TABLE OF CONTENTS CHAPTER 1 GENERAL INFORMATION TO THE OWNER . RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE IDENTIFICATION NUMBERS cee MACHINE COMPONENTS . . CHAPTER 2 SAFETY AND DECALS TABLE OF CONTENTS: SAFETY RULES ee BEFORE OPERATION .... PERSONAL SAFETY UTILITY SAFETY MACHINE OPERATION PARKING THE MACHINE FIRE EXTINGUISHER BURN PREVENTION HAZARDOUS CHEMICALS FIRE OR EXPLOSION PREVE? MAINTENANCE DUCTILE IRON . ‘SAFETY DECALS CHAPTER 3 INSTRUMENTS AND CONTROLS: ‘TABLE OF CONTENTS INSTRUMENT PANEL ...... — BRAKE, DECELERATOR AND FOOTREST . 39 PARKING BRAKES. , we 38 DIRECTION CONTROL LEVER, TRANSMISSION CONTROL, HAND THROTTLE 3-10 DOZER BLADE CONTROL LEVER : . _— - 312 CONTROL HANDLE POSITIONS 314 34 38 RIPPER CONTROL LEVER 3-14 OPERATORS SEAT 2315 CAB 316 OPERATORS SEATBELT... 0... sosevcsceeeseeees eee 3-21 CHAPTER 4 OPERATING INSTRUCTIONS TABLE OF CONTENTS: : RUN-IN PERIOD OF A NEW MACHINE ENGINE OPERATION ...... : CRAWLER OPERATION MOVING A DISABLED CRAWLER TRANSPORTING THE MACHINE . OPERATING IN HOT WEATHER OPERATING IN COLD WEATHER ... BOOSTER BATTERY CONNECTION TO MACHINE BATTERY TILTING THE CAB... DOZER OPERATION . TRACK SYSTEMS . . FACTORS CONTROLLING UNDERCARRI 6.05081NA lesued 12.05. Bur 1CHAPTER 5 LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS ...... BA GENERAL SAFETY BEFORE YOU SERVICE , Boqooo0000c0 <) SYSTEMGARD LUBRICATION ANALYSIS PROGRAM ceeeeeeeeeeees 5-4 PLASTIC AND RESIN PARTS . cece Bb ENGINE HOURMETER cette pq ceeeeees 54 FLUIDS AND LUBRICANTS... . 55 LUBRICATION AND MAINTENANCE CHART . 56 GREASE FITTINGS .. a . 57 ACCESS DOORS .. 59 ENGINE LUBRICATION 510 ENGINE SERVICE «2.00.00... cc cece cece St AIR FILTER SYSTEM .. BA ENGINE COOLING SYSTEM 517 DIESEL FUEL SYSTEM . ceeeeeeeee ceeeeeee 519 HYDRAULIC SYSTEM ee ooeooo cece s 522 TRANSMISSION .... ba ceceee ee eeeeeees SeO4 FINAL DRIVES - 5-26 CHAPTER 6 MAINTENANCE AND ADJUSTMENTS. TABLE OF CONTENTS . TRACKS .... REVERSIBLE FAN POSITIONS (IF EQUIPPED) . ROLL-OVER PROTECTIVE STRUCTURE .... MACHINE CLEANING ............ ADJUSTING THE RIPPER SHANKS: DOZER BLADE PITCH ADJUSTMENT . 6-10 FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) FAN AND AIR CONDITIONING DRIVE BELT : 610 MACHINE STORAGE . sees et CHAPTER 7 ELECTRICAL TABLE OF CONTENTS 7A ELECTRICAL SYSTEM 73 FUSES AND RELAYS 0.0.0... cece cece veo . 175 INSTRUMENT CLUSTER ....... : a ceeeeeee TT ACCESSORY OUTLETS ce - vee 78 CHAPTER 8 SPECIFICATIONS TABLE OF CONTENTS . a4 ENGINE SPECIFICATIONS 83 HYDRAULIC SYSTEM . 133 TRAVEL SPEEDS 83 TRACK SYSTEM . ceeeeee a4 TRANSPORT LENGTH AND WIDTH WITH BLADE FULLY ANGLED 25 DEGREES 2. 85 OPERATING DATA AND DIMENSIONS rn ceeeeees 86 OPERATING DATA AND DIMENSIONS - RIPPER . 88 WEIGHTS - 88 CHAPTER 9 INDEX 6-05641NA Issued 12.05. BurCHAPTER 1 - GENERAL INFORMATION. Chapter 1 GENERAL INFORMATION TO THE OWNER Figure t 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 Crawlet 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 cbtain additional manuals. Contact your dealer for any further information or assistance about your machine. Your dealer has approved service parts. Your dealet has technicians with special training that know the best methods of repair and maintenance for your Crawler. e.se41NA Issued 1205 ur ttCHAPTER 1 - GENERAL INFORMATION RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE, 8 Figure? OPERATOR'S MANUAL POUCH ATTACHED TO SEAT BACK ‘SOT Figures 1. FRONT 3, RIGHTHAND 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 ae seen from the operators seat. 12 lesued 1205 Bur 6-95643NCHAPTER 1 - GENERAL INFORMATION IDENTIFICATION NUMBERS Write your machine mode! number, Product Identification Number (P!.N.) and serial numbers on the lines provided below. if needed, give these numbers to your dealer when you need pars 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. f the machine is stolen, report the numbers to your local law enforcement agency. Machine > ‘Machine Medel and Type > ‘Product Idenification Number: PIN, > Year of Bul ‘Component Serial Numbers > = Engine serial number eee oo (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 umber ‘THE ENGINE (4 AND 6 CYLINDER) > Dozer blade serial number > DONO Figure 4 PRODUCT IDENTIFICATION NUMBER (P.LN.) FROPS CANOPY IS LOCATED ON THE LEFT-HAND UPPER i 6-85041NA Issued 1205. Bur 13CHAPTER 1 - GENERAL INFORMATION eorenie Figure 6 Saar Figues DOZER BLADE 1-4 Issued 1205. Bur e-ase4inaCHAPTER 1 - GENERAL INFORMATION MACHINE COMPONENTS: ae Figures 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: 4, LEFT-HAND ENGINE ACCESS 4, TRACK Be a By ae OD Ee i te maa Figure 1. RIGHT-HAND ACCESS DOOR 4. BLADE PITCH ADJUSTMENT 2. STEPS 5, RIGHT-HAND ENGINE ACCESS DOOR 3. HAND RAILS e-escuin Issued 1205 Bur 15CHAPTER 1 - GENERAL INFORMATION = ~ Figue Ti RIPPER 1. RIPPER SHANK — 2, TOOTH fone ‘oe? 0 ron DRAWBAR row 16 ‘ssued 12.05. But e-as041NASAFETY RULES... BEFORE OPERATION . PERSONAL SAFETY UTILITY SAFETY MACHINE OPERATION PARKING THE MACHINE FIRE EXTINGUISHER BURN PREVENTION HAZARDOUS CHEMICALS FIRE OR EXPLOSION PREVENTION MAINTENANCE DUCTILE IRON SAFETY DECALS 6-85041NA CHAPTER 2 - SAFETY AND DECALS: Chapter 2 SAFETY AND DECALS TABLE OF CONTENTS 24CHAPTER 2 - SAFETY AND DECALS 22 NOTES 6-05041NA lesued 12.05 BurCHAPTER 2 - SAFETY AND DECALS SAFETY RULES WARNING: This safety alert symbol indicates important safety messages in this ‘manual. When you see this symbol, carefully read the message that follows and be alert to the possibilty of death or serious injury. Most accidents involving machine operation and maintenance can be avoided by following basic safety rules and precautions. Read and understand all the safety messages in this manual, the safety manual, and the safety decals on the machine before you operate or service the machine. See your dealer if you have any questions. READ THIS MANUAL COMPLETELY and make sure you understand the controls. All equipment has a limit. Make sure you understand the speed, brakes, steering, stability and load characteristics of this machine before you start to operate. Do not remove this manual or the safety manual from the machine. See your dealer for additional manuals. ‘The safety information given in this manual does not replace safety codes, insurance needs or, federal, state, and local laws. Make sure your machine has the correct equipment according to these rules or Se Figure t 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 * Avoid loose fitting clothing, loose or uncovered long hair, jewelry and loose personal articles. -05641NA Issued 12.05. Bur * Different jobs will require different protective equipment. items such as hard hats, protective shoes, heavy gloves, reflector type vests, respirators, and ear protection can be required. Know and use the equipment that is required before you start the job. * Be prepared for emergencies. Always have a first aid kit and a fire extinguisher with you. Be sure that the fire extinguisher is properly maintained. Be familiar with the correct use. * Know the signals used on your job. Follow the instructions of the flagman, signs, etc. © Check that all doors, guards, and covers are installed correctly and closed. ‘© Foreign material or grease on the steps and hand rails cant cause an accident. Keep the steps and hand rails clean. * Before you start each day, walk around the machine and check for oil or fluid leaks. Replace all broken or missing parts and do the required lubrication and maintenance as shown in this manual. Clean all trash and debris from the machine, oo Figure? sen Figu * Always face the machine and use the hand rails when getting on, Do not rush. 28CHAPTER 2 - SAFETY AND DECALS '* Remove all loose objects from the operators area and from the machine. Loose objects can jam. controls and cause accidents. ‘© Before you start the engine, always fasten the seat belt, sound the horn and make sure all personnel are clear of the machine safety area. ‘© Engine exhaust fumes can cause death. If you operate this machine in an enclosed area, be sure there is good ventilation to replace the exhaust fumes with fresh air. * Know the rules, laws, and safety equipment necessary for transporting this machine on a road or highway, 24 PERSONAL SAFETY If Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows: The first panel indicates the nature of the hazard. * The second panel indicates the appropriate avoidance of the hazard. ‘© Background color is YELLOW. Prohibition symbols such as 1) X and if used, are RED. UTILITY SAFETY Safety precaution MUST be followed when working rear buried Utility Lines. During operation itis 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. lesued 1205 Bur 6-aSe41NACHAPTER 2 - SAFETY AND DECALS 2D FT Fguet CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION Know the utility color code (U.S.A. and Canad: Electric...... ; se Red Gas, Oil, or Petroleum Yellow ‘Communication, Telephone, Television ..... Orange Water - Blue Sewer. cece Green/Brown Proposed Excavation. white Surveying. ........eecee Pink Reclaimed Water and Slurry Purple After locating the utility ines, carefully dig a hole by hand and/or automatic vacuum equipment to the uly line to verity the location and depth of the line. 6.5041NA lssved 1205 Bur 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 ar accident. © Dust, fog, smoke, etc., can decrease your visior and cause an accident. Stop the machine o1 decrease the speed until you can see everything around you in the work area © Contact with high voltage lines, undergrounc cables, etc., can cause serious injury or deatt from electrocution. © Before you drive or operate in an area with hig lines or cables, tell the power or utility company ‘what you are going to do. You MUST HAVE THE POWER DISCONNECTED OR KEEP A SAFE WORKING DISTANCE from the lines or cables ‘You must know the safe working distance from the high voltage power equipment and must know any federal, state/provincial or local safety codes o1 regulations that apply to the job site. © When the machine is in reverse an alarm wil sound ‘© Electrical cables, gas pipes, water pipes, sewers. or other underground objects can cause injury o1 death. Learn the location of underground hazards before you operate your machine in a new area. © If this machine rolls over you can be injured o1 killed. You must make a judgment if weather, road. or earth conditions will permit safe operation on hill, ramp, or rough ground. Always fasten the seal belt. © Stay away from hazardous areas such as ditches, ‘overhargs, etc. Walk around the work area before you start and look for hazards. * Be alert and always know the location of al workers in your area. Keep all other persons completely away from your machine. Injury o1 death can result if you do not follow these instructions. ‘Operate the machine controls from the operators seat only. Always fasten the seat belt,CHAPTER 2 - SAFETY AND DECALS PARKING THE MACHINE 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. 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. Tum 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 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. 26 FIRE EXTINGUISHER It is recommended that the fire extinguisher be maintained on the crawler when it is in operation to aid in event of a fire. See your dealer for further information. WARNING: it is good practice to carry a fire extinguisher on the machine. Be sure that the extinguisher is properly maintained and be familiar with its proper use. ra Figures BURN PREVENTION © Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote - EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call 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, ets., used with your machine can be hazardous, Issued 1205. Bur 6-95641H4CHAPTER 2 - SAFETY AND DECALS ‘* Material Safety Data Sheets (MSDS) provide information about the chemical substances within a product, safe handling procedures, first aid measures and procedures to be taken when the product is accidentally spilled or released. MSDS ate available from your dealer. ‘Before you service the machine, check the MSDS for each fluid, lubricant, etc., used in your machine. This information indicates what the risks are and how to service the machine safely. Follow this information when servicing the machine. '* Before you service this machine and before you dispose of the old fluids and lubricants, always remember the environment. DO NOT put oil or fluids into the ground or into containers that can leak. © Check with your local environmental or recycling center or your dealer for correct disposal information, ‘* Fluids such as Gasoline, Kerosene, Diesel Fuel, Hydraulic Oil, ete. contain chemicals that can be ‘dangerous to your health and can cause cancer andior birth defects. Contact either internally or externally can cause infection or other injury. If any internal or external contact occurs, see your local Poison Control Center or doctor IMMEDIATELY. FIRE OR EXPLOSION PREVENTION © 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 8. 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 ‘ot fil the fuel tank with the engine running, it you are near an open fire, or it you are welding, smoking, et. Use nonflammable cleaning solvent o clean parts. easeuina lesved 12.05. But Aire can cause injury or death. Always have a fire extinguisher near or on the machine. Make sure the fire extinguisher is serviced according to the manufecturers instructions. ‘© Ifa fie extinguisher has been used, always recharge or replace the fire extinguisher before operating the machine, * Remove all trash or debris from the machine eact day. Especially check the engine area anc exhaust system, If the machine has an oil, fuel, or hydraulic leak always repair the leak and clean the area before ‘operating, * Keep the cooling system clean and maintain the correct coolant level ‘© Make sure that you do not store oily rags or othe! flammable materials on the machine. If you weld, grind, or use a cutting torch on this machine, 1. Disconnect or isolate the drive train controller. 2. Keep the ground cable from the welder as neal the werk area as possible. 3. Before welding or using a torch on the machine clean the area to be repaired. '* Check the electrical system for loose connections or frayed insulation. Repair or replace the loose o1 damaged parts. 27CHAPTER 2 - SAFETY AND DECALS 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. ‘© I 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 * Bofore 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 ifa partis, cast ductile iron, 28 Issued 32.05. Bur 6-95641NACHAPTER 2 - SAFETY AND DECALS SAFETY DECALS WARNING: injury or death can result if you cannot read a safety decal or ifa safety decal| A is missing. Replace any missing or damaged safety decal and keep all safety decals clean. See your dealer for new safety decals. Make sure that you read all the safety decals and all instructional decals. Check these decals every day before you start. Clean these decals if you cannot read the words. NOTE: When you clean the decals, use only a cloth, water, and soap. Do not use solvent, gasoline, etc. You must replace a decal ifthe 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. pore Figures 4, a8a97aa1 2. 824-7040 (2) 6-a5e41Na Issued 12.05, Bur EXPLOSION HAZARD RUN OVER HAZARD Read procedure in Operator's Manual before jump start or service to avoid injury. Sg Starting in gear can cause death. Start engine only from operator seat with transmission controls) in NEUTRAL. 29CHAPTER 2 - SAFETY AND DECALS || HoT LiauD UNDER PRESSURE HAZARD Service when cool. 3, S20084A1 Figure 10 Awaanine | Do not modify or repair ROPS in any manner, fj a Faure ti 4. 38307241 (2) ONE EACH SIDE ‘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. © PNG ENTANGLEMENT HAZARD Keep clear or stop engine before servicing. —_—_ coin RANE a 100 i 5, $32512Al (2) ONE EACH SIDE Figure 12 Issued 12.05 Bur .a5641NACHAPTER 2 - SAFETY AND DECALS aa Figue ts 6, 38262241 7, 321-7030 6.05681 Iseved 1205 aur 211CHAPTER 2 - SAFETY AND DECALS = AAWARNING an Fue 8. 28097141 212 Wseved 1205 Br e-ase4inCHAPTER 3 - INSTRUMENTS AND CONTROLS Chapter 3 INSTRUMENTS AND CONTROLS, TABLE OF CONTENTS INSTRUMENT PANEL, . BRAKE, DECELERATOR AND FOOTREST PARKING BRAKES : DIRECTION CONTROL LEVER, TRANSMISSION CONTROL, HAND THROTTLE DOZER BLADE CONTROL LEVER CONTROL HANDLE POSITIONS ......... : ceeeeeee : RIPPER CONTROL LEVER OPERATORS SEAT........ ceceeeeeees ceeeees SEAT CONTROLS caB . ceeeeeeeeees ceeeeeee OPERATORS SEAT BELT To Fasten To Release 95681 lesued 1205 Bur BE ae ae 34¢ B42 344 2314 B48 S18 SHE 3.21 3.21 321 a1CHAPTER 3 - INSTRUMENTS AND CONTROLS. NOTES 6-5041NA lesued 1205 BurCHAPTER 3 - INSTRUMENTS AND CONTROLS INSTRUMENT PANEL sonore Figure 1 NOTE: To check the condition of the warning lamps turn the key switch to on. The warning lamps will illuminate fo 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 ee OFF. To tum ON press the icon. The LEE} | amp will illuminate and the service SS" | switch icon wil illuminate. message can be read on the digital display. NOTE: See Operating Instructions in this ae Figure < ‘Maral for programming. 4, FRONT AND REAR WINDSHIELD soma Figur2 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 | AD [Ser Tem oN press teicon Tuning ss anes JN | the switch on iluminates the instrument 7 face and is confirmed by the illuminated 5. FRONT AND REAR WINDSHIELD WASHER (IF EQUIPPED) Push the rocker switch icon to activate the front and rear windshield washer. Release the rocker switch to stop the front and rear windshield washer. symbol (A). The switch icon will illuminate, Sas Figures ome Figure € 6-05047N lesvas 12.08. ButCHAPTER 3 - INSTRUMENTS AND CONTROLS. YP ae Figure 8 7.LEFFHAND AND RIGHTHAND DOOR WINDSHIELD WASHERS (IF EQUIPPED) Push the rocker switch icon to activate the left and right door windshield washers. Release the rocker switch to stop the left and sight door windshield washer. Figure 9 6.RIGHTHAND AND LEFT-HAND. DOOR WINDSHIELD WIPERS (IF EQUIPPED) This switch has two positions, ON and OFF. To turn ON press the icon, 8. MENU UP/DOWN Use this UP / DOWN switch to scroll through the menus. NOTE: Push the UP arrow at start up to v display engine 1pms on the digital display. Figure 10 34 io L__} Figure 7 9. DISPLAY - SERVICE/ENTER Use this switch to select between display and service menus or enter selections. The Diamond icon, or top portion of the ‘switch, is used to select displays. The 90 Degree Arrow icon, or bottom Portion of the switch, is used to enter selected choices. NOTE: Pressing the Service/Enter portion of the switch with the key switch OFF will allow the operator or service technican to monitor the fuel gauge without powering up. Figure 11 10. HORN Push the switch to activate the horn. NOTE: The horn has constant power and ‘may be used with the key switch in OFF. Figure 12 Issued 1205 Bor 6-ase41NACHAPTER 3 - INSTRUMENTS AND CONTROLS. 11. KEY SWITCH The key switch has four positions: 4 © 6 ACCESSORY POSITION This position energizes the drivetrain controller, accessory switches and instrument cluster. ENGINE STOP (OFF POSITION) To stop the engine, turn the key to STOP. After the engine has stopped, remove the key. ENGINE ON (ON POSITION) Turn the key clockwise to ON and check the warning lamps. This is the normal position of the key switch when the engine is running, ENGINE START (START POSITION) ‘Turn the key completely clockwise to the START position to actuate the starter motor. After the engine starts, release the key. The key will return automatically toON. SRB rena eRBEDITE Figure 13 -aSG41NA Issued 1205 Ou eranesss Figure Te 35CHAPTER 3 - INSTRUMENTS AND CONTROLS Qe ©. 36 12, TRANSMISSION FILTER WARNING LAMP, This warning lamp shows the condition of the transmission filter. If the warning lamp illuminates during normal operation, (transmission oil at operating temperature and engine at full throttle), stop the engine and replace the filter. Figure 16 13. CHARGE PRESSURE WARNING LAMP This warning lamp illuminates and warning buzzer will sound if, (1) the engine is stopped and the key switch is Cn, or (2) there is no or low oil pressure in the transmission. Do not run the machine if the warning lamp illuminates. Figure 17 14. LOW ENGINE OIL PRESSURE This warning lamp illuminates and warning buzzer will sound when the engine is stopped and the key switch is on, or there is no or low oil pressure in the engine. Do not run the engine if the warning lamp illuminates. Figue 18 sy ae 15. PARKING BRAKE ENGAGED This lamp illuminates when one or both the parking brake levers are pulled ON. The parking brake can be set by pulling either brake handle into the ON position, depressing the brake pedal completely, of letting the machine set in neutral for 380 seconds. Figure 19 16. ALTERNATOR This lamp illuminates when the battery condition drops below proper operating voltage. This lamp illuminates with the key switch in the ON position but should go OUT with the engine running. The gauge (B) should be monitored by the operator. Figure 20 17. HYDRAULIC FILTER WARNING LAMP This warning lamp shows the condition of the hydraulic fiter. If the warning lamp illuminates during normal operation, (hydraulic oll at operating temperature and engine at full throttle), stop the engine and replace the filter. Figure 21 18. ENGINE FILTER RESTRICTION This warning lamp illuminates when, the key switch is in the START position or, when the engine air filter element requires service. AIR Figure 22 Issued 12.08. Bur -asc4iNACHAPTER 3 - INSTRUMENTS AND CONTROLS ae @ G| 564A COOLANT 19. ENGINE TEMPERATURE This warning lamp illuminates and the warning buzzer sounds when the engine coolant temperature is too high. The temperature should be monitored by watching the gauge (C). The temperature of the coolant is normal when the gauge needle is in the green area. Figure 24 20. TRANSMISSION FAULT This warning lamp illuminates when the transmission controller encounters an error. NOTE: Contact your dealer if this lamp iluminates. Figure 25 21. TRANSMISSION ol, TEMPERATURE WARNING This warning lamp will glow and the warming 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. Figure 26 Issued 1205. Bur Fquez 22. GRID HEATER LAMP Turn the key switch to on. When the incoming engine air needs to be preheated, due to cold temperatures, the lamp will illuminate. Wait until. the indicator lamp goes off before turning the key switch to the start position. Figure 2; 23, FUEL WARNING LAMP This warning lamp will glow and the warning buzzer will sound for a few moments when the machine is low on fuel E.The operator may monitor the gauge with the key switch on, the engine running or by pushing the Service/Enter button with the key switch off, (90 degree arrow icon), Figue 2CHAPTER 3 - INSTRUMENTS AND CONTROLS 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. Service messages and information will be displayed across the center portion of the display. 25, TRANSMISSION SPEED GAUGE This gauge shows the transmission speed selected by the operator. The maximum speed is selectable in a range of 10 increments. The range is controlled by the Transmission UP/DOWN buttons on the Direction Control Lever. ‘Once the key switch has been shut off it will default the Transmission Speed to 60% as shown, below on start up. ‘BOON Figure 30 38 sows Figure Si ‘TRANSMISSION CONTROL BUTTONS ‘A. TRANSMISSION SPEED UP BUTTON 5. TRANSMISSION SPEED DOWN BUTTON Issued 1205 Bur .5641NACHAPTER 3 - INSTRUMENTS AND CONTROLS PARKING BRAKES BRAKE, DECELERATOR AND FOOTREST Figures 4. 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. 3, LEFT AND RIGHT FOOTREST 6.05081NA lesved 1205. Bur some Figure 3 4, PARKING BRAKE LEVERS (ONE EACH SIDE) sure Figure 35 Y i soon Figure 38 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 (SAHA). NOTE: Any time the crawler is not moving for 36 seconds or more the SAHR brake applies. 39CHAPTER 3 - INSTRUMENTS AND CONTROLS. DIRECTION CONTROL LEVER, TRANSMISSION CONTROL, HAND THROTTLE 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 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 = Figure ae displayed on the instrument gauge. 2, TRANSMISSION SPEED 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 increase track speed push the upper button. To decrease track speed push the lower button. The Sue operator may choose to hold the appropriate ono Figure 38 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. lesved 12.05. Bur e-asc4iNa 310CHAPTER 3 - INSTRUMENTS AND CONTROLS. 3. ENGINE HAND THROTTLE Pull the throttle lever BACK to increase the engine speed. Push the throttle lever FORWARE to decrease the engine speed. 4, REVERSE TO FORWARD SPEED ATIC CONTROL This control knob allows the operator to contro the reverse speed in relation to the forwarc speed. Rotate the knob clockwise to increase the speed of reverse faster than forward. The knot will stay in the desired position. NOTE: Maximum reverse speed is limited tc maximum machine speed. The speed ranges are 80%, 100%, 115%, and 130% of forward speed. REVERSE SLOWER THA oRWARD REVERSE FASTER THAN FoRwanD su0s8 aaa jae a 6-a5041NA Issued 12.05. Bur ealCHAPTER 3 - INSTRUMENTS AND CONTROLS. DOZER BLADE CONTROL LEVER 1. THE DOZER BLADE CONTROL LEVER aA SmaE Figure A. FLOAT: Float (Detent): This is a detent position. When in the FLOAT (Detent) position, the blade can follow the level of the ground without movement of the control lever. _ H (| RET Figue a3 B. LOWER: C. HOLD: The blade will stop moving in the HOLD position When released, the control lever will return automatically to the HOLD position. You must manually move the control lever from the FLOAT position to the HOLD position, Figure a4 Figure a7 a12 lsoved 1205. ur 6.95641NACHAPTER 3 - INSTRUMENTS AND CONTROLS. A es FUE E.TILT LEFT acs = Figure 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 RET Figure 50 G.ANGLE LEFT Rotate the lever counter- clockwise to angle the blade left. ger H.ANGLE RIGHT Rotate the lever clockwise to angle the blade right. e-senina Ieeved 12.05. Bur Bg 343CHAPTER 3 - INSTRUMENTS AND CONTROLS CONTROL HANDLE POSITIONS RIPPER CONTROL LEVER 1. dam Nut Figure The position of the control handle can be adjusted to * a suitable operator’ 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. 1, LOWER: 88 2. RAISE: 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. Figure s7 344 Issued 12.05 our ‘-85641NACHAPTER 3 - INSTRUMENTS AND CONTROLS 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 sous? 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. sown ~ Figure 58 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 6-5e41N lesued 12.05. Bur 3, OPERATOR COMFORT CONTROL On the mechanical suspension seat use the contre! knob/crank (3) and follow the directions on the decal (A). Sit in the seat and adjust the knob/crank until the yellow pointer reaches the end of the adjustment barrel. See photo below.CHAPTER 3 - INSTRUMENTS AND CONTROLS: CAB Sore? Figure 63 (On the air suspension seat pull the control knob (A) out to lower the seat. Push in to raise. The key switch must be in the ON position to activate the compressor. NOTE: Over time there will be some air loss and the operator should re-adjust at the beginning of the work day. NOTE: Adjust the seat so that you can apply the foot brake when your back is against the seat backrest. boner — Figure 68 4, LUMBAR ADJUSTMENT CONTROL This adjustment is on the left-hand shoulder side for the air suspension seat and on the lower left-hand rear side for the mechanical suspension seat. sooner Figure 6 346 aoa Figure 66 1. CAB DOOR RELEASE AND LOCK The cab door may be opened and locked into position, cone 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. Boomors Figure 6B 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. Issued 12.05, sur .85641NACHAPTER 3 - INSTRUMENTS AND CONTROLS: 4. COAT HANGER aaT0 /eOREHTTE Figure 7: 8. RETRACTABLE SUN VISOR, FRONT a moat Figure 70 5. CLIMATE CONTROL PANEL This panel controls the temperature and fan functions for the cab. See Operating Instructions, inthis Manual for specific instructions. 6. CAB VENT One of six louvered vents for operator comfort Boose Figure 9. RETRACT LEVER FOR SUN VISOR Hold the lever to the right and fold the sun visor back up carefully. mae 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 (©. 6-95081NA lesued 1205. Bur 317CHAPTER 3 - INSTRUMENTS AND CONTROLS. sows Figure 74 10. RETRACTABLE SUN VISOR, REAR (IF EQUIPPED) oaeMi3 Figure 75, 11, RETRACT CORD FOR REAR SUN VISOR (IF EQUIPPED) Pull the cord down and fold the sun visor back up carefully, boomer Figure 76 12, ADJUSTABLE REAR VIEW MIRROR, 348 Issued 1205 BurCHAPTER 3 - INSTRUMENTS AND CONTROLS ane ~ Figure 18. OPERATOR COMFORT VENTS 14, 12V AUX POWER SUPPLY (2) 15, LEFT REAR SPEAKER (One each side) Boears Figure 76 17. SLIDING WINDOW ADJUSTMENT AND LOCK (IF EQUIPPED) Press the lock in to adjust the window up anc cess 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 lockec EQUIPPED into the slot before moving. 6-s0c1na Issued 12.05. Bu ateCHAPTER 3 - INSTRUMENTS AND CONTROLS ee - Figure sd 1. CAB TILT HYDRAULIC JACK: This jack is used to tilt the cab off for service access. The handle for the jack is located under the access door on the left-hand side. (Fig. 81) Baa Figure ai NOTE: See the Operating Instructions in this Manual for Cab Tilt procedures. 3-20 Bara Figure &2 2, MASTER DISCONNECT SWITCH This switch allows the operator or service technican to stop all power from the battery. 0 =OFF, 1 = ON. oa “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, Issued 1205 Bur 6-85641NACHAPTER 3 - INSTRUMENTS AND CONTROLS 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 BA Goerate nis machine, avays fasten he 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. TO FASTEN Pull the right-hand belt from holder. Fasten the belt ‘end into the left-hand buckle, RELEASE BAR Figure 64 Make sure the belt end and buckle are securely fastened. The left-hand receiving end of the belt (buckle) will not pull out. TO RELEASE There are two releases on the belt.To release the ‘seat belt, push the red button or the red bar on the buckle, Figure & RELEASE BUTTON sean ‘ssued 1205 Bor 3.21CHAPTER 3 - INSTRUMENTS AND CONTROLS 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 Pee oa ae Engine Operation rr ac Brake Pedal : veces ceneeeeeee AE Track Shoe Bolts 4g ENGINE OPERATION «22... 00000000 eee e teeter eee t ett tttneeseeeeeeteeeseeeeeees 4c Walk-Around Inspection . , and Poe beteeeeeeeeeeneeese Ah Starting the Engine , feceeeeeee tee cae Engine Speed - a o cae Extreme engine conditions... ceeeeee : : ae Parking the Machine and Stopping the Engine : : Dae CRAWLER OPERATION Before You Start Each Day Direction Control Lever Turning Steering Gradual Turn Power Tum .. Counter-rotation . Adjusting steering sensitivity Transmission speed controls. Decelerator pedal . ‘Onboard diagnostics and computer operation . Digital display and control Display menus Activating the service reminder to (AUTO): Activating the service reminder to (Man): . Setting the next service to (NONE): Climate control system . MOVING A DISABLED CRAWLER Opening the pressure relief valves Releasing The Brakes ‘TRANSPORTING THE MACHINE Lifting the machine vette OPERATING IN HOT WEATHER ......--.200+ OPERATING IN COLD WEATHER . Engine Starting Aids . Starting the Engine Engine Coolant Heater (If Equipped) Engine Oil Heater (If Equipped) BOOSTER BATTERY CONNECTION TO MACHINE BATTERY TILTING THE CAB .. Lowering the rops cab or canopy Fete tteeeeeee nee 427 DOZER OPERATION Cette teen ett neneeee ces cece eee 28 Engine Speed . fiteeeeenees Blade Pitch TRACK SYSTEMS ‘Components of the Undercarriage . 4-29 ‘Components of the Undercarriage Fete netteeeeeeeees 4:30 Factors Controlling Undercarriage Wear me vee 480 Issued 12.05, Bur 6-95641NA “4CHAPTER 4 - OPERATING INSTRUCTIONS Wear Factors You Can Control ............ . : 4-30 How to Extend the Life of Sealed Track and the Case Lubricated Track (CLT) ... ener! Case Extended Life Track (CELT) parece 1431 FACTORS CONTROLLING UNDERCARRIAGE WEAR 43 Bushing and Sprocket Wear Chart 2435 lesved 1205 Bur S-85641NA 42CHAPTER 4 - OPERATING INSTRUCTIONS 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. 8. 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, chesk 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 Ib ft) for the standard link bolts and 430 to 470 Nm (318 to 346 Ib 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. Itis 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. e5641NA leeued 1205 Bur 43CHAPTER 4 - OPERATING INSTRUCTIONS CRAWLER OPERATION BEFORE YOU START EACH DAY ‘The drive and steering on the K Series 2 crawlers are controlled by a microprocessor. The Direction Control Lever sends an electronic signal to the controller. There is no mechanical linkage and therefore an entirely different “feel” and sensitivity will be noticed by the operator. Onboard diagnostics allow the operator to monitor the service intervals and custom tailor Service Messages to the work environment. The operator may also adjust the sensitivity of the machine control by selecting one of three settings through the onboard computer. Be a careful operator, you can prevent accidents. Read the following information. WARNING: Always know the location of all] workers in your area. Warn them before you start working the machine. Always keep all ‘other persons away from your area. Serious injury or death can result if you do not follow | these instructions. 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| Aa Sorao tis machine, aways aston 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. WARNING: DO NOT operate the machine while under the influence of alcohol or drugs. 46 are Figure 1, Adjust the seat and fasten your seat belt. Make sure you can push the brake pedal completely down with your back against the seat cushion. 2. Turn the ignition switch to ON and monitor the display gauges. 3. Place the Direction Control Lever in Neutral. NOTE: N should be seen on the Digital Display. Boner Figure 3 ‘ssued 1205 Bur 6-05681NA,CHAPTER 4 - OPERATING INSTRUCTIONS sooner Figure ¢ 4, Sound the horn to alert those around that you are starting the machine. 5. Start the engine and allow proper warm up. 6. When the temperature is cold, -17°C (0°F) and below, see Oparating in Cold Weather in this 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 Tiansmission 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, oases ~ Figure 5 1, DECELERATOR PEDAL 10. Press the Decelerator Pedal all the way down. 11, Place the Direction Control Lever in F (Forward) and slowly release pressure on the Decelerator Pedal. NOTE: The crawler will not move if the engine rpm is below 1000. 6-a50¢1NA Yasue 1205. Bue 12, Test the foot brake by operating the crawle: forward and pushing the brake pedal. The crawler must stop in a straight line. NOTE: Pressing the brake pedal all the way dowr will engage the parking brake. WORKING OPERATIONS This crawler is designed to operate efficiently witt the hydrostatic pumps running at full engine rpm’s, This provides optimum power and cooling of the hydrostatic components. Use of the bump up anc down buttons is recommended for reduction o machine speed. Operation with low engine speeds may cause excessive heating of hydrostatic ‘components, For continuous roading situations, it is recommendec nat to bump the machine speed above &CHAPTER 4 - OPERATING INSTRUCTIONS DIRECTION CONTROL LEVER 1, DIRECTION CONTROL LEVER The drive and steering are controlled 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. Eonar Figure 7 Push the Direction Control Lever into the position you wish the crawler to go and verify the selection by reading the Digital Display. See Figure 7 above (Neutral shown). NOTE: The crawler will not move unless engine rpm is above 1000. To turn the crawler push the Direction Control Lever toward the direction desired. Turning must always be ‘commanded through Forward or Reverse. TURNING Forward or reverse motion must always be commanded in conjunction with turning. Moving the direction control lever only left or right will resutt in no motion. Turns must be taken through forward or reverse. 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. 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 aa Figuw8 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 1. To counter-rotate the crawler to the left, push the Decelerator Pedal all the way down, push the Direction Control Lever forward and then straight left to the nine o'clock position. Slowly release the Decelerator Pedal. 2. To counter-rotate the crawler to the right, push the Decelerator Pedal all the way down, push the Direction Control Lever forward and then straight right to the three o'clock position. Slowly release the Decelerator Pedal. NOTE: The Steering sensitivity has three settings and may be adjusted for operator or work preference. Weeved 12.05. Bur 6-85041NACHAPTER 4 - OPERATING INSTRUCTIONS ADJUSTING STEERING SENSITIVITY The Direction Control Lever has three sensitivity settings (1,2,3) and will be set at 2 from the factory. STEER 1 Boo Smooth STEER 2 : : Normal STEER 3 : Fast To change the sensitivity: eC Panes Figures 1, Press and release the Service/Enter switch (1). 0X (SETTINGS) 7 Panera Tas Figure To 2. Use the up or down arrow to display the settings menu, (SETTINGS) on the Digital Display. \ (STEER?) Fanerg ane Figue Ti 3. Select the SETTINGS menu by pressing the Service/Enter switch (3) 6-ase41NA Issued 1205. Bur 4, Toggle through the setting menu by using the Ur ‘or Down arrows (2) until (STEER 2) is shown or the Digital Display. NOTE: (STEER 2), Normal is the setting from the factory. 5. When, (STEER_#) is on the Digital Display screen press the Service/Enter button (3). The # 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 contacting your Dealer. ADJUSTING SHUTTLE PARAMETER To adjust the Shuttle parameter follow the same steps as for Steering Sensitivity, At step 5: (SHUTTLE _#) At this display where the # ic located the value can be 1, 2 or 3. 1 beinc smooth and 3 being fast. After selecting desired value press the Service/Ente, switch, ADJUSTING MAXIMUM TRANSMISSION SPEED PARAMETER To adjust the Maximum Transmission speed follow the same steps as for Steering Sensitivity. At step 5: (MAX_SP###t) At this display where the ### are located the value can be 70,80,90 or 100. After selecting desired value press the Service/Ente! switch,CHAPTER 4 - OPERATING INSTRUCTIONS ‘TRANSMISSION SPEED CONTROLS Figure 72 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%. Boor Figure 13 4, 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. 440 ‘The Digital Display (4) will reflect the position of the Direction Control Lever as Forward, Neutral or Reverse. NOTE: The crawler will not move unless the engine 1pm is above 1000. NOTE: A flashing F or A indicates the directional contro! lever must be retumed to neutral before movement is allowed. WARNING: The Direction Control Lever has three sensitivity settings. Be familiar with the setting that best suits the work and operator requirements. Issued 12.05. Bu 6-85641NACHAPTER 4 - OPERATING INSTRUCTIONS DECELERATOR PEDAL Figuie 14 5. DECELERATOR PEDAL The Decelerator Pedal can be used by the operator to slow or stop the vehicle. It reduces the throttle setting as it is depressed. The decelerator works in any direction, forward or reverse. DUNS Figure 15 8. 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. e-se41Na Sssued 12.05. But | AAWARNING ENGINE DECELERATOR PEDAL Depress - SLOW Release - FAST 7. ENGINE HAND THROTTLE Figure 17 41. Pull the Throttle Lever back to increase the engine speed. 2. Push the Throttle Lever forward to decrease the ‘engine speed, NOTE: Alvays shut the engine down withthe throttle at its lowest setting to keep from damaging the turbocharger.CHAPTER 4 - OPERATING INSTRUCTIONS ONBOARD DIAGNOSTICS AND COMPUTER OPERATION DIGITAL DISPLAY AND CONTROL The Digital Display (1) may be used to view Service and Operating Information. By using the Menu Up/Down Arrow Switch (2) and the Display - Service/Enter Switch (3) the operator or service technician may display fault codes, monitor service schedules or change operating parameters. DISPLAY MENUS To access the Display Menus: Soar Figure 9 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. Figure 18 4. The engine r/min (rpm) display will show, engine rimin (rpm) on the right hand side of the Digital Display, if selected. FNR will show on the left hand side. 5. The Next Service display will show NS on the left hand side of the Digital Display. The right hand side of the Digital Display will show the engine hours until the next service is due. If the service interval has passed the display will show service interval hours in negative numbers -##.# NOTE: A flashing F or R indicates the Direction Control Lever must be returned to neutral before ‘movement is allowed. lesved 12.05. Bur e.se41nACHAPTER 4 - OPERATING INSTRUCTIONS, 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). J Ear 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. 6-05041NA Issued 12-05. But 413CHAPTER 4 - OPERATING INSTRUCTIONS When the Service Reminder has been activated and set to (MAN): 1. The operator will be notified when the crawler reaches within 10 hours of the "Next Service” (NS) 2. The Service Soon lamp (1) will luminate for 5 seconds and the exact information will be on the 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 service technican manually resets the interval. Soran 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 owitch (2). The computer will automatically calculate when the next service (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 the Service/Enter switch (3). 4, The Digital Display will read (RESET?_), 5.Use the Up/Down arrows (2) to change the intervals, LE., 50 to 100. an4 6. Press the Service/Enter switch (3) to store the information. NOTE: Atter changing the Service Interval, the Service Reminder feature must be reset before Next Service (NS) will be updated. NOTE: Factory default for Service Interval (Si) is 250 hours. Issued 1205. Bur 6.85041NACHAPTER 4 - OPERATING INSTRUCTIONS 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_RMOR). 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 5, Press and release the Service/Enter switch (3) and the setting is changed. ACTIVATING THE SERVICE REMINDER TO (MAN): 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). 3, Select the service reminder menu by depressing the Service/Enter switch (3). 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): 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) 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 prassing the Service/Enter Switch (3). 4. Use the Up or Down arrow switch (2) to display the “NONE” selection. Press Service/Enter switch (8) to select it. 5, Reset the service reminder using the procedure described above to update NS. 6-85041NA Issued 12.05. Bur Figure 415CHAPTER 4 - OPERATING INSTRUCTIONS CLIMATE CONTROL SYSTEM soaKees 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. 416 lesued 12.05 Bue 6.8564 1NACHAPTER 4 - OPERATING INSTRUCTIONS MOVING A DISABLED CRAWLER for moving the machine a short distance only. 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 BA ceca thycraut cout emptios or overhoat. WARNING: Tow option bypasses high pressure relief valves. Catastrophic hydrostatic motor damage can Fag If your machine is disabled, you must make a judgment if the machire can be moved without more damage. | 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 tw 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, 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 disabled machine to assist with additional control or braking, 4. Attach a rigid drawbar or cables to the disabled ‘machine. Baar Figure 25 1, TOP OR UPPER RELIEF VALVES FOR MOVING THE CRAWLER FORWARD 6-25c41NA Issued 12.05. Bur Sane Figure 2 2, LOWER RELIEF VALVES FOR MOVING THE CRAWLER IN 'A REARARD DIRECTION (SHOWN LOOKING TO THE REAR OF THE CRAWLER) NOTE: The belly pan will have to be removed t access the lower relief valves. moana Figure 2: 5. Remove the relief valve plastic protective caps. an