Case W20F User manual

1/1
W20F
Wheel Loader
SERVICE MANUAL
Wheel Loader
W20F
Part number 48096018A
2nd edition English
May 2018
© 2018 CNH Industrial Latin America LTDA. All Rights Reserved.
SERVICE MANUAL
Part number 48096018

SERVICEMANUAL
W20FStandardmodel,withcab,Tier3,madeinBrazil
W20FFertilizermodel,withcab,Tier3,madeinBrazil
48096018A18/05/2018
EN
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LinkProduct/Engine
ProductMarketProductEngine
W20FStandardmodel,withcab,
Tier3,madeinBrazil
AustraliaNewZealandF4GE9684T*J601
W20FStandardmodel,withcab,
Tier3,madeinBrazil
NorthAmericaF4GE9684T*J601
W20FStandardmodel,withcab,
Tier3,madeinBrazil
EuropeF4GE9684T*J601
W20FStandardmodel,withcab,
Tier3,madeinBrazil
AsiaPacicF4GE9684T*J601
W20FStandardmodel,withcab,
Tier3,madeinBrazil
MiddleEastAfricaF4GE9684T*J601
W20FStandardmodel,withcab,
Tier3,madeinBrazil
LatinAmericaF4GE9684T*J601
W20FFertilizermodel,withcab,
Tier3,madeinBrazil
AsiaPacicF4GE9684T*J601
W20FFertilizermodel,withcab,
Tier3,madeinBrazil
AustraliaNewZealandF4GE9684T*J601
W20FFertilizermodel,withcab,
Tier3,madeinBrazil
EuropeF4GE9684T*J601
W20FFertilizermodel,withcab,
Tier3,madeinBrazil
LatinAmericaF4GE9684T*J601
W20FFertilizermodel,withcab,
Tier3,madeinBrazil
NorthAmericaF4GE9684T*J601
W20FFertilizermodel,withcab,
Tier3,madeinBrazil
MiddleEastAfricaF4GE9684T*J601
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Contents
INTRODUCTION
Engine.......................................................................................10
[10.001]Engineandcrankcase.............................................................10.1
[10.102]Panandcovers....................................................................10.2
[10.202]Aircleanersandlines..............................................................10.3
[10.216]Fueltanks..........................................................................10.4
[10.400]Enginecoolingsystem.............................................................10.5
Maingearboxanddrive...............................................................14
[14.100]Maingearboxanddrive............................................................14.1
Transmission..............................................................................21
[21.114]Mechanicaltransmission...........................................................21.1
[21.113]Powershifttransmission............................................................21.2
[21.135]Powershifttransmissionexternalcontrols..........................................21.3
[21.155]Powershifttransmissioninternalcomponents......................................21.4
Frontaxlesystem.......................................................................25
[25.100]Poweredfrontaxle.................................................................25.1
[25.102]Frontbevelgearsetanddifferential...............................................25.2
[25.108]Finaldrivehub,steeringknuckles,andshafts.....................................25.3
Rearaxlesystem........................................................................27
[27.100]Poweredrearaxle..................................................................27.1
[27.106]Rearbevelgearsetanddifferential................................................27.2
[27.120]Planetaryandnaldrives..........................................................27.3
[27.124]Finaldrivehub,steeringknuckles,andshafts.....................................27.4
Hydrostaticdrive.........................................................................29
[29.204]Reservoir,cooler,andlines........................................................29.1
[29.218]Pumpandmotorcomponents......................................................29.2
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Brakesandcontrols....................................................................33
[33.202]Hydraulicservicebrakes...........................................................33.1
[33.110]Parkingbrakeorparkinglock......................................................33.2
Hydraulicsystems.......................................................................35
[35.000]Hydraulicsystems..................................................................35.1
[35.102]Pumpcontrolvalves................................................................35.2
[35.106]Variabledisplacementpump.......................................................35.3
[35.300]Reservoir,cooler,andlters........................................................35.4
[35.359]Maincontrolvalve..................................................................35.5
[35.204]Remotecontrolvalves.............................................................35.6
[35.701]Frontloaderarmhydraulicsystem.................................................35.7
[35.736]Boomhydraulicsystem............................................................35.8
Framesandballasting.................................................................39
[39.100]Frame..............................................................................39.1
Steering.....................................................................................41
[41.200]Hydrauliccontrolcomponents......................................................41.1
[41.206]Pump...............................................................................41.2
[41.216]Cylinders...........................................................................41.3
[41.101]Steeringcontrol....................................................................41.4
Wheels......................................................................................44
[44.520]Rearwheels........................................................................44.1
[44.511]Frontwheels........................................................................44.2
Cabclimatecontrol.....................................................................50
[50.104]Ventilation..........................................................................50.1
[50.200]Airconditioning.....................................................................50.2
Electricalsystems.......................................................................55
[55.000]Electricalsystem...................................................................55.1
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[55.525]Cabenginecontrols................................................................55.2
[55.201]Enginestartingsystem.............................................................55.3
[55.301]Alternator...........................................................................55.4
[55.302]Battery..............................................................................55.5
[55.610]Groundspeedcontrol..............................................................55.6
[55.050]Heating,Ventilation,andAir-Conditioning(HVAC)controlsystem.................55.7
[55.100]Harnessesandconnectors.........................................................55.8
[55.404]Externallighting....................................................................55.9
[55.408]Warningindicators,alarms,andinstruments....................................55.10
Booms,dippers,andbuckets.......................................................84
[84.100]Bucket..............................................................................84.1
Platform,cab,bodywork,anddecals.............................................90
[90.114]Operatorprotections...............................................................90.1
[90.151]Cabinterior.........................................................................90.2
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INTRODUCTION
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Contents
INTRODUCTION
Foreword-Importantnoticeregardingequipmentservicing....................................3
Foreword-Howtouseandnavigatethroughthismanual.....................................4
Safetyrules.....................................................................................9
Safetyrules(Signalworddenitions).........................................................10
Safetyrules...................................................................................11
Safetyrules...................................................................................13
Safetyrules...................................................................................15
Safetyrules(Weldworks).....................................................................19
Safetyrules-(Machineservice)..............................................................21
Torque........................................................................................29
Torque-Standardtorquedataforhydraulics.................................................33
Basicinstructions-Shopandassembly......................................................35
Basicinstructions(Dailyinspection)..........................................................37
Generalspecications........................................................................38
Overalldimensions...........................................................................42
Operatingweights............................................................................46
Conversionfactors............................................................................47
Consumables.................................................................................59
Hydrauliccontamination......................................................................61
Productidentication(Sidesofthemachine).................................................62
Partidentication-(Identicationplates).....................................................63
Partidentication(Securitylock,transportandservice)......................................65
Partidentication(Accessdoors,llinglocations,andlters)................................66
Productoverview-(MachineComponents)..................................................73
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INTRODUCTION
Foreword-Importantnoticeregardingequipmentservicing
Allrepairandmaintenanceworklistedinthismanualmustbecarriedoutonlybyqualieddealershippersonnel,
strictlycomplyingwiththeinstructionsgiven,andusing,wheneverpossible,thespecialtools.
Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein
shallberesponsibleforanysubsequentdamages.
Themanufacturerandalltheorganizationsofitsdistributionchain,including-withoutlimitation-national,regional,or
localdealers,rejectanyresponsibilityfordamagescausedbypartsand/orcomponentsnotapprovedbythemanu-
facturer,includingthoseusedfortheservicingorrepairoftheproductmanufacturedormarketedbythemanufacturer.
Inanycase,nowarrantyisgivenorattributedontheproductmanufacturedormarketedbythemanufacturerincase
ofdamagescausedbypartsand/orcomponentsnotapprovedbythemanufacturer.
Themanufacturerreservestherighttomakeimprovementsindesignandchangesinspecicationsatanytimewithout
noticeandwithoutincurringanyobligationtoinstallthemonunitspreviouslysold.Specications,descriptions,and
illustrativematerialhereinareasaccurateasknownattimeofpublicationbutaresubjecttochangewithoutnotice.
Incaseofquestions,refertoyourCASECONSTRUCTIONSalesandServiceNetworks.
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INTRODUCTION
Foreword-Howtouseandnavigatethroughthismanual
Thismanualhasbeenproducedbyanewtechnicalinformationsystem.Thisnewsystemisdesignedtodeliver
technicalinformationelectronicallythroughwebdelivery(eTIM),DVD,andpapermanuals.Acodingsystemcalled
SAPhasbeendevelopedtolinkthetechnicalinformationtootherProductSupportfunctions,e.g.,Warranty.
Technicalinformationiswrittentosupportthemaintenanceandserviceofthefunctionsorsystemsonacustomer's
machine.Whenacustomerhasaconcernontheirmachineitisusuallybecauseafunctionorsystemontheirma-
chineisnotworkingatall,isnotworkingefciently,orisnotrespondingcorrectlytotheircommands.Whenyourefer
tothetechnicalinformationinthismanualtoresolvethatcustomer'sconcern,youwillndalltheinformationclassied
usingtheSAPcoding,accordingtothefunctionsorsystemsonthatmachine.Onceyouhavelocatedthetechnical
informationforthatfunctionorsystem,youwillthenndallthemechanical,electricalorhydraulicdevices,compo-
nents,assemblies,andsubassembliesforthatfunctionorsystem.Youwillalsondallthetypesofinformationthat
havebeenwrittenforthatfunctionorsystem:thetechnicaldata(specications),thefunctionaldata(howitworks),
thediagnosticdata(faultcodesandtroubleshooting),andtheservicedata(remove,installadjust,etc.).
ByintegratingSAPcodingintotechnicalinformation,youwillbeabletosearchandretrievejusttherightpieceof
technicalinformationyouneedtoresolvethatcustomer'sconcernonhismachine.Thisismadepossiblebyattaching
3categoriestoeachpieceoftechnicalinformationduringtheauthoringprocess.
TherstcategoryistheLocation,thesecondcategoryistheInformationTypeandthethirdcategoryistheProduct:
•LOCATION-thecomponentorfunctiononthemachine,thatthepieceoftechnicalinformationisgoingtodescribe
(e.g.,Fueltank).
•INFORMATIONTYPE-thepieceoftechnicalinformationthathasbeenwrittenforaparticularcomponentorfunc-
tiononthemachine(e.g.,CapacitywouldbeatypeofTechnicalDatadescribingtheamountoffuelheldbythefuel
tank).
•PRODUCT-themodelforwhichthepieceoftechnicalinformationiswritten.
Everypieceoftechnicalinformationwillhavethosethreecategoriesattachedtoit.Youwillbeabletouseanycombi-
nationofthosecategoriestondtherightpieceoftechnicalinformationyouneedtoresolvethatcustomer'sconcern
ontheirmachine.
Thatinformationcouldbe:
•theprocedureforhowtoremovethecylinderhead
•atableofspecicationsforahydraulicpump
•afaultcode
•atroubleshootingtable
•aspecialtool
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INTRODUCTION
Manualcontent
ThismanualisdividedintoSections.EachSectionisthendividedintoChapters.Contentspagesareincludedatthe
beginningofthemanual,theninsideeverySectionandinsideeveryChapter.AnalphabeticalIndexisincludedat
theendofeachChapter.Pagenumberreferencesareincludedforeverypieceoftechnicalinformationlistedinthe
ChapterContentsorChapterIndex.
EachChapterisdividedintofourInformationtypes:
•TechnicalData(specications)forallthemechanical,electricalorhydraulicdevices,components,assembliesor
sub-assemblies.
•FunctionalData(howitworks)forallthemechanical,electricalorhydraulicdevices,components,assembliesor
sub-assemblies.
•DiagnosticData(faultcodes,electricalandhydraulictroubleshooting)forallthemechanical,electricalorhydraulic
devices,components,assembliesorsub-assemblies.
•ServiceData(removedisassemble,assemble,install)forallthemechanical,electricalorhydraulicdevices,com-
ponents,assembliesorsub-assemblies.
Sections
Sectionsaregroupedaccordingtothemainfunctionsorasystemsonthemachine.EachSectionisidentiedbya
number(00,35,55,etc.).TheSectionsincludedinthemanualwilldependonthetypeandfunctionofthemachinethat
themanualiswrittenfor.EachSectionhasaContentspagelistedinalphabetic/numericorder.Thistableillustrates
whichSectionscouldbeincludedinamanualforaparticularproduct.
PRODUCT
Tractors
Vehicleswithworkingarms:backhoes,excavators,
skidsteers,….
Combines,forageharvesters,balers,….
Seeding,planting,oating,spraying
equipment,….
SECTIONMountedequipmentandtools,….
00-MaintenanceXXXXX
05-MachinecompletionandequipmentXXXXX
10-EngineXXXX
14-MaingearboxanddriveXXXX
18-ClutchXXX
21-TransmissionXXXX
23-Fourwheeldrive(4WD)systemXXXX
25-FrontaxlesystemXXXX
27-RearaxlesystemXXXX
29-HydrostaticdriveXXXX
31-PowerTake-Off(PTO)XX
33-BrakesandcontrolsXXXX
35-HydraulicsystemsXXXX
36-PneumaticsystemXXXX
37-Hitches,drawbarsandimplementcouplingsXXX
39-FramesandballastingXXXXX
41-SteeringXXXX
44-WheelsXXXX
46-Steeringclutches
48-TracksandtracksuspensionXXX
50-CabclimatecontrolXXXX
55-ElectricalsystemsXXXXX
56-Grapeharvestershaking
58-Attachments/headersX
60-ProductfeedingX
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INTRODUCTION
61-MeteringsystemX
62-Pressing-BaleformationX
63-ChemicalapplicatorsX
64-ChoppingX
66-ThreshingX
68-Tying/Wrapping/TwistingX
69-Balewagons
70-EjectionX
71-LubricationsystemXXXXX
72-SeparationX
73-ResiduehandlingX
74-CleaningX
75-Soilpreparation/Finishing
76-Secondarycleaning/Destemmer
77-SeedingX
78-SprayingX
79-PlantingX
80-Cropstorage/UnloadingX
82-FrontloaderandbucketXX
83-TelescopicsinglearmXX
84-Booms,dippersandbucketsXX
86-DozerbladeandarmXX
88-AccessoriesXXXXX
89-ToolsXXXXX
90-Platform,cab,bodyworkanddecalsXXXX
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INTRODUCTION
Chapters
EachChapterisidentiedbyanumbere.g.Engine-Engineandcrankcase-10.001.Therstnumberisidentical
totheSectionnumberi.e.Chapter10.001isinsideSection10,Engine.Thesecondnumberisrepresentativeofthe
ChaptercontainedwithintheSection.
CONTENTS
TheChapterContentslistsallthetechnicaldata(specications),functionaldata(howitworks),diagnosticdata(fault
codesandtroubleshooting),andservicedata(remove,install,adjust,etc.),thathavebeenwritteninthatChapterfor
thatfunctionorsystemonthemachine.
Contents
ENGINE
ENGINE-Engineandcrankcase–10.001
TECHNICALDATA
ENGINE-Engineandcrankcase-Generalspecication(10.001-D.40.A.10)4
FUNCTIONALDATA
ENGINE-Engineandcrankcase-Dynamicdescription(10.001-C.30.A.10)6
SERVICE
ENGINE-Engineandcrankcase-Remove(10.001-F.10.A.10)8
DIAGNOSTIC
ENGINE-Engineandcrankcase-Troubleshooting(10.001-G.40.A.10)10
INDEX
TheChapterIndexlistsinalphabeticalorderallthetypesofinformation(calledinformationunits)thathavebeen
writteninthatChapterforthatfunctionorsystemonthemachine.
Index
ENGINE-10
ENGINE
ENGINE-Engineandcrankcase-Dynamicdescription(10.001-C.30.A.10)6
ENGINE-Engineandcrankcase-Generalspecication(10.001-D.40.A.10)4
ENGINE-Engineandcrankcase-Remove(10.001-F.10.A.10)8
ENGINE-Engineandcrankcase-Troubleshooting(10.001-G.40.A.10)10
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INTRODUCTION
Informationunitsandinformationsearch
Eachchapteriscomposedofinformationunits.EachinformationunithastheSAPcodeshowninparentheses.This
indicatesthefunctionandtypeofinformationinthatinformationunit.Eachinformationunithasapagereferencewithin
thatChapter.Theinformationunitsprovideaquickandeasywaytondjusttherightpieceoftechnicalinformation
youarelookingfor.
Exampleinformation
unit
Engineblockcover-Front–Remove(10.102.AP.01-F.10.A.10)
InformationUnitSAP
code
10102AK01F10.A.10
SAPcodeclassicationEnginePanandcoversEngineblock
cover
FrontServicedataRemove
NHIL12GEN0070A1
Navigatetothecorrectinformationunityouaresearchingforbyidentifyingthefunctionandinformationtype
fromtheSAPcode.
•(1)Locationand(2)Informationtype.
•(A)correspondstothesectionsoftheservicemanual.
(B)correspondstothechaptersoftheservicemanual.After(B)theremaybesomeadditionalinformation.Inthis
caseitshows“.01”,whichrepresentsthe“Front”blockcover.Theseoptionsmaybefront/rear,left/right,hydraulic/
mechanicaletc.
(C)correspondstothetypeofinformationlistedinthechaptercontents:TechnicalData,FunctionalData,Diagnos-
tic,orService.
(A)and(B)arealsoshowninthepagenumberingonthepagefooter.
THERESTOFTHECODINGISNOTLISTEDINALPHANUMERICORDERINTHISMANUAL.
•Youwillndatableofcontentsatthebeginningandendofeachsectionandchapter.
Youwillndanalphabeticalindexattheendofeachchapter.
•Byreferringto(A),(B)and(C)ofthecoding,youcanfollowthecontentsorindex(pagenumbers)andquicklynd
theinformationyouarelookingfor.
Pageheaderandfooter
Thepageheaderwillcontainthefollowingreferences:
•SectionandChapterdescription
Thepagefooterwillcontainthefollowingreferences:
•PublicationnumberforthatManual.
•Versionreferenceforthatpublication.
•Publicationdate
•Section,chapter,andpagereferencee.g.10.102/9
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INTRODUCTION
Safetyrules
Ecologyandenvironment
Soil,airandwaterarevitalfactorsoflifeingeneral.Disposingofwasteimproperlyrepresentsadangerforthe
environment.
NOTE:Somerecommendationsmustbefollowed:
•Obtaininformationaboutthecorrectmethodstorecycleordisposeofwastefromlocalauthorities,collectioncenters
oryourdealer.
•Donotdisposeofwasteontotheground,intodrains,orinwaterbeds.
•Donotllreservoirsusingcansorinappropriatepressurizeduiddeliverysystems,astheymaycauseconsiderable
spillage.
•Usesealedcontainerswhendrainingtheuids.Donotusecontainersforfoodorbeverageswhichmayinduce
ingestion.
•Theairconditioningsystemisunderpressure,andcontainsgasesthatshouldnotbereleasedintotheatmosphere.
Donotdisconnectorremoveanycomponentfromthepressurelineoftheairconditioningsystem.Ifyouneed
repairstotheairconditioningsystem,contactadealer.
•Immediatelyrepairanyleaksordefectsinthemachine'senginecoolingandhydraulicsystems.
•Generallyavoidskincontactwithanyfuels,oils,uids,acids,solvents,etc.Mostofthemcontainsubstanceswhich
maybeharmfultoyourhealth.
•Avoidspillswhendraininguid.Storethemsafelyuntiltheycanbedisposedofproperlyincompliancewithlocal
legislation.
•Protecthosesandpipesduringweldingworks,becausethesparksgeneratedduringtheweldingworkcandamage
them,allowingtheuidtoleak.
Mandatoryrecycling
Thebatteryisessentiallycomposedofleadplatesand
sulfuricacidsolution.Becausethebatterycontainsheavy
metalssuchaslead,resolution401de2008ofCONAMA
ordersthatallusedbatteriesmustbereturnedtothebat-
terydealeratthetimeofreplacement.Donotdisposeof
thebatteryinthegarbage.Pointsofsaleareobligedto
acceptthereturnofyourusedbattery,andtostoreitina
suitableplaceandreturnittothemanufacturerforrecy-
cling.
Improperdisposalofbatteriescancontaminatethesoil,
groundwaterandwaterways.Consumptionofcontami-
natedwatercancauseserioushealthrisks.Contactof
theacidsolutionwiththeskinoreyescancauseserious
injuryandblindness.Incaseofaccidentalcontactwith
theeyesorskin,immediatelywashwithrunningwaterand
seekemergencymedicalcare.
CUIL13TRO0091AA1
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9

INTRODUCTION
Safetyrules(Signalworddenitions)
PersonalSafety
Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialpersonalinjuryhazards.Obeyall
safetymessagesthatfollowthissymboltoavoidpossibledeathorinjury.
Throughoutthismanualandonmachinesafetysigns,youwillndthesignalwordsDANGER,WARNING,andCAU-
TIONfollowedbyspecialinstructions.Theseprecautionsareintendedforyourpersonalsafetyandforallthose
involvedintheworkactivityduringoperationofthemachine.
Readandunderstandallthesafetymessagesinthismanualbeforeyouoperateorservicethemachine.
DANGER:
Indicatesanimmediatedangerthat,ifnotavoided,willcausedeathorseriousinjury.Thecolorassociated
withDangerisRED.
WARNING:
Indicatesapotentialdangerthat,ifnotavoided,willcauseseriousinjury.ThecolorassociatedwithWarningis
ORANGE.
CAUTION:
Indicatesapotentialdangerthat,ifnotavoided,cancauseminorormoderateinjury.ORANGEalsoalertsthe
operatortounsafepractices.ThecolorassociatedwithCautionisYELLOW.
FAILURETOFOLLOWDANGER,WARNINGANDCAUTIONMESSAGESCOULDRESULT
INDEATHORSERIOUSINJURY.
Machinesafety
NOTICE:Indicatesasituationthat,ifnotavoided,couldresultinmachineorpropertydamage.Thecolorassociated
withNoticeisBLUE.
ThroughoutthismanualyouwillndthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor
propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety.
Information
NOTE:Indicatesadditionalinformationwhichclariessteps,procedures,orotherinformationinthismanual.
ThroughoutthismanualyouwillndthewordNOTEfollowedbyadditionalinformationaboutastep,procedureor
otherinformationinthemanual.ThewordNOTEisnotintendedtoaddresspersonalsafetyorpropertydamage.
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INTRODUCTION
Safetyrules
Standardsafetyprecautions
Beinformedandnotifypersonnelofthelawsinforceregulatingsafety,andprovidedocumentationavailablefor
consultation.
•Keepworkingareasascleanaspossible.
•Ensurethatworkingareasareprovidedwithemergencyboxes.Theymustbeclearlyvisibleandalwayscontain
adequatesanitaryequipment.
•Fireextinguishersmustbeproperlyidentiedandalwaysbeclearofobstructions.Theirefciencymustbechecked
onaregularbasisandpersonnelmustbetrainedonproperinterventionsandpriorities.
•Keepallemergencyexitsfreeofobstructionsandclearlymarked.
•Smokinginworkingareassubjecttoredangermustbestrictlyprohibited.
Preventionofinjury
•Wearsuitableworkattireandsafetyglasseswithnojewelrysuchasringsandchainswhenworkingclosetoengines
andequipmentinmotion.
•Wearsafetyglovesandgoggleswhenperformingthefollowingoperations:
•Toppingofforchanginglubricationoils.
•Usingcompressedairorliquidsatapressuregreaterthan2bar(29psi).
•Wearasafetyhelmetwhenworkingclosetohangingloadsorequipmentworkingatheadlevel.
•Alwayswearsafetyshoesandttingclothes.
•Useprotectioncreamforhands.
•Changewetclothesassoonaspossible.
•Inthepresenceofvoltagesexceeding48–60V,verifytheefciencyofthegroundandmasselectricalconnections.
Ensurethathandsandfeetaredryanduseisolatingfootboards.Workersshouldbeproperlytrainedtoworkwith
electricity.
•Donotsmokeorstartanopenameclosetobatteriesandanyfuelmaterial.
•Placesoiledragswithoil,dieselfuelorsolventsinspeciallyprovidedanti-recontainers.
•Donotuseanytoolorequipmentforanyuseotherthanwhatitwasoriginallyintendedfor.Seriousinjurymay
occur.
•Ifrunninganengineindoors,makesurethereisasufcientexhaustfaninusetoeliminateexhaustfumes.
Duringmaintenance
•Neveropenthellercapofthecoolingsystemwhentheengineishot.Hightemperatureliquidatoperatingpressure
couldresultinseriousdangerandriskofburn.Waituntilthetemperaturedecreasesunder50°C(122°F).
•Neveraddcoolanttoanoverheatedengineanduseonlyappropriateliquids.
•Alwaysworkwhentheengineisturnedoff.Certaincircumstancesrequiremaintenanceonarunningengine.Be
awareofalltherisksinvolvedwithsuchanoperation.
•Alwaysuseadequateandsafecontainersforengineuidsandusedoil.
•Keepenginecleanofanyspilleduidssuchasoil,dieselfuel,andorchemicalsolvents.
•Useofsolventsordetergentsduringmaintenancemayemittoxicvapors.Alwayskeepworkingareasaerated.
Wearasafetymaskifnecessary.
•Donotleavesoiledragsthatmaycontainanyammablesubstancesclosetotheengine.
•Alwaysusecautionwhenstartinganengineafteranyworkhasbeenperformed.Bepreparedtocutoffintakeair
incaseofenginerunaway.
•Neverdisconnectthebatterieswhiletheengineisrunning.
•Disconnectthebatteriespriortoperforminganyworkontheequipment.
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INTRODUCTION
•Disconnectthebatteriestoplacealoadonthemwithaloadtester.
•Afteranyworkisperformed,verifythatthebatteryclamppolarityiscorrectandthattheclampsaretightandsafe
fromaccidentalshortcircuitandoxidation.
•Beforedisconnectinganypipelines(pneumatic,hydraulic,fuelpipes,etc.),verifythatallpressurehasbeenre-
leased.Takeallnecessaryprecautionsbleedinganddrainingresidualpressure.Alwayswearthepropersafety
equipment.
•Donotalterthelengthsofanywires.
•DonotconnectanyelectronicservicetooltotheengineelectricalequipmentunlessspecicallyapprovedbyCASE
CONSTRUCTION.
•DonotmodifythefuelsystemorhydraulicsystemunlessapprovedbyCASECONSTRUCTION.Anyunauthorized
modicationwillcompromisewarrantyassistanceandmayaffectengineoperationandlifespan.
Forengineequippedwithanelectroniccontrolunit
•Donotweldonanypartoftheequipmentwithoutremovingthecontrolunit.
•Removetheincaseofworkrequiringheatingover80°C(176°F).
•Donotpaintthecomponentsandtheelectronicconnections.
•Donotalteranydataledintheelectroniccontrolunitdrivingtheengine.Anymanipulationoralterationofelectronic
componentswillvoidenginewarrantyassistanceandmayaffectthecorrectworkingorderandlifespanofthe
engine.
RespectoftheEnvironment
•Respectoftheenvironmentshouldbeofprimaryimportance.Takeallnecessaryprecautionstoensurepersonnel's
safetyandhealth.
•Informthepersonnelofthelawsregardingthedispensingofusedengineuids.
•Handlebatterieswithcare,storingtheminawellventilatedenvironmentandwithinanti-acidcontainer.
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INTRODUCTION
Safetyrules
Generalsafetyregulations
GeneralAspects
•Strictlyfollowrepairandmaintenanceprocedures.
•Donotwearrings,wristwatches,jewelry,accessories,unbuttoneditemsofclothing,unsecuredclothingliketies,
tornclothing,scarves,oropenjacketsorshirtswithopenzippersthatcouldgetcaughtinmovingparts.Useap-
provedsafetyclothing,suchasanti-slipfootwear,sleeves,protectivegoggles,helmets,etc.
•Wearsafetygoggleswithsideshieldswhencleaningpartsusingcompressedair.
•Wornordamagedcablesandchainsarenotreliable.Donotusetheseelementsinliftingortowingoperations.
•Useregulationsafetyequipment,suchasapprovedeyeprotection,helmets,clothes,sleeves,andspecialfootwear
wheneveryouarewelding.Allindividualsneartheweldingprocessmustuseregulationeyeprotection.Neverlook
attheweldingarcwithoutusingsuitableeyeprotection.
•Neverperformanyrepairsonthemachineifthereissomeoneintheoperatorseat,exceptwhenthepersonisa
qualiedoperatorwhoishelpingwiththeservicetobeperformed.
•Neveroperatethemachineoruseaccessoriesfromaplaceotherthantheoperatorseatornexttothemachine
whenoperatingthefenderswitches.
•Neverperformanyoperationsonthemachinewiththeenginerunning,exceptwhenspecicallyinstructedtodo
so.Shutdowntheengineandreleaseallthepressurefromthehydrauliccircuitsbeforeremovingcovers,cases,
valves,etc.
•Youmustconductallrepairandmaintenanceoperationswiththeutmostcareandattention.
•Disconnectthebatteriesandputwarninglabelsonallofthecontrolstowarnthatthemachineisbeingrepaired.
Lockthemachineandalltheequipmentthatyouremove.
•Nevercheckorllthefueltankorbatteriesorusestartinguidwhenyouaresmokingornearanakedame,
becausetheseuidsareammable.
•Thefuelllinggunmustremainincontactwiththellerneck.Maintainthecontactuntilthefuelstopsowinginto
thetankinordertoavoidsparkscausedbystaticelectricitybuild-up.
•Totransportafaultymachine,useatraileroralowloaderplatformtrolley,ifavailable.
•Toloadandunloadthemachinefromthemodeoftransportation,chooseaatareathatoffersrmsupportforthe
wheelsofthetruckortrailer.Securelyfastenthemachinetotheplatformofthetrailerortruck,inaccordancewith
thetransporter’srequirements.
•Alwaysusehoistmechanismswithanappropriatecapacityforliftingormovingheavycomponents.
•Chainsmustalwaysbesecurelyfastened.Thefasteningdevicemusthavesufcientcapacitytosupportthein-
tendedload.Itisprohibitedforbystanderstobenearthefasteningposition.
•Theworkareamustalwaysbecleananddry.Cleanitimmediatelyifanywateroroilisspilled.
•Neverusegasoline,diesel,orotherammableliquidsforcleaning.Useonlynon-toxicsolvents.
•Donotallowclothssoakedwithoilorgreasetoaccumulatebecausetheycancausearerisk.Alwayskeepthese
clothsinametalcontainer.
Starting
•Neverstarttheengineinenclosedspacesthatarenotequippedwithasuitableexhaustsystemorgas-extraction
system.
•Neverbringyourhead,body,arms,legs,feet,hands,orngersclosetofansorrotatingbelts.
Engine
•Alwaysloosentheradiatorcapslowlybeforeremovingit,inordertodissipatethesystempressure.Youmusttop
upthecoolantwiththeenginestopped.
•Donotllupthefueltankwhentheengineisrunning.
•Neveradjustthefuelinjectionpumpwhenthemachineisinmotion.
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