed.

NOTE: A qualified technician is required to perform A/C system service.

6. Periodically check external cleaning of condenser (never operate condenser if it is 20% blocked or more).

For leak test and/or gas charging use air compressor taps A and B only.

7. Close all doors and windows when operating the A/C.

1. Add 50 grams R134a and allow system to build up 10 bar pressure (145Psig) by applying gaseous nitrogen.

8. For fast cooling, use cabin internal air recirculation control.

2. Proceed with a gas leak test. Should a leak be CONFIRMED, evacuate the system and repair the leak. Repeat the test.

2.3- SYSTEM MAINTENANCE

3. Connect he manifold hoses.

1. Clean condenser monthly or whenever the condenser air inlet shows 20% obstruction.

4. Connect vacuum pump to manifold center fitting.

2. Check screw torque and belt tensioning yearly.

5. Open the manifold valves and turn pump on.

3. Clean air conditioning filter monthly or whenever air flow reduction is noticed.

6. Allow 20 minutes for pressure gages to indicate 26 inHg vacuum.

7. Close valves and disconnect vacuum. Close valves and disconnect vacuum pump.

8. Connect charging cylinder hose, open the manifold valve high side and apply 1200 grams of gas R134a.

9. Close the manifold valve, remove gas hose and repeat the test.

10.Disconnect manifold and install service valve covers.

48

INSTRUMENTS/CONTROLS

GROUP 4

OPERATORS SEAT Standard Seat 2 2

1 4 3 5

6

1. LUMBAR ADJUSTMENT KNOB:

5. WEIGHT ADJUSTMENT KNOB:

Turn the knob clockwise to increase the lumbar support, turn the knob counterclockwise to decrease the lumbar support.

To adjust the seat for your weight you must pull the release lever out of the knob, Use the release lever to turn the knob clockwise to increase the weight resistance. Turn the knob counterclockwise to decrease the weight resistance.

2. ARMREST HEIGHT CONTROL ADJUSTMENT: Turn the knob to raise or lower the armrest to the desired position.

6. HEIGHT ADJUSTMENT, STANDARD SEAT:

NOTE: Each armrest will pivot to the up position.

Lift the seat all the way up, drop the seat to the lowest position. Lift the seat to the desired position. The seat will lock into accepted positions.

3. RECLINER ADJUSTMENT HANDLE: Lift up on the handle, move the backrest to the desired position, release the handle to lock the backrest in position.

4. SLIDE ADJUSTMENT LEVER: Pull this lever up and adjust the seat forward or rearward as required. Release the lever to lock the seat in position.

49

INSTRUMENTS/CONTROLS

Optional Air Ride Seat

2 2

1

6 7

3 4 5

1. LUMBAR ADJUSTMENT KNOB:

5. HEIGHT ADJUSTMENT HANDLE:

Turn the knob clockwise to increase the lumbar support, turn the knob counterclockwise to decrease the lumbar support.

A. (Automatic Adjustment): With the operator sitting in the seat. Lift the handle UP and release. The seat will automatically adjust UP and then bleed off air pressure to the optimum air pressure for the weight of the operator.

2. ARMREST HEIGHT CONTROL ADJUSTMENT:

B. (Manual Adjustment): The seat can be raised or lowered by increasing or decreasing the air pressure in the seat. Lift the handle UP to increase the air pressure. Push the handle DOWN to decrease the air pressure and lower the seat.

Turn the knob to raise or lower the armrest to the desired position.

NOTE: Each armrest will pivot to the up position.

3. RECLINER ADJUSTMENT HANDLE:

6. SEAT DEPTH HANDLE:

Lift up on the handle, move the backrest to the desired position, release the handle to lock the backrest in position.

Lift handle up and move the cushion to the desired position. Release the handle to lock the cushion in position.

4. SLIDE ADJUSTMENT LEVER:

7. SEAT CUSHION ANGLE ADJUSTMENT HANDLE:

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

Lift up on the handle. Move the seat to the desired angle. Release the handle to lock the cushion angle.

NOTE: When adjusting the seat height for the first time or for a different operator. Sit in the operators seat, lift up momentarily on the height adjustment handle. The seat will automatically adjust to the operators weight. See height adjustment handle for final adjustments.

50

INSTRUMENTS/CONTROLS

8. DAMPENING ADJUSTMENT LEVER: 5

The dampening adjustment lever has four positions from soft to hard. The first adjustment is with the small end of the adjustment lever pointing toward the front of the seat, as shown.

The other three adjustments can be obtained by rotating the small end of the adjustment lever out away from the seat. Each of the adjustments has a slight detent. The suspension can be adjusted to various operating conditions.

8

SEAT BELT

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

2. To release the seat belt, push the red button on the buckle.

NOTE: Make sure the belt end and buckle are securely fastened. Do not pull out the right-hand buckle.

!

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

51

INSTRUMENTS/CONTROLS

PARKING BRAKE

GROUP 5 CAB The cab provides operator comfort in any ambient condition.

1

The parking brake is hand operated. When the lever is pulled up, the ratchet teeth allow a partial or full brake application (the lever system permits other actuation positions).

1. DOOR

To release the brake, pull the lever slowly upward, press the lock button (A) and push the lever down.

Turning the handle (1), the door opens. To keep the door opened while operating the machine or servicing cab, open the door until it reaches the automatic lock.

2

Pull lever (2) to release the automatic lock. This lever is located inside the cab, to the operator’s left.

52

INSTRUMENTS/CONTROLS

2. DIFFUSERS / DEFROSTER / AIR CONDITIONER 1

1

3. WINDSHIELD WIPER

1

2

1

1. FRONT WINDSHIELD WIPER 2. REAR WINDSHIELD WIPER

The air deflectors (1) and the fan that are located inside the cab have the function to circulate the air in the cab and to serve also as defrosters for the front and rear windshields.

To change the front and rear windshield wiper blades (A), lift the wiper blade support arm, unlock the wiper blade from the lock pin and remove it.

To assemble repeat the process in reverse order.

4. DOME LIGHT

2

1

4

3

The dome light is found in the cab roof. The fixed light (1) is lit using the switch (2). The movable light (3) is lit using the switch (4).

53

INSTRUMENTS/CONTROLS

!

WARNING: Always check work area to avoid accidents. The following are examples of dangerous work areas: slopes, overhangs, timber, demolitions, fire, high walls, drop offs, backfills, rough terrain, ditches, ridges, excavation, crowded parking lots, heavy traffic and closed areas.

Use extreme care when in areas such as these.

Be on the look out for edges, slides or falling objects.

Beware of brush and undergrowth or other obstacles that conceal dangerous conditions.

For night operation keep all the machine mounted lights on. Replace burned out lights immediately.

Always shut-off engine when leaving operator’s seat.

Before moving machine or attachments, be sure people in the area are clear of the unit. Walk completely around the machine before mounting and sound horn.

Do not start suddenly at full throttle against a tow chain or cable. Take up slack carefully.

Be sure exhaust system is free from leaks under the hood. (When operating inside a closed cab, always keep a vent to outside air open at all times) Avoid applying brakes continuously on long grades. Select the proper gear entering the grade.

Keep engine exhaust manifolds clear of combustible trash. Shut engine off before cleaning it.

Keep people clear of the attachments and tools while they are in a raised position to prevent injury.

54

Operating Instructions OPERATING INSTRUCTIONS

OPERATING INSTRUCTIONS BEFORE STARTING THE ENGINE

!

CAUTION: Quickly respond to initial problems requiring maintenance and downtime will be reduced. Check the machine each morning before beginning work make a walk around inspection.

1. Check if the tires are worn, cut or not properly inflated.

2. Check if the blade, cutting edges and bits are worn or damaged.

3. Check circle adjustment.

4. Check for damaged or failed instruments and other operator’s compartment components.

5. Check leakage on tandem case.

6. Check any leakage or damage to cooling system hoses.

7. Check engine oil and hydraulic lines and hoses for leaks.

It’s also recommended to check Electrical system Check insulation parts, worn cables and terminals loose Bolts

Check for loose or missing parts

Hydraulic system Check leakages, twisted hoses, hoses rubbing against other components Lubrication

55

Check all grease points related on periodic maintenance table

OPERATING INSTRUCTIONS

1. Fill the fuel tank only with the specified fuel, with the engine off. Take care to avoid entrance of dirt or foreign matter while filling tank.

6. Start engine. Check all instruments and gauges for normal indication. Operate controls and check for normal operation.

WARNING: Extinguish all ! smoking materials or open flames before checking and/or filling the fuel tank.

2. Check the fluid levels of the following:

!

WARNING: Do not use hands to search for pressure leaks.

Fluid escaping under high pressure can penetrate skin causing serious injury.

!

WARNING: Remove front wheel lean shipping bolt before operating machine.

a) Engine crankcase b) Engine cooling system c) Transmission system d) Hydraulic system e) Axle housing and rear tandem housings 3. Lubricate all points where lube fittings are provided. Refer to lubrication and service guide for instructions and location.

4. Check tire inflation pressure.

WARNING: Do not inflate tires with flammable gases or air from systems utilizing alcohol injectors. Explosion and personal injury may be resulted.

5. The cooling system of the unit is filled at the factory with a 50/50 mixture of water and Ethylene Glycol Case 331-511 antifreeze for protection to -37ºC (-34ºF). It is not necessary to drain this solution before placing the machine in service.

Before unloading the machine from the truck, remove the wheel lean lock bolt and store it in the block provided on the front axle. Whenever the machine is to be transported by truck, install the lock bolt with spacer after loading. Operating the machine with the lock bolt installed will result in reduced maneuverability.

!

NOTE: The lock bolt may be used to maintain the front wheels in a vertical position in the event of a damaged wheel lean hydraulic hose.

IMPORTANT: Do not run the engine in closed areas without proper ventilation to remove poison exhaust gases.

Warn all people who may be working around your machine before starting the engine.

Sound horn before starting or operating the machine.

Never leave the machine unattended with the engine running.

56

OPERATING INSTRUCTIONS

2

1

1. WHEEL LEAN LOCK BOLT LOCATION

2. ARTICULATION LOCK PIN (STORAGE POSITION) SHALL BE USED ONLY FOR MACHINE TRANSPORT

FIRST SERVICE INTERVALS The following items are to be done during the Run-In Period and are in addition to the items in the Lubrications/Maintenance Charts in this manual.

AFTER FIRST 100 HOURS OF OPERATION Have your dealer do the After Delivery Check .........................................................See After Delivery Check in this manual Change the rear axle differential and planetary oil when the axles are new or repaired ................................................. See Rear Axle in this manual Change the transmission oil and filter when the transmission is new or repaired .................................See Transmission Specifications in this manual Check all hose clamps, tighten as required.

SEAT BELT Always securely fasten your seat belt before operating the machine. From time to time, carefully inspect the seat belts for worn areas and replace belts when needed.

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

57

OPERATING INSTRUCTIONS

RUN-IN The tightening torque of the 16 mounting capscrews is 508 Nm (51,6 kgf.m; 375 lb.ft).

1. Operate the machine with a light load for the first 50 hours. Efficient engine operation is obtained with the engine coolant temperature held in the GREEN area of the gauge.

Operating engine with coolant temperature below this range will result in incomplete combustion of fuel, higher fuel consumption with less power and will cause harmful gummy deposits within the engine.

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If cab enclosures are installed, be sure all cab accessories, such as windshields wipers, latches, glass, hinges, seat belts, etc. are in good condition. Always keep windows clean.

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WARNING: Never lubricate, service or adjust the machine with the engine running, except as called for in the Operation and Maintenance Instruction Manual to prevent accidents.

WARNING: If replacement of glass is necessary, be sure to use safety glass or equivalent.

d) Check tandem wheel nuts. e) Check wheel lock nuts.

2. Inspect entire unit after the first 10 hours of operation.

Tighten all loose bolts and check all brake and control adjustments. Check the hydraulic and electrical systems.

After the first 100 hours of operation on a new unit or after major repairs perform the following services: a) Change transmission oil filter element.

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WARNING: Fluid under pressure. Turn cap or cover slowly to relieve pressure before removing it.

IMPORTATNT: DISCONNECT THE MASTER SWITCH AND CONNECTORS J1, J2, J3 FROM E.C.U. AND T7 FROM T.V.P. BEFORE WELDING ON MACHINE.

b) Change hydraulic oil filter element. c) Check the ROPS mounting capscrews after the first 50 hours of operation and periodically thereafter.

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WARNING: The protection offered by the ROPS structure may be impaired if it has been subjected to any modification or damage.

58

OPERATING INSTRUCTIONS

BOOSTER BATTERY CONNECTIONS TO MACHINE BATTERIES (JUMP START)

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WARNING: Batteries contain acid and explosive gas. Explosion can result from sparks, flames or wrong cable connections. To connect the jumper cables correctly to the battery of this machine, see the correct method shown on this page. Failure to follow these instructions can cause serious injury or death.

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WARNING: Battery explosion and/or damage to electrical components can result from improper connection of booster batteries or charger.

Connect positive to positive and negative to negative. Externally, battery acid can cause burns and blindness, and taken internally it is poison.

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

NOTE: Make sure the batteries are not frozen. Do not use batteries that have been frozen. Replace the batteries if the batteries have been frozen.

1. Open the engine hood. Sit in the operators seat and have the other person make the connections.

2. Make sure the jumper batteries are 24 volts.

3. If using another machine for power, make sure the two machines DO NOT touch.

4. Connect the positive (+) jumper cable to the positive (+) battery terminals first.

5. Connect the negative (-) jumper cable to the negative (-) terminal on the jumper batteries on the other machine. Connect the other end of the negative (-) jumper cable to a good frame ground away from the batteries.

6. Start the engine according to the instructions in this manual. See Starting the Engine in this manual.

7. Have the other person disconnect the jumper cables in the reverse order that they were connected in. Close the engine hood.

59

OPERATING INSTRUCTIONS

OPERATING INSTRUCTIONS Turn master switch key, located in operator’s compartment to the “ON” position. Pull throttle lever back to full speed position if engine is cold (1/4 speed position, if engine is warm).

STARTING THE ENGINE

Turn ignition key to the start position. When the engine starts, release the key. Immediately pull throttle lever into low idle. Then set at one half speed. Maintain one half maximum speed until coolant temperature gauge needle moves from its minimum position.

2. Do not accelerate the engine just after starting.

1. Start the engine and keep it running at one half speed for 3 to 4 minutes, before machine operation.

STOPPING THE ENGINE Before shutting down the engine, keep it running a few minutes at low idle speed to permit turbo charger deceleration and stabilization at a low speed. Avoid shutting off the engine at a high speed, because the turbocharger shaft bearings will be damaged due to poor lubrication.

NOTE: Do not use the starter for more than 30 seconds without a pause of two minutes to allow it to cool down. Observe all instruments for proper reading.

CHANGING ENGINE SPEEDS

It is extremely important to allow the engine to run for three to five minutes at 1/4 to 1/2 throttle to permit the lubrication oil to warm and circulate freely through the bearings. This procedure is mandatory for cold weather operation.

Prolonged engine idling causes engine coolant operating temperature to fall below operating range.

Since engines are readily started, there should be no reason for prolonged engine idling.

However, if it is necessary to keep the engine running, run at a speed fast enough to maintain normal oil pressure and engine coolant temperature. Place the transmission control lever in the neutral position and apply the parking brake.

Lower the moldboard to the ground. Do not leave the machine unattended.

Check engine lubricating oil pressure. With engine running at high speed and the coolant at normal operating temperature, oil pressure must be within normal operating range. When the oil is cold no pressure may be indicated on the gauge for several seconds after the engine starts. If the pressure does not rise to normal or above, after a few seconds, the engine must be stopped immediately and the cause determined and corrected. Check the transmission fluid pressure.

Within a few seconds after the engine starts the transmission oil pressure gauge must register in or near the green range.

This machine and its attachments are to be operated only by a qualified operator stationed at the operator’s controls either seated or standing as conditions require.

60

OPERATING INSTRUCTIONS

The use of seat belts is always required, even on ROPS equipped machines.

To start machine motion, raise moldboard, release parking brake, shift into the desired range and direction and move the throttle lever to meet the operational requirements.

Before starting the machine, check, adjust and lock the operator’s seat assembly for maximum comfort and control of the machine.

Range changes will be governed by the speed attained or desired.

This machine is equipped with power steering which is effective only when the engine is running.

If engine fails, stop the machine immediately.

Select a transmission range that will maintain engine speed appropriate for the load required.

Low engine speed can be corrected by downshifting or lightening the load. Over revving the engine should be avoided. Slow the machine by applying the brakes.

For emergency stops, apply foot brakes as required or pull parking/ emergency brake lever.

Check the torque of the wheel bolts after every 20 hours of operation until the wheel bolts stay tight, if the machine is new or if a wheel has been removed and installed. Tighten according to procedure and specifications manual instructions.

Observe the following instructions: 1. Down shift only when the ground speed for the selected range has been achieved.

Always travel with the scarifier in the full raised position and lower to the ground when parked.

2. Down shift only one range at a time.

Use extra care when using down pressure on the blade when working on hills, banks and slopes.

NOTE: When the Grader wheels have been turned to the maximum (in either direction), do not continue to turn the steering wheel in the same direction. This causes unnecessary wear on pump and valve components.

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WARNING: Do not coast the machine at any time with the transmission in neutral. Do not attempt to decelerate on grades by shifting. Decelerate the engine and apply the foot brakes. Anticipate grades before starting down. Select the proper gear range to maintain the control. Engage transmission to start up only when the engine is at low idle. Down or up shift only one range at a time and only when the speed of the machine approximates the speed of the next range.

TOWING

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WARNING: Do not start suddenly at full throttle against a tow chain or cable. Take up slack carefully. Only designated towing or pulling attachments points should be used for towing or pulling operations.

61

OPERATING INSTRUCTIONS

The transmission range and engine speed should be set before beginning the grading operation.

Never overload the moldboard, so that the rear wheels begin to slip.

Cast the material between the rear wheels. The first cut should be light enough to maintain control of the grader and cut a straight ditch line. When the material accumulates under the machine, it should be cast aside before taking another cut in ditch line. Deeper ditch requires more side casting of material. If a “V” ditch is required, each side of the ditch must be cut alternately to permit the front and rear wheels to travel in the center of the ditch.

This not only alters the grade but causes unnecessary wear to rear tires.

Increasing the blade angle (putting one blade tip farther forward than the other tip) will reduce the load. The blade should be set to cast the dirt either inside or outside of the rear wheels, not under the wheels unless it is for compaction purposes.

When it is necessary to cast material over the edge of a fill, side shift the moldboard to its extreme, so that the grader wheels are not on edge of fill. The weight of the machine could cause the edge to give way endangering the operator.

Articulation also helps in this situation.

The moldboard pitch can be changed to suit various operations. When the top of the moldboard is tilted forward the cutting edge will not slice the material, but push it. This is advantageous when pushing dirt from one location to another. Tilting the top of the moldboard to the rear will angle the cutting edge so that it will slice and create a bite into the material. This can be advantageous in heavy material because the material will roll against the moldboard, breaking it up and making it easier to move.

When grading a road shoulder, it may be necessary to grade around objects, such as mailboxes abutments or utility poles. The moldboard can be side shifted around the object without changing the grade level.

BANK OR BACK SLOPING To position the moldboard (in this case to the right side) proceed as follows:

Using the moldboard to back drag material should be avoided if possible. This can cause heavy wear on the moldboard guides and possibly damage the side shift cylinder piston rod. If back dragging cannot be avoided, make certain material does not contact the positioning piston rod.

1. Turn the circle until blade is at a right angle (90º) to the grader.

Worn or poorly adjusted moldboard guides will cause an unstable moldboard for fine grading.

When making heavy cuts or moving heavy loads that tend to side shift the Grader, lean the front wheels toward the load to counteract side shift.

When starting a ditch, position moldboard so that one cutting edge (right or left) is directly behind and 3" (76 mm) below the front wheel, with the other end of the blade as high as possible.

BLADE POSITIONED AT RIGHT ANGLE (90º) TO GRADER

62

OPERATING INSTRUCTIONS

2. Side shift blade to the extreme right, then side shift the circle until cylinder rod shows about 5" (127 mm) extension. Lower moldboard to the ground.

4. Raise the blade slightly from the ground, then raise the right end of the blade while turning the circle so that right end of the blade moves toward the right front of the grader (this will keep the left end of the blade from hitting the ground).

At the same time, shift the circle to the right (this will pivot the complete circle/blade assembly upward).

NOTE: As the left end of the blade is raised from the ground, it is necessary to lower the left end of the blade and raise the right end of it at the same time.

BLADE POSITIONED AT RIGHT SIDE TO GRADER

3. Disengage the saddle lock pins. Using the blade lift levers, extend the right blade lift cylinder rod and retract the left blade lift cylinder rod (moldboard on the ground). After the saddle has been rotated to the desired position (fully for 90º position), align the saddle pin holes (by sight) and reengage the saddle lock pins.

BLADE AT 90º BANK SLOPE INTERMEDIATE POSITION

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5. Continue the operation (as in item 4) until the moldboard is positioned as in the illustration.

Then turn the blade (using the circle turn) to the desired position.

IMPORTANT: When cutting a bank an excellent blade control can be obtained using the wheel lean to push the blade toward or away from the bank.

1. ROTATING SADDLE (5 HOLES)

63

OPERATING INSTRUCTIONS

2

CIRCLE POSITIONING (5 HOLES SADDLE)

2. FRONT SCARIFIER

To scarify a surface it is advised to use all the teeth with less penetration than to use less teeth with deeper penetration. It is advantageous to break the surface material into smaller bits.

When operating a grader and a sharp non articulated turn is to be made, reduce speed and lean the front wheels in the direction of the turn.

After completing the turn, straighten the front wheels to the normal position and resume normal speed.

Use the lowest speed (1st or 2nd gear) with high engine speed to maintain better control of the grader and to provide good breaking of surface material.

When roading a grader from one location to another, carry the moldboard within the wheel width and raised as high as possible to prevent accidents.

The scarifier teeth must be in good condition for best results. Never back drag the scarifier teeth.

This can seriously damage the tool bar.

When driving or operating the grader in traffic always set the hand throttle at low idle. Select the gear range desired, then use the accelerator/ decelerator pedal to change the machine’s road speed.

SCARIFING

Be sure that the engine speed control system is functioning properly, so that the engine speed returns to idle when the operator takes his foot from the accelerator/ decelerator pedal.

When roading the grader, obey all traffic regulations and be aware of other traffic. Be prepared for any emergency.

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If the grader is used in congested areas or roads, put adequate warning signs to prevent accidents.

Always be aware of other traffic, especially before change of direction or working across traffic flow.

1. REAR SCARIFIER

64

OPERATING INSTRUCTIONS

STOPPING AND PARKING THE GRADER

COLD WEATHER PRECAUTIONS The machine’s cooling system is filled at the factory with a 50/50 mixture of water and Ethylene Glycol.

Position the grader in the desired parking area.

Position the moldboard with the ends of the blade within the wheel width and lower the moldboard to the ground.

The Ethylene Glycol solution protects the engine to -37ºC (-34º F). It is not necessary to drain this solution before placing the unit in service.

Place the transmission forward/reverse lever in neutral.

OPERATING IN HOT WEATHER

Before stopping engine, allow engine to run at 1/4 throttle for 3 to 4 minutes to gradually cool the engine. Then move the throttle lever to idle position and turn off key switch.

To prevent damage to the machine: 1. Keep the coolant at the correct level in the radiator.

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

Turn the master switch key to the “OFF” position and remove it. Lock the cab door.

3. Clean all dirt and debris from the cooling system and engine area.

4. Check the condition of the drive belts.

5. Use lubricants of the correct viscosity.

65

OPERATING INSTRUCTIONS

OPERATING TIPS Articulated motor graders can be operated with the frame ARTICULATED OR OFF SET (CRAB).

The OFFSET position permits the operator to maintain the machine on firm ground when working in ditches, and reduce the number of passes necessary to spread material. This permits a better weight concentration, behind the blade in severe operation conditions.

Although the grader permits the circle turn 360°, most of the grading operations are done with the blade between 15° and 45° in relation to the work direction.

Increasing the angle of the blade reduces the side movement of the material cut by the blade.

However this permits deeper cuts and more “severe” grading.

The change of the attack angle, blade pitch is also very important for productivity.

The blade with the involute “ROLL-AWAY” profile maintains the capacity to roll material, with the top of the blade inclined to the rear.

NON ARTICULATED frame is normally used for grading large areas and for road maintenance and conservation.

Changing blade angle while cutting, generates side forces on the machine. These forces should be compensated by leaning the front wheels and/ or articulating the frame in the direction of the blade cutting forces.

With the frame ARTICULATED, the turning radius is reduced, making machine control easier in restricted areas. In addition, a more precise control of material spreading is permitted.

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1. LEANED FRONT WHEELS 2. ARTICULATED CHASSIS

66

2

OPERATING INSTRUCTIONS

TYPICAL OPERATION Align the top of the moldboard with the center of the rear tire. Position the end of the blade outside of the front tire and pitch the blade slightly toward the front. Turn the wheels toward the “U” ditch in such a way that material from the bank is deposited inside the ditch.

CUTTING A “V” DITCH Keep the frame straight if the ditch is being cut in solid material.

If the dirt is loose, articulate the machine so that the rear frame and tandems are maintained on the most firm ground.

Make a cleaning pass to remove material from the ditch, pushing it on the road and spreading it out when necessary.

With the circle directly under the frame, position the blade end bit slightly outside the front wheel.

Incline the blade forward so that the top edge of it is in line with the center of the front tire.

Position the blade in such a way that the discharge of the material is in the center of the machine, between the tandems, lean the front wheels in the direction of discharge.

From the first pass, in 1st or 2nd gear, cut only the material necessary to maintain the ditch line.

TERRACING - LEVEL CURVES One of the most important applications for motor graders in agriculture is terracing level curves that provide for the retention and distribution of water in the fields, permitting an increase in productivity and preventing soil erosion on hill sides.

For the second pass, position the wheels inside the ditch and with a speed slightly higher than first pass maintain 3:1 ratio between the ditch walls and depth.

This work consists of “V” ditches following the level curves of the ground with a distance between them of 10 to 100 meters (34 - 338 ft), with the greater distance for small slopes and the smaller distance for steeper slopes.

The material discharge should be maintained between the tandems. A cleaning pass is necessary. Move the circle and the blade in the direction of the ditch with the blade extended well behind the column of material, in such a way that the dirt cannot fall into the ditch. The blade end bits should be positioned between the rear wheels with the blade tilted slightly forward, to make material rolling easier. All the ditches should be cut with the differential locked (if equipped).

DITCH CUTTING ON FLAT PLAIN The opening of a ditch on a flat plain is a continuation of “V” ditching.

With the circle centered on the frame in a straight position, position the blade end bit behind the outside edge of the front tire. Angle the blade in such a way that the other end reaches the width and depth of the ditch desired (with front scarifiers it is possible to position the blade at 90º if necessary).

To cut ditches with walls with a 1,5:1 and 2:1 slope, shift the circle and blade against the bank.

67

OPERATING INSTRUCTIONS

Tilt the blade slightly toward the front, so that material is spread along the sides of ditch.

Move the circle and blade toward the ditch, with the blade angled in such a way to bring the material toward the road bed.

This pass should be done in 1st or 2nd gear (with the differential locked if available on the machine).

Some ditches may be so steep that the upper front wheel tends to loose contact with the ground.

This is not an acceptable operating condition. Use articulation of frame and blade position to maneuver the machine into a more favorable position.

On the following pass, push the material outside the ditch and on the road side. For this, move the circle and blade outside the pile and angle the blade in such a way that the material does not return into the ditch.

Frequently tire marks on the sides of a ditch can be avoided by articulating the frame positioning the driving wheels in a more favorable position.

Maintain the edge of the blade near the front tire, to keep small mounds of material from returning into the ditch. For the next pass, spread the material lightly from the road shoulder toward the center of the road.

The articulated grader makes the cleaning of wet ditches a relatively simple operation.

Articulate the frame in the OFFSET position, in such a way that the rear wheels are on firm ground, while the front wheels are on the side of the bank.

68

OPERATING INSTRUCTIONS

ROAD BED After preparing the drainage, the next step is to prepare and level the road bed.

Maintain the frame straight, circle centered and blade almost perpendicular to the machine, in such a way that the material leaves from both sides and cuts the crest of the road rather high to permit drainage on both sides.

In subsequent passes, angle the blade between 10º and 25º tilting it a little toward the front to permit the material to roll toward the road shoulders.

Make these passes at relatively high speeds, so that the loose material passes under the blade before touching the ends.

On the final pass, for each road shoulder position the blade end bit in line with tandem, so that the rear tires can compact the material that may slide off the sides of the blade.

69

OPERATING INSTRUCTIONS

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70

Wheels/Tires WHEELS/TIRES

WHEELS/TIRES WHEELS AND TIRES

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WARNING: EXPLODING TIRES AND/OR RIM PARTS CAN CAUSE INJURY OR DEATH. KEEP YOURSELF AND OTHERS OUT OF THE DANGER AREA. STAND ON THE TREAD SIDE OF THE TIRE. ALWAYS USE THE CORRECT AIR PRESSURE AND FOLLOW THE INSTRUCTIONS IN THIS MANUAL FOR ADDING AIR OR SERVICING THE TIRES.

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WARNING: EXPLOSIVE SEPARATION OF THE TIRE AND/OR RIM PARTS CAN CAUSE INJURY OR DEATH. WHEN TIRE SERVICE IS NECESSARY, HAVE A QUALIFIED TIRE MECHANIC SERVICE THE TIRE.

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WARNING: DO NOT WELD TO WHEEL OR RIM WHEN A TIRE IS INSTALLED. WELDING WILL CAUSE AN EXPLOSIVE AIR/GAS MIXTURE THAT WILL BE IGNITED WITH HIGH TEMPERATURES. THIS CAN HAPPEN TO TIRES INFLATED OR DEFLATED. REMOVING AIR OR BREAKING BEAD IS NOT ADEQUATE. TIRE MUST BE COMPLETELY REMOVED FROM THE RIM PRIOR TO WELDING.

71

WHEELS/TIRES

The above illustration show danger areas caused by exploding tires and/or rim parts.

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WARNING: KEEP YOURSELF AND OTHERS OUT OF THESE DANGER AREAS.

The next page shows the correct methods that you MUST use when adding air or servicing a tire.

72

WHEELS/TIRES

Adding Air to the Tires

Tire or Rim Service

This procedure is only for adding air to the tire. If the tire has lost most or all of the air, do the following:

Always have a qualified tire mechanic service the tires and rims for this machine. It is recommended that you have this mechanic inflate the tires. To prevent accidents, use a restraining device (tire inflation cage), correct equipment, and correct procedure.

1. Before you add air, have the wheel correctly installed on the machine or put the wheel in a restraining device (tire inflation cage).

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EXPLOSIVE WARNING: SEPARATION OF THE TIRE (SINGLE PIECE RIM) OR THE TIRE AND/OR RIM PARTS (MULTI-PIECE RIM) CAN CAUSE SERIOUS INJURY OR DEATH.

Tire Tread Direction When the tire is installed on the wheel make sure the tire tread is in the direction shown.

2. Use an air hose with remote shut off valve and a self-locking air chuck.

3. Stand BEHIND the tread of the tire and make sure ALL persons are away from the side of the tire before you start to add air.

FORWARD FOR TRACTION

FORWARD FOR STEERING

4. Inflate the tire to the recommended air pressure. DO NOT inflate the tire more than the recommended pressure given on the following page.

73

WHEELS/TIRES

WHEEL NUTS TORQUE AND TIRE PRESSURE Tandem Wheel Lug Nuts

Tire Pressure Check

The tandem wheel lug nuts should be periodically checked for tightness.

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Torque the nuts to 625Nm (63,7kgf.m; 460lb.ft).

1

WARNING: Do not inflate the tires with flammable gases or with air from systems that use alcohol injectors. This could cause explosion and/or accidents.

Check the pressure with a tire pressure gauge.

The normal pressure is: 13,00 x 24 - 12 ply tires - 2.5 bar (35PSI) 14,00 x 24 - 10 ply tires - 2.1 bar (30PSI) 14,00 x 24 - 12 ply tires - 2.5 bar (35PSI) 16,00 x 24 - 12 ply tires - 2.1 bar (30PSI) 17,50 x 25 - 12 ply tires - 3.5 bar (50PSI)

1. TANDEM WHEEL LUG NUTS

17,50 x 25 - 16 ply tires - 3.5 bar (50PSI) 2

3 2. TANDEM WHEEL LUG NUTS (OPTIONAL)

3. TIRE VALVE

Do not stand directly in front of tire while performing maintenance. Always stand to one side and extend your arm to filler valve.

Be sure tires are properly inflated to the specified pressure. Inspect for damage periodically.

Check tires only when the wheels and tires are cool to avoid under inflation. Do not use reworked wheel parts. Improper welding, heating or brazing, weakens them and can cause failure.

WHEEL NUTS TIGHTENING SEQUENCE

74

WHEELS/TIRES

Always use an inflation cage, safety cables or chains when removing tire lock rings or inflating tires. Always deflate tires before removing lock rings or objects from tread, according to local or national requirements.

If 24 hour operation does not permit checking inflation pressure on completely cooled tires, a correction factor can be determined by experiment.

Check as many times as possible when “cold” and again after two hours of operation. The average difference must be added to the recommended pressure when checking the tires during constant operation.

Never begin to inflate a tapered bead tire unless bead seat band is securely in place over the lock ring.

Improper inflation is a large contributor to tire failures. Under inflation will cause damage to the cord body of the tire. The repeated excessive flexing of the sidewall area may eventually cause a series of breaks and separation in the cord fabric.

Continuous operation of equipment builds up heat and accompanying higher pressure in the tire.

These normal increases are allowed for in the design of the tires.

Over inflation must also be avoided. For maximum flotation in very soft footing, inflation may be decreased.

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WARNING: Travel pressures are recommended to optimize the performance of the machine during long transfer trips on open roads with no load. Before putting the machine back to work, it is imperative to reinflate the tires to working pressure to avoid damaging the tire sidewalls.

NOTE: Never exceed the maximum pressure stamped onto tire sidewalls.

75

WHEELS/TIRES

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76

LUBRICATION/FILTERS/FLUIDS

GENERAL SAFETY BEFORE YOU SERVICE WARNING: Improper service or repair can cause injury or death. If you

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do not understand the service procedures for this machine, see your dealer or the service manual for this machine.

WARNING: Raised equipment on the machine without an operator can

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cause injury or death. Before you leave the operators compartment, always support or lower the equipment (blade, scarifier, ripper, etc.) to the ground and stop the engine.

Read the safety decals and information decals on the machine. Read and understand the operators manual and safety manual.

Use the correct safety clothing and safety equipment. Understand how to use a fire extinguisher and first aid kit.

Understand the operation of the machine before you start servicing.

Before you service the machine, put a DO NOT OPERATE tag on the instrument panel. One Do Not Operate tag is included with your machine.

Additional tags are available from your dealer.

77

LUBRICATION/FILTERS/FLUIDS

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

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

78

LUBRICATION/FILTERS/FLUIDS

TRANSPORT/SERVICE PIN WARNING: Keep clear of this area when engine is running. Machine could

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pivot unless the transport and service pin is in its LOCKED position.

After servicing is completed, unlock the transport and service pin and secure in place on the rear frame pivot.

Before you transport or service this machine, always put the Transport/Service pin in the LOCKED position.

STRAIGHT AHEAD LOCKED POSITION

OPERATING POSITION

After servicing and before you move the machine, return the Transport/Service pin in the OPERATING position.

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

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

79

LUBRICATION/FILTERS/FLUIDS

SYSTEMGARD LUBRICATION ANALYSIS PROGRAM Ask your dealer about our lubricant analysis program, Systemgard. Through this service, your lubricants are tested in an independent laboratory. You simply remove a sample of lubricant from your machine and send the sample to the independent Systemgard laboratory. After the sample is processed, the laboratory will report back to you and guide you with maintenance requirements. Systemgard can help support your equipment up time and provide you with a service that can pay back dividends when you trade for another piece of Case equipment.

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

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

80

LUBRICATION/FILTERS/FLUIDS

ENGINE HOOD 1. HANDLE Push lock button and raise hood to open. Open hood until support strut locks full open.

1

2. ASSIST CABLE

2

To close hood, pull down on assist cable while pushing strut release tab.

81

LUBRICATION/FILTERS/FLUIDS

MAINTENANCE GENERAL Always check oil level and drain or fill all the reservoirs with the engine off and machine on a flat ground.

The intervals specified here refer to normal operating conditions. During the initial period of use (run-in) and under severe working conditions, the servicing intervals need to be shortened.

Consult your Case Dealer for more information.

Drain the engine oil immediately after shutting off the engine while the oil is warm and flows more easily. After refilling system the oil should be checked only after engine has been run at low idle for a few minutes. This procedure insures that the oil cooler, filters, lines, etc., are completely full before the oil level check is made.

Maintenance and lubrication chart decal is located on the rear of the cab in the lower left corner.

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1. MAINTENANCE AND LUBRICATION CHART DECAL

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LUBRICATION/FILTERS/FLUIDS

FLUIDS AND LUBRICANTS CAPACITY COMPONENTS

Liters

US Gal.

Fuel tank

341.0

90.0

SPECIFICATIONS Diesel Nº2

(with filter change)

21.1

5.5

SAE15W-40 API CH-4 or CG-4

(without filter change)

18.9

4.8

(total capacity) Engine oil

Nº1 Engine Oil

Engine Cooling System (total capacity)

MAT 3507 (MS 1121) WATER (50%) + ETHYLENE GLICOL (50%)

40.0

10.5

MS 1710

Total capacity

180.0

47.5

HY-TRAN ULTRA

Hydrauic tank with filter

94,6

25.0

MAT 3505 (MS 1209)

Hydraulic System

Transmission Refill capacity (with filter change)

25.0

6.4

HY-TRAN ULTRA

Refill capacity (without filter change)

19.0

5.0

MAT 3505 (MS 1209)

Rear Axle Graziano Model - STD - Center compartment

29.0

7.7

HY-TRAN ULTRA

- End/Brake compartment (each)

5.0

1.33

MAT 3505 (MS 1209)

Rear Axle Clark Model - OPTIONAL - Center compartment

12.0

3.2

HY-TRAN ULTRA

- Planetary hubs (each)

6.0

1.6

MAT 3505 (MS 1209)

29.0

7.7

SAE 80W-90 135H EPAPI GL5

22.5

5.9

SAE 80W-90 135H EPAPI GL5

2,8

0.75

SAE 80W-90 135H EPAPI GL5

--

--

Tandem Drive Case (Graziano Axle) Refill capacity (each) Tandem Drive Case (Clark Axle) Refill capacity (each) Circle Turn Gear Reducer Refill capacity Grease fittings , Rear Ripper Rear Ripper , Front Scarifier or Dozer Blade

83

CASE molydisulfide grease

LUBRICATION/FILTERS/FLUIDS

LUBRICATION & MAINTENANCE CHART SERVICE INTERVAL (hours) H O U R S

As needed

P O I N T S

SERVICE POINTS

Air cleaner (Note 1)

Hydraulic filter (Note 2)

Alternator / Air conditioner belt 10h or daily 50h or weekly

C H A N G E

Engine oil level (including filters)

1

10

Radiator (coolant level) (Note 3)

1

10

Transmission oil level (warm, engine running)

1

10

Hydraulic tank (complete system)

1

50

Fuel filters / separator filter (drain water)

2

50

Blade lift cylinder pivots

2

100

Side shift cylinder pivots

2

100

1

100

2

100

2

100

Articulation cylinders pivots

4

10 0

Drawbar pivot and socket 100h or Front axle pivot each 15 days Articulation pivots

Moldboard lift cylinders balls

2

Engine oil and oil filter (if used CG-4 engine oil)

1

Universal joints and drive shaft

2

Differential and planetary drives oil level (Note 4)

3

25 0

1/2

250

Circle turn gear housing

1

25 0

Alternator and ar conditioning belts

2

250

Moldboard adjusting link ends

4

250

Moldboard side shift link ends

2

250

Front wheel lean link and knuckle pivot

8

250

Front axle spindle pivot

2

250

Front wheel lean cylinder

2

250

Batteries (2) 250h or monthly

C H E C K

L U B R I C A T E

84

100 25 0 250

A D J U S T

C L E A N / D R A I N

LUBRICATION/FILTERS/FLUIDS

SERVICE INTERVAL (hours) H O U R S

P O I N T S

SERVICE POINTS

Fuel sediment bowl (wash filter screen) 250h or monthly

C H E C K

C H A N G E

1

C L E A N / D R A I N

250 250

Tandem case

250

Steering arm pivot

4

Tire condition and pressure

4

Fuel filters

2

Front wheel bearing grease

2

Tandem drive case oil level

2

250 250 500 500 500

8

500

1

500

1

500

Engine oil and oil filter (if used CH-4 engine oil)

1

Fuel tank drain plug (drain sediment)

1

500 500

Rops and seat belts bolts torque

50 0

Transmission oil (Note 5)

1

1000

Transmission screen

1000

Fuel pump and injectors (Note 6)

6

1000

Engine valves clearance (Note 6)

1/2

1000

Air cleaner elements

Circle turn gearbox oil

1000 100 0

Hydraulic oil and filter (Note 7) 2000h or each year

A D J U S T

Cab air filter (if equipded)

Tandem wheel shaft bearings 500h or Transmission oil filter (Note 5) each 3 months Rear axle cooling system filter

1000h or each 6 months

L U B R I C A T E

1

2000

Differential and planetary drives oil (Note 4)

1

200 0

Front wheel bearing (repack)

2

2000

Tandem drive case oil

2

2000

Engine coolant

10

Turbocharger bolts torque

2000 200 0

85

LUBRICATION/FILTERS/FLUIDS

NOTE: See “FLUIDS AND LUBRICANTS” table on previous pages for lubricants and fluids detailed specifications and capacities.

NOTE 1: Service the air filter elements if air filter restriction indicator is in the red area.

NOTE 2: Service the hydraulic filters if hydraulic filter indicator lamp iluminates.

NOTE 3: Check the radiator coolant level if the coolant level warning lamp iluminates.

NOTE 4: Change the rear axle oil after the first100 hours of operation.

NOTE 5: Change the transmission oil and replace the filter after the first100 hours of operation.

NOTE 6: Contact your dealer and see the service manual.

NOTE 7: Change every 2.000 hours or once a year, whichever comes first. : As needed

86

LUBRICATION/FILTERS/FLUIDS

ACCESS DOORS

FUSE BOX

ENGINE ACCESS HOOD

HYDRAULIC FLUID

CAB FILTER ACCESS DOOR

WINDSHIELD WASHER RESERVOIR

87

LUBRICATION/FILTERS/FLUIDS

FLUID LEVELS EACH 10 HOURS OR DAILY SERVICES Engine Crankcase

Engine Coolant Level

Check oil level shortly after engine is warm and has been stopped. Remove the engine oil dipstick (1), and check oil level. If the oil level is below the minimum mark or above the maximum mark, do not operate the engine. Add oil if necessary through the filler neck (2).

Check coolant when engine is cold. Make sure coolant is visible in sight glass on radiator.

If necessary, add coolant to the radiator. Turn the radiator cap slowly to remove pressure. Add coolant until level is at the bottom of the filler neck.

NOTE: Never add anti freeze to cooling system without checking existing level of protection. Add coolant as necessary to bring it to the proper level.

Tighten radiator cap.

2

1

1. ENGINE OIL FILLER 2. ENGINE OIL DIPSTICK

Radiator

Fluid under pressure. Turn the cap slowly to relieve pressure before removing or until the pressure has been relieved. The coolant may boil over and cause personal injury.

WARNING:

!

! WARNING HOT LIQUID UNDER PRESSURE HAZARD Service when cool.

329044A1

88

LUBRICATION/FILTERS/FLUIDS

Transmission Fluid Level Check the transmission oil level when the oil is hot and the system is charged. Place transmission in NEUTRAL, keep the engine idling and apply parking brake. Turn the handle counterclockwise to loosen the cap. Remove the cap and check oil level with the dipstick. Add oil as necessary to bring it to the proper level. Make sure the cap is tight on the filler neck after checking oil.

ENGINE RUNNING

TRANSMISSION DIPSTICK

89

WARM

LUBRICATION/FILTERS/FLUIDS

FLUID LEVELS EACH 50 HOURS SERVICES Hydraulic tank

!

WARNING: Fluid under pressure. Turn the cap slowly to relieve the

pressure, before removing.

Be sure the machine is on level ground with the engine off. Lower the moldboard to the ground.

Check the oil level through sight gauge. The oil level should be at the center of the gauge. If necessary, remove the hydraulic tank filler cap and add oil

2

2. HYDRAULIC TANK FILLER CAP

1

3

1. OIL LEVEL GAUGE

3. WATER SEPARATOR AND FUEL FILTER

Engine fuel filter Open the drain cock (3) located on the bottom of the filter to remove the accumulated water.

IMPORTANT: The drain cock is made

of plastic material. Do not over tighten when closing.

90

LUBRICATION/FILTERS/FLUIDS

GREASE FITTINGS EACH 100 HOURS SERVICES See Fluids and Lubricants for grease specifications.

Moldboard lift cylinders balls

Articulation, hydraulic cylinders and pivot joints

There are two (2) lube points. Lubricate with 6 to 12 shots each.

There are four (4) lube points , two (2) on each side. Lube with 6 to 10 shots on cylinders ends.

Lube, with 6 to 14 shots on pivot bearings.

1 1 5 3

4

3 1. LIFT CYLINDERS BALL JOINT

Drawbar ball and socket

3. ARTICULATION CYLINDERS JOINTS 4. LOWER ARTICULATION JOINT 5. UPPER ARTICULATION JOINT

There is one (1) lube point. Lubricate with 6 to 14 shots.

Moldboard tilt cylinders balls There are two (2) lube points. Lubricate with 6 to 12 shots each.

6

2

6 2. DRAWBAR BALL AND SOCKET

6. TILT CYLINDER BALL JOINT

91

LUBRICATION/FILTERS/FLUIDS

Moldboard lift cylinders pivots

Moldboard tilt cylinder pivot

There are two (2) lube points. Lubricate with 4 to 6 shots each.

There are two (2) lube points. Lubricate with 4 to 6 shots each.

8 8 8

8. LIFT CYLINDERS PIVOT 8. TILT CYLINDER PIVOT

Moldboard tilt pivot There are two (2) lube points. Lubricate with 4 to 6 shots each.

10

10. TILT PIVOT

92

LUBRICATION/FILTERS/FLUIDS

GREASE FITTINGS EACH 250 HOURS SERVICES See Fluids and Lubricants for grease specifications.

Front wheel knuckle

Wheel lean link

There are four (4) lube points. Lubricate with 4 to 6 shots on each side.

There are two (2) lube points. Lubricate with 4 to 6 shots on each side.

1

3

1. FRONT WHEEL KNUCKLE

3. WHEEL LEAN LINK

Steering arm pivot

Front wheel lean cylinder

There are four (4) lube points. Lubricate with 4 to 6 shots on each side.

There are two (2) lube points. Lubricate with 4 to 6 shots on each side.

2

4

2. STEERING ARM PIVOT

4. FRONT WHEEL LEAN CYLINDER

93

LUBRICATION/FILTERS/FLUIDS

Front axle spindle pivot

Tandem wheel shaft bearings

There are two (2) lube points. Lubricate with 6 to 12 shots each.

There are eight (8) lube points. Lubricate with 6 to 12 shots each.

5

5 8

5. FRONT AXLE SPINDLE PIVOT

8. WHEEL SHAFT BEARINGS

Universal joint and drive shaft There are tree (3) lube points. Lubricate with 4 to 6 shots each.

6

6. UNIVERSAL JOINT

7

6

7. DRIVE SHAFT

94

LUBRICATION/FILTERS/FLUIDS

GREASE FITTINGS EACH 500 HOURS SERVICES See Fluids and Lubricants for grease specifications.

Tandem central bearings

Rear ripper pivots and cylinder

There are four (4) lube points for each tandem.

Lubricate wit 14 to 20 grease shots.

There are eight (8) lube points for ripper linkage and two (2) for the cylinder. Lubricate wit 4 to 6 grease shots.

4

1

3

1. TANDEM CENTRAL BEARINGS 3. RIPPER PIVOTS 4. RIPPER CYLINDER

Front wheel bearings Loosen fixing bolts and remove cover.

Remove grease, clean bearing housing and fill it with 0.9 kg (each) of the specified grease. For more information see Fluids and Lubricants.

2

2. FRONT WHEELS BEARINGS

95

LUBRICATION/FILTERS/FLUIDS

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

If Case Multi-Viscosity Engine Oil is not available, use only oil meeting API engine oil service category CH-4 (preferred) or CG-4.

See the chart on following page for recommended viscosity at ambient air temperature ranges.

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

96

LUBRICATION/FILTERS/FLUIDS

Oil Viscosity and Temperature Ranges

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

97

LUBRICATION/FILTERS/FLUIDS

Engine Service Specifications Oil Level check interval .............................................................. Every 10 hours of operation or each day, whichever occurs first.

Oil Change interval ............................................ Every 250 hours of operation if used CG-4 engine oil or every 500 hours of operation if used CH-4 engine oil Oil filter change interval ...................................... Every 250 hours of operation if used CG-4 engine oil or every 500 hours of operation if used CH-4 engine oil or once a year whichever occurs first.

Oil type ...................................................................................................... See Fluids and Lubricants Oil Capacity - with filter change .................................................................... 21.1 liters (5.5 U.S. gal)

Engine Oil Change and Filter Replacement

Engine Oil Level To check the engine oil level put the machine on a level surface and stop the engine. Remove engine oil dipstick and wipe clean with a cloth.

Replace dipstick in tube and push the engine oil dipstick completely DOWN and then remove. If the oil level is below the ADD mark, add oil to raise the oil level to the FULL mark.

1

Make sure engine is at operating temperature.

Shut-off the engine. Remove the drain plug (A) located on the lower right side of the engine crankcase and allow all the oil to drain.

Make sure the seal is in good condition and install the drain plug.

2

Remove the oil filter. Carefully clean the gasket seat on the filter.

1. ENGINE OIL FILLER 2. ENGINE OIL LEVEL DIPSTICK

NOTE: The filter’s sealing gasket normally stays attached to the filter gasket seat.

98

LUBRICATION/FILTERS/FLUIDS

IMPORTANT: Before installing , fill the oil filter with new and clean oil. Before installing the filter, apply also a light film of oil in the area of the filter gasket seal.

IMPORTANT: Tightening the filter with a wrench can damage it, therefore tighten it

by hand. Then check if there are leaks around the base when the engine is running.

Tighten it more if necessary. The proper torque is completed with 3/4" of a turn after contact by grasping the base with both hands.

ENGINE OIL FILTER

Systemgard Lubrication Analysis Program

Add specified oil, through the filler neck. Start the engine and keep it running for 15 minutes to fill the filters and lubricate the engine. Check the oil level and top off as necessary.

The normal engine oil change interval is every 250 hours of operation or once a year whichever occurs first .

Check if there is any leakage from the filters.

Operating conditions, quality of the engine oil and sulphur content of the fuel can change this interval. It is recommended to use the Systemgard Lubrication Analysis Program. See your dealer.

IMPORTANT: Never drain oil or remove oil filter while engine is running.

!

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

machine. NEVER operate the machine with covers or guards removed.

99

LUBRICATION/FILTERS/FLUIDS

AIR FILTER SYSTEM Service Specifications Air filter element service interval Primary (Outer) Element ..................................... Service the element if the air filter restriction indicator is in the red area. Replace the element after three washings. Also, replace the element after 1000 hours of operation or each year, whichever occurs first.

Secondary (Inner) Element .................................. Replace the element after the primary (outer) element has been cleaned three times, or after the primary element has been cleaned or replaced and the air filter restriction indicator is still in the red area with the engine running. Also, replace the element every 1000 hours or each year, whichever occurs first.

Cleaning the Air Filter Element The outer element of the air cleaner should be disassembled only when the air restriction indicator is in the red area.

For correct maintenance of the air filter proceed as following: a) Clean dirt and oil from air cleaner assembly. b) Loosen clamp (2) attaching cup to air cleaner body.

Remove cup (7) and deflector (6). c) Remove outer element by loosening wing nut and gasket. d) The filter may be cleaned with compressed air.

NOTE: Visually check inner element each time outer element is cleaned or replaced. Do not attempt to clean the inner element.

1. INNER ELEMENT 2. NUT 3. T-BOLT 4. NUT 5. CLAMP 6. O-RING 7. CUP 8. NUT 9. FILTER HOUSING 10. OUTER ELEMENT

100

LUBRICATION/FILTERS/FLUIDS

!

WARNING: Wear safety glasses with side shield or goggles when using compressed air for cleaning. This reduces the danger of accidents caused by flying particles. Limit the pressure to 30 PSI (2 bar) according to local or national requirements.

If required clean fins inside air cleaner with a stiff fiber brush.

g) Inspect inner element retaining wing nut (4).

Change wing nut if it is damaged.

e) To clean element with compressed air, direct dry clean air up and down plates on clean air side of element until all dust is removed.

IMPORTANT: The inner element of the

h) Clean inside of the air cleaner body and cup (7) before reinstalling element (5). Insert element in air cleaner body and tighten wing nut.

air cleaner is extremely important. It is suggest to change it after 3 outer elements have been changed.

i) Install cup (7) unloader valve at bottom and tighten clamp securely. Check to see that the clamp is correctly positioned. j) Check unloader valve lips (8). The lips must be free of debris. Dirt and mud can lodge in the lips and hold them open during operation.

The valve lips must be open when the engine is at low idle or is stopped. The lips must point down to function. l) Check the air cleaner tube cap. If there is dirt, remove tube cap and blow dust from cap, remove debris if any is apparent.

f) After the filter has been cleaned and dried, it must be inspected for ruptures or holes. Place a bright light inside the element and inspect it from the outside. The light will shine through any holes or tears. If any holes are evident, install a new element.

m) Start engine. Observe air cleaner restriction indicator with engine running at high idle. If restriction is indicated, air cleaner inner element must be replaced. As the inner element is not cleanable, always replace it after one year of service or if a restriction is still indicated after the outer element has been cleaned.

101

LUBRICATION/FILTERS/FLUIDS

ENGINE COOLING SYSTEM Service Specifications Cooling System Capacity ..............................................................................40 liters (10.5 U.S. Gal.) Cooling system drain, flush, and refill interval ..................................... Every 2000 hours of operation or each year, whichever occurs first.

Radiator coolant fluid level check................................................................... Every 10 hours of operation

Thermostat Starts to open ................................................................................................................. 82°C (180°F) Completely open ........................................................................................................... 94°C (202°F) Radiator cap ................................................................................................ 103.4 kPa, 1 bar (15 psi)

Coolant Mixture A mixture of 50% Ethylene Glycol and 50% water must be used in this machine.

This mixture is used if the lowest ambient temperature is above -37°C (-34°F). If the ambient temperature is lower, adjust the mixture to 60% Ethylene Glycol and 40% water. It is recommended that Ethylene Glycol and water be used in your machine all year.

Use only Ethylene Glicol Case 331-511.

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

!

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

Scalding can result from fast removal of radiator cap. Check and service engine cooling system according to maintenance instructions.

102

LUBRICATION/FILTERS/FLUIDS

Draining and Flushing the Cooling System

!

WARNING: Hot fluid under pressure. Follow the Operator’s Manual

instructions to relieve the pressure before opening the radiator cap.

Turn the radiator cap slowly to relieve pressure.

Open radiator drain cock located under the radiator (3) and the drain cock located on the oil cooler. Let the coolant drain.

Check to see that all hoses are in good condition and the clamps are not damaged or loose.

Replace if necessary.

Install radiator cap. Start and run engine until coolant reaches normal operating temperature.

Stop engine. Check level of coolant and add if necessary.

Radiator Cleaning

! WARNING HOT LIQUID UNDER PRESSURE HAZARD Service when cool.

329044A1

After draining, flush the radiator with clean water.

Be sure that the water does not contain large amounts of calcium.

Fill the cooling system with a mixture of 50% of Ethylene Glycol and 50% of clean water to about 1 1/4" (30 mm) below the filler neck.

AIR FLOW DIRECTION WHEN WORKING

1. AIR NOZZLE 2. RADIATOR TUBES 3. RADIATOR FINS 4. DEBRIS

103

LUBRICATION/FILTERS/FLUIDS

WARNING: Wear safety glasses with side shield or goggles when using

!

compressed air for cleaning. This reduce the danger of accidents caused by flying particles. Limit the pressure to 30 PSI (2 bar) according to local or national requirements.

Use an air compressor and a suitable nozzle to direct a stream of air over and through radiator core in the opposite direction of normal air flow to remove all dirt and debris.

NOTE: It may be necessary to spray the exterior of radiator core with water and detergent to remove caked dirt.

104

LUBRICATION/FILTERS/FLUIDS

DIESEL FUEL SYSTEM Service Specifications Fuel Tank Capacity ................................................................................... 341 liters (90 U.S. Gallons) Interval for draining water from the fuel filter ..................................................... 50 hours of operation Fuel filter replacement interval ........................................................................ 500 hours of operation or once each year, whichever occurs first Adjust fuel injector ....................................................................................... 1000 hours of operation or once each year, whichever occurs first Clean and calibrate fuel injectors and fuel pump ...................................... 1000 hours of operation or every 6 months, whichever occurs first.

Fuel Conditioner Diesel fuel conditioner is available from your dealer. Follow the instructions on the can.

2. Disperse insoluble gummy deposits that can form in the fuel system.

The conditioner will:

3. Separate moisture from the fuel.

1. Clean the fuel injectors, valves and manifold for increased service life.

4. Stabilize the fuel in storage.

!

WARNING: Engine fuel is flammable and can cause a fire or an explosion.

Do not fill the fuel tank or service the fuel system near an open flame, welding, burning cigars, cigarettes, etc.

!

WARNING: Never refuel the machine when the engine is hot or running.

Never smoke while refueling.

Fuel Filler Cap

105

LUBRICATION/FILTERS/FLUIDS

Diesel Fuel Use No. 2 Diesel fuel in the engine of this machine. The use of other fuels can cause the loss of engine power and high fuel consumption.

In very cold temperatures, a mixture of No. 1 and No. 2 diesel fuels is temporarily permitted. See the following note.

NOTE: See your fuel dealer for winter fuel requirements in your area. If the temperature of the fuel lowers below the cloud point (wax appearance point), wax crystals in the fuel will cause the engine to lose power or not to start.

The diesel fuel used in this machine must meet the specifications in the chart below or Specification D975-81 of the American Society for Testing and Materials.

Fuel Storage If you keep fuel in storage for a period of time, you can get foreign material or water in the fuel storage tank. Many engine problems are caused by water in the fuel.

Keep the fuel storage tank outside and keep the fuel as cool as possible. Remove water from the storage container at regular periods of time.

Fill the fuel tank at the end of the daily operating period to prevent condensation in the fuel tank.

Specifications for Acceptable No. 2 Diesel Fuel API gravity, minimum ...................................................................................................................... 34 Flash point, minimum .................................................................................................... 140°F (60°C) Cloud point (wax appearance point), maximum......................................... -5°F (-20°C) See Note above Pour point, maximum ................................................................................ -15°F (-26°C) See Note above Distillation temperature, 90% point................................................................ 540 to 640°F (282 to 338°C) Viscosity, at 100°F (38°C) - Centistokes .............................................................................. 2.0 to 4.3 Saybolt Seconds Universal ...................................................................................................... 32 to 40 Cetane number, minimum.............................................................. 43 (45 to 55 for winter or high altitudes) Water and sediment, by volume, maximum ............................................................................. 0,05% WARNING: Engine fuel is flammable and can cause a fire or an explosion.

!

Do not fill the fuel tank or service the fuel system near an open flame, welding, burning cigars, cigarettes, etc. Never refuel the machine when the engine is hot or running. Never smoke while refueling.

106

LUBRICATION/FILTERS/FLUIDS

Fuel Tank Drain Cock Clean

!

Changing the Fuel Filters

WARNING: Extinguish all smoking materials or open flames before opening the sediment drain due to presence of flammable fluids.

EACH 500 HOURS OF SERVICE These are lock ring type cartridge filters.

Clean the area around the fuel filters.

Remove the filters and clean carefully the area around the filter base gasket.

Change the filters and sealing rings. Fill the filters with fuel and lubricate the sealing rings with engine oil.

1 2

Open the drain cock, before engine start and allow water or sediment to drain. Close the drain cock when fuel runs out.

FUEL FILTER

Then assemble the new filters and lock them.

Bleed air from the fuel system as follows: Loosen the bleeder screw (1) a few turns, on the fuel filters. Prime the knob of the fuel pump (2) several times until fuel flows out of the bleeder screw (1) without air bubbles.

Then, tighten the bleeder screw (1) and continue pumping the knob (2), of the fuel pump several more times and stop.

107

LUBRICATION/FILTERS/FLUIDS

Checking the Fuel Injector Nozzles

Adjusting Engine Valves

FUEL INJECTOR NOZZLES

Adjust the valve clearance always when the engine is cold, i.e., the water temperature should be under 60ºC (140ºF). Initially determine the first cylinder top dead center. For that, turn the engine manually and slowly, using a 1/2" square wrench and a manual turning device.

!

EACH 1000 HOURS

WARNING: Keep hands away from nozzle tip when popping a nozzle. The finely atomized fuel is ejected with a sufficient force to penetrate the skin and cause blood poisoning. Also, wear safety glasses with side shields or goggles when popping a nozzle.

The valves clearance must be: Intake valves: ...................... 0,30 mm (0.012 in) Exhaust valves: ................... 0,61 mm (0.024 in)

Remove the fuel lines from top of injectors and cover the fuel lines to prevent contamination.

Remove nozzle clamp stud nuts and remove the nozzles from cylinder head.

NOTE: The clearance will be correct when the feeler gauge is passed between the valve rod and the rocker, with a little resistance.

Cover all openings in cylinder head to prevent contamination.

The nozzle should be checked by a qualified person in a well equipped shop.

The nozzle relief pressure should be 205 bar.

Make certain sealing washers are in good condition and seats clean.

Install nozzle assemblies in cylinder head, and secure with stud nuts to a torque of 25 Nm (18 lbs.ft).

Install fuel lines so they are only finger tight (for priming). Crank the engine with starter to bleed the lines then secure fuel line nuts.

Check at each fitting for leaks and retighten nuts if necessary to correct leaks.

108

LUBRICATION/FILTERS/FLUIDS

HYDRAULIC/BRAKE SYSTEM Service Specifications Hydraulic/Brake System Fluid Chart Hydraulic Reservoir Refill Capacity w/filter change ........................................... 94,6 Liters (25 gallons) Total System + Tank Capacity ...............................................................................180 Liters (47.5 gallons) Type of Fluid ............................................................................................. See Fluids and Lubricants Hydraulic Reservoir Fluid Level Check Interval .......................................................... Every 50 Hours Filter Replacement Interval ........................................................... Every 2000 Hours of Operation or when the Hydraulic Filter Warning Lamp Illuminates Hydraulic Fluid Change Interval .......................................................................... Every 2000 Hours or once each year, whichever occurs first.

WARNING: Pressurized hydraulic system. Before you replace the

!

hydraulic filter or service the hydraulic system, wear face protection and slowly loosen the hydraulic reservoir fill cap to relieve the air pressure. If you do not follow these instructions, you can be injured.

Hydraulic/Brake System - Temperature Ranges

109

LUBRICATION/FILTERS/FLUIDS

Hydraulic System Oil Filter

Loosen filler cap (1) to relieve pressure.

CHECK EACH 500 HOURS

Remove cover (2) from top of the tank. Remove spring (3), cap (4) and o-ring (5), from top of element (6). Remove element from tank and discard.

Make certain o-ring (8) is in good condition, then install a new filter over the discharge tube. Position o-ring (5), cap (4) and spring (3) on top of the element.

Make certain o-ring (5) is in good condition and properly positioned as shown. Install cover (2) on tank and secure with capscrews (7). Torque capscrews to 47.5 - 54.2 Nm (35 - 40 lb.ft).

Fluid under pressure. Turn cap slowly to relieve pressure before removing it.

WARNING:

!

Cleaning the Suction Line Filter Loose the filler neck cap (1) to relieve the pressure. Remove the filler neck capscrews (9), the tube and the filter. Remove the filler neck cover, the tube (10) and filter (14) from the hydraulic. Remove and replace the rubber ring (11) from filter, if necessary.

IMPORTANT: Do not use gasoline,

solvent or another flammable fluids to wash the components.

Use recommended commercial, non toxic solvent. Wear safety glasses with side shields when using compressed air for cleaning to reduce the danger of personal injury from flying particles. Limit the air pressure to 30 PSI (2 bar).

Wash the strainer with a commercial solvent. Use compressed air to clean the element. Blow it from inside to outside.

Install a new o-ring in the groove and then install the tube assembly (pre cleaner) (10).

Install the capscrews (9) and torque them with 47.5 - 54.2 Nm (35 - 40 lb.ft). Make sure that valve assembly and strainer are properly positioned in the tube assembly.

Fill the tank to the proper level indicated on the sight gauge (13). Install a new o-ring (12) on the filler cap and install it.

110

LUBRICATION/FILTERS/FLUIDS

HYDRAULIC/BRAKE OIL CHANGE Change the hydraulic/brake oil every 2000 hours of operation or one time each year, or when ambient operating temperatures require, whichever occurs first . When changing the hydraulic oil also replace the hydraulic oil filter. Have a container available that is capable of holding 200 liters (53 gal).

1. Make sure the hydraulic oil is at operating temperature.

2. Park the machine on a level surface. Lower implements to the ground and apply the parking brake.

3. Stop the engine. Put a DO NOT OPERATE tag on the steering wheel.

WARNING: Fluid under pressure. Lower implements to ground, shut off

!

engine and move control levers several times.

Loosen filler cap to relieve pressure, before loose fittings.

4. Remove the drain plugs, and drain oil in a container.

5. Remove the filler cap to vent the tank as it drains. The filler element should be changed and the strainer cleaned at this time.

6. Install drain plug and fill tank with new oil.

7. Install filler cap.

8. Start the engine and operate controls so that all lines are filled.

9. Stop the engine. Check oil level. Add oil as necessary to bring to proper level.

2 1

1. HYDRAULIC OIL LEVEL GAUGE

2. HYDRAULIC OIL LEVEL FILLER

111

LUBRICATION/FILTERS/FLUIDS

TRANSMISSION Service Specifications Total system filling capacity with filters .................................................... ... 25.0 liters (6.4 U.S. Gal) Type of oil .................................................................................................. See Fluids and Lubricants Oil level check interval .......................................................................................................... 10 hours Filter replacement interval .......................................................... After the first 100 hours of operation and then every 500 hours there after.

Breather screen cleaning interval ...................................................................................... 1000 hours Oil change interval ..................................................................... After the first 100 hours of operation and then every 1000 hours there after.

IMPORTANT: If the machine is new or the transmission has been replaced or rebuilt,

change the transmission oil and replace the filter after the first 100 hours of operation.

IMPORTANT: Change the transmission oil and replace the filter after the first 100

hours of operation.

!

WARNING: Never drain oil or remove oil filter while engine is running.

Transmission Oil Level Check EACH 10 HOURS OR DAILY SERVICES 1

Check the transmission oil level when the oil is hot and the system is charged. Place transmission in NEUTRAL, keep the engine idling and apply parking brake.

Turn the handle counterclockwise to loosen the cap. Remove the cap and check oil level with the dipstick. Add oil as necessary to bring it to the proper level. Make sure the cap is tight in the filler neck after checking oil.

1. TRANSMISSION OIL LEVEL DIPSTICK

112

LUBRICATION/FILTERS/FLUIDS

Transmission Oil Filter Change

Transmission Oil Change and Screen Cleaning

EACH 500 HOURS

EACH 1000 HOURS Run engine until transmission oil reaches operating temperature.

Never use gasoline, solvent or other flammable fluids to clean parts.

Use authorized commercial, nonflammable, nontoxic solvents.

WARNING:

!

Park grader on a level surface, apply parking brake, lower moldboard to ground and shut-off engine.

Clean filter and surrounding area. Then remove the filter housing (1), change the elements and gaskets. Clean the inside of the filter housing (1) and contact surface. Install the new filter.

Remove the drain plug and screen, and let the oil drain into a container that holds at least 25 liters (26.5 US quarts). Clean the suction screen completely. Reinstall the screen and drain plug.

The transmission oil filter, should be changed at this time.

Fill the system to the level mark with the specified oil. Operate transmission to warm oil and top off as necessary.

1

1. TRANSMISSION OIL FILTER

DRAIN PLUG (1) AND SCREEN (2).

113

LUBRICATION/FILTERS/FLUIDS

REAR AXLE Service Specifications Rear Axle “Housing Center” Compartment Capacity (Graziano) ................ 29.0 liters (7.7 U.S. Gal.) Rear Axle “Planetary Gear” Capacity (each) (Graziano) ............................. 5.0 liters (1.33 U.S. Gal.) Rear Axle “Housing Center” Compartment Capacity (Clark - Optional) ...... 12.0 liters (3.2 U.S. Gal.) Rear Axle “Planetary Gear” Capacity (each) (Clark - Optional) .................... 6.0 liters (1.6 U.S. Gal.) Type of oil .................................................................................................. See Fluids and Lubricants Oil change interval ..................................................................... After the first 100 hours of operation and then every 2000 hours there after.

NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result of using an alternate oil.

Rear Axle Oil Change

REAR AXLE GRAZIANO

REAR AXLE HOUSING COMPARTMENT Change the axle oil every 2000 hours of operation.

1. Park the machine on a level surface. Apply the parking brake and stop the engine.

2. Clean the oil level and drain plugs.

3. Make sure the oil in the rear axle is near normal operating temperature.

REAR AXLE CLARK (Option)

4. Remove drain plug (2) and filler plug (1) to help oil drain more rapidly.

5. After draining, reinstall the drain plug and fill the housing to the level of the filler hole with the specified oil. Allow sufficient time for oil to fill all axle compartments. Wait 15 minutes and top off. Install and tighten filler plug.

1. FILLER AND LEVEL PLUG 2. DRAIN PLUG

Axle Oil Level Remove level/ filler plug (1). Add oil as necessary to bring oil level to bottom of plug hole.

Install plug and be sure it is properly tightened.

114

LUBRICATION/FILTERS/FLUIDS

Rear Axle End Compartment Oil Level (Opcional) Clean drain plugs, reinstall and tighten plugs securely. Remove each oil level (2) and filler plug (1) and fill each compartment with the specified lubricant to level even with filler plug openings.

Install and tighten oil level and filler plugs securely.

1

2 3

1. FILLER PLUG 2. LEVEL PLUG 3. DRAIN PLUG

4

Make certain oil in rear axle end compartment is near operating temperature. Remove drain plugs (3) located on bottom of each end compartment and allow oil to drain.

4. COVER PLUG

115

LUBRICATION/FILTERS/FLUIDS

SWING/CIRCLE TURN GEAR BOX Service Specifications Circle Turn Gear Housing Refill Capacity .................................................... 2.8 liters (0.75 U.S. Gal.) Type of oil .................................................................................................. See Fluids and Lubricants Oil check interval ........................................................................................................ each 250 hours Oil change interval ............................................................................................................ 1000 hours

Checking Circle Turn Gear Box Oil EACH 250 HOURS Remove oil level plug. If the oil does not drain from the hole, remove the filler plug and add oil until it comes out of the level plug hole. Then install level plug and filler plug.

3

1. FILLER PLUG 2. LEVEL PLUG

3. CIRCLE TURN GEAR BOX

NOTE: See Circle Guides Check and Adjustments.

116

LUBRICATION/FILTERS/FLUIDS

TANDEM Service Specifications Tandem Drive Case Refill Capacity (Graziano Axle) .................................... 29.0 liters (7.7 U.S. Gal) Tandem Drive Case Refill Capacity (Clark Axle) .......................................... 22.5 liters (5.9 U.S. Gal) Type of oil .................................................................................................. See Fluids and Lubricants Oil check interval ........................................................................................................ each 500 hours Oil change interval ................................................................................................... each 2000 hours Grease check interval (Tandem Case) ....................................................................... each 250 hours Type of grease .......................................................................................... See Fluids and Lubricants

Tandem Drive Case Oil Level Check

Tandem Wheel Nut

Park grader on a level surface. Remove level plug (2) from each tandem case. The oil must be level with the oil level plug hole. Add oil until it is brought to the proper level. Install all plugs.

The tandem wheel nuts should be periodically torqued. Torque nut to 637 Nm (469 lb.ft). Then turn to next slot and install cotter pin.

TORQUE EACH 2000 HOURS

Tandem Drive Case Oil Change CHANGE OIL EACH 2000 HOURS Remove the drain plug from each case and drain the oil. Remove the level and filler plugs from each case. Install the drain plugs. Add specified oil through the filler holes until oil runs out of the oil level hole.

Install and tighten level plugs and filler plugs in each case.

1. FILLER PLUG 2. LEVEL PLUG 3. DRAIN PLUG

117

TION/FILTERS/FLUIDS

ASHER VOIR (IF EQUIPPED)

1

1. WASHER RESERVOIR

The windshield washer reservoir is located on the side of the cab, as shown above. To add washer fluid, pull the cap up.

ANT: When the ambient °C (32°F)

, always use an antifreeze type

118

Maintenance/Adjustment

MAINTENANCE/ADJUSTMENT

PARKING BRAKE CHECK Check parking brake hand lever.

It should have a distinct over-center action.

Adjust the brake by turning the top of the handle, clockwise (with brake released) to obtain overcenter action. If handle adjustment is all takenup, loosen the handle all the way and adjust the lower linkage.

1

Remove the clevis pin (1) and turn yoke (3) clockwise several turns so that by lifting up on the lever (2) the hole in the clevis pin lines-up with the hole in the lever.

Install clevis pin and secure with cotter pin tighten jam nut and readjust handle.

1. PARKING BRAKE LINKAGE

ROLL-OVER PROTECTIVE STRUCTURE Your machine has a Roll -Over Protective Structure (ROPS). A ROPS label shows the serial number of the ROPS, gross weight, approval, regulation, and model numbers of the machine.

See Identification Numbers in this manual.

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

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

ROPS CANOPY LABEL

1. Keep the seat belts away from objects that can damage them.

4. Keep the seat belts clean. Wash the seat belts only in soap and water.

2. Check the seat belts for damage. Replace all parts that are damaged.

5. Do not put the seat belts in bleach or dye.

3. Make sure that the mounting bolts of the seat belts are tight. See Torque Specifications for Seat in this manual.

119

MAINTENANCE/ADJUSTMENT

Maintenance and Inspection of ROPS

Torque Specifications for ROPS Cab and ROPS

After the first 20 hours of operation and after every 500 hours of operation, do the following: 1. Check the torque of the ROPS mounting bolts.

If necessary, tighten the bolts to the correct torque. See torque specifications on this page.

2. Check the operators seat and the mounting parts for the seat belt. Tighten the bolts to the correct torque. See Torque Specifications in this manual. Replace parts that have wear or damage.

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

1

CANOPY 1. ROPS CAB AND ROPS CANOPY MOUNTING BOLTS (BOTH SIDES), TIGHTEN THE 16 BOLTS TO 772 TO 854Nm (570 to 630 lb.ft)

NOTE: Torque specifications are for clean, dry threads.

120

MAINTENANCE/ADJUSTMENT

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

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

See the Parts Catalog or your dealer for components that are replaceable.

IMPORTANT: DO NOT TRY TO WELD OR STRAIGHTEN THE ROPS.

After an accident, check the following for damage.

A. ROPS canopy or cab.

B. Operators seat.

C. Seat belt mounting bolts and seat belt.

!

WARNING: IMPROPER ROPS INSPECTION OR MAINTENANCE CAN CAUSE INJURY OR DEATH. DO THE RECOMMENDED ROPS INSPECTION SHOWN IN THIS MANUAL. IF YOU MUST REPLACE THE ROPS, ROPS PARTS, OR ROPS MOUNTING HARDWARE, USE ONLY THE REPLACEMENT PARTS SHOWN IN THE CASE PARTS CATALOG FOR THIS MACHINE

!

WARNING: DO NOT MODIFY ROPS IN ANY MANNER. UNAUTHORIZED MODIFICATIONS SUCH AS WELDING, DRILLING, CUTTING OR ADDING ATTACHMENTS CAN WEAKEN THE STRUCTURE AND REDUCE YOUR PROTECTION. REPLACE ROPS IF SUBJECTED TO ROLL-OVER OR DAMAGE. DO NOT ATTEMPT TO REPAIR.

!

WARNING: IF YOU OPERATE THIS MACHINE WITHOUT A ROPS AND THE MACHINE ROLLS OVER, YOU CAN BE INJURED OR KILLED. REMOVE THE ROPS ONLY FOR SERVICE OR REPLACEMENT. DO NOT OPERATE THIS MACHINE WITH THE ROPS REMOVED.

!

WARNING: ADDING ADDITIONAL WEIGHT (ATTACHMENTS, ETC.) TO THE MACHINE CAN CAUSE INJURY OR DEATH. DO NOT EXCEED THE GROSS WEIGHT PRINTED ON THE ROPS LABEL

!

WARNING: ALWAYS FASTEN THE SEAT BELT SECURELY BEFORE STARTING THE ENGINE

121

MAINTENANCE/ADJUSTMENT

TORQUE SPECIFICATIONS FOR SEAT AND SEAT BELTS

2

1

1. 73-87 Nm (54-64 lb.ft) 2. 54-61 Nm (40-45 lb.ft)

Operators Seat Remove dust and dirt from the seat with a vacuum cleaner or soft brush. Clean stains with the correct use of a 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.

CLEANER 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 knife that is not sharp. Use very little cleaner, no pressure, and clean cloths. Move the cloth from the outside of the stain toward the center of the stain and constantly change to a clean section of cloth.

When the stain is removed from the material, immediately use a cloth dry the area and to prevent a cleaner circle pattern. If a circle pattern occurs, clean the complete area.

NOTE: A difficult stain may need a second application of cleaner fluid followed immediately by the use of a soft brush to completely remove the stain.

!

WARNING: NEVER USE GASOLINE, NAPHTA OR ANY OTHER VOLATILE MATERIAL FOR ANY CLEANING PURPOSES. THESE MATERIALS MAY BE TOXIC AND/OR FLAMMABLE.

122

MAINTENANCE/ADJUSTMENT

Cab Headliner The foam headliner in your cab decreases noise.

To keep the headliner in good operating condition, remove dust with a vacuum cleaner.

IMPORTANT: DO NOT wash the headliner with water. Water can cause damage to the headliner and lower the noise control capacity of the headliner.

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

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

Doors Hinges Use graphite to lubricate all hinges.

DO NOT use oil.

Inspection and Care

Hoses and Wiring Check all hoses and wiring for damage.

If damage occurred, see your dealer for repair or replacement.

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

EVERY 6 MONTHS - Have the dry chemical removed and refilled by a fire equipment technician.

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

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

123

MAINTENANCE/ADJUSTMENT

ALTERNATOR BELT AND AIR CONDITIONING COMPRESSOR BELT Service Interval Belt service interval ................................................................................................ Check as required Air conditioning compressor belt service interval ........................................... Check every 250 hours 1. Park the machine on a level surface and apply the parking brake.

2. Turn the master disconnect to OFF. The belt tension is maintained by the action of a spiral tensioning spring.

NOTE: Check that the belts are not cracked or damaged. Replace if it is necessary.

Alternator Belt and Tensioner Remove the drive belt using a 1/2" square socket wrench handle, to release belt tension.

ENGINE DRIVE BELT 1. WATER PUMP PULLEY 2. CRANKSHAFT PULLEY 3. SQUARE HOLE OF 1/2" (13 MM) 4. BELT TENSIONER 5. ALTERNATOR

NOTE: Panels behind seat must be removed to access engines belt.

124

MAINTENANCE/ADJUSTMENT

Drive Belt and Tensioner Inspection

Circle Guides Check and Adjust The circle and circle guides must be kept clean to prevent caking. If the circle guides are excessively loose, the gear teeth will wear, causing the circle turn to function erratically.

Guide nuts Tightening torque: 110 kgf.m

Radial clearance max. 0.76mm

After removing, examine the belt for damage.

Drive Belt Tensioner

Blade

Shims

The drive belt tensioner pulley must rotate freely with no point showing resistance, locking up, etc., when turned by hand. Check belt tensioner bearing carefully also.

Lock nut

Reinstalling the Drive Belt Using a 1/2" socket wrench handle and the tensioner, install the belt carefully, observing that the multi-V’s ribs fit perfectly with the existing channels of the alternator pulley and vibration damper.

1

1. CIRCLE GUIDES

Wear Plate Adjustment Proceed as follows: The first adjustment is to eliminate play between the upper wear plates and the upper circle guides (vertical clearance).

To make this adjustment, shims between wear plates and the upper circle surface must be removed.

NOTE: Do not throwaway the shims that were removed. They can be used again in other new adjustment.

125

MAINTENANCE/ADJUSTMENT

Make sure that the maximum clearance does not exceed 1.52 mm. This adjustment must be completed on each of the four (4) guides, one at a time, beginning with one closest to the circle turn motor pinion gear.

1

After vertical adjustment rotate the circle 360° to be sure that the circle turns freely.

Next, adjust the clearance between the wear plates and the inner circle guides (radial clearance), proceeding as follows: CIRCLE TURN CLEARANCES 1. CIRCLE GUIDE PINION Shims

After adjustment of the front guide radial play, tighten lock nuts and perform rear guides radial adjustment to a maximum clearance 0,76 mm between the inner circle guides and the curved circle guide wear plates using the adjusting screws.

Circle upper surface Vertical clearance max 1.52mm Circle

Tighten the adjusting screw jam nuts and circle guide lock nuts. Rotate the circle 360° to be sure it turns freely.

Radial clearance min 0.76mm max 1.52mm

With the vertical clearance already adjusted, loosen the circle guide nuts and the jam nuts of radial clearance adjusting screws.

Should the circle not turn freely, perform the adjustment again, increasing clearance between tooth flanks. Do not exceed the upper limit.

Position the circle turn motor pinion in such a way that the tooth engagement is as shown below.

Make sure that the center of the circle turn motor pinion, center line of the engaged tooth and the front guide center locknut are aligned.

Drawbar DRAWBAR BALL NUT TORQUE CHECK

Put one flank of the pinion tooth in contact with one circle tooth. Turn adjusting screws of front guide as necessary to provide 0,76 mm between the opposite flanks of the circle and pinion tooth.

Guide Teeth clearance min 0.76mm max 1.52mm Guide

Check drawbar ball nut. Torque should be 732 to 895 N.m (540 to 660 lb.ft).

126

MAINTENANCE/ADJUSTMENT

HYDRAULIC DIAGNOSTIC PANEL CHECK

When hydraulic system pressure failures occurs, pressure specifications are as follow: 1. Hydraulic System *1 (193 ±4bar; 2800±50PSI)

1

2. Steering Hydraulic System*2 (140-145bar; 2030-2175PSI) 3. Brake Accumulators LH *1 (80-95bar; 1160-1380PSI) *3 (110-120bar; 1600-1750PSI) *4 4. Brake Accumulators RH *1 (80-95bar; 1160-1380PSI) *3 (110-120bar; 1600-1750PSI) *4

1. DIAGNOSTIC TEST PANEL

5. Brake System LE *1 (65 ± 3bar; 940±43PSI) 6. Brake System LD *1 (65 ± 3bar; 940±43PSI) 7. Blade Lift Cylinder RH *1 (100-115bar; 1450-1670PSI) 8. Blade Lift Cylinder LH *1 (100-115bar; 1450-1670PSI) NOTE:

127

*1 Engine speed 2200rpm *2 Engine speed 900rpm *3 Minimum accumulator pressure *4 Maximum accumulator pressure

MAINTENANCE/ADJUSTMENT

This page was left blank intentionally.

128

Electrical System ELECTRICAL SYSTEM

ELECTRICAL SYSTEM Battery Safety

!

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

!

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

!

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

WARNING: Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following:

1. When you disconnect the battery cables, always disconnect the negative (1) battery cable first.

!

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

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

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

129

ELECTRICAL SYSTEM

BATTERY SERVICE NOTE: The electrical system in this machine is 24 volts. Each battery is 12 volts.

Before you service components of the electrical system, always disconnect the NEGATIVE (-) battery cable.

Do not run the engine with the battery cables disconnected or with the alternator wires disconnected.

Before you use an electric welder, disconnect the alternator wires, instrument cluster, transmission electronic control unit and turn the master disconnect switch to OFF.

Cleaning the Batteries Check the batteries and battery compartment regularly for dirt, corrosion and damage. Dirt mixed with electrolyte or moisture on the top of the batteries can cause a discharged condition in the batteries. Use one of the following methods to clean the batteries.

1. Use Case Battery Saver, Part Number M20376. Follow the instructions on the container. This cleaner does not need water.

2. Use baking soda or ammonia and flush the outside of the batteries with water.

Do not use a steam cleaner or cleaning solvent to clean the alternator.

Battery Fluid Level The batteries are “Maintenance Free” type and electrolyte level check is not required. Do not leave lamps switched on for long intervals of time with the engine stopped or idling. Keep batteries clean, specially on its top surface.

Make sure of that cable terminals are correctly fixed on the battery poles. Always disconnect master switch before servicing batteries.

Battery Vents Keep the battery vents clean, make sure the vents are not restricted.

130

If you do not have Case Battery Saver, use other special cleaners to prevent corrosion on the battery terminals.

ELECTRICAL SYSTEM

TRANSMISSION AUXILIARY SYSTEM Limp-Home The Limp-HOME is an emergency function, used in event of failure of the transmission control module. If the immediate replacement of the module is not possible, this function allows the driving of the machine to the nearest repair shop.

The switch (8) on the instrument panel is a threeposition switch: forward, neutral and reverse. To enable the system, turn off the machine, apply the parking brake and put the switch in the neutral position.

Open the cover on the right hand side of the operator’s cab. This allows the access to two gray connectors and one black connector.

LIMP-HOME ACTIVATED

Close the side-cover, be sure the parking brake is applied, then start the engine.

NOTE: After releasing the parking brake, select the desired driving direction (forward - reverse) through the LIMP-HOME switch on the instrument panel.

Moving the LIMP-HOME switch to the “forward” position the system will select the second forward gear. Moving the LIMP-HOME switch to the “reverse” position, the system will select the first backup gear.

!

SIDE COVER

WARNING: THE INCHING PEDAL DOES NOT FUNCTION WHEN THE LIMP-HOME MODE IS ACTIVATED.

After repairs, reconnect the connectors to their former positions. Connect the connector 1 with connector 2 and connector 3 with connector 4.

Welding service If welding service should be performed on the machine, be sure to have the black connector, on the right hand-side of the operator’s cab, disconnected.

BLACK CONNECTOR LIMP-HOME NOT ACTIVATED

Disconnect the gray 1 and 2, 3 and 4 connectors.

Then connect the 2 and 3 connectors.

ATTENTION: Welding service without disconnecting the black connector may cause serious damage to the transmission control module.

131

ELECTRICAL SYSTEM

FUSE BOX The fuse box is located inside the right console.

To access the fuses for replacement or service of fuse box, open the front cover of the console.

Fuse and Relay List Fuse Box 1 F1 - Turn signal and hazard warning light fuse F2 - Dual power solenoid and power outlet fuse F3 - Dome lights and strobe lights fuse F4 - Head lights low beam fuse F5 - Horn fuse F6 - E.D.M (electronic data monitor) and buzzer fuse F7 - Transmission fuse F8 - Transmission fuse F9 - Transmission fuse F10 - Cab fan fuse F11 - Front wiper and washer fuse F12 - Solenoid valves auxiliary hydraulic fuse F13 - Rear work iight fuse F14 - Headlights high beam fuse F15 - Cold starting fuse F16 - Rear wiper and washer fuse

Fuse Box 2 F1 - Air conditioning fuse F2 - Air conditioning fuse (not used) F3 - Air conditioning fuse (not used) F4 - Recirculation air conditioning fuse F5 - Front wheel drive fuse F6 - Differential lock fuse F7 - Back-up alarm fuse F8 - Fuel shutoff solenoid fuse (hold solenoid) F9 - Brake light fuse F10 - Lower front wiper lower and washer fuse F11 - Cab light fuse F12 - Work light fuse (After blade) F13 - Work light fuse (before blade) F14 - Radio fuse F15 - Lift fuel Pump fuse (not used) F16 - Front attachment light fuse (opt.)

R1 - Safety fuel lift electric pump relay (not used) R2 - Safety fuel lift electric pump relay (not used) R3 - Auxiliary starter relay R4 - Headlights low beam relay R5 - Headlights high beam relay R6 - Rear work lights relay R7 - Horn relay R8 - Back-up alarm relay R9 - Cold Starting relay R10 - Differential lock relay R11 - Dual power solenoid relay R12 - Air conditioning blower fan relay R13 - Air conditioner heat fan relay R14 - Front attachment work light relay

132

ELECTRICAL SYSTEM

ELECTRONIC ENGINE - LOGIC Engine Protection System The engine protection system monitors temperatures and pressures and registers diagnostic failures whenever a abnormal operation condition occurs.

In this case, the engine power starts to decrease and the operator is warned by the stop indicator or warning indicator.

When this condition happens, the operator must stop and park the machine in order to prevent damage to the engine.

Stop by protection The engines stops automatically when one of the temperature, level or pressure sensors detect that the engine is operating in a below or above the normal operation conditions.

The stop indicator will flash for 30 seconds to warn the operator.

Inlet air heating The engine admission inlet air is heated when the engine is started in cold wheather conditions, resulting in better starting and reduction of white smoke.

The indicator light at the instrument panel indicate when starting of the engine is possible.

The ECM (Engine Control Module) determines the heating total time based on the inlet manifold temperature (pre-heating).

Once the engine is started, the air heater will be on until the inlet air temperature and cooling fluid temperature reach the required values.

The heater is switched off whenever one of the following situations occur: - Heating time exceeds 11 seconds; - The inlet manifold temperature is greater than 19°C.

Water in fuel detector sensor When there is water in the filter housing, the indicator light will flash, indicating that the water should be drained.

Troubleshooting codes Operation failures are identified by failure codes, that are registred and shown by the control system.

These failure codes are shown using the indication lights at the maintenance panel.

133

ELECTRICAL SYSTEM

NOTE: The failure codes do not cover all failures that an engine may have. There are 2 kinds of failure codes: The failures codes from the electronic fuel system and the engine protection failure codes.

Maintenance panel The maintenance panel indicates the operator when a maintenance operation is necessary (like engine oil change interval).

NOTE: Probelms with the VSS (Vehicle Speed Sensor) or with the batteries may influence the data shown by the maintenance panel.

Indication lights

[A] - Warning light: (yellow) Indicates a problem that may be verified by the operator. Does not require imediate stop of the machine.

[B] - Stop light: (red) Indicates a serious problem with the engine. Requires imediate stop of the machine.

[C] - Maintenance light: Indicates that an engine maintenance operation must be performed. The system monitors the distance and time that the machine has been used.

[D] - Start light: The operator must wait until this light turns off to start the machine.

[E] - Water in fuel light: This light indicates that water must be drained from the fuel filter.

[F] - Low pressure light: This light indicates that the pressure of the diesel is low. Water must be drained from the fuel filter.

134

ELECTRICAL SYSTEM

Work/Diagnosis switch Work position Security lock

Diagnosis position

Increase/Decrease switch Increase speed / next code

Decrease speed / previous code

[G] - Work/Diagnosis switch: The work position is used when the engine is running OK, without any problems. The diagnosis position is used to read the error codes when a problem with the engine occurs.

[H] - Increase/Decrease switch: This switch has 2 functions, depending on the position of the work/ diagnosis switch.

When the work/diagnosis switch is on the work position, this switch is used to increase or decrease the engine speed by 20 rpm.

When the work/diagnosis switch is on the diagnosis position, this switch is used to read the next error code that is registred by the system.

135

ELECTRICAL SYSTEM

Indicator lights illumination logic and error codes When the master key of the machine is ON, and the ignition switch is either on position OFF or ACC, no indicator light must flash, and the buzzer mut not emit any sound, regardless of the position ot the work/diagnosis switch.

When the master key of the machine is ON, and the ignition switch is on position IGN, the indication lights A, B, C, D and E will lit, the buzzer will sound (2 to 4 times) and then the checup procedure will start. Each of the indication lights will go out with a sound from the buzzer, beggining with light A, the B, C, D , E. Light F is kept lit and the buzzer continues to sound. (the work/diagnosis switch must be on the work position) When the master key of the machine is ON, and the ignition switch is on position ST (start), the chekup procedure is finished and all lights are off. The engine will be ready to start. (the work/diagnosis switch must be on the work position) NOTE: If the indication lights A or B goes on (lit), the engine must be shut off immediately. These lights indicate a problem with the engine and the error codes must be verified.

Error codes interpretation Turn off the ignition switch and turn on again, without starting the engine.

Unlock the security lock and place the Work/Diagnosis switch on position Diagnosis (down).

The indication lights A and B start to indicate the error codes through a flashing pattern as described below. When there are more than one error code, the codes can be read using the Increase/Decrease switch.

Seriousness

Error code example: Yellow indication: Not serious error

1 flash

Pause

1st Digit 1st digit reading: (3 flashes) 3 flashes

136

3

ELECTRICAL SYSTEM

Pause

2nd Digit 2nd digit reading: (6 flashes)

6

3rd digit reading: (3 flashes)

3

6 flashes

Pause

3rd Digit

3 flashes

Repeat seriousness

When the seriusness light flashes again, the indication of the error code is finished.

For this example, the error code is

1 flash

137

363.

ELECTRICAL SYSTEM

Code / Lamp

Reason

Effect (when fault code is active)

115 yellow

No engine speed or position signal detectedt at pin number 17 of the engine harness

122 Yellow

Higth voltage detected at boost pressure sensor signal pin Engine will derate to no-boost fueling number 45 of the engine harness

123 Yellow

Low voltage detected at boost pressure sensor signal pin number 45 of the engine harness

131 Yellow

itch indicates idlea and ramps up High voltage detected a throttle position signal pin number Etongaindeefiaduleltssveat lisdpaetieodn wsw hen the idle validation switch 30 of the OEM harness indicates off-idle

132 Yellow

Low voltage detected at throttle position signal pin number Engine idles when idle validation switch indicates idle and ramps up to a default set speed when idle validation switch 30 of the OEM harness indicates off-idle

135 Yellow

High voltage detected at oil presure signal pin number 33 of the engine harness

141 Yellow

Low voltage detected at oil pressure signal pin number 33 Default value used for oil pressure no engine protection for of the engine harness oil pressure

143 Yellow

Oil pressure signal indicates oil pressure below the low minimum engine protection limit

Power derate and possible engine shutdown if engine protection shutdown feature enabled

144 Yellow

High voltage detected at coolant temperature signal pin number 23 of the engine harness

Default value used coolant temperature. No engine protection for coolant temperature.

145 Yellow

Low voltage detected at coolant temperature signal pin number 23 of the engine harness

Default value used for coolant temperature. No engine protection for coolant

146 Yellow

Coolant Temperatue signal indicates coolant temperature has exceeded the minimum engine protection limit

Power derate and possible engine shutdown if engine protection shutdown feature is enabled

147 Yellow

A frequency below a calibrated value has been detectedat Engine will not respond to changes in frequency trhottle. the frequency thrttle signal pin number 4 of the engine Engine will go to low idle harness

148 Yellow

A frequency a bove a calibrated value has been detected ah the frequency value

Engine will not responde to chenges in frequency thtotle.

Engine will go to idle

151 Red

Coolant temperature signal indicates coolant temperature has exceed the maximum engine protection limit

Speed derate and possible engine shutdown if engine protection shutdown feature is enabled

153 Yellow

High voltage detected at intake manifold temperature signal pin number 34 of the engine harness

Default value used for intake manifold temperature .No engine protection for intake manifold temperature.

154 Yellow

Low voltage detected at intake manifold temperature signal pin number 34 at the engine harness

Default value used for intake manifold temperatute .

No engine protection for intake manifold temperature

155 Yellow

Intake manifold temperature signal indicates intake manifold temperature is above the maximum engine protection limit

Speed derate and possible engine shutdown if engine protection shutdown feature

184 Yellow

Error detected in multi Unit Syncronization

Engines will default to idle speed

234 Red

Engine speed signal indicates engine speed has exceeded the overspeed limit.

Fuel to injectors disabled until engine speed falls below the overs

235 Red

Coolant level signal at pin number 37 of the engine harness indicates coolant level is low

Power derate and possible engine shutdown if engine shutdown feature is enabled

241 yellow

Vehicle speed signal on pin numbers 8 and 18 of the OEM harness has been lost

Engine spped limited to max Engine speed without VSS Cruise control, gear down protection and the road speed governor will not work . Trip information data that is based on milsage wiil be oincorrect.

138

Engine power derate. Possible white smoke

Engine will derate to no-boost fueling

Default value used for oil pressure. No engine protection for oil pressure

ELECTRICAL SYSTEM

242 Yellow

ngine speed limited to MAX . Engine spped without VSS. Invalid or inapropriate vehicle spped signal indicated on E Cruise control, gear -down protectionand the road speed pins number 8 and 18 of the OEM harness indicating an governor will not work. Trip information data that is based intermitent connection or possible tampering on mileage will be incorrect

261 Yellow

VP44 Fuel pump Control Module indicates the fuel temperatute has exceeded the pump protection limit

Power derate

264 Yellow

High or low voltage detected at the fuel temperature sensor signal circuit inside the VP44 pump controller

Default value used for fuel temperature . Possible low power

278 Yellow

Error detected in lift pump circuit at pin number 11 of the engine harness

Possible low power, engine may die, run rougth or be difficult to start

283 Yellow

Higth voltage detected at main engine speed / position ECM will use VP44 fuel pump speed or the engine position sensor voltage supply pin number 8 of the engine harness signal as a backup. Possible white smoke and power loss

284 Yellow

ECM will use the VP44 fuel pump speed or the engine Low voltage detected at main engine speed/position sensor voltage supply pin number 8 of the engine harness paonsditpioonwseirgnloaslsa. s a back up. Possible white smoke a

319 Maint

Power to the real time clock has been interrupted and its setting is no longer valid.

349 Yellow

The auxiliary speed frequency on pin number 8 and 18 of Engine will go to idle and lose ability to control the speed the OEM harness is above a calibrated threshold. of the ayxiliary device

361 Red

High current detected at the VP44 fuel pump control valve Fduoewlnling to the injectors is disabled and engine is shut

362 Yellow

Low or no voltage detected at the VP44 fuel pump control Engine will lose power and may shut down valve

363 Yellow

No fuel control valve moviment detected by the VP44 fuel pump controller

364 Yellow

No communications or invalid data transfer rate detected Engine will run at a backup mode set speed when throttle on data link between ECM and VP44 fuel pump controller is off-idle at pins 4 and 13 of the engine harness

365 yellow

Low voltage detect at the VP44 fuel pump controller supply voltage circuit

366 yellow

VP44 fuel pump conbtroller battery voltag e measurement Engine will lose power and may shut down is outside the range between 6 and 24 volts

367 Yellow

VP44 fuel pump spedd/ possition sensor signal lost.

Fueling to the injectors is disabled and engine will shutdown

368 Yellow

The VP44 fuel pump controller cannot achleve the timing value being commanded by the engine ECM

Significant engine power loss.

369 Yellow

VP44 fuel pump controller does not detect engine position Significant engine power loss. Possible white smoke pulse at pin 7 of engine harness

372 Yellow

VP44 fuel pump controller detecs continous voltage at idle If communication is lost between the ECM and the VP44 select pin 16 of the engine harnness...OR... fuel pump controller detects an open circuit or short circuit to ground sfulieglhptlyumhpigchoenrtrtohlalenr,idelneg, irneegawridllnoenslsy oofptehrraotteleapt oasistipoened at idle select pin 16 of the engine harness

373 Red

Higth voltage detect at the VP 44 fuel shut off signal pin 6 Fuelling to injectors is disabled and engine will shut down of the engine harness

374 Yellow

VP44 fuel pump controller has detects an internal eroor

Response wll vary from some power loss to the engine shutting down

375 Yellow

Engine ECM is comma nding a fuelling or timming value that the VP44 fuel pump cannot achieve

Possible no effect or engine may exhibit some power loss

376 Red

No calibration in the VP44 fuel pump

Fuelling to the injectors is disabled and engine will shut down

377 Yellow

VP44 fuel pump controller is not powering down when key Equipment batteries may be drained low during long shut switch power is remover from the engine control module down periods

139

Time stamp in ECM powerdown data will be incorrected

Engine power loss

Engine may lose power and may shut down

ELECTRICAL SYSTEM

381 Yellow

Error detected in cold start aid relay 2 enable circuit at pin number 31 of the OEM harness

Intake air cannot be fully energized by the ECM. Possible white smoke and/or hard starting

382 Yellow

Error detected in cold start aird relay 2 enable circuit at pin number 31 of the OEM harness

Intake air heater cannot be fully energized by the ECM Possible white smoke and/ or hard starting

387 Yellow

High voltage detected at throttle position sensor +5 VDC supply pin number 29 of the OEM harness

Engine idles when idle validation switch indicates idle and ramps up to default set speed when idle validation switch indicates off idle

391 yellow

Error detected in VP44 power suplly relay enable circuit at pin 43 of engine harness

Possible no effects on performance or engine may not run

415 Yellow

Oil pressure signal indicates oil pressure below the very low engine protection limit.

Speed derate and possible engine shutdown if engine protection shutdown feature enable

418 Yellow

Water in fuel signal indicates the water in the fuel filter needs to be drained

Excessive water in the fuel can lead to severate fuel system damage

422 yellow

Voltage detected simultaneously on both the coolant level high and low signal pin numbers 27 and 37 of the engine harness....OR....no voltage detected on either pin(F ault is No engine protection for coolant level active for switch type coolant level sensors only)

429 Yellow

Low voltage delected at water -in-fuel signal pin number 40 of the OEM harness

431

Idle validation signals on pin number 25 and 26 of the OEM harness indicate voltage detected simultaneously on No effect on performance, but loss of idle validation both pins (Open Circuit)

432 Yellow

Idle validation signla at pin 26 of the OEM harness indicates the throttle is at the idle position when the throttle position signal at pin 30 of the OEM harness indicates the throttle is not at the idle validation signal at pin number 26 of the OEM harness indicates the throtlle position signal at pin number 30 of the OEM harness indicates the throtlle is at the idle position.

Engine will only idle

433 Yellow

Boost presure signal indicates boost pressure is high when other engine parameters (i.e. speed and load) indicate boost pressure should

Possible overfuelling during acceleration. Increase in black smoke

434 Yellow

Supply voltage to the ECM fell bellow 6.0 volts for a fracttion of a second ....OR....the ECM was not allowed to power down correctly ( retain battery voltagde for 30 seconds after key OFF)

Possible no noticeable performance effects....or....engine dying or hard starting.Fault information, trip information, maintenance monitor data,trending data, and user activated datalogger data may be inaccurate.

441 Yellow

Voltage detected at ECM power supply pin numbers 38,39 and 40 of the engine harness indicates ECM supply Engine will die or run rough voltage is above the maximum system voltage level

442 Yellow

Voltage deleted at ECM power supply pin numbers 38,39 and 40 of the engine harness indicates ECM supply voltage is above the maximum system voltage level.

none on perforamnce

443 Yellow

Low voltage detected at throttle position sensor +5 VDC supply pin number 29 of the OEM harness

Engine idles when idle validation switch indicates idle ramps up to a default set speed when idle validation switch indicates off-idle

488 Yellow

Intake manifold temperature signal indicates intake manifold temperature is above the minimum engine protection threshold

Power derate and possible engine shutdown if engine protection shutdown feature is inabled.

489 Yellow

The auxiliary speed signal frequency on pin number 8 and ill go to idle and lose ability to control the speed 18 of the OEM harness indicates the frequency is bellow a Eofngthineeaw uxiliary device calibrated threshold value.

515 Yellow

High voltagedetected at the coolant level +5VDC Sensor supply voltage pin number 49 of the engine harness

No engine protection for coolant level

516 Yellow

Low voltage detected at the coolant level + 5VDC sensor suply voltage pin number 49 of the engine harness

No engine protection for coolant level

140

No water -in-fuel detection

ELECTRICAL SYSTEM

517 Yellow

A mechanically stuck fuel control valve has been detected Engine may be shutdown by the vp 44 fuel pump controller

528 Yellow

Error detected on the Torque curve selection switch input pin number 39 of the OEM harness

Operator cannot select alternate torque curves Normal torque curve is used

551 Yellow

Idle validation signals on pin number 25 and 26 of the OEM harness indicate no voltage detected on either pin

Engine will only idle

599 Red

611

The dual output feature is a customer specialized calibration and it has initiated an engine shutdown based on the customers specified operating conditions, engine engine will shutdown sensor value and or OEM inputs value and or oem inputs to the ECM ECM detected the engine has initiated a protection shutdown or has been keyed -off while above a specified No effect load limit

141

ELECTRICAL SYSTEM

142

Machine Storage MACHINE STORAGE

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

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

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

10. Drain the cooling system. Leave the drain open and do not tighten the radiator cap. Put a Do Not Operate tag in the cab.

1. Wash the machine.

11. Clean or replace the primary air filter element.

2. Lubricate the machine at all grease fittings.

12. Cover the exposed steering cylinder rods and equipment valve spools with Case Rust and Corrosion Preventative (Part Number B17510).

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

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

5. Drain the fuel tank.

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

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

Make sure the batteries are clean.

7. Drain the flushing oil from the fuel tank.

143

MACHINE STORAGE

Removal from Storage Do not start the engine until steps 1 through 10 have been done.

1. Change the fuel filter.

2. Put coolant in the engine cooling system.

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

4. Check the engine oil level.

5. Check the hydraulic oil level.

6. Check the transmission oil level.

7. Check the oil level of both axles.

8. Lubricate the machine at all grease fittings.

9. Use petroleum base solvent and remove the Case Rust and Corrosion Preventive from the hydraulic cylinder rods.

10. See Battery Service in this manual and install the batteries.

11. Fill the fuel tank.

12. Prime the turbocharger with clean engine oil.

See your Service Manual or your dealer.

13. Start the engine. It is important that you use the Starting the Engine procedure in this manual for priming the turbocharger lines with oil.

144

Specification SPECIFICATION

SPECIFICATIONS ENGINE Model ................................................................................................................... Cummins QSB 5.9 Diesel, 4 stroke,direct injection, turbocharged and emissions compliant.

No. of cylinders ........................................................................................................................ 6 (six) Displacement .................................................................................................................... 5.880 cm3 Bore and stroke: .......................................................................................................... 102 x 120 mm Power: (SAE J 1995) Gross ............................................................... 183 HP(136 kW) @ 2200 rpm Power: (SAE J 1995) Net ................................................................... 170 HP(126 kW) @ 2200 rpm Torque, max. (net) ............................................................................................ 862 Nm @ 1500 rpm TRANSMISSION Type ......................................................... Direct drive, by countershaft, power shift, with electronic gear change control and inching pedal.

Pump flow at 2.200 rpm ........................................................................................................ 91 l/min Oil sump ................................................................................................................................. integral Gears .......................................................................................................... 8 forward and 4 reverse Ground speed control ........................................... Electronic auto control, “bump” type single lever Diagnosis system ................................................................................................................ on board Speeds - km/h(mph) Forward 1st ......................................................................................................................................... 3,6(2,2) 2nd ........................................................................................................................................ 5,1(3,2) 3rd ......................................................................................................................................... 7,2(4,4) 4th ....................................................................................................................................... 10,0(6,2) 5th ....................................................................................................................................... 14,3(8,9) 6th ..................................................................................................................................... 20,0(12,4) 7th ..................................................................................................................................... 28,5(17,7) 8th ..................................................................................................................................... 42,9(26,6) Speeds - km/h(mph) Reverse 1st ......................................................................................................................................... 3,6(2,2) 2nd ........................................................................................................................................ 7,2(4,4) 3rd ....................................................................................................................................... 14,3(8,9) 4th ..................................................................................................................................... 28,5(17,7) STEERING Front wheels: Type ........................................................................................................................... servo assisted Wheel turn angle ............................................................................................. 48o to the left or right Steering cylinders .................................................................................................................. 2 (two) Bore and stroke ....................................................................................................... 63,2 x 266,7 mm 145

SPECIFICATION

Articulated frame Hydraulically controlled articulation Articulation angle (RH and LH) ................................................................................................... 250 Cylinders ................................................................................................................................ 2 (two) Bore and stroke ............................................................................................................. 80 x 377 mm Turning radius, min. ............................................................................................. 7.250 mm (23,7 ft) TIRES 13.00 X 24 - 12 PR ........................................................................................................ STANDARD 14,00 X 24 - 10 PR ; 14,00 X 24 - 12 PR ; 17,50 X 25 - 12 PR ...................................... OPTIONAL FLUID CAPACITIES (Liters) Fuel tank ................................................................................................................................. 340,0 l Coolant (Total) ................................................................................................... 10.5 US gal (40,0 l) Crankcase (with filter) ......................................................................................... 4.3 US gal (16,4 l ) Transmission ........................................................................................................ 6.6 US gal (25,0 l) Tandem(each) (DANA axle) ................................................................................. 5.9 US gal (22,7 l) Tandem(each) (Graziano axle) ................................................................................. 7 US gal (29,0 l Hydraulic system and reservoir ........................................................................... 5.9 US gal (180,0 l) Rear axle (STD Graziano) ...................................................................................... 7 US gal (29,0 l) Rear axle (DANA OPT) ........................................................................................ 3.2 US gal (12,0 l) Circle swing reduction ............................................................................................ 0.7 US gal (2,8 l) ELECTRICAL SYSTEM Voltage ............................................................................................................... 24 volts, 2 batteries Battery rating ................................................................................................................... (20h)100Ah Alternator .................................................................................................................................... 45A BRAKES Service: Multiple wet disc, self-adjusting, hydraulically engaged, 2 independent circuits for each side.

Safety: Service brake supply by two nitrogene accumulatores, one for each circuit, automatically engaged in the event of a system pressure drop.

Parking: Mechanical, disc type acting through the transmission.

TANDEM COMPARTMENT Rectangular section, welded, using 19.0 (0.7 in) mm and 16.0 mm thick plates.

Interchangeable shafts and gears, assembled on taper bearings.

Chain pitch ................................................................................................................. 50,8 mm (2 in) Tandem oscillation either way ...................................................................................................... 200

146

SPECIFICATION

FRONT AXLE Housing built from high strength steel weldment, with 19° oscillation up or down.

Lateral wheel angle of 17° 30' to the right or to the left, hydraulically actuated.

Ground clearance ................................................................................................................ 640 mm REAR AXLE ( GRAZIANO - STD ) Cast iron housing for severy applications. Axle built from heat treated seteel, mounted on taper bearings.

Ground clearance ..................................................................................................... 370 mm(15,67") Differential ................................................................................................................. Super Max Trac REAR AXLE ( DANA - OPC ) Cast iron housing for severy applications. Axle builtfrom heat treated seteel, mounted on taper bearings.

Ground clearance ..................................................................................................... 398 mm(15,67") OPERATING WEIGHTS With all fluids, including radiator coolant, hydraulic oil, full fuel tank and operator«s weight.

Over front axle ................................................................................................... 9874 lbs (4.470 Kg) Over rear axle ................................................................................................ 24413 lbs (10.620 Kg) Total ............................................................................................................... 33267 lbs (15.090 Kg) Machine similar its predecessor, fitted with ROPS cab, side shift and blade tilt, rear tow hook and front ripper.

Over front axle ................................................................................................ 11089 lbs ( 5.030 Kg) Over rear axle ................................................................................................ 23501 lbs (10.660 Kg) Total ............................................................................................................... 34590 lbs (15.690 Kg) DRAW BAR Built from welded “A” shaped box section, with circle swing hydraulic motor mounted at the center.

Connection by means of a ball joint adjusted with spacers.

FRAME Built from welded box section.

Front: Section ......................................................................................................................... 254 x 298 mm Weight per lineal meter ...................................................................................................... 153 Kg/m Rear (each end) : Section ........................................................................................................................ 121 x 298 mm Weight per lineal meter .......................................................................................................... 75 kg/m

147

SPECIFICATION

CIRCLE Built from one-piece steel forging, “T” cross section ..................................................................................... 177 x168 x 38mm.

Outside diameter ............................................................................................................... 1.753 mm Turning angle .......................................................................................................... 3600 continuous Supported on 4 guides with interchangeable phenolic resin inserts.

Guide contact area ............................................................................................................ 2.845 cm2 Oil bath circle swing gears.

BLADE Build from one-piece hot stamped carbon steel. Unique “Roll Away” surround profile.

Replaceable bits and cutting edge.

Hydraulic controls for side shift and blade tilt.

Available sizes: (12ft) 3,658x622x22mm ...................................................................................................... standard (13ft) 3,960x671x22mm ........................................................................................................ optional (14ft) 4.267x671x22mm ........................................................................................................ optional Maximum raise height from ground ..................................................................................... 435 mm Maximum slope angle to either side ........................................................................................... 900 Hydraulically adjustable blade pitch ........................................................... 40° forward, 5° roll-back BLADE REACH (MEASURED OUTSIDE TIRES), NON-ARTICULATED FRAME With circle displacement only Right side .................................................................................................................. 33 in (847 mm) Left side ................................................................................................................. 32.8 in (834 mm) With blade displacement only Right side ................................................................................................................ 48 in (1221 mm) Left side .................................................................................................................. 45 in (1145 mm) With circle and blade displacement Right side ............................................................................................................. 58.8 in (1494 mm) Left side ............................................................................................................... 55.3 in (1405 mm) With circle, blade displacement and saddle rotatated in hole number one Right side ............................................................................................................. 71.5 in (1817 mm) Left side ................................................................................................................ 60.5 in (60.5 mm) BLADE REACH (MEASURED OUTSIDE TIRES), ARTICULATED FRAME With machine articulated a full 250 to the right and tothe left, add 684 mm for all above dimensions.

3-hole saddle .... tire 13x24 ................................................................................................ blade12 ft 5-hole saddle .. tire14x24 ................................................................................................... blade12 ft 148

SPECIFICATION

HYDRAULIC SYSTEM Full hydraulic control, supplied by a “Load Sensing” type gear pump. Closed center circuits. Blade raise cylinders mounted over the saddle. Saddle lock system by a hydraulic cylinder controlled by a solenoid valve activated by a switch located on the side console. Relief and check valves for all controls.

Maximum flow Implements ......................................................................................................... (51 gpm) 193 l/min Steering / brakes ................................................................................................................ 37,0 l/min Maximum pressure Implements .................................................................................................................... 197 Kg/cm2 Brakes .............................................................................................................................. 65 Kg/cm2 ACCESSORIES SCARIFIER Parallelogram type, front mounted Weight (5 teeth) ..................................................................................................... 1428 lbs (648 Kg) Weight (11 teeth) ................................................................................................... 1521 lbs (690 Kg) Width ....................................................................................................................... 46 in (1.168mm) Number of teeth ..................................................................................................................... 5 ou 11 TMaximum raise height from the ground .................................................................... 21 in (527mm) Maximum ground penetration ................................................................................. 12,5 in (318mm) Overall machine length with scarifier .................................................................... 372 in (9.452 mm) REAR RIPPER Type ..................................................................................................... parallelogram, rear mounted Weight .................................................................................................................................... 617 Kg Number of teeth .............................................................................................................................. 5 Tooth spacing ......................................................................................................... 20.8 in (530 mm) Width ....................................................................................................................... 88 in (2337 mm) Maximum raise height from ground ........................................................................ 22.9 in (582 mm) Maximum ground penetration ................................................................................ 13.7 in (350 mm) Machine length with rear ripper fully retracted ...................................................... 377 in (9576 mm) FRONT BLADE Weight ..................................................................................................................... 2.56 lbs(165 Kg) Dimensions .............................................................................................................. 2.762 x 953 mm Maximum penetration .............................................................................................. 6.4 in (165 mm) Machine length with front blade fully retracted ................................................................... 9.404mm

149

SPECIFICATION

D

A B C

OPERATING DATA AND DIMENSIONS A. Wheel tread ........................................................................................................... 7 ft (2134 mm) B. Outside edges of tires .................................................................................... 8 ft 3 in (2510 mm) C. Blade width ......................................................................................... 12 ft (3658 mm) (standard) 13 ft (3962 mm) (optional) 14 ft (4267 mm) (optional) D. ROPS overall height (high profile cab) .................................................... 10 ft 11,5 in (3340 mm) ROPS overall height (low profile cab) ........................................................... 10 ft 4 in (3140 mm)

150

SPECIFICATION

N

M

L

J

K

I H

O

E F G

R

E. F. G. H. I. J. K. L. M. N. O. P. Q. R. -

P

Q

Tandem center to rear end of machine ........................................................... 5 ft 5 in (1650 mm) Distance from front axle and rear end of machine ..................................... 25 ft 10 in (7869 mm) Overall length ...................................................................................................... 28 ft (8534 mm) Rear axle to rear wheels .................................................................................. 2 ft 7 in (797 mm) Tandem wheelbase ........................................................................................ 5 ft 2 in (1594 mm) Center articulation to rear axle ....................................................................... 6 ft 5 in (1958 mm) Front axle to moldboard blade (blade base) ................................................... 8 ft 5 in (2562 mm) Tire radius ................................................................................................................ 2 ft (610 mm) Lift cylinder height ............................................................................................... 10 ft (3047 mm) Height to top of exhaust pipe ................................................................... 10 ft 10.8 in (3323 mm) Wheel base .................................................................................................. 20 ft 5 in (6219 mm) Distance between rear tires and rear ripper ................................................... 6 ft 8 in (2028 mm) Distance between front tires and front scarifier .............................................. 5 ft 0 in (1520 mm) Distance between front tires and front dozer blade ........................................ 5 ft 4 in (1620 mm) Outside tire turning radius ............................................................................ 23 ft 9 in (7250 mm) Ground clearance (rear axle) ............................................................................ 14.9 in (380 mm) Ground clearance (front axle) ............................................................................ 24.5 in (622 mm)

151

SPECIFICATION

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152

Alphabetical Index ALPHABETICAL INDEX

A Access Doors ............................................... 87 Accessories ............................................... 141 Adding Air to the Tires ................................. 73 Additional Safety Rules ............................... 15 Adjusting Engine Valves ............................ 108 Adjustment Circle Guides ......................................... 125 After Delivery Check ............................ 4, 149 Air Conditioner ............................................. 47 Refrigerant Charge .................................. 48 Switch ...................................................... 44 Air Filter System ........................................ 100 Air Recirculation Switch ............................... 44 Alternator and Air Conditioning Belt .......... 124 Articulation, Hydraulic Cylinders and Pivot Joints .......................................... 91 Auxiliary Electrical Current Receptacle ....... 46

B Bank or Back Sloping .................................. 62 Battery Fluid Level ............................................. 130 Safety .................................................... 129 Service ................................................... 130 Vents ...................................................... 130 Before Operation ......................................... 12 Before Starting the Engine .......................... 55 Before you Service ...................................... 77 Belt and Tensioner ..................................... 124 Blower Fan Speed Switch ........................... 45 Booster Battery Connections ....................... 59 Brake System ............................................ 109 Oil Change ............................................. 111 Brakes ........................................................ 137 Burn Prevention ........................................... 17

C Cab .............................................................. 52 Cab Headliner ............................................ 123 Cab Heat Control ......................................... 45 Center of Gravity Position .......................... 144 Changing Engine Speeds ............................ 60

Changing the Fuel Filters .......................... 107 Checking Circle Turn Gear Box Oil ........... 116 Circle Guides Check and Adjustment ........................... 125 Circle Turn Clearances .............................. 126 Cleaning Air Filter Element ........................ 100 Cleaning Filter Suction Line ...................... 110 Cleaning the Batteries ............................... 130 Cold Start Switch ......................................... 43 Cold Weather Precautions ........................... 65 Console Tilt Pedal ........................................ 40 Cooling System .......................................... 102 Draining and Flushing ............................ 103 Radiator Cleaning .................................. 103 Cutting a “V” Ditch ....................................... 67

D Damage to the ROPS ................................ 121 Diesel Fuel System .................................... 105 Differential Lock Switch ............................... 39 Diffusers ....................................................... 53 Ditch Cutting on Flat Plain ........................... 67 Dome Light .................................................. 53 Doors Hinges ............................................. 123 Draining and Flushing the Cooling System 103 Drawbar ..................................................... 141 Drawbar Ball and Socket ............................. 91 Drawbar Ball Nut Torque Check ................ 126 Drive Belt and Tensioner Inspection .......... 125

E Electrical System ............................. 129, 138 Electronic Monitor ........................................ 37 Engine Coolant Temperature gauge .................... 45 Cooling System ..................................... 102 Crankcase ............................................... 88 Dual Power ............................................ 136 Filter Replacement................................... 98 Fuel Filter ................................................. 90 Hood ........................................................ 81 Lubrication ............................................... 96 Oil Change ............................................... 98 Oil Level ................................................... 98 153

ALPHABETICAL INDEX

Oil Pressure Gauge ................................. 45 Oil Selection ............................................ 96 Standard ................................................ 135 Valves Adjustment ................................. 108 Error Code Display ...................................... 39 Explosion Prevention ................................... 18

F Fire Extinguisher ................................ 18, 123 First Service Intervals .................................. 57 Floodlights ................................................... 36 Fluid Levels .................................................. 88 Fluids and Lubricants .................................. 83 Front Axle ................................................... 137 Front Axle Spindle Pivot .............................. 94 Front Blade Float Switch ............................. 43 Front Console .............................................. 34 Front Floodlight Switch ................................ 44 Front Wheel Bearings .................................................. 95 Knuckle .................................................... 93 Lean Cylinder .......................................... 93 Front Windshield Washer Switch ................. 44 Front Windshield Wiper Switch ................... 44 Fuel Conditioner ........................................ 105 Fuel Filters ................................................... 90 Change .................................................. 107 Fuel Injector Nozzles ................................. 108 Fuel Level Indicator Gauge ......................... 45 Fuel Storage .............................................. 106 Fuel System ............................................... 105 Fuel Tank Drain Cock ................................ 107 Fuse Box ............................................ 41, 132

G Gauge Panel ................................................ 45 Gauges Engine Coolant Temperature ................... 45 Fuel Level Indicator ................................. 45 Transmission Oil Pressure ....................... 46 Gear and Error Code Display ...................... 39 General Safety before you service .............. 77 Grease Fittings ............................................ 91

H Hand Signals ............................................... 30 Headlights .................................................... 36 Heat Control ................................................. 45 Horn ............................................................. 36 Hoses and Wiring ...................................... 123 Hourmeter ............................................ 37, 78 Hydraulic Diagnostic Panel ........................ 127 Hydraulic System ............................. 109, 141 Oil Change ............................................. 111 Hydraulic Tank ............................................. 90

I Identification Numbers ................................... 5 Ignition Switch .............................................. 46 Implement Control Levers Feft Side .................................................. 34 Right Side ................................................ 34 Indicators Air Filter Restriction ................................. 39 Hydraulic Oil Filter Restriction ................. 39 Instrument Panel ..................................... 38 Transmission Oil Filter Restriction ........... 39 Warning Flasher ...................................... 39 Inspection of ROPS ................................... 120

L Lean Cylinder ............................................... 93 Levers Articulation ............................................... 34 Blade Lift .......................................... 34, 35 Blade Pitch .............................................. 34 Blade Side Shift ....................................... 34 Circle Side Shift ....................................... 34 Circle Turn ............................................... 34 Front Scarifier, Blade or Ripper ............... 34 Front Wheel Lean .................................... 35 Parking Brake .......................................... 52 Throttle Control ........................................ 41 Lift Cylinders Balls ....................................... 91 Limp-Home Switch ....................................... 44 List Fuse and Relay ..................................... 132

154

ALPHABETICAL INDEX

M

R

Machine Components .................................... 7 Machine Operation ...................................... 13 Maintenance ........................................ 19, 82 Air Conditioner ......................................... 47 Maintenance of ROPS ............................... 120 Master Switch .............................................. 46 Moldboard Antishock Function Switch ....................... 43 Float Switch ............................................. 43 Lift Cylinders Balls ................................... 91 Lift Cylinders Pivots ................................. 92 Reach .................................................... 140 Side Shift Link Ends ................................ 92 Tilt Cylinder Pivot ..................................... 92 Tilt Cylinders Balls ................................... 91 Tilt Pivot ................................................... 92 Monitor ......................................................... 37

Neutral Lock ................................................. 42

Radiator ....................................................... 88 Radiator Cleaning ...................................... 103 Read Operators Manual .............................. 21 Rear Axle .......................................... 114, 137 End Compartment Oil Level .................. 115 Oil Change ............................................. 114 Rear Floodlight Switch ................................. 44 Rear Ripper Pivots and Cylinder ................. 95 Rear Window Washer Switch ...................... 44 Rear Window Wiper Switch ......................... 44 Removal from Storage ............................... 134 Ripper / Scarifier Switch .............................. 43 Road Bed ..................................................... 69 Roll-Over Protective Structure ............ 20, 119 ROPS Damage ................................................. 121 Maintenance and Inspection .................. 120 ROPS Cab and ROPS Torque Specifications ............................ 120 Run-in .......................................................... 58

O

S

Oil Viscosity and Temperature Ranges ....... 97 Operating Data and Dimensions ............... 142 Operating in Hot Weather ............................ 65 Operating Instructions ................................. 60 Operating Tips ............................................. 66 Operator Manual Storage Compartment ....... 3 Operators Compartment .............................. 33 Operators Manual ........................................ 21 Operators Seat .......................................... 122 Optional Air Ride Seat ............................. 50 Standard Seat .......................................... 49

Saddle Lock Pin Switch ............................... 43 Safety Decals ............................................... 21 Safety Rules ................................... 9, 15, 24 Scarifing ....................................................... 64 Seat Optional Air Ride ...................................... 50 Standard .................................................. 49 Seat Belt ............................................. 57, 119 Secondary Steering Light (Optional) ........... 39 Service Pin ................................................... 79 Service Specifications Engine ..................................................... 98 Rear axle ............................................... 114 Swing/Circle Turn Gear Box .................. 116 Tandem .................................................. 117 Shut Down ................................................... 14 Specifications ............................................. 135 Speedometer ............................................... 37 Start Up ........................................................ 14 Starting the Engine ...................................... 60 Steering ...................................................... 138

N

P Parking Brake ..................................... 52, 119 Parking the Grader ...................................... 65 Parking the Machine .................................... 17 Pedal Inching ..................................................... 39 Personel Safety ........................................... 11 Plastic and Resin Parts ............................... 80

155

ALPHABETICAL INDEX

Steering Arm Pivot ....................................... 93 Steering Wheel Console and Pedals ................................ 35 Tilt Lever .................................................. 39 Stopping the Grader .................................... 65 Storage Preparation .................................. 133 Swing/Circle Turn Gear Box ...................... 116 Symbols used in this Manual ....................... 22 Systemgard Lubrication Analysis Program ................................ 80, 99

T Tandem ............................................. 117, 137 Central Bearings ...................................... 95 Oil change ............................................. 117 Oil Level Check ..................................... 117 Wheel Nut .............................................. 117 Wheel Shaft Bearings .............................. 94 Tandem Wheel Lug Nuts ............................. 74 Terracing - Level Curves .............................. 67 Tire or Rim Service ...................................... 73 Tires ................................................... 71, 137 Adding Air ................................................ 73 Pressure .................................................. 74 Pressure Check ....................................... 74 Service ..................................................... 73 Tread Direction ........................................ 73 To the Owner ................................................. 1 Torque Specifications ROPS Cab and ROPS ........................... 120 Seat and Seat Belts ............................... 122 Towing .......................................................... 61 Transmission ..................................... 112, 137 Fluid Level ............................................... 89 Oil Change and Screen Cleaning .......... 113 Oil Filter Change .................................... 113 Oil Level Check ..................................... 112 Oil Pressure Gauge ................................. 46 Transmission auxiliary system ................... 131 Transport Service Pin .................................. 79 Turning Signals ............................................ 36 Typical Operation ......................................... 67

U Universal Joint and Drive Shaft ................... 94 Utility Safety ................................................. 10

W Warning Flasher........................................... 35 Wear Plate Adjustment .............................. 125 Weights ...................................................... 139 Welding service on the machine................ 131 Wheel and Tire Maintenance ............................................ 20 Wheel Lean Link .......................................... 93 Wheels ......................................................... 71 Nuts Torque ............................................. 74 Windshield Washer Reservoir ................... 118 Windshield Wiper ......................................... 53 Work Lights Switch ...................................... 44

156

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

Your Dealer can expedite your order for operators manuals, parts catalogs, service manuals and maintenance records.

Always give the Machine Name , Model and P.I.N. (product identification number) or S.N. (serial number) for your machine so your Dealer can provide the correct manuals for your machine.

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and ot her reproductive harm.

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

NOTE: Case Corporation reserves the right to make improvements in design changes in specifications at any time without incurring any obligation to install them on units previously sold.

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

Part Number North American English Printed in U.S.A.

6-84181NA March 05 Brz