Case NCDC16500 User manual

SERVICE MANUAL
1/2
1650M
Stage IIIB
Crawler Dozer
PIN NCDC16500 and above;
PIN NDDC16500 and above;
PIN NEDC16000 and above;
PIN NFDC16000 and above
SERVICE MANUAL
1650M
Stage IIIB
Crawler Dozer
PIN NCDC16500 and above; PIN NDDC16500 and above;
PIN NEDC16000 and above; PIN NFDC16000 and above
Part number 47907869
2nd edition English
October 2015
Replaces part number 47619918
© 2015 CNH Industrial America LLC. All Rights Reserved.
Part number 47907869

SERVICEMANUAL
1650MExtraLongTrack(XLT),Bulldozer(BD)Blade[NCDC16500-],1650M
ExtraLongTrack(XLT),Bulldozer(BD)Blade[NDDC16500-],1650MExtra
LongTrack(XLT),Bulldozer(BD)Blade[NEDC16000-],1650MExtraLong
Track(XLT),Bulldozer(BD)Blade[NFDC16000-],1650MExtraLongTrack
(XLT),PowerAngleTilt(PAT)Blade[NCDC16500-],1650MExtraLongTrack
(XLT),PowerAngleTilt(PAT)Blade[NDDC16500-],1650MExtraLongTrack
(XLT),PowerAngleTilt(PAT)Blade[NEDC16000-],1650MExtraLongTrack
(XLT),PowerAngleTilt(PAT)Blade[NFDC16000-],1650MWideTrack(WT)/
LowGroundPressure(LGP),PowerAngleTilt(PAT)Blade[NCDC16500-],
1650MWideTrack(WT)/LowGroundPressure(LGP),PowerAngleTilt(PAT)
Blade[NDDC16500-],1650MWideTrack(WT)/LowGroundPressure(LGP),
PowerAngleTilt(PAT)Blade[NEDC16000-],1650MWideTrack(WT)/Low
GroundPressure(LGP),PowerAngleTilt(PAT)Blade[NFDC16000-]
4790786906/10/2015
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LinkProduct/Engine
ProductMarketProductEngine
1650MExtraLongTrack(XLT),
Bulldozer(BD)Blade[NCDC16500
-]
EuropeF4HFE6132*A004
1650MExtraLongTrack(XLT),
Bulldozer(BD)Blade[NDDC16500
-]
EuropeF4HFE6132*A004
1650MExtraLongTrack(XLT),
Bulldozer(BD)Blade[NEDC16000
-]
EuropeF4HFE6132*A004
1650MExtraLongTrack(XLT),
Bulldozer(BD)Blade[NFDC16000
-]
EuropeF4HFE6132*A004
1650MExtraLongTrack(XLT),
PowerAngleTilt(PAT)Blade
[NCDC16500-]
EuropeF4HFE6132*A004
1650MExtraLongTrack(XLT),
PowerAngleTilt(PAT)Blade
[NDDC16500-]
EuropeF4HFE6132*A004
1650MExtraLongTrack(XLT),
PowerAngleTilt(PAT)Blade
[NEDC16000-]
EuropeF4HFE6132*A004
1650MExtraLongTrack(XLT),
PowerAngleTilt(PAT)Blade
[NFDC16000-]
EuropeF4HFE6132*A004
1650MWideTrack(WT)/
LowGroundPressure(LGP),
PowerAngleTilt(PAT)Blade
[NCDC16500-]
EuropeF4HFE6132*A004
1650MWideTrack(WT)/
LowGroundPressure(LGP),
PowerAngleTilt(PAT)Blade
[NDDC16500-]
EuropeF4HFE6132*A004
1650MWideTrack(WT)/
LowGroundPressure(LGP),
PowerAngleTilt(PAT)Blade
[NEDC16000-]
EuropeF4HFE6132*A004
1650MWideTrack(WT)/
LowGroundPressure(LGP),
PowerAngleTilt(PAT)Blade
[NFDC16000-]
EuropeF4HFE6132*A004
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Contents
INTRODUCTION
Engine.......................................................................................10
[10.001]Engineandcrankcase.............................................................10.1
[10.202]Aircleanersandlines..............................................................10.2
[10.206]Fuellters..........................................................................10.3
[10.216]Fueltanks..........................................................................10.4
[10.304]Enginelubricationsystem..........................................................10.5
[10.310]Aftercooler..........................................................................10.6
[10.400]Enginecoolingsystem.............................................................10.7
[10.414]Fananddrive......................................................................10.8
[10.500]SelectiveCatalyticReduction(SCR)exhausttreatment...........................10.9
Hydrostaticdrive.........................................................................29
[29.218]Pumpandmotorcomponents......................................................29.1
Brakesandcontrols....................................................................33
[33.110]Parkingbrakeorparkinglock......................................................33.1
[33.202]Hydraulicservicebrakes...........................................................33.2
Hydraulicsystems.......................................................................35
[35.000]Hydraulicsystems..................................................................35.1
[35.300]Reservoir,cooler,andlters........................................................35.2
[35.104]Fixeddisplacementpump..........................................................35.3
[35.105]Chargepump.......................................................................35.4
[35.359]Maincontrolvalve..................................................................35.5
[35.741]Dozerbladecylinders..............................................................35.6
Tracksandtracksuspension........................................................48
[48.130]Trackframeanddrivingwheels....................................................48.1
[48.100]Tracks..............................................................................48.2
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[48.134]Tracktensionunits.................................................................48.3
[48.138]Trackrollers........................................................................48.4
[48.140]Dropboxandnaldrive............................................................48.5
Cabclimatecontrol.....................................................................50
[50.100]Heating.............................................................................50.1
[50.104]Ventilation..........................................................................50.2
[50.200]Airconditioning.....................................................................50.3
Electricalsystems.......................................................................55
[55.000]Electricalsystem...................................................................55.1
[55.011]Fueltanksystem...................................................................55.2
[55.014]Engineintakeandexhaustsystem.................................................55.3
[55.015]Enginecontrolsystem..............................................................55.4
[55.030]Servicebrakeelectricalsystem....................................................55.5
[55.050]Heating,Ventilation,andAir-Conditioning(HVAC)controlsystem.................55.6
[55.100]Harnessesandconnectors.........................................................55.7
[55.201]Enginestartingsystem.............................................................55.8
[55.202]Coldstartaid.......................................................................55.9
[55.301]Alternator.........................................................................55.10
[55.302]Battery............................................................................55.11
[55.408]Warningindicators,alarms,andinstruments....................................55.12
[55.512]Cabcontrols......................................................................55.13
[55.518]Wiperandwashersystem........................................................55.14
[55.988]SelectiveCatalyticReduction(SCR)electricalsystem..........................55.15
[55.DTC]FAULTCODES..................................................................55.16
Dozerbladeandarm...................................................................86
[86.110]Dozerblade........................................................................86.1
[86.124]Dozerpushbeamsandstruts......................................................86.2
Tools.........................................................................................89
[89.128]Ripperassembly...................................................................89.1
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Platform,cab,bodywork,anddecals.............................................90
[90.150]Cab.................................................................................90.1
[90.160]Cabinteriortrimandpanels........................................................90.2
[90.124]Pneumatically-adjustedoperatorseat..............................................90.3
[90.100]Enginehoodandpanels...........................................................90.4
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INTRODUCTION
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Contents
INTRODUCTION
Foreword-Importantnoticeregardingequipmentservicing(*)................................3
Safetyrules(*)..................................................................................4
Safetyrules-Ecologyandtheenvironment(*).................................................5
Safetyrules-Donotoperatetag(*)............................................................6
Safetyrules(*)..................................................................................7
Basicinstructions-Shopandassembly(*)...................................................15
Torque-Minimumtighteningtorquesfornormalassembly(*)...............................17
Torque-Standardtorquedataforhydraulics(*)..............................................20
Maintenancechart(*).........................................................................22
Basicinstructions-Movingadisabledmachine(*)...........................................24
Hydrauliccontamination(*)...................................................................33
ConsumablesLoctite®ProductChart(*).....................................................34
Conversionfactors(*).........................................................................40
Generalspecication(*)......................................................................42
Capacities(*).................................................................................46
Productidentication(*)......................................................................47
Productidentication-Machineorientation(*)...............................................49
(*)Seecontentforspecicmodels
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INTRODUCTION
Foreword-Importantnoticeregardingequipmentservicing
1650MWE
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
Safetyrules
1650MWE
Personalsafety
Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialpersonalinjuryhazards.Obeyall
safetymessagesthatfollowthissymboltoavoidpossibledeathorinjury.
ThroughoutthismanualyouwillndthesignalwordsDANGER,WARNING,andCAUTIONfollowedbyspecialin-
structions.Theseprecautionsareintendedforthepersonalsafetyofyouandthoseworkingwithyou.
Readandunderstandallthesafetymessagesinthismanualbeforeyouoperateorservicethemachine.
DANGERindicatesahazardoussituationthat,ifnotavoided,willresultindeathorseriousinjury.
WARNINGindicatesahazardoussituationthat,ifnotavoided,couldresultindeathorseriousinjury.
CAUTIONindicatesahazardoussituationthat,ifnotavoided,couldresultinminorormoderateinjury.
FAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT
INDEATHORSERIOUSINJURY .
Machinesafety
NOTICE:Noticeindicatesasituationthat,ifnotavoided,couldresultinmachineorpropertydamage.
ThroughoutthismanualyouwillndthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor
propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety.
Information
NOTE:Noteindicatesadditionalinformationthatclariessteps,procedures,orotherinformationinthismanual.
ThroughoutthismanualyouwillndthewordNotefollowedbyadditionalinformationaboutastep,procedure,or
otherinformationinthemanual.ThewordNoteisnotintendedtoaddresspersonalsafetyorpropertydamage.
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INTRODUCTION
Safetyrules-Ecologyandtheenvironment
1650MWE
Soil,air,andwaterqualityisimportantforallindustriesandlifeingeneral.Whenlegislationdoesnotyetrulethe
treatmentofsomeofthesubstancesthatadvancedtechnologyrequires,soundjudgmentshouldgoverntheuseand
disposalofproductsofachemicalandpetrochemicalnature.
Familiarizeyourselfwiththerelativelegislationapplicabletoyourcountry,andmakesurethatyouunderstandthis
legislation.Wherenolegislationexists,obtaininformationfromsuppliersofoils,lters,batteries,fuels,anti-freeze,
cleaningagents,etc.,withregardtotheeffectofthesesubstancesonmanandnatureandhowtosafelystore,use,
anddisposeofthesesubstances.
Helpfulhints
•Avoidtheuseofcansorotherinappropriatepressurizedfueldeliverysystemstolltanks.Suchdeliverysystems
maycauseconsiderablespillage.
•Ingeneral,avoidskincontactwithallfuels,oils,acids,solvents,etc.Mostoftheseproductscontainsubstances
thatmaybeharmfultoyourhealth.
•Modernoilscontainadditives.Donotburncontaminatedfuelsandorwasteoilsinordinaryheatingsystems.
•Avoidspillagewhenyoudrainuidssuchasusedenginecoolantmixtures,engineoil,hydraulicuid,brakeuid,
etc.Donotmixdrainedbrakeuidsorfuelswithlubricants.Storealldraineduidssafelyuntilyoucandisposeof
theuidsinaproperwaythatcomplieswithalllocallegislationandavailableresources.
•Donotallowcoolantmixturestogetintothesoil.Collectanddisposeofcoolantmixturesproperly.
•Theair-conditioningsystemcontainsgasesthatshouldnotbereleasedintotheatmosphere.Consultanair-condi-
tioningspecialistoruseaspecialextractortorechargethesystemproperly.
•Repairanyleaksordefectsintheenginecoolingsystemorhydraulicsystemimmediately.
•Donotincreasethepressureinapressurizedcircuitasthismayleadtoacomponentfailure.
•Protecthosesduringwelding.Penetratingweldsplattermayburnaholeorweakenhoses,allowingthelossofoils,
coolant,etc.
Batteryrecycling
Batteriesandelectricaccumulatorscontainseveralsubstancesthatcanhaveaharmful
effectontheenvironmentifthebatteriesarenotproperlyrecycledafteruse.Improper
disposalofbatteriescancontaminatethesoil,groundwater,andwaterways.CASE
CONSTRUCTIONstronglyrecommendsthatyoureturnallusedbatteriestoaCASE
CONSTRUCTIONdealer,whowilldisposeoftheusedbatteriesorrecycletheused
batteriesproperly.Insomecountries,thisisalegalrequirement.
Mandatorybatteryrecycling
NOTE:ThefollowingrequirementsaremandatoryinBrazil.
Batteriesaremadeofleadplatesandasulfuricacidsolution.Becausebatteriescontainheavymetalssuchaslead,
CONAMAResolution401/2008requiresyoutoreturnallusedbatteriestothebatterydealerwhenyoureplaceany
batteries.Donotdisposeofbatteriesinyourhouseholdgarbage.
Pointsofsaleareobligedto:
•Acceptthereturnofyourusedbatteries
•Storethereturnedbatteriesinasuitablelocation
•Sendthereturnedbatteriestothebatterymanufacturerforrecycling
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INTRODUCTION
Safetyrules-Donotoperatetag
1650MWE
WARNING
Maintenancehazard!
Beforeyoustartservicingthemachine,attachaDONOTOPERATEwarningtagtothemachineina
visiblearea.
Failuretocomplycouldresultindeathorseriousinjury.W0004A
AttachaDONOTOPERATE(TAG)tothemachineinanareathatisclearlyvisiblewheneverthemachineisnot
operatingproperlyand/orrequiresservice.
Completethetaginformationforthe"REASON"thetagisattachedbydescribingthemalfunctionorservicerequired.
Validatethereasonforattachingthetagbysigningyournameinthedesignatedareaonthetag.
Thetagshouldonlyberemovedbythepersonwhosignedandattachedthetag,aftervalidatingtherepairsorservices
havebeencompleted.
(A)(D)
(E)
(B)
(F)
(C)
873586971
TagComponents
A.DONOTREMOVETHISTAG!-(Warning)Thetagshouldonlyberemovedbythepersonwhosignedandat-
tachedthetag,aftervalidatingtherepairsorserviceshavebeencompleted.
B.SeeOtherSide-(Referencetoadditionalinformationonoppositesideofthetag.)
C.CNHPartNumber-(RequestthispartnumberfromyouServicePartsDealertoobtainthisDONOTOPERATE
tag.)
D.DONOTOPERATE-(Warning!)
E.REASON-(Areafordescribingmalfunctionorservicerequiredbeforeoperation.)
F.Signedby-(Signaturearea-tobesignedbythepersonvalidatingthereasonforinstallationofthetag.)
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INTRODUCTION
Safetyrules
1650MWE
Generalsafetyrules
Usecautionwhenoperatingthemachineonslopes.Raisedequipment,fulltanksandotherloadswillchangethe
centerofgravityofthemachine.Themachinecantiporrolloverwhennearditchesandembankmentsoruneven
surfaces.
Neverpermitanyoneotherthantheoperatortorideonthemachine.
Neveroperatethemachineundertheinuenceofalcohol,drugs,orwhileotherwiseimpaired.
Whendiggingorusinggroundengagingattachmentsbeawareofburiedcables.Contactlocalutilitiestodetermine
thelocationsofservices.
Payattentiontooverheadpowerlinesandhangingobstacles.Highvoltagelinesmayrequiresignicantclearance
forsafety.
Hydraulicoilordieselfuelleakingunderpressurecanpenetratetheskin,causingseriousinjuryorinfection.
•DONOTuseyourhandtocheckforleaks.Useapieceofcardboardorpaper.
•Stopengine,removekeyandrelievethepressurebeforeconnectingordisconnectinguidlines.
•Makesureallcomponentsareingoodconditionandtightenallconnectionsbeforestartingtheengineorpressur-
izingthesystem.
•Ifhydraulicuidordieselfuelpenetratestheskin,seekmedicalattentionimmediately.
•Continuouslongtermcontactwithhydraulicuidmaycauseskincancer.Avoidlongtermcontactandwashthe
skinpromptlywithsoapandwater.
Keepclearofmovingparts.Looseclothing,jewelry,watches,longhair,andotherlooseorhangingitemscanbecome
entangledinmovingparts.
Wearprotectiveequipmentwhenappropriate.
DONOTattempttoremovematerialfromanypartofthemachinewhileitisbeingoperatedorcomponentsarein
motion.
Makesureallguardsandshieldsareingoodconditionandproperlyinstalledbeforeoperatingthemachine.Never
operatethemachinewithshieldsremoved.Alwayscloseaccessdoorsorpanelsbeforeoperatingthemachine.
Dirtyorslipperysteps,ladders,walkways,andplatformscancausefalls.Makesurethesesurfacesremaincleanand
clearofdebris.
Apersonorpetwithintheoperatingareaofamachinecanbestruckorcrushedbythemachineoritsequipment.DO
NOTallowanyonetoentertheworkarea.
Raisedequipmentand/orloadscanfallunexpectedlyandcrushpersonsunderneath.Neverallowanyonetoenter
theareaunderneathraisedequipmentduringoperation.
Neveroperateengineinenclosedspacesasharmfulexhaustgasesmaybuildup.
Beforestartingthemachine,besurethatallcontrolsareinneutralorparklockposition.
Starttheengineonlyfromtheoperator’sseat.Ifthesafetystartswitchisbypassed,theenginecanstartwiththe
transmissioningear.Donotconnectorshortacrossterminalsonthestartersolenoid.Attachjumpercablesas
describedinthemanual.Startingingearmaycausedeathorseriousinjury.
Alwayskeepwindows,mirrors,alllighting,andSlowMovingVehicle(SMV)emblemcleantoprovidethebestpossible
visibilitywhileoperatingthemachine.
Operatecontrolsonlywhenseatedintheoperator’sseat,exceptforthosecontrolsexpresslyintendedforusefrom
otherlocations.
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INTRODUCTION
Beforeleavingthemachine:
1.Parkmachineonarmlevelsurface.
2.Putallcontrolsinneutralorparklockposition.
3.Engageparkbrake.Usewheelchocksifrequired.
4.Lowerallhydraulicequipment—Implements,header,etc.
5.Turnoffengineandremovekey.
When,duetoexceptionalcircumstances,youwoulddecidetokeeptheenginerunningafterleavingtheoperator’s
station,thenthefollowingprecautionsmustbefollowed:
1.Bringtheenginetolowidlespeed.
2.Disengagealldrivesystems.
3.WARNING
Somecomponentsmaycontinuetorundownafterdisengagingdrivesystems.
Makesurealldrivesystemsarefullydisengaged.
Failuretocomplycouldresultindeathorseriousinjury.W0113A
Shiftthetransmissionintoneutral.
4.Applytheparkingbrake.
Generalmaintenancesafety
Keepareausedforservicingthemachinecleananddry.Cleanupspilleduids.
Servicemachineonarmlevelsurface.
Installguardsandshieldsafterservicingthemachine.
Closeallaccessdoorsandinstallallpanelsafterservicingthemachine.
Donotattempttoclean,lubricate,clearobstructionsormakeadjustmentstothemachinewhileitisinmotionorwhile
theengineisrunning.
Alwaysmakesureworkingareaisclearoftools,parts,otherpersonsandpetsbeforeyoustartoperatingthemachine.
Unsupportedhydrauliccylinderscanlosepressureanddroptheequipmentcausingacrushinghazard.Donotleave
equipmentinaraisedpositionwhileparkedorduringservice,unlesssecurelysupported.
Jackorliftthemachineonlyatjackorliftpointsindicatedinthismanual.
Incorrecttowingprocedurescancauseaccidents.Whentowingadisabledmachinefollowtheprocedureinthisman-
ual.Useonlyrigidtowbars.
Stoptheengine,removekeyandrelievepressurebeforedisconnectingorconnectinguidlines.
Stoptheengineandremovekeybeforedisconnectingorconnectingelectricalconnections.
Scaldingcanresultfromincorrectremovalofcoolantcaps.Coolingsystemoperatesunderpressure.Hotcoolant
cansprayoutifacapisremovedwhilethesystemishot.Allowsystemtocoolbeforeremovingcap.Whenremoving
acapturnitslowlytoallowpressuretoescapebeforecompletelyremovingthecap.
Replacedamagedorworntubes,hoses,electricalwiring,etc.
Engine,transmission,exhaustcomponents,andhydrauliclinesmaybecomehotduringoperation.T akecarewhen
servicingsuchcomponents.Allowsurfacestocoolbeforehandlingordisconnectinghotcomponents.Wearprotective
equipmentwhenappropriate.
Whenwelding,followtheinstructionsinthemanual.Alwaysdisconnectthebatterybeforeweldingonthemachine.
Alwayswashyourhandsafterhandlingbatterycomponents.
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INTRODUCTION
Wheelsandtires
Makesuretiresarecorrectlyinated.Donotexceedrecommendedloadorpressure.Followinstructionsinthe
manualforpropertireination.
Tiresareheavy.Handlingtireswithoutproperequipmentcouldcausedeathorseriousinjury.
Neverweldonawheelwithatireinstalled.Alwaysremovetirecompletelyfromwheelpriortowelding.
Alwayshaveaqualiedtiretechnicianservicethetiresandwheels.Ifatirehaslostallpressure,takethetireand
wheeltoatireshoporyourdealerforservice.Explosiveseparationofthetirecancauseseriousinjury.
DONOTweldtoawheelorrimuntilthetireiscompletelyremoved.Inatedtirescangenerateagasmixturewith
theairthatcanbeignitedbyhightemperaturesfromweldingproceduresperformedonthewheelorrim.Removing
theairorlooseningthetireontherim(breakingthebead)willNOTeliminatethehazard.Thisconditioncanexist
whethertiresareinatedordeated.ThetireMUSTbecompletelyremovedfromthewheelorrimpriortowelding
thewheelorrim.
Drivingonpublicroadsandgeneraltransportationsafety
Complywithlocallawsandregulations.
Useappropriatelightingtomeetlocalregulations.
MakesureSMVemblemisvisible.
Makesurebrakepedallatchisengaged.Brakepedalsmustbelockedtogetherforroadtravel.
Usesafetychainsfortrailedequipmentwhenprovidedwithmachineorequipment.
Liftimplementsandattachmentshighenoughabovegroundtopreventaccidentalcontactwithroad.
Whentransportingequipmentormachineonatransporttrailer,makesureitisproperlysecured.BesuretheSMV
ontheequipmentormachineiscoveredwhilebeingtransportedonatrailer.
Beawareofoverheadstructuresorpowerlinesandmakesurethemachineand/orattachmentscanpasssafely
under.
Travelspeedshouldbesuchthatcompletecontrolandmachinestabilityismaintainedatalltimes.
Slowdownandsignalbeforeturning.
Pullovertoallowfastertrafctopass.
Followcorrecttowingprocedureforequipmentwithorwithoutbrakes.
Makesuretheboomsarelockedinthecradleswiththelockingpinsprovided.
Fireandexplosionprevention
Fueloroilleakedorspilledonhotsurfacesorelectricalcomponentscancauseare.
Cropmaterials,trash,debris,birdnests,orammablematerialcanigniteonhotsurfaces.
Alwayshaveareextinguisheronornearthemachine.
Makesurethereextinguisher(s)ismaintainedandservicedaccordingtothemanufacturer’sinstructions.
Atleastonceeachdayandattheendofthedayremovealltrashanddebrisfromthemachineespeciallyaround
hotcomponentssuchasengine,transmission,exhaust,battery,etc.Morefrequentcleaningofyourmachinemaybe
necessarydependingontheoperatingenvironmentandconditions.
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INTRODUCTION
Atleastonceeachday,removedebrisaccumulationaroundmovingcomponentssuchasbearings,pulleys,belts,
gears,cleaningfan,etc.Morefrequentcleaningofyourmachinemaybenecessarydependingontheoperating
environmentandconditions.
Inspecttheelectricalsystemforlooseconnectionsorfrayedinsulation.Repairorreplacelooseordamagedparts.
Donotstoreoilyragsorotherammablematerialonthemachine.
Donotweldoramecutanyitemsthatcontainammablematerial.Cleanitemsthoroughlywithnon-ammable
solventsbeforeweldingorame-cutting.
Donotexposethemachinetoames,burningbrush,orexplosives.
Promptlyinvestigateanyunusualsmellsorodorsthatmayoccurduringoperationofthemachine.
Generalbatterysafety
Alwaysweareyeprotectionwhenworkingwithbatteries.
Donotcreatesparksorhaveopenamenearbattery.
Ventilatewhenchargingorusinginanenclosedarea.
Disconnectnegative(-)rstandreconnectnegative(-)last.
Whenweldingonthemachine,disconnectbothterminalsofthebattery.
Donotweld,grind,orsmokenearabattery.
Whenusingauxiliarybatteriesorconnectingjumpercablestostarttheengine,usetheprocedureshownintheoper-
ator’smanual.Donotshortacrossterminals.
Followmanufacturer’sinstructionswhenstoringandhandlingbatteries.
Batterypost,terminals,andrelatedaccessoriescontainleadandleadcompounds.Washhandsafterhandling.This
isaCaliforniaProposition65warning.
Batteryacidcausesburns.Batteriescontainsulfuricacid.Avoidcontactwithskin,eyes,orclothing.Antidote(ex-
ternal):Flushwithwater.Antidote(eyes):ushwithwaterfor15minutesandseekmedicalattentionimmediately.
Antidote(internal):Drinklargequantitiesofwaterormilk.Donotinducevomiting.Seekmedicalattentionimmedi-
ately.
Keepoutofreachofchildrenandotherunauthorizedpersons.
Instructionalseatsafety
Passengersarenotpermittedtorideonthemachine.
Theinstructionalseatistobeusedonlywhentraininganewoperatororwhenaservicetechnicianisdiagnosinga
problem.
Whenrequiredforthepurposesoftrainingordiagnostics,onlyonepersonmayaccompanytheoperatorandthat
personmustbeseatedintheinstructionalseat.
Whentheinstructionalseatisoccupied,thefollowingprecautionsmustbefollowed:
•Machineshouldbedrivenonlyatslowspeedsandoverlevelground.
•Avoiddrivingonhighwaysorpublicroads.
•Avoidquickstartsorstops.
•Avoidsharpturns.
•Alwayswearcorrectlyadjustedseatbelts.
•Keepdoorclosedatalltimes.
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INTRODUCTION
Operatorpresencesystem
Yourmachineisequippedwithanoperatorpresencesystemtopreventtheuseofsomefeatureswhiletheoperator
isnotintheoperator’sseat.
Theoperatorpresencesystemshouldneverbedisconnectedorbypassed.
Ifthesystemisinoperable,thesystemmustberepaired.
Reectorsandwarninglights
Flashingamberwarninglightsmustbeusedwhenoperatingonpublicroads.RefertoChapter5—TransportOper-
ationsforcompleteidenticationandoperatinginstructions.
Seatbelts
Seatbeltsmustbewornatalltimes.
Seatbeltinspectionandmaintenance:
•Keepseatbeltsingoodcondition.
•Keepsharpedgesanditemsthatcancausedamageawayfromthebelts.
•Periodicallycheckbelts,buckles,retractors,tethers,slacktake-upsystem,andmountingboltsfordamageand
wear.
•Replaceallpartsthathavedamageorwear.
•Replacebeltsthathavecutsthatcanmakethebeltweak.
•Checkthatboltsaretightontheseatbracketormounting.
•Ifbeltisattachedtoseat,makesureseatorseatbracketsaremountedsecurely.
•Keepseatbeltscleananddry.
•Cleanbeltsonlywithsoapsolutionandwarmwater.
•Donotusebleachordyeonthebeltsbecausethiscanmakethebeltsweak.
•RefertoChapter4—OperatingInstructionsforproperuseandadjustmentofseatbelts.
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INTRODUCTION
Air-conditioningsystem
Theair-conditioningsystemisunderhighpressure.Donotdisconnectanylines.Thereleaseofhighpressurecan
causeseriousinjury.
Theair-conditioningsystemcontainsgasesthatareharmfultotheenvironmentwhenreleasedintotheatmosphere.
Donotattempttoserviceorrepairthesystem.
Service,repair,orrechargingmustbeperformedonlybyatrainedservicetechnician.
PersonalProtectiveEquipment(PPE)
WearPersonalProtectiveEquipment(PPE)suchashardhat,eyeprotection,heavygloves,hearingprotection,pro-
tectiveclothing,etc.
DoNotOperatetag
Beforeyoustartservicingthemachine,attacha‘DoNotOperate’warningtagtothemachineinanareathatwillbe
visible.
Hazardouschemicals
Ifyouareexposedtoorcomeincontactwithhazardouschemicalsyoucanbeseriouslyinjured.Theuids,lubricants,
paints,adhesives,coolant,etc.requiredforthefunctionofyourmachinecanbehazardous.Theymaybeattractive
andharmfultodomesticanimalsaswellashumans.
MaterialSafetyDataSheets(MSDS)provideinformationaboutthechemicalsubstanceswithinaproduct,safehan-
dlingandstorageprocedures,rstaidmeasuresandprocedurestobetakenintheeventofaspilloraccidental
release.MSDSareavailablefromyourdealer.
BeforeyouserviceyourmachinechecktheMSDSforeachlubricant,uid,etc.usedinthismachine.Thisinformation
indicatestheassociatedrisksandwillhelpyouservicethemachinesafely.FollowtheinformationintheMSDS,on
manufacturercontainers,aswellastheinformationinthismanualwhenservicingthemachine.
Disposeofalluids,lters,andcontainersinanenvironmentallysafemanneraccordingtolocallawsandregulations.
Checkwithlocalenvironmentalandrecyclingcentersoryourdealerforcorrectdisposalinformation.
Storeuidsandltersinaccordancewithlocallawsandregulations.Useonlyappropriatecontainersforthestorage
ofchemicalsorpetrochemicalsubstances.
Keepoutofreachorchildrenorotherunauthorizedpersons.
Additionalprecautionsarerequiredforappliedchemicals.Obtaincompleteinformationfromthemanufactureror
distributorofthechemicalsbeforeusingthem.
Utilitysafety
Whendiggingorusingground-engagingequipment,beawareofburiedcablesandotherservices.Contactyourlocal
utilitiesorauthorities,asappropriatetodeterminethelocationsofservices.
Makesurethemachinehassufcientclearancetopassinalldirections.Payspecialattentiontooverheadpower
linesandhangingobstacles.Highvoltagelinesmayrequiresignicantclearanceforsafety.Contactlocalauthorities
orutilitiestoobtainsafeclearancedistancesfromhighvoltagepowerlines.
Retractraisedorextendedcomponents,ifnecessary.Removeorlowerradioantennasorotheraccessories.Should
acontactbetweenthemachineandanelectricpowersourceoccur,thefollowingprecautionsmustbetaken:
•Stopthemachinemovementimmediately.
•Applytheparkbrake,stoptheengine,andremovethekey.
•Checkifyoucansafelyleavethecaboryouractualpositionwithoutcontactwithelectricalwires.Ifnot,stayinyour
positionandcallforhelp.Ifyoucanleaveyourpositionwithouttouchinglines,jumpclearofthemachinetomake
sureyoudonotmakecontactwiththegroundandthemachineatthesametime.
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INTRODUCTION
•Donotpermitanyonetotouchthemachineuntilpowerhasbeenshutofftothepowerlines.
Electricalstormsafety
Donotoperatemachineduringanelectricalstorm.
Ifyouareonthegroundduringanelectricalstorm,stayawayfrommachineryandequipment.Seekshelterina
permanent,protectedstructure.
Ifanelectricalstormshouldstrikeduringoperation,remaininthecab.Donotleavethecaboroperator’splatform.
Donotmakecontactwiththegroundorobjectsoutsidethemachine.
Mountinganddismounting
Mountanddismountthemachineonlyatdesignatedlocationsthathavehandholds,steps,orladders.
Donotjumpoffthemachine.
Makesuresteps,ladders,andplatformsremaincleanandclearofdebrisandforeignsubstances.Injurymayresult
fromslipperysurfaces.
Facethemachinewhenmountinganddismounting.
Maintainathree-pointcontactwithsteps,ladders,andhandholds.
Nevermountordismountfromamovingmachine.
Donotusethesteeringwheelorothercontrolsoraccessoriesashandholdswhenenteringorexitingthecabor
operator’splatform.
Workingatheights
Whenthenormaluseandmaintenanceofthemachinerequiresworkingatheights:
•Correctlyuseinstalledsteps,ladders,andrailings.
•Neveruseladders,steps,orrailingswhilethemachineismoving.
•Donotstandonsurfaceswhicharenotdesignatedasstepsorplatforms.
Donotusethemachineasalift,ladder,orplatformforworkingatheights.
Spraying
•Besuretocleanandushallresidualchemicalsfromthesprayerbeforechangingtoanothertypeofchemical.
Onsomemodels,itmaybenecessarytoremovetheendcapsfromthespraybarstothoroughlyushtheboom
plumbing.Insomecasesadecontaminationsolutionisrecommendedbythechemicalmanufacturer.
•Alwaysfollowchemicalmanufacturerssafetyinstructionswhenmixingandapplyingherbicidesandchemicalsto
preventseriousharmtopeopleortheenvironment.
•ObserveallFederalandStateEPAregulationsandallLocal,StateandFederalcodesand/orlawsregardingli-
censing,handling,storage,transportation,applicationandwastedisposalofherbicidesorotherchemicals.
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