OMTD25MS1T4FSV20V2E

910222724221 OMTD25MS1T4FSV20V2E
OPERATOR'S MANUAL
CRAWLER DOZER
TD-25M
series-1
EPA Tier 4 Final / EU Stage V
FOR S/N P000535 AND ABOVE
TRANSLATION OF THE ORIGINAL MANUAL

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.
Read this manual thoroughly and learn your machine before you attempt to operate it.
This manual has been prepared to help you operate and maintain your machine with utmost
efficiency and safety.
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. Detailed information on these subjects are available at authorized distributors and
the Manufacturer.
We hope you enjoy operating Dressta machines.
DRESSTA
This material is proprietary used, or disclosed excerpt from Dressta not to be reproduced, used, or
disclosed except in accordance with written authorization from Dressta.
DRESSTA TD-25 T4F / Stage V

SECTION INDEX
SECTION 1 – INTRODUCTION
This section discusses the use of this manual and 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.
At the end of the section a description of energy-efficient machine operation is described.
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.
SECTION 6 – SPECIFICATIONS
This section covers the diagrams, general dimensions and weights, refill capacities, ground speeds
and the standard and special torque values.

SECTION 1
INTRODUCTION
SECTION 1
INTRODUCTION
CONTENTS
PAGE
1.1. INTRODUCTORY INFORMATION ...........................................................................................3
1.2. MACHINE MARKING ...............................................................................................................4

SECTION 1
INTRODUCTION
PAGE 3
1.1. INTRODUCTORY INFORMATION
Fig. 1.1. Crawler Dozer TD-25M series-1

1 – Right Hand Side of the Machine 3 – Front of the Machine
2 – Left Hand Side of the Machine 4 – Rear of the Machine
GENERAL
Throughout this manual there will be two types of cross references. To sections and figures. The
ones without any symbols refer to the section where they are used, while the other with additional
symbols are valid for sections they refer to. Each section has section contents which facilitates
reference to a given page.
Some illustrations are of a general application of this model and may not show your machine and
component parts 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. (Fig. 1.1.)
The dozer TD-25M series-1 can be equipped with one of the below described hydraulic systems
for the blade control:
1. blade tilt control system D2,
2. blade tilt and pitch control system D2
3. blade tilt control system G2,
In addition to that the dozer can be equipped with the ripper:

1. single shank ripper
2. multishank ripper.
3. electrical and hydraulic ripper shank locking pin extension control (single shank ripper).

SECTION 1
INTRODUCTION
PAGE 4
Throughout this manual the following warning symbols and notes are used to warn the persons
against danger.
DANGER! This sign and the text accompanying in bold letters used throughout
this Manual indicates a serious danger, which, if not avoided, will result in injury
or death.
WARNING! This sign and the text accompanying in bolt letters used throughout
this Manual indicates an emergency, which, if not avoided, may result in injury or
death.
CAUTION! This sign and the text accompanying in bolt letters used throughout
this Manual indicates an emergency, which, if not avoided, may result in minor
injury.
The two following signs and text in italics are used throughout this manual related to possible
damage of machine units, its functioning or facilitating the maintenance, beneficiary influence on
machine operation and period to overhaul.
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 the 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. MACHINE MARKING
Fig. 1.2. Serial Number on Machine

The machine serial number is stamped on the plate fixed on the front left side of the machine
(Fig. 1.2).
TD-25 T4F / Stage V DRESSTA

SECTION 1
INTRODUCTION
PAGE 5
Fig. 1.3. Machine Serial Number at Main Frame
The machine serial number is stamped on the plate fixed in the upper corner of the main frame on
the right hand side under the fender (Fig. 1.3).
Fig. 1.4. Blade Serial Number
The equipment model designation is stamped on the back of the blade (Fig. 1.4) or stamped on the
plate attached in this same place, near the top right hand corner.

SECTION 1
INTRODUCTION
PAGE 6
Fig. 1.5. Ripper Serial Number
The ripper designation is stamped on the right side of the ripper's frame (Fig. 1.5) or stamped on
the plate attached in the same place.
The engine serial number and performance are placed on a data plate (1, Fig. 1.6) and (ECM) (2)
engine electronic module plate.
2
Fig. 1.6. Engine Plate Location
1 – Engine Data Plate 2 – Engine ECM Module Plate

SECTION 1
INTRODUCTION
PAGE 7
1 2 3 4
Fig. 1.7. Engine Data Plate

The engine data plate (Fig. 1.7) provides important information about the engine:
1 – Engine No – Engine serial number
2 – Model – engine model
3 – Adv. HP/KW – rated power
4 – CPL – parts checklist number
Fig. 1.8. Engine ECM Module Plate

Engine ECM Module Plate (2, Fig. 1.6) provides information:
ESN – engine serial number
P/N – ECM assembly number
S/N – unit serial number
D/C – calibration date
E/C – engine calibration code (software)

SECTION 1
INTRODUCTION
PAGE 8
Fig. 1.9. ROPS/FOPS Integrated Cab Plate
The ROPS/FOPS cab plate (Fig. 1.9) contains information on the ROPS/FOPS cab marking, serial
number, machine model, maximum machine weight, manufacture year as well as the standard
requirements met by the ROPS/FOPS integrated cab.
All other components having serial numbers are each equipped with a separate stamped serial
number plate.
When ordering parts or requesting information, the relevant numbers must be provided from the
Parts Catalogue with machine Serial Number.
Engine Serial Number must be provided when ordering parts for this unit.

SECTION 2
SAFETY PRECAUTIONS
SAFETY PRECAUTIONS SECTION 2
CONTENTS
PAGE
2.1. GENERAL ............................................................................................................................. 3
2.2. BEFORE STARTING THE ENGINE ...................................................................................... 7
2.3. OPERATION ........................................................................................................................10
2.4. MAINTENANCE ...................................................................................................................16
2.5. WHEN PARKING .................................................................................................................23
2.6. SAFETY SIGNS LOCATION ................................................................................................24
2.6.1. SAFETY SIGNS .........................................................................................................25
2.7. ADDITIONAL INFORMATION ..............................................................................................31

Page 3
WORK SAFETY – FOLLOW THESE RULES
2.1. GENERAL
Safety Related Information
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.
The customer is obliged to provided the appropriately organized workplace

as regards the permissible visibility and machine operation.
Be Careful
Human error is an important factor in most equipment-related injuries. Haste, carelessness and
lack of training are the primary causes of injuries.
Think before you act. A careful operator or maintenance man is the best insurance against an
accident.
Most operating injuries occur because of excessive speed, loss of control, failure to observe warning
signs, slipping or falling while entering or descending the machine, lack of a ROPS / FOPS structure
that protects the operator when the machine falls or a seat belt, or not watching in the direction of
travel.
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.
Most maintenance injuries occur during welding or when using hammers or wrenches. improper work
position, a slipped tool, missed aim, a broken tool, flying chips and no welding hood.

SECTION 2
SAFETY PRECAUTIONS
Page 4
Using Safety Equipment
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.
Be Prepared for Emergency Situations
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.
The fire extinguisher is fixed in the operator’s cab, LH side of the instrument panel.

Page 5
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.
The first aid kit is installed on the left side, behind the operator seat.
When your life or health is threatened because you are not able to leave the cab break the glass
with the hammer and get off the cab. The hammer is located on the left rear post in the cab.

SECTION 2
SAFETY PRECAUTIONS
Page 6
Jump Starting the Machine
Electrical system is 24 [V] 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. urn 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. Attach one end of second cable to the negative terminal (-) of booster battery and other end to
the machine's frame away from the battery.
5. Start the engine as described in Section 4.
6. After the machine has been started from the external power source, wait 5 minutes in order to
partially charge the machine batteries.
7. To remove cables, reverse above sequence exactly to avoid sparks near the battery.
Battery Explosion Danger

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.
Seat Belt
Every machine is factory equipped with a safety belt mounted to the operator’s seat.

Page 7
2.2. BEFORE STARTING THE ENGINE
Health Hazard While 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.
Follow the Safety Precautions

Before starting the engine, place the drive train lock lever (1) in the locked position (A) – bottom
lever position (A). Drive train control lever should be placed in neutral position.
Safety must always be the operator's most important concern.

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.
He must refuse to operate when he knows it is unsafe and consult his supervisor when safety is in
doubt.
Follow all machine-mounted safety signs before starting the machine engine.

SECTION 2
SAFETY PRECAUTIONS
Page 8
Mounting and Leaving the Machine
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 or
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.
Machine Inspection
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. Secure all caps and filler plugs.
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.

Page 9
Safety Within the Machine Working Area
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.
Preventing Fire
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.

SECTION 2
SAFETY PRECAUTIONS
Page 10
2.3. OPERATION
Follow the Safety Precautions

Before operating the machine read and know the Operator’s Manual. Know the ALL SAFETY
GRAPHICS.
Before starting the engine, be sure you understand all control functions. Check all drive train controls,
including the brake pedal and the drive train control lever. Check all gauges, warning lights and safety
devices. Correct malfunctions if any.
Avoid Dangers in the Work Area

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.
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.
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.
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.

Page 11
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.
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.
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.
Immediately Before Work
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.
Safety Precautions While Operating the Machine
After starting the engine, but before moving the machine, warn nearby personnel by giving
a couple of short horn blasts.
Only one person, the operator, should be permitted to ride on the machine when it is in operation.
Never hold the attachment controls in their extreme position after the attachment 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.
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 gear
before starting downhill. Use the decelerator and brake pedal to slow the machine.

SECTION 2
SAFETY PRECAUTIONS
Page 12
Using the Seat Belt
The machine is equipped with cab with integrated ROPS / FOPS structure, 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.
Preventing Fire
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.
Keep engine exhaust system and exhaust pipe clear of combustible material for your personal
protection.

Page 13
Safe Use of Mounted Equipment
Be sure cables and their anchor points are strong enough to handle the expected load. Inspect
carefully 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 or chain under load.
Be sure that the rear screen is securely fastened to the cab with integrated ROPS / FOPS structure
before operating the winch (if equipped). 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.
Health Hazards While Operating
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.
Do not operate the machine in a condition of extreme fatigue or illness.
Where noise exposure during machine operation or after repair exceeds levels defined by
applicable standards wear proper ear protective equipment.

SECTION 2
SAFETY PRECAUTIONS
Page 14
Machine Rollover (Tipping)
Use the seat belt all the time while operating the machine.
Do not jump off the machine in case of rollover (tipping) risk.
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.
Preventing Uncontrolled Machine Movement

When leaving the machine unattended for longer time, lock the drive train control lever with a lock
lever, lower mounted equipment completely to the ground, stop the engine, apply and lock the
brake, and turn the electrical master switch to the “off” position. If the machine is equipped with a
cab make sure that the cab door is locked.
Emergency Exits
Observe and know the use of emergency exits from the operator compartment.
Emergency Exit – RH Side Cab Door

Page 15
Internal Cab Door Lock Lever (LH And RH Side Of The Cab)
Open Cab Door Lock Release Lever (Left And Right Side Of The Cab)
Cab Window Latch (Side Window) (LH And RH Side Of The Cab)

SECTION 2
SAFETY PRECAUTIONS
Page 16
2.4. MAINTENANCE
Safety During Maintenance
Servicemen and their helpers only are allowed to remain at operator’ s stand 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.
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.
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.
Keep work area clean and dry. Remove oil and water spills immediately.
Never stand on the tracks or near the blade while the engine is operating.
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.
Safety While Servicing the Cooling System

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.

Page 17
Safety While Working on the Hydraulic System

Have all equipment resting on the ground and relieve all hydraulic system pressure by moving
control lever in various directions before removing any hydraulic component. Then lower
equipment on the ground.
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.
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.
Working Under Raised Equipment
Never work beneath the blade and/or ripper without proper blocking. Improper blocking could result
in serious injuries.
Never allow anyone to walk under or be near unblocked raised equipment.

SECTION 2
SAFETY PRECAUTIONS
Page 18
Servicing Tools and Equipment

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.
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.
Personal Safety Equipment

Do not carry loose objects in pockets that might catch on the machine or fall unnoticed into open
compartments.
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.
When using compressed air for cleaning parts, wear goggles or safety glasses with side shields.
Use an air nozzle, which limits the pressure to 210 [kPa].
Safety While Working on the Electric System

Before working on the machine, turn OFF the electrical system master switch and remove the
machine electronic system switch key so no one will start it unexpectedly. The electrical system
master switch is installed inside the right machine box.
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 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.

Page 19
Operating the Machine Indoors
Provide proper ventilation when operating in a closed building to avoid danger of exhaust gases.
Exhaust gases are dangerous and can cause severe poisoning, unconsciousness and death.
Safe Distance from Moving Parts of the Machine
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.
Be Careful with Chemical Products
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.
Safety While Lifting the Machine
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.

SECTION 2
SAFETY PRECAUTIONS
Page 20
Fire Hazard
Do not use an open flame to check for leaks or fluid levels anywhere around the machine.
Do not pile up oily or greasy rags. They are a fire hazard. Store them in an approved, closed metal
container.
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.
Cab With Integrated ROPS / FOPS Structure Maintenance
Do not attempt to repair the ROPS / FOPS after an accident. Repaired ROPS / FOPS do not
provide the original strength and protection. Contact your distributor for information on structure
replacement. Do not operate the machine until ROPS / FOPS replacement is done. Do not cut,
drill, weld, grind the integrated ROPS / FOPS cab as all these operations have a detrimental effect
on its structure and safety.
Safety While Working on Batteries
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, non-ventilated area. Provide
proper ventilation to guard against accidental explosion of an accumulation of the explosive gas
given off in the charging process.
Seat Belt
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.
Proper Waste Handling
ALWAYS KEEP IN MIND THE PROTECTION OF THE ENVIRONMENT. Do not pollute the
environment with oil, fuel or other environmentally hazardous substances. Used filters, residual oil
and fuel should always be disposed in accordance with the relevant environment protection
procedures.

Page 21
Improper waste disposal may be dangerous for the environment.

Some materials used in the machine, such as oil, fuel, coolant, brake fluid, filters and batteries,
may be a source of potentially harmful waste.
Use sealed containers for drained fluids. Do not use containers intended for food or beverages so
no one can consume the content by mistake.
Do not pour waste on the ground, into the sewage system or any water source.
Refrigerant can damage the atmosphere if released from the air conditioning system into the air.
Government regulations may required that a certified air conditioning service center is contacted
for the recovery and recycling of used refrigerant.
Please consult your local environment protection inspector or an Authorized Construction

Equipment Distributor about proper waste disposal.
Precautions Regarding DEF
General Characteristics and Precautions Regarding Behaviour

DEF is a colourless, transparent, aqueous urea solution with the concentration of 32.5%. It is
mainly composed of urea used in the cosmetic, medical and pharmaceutical industry, among other
things as well, as to produce artificial fertilizers. The following situations require immediate action:
• If DEF contacts skin you can experience inflammatory state. Immediately take the
contaminated cloths or shoes off and wash your skin with water. You can use soap to
improve washing effectiveness. When the skin inflammatory state or pain is diagnosed
immediately see the physician.
• In case you swallow DEF do not induce vomiting. If the fluid is swallowed rinse mouth
carefully with water and see the physician.
• Avoid eye contact. If the fluid gets into the eyes wash them with clean water for several
minutes and then see the physician.
• Use protective goggles when handling DEF. Use also protective gloves to avoid skin
contact.

SECTION 2
SAFETY PRECAUTIONS
Page 22
Precautions Regarding Fluid Filling

The DEF tank can be filled only with DEF. If you fill the tank with diesel oil or petrol you can cause
fire. Adding some fluids or means may results in toxic gases.
When the DEF tank cap is open the ammonia vapours may be released. Do not out your face
close to the filler hole when filling the fluid.
Precautions Regarding Storage

If DEF is hot, harmful ammonia vapours may develop. The fluid tank must be tightly closed. The
fluid containers can be opened only in a well-ventilated room.
Protect DEF from sun. Always use the original container. Do not replace the DEF container with
other container. If DEF is stored in the iron or aluminum container it may release toxic gas and the
container can corrode due to the resulting chemical reaction.
Precautions Regarding Fire and Leak Risk

DEF is nonflammable but in the case of fire it can contribute to ammonia vapours.
If you spill DEF wipe the stain and flush the contaminated place with water. If you do not removed
the spilled DEF or clean the contaminated place the surface may be damaged and toxic gases
may be released.
Other Precautions.
When DEF is disposed treat it as an industrial waste. The DEF container is also the industrial
waste. It should be disposed in the same manner.
Do not dispose DEF in the iron or aluminum containers because the fluid can react with them
releasing toxic gases or causing corrosion. Use the resin (PP, PE) or stainless steel container.
Do not touch the fluid leaked from Urea SCR. This fluid becomes an acid when it reacts with sulfur
present in the fuel or integrated oxidizing catalyst. When the fluid contacts your skin flush it with
plenty of water.
Do not relocate or modify the fuel treatment equipment. It poses a risk of harmful gas release
which is dangerous for the environment as well as violates the law.

Page 23
2.5. WHEN PARKING
Parking Place
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.
How to Secure the Machine

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 to lock position, shut off the engine, apply and lock the parking brake. Turn on
the electrical system master switch. Take the keys out both from the electrical system master switch
and the starter switch. Always lock up the machine when leaving it unattended, including any anti-
vandalism attachments.
Parking the Machine

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.
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.
Loading and Unloading the Machine From a Transport Platform

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.

SECTION 2
SAFETY PRECAUTIONS
Page 24
2.6. SAFETY SIGNS LOCATION
Fig. 2.1. Safety Sign Location on the Machine

Page 25
Legend for Fig. 2.1.

1 – Safety Sign – Runover/Backover (Both Sides - 2 Pcs)
2 – Safety Sign – Engine Guard (Both Sides – 2pcs)
3 – Safety Sign – Cranking (On The Visible Side Of The Cranking Motor)
4 – Safety Sign – Hydraulic Pressure (At Track Adjuster – Inner Side; Both Sides – 2pcs)
5 – Safety Sign – Fall (Front And Rear – 2pcs)
6 – Safety Sign – Cooling System (Engine Hood, Next To Radiator Filler Plug)
7 – Safety Sign – Pressurized Hydraulic System Reservoir (Reservoir Rear Surface)
8 – Safety Sign – Battery (Battery Compartment Housing - RH Side Of The Machine)
9 – Safety Sign – Electric System (Battery Compartment Housing - RH Side Of The Machine)
10 – Safety Sign – Safety Precautions (Cab's Interior)
11 – Safety Sign – Emergency Exit (RH Side Cab Door)
2.6.1. SAFETY SIGNS
The machine is provided with safety signs (pictograms) what positively identify hazards involved.
The section which follows will explain the hazards presented in the safety signs and a way how to
cope with them.
Run over danger

 while reversing.
 resulting in death or injury.
DO:
 stay at a safe distance from the dozer when the engine
is running.
Decal 1. Safety Sign – Run Over

SECTION 2
SAFETY PRECAUTIONS
Page 26
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.
Switch off the engine and the electrical system master

switch, and remove the machine electronic system switch
key before performing maintenance or repair work. Wait
until the engine exhaust gets cool.
Decal 2. Safety Sign – Engine Guard
Risk of accident
 caused by starting the engine outside the
operator's position;
Do not:
 start the engine outside the operator's position.
Do:
 start the engine from operator's seat only.
Decal 3. Safety Sign – Cranking

Page 27
Danger of flesh erosion

 caused by high-pressure spray
 resulting in injury.
Pressure! – in the track tensioner hydraulic system.
Do:
 Switch off the engine and the electrical system master
switch, and remove the machine electronic system switch
key before performing maintenance or repair work;
 during servicing or repair, follow the guidelines given in
the Operator’s Manual or Service Manual – before
removing any part of the hydraulic system remember to
reduce the fluid pressure by loosening the valve by one
complete turn.
Decal 4. Safety Sign – Hydraulic system pressure
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 5. Safety Sign – Fall from Height

SECTION 2
SAFETY PRECAUTIONS
Page 28
High-pressure spray – Erosion of flesh.
Engine Cooling System Pressure.
Remember to shut off the engine, remove the key from the
electric system master switch and remove slowly the filter plug
before attempting any service or repair operation.
Decal 6. Safety Sign – Cooling System
Risk of skin injury by high-pressure spray.
Do:
1 Fill the reservoir to the allowable level only.
2 During servicing or repair, follow the instructions given in
this Operator’s Manual – loosen the reservoir fill cap
prior to removal of any system component.
Do not “overfill” – the reservoir is to be top off to allowable

level only.
Decal 7. Safety Sign – Pressurized Hydraulic System Reservoir

Page 29
Danger of explosion
— danger of gas explosion produced during the battery

charging.
— resulting in death or injury.
Do not:
— use open flame near the battery.
Do:
— when charging the battery, follow the instructions given in
the Operator's Manual – charge the battery with an open
cover, in well-ventilated areas.
Decal 8. Safety Sign – Battery
Danger of electric shock

24 [V] Electrical system – negative ground
Do not:
 connect cables, for example starting battery to the cab's
components and/or base of the operator's cab.
Do:
 make all electrical connections with the engine and cranking
system off.
 Follow the recommendations provided in the Operator's
Manual.
 When an additional power source such as an auxiliary
battery is needed:
● first (1), you should connect the positive terminals
(+) of the machine and booster battery with one
cable.
● then (2), attach the cable from the negative (-)
terminal of booster battery to vehicle frame away
from battery;
● disconnect the cables in reverse order.
Decal 9. Safety Sign – Electrical System

SECTION 2
SAFETY PRECAUTIONS
Page 30
Risk of accident
 caused by the operation or servicing the machine by
untrained personnel and/or failure to comply with safety
rules and recommendations, and use of improper
protective structure – integrated ROPS / FOPS cab;
Do not:
 start, road and operate the machine if untrained or
unauthorized.
 stay and remain on machine areas marked with this
sign.
 repair and/or modernize the ROPS / FOPS operator's
protective structure.
DO:
 read and adhere to safety rules and recommendations
provided in the Operator's Manual before starting the
operations,
 adjust the operator's seat and fasten the seat belt,
 lower equipment to the ground, apply parking brake
and shut the engine off prior to service and inspection
works.
 integrated ROPS / FOPS cab, which was involved in
machine rollover accident, was repaired or modernized
– is to be replaced by a new one installed as described
by the manufacturer assembly instruction.
Decal 10. Safety Sign – Safety Rules
Marking: "Emergency exit"

 to leave the operator's position in cases of normal
access blocking.
Do:
 in the case of the access blocking and having to
leave the operator's seat – open a marked window or
door.
Decal 11. Safety Sign – Emergency Exit

Page 31
2.7. ADDITIONAL INFORMATION
1. Vibrations
CAUTION: Vibrations that the machine operator’s body is subjected to will depend
to a large extend on a number of factors, that can include but are not limited to the
way the machine is being operated, terrain conditions and roading speed. All of
these are independent of the machine design. Due to this it is impossible to
determine in an unambiguous way the vibrations levels that will be representative
for the operator’s body exposure to vibrations. The vibrations levels transmitted to
the operator’s body and determined below as per the EN 474-1 are not designed to
be used to determine the operator’s exposure to vibrations while operating this
machine.
The field experience has proven that the appropriate operator’s seat design is the most effective
way to limit and lower the vibrations that are transmitted to the entire body coming from the defined
machine group. The factory installed CAB operator’s seat will fulfill the requirements that are
imposed by the EN ISO 7096: 2000, in most demanding vibrations range that can be found in real
operating conditions.
Machine operated in real operating conditions will originate vibrations transferred to the operator’s
body, conditioned that the operator’s seat is used as specified, that can rang over a level less than
0.5 [m/ sek2] to a momentary exposure equal to 1.4 [m/ sek2].
The equivalent weighted vibrations acceleration level measured at the operator’s seat in conditions
defined according to PN-EN 1032: 2010 Standard does not exceed a value of 0.5 [m/s²] 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/s²].
2. Noise
The equivalent noise level for a new machine at the operator’s seat (cab) measured according to
ISO-6396 Standard does not exceed an admitted value of 78 [dB (A)].
Acoustic power level (LwA) around the machine – refer to a value on the decal that can be found
on the operator’s cab outboard rear wall, L.H. side. The test has been carried out per 2000/14/EC
Directive with extensions used the test method as per ISO 6395.
3. Temperature range and operational conditions
A dozer can be operated in temperature ranging from -31 [ºC] to +45 [ºC]. A dozer in standard
configuration is not adapted to operation in terrain where a mixture of gasses, vapors, aerosols or
dust with air creates explosion hazard zones.
4. Waste gases emission
The diesel engine used in the machine fulfills the international standards on waste gases
emissions EPA Tier 4 Final and EU Stage V for diesel engines provided with automatic ignition
designated to power the construction machinery.

SECTION 3
MACHINE TRANSPORT
AND STORAGE
MACHINE TRANSPORT AND SECTION 3
STORAGE
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 .............................................................................................. 5
3.3. MOVING A DISABLED MACHINE ............................................................................................ 6
3.4. MACHINE STORAGE ............................................................................................................. 11
3.4.1. PREPARING FOR STORAGE ................................................................................... 11
3.4.2. SERVICING MACHINE DURING STORAGE............................................................. 14
3.4.3. PREPARING FOR OPERATION AFTER STORAGE ................................................ 15

PAGE 3
STORAGE
3.1. MACHINE TRANSPORT
3.1.1. GENERAL
IMPORTANT: When shipping this machine secure the air pre-cleaner and the exhaust
outlet. 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. While loading the machine, block the wheels of
the trailer and the truck with wheel chocks (Fig. 3.1).
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,
turn the electrical system master switch to the OFF position, remove the keys from the
electronic machine and system switch, and the master switch.
6. Tie the machine down securely to prevent unintentional movement and block it at the front and
rear with wooden props.
DANGER! Failure to secure the machine to the truck during transporting can
result in property damage, personal injury or death.
7. Confirm that the height of the load clears various limitations on the way (width and height of
tunnels, size of guards, branches of trees, etc.) and meets all laws and regulations governing
transportation.

SECTION 3
MACHINE TRANSPORT AND
PAGE 4
STORAGE
Fig. 3.1. Vehicle and Machine Protection during Trailer Loading

1 - Vehicle Protective Chocks
2 - Machine on Trailer Protective Chocks
8. 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.
Fig. 3.2. Machine Protection during Rail Car Loading

1 - Machine on Rail Car Protective Chocks
2 - Placement (center of gravity in the car symmetry axis)
3 - Cab Packaging - Special Chest

PAGE 5
STORAGE
3.2. LIFTING MACHINE ON SLINGS
Fig. 3.3. Lifting Machine on Slings

1. Slings Attach Points
2. Sling (2)
3. Strut
4. 28” Track Shoe Width
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 41250 [kg].

SECTION 3
PAGE 6
STORAGE
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 tow bar pins or tow hooks (if equipped). Do not use
cables having broken wires, thin spots or loops. Do not use a chain for towing.
The strength of the towing cable or bar must withstand a load of at least
150 percent of the gross weight of the machine being towed.
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 compartments are 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. After pumping grease on the brake pistons 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 are
damaged. 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 to 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.
If the machine can be towed but the engine, steering drive and steering hydraulic system are
operable, than the machine can be towed with a rope or rigid tow bar following the procedure
described below:
1. Lock the drive train with a lock lever.
2. Attach a towing cable or a drawbar of a sufficient strength to a pull hook (1, Fig. 3.4) or drawbar
(1, Fig. 3.5).
3. Start the engine and unlock the drive train lock lever.
4. Release the brake pedal and tow the machine for a short distance only. Keep the engine
running at half throttle while towing.

PAGE 7
STORAGE
Fig. 3.4. Pull Hook Location at Machine

1 – Front Pull Hook
Fig. 3.5. Towing Hitch Location at Machine

1 – Rigid Drawbar at Machine Rear
TOWING BROKEN MACHINE – MACHINE IS NOT EQUIPPED WITH BRAKE UNLOCKING

SYSTEM
If the tractor can be towed but the engine and/or steering hydraulic system are inoperable, so the
brakes are applied and machine cannot be moved. The machine can be towed following the
procedure described below:
1. Lock the drive train with a lock lever.
2. If the machine is on a slope, then:
- 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 tow bar 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 larger 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.

SECTION 3
PAGE 8
STORAGE
3. Remove output shafts linking steering drive to final drives. To do it proceed as follows:
- Remove bolts with washers (1, Fig. 3.6) that secure cover (2). Remove shims (7).
- Remove retaining ring (3).
- Thread screw (1) into the retainer opening (4) and remove the retainer with O-ring,
- Screw the bolt (1) into the output shaft (5) hole and remove the shaft.
- install retainer with O-ring (4) and retaining ring (3).
- Install cover (2) together with shims (7).
- 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, Section 7F.
Fig. 3.6. Removal of Output Shaft Linking Steering Drive to Final Drive
1. Bolt with Washer 5. Output Shaft
2. Deck Plate 6. Where to Apply Loctite 120
3. Retaining Ring 7. Shims
4. Retainer with O-ring

PAGE 9
STORAGE
TOWING DAMAGED MACHINE EQUIPPED WITH THE BRAKE UNLOCKING SYSTEM
(if applicable)
If the machine can be towed but the engine and/or drive hydraulic system are inoperable, than the
brakes are applied and machine cannot be moved. If the machine is equipped with the brake
unlocking system (Fig. 3.7) it can be towed following the procedure described below:
1. Put the drive train lock levers in the “Locked” position (drive train lock lever in the bottom
position.) Engine not running.
2. If the machine is on a slope, then:
a. with a small grade and hard ground, block the machine track chains with wooden throngs;
b. with a steep slope, block the machine with a tow bar attached to a tow bar 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. The brake pedal must be in the “released” position.
4. Release the brakes, supplying the pressurized grease to the L.H. and R.H side brakes To do it
proceed as follows:
a. unscrew the bolts of the access covers at the rear L.H and R.H side and lift the cover to gain
access to the brake release valve assembly;
b. shift the tow valve lever (1, Fig. 3.7) to the position parallel to the valve supply rigid hoses –
tow ON.
c. open the door at the machine L.H side and attach two pressure gauges (having a reading
range of 0 – 4 [MPa]) to quick disconnects (1 and 2, Fig. 3.8) at the drive train diagnostic
center, to take a reading of pressurized pumped grease.
d. attach a hand lubricator to one of the quick disconnects (2, Fig. 3.7). Pump a sufficient amount
of grease to release the brakes. The teed pressure gauge is to read a pressure ranging from
1500 to 1800 [kPa]. The amount of grease required depends on the amount of pressure
dissipation in the system.
e. Repeat operation from Step "d" for the second quick disconnect (2); in this state the brakes
are released and the machine can be towed;
f. Pumping an extra grease to a quick disconnect (2) may prove necessary to compensate for
the pressure dissipation as the pressure drop below 700 [kPa] will cause the brakes to apply
automatically.
NOTE: Bear in mind that applied brake pedal will cause that the system pressure will
dissipate and, consequently, the brakes will apply.
g. once the towing is completed and the hand lubricator is removed, disconnect the tow bar and
shift the tow valve lever (1, Fig. 3.6) to the position perpendicular to the supply rigid hoses –
towing OFF.
h. screw the covers located on RH and LH side in the rear of the machine.

SECTION 3
PAGE 10
STORAGE
1 2
Fig. 3.7. Tow Valve and Quick Disconnects (Rear of the Machine)
1. Valve lever parallel to the flow direction – Tow OFF
2. Quick Disconnects for Brakes Releasing
i. Once the machine repaired, start the engine, apply the brake pedal until all grease has been
removed from the brake system and both brake pressure will dissipate to zero with a brake
pedal applied; Disconnect the pressure gauges from the quick disconnects on the diagnostic
center (1 and 2, Fig. 3.8) and close the door on the LH side of the machine.
j. Remove grease from hydraulic lines and fittings hooked to quick disconnects (1 and 2,
Fig. 3.8) before starting the machine operation.
2 1
Fig. 3.7. Diagnostic Center (Machine LH Side)

1 – Quick Disconnect RB – Right Brake Clutch
2 – Quick Disconnect LB – Left Brake Clutch

PAGE 11
STORAGE
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. Correct any defects found. If required, Consult Authorized Distributor of Construction Equipment.
3. Thoroughly clean the machine, be sure to rinse off any corrosive deposits.
COOLING SYSTEM
4. Clean the cooler. Refer to “COOLING SYSTEM” in Section 5.
5. 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 "COOLING SYSTEM“ and "REFILL LUBRICANT AND FLUID SPECIFICATIONS
CHART" for the proper antifreeze and conditioner concentrations.
IMPORTANT: Under no circumstances should the vehicle be stored with a dry cooling
system.
6. 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 have no contact with oil.
It is recommended that the application of the vapor corrosion inhibitor is injected or sprayed into
the hollow space of the tank or system.
Available vapor corrosion inhibitors, VCI have been listed below:
Inhibitor I - ANTICORIT VCI UNI O-40 FUCHS OIL CORPORATION
Inhibitor II - NOX RUST VCI 10 OIL by DAUBERT CHEMICAL COMPANY (approved for use
corrosion inhibitor; use carefully according to the manufacturer instructions.)
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. Store a container in a cool,
well-ventilated place.
CAUTION! Volatile corrosion inhibitors may cause eye or skin irritation. Avoid
prolonged exposure to vapor.

SECTION 3
PAGE 12
STORAGE
EQUIPMENT SYSTEM
7. Add VCI into hydraulic equipment oil reservoir.
Inhibitor I – 3900 [ml]
Inhibitor II – 2460 [ml]
DRIVE TRAIN
8. Add VCI into final drives. Per each of both final drives pour VCI through the level and filler oil
plugs.
9. Add VCI into pivot shaft housings. Per each of both pivot shaft housings pour VCI through the
hole of oil filler plug and dipstick.
10. Add VCI through oil filler sleeve to oil reservoir in the main frame.
FUEL SYSTEM
11. Drain the water from the fuel tank.
12. Replace the fuel filter and vent the fuel system. Refer to “FUEL SYSTEM” in Section 5.
13. Add VCI in a fuel tank to protect its inner surfaces.
Inhibitor I – 1200 [ml] (the quantity of fuel in the tank 40 [l])
Inhibitor II – 1040 [ml] (the quantity of fuel in the tank 40 [l])
14. 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.
15. Start the engine and run idle at half throttle for 3 minutes and then stop the engine.
ENGINE LUBRICATION SYSTEM

16. Replace engine oil and oil filter. Refer to “ENGINE” in Section 5.
17. Add VCI into engine crankcase by oil filler tube.
18. Start the engine and run idle at half throttle for 30 minutes and then stop the engine.
19. Add VCI into engine flywheel housing.

PAGE 13
STORAGE
AIR INTAKE SYSTEM AND EXHAUST SYSTEM
20. Clean or replace the air cleaner filter elements. Refer to “AIR INTAKE (AIR CLEANING) AND
EXHAUST SYSTEM” in Section 5.
21. Add VCI into intake manifold to protect the part of cylinders surface above the pistons against
corrosion. Pour one portion of VCI into the air intake manifold after removing the rubber
connection between connection tube and manifold. The second portion of VCI pour into air inlet
tube after removing the air cleaner elements.
Inhibitor I – 60/60 [ml]
Inhibitor II – 110/110 [ml]
22. Immediately after the spreading of the VCI in the engine block, seal all external openings
(i.e. air precleaner inlet, engine exhaust pipe outlet, filler plugs, breathers, 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.
DEF DIESEL EXHAUST FLUID TANK

DEF is sensitive to high and low temperature. If the machine is used at the temperature higher
than 25[°C] DEF decomposition starts releasing ammonia that is corrosive and at the temperature
below -11 [°C] DEF starts freezing.
23. Fill the tank with DEF completely (green gauge range) when the storage temperature ranges
from -11 [°C] up to +25 [°C] . If the tank interior is dry the urea sediments will be formed which
may results in the component malfunction.
24. If the storage temperature is below -11 [°C] or above +35 [°C] drain DEF from the system.
Dispose the drained DEF according to the local regulations.
ELECTRICAL SYSTEM
25. Remove the battery and place it on wooden platform. Then store it in a cool, clean, dry, well-
ventilated place away from areas provided for storing or dispensing fuel and oil, not near any
heat sources. Preferable storage temperature range is between 0 [°C] to +21 [°C]. Be sure the
battery is fully charged.
IMPORTANT: Do not place battery on a concrete floor in temperature below 0 [°C].
WARNING! Be sure the electrical master switch id OFF during battery

disassembly to eliminate a risk of sparking.
MOUNTED EQUIPMENT AND OTHER MACHINED SURFACES

26. If the blade is detached for storage retract piston rod into the tube and secure (e.g. with wire)
against sliding. Attach the cylinders to the machine using hangers to avoid damage.
27. Coat all machined surfaces (especially piston rods and bushing bearing surface) and unpainted
surfaces with chassis grease (e.g. Naftochem AKORIN N-2 or Valvoline TECTYL 502 C
grease; for arctic conditions: Orlen GREASEN SYNTEX HT 2 or Lotos TYTALIT AV 395) to
prevent rust.

SECTION 3
PAGE 14
STORAGE
28. Lubricate all lube points of the machine as outlined in the SCHEDULED MAINTENANCE
GUIDE in Section 5. Naftochem LITOMOS EP-23 or other grease may be used, refer to the
“RECOMMENDED LUBRICANT CHART” in Section 5.
NOTE: Be sure to lubricate or grease all linkage connections, joints, nuts, pins, shafts, and
bushings which are endangered by corrosion.
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.
WARNING! Charge the battery in well ventilated room only. Hydrogen released while
charging can cause the explosion.
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. If required, Consult Authorized Distributor of Construction Equipment.
2. Remove all storage seals from the machine. (i.e. engine air precleaner, engine exhaust pipe
outlet, filler plugs, breathers, etc.).
3. Install fully charged battery. Refer to “ELECTRICAL SYSTEM” in Section 5.
WARNING! Be sure the electrical master switch id 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! Always connect the negative ground cable last to minimize the chance
of sparks or an explosion. Battery cables should not rub the mounting brackets.
4. Check the coolant level in the radiator and add proper concentrations of antifreeze, 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. When the machine is stored at the temperature of -11 [°C] up to +25 [°C] check the DEF fluid
level in the tank and fill the tank completely if necessary (green gauge range).
6. Follow steps 7 through 28 of "PREPARING FOR STORAGE".

PAGE 15
STORAGE
3.4.3. PREPARING FOR OPERATION AFTER STORAGE
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 the 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: air cleaner primary filter, engine exhaust pipe, fill
plugs, breathers, etc.
7. Service the air cleaner. Refer to “AIR INTAKE (AIR CLEANING) AND EXHAUST SYSTEM” in
Section 5.
8. Replace fuel filters. Refer to “FUEL SYSTEM” in Section 5.
9. Refill the fuel tank with an approved Diesel fuel. Refer to “REFILL LUBRICANT AND FLUID
SPECIFICATIONS CHART" in Section 5.
10. Lubricate all points of the machine, particularly as outlined in the "SCHEDULED
MAINTENANCE GUIDE", Section 5.
NOTE: Be sure to lubricate or grease all linkage connections, joints, nuts, pins, shafts, and
bushings which are endangered by corrosion.
11. Drain engine oil from the crankcase and replace the engine lubricating oil filters. Refer to
“ENGINE” in Section 5.
12. Before the engine is started after storage replace the DEF filter and fill the tank with the fresh
DEF fluid according to the procedure described in the INSTRUCTION MANUAL, Chapter 5.
NOTE: When you have to clean the DEF tank we recommend that you contact the
Authorized Construction Machinery Distributor.
13. When the DEF tank is empty rinse it with the fresh DEF before it is filled again. Do not re-use
the old fluid. Rinsing the tank with distilled or regular water may result in the system alarm
connected with the inappropriate DEF quality.
Dispose the drained DEF according to the local regulations.
14. 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! Always connect the negative ground cable last to minimize the chance
of sparks or an explosion. Battery cables should not rub the mounting brackets.

SECTION 3
PAGE 16
STORAGE
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.
15. Start the engine. Refer to “STARTING THE ENGINE” in Section 4. After starting the engine,
observe all the gauges and lights on the instrument panel for proper operation of engine.

SECTION 4
OPERATION
OPERATION SECTION 4
CONTENTS
PAGE
4.1. MACHINE PRECAUTIONS............................................................................................................ 3
4.2. UNIVERSAL SYMBOLS FOR INSTRUMENTS AND CONTROLS ............................................... 4
4.3. MACHINE INSTRUMENT PANEL ................................................................................................. 6
4.3.1. MACHINE INSTRUMENT PANEL ................................................................................. 6
4.3.2. DRIVE TRAIN MONITORING DISPLAY WITH ENGINE HOURMETER ...................... 18
4.3.2.1. DRIVE TRAIN SYSTEM MONITORING DISPLAY NORMAL OPERATING
MODE (DRIVE TRAIN CONTROL SYSTEM NORMAL OPERATION) ............ 19
4.3.2.2. DRIVE TRAIN SYSTEM MONITORING DISPLAY DIAGNOSTICS MODE
– DRIVE TRAIN CONTROL SYSTEM DIAGNOSTICS FUNCTION ................ 19
4.3.2.3. MONITORING (DIAGNOSTICS) OF SELECTED ENGINE
OPERATING PARAMETERS .......................................................................... 24
4.3.3. ENGINE SPEED CONTROL POTENTIOMETER PANEL............................................ 25
4.3.4. AIR CONDITIONING AND HEATING SYSTEM PANEL .............................................. 26
4.4. CAB CONTROLS......................................................................................................................... 28
4.4.1. CAB WINDOW WIPER PANEL ................................................................................... 28
4.4.2. DOME LIGHT .............................................................................................................. 28
4.4.3. FLASHLIGHT (OPTION) ............................................................................................. 29
4.4.4. POWER SOCKETS (12 V) AND USB SOCKETS ........................................................ 29
4.4.5. AUDIO SYSTEM ......................................................................................................... 30
4.4.6. REVERSING CAMERA ............................................................................................... 42
4.5. CONTROLS AND ADJUSTMENT ............................................................................................... 43
4.5.1. OPERATOR'S SEAT ................................................................................................... 43
4.5.2. SEAT BELT ................................................................................................................. 46
4.5.3. DRIVE TRAIN CONTROL LOCK LEVER ................................................................... 47
4.5.4. DRIVE TRAIN CONTROL LEVER ............................................................................... 47
4.5.5. BRAKE PEDAL............................................................................................................ 48
4.5.6. DECELERATOR PEDAL ............................................................................................. 48
4.5.7. ELECTRICAL SYSTEM MASTER SWITCH ................................................................ 49
4.5.8. EQUIPMENT CONTROL LEVERS .............................................................................. 50
4.5.9. OPERATOR'S CAB ..................................................................................................... 50
4.6. STARTING THE ENGINE ............................................................................................................ 52
4.6.1. NORMAL START (TEMPERATURE ABOVE 4 [°C]).................................................... 53
4.6.2. ETHER INJECTOR START (TEMPERATURE BELOW 4 [°C]) ................................... 55
4.6.3. STARTING AFTER OIL CHANGE OR LONGER STORAGE....................................... 56
4.7. STOPPING THE ENGINE............................................................................................................ 56
4.8. PROPER ENGINE OPERATION RULES .................................................................................... 57
4.9. DRIVING THE MACHINE ............................................................................................................ 57
4.10. MACHINE SPEED AND DIRECTION CHANGES ..................................................................... 58
4.10.1. MACHINE SPEED CHANGE – MANUAL CONTROL ................................................ 59
4.10.2. GEAR PRESETING MODE ....................................................................................... 61
4.10.3. AUTO-DOWNSHIFT MODE ...................................................................................... 61
4.11. CONVERTER OVERHEATING ................................................................................................. 62
4.12. DOWNGRADE OPERATION..................................................................................................... 62
4.13. OPERATING OVER AN OBSTRUCTION.................................................................................. 62
4.13.1. ALLOWABLE WATER IMMERSION .......................................................................... 62
4.14. STOPPING THE MACHINE ....................................................................................................... 63
4.15. PARKING THE MACHINE ......................................................................................................... 64
4.16. OPERATING MOUNTED EQUIPMENT .................................................................................... 64
4.16.1. BLADE CONTROL LEVER ........................................................................................ 65
4.16.2. RIPPER CONTROL LEVER ...................................................................................... 67
4.16.3. RIPPER SHANK PIN CONTROL ............................................................................... 68

SECTION 4
OPERATION
4.17. POSITIONING THE BLADE ...................................................................................................... 70
4.17.1. POSITIONING THE DOZER BLADE WITH A TILT CYLINDER ................................. 70
4.17.1.1. BLADE TILT ................................................................................................71
4.17.1.2. PITCHING THE BLADE WITH HYDRAULIC TILT/PITCH............................ 71
4.17.1.3. LEVELING THE BLADE ................................................................................72
4.17.2. BULLGRADER BLADE POSITIONS “C” – FRAME (G-2 EQUIPMENT)
(MECHANICAL OPTION) ..........................................................................................73
4.17.2.1. ANGLING THE BLADE .................................................................................73
4.17.2.2. TILTING THE BLADE ....................................................................................75
4.17.2.3. LEVELING THE BLADE ................................................................................76
4.18. OPERATING TECHNIQUES ..................................................................................................... 77
4.18.1. DIGGING AND CLEARING........................................................................................77
4.18.2. TRANSPORTING, LOADING AND PILING ............................................................... 82
4.18.3. BREAKING PILES AND SPREADING ....................................................................... 83
4.18.4. RIPPING ....................................................................................................................85
4.18.4.1. PRIOR TO OPERATION ...............................................................................85
4.18.4.2. OPERATING TECHNIQUES ......................................................................... 86
4.18.4.3. COLD WEATHER OPERATION .................................................................... 86
4.19. ECONOMICAL OPERATION OF THE MACHINE..................................................................... 86
4.20. OPERATING ELECTRIC WINCHES TO LOWER BOTTOM ENGINE COVER
AND BOTTOM TRANSMISSION COVER (OPTION)............................................................... 87
4.20.1. WINCH OPERATION CONTROL ..............................................................................87
4.20.2. BOTTOM TRANSMISSION AND ENGINE COVERS ADAPTED TO WORK
WITH THE WINCH ....................................................................................................90
4.20.3. LOWERING AND RAISING THE BOTTOM COVER WITH THE WINCHE ................ 92
4.20.4. WINCH ELECTRIC SYSTEM DIAGRAM ................................................................... 93

OPERATION SECTION 4
PAGE 3
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 Operation Manual carefully and follow all instructions and
precautions. Refer to and read Section 2 carefully and follow all precautions.
Before starting or operating this machine, 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 function of steering lever, brakes control,
hydraulic controls, instruments, 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.
Do not load the machine when the engine is started. Upon starting check the indicated engine oil
pressure. Stop the engine if the proper lubrication pressure is not reached after 15 [sec.]. Allow the
engine to idle for 3 to 5 minutes before placing under load. Do not allow the engine to idle for a long
time (longer than 10 minutes).
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 machine unattended.
If the machine 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 machine 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 machine 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 let it run at low speed 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.
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 machine to the load, drive the machine forward slowly until all
slack is taken out.
Before shutting down, operate the engine at low idle (no load) for three to five minutes. This will aid in
cooling the engine and turbocharger.

SECTION 4
OPERATION
PAGE 4
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
Control Lever
REVERSE or FWD or Next speed Next speed
ON (GENERAL) OFF (GENERAL) FWD or UP Operation
DOWN REVERSE rotation (straight-line)
Directions
1 2
Variable
Read Operator’s NEUTRAL Machine direction Machine direction Performance setup
Performance Note - warning Hourmeter
Manual position – forward – backward – low range
Control
N F R L
Performance Efficiency
Time, operational Battery and/or Air conditioner Air conditioning Temperature
setup – high measurement Socket
lag, e.x. 120 s power - off and/or heater filter system checking
range and/or control
H TEST
Front working Rear window
Battery switch Voltmeter Dome light Windscreen wiper Window washer Fan
lights wiper
Coolant Engine rotational

Horn Fuel filler Fuel level Air cleaner Coolant level Engine (general)
temperature speed
Engine oil Engine start Drive train oil Hydraulic oil

Oil pressure Oil filter Oil level Oil temperature
pressure support filler pressure
Hydraulic oil filler Hydraulic oil level Vehicle FWD or REVERSE LH Track driven RH Track driven
Dozer attachment
Undercarriage RH Track brake LH Track brake Hydraulic filter Raise Hold Lower
- blade
Fig. 4.1. Universal Graphic Signs

OPERATION SECTION 4
PAGE 5
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 Reading engine Transmission oil Transmission oil Transmission oil Clutch oil
Brake ON Lift or lift point
(general) fault codes filter temperature level pressure
High exhaust
Interior Engine fan driver STOP the engine Check the
Engine low RPM Engine high RPM Engine failure system
Heater/heating system filter immediately engine
temperature
Aftertreatment
Aftertreatment Engine ECM power
diesel particulate Ether fluid Rotating
diesel particulate
filter regeneration
Low DEF level intake air supply. Data
container Flashlight
Fuel cut-off
filter recording
disabled filter
Pump Control system

Door lock Door lock Washer filler LWA plate Brake lock Reversing camera
pressure pressure
Fig. 4.1. Universal Graphic Signs

SECTION 4
OPERATION
PAGE 6
4.3. MACHINE INSTRUMENT PANEL
GENERAL
This section covers the location and function of the machine instruments and controls. More detailed
information regarding operation of controls is described in the following text within this section.
Regardless of previous experience as an operator; you must be thoroughly familiar with the location
and functions 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
Fig. 4.2. Machine Instrument Panel

OPERATION SECTION 4
PAGE 7
Description for Fig. 4.2.

1. Integrated Display
2. “Menu” Button For Turning Off The Drive Train And Engine Diagnostics Program And For Adjustment Of
Display Screen Brightness
3. “ENTER” Button For Turning On The Machine And Engine Diagnostics Program
4. Machine And Ripper Lights On/Off Button
5. Cab Lights On/Off Button – Rear (Front – Option)
6. Side Lights On/Off Button
7. Flashlight On/Off Button
7(*). Button To Select Individual Engine Diagnostics Or Drive Train Diagnostics Program Parameters (Scrolling
Forward) – In The Diagnostics Program Mode
8. Reversing Camera On Button
8(*). Button To Select Individual Engine Diagnostics Or Drive Train Diagnostics Program Parameters (Scrolling
Backward) – In The Diagnostics Program Mode
9. Engine “START” Button
10. “STOP” Engine Stopping Button
11. Ether Injector Button (Option)
12. Engine Fault Codes Readout Switch and Exhaust System (SCR) Stationary Cleaning Process Activation or
(SCR) Stationary Cleaning Process Blocking Switch
13. Engine Fault Codes Readout And Intermediate Speed Control (ISC) Selector Momentary Switch
14. Gear presetting mode switch
15. Automatic Gear Downshift Mode Switch
16. Machine Electrical System Switch
17. Low Engine Coolant Level, Coolant High Temperature, High Equipment Hydraulic System Oil Temperature
and Low Engine Lube Oil Pressure Alarm (Installed at the Instrument Panel Rear Side).
(*) - Buttons active in the engine diagnostics or drive train diagnostics program
1. INTEGRATED DISPLAY Refer to Fig. 4.2A
2. “MENU” BUTTON FOR TURNING OFF THE DRIVE TRAIN AND ENGINE DIAGNOSTICS
PROGRAM AND FOR ADJUSTMENT OF DISPLAY SCREEN BRIGHTNESS
Press the button to leave the drive train and engine diagnostics program and change the brightness
level of the display screen.
When the “ENTER” button is depressed in the drive train and engine diagnostics program mode,
normal display operation of the drive train system monitoring is restored (1.6, Fig. 4.2A).
Display screen brightness adjustment - to change the screen brightness, press the "MENU" button (2,
Fig.4.2) on the main display panel, Then adjust the brightness level to the individual operator's needs
using the buttons (5 and 6) corresponding to the brightness adjustment arrows. Return to the main
screen after pressing the "MENU" button (2) again.

SECTION 4
OPERATION
PAGE 8
IMPORTANT: Adjust the display screen brightness level to the individual requirements of the
operator, taking into account the prevailing weather conditions (including lighting) and safety during
operation.
3. “ENTER” SWITCH TO SWITCH ON THE DRIVE TRAIN SYSTEM AND THE ENGINE
DIAGNOSTICS PROGRAM
The switch is used to enter the drive train diagnostics program including the engine diagnostics
and the possibility to view the selected parameters on the drive train system monitoring display
(1.6, Fig. 4.2A). The parameters are selected from the list with the scrolling buttons (7 and 8). The list
of drive train system diagnostics parameters or the engine operating parameters is selected with the
button (3). When the light (1.4) comes on it means that you have entered the engine diagnostics
parameter list – see “Monitoring (diagnostics) selected engine operating parameters” in item
4.3.2.3.
When the light (1.8) is lit it means that you have entered the drive train diagnostics parameter list
– see Inspection diagnostics in 4.3.2.
Press the button (2) to restore monitoring display normal mode.
4. MACHINE AND RIPPER LIGHTS ON/OFF BUTTON – see Fig. 4.2B
5. CAB LIGHT ON/OFF BUTTON – REAR (FRONT – OPTION) – see Fig. 4.2B
6. SIDE LIGHTS ON/OFF BUTTON – see Fig. 4.2B
7. FLASHLIGHT ON/OFF BUTTON - see Fig 4.5

This button is inactive in the mode where the individual diagnostics program parameters are selected.
7(*). BUTTON TO SELECT INDIVIDUAL DIAGNOSTICS PROGRAM PARAMETERS (SCROLLING
FORWARD) – IN THE DIAGNOSTICS PROGRAM MODE
Each time the button is pressed the next list parameter is displayed. The button is enabled with the
“ENTER” button (3) after enabling the diagnostics program.
8. REVERSING CAMERA ON/OFF BUTTON - see Fig. 4.2B.

This button is inactive in the mode where the individual diagnostics program parameters are selected.
8(*). BUTTON TO SELECT INDIVIDUAL DIAGNOSTICS PROGRAM PARAMETERS (SCROLLING
BACKWARD) – IN THE DIAGNOSTICS PROGRAM MODE
Each time the button is pressed the next list parameter is displayed. The nutton is enabled with the
“ENTER” button (3) after enabling the diagnostics program.
9. “START” ENGINE STARTING BUTTON – see Fig. 4.2B
10. “STOP” ENGINE STOPPING BUTTON – see Fig. 4.2B
11. ETHER INJECTOR BUTTON – OPTION

This button controls the ether injector for cold weather starting. It is active during the engine start-up
(after pressing 9(I) “START” and when the ambient temperature is below 4 [°C]. Starting the engine
with the ether injector – refer to “STARTING THE ENGINE” in this Section.
12 SWITCH TO READ THE ENGINE FAULT CODES AND SWITCH ON THE STATIONARY
CLEANING OF THE EXHAUST SYSTEM OR TO LOCK THE EXHAUST SYSTEM CLEANING
PROCESS.
This switch is provided with three positions: center (neutral), upper and lower. The switch
automatically returns to the center position from the upper position.
With the engine stopped and the switch in its lower position will allow to read the faults first code with
warning lights (1.5 and 1.7, Fig. 4.2A). Codes reading – see 4.6.1. The switch is provided with a self
revert feature to its initial position.

OPERATION SECTION 4
PAGE 9
With the engine operating, the switch kept in its upper position activates the exhaust system stationary
cleaning (SCR), if the particulate filter requires regeneration (light 1.5 glows solid, and light 1.15
flashes). Refer to 5.13.3 in Section 5, Parked exhaust aftertreatment system (SCR) cleaning
process.
If the engine is running, the switch kept in its lower position is used to block the regeneration of the
parked exhaust aftertreatment system (SCR) cleaning process and to disable both, automatic and
parked exhaust aftertreatment (SR) cleaning process. This is indicated by light (1.13). The lock is
released by manual switch to the center position.
13. ENGINE ECM FAULT CODE READOUT AND INTERMEDIATE SPEED CONTROL (ISC)
SELECTOR MOMENTARY SWITCH
The switch has three positions: center, lower and upper. With the engine stopped it is used (together
with switch (12) to display successive engine faults codes with warning lights (1.5 and 1.7, Fig. 4.2A),
if there is more than one fault code, read as first one with switch (12). Codes reading – see 4.6.1. The
switch is provided with a self revert feature to its center position.
With the engine operating, the switch is used to gradually change the engine low RPM (every
25 RPM) over 800 to 1200 RPM. When the engine is stopped and started, the engine RPM will
default to the last switch (ISC) setting. The switch is provided with a self revert feature to its center
position.
14. GEAR PRESETTING MODE SWITCH

Gear presetting mode switch enables two modes of machine operation:
O – manual control position – gear shifting can be made with drive train control lever (joystick)
embedded buttons only. (option)
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.
15. AUTOMATIC GEAR DOWNSHIFT MODE SWITCH

Switch has two positions:
O. Auto-downshift Mode OFF
(3  2  1) – Auto-downshift function is ON. Automatic downshift is enabled if the drive train is in
overloaded condition. This function is only active when the gear presetting mode switch (15,
Fig. 4.2) is in the manual control mode position (O).
16. MACHINE ELECTRONIC SYSTEM SWITCH
Switch without the key Switch with the key
Machine electronic system switch

SECTION 4
OPERATION
PAGE 10
The switch is used to switch on and off the engine ECM, electronic machine controller and integrated
display activation circuits as well as other machine electrical system circuits.
The switch is also used to stop the engine in an emergency. It is equipped with a key.
Key positions:
“O” position – electronic and electric circuits are turned off.
“I” position – right – electronic and electrical circuits on including the electronic engine and drive train
system pilot system
After turning the switch to the ON position the display (1, Fig. 4.2) performs the self-test and displays
indicators and symbols of the monitored parameters for a few seconds. When the test sequence is
completed, the instrument panel only shows the gauges and symbols pertaining to the current state of
the parameters being monitored.
CAUTION: Turning the switch to the “O” position while the engine is running will
result in emergency stopping.
17. LOW ENGINE COOLANT LEVEL, HIGH COOLANT TEMPERATURE, HIGH EQUIPMENT
HYDRAULIC SYSTEM OIL TEMPERATURE AND LOW ENGINE OIL PRESSURE ALARM
The alarm is triggered when one of the following parameters goes below or above the allowable
value: decrease of engine lube oil pressure, increase of coolant temperature, increase of equipment
hydraulic system temperature or decrease of coolant level. If so, stop the machine and find out which
warning light (1.9, 1.10, 1.12 or 1.31, Fig. 4.2A) glows and check gauge indication. The alarm signal
can be found on the instrument panel rear plate.
DESCRIPTION OF ELEMENTS – INTEGRATED DISPLAY (1, Fig. 4.2)
Fig. 4.2A Integrated Display – Main Panel

OPERATION SECTION 4
PAGE 11
Description for Fig. 4.2.

1.1. Tachometer
1.2. High Drive Train Oil Temperature Warning Light (Yellow)
1.3. Drive Train Oil Temperature Gauge
1.4. Engine Diagnostics Program Signal Light (green)
1.5. “STOP” Engine Fault Warning Light (red)
1.6. Drive Train Function and Diagnostics Display with Hourmeter
1.7. “!” Engine Fault Warning Light (yellow)
1.8. Drive Train Diagnostics Program Signal Light (green)
1.9. Low Engine Coolant Level Warning Light (yellow)
1.10. Low Engine Lube Oil Pressure Warning Light (Red)
1.11. Engine coolant temperature gauge
1.12. High Engine Coolant Temperature Warning Light (red)
1.13. Exhaust Aftertreatment System (SCR) Cleaning Disable Signal Light
1.14. Restricted Air Cleaner Warning Light (Yellow)
1.15. Restricted Exhaust Aftertreatment System (SCR) Filter Warning Light (yellow)
1.16. Ether Injector Warning Light (Green) (option)
1.17. Clogged Fan Drive Oil Filter Warning Light (yellow)
1.18. Fuel tank level gauge
1.19. Low Fuel Tank Level Warning Light (yellow)
1.20. High Exhaust System Temperature Warning Light (red)
1.21. “RUN” Indicator Light for Normal Operation of Drive Train Monitoring Display (green)
1.22. DEF Exhaust Reduction Fluid Tank Level Gauge
1.23. Low DEF Exhaust Reduction Fluid Tank Level Warning Light (yellow)
1.24. Drive Train Monitoring Display Diagnostic Mode “WARNING” Light (red)
1.25. Battery Charge Level Warning Light (red)
1.26. Voltmeter
1.27. Clogged Equipment Hydraulic System Oil Filter Warning Light (yellow)
1.28. Low Oil Pressure Warning Light for Direction and Gear Clutches (red)
1.29. Restricted Drive Train Pressure Filters' Warning Light (Yellow)
1.30. Machine Parking Brake On Signal Light (Red)
1.31. High Equipment Hydraulic System Oil Temperature Warning Light (Red)
1.1. SPEEDOMETER
Shows engine actual RPM. Use a 100 multiplier for readings.
1.2. HIGH DRIVE TRAIN OIL TEMPERATURE WARNING LIGHT (Yellow)
The light is on when the drive train oil temperature is too high – over 121 [°C]. If alights check what
follows:
— check if machine operates in proper gear,
— check the drive train oil level,
— check if the cooler unit is clean,
If the above operations fail to remedy the cause, contact the Authorized Distributor of Construction
Equipment.
1.3. DRIVE TRAIN SYSTEM OIL TEMPERATURE GAUGE.
This gauge shows the temperature of the drive train oil. When the machine operates, the pointer
should be in the green area. If the pointer is above the green area refer to Item 1.2.
1.4. ENGINE DIAGNOSTICS PROGRAM TEST MODE INDICATOR LIGHT (green)
When this light comes on it means that you have entered the engine diagnostics mode after pressing
“ENTER” button – see description of “ENTER” button (3, Fig. 4.2). The light goes off when you exit the
engine diagnostics program by pressing “MENU” button (2).

SECTION 4
OPERATION
PAGE 12
1.5. “STOP” ENGINE FAULT WARNING LIGHT (red)

The light indicates engine fatal failure. If it comes on while operating it tells the operator this is a fatal
failure and may cause the engine shutdown. Stop the engine safe as soon as possible and find a
reason of the fault.
1.6. MACHINE MONITORING DISPLAY WITH HOURMETER
The lower part of the display (1, Fig 4.2) contains a separate field which shows the drive train system
status (gear and range) and operating time. The diagnostics mode displays the selected engine or
drive train system diagnostics list parameters. Refer to the description of the drive train monitoring
display in Item 4.3.2.
At the upper part of the display “1”, “2” or “3” and range “L” or “H” is depicted when operating the
machine in the normal conditions – see Fig. 4.2D. If the gear presetting function (e.g. “F1 – R2”) or the
automatic gear reduction function (“3→2→1”) is enabled the display shows information on enabling
either of these functions.
The hourmeter registers the machine real operating time in hours. The purpose of the hourmeter is to
indicate when to perform the recommended maintenance and lubrication operations. The hourmeter
records the actual hours of operation only when the machine engine is running.
Apart from this the display allows:

 drive train control component diagnostics,
 monitoring the selected engine operating parameters.
1.7. ENGINE “!” WARNING LIGHT (yellow)
It tells that engine maintenance is required. If the lamp lights up while the engine is running, it means
that the security system has detected the presence of water in the fuel or a low level of coolant in the
cooling system. The engine may still run, but for protection against damage some of the operating
parameters can be changed. This failure must be corrected without delay.
1.8. DRIVE TRAIN DIAGNOSTICS PROGRAM TEST MODE INDICATOR LIGHT (green)
The light turns on to indicate that the engine diagnostics mode has been entered by pressing the
“ENTER” button – refer to the “ENTER” button (3, Fig. 4.2) description. The light is off when you exit
the engine diagnostics program by pressing “MENU” button (2).
1.9. LOW ENGINE COOLANT LEVEL WARNING LIGHT (yellow)
Will alight if cooling system coolant level drops below allowable limit. Alarm signal (17, Fig. 4.2) will be
also active when the light is on.
1.10. LOW ENGINE LUBE OIL PRESSURE WARNING LIGHT (red)
The engine lube oil pressure warning light will glow and the alarm sounder (17, Fig. 4.2) will be
activated when the engine oil pressure is below minimum limit. Glowing of this lamp obliges the
operator to stop the engine without delay and to investigate the reason for low oil pressure.
1.11. ENGINE COOLANT TEMPERATURE GAUGE
This gauge shows the temperature of the coolant circulating through the engine. When the engine
reaches its operating temperature and operates normally, the gauge pointer must be placed within the
gauge green area. Engine operation with coolant temperature outside green area of the gauge is
detrimental to the engine.
NOTE: To have a coolant temperature within specification, it may occur that engine
compartment have to be shielded in low ambient temperatures.

OPERATION SECTION 4
PAGE 13
1.12. HIGH ENGINE COOLANT TEMPERATURE WARNING LIGHT (red)

Both the light and the alarm sounder (17, Fig. 4.2) tell that engine allowable coolant temperature of
107 [°C] has been exceeded. Continuous engine operating above the maximum temperature is
harmful to the engine.
1.13. EXHAUST SYSTEM (SCR) CLEANING DISABLED INDICATOR LIGHT (Yellow)
The light indicates that the regeneration function is disabled. It lights up when the switch is
(12, Fig. 4.2) in the lower position. Automatic and parked regeneration of the filter (SCR) is impossible.
1.14. RESTRICTED AIR CLEANER WARNING LIGHT (yellow)
The warning lamp comes on when the cleaner element is restricted above the allowable limit. When
this happens, filter service is required, refer to “AIR CLEANER” in Section 5.
1.15. RESTRICTED EXHAUST AFTERTREATMENT SYSTEM (SCR) FILTER WARNING LIGHT
(yellow)
The light indicates that the exhaust aftertreatment system (SCR) filter requires automatic or parked
cleaning.
When illuminated or flashing accomplish the following:
• change to a more challenging duty cycle, increase the engine RPM for at least 20 minutes to
complete the cleaning process (automatic exhaust aftertreatment system cleaning),
or
• perform stationary cleaning – Refer to 5.13. in Section 5.
A flashing (1.15) warning light combined with an illuminated warning or engine fault light (1.7)
indicates that the manual regeneration is required, refer to 5.13. in Section 5.
IMPORTANT: If the exhaust aftertreatment system (SCR) is not cleaned in time, it may result
in the system being full. In this case the lights (1.15) and (1.7) turn off, the light (1.5) lights up
and the engine stops. Only an Authorized Construction Equipment Distributor may perform
exhaust aftertreatment system (SCR) cleaning and start the engine.
1.16. ETHER INJECTOR WARNING LIGHT (Green) – OPTION

This light comes on when the button (11) is pressed and the specified ether does is fed to the engine
inlet manifold.
1.17. RESTRICTED FAN DRIVE SYSTEM FILTER WARNING LIGHT (Yellow)
It will come on when the filter clogging is above the allowable limit. When this is the case, stop the
machine operation and replace the filter.
1.18. FUEL TANK LEVEL GAUGE
The gauge indicates the quantity of fuel available for operation in the fuel tank. When the fuel level in
the tank falls below minimum, the gauge pointer will be in the red area indicating the need to fill fuel
and the yellow warning light (1.18) will come on at the same time. When this happens, the fuel tank
should be filled without delay.
1.19. LOW FUEL TANK LEVEL WARNING LIGHT (yellow)
The warning light indicates low fuel level in the tank. Fill the fuel tank without delay as described in
Item 1.18 (above).

SECTION 4
OPERATION
PAGE 14
1.20. HIGH EXHAUST SYSTEM TEMPERATURE WARNING LIGHT (red)

The light indicates high temperature of the engine exhaust system components during the automatic
or stationary SCR exhaust system cleaning process. The light goes off when the cleaning is
completed.
IMPORTANT: When the warning light flashes, make sure that the exhaust outlet of the
machine is not directed towards the surface of the liquid or material that can melt, ignite or
explode.
1.21. “RUN” SIGNAL LIGHT INDICATING NORMAL OPERATION OF MACHINE MONITORING
SYSTEM (Green)
The light glows solid during normal operation of the machine and engine monitoring system. When the
light is off it means that there are faults in the drive train and/or engine control system. This
information may be confirmed by engine fault lights (1.5 and 1.7) coming on, flashing of the light (1.24)
and a message on the monitoring display (1.6).
1.22. DEF EXHAUST REDUCTION FLUID TANK LEVEL GAUGE
The gauge shows the current DEF exhaust reduction fluid level in the tank. When the fluid level
decreases to minimum level the pointer will be in the red range which means that the tank must be
filled. You should immediately add the fluid to the tank. See DEF exhaust reduction fluid low level
warning light (1.23) below.
1.23. LOW DEF EXHAUST REDUCTION FLUID TANK LEVEL WARNING LIGHT (Yellow)
This light comes on and illuminates continuously when the fluid level reach the value 10% of the tank
capacity. When the level falls below 5%, the light will start flashing. Below 2.5% the light goes off and
the fault code lamp is displayed.
IMPORTANT: When the light starts flashing, the operator should stop the machine
immediately and fill the tank with the DEF exhaust reduction fluid.
NOTE: It is always recommended to fill the DEF exhaust reduction fluid tank to the top to
avoid any associated failure.
1.24. MACHINE MONITORING DISPLAY DIAGNOSTIC MODE “WARNING” LIGHT (Red)
When the light is on it means that there is a fault in the drive train or engine control system. The fault
is indicated by the blinking “WARNING” light and the “RUN” (1.21) light that is illuminated
continuously. What’s more the fault is indicated on the monitoring display screen (1.6) with the
respective message – see point 4.3.2. in this Section.
The light starts to glow solid after the test mode of the engine diagnostics program (the light (1.4) is
on) and the machine diagnostics program (the light (1.8) is on) is entered.
1.25. BATTERY VOLTAGE LEVEL WARNING LIGHT (Red)
When this light is on while the engine is stopped the battery voltage is low. When this light is on while
the engine is running, the battery charging system has failed. Glowing of the light corresponds to
voltmeter readings – the pointer should be then within one of the red areas of the voltmeter – refer to
1.26.
1.26. VOLTMETER
The voltmeter indicates battery voltage. When the engine is off, the voltmeter pointer should be within
the “BAT” green area. While the engine is running, the pointer should be within the “ALT” green area,
which is the normal operating range of the electrical system. If the pointer drops below or exceeds this
green area, the battery, alternator and/ or wiring may be at fault.

OPERATION SECTION 4
PAGE 15
1.27. RESTRICTION EQUIPMENT SYSTEM OIL FILTER WARNING LIGHT (Yellow)

The warning light provided for the equipment system oil filters comes on when the return or the pilot
system filter contamination exceeds the allowable limit. When this happens, filter change is required.
1.28. TRANSMISSION DIRECTION AND SPEED CLUTCH LOW OIL PRESSURE WARNING LIGHT
(red)
This light comes on when the transmission directional (FR) and/or range (Pc) clutch oil pressure is too
low with the drive train system control level shifted forward (“forward” travel direction) or backward
(“backward” travel direction).
If this light is on you should stop the engine and check and fill the drive train system with oil. Refer to
“DRIVE TRAIN SYSTEM” in Section 5.
If the light continues to glow, stop the engine and contact the Authorized Distributor of Construction
Equipment.
1.29. RESTRICTED DRIVE TRAIN SYSTEM OIL PRESSURE FILTERS WARNING LIGHT (Yellow)
It will come on when the filter restriction is above the allowable limit. When this happens, filter change
is required.
1.30. MACHINE PARKING BRAKE ON SIGNAL LIGHT

The light will lit when the drive train control lock lever is in the lock position (A, Fig. 4.10). The machine
cannot move.
1.31. HIGH EQUIPMENT HYDRAULIC SYSTEM OIL TEMPERATURE WARNING LIGHT (RED)
The warning lamp indicates that the permissible hydraulic oil temperature of the equipment system
exceeds 101 [°C]. In addition, the display (1.6) shows "Toh ?!" message and the alarm signal is
activated (17, Fig. 4.2). Long-term operation at exceeded oil temperature is harmful to the equipment
system and threatens to damage it.

SECTION 4
OPERATION
PAGE 16
DESCRIPTION OF INTEGRATED DISPLAY SIDE PANEL BUTTONS AND LIGHTS (1, Fig. 4.2)
Fig. 4.2B. Integrated Display – Side Panel Button Functions

4. Machine Lights On/Off Button
5. Cab Lights On/Off Button – Rear (Front – Option)
6. Side Lights On/Off Button
7. Flashlight On/Off Button
8. Reversing Camera On/Off Button
9. Engine “Start” Button
10. “Stop” Engine Stopping Button
11. Ether Injector ON Button (Option)
1.31. Headlights ON Indicator Light (green)

1.32. Cab Lights ON Indicator Light (green)
1.33. Active Side Lights Indicator Light (green) – option
1.34. Active Warning Light Indicator Light
1.35. Active Reversing Camera Indicator Light
1.36. Engine “START” Indicator Light
1.37. Engine ““STOP” Indicator Light
1.38. Ether Injector ON Indicator Light (Option)
4. MACHINE LIGHTS ON/OFF BUTTON

The switch is used to switch on/off the dozer cylinder headlamps and the machine rear lamps.
5. CAB LIGHTS ON/OFF SWITCH – REAR (FRONT – OPTION)

The switch is used to switch on/off the cab front and rear lamps (if the machine is equipped with front
headlamps.
6. SIDE LIGHTS ON/OFF BUTTON

This button is used to switch on and off the side headlamps on the cab.
7. FLASHLIGHT ON/OFF BUTTON

This button is used to switch on/off the flashlight (Option). Refer to 4.4.3 in this Section.

OPERATION SECTION 4
PAGE 17
8. REVERSING CAMERA ON/OFF BUTTON

This button is used to switch on/off the reversing camera. Refer to the description in Section 4.4.6. in
this Section.
9. ENGINE “START” BUTTON
The button is used for starting the engine. Press and release the start button in order to start the
engine. The indicator light (1.36) blinks a few times and starts illuminating with solid green light. Now,
you should start the engine by pressing the button again – see description in Point 4.6. When starting
the engine the light (1.36) is off and the indicator light (1.37) is on.
IMPORTANT: Do not hold the switch (9) in the starting position for longer than 30 seconds.
Allow a 2 minute interval between cranking. Never press the button (9) when the engine is
running.
10. “STOP” ENGINE STOPPING BUTTON
The button is used for turning off the engine. When this switch is pressed the engine is stopped, the
indicator light (1.37) is off – see description in Point 4.7.
11. ETHER INJECTOR ON BUTTON (OPTION)
Refer to the button (11, Fig. 4.2) description in this Section.
1.31. ACTIVE MACHINE LIGHT INDICATOR LIGHT (green)

When this light is on it means that the headlamps provided on the machine have been switched on
with the switch (4, Fig. 4.2).
1.32. ACTIVE CAB LIGHT INDICATOR LIGHT (green)

When this light is on it means that the headlamps provided on the cab have been switched on with the
switch (5, Fig. 4.2 – see description above).
1.33. ACTIVE SIDE LIGHTS INDICATOR LIGHT (Green)

When this light is on it means that the cab side headlamps have been switched on with the button (6,
Fig. 4.2).
1.34. ACTIVE WARNING LIGHT INDICATOR LIGHT

This light indicates that the flashlight is on – see button description (7) above.
1.35. ACTIVE REVERSING CAMERA INDICATOR LIGHT

This light indicates that the reversing camera is on – see button description (8) above.
1.36. ENGINE STARTING INDICATOR LIGHT

The light indicates the beginning of the starting procedure and is off when the engine starts operating
– see description of the switch (9) and description in 4.6.
1.37. “STOP” ENGINE STOPPING SWITCH INDICATOR LIGHT

The light is on when the engine is started and off when the engine is stopped – see description of
switch (10) and description in 4.7.
1.38. ETHER INJECTOR ON SIGNAL LIGHT (OPTION)

The light shows that the ether injector function has been enabled with the Ether injector button (11) –
see light (1.16, Fig. 4.2A) description in this Section.

SECTION 4
OPERATION
PAGE 18
MESSAGE DISPLAYED AFTER DISCONNECTING THE MACHINE ELECTRONIC SYSTEM

SWITCH – see description of the machine electronic system switch (16, Fig. 4.2).
Fig. 4.2C. Integrated Display – Message after Turning off the Machine Electronic System Switch
Wait … 120 [sec] before master switch disconnection.
CAUTION: Do not turn off the electric system master switch (Fig. 4.14) before the
screen with the final message goes off automatically (Fig. 4.2C).
4.3.2. DRIVE TRAIN MONITORING DISPLAY WITH ENGINE HOURMETER
Fig. 4.2D. Drive Train Function and Diagnostics Display with Hourmeter
1. “1”, “2” or “3” Gear Display
2. “High – H” or “Low – L” Actual Range
3. Display of the gear presetting function or automatic
gear reduction (is this function is enabled)
4. Machine hourmeter

OPERATION SECTION 4
PAGE 19
4.3.2.1. Drive train system monitoring display normal operating mode (drive train control
system normal operation)
When the electronic switch key (16, Fig. 4.2) is set to 1 the display screen (Fig. 4.2D) shows:
a) The “1” gear and “L” or “H” range is displayed (depending on range change rocker switches
position), actual hours of machine operation are displayed as well,
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.
d) when the gear presetting function or the automatic gear reduction is enabled the respective
symbols that inform of enabling of the respective function are displayed.
At the same time the light (1.21, Fig. 4.2A) is on, indicating normal display operation.
4.3.2.2. Drive train system monitoring display diagnostics mode – drive train control system
diagnostics function
Machine drive train control system diagnostic can be made in two modes: “ON GOING
DIAGNOSTICS” and “INSPECTION DIAGNOSTICS”.
I. 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 the “WARNING” flashing light (1.24, Fig. 4.2A). At the same
time the “RUN” (1.21, Fig. 4.2A) light will come on solid. “RUN” 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 on the display screen (see “Main Catalog”
below).
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 machine electronic system is off.
System ongoing diagnostics will include: Main Catalog of drive train electronic controller input and
output (IN/OUT) signals.
Main catalog of input and output (IN/OUT) signals
INPUT SIGNALS (IN):
returns to normal operation mode. If the fault is not corrected, a fault message will display
1. Battery voltage:
Bat Volt
00.0 V

SECTION 4
OPERATION
PAGE 20
Battery voltage will be checked automatically after both the electrical master switch and machine
electronic system switch are turned ON. Voltage required: 19.6 to 29.4 [V].
If the voltage meets the requirements, green light (1.21, Fig. 4.2A) will come on and drive train
message will be displayed, e.g. “1 L”.
When the voltage is below the required range the light (1.21, Fig. 4.2A) is off and the light
(1.24, Fig. 4.2A) is blinking.
The fault will display a message:
An example of the battery fault (low battery voltage)
2. Electrical system voltage with alternator (engine) operating.
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: 19.6 to 29.4 [V].
If the voltage is within this range, green light (1.21, Fig. 4.2A) will come on and drive train message
will display, e.g. “1 L”.
If the battery voltage is above or below the required range, then light (1.21, Fig. 4.2A) will be off, while
the light (1.24, Fig. 4.2A) will flash which means the power to machine electric system is faulty.
An example of the alternator voltage info (alternator voltage too low)
3. “CS” – CANBus J1939 engine RPM signal.

J1939
ERROR
Apart from indicating the fault by a displayed message the light (1.24, Fig. 4.2A) is blinking.
IMPORTANT: This fault is of great 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.

IMPORTANT: The fault message will persist until cleared.

OPERATION SECTION 4
PAGE 21
5. ACC – engine RPM control potentiometer calibration [%],
6. DEC – deceleration potentiometer calibration [%],
7. “TC Temp” – drive train oil temperature (at torque converter output [°C]).
8. “WF” and “?!” – signal from travel direction pressure switch – forward.
WF ?!
9. “WR” and “?!” – signal from travel direction pressure switch – backward.
WR ?!
IMPORTANT: “WF” and “WR” can be checked only when the machine moves or the brake
pedal is applied and drive train lock lever in upper, unlocked position.
10. „- - INFO - - i WKMR ?!” – signal from the drive train lock / engine start-up lock switch
The position of the drive train lock lever is indicated by the message:
- - INFO - -
WKMR ?!”
This message indicates that the engine cannot be started when the drive train lock lever is in the
upper (unlocked) position.
OUTPUT SIGNALS (OUT):

returns to normal operation mode. If the fault is not corrected, a fault message will display
1. “EZ2” – transmission solenoid valve control signal (second gear):

EZ2 ?!
2. “EZ3” – transmission solenoid valve control signal (third gear):

EZ3 ?!

SECTION 4
OPERATION
PAGE 22
3. “EZL” Output – solenoid valve for steering system High/Low range change (left side):
EZL ?!
4. “EZR” – solenoid valve for steering system High/Low range change (right side):
EZR ?!
5. “EZW” – fan drive pump control solenoid valve control signal.

EZW ?!
Inspection diagnostics
Inspection diagnostics is used to check selected components of drive train control system. This takes
place when the controller is unable to decide at normal operation, if the controller input is active or the
external signal fails to reach the controller.
Press the “ENTER” button (3, Fig. 4.2) to enter the inspection diagnostics mode. The lights
(1.4 i 1.24, Fig. 4.2A) will glow solid.
The display will present the first page of messages:
1. “UP” button upshift signal is checked at drive train control lever.
UP ?!
If the circuit hooked to this input is OK, then “UP” and “OK!” message will display after the drive train
control lever “UP” button is pressed.
UP OK!
The message will display for as long as button is depressed if button (UP, DN) input is checked.
If the switch input is checked (HL, HR, WB, WO, WF, WR, etc), this message appears on
a permanent basis until one is on the side of the display.
If message:
UP ?!
does not change, this means:

 circuit discontinuity or
 controller input faulty or controller failure.
The subsequent pages of messages can be displayed by pressing the button (7, Fig. 4.2) or
(8, Fig. 4.2). When you press “MENU” (2, Fig. 4.2) you will return to the normal display operation
mode (lights (1.8 and 1.24, Fig. 4.2A) will be off).

OPERATION SECTION 4
PAGE 23
Following are messages for inspection diagnostics:

2. “DN” and “?!” – checking the downshift button signal (drive train control lever)
3. “HL” and “?!” – checking left high range rocker switch signal (drive train control lever)
4. “HR” and “?!” – checking right high range rocker switch signal (drive train control lever)
5. “WB1/2” and “?!” – checking the presetting switch – setting 1/2 ( instrument panel)
6. “WB2/2” and “?!” – inactive function
7. “WO” and “?!” – checking auto downshift switch mode (instrument panel)
IMPORTANT: “WO” can be checked with the brake pedal released. The fault will display
a message “WO” and “?!”. Care should be taken when the brake pedal is released.
8. “WF” and “?!” – checking pressure switch for forward machine travel detection:
9. “WR” and “?!” – checking pressure switch for backward machine travel detection.
IMPORTANT: “WF” and “WR” can be checked only when the engine is operating and the
machine moves or the brake pedal is applied and the drive train lock lever is in the upper,
unlocked position. The fault will display a message “WF/WR” and “?!”. Be careful.
10. “EZ2” and “OK” – checking solenoid valve circuit for 2 gear engaged
11. “EZ3” and “OK” – checking solenoid valve circuit for 3 gear engaged
12. “EZL” and “OK” – checking solenoid valve circuit for high range (left) engaged
13. “EZR” and “OK” – checking solenoid valve circuit for high range (right) engaged
14. “Wpc” and “?!” – checking the “Pc” transmission speed clutch pressure sensor signal.
IMPORTANT: “Wpc” can be checked only when the engine is operating and the machine
moves or the brake pedal is applied and the drive train lock lever is in the upper, unlocked
position. The fault will display a message “Wpc” and “?!”. Be careful.
15. “Wfr” and “?!” – checking the “FR” transmission direction clutch pressure sensor signal.
IMPORTANT: “Wfr” can be checked only when the engine is operating, the machine moves
or the brake pedal is applied and the drive train lock lever is in the upper, unlocked position.
The fault will display a message “Wfr” and “?!”. Be careful.
16. “CIW” and “?!” – checking the signal from the torque converter output shaft rotational speed
sensor
IMPORTANT: “CIW” can be checked only when the engine is operating.
17. “CS” and “OK” – checking the signal from the engine RPM sensor at engine CANBus J1939
18. “ACC” and “OK” – checking the signal from the engine RPM control potentiometer
19. “DEC” and “OK” – checking the signal from the engine RPM deceleration potentiometer
20. “Sys Volt” and “0.00V” – checking and readout of the machine electric system voltage with the
alternator (engine) operating – Refer to IN/OUT Signals Main Catalog
or
“Bat Volt” and “0,00V” – checking and readout of the machine electric system voltage with the engine
shut off – Refer to Point 1A. IN/OUT Signals Main Catalog

SECTION 4
OPERATION
PAGE 24
4.3.2.3. Monitoring (diagnostics) of selected engine operating parameters
Start the engine to diagnose selected engine operating parameters. Press the “ENTER” button
(3, Fig. 4.2) to enter the engine diagnostics mode. The lights (1.8 i 1.24, Fig. 4.2A) will glow solid.
The display will present the first page of messages:
1. “Eng RPM” – engine [RPM]
Eng RPM
1700
Information displayed – engine [RPM] as an example
The subsequent pages of messages can be displayed by pressing the button (7, Fig. 4.2) or
(8, Fig. 4.2). Pressing the “MENU” button (2, Fig. 4.2) restores the normal operating mode of the
display (the lights (1.8 and 1.24, Fig. 4.2A) go off).
Successive engine diagnostics messages:
2. “Oil Pres” [kPa] – engine lube oil pressure
Oil Pres
00 kPa
3. “Cool Tmp” [°C] – engine coolant temperature.
Cool Tmp
00.0 °C
4. “Mani Tmp” [°C] – intake manifold air temperature.
Mani Tmp
00.0 °C
5. “Eng Hrs” [h] – engine total hours.
Eng Hrs
00.0 h
6. “Bst Pres” [kPa] – engine intake manifold air pressure.
Bst Pres
00 kPa
7. “Fuel Econ” [l/h] – momentary fuel consumption.
Fuel Econ
0.0 l/h

OPERATION SECTION 4
PAGE 25
8. “TC Tmp” [°C] – drive train oil temperature (at torque converter output).
TC Tmp
00 [°C]
9. “Load@RPM” [°C] – engine load function for given engine speed in [%] (the ratio between
the actual engine torque and the maximum torque for given engine speed).
Load @ RPM
000.0 %
10. “ACC POS” [%] – engine RPM control potentiometer position (throttle)
ACC POS
0 %
11. “DEC Pos” [%] – engine deceleration control potentiometer position
DEC POS
0 %
CAUTION: You will not be able to read some of the above parameters when the
engine is stopped.
4.3.3. ENGINE SPEED CONTROL POTENTIOMETER PANEL
Fig. 4.3. Engine Speed Control Potentiometer Panel

1. Engine Speed Control Potentiometer Knob

SECTION 4
OPERATION
PAGE 26
1. ENGINE SPEED CONTROL POTENTIOMETER KNOB
Fig. 4.3A Engine Speed Control Potentiometer Knob

A. Engine Startup and Low Idle Speed
B. Medium Speed
C. High Speed
Is used to control engine speed. Rotate this knob in direction (1) to decrease engine speed. Rotate
this knob in direction (2) to increase engine speed.
Position this knob in the (A) position before shutting down the engine.
4.3.4. AIR CONDITIONING AND HEATING SYSTEM PANEL
4.3B. Air Conditioning and Heating Panel – Button Functions

1. Fan speed control „▲▼”
2. “OFF” button
3. “ON” button
4. “AUTO” operation mode
5. “DEF” Window Defrost
6. Temperature Control “▲▼”
7. Temperature degree display mode “Celsius/Fahrenheit”
8. “ECON” Operation Mode
9. Cab Temperature Numerical Display
The cab is fitted with the automatic air conditioning system. The air conditioning system is controlled
with the panel located in the cab ceiling. The temperature set for the cab is displayed in the middle of
the panel.

OPERATION SECTION 4
PAGE 27
BUTTON FUNCTIONS
ON/OFF
The ON (3) and OFF (2) buttons are used to switch on and off the air conditioning system. The LED
numerical display (9) is on when the heating and air conditioning system is running. The display
shows the currently set temperature
AUTO
The AUTO button (4) enables the automatic adjustment mode of the system, including the fan speed.
The illuminated button icon shows when the mode is active. The system adjusts the blower fan speed
to the lowest setting that is required to keep the set cab temperature displayed on the panel.
DEF
When the DEF button (5) is pressed the air conditioning system efficiency is increased to quickly
remove humidity from the cab. The illuminated button icon shows when the mode is active.
FAN UP/DOWN
The “▲▼” (1) buttons replace the automatic fan speed adjustment function. They increase and
decrease the fan speed in 11 increments. The panel display (9) shows the fan speed setting in
percents or displays “HI” when the maximum fan speed is achieved; or “LO” when the minimum fan
speed is achieved, then it returns to the normal display 5 seconds after any button is pressed. The set
fan speed is maintained until the button (1) is changed or the AUTO button is pressed.
TEMPERATURE UP/DOWN
You can use the “▲▼” (6) buttons to increase or decrease the set temperature value. The system will
control the electronic water valve and/or the air conditioning system compressor clutch to maintain the
cab temperature as close to the set temperature as possible.
°C/°F
Button (7) is used to change the temperature display mode (between Celsius and Fahrenheit
degrees.) The panel display will show the selected temperature units.
ECON (economic mode)

When you press the “ECON” button (8) the automatic air conditioning function is locked. The air
conditioning system control uses only fresh air, fan speed and water valve control to maintain the set
temperature. When you press the ECON key the system will return to normal operation. The button
icon on the panel shows when the mode is active. Please remember that the “DEF” defrost function
replaces the ECON function in the economic mode.

SECTION 4
OPERATION
PAGE 28
4.4. CAB CONTROLS
4.4.1. CAB WINDOW WIPER PANEL
Fig. 4.4. Key Switches for the Cab Window Wipers and Washers
1. Left Door Window Wiper and Washer Switch
2. Windscreen Wiper and Washer Switch
3. Right Door Window Wiper and Washer Switch
4. Rear Window Wiper and Washer Switch
5, 6. Slots for Additional Switches (Capped).
The momentary rocker switches (1 ÷ 4, Fig. 4.4) activate the window wipers and washers. Each
button activates three wiper operating ranges, when the upper part of the button is pressed once the
intermittent mode is enabled, two times – low speed continuous mode, three times – continuous faster
mode. When the switch is held for a longer time the wiper will be switched off. Pressing the bottom
part of the switch starts the windscreen washer fluid pump.
4.4.2. DOME LIGHT

Dome light is switched on with a switch mounted in the lamp.
Fig. 4.4A Dome Light with Switch

OPERATION SECTION 4
PAGE 29
4.4.3. FLASHLIGHT (option)

The flashlight is located on the right side of cab (Fig. 4.5.)
Fig. 4.5. Rotating Flashlight

The flashlight is activated with the button (7, fig. 4.2B.) The lamp (1.36, Fig. 4.2B) on the display
shows when the light is on. See also Fig. 4.6 below.
Fig. 4.6. Warning Flashlight Switch Location

1. Warning Flashlight and button
4.4.4. POWER SOCKETS (12 V) AND USB SOCKETS
1 2
Fig. 4.6A Additional sockets 12 [V] and 5 [V]

1. Power USB socket (2 x 5 [V]) 2. Additional socket 12 [V]
An additional socket 12 [V] is attached in the cab, on the right side of the operator's seat. You can
plug to the socket an additional device requiring current of max. 6 [A}. The USB socket with two inputs
(5 [V], 2 x 2.5 [A] max) is located next to it.

SECTION 4
OPERATION
PAGE 30
4.4.5. AUDIO SYSTEM
The audio system in the cab is composed of the main module, speaker and aerial.
4.6B. Audio System – Control Panel

1. Microphone
2. LCD Display
3. Programmed Station 1/Play/Stop
4. Programmed Station 2/Play Track (Fast Scan)
5. Programmed Station 3/Repeat Track
6. Programmed Station 4/Random Track
7. Programmed Station 5/Information Display
8. Programmed Station 6/Received Calls
9. Mute/Volume
10. FM/AM Selection/Automatic Band Save
11. AUX Port
12. USB Port
13. On/Mode Selection
14. Clock/Menu/End Call/Reject Call
15. Volume Up
16. Volume Down
17. Increase Tune/Next Track
18. Decrease Tune/Previous Track
WARNING! The negative battery terminal should be connected only after the audio
system is installed to avoid short-circuit. When you are adjusting the volume please
ensure you can still hear the traffic (horns, sirens etc.).

OPERATION SECTION 4
PAGE 31
LCD Display
1. Played Track Indicator (Fast Scan) 8. Programmed Station Indicator

2. Repeat Track Function Indicator 9. FLAT (Original) Track Effect Indicator
3. Random Track Function Indicator 10. CLASS (Classic Music) Track Effect Indicator
4. Path Indicator 11. Main Display Field
5. Volume Indicator 12. ROCK (Rock Music) Track Effect Indicator
6. Bluetooth Mode Indicator 13. PO (Pop Music) Track Effect Indicator
7. FM Stereo Volume Indicator
Turn On/Off
1. Press the button (1) to turn on the radio.

2. Press and hold the button (1) to turn off the radio.
Equalizer

SECTION 4
OPERATION
PAGE 32

2. Press the button (2) to select a function between: volume, TREB, BASS, BAL, LxRx.
3. Select the required function according to the table below:
Function Button (4) Button (3)
Clock Hour/Minutes/Format (for details see later part of the manual)
Main Volume Volume Down Volume Up
TREB (Treble) Tone Down Tone Up
BASS Bass Down Bass Up
BAL LxRx (Balance, Left/Right of the Cab) Balance Up Balance Down
4. After 5 [s] of inactivity the audio system will exit the function selection mode and save the last
settings.
Setting the Clock
Setting the Time
1. Press the button (1) when the radio is on – the display will show the time. Press and hold the
button (1) for more than 2 [s] – the hour digit will start flashing. Set the hour with the buttons (2)
and (3).
2. When step 1 is completed press the button (1) – the minute digit will start flashing. Set the minutes
with the buttons (2) and (3).
Setting the Time Format
1. When the time is adjusted press and hold the button (1) to enter the time format change mode.
Change the format between 12h and 24h pressing the button (1).
Exiting the Settings
1. If you do not perform any action within 5 [s] the settings will be automatically closed.

OPERATION SECTION 4
PAGE 33
Mute Function
1. Press the button (1) to mute. The display will show MUTE.
Volume Function
1. Press and hold the button (1) to turn on the loud function. When the “loud” function is enabled the
display will show “LOUD” and vice versa.
Setting the Volume Level
1. Set the volume level with the buttons (1) and (2).

SECTION 4
OPERATION
PAGE 34
Selecting the Operation Mode

2. Press the button (1) again to change the mode. The mode sequence is as follows: RADIO, AUX
IN, Bluetooth, USB.
Tuning the Radio
FM1, FM2, FM3 frequencies are the same.

AM1 and AM2 frequencies are the same.
Automatic Search Function
1. Press the button (1) to select between FM1, FM2, FM3, AM1 or AM2.
2. Search the station by tuning up or down with the buttons (2) and (3). When you find the station
you are looking for the search function will be stopped.
3. Press the button (2) or (3) when searching the station to discontinue searching.

OPERATION SECTION 4
PAGE 35
Manual Search Function
1. Press the button (1) to select between FM1, FM2, FM3, AM1 or AM2.
2. Press and hold the button (2) or (3) for 2 [s] to enter the manual search mode. Each time you
press the button the frequency will increase or decrease by the specified wave length.
3. After 5 [s] of inactivity you will return to the automatic search function.
Automatic Station Programming
1. Press the button (1) to select the required band between FM1, FM2, FM3, AM1 or AM2.
2. Press and hold the button (1) for 2 [s] to enter the automatic station programming mode. The
programmed stations will be saved from the lowest to the highest frequency. During scanning
each effective station will be played for 2 seconds and the scan will be continued. Press the button
(1) again to discontinue and stop the automatic programming function. 6 stations with the
strongest signal will be saved during each programming process. When you press the button (2)
when the automatic programming process is complete, the respective radio station will be shown
(see example below).
If you reset the programmed station again the previous programmed station may be overwritten
(see example below).

SECTION 4
OPERATION
PAGE 36
Manual Station Programming
1. Press the button (7) to select the required band between FM1, FM2, FM3, AM1 or AM2.
2. Press the button (8) or (9) to search and save the station with the required frequency.
3. Press and hold any button (1, 2, 3, 4, 5, 6) for 2 seconds to save the currently played back station
with the required frequency.
Repeat the above actions for the other buttons (1 to 6). You can save up to 6 stations for FM1,
Fm2, FM3, AM1, AM2. If a station was programmed before it will be replaced with the new
programmed station.
Selecting Frequency Bands for Regions
Wave
Procedure Region FM/AM Frequency
Length
FM 87.5-108.0 MHz 0.1 MHz
1: China/Europe
AM 522–1620 kHZ 9 kHz
Press the buttons in the following FM 87.5-108.0 MHz 0.1 MHz
2: Middle East
sequence in the standby mode: AM 531-1602 kHz 9 kHz
7>10>9>8 and any button from 1 FM 87.5-107.9 MHz 0.2 MHz
to 5 that represent the respective 3: America
region to complete the selection. AM 530-1710 kHz 9 kHz
The time between pressing the two FM 76-90 MHz 0.1 MHz
4: Japan
successive button is 2 seconds. AM 522–1692 kHz 9 kHz
FM 65-74 MHz 0.1 MHz
5: Russia
AM 522-1602 kHz 9 kHz
USB Mode

OPERATION SECTION 4
PAGE 37
2. Insert a USB device into the port (2).
3. If the MP3 files are stored on the device the number of all files will be displayed after a few
seconds.
4. The current file sequence will be displayed after a few seconds.
5. The current track time will be displayed after a few seconds.
USB Mode – Operations
Button Function
1 Press to play/pause a track, hold to stop
Press “SCAN”, “INT” will be displayed. Starting from the next track each next track will be played for
8 seconds and jump to the next one until “SCAN” is pressed again
Press “RPT”, “RPT” will be displayed. The current track will be played in a loop until “RPT” is
pressed again.

SECTION 4
OPERATION
PAGE 38
Press “RDM”, “RDM” will be displayed. The tracks will be played in the random sequence until
“RDM” is pressed again
Press “DISP” to switch between the displayed track number and its current time.
6 Press to go to the next track, hold to fast-forward.

7 Press to go to the previous track, hold to rewind.
Bluetooth Mode
When the power is on the Bluetooth mode is ready to connect.
Enable the Bluetooth module in the phone you want to connect to use the Bluetooth mode. Search
and connect with the device named: ORTEK TD68XXXXX
Bluetooth – connection
1. Enable Bluetooth in your phone.

2. Enable searching for new devices. Click “connect” if the radio is found. If the phone is connected
with the radio the display will show the icon (2).
3. After connection press the button (1) to enter the BT PLAY mode.
Different phones may lead to different procedures during connection. The example above is an
example only.

OPERATION SECTION 4
PAGE 39
Bluetooth – Music Player
Button Function
Press to start/pause a track. If the track is paused “PAUSE” is displayed (the function requires the
1
phone hardware support).
2 Press to play the next track (the function requires the phone hardware function).
3 Press to play the previous track (the function requires the phone hardware function).
Bluetooth – Phone Function
Button Function
1 Microphone
Press the answer the incoming call.
2
Press to end the call during the discussion.
Press the reject the incoming call.
3
Press to end the call during the discussion.

SECTION 4
OPERATION
PAGE 40
Phone Number Display
1. When the phone is ringing

2. The display will show the phone number.
3. If the caller has hidden the number the display will show “CALL”.
Adjusting Volume During Call
Use the buttons (1) and (2) to adjust the volume during a call.

OPERATION SECTION 4
PAGE 41
AUX IN
1. Press the button (1) to enter the AUX IN mode.

2. Connect the 3.5mm AUX cable to the port (2) to play the MP3 files from the external devices
(including the MP3 player/phone).
Display
Display Meaning
FM1+value FM1 station (you can program up to 6 stations)
FM2+value FM2 station
FM3+value FM3 station
AM1+value AM1 station
AM2+value AM2 station
USB IN USB Mode
MAX+value Number of all MP3 files on the connected device
CUR+value Number of the currently played track on the connected device
PAUSE Pause
MUTE Mute
MAIN-V+value Volume
VOL+value Volume (like MAIN-V)
TREB+value Treble
BASS+value Bass
BAL L+value/R+value Balance
LOUD ON Sound on
LOUD OFF Sound off
BT PLAY Bluetooth Mode
CALL Call on the display
AUX IN AUX Mode
12 HOUR 12-hour time format
24 HOUR 24-hour time format

SECTION 4
OPERATION
PAGE 42
4.4.6. REVERSING CAMERA
The reversing camera is installed under the air conditioner housing, at the rear of the cab. The camera
bracket allows you to adjust the camera position, and thus change the field of view observed on the
display. At the basic position of the camera, the field of view mainly covers the ripper tooth position.
When the camera position is changed, the field of view is directed to the further area behind the
machine.
Fig. 4.6C. Reversing Camera with Bracket (Possibility To Change Camera Field Of View)
The reversing camera could be enable and disable with the button (1, Fig. 4.6D) on the instrument
panel. When using the reversing camera, the display shows the image (3) from the reversing camera
range.
Before operating the machine, the operator should adjust the camera position (Fig. 4.6C) to ensure
that the image on the display is clear and covers the requested field of jobsite view.
2
1
3
Fig. 4.6D. Integrated Display when Using Reversing Camera

1. Reversing Camera On Button 3. Reversing Camera Display Image
2. Reversing Camera Indicator Light
.

OPERATION SECTION 4
PAGE 43
4.5. CONTROLS AND ADJUSTMENT
4.5.1. OPERATOR'S SEAT
The operator’s seat is adjustable in a following way:
• Move the back rest tilt adjustment lever (4) upward to set the seat back rest tilt angle suitable
for the operator,
• Set the seat height using the levers (1), (6), (7).
• Release lever (2) to adjust the seat fore and aft slide,
• Shift upper back (3) up or down to suit operator's requirements.
• The operator’s seat is provided with a safety belt. The safety belt is of inertia type and requires
no adjustment,
• Set the seat angle and longitudinal offset using the levers (8) and (9).
SEAT ADJUSTMENT LEVERS (STD)
Fig. 4.7. STD Operator Seat

1. Automatic Load Adjustment Lever
2. Seat Slide Adjustment Lever
3. Head Restraint Adjustment
4. Back Rest Angle Adjustment Lever
5. Seat Amortization Pump Electrical Connection
6. Absorber Stroke Adjustment
7. Seat Height Adjustment
8. Seat Angle Adjustment
9. Seat Longitudinal Adjustment

SECTION 4
OPERATION
PAGE 44
SEAT ADJUSTMENT LEVERS (ADDITIONAL OPTIONS)
Fig. 4.7A Operator’s Seat (Option with Heating)

1. Automatic Load Adjustment Lever 6. Absorber Stroke Adjustment
2. Seat Slide Adjustment Lever 7. Seat Height Adjustment
3. Head Restraint Adjustment 8. Seat Angle Adjustment
4. Back Rest Angle Adjustment Lever 9. Seat Longitudinal Adjustment
5. Seat Amortization Pump Electrical Connection 10. Seat Heating Switch
SEAT ADJUSTMENT LEVERS (MECHANICAL SUSPENSION)
Fig. 4.7B. Operator’s seat

1. Load Adjustment Lever 6. Absorber Stroke Adjustment
2. Seat Slide Adjustment Lever 8. Seat Angle Adjustment
3. Head Restraint Adjustment 9. Seat Longitudinal Adjustment
4. Back Rest Angle Adjustment Lever

OPERATION SECTION 4
PAGE 45
ARMRESTS
The right or left armrest can be adjusted in the horizontal and vertical direction as well as by turning it.
To raise or lower the armrest or turn it to the left or right side, unscrew the knob (2) and set the
armrest to the desired position (changing the height and angle setting). Tighten the knob (1) after
desired position has been obtained.
To move the armrest forward or backward, release the screws (3), set the armrest to the required
position and tighten the screws (3).
Fig. 4.7C. Operator’s Armrest

1. Armrest
2. Mounting Knob
3. Mounting bolts

SECTION 4
OPERATION
PAGE 46
4.5.2. SEAT BELT
WARNING! Before driving the machine adjust the seat belt and fasten the seat belt.
Adjust the belt to fit snugly and low around the hips to lessen the chance and
severity of injury in the event of an accident. Never wear the belt across the
abdomen.
To buckle, insert the tongue portion (1) of the buckle into the locking portion (2). To release, press the
release button (3) on the locking portion of the buckle and pull the tongue portion out. The belt retracts
automatically into the cassette.
WARNING! Do not 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.
Clean the belt in warm water with mild detergents.

Do not place heavy or sharp object on the belt.
The belt when not in use, should be rolled by the tensioning mechanism and stay in the cassette.
Fig. 4.9. Seat Belt

1. Belt Tongue Portion
2. Belt Locking Portion
3. Belt Release Button

OPERATION SECTION 4
PAGE 47
4.5.3. DRIVE TRAIN CONTROL LOCK LEVER
Fig. 4.10. Drive Train Control Lock Lever

1. Drive Train Lock Lever in Unlocked Position
A. Lever Shift Direction – Drive Train Locking
The lever (1, Fig. 4.10) is used for locking the drive train. This lever in the vertical (A) (down), lock,
position will get the drive train control valve deactivated. Consequently, it will not be possible to
engage neither gear nor range in the drive train system.
The machine engine cannot be started unless the lock lever is in the vertical (down) (A) – locked –
position. When the lever is in the drive train lock position the parking brake applied signal lamp (1.24,
Fig. 4.2A) is on.
4.5.4. DRIVE TRAIN CONTROL LEVER
Fig. 4.11. Drive Train Control Lever

1. Up-shift Button “UP” F. Lever Setting – Forward Travel
2. Down-shift Button “DN” R. Lever Setting – Reverse Travel
3. Information Label r – Right Pivot Turn
4. RH Side Rocker Switch for “H” – “L” RH Track Travel Range Change l – Left Pivot Turn
5. LH Side Rocker Switch for “H” – “L” LH Track Travel Range Change

SECTION 4
OPERATION
PAGE 48
The drive train control lever is used for machine direction change, while the buttons are used for gear
selection. The switches are used to control the machine turning by directing engine power to the
tracks and by applying and releasing respective speed range clutch packs and brake clutch packs.
If reversing is enabled the reversing signal will be turned on automatically. The reversing camera will
also be started.
4.5.5. BRAKE PEDAL
Fig. 4.12. Brake Pedal

1. Brake Pedal
Brake pedal stops the machine when fully depressed.
4.5.6. DECELERATOR PEDAL
2
3
Fig. 4.13. Decelerator Pedal

1. Decelerator Pedal Stop Bolt 2. Decelerator Pedal 3. Brake Pedal

OPERATION SECTION 4
PAGE 49
The decelerator pedal is used to temporarily decrease engine speed to gently change the travel
direction and machine load
Release the pedal to accelerate the engine up to the speed control knob setting.
Decelerated engine speeds 1050 – 1150 [RPM].
4.5.7. ELECTRICAL SYSTEM MASTER SWITCH
The electrical system master switch is used to disconnect power from the battery of all the electrical
loads of the machine. It is installed inside the right machine box. It has two positions: horizontal switch
position – electrical machine system power on, vertical switch position – power off. The position is
changes by turning the switch (left/right).
IMPORTANT: Keep the switch on while the engine is running.
Fig. 4.14. Electrical System Master Switch (right side of the machine)
IMPORTANT: Do not turn off the electric system master switch (Fig. 4.14) before the warning
screen with the message goes off (Fig. 4.2C).

SECTION 4
OPERATION
PAGE 50
4.5.8. EQUIPMENT CONTROL LEVERS
These levers are used for control of the machine working equipment that is blade and ripper. They are
located at the operator's RH side. The levers the machine is provided with reflect the machine
equipment order.
The detailed description how to operate is included in “OPERATING MOUNTED EQUIPMENT”.
Blade Tilt Option Option with Blade Tilt and Pitch

Fig. 4.15. Equipment Control Levers
1. Blade Control Lever 4. Blade Pitch Button
2. Ripper Control Lever 5. Blade Dual Tilt Button
3. Ripper Shank Pin Control Button
BLADE CONTROL LEVER

The blade can be lifted/ lowered, tilted and pitched by shifting the blade control lever (1) to the
required position.
RIPPER CONTROL LEVER
The ripper can be lifted, and its shanks pitched, by shifting the ripper control lever (2) to the required
position.
RIPPER SHANK PIN CONTROL BUTTON (if equipped).
The ripper shank pin control button (3) (if equipped) can be used for controlling ripper shank lock pin
displacement with the buttons and solenoid valves.
4.5.9. OPERATOR'S CAB
Cab has two doors on the left and right side, that open outward.
CAB DOOR – OPENING AND CLOSING
To open the cab door from the outside insert the key to the cab's lock and open the lock. Then press
the lock and open the door towards the rear of the machine – refer to Fig. 4.15A.
To open the cab door from the inside, press the lever inside the door lock (Fig. 4.15B) to release the
latch and swing the door to the rear.
To secure the door in the fully open position tilt cab doors until the actuation of the lock. The door will
be automatically blocked when fully opened. Lock release - refer to CAB OPEN DOOR LOCK.

OPERATION SECTION 4
PAGE 51
Fig. 4.15A Cab's door outside handle with lock 4.15B. Cab's Door Lock Inside Lever
OPEN CAB DOOR LOCK

The lock activation and securing the door in the open position is possible when fully opening the door
and activation of the latch lock.
To release the lock and close the door press the lever with the knob – refer to Fig. 4.15C.
CAB WINDOW LOCK LATCH (REAR WINDOW AND SIDE WINDOWS)

Press the latch of the cab window and move the window to the desired open position. To close the
window, slide the window to the end position, set the latch and secure – refer to Fig. 4.15D.
Fig. 4.15C. Cab Door Open Position Lock Fig. 4.15D. Cab Window Latch (Side Windows)

SECTION 4
OPERATION
PAGE 52
4.6. STARTING THE ENGINE
Fig. 4.16. Starting the Engine

1. Brake Pedal 6. Horn Button
2. Engine Coolant Gauge and Light 7. Drive Train Control Lever
3. Engine Lube Oil Pressure Gauge and Light 8. Engine Speed Control Knob
4. Machine Electrical System Switch 9. Drive Train Lock Lever
5. Decelerator Pedal
IMPORTANT: Before operating the machine perform each of the 10 hour maintenance
requirements referred to in Section 5.2. SCHEDULED MAINTENANCE. This engine cannot
be started by towing, pushing or coasting the machine.
WARNING! Before entering the operator s compartment, walk completely around the
machine and clear the area of personnel and obstructions.
WARNING! Read all product graphics before starting, operating, maintaining, or

repairing the machine.
WARNING! Lock the drive train lock lever and lower any raised attachment before
starting the engine.
WARNING! Understand all control functions before starting the engine.

OPERATION SECTION 4
PAGE 53
WARNING! Never start the engine indoors unless proper exhaust ventilation is
provided to remove deadly exhaust gases. Once the engine is running, move the
machine outdoors as soon as possible. Exhaust gases are hazardous and can cause
unconsciousness and death.
WARNING! Be sure all personnel are clear of the machine before starting the engine.
Sound the horn.
WARNING! Make sure the operator's seat is adjusted properly and fasten the safety
seat belt.
4.6.1. NORMAL START (temperature above 4 [°C])
Fig. 4.16A Engine speed control knob positions

A – Low Idle Speed
B – Medium Speed
C – High Speed
1. Turn on electrical system master switch ( Fig. 4.14) to (“ON”).
NOTE: When the machine is parked on a slope press the brake pedal before the driving
system is unlocked with the engine running. This will prevent uncontrolled machine rollover
down the slope.
2. Press the brake pedal (1).

3. Move the engine speed control knob to low idle speed position (A, Fig. 4.16A).
4. Move the lock lever (9) to its lower locked position.
NOTE: The engine cannot be started unless the drive train lock lever is in its upper unlocked
position.
5. Turn the machine electronic system switch key (16, Fig. 4.2) from “O” position to the “1” position,
Check the function of the display on the instrument panel.
6. The following lights will come on and off at the same time “STOP” “!” (1.5 and 1.7, Fig. 4.2A).
If the lights “STOP” and “!” (1.5 and 1.7) come on again, refer to the NOTE below.
7. Sound the horn (6, Fig. 4.16) to warn all personnel to keep a safe distance.
8. Press the engine “START” button once (9, Fig. 4.2B). After a few flashes the light (1.36) will turn
green and the engine will be ready for starting.
9. Press and hold engine “START” button (9) again to start the engine.

SECTION 4
OPERATION
PAGE 54
10. When the engine is started the engine start light (1.36) comes off and the engine “STOP” signal
light (1.37) glows.
IMPORTANT: The engine protection system protects the engine against damage. To this end
it will derate the engine operational features to their safe level.
NOTE: The engine ECM module controls and records parameters of engine operation. ECM
stores out of specification parameters and they will be displayed as codes for easier
troubleshooting.
There are two kinds of faults codes: fuel system electronic control and engine protection
system against damage.
All faults can be divided into active – steady failures (persisting) and inactive – intermittent.
Active codes can be read with engine faults warning lamps.
The inactive codes can be read with the electronic devices (computer with dedicated software)
only.
If an engine fault code occurs, the information of its occurrence is indicated on the integrated
display by means of the “STOP” light (1.5, Fig. 4.2A) and the “!” light (1.7).
To read the active faults code(s), toggle the switch (12, Fig. 4.2) to its upper position. The first
failure code will display. To read the second code (if any) toggle the switch (13, Fig. 4.2) to its
upper position and release the switch.
Repeat the procedure to read the codes for successive faults. With the last fault code
displayed, and the switch (Fig. 13) turned to its upper position will display the first fault code
again. The code for every previous fault can be read with the switch (13) turned to its lower
position and released.
Lights (1.5 and 1.7, Fig. 4.2A) will display the fault code. Light “!” will flash once and proceed
and follow faults code display. (1.7 – yellow).
1 blink 1 blink 4 blinks 6 blinks 1 blink

Fig. 4.17. Failure code display (example)
Fault code display (example):
Failure code 146 – high engine coolant temperature (refer to Fig. 4.17).
P - 1 Second Pause
There will be a 2 second pause between each fault code displayed.

For fault code list – refer to Diagnosing the Engine with the QSX (X) Engine Fault Codes
(English manual).
Contact an Authorized Construction Equipment Distributor in case you find out any engine
active fault codes.
IMPORTANT: Do not crank an engine for more than 30 seconds at a time. If the engine does
not start, allow the cranking motor to cool for 2 minutes before cranking again.
11. Check oil pressure. Allow the engine to idle for 3 to 5 minutes before increasing the engine
speed and placing under load.
IMPORTANT: The engine oil pressure is to register within 15 seconds after startup. The engine
oil pressure warning light is to come off or the engine oil pressure is to register or after startup
within 15 seconds; if not, immediately stop the engine and found the cause.

OPERATION SECTION 4
PAGE 55
12. Check indications of all instruments to ensure that machine is operating correctly. Refer to
INSTRUMENT PANEL.
IMPORTANT: Do not operate engine at low idle for long periods with engine coolant
temperature below the minimum specification.
IMPORTANT: After starting a cold engine, increase the engine speed slowly to provide
adequate lubrication to the bearings and to allow the oil pressure to stabilize.
4.6.2. ETHER INJECTOR START (temperature below 4 [°C])
WARNING! Ether starting fluid is highly flammable. Follow the precautions on the
container. An explosion can result if sparks or flame contact the ether or when
storing ether container when the air temperature is above 70 [°C].
Observe the following precautions:

• Do not use the ether injector when the air temperature is above 4 [°C].
• Do not use open flame when using ether starting fluid.
• Do not store fluid container in the operator's compartment.
• Store the containers in a cool, well ventilated place.
• Keep the fluid containers out reach of children.
• Do not breathe hazardous ether vapor.
• Do not let ether contact you skin, because it can cause frostbite.
• Never puncture the fluid container or put it into a fire.
• Dispose of empty containers per instructions printed on the container
• For your safety, remove the ether container when welding, grinding, or using a torch on
the machine.
• Follow the correct method for starting the engine.
• Before any attempt to start the engine, check the ether container or insure that a supply
of starting fluid is available under pressure and the system is in working condition.
Pressing the switch in the instrument panel makes ether injection.
IMPORTANT: The ether injector is to be used for engine starting only. Misuse of the ether
injector while the engine is running can result in a serious damage to the engine.
1. Perform all steps as described in steps 1 through 8 Refer to “NORMAL START” (temperature
above 0 [°C]).
2. Press and hold engine “START” button (9, Fig. 4.2B) to start the engine. Depress the ether
injector button (11) and keep it depressed for 1 to 2 [sec] with the engine crankshaft rotating. The
defined ether shot will be delivered to the intake manifold when the ether injector button is once
depressed and then released.
NOTE: If the engine fails to start within 15 [sec}, reuse the ether injector. If the engine does not
start with maximum of two ether injections determine and correct the cause before attempting to
start the engine again.
IMPORTANT: Do not crank an engine for more than 30 seconds at a time. If the engine does
not start, allow the cranking motor to cool for 2 minutes before cranking again.
3. Follow the steps described in the steps 10 thru 12. Refer to “NORMAL START”.

SECTION 4
OPERATION
PAGE 56
4.6.3. STARTING AFTER OIL CHANGE OR LONGER STORAGE

Start the engine as in normal conditions. The engine will not start unless the ECM registers minimum
oil pressure for start up. Accordingly, the engine start can take longer after oil change or prolonged
storage.
4.7. STOPPING THE ENGINE
Fig. 4.18. Stopping the Engine

1. Brake Pedal 6. Drive Train Control Lever
2. Engine Coolant Temperature Gauge 7. Engine Speed Control Knob
3. Ripper Control Lever 8. Drive Train Lock Lever
4. Machine Electrical System Switch 9. “STOP” Engine Stopping Switch
5. Decelerator Pedal
1 Stop the machine. Refer to Section 4.14. “STOPPING THE MACHINE”.

2 Operate it at idle speed for 3 to 5 minutes to allow the engine to cool down in a gradual and
uniform manner.
IMPORTANT: Immediate engine shutdown after operation under load may result in engine
damage.
3 Press “STOP” button (9, Fig. 4.18). The engine will shut off. Next turn the machine electronic
system switch key (4) left, to the (O) position.
4 Wait until the message on the integrated display is closed (see Fig. 4.2C).
5 Turn the electric system master switch (Fig. 4.14) to the OFF position.
IMPORTANT: When you disconnect the main switch before the message on the integrated
display is removed (Fig. 4.2), no data will be stored in the engine ECM and the DEF injection
system may be damaged.

OPERATION SECTION 4
PAGE 57
4.8. PROPER ENGINE OPERATION RULES
1. Allow the engine to idle 3 to 5 minutes before turning it off after operation under full load.
This allows adequate cool down of engine and turbocharger components.
2. Do not place the engine under load if the coolant temperature is below 60 [°C] or exceeds
107 [°C].
3. If the coolant temperature comes close to the admissible temperature (gauge’s GREEN area
extreme end) reduce the engine load (lower the engine [RPM] and/or downshift the gear) until the
coolant temperature comes to its specified reading.
4. Shut down the engine if the lube pressure comes below the minimum reading or exceeds the
specified maximum.
5. Most failures give an early warning. Look and listen for changes in performance, sound and
engine appearance that can indicate service or engine repair is needed. Some examples of
engine problems:
• Engine misfire,
• Excessive vibration,
• Unusual engine noises,
• Sudden changes in engine operating temperature or pressure,
• Excessive smoke,
• Loss of power,
• An increase in oil consumption,
• An increase in fuel consumption,
• Fuel, oil, or coolant leaks.
4.9. DRIVING THE MACHINE
CAUTION! Read the SAFETY PRECAUTIONS in Section 2 before operating the

machine.
IMPORTANT: Before operating check all instruments.
WARNING! Never haul passengers. Only the operator should be on the machine
when it is moving.
WARNING! Sit in the operator seat before operating the controls. Keep hands and
footwear free of grease, water and mud to insure positive control movements.
WARNING! Before operating the machine adjust the seat to allow full access of all
controls. Fasten the seat belt. Failure to do so could result in serious injuries or
death.
WARNING! Never get on or off the machine while it is moving because serious injury
or death could result.

SECTION 4
OPERATION
PAGE 58
Fig. 4.19. Driving the Machine

1. Brake Pedal 4. Engine Speed Control Knob
2. Decelerator Pedal 5. Drive Train Lock Lever
3. Drive Train Control Lever
1. Set the engine speed control knob (4) in high RPM.

2. Depress the decelerator pedal (2) to decrease the engine speed.
3. With the blade control lever lift the blade 0.4 to 0.5 [m] above the ground. Lift the ripper ( or other
additional attachment) 0.4 to 0.5 [m] above the ground (if equipped).
4. Shift the drive train lock lever (5) up from its lock position to its unlock position.
5. Use the drive train control lever (3) to choose the machine direction – first gear is a default gear
(when the gear presetting switch is in the “O” position).
6. Gradually release the decelerator pedal (2).
4.10. MACHINE SPEED AND DIRECTION CHANGES
IMPORTANT: In case of failure of the drive drive electronic controller or its electrical circuit the
operator can not shift the gears. The drive train system will operate in an emergency mode,
the operator can continue to ride the machine in the first gear only and low range as well as to
make pivot turns. Those functions may be accomplished by shifting the drive train control lever
in respective direction.
IMPORTANT: In case of failure of the drive train lock electrical circuit machine cannot be
operated at all. Clear the fault as described in the Service Manual.

OPERATION SECTION 4
PAGE 59
4.10.1. MACHINE SPEED CHANGE – MANUAL CONTROL
Fig. 4.20. Drive Train Control Lever and Gear and Range Display
1. Up-shift Button “UP”
2. Down-shift Button “DN”
3. Gear and Range Display
4. RT – “Hi”-”Lo” RH Speed Range Rocker Switch
5. LT “Hi”-”Lo” LH Speed Range Rocker Switch
F. Lever Setting – Forward Travel

R. Lever Setting – Reverse Travel
r – Right Pivot Turn
l – Left Pivot Turn
If machine is manually controlled the drive train control lever and buttons are used to change direction
and machine speed. This action is enabled if gear presetting mode rotational switch (A, Fig. 4.21) is in
the “O” position and auto-downshift mode switch (B, Fig.4.22) is in the “O” position).
Use the buttons (1 and 2, Fig. 4.20) for gear change and switches (4 and 5) for range change.
The buttons (1, 2) are used for gear upshift or downshift. The display (3) on the instrument panel will
tell the operator what gear he actually is operating in.
If the gear engaged right now is the 2nd gear – the digit “2’ will display and if you press the button (1)
you up-shift to the 3rd gear – the display will change to “3”, as a way of example. However, if you
depress the button (2) you down-shift to the 1st gear and the display will show “1” in such a case.
Switches (4 and 5) are used for speed range change. The machine is provided with two speed ranges
“L” – low and “H” – high.
The display (3) located at the instrument panel will tell you the range you are operating in at the any
given moment.
If a speed range you are operating at the moment is “L” – meaning low – the letter “L” will display and
if you turn switches (4, 5) to their upper position, the speed range will change to high and the letter
displayed will show “H”.
The switches (4, 5) reverted to their lower position will reengage the low speed range.
There is no need to stop the machine to change gear, range or direction. The machine system is
equipped with power shift that makes possible to shift gears under load.

SECTION 4
OPERATION
PAGE 60
MACHINE DIRECTION CHANGE
Shift the drive train control lever forward or rearward to get the machine direction change forward –
rearward, respectively.
Shifting this lever from its central (neutral) position forward (A) latched will cause the transmission to
be engaged for forward machine direction. The lever will remain in this position until it is returned to
the neutral position.
Shifting this lever from its central (neutral) position rearward (B) latched will cause the transmission to
be engaged for rearward machine direction. The lever will remain in this position until it is returned to
the NEUTRAL position.
TURN
Making turns is possible after selection of direction of travel.
Machine gradual turn using control lever “Hi - Lo” range switches
Press the switch (5) to its upper position and the switch (4) to its lower position to get the machine to
make the right gradual turn. Both machine tracks are engaged, while the left track features the higher
speed and, as a result, the machine will make a gradual turn to the right.
Press the switch (4) to its upper position and the switch (5) in its lower position to get the machine
make the left gradual turn. Both machine tracks are engaged, while the right track features the higher
speed and, as a result, the machine will make a gradual turn to the left.
The machine will make a gradual turn so long as one of the rocker switches gets reactivated. Then
the machine will revert to straight travel in a range it was engaged in prior to the gradual turn
activation.
Machine turn using drive train control lever
Shift the drive train control lever to the right – (r) to cause the machine to make a turn to the right by
controlling power to the right hand track. The speed of left hand track remains unchanged during the
entire right turn cycle. Gradual turn is accomplished with a lever leaned a bit. This is due to RH track
speed being diminished.
The more you lean the lever, the more intense the turn will be. The RH track speed will diminish until
power to the track gets disengaged. If you continue to lean the lever the turn will increase. This is due
to RH track being braked. With the lever at its limit position the RH track will come to a standstill with a
resultant pivot turn taking place.
Shift the drive train control lever to the left – (I) to cause the machine to make a pivot turn to the left in
a similar manner by controlling power to the left hand track. The speed of left hand track remains
unchanged during the entire left turn cycle.

OPERATION SECTION 4
PAGE 61
4.10.2. GEAR PRESETING MODE
Fig. 4.21. Gear Presetting Mode Switch

A. Switch 1F/2R – Mode 1F-2R Position
O. Manual Mode Position
For repetitive operation under tough operating conditions to facilitate machine operation place switch
(A, Fig. 4.21) to position (1F/2R). The machine will move forward at 1st gear for earthmoving when
control lever is moved forward and return to original position at 2nd gear reverse after moving the
control lever backward and the manual gear shifting with the control lever buttons will not be required.
4.10.3. AUTO-DOWNSHIFT MODE
Fig. 4.22. Auto Downshift Mode Switch

B. Switch (3 - 2 - 1 ) - Auto-downshift function is ON.
O - Auto-downshift Mode OFF.
Auto-downshift mode OFF Operation with torque converter overload may cause drive train oil
overheating and consequently low effectiveness of operation. An auto downshift system has been
used to minimize occurrence of such condition.
To activate this feature, turn the rotational switch (A, Fig. 4.21) into (O) position, while the
(B, Fig. 4.22) switch into (3→2→1) position.
If machine is operating with overload for a given engine RPM and gear, then the transmission
automatic downshift will take place. This can mean to downshift from 3rd gear to 2nd, and/or from 2nd
to 1st. The up shift will not be operational unless you depress the “UP” button. The manual up-shift is
inactive unless the machine load has reduced for a given gear. The machine auto-downshift mode is
valid for transmission manual mode position only (presetting switch (A, Fig. 4.21) to be set to (O)
mode).

SECTION 4
OPERATION
PAGE 62
4.11. CONVERTER OVERHEATING
If machine is operating with auto-downshift mode inactive and the pointer of the torque converter oil
temperature gauge moves out of the “RUN” area of the dial during operation, the transmission may be
in a gear range, which is too high for the load. Shift down into the next lower gear range. The
temperature should reduce; if not, downshift again. If the dial pointer remain out of the “RUN” range in
first gear, stop the machine, shift into neutral and run the engine at 1000 RPM until the gauge pointer
moves into the “RUN” area.
If the converter still remains overheated, despite the correct mainframe oil level, cleaned the engine
radiator and suction filter, stop the engine and consult Authorized Distributor of Construction
Equipment before operating the machine again.
4.12. DOWNGRADE OPERATION
WARNING! When operating a machine downhill, always put the transmission in the
low range position. Use the brake pedal to slow the machine. Never go downhill with
the transmission control in neutral. Failure to do so could result in losing control of
the machine and rollover could result.
Before going downgrade, select the gear, which will provide full tractor control without overspeeding
the engine.
4.13. OPERATING OVER AN OBSTRUCTION
When crossing a log or ditch bank, use the decelerator pedal to slow the machine, and when possible,
cross at an angle. Then gradually increase the power to the tracks as the machine moves forward,
over, and down. If the load is light, it may also be necessary to use the brake pedal to avoid abrupt
movements.
4.13.1. ALLOWABLE WATER IMMERSION

When a machine operates in water (Fig. 4.23) its maximum immersion is to be below the top roller
axis, that being ca. 1010 [mm]. The fan blades should not contact water in any case.
Fig. 4.23. Allowable Water Immersion
IMPORTANT: If these recommendations are not observed the machine drive train and/ or fan
blades can get damaged.

OPERATION SECTION 4
PAGE 63
4.14. STOPPING THE MACHINE
Fig. 4.24. Stopping the Machine

1. Brake Pedal 4. Drive Train Control Lever
2. Decelerator Pedal 5. Engine Speed Control Knob
3. Ripper Control Lever 6. Drive Train Lock Lever
To stop a machine proceed as follows:

1. Rotate the engine speed control knob (5, Fig. 4.24) to the low idle position
2. Depress the brake pedal (1) until the machine is stopped.
3. Shift the drive train control lever to neutral position.
4. Lock the drive train with the drive lock lever (6); the lever should be in the bottom locked position.
5. Lower the mounted equipment to the ground.
WARNING! Never leave a machine unattended with the engine running.

SECTION 4
OPERATION
PAGE 64
4.15. PARKING THE MACHINE
A few DO suggestions to protect both lives and equipment when parking.
DO park a tractor on planks in freezing weather to prevent tracks from freezing to ground.
The hydraulic driven equipment is to be lowered to the ground and the system pressure reduced to
diminish the danger of personal injury and enhance the machine stability.
Fig. 4.25. Parking on a Slope
Parking on a slope is not recommended. Park a tractor on level ground, if at all possible to:
a) Avoid unexpected movement.
b) Obtain accurate coolant, lubricant and fuel level checks
Avoid parking on a slope because unexpected machine movement may occur. However if necessary,
park at a right angle and secure the tracks with blocks (front and rear) (Fig. 4.25).
4.16. OPERATING MOUNTED EQUIPMENT
GENERAL
The hydraulic system provides power for the blade equipment, ripper or various other types of
equipment. Specific instructions for the operation of the blade and ripper are included in this section.
IMPORTANT: Holding a control lever in any position except HOLD or FLOAT for an extended
period off time after the hydraulic cylinder rod has reached the limit of its travel will produce
excessive heat in the hydraulic system which may affect equipment performance.

OPERATION SECTION 4
PAGE 65
4.16.1. BLADE CONTROL LEVER
Tilt Option Dual Tilt and Pitch Option

Fig. 4.26. Blade Control Lever Positions (1)
1. Blade Control Lever l. Blade Lower
2. Ripper Control Lever II. UNLOCK Position
3. Pitch Button lll. Blade Raise
4. Blade Dual Tilt Button II. FLOAT Position
V. LH Blade Tilt
Vl. RH Blade Tilt
POSITIONING THE BLADE
The blade control lever (1, Fig. 4.26) once released will revert by itself to the HOLD position (from any
position) excepting the FLOAT position. The blade will hold its position as it was at the time of the
lever was released.
BLADE RAISE
Pull the control lever (1) back (direction III) to raise the blade to desired height. When released the
lever will return to the HOLD position.
BLADE LOWER
Push the control lever (1) forward (direction I) to lower the blade. When released the lever will return
to the HOLD position.

SECTION 4
OPERATION
PAGE 66
BLADE FLOAT
With the control lever (1) in the FLOAT position, the blade is free to follow the contour of the ground.
To place the control lever in the FLOAT position, push all the way forward to its detented position in
direction (IV). The lever will remain in this position until it is manually returned to the HOLD position.
BLADE TILT
LH TILT
Pull the control lever (1) to the left (direction V) to lower the left hand corner of the blade.
To get the dual tilt depress the button at the same time (4, Fig. 4.26).
The released lever will return the the HOLD position.
RH TILT
Pull the control lever (1) to the right (direction VI) to lower the right hand corner of the blade.
To get the dual tilt depress the button at the same time (4, Fig. 4.26).
The released lever will return the the HOLD position.
BLADE PITCH (Fig. 4.27)
1. To pitch the blade backward (decrease suction angle) press the button (3) while holding it in this
position and push the blade control lever to the left (direction III). The released lever will return the
the HOLD position.
2. To pitch the blade forward (increase suction angle) press the button (3) while holding it in this
position and push the blade control lever to the right (direction I). The released lever will return the
the HOLD position.
Fig. 4.27. Pitching the Blade w ith H ydraulic T ilt/P itch

1. Blade Control Lever I – Forward Blade Pitch
2. Ripper Control Lever II – UNLOCK Position
3. Blade Tilt Button III – Reverse Blade Pitch
4. Blade Dual Tilt Button

OPERATION SECTION 4
PAGE 67
4.16.2. RIPPER CONTROL LEVER
NOTE: The operator seat is rotated by 15 [°] to the right so that the operator is able to
correctly seat and operate the ripper assembly control lever and observe the cutting tool.
Fig. 4.28. Ripper Control Lever Positions

1. Blade Control Lever I. Forward Shank Point Lean
2. Ripper Control Lever II. Rearward Shank Point Lean
II. Ripper Raise
IV. Ripper Lower
V. HOLD Position
The ripper is illuminated during operation. The headlamp switches on automatically with the machine
headlamps (4, Fig. 4.2).
Fig. 4.28A Ripper Lighting Lamp During Operation

SECTION 4
OPERATION
PAGE 68
RIPPER SHANK PITCH (point moves forward or rearward)
To change point pitch angle, shift the ripper control lever (2).
a) To “I” position – point will move forward.
b) To “II” position – point will move rearward.
When released the lever will return to the HOLD position.
RAISE AND LOWER THE RIPPER
RIPPER RAISE
To raise ripper to a required height shift the control lever (2): to the “III” position. When released the
lever will return to the HOLD position.
RIPPER LOWER
“To lower the ripper, move the lever (2): to the “IV” position.” When released the lever will return to the
HOLD position.
4.16.3. RIPPER SHANK PIN CONTROL
Fig. 4.29. Ripper Shank Pin Control Button Position

1. Blade Control Lever I – Pin Pull Out Position
2. Ripper Control Lever II – HOLD Position
3. Three-Position Ripper Shank Pin Control Button III – Pin Pull In Position
PIN PULL OUT

Pressing the button (3, Fig. 4.29) at the front (position I) pulls the ripper shank lock pin out. While
pulling out raise or tilt the ripper shank to facilitate pin displacement in a bore. The button will
automatically revert to its HOLD position (II) on release.

OPERATION SECTION 4
PAGE 69
PIN PULL IN
Press the button (3) at the rear to retract the ripper shank lock pin.
While pulling out raise or tilt the ripper shank to facilitate pin displacement in a bore. The button will
automatically revert to its HOLD position (II) on release.
Fig. 4.29A Positioning the Ripper Shank

1. Reference for Setting
2. Ripper Shank
3. Position Line of Reference for Setting
Use reference (1) for setting ripper shank (2, Fig. 4.29A) to line (3) (edge of the tool beam socket). If
the reference (1) is set precisely as shown in the figure, this will make easy to insert the pin.
Insert the pin into ripper shank opening pressing the button (3, Fig. 4.29) at the front.
To avoid damage to the assemblies while pin inserting, keep the engine RPM at minimum level that
would make possible to control the pin insert hydraulic cylinder.

SECTION 4
OPERATION
PAGE 70
4.17. POSITIONING THE BLADE
4.17.1. POSITIONING THE DOZER BLADE WITH A TILT CYLINDER
IMPORTANT: Do not expose any portion of the eyebolt threads.
WARNING! Be careful when operating with raised blade. Inadvertent shifting of the
blade control lever may result in serious injury. Remember that blade may slowly
drop due to lift cylinders’ drifting.
Fig. 4.30. Bulldozer Equipment D2

1. Push arm 4. Bulldozer Blade
2. Blade Tilt Cylinder 5. Upper Strut
3. Diagonal Strut 6. Upper Strut Lock Pin

OPERATION SECTION 4
PAGE 71
4.17.1.1. Blade Tilt
Fig. 4.31. Blade Tilt

1. LH Tilt 2. RH Tilt
1. Raise the blade off the ground.

2. Shift the blade control lever to the tilt position on the side to which the blade is to be tilted until the
desired tilt is obtained.
4.17.1.2. Pitching the Blade w ith H ydraulic Tilt/Pitch
Fig. 4.32A Pitching the Blade Fig. 4.32B. Pitching the Blade
with Hydraulic Tilt with Hydraulic Tilt/Pitch
1. Decreased Suction Angle for Soft Material
2. Increased Suction Angle for Hard Material
3. Upper Strut (Fig. 4.32A) or Pitch Cylinder (Fig. 4.32B)
PITCHING THE BLADE WITH TILT CYLINDER AND STRUT (Fig. 4.32A)
1. Raise the blade some centimeters off the ground. Stop engine.
2. Remove the upper strut (3) locking pin. To decrease suction angle shorten the upper strut the
desired value. To increase suction angle extend the upper strut the desired value.
3. Level the blade with the blade control lever.
4. After making the adjustments, secure the upper strut with the locking pin so it will not rotate.
Change of the blade suction angle cause that the blade tilt parameters will change also.

SECTION 4
OPERATION
PAGE 72
PITCHING THE BLADE WITH TILT AND PITCH CYLINDERS (Fig. 4.32B)
1. Raise the blade some centimeters off the ground.
2. To pitch the blade forward (increasing the suction angle) depress button (4, Fig. 4.15) of blade
control lever while shifting the blade control lever to right (outwards) until the desired pitch is
obtained.
3. To pitch the blade backward (decreasing the suction angle) depress the blade control lever
embedded button (4) while shifting the lever to the left (inwards) until the desired pitch is obtained.
4.17.1.3. Leveling the Blade
LEVELLING THE BLADE WITH TILT CYLINDER (Fig. 4.32C)
1. Lift the blade off the ground and shut off the engine.
2. Remove the upper strut locking pins and adjust the upper strut so the gap between the shoulder of
the eye (4, Fig. 4.32C) and the strut body (2), is “A” = 70 [mm] (distance between the strut cover
center line (1) and the eye center line (4) should be 1356 [mm]). This will position the blade in its
neutral position. If the blade is not leveled entirely, a half turn of the upper strut in either direction
will help to level the blade.
3. Rest the blade its lower end on the ground
4. Shift the blade control lever to the tilt position on the side to which the blade is to be lowered until
the blade is leveled on the ground.
5. Reinstall the upper struts’ locking pins.
Fig. 4.32C. Upper Strut

1. Strut Ball 3. Locking Pin
2. Strut Body 4. Eyebolt
LEVELLING THE BLADE WITH TILT/PITCH CYLINDERS

1. Rest the blade its lower end on the ground
2. Shift the blade control lever to the tilt position on the side to which the blade is to be lowered until
the blade is leveled on the ground.

OPERATION SECTION 4
PAGE 73
4.17.2. BULLGRADER BLADE POSITIONS “C” – FRAME (G-2 EQUIPMENT)

(MECHANICAL OPTION)
IMPORTANT: Do not expose any portion of the eyebolt threads.
WARNING! Be careful when operating with raised blade. Inadvertent shifting of the
blade control lever may result in serious injury. Remember that blade may slowly
drop due to lift cylinders’ drifting.
Fig. 4.33. G-2 Bullgrader Equipment (“C” frame)

1. “C” Frame 5. Lower Pin
2. Upper Strut (or Blade Tilt Cylinder) 6. Straight Blade
3. Lower Strut 7. Upper Strut (or Blade Tilt Cylinder)
4. Blade Pin
4.17.2.1. ANGLING THE BLADE
1. Lift the blade off the ground and shut off the engine. Refer to “STOPPING THE ENGINE”
2. Remove one strut trunnion from the trunnion bracket on the “C” frame, keep it close to the “C”
frame.
3. Remove the strut trunnion from the trunnion bracket on the opposite side of the “C” frame, and
carefully swing the strut assembly out as far as it will go.
WARNING! When performing the above stay clear of the blade. The blade will drop
(tilt) on this side due to the loss of balance caused by the extended lower strut.

SECTION 4
OPERATION
PAGE 74
4. Swing the first disconnected strut assembly outward to regain blade balance. Next, level the blade
and maintain this level position while repositioning the blade (changing the angle).
5. Assemble the first strut to the blade “C” frame as follows:
a) When attaching a blade angled to the right or the left, attach the rear most strut assembly first.
b) When connecting a straight blade (not angled), swing each strut in until they contact the frame
(refer to WARNING below). Next, level the blade, then assemble either strut assembly and
secure it.
WARNING! The blade will drop (tilt) on the side with the extended strut assembly.
Fig. 4.34. Adjusting the Diagonal Angle of Blade
6. Assemble the remaining strut assembly to the “C” frame. If necessary, adjust the upper struts to
obtain strut trunnion alignment with the trunnion brackets on the frame. Secure the trunnion with
a pin.
7. The lower strut can move forward or backward in the eye of the lower strut trunnion. When the
eyebolt (1, Fig. 4.35) of the lower strut is properly adjusted to have a correct “A” distance equal to
25 [mm], the gap (2) must be toward the rear of the swivel eye so the body (3) of the lower strut
will be tight against the trunnion swivel eye (4) of the lower strut.
8. Level the blade so one end does not dig in deeper than the other. This can be done by
adjusting either one or both upper struts. Retorque the strut eyebolt clamping cap bolts and nuts to
450 [Nm]. to 450 [Nm] Refer to “LEVELING THE BLADE” in this section.
NOTE: Make this adjustment so that to maintain gaps as shown in Fig. 4.35 and 4.36.

OPERATION SECTION 4
PAGE 75
Fig. 4.35. Lower Strut Adjustment of the Angled Blade

1. Eyebolt 3. Strut Body
2. Gap 4. Trunnion Swivel Eye
Fig. 4.36. Blade Trunnion Ball Gap Adjustment

1. “C” Frame 2. Swivel Pin 3. Gap
4.17.2.2. Tilting the Blade
1. Raise the blade 300 [mm] above the ground and shut off the engine.
2. Remove the lower strut trunnion from its bracket on the side to be raised, and position the strut
close to the “C” frame.
3. Adjust the opposite side to get the desired tilt by shortening the upper strut.
WARNING! Always lower the side being adjusted first so that the lack of balance will
not cause the loose strut assembly to swing out and result in unexpected injury or
damage.
4. Return to the side of the machine on which the lower strut was disengaged and lengthen the
upper strut until the lower strut trunnion can be inserted in its bracket on the “C” frame. Install the
lower strut to the “C” frame and secure with a pin.
IMPORTANT: Do not tilt the blade more than 300 [mm] tip to tip.

SECTION 4
OPERATION
PAGE 76
5. After tilting the blade raise it 300 [mm] above the ground and shut off the engine. Adjust the upper
struts to a “neutral” position (no compression or stretching) so the blade connecting pins are free
in their brackets.
6. Whenever the blade is tilted, adjustments to one upper strut must always be equal and opposite to
the adjustment made on the other upper strut. (For example: if a strut on one side is shortened
11/2 turns, lengthen the opposite strut 11/2 turns).
4.17.2.3. Leveling the Blade
3. Lift the blade off the ground and shut off the engine.
4. Remove the upper strut locking pins and adjust both upper struts so the gap between the
shoulder of the eye (4, Fig. 4.37) and the strut body (2), is “A” = 35 [mm]. This will position the
blade in its neutral position. If the blade is not leveled entirely, a half turn of the upper strut in
either direction will help to level the blade.
5. After leveling the blade raise it 300 [mm] above the ground and shut off the engine. Adjust the
upper struts to a “neutral” position (no compression or stretching) so the blade connecting pins
are free in their brackets.
6. Having determined the “neutral” position, shorten each upper strut by one full turn.
Fig. 4.37. Upper Strut

1. Strut Ball 3. Locking Pin
2. Strut Body 4. Eyebolt
IMPORTANT: Adjustment made in step 4 must be made only if all strut adjustments have
been made with blade raised off the ground.
7. Reinstall the upper struts’ locking pins.

OPERATION SECTION 4
PAGE 77
4.18. OPERATING TECHNIQUES
WARNING! Before operating the machine, be sure the area of the operator's
compartment, all steps and handles are free of oil, grease, loose objects, ice, snow
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. Failure
to follow these instructions may result in serious injury.
When the blade is held hydraulically it becomes a rigid part of the machine, except when the valve is
in “FLOAT” position, and will follow all movements of the machine. When rough terrain encountered it
will be necessary to vary the height of the blade while pitching to obtain a smooth cut.
When possible, start all jobs from relatively level ground. If necessary, level an area large enough to
provide sufficient working space for the machine. This prevents back and forth pitch of the machine
and will result in easier digging.
Avoid track spinning whenever possible; this wastes effort and converts a relatively smooth working
area into ruts and piles that pitch and tilt a machine. In cold weather this material can freeze and
cause additional difficulty the following day. Crossing ditches, ridges, rock or logs should be done
slowly and, at an angle. This slows the fall, lessens the danger of upsetting the machine and reduces
the fall jolt, which can be harmful to the operator and machine.
4.18.1. DIGGING AND CLEARING
WARNING! Prior to operating know the locations of gas lines, utility lines, sewers,
overhead and buried power lines, and the other obstructions or hazards are known.
A ruptured gas line or cut electrical cable could result in personal injury.
Always feed the blade into the ground gradually until the desired depth of cut is obtained. When
selecting the gear range and determining the depth of cut, allow for an increase in resistance as the
load increases. When raising the blade at the end of a cut, do it gradually to avoid an abrupt ridge or
bump in the path of the machine. Move material downgrade whenever possible to take advantage of
the reduced effort required. Fig. 4.38.
Fig. 4.38. Moving Material Downgrade

SECTION 4
OPERATION
PAGE 78
Fig. 4.39. Cutting Down a Pile or Hill

1. Method 1 2. Method 2
Two methods of cutting down a pile or hill are shown in Fig. 4.39.
Type of material and local conditions may dictate which method is preferred. Further information is
included in “BREAKING PILES AND SPREADING”. When using Method 1, never allow the high face
to become a hazard to the operator or machine. With the tractor at right angles to the face, raise the
blade and dislodge the high bank before returning to the original direction of cut.
When using Method 2, make the cut wide enough to avoid trapping the machine.
WARNING! Avoid high overhangs. Ramp up and remove the top layers first. Avoid
high banks. Operate the machines as far away from the trench as possible. Cave-in
may result if the trench edge collapses.
A hillside cut can be started more easily if a small bench cut is first made as shown in Fig. 4.40.
Fig. 4.40. Hillside Cut

1. Cut I 2. Cut II 3. Final Level

OPERATION SECTION 4
PAGE 79
Then, when digging as in Fig. 4.41, keep the inside (uphill) surface slightly lower to gain greater
machine stability. Tilting the blade will provide this type of cut with less effort on the operator's part.
Fig. 4.41. Hillside Cut

1. Horizon, 2. Lower surface
Always cut the shelf wide enough to provide solid support for equipment using it later. If possible,
move the material downhill. This allows to gain the advantage of gravity, reduce effort and increase
machine stability. Soft soil or shallow slopes may allow the hillside cut to be made as shown in
Fig. 4.42. in Fig. 4.41. Increased stability is realized by running the uphill track inside the ridge left by
the first (1) cut. Cuts (3, 4 and 5 Fig. 4.42) illustrate the completion of the shelf.
Fig. 4.42. Shallow Slope Hillside Cut

SECTION 4
OPERATION
PAGE 80
Once again, pushing the loosened material to the lower side of the slope (Fig. 4.43) will normally
reduce time and cost. Do not push material beyond the point required to retain firm track support.
Fig. 4.43. Slope Edge Operation
When backing up, do not raise the blade as this puts extra weight on the front idlers causing greater
track penetration. Let the blade FLOAT as you back away from the edge of soft fills.
Initial work on steep hillsides can be safer by either securing the tractor with a winch to a suitable
uphill anchor point or by operating a tandem arrangement as shown in Fig. 4.44.
Fig. 4.44. Operating a Tandem Arrangement
When clearing trees, raise the blade high to gain leverage and make contact gently to reduce possible
harm to the operator and machine (Fig. 4.45).
Fig. 4.45. Machine Equipped with Sweeps

OPERATION SECTION 4
PAGE 81
Heavy roots of large trees may require pushing and digging or cutting from several sides of the tree.
Use a cable to topple and remove trees from soft ground (Fig. 4.46).
Fig. 4.46. Using Cable to Remove Trees
CAUTION! Falling trees and dead limbs can cause injuries. When clearing trees,
operator protection must be used.
When clearing a rocky area, remove the small and loose rocks first. Large and solid rocks can then be
loosened and moved with less difficulty. When loosening large or solid rocks, greater force and
penetration can be obtained by tilting the blade and prying under the rock with the lower edge of the
blade (Fig. 4.47). Lifting the rock with the blade while pushing will increase traction and reduce track
spinning.
Fig. 4.47. Loosening Rocks with Lower Edge of the Blade
Penetration on hard, frozen or rocky ground can be made easier by tilting the blade. This will add
weight and power to the lower cutting edge.
When the ground is frozen and the area must be ripped before it can be worked, rip a relatively small
section and work it to grade before enlarging the cut. This will require ripping each section only once,
not every morning after the ground has refrozen. Snow can act as an insulating blanket and reduce or
eliminate the need for a ripper. Leave the rest to insulate the ground.

SECTION 4
OPERATION
PAGE 82
4.18.2. TRANSPORTING, LOADING AND PILING
The transporting of material with a bulldozer is not always a most economical method. Natural ridges,
a window formed by side blade spillage on earlier passes or side-by-side dozing will improve the
productivity (Fig. 4.48). Where the quantity of material or distance involved becomes excessive,
a loader, scraper or truck should be considered.
Fig. 4.48. Side-by-Side Dozing
A usual method of piling is shown in Fig. 4.49. When the piling reaches stages “D” or “E” the operator
may elect to continue one of the other depending on height or area desired. When the machine is
used as a pusher, aiding scraper loading (Fig. 4.50), the machine power must be carefully controlled.
Excessive “push” effort can cause the scraper unit to “jackknife”, with resulting injury or damage.” On
turns, be sure the blade of the pusher machine does not come in contact with the rear wheels of the
scraper.
Fig. 4.49. A Usual Method of Piling

OPERATION SECTION 4
PAGE 83
Fig. 4.50. Aiding Scraper Loading

The bulldozer can be used directly as a loader if the method shown in Fig. 4.51 is used.
Fig. 4.51. Loading Directly
4.18.3. BREAKING PILES AND SPREADING
Two methods of breaking down a pile are shown in Fig. 4.52. When spreading is to be in some
directions or if the pile is large or hard, Method 1 is usually desired. When using Method 1, cut into the
side of the pile from different angles.
When Method 2 is used, and access to the top of the pile is difficult, a slot may be started as shown
below. Loosen material at the base and form a dirt “ramp” to provide a decreased angle of approach
and cut.

SECTION 4
OPERATION
PAGE 84
Method 1
Method 2
Fig. 4.52. Cutting Down a Pile or Hill
1. Ramp 2. Original Slope
When trucks or wagons are used for hauling, bulldozers are ideal spreading tools at the fill (Fig. 4.53).
Blade should be kept in a straight position so that material is drifted directly under the cutting edge
(Fig. 4.53). When finishing in non-solid materials, such as earth, drag the blade backward for
a smooth job as shown in Fig. 4.54. Rock, of course, may damage the blade base, therefore, such
practice is not recommended where abrasive material is common.
Fig. 4.53. Spreading Material Forward

OPERATION SECTION 4
PAGE 85
Fig. 4.54. Back Dragging
Angling blade dozers are ideal for widening fills. Travel about 30 [cm] from the slope blind so that
earth rolling off the blade end will fall over the edge as shown in Fig. 4. 55.
Fig. 4.55. Widening a Fill
4.18.4. RIPPING
4.18.4.1. PRIOR TO OPERATION
Before operating the ripper proceed as follows:

1. Check all mounting hardware for torque.
2. Check hydraulic connections for leaks.
3. Check the condition of the ripper, bits, mounting hardware for completeness and torque.

SECTION 4
OPERATION
PAGE 86
4.18.4.2. Operating techniques
When starting ripping lower the ripper teeth slowly to required depth. Ripping of rock material must be
performed in direction of easier ripping what may be established by carrying out test ripping in various
directions and under various angle of inclination of the shanks. During test ripping lower the shank to
half of working depth. Machine efficiency can be improved when several centimeters of loose material
is left on solid rock. Ripping should be performed at a depth the best results are obtained without
overloading the engine. Keep loose ground level and horizontal as much as possible. Never make
turns with the machine with ripper teeth are at full depth in rocky ground. Use the common sense
when working in hard ground not to damage the ripper and the machine. Do not accelerate the
machine and simultaneously lower the ripper teeth into the ground – this will damage the ripper.
Pay attention not at allow rear of the machine to lift off the ground during ripping operations, as this
decreases traction and accelerates wear of track system. Use new and sharp points for hard ground.
4.18.4.3. COLD WEATHER OPERATION
Start the engine as described in “STARTING THE ENGINE” and then proceed as follows:
• move slightly and slowly ripper control to warm oil in hydraulic cylinders,
• raise the ripper at max. height and then lower it slowly until it rests on the ground,
• increase gradually pressure in ripper cylinders by keeping the control lever in LOWER position
until rear of the machine is off the ground,
• prior to normal ripping operations operate the ripper at low depth for a couple of minutes to warm
shank points,
• protect shank and points when parking the machine.
4.19. ECONOMICAL OPERATION OF THE MACHINE
Fuel consumption during operation of the dozer depends on many factors as: engine characteristics,
load, terrain, operator’s skill and experience, manner of operation.
Relatively objective ratio of fuel consumption is quantity of moved material per unit of consumed fuel.
To reach the most favorable value of this ratio observe the following principles of dozer operation:
• Avoid long distance transporting of material;
• Loading and pushing of material must be performed at gear which ensures maximum drawbar pull
(1st or 2nd gear) with high blade fill ratio without loosing material in blade;
• Reverse travel at top gear but keep engine speed above medium, not maximum;
• Avoid stopping machine due to a stall of the torque converter;
• Avoid track slippage;
• For digging hard material pitch the blade forward, for transportation of material pitch the blade
backward.

OPERATION SECTION 4
PAGE 87
4.20. OPERATING ELECTRIC WINCHES TO LOWER BOTTOM ENGINE COVER

AND BOTTOM TRANSMISSION COVER (OPTION)
4.20.1. WINCH OPERATION CONTROL

The machine with access the engine and transmission compartments is provided from underside are
equipped with the electric winches to lower the bottom engine cover and the transmission cover.
The winches are controlled by a remote winch control switch with a connecting cable (Fig. 4.57).
The engine bottom cover winch (1, fig. 4.61) is installed in front of the machine, on the frame cross
bar. The transmission cover bottom winch (2, fig. 4.61) is installed inside the main frame, at the left of
the transmission compartment.
2 3 1
Fig. 4.56. Winch Control Panel (LH Side of the Front Engine Compartment)
1. Transmission Cover Winch Remote Control Switch Socket
2. Engine Cover Winch Remote Control Switch Socket
3. Winch Control Panel Power Switch
1 - TRANSMISSION COVER WINCH REMOTE CONTROL SWITCH SOCKET

To control the raising / lowering of the bottom transmission cover, connect the plug of the remote
control switch to the control panel socket (1, Fig. 4.56).
2 - REMOTE SWITCH ENGINE GUARD WINCH CONTROL SOCKET
To control the raising / lowering of the bottom engine cover, connect the plug of the remote control
switch to the control panel socket (2, Fig. 4.56).
3 - THE WINCH CONTROL PANEL POWER SWITCH (3, Fig. 4.56)
The winch power switch has two positions: horizontal switch position - power ON, vertical switch
position - power OFF. Changing position is done by turning the switch (left / right).

SECTION 4
OPERATION
PAGE 88
Rys. 4.57. Winch Motor Remote Control Switch with Connecting Cable
1 – Switch button controlling the direction of movement of the winch drum
CAUTION! Power should be switched on for the winch operation only.
WINCH MOTOR REMOTE CONTROL SWITCH (Fig. 4.57)
To control the bottom cover raising / lowering, the machine is equipped with the remote control switch
with a connection cable (Fig. 4.57) stored in the toolbox (refer to TOOL BOX in Section 5).
Plug the cable into the control panel socket (Fig. 4.56):
- into the socket (1) when lowering/raising the transmission cover.
- into the socket (2) when lowering/raising the engine cover.
This toggle switch is provided with three positions, which are as follows:
“OUT” position to unwind the winch drum rope and lower the bottom engine/transmission cover.
“IN” position to wind the winch drum rope and raise the bottom engine/transmission cover.
When the switch is released it automatically returns to the center position – neutral position.

OPERATION SECTION 4
PAGE 89
The machine is equipped with two engine and transmission cover winch limit switches, one for each
bottom cover.
The engine cover winch limit switch is located on the left side of the internal main frame surface, in the
engine compartment (1, fig. 4.58).
The transmission cover winch limit switch is located under the winch, on the left side of the main
frame, in the transmission compartment (1, Fig. 4.59).
These switches protect the winch motors. When the cover raised by the winch reaches the upper
position (mounting position) it presses the limit switch lever and switches off the winch motor.
1 1
2 2
Fig. 4.58. Bottom Engine Cover Winch Fig. 4.59. Bottom Transmission Cover Winch
Limit Switch Limit Switch
1. Engine Cover Limit Switch 1. Transmission Cover Limit Switch
2. Limit Switch Lever 2. Limit Switch Lever

SECTION 4
OPERATION
PAGE 90
4.20.2. BOTTOM TRANSMISSION AND ENGINE COVERS ADAPTED TO WORK WITH

THE WINCH
The bottom engine cover is hinged at rear and it may swing on the hinges when the side edge
fastening bolts are loosened.
The winch rope (3, fig. 4.60) is fastened on the front cover part (1) to the catch (2) so that the cover
may be raised and lowered with the winch.
The bottom transmission cover is raised and lowered in a similar manner. The cover is hinged with the
hinges installed on both sides of the main frame, under the transmission compartment. The rope is
fastened to the cover catch on the left side of the cover.
2
1
Fig. 4.60. Bottom Engine Cover (lowered)
1. Bottom Engine Cover 2. Winch Rope Hook 3. Winch Rope
2
1
Fig. 4.61. Bottom Engine Cover and Transmission Cover Winches
1. Engine Cover Winch 2. Transmission Cover Winch

OPERATION SECTION 4
PAGE 91
The engine cover lock (Fig. 4.62) is installed for the engine cover at the front of the main frame, on the
left side. The lock protects the cover against falling when all fastening bolts are loosened and
tightened.
The transmission cover is locked by one of two hinges (Fig. 4.63). When the machine is not equipped
with a transmission cover winch, unlock the hinge (remove the screw and nut from the hinge) installed
opposite to the cover opening direction to open the cover.
When the machine is equipped with the winch, unlock the left hinge.
CAUTION! Do not loosen or install the cover fastening bolts to the main frame if the
covers are not locked.
Fig. 4.62. Engine Cover Lock (“Locked” Position)

1 – Lock Lever A – Unlock Direction
2 – Lock Lever Locking Plate B – Lock Direction
3 – Lock Bolt
In the lock position the lock bolt (3) overlaps the cover so that it cannot fall. The lock lever (1) is used
to move the lock bolt (3) backwards. The lock lever (1) is in the lock position screwed in the locking
plate (2).
Fig. 4.63. Transmission Cover Hinge Locations

SECTION 4
OPERATION
PAGE 92
4.20.3. LOWERING AND RAISING THE BOTTOM COVER WITH THE WINCHE
CAUTION! Lower and raise the cover carefully to avoid any severe injuries. Do not
stand under the cover when it is not mechanically locked.
The following procedure describes lowering and raising of the cover with the electric winch and should
be followed when operating the bottom engine cover and the transmission cover.
CAUTION! Do not loosen or install the cover fastening bolts if the cover is not
locked.
1. Lock the bottom engine cover with the cover lock (Fig. 4.62) and/or the transmission cover
(Fig. 4.63). Then loosen the screws that fasten the given cover to the main machine frame.
2. Unlock the cover:
a) engine – remove the lock lever (1, Fig. 4.62) from the lock plate (2). Move the lock lever (1)
in the “A” direction to turn the lock and move the bolt (3) outside of the bottom cover.
b) transmission – remove the screw and nut from the left cover hinge (Fig. 4.63).
3. Open the LH side engine cover access door. Plug the remote control switch cable into the control
panel socket (1 or 2, Fig. 4.56)
4. Turn the winch control panel power switch (3, Fig. 4.56) to the ON position.
5. Press the winch motor switch button (1. Fig. 4.57) to the “OUT” position (LH side) and lower the
required cover on the ground.
6. Complete the specified service and/or maintenance in the engine or transmission compartment.
7. Press the remote winch control switch button (1. Fig. 4.57) to the “IN” position (RH side) and
raise the required cover to the mounting position.
CAUTION! Do not loosen or install the cover fastening bolts if the cover is not
locked.
8. Lock the bottom engine cover moving the lock lever (1, fig. 4.62) in the “B” direction and putting
the lock bolt (3) under the cover. Screw the lock lever (1) in the lock plate hole (2). Remove the
bolts that fasten the cover to the machine main frame and fasten the bottom cover with the bolts.
9. Lock the transmission cover with the screw and nut for the left hinge. Remove the bolts that
fasten the cover to the machine main frame and fasten the bottom cover with the bolts.
10. Turn the winch control panel power switch (3, Fig. 4.56) to the off position.
11. Unplug the remote control switch from the control panel socket and store it in the tool box. Close
the side cover door.

OPERATION SECTION 4
PAGE 93
4.20.4. WINCH ELECTRIC SYSTEM DIAGRAM
Fig. 4.64. Winch Electric System Diagram

1. Batteries
2. Electric System Master Switch
3. Engine Cover Limit Switch
4. Fuse – 80 [A] – Winch Power Circuit
5. Winch Power Switch
6. Remote Control Switch (Engine Cover Winch) with Cable
7. Transmission Cover Winch Remote Control Switch
8. Transmission Cover Limit Switch
9. Transmission Cover Winch with Motor
10. Contactor – Transmission Cover Winch Control
11. Contactor – Engine Cover Winch Control
12. Engine Cover Winch with Motor
WIRE COLOR CODE

Code Color Code Color
R Red P Rose
T Amber V Violet
W White DB Dark Blue
Y Yellow LB Light Blue
B Black DG Dark Green
BR Brown LG Light Green
G Gray GR Green
O Orange

SECTION 5
MAINTENANCE
SECTION 5
MAINTENANCE
CONTENTS
PAGE
5.1. SERVICE PRECAUTIONS ............................................................................................................ 3
5.2. SCHEDULED MAINTENANCE GUIDE ......................................................................................... 4
5.2.1. MACHINE GROUND LEVEL INSPECTION ................................................................... 7
5.3. MACHINE MAINTENANCE AND SERVICE DIAGRAM AND CHART .......................................... 7
5.3.1. MACHINE SERVICE AND MAINTENANCE CHART ..................................................... 8
5.3.2. MACHINE SERVICE AND MAINTENANCE CHART ..................................................... 9
5.3.3. REFILL LUBRICANT AND FLUID SPECIFICATIONS CHART .................................... 11
5.4. LUBRICATION ............................................................................................................................. 12
5.4.1. WHEN SHIPPED ......................................................................................................... 12
5.4.2. SCHEDULED LUBRICATION ...................................................................................... 12
5.4.3. SELECTION ................................................................................................................ 12
5.4.4. VISCOSITIES .............................................................................................................. 12
5.4.5. RECOMMENDED LUBRICANT CHART ...................................................................... 13
5.5. SEASONAL PREPARATION ....................................................................................................... 14
5.5.1. PREPARING THE FUEL SYSTEM .............................................................................. 14
5.5.2. PREPARING THE COOLING SYSTEM....................................................................... 14
5.5.3. PREPARING THE ELECTRIC SYSTEM ..................................................................... 14
5.6. ENGINE AIR INTAKE SYSTEM................................................................................................... 15
5.6.1. PRE-CLEANER ........................................................................................................... 15
5.6.2. AIR CLEANER............................................................................................................. 15
5.6.3. CHECKING CONNECTIONS AND CHARGE AIR COOLER (CAC) FOR LEAKS ........ 17
5.7. BELTS.......................................................................................................................................... 18
5.7.1. BELT CONDITION VISUAL INSPECTION .................................................................. 19
5.7.2. BELT REPLACEMENT ................................................................................................ 19
5.8. COOLING SYSTEM..................................................................................................................... 20
5.8.1. COOLANT ................................................................................................................... 20
5.8.2. INHIBITORS / CONDITIONERS .................................................................................. 21
5.8.3. RADIATOR .................................................................................................................. 21
5.8.3.1. COOLING SYSTEM FILLER CAP ................................................................... 21
5.8.3.2. CLEANING THE RADIATOR CORE ............................................................... 22
5.8.4. CHECKING COOLANT LEVEL.................................................................................... 22
5.8.5. CHANGING THE COOLANT ....................................................................................... 23
5.8.5.2. DRAINING THE SYSTEM (FIG. 5.7) ............................................................... 23
5.8.5.2. FILLING THE DRAINED SYSTEM .................................................................. 23
5.8.6. CHANGING THE COOLANT FILTER .......................................................................... 24
5.8.7. COOLING SYSTEM CLEANING ................................................................................. 25
5.9. FAN .............................................................................................................................................. 25
5.10. ELECTRICAL SYSTEM ............................................................................................................. 25
5.10.1. ELECTRIC WIRES AND CONNECTIONS ................................................................. 26
5.10.2. MAIN POWER COMPONENTS ................................................................................. 26
5.10.3. BATTERIES............................................................................................................... 27
5.11. ENGINE ..................................................................................................................................... 29
5.11.1. CHECKING ENGINE OIL LEVEL .............................................................................. 29
5.11.2. CHANGING THE CRANKCASE OIL AND OIL FILTERS ........................................... 30
5.11.3. ETHER INJECTOR (IF EQUIPPED) .......................................................................... 32
5.11.4. ENGINE VENTILATION SYSTEM ............................................................................. 34
5.11.5. CHECKING GENERAL CONDITION OF ENGINE..................................................... 34
5.12. FUEL SYSTEM .......................................................................................................................... 35
5.12.1. FILLING THE FUEL TANK ........................................................................................ 35
5.12.2. FUEL TANK FILLER STRAINER ............................................................................... 35
5.12.3. FUEL TANK SHUT-OFF VALVE................................................................................ 36

SECTION 5
MAINTENANCE
5.12.4. FUEL FILTERS .......................................................................................................... 36
5.12.4.1. FUEL FILTER WATER SEPARATOR SERVICING ....................................... 36
5.12.4.2. REPLACING FUEL FILTERS ........................................................................ 37
5.12.4.3. FUEL SYSTEM VENTING ............................................................................. 39
5.12.5. DRAINING SEDIMENT AND WATER FROM FUEL TANK ........................................ 39
5.12.6. SERVICING FUEL TANK CAP-BREATHER .............................................................. 40
5.13. ENGINE EXHAUST SYSTEM ................................................................................................... 40
5.13.1. CLEANING THE EXHAUST SYSTEM (SCR) ............................................................ 41
5.13.1.1. PASSIVE CLEANING (AUTOMATIC) ............................................................ 41
5.13.1.2. ACTIVE (ASSISTED) CLEANING ................................................................. 41
5.13.1.3. STATIONARY CLEANING (INITIATED MANUALLY) .................................... 41
5.13.1.4. DIESEL OXIDATION CATALYST (DOC) AND DIESEL
PARTICULATE FILTER (DPF) CLEANING ................................................... 42
5.13.1.5. CLEAN FUEL DISPENSER (INJECTOR) ...................................................... 42
5.13.2. DIESEL EXHAUST FLUID (DEF) DOSING MODULE SERVICE ............................... 43
5.13.3. DIESEL EXHAUST FLUID (DEF) TANK SERVICE .................................................... 44
5.13.4. CHECKING EXHAUST SYSTEM FOR LEAKS .......................................................... 44
5.14. EQUIPMENT SYSTEM HYDRAULICS ..................................................................................... 45
5.14.1. CHECKING OIL LEVEL ............................................................................................. 45
5.14.2. CHANGING HYDRAULIC OIL ................................................................................... 45
5.14.3. REPLACEMENT THE RETURN FILTER AND PILOT FILTER .................................. 46
5.14.4. REPLACING THE FAN DRIVE SYSTEM RETURN FILTER ...................................... 47
5.14.5. SERVICING THE SUCTION STRAINERS AND FILLER STRAINER ......................... 48
5.13.6. SERVICING THE HYDRAULIC TANK BREATHER ..................................................... 49
5.14.7. HYDRAULIC SYSTEM VENTING .............................................................................. 50
5.15. LUBRICATION POINTS ............................................................................................................ 51
5.16. MOUNTED EQUIPMENT .......................................................................................................... 56
5.16.1. COMPLETE BLADE REMOVAL AND INSTALLATION.............................................. 56
5.16.2. ADJUSTING THE TILT CYLINDER AND UPPER BLADE STRUT (FIG. 5.44).............. 58
5.16.4. PITCH CYLINDER CLEARANCE ADJUSTMENT ...................................................... 59
5.16.5. CHECKING THE BLADE CONDITION ...................................................................... 60
5.16.5.1. TRUNNION AND CAP MOUNTING BOLTS (FIG. 5.46) ............................... 60
5.16.5.2. BLADE CUTTING EDGE AND END BITS MOUNTING BOLTS .................... 60
5.16.5.3. ALLOWABLE WEAR OF BLADE CUTTING EDGE AND END BITS ............. 61
5.16.6. SERVICING THE RIPPER ......................................................................................... 61
5.16.7. ADJUSTMENT AND VENTING OF THE “C” FRAME BLADE TILT
HYDRAULIC SYSTEM (FIG. 5.48) ............................................................................ 62
5.17. SEAT BELT ............................................................................................................................... 64
5.18. FINAL DRIVES .......................................................................................................................... 65
5.18.1. CHECKING OIL LEVEL ............................................................................................. 65
5.18.2. CHANGING THE OIL................................................................................................. 65
5.19. DRIVE TRAIN ............................................................................................................................ 66
5.19.1. CHECKING THE OIL LEVEL OF THE MAINFRAME REAR PART ............................ 66
5.19.2. CHANGING MAINFRAME OIL .................................................................................. 67
5.19.3. DRIVE TRAIN PRESSURE FILTER REPLACING ..................................................... 67
5.19.4. DRIVE TRAIN SUCTION FILTER SERVICE ............................................................. 68
5.19.5. SERVICING THE TRANSMISSION SCAVENGER STRAINER (FIG. 5.56) ............... 69
5.19.6. DRIVE TRAIN BREATHER SERVICE ....................................................................... 70
5.20. SUSPENSION ........................................................................................................................... 70
5.20.1. TRACK SHOE BOLTS ............................................................................................... 71
5.20.2. EFFECT OF TRACK ADJUSTMENT ON UNDERCARRIAGE WEAR ....................... 71
5.20.3. CHECKING THE TENSION ....................................................................................... 72
5.20.4. ADJUSTING TENSION.............................................................................................. 72

SECTION 5
MAINTENANCE
5.20.5. TRACK FRAME GUIDE ............................................................................................. 74
5.20.6. TRACK FRAME SUSPENSION ................................................................................. 75
5.20.7. FRONT IDLER GUIDES ............................................................................................ 75
5.21. ADJUSTING HAND AND FOOT CONTROLS ........................................................................... 76
5.21.1. ADJUSTING BRAKE PEDAL ..................................................................................... 76
5.21.1.1. BRAKE TEST ................................................................................................ 77
5.21.2. CHECKING ENGINE AND DECELERATION RPM ................................................... 77
5.22. OPERATOR’S CAB ................................................................................................................... 78
5.22.2. CAB REMOVAL AND INSTALLATION ........................................................................ 78
5.22.3. CAB AIR FILTERS..................................................................................................... 84
5.23. WINDSHIELD WASHERS ......................................................................................................... 85
5.24. UTILITY BOX ............................................................................................................................. 85
5.25. SERVICING THE AIR CONDITIONER ...................................................................................... 86

SECTION 5
MAINTENANCE
PAGE 3
5.1. SERVICE PRECAUTIONS
CAUTION! Only authorized personnel, thoroughly trained with the design and
operation of all assemblies and mechanisms may be allowed to service this
machine.
WORK SAFETY – FOLLOW THESE RULES
CAUTION! If a machine is operated in any circumstances involving dust or

flammable materials as in coalmines, wash the inside of the engine compartment
and under the fuel tank and cab at least once a week. Check the fuel lines for
tightness and check the electric system cables.
IMPORTANT: Protect all electrical working and control components (control modules,
electrical connectors, etc.) against direct water or stream jet impact while washing the
machine.
A CAREFUL OPERATOR IS THE BEST INSURANCE AGAINST AN ACCIDENT
WELDING ON THE MACHINE

The machine engine is equipped with the electronic control module ECM and the machine drive
train is equipped with the machine electronic controller.
When welding is required on the machine observe the following rules:
 disconnect both the positive (+) and negative (-) battery cables,
 disconnect the two connectors of the engine harness (OEM) at the engine left hand side,
 disconnect drive train controller connector. To do this, open the left fender cover and
disconnect two connectors that supply power to the controller.
 do not connect the welder ground cable (-) to the ECM,
 attach the welder ground cable (-) no more than 0.6 [m] away from the part being welded.
SERVICE PRECAUTIONS
The procedures in this section contain many notes and precautions, which should be followed
along with standard safety procedures to minimize a possibility of personal injury or improper
service. Improper service could compromise a machine's safety or cause it to function improperly,
which could result in personal injury. Review the precautions listed in Section 2, “SAFETY
PRECAUTIONS”.
Do not attempt to do repairs you do not understand. Use your “Service Manual” or consult your
Authorized Distributor for information.
Do not jump on or off a machine. When working under a machine or servicing in the area of the
engine fan or belts, turn the electric system master switch OFF, apply and lock the parking brake
and tag controls to warn against starting the machine.
Whenever servicing, take care to prevent accidental cranking of the engine. Turn the electric
master switch OFF and remove the machine electronic system switch key.
It is not possible to anticipate all conceivable ways or conditions under which a machine may be
serviced or to provide precautions for all the possible hazards that may result. Safety is always the
most important rule.
Constantly be aware of dangers involved in working on a machine and take proper precautions.
Standard and accepted safety precautions and equipment should be used.

SECTION 5
MAINTENANCE
PAGE 4
This machine is assembled using high strength fasteners (bolts, nuts and washers). Do not
substitute fasteners. Replacement fasteners must be of the same size and strength as the originals
(refer to Section 6). Tighten fasteners to the proper torque value specified in Section 6, unless
otherwise specified.
Refer to Spare Parts Catalogue for all replacement parts.
Use safety goggles, hard hats, safety shoes, heavy duty gloves and other protection during cutting,
grinding, chiseling, prying or any other process which could cause material removal or projectiles.
Many machined parts are hardened and can chip.
Use the proper size and type of tool for the job being done. Select a wrench that fits and be sure it
is on straight. Keep your tools clean and in good condition.
Some procedures require the use of tools specially designed for that specific purpose. Before
substituting another tool or procedure, you must be completely satisfied that neither personal
safety nor the performance of the machine will be endangered.
5.2. SCHEDULED MAINTENANCE GUIDE
Scheduled maintenance is the normal maintenance necessary to provide proper and efficient
equipment operation and to prolong of your machine’s service life.
Service the engine in accordance with Scheduled Maintenance Guide. Engine maintenance
intervals should be shortened if the machine is operating continuously at temperatures
below -18 [°C] and above +38 [°C] and/or in dusty conditions. Some engine maintenance
operations require the use of special tools or must be performed by an Authorized Distributor of
Construction Equipment.
To this end the following maintenance is to be done.
Every 10 hours of operation (every day)

1. Carry out basic machine inspection. Refer to 5.2.1.
2. Check the coolant level. Refer to 5.8.5
3. Check the condition of the fan. Refer to 5.9.
4. Check the oil level at hydraulic reservoir. Refer to 5.14.1.
5. Check the engine oil level. Refer to 5.11.1.
6. Check engine breather tube. Refer to 5.11.4.
7. Drain sediments from fuel filter separator. Refer to 5.12.4.1.
8. Check precleaner screen and air intake system connections. Refer to 5.6.1 and 5.6.3
9. Check the condition of the exhaust system connections. Refer to 5.13.4.
10. Visually check the condition of drive belts. Refer to 5.7.1
11. Check and refill the reservoir with windshield washer liquid daily, if necessary. Refer to 5.22.3.
12. Clean windows, lights and instrument panel.
13. Check instruments and warning lights for operation. Refer to 4.3.
14. Check the diesel exhaust fluid (DEF) level. Refer to 5.13.3.
15. Check general condition of engine. Refer to 5.11.5
16. Refill fuel tank at the end of each day’s operation. Refer to 5.12.1.
17. Clean all traction frames moving elements (from mud, stones, etc.) after a day’s work. Refer to
5.20.
Every 50 Hours of operation

1. Clean radiator cores. Refer to 5.8.4.2.
2. Lubricate ripper pins. Refer to 5.15.
3. Lubricate the blade equipment pins. Refer to 5.15.
4. Check drive train oil level. Refer to 5.19.1.
5. Check and adjust tracks tension, if necessary. Refer to 5.20.

SECTION 5
MAINTENANCE
PAGE 5
6. (*) Replace the return filters of the equipment system. Refer to 5.14.3.
7. (*) Replace hydraulic equipment pilot filter. Refer to 5.14.3.
8. (*) Replace drive train system pressure filter. Refer to 5.19.3.
9. (*) Replace the fan drive system filter. Refer to 5.14.4.
*– after initial 50 hours of operation only.

1. Replenish grease in blade lift cylinders' trunnions. Refer to 5.15.
Every 250 hours of operation or every 6 months

1. Drain fuel tank sediment. Refer to 5.12.5.
2. (**) Replace the first and second stage engine fuel filter element. Refer to 5.12.4.
3. Check connections and cooler: air, CAC, engine coolant and drive train oil. Refer to 5.6.3 and
5.8.3.
4. Lubricate blade accessories upper struts. Refer to 5.15.
5. Lubricate blade accessories diagonal struts. Refer to 5.15.
6. Check final drive oil level. Refer to 5.18.1.
(**) - The first stage fuel filter element replacement period may be extended – see 5.12.4.
Every 500 hours of operation or every 6 months

1. Change engine oil and engine oil filter. Refer to 5.11.2.
2. Check the cooling system filler cap (plug). Refer to 5.8.3.1.
3. Check coolant for SCA concentration. Refer to 5.8.2.
4. Check oil level in track frame pivot shaft housing. Refer to 5.20.6.
Every 1000 Hours of operation or every year

1. Replenish grease in blade lift cylinders’ gimbal cross tube. Refer to 5.15.
2. Replace equipment hydraulic system return filters. Refer to 5.14.3.
3. Replace drive train system pressure filter. Refer to 5.19.3.
4. Replace the fan drive system filter. Refer to 5.14.4.
5. Change oil in main frame. Refer to 5.19.2.
6. Replace main frame breather. Refer to 5.19.6.
7. Clean drive train suction filter. Refer to 5.19.4.
8. Clean transmission scavenger strainer. Refer to 5.19.5.
9. Change final drives' oil. Refer to 5.18.2.
10. Clean the fuel tank breather. Refer to 5.12.6
11. Check sprocket bolts for torque. Refer to 5.20.
12. Check and clean the DEF tank cap. Refer to 5.13.3.

1. Clean the fuel dispenser (injector) in the diesel exhaust system. Refer to 5.13.1.5.
Every 1500 Hours of operation or once a year

(see Engine Manual)
1. Check the engine electrical system wiring condition.
2. Check the engine belt automatic tensioners condition.
3. Check engine air intake and exhaust system connections (hoses, clamps).
4. Replace engine coolant filter. Refer to 5.8.7.
5. (***) Replace the engine air primary and safety filter elements. Refer to 5.6.2.
(***)The air safety filter elements should be replaced every other time primary filter elements are
replaced, at least once a year.

SECTION 5
MAINTENANCE
PAGE 6
Every 2000 Hours of operation or every year

1. Change oil in the hydraulic reservoir. Refer to 5.14.2.
2. Replace hydraulic equipment pilot filter. Refer to 5.14.3.
3. Clean the suction strainers of the hydraulic (equipment) system tank. Refer to 5.14.5.
4. Replace the hydraulic oil tank cap with breather. Refer to 5.14.6.

1. Replace the filter - engine venting breather oil separator. Refer to 5.11.4

1. Clean or replace the particulate filter (DPF) of the exhaust aftertreatment system. Refer to
5.13.1.4.
2. Replace the diesel exhaust fluid (DEF) filter. Refer to 5.13.2.
Every 6000 hours of operation or every two years

(see Engine Manual)
1. Clean the engine.
2. Replace the engine cooling system fluid. Refer to 5.8.6.
3. Check engine mounting bolts’ for torque.
4. Check the condition of engine crankshaft vibration dumper.
5. Check engine hoses and connections for tightness.
6. Check engine valve for lash.
Periodic (at least once a year or as required)

1. Clean fuel tank filler strainer. Refer to 5.12.2.
2. Clean the hydraulic filler strainer. Refer to 5.14.5.
3. Clean the cab air filter and cab recirculation filter (if equipped). Section 5.22.1.
4. Lubricate the foot controls, check for operation and adjust. Refer to 5.21 and 5.15.
5. Lubricate hydraulic equipment pilot valve plungers ends and drive train control valve plunger
dome nuts. Refer to 5.15.
6. Check battery charge and condition. Refer to 5.10.3.
7. Check condition of electrical wires and connections. Refer to 5.10.1.
8. Check engine RPM with decelerator depressed. Refer to 5.21.
9. Check undercarriage components for wear. Refer to 5.21.
10. Check traction frames guide clearance, adjust and lubricate traction frame guides. Refer to
5.20.5.
11. Check and adjust the clearance at diagonal strut socket as well as tilt cylinder and upper strut
or pitch cylinder. Refer to 5.16.2 and 5.16.3.
12. Check condition of safety belt. Refer to 5.17.
13. Check torque:
 track shoes. Refer to 5.20.1.
 blade cutting edges. Refer to 5.16.5.2.
 trunnion cap bolts and trunnion mounting bolts. Refer to 5.16.5.1.
16. Check the RPOS/FOPS cab mounting screw locknuts. Refer to 5.22.1
17. Check the blade cutting edge wear. Refer to 5.16.5.3.
18. Check the ripper points for wear. Refer to 5.16.6.

SECTION 5
MAINTENANCE
PAGE 7
19. Wash the machine inside.

20. Check idler guide clearance and lubricate the guides. Refer to 5.20.7.
21. Lubricate door hinges.
22. Servicing the air conditioner. Refer to 5.25.
23. Perform the stationary cleaning (regeneration) of the particulate filter (DPF). Refer to 5.13.1.3.
24. Clean/refill the diesel exhaust fluid (DEF) tank. Refer to 5.13.3.
5.2.1. MACHINE GROUND LEVEL INSPECTION
1. Mounted equipment for damage and proper fastening.

2. Radiator: for damage, evidence of leakage and condition of grill guard.
3. Hydraulic components for damage or leakage.
4. Track system: inspect undercarriage, i.e. front idlers, top rollers, track rollers, sprockets, track
frames, track shoes for: cracks, excessive wear, loose components and leaks.
5. Drive train system and final drives: for possible leakage.
6. Engine compartment: for possible fuel, oil and coolant leaks.
7. Guards: for damage or missing.
8. Operator’s protection: check general condition (no ROPS/FOPS defects are permissible that
may adversely affect its protection in case of machine rollover).
WARNING! To ensure personal protection perform all maintenance services in

accordance with Scheduled Maintenance Guide and Instructions.
To extend the service life of your equipment follow the scheduled maintenance listed in Scheduled
Maintenance Guide.
5.3. MACHINE MAINTENANCE AND SERVICE DIAGRAM AND CHART
IMPORTANT: Machine maintenance and service points are explained in detail further in
this section. Always use clean grease and containers. Remove dirt from grease nipples
prior to lubrication. Service intervals should be based on the hourmeter readings. Service
intervals should not be based on warning light indications.
IMPORTANT: Service and maintenance intervals are based on average operating

conditions. Under unusually severe conditions of operation, shorten the service interval.
Service the machine according to “SCHEDULED MAINTENANCE GUIDE” instructions at
least once a year.
IMPORTANT: If the machine is equipped with the central lubrication system do not
lubricate periodically points 7, 8, 9, 13, 14 and 29 shown in the Diagram and the Machine
Service and Maintenance Chart.

SECTION 5
MAINTENANCE
PAGE 8
5.3.1. MACHINE SERVICE AND MAINTENANCE CHART
Fig. 5.1. Machine Maintenance and Service Diagram (maintenance and lubrication points)
The Machine Maintenance and Service Diagram is described in Item 5.3.2.

SECTION 5
MAINTENANCE
PAGE 9
5.3.2. MACHINE SERVICE AND MAINTENANCE CHART

CODE
SERVICE REF. SERVICE SERVICE
POINT / PLACE OF SERVICE of service
INTERVAL No POINTS product ACTION
1 Fuel Filter Water Separator 1 - drain
2 Engine Oil Level 1 EO check
10 h 3 Equipment System Tank Oil Level 1 HDTF check
4 Coolant Level 1 AF check
5 Engine Venting Breather Tube 1 - clean
6 Main Frame Oil Level 1 HDTF check
50 h 7 Ripper Frame and Cylinder Pins 12 MPG grease
8 Blade Lift Cylinder Ball Joint 2 MPG grease
100 h 9 Blade Hydraulic Lift Cylinders’ Joke 4 MPG grease
10 Final Drive Oil Level 2 MPL check
11 Clean radiator cores 1 - check
12 Fuel Tank Sediment Decanter 1 - drain
250 h
13 Upper Struts Sockets 4 MPG grease
14 Diagonal Struts’ Sockets 2 MPG grease
15 Engine Fuel Primary and Safety Filter Element. 1+1 - check/replace
16 Engine Oil Filter 1 - change
17 Engine Oil 1 EO change
500 h
18 Track Frame Pivot Shaft Housing Oil Level 2 MPL check
19 Coolant SCA Concentration/Filler Cap 1 to 1 AF check
20 Final Drive Oil 2 MPL change
21 Drive Train System Oil 2 HDTF change
22 Drive Train Suction Strainer 1 - clean
23 Drive Train Pressure Filter 2 - change
1000 h 24 Transmission Scavenger Strainer 1 - clean
or once Equipment System Return Filter and Fan Drive System
25 2 - change
a year Filter
26 Main Frame Breather 1 - change
27 Fuel Tank Cap - Breather 1 - clean
28 Lift Cylinder Mounting Gimbal Cross Tube 2 MPG grease
29 Diesel exhaust fluid (DEF) tank cap 1 check/clean
30 Air Primary And Safety Filter Elements 2+2 - change
1500 h 31 Intake and Exhaust System Connections 10 - check

)
or once 32 * Exhaust aftertreatment system (HC) fuel injector 1 - clean
a year 33 Diesel Exhaust Fluid Filter 1 - check
34 Engine Coolant Filter 1 - change
35 Equipment System Pilot Filter 1 - change
36 Equipment System Oil 1 HDTF change
2000 h
37 Suction Strainers Of Equipment System Tank 1+1 - clean
38 Equipment System Oil Tank Breather 1 change
)
3000 h 39 ** Engine Venting Breather Oil Separator Filter 1 - change
)
40 ** Particulate Filter (DPF) 1 - clean
4500 h
41 DEF Diesel Exhaust Fluid Filter 1 - change

SECTION 5
MAINTENANCE
PAGE 10
POINT OF SERVICE Code

SERVICE REF. SERVICE
of service Service action
INTERVAL No of service POINTS
product
6000 h or 42 Engine Cooling System Coolant 1 AF change
every 2 )
years 43 ** Engine Valve Lash 1 - check
Hand and Foot Control Mechanisms and Door

44 3+4+4 MPG grease
Hinges
Once a year 45 Fuel Tank Filler Strainer 1 - Clean/ replace
(minimum)
46 Equipment System Tank Filler Strainer 1 - clean
47 External cab filter and recirculation filter 1+1 - clean/ replace
47 Diesel Particulate Filter (DPF) 1 regenerate
as reqd.
48 DEF Diesel Exhaust Fluid Tank 1 DEF Clean/refill
*) Clean/check/replace after the specified service interval

**) Service performed by the Cummins Authorized Representative.

SECTION 5
MAINTENANCE
PAGE 11
5.3.3. REFILL LUBRICANT AND FLUID SPECIFICATIONS CHART
Lubricant used at ambient temperature range [°C]

Lubricant/ Point of Service
- 7 to + 49 - 23 to + 21 - 34 to -12 - 54 to - 12
Engine oil
per CES 20081 //
EO
Engine lube system API: CJ-4
(sump) SAE 15W/40
SAE 10W/30
SAE 5W/20
SAE 0W/20
SAE 10W/40 SAE 5W/30
SAE 5W/30
SAE 15W/40 SAE 5W/40
Hydraulic – Transmission Oil*) Hydraulic -
Drive Train System per C-4 and TO-4 Transmission Oil
(rear frame oil reservoir) (arctic)*)
SAE 10W SAE 10W SAE 10W passing tests:
Hydraulic - Transmission Oil C-4 and TO-4
Hydraulic D-2 Equipment per C-4 and TO-4
system or Engine Oil (for for Hydraulic Equipment System or
(Hydraulic only ) per API CD
reservoir) Ripper with Shank Tilt Engine oil (for
HDTF SAE 10W SAE 10W SAE 10W
Hydraulic Equipment
System only)
Undercarriage Track Roller (arctic)
components per API CD
lubricated for Top Idler SAE 30 SAE 30 SAE 30

life SAE 0W/20
(when rebuild) SAE 5W/30
Front Idler SAE 5W/40
Gear Oil Gear Oil (arctic)

Final Drive per API GL-5 per API GL-5
SAE 85W/140 SAE 80W/90

Track Frame Pivot Shaft Housing SAE 85W/140
SAE 80W/90 SAE 75W/90
MPL
Track Chain Link SAE 75W
(lube option – filled with oil for life) SAE 85W/140 SAE 85W/140 SAE 85W/140
– when rebuild
Lubricating Fittings Lithium Grease NLGI 2: - with EP

Grease (arctic)
MPG (parts subject to lubrication or - with 3% MoS2
NLGI 1 - from EP
– as per Operator’s Manual) or NLGI 2 - from EP
Coolant: Coolant
AF Cooling System 50% glycol / 50% water 62% glycol / 38% water
(solution used: to -37 oC) per CES14603 per CES14603
DEF DEF diesel exhaust fluid tank Aqueous ammonia solution AUS32 acc. to ISO 22241
Diesel Oil for Arctic

Diesel Oil
Conditions
per PN-EN 590
D
Fuel tank or per ASTM D975 (S-15)
per PN-EN 590 or
(fuel) per ASTM D975 (S-
(sulphur max. 15 ppm)
15) (sulphur max. 15
(adjusted to ambient temperature)
ppm)
Windows Washer Fluid for Automotive

WF Windows Washer Reservoir (adjusted to ambient temperature)
RF Air Conditioner Refrigerant: R134a
)
* Drive train oil should be free of viscosity index improving additives.

SECTION 5
MAINTENANCE
PAGE 12
5.4. LUBRICATION
5.4.1. WHEN SHIPPED

This machine has been lubricated at the factory for operation in an air temperature range
of -23 [°C] to +21 [°C]. If this machine is to be operated above or below this range, change to the
correct lubricants.
Unless an exception is shown below, all lubricants can be used (within above temperature range)
until regular scheduled (normal) change intervals occur. Refer to “MAINTENANCE AND SERVICE
CHART” for the scheduled (normal) change intervals and to “REFILL LUBRICANT AND FLUID
SPECIFICATIONS CHART” for the proper oil grades for ambient temperatures.
Front idlers, track idlers and track rollers are permanently lubricated with a SAE 30, per API CD
engine oil. Lubricated track chain links are lubricated for life with a SAE 85W/140 multi-purpose
lubricant. Level check of these compartments is not required.
5.4.2. SCHEDULED LUBRICATION

WARNING! When you service a machine, always follow the Operator’s or Service
Manual. Never grease, oil or perform any maintenance without any assistance with
the engine running.
Always have another experienced person helping in the operator's compartment
when maintenance must be done with the engine running. Do not leave the
operator's seat with the engine running. Failure to follow these instructions could
result in serious injury or death.
The life and performance of a machine and its equipment depends on the service that it is given.
Proper lubrication is an important part of maintenance service. Thorough lubrication service performed
at specified intervals will aid in prolonging the life of the machine and its equipment and in reducing
operating expense. The type of work being done, load, ground and weather conditions are all factors
to consider in frequency of lubrication.
The scheduled intervals between lubrication periods shown on the “Scheduled Maintenance
Guide” are approximate, based on average operating conditions.
It may be necessary to lubricate after shorter working periods under severe operating conditions
such as extreme dust, low engine temperatures, intermittent operation, excessively heavy loads
with high oil temperatures, or when diesel fuel with a high sulfur content is used.
However, the time intervals between lubrication periods must never exceed those indicated in this
manual.
5.4.3. SELECTION
The selection of the proper type (specification) and the grade (weight or viscosity) of lubricant is
important. Many tests have been made to determine the correct lubricants for this tractor and its
equipment. Refer to “REFILL LUBRICANT AND FLUID SPECIFICATIONS CHART” for the
recommended time intervals and grades of lubricants. Refer to the “RECOMMENDED LUBRICANT
CHART.”
5.4.4. VISCOSITIES
During cold weather, base the selection of crankcase lubricating oil viscosity on the lowest
anticipated temperature for the day to make starting easier. For hot weather operation, base the
selection on the highest anticipated temperature. Refer to the “REFILL LUBRICANT AND FLUID
SPECIFICATIONS CHART”.

SECTION 5
MAINTENANCE
PAGE 13
5.4.5. RECOMMENDED LUBRICANT CHART

Designation and Type Maker and Brand Name
Texaco
Shell URSA ULTRA
RIMULA R4 L SAE 15W/40
Orlen SAE 15W/40
Texaco
Engine oil PLATINUM ULTOR FUTURO URSA ULTRA
SAE 15W/40 SAE 10W/30
EO Fuchs
TITAN CARGO Valvoline
SAE 15W/40 VALVOLINE PREMIUM BLUE E
SAE 15W/40
Valvoline
Orlen
VALVOLINE PREMIUM BLUE
Engine Oil (arctic) PLATINUM ULTOR MAX -
EXTREME
SAE 5W/40
SAE 5W/40
Lotos Shell Texaco
GERAX TKD SPIRAX S4 CX TEXTRAN HD
Hydraulic – SAE 10W SAE 10W SAE 10W
Transmission Oil *) Orlen Fuchs Total
PLATINUM MULTI PTF M TITAN UTTO LF DYNATRANS AC
SAE 10W SAE 10W SAE 10W
Engine oil Fuchs TITAN SUPERSYN
) SAE 5W/40
(arctic) * - -
(for Drive Train System Fuchs TITAN SUPERSYN
only) SAE 5W/50
Orlen SUPEROL CD Shell RIMULA R3
Engine oil SAE 10W SAE 10W Texaco
(for Hydraulic Equipment URSA SUPER LA
System only) Lotos SUPEROL CD Fuchs TITAN HYD LF 10 SAE 10W
HDTF SAE 10W SAE 10W
Hydraulic –
Transmission Oil Lotos
Fuchs
(arctic) HYDROMIL SUPER ARCTIC
RENOLIN MR 520 -
(for Hydraulic Equipment L-HV 22 ISO VG 22
System only)
Hydraulic –
Transmission Oil Lotos Shell Texaco
(for Undercarriage GERAX TKD SPIRAX S4 CX TEXTRAN HD
Components only : rollers SAE 30 SAE 30 SAE 30
and front idler)
Engine Oil
Shell Texaco
(for Undercarriage Orlen SUPEROL CD
RIMULA R3 URSA SUPER LA
Components only: rollers SAE 30
SAE 30 SAE 30
and front idler)
Orlen HIPOL
SAE 85W/140 Shell Texaco
Lotos SPIRAX S2 A GEARTEX EP-C
GL-5 Chlorine Free Oil SAE 85W/140 SAE 85W/140
Gear Oil SAE 85W/140
Orlen HIPOL
MPL Shell Texaco
SAE 80W/90
SPIRAX S2 A GEARTEX EP-C
Lotos TITANIS GL-5 SAE 80W/90 SAE 80W/90
SAE 80W/90
Lotos Fuchs
Texaco MULTIGEAR S
Gear Oil (arctic) TITANIS SUPER GL-5 TITAN CYTRAC HSY
SAE 75W/90
SAE 75W/90 SAE 75W/90
Lotos
MONILIT EP 23 Shell Texaco
Lithium grease
Naftochem GADUS S2 V220AD 2 MOLYTEX EP-2
LITOMOS EP-23
MPG
Orlen
GREASEN SYNTEX HT 2 Fuchs
Grease (arctic) -
Lotos RENOLIT CLX2
TYTALIT AV 395
Fleetguard
AF Coolant - -
ES CompleatTM
Valvoline
DEF Diesel Exhaust Fluid NOXy® AdBlue®
Air Shield
*) Drive train oil should be free of viscosity index improving additives

SECTION 5
MAINTENANCE
PAGE 14
5.5. SEASONAL PREPARATION
GENERAL
Mechanical efficiency is enhanced during seasonal air temperature changes, when these
instructions are followed.
OUTSIDE SOURCE OF HEAT
Machines left outside for prolonged periods in sub-zero weather will suffer from “cold-soak”.
Lubricants become viscous and incapable of lubricating moving parts. Extreme wear could result to
the engine, transmission and final drives unless proper precautions are taken before starting the
engine.
A source of outside heat is necessary under these conditions. There are electric as well as
propane-fired engine coolant heaters available. Gas-fired forced air heaters may also be obtained
to heat the transmission and final drives.
When using such heaters follow manufacturer’s safety instructions.
WARNING! For your personal safety, use caution and follow the manufacturer's
instructions when using external heaters to warm the machine.
5.5.1. PREPARING THE FUEL SYSTEM
Refer to “RECOMMENDED LUBRICANT CHART” for the diesel fuel selection, which will give the
most satisfactory performance in the ambient temperature.
5.5.2. PREPARING THE COOLING SYSTEM
Prepare the cooling system as follows:

1. Check the entire system for leaks.
2. Check the condition of all hoses and connections. Replace damaged hoses and hose clamps.
3. Check the drive belts condition Refer to “BELTS”.
4. Clean cooling system. Refer to “COOLING SYSTEM CLEANING”.
5. Clean radiator cores. Refer to “RADIATOR”
6. Protect your cooling system from damage by using approved antifreeze and coolant. Refer to
“CHANGING THE COOLANT”.
7. Keep your cooling system clean and minimize corrosion by adding VCI at the correct intervals.
Refer to “COOLING SYSTEM.”
8. Check the condition of the fan blades. Refer to “FAN”.
5.5.3. PREPARING THE ELECTRIC SYSTEM
Inspect the harnesses and conductors. Repair or replace all wires, which have worn, cracked or
frayed insulation and broken wires or loose terminals. Clean and secure battery cable terminals.
Service the battery. Refer to “BATTERIES”.

SECTION 5
MAINTENANCE
PAGE 15
5.6. ENGINE AIR INTAKE SYSTEM
The engine air intake system consists of a precleaner and an air cleaner assembly with
replaceable filter elements. The degree of contamination of the filter elements is signaled by the
restricted air cleaner warning light in the operator’s cab.
5.6.1. PRE-CLEANER
Fig. 5.2. Pre-cleaner Assy

1. Filter Housing 4. Clamp
2. Housing Gap 5. Extension Unit
3. Housing Mounting Bolts
The centrifugal pre-cleaner screen (Fig. 5.2) prevents the system against contamination.
The pre-cleaner screen includes the housing (1) which is bolted to the filter body (3). The filter
body is secured on the expansion unit (5) with the clamp (4). The housing includes the moving
rotor acting as a contamination separator.
The housing has a gap (2) to remove the contamination outside of the housing.
You should periodically remove the pre-cleaner screen and clean it inside with compressed air or
water. Check the filter rotor for smooth, resistance and jam free rotation.
IMPORTANT: Never wash the pre-cleaner or its rotor installed on the machine with water
as water may penetrate to the engine and cause a serious damage.
5.6.2. AIR CLEANER
Dry-type air cleaner assembly with replaceable filter elements and high cleaning capacity in dusty
conditions. The unit consists of the housing (4), Fig. 5.2A) with the replaceable filter elements:
primary (2) and safety (3). There is a switch for the restricted air cleaner signal light mounted in the
air cleaner housing as well as a temperature and barometric air pressure sensor (TBAP) for the
turbocharger intake air connected to the engine control module (ECM).
IMPORTANT: As a precaution against dirt entering the engine, check that the air cleaner
connections are in good condition ensuring the system tightness. Never operate the
engine unless a filter element is in place and filter cover is installed. Never remove the
element from the air cleaner or service the air cleaner while the engine is running.

SECTION 5
MAINTENANCE
PAGE 16
Fig. 5.2A The air cleaner unit

1. Air Cleaner Cover 4. Filter Housing
1A. Spring Clips 5. Air Pre-cleaner
2. Primary Elements 6. Air Precleaner Connector
2A. Handles 7. Clamp
3. Safety Elements 8. Expansion Unit with Flange
3A. Handles 9. Temperature and Pressure Sensor (TBAP)

SECTION 5
MAINTENANCE
PAGE 17
MAINTENANCE (Fig. 5.2A)

The air cleaner primary element must be serviced whenever indicated by the air cleaner warning
light. Refer to “Restricted Air Cleaner Warning Light” in Section 4.
The air safety filter elements should be replaced every other time primary filter elements are
replaced; at least once a year.
IMPORTANT: When the air cleaner warning light comes, on do operate the machine.
Otherwise the filter elements or air filter and turbocharger connections may be physically
destroyed.
IMPORTANT: Do not remove the filter elements from the housing for visual inspection until
maximum restriction level is reached and the warning light comes on.
IMPORTANT: Do not clean filters with compressed air. Replace filters with new ones when
allowable restriction level is reached and the restricted air cleaner warning light comes on.
IMPORTANT: Use only recommended filter elements available from an Authorized
Construction Equipment Distributor.
NOTE: Store the air cleaner elements in the original packaging. If the element is to be
stored for later use, protect it against dirt and damage.
REMOVAL
1. Release the spring latches (1A) that secure the filter cover (1) to the housing (4).
2. Remove the filter cover (1).
3. Pull the protruding grip (2A), remove the primary cartridge (2).
4. Pull the protruding grips (3A), remove the safety cartridge (3).
5. Remove all dirt from the inside of the air cleaner housing (4) with a damp cloth. A small amount
of non-sudsing detergent added to the water will help to remove the dirt.
6. Inspect the gasket around the base of cover and air cleaner housing inside in place of air
cleaner element mounting. Damaged surfaces, cover and housing cracks, and others that
cause the leak in the system must be repaired or replace the filter housing.
INSTALLATION
1. Insert the safety element (3) into the air cleaner housing (4).
2. Insert the primary element (2) into the air cleaner housing (4).
3. Place the filter housing cover (1) so that its inside slots hit the element handle (2A).
4. Push the cover and attach to the housing (4) with the spring clips (1A).
IMPORTANT: Do not leave the filter housing without the elements inserted. Remove the air
cleaner element only for change.
5.6.3. CHECKING CONNECTIONS AND CHARGE AIR COOLER (CAC) FOR LEAKS
Check the air intake system connections for hose cracks, loose clamps. Tighten loose connection,
replace broken parts to eliminate leaks, which may damage the engine. Check the air cooler for
restrictions that will obstruct the air flow in the system, cracks or other mechanical damage.
Check the air cooler for restrictions that will obstruct the air flow in the system, cracks or other
mechanical damage.
IMPORTANT: No leakage is permitted between the air cleaner, turbocharger, radiator and
the engine intake manifold.

SECTION 5
MAINTENANCE
PAGE 18
5.7. BELTS
GENERAL
WARNING! Keep clear of the pulleys and drive belt when the engine is running.
Rotating pulleys and belt contact can cause injury.
Fig. 5.3. Engine Accessory Belt Drive

1. Crankshaft Pulley 5. Air Conditioner Compressor Pulley
2. Water Pump Pulley 6. Alternator Pulley
3. Coolant Pump and Alternator Drive 7. Air Conditioner Compressor and Alternator Drive Belt
4. Belt Tensioner 8. Belt Tensioner
Water pump, alternator and air conditioner compressor drive belts are provided with automatic belt
tensioners.
Accordingly, their tension does not have to be checked.

SECTION 5
MAINTENANCE
PAGE 19
5.7.1. BELT CONDITION VISUAL INSPECTION
Fig. 5.4. Belt Inspection
Replace badly worn, greasy or cracked belts immediately (Fig. 5.4). These conditions prevent
proper belt function. Visually inspect the drive belts for intersecting cracks. Transverse (across the
belt width) cracks are acceptable. Longitudinal (direction of belt length) cracks that intersect with
transverse cracks are not acceptable. Replace a belt if it is frayed or has pieces of material
missing.
5.7.2. BELT REPLACEMENT
In case of a replacement always inspect the belt and, if necessary, replace all that need to be
replaced.
Prior to installing a new belt make sure all pulley grooves are clean and not worn. If a pulley is
damaged or its grooves are worn, it must be replaced.
When replacing belts and pulleys, the pulley alignment must be checked. A misalignment that can
be detected with a naked eye is detrimental to the belt performance.
To remove or install the drive belt, use a pry bar with a ½” square tip to swing the belt tensioner
away using.
IMPORTANT: Rotate the belt tensioner away from the drive belt. Rotation in the opposite
direction, or the use of excessive force may damage the tensioner.
During a belt installation, do not force the belt into the pulley grooves by prying with a screwdriver
or pry bar.
Belt side fibers can be damaged and as a result the belt itself can be damaged while operating.

SECTION 5
MAINTENANCE
PAGE 20
5.8. COOLING SYSTEM
GENERAL
The cooling system operates under pressure controlled by a pressure relief valve in the radiator
auxiliary tank cap.
Proper cooling is assured only when the system is filled to the proper level, sealed, the thermostat
operates properly and is free of air flow restrictions. The air flow through the radiator must not be
restricted.
The selection and maintenance of the system coolant is important to long engine life. The following
information provides recommendations for selecting engine coolant, maintaining coolant inhibitors,
and servicing the cooling system. This system will operate with a water/antifreeze mixture or
inhibited water as coolant.
Never use water alone because water will allow rust, scale deposits, and corrosion to occur within
the system.
5.8.1. Coolant
Use a ready mixed coolant or a 50/50% mixture of water and ethylene glycol based antifreeze to
ensure optimal engine cooling system protection. Antifreeze concentration over 60% will reduce
the coolant recirculation and can be used for arctic purposes only.
Antifreeze concentration under 40% will increase the coolant freezing temperature.
For the preparation of coolant use distilled or deionized water. Water with high contents of calcium
and magnesium will cause sediments while increased contents of chlorides and sulfates results in
systems’ corrosion.
The water components described above should not be allowed to exceed:
Calcium and magnesium (CaCO3 + MgCO3) – a maximum of 170 [ppm] (parts per million)
Chlorides (Cl) – a maximum of 40 [ppm]
Sulphates (SO4) – a maximum of 100 [ppm].
IMPORTANT: Do not mix different types of antifreeze solutions. Mixed solutions make it
impossible to determine the protection against freezing.
IMPORTANT: Antifreeze containing sealer or anti-leak additives should not be used in this
system. Sealer or anti-leak additives will plug the coolant filter and cause plugging problems
in the cooling system.
WARNING! Exercise extreme caution while topping the coolant into the hot
radiator to avoid getting burned. Use gloves and protective goggles and keep
away face from the filler neck. Refer to “Cooling System Filler Plug”
IMPORTANT: Do not use oil-soluble in the cooling system, their use results in corrosion of
aluminum, bronze and copper destroys the heat exchange surfaces and reduces the heat
transfer.
Periodically check the coolant, particularly if the cooling system is refilled with water. Measuring the
concentration of the concentrate and determining the freezing point of the coolant is made with
a refractometer No. CC-2800.
IMPORTANT: Mixing different kinds of coolant is not recommended as no tester is currently

available for measuring the concentration of such solutions.

SECTION 5
MAINTENANCE
PAGE 21
5.8.2. INHIBITORS / CONDITIONERS

1 All cooling system inhibitors, including those in antifreeze solutions, become depleted through
normal operation. If the inhibitors in antifreeze are allowed to become depleted, the antifreeze
becomes corrosive and corrodes the metallic surfaces of the cooling system. If the
concentration of SCA is too high it causes plugging problems in the cooling system, which
reduces heat transfer. To ensure an adequate anti-corrosion protection, service the system as
described in this Operator’s Manual.
2 THE SOLUBLE OILS ARE NOT RECOMMENDED for this engine as if used they diminish the
heat transfer.
REPLENISHING COOLANT CONDITIONER

Replenishing coolant conditioner is performed by periodical replacement of the filter containing
SCA inhibitor protecting the cooling system against corrosion and cavitation erosion of the cylinder
sleeves and coolant pump blades.
COOLANT TESTING FOR CONDITIONER CONCENTRATION
Coolant testing for SCA concentration should be performed with a CC2602 M test kit.
The testing procedure is included in TEST KIT INSTRUCTION.
IMPORTANT: Mixing different kinds of coolant is not recommended as no tester is
currently available for measuring the concentration of such solutions.
5.8.3. RADIATOR
5.8.3.1. Cooling system filler cap
Fig. 5.5. Cooling System Filler Cap

GENERAL INFORMATION
The cooling system filler cap (Fig. 5.5) seals the coolant filler opening of the auxiliary tank of the
radiator.
Positive sealing requires a cap gasket and its contacting surfaces in good condition, and a properly
tightened cap.
Filler cap features the relief valve which ensures a correct pressure in the radiator auxiliary tank.
IMPORTANT: Operating a machine without a filler cap or with a cap fitted with a relief valve
that fails to act at the correct pressure can cause the cooling system improper operation.

SECTION 5
MAINTENANCE
PAGE 22
CAP REMOVAL
WARNING! Do not remove the pressure cap from a hot engine. Wait until the
coolant temperature is below 50 [°C] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
To remove the cap turn the cap to the left or counterclockwise up to the safety stop and wait until all
pressure is released.
Then press down on the cap and continue to turn until the cap is free to be removed.
INSTALLATION
When installing the cap, gasket and contacting surfaces must be clean. Turn the cap to the right until
snug and close the cap door.
5.8.3.2. Cleaning the radiator core
Check the condition and tightness of the radiator rubber connectors and clamps periodically.
Remove dirt from the radiator core, CAC and oil cooler.
Remove all debris from the radiator core using air or water under pressure. Direct the flow through
the core, opposite the normal direction of airflow. Clean the radiator guard and the outside of the
core.
CAUTION! For your personal protection, water pressure should not exceed
270 [kPa] and air pressure should not exceed 210 [kPa]. Use safety goggles.
5.8.4. CHECKING COOLANT LEVEL
Fig. 5.6. Radiator Sight Gauge
Check the coolant level daily before starting the engine to be sure that the level is proper.
For checking coolant level place the machine on the level ground and lower the mounted
equipment to the ground. Coolant level must be seen in the sight gauge. If coolant has to be added
check and replenish SCA.

SECTION 5
MAINTENANCE
PAGE 23
5.8.5. CHANGING THE COOLANT
5.8.5.2. Draining the System (Fig. 5.7)
1. Position the machine on level ground.

2. Run the engine until it reaches the temperature of 50 [ºC]. Shut the engine off.
Fig. 5.7. Cooling System Coolant Drain Valve (Bottom View)
3. Remove the filler cap. Refer to “Cooling System Filler Plug”

4. Open cab heating shut-off valves at the engine (3, Fig. 5.8).
5. Remove the access cover in the lower engine guard.
6. Remove the protective plug and thread on the drain hose to the drain valve (Fig. 5.7) and drain
the coolant to the container.
7. Unthread the drain hose from the valve and install the protective cap.
5.8.5.2. Filling the drained system
IMPORTANT: Do not fill a cooling system with water alone. Use antifreeze and water
solution fitted to the ambient temperature. Refer to the “REFILL LUBRICANT AND FLUID
SPECIFICATIONS CHART”.
1. Fill the cooling system slowly (Fig. 5.5) up to the proper level. This allows for better venting.
2. Wait 2 to 3 minutes to allow the coolant level to stabilize. Add coolant to bring the correct
coolant level in the sight gauge.
3. Turn the starting switch key to activate the electrical circuits. Turn the cab heater temperature
knob to max temperature in order to allow maximum coolant flow through the heater core. The
blower fan does not have to be turned ON.
4. Operate the engine at low idle for 2 minutes with the radiator pressure cap removed. Turn off
the engine and add coolant to bring the correct coolant level.
5. Run the engine at high idle until the thermostat opens. Reduce and operate the engine at low
idle for 2 minutes. Shut the engine off.
6. Check the coolant level. Add coolant, if necessary to bring the correct cooling system level.
Refer to “CHECKING THE COOLANT LEVEL”.
7. Install the filler cap. Run the engine at high idle until the coolant reaches 80 [°C]. Check the
cooling system connections for leaks.

SECTION 5
MAINTENANCE
PAGE 24
5.8.6. CHANGING THE COOLANT FILTER
Periodically according to the maintenance guide SCA conditioner concentration level should be
checked with the CC2602M inspection kit for coolant checking.
WARNING! Do not remove the pressure cap from a hot engine. Wait until the
coolant temperature is below 50 [°C] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
1. Remove the filler cap. Refer to “Cooling System Filler Plug”

2. Close the shut-off valves (2, Fig. 5.8), prior to unscrewing the coolant system filter (1).
3. Remove coolant filter.
IMPORTANT: Use only genuine filters available at Authorized Distributor of Construction

Equipment.
4. Apply a little of clean engine oil to the seal of a new filter and thread the filter on by hand until it
contacts the head. Then turn it an additional ½ to ¾ turn.
5. After installation of a new filter turn the valves (2) to the open position (ON). Install the cooling
system filler plug.
3
2
Fig. 5.8. Cooling System Filter
1. Coolant Filter 2. Shut-off Valves 3. Heater Shut-off Valves

SECTION 5
MAINTENANCE
PAGE 25
5.8.7. COOLING SYSTEM CLEANING
Periodically, when changing the coolant, clean the cooling system with chemical agents to remove
deposits which hinder circulation. Clean the cooling system per the Engine Operation and
Maintenance Manual as well as the cleaning agent manufacturer’s instructions.
5.9. FAN
Fig. 5.9. Fan
WARNING! Keep clear of fan when the engine is running. Rotating fan may cause
serious personal injury.
Visually check the fan condition (Fig. 5.9) and fan shroud mounting. Check fan blades for cracks
and missing material. Damaged shroud or fan call for replacement.
5.10. ELECTRICAL SYSTEM
PRECAUTIONS
WARNING! Before working on an engine or electric system, turn off the electric
system master switch and remove the key. All terminals must be clean and fastened
securely. Replace frayed, cracked, and poorly insulated wiring.
The electric system shall not be tampered with. Unauthorized alterations may
cause machine damage or fire.

SECTION 5
MAINTENANCE
PAGE 26
5.10.1. ELECTRIC WIRES AND CONNECTIONS
The contact surface under all terminals must be clean, and good electrical connections must be
established after any reassembly. Also, all clips must grip cables tightly to prevent vibrations and rapid
cable wear. All clips and straps must be closed in a workmanlike manner, so as not to damage the
insulation.
5.10.2. MAIN POWER COMPONENTS

The separated front part of the left fender includes:
— PDM1 and PDM2 power distribution modules; fuse box,
— machine electronic controller;
— 24/12[V] voltage converter
The fuse box supplies the main power to:
— engine ECM;
— integrated display;
— machine electronic controller;
— PDM1 power distribution module;
— PDM2 power distribution module.
PDM1 and PDM2 modules are controlled by the CAN bus according to the software that controls
the machine equipment.
The machine electronic controller controls the machine operation by collaborating with the
modules: engine ECM, PDM1, PDM2 and display.
Fig. 5.10. Main Power Components

1. Fuse Box (1) 4. Machine Electronic Controller
2. PDM1 Module 5. 12/24 [V] Voltage Converter
3. PDM2 Module 6 Fuse and Relay Box (2)

SECTION 5
MAINTENANCE
PAGE 27
5.10.3. BATTERIES
GENERAL
The machine is equipped with four12 [V] batteries installed in the box on the right fender covered
with the lifting cover.
Battery recharging is to be done through the receptacle that can be found at the engine. The same
receptacle can be used for auxiliary power supply, for booster engine start up, for example.
Never allow a battery to stand on concrete, ground or a metal support unless proper insulation is
provided.
WARNING! A battery gives off highly flammable gas (hydrogen). Never allow sparks,
open flame or lighted smoking material near the battery. Avoid spilling any
electrolyte on hands or clothing. Always wear safety glasses when working on
a battery.
WARNING! Never check a battery charge by placing a metal object across the
terminals. The sparks could cause a battery explosion. Use a voltmeter or
hydrometer to measure the charge.
WARNING! Be sure the electric system master switch is off when connecting or
disconnecting a battery to minimize the chance of sparks and explosion.
BATTERY MAINTENANCE
Proper battery maintenance will assure maximum service. Following are a few simple rules:
Keep battery cable terminals clean and tight. Replace worn, cracked, broken or corroded cables.
Keep the filler cap vent hole unplugged. Be sure the battery in a machine is fastened securely to
avoid damage from vibration. Maintain the correct battery electrolyte level. Refer to
“ELECTROLYTE LEVEL” below.
Always charge a battery in a ventilated area. Keep a battery clean. Refer to “BATTERIES”.
REMOVAL AND INSTALLATION (Refer to Fig. 5.10A)
WARNING! When disconnecting the cables to the battery terminals first

disconnect the negative cable (-) When connecting cables to the battery terminals
first connect the positive cable (+).
1 Remove the screws and open the cover.

2 Disconnect the negative cable (-) from the battery (1).
3 Disconnect the positive cable (+) from the battery (2).
4 Disconnect and remove the cable (3) connecting the positive and negative battery terminal.
5 Loosen the bolts (4), remove the flat and remove the batteries from the box.

SECTION 5
MAINTENANCE
PAGE 28
SYSTEM
24 V
+ -
+ + - -
12 V
12 V
12 V
12 V
- - + +
Fig. 5.10A Battery Box And Terminal Connection Diagram

1. Negative end of the cable (-) 3. Cable connecting the battery terminals
2. Positive end of the cable (+) 4. Mounting bolts
Installation of batteries should be performed repeating the above steps in reverse order. Tighten
the bolts that secure the cables to the battery terminals at the moment of 30 [Nm] and mounting
bolts 9 [Nm].
IMPORTANT: Excessive tightening of the mounting bolts can warp or crack the battery
case.
CAUTION! The following precautions must be taken when working around batteries:
 Use a battery carrier to avoid spilling electrolyte on clothing.
 Wearing rubber aprons and gloves is advisable.
 Be careful that tools or other metallic objects do not fall across the battery
terminals.
 Never break a live circuit at the terminals. This could cause sparks.
 Make sure charger cable clamps or booster leads are clean and making good
contact.
 If it becomes necessary to prepare electrolyte of a desired specific gravity,
always pour acid into water.
 Always turn the charger to the OFF position before connecting or removing
charger cables to a battery.
CLEANING THE BATTERIES

If the top of a battery is dirty, it may be cleaned with a brush dipped in ammonia or soda solution
and then rinsed with water.

SECTION 5
MAINTENANCE
PAGE 29
ELECTROLYTE LEVEL
The electrolyte in each cell must be at the proper level (21 to 27 [mm] above the plates) at all times
to prevent battery failure. Check periodically the level of electrolyte. When the electrolyte is below
this level, pure distilled water must be added. Never use hydrant water or any water, which has
been in a metal container. Acid or electrolyte must never be added except by a skilled battery man.
Under no circumstances add any special battery solutions or powders. It is important to keep
a battery at full charge for cold weather operation. Add distilled water to the battery in freezing
temperatures only when the engine is to operate for several hours, to thoroughly mix the water and
the electrolyte, or damage to the battery may occur.
BATTERY CHARGE
When a machine is not in use for an extended period, the maintenance-free battery can become
discharged. For this reason, when a machine is not to be used for over 30 days, it is recommended
that the ground terminal cable be disconnected. Prior to starting up a machine that has been idle,
always make a visual inspection of the battery and take the open circuit voltage test. A reading of
12.4 [V] or less indicates a state of discharge and the battery should be charged per “SERVICE
MANUAL” recommendation.
Check the state-of charge of batteries (specific gravity of electrolyte):
100 [%] of full charge ............................ 1.26 ÷ 1.28 [g/cm³]
75 [%] of full charge.............................. 1.23 ÷ 1.25 [g/cm³]
50 [%] of full charge.............................. 1.20 ÷ 1.22 [g/cm³]
Fully discharged ................................... 1.11 ÷ 1.13 [g/cm³]
5.11. ENGINE
5.11.1. CHECKING ENGINE OIL LEVEL
Fig. 5.11. Engine Oil Dipstick

WARNING! Park the machine on level ground, lower all mounted equipment to the
ground, stop the engine, lock the drive train, apply the brake pedal lock, turn off
the electric system master switch.

SECTION 5
MAINTENANCE
PAGE 30
IMPORTANT: Do not start the engine if dipstick oil level is low, below the “ADD” horizontal
line or above the “FULL” line (Fig. 5.11).
The machine is to be on a flat ground for checking the engine oil to be correct.
The engine is to be shut off while checking the engine oil level.
Wait some 15 minutes after engine shut down for the engine sump oil to remain stable.
Keep the engine oil level between the dipstick marks; top off the oil from time to time. Refer to
“REFILL LUBRICANT AND FLUID SPECIFICATIONS CHART” for type and viscosity of oil
specified.
Secure the dipstick after checking the oil level against dropping off.
IMPORTANT: The engine has a block air pressure sensor. Filler cap and dipstick must be
properly installed. When you install the filler plug or the oil level indicator improperly the
warning light on the machine panel will be lit.
5.11.2. CHANGING THE CRANKCASE OIL AND OIL FILTERS
WARNING! Hot parts – wear gloves. Fire hazard – do not smoke.
WARNING! Whenever working under a machine, turn off the electric system
master switch, remove the key and tag the controls to prevent inadvertent
starting.
1. If the engine is cool start it and run it until it reaches 60 [°C] (beginning of gauge green area).
Stop engine.
2. Unscrew the engine oil drain plug cover bolt, slide the cover aside Fig. 5.12.
3. Unscrew the protective plug (1. Fig. 5.13) and thread in the oil drain hose (2). Threading the
drain hose in will cause the drain valve to open and the oil to drain.
4. Allow the lubricant to drain into a suitable container. Unthread the drain hose (2) and restore
the protective cap (1).
Fig. 5.12. Cover Hiding Engine Oil Drain Plug

SECTION 5
MAINTENANCE
PAGE 31
Fig. 5.13. Engine Oil Drain Plug

1. Protective Cap 2. Drain Hose 3. Engine Crankcase
5. Remove all outside dirt from the contact area between the oil filter (Fig. 5.14) and filter head.
6. Remove the filter using a filter wrench.
7. Clean the filter head in the seal contact area.
1 2
Fig. 5.14. Engine Oil Filler and Engine Oil Filter
1. Engine Oil Filler 2. Engine Oil Filter
IMPORTANT: Use only recommended filters available from an Authorized Construction

Equipment Distributor.
8. Fill the filter with oil and apply oil to the seal (Fig. 5.14).
IMPORTANT: Use the recommended engine oil for the expected operating conditions. Refer
to “REFILL LUBRICANT AND FLUID SPECIFICATIONS CHART” for quality and viscosity of
oil specified.

SECTION 5
MAINTENANCE
PAGE 32
9. Screw the filter until it contacts the filter head and give it ¾ extra turn.
IMPORTANT: Thread the filters by hand. Do not use any tools to install a filter because
this can damage it.
Fig. 5.15. Engine Oil Filter Change
IMPORTANT: Use only recommended filters available from an Authorized Construction

10. Fill the crankcase with fresh oil (1, Fig. 5.14).
11. Check the oil level with the oil dipstick as described in 5.11.1.
IMPORTANT: After the oil has been replaced, start the engine according to the
instructions specified in Section 4 “ENGINE START AFTER OIL CHANGE OR
PROLONGED STANDSTILL”.
12. Start the engine and check the drain plug and oil filters for tightness. Restore the cover.
13. Shut the engine off and after 15 minutes elapsed recheck the oil level and top off to FULL at
the dipstick.
5.11.3. ETHER INJECTOR (if equipped)
PRECAUTIONS
WARNING! Ether starting fluid is highly flammable. An explosion can result if

sparks or flame contact the ether or when storing ether container when the air
temperature is above 70 [°C].
Follow the precautions on the container.
Observe the following precautions:
 Do not use the ether injector when air temperature is above 0 [°C].
 Do not use open flame when using ether starting fluid.
 Do not store fluid containers in the operator's compartment.
 Store containers in a cool, well ventilated place.
 Keep fluid containers out of reach of unauthorized personnel.
 Do not breathe hazardous ether vapor.
 Do not let ether contact your skin, because it can cause frostbite.
 Never puncture a fluid container or put it into fire.
 Dispose of empty containers properly.
 For your safety, remove the ether container when welding, grinding, or using a
torch on a machine.

SECTION 5
MAINTENANCE
PAGE 33
Follow the correct method of starting the engine. Refer to “STARTING THE ENGINE” in Section 4
of the Operator’s Manual.
IMPORTANT: An ether starting valve must be sealed against the entry of dirt at all times
by having a fluid container installed or by installing the dust cap provided with the valve.
INSPECTION AND CLEANING
4 3
Fig. 5.16. Ether fluid container
1. Clamp 3. Injector
2. Ether Container 4. Ether Injector Tube
NOTE: The ether injector cannot be tested unless the coolant temperature is below
+4 [°C].
Test the ether injector as follows:
1. Disconnect the ether tube (4) at the spray nozzle in the engine manifold.
2. Turn the key in the machine electronic system switch from the OFF to the ON position. Depress
the ether injector button (direct the nozzle away from the engine). Dribbling or no spray
indicates a blocked spray nozzle or tube. Revert the switch key to the OFF position.
CHANGING THE FLUID CONTAINER

1. Remove the plug (1).
2. Unscrew and container (2) from ether valve (3).
3. Install new container (2) in valve (3).
4. Secure the container against unscrewing by tightening clamp bolt (1).
NOTE: Use plug to protect valve (3) against dirt if ether container (2) is not installed.

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5.11.4. ENGINE VENTILATION SYSTEM
Inspect the breather tube for sludge or debris on or in the tube (2, Fig. 5.17)
If necessary, disassemble the breather tube and remove sludge or debris. Inspect the tube more
frequently if machine operates in icy conditions to prevent it from clogging.
Fig. 5.17. Crankcase Ventilation Breather Tube and Filter

1. Engine Ventilation Breather Filter Unit 3. Air Cleaner Cover
2. Engine Breather Tube 4. Filter Element
Replacing the oil separator filter in the engine breathing system:

remove the filter cover (3), remove the element (4) and clean the internal housing surfaces. Install
the new filter element and the cover. Torque the filter cover bolts to 5.2 [Nm].
5.11.5. CHECKING GENERAL CONDITION OF ENGINE

Perform general checkup and inspection for damage and leaks. Check the engine electrical
harness for damage.
With the engine operating, check for excessive vibrations, excessive fuel and oil consumption and
leaks which can suggest that a machine maintenance or repair is inevitable.

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5.12. FUEL SYSTEM
GENERAL
Cleanness of diesel fuel determines the service life of the fuel system components. Water and
contaminants, allowed to reach precision components, cause rapid wear and poor performance.
Clean fuel and regular servicing of the fuel tank and fuel filtering components are necessary for
long service life.
Always clean the area around the fuel tank filler cap before refueling.
WARNING! Fire hazard – never mix gasoline and/or alcohol with diesel fuel. This
practice creates an extreme fire hazard and under certain conditions could cause
explosion, which could result in personal injury or death.
WARNING! Never remove the fuel tank filler cap or refill the fuel tank while the
engine is running or hot or when a machine is indoors. Diesel fumes are
dangerous, a spark or flame could result in a fire or explosion.
5.12.1. FILLING THE FUEL TANK

Be sure the fuel tank is full. Fill the tank at the end of each day's operation to reduce condensation
of moisture.
5.12.2. FUEL TANK FILLER STRAINER
Fig. 5.18. Fuel Tank Filler Strainer
This screen cleans the fuel entering the tank and eases the job of the fuel filters. Remove the
retaining ring then remove the filter and clean with nonflammable commercial cleaning solvent.

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5.12.3. FUEL TANK SHUT-OFF VALVE
The fuel shut-off valve is installed in the filter box on the left side of the machine. It should always
be put in the open position.
Fig. 5.19. Fuel Tank Shutoff Valve

1. Fuel Shutoff Valve (open position)
5.12.4. FUEL FILTERS
5.12.4.1. Fuel Filter Water Separator Servicing
5 4 2 4 5
Fig. 5.20. Engine Fuel Filters
1. First Stage Fuel Filter Element Unit 4. Second Stage Fuel Filter Unit
2. WIF Water in Fuel Sensor 5. Quick Coupling Connector
3. Water Drain Valve

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The engine has a two-stage fuel filtering system using replaceable filters. (Fig. 5.20).
The filters are highly capable of removing water emulsion from fuel and feature high filtration ratio.
The first stage filter with water separator (1) has a WIF water sensor (2) and a drain valve (3) at the
bottom. Water and foreign materials separated from fuel, which settle at the bottom of the filter, are
drained from the fuel through drain valve.
Before you start the engine open the filter valve (3) and drain sediment from the filter to the container
through the drain hose until clean fuel appears. Close the valve.
IMPORTANT: Water contaminated with sediment and fuel as well as oil are detrimental to
environment. Drain water into a suitable container and utilize in the environment friendly
way.
5.12.4.2. Replacing Fuel Filters
Fuel filter is to be changed as per Scheduled Maintenance Guide.

Keep new filter in its original package until ready for installation. Before loosening the filter, clean
the filter head to prevent dirt or foreign material from entering the system.
Replace the first stage fuel filter element (1, Fig. 5.20) when the fuel level in the upper glass shield
reaches the upper element edge (red strip) with the engine operating. To replace the filtering
element do as follows (refer to Fig. 5.21):
1. Close the fuel shut-off valve in the filter box on the left side of the machine (1, Fig. 5.19).
2. Remove the upper filter plug, open the valve (3, Fig. 5.20) and drain fuel from the filter to the
container.
3. Use the special wrench to remove the flange nut that secures the filter housing.
4. Remove the filter element, seal installed under the filter and the housing O-ring.
5. Install a new filter element, seal installed under the filter a new housing O-ring.
6. Install the filter cover and the flange nut.
IMPORTANT: Hand tighten the flange nut without any tools.
7. Add clean fuel to the filter element center line.

8. Install the filter plug and the O-ring.
IMPORTANT: Hand tighten the plug without any tools.
9. Open the fuel shut-off valve in the filter box on the left side of the machine (1, Fig. 5.19).

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Fig. 5.21. First Stage Fuel Filter Element Replacement
Second stage fuel filter replacement (Fig. 5.21A)

1. Remove all dirt from the contact area between the fuel filter and filter head.
2. Remove the fuel filter (4) using a filter wrench.
3. Clean the filter head in the seal contact area.
4. Apply a light coating of oil to the entire seal surface of the new filter (Fig. 5.21A).
5. Install the new filter, turning it until the seal just contacts the filter head and tighten the filter an
additional 1/2 to 3/4 turn.
Fig. 5.21A. Second Stage Fuel Filter Replacement
IMPORTANT: Do not fill the fuel filter before installation. The filling of filter can introduce
the contaminated fuel to fuel system critical components and damage them.
NOTE: Use only recommended filters available from an Authorized Construction

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5.12.4.3. Fuel System Venting
The fuel system is self-venting thru the fuel return line after engine start.
After replacing the filters in order to vent the 2nd degree fuel filter (4, Fig. 5.20) before starting the
engine proceed as follows:
1. Fasten the quick coupling P/N 864-01-0059 to the connector (5, Fig. 5.20).
2. Turn the starting key in the starting switch to the start position. Do not start the engine.
3. The priming electrical fuel pump fills the filter (4).
4. Disconnect the quick coupling (5) when fuel starts to flow out.
5. Start the engine and allow the low idle to stabilize.
NOTE: Check the filters for tightness after the engine start.
WARNING! Avoid the fuel system leaking condition with the engine operating. The
system is high pressure while operating. The high pressure fuel jet can cause
personal injury or death.
5.12.5. DRAINING SEDIMENT AND WATER FROM FUEL TANK
Fig. 5.22. Fuel Tank Drain Valve

1. Fuel Tank Drain Valve (closed position)
Open the drain valve (1, Fig. 5.22) to drain water and sediment from the fuel tank drain trap. Wait
until clean diesel fuel starts flowing out. Close the valve.

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5.12.6. SERVICING FUEL TANK CAP-BREATHER

Fuel tank breather (located in the filler cap) is to be cleaned periodically as per Scheduled
Maintenance Guide (Fig. 5.23).
Fig. 5.23. Fuel Tank Filler Cap-Breather
5.13. ENGINE EXHAUST SYSTEM
3
Fig. 5.24. Machine Engine Exhaust System Units
1. Reducer Unit (SCR) 2. Catalyst Unit (DOC + DPF) 3. Fuel Injector

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The machine engine exhaust system (Fig. 5.24) is used to neutralize harmful substances that are
present in the exhaust gas according to the current exhaust gas emission standards. The main
system components are: oxidation catalyst (DOC) with the particulate filter, pipe with the DEF
dosing module (DRT) and the nitrogen oxide selective reduction catalyst (SCR).
The nitrogen oxide (NOx) reducing fluid dosing system consists of the DEF tank, supply module
(SM) and the dosing module (DM). DEF is a solution containing 32.5% of ammonia and
demineralized water. The amount of the fluid supplied depends on the measured catalyst operating
parameters, reducer temperature and the content of nitrogen oxide in exhaust. It results in the
continuous nitrogen oxide, carbon oxide and hydrocarbon and particulate matter reduction to free
nitrogen and steam that are not harmful to people or the environment.
5.13.1. CLEANING THE EXHAUST SYSTEM (SCR)
The catalyst exhaust pressure sensors measure the restriction of flow to determine the amount of
accumulated particulate matter. During normal machine operation particulate matter collects in the
particulate filter and must be removed during cleaning (oxidizing). The cleaning process requires
a lot of heat to occur.
The cleaning process is classified into three different types: passive cleaning (automatic), active
cleaning (assisted) and stationary (manual) initiated by the operator.
5.13.1.1. Passive cleaning (automatic)

Passive cleaning occurs when the machine is operated under heavy load. Suitably high
temperature in the exhaust system allows the removal (oxidation) of collecting particulate matter
faster than its deposition occurs. This process takes place automatically.
5.13.1.2. Active (assisted) cleaning

Active filter cleaning occurs when the machine is operated under low load and in stop and go duty
cycles. The temperature in the exhaust system is not high enough for the process of cleaning of
particulate matter collected to be carried out faster than it is collected.
Active cleaning is initiated and stopped from the engine ECM, if the particulate matter
accumulation has reached a specified limit. After starting the process, in order to increase the
exhaust system catalyst temperature a small amount of fuel is injected which is oxidized in the
catalyst. Generated heat is needed to oxidize the particulate matter collected in the DPF.
IMPORTANT: During active cleaning the exhaust gas temperature can be higher than
when the engine is operating normally at full load and can reach 800 [°C]. When this is the
case, the high exhaust system temperature warning light will come on. The operator may
notice an increase in engine turbocharger noise during the cleaning process.
5.13.1.3. Stationary cleaning (initiated manually)

If the conditions for passive or active cleaning are not fulfilled during machine operation and the
exhaust system requires cleaning (the restricted exhaust aftertreatment system light is on or
flashes), stationary cleaning must be initiated. Stationary cleaning is a form of active oxidation that
is initiated by the operator with the switch (12, Fig. 4.2) (see Section 4.3.1).
To perform the cleaning process, follow the steps listed:
1 Select an appropriate location to park the machine at a safe distance from flammable or
hazardous materials.
2 Keep fire extinguishers nearby or other equipment in case of fire.

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3 Start the engine and initiate the oxidation process by toggling the switch on the instrument
panel.
DANGER! During stationary cleaning, the exhaust gas temperature increases

significantly. Position the machine on level ground and keep a safe distance from
flammable materials and trees.
IMPORTANT: To initiate the process, the engine must operate at low speed.
IMPORTANT: Once the cleaning process is initiated, the engine speed will increase, the
turbocharger noise will increase and the High Exhaust System Temperature Warning
Lamp will illuminate.
4 Monitor the stationary cleaning process and stop it when its continuation is dangerous.
IMPORTANT: The manual cleaning process can be stopped before it is completed. To do

this, toggle the switch (12, Fig. 4.2) to the disable position or turn off the engine.
5 After the cleaning process is completed, the minimum engine operating parameters will be
restored.
IMPORTANT: The time length of regeneration of the exhaust system will vary depending
on its contamination and will typically take from 45 minutes to 1.5 hours to complete. Do
not operate the machine during the cleaning process.
5.13.1.4. Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF) Cleaning
Periodic maintenance per the “SCHEDULED MAINTENANCE GUIDE” of the catalyst and
particulate filter cleaning and checking should be performed by the trained Authorized Construction
Machinery Distributor personnel or the CUMMINS Engine Authorized Service.
The catalyst can be removed and passed to authorized service centers for cleaning.
Before removing the catalyst from the machine, tag all elements connected to the exhaust system
to ensure proper re-installation.
IMPORTANT: The catalyst inner elements are made of brittle material. Do not drop or strike
the catalyst because it can cause permanent damage.
5.13.1.5. Clean Fuel Dispenser (Injector)
Periodically remove and clean the fuel dispenser (3, Fig. 5.24) according to the engine
manufacturer requirements. Cleaning is aimed at removing the varnish deposits from the injector
surface with chemical agents and mechanical means. For installation use new seals.
IMPORTANT: Use only brass brush for cleaning.
IMPORTANT: The service should be performed by the Authorized Construction Machinery

Distributor or the CUMMINS Engine Authorized Service.

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5.13.2. DIESEL EXHAUST FLUID (DEF) DOSING MODULE SERVICE
The dosing module (1, Fig. 5.25) is installed on the bracket under the operator cab floor cover. The
module is equipped with the replaceable filter that needs to be checked or replaces from time to
time.
Fig. 5.25. Diesel Exhaust Fluid (DEF) Dosing Module with the Filter
1. Dosing Module 4. Filter Element Extractor
2. Plug 5. Filtering Element
3. Filter Element Compensator
To check/replace the filter proceed as follows:

1. Remove the floor cover inside the operator cab.
2. Remove plug (2) with a 27 [mm] socket wrench.
3. Remove the filter element compensator (3).
4. Using the tool (4) remove the filter element (5).
WARNING! Diesel exhaust fluid (DEF) contains ammonia. Protect your eyes while
servicing the filter. In case of contact with eyes immediately rinse with lots of
water. Do not inhale the vapor. If you intake the fluid or its vapor, consult
a physician immediately.
CAUTION: The diesel exhaust fluid (DEF) injection system is under a slight
pressure when the engine is running. Do not disconnect any system connectors
while the engine is running or after stopping the engine, unless the system has
been vented thoroughly.
IMPORTANT: Do not turn off the battery pack master switch until the DEF dosing
system is thoroughly vented.
After stopping the engine, wait for 5 minutes before disconnecting any connection in the
diesel exhaust fluid dosing system. The system is self-venting.
IMPORTANT: Do not clean the DEF dosing module with pressurized water or steam. Use
compressed air for cleaning.
5. Check the condition of all removed filter parts. Any visible damage is not allowed. If you find
a damage, replace the damaged part with a new one.
6. Install the filter (5), the compensator (3) and the plug (2).
IMPORTANT: Torque-tighten the plug (2) to 20 [Nm].

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5.13.3. DIESEL EXHAUST FLUID (DEF) TANK SERVICE
IMPORTANT: Before the containers, funnels etc. are used to add DEF wash them and
rinse with distilled water to remove any contaminations and the dry them thoroughly. Be
careful while adding the fluid. Dirt can block the filter inside the tank and cause injection
system failure.
NOTE: Do not add DEF using the strainer funnel. The strainer may be damaged.
Add DEF only to the clearly marked DEF tanks equipped with the blue cap according to
the emission regulations.
WARNING! Diesel exhaust fluid (DEF) contains ammonia. Protect your eyes while
servicing the filter. In case of contact with eyes immediately rinse with lots of
water. In case of contact with skin immediately wash the contact surface with
water and soap. Do not inhale the vapor. If you intake the diesel exhaust fluid
(DEF) or its vapor, consult a physician immediately.
Fig. 5.26. Diesel exhaust Fluid (DEF) Filler Tank cap
The cap has a breather, check periodically whether the breather has not been blocked by
crystallized fluid. If required, clean the cap by immersing it in water for a few minutes. Dry the cap
with compressed air before installing it. In winter water can freeze and block the ventilation valve.
5.13.4. CHECKING EXHAUST SYSTEM FOR LEAKS
Check the exhaust system joints for leaks, cracks and loosen mounting clamps. Tighten the
clamping screws with the appropriate torque if necessary.
Replace all damaged exhaust system elements for new to ensure that the connections are leak
proof.
Check all joints for leaks where the mounting clamps are installed.

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5.14. EQUIPMENT SYSTEM HYDRAULICS
GENERAL
WARNING! Always lower all mounted equipment to the ground before performing
work on the hydraulic system. With all mounted equipment lowered to the ground
and the engine off, cycle all hydraulic controls in all directions to relieve trapped
pressure.
Slowly loosen the hydraulic reservoir filler cap to relieve trapped reservoir pressure.
5.14.1. CHECKING OIL LEVEL
1. Park the machine on level ground, lower the blade and the ripper to the ground and stop the
engine.
2. The hydraulic oil tank is installed on the right fender, check oil level in the sight glass on the
tank side. Add oil if the level is below the centerline of the gauge. Refer to “CHANGING
HYDRAULIC OIL”.
Fig. 5.27. Hydraulic Reservoir Sight Gauge
5.14.2. CHANGING HYDRAULIC OIL
IMPORTANT: Before removing any components from the reservoir or servicing, wipe the
front surface of the reservoir, using a commercial cleaning solvent.
1. Start the engine and operate the blade to warm the oil for easy draining.
2. Park the machine on level ground, lower the equipment to the ground.
3. Shut the engine off. Shift the drive train control lever to neutral position and apply the neutral
lock lever. Apply and lock the parking brake. Turn the electric system master switch to the OFF
position and remove the key. Slowly loosen the reservoir filler plug to relieve reservoir
pressure.
4. Undo bolts of filler plug cover (Fig. 5.28) under the reservoir and unscrew the filler plug to drain
the reservoir into a suitable container. If the reservoir is equipped with a drain valve
(Fig. 5.28A), remove protective cap (1) of the drain valve and thread hose (2) into the plug
opening and drain the oil into a suitable container. When threaded in, drain hose (2) opens the
drain valve and allows the oil to flow out.

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Fig. 5.28. Hydraulic Oil Reservoir Drain Valve (viewed from the bottom with cover removed)
a) Valve closed b) Valve opened

Fig. 5.28A Hydraulic Oil Drain Valve (if equipped)
1. Protective Cap 2. Drain Hose 3. Reservoir Bottom
5. Replace the two return filters of the hydraulic system and equipment pilot pressure filter. Refer
to “REPLACEMENT THE RETURN FILTER AND PILOT FILTER”. Clean. Refer to
“SERVICING THE SUCTION STRAINERS AND FILLER STRAINER.” Clean the suction
strainers and oil filler strainer.
IMPORTANT: Use clean oil from a clean container. Maintain all packaging and fittings
in good condition so as to prevent leakage.
6. Reinstall the drain plug. Fill the reservoir with hydraulic oil up to the center line of the sight
gauge. Refer to “REFILL SPECIFICATIONS AND CAPACITIES” for the quantity oil specified.
Reinstall the filler cap. Reinstall the filler plug cover under the reservoir.
7. Vent the system. Refer to “VENTING THE HYDRAULIC SYSTEM”.
5.14.3. REPLACEMENT THE RETURN FILTER AND PILOT FILTER
IMPORTANT: If the filter warning light on the instrument panel remains on at the operating
oil temperature with the engine running, the appropriate filter that caused the light on is to
be replaced.
The two hydraulic return filters and equipment pilot pressure filter must be replaced according the
“MAINTENANCE SCHEDULE GUIDE” as described below:
IMPORTANT: Before removing the filters remove the oil filler cap to balance the air
pressure in the tank with the atmospheric pressure.

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1. Park the machine on level ground, lower the equipment to the ground and stop the engine.
Turn the electrical system master switch to the OFF position.
2. With the engine stopped, operate the equipment lever several times in all directions to relieve
any system pressure. Open the filters’ access door located on the R.H. side in front of the
hydraulic reservoir, remove all outside dirt from the filters.
3. Using a filter wrench, remove the filters. Wipe the filter head, removing all of the old oil from the
seal area.
4. Coat the seal of the new filter with clean oil. Install the new filters by threading them onto the
filter head until the seal contacts the head, then turn the filters by hand an additional 1/4 to 1/2
turn. Check the oil level in the reservoir as outlined in “CHECKING THE OIL LEVEL.”
Fig. 5.29. Hydraulic Equipment System Oil Filters

1. Hydraulic Return Filters 2. Hydraulic Equipment System Pilot Filter
5.14.4. REPLACING THE FAN DRIVE SYSTEM RETURN FILTER
Fig. 5.30. Fan Drive System Filter

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IMPORTANT: If the filter warning light on the instrument panel is a light at the operating oil
temperature with the engine running, the restricted filter must be replaced.
IMPORTANT: Before removing the filter remove the oil filler cap to balance the air
pressure in the tank with the atmospheric pressure.
1. Park the machine on level ground, lower the equipment to the ground and stop the engine.
Turn the electrical system master switch to the OFF position.
2. Open the L.H. side filters access door. Remove all outside dirt from the filter and using a filter
wrench remove the fan drive train filter (refer to Fig. 5.30). Wipe the filter head.
3. Coat the seal ring of the new filter with clean oil. Install the filter (2) by threading it onto the filter
head (3) until the sealing ring (1) contacts the head, turn the filter by hand an additional 1/4 to
1/2 turn. Start the engine and let it idle for approximately 5 minutes. Check the filter for
tightness and remove any possible leaks.
4. Check the oil level in the hydraulic tank as outlined in “CHECKING THE OIL LEVEL.”
5.14.5. SERVICING THE SUCTION STRAINERS AND FILLER STRAINER
Fig. 5.31. Equipment system oil reservoir strainers

1. Suction Strainers 2. Filler Strainer 3. Inspection Cover
Park the machine on level ground lower the blade to the ground and stop the engine. Turn the
electrical system master switch to the OFF position. With the engine stopped, operate the
equipment lever several times to relieve system pressure. Drain the hydraulic system. Refer to
“CHANGING HYDRAULIC OIL”.
Filler Strainer
1. Loosen the oil filler plug (installed in the right box) (2, Fig. 5.31), remove the retaining ring that
fastens the filler filter, remove and clean the filler filter. Dry and install in the filler tube.

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Suction Strainers
1. Remove the screws that fasten the inspection cover (3, Fig. 5.31) to the hydraulic tank wall.
Remove the cover and the O-ring.
2. Remove the strainers (1) through the inspection hole in the tank wall. Use a flat wrench
106 [mm] and 70 [mm] for removal (and installation).
3. Use inflammable kerosene and compressed air to wash the strainers (1). Thoroughly clean the
inside of the tank, remove dirt in the tank corners.
IMPORTANT: Replace the suction filter with a new one if it is damaged or deformed.
WARNING! Fire hazard – do not use kerosene, diesel fuel or flammable liquids to
clean parts. A spark or a flame could cause a fire or an explosion. Use
a nonflammable commercial solvent.
4. Install the strainers, fasten them and install the hydraulic tank cover with a new O-ring.
5. Fill the system. Refer to “CHANGING HYDRAULIC OIL”.
5.13.6. SERVICING THE HYDRAULIC TANK BREATHER

Replace the hydraulic oil tank breather every 2000 hours of operation.
Fig. 5.32. Equipment System Oil Tank Cap with Breather
1. Park the machine on level ground, lower the working equipment to the ground then stop the
engine. Turn the electrical system master switch to the OFF position. With the engine stopped,
operate the equipment lever several times to relieve system pressure. Remove all outside dirt
from the filler with breather.
2. Open the right box. Slowly loosen the filler cap on the tank in order to relieve any pressure in
the tank.

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CAUTION! Pressurized Reservoir. Always loosen the filler plug slowly in case
there is still some pressure in the system.
3. Replace the breather with a new one. Reinstall the tank filler cap.
5.14.7. HYDRAULIC SYSTEM VENTING
1. The hydraulic system has to be vented of air if the system has been drained and filled, the
hydraulic lines have been disconnected or tightened or after noting hydraulic leaks or the
hydraulic system has been operated with excessively low oil level.
2. Start the engine and run it at low idle speed. Operate all the controls through all positions four
or five times, extend and retract the cylinders to remove air from the hydraulic system.
3. Check the oil level as described in “CHECKING OIL LEVEL”. Repeat this procedure until the oil
level remains at the specified level in the reservoir.

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5.15. LUBRICATION POINTS
WARNING! Before starting any maintenance service lower all mounted equipment
to the ground. Shift all control levers to their respective neutral positions. Apply
and lock the parking brake. Shift the drive train lock lever to its locked position.
Turn the electric master switch OFF.
IMPORTANT: When the machine is equipped with the central lubrication system do not
add grease through the grease nipples shown in figures 5.35, 5.36, 5.37, 5.38, 5.39 and
5.40.
GENERAL
The following lubrication fittings are to be greased at the intervals indicated in the SCHEDULED
MAINTENANCE GUIDE. Apply grease until clean lubricant is visible. Always use a clean lubricator
and wipe dirt from the fittings before fresh grease is applied. If grease fails to go through a fitting,
determine the cause and correct it.
DRIVE TRAIN CONTROL LEVER AND BRAKE CONTROL LINKAGE (3 lubricating fittings)
Fig. 5.33. Drive Train Control Lever and Brake Control Linkage Lubrication Points
1. Drive Train Control Lever (Valve Plungers’ Dome Nuts)
2. Brake Pedal Bracket
3. Brake Pedal Lever
4. Steering Valve Brake Lever

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BLADE AND RIPPER CONTROL VALVES
Fig. 5.34. Lubricating the Hydraulic Equipment Pilot Valve Plungers Ends
and Drive Train Control Valve Plunger Dome Nuts
CYLINDER PIN OF THE BLADE LIFT CYLINDER PISTON ROD FITTINGS

(A lubrication fitting in each cylinder.)
Fig. 5.35. Lubrication Fitting of Blade Lift Cylinder Piston Rod Pin

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BLADE LIFT CYLINDER YOKE (4 fittings)
Fig. 5.36. Blade Lift Cylinder Yoke Fittings
BLADE LIFT CYLINDER GIMBAL CROSS TUBE (2 fittings)

Apply grease until fresh grease flows out of the breather.
Fig. 5.37. Blade Lift Cylinder Gimbal Cross Tube Fittings

1. Breather 2. Lubricating fittings

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DOZER BLADE
- Angle Blade
Fig. 5.38. Dozer Blade Greasing Points (mechanical tilt)
- Dozer Blade (U / 1/2 U, for coal)
Fig. 5.39. Dozer Blade Cylinder/ Strut Lubricating Fittings (hydraulic tilt/ pitch)

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RIPPER EQUIPMENT WITH CYLINDERS (12 fittings),

RIPPER EQUIPMENT WITH HYDRAULIC RIPPER SHANK LOCK PIN CYLINDER CONTROL
(12 lubrication fittings)
Fig. 5.40. Ripper Equipment Lubricating Fittings

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5.16. MOUNTED EQUIPMENT
5.16.1. COMPLETE BLADE REMOVAL AND INSTALLATION
Fig. 5.41. Complete Dozer Blade

1. Blade Lift Brackets
If for any reason the complete blade is to be removed from the machine proceed as follows:
1. Place the blade on level ground and block up the ends of the push arms close to the trunnions.
This will maintain the proper height for blade reassembly.
2 1 2
Fig. 5.42. Blade Tilt Hoses Connection and Trunnion Bearing Cover
1. Blade Tilt Hoses Connection Cover 2. Cover Bolts

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2. Remove pins to separate the hydraulic cylinders’ piston rods from lift brackets at the back of
the blade. Retract the piston rods to the cylinders and secure the rods to the machine using
shipping hanger bars to prevent damage to the piston rods.
3. Machines with tilt only (connection at RH side), and with tilt and pitch (connection at both
sides). Remove bolts (2, Fig. 5.42) and remove cover (1). Unscrew the separate flanges that
secure hydraulic lines to the trunnion.
Fig. 5.43. Push Arm Mounting

1. Trunnion Ball 5. Hydraulic Hose
2. Trunnion Cover 6. Push arm
3. Trunnion Bolts 7. Shims
4. Hydraulic Hose
4. Remove two trunnion bearing cap bolts (3) and remove caps (2) and shims (7) of the R.H. and
L.H. side trunnion (1) located at the back of the push arms (6).
5. Back the machine straight out and away from the push arms. Cap the hydraulic lines with
plastic caps.
6. Reassemble shims and bearing caps to the push arms and secure with the bearing cap bolts to
prevent their damage or being lost. If the blade is to be stored outdoors, grease the blade to
prevent corrosion.
To reassemble the blade, perform the above in reverse order. Take care that the hydraulic
cylinder having a larger diameter (Ø 238) was at the RH side while that of smaller diameter
(Ø 216) at LH side. Refer to Fig. 5.36.
7. Check if the blade is positioned symmetrically to the machine axis. Operating with a blade non-
symmetrical to the machine axis results in damage to the blade.

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5.16.2. ADJUSTING THE TILT CYLINDER AND UPPER BLADE STRUT (Fig. 5.44)
Periodically check the call ends clearance in the tilt cylinder and upper strut (or pitch cylinder)
seats. Adjust if the ball end clearance is higher than 1.3 [mm].
Lower the blade to the ground.
The adjust procedure is as follows:
1. Attach a hoist sling to tilt cylinder (1).

2. Remove the bolts (2) securing the cover (5) to the socket (4) on the blade.
3. Retract the cylinder rod (1), keep the cylinder on the sling, remove the shims (3).
4. Clean the ball end (6) and seat (4). Move the ball end (6) into the seat (4) until it rests in the
seat.
5. Install the cover (5). Tighten the bolts (2) equally to 270 [Nm].
There should be equal gap between the cover and the seat on both sides.
6. Using the shims (3) determine the maximal number of shims to fill the gap between the cover
(5) and the seat (4).
7. Add one shim to the specified number of shims (3). It will ensure correct joint clearance. A shim
is 0.75 [mm] thick.
8. Remove the bolts (2), retract the cylinder rod. Install the specified shim package (3), cover (5)
and bolts (2). Tighten the bolts (2) equally to 1,050 [Nm].
9. Grease the joint through the grease nipple (Fig. 5.39).
Fig. 5.44. Blade Tilt Cylinder

1. Blade Tilt Cylinder 4. Blade Socket
2. Cap Bolts 5. Strut Cap
3. Shims 6. Cylinder Ball End
Adjust the upper left ball end strut or tilt cylinder clearance as per the above instructions.

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5.16.3. BLADE DIAGONAL STRUT ADJUSTMENT (Fig.5.45)
Periodically check the ball end clearance in the seats and adjust the diagonal blade strut length.
Adjust if the ball end clearance is higher than 1.3 [mm].
Lower the blade to the ground.
The adjust procedure is as follows:
1. Attach the hoist sling to the diagonal strut.

2. Remove the eye end pin (1) of the left and right strut.
3. Check the blade beam distance from the track plate edge (equal on both sides).
4. Adjust the ball end clearance as per section 5.15.2.
5. Insert the eye end (1) into the blade beam bracket. Loosen the clamping screws (2).
6. Rotate the strut so that the eye end holes overlap the blade holes on the beam.
7. Install and secure the pin in the bracket connection on the blade beam.
8. Shorten (rotate the strut) so that the ball strut end (3) lightly rests on the cover (7).
9. Tighten the clamping screws (2).
10. Grease the ball strut end through the grease nipple (Fig. 5.39).
Fig. 5.45. Blade Diagonal Strut

1. Diagonal Strut Eyebolt 5. Shims
2. Clamping Bolts 6. Cap Bolts
3. Strut Ball 7. Strut Cap
4. Blade Socket
5.16.4. PITCH CYLINDER CLEARANCE ADJUSTMENT
If the left hand blade side upper strut is to be replaced with the pitch cylinder, the clearance of the
pitch cylinder strut ball shall be adjusted in the same way as the adjustment of the upper strut and
the blade tilt cylinder described above.

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5.16.5. CHECKING THE BLADE CONDITION
5.16.5.1. Trunnion and Cap Mounting Bolts (Fig. 5.46)
Periodically check the torque of the trunnion mounting bolts, push arm bearing cap bolts.
Torque the bolts as per the following when the equipment is to be installed.
 Tighten the push arm trunnion bolts (1) to a torque of 845 [Nm].
 Tighten the push arm trunnion bearing cover bolts (2) to a torque of 2100 [Nm].
Fig. 5.46. Tightening Trunnion and Pusharm Bearing Cap Bolts

1. Trunnion Bolts 2. Trunnion Bearing Cover Bolts
5.16.5.2. Blade Cutting Edge and End Bits Mounting Bolts
Periodically check the torque of the blade cutting edges and end bit bolts. Lift the blade off the ground
and block it. Stop the engine. Turn the electric system master switch off and remove the key.
WARNING! For your personal safety never work beneath the blade without
securing it with wooden blocks.
Check the torque of the cutting edges and end bits bolts. It should be 1050 [Nm].

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Fig. 5.47. Tightening Blade Cutting Edge Bolts

1. Bolt 2. Nut
5.16.5.3. Allowable Wear of Blade Cutting Edge and End Bits
Reverse or replace the cutting edge and end bits before the mounting plate is worn or damaged.
If the distance between a cutting edge mounting bolt axis and the cutting edge bottom edge is
smaller than 85 [mm] it should be reversed or replaced if it had already been reversed before.
An end bit should be replaced if the distance between the axis of a mounting bolt in the lower row
and the bottom edge is smaller than 95 [mm].
To replace the cutting edge and the end bits proceed as follows:
1. Raise the blade about 300 [mm] above the ground and set the control valve lever in the
“HOLD” position. Prop up the push arms and stop the engine.
WARNING! For your personal safety never work beneath the blade without
securing it with wooden blocks.
2. Remove the cutting edge and end bits mounting bolts.

3. Install the cutting edge or the end bits and tighten the bolts to a torque of 1050 [Nm].
Authorized Distributor of Construction Equipment can supply these specially heat-treated bolts.
CAUTION! Do not substitute bolts. Loosening of the bolts securing a cutting edge
and end bits may result in tearing off of the cutting edge or end bits and blade
damage or personal injury.
5.16.6. SERVICING THE RIPPER
Prior to each day’s work carry out ripper inspection and remedy if any malfunction is found. If any
element is found malfunctioning clear this condition prior to operation. Operating defective ripper
results in reduced job efficiency and may cause its damage.
The following table specifies services to be carried out during inspection:

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POINT OF SERVICE DESCRIPTION

SERVICE
Ripper Assy Visually check for cracks, breakage, loose parts and completeness.
Hydraulic hoses and
Check for leaks and remedy, if any.
connections
Check if pins are secured correctly and tighten loosened bolts if
Ripper pins
necessary.
Check for wear. Replace, if the total length of the point is smaller than
Ripper shank points 210 [mm]. Shank point worn to excess makes ripping difficult and results
in its damage.
Replace a ripper shank point as follows:

1. Raise the ripper tooth about 300 [mm] above the ground and prop up to prevent the ripper
tooth from lowering during service.
2. Turn the electric system master switch off and remove the key.
3. Remove the shank point mounting pin.
4. Insert a new shank point and new mounting pin.
5.16.7. ADJUSTMENT AND VENTING OF THE “C” FRAME BLADE TILT HYDRAULIC
SYSTEM (Fig. 5.48)
Fig. 5.48. Blade with Tilt Cylinders on „C” Frame

1. Clearance 5. Clearance
2. No Clearance 6. LH Cylinder Venting Plug
3. Lower Strut 7. No Clearance
4. RH Cylinder Venting Plug
The system filling and venting may proof necessary:

 immediately after the tilt hydraulic system was installed on the „C” frame
 after repair and reinstallation of hydraulic tilt components on the „C” frame

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IMPORTANT: Adjust the blade lower struts (3) after the equipment installation so that only
places marked at the Fig. 5.48 are provided with clearance. The struts are not to differ in
length more than 6 [mm].
1. Unthread the vent plugs (4 and 6) from blade tilt cylinders.

2. Start the engine at low idle. Raise the blade to some 1000 [mm] above the ground.
IMPORTANT: Shift SLOWLY to the LEFT ONLY the blade tilt control lever while venting
the system. The blade control lever is to remain unchanged during the system venting. If
the control lever is moved to the right both cylinders will outreach at the side and may
cause the surplus stresses at the blade suspension pin at the “C” frame and a damage to
suspension pivot.
3. Move slowly the blade control lever to the left until the blade left corner is seen to lower its
position and the RH cylinder piston rod moves out. Keep the control lever in this position until
oil exempt of air bubbles starts flowing out of the RH cylinder vent hole i.e. the air was
removed.
NOTE: If the blade control lever has been shifted to the left and, as a result, the RH corner
of the blade will get lowering while the LH cylinder piston rod will start sliding out, stop this
action and cross hydraulic hoses' tilt cylinders hooking.
4. Release the blade control lever to neutral. Thread the vent plug into the RH cylinder vent hole.
5. Move the blade control lever slowly to the left again and have it in this position until oil exempt
of air bubbles starts flowing out of the LH cylinder vent hole i.e. the air was removed.
6. Release the blade control lever to neutral. Thread the vent plug into the LH cylinder vent hole.
7. Move the blade control lever to the left again and have it in this position for about 60 [s]. Raise
the engine RPM at the same time.
8. Release the blade control lever and check if the right and left blade tilt operates correctly.
Stop engine.
9. Check hydraulic connections for leaks.
10. Top off the hydraulic reservoir.

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5.17. SEAT BELT
WARNING! Seat belt – do not clean with solvents or bleach or re-dye color of
webbing as this may cause a severe loss of strength. This could cause the
webbing to break and result in personal injury. Wash in warm water with mild
detergent.
Keep the belt flat to avoid twisting and roping when not being used. Do not place heavy or sharp
objects on the belt. The entire seat belt assembly should be inspected periodically for corrosion,
wear, fraying or weak spots. The seat belt mounting bolts should also be periodically inspected for
tightness.
Fig. 5.49. Seat Belt

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5.18. FINAL DRIVES
5.18.1. CHECKING OIL LEVEL
Position the machine on level ground so that the “OIL LEVEL” mark on the final drive housing is
positioned horizontally at the RH side when viewing the final drive cover. Remove the magnetic level
and filler plug (2), check the lubricant and, if the lubricant is low, fill to the level of the plug opening.
Also, check the plug for metallic particles that may be present. If this condition continues after periodic
checks, consult Authorized Distributor of Construction Equipment. Reinstall the plug.
Fig. 5.50. Checking the Lubricant Level

1. Drain Plug 2. Level and Filler Plug 3. Drain Plug
5.18.2. CHANGING THE OIL
1. While the oil is at operating temperature, park the machine on level ground so that drain plug
(1) is in its bottom position. Remove the level and filler plug (2) and drain plugs (1 and 3) and
allow the lubricant to drain into a suitable container. Remove metal particles from the magnetic
plugs. Install and tighten the drain plugs (1 and 3). Fill app.8 liters of fuel oil up to the housing
and install the plugs (2).
2. Operate the machine in low gear (with no load) for a few minutes. Park the machine so that
drain plug (1) is in its bottom position. Remove the plugs (2) and drain plugs (1 and 3) and
allow the diesel oil to drain into a suitable container. Reinstall the drain plugs. Position
the machine so the “OIL LEVEL” mark on the final drive housing is positioned horizontally
at the RH side when viewing the final drive cover. Fill the both final drives with fresh oil
up through plug (2) opening to the bottom line of the plug opening. Refer to “REFILL
LUBRICANT AND FLUID SPECIFICATIONS CHART” for amount and type of oil specified.
Reinstall and tighten plugs (2).

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5.19. DRIVE TRAIN
GENERAL
The rear part of the main frame is the common oil reservoir for the transmission, torque converter
and hydraulic steering drive. The system has pressure filters and a suction strainer which require
service.
Periodically, clean the outside surface of the transmission, torque converter, rear frame cover,
engine and the frame inside components. This is especially true if the machine operates in an
aggressive, dusted atmosphere, flammable.
5.19.1. CHECKING THE OIL LEVEL OF THE MAINFRAME REAR PART
1. With the engine shut down undo the cover bolts at the machine rear, unscrew the T handle of
the oil dipstick (1), remove the dipstick and wipe it clean.
2 1
Fig. 5.51. Drive Train System Oil Level in Main Frame

1. Oil Dipstick and Oil Filler in Main Frame
2. Main Frame Breather
2. Insert the dipstick fully into the filler sleeve. Do not thread. Remove the dipstick and check the
lubricant level. If necessary, add oil through the filler to bring the level up. Reinstall and secure
the dipstick. The dipstick has two marks: for minimum oil level (ADD) and for maximum oil level
(FULL) for HOT OIL on one side and two marks: for minimum oil level (ADD) and for maximum
oil level (FULL) for COLD OIL on the other side. Check the oil level with the engine stopped.
IMPORTANT: Never operate a machine if the oil level is below the ADD mark on the Oil
Level Dipstick.

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5.19.2. CHANGING MAINFRAME OIL

(Fig. 5.52)
Fig. 5.52. Mainframe Drain Plugs
The drive train system lubricant must be changed at least once a year, even if the 1000 hours
operational period has not elapsed.
1. To drain oil, warm it, remove the oil dipstick and remove the drain plugs (2 plugs) in the bottom
of the rear part of the main frame.
2. Drain out the used oil into a suitable container restore the drain plugs and pour new lubricant
into the main frame through the filler tube (Fig. 5.51) to bring the level up to the (FULL) mark on
the dipstick.
3. Check the oil level and reinstall the dipstick.
5.19.3. DRIVE TRAIN PRESSURE FILTER REPLACING
Fig. 5.53. Drive Train Oil Pressure Filters
IMPORTANT: If the pressure filter warning light on the instrument panel remains on at the
operating oil temperature with the engine running, the restricted pressure filter must be
changed.

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1. With the engine stopped, operate the steering levers several times to relieve any pressure.
2. Remove all outside dirt from the filter, Fig. 5.53 and using a filter wrench remove the filter.
Clean the filter head in the seal contact area.
3. Fill the new filter with the clean oil and coat the seal of the new filter with clean oil (Fig. 5.54).
Install the new filter, turning it until the seal just contacts the filter head and tighten the filter an
additional 1/4 to 1/2 turn.
4. Start the engine and let it idle for approximately 5 minutes. During this time operate the
steering levers several times, check filters for leaks and remove leaks if any.
5. Check the oil level in the rear part of mainframe.
Fig. 5.54. Drive Train Pressure Filter Replacing
5.19.4. DRIVE TRAIN SUCTION FILTER SERVICE
IMPORTANT: Keep the disassembled filter parts clean. Protect them from dirt.
The suction strainer should be serviced with every change of oil in main frame.
1. Remove all outside dirt from the filter (2, Fig. 5.55) between the housing (8, Fig. 5.55) and
head (1).
2. Remove the four nuts and separate the housing from the head. Remove the housing.
3. Remove the element (3) with ceramic magnets (4). Clean the magnets with clean soft cloth.
IMPORTANT: Do not strike the magnets.

4. Wash the element (3) and housing (8) using the commercial solvent and dry thoroughly.
5. Install magnets (4) with retainer rings (5) on the element (3).
6. Install new O-rings. Check that the O-ring (7) is in place in the groove in the element (8).
7. Install the spring (6) with housing (8) into head. Tighten the nuts to 17 – 21 [Nm].
8. Start the engine and let it idle for approximately 5 minutes. During this time, check the strainer
for leaks. Check the oil level in the rear part of mainframe.

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view from machine bottom

Fig. 5.55. Drive Train System Oil Suction Strainer
1. Filter Head 4. Magnet (6 pcs.) 7. O-ring
2. O-ring 5. Pressing Ring 8. Housing
3. Filter Element 6. Spring
5.19.5. SERVICING THE TRANSMISSION SCAVENGER STRAINER (Fig. 5.56)
With the transmission system drained after 1000 hours of operation, remove the scavenger oil
strainer and clean as described below:
1. To gain access to the oil strainer first remove the transmission guard.
2. Disconnect the transmission scavenger hose from intake pipe.
3. Remove the strainer from the transmission housing.
4. Clean the strainer with nonflammable commercial cleaning solvent.
5. Reinstall the strainer into the transmission housing.
6. Reinstall the transmission scavenger hose to pipe.
7. Reinstall the transmission guard.
Fig. 5.56. Transmission Scavenger Oil Strainer

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5.19.6. DRIVE TRAIN BREATHER SERVICE
IMPORTANT: To prevent dirt from entering the critical areas of the drive train, keep the
breather clean.
Replace the breather (2, Fig. 5.51) when changing oil in the mainframe. The breather is located
next to the filler tube at rear part of the main frame. Unthread the breather from the reducer nipple.
Thread the new breather to the nipple.
5.20. SUSPENSION
CHECKING THE UNDERCARRIAGE CONDITION
Periodically make observation checks on your undercarriage components. Check the tracks, track
rollers, track idlers, front idlers etc. for abnormal wear. Make adjustments to these problems before
damage to the components occur. Once the wear on these components drops below zero percentage
the option to recondition will also be lost.
Refer to the machine Service Manual for dimensions indicating percentage of allowable wear. If
this Service Manual is not available contact Authorized Distributor of Construction Equipment.
Regular chassis component cleaning decreases their wear and extends their life during their
operation. Dirt removal aims at avoiding unnecessary material excess buildup and solidification. It
is recommended to remove excess dirt, mud, rubbish and other contamination from the side
gearboxes, sprocket and tightening wheel, stabilizer beam ends, transverse shaft, track and
supporting rollers at the end of each shift – see Fig. 5.57. The machine equipment also includes
a shovel to facilitate cleaning (Fig. 5.58).
Fig. 5.57. Chassis System Components – Cleaning Location for Daily Service

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Fig. 5.58. Location of Shovel to Remove Contamination from Chassis Components

After each 1000 hours of operation check the torque of the sprocket rim mounting hardware and
torque, if necessary. Sprocket segments mounting nuts tightening torque is 900 [Nm].
WARNING! Special knowledge and equipment are required to service sealed and
lubricated track systems and their components. Unless you are completely
familiar with servicing lubricated track systems do not make any attempt to
remove them. Disconnecting the master link could cause the chain to whip off the
front idler causing serious personal injury.
Improper track tension, undercarriage track components blocked by mud and other foreign objects
as well as loose track shoes will cause damage and premature wear to the track.
5.20.1. TRACK SHOE BOLTS
The bolts used for attaching the track shoes to the tracks are heat-treated alloy bolts and will stand
a considerable tightening strain. Ordinary bolts and nuts must not be used. Nuts must be
assembled so that washer face is not against track link. Radius side of nuts must be against track
link. If removed or new coat bolt threads and area under the head with engine oil. Check the torque
value for 1100 [Nm]. The full torque for new bolts or retorquing is obtained by torquing a bolt to
a value of 650 ± 70 [Nm] and then turning the bolt an additional 120 degrees.
5.20.2. EFFECT OF TRACK ADJUSTMENT ON UNDERCARRIAGE WEAR
Tracks adjusted too tightly increase operating loads on final drives and accelerate wear on
undercarriage components, especially in packing conditions. A machine in forward operation with
correctly adjusted tracks will experience track loads only along the ground from the front idler to
where the bushings engage the sprocket.
Lubricated track systems are to be adjusted to provide a sag in the track chain between the front
top idler and the front idler. Correct tension reduces stress levels throughout the undercarriage
system.

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5.20.3. CHECKING THE TENSION
Fig. 5.59. Checking Track Tension

A. Track Sag of Lubricated Chain
1. Drive the machine forward until the track chain is tight along the ground and around the
sprocket. Apply and lock the brake pedal, lock the transmission shift lever in NEUTRAL
position and stop the engine, turn the master switch off and remove the key. Track tension
measurement after drive in reverse and stopping shall give incorrect results.
2. Stand on the track between the front idler and the first track idler in order to accumulate all the
chain slack at this point.
3. Place a straightedge on the track so the ends rest over the front idler and track idler. Measure
the clearance between the bottom of the straightedge and the top of the shoe grouser with
a ruler at the midway point between the idlers. If the distance is more than 64 [mm] or less than
38 [mm], adjust the track tension.
4. For mud and snow packing conditions lubricated track should be adjusted so its sag is
64 to 76 [mm], respectively.
5.20.4. ADJUSTING TENSION

The track chains are adjusted by hydraulic pressure. When lubricant is introduced into the front
idler fork through the lubrication fitting, it acts upon the piston within the front idler fork forcing the
front idler fork and front idler forward for track adjustment.
DANGER! To avoid possible injury, always stand to the side of the bleeder plug
when making track adjustment. The pressure in the front idler fork is held by the
check valve and safety valve. A loose or improper thread fit of either of these parts
can allow them to be ejected by the pressure of lubricant, causing possible injury.
When relieving track tension, never loosen the check and safety valves more than
2 – 2 ½ turns.

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1. Remove the bolts and track adjuster cover.
WARNING! Before adding lubricant for track adjustment, be sure the ball check
and relief valves are properly torqued to 61 – 75 [Nm].
Fig. 5.60. Hydraulic Track Adjuster

1. Safety Valve 2. Lubrication Fitting (Check Valve)
2. To increase track tension, connect a lubricator nozzle to lubrication fitting (2). Determine the
amount of adjustment necessary, and add lubricant to obtain the proper track chain tension. It
is advisable to move the machine forward and backward slightly to be sure the correct tension
has been obtained.
3. To reduce track tension, clean relief passages with wire first and then loosen relief valve (1)
half to one full turn to allow the pressurized lubricant to escape through the relief passage. If
lubricant does not appear, loosen the ball check valve (located under grease fitting (2)) ½ to
one full turn to allow the pressurized lubricant to escape from the second relief passage.
4. If lubricant still does not appear, use the following emergency method. Should the relief
passages still be blocked, unscrew the relief valve and/or return valve that is beneath the lube
fitting an additional 1 to 2 turns (2 ½ total turns).
DANGER! Use extreme care when relieving pressure with the following emergency
method. If loosened excessively, the cylinder pressure can eject the ball check or
relief valve. NEVER loosen these parts more than a total of 2 ½ turns.
5. When the proper tension has been obtained, tighten the ball check and/or relief valve to
61–75 [Nm]. Install the cover and secure with the removed hardware.
IMPORTANT: Never remove one link to bring a stretched track to within the range of
proper track adjustment. A track that is worn badly enough to take up the length of one
link, will be so far out of pitch that the increased wear on the sprocket will far more than
offset the saving obtained by the removal of one link in the track chain.

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5.20.5. TRACK FRAME GUIDE
To avoid excessive wear of undercarriage components and track frame suspension points, the
track frame guide must be lubricated and checked and adjusted for wear periodically.
Fig. 5.61. Track Frame Guide Lubrication
Fig. 5.61A Track Frame Guide

1. Outer Wear Plate 5. Inner Wear Plate
2. Track Frame 6. Guide Plate Shims
3. Shims 7. Track Frame Guide Plate
4. Guide Bar Block 8. Track Frame Guide Plate
Measure clearances “A” and “B”. If the total is 6.5 [mm] or more, adjust by removing shims (3) from
between spacer blocks (4) and inner wear plate (5). The same number of shims is to be removed from
upper and lower guide. Remove enough shims to reduce the total clearance (A+B) to 0.8 [mm]. Keep
the removed shims for future use.
If the removal of all shims (4) do not provide a total clearance of substantially less than 6.5 [mm],
replace wear plates (1 and 5), worn guide plate (7), as required. Reinstall the shims and repeat the
check. Lubricate track frame guides in clearances “A” and “B”.

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5.20.6. TRACK FRAME SUSPENSION
Fig. 5.62. Filler Plug and Dipstick in the Track Frame Pivot Shaft Housing
Remove the plug with the dipstick (one at each side) and check the oil level in the pivot shaft
housing. If the oil level is below the bottom dipstick line add oil up to the upper line. Refer to the
“REFILL LUBRICANT AND FLUID SPECIFICATIONS CHART” for grade of lubricant specified.
Install the plug with the dipstick.
5.20.7. FRONT IDLER GUIDES
Periodically check the front idler guide’s thickness (Fig. 5.63) at the RH and LH side of the track
frame. If the guide “A” thickness does not exceed 20.3 [mm], the guide is to be replaced.
Fig. 5.63. Front Idler Guides

1. Guide A. Minimum Guide Thickness 20.3 [mm]

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5.21. ADJUSTING HAND AND FOOT CONTROLS
5.21.1. ADJUSTING BRAKE PEDAL
Check adjustment of the brake pedal as described in Fig. 5.64 and Fig. 5.65.
Adjust the brake pedal position by the length (3, Fig. 5.65) to maintain dimensions [mm] of the
following positions per Fig. 5.64:
Fig. 5.64. Adjusting Brake Pedal

A – Brake Pedal in Position “OFF”, RB; and LB Brakes Released (~57 mm)
B – Brake Pedal in Position “beginning of braking - ~110 [mm]
C – Brake Pedal in Position “full braking” ~117 [mm]
(Brakes Fully Applied – Pressures RB and LB = 0,0 [MPa] (~117 mm)
Fig. 5.65. Adjusting Brake Pedal

1. Brake Pedal Lever 3. Brake Pedal Rod A – Spring Distortion
2. Locknut 4. Fork B – Gap 6 [mm]

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When the brake is in fully depressed position, the rod spring distorts and the gap occurs at
point “A”. In this position, the distance “B” of the brake lever from the panel should be about
6 [mm];
After the adjustment has been made secure adjusted linkage with locknuts, lubricate linkage and fill
bearings with grease through the lubricating fittings (refer to “LUBRICATING POINTS”) and check if
the machine is stopped with the brake pedal applied.
5.21.1.1. BRAKE TEST
DANGER! Use extreme care when performing brake checking operations on the
machine.
Perform a brake test as follows:

 Start the engine and bring the drive train system to the operating temperature by applying
periodically the third gear with the brake applied and engine maximum RPM,
 Apply the 2nd low range gear with the brake engaged and the engine at maximum RPM.
The machine is to remain motionless if the brake is adjusted correctly.
If in doubt, contact Authorized Distributor of Construction Equipment.
5.21.2. CHECKING ENGINE AND DECELERATION RPM
Check the engine high, low and deceleration RPM.

1. Start the engine.
2. Set the engine speed control knob at low RPM. The corresponding RPM for this knob position
ranges from 700 to 800 [RPM]/
Set the engine speed control knob at high RPM. Corresponding RPM shall range from 2000 to
2100 [RPM].
3. Set the engine speed control knob at high RPM. Depress decelerator pedal. Corresponding
RPM shall range from 1100 ± 50 [RPM].
Fig. 5.66. Decelerator Pedal Adjust Bolt

If engine low and/or high RPM falls outside specification at a given speed ranges, do not hesitate to
contact the Authorized Construction Machinery Distributor.
Use a adjust bolt (Fig. 5.66) to set the deceleration speed if this is a case.

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5.22. OPERATOR’S CAB
5.22.1. CAB FASTENING
TD-25M series-1 dozer is equipped with the integrated ROPS/FOPS cab.

Periodically perform manual inspection for loosen M27 nuts (4 pcs) of the ROPS/FOPS cab
securing bolts – on both machine sides (refer to Fig. 5.66).
Check and tighten the mounting bolts of the mirrors, lamps and shields.
Fig. 5.67. M27 Nuts for Operator's Cab Mounting Bolts
5.22.2. CAB REMOVAL AND INSTALLATION
CAB REMOVAL
Fig. 5.68. ROPS/FOPS Cab

1. ROPS/FOPS Cab RH Side Box

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1. Position the machine in place suitable for using hoisting equipment for disassembled
assembles.
2. Turn electrical master switch to the "OFF" position.
WARNING! Before working on a machine, be sure that the blade and ripper have
been lowered to the ground, the engine is OFF, the drive train lock lever is in its
lower locked (ON) position and parking brake is applied. The machine electronic
system switch and the electrical system master switch are both turned OFF, keys
are removed and controls are tagged to prevent inadvertent engine starting.
3. Remove the RH box (2, Fig. 5.68) and the box located on the left side of the machine.
4 1
2
5
Left side Behind the Cab RH Side Box

Fig. 5.69. Air Conditioning System Connection Disassembly Points
1. Hose Quick Coupling (Evaporator – Compressor)
2. Hose Quick Coupling (Heater – Engine)
3. Hose Quick Coupling (Heater – Engine)
4. Bolt
5. Cover
4. Remove 4 bolts (4, Fig. 5.69) and remove the covers (5) on both sides of machine.
5. Disconnect the quick couplings of the condenser hoses and the electrical harness under the
cover (5) on the left machine side. Protect them against damage and dirt.
6. Disconnect the quick couplings of the air conditioning system hoses (1, 2 and 3) on the right
side of the machine. Protect them against damage and dirt.
7. Remove the right and left plastic covers (4 and 6, Fig. 5.70) and the rear (5) cover inside the
cab.
8. Remove the floor mat (7).
9. Disconnect the cab power electrical harnesses (2 and 3).
NOTE: Disconnected electrical harnesses (plugs) must be protected against damage, dirt, oil,
grease and water.

SECTION 5
MAINTENANCE
PAGE 80
10. Tag and disconnect the window washer hoses (1) where they connect to the check valve.
11. Attach crane hoist to the cab lifting points.
12. Remove the bolts (1, Fig. 5.72) on the cab door frame (on both machine sides).
Fig. 5.70. Cab Disconnection Points – Electrical System Harnesses

1. Window Washer Hose 5. Rear Plastic Cover
2. Cab Power Harness Connector 6. Left Plastic Cover
3. Cab Power Harness Connector 7. Floor Mat
4. Right Plastic Cover
13. Remove the bolts and remove the strips from the door tresholds and remove the bolts (2) on
both cab entrance sides.
14. Remove the bolts (5) on the cab rear and the bolts (3) on the left and right cab side.
15. Remove the nuts and remove the bolts (4) that fasten the cab to the ROPS brackets (both cab
sides.)
16. Lift the cab and position the cab at prior prepared stand, protect cab seal against damage.
CAB INSPECTION
1. Check the cab structure and components for damage.
2. Check and complete the lacking insulation’s elements of cab.
3. Inspect the electrical harnesses, repair broken plugs, cables and braids, if necessary.
4. Check the air conditioning and window washer hoses.
5. Check the seal gasket between the cab and platform for defects in spots where dust could
penetrate inside the cab.

SECTION 5
MAINTENANCE
PAGE 81
CAB INSTALLATION
1. Attach the hoist to the cab lifting points, position the cab on the platform.
NOTE: The ROPS-FOPS cab bolt tightening sequence must be kept accurately (see points 2 to 8
below.) Any change in torquing procedure may lead to cab stress and deformation.
2. Tighten the cab to the platform with two M14 bolts (without mounting sleeves) until the mating
surfaces are flush (Fig. 5.71). Access to bolts after opening the side boxes.
Fig. 5.71. Cab Attachment Points to The Platform - 2 pcs M14 Bolts Location
3. Install bolts (4 pcs) with washers (3, Fig.5.72) on both cab sides and tighten them alternately
to feel the resistance on the wrench.
4. Install the bolts (4 pcs) with washers (2) on both cab sides and tighten them alternately to feel
the resistance on the wrench.
5. Install the bolts (2 pcs) with washers (5) on the rear of the cab and tighten them alternately to
feel the resistance on the wrench.
6. Remove the bolts (2 pcs) with washers (1, Fig.5.71). Install the sleeves and reinstall them;
then torque-tighten the bolts (1) to 125 [Nm] ± 10%.
7. Torque-tighten the bolts (5, 3, 2, Fig.5.72) alternately to 125 [Nm] ± 10%.
8. Install the bolts (4 pcs) of the ROPS support brackets on both sides of the cab and pre-tighten
them with nuts and washers - see Fig. 5.73. Keep the gap S = 5 ÷ 7 [mm] between the washer
and bottom surface of ROPS bracket (see Fig. 5.74). After checking the gap setting, tighten
the 4 nuts alternately to 980 ± 50 [Nm].

SECTION 5
MAINTENANCE
PAGE 82
Fig. 5.72. Cab Mounting Points to Platform - Location M14 bolts (10 pcs) (Top View of the Cab)
1. Front bolts (both sides) 4. ROPS bracket bolts and nuts (both sides)
2. Door sill bolts (both sides) 5. Rear bolts
3. Side bolts (both sides)
Fig. 5.73. ROPS Bracket Bolts Location (4 pcs)

SECTION 5
MAINTENANCE
PAGE 83
Fig.5.74.Point (A, Fig. 5.73) - Setting the gap S = 5 ÷ 7 [mm] between the washer and bottom
surface of ROPS bracket
9. Connect the window washer hoses (1, Fig. 5.70) with the return valve as indicated.
10. Connect the cab power electrical harnesses (2 and 3).
11. Install the floor mat (7).
12. Install the RH and LH side plastic covers (4 and 6) and the rear cover (5) inside the cab using
the suitable screws.
13. Connect the quick couplings of the air conditioning system hoses (1, 2 and 3, fig. 5.69) on the
RH side of the cab.
14. Connect the quick couplings of the condenser hoses and the electrical harness under the
cover (5) on the LH machine side.
15. Install the RH side and LH side cab box (2, Fig. 5.68), if removed.
16. Install the covers (5) on both machine sides and secure with 4 pcs bolts (4, Fig. 5.69)
17. Turn the electrical master switch to the „ON” position. Start the engine. Refer to Operator’s
Manual. Check previously disconnected hydraulic lines for leaks. Shut the engine off.

SECTION 5
MAINTENANCE
PAGE 84
5.22.3. CAB AIR FILTERS
Periodically clean the cab outer air filter (Fig. 5.75).

Undo two latches and remove the filter. Clean the filter with compressed air directing the air in the
reverse direction to that of normal operation. Clean the filter housing inside. Reinstall the filter and
tighten the nuts that secure the cover.
Fig. 5.75. Cab Outer Air Filter

Periodically clean the cab air recirculation filter (Fig. 5.76).
Remove the ventilation grid and remove the air recirculation filter element.
Clean the filter with compressed air directing the air in the reverse direction to that of normal
operation.
Clean the filter elements’ housing inside. Install the filter and reinstall the ventilation grid.
Fig. 5.76. Cab Air Recirculation Filter

1. Cab Air Recirculation Filter
NOTE: If compressed air fails to remove the filter restriction, replace it with a new one.

SECTION 5
MAINTENANCE
PAGE 85
5.23. WINDSHIELD WASHERS
Refill the reservoir with washer liquid daily.
Fig. 5.77. Windshield Washer Reservoirs’ Filler Spout (Machine Left Side)
5.24. UTILITY BOX
This box (Fig. 5.78) is located in the engine roof. It can be used to hold tools needed for machine
operation and maintenance. The tools can be chosen from the list in Section 6. “LIST OF
SERVICE TOOLS FOR TD-25M series-1”.
The box should be locked with a key.
If you want to open the tool box insert the key (1) in the lock installed in the cover, turn if let and lift
the cover (2).
2
Fig. 5.78. Utility Box
1. Key 2. Deck Plate
To close, pull down on the deck plate (2) so the lock gets latched. Protect the box from opening
turning the key (1) right.

SECTION 5
MAINTENANCE
PAGE 86
5.25. SERVICING THE AIR CONDITIONER
IMPORTANT: During the season, in which the air conditioner does not operate for a long
time, periodically turn the conditioner on for several minutes. Set the conditioner for
maximum cooling to distribute the system oil to prevent compressor shaft seals from
drying.
NOTE: Periodically, depending on ambient conditions, clean the condenser, blowing it with
compressed air.
Periodically, check the following:

Possible system leak locations. Visible oil signs will indicate where leaks can be found.
In particular, check the compressor shaft seal for dirty oil which indicates the oil leak and damaged
seal. The inspection should be performed every 3 months.
A/C cooling efficiency;
- Ineffective A/C operation will point to dirty or dusty condenser fins. If this is the case, clean the
condenser taking care not to damage its fins. The inspection should be performed every
3 months.
- Remove dirt and dust as well as other contamination from the evaporator fins. The inspection
should be performed every 3 months.
- Clogged an air filter can decrease cooling effectiveness. Clean or replace the filter as described
in “CAB AIR FILTERS” in this Section.
Air Conditioning System Dryer Servicing (Fig. 5.79)
ASSESSING AMOUNT OF REFRIGERANT

When the air conditioning is enabled check if there are no bubbles in the refrigerant using the sight
glass to evaluate if there is a sufficient amount of the refrigerant. High amount of bubbles indicates
that the refrigerant level is too low while small amount or no bubbles indicate the sufficient level of
refrigerant.
DRYER REPLACEMENT PROCEDURE

Using the dryer with the dehydrant which is no longer capable of absorbing moisture will result in
blockage of the refrigerant circuit and may lead to the compressor damage.
If the dryer is fitted with the air conditioning system moisture level indicator replace the dryer if A/C
system gets compromised or if moisture indicator turns from blue to pink or white after a long
period of operation. Before the dryer installation and during the first 20 minutes of its operation the
color shown by moisture indicator can be disregarded.
When the moisture indicator is not used replace the dryer every 2 years.
NOTE: The dryer may be replaced earlier depending on the dryer operation conditions.
Replace the dryer if A/C system gets depressurized.
NOTE: Contact the Authorized Service of A/C equipment or Authorized Construction

Machinery Distributor to replace the dryer and to charge the A/C system with R134a
refrigerant.
Contact the Authorized Distributor of Construction Equipment if noisy operation of compressor or

blower is found.

SECTION 5
MAINTENANCE
PAGE 87
Fig. 5.79. Air Conditioner Dryer Location (Cab Rear)

1. Hydraulic Hoses
Fig. 5.80. A/C Condenser Location
IMPORTANT: A/C system condenser must be cleaned at regular intervals and kept clean.
If air flow through condenser coil and its fins is restricted, the A/C system pressure will
increase and system will get inoperative. Use compressed air of adequate pressure for
condenser cleaning making sure that its fins do not get damaged or bent. Deformed fins
must be restored to their original condition.
IMPORTANT: Drain tubes in the evaporator assembly that are used to evacuate
condensate (water) which is made during A/C operation must be kept clean. Cab windows
will get fogged after heating is put into operation if water is present in evaporator assy
housing. At high air temperature and humidity water accumulates in large volume what is
a normal
IMPORTANT: Evaporator may get frosted if air humidity is high resulting in that the air
output supplied to the cab by the blower in the evaporator assembly will diminish. In this
case turn off the A/C system and operate the blower at maximum speed for 2-3 minutes.

SECTION 5
MAINTENANCE
PAGE 88
AIR CONDITIONING SYSTEM FAULT DIAGNOSIS
Fault Codes
Press ON quickly three times to display the fault codes. The digital display will show all active fault
codes. When you press ON again the existing fault codes will be scrolled.
If the buttons are not pressed within 5 seconds the system will exit the diagnostic mode and normal
operation will be restored.
No fault ................................................................................................................ E0
CAB cab sensor circuit short-circuit ..................................................................... E1
Interrupted CAB cab sensor circuit ..................................................................... E2
EVAP probe circuit short-circuit .......................................................................... E3
Interrupted EVAP probe circuit ........................................................................... E4
DUCT duct sensor circuit short-circuit ................................................................. E5
Interrupted DUCT duct sensor circuit .................................................................. E6
Error – water valve circuit short-circuits ............................................................... E9
Error – interrupted water valve circuit ................................................................ E10
None Water valve does not respond.................................................................. E13
Inactive external/internal air circulation .............................................................. E14
Electronic or communication system error ......................................................... E17
Advanced Diagnostics:
The air conditioning advance diagnostic control panel provided the user with the system real-time
information on the control panel display that help with the air conditioning and heating system
service. The real-time information may help diagnose certain system problems.
Quickly press ON three times to enter the advanced diagnostics mode (error codes will be
displayed) and then immediately press and hold ON for 5 seconds. “CAB” will be displayed.
The real-time cab air temperature is displayed after a few seconds. This value is constantly
updated as well as any other value displayed on the control panel. When you press ON multiple
times again all available diagnostic information will be scrolled.
CAB – Cab air temperature

EVAP – Evaporator core temperature
DUCT – Cab air conditioning duct air temperature
HEAT – Water valve position (valve opening in [%])
A-C – A/C clutch engagement request (engaged/disengaged)
FAN – Blower fan speed (from 0 up to 100%)
Remember that the system may operate normally when the temperature is set or the blower fan
speed is changed in the advanced diagnostics mode to evaluate the system response.
Exit the Advanced Diagnostics Mode
SWITCH OFF the system to exit the advanced diagnostics mode.

SECTION 5
MAINTENANCE
PAGE 89
ADDITIONAL AIR CONDITIONING SYSTEM DIAGNOSTICS
No display on the screen

 Switch on the control panel pressing ON
 Check if the display is illuminated
 Check if the control panel is connected to the harness
 Check if the harness is correctly connected to the machine
Fan does not work
 Increase fan speed pressing the fan UP button
 Ensure the fan is connected to the harness, check all harness connections
 Check if the thermal switches and fuses are intact.
 If all other functions operate properly replace the electronic control unit (ECU)
No air conditioning system heating function
 Increase the heating temperature using the temperature UP button. Use the advanced
diagnostics to check if the water valve is open.
 Check all electrical harness connections.
 Check if all engine coolant shut-off valves are open.
 Check if the hot coolant enters the heater core verifying the flexible hose temperature.
 Check and replace the electronic water valve, if necessary.
 Check and replace the electronic control unit (ECU), if necessary.
No air conditioning system cooling function
 Decrease the temperature pressing the temperature DOWN button and activate the
defrosting mode. Use the advanced diagnostics to check if the A/C clutch is engaged.
 Check if the system is fully charged with the refrigerant.
 Check if there is voltage on the compressor clutch.
 Check if there is correct voltage on the clutch relay in the harness.
 Check all electrical harness connections.
 Check the clutch relay and replace it, if necessary.
 Check the high and/or low refrigerant pressure switches and replace them, if necessary.
 Check the compressor and clutch assembly and replace the clutch, if necessary.
System does not control the proper cab temperature.
 Check the cab air temperature sensor.
 Check if the recirculation inlet is not blocked.
 Check and replace the outlet air recirculation filter, if necessary.
 Change the temperature set point with small steps.
 Check if the water valve is operational (refer to – No air conditioning system heating
function above)
 Check if the compressor clutch is operational (refer to No air conditioning system cooling
function above)
The evaporator core is covered with ice and restricts air flow.
 Check the evaporator core probe.
 Check if the probe contacts the evaporator fins and is not inserted loosely.
 Relocate the probe and check the core temperature during operation using the advanced
diagnostics.
 Replace the evaporator core, if necessary.

SECTION 6
SPECIFICATION
SPECIFICATION SECTION 6
CONTENTS
PAGE
6.1. APPLICATION ............................................................................................................................... 3
6.2. TECHNICAL DESCRIPTION ......................................................................................................... 3
6.3. TECHNICAL PARAMETERS ......................................................................................................... 5
6.3.1. OVERALL DIMENSIONS OF DOZER: .......................................................................... 5
6.3.2. ENGINE.........................................................................................................................6
6.3.3. TORQUE CONVERTER ................................................................................................ 6
6.3.4. TRAVEL SPEEDS MAX [km/h] ...................................................................................... 6
6.3.5. TRANSMISSION ...........................................................................................................7
6.3.6. STEERING DRIVE ........................................................................................................ 7
6.3.7. FINAL DRIVES ..............................................................................................................7
6.3.8. TRACK FRAMES .......................................................................................................... 7
6.3.9. TRACKS ........................................................................................................................7
6.3.10. ELECTRICAL SYSTEM ............................................................................................... 7
6.3.11. WEIGHT (APPROXIMATE) ......................................................................................... 7
6.3.12. DRAWBAR PULL MAXIMUM ...................................................................................... 7
6.3.13. BLADE (Fig. 6.1) .........................................................................................................8
6.3.14. RIPPER .......................................................................................................................8
6.4. REFILL CAPACITIES [l] ................................................................................................... 9
6.5. SPECIAL TORQUES ................................................................................................................... 10
6.6. TORQUES VALUES FOR STANDARD METRIC FASTENERS.................................................. 11
6.7. TORQUE VALUES FOR STANDARD ENGLISH FASTENERS .................................................. 11
6.8. TIGHTENING TORQUES 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. WLIST OF SERVICE TOOLS FOR TD-25M series-1 ............................................................... 15
6.14. KINEMATIC SCHEMATIC ......................................................................................................... 17
6.15. DRIVE TRAIN HYDRAULIC SYSTEM ....................................................................................... 18
6.16. EQUIPMENT HYDRAULIC SYSTEM DIAGRAMS........................................................ 20
6.17. DOZER FUSE AND RELAY BOX DESCRIPTION..................................................................... 23

PAGE 3
6.1. APPLICATION
The TD-25M series-1 Crawler dozer has been designed to perform many different jobs at
housing and industrial construction sites in a variety of soils, bulk materials, etc.
• loosening the ground
• transporting materials at short distances
• leveling and terrain clearing,
• excavating,
• piling
• breaking piles and spreading,
• and other jobs using blade, ripper, winch and other specialty equipment.
The TD-25M EXTRA standard dozer is designed to operate in a tempered climate. The machine
can be adapted for operation in ambient temperature range +50 to –50 [°C].
6.2. TECHNICAL DESCRIPTION
The TD-25M series-1 includes the following main assemblies / systems:

• undercarriage
• mainframe
• superstructure
• drive train
• drive train hydraulic system
• mounted equipment
• equipment hydraulic system
• electrical system
UNDERCARRIAGE:
Undercarriage includes two box section track frames with track rollers, track idlers and front idlers.
Track frames are attached to the rear part of the mainframe by the pivot shaft and to pinned
equalizer bar flexibly attached to the saddle in the front mainframe. The track chain with track
shoes envelops the sprocket, track idlers, front idler and track rollers.
Track tension can be hydraulically increased with a hydraulic cylinder filled with grease to force the
front idler forward for track chain adjustment.
MAINFRAME
The mainframe includes the front frame that is welded to the mainframe.
The frame provides room for bolted radiator/coolers, engine, transmission, steering, final drives
and superstructure elements.
SUPERSTRUCTURE
Superstructure includes engine hood and side guards, instrument panel, operator’ s platform and
operator’ s seat, fenders, battery box, fuel tank, hydraulic reservoir, cab with air conditioner.
DRIVE TRAIN
The drive train includes the following components:
• engine with radiator
• torque converter (TK),

SECTION 6
SPECIFICATION
PAGE 4
• universal joint,
• transmission,
• pinion/bevel gear set and steering drive,
• final drives.
Engine power is transmitted through a torque converter, universal joint, transmission, pinion/bevel
gear set and steering drive to two final drives with mounted sprockets.
A three-speed powershift transmission combined with two-speed steering gives six speeds forward
and six speeds reverse.
Steering is accomplished by the application of clutch packs in the steering drive.
DRIVE TRAIN HYDRAULIC CONTROL SYSTEM

The transmission system includes an oil tank which is the rear frame, suction , dual gear pump,
pressure s, main regulator valve, rate of rise valve, range selector valve and transmission and
steering drive control valves.
MOUNTED EQUIPMENT
• Semi-U Blade (D-2 attachment)
• Full-U Blade (D-2 attachment)
• G-2 Straight Angle Blade (on C Frame)
• Coal Blade (D-2 attachment)
• Single and Multi Shank Ripper
• Drawbar
Blade lift and lower movements are accomplished with two blade lift cylinders, while blade tilt to the
right and left – is accomplished with two or one hydraulic cylinder(s). Forward or backward blade
pitch is ensured with two hydraulic cylinders or mechanically.
Multi-shank ripper – 3 shanks, tool beam raised and lowered with hydraulic cylinders, ripper
shanks are equipped with hydraulic pitch and can be adjusted in two vertical positions for slight
and deep ground penetration.
Single-shank ripper may be equipped with hydraulic pin puller to lock the ground penetration depth
(shank pushing).
Fixed drawbar with vertical pin.
EQUIPMENT HYDRAULIC SYSTEM

The equipment hydraulic system consists of:
• hydraulic reservoir with sight gauge and positive and vacuum pressure valve with filter
• suction filter
• hydraulic three section vane pump
• pilot valves
• control valves with a pressure relief valves
• hydraulic cylinders
• return filters
• various valves, pilot pressure filter
• oil cooler
• variable output piston pump, oil cooler, hydraulic motor providing drive to the fan and return
filter

PAGE 5
6.3. TECHNICAL PARAMETERS
6.3.1. OVERALL DIMENSIONS OF DOZER:
Fig. 6.1. Dimensions
[mm]
H1. Height with cab .......................................................................................................... 3743
H2. Height with warning beacon ....................................................................................... 3910
H3. Height to exhaust pipe .............................................................................................. 3759
H4. Semi-U blade height ................................................................................................ 1760
H5. Maximum blade rise .................................................................................................. 1270
H6. Maximum blade penetration ........................................................................................ 600
H7. Clearance ...................................................................................................................575
H8. Maximum blade tilt ...................................................................................................... 880
H9. Maximum ripper shank point rise ................................................................................ 868
H10. Maximum ripper shank point penetration .................................................................. 760
H11. Height to air cleaner ................................................................................................ 3158
H12. Height to operator’s seat backrest ........................................................................... 3328
L1. Length between sprocket and front idler .................................................................... 3270
L2. Length between radiator enclosure and sprocket grouser .......................................... 5083
L3. Length between radiator enclosure and ripper outmost point ..................................... 7128
L4. Length between blade cutting edge and ripper toolbeam rear face
(vertical shank – semi-U blade) ............................................................................... 8375
L5. Length between blade corner and radiator enclosure
(semi-U blade) ......................................................................................................... 1475
L6. Length between main frame rear face and radiator enclosure ................................... 4432
L7. Length between main frame rear face and toolbeam rear face
(ripper shank in its front outmost position and mounted at bottom hole) ................... 2475
L8. Length between radiator enclosure and drawbar rear face ........................................ 5402
W1. Gauge ...................................................................................................................... 2140
W2. Semi-U blade width without end cutting edges ......................................................... 3930
with end cutting edges ............................................................................................ 4050
W3. Width, including trunnions ........................................................................................ 3372
α. Blade maximum pitch angle ....................................................................................... 10 [°]
CAUTION: Vertical dimensions as showed include the track grouser height

(76 [mm]).

SECTION 6
SPECIFICATION
PAGE 6
6.3.2. ENGINE
*Make and Model ........................................................................................... CUMMINS X15

Type .................................................................................................................. 4-cycle diesel,
turbocharged with CAC, electronically controlled Common Rail fuel system (HPCR)
Displacement...............................................................................................................15 [dm³]
No of cylinders........................................................................................................................6
Bore diameter and piston stroke ..................................................................... 137 x 169 [mm]
Control ..................................................................................................................... electronic
Gross flywheel power @ 2000 RPM per SAE J1995 ..................................................280 [kW]
**Net flywheel maximum power @ 2000 RPM per SAE J 1349/ ISO 9249 ................ 277 [kW]
Torque max. @ 1200 RPM ..................................................................................... 2169 [Nm]

RPM:
low................................................................................................................. 700 ÷ 800 [RPM]
high .......................................................................................................... 2000 ÷ 2100 [RPM]
decelerator ................................................................................................... 1100 ± 50 [RPM]
Cranking .................................................................................................................... Electrical
*Meets the US EPA Tier4 Final and EU Stage V emission standards.

** Maximum net power at minimum cooling system fan speed
Remark
Engine rated net power @ 2000 [rpm] according to SAE J1349/ISO 9249
at maximum cooling system fan speed ..................................................................... 246 [kW]
6.3.3. TORQUE CONVERTER

Type ....................................................................... single-stage, single phase, engine mount
Rotor Dia. .................................................................................................................. 415[mm]
Dynamic ratio .............................................................................................................. 2.45 : 1
6.3.4. TRAVEL SPEEDS MAX [km/h]

Forward: [km/h]
1st, low range ............................................................................................................... 0 ÷ 3.0
1st, high range .............................................................................................................. 0 ÷ 3.9
2nd, low range ............................................................................................................... 0 ÷ 5.1
2nd, high range ............................................................................................................ 0 ÷ 6.6
3rd, low range ............................................................................................................... 0 ÷ 8.0
3rd, high range ........................................................................................................... 0 ÷ 10.1
Reverse:
1st, low range ............................................................................................................... 0 ÷ 3.7
1st, high range .............................................................................................................. 0 ÷ 4.8
2nd, low range ............................................................................................................... 0 ÷ 6.2
2nd, high range ............................................................................................................ 0 ÷ 7.9
3rd, low range ............................................................................................................... 0 ÷ 9.3
3rd, high range ........................................................................................................... 0 ÷ 11.7

PAGE 7
6.3.5. TRANSMISSION
The transmission provided with “POWER SHIFT” parallel shafts and multi-disk clutch packs
hydraulically actuated.
Gears ................................................................................................ 3 forward and 3 reverse
6.3.6. STEERING DRIVE

Type: 2-speed with a planet gear on each side and hydraulic powered multiple-disc clutches and
brakes. Separate steering for each side. Separate steering for each side. Brakes applied
automatically at engine shut down.
6.3.7. FINAL DRIVES

Type: 2-stage, planet. Sprocket rim split: 8-segment set.
6.3.8. TRACK FRAMES

No of track rollers on each side .............................................................................................7
No of top idlers on each side ..................................................................................................2
All rollers and front idlers: ........................................................................... life time lubricated
Track frame pivot swing amplitude at the front idler axis ........................................... 406 [mm]
6.3.9. TRACKS
Track chain lubricated with a standard split link.
Track shoe width, standard ...................................................................................... 560 [mm]
Track shoe width, optional ......................................................610 [mm], 660 [mm], 710 [mm]
No of shoes, each side .......................................................................................................39
Track on ground for standard shoes .......................................................................... 3.66 [m²]
Track shoe grouser height ........................................................................................... 76 [mm]
Track chain adjustment ..............................................................................................hydraulic
6.3.10. ELECTRICAL SYSTEM
Voltage ............................................................................................... 24 [V] (negative ground)

Batteries (maintenance-free) ................................................................................. four,12 [V]
Alternator ..................................................................................................................... 105 [A]
6.3.11. WEIGHT (APPROXIMATE)

Machine with a dozer equipment (semi-U blade) and drawbar ............................... 35980 [kg]
Machine with a dozer equipment and single shank ripper ....................................... 41250 [kg]
6.3.12. DRAWBAR PULL MAXIMUM

The dozer maximum draw bar pull with the 1st gear engaged and at maximum engine RPM will be:
794 [kN].

SECTION 6
SPECIFICATION
PAGE 8
6.3.13. BLADE
(Fig. 6.1)
Coal
Type Full (U) Semi-U Bull
blade
Max capacity acc. to SAE J-1265 [m³] 11.5 9.6 5.7 21.0
Max effective shoe width [mm] 711 711 711 711
Blade dimensions:
 Width (bit to bit) [m] 4.35 4.05 4.95 5.61
 Height [m] 1.76 1.76 1.26 2.10
Max. blade rise to corner
 in horizontal position [m] 1.27 1.27 1.37 1.27
Max. blade drop (below the ground level, [m] 0.6 0.6 0.66 0.6
Max. blade tilt [m] 0.945 0.88 0.435 1.22
Max. blade pitch angle [º] [°] 10 10 ---- 10
Average blade lift rate (@ nominal engine
[m/s] 0.40 0.40 0.40 0.40
[RPM])
Blade weight [kg] 6280 5640 5460 7720
Angle [º] [°] ---- ---- ±25 ----
6.3.14. RIPPER
Type multi-shank single-shank

Type of shank standard standard deep dig
Tool Beam
 Width, total [mm] 2485 1450 1450
 Section (height x width) [mm] 380x478 400x550 400x550
Clearance under tool beam:
 with fully raised ripper [mm] 1544 1565 1565
 with ripper lowered [mm] 171 154 154
Shanks:
 max. number of shanks 3 1 1
 spacing [mm] 1067 ---- ----
 max. penetration [mm] 760 1250 1700
 clearance when fully raised [mm] 868 770 760
 no of shank penetration positions 2 4 6
Weight:
 - total with one shank [kg] 5100 5280 5370
 - each additional shank [kg] 320 ---- ----

PAGE 9
6.4. REFILL CAPACITIES [l]
Service
Total System
No. Name of the Machine System capacity
Capacity
(± 0.5 [dm3])
[dm3] [dm3]
1. Engine Lube System with Oil Filter 49 48
Drive Train System

2. (rear frame, suction strainer, pressure filters, gear box 240 195
strainer)
Attachment D-2
195 —
(without ripper)
Equipment and Fan Drive
Blade tilt assy 12 —
System (oil tank, return
3.
filters, control filters, fan Ripper with shank pitch 63 —
system filter)
Hydraulic Oil Tank with
— 131
Filters
0,9
Track Roller —
(each)
1,1
Top Idler —
(each)
Drive Train Components
4.
(lubricated for life)
0,8
Front Idler —
(each)
0,03
Track chain link —
(each)
64 54
5. Final Drive
(each) (each)
17 17
6. Track Frame Pivot Shaft Housing
(each) (each)
7. Engine cooling system 66 66
8. DEF Reservoir 38 —
9. Fuel tank 770 —
3,8
10. Windows Washer Reservoir —
(each)
11. Air Conditioner 1.35 [kg] —
12. Grease Fittings as needed as needed

SECTION 6
SPECIFICATION
PAGE 10
6.5. SPECIAL TORQUES
Size of [Nm]
thread
1. Battery Hold Down Bolt M10 9
2. Battery Terminal Nut 3/8-16 31
3. Headlamp Stud Nut M8 51
4. Track Adjuster Relief Valve 5/8-18 70
5. Track adjuster check valve 5/8-18 70
6. Alternator Mounting Hardware 1/2-13 90
7. Alternator Pulley Nut 5/8-18 95-108
8. Blade Lift Cylinder Yoke Bearing Cap Bolt 1/2 130
9. Main Frame Cover Bolt 3/4-10 450
10. Lift Cylinder Yoke Bolt 3/4 450
11. Diagonal Strut Clamping Bolt 3/4 450
12. Sprocket Upper Rock Deflectors Mounting Bolt M20 520
13. Track Frame Pivot Shaft End Mounting Bolt M20 520
14. Equalizer Bar Rebound Bracket Mounting Bolt M20 520
15. Cab platform to Cab Shock Absorber Mounting Nut M20 600±50
16. Track Roller Shield Bolt and Nut M24 845
17. Sprocket Lower Rock Deflectors Mounting Bolt M24 845
18. Top Roller Bracket Mounting Bolt M24 845
19. Pusharm Trunnion Guard Mounting Bolt M24 845
20. Rock Deflector Mounting Bolt under Final Drive 1 845
21. Sprocket Segment Mounting Nut 7/8-14 900
22. Final Drive to Mainframe Mounting Bolt 1-8 920
23. Steering Drive to Mainframe Mounting Bolt 1-8 920
24. Transmission to Mainframe Mounting Bolt 1-8 920
25. Engine Front Support Bar Bolt 1-8 920
26. ROPS/FOPS Cab To Platform Mounting Bolt Nut M27 980±5%
27. Blade Cutting Edge Nut 1 1050
28. Diagonal Strut Socket Cap Bolt 1 1050
29. Upper Strut and Tilt or Pitch Cylinder Socket Cap Bolt 1 1050
30. Engine Rear Support Bar Bolt 1-8 1110
31. Track Shoe Bolt 7/8-14 1100 (*)
32. Track Frame Guide Plate Bolt M30 1500
33. Blade Pusharm Bearing Cap Bolt 1-1/4 2100
34. Counterweight and Drawbar Mounting Bolt 1-1/2-12 3100±5%
35. Ripper Frame Mounting Bolt 1-1/2-6 3100±5%
NOTE
1. Torque values apply to phosphated and oiled fasteners such as screws, nuts, washers except for the
electrical fasteners.
2. Torques tolerances must be within ±10%, unless otherwise specified.
3. (*) Check torque 1100 [Nm]. When tightening the screws the surface of the thread and the face of the
screw head should be lubricated with engine oil. Tighten with the initial torque 650 ±70 [Nm], and then
tighten the screws by rotating through 120 [°].

PAGE 11
6.6. TORQUES VALUES FOR STANDARD METRIC FASTENERS
This chart provides tightening torque for general-purpose applications using original equipment
standard hardware.
Original equipment standard hardware is defined as coarse thread metric class 10.9 bolts and
class 10.0 nuts and thru hardened flat washers (Rockwell “C” 38-45), all phosphate coated and
assembled without supplemental lubrication (as received condition). The torques shown apply to
phosphate coated fasteners designed for 60% of yield strength. The torques shown also apply to
the following: phosphate coated bolts used in tapped holes in steel or gray iron; phosphate coated
bolts used with phosphate coated prevailing torque nuts (nuts with distorted threads or plastic
inserts), phosphate coated bolts used with copper plated weld nuts.
NOMINAL THREAD STANDARD TORQUE ±10%

[mm] [Nm]
6 10
7 16
8 23
10 46
12 80
14 125
16 200
18 275
20 385
22 530
24 670
27 980
30 1330
33 1790
36 2325
39 3010
6.7. TORQUE VALUES FOR STANDARD ENGLISH FASTENERS
This chart provides tightening torque for general purpose applications using original equipment
standard hardware as listed in the Parts Catalog for the machine involved. DO NOT SUBSTITUTE
HARDWARE. Original equipment standard hardware is defined as Type 8, coarse thread bolts and
nuts and through hardened flat washers (Rockwell “C” 38-45), all phosphate coated and
assembled without supplemental lubrication (as received condition). The torques shown below also
apply to the following: phosphate coated bolts used in tapped holes in steel or gray iron, phosphate
coated bolts used with phosphate coated prevailing torque nuts (nuts with distorted threads or
plastic inserts)., phosphate coated bolts used with copper plated weld nuts. Markings on bolt heads
or nuts indicate material grade only and are not to be used to determine required torque.

SECTION 6
SPECIFICATION
PAGE 12
NOMINAL THREAD STANDARD TORQUE 10%

DIAMETER [in] [Nm]
1/4 10
5/16 21
3/8 38
7/16 60
1/2 92
9/16 130
5/8 180
3/4 325
7/8 520
1 780
1-1/8 1110
1-1/4 1565
1-3/8 2050
1-1/2 2720
1-3/4 3380
2 5080
6.8. TIGHTENING TORQUES FOR SPLIT FLANGE CONNECTIONS
The following chart provides the tightening torques for split flange connections used in hydraulic
systems. Split flanges and fitting shoulders should fit squarely. Install all bolts, finger tight and then
torque evenly. Overtorquing bolts will damage the flanges and/or bolts, which may cause leakage.
Flange size [in]* Bolt Size [in] Torque Value [Nm]

1/2 5/16 20-24
3/4 3/8 30-37
1 3/8 37-47
1-1/4 7/16 47-61
1-1/2 1/2 62-79
2 1/2 75-88
2-1/2 1/2 107-123
3 5/8 187-203
3-1/2 5/8 159-180
* Inside diameter of hydraulic tube or hose fitting.

PAGE 13
6.9. TORQUE VALUES FOR HYDRAULIC TUBES AND FITTINGS
Torque values Torque values for O-ring

Tubing boss plugs, locknuts
O.D. Thread size for 37 [°] flared
Size fittings and 37 [°] flared fittings
in in inches
inches [Nm] [Nm]
4 1/4 7/16-20 12-16 8-14
5 5/16 1/2-20 16-20 14-20
6 3/8 9/16”-18 29-33 20-27
8 1/2 3/4-16 47-54 34-41
10 5/8 7/8-14 72-79 47-54
12 3/4 1-1/16-12 104-111 81-95
14 7/8 1-3/16-12 122-138 95-109
16 1 1-5/16-12 149-163 108-122
20 1-1/4 1-5/8-12 190-204 129-156
24 1-1/2 1-7/8-12 217-237 163-190
32 2 2-1/2-12 305-325 339-407
Above torque figures are recommended for plain, cadmium or zinc plated fittings, dry or wet
installations. These torques are not recommended for tube with wall thickness of 0.89 [mm] or less.
6.10. TORQUE VALUES FOR HOSE CLAMPS

The following chart provides the tightening torques for hose clamps used in all rubber applications
(radiator, air cleaner, operating lever boots, hydraulic system, etc.).
TORQUE ± 0.6 [Nm]

CLAMP TYPE AND SIZE Radiator, air cleaner, Hydraulic
booths [Nm] System[Nm]
“T” Bolt (any diameter) 6.2 to 7.3 -----
Worm clamp – open diameter up to and

2.2 to 3.3 4.5 to 5.6
including 1-3/4 [“]
Worm clamp – open diameter over 1-3/4” 4.5 to 5.6 -----
Worm Drive – ULTRA-TITE 10.7 to 11.8 4.5 to 5.6

SECTION 6
SPECIFICATION
PAGE 14
6.11. TORQUE VALUES FOR AIR CONDITIONING TUBES AND FITTINGS [°]
Torque values for materials [Nm]

Thread size
SIZE
[in] Copper- Aluminum-
Steel-steel bronze-steel
steel steel
1/4” 7/16-20 16/23” 15/20” 15/20” 12/18”
3/8” 5/8”-18 27/33” 23/38” 23/38” 20/25”
1/2” 3/4-16 47/54” 38/46” 38/46” 28/36”
5/8” 7/8-14 61/68” 45/53” 45/53” 34/42”
3/4” 1-1/16-12 72/80” 49/57” 49/57” 45/53”
1-1/16-14 72/80” 49/57” 49/57” 45/53”
6.12. TORQUE VALUES FOR AIR CONDITIONING O-RING CONNECTIONS
Torque values for materials

Connection [Nm]
Thread size [in]
size
Steel-steel
1/4” 7/16”-20 15/25”
3/8” 5/8”-18 27/33”
1/2” 3/4”-16 40/48”
5/8” 7/8”-14 47/54”
3/4” 1-1/16”-12 54/61”
1-1/16”-14 54/61”

PAGE 15
6.13. LIST OF SERVICE TOOLS FOR TD-25M series-1
No. Tool- Tool (across flats)

wrench Service (removal and installation)
size
1x5x100m
1 Flat Screwdriver Ether Reservoir Mounting Clamp Screw
m
2 6 mm Allen Hexagonal Key Fuel System Venting Plug
3 7/16 Open ended - Box spanner Air Intake Hose Clamp Bolts
Hydraulic Oil Reservoir Drain Plug (Standard

4 1/2” Allen Square Key
version)
Open ended - Box spanner Drive Train Suction Strainer Body Bolts
5 9/16
Open ended - Box spanner Battery Electric Cables Nuts
Open ended - Box spanner Battery Hold Down Strip Bolts
6 16 [mm]
Cab floor bolts
7 11/16 Open ended - Box spanner Mainframe Breather
Open ended - Box spanner Battery Box Cover Bolts
8 18 [mm]
Open ended - Box spanner Track Tension Adjuster Cover Bolts
Open ended - Box spanner Transmission Scavenger Strainer Hydraulic Tube
Flange Bolts
Open ended - Box spanner Coolant Shut off Valves
9 3/4” Open ended - Box spanner Track Adjuster (Relief and Check Valve)
Open ended - Box spanner Crankcase Oil Drain Plug Cover Bolt at Bottom
Guard
Open ended - Box spanner Hydraulic Reservoir Cover Bolts
Socket Radiator Assy Enclosure Bolts

10 24 [mm] Socket Transmission Bottom Guard Service Cover Bolts
Socket Hydraulic Reservoir Suction Strainer Nut
11 27 [mm] Socket Fluid Filter Cap (DEF)
Socket Blade Pusharm Trunnion Cap Bolts
12 30 [mm]
Socket Transmission Bottom Guard Bolts
13 36 [mm] Socket Blade Pusharm Suspension Trunnion Bolts
14 41 [mm] Socket Śruby mocowania kabiny ROPS/FOPS
15 46 [mm] Open ended - Box spanner Equipment System Oil Reservoir Breather.
Socket Blade Pusharm Suspension Trunnion Cap Bolts
16 46 [mm]
Socket Track Frame Guide Bolts
Socket Track Shoe Bolts
17 1 5/16”
Socket Sprocket Segment Bolts

SECTION 6
SPECIFICATION
PAGE 16
Tool-
No. Tool (across flats) Service action
wrench size
Socket Wrench Blade and Cylinder Strut Ball End Cover Bolts
18 1 1/2”
Socket Blade Cutting Edge Nuts
1 ½” Final Drive Drain, Fill and Level Plugs, Mainframe Drain
Socket or Allen Plug
19 or
Square Key
½” Track Frame Pivot Shaft Housing Oil Filler Plugs
20 2 ¼” Socket Ripper Frame and Mainframe Drawbar Bolts
21 ¾” Knob
22 ¾”x200 [mm] Extension Tool
23 ½”x125[mm] Extension Tool
24 600 [mm] Pry Bar
25 20x175 Chisel
26 ~1000[g] Hammer
Drain Valve: Engine Oil, Hydraulic Reservoir (option)
27 ECO Drain Hose
and Coolant (option)
Coolant, Fuel and Engine Oil Filter
Ømax. Drive Train Pressure Filter, Fan Drive System Return
28 Filter Wrench
160 [mm] Filter, Equipment System Return Filter and Equipment
System Control System Filter
29 L-180 Snap Ring Pliers Hydraulic Reservoir Breather Filter Cover Snap Ring
30 CC2602 Test Kit Check engine coolant for concentration.
Check coolant freezing point and the density of the
31 CC2800 Refractometer
batteries electrolyte
32 Feeler Gauge Valve Lash Adjustment
Screen Fuel Filter
33 851-01-8157 Screen Fuel Filter Element Replacement
Flange Key
Range Pointer torque
34 Valve Lash Adjustment
0 ÷ 28 [Nm] wrench

PAGE 17
6.14. KINEMATIC SCHEMATIC
Fig. 6.2. Kinematic Schematic

1. Torque Converter
2. Drive Shaft
3. Transmission
4. Sprocket
5. Final Drive
6. Mainframe
7. Steering Drive

SECTION 6
SPECIFICATION
PAGE 18
6.15. DRIVE TRAIN HYDRAULIC SYSTEM
Fig. 6.3. Drive Train Hydraulic Schematic

PAGE 19
DESCRIPTION TO DRIVE TRAIN HYDRAULIC SYSTEM SCHEMATIC (Fig. 6.3)
1. Transmission
2. Screen Filter
2A. Suction Strainer
3. Double Pump
4. Lower Manifold
5. Pressure Filters
6. Torque Converter
7. Coolant Pump
8. Oil Cooler
9. ––
10. Mainframe
11. Steering Valve
12. Drive Train Control Valve
13. Range Selector Valve
14. Rate of Rise Valve
15. Pressure Regulator Valve
16. Pressure Diagnosis Center
PC – Gear Clutch Pressure M – (0.10÷0.17) [MPa]
FR – Direction Clutch Pressure M – (0 to 0.079) [MPa]
L – Lubrication Pressure 0.28÷0.45 [MPa]
C – Torque Converter Pressure 0.65 to 0.935 [MPa]
M – Main Pressure (1.79÷1.93) [MPa]
RB – RH Brake Pressure M – (0 to 0.035) [MPa]
Rc – RH Clutch Pressure M – (0 to 0.035) [MPa]
LB – LH Brake Pressure M – (0 to 0.035) [MPa]
Lc – LH Clutch Pressure M – (0 to 0.035) [MPa]
M1 – Control Pressure M + (0.10 to 0.20) [MPa]
17. Steering Drive

18. Drive Train Lock Solenoid Valve
19. Priority Valve
20. Gear Selector Valve
21. Hydraulic Damper
22. Towing Valve
23. Ripper Shank Pin Shifting Control System Connection
24. Pressure Switches - Driving System Control
PC – Pressure Switch – Transmission Gear Clutch (1.4 [MPa])
FR – Pressure Switch – Transmission Direction Clutch (1.4 [MPa])
F – Pressure Switch – Driving Forward [(0.5 MPa])
R – Pressure Switch – Reversing [(0.5 MPa])

SECTION 6
SPECIFICATION
PAGE 20
6.16. EQUIPMENT HYDRAULIC SYSTEM DIAGRAMS
EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
BLADE TILT CONTROL
RIPPER SHANK PIN PULLER CONTROL BLADE TILT AND PITCH CONTROL
Fig. 6.4. Mounted Equipment System Hydraulic Schematic

PAGE 21
DESCRIPTION TO DRIVE EQUIPMENT HYDRAULIC SYSTEM SCHEMATIC (Fig. 6.4)
1. Ripper Lift Cylinders

2. Ripper Pitch Cylinders
3. Blade Lift Cylinders
4. Blade Tilt Cylinder
4A. Blade Tilt and Pitch Cylinder
5. Main Control Valve (17,15 ÷ 17,85 [MPa])
6. Blade Quick Drop Valve
7. Main Control Valve
8. Blade Tilt and Pitch Control Valve (18,35 ÷ 19,1 [MPa])
8A Blade Tilt Control Valve (18,35 ÷ 19,1 [MPa])
9. Automatic Valve
10. Ripper Pilot Valve
11. Blade Pilot Valve
12. Direction Valve
13. Pressure Regulator (2.72 – 2.88 [MPa])
14. Return Filters
15. Filler Cap with Tank Breathing Valve
16. Hydraulic Pilot System Filter
17. Hydraulic Reservoir
18. Hydraulic Three Section Vane Pump
19. Equipment System Suction Strainer
20. Solenoid Ripper Shank Pin Control Valve
20A. Ripper Shank Pin Extension Solenoid Valve Coil
20B. Ripper Shank Pin Retraction Solenoid Valve Coil
21. Ripper Shank Pin Puller Cylinder
22. Blade Tilt and Pitch Solenoid Valve
22A. Blade Pitch Solenoid Valve Coil
22B. Blade Double Tilt Solenoid Valve Coil
A – Drive Train Connection (Steering Valve)
B – Overflow (Main Frame)

SECTION 6
SPECIFICATION
PAGE 22
FAN DRIVE HYDRAULIC DIAGRAM
Fig. 6.5. Fan Drive Hydraulic Diagram

1. Hydraulic Reservoir
1A. Fan Drive System Suction Filter
2. Pump with Control Module
3. Fan Hydraulic Motor
4. Cooling Module
5. By-pass Valve
6. Return Filter
7. Check Valve
8. Pressure Measurement Point

PAGE 23
6.17. DOZER FUSE AND RELAY BOX DESCRIPTION
The fuse box is located on the left side of the machine, in the fender (Fig. 6.6)
Fig. 6.6. Fuse Box Location
Fig. 6.7. Fuse and Relay Location (for machines S/N P000535 and above)

SECTION 6
SPECIFICATION
PAGE 24
Machine Fuse Box - RH Side

A. 15 [A] - ECM Engine Control Module Power
B. 15 [A] - ECM Engine Control Module Power
C. —
D. —
E. 10 [A] - PV780 Integrated Display Power
F. 15 [A] - Machine TTC60 Electronic Controller Power
1. 80 [A] - PDM1 Machine Power Distribution Power

2. 50 [A] - PDM2 Cab Power Distribution Power
3. 120 [A] - Engine Intake Air Heater Power
4. 80 [A] - Bottom Cover Winch Power (OPTION)
Machine Electrical System Power Fuse and Relay Strip - LH Side

1. 15 [A] - 24/12[V] Voltage Converter
4. 5 [A] - Machine Electronic System Switch
6. 5 [A] - Dome Light
13. 30 [A] - Ground Leveling System

14. 15 [A] - Lighter
15. 15 [A] - Operator Seat
16. 15 [A] - Cab Headlamp : 2 x left, 2 x right
17. 15 [A] - Cab LED Headlamps : 2 x rear (2 x front - OPTION)
18. 15 [A] - Cab Air Conditioning System
19. 15 [A] - Cab Air Conditioning Condenser Fans
20. 15 [A] - Cab Air Conditioning Condenser Fans
21. 10 [A] - CLEANFIX Reverse Fan Power System (OPTION)
22. 20 [A] - First Stage Fuel Filter Heater
S1 - Cab LED Headlamp Power Relay : 2 x left, 2 x right

S2 - Cab LED Headlamp Power Relay : 2 x rear (2 x front - OPTION)
S3 - CLEANFIX Reverse Fan Power System Relay (OPTION)
S4 - First Stage Fuel Filter Heater Relay

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FOR S/N P000535 AND ABOVE

TRANSLATION OF THE ORIGINAL MANUAL

We hope you enjoy operating Dressta machines.

DRESSTA TD-25 T4F / Stage V

SECTION 2 – SAFETY PRECAUTIONS

SECTION 3 – MACHINE TRANSPORT AND STORAGE

This section discusses how to ship or store this machine.

DRESSTA TD-25 T4F / Stage V

DRESSTA TD-25 T4F / Stage V

Fig. 1.1. Crawler Dozer TD-25M series-1

In addition to that the dozer can be equipped with the ripper:

DRESSTA TD-25 T4F / Stage V

1.2. MACHINE MARKING

Fig. 1.2. Serial Number on Machine

TD-25 T4F / Stage V DRESSTA

Fig. 1.3. Machine Serial Number at Main Frame

Fig. 1.4. Blade Serial Number

DRESSTA TD-25 T4F / Stage V

Fig. 1.5. Ripper Serial Number

TD-25 T4F / Stage V DRESSTA

Fig. 1.7. Engine Data Plate

Fig. 1.8. Engine ECM Module Plate

DRESSTA TD-25 T4F / Stage V

Fig. 1.9. ROPS/FOPS Integrated Cab Plate

TD-25 T4F / Stage V DRESSTA

DRESSTA TD-25 T4F / Stage V

WORK SAFETY – FOLLOW THESE RULES

Safety Related Information

The customer is obliged to provided the appropriately organized workplace

DRESSTA TD-25 T4F / Stage V

Using Safety Equipment

Be Prepared for Emergency Situations

TD-25 T4F / Stage V DRESSTA

DRESSTA TD-25 T4F / Stage V

Jump Starting the Machine

Electrical system is 24 [V] negative ground.

Battery Explosion Danger

TD-25 T4F / Stage V DRESSTA

2.2. BEFORE STARTING THE ENGINE

Health Hazard While Starting the Engine

Follow the Safety Precautions

Safety must always be the operator's most important concern.

DRESSTA TD-25 T4F / Stage V

Mounting and Leaving the Machine

TD-25 T4F / Stage V DRESSTA

Safety Within the Machine Working Area

DRESSTA TD-25 T4F / Stage V

Follow the Safety Precautions

Avoid Dangers in the Work Area

TD-25 T4F / Stage V DRESSTA

Immediately Before Work

Safety Precautions While Operating the Machine

DRESSTA TD-25 T4F / Stage V

Using the Seat Belt

Never place gasoline or diesel fuel in open pan.

TD-25 T4F / Stage V DRESSTA

Safe Use of Mounted Equipment