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Buhler Genesis II 2145 User manual

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2145
2160
2180
2210
Buhler
Versatile
89007102 01/06
Genesis II
TO THE OWNER:
The warranty coverage that is extended to your tractor is explained in the Warranty and Limitation of Liability form.
Your dealer will provide you with a copy of the warranty and retain a copy which you have signed. After you read
the warranty, ask your dealer to explain any points that you may not understand.
This tractor was designed to power and propel itself. It is intended for use in normal and customary agricultural
applications.
Do not modify or alter or permit anyone else to modify or alter this tractor or any of its components or any tractor
function without first consulting an authorized Buhler Versatile dealer. If you have any questions regarding tractor
modifications, contact Buhler Versatile Inc., 1260 Clarence Avenue, Winnipeg, MB R3C 4E8
A safety cab incorporating a Roll Over Protection Structure (ROPS) and a seat belt were standard equipment
for the tractor at the time of factory assembly. If the safety cab/ROPS has been modified or removed by the origi-
nal purchaser, it is recommended that you equip your tractor with a safety cab/ROPS and seat belt. A safety
cab/ROPS is effective in reducing injuries during tractor overturn accidents. Overturning a tractor without a
ROPS can result in serious injury or death. Safety cab/ROPS and seat belts are available for your tractor. If your
tractor is not equipped with a safety cab/ROPS and seat belt, see your Buhler Versatile dealer.
Your safety and the safety of those around you depends upon the care and good judgment you use while operat-
ing this equipment. Read the safety precautions carefully.
For a complete list of the delivery service checks performed by your dealer, refer to DELIVERY REPORT in this
manual. The first copy is your record of the service performed and the second copy, which is to be removed from
the manual, is your dealer’s record. MAKE SURE THAT YOU AND THE DEALER SIGN BOTH COPIES.
After you have operated the tractor for 50 hours, take your tractor and this manual to your selling dealer. He will
perform the factory recommended 50-hour service. You will be responsible for the cost of lubricants, fluids, filters
and other items replaced as part of normal maintenance. Prior to taking the tractor to your selling dealer for ser-
vice, it is recommended that you contact them to determine any other charges for which you may be responsible.
All data given in this book is subject to production variations. Dimensions and weights are approximate only and
the illustrations do not necessarily show tractors in standard condition. For exact information about any particular
tractor please consult your Buhler Versatile dealer.
CAUTION
This symbol is used throughout this book whenever personal safety is involved. Take time to read and
follow the instructions. Be careful!
Pictures in this manual may show protective shielding open or removed to better illustrate a particular
feature or adjustment.
Be certain, however, to close or replace all shielding before operating the machine.
IMPROVEMENTS
Buhler Versatile Inc. is continually striving to improve its products. We reserve the right to make improvements
or changes when it becomes practical and possible to do so, without incurring any obligation to make changes
or additions to the equipment sold previously.
0-1
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board and Buhler Versatile are pleased to explain the emission control system warranty on your engine. In Califor-
nia, new 1996 and later heavy-duty off-road engines from 175 to 750 HP must be designed, built, and equipped to meet the State’s stringent
anti-smog standards. Buhler Versatile must warrant the emission control system on your engine for the periods of time listed below, provided
there has been no abuse, neglect, or improper maintenance of your engine.
Your emission control system includes parts such as the fuel injection system and the air induction system.
Where a warrantable condition exists, Buhler Versatile will repair your heavy-duty off-road engine at no cost to you, including diagnosis, parts,
and labor.
Manufacturer’s Warranty Coverage:
The 1996 and later heavy-duty off-road engines are warranted from the original date of delivery for five years or 3,000 hours of operation,
whichever occurs first. If any emission-related part on your engine is defective, the part will be repaired or replaced by Buhler Versatile.
Owner’s Warranty Responsibilities:
DAs the heavy-duty off-road engine owner, you are responsible for the performance of the required maintenance listed in your owner’s
manual. Buhler Versatile recommends that you retain all receipts covering maintenance on your heavy-duty off-road engine, but Buhler
Versatile cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
DAs the heavy-duty off-road engine owner, you should, however, be aware that Buhler Versatile may deny you warranty coverage if your
heavy-duty off-road engine or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications.
DYour engine is designed to operate on commercially available diesel fuel only. Use of any other fuel may result in your engine no longer
operating in compliance with California’s emissions requirements.
DYou are responsible for initiating the warranty process. The ARB suggests that you present your heavy-duty off-road engine to a Buhler
Versatile dealer as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible.
If you have questions regarding your warranty rights and responsibilities, you should contact the Buhler Versatile Warranty Department.
DPrior to the expiration of the warranty, you must give notice of any failure of an emission control warranted part. Such notice must be
given to Buhler Versatile or an authorized dealer, and you must deliver the engine to the repair location.
DYou, the owner, are responsible for incidental costs incurred by yourself or your employees as a result of a warrantable failure. Examples
of such costs are communication expenses, meals and lodging.
DThe owner is responsible for any business costs or losses, any “downtime” expenses and any “cargo” damage which result from the
failure of a warranted part. Buhler Versatile is not responsible for other incidental or consequential damages, including but not limited
to fines, theft, vandalism or collisions.
Parts covered:
This emission control system warranty applies to the following 675TA/KA emission control parts.
Fuel Injection Pump
Fuel Injectors
Turbocharger
Intake Manifold
Charge Air Cooler
Exhaust Manifold
Any replacement part, equivalent in performance and durability, may be used in the performance of any maintenance or repairs and must
be provided without charge to the owner. The use of these parts does not reduce the warranty obligations of Buhler Versatile. However, Buhler
Versatile recommends the use of new, genuine Buhler Versatile service parts or Buhler Versatile approved rebuilt parts and assemblies. Buh-
ler Versatile also recommends that the engine be serviced by a Buhler Versatile authorized dealer.
Buhler Versatile Responsibilities
Warranty work will be provided at no charge to the owner at any authorized dealer, using new genuine Buhler Versatile service parts or Buhler
Versatile approved rebuilt parts or assemblies..
The owner will not be charged for diagnostic labor which leads to the determination that a warranted part is defective, if the diagnostic work
was performed at a warranty station.
Buhler Versatile is liable for damages to other engine components caused by the failure under warranty of any warranted part.
Warranty Limitations
Buhler Versatile is not responsible for failures resulting from abuse or neglect by owner or operator.
Buhler Versatile warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built, and equipped so as
to conform with all applicable regulations adopted by the Air Resources Board, and that it is free from defects in materials and workmanship
which cause the failure of a warranted part.
Any warranted part which is not scheduled for replacement as required maintenance, or which is scheduled only for regular inspection to
the effect of “repair or replace as necessary” is warranted for the warranty period.
Any warranted part which is scheduled for replacement as required maintenance is warranted for the period of time prior to the first scheduled
replacement point for that part.
Buhler Versatile is liable for damages to other engine components caused by the failure under warranty of any warranted part.
SECTION 0 -- SAFETY
0-2
FEDERAL EMISSIONS WARRANTY
Buhler Versatile warrants that your new 2003 and later heavy-duty off-road diesel engine was designed, built, and equipped to conform to
applicable U.S. Environmental Protection Agency regulations for a period of use of five years or 3,000 hours of operation, whichever occurs
first.
The new model year, class of diesel engine, and emission application determination for your engine are identified on the emission control
information label affixed to the top of your engine’s rocker arm cover. The warranty period begins on the date the new equipment is sold to
the first retail purchaser.
Any emission control system parts which are proven defective during normal use will be repaired or replaced during the warranty period. The
warranty repairs and service will be performed by any authorized Buhler Versatile dealer at the dealer’s place of business, with no charge
for parts or labor (including diagnosis).
As the engine owner, you are responsible to perform all the required maintenance listed in your owner’s manual. Buhler Versatile will not deny
an emission warranty claim solely because you have no record of maintenance; however, a claim may be denied if your failure to perform
maintenance resulted in the failure of a warranted part. Receipts covering regular maintenance should be retained in the event of questions
and these receipts should be passed on to each subsequent owner of the engine.
It is recommended replacement parts used for maintenance or repairs be Buhler Versatile Service Parts to maintain the quality originally
designed into your emission certified engine. The use of non-Buhler Versatile parts does not invalidate the warranty on other components
unless the use of such parts causes damage to warranted parts.
Buhler Versatile wishes to assure the emission control systems warranty is being properly administered. If you believe you have not received
the service entitled to under this warranty, you should contact the Buhler Versatile Service Department.
Service Department
Buhler Versatile Inc.
1260 Clarence Avenue, Box 7300
Winnipeg, MB R3C 4E8
(204) 284--6100
Please note that the Emission Warranty does not cover:
1. Systems and parts that were not first installed on the new equipment or engine as original equipment by Buhler Versatile.
2. Part malfunctions caused by abuse, misuse, improper adjustment, modification, alteration, tampering, disconnection, improper or
inadequate maintenance, or use of non-recommended fuels and lubricating oils.
3. Accident caused damage, acts of nature, or other events beyond Buhler Versatile’s control.
4. Replacement of expendable items made in connection with scheduled maintenance.
5. Parts requiring replacement, inspection or adjustment maintenance intervals for reasons other than being defective.
6. Parts which are not Buhler Versatile Service Parts.
7. Loss of time, inconvenience, loss of use of equipment/engine or commercial loss.
8. Equipment with altered or disconnected hourmeter where the hours cannot be determined.
9. Equipment normally operated outside the United States.
10. Non-defective parts replaced by other than Buhler Versatile dealers.
Coverage
This emission control system warranty applies to the following 675TA/** emission control parts.
Fuel Injection Pump
Fuel Injectors
Turbocharger
Intake Manifold
Charge Air Cooler
Exhaust Manifold
SECTION 0 -- SAFETY
0-3
CONTENTS
SAFETY 0-4........................................................
GENERAL INFORMATION 1-1.......................................
OPERATION 2-1...................................................
LUBRICATION AND MAINTENANCE 3-1..............................
TROUBLESHOOTING 4-1...........................................
SPECIFICATIONS 5-1..............................................
INDEX 5-27.........................................................
DELIVERY REPORT 5-31............................................
SERVICE REPORTS 5-40.............................................
SECTION 0 -- SAFETY
0-4
PRECAUTIONARY STATEMENTS
PERSONAL SAFETY
Throughout this manual and on machine decals, you will find precautionary statements (“CAUTION”,
“WARNING”, and “DANGER”) followed by specific instructions. These precautions are intended for the personal
safety of you and those working with you. Please take the time to read them.
CAUTION
The word “CAUTION” is used where a safe behavioral practice according to operating and maintenance
instructions and common safety practices will protect the operator and others from accident
involvement.
WARNING
The word “WARNING” denotes a potential or hidden hazard which has a potential for serious injury. It
is used to warn operators and others to exercise every appropriate means to avoid a surprise
involvement with machinery.
DANGER
The word “DANGER” denotes a forbidden practice in connection with a serious hazard.
FAILURE TO FOLLOW THE “CAUTION”, “WARNING”, AND “DANGER” INSTRUCTIONS MAY RESULT IN
SERIOUS BODILY INJURY OR DEATH.
MACHINE SAFETY
Additional precautionary statements (“ATTENTION” and “IMPORTANT”) are followed by specific instructions.
These statements are intended for machine safety.
ATTENTION: Theword“ATTENTION” is used to warn the operator of potential machine damage if a certain
procedure is not followed.
IMPORTANT: Theword“IMPORTANT” is used to inform the reader of something he needs to know to prevent
minor machine damage if a certain procedure is not followed.
SECTION 0 -- SAFETY
0-5
SECTION 0 -- SAFETY
0-6
SAFETY PRECAUTIONS
A careful operator is the best operator. Most
accidents can be avoided by observing certain
precautions. To help prevent accidents, read and
take the following precautions before operating
the tractor. Equipment should be operated only
by those who are responsible and instructed to
do so.
THE TRACTOR
1. Read the Operator’s Manual carefully before
using the tractor. Lack of operating knowl-
edge can lead to accidents.
2. Only allow properly trained and qualified
persons to operate the tractor.
3. To prevent falls, use the assist rails and step
plates when getting on and off the tractor.
Keep steps and platform clear of mud and
debris.
4. Do not permit anyone but the operator to ride
on the tractor. There is no safe place for extra
riders.
5. Replace all missing, illegible or damaged
safety decals.
6. Keep safety decals free of dirt or grime.
7. Do not modify or alter or permit anyone else
to modify or alter the tractor or any of its
components or any tractor function without
first consulting an authorized dealer.
8. Install all shields before starting or operating
the tractor.
DRIVING THE TRACTOR
1. Always sit in the driver’s seat while starting
or driving the tractor.
2. When driving on public roads, have consider-
ation for other road users. Pull to the side of
the road so that any following traffic may
pass.
3. Dim the tractor lights when meeting a vehicle
at night. Make sure the lights are adjusted to
prevent blinding the driver of an oncoming
vehicle.
4. Reduce speed before turning or applying the
brakes. Lock the brake pedals together when
travelingatroadspeedsorwhenonthe
highway. Brake both wheels simultaneously
when making an emergency stop.
5. Use extreme caution and avoid hard applica-
tion of the tractor brakes when towing heavy
loads at road speeds.
6. Any towed vehicle whose total weight
exceeds that of the towing tractor must be
equipped with brakes for safe operation.
7. Never apply the differential lock when
turning. When engaged, the differential lock
will prevent the tractor from turning.
8. Always check overhead clearance, especial-
ly when transporting the tractor. Watch where
you are going, especially at row ends, on
roads and around trees and low overhanging
obstacles.
9. Use extreme caution when operating on
steep slopes.
10. To avoid overturns, drive the tractor with care
and at speeds compatible with safety,
especially when operating over rough
ground, when crossing ditches or slopes and
when turning corners.
11. If the tractor becomes stuck or the tires are
frozen to the ground, engage a reverse gear
to free the tractor and prevent overturning.
12. Keep the tractor in the same gear when going
downhill as would be used when going uphill.
Do not coast or freewheel down hills.
SECTION 0 -- SAFETY
0-7
OPERATING THE TRACTOR
1. Apply the parking brake, place the PTO
control in the “OFF” position, the lift control
lever in the down position, the remote control
valve levers in the neutral position and the
transmission lever in neutral before starting
the tractor.
2. Do not start the engine or operate controls
(other than the external hydraulic lift
switches) while standing beside the tractor.
Always sit in the tractor seat when starting
the engine or operating the controls.
3. Do not bypass the transmission neutral start
switch. Consult your authorized dealer if
your neutral start controls malfunction. Use
jumper cables only in the recommended
manner. Improper use can result in a tractor
runaway.
4. Avoid accidental contact with the gear shift
lever while the engine is running. Unex-
pected tractor movement can result from
such contact.
5. Do not get off the tractor while it is in motion.
6. Shut off the engine and PTO and apply the
parking brake before getting off the tractor.
7. Do not park the tractor on a steep incline.
8. Do not operate the tractor engine in an
enclosed building without adequate ventila-
tion. Exhaust fumes can cause death.
9. The cab air filter is designed to remove dust
from the air but will not exclude chemical
vapor. Follow the chemical manufacturers
directions regarding protection from danger-
ous chemicals.
10. Always wear a protective mask when working
with toxic spray chemicals. Follow the
directions on the chemical container.
11. If the power steering or engine ceases to
operate, stop the tractor immediately as the
tractor will be more difficult to control.
12. Stop the engine and relieve pressure before
connecting or disconnecting hydraulic,
steering or fuel lines.
13. Tighten all connections before starting the
engine or pressurizing lines.
14. Pull only from the swinging drawbar. Use
only a drawbar pin that locks in place. Pulling
from the tractor rear axle or any point above
the axle may cause the tractor to overturn.
15. If the front end of the tractor tends to rise
when heavy implements are attached to the
three-point hitch, install front end weights.
Do not operate the tractor with a light front
end.
16. Always select Position Control when attach-
ing equipment and when transporting equip-
ment. Be sure hydraulic couplers are
properly mounted and will disconnect safely
in case of accidental detachment of the
implement.
17. Do not leave equipment in the raised position
when the vehicle is stopped or unattended.
18. Ensure any attached equipment or accesso-
ries are correctly installed, are approved for
use with the tractor, do not overload the
tractor and are operated and maintained in
accordance with the instructions issued by
the equipment or accessory manufacturer.
19. Remember that your tractor, if abused or
incorrectly used, can be dangerous and
become a hazard both to the operator and to
bystanders. Do not overload or operate with
attached equipment which is unsafe, not
designed for the particular task or is poorly
maintained.
20. The cab is designed to provide the minimum
noise level at the operator’s ears and, in fact,
meets or exceeds applicable standards in
this respect. However, noise (sound pressure
level) in the workplace can exceed 86dB(A)
when working between buildings or in
confined spaces, when the cab windows are
open. Therefore, it is recommended that the
operators wear suitable ear protectors when
operating in high noise level conditions.
SECTION 0 -- SAFETY
0-8
OPERATING THE PTO
1. When operating PTO-driven equipment, shut
off the engine and wait until the PTO stops
before getting off the tractor and disconnect-
ing the equipment.
2. Do not wear loose clothing when operating
the power take-off or when near rotating
equipment.
3. When operating stationary PTO-driven
equipment, always apply the tractor parking
brake and block the rear wheels front and
back.
4. To avoid injury, do not clean, adjust, unclog
or service PTO driven equipment when the
tractor engine is running.
5. Make sure the PTO master shield is in
position at all times and always replace the
PTO cover when the PTO is not in use.
SERVICING THE TRACTOR
Most accidents can be avoided by observing
certain precautions. To help prevent accidents,
read and take the following precautions before
servicing the tractor.
1. The cooling system operates under pressure
which is controlled by the radiator cap. It is
dangerous to remove the cap while the
system is hot. Always turn the cap slowly to
the first stop and allow the pressure to
escape before removing the cap entirely.
2. Do not smoke while refuelling the tractor.
Keep any type of open flame away. Wait for
the engine to cool before refuelling.
3. Keep the tractor and equipment, particularly
brakes and steering, maintained in a reliable
and satisfactory condition to ensure your
safety and comply with legal requirements.
4. To prevent fire or explosion, keep open
flames away from battery or cold weather
starting aids. To prevent sparks which could
cause explosion, use jumper cables accord-
ing to instructions.
5. Do not attempt to service the air conditioning
system. It is possible to be severely frost
bitten or injured by escaping refrigerant.
Special equipment and instruments are
required to service the air conditioning
system. See your authorized dealer for
service.
6. Stop the engine before performing any
service on the tractor.
7. Escaping diesel/hydraulic fluid under pres-
sure can penetrate the skin causing serious
injury.
•DO NOT use your hand to check for leaks.
Use a piece of cardboard or paper to
search for leaks.
•Stop the engine and relieve pressure
before connecting or disconnecting
lines.
•Tighten all connections before starting
the engine or pressurizing lines.
•If fluid is injected into the skin, obtain
medical attention immediately or gan-
grene may result.
8. Do not modify or alter or permit anyone else
to modify or alter the tractor or any of its
components or any tractor function without
first consulting an authorized dealer.
9. The fuel oil in the injection system is under
high pressure and can penetrate the skin.
Unqualified persons should not remove or
attempt to adjust a pump, injector nozzle or
any other part of the fuel injection system.
Failure to follow these instructions can result
in serious injury.
10. Continuous long term contact with used
engine oil may cause skin cancer. Avoid
prolonged contact with used engine oil.
Wash skin promptly with soap and water.
11. Tractor wheels are very heavy. Handle with
care and ensure, when stored, that they
cannot fall and cause injury.
12. Dispose of all drained fluids and removed
filters properly.