DOWNLOAD PDF Terex S17E Dump Truck Operation Safety Maintenance Manual PN 15273732

S17E Operation - Safety - Maintenance

WHEN RE-ORDERING THIS HANDBOOK, SPECIFY - PART NUMBER 15273732

TECHNICAL PUBLICATIONS DEPARTMENT TEREX EQUIPMENT LIMITED MOTHERWELL, SCOTLAND ML1 5RY Ref No. OHE 803 Jan 2001

ONLY TRAINED PERSONNEL SHOULD BE ALLOWED TO OPERATE THIS VEHICLE The operator is responsible and must be familiar with the contents of the Operator's Handbook and any local regulations prior to operating this vehicle.

CALIFORNIA Proposition 65 Warnings WARNING: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

WARNING: Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive har m.

Wash hands after handling.

SPARE PARTS STATEMENT When carrying out repairs, alterations or fitting attachments, it is important that only genuine spare parts are used to ensure the operating safety of the machine is not impaired.

It is only by using genuine parts that the technical requirements stipulated by the manufacturer can be maintained.

If a General Operating Approval is issued for this machine, it may be considered null and void if non-genuine parts are used.

CONTENTS 1. INTRODUCTION Introduction ........................................ 1-2 Safety Precautions ............................ 1-2 Machine Identification ........................ 1-3 Theft Deterrent Practices ................. 1-4 2. SAFETY PRECAUTIONS General .............................................. 2-2 Preventing Fire Hazards ................... 2-3 Mounting and Dismounting ................ 2-5 Pre-Starting ....................................... 2-6 Starting ............................................... 2-6 Operating ........................................... 2-7 Roading .............................................. 2-8 Lubrication and Servicing ................ 2-10 Wheels and Tyres ........................... 2-11 Avoid Tyre Explosion Hazard ......... 2-12 3. CONTROLS AND OPERATING Controls and Instruments ................. 3-3 Basic Data ......................................... 3-4 Indicator/Warning Lights ............... 3-4 Instruments .................................... 3-5 Switches ........................................ 3-6 Controls ......................................... 3-9 Heater .......................................... 3-10 Air Conditioner ............................. 3-10 Operator's Seat Air Suspension ............................ 3-11 Seat Belt ....................................... 3-12 Machine Controls .............................. 3-13 Braking ......................................... 3-13 Service Brake ............................... 3-13 Park/Emergency Brake ................ 3-13

3. CONTROLS AND OPERATING (cont) Engine .............................................. 3-14 Electronic Foot Pedal ................... 3-14 HEUI Electronic Management System ......................................... 3-14 Description .................................... 3-16 Operation ...................................... 3-17 Steering ............................................ 3-30 Transmission .................................... 3-31 System Components .................... 3-33 General Transmission Operation ...... 3-35 Power-Locking Differential ................ 3-36 Hydraulic System Controls ............... 3-37 4. OPERATING THE SCRAPER Pre-Starting Inspection ..................... 4-2 Component Checks - Tractor .......... 4-3 Component Checks - Scraper ......... 4-5 Engine Operation ............................... 4-6 Starting the Engine ............................. 4-7 Starting the Engine at Low Ambient Temperatures ............ 4-9 Starting the Engine with Jumper Cables ..................... 4-10 Pre-Operating Checks .................... 4-10 Brake Function Checks .................. 4-10 Driving and Stopping ....................... 4-13 Stopping the Engine ........................ 4-15 Parking ............................................. 4-16 5. WORKING THE SCRAPER Standard Functions ........................... 5-2 Loading .............................................. 5-3 Loading Tips ...................................... 5-5 Transporting the load ........................ 5-6 Spreading the load .............................. 5-6 Elevator Adjustments ......................... 5-8

5. WORKING THE SCRAPER (cont) Elevator Mode Adjustment ................. 5-9 Elevator Height Adjustment ................ 5-9 Idler Roller Adjustment ..................... 5-10 Types Of Cuts .................................. 5-11 Cutting Through Hills .................... 5-11 Cutting Banks ............................... 5-11 Stripping Topsoil ........................... 5-11 Starting A Ditch ............................ 5-12 Types Of Fills ................................... 5-12 Finishing And Grading ...................... 5-13 6. ROADING Roading .............................................. 6-2 General .......................................... 6-2 Preparation Prior to Roading ......... 6-2 In Case Of Trouble ........................ 6-4 7. MOVING DISABLED SCRAPER Moving Disabled Scraper .................. 7-2 8. LUBRICATION AND SERVICING Safety Precautions ............................ 8-2 Lubrication and Servicing ................... 8-3 Tractor Lubrication and Service Chart ............. 8-5 Remote Lubrication Points ................. 8-7 Scraper Lubrication and Service Chart ............. 8-9 Remote Lubrication Points ............... 8-10 Tractor and Scraper Additional Miscellaneous Servicing Information .................... 8-12 Recommended Lubricants ................ 8-15 9. TECHNICAL DATA 10. SYMBOL IDENTIFICATION

1-1

INTRODUCTION This Handbook is provided as a guide to familiarize the operator and serviceman with the controls, recommended inspections, start-up, operating, shutdown and parking procedures for S17E Scrapers.

Look for this symbol to point out important safety precautions. It means: ATTENTION! BECOME ALERT! YOUR SAFETY AND THE SAFETY OF OTHERS IS INVOLVED!

Safety Precautions The machine should be properly operated and maintained to keep it in safe, efficient operating condition. Be sure that all controls are free of mud, grease, or other matter that might cause slips hazardous to the operator, serviceman, or other personnel or equipment. Report all malfunctions to those responsible for maintenance, and, do not operate the equipment until corrected. Normal service or maintenance performed as required can prevent unexpected and unnecessary downtime.

This Handbook describes general inspections, servicing and operation with the normal safety precautions required for normal servicing and operating conditions. It is not a guide however, for other than normal conditions or situations, and therefore, servicemen and operators must be safety conscious and alert to recognize potential servicing or operating safety hazards at all times, and take, necessary precautions to assure safe servicing and operation of the machine.

1-2

READ the CIMA Safety Manual supplied with this machine.

All information, illustrations and specifications contained in this publication are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

Continuing improvement and advancement of the design may cause changes to your machine which may not be included in this publication. Each publication is reviewed and revised, as required, to update and include these changes in later editions.

This Handbook contains lubrication and routine servicing instructions, most of which can be performed in the field. Maintenance manuals containing repair/rebuild procedures can be obtained from your dealer.

Machine Identification While reading this handbook you will notice references to controls and equipment which may not be found on all machines. It is important that you know your machine and its equipment and how to operate it properly.

Information regarding the machine model, code and chassis serial number is found on the unit serial number plates on the front left hand side of the tractor and rear right hand side of the scraper. The machine model and serial number should always be referenced in any correspondence with your dealer or factory.

There is a dealer serving every part of the world where these products are sold.

Your dealer is ready to provide you with any additional information needed and should be consulted for additional publications for this machine.

1-3

Theft Deterrent Practices General The owner/operator should take the following precautions to discourage theft, to aid in the recovery in the event that the machine is stolen, or to reduce vandalism.

Actions to Discourage Theft and Vandalism Remove all keys any time the machine is left unattended.

At night lock all doors and attach, secure or lock all anti-vandalism and anti-theft devices on the machine.

Immobilize the machine by removing a critical electrical or starting system device.

Upon receipt of a machine, record the machine serial number and the serial numbers of all major components and attachments. Keep this list up to date and filed in a safe location for fast retrieval.

Place a decal or notice on the machine that all serial numbers are recorded.

Discourage the thief! Inspect the gates and fences of the machinery storage yard or

1-4

construction site. Keep machines in well-lit areas and ask the local law enforcement authorities to make frequent checks around the storage yard or work site.

Establish liaison with neighbours and ask them to watch equipment left at job sites and to report any suspicious activities to the local law enforcement authorities.

Make frequent inventories of machines to promptly detect losses or vandalism.

Actions to Aid in Recovery of Stolen Machines In the event of theft, immediately notify the law enforcement authorities having jurisdiction. Provide the investigating officer with name, type of equipment, chassis and serial numbers of major attachments and components. It is helpful to show the investigating officer an Operator’s Handbook, photographs, and advertising, to familiarize him with the appearance of the machine.

Report the theft to the insurance company. Provide the model and all serial numbers.

Report the model and serial numbers of the stolen machine to a dealer handling the respective line of equipment. Request that the dealer forward this same information to the equipment manufacturer.

1-5

1-6

2 - Safety Precautions 2-1

SAFETY PRECAUTIONS General

2-2

*

Read this Operator’s Handbook and learn the operating characteristics and limitations of the machine. Know what operating clearances the machine requires.

*

Read the CIMA Safety Manual and follow the recommended safety precautions.

*

Know clearances of all side and overhead obstructions such as wires, bridges, etc., for operating safely.

*

Always know all traffic rules, signs, flags and hand signals used on the job and know who has the responsibility for signalling.

*

Be aware of operating hazards that weather changes can create on the job.

Know proper procedures to follow when a severe rain or electrical storm strikes.

*

Never attempt to operate or work on a machine when not feeling physically fit.

*

Know what safety equipment is required and use it. Such equipment may be: Hard hat, safety glasses, reflector type vests, respirators and ear plugs.

*

Never wear loose clothing, rings, watches etc., that might catch levers and controls and cause loss of control.

*

Keep hands and controls free from water, grease and mud to assure nonslip control.

*

Handle fuels and lubricants carefully and clean up spills to avoid fire and slipping hazards.

*

Clean any mud, grease or oil from controls, handrails, ladders and decks.

Lash necessary tools securely and remove all loose items before operating machine.

*

Never carry passengers on the machine.

WARNING The protection offered by the roll over and falling object protective structure may be impaired if it has been subjected to any modification or damage.

Preventing Fire Hazards General Fire Precautions * Make sure machine has a fire extinguisher and that it is accessible and fully charged. (Not furnished with machine). *

Never use an open flame as a light anywhere on, or around, the machine.

*

Clean all dirt, oil, grease and other fluids from systems and components to minimize fire hazards and aid in spotting loose or leaking lines, fittings etc..

*

Check the engine compartment for rubbish, oily rags or other debris that could cause fires before starting the engine.

*

Don’t let greasy, oily rags or similar hazards accumulate in the cab.

*

If the machine has been operated with an under inflated tyre. Make sure that the tyre has cooled sufficiently before parking and leaving the machine unattended.

2-3

Flammable Fluid Precautions * Do not use diesel fuel or other flammable fluids for cleaning purposes. Use approved, nonflammable solvents.

2-4

*

Make sure all fluid system caps, drain cocks, valves, fittings, lines etc., are secure and leak free.

*

Never use an open flame (match, lighter etc.) when checking fuel, lubricant, coolant and battery fluid levels or when checking for fluid leaks. Use a flashlight or other safe lighting only.

*

Shut off engine and use extra caution if engine is hot when refuelling. Ground the hose spout to prevent sparks when spout is touched to fuel tank filler tube.

*

Never smoke while checking or adding fuel or other fluids or handling fluid containers and lines.

*

Use care and do not stand downwind when adding fuel or other flammable fluids to tanks and reservoirs to avoid fluids being blown or splashed onto clothing.

*

Close fuel tank shut-off valves, if used, before servicing fuel system.

*

When preparing machines or components for storage, seal and tape all openings and close containers tightly to seal in all volatile inhibitor fluids and compounds used.

*

Follow manufacturer’s recommendations when handling and using enginestarting fluids and disposing of spent containers. Do not puncture or burn empty containers. These fluids are explosive and highly flammable.

Electrical Hazard Precautions * Never smoke or allow open flames or sparks near batteries. *

Leave battery box open when charging batteries in machine for adequate ventilation of explosive gas (hydrogen) produced.

*

Always disconnect batteries before repairing electrical system to avoid danger of fire-causing sparks. Disconnect battery ground cable first and reconnect last.

*

Always disconnect battery equalizer, batteries, ECU electrical connections and alternator leads before carrying out any welding on the machine.

Disconnect ground cables first and reconnect last.

*

Never check battery charge by placing metal objects across battery posts to avoid sparks at battery posts.

*

Use jumper cables only as recommended. Improper use can result in battery explosion or unexpected machine motion.

*

Never operate engine starter for more than 30 seconds and allow two minutes between cranking periods for cooling. An overheated starter could cause a fire.

*

If electric coolant or lubricant heaters are used, be sure to follow heater manufacturer’s recommendations for use to avoid electrical and/or fire hazards.

Mounting and Dismounting *

Only use steps and hand holds provided to mount or dismount machine. Do not grasp steering wheel.

2-5

*

Always face the access system and maintain at least three points of support to mount or dismount the machine.

*

Always use care when mounting machine with oil covered, frosted, or iced fenders, decks, hand holds or steps.

*

Never mount or dismount a moving machine. Never jump off the machine.

Pre-Starting *

If engine is to be started and run indoors, ensure proper ventilation to remove deadly exhaust gases.

*

Always perform 'Pre-Starting Inspection' instructions described on page 4-2 to ensure the machine is ready for operation.

*

Always walk around the machine to make sure no-one is working on, underneath or close to the machine before starting the engine or operating the machine.

*

Adjust, secure and latch the seat and fasten the seat belt before starting the machine.

*

Sound horn before starting the engine or beginning to move the machine; two blasts for forward and three blasts for reverse.

Starting

2-6

*

Do not start the engine or operate any control if there is a 'DO NOT OPERATE' or similar warning sign attached to any control.

*

Use jumper cables only as recommended. Improper use can result in battery explosion or unexpected machine motion.

*

Always obey 'Starting the Engines' instructions described on page 4-7.

*

Do not bypass the machine’s neutral-start system. The neutral-start system must be repaired if it malfunctions.

*

Start and operate the machine only from the operator’s cab.

Operating *

Ensure all cab glass, mirrors and light lenses are clean during machine operation for maximum visibility.

*

Always keep cab floor clear of anything that could restrict full operation of pedals.

*

Always make sure all gauges, warning/indicator lights and controls are working properly before operating machine.

*

Always perform 'Pre-Operating Checks' described on page 4-11 to ensure the machine is ready for operating.

*

Always wear seat belts when operating the machine.

*

Do not operate if exposed personnel enter the immediate work area.

*

Sound horn before starting engine or beginning to move machine; two blasts for forward and three blasts for reverse.

*

Watch for ground crew and other personnel on foot. Sound horn as a warning before setting machine in motion and when approaching ground crew.

*

Never release the parking brake or move the machine until the needle in the air pressure gauge is in, or approaching the centre of the green zone.

2-7

Roading WARNING Be extra cautious at raised rail crossings, other raised portions of roads and overpasses to make sure the scraper and raised bowl will clear as it passes. Personal injury or property damage may result if the bowl is not adjusted properly and clearance is not significant.

1398

2-8

*

Fully raise bowl so as to clear any obstacle in the path of the scraper. If in doubt as to the clearance, stop the machine and check clearance.

*

Always try to face or look in the direction the machine is traveling.

*

Slow down when moving in congested areas. Do not race with other machines.

Stop in authorized areas only, except in emergencies.

*

Use extreme caution and turn on lights at night or when fog, dust, or similar hazards limit visibility. Do not overdrive your headlights.

*

Know clearances of all side and overhead obstructions such as wires, bridges, etc., for operating safely.

*

Always know all traffic rules, signs, flags and hand signals used on the job and know who had the responsibility for signaling.

*

Be alert for soft ground conditions, especially when working on slopes, near drop-offs or excavations or fill material, which could lead to sudden tipping of the machine.

*

Be aware of operating hazards that weather changes can create on the job.

Know proper procedures to follow when a severe rain or electrical storm strikes.

Raise Bowl Fully

*

Observe instruments frequently. Report any defects or unusual noises in machine during operation.

*

Stop at appropriate intervals to inspect the machine and allow the tyres to cool. Tyre air pressure will rise during operation. Do not reduce tyre pressure.

Excess speed will cause tyres to heat up. Reduce your travel speed, not tyre pressure.

*

Always shut off the engine when leaving the machine unattended. Apply the parking brake, place the shift lever in the 'Neutral' position, lower the bowl to the ground, place the battery master switch in the 'Off' position and block all road wheels.

*

Match speed to road conditions.

*

Yield the right of way when required. Always give loaded machines the rightof-way when your machine is empty. On narrow or hilly roads, loaded machines should stay next to the high wall. Obey the rules of the road.

*

Always be sure the bowl is in a travel position high enough to clear any obstacles in its path. If in doubt as to clearance, stop the machine and check clearance.

*

Brake firmly in one application. Frequent and repeated light applications may exhaust air from reservoir faster than it can be replaced by the compressor.

Never operate the machine if a warning light or gauge indicates low air pressure.

*

Stay in gear when driving downhill. Do not coast with transmission in neutral.

Select the proper gear and maintain safe speed with the service brakes or/ and retarder. Always maintain safe speeds for haul road operating conditions for maximum control. Reduce speed before turning.

*

Always operate straight up or down slopes whenever possible, side hill operation can cause sideslip and possible roll-over. If the machine starts slipping sideways, turn down-hill immediately.

2-9

*

Stay as close to the side of the road as possible. Pass other equipment only when the road is clear and enough room and reserve power are available.

*

Use accessory lights and devices at night or in poor visibility. Carry a flare kit.

Do not overdrive your headlights.

Lubrication and Servicing

2-10

*

Do not allow unauthorized personnel to service or maintain this machine. Study the Operator’s Handbook and Maintenance Manual before starting, operating or servicing this machine. Always follow procedures and safety precautions detailed in the Maintenance Manual.

*

Never allow anyone to work on the machine while it is moving.

*

Make sure no one is on the machine before working on it.

*

Do not work under or near any unblocked or unsupported linkage, part or machine.

*

Always shut down machine according to the procedure under 'Stopping The Engine', described on page 4-15, and turn off the master switch before cleaning, lubricating or servicing the machine except as called for in this Handbook or Maintenance Manual.

*

Always deflate tyre before attempting to remove any embedded objects or removing the tyre and rim assembly from the machine.

*

Always use a self-attaching chuck with a long airline and stand to one side while the tyre is inflating.

*

Always relieve pressure before servicing any pressurized system.

*

Always attach a 'DO NOT OPERATE' or similar warning sign to ignition switch or a control before cleaning, lubricating or servicing the machine.

Wheels and Tyres If tyres on a machine were inflated at the factory with dry nitrogen gas, the tyre walls will be marked 'N' and the following factory installed decal will be found mounted on the fenders.

NOTICE TYRES ON THIS MACHINE ARE FACTORY INFLATED WITH DRY NITROGEN. IT IS RECOMMENDED THAT DRY NITROGEN BE USED EXCLUSIVELY FOR ALL TYRE PRESSURE ADJUSTMENTS AS WELL AS INFLATION OF REPLACEMENT TYRES. Nitrogen gas improves tyre pressure retention, increases tyre life by reducing carcass oxidation from within, minimizes rim rust, and has no known detrimental effect on the tyre. It also reduces the potential of a tyre explosion because it is an inert gas and will not support combustion inside the tyre. The same tyre inflation pressure used for air inflation should be used for nitrogen inflation. Refer to Section 160-0050, 'NITROGEN INFLATION OF TYRES' of machine Maintenance Manual for recommended procedures for inflating and pressure adjusting tyres with dry nitrogen gas. Only proper nitrogen charging equipment operated by personnel trained in its use should be used.

WARNING Never mix components of one manufacturer’s rims with those of another. Using the rim base of one manufacturer with the lock ring of another or vice versa is dangerous. The lock ring of one may not fully engage with the lock ring groove of the other. Always consult the rim manufacturers for proper matching, assembly and safety instructions.

Also, use and servicing of damaged, worn out or improperly assembled rim assemblies is a very dangerous practice. Failure to comply with the above warnings could result in an explosion from tyre pressure causing serious property damage and serious personnel injury or death.

2-11

Avoid Tyre Explosion Hazard 15 m

(50 ft)

WARNING Whenever a machine’s tire (s) is (are) exposed to excessive heat such as a machine fire or extremely hot brakes, the hazard of a subsequent violent tire explosion must be recognized. All nearby persons must avoid approaching the machine so as not to be physically endangered in the event of an explosion of the tire and rim parts.

The machine should be moved to a remote area, but only when this can be done with complete safety of the operator operating or towing the machine. All other persons should stay clear of the machine. The fire or overheated brakes, wheel, etc., should be extinguished or cooled from a safe distance. Do not attempt to extinguish the fire or cool the machine by use of hand held fire extinguishers. If it is absolutely necessary to approach a machine with a suspect tire, approach only from the front or the back. Stay at least 15 m (50 ft.) from the tread area. Keep observers out of the area and at least 460 m (1 500 ft) from the tire sidewall. Refer to the accompanying sketch. The tire (s) should be allowed at least 8 hours cooling time after the machine is shut down or the fire extinguished before approaching closer.

460 m (1 500 ft)

460 m (1 500 ft)

460 m (1 500 ft)

15 m 1399

2-12

460 m (1 500 ft)

(50 ft)

3 - Controls and Operating 3-1

1

2

3

4

5

6

7

8

9

10

11

12

13 14 15 32 16 17 26

30

31

25

18 19 20

DIFF

27

DIFF

29

28

24

23 22 21

3-2

1400

CONTROLS AND INSTRUMENTS 1. Windshield Demister 2. Face Vent 3. Warning Lights 4. Tachometer/Hourmeter 5. Transmission Oil Temperature Gauge 6. Air Pressure Gauge 7. Gear/Diagnostic Display Unit 8. Warning Lights 9. Face Vent 10. Windshield Demister 11. Side Window Demister 12. Windshield Screen Control (Top) 13. Switches 14. Park/Emergency Brake Control 15. Gear Shift Selector 16. Bowl Height Control 17. Ejector (Endgate) Control 18. Elevator Control (Forward High and Low) 19. Elevator Control (Neutral and Reverse)

20. Side Window Demister 21. Heater Control 22. Temperature Control 23. Blower Control 24. Accelerator Pedal 25. Ignitions and Starter Key Switch 26. Accessory Lamp Socket 27. Steering Wheel 28. Service Brake Pedal 29. Power-Locking Differential Button 30. Headlight Dimmer, Directional Indicator, Windshield Wiper/Washer, Horn Control 31. Fuse Box Cover 32. Radio/Cassette Player 33. Interior Light (not shown). Located above RH dash panel 34. Emergency Exit Hammer (not shown) Located on RH cab pillar 35. Cup Holder (not shown) Located on LH cab pillar

3-3

BASIC DATA Indicator/Warning Lights

1

3

5

7

SERVICE ENGINE SOON

1. Engine Check Light (Amber) - When the 'Check Engine' light comes on, the computer has detected a fault in the engine. The fault should be diagnosed and corrected at the earliest opportunity.

STOP

2. Engine Stop Light (Red) - When the 'Stop Engine' light comes on, the computer has detected a major malfunction in the engine that requires immediate attention.

It is the operators responsibility to shut down the engine to avoid serious damage.

An alarm also sounds.

2 1283

3. Engine Service Light (Red) - Illuminates when the engine is due to be serviced.

Engine should be serviced at the earliest opportunity.

4

6

8

Left Hand Panel

9

11

4. Transmission Oil Pressure (Red) - Illuminates if pressure is low. Illuminates when the ignition is turned on and should go out when the engine starts. If the light illuminates during operation, stop the engine and investigate the cause. Light flickering when gear shifting is permissible.

5. Converter Indicator Light - Illuminates to indicate when the transmission is in torque converter drive.

10

6. Transmission Oil Filter Restriction (Amber) - Illuminates when the filter is restricted, indicating that a filter change is required.

1284

7. Headlight Main Beam (Blue) - Illuminates when headlights are operated on main beam.

11. Low Air Pressure Warning Light Illuminates when there is a loss of air pressure in the following circuits: a. Front service circuit air pressure falls below 4.1 bar (60 lbf/in²). b. Rear service circuit air pressure falls below 4.1 bar (60 lbf/in²). c. Park/emergency brake circuit air pressure falls below 5.5 bar (80 lbf/in²).

8. Alternator Charging (Red) - Illuminates to indicate when the alternator is not charging.

9. Bowl Suspension Indicator Light (Red) - Illuminates to indicate when the bowl suspension switch is in operation.

10. Direction Indicator (Green) - Flashes when the indicator lights are operating.

3-4

Right Hand Panel

Instruments 1

2

1. Tachometer/Hourmeter - Driven from the alternator, the tachometer indicates the number of engine crankshaft revolutions per minute. The needle shows variations in engine operating speed. Never accelerate the engine to speeds indicated by the red zone on the dial face. A digital hourmeter is incorporated in the tachometer to record total hours of engine operation. The readings can be used for operating and service records.

3

15 10 RPM x100 20 5

25 30

0

120

50

TRANS OIL

140 150

AIR

SERVICE PRESS

TEMP

SERVICE ENGINE SOON

STOP

2. Transmission Oil Temperature Gauge - Indicates converter and transmission oil operating temperature. This gauge should read in the green zone at all times. Stop the engine immediately if the needle goes into the red zone until the fault is corrected.

3. Air Pressure Gauge - Indicates air reservoir pressure.

During normal operation, the needle in this gauge should be showing in the centre of the green zone. Do not operate if the needle remains in the red zone.

1402

890

WARNING Never release the parking brake or move the machine until the needle is at least approaching the centre of the green zone.

4

4. Air Cleaner Restriction Gauge - Indicates the degree of air cleaner element restriction as the red band rises in the gauge window. The filter elements must be cleaned or replaced if the red band locks in place when the engine is shut down. Reset the restriction gauge by pushing the plunger at the top of the gauge with the engine running.

3-5

Switches

1

1. Engine Diagnostic Request Switch - Operates as a diagnostic request switch when: a. - the engine is not running and ignition is 'On'.

Pressing and releasing the switch will flash out the engine codes. Pressing the switch a second time will stop the engine codes flashing.

Note: Active codes are displayed initially, followed by inactive codes. Refer to pages 19 to 29 for fault code details.

HAZARD

1287

2. Hazard Warning Light - Press bottom of switch to make turn indicators flash simultaneously as hazard warning lights. The direction indicator warning light on the instrument panel will flash. To switch hazard lights off; press the top of the switch.

3. Sidelight and Headlight - Press bottom of switch to the first position to operate side, tail and panel lights. The lights in the other switches will illuminate. Press switch to the second position to operate the headlights. To switch lights off; press the top of the switch.

4. Cutting Edge Light Switch - Press bottom of switch to operate the flood lights to illuminate the bowl. To switch off; press top of switch.

3-6

2

3

4

5

6

TEST

1403

7

8

5. Rear Windscreen Wiper and Washer Switch - Press bottom of switch to operate the rear windscreen wiper. Press the switch again for wash. To switch off; press top of switch.

6. Warning Light Test Switch - Pressing the switch with the ignition switched on will illuminate the warning lights to provide a bulb and system check.

Note: All warning/indicator lights, with the exception of the main beam, direction indicators, alternator charging, 'Stop' engine, 'Check' engine and service engine soon, will illuminate to provide a bulb and system check when the ignition is on and the test switch is pressed.

7. Bowl Suspension Switch - Press bottom of switch to operate the bowl suspension system. This will allow movement and provide the operator with a smoother ride.

Note: Bowl suspension system should only be operated when travelling, never while loading the scraper.

8. Bowl Drop Switch - Press bottom of switch to lower the bowl to the ground.

Press top of switch to stop bowl lowering.

Note: The bowl drop switch is for use only when the bowl cannot be lowered using the normal hydraulic control.

9. Ignition and Starter Key Switch - The combined switch operates the ignition and starter motor. The key can only be withdrawn from position '0'.

'0' - Ignition switched off. All electrical systems are inoperative. This position also cuts off fuel to shut the engine.

'1' - Ignition switched on, instruments, gauges and warning lights register as appropriate. All electrical systems are operative. The key must remain in this position whilst operating the machine.

9 1438

'2' - Starter motor operates. The key when released will return to position '1'.

3-7

10. Battery Master Switch - Located on the front right hand side of the tractor frame, adjacent to the battery box. Turn key clockwise to connect the batteries to the electrical circuits. Switch key off and remove when leaving machine unattended.

1126

10

1404

11

1451

12

11. Engine Diagnostic Test Point - Plug in connector for diagnostic data reader (DDR). A diagnostic test point is located on the right hand side of the fuse box, under the dash panel.

12. Transmission Diagnostic Diagnostics and Calibration - Plugs are located located adjacent to the fuse box, under the dash panel. Fuse box cover needs to be removed for access.

3-8

Controls Headlight Dipper, Direction Indicator, Windscreen Wiper/Washer and Horn

340

1

342

3

1. Headlight Dipper and Flasher: Control downwards = Main Beam Neutral Position = Dipped Beam Control Upwards = Headlight Flash 2. Direction Indicator: Control rearwards = Left Indicators Control forwards = Right Indicators

341

2

343

4

3. Windscreen Wiper/Washer: Position J = Intermittent Wash/ Wipe Position 0 = Neutral Position Position 1 = Wiper Slow Speed Position 2 = Wiper Fast Speed Ring Pushed = Windscreen Wash 4. Horn: Button pushed in = Horn Sounds

3-9

Heater

1 2

Blower control (1) is rotated to select one of three blower speeds.

Temperature control (3) is rotated to vary heater output temperature. Heater output air is unheated with the control turned fully anticlockwise and heated by turning clockwise.

Heater/air conditioner outlets (4) may be adjusted to control air flow output by opening and closing the control flaps. Air direction can be adjusted by rotating complete outlet.

MED

HI

LO

LO OFF

3

OFF HI

AIR

TEMP

1292

Air Conditioner 4

Keep all windows and vents closed.

Blower control (1) is rotated to select one of three blower speeds. The air conditioning will not operate if the blower control is not switched on.

Temperature control (2) adjusts the air conditioner output temperature. Rotating the control right provides maximum cooling.

Heater/air conditioner outlets (4) may be adjusted to control air flow output by opening and closing the control flaps. Air direction can be adjusted by rotating complete outlet.

3-10

4

4 4

1452

Operator’s Seat - Air Suspension The air seat only reacts when the driver sits on the seat.

When unoccupied, the seat sinks to the lowest position to allow easier access. The incorporated suspension block out maintains the seat in position for driving.

8

The following is the list of controls to adjust the seat: 6

1. Height and slope adjustment, front.

2. Height and slope adjustment, rear.

3

3. Backrest angle adjustment.

4. Weight adjustment.

2 1

7

5. Horizontal adjustment (sliderails).

6. Lumber support adjustment (5 positions).

4

7. Seat belt anchorage.

8. Armrest adjustment.

5 1097

Operators Seat - Air Suspension

WARNING Do not attempt to adjust the seat or seat belt while the machine is moving. Loss of control may result.

Stop the machine; apply the brakes; then adjust.

3-11

Seat Belt A retractable seat belt is installed on the operators seat. The seat belt requires no external adjustment and allow freedom of movement for proper manipulation of all controls.

WARNINGS Always wear seat belt when operating the machine.

Always check condition of seat belts and mounting hardware before operating the machine.

Any signs of looseness or wear should be reported to your Service Department or Dealer for repair or replacement immediately.

Replace seat belt at least once every three years, regardless of appearance.

Do not attempt to adjust the seat or seat belt while the machine is moving. Loss of control may result. Stop the machine; apply the brakes; then adjust.

3-12

495

Typical Retractable Seat Belt

MACHINE CONTROLS Braking

1405

Service Brake Pedal

The dual safety brake system installed on this machine is applied using the service brake pedal or park/emergency brake control lever, or automatically should the air pressure drop below 5.2 bar (75 lbf/in²) to slow or stop the machine. For effective braking, the air system pressure gauge should read around the centre of the green zone 7.2 - 8.6 bar (105 - 125 lbf/in²). If the gauge indicates a pressure drop for extended periods or the Low Air Pressure warning light illuminates, the machine should be shut down until the fault is corrected.

Service Brake This is a floor mounted pedal operated by the left foot. Depress the pedal as required by speed, load and road conditions to slow or stop the machine.

Release the pedal as the machine slows until, when stopped, the pedal is depressed just enough to hold it stationary. Do not 'FAN' the pedal, as this needlessly wastes the air supply in the reservoirs.

1294

WARNING Never release the park/ emergency brake or move the machine until the needle is at least approaching the centre of the green zone.

Park/Emergency Brake This is a modulated brake control valve, located on the right hand dash panel.

When the lever is moved towards the 'PARK' position, there is a gradual increase in brake application until the lever is fully back in the 'PARK' position and the brakes are fully applied. The brake lights are automatically applied. To release the brakes, move the lever forward to the 'RELEASE' position.

Note: Moving the lever to the 'PARK' position will apply the brakes to stop the machine, but this should be done only in emergencies; never for normal braking. For normal braking the service brake pedal should be used.

WARNING Always apply the park/emergency brake before leaving the operator's seat.

3-13

Engine Electronic Foot Pedal An electronic foot pedal is mounted on the cab floor. The electronic foot pedal provides an electrical signal to the engine's fuel control system in proportion to the degree of pedal actuation.

Note: The electronic controlled engine will override the electronic foot pedal position until the engine is warmed up to the correct operating temperature. The engine MUST be started with the foot 'OFF' the electronic foot pedal.

1406

HEUI Electronic Management System This machine is equipped with the HEUI electronic management system which continually monitors the engine and warns the operator when a problem develops. The system also takes action to prevent damage to the engine and, provides the serviceman with diagnostic capabilities so that problems can be corrected quickly and easily.

3-14

WARNING Before any welding is done on a machine equipped with the HEUI electronic management system, disconnect the following in this order: Battery earth cable, battery supply cable, alternator earth cables, alternator supply cables, transmission ECU connectors (located behind access door below cab door) and engine ECU connectors (located on LH side of engine).

Turn off battery master switch before disconnecting any components.

After welding connect all of the above in the reverse order.

SERVICE ENGINE SOON

7 6 STOP

3

1,2 8 HAZARD

4

9 5

1 - Electronic Control Module (ECM) 2 - Programmable Read Only Memory (PROM) 3 - HEUI Fuel System Injectors 1312

4 - Batteries 5 - Electronic Foot Pedal 6 - Stop Light

7 - Check Light 8 - Diagnostic Switch 9 - Diagnostic Test Points

3-15

HEUI Electronic Management System - Description 1. Electronic Control Module (ECM) - Receives electronic inputs from the driver as well as from sensors that provide information electronically, such as oil pressure and temperature and intake manifold pressure. This information is used to control both the quantity of fuel injected and injection timing.

2. Programmable Read Only Memory (PROM) - Located in the ECM and encoded with the operating software. Additional information is programmed into the EEPROM. This information controls the horsepower rating, torque curve, maximum engine speed and engine protection devices. The ECM processes this information and sends electronic signals to the Electronic Fuel System Injectors where the precise amount of fuel is injected into the engine.

3. Electronic Fuel System Injectors - The injector is a lightweight, compact unit that injects diesel fuel directly into the combustion chamber. The amount of fuel injected and the beginning of injection timing is determined by the ECM. The ECM sends a command pulse which activates the injector solenoid.

The injector performs four functions: a - Creates the high fuel pressure required for efficient injection. b - Meters and injects the exact amount of fuel required to handle the load. c - Atomizes the fuel for mixing with the air in the combustion chamber. d - Permits continuous fuel flow for component cooling.

Electronic fuel system injectors are self compensating and virtually eliminate engine tune-ups.

Note: Never apply 12 or 24 volts directly to terminals on the injector or engine sensors as they will burn out. Before removing injectors, the fuel passages must be blown out to prevent fuel flow from entering the cylinder head.

3-16

HEUI Electronic Management System - Operation When either 'Stop' engine light on the dash panel illuminates, the computer has detected a major malfunction in the respective engine that requires immediate attention. It is the operators responsibility to shut down the engine to avoid serious damage.

The machine is equipped with an engine protection system, which records fault codes when an out-of-range conditions is found. The stop engine and check engine lights illuminate when the engine protection system is initiated. The operator MUST shut down the engine, at the first safe opportunity, to avoid serious damage.

The engine should not be restarted after it has been shut down after activation of the engine protection derate system unless the problem has been diagnosed and corrected.

Conditions that will cause the Stop Engine light to come on are; Low coolant level, High coolant temperature, Low oil pressure and High oil temperature.

Whenever the Check Engine light or Stop Engine light comes on, the Electronic Management System computer will determine where the problem is and will store this information in its memory. If the malfunction is intermittent, the lights will come on and go off as the computer senses the changing engine condition.

The operator can check for fault codes by turning the ignition key switch to the 'OFF' position, pressing the diagnostic request switch 'ON' and holding it down, turning the ignition key switch to position '1' and then releasing the diagnostic request switch. Do NOT start the engine.

To retrieve any active or inactive (historic) codes recorded, press the diagnostic request switch. The fault codes flash in the following sequence: the red Stop light flashes once, then there is a pause where both lights are off. Then the numbers of the recorded fault code flash in amber (Check light). There is a pause between each number. When the number is done, the red light flashes again. e.g. red flashes once - pause - amber flashes twice - pause - amber

3-17

flashes three times - pause - amber flashes five times - pause - red flashes once, indicates fault code 235. If the red light flashes once again, this indicates that there are more active codes recorded. If code 111 is flashed, no faults have been detected. All of the active codes will be displayed first. Once all the active codes have been displayed, the red Stop light will flash twice, indicating the start of the inactive code transmission. These are displayed in the same manner as the active codes. On completion of the inactive code transmission, the red Stop light will flash three times.

Refer to 'Electronic Fuel System Diagnostic Codes' tables for fault code descriptions.

A special diagnostic data reader (DDR) is available that can be plugged into the engine computer memory to extract information related to the cause of the problem.

Once the malfunction has been corrected, the Electronic Management System will return the engine to normal operation. The fault code recorded in the ECM memory will remain until it is erased by a technician.

Clearing Fault Codes 1. Depress and the hold the diagnostic request switch.

2. Turn on ignition power (key-on and engine-off).

3. Depress the accelerator pedal 3 times within 10 seconds.

4. The ECM clears all active/inactive fault codes (no affect on Service Indicator).

Reset of Service Indicator 1. Turn ignition key to ON position.

2. Push the diagnostic request switch twice, and then a third time, only now hold the button 3 seconds and release. This entire sequence must be done within 10 seconds.

The service indicator light triggers at 95% of the normal oil change interval, based on fuel consumption. This is the default value set at the engine factory.

This can be reset with the MPSI reader with the Navistar card. With the reader, it can be programmed on hours or fuel.

3-18

ELECTRONIC MANAGEMENT SYSTEM DIAGNOSTIC CODES Code

Description

Fault Lamp

Additional Actions Taken

None

1. None.

2. Engine cannot be started.

112

Detectable problems may be present, but do not have a dedicated code: 1. No faults.

2. TRS signal problem not identified with Code 143, 144, 145 or 612.

3. Fan control or transmissionrelay circuit may not be functioning properly.

4. Simultaneously energizing PTO control pins 36 & 37.

5. Main power relay may not be functioning properly.

A voltage more than 28V was provided to the ECM.

113

A voltage less than 6V was provided to the ECM.

None

114

CTS signal less than 0.127V for more than 0.1 seconds.

Check

115

CTS signal more than 4.6V for more than 0.1 seconds.

Check

121

MAPS signal more than 4.9V for more than 0.1 seconds.

Check

122

MAPS signal less than 0.39V for more than 0.1 seconds.

Check

123

MAPS signal more than 16.7 lb/in² (115 kPa) at low idle.

Check

111

3. Functionality will be degraded.

None

4. PTO control will be disabled.

5. None - functionality may be affected.

Intermittent voltage gives inactive code.

Continuous supply causes power down.

Intermittent voltage gives inactive code.

Continuous supply causes power down.

ECM will ignore CTS signal & assume a coolant temp of -29°F (-34°C) for start & 180°F (82°C) for engine operation. Fan control feature is disabled, fan is kept on all the time.

ECM will ignore CTS signal & assume a coolant temp of -29°F (-34°C) for start & 180°F (82°C) for engine operation. Fan control feature is disabled, fan is kept on all the time.

ECM will ignore MAPS signal & operate engine using program default values.

ECM will ignore MAPS signal & operate engine using program default values.

ECM will ignore MAPS signal & operate engine using program default values.

3-19

ELECTRONIC MANAGEMENT SYSTEM DIAGNOSTIC CODES

3-20

Code

Description

124

IPS signal less than 0.039V for more than 1 second.

Fault Lamp Check

125

IPS signal more than 4.9V for more than 1 second.

Check

131

TPS signal less than 0.146V for more than 0.5 seconds.

Check

132

TPS signal more than 4.55V for more than 0.5 seconds.

Check

133

TPS & IVS signals disagree. Code caused by an intermittent condition.

Check

134

TPS & IVS signals disagree. Either TPS or IVS is varying: TPS & IVS signal are varying or ECM cannot determine fault/code in allotted time. Code caused by intermittent condition.

Check

135

IVS signal is varying, while TPS signal is constant. Code caused by intermittent condition.

Check

141

Test voltage across VSS too low for more than 0.5 seconds.

None

Additional Actions Taken ECM will ignore IPS signal & use open loop strategy (ECM uses calibrated value based on engine load, speed & temp to estimate it).

ECM will ignore IPS signal & use open loop strategy (ECM uses calibrated value based on engine load, speed & temp to estimate it).

Engine speed reduced to low idle setting, LO-IDLE-SPEED while code active.

Engine speed reduced to low idle setting, LO-IDLE-SPEED while code active.

ECM assumes TPS is the conflict source.

Engine speed reduced to low idle setting, LO-IDLE-SPEED. Code remains active until engine is shutdown & restarted. Will not recover without cycling the ignition switch.

Engine speed reduced to low idle speed settting, LO-IDLE-SPEED. Code remains active until engine is shutdown & restarted. Will not recover without cycling the ignition switch.

Engine speed reduced to 50% ofthrottle requested. Code remains active until engine is shutdown & restarted. Will not recover without cycling the ignition switch.

ECM will disable, cruise control, PTO operation, fast idle control & road speed limiting, if enabled and limites engine speed in all gears.

ELECTRONIC MANAGEMENT SYSTEM DIAGNOSTIC CODES Code

Description

142

Test voltage across VSS too high for more than 0.5 seconds.

None

143

None None Check

If condition persists, engine may stop running.

Code will cause a not start condition.

151

23 wide-window TRS signals were not received between two narrow signals.

TRS signal has detected a voltage spike.

Inactive TRS, during cranking when ICP pressure is sufficient to start engine.

BAPS signal more than 4.95V for more than 1 seconds.

ECM will disable, cruise control, PTO operation, fast idle control & road speed limiting, if enabled and limites engine speed in all gears.

If condition persists, engine will stop running.

None

152

BAPS signal less than 1.0V for more than 1 seconds.

None

154

ATS signal less than 0.127V for more than 0.2 seconds.

None

155

ATS signal more than 4.6V for more than 0.2 seconds.

None

211

OPS signal less than 0.39V for more than 0.1 seconds.

None

ECM uses MAPS signal generated at low idle to determine barometric pressure, calculate altitude & adjust fuel quantity & timing to optimise engine operation and smoke control. If MAPS signal is bad, sea level is assumed.

ECM uses MAPS signal generated at low idle to determine barometric pressure, calculate altitude & adjust fuel quantity & timing to optimise engine operation and smoke control. If MAPS signal is bad, sea level is assumed.

ECM will ignore ATS signal & assume air temp is 77°F (-25°C). Fan control feature is disabled, fan is kept on all the time.

ECM will ignore ATS signal & assume air temp is 77°F (-25°C). Fan control feature is disabled, fan is kept on all the time.

ECM will ignore OPS signal & disable oil press warning & critical level alerts of engine warning & protection feature, with an active code.

144 145

Fault Lamp

Additional Actions Taken

3-21

ELECTRONIC MANAGEMENT SYSTEM DIAGNOSTIC CODES

3-22

Code

Description

212

OPS signal more than 4.9V for more than 0.1 seconds.

Fault Lamp Check

213

Secondary throttle device signal is/was less than 0.25V.

None

214

Secondary throttle device signal is/was more than 4.5V.

None

215

VSS signal frequency is/was more than 4,365Hz.

None

216 221

HPS signal voltage less than 0.39V for more than 0.1 seconds.

Speed adjustment switch signal is different than ECM expected.

None None

222

Brake switch status signals at pins 44 and 43 differ.

None

224 225

Flash memory fault.

OPS signal is/was more than 40lb/in², when key was ON and the engine was OFF.

None None

226 231

HPS voltage signal is/was more than 4.9V for more than 0.1 sec.

ECM can't communicate with data link: data link wiring and/or connector fault; interference on data bus; or faulty ECM (eg. dash or WTEC controller).

None None

Additional Actions Taken ECM will ignore OPS signal & disable oil warning & critical level alerts of engine warning & protection feature, with an active code.

Device will be disabled. Engine speed will return to idle speed setting.

Device will be disabled. Engine speed will return to idle speed setting.

ECM will disable, cruise control, PTO operation, fast idle control & road speed limiting, if enabled and limites engine speed in all gears.

HPG is disabled when active.

ECM will disable, cruise control, PTO operation & fast idle control. TPS position will be used when this code is active.

All features using brake signal inputs will be disabled, when this code is active (ie. cruise control, fast idle, HPG, PTO control, CAP & idle shutdown).

ECM will ignore OPS signal & disable oil press warning & critical level alerts of engine warning & protection feature, with an active code.

HPG is disabled when active.

Devices requiring information from data link won't function, including DDR, speedo, tacho etc. Use diagnostic data switch to retrieve codes.

ELECTRONIC MANAGEMENT SYSTEM DIAGNOSTIC CODES Code

Description

241

Injection pressure regulator failed the output circuit check, during the key ON engine OFF standard diagnostic test (ie. voltage drop across pins 17 & 37 was not between 5 - 20 Ohms).

Main power relay failed the output circuit check, during key ON engine OFF standard diagnostic test.

Transmission relay failed the output circuit check, during key ON engine OFF standard diagnostic test (ie. relay resistance was not between 80 - 120 Ohms as measured across pins 85 & 86).

Fan control relay failed the output circuit check, during key ON engine OFF standard diagnostic test.

Radiator shutter relay failed the output circuit check, during key ON engine OFF standard diagnostic test.

SIL lamp failed the output circuit check, during the key ON engine OFF standard diagnostic test (ie. voltage is not between 0.62 and 12/24V).

SEL lamp failed the output circuit check, during the key ON engine OFF standard diagnostic test (ie. voltage is not between 0.62 and 12/24V).

Vehicle retarder relay failed the output circuit check, during key ON engine OFF standard diagnostic test.

The check lamp circuit failed the output circuit failed the output circuitcheck, during the key ON, engine OFF standard diagnostic test(i.e., voltage is not between .62 and 12/24V).

The OTS signal is/was less than 0.2V for more than 0.1 seconds.

243 244

246 256 262

263

265 266

311

Fault Lamp

Additional Actions Taken

None

Engine will not run when this code is active.

None

None.

None

None.

None

None.

None

None.

None

Engine will not run when this code is active.

None

Engine will not run when this code is active.

None

None.

None

None.

Check

The ECM will ignore the OTS signal and use the CTS signal. If both sensors are dysfunctional, the ECM will assume the oil temperature is 29°F(-2°C) for starting and 212°F (100°C) otherwise.

3-23

ELECTRONIC MANAGEMENT SYSTEM DIAGNOSTIC CODES Code

Description

312

The OTS signal is/was less than 4.78V for more than 0.1 seconds

Check

313

Engine oil pressure is/was below one of the warning limits [5Ib/in² @ 700r/min, 10Ib/in² @ 1400r/min, 20 Ib/in² @ 2000r/min].

Stop

314

The engine oil pressure is/was below one of the warning limits [2Ib/in² @ 700r/min, 5Ib/in² @ 1400r/min, 12 Ib/in² @ 2000r/min].

Stop

315

The engine speed was/is above 3 000 r/min.

Check

316

The ECM was not able to warm the coolant temperature to a satisfactory level within 120 min of operation ,using Cold Ambient Protection strategy (ie. 142°F (61°C) for manual transmissions, 106°F (41°C) for automatic transmissions).

The engine coolant temperature is/was above the warning limit [109.0°C (228.2°F)].

None

321

3-24

Fault Lamp Additional Actions Taken

Stop

The ECM will ignore the OTS signal and use the CTS signal. If both sensors are dysfunctional, the ECM will assume the oil temperature is 29°F (-2°C) for starting and 212°F (100°C) otherwise.

To avoid irreparable damage to the engine do not continue to operate the engine when this code is active, unless it is unsafe to shut it down.

To avoid irreparable damage to the engine do not continue to operate the engine when this code is active, unless it is unsafe to shut it down. This code event is stored as a permanent record in the ECM; it can not be erased with a DDR or the DRB. The last two events will be recorded with an engine hour and mileage stamp.

To avoid irreparable damage to the engine, do not continue to operate the engine when this code is active, unless it is unsafe to shut it down. Note: If the coolant temperature drops below 109°C (228.2°F), Code 321 it will become inactive.

ELECTRONIC MANAGEMENT SYSTEM DIAGNOSTIC CODES Code

Description

322

The engine coolant temperature is/was above the warning limit [112.5°C(234.5°F)].

Stop

323

The engine coolant level is/was below the critical limit [98% of Drawdown].

Stop

324

The engine was shutdown in compliance with the Idle Shutdown Control feature settings.

Coolant Temperature Compensation Control is activated.

Stop

325

Fault Lamp

None

331

The IPS signal is/was greater than 3675 Ib/in² (2.5 MPa) for 1.5 seconds.

Check

332

The IPS signal was higher than expected during the standard test (ie. IPS signal was greater than 1.625 V [1160 lb/in² (8 MPa)]).

Check

333

The IPS signal within 362 Ib/in² (2.5 MPa) of the expected value for a period of more than 7 seconds.

Check

Additional Actions Taken To avoid irreparable damage to the engine, do not continue to operate the engine when this code is active, unless it is unsafe to shut it down, Note: If the coolant temperature drops below 112.5°C (234.5°F), Code 322 will become inactive.

To avoid irreparable damage to the engine, do not continue to operate the engine when this code is active, unless it is unsafe to shut it down. After the coolant tank has been filled to the proper level, code 323 will switch from active to inactive status, and the event will be recorded and the total number of occurrences will be incremented.

Engine is shutdown.

Engine power is reduced at a rate of 6% for each degree Celsius above 224.6°F (107°C), due to high coolant temperature.

ECM ignores the IPS signal and attempts to control the engine with the desired values (vs. measured).

The ECM will ignore the IPS signal and use open loop strategy (i.e., The ECM will use a calibrated value based on engine load, engine speed, and temperature to estimate it).

The ECM will ignore the IPS signal and use open loop strategy (i.e., The ECM will use a calibrated value based on engine load, engine speed, and temperature to estimate it).

3-25

ELECTRONIC MANAGEMENT SYSTEM DIAGNOSTIC CODES Code

Description

334

None

421

The actual injection control pressure differs from the desired pressure by more than 1300Ib/in² (9MPa) for more than 3 secs. (ie. the pressure didn’t get to the commanded pressure within the allocated time frame).

The ICP signal was insufficient during cranking speed is at least 130 r/min. (ie. less than 725 Ib/in² (5 MPa) for more than 8 to 10 seconds, varying based on temperature).

The HPG control pressure didn’t get to the commanded pressure within the allocated time frame.

Injector solenoid #1 circuit fault: High side to low side is open.

422

Injector solenoid #2 circuit fault: High side to low side is open.

Stop

423

Injector solenoid #3 circuit fault: High side to low side is open.

Stop

424

Injector solenoid #4 circuit fault: High side to low side is open.

None

425

Injector solenoid #5 circuit fault: High side to low side is open.

None

426

Injector solenoid #6 circuit fault: High side to low side is open.

None

431

Injector solenoid #1 circuit fault: High side shorted to low side.

None

432

Injector solenoid #2 circuit fault: High side shorted to low side.

None

433

Injector solenoid #3 circuit fault: High side shorted to low side.

None

434

Injector solenoid #4 circuit fault: High side shorted to low side.

None

335

336

3-26

Fault Lamp

Additional Actions Taken

None

The ECM will ignore the IPS signal and use open loop strategy (i.e., The ECM will use a calibrated value based on engine load, engine speed, and temperature to estimate it).

Starting difficulty.

None

HPG is disabled when active.

Stop

The ECM will compensate for engine misfire to keep the engine running.

The ECM will compensate for engine misfire to keep the engine running.

The ECM will compensate for engine misfire to keep the engine running.

ECM will compensate for engine misfire to keep engine running.

ECM will compensate for engine misfire to keep engine running.

ECM will compensate for engine misfire to keep engine running.

ECM will compensate for engine misfire to keep engine running.

ECM will compensate for engine misfire to keep engine running.

ECM will compensate for engine misfire to keep engine running.

ECM will compensate for engine misfire to keep engine running.

ELECTRONIC MANAGEMENT SYSTEM DIAGNOSTIC CODES Code

Description

435

Injector solenoid #5 circuit fault: High side shorted to low side.

Fault Lamp None

436

Injector solenoid #6 circuit fault: High side shorted to low side.

None

451

Injector solenoid #1 circuit fault: High side shorted to ground.

None

452

Injector solenoid #2 circuit fault: High side shorted to ground.

None

453

Injector solenoid #3 circuit fault: High side shorted to ground.

None

454

Injector solenoid #4 circuit fault: High side shorted to ground.

None

455

Injector solenoid #5 circuit fault: High side shorted to ground.

None

456

Injector solenoid #6 circuit fault: High side shorted to ground.

None

461 462 463 464 465 466

Injector #1 failed the contribution test.

Injector #2 failed the contribution test.

Injector #3 failed the contribution test.

Injector #4 failed the contribution test.

Injector #5 failed the contribution test.

Injector #6 failed the contribution test.

None None None None None None

Additional Actions Taken ECM will compensate for engine misfire to keep engine running.

ECM will compensate for engine misfire to keep engine running.

ECM will disable an entire bank of cylinders, this includes faulty solenoid & other two on the same pigtail (ie. #1, #2, #3).

ECM will disable an entire bank of cylinders, this includes faulty solenoid & other two on the same pigtail (ie. #1, #2, #3).

ECM will disable an entire bank of cylinders, this includes faulty solenoid & other two on the same pigtail (ie. #1, #2, #3).

ECM will disable an entire bank of cylinders, this includes faulty solenoid & other two on the same pigtail (ie. #4, #5, #6).

ECM will disable an entire bank of cylinders, this includes faulty solenoid & other two on the same pigtail (ie. #4, #5, #6).

ECM will disable an entire bank of cylinders, this includes faulty solenoid & other two on the same pigtail (ie. #4, #5, #6).

3-27

ELECTRONIC MANAGEMENT SYSTEM DIAGNOSTIC CODES Code

Description

513

Low side to Bank #1 (cylinders 1, 2 & 3) is open.

Check

514

Low side to Bank #2 (cylinders 4, 5 & 6) is open.

Check

515

Bank #1 (cylinders 1, 2 & 3) has a low side short to ground. (ie. excessive current draw).

Check

521

Bank #2 (cylinders 4, 5 & 6) has a low side short to ground. (ie. excessive current draw).

Check

525 612

Injector driver circuit fault has been detected.

ECM does not recognise the signal generated by timing disk and TRS, or incorrect TRS installed.

The engine family rating code and ECM configuration do not match.

Programmable parameters for ECM were never changed from the manufacturing defaults.

Programmable parameters for ECM were never changed from the field rating defaults.

None Check

The drivers for cylinders 1, 2 & 3 are disabled. The ECM will compensate for misfire to keep engine running.

The drivers for cylinders 4, 5 & 6 are disabled. The ECM will compensate for misfire to keep engine running.

The drivers for cylinders 1, 2 & 3 are disabled. The ECM will compensate for misfire to keep engine running.

The drivers for cylinders 4, 5 & 6 are disabled. The ECM will compensate for misfire to keep engine running.

Starting difficulty.

Engine won't start.

Check

Starting difficulty or low power.

Check

Engine will produce only 25 hp.

Check

Engine will produce lowest power in its class.

Features won't function. Modify parameters.

Starting difficulty or low power. Reprogram ECM. Engine will produce lowest power in its class.

Features won't function. Attempt to reprogram the ECM.

614 621 622

623 624

3-28

The engine family rating code and ECM strategy configuration do not match.

Programmable parameters for ECM were never changed from the field parameter defaults.

Fault Lamp

Check None

Additional Actions Taken

ELECTRONIC MANAGEMENT SYSTEM DIAGNOSTIC CODES Code

Description

626

Intermittent power loss through main power relay.

Fault Lamp None

631 632 655

Self-test ROM fault.

Self-test RAM fault.

Incompatible programmable parameters list.

Check None None

661

Programmable parameter memory (RAM) content is corrupt.

None

664

Incompatible software calibration level.

None

665

Programmable parameter memory (ROM) content is corrupt.

None

Additional Actions Taken Main power relay is reset. ECM will power down. Operation will be erratic in a power down/reboot loop.

Replace ECM. Replace ECM. Starting difficulty or low power. Features will not function.

Starting difficulty or low power. Features will not function. Replace ECM. Starting difficulty or low power & features will not function. Attempt to reprogram ECM. Starting difficulty or low power & features will not function. Attempt to reprogram ECM.

3-29

Steering Full hydraulic type steering is provided by two single stage, double acting steering cylinders.

To steer the front wheels, rotate the steering wheel in the desired direction to the required radius of turn. The front wheels will turn only as the steering wheel is turned and at a rate of turning directly proportional to steering wheel movement.

The front wheels will stop and hold position when the steering wheel is returned to the central position. To return the front wheels to the straight ahead position or to the opposite direction, turn the steering wheel in the opposite direction.

Allow sufficient room when turning, to avoid scuffing the tyres against kerbs or other obstacles. Turn wide enough to avoid other vehicles parked near intersections. If possible, avoid any debris on the road to prevent unnecessary abuse of the tyres.

WARNINGS Improper steering control unit repair or hose connections can cause sudden and forceful steering wheel movement when engine is started.

Keep hands off steering wheel and ensure area around the scraper is clear when starting the engine.

3-30

1296

Steering Wheel Rotation

Transmission This machine is fitted with a Funk DF250 Powershift transmission equipped with the Funk DF250 Electronic Control Unit (ECU), to operate the transmission.

Upshifting and downshifting are the main functions of the ECU. Another function of the ECU is the capability to communicate with a panel mounted gear/ diagnostic display unit.

WARNING Before any welding is done on the machine, disconnect battery cables from terminal posts (ground cables first) and electrical connections at the ECU to avoid damage to electrical components. Turn off the battery master switch before disconnecting any components.

General Theory of Operation The transmissions performance is determined by the various inputs to the ECU. Based upon these inputs the ECU commands the transmission so that maximum performance can be achieved under the present operating conditions. All functions of the ECU are under software control.

Switching the vehicle's ignition to the 'On' position supplies power to the ECU and related system components from the batteries, through the transient voltage protection (TVP) module. At this point the ECU begins to monitor all inputs and outputs. If a known conflict in inputs or a fault condition is detected, the ECU will command the transmission to stay in Neutral regardless of the shift lever position. A flashing error code will be displayed on the gear/diagnostic display unit, and will remain displayed until the error has been corrected and the shift lever cycled back through the Neutral position.

If no error conditions are detected, the ECU will calculate a speed ratio between the engine speed (derived from the engine speed MPU signal) and the transmission output speed (derived from the transmission output speed MPU).

3-31

Based upon this speed ratio and the combination of inputs from the shift lever and any other applicable inputs, the ECU will select the proper transmission gear and command the transmission to shift to this gear. The gear/diagnostic display unit will show the actual gear selected.

The transmission uses electrohydraulic valves to control the operation of the transmission. The solenoids controlling the transmission clutches (solenoids A through D and 1 through 4) are driven by a pulse width modulated (PWM) signal that produces proportional pressure/flow changes. This is achieved by pulsing the solenoid at a constant frequency and varying the 'on time' of each cycle. The ratio of 'on time' to cycle time is called duty cycle. These transmission solenoids are driven with a maximum duty cycle considerably less than this and ramped up to full on. The initial duty cycle is dependant upon several factors and is not a preset value. The process of modulating these clutches greatly enhances shift quality.

3-32

System Components Description and Operation 1. Electronic Control Unit (ECU) - There is an electronic control unit located beneath the cab. The ECU is the brain of the system. It is responsible for the logic, computation, and decision making processes and the control of the transmission based on these calculations. How the ECU performs is determined by software programmed into the ECU's memory. The ECUs application is specific, therefore ECUs from different vehicles are not interchangeable.

2. Transient Voltage Protection (TVP) Module - The TVP module is responsible for supplying electrical power to the system and protecting the systems electrical components. It provides 40 volt limiting during an electrical load dump malfunction and protection from reverse battery connection. Protection is provided only while the ignition is switched on, thus energizing an internal relay which provides an electrical connection between vehicle power and the protection device inside the module.

3. Engine Speed Magnetic Pickup (MPU) - The engine speed MPU is located in the input housing of the transmission. The MPU provides a signal to the ECU which represents engine speed. This signal is of a sinusoidal nature, varying in amplitude and frequency relative to engine speed. The ECU conditions this signal and converts it into pulses. It then measures the width of these pulses in microseconds, and based on a preprogrammed value in the ECU which represents the number of pulses per revolution of the engine, calculates the engine speed.

4. Transmission Output Speed MPU - The transmission output speed MPU is located in the rear housing of the transmission and provides a signal to the ECU which represents transmission output speed. This signal is of a sinusoidal nature, varying in amplitude and frequency relative to output speed. The ECU conditions this signal and converts it into pulses. It then measures the width of these pulses in microseconds, and based on a preprogrammed value in the ECU which represents the number of pulses per revolution of the transmission output, calculates output speed.

3-33

5. Gear Shift Lever - The transmission provides eight forward ranges, one reverse gear and a neutral position. The lever is detented in the Forward, Neutral and Reverse positions with a positive lock only in the Neutral position.

To move out of the Neutral position, the operator must pull up on the collar.

F N R

The gear shift lever is spring loaded to the centre position. 'Bumping' the shift lever to the upshift or downshift direction sends a corresponding signal to the ECU. 1297

WARNING Do not allow the vehicle to coast in Neutral. This practice can result in severe transmission damage.

When Reverse is selected an audible alarm sounds. This feature warns personnel to the immediate rear of the machine that the operator has shifted the transmission to Reverse.

WARNING Always select Neutral and apply the parking brake before leaving the operator’s seat.

6. Wiring Harness - The wiring harness consists of the various wires needed to provide electrical connections between the components of the system. All connectors in the system are sealed to protect the connections from the environment and to prevent corrosion of the contacts, which would eventually result in a failure.

3-34

Gear Shift Lever

7. Gear/Diagnostic Display Unit - A dash mounted gear/diagnostic display unit provides the operator with information about the system. Under normal operating conditions the display shows the actual forward or reverse transmission gear and the state of the disconnect.

120

50

TRANS OIL

1408

140 150

TEMP

AIR

SERVICE PRESS

Gear/Diagnostic Display Unit

When an error has occurred, the display will flash an error code indicating that a problem has been detected in the system. This error code will continue to flash until the shift lever has been placed in Neutral. Once the ECU has detected a legal Neutral condition, the error will clear and 'NEU' will be displayed. Once the shift lever is moved out of Neutral the error will once more begin to flash. This condition will continue until the error has been corrected and the shift lever cycled through Neutral again. If the error is related to the Neutral signal making it impossible for the ECU to see a legal Neutral signal, the error will continue to flash even in the Neutral position until it is resolved.

8. Diagnostic Test Points - The diagnostic test point for the transmission are located at the front of the fuse box, under the dash panel.

GENERAL TRANSMISSION OPERATION Watch for wide deviations from normal readings on the transmission oil temperature gauge during machine operation. If the transmission oil temperature gauge shows oil temperature consistently rising above the green zone under normal operating conditions; check for external causes. If none are evident shift to Neutral (N) and operate the engine at 1 200 - 1 500 rev/min. If the transmission oil temperature does not decrease into the green zone within 2 or 3 minutes, the cause of the overheating should be corrected before the machine is operated further. Watch the oil temperature gauge when operating on upgrades, also. If the oil temperature goes into the yellow zone, select the range which will limit upshifts to the highest range in which the transmission will operate closest to the normal temperature range (green zone). If upshifting must be consistently limited to ranges lower than normal for the loads and the grades encountered to prevent overheating the transmission oil, the causes should be determined and corrected.

3-35

Power-Locking Differential The power-locking differential allows the operator to increase traction on slippery surfaces where normal differential action between drive wheels is not desirable.

Note: Continued wheel spinning without the power-locking differential applied will result in rapid wear of pinion bushings and tyres.

If one wheel spins on a slippery spot with the other wheel on firm footing, decelerate the engine until the spinning wheel stops then depress the powerlocking differential button. This provides a locking action between the axles, wheels and differentials.

Precautions Note: The following precautions should be observed when using the power-locking differential. Failure to adhere to these practices amounts to abuse of the equipment.

1. The power-locking differential may only be used in first gear.

2. Always apply the power-locking differential before engaging in a potential wheel spinning situation (except in a turn).

3. Never apply the power-locking differential while in a turn or when steering is required.

4. Never apply the power-locking differential with one wheel spinning rapidly on a slippery spot. Decelerate the engine until the spinning wheel stops before locking the differential.

5. Never apply the power-locking differential at speeds in excess of maximum speed attainable in first gear and engine at wide open throttle.

For maximum utilisation of the power-locking differential, it is suggested that it be applied when entering the cut and left on until leaving the cut, wherever possible.

3-36

Apply power-locking action only as required for added traction to prevent bogging down in soft footing either before starting to move, or when momentum has been lost.

1409

Hydraulic System Controls

1 2 3 4

1410

Located to the right hand side of the operator’s seat are four hydraulic control levers. The front lever operates the bowl height, the second lever operates the ejector, the third lever operates the forward elevator speeds, and the last lever operates the neutral and reverse elevator speeds. Operation of these controls are as follows: 1. Bowl - Pull the lever to raise the bowl and push to lower. The control lever will return to the ‘neutral’ (centralized) position when released. The bowl can also be lowered by pressing the bowl drop switch, located on the switch cluster on the dash, but should only be used in an emergency, when the bowl cannot be lowered using the bowl control lever.

2. Ejector - Pull the lever to slide the ejector forward and the floor back (dumping the load) and push the lever to close the ejector and the floor (for material loading position). When pushing the lever to close the ejector, the valve has an electric detent so that the lever will remain in the pushed position until the ejector is in the full closed position. It will then return to the ‘neutral’ (centralized) position without any intervention.

3. Forward Elevator Speed - Pull the lever to set the elevator in low forward speed. Push the lever to set the elevator in high forward speed. The centralized position is neutral. The elevator should be in neutral when no elevator motion is desired or when reverse is selected.

4. Reverse Elevator Speed - Pull the lever to stop the elevator motion. Push the lever to set the elevator in reverse speed. Always set lever 3 (forward speed lever) in the neutral position before activating the reverse speed.

WARNING If the elevator will not engage, check that both the forward and reverse levers are not engaged at the same time.

3-37

3-38

4 - Operating The Scraper 4-1

OPERATING THE SCRAPER Pre-Starting Inspection * Before the engine is started, ensure the machine is ready for operation. * The machine should be in a level position to permit accurate checking of fluid quantities in the engine and other components. * Make sure the parking brake is applied and block wheels securely to prevent accidental movement of the machine while checking component levels. * Test all lights, warning signals, controls and instruments for proper operation. * Walk around the machine and carry out the Inspections and Component Checks described in the drawing opposite and on the following pages.

FUEL TANK Check fuel level. Ensure fuel tank is full.

CAB, PLATFORM AND STEPS Check for cleanliness.

Check seat belts.

WHEELS AND TYRES Check condition, inflation, wheel nuts and for damaged rims.

DIFFERENTIAL Check for leaks.

PIVOT AREA Check for debris.

STEERING CYLINDERS Check for debris, leaks and damage.

Check lines for wear and leaks.

CUTTING EDGES Check for wear and damage ELEVATOR FLIGHTS Check for damage and loose bolts

ENGINE Check oil level.

Check for leaks WHEEL PLANETARIES Check for leaks and damage.

HYDRAULIC SYSTEM Check oil level.

Check for leaks.

TRANSMISSION Check oil level.

Check for leaks.

RIDE CYLINDERS Check for debris, leaks and damage.

BOWL CYLINDERS Check for debris, leaks and damage.

ELEVATOR SYSTEM Check for wear and damage.

ENDGATE AND FLOOR CYLINDERS Check for wear, leaks and damage.

WHEELS AND TYRES Check condition, inflation, wheel nuts and for damaged rims.

4-2

RADIATOR Check coolant level and for leaks and debris in the fins.

1411

LIGHTS Check for debris and damage.

Component Checks - Tractor 1. Engine - With the engine off, check the oil level. Oil should be above the 'Low' mark but not over the 'Full' mark.

Add oil if low.

2. Fuel Strainer - Drain sediment and water from sump until fuel runs clear.

762

1

4

890

3. Radiator - Check coolant level. Add if low.

WARNING Press button in centre of cap to bleed pressure before removing cap completely. Fill to bottom of filler neck.

763

2

5

041

In subfreezing temperatures, be sure that the coolant contains sufficient antifreeze.

4. Air Cleaner Restriction Gauge Check air cleaner restriction gauge, replace elements if required.

5. Tyres - Carefully inspect all tyres for cuts, bruises, or other damage and proper inflation for the loads to be carried. Inflate all tyres to the recommended pressure while cold.

764

3

766

Typical Air Tank Drain Cock

6

6. Air Tanks - Make sure all drain cocks are securely closed.

4-3

7. Hydraulic Tank - Cold Oil Level The oil should be at the 'Cold Level' mark on the sight gauge. Add oil, if low.

Note: Remove filler cap slowly to bleed any air from the hydraulic tank.

8. Transmission - Cold Oil Level This check is made only to determine if the transmission contains sufficient oil for safe starting. Remove cover to access dipstick and make sure there is some oil showing on the dipstick before starting the engine. Add oil if low.

904

7

1096

9

903

8

472

10

9. Fuel Tank - Check fuel level. Tank should be filled at end of each shift to prevent condensation.

10. Seat and Seat Belts - Adjust the seat position and lap belt as required to allow complete machine control at all times with minimum fatigue. Make sure the seat belt does not restrict movement for proper machine operation.

Note: Firmness control will not operate until air pressure has built up.

4-4

Component Checks - Scraper 1. Hydraulic Oil - Located on the right rider fender. With engine off check the oil level. The oil should be at the 'cold level' mark on the sight gauge. Add oil if low.

1418

3

1

2. Elevator System - Check that all bolts are tight, there are no oil leaks.

Check for any loose bearings or bushings. Check for worn or damaged parts.

3. Air Tanks - Drain the air tanks daily and check for leaks.

1419

2

041

4

4. Tyres - Carefully inspect all tyres for cuts, bruises, or other damage and proper inflation for the loads to be carried. Inflate all tyres to the recommended pressure while cold.

4-5

Engine Operation Do not place engine under FULL LOAD at FULL SPEED IMMEDIATELY after starting. ALWAYS allow the engine to fully circulate lubricant and warm up gradually before operating at full speed and full load.

Operate engine at top rated speed when maximum power is needed for the load.

Operation of the engine below top rated speed can occur during gear shifting due to the difference of ratios between transmission gears, but engine operation MUST NOT be sustained more than 30 seconds at full throttle below top rated speed.

NEVER idle the engine more than 5 minutes at a time; shut it off.

If any gauge operates outwith its normal operating range or a warning light illuminates, shut engine down immediately and report to service or maintenance personnel.

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.

Operating the engine beyond high idle speed can cause severe engine damage. The engine speed must not exceed 2 400 rev/min under any circumstances. When descending a steep grade, use a combination of transmission gears, retarder and service brakes to control the vehicle and engine speed.

4-6

STARTING THE ENGINE F N R

1300

1

1302

Above 0° C (32° F) Attention to the warning lights and instruments when starting and operating the engine, will help the operator monitor the machine systems and components.

4

1. Make sure the park/emergency brake control lever is in the 'Park' position.

2. Turn the master switch to the 'On' position.

3. Make sure the scraper control levers are in the 'Neutral' position.

4. Make sure the transmission shift selector is in the 'Neutral' position.

5. Press horn control to sound horn.

1141

2

1412

3

314

5

Note: Always sound horn before starting engine or operating any control.

4-7

6. Turn key switch to clockwise to the first position 'IGN'. Press the warning light test switch to test operation of the warning lights.

0 1

Turn the key further clockwise against spring pressure to crank the engine.

Release the key as soon as the engine starts firing.

2

Note: Never crank the engine more than 30 seconds continuously. Allow starter at least 2 minutes cooling time between cranking periods to avoid overheating.

6

249

7. The amber 'Check Engine' and red 'Stop Engine' lights should come on, and then go out after 6 - 10 seconds. If the amber 'Check Engine' light does not go out, have the system checked out as soon as possible. If the red 'Stop Engine' light does not go out after 6 - 10 seconds, or illuminates during operation, stop the engine immediately.

SERVICE ENGINE SOON

STOP

1303

7

379

8

8. Do not release the parking brake until the air pressure gauge registers a pressure of 6.2 bar (90 lbf/in²) or more.

4-8

Starting the Engine at Low Ambient Temperatures Optional Cold Start Kit (Below 0° C (32° F) Follow steps 1 through 6 for 'Above 0° C (32° F)' described on page 4-8 then the totally automatic fluid cold start system operates as follows: 1. When starter key is turned under cold conditions, a solenoid valve opens automatically, allowing starting fluid to flow out of a pressurized cylinder, through a flow restricting vaporizing orifice and into the engine air intake. A reservoir is built into the valve to maintain a flow of starting fluid for several seconds after the engine starts to prevent the just started engine from faltering Ensure starting aid reservoir has sufficient fluid.

2. Follow normal starting procedures but limit engine speed to 1 200 rev/min and run for two to five minutes, depending on the temperature. Before moving, operate the hydraulic controls to circulate warm oil throughout the hydraulic systems.

WARNING Starting fluid is poisonous and flammable. Breathing vapours or repeated contact with skin can cause personal injury. Use only in well ventilated areas. Use with care to avoid fires. Do not smoke when changing cylinders. Do not store cylinders in the operators compartment, living areas, in direct sunlight or at temperatures above 490 C (1020 F). Discard cylinders properly. Do not puncture or burn cylinders. Keep cylinders out of the reach of unauthorized personnel.

4-9

Starting the Engine with Jumper Cables WARNING Hazardous hydrogen gas and sulphuric acid. Check for required voltage and polarity connections to discharged batteries. Excessive booster voltage and/or incorrect jumper cable connections, open flame, lighted cigar, or other ignition source can cause battery explosion/fire. Keep all sources of ignition away from batteries. Do not lean over batteries, and wear eye protection at all times to prevent personal injury.

Do not jump start a vehicle by using arc welding equipment. Currents and voltages are dangerously high and cannot be sufficiently reduced to make the method safe.

Note: Be sure machines are not touching each other. Use cables that are equal to cable size on the machine, for example (1/0) or (2/0).

If jumper cables are used to start an engine, be sure to follow this procedure: Connect one end of a jumper cable, usually coloured red, to the discharged battery 'POSITIVE' (+) post. Connect the other end of the same cable to the 'POSITIVE' (+) post on the booster or charged battery.

Connect one end of the second cable, usually coloured black, to the 'NEGATIVE' (-) post of the booster battery. Connect the other end of the 'NEGATIVE' (-) cable to machine frame for grounding so that if a spark occurs, it is away from battery fumes (explosive hydrogen).

Check for cause of failure on the dead battery.

4-10

Pre-Operating Checks Make sure all cab glass, mirrors and lights are clean. Test all controls to ensure they are functioning properly. Check all gauges and stop the engine immediately if any gauge is operating outwith its recommended operating range. Select 'REVERSE' momentarily on the transmission shift selector to make sure the reverse alarm sounds.

903

912

1

2

1. Transmission - Hot Oil Level - Adjust bowl height to level the transmission, apply the parking brake and securely block the road wheels. With the engine idling, transmission in 'Neutral' and at normal operating temperature, the oil level should be up to, but not over, the 'FULL' mark on the dipstick. Add oil if low. Do not overfill.

2. Hydraulic Tanks - Hot Oil Level - With the scraper on a level surface, operate the bowl, elevator and ejector controls several times to warm the hydraulic oil and fill all hydraulic lines and cylinders. With the bowl on the ground, elevator stopped and ejector returned, shut off the engine and allow thirty seconds for ride cylinders to retract and steering accumulator to discharge oil back to the tank.

Check the oil level in the Tractor and Scraper hydraulic tank sight gauges. If oil level is below the 'Cold' level, loosen the filler cap slowly to release any pressure developed in the tanks. Remove filler cap and add oil until oil level is between the 'Cold' and 'Hot' marks.

BRAKE FUNCTION CHECKS In addition to the above checks, the following brake function checks can be carried out to determine if both the service and park/emergency brake systems are functional before operating the machine.

WARNING Make sure the area around the machine is clear of personnel and obstructions before carrying out these checks.

4-11

WARNING If the machine moves during these checks, stop the machine, apply the parking brake and do not operate until the fault is corrected.

Note: The following checks are NOT intended to measure maximum brake holding ability. If NEW brake pads are fitted, they MUST be burnished as per the manufacturers recommendations before carrying out the checks.

Service Brake Holding Ability Check With the bowl in the 'Fully Raised' position, depress service brake pedal and select 1st gear on the transmission shift selector. Move the park/emergency control lever to the 'Release' position. Depress engine accelerator control and accelerate engine to 1 350 rev/min. The machine should not move. Decelerate the engine, shift transmission to 'Neutral' and apply the park/emergency brake before releasing the service brake.

Park/Emergency Brake Holding Ability Check With the bowl in the 'Fully Raised' position, move the park/emergency control lever to the 'Park' position and select 1st gear on the transmission shift selector.

Depress engine accelerator control and accelerate engine to 1 350 rev/min. The machine should not move. Decelerate the engine, shift transmission to 'Neutral' and move the park/emergency control lever to the 'Park' position.

Note: Brake holding effort required to hold a machine static at a specific engine speed, can vary from machine to machine due to differences in engine performance, powertrain efficiency, etc., as well as differences in brake holding ability.

Note: As an indication of system deterioration, engine speed at which point the machine moved, with the service or park/emergency brakes applied, can be compared against engine speed your machine was able to hold to on a previous check.

4-12

Driving and Stopping Before driving off observe all instruments and warning lights. All instruments should operate in their normal range and all warning lights should be out.

Make sure the area around the machine is clear of personnel and obstructions before driving off.

1398

Raise Bowl Fully

1

In the first few minutes of travel, check carefully for the required steering, braking, engine and transmission power response for maximum operating safety.

1. Make sure the bowl is fully raised and the hydraulic control levers are in the 'Neutral' position.

2. Apply the service brake and release the park/emergency brake.

3. Select the driving direction required.

2

1414

F N R

1307

3

4-13

4. Sound the horn; two blasts for forward and three blasts for reverse.

F N R

5. Release the service brake, apply power to the tractor wheels by depressing the engine accelerator and move off.

6. To stop the machine release the accelerator pedal and depress the service brake pedal. Release the service brake as the machine slows until, when stopped, the pedal is depressed just enough to hold the machine stationary. Do not 'Fan' the brake pedal as this needlessly wastes the air supply in the air reservoirs.

7. When the machine has stopped, shift the transmission to 'Neutral', apply the park/emergency brake and release the service brake.

314

4

1308

7

1414

5

1300

8

8. If the service brake does not stop the machine. Apply the park/ emergency brake. This should only be applied to stop the machine in an emergency.

4-14

1415

6

WARNING There is no mechanical connection between the engine and wheels on machines with converter transmissions. The parking brake must always be applied when the engine is switched off.

Stopping the Engine 1. Lower the bowl to the ground and return the ejector to the back position.

Place all control levers in the 'Neutral' position.

2. Make sure the park/emergency brake control lever is in the 'PARK' position.

1

1412

3. Make sure the transmission is in 'NEUTRAL'.

Note: Test the application of the brake shoes by momentarily shifting the transmission to 1st gear and accelerating the engine sufficiently to determine that the brake shoes are locked in the 'Applied' position. Return transmission shift lever to the 'Neutral' position.

2

1300

281

5

F N R

4. Allow the engine to idle 3 to 5 minutes after a full load operation before shutting it off. This allows the engine to cool gradually and uniformly.

5. Turn the ignition key switch to the 'OFF' position to shut off fuel and stop engine.

6. Turn the battery master switch to the 'OFF' position.

1302

3

1140

6

4-15

Parking When parking the machine overnight, or for an extended period, the following procedure in addition to that given in 'Stopping the Engine' will help maintain it in good condition for subsequent use: 1. Fill the fuel tanks completely, to prevent condensation. If security kit is supplied, keep it locked.

1096

1

1416

796

2

766

3

2. Always park the machine on level ground where possible. If the machine must be parked on a grade, position the machine at right angles to the grade and block the wheels securely.

3. Place the transmission in 'Neutral' and lower the bowl, stop the elevator and return ejector completely.

Note: If the scraper is to be parked for an extended period, it is good practice to place planks or timbers under the bowl edges to keep the edges off the ground.

4-16

4. Open the drain cocks on all air tanks and leave open so that all condensation will drain completely.

This is especially important in cold weather operation.

Typical Air Tank Drain Cock

4

5. If below freezing temperatures are expected, make sure the cooling system has sufficient antifreeze to prevent the coolant freezing. If antifreeze cannot be added to the cooling system, drain the cooling system completely.

6. Check all tires, hoses, wiring, tubing and fittings for cuts, ply separation, abrasion, fraying, or other damage or deterioration. Inspect for structural damage to the cab, body and chassis. Attach warning signs to the steering wheel or to a control to alert others if lubricant has been drained, batteries removed etc..

7. Clean dirt, mud or other matter from steering, ride, floor and endgate cylinders and bowl and ejector cylinders, particularly from the piston rods. Take care not to damage polished surfaces.

8. Lubricate grease points at the intervals and points specified and with grease specified in Section 8, Lubrication and Servicing, in this handbook.

Note: The above grease points must be lubricated at the proper intervals without fail.

4-17

4-18

5 - Working The Scraper 5-1

WORKING THE SCRAPER Standard Functions 1. Before entering the cut, activate the elevator and then lower the scraper bowl until the cutting blade reaches the desired depth of cut.

2. When the bowl is filled, deactivate the elevator. Raise the bowl sufficiently to clear any obstacles that you may encounter.

3. At the fill area, lower the scraper bowl to the desired depth of fill.

Activate the dump lever. The floor will begin to roll back followed by the endgate moving forward to facilitate the removal of the material from the bowl. Make sure that as the floor rolls back, the strike-off blade drops down to provide the correct leveling action of the scraper.

1413

1

1426

2

1427

3

WARNING Always be aware of obstacles that are higher than the cutting edge.

Never make sharp turns at a high rate of speed.

5-2

Loading 1. When loading, apply the power locking differential (if fitted). Approach the cut squarely and select a relatively slow forward speed, using maximum engine horsepower. Always operate unit as closely to governed RPM as possible. Be sure the endgate is fully closed.

DIFF DIFF

1443

1 2. Engage the elevator in forward (high or low). High speed is used for light loose material. Low speed is used for tough hard to load material. Reverse speed is used to aid in unloading sticky material by preventing the bridging of material between the fixed floor and the elevator. The reverse speed may also be used to free any objects that become lodged between the elevator flights and the cutting edge.

1444

2 3. Lower the bowl to the desired depth or to a depth that will permit the elevator and tractor to operate as a full, constant engine speed. If tire slippage occurs, raise the bowl slightly until traction resumes. The maximum cutting depth will be determined by the material and conditions as well as the height of the elevator adjustment block. (see Elevator Adjustments Section for details on how to adjust the elevator block height).

1421

3

5-3

4. A loading pattern should be established by making the first cut on one extreme side of the loading area.

The second pass should skip, leaving a 8 to 9 feet wide berm for straddle loading. All cuts thereafter follow the same pattern across the work area so that a series of berms will be established. The next level of cuts should be started over the offset berms, which will reestablish the pattern. The berms may be at any width, but not exceeding the inside width of the scraper wheels. The scraper wheels must be able to straddle the berms.

5-4

1 6 1422

5

2 7

4

3 8

4

Loading Tips Loading characteristics of the elevating scraper will be dependent upon the material and conditions, the cutting edge configuration, the elevator block height adjustment, and the elevator mode setting.

Straight Edge 1423

Sand and loose material should use a drop center blade configuration whenever possible. The elevator height block should be turned to one of its two lowest positions (level 1 or 2). If the material is gathering in front of the cutting edge, then the elevator may be placed in the finish mode position in order to move the elevator flights further forward from the cutting edge and facilitate loading of the material.

Hard packed and consolidated material may require shallower cuts to avoid traction slip and elevator stall. Chisel teeth should be used to break up the material in conjunction with the drop center blade configuration. The elevator block height should be set in the highest position (level 4).

Drop Center

General dirt moving should utilize the drop center blade configuration. Chisel teeth are optional. The elevator should be set in the third highest position (level 3).

Windrowed material requires a special elevator configuration. The blade configuration should be be straight without chisel teeth. The elevator should be placed in the finish mode and dropped to the lowest block height adjustment.

1424

Wet or plastic material requires the cutting edges to be in the drop center configuration. Chisel teeth are recommended. The elevator block height should be placed in the highest position (level 4).

Chisel Teeth 1425

5-5

Transporting the load As soon as the rear wheels clear the cut, progressively shift to the speed range which will provide the shortest, safest time cycle practicable, depending on the condition of the haul road. Carry the bowl at the lowest position permissible while traveling to the fill area. Raise bowl higher only when necessary to clear obstacles in the haul road. This will improve the ride and handling characteristics of the scraper by lowering the center of gravity. Reduce speed when approaching corners. Avoid sharp turns at high speeds.

1426

Spreading the load The unit must be kept moving while approaching the fill area. This is necessary to prevent chocking of the ejection system and consequential rough spreading.

Spreading depth can be judged from the operator’s position by observing the distance from the cutting edge to the ground. The strike-off blade can assure an even spread only if the ejection system is operated properly. The ejection system operates rapidly, so care must be exercised not to dump too much material too soon. Weather conditions, type of material, terrain, compaction requirements and length and breadth of fill area are to be considered in selecting a speed range for ejecting and spreading.

1427

A slow speed range should be selected by the operator for the first unloading effort. Raise and lower the bowl position yielding the desired spread depth. Push the ejection control lever until the rolling floor is approximately one-half retracted, then release the ejection control lever momentarily.

The ejector is controlled in the same manner. To stop the ejector momentarily, release the ejection control lever. Actuate the lever again and allow the ejection cylinder to extend to its full length. As the unit progresses over the fill, lower the bowl the required amount to maintain a level spread.

5-6

1427

Watch Bowl Height

Maintain a slow speed throughout the ejection cycle until completely familiar with the unit. Speed will come with practice and experience. An experienced operator will be able to eject and spread with one continuous motion while maintaining a faster speed.

Note: Always retract the ejection system immediately after ejection is completed.

1446

Retract ejection system after ejection is completed

When spreading plastic materials such as gumbo or clay, operate the elevator in reverse, and alternately eject and retract the ejection system, allowing the material to settle rather than compressing into a solid, unworkable mass.

1447

Operator elevator in reverse for ejection of sticky materials

As a general rule, when operating in wet clay or gumbo, use a shallow cut and spread the material heavily. Shallower cuts insure more efficient use of available tractive effort. Heavier spreads are necessary because the wet plastic materials will not eject properly if an attempt is made for a light spread. Avoid packing the bowl too tight with material.

In dry or sandy conditions, use deep cuts and spread shallow. A shallow spread will provide better compaction and better tractive effort.

5-7

Elevator Adjustments There are two elevator adjustments that the operator should be able to make to match the material conditions. The first adjustment is the elevator mode (general dirt moving mode and the finish mode). The second adjustment is the elevator block height.

General Dirt Moving Mode

To change the mode from finish to general dirt moving, use the following procedure: 1. Lift the scraper bowl. Connect a chain from the lug in the center of the yoke to the bottom elevator cross-member. Leave a little slack in the chain and lower the scraper bowl. This will serve to suspend the elevator frame.

2. Connect two chains (a single chain on each side) from the lug on the ejector to the lug on the lower elevator arm. Move the ejector back to tighten the chain. Do not over-tighten the chain. (see figure 3)

Elevator Block Slider Mechanism

1428

Finish Mode

3. Loosen (do not remove) the lower bolt in the slider mechanism. (see figure 2) 4. Remove the top two bolts.

5. After everyone has cleared the area inside the bowl, move the ejector back, thus pulling the elevator back into the general dirt moving mode position.

6. Replace the two top bolts and tighten. Tighten the bottom bolt.

1429

Lower Bolt (do not remove)

A

Chain

Elevator Frame

7. Lift the bowl to allow the elevator to rest on the stops and remove the chains.

Lower Elevator Arm

Ejector

5-8

1430

B

Elevator Mode Adjustment To change the elevator mode setting from the general dirt moving mode to the finish mode, reverse the proceeding procedure.

WARNING Never remove the top slider mechanism bolts before attaching the chains to the ejector. Bodily harm may occur when the elevator moves forward.

Never move the elevator with someone in the scraper bowl or standing in front of the elevator.

Elevator Height Adjustment Block

Lower Elevator Arm

1. Lift the scraper bowl. Connect a chain from the lug in the center of the yoke to the bottom elevator cross-member. Leave a little slack in the chain and lower the scraper bowl. This will serve to suspend the elevator frame. (see figure A)

Chain

Lower Elevator Cross-member 1431

Elevator Frame

2. Once the block is off of the elevator rest, the height adjustment block may be rotated to the selected height setting. Both sides must be adjusted to the same setting for proper elevator function.

A 3. Lift the bowl to allow the elevator to rest on the stops and remove the chains.

WARNING Never place any body part under the adjustment block.

Elevator Height Block (rotate to adjust height) 1432

5-9

Idler Roller Adjustment During the normal course of the life of the elevator chain, a certain degree of stretching will occur. Periodic idler roller adjustment will be necessary to maintain the proper chain tension. To tighten the chain, use the following procedure.

1. Measure the chain tension. Measure from the bottom of the elevator frame to the top of the flight. Take measurements on both sides. When adjustments have been completed, both sides should measure the same.

Elevator Frame

2. Connect a power pull to the lug on the yoke cross-member and connect the other end to the connector on the idler roller arm.

1433

3. Tighten the power pull enough to loosen and remove the top bolt in the idler arm stabilizer.

El

5. Realign bolt in the idler arm stabilizer to the closest bolt hole and tighten.

9"

or

at ev

4. Tighten the power pull and measure the chain tension. Continue to tighten until the tension measures as close to 9 Inches as possible.

e

5-10

1434

am

Fr

6. Release the power pull and adjust the opposite side as needed.

A

B A

B

TYPES OF CUTS Cutting Through Hills To cut out the centre of a hill, the first cut should be taken at stakes 'A'. Work across the hill taking cuts until stakes 'B' are reached. The next cut should be taken one scraper width from the first cut, forming a step. Take cuts across the hill until one scraper width from Stakes 'B' is reached.

This will form a step at stakes 'B' side of the hill. All cuts should be made with the centre of the cut higher than both ends of the cut. Repeat this procedure until the required depth is reached. The steps can be smoothed out with a grader if the slope is gentle, or a crawler if the slope is steep.

Cutting Through Hills

746

STAKE 1

Cutting Banks

2 3

4 5

6

7 9

8

10

11

When cutting down a bank, the first cut should be made at the stakes and then cuts should be made as shown by the numbered sequence shown in the illustration.

This method will keep the scraper level, or leaning toward the bank, and prevent the possibility of the scraper slipping down the bank. A grader or crawler can then smooth out the bank slope after the cuts have been made.

Cutting Banks

747

Stripping Topsoil The cuts should proceed across the cutting area, using the step method of loading.

To step load, a cut is taken on both sides of a scraper wide strip leaving a step in the middle where a third cut can be quickly loaded.

1 748

3 Stripping Topsoil

2

5-11

Starting A Ditch To start a ditch, take several cuts along the ditch grade stakes until the cut is deep enough to allow the scraper cutting edge to approximate the slope required. Place one set of wheels in the cut, the other on the bank and cut the ditch at the required angle. To finish the ditch, use a scraper equipped with a straight cutting edge arrangement.

5 10

4

6

1

9

7

2

11 12

3 8

749

Starting Ditch

TYPES OF FILLS To start a fill, spread the first loads a few feet away from the fill and grade stakes.

This practice compensates for the dirt being pushed out by the scraper and tractor wheels as the fill deepens. If the first loads are spread in line with the stakes, the machine's wheels will push the dirt beyond these stakes resulting in unnecessary bulldozing work to clean up the fill.

5 1

750

2

Starting Fill

When building a fill, the outside edges or shoulders should be kept higher than the centre. This allows the scraper to spread close to the edge without danger of sliding over it. The fill slope can be built at the proper angle, reducing the bulldozer work required to back-finish it.

5-12

1448

Building Fill

3

4

Spread equal layers at the fill site, keeping the centre lower than the sides. When the shoulders reach grade level, it is very easy to finish the fill by filling the centre.

At the end of the work day or when the fill is to be left for a time, always fill in the centre for better drainage.

752

Spread Equal Layers

Where the fill must meet specific compactation requirements, the load must be spread in thin, equal thicknesses, or 'Lifts'. To accomplish this, set the bowl to give the desired lift before entering the fill. As the load is spread, the scraper wheels pull up on the freshly spread material and raise the height of the bowl from the ground.

To compensate for this, lower the bowl to maintain the same lift. If the bowl is not lowered, the spread will be much thicker at the end than it was at the beginning.

1427

Allow for Lift

FINISHING AND GRADING The scraper can be used to finish level ground and moderate slopes, by using a straight edge blade arrangement. If it is necessary to carry dirt from one spot to another, load in the usual manner; however, for grading work, position the ejector forward to produce the same effect as a bulldozer/grader blade.

When finishing a slope, DO NOT attempt to load as the dirt will fall to the lower side of the bowl, resulting in this side cutting deeper than the high side. Always keep tyres at the same inflation pressure. A low tyre pressure on one side will cause the blade to cut deeper on that side.

5-13

5-14

6 - Roading 6-1

ROADING WARNING These machines are equipped with cylinders containing compressed nitrogen gas. Transportation of these machines by any method may require a special permit from the appropriate authority of the country involved. Consult your Dealer for details.

General 'Roading' (operating a scraper over public highways) requires special care and attention. Scrapers, because of their large size, are slower and less manoeuvrable than most other machines encountered on the road. Yet, while on the road, they must be operated for extended periods of time at, or near, maximum speeds.

Before 'Roading' a scraper for an extended distance between jobs, or between widely scattered sections of a job, the machine must be properly equipped and in good condition. It is also recommended to carry a 'Warning Triangle'.

The operator must use extra care while on the public highways and remain constantly alert, especially for overhead cables and low bridges.

Necessary permits must be obtained from the proper authorities before the machine is 'Roaded' on public highways.

Preparation Prior to Roading Lubrication Thoroughly lubricate and service all components and systems as described under 'LUBRICATION AND SERVICING' in this handbook and/or Maintenance Manuals for this machine.

6-2

Inspection Perform all pre-starting and post-starting checks described in this Handbook.

Pay particular attention to the function of all instruments and lights, and make any repairs necessary.

Note: Improper tyre inflation during over-the-road operation can cause rapid tyre deterioration by overheating. Tyre pressures increase with heat. Always check pressures while tyre is cold. Consult your tyre dealer for proper pressures and tyre speed limits for roading.

Check the inflation pressures of all tyres, while cold, with an accurate tyre pressure gauge. Inflate tyres if necessary, while cold, to the recommended pressure for 'Roading'. Inspect all tyres thoroughly and carefully for stones or other debris embedded in the treads or carcasses. Inspect for cuts, bruises, burned beads abnormal wear and damaged wheels rims. Replace any damaged or excessively worn tyres.

Check all hoses, drain cocks, fuel level check cocks, and other potential sources of air or fluid leaks. Make sure that all leaks are repaired and that all drain cocks are sufficiently tightened to avoid subsequent loosening. Make sure that all warning flags, oversize load signs etc. are in place and secure.

Clean all glass and adjust the seat for proper operation of all controls.

Check the lights, horn, windscreen wipers, heater, defroster, headlight dip control, and all controls for proper operation.

Make sure the scraper bowl is empty and in a fully raised position and the ejector fully retracted.

Make sure all hydraulic control levers are in the 'Hold' position.

6-3

In Case of Trouble If trouble develops enroute, move machine off the road at the first safe parking place, and shut off the engine. Carefully note as many of the symptoms of the trouble as possible, such as rough engine operation with loss of power and overheating, or loss of speed and transmission clutch pressure with normal engine operation etc..

If the area in which the trouble occurs requires that the machine be left unattended while the trouble is reported by phone, disconnect a battery cable and apply security locks, if so equipped, before leaving the parked machine.

Make sure bowl is completely lowered, if it has not been blocked up in the travel position, and the parking brake is applied.

Report the following data as soon as possible: 1. Exact location.

2. Destination.

3. The nature of the trouble (with as many details as possible) and the time and conditions under which it happened.

4. The telephone number at which the machine operator can be reached.

Note: Do not attempt to restart or operate the machine unless instructed to do so.

An engine, pump, transmission or other component that develops a minor defect can be completely destroyed in just a few extra minutes of unnecessary operation.

6-4

7 - Moving Disabled Scraper 7-1

MOVING DISABLED SCRAPER Any unusual powertrain noises noted while operating the scraper should be reported to those responsible for maintenance. Should the powertrain, air, hydraulic or electrical systems fail, the machine should be stopped and shut down immediately until suitable repairs can be made. If the failure is in the powertrain and the scraper must be moved to a service area or workshop to make required repairs, remove the planetary flange covers from the tractor wheels and pull out the axle shafts. This will prevent any possible additional damage which may be caused by the drive wheels turning the powertrain as the machine is towed. Replace the covers on the drive wheels to retain lubricant and prevent entry of dirt.

If possible, start the engine to provide the required air and hydraulic pressure for steering and braking. Never allow riders on a machine being towed without sufficient hydraulic pressure for safe steering and braking.

If the nature of the trouble prevents engine operation, repairs must be made on the site of the breakdown, or special arrangements made for towing the machine safely to the repair area without braking and steering power.

WARNING Uncontrolled machine movement hazard. There is no mechanical connection between the machine wheels and the engine when the parking brake is released. Before releasing the parking brake, make sure the machine wheels are secured with chock blocks to prevent or restrict unexpected machine movement. When moving the machine with insufficient air and hydraulic pressure, for safe braking and steering, use extreme caution to ensure personnel and property safety.

7-2

098

If the safety or parking brake has been applied and the engine cannot be started, the air tanks must be recharged by an external source to release the brakes before the scraper can be moved.

WARNING When using a chain or cable, be sure it is strong enough for the expected load and properly secured.

When pulling, take up the slack slowly to avoid jerking. A chain or cable which fails under load can cause serious injury. Stand clear. Do not pull through a kinked chain or cable. Do not pull or tow unless the operator's compartment is guarded against, or out of reach of, a whipping chain or cable. Attach only to the towing hook. Failure to follow these instructions could cause serious injury or death.

7-3

7-4

8 - Lubrication and Servicing 8-1

SAFETY PRECAUTIONS Do not allow unauthorized personnel to service or maintain this vehicle. Study the Operator’s Handbook and Maintenance Manual before starting, operating or servicing this vehicle. Always follow procedures and safety precautions detailed detailed in the Maintenance Manual.

Never allow anyone to work on the vehicle while it is moving.

Make sure there is no one on the vehicle before working on it.

Do not work under or near any unblocked or unsupported linkage, part or vehicle.

Always shut down machine according to the procedure under 'Stopping The Engine', described in page 4-15 of the Operator's Handbook. Turn off the master switch before cleaning, lubricating or servicing the machine except as called for in the Operator's Handbook or the Maintenance Manual.

Always relieve pressure before servicing any pressurized system. Follow the procedures and safety precautions detailed in the relevant Maintanance Manual section.

When changing oil in the engine, transmission and hydraulic systems, or removing hydraulic lines, remember that the oil may be hot and can cause burns to unprotected skin.

When working on or around exhaust components, remember that the components may be hot and can cause burns to unprotected skin.

Always deflate the tyre before attempting to remove any embedded objects or removing the tyre and rim assembly from the vehicle.

Always use a self-attaching chuck with a long airline, and, stand to one side while the tyre is inflating. Refer to Maintenance Manual Section 160-0050, WHEEL RIM AND TYRE.

8-2

Always attach a 'DO NOT OPERATE' or similar warning sign to the ignition switch or a prominent control before cleaning, lubricating or servicing the vehicle.

LUBRICATION AND SERVICING WARNING These vehicles are equipped with engine and transmission oil pans which permit operation on longitudinal slopes up to 30° (57%). For operation on steeper slopes, the factory should be consulted.

Lubrication is an essential part of preventive maintenance. It is important that the instructions, regarding types of lubricants and the frequency of their application, be followed to prolong the useful life of the vehicle. Periodic lubrication of moving parts reduces to a minimum the possibility of mechanical failures.

Thoroughly clean all fittings, caps, plugs etc., to prevent dirt from entering any system while servicing .

Lubricants must be at operating temperature when draining.

Do not operate any system unless oil level is within the recommended operating levels as indicated on oil level dipstick, sight gauge or level plug.

Small circles on the following illustration represent points at which lubrication and/or servicing must take place, at the intervals indicated on the left hand side of the lubrication and service chart.

The numbered circles on the illustration contain reference numbers which correspond to the reference numbers in the 'Ref. Points' column of the lubrication and service chart.

All change and service periods are recommendations based on average operating conditions. Lubricants showing evidence of excessive heat, oxidation or dirt should be changed more frequently to prevent these conditions. Lubricant change and service periods must be established on the basis of individual job conditions.

Note: At each scheduled maintenance interval, perform all previous checks in addition to the ones specified.

8-3

TRACTOR 1

6

13

8-4

1310

3

10 12

7

11

9

10

12

7

11

4

8

2

9

10

5

4

LUBRICATION AND SERVICE CHART - TRACTOR Interval Hours

10

50

150

Ref. Points Identification

No. of Points

Lubricant

Service/Quantities

Check oil level. Add if low Check oil level. Add if low Check oil level. Add if low Check coolant level. Add if low Drain water Drain water and sediment Visually inspect for debris & damage Visually inspect all belts Drain all air tanks Check gauge. Replace element if reqd Drain water Check condition. Check pressures when tyres are cold Check for proper operation Check for leaks and damaged parts.

Repair/replace as required

1 1 1 1 1 1 1 3 1 1 2

EO HTF HO Antifreeze -

As required As required As required As required See page 13 Sec. 160-0050, Main.Man.

-

-

Service Instructions

1 2 -

Engine Transmission Hydraulic Oil Tank Coolant Level Fuel Tank Fuel Filter/Water Separator Cooling Fan Drive Belts Air Reservoirs Air Cleaner Restriction Air/Water Separator Tyres

-

Controls and Instruments General Inspection

3 4 5 -

Steering Frame Pins Steering Cylinder Pins Reversing Valve Rollers Remote Lubrication Points - Basic

Lube Lube Lube Lube

2 4 2 3

EP, NLGI EP, NLGI EP, NLGI EP, NLGI

See Note 1 on page 11 See Note 1 on page 11 See Note 1 on page 11 See Note 1 & page 7

7 8 9 10 11 12 13 -

Cooling System Planetary Assemblies Differential Driveline Slip Joints Universal Joints Brake Cam Shafts Brake Shoe Anchor Pins Steering Gear Differential Breather Remote Lubrication Points - Brakes

Check antifreeze concentration Check oil level. Add if low Check oil level. Add if low Lube Lube Lube Lube Lube Clean Lube

2 1 2 4 2 4 1 1 1

EPL EPL EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI

Ref. Engine Manual As required As required See Note 1 on page 11 See Note 1 on page 11 See Note 1 on page 11 See Note 1 on page 11 See Note 1 on page 11 See Note 1 & page 7

-

8-5

LUBRICATION AND SERVICE CHART - TRACTOR (Continued) Interval Hours

Service Instructions

No. of Points

Lubricant

Service/Quantities

250

-

Trans. Input Flange/Yoke

Lube

1

300

1

Engine Lube Oil Filters Engine

Replace Drain oil and refill

1

EO

Ref. Engine Manual 24.6 litres (6.5 US gal)

-

Transmission Oil Filter

Replace

1

-

-

-

Fuel Filters and Strainer Drive Belts Hydraulic Filter Hydraulic Tank Breather Air Compressor Governor Coolant Inhibitor

Replace filters and clean housings Check tension. Adjust if required Change filter element Clean Clean or replace filters Replenish

1 1 1

-

Ref. Engine Manual Ref. Engine Manual -

500

600

EP, NLGI See Page 13

900

-

Engine Coolant Filter

Replace filter/conditioner element

1

-

1 000

2 -

Transmission Transmission Oil Filter

Drain oil and refill Replace

1 1

HTF -

48.5 litres (12.8 US gal) -

6 7 8 -

Engine Power Takeoff Engine Air Cleaner Engine Crankcase Breather Planetary Assemblies Differential Cooling System

Drain oil and refill Clean inlet hood and tubes Replace element Drain oil and refill Drain oil and refill Drain coolant and refill

1 1 2 1 1

EPL EPL EPL Antifreeze

See Page 14 43 litres (11.4 US gal)

1 800

-

Hydraulic System Hydraulic Oil Tank Screen

Drain oil and refill Remove and clean

1

HO -

204 litres (54 US gal) -

2 000

-

Air Drier

Replace dessicant cartridge.

1

-

-

2 400

-

Engine Cooling System

Drain coolant and refill. Replace filters

-

-

Ref. Engine Manual

1 200

8-6

Ref. Points Identification

TRACTOR Remote Lubrication Points

1. BRAKE CAMSHAFT 2. BRAKE SAFETY CHAMBER 3. BRAKE SAFETY CHAMBER 4. BRAKE SHOE ANCHOR PIN 5. BRAKE SHOE ANCHOR PIN 6. BRAKE SHOE ANCHOR PIN 7. BRAKE SHOE ANCHOR PIN 8. BRAKE CAMSHAFT

For improved accessibility, remote lube lines are run to manifold blocks mounted on the front right hand side engine cover and the front right hand side of the yoke. These lines should be inspected periodically for damage.

1 3 5 7 2 4 6 8

Apply sufficient grease into each nipple until there is clear evidence of grease emerging from one or two of the clearly visible connected bearing points.

Do not over grease the brake system.

BULKHEAD CONNECTOR ENGINE COWLING

1. ROLLER 2. STEERING FRAME PIN 3. ROLLER 4. STEERING FRAME PIN 5. STEERING CYLINDER PIN 6. STEERING FRAME PIN 7. STEERING CYLINDER PIN 8. DRIVE BEARING

1450

1 3 5 7 2 4 6 8

When a component is lubricated, the general condition of the component should also be visually checked. Look for cracked parts, loose fasteners, excessive wear, or improper clearance as applicable to the component being lubricated.

Follow procedures detailed in Section 300-0020 of the Maintenance Manual.

8-7

SCRAPER 8

9

10

7

8-8

1435

11

6

12

5

4

13

20

14

3

2

20

15

16

17

1

18

19

LUBRICATION AND SERVICE CHART - SCRAPER Interval Hours 10

50 150 250 1 000

1 800

Ref. Points -

Identification Air Reservoirs Tyres

-

General Inspection

1 2 3 4 5 6 7 9 10 11 12 14 15 16 17 20 8 18 19 -

Hydraulic Reservoir Upper Elevator Arm Idler Roller Lower Elevator Arm Lower Elevator Arm Lower Stub Spindle Lower Cylinder Pin Upper Cylinder Pin Upper Cylinder Pin Lower Cylinder Pin Lower Stub Spindle Lower Elevator Arm Idler Roller Upper Stub Spindle Upper Elevator Arm Actuator System Floor Rollers Kingpin, Steering Cylinder RH Brake Remote Valve LH Brake Remote Valve Hydraulic Filter Elevator Gearbox Wheel Bearings Idler Roller Hydraulic System

Service Instructions Drain all air tanks Check condition. Check pressure when tyres are cold.

Check for leaks and damaged parts Repair/replace as required Check oil level, Add if low Lube Lube Lube Lube Lube Lube Lube Lube Lube Lube Lube Lube Lube Lube Lube Lube Lube Lube Lube Change Filter Element Drain and replace oil Clean and repack bearings Clean and repack bearings Drain and replace oil

No. of Points 2 2

Lubricant Service/Quantities -

-

-

1 2 1 1 1 1 1 1 1 1 1 1 1 1 2 1 4 1 1 1 1 1 2 2 1

HO EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI EPL EP,NLGI EP,NLGI HO

As Required See Note 1 on page 11 See Note 1 on page 11 See Note 1 on page 11 See Note 1 on page 11 See Note 1 on page 11 See Note 1 on page 11 See Note 1 on page 11 See Note 1 on page 11 See Note 1 on page 11 See Note 1 on page 11 See Note 1 on page 11 See Note 1 on page 11 See Note 1 on page 11 See Note 1 on page 11 See Note 1 on page 11 See Note 1 on page 11 See Note 1 on page 11 See Note 1 on page 11 See Note 1 on page 11 See Parts Book -

8-9

RHS REAR PUSH-BLOCK

RHS OF YOKE 1 3 5 2 4 6

1 3 5 2 4 6

1. UPPER KINGPIN 2. LOWER KINGPIN 3. PLUGGED 4. PLUGGED 5. STEERING CYLINDER PIN 6. STEERING CYLINDER PIN

1 3 5 2 4 6

1. UPPER ACTUATOR PIN 2. UPPER ACTUATOR PIN 3. ACTUATOR CYLINDER PIN 4. FLOOR STABILIZER PIN 5. PLUGGED 6. PLUGGED

1 3 5 2 4 6

8-10

1436

1. BRAKE SHOE ANCHOR PIN 2. BRAKE SHOE ANCHOR PIN 3. SPIDER BEARING 4. CAM SHAFT SUPPORT 5. CAM SHAFT SUPPORT 6. SLACK ADJUSTER

1. BRAKE SHOE ANCHOR PIN 2. BRAKE SHOE ANCHOR PIN 3. SPIDER BEARING 4. CAM SHAFT SUPPORT 5. CAM SHAFT SUPPORT 6. SLACK ADJUSTER

SCRAPER Remote Lubrication Points For improved accessibility, remote lube lines are run to a manifold block mounted on the right rear of the pushblock and on the right side of the yoke. These lines should be inspected for damage periodically.

Apply sufficient grease into each nipple until there is clear evidence of grease emerging from one or more of the visible connected greasing points.

Do not over-grease the brake system.

When a component is lubricated, the general condition of the component should be visually checked. Look for cracked parts, loose fasteners, excessive wear, or improper clearances as applicable to the component being lubricated.

NOTE: Capacities in lubrication charts given are approximate. Work to dipstick, sight gauges or level plugs. Use charts in conjunction with 'Recommended Lubricants' table pages 15 and 16.

Note 1

- Lubricate slowly until excess lube is seen.

EO

- Engine Oil. Refer to 'Recommended Lubricants' table.

*

- Refer to 'Recommended Lubricants' table.

EPL

- Extreme Pressure Gear Lubricant spec. MIL-L-2105D.

HTF

- Hydraulic Transmission Fluid Type C-4. Refer to 'Recommended Lubricants' table.

HO

- Hydraulic Transmission Oil. Refer to 'Recommended Lubricants' table.

EP, NLGI - Extreme Pressure Lithium No. 2 Grease. Refer to 'Recommended Lubricants Table'.

Follow procedures detailed in Section 300-0020 of the Maintenance Manual.

8-11

ADDITIONAL MISCELLANEOUS SERVICING INFORMATION EVERY 10 HOURS OF OPERATION (DAILY) Walk Around Inspection - Inspect machine (As per Section 4).

Engine -

Visually check engine for damage, loose or frayed belts and listen for any unusual noises.

Engine Air Cleaner -

Change air cleaner element only when air restriction gauge locks up in the red. Service dust cup daily.

Note: Service air cleaners more often when operating under extremely dusty conditions.

Engine Crankcase -

Check oil level and add oil if low. With the engine off, the oil should be between the 'Low' and 'Full' marks on the dipstick, up to the 'Full' mark is preferable.

Transmission -

Adjust bowl height to level the transmission and, with the engine running and oil at normal operating temperature, check oil level. Add oil if the level is below the 'FULL' line on the dipstick. Do not overfill.

Cooling System -

Check coolant level, add if low. Add coolant to the botom of the filler neck.

AFTER FIRST 50 HOURS OF OPERATING NEW OR REBUILT COMPONENTS Transmission -

Drain oil, replace filter and refill.

AFTER FIRST 150 HOURS OF OPERATING NEW OR REBUILT COMPONENTS Differential Drain oil and refill.

8-12

Planetaries -

Drain oil and refill.

EVERY 150 HOURS OF OPERATION General Inspection -

Check entire scraper for leaks, loose bolts and nuts or damaged parts. Examine the scraper, particularly the chassis, for cracks or broken welds. Repair where necessary.

Oil Can Points -

Oil brake treadle rollers and other working parts with engine oil.

Drive Belts -

Visually check the belts and replace if they are cracked or frayed. Adjust belts that have a glazed or shiny surface which indicates belt slippage. Correctly installed and tensioned belts will show even pulley and belt wear. Refer to 'Engine Operation and Maintenance Manual' for drive belt tension and adjustment of new and used belts.

Note: The fan belt is maintained to the correct belt tension by a spring loaded idler arm, therefore, there is no need to adjust belt tension.

EVERY 250 HOURS OF OPERATION Transmission Input Flange/Yoke -

Cooling Fan -

Remove the breather and lubricate through the lube fitting with a hand grease gun until grease exits the breather hole. Do not over grease. Reinstall breather.

Note: Failure to lubricate with a No. 2 Consistency grease could cause premature failure of the input bearing.

Visually check fan for cracks, loose rivets, and bent or loose blades. Check fan mounting and tighten if required. Replace any fan that is damaged.

8-13

EVERY 600 HOURS OF OPERATION Coolant Inhibitor -

Check and replenish coolant inhibitor as described in Engine 'Operation and Maintenance Manual'.

EVERY 1 200 HOURS OF OPERATION Engine Power Takeoff -

Drain and refill. Remove bottom pipe plug in PTO cover and drain oil into a suitable container. Reinstall pipe plug and refill to level of check cock.

EVERY 1 800 HOURS OF OPERATION Hydraulic Oil Tanks -

Drain tanks, remove and clean filter screen assembly and discard filter elements. Reinstall filter screens, new filter elements - including the return oil filter element located on the pull yoke - and refill with clean hydraulic oil. Refer to Section 235-0040, HYDRAULIC TANK in the Maintenance Manual.

ENGINE AND TRANSMISSION All information contained in the 'Lubrication and Service Chart' was extracted from the relevant manufacturers Operators Manual and was correct at time of publication. User should ensure that information contained in this chart, regarding the Engine and Transmission, reflects the information shown in the relevant manufacturers Operators Manuals, supplied with the machine.

Maintenance procedures should be carried out in conjunction with any additional procedures contained in the relevant manufacturers 'Operation and Maintenance Manual', at the intervals specified.

8-14

RECOMMENDED LUBRICANTS COMPONENT

LUBRICANT

Engine

Engine oil with 1.00% sulphated ash is recommended.

Sulphated ash must not exceed 1.85% limit.

API Classification Military Specifications SAE Grade Transmission

VISCOSITY (See Note 1) The use of low viscosity oils, such as 10W or 10W-30, can be used to aid in starting the engine and providing sufficient oil flow at ambient temperatures below -5°C (23°F).

Continuous use of low viscosity oils can CG-4 or CF-4 decrease engine life due to wear.

MIL-L-2104E 15W-40

Hydraulic Transmission Oil, Type C-4. See Note 3.

Ambient

Recommendation

-30° to 30° C -25° to 30° C -15° to 30° C -10° to 30° C -5° to 50° C 0° to 50° C

SAE 0W-20 (Arctic) DEXRON-III SAE 10W SAE 15W SAE 30 SAE 40

Differential, Planetary Gears, Power Takeoff, Steering Gear

Multipurpose Extreme Pressure type gear oil meeting MIL-L-2105C Specifications (No Zinc Additive).

SAE 80W-90 at ambient temperatures of -18° to 32° C

Grease Fittings

Multipurpose Extreme Pressure Lithium Grease with a typical melting point of 190° C.

No. 2 Consistency

8-15

RECOMMENDED LUBRICANTS (Continued) COMPONENT

LUBRICANT

Cooling System

Antifreeze, Ethylene Glycol

VISCOSITY (See Note 1)

Fuel Tank

Diesel Fuel Oil with maximum sulphur 0.5%

DIN EN590

Hydraulic System

Hydraulic Transmission Oil meeting MIL-L-2104C Specifications or API Service Code CC or CD/SC

SAE 10W at ambient temperatures of -18° to 32° C

Drivelines, Steering Column

Multipurpose Extreme Pressure Lithium Grease (without 'Molybdenum'), with a typical melting point of 190° C.

No. 2 Consistency

Note 1 - Consult your lubricant supplier for the correct viscosity of lubricant to use when ambient temperatures are consistently above or below those listed.

Note 2 - Detroit Diesel does not recommend any specific brand of engine oil but the use of oils that meet API categories.

Detroit Diesel recommends use of only the multi-graded viscosity oils shown for the various ambient temperatures listed.

Note 3 - Preheat is required below minimum temperatures shown. Operation below the minimum temperatures listed for the oil used without proper preheat or warm-up results in greatly reduced transmission life. Proper warm-up requires 20 minutes minimum operation in neutral (with engine at part throttle) before operating the transmission in gear.

Hydraulic Transmission Oil meeting Specification EMS19058 may also conform to type C-4 requirements. Consult your lubricant supplier for confirmation.

Temperature Conversions

8-16

° Celsius

-32

-30

-27

-25

-20

-18

-15

-10

-5

0

10

15

25

32

35

38

50

93

° Fahrenheit

-26

-22

-17

-13

-4

0

5

14

23

32

50

59

77

90

95

100 122 200

9 - Technical Data 9-1

3 405 (11-2) Maximum Width

3 150 (10-4) 2 340 (7-8)

2 340 (7-8) 2 945 (9-8)

3 150 (10-4)

8 965 (29-5)

3 300 (10-10)

3 250 (10-8)

368 (0-14) 230 (0-9) 3 100 (10-2)

7 365 (24-2) 12 295 (40-4)

All vertical dimensions with bowl at 370 mm (14.5 in) carry position. Unit empty.

9-2

1453

1 855 (6-1)

Dimensions in mm (ft-in)

S17E TECHNICAL DATA

TRANSMISSION

DIMENSIONS

Funk DF250 Powershift, counter-shaft type transmission with integral torque converter. Eight speeds forward and one reverse.

Automatic lockup in the top six forward gears. Manual, electric shifting and downshift inhibitor.

Wheelbase ................................................................ 7 365 (24-2) Length - overall ........................................................ 12 295 (40-4) Length - scraper hitch to push block ......................... 8 965 (29-5) Width - overall maximum ........................................... 3 405 (11-2) Elevator Height - maximum at Bowl carry ................. 3 300 (10-10) Elevator Height - Blade down .................................... 3 090 (10-2) Width of Cut (cutting edge) ...................................... 3 110 (9-10.5) Depth of Cut - maximum ................................................ 230 (0-9) Depth of Spread - maximum .......................................... 318 (12.5) Clearance under Bowl .................................................. 368 (0-14) Non-stop 180o Turning Width for vehicle clearance ................................................ 18.1 m (59-6)

ENGINE Make ...................................................................... Detroit Diesel Model/Type ................................ Series 40, 4 Cycle Turbocharged Gross Power @ 2 000 rev/min ............................ 224 kW (300 hp) Net Power @ 2 000 rev/min ................................. 213 kW (285 hp) Gross power rated to SAE J1995 June 90.

Engine emission meets USA EPA / CARB MOH 40 CFR and EU NRMM (Non-Road Mobile Machinery) Directive.

Maximum Torque @ 1 300 rev/min ............. 1 458 Nm (1 075 lb ft) Cylinder Configuration ....................................................... 6 in line Bore and Stroke .......................... 117 x 136 mm (4.59 in x 5.35 in) Piston Displacement ........................................... 8.7 litre (530 in3) Air cleaner ............................................................. Dry, Aspirated Starting ............................................................................. Electric Maximum Speed (No load) ....................................... 2 450 rev/min Maximum Speed (Full load) ...................................... 2 200 rev/min Idle Speed .................................................................. 700 rev/min Safe Operating Angle ......................................... 30°/57% Grade

Maximum Speed ....................................... 51 km/h (31.5 mile/h) Stall Speed ............................................................ 2 013 rev/min Torque Converter Ratio (front and rear) ........................ 2.133:1

SPEEDS WITH STANDARD DIFFERENTIAL Forward Gear 1 2 3 4 5 6 7 8 Ratio 8.04 5.73 4.11 2.43 2.03 1.44 1.04 0.739 km/h 4.38 6.15 8.53 11.97 17.28 24.34 33.72 47.45 mile/h 2.72 3.821 5.30 7.44 10.74 15.13 20.96 24.49 Reverse Ratio 4.11 km/h 9.06 mile/h 5.63

AXLES Heavy duty axles with fully-floating axle shafts, single reduction bevel gear differential and planetary reduction in each wheel. A pedal controlled power-locking differential is standard, operational in first gear only.

Ratios: Differential ..................................................................... 4.60:1 Planetary ....................................................................... 4.59:1 Total Reduction ........................................................... 21.11:1

9-3

TYRES AND WHEELS

ELEVATOR

Tractor and Scraper ................................................... Rim Width Standard 29.5 R 25 (**) Radial ............................................ 25 in Optional 29.5-25 (28 PR) E-3 .............................................. 25 in Consult tyre manufacturers for optimum tyre selection and correct t-km/h (ton-mile/h) capacity for application.

Drive ...................... Vane type hydraulic motor with gear reduction Elevator Pump: Type .................................................................................. Gear Drive ................................................................................ Gear Capacity @ 2 200 rev/min and 128 bar (1 850 lbf/in2) Low Speed ................................. 5.5 litre/sec (87 US gal/min) High Speed ............................... 7.8 litre/sec (123 US gal/min) System Pressure ........................................ 138 bar (2 000 lbf/in2) Reduction Ratio .................................................................. 58.4:1 Drive Sprockets: ......................................................................... 2 Teeth per Sprocket ............................................................... 18 Speeds: Low .......................................................... 32.7 rev/min High ......................................................... 49.7 rev/min Reverse ................................................... 32.7 rev/min Chains: ....................................................................................... 2 Links per Chain ..................................................................... 71 Pitch ........................................................... 103.2 mm (4.063 in) Speeds: Low .......................................... 59.1 m/min (194 ft/min) High ......................................... 81.4 m/min (267 ft/min) Reverse ................................... 59.1 m/min (194 ft/min) Flights: ...................................................................................... 14 Length ................................................................ 2 134 mm (84 in) Width ..................................................................... 203 mm (8 in)

BRAKES Full air operated drum brakes with automatic application on loss of air pressure. Secondary system can also be manually applied. Spring-applied parking brake actuators. Independant brake circuits front and rear. Air drier standard.

Braking Lining: Diameter ...................................................... 508 mm (20 in) Shoe Width .................................................... 152 mm (6 in) Lining Thickness ........................................ 19 mm (0.75 in) Lining Area - Each Axle ......................... 3 355 cm² (520 in²) Air Compressor Capacity ............... 374 litre/min (13.2 ft³/min) STEERING SYSTEM

9-4

Full hydraulic type provided by two interchangeable single stage, double acting steering cylinders. Steering cylinders are mounted below the gooseneck to aid stability.

System Pressure @ 1 500 rev/min .......... 135 bar (1 950 lbf/in²) Pump: Type ................................................................................. Gear Drive .......................................... In tandem with hydraulic pump Capacity @ 2 200 rev/min ........... 2.4 litre/sec (38.7 US gal/min) Steering Cylinder: Bore and Stroke ........................... 140 x 445 mm (5.5 x 17.5 in) Steering Angle to either side ................................................. 90°

CUTTING EDGE The cutting edge is in three sections with variable length (depth?) drop centre. Six bolt-on teeth provide maximum penetration. The two end sections are interchangeable. All the sections are reversible.

Dimensions: Outside sections ...... 432 x 746 x 25 mm (17.0 x 29.4 x 1.0 in) Centre sections ... 432 x 1 521 x 25 mm (17.0 x 59.88 x 1.0 in)

BOWL

VOLUMES

The bowl employs two single-stage double-acting interchangeable hydraulic cylinders.

Bowl Cylinder Bore and Stroke ............... 203 x 457 mm (8 x 18 in)

Heaped 1:1 (SAE) .............................................. 13m³ (17.0 yd³)

EJECTION Combination sliding floor and ejector end gate controlled by two single-stage double-acting hydraulic cylinders. As sliding floor opens, strike-off blade automatically swings into position to provide smooth, even spreading of material.

Sliding Floor Control Cylinder: Bore and Stroke ................................. 127 x 457 mm (5 x 18 in) Ejector and Gate Control Cylinder: Bore and Stroke ........................... 127 x 1 194 mm (5 x 47 in)

SERVICE CAPACITIES Tractor Cooling System ........................................... 43 litres (11.4 US gal) Fuel Tank .................................................. 408 litres (108 US gal) Engine Crankcase & filters (dry fill) ................................................... 24.6 litres (6.5 US gal) Transmission and Converter .................... 48.5 litres (12.8 US gal) Hydraulic System, Bowl, Ejection and Steering ....................... 204 litres (54 US gal) Hydraulic System, Elevator .................................................... 193 litres (51 US gal) Drive Axle ..................................................... 17 litres (4.5 US gal)

HYDRAULICS AND CONTROLS The hydraulic system is filtered and has one reservoir with two tandem pumps each with two sections. One pump has one section to supply the elevator at low speed and one at high speed.

The other pump has one section to supply the bowl and ejector functions, while the other section supplies the steering.

Two lever control for bowl and ejection. Separate two lever hydraulic control for elevator operations - one for direction and one for high/low speed.

WEIGHTS (MASS)

ELECTRICAL SYSTEM

Gross Distribution Tractor Axle Scraper Axle

Type ................................................... 24 volt, Negative Ground.

Battery ............................................... Two, 12 Volt, 165 Ah each Accessories ...................................................................... 24 Volt Alternator ........................................................................ 70 Amp

Standard Unit

%

kg

lb

Net Distribution Tractor Axle Scraper Axle

64 36

18 870 10 640

41 600 23 460

Vehicle, Net

29 510

65 060

Payload

18 506

40 800

24 510 23 550

54 040 51 920

48 060

105 960

Vehicle, Gross

51 49

9-5

9-6

10 - Symbol Identification

SYMBOL IDENTIFICATION These pages explain the meaning of symbols that may appear on your machine.

10-2

Basic Warning Symbol

Switch 'Off'

Hourmeter

Unlock

Pressurised Compartment

Negative Ground

Fast

Basic Engine

Master Switch

Ammeter

Slow

Engine Starter

Switch 'On'

Circuit Breaker

Lock

Engine Rev/Min

Engine 'Off'

Basic Transmission

Transmission Converter Lockup

Minimum or Low

Emergency Engine Shut Off

Transmission Oil

Air Pressure

Maximum or High

Engine Oil

Transmission Oil Pressure

Air Filter or Restriction

Basic Hydraulic Oil Symbol

Engine Oil Pressure

Transmission Oil Temperature

Starter Air Pressure

Hydraulic Oil Filter

Engine Oil Filter

Transmission Oil Filter

Oil Level

Hydraulic Oil Filter Pressure

10-3

10-4

Hot Hydraulic Oil

Heating

Light Flood

Horn

Coolant Temperature

Fuel Gauge or Fill Tube

Light Low Beam

Windshield Wiper

Coolant 'Cold'

Fuel Filter

Light High Beam

Windshield Defroster

Coolant 'Hot'

Fuel Shut-Off

Instrument Panel Light

Windshield Washer

Cooling

Basic Lights Symbol

Lamp Test

Blower Fan

Heater

Parking Brake

Low Steering Pressure

Body 'Hold'

Air Conditioner

Brake Oil Temperature

High Speed or Level

Body 'Lower'

Inside Air Circulation

Turn Left

Low Speed or Level

Body 'Float'

Outside Air Circulation

Turn Right

Body Up

Dumptruck 'Retarder'

Parking Brake

Tilt Steering Column

Body 'Raise'

Neutral

10-5

Lift Point

Clutch 'Disengage'

Do Not Lift

Brake Applied Clutch Engaged

Forward

Brake Applied Clutch Disengaged

Reverse

Clutch 'Engaged'

10-6

Notes 10-7

NOTES

10-8

NOTES

10-9

NOTES

10-10