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1650K
CRAWLER DOZER
Service
Manual
Print No. Bur 6-46470
THIS
ALERTSYMBOLSIGNALS IMPORTANTMESSAGESINVOLVINGYOUR SAFETY.
Read and heed carefully the safety instructions listed and follow the precautions recommended to avoid
potential risks and to safeguard your health and your safety.
You will find this symbol
in
the text of this Manual referred to the following key words:
WARNING -Cautionsdirected
to
avoidimproperrepairinterventionsinvolvingpotentialconsequencesfor
the
safety
of
the
personnelperforming
the
repairs.
DANGER-These warnings qualifyspecificallypotentialdangers for
the
safety
of
the
operatororotherpersons
directlyorindirectlyinvolved.
IMPORTANTNOTICE
All maintenance and repair interventions explained
in
this Manual must be performed exclusively by the Service
Organisation of the Manufacturer, observing strictly the instructions explained using, whenever necessary, the recom-
mended specific tools.
Whoever performs the operations reported without following exactly the precautions
is
responsible
on
his own, for the
damages that may result.
Neither the Factory nor any Organisations
in
its Distribution Network, including but not limited to national, regional or local
distributors, are responsible for any liability arising from any damage resulting from defects caused by parts and/or
components not approved by the Factory for use
in
maintaining and/or repairing products manufactured or merchandised
by the Factory.
In
any case, no warranty of any kind
is
made or shall
be
imposed with respect to products manufactured or merchandised
by the Factory, when failures are caused by the use of parts and/or components not approved by the Factory.
AVOID ACCIDENTS
Most accidents, whether they occur
in
industry,
on
the
farm, at home or
on
the road, are caused bythe failure
of some individuals to follow simple and fundamental
safety rules and precautions. For this reason MOST
ACCIDENTS CAN
BE
PREVENTED by recognising
the real cause and doing something aboiut it before the
accident occurs.
Regardless of the care used
in
the design and
construction of any type of equipment, there are many
conditions that cannot
be
completely safeguarded
against
without
interfering
in
the
reasonable
accessibility and efficient operation.
A careful! operator is the best insurance against
an
accident. The complete observance of one simple rule
would prevent many serious accidents.
The rule is simple: never attempt to clean, lubricate or
maintain a machine while it is
in
motion.
WARNING
Prior to engaging
in
any maintenance, adjustment
or
repair
operation
on
machines
having
hydraulically,
mechanically,
and/or
cable
controlled equipment (such as shovels, loaders,
dozers,excavatorsetc.) becertain theequipmentis
lowered to the ground.
If it is necessary to have the equipment partially or
fully raised to gain access to certain items,
be
sure
the equipment is suitably supported by means
other than the devices used for controlling the
equipment.
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SUMMARY
GENERALITIES SECT. 0
ENGINE SECT. 1
TRANSMISSION SECT. 2
FINAL DRIVES SECT. 3
STEERING -BRAKES SECT. 4
UNDERCARRIAGE SECT. 5
DOZER EQUIPMENT SECT. 6
HYDRAULIC SYSTEM
ELECTRICAL SYSTEM SECT. 7
7
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SUBJECT
SECTION 0
GENERALITIES
TABLE
OF
CONTENTS
PAGE
SAFETY
RULES .......................................................................................................................................1- VIII
TABLE
OF
CAPACITIES .................................................................................................................................. 1
TABLE
OF
CENTRE
OF
GRAVITY
.................................................................................................................. 2
MAIN
DIMENSIONS
........................................................................................................................................ 3
TABLES
OF
TECHNICAL
DATA
........................................................................................................................ 5
CHECK
DATA
ON
THE
MACHINE ...................................................................................................................16
EQUIPMENT
MANOEUVRE
TIMES
...............................................................................................................17
TABLE
OF
WEIGHTS
.....................................................................................................................................18
LEAKAGES
....................................................................................................................................................19
GENERAL
INSTRUCTIONS............................................................................................................................20
DIAGNOSTIC
CHECKS
..................................................................................................................................25
UNITS
OF
MEASURE
....................................................................................................................................26
TABLE
OF
TIGHTENING
TORQUES
...............................................................................................................28
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A WARNING
Study carefully this Manual before starting, operating, maintaining, fuelling or servicing the
machine.
Read and heed all safety rules before any intervention.
SAFETY RULES
Do
not allow unauthorised personnel to operate service
or maintain this machine.
-
Do
not wear rings, wrist watches, jewellery, loose or
hanging apparels, such as ties, torn clothing, scarves,
unbuttoned or unzipped jackets that can catch
on
mov-
ing parts. Wearpropersafetyequipmentas recommend-
ed
for the job. Examples: hard hat, heavy gloves, ear
protection, safety glasses or goggles, reflector vests,
respirator. Consult your employer for specific safety
equipment requirements.
-Keep operator's compartment, stepping points, grab-
rails and handles clear of foreign objects, oil, grease,
mud or snow accumulation to minimise the danger of
slipping or stumbling. Clean mud or grease from shoes
before attempting to mount or operate the machine.
-
Do
not jump on or off the machine. Keep two hands and
one foot, or two feet and one hand
in
contact with step
grab rails and handles at all times.
-
Do
not use controls or hoses as hand holds when
climbing
on
or off machine. Hoses and controls are
movable and do not provide a solid support. Also,
controls may
be
inadvertently moved causing acciden-
tal machine or equipment movement.
-Never attempt to operate the machine or its tools from
any position other than seated
in
the operator's seat.
Keep head, body, limbs, hands and feet inside opera-
tor's compartment at all times, to reduce exposure to
hazards outside the operator's compartment.
Be careful of slippery conditions
on
stepping points,
hand rails, and on the ground. Wear safety boots or
shoes that have a high slip resistant sole material.
-
Do
not leave the machine until it
is
completely stopped.
-Check the seat safety belt at least twice a year.
If
there
are signs of wear or fraying or other signs of weakness
that could lead to failure, replace
it.
STARTING
-NEVER START NOR OPERATE
AN
UNSAFE MA-
CHINE. Before operating a machine, always ensure that
any unsafe condition has been satisfactorily remedied.
-Check brakes, steering and attachment controls before
moving. Advise the proper maintenance authority of any
malfunctioning part or system.
-Be sure all protective guards or panels are
in
place, and
all safety devices provided are
in
place and
in
good
operating conditions.
-Be sure exposed personnel
in
the area of operation are
clear of the machine before moving it orits attachments.
WALK COMPLETELY AROUND the machine before
mounting. Sound horn.
Before starting machine, check, adjust and lock the
operator's seat for maximum comfort and control of the
machine.
-Fasten your seat belt (when provided).
Obey all flag signals and signs.
-Due to the presence
on
the machine offlammable fluids,
never check or fill fuel reservoirs or batteries near open
flames, smoking materials or sparks.
-REMEMBER THAT STARTING FLUID
IS
FLAMMA-
BLE. Follow strictly the recommendations printed on
containers and
in
the Operation and Maintenance
Manual.
-
DO
NOT PUNCTURE OR BURN CONTAINERS.
-Containers must
be
stored
in
fresh, well ventilated plac-
es, out of reach of unauthorised persons. Follow strictly
the instructions provided by the Manufacturer.
-Never use these products near open flames, smoking
materials or sparks.
OPERATION
-
Do
not
run
the engine of this machine
in
closed areas
without proper ventilation to remove deadly exhaust
gases.
-Roll Over Protective Structures are required
on
loaders,
dozers, graders, excavators. NEVER OPERATE ma-
chines without ROPS.
- Make sure the Operator's compartment is free of foreign
objects, especially if not firmly secured. Never use the
machine to transport objects, unless proper securing
points are provided.
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SAFETYRULES
-Check monitoring instruments at start-up and frequently
during operations.
in
case the brake pressure gauge
shows a pressure lower than the minimum operating
pressure, stop immediately the machine .
-DO NOT CARRY RIDERS
ON
MACHINE
-Study and familiarise with escape routes alternate to
normal exit routes.
-Seat belts are required by current regulations to be
provided with Roll Over Protection Structures or cabs.
Keep safety belts fastened around you during operation.
-For your personal protection, do not climb
on
or off
machine while machine
is
in
motion.
- Make sure that exposed persons
in
the area ofoperation
are clear of the machine, before starting the engine and
operating the equipment. Sound horn. Obey all indica-
tions provided by flags and signals.
-NEVER COAST the machine down grades and slopes
with the transmission
in
neutral or neutralised.
Choose and shift into the most appropriate gearto keep
the speed required, thus preventing any loss of control.
-Do not operate machinery
in
a condition of extreme
fatigue or illness. Be especially careful towards the end
of working shift.
-Do not operate machine with brakes out of adjustment.
-Operate the machine at speeds slow enough to ensure
complete control at all times.
-Travel slowly over rough terrain,
on
slopes or neardrop-
offs,
in
congested areas or
on
ice or slippery surfaces.
-When backing, always look to where the machine is to
be moved.
Be
alertto the position ofexposed personnel.
DO NOT OPERATE if exposed personnel enter the
immediate work area. STOP THE MACHINE.
-Maintain a safe distance from other machines. Provide
sufficient clearance for ground and visibility conditions.
Yield right-of-way to loaded machines.
-Maintain clearvision of areas oftravel orwork. Keep cab
windows clean and repaired.
-When machines are operating
in
tandem, the pusher
(rear) must be equipped with the appropriate deflectors
to protectthe unit
in
frontfrom the air streamcoming from
the radiator.
-When pulling or towing through a cable or chain, do not
start suddenly at full throttle; take-up slack carefully.
Inspect carefully for flaws or troubles before using.
Avoid kinking chains or cables. Do not pull through a
kinked chain orcable to the high stresses and possibility
of failure of the kinked area. Always wear heavy gloves
when handling chains or cables.
II
-
Be
sure chains and cables are anchored and the anchor
points are strong enough to handle the expected load.
Keep exposed personnel clear of anchor points and
cables or chains.
DO NOT PULL UNLESS OPERATOR's COMPART-
MENT OF MACHINES INVOLVED ARE PROPERLY
GUARDED AGAINST POTENTIAL CABLE OR CHAIN
BACKLASH.
-
Be
alert to soft ground conditions close to newly con-
structedwalls. Thefill material and weightofthe machine
may cause the wall collapse under the machine.
-
In
darkness, check area of operation carefully before
moving
in
with machine. Use all lights provided.
Do
not
move into area of restricted visibility.
-If engine has a tendency to stall for any reason under
load or idle, report this for adjustment to proper mainte-
nance authority immediately. Do not continue to operate
machine, until condition has been corrected.
-On machinessuppliedwith suction radiatorfans, be sure
to periodically check engine exhaust parts for leaks, as
exhaust fumes are dangerous to the operator.
-
In
caseofclosed typecabs, always keep an opening with
the outside, to ensure a constant air circulation.
-Operators must know thoroughly the performances of
the machine they are operating. When working
on
slopes or near sudden level drops of the terrain, avoid
areas where ground is loose or soft since rolling-over or
loss of control of machine could result.
-Where noiseexposure exceeds 90 dBAfor8 hours, wear
approved ear protection.
-When counterweights are provided, do not work ma-
chine
if
they have been removed.
-Overtaking manoeuvres must be performed only when
absolutely necessary and unavoidable. Beware of pos-
sible uneven terrains, poorvisibilityconditions, the pres-
ence of other machinery or persons out of sight.
-Operatethe machine at aspeed adequatetothe working
conditions
in
the site and slow enough to ensure com-
plete control at all times.
-Neveruse the machineas awork platform orscaffolding,
nor other inappropriate operations (i.e. pushing railway
cars, trucks or other machines).
-
Be
alert of people
in
the operating area of the machine.
-When operating a machine, know
in
advance what
clearances will be encountered, overhead doors, ca-
bles, pipes, bearing load limitations of ground, bridges,
floors or ramps.
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SAFETYRULES
-When roading, find-out what conditions are likely to
be
encountered, clearances, trafficcongestion, type of road
surfacing, etc. Beware of fog, smoke or dust elements
that obscure visibility.
-When crossing gullies orditches, move at
an
angle with
reduced speed after ensuring ground conditions will
permit a safe traverse.
-Explore the working area to identify potential risks such
as:
slopes, overhangs, pits, demolition rubble, fires,
ravines, ditches, softterrain, heavytraffic, crowded park-
ing areas, closed ambients.
In
such conditions, proceed
with extreme care.
-Whenever possible, avoid going over obstacles such as
rough terrain, rocks, logs highly irregular ground, steps,
ditches, railroad tracks. When obstructions must
be
crossed, dosowith extreme care at
an
angle, if possible.
Reduce speed, shift-down. Ease
up
to the break over
point, pass the balance point slowly
on
the obstruction
and ease down
on
the other side.
-
In
steep down-hill operation, do not allowengine toover-
speed. Select proper gear before starting down grade.
-Avoid side hill travel, whenever possible. Drive up and
down the slope. Should the machine slipping sideways,
turn it immediately downhill.
-The grade of slope you should attempt will
be
limited by
factors such as condition of the ground, load being
handled, type of machine, speed of machine and visibil-
ity.
-There
is
no substitute for good judgementwhen working
on
slopes.
Avoid operating equipment too close to
an
overhang or
high wall, either above or below the machine.
Be
on
the
look-out for caving edges, falling objects and slides.
Beware of concealment by brush and undergrowth of
these danger.
When pushing-over trees, the machine must be
equipped with proper overhead guarding. Never allow
a machine to climb
up
on
the root structure particularly
while the tree
is
being felled. Use extreme care when
pushing over any tree with dead branches.
-When pushing trees with dead limbs, proceed with
extreme care. Avoid brush piles, logs or rocks.
-NEVER DRIVE OVER THEM or other surface irregular-
ities that brake traction with the ground, especially when
on
slopes or near drop-offs.
-
Be
alertto avoid changes
in
traction conditionsthatcould
cause loss of control.
DO
NOT DRIVE on ice or frozen
ground conditions when working the machine
on
steep
slopes or near drop-offs.
111
-Working
in
virgin and rough terrains
is
characterised by
the presence of all the perils and risks listed above.
In
these conditions, it
is
emphasised the dangerrepresent-
ed
by large tree limbs (possibly falling
on
the machine),
large roots (acting as a leverage under the machine
when up-rooted causing the roll-over of the unit) etc
..
STOPPING
-When the machine is stopped for whatever reason,
follow the instructions of chapters
"Stopping
the
ma-
chine"
and
"Stopping
the
engine"
ofthe Operation and
Maintenance Instruction Manual.
-Always remember to position the transmission drive
control
in
neutral and engage the control lock to secure
the machine.
-The parking brake
is
automatically set, when the trans-
mission safety lever
is
lowered.
-NEVERLEAVETHE MACHINE UNATTENDEDwith the
engine running.
-Always, before leaving the operator's seat and after
making sure all people are clear of the machine, slowly
lower the attachments or tools flat to the ground
in
a
positive ground support position.
-Return the controls to rest position. Place the gearshift
lever
in
neutral. Disconnect the master switch and ex-
tract the key.
-Park
in
a non- operating and no-trafficarea oras instruct-
ed. Park
on
firm level ground if possible. Where not
possible, position machine at a right angle to the slope,
making sure there
is
no danger of uncontrolled sliding
movements.
-
If
parking
in
traffic lanes cannot
be
avoided, provide
appropriate flags, barriers, flares and signals as
re-
quired. Also provide advance warning signals
in
the
traffic lane of approaching traffic.
-Keep head, body, limbs, feet, fingers orhandsawayfrom
bucket, blade or ripper when
in
raised position.
-Always disconnect the master switch before any inter-
vention (i.e. cleaning, repairing, maintaining, refuelling
etc.).
Do
the same when parking for prolonged periods
of time to avoid accidental or unauthorised starting.
-Never lower attachments or tools other than seated
in
operator's seat. Sound horn. Make sure area near the
attachment
is
clear. Lower the attachment slowly.
DO
NOT USE FLOAT POSITION of hydraulic system.
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SAFETYRULES
-Place masterswitch
in
OFF,
securely blockthe machine
and lock it every time you leave it unattended. Return
keys to authorised security. Heed all shut-down opera-
tions of the Operation and Maintenance Instruction
Manual are followed.
MAINTENANCE
GENERALITIES
-Before operating or performing any intervention
on
the
machine:
•
read
carefully all the rules contained by this Manual;
•
read
and obey all safety related plates and instruc-
tions located
on
the machine.
-
Do
not allow unauthorised personnel to perform any
maintenance operation. Do not perform maintenance
operation without prior authorisation. Follow all recom-
mended maintenance and service procedures.
-Keep operator's compartment free of all loose objects
that are not properly secured.
-
Do
not wear rings, wrist watches, jewellery, loose or
hanging apparels, such as ties, torn clothing, scarves,
unbuttoned or unzipped jackets that can catch
on
mov-
ing parts. Wearpropersafetyequipmentas recommend-
ed
for the job. Examples: hard hat, heavy gloves, ear
protection, safety glasses or goggles, reflector vests,
respirator. Consult your employer for specific safety
equipment requirements.
-
Do
not use controls or hoses as hand holds when
climbing
on
or off machine. Hoses and controls are
movable and do not provide a solid support. Also,
controls may
be
inadvertently moved causing acciden-
tal machine or equipment movement.
-
Do
not jump
on
or off the machine. Keep two hands and
one foot, or two feet and one hand
in
contact with step
grab rails and handles at all times.
-
Do
not perform any service operation
on
the machine
with a person seated
in
the operator's compartment,
unless he
is
an authorised operator co-operating
in
the
operation to
be
performed.
-Keep operator's compartment, stepping points, grab-
rails and handles clear of foreign objects, oil, grease,
mud or snow accumulation to minimise the danger of
slipping or stumbling. Clean mud or grease from shoes
before attempting to mount or operate the machine.
-Keep shoes free of mud or grease before climbing or
driving the machine.
IV
-Never attempt to operate the machine or its tools from
any position other than seated
in
the operator's seat.
-When maintenance operations require moving hydrau-
lically operated attachments by means of machine's
hydraulic system remember that all manoeuvres must
be
made only when seated
in
the operator'sseat. Before
starting machine or moving attachment or tools, set
brakes , sound horn and call for
an
all clear. Raise
attachment slowly.
-Always block booms or parts of the machine which must
be
raised to perform interventions under them with
external devices. Do not allow persons to move into the
vicinities nor standing under equipment not being
blocked. Unless you are totally sure about your safety,
avoid staying under raised equipment, even
in
case it
is
blocked.
-
Do
not place the body, limbs or fingers into sharp articu-
lation uncontrolled openings of the machine and without
proper protections, unless they are blocked
in
a safe
manner.
-Never perform interventions with engine running, ex-
cept as called for
in
a Manual.
Do
notwear loose clothing
or jewellery near moving parts.
-When servicing or maintenance require access to areas
that cannot
be
reached from the ground, use a ladder or
step platform that meet local and national regulations, to
reach the service point.
If
such ladderor platform are not
available, use the machine hand holds and steps as
provided. Perform all service or maintenance carefully.
-Shop and/or field service platforms or ladders must
be
constructed and maintained
in
accordance with local
and national regulations.
-Disconnect batteries and tag all controls according to
current regulationsto warn thatwork
is
in
progress. Block
machineand all attachmentsthat must
be
raised accord-
ing to current regulations.
-Due to the presence of flammable fluids, never check or
fill fuel tanks, batteries, nor use starting fluid nearlighted
smoking materials or open flames.
-Brakes are inoperative when manually released for
servicing. Provisions must be made to maintain control
of the machine by blocking or other means.
-The fuel filling nose must
be
kept constantly inside the
filling neck. Keep this contact from the beginning to the
end of the fuelling operation to avoid the possibility that
sparks due to static electricity are generated.
-Use only designated towing or attaching points. Use
care
in
makingattachments. Makesurepins and/or locks
are secure before pulling. Stayclear of drawbars, cables
or chains under load.
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