SECTIONINDEX
Thisshopmanualincludesinformationforlocations,
INTRODUCTION—SECTION1 specifications,service/specialtools,tolerances,pressures, lubricantsandsealants,specialtorques,testsandadjustments,assemblytipsandservicebulletinreferencesfor variouscomponentsofthemachine.Thisshopmanualis dividedintomajorsections.Thesesectionsareindexedby titleanddividedbyindividualsectionindextab.Tousethis shopmanual,locatethesectionrequiredandturntothat sectionindextab.
MISCELLANEOUS—SECTION2 —SECTION4 —SECTION5 COOLING—SECTION6
DRIVETRAIN—SECTION7
TORQUECONVERTER—SECTION7B
ELECTRICAL—SECTION8 —SECTION9 HYDRAULICS—SECTION10
PUMPSANDMOTORS—SECTION10A CONTROLVALVE—SECTION10B CYLINDERS—SECTION10C —SECTION11 POWER—SECTION12 —SECTION13
UNDERCARRIAGE—SECTION14
TRACKCHAIN—SECTION15
MOUNTEDEQUIPMENT—SECTION17
AVOIDACCIDENTS
WORKSAFETY--FOLLOWTHESERULES
ACAREFULMECHANICISTHEBESTINSURANCEAGAINSTANACCIDENT
GENERAL
THISSYMBOLISUSEDTHROUGHOUTTHISSHOPMANUALTOCALLYOURATTENTION TOINSTRUCTIONSCONCERNINGPERSONALSAFETY.OBSERVEANDFOLLOWTHESE INSTRUCTIONS.BECERTAINANYONEOPERATINGORSERVICINGTHISMACHINEIS AWAREOFTHESERULES.FAILURETOFOLLOWTHESERULESMAYRESULTININJURY ORDEATH.
Humanerrorisacontributingfactorinmostequipmentrelatedinjuries.Haste,carelessnessandlackoftrainingarethe primarycausesofinjuries.Mostoperatinginjuriesoccurbecauseofexcessivespeed,lossofcontrol,failuretoobserve warningsigns,slippingorfallingwhileenteringordismounting,alackofbermsonroadwaysorpiles,lackofaROPS orseatbelt,ornotwatchinginthedirectionoftravel.Mostmaintenanceinjuriesoccurduringweldingorwhenusing hammersorwrenches.Themostcommonfaultsareimproperworkposition,aslippedtool,missedaim,abrokentool, flyingchipsand/ornoweldinghood.Thinkbeforeyouact.Acarefuloperatorormaintenancepersonisthebest insuranceagainstanaccident.
Alwayswearpropersafetyequipment.Avoidwearingjewelryandloosefittingclothing;theycouldcatchonmovingparts whichcouldresultinseriousinjuryordeath.Hardhat,sturdyroughsoledworkshoesorsafetyshoes,earprotectors, reflectiveclothing,safetyglassesandheavyglovesmayberequired.Consultyouremployerforspecificsafety equipmentrequirements.
Eachjobsiteandapplicationmayhavepersonalsafetyrequirements.Carefullyevaluateyourparticularapplicationand machineforequipmentsuchaswarninglights,sideviewandrearviewmirrors,backupalarms,fireextinguisher,rotating beaconsandadditionallights.Ifindoubt,contactyourdistributor.
Themachineshouldbeequippedwithafullychargedfireextinguisher.Allpersonnelshouldbeinstructedinproper usage.Rechargeimmediatelyafteruse.
Themachineshouldnotbeservicedwithanyoneintheoperator'scompartmentunlesssaidpersonisqualifiedto operatethemachineandisassistingintheservicing.Nounauthorizedpersonnelshouldbeallowedtooperate,maintain orservicethismachine.Donotrush.Hurryingcanleadtoaccidents.Donotjumponoroffthemachine.Keeptwo handsandonefootortwofeetandonehandincontactwithstepsandgrabhandlesandrailsatalltimes.Placeobjects onmachinefromgroundlevelbeforemountingmachine.
Electricalsystemis12voltnegativeground.Whenusingjumpercables,precautionsmustbetakentominimize chancesofinjuryordamagetoelectricalparts.
1.Attachoneendofjumpercabletopositiveterminalofboosterbatteryandotherendtopositiveterminalofmachine battery.
2.Attachoneendofsecondcabletonegativeterminalofboosterbatteryandotherendtomachine'sframeawayfrom thebattery.
3.Toremovecables,reverseabovesequenceexactlytoavoidsparksnearthebattery.Afrozenbatterycanexplode whentheboostercablesareattached.
NEVERcheckbatterychargebyplacingametalobjectacrossthebatteryposts.Thesparkscouldcauseanexplosion. Useavoltmeterforcheckingbatterystateofcharge.
BEFORESTARTINGTHEENGINE
Alwaysplacethetransmission/steeringleverinneutralandapplytheneutralsafetylockandlocktheparkingbrake beforestarting.Theoperatormustbealert,physicallyfitandfreefromtheinfluencesofalcohol,drugsormedications thatmightaffecthiseyesight,hearing,reactionsorjudgement.Observeandknowtheuseofalternateexitsfromthe
operatorcompartment.Safetymustalwaysbetheoperator'smostimportantconcern.Hemustrefusetooperatewhen heknowsitisunsafeandconsulthissupervisorwhensafetyisindoubt.Thebestsafetydeviceisasafeoperator.Do notusecontrolsorhosesashandholdswhenclimbingonoroffthemachine.Hosesandcontrolscanmoveanddo notprovidesolidsupport.Movementofthecontrolsmaycauseinadvertentandunexpectedmovementofthemachine oritsequipment.Followallmachinemountedsafetysignsbeforestarting,operating,maintainingorservicingthe machine.Besuretheareaoftheoperator'scompartment,allmountingstepsandgrabhandlesarefreeofoil,grease, looseobjects,iceandmudtolessenthepossibilityofslipping.Removeorsecureallmaintenanceandpersonalitems sotheywillnotinterferewiththeoperatororjamthecontrols.
Performavisualcheckofthemachinebeforestartingtheengine.Lookforsuchthingsasimproperfluidlevels,oilleaks, andloose,damagedormissingparts.Donotstarttheengineuntilanyunsafeconditionsarecorrected.Secureallcaps andfillerplugs.
Knowandunderstandthetrafficflowpatternsofyourjobandobeyflagman,signsandsignals.Checkworkareafor hazardousconditions.Bealertforsoftgroundconditions,especiallywhenworkingonslopes,neardropoffsor excavationsorfillmaterial,whichcouldleadtosuddentippingofthemachine.Atnightandtimesofpoorvisibility, carefullychecktheworkareabeforemovinginwiththemachine.Usealllightsprovided.
Beforeenteringtheoperator'scompartment,cleartheimmediateareasurroundingthemachineofpersonneland obstructions.Walkcompletelyaroundthemachine.Afterenteringtheoperator'scompartment,soundthehorntoclear theimmediateareaofthemachine.
Duetothedangeroffireandexplosion,nevercheckorfillfueltankorbatteriesnearlightedsmokingmaterialsoropen flameorsparks.
OPERATION
Beforestartingtheengine,besureyouunderstandallcontrolfunctions.Onlyoneperson,theoperator,shouldbe permittedtorideonthemachinewhenitisinoperation.Neverhaulpassengers.Performanoperationalcheckofthe machineinasafeareabeforeputtingittowork.Checkallcontrols,includingthebrakepedal,steeringpedalsand transmissionselector.Checkallgauges,warninglightsandsafetydevices.Correctanymalfunctions.Alwayssitinthe operator'sseatbeforeoperatinganycontrols.Keepoperatingcontrols,handsandshoesfreeofgrease,waterandmud toinsurepositivecontrolfunctions.
ThemachineisROPSequipped,foryourpersonalprotection,wearyourseatbelt.Intheeventofarollover,staywith themachine.Experiencehasshownthiswillreducetheseriousnessorchanceofinjury.Beforedrivingthemachine, adjusttheseatandfastentheseatbelt.Adjusttheseatbelttofitsnuglyandflowaroundthehipstolessenthechance andseverityofinjuryintheeventofanaccident.Neverweartheseatbeltacrosstheabdomen.
Checkoverheadclearancecarefullybeforeoperatingthemachineinareaswithlowoverheadclearance,suchasguy wires,powerlines,bridges,lowhangingtreebranchesandbuildingentrancesorexits.Theseoverheadobstructions couldcauseanaccident.
Neverstarttheengineindoorsunlessproperexhaustventilationisprovidedtoremovedeadlyexhaustgases.Oncethe engineisoperating,movethemachineoutdoorsassoonaspossible.Exhaustgasesaredangerousandcause unconsciousnessanddeath.Neveroperatetheengineatmorethantheregulargovernedspeedshowninthe OPERATION&MAINTENANCEMANUAL.Excessivespeedsareharmfulanddangerous.
Afterstartingtheengine,butbeforemovingthemachine,warnnearbypersonnelbygivingacoupleofshorthornblasts. Whenoperatingthemachine,lookintheintendeddirectionoftraveltobesurepersonneloralliedequipmentdoesnot interferewiththemachineworkpattern.Nevertrytogetonoroffthemachinewhileitismoving.Aseriousinjuryordeath couldresult.
Nevermixgasoline,gasoholand/oralcoholwithdieselfuel.Thispracticecreatesanextremefirehazardandunder certainconditionsanexplosionwhichcouldresultinpersonalinjuryordeath.Neverremovethefueltankfillercapsor refillthefueltankswhiletheengineisrunningorhotorwhenthemachineisindoors.Fumesaredangerous,aspark orflamecouldresultinafireorexplosion.
Avoidsidehilltravelwheneverpossible.Drivestraightupanddowntheslope.Ifthemachinestartsslippingsideways onagrade,turndownhillimmediately.Becarefulandalertwhenoperatingsidewaysonasteepslopeasarolloverand seriousinjuriescouldresult.Thereisnosubstituteforgoodjudgementwhenworkingthemachineonaslope.
Ifpossibleavoidcrossingobstaclessuchasridges,rocksorlogs.Ifyoucan'tavoidthem,reducespeedandeaseover theobstacleatanangle.
Amachine'sweightandthevibrationitcreatescancausetheedgeofahighwalltocollapse.Keepyourmachineback fromtheedgesofbanksandexcavations.
Operatinginroughvirginterrainwithsuchhazardsastrees,logs,largerocksandbrushiscalledpioneering.Besure youknowtheoperatingtechniquesrequired.Dangerfromfallingbranchesandupturningrootsisacuteinpioneering. Whenpushingovertrees,themachinemustbeequippedwithproperoverheadguards.Neverallowthemachinetoclimb uptherootstructure,especiallywhenthetreeisbeingfelled.Useextremecarewhenpushingoveranytreewithdead branches.
Ifenginehasatendencytostallforanyreasonunderloadoratidle,reportthisconditionimmediately.Donotoperate themachineuntiltheconditionhasbeencorrected.Periodicallychecktheengineexhaustsystemforleaks.Exhaust gasesaredangeroustotheoperator.
Usecommonsense,careandgoodjudgementtoavoidaccidents.Operateatspeedsslowenoughtoinsurecomplete controlofthemachine.Travelslowlyincongestedareasoronroughground,slopesorneardropoffsoronsnow,ice orslipperysurfaces.Maintainasafedistancebetweenyourmachineandothervehiclesaccordingtotheconditionof theroadandload.Keepthemachineasclosetothesideoftheroadasispossibletoprovideforoncomingorpassing vehicles.
Observeinstrumentsandwarninglightsfrequently.Reportanydefectsorunusualnoisesinmachineduringoperation. Bealerttothelocationofotherpersonnel.Donotoperateifexposedpersonnelentertheimmediateworkarea.Warn allgroundpersonstoleavetheareaofthemachine.
Donotoperatethemachineinaconditionofextremefatigueorillness.Beespeciallycarefulattheendofaworkshift.
Keepyourworkareaassmoothaspossibleandfreeofobstructions.
Whenpullingortowingwithachainorcable,takeuptheslackcarefully.Asuddenjerkcouldsnapthechainorcable causingittowhipdangerously.Donotpullortowunlesstheoperatorcompartmentisguardedforawhippingchainor cable.Clearpersonnelfromthearea.Besurechainsorcablesandtheiranchorpointsarestrongenoughtohandlethe expectedload.Inspectcarefullyforflawsbeforeusing.Alwaysweargloveswhenhandlingchainsorcables.Avoid kinkingthechainorcable.Donotpullwithakinkedchainorcableasthehighstresscouldcauseafailureinthekinked area.Useonlydesignatedtowingorpullingattachmentpoints.Besurepinsareattachedsecurelybeforepulling.Stand clearofchainsorcablesunderload.
Wherenoiseexposureexceeds90dBAfor8hours,wearauthorizedearprotectiveequipment.
Keepengineexhaustsystemandexhaustmanifoldclearofcombustiblematerialforyourpersonalprotection.
Knowthelocationsofundergroundcables,watermains,gaslines,etc.Arupturedgaslineorcutelectricalcablecould resultinpersonalinjuryordeath.
Neverusethemountedequipmentasabrakeexceptinanemergency.Donotadjusttheseatpositionwhilethe machineisinmotion.Alossofcontrolmayresult.Completelystopthemachine,applyandlocktheparkingbrakeand thenadjusttheseat.Duringoperationalwayscarryripperinfullraisedpositionwhennotinuseandlowertoground whenparked.Keephead,body,feet,handsandfingersawayfromthebladeandripperwhentheyareinaraised position.Carrythebladelowformaximumstabilityandvisibility.
Neverleavethemachineunattendedwhiletheengineisoperating.Whenparkingthemachine,besureallmounted equipmentisloweredcompletelytominimizedamageorinjurypossibilities.Donotallowthehydraulicsystemto
supportthemountedequipmentwhenleavingthemachineunattended.Whenleavingthemachineunattendedforany lengthoftime,makesurethetransmission/steeringleverispositionedandlockedinneutral(N),thebladeandrear mountedequipmentarecompletelylowered,theengineisstoppedandtheelectricalmasterswitchislockedintheOFF position.Neverholdthehydrauliccontrolsintheirextremepositionaftertheequipmenthasreacheditsmaximumtravel. Thiscouldcauseoverheatingofthehydraulicsystem.
MAINTENANCE
Lowerthebladetothegroundorholdupwithblocking,safetybarorhoist.Lowerallequipmenttotheground.Shiftall controlstoNEUTRALposition.LockthetransmissionselectorinNEUTRALtoneutralizethetransmissionandapply theparkingbrake.Turnofftheelectricalsystemmasterswitch.Removethekey.
ReadandknowyourOPERATION&MAINTENANCEMANUALandSHOPMANUALbeforeperforminganyworkon themachine.ReadALLproductgraphicsandsafetyprecautions.Neverworkbeneaththebladewithoutproperblocking and/orasafetybarproperlyinstalled.Improperblockingcouldresultinseriousinjuries.
Donotattempttomakerepairsthatyoudonotunderstand.Consultyourdistributor.Useonlyapprovedpartsforrepairs andmaintenance.Failuretodosocouldcompromiseyourpersonalsafetyandmachineperformanceandreliability. Therolloverprotectivestructure(ROPS)providesoperatorprotectionintheeventofmachinerolloverorupset.This structureisdesignedtobendduringarollovertoprotecttheoperatorfromsuddenimpactloads.Donotattempttorepair aprotectivestructureafteranaccident.
Repairedstructuresdonotprovidetheoriginalstrengthandprotection.Contactyourdistributorforinformationon structurereplacement.DonotoperatethemachineagainuntiltheROPShasbeenreplaced.Useonlyreplacement partsshowninyourPARTSBOOK.
Donotcut,grind,weld,drillortapholesintheROPS.Thiscouldweakenthestructure,oraffecttheoverallenergy absorptioncapabilities.
Donotsmokewhenrefuelingorservicingthemachine.Afirecouldresult.Neverplacegasolineordieselfuelinanopen pan.Neverremovethefueltankfillercaporrefillthefueltankwhiletheengineisoperatingorhotorwhenthemachine isindoors.Thefumesaredangerousandasparkorflamecouldresultinafireorexplosion.
Loosentheradiatorcapslowlytorelieveallpressureinthesystemandusecautionwhenremovingthecaps.Loosen thefillercapslowlytorelievereservoirpressuretopreventpossibleinjury.Alwaysventthehydraulicsystembefore workingonanyhydrauliccomponent.Haveallequipmentrestingonthegroundorblockedbeforeremovingany component.
Whenserviceormaintenancerequiresaccesstoareasthatcannotbereachedfromtheground,usealadderor platform.Ifsuchladdersorplatformsarenotavailable,usethemachinehandholdsandstepsprovided.Performall serviceormaintenancecarefully.
Neveralignholeswithfingersorhands.Useaproperaligningtool.Besurealltoolsareingoodcondition.Donotuse toolswhichareworn,bentorhavemushroomedheads.Usethepropertoolforthejob.Removesharpedgesandburrs fromreworkedparts.
Beforeworkingonthemachine,tagandlocktheelectricalsystemmasterswitchsonoonewillstartitunexpectedly.
Forfieldservice,movemachinetolevelgroundifpossibleandblockthetracks.Ifworkisabsolutelynecessaryonan incline,blockthemachineanditsattachmentssecurely.Movethemachinetolevelgroundassoonaspossible.
Donotcarrylooseobjectsinpocketsthatmightcatchonthemachineorfallunnoticedintoopencompartments.
Beforeworkingonanypartoftheengineorelectricalsystem,disconnectthebatterygroundcable.Tagthecableand allcontrolstoalertpersonnelthatworkisinprogress.
Whenitisnecessarytomakeanychecksoradjustmentswiththeengineoperating,alwaysusetwopeople.One
trainedpersonmustbeintheoperator'sseattosafeguardthesecondpersonmakingthechecksoradjustment.Asan addedprecaution,whenmakingchecksoradjustmentswiththeengineoperating,makesurethetransmissionshiftlever islockedinneutral(N).
Neverstandonthetracksornearthebladewhileengineisoperating.Iftheengineisrunningandthesidedoorsare openorremovedbecarefulofrotatingpartssuchasthefanandbeltsthatcancauseseriousinjury.Neverrunthe enginewhencleaningorlubricatingthemachine.Seriousinjurycouldresultfromcontactingmovingparts.
Useanontoxic,nonflammablecommercialsolventforcleaningparts,unlessotherwisespecified.Neverusegasoline, dieselfuel,keroseneorotherflammablesolventsforcleaningparts.Excessiveorrepeatedskincontactwithsealants orsolventsmaycauseskinirritation.Incaseofskincontact,removesealantorsolventpromptlybywashingwithsoap andwater.Followthemanufacturer'sadvisewhenevercleaningagentsorotherchemicalsareused.
Lowerthebladebeforemakinghydraulicadjustments.Topreventpersonalinjury,besurepersonnelarenotstanding inthewayofthebladewhenitisbeinglowered.Neverallowanyonetowalkunderorbenearunblockedraised equipment.Provideproperventilationwhenoperatinginaclosedbuildingtoavoiddangerofexhaustgases.Exhaust gasesaredangerousandcancauseunconsciousnessanddeath.Hydraulicfluidescapingunderpressurefromavery smallholecanbealmostinvisible,yethavesufficientforcetopenetratetheskin.Useapieceofcardboardorwoodto searchforsuspectedleaks.Donotusehands.Ifinjuredbyescapingfluid,seeadoctoratonce.Seriousinfectionor reactioncanoccurifpropermedicaltreatmentisnotadministeredimmediately.
Whenwelding,wearproperprotectiveequipmentsuchasahelmet,darksafetyglasses,protectiveglassesnear welding.Donotlookatarcwithoutpropereyeprotection.
Wearproperprotectiveequipmentsuchasgogglesorsafetyglasseswithsideshields,hardhat,safetyshoesand heavygloveswhenmetalorotherparticlesareapttoflyorfall.Manyofthemachine'spartsarehardenedandcanchip.
Liftandhandleallheavypartswithaliftingdeviceofpropercapacity.Besurepartsaresecuredbyproperslingsand hooks.Useliftingeyesifprovided.Warnpeopleintheareatostandclear.
Whenusingcompressedairforcleaningparts,weargogglesorsafetyglasseswithsideshields.Useanozzlewhich limitsthepressureto207kPa(30psi).
Donotuseanopenflametocheckforleaksorfluidlevelsanywherearoundthemachine.Keepworkareacleanand dry.Removeoilandwaterspillsimmediately.Donotpileupoilyorgreasyrags.Theyareafirehazard.Storethemin anapproved,closedmetalcontainer.
Useasoftironornonferroushammertoinstallorremoveripperteeth.Itisdangeroustohammerontheteeth.Wear safetyglasseswithsideshieldsorgogglestoreducethechancesofinjury.
Batteriesgiveoffahighlyflammablegas.Neverallowsparksoropenflamenearthebatteries.Afireorexplosioncould occur.Donotchargebatteriesinaclosedarea.Provideproperventilationtoguardagainstaccidentalexplosivegas givenoffinthechargingprocess.Wheninstallingbatteries,besuretheelectricalmasterswitchislockedintheOFF position.Besuretoconnectthepositivecabletothepositiveterminalandthenegative(ground)cabletothenegative terminal.
Etherfluidisflammable.Followtheprecautionsprintedonthecontainer.Anexplosioncanresultifsparksorflame contacttheetherinthecontainerorifthecontainerisstoredinanareainwhichthetemperatureexceeds120•F(49•C). Observethefollowingprecautions:
1.Followcorrectmethodforstartingtheengine.RefertotheOPERATION&MAINTENANCEMANUAL.
2.Donotusetheetherinjectorwhentheambienttemperatureisabovefreezing.
3.Foryourownpersonalsafety,alwaysremovetheethercontainerwhenwelding,grindingorusingatorchonthe machine.
4.Donotletethercomeincontactwithyourskin,asitcancauselocalizedfreezing.
5.Donotbreathethehazardousethervapor.
6.Keepthefluidcontaineroutofthereachofchildren.
7.Neverpuncturethefluidcontainerorputitintoafire.Disposeofemptycontainerproperly.
8.Donotstorefluidcontainersintheoperator'scompartment.
Nevermixgasoline,gasoholoralcoholwithdieselfuel.Thiscreatesanextremefireorexplosionhazardwhichcould resultinpersonalinjuryordeath.
Donotusebleach,colordyeorsolventsontheseatbeltwebbing.Thismaycauseaseverelossoftensilestrength. Thiscouldcausethewebbingtobreakresultinginpersonalinjury.Itisrecommendedthattheseatbeltbecleanedonly withwarmwaterandamilddetergent.
SHUTDOWN
Ifparkingonorneartrafficlanescannotbeavoided,provideappropriateflags,barriers,flaresandwarningsignals.Also provideadvancewarningsignalsinthetrafficlaneforapproachingtraffic.Parkthemachineinanonoperatingandnon trafficarea.Parkmachineonlevelgroundwheneverpossible.Ifyoumustparkonaslope,parkatrightanglestothe slope.Lockthetransmissionselectorinneutral.Neverleavethemachineunattendedwiththeenginerunning.When leavingthemachineunattended,slowlylowerallhydraulicequipmenttotheground,shiftthetransmissionselectorinto neutralandapplytheneutrallockleverandshutofftheengine.Relievetrappedpressureinthehydraulicsystemby movingthecontrolinbothdirections.Turnofftheelectricalsystemmasterswitch.Removethekey.Alwayslockup machinewhenleavingitunattended,includinganyantivandalismattachments.Donotjumpoffthemachine.
Whenoperatinginbadweatherandstormlightningisnearby,dismountandseekshelterawayfromthemachine. Lightningwillbeattractedtothemachineandcauseseriousinjuryordeath.
Whenthemachineistobeloadedontoatransporttruckandtrailerdosocarefully.Loadonlywhenthetrailerislevel. Thesteeltrackshoeswillslideeasilyonthetrailer.Whenthemachineisproperlypositionedchainitsecurelysoitcan notmoveonthetrailer.
1.GeneralCaution
4.TrackAdjusterCaution (737994C3)(655434C2)
2.DoorCaution (667460C2)
3.InstructionalCaution (628135C4)
5.PressurizedReservoir (2754473R3)
6.SafetyCaution (1120363C2)
7.ROPSCaution (737993C3)
