650K 750K 850K Series 2 Op's Manual

650K, 750K, 850K
SERIES 2 CRAWLER
OPERATOR’S MANUAL
6-85641 NA
Issued 12-2005
OPERATORS MANUAL
CRAWLER DOZER
650K, 750K, 850K
SERIES 2
Bur • Issued 12-2005

Printed in U.S.A. • Book/Form Number 6-85641 NA
Copyright © 2005. CNH America, LLC. All Rights Reserved.
CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not
necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer
REVISION HISTORY
Issue Issue Date Applicable Machines Remarks
First Edition 12-2004 650K, 750K, 850K SERIES 2 6-85640
Revision 1 12-2005 650K, 750K, 850K SERIES 2 6-85641
Any use of editorial or pictorial content is strictly prohibited without express written permission from
CNH America, LLC. Racine, WI 53403 U.S.A..
TABLE OF CONTENTS
CHAPTER 1
GENERAL INFORMATION
TO THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
MACHINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
CHAPTER 2
SAFETY AND DECALS
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
BEFORE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
PERSONAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
UTILITY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
FIRE EXTINGUISHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
BURN PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
HAZARDOUS CHEMICALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
FIRE OR EXPLOSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
DUCTILE IRON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
CHAPTER 3
INSTRUMENTS AND CONTROLS
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
BRAKE, DECELERATOR AND FOOTREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
PARKING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
DIRECTION CONTROL LEVER,TRANSMISSION CONTROL, HAND THROTTLE . . . . . . . . . . . . . . . . 3-10
DOZER BLADE CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
CONTROL HANDLE POSITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
RIPPER CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
OPERATORS SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
OPERATORS SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
CHAPTER 4
OPERATING INSTRUCTIONS
RUN-IN PERIOD OF A NEW MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
CRAWLER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
MOVING A DISABLED CRAWLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
OPERATING IN HOT WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
OPERATING IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
BOOSTER BATTERY CONNECTION TO MACHINE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
TILTING THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
DOZER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
TRACK SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
FACTORS CONTROLLING UNDERCARRIAGE WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
6-85641NA Issued 12-05 Bur I

CHAPTER 5
LUBRICATION, FILTERS, AND FLUIDS
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
GENERAL SAFETY BEFORE YOU SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
SYSTEMGARD LUBRICATION ANALYSIS PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
PLASTIC AND RESIN PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
ENGINE HOURMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
LUBRICATION AND MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
GREASE FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
ACCESS DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
AIR FILTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
FINAL DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
CHAPTER 6
MAINTENANCE AND ADJUSTMENTS
TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
REVERSIBLE FAN POSITIONS (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
ROLL-OVER PROTECTIVE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
MACHINE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
ADJUSTING THE RIPPER SHANKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
DOZER BLADE PITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
FAN AND AIR CONDITIONING DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
CHAPTER 7
ELECTRICAL
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
ACCESSORY OUTLETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
CHAPTER 8
SPECIFICATIONS
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
TRAVEL SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
TRACK SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
TRANSPORT LENGTH AND WIDTH WITH BLADE FULLY ANGLED 25 DEGREES . . . . . . . . . . . . . . . 8-5
OPERATING DATA AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
OPERATING DATA AND DIMENSIONS - RIPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
CHAPTER 9
INDEX
II 6-85641NA Issued 12-05 Bur

CHAPTER 1 - GENERAL INFORMATION
Chapter 1
GENERAL INFORMATION
TO THE OWNER
BD04N031 Figure 1
K SERIES 2 CRAWLER
This manual contains important information about the safe operation, adjustment and maintenance of your Crawler.
Refer to the Detail Index at the end of this manual for locating specific items about your machine. The Crawler
conforms to current safety regulations.
Use this manual as a guide. Your Crawler will remain a reliable working tool as long as it is kept in good working
condition and serviced properly.
Do Not operate or permit anyone to operate or service this machine until you or the other persons have read and
understand the safety, operation and maintenance instructions in this manual. Use only trained operators who have
demonstrated the ability to operate and service this machine correctly and safely.
This Crawler, with standard equipment and authorized attachments, is intended to be used for above ground
material handling.
Do Not use this machine for any application or purpose other than those described in this manual. Consult an
authorized dealer on changes, additions or modifications that can be required for this machine to comply with
various country regulations and safety requirements. Unauthorized modifications will cause serious injury or death.
Anyone making such unauthorized modifications is responsible for the consequences.
This 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 your dealer to obtain additional manuals. Contact your dealer
for any further information or assistance about your machine. Your dealer has approved service parts. Your dealer
has technicians with special training that know the best methods of repair and maintenance for your Crawler.
6-85641NA Issued 12-05 Bur 1-1

RIGHT, LEFT, FRONT, AND REAR OF

THE MACHINE
A25808 Figure 2
OPERATOR’S MANUAL POUCH ATTACHED TO
SEAT BACK
4 3
2
B830800J Figure 3
1. FRONT 3. RIGHT-HAND SIDE

2. REAR 4. LEFT-HAND SIDE
BASIC MACHINE, DOZER AND RIPPER

The terms Right-hand, Left-hand, Front, and Rear
are used in this manual to indicate the sides as they
are seen from the operator's seat.
1-2 Issued 12-05 Bur 6-85641NA

IDENTIFICATION NUMBERS
Write your machine model number, Product Identification Number (P.I.N.) and serial numbers on the lines provided
below. If needed, give these numbers to your dealer when you need parts or information for your machine.
Make a record of the numbers. Keep the record and your Manufacturer’s Statement of Origin in a safe place. If the
machine is stolen, report the numbers to your local law enforcement agency.
Machine
➤
Machine Model and Type
➤
Product Identification Number: P.I.N.
➤
Year of Build
Component Serial Numbers
➤
BD02J092 Figure 5
Engine serial number
CAB PLATE IS LOCATED ON THE RIGHT-HAND SIDE REAR
➤ POST
Transmission and serial number

ENGINE
➤
ENGINE PLATE IS LOCATED ON THE LEFT REAR SIDE OF
ROPS cab or canopy serial number THE ENGINE (4 AND 6 CYLINDER)
➤
Dozer blade serial number
BD04N009 Figure 4
PRODUCT IDENTIFICATION NUMBER (P.I.N.)
ROPS CANOPY IS LOCATED ON THE LEFT-HAND UPPER
SIDE
6-85641NA Issued 12-05 Bur 1-3

1
BD02H141 Figure 6
TRANSMISSION
BD02J108 Figure 7
1. ON THE HOUSING UNDER THE CAB
BD99J147 Figure 8
DOZER BLADE
1-4 Issued 12-05 Bur 6-85641NA

MACHINE COMPONENTS
11
10
2
8
9
3
5
4
7 6
BD04N003 Figure 9
1. ROPS 5. CARRIER ROLLER 9. BLADE

2. LEFT-HAND REAR ACCESS DOOR 6. TRACK ROLLER 10. RADIATOR DOOR
3. SPROCKET 7. IDLER 11. HAND RAILS & HANDLES
8. LEFT-HAND ENGINE ACCESS
4. TRACK
DOOR
3
5
BD04N033 Figure 10
1. RIGHT-HAND ACCESS DOOR 4. BLADE PITCH ADJUSTMENT
2. STEPS 5. RIGHT-HAND ENGINE ACCESS DOOR
3. HAND RAILS
6-85641NA Issued 12-05 Bur 1-5

1 2
BD02J032 Figure 11
RIPPER
1. RIPPER SHANK 2. TOOTH
BD02M132 Figure 12 BD02M171 Figure 13

DRAWBAR HITCH
1-6 Issued 12-05 Bur 6-85641NA

CHAPTER 2 - SAFETY AND DECALS
Chapter 2
SAFETY AND DECALS
TABLE OF CONTENTS
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

BEFORE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
PERSONAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
UTILITY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
FIRE EXTINGUISHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
BURN PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
HAZARDOUS CHEMICALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
FIRE OR EXPLOSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
DUCTILE IRON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
6-85641NA Issued 12-05 Bur 2-1

NOTES
2-2 6-85641NA Issued 12-05 Bur

SAFETY RULES
• Different jobs will require different protective
WARNING: This safety alert symbol equipment. Items such as hard hats, protective
indicates important safety messages in this shoes, heavy gloves, reflector type vests,
manual. When you see this symbol, carefully respirators, and ear protection can be required.
read the message that follows and be alert to Know and use the equipment that is required
the possibility of death or serious injury. before you start the job.
M171C
Most accidents involving machine operation and

• Be prepared for emergencies. Always have a first
aid kit and a fire extinguisher with you. Be sure
maintenance can be avoided by following basic
that the fire extinguisher is properly maintained.
safety rules and precautions. Read and understand
Be familiar with the correct use.
all the safety messages in this manual, the safety
manual, and the safety decals on the machine before • Know the signals used on your job. Follow the
you operate or service the machine. See your dealer instructions of the flagman, signs, etc.
if you have any questions.
• Check that all doors, guards, and covers are
READ THIS MANUAL COMPLETELY and make sure installed correctly and closed.
you understand the controls. All equipment has a
limit. Make sure you understand the speed, brakes, • Foreign material or grease on the steps and hand
steering, stability and load characteristics of this rails can cause an accident. Keep the steps and
machine before you start to operate. hand rails clean.
Do not remove this manual or the safety manual from

• Before you start each day, walk around the
machine and check for oil or fluid leaks. Replace
the machine. See your dealer for additional manuals.
all broken or missing parts and do the required
The safety information given in this manual does not lubrication and maintenance as shown in this
replace safety codes, insurance needs or, federal, manual. Clean all trash and debris from the
state, and local laws. Make sure your machine has machine.
the correct equipment according to these rules or
laws.
BD02J018 Figure 2
A25808 Figure 1
IMPORTANT: Safety messages in this section point
out situations which can be encountered during the
normal operation and maintenance of your machine.
These safety messages also give possible ways of
dealing with these conditions.
NOTE: Additional safety messages are used in the
text of the manual to show specific safety hazards.
BEFORE OPERATION BD02J019 Figure 3

• Avoid loose fitting clothing, loose or uncovered • Always face the machine and use the hand rails
long hair, jewelry and loose personal articles.
when getting on. Do not rush.
6-85641NA Issued 12-05 Bur 2-3

• Remove all loose objects from the operators area PERSONAL SAFETY
and from the machine. Loose objects can jam
If Safety Decals on this machine are ISO two panel
controls and cause accidents.
Pictorial, decals are defined as follows:
• Before you start the engine, always fasten the seat • The first panel indicates the nature of the hazard.
belt, sound the horn and make sure all personnel
are clear of the machine safety area. • The second panel indicates the appropriate
avoidance of the hazard.
• Engine exhaust fumes can cause death. If you
operate this machine in an enclosed area, be sure
• Background color is YELLOW.
there is good ventilation to replace the exhaust Prohibition symbols such as and STOP if
fumes with fresh air. used, are RED.
• Know the rules, laws, and safety equipment
necessary for transporting this machine on a road UTILITY SAFETY
or highway. 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
Before beginning any trenching, 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.
ALWAYS have all local utility companies mark the
location of their lines.
In U.S.A. and Canada call one of many One Call
System Director services. If you do not know the
local number, call the national number (U.S.A. and
Canada only): 1-888-258-0808.
Check with local authorities for laws, regulations
and/or strict penalties requiring you to locate and
avoid existing utilities.
2-4 Issued 12-05 Bur 6-85641NA

MACHINE OPERATION
• Check all controls in a clear area and make sure
the machine is operating correctly.
• Do not permit other persons to ride on the
machine. Other persons can fall or can cause an
accident.
• 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.
• Contact with high voltage lines, underground
cables, etc., can cause serious injury or death
from electrocution.
• Before you drive or operate in an area with high
lines or cables, tell the power or utility company
RH99G001 Figure 4 what you are going to do. You MUST HAVE THE
CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU
POWER DISCONNECTED OR KEEP A SAFE
PERFORM ANY MACHINE OPERATION WORKING DISTANCE from the lines or cables.
Know the utility color code (U.S.A. and Canada): You must know the safe working distance from the
high voltage power equipment and must know any
Electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red
federal, state/provincial or local safety codes or
Gas, Oil, or Petroleum . . . . . . . . . . . . . . . . . . . Yellow regulations that apply to the job site.
Communication, Telephone, Television . . . . . Orange
Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue
• When the machine is in reverse an alarm will
sound.
Sewer. . . . . . . . . . . . . . . . . . . . . . . . . . Green/Brown
Proposed Excavation. . . . . . . . . . . . . . . . . . . . White • Electrical cables, gas pipes, water pipes, sewers,
or other underground objects can cause injury or
Surveying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pink
death. Learn the location of underground hazards
Reclaimed Water and Slurry . . . . . . . . . . . . . . Purple before you operate your machine in a new area.
After locating the utility lines, carefully dig a hole by • If this machine rolls over you can be injured or
hand and/or automatic vacuum equipment to the killed. You must make a judgment if weather, road,
utility line to verify the location and depth of the line. or earth conditions will permit safe operation on a
hill, ramp, or rough ground. Always fasten the seat
belt.
• 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.
• Operate the machine controls from the operators
seat only. Always fasten the seat belt.
6-85641NA Issued 12-05 Bur 2-5

PARKING THE MACHINE FIRE EXTINGUISHER

1. When the work day is finished, make sure the It is recommended that the fire extinguisher be
machine is parked on level ground. maintained on the crawler when it is in operation to
aid in event of a fire. See your dealer for further
IMPORTANT: If you must temporarily park the
information.
machine on a hillside, put the front of the machine
toward the bottom of the hill. Make sure the machine
WARNING: It is good practice to carry a
is behind an object that will not move.
fire extinguisher on the machine. Be sure
2. Lower the dozer blade and ripper (if equipped) to ! that the extinguisher is properly maintained
the ground. and be familiar with its proper use.
M103B
3. Shift the direction controls to NEUTRAL.
4. Pull both parking brake levers back into the
applied position.
5. Run the engine for a few minutes with no load.
This decreases the temperature of the engine
parts evenly.
6. Make sure the engine is at its lowest idle.
7. Turn the key switch to OFF to stop the engine.
8. Always face the machine and use the hand rails
when leaving the machine. Do not rush and do
not jump from the machine.
9. When you park the machine, make sure the track 72L95 Figure 5
system is clean. In cold weather place the
machine on planks. This will prevent the tracks BURN PREVENTION
from freezing to the ground.
• Battery acid causes severe burns. Batteries
If your machine is frozen to the ground, do not try to contain sulfuric acid. Avoid contact with skin,
drive the machine. This will cause damage to the eyes, or clothing. Antidote - EXTERNAL: Flush
power train. with water. INTERNAL: Drink large quantities of
water or milk. Follow with milk of magnesia,
beaten egg or vegetable oil. Call a doctor
immediately. EYES: Flush with water for 15
minutes and get prompt medical attention.
• 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.
• Hot coolant can spray out if the radiator cap is
removed. To remove the radiator cap, let the
cooling system cool, turn the radiator cap to the
first notch, wait until the pressure is released, then
remove the radiator cap.
HAZARDOUS CHEMICALS
• 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.
2-6 Issued 12-05 Bur 6-85641NA

• Material Safety Data Sheets (MSDS) provide • A fire can cause injury or death. Always have a fire
information about the chemical substances within extinguisher near or on the machine. Make sure
a product, safe handling procedures, first aid the fire extinguisher is serviced according to the
measures and procedures to be taken when the manufacturers instructions.
product is accidentally spilled or released. MSDS
are available from your dealer.
• If a fire extinguisher has been used, always
recharge or replace the fire extinguisher before
• Before you service the machine, check the MSDS operating the machine.
for each fluid, lubricant, etc., used in your
machine. This information indicates what the risks
• Remove all trash or debris from the machine each
day. Especially check the engine area and
are and how to service the machine safely. Follow
exhaust system.
this information when servicing the machine.
• If the machine has an oil, fuel, or hydraulic leak,
• Before you service this machine and before you always repair the leak and clean the area before
dispose of the old fluids and lubricants, always
operating.
remember the environment. DO NOT put oil or
fluids into the ground or into containers that can • Keep the cooling system clean and maintain the
leak. correct coolant level.
• Check with your local environmental or recycling • Make sure that you do not store oily rags or other
center or your dealer for correct disposal flammable materials on the machine.
information.
• If you weld, grind, or use a cutting torch on this
• Fluids such as Gasoline, Kerosene, Diesel Fuel, machine.
Hydraulic Oil, etc. contain chemicals that can be 1. Disconnect or isolate the drive train controller.
dangerous to your health and can cause cancer
and/or birth defects. Contact either internally or 2. Keep the ground cable from the welder as near
externally can cause infection or other injury. If the work area as possible.
any internal or external contact occurs, see your 3. Before welding or using a torch on the machine,
local Poison Control Center or doctor clean the area to be repaired.
IMMEDIATELY.
• Check the electrical system for loose connections
or frayed insulation. Repair or replace the loose or
FIRE OR EXPLOSION PREVENTION damaged parts.
• Sparks or flame can cause the hydrogen gas in a
battery to explode. To prevent an explosion, do the
following:
1. Connect the negative (-) cable last.
2. When connecting jumper cables to start the
engine, use the procedure shown in this manual
on. See Booster Battery Connection in this
manual.
3. Do not short circuit the battery posts with metal
items.
4. Do not weld, grind, or smoke near a battery.
• Sparks from the electrical system or engine
exhaust can cause an explosion and fire. Before
you operate this machine in an area with
flammable dust or vapors, use good ventilation to
remove the flammable dust or vapors before you
start.
• Engine fuel can cause an explosion or fire. Do
not fill the fuel tank with the engine running, if you
are near an open fire, or if you are welding,
smoking, etc.
• Use nonflammable cleaning solvent to clean parts.
6-85641NA Issued 12-05 Bur 2-7

MAINTENANCE
• Before you service the machine, put a Do Not
Operate tag on the instrument panel.
• Improper service or repair 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 dealer.
• Know and understand how to release hydraulic
pressure before servicing the crawler.
• Unauthorized modifications to this machine can
cause injury or death. Do not make unauthorized
modifications to this machine.
• 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 operators seat with the engine
running.
• 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.
• Hydraulic fluid or grease injected into your skin
can cause severe injury or death. Keep your
hands and body away from any pressurized leak.
If fluid is injected into your skin, see a doctor
immediately and have the fluid removed.
• When you service this machine, always wear face
or eye protection, safety shoes, and other
protective items as required.
DUCTILE IRON
• Before you weld, cut or drill holes in a part on this
machine, make sure the part is not cast ductile
iron. See your dealer if you do not know if a part is
cast ductile iron.
2-8 Issued 12-05 Bur 6-85641NA

SAFETY DECALS
WARNING: Injury or death can result if you 1

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 dealer for new safety decals.
SC002
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.
NOTE: When you clean the decals, use only a cloth,
water, and soap. Do not use solvent, gasoline, etc.
You must replace a decal if the decal is damaged,
missing, or cannot be read. If a decal is on a part that
is replaced, make sure the decal is on the new part.
See your dealer for new decals.
383973A1 Figure 8
2
2
1
BD02J074 Figure 6
1. 383973A1
2. 321-7040 (2)
321-7040 Figure 9
BD02M045 Figure 7
6-85641NA Issued 12-05 Bur 2-9

3 5
329044A1 / BD02M133 Figure 10 5

3. 329044A1
383972A1 Figure 11
4. 383972A1 (2) ONE EACH SIDE
5
These decals are located on the left and right side of
the ROPS facing away from the operator and warns
that no modification may be made.
332512A1 / BD99M009 Figure 12

5. 332512A1 (2) ONE EACH SIDE
2-10 Issued 12-05 Bur 6-85641NA

6
6
321-7030 Figure 13
6. 382622A1
7. 321-7030
6-85641NA Issued 12-05 Bur 2-11

383971A1 Figure 14
8. 383971A1
2-12 Issued 12-05 Bur 6-85641NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS
Chapter 3
INSTRUMENTS AND CONTROLS
TABLE OF CONTENTS
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

BRAKE, DECELERATOR AND FOOTREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
PARKING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
DIRECTION CONTROL LEVER, TRANSMISSION CONTROL, HAND THROTTLE . . . . . . . . . . . . . . . . . . . . 3-10
DOZER BLADE CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
CONTROL HANDLE POSITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
RIPPER CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
OPERATORS SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
SEAT CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
OPERATORS SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
To Fasten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
To Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
6-85641NA Issued 12-05 Bur 3-1

NOTES
3-2 6-85641NA Issued 12-05 Bur

INSTRUMENT PANEL
2
3 4 5
BD04N010 Figure 1
NOTE: To check the condition of the warning lamps turn the key switch to on. The warning lamps will illuminate for
approximately three seconds. If the lamp does not illuminate, replace the bulb. See the Electrical section in this
manual for the warning lamp replacement.
1. SERVICE SOON LAMP 3. REAR WORK LIGHT SWITCH (IF
This lamp will illuminate when the EQUIPPED)
machine has been programed to notify This switch has two positions, ON and
the operator of service intervals.The OFF. To turn ON press the icon. The
lamp will illuminate and the service switch icon will illuminate.
message can be read on the digital
display.
NOTE: See Operating Instructions in this
BS98M034 Figure 4
Manual for programming. 4. FRONT AND REAR WINDSHIELD
BC00G075 Figure 2 WIPERS (IF EQUIPPED)
2. FRONT WORK LIGHT SWITCH (IF This switch has two positions, ON and
EQUIPPED) OFF. To turn ON press the icon.
This switch has two positions, ON and
OFF. To turn ON press the icon. Turning 0097 Figure 5
the switch on illuminates the instrument
face and is confirmed by the illuminated 5. FRONT AND REAR WINDSHIELD
symbol (A). The switch icon will WASHER (IF EQUIPPED)
illuminate. Push the rocker switch icon to activate
BS98M034 Figure 3 the front and rear windshield washer.
Release the rocker switch to stop the
front and rear windshield washer.
0099 Figure 6
6-85641NA Issued 12-05 Bur 3-3

7 8 9 10
6
BD04N010 Figure 7
6. RIGHT-HAND AND LEFT-HAND 9. DISPLAY - SERVICE/ENTER

DOOR WINDSHIELD WIPERS (IF Use this switch to select between display
EQUIPPED) and service menus or enter selections.
This switch has two positions, ON and
The Diamond icon, or top portion of the
OFF. To turn ON press the icon.
switch, is used to select displays.
The 90 Degree Arrow icon, or bottom
BC00G12 Figure 8
portion of the switch, is used to enter
7. LEFT-HAND AND RIGHT-HAND selected choices.
DOOR WINDSHIELD WASHERS NOTE: Pressing the Service/Enter portion of
(IF EQUIPPED) the switch with the key switch OFF will allow
the operator or service technican to monitor
Push the rocker switch icon to activate
the fuel gauge without powering up.
the left and right door windshield
BS02M143 / BS02M144 Figure 11
washers. Release the rocker switch to
\
stop the left and right door windshield
10. HORN
washer.
Push the switch to activate the horn.
NOTE: The horn has constant power and
BC00B132 Figure 9 may be used with the key switch in OFF.
BS98M064 Figure 12
8. MENU UP/DOWN
Use this UP / DOWN switch to scroll
through the menus.
NOTE: Push the UP arrow at start up to
display engine rpms on the digital display.
BS02M141 / BS02M142 Figure 10
3-4 Issued 12-05 Bur 6-85641NA

11. KEY SWITCH

The key switch has four positions:
ACCESSORY POSITION
This position energizes the drivetrain
controller, accessory switches and
instrument cluster.
ENGINE STOP (OFF POSITION)
To stop the engine, turn the key to STOP.
After the engine has stopped, remove 11
the key.
ENGINE ON (ON POSITION)
Turn the key clockwise to ON and check
the warning lamps. This is the normal
position of the key switch when the
engine is running.
ENGINE START (START POSITION)
Turn the key completely clockwise to the
START position to actuate the starter
motor. After the engine starts, release
the key. The key will return automatically
to ON.
BS98M031/RB99J175/RB99J178/RB99J176 Figure 13
BD04N012/ 87412595 Figure 14
6-85641NA Issued 12-05 Bur 3-5

15 16 17
13 14 18
12
BC02J064 Figure 15
12. TRANSMISSION FILTER WARNING 15. PARKING BRAKE ENGAGED

LAMP This lamp illuminates when one or both
This warning lamp shows the condition the parking brake levers are pulled ON.
of the transmission filter. If the warning The parking brake can be set by pulling
lamp illuminates during normal either brake handle into the ON position,
operation, (transmission oil at operating depressing the brake pedal completely,
temperature and engine at full throttle), or letting the machine set in neutral for
stop the engine and replace the filter. 30 seconds.
BS99J182 Figure 16 BS96H049 Figure 19
13. CHARGE PRESSURE WARNING 16. ALTERNATOR

LAMP This lamp illuminates when the battery
This warning lamp illuminates and condition drops below proper operating
warning buzzer will sound if, (1) the voltage. This lamp illuminates with the
engine is stopped and the key switch is key switch in the ON position but should
on, or (2) there is no or low oil pressure go OUT with the engine running. The
in the transmission. Do not run the gauge (B) should be monitored by the
machine if the warning lamp illuminates. operator.
BS98M032 Figure 17 BS99J181 Figure 20
14. LOW ENGINE OIL PRESSURE 17. HYDRAULIC FILTER WARNING

This warning lamp illuminates and LAMP
warning buzzer will sound when the This warning lamp shows the condition
engine is stopped and the key switch is of the hydraulic filter. If the warning lamp
on, or there is no or low oil pressure in illuminates during normal operation,
the engine. Do not run the engine if the (hydraulic oil at operating temperature
warning lamp illuminates. and engine at full throttle), stop the
BS99J182 Figure 18 engine and replace the filter.
BS99J182 Figure 21
18. ENGINE AIR FILTER

RESTRICTION
This warning lamp illuminates when, the
key switch is in the START position or,
when the engine air filter element
requires service.
BS99J183 Figure 22
3-6 Issued 12-05 Bur 6-85641NA

19
20
21
D E
E e
22
EE
C E e
EE
23
BC02J064 Figure 23
19. ENGINE COOLANT

TEMPERATURE 22. GRID HEATER LAMP
This warning lamp illuminates and the Turn the key switch to on. When the
warning buzzer sounds when the engine incoming engine air needs to be
coolant temperature is too high. The preheated, due to cold temperatures, the
temperature should be monitored by lamp will illuminate. Wait until the
watching the gauge (C). The indicator lamp goes off before turning the
temperature of the coolant is normal key switch to the start position.
when the gauge needle is in the green
area. BS99J185 Figure 27
BS96H053 Figure 24
23. FUEL WARNING LAMP
This warning lamp will glow and the
20. TRANSMISSION FAULT warning buzzer will sound for a few
This warning lamp illuminates when the moments when the machine is low on
transmission controller encounters an fuel.
error.
E.The operator may monitor the gauge
NOTE: Contact your dealer if this lamp
with the key switch on, the engine
illuminates.
running or by pushing the Service/Enter
TRAN_FLT Figure 25
button with the key switch off, (90 degree
21. TRANSMISSION OIL arrow icon).
TEMPERATURE WARNING
This warning lamp will glow and the BS99J185 Figure 28
warning buzzer will sound when the
transmission operating temperature is
too high. The temperature should be
monitored by watching the gauge (D).
The transmission operating temperature
is normal when the gauge needle is in
the green area.
BS98M048 Figure 26
6-85641NA Issued 12-05 Bur 3-7

25
24
BD99K104 Figure 29
24. DIGITAL DISPLAY
This display is used to monitor engine and
transmission control information. The Direction
Control Lever position, (FNR) will be displayed
on the left side of the display. Machine hours or
operating RPMs will be displayed on the right
side of the display.
Ser vice messages and infor mation will be
displayed across the center por tion of the
display.
25. TRANSMISSION SPEED GAUGE
This gauge shows the transmission speed BD02M165 Figure 31
selected by the operator. The maximum speed TRANSMISSION CONTROL BUTTONS
is selectable in a range of 10 increments.The
r a n g e i s c o n t r o l l e d by t h e Tr a n s m i s s i o n
UP/DOWN buttons on the Direction Control
A
Lever.
Once the key switch has been shut off it will
default the Transmission Speed to 60% as shown B
below on start up.
BD02M166 Figure 32
A. TRANSMISSION SPEED UP BUTTON
B. TRANSMISSION SPEED DOWN BUTTON
BD04N011 Figure 30
3-8 Issued 12-05 Bur 6-85641NA

BRAKE, DECELERATOR AND PARKING BRAKES

FOOTREST
2
1
3 3
BD02H120 Figure 34
BD99J224 Figure 33
4. PARKING BRAKE LEVERS (ONE EACH SIDE)
1. BRAKE PEDAL
Push this pedal to slow or stop the machine.
Pushing the pedal all the way down will engage
the parking brake.
2. DECELERATOR PEDAL
Push this pedal down to reduce the machine
speed. This command can reduce the speed all
the way to zero by destroking the drive pumps
along with decreasing engine RPM.
NOTE: A good way to control the dozer for precision
work is to use the decelerator like the brake pedal on
a car with an automatic transmission. BD02H121 Figure 35
PARKING BRAKE ENGAGED
3. LEFT AND RIGHT FOOTREST
BD02H122 Figure 36
PARKING BRAKE DISENGAGED (WORK POSITION)
Both parking brake levers need to be down for the
machine to operate. These brakes are spring applied
hydraulic released (SAHR).
NOTE: Any time the crawler is not moving for 30
seconds or more the SAHR brake applies.
6-85641NA Issued 12-05 Bur 3-9

DIRECTION CONTROL LEVER,TRANSMISSION CONTROL, HAND THROTTLE
BD02K029 Figure 37
1. DIRECTION CONTROL LEVER
This lever controls the forward speed, neutral or
reverse speed, as well as turning.
To turn, push or pull the lever to the direction you
want the crawler to go, in forward or reverse. The
2 crawler will not move unless engine rpms are
1000 or higher.
This lever has detent positions in forward and
reverse. The lever will stay in the forward or
reverse position until the operator pulls it out. At
start up the crawler must be in Neutral for several
seconds before it will move.
The Direction Control Lever position will be
BD02J061 Figure 38 displayed on the instrument gauge.
2. TRANSMISSION SPEED
A UP/DOWN BUTTONS
A. UP BUTTON (transmission speed increase)
B. DOWN BUTTON (transmission speed
decrease)
These two buttons change the speed of the
crawler from low to high. The maximum speed is
selectable in a range of 10 increments. To
B increase track speed push the upper button. To
decrease track speed push the lower button. The
operator may choose to hold the appropriate
BD02M166 Figure 39 button in the DOWN or UP position to allow the
speed to increment. The speed range will be
indicated by the needle on the Transmission
Speed Gauge.
NOTE: Top speed is limited to 90% from the factory.
3-10 Issued 12-05 Bur 6-85641NA

3. ENGINE HAND THROTTLE

Pull the throttle lever BACK to increase the
engine speed. Push the throttle lever FORWARD
to decrease the engine speed.
3
3 4. REVERSE TO FORWARD SPEED RATIO
CONTROL
This control knob allows the operator to control
the reverse speed in relation to the forward
speed. Rotate the knob clockwise to increase the
speed of reverse faster than forward. The knob
will stay in the desired position.
NOTE: Maximum reverse speed is limited to
maximum machine speed. The speed ranges are:
80%, 100%, 115%, and 130% of forward speed.
BD02H134 / 8371L92 Figure 40
87403197 Figure 41
6-85641NA Issued 12-05 Bur 3-11

DOZER BLADE CONTROL LEVER

1. THE DOZER BLADE CONTROL LEVER
BD02J038 Figure 45
A
BS99J212 Figure 42 B
A. FLOAT:
Float (Detent): This is a detent position. When in the
FLOAT (Detent) position, the blade can follow the C
level of the ground without movement of the control
lever.
BS99J213 Figure 43
B. LOWER: BD02J038 Figure 46
C. HOLD:
The blade will stop moving in the HOLD position.
W h e n r e l e a s e d , t h e c o n t r o l leve r w i ll r e t u r n
automatically to the HOLD position.You must
manually move the control lever from the FLOAT
position to the HOLD position.
D
BS99J214 Figure 44
D. LIFT:
BD02J038 Figure 47
3-12 Issued 12-05 Bur 6-85641NA

BS99J21 Figure 48
E. TILT LEFT
F
BS99J218 Figure 49
C
E
F. TILT RIGHT
C. HOLD
The blade will stop moving when the control lever
is in the HOLD position. When released, the
control lever will return automatically to the
HOLD position.
BS99J217 Figure 50
G. ANGLE LEFT BD02J038 Figure 52
Rotate the lever counterclockwise to angle the
blade left.
BS99J219 Figure 51
H. ANGLE RIGHT
Rotate the lever clockwise to angle the blade
right.
BD02J038 Figure 53
6-85641NA Issued 12-05 Bur 3-13

CONTROL HANDLE POSITIONS RIPPER CONTROL LEVER
1 1
2
BD02J038 Figure 54
1. Jam Nut
BD02J038 Figure 55
The position of the control handle can be adjusted to
1. LOWER:
a suitable operator’s position. Loosen jam (1) nut on
the control lever. Adjust the handle to a suitable
position. Tighten jam nut on the control lever.
The position of the handle may be adjusted Up,
Down, or Angled Side to Side for operator comfort.
BS99J221 Figure 56
2. RAISE:
BS99J222 Figure 57
3. HOLD:
The ripper will stop moving when the control lever is
in the HOLD position. When released, the control
lever will return to the HOLD position automatically.
3-14 Issued 12-05 Bur 6-85641NA

OPERATORS SEAT
A vinyl mechanical suspension or vinyl air suspension seat may be ordered on a K Series 2 crawler ROPS
machine. Cab machines come standard with cloth air suspension seats.
SEAT CONTROLS
BD02120 Figure 60
BD02H137 Figure 58
1. BACKREST TILT ADJUSTMENT LEVER
Located between the left-hand console and the
seat on the air suspension and slightly further
back for the mechanical suspension seat, see
photo below.
)
3 A
BD02K005 Figure 61
3. OPERATOR COMFORT CONTROL
On the mechanical suspension seat use the
control knob/crank (3) and follow the directions
on the decal (A). Sit in the seat and adjust the
knob/crank until the yellow pointer reaches the
BD02K003 Figure 59
end of the adjustment barrel. See photo below.
Lift up the lever, move the backrest forward or
rearward, and release the lever. The backrest is
locked in that position.
2. FORWARD/REARWARD ADJUSTMENT
LEVER
This bar is located in the same position for both
seats.
Pull this bar up and adjust the seat forward or
rearward as required. Release the bar to lock the
seat in that position.
BD02K006 Figure 62
6-85641NA Issued 12-05 Bur 3-15

CAB
BD99J182 Figure 63
BD02K015 Figure 66
On the air suspension seat pull the control knob
1. CAB DOOR RELEASE AND LOCK
(A) out to lower the seat. Push in to raise. The
key switch must be in the ON position to activate The cab door may be opened and locked into
the compressor. position.
NOTE: Over time there will be some air loss and the
operator should re-adjust at the beginning of the
work day.
NOTE: Adjust the seat so that you can apply the foot
brake when your back is against the seat backrest.
2
4
BD02K014 Figure 67
2. OUTSIDE CAB DOOR RELEASE
The cab door may be released from the locked
open position by pulling the lever toward the
operator.
BD02H139 Figure 64
4. LUMBAR ADJUSTMENT CONTROL 3
This adjustment is on the left-hand shoulder side for
the air suspension seat and on the lower left-hand
rear side for the mechanical suspension seat.
BD02K013 Figure 68
4 3. INTERIOR CAB DOOR RELEASE
The cab door may be released from the locked
open position by pushing the knob back and
away from the operator.
BD02N037 Figure 65
3-16 Issued 12-05 Bur 6-85641NA

BD02M064 Figure 69
4. COAT HANGER
8
BD02H110 / BD02H112 Figure 72
8. RETRACTABLE SUN VISOR, FRONT
BD02H131 Figure 70
5. CLIMATE CONTROL PANEL
This panel controls the temperature and fan
functions for the cab. See Operating Instructions
in this Manual for specific instructions.
6. CAB VENT
One of six louvered vents for operator comfort.
9
7
BD02H113 Figure 73
9. RETRACT LEVER FOR SUN VISOR
Hold the lever to the right and fold the sun visor
back up carefully.
B
C
A
BD02H108 Figure 71
7. ADJUSTABLE SPOT OR DOME LIGHT
By using the switch (A) the operator may select
the adjustable spot light (B) or the Full dome light
(C).
6-85641NA Issued 12-05 Bur 3-17

10
BD02M134 Figure 74
10. RETRACTABLE SUN VISOR, REAR (IF
EQUIPPED)
11
BD02M135 Figure 75
11. RETRACT CORD FOR REAR SUN VISOR (IF
EQUIPPED)
Pull the cord down and fold the sun visor back up
carefully.
12
BD02H111 Figure 76
12. ADJUSTABLE REAR VIEW MIRROR
3-18 Issued 12-05 Bur 6-85641NA

13
13
14
15
BD021H130 Figure 77
13. OPERATOR COMFORT VENTS
14. 12V AUX POWER SUPPLY (2)
15. LEFT REAR SPEAKER (One each side)
17
BD02H109 Figure 79
17. SLIDING WINDOW ADJUSTMENT AND LOCK
(IF EQUIPPED)
Press the lock in to adjust the window up and
BD02H129 Figure 78
down. Release the lock and the window will stay
16. STORAGE AREA AND TIE DOWN STRAPS (IF in this position. Make sure the window is locked
EQUIPPED into the slot before moving.
6-85641NA Issued 12-05 Bur 3-19

2
1
BD02F002 Figure 80
1. CAB TILT HYDRAULIC JACK:
BD02F033 Figure 82
This jack is used to tilt the cab off for service
2. MASTER DISCONNECT SWITCH:
access. The handle for the jack is located under
the access door on the left-hand side. (Fig. 81) This switch allows the operator or ser vice
technican to stop all power from the battery.
0 =OFF, 1 = ON.
O 1
BD02F028 Figure 81
NOTE: See the Operating Instructions in this Manual
for Cab Tilt procedures.
379422A2 Figure 83
VANDAL LOCKUP ROPS MODEL (Not Shown)
Pull the locking plate from its storage position and
lock it over the instrument panel to lock the machine
from operation.
3-20 Issued 12-05 Bur 6-85641NA

OPERATORS SEAT BELT

The illustrations that follow show the correct procedure to fasten and release the belt.
WARNING: You are protected by the ROPS

(Roll-Over Protective Structure) system on
this machine. The seat belt is an important
part of that ROPS system. Before you
operate this machine, always fasten the seat
belt. If the machine rolls over and you DO
NOT have the seat belt fastened, you can be
crushed by the ROPS or the machine.
SA080
TO FASTEN
Pull the right-hand belt from holder. Fasten the belt
end into the left-hand buckle.
BD02M168 Figure 86
RELEASE BAR
BD02M167 Figure 84
Make sure the belt end and buckle are securely
fastened. The left-hand receiving end of the belt
(buckle) will not pull out.
TO RELEASE
There are two releases on the belt.To release the
seat belt, push the red button or the red bar on the
buckle.
BD99J184 Figure 85
RELEASE BUTTON
6-85641NA Issued 12-05 Bur 3-21

NOTES
3-22 Issued 12-05 Bur 6-85641NA

CHAPTER 4 - OPERATING INSTRUCTIONS
Chapter 4
OPERATING INSTRUCTIONS
TABLE OF CONTENTS
RUN-IN PERIOD OF A NEW MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Track Shoe Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Walk-Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Extreme engine conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Parking the Machine and Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
CRAWLER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Before You Start Each Day . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Direction Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Steering Gradual Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Power Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Counter-rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Adjusting steering sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Transmission speed controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Decelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Onboard diagnostics and computer operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Digital display and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Display menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Activating the service reminder to (AUTO): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Activating the service reminder to (Man): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Setting the next service to (NONE): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Climate control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
MOVING A DISABLED CRAWLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Opening the pressure relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Releasing The Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Lifting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
OPERATING IN HOT WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
OPERATING IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Engine Starting Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Engine Coolant Heater (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Engine Oil Heater (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
BOOSTER BATTERY CONNECTION TO MACHINE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
TILTING THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Lowering the rops cab or canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
DOZER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Blade Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
TRACK SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Components of the Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Components of the Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Factors Controlling Undercarriage Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Issued 12-05 Bur 6-85641NA 4-1

Wear Factors You Can Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30

How to Extend the Life of Sealed Track and the Case Lubricated Track (CLT) . . . . . . . . . . . . . . . . . . . . . . .4-31
Case Extended Life Track (CELT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31
FACTORS CONTROLLING UNDERCARRIAGE WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Bushing and Sprocket Wear Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35
4-2 Issued 12-05 Bur 6-85641NA

RUN-IN PERIOD OF A NEW MACHINE

ENGINE OPERATION
During the first 20 hours of operation, or if you rebuild the engine, make sure you do the following:
1. Operate the machine with normal loads for the first eight hours. Do not work the engine hard at stall speeds
(tracks stopped and the engine running at full throttle).
2. Keep the engine at normal operating temperature.
3. Do not run the engine at idle speeds for long periods of time.
BRAKE PEDAL
Check the operation of the brake on a hard level surface when the machine is new.
TRACK SHOE BOLTS

When the machine is new or if the track shoes have been removed, check the track shoe bolt torque after the first
20 hours of operation with a new machine or if the shoes are removed. Then, check the track shoe bolt torque
every 100 hours of operation until the track shoe bolts remain tight. Tighten to a torque of 406 to 447 Nm (300 to
330 lb ft) for the standard link bolts and 430 to 470 Nm (318 to 346 lb ft) for the master link bolts. Do not over
tighten the track shoe bolts.
WARNING: Before starting engine, study operators manual safety messages. Read all safety signs on
machine. Clear the area of other persons. Learn and practice safe use of controls before operation. It is your
responsibility to understand and follow manufacturers instructions on machine operation, service, and to
observe pertinent laws and regulation. Operators and service manuals can be obtained from your dealer.
SB055
6-85641NA Issued 12-05 Bur 4-3

ENGINE OPERATION
WALK-AROUND INSPECTION 6. Turn the key switch to the START position. If the
Do the following items each day before you start the engine star ts and stops, do not engage the
engine. starter motor again until the starter motor stops
turning.
1. Check for leaks under the machine.
NOTE: Do not operate the starter motor more
2. Check track tension and check for loose,
than 30 seconds at one time. Let the starter
missing, or broken parts.
motor cool for three minutes before you engage
3. Check the machine and equipment (dozer, the starter motor again. While the starter motor is
ripper, etc.) for wear, damage, missing, or broken engaged, white or black smoke must be seen at
parts. the exhaust pipe. If no smoke is seen, check the
4. Check the machine for debris, especially around fuel supply.
the engine area and radiator. Make sure these 7. After the engine starts, check the instruments to
areas are clean. make sure the gauge indications are correct.
5. Clean or replace any safety or instructional Run the engine at 1000 rpm until the coolant
decals that cannot be read. temperature is warm.
6. Clean the steps, hand rails, and operators
ENGINE SPEED
compartment. Remove any loose items in the
operators compartment. Do not run the engine at idle speed for long periods.
This can cause a low operating temperature, which
7. See the Lubrication/Maintenance Chart in this
can cause acids and deposits in the engine oil. It is
manual and do the items under 10 Hours.
recommended that you run the engine at full throttle
when operating conditions permit and when safe.
STARTING THE ENGINE
NOTE: If the weather is cold, if the machine has not IMPORTANT: Turbocharged Engines: If the engine
been run for several weeks, or if the engine oil filter stalls during normal operation, start the engine
has been replaced, see Priming the Turbocharger immediately. This will prevent damage to the
Lines with Oil in this manual. turbocharger.
1. Adjust the seat and fasten your seat belt. Make

sure you can push the brake pedal completely
down with your back against the seat cushion.
2. Make sure the parking brakes are engaged by
pulling both levers all the way back.
3. Make sure the equipment control levers are in
NEUTRAL with the equipment on the ground.
NOTE: The Direction Control Lever must be in
Neutral or the engine will not crank. N will be
displayed on the left side of the Digital Display.
4. Sound the horn to alert those around the
machine that you intend to start.
NOTE: See Operating in Cold Weather in this
manual for starting the engine during cold weather.
5. Turn the key switch to the ON position. Monitor
the display panel for gauge and m achine
functions.
4-4 Issued 12-05 Bur 6-85641NA

PARKING THE MACHINE AND STOPPING THE

ENGINE
1. When the work day is finished, make sure the
machine is parked on level ground.
IMPORTANT: If you must temporarily park the
machine on a hillside, put the front of the machine
toward the bottom of the hill. Make sure the machine
is behind an object that will not move.
2. Lower the dozer blade and ripper (if equipped) to
the ground.
3. Place the Direction Control Lever to NEUTRAL.
4. Engage the parking levers by pulling them all the
way back to the engaged position.
5. Run the engine at low idle speed for a few
minutes if the engine has been working with a
heavy load. This decreases the temperature of
the engine parts evenly.
IMPORTANT: The turbocharger may be damaged if
the engine is not properly shut down.
6. Make sure the engine is at its lowest idle.
7. Turn the key switch to OFF to stop the engine.
8. When you park the machine, make sure the track
system is clean. In cold weather place the
machine on planks. This will prevent the tracks
from freezing to the ground.
If your machine is frozen to the ground, do not try to
drive the machine. This will cause damage to the
power train.
WARNING: Raised equipment on the

machine without an operator can cause injury
or death. Before you leave the operators
compartment, always support or lower the
equipment (backhoe, blade, boom, bucket,
etc.) to the ground and stop the engine.
SA044
WARNING: Jumping on or off the machine

can cause an injury. Always face the
machine, use the hand rails and steps, and
get on or off the machine slowly.
SA038
6-85641NA Issued 12-05 Bur 4-5

CRAWLER OPERATION
The drive and steering on the K Series 2 crawlers are BEFORE YOU START EACH DAY
controlled by a microprocessor. The Direction Control
Lever sends an electronic signal to the controller.
There is no mechanical linkage and therefore an
entirely different “feel” and sensitivity will be noticed
by the operator.
Onboard diagnostics allow the operator to monitor
the service intervals and custom tailor Service
Messages to the work environment. The operator
may also adjust the sensitivity of the machine control
by selecting one of three settings through the
onboard computer.
Be a careful operator, you can prevent accidents.
Read the following information. BD99J183 Figure 1
1. Adjust the seat and fasten your seat belt. Make
WARNING: Always know the location of all sure you can push the brake pedal completely
workers in your area. Warn them before you down with your back against the seat cushion.
start working the machine. Always keep all
other persons away from your area. Serious 2. Turn the ignition switch to ON and monitor the
injury or death can result if you do not follow display gauges.
these instructions.
SA015
WARNING: You are protected by the ROPS F

part of that ROPS system. Before you N
NOT have the seat belt fastened, you can be R
SA080
WARNING: DO NOT operate the machine BD02K029 Figure 2

while under the influence of alcohol or drugs. 3. Place the Direction Control Lever in Neutral.
CM112
NOTE: N should be seen on the Digital Display.
BD04N011 Figure 3
4-6 Issued 12-05 Bur 6-85641NA

12. Test the foot brake by operating the crawler

forward and pushing the brake pedal. The
crawler must stop in a straight line.
NOTE: Pressing the brake pedal all the way down
will engage the parking brake.
WORKING OPERATIONS
This crawler is designed to operate efficiently with
the hydrostatic pumps running at full engine rpm’s.
This provides optimum power and cooling of the
hydrostatic components. Use of the bump up and
BD02H122 Figure 4 down buttons is recommended for reduction of
4. Sound the horn to alert those around that you machine speed. Operation with low engine speeds
are starting the machine. m ay c a u s e ex c e s s i ve h e a t i n g o f hy d r o s t a t i c
5. Start the engine and allow proper warm up. components.
6. When the temperature is cold, -17°C (0°F) and For continuous roading situations, it is recommended
below, see Operating in Cold Weather in this not to bump the machine speed above 8.
manual.
7. Push the Parking Brake Levers Down into the
Disengaged position. Both the right and left
levers must be down.
8. Use the Transmission Speed Down Button to
place the machine in a lower speed. The
Transmission Speed Gauge will reflect the speed
selected.
NOTE: The Transmission Speed will default to the

60% speed each time the machine is shut off.
9. Raise the blade above the ground and make sure
the ripper, if equipped, is in the TRANSPORT
position.
BD02H125 Figure 5
10. Press the Decelerator Pedal all the way down.
11. Place the Direction Control Lever in F (Forward)
and slowly release pressure on the Decelerator
Pedal.
NOTE: The crawler will not move if the engine rpm is
below 1000.
6-85641NA Issued 12-05 Bur 4-7

DIRECTION CONTROL LEVER TURNING

Fo r w a r d o r r eve r s e m o t i o n m u s t a l w ay s b e
commanded in conjunction with turning. Moving the
F direction control lever only left or right will result in no
motion. Turns must be taken through forward or
reverse.
1
N STEERING GRADUAL TURN
1. To turn the crawler to the left push the Direction
Control Lever forward and to the eleven o’clock
position. The crawler will gradually turn to the
left.
R
2. To turn the crawler to the right, push the Direction
Control Lever forward and to the one o’clock
position. The crawler will gradually turn to the
right.
BD02K029 Figure 6
1. DIRECTION CONTROL LEVER
T h e d r i ve a n d s t e e r i n g a r e c o n t r o l l e d by a
microprocessor. The Direction Control Lever sends
an electronic signal to the controller. There is no
mechanical linkage and therefore the “feel” and
“sensitivity” may be significantly different from
conventional crawlers.
The Direction Control Lever will detent into Forward
or Reverse. The operator must pull the Direction
Control Lever out of these positions. See Turning on
the this page. B911447JFX Figure 8
POWER TURN
1. By pushing the Direction Control Lever toward
the ten o’clock position the crawler will turn
sharper to the left with appropriate power to each
track.
2. By pushing the Direction Control Lever toward
the two o’clock position the crawler will turn
sharper to the right with appropriate power to
each track.
COUNTER-ROTATION
BD04N011 Figure 7 1. To counter-rotate the crawler to the left, push the
Push the Direction Control Lever into the position you Decelerator Pedal all the way down, push the
wish the crawler to go and verify the selection by Direction Control Lever forward and then straight
reading the Digital Display. See Figure 7 above left to the nine o’clock position. Slowly release
(Neutral shown). the Decelerator Pedal.
NOTE: The crawler will not move unless engine rpm 2. To counter-rotate the crawler to the right, push
is above 1000. the Decelerator Pedal all the way down, push the
Direction Control Lever forward and then straight
To turn the crawler push the Direction Control Lever
right to the three o’clock position. Slowly release
toward the direction desired. Turning must always be
the Decelerator Pedal.
commanded through Forward or Reverse.
NOTE: The Steering sensitivity has three settings
and may be adjusted for operator or work preference.
4-8 Issued 12-05 Bur 6-85641NA

ADJUSTING STEERING SENSITIVITY 4. Toggle through the setting menu by using the Up
The Direction Control Lever has three sensitivity or Down arrows (2) until (STEER 2) is shown on
settings (1,2,3) and will be set at 2 from the factory. the Digital Display.
STEER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Smooth NOTE: (STEER 2), Normal is the setting from the
STEER 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normal factory.
STEER 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fast 5. When, (STEER_#) is on the Digital Display
screen press the Service/Enter button (3). The #
To change the sensitivity:
will blink.
6. Change the # by using the Up or Down arrow (2).
7. After selecting the sensitivity desired press the
Service/Enter switch (3) again to store the
information.
NOTE: The Settings Menu may be hidden entirely by
1
contacting your Dealer.
ADJUSTING SHUTTLE PARAMETER

To adjust the Shuttle parameter follow the same
steps as for Steering Sensitivity.
BC02M138 Figure 9 At step 5:
1. Press and release the Service/Enter switch (1). (SHUTTLE _#) At this display where the # is
located the value can be 1, 2 or 3. 1 being
smooth and 3 being fast.
SETTINGS
After selecting desired value press the Service/Enter
switch.
2 ADJUSTING MAXIMUM TRANSMISSION SPEED

PARAMETER
To adjust the Maximum Transmission speed follow
the same steps as for Steering Sensitivity.
At step 5:
(MAX_SP###) At this display where the ### are
BC02M138 Figure 10 located the value can be 70,80,90 or 100.
2. Use the up or down arrow to display the settings After selecting desired value press the Service/Enter
menu, (SETTINGS) on the Digital Display. switch.
STEER 2
BC02M138 Figure 11
3. Select the SETTINGS menu by pressing the
Service/Enter switch (3).
6-85641NA Issued 12-05 Bur 4-9

TRANSMISSION SPEED CONTROLS The Digital Display (4) will reflect the position of the
Direction Control Lever as Forward, Neutral or
Reverse.
1
NOTE: The crawler will not move unless the engine
rpm is above 1000.
NOTE: A flashing F or R indicates the directional
control lever must be returned to neutral before
movement is allowed.
WARNING: The Direction Control Lever has three
sensitivity settings. Be familiar with the setting that
2 best suits the work and operator requirements.
BD02M166 Figure 12
1. TRANSMISSION SPEED UP BUTTON
2. TRANSMISSION SPEED DOWN BUTTON
The CASE K Series 2 Crawlers have infinitely
variable speeds in Forward and Reverse from 0 to
9.7 km/h (0 to 6.7 mph). The maximum speed is
selectable in a range of 10 increments. To move from
one speed to another press the UP (1) or DOWN (2)
button. The operator may increment up one touch at
a time or hold the button to move through the
transmission speeds.
NOTE: The speed can only be increased to the
maximum transmission speed setting, which can be
adjusted. See page 4-9. From the factory 90% is the
highest speed.
NOTE: When the crawler engine is shut off the

Transmission Speed will default to 60%.
BD04N011 Figure 13
3. TRANSMISSION SPEED GAUGE
4. DIGITAL DISPLAY
The Transmission Speed Gauge (3) will allow the

operator to know which Speed is selected. When the
crawler engine is shut off the Transmission Speed will
default to 60%, as shown above.
4-10 Issued 12-05 Bur 6-85641NA

DECELERATOR PEDAL
BD02H125 Figure 14
383971A1 Figure 16
The Decelerator Pedal can be used by the operator
to slow or stop the vehicle. It reduces the throttle
setting as it is depressed. The decelerator works in
any direction, forward or reverse. 7
BD02K029 Figure 17
7. ENGINE HAND THROTTLE
1. Pull the Throttle Lever back to increase the
BD02M025 Figure 15 engine speed.
6. REVERSE TO FORWARD SPEED RATIO CONTROL
2. Push the Throttle Lever forward to decrease the
This control knob allows the operator to control the engine speed.
reverse speed in relation to the forward speed.
NOTE: Always shut the engine down with the throttle
Rotate the knob clockwise to increase the speed of
at its lowest setting to keep from damaging the
reverse faster than forward. The knob will stay in the
turbocharger.
desired position.
6-85641NA Issued 12-05 Bur 4-11

ONBOARD DIAGNOSTICS AND COMPUTER OPERATION
3
1 2
BD04N010 Figure 18
DIGITAL DISPLAY AND CONTROL 4. The engine r/min (rpm) display will show, engine
The Digital Display (1) may be used to view Service r/min (rpm) on the right hand side of the Digital
and Operating Information. By using the Menu Display, if selected. FNR will show on the left
Up/Down Arrow Switch (2) and the Display - hand side.
Service/Enter Switch (3) the operator or service 5. The Next Service display will show NS on the left
technician may display fault codes, monitor service hand side of the Digital Display. The right hand
schedules or change operating parameters. side of the Digital Display will show the engine
hours until the next service is due. If the service
DISPLAY MENUS interval has passed the display will show service
interval hours in negative numbers -##.#.
To access the Display Menus:
NOTE: A flashing F or R indicates the Direction
Control Lever must be returned to neutral before
movement is allowed.
3
BC02M13 Figure 19
1. Press the Display-Service / Enter Switch (3).
2. Press the Up or Down arrow (2) to select the
desired display.
3. The driving display will show hour meter reading
or engine RPM on the right hand side of the
Digital Display. The left side of the display will
show the transmission FNR selection.
4-12 Issued 12-05 Bur 6-85641NA

When the Service Reminder has been activated

and set to (AUTO):
1. The operator will be notified when the crawler
reaches within 10 hours of the “Next Service”
(NS).
BD04N010 Figure 20
2. The Service Soon lamp (1) will illuminate for 5
seconds and the exact information will be on the
Digital Display.
3. When the crawler is at NS the service reminder
will automatically reset to the next service due.
NOTE: The service reminder message may be
custom tailored to your work environment or turned
off, if desired. From the factory the service reminder
will be NONE.
NOTE: Viewing any service menu for more than 30

seconds without pressing a button will cause the
display to default back to the driving display.
6-85641NA Issued 12-05 Bur 4-13

When the Service Reminder has been activated 6. Press the Service/Enter switch (3) to store the
and set to (MAN): information.
1. The operator will be notified when the crawler NOTE: After changing the Service Interval, the
reaches within 10 hours of the “Next Service” Service Reminder feature must be reset before Next
(NS). Service (NS) will be updated.
2. The Service Soon lamp (1) will illuminate for 5
NOTE: Factory default for Service Interval (SI) is 250
seconds and the exact information will be on the
hours.
Digital Display.
3. When the crawler is at, or goes past NS the
Service Soon lamp will remain illuminated and
the Digital Display will show negative (-) in front
of the hours until the operator or ser vice
technican manually resets the interval.
1
2
3
BC02M138 Figure 21
Resetting The Service Reminder:
This procedure will allow the operator or service
technican to reset the next service due (NS).
1. Press and release the Service/Enter switch (3).
2. Use the Up/Down arrows (2) to display the
service reminder menu, (SERV_RMDR).
3. Select the service reminder menu by pressing
the Service/Enter switch (3).
4. The Digital Display will read (RESET?_).
5. Press the Service/Enter switch (3).
The computer will automatically calculate when
the next ser vice (NS) is due, based on the
Service Interval (SI).
Changing the Service Interval:
This procedure will allow the operator or service
technican to customize the service intervals.
1. Press and release the Service/Enter switch (3).
2. Use the Up/Down arrows (2) to display the
service reminder menu, (SERV_RMDR).
3. Select the service reminder menu by pressing
4. The Digital Display will read (RESET?_).
5. Use the Up/Down arrows (2) to change the
intervals, I.E., 50 to 100.
4-14 Issued 12-05 Bur 6-85641NA

ACTIVATING THE SERVICE REMINDER TO

(AUTO):
1. Press and release the Service/Enter switch (3) to
enter to service menus.
2. Use the Up or Down arrow switch (2) to display
the service reminder menu, (SERV_RMDR).
2
3. Select the service reminder menu by depressing
the Service/Enter (3) switch.
4. Use the Up or Down arrows (2) until (AUTO) is
displayed. 3
5. Press and release the Service/Enter switch (3)
and the setting is changed. BC02M138 Figure 22
ACTIVATING THE SERVICE REMINDER TO

(MAN):
3. Select the service reminder menu by depressing
4. Use the Up or Down arrows (2) until (MAN) is
displayed.
5. Press and release the Service/Enter switch (3)
and the setting is changed.
SETTING THE NEXT SERVICE TO (NONE):

Press the Service/Enter switch (3) to select it.
3. Use the Up or Down arrows (2) to display the
service interval parameter (SI). Select it by
pressing the Service/Enter Switch (3).
the “NONE” selection. Press Ser vice/Enter
switch (3) to select it.
5. Reset the service reminder using the procedure
described above to update NS.
6-85641NA Issued 12-05 Bur 4-15

CLIMATE CONTROL SYSTEM
1
2
BD02K025 Figure 23
1. AIR CONDITION CONTROL KNOB - Turn the
knob to the snowflake icon to activate the air
conditioner.
WATER SHUTOFF VALVE
Turn the water shutoff valve off or clockwise all
the way to maximize the air conditioning.
2. TEMPERATURE CONTROL - Adjust this knob to
control the cab temperature. Red zone is warmer
and Blue zone cooler.
3. AIR RECIRCULATION - This control allows the
operator to choose, outside air or cab only
circulation.
A. Turn the knob all the way counter clockwise for
cab only recirculation.
B. Turn the knob all the way clockwise for outside
air to be recirculated in the cab.
4. FAN - Set the 3-speed fan at desired comfort
setting.
4-16 Issued 12-05 Bur 6-85641NA

MOVING A DISABLED CRAWLER
WARNING: Personal injury or death can result if you move this crawler incorrectly. Attach a towing machine
or block the tracks of the disabled crawler to prevent movement before you release the brakes or relieve
pressure. The machine can move out of control if you do not block the tracks. The following instructions are
for moving the machine a short distance only.
SÁ129
WARNING: Tow option bypasses high pressure relief valves. Catastrophic hydrostatic motor damage can
occur if hydraulic circuit empties or overheats.
Figure 24
If your machine is disabled, you must make a judgment if the machine can be moved without more damage. If
possible, repair the machine at the job site. If necessary, contact your dealer.
To move the machine you must:
1. Tilt the cab to access the service area. See tilting the cab in this section on page 4-25.
IMPORTANT: The cab may only be tilted on a hard and level surface.
2. Open pressure relief valves to bypass the hydrostatic motors. (two upper valves for forward movement and two
lower valves for rearward movement.
3. Release the brakes.
OPENING THE PRESSURE RELIEF VALVES

This instruction is for moving the machine a few feet
and no faster than 1.6 km/hr (1 mph). Park the haul
trailer as close as possible to the machine.
1. Make sure the machine used for moving the
disabled one has the braking capacity, weight, 2
and power to control both machines.
2. The towing machine must be equipped with a
rear shield to protect the operator if the cable or
tow bar disengages. Do not use chain to tow this
machine.
3. If required, attach a second machine behind the BD02M124 Figure 26
disabled machine to assist with additional control 2. LOWER RELIEF VALVES FOR MOVING THE CRAWLER IN
or braking. A REARWARD DIRECTION (SHOWN LOOKING TO THE
REAR OF THE CRAWLER)
4. Attach a rigid drawbar or cables to the disabled
machine. NOTE: The belly pan will have to be removed to
access the lower relief valves.
BD02M127 Figure 25
BD02N033 Figure 27
1. TOP OR UPPER RELIEF VALVES FOR MOVING THE 5. Remove the relief valve plastic protective caps.
CRAWLER FORWARD
6-85641NA Issued 12-05 Bur 4-17

RELEASING THE BRAKES

This machine is equipped with SAHR (spring applied
hydraulically released) parking brakes. Hydraulic
pressure must release the brakes. If the engine will
not run, you MUST use a hand pump to release the
brakes.
BD02N036 Figure 28
6. Use a 4 mm allen wrench and turn the
engagement screw out three turns on each relief
valve.
BD02H050 Figure 29
1. Connect a vacuum pump, if available, to the
hydraulic reservoir and hold a vacuum to keep
from losing fluid.
BD02F009 / 4195 Figure 30

2. Disconnect the fitting (2) at the brake solenoid
and cap it as shown in Fig 33.
BD02H057 Figure 31
4-18 Issued 12-05 Bur 6-85641NA

BD02M125 Figure 32
CAP INSTALLED
BD02M126 Figure 33
3. Connect a hand pump with the capacity to reach
and maintain 2275 kPa, 22.7 bar (330 ±20 psi).
4. Operate the pump until the correct pressure is
reached and the brakes are now released.
IMPORTANT: Check and maintain 2275 kPa, 22.7
bar (330 ± 20 psi) maximum in the brake line when
moving the machine. Damage to the brake system
can result if the pressure is reduced.
5. Remove tools and equipment from the service
area and slowly lower the cab to the operating
position.
6. The machine is now ready to be moved.
7. After moving raise the cab back up all the way to
over center by making sure the retaining cable is
fully extended. See Cab Tilt procedure in this
manual.
8. Disconnect the hand pump.
9. Remove the plug and reconnect the line to the
brake solenoid.
10. Remove the vacuum pump, if used.
11. Tighten the relief valve engagement screws back
in carefully until it stops.
12. Install the belly pan if the lower relief valves were
used.
6-85641NA Issued 12-05 Bur 4-19

TRANSPORTING THE MACHINE
WARNING: The machine can slip and fall

from a trailer or ramp and cause injury or
death. Make sure the trailer and ramp is not
slippery. Remove all oil, grease, ice, etc.
Carefully move the machine off or onto the
trailer with the machine centered on the trailer
and ramp.
SB042
You must know the rules or laws for safety that are
used in each area that you will be in. Make sure that
your truck and crawler are equipped with the correct BD02M166 Figure 36
safety equipment. 9. When moving the crawler off of the trailer, select
a slower drive speed by using the Transmission
Speed Down button on the Direction Control
Lever.
10. Drive slowly and keep the machine centered on
1 the trailer and ramp.
1
WARNING: When moving the machine on or
off of the trailer, drive slowly and keep the
machine centered on the trailer and ramp.
CM113
B835873F Figure 34
1. BLOCKS FOR TRAILER WHEELS
1. Put a block on both sides of the trailer wheels.
2. Be careful. Move the crawler slowly onto the
trailer. Place the Direction Control Lever in the
neutral position.
3. Lower the blade and ripper, if equipped, to the
trailer.
4. Put the parking brakes into the engaged position
by pulling both levers all the way back.
5. Stop the engine and remove the key.
BD02M052 Figure 35
6. Use chains to fasten the crawler to the trailer.
7. Put blocks at both ends of the tracks.
8. Remove the blocks from the trailer wheels.
4-20 Issued 12-05 Bur 6-85641NA

LIFTING THE MACHINE

IMPORTANT: Only personnel with heavy machine lifting experience should attempt lifting the crawler. Contact your
Dealer.
BS02N080 / BS02N081 Figure 37

Lifting equipment must be passed around the track evenly front and rear, right and left sides.
IMPORTANT: Lifting equipment and rigging must have a capacity rating sufficient to handle the weight of the
machine.
IMPORTANT: All personnel should be clear of the general area before lifting the crawler.
BS02N082 Figure 38
6-85641NA Issued 12-05 Bur 4-21

OPERATING IN HOT WEATHER 4. COOLING SYSTEM: Check the coolant mixture

before you operate in cold temperatures. A
To prevent damage to the machine, do the following: mixture of 50% ethylene glycol and 50% water
1. Keep the coolant at the correct level in the must be used in this machine. This mixture is
coolant reservoir and in the radiator. used if the lowest ambient temperature is above
2. Test the radiator cap before hot weather starts. -37°C (-34°F). If the ambient temperature is
Replace the cap as required. lower, adjust the mixture to 60% ethylene glycol
and 40% water. It is recommended that ethylene
3. Clean all dirt and debris from the radiator and glycol and water be used in your machine all
engine area daily. year.
4. Check the condition of the fan drive belt.
5. COLD TEMPERATURE STARTING AIDS: See
5. Use lubricants of the correct viscosity. your dealer for extra starting aids such as battery
6. Use the correct solution of ethylene glycol and heater, coolant heater, engine oil heaters, etc.
water in the cooling system. 6. GENERAL: Before you operate, move the
7. Check the dust valve for the air cleaner more machine slowly in LOW gear and actuate each
frequently during extreme dust conditions. hydraulic control for about ten minutes.
8. Check the battery at 250 hours when conditions When you park the machine, make sure the track
require. system is clean. In cold weather place the machine
9. Clean dirt from the precleaner daily. on planks. This will prevent the tracks from freezing
to the ground.
OPERATING IN COLD WEATHER If your machine is frozen to the ground, do not try to
drive the machine. This will cause damage to the
Cold weather conditions cause special problems.
power train.
During these conditions, your machine will require
special attention to prevent serious damage. Cold
weather maintenance will extend the service life of ENGINE STARTING AIDS
your machine.
GRID HEATER (IF EQUIPPED)
1. BATTERY AND ELECTRICAL SYSTEM: Clean
This machine is equipped with an manifold grid
the battery and make sure the battery is at full
heater cold weather starting aid which is effective in
charge.
temperatures down to -18°C (0°F). The manifold grid
NOTE: A fully charged battery at -17°C (0°F) has heater heats indrawn air, prior to it entering the
only 40 percent of the normal starting power. combustion chamber.
Then, when the temperature decreases to -29°C
WARNING: Ether must not be used.
(-20°F), the battery has only 18 percent of the
power remaining. To use the grid heater in temperatures below 4°C
If you add water to the battery and the temperature is (40°F) open the throttle fully. Turn the key switch to
below 0°C (32°F), make sure you charge the battery the ON position and check the instrument cluster.
or run the engine for approximately two hours. This Wait for the cold start indicator light to go OFF before
procedure will prevent battery freezing. turning the key switch to the START position. Turn
the key switch the START position until the engine
Inspect the battery cables and terminals. starts, then release the key.
2. LUBRICANTS: Use the correct viscosity oil in If the engine fails to start after a maximum of 60
each component. As an example: SAE 30 engine seconds of cranking repeat the starting procedure.
oil at 0°C (32°F) increases the starting load by Do not operate the starting motor for more than 60
about 250 percent. Make sure you follow the seconds.
recommended oil and filter service as shown in
this manual. NOTE: If the operator does not crank the engine
within 30 seconds after the grid heater lamp has
3. FUEL SYSTEM: Check with your fuel supplier for
gone out the process must be started over.
the correct cold weather fuel. Engine power will
be reduced if wax particles are in the fuel filters.
Make sure to check for water in the fuel system. Cold
temperatures can cause water to collect in the fuel
tank. Check the first stage fuel filter for water. If no
water is found, extend the interval.
4-22 Issued 12-05 Bur 6-85641NA

ENGINE COOLANT HEATER (IF EQUIPPED) ENGINE OIL HEATER (IF EQUIPPED)
The right side of the engine cylinder block is provided The engine oil heater is installed on the right side of
with a passage for installing a coolant heater. See the engine oil pan. See your dealer for this option.
your dealer for this option. Follow the heater Follow the heater manufacturers instructions for
manufacturers instructions for installing. installing.
1. ENGINE OIL HEATER LOCATION
BD99J214 Figure 39
1. COOLANT HEATER PASSAGE
B830661M Figure 41
B830661M Figure 40
6-85641NA Issued 12-05 Bur 4-23

BOOSTER BATTERY CONNECTION TO

MACHINE BATTERY 1
WARNING: Batteries produce explosive

gases. Keep sparks, flame, and cigarettes
away. Ventilate when charging or using in an
enclosed space. Always shield eyes when
2
working near batteries.
SA031
Two persons are required for this procedure. Make

sure the person making the connection is wearing
face protection.
1. Sit in the operators seat and have the other
person make the connections. Make sure the BD02J063 Figure 42
booster battery is 12 volts.
1. POSITIVE (+) JUMPER CABLE
2. If using another machine for power, make sure 2. NEGATIVE (-) JUMPER CABLE
the two machines do not touch.
3. Connect the positive (+) jumper cable to the
positive (+) battery terminal.
4. Connect the negative (-) jumper cable to a good
frame ground away from the battery.
5. See Starting the Engine in this manual and use
the correct procedure to start the engine. Have
the other person disconnect the negative (-)
jumper cable first and the positive (+) jumper
cable last.
4-24 Issued 12-05 Bur 6-85641NA

TILTING THE CAB
WARNING: Make sure there are no loose objects in the cab or canopy prior to tilting. Falling objects could
cause death and serious injury.
M853
WARNING: The cab may only be tilted when the crawler is on a level and firm surface.
Figure 43
IMPORTANT: The left and right hand ROPS side panels must be OPEN to prevent interference with frame
components. The left and right engine compartment panels and cab doors must be CLOSED.
1. Park the machine on a level, and hard surface.
WARNING: Use additional support to hold the cab
over if the machine is not on level ground. The
operator or service technican must make a judgement
if conditions are safe to lilt the cab.
2. Engage the parking brakes by pulling both levers
all the way back.
3. Open the right and left side panels under the
cab.
BD02F005 Figure 46
BD02F033 Figure 44
4. Turn the master disconnect switch to the “power
off” position as shown. BD02M058 Figure 47
6. Tip the brush guard back and block with suitable
hardware to keep it from coming back down into
contact with the canopy.
BD02F003 Figure 45
5. Remove the two bolts that attach the brush guard
to the canopy, if equipped. (one each side)
BD02F006 Figure 48
7. Remove the six support mount bolts on the right
side of the cab.
6-85641NA Issued 12-05 Bur 4-25
BD02F008 Figure 49 BD02M120 Figure 52

8. Remove the clevis pins from the control valve IMPORTANT: Be certain that the cab is tilted clear
behind the right-hand middle access door. over to the maximum over center degree and that the
retaining cable is tight.
BD02F021 Figure 50
BD02M164 Figure 53
9. Open the left engine compartment panel and
RETAINING CABLE
disconnect the throttle linkage quick disconnect.
Pull the outer collar toward you and slip the
Refilling and Bleeding the Tilt System
coupler off of the pivot ball.
BD02F024 Figure 54
BD02F020 Figure 51 1. Make sure that the cylinder rod is fully retracted.
10. Turn the pump diverter valve (1) into the cab tilt 2. Remove the fill check plug (2) and fill with
position. (long portion of the handle to the left of MS-1209 Hy Tran.
center) Actuate the hand pump and tilt the cab
3. Tilt and lower the cab two to three times to
slowly.
remove air from the system.
4. If necessary top off with oil and install the fill
check plug.
4-26 Issued 12-05 Bur 6-85641NA

LOWERING THE ROPS CAB OR CANOPY
BD02F008 Figure 58
BD02F018 Figure 55 5. Connect the control rods to the hydraulic control
1. Turn the diverter valve to the lower position. (long valve.
portion of the handle to five o’clock) Actuate the NOTE: Align the spool in the direction of linkage
hand pump and lower the cab slowly. travel.
BD02F007 Figure 56 BD02F021 Figure 59

2. Install the six support mount bolts and torque to 6. Open the left engine compartment panel and
550 - 623 Nm (406 - 460 ft lb). connect the throttle linkage quick disconnect.
3. If equipped with a brush guard, lower the brush Pull the outer collar towards you and slip the
guard into alignment with the cab. coupler over the pivot ball.
BD02F004 Figure 57
4. Install the bolts and torque to 570 to 730 Nm
(420 to 540 ft lb).
6-85641NA Issued 12-05 Bur 4-27

DOZER OPERATION
BLADE PITCH
WARNING: Always know the location of all
workers in your area. Warn them before you
start working the machine. Always keep all 1 2
other persons away from your area. Serious
injury or death can result if you do not follow
these instructions.
SA015
WARNING: You are protected by the ROPS

part of that ROPS system. Before you
operate this machine, always fasten the seat BC00G049 Figure 60
1. REARWARD POSITION (52 DEGREE PITCH)
NOT have the seat belt fastened, you can be 2. FORWARD PITCH (60 DEGREE PITCH)
SA080 Rearward Position Advantages
1. Blade is able to push larger load.
WARNING: DO NOT operate the machine
while under the influence of alcohol or drugs. 2. Blade will stay on top in soft ground.
CM112 3. Blade will not dig into ground.
WARNING: Raised equipment on the 4. Blade best used for fine grading.
Forward Position Advantages
compartment, always support or lower the 1. Load slides off the blade as the crawler travels in
equipment (backhoe, blade, boom, bucket, reverse.
etc.) to the ground and stop the engine. 2. Blade will dig into hard ground.
SA044
3. Less load spillage over top of blade.
WARNING: Jumping on or off the machine NOTE: See Blade Pitch Adjustment in this manual
can cause an injury. Always face the for adjustment procedure.
machine, use the hand rails and steps, and
get on or off the machine slowly. BLADE LIFT EYE
SA038
WARNING: Hillside operations can be

dangerous. Rain, snow, ice, loose gravel, soft
ground, etc., change the ground conditions.
You must make a judgment if your machine
can be safely operated on any hillside or
ramp.
SB013
The operating tips given in this section do not include

all possible conditions. This is basic information that
can help you move more material in less time.
If you are a new operator, always operate the
machine in an open area at decreased speed until
BD99J147 Figure 61
you know the function of each control.
Do not pull, tow, or lift the machine using the blade lift
eye.
ENGINE SPEED
Run the engine at full throttle when safe. The ground
condition and type of job will control the track speed
and range position that you use.
4-28 Issued 12-05 Bur 6-85641NA

TRACK SYSTEMS
2
1 8
3
7
4
5 6
BD04N014 Figure 62
COMPONENTS OF THE UNDERCARRIAGE

To fully understand the undercarriage, it is important to understand the purpose of each component. It is also very
important to know how the component functions with the other components in the system.
1. IDLER 6. TRACK ADJUSTER GREASE FITTING
The idler carries the track chain around the front The track adjuster is a grease filled hydraulic
of the track frame. This assembly can slide cylinder used to maintain or adjust track tension.
forward or rearward on the track frame against To change track tension, add grease or remove
the recoil spring to absorb any shock loads. grease from the track adjuster.
These shock loads can be from changes in the
7. TRACK FRAME
terrain or temporary material buildup on the
tracks. The track frames are attached to the machine
chassis on each side. All of the track
2. CARRIER ROLLER components, except the drive sprockets are
The roller is mounted on the top of the track attached to the track frames.
frame to support the track chain between the
8. TRACK LINKS
drive sprocket and idler. This roller also helps to
maintain alignment of the chain between the idler A number of track links make up the track chain
and drive sprocket. assembly. Each link assembly consists of a
right-hand and a left-hand link, the track pin is
3. TRACK CHAIN solid with sealed track chains and hollow with
The track chain includes a number of link (Case Lubricated Track) chains, bushings and
assemblies that are connected together to form a seals. Each link assembly is bored at both ends
complete chain. Shoes are bolted to the track to hold the pins and bushing that connect the two
chain to provide traction for the machine. The links. The bushing is pressed into each link. A pin
drive sprocket rotates the track chain around the is inserted through the bushing and the next set
undercarriage assembly. of links is pressed onto the pin. It is important to
understand the construction of the track
4. DRIVE SPROCKET
chain. The pins and bushings of the sealed
The drive sprockets transmit engine power to the track are generally the first items of the
tracks. The drive sprockets do not support the undercarriage to wear. This wear will affect
weight of the machine. the rest of the components in the
5. TRACK ROLLERS system.Wear par ts are not covered under
machine warranty.
The track rollers are mounted to the bottom of
the track frame. These rollers carry the weight of
the machine on the track chain.
6-85641NA Issued 12-05 Bur 4-29
COMPONENTS OF THE UNDERCARRIAGE
10
10
BD99J230 Figure 63
9. TRACK SHOES Severe packing of materials between undercarriage
The track shoes are installed on the track chain components causes wear by increasing track
to give traction and flotation to the machine. tension.
10. TRACK GUIDES NOTE: Running tracks that are too tight reduces
bushing and sprocket life 2.5 to 3 times.
To prevent rocks and debris from entering
between front roller, idler, and rear roller and Operating techniques and maintenance also greatly
sprocket. affect undercarriage life. Unlike the other wear
fa ctor s that yo u can not control, yo u can do
FACTORS CONTROLLING UNDERCARRIAGE something about the way you operate and maintain
WEAR the machine.
Undercarriage wear is an inevitable part of owning a NOTE: Avoid spinning the tracks as much as
track machine. Sooner or later, even the best possible, especially in abrasive soil conditions.
undercarriage will need to be replaced.
NOTE: Avoid long runs at high speed and limit the
You can prolong undercarriage life by understanding amount of reverse travel.
factors that contribute to wear.
NOTE: Avoid frequent reverse operation. If
Soil conditions are a major factor in determining the necessary to work in reverse, keep travel speed to a
amount of life you can expect from an undercarriage. minimum.
Nonabrasive soils, such as silt and clay, cause the
least amount of wear. Wet, sandy soils are the most Speed impact, turning and direction of operation
abrasive and cause the most wear. greatly affect wear.
Working in rocky conditions and other surfaces, NOTE: When possible, work up and down a slope
where the grousebars do not penetrate, causes high instead of across it. This decreases wear on roller
impact and twisting loads on the track chains. flanges and link side rails.
Now that you know the major factors contributing to Check track tension and clean the undercarriage
track wear and you are serious about reducing the more frequently when working in high packing
maintenance and repair of your undercarriage, here conditions.
are a few operating and maintenance tips to help you
get the most life from your machine’s undercarriage. NOTE: Tracks that are too tight rob power and cause
early bushing and sprocket wear. Periodically check
WEAR FACTORS YOU CAN CONTROL tracks for correct tension.
NOTE: Minimize the effects of packing by checking Constantly turning the crawler in the same direction
track sag frequently when working in mud, snow and will cause uneven wear.
wet sand. Packing can cause track jumping and Use the smallest track shoes possible to minimize
banging. track chain twisting. Limit the use of wide track shoes
to flotation applications.
Park the machine on level ground to prevent seal
distortion (Case Lubricated Track).
4-30 Issued 12-05 Bur 6-85641NA

Clean the undercarriage more often when operating The major reduction in wear on the CELT chain is the
in freezing conditions and park the machine on exter nal bushing wear caused by the sprocket
planks or a surface that the machine will not freeze contact. The CELT bushing rotates with the sprocket.
to. The wear point is primarily between the outer and
inner bushing, and therefore as the chain wears it
HOW TO EXTEND THE LIFE OF SEALED TRACK may become somewhat more “noisy” under certain
AND THE CASE LUBRICATED TRACK (CLT) transporting conditions due to the wear between the
NOTE: Turn the pins and bushings at the 100% wear inner and outer bushings. This is normal.
limit. Operating past the 100% wear limit can cause Recommended Application
the bushings to crack or to wear completely through
to the pin. T h e C a s e E x t e n d e d L i fe Tr a c k ( C E LT ) i s
r e c o m m e n d e d i n h i g h a b r a s i ve / l ow i m p a c t
NOTE: Letting the pins and bushings run to applications where bushing wear is severe. The
destruction results in accelerated wear of other narrowest possible track shoe th at will give
components. Turn the pins and bushings to extend a d e q u a te fl o ta t i o n s h o u l d b e u s e d to o b ta i n
track life. maximum life from the sealed and lubr icated
standard pin and bushing joint. Field testing in
CASE EXTENDED LIFE TRACK (CELT) abrasive conditions has proven the CELT bushing will
T he C a s e E x te n de d Li fe Tra ck (CE LT ) c h ain obtain up to twice the wear life as the conventional
incorporates a bushing that is free to rotate on the lubricated track bushings.
standard lubricated track bushing. This method NOTE: If the machine has sat for extended periods
allows wear to be distr ibuted over the entire of time or is working in corrosive environmental
circumference of the bushing and because the applications, it is recommended that the bushings be
bushing is free to rotate it does not create the checked before operating the machine. If the
scrubbing action between the sprocket and the bushings will not rotate, they should be loosened
bushing as the conventional crawler track chain does. using an acceptable tool. This is especially
necessary on new chains where the clearance
between bushings is minimal.
FACTORS CONTROLLING UNDERCARRIAGE WEAR

WEAR FACTORS YOU CAN NOT CONTROL High Abrasiveness
You can not stop normal undercarriage wear - even if These soils contain a high amount of sharp, irregular
you have the best design and top quality parts. You shaped sand particles.
can however, increase the undercarriage life if you
Impact
understand the causes of wear. Soil and underfoot
conditions can not be controlled. These include Impact is best described as the amount of grouser
abrasive soils, impact, packing and moisture. penetration in the ground. The effect of high impact
loads can be reduced by reducing the machine
Abrasive Soils speed and by using the smallest track shoes
Each type of soil a machine works in has a different possible.
level of abrasiveness. Generally, the higher the
Low Impact
abrasiveness, the higher the wear rate.
Track shoe grousers will completely penetrate the
Moisture also plays a major roll in the abrasiveness
ground surface with little or no rock or other
of soils. A sand slurry will be less abrasive than a
irregularities.
damp sand, especially if the sand is packing the
sprocket roots and around the bushings. Wet High Impact
abrasives act like grinding compounds. Track shoe grousers will not penetrate the ground
Low Abrasiveness surface. Large rock or large irregularities cause high
impact loads on the undercarriage system. Rocky
Silts and clays are in this category. When wet, this
terrain causes bending, breaking and chipping of the
type soil feels slick and can be easily molded.
components. Reduce the machine speed and use
Moderate Abrasiveness the smallest track shoes possible.
Silts or clays that contain a low amount of rounded
sand particles and enough moisture to stick together,
are in this category.
6-85641NA Issued 12-05 Bur 4-31

Packing Track Shoes

Packing materials are any material that sticks to or The shoes must provide adequate traction and
packs around the moving components. To maintain flotation but must be no wider than absolutely
correct track tension, the tracks must be adjusted as necessary. Flotation is the ability to stay on the
often as required when working in this type of soil surface of soft ground or mud. Correct flotation
condition. occurs when the grousers penetrate fully into the
Packing materials cause a mismatch between ground without letting the track shoes go below the
components, particularly between the chain and surface.
sprocket. The packing materials tighten the chain Track shoes that are too wide can have a damaging
causing increased stress and strain on links, pins, effect on many of the undercarriage components.
bushings and the contact surfaces between mating Because the middle of the track shoe is fastened to
parts. For example, as mismatch occurs due to the track links, the links act as a fulcrum and must
packing in the sprocket root, each track bushing rides absorb or transmit any leverage or twisting forces
higher in the sprocket. This condition causes rapid that occur as the machine moves over uneven or
and severe, forward and reverse wear and chain to rocky terrain. All of the other components (sprockets,
sprocket “jumping” that is indicated by a loud track rollers and idlers) resist and restrict the twisting
“banging” noise. This results in high impact loads that forces of the links. As a result, most of the wear and
causes additional wear and cracking. damage caused by this twisting action affects the
This packing condition can also stop rollers from links, pins, bushings and track plate mounting
turning. When this happens, the track chain slides hardware. Listed below are some of the effects of
over that spot on the roller causing a flat spot. wide track shoes:
Packing materials increase the abrasive effect of 1. Resistance to turning - results in wear on the
most material by not allowing the material to escape. shoe corners and twists the track chain.
Wear is then accelerated. 2. Bending, cracking or breaking the track shoes,
When a packing problem continues install relieved shoe hardware and links.
track sprockets. 3. Constant problems with loose shoe hardware
INTERMITTENT PACKING - Packing can also occur that makes the bolt holes larger.
between some of the sprocket teeth. When this 4. Increased wear on links, roller flanges and idler
happens, the track is tightened and released rapidly flanges caused by a constant twisting of the track
causing the recoil spring to compress and release. A chain.
loud “banging” noise will result.
5. Decreased pin and bushing life or decreased link
EXTREME REVERSE LOADING - During this life due to elongated pin and bushing bores. This
operation the machine is backing up a hill and the top is a result of the twisted links.
of both track chains are tight, compressing the recoil
springs. You suddenly drive the machine forward. 6. Possible loss of lubricant in the Case Lubricated
The loud “banging” noise that you hear can be from Track pins. This will result in early pin and
one or both recoil springs releasing. bushing wear.
WEAR FACTORS YOU CAN CONTROL WEAR FACTORS YOU CAN PARTIALLY
CONTROL
Good operating techniques and a good maintenance
program will help you to get the longest life from your Speed
undercarriage. Unnecessary speed directly affects the wear rate on
Track Tension pins, bushings and sprockets. The faster the speed,
the faster the wear rate. High speed reverse
NOTE: Running tracks that are too tight reduces accelerates bushing and sprocket wear. Reverse
bushing and sprocket life 2.5 to 3 times. speeds are faster than forward speeds. Wear rate is
Check the track tension frequently when you operate. a function of speed and distance traveled, not just
When wor king in mud, snow and some sandy hours worked.
conditions, check the track tension more often. Impact
Material will pack on the undercarriage parts and
cause the tracks to become too tight. Always High speed will increase impact loading when there
maintain the correct track tension and always clean is low grouser penetration on hard surfaces or when
the undercarriage when you are done for the day. working in rock.
4-32 Issued 12-05 Bur 6-85641NA

Impact can cause structural problems such as Terrain

bending, cracking or breakage of components. This Changes in the terrain changes the attitude of your
can also affect pin and bushing retention and bushing machine the same way as the varying machine
cracking. And, if a chain is worn, can cause fractures. applications. This condition shifts the center of
Turning gravity and increases the weight of the machine on
different parts of the undercarriage.
Wear rate increases with increased turning. Turning
increases interference loads between moving 1. Working Uphill - This condition moves the
components. Turning in reverse accelerates bushing we i g h t o f t h e m a c h i n e r e a r wa r d c a u s i n g
and sprocket wear due to increased loads transferred increased wear of the rear rollers and increases
from the rotation of the bushings against the sprocket fo r wa r d d r i ve w e a r o f t h e s p r o cke t s a n d
in reverse. bushings.
Track Slip
Wear rate on all components increase when tracks
are slipping. Track shoe grousers are affected due to
increased sliding between the grouser and the
ground.
Favored Side Operation
Wear rates will increase on all components when
only one side of the machine is favored. Wear
increases as more power is applied to the favored
side. Also, more packing and slippage will occur on 912285 Figure 64
the favored side that results in an increased wear
2. Working Downhill - The machine weight is
rate.
moved forward causing increased wear of the
Reverse Operation front rollers. However, due to the design of the
track system, working downhill reduces the wear
Avoid excessive use of reverse operation. This is not
of the sprockets and bushings.
only nonproductive use of the machine but it also
accelerates bushing and sprocket wear. Most speeds
are faster in reverse than forward.
Applications
Application is often used to describe underfoot
conditions. In this section application will describe
what the machine is doing, without regarding the
under foot conditions.
Dozing - This operation shifts the machine weight to
the front causing a faster wear rate on the front
rollers and idlers.
Ripping - This operation will shift the machine weight 912286 Figure 65
toward the rear causing a faster wear rate on the rear 3. Working on the Side of the Hill - This moves
rollers. Then, dur ing severe applications, the the weight of the machine toward the downhill
sprockets and track bushings wear much faster. side of the machine. Wear is increased on the rail
sides, roller and idler flanges, bushing ends and
track shoe ends that are on the downside of the
hill.
6-85641NA Issued 12-05 Bur 4-33

Correct Tension
CORRECT TRACK ADJUSTMENT IS THE MOST
IMPORTANT FACTOR THAT HELPS TO CONTROL
UNDERCARRIAGE WEAR. Track sag of 38 to 51
mm (1-1/2 to 2 inches) must be maintained for all
Case crawlers.
IMPORTANT: When operating in packing conditions
(mud, snow, etc.) material will stick to the track parts
and cause the track tension to be too tight. Check
and adjust the track tension often during these
conditions.
912287 Figure 66 The following char t shows track tension (% of
4. Working on a Crown - The inner components tightness). A tight track requires more horsepower to
carry the heaviest load. The wear is increased on move the machine, increases fuel consumption, and
the inner links, roller treads, idler treads and can reduce bushing and sprocket life up to 2.5 to 3
track plate ends. In extreme situations, the inner times.
sprocket/bushing wear is greatly increased.
Track Sag Adjustment Chart
100
90%
75%
60%
45%
30%
15%
0%
13 MM 38 MM 51 MM
912288 Figure 67 (0.5 INCH) (1.5 INCH) (2.0 INCH)
5. Working in a Depression - The outer 912346 Figure 69
components carry the heaviest load. The wear is 1. TRACK TENSION (PERCENT TIGHT)
increased on the outer links, roller treads, idler
t r e a d s, a n d t ra ck p la t e e n d s. I n ex t r e m e High speed reverse operation or long periods of
situations, the outer sprocket/bushing wear is reverse operation also increases track wear.
greatly increased.
912289 Figure 68
Clean Tracks
W h e n t h e d ay i s f i n i s h e d , a l way s c l e a n t h e
undercarriage. Park the machine on a level surface to
prevent distortion of the track seals (Case Lubricated
Track). If the temperature is cold, park the machine
on a surface that will not freeze to the track shoes.
4-34 Issued 12-05 Bur 6-85641NA
BUSHING AND SPROCKET WEAR CHART

The tighter you have the tracks, the faster the wear.
The following char t illustrates the relationship
between wear rate and track sag.
NOTE: It is recommended that you turn the pins and
bushings at the 100% wear limit.
912347 Figure 70
PERCENT OF WEAR
1. 38 TO 51 MM (1.5 TO 2 INCH) TRACK SAG
2. 25 MM (1 INCH) TRACK SAG
3. 13 MM (0.5 INCH) TRACK SAG
4. HOURS OF USEFUL TRACK LIFE
NOTE: 120% Wear is Running the Track to

Destruction.
NOTE: The chart indicates how many less hours of
track wear when tracks are operated to tight.
6-85641NA Issued 12-05 Bur 4-35

NOTES
4-36 Issued 12-05 Bur 6-85641NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS
Chapter 5
LUBRICATION, FILTERS, AND FLUIDS
TABLE OF CONTENTS
GENERAL SAFETY BEFORE YOU SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

SYSTEMGARD LUBRICATION ANALYSIS PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
PLASTIC AND RESIN PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
ENGINE HOURMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Engine Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Hydraulic Reservoir/Transmission Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Final Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Grease Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
LUBRICATION AND MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
GREASE FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Ripper - 50 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Drive Shaft slip spline- 1000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
ACCESS DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Engine Oil Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Oil Viscosity/Temperature Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Engine Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Oil Change and Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Priming the Turbocharger Oil Lines with Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
AIR FILTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Warning Lamp for Air Filter Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Primary (Outer) Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Secondary (Inner) Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Dust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Turbo Precleaner (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Cleaning the Primary (Outer) Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Cab filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Coolant Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Cleaning Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Fuel Line Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Draining Water and Sediment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
First and second stage filter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
In line filter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Removing Air From the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Fuel Tank Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Issued 12-05 Bur 6-85641NA 5-1

Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23

Fluid Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
Hydraulic and Transmission Fluid Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
Suction screen cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
Hydraulic Reservoir Breather and Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Fluid Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25
Transmission Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25
Transmission and Hydraulic Fluid Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26
Suction screen cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26
FINAL DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27
Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27
5-2 Issued 12-05 Bur 6-85641NA

GENERAL SAFETY BEFORE YOU SERVICE
WARNING: Before you begin any service or repair work you must know and understand how to relieve
hydraulic pressure properly. Always have tools and attachments down in safe positions.
Figure 1
WARNING: Improper service or repair can

cause injury or death. If you do not
understand the service procedures for this
machine, see your dealer or the service
manual for this machine.
SC021
WARNING: Raised equipment on the

compartment, always support or lower the
equipment (backhoe, blade, boom, bucket,
etc.) to the ground and stop the engine. B770996R Figure 3
SA044
Read the safety decals and information decals on the

machine. Read the operators manual and safety
manual. Understand the operation of the machine
before you start servicing.
321-4614 Figure 4
B801147T Figure 2
Before you ser vice the machine, put a Do Not
Operate tag on the instrument panel. One Do Not
Operate tag is included with your machine. Additional
tags are available from your dealer.
Use the correct safety clothing and safety equipment.
Understand how to use a fire extinguisher and first
aid kit.
6-85641NA Issued 12-05 Bur 5-3

SYSTEMGARD LUBRICATION ANALYSIS PROGRAM
BP97H063 Figure 5
Ask your dealer about our lubr icant analysis ENGINE HOURMETER
program, Systemgard. Through this service, your
Service your machine at the intervals and locations
lubricants are tested in an independent laboratory.
given in the Lubrication/Maintenance Chart. When
You simply remove a sample of lubricant from your
you service your machine, use only high quality
machine and send the sample to the independent
lubricants.
S y s t e m g a r d l a b o r a t o r y. A f t e r t h e s a m p l e i s
processed, the laboratory will report back to you and
g u i d e yo u w i t h m a i n t e n a n c e r e q u i r e m e n t s .
Systemgard can help support your equipment up
time and provide you with a service that can pay back
dividends when you trade for another piece of Case
equipment.
The normal engine oil change interval is every 250
hours of operation. Operating conditions, quality of
the engine oil and sulphur content of the fuel can
change this interval. It is recommended that you use
the Systemgard Lubricant Analysis program. See
your dealer. BD02N037 Figure 6
The engine hourmeter shows the amount of actual
PLASTIC AND RESIN PARTS hours the engine has run. The first number to the
right displays tenths of an hour and the remaining
Avoid using gasoline, kerosene, paint thinner, etc.,
numbers to the left display hours. Use the engine
when cleaning plastic windows, console, instrument
hourmeter along with the Lubrication/Maintenance
cluster, monitor, gauges, etc. Use ONLY water, mild
Chart to service your machine at the correct time
soap and a soft cloth when you clean these parts.
periods.
Using gasoline, kerosene, thinners, etc., will cause
Engine hours are displayed with the key switch off or
discoloration, cracking or deformation of the part
with the engine running, if the operator chooses.
being cleaned.
5-4 Issued 12-05 Bur 6-85641NA

FLUIDS AND LUBRICANTS

ENGINE CRANKCASE
Capacity with Filter Change, 650K Series 2, 750K Series 2................................................ 13.6 Liters (14.4 qts)
Capacity w/o Filter, 650K Series 2, 750K Series 2 ...............................................................12.8 Liters (13.5 qts)
Capacity with Filter Change, 850K Series 2 ..........................................................................14.9 Liters (15.8 qts)
Capacity w/o Filter Change, 850K Series 2...........................................................................14.2 Liters (15.0 qts)
Specifications ...................................................................................................................... CASE AKCELA No. 1
FUEL TANK
Capacity .................................................................................................................................189.3 Liters (50 gal)
COOLING SYSTEM
Capacity .....................................................................................................................................18.9 Liters (5 gal)
Specifications ............................................................................................. 50% Water and 50% Ethylene Glycol
NOTE: If the ambient temperature is lower than -37°C (-34°F), adjust the mixture according to the coolant
manufacturer specifications.
HYDRAULIC RESERVOIR/TRANSMISSION REFILL

Capacity ...................................................................................................................................75.7 Liters (20 gal)
Specifications ................................................................................................................ MS-1209, Hy-Tran® Ultra
FINAL DRIVES
Capacity - Each Side ............................................................................................................... 14.2 Liters (15 qts)
Specifications ............................................................................................................... MS-1209, Hy-Tran® Ultra
GREASE FITTINGS
Quantity ............................................................................................................................................. As Required
Specifications ............................................................................................................. Case Molydisulfide Grease
6-85641NA Issued 12-05 Bur 5-5

LUBRICATION AND MAINTENANCE CHART

FREQUENCY IN HOURS
NUMBER OF
LUBRICATE
REPLACE
SERVICE
NUMBER
CHANGE
SERVICE POINTS
POINTS
CHECK
CLEAN
INTERVAL
DRAIN
PAGE
6-10 Fan and Air Conditioning Drive Belt AR
5-13 Air Filter (See Notes 1) AR
5-24 Transmission Filter (See Notes 2) AR
5-22 Hydraulic Filter (See Note 2) AR
As Required (AR) 6-3 Steel Track Shoe Bolt Torque (See Note 5) AR
6-3 Clean Tracks AR
6-3 Track Chain Tension (See Note 5) AR
5-20 In Line Fuel Filter AR
5-16 Cab Filters (If Equipped AR
5-11 Engine Oil Level 10
5-22 Transmission and Hydraulic Fluid Level 10
Every 10 Hours.
5-7 Equipment Pivot Points 14 10
See Note 3
5-17 Coolant Reservoir Fluid Level 10
5-8 Ripper Grease Points (If Equipped) 10
5-14 Air Filter Dust Valve 50
Every 50 Hours 5-17 Radiator Fluid Level 50
5-19 First Stage Fuel Filter for Water 50
5-11 Engine Oil 250
5-11 Engine Oil Filter 250
Every 250 Hours
5-26 Final Drive Oil Level 250
6- Drive Belt 250
7-4 Battery Fluid Level 500
Every 500 Hours 5-19 Fuel Filters 500
5-20 In Line Fuel Filter 500
5-23 Hydraulic Reservoir Breather Relief Valve 1000
5-21 Fuel Cap Breather 1000
6-5 Engine Valve Clearance 1000
Every 1000 Hours
5-19 Fuel Tank for Water 1000
5-8 Drive Shaft Slip Spline 1 1000
5-26 Final Drive Oil 1000
5-23 Transmission Suction Screen 2000
5-23 Hydraulic Suction Screen 2000
5-22 Hydraulic Oil Filter 2000
Every 2000 Hours 5-25 Transmission and Hydraulic Fluid 2000
5-24 Transmission Filter (See Note 6) 2000
5-18 Engine Coolant (See Note 7) 2000
5-13 Air Filter Elements (See Note 7) 2000
NOTE 1: Service the air filter elements if the air filter warning lamp illuminates.
NOTE 2: Replace the transmission filter or hydraulic filter if the filter restriction warning lamp illuminates or at 2000 hours.
NOTE 3: Every 10 hours of operation or once each day, whichever comes first.
NOTE 4: If the machine is new or if the track shoes have been removed, check the torque of the steel track shoe bolts after the first 20 hours of
operation and then every 100 hours of operation until the track shoe bolts remain tight.
NOTE 5: For increased track life, always keep the track tension correct. Adjust the tracks for 38 to 51 mm (1.5 to 2 Inches) of track sag.
NOTE 6: If the machine is new or the transmission has been overhauled, replace the filter at 250 hours for the first and second filter change.
NOTE 7: Every 2000 hours of operation or each year, whichever occurs first.
5-6 Issued 12-05 Bur 6-85641NA

GREASE FITTINGS
DOZER - 10 HOURS
Use Case Molydisulfide Grease
8
9
2
1
3
BD02H020 Figure 10
8. Angle cylinder closed end . . . . . . . 2 (1 ea. side)
9. C frame pivot pin . . . . . . . . . . . . . . 2 (1 ea. side)
BD02H017 Figure 7
1. Tilt cylinder, closed end. . . . . . . . . . . . . . . . . . . 1 DOOR HINGES - AS REQUIRED
2. Angle cylinder, rod end . . . . . . . . . .2 (1 ea. side)
3. Trunnion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5 10
BD02J017 Figure 11
10. Access door hinges . . . . . . . . . . . . 2 per door (6)
BD02F026 Figure 8
4. Tilt cylinder, rod end . . . . . . . . . . . . . . . . . . . . . 1
5. Center pivot. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
11
6
BD02H102 Figure 12
11. Cab door hinges. . . . . . . . . . . . . . . 4 (2 ea. side)
BD02H019 Figure 9
6. Lift cylinder, rod end . . . . . . . . . . . .2 (1 ea. side)
7. Lift cylinder, closed end. . . . . . . . . .2 (1 ea. side)
6-85641NA Issued 12-05 Bur 5-7

RIPPER - 50 HOURS
Use Case Molydisulfide Grease
12
1
BBD02J017 Figure 13
12. Ripper lift cylinder . . . . . . . . . . . . . 2 (1 ea. side)
DRIVE SHAFT SLIP SPLINE- 1000 HOURS

NOTE: Universal Joints are Lubricated for life.
Use Case Molydisulfide Grease BD02H004 Figure 15
NOTE: The cab must be tilted to access the drive

shaft spline.
B911749 Figure 14
1. SLIP SPLINE . . . . . . . . . . . . . . . . . . . . . . . . . . .1
5-8 Issued 12-05 Bur 6-85641NA

ACCESS DOORS
BD02J033 Figure 16 BD99J173 Figure 19

LEFT REAR COMPARTMENT RIGHT REAR COMPARTMENTS
BD02H097 Figure 17 BD02H098 Figure 20

ENGINE SIDE PANEL - RIGHT IMPORTANT: The right rear access door must be
locked into the up position with the support strut.
BD02J081 Figure 18
RADIATOR
BD02J067 Figure 21
ENGINE SIDE PANEL - LEFT
6-85641NA Issued 12-05 Bur 5-9

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
CE. RH99K130 Figure 22
See the chart below 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.
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.
NOTE: The use of low viscosity oils, such as 10W-30
can be used to aid in starting the engine and in
providing sufficient oil flow at ambient temperatures
below -5°C (23°F). The continuous use of low BP97H064 Figure 23
viscosity oils can decrease engine life due to wear.
See the chart above for the correct oil for ambient
temperatures.
OIL VISCOSITY/TEMPERATURE RANGES
BC02N250 Figure 24
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.
NOTE: The use of low viscosity oils, such as 10W-30 can be used to aid in starting the engine and in providing
sufficient oil flow at ambient temperatures below -5°C (23°F). The continuos use of low viscosity oils can decrease
engine life due to wear. See chart above for the correct oil for ambient temperatures.
5-10 Issued 12-05 Bur 6-85641NA

ENGINE SERVICE
ENGINE SERVICE SPECIFICATIONS
Oil Level Check Interval ....................................................................Every 10 hours of Operation or Once Each Day
Oil Change and Filter Replacement Interval................................................................ Every 250 Hours of Operation
Oil Type.....................................................................................................................................................CASE No. 1
Oil Capacity - with Filter Change
650K Series 2, 750K Series 2 ..........................................................................................13.6 Liters (14.4 qts)
850K Series 2....................................................................................................................14.9 Liters (15.8 qts)
ENGINE OIL LEVEL OIL CHANGE AND FILTER REPLACEMENT

Check the engine oil level before you start the engine NOTE: For more complete removal of foreign
each day or before the start of each 10 hour shift. material, change the engine oil while the engine is
Always check the oil level with the engine stopped still warm from operation.
and when the machine is on level ground.
IMPORTANT: You must shorten the oil change
Push the engine oil level dipstick completely down interval if you use diesel fuel with a sulphur content of
and pull out before you check the oil level. more than 0.5%.
If the oil level is below the ADD mark, add oil to raise Change the engine oil more frequently than every
the oil level up to the FULL mark. 250 hours when the engine operating conditions are
severe (frequent stopping and starting and high or
low engine temperatures).
1. Before draining the oil, have a container that will
hold the suitable quantity.
2
1
BD02J026 Figure 25
1. ENGINE OIL DIPSTICK
2. ENGINE OIL FILL TUBE
BD02K002 Figure 26
2. Remove this plate (1) to access the oil pan.
P320073 Figure 27
3. Remove the engine oil drain plug (2).
6-85641NA Issued 12-05 Bur 5-11

PRIMING THE TURBOCHARGER OIL LINES WITH

OIL
ENGINES WITH TURBOCHARGER: In cold
weather, after several weeks of storage, or after the
engine oil filter has been replaced, prime the
turbocharger oil lines with oil.
1. Disconnect the plug to the injection pump
solenoid.
3
2. Actuate the starter motor for 10 to 20 seconds.
3. Connect the wire to the injection pump solenoid
and start the engine.
B4140898S Figure 28
4. Run the engine at idle speed for a few minutes.
4. Turn the oil filter (3) counterclockwise to remove.

Discard the filter.
5. Use a clean cloth and wipe the sealing surface of
the oil filter base to remove all dirt or gasket
material.
6. Apply a thin layer of clean grease or oil to the
gasket of the new oil filter.
7. Turn the new oil filter onto the base until the
gasket makes contact with the base. Continue to
tighten the filter for 3/4 turn with your hand.
IMPORTANT: Do not use a filter strap wrench to
install the oil filter. An oil filter strap wrench can cause
a leak if the filter is dented.
IMPORTANT: Clean all dirt and foreign material from
the front engine guard a minimum of every thirty
days. Dirt will cause rust on the engine oil pan and a
loss of engine oil.
8. Install the drain plug. Tighten the drain plug to a
torque of 68 to 82 Nm (50 to 60 lb ft).
Overtightening can damage the oil pan. Install
the guard plate.
9. Put new oil into the engine oil fill tube.
10. Before you start the engine, prime the
turbocharger oil lines with oil. See the following
topic.
11. Start the engine and run at idle speed. Check the
engine oil filter for leaks. After two minutes, stop
the engine, wait for 2 or 3 minutes, and check the
engine oil level with the dipstick.
5-12 Issued 12-05 Bur 6-85641NA

AIR FILTER SYSTEM

SERVICE SPECIFICATIONS
Air Filter Dust Valve ................................................................................................................. Check Every 50 Hours
Air Filter Element Replacement....................................................................... Every 2000 Hours or Once Each Year
NOTE: Service the elements if the warning lamp for the air filter restriction illuminates.
1. Do not install a new element that is more than PRIMARY (OUTER) ELEMENT
five years old. The date of manufacture is on the Replace the primary (outer) element after three
end cap of the element. washings or after the element has been in the
2. Replace both elements after one year in the machine for one year. See cleaning the primary
machine. (outer) element. To service:
3. Do not remove the elements from the machine to 1. Open the access panel.
c h e c k fo r r e s t r i c t i o n . A l w ay s fo l l o w t h e 2. Pull the cover clamp (1) of the air cleaner cover
recommended ser vice instr uctions in this out and rotate counter clockwise. Remove the
section. end cover.
4. Each time you service the air cleaner system,
make sure all hose connections and flanges are
air tight. Replace all damaged parts. 1
WARNING LAMP FOR AIR FILTER RESTRICTION
1
BD04N021 Figure 30
1. CLAMP
2. END COVER
3. Carefully remove the primary (outer) element.
BC02J064 Figure 29
1. AIR FILTER INDICATOR LAMP
You must service the air filter if the air filter warning
lamp illuminates when the engine is running. After
the shift or at the end of the day, service the air
cleaner. Make sure you check the condition of the 3
warning lamp bulb each day before you operate the
machine.
BD04N022 Figure 31
3. PRIMARY (OUTER) ELEMENT
4. Use a clean damp cloth and clean inside of the

filter body.
5. Install a clean or new primary (outer) element.
Make sure the element has full gasket contact.
6. Install the end cover.
6-85641NA Issued 12-05 Bur 5-13

7. Make sure other persons are clear of the DUST VALVE

machine. Start the engine and check the air filter
warning lamp. If the lamp is still illuminated,
replace the secondary (inner) element.
SECONDARY (INNER) ELEMENT

Replace the secondary (inner) element (1) after the
primary (outer) element has been cleaned three
times, (2) after one year in the machine, or (3) after
the primary (outer) element has been cleaned or
replaced and the air filter warning lamp is still
illuminated with the engine running. DO NOT clean
the secondary element.
1. Open the access panel. Remove the end cover BD02J088 Figure 33
and remove the primary (outer) element. The Dust Valve should be checked every 50 hours of
2. Remove and discard the secondary (inner) machine operation or more often if work is being
element. performed in severe environments.
1. Remove the valve and wipe it clean.
TURBO PRECLEANER (OPTIONAL)

The optional turbo precleaner requires no service.
BD04N023 Figure 32
1. SECONDARY (INNER) ELEMENT
3. Use a clean damp cloth and clean the inside of

the filter body.
4. Install a new secondary (inner) element. Make
sure the gasket is making full contact.
5. Install the primary (outer) element and the end
cover.
5-14 Issued 12-05 Bur 6-85641NA

CLEANING THE PRIMARY (OUTER) ELEMENT

Check the dirty element for damage and check the
rubber seal on the end. Push the rubber seal with
your finger. If the rubber seal feels hard and does not
move back to original shape, discard the element.
1. Wear face protection. Remove the loose dirt with
compressed air at 207 kPa, 2.1 bar (30 psi)
maximum. Hold the nozzle at least 25 mm (one
inch) from the element.
CA5002J Figure 36
5. Allow the element to air dry. If you use a drier, do
not exceed 71°C (160°F) and make sure the air
is circulating in the drier.
6. Use a light and inspect the element for holes or
splits in the pleats. Check for damage to the
metal par ts and rubber gasket. Replace the
element if damaged.
CA5000J Figure 34
2. Mix two tablespoons of D1400 detergent (Case
par t number A40910) with 7.5 Liters (two
gallons) of water, one cup for 60 Liters (16
gallons) of water.
3. Soak the element in the soap solution for 15
minutes and then move the element up and
down rapidly to loosen as much dirt as possible.
CA5003J Figure 37
CA5001J Figure 35
4. Use a water hose without a nozzle with pressure
less than 275 kPa, 2.8 bar (40 psi) to remove all
soap from the element.
6-85641NA Issued 12-05 Bur 5-15

CAB FILTERS
There are two cab air filters that require service.
BD02K024 Figure 38
The internal cab filter is located between the seat
and left side console. Remove the two thumbscrews,
the cover screen and clean or replace as required.
BD02K019 Figure 39
The external cab filter is located behind the battery
and the left rear access door.
BD02K020 Figure 40
Remove the four thumb screws and the frame that
holds the external filter in place. Clean or replace the
filter as required.
5-16 Issued 12-05 Bur 6-85641NA

ENGINE COOLING SYSTEM

Coolant Reservoir Level Check Interval ....................................................................... Every 10 Hours Of Operation
Radiator Coolant Level Check Interval ......................................................................... Every 50 Hours Of Operation
Check and Tighten Coolant Hose Clamps .............................................................................................. As Required
Coolant System Change Interval ................................................ Every 2000 hours of operation or once every year.
Coolant Capacity .............................................................................................................................18.9 Liters (5 gal)
COOLANT SOLUTION
A mixture of 50% ethylene glycol and 50% water
must be used in this machine. This mixture is used if
the lowest ambient temperature is above -37° C
(-34° F). If the ambient temperature is lower, adjust
the mixture to attain a lower freeze point using the
freeze point-concentration chart on the label of your
antifreeze concentrate. Never use a coolant solution
containing more than 60% glycol. It is recommended
that ethylene glycol and water be used in your 1
machine all year.
IMPORTANT: After you fill the cooling system, mix
the ethylene glycol and water completely by running
BD02J084 Figure 42
the engine at operating temperature for
approximately five minutes. This procedure must be 1. SIGHT GAUGE
done when the machine is in temperatures below NOTE: If the radiator coolant level is low and the
0° C (32° F). coolant reservoir level is at the FULL mark, check for
COOLANT RESERVOIR FLUID LEVEL air leaks in the hose between the radiator and
coolant reservoir.
Check the coolant reservoir fluid level every 10 hours
of operation, when the coolant is cold and the engine WARNING: Hot coolant can spray out if
is stopped. Do not remove the radiator cap during radiator cap is removed. To remove radiator
this check. The coolant level must be between the cap: Let system cool, turn to first notch, then
FULL and ADD marks on the reservoir. Add coolant wait until all pressure is released. Scalding
as required to the coolant reservoir. can result from fast removal of radiator cap.
Check and service engine cooling system
according to maintenance instructions.
SA023
BD02K017 Figure 41
1. COOLANT RESERVOIR
RADIATOR COOLANT LEVEL

Check the radiator coolant level at the sight gauge
every 50 hours of operation when the coolant is cold
and the engine is stopped. The coolant level must be
in the sight gauge.
6-85641NA Issued 12-05 Bur 5-17

CLEANING COOLING SYSTEM 12. Make sure all persons are clear of the machine.
Drain, flush, and replace the engine coolant every Start the engine and increase the temperature of
2000 hours of operation or each year whichever the engine coolant. When the coolant is at
occurs first. Clean the system and replace the operating temperature, stop the engine and allow
coolant if the coolant becomes dirty or has the color to cool. Check the coolant level at the coolant
of rust. reservoir only. Do not remove the radiator cap.
If possible, drain the cooling system when the coolant

is warm. DO NOT remove the radiator cap if the
coolant is hot.
1. Open the radiator door.
BD99J218 Figure 43
1. RADIATOR DOOR
2. Loosen and remove the radiator cap.

3. Place a container of suitable capacity under the
drain valve and drain the radiator.
4. After all the coolant is removed, close the drain
valve.
5. Add a cleaning solution to the cooling system
and fill the cooling system with clean water.
Follow the directions included with the cleaning
solution.
6. After you drain the cleaning solution, flush with
clean water.
7. Check the hoses, elbow, and water pump for
leaks.
8. Make sure that the outside of the engine and
radiator is clean.
9. Fill the cooling system slowly until the coolant
level is up to the top of radiator opening.
NOTE: Allow the venting of entrapped air when filling
the cooling system until you have the correct quantity
of coolant in the system.
10. Install the radiator cap.
11. Fill the coolant reservoir up to the FULL mark on
the reservoir.
5-18 Issued 12-05 Bur 6-85641NA

DIESEL FUEL SYSTEM

Drain First Stage Fuel Filter.......................................................................................................................... 50 Hours
Replacing the Fuel Filter............................................................................................................................. 500 Hours
Draining Water From The Fuel Tank......................................................................................................... 1000 Hours
Clean Fill Cap Breather ............................................................................................................................ 1000 Hours
Fuel Tank Capacity .......................................................................................................... 189.3 Liters (50.0 U.S. Gal)
FUEL LINE SHUTOFF VALVE DRAINING WATER AND SEDIMENT

Close the shutoff valve at the hand primer when the Check the first stage fuel filter for water and sediment
fuel filter is replaced or the fuel system is serviced. every 50 hours of operation.
NOTE: If the fuel filter has any water and
FUEL GAUGE
sediment, go to step 2 and drain any water and
sediment from the fuel tank.
BD99J195 Figure 44
BD02J026 Figure 45
1. FUEL FILTER
1. Open the drain plug at the bottom of the fuel tank

to drain water and sediment from the fuel tank.
BD02K022 Figure 46
6-85641NA Issued 12-05 Bur 5-19

FUEL FILTER REPLACEMENT REMOVING AIR FROM THE FUEL SYSTEM

Replace the fuel filter after every 500 hours of Air must be removed from the fuel system if one or
operation. more of the following conditions occurs:
A. If the engine stops because of no fuel in the
tank.
B. If the fuel filters are replaced.
C. If the fuel system is serviced.
D. If the machine has been in storage.
1. If necessary, fill the fuel tank.
2. Make sure the fuel tank shutoff valve is in the ON
position.
3. Loosen the air bleed screw (1) on the filter head
1 or 2 turns.
BD02J026 Figure 47
2. Clean the filter head and the outside of the fuel
filter.
1
3. Turn the filter counterclockwise and remove from
the filter head.
4. Apply a thin layer of clean oil to the gasket of the
new filter.
5. Install the filter. Use your hands to tighten the
filters 1/2 turn after the filter makes contact with
the filter head.
6. Loosen the filter approximately one turn.
7. Tighten the filter until the filter is touching the BD02J026 Figure 49
filter head and then tighten 1/2 to 3/4 turn. Do not 1. AIR BLEED SCREW
use a strap wrench.
4. Operate the hand primer until fuel with no air
8. Open the shutoff valve at the hand primer. bubbles flows from around the air bleed screw.
9. Remove the air from the fuel system. See 5. Tighten the air bleed screw.
removing air from the fuel system.
6. Start the engine and check for fuel leaks.
IN LINE FILTER REPLACEMENT
Replace the in line filter after 500 hours of operation.
BD02M137 Figure 48
Make sure the filter is placed in line with the correct
flow direction.
5-20 Issued 12-05 Bur 6-85641NA

FUEL TANK BREATHER

Clean the fuel cap breather every 1000 hours of
operation or if the breather is coated with dirt.
1. Remove the fuel cap.
2. Clean the fuel cap and breather with cleaning
solvent.
3. Dry the fuel cap and breather with compressed
air.
4. Install the fuel cap.
2
3
BD02H106 Figure 50
1. FUEL TANK BREATHER
2. FUEL TANK CAP
3. LOCKING HARDWARE
6-85641NA Issued 12-05 Bur 5-21

HYDRAULIC SYSTEM
Fluid Level Check ......................................................................................................... Every 10 Hours Of Operation
Filter Change .............. Every 2000 hours of operation or when the respective warning lamp for the filter illuminates
Clean Hydraulic Reservoir Breather ........................................................................ Every 1000 Hours Of Operation
Clean Suction Screen............................................................................................... Every 2000 Hours Of Operation
Change Hydraulic Fluid ........................................................................................... Every 2000 Hours Of Operation
Type of Fluid ........................................................................................................................MS-1209, Hy-Tran® Ultra
Reservoir Refill Capacity With Filter Change ............................................................................... 75.7 Liters (20 gal)
WARNING: Hydraulic fluid or grease

injected into your skin can cause severe
injury or death. Keep your hands and body
away from any pressurized leak. If fluid is
injected into your skin, see a doctor
SA024
1
FLUID LEVEL CHECK

Check the oil level every 10 hours of operation or
each day, whichever occurs first. BC02J064 Figure 52
NOTE: Check the oil level of the hydraulic reservoir 1. HYDRAULIC FILTER INDICATOR LAMP
only when the machine is level, front mounted NOTE: If machine is new or any part of the hydraulic
equipment is on the ground, the ripper, (if equipped) or transmission system has been serviced, replace
is on the ground, and the engine is stopped. the filter at 250 hours for the first and second filter
Check the oil level at the sight gauge on the hydraulic change.
reservoir. The oil level must be between the RED 1. Open the side access door.
(full) and BLACK (add) marks on the gauge. If the oil
2. Clean the outside of the filter and filter head with
level is below the BLACK (add) mark, add oil to raise
cleaning solvent.
the level up to the RED (full) mark.
3. Rotate the filter counterclockwise and remove
the filter. Discard the old filter.
1
1
BD02H105 Figure 51 BD02J102 Figure 53

1. HYDRAULIC RESERVOIR FILL TUBE 1. HYDRAULIC FILTER
2. OIL LEVEL SIGHT GAUGE
4. Clean the gasket surface on the filter head with a
clean cloth, make sure all dirt and gasket parts
HYDRAULIC FILTER
are removed.
Replace the filter every 2000 hours of operation or if
the hydraulic filter warning lamp illuminates. 5. Put clean oil on gasket of the new filter.
6. Turn the filter clockwise until the gasket makes
contact, then tighten an additional 1/2 turn.
7. Start engine and check for oil leaks.
5-22 Issued 12-05 Bur 6-85641NA

HYDRAULIC AND TRANSMISSION FLUID SUCTION SCREEN CLEANING

CHANGE
1. Make sure the oil is warm. 1 2
2. Lower the equipment to the ground and stop the
engine.
3. Put a Do Not Operate tag on the instrument
panel.
4. Have a suitable container that will hold the
quantity of fluid.
5. Loosen hydraulic fill cap slowly.
BD02J108 Figure 56
1. TRANSMISSION SUCTION SCREEN
2. HYDRAULIC SUCTION SCREEN
To access the suction screens it will be necessary to

tilt the cab over.
Remove the fittings and pull the screens through and
service or replace as necessary.
HYDRAULIC RESERVOIR BREATHER AND

BD02M047 Figure 54 RELIEF VALVE
6. Remove the drain plug and remove all fluid from 1. Open the side access door and clean the area
the reservoir. around the breather and relief valve.
7. Change the hydraulic filter. 2. Remove the breather and relief valve.
8. Install the drain plug.
BD02H050 Figure 57
1. BREATHER AND RELIEF VALVE
BD02H105 Figure 55
1. FILLER CAP 3. Clean the valve with cleaning solvent and dry
with compressed air.
9. Remove the filler cap.
4. Install the breather and close the access door.
10. Put new MS-1209, Hy-Tran® Ultra fluid into the
reservoir.
11. Install the filler cap.
12. Operate the hydraulic equipment and
transmission at 20% with no load and then check
the oil level.
13. Add oil as required. Check for leaks.
6-85641NA Issued 12-05 Bur 5-23

TRANSMISSION
Fluid Level Check ......................................................................................................... Every 10 Hours Of Operation
Filter Change ...................................................Every 2000 Hours Of Operation Or If The Warning Lamp Illuminates
Clean Hydraulic Reservoir Breather ........................................................................ Every 1000 Hours Of Operation
Clean Suction Screen............................................................................................... Every 2000 Hours Of Operation
Change Transmission Fluid ...................................................................................... Every 2000 Hours Of Operation
Type of Fluid ........................................................................................................................MS-1209, Hy-Tran® Ultra
Refill Capacity With Filter Change................................................................................................. 75.7 Liters (20 gal)
WARNING: Hydraulic fluid or grease 1

injected into your skin can cause severe
injury or death. Keep your hands and body
away from any pressurized leak. If fluid is
injected into your skin, see a doctor
SA024
FLUID LEVEL CHECK

Check the oil level every 10 hours of operation or
each day, whichever occurs first. BC02J064 Figure 59
NOTE: Check the oil level of the hydraulic reservoir 1. TRANSMISSION FILTER WARNING LIGHT
only when the machine is level, front mounted NOTE: If machine is new or any part of the hydraulic
equipment is on the ground, the ripper is on the system has been serviced, replace the filter at 250
ground, and the engine is stopped. hours for the first and second filter change.
Check the oil level at the sight gauge on the hydraulic 1. Open the access door.
reservoir. The oil level must be between the RED
(full) and BLACK (add) marks on the gauge. If the oil 2. Clean the outside of the filter and filter head with
level is below the BLACK (add) mark, add oil to raise cleaning solvent.
the level up to the RED (full) mark. 3. Rotate the filter counterclockwise and remove
the filter. Discard the filter.
2 2
BD02H105 Figure 58 1
1. HYDRAULIC RESERVOIR FILL TUBE BD02J102 Figure 60
2. OIL LEVEL SIGHT GAUGE
1. TRANSMISSION FILTER
TRANSMISSION FILTER 4. Clean the gasket surface on the filter head with a
Replace the filter every 2000 hours of operation or if clean cloth, make sure all dirt and gasket parts
the transmission filter warning lamp illuminates. are removed.
5. Put clean oil on gasket of the new filter.
6. Turn the filter clockwise until the gasket makes
contact, then tighten an additional 1/2 turn.
7. Start the engine and check for oil leaks.
5-24 Issued 12-05 Bur 6-85641NA

TRANSMISSION AND HYDRAULIC FLUID SUCTION SCREEN CLEANING

CHANGE
1. Make sure the oil is warm. 1 2
2. .Lower the equipment to the ground and stop the
engine.
3. Put a Do Not Operate tag on the instrument
panel.
4. Have a suitable container that will hold the
quantity of fluid.
5. Loosen hydraulic fill cap.
6. Remove the drain plug and remove all fluid from
the reservoir.
BD02J108 Figure 62
7. Change the transmission filter.
1. TRANSMISSION SUCTION SCREEN
8. Install the drain plug. 2. HYDRAULIC SUCTION SCREEN
To access the suction screens it will be necessary to

tilt the cab over. See Tilting the Cab in the Operating
1 Instructions Section.
Remove the fittings and pull the screens through and
service or replace as necessary.
BD02H105 Figure 61
1. FILLER CAP
9. Remove the filler cap.

10. Put new MS-1209, Hy-Tran® Ultra fluid into the
reservoir.
11. Install the filler cap.
12. Operate the hydraulic equipment and then check
the oil level.
13. Add oil as required. Check for leaks.
6-85641NA Issued 12-05 Bur 5-25

FINAL DRIVES
OIl Level Check Interval.............................................................................................. Every 250 Hours Of Operation
OiL Change Interval.................................................................................................. Every 1000 Hours Of Operation
Type Of Oil...........................................................................................................................MS-1209, Hy-Tran® Ultra
Capacity (each side)...................................................................................................................... 14.2 Liters (15 qts)
OIL LEVEL CHECK OIL CHANGE

Park the machine on a level surface. Stop the engine. Park the machine on a level surface. Stop the engine.
NOTE: If possible, drain the final drives when the oil
is warm. You will remove more contamination from
the final drives with warm oil.
1
3
BD02M131 Figure 63
1. Remove the check plug (1) slowly to release the
pressure. Oil should be to the top of this plug
orfice.
BD02H107 Figure 65
1. Clean the area around the fill (2), check (1) and
drain plug (3)with cleaning solvent.
2
2. Remove the fill plug slowly to relieve pressure.
3. Remove the drain plug (3) and drain the final
drive oil into a container.
4. Install the drain plug (3) and put new oil in the
final drive.
5. Fill until a small amount leaves the check plug (1)
orfice and install the plug.
6. Install the fill plug.
BD02J069 Figure 64 7. Repeat steps 1 through 6 for the other final drive.
2. If necessary, add oil to the final drive through the
fill plug (2).
3. Install the fill plug.
4. Repeat steps 1 through 4 for the other final drive.
5-26 Issued 12-05 Bur 6-85641NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS
Chapter 6
MAINTENANCE AND ADJUSTMENTS
TABLE OF CONTENTS
TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Procedure to adjust track tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Track Shoe Bolts - Steel Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Engine valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Welding on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
REVERSIBLE FAN POSITIONS (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
ROLL-OVER PROTECTIVE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Maintenance and Inspection of ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Damage to the ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
MACHINE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
ADJUSTING THE RIPPER SHANKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
DOZER BLADE PITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Rearward Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Forward Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Type of Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Inspection and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
FAN AND AIR CONDITIONING DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Service Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Storage Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Removal From Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Issued 12-05 Bur 6-85641NA 6-1

NOTES
6-2 Issued 12-05 Bur 6-85641NA

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

1. Do not clean the tracks before adjustment.
2. Move the machine rearward and forward the
length of the track. This will make the bottom of
the track tight. Do not use the brakes to stop the
machine.
B911469J Figure 3
BD02H010 Figure 1
3. Stop the machine so that a pin (1) in the track
chain is over the carrier roller (2).
4. Put a straightedge over the track.
BD02H013 Figure 2
5. Measure the track deflection midway between
the top roller and the idler wheel. The correct
adjustment is between 38 to 51 mm (1-1/2 to 2
inches).
6-85641NA Issued 12-05 Bur 6-3

TO TIGHTEN THE STEEL TRACK TO LOOSEN THE STEEL TRACK
BD02H015 Figure 4 BD02H016 Figure 5

1. Put grease into the adjuster grease fitting until 1. Use a deep socket and loosen the large adapter
deflection is between 38 to 51 mm (1-1/2 to 2 two turns. DO NOT remove the large adapter. Let
inches). the grease come out until the track deflection is
2. Install the cap on the track adjuster. 38 to 51 mm (1-1/2 to 2 inches).
3. Move the machine rearward and forward the 2. Tighten the large adapter 60 to 51 Nm (45 to 55
length of the track. Do not use the brakes to stop. pound-feet).
4. Check the deflection of the track again and 3. Install the cap on the track adjuster.
adjust as required. 4. Move the machine rearward and forward the
5. Adjust the other track. length of the track. Do not use the brakes to stop.
Check the track tension again.
NOTE: During the operation of the machine,
5. Adjust the other track.
material can build up in the root of the sprocket
forcing the bushing out of the sprocket tooth. When
TRACK SHOE BOLTS - STEEL TRACK
the bushing gets high enough it will move over one
sprocket tooth causing a loud noise. Check the torque of the track shoe bolts after the first
This problem can be reduced by loosening the track 20 hours of operation with a new machine. Then, if
or installing relieved sprockets. the machine is new or if the track shoes have been
removed, check the torque of the track shoe bolts
every 100 hours of operation until the track shoes
remain tight.
Tighten the standard link bolts 406 to 447 Nm (300 to
330 pound-feet) and 430 to 470 Nm (318 to 346 lb ft
for the master link bolts.
6-4 Issued 12-05 Bur 6-85641NA

ENGINE VALVE CLEARANCE

The engine valves should be checked by a service
technician every 1000 hours.
WELDING ON THE MACHINE

Whenever carrying out a welding operation on the
crawler as authorized by the manufacturer and in
accordance with correct procedures:
1. Disconnect the batteries.
2. Disconnect the alternator B+ and D+ terminal
wires.
BD02M046 Figure 6
3. Disconnect the three deutsch connectors located
to the right and above the battery behind the left
rear access door. ROPS model shown.
NOTE: Cab models have the deutch connectors
located slightly higher than the ROPS machines.
4. Connect the welding apparatus ground cable to
the component on which the welding operation is
to be performed.
IMPORTANT: Welding in certain areas of the crawler
may require that the controller itself be disconnected
and grounded. Contact your dealer.
6-85641NA Issued 12-05 Bur 6-5

REVERSIBLE FAN POSITIONS (IF EQUIPPED)

This fan has two positions, PUSHER and SUCTION. 7. Release the belt tensioner and install the right
The fan blades can be rotated manually. front side panel.
1. Stop the engine and put a Do Not Operate tag on 8. Remove the Do Not Operate tag.
the instrument panel.
2. Pull both parking brake levers back to the
engaged position.
3. Turn the master disconnect to off.
4. Remove the left front engine side panel.
5. To rotate the fan as you change each blade,
install a 1/2 inch breaker bar in the automatic belt
tensioner. Lift up to release the belt tension.
6. Push in each fan blade, rotate to the required
position, and release. Make sure each blade is in
the LOCKED position.
IMPORTANT: Make sure all six blades are rotated to BD02J086 Figure 8
the same position before you start the engine.
Make sure all blades are rotated to the same
position.
1
B911784J Figure 7
1. AIR FLOW
2. SUCTION POSITION
3. PUSHER POSITION
NOTE: Spray a small amount of penetrating oil on

the shaft of each blade at least five or six times a
year. This action will help blade rotation.
6-6 Issued 12-05 Bur 6-85641NA

ROLL-OVER PROTECTIVE STRUCTURE

Your machine has a roll-over protective structure Before you operate the machine, replace all ROPS
(ROPS). A ROPS label shows the serial number of components that are damaged.
the ROPS, gross weight, approval, regulation, and See the parts catalog or your dealer for components
model numbers of the machine. The label is on the that can be replaced.
left-hand side.
DO NOT TRY TO WELD OR STRAIGHTEN THE
Before you operate this machine, always make sure ROPS.
that the ROPS and operators seat belt is correctly
installed. WARNING: Do not modify ROPS in any
manner. Unauthorized modifications such as
MAINTENANCE AND INSPECTION OF ROPS welding, drilling, cutting or adding
1. Check the torque of the ROPS mounting bolts. If attachments can weaken the structure and
necessary, tighten the bolts to the correct torque. reduce your protection. Replace ROPS if
See ROPS Torque Specifications in this manual. subjected to roll-over or damage. Do not
attempt to repair.
2. Check the operators seat and the mounting parts SB026
for the seat belt. Tighten the bolts to the correct
torque. See “Operators Seat” in this manual. WARNING: If you operate this machine
Replace the parts that have wear or damage. without a ROPS and the machine rolls over,
you can be injured or killed. Remove the
3. Check for cracks, rust, or holes in the ROPS and
ROPS only for service or replacement. Do not
ROPS parts. Age, weather, and accidents can
operate this machine with the ROPS
cause damage to the ROPS and ROPS parts. If
removed.
you have any doubt about the ROPS system, see
SA027
your dealer.
WARNING: Adding additional weight
SEAT BELT (attachments, etc). to the machine can cause
The seat belt is an important part of your ROPS. You injury or death. Do not exceed the gross
must wear the seat belt at all times when you operate weight printed on the ROPS label.
the machine. SA028
Before you operate this machine, always make sure WARNING: Improper ROPS inspection or
that the ROPS and operator’s seat belts are correctly maintenance can cause injury or death. Do
installed. the recommended ROPS inspection shown
in this manual. If you must replace the ROPS,
WARNING: You are protected by the ROPS ROPS parts, or ROPS mounting hardware,
(Roll-Over Protective Structure) system on use only the replacement parts shown in the
this machine. The seat belt is an important Case parts catalog for this machine.
part of that ROPS system. Before you SA029
NOT have the seat belt fastened, you can be WARNING: Before you start the engine,
crushed by the ROPS or the machine. always sit in the operators seat, fasten the
SA080 seat belt, apply the parking brake, and make
sure the transmission direction control is in
DAMAGE TO THE ROPS NEUTRAL. Give a warning to all persons
If the machine has rolled over or the ROPS has been around you that you are starting the engine.
in some other type of accident (such as hitting an SB037
overhead object during transport), you must replace
the damaged ROPS components to get as much
protection as you had originally.
After an accident, check the following for damage.
A. ROPS canopy.
B. Lower ROPS frame.
C. Operator’ s seat.
D. Seat belt mounting and seat belt.
6-85641NA Issued 12-05 Bur 6-7

TORQUE SPECIFICATIONS MACHINE CLEANING

Seat It is recommended that the complete machine be
kept clean. Machine operation in water, mud, dust,
33.9 to 47.4 Nm (25 to 35 lb ft) - 2 per side landfill, land clearing or forestry will require complete
machine clean up. Cleaning includes periodically
Seat Belt Mounting Bolts - Both Sides removal of inspection covers and guards to gain
46.7 to 54.2 Nm (34 to 40 lb ft) - both sides access for cleaning and removal of dirt or debris.
Clean all dirt and foreign material from the front
ROPS Mounting Bolts - Both Sides engine guard. Dirt will cause rust on the engine oil
pan and the loss of engine oil.
203 to 237 Nm (150 to 175 lb ft) - both sides
After cleaning is complete, install ALL covers and
guards.
DO NOT operate machine with covers or guards
removed.
WARNING: Replace all covers or guards

after servicing or cleaning the machine.
NEVER operate the machine with covers or
guards removed.
CM115
ADJUSTING THE RIPPER SHANKS
BC02M137 Figure 9
1. Remove the retaining clip (1).
2. Drive the pin (2) out and adjust the shank to the
position desired.
3. Replace the pin and retaining clip.
The ripper shanks have three positions. Use the
appropriate depth for the working condition.
6-8 Issued 12-05 Bur 6-85641NA

DOZER BLADE PITCH ADJUSTMENT

1. Raise dozer blade up approximately 100 mm (4 6. The cover guard may be used as a tool to turn
in). the turnbuckle.
2. Release the dozer blade control lever and shut 7. Replace the cover guard and retaining pin.
the engine off.
3. Remove the ignition key and set the parking REARWARD POSITION
brakes. BLADE PITCHED REARWARD
WARNING: Be careful with this procedure and raise When dozer blade is pitched in the rearward position,
the blade only high enough to make the necessary the blade will be able to push a larger load. Blade will
adjustment. stay on top in soft ground.
REARWARD POSITION ADVANTAGES
1. Blade is able to push a larger load.
2. Blade will stay on top in soft ground.
3. Blade will not dig into the ground.
4. Blade best used for fine grading.
FORWARD POSITION
BLADE PITCHED FORWARD
When dozer blade is pitched in the forward position,
the load slides off of blade as crawler travels in
BD02J077 Figure 10 reverse. Blade will dig into hard ground.
4. Remove the retaining pin to release the cover
FORWARD POSITION ADVANTAGES
guard.
1. Load slides off of blade as the crawler travels in
reverse.
2. Blade will dig into hard ground.
3. Less load spillage over top of blade.
BD02J079 Figure 11
5. Adjust the turnbuckle clockwise or counter
clockwise until the desired pitch angle is
reached.
BD02J078 Figure 12
6-85641NA Issued 12-05 Bur 6-9

FIRE EXTINGUISHER MOUNTING (IF FAN AND AIR CONDITIONING DRIVE

EQUIPPED) BELT
TYPE OF FIRE EXTINGUISHER SERVICE INTERVAL
It is recommended that you have a fire extinguisher Check the tension of a new drive belt after the first 10
on your machine. The fire extinguisher shown below hours of operation.
is available from your dealer and can be installed on Check tension . . . . . . . . . . . . . . . . . Every 250 hours
the machine.
1. Park the machine on a level surface and apply
This dry chemical fire extinguisher has a 5 pound the parking brake.
capacity and is approved for Class A, B and C type
2. Turn the master disconnect to OFF.
fires. The operating temperature is from -54° to 49°C
(-65° to 120°F). 3. Install a 1/2 inch breaker bar in the tension pulley
bracket.
INSPECTION AND CARE 4. Push the breaker bar forward just enough to
EVERY MONTH - It is recommended that you release the tension on the drive belt. Remove the
inspect the fire extinguisher once each month for drive belt from the water pump pulley first and
damage and to insure that the gauge is working then from the other pulleys.
correctly.
E V E RY 6 M O N T H S - H ave t h e d r y c h e m i c a l
removed and refilled by a fire equipment technician.
ONCE EACH YEAR - Have the fire equipment
technician inspect the fire extinguisher.
BD02M057 Figure 13
4. DO NOT mount the Fire Extinguisher on any part
of the ROPS structure. DO NOT make any
modifications to the ROPS structure.
6-10 Issued 12-05 Bur 6-85641NA

MACHINE STORAGE
STORAGE PREPARATION REMOVAL FROM STORAGE
If the machine is to be in storage for more than 30 Do not start the engine until steps 1 through 13 have
days, park the machine inside a building. If a building been done.
is not available, park the machine in a dry area on 1. Change the fuel filters.
planks and cover the machine with a waterproof
covering. 2. Put coolant in the engine cooling system.
1. Wash the machine. 3. Check the condition of the drive belt. Replace if
required.
2. Lubricate the machine at all grease fittings.
4. Check the engine oil level.
3. Paint any area where the paint has been
damaged. 5. Check the hydraulic oil level.
4. Drain the fuel tank. 6. Check the transmission oil level.
5. Put approximately 8 liters (2 U.S. gallons) of 7. Check the final drives oil level.
diesel flushing oil in the fuel tank. Run the engine 8. Lubricate the machine at all grease fittings.
until the exhaust smoke is blue white. 9. Use petroleum base solvent and remove the
6. Drain the flushing oil from the fuel tank. Case Rust and Corrosion Preventive from the
7. Put 15 ml (one teaspoon) of Shell Oil Company hydraulic cylinder rods, equipment valve spools
VPI crystals in the fuel tank. and transmission valve spools.
8. Move all hydraulic controls to relieve any 10. See Battery Service in this manual. Install the
pressure in the hydraulic circuits. battery.
9. Change the engine oil and replace the oil filter. 11. Fill the fuel tank.
10. Drain the cooling system. Leave the drain valves 12. Remove the air from the fuel system. See
open and do not tighten the radiator cap. Put a Removing Air from Fuel system in this manual.
Do Not Operate tag on the instrument panel. 13. If the machine is equipped with a turbocharger,
11. Clean the primary element for the air filter. you must prime the turbocharger oil lines with oil.
See Priming the Turbocharger in this manual.
12. Cover the exposed cylinder rods, equipment
valve spools, and transmission valve spools with 14. Start the engine. It is important that you refer to
Case Rust and Corrosion Preventive. the procedure on Starting the Engine in this
manual.
13. Charge the battery. Remove the battery from the
machine and put the battery on a wooden pallet
in a cool dry area. If possible, keep the battery in
a building where the temperature is above
freezing 0°C (32°F). Make sure the battery is
clean.
NOTE: Check the battery periodically for the
correct electrolyte level. Test the electrolyte with
a hydrometer. When the hydrometer reading is
near 1.215, charge the battery.
6-85641NA Issued 12-05 Bur 6-11

REAR ATTACHMENT TORQUE VALUES
BD02J032 Figure 14
Ripper ................................................................................................................. 1 300 to 1 160 Nm (855 to 960 ft lb)
BD02M132 Figure 15 BD02M171 Figure 16
Drawbar . . . . . . 1 300 to 1 160 Nm (855 to 960 ft lb) Hitch . . . . . . . . . . . . 430 to 485 Nm (315 to 355 ft lb)
6-12 Issued 12-05 Bur 6-85641NA

CHAPTER 7 - ELECTRICAL
Chapter 7
ELECTRICAL
TABLE OF CONTENTS
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Battery Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Battery Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Cleaning the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Additional Fuse Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Removal of the instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Installation of the instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Replacing a bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
ACCESSORY OUTLETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Issued 12-05 Bur 6-85641NA 7-1

NOTES
7-2 Issued 12-05 Bur 6-85641NA

ELECTRICAL SYSTEM
BATTERY SAFETY
WARNING: Sparks or flame can cause
hydrogen gas in a battery to explode. To
WARNING: Batteries give off explosive
prevent an explosion, do the following:
gases. Keep all open flames, sparks and
cigarettes away. Ensure adequate ventilation 1. When you DISCONNECT the battery
when charging batteries or when using in a cables, always disconnect the negative
confined place. Always protect your eyes (1) battery cable first.
when working near batteries. 2. When you CONNECT the battery cables,
SAFETY_ID_1C02
always connect the negative (-) cable
last.
WARNING: Do not reverse battery 3. Do not short circuit the battery posts with
terminals. Connect positive cable ends to metal items.
positive (+) terminals and negative cable
4. Do not weld, grind, or smoke near a
ends to negative terminals (-).
battery.
SAFETY_ID_1C02
SB034
WARNING: Before you service a battery,
always wear face protection, protective BATTERY SERVICE
gloves and protective clothing. Battery acid or
battery explosion can cause serious injuries.
SA046
WARNING: Battery acid causes severe 1 2

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. BD02J017 Figure 1
SB032 1. NEGATIVE BATTERY CABLE
WARNING: When the battery electrolyte is 2. POSITIVE BATTERY CABLE
frozen, the battery can explode if, (1) you try NOTE: The electrical system in this machine is 12
to charge the battery, or (2) you try to jump volts negative ground.
start and run the engine. To prevent the
Before you service components of the electrical
battery electrolyte from freezing, try to keep
system, always disconnect the NEGATIVE (-) battery
the battery at full charge. If you do not follow
cable.
these instructions, you or others in the area
can be injured. Dirt, moisture, and corrosion on the battery will
SA033 discharge the battery. Clean the battery with Case
Battery Saver and Cleaner. Follow the instructions on
WARNING: Before any operation on the the can.
components of the electrical circuit, put the
key switch in the shut down position. When Disconnect the alternator wires if you must run the
disconnecting the battery cables, always engine with the battery wires disconnected.
disconnect the negative (-) cable first. When Before you use an electric welder, disconnect the
reconnecting the battery cables, always alternator wires, instrument cluster, and turn the
connect the negative (-) cable last. master disconnect switch to OFF.
SAFETY_ID_1C02 Do not use a steam cleaner or cleaning solvent to
WARNING: Connecting auxiliary cables clean the alternator.
wrongly or short-circuiting batteries terminals
can cause an accident. Connect auxiliary
starting cables as per the following
instructions.
SAFETY_ID_1C02
6-85641NA Issued 12-05 Bur 7-3

BATTERY FLUID LEVEL

Check the fluid level of the batteries every 500 hours
of operation. If the fluid level is low, add clean or
distilled water to each cell until the fluid level is at the
split ring at the bottom of each cell opening.
In extreme heat conditions check battery fluid every
250 hours.
IMPORTANT: If the temperature is 0°C (32°F) or
below and you have added water to the batteries, do
the following; Connect a battery charger to the
batteries or operate the machine for approximately
two hours. This procedure is necessary to mix the
water with the electrolyte.
BATTERY VENTS
Keep the battery vents clean, make sure the vents
are not restricted.
CLEANING THE BATTERIES

Check the batteries and batter y compar tment
regularly for dirt, corrosion and damage. Dirt mixed
with electrolyte or moisture on the top of the batteries
can cause a discharged condition in the batteries.
Use one of the following methods to clean the
batteries.
1. Use Case Battery Saver, Part Number M20376.
Follow the instructions on the container. This
cleaner does not need water.
Use baking soda or ammonia and flush the outside of
the batteries with water. If you do not have Case
Battery Saver, use other special cleaners to prevent
corrosion on the battery terminals.
7-4 Issued 12-05 Bur 6-85641NA

FUSES AND RELAYS
2
1
3 4 5
6 7 8
9 10 11
12 13
A B C D
E F G H
J K L M
BD02J104 / BD99M013 Figure 2
1. INJECTION PUMP RELAY 8. NEUTRAL OK

2. STARTER RELAY 9. AC
3. HEATER/SEAT 10. TRACTOR
4. BACK UP ALARM 11. SAFETY
5. FLEET MANAGEMENT 12. CAB
6. BRAKE 13. DRIVETRAIN CONTROLLER
7. FNR (FORWARD,NEUTRAL,REVERSE)
A. Not Used G. Drivetrain Controller 1 amp

B. Cab Unswitched Power 30 amp H. Safety Relay 25 amp
C. Not Used J. Tractor Relay 30 amp
D.Heater/Seat Relay 30 amp K. 30 amp
E. Brake/Back Up Relay 10 amp L. Cab Relay 10 amp
F. FNR DirectionControl 1 amp M. Ignition Switch 10 amp
6-85641NA Issued 12-05 Bur 7-5

ADDITIONAL FUSE LOCATIONS
BD02K011 Figure 3 BD02K010 Figure 4

Additional fuses are located on the left-hand side of the front console. Remove the cover for access.
FSETIF Figure 5
F1B - Front Lights Switch ................................................................................................................................. 10A
F2B - Blower & AC Switch................................................................................................................................ 20A
F3B - Right- Hand Door Wiper Switch, Motor ................................................................................................. 7.5A
F4B - Left- Hand Door Wiper Switch, Motor, Washer Switch and Motor......................................................... 7.5A
F5B - Rear Wiper Switch, Motor ..................................................................................................................... 7.5A
F6B - Front Wiper Switch, Motor, Front/Rear Washer Switch, Motor .............................................................. 7.5A
F7B - AC Relay for Condenser Fans, AC Clutch .............................................................................................. 20A
F8B - ......................................................................................................................................................... optional
F9B - Heater Control Module ............................................................................................................................. 3A
F10B - ....................................................................................................................................................... optional
F11B - ...................................................................................................................................................... not used
F1A - Microcontroller, Heater, Seat, Cab Relay ................................................................................................. 5A
F2A - Proximity Switches, Injector Pump, Hold Relay ........................................................................................ 5A
F3A - Start/Injector Relays ................................................................................................................................. 5A
F4A - Instrument Cluster Power, Buzzer ............................................................................................................ 5A
F5A - Lighter/Radio (Cab) ................................................................................................................................ 15A
F6A - Horn Switch + Unswitched Battery Power to Instrument Cluster........................................................... 7.5A
F7A - ........................................................................................................................................................ not used
F8A - ........................................................................................................................................................ not used
F9A - Lighter/12v Jack, Radio Memory, Interior Lights ...................................................................................... 7.5
F10A.......................................................................................................................................................... not used
F11A - Rear Light Switch ................................................................................................................................. 10A
7-6 Issued 12-05 Bur 6-85641NA

INSTRUMENT CLUSTER
REMOVAL OF THE INSTRUMENT CLUSTER
1. Turn the master disconnect off.
2. Loosen and remove the 2 screws that fasten the
instrument cluster in the console. 4
3. Pull the instrument cluster out of the console far
enough to disconnect the electrical connector
from the rear of the instrument cluster.
4. Disconnect the electrical connector from the
socket on the rear of the instrument cluster and
remove the instrument cluster from the console.
INSTALLATION OF THE INSTRUMENT CLUSTER BD00H150 Figure 8

1. Reverse the removal instructions to re-install the 4. Turn the socket assembly (4) counter clockwise
cluster. to remove. The bulb and the socket assembly (4)
are ser viced together. Replace the socket
REPLACING A BULB assembly (4) as required.
1. Remove the instrument cluster from the console.
BD00H152 Figure 6
2. Remove the 2 screws that fasten the rear cover
to the frame.
BD00H151 Figure 7
3. Remove the rear cover (1) from the frame (2).
NOTE: Make sure the O-ring (3) is in the correct
position on the rear cover (1) before the rear
cover (1) is installed onto the frame (2).
6-85641NA Issued 12-05 Bur 7-7

ACCESSORY OUTLETS
There is one 12 volt accessory outlet behind the seat
on ROPS models.
Cab models have two outlets, one behind and to the
left of the operator, shown below, and one near the
right arm of the operator, not shown.
BDO2H130 Figure 9
1. 12 VOLT ACCESSORY OUTLET BEHIND OPERATOR IN
CAB
7-8 Issued 12-05 Bur 6-85641NA

CHAPTER 8 - SPECIFICATIONS
Chapter 8
SPECIFICATIONS
TABLE OF CONTENTS
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
TRAVEL SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
TRACK SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
TRANSPORT LENGTH AND WIDTH WITH BLADE FULLY ANGLED 25 DEGREES . . . . . . . . . . . . . . . . . . . . 8-5
OPERATING DATA AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
OPERATING DATA AND DIMENSIONS - RIPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Additional Weights of Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Issued 12-05 Bur 6-85641NA 8-1

NOTES
8-2 Issued 12-05 Bur 6-85641NA

ENGINE SPECIFICATIONS
NOTE: All specifications are given according to SAE Standards or Recommended Practices where the
specification applies.
Make and Model 650K Series 2 / 750K Series 2.......................................................................................... 445T/M2
850K Series 2 .......................................................................................................................................668T/M2
Firing Order 650K Series 2 / 750K Series 2 ................................................................................................... 1-3-4-2
850K Series 2 ...................................................................................................................................1-5-3-6-2-4
Bore and Stroke 650K Series 2 / 750K Series 2 .................................................... 104 x 132 mm (4.09 in x 5.20 in)
850K Series 2 ................................................................................................. 104 x 132 mm (4.09 in x 5.20 in)
Displacement 650K Series 2 / 750K Series 2......................................................... 4.5 L, 4 485 cm3 (274 cubic inch)
850K Series 2 ................................................................................................ 6.8 L, 6 729 cm3 (411 cubic inch)
Compression Ratio 650K Series 2 / 750K Series 2...................................................................................... 17.0 to 1
850K Series 2 ...................................................................................................................................... 17.0 to 1
Horsepower, Max. Rated Gross @ 2 000 rpm
650K Series 2 .......................................................................................................................... 60.0 kW (80 hp)
750K Series 2 ........................................................................................................................... 67.1 kW (90 hp)
850K Series 2 ........................................................................................................................... 73.8 kW (99 hp)
Engine Speeds
High Idle All Models ................................................................................................................. 2 170 to 2 270 rpm
Rated Speed All Models......................................................................................................................... 2 000 rpm
Low Idle All Models ..................................................................................................................... 800 to 1 050 rpm
NOTE: All specifications were reached using Number 2 diesel fuel.
HYDRAULIC SYSTEM
System Relief Pressure ............................................................................ 20 340 to 21 370 kPa (2 950 to 3 100 psi)
Pump Capacity .................................................................................. 20.3 gal/min @ 3 000 psi @ 2 000 engine rpm
TRAVEL SPEEDS
Speeds Forward ..........................................................................Infinitely variable from 0 to 9.7 km/h (0 to 6.0 mph)
Speeds Reverse ..........................................................................Infinitely variable from 0 to 9.7 km/h (0 to 6.0 mph)
Track Pull (Maximum / Both Tracks....................................................................................... 186 824 N (42 000 LBF)
NOTE: Track speed and track pull are with CLT chain. If machine is equipped with CELT chain speed will be
reduced 4% and track pull will be increased 4%.
6-85641NA Issued 12-05 Bur 8-3

TRACK SYSTEM
Track Gauge
650K Series 2 LT ........................................................................................................................ 1 448 mm (57 in)
650K Series 2 WT & LGP ............................................................................................................1 702 mm (67 in)
750K Series 2 / 850K Series 2 LT ................................................................................................1 575 mm (62 in)
750K Series 2 / 850K Series 2 WT & LGP...................................................................................1 778 mm (70 in)
Track Rollers Per Side
650K Series 2 / 750K Series 2 .............................................................................................................................. 6
850K Series 2........................................................................................................................................................ 7
Length of Track on Ground (With Standard CASE Lubricated Track)
650K Series 2............................................................................................................................2 230 mm (87.8 in)
750K Series 2............................................................................................................................2 266 mm (89.2 in)
850K Series 2............................................................................................................................2 352 mm (92.6 in)
Length of Track on Ground (With Optional CASE Extended Life Track)
650K Series 2............................................................................................................................2 251 mm (88.6 in)
750K Series 2............................................................................................................................2 288 mm (90.1 in)
850K Series 2............................................................................................................................2 373 mm (93.4 in)
Number of Track Shoes Per Side
650K Series 2...................................................................................................................................................... 38
750K Series 2...................................................................................................................................................... 39
850K Series 2...................................................................................................................................................... 40
Number of Carrier Rollers Per Side All Models ........................................................................................................ 1
Ground Pressure with CLT chain
650K Series 2 LT (57 “ Gauge / 98 “ Blade w/ 406 mm (16 in) shoe) .................................... 44.61 kPa (6.47 psi)
650K Series 2 WT (67 “ Gauge / 110 “ Blade w/ 559 mm (22 in) shoe)..................................33.99 kPa (4.93 psi)
650K Series 2 LGP (67 “ Gauge / 120 “ Blade w/ 635 mm (25 in) shoe .................................30.54 kPa (4.43 psi)
750K Series 2 LT (62 “ Gauge / 104 “ Blade w/ 457 mm (18 in) shoe.....................................40.54 kPa (5.88 psi)
750K Series 2 WT (70 “ Gauge / 120 “ Blade w/ 610 mm (24 in) shoe...................................31.78 kPa (4.61 psi)
850K Series 2 WT (70 “ Gauge / 120 “ Blade w/ 610 mm (24 in) shoe...................................31.30 kPa (4.54 psi)
NOTE: If machine is equipped with optional CELT chain ground pressure will be 0.7 kPa (0.1 psi) greater.
CASE Lubricated Track (CLT)...................................................................................................................... Standard
CASE Extended Life Track (CELT) ................................................................................................................ Optional
LT = Long Track
WT = Wide Track
LGP = Low Ground Pressure
8-4 Issued 12-05 Bur 6-85641NA

TRANSPORT LENGTH AND WIDTH WITH BLADE FULLY ANGLED 25 DEGREES
BS02K072 Figure 1
B 650K Series 2 w/o B 750K Series 2 w/o B 850K Series 2 w/o

Blade width A Transport width
Drawbar Drawbar Drawbar
2 489 mm (98 in) 2 308 mm 90.9 in 4 618 mm 181.8 in
2 642 mm (104 in) 2 446 mm 96.3 in 4 649 mm 183.0 in 4 696 mm 184.9 in 4 782 mm 188.3 in
3 302 mm (130 in) 3 043 mm 119.8 in 4 835 mm 190.4 in 4 921 mm 193.7 in
NOTE: Add 150 mm (5.9 in) for drawbar.
6-85641NA Issued 12-05 Bur 8-5

OPERATING DATA AND DIMENSIONS
BS02K102 Figure 2
A. Top of Exhaust Stack 650K Series 2 / 750K Series 2 ...........................................................2 624 mm (103.3 in)
850K Series 2 .....................................................................................................................2 614 mm (102.9 in)
B. Blade Height .................................................................................................................................914 mm (36 in)
C. Ground Clearance at Belly Pans 650K Series 2 ........................................................................383 mm (15.1 in)
750K Series 2 / 850K Series 2.................................................................................................379 mm (14.9 in)
D. Shank Height (Transport Position) .............................................................................................450 mm (17.3 in)
E. Top of Seat Head Rest ............................................................................................................2 229 mm (87.8 in)
F. Height of Cab w/o Air Conditioning ...................................................................................... 2 773 mm (109.2 in)
with Air Conditioning ...........................................................................................................2 788 mm (109.8 in)
ROPS Height ......................................................................................................................2 773 mm (109.2 in)
G. Blade Depth Below Ground ...................................................................................................... 495 mm (19.5 in)
Blade Angle Both Directions ................................................................................................... 0 to 25 Degrees
Blade Tilt, Each End (0 to 8.3 Degrees) ....................................................................................356 mm (14 in)
NOTE: Ground clearance and overall height dimensions are with the Grouser fully penetrated per SAE J1234.
Add 52.5 mm (2.06 in) if machine is on solid surface.
8-6 Issued 12-05 Bur 6-85641NA

BS02K101 Figure 3
A. Length, no blade, no rear equipment and CLT chain
650K Series 2 .....................................................................................................................3 076 mm (121.1 in)
750K Series 2 .................................................................................................................... 3 153 mm (124.1 in)
850K Series 2 .................................................................................................................... 3 261 mm (128.4 in)
Width - Blade Angled ...........................................................................................................2 530 mm (99.7 in)
B. Overall Length, blade straight, no rear equipment
650K Series 2 .....................................................................................................................4 126 mm (162.4 in)
750K Series 2 .....................................................................................................................4 171 mm (164.2 in)
850K Series 2 .....................................................................................................................4 258 mm (167.6 in)
C. Overall Length, blade straight, w/drawbar
650K Series 2 .....................................................................................................................4 276 mm (168.3 in)
750K Series 2 .....................................................................................................................4 322 mm (170.2 in)
850K Series 2 .....................................................................................................................4 408 mm (173.5 in)
D. Overall Length, blade straight, w/ripper
650K Series 2 .....................................................................................................................5 101 mm (200.8 in)
750K Series 2 .....................................................................................................................5 147 mm (202.6 in)
850K Series 2 .....................................................................................................................5 233 mm (206.0 in)
NOTE: Overall Length is with blade pitch at 55 degrees (factory setting). If blade pitch is adjusted to 60
degrees length will decrease 15 mm (0.6 in).
6-85641NA Issued 12-05 Bur 8-7

OPERATING DATA AND DIMENSIONS - RIPPER

Overall Width (Maximum) .............................................................................................................1 839 mm (72.4 in)
Width of Cut (Maximum) ...............................................................................................................1 781 mm (70.1 in)
Dig Depth (Maximum) ......................................................................................................................363 mm (14.3 in)
Ground Clearance (lowest position transport) ..................................................................................302 mm (11.9 in)
Number of Teeth (Standard) ...................................................................................................................................... 3
Number of Teeth (Maximum) ................................................................................................................................... 5
Torque (rear mounted equipment) ...................................................................... 1 300 to 1 160 Nm (855 to 960 ft lb)
WEIGHTS
OPERATING WEIGHT
Operating weights include ROPS full fuel and hydraulic tank, 77 kg (170 lb) operator, CLT chain, front and rear pull
hooks, side shields, track guides.
650K Series 2 LT w/16 in shoes and 98 in blade...................................................................... 8 244 kg (18 177 lbs)
650K Series 2 LGP w/25 in shoes and 120 in blade ................................................................ 8 813 kg (19 433 lbs)
750K Series 2 LT w/18 in shoes and 104 in blade.................................................................... 8 569 kg (18 895 lbs)
750K Series 2 LGP w/28 in shoes and 124 in blade ................................................................. 9 157 kg (20 191 lbs)
850K Series 2 LT w/20 in shoes and 104 in blade..................................................................... 8 902 kg (19 629 lbs)
850K Series 2 LGP w/28 in shoes and 124 in blade ................................................................. 9 399 kg (20 724 lbs)
ADDITIONAL WEIGHTS OF OPTIONAL EQUIPMENT

Approximate Add-On Weight
Dual Batteries for ROPS or CAB ........................................................................................................... 29 kg (64 lbs)
Rear Screen (For Cab) .......................................................................................................................... 32 kg (71 lbs)
Center Rockguards 650K Series 2 ...................................................................................................... 72 kg (159 lbs)
Center Rockguards 750K Series 2 .................................................................................................... 100 kg (221 lbs)
Center Rockguards 850K Series 2 .................................................................................................... 106 kg (234 lbs)
ROPS Canopy or Cab Canopy Brush Guard....................................................................................... 47 kg (104 lbs)
Forestry Side Screens ........................................................................................................................... 35 kg (77 lbs)
Hydraulic Equipment Pump w/PTO ....................................................................................................... 24 kg (53 lbs)
Heater for ROPS Unit ............................................................................................................................ 32 kg (71 lbs)
4 Spool Valve w/Plugs (Mechanical Controls) ......................................................................................... 8 kg (18 lbs)
Tractor Lift Hooks..................................................................................................................................... 5 kg (11 lbs)
Front Counterweight w/Pull Hook ...................................................................................................... 399 kg (880 lbs)
Radiator Brush Screen ............................................................................................................................ 8 kg (18 lbs)
Allied Equipment Add-On Weight
Winch (Carco Model 30B-PS.......................................................................................................... 454 kg (1 000 lbs)
Winch (Hyster Model W3C ............................................................................................................. 612 kg (1 350 lbs)
Log Arch (Hyster) .............................................................................................................................. 227 kg (500 lbs)
8-8 Issued 12-05 Bur 6-85641NA

CHAPTER 9 - INDEX
Chapter 9
INDEX
A Control Handle Positions ....................................3-14
Access Doors ...................................................... 5-9 Coolant Levels
Accessory Outlet ................................................. 7-8 Coolant Reservoir ..........................................5-17
Radiator .........................................................5-17
Adjustable Cab Dome Light ............................... 3-17
Coolant Reservoir ...............................................5-17
Air Filter System ................................................ 5-13
Cleaning the Primary (Outer) Element .......... 5-15 Coolant Solution, Engine Cooling System ..........5-17
Primary (Outer) Element ............................... 5-13 Crawler Operation ................................................4-6
Secondary (Inner) Element ........................... 5-14 Before You Start Each Day ..............................4-6
Service Specifications ................................... 5-13 Power Turn .......................................................4-8
Warning Lamp ............................................... 5-13 Steering Gradual Turn ......................................4-8
Transmission Control Levers ...........................4-8
B
Backrest Tilt Adjustment Lever .......................... 3-15 D
Battery Decelerator Pedal .................................................3-9
Cleaning .......................................................... 7-4 Decelerator Pedal Operating Instructions ..........4-11
Fluid Level ....................................................... 7-4 Diagnostics/Computer Operation .......................4-12
Safety .............................................................. 7-3 Diesel Fuel System ............................................5-19
Service ............................................................ 7-3 Draining Water and Sediment ........................5-19
Vents ............................................................... 7-4 Fuel Line Shutoff Valve ..................................5-19
Before Operation Safety ...................................... 2-3 Fuel Tank Breather ........................................5-21
Before You Start Each Day ................................. 4-6 Removing Air From the Fuel System .............5-20
Blade Lift Eye .................................................... 4-28 Service Specifications ....................................5-19
Booster Battery Connection to Machine Battery 4-24 Digital Display .......................................................3-8
Brake Release for Towing ................................. 4-18 Direction Control Lever .......................................3-10
Burn Prevention Safety ........................................ 2-6 Display-Service/Enter Switch ...............................3-4
Bushing and Sprocket Wear Chart .................... 4-35 Dozer Blade Control Lever .................................3-12
Angle Left .......................................................3-12
Angle Right ....................................................3-12
C
Float ...............................................................3-12
Cab Door Release/Lock .................................... 3-16 Hold ................................................................3-13
Cab Tilt Hydraulic Jack ...................................... 3-20 Lift ..................................................................3-12
Cab Tilt System Oil ............................................ 4-26 Lower .............................................................3-12
Cab Vent ............................................................ 3-17 Tilt Left ...........................................................3-12
Carrier Roller ..................................................... 4-29 Tilt Right .........................................................3-12
Case Extended Life Track (CELT) ..................... 4-31 Dozer Operation .................................................4-28
Cleaning Cooling System .................................. 5-18 Draining Water and Sediment ............................5-19
Cleaning the Primary (Outer) Element .............. 5-15 Drive Sprocket ....................................................4-29
Climate Control Operation ................................. 4-16 Ductile Iron Safety ................................................2-8
Climate Control Panel ........................................ 3-17
E
Coat Hanger ...................................................... 3-17
Electrical Service
Components of the Undercarriage .................... 4-29
Accessory Outlet ..............................................7-8
Carrier Roller ................................................. 4-29
Drive Sprocket ............................................... 4-29 Electrical System ..................................................7-3
Idler ............................................................... 4-29 Engine
Recoil Spring Housing ................................... 4-29 Hourmeter ........................................................5-4
Track Adjuster (Steel Track) ......................... 4-29 Specifications ...................................................8-3
Track Chain ................................................... 4-29 Engine Coolant Heater .......................................4-23
Track Frame .................................................. 4-29 Engine Cooling System ......................................5-17
Track Links .................................................... 4-30 Cleaning Cooling System ...............................5-18
Track Rollers ................................................. 4-29 Coolant Solution .............................................5-17
Track Shoes .................................................. 4-30
6-85641NA Issued 12-05 Bur 9-1
CHAPTER 9 - INDEX
Service Specifications ................................... 5-17 G

Engine Hand Throttle ......................................... 3-11 General Information ..............................................1-1
Engine Lubrication ............................................. 5-10 General Safety .....................................................5-3
Engine Oil Selection ...................................... 5-10
Engine Oil Heater .............................................. 4-23 H
Engine Oil Level ................................................ 5-11 Hazardous Chemicals Safety ...............................2-6
Engine Oil Selection .......................................... 5-10 Horn ......................................................................3-4
Engine Operation .......................................... 4-3, 4-4 Hourmeter, Engine ...............................................5-4
Engine Speed .................................................. 4-4 How to Extend the Life of Sealed Track and the Case
Parking the Machine and Stopping the Engine 4-5 Lubricated Track (CLT) ................................4-31
Starting the Engine .......................................... 4-4
Hydraulic Filter ...................................................5-22
Engine Service .................................................. 5-11
Hydraulic Fluid Change ............................ 5-23, 5-25
Engine Oil Level ............................................ 5-11
Engine Service Specifications ....................... 5-11 Hydraulic System ...............................................5-22
Oil Change and Filter Replacement .............. 5-11 Fluid Level Check ..........................................5-22
Priming the Turbocharger Oil Lines with Oil .. 5-12 Hydraulic Filter ...............................................5-22
Hydraulic Fluid Change ........................ 5-23, 5-25
Engine Service Specifications ........................... 5-11
Relief and Check Valves Service ...................5-23
Engine Speed ...................................................... 4-4 Service Specifications ....................................5-22
Engine Starting Aids .......................................... 4-22 Specifications ...................................................8-3
Ether Start Aid
Engine Coolant Heater .................................. 4-23 I
Engine Oil Heater .......................................... 4-23 Identification Numbers
Ether Starting Fluid .............................................. 6-4 Engine ..............................................................1-3
Extinguisher Mounting, Fire ............................... 6-10 Product Identification Number (P.I.N.) .............1-3
ROPS Canopy .................................................1-4
F Transmission ....................................................1-4
Factors Controlling Undercarriage Wear ........... 4-30 Idler ....................................................................4-29
Wear Factors You Can Control ..................... 4-32 Instructions, General Safety .................................5-3
Wear Factors You Can Not Control .............. 4-31 Instrument Panel ..................................................3-3
Factors Controlling Undercarriage Wear - Wear Water Temperature Gauge ..............................3-7
Factors You Can Not Control ...................... 4-31 Instruments/Controls
Filter Dozer Blade Control Lever .............................3-12
Engine ........................................................... 5-11 Control Handle Positions ...........................3-14
Hydraulic ....................................................... 5-22 Operators Seat ...............................................3-15
Transmission ................................................. 5-24 Operators Seat Belt .......................................3-21
Final Drives ........................................................ 5-26 Ripper Control Lever ......................................3-14
Oil Change .................................................... 5-26 Interior Cab Door Release ..................................3-16
Oil Level Check ............................................. 5-26
Service Specifications ................................... 5-26 K
Fire and Explosion Prevention Safety ................. 2-7 Key Switch, Ignition ..............................................3-5
Fire Extinguisher Mounting ................................ 6-10
Fire Extinguisher Safety ...................................... 2-6 L
Fluid and Lubricants ............................................ 5-5 Lifting the crawler ...............................................4-21
Fluid Level Check Lowering the cab ................................................4-27
Hydraulic System .......................................... 5-22 Lubrication/Filters/Fluid
Transmission ................................................. 5-24 Air Filter System .............................................5-13
Forward/Rearward Adjustment Lever ................ 3-15 Engine Cooling System ..................................5-17
Front Console Engine Service ...............................................5-11
Key/Ignition Switch .......................................... 3-5 Final Drives ....................................................5-26
Fuel guage monitor, no power ............................. 3-4 Hydraulic System ...........................................5-22
Transmission ..................................................5-24
Fuel Line Shutoff Valve ..................................... 5-19
Lubrication/Filters/Fluids
Fuel Tank Breather ............................................ 5-21
Access Doors ...................................................5-9
Fuel Warning Lamp ............................................. 3-7 Diesel Fuel System ........................................5-19
9-2 Issued 12-05 Bur 6-85641NA

CHAPTER 9 - INDEX
Engine Lubrication ........................................ 5-10 Outside Cab Door Release ................................3-16

Fluid and Lubricants ........................................ 5-5 Owner, To The .....................................................1-1
Transmission ................................................. 5-24
P
M Parking Brake Levers ...........................................3-9
Machine Cleaning ................................................ 6-8 Parking the Machine and Stopping the Engine ....4-5
Machine Components .......................................... 1-5 Parking The Machine Safety ................................2-6
Machine Operation Safety ................................... 2-5 Personal Safety ....................................................2-4
Machine Storage ............................................... 6-11 Plastic and Resin Parts ........................................5-4
Removal From ............................................... 6-11
Power Turn ...........................................................4-8
Storage Preparation ...................................... 6-11
Pressure Relief Valves .......................................4-17
Maintenance Safety ............................................. 2-8
Primary (Outer) Element ....................................5-13
Maintenance/Adjustments
Ether Starting Fluid ......................................... 6-4 Priming the Turbocharger Oil Lines with Oil .......5-12
Machine Cleaning ........................................... 6-8
Reversible Fan Positions ................................ 6-6 R
Roll-Over Protective Structure ........................ 6-7 Radiator ..............................................................5-17
Seat Belt .......................................................... 6-7 Rear Attachment Torque Values ........................6-12
Spark Arrester Muffler ..................................... 6-8 Recoil Spring Housing ........................................4-29
Torque Specifications for Seat and Seat Belt
Relief and Check Valves Service .......................5-23
Mounting Bolts ........................................ 6-8
Removing Air From the Fuel System .................5-20
Master disconnect switch .................................. 3-20
Reverse/Forward Speed Ratio Control ..............3-11
Menu Up/Down Switch ........................................ 3-4
Reversible Fan Positions ......................................6-6
N Ripper
Operating Data and Dimensions ......................8-8
Next Service to (NONE) .................................... 4-15
Ripper Control Lever ..........................................3-14
Hold ................................................................3-14
O
Lower .............................................................3-14
Oil Change Raise ..............................................................3-14
Engine ........................................................... 5-11
Ripper Shank Adjustment .....................................6-8
Final Drives ................................................... 5-26
Roll-Over Protective Structure ..............................6-7
Oil Level Check
Final Drives ................................................... 5-26 ROPS
Damage To ......................................................6-7
Oil Viscosity/Temperature Ranges .................... 5-10
Maintenance and Inspection ............................6-7
Operating Data and Dimensions
RPM display .........................................................3-4
Long Track (LT) and Rubber Track Crawlers .. 8-6
Ripper .............................................................. 8-8 Run-In Period of a New Machine .........................4-3
Track Shoe Bolts ..............................................4-3
Operating in Cold Weather ................................ 4-22
Engine Starting Aids ...................................... 4-22
S
Operating in Hot Weather .................................. 4-22
Safety Decals .......................................................2-9
Operating Instructions ......................................... 4-4
Booster Battery Connection to Machine Battery ... Safety Instructions, General .................................5-3
4-24 Safety, Battery ......................................................7-3
Crawler Operation ........................................... 4-6 Safety, Decals, and Hand Signals
Dozer Operation ............................................ 4-28 Personal Safety ................................................2-4
Operating in Cold Weather ............................ 4-22 Safety Rules .....................................................2-3
Operating in Hot Weather ............................. 4-22 Utility Safety .....................................................2-4
Run-In Period of a New Machine .................... 4-3 Safety/Decals/Hand Signals
Track Systems .............................................. 4-29 Before Operation ..............................................2-3
Transporting the Machine ............................. 4-20 Burn Prevention ...............................................2-6
Vandal Lockup .............................................. 3-20 Ductile Iron .......................................................2-8
Operating Weight ................................................. 8-8 Fire and Explosion Prevention .........................2-7
Operators Seat Belt ........................................... 3-21 Fire Extinguisher ..............................................2-6
Optional Equipment Hazardous Chemicals ......................................2-6
Weights ........................................................... 8-8 Machine Operation ...........................................2-5
6-85641NA Issued 12-05 Bur 9-3
CHAPTER 9 - INDEX
Maintenance .................................................... 2-8 Releasing the Brakes .....................................4-17

Parking The Machine ...................................... 2-6 Track Adjuster (Steel Track) ...............................4-29
Safety Decals .................................................. 2-9 Track Chain ........................................................4-29
Seat Belt .............................................................. 6-7 Track Frame .......................................................4-29
Torque Specifications ...................................... 6-8
Track Links .........................................................4-30
Seat Comfort Control ......................................... 3-15
Track Rollers ......................................................4-29
Seat Lumbar Control ......................................... 3-16
Track Shoe Bolts ..................................................4-3
Secondary (Inner) Element ................................ 5-14
Track Shoe Bolts - Steel Track .............................6-4
Service Interval Change .................................... 4-14
Track Shoes .......................................................4-30
Service Reminder (AUTO) ................................. 4-13
Track System
Service Reminder (MAN) ................................... 4-14 Specifications ...................................................8-4
Service Reminder Activation to (AUTO) ............ 4-15 Track Systems ....................................................4-29
Service Reminder Activation to (MAN) .............. 4-15 Blade Lift Eye .................................................4-28
Service Reminder Reset .................................... 4-14 Bushing and Sprocket Wear Chart ................4-35
Service Soon Lamp ............................................. 3-3 Case Extended Life Track (CELT) .................4-31
Service Specifications ....................................... 5-13 Components of the Undercarriage .................4-29
Diesel Fuel System ....................................... 5-19 Factors Controlling Undercarriage Wear .......4-30
Engine Cooling System ................................. 5-17 Factors Controlling Undercarriage Wear - Wear
Final Drives ................................................... 5-26 Factors You Can Not Control ................4-31
Hydraulic System .......................................... 5-22 How to Extend the Life of Sealed Track and the
Transmission ................................................. 5-24 Case Lubricated Track (CLT) ................4-31
Track Shoe Bolts - Steel Track ........................6-4
Shuttle Parameter Adjustment ............................. 4-9
Wear Factors You Can Control ......................4-30
Sides of the machine
Transmission ......................................................5-24
Right-hand, left-hand, front, and rear .............. 1-2
Fluid Level Check ..........................................5-24
Spark Arrester Muffler ......................................... 6-8 Service Specifications ....................................5-24
Specifications Transmission Filter .........................................5-24
Engine Specifications ...................................... 8-3 Transmission Control Levers ................................4-8
Hydraulic System ............................................ 8-3
Transmission Filter .............................................5-24
Operating Data and Dimensions .............. 8-6, 8-8
Track System .................................................. 8-4 Transmission Speed Gauge .................................3-8
Travel Speeds ................................................. 8-3 Transmission Speed Parameter Adjustment ........4-9
Weights ........................................................... 8-8 Transmission Speed Up/Down Buttons ..............3-10
Standard Seat Controls Transporting the Machine ...................................4-20
Backrest Tilt Adjustment Lever ..................... 3-15 Travel Speeds
Forward/Rearward Adjustment Lever ........... 3-15 8-3
Starting the Engine .............................................. 4-4 Steel Track Crawler .........................................8-3
Steering Gradual Turn ......................................... 4-8 Turbo Precleaner ................................................5-14
Steering Sensitivity Adjustment ........................... 4-9
Storage U
Machine Storage ........................................... 6-11 Utility Safety Rules Message ................................2-4
Preperation .................................................... 6-11
Removal From ............................................... 6-11 V
Sun Visor, Front ................................................. 3-17 Vandal Lockup ....................................................3-20
Sun Visor, Rear ................................................. 3-18
Switch W
Key/Ignition ..................................................... 3-5 Walk-Around Inspecion ........................................4-4
Warning Lamp for Air Filter Restriction ..............5-13
T Water Shutoff .....................................................4-16
Tilting the cab .................................................... 4-25 Water Temperature Gauge ..................................3-7
To the Owner ....................................................... 1-1 Wear Factors You Can Control ..........................4-30
Torque Specifications WEIGHTS .............................................................8-8
Seat Belt Mounting Bolts ................................. 6-8
Weights ................................................................8-8
Towing a Disabled Crawler Operating Weight .............................................8-8
9-4 Issued 12-05 Bur 6-85641NA

CHAPTER 9 - INDEX
Optional Equipment ......................................... 8-8

Welding on the Machine ...................................... 6-5
6-85641NA Issued 12-05 Bur 9-5

CHAPTER 9 - INDEX
9-6 Issued 12-05 Bur 6-85641NA

650K 750K 850K Series 2 Op&#39;s Manual

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Bur • Issued 12-2005

6-85641NA Issued 12-05 Bur I

II 6-85641NA Issued 12-05 Bur

6-85641NA Issued 12-05 Bur 1-1

RIGHT, LEFT, FRONT, AND REAR OF

1. FRONT 3. RIGHT-HAND SIDE

BASIC MACHINE, DOZER AND RIPPER

1-2 Issued 12-05 Bur 6-85641NA

Component Serial Numbers

Transmission and serial number

6-85641NA Issued 12-05 Bur 1-3

1-4 Issued 12-05 Bur 6-85641NA

1. ROPS 5. CARRIER ROLLER 9. BLADE

6-85641NA Issued 12-05 Bur 1-5

1. RIPPER SHANK 2. TOOTH

BD02M132 Figure 12 BD02M171 Figure 13

1-6 Issued 12-05 Bur 6-85641NA

SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

6-85641NA Issued 12-05 Bur 2-1

2-2 6-85641NA Issued 12-05 Bur

Most accidents involving machine operation and

Do not remove this manual or the safety manual from

BEFORE OPERATION BD02J019 Figure 3

6-85641NA Issued 12-05 Bur 2-3

2-4 Issued 12-05 Bur 6-85641NA

6-85641NA Issued 12-05 Bur 2-5

PARKING THE MACHINE FIRE EXTINGUISHER

2-6 Issued 12-05 Bur 6-85641NA

6-85641NA Issued 12-05 Bur 2-7

2-8 Issued 12-05 Bur 6-85641NA

WARNING: Injury or death can result if you 1

6-85641NA Issued 12-05 Bur 2-9

329044A1 / BD02M133 Figure 10 5

332512A1 / BD99M009 Figure 12

2-10 Issued 12-05 Bur 6-85641NA

6-85641NA Issued 12-05 Bur 2-11

2-12 Issued 12-05 Bur 6-85641NA

INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

6-85641NA Issued 12-05 Bur 3-1

3-2 6-85641NA Issued 12-05 Bur

6-85641NA Issued 12-05 Bur 3-3

6. RIGHT-HAND AND LEFT-HAND 9. DISPLAY - SERVICE/ENTER

BS02M141 / BS02M142 Figure 10

3-4 Issued 12-05 Bur 6-85641NA

11. KEY SWITCH

BD04N012/ 87412595 Figure 14

6-85641NA Issued 12-05 Bur 3-5

12. TRANSMISSION FILTER WARNING 15. PARKING BRAKE ENGAGED

13. CHARGE PRESSURE WARNING 16. ALTERNATOR

14. LOW ENGINE OIL PRESSURE 17. HYDRAULIC FILTER WARNING

18. ENGINE AIR FILTER

3-6 Issued 12-05 Bur 6-85641NA

19. ENGINE COOLANT

6-85641NA Issued 12-05 Bur 3-7

3-8 Issued 12-05 Bur 6-85641NA

BRAKE, DECELERATOR AND PARKING BRAKES

6-85641NA Issued 12-05 Bur 3-9

DIRECTION CONTROL LEVER,TRANSMISSION CONTROL, HAND THROTTLE

3-10 Issued 12-05 Bur 6-85641NA

3. ENGINE HAND THROTTLE

BD02H134 / 8371L92 Figure 40

6-85641NA Issued 12-05 Bur 3-11

DOZER BLADE CONTROL LEVER

650K 750K 850K Series 2 Op's Manual

650K 750K 850K Series 2 Op's Manual