OMTD25MEX07_3E
Short Description
Operator manuel TD-25M Extra...
Description
OMTD25MEX07/3E
OPERATOR`S MANUAL
TD-25M EXTRA
TRANSLATION OF ORIGINAL MANUAL SERIAL NUMBER: 75001 AND UP
FOREWORD Welcome to the growing group of value-conscious people who operate DRESSTA machines! This manual covers the instructions for safe operation, lubrications, adjustments and maintenance for normal daily care. These instructions are divided into six sections to simplify your reference to the information most important to you. Refer to the contents page at the beginning of the section for a complete list of the subjects covered except for Section 1, which should be read entirely. This manual has been prepared to help you operate and maintain your machine with utmost efficiency and safety. Read this manual thoroughly and learn your machine before you attempt to operate it. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision. We hope you enjoy operating Dressta machines.
DRESSTA Co. Ltd.
THIS MATERIAL IS PROPRIETARY USED, OR DISCLOSED EXCEPT FROM DRESSTA Co. Ltd. NOT TO BE REPRODUCED, USED, OR DISCLOSED EXCEPT IN ACCORDANCE WITH WRITTEN AUTHORIZATION FROM DRESSTA Co. Ltd. IT IS OUR POLICY TO IMPROVE OUR PRODUCTS WHENEVER IT IS POSSIBLE AND PRACTICAL TO DO SO. WE RESERVE THE RIGHT TO MAKE CHANGES OR ADD IMPROVEMENTS AT ANY TIME WITHOUT INCURRING ANY OBLIGATION TO INSTALL SUCH CHANGES ON PRODUCTS SOLD PREVIOUSLY. DUE TO THIS CONTINUOUS PROGRAM OF RESEARCH AND DEVELOPMENT, PERIODIC REVISIONS MAY BE MADE TO THIS PUBLICATION. IT IS RECOMMENDED THAT CUSTOMERS CONTACT THEIR DISTRIBUTOR FOR INFORMATION ON LATEST REVISION.
CONTENTS 1. INTRODUCTION 2. SAFETY PRECAUTIONS 3. MACHINE TRANSPORT AND STORAGE 4. OPERATING 5. MAINTENANCE 6. SPECIFICATIONS
SECTION INDEX SECTION 1 – INTRODUCTION This section discusses the use of this manual, serial number locations. SECTION 2 – SAFETY PRECAUTIONS This section lists safety rules concerning personal safety. Read this section carefully! Maintain this manual and review it frequently for continuing safe operation and instructing new operators. SECTION 3 – MACHINE TRANSPORT AND STORAGE This section discusses how to ship or store this machine. SECTION 4 – OPERATING The front portion of this section provides you with instructions for trouble free operation of the machine, machine precautions and a universal symbol chart, text and illustrations for instruments and controls. The instrument and controls area is designed to tell you “where it is, what it does and how to use it”. Read this area carefully. The remaining portion of this section outlines and illustrates the step-by-step procedures for starting, operating and stopping the machine and discusses a few operating suggestions and techniques and simple ideas to help ease the work and lengthen the useful life of your machine. SECTION 5 – MAINTENANCE The beginning of this section outlines a complete scheduled maintenance program, which helps to reduce down-time and expense, and increase the profit and work from your machine. Read and use this area. Following the maintenance program are the lubrication recommendations and requirements for the machine. The remainder of the section is devoted to clearly explaining the “how to” of the many maintenance and adjustment procedures listed in the maintenance program. The explanations are prepared in an easy style to help you “do it yourself” and get it right. SECTION 6 – SPECIFICATIONS This section covers the diagrams, general dimensions and weights, refill capacities, ground speeds and the standard and special torque values.
SECTION CONTENTS 1.
INTRODUCTION
1.1. Introduction............................................................................................................................... 3 1.2. Serial Numbers......................................................................................................................... 4
2.
SAFETY PRECAUTIONS
2.1. General .................................................................................................................................... 3 2.2. Before Starting the Engine ...................................................................................................... 5 2.3. Operation.................................................................................................................................. 6 2.4. Maintenance ............................................................................................................................. 8 2.5. When Parking ........................................................................................................................ 11 2.6. Safety Product Graphic Location ........................................................................................... 12 2.7. Additional Information............................................................................................................. 18
3.
MACHINE TRANSPORT AND STORAGE
3.1. Machine Transport ................................................................................................................... 3 3.2. Lifting Machine on Slings ......................................................................................................... 4 3.3. Moving a Disabled Machine ..................................................................................................... 5 3.4. Machine Storage ...................................................................................................................... 7
4.
OPERATING
4.1. Machine Precautions ............................................................................................................... 3 4.2. Universal Symbols for Instruments and Controls .................................................................... 4 4.3. Instrument Panels .................................................................................................................... 6 4.4. Cab Controls .......................................................................................................................... 13 4.5. Controls and Adjustment ....................................................................................................... 14 4.6. Starting the Engine ................................................................................................................. 21 4.7. Stopping the Engine ............................................................................................................... 26 4.8. Engine Proper Operation Rules ............................................................................................. 27 4.9. Driving the Machine................................................................................................................ 27 4.10. Machine Speed and Direction Changes ................................................................................. 28 4.11. Converter Overheating ........................................................................................................... 32 4.12. Downgrade Operation ............................................................................................................ 32 4.13. Operating Over an Obstruction ............................................................................................. 32 4.13A. Allowable Water Immersion ................................................................................................ 32 4.14. Stopping the Machine ............................................................................................................ 33 4.15. Parking the Machine............................................................................................................... 34 4.16. Operating Mounted Equipment .............................................................................................. 34 4.17. Positioning the Blades ............................................................................................................ 37 4.18. Operating Techniques ............................................................................................................ 45 4.19. Economical Operation of the Machine ................................................................................... 54
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5.
MAINTENANCE
5.1. Service Precautions .................................................................................................................. 3 5.2. Scheduled Maintenance Guide ................................................................................................ 4 5.3. Maintenance and Service Chart ............................................................................................... 7 5.4. Lubrication .............................................................................................................................. 10 5.5. Seasonal Preparation ............................................................................................................. 12 5.6. Air Intake System (Air Cleaning) and Exhaust System .......................................................... 14 5.7. Belts ........................................................................................................................................ 18 5.8. Cooling System ...................................................................................................................... 19 5.9. Fan ......................................................................................................................................... 24 5.10. Electric System ....................................................................................................................... 24 5.11. Engine .................................................................................................................................... 27 5.12. Fuel System ............................................................................................................................ 32 5.13. Hydraulic System .................................................................................................................... 35 5.14. Lubricating Fittings ................................................................................................................. 41 5.15. Mounted Equipment ............................................................................................................... 45 5.16. Safety Belt .............................................................................................................................. 53 5.17. Final Drives ............................................................................................................................. 53 5.18. Drive Train .............................................................................................................................. 54 5.19. Undercarriage ......................................................................................................................... 59 5.20. Adjusting Hand and Foot Controls .......................................................................................... 64 5.21. Cab and ROPS ....................................................................................................................... 66 5.22. Windshield Washers ............................................................................................................... 68 5.23. Utility Box ................................................................................................................................ 69 5.24. Servicing the Air Conditioner .................................................................................................. 69
6.
SPECIFICATIONS
6.1. Application ...............................................................................................................................3 6.2. Technical Description ..............................................................................................................3 6.3. Specifications ..........................................................................................................................5 6.4. Refill Capacities .......................................................................................................................9 6.5. Special Torque’s ................................................................................................................... 10 6.6. Torque Valves for Standard Metric Fasteners ...................................................................... 11 6.7. Torque Values for Standard English Fasteners .................................................................... 12 6.8. Torque Values for Split Flange Connections ........................................................................ 12 6.9. Torque Values for Hydraulic Tubes and Fittings ................................................................... 13 6.10. Torque Values for Hose Clamps .......................................................................................... 13 6.11. Torque Values for Air Conditioning Tubes and Fittings ........................................................ 14 6.12. Torque Values for Air Conditioning O-Ring Connections ..................................................... 14 6.13. List of Service Tools ............................................................................................................. 15 6.14. Cinematic Schematic ............................................................................................................ 17 6.15. Drive Train Hydraulic Schematic .......................................................................................... 18 6.16. Equipment Hydraulic System Diagram ................................................................................. 19 6.17. Wiring Diagram ..................................................................................................................... 22
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SECTION 1 INTRODUCTION
INTRODUCTION
SECTION 1
SECTION CONTENTS
PAGE 1.1. INTRODUCTION ............................................................................................................................ 3 1.2. MACHINE MARKING ..................................................................................................................... 4
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INTRODUCTION
SECTION 1 PAGE 3
1.1. Introduction
Fig. 1.1. Crawler Dozer TD-25M EXTRA 1. Right Hand Side of the Machine 2. Left Hand Side of the Machine
3. Front of the Machine 4. Rear of the Machine
General Throughout this manual there will be two types of cross references. One type is to a heading within the same section. The others to a heading in another section. Unless it is otherwise stated, references will be to the same section. Refer to the section contents page at the beginning of the individual sections for specific page numbers. Some illustrations are of general application and may not show your machine accurately in all details. Throughout this manual the use of the terms: “left”, “right”, “front”, and “rear” must be understood to avoid confusion when following instructions. The dozer TD-25M EXTRA can be equipped with one of the below described hydraulic systems for the blade control: 1. 2. 3.
blade tilt control system D2, blade tilt and pitch control system D2, blade tilt control system G2.
In addition to that the dozer can be equipped with the ripper: 1. single shank ripper 2. multishank ripper. as well as hydraulic control for ripper point lock pin shifting.
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INTRODUCTION
These terms indicate the sides of the machine when facing forward in the operator's seat. The three following symbols and text in bold letters are used throughout this manual to call your attention to instructions concerning your personal safety: DANGER! This symbol and text in bold letters is used throughout this manual to call your attention to an emergency which, if not avoided, will result in injury or death. WARNING! This sign indicates an emergency which, if not avoided, may result in injury or death. CAUTION! This symbol and text in bold letters is used throughout this manual to call your attention to an emergency which, if not avoided, may result in minor or slight injury. The two following signs and text in italics are used throughout this manual to call your attention to important procedures or steps having influence on the right functioning of a machine. Failure to follow such instructions may result in the damage of a machine or affect machine's lifetime. IMPORTANT: This sign and text in italics is used throughout this manual to call your attention to key problems for machine operation. Failure to follow such instructions may result in damage of a machine and heavy material losses. NOTE: This sign and text in italics is used throughout this manual to call your attention to an important function having influence on the right functioning of a machine or for informational purposes.
1.2. Serial numbers
Fig. 1.2. Machine Serial Number
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Fig. 1.3. Machine Serial Number on RMF
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INTRODUCTION
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The serial number is stamped on a plate attached to the front wall of the control console at the left hand side of the operator’s seat (Fig. 1.2). It is also stamped on the upper rear corner of the main frame at the right hand side under the fender (Fig. 1.3).
Fig. 1.4. Blade Serial Number The blade serial number is stamped on the back of the blade, near the top right hand corner (Fig. 1.4).
Fig. 1.5. Ripper Serial Number
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INTRODUCTION
Fig. 1.6. Engine Serial Number Plate The engine serial number and performance are placed on a front plate attached on the left hand side (Fig. 1.6). All other components having serial numbers are equipped with a separate serial number plate. Use serial numbers when requesting information or ordering parts and proper numbers from Parts Catalogue and the product serial number.
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SECTION 2 SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
SECTION 2
SECTION CONTENTS
PAGE 2.1. GENERAL ..............................................................................................................................3 2.2. BEFORE STARTING THE ENGINE.......................................................................................5 2.3. OPERATION ..........................................................................................................................6 2.4. MAINTENANCE .....................................................................................................................8 2.5. WHEN PARKING .................................................................................................................11 2.6. SAFETY GRAPHIC LOCATION ...........................................................................................12 2.6.1. SAFETY GRAPHICS ..................................................................................................14 2.7. ADDITIONAL INFORMATION ..............................................................................................18
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SAFETY PRECAUTIONS
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WORK SAFETY – FOLLOW THESE RULES
2.1. GENERAL This symbol and text with bold letters is used throughout this manual to call your attention to instructions concerning your personal safety. Observe and follow these instructions. Be certain anyone operating and servicing this machine is aware of these rules. Failure to follow these rules may result in injury or death.
WARNING! The machine can only be operated by a person who is familiar with this manual, knows operation of the machine and its mechanisms, experienced and properly licensed to operate such machines. The instructions and information given in this section do not cover all you ought to know to operate the machine safely. Detailed instructions regarding operational safety appear in the following sections of this manual. Carefully observe and follow all instructions provided in this manual. Human error is an important factor in most equipment-related injuries. Haste, carelessness and lack of training are the primary causes of injuries. Most operating injuries occur because of excessive speed, loss of control, failure to observe warning signs, slipping or falling while entering for dismounting, a lack piles on roadways, lack of a ROPS or seat belt, or not watching in the direction of travel.
Most maintenance injuries occur during welding or when using hammers or wrenches. The
most common faults are: improper work position, a slipped tool, missed aim, a broken tool, flying chips and no welding hood.
Think before you act. A careful operator or maintenance man is the best insurance against an accident. Always wear proper safety equipment. Avoid wearing jewelry and loose fitting clothing; they could catch on moving parts, which could result in serious injury or death. Hard hat, sturdy rough-soled work shoes or safety shoes, ear protectors, reflective clothing, safety glasses and heavy gloves may be required. Each job site and application may have personal safety requirements. Carefully evaluate your particular application and machine for equipment such as: heater and defroster, all windshield wipers, warning lights, side view and rearview mirrors, back-up alarms, fire extinguisher, rotating beacons and additional lights. If in doubt, contact Authorized Distributor of Construction Equipment. It is recommended that the machine be equipped with a fully charged fire extinguisher and the first aid kit. All personnel should be instructed in fire extinguisher proper usage. Recharge immediately after use.
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SAFETY PRECAUTIONS
The fire extinguisher is to be placed in a operator’s cab to the right of his seat, on a platform – (Fig. 2.1). The fire extinguisher is to be secured in its holder to prevent its displacement while the machine is in motion. In case of fire the fire extinguisher is easy to get hold off. The fire extinguisher plate provides you with how to use (put into operation) the extinguisher and its designation. The operator is to be trained and familiar how to operate the fire extinguisher.
Fig. 2.1. Fire Extinguisher Location in Machine Electrical system is 24-volt negative ground. Each machine is equipped with a booster receptacle that is to be used during the engine start up with a booster battery. When the use of the booster receptacle socket is impossible in out-of-normal situations, follow the precautions given below to prevent chances of injury or damage to electrical circuits: 1. Turn the electrical master switch to the OFF position. 2. Attach one end of jumper cable to the positive terminal (+) of booster battery and other end to the positive terminal of machine battery. 3. Attach one end of second cable to the negative terminal (-) of booster battery and other end to the
machine's ground terminal away from the battery.
4. To remove cables, reverse above sequence exactly to avoid sparks near the battery. A frozen battery can explode when the booster cables are attached. NEVER check battery charge by placing a metal object across the battery posts. The sparks could cause an explosion. Use a voltmeter or aerometer for checking. Every machine is factory equipped with a safety belt mounted to the operator’s seat.
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SAFETY PRECAUTIONS
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2.2. BEFORE STARTING THE ENGINE Never start the engine indoors unless proper exhaust ventilation is provided to remove deadly exhaust gases. Once the engine is operating, move the machine outdoors as soon as possible. Exhaust gases are dangerous and can cause unconsciousness and death. Apply the parking brake before starting the engine. Place the drive train neutral lock lever in locked position. Drive train control lever should be placed in neutral position. The operator must be alert, physically fit and free from the influences of alcohol, drugs or medications that might affect his eyesight, hearing, reactions or judgment. Observe and know the use of alternate exits from the operator compartment. Safety must always be the operator's most important concern. He must refuse to operate when he knows it is unsafe and consult his supervisor when safety is in doubt. Do not jump onto or of the machine. When mounting or leaving the machine always use two feet and one hand or one foot and two hands to ensure contact with machine steps, holders or rails. Do not use controls or hoses as hand holds when climbing on or off the machine. Hoses and controls can move and do not provide solid support. Movement of the controls may cause inadvertent and unexpected movement of the machine or its equipment. Follow all machine-mounted safety signs before starting, operating, maintaining or servicing the machine. The area of the operator's compartment, all mounting steps and grab handles are free of oil, grease, loose objects, ice and mud to lessen the possibility of slipping. Remove or secure all maintenance and personal items so they will not interfere with the operator or jam the controls. Perform a visual check of the machine before starting the engine. Look for such things as improper fluid levels, oil leaks, and loose, damaged or missing parts. Do not start the engine until any unsafe conditions are corrected. Secure all caps and filler plugs. Know and understand the traffic flow patterns of your job and obey flagman, signs and signals. Before entering the operator's compartment, clear the immediate area surrounding the machine of personnel and obstructions. Walk completely around the machine. After entering the operator's compartment, sound the horn to clear the immediate area of the machine. Due to the danger of fire and explosion, never check or fill fuel tank or batteries near lighted smoking materials or open flame or sparks.
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SECTION 2 PAGE 6
SAFETY PRECAUTIONS 2.3. OPERATION
Check the work area for hazardous conditions. Be alert for soft ground conditions, especially when working on slopes, near drop-offs or excavations or fill material, which could lead to sudden land collapse and tipping of the machine. At night and at times of poor visibility, carefully check the work area before moving in with the machine. Use all lights provided. Keep the windshield, windows and mirrors (if equipped) clean. Before starting the engine, be sure you understand all control functions. Check all controls, including the brakes, decelerator, steering and transmission. Check all gauges, warning lights and safety devices. Correct malfunctions if any. Only one person, the operator, should be permitted to ride on the machine when it is in operation. Perform an operational check of the machine in a safe area before putting it to work. Keep operating controls, hands and shoes free of grease, water and mud to insure positive control functions. If the machine is ROPS equipped, for your personal protection, wear your seat belt. Before driving the machine, adjust the seat and fasten the seat belt. Adjust the seat belt to fit snugly and flow around the hips to lessen the chance and severity of injury in the event of an accident. Never wear the seat belt across the abdomen. Check overhead clearance carefully before operating the machine in areas with low overhead clearance, such as guy wires, power lines, bridges, low-hanging tree branches and building entrances or exits. These overhead obstructions could cause an accident. After starting the engine, but before moving the machine, warn nearby personnel by giving a couple of short horn blasts. Be sure that the rear screen is securely fastened to the ROPS structure before operating the winch. Operating without correctly installed screen could result in serious injuries. Operate the winch from the driver’s seat only. Always engage the parking brake before winching if the machine is stopped., Use caution when installing or removing cable from the winch. Keep all persons clear of a cable under tension. Never use a cable that is damaged. Failure to follow these instructions could result in serious injuries. Never mix gasoline, gasohol and/or alcohol with diesel fuel. This practice creates an extreme fire hazard and under certain conditions an explosion, which could result in personal injury or death. Do not smoke when refueling or servicing the machine. A fire could result. Never place gasoline or diesel fuel in open pan. Never remove the fuel tank filler caps or refill the fuel tanks while the engine is running or hot or when the machine is indoors. Fumes are dangerous, a spark or flame could result in a fire or explosion. On machines equipped with a suction fan or a reversible fan in the suction position, periodically check the engine exhaust system for leaks. Exhaust gases are dangerous to the operator.
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Do not operate the machine in a condition of extreme fatigue or illness. Be sure that the rear screen is securely fastened to the ROPS structure. Be sure cables and their anchor points are strong enough to handle the expected load. Inspect carefully chains and cables for flaws before using them. Always wear gloves when handling cables. Avoid looping or knotting a cable. Do not pull with a kinked cable as excessively high stress in bent area may cause cable failure. Cables for towing or winching should be fastened to attachment points designed to this purpose only. Be sure the attachment pins are securely inserted immediately before pulling with the cable. Stand clear of cables under load. Keep engine exhaust system and exhaust manifold clear of combustible material for your personal protection. Know the locations of underground cables, water mains, gas lines, etc. A ruptured gas line or cut electrical cable could result in personal injury or death. When leaving the machine unattended for any length of time, make sure mounted equipment is completely lowered, the engine is stopped, the parking brake is applied, and the electrical master switch is in the “off” position and drive train control lever is locked in neutral position. If the machine is equipped with a cab make sure that the cab door is locked. Before operating the machine read and know the Operator’s Manual. Know the ALL SAFETY GRAPHICS. The roll-over protective structure (ROPS) provides the operator’s protection in the event of machine rollover or upset. This structure is designed to bend during rollover to protect the operator from sudden impact loads. When operating the machine, look in the intended direction of travel and the immediate machine operational area to be sure personnel or allied equipment does not interfere with the machine work pattern and not to make serious accident. Never try to get on or off the machine while it is moving. A serious injury or death could result. Never shift the transmission into neutral (N) when traveling downhill. The machine may go out of control and a rollover could result or the transmission, torque converter or engine could be damaged when the transmission is again placed in gear. Always put the transmission in low range before starting downhill. Use the decelerator and brake pedal to slow the machine. Avoid side hill travel whenever possible. Drive straight up and down the slope. If the machine starts slipping sideways on a grade, turn downhill immediately. If possible avoid crossing obstacles such as ridges, rocks or logs. If you can't avoid them, reduce speed and ease over the obstacle at an angle. A machine's weight and the vibration it creates can cause the edge of a high wall to collapse. Keep your machine away from the edges of banks and excavations. If it is not possible to avoid turn the machine front towards the bank edge or excavation.
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SAFETY PRECAUTIONS
Travel slowly in congested areas or on rough ground, slopes or near drop-offs or on snow, ice or slippery surfaces. Maintain a safe distance between your machine and other vehicles according to the condition of the road and load. Never hold the hydraulic controls in their extreme position after the equipment has reached its maximum travel. This could cause overheating of the hydraulic system. Do not adjust the seat position while the machine is in motion. A loss of control may result. Completely stop the machine, apply and lock the parking brake and then adjust the seat. Never use the blade as a brake except in an emergency. Carry the blade low for maximum stability and visibility. Where noise exposure during machine exploitation or after repair operations exceeds levels defined by proper health and safety authorities and applicable standards wear authorized ear protective equipment.
2.4. MAINTENANCE Servicemen and their helpers only are allowed to remain at operator’ s post while maintaining or repairing the machine. Authorized personnel only is allowed to control, maintain or repair a machine. Do not hurry. Haste could result in accident. Load things into the machine from the ground level before mounting the machine. Take care before removing the engine radiator filler cap. Loosen the radiator cap slowly to relieve all pressure in the system and use caution when removing the caps. Have the blade and ripper raised, shut the engine off and relieve all hydraulic system pressure by moving blade and ripper control lever several times in various directions before removing any hydraulic component from a machine without the blade pitch. When a machine is equipped with a blade pitch, on top of that have the starting switch turned to a position (1, Fig. 4.3A), Section 4, depress the blade pitch button and move the blade control lever several times in various directions. Then lower equipment on the ground. Never work beneath the blade and/or ripper without proper blocking. Improper blocking could result in serious injuries. When service or maintenance requires access to areas that cannot be reached from the ground, use a ladder or platform. If such ladders or platforms are not available, use the machine hand holds and steps provided. Perform all service or maintenance carefully. Use only approved parts for repairs and maintenance show in your parts catalog. Failure to do so could compromise your personal safety and machine performance and reliability. Never align holes with fingers or hands. Use a proper aligning tool. Be sure all used tools are in good condition. Do not use tools which are worn, bent or have mushroomed heads. Use the proper tool for the job. Remove sharp edges and burrs from reworked parts. TD-25M EXTRA
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SAFETY PRECAUTIONS
For field service, move machine to level ground if possible and blocks the tracks. If work is absolutely necessary on an incline, block the machine and its attachments securely. Move the machine to level ground as soon as possible. Before working on the machine, turn OFF the electrical system master switch and remove the starting switch key so no one will start it unexpectedly. Do not carry loose objects in pockets that might catch on the machine or fall unnoticed into open compartments. Before working on any part of the engine or electrical system, disconnect the battery ground cable. Tag the cable and all controls to alert personnel that work is in progress. When it is necessary to make any checks or adjustments with the engine operating, always use two people. One trained person must be in the operator's seat to safeguard the second person making the checks or adjustment. As an added precaution, when making checks or adjustments with the engine operating, apply the parking brake. Never stand on the tracks or near the blade while the engine is operating. If the engine is running and the side doors are open or removed be careful of rotating parts such as the fan and belts that can cause serious injury. Do not clean or lubricate the machine subassemblies while the engine is operating. The parts in motion when contacted can cause personal injury. Use a non-toxic, nonflammable commercial solvent for cleaning parts, unless otherwise specified. Never use gasoline, diesel fuel, kerosene or other flammable solvents for cleaning part. Excessive or repeated skin contact with sealant or solvents may cause skin irritation. In case of skin contact, remove sealant or solvent promptly by washing with soap and water. Follow the manufacturer’s advice whenever cleaning agents or other chemicals are used. Lower blade and ripper before making hydraulic adjustments. To prevent personal injury, be sure no personnel are standing in the way of the blade and/or ripper when it is being lowered. Never allow anyone to walk under or be near unblocked raised equipment. Provide proper ventilation when operating in a closed building to avoid danger of exhaust gases. Exhaust gases are dangerous and can cause unconsciousness and death. Exhaust gases are dangerous and can cause unconsciousness and death. Hydraulic fluid escaping under pressure from a very small hole can be almost invisible, yet have sufficient force to penetrate the skin. Use a piece of cardboard or wood to search for suspected leaks. Do not use hands. If injured by escaping fluid, see a doctor at once. Serious infection or reaction can occur if proper medical treatment is not administered immediately. Wear proper protective equipment such as goggles or safety glasses with side shields, hard hat, safety shoes and heavy gloves when metal or other particles are apt to fly or fall. Lift and handle all heavy parts with a lifting device of proper capacity. Be sure parts are secured by proper slings and hooks. Use lifting eyes if provided. Warn people in the area to stand clear. DRESSTA
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SAFETY PRECAUTIONS
Do not attempt to repair the ROPS protective structure after an accident. Repaired structures do not provide the original strength and protection. Contact your distributor for information on structure replacement. Do not operate the machine until ROPS replacement is done. Do not cut, drill, weld, grind the ROPS protective structure as all these operations have a detrimental effect on its structure and safety. When using compressed air for cleaning parts, wear goggles or safety glasses with side shields. Use a air nozzle, which limits the pressure to 200 [kPa]. Do not use an open flame to check for leaks or fluid levels anywhere around the machine. Keep work area clean and dry. Remove oil and water spills immediately. Do not pile up oily or greasy rags. They are a fire hazard. Store them in an approved, closed metal container. Use a soft iron or nonferrous hammer to install or remove ripper point. It is dangerous to hammer on the point. Wear safety glasses with side shields or goggles to reduce the chances of injury. Batteries give off a highly inflammable gas. Never allow sparks or open flame near the batteries. A fire or explosion could occur. Do not charge batteries in a closed area. Provide proper ventilation to guard against accidental explosion of an accumulation of the explosive gas given off in the charging process. When installing batteries, electric system master switch must be disconnected. Connect positive cable to positive terminal of the battery first and then negative cable (ground) to negative terminal of the battery. Ether starting fluid is flammable. Follow the precautions printed on the container. An explosion can result if sparks or flame contact the ether in the container or if the container is stored in an area in which the temperature exceeds 70 [°C]. Observe the following precautions: 1. Follow the correct method for starting the engine. Refer to "STARTING THE ENGINE" in
Section 4.
2. Do not use the ether injector when the ambient temperature is above freezing. 3. For your own personal safety, always remove the ether container when welding, grinding or fusing a torch on the machine. 4. Do not let ether come in contact with your skin, as it can cause localized freezing. 5. Do not breathe the hazardous ether vapor. Keep the fluid container out of the reach of children.
6. Keep the fluid container out of the reach of children. 7. Never puncture the fluid container or put it into a fire. Dispose of empty container as per attached
instruction to the container.
8. Do not store fluid containers in the operator's compartment. Never mix gasoline, gasohol and/or alcohol with diesel fuel. This creates an extreme fire or explosion hazard, which could result in personal injury or death. Do not use bleach, color dye or solvents on the seat belt webbing. This may cause a severe loss of tensile strength. This could cause the webbing to break resulting in personal injury. It is recommended that the seat belt be cleaned only with warm water and mild detergent.
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2.5. WHEN PARKING If parking on or near traffic lanes cannot be avoided, provide appropriate flags, barriers, flares and warning signals. Also provide advance-warning signals in the traffic lane for approaching traffic. Park the machine in a non-operating and non-traffic area. Park machine on level ground whenever possible. If you must park on a slope, park at right angles to the slope. Apply the parking brake. Never leave the machine unattended with the engine running. When leaving the machine unattended, slowly lower the hydraulic equipment to the ground, shift the drive train control lever into neutral and lock the lever in this position, shut off the engine and apply the parking brake. Turn off the electrical system master switch. Take the keys out both from the electrical system master switch and the starter switch. Always lock up machine when leaving it unattended, including any anti-vandalism attachments. Do not jump off the machine. When operating in bad weather and storm lightening is nearby, dismount and seek shelter away from the machine. Lightening will be attracted to the machine and can cause serious injury or death. When the machine is to be loaded onto a transport truck and trailer do so carefully. Load only when the trailer is level. The steel track shoes will slide easily on the trailer. When the machine is properly positioned tie it securely with a rope and block with wooden pieces so it cannot move on the trailer. Keep your head, body, legs, hand, fingers away from the blade and ripper when they are in a raised position. Do not allow the hydraulic system to support the mounted equipment without its proper blocking when leaving the machine unattended, to eliminate the possibility of unexpected drop of the blade or ripper.
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SAFETY PRECAUTIONS 2.6. SAFETY GRAPHIC LOCATION
Fig. 2.3. Safety Graphic Location – Machine 1. Engine Guard Door 2. Track Tensioner
Fig. 2.3. Safety Graphic Location – Machine 1. Engine Guard Door 3. Pressurized Reservoir Caution 8. Before Undoing the Radiator Cap 9. Safety Belt
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Fig. 2.4. Safety Graphic Location – Machine 6. ROPS
10. Battery Cables
W
Fig. 2.5. Safety Graphic Location – Cab 4. What to do Before Leaving Operator’s Seat 5. Safe Servicing 7. What to do Before Starting Machine
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2.6.1. SAFETY GRAPHICS The machine is provided with safety graphics (pictograms) what positively identify hazards involved. The section which follows will explain the hazards presented in the graphics and a way how to cope with them.
Fingers or palm can be cut off with engine fan drive belt components, or fingers or palm can be burned with engine hot exhaust system parts. Shut off the engine and remove the key from the starting switch before performing maintenance or repair work. Wait until the engine exhaust gets cool.
Decal 1. Safety Graphics – Engine Guard
High-pressure spray – Erosion of flesh. Pressurized reservoir. The reservoir is to be top off to allowable level only. Loosen the reservoir fill cap before removal of any hydraulic system component.
Safety Sign 2 – Pressurized Reservoir
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DANGER The grease high pressure is held by the safety and check valves and can cause serious injury or death. •
•
When adjusting track tension, turn safety and/or check valves ONE TURN only. Turning a valve further could cause a valve to fly off and hurt you. If loosening valves two and half turns does not relief track tension, contact Authorized Distributor for track repair. Decal 3
High-pressure spray – Erosion of flesh. Cooling system pressure. Shut the engine off, remove the key from the starting switch and remove slowly the filler plug before attempting any service or repair operation.
Decal 4. Safety Graphics – Cooling System
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Danger of gas explosion produced during the battery charging. Charge the battery with an open cover, away from open fire and sparks. Do not charge the battery in closed or unventilated room.
Decal 5. Safety Graphics - Battery
Falling from high place DO NOT stay and remain on machine areas marked with this sign. USE extra platforms or ladders to provide access for maintenance and repair.
Decal 6. Safety Graphics - Danger of Accident at Work
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Run over/ back over - dozer. Stay a safe distance of the dozer when the engine is running.
Decal 7. Safety Graphics – Run over
Death or serious injury can result with machine operated and serviced unduly, and by untrained operator or unauthorized individuals. Do: 1. Read and understand the Operator’s Manual before starting the operations. 2. Adhere to safety rules and recommendations provided in the Operator’s Manual. 3. Lower equipment to the ground, apply parking brake and shut the engine off prior to service and inspection works. 4. ROPS structure, which was involved in machine rollover accident, was repaired or modernized – is to be replaced by a new installed as described by the manufacturer assembly instruction. Do NOT start, road and operate the machine if untrained or unauthorized. Decal 8. Safety Graphics - Regulations
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CAUTION • •
•
Safety belt is always to be fastened during machine operation. Every time check the condition of safety belt, its brackets and mounting bolts before fastening safety belt. Position operator’s seat in place that will make possible to press the brake pedal all its stroke with your back against the seat. Decal 9
2.7. ADDITIONAL INFORMATION The equivalent noise level for a new machine at the operator’s seat (cab) measured according to ISO6396 Standard does not exceed an admitted value of 85 [dB(A)]. The equivalent weighted vibrations acceleration level measured at the operator’s seat in conditions defined according to PN-EN 1032:2003 Standard does not exceed a value of 0,5 [m/sec2] in any direction. The equivalent weighted vibrations acceleration level measured at the control levers for travel direction and blade control, measured as described above does not exceed a value of 2,5 [m/sec2]. The equivalent weighted vibrations acceleration level measured at the control levers for travel direction and blade control, measured as described above does not exceed a value of 2,5 [m/sec2].
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SECTION 3 MACHINE TRANSPORT AND STORAGE
MACHINE TRANSPORT AND STORAGE
SECTION 3
SECTION CONTENTS PAGE
3.1. MACHINE TRANSPORT ............................................................................................................ 3 3.1.1. GENERAL .......................................................................................................................... 3 3.1.2. TRUCK ............................................................................................................................... 3 3.1.3. RAILROAD FLAT CAR ....................................................................................................... 4 3.2. LIFTING MACHINE ON SLINGS................................................................................................ 4 3.3. MOVING A DISABLED MACHINE ............................................................................................. 5 3.4. MACHINE STORAGE ................................................................................................................ 7 3.4.1. PREPARING FOR STORAGE ............................................................................................ 7 3.4.2. SERVICING MACHINE DURING STORAGE ..................................................................... 9 3.4.3. PREPARING FOR OPERATION ...................................................................................... 10
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MACHINE TRANSPORT AND STORAGE 3.1. MACHINE TRANSPORT 3.1.1. GENERAL
IMPORTANT: When shipping this machine by high-speed means of transport secure the air intake cap and the exhaust outlet to protect the turbocharger from damage. Turn the system master switch to the OFF position. Turn the system master switch to the OFF position. WARNING! When transporting a machine, use caution when loading and unloading. Load and unload a machine in a level area which fully supports the machine and the transport vehicle. Block the transport vehicle so it cannot move. Use loading ramps of adequate strength, low angle (15 [°] max.) and proper height and width. Remove all dirt from the machine undercarriage to prevent the machine from skidding while loading. Under no circumstances the travel direction change is allowed while on the ramp. For the machine travel direction change leave the ramp, alter the direction as needed and re-ascend the ramp.
3.1.2. TRUCK When shipping this machine by truck learn obligatory regulations. Contact local authorities for the proper shipping and loading regulations. When preparing to transport the machine by truck, have truck and trailer level. 1. Use ramps or loading dock to maintain stability. 2. Drive the machine in its lowest gear. 3. Use the lowest engine RPM that will move the machine and not stop the engine. 4. The machine can be "inched" into place. Be careful otherwise the machine will skid. 5. When the machine is properly located, lower the mounted equipment, stop the engine, place drive train control lever in NEUTRAL, apply the safety lock lever and apply and lock the brake with a lock knob, turn the electrical system master switch to the OFF position, remove the keys from both the starting and master switch. 6. Tie the machine down securely to prevent unintentional movement and block it at the front and rear with wooden props.
Fig. 3.1. How to Secure the Machine 1. Wooden Block DRESSTA
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DANGER! Failure to secure the machine to the truck during transporting can result in property damage, personal injury or death. 1. Confirm that the height of the load clears various limitation on the way (width and height of tunnels, size of guards, branches of trees, etc.) and meets all laws and regulations governing transportation. 2. Obey all state and local laws governing the weight, width, length and weight of a load. Observe all regulations governing wide loads.
3.1.3. RAILROAD FLAT CAR Respective railroad loading rules and specifications must be followed when shipping this machine on open top railroad cars.
3.2. LIFTING MACHINE ON SLINGS
Fig. 3.2. Lifting Machine on Slings 1. Prior to lifting the machine depress brake pedal and lock with a brake button. 2. Use slings of sufficient strength for the machine weight. 3. Wrap the machine slings as shown in Fig. 3.2 and attach to tracks in the places marked by letter "A" in the way securing the sling against sliding out of the track spur and preventing the track from shifting. 4. Attach spreader beams to the lifting slings and secure them against falling down. 5. Machine weight with a cab, ROPS, air conditioner, blade and ripper is 38620 [kg].
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3.3. MOVING A DISABLED MACHINE CAUTION! When using a cable, be sure it is strong enough for the expected load and is properly secured to the drawbar pins or tow hooks (if equipped). Do not use cables having broken wires, thin spots or loops. WARNING! When towing with a cable, take up the slack slowly to avoid jerking. A cable, which fails under load, can whip and cause serious injury. Stand clear. Do not pull or tow unless the operator's compartment is guarded against or out of reach of a whipping cable. Attach only to the machine tow hook or drawbar. Failure to follow these instructions could cause serious injury. WARNING! Personal injury or death could result when towing a disabled machine incorrectly. Block the machine to prevent movement before and after releasing the brakes. When the output shafts of final drives are removed, the machine has NO brakes. The machine can roll freely and cause personal injury or death. IMPORTANT: A machine MUST NOT be towed if the steering drive and/ or final drive is out of order. It must be transported to avoid further damage. To avoid the possibility of power train damage, limit towing to a distance of 1.0 [km] at speeds less than 2.0 [km/h]. The brakes on this machine are springs applied automatically when the engine is stopped or the steering hydraulic system fails. Keep the tow line or bar angle to a minimum. Do not exceed a 30 degree angle from the straight ahead position. Do not allow an operator to be on the machine that is being towed unless the operator can control the steering and/or the braking.
Fig. 3.3. Front Pull Hook Location at Machine 1. Front Pull Hook
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Fig. 3.4. Rigid Drawbar Location at Machine 1. Rigid Drawbar
Fig. 3.5. Removal of Output Shaft Linking Steering Drive to Final Drive 1. Bolt with Washer 2. Cover 3. Retaining Ring
4. Retainer with O-Ring 5. Output Shaft
6. Where to apply Loctite #120 7. Shims
If the tractor can be towed and the engine, steering and steering hydraulic system are operable, than the machine can be towed with a towing cable or rigid tow bar following the procedure described below: 1. Lock the drive train lever with a lock lever. 2. Attach a towing cable or a tow bar of a sufficient strength to a pull hook (1, Fig. 3.3) or drawbar (1, Fig. 3.4). 3. Start the engine and release the drive train lock lever. 4. Release the brake pedal and tow the machine for a shortest possible distance only. Keep the engine running at half throttle. TD-25M EXTRA
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If the tractor can be towed but the engine and/or steering hydraulic system are inoperable, than the brakes are applied and machine cannot be moved. The machine can be towed following the procedure described below: 1. Lock the drive train lever with a lock lever. 2. If the machine is on a slope, than: - with a small grade and hard ground, block the machine track chains with wooden throngs. - with a steep slope, block the machine with a tow bar attached to a drawbar or hitch and the towing machine. Make sure that the towing machine has enough brake capacity, enough weight and enough power; the towing machine must be as large as the disabled machine or larger. When towing a disabled machine on a slope, one or more towing machines must be able to provide good control and braking capacity. This can demand a larger towing machine and extra machines attached at the back. This will prevent uncontrolled machine rollover down the slope. 3. Remove output shafts linking steering system to final drives. Follow the procedure provided below: - Remove bolts with washers (1, Fig. 3.5) that secure cover (2). Remove shims (7). - Remove retaining ring (3). - Screw the bolt (1) into the retainer (4) hole and remove the retainer with O-Ring. - Screw the bolt (5/8”-11UNC-2B) into the output shaft (5) hole and remove the shaft. - Install retainer (4) with O-Ring and retaining ring (3). - Install cover (2) together with shims. - Repeat the above procedure for the other output shaft. When the repair completed, (towing ended) install the output shafts (5) as detailed in the Service Manual TD-25M EXTRA, Section 7F.
3.4. MACHINE STORAGE 3.4.1. PREPARING FOR STORAGE When a machine is taken out of service and stored for more than 30 days, steps must be taken to protect the machine. Leaving machine outdoors exposed to the elements will materially shorten its life. An enclosure will protect the machine from rapid temperature changes and lesson the amount of condensation that forms in hydraulic components, engine, fuel tank and final drives. If it is not possible to put the machine in an enclosure, cover it with a tarpaulin. After the machine has been positioned for storage and the engine shutdown, perform the following operations: 1. Visually inspect the machine for external leakage and other defects. 2. Clean the radiator. Refer to “RADIATOR” in Section 5. 3. Thoroughly clean the machine; be sure to rinse off any corrosive deposits. 4. Correct any defects found. Consult Authorized Distributor of Construction Equipment. 5. Clean or replace the air cleaner filter elements. Refer to “AIR INTAKE SYSTEM (AIR CLEANING) AND EXHAUST SYSTEM” in Section 5. 6. The cooling system should be completely drained, chemically flushed, and refilled with a conditioned water/antifreeze solution suitable for the lowest temperature anticipated. Refer to Section 5 “REFILL SPECIFICATION AND CAPACITIES CHART” for the proper antifreeze and conditioner concentrations.
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IMPORTANT: Under no circumstances should the vehicle be stored with a dry cooling system. 7. Drain the water from the fuel tank. 8. Replace the fuel filter. Refer to “FUEL SYSTEM” in Section 5. 9. It is recommended to use vapor corrosion inhibitors VCI to prevent empty cavities in tanks/reservoirs and systems against corrosion. Vapor corrosion inhibitors VCI protect against corrosion the areas that do not contact the oil. Vapor corrosion inhibitors VCI available have been listed below: - NOX RUST VCI 105 DAUBERT CHEMICAL COMPANY - TECTYL 859AOX VCI 105 VALVOLINE OIL COMPANY Vapor corrosion inhibitors VCI are to be used as per their manufacturer’s instruction, that is how much, application procedure, etc. WARNING! Corrosion inhibitors are volatile and flammable. Use them only in a well-ventilated area. Keep flames and sparks away. DO NOT SMOKE. Store a container in a cool, well-ventilated place. CAUTION! Avoid prolonged exposure to volatile corrosion inhibitors because eye and skin irritation may occur. 10. Use volatile corrosion inhibitor (VCI) in a fuel tank to protect its inner confines. The fuel remaining in the fuel tank is to be protected against bacteria and fungus buildup. Aid biocides suitable for crude oil derivates like: Fleet-tech Microbicide of Fleetguard Company product. 11. Vent the fuel system. Refer to “FUEL SYSTEM” in Section 5. 12. Start the engine and run idle at half throttle for 4 minutes and then stop the engine. 13. Lubricate all points of the machine as outlined in the "SCHEDULED MAINTENANCE GUIDE", in Section 5. NOTE: Be sure to oil or grease all linkage connections, joints, nuts, pins, shafts, and bushings that can be subject to corrosion. 14. Drain the engine oil, replace the engine oil filter and fill them with proper grade of oil. Refer to “ENGINE” in Section 5. 15. Add 15 [ml] VCI for each liter of engine oil to the crankcase. Example: if the total capacity of a crankcase is 10 [l] add 150 [ml] VCI. 16. Start the engine and run idle at half throttle for 30 seconds and then stop the engine. 17. Remove the air cleaner elements. 18. Pour 120 [ml] VCI to the air intake manifold thru an opening in the air intake manifold to prevent corrosion of cylinder bearing surface over pistons. 19. Pour 350 [ml] VCI agent to the hydraulic reservoir. 20. Seal all external openings (i.e. air precleaner inlet, engine exhaust pipe outlet, crankcase and hydraulic reservoir breather, fuel tank vent hose, etc.) with a waterproof tape wide enough to cover the opening, regardless of its size. NOTE: When sealing with tape, be sure to extend tape approximately 25 [mm] beyond an opening to insure good sealing.
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21. Remove the battery and place it on wooden platform. Then store them in a cool, clean, dry, wellventilated place away from areas provided for storing or dispensing fuel and oil, not near any heat source and preferably where the temperature range is between 0 [°C] to +21 [°C]. Be sure the batteries are fully charged. IMPORTANT: Do not leave batteries on a concrete floor in freezing temperatures. IMPORTANT: If the machine is stored with dry charged batteries or no batteries, the alternator output lead must be disconnected and insulated. Failure to do so may result in permanent damage to the alternator. Alternator output lead is not to be reconnected unless the battery is filled with electrolyte. Refer to “ELECTRICAL SYSTEM” in Section 5. 22. If the blade is detached for storage, secure the cylinders to the machine to avoid their damage. 23. Coat all machined unpainted surfaces with chassis grease to prevent rust.
3.4.2. SERVICING MACHINE DURING STORAGE ONE-MONTH REPETITIVE SERVICE PERIOD MACHINES WITH LOW MAINTENANCE BATTERIES Check if batteries are fully charged. Never allow batteries to run down below ¾ full charge. SIX MONTH REPETITIVE SERVICE PERIOD 1. Visually inspect the engine and radiator for leakage and other defects. Attend to all leaks and other failures detected. Consult Authorized Distributor of Construction Equipment. 2. Remove all storage seals from the machine. (i.e. air precleaner inlet, engine exhaust pipe outlet, crankcase and hydraulic reservoir breather, fuel tank vent hose, etc.). 3. Install fully charged battery. Refer to “ELECTRICAL SYSTEM” in Section 5. WARNING! Be sure the electrical master switch is OFF during battery installation to eliminate a risk of sparking. IMPORTANT: Check that batteries are level in the holders and securely held. The hold- down fasteners should hold the battery firmly but not tight enough to warp or damage either the hold-down bar or battery. WARNING! Lay the cables terminals so they do not hinder the vent plug removal nor chafe against the hold-down bar their fasteners. Always connect the negative cable last to minimize the chance of sparks or an explosion. Always connect the negative ground cable last to minimize the chance of sparks or an explosion. 4. Check the coolant level in the radiator and add proper concentrations of antifreeze and coolant additives DCA-4, if required. Refer to “COOLING SYSTEM” in Section 5. NOTE: If excessive loss of coolant is detected, the problem should be corrected. Refer to “COOLING SYSTEM” in Section 5. NOTE: Ride the machine forward and backward a few times and operate mounted equipment in order to distribute oil and check to tightness. 5. Follow steps 7 through 23 of "PREPARING FOR STORAGE".
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3.4.3. PREPARING FOR OPERATION 1. Visually inspect the machine for external leakage and other defects. 2. Clean the radiator, refer to “COOLING SYSTEM” in Section 5. 3. Thoroughly clean the machine; be sure to remove all traces of corrosive substances. 4. Use kerosene Antykor to remove grease from all protected surfaces (especially from the piston rod surface). 5. Correct any defects found. Consult Authorized Distributor of Construction Equipment if a need arises. 6. Remove all storage seals from the machine. (i.e. air precleaner inlet, engine exhaust pipe outlet, crankcase and hydraulic reservoir breather, fuel tank vent hose, etc.). 7. Service air cleaner. Refer to “AIR INTAKE SYSTEM (AIR CLEANING) AND EXHAUST SYSTEM” in Section 5. 8. Replace the fuel filter. Refer to “FUEL SYSTEM” in Section 5. 9. Refill the fuel tank with Diesel oil. Refer to “REFILL SPECIFICATION AND CAPACITIES CHART” in Section 5. 10. Lubricate all points of the machine especially those outlined in the "LUBRICATION POINTS" in Section 5. NOTE: Be sure to lubricate or grease all linkage connections, joints, nuts, pins, shafts, and bushings not specified in the “SCHEDULED MAINTENANCE GUIDE" in Section 5. 11. Drain engine oil from the crankcase and replace the engine lubricating oil filter. Refer to “ENGINE” in Section 5. 12. Install fully charged battery. Refer to “ELECTRICAL SYSTEM” in Section 5. IMPORTANT: Check that batteries are level in the holders and securely held. The hold-down fasteners should hold the battery firmly but not tight enough to warp or damage either the hold-down bar or battery. CAUTION! Lay the cables terminals so they do not hinder the vent plug removal nor chafe against the hold-down bar their fasteners. Always connect the negative ground cable last to minimize the chance of sparks or an explosion. WARNING! Never start the engine indoors unless proper exhaust ventilation is provided. Once the engine is running, move the machine outdoors as soon as possible. 13. Start the engine; refer to “STARTING THE ENGINE” in Section 4. Observe all the gauges and lamps on the instrument panel for proper operation of engine.
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SECTION 4
SECTION CONTENTS PAGE 4.1. MACHINE PRECAUTIONS ............................................................................................................3 4.2. UNIVERSAL SYMBOLS FOR INSTRUMENTS AND CONTROLS..............................................4 4.3. INSTRUMENT PANELS .................................................................................................................6 4.3.1. MACHINE INSTRUMENT PANEL (for machine up to S/N 75237)......................................6 4.3.1A. MACHINE INSTRUMENT PANEL (for machine S/N 75238 and up) ........................13 4.3.1B. GEAR, RANGE AND DRIVE TRAIN DIAGNOSTIC DISPLAY WITH HOURMETER (for machine S/N 75238 and up) ............................................................ 19 4.3.1A.1. DISPLAY NORMAL OPERATING MODE (DRIVE TRAIN CONTROL SYSTEM NORMAL OPERATION) .................19 4.3.1A.2. DISPLAY DIAGNOSTIC OPERATING MODE - DRIVE TRAIN CONTROL DIAGNOSTIC FUNCTION ............................19 4.3.1C. STARTING SWITCH (for machine S/N 75238 and up) .................................................. 26 4.3.2. GEAR PRESETTING AND DOWNSHIFT PANEL (for machine up to S/N 75237).......... 27 4.4. CAB CONTROLS ........................................................................................................................ 28 4.5. CONTROLS AND ADJUSTMENT .............................................................................................. 29 4.5.1. SEAT ................................................................................................................................... 29 4.5.2. SEAT BELT ......................................................................................................................... 29 4.5.3. ENGINE SPEED LEVER.................................................................................................... 30 4.5.4. DRIVE TRAIN LOCK LEVER ............................................................................................. 31 4.5.5. DRIVE TRAIN CONTROLLEVER ...................................................................................... 31 4.5.6. BRAKE PEDAL ................................................................................................................... 32 4.5.6.1. BRAKE PEDAL LOCK ............................................................................................... 33 4.5.7. DECELERATOR PEDAL.................................................................................................... 33 4.5.8. ELECTRICAL SYSTEM MASTER SWITCH ..................................................................... 34 4.5.9. EQUIPMENT CONTROL LEVERS .................................................................................... 35 4.6. STARTING THE ENGINE ........................................................................................................... 36 4.6.1. NORMAL START (TEMPERATURE ABOVE 0 [°C]) ........................................................ 37 4.6.2. ETHER INJECTOR START (TEMPERATURE BELOW 0 [°C]) (machine up to S/N 75083, if equipped) ............................................................................. 40 4.6.3. START-UP WITH ENGINE INTAKE AIR PREHEATER IN LOW TEMPERATURES (machine S/N 75084 and up) .............................................................................................. 41 4.6.4. STARTING AFTER OIL CHANGE OR LONGER STORAGE .......................................... 41 4.7. STOPPING THE ENGINE ........................................................................................................... 42 4.8. ENGINE PROPER OPERATION RULES................................................................................... 43 4.9. DRIVING THE MACHINE ............................................................................................................ 43 4.10. MACHINE SPEED AND DIRECTION CHANGES ................................................................... 45 4.10.1. GEAR PRESETTING MODE ........................................................................................... 47 4.10.2. AUTO-DOWNSHIFT MODE ............................................................................................ 48 4.11. CONVERTER OVERHEATING ................................................................................................ 48 4.12. DOWNGRADE OPERATION .................................................................................................... 49 4.13. OPERATING OVER AN OBSTRUCTION ................................................................................ 49 4.13.1. ALLOWABLE WATER IMMERSION ............................................................................... 49 4.14. STOPPING THE MACHINE ...................................................................................................... 49 4.15. PARKING THE MACHINE ........................................................................................................ 50 4.16. OPERATING MOUNTED EQUIPMENT ................................................................................... 51 4.16.1. BLADE CONTROL .......................................................................................................... 51 4.16.2. RIPPER CONTROL.......................................................................................................... 53 4.16.3. RIPPER SHANK PIN CONTROL..................................................................................... 54 4.17. POSITIONING THE BLADES ................................................................................................... 55 4.17.1. POSITIONING THE DOZER BLADE WITH A TILT CYLINDER .................................... 55 4.17.1.1. TILTING THE BLADE .............................................................................................. 56 DRESSTA
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4.17.1.2. PITCHING THE BLADE ...........................................................................................56 4.17.2. BULLGRADER BLADE POSITIONS “C” - FRAME (MECHANICAL OPTION)...............57 4.17.2.1. ANGLING THE BLADE ............................................................................................58 4.17.2.2. TILTING THE BLADE...............................................................................................59 4.17.2.3. LEVELING THE BLADE...........................................................................................60 4.18. OPERATING TECHNIQUES .....................................................................................................61 4.18.1. DIGGING AND CLEARING...............................................................................................61 4.18.2. TRANSPORTING, LOADING AND PILING .....................................................................66 4.18.3. BREAKING PILES AND SPREADING .............................................................................68 4.18.4. RIPPING ............................................................................................................................69 4.18.4.1. PRIOR TO OPERATION..........................................................................................69 4.18.4.2. RIPPING TECHNIQUES ..........................................................................................70 4.18.4.3. COLD WEATHER OPERATION..............................................................................70 4.19. ECONOMICAL OPERATION OF THE MACHINE ....................................................................70
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4.1. MACHINE PRECAUTIONS During operation stay alert and watch what you are doing. Use common sense and do not operate when fatigued. Know your machine. For your personal safety read this manual carefully and follow all instructions and precautions. Refer to and read Section 2 carefully and follow all precautions. Before starting or operating this tractor, read the following general precautions. These are listed there to help you protect the machine and to remind you of protection for yourself and those around you. Sound judgment and observance of these rules will help make your job a safer one. Visually check out the machine for leaks and broken, missing or malfunctioning parts. Be sure all caps, dipsticks, battery covers, etc. are secure before starting. Correct any problems before operating the machine. Before starting operation, check the machine for correct functioning of drive train, brake system, equipment hydraulics system, horn, backup alarm and safety equipment. Make all necessary repairs or adjustments before operating the machine. Keep the transmission in low gear when going downhill. Never coast downhill with the transmission in neutral. The machine could go out of control and tip over. Always drive the machine slowly when on hillsides, ramps or rough terrain. Be extremely careful when working around trenches or banks. Excessive speed or carelessness could cause the machine to roll over. The oil pressure should register on a pressure gauge within 15 seconds after starting the engine. After starting the engine, increase the engine speed to about 1000 [RPM] and keep the engine at this RPM for 3 to 5 minutes for the lube oil to distribute within the lube system and to stabilize the engine oil pressure. Do not place the machine under load after starting the engine, before reaching the specified both the coolant temperature and lube oil pressure of the engine. Do not allow the engine to operate on low RPM for a long time with the coolant at low temperature (below the green area on the pressure gauge). To prevent any possible damage to the alternator, the electrical system master switch must be in the "ON" position when the engine is running. The switch must be in the "OFF" position only when the engine is shut down at the end off each day or when the operator leaves the tractor unattended. If the tractor is left outside during cold weather and the tracks become frozen to the ground, do not attempt to jerk them free with the power of the engine. Start the tractor slowly and, if the tracks do not break free, pry them loose. A torch can be used, in necessary but be careful not to start a fire. To prevent the tracks from freezing in the ground, park the tractor on planks. In freezing weather thoroughly clean all ice and mud from the track system after each day's operation to prevent freeze-up of the system. Be sure to clean the seal area off the sprocket drives, front idlers, top idlers and rollers. Never pour cold coolant into the radiator if the engine is very hot unless conditions make it absolutely necessary. Use extreme caution as hot coolant could burn you. Keep face away from filler neck. Under such conditions, start the engine and keep at low RPM while slowly pouring the coolant into the radiator. Allow the engine to cool down to 50 [°C]. Pouring cold coolant into the engine may result in damage to cast components of the engine.
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Never use water alone in the cooling system. Fill the fuel tank at the end of each day's work to reduce moisture condensation in the tank. When using a long cable to hitch the tractor to the load, drive the tractor forward slowly until all slack is taken out. After operating under load, before shutting down, operate the engine at low RPM (no load) for three to five minutes in the purpose of the cooling. This will ensure the controlled cooling of the engine components: pistons, cylinders, bearings and turbocharger.
4.2. UNIVERSAL SYMBOLS FOR INSTRUMENTS AND CONTROLS The use of universal symbols will pictorially identify various instruments and controls. These symbols are an effort to overcome language differences for all operators in a positive way, thus enhancing their safety through quicker recognition of the instruments and controls while operating the equipment. Study the following symbols so you will know their meaning immediately and at a glance. Some symbols may not pertain to your machine. ON (GENERAL)
OFF (GENERAL)
FWD or UP
REVERSE or DOWN
FWD or REVERSE
Next speed rotation 1
Next speed (straight-line) 2
Caution high pressure
Variable slide control
Read Operator’s Manual
Note- WARNING
Hourmeter
NEUTRAL position
A/C
Electrical receptacle
Temperature checking
Battery switch
Voltmeter
Lights
Dome light
Windshield wiper
Rear window wiper
Window washer
Fan
Horn
Fuel filler
Fuel level
Air cleaner
Coolant level
Coolant temperature
Engine
RPM
Fig. 4.1. Universal Graphic Symbols
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OPERATING Engine oil pressure
Starting aid
Drive train oil filler
Oil pressure
Oil filter
Oil level
Oii temperature
Hydraulic oil pressure
Hydraulic oil filter
Hydraulic oil level
Undercarriage
Vehicle FWD or REVERSE
LH Track driven
RH Track driven
RH Track brake
LH Track brake
Hydraulic filter
Blade
Raise
Hold
Lower
Float
Tilt left
Tilt right
Angle left
Angle right
Pitch FWD
Pitch AFT
Ripper
Raise
Hold
Lower
Pitch FWD
Pitch AFT
Coolant filler
Grease lubricant
Engine starting
Parking brake(general)
Brake ON
Lift or lift point
Fan speed low range
Transmission oil filter
Transmission oil temperature
Transmission oil level
Clutch oil pressure
Interior Heater/heating
Engine low RPM
Engine high RPM
Fig. 4.1. Universal Graphic Symbols
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OPERATING 4.3. INSTRUMENT PANELS
GENERAL This section covers the location and function of the various instruments and controls. More detailed information regarding operation of controls can be found in the following text within this section. Regardless of previous experience as an operator; you must be thoroughly familiar with the location and use of all instruments and controls before operating the machine. CAUTION! Understand all control functions before starting the engine. IMPORTANT: After starting and while operating observe instruments and warning lights frequently.
4.3.1. MACHINE INSTRUMENT PANEL (for Machine up to S/N 75237)
Fig. 4.2. Machine Instrument Panel (machine up to S/N 75083)
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Fig. 4.2A. Machine Instrument Panel (machine S/N 75084 up to S/N 75237) 1. Fuel Level Gauge 2A. Engine ECM Failure Code Display Momentary Switch 2B. ECM Failure Code Activation Momentary Switch 3. Low Engine Coolant Level Warning Light 4. Air Cleaner Clogging Warning Light 5. Engine Failure Warning Lights (ECM) 6. Drive Train Oil Pressure Filters’ Warning Light 7. Hydraulic Oil Filters’ and Hydraulic Pilot Filter Warning Light 8. Low Transmission Main Pressure and Low Clutch Oil Pressure Warning Light 9. Engine Coolant Temperature Gauge 10. Engine Oil Pressure Gauge 11. Low Engine Coolant Level and Low Engine Lube Oil Pressure Alarm 12. Voltmeter 13. Drive Train System Oil Temperature Gauge 14. Fan Drive System Oil Filter Clogging Warning Light 15. Hourmeter 16. Starting Switch DRESSTA
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17. Dozer Lights Switch 18. Cab Lights Switch 19. Ether Injector Switch (machine up to S/N 75083, if equipped) 20. Brake Lock 21. Gear and Range Display 22. Low Engine Oil Pressure Warning Light 23. Engine Intake Air Preheater Button (machine S/N 75083 and up)
1. FUEL LEVEL GAUGE The gauge indicates quantity of fuel available for operation in fuel tank. 2A. ENGINE ECM FAILURE CODE DISPLAY MOMENTARY SWITCH This momentary switch is provided with three positions, which are as follows: the central position which is also operating position and lower and upper positions which can be used to display the ECM failure codes with the warning lights (5, Fig. 4.3). 2B. ECM FAILURE CODE ACTIVATION MOMENTARY SWITCH This is a two position switch and in its lower position it makes possible to display successive failure codes with a switch (2A, Fig. 4.2.). The switch is provided with a self revert feature to its upper position. 3. LOW ENGINE COOLANT LEVEL WARNING LIGHT The engine coolant level indicator will glow if coolant level drops below allowable limit, this light is supplemental to low engine coolant and oil pressure alarm (11) on the instrument panel. 4. AIR CLEANER CLOGGING WARNING LIGHT The air cleaner warning light will glow amber when the filter element reaches the maximum allowable restriction. When this happens, filter element service is required. Refer to "AIR CLEANER" in Section 5. 5. ENGINE FAILURE WARNING LIGHTS (ECM) If any of the engine operating parameters is out-of-range, or the sensor fails, the engine ECM will store this event and the lights will get activated. This is the first warning for the operator that the engine parameter is out-of-range. If this is a case read the failure code as described in 4.6.1 “ENGINE START”.
Fig. 4.3. Warning Lights TD-25M EXTRA
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OPERATING 5.1 WARNING LIGHT “STOP” (RED)
This light indicates a serious malfunction of the engine. If it comes on while operating it tells the operator this is a fatal failure and will cause the engine shutdown. Stop the engine safely as soon as possible. 5.2 WARNING LIGHT “WARNING” (YELLOW) If it comes on while operating the engine can continue but some fuel system parameters will be altered with a resultant engine reduced performance. This failure MUST be corrected without delay. 5.3 WARNING LIGHT “FLUID” (AMBER) If the light comes on while operating, it tells that the failure code has been recorded. The light will stay on as long as the failure is valid. The light will blink if the engine operating conditions degrade. The engine power and RPM may downgrade to protect engine against damage. 6. DRIVE TRAIN SYSTEM OIL PRESSURE FILTERS’ CLOGGING WARNING LIGHT The drive train oil filters’ warning lamp will glow amber when one of the oil filters’ clogging is in excess of the maximum allowable restriction. Then the filter is to be changed. 7. HYDRAULIC OIL FILTERS AND HYDRAULIC PILOT FILTER WARNING LIGHT The hydraulic oil filters warning light will glow amber when one of the oil filters’ clogging is in excess of the maximum allowable restriction. Then the filter is to be changed. 8. LOW TRANSMISSION MAIN PRESSURE AND LOW CLUTCH OIL PRESSURE WARNING LIGHT The warning light will glow when there is insufficient main oil pressure with the drive train lock lever in its locked position or there is insufficient oil pressure available for the transmission gears clutches with the drive train lock lever in its unlocked position. When this warning light is activated stop the engine, clean drive train system suction filter and check oil level in the main frame. Refer to "DRIVE TRAIN SYSTEM" in Section 5. If the light continues to glow, stop the engine and consult Authorized Distributor of Construction Equipment before operating the machine. 9. ENGINE COOLANT TEMPERATURE GAUGE This gauge shows the temperature of the coolant circulating through the engine. After the engine has operated a sufficient length of the time, the pointer of the gauge must be in the GREEN area of the gauge. During normal operation the gauge readings may vary between the minimum and maximum indicated by the GREEN area of the gauge. Continuous engine operating above the maximum temperature is harmful to the engine. Low coolant temperatures will also cause exhaust smoke and increase the rate of fuel consumption. NOTE: In cold weather, if no louver is mounted, it may be necessary to cover part of the radiator to maintain the minimum coolant temperature indicated at the lower end of the GREEN area. The engine temperature under full load should remain in the GREEN area of the gauge.
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10. ENGINE OIL PRESSURE GAUGE This gauge shows the pressure at which the lubricating oil is circulating through the engine. The pressure gauge pointer must register in the GREEN area during operation of the engine. The gauge is provided with a red light; when it comes on, the operator is to stop the engine immediately. 11. ENGINE COOLANT LOW LEVEL AND LOW ENGINE LUBE OIL PRESSURE ALARM. This alarm will sound when lubricating engine oil pressure or coolant level in radiator drops below normal. If so, stop the machine immediately, shut the engine down and find out which warning light glows and check gauge indication. This signal can be found beneath the instrument panel gauges. 12. VOLTMETER The voltmeter indicates the condition of the batteries. At low idle speed, the gauge pointer should be within the green with white stripe area, which indicates a good battery charge. If the voltage drops below this area, the battery should be checked. With the engine operating above low idle speed, the pointer should be within the upper green area, which is the normal operating range. If the pointer drops below or exceeds this area, the battery, alternator and/ or wiring may be at fault. 13. DRIVE TRAIN SYSTEM OIL TEMPERATURE GAUGE This gauge shows the temperature of the drive train system oil. The pointer of the gauge must be in the GREEN area of the gauge. If the pointer is above the green area do the following: -
check if in machine operates in proper gear,
-
check the main frame oil level,
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clean the radiator core,
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check the suction filter for contamination and suction line for tightness.
If the above operations fail to remedy the cause, contact the Authorized Distributor of Construction Equipment. 14. FAN DRIVE SYSTEM OIL PRESSURE FILTER CLOGGING WARNING LIGHT Yellow light. It will come on when the filter clogging is above the allowable limit. When this is a case, stop the machine operation and replace the filter. 15. HOURMETER The hourmeter electrically records the actual hours of engine operation. The purpose of the hourmeter is to indicate when to perform the recommended maintenance and lubrication operations. The hourmeter will register only when the engine is running.
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16. STARTING SWITCH (KEY)
Fig. 4.3A. Starting Switch-Key Positions The starting switch equipped with a key is used to connect and disconnect electrical circuits, for checking the warning lights operation and for starting and stopping the machine engine. Starting switch key positions: 1 – to the left – activation of electrical system excepting the warning lights testing and alarm signal, 2 – after inserting the key – disconnects electrical circuits, 3 – to the right – activates electrical circuits, 4 – to the right with automatic return to position (3) on key release – engine startup or the warning/signal lights testing - temporary cutting off the electrical circuits hooked to the (1) contact. Before starting the engine check warning lights for operation: - move the drive train lock lever to its up shifted position, - turn the electrical system master switch to the ON position, - turn the key to the (4) START position and check if all warning lights glow. If any warning light fails to glow that indicates that the bulb is defective or its circuit is broken. IMPORTANT: Do not hold the key in the START position for more than 30 second. Allow a 2 minute interval between cranking. Never place the key in (4) position when engine is running. 17. DOZER LIGHTS SWITCH Rocker type switch can be used for activation of both front lights located at the blade hydraulic cylinders and machine rear lights. 18. CAB LIGHTS SWITCH The rocker type switch used to activate both the cab front headlamps and rear lamp. 19. ETHER INJECTOR SWITCH (machine up to S/N 75083, if equipped) This switch controls the ether injector for cold weather starting. Refer to "STARTING THE ENGINE" for proper operation of this switch. 20. BRAKE PEDAL LOCK This handle locks the brake pedal in the applied position for parking the machine. To lock the brake pedal, fully depress the pedal, pull out the lock handle and hold it on, remove your foot from the pedal and then release the lock handle. To release the brake, simultaneously depress the brake pedal and push in the lock handle. DRESSTA
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21. GEAR AND RANGE DISPLAY
Fig. 4.3B. Gear and Range Display 1. "1", "2" or "3" Gear Display 2. "High – H" or "Low – L" Range Display
Display is showing: a) after starting of engine "1" gear and "L" low range is displayed, b) "1", "2" or "3" and range "L" or "H" is displayed when operating machine, c) after shifting drive train control lever to neutral a gear and range actual while operating the machine is displayed. 22. LOW ENGINE OIL PRESSURE WARNING LIGHT The engine oil pressure warning light red in color will glow when engine oil pressure drops below the allowed minimum. When this light comes on, stop the machine immediately and shut the engine off. 23 – ENGINE INTAKE AIR PREHEATER BUTTON (machine S/N 75084 and up) The button is used to activate the intake air preheater to facilitate the engine starting in low temperatures. Refer to „STARTING THE ENGINE”.
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OPERATING 4.3.1A. MACHINE INSTRUMENT PANEL (for machine S/N 75238 and up)
Fig. 4.4. Instrument Panel (for Machine S/N 75238 and up) 1. Fuel Level Gauge 2A. Engine ECM Failure Codes Readout Selector Momentary Switch 2B. Engine ECM Failure Code Activation Selector Momentary Switch 3. Low Engine Coolant Level Warning Light 4. Air Cleaner Clogging Warning Light 5. Engine Failure Warning Lights (ECM) 6. Drive Train Oil Pressure Filters’ Clogging Warning Light 7. Hydraulic Oil Filters’ and Hydraulic Pilot Filter Clogging Warning Light 8. Low Transmission Main Pressure and Low Clutch Oil Pressure Warning Light 9. Engine Coolant Temperature Gauge DRESSTA
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10. Engine Oil Pressure Gauge 11. Low Engine Coolant Level and Low Engine Lube Oil Pressure Alarm 12. Voltmeter 13. Drive Train System Oil Temperature Gauge 14. Fan Drive System Oil Filter Clogging Warning Light 15. N/A 16. N/A 17. Dozer Lights Switch 18. Cab Lights Switch 19. Engine Intake Air Preheater Button 20. Brake Lock 21. Gear, Range and Drive Train Diagnostic Display with Hourmeter 22. Low Engine Oil Pressure Warning Light 23. Gear Presetting Mode Switch 24. Automatic Gear Downshift Mode Switch
1. FUEL LEVEL GAUGE The gauge indicates quantity of fuel available for operation in fuel tank. 2A. ENGINE ECM FAILURE CODES READOUT SELECTOR MOMENTARY SWITCH The switch has three positions: center, lower and upper. With the engine stopped it is used (together with switch (2B) to display successive engine faults codes with warning lights (5), if there is more than one fault code, read as first one with switch (2A). Refer to 4.6.1 for codes reading. The switch is provided with a self revert feature to its center position. 2B. ENGINE ECM FAILURE CODE ACTIVATION SELECTOR MOMENTARY SWITCH This switch is a two position switch. With the engine stopped and the switch in its lower position will allow to read the faults first code with warning lights (5). Refer to 4.6.1 for codes reading. The switch is provided with a self revert feature to its initial position. 3. LOW ENGINE COOLANT LEVEL WARNING LIGHT The engine coolant level indicator will glow if coolant level drops below allowable limit, this light is supplemental to low engine coolant and oil pressure alarm (11) on the instrument panel. 4. AIR CLEANER CLOGGING WARNING LIGHT The air cleaner warning light will glow yellow when the filter element reaches the maximum allowable restriction. When this happens, filter element service is required. Refer to "AIR CLEANER" in Section 5. 5. ENGINE FAILURE WARNING LIGHTS (ECM) If any of the engine operating parameters is out-of-range, or the sensor fails, the engine ECM will store this event and the lights will get activated. This is the first warning for the operator that the engine parameter is out-of-range. If this is a case read the failure code as described in 4.6.1 “ENGINE START”.
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Fig. 4.4A. Warning Lights 5.1 WARNING LIGHT “STOP” (RED) This light indicates a serious malfunction of the engine. If it comes on while operating it tells the operator this is a fatal failure and will cause the engine shutdown. Stop the engine safely as soon as possible. 5.2 WARNING LIGHT “WARNING” (YELLOW) If it comes on while operating the engine can continue but some fuel system parameters will be altered with a resultant engine reduced performance. This failure MUST be corrected without delay. 5.3 WARNING LIGHT “FLUID” (AMBER) If the light comes on while operating, it tells that the failure code has been recorded. The light will stay on as long as the failure is valid. The light will blink if the engine operating conditions degrade. The engine power and RPM may downgrade to protect engine against damage. 6. DRIVE TRAIN SYSTEM OIL PRESSURE FILTERS’ CLOGGING WARNING LIGHT The drive train oil filters’ warning lamp will glow yellow when one of the oil filters’ clogging is in excess of the maximum allowable restriction. Then the filter is to be changed. 7. HYDRAULIC OIL FILTERS AND HYDRAULIC PILOT FILTER CLOGGING WARNING LIGHT The hydraulic oil filters warning light will glow yellow when one of the oil filters’ clogging is in excess of the maximum allowable restriction. Then the filter is to be changed. 8. LOW TRANSMISSION MAIN PRESSURE AND LOW CLUTCH OIL PRESSURE WARNING LIGHT The warning light will glow red when there is insufficient main oil pressure with the drive train lock lever in its locked position or there is insufficient oil pressure available for the transmission gears clutches with the drive train lock lever in its unlocked position. When this warning light is activated stop the engine, clean drive train system suction filter and check oil level in the main frame. Refer to "DRIVE TRAIN SYSTEM" in Section 5. If the light continues to glow, stop the engine and consult Authorized Distributor of Construction Equipment before operating the machine.
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9. ENGINE COOLANT TEMPERATURE GAUGE This gauge shows the temperature of the coolant circulating through the engine. After the engine has operated a sufficient length of the time, the pointer of the gauge must be in the GREEN area of the gauge. During normal operation the gauge readings may vary between the minimum and maximum indicated by the GREEN area of the gauge. Continuous engine operating above the maximum temperature is harmful to the engine. Low coolant temperatures will also cause exhaust smoke and increase the rate of fuel consumption. NOTE: In cold weather, if no louver is mounted, it may be necessary to cover part of the radiator to maintain the minimum coolant temperature indicated at the lower end of the GREEN area. The engine temperature under full load should remain in the GREEN area of the gauge. 10. ENGINE OIL PRESSURE GAUGE This gauge shows the pressure at which the lubricating oil is circulating through the engine. The pressure gauge pointer must register in the GREEN area during operation of the engine. 11. ENGINE COOLANT LOW LEVEL AND LOW ENGINE LUBE OIL PRESSURE ALARM. This alarm will sound when lubricating engine oil pressure or coolant level in radiator drops below normal. If so, stop the machine immediately, shut the engine down and find out which warning light glows and check gauge indication. 12. VOLTMETER The voltmeter indicates the condition of the batteries. At low idle speed, the gauge pointer should be within the green with white stripe area, which indicates a good battery charge. If the voltage drops below this area, the battery should be checked. With the engine operating above low idle speed, the pointer should be within the upper green area, which is the normal operating range. If the pointer drops below or exceeds this area, the battery, alternator and/ or wiring may be at fault. 13. DRIVE TRAIN SYSTEM OIL TEMPERATURE GAUGE This gauge shows the temperature of the drive train system oil. The pointer of the gauge must be in the GREEN area of the gauge. If the pointer is above the green area do the following: - check if in machine operates in proper gear, - check the main frame oil level, - clean the radiator core, - check the suction filter for contamination and suction line for tightness. If the above operations fail to remedy the cause, contact the Authorized Distributor of Construction Equipment. 14. FAN DRIVE SYSTEM OIL PRESSURE FILTER CLOGGING WARNING LIGHT Yellow light. It will come on when the filter clogging is above the allowable limit. When this is a case, stop the machine operation and replace the filter. 15. N/A 16. N/A
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OPERATING 17. DOZER LIGHTS SWITCH
Rocker type switch can be used for activation of both front lights located at the blade hydraulic cylinders and machine rear lights. 18. CAB LIGHTS SWITCH The rocker type switch used to activate both the cab front and rear headlamps. 19. ENGINE INTAKE AIR PREHEATER BUTTON The button is used to activate the intake air preheater to facilitate the engine starting in low temperatures. Refer to „STARTING THE ENGINE” for proper operation of this switch. 20. BRAKE PEDAL LOCK This handle locks the brake pedal in the applied position for parking the machine. To lock the brake pedal, fully depress the pedal, pull out the lock handle and hold it on, remove your foot from the pedal and then release the lock handle. To release the brake, simultaneously depress the brake pedal and push in the lock handle. 21. GEAR, RANGE AND DRIVE TRAIN DIAGNOSTIC DISPLAY with HOURMETER The machine features a display being part of machine instrument panel. The display helps the operator to monitor the drive train operation and makes it possible to monitor display functions with buttons described in Item 4.3.1B. At the upper part of the display "1", "2" or "3" and range "L" or "H" is depicted when operating machine in the normal conditions. The lower part of the display indicates the actual hours of engine operation. The purpose of the hourmeter is to indicate when to perform the recommended maintenance and lubrication operations. The hourmeter will register only when the engine is running. What is more, the display enables: — drive train control diagnostics, — monitoring the selected engine operating parameters.
Fig. 4.4B. Gear, Range and Drive Train Diagnostic Display with Hourmeter 1. "1", "2" or "3" Engaged Gear 2. "High – H" or "Low – L" Actual Range 3. Hourmeter
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22. LOW ENGINE OIL PRESSURE WARNING LIGHT The engine oil pressure warning light red in color will glow when engine oil pressure drops below the allowed minimum. When this light comes on, stop the machine immediately and shut the engine off. 23. GEAR PRESETTING MODE SWITCH Gear presetting mode switch enables three modes of machine operation: F/R – manual position – gear shifting can be made with control lever (joystick) embedded buttons only. 1/2 – mode position 1F/2R - machine will move forward at 1st gear and at 2nd gear reverse after moving the control lever in respective direction. Only LO/HI range control switches are operational. 2/2 – mode position 2F/2R - machine will move forward at 2nd gear and at 2nd gear reverse after moving the control lever in respective direction. Only LO/HI range control switches are operational. 24. AUTOMATIC GEAR DOWNSHIFT MODE SWITCH Automatic downshift is enabled if the drive train is in overloaded condition. O - Auto-downshift Mode OFF. I - automatic gear reduction (auto-downshift) function is ON. This mode is only active when gear presetting mode switch (23) is in manual mode position (F/R).
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4.3.1B. GEAR, RANGE AND DRIVE TRAIN DIAGNOSTIC DISPLAY WITH HOURMETER (for machine S/N 75238 and up)
Fig. 4.4C. Gear, Range and Drive Train Diagnostic Display with Hourmeter A. Display Screen (indicates gear and range engaged in normal operation (upper part) and actual hours of engine operation (lower part) B. "RUN" Indicator Light for normal operation (green) C. “WARNING” Warning Light (Red) D. "BAT" Warning Light (Red) E. Display Functions Selection Button (right scroll) F. Drive Train Diagnostics Toggle Button E. Display Functions Selection Button (left scroll)
4.3.1B.1. Display normal operating mode (drive train control system normal operation) After the key is inserted into starting switch and turned into (3, Fig. 4.4D) position, the display screen upper part (A, Fig. 4.4C) will show: a) once the engine has been started, the "1" gear and "L" or "H" range is displayed (depending on range change rocker switches position), actual hours of engine operation is displayed in lower part as well, b) "1", "2" or "3" actual gear and "L" or "H" range is displayed when operating machine, c) after shifting drive train control lever to neutral a last gear and range the machine was operated is displayed. At the same time (B) light is alight - normal display operation.
4.3.1B.2. Display diagnostic operating mode - drive train control system diagnostic function Machine drive train control system diagnostic can be made in two modes: "On going diagnostics” and "Inspection diagnostics”.
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1. On going diagnostics Drive train control system on going diagnostics is made all the time during machine operation without any intervention on part of the operator. Drive train electronic controller input and output signals are monitored on on going basis for this diagnosis. Each fault found will be indicated with a "WARNING" flashing light (C, Fig. 4.4C). At the same time "RUN" (B) light will come on solid. "RUN" (B) light will stay alight all the time, as machine can operate in the "1" gear and selected travel operations despite an existing fault. The fault is indicated also with a fault symbol from Signals Catalog (Refer to Main Catalog (Item 1A) below at the display screen. IMPORTANT: Display will screen a fault message for some 5 seconds after which the display will return to normal operation mode. If the fault is not corrected, a fault message will display each time the starting switch is turned on. System on going diagnostics will include: ⎯
Main Catalog of drive train electronic controller input and output (IN/OUT) signals,
1A. Main catalog of input and output (IN/OUT) signals INPUT SIGNALS (IN): IMPORTANT: Display will screen a fault message for some 5 seconds after which the display will return to normal operation mode. If the fault is not corrected, a fault message will display each time the starting switch is turned on. 1. Battery voltage: Bat Volt 00.0 V Battery voltage will be checked automatically after both the electrical master switch and starting switch are turned ON. Battery voltage required: 19.6 to 25.6 [V]. If the battery voltage is within this range, green light (B) will come on and drive train message will display, e.g. "1 L". If the battery voltage is outside this range, then light "D" will glow solid, while "C" light will flash. The fault will display a message:
An example of battery fault (battery volts too low) TD-25M EXTRA
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2. Alternator voltage Sys Volt 00,0 V Voltage will be checked automatically after engine startup and when a minimum speed of 400 RPM is reached. Voltage required: 25.6 to 29.4 [V]. If the battery voltage is within this range, green light (B) will come on and drive train message will display, e.g. "1 L". If the battery voltage is outside this range, then light "D" will glow solid, while "C" light will flash which means the power to machine electric system is faulty. The fault will display a message:
An example of alternator voltage info (alternator volts too low) 3. "CS” - CANBus J1939 engine RPM signal. The fault will display a message: Eng RPM
?!
All three lights E, F, G will flash in addition to display fault signaling. IMPORTANT: For "CS" signal to be checked, the engine has to operate. IMPORTANT: This fault is of vital importance as the drive train controller forces engine RPM. Failure to transmit along the J1939 bus will make the machine operation impossible. IMPORTANT: The fault message will persist until cleared. 4. CIW - Torque converter output speed sensor signal: CIW
?!
IMPORTANT: For "CIW" to be checked, the engine has to operate. The fault will display a message: "CIW" and "?!".
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5. FUEL Tmp – fuel temperature [°C], entering 2 nd stage fine filters. 6. OEM Tmp – drive train oil temperature (at TC outlet) [°C]. 7. WF – signal from travel direction pressure switch – forward. The fault will display a message: WF
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8. WR – signal from travel direction pressure switch – backward. The fault will display a message: WR
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(OUT) OUTPUT SIGNALS IMPORTANT: Display will screen a fault message for some 5 seconds after which the display will return to normal operation mode. If the fault is not corrected, a fault message will display each time the starting switch is turned on. 1. "EZ2”- transmission solenoid valve (second gear): The fault will display a message: EZ2
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2. "EZ3”- transmission solenoid valve (third gear): The fault will display a message: EZ3
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3. "EZL” Output - solenoid valve for steering system High/Low range change (left side): The fault will display a message: EZL
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4. "EZR” Output - solenoid valve for steering system High/Low range change (right side): The fault will display a message: EZR
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OPERATING 2. Inspection diagnostics
Inspection diagnostics is used to check selected components of drive train control system. This happens when the controller is unable to decide at normal operation, if the controller input is active or the output external signal fails to enter the controller. Depress the "F” (Fig. 4.4C) button to enter the inspection diagnostics mode. Light "C" is solid then. The display will present the first page of messages: 1. "UP" button upshift signal is checked at drive train control lever. UP
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If the circuit hooked to this input is OK, then "UP” and "OK!" message will display after the drive train control lever button is depressed. UP
OK
The message will display for as long as button is depressed if button (UP, DN) input is checked. If switch input is checked (HL, HR, WB, WO, WF, WR, etc), then the message displays all the time until a change to display page is made. If message: Does not change, this means: UP
?!
- circuit discontinuity or - controller input faulty or - controller failure. Depress button ">E" or "
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