650M
Tier 4B (final) Crawler Dozer
PIN NHC100263 and above
SERVICE MANUAL
Part number 48153338
1st edition English
April 2018
650M Long T rack - T ier (final) [NHC100263 - ] 650M W ide T rack (WT) / Low Ground Pressure (LGP) - T ier (final) [NHC100263 - ] 48153338 04/04/2018
SER VICE MANUAL
Link Product / Engine
650M Long T rack - T ier (final) [NHC100263 - ] North America F5HFL463D*G805
650M Wide T rack (WT) / Low
Ground Pressure (LGP) - T ier (final) [NHC100263 - ]
Product Market Product Engine
48153338 04/04/2018
North America F5HFL463D*G805
Contents INTRODUCTION Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [00.AAA] Maintenance generic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine and crankcase Fuel tanks Fuel filters Fuel injection system Air cleaners and lines T urbocharger and lines Exhaust Gas Recirculation (EGR) exhaust treatment Engine cooling system Fan and drive Aftercooler Engine lubrication system 1 Power coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [19.100] Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1 Hydrostatic drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump and motor components Brakes and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10] Parking brake parking lock Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [35.000] Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 Reservoir , cooler , and filters [35.106] V ariable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 48153338 04/04/2018
Main control valve
Dozer blade cylinders Hitches, drawbars, and implement couplings
Drawbars and towing hitches
T racks and track suspension
rack frame and driving wheels
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [48.130] T
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.1 [48.100] T
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.2 [48.134] T
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.3 T rack rollers Dropbox and final drive Cab climate control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V entilation [50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2 Electrical systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical system Harnesses and connectors Engine control system Engine starting system Alternator Battery Cold start aid Exhaust Gas Recirculation (EGR) electrical system Electronic modules External lighting W arning and instruments 1 T elematics F AUL T CODES Lubrication system 48153338 04/04/2018
racks
rack tension units
Grease lubrication system Dozer blade and arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [86.1 10] Dozer blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.1 [86.124] Dozer pushbeams and struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.2 T ools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ripper assembly Platform, cab, bodywork, and decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.151] Cab interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.154] Cab doors and hatches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3 [90.1 10] Operator platform less cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4 [90.1 14] Operator protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.5 [90.120] Mechanically-adjusted operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.6 [90.124] Pneumatically-adjusted operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.7 [90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.8 48153338 04/04/2018
INTRODUCTION 48153338 04/04/2018 1
Foreword - Important notice regarding equipment servicing
650M Long T rack - T ier (final) [NHC100263 - ]
650M Wide T rack (WT) / Low Ground Pressure (LGP) - T ier (final) [NHC100263 - ]
All repair and maintenance work listed this manual must carried out only qualified dealership personnel, strictly complying with the instructions and whenever the special
Anyone who performs repair and maintenance operations without complying with the procedures provided herein shall responsible for any subsequent
The manufacturer and all the organizations its distribution chain, including - without limitationnational, regional, local reject any responsibility for damages caused parts and / components not approved the facturer , including those used for the servicing repair the product manufactured marketed the manufacturer any case, warranty given attributed the product manufactured marketed the manufacturer case damages caused parts and / components not approved the manufacturer
The manufacturer reserves the right make improvements design and changes specifications any time without notice and without incurring any obligation install them units previously and illustrative material herein are accurate known time publication but are subject change without case refer your CASE
CONSTRUCTION Sales and Service
INTRODUCTION
48153338 04/04/2018 3
Safety rules
650M Long T rack - T ier (final) [NHC100263 - ]
650M Wide T rack (WT) / Low Ground Pressure (LGP) - T ier (final) [NHC100263 - ]
Personal safety
This the safety alert used alert you potential personal injury Obey all safety messages that follow this symbol avoid possible death injury
Throughout this manual you will find the signal words W and CAUTION followed special structions. These precautions are intended for the personal safety you and those working with you.
Read and understand all the safety messages this manual before you operate service the
DANGER indicates a hazardous situation not will result death serious injury
W ARNING indicates a hazardous situation not could result death serious injury
CAUTION indicates a hazardous situation not could result minor moderate injury
F AILURE T O FOLLOW DANGER, W ARNING, AND CAUTION MESSAGES COULD RESUL T DEA SERIOUS INJUR Y .
Machine safety
NOTICE: Notice indicates a situation that, not avoided, could result machine property damage.
Throughout this manual you will find the signal word Notice followed special instructions prevent machine property The word Notice used address practices not related personal safety
Information
NOTE: Note indicates additional information that clarifies other information this
Throughout this manual you will find the word Note followed additional information about a step, procedure, other information the The word Note not intended address personal safety property
INTRODUCTION
48153338 04/04/2018 4
Safety rules - Personal safety
650M Long T rack - T ier (final) [NHC100263 - ]
650M Wide T rack (WT) / Low Ground Pressure (LGP) - T ier (final) [NHC100263 - ]
General maintenance safety
Keep the area used for servicing the machine clean and dry Clean spilled
Service the machine a level
Install guards and shields after you service the
Close all access doors and install all panels after servicing the not attempt clean, lubricate, clear obstructions, make adjustments the machine while motion while the engine
Always make sure that working area clear other persons and pets before you start operating the
Unsupported hydraulic cylinders can lose pressure and drop the causing a crushing not leave equipment a raised position while parked during unless the equipment securely
Jack lift the machine only jack lift points indicated this
Incorrect towing procedures can cause When you tow a disabled machine follow the procedure this Use only rigid tow
Stop the remove the key , and relieve pressure before you connect disconnect fluid
Stop the engine and remove the key before you connect disconnect electrical
Scalding can result from incorrect removal coolant Cooling systems operate under Hot coolant can spray out you remove a cap while the system Allow the system cool before you remove the When you remove the cap, turn slowly allow pressure escape before you completely remove the
Replace damaged worn electrical
The exhaust and hydraulic lines may become hot during T ake care when you service such Allow surfaces cool before you handle disconnect hot W ear protective equipment when appropriate.
When follow the instructions the Always disconnect the battery before you weld the Always wash your hands after you handle battery components.
General battery safety
Always wear eye protection when you work with batteries. not create sparks have open flame near a battery
V entilate the area when you charge a battery use a battery enclosed area.
Disconnect the negative ( terminal first and reconnect the negative ( terminal
When you weld the disconnect both terminals the battery not smoke near a battery
When you use auxiliary batteries connect jumper cables start the use the procedure shown the ator ’ s not short across
Follow the manufacturer ’ s instructions when you store and handle
48153338 04/04/2018
INTRODUCTION
5
Battery and related accessories contain lead and lead
W ash hands after This a California Proposition
Battery acid causes Batteries contain sulfuric A void contact with Antidote ternal): Flush with water Antidote (eyes): flush with water for minutes and seek medical attention immediately Antidote (internal): Drink large quantities water not induce Seek medical attention ately
Keep out reach children and other unauthorized persons.
Air - conditioning system
The air - conditioning system under high not disconnect any
The release high pressure can cause serious injury
The air - conditioning system contains gases that are harmful the environment when released into the atmosphere. not attempt service repair the
Only trained service technicians can service, repair , recharge the air - conditioning system.
Personal Protective Equipment (PPE)
W ear Personal Protective Equipment (PPE) such hard hat, eye protection, heavy gloves, hearing protection, tective
Not Operate tag
Before you start servicing the attach a Not warning tag the machine area that will
INTRODUCTION
48153338 04/04/2018 6
Safety rules - Ecology and the environment
650M Long T rack - T ier (final) [NHC100263 - ]
650M Wide T rack (WT) / Low Ground Pressure (LGP) - T ier (final) [NHC100263 - ]
air , and water quality important for all industries and life When legislation does not yet rule the treatment some the substances that advanced technology sound judgment should govern the use and disposal products a chemical and petrochemical
Familiarize yourself with the relative legislation applicable your country , and make sure that you understand this Where legislation obtain information from suppliers anticleaning agents, etc., with regard the fect these substances man and nature and how safely store, use, and dispose these
Helpful hints
• A void the use cans other inappropriate pressurized fuel delivery systems fill Such delivery systems may cause considerable
• avoid skin contact with all
Most these products contain substances that may harmful your
• Modern oils contain not burn contaminated fuels and waste oils ordinary heating
• A void spillage when you drain fluids such used engine coolant engine hydraulic brake etc. not mix drained brake fluids fuels with lubricants. Store all drained fluids safely until you can dispose the fluids a proper way that complies with all local legislation and available
• not allow coolant mixtures get into the Collect and dispose coolant mixtures properly
• The air - conditioning system contains gases that should not released into the Consult airtioning specialist use a special extractor recharge the system properly
• Repair any leaks defects the engine cooling system hydraulic system immediately
• not increase the pressure a pressurized circuit this may lead a component
• Protect hoses during Penetrating weld splatter may burn a hole weaken allowing the loss
Battery recycling
Batteries and electric accumulators contain several substances that can have a harmful fect the environment the batteries are not properly recycled after Improper disposal batteries can contaminate the groundwater , and CASE CONSTRUCTION strongly recommends that you return all used batteries a CASE CONSTRUCTION dealer , who will dispose the used batteries recycle the used batteries properly some this a legal
Mandatory battery recycling
NOTE: The following requirements are mandatory
Batteries are made lead plates and a sulfuric acid solution. Because batteries contain heavy metals such lead, CONAMA Resolution 401 / 2008 requires you return all used batteries the battery dealer when you replace any not dispose batteries your household
Points sale are obliged to:
• Accept the return your used batteries
• Store the returned batteries a suitable location
• Send the returned batteries the battery manufacturer for recycling
INTRODUCTION
48153338 04/04/2018 7
Engine 650M Long T rack - T ier (final) [NHC100263 - ] 650M W ide T rack (WT) / Low Ground Pressure (LGP) - T ier (final) [NHC100263 - ] 48153338 04/04/2018
SER VICE MANUAL
Engine - Engine and crankcase
Engine - Remove
650M Long T rack - T ier (final) [NHC100263 - ]
650M Wide T rack (WT) / Low Ground Pressure (LGP) - T ier (final) [NHC100263 - ]
W ARNING
Heavy object!
W A YS use adequate lifting equipment (heavy - duty loader , forklift) lift the Failure comply could result death serious injury .
Park machine a level
Lower all equipment the Engage parking brake and shut engine
Relieve system hydraulic pressure actuating all hydraulic Remove key when T urn master battery disconnect switch the OFF
Disconnect all battery cables
Remove cooling package. See Radiator - Remove (10.400)
NOTICE: Emissions sensors the exhaust system and the vehicle may damaged vibration from use impact wrenches hammers during service A void using these tools when servicing components close the Remove the sensors with care use these tools cannot Remove two clamps (1) and remove turbocharger diesel oxidation catalyst flex tube (2) Close all openings prevent contamination damage.
Disconnect exhaust pressure sensor connector (1) , lambda sensor connector (2) , and two exhaust perature sensor connectors (3)
W0101A
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10. Remove clamp (1) from exhaust extension pipe (2) and remove exhaust extension Close all
1 Disconnect aspirator tube (3) Close all openings.
NOTICE: Diesel oxidation catalyst weighs approximately ( 100 ) . Use caution when removing prevent personal injury property
Attach appropriate lifting device diesel oxidation
Remove four bolts and washers and remove diesel oxidation
14. Remove four bolts and remove right rear fuel filter cess
Engine - Engine and crankcase
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15. Close fuel supply valve.
Disconnect fuel return line from
Engine - Engine and crankcase
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Remove two thumb screws (1) and remove backup alarm cover (2) .
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18. Disconnect fuel supply and return lines engine. RAIL13DOZ0366AA
Remove wiring harness clamps and remove wiring harness from rear
Disconnect all electrical connections from alternator RAIL13DOZ0328AA
Engine - Engine and crankcase
9
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Engine - Engine and crankcase
Remove lower starter bolt and disconnect ground
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Disconnect electrical connections from starter
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Rotate lifting brackets provide clearance for stalling lifting
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NOTICE: Engine weighs approximately 386 ( 850 ) Use proper lifting equipment prevent personal injury property
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24. Attach appropriate lifting device engine.
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Remove four bolts and washers and remove middle front belly pan.
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Remove four motor mount bolts and
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Move engine forward disengage driveshaft from draulic pump. Remove engine from machine.
28. Repair replace components necessary .
Engine - Engine and crankcase
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Engine - Engine and crankcase
Engine - Install
650M Long T rack - T ier (final) [NHC100263 - ]
650M Wide T rack (WT) / Low Ground Pressure (LGP) - T ier (final) [NHC100263 - ]
NOTICE: Engine weighs approximately 386 ( 850 ) . Use proper lifting equipment prevent personal injury property
Attach appropriate lifting device
Install engine machine and engage driveshaft draulic Grease driveshaft
Install four motor mount bolts and washers and tighten 205 – 230 N·m ( 151 – 170 )
Install middle front belly pan with four bolts and ers.
Remove lifting device from
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Connect electrical connections starter .
Apply L OCTITE ® 242® lower starter bolt and install ground cable starter .
Connect electrical connections alternator
Engine - Engine and crankcase
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5
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Engine - Engine and crankcase Install wiring harness and clamps rear engine. RAIL13DOZ0370AA 7 Connect fuel supply and return lines RAIL13DOZ0366AA 8 1 Connect fuel return line RAIL13DOZ0365AA 9 48153338 04/04/2018 10.1 [10.001] / 1 1
Engine - Engine and crankcase
NOTICE: Emissions sensors the exhaust system and the vehicle may damaged vibration from use impact wrenches hammers during service A void using these tools when servicing components close the Remove the sensors with care use these tools cannot
NOTICE: Diesel oxidation catalyst weighs approximately ( 100 ) Use caution when installing prevent personal injury property
15. Attach appropriate lifting device diesel oxidation
12. Install backup alarm cover (1) with two thumb screws (2)
supply
RAIL13DOZ0324AA Open fuel
1 1
RAIL13DOZ0363AA
Install right rear fuel filter access panel with four
RAIL13DOZ0362AA
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16. Install diesel oxidation catalyst machine with four bolts and
Remove lifting device from diesel oxidation Connect aspirator tube (1)
19. Install exhaust extension pipe (2) with clamp (3) . Connect two exhaust temperature sensor connectors (1) , lambda sensor connector (2) , and exhaust sure sensor connector (3)
Engine - Engine and crankcase
RAIL13DOZ0347AA
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21. Install turbocharger diesel oxidation catalyst flex tube (1) with two clamps (2)
Install cooling See Radiator - Install (10.400) . Connect
- Engine and crankcase
Engine
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Engine - Engine and crankcase
Engine - Assemble - Driveshaft alignment, engine and tandem pumps
NOTE: All instructions specified are from the perspective someone sitting the operator ’ s facing the Angle the driveshaft °
Coming f the pump shaft the driveshaft angled down .75 ° and the left 5.41 °
The distance from the flywheel housing the pump mounting bracket 149 ( 5.9 )
Measuring from the centerline the flywheel holes the 2:30 and 9:30 position, the distance from the 2:30 hole a vertical plane through the pump shaft
201.00 ( 7.91 ) , and the distance from the 9:30 hole a vertical plane through the pump shaft
213.00 ( 8.39 )
Long T rack - T ier (final) [NHC100263 - ] 650M Wide T rack (WT) / Low Ground Pressure (LGP) - T ier (final) [NHC100263 - ]
650M
Item Description 1 Shaft center center 9:30 hole 2 Shaft center center 2:30 hole 3 Flywheel housing 4 Pump shaft
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Engine - Engine and crankcase
Engine - Check - Check oil level
650M Long T rack - T ier (final) [NHC100263 - ]
650M Wide T rack (WT) / Low Ground Pressure (LGP) - T ier (final) [NHC100263 - ]
The engine oil fill (1) and the oil dipstick (2) are located the left side the machine the front engine partment.
Remove the dipstick (2) check the engine oil
Wipe the dipstick clean and The oil level should register between the minimum and the mum
Add oil through the engine oil fill (1) , necessary not over fill engine
2
NOTE: This procedure best performed the beginning the work day with the engine cool and all oil drained the
Service specifications T ype oil CASE AKCELA UNITEK SBL - 4 SAE 10WCapacity (with filter) 8.0 l ( 8.45 )
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Engine - Engine and crankcase
Engine - Replace - Engine oil and filter
650M Long T rack - T ier (final) [NHC100263 - ]
650M Wide T rack (WT) / Low Ground Pressure (LGP) - T ier (final) [NHC100263 - ]
Open the left - hand side front access door and secure with door
Remove the lower engine access
Remove the oil
NOTE: W arm oil (not hot) along with the removal the oil dipstick allows the oil drain faster .
NOTE: the machine and the special draining equipment use the engine oil tal drain located inside the left side engine access door
CAUTION
Heavy object!
The component heavy . Use care not drop the component when installing, removing,
Failure comply could result minor moderate injury .
C0095A
Remove the bolts that secure the engine oil access Remove the engine oil access
Use a suitable container collect the drained
Remove the engine oil drain and allow the oil
specifications T ype oil CASE AKCELA UNITEK SBL - 4 SAE 10WCapacity (with filter change) 8.0 L ( 8.5 )
Service
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Engine - Engine and crankcase
Replace oil filter
Locate the oil filter the left front engine
Clean the area around the filter dirt and
T urn the oil filter housing counterclockwise Remove and discard the filter following local mental and waste
Apply a thin layer clean oil the new filter
T urn the new oil filter onto the base until the gasket makes contact with the base, and then turn hand additional 3 / 4 Never use a filter wrench install a new filter .
1 Install the engine oil drain Fill the engine with the proper amount oil through the fill port (1)
Start the engine and run idle Check the engine oil filter and remote drain for
After two minutes stop the W ait for the engine oil drain down for accurate reading the dipstick (2)
16. Check the oil dipstick (2) , and add additional oil, necessary
Check for leaks around the filter and
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