New Holland 200 Tier III Motor Grader Operator's Manual 75314534 - PDF DOWNLOAD

OPERATOR’S MANUAL MOTOR GRADER

200 TIER III

Bur • Issued 11-2006 Printed in U.S.A. • Book/Form Number 75314534 NA Copyright © 2006. CNH America, LLC. All Rights Reserved.

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer.

REVISION HISTORY

Issue

Issue Date

Applicable Machines

Remarks

First Edition

11-2006

200 TIER III

75314534 NA

Any use of editorial or pictorial content is strictly prohibited without express written permission from CNH America LLC. Carol Stream, IL 60188 U.S.A.

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75314534 NOVEMBER - 2006 1 st EDITION

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G200 MOTORGRADER

OPERATOR'S AND MAINTENANCE MANUAL

LITERARY AND ART PROPERTY OF NEWHOLLAND, TECHNICAL PUBLICATIONS. ALL REPRODUCTION, EITHER TOTAL OR PARTIAL, PROHIBITTED. The information and illustrations in this Manual are not binding upon NEW HOLLAND which reserves the right to make changes at any time without revising this publication, when changes to components, details or accessories are deemed necessary for product improvement or for manufacturing or commercial reasons, but in all cases retaining the basic features of the units concerned.

A COPY OF THIS MANUAL IS SUPPLIED WITH EACH MACHINE MACHINE - FRAME Nº 1ST EDITION - 75314534 NOVEMBER - 2006

PRINTED IN BRAZIL

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SERVICE The Service Department of NEW HOLLAND, is at the full service of our Customers to provide information or guidance or to provide Service by its own specialized service people whenever you have any questions concerning machine operation.

In addition to the NEW HOLLAND Service Department, owners can call on our dealers and Authorized Service Shops for service or replacement parts.

SERVICE DEPARTMENT

REPLACEMENT PARTS For proper machine operation, when replacing parts or components use only genuine NEWHOLLAND parts.

When ordering parts, state: Machine model; Engine and chassis serial numbers; Parts catalog number of the ordered part.

NEW HOLLAND REPLACEMENT PARTS DEPARTMENT

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TABLE OF CONTENTS TO THE OWNER ................................................................................................................................... 1 OPERATOR MANUAL STORAGE COMPARTMENT ............................................................................................................... 3 RIGHT, LEFT, FRONT AND REAR SIDES ............................................................................................................................... 3 OF THE MACHINE ................................................................................................................................................................... 3 IDENTIFICATION NUMBERS .................................................................................................................................................. 4 MACHINE COMPONENTS ...................................................................................................................................................... 6

SAFETY/DECALS/HAND SIGNALS ..................................................................................................... 9 SAFETY RULES ....................................................................................................................................................................... 9 UTILITY SAFETY ................................................................................................................................................................... 10 PERSONAL SAFETY ............................................................................................................................................................. 10 BEFORE OPERATION ........................................................................................................................................................... 11 MACHINE OPERATION ......................................................................................................................................................... 12 ADDITIONAL SAFETY RULES .............................................................................................................................................. 14 PARKING THE MACHINE AND STOPPING THE ENGINE ................................................................................................... 16 BURN PREVENTION ............................................................................................................................................................. 16 FIRE EXTINGUISHER ........................................................................................................................................................... 16 FIRE OR EXPLOSION PREVENTION ................................................................................................................................... 17 MAINTENANCE ..................................................................................................................................................................... 18 WHEEL AND TIRE MAINTENANCE ...................................................................................................................................... 18 ROLL-OVER PROTECTIVE STRUCTURE ............................................................................................................................ 18 MAINTENANCE ..................................................................................................................................................................... 19 READ OPERATORS MANUAL .............................................................................................................................................. 22 SAFETY DECALS .................................................................................................................................................................. 22 SYMBOLS .............................................................................................................................................................................. 23 SAFETY RULES ..................................................................................................................................................................... 25 DECALS ................................................................................................................................................................................. 26 HAND SIGNALS ..................................................................................................................................................................... 31

INSTRUMENTS/CONTROLS .............................................................................................................. 35 OPERATOR’S COMPARTMENT ............................................................................................................................................ 35 FRONT CONSOLE ................................................................................................................................................................. 36 INSTRUMENT PANEL INDICATORS ..................................................................................................................................... 40 AIR CONDITIONER ............................................................................................................................................................... 47 OPERATORS SEAT ............................................................................................................................................................... 49 SEAT BELT ............................................................................................................................................................................. 51

OPERATING INSTRUCTIONS ............................................................................................................ 55 BEFORE STARTING THE ENGINE ....................................................................................................................................... 55 FIRST SERVICE INTERVALS ................................................................................................................................................ 57 SEAT BELT ............................................................................................................................................................................. 57 RUN-IN ................................................................................................................................................................................... 58 BOOSTER BATTERY CONNECTIONS TO MACHINE BATTERIES (JUMP START) ........................................................... 59 OPERATING TIPS .................................................................................................................................................................. 64 TYPICAL OPERATION ........................................................................................................................................................... 65

WHEELS AND TIRES ......................................................................................................................... 69 ADDING AIR TO THE TIRES ................................................................................................................................................. 70 TIRE OR RIM SERVICE ......................................................................................................................................................... 70 TIRE TREAD DIRECTION ...................................................................................................................................................... 70 WHEEL NUTS TORQUE AND TIRE PRESSURE .................................................................................................................. 71 TANDEM WHEEL LUG NUTS ................................................................................................................................................ 71 TIRE PRESSURE CHECK ..................................................................................................................................................... 71

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TABLE OF CONTENTS LUBRICATION/FILTERS/FLUIDS ....................................................................................................... 73 GENERAL SAFETY BEFORE YOU SERVICE ...................................................................................................................... 73 ENGINE HOURMETER .......................................................................................................................................................... 73 TRANSPORT/SERVICE PIN .................................................................................................................................................. 74 ENGINE HOOD ...................................................................................................................................................................... 74 MAINTENANCE ..................................................................................................................................................................... 75 FLUIDS AND LUBRICANTS ................................................................................................................................................... 76 LUBRICATION & MAINTENANCE CHART ............................................................................................................................ 77 ACCESS DOORS ................................................................................................................................................................... 79 FLUID LEVELS ....................................................................................................................................................................... 80 GREASE FITTINGS ............................................................................................................................................................... 82 OIL VISCOSITY AND TEMPERATURE RANGES ................................................................................................................. 87 ENGINE .................................................................................................................................................................................. 88 AIR FILTER SYSTEM ............................................................................................................................................................. 90 ENGINE COOLING SYSTEM ................................................................................................................................................ 92 DIESEL FUEL SYSTEM ......................................................................................................................................................... 95 HYDRAULIC/BRAKE SYSTEM .............................................................................................................................................. 99 TRANSMISSION .................................................................................................................................................................. 102 REAR AXLE .......................................................................................................................................................................... 104 SWING/CIRCLE TURN GEAR BOX ..................................................................................................................................... 106 TANDEM .............................................................................................................................................................................. 107 WINDSHIELD WASHER RESERVOIR (OPTIONAL) ........................................................................................................... 108

MAINTENANCE/ADJUSTMENT ....................................................................................................... 109 PARKING BRAKE CHECK ................................................................................................................................................... 109 ROLL-OVER PROTECTIVE STRUCTURE .......................................................................................................................... 109 SEAT BELT ........................................................................................................................................................................... 110 MAINTENANCE AND INSPECTION OF ROPS ................................................................................................................... 110 TORQUE SPECIFICATIONS FOR ROPS CAB AND ROPS ................................................................................................ 110 DAMAGE TO THE ROPS ...................................................................................................................................................... 111 TORQUE SPECIFICATIONS FOR SEAT AND SEAT BELTS .............................................................................................. 112 OPERATORS SEAT ............................................................................................................................................................. 112 CAB HEADLINER ................................................................................................................................................................. 113 FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) ........................................................................................................... 113 TYPE OF FIRE EXTINGUISHER ......................................................................................................................................... 113 INSPECTION AND CARE .................................................................................................................................................... 113 DOORS HINGES .................................................................................................................................................................. 113 HOSES AND WIRING .......................................................................................................................................................... 113 ALTERNATOR BELT AND AIR CONDITIONING COMPRESSOR BELT ............................................................................. 114 SERVICE INTERVAL ............................................................................................................................................................ 114 ALTERNATOR BELT AND TENSIONER .............................................................................................................................. 114 DRIVE BELT AND TENSIONER INSPECTION .................................................................................................................... 115 DRIVE BELT TENSIONER ................................................................................................................................................... 115 REINSTALLING THE DRIVE BELT ...................................................................................................................................... 115 CIRCLE GUIDES CHECK AND ADJUST ............................................................................................................................. 116 WEAR PLATE ADJUSTMENT .............................................................................................................................................. 116 DRAWBAR ........................................................................................................................................................................... 117 HYDRAULIC DIAGNOSTIC PANEL CHECK ....................................................................................................................... 118

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TABLE OF CONTENTS ELECTRICAL SYSTEM ...................................................................................................................... 119 BATTERY SAFETY .............................................................................................................................................................. 119 BATTERY SERVICE ............................................................................................................................................................. 120 BATTERY FLUID LEVEL ...................................................................................................................................................... 120 BATTERY VENTS ................................................................................................................................................................ 120 CLEANING THE BATTERIES .............................................................................................................................................. 120 STARTING THE ENGINE USING BOOSTER BATTERIES ................................................................................................. 121 CONNECTING BOOSTER BATTERIES .............................................................................................................................. 121 DISCONNECTING BOOSTER BATTERIES ........................................................................................................................ 121 TRANSMISSION AUXILIARY SYSTEM ............................................................................................................................... 122 COME-HOME ....................................................................................................................................................................... 122 CARE TO BE TAKEN PRIOR TO PERFORMING ANY WELDING PROCEDURE ON THE MACHINE .............................. 123 FUSE BOX ........................................................................................................................................................................... 125 FUSE AND RELAY LIST ....................................................................................................................................................... 125 LOGIC CHECKING FOR TIER3 CUMMINS ENGINE OPERATION .................................................................................... 126 ENGINE PROTECTION SYSTEM ....................................................................................................................................... 126 ENGINE STOP ..................................................................................................................................................................... 126 STANDBY LIGHT FOR STARTING ...................................................................................................................................... 126 TROUBLESHOOTING CODES ............................................................................................................................................ 126 INDICATOR LIGHTS ............................................................................................................................................................ 126 TROUBLESHOOTING SWITCHES ..................................................................................................................................... 127 CHECKING AND INTERPRETATION OF THE TROUBLESHOOTING CODES ................................................................. 128 RADIO .................................................................................................................................................................................. 134 COMPONENTS LIST ........................................................................................................................................................... 135 ELECTRIC DIAGRAMS ........................................................................................................................................................ 139

MACHINE STORAGE ........................................................................................................................ 163 STORAGE PREPARATION .................................................................................................................................................. 163 REMOVAL FROM STORAGE .............................................................................................................................................. 163

SPECIFICATIONS ............................................................................................................................. 165 ENGINE ................................................................................................................................................................................ 165 TRANSMISSION .................................................................................................................................................................. 165 STEERING ........................................................................................................................................................................... 166 TIRES ................................................................................................................................................................................... 166 ELECTRICAL SYSTEM ........................................................................................................................................................ 166 BRAKES ............................................................................................................................................................................... 166 TANDEM .............................................................................................................................................................................. 166 FRONT AXLE ....................................................................................................................................................................... 167 OPERATING WEIGHTS ....................................................................................................................................................... 167 DRAW BAR .......................................................................................................................................................................... 167 FRAME ................................................................................................................................................................................. 167 CIRCLE ................................................................................................................................................................................ 167 BLADE .................................................................................................................................................................................. 168 BLADE REACH (MEASURED OUTSIDE TIRES), NON-ARTICULATED FRAME .............................................................. 168 BLADE REACH (MEASURED OUTSIDE TIRES), ARTICULATED FRAME ........................................................................ 168 HYDRAULIC SYSTEM ......................................................................................................................................................... 168 ACCESSORIES .................................................................................................................................................................... 169 OPERATING DATA AND DIMENSIONS ............................................................................................................................... 170

ALPHABETICAL INDEX ................................................................................................................... 177

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TABLE OF CONTENTS

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IV

TO THE OWNER G200

TO THE OWNER MOTORGRADER NEW HOLLAND G200 ELECTRONIC ENGINE TIER3

Read this manual before you start the engine or operate the machine. If you need more information, see your dealer.

Your dealer can give you help with NEW HOLLAND approved service parts. Your dealer has specially trained technicians who know the best methods of repair and maintenance for your machine.

Use this manual as a guide. Your Motorgrader will remain a reliable working tool as long as it is kept in working condition and serviced properly.

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TO THE OWNER

DO NOT operate or permit anyone to operate or service this machine until you or the other persons have read and understand the safety, operation and maintenance instructions in this manual. Use only trained operators who have demonstrated the ability to operate and service this machine correctly and safely.

This motorgrader, with standard equipment and attachments, is intended to be used for above ground level general earth moving purpose such as land leveling and material rehandling.

DO NOT use this machine for any application or purpose other than those described in this manual.

If the motorgrader is to be used in an application that involves special attachments or equipment, such as forestry, etc., consult an authorized dealer or the NEW HOLLAND. Consult an authorized dealer or NEW HOLLAND on changes, additions or modifications that can be required for this machine to comply with various country regulations and safety requirements.

Unauthorized modifications can cause serious injury or death. Anyone making such unauthorized modifications is responsible for the consequences.

This Operators Manual is to be stored in the manual compartment equipped on this machine. Make sure this manual is complete and in good condition. Contact you dealer to obtain additional manuals. Contact your dealer for any further information or assistance about your machine. Your dealer has NEW HOLLAND approved service parts. Your dealer has technicians with special training that know best methods of repair and maintenance for your motorgrader.

Before permitting a new operator on this machine, make sure: 1. That the operator has received the necessary training on how to operate the machine correctly and safely in one of our training centers or from an approved organization.

2. That the operator has read and understood the instructions given in this manual.

Call your dealer if you need any assistance or information.

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TO THE OWNER OPERATOR MANUAL STORAGE COMPARTMENT READ THIS MANUAL COMPLETELY and make sure you understand the controls. All equipment has a limit.

Make sure you understand the speed, brakes, steering, stability and other characteristics of this machine before you start to operate.

DO NOT remove this manual or the safety manual from the machine. See your dealer for additional manuals.

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Also see the manual information on the inside of the rear cover of this manual.

1. OPERATORS MANUAL STORAGE COMPARTMENT

RIGHT, LEFT, FRONT AND REAR SIDES OF THE MACHINE Right-hand and left-hand, when used in this manual, indicate the right and left sides of the machine as seen from the operators seat.

FRONT

RIGHT SIDE

LEFT SIDE

REAR

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TO THE OWNER IDENTIFICATION NUMBERS Write your machine Product Identification Number (P.I.N.) and Serial numbers on the lines provided below.

If needed, give these numbers to your dealer when you need parts or information for your machine.

Make a record of the numbers. Keep the record in a safe place. If the machine is stolen, report the numbers to your local law enforcement agency.

MACHINE MODEL NUMBER PRODUCT IDENTIFICATION NUMBER ENGINE SERIAL NUMBER TRANSMISSION MODEL AND SERIAL NUMBER ROPS CAB OR CANOPY SERIAL NUMBER FRONT AXLE MODEL AND SERIAL NUMBER REAR AXLE MODEL AND SERIAL NUMBER Product Identification Number - P.I.N.

4

Engine

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TO THE OWNER Transmission

ROPS Cab and Canopy

Rear Axle (Dana)

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TO THE OWNER MACHINE COMPONENTS

2

1 7

3 4

5

1.

2.

3.

4.

HAND RAILS ROPS CAB BLADE LIFT CYLINDER BLADE CIRCLE

8. BLADE LIFT CYLINDERS 9. CIRCLE SIDE SHIFT CYLINDER 10. BLADE PITCH CYLINDER 11. BLADE SIDE SHIFT CYLINDER

6

6

5. ARTICULATION CYLINDER 6. STEPS 7. ENGINE ACCESS HOOD

12. TRANSPORT SERVICE PIN

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TO THE OWNER

1

4

2

5

3

1. ENGINE ACCESS HOOD 2. HAND RAILS 3. REAR RIPPER

4. RADIATOR AND FAN 5. DRAWBAR CIRCLE AND BLADE

8

7

6. A/C CONDENSER

7. HYDRAULIC FILTER

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TO THE OWNER

This page was left blank intentionally.

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SAFETY/DECALS/HAND SIGNALS G200

SAFETY/DECALS/HAND SIGNALS ! SAFETY RULES !

Most accidents involving machine operating and maintenance can be avoided by following basic safety rules and precautions. Read and understand all the safety messages in this manual, and the safety signs on the machine before you operate or service the machine. See your dealer if you have any questions.

READ THIS MANUAL COMPLETELY and make sure you understand the controls. All equipment has a limit.

Make sure you understand the speed, brakes, steering, stability and other characteristics of this machine before you start to operate.

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DO NOT remove this from the machine. See your dealer for additional manuals.

Also see the manual information on the inside of the rear cover of this manual.

1. OPERATORS MANUAL STORAGE BOX

The safety information given in this manual does not replace safety codes, insurance needs, federal, state or local laws. Make sure that your machine has the correct equipment according to these rules or laws.

IMPORTANT: Safety messages in this section point out situations which can happen during the normal

operation and maintenance of your machine. These safety messages also give possible ways of dealing with these conditions.

Additional safety messages are used in the text of the manual to show specific safety hazards.

!

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH.

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SAFETY/DECALS/HAND SIGNALS ! UTILITY SAFETY !

Safety precaution MUST be followed when working near buried Utility Lines.

During operation it is likely that you will be working around or near buried utility lines which may include, but are not limited to: • Electrical Power Line • Gas Line • Water Line • Communication Line - Telephone or Cable Television • Sewer Line CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU TRENCH/DRILL

Before beginning any loading or other construction work it is your responsibility to be aware of all such utility lines buried in the area of your project and to avoid them.

Know the utility color code (U.S.A. and Canada): 1. Electric ........................................................ Red

ALWAYS have all local utility companies mark the location of their lines.

2. Gas, Oil or Petroleum ............................. Yellow 3. Communication, Telephone,

In U.S.A. and Canada call one of many “One Call System Directory” services. If you do not know the local number, call the national number (U.S.A. and Canada only): 1-888-258-0808.

Television ............................................... Orange 4. Water ...........................................................Blue 5. Sewer ............................................ Green/Brown

Check with local authorities for laws, regulations and/ or strict penalties requiring you to locate and avoid existing utilities.

6. Proposed Excavation ................................ White 7. Surveying .................................................... Pink 8. Reclaimed Water, Slurry ......................... Purple After locating the utility lines, carefully dig a hole by hand and/or automatic vacuum equipment to the utility line to verify the location and depth of the line.

! PERSONAL SAFETY !

Safety Decals on this machine use the words Danger, Warning or Caution, which are defined as follows: • DANGER: Indicates an immediate hazardous situation which, if not avoided, may result in death or serious injury. The color associated with Danger is RED. • WARNING: Indicates a potentially hazardous situation which, if not avoided may result in serious injury.

The color associated with Warning is ORANGE. • CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW. ISO two panel pictorial symbol decals are defined as follows: • The first panel indicates the nature of the hazard.

• The second panel indicates the appropriate avoidance of the hazard.

• Background color is YELLOW. • Prohibition symbols such as

10

,

and

STOP

if used are RED.

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SAFETY/DECALS/HAND SIGNALS ! BEFORE OPERATION !

• Avoid loose fitting clothing, loose or uncovered long hair, and jewelry.

• Remove all loose objects from the cab. Loose objects can jam controls and cause accidents.

• Different jobs will require different protective equipment. Items such as hard hats, protective shoes, heavy gloves, reflector type vests, respirators, ear protection, and eye protection can be required. Before you start the job, determine what protective equipment is required. Use this equipment at all times.

• Before you start each day, walk around the machine and check for oil or fluid leaks. Replace all broken or missing parts and do the required lubrication and maintenance as shown in this manual. Clean all trash and debris from the machine, especially from the engine area.

• Be prepared for emergencies. Always have a first aid kit and a working fire extinguisher with you and know how to use each.

• Know the hand signals used on your job. Follow the instructions of the flagman, signs, etc. See Hand Signals for more information.

• Check that all doors, guards, and covers are installed correctly or closed.

• Foreign material or grease on the steps and hand rails can cause an accident. Keep the steps and hand rails clean.

• To avoid falling, always face the machine and use the hand rails and steps when getting on or getting off. Do not rush.

• Make sure all persons are away from the machine before you start the engine.

• Before you start the engine, always fasten the seat belt.

• Before you operate at night, check that all lamps illuminate.

• Engine exhaust fumes can cause death. If you operate this machine in an enclosed area, make sure there is ventilation to replace the exhaust fumes with fresh air.

• Know the rules, laws, and safety equipment necessary for transporting this machine on a road or highway.

• If your machine has a cab make sure that all windows are clean and that the windshield wipers work correctly.

1 2

1

1. HAND RAILS 2. STEPS

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SAFETY/DECALS/HAND SIGNALS ! MACHINE OPERATION !

• Check all controls in a clear area and make sure the machine is operating correctly.

• Do not allow other persons to ride on the machine.

Other persons can fall or can cause an accident.

This is a one person machine with one operator’s seat.

• Dust, fog, smoke, etc., can decrease your vision and cause an accident. Stop the machine or decrease the speed until you can see everything around you in the work area. Make sure the machine lamps are ON. • Contact with high voltage power lines, underground cables, etc., can cause serious injury or death from electrocution.

• Before you drive or operate in an area with high voltage lines, cables, or a power station, tell the power or utility company what you are going to do.

You MUST HAVE THE POWER DISCONNECTED OR KEEP A SAFE WORKING DISTANCE from the lines, cables, or power station. Keep all parts of the machine at least 5 m (15 feet) away from the power source. You must also know any federal, state/ provincial, or local safety codes or regulations that apply to the job site.

• If a part of the machine touches high voltage power.

• Warn other workers NOT TO TOUCH THE MACHINE and to stay away from the machine.

• If you can break contact, reverse the operation that caused contact with the high voltage power, and move the machine away from the danger area.

If you cannot break contact, stay in the machine until the utility company de-energizes the line and tells you that the power is off.

• If you have extreme conditions, such as a fire, etc., and you are forced to leave the machine, do not step off the machine. Jump as far from the machine as possible with your feet together and do not touch the ground with your hands.

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• Then, hop away with your feet together until you are a safe distance from the machine and the electrical current. Do not take large steps. Because of the voltage differential across the ground, one foot can be in a higher voltage area than the other foot. This difference can kill you.

• Do not operate the machine if you do not feel well.

This can be dangerous for you and for the people around you.

• You must make a judgment if weather, road, or earth conditions will permit safe operation on a hill, ramp, or rough ground.

• Stay away from hazardous areas such as ditches, overhangs, etc. Walk around the work area before you start and look for hazards.

• Be alert and always know the location of all workers in your area. Keep all other persons completely away from your machine. Injury or death can result if you do not follow these instructions.

• Operate the machine within the specified capacities and limits. See Specifications section of this manual.

• Operate the machine controls from the operators seat only.

• Digging through underground cables, pipes, lines, etc., can cause injury or death. Learn the location of all underground hazards before you operate your machine in any area.

• When working in areas where traffic is heavy always have a person direct the traffic and direct other persons for you. Have guard rails, warning signs, etc., as required for your job.

• Stop operating the machine if a malfunction occurs.

Watch the indicator and warning lamps in the machine. Listen and smell for things that are not normal on your machine.

• Drive around large objects such as large rocks or trees.

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SAFETY/DECALS/HAND SIGNALS Start Up Do not start or operate an unsafe machine. Before working the machine, be sure that any unsafe condition has been satisfactorily remedied.

Check brakes and steering and attachment controls before moving. Advise the proper maintenance authority of any malfunction part or system.

Before starting machine, check, adjust and lock the operator’s seat for maximum comfort and control of the machine.

Be sure all people in the area are clear of the unit before releasing the parking brake or moving the machine or its attachments. Walk completely around machine before mounting. Sound horn.

Obey flagman, safety signals and signs.

Due to the presence of flammable fluid, never check or fill fuel tanks, storage batteries, or use starter fluid near lighted smoking materials or open flame or sparks.

Operating Do not run the engine of this machine in closed area without proper ventilation to remove deadly exhaust gases.

Do not use machine to carry loose objects by means other than attachments designed for such objects.

Do not carry riders unless the machine is equipped for carrying people to reduce personal exposure to being thrown off.

Observe and know the mechanics of alternate exit routes.

Do not attempt to climb on or off machine while it is in motion.

When operating always look at the direction of the movement of the machine. Be sure exposed personnel in the area of operation are clear of the unit before moving the machine or its attachments, mainly children. If someone arrives in operation area, stop the machine immediately.

Maintain a safe distance from other machines.

Provide sufficient clearance for ground and visibility conditions.

Yield right-of-way to loaded machines.

Shut Down Never leave the machine unattended with the engine running.

Always before leaving the operator’s seat and after making certain all people are clear of the machine, slowly lower attachments or tools flat to the ground in a positive ground support position. Move any multipurpose tool or attachment to positive closed position. Return the controls to hold. Place transmission control in neutral and move engine controls to off position. Engage all control locks, set parking brake, and open and lock the master (key) switch.

Park in a nonoperating and non-traffic area or as instructed. Park on firm level ground if possible.

Where not possible, position machine at a right angle to the slope, making sure there is no danger of uncontrolled sliding movement. Set the parking brake. If parking in traffic lanes cannot be avoided, provide appropriate flags, barriers, flares and warning signals in the traffic lane for approaching traffic.

Never lower attachments or tools from any position other than seated in operator’s seat.

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SAFETY/DECALS/HAND SIGNALS ADDITIONAL SAFETY RULES NEUTRAL START AND REVERSE WARNING CHECKS IMPORTANT: Perform these checks before operating

machine

2. Move the transmission control lever to the neutral position.

NEUTRAL START CIRCUIT CHECK:

• Engage the parking brake.

• Be sure the area around machine is clear of personnel.

• Turn the key switch to START.

• Disengage the parking brake.

3. Move the transmission control lever to the forward position.

• Completely depress the inching control pedal.

• LISTEN: The starting motor should run

• Move transmission control lever to the forward position.

• Engage the parking brake.

• Turn the key switch to START.

• LISTEN: The starting motor should run

• LISTEN: The starting motor must not run.

REVERSE WARNING ALARM CHECK:

• Move the transmission control lever to the reverse position.

• Be sure area around machine is clear of personnel.

• Turn the key switch to START. • LISTEN: The starting motor must not run.

IMPORTANT: 1. Move the transmission control lever to the reverse position.

• Engage the parking brake.

• Turn the key switch to START. • LISTEN: The starting motor should run

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• Turn the key switch to START.

• Engage the parking brake.

• Completely depress the inching control pedal.

• Move transmission control lever to 1st gear in Reverse.

• LISTEN: The reverse warning alarm must sound.

For more information, see inching control pedal, transmission control lever, ignition switch, in the section Instruments and controls.

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SAFETY/DECALS/HAND SIGNALS TRANSMISSION OPERATING INSTRUCTIONS Starting engine

Transmission must be in neutral before engine can be started.

Parking brake

Transmission will not engage a gear with park brake on.

Starting machine

Move gear selector to desired gear which will be indicated on display and drive away. Inching pedal can be used also in a manner similar to a mechanical clutch. Most operators will find this to be a very natural operation.

Inching pedal

Use when starting or stopping. Use for grader finishing work requiring “ Creeper gear” or very slow speeds. Use for very slow ground speed work to increase engine speed for hydraulic performance (This should rarely be necessary because of the wide range performance of the hydraulic system). WARNING: Do not abruptly depress and release inching pedal to start a heavy load or free a stuck machine.

Upshifting

Upshift normally as speed, grade, and traction conditions permit.

Power shift, do not use inching pedal.

Downshifting

Downshift one range at a time. Do not lug down the engine below 1700 RPM. Watch tachometer. Power shift, do not use inching pedal.

Shifting while descending steep grades

During transport while descending short, steep grades, the engine may be driven from the ground by the wheels. In order to maintain a higher speed it could be necessary to upshift to protect the engine while using brakes for retardation. Normally the safe and recommended procedure is to descend slowly using a lower gear together with the brakes, particularly for longer distances.

Shifting forward to reverse and reverse to forward

Operator can make these shifts as required by normal working conditions. The transmission will automatically select the appropriate gear in the opposite direction and has built in shock protection.

Lugging engine down under heavy blade or ripper load

Do not repeatedly depress and release inching pedal to force movement of machine.

Stopping and starting with display indicating a gear higher than 3.

When moving and then stopping with the inching pedal depressed, the machine will always select 3rd gear to start. On level terrain or moderate grades start in 4th and upshift as conditions permit. On steep grades or when under load shift to lower gear and drive away.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel.

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SAFETY/DECALS/HAND SIGNALS ! PARKING THE MACHINE AND STOPPING THE ENGINE !

1. Before you leave the machine, make sure the machine is parked on a level surface. The machine must be on level ground before you do any maintenance.

NOTE: Turning the engine OFF at higher than IDLE

IMPORTANT: If you must temporarily park the machine on a hillside, put the front of the machine toward the bottom of the hill. Make sure the machine is behind an object that will not move.

6. Turn the key switch to OFF to stop the engine.

Remove the key.

2. Lower the implements to the ground (moldboard, scarifier and ripper).

RPM will damage the turbocharger.

5. Move the hand throttle forward to the IDLE position and stop the engine.

WARNING: Jumping on or off the machine

!

can cause an injury. Always face the machine, use the hand rails and steps, and get on or off the machine slowly.

3. Apply the parking brake and shift the transmission control lever to NEUTRAL position.

4. Let the engine run at idle speed for two minutes or more if the engine has been working at full load.

This procedure will cool the engine parts evenly.

! BURN PREVENTION !

• Batteries contain sulfuric acid which can cause severe burns. Avoid contact with skin, eyes, or clothing. Antidote - EXTERNAL - Flush with water.

INTERNAL - Drink large quantities of water or milk.

DO NOT induce vomiting. Seek medical attention immediately. EYES - Flush with water for 15 minutes and seek medical attention immediately.

BATTERIES PRODUCE EXPLOSIVE GASES. Keep sparks, flame, cigars and cigarettes away.

Ventilate when charging or using in enclosed area.

Always wear eye protection when working with the batteries. Wash hands after handling. KEEP OUT OF REACH OF CHILDREN.

• When the battery electrolyte is frozen, the battery can explode if, (1) you try to charge the battery, or (2) you try to jump start and run the engine. To prevent the battery electrolyte from freezing, keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.

• Hot coolant can spray out if the radiator cap is removed too quickly. To remove the radiator cap, let the cooling system cool, turn the cap to the first notch, wait until the pressure is released, then remove the cap.

! FIRE EXTINGUISHER !

It is recommended that you have a fire extinguisher on your machine. See your NEW HOLLAND dealer for availability.

A dry chemical fire extinguisher is approved for Class A, B, and C fires.

16

G200

SAFETY/DECALS/HAND SIGNALS ! FIRE OR EXPLOSION PREVENTION !

• Sparks or flame can cause the hydrogen gas in a battery to explode. To prevent an explosion, do the following:

• If a fire extinguisher has been used, always recharge or replace the fire extinguisher before operating the machine.

1. When disconnecting the battery cables, disconnect the negative (-) cable first; when connecting the battery cables, connect the negative (-) cable last.

• Remove all trash or debris from the machine as required. Especially check the engine area and exhaust system.

2. When connecting jumper cables to start the engine, use the procedure as shown in Booster Battery Connection on section Operating Instructions.

• If the machine has an oil, fuel, or hydraulic leak, always repair the leak and clean the area before operating.

• Keep the cooling system clean and maintain the correct coolant level.

3. Do not short circuit the battery posts with metal items.

• Make sure you do not store oily rags or other flammable materials on the machine.

4. Do not weld, grind, or smoke near a battery.

Keep open flame away from the battery.

• Starting fluid (ether) can explode and cause injury or death. Do not breathe starting fluid vapors. Wear face protection when you remove or install a starting fluid container or when you use an aerosol spray starting fluid. Use starting fluid according to the instructions in this manual.

• Sparks from the electrical system or engine exhaust can cause an explosion or fire. Before you operate this machine in an area with flammable dust or vapors, use good ventilation to remove the flammable dust or vapors.

• Engine fuel can cause an explosion or fire. Do not fill the fuel tank while the engine is running.

• DO NOT smoke while refueling the machine.

• Use nonflammable cleaning solvent to clean parts.

• A fire can cause injury or death. Always have a fire extinguisher near or on the machine. Make sure the fire extinguisher is serviced according to the manufacturer’s instructions.

• If you weld, grind, or use a cutting torch on the machine, always remove the starting fluid container from the machine. Use compressed air to remove any ether fumes from the area.

• Before welding on this machine, disconnect the battery ground (-).

• Check the electrical system for loose connections or frayed insulation. Repair or replace the loose or damaged parts.

17

G200

SAFETY/DECALS/HAND SIGNALS ! MAINTENANCE !

• Improper service or repair procedures can cause injury or death. If you do not understand a service or adjustment procedure, see the service manual for this machine or see your NEW HOLLAND dealer.

• Unauthorized modifications to this machine can cause injury or death. Do not make unauthorized modifications to this machine. Always see your NEW HOLLAND dealer before you weld, cut, or drill holes in your machine.

• If you must service this machine with the engine running, have another person help you. Follow the instructions in this manual or the service manual.

Do not leave the operator’s seat while the engine is running.

• Disconnect the batteries before working on the electrical system.

• If you are exposed to or come in contact with hazardous chemicals you can be seriously injured.

The fluids, lubricants, paints, adhesives, coolants, etc., used with your machine can be hazardous.

Material Safety Data Sheets (MSDS) provide (1) information about the chemical substances within a product, (2) safe handling procedures, (3) first aid measures, and (4) procedures to be taken when the product is accidentally spilled or released. Material Safety Data Sheets (MSDS) are available from your NEW HOLLAND dealer.

Before you service your machine, check the MSDS for each fluid, lubricant, etc., used in this machine.

This information indicates what the risks are and how to service the machine safely. Follow this information when servicing the machine.

• Before you service this machine and before you dispose of the old fluids and lubricants, always remember the environment. Do not put oil or fluids into the ground or into containers that can leak.

Check with your local environmental or recycling center or your NEW HOLLAND dealer for correct disposal information.

• When you service this machine, always wear face or eye protection, safety shoes, and other protective items as required.

• Metal chips or debris can cause eye injury. Always wear eye or face protection when you use a hammer on this machine. Use a hammer with a soft face, such as brass, to drive hardened pins.

• Clean the machine regularly. A buildup of grease, dirt, and debris can cause possible injury or machine damage. Keep your work shop clean.

• Before welding on this machine, disconnect the battery ground (-).

• Fluids such as Gasoline, Kerosene, Diesel Fuel, Hydraulic Oil, etc. contain chemicals that can be dangerous to your health and can cause cancer and/or birth defects. Contact either internally or externally can cause infection or other injury. If any internal or external contact occurs, see your local Poison Control Center or doctor IMMEDIATELY.

! WHEEL AND TIRE MAINTENANCE !

• DO NOT weld to wheel or rim when a tire is installed. Welding may cause an explosive air/gas mixture that will be ignited with high temperatures.

This can happen to tires inflated or deflated.

Removing air or breaking bead is not adequate.

Tire MUST be completely removed from the rim prior to welding.

• Explosive separation of the tire and/or rim parts can cause injury or death. When tire service is necessary, have a qualified tire mechanic service the tire.

! ROLL-OVER PROTECTIVE STRUCTURE !

• Do not modify ROPS in any manner. Unauthorized modifications such as welding, drilling, cutting, or adding attachments can weaken the structure and reduce your protection. Replace ROPS if it is subjected to roll-over or damage. Do not attempt to repair.

18

G200

SAFETY/DECALS/HAND SIGNALS ! MAINTENANCE !

General Prior to working on or servicing the machine: 1. Read carefully all safety rules in this Manual; 2. Read and follow all safety decals and instructions attached to the machine.

Do not allow non-authorized people to operate or carry out any servicing on the machine. Do not carry out any servicing without prior authorization. Follow the procedures provided in this manual for maintenance and servicing.

Where the servicing operation contemplates access to components that cannot be reached from the ground, use a ladder or raised catwalk. If neither of these are available, use any means of access available on the machine. All servicing operations shall be carried with maximum care and caution.

Do not check or fill the fuel tank and batteries while smoking or near a naked flame or sparks as the fluid and fluid vapors are highly flammable.

Do not carry rings, wrist watches, jewelry, loose clothing such as ties, torn clothes, neck scarfs, unbottoned or zippered shirts or sweaters that may get caught in moving parts. Use of helmets, slip proof shoes, safety gloves, ear mufflers, safety goggles, etc., is recommended.

Keep all hand rails, ladders and steps clean and free from any foreign objects or oil spots, grease or mud to keep the chance of slipping or stumbling to a minimum.

Do not jump on or off the machine.

Always keep both hands and one foot or both feet and one hand on the ladders and grab handles.

Do not carry out any servicing on the machine with people seated on the operator’s seat other than an experienced and licensed operator who is assisting in the operation.

If an implement must be operated during servicing or while working on the machine, ensure the operation is carried out from the seat operator’s position only.

Keep the operator’s immediate vicinity free from any loose objects at all times. Always lock the implements or the machine parts that will be raised, prior to carrying out any work under these parts while they are in the raised position.

Do not allow any persons to circulate near or under the raised implement in the unlocked condition. Avoid as much as possible standing under an attachment in the raised position, even if it is locked.

Never carry out any servicing on the machine with the engine running, other than as recommended.

If the machine must be towed, use only tiedowns provided. Engage carefully, ensuring prior to towing that the required pins and locks are firmly attached in place.

When transporting a damaged machine, utilize as much as possible a flat, low deck trailer. If the machine must be towed, use local traffic signs and signaling. To load and unload the machine, choose a flat area that offers good ground support for the truck wheels.

Use loading ramps of sufficient height and slope.

Quickly attach machine to loading deck of the truck and block the wheels with wedged chocks.

If there is a need for lifting or transportation of heavy parts, use a hoist or similar equipment of proper capacity. Use lifting supports, if provided. Ensure there are no other persons in the vicinity.

For cleaning purposes, never use gasoline, diesel fuel or other flammable fluids such as detergents. Use authorized commercial, non-flammable, non-toxic solvents.

When using compressed air to clean parts, use sideflapped safety glasses. Keep air pressure to 2 kg/cm2 maximum.

Never operate the machine in closed areas, unless there is an efficient system for aspiration of the exhaust gases.

19

G200

SAFETY/DECALS/HAND SIGNALS Do not smoke, light flames or cause sparks when refueling or using readily flammable products.

Do not use naked flames as lighting means when servicing or looking for leaks.

When carrying out any servicing on the braking system, which will likely make them temporarily inoperative, park machine on level ground and chock all wheels with proper chocks.

When working under the machine or beneath raised attachments, move with caution. Wear proper safety equipment such as: safety helmet, safety goggles, anti-slip shoes and ear mufflers.

Check that all tools are in good state of repair.

When carrying out any checks where the engine must be kept running, use the help of an operator who must be in the operator’s seat and keep him at all times within your area of visibility.

Never carry out any service for which you have not been authorized. Follow procedures and recommendations provided in the technical service publications.

In the event of carrying out any work outside the workshop, park machine on level ground and chock all wheels. Do not rely on damaged cables or chains.

Never use them for lifting or towing. Use only proper safety gloves to handle them.

The area where service operations are carried out must be kept clean and dry at all times. Immediately eliminate any impounded water or oil spills on the floor.

Do not pile up rags or cloth soaked in oil, grease or flammable fluid. These are serious fire hazards.

Dispose of them in closed metal containers.

Prior to operating the machine or engaging any implements or attachments, check, adjust and lock the operator’s seat in position. Ensure no one is within the machine’s area of operation.

20

Rust inhibitors usually are volatile, flammable products. These must always be used in properly ventilated environments. Containers must be kept in fresh, dry, ventilated places not accessible to nonauthorized people.

Do not carry in your pockets objects that can drop into machine slots or openings.

Clutches, brakes and other auxiliary equipment (distributor, cylinders, etc.) must be properly adjusted according to procedures published in the technical literature. Do not adjust with the engine running.

When welding, use of safety welder’s glasses, safety helmet, leather apron, gloves and safety shoes is mandatory. Safety glasses must also be used by persons in the adjacent area, even if not participating in the work.

Never stare into the weld beam without proper eye protection.

Prior to performing any welding work on fuel tanks or adjacent to fuel tanks, drain all the contents from the tank and flush it properly to remove all residue and fumes that may have remained inside the tank.

Try to become thoroughly familiar with the capacity and operation of hydraulic jacks or other lifting devices.

Remember that the attaching point for lifting the machine must be appropriate to the load to be lifted and that the machine area of support on the ground must be stable.

Any loads lifted with a hydraulic jack or loads lifted with other lifting means are hazardous. Prior to lifting, transfer the weight from the hydraulic jacks to other more secure means (stands, etc.).

Wire cables fray out with use. When handling wire cables, wear proper protection (safety goggles, leather rasp safety gloves, etc.).

Handle all parts with extreme care. Keep your hands and fingers out of slots, gears and similar items.

G200

SAFETY/DECALS/HAND SIGNALS Starting

Hydraulic System

Do not run engine in closed areas without proper ventilation systems for the exhaust gases.

Fluid gushing from a hole can be invisible to the eye but have sufficient force to penetrate the skin causing serious injuries. Under these circumstances, if you have to locate leaks, use a piece of cardboard or wood.

Never expose your head, body, feet, hands and fingers close to rotating fans or belts.

Engine Turn radiator cap slowly to relieve system pressure, prior to removing the cap. If any coolant is needed, add only to a cold or slow running engine.

Never use your bare hands: if the fluid penetrates your skin, see a doctor immediately. Lack of quick medical attention may lead to serious complications and skin disease.

Do not refuel machine with the engine running, particularly if it is too hot, so as to prevent fire.

Relieve internal system pressure prior to removing any caps, plugs, etc. (See applicable instructions).

Never attempt to check or adjust belt tensions with the engine running.

When checking system pressures, use appropriate measuring instruments.

Avoid running the engine with air intakes open without the protective guards.

Implements

If for any technical reasons, this is not possible, fit proper protections over these openings prior to servicing or operation.

Electrical System If you have to jump start, remember cable ends must be connected as follows: (+) to (+) and (-) to (-). Avoid short-circuits. Follow carefully the instructions in this Manual. Prior to any servicing of the electrical system, ensure that the battery master switch is disconnected.

The fumes released by the battery are highly flammable. While recharging, leave batteries uncovered for better ventilation. Never check battery charge by short-circuiting the battery terminals. Do not smoke near batteries to prevent explosions.

Prior to carrying out any servicing, check for fuel or battery electrolyte leaks. Eliminate these leaks prior to proceeding with the work.

Do not charge batteries in closed areas. Check for proper ventilation to prevent possible inadvertent explosion caused by fumes buildup from the charging operation.

Keep your head, body, feet and hands away from the raised implements. Use supports provided as a safety measure, prior to proceeding to servicing and repair operations. Use proper safety elements.

If you must operate an attachment using the hydraulic machine control system, remember that this operation must be carried out only from the operator’s seat position. The operator is responsible for any nonauthorized persons allowed into the cab.

Ensure no other persons are within the machine’s radius of operation.

Give warnings using the horn or using your own voice.

Lift the attachment slowly.

Do not use the machine for transporting loose objects, unless suitable means are provided for this purpose.

When leaving the operator ’s cab, lower the attachment to the ground.

Prior to carrying out any servicing or repair operation with raised attachments, these must be supported on stable supports.

It is recommended that you carry a FIRST AID kit in the machine.

21

G200

SAFETY/DECALS/HAND SIGNALS ! READ OPERATORS MANUAL !

READ OPERATORS MANUAL

READ SERVICE MANUAL

Decals which display the “Read Operators Manual” symbol are intended to direct the operator to the Operators Manual for further information regarding safety, maintenance, adjustments and/or procedures for specific areas of the machine. When a decal displays the following symbol refer to the Operators Manual.

When a decal displays the symbol shown below, refer to the appropriate page of the Service Manual.

! SAFETY DECALS !

Make sure that you read all the safety decals and all instructional decals. Check these decals every day before you start. Clean these decals if you cannot read the words.

When you clean the decals, use only a cloth, water, and soap. Do not use solvent, gasoline, etc.

You must replace a decal if the decal is damaged, missing, or cannot be read. If a decal is on a part that is replaced, make sure the decal is on the new part. See your NEW HOLLAND dealer for new decals.

WARNING: Injury or death can result if you cannot read a safety decal or if a safety decal is

!

22

missing. Replace any missing or damaged safety decal and keep all safety decals clean. See your NEW HOLLAND dealer for new safety decals.

G200

SAFETY/DECALS/HAND SIGNALS ! SYMBOLS !

MAIN SYMBOLS USED IN THIS MANUAL

!

!

WARNING (Warning signal)

LIGHTS

FUELING

LOW TRANSMISSION HYDRAULIC OIL PRESSURE

AIR CLEANER RESTRICTION

LOW ENGINE OIL PRESSURE

PARKING BRAKE

DIFFERENTIAL LOCK

HYDRAULIC OIL FILTER RESTRICTION

HOURMETER

TRANSMISSION OIL FILTER RESTRICTION

OPERATOR’S SEAT ADJUSTMENT

BATTERY

LOCKED

BRAKE OIL - LOW PRESSURE

UNLOCKED

ENGINE WATER TEMPERATURE

BLADE FLOATATION (Right cylinder)

ELECTRICAL SYSTEM

BLADE FLOATATION (Left cylinder)

HYDRAULIC OIL TEMPERATURE

FRONT BLADE FLOATATION

TRANSMISSION OIL TEMPERATURE

RIPPER

HAZARD WARNING LIGHTS

SCARIFIER

SUPPLEMENTAL STEERING

SADDLE LOCK

23

G200

SAFETY/DECALS/HAND SIGNALS

HORN

STROBE LIGHT (OPTIONAL)

RIGHT TURN SIGNAL

POSITION LIGHTS

LEFT TURN SIGNAL

HEADLIGHTS - HIGH BEAM

LOW ENGINE RPM

BLADE ANTI - SHOCK SYSTEM

HIGH ENGINE RPM

COLD STARTING (OPTIONAL)

FRONT WINDSHIELD WIPER (OPTIONAL)

WARNING (Fluid under pressure)

WIPER/LOWER FRONT WINDSHIELD WASHER - LEFT AND RIGHT (OPTIONAL)

WARNING (Toxic gas)

FRONT WINDSHIELD WASHER (OPTIONAL)

WARNING (Electrical shock)

FAN / HEATER (OPTIONAL)

WARNING (Tire pressure)

WINDSHIELD - DEFROSTER

WARNING (Blood poisoning)

REAR LIGHT

WARNING (Radiator heat)

CAB LIGHT

DANGEROUS (Your safety is involved)

BLADE LIGHT

ARTICULATION

REAR WINDOW - WASHER AND WIPER (OPTIONAL)

24

G200

SAFETY/DECALS/HAND SIGNALS ! SAFETY RULES !

!

This symbol is your safety alert sign. It means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Read and heed all safety instructions carrying the signal words WARNING and DANGER. BEFORE STARTING, OPERATING, MAINTAINING, FUELING OR SERVICING THIS MACHINE. Machine mounted safety signs have been color coded yellow with black borders and lettering for warning and red with white borders and lettering for danger points.

MOST ACCIDENTS ARE CAUSED BY FAILURE OF SOME INDIVIDUAL TO FOLLOW SIMPLE AND FUNDAMENTAL SAFETY RULES. FOR THIS REASON MOST ACCIDENTS CAN BE PREVENTED

BY RECOGNIZING THE REAL CAUSE AND DOING SOMETHING ABOUT IT BEFORE ACCIDENT OCCURS. REGARDLESS OF THE CARE USED IN THE DESIGN AND CONSTRUCTION OF ANY TYPE OF EQUIPMENT THERE ARE MANY CONDITIONS THAT CAN’T BE COMPLETELY SAFEGUARDED AGAINST WITHOUT INTERFERING WITH REASONABLE ACCESSIBILITY AND EFFICIENT OPERATION.

25

G200

SAFETY/DECALS/HAND SIGNALS DECALS INTERIOR CAB VIEW

26

G200

SAFETY/DECALS/HAND SIGNALS

27

G200

SAFETY/DECALS/HAND SIGNALS

REAR VIEW

28

G200

SAFETY/DECALS/HAND SIGNALS

SIDE VIEW

! WARNING ENTANGLEMENT HAZARD Keep clear or stop engine before servicing.

384267A1

29

G200

SAFETY/DECALS/HAND SIGNALS

UPPER VIEW

30

G200

SAFETY/DECALS/HAND SIGNALS HAND SIGNALS It is recommended that you and the flagman on the job use hand signals for communications. Before you start, make sure that you both understand the signals that will be used.

START ENGINE

COME TO ME

Move hands forward and rearward (palms in)

STOP ENGINE

ALL STOP AND HOLD

Move hands forward and rearward (palms out).

31

G200

SAFETY/DECALS/HAND SIGNALS

GO THIS FAR

ALL STOP AND HOLD

STOP

EMERGENCY STOP

Move one hand back and forth.

RAISE EQUIPMENT

32

LOWER EQUIPMENT

G200

SAFETY/DECALS/HAND SIGNALS

RAISE EQUIPMENT SLOWLY

LOWER EQUIPMENT SLOWLY

TURN MACHINE LEFT SWING BLADE LEFT

TURN MACHINE RIGHT SWING BLADE RIGHT

To stop movement, stop moving hand and make a fist.

To stop movement, stop moving hand and make a fist.

33

G200

SAFETY/DECALS/HAND SIGNALS

This page was left blank intentionally.

34

INSTRUMENTS/CONTROLS G200

INSTRUMENTS/CONTROLS OPERATOR’S COMPARTMENT WARNING: When the terms right and left are used in this manual, the reference point is the operator`s post

(seat) in driving position, looking toward the front part of the machine.

Some of the following descriptions and instructions refer to optional items. Consult your NEW HOLLAND dealer with respect to the optional equipment available for your machine.

To facilitate reading and learning about the instruments and controls of this machine, it has been separated in 5 groups, as shown in the figure.

GROUP 1 Implement control levers (left side).

Implement control levers (right side).

GROUP 2 Steering wheel, console, pedals and hourmeter.

GROUP 3 Dashboard, transmission control lever, throttle control lever, fuse box and master switch.

GROUP 4 Operator’s seat and parking brake.

GROUP 5 Cab

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

35

G200

INSTRUMENTS/CONTROLS FRONT CONSOLE GROUP 1

4. BLADE PITCH LEVER

Implement control levers (left side)

This lever allows the change of the blade pitch angle.

Push the control lever forward (increase) or pull it rearward (decrease) until the desired pitch angle is achieved.

2

4

Release the lever to return it the neutral position.

5

1

5. CIRCLE TURN LEVER This lever is used to return the circle in clockwise or counterclockwise rotations.

3

Push the lever forward to rotate counterclockwise or pull it rearward to rotate the circle clockwise.

After moving the circle to the desired position, release the lever to return it the desired position.

1. BLADE LIFT LEVER (LEFT END)

Implement control levers (right side)

This lever is used to lower or raise the left end of the blade.

Move the lever forward to lower or rearward to raise the blade. After reaching the desired height, release the lever to return it the neutral position.

7 6 8

2. FRONT SCARIFIER/BLADE OR RIPPER LEVER

9

This lever is used to lower or raise the front scarifier/ blade or ripper.

Move the lever forward to lower or rearward to raise.

After reaching the desired height, release the lever to return it the neutral position.

3. BLADE SIDE SHIFT LEVER This lever shifts the blade to the right or left. Push the lever forward to shift the blade to the left or pull it rearward to move the blade to the right. After shifting the blade to the desired position, release the lever to return it the neutral position.

6. CIRCLE SIDE SHIFT LEVER This lever is used to move the circle to the right or to the left. Move the lever forward to shift the circle to the left or rearward to shift the circle to the right. After moving the circle to the desired position, release the lever to return it to the neutral position.

7. ARTICULATION LEVER Move the lever forward for left articulation or rearward for right articulation until the desired articulation angle is achieved. Release the lever to return it to the neutral position.

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

36

G200

INSTRUMENTS/CONTROLS 8. FRONT WHEEL LEAN LEVER

GROUP 2

The front wheel lean lever leans the front wheels to the left or to the right to maintain stability when grading or ditching and to reduce turning radius.

Steering wheel, console and pedals

Move the lever forward to lean the wheels to the left or rearward to lean the wheels to the right. After reaching the desired position, release the lever to return it to the neutral position.

4

1

7 3

5

9. BLADE LIFT LEVER This lever is used to lower or raise the right end of the blade. Move the lever forward to lower or rearward to raise the blade. After reaching the desired height, release the lever to return it to the neutral position.

2

6

10. WARNING FLASHER

10

1. FLOODLIGHTS, HEADLIGHTS LOW AND HIGH BEAM, DIRECTIONAL LIGHTS AND HORN LEVER 2. STEERING WHEEL 3. ELECTRONIC MONITOR, SPEEDOMETER, HOURMETER AND ENGINE RPM DIGITAL DISPLAYS 4. DIFFERENTIAL LOCK (OPTIONAL) 5. GEAR/ERROR DISPLAY 6. STEERING WHEEL TILT LEVER 7. HOURMETER

To activate the warning flasher press the button located on the right side of the front plastic console.

To turn it off, press it once again.

9 8

10

11

8. “INCHING” PEDAL 9. CONSOLE TILT PEDAL 10. BRAKE PEDAL 11. ACCELERATOR/DECELERATOR PEDAL

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

37

G200

INSTRUMENTS/CONTROLS 1. FLOODLIGHTS, HEADLIGHTS LOW AND HIGH BEAM, TURNING SIGNALS AND HORN LEVER

To sound the horn: push in on the end of the directional signal lever.

To activate the right directional signal, push the directional signal lever away from the operator seat.

To activate the left directional signal, pull the directional signal lever towards the operator seat.

2. STEERING WHEEL The steering wheel is attached to an orbitrol steering control unit. The orbitrol is a combination valve and oil pump which is responsible for the supply of oil to the steering cylinder.

The steering wheel may be tilted to achieve a better operator’s working position using steering wheel tilt lever.

To turn on the Parking Lights: rotate the light switch on the end of the directional signal lever one position.

To turn on the Driving Lights: rotate the light switch on the end of the directional signal lever two positions.

To Operate the High and Low Beams: Move the lever up (vertically) one position (with the light switch rotated to the “ON” position) and the hi-beam lights come on.

Move the lever up (vertically) two positions (with the light switch rotated to the “ON” position) and the lowbeam lights come on.

Move the lever up (vertically) to the top momentary position and release the lever (with the light switch rotated to the “ON” position) and the hi-beam lights will flash and return to the low-beam position.

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

38

G200

INSTRUMENTS/CONTROLS 3. ELECTRONIC MONITOR, SPEEDOMETER, HOURMETER AND ENGINE RPM DISPLAY DIGITALS

Q15

20

O G

10

L

30 20

10

F5

A

C

I

K

40 25

km/h mph

46

0

E

The control panel indicates any problem in machine function.

RPM h

N

M

B

J

H T

P EMERGÊNCIA

D P

R S

2. After the test phase the following indicators will be turned off until the engine is kept turned off:

For easy identification the signals are transmitted by activating a light emitting diode - LED.

• Low battery charge, E;

This electronic monitor permits the operator to monitor all the machine functions from the work station.

• Low engine oil pressure, G;

FUNCTIONAL DESCRIPTION

• Parking brake, when the lever is pulled up, D.

Electronic monitor check:

All the LED’s indicators listed above will turn off except parking brake D (when activeted), and brake pressure H.

1. With engine shut-off and ignition key switch in the RUN position all the circuits are turned on.

The LED indicator lights flash in all functions for few seconds (test phase).

IMPORTANT: When starting the engine and the key

• Low transmission oil pressure, F; • Low brake oil pressure, H;

3. If any faults occur (for the functions described on this monitor), the corresponding LED light and the red warning light will flash followed by an audible warning (see item 4).

goes to START position the electronic monitor will turn OFF. Only the parking brake light will stay ON if activated. When the ignition key goes to run position the electronic monitor will do the check again.

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

39

G200

INSTRUMENTS/CONTROLS 4. The following LED’s indicators do not activate the audible warning: • Parking brake, D;

5. Differential lock functions only with the parking brake disengaged and only in 1st to 7th gears.

6. Q - Speedometer registers the travel speed.

• Steering secondary (optional), P;

R - Indicates the engine RPM during operation.

• Differential lock, T;

S - Not available.

• General warning light, L; • High beam, N; • Turn signals, O and M.

INSTRUMENT PANEL INDICATORS A. ENGINE WATER TEMPERATURE

E. LOW BATTERY CHARGE

When the light is ON, it means that the engine coolant has overheated which could be caused by:

When this light is ON, with the engine running, indicates defects in the charging system, caused by:

•

Lack of coolant in the system

•

Defective alternator

•

Radiator cooling fins clogged

•

Charging resistor damaged

•

Radiator circuit clogged

F. LOW TRANSMISSION OIL PRESSURE

•

Fan hydraulic drive system malfunction

•

Defective thermostat.

When the light is ON, this indicates insufficient oil pressure that may be caused by:

B. HYDRAULIC OIL TEMPERATURE

•

Use of oil with improper viscosity

When the light is ON, it means that the oil is overheated which could be caused by:

•

Low transmission oil level

•

Defective switch and/or defective panel.

•

Use of oil with improper viscosity

G. LOW ENGINE OIL PRESSURE

•

Low oil level.

When the light is ON, this indicates insufficient oil pressure that may be caused by:

C. TRANSMISSION OIL TEMPERATURE When the light is ON, it means that the oil is overheated and its probable causes are:

•

Use of oil with improper viscosity

•

Low engine oil level

•

Suction line filter clogged

•

Engine oil leak

•

Low oil level

•

Defective pressure switch

•

High oil level

•

Transmission hydraulic oil circuit troubles.

D. PARKING BRAKE When the light is ON, it means that the brake is actuated.

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G200

INSTRUMENTS/CONTROLS H. LOW BRAKE OIL PRESSURE

4. DIFFERENTIAL LOCK SWITCH OPTIONAL

When the light is ON, this indicates insufficient oil pressure that may be caused by:

This switch is used to lock or unlock the differential when it is necessary. Use the differential lock switch only in straight line operation. To steer or articulate the machine the operator must turn off the differential lock switch.

•

Pump abnormalities

•

Air in the brake system

•

Oil leak on brake lines

•

Defective pressure switch.

IMPORTANT: Do not turn off the differential lock

system when the motorgrader is operating.

I. AIR FILTER RESTRICTION

5. GEAR AND ERROR CODE DISPLAY

When the indicator remains on constantly, the air filter element is clogged and it will be necessary to clean or replace it.

This display shows the actual neutral, forward or reverse transmission gear selected.

•

Defective switch and/or defective panel.

J. HYDRAULIC OIL FILTER RESTRICTION When the indicator remains on constantly, the oil filter element is clogged and it will be necessary to replace it.

K. TRANSMISSION OIL FILTER RESTRICTION When the indicator remains on constantly, the oil filter element is clogged and it will be necessary to replace it.

L. WARNING FLASHER This indicator flashes when the button located on the right console is pressed in.

When an error occurs the display will flash an error code indicating that a problem has been detected in the system.

When the ignition key is first turned on, the display will show three sets of double letters (TD DC ER) at the top and three 8’s. The first 8 will have a diagonal line through it. This is a system light check.

If the key is left in this position without starting the engine, the display will next flash ER100 few times.

This designates the revision version of the transmission’s computer software.

There is also an error code ER100 but this error code only appears during recalibration.

M. RIGHT TURN SIGNAL

The revision code may change. The next code will be ER101, ER102, etc.

N. HIGH BEAM

6. STEERING WHEEL TILT LEVER

O. LEFT TURN SIGNAL

Loosen the lever and adjust the steering wheel position to obtain more comfortable operating position. Tighten lever again to assure the steering wheel does not move.

P. SECONDARY STEERING LIGHT (OPTIONAL) Not available.

7. HOURMETER The hourmeter indicates operating hours with the engine off and key switch in the RUN position.

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G200

INSTRUMENTS/CONTROLS 8. “INCHING” PEDAL

GROUP 3

The “inching control pedal” is helpful under the following conditions:

Dashboard, transmission control lever, throttle control lever, fuse box and master switch.

•

When starting or stopping

•

For motorgrader finishing work requiring “creeper gear” or very slow speeds

•

5

2 3

6

For very slow ground speed work to increase engine speed for hydraulic performance (this should rarely be necessary because of the wide range performance of the hydraulic system).

7

CAUTION: Do not abruptly depress and release

inching pedal to start a heavy load or free a stuck machine.

4 1

9. CONSOLE TILT PEDAL 1.

2.

3.

4.

5.

6.

7.

8.

8

FUSE BOX THROTTLE CONTROL LEVER TRANSMISSION CONTROL LEVER TOGGLE/ROCKER SWITCH PANEL GAUGE PANEL IGNITION SWITCH MASTER SWITCH POWER TAKE OFF

1. FUSE BOX

The console may be adjusted to improve operator comfort. Push the pedal to free the console. Position the console in the desired position and then release the pedal to lock the console again.

10. BRAKE PEDAL This pedal actuates the service brakes. To stop the motorgrader press down on brake pedal.

NOTE: Do not descend steep slope using only the

service brake. Reduce the speed and apply the brakes. Select an appropriate speed, allowing total machine control. This will avoid brake heating, and will increase the life of the components.

In the fuse box are installed all the motorgrader fuses.

For the identification of the fuses, refer to the electrical diagram.

11. ACCELERATOR/DECELERATOR PEDAL The accelerator/decelerator pedal is connected to the engine throttle controls. To accelerate the engine, press down on the front part of the pedal and to decelerate press down on the rear of the pedal. When the pedal is released, the engine speed will return to the hand throttle setting.

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G200

INSTRUMENTS/CONTROLS 2. THROTTLE CONTROL LEVER

The transmission control lever is used to select the desired forward or rearward speeds.

These machines are equipped with a 8 speed forward and 4 speed reverse transmission.

The gear speed change is done using a shift lever.

To obtain forward speeds place this lever to the front.

To obtain reverse speeds place this lever to the rear.

2

By using this lever the proper speed (1st, 2nd, etc.) can be selected. Observe the gear display readout for confirmation of the gear selected. If the display shows an “error code” it means that some fault has occurred in the transmission system. Therefore it is necessary to contact a NEW HOLLAND dealer.

The engine will remain at low idle with the throttle control lever all the way forward and engine speed will increase as the lever is pulled back.

3. TRANSMISSION CONTROL LEVER

When the machine is stopped, any gear lower than F3 or R2 may be selected to start again.

A single speed change is done with a single push and release of shift lever.

If the shift control lever is pushed and held to the right or left the gear speeds will change automatically.

3

NEUTRAL LOCK

LOCK RING

To move the shift lever out of neutral position, release the “Neutral Lock” by raising the release ring located under the shift handle knob.

SHIFT PATTERN: R • Reverse F • Forward N • Neutral DS • Down shift US • Up shift

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G200

INSTRUMENTS/CONTROLS 4. TOGGLE SWITCH PANEL 1

13

2

3

4

5

8

7

14

15 16 17

1. SADDLE LOCK PIN SWITCH

The saddle lock pin switch activates a solenoid valve which sends hydraulic fluid for cylinder rod movements to release and engage the saddle pins.

With the toggle switch pushed away from the operator’s seat, the pins remain retracted from the saddle and with the toggle switch pushed towards the operator’s seat, the pins will extend and engage the locator hole in the saddle.

Use the blade lift cylinders to assist movement of the saddle lock pins.

2. RIPPER / SCARIFIER SWITCH The ripper / scarifier switch activates a solenoid valve which sends hydraulic fluid to the rear ripper or the front scarifier cylinders.

To move the rear ripper, push the toggle switch away from the operator’s seat. To move the front scarifier, push the toggle switch towards the operator’s seat.

3. MOLDBOARD FLOAT SWITCH - LEFT SIDE This switch activates or deactivates the moldboard float function for the left side of the blade. To activate the float function, push the toggle switch away from the operator’s seat. To deactivate the float function, push the toggle switch towards the operator’s seat.

4. MOLDBOARD FLOAT SWITCH - RIGHT SIDE This switch activates or deactivates the moldboard float function for the Right side of the blade. To activate the float function, push the toggle switch away from the operator’s seat. To deactivate the float function, push the toggle switch towards the operator’s seat.

6

18

9

10 11 12

5. FRONT BLADE FLOAT SWITCH This switch activates or deactivates the front blade float function. To activate the float function, push the toggle switch away from the operator’s seat. To deactivate the float function, push the toggle switch towards the operator’s seat.

6. MOLDBOARD SWITCH

ANTISHOCK

FUNCTION

This switch activates and deactivates the moldboard cylinders antishock function. To activate the antishock function, push the toggle switch away from the operator’s seat. To deactivate the antishock function, push the toggle switch towards the operator’s seat.

7. ENGINE LOGIC SWITCHES These switches are used to check the logic of operation of the engine.

8. COME-HOME SWITCH This switch is used to move the machine in the event of a transmission electronic control unit problem. The rocker switch has three positions: Forward, Neutral and Reverse.

The switch must be in the Neutral position with the park brake applied to start the machine, when the come-home mode is activated.

The transmission shifter and the inching pedal are bypassed when in the come-home mode.

See the Maintenance Section for more details on how to activate the come-home mode.

9. FRONT WINDSHIELD WIPER SWITCH This switch is used to activate the front windshield wiper.

The rocker switch has three positions: OFF, Low and High.

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G200

INSTRUMENTS/CONTROLS 10.FRONT WINDSHIELD WASHER SWITCH This switch is used to activate the front windshield washer.

1

11. REAR WINDOW WIPER SWITCH This switch is used to activate the rear window wiper.

The rocker switch has three positions: OFF, Low and High.

12.REAR WINDOW WASHER SWITCH

2

This switch is used to activate the rear window washer.

13.AIR CONDITIONER SWITCH This switch activates the cab air conditioner.

To turn the air conditioner on, push on the symbol side of the rocker switch.

14.CAB AIR RECIRCULATION SWITCH This switch closes the cab recirculation door to prevent outside air from coming into the cab.

1. CAB HEAT CONTROL To increase the temperature in the cab, turn the cab temperature control knob clockwise. To decrease the temperature in the cab, turn the cab temperature control knob counterclockwise.

2. BLOWER FAN SPEED SWITCH

To close the recirculation door to recirculate the cab air, push on the symbol side of the rocker switch.

To increase the cab blower fan speed, turn the cab blower fan control counterclockwise until the desired fan speed is obtained.

15.WORK LIGHTS SWITCH

The blower fan speed switch has four positions:

This switch activates the work lights above the moldboard and below the cab.

0. OFF

The work lights switch is a three-position switch.

II. Medium

The first position turns the lights OFF.

III.High

To turn on the lights above the moldboard, push the symbol side of the rocker switch to the second position.

I. Low

5. GAUGE PANEL

To turn on the lights under the cab, push the symbol side of the rocker switch to the third position. The lights above the moldboard will stay on with the switch in the third position.

16.REAR FLOODLIGHT SWITCH This switch activates the rear floodlights.

To turn on the rear floodlights, push the symbol side of the rocker switch.

17.FRONT FLOODLIGHT SWITCH

A. ENGINE OIL PRESSURE GAUGE

This switch activates the front floodlights.

The engine oil gauge indicates the pressure at which the engine oil is circulating through the engine.

To turn on the front floodlights, push the symbol side of the rocker switch.

18.LOWER FRONT WINDSHIELD WIPERS SWITCH This switch is used to activate the lower front windshield wipers.

The red area means insufficient pressure.

The green area means normal operating pressure, and the yellow area, excessive engine oil pressure.

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G200

INSTRUMENTS/CONTROLS B. ENGINE COOLANT TEMPERATURE GAUGE •

The marker in the GREEN area indicates the normal operating temperature range 80° to 95°C (176° - 203°F)

•

The WHITE area indicates low temperature.

•

The RED area indicates high temperature.

7. AUXILIARY ELECTRICAL CURRENT RECEPTACLE

If during the work cycle, the coolant temperature stays either in the WHITE or RED area, stop the engine to check the cause of the problem.

C. FUEL LEVEL INDICATOR GAUGE The green area indicates the normal operating level.

Refill the tank using filtered fuel as recommended.

Refill the tank at the end of each work day, to avoid water condensation.

Never let the fuel tank run-dry, this will cause air to enter the fuel system.

Never refill the fuel tank with the engine running.

The machine is equipped with a 24V auxiliary electrical power supply.

8. IGNITION SWITCH This switch is a rotary type and is activated with a key.

D. TRANSMISSION OIL PRESSURE GAUGE OFF

The marker of the transmission oil pressure gauge must stay within the green area which indicates normal operating pressure. If the marker enters the red area, it is a signal that the oil pressure is too low.

RUN ACC

Do not operate the machine with low transmission oil pressure. Stop and check the cause of the problem.

START

E. TRANSMISSION OIL TEMPERATURE GAUGE The marker must register in the green area. Do not operate the machine when the gauge is in the red area.

Stop the machine and determine the cause of high temperature.

6. MASTER SWITCH The machine electrical functions can only be actuated if the rotary master switch is activated.

The master switch is activated by the starting switch in the “ON” position.

It has four positions: ACC - Acessories In this position some circuits such as the wipers and lights, are energized for use.

OFF In this position all key activated electrical circuits are off. The key can be removed.

RUN In this position all key activated electrical circuits are “ON”.

START In this position, the starting circuits are energized.

The switch is spring controlled for start and will return to the “RUN” position when the key is released.

CAUTION: Never leave the key in the “ON” position

when the engine is not running.

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G200

INSTRUMENTS/CONTROLS AIR CONDITIONER 1- A/C OPERATION The air conditioning control panel in the cab is on the right-hand side of the operator’s console.

B3 - AIR CIRCULATION SWITCH ON/OFF push-button for start/stop system operation for air recirculation or outside ventilation.

B4 - AIR CONDITIONING SWITCH ON/OFF push-button for air conditioning compressor.

To operate the air conditioning, air recirculation or heater systems, follow the sequence below: 1. Start the engine. This will energize the machine’s basic functions.

2. Turn the cab fan switch (1) to desired speed position (3).

A - IGNITION SWITCH

3. Select either heat B2, fresh air B3, or cool air B4.

B1 - CAB FAN SWITCH

2- A/C MAINTENANCE

It is a rotatory button switch, with four positions:

The air conditioning/heating system maintenance is limited to three items.

A. Air filter in evaporator case.

0 - Off

B. Air compressor

1 - Low speed

C. Condenser

2 - Medium speed 3 - High speed 1

B2 - CAB HEATER SWITCH The machine is equipped with a system that utilizes heat taken from the engine coolant.

This switch can be operated only if the engine coolant tap is open. The coolant flow through the cab heater motor is controled by a solenoid valve operated by the cab heater switch.

ON/OFF push-button for start/stop heating system and front/rear windshield heater operation.

1. THE AIR FILTER IN EVAPORATOR BOX MUST BE CLEANED WHEN NEEDED OR EACH 250 HOURS.

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G200

INSTRUMENTS/CONTROLS 2.2- RECOMMENDATIONS 1. Turn on A/C only when ventilation is turned on.

2. Make sure the evaporator inlet is not blocked.

2

3. Should the system performance fall below specification, inspect: • System refrigerant pressure; • Operation of fan unit.

• Evaporator for obstructions.

4. Operate A/C at least 10 minutes per week.

2. AIR CONDITIONER COMPRESSOR

2.1- A/C REFRIGERANT CHARGE NOTE: A qualified technician is required to perform

A/C system service.

For leak test and/or gas charging use air compressor taps A and B only.

1. Add 50 grams R134a and allow system to build up 10 bar pressure (145Psig) by applying gaseous nitrogen.

2. Proceed with a gas leak test. Should a leak be CONFIRMED, evacuate the system and repair the leak. Repeat the test.

3. Connect he manifold hoses.

4. Connect vacuum pump to manifold center fitting.

5. When engine is at high speed operate fan at maximum speed.

6. Periodically check external cleaning of condenser (never operate condenser if it is 20% blocked or more).

7. Close all doors and windows when operating the A/C. 8. For fast cooling, use cabin internal air recirculation control.

2.3- SYSTEM MAINTENANCE 1. Clean condenser monthly or whenever the condenser air inlet shows 20% obstruction.

2. Check screw torque and belt tensioning yearly.

3. Clean air conditioning filter monthly or whenever air flow reduction is noticed.

5. Open the manifold valves and turn pump on.

6. Allow 20 minutes for pressure gages to indicate 26 inHg vacuum.

7. Close valves and disconnect vacuum. Close valves and disconnect vacuum pump.

8. Connect charging cylinder hose, open the manifold valve high side and apply 1200 grams of gas R134a.

9. Close the manifold valve, remove gas hose and repeat the test.

10.Disconnect manifold and install service valve covers.

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G200

INSTRUMENTS/CONTROLS GROUP 4

OPERATORS SEAT Standard Seat 4. SLIDE ADJUSTMENT LEVER Pull this lever up and adjust the seat forward or rearward as required. Release the lever to lock the seat in position.

2 1

2

5. WEIGHT ADJUSTMENT KNOB To adjust the seat for your weight you must pull the release lever out of the knob, Use the release lever to turn the knob clockwise to increase the weight resistance. Turn the knob counterclockwise to decrease the weight resistance.

6. HEIGHT ADJUSTMENT, STANDARD SEAT

1. LUMBAR ADJUSTMENT KNOB Turn the knob clockwise to increase the lumbar support, turn the knob counterclockwise to decrease the lumbar support.

2. ARMREST HEIGHT CONTROL ADJUSTMENT

Lift the seat all the way up, drop the seat to the lowest position. Lift the seat to the desired position. The seat will lock into accepted positions.

Optional Air Ride Seat

Turn the knob to raise or lower the armrest to the desired position.

2

NOTE: Each armrest will pivot to the up position.

2

1

4 3 1. LUMBAR ADJUSTMENT KNOB 5

6

Turn the knob clockwise to increase the lumbar support, turn the knob counterclockwise to decrease the lumbar support.

3. RECLINER ADJUSTMENT HANDLE

2. ARMREST HEIGHT CONTROL ADJUSTMENT

Lift up on the handle, move the backrest to the desired position, release the handle to lock the backrest in position.

Turn the knob to raise or lower the armrest to the desired position.

NOTE: Each armrest will pivot to the up position.

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G200

INSTRUMENTS/CONTROLS 6. SEAT DEPTH HANDLE Lift handle up and move the cushion to the desired position. Release the handle to lock the cushion in position.

7. SEAT CUSHION ANGLE ADJUSTMENT HANDLE

6 7 3

Lift up on the handle. Move the seat to the desired angle. Release the handle to lock the cushion angle.

4 5

3. RECLINER ADJUSTMENT HANDLE Lift up on the handle, move the backrest to the desired position, release the handle to lock the backrest in position.

5 8

4. SLIDE ADJUSTMENT LEVER Pull this lever up and adjust the seat forward or rearward as required. Release the lever to lock the seat in position.

NOTE: When adjusting the seat height for the first

time or for a different operator. Sit in the operators seat, lift up momentarily on the height adjustment handle. The seat will automatically adjust to the operators weight. See height adjustment handle for final adjustments.

5. HEIGHT ADJUSTMENT HANDLE A. (Automatic Adjustment): With the operator sitting in the seat. Lift the handle UP and release. The seat will automatically adjust UP and then bleed off air pressure to the optimum air pressure for the weight of the operator.

8. DAMPENING ADJUSTMENT LEVER The dampening adjustment lever has four positions from soft to hard. The first adjustment is with the small end of the adjustment lever pointing toward the front of the seat, as shown. The other three adjustments can be obtained by rotating the small end of the adjustment lever out away from the seat. Each of the adjustments has a slight detent. The suspension can be adjusted to various operating conditions.

B. (Manual Adjustment): The seat can be raised or lowered by increasing or decreasing the air pressure in the seat. Lift the handle UP to increase the air pressure. Push the handle DOWN to decrease the air pressure and lower the seat.

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G200

INSTRUMENTS/CONTROLS SEAT BELT

1. Pull belt from holder. Fasten the belt end into the right-hand buckle.

2. To release the seat belt, push the red button on the buckle.

NOTE: Make sure the belt end and buckle are

securely fastened. Do not pull out the right-hand buckle.

!

WARNING: Securely fasten your seat belt. Your machine is equipped with a ROPS cab, ROPS canopy or ROPS frame for your protection. The seat belt can help insure your safety if it is used and maintained. Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members.

Parking Brake

1

The parking brake is hand operated. When the lever is pulled up, the ratchet teeth allow a partial or full brake application (the lever system permits other actuation positions).

To release the brake, pull the lever slowly upward, press the lock button (A) and push the lever down.

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G200

INSTRUMENTS/CONTROLS 2. DIFFUSERS/DEFROSTER/AIR CONDITIONER

GROUP 5 Cab The cab provides operator comfort in any ambient condition.

1

1. DOOR Turning the handle (1), the door opens. To keep the door opened while operating the machine or servicing cab, open the door until it reaches the automatic lock.

2

The air deflectors and the fan that are located inside the cab have the function to circulate the air in the cab and to serve also as defrosters for the front and rear windshields.

3. WINDSHIELD WIPER

Pull lever (2) to release the automatic lock. This lever is located inside the cab, to the operator’s left.

1. FRONT WINDSHIELD WIPER 2. REAR WINDSHIELD WIPER

To change the front and rear windshield wiper blades, lift the wiper blade support arm, unlock the wiper blade from the lock pin and remove it. To assemble repeat the process in reverse order.

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G200

INSTRUMENTS/CONTROLS 4. DOME LIGHT

2

1

4

3

The dome light is found in the cab roof. The fixed light (1) is lit using the switch (2). The movable light (3) is lit using the switch (4).

!

WARNING: Always check work area to avoid accidents. The following are examples of dangerous

work areas: slopes, overhangs, timber, demolitions, fire, high walls, drop offs, backfills, rough terrain, ditches, ridges, excavation, crowded parking lots, heavy traffic and closed areas. Use extreme care when in areas such as these.

Be on the look out for edges, slides or falling objects.

Beware of brush and undergrowth or other obstacles that conceal dangerous conditions.

For night operation keep all the machine mounted lights on. Replace burned out lights immediately.

Always shut-off engine when leaving operator’s seat.

Before moving machine or attachments, be sure people in the area are clear of the unit. Walk completely around the machine before mounting and sound horn.

Do not start suddenly at full throttle against a tow chain or cable. Take up slack carefully.

Be sure exhaust system is free from leaks under the hood. (When operating inside a closed cab, always keep a vent to outside air open at all times) Avoid applying brakes continuously on long grades. Select the proper gear entering the grade.

Keep engine exhaust manifolds clear of combustible trash. Shut engine off before cleaning it.

Keep people clear of the attachments and tools while they are in a raised position to prevent injury.

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G200

INSTRUMENTS/CONTROLS

This page was left blank intentionally.

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OPERATING INSTRUCTIONS G200

OPERATING INSTRUCTIONS BEFORE STARTING THE ENGINE

!

CAUTION: Quickly respond to initial problems requiring maintenance and downtime will be reduced.

Check the machine each morning before beginning work make a walk around inspection.

1. Check if the tires are worn, cut or not properly inflated.

2. Check if the blade, cutting edges and bits are worn or damaged.

3. Check circle adjustment.

4. Check for damaged or failed instruments and other operator’s compartment components.

5. Check leakage on tandem case.

6. Check any leakage or damage to cooling system hoses.

7. Check engine oil and hydraulic lines and hoses for leaks.

IT’S ALSO RECOMMENDED TO CHECK Electrical system

Check insulation parts, worn cables and terminals loose

Bolts

Check for loose or missing parts

Hydraulic system

Check leakages, twisted hoses, hoses rubbing against other components

Lubrication

Check all grease points related on periodic maintenance table

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G200

OPERATING INSTRUCTIONS 1. Fill the fuel tank only with the specified fuel, with the engine off. Take care to avoid entrance of dirt or foreign matter while filling tank.

6. Start engine. Check all instruments and gauges for normal indication. Operate controls and check for normal operation.

WARNING: Extinguish all smoking

!

materials or open flames before checking and/or filling the fuel tank.

WARNING: Do not use hands to search

!

2. Check the fluid levels of the following:

for pressure leaks. Fluid escaping under high pressure can penetrate skin causing serious injury.

a) Engine crankcase b) Engine cooling system c) Transmission system d) Hydraulic system e) Axle housing and rear tandem housings 3. Lubricate all points where lube fittings are provided.

Refer to lubrication and service guide for instructions and location.

4. Check tire inflation pressure.

WARNING: Do not inflate tires with

!

flammable gases or air from systems utilizing alcohol injectors. Explosion and personal injury may be resulted.

5. The cooling system of the unit is filled at the factory with a 50/50 mixture of water and AGRIFLU antifreeze for protection to -37°C (-34°F). It is not necessary to drain this solution before placing the machine in service.

IMPORTANT: Do not run the engine in closed areas

without proper ventilation to remove poison exhaust gases.

Warn all people who may be working around your machine before starting the engine.

Sound horn before starting or operating the machine.

Never leave the machine unattended with the engine running.

!

WARNING: Remove front wheel lean

shipping bolt before operating machine.

Before unloading the machine from the truck, remove the wheel lean lock bolt and store it in the block provided on the front axle. Whenever the machine is to be transported by truck, install the lock bolt with spacer after loading. Operating the machine with the lock bolt installed will result in reduced maneuverability.

NOTE: The lock bolt may be used to maintain the

front wheels in a vertical position in the event of a damaged wheel lean hydraulic hose.

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G200

OPERATING INSTRUCTIONS

2

1. WHEEL LEAN LOCK BOLT LOCATION

2. ARTICULATION LOCK PIN (STORAGE POSITION) SHALL BE USED ONLY FOR MACHINE TRANSPORT

FIRST SERVICE INTERVALS The following items are to be done during the Run-In Period and are in addition to the items in the Lubrications/ Maintenance Charts in this manual.

AFTER FIRST 100 HOURS OF OPERATION Change the rear axle differential and planetary oil when the axles are new or repaired ........................................................... See Rear Axle in this manual Change the transmission oil and filter when the transmission is new or repaired ......................................... See Transmission Specifications in this manual Check all hose clamps, tighten as required.

SEAT BELT Always securely fasten your seat belt before operating the machine. From time to time, carefully inspect the seat belts for worn areas and replace belts when needed.

WARNING: Securely fasten your seat belt. Your machine is equipped with a ROPS cab or canopy

!

for your protection. The seat belt can help insure your safety if it is used correctly and maintained.

Never wear a seat belt loosely or with slack in the belt system. Never wear the seat belt in a twisted condition.

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G200

OPERATING INSTRUCTIONS RUN-IN 1. Operate the machine with a light load for the first 50 hours. Efficient engine operation is obtained with the engine coolant temperature held in the GREEN area of the gauge. Operating engine with coolant temperature below this range will result in incomplete combustion of fuel, higher fuel consumption with less power and will cause harmful gummy deposits within the engine.

WARNING: Never lubricate, service or

!

adjust the machine with the engine running, except as called for in the Operation and Maintenance Instruction Manual to prevent accidents.

2. Inspect entire unit after the first 10 hours of operation.

Tighten all loose bolts and check all brake and control adjustments. Check the hydraulic and electrical systems.

!

WARNING: The protection offered by the ROPS structure may be impaired if it has been subjected to any modification or damage.

The tightening torque of the 16 mounting capscrews is 508 Nm (51,6 kgf.m; 375 lb.ft).

If cab enclosures are installed, be sure all cab accessories, such as windshields wipers, latches, glass, hinges, seat belts, etc. are in good condition.

Always keep windows clean.

WARNING: If replacement of glass is

!

necessary, be sure to use safety glass or equivalent.

d) Check tandem wheel nuts. e) Check wheel lock nuts.

After the first 100 hours of operation on a new unit or after major repairs perform the following services: a) Change transmission oil filter element.

!

WARNING: Fluid under pressure. Turn cap or cover slowly to relieve pressure before removing it.

b) Change hydraulic oil filter element. c) Check the ROPS mounting capscrews after the first 50 hours of operation and periodically thereafter.

IMPORTANT: DISCONNECT THE MASTER

SWITCH AND CONNECTORS J1, J2, J3 FROM E.C.U. AND T7 FROM T.V.P. BEFORE WELDING ON MACHINE.

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G200

OPERATING INSTRUCTIONS BOOSTER BATTERY CONNECTIONS TO MACHINE BATTERIES (JUMP START) WARNING: Batteries contain acid and explosive gas. Explosion can result from sparks, flames or

!

wrong cable connections. To connect the jumper cables correctly to the battery of this machine, see the correct method shown on this page. Failure to follow these instructions can cause serious injury or death.

WARNING: Battery explosion and/or damage to electrical components can result from improper

!

connection of booster batteries or charger. Connect positive to positive and negative to negative.

Externally, battery acid can cause burns and blindness, and taken internally it is poison.

Two persons are required for this procedure. Make sure the person making the connections is wearing face protection.

NOTE: Make sure the batteries are not frozen. Do not

use batteries that have been frozen. Replace the batteries if the batteries have been frozen.

1. Open the engine hood. Sit in the operators seat and have the other person make the connections.

2. Make sure the jumper batteries are 24 volts.

3. If using another machine for power, make sure the two machines DO NOT touch.

4. Connect the positive (+) jumper cable to the positive (+) battery terminals first.

5. Connect the negative (-) jumper cable to the negative (-) terminal on the jumper batteries on the other machine. Connect the other end of the negative (-) jumper cable to a good frame ground away from the batteries.

6. Start the engine according to the instructions in this manual. See Starting the Engine Using Booster Batteries, in this manual.

7. Have the other person disconnect the jumper cables in the reverse order that they were connected in. Close the engine hood.

Turn master switch key, located in operator’s compartment to the “ON” position. Pull throttle lever back to full speed position if engine is cold (1/4 speed position, if engine is warm).

Turn ignition key to the start position. When the engine starts, release the key. Immediately pull throttle lever into low idle. Then set at one half speed.

Maintain one half maximum speed until coolant temperature gauge needle moves from its minimum position.

NOTE: Do not use the starter for more than 15 seconds

without a pause of 30 seconds to allow it to cool down. Observe all instruments for proper reading.

It is extremely important to allow the engine to run for three to five minutes at 1/4 to 1/2 throttle to permit the lubrication oil to warm and circulate freely through the bearings. This procedure is mandatory for cold weather operation.

Check engine lubricating oil pressure. With engine running at high speed and the coolant at normal operating temperature, oil pressure must be within normal operating range. When the oil is cold no pressure may be indicated on the gauge for several seconds after the engine starts. If the pressure does not rise to normal or above, after a few seconds, the engine must be stopped immediately and the cause determined and corrected. Check the transmission fluid pressure. Within a few seconds after the engine starts the transmission oil pressure gauge must register in or near the green range.

STARTING THE ENGINE 1. Start the engine and keep it running at one half speed for 3 to 4 minutes, before machine operation.

2. Do not accelerate the engine just after starting.

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59

G200

OPERATING INSTRUCTIONS STOPPING THE ENGINE Before shutting down the engine, keep it running a few minutes at low idle speed to permit turbo charger deceleration and stabilization at a low speed. Avoid shutting off the engine at a high speed, because the turbocharger shaft bearings will be damaged due to poor lubrication.

CHANGING ENGINE SPEEDS Prolonged engine idling causes engine coolant operating temperature to fall below operating range.

Since engines are readily started, there should be no reason for prolonged engine idling. However, if it is necessary to keep the engine running, run at a speed fast enough to maintain normal oil pressure and engine coolant temperature. Place the transmission control lever in the neutral position and apply the parking brake. Lower the moldboard to the ground. Do not leave the machine unattended.

This machine and its attachments are to be operated only by a qualified operator stationed at the operator’s controls either seated or standing as conditions require.

The use of seat belts is always required, even on ROPS equipped machines.

Before starting the machine, check, adjust and lock the operator’s seat assembly for maximum comfort and control of the machine.

This machine is equipped with power steering which is effective only when the engine is running. If engine fails, stop the machine immediately.

Check the torque of the wheel bolts after every 20 hours of operation until the wheel bolts stay tight, if the machine is new or if a wheel has been removed and installed. Tighten according to procedure and specifications manual instructions.

Always travel with the scarifier in the full raised position and lower to the ground when parked.

Use extra care when using down pressure on the blade when working on hills, banks and slopes.

NOTE: When the Motorgrader wheels have been

turned to the maximum (in either direction), do not continue to turn the steering wheel in the same direction. This causes unnecessary wear on pump and valve components of steering system.

To start machine motion, raise moldboard, release parking brake, shift into the desired range and direction and move the throttle lever to meet the operational requirements.

Range changes will be governed by the speed attained or desired.

Select a transmission range that will maintain engine speed appropriate for the load required. Low engine speed can be corrected by downshifting or lightening the load. Over revving the engine should be avoided.

Slow the machine by applying the brakes.

Observe the following instructions: 1. Down shift only when the ground speed for the selected range has been achieved.

2. Down shift only one range at a time.

For emergency stops, apply foot brakes as required or pull parking/ emergency brake lever.

WARNING: Do not coast the machine at any time with the transmission in neutral. Do not attempt

!

to decelerate on grades by shifting. Decelerate the engine and apply the foot brakes. Anticipate grades before starting down. Select the proper gear range to maintain the control. Engage transmission to start up only when the engine is at low idle. Down or up shift only one range at a time and only when the speed of the machine approximates the speed of the next range.

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G200

OPERATING INSTRUCTIONS TOWING

!

WARNING: Do not start suddenly at full throttle against a tow chain or cable. Take up slack carefully.

Only designated towing or pulling attachments points should be used for towing or pulling operations.

The transmission range and engine speed should be set before beginning the grading operation. Never overload the moldboard, so that the rear wheels begin to slip.

This not only alters the grade but causes unnecessary wear to rear tires.

Increasing the blade angle (putting one blade tip farther forward than the other tip) will reduce the load.

The blade should be set to cast the dirt either inside or outside of the rear wheels, not under the wheels unless it is for compaction purposes.

The moldboard pitch can be changed to suit various operations. When the top of the moldboard is tilted forward the cutting edge will not slice the material, but push it. This is advantageous when pushing dirt from one location to another. Tilting the top of the moldboard to the rear will angle the cutting edge so that it will slice and create a bite into the material.

This can be advantageous in heavy material because the material will roll against the moldboard, breaking it up and making it easier to move.

Using the moldboard to back drag material should be avoided if possible. This can cause heavy wear on the moldboard guides and possibly damage the side shift cylinder piston rod. If back dragging cannot be avoided, make certain material does not contact the positioning piston rod.

Cast the material between the rear wheels. The first cut should be light enough to maintain control of the motorgrader and cut a straight ditch line. When the material accumulates under the machine, it should be cast aside before taking another cut in ditch line.

Deeper ditch requires more side casting of material.

If a “V” ditch is required, each side of the ditch must be cut alternately to permit the front and rear wheels to travel in the center of the ditch.

When it is necessary to cast material over the edge of a fill, side shift the moldboard to its extreme, so that the motorgrader wheels are not on edge of fill.

The weight of the machine could cause the edge to give way endangering the operator. Articulation also helps in this situation.

When grading a road shoulder, it may be necessary to grade around objects, such as mailboxes abutments or utility poles. The moldboard can be side shifted around the object without changing the grade level.

BANK OR BACK SLOPING To position the moldboard (in this case to the right side) proceed as follows: 1. Turn the circle until blade is at a right angle (90°) to the motorgrader.

Worn or poorly adjusted moldboard guides will cause an unstable moldboard for fine grading.

When making heavy cuts or moving heavy loads that tend to side shift the Motorgrader, lean the front wheels toward the load to counteract side shift.

When starting a ditch, position moldboard so that one cutting edge (right or left) is directly behind and 3" (76 mm) below the front wheel, with the other end of the blade as high as possible.

BLADE POSITIONED AT RIGHT ANGLE (90°) TO MOTORGRADER

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G200

OPERATING INSTRUCTIONS 2. Side shift blade to the extreme right, then side shift the circle until cylinder rod shows about 5" (127 mm) extension. Lower moldboard to the ground.

At the same time, shift the circle to the right (this will pivot the complete circle/blade assembly upward).

NOTE: As the left end of the blade is raised from the

ground, it is necessary to lower the left end of the blade and raise the right end of it at the same time.

BLADE POSITIONED MOTORGRADER

AT

RIGHT

SIDE

TO

3. Disengage the saddle lock pins. Using the blade lift levers, extend the right blade lift cylinder rod and retract the left blade lift cylinder rod (moldboard on the ground). After the saddle has been rotated to the desired position (fully for 90° position), align the saddle pin holes (by sight) and reengage the saddle lock pins.

BLADE AT 90° BANK SLOPE INTERMEDIATE POSITION

5. Continue the operation (as in item 4) until the moldboard is positioned as in the illustration. Then turn the blade (using the circle turn) to the desired position.

IMPORTANT: When cutting a bank an excellent blade

control can be obtained using the wheel lean to push the blade toward or away from the bank.

1. ROTATING SADDLE (5 HOLES)

4. Raise the blade slightly from the ground, then raise the right end of the blade while turning the circle so that right end of the blade moves toward the right front of the motorgrader (this will keep the left end of the blade from hitting the ground).

CIRCLE POSITIONING (5 HOLES SADDLE)

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G200

OPERATING INSTRUCTIONS SCARIFING To scarify a surface it is advised to use all the teeth with less penetration than to use less teeth with deeper penetration. It is advantageous to break the surface material into smaller bits.

When driving or operating the motorgrader in traffic always set the hand throttle at low idle. Select the gear range desired, then use the accelerator/ decelerator pedal to change the machine’s road speed.

Use the lowest speed (1st or 2nd gear) with high engine speed to maintain better control of the motorgrader and to provide good breaking of surface material.

Be sure that the engine speed control system is functioning properly, so that the engine speed returns to idle when the operator takes his foot from the accelerator/decelerator pedal.

The scarifier teeth must be in good condition for best results. Never back drag the scarifier teeth. This can seriously damage the tool bar.

When roading the motorgrader, obey all traffic regulations and be aware of other traffic. Be prepared for any emergency.

If the motorgrader is used in congested areas or roads, put adequate warning signs to prevent accidents. Always be aware of other traffic, especially before change of direction or working across traffic flow.

STOPPING AND PARKING THE MOTORGRADER

1

Position the motorgrader in the desired parking area.

Position the moldboard with the ends of the blade within the wheel width and lower the moldboard to the ground.

Place the transmission forward/reverse lever in neutral.

1. REAR SCARIFIER

Before stopping engine, allow engine to run at 1/4 throttle for 3 to 4 minutes to gradually cool the engine.

Then move the throttle lever to idle position and turn off key switch.

Turn the master switch key to the “OFF” position and remove it. Lock the cab door.

COLD WEATHER PRECAUTIONS The machine’s cooling system is filled at the factory with a 50/50 mixture of water and AGRIFLU.

2

The AGRIFLU solution protects the engine to -37°C (-34°F). It is not necessary to drain this solution before placing the unit in service.

OPERATING IN HOT WEATHER

2. FRONT SCARIFIER

When operating a motorgrader and a sharp non articulated turn is to be made, reduce speed and lean the front wheels in the direction of the turn. After completing the turn, straighten the front wheels to the normal position and resume normal speed.

When roading a motorgrader from one location to another, carry the moldboard within the wheel width and raised as high as possible to prevent accidents.

To prevent damage to the machine: 1. Keep the coolant at the correct level in the radiator.

2. Use the correct solution of AGRIFLU and water in the cooling system.

3. Clean all dirt and debris from the cooling system and engine area.

4. Check the condition of the drive belts.

5. Use lubricants of the correct viscosity.

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G200

OPERATING INSTRUCTIONS OPERATING TIPS Articulated motor graders can be operated with the frame ARTICULATED OR OFF SET (CRAB).

Although the motorgrader permits the circle turn 360°, most of the grading operations are done with the blade between 15° and 45° in relation to the work direction.

Increasing the angle of the blade reduces the side movement of the material cut by the blade. However this permits deeper cuts and more “severe” grading.

The change of the attack angle, blade pitch is also very important for productivity.

The blade with the involute “ROLL-AWAY” profile maintains the capacity to roll material, with the top of the blade inclined to the rear.

ARTICULATED

OFF-SET

Changing blade angle while cutting, generates side forces on the machine. These forces should be compensated by leaning the front wheels and/or articulating the frame in the direction of the blade cutting forces.

NON ARTICULATED frame is normally used for grading large areas and for road maintenance and conservation.

With the frame ARTICULATED, the turning radius is reduced, making machine control easier in restricted areas. In addition, a more precise control of material spreading is permitted.

2 1

1. LEANED FRONT WHEELS 2. ARTICULATED CHASSIS

The OFFSET position permits the operator to maintain the machine on firm ground when working in ditches, and reduce the number of passes necessary to spread material. This permits a better weight concentration, behind the blade in severe operation conditions.

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G200

OPERATING INSTRUCTIONS TYPICAL OPERATION CUTTING A “V” DITCH Keep the frame straight if the ditch is being cut in solid material.

If the dirt is loose, articulate the machine so that the rear frame and tandems are maintained on the most firm ground.

With the circle directly under the frame, position the blade end bit slightly outside the front wheel. Incline the blade forward so that the top edge of it is in line with the center of the front tire.

Align the top of the moldboard with the center of the rear tire. Position the end of the blade outside of the front tire and pitch the blade slightly toward the front.

Turn the wheels toward the “U” ditch in such a way that material from the bank is deposited inside the ditch.

Make a cleaning pass to remove material from the ditch, pushing it on the road and spreading it out when necessary.

Position the blade in such a way that the discharge of the material is in the center of the machine, between the tandems, lean the front wheels in the direction of discharge.

TERRACING - LEVEL CURVES

From the first pass, in 1st or 2nd gear, cut only the material necessary to maintain the ditch line. For the second pass, position the wheels inside the ditch and with a speed slightly higher than first pass maintain 3:1 ratio between the ditch walls and depth.

The material discharge should be maintained between the tandems. A cleaning pass is necessary.

Move the circle and the blade in the direction of the ditch with the blade extended well behind the column of material, in such a way that the dirt cannot fall into the ditch. The blade end bits should be positioned between the rear wheels with the blade tilted slightly forward, to make material rolling easier. All the ditches should be cut with the differential locked (if equipped).

One of the most important applications for motor graders in agriculture is terracing level curves that provide for the retention and distribution of water in the fields, permitting an increase in productivity and preventing soil erosion on hill sides.

This work consists of “V” ditches following the level curves of the ground with a distance between them of 10 to 100 meters (34 - 338 ft), with the greater distance for small slopes and the smaller distance for steeper slopes.

To cut ditches with walls with a 1,5:1 and 2:1 slope, shift the circle and blade against the bank.

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G200

OPERATING INSTRUCTIONS DITCH CUTTING ON FLAT PLAIN The opening of a ditch on a flat plain is a continuation of “V” ditching.

With the circle centered on the frame in a straight position, position the blade end bit behind the outside edge of the front tire. Angle the blade in such a way that the other end reaches the width and depth of the ditch desired (with front scarifiers it is possible to position the blade at 90° if necessary).

Tilt the blade slightly toward the front, so that material is spread along the sides of ditch.

Move the circle and blade toward the ditch, with the blade angled in such a way to bring the material toward the road bed.

Some ditches may be so steep that the upper front wheel tends to loose contact with the ground. This is not an acceptable operating condition. Use articulation of frame and blade position to maneuver the machine into a more favorable position.

Frequently tire marks on the sides of a ditch can be avoided by articulating the frame positioning the driving wheels in a more favorable position.

This pass should be done in 1st or 2nd gear (with the differential locked if available on the machine).

On the following pass, push the material outside the ditch and on the road side. For this, move the circle and blade outside the pile and angle the blade in such a way that the material does not return into the ditch.

Maintain the edge of the blade near the front tire, to keep small mounds of material from returning into the ditch. For the next pass, spread the material lightly from the road shoulder toward the center of the road.

The articulated motorgrader makes the cleaning of wet ditches a relatively simple operation.

Articulate the frame in the OFFSET position, in such a way that the rear wheels are on firm ground, while the front wheels are on the side of the bank.

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G200

OPERATING INSTRUCTIONS ROAD BED After preparing the drainage, the next step is to prepare and level the road bed.

Maintain the frame straight, circle centered and blade almost perpendicular to the machine, in such a way that the material leaves from both sides and cuts the crest of the road rather high to permit drainage on both sides.

In subsequent passes, angle the blade between 10° and 25° tilting it a little toward the front to permit the material to roll toward the road shoulders.

Make these passes at relatively high speeds, so that the loose material passes under the blade before touching the ends.

On the final pass, for each road shoulder position the blade end bit in line with tandem, so that the rear tires can compact the material that may slide off the sides of the blade.

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67

G200

OPERATING INSTRUCTIONS

This page was left blank intentionally.

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

68

WHEELS AND TIRES G200

WHEELS/TIRES WARNING: Exploding tires and/or rim parts can cause injury or death. Keep yourself and others

!

out of the DANGER AREA. Stand on the tread side of the tire. Always use the correct air pressure and follow the instructions in this manual for adding air or servicing the tires.

!

WARNING: Explosive separation of the tire and/or rim parts can cause injury or death. When tire

service is necessary, have a qualified tire mechanic service the tire.

WARNING: DO NOT weld to wheel or rim when a tire is installed. Welding will cause an explosive

!

air/gas mixture that will be ignited with high temperatures. This can happen to tires inflated or deflated. Removing air or breaking bead is not adequate. Tire MUST be completely removed from the rim prior to welding.

The above illustration show danger areas caused by exploding tires and/or rim parts.

!

WARNING: KEEP YOURSELF AND OTHERS OUT OF THESE DANGER AREAS.

The next page shows the correct methods that you MUST use when adding air or servicing a tire.

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69

G200

WHEELS/TIRES Adding Air to the Tires

Tire or Rim Service

This procedure is only for adding air to the tire. If the tire has lost most or all of the air, do the following:

Always have a qualified tire mechanic service the tires and rims for this machine. It is recommended that you have this mechanic inflate the tires. To prevent accidents, use a restraining device (tire inflation cage), correct equipment, and correct procedure.

1. Before you add air, have the wheel correctly installed on the machine or put the wheel in a restraining device (tire inflation cage).

WARNING: Explosive separation of the tire

!

(single piece rim) or the tire and/or rim parts (multi-piece rim) can cause serious injury or death.

Tire Tread Direction When the tire is installed on the wheel make sure the tire tread is in the direction shown.

2. Use an air hose with remote shut off valve and a self-locking air chuck.

3. Stand BEHIND the tread of the tire and make sure ALL persons are away from the side of the tire before you start to add air.

FORWARD FOR TRACTION

FORWARD FOR STEERING

4. Inflate the tire to the recommended air pressure.

DO NOT inflate the tire more than the recommended pressure given on the following page.

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G200

WHEELS/TIRES WHEEL NUTS TORQUE AND TIRE PRESSURE Tandem Wheel Lug Nuts

Tire Pressure Check

The tandem wheel lug nuts should be periodically checked for tightness.

Torque the nuts to 625Nm (63,7kgf.m; 460lb.ft).

WARNING: Do not inflate the tires with

!

flammable gases or with air from systems that use alcohol injectors. This could cause explosion and/or accidents.

Check the pressure with a tire pressure gauge. The normal pressure is: 1

14.0 x 24-12 PR G2 ....................... 2,4 bar (35 psi) 16.0 x 24-12 PR G2 ....................... 2,1 bar (30 psi) 17.5 x 25-12 PR L2 ........................ 3,5 bar (50 psi) 17.5 x 25-16 PR L3 ........................ 3,5 bar (50 psi) 20.5 x 25-12 PR L2 ........................ 2,8 bar (40 psi) 20.5 x 25-16 PR L3 ........................ 3,5 bar (50 psi) 14.00 R24 XGLA ............................ 3,1 bar (45 psi)

1. TANDEM WHEEL LUG NUTS

3

3. TIRE VALVE 2. TANDEM WHEEL LUG NUTS (OPTIONAL)

Do not stand directly in front of tire while performing maintenance. Always stand to one side and extend your arm to filler valve.

Be sure tires are properly inflated to the specified pressure. Inspect for damage periodically.

Check tires only when the wheels and tires are cool to avoid under inflation. Do not use reworked wheel parts. Improper welding, heating or brazing, weakens them and can cause failure.

WHEEL NUTS TIGHTENING SEQUENCE

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G200

WHEELS/TIRES Always use an inflation cage, safety cables or chains when removing tire lock rings or inflating tires. Always deflate tires before removing lock rings or objects from tread, according to local or national requirements.

Never begin to inflate a tapered bead tire unless bead seat band is securely in place over the lock ring.

Improper inflation is a large contributor to tire failures.

Under inflation will cause damage to the cord body of the tire. The repeated excessive flexing of the sidewall area may eventually cause a series of breaks and separation in the cord fabric.

If 24 hour operation does not permit checking inflation pressure on completely cooled tires, a correction factor can be determined by experiment.

Check as many times as possible when “cold” and again after two hours of operation. The average difference must be added to the recommended pressure when checking the tires during constant operation.

Continuous operation of equipment builds up heat and accompanying higher pressure in the tire. These normal increases are allowed for in the design of the tires.

Over inflation must also be avoided. For maximum flotation in very soft footing, inflation may be decreased.

WARNING: Travel pressures are recommended to optimize the performance of the machine during

!

long transfer trips on open roads with no load. Before putting the machine back to work, it is imperative to reinflate the tires to working pressure to avoid damaging the tire sidewalls.

NOTE: Never exceed the maximum pressure stamped onto tire sidewalls.

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72

LUBRICATION/FILTERS/FLUIDS G200

LUBRICATION/FILTERS/FLUIDS GENERAL SAFETY BEFORE YOU SERVICE

!

WARNING: Improper service or repair can cause injury or death. If you do not understand the service procedures for this machine, see your dealer or the service manual for this machine.

WARNING: Raised equipment on the machine without an operator can cause injury or death.

!

Before you leave the operators compartment, always support or lower the equipment (blade, scarifier, ripper, etc.) to the ground and stop the engine.

Read the safety decals and information decals on the machine. Read and understand the operators manual and safety manual.

Use the correct safety clothing and safety equipment.

Understand how to use a fire extinguisher and first aid kit.

Understand the operation of the machine before you start servicing.

ENGINE HOURMETER Service your machine at the intervals and locations given in the Lubrication/Maintenance Chart. When you service your machine, use only high quality lubricants.

The engine hourmeter shows the amount of actual hours the engine has run. The first number to the right displays tenths of an hour and the remaining numbers to the left display hours. Use the engine hourmeter along with the Lubrication/Maintenance Chart to service your machine at the correct time periods.

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73

G200

LUBRICATION/FILTERS/FLUIDS TRANSPORT/SERVICE PIN WARNING: Keep clear of this area when engine is running. Machine could pivot unless the transport

!

and service pin is in its LOCKED position. After servicing is completed, unlock the transport and service pin and secure in place on the rear frame pivot.

Before you transport or service this machine, always put the Transport/Service pin in the LOCKED position.

STRAIGHT AHEAD LOCKED POSITION

OPERATING POSITION

After servicing and before you move the machine, return the Transport/Service pin in the OPERATING position.

ENVIRONMENT Before you service this machine and before you dispose of the old fluids and lubricants, always remember the environment. DO NOT put oil or fluids into the ground or into containers that can leak.

Check with your local environmental or recycling center or your dealer for correct disposal information.

ENGINE HOOD 1. HANDLE 1 2

Push lock button and raise hood to open. Open hood until support strut locks full open.

2. ASSIST CABLE To close hood, pull down on assist cable while pushing strut release tab.

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74

G200

LUBRICATION/FILTERS/FLUIDS MAINTENANCE GENERAL Always check oil level and drain or fill all the reservoirs with the engine off and machine on a flat ground.

The intervals specified here refer to normal operating conditions. During the initial period of use (run-in) and under severe working conditions, the servicing intervals need to be shortened. Consult your NEW HOLLAND Dealer for more information.

Drain the engine oil immediately after shutting off the engine while the oil is warm and flows more easily.

After refilling system the oil should be checked only after engine has been run at low idle for a few minutes.

This procedure insures that the oil cooler, filters, lines, etc., are completely full before the oil level check is made.

Maintenance and lubrication chart decal is located on the rear of the cab in the lower left corner.

1

1

1. MAINTENANCE AND LUBRICATION CHART DECAL

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G200

LUBRICATION/FILTERS/FLUIDS FLUIDS AND LUBRICANTS COMPONENTS

CAPACIDADE

SPECIFICATIONS

Liters

US Gal.

341.0

90.0

Nº 2 DIESEL

With filter change

18.5

4.7

SAE 15W-40 API CH4 / NH 330 H

Without filter change

17.5

4.4

(AMBRA MASTER GOLD HSP)

40.0

10.5

Fuel tank Total capacity Engine oil

Nº1 ENGINE OIL

Engine Cooling System Total capacity

50% Water + 50% AGRIFLU

Hydraulic System Total capacity

180.0

47.5

MAT 3505 / MS 1209

Hydrauic tank with filter

94.6

25.0

(AMBRA MASTERTRAN)

Transmission Refill capacity (with filter change)

25.0

6.6

MAT 3505 / MS 1209

Refill capacity (without filter change)

19.0

5.0

(AMBRA MASTERTRAN)

Rear Axle Dana Model - Center compartment

12.0

3.2

MAT 3505 / MS 1209

- Planetary hubs (each)

6.5

1.7

(AMBRA MASTERTRAN)

22.7

6.0

SAE 80W-90 API GL-5 / NH 520 A

Tandem Drive Case (Dana Axle) Refill capacity (each)

(AMBRA HIPOIDE 90)

Circle Turn Gear Reducer Refill capacity

SAE 80W-90 API GL-5 / NH 520 A 2.8

0.75

Grease Fittings, Rear Ripper, Front Scarifier or Dozer Blade

(AMBRA HIPOIDE 90) Litium based Grease with Molydissulfide

--

--

NLGI-2 / NH 720 A (AMBRA GR-75 MD)

Front Axle Wheel Hub and Bearings

Litium based Grease with Molydissulfide --

--

NLGI-2 / NH 720 A (AMBRA GR-75 MD)

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G200

LUBRICATION/FILTERS/FLUIDS

As needed

*

Cab Air Filter (if equipped)

1

*

Batteries (See Electrical System)

2

Engine oil level (including filters)

1

CLEAN - DRAIN

*

1

ADJUST

1

Hydraulic filter (Note 2)

LUBRICATE

VERIFY

Air cleaner (Note 1)

SERVICE POINTS

REPLACE

POINTS

LUBRICATION & MAINTENANCE CHART

* 10

10 hours Radiator (coolant level) (Note 3) or daily Transmission oil level (warm, engine running)

1

10

1

10

Differential Lock Oil Filter (Dana)

1

10

Fuel Reservoir Filter (wash screen)

1

50

2

50

50 hours Fuel Water Separator (drain water) or weekly Hydraulic tank (complete system)

1

50

Moldboard Lift Cylinder Pivots

4

100

Moldboard Lift Cylinders Balls

2

100

Moldboard Side Shift Cylinders Balls 100 hours Articulation of Tilt Cylinders or each 15 days Moldboard Tilt Pivots Articulation Cylinders Pivots

2

100

2

100

2

100

4

100

Articulation Bearings

2

100

Drawbar Ball and Socket

1

Alternator and Air Conditioner Belt

2

Universal Joints and Drive Shaft

2

Circle Turn Gearbox Oil Level

1

100 250 250 250

Differential Lock Oil Filter (Dana)

1

Front Axle Pivot

2

250 250

Front Wheel Lean Bar Pivots

2

250

Front Wheel Lean Cylinder Pivots

2

250

250 hours Front Wheel Knuckle Lean Pivots or monthly Knucle King Pin Bearings Moldboard Lift Cylinder Articulation Bearings

4

250

4

250

2

250

Tandem Swing Bearing

2

Tires Condition and Pressure

6

250

Cab Air Filter (if equipped)

1

Steering Bar Ball Joints

4

Moldboard Articulation Pivots

4

250

Moldboard Side Shift Pivots

2

250

250 250 250

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

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G200

Fuel Filters and Water Separator

2

Fuel Tank Drain Plug (drain sediment)

1

Engine Oil and Oil Filter

2

500

Hydraulic System Oil Filter

1

500

Transmission Oil and Oil Filter (Note 5)

2

500

Front Wheel Bearing Grease

2

500

500 hours Tandem Wheel Shafts Bearings (Graziano) or each 3 Tandem Case Oil Level months Rear Axle Center Bowl Oil Level (Dana)

500 500

8

500

2

500

1

500

3

500

Planetary Gear Oil Level (Dana) (Nota 4)

4

500

ROPS Fixing Bolts Torque

16

500

Seat Belts Fixing Bolts Torque

2

500

Rear Axle Differential and Planetary Gear Oil Level (Graziano) (Nota 4)

Transmission Screen 1000 hours or each 6 months

2000 hours or yearly

NOTE:

CLEAN - DRAIN

ADJUST

LUBRICATE

REPLACE

VERIFY

SERVICE POINTS

POINTS

LUBRICATION/FILTERS/FLUIDS

1000

Rear Axle Screen Filter (Graziano)

1

Engine Valves Clearance (Note 6)

12

1000 1000

Circle Turn Gear Housing Oil

1

1000

Alternator and Ar Conditioning Belts

2

1000

Air Cleaner Elements (See Air Cleaner System)

2

1000

Rear Axle Differential and Planetary Gear Oil (Graziano) (Nota 4)

3

2000

Rear Axle Center Bowl Oil (Dana)

1

2000

Hydraulic System Oil (Nota 6)

1

2000

Planetary Gear Oil (Dana) (Nota 4)

4

2000

Tandem Case Oil

2

2000

Engine Coolant

2

2000

Turbocharger Fixing Bolts Torque

4

2000

See “FLUIDS AND LUBRICANTS” table on previous pages for lubricants and fluids detailed specifications and capacities.

NOTE 1: Service the air filter elements if air filter restriction indicator is in the red area.

NOTE 2: Service the hydraulic filters if hydraulic filter indicator lamp iluminates.

NOTE 3: Check the radiator coolant level if the coolant level warning lamp iluminates.

NOTE 4: Change the rear axle oil after the first 100 hours of operation.

NOTE 5: Change the transmission oil and replace the filter after the first 100 hours of operation.

NOTE 6: Change every 2.000 hours or once a year, whichever comes first. : As needed

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

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G200

LUBRICATION/FILTERS/FLUIDS ACCESS DOORS

ENGINE ACCESS HOOD

FUSE BOX

CAB FILTER ACCESS DOOR

WINDSHIELD WASHER RESERVOIR

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

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G200

LUBRICATION/FILTERS/FLUIDS FLUID LEVELS EACH 10 HOURS OR DAILY SERVICES Engine Crankcase

! WARNING

Check oil level shortly after engine is warm and has been stopped. Remove the engine oil dipstick (2), and check oil level. If the oil level is below the minimum mark or above the maximum mark, do not operate the engine. Add oil if necessary through the filler neck (1).

HOT LIQUID UNDER PRESSURE HAZARD Service when cool.

329044A1

Engine Coolant Level Check coolant when engine is cold. Make sure coolant is visible in sight glass on radiator.

2

1

If necessary, add coolant to the radiator. Turn the expansion tank cap slowly to remove pressure. Add coolant until level is at the bottom of the filler neck.

NOTE: Never add only anti freeze to cooling system

without checking existing level of protection. Add coolant as necessary to bring it to the proper level.

Tighten expansion tank cap.

1. ENGINE OIL FILLER

Transmission Fluid Level

ENGINE STOPPED

HOT

COLD

Check the transmission oil level when the oil is hot and the system is charged. Place transmission in NEUTRAL, keep the engine idling and apply parking brake. Turn the handle counterclockwise to loosen the cap. Remove the cap and check oil level with the dipstick. Add oil as necessary to bring it to the proper level. Make sure the cap is tight on the filler neck after checking oil.

2. ENGINE OIL DIPSTICK

Radiator ENGINE RUNNING

WARNING: Fluid under pressure. Turn the

!

cap slowly to relieve pressure before removing or until the pressure has been relieved. The coolant may boil over and cause personal injury.

TRANSMISSION DIPSTICK

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

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WARM

G200

LUBRICATION/FILTERS/FLUIDS FLUID LEVELS EACH 50 HOURS SERVICES Hydraulic Tank

!

WARNING: Fluid under pressure. Turn the cap slowly to relieve the pressure, before removing.

Be sure the machine is on level ground with the engine off. Lower the moldboard to the ground. Check the oil level through sight gauge. The oil level should be at the center of the gauge. If necessary, remove the hydraulic tank filler cap and add oil.

Engine Fuel Filter Open the drain cock (4) located on the bottom of the filter to remove the accumulated water.

IMPORTANT: The drain cock is made of plastic

material. Do not over tighten when closing.

1

3

1. OIL LEVEL GAUGE 3. WATER SEPARATOR AND FUEL FILTER

2

2. HYDRAULIC TANK FILLER CAP

4 4. DRAIN BOLT

3. WATER SEPARATOR AND FUEL FILTER

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

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G200

LUBRICATION/FILTERS/FLUIDS GREASE FITTINGS EACH 100 HOURS SERVICES See Fluids and Lubricants for grease specifications.

Moldboard Lift Cylinders Balls There are two (2) lube points. Lubricate with 6 to 12 shots each.

Articulation, Hydraulic Cylinders and Pivot Joints There are four (4) lube points, two (2) on each side.

Lube with 6 to 10 shots on cylinders ends. Lube, with 6 to 14 shots on pivot bearings.

5 3

3

1. LIFT CYLINDERS BALL JOINT

Drawbar Ball and Socket There is one (1) lube point. Lubricate with 6 to 14 shots.

4 3. ARTICULATION CYLINDERS JOINTS 4. LOWER ARTICULATION JOINT 5. UPPER ARTICULATION JOINT

Moldboard Tilt Cylinders Balls There are two (2) lube points. Lubricate with 6 to 12 shots each.

6

6 2. DRAWBAR BALL AND SOCKET

6. TILT CYLINDER BALL JOINT

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

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G200

LUBRICATION/FILTERS/FLUIDS Moldboard Tilt Cylinder Pivot

Lift cylinder pivots

There are two (2) lube points. Lubricate with 4 to 6 shots each.

There are four (4) lube points for the pivots. Lubricate the pivots with 1 to 2 shots each.

9

7 7

7. TILT CYLINDER PIVOT

9. LIFT CYLINDER PIVOTS

Moldboard Tilt Pivot There are two (2) lube points. Lubricate with 4 to 6 shots each.

8

8. TILT PIVOT

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

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G200

LUBRICATION/FILTERS/FLUIDS GREASE FITTINGS EACH 250 HOURS SERVICES See Fluids and Lubricants for grease specifications.

Front Wheel Knuckle

Wheel Lean Link

There are four (4) lube points. Lubricate with 4 to 6 shots on each side.

There are two (2) lube points. Lubricate with 4 to 6 shots on each side.

1. FRONT WHEEL KNUCKLE

3. WHEEL LEAN LINK

Steering Arm Pivot

Front Wheel Lean Cylinder

There are four (4) lube points. Lubricate with 4 to 6 shots on each side.

There are two (2) lube points. Lubricate with 4 to 6 shots on each side.

2. STEERING ARM PIVOT

4. FRONT WHEEL LEAN CYLINDER

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

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G200

LUBRICATION/FILTERS/FLUIDS Front Axle Spindle Pivot

Tandem Swing Bearing

There are two (2) lube points. Lubricate with 6 to 12 shots each.

There are four (4) lube points. Lubricate with 14 to 20 shots each.

5

5

5. FRONT AXLE SPINDLE PIVOT

8. TANDEM SWING BEARING

Universal Joint and Drive Shaft

Lift Cylinder Bearings

There are tree (3) lube points. Lubricate with 4 to 6 shots each.

There are two (2) lube points for the bearings.

Lubricate the bearings with 4 to 6 shots each.

6 9

9. LIFT CYLINDER BEARINGS

7 6

6. UNIVERSAL JOINT 7. DRIVE SHAFT

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

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G200

LUBRICATION/FILTERS/FLUIDS GREASE FITTINGS EACH 500 HOURS SERVICES See Fluids and Lubricants for grease specifications.

Tandem Wheel Shaft Bearings

Rear Ripper Pivots and Cylinder

There are eight (8) lube points. Lubricate with 14 to 20 shots each.

There are eight (8) lube points for ripper linkage and two (2) for the cylinder. Lubricate wit 4 to 6 grease shots.

4

1

3

1. WHEEL SHAFT BEARINGS

Front Wheel Bearings

3. RIPPER PIVOTS 4. RIPPER CYLINDER

Loosen fixing bolts and remove cover.

Remove grease, clean bearing housing and fill it with 0.9 kg (each) of the specified grease. For more information see Fluids and Lubricants.

2

2. FRONT WHEELS BEARINGS

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

86

G200

LUBRICATION/FILTERS/FLUIDS OIL VISCOSITY AND TEMPERATURE RANGES

NOTE: Use of an engine oil pan heater or an engine coolant heater may be required

when operating temperatures are in Winter or Arctic conditions.

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

decrease engine life due to wear. See the chart above for the correct oil for ambient temperatures.

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

87

G200

LUBRICATION/FILTERS/FLUIDS ENGINE Engine Service Specifications Oil Level check interval ................................................................ Every 10 hours of operation or each day, whichever occurs first.

Oil Change interval .................................................... Every 250 hours of operation if used CG-4 engine oil or every 500 hours of operation if used CH-4 engine oil.

Oil filter change interval ............................................. Every 250 hours of operation if used CG-4 engine oil or every 500 hours of operation if used CH-4 engine oil or once a year whichever occurs first.

Oil type ................................................................................................................ See Fluids and Lubricants Oil Capacity - with filter change ........................................................................ 18.5 liters (4.7 U.S. Gallons)

Engine Oil Level To check the engine oil level put the machine on a level surface and stop the engine. Remove engine oil dipstick and wipe clean with a cloth. Replace dipstick in tube and push the engine oil dipstick completely DOWN and then remove. If the oil level is below the ADD mark, add oil to raise the oil level to the FULL mark.

1

1. ENGINE OIL FILLER 2. ENGINE OIL LEVEL DIPSTICK

Engine Oil Change and Filter Replacement Make sure engine is at operating temperature. Shutoff the engine. Remove the drain plug (A) located on the lower right side of the engine crankcase and allow all the oil to drain.

Make sure the seal is in good condition and install the drain plug.

2

Remove the oil filter. Carefully clean the gasket seat on the filter.

NOTE: The filter’s sealing gasket normally stays

attached to the filter gasket seat.

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

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G200

LUBRICATION/FILTERS/FLUIDS IMPORTANT: Before installing, fill the oil filter with new and clean oil. Before installing the filter, apply also a

light film of oil in the area of the filter gasket seal.

IMPORTANT: Tightening the filter with a wrench can damage it, therefore tighten it by hand. Then check if

there are leaks around the base when the engine is running. Tighten it more if necessary. The proper torque is completed with 3/4" of a turn after contact by grasping the base with both hands.

1

1. ENGINE OIL FILTER

Lubrication Analysis

Add specified oil, through the filler neck. Start the engine and keep it running for 15 minutes to fill the filters and lubricate the engine. Check the oil level and top off as necessary.

The normal engine oil change interval is every 500 hours of operation or once a year whichever occurs first.

Check if there is any leakage from the filters.

Operating conditions, quality of the engine oil and sulphur content of the fuel can change this interval.

See your dealer.

IMPORTANT: Never drain oil or remove oil filter while engine is running.

!

WARNING: Replace all covers or guards after servicing or cleaning the machine. NEVER operate

the machine with covers or guards removed.

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

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G200

LUBRICATION/FILTERS/FLUIDS AIR FILTER SYSTEM Service Specifications Air filter element service interval Primary (Outer) Element .......................................... Service the element if the air filter restriction indicator is in the red area. Replace the element after three washings. Also, replace the element after 1000 hours of operation or each year, whichever occurs first.

Secondary (Inner) Element ..................................... Replace the element after the primary (outer) element has been cleaned three times, or after the primary element has been cleaned or replaced and the air filter restriction indicator is still in the red area with the engine running. Also, replace the element every 1000 hours or each year, whichever occurs first.

Cleaning the Air Filter Element The outer element of the air cleaner should be disassembled only when the air restriction indicator is in the red area.

For correct maintenance of the air filter proceed as following: 1. Clean dirt and oil from air cleaner assembly.

2. Loosen clamp (5) attaching cup to air cleaner body.

Remove cup (7) and o-ring (6).

3. Remove outer element (10) by loosening wing nut (8) and gasket.

4. The filter may be cleaned with compressed air.

NOTE: Visually check inner element each time outer

element is cleaned or replaced. Do not attempt to clean the inner element.

1. INNER ELEMENT 2. NUT 3. T-BOLT 4. NUT 5. CLAMP 6. O-RING 7. CUP 8. NUT 9. FILTER HOUSING 10. OUTER ELEMENT 11. VALVE DUST

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

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G200

LUBRICATION/FILTERS/FLUIDS WARNING: Wear safety glasses with side shield or goggles when using compressed air for

!

cleaning. This reduces the danger of accidents caused by flying particles. Limit the pressure to 30 PSI (2 bar) according to local or national requirements.

If required clean fins inside air cleaner with a stiff fiber brush.

7. Inspect inner element retaining nut (2). Change nut if it is damaged.

5. To clean element with compressed air, direct dry clean air up and down plates on clean air side of element until all dust is removed.

8. Clean inside of the air cleaner body (9) and cup (7) before reinstalling element (10). Insert element in air cleaner body and tighten wing nut (8).

IMPORTANT: The inner element of the air cleaner is

extremely important. It is suggest to change it after 3 outer elements have been changed.

9. Install cup (7) dust valve (11) at bottom and tighten clamp (5) securely. Check to see that the clamp is correctly positioned.

10. Check dust valve lips (11). The lips must be free of debris. Dirt and mud can lodge in the lips and hold them open during operation. The valve lips must be open when the engine is at low idle or is stopped. The lips must point down to function.

11. Check the air cleaner tube cap. If there is dirt, remove tube cap and blow dust from cap, remove debris if any is apparent.

6. After the filter has been cleaned and dried, it must be inspected for ruptures or holes. Place a bright light inside the element and inspect it from the outside. The light will shine through any holes or tears. If any holes are evident, install a new element.

12. Start engine. Observe air cleaner restriction indicator with engine running at high idle. If restriction is indicated, air cleaner inner element must be replaced. As the inner element is not cleanable, always replace it after one year of service or if a restriction is still indicated after the outer element has been cleaned.

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

91

G200

LUBRICATION/FILTERS/FLUIDS ENGINE COOLING SYSTEM Service Specifications Cooling System Capacity .................................................................................. 40 liters (10.5 U.S. Gallons) Cooling system drain, flush, and refill interval ............................................... Every 2000 hours of operation or each year, whichever occurs first.

Radiator coolant fluid level check ...................................................................... Every 10 hours of operation

Thermostat Starts to open ........................................................................................................................... 82°C (180°F) Completely open ...................................................................................................................... 95°C (202°F) Expansion tank cap ................................................................................................ 103.4 kPa, 1 bar (15 psi)

Coolant Mixture A mixture of 50% AGRIFLU and 50% water must be used in this machine.

This mixture is used if the lowest ambient temperature is above -37°C (-34°F). If the ambient temperature is lower, adjust the mixture to 60% AGRIFLU and 40% water. It is recommended that AGRIFLU and water be used in your machine all year.

NOTE: After you fill the cooling system, mix the

AGRIFLU and water completely by running the engine at operating temperature for approximately five minutes. This procedure must be done when the machine is in temperatures below 0°C (32°F).

1

2

1. EXPANSION TANK CAP 2. HYDRAULIC OIL LEVEL GAUGE

WARNING: Hot coolant can spray out if expansion tank cap is removed. To remove expansion

!

tank cap: Let system cool, turn to first notch, then wait until all pressure is released.

Scalding can result from fast removal of expansion tank cap. Check and service engine cooling system according to maintenance instructions.

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

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G200

LUBRICATION/FILTERS/FLUIDS Draining and Flushing the Cooling System

!

WARNING: Hot fluid under pressure. Follow the Operator’s Manual instructions to relieve the pressure before opening the expansion tank cap.

Turn the expansion tank cap slowly to relieve pressure. Open radiator drain cock located under the radiator and the drain cock located on the oil cooler.

Let the coolant drain.

! WARNING HOT LIQUID UNDER PRESSURE HAZARD Service when cool.

329044A1

After draining, flush the radiator with clean water. Be sure that the water does not contain large amounts of calcium.

Fill the cooling system with a mixture of 50% of AGRIFLU and 50% of clean water to about 1 1/4" (30 mm) below the filler neck.

1

1. RADIATOR DRAIN COCK

Install expansion tank cap. Start and run engine until coolant reaches normal operating temperature.

Check to see that all hoses are in good condition and the clamps are not damaged or loose. Replace if necessary.

Stop engine. Check level of coolant and add if necessary.

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

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G200

LUBRICATION/FILTERS/FLUIDS Radiator Cleaning WARNING: Wear safety glasses with side shield or goggles when using compressed air for cleaning.

!

This reduce the danger of accidents caused by flying particles. Limit the pressure to 30 PSI (2 bar) according to local or national requirements.

O O O O O O

AIR FLOW DIRECTION WHEN WORKING

Use an air compressor and a suitable nozzle to direct a stream of air over and through radiator core in the opposite direction of normal air flow to remove all dirt and debris.

NOTE: It may be necessary to spray the exterior of

radiator core with water and detergent to remove caked dirt.

1.

2.

3.

4.

AIR NOZZLE RADIATOR TUBES RADIATOR FINS DEBRIS

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

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G200

LUBRICATION/FILTERS/FLUIDS DIESEL FUEL SYSTEM Service Specifications Fuel Tank Capacity ............................................................................................. 341 liters (90 U.S. Gallons) Interval for draining water from the fuel filter ............................................................... 50 hours of operation Fuel filter replacement interval .................................................................................. 500 hours of operation or once each year, whichever occurs first Adjust fuel injector ................................................................................................... 1000 hours of operation or once each year, whichever occurs first Clean and calibrate fuel injectors and fuel pump ................................................ 1000 hours of operation or every 6 months, whichever occurs first.

Fuel Conditioner Diesel fuel conditioner is available from your dealer.

Follow the instructions on the can.

The conditioner will:

2. Disperse insoluble gummy deposits that can form in the fuel system.

3. Separate moisture from the fuel.

4. Stabilize the fuel in storage.

1. Clean the fuel injectors, valves and manifold for increased service life.

! !

WARNING: Engine fuel is flammable and can cause a fire or an explosion. Do not fill the fuel tank or service the fuel system near an open flame, welding, burning cigars, cigarettes, etc.

WARNING: Never refuel the machine when the engine is hot or running. Never smoke while

refueling.

Fuel Filler Cap

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

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G200

LUBRICATION/FILTERS/FLUIDS Diesel Fuel

Fuel Storage

Use No. 2 Diesel fuel in the engine of this machine.

The use of other fuels can cause the loss of engine power and high fuel consumption.

If you keep fuel in storage for a period of time, you can get foreign material or water in the fuel storage tank. Many engine problems are caused by water in the fuel.

In very cold temperatures, a mixture of No. 1 and No. 2 Diesel fuels is temporarily permitted. See the following note.

NOTE: See your fuel dealer for winter fuel

requirements in your area. If the temperature of the fuel lowers below the cloud point (wax appearance point), wax crystals in the fuel will cause the engine to lose power or not to start.

Keep the fuel storage tank outside and keep the fuel as cool as possible. Remove water from the storage container at regular periods of time.

Fill the fuel tank at the end of the daily operating period to prevent condensation in the fuel tank.

The Diesel fuel used in this machine must meet the specifications in the chart below or Specification D975-81 of the American Society for Testing and Materials.

Specifications for Acceptable No. 2 Diesel Fuel API gravity, minimum ................................................................................................................................ 34 Flash point, minimum ............................................................................................................... 140°F (60°C) Cloud point (wax appearance point), maximum .............................................. -5°F (-20°C) See Note above Pour point, maximum ................................................................................... -15°F (-26°C) See Note above Distillation temperature, 90% point ................................................................. 540 to 640°F (282 to 338°C) Viscosity, at 100°F (38°C) - Centistokes ....................................................................................... 2.0 to 4.3 Saybolt Seconds Universal ............................................................................................................. 32 to 40 Cetane number, minimum .............................................................. 43 (45 to 55 for winter or high altitudes) Water and sediment, by volume, maximum ........................................................................................ 0,05%

!

WARNING: Engine fuel is flammable and can cause a fire or an explosion. Do not fill the fuel tank or service the fuel system near an open flame, welding, burning cigars, cigarettes, etc. Never refuel the machine when the engine is hot or running. Never smoke while refueling.

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

96

G200

LUBRICATION/FILTERS/FLUIDS Fuel Tank Drain Cock Clean

Fuel System Air Bleed

Open the drain cock, before engine start and allow water or sediment to drain. Close the drain cock when fuel runs out.

1. Clean the area around the water separator filter head to avoid contamination.

2. Completely loose the aluminum bleeder screw (3) located on the filter head, with a screw driver.

3. Be sure that the water drain bolt (4) on the lower part of the filter is completely tight.

4. Manually loose 3 to 4 turns the filter pumping knob (5).

5. Prime the knob until the Diesel fuel comes out through the bleeder screw (3) hole without the presence of bobbles.

6. Manually tight the knob (5) and the bleeding bolt (3).

3

WARNING: Extinguish all smoking

!

5

materials or open flames before opening the sediment drain due to presence of flammable fluids.

Fuel Filters These are lock ring type cartridge filters. Clean the area around the fuel filter (1) and fuel water separator filter (2) to avoid contamination.

4

2

1

3. BLEEDER SCREW 4. DRAIN BOLT 5. PUMPING KNOB

1. FUEL FILTER 2. WATER SEPARATOR FILTER

Remove the filters and clean carefully the area around the filter head gasket. Change the fuel filters and sealing rings. Fill the filters with clean fuel and lubricate the sealing rings with new engine oil.

Assemble the filters and tight them manually. After the assembly, make the fuel system air bleed procedure.

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

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G200

LUBRICATION/FILTERS/FLUIDS Valve Clearance Adjustment EACH 1000 HOURS Always adjust the valve clearance with engine cold, that is, with engine coolant temperature below 140ºF (60°C). First determine the top dead center (TDC) on engine nº 1 cylinder. To perform so, rotate the crankshaft slowly, using the adapter and gear of the manual rotating tool. Install the synchronizing pin and adjust the following valves: 1A, 1E, 2A, 3E, 4A, 5E. Remove the synchronizing pin, rotate the crankshaft 360° and install again the synchronizing pin. Perform the adjustment of the following valves: 2E, 3A, 4E, 5A, 6A, 6E. Clearance of valves must meet the specifications of table below: Valves

min.

max.

rated

Intake

0,152 mm

0,381 mm

0,254 mm

Exhaust

0,381 mm

0,762 mm

0,508 mm

NOTES: Clearance will be correct if a slight effort is

felt when the feeler gauge is introduced between the valve stem and the rocker arm. Tighten the lock nut to 24Nm (212 lb.in) torque.

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

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G200

LUBRICATION/FILTERS/FLUIDS HYDRAULIC/BRAKE SYSTEM Service Specifications Hydraulic/Brake System Fluid Chart Hydraulic Reservoir Refill Capacity w/filter change ........................................... 94.6 liters (25 U.S. Gallons) Total System + Tank Capacity ......................................................................... 180 liters (47.5 U.S. Gallons) Type of Fluid ........................................................................................................ See Fluids and Lubricants Hydraulic Reservoir Fluid Level Check Interval ................................................................... Every 50 Hours Filter Replacement Interval ..................................................................... Every 2000 Hours of Operation or when the Hydraulic Filter Warning Lamp Illuminates Hydraulic Fluid Change Interval ................................................................................... Every 2000 Hours or once each year, whichever occurs first.

WARNING: Pressurized hydraulic system. Before you replace the hydraulic filter or service the

!

hydraulic system, wear face protection and slowly loosen the hydraulic reservoir fill cap to relieve the air pressure. If you do not follow these instructions, you can be injured.

Hydraulic/Brake System - Temperature Ranges

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

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G200

LUBRICATION/FILTERS/FLUIDS Hydraulic System Oil Filter

Loosen filler cap (1) to relieve pressure.

CHECK EACH 500 HOURS

Remove cover (2) from top of the tank. Remove spring (3), cap (4) and o-ring (5), from top of element (6). Remove element from tank and discard.

Make certain o-ring (8) is in good condition, then install a new filter over the discharge tube. Position o-ring (5), cap (4) and spring (3) on top of the element.

Make certain o-ring (5) is in good condition and properly positioned as shown. Install cover (2) on tank and secure with capscrews (7). Torque capscrews to 47.5 - 54.2 Nm (35 - 40 lb.ft).

Cleaning the Suction Line Filter

!

WARNING: Fluid under pressure. Turn

cap slowly to relieve pressure before removing it.

Loose the filler neck cap (1) to relieve the pressure.

Remove the filler neck capscrews (9), the tube and the filter. Remove the filler neck cover, the tube (10) and filter (14) from the hydraulic. Remove and replace the rubber ring (11) from filter, if necessary.

IMPORTANT: Do not use gasoline, solvent or another flammable fluids to wash the components. Use recommended commercial, non toxic solvent. Wear safety glasses with side shields when using compressed air for cleaning to reduce the danger of personal injury from flying particles. Limit the air pressure to 30 PSI (2 bar).

Wash the strainer with a commercial solvent. Use compressed air to clean the element. Blow it from inside to outside.

Install a new o-ring in the groove and then install the tube assembly (pre cleaner) (10). Install the capscrews (9) and torque them with 47.5 - 54.2 Nm (35 - 40 lb.ft). Make sure that valve assembly and strainer are properly positioned in the tube assembly.

Fill the tank to the proper level indicated on the sight gauge (13). Install a new o-ring (12) on the filler cap and install it.

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

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G200

LUBRICATION/FILTERS/FLUIDS Hydraulic/Brake Oil Change Change the hydraulic/brake oil every 2000 hours of operation or one time each year, or when ambient operating temperatures require, whichever occurs first. When changing the hydraulic oil also replace the hydraulic oil filter. Have a container available that is capable of holding 180 liters (47.5 Gal).

1. Make sure the hydraulic oil is at operating temperature.

2. Park the machine on a level surface. Lower implements to the ground and apply the parking brake.

3. Stop the engine. Put a DO NOT OPERATE tag on the steering wheel.

WARNING: Fluid under pressure. Lower implements to ground, shut off engine and move control

!

levers several times.

Loosen filler cap to relieve pressure, before loose fittings.

4. Remove the drain plugs, and drain oil in a container.

5. Remove the filler cap to vent the tank as it drains. The filler element should be changed and the strainer cleaned at this time.

6. Install drain plug and fill tank with new oil.

7. Install filler cap.

8. Start the engine and operate controls so that all lines are filled.

9. Stop the engine. Check oil level. Add oil as necessary to bring to proper level.

1

2

1. HYDRAULIC OIL LEVEL GAUGE

2. HYDRAULIC OIL LEVEL FILLER

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G200

LUBRICATION/FILTERS/FLUIDS TRANSMISSION Service Specifications Total system filling capacity with filters ................................................................ 25 liters (6.6 U.S. Gallons) Type of oil ............................................................................................................ See Fluids and Lubricants Oil level check interval .................................................................................................................... 10 hours Filter replacement interval .................................................................... After the first 100 hours of operation and then every 500 hours there after.

Breather screen cleaning interval ................................................................................................ 1000 hours Oil change interval ............................................................................... After the first 100 hours of operation and then every 1000 hours there after.

IMPORTANT: If the machine is new or the transmission has been replaced or rebuilt, change the transmission

oil and replace the filter after the first 100 hours of operation.

IMPORTANT: Change the transmission oil and replace the filter after the first 100 hours of operation.

!

WARNING: Never drain oil or remove oil filter while engine is running.

Transmission Oil Level Check EACH 10 HOURS OR DAILY SERVICES Check the transmission oil level when the oil is hot and the system is charged. Place transmission in NEUTRAL, keep the engine idling and apply parking brake.

1

Turn the handle counterclockwise to loosen the cap.

Remove the cap and check oil level with the dipstick.

Add oil as necessary to bring it to the proper level.

Make sure the cap is tight in the filler neck after checking oil.

1. TRANSMISSION OIL LEVEL DIPSTICK

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G200

LUBRICATION/FILTERS/FLUIDS Transmission Oil Filter Change EACH 500 HOURS WARNING: Never use gasoline, solvent or

!

other flammable fluids to clean parts. Use authorized commercial, nonflammable, nontoxic solvents.

Clean filter and surrounding area. Then remove the filter housing (1), change the elements and gaskets.

Clean the inside of the filter housing (1) and contact surface. Install the new filter.

Transmission Oil Change and Screen Cleaning EACH 500 HOURS Run engine until transmission oil reaches operating temperature.

Park motorgrader on a level surface, apply parking brake, lower moldboard to ground and shut-off engine.

Remove the drain plug and screen, and let the oil drain into a container that holds at least 25 liters (6.6 U.S. Gallons). Clean the suction screen completely. Reinstall the screen and drain plug. The transmission oil filter, should be changed at this time.

Fill the system to the level mark with the specified oil. Operate transmission to warm oil and top off as necessary.

1

1. TRANSMISSION OIL FILTER

1. DRAIN PLUG 2. SCREEN

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G200

LUBRICATION/FILTERS/FLUIDS REAR AXLE Service Specifications Rear Axle “Housing Center” Compartment Capacity (Dana) ........................... 12.0 liters (3.2 U.S. Gallons) Rear Axle “Planetary Gear” Capacity (each) (Dana) .......................................... 6.5 liters (1.7 U.S. Gallons) Type of oil ............................................................................................................ See Fluids and Lubricants Oil change interval ............................................................................... After the first 100 hours of operation and then every 2000 hours there after.

NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as

a result of using an alternate oil.

REAR AXLE DANA

Rear Axle Oil Change REAR AXLE HOUSING COMPARTMENT Change the axle oil every 2000 hours of operation.

1. Park the machine on a level surface. Apply the parking brake and stop the engine.

2. Clean the oil level and drain plugs.

3. Make sure the oil in the rear axle is near normal operating temperature.

4. Remove drain plug (2) and filler plug (1) to help oil drain more rapidly.

1. FILLER AND LEVEL PLUG 2. DRAIN PLUG

Axle Oil Level Remove level/ filler plug (1). Add oil as necessary to bring oil level to bottom of plug hole.

5. After draining, reinstall the drain plug and fill the housing to the level of the filler hole with the specified oil. Allow sufficient time for oil to fill all axle compartments. Wait 15 minutes and top off.

Install and tighten filler plug.

Install plug and be sure it is properly tightened.

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G200

LUBRICATION/FILTERS/FLUIDS Rear Axle End Compartment Oil Level

1

Make certain oil in rear axle end compartment is near operating temperature. Remove drain plugs (3) located on bottom of each end compartment and allow oil to drain.

Clean drain plugs, reinstall and tighten plugs securely.

Remove each oil level (2) and filler plug (1) and fill each compartment with the specified lubricant to level even with filler plug openings. Install and tighten oil level and filler plugs securely.

2 3

1. FILLER PLUG 2. LEVEL PLUG 3. DRAIN PLUG

4

4. COVER PLUG

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G200

LUBRICATION/FILTERS/FLUIDS SWING/CIRCLE TURN GEAR BOX Service Specifications Circle Turn Gear Housing Refill Capacity ......................................................... 2.8 liters (0.75 U.S. Gallons) Type of oil ............................................................................................................ See Fluids and Lubricants Oil check interval .................................................................................................................. each 250 hours Oil change interval ...................................................................................................................... 1000 hours

Checking Circle Turn Gear Box Oil EACH 250 HOURS Remove oil level plug. If the oil does not drain from the hole, remove the filler plug and add oil until it comes out of the level plug hole. Then install level plug and filler plug.

3. CIRCLE TURN GEAR BOX

NOTE: See Circle Guides Check and Adjustments.

1. FILLER PLUG 2. LEVEL PLUG

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G200

LUBRICATION/FILTERS/FLUIDS TANDEM Service Specifications Tandem Drive Case Refill Capacity (Dana Axle) .............................................. 22.7 liters (6.0 U.S. Gallons) Type of oil ............................................................................................................ See Fluids and Lubricants Oil check interval .................................................................................................................. each 500 hours Oil change interval ............................................................................................................. each 2000 hours Grease check interval (Tandem Case) ................................................................................. each 500 hours Type of grease .................................................................................................... See Fluids and Lubricants

Tandem Drive Case Oil Level Check Park motorgrader on a level surface. Remove level plug (2) from each tandem case. The oil must be level with the oil level plug hole. Add oil until it is brought to the proper level. Install all plugs.

Tandem Drive Case Oil Change CHANGE OIL EACH 2000 HOURS Remove the drain plug from each case and drain the oil. Remove the level and filler plugs from each case.

Install the drain plugs. Add specified oil through the filler holes until oil runs out of the oil level hole.

Install and tighten level plugs and filler plugs in each case.

1. FILLER PLUG 2. LEVEL PLUG 3. DRAIN PLUG

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G200

LUBRICATION/FILTERS/FLUIDS WINDSHIELD WASHER RESERVOIR (OPTIONAL)

1

1. WASHER RESERVOIR

The windshield washer reservoir is located on the side of the cab, as shown above. To add washer fluid, pull the cap up.

IMPORTANT: When the ambient temperature decreases to 0°C (32°F) and below, always use an antifreeze type washer solution.

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MAINTENANCE/ADJUSTMENT G200

MAINTENANCE/ADJUSTMENT PARKING BRAKE CHECK Park the machine on a leveled surface. Wedge the wheels and lower the blade to the ground to avoid the machine from moving. Keep engine stopped.

1

Apply the parking brake lever to check its operation.

The effort to move the lever must increase, starting from the center position of its stroke.

The parking brake lever stroke adjustment is done by adjusting the cable and the position of the caliper lever (4) on the transmission. The access is possible through the rear of the machine by removing the lower plastic protection of the fan (1), or if desired, by remove the engine crankcase protection.

With the parking brake released, loosen the cable cap fixing nuts (2). Loosen the nut lock-pin (3) and adjust the position of the pads, on the brake disc, by turning clockwise the nut (3) in order to reduce the pads gap.

1. FAN LOWER PLASTIC PROTECTION

2

Note: A gap must always exist between the disc and the pads. If no gap exists, the disc will overheat and the pads will worn prematurely.

Install the lock-pin on nut (3). Position the cable cap and eliminate its gap, so that it remains in a position of approximately 90° regarding the caliper lever (4).

Retighten the nuts (2). Check if the increase of effort necessary to apply the parking brake lever occurs after the half of its stroke.

2 3

4

2. CABLE FIXING NUTS 3. CALIPER DRIVE LEVER NUT 4. CALIPER DRIVE LEVER

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G200

MAINTENANCE/ADJUSTMENT ROLL-OVER PROTECTIVE STRUCTURE Your machine is equipped with an operator Protective Structure, such as: a Rollover Protective Structure (ROPS) or Falling Object Protective Structure (FOPS) or Cab with ROPS. A ROPS may be a cab frame or a two-posted or four-posted structure used for the protection of the operator to minimize the possibility of serious injury. The mounting structure and fasteners forming the mounting connection with the machine are part of the ROPS. A ROPS label shows the serial number of the ROPS, gross weight, approval, regulation, and model numbers of the machine. See Identification Numbers in this manual.

• The mounting or suspension for the Protective Structure, operator seat and suspension, seat belts and mounting components and wiring within the operator’s protective system MUST be carefully inspected for damage.

• All damaged parts MUST be replaced.

WARNING: Do not weld, drill holes, attempt

!

to straighten or repair the protective structure. Modification in any way can reduce the structural integrity of the structure which could cause death or serious injury in the event of fire, tip, rollover, collision or accident.

Seat Belt The seat belt is an important part of your ROPS. You must wear the seat belt at all times when you operate the machine.

1. Keep the seat belts away from objects that can damage them.

2. Check the seat belts for damage. Replace all parts that are damaged.

ROPS CANOPY LABEL

The Protective Structure is a special safety component of your machine. Before you operate this machine, always make sure that the ROPS and operator’s seat belts are correctly installed.

DO NOT attach any device to the Protective Structure for pulling purposes. DO NOT drill holes to the Protective Structure.

The Protective Structure and interconnecting components are a certified system. Any damage, fire, corrosion or modification will weaken the structure and reduce your protection. If this occurs, the Protective Structure MUST be replaced so that it will provide the same protection as a new Protective Structure. Contact your dealer for Protective Structure inspection and replacement.

After an accident, fire, tip or roll over, the following MUST be performed by a qualified technician before returning the machine to field or job site operation: • The Protective Structure MUST be replaced.

3. Make sure that the mounting bolts of the seat belts are tight. See Torque Specifications for Seat in this manual.

4. Keep the seat belts clean. Wash the seat belts only in soap and water.

5. Do not put the seat belts in bleach or dye.

Maintenance and Inspection of ROPS After the first 20 hours of operation and after every 500 hours of operation, do the following: 1. Check the torque of the ROPS mounting bolts. If necessary, tighten the bolts to the correct torque.

See torque specifications on this page.

2. Check the operators seat and the mounting parts for the seat belt. Tighten the bolts to the correct torque. See Torque Specifications in this manual.

Replace parts that have wear or damage.

3. Check for cracks, rust, or holes in the ROPS and ROPS parts. Age, weather, and accidents can cause damage to the ROPS and ROPS parts. If you have any doubt about the ROPS system, see your NEW HOLLAND Dealer.

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G200

MAINTENANCE/ADJUSTMENT Torque Specifications for ROPS Cab and ROPS

Damage to the ROPS If the machine has rolled over or the ROPS has been in some other type of accident (such as hitting an overhead object during transport), you must replace the damaged ROPS components to get as much protection as you had originally.

After an accident, check the following for damage.

A. ROPS canopy or cab.

B. Operators seat.

1

C. Seat belt mounting bolts and seat belt.

Before you operate the machine, replace all ROPS components that are damaged.

CANOPY 1. ROPS CAB AND ROPS CANOPY MOUNTING BOLTS (BOTH SIDES), TIGHTEN THE 16 BOLTS TO 772 TO 854 N.m (570 to 630 lb.ft)

See the Parts Catalog or your dealer for components that are replaceable.

IMPORTANT: DO NOT TRY TO WELD OR

STRAIGHTEN THE ROPS.

NOTE: Torque specifications are for clean, dry

threads.

WARNING: Improper ROPS inspection or maintenance can cause injury or death. Do the

!

recommended ROPS inspection shown in this manual. If you must replace the ROPS, ROPS parts, or ROPS mounting hardware, use only the replacement parts shown in the NEW HOLLAND parts catalog for this machine.

WARNING: Do not modify ROPS in any manner. Unauthorized modifications such as welding,

!

drilling, cutting or adding attachments can weaken the structure and reduce your protection. Replace ROPS if subjected to roll-over or damage. Do not attempt to repair.

WARNING: If you operate this machine without a ROPS and the machine rolls over, you can be

!

injured or killed. Remove the ROPS only for service or replacement. Do not operate this machine with the ROPS removed.

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WARNING: Adding additional weight (attachments, etc.) to the machine can cause injury or death.

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WARNING: Always fasten the seat belt securely before starting the Engine.

Do not exceed the gross weight printed on the ROPS label.

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G200

MAINTENANCE/ADJUSTMENT TORQUE SPECIFICATIONS FOR SEAT AND SEAT BELTS

2

1

1. 73-87 N.m (54-64 lb.ft) 2. 54-61 N.m (40-45 lb.ft)

Operators Seat Remove dust and dirt from the seat with a vacuum cleaner or soft brush. Clean stains with the correct use of a material cleaner.

Before removing stains, try to find what type and how old the stains are. Some stains can be removed with water or soap solution.

CLEANER FLUID - This type of cleaner can be used for grease or oil stains.

Carefully remove the item that caused the stain with a scraper or a knife that is not sharp. Use very little cleaner, no pressure, and clean cloths. Move the cloth from the outside of the stain toward the center of the stain and constantly change to a clean section of cloth.

When the stain is removed from the material, immediately use a cloth dry the area and to prevent a cleaner circle pattern. If a circle pattern occurs, clean the complete area.

NOTE: A difficult stain may need a second application

of cleaner fluid followed immediately by the use of a soft brush to completely remove the stain.

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WARNING: Never use gasoline, naphta or any other volatile material for any cleaning purposes.

These materials may be toxic and/or flammable.

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G200

MAINTENANCE/ADJUSTMENT Cab Headliner

Doors Hinges

The foam headliner in your cab decreases noise. To keep the headliner in good operating condition, remove dust with a vacuum cleaner.

Use graphite to lubricate all hinges.

IMPORTANT: DO NOT wash the headliner with

water. Water can cause damage to the headliner and lower the noise control capacity of the headliner.

DO NOT use oil.

Hoses and Wiring Check all hoses and wiring for damage.

If damage occurred, see your dealer for repair or replacement.

FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) Type of Fire Extinguisher It is recommended that you have a fire extinguisher on your machine. The fire extinguisher shown below is available from your dealer and can be installed on the machine.

This dry chemical fire extinguisher has a 5 pound capacity and is approved for Class A, B and C type fires. The operating temperature is from -65° to 120°F (-54° to 49°C).

Inspection and Care EVERY MONTH - It is recommended that you inspect the fire extinguisher once each month for damage and to insure that the gauge is working correctly.

EVERY 6 MONTHS - Have the dry chemical removed and refilled by a fire equipment technician.

IMPORTANT: DO NOT mount the Fire Extinguisher

on any part of the ROPS/FOPS structure. DO NOT make any modifications to the ROPS/FOPS structure.

ONCE EACH YEAR - Have the fire equipment technician inspect the fire extinguisher.

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G200

MAINTENANCE/ADJUSTMENT ALTERNATOR BELT AND AIR CONDITIONING COMPRESSOR BELT Service Interval Belt service interval .................................................................... Check daily and replace every 1000 hours Air conditioning compressor belt service interval ..................................................... Check every 250 hours 1. Park the machine on a level surface and apply the parking brake.

2. Turn the master disconnect to OFF. The belt tension is maintained by the action of a spiral tensioning spring.

NOTE: Check that the belts are not cracked or

damaged. Replace if it is necessary.

Alternator Belt and Tensioner

1. ALTERNATOR BELT 2. AIR CONDITIONING COMPRESSOR BELT

Remove the drive belt using a 1/2" square socket wrench handle, to release belt tension.

ENGINE DRIVE BELT 1. WATER PUMP PULLEY 2. CRANKSHAFT PULLEY 3. SQUARE HOLE OF 1/2" (13 MM) 4. BELT TENSIONER 5. ALTERNATOR

NOTE: Panels behind seat must be removed to

access engines belt.

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G200

MAINTENANCE/ADJUSTMENT Drive Belt and Tensioner Inspection

Reinstalling the Drive Belt

After removing, examine the belt for damage.

Using a 1/2" socket wrench handle and the tensioner, install the belt carefully, observing that the multi-V’s ribs fit perfectly with the existing channels of the alternator pulley and vibration damper.

Drive Belt Tensioner The drive belt tensioner pulley must rotate freely with no point showing resistance, locking up, etc., when turned by hand. Check belt tensioner bearing carefully also.

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G200

MAINTENANCE/ADJUSTMENT CIRCLE GUIDES CHECK AND ADJUST The circle and circle guides must be kept clean to prevent caking. If the circle guides are excessively loose, the gear teeth will wear, causing the circle turn to function erratically.

Guide nuts Tightening torque: 110 kgf.m

Wear Plate Adjustment Proceed as follows: The first adjustment is to eliminate play between the upper wear plates and the upper circle guides (vertical clearance).

To make this adjustment, shims between wear plates and the upper circle surface must be removed.

NOTE: Do not throwaway the shims that were

Radial clearance max. 0.76mm

Blade

Shims Lock nut

removed. They can be used again in other new adjustment.

Make sure that the maximum clearance does not exceed 1.52 mm. This adjustment must be completed on each of the four (4) guides, one at a time, beginning with one closest to the circle turn motor pinion gear.

After vertical adjustment rotate the circle 360° to be sure that the circle turns freely.

Next, adjust the clearance between the wear plates and the inner circle guides (radial clearance), proceeding as follows: CIRCLE TURN CLEARANCES

1

1. CIRCLE GUIDES

Shims Circle upper surface

Guide

Vertical clearance max 1.52mm Circle Radial clearance min 0.76mm max 1.52mm

With the vertical clearance already adjusted, loosen the circle guide nuts and the jam nuts of radial clearance adjusting screws.

Position the circle turn motor pinion in such a way that the tooth engagement is as shown below. Make sure that the center of the circle turn motor pinion, center line of the engaged tooth and the front guide center locknut are aligned.

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G200

MAINTENANCE/ADJUSTMENT Put one flank of the pinion tooth in contact with one circle tooth. Turn adjusting screws of front guide as necessary to provide 0,76 mm between the opposite flanks of the circle and pinion tooth.

Drawbar DRAWBAR BALL NUT TORQUE CHECK

Guide Teeth clearance min 0.76mm max 1.52mm Guide

Check drawbar ball nut. Torque should be 732 to 895 N.m (540 to 660 lb.ft).

1. CIRCLE GUIDE PINION

After adjustment of the front guide radial play, tighten lock nuts and perform rear guides radial adjustment to a maximum clearance 0,76 mm between the inner circle guides and the curved circle guide wear plates using the adjusting screws.

Tighten the adjusting screw jam nuts and circle guide lock nuts. Rotate the circle 360° to be sure it turns freely.

Should the circle not turn freely, perform the adjustment again, increasing clearance between tooth flanks. Do not exceed the upper limit.

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G200

MAINTENANCE/ADJUSTMENT HYDRAULIC DIAGNOSTIC PANEL CHECK

1

1. DIAGNOSTIC TEST PANEL

When hydraulic system pressure failures occurs, pressure specifications are as follow: 1. Hydraulic System (193 ±3,4bar; 2800±50PSI) *1 2. Steering Hydraulic System (151bar; 2200PSI) *2 3. Brake Accumulators LH (81-87bar; 1175-1262PSI) *1,3 (120-126bar; 1740-1827PSI) *1,4 4. Brake Accumulators RH (81-87bar; 1175-1262PSI) *1,3 (120-126bar; 1740-1827PSI) *1,4 5. Brake System LH (65 ± 3bar; 943±44PSI) *1 6. Brake System RH (65 ± 3bar; 943±44PSI) *1 7. Blade Lift Cylinder RH (98-113bar; 1420-1640PSI) *1 8. Blade Lift Cylinder LH (98-113bar; 1420-1640PSI) *1 NOTE: *1 Engine speed 2200 rpm *2 Engine speed 900 rpm *3 Minimum accumulator pressure *4 Maximum accumulator pressure

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ELECTRICAL SYSTEM G200

ELECTRICAL SYSTEM Battery Safety

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WARNING: Before you service a battery, always wear face protection, protective gloves and

protective clothing. Battery acid or battery explosion can cause serious injuries.

WARNING: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote - EXTERNAL: flush with water. INTERNAL: drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately. EYES: flush with water for 15 minutes and get prompt medical attention.

WARNING: When the battery electrolyte is frozen, the battery can explode if, (1) you try to charge

!

the battery, or (2) you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.

WARNING: Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an

explosion, do the following:

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1. When you disconnect the battery cables, always disconnect the negative (1) battery cable first.

2. When you connect the battery cables, always connect the negative (-) cable last.

3. Do not short circuit the battery posts with metal items.

4. Do not weld, grind, or smoke near a battery.

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G200

ELECTRICAL SYSTEM BATTERY SERVICE NOTE: The electrical system in this machine is 24 volts.

Each battery is 12 volts.

Before you service components of the electrical system, always disconnect the NEGATIVE (-) battery cable.

Do not run the engine with the battery cables disconnected or with the alternator wires disconnected.

Before you use an electric welder, disconnect the alternator wires, instrument cluster, transmission electronic control unit and turn the master disconnect switch to OFF. Do not use a steam cleaner or cleaning solvent to clean the alternator.

Battery Fluid Level

Cleaning the Batteries Check the batteries and battery compartment regularly for dirt, corrosion and damage. Dirt mixed with electrolyte or moisture on the top of the batteries can cause a discharged condition in the batteries.

Use one of the following methods to clean the batteries.

1. Use New Holland Battery Saver. Follow the instructions on the container. This cleaner does not need water.

2. Use baking soda or ammonia and flush the outside of the batteries with water.

If you do not have New Holland Battery Saver, use other special cleaners to prevent corrosion on the battery terminals.

The batteries are “Maintenance Free” type and electrolyte level check is not required. Do not leave lamps switched on for long intervals of time with the engine stopped or idling. Keep batteries clean, specially on its top surface.

Make sure of that cable terminals are correctly fixed on the battery poles. Always disconnect master switch before servicing batteries.

Battery Vents Keep the battery vents clean, make sure the vents are not restricted.

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G200

ELECTRICAL SYSTEM STARTING THE ENGINE USING BOOSTER BATTERIES

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WARNING: Explosive gas is produced while batteries are in use or being charged. Keep open flames and/or sparks away from the battery charging area. Charge the batteries in a well ventilated place. Park the machine on a dry firm, surface. Do not park on metal surfaces. Take care to make correct connections. Never connect a positive terminal (+) to a negative terminal (-).

IMPORTANT: The machine electrical system is 24 V

with negative (-) ground. Use only booster batteries with same voltage.

Connecting booster batteries

B

C

A

Proceed in the following order: • Connect one terminal of the red cable (1) to the positive (+) pole of machine batteries and the other terminal of same cable to the positive (+) pole of booster batteries (loaded).

• Connect one terminal of the black cable (2) to the negative (-) pole of booster batteries and the other terminal of same cable to ground (machine frame).

• Start the engine.

IMPORTANT: The connection of booster batteries should not be accomplished by non-authorized personnel.

batteries (loaded)

batteries (unloaded)

D

Cable connection order: A

B

C

D

Cable disconnection order: D

C

B

A

Disconnecting booster batteries Proceed in the following order: • Disconnect the black cable (2) terminal from ground (machine frame), then disconnect the other terminal of same cable from the negative (-) pole of booster batteries (loaded).

• Disconnect the red cable (1) terminal from the positive (+) pole of booster batteries, then disconnect the other terminal of same cable from the positive (+) pole of machine batteries (unloaded).

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G200

ELECTRICAL SYSTEM TRANSMISSION AUXILIARY SYSTEM COME-HOME The COME-HOME is an emergency function, used in event of failure of the transmission control module.

If the immediate replacement of the module is not possible, this function allows the driving of the machine to the nearest repair shop.

The switch (8) on the instrument panel is a threeposition switch: forward, neutral and reverse. To enable the system, turn off the machine, apply the parking brake and put the switch in the neutral position.

Open the cover on the right hand side of the operator’s cab. This allows the access to two gray connectors and one black connector.

COME-HOME ACTIVATED

Close the side-cover, be sure the parking brake is applied, then start the engine.

NOTE: After releasing the parking brake, select the

desired driving direction (forward - reverse) through the COME-HOME switch on the instrument panel.

Moving the COME-HOME switch to the “forward” position the system will select the second forward gear. Moving the COME-HOME switch to the “reverse” position, the system will select the first backup gear.

!

SIDE COVER

1

3

2

4

WARNING: The inching pedal does not function when the COME-HOME mode is activated.

After repairs, reconnect the connectors to their former positions. Connect the connector 1 with connector 2 and connector 3 with connector 4.

COME-HOME NOT ACTIVATED

Disconnect the gray 1 and 2, 3 and 4 connectors.

Then connect the 2 and 3 connectors.

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G200

ELECTRICAL SYSTEM CARE TO BE TAKEN PRIOR TO PERFORMING ANY WELDING PROCEDURE ON THE MACHINE Disconnect the positive (+) and negative (-) cables from batteries prior to performing any welding service on the machine. Connect the welding equipment ground cable to a 0,6 m (2 feet) maximum distance from the area being welded. Do not connect the welding equipment ground cable to the module cooling plate or to the engine control module (ECM) itself. Welding work is not recommended on installed engine or components.

Transmission Control Module (TCM) Connectors

X23

Engine Control Module (ECM) Connectors

X24 B

TRANSMISSION CONTROL MODULE (TCM) X24 BLACK CONNECTOR AND X23 GRAY CONNECTOR

When welding service is necessary to be performed on the machine, make sure to disconnect the X24 connector and the X23 connector from the right handside of the operator’s cab.

CAUTION: If welding service is performed

!

A

without disconnecting the X24 and X23 connectors shown in illustration, damages can be caused to the transmission control module (TCM).

C

ENGINE CONTROL MODULE (ECM) DETAILS, SHOWING LOCATION OF CONNECTORS A, B, AND C TO BE DISCONNECTED

POSITION OF THE ENGINE CONTROL MODULE (ECM), ON LEFT HAND-SIDE OF THE MACHINE, IN ENGINE COMPARTMENT.

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G200

ELECTRICAL SYSTEM

J6

Prior to perform any welding service on the machine, disconnect J6 connector on left hand-side of the machine, next to the transmission.

J4

When welding service is necessary to be performed on the machine, make sure to disconnect the transmission control lever J4 connector, located on the right hand-side console, above the fuse block.

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

124

G200

ELECTRICAL SYSTEM FUSE BOX The fuse box is located inside the right console. To access the fuses for replacement or service of fuse box, open the front cover of the console.

Fuse and Relay List Fuse Box 1 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12

7.5 amp 15 amp 7.5 amp 7.5 amp 15 amp 3 amp 10 amp 10 amp 10 amp 7.5 amp 10 amp 15 amp

F13 F14 F15 F16

7.5 amp 7.5 amp 10 amp 10 amp

To flasher relay and turn signal lights To power outlet and Dual Power system To rotating beacon and cab dome light To head lights (low beam) To horn To E.D.M. (Electronic Data Panel) and buzzer To Funk transmission system To Funk transmission system To Funk transmission system To cab fans To front wiper and washer pump To hydraulic solenoid valves saddle lock pin and float control (opt) To rear flood lights To high beam To starting aid (opt) To rear wiper and washer pump

Fuse Box 2 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26

20 amp 3 amp 3 amp 3 amp 10 amp 3 amp 3 amp 5 amp 3 amp 15 amp

F27 F28 F29 F30 F31 F32

7.5 amp 7.5 amp 7.5 amp 10 amp 7.5 amp 7.5 amp

To air conditioner system (opt) To reverse fan solenoid valve (opt) To reverse signal on the gear selector To air conditioner system mode door (opt) To front wheel drive system To differential lock (opt) To back-up alarm (opt) To electrical engine shut off To brake light To front lower wipers/washer/and air suspension seat (opt) To cab lights To working lights before moldboard (opt) To working lights after moldboard (opt) To radio and cigarette lighter To alternator regulator and hability relay To front equipment lights (opt)

Relays K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14

Hability Relay “Dual Power (QSB, Tier 2 and Tier 3) Relay (See Note 1)” Auxiliary starting relay Low beam relay High beam relay Rear flood lights and rear work lights relay Horn relay Back-up alarm relay Starting Aid (opt) (See Note 2) Differential lock relay “Dual power relay (Opt Tier 0, 1 and 2) (See Note 2)” Magnetic clutch/compressor relay air conditioner system (opt) On-off fan drive relay (opt) Work light before moldboard relay (opt)

Note1:

To QSB and Tier2 engine/To Tier3 engine 140 hp class

Note2:

Only to mechanical engine

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

125

G200

ELECTRICAL SYSTEM LOGIC CHECKING FOR TIER3 CUMMINS ENGINE OPERATION Engine Protection System

Troubleshooting Codes

The engine protection system monitors the sensor readings of the engine control system and records failure codes when an abnormal operation condition occurs. The engine power can be reduced depending to the type of the occurred failure. The system informs the operator through the warning (A) and the stop (B) indicator lights.

The engine protection system can indicate and record operation failures that are identified by failure codes.

These codes facilitate the Troubleshooting.

These codes can be read through the indicator lights interpretation, or by performing the software Insite of Cummins with a lap top.

Engine Stop

See Section Troubleshooting Codes Checking and Interpretation.

Turn on the main switch and turn the start switch to the IGN (Ignition) position.

NOTE: The failure codes do not indicate all anomalies

At that moment, the system checks the indicator and warning lights. If any of the lights does not light, replace the bulb. If no failure is detected, all lights will go off.

Indicator Lights

of the engine.

Standby Light For Starting The standby light for starting (C) (GRID HEATER light) will remain on, during the intake air preheating period. During this period the engine must not be started.

When the heating is completed, the standby light for starting (C) (GRID HEATER light) will go off and the engine can be started.

The intake air heating time occurs according to the environment temperature. Therefore, in case of very cold climates the standby light for starting (C) will remain on for a longer time, which does not mean that a failure is present.

IMPORTANT: Never turn off the main switch when

the starting switch is on the IGN (Ignition) position.

This procedure will accumulate failure codes in the ECM memory, which will not be informed by the indicator lights.

The indicator lights are located on the front instrument panel behind the steering wheel, and are: A. Warning indicator light (Yellow) B. Stop indicator light (Red) C. GRID HEATER standby light for starting

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

126

G200

ELECTRICAL SYSTEM A. Warning indicator light

1. Work and troubleshooting switch

Needs the operator’s attention when this light is on.

Indicates a slight failure.

Work position

B. Stop indicator light

Safety lock

Machine must be immediately stopped when this light is on. Indicates a serious failure.

The specific high temperature of the engine coolant and the low pressure of the oil are not indicated by the indicator lights flashing code. In this condition the red bulb is on as long as the engine is running and the ECM will advance the reduction of the engine power.

If this occurs, stop the machine for repairs to be performed by a CUMMINS Dealer.

C. Standby light for starting (C) (GRID HEATER light) The operator must wait until this light goes off in order to star the engine. The GRID HEATER is automatically activated and deactivated by the ECM.

Move downwards for unlocking Troubleshooting Position

The Work and troubleshooting switch consists of two positions: Work - Used when no failure exists during normal operation of the machine.

Troubleshooting - Used when an active failure exists.

This function can be activated with engine stopped only and by moving downwards the switch safety lock, as shown on illustration.

NOTE: In case of very cold climates the GRID

2. Increase and decrease switch

HEATER can be activated during normal operation of the machine, allowing the indicator light to go on, which doesn’t means that a failure exists.

The Increase and decrease switch (2) also consists of two functions, depending of the work and troubleshooting switch (1) position.

Troubleshooting Switches

Increases the engine rotation

Reduces the engine rotation

1

2

When the work and troubleshooting switch (1) is on work position and the engine is running, the increase and decrease switch reduces or increases the engine rotation by 20 rpm at every touch.

Increase, next code 1. WORK AND TROUBLESHOOTING SWITCH 2. INCREASE AND DECREASE SWITCH

The two switches for the engine troubleshooting are located on the side panel of the cab.

Decrease, prior code

When the work and troubleshooting switch (1) is on troubleshooting position, with the engine stopped and the start switch on IGN (Ignition) position, we can advance to the next troubleshooting code (increase) or go back to the prior troubleshooting code (decrease).

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

127

G200

ELECTRICAL SYSTEM Checking and Interpretation of the Troubleshooting Codes Have a paper-block and a pen in hands in order to record the failure codes as per steps below.

Stop the engine wait for 10 seconds. Put the ignition switch on IGN (Ignition) position.

Release the work and troubleshooting switch safety lock by moving it downwards and place switch to the troubleshooting position.

The failure code consists of 3 or 4 digits, interpreted from the number of flashes of the warning indicator light (A) which will be 3 or 4 blocks separated by a small pause.

Example: Reading of the first code (example: 3) 3 flashes followed by a pause 3 flashes

Reading of the second code (example: 6) 6 flashes followed by a pause

6 flashes

Reading of the third code (example: 3) 3 flashes followed by a pause

3 flashes Formed code is 363. See failure codes table on following pages.

The increase and decrease switch (2) must be used to pass to the next failure, and so on. When a failure code has been already shown, there will be no more failures on the system.

When reading is completed, move upwards the work and troubleshooting switch (1) lock and place it on the work position.

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

128

G200

ELECTRICAL SYSTEM Fault Code

Lamp Color

Cummins Description

111

Red

Engine Control Module Critical internal failure - Bad intelligent Device or Component

115

Red

Engine Speed/Position Sensor Circuit Lost Both of Two Signals from the Magnetic Pickup Sensor Data Erratic, Intermittent, or incorrect

122

Amber

Intake Manifold Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Source

123

Amber

Intake Manifold Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source

131

Red

Accelerator Pedal or Lever Position Sensor Circuit - Voltage Above Normal, or Shorted to High Source

132

Red

Accelerator Pedal or Lever Position Sensor Circuit - Voltage Below Normal, or Shorted to Low Source

133

Red

Remote Accelerator Pedal or Lever Position Sensor Circuit - Voltage Above Normal, or Shorted to High Source

134

Red

Remote Accelerator Pedal or Lever Position Sensor Circuit - Voltage Below Normal, or Shorted to Low Source

135

Amber

Oil Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Source

141

Amber

Oil Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source

143

Amber

Oil Pressure Low - Data Valid but Below Normal Operational Range - Moderately Severe Level

144

Amber

Coolant Temperature Sensor Circuit - Voltage Above Normal, or Shorted to High Source

145

Amber

Coolant Temperature Sensor Circuit - Voltage Below Normal, or Shorted to Low Source

146

Amber

Coolant Temperature High - Data Valid but Above Normal Operational Range - Moderately Severe Level

147

Red

Accelerator Pedal or Lever Position Sensor Circuit - Abnormal Frequency, Pulse Width, or Period

148

Red

Accelerator Pedal or Lever Position Sensor Circuit - Abnormal Frequency, Pulse Width, or Period

151

Red

Coolant Temperature Low - Data Valid but Above Normal Operational Range - Most Severe Level

153

Amber

Intake Manifold Air Temperature Sensor Circuit - Voltage Above Normal, or Shorted to High Source

154

Amber

Intake Manifold Air Temperature Sensor Circuit - Voltage Below Normal, or Shorted to Low Source

155

Red

Intake Manifold Air Temperature High - Data Valid but Above Normal Operational Range - Most Severe Level

187

Amber

Sensor Supply Voltage #2 Circuit - Voltage Below Normal, or Shorted to Low Source

195

Amber

Coolant Level Sensor Circuit - Voltage Above Normal, or Shorted to High Source

196

Amber

Coolant Level Sensor Circuit - Voltage Below Normal, or Shorted to Low Source

221

Amber

Barometric Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Source

222

Amber

Barometric Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source

227

Amber

Sensor Supply Voltage #2 Circuit - Voltage Above Normal, or Shorted to High Source

234

Red

Engine Speed High - Data Valid but Above Normal Operational Range - Most Severe Level

235

Red

Coolant Level Low - Data Valid but Below Normal Operational Range - Most Severe Level

237

Amber

External Speed Input (Multiple Unit Synchronization) - Data Erratic, Intermittent, or Incorrect

238

Amber

Sensor Supply Voltage #3 Circuit - Voltage Below Normal, or Shorted to Low Source

241

Amber

Vehicle Speed Sensor Circuit - Data Erratic, Intermittent, or Incorrect

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

129

G200

ELECTRICAL SYSTEM Fault Code

Lamp Color

Cummins Description

242

Amber

Vehicle Speed Sensor Circuit tampering has been detected - Abnormal Rate of Change

245

Amber

Fan Control Circuit - Voltage Below Normal, or Shorted to Low Source

249

Amber

Ambient Air Temperature Sensor Circuit - Voltage Above Normal, or Shorted to High Source

256

Amber

Ambient Air Temperature Sensor Circuit - Voltage Below Normal, or Shorted to Low Source

268

Amber

Fuel Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect

271

Amber

High Fuel Pressure Solenoid Valve Circuit - Voltage Below Normal, or Shorted to Low Source

272

Amber

High Fuel Pressure Solenoid Valve Circuit - Voltage Above Normal, or Shorted to High Source

275

Amber

Fuel Pumping Element (Front) - Mechanical System Not Responding Properly or Out of Adjustment

281

Amber

High Fuel Pressure Solenoid Valve #1 - Mechanical System Not Responding Properly or Out of Adjustment

284

Amber

Engine Speed/Position Sensor (Crankshaft) Supply Voltage Circuit - Voltage Below Normal, or Shorted to Low Source

285

Amber

SAE J1939 Multiplexing PGN Timeout Error - Abnormal Update Rate

286

Amber

SAE J1939 Multiplexing Configuration Error - Out of Calibration

287

Red

SAE J1939 Multiplexing Accelerator Pedal or Lever Sensor System Error - Received Network Data In Error

288

Red

SAE J1939 Multiplexing Remote Accelerator Pedal or Lever Data Error - Received Network Data In Error

293

Amber

Auxiliary Temperature Sensor Input # 1 Circuit -Voltage Above Normal, or Shorted to High Source

294

Amber

Auxiliary Temperature Sensor Input # 1 Circuit -Voltage Below Normal, or Shorted to Low Source

295

Amber

Barometric Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect

297

Amber

Auxiliary Pressure Sensor Input # 2 Circuit - Voltage Above Normal, or Shorted to High Source

298

Amber

Auxiliary Pressure Sensor Input # 2 Circuit - Voltage Below Normal, or Shorted to Low Source

322

Amber

Injector Solenoid Cylinder #1 Circuit - Current Below Normal, or Open Circuit

323

Amber

Injector Solenoid Cylinder #5 Circuit - Current Below Normal, or Open Circuit

324

Amber

Injector Solenoid Cylinder #3 Circuit - Current Below Normal, or Open Circuit

325

Amber

Injector Solenoid Cylinder #6 Circuit - Current Below Normal, or Open Circuit

331

Amber

Injector Solenoid Cylinder #2 Circuit - Current Below Normal, or Open Circuit

332

Amber

Injector Solenoid Cylinder #4 Circuit - Current Below Normal, or Open Circuit

334

Amber

Coolant Temperature Sensor Circuit - Data Erratic, Intermittent, or Incorrect

341

Amber

Engine Control Module data lost - Data Erratic, Intermittent, or Incorrect

343

Amber

Engine Control Module Warning internal hardware failure - Bad Intelligent Device or Component

351

Amber

Injector Power Supply - Bad Intelligent Device or Component

386

Amber

Sensor Supply Voltage #1 Circuit - Voltage Above Normal, or Shorted to High Source

387

Amber

Accelerator Pedal or Lever Position Sensor Supply Voltage Circuit - Voltage Above Normal, or Shorted to High Source

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

130

G200

ELECTRICAL SYSTEM Fault Code

Lamp Color

Cummins Description

415

Red

Oil Pressure Low - Data Valid but Below Normal Operational Range - Most Severe Level

418

––

Water in Fuel Indicator High - Data Valid but Above Normal Operational Range - Least Severe Level

428

Amber

Water in Fuel Sensor Circuit - Voltage Above Normal, or Shorted to High Source

429

Amber

Water in Fuel Sensor Circuit - Voltage Below Normal, or Shorted to Low Source

431

Amber

Accelerator Pedal or Lever Idle Validation Circuit - Data Erratic, Intermittent, or Incorrect

432

Red

Accelerator Pedal or Lever Idle Validation Circuit - Out of Calibration

433

Amber

Intake Manifold Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect

434

Amber

Power Lost without Ignition Off - Data Erratic, Intermittent, or Incorrect

435

Amber

Oil Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect

441

Amber

Battery #1 Voltage Low - Data Valid but Below Normal Operational Range - Moderately Severe Level

442

Amber

Battery #1 Voltage High - Data Valid but Above Normal Operational Range - Moderately Severe Level

443

Amber

Accelerator Pedal or Lever Position Sensor Supply Voltage Circuit - Voltage Below Normal, or Shorted to Low Source

449

Red

Fuel Pressure High - Data Valid but Above Normal Operational Range - Moderately Severe Level

451

Amber

Injector Metering Rail #1 Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Source

452

Amber

Injector Metering Rail #1 Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source

497

Amber

Multiple Unit Synchronization Switch Circuit - Data Erratic, Intermittent, or Incorrect

523

Amber

OEM Intermediate (PTO) Speed switch Validation - Data Erratic, Intermittent, or Incorrect

551

Amber

Accelerator Pedal or Lever Idle Validation Circuit - Voltage Below Normal, or Shorted to Low Source

553

Amber

Injector Metering Rail #1 Pressure High - Data Valid but Above Normal Operational Range - Moderately Severe Level

554

Amber

Fuel Pressure Sensor Error - Data Erratic, Intermittent, or Incorrect

559

Amber

Injector Metering Rail #1 Pressure Low - Data Valid but Below Normal Operational Range - Moderately Severe Level

584

Amber

Starter Relay Circuit - Voltage Above Normal, or Shorted to High Source

585

Amber

Starter Relay Circuit - Voltage Below Normal, or Shorted to Low Source

595

Amber

Turbocharger #1 Speed High - Data Valid but Above Normal Operational Range - Moderately Severe Level

596

Amber

Electrical Charging System Voltage High - Data Valid but Above Normal Operational Range - Moderately Severe Level

597

Amber

Electrical Charging System Voltage Low - Data Valid but Below Normal Operational Range - Moderately Severe Level

598

Red

Electrical Charging System Voltage Low - Data Valid but Below Normal Operational Range - Most Severe Level

649

––

Change Lubricating Oil and Filter - Condition Exists

687

Amber

Turbocharger #1 Speed Low - Data Valid but Below Normal Operational Range - Moderately Severe Level

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

131

G200

ELECTRICAL SYSTEM Fault Code

Lamp Color

Cummins Description

689

Amber

Primary Engine Speed Sensor Error - Data Erratic, Intermittent, or Incorrect

691

Amber

Turbocharger #1 Compressor Inlet Temperature Sensor Circuit - Voltage Above Normal, or Shorted to High Source

692

Amber

Turbocharger #1 Compressor Inlet Temperature Sensor Circuit - Voltage Below Normal, or Shorted to Low Source

731

Amber

Engine Speed/Position #2 mechanical misalignment between camshaft and crankshaft sensors Mechanical System Not Responding Properly or Out of Adjustment

753

Amber

Engine Speed/Position #2 Camshaft sync error -Data Erratic, Intermittent, or Incorrect

778

Amber

Engine Speed Sensor (Camshaft) Error - Data Erratic, Intermittent, or Incorrect

779

Amber

Warning Auxiliary Equipment Sensor Input # 3 (OEM Switch) - Root Cause Not Know

1117

––

Power Lost With Ignition On - Data Erratic, Intermittent, or Incorrect

1139

Amber

Injector Cylinder #1 - Mechanical System Not Responding Properly or Out of Adjustment

1141

Amber

Injector Cylinder #2 - Mechanical System Not Responding Properly or Out of Adjustment

1142

Amber

Injector Cylinder #3 - Mechanical System Not Responding Properly or Out of Adjustment

1143

Amber

Injector Cylinder #4 - Mechanical System Not Responding Properly or Out of Adjustment

1144

Amber

Injector Cylinder #5 - Mechanical System Not Responding Properly or Out of Adjustment

1145

Amber

Injector Cylinder #6 - Mechanical System Not Responding Properly or Out of Adjustment

1239

Amber

Accelerator Pedal or Lever Position Sensor #2 Supply Voltage Circuit - Voltage Above Normal, or Shorted to High Source

1241

Amber

Accelerator Pedal or Lever Position Sensor #2 Supply Voltage Circuit - Voltage Below Normal, or Shorted to Low Source

1242

Red

Accelerator Pedal or Lever Position Sensor #1 and #2 Supply Voltage Circuit - Data Erratic, Intermittent, or Incorrect

2185

Amber

Sensor Supply Voltage #4 Circuit - Voltage Above Normal, or Shorted to High Source

2186

Amber

Sensor Supply Voltage #4 Circuit - Voltage Below Normal, or Shorted to Low Source

2215

Amber

Fuel Pump Delivery Pressure - Data Valid but Below Normal Operational Range - Moderately Severe Level

2216

Amber

Fuel Pump Delivery Pressure - Data Valid but Above Normal Operational Range - Moderately Severe Level

2217

Amber

ECM Program Memory (RAM) Corruption - Condition Exists

2265

Amber

Fuel Priming Pump Control Signal Circuit - Voltage Above Normal, or Shorted to High Source

2266

Amber

Fuel Priming Pump Control Signal Circuit - Voltage Below Normal, or Shorted to Low Source

2311

Amber

Fueling Actuator #1 Circuit Error - Condition Exists

2321

––

Engine Speed/Position Sensor #1 - Data Erratic, Intermittent, or Incorrect

2322

––

Engine Speed/Position Sensor #2 - Data Erratic, Intermittent, or Incorrect

2345

Amber

Turbocharger speed invalid rate of change detected - Abnormal Rate of Change

2346

––

Turbocharger Turbine Inlet Temperature (Calculated) - Data Valid but Above Normal Operational Range - Least Severe Level

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

132

G200

ELECTRICAL SYSTEM Fault Code

Lamp Color

2347

––

Turbocharger Compressor Outlet Temperature (Calculated) - Data Valid but Above Normal Operational Range - Least Severe Level

2362

Amber

Engine Brake Actuator Circuit #1 - Voltage Below Normal, or Shorted to Low Source

2363

Amber

Engine Brake Actuator Circuit #2 - Voltage Below Normal, or Shorted to Low Source

2366

Amber

Engine Brake Actuator Circuit #1 - Voltage Above Normal, or Shorted to High Source

2367

Amber

Engine Brake Actuator Circuit #2 - Voltage Above Normal, or Shorted to High Source

2377

Amber

Fan Control Circuit - Voltage Above Normal, or Shorted to High Source

2384

Amber

VGT Actuator Driver Circuit - Voltage Below Normal, or Shorted to Low Source

2385

Amber

VGT Actuator Driver Circuit - Voltage Above Normal, or Shorted to High Source

2555

Amber

Intake Air Heater #1 Circuit - Voltage Above Normal, or Shorted to High Source

2556

Amber

Intake Air Heater #1 Circuit - Voltage Below Normal, or Shorted to Low Source

2557

Amber

Auxiliary PWM Driver #1 - Voltage Above Normal, or Shorted to High Source

2558

Amber

Auxiliary PWM Driver #1 - Voltage Below Normal, or Shorted to Low Source

2963

––

Engine Coolant Temperature High - Data Valid but Above Normal Operational Range - Least Severe Level

2964

––

Intake Manifold Temperature High - Data Valid but Above Normal Operational Range - Least Severe Level

2973

Amber

Intake Manifold Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect

Cummins Description

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

133

G200

ELECTRICAL SYSTEM RADIO The radio power is independent from the master key, so the memorized radio stations are not lost when the batteries are changed or when the master key is switched off.

Radio voltage is 12V, obtained by a converter that transform the 24V of the machine electrical system into 12V. Since the converter is always using battery power, it is necessary to disconnect the connection below (A and B connectors) every time the machine is stored for more than 10 days, so the battery is not drained during the storage period.

When the machine is to be used again, reconnect the radio connectors A and B.

Master Key Engine starter Ground (Chassis)

Battery

Battery

Black connector (female) White connector (male)

Radio Converter

Radio connectors A and B Connectors A and B are located inside the cab, beside the lateral panel and the master key.

A

B

A - White connector (male) B - Black connector (female)

Read the SAFETY RULES on the preceding pages for machine protection and the safety of employees

134

G200

ELECTRICAL SYSTEM COMPONENTS LIST NAME

DESCRIPTION

SHEET

NAME

DESCRIPTION

SHEET

G1

BATTERY 12V

4-1

S35

FRONT WIPER SWITCH

17-2

G2

BATTERY 12V

4-1

S36

FRONT WASHER PUMP SWITCH

17-4

G3

ALTERNATOR 24 VOLTS 50 OR 80 AMP

4-2

S37

REAR WIPER SWITCH

17-5

ST1

INSTRUMENT ELECTRONIC PANEL

9

S38

REAR WASHER PUMP SWITCH

18-1

ST2

ELECTRONIC DATA MONITOR

10

S39

FRONT LOWER WIPER

ST3

ANALOGIC HOURMETER

11-1

ST4

DISPLAY GEAR/DIAGNOSTIC

23-1

AND WASHER SWITCH - OPT.

18-2

S40

FANS SWITCH - OPT.

18-2

S41

HIGH PRESSURE SWITCH

S1

MASTER SWITCH

4-1

S2

IGNITION SWITCH

5-1

S42

5-4

S43

S3

WORK LIGHT BEFORE AND AFTER MOLD BOARD SWITCH

S4

TO AIR CONDITIONER SYSTEM - OPT.

FLOOD/HEAD LIGHTS HORN AND TURN SIGNAL SWITCH

S44 6-3/6-4

19-3

3 SPEED SWITCH TO FANS AIR CONDITIONER SYSTEM - OPT.

19-3

AIR CONDITIONER SWITCH - OPT.

19-4

MOTOR DAMPER SWITCH TO AIR CONDITIONER SYSTEM - OPT.

19-6

S5

WARNING FLASHER SWITCH

6-4

S47

BUMP GEAR SELECTOR

23-3

S6

REAR FLOOD LIGHTS SWITCH

7-5

S48

PARKING BRAKE SWITCH

23-7

S7

CAB HEAD LIGHT SWITCH - OPT.

8-1

S49

COME-HOME SWITCH

23-11

S8

FRONT BLADE BOARD SWITCH - OPT.

8-2

S50

ENGINE SPEED MAGNETIC PICKUP SENSOR

23-11

S9

BRAKE LIGHT SWITCH

8-4

S51

OUTPUT SPEED MAGNETIC PICKUP SENSOR

23-11

S10

ENGINE OIL PRESSURE SENSOR AND SWITCH

9-2

S52

CYLINDER SPEED MAGNETIC PICKUP SENSOR

23-12

S11

ENGINE COOLANT TEMPERATURE SENSOR

9-3

S53

TEMPERATURE SENSOR - TRANSMISSION FUNK

23-12

S12

TRANSMISSION OIL PRESSURE SENSOR

9-4

S55

FAN DRIVE INVERTER SWITCH

11-4

S13

TRANSMISSION OIL TEMPERATURE SENSOR

9-5

S56

DIAGNOSE SWITCH-ENGINE QSB TIER 2

S14

FUEL SENSOR LEVEL

9-5

S15

ENGINE COOLANT TEMPERATURE SWITCH

10-1

S16

AIR CLEANER SWITCH

10-1

S17

TRANSMISSION OIL FILTER RESTRICTION SWITCH

10-2

S65

TIRES INFLATOR SWITCH

24-6

S18

TRANSMISSION OIL PRESSURE SWITCH

10-2

S67

ON-OFF FAN DRIVE SWITCH - OPT.

15-3

S19

TRANSMISSION OIL TEMPERATURE SWITCH

10-3

S68

S20

HYDRAULIC OIL TEMPERATURE SWITCH

10-4

S21

BRAKE LOW PRESSURE SWITCH

10-4

S69

S22

MACHINE SPEED SENSOR

10-5

S70

S23

HYDRAULIC OIL FILTER RESTRICTION SWITCH

10-6

S24

DIFFERENTIAL LOCK SWITCH - OPT.

11-2

S71

S25

STARTING AID SWITCH - OPT.

16-3

S72

S26

SADDLE LOCK PIN SWITCH

11-6

S27

RIPPER OR SCARIFIER SWITCH - OPT.

12-3

S28

MOLD BOARD FLOAT L.H. SWITCH - OPT.

13-3

S29

MOLD BOARD FLOAT R.H. SWITCH - OPT.

13-4

S30

LIFT SHOCK DAMPENER SWITCH - OPT.

14-3

S31

FRONT BLADE BOARD FLOAT SWITCH - OPT.

15-1

S32

LEFT CAB DOME LIGHT

16-3

S33

RIGHT CAB DOME LIGHT

16-4

S34

STROBE LIGHT SWITCH - OPT.

16-5

AND TIER 3 S57

SWITCH - ENGINE QSB TIER 2 AND TIER 3

WATER TEMPERATURE 87 C SWITCH 15-4

OIL PRESSURE SWITCH - ENGINE QSB TIER 3

28-4

CAM SHAFT POSITION SENSOR ENGINE QSB TIER 3

29-7

WATER IN FUEL SENSOR - ENGINE QSB TIER 3

29-8

AIR INTAKE TEMPERATURE

29-11

COOLANT TEMPERATURE SENSOR ENGINE QSB TIER 3

S76

29-10

CRANK SHAFT POSITION SENSOR ENGINE QSB TIER 3

S75

29-9

FUEL RAIL PRESSURE SENSOR ENGINE QSB TIER 3

S74

28-10

TO ON-OFF FAN DRIVE - OPT.

AND PRESSURE - ENGINE QSB TIER 3 S73

28-9

INCREMENT/DECREMENT ERROR CODES

29-11

AMBIENT AIR PRESSURE SENSOR ENGINE QSB TIER 3

29-12

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135

G200

ELECTRICAL SYSTEM NAME

DESCRIPTION

SHEET

NAME V1

DESCRIPTION

EV2

DIFFERENTIAL LOCK SOLENOID VALVE - OPT.

11-2

EV3

STARTING AID SOLENOID VALVE - OPT.

16-2

EV4

SADDLE LOCK PIN SOLENOID VALVE

11-6

V2

EV5

RIPPER OR SCARIFIER SOLENOID 12-2

V3

12-3

V4

12-5

V5

12-6

V6

13-2

V7

13-3

V8

13-5

V9

13-6

V10

VARISTOR TO MOLD BOARD FLOAT

14-1

V11

VARISTOR TO MOLD BOARD FLOAT

14-2

V12

14-5

V13

14-6

V14

15-1

V17

15-3

V18

VARISTOR TO RIGHT LIFT CYLINDER

VALVE LEFT - OPT. EV6

VALVE LEFT - OPT. EV7 EV8

VALVE RIGHT - OPT. EV9

VALVE LEFT - OPT. EV10 EV11 EV12 EV13 EV14 EV17 EV18

ANTI-SHOCK SOLENOID VALVE - OPT.

FAN DRIVE INVERTER SOLENOID VALVE - OPT.

11-4

EV28

SOLENOID ON/OFF FAN DRIVE - OPT.

15-6

V19

VARISTOR TO FRONT BLADE BOARD FLOAT

FUEL PUMP COMMON RAIL - ENGINE QSB TIER 3

29-2

V20

VARISTOR TO FRONT BLADE BOARD FLOAT

EVT1

PROPORT. AND DIRECTIONAL SOLENOID VALVE 1

23-9

EVT2

PROPORT. AND DIRECTIONAL SOLENOID VALVE 2

23-8

ANTI-SHOCK SOLENOID VALVE - OPT. SOLENOID VALVE - OPT.

EVT3

PROPORT. AND DIRECTIONAL SOLENOID VALVE 3

23-9

EVTA

PROPORT. AND SPEED SOLENOID VALVE A

23-9

SOLENOID VALVE - OPT. V21

14-1 14-2 14-5 14-6 15-1 15-2

VARISTOR TO MAGNETIC CLUTCH/ COMPRESSOR - OPT.

V27

13-5

VARISTOR TO RIGHT LIFT CYLINDER ANTI-SHOCK SOLENOID VALVE - OPT.

PROPORTIONAL SOLENOID OF REGULATOR

13-4

VARISTOR TO LEFT LIFT CYLINDER

EV27 EV CR

13-3

VARISTOR TO LEFT LIFT CYLINDER ANTI-SHOCK SOLENOID VALVE - OPT.

FRONT BLADE BOARD FLOAT SOLENOID VALVE - OPT.

13-1

VARISTOR TO MOLD BOARD FLOAT SOLENOID VALVE R.H. - OPT.

FRONT BLADE BOARD FLOAT SOLENOID VALVE - OPT.

EV20

SOLENOID VALVE R.H. - OPT.

RIGHT LIFT CYLINDER ANTI-SHOCK SOLENOID VALVE - OPT.

EV19

SOLENOID VALVE L.H. - OPT.

RIGHT LIFT CYLINDER ANTI-SHOCK SOLENOID VALVE - OPT.

12-5

VARISTOR TO MOLD BOARD FLOAT SOLENOID VALVE L.H. - OPT.

LEFT LIFT CYLINDER ANTI-SHOCK SOLENOID VALVE - OPT.

12-4

VARISTOR TO RIPPER OR SCARIFIER SOLENOID VALVE RIGHT - OPT.

LEFT LIFT CYLINDER ANTI-SHOCK SOLENOID VALVE - OPT.

12-2

VARISTOR TO RIPPER OR SCARIFIER SOLENOID VALVE RIGHT - OPT.

MOLD BOARD FLOAT SOLENOID VALVE RIGHT - OPT.

12-1

VARISTOR TO RIPPER OR SCARIFIER SOLENOID VALVE LEFT - OPT.

MOLD BOARD FLOAT SOLENOID VALVE RIGHT - OPT.

11-5

VARISTOR TO RIPPER OR SCARIFIER SOLENOID VALVE LEFT - OPT.

MOLD BOARD FLOAT SOLENOID VALVE LEFT - OPT.

16-1

VARISTOR TO SADDLE LOCK PIN SOLENOID VALVE

MOLD BOARD FLOAT SOLENOID

11-2

VARISTOR TO STARTING AID SOLENOID VALVE - OPT.

RIPPER OR SCARIFIER SOLENOID

6-6

VARISTOR TO DIFFERENTIAL LOCK SOLENOID VALVE - OPT.

RIPPER OR SCARIFIER SOLENOID VALVE RIGHT - OPT.

VARISTOR TO FLASHER AND TURN SIGNAL RELAY

RIPPER OR SCARIFIER SOLENOID

SHEET

19-1

VARISTOR TO SOLENOID FAN DRIVE

EVTB

PROPORT. AND SPEED SOLENOID VALVE B

23-10

EVTC

PROPORT. AND SPEED SOLENOID VALVE C

23-10

EVTD

PROPORT. AND SPEED SOLENOID VALVE D

23-11

EJ1

INJECTOR CYLINDER 1 ENGINE QSB TIER 3

29-3

D5

DIODE TO NEUTRAL POSITION TO START

23-6

EJ2

INJECTOR CYLINDER 2 ENGINE QSB TIER 3

29-4

D6

DIODE TO PARKING BRAKE APPLIED

23-7

EJ3

INJECTOR CYLINDER 3 ENGINE QSB TIER 3

29-4

D8

DIODE TO ON-OFF FAN DRIVE SYSTEM - OPT

15-4

EJ4

INJECTOR CYLINDER 4 ENGINE QSB TIER 3

29-5

D9

DIODE TO COIL PROTECTION OF THE GRID

EJ5

INJECTOR CYLINDER 5 ENGINE QSB TIER 3

29-6

EJ6

INJECTOR CYLINDER 6 ENGINE QSB TIER 3

29-7

INVERTER - OPT. V28

FAN DRIVE - OPT.

15-5

HEATER AUXILIARY MAGNETIC SWITCH ENGINE QSB TIER 3 DB DBM

DIODE BOX - LATERAL CONSOLE

29-1 21

DIODE BOX TO ENGINE QSB TIER 2 AND TIER 3 ANOMALY LIGHTS

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136

11-3

VARISTOR TO SOLENOID ON/OFF

28-8

G200

ELECTRICAL SYSTEM NAME

DESCRIPTION

SHEET

NAME

DESCRIPTION

SHEET

HA1

HORN

6-1

H38

DASH LIGHT - LATERAL PANEL

9-2

HA2

BUZZER

10-5

H39

REAR LEFT STROBE LIGHT - OPT.

16-4

HA3

BACK-UP ALARM - OPT.

8-5

H40

FRONT RIGHT STROBE LIGHT - OPT.

16-6

HA4

BACK-UP ALARM STRADALE - OPT.

8-6

H41

ENGINE WARNING LAMP - ENGINE QSB TIER 2

HA5

BUZZER TO ENGINE QSB TIER 2 AND TIER 3

28-7 H42

ENGINE STOP LAMP - ENGINE QSB TIER 2

H45

ENGINE GRID HEATER LAMP - ENGINE

FG1

MAXI FUSE 80.0 AMP TO PROTECTION ALTERNATOR

FG2

FA1 FA2

28-2

28-7

R1

RESISTOR 910 0HMS 1/2 WATT

9-4

R3

CIGARETTE LIGHTER 12 VOLTS

24-2

R G.H. 2 RESISTOR OF GRID HEATER ENGINE QSB TIER 3 6-2

R DP

AUXILIARY FUSE 5.0 AMP TO POSITION LIGHTS LEFT FRONT & RIGHT REAR

FGH2

QSB TIER 2 AND TIER 3

AUXILIARY FUSE 7.5 AMP TO POSITION LIGHTS R.F. & L.R. AND INSTRUMENTS LIGHTS

28-6

4-6

MAXI FUSE 30.0 AMP TO PROTECTION ENGINE QSB TIER 3 ELECTRICAL SYSTEM

28-6

AND TIER 3 4-6

MAXI FUSE 80.0 AMP TO MASTER PROTECTION CIRCUITS OF THE MACHINE

FG3

AND TIER 3

29-2

RESISTOR OF DUAL POWER TO ENGINE QSB TIER 2 AND TIER 3

30-1

6-3

MEGA FUSE 125.0 AMP TO GRID HEATER -

M1

ENGINE STARTER

4-5

M2

FRONT WIPER

17-2

ENGINE QSB TIER 3

29-2

M3

FRONT WASHER PUMP

17-4

H1

RIGHT WORK LIGHT BEFORE MOLD BOARD

5-4

M4

REAR WIPER

17-5

H2

LEFT WORK LIGHT BEFORE MOLD BOARD

5-5

M5

REAR WASHER PUMP

18-1

H3

RIGHT WORK LIGHT AFTER MOLD BOARD

5-6

M6

FRONT LOWER WASHER PUMP - OPT.

18-2

H4

LEFT WORK LIGHT AFTER MOLD BOARD

5-6

M7

FRONT LOWER WIPER - OPT.

18-3

H5

FRONT POSITION LIGHT L.H.

6-2

M8

AIR SUSPENSION SEAT - OPT.

18-5

H6

REAR POSITION LIGHT R.H.

6-2

M9

FAN L.H. - OPT.

18-5

H7

REAR POSITION LIGHT R.H. - OPT. STRADALE

6-2

M10

FAN R.H. - OPT.

18-6

H8

REAR TURN SIGNAL LIGHT R.H. OPT. STRADALE

6-3

M11

MOTOR DAMPER TO AIR CONDITIONER

19-5 19-4

H9

FRONT TURN SIGNAL LIGHT R.H. CAB.

6-3

M.T.

EVAPORATOR UNIT - OPT. AIR CONDITIONER

H10

REAR TURN SIGNAL LIGHT R.H.

6-3

E.M.

ELECTRIC MAGNETIC CLUTCH/

H11

FRONT TURN SIGNAL LIGHT R.H.

6-4

H12

FRONT TURN SIGNAL LIGHT L.H.

6-4

H13

REAR TURN SIGNAL LIGHT L.H.

6-4

H14

FRONT TURN SIGNAL LIGHT L.H. CAB.

6-5

H15

REAR TURN SIGNAL LIGHT L.H. - OPT. STRADALE 6-5

H16

LEFT HEAD LIGHT (HIGH BEAM)

7-1

H17

RIGHT HEAD (HIGH BEAM)

7-2

H18

LEFT HEAD LIGHT (LOW BEAM)

7-2

H19

RIGHT HEAD LIGHT (LOW BEAM)

7-3

H20

FRONT POSITION LIGHT R.H.

7-3

H21

REAR POSITION LIGHT L.H.

7-3

H22

LICENSE PLATE LIGHT - OPT.

7-4

H23

REAR POSITION LIGHT L.H. - OPT. STRADALE

7-4

H24

LICENSE PLATE LIGHT - OPT. STRADALE

7-4

H27

REAR FLOOD LIGHT R.H. (CAB)

H28 H29 H30 H31

M PT K ECU

COMPRESSOR OPT. AIR CONDITIONER

19-2

TIRES INFLATOR COMPRESSOR

24-5

ELECTRONIC UNIT TRANSMISSION FUNK

23

K IP

INCH PEDAL FUNK TRANSMISSION

23-2

K TVP

TRANSIENT VOLTAGE PROTECTION

23-1

K ECM 2 ENGINE CONTROL MODULE QSB TIER 3 K ET

28/29/31

ACCELERATOR/ DECELERATOR AND HAND THROTTLE ASS’Y - ENGINE QSB TIER 2 AND TIER 3 28-11

K G.H.2 AUXILIARY MAGNETIC SWITCH TO GRID HEATER - ENGINE QSB TIER 3

29-2

K PT

AUXILIARY MAGNETIC SWITCH TO TIRES INFLATOR

24-5

7-6

K3P

ELECTRONIC MODULE THREE POWER

30-3

REAR FLOOD LIGHT L.H. (CAB)

7-6

K15

FLASHER AND TURN SIGNAL RELAY

6-9

CAB HEAD LIGHT L.H. - OPT.

8-1

K16

ELECTRONIC STROBE LIGHT - OPT.

16-5

CAB HEAD LIGHT R.H. - OPT.

8-1

K C1

FRONT BLADE BOARD LIGHT L.H. - OPT.

8-2

H32

FRONT BLADE BOARD LIGHT R.H. - OPT.

8-3

H33

BRAKE LIGHT L.H.

8-4

H34

BRAKE LIGHT R.H.

H35

BRAKE LIGHT L.H. - OPT. STRADALE

H36 H37

CONVERTER VOLTAGE TO RADIO AND CIGARETTE LIGHTER 24/12 VOLTS MAX. 10.0 AMP

24-2

KR

RADIO 12 VOLTS

24-4

8-4

SP1

SPEAKER L.H.

24-4

8-4

SP2

SPEAKER R.H.

24-4

BRAKE LIGHT R.H. - OPT. STRADALE

8-5

AT

ANTENNA RADIO

24-3

DASH LIGHT - LATERAL PANEL

9-1

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137

G200

ELECTRICAL SYSTEM NAME

DESCRIPTION

SHEET

NAME

DESCRIPTION

SHEET

XD1

DERIVATION BOX (NEAR ENGINE)

4-4

F22

3 AMP TO DIFFERENTIAL LOCK (OPT.)

XD2

DERIVATION BOX (IN THE LATERAL CONSOLE)

5-3

F23

3 AMP TO BACK-UP ALARM (OPT.)

8-5

XD4

DERIVATION POINT TO ENGINE STARTER,

F24

5 AMP TO ELECTRICAL ENGINE SHUT OFF

28-5

F25

3 AMP TO BRAKE LIGHT

8-4

F26

15 AMP TO FRONT LOWER WIPERS/WASHER/

ALTERNATOR, GRID HEATER ENGINE QSB TIER 3 F1

7.5 AMP TO FLASHER RELAY AND TURN SIGNAL LIGHTS

F3

4-5

6-6

7.5 AMP TO ROTATING BEACON AND CAB DOME LIGHT

16-5

F4

7.5 AMP TO HEAD LIGHTS (LOW BEAM)

7-2

F5

15 AMP TO HORN

6-1

F6

3 AMP TO E.D.M. (ELECTRONIC DATA PANEL)

AND AIR SUSPENSION SEAT (OPT.)

18-2

F27

7.5 AMP TO CAB LIGHTS

8-1

F28

7.5 AMP TO WORKING LIGHTS BEFORE MOLDBOARD (OPT.)

F29 F30

AND BUZZER

9-6

F7

10 AMP TO FUNK TRANSMISSION SYSTEM

23-2

F8

10 AMP TO FUNK TRANSMISSION SYSTEM

23-2

F31 F32

AFTER MOLDBOARD (OPT.)

5-5

10 AMP TO RADIO AND CIGARETTE LIGHTER

24-2

7.5 AMP TO ALTERNATOR REGULATOR AND HABILITY RELAY

4-3

7.5 AMP TO FRONT EQUIPMENT LIGHTS (OPT.)

8-3

F9

10 AMP TO FUNK TRANSMISSION SYSTEM

23-2

7.5 AMP TO CAB FANS

18-5

K1

HABILITY RELAY

F11

10 AMP TO FRONT WIPER AND WASHER PUMP

17-1

K2

DUAL POWER (QSB, TIER 2 AND TIER 3) RELAY

15 AMP TO HYDRAULIC SOLENOID VALVES

5-3

7.5 AMP TO WORKING LIGHTS

F10 F12

11-2

23-5 30-1/30-6

K3

AUXILIARY STARTING RELAY

23-3

SADDLE LOCK PIN AND FLOAT CONTROL (OPT.)

11-5

K4

LOW BEAM RELAY

7-2

F13

7.5 AMP TO REAR FLOOD LIGHTS

6-5

K5

HIGH BEAM RELAY

7-1

F14

7.5 AMP TO HIGH BEAM

7-1

K6

REAR FLOOD LIGHTS

F15

10 AMP TO STARTING AID (OPT.)

16-2

F16

10 AMP TO REAR WIPER AND WASHER PUMP

17-4

F17

20 AMP TO AIR CONDITIONER SYSTEM (OPT.)

19-2

F18

3 AMP TO REVERSE FAN SOLENOID VALVE (OPT.)

11-4

F19

3 AMP TO REVERSE SIGNAL ON THE GEAR SELECTOR

F20

7-5

HORN RELAY

6-1

K8

BACK-UP ALARM RELAY

8-5

K9

STARTING AID (OPT.)

16-3

K10

DIFFERENTIAL LOCK RELAY

11-2

K12

MAGNETIC CLUTCH/COMPRESSOR RELAY

8-6

3 AMP TO AIR CONDITIONER SYSTEM MODE DOOR (OPT.)

AND REAR WORK LIGHTS RELAY K7

19-6

AIR CONDITIONER SYSTEM (OPT.)

19-2

K13

ON-OFF FAN DRIVE RELAY (OPT.)

15-4

K14

WORK LIGHT BEFORE MOLDBOARD RELAY (OPT.)

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138

5-5

G200

ELECTRICAL SYSTEM ELECTRIC DIAGRAMS DIAGRAM 1 - SHEET 4

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139

G200

ELECTRICAL SYSTEM DIAGRAM 2 - SHEET 5

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140

G200

ELECTRICAL SYSTEM DIAGRAM 3 - SHEET 6

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141

G200

ELECTRICAL SYSTEM DIAGRAM 4 - SHEET 7

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142

G200

ELECTRICAL SYSTEM DIAGRAM 5 - SHEET 8

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143

G200

ELECTRICAL SYSTEM DIAGRAM 6 - SHEET 9

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144

G200

ELECTRICAL SYSTEM DIAGRAM 7 - SHEET 10

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145

G200

ELECTRICAL SYSTEM DIAGRAM 8 - SHEET 11

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146

G200

ELECTRICAL SYSTEM DIAGRAM 9 - SHEET 12

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147

G200

ELECTRICAL SYSTEM DIAGRAM 10 - SHEET 13

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148

G200

ELECTRICAL SYSTEM DIAGRAM 11 - SHEET 14

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149

G200

ELECTRICAL SYSTEM DIAGRAM 12 - SHEET 15

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150

G200

ELECTRICAL SYSTEM DIAGRAM 13 - SHEET 17

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151

G200

ELECTRICAL SYSTEM DIAGRAM 14 - SHEET 18

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152

G200

ELECTRICAL SYSTEM DIAGRAM 15 - SHEET 19

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153

G200

ELECTRICAL SYSTEM DIAGRAM 16 - SHEET 21

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154

G200

ELECTRICAL SYSTEM DIAGRAM 17 - SHEET 23

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155

G200

ELECTRICAL SYSTEM DIAGRAM 18 - SHEET 24

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156

G200

ELECTRICAL SYSTEM DIAGRAM 19 - SHEET 28

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157

G200

ELECTRICAL SYSTEM DIAGRAM 20 - SHEET 29

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158

G200

ELECTRICAL SYSTEM DIAGRAM 21 - SHEET 30

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159

G200

ELECTRICAL SYSTEM DIAGRAM 22 - SHEET 31

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160

G200

ELECTRICAL SYSTEM DIAGRAM 23 - SHEET 32

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161

G200

ELECTRICAL SYSTEM

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162

MACHINE STORAGE G200

MACHINE STORAGE Storage Preparation

Removal from Storage

If the machine is to be in storage for more than 30 days, park the machine inside a building. If a building is not available, park the machine in a dry area on planks and cover the machine with a waterproof covering.

Do not start the engine until steps 1 through 10 have been done.

1. Wash the machine.

3. Check the condition of the drive belts. Replace if required.

2. Lubricate the machine at all grease fittings.

3. Paint any areas where the paint has been damaged.

1. Change the fuel filter.

2. Put coolant in the engine cooling system.

4. Check the engine oil level.

5. Check the hydraulic oil level.

4. Move all hydraulic controls to relieve any pressure in the hydraulic circuits.

6. Check the transmission oil level.

5. Drain the fuel tank.

8. Lubricate the machine at all grease fittings.

6. Put approximately 8 liters (2 U.S. Gallons) of diesel flushing oil in the fuel tank. Run the engine until the exhaust smoke is blue-white.

9. Use petroleum base solvent and remove the NEW HOLLAND Rust and Corrosion Preventive from the hydraulic cylinder rods.

7. Drain the flushing oil from the fuel tank.

10.See Battery Service in this manual and install the batteries.

8. Put 15 ml (one tablespoon) of Shell Oil Company VPI crystals in the fuel tank.

9. Change the engine oil and replace the oil filter.

10.Drain the cooling system. Leave the drain open and do not tighten the radiator cap. Put a Do Not Operate tag in the cab.

11. Clean or replace the primary air filter element.

7. Check the oil level of both axles.

11.Fill the fuel tank.

12.Prime the turbocharger with clean engine oil. See your Service Manual or your dealer.

13.Start the engine. It is important that you use the Starting the Engine procedure in this manual for priming the turbocharger lines with oil.

12.Cover the exposed steering cylinder rods and equipment valve spools with NEW HOLLAND Rust and Corrosion Preventative.

13.Charge the batteries. Remove the batteries from the machine and put the batteries on a wooden pallet in a cool dry area. If possible, keep the batteries in a building where the temperature is above freezing (0°C [32°F]). Make sure the batteries are clean.

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G200

MACHINE STORAGE

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164

SPECIFICATIONS G200

SPECIFICATIONS Engine Model ............................................................ Cummins QSB 6.7L - Diesel, Common Rail, direct injection, water cooled, charge air cooled, 4 stroke, turbocharged, variable power Number of cylinders ........................................................................................................................... 6 (six) Displacement ................................................................................................................. 407.6 in3 (6.7 litros) Bore and stroke .................................................................................. 4.21 in x 4.88 in (107 mm x 124 mm) Compression ratio .............................................................................................................................. 17.2: 1 Firing order ........................................................................................................................ 1 - 5 - 3 - 6 - 2 - 4 Low idle .................................................................................................................................... 850 ± 50 rpm High idle ................................................................................................................................. 2390 ± 50 rpm Governed speed ............................................................................................................................. 2200 rpm Fuel Pump ........................................................................................................................ Bosch - Electronic Power (SAE J 1995, Gross) ......................................................................... 220 HP (164 kW) @ 2200 rpm Power: (SAE J 1349, Net Flywheel) .............................................................. 205 HP (153 kW) @ 2200 rpm Torque (SAE J 1995, Maximum) ................................................................. 650 ft.lb (881 N.m) @ 1500 rpm Torque (SAE J 1349, Net) ........................................................................... 592 ft.lb (803 N.m) @ 1500 rpm [Complies with U.S. EPA Tier 3, CARB Tier 3, EU Stage III for 100-750 HP (75-560 KW) engines]

Transmission Type .................................................................... Direct drive, by countershaft, power shift, with electronic gear change control and inching pedal.

Oil sump ........................................................................................................................................... integral Gears ..................................................................................................................... 8 forward and 4 reverse Ground speed control ....................................................... Electronic auto control, “bump” type single lever Diagnosis system ........................................................................................................................... on board

Speeds - Forward

Speeds - Reverse

1st ................................................................ 3,9 km/h (2.4 mph)

1st ................................................................ 3,9 km/h (2.4 mph)

2nd ............................................................... 5,5 km/h (3.4 mph)

2nd ............................................................... 7,6 km/h (4.7 mph)

3rd ................................................................ 7,6 km/h (4.7 mph)

3rd .............................................................. 15,5 km/h (9.6 mph)

4th .............................................................. 10,6 km/h (6.6 mph)

4th ............................................................ 30,6 km/h (19.0 mph)

5th .............................................................. 15,5 km/h (9.6 mph) 6th ............................................................ 21,7 km/h (13.5 mph) 7th ............................................................ 30,6 km/h (19.0 mph) 8th ............................................................ 43,0 km/h (26.7 mph)

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G200

SPECIFICATIONS Steering Front wheels: Type .................................................................................................................. Hydrostatic Power Steering Wheel turn angle .......................................................................................................... 48º to the left or right Steering cylinders ............................................................................................................................... 2 (two) Bore and stroke ........................................................................2.5 x 10.5 x 1.5 in (63.5 x 266.7 x 38.1 mm) Articulated frame Hydraulically controlled articulation Articulation angle (RH and LH) ................................................................................................................ 25º Cylinders ............................................................................................................................................ 2 (two) Bore and stroke ...........................................................................3.15 x 14.84 x 1.77 in (80 x 377 x 45 mm)

Tires 17.5x25-12PR .......................................................................................................................... STANDARD 14.0 R24; 14.0x24-12PR; 16.0x24-12PR; 17.5x25-16PR; 20.5x25-12PR; 20.5x25-16PR; ......................................................................... OPTIONAL

Electrical System Voltage ........................................................................................................................... 24 volts, 2 batteries Batteries ............................................................................................................................ (20h rate) 100 Ah Alternator ...............................................................................................................................80 A (standard) Starter ...................................................................................................................................... 24V - 4.0 kW

Brakes Service: Multiple wet disc, self-adjusting, hydraulically engaged, 2 independent circuits for each side.

Safety: Service brake supply by two nitrogene accumulators, one for each circuit, automatically engaged in the event of a system pressure drop.

Parking: Mechanical, caliper disk mounted on transmission output.

Tandem Rectangular section, welded, using 19 mm (0.75 in) and 16 mm (0.625 in) thick plates.

Interchangeable shafts and gears, assembled on taper bearings.

Tandem oscillation either way .................................................................................................................. 20º

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166

G200

SPECIFICATIONS Front Axle Housing built from high strength steel weldment, with 19° oscillation up or down.

Lateral wheel angle of 17° 30' to the right or to the left, hydraulically actuated.

Rear Axle (DANA) Cast iron housing for severe applications. Axle built from heat treated steel, mounted on taper bearings.

Operating Weights With all fluids, cab with heater, lights, batteries, 17.5x25-10PR tires, 14ft moldboard.

Over front axle .............................................................................................................. 11227 lbs (5103 kg) Over rear axle ............................................................................................................ 26433 lbs (12015 kg) Total ............................................................................................................................ 37660 lbs (17118 kg) Component weights Cab ................................................................................................................................... 1705 lbs (775 kg) ROPS canopy .................................................................................................................. 1166 lbs (530 kg) Front counterweight ......................................................................................................... 1084 lbs (492 kg)

Draw Bar Built from welded “A” shaped box section, with circle swing hydraulic motor mounted at the center.

Connection by means of a ball joint adjusted with spacers.

Frame Front Section ...................................................................... All welded box: 10.0 x 11.73 in (254 x 298 mm) Weight .................................................................................................................... 124.7 lb/ft (172.8 Kg/m) Rear Section ...................................................................... All welded box: 4.75 x 11.75 in (121 x 299 mm) Weight ............................................................................................................................ 56.5 lb/ft (84 Kg/m)

Circle Built from one-piece steel forging, “T” cross section ..................... 7.0x6.62x1.5 in (177.8x168.3x 38.1 mm) Outside diameter ............................................................................................................. 69 in (1.752.6 mm) Turning angle ..................................................................................................................... 360º continuous Total wear plate area ....................................................................................................... 441 in2 (2845 cm2)

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167

G200

SPECIFICATIONS Blade Build from one-piece hot stamped carbon steel. Unique “Roll Away” surround profile.

Replaceable bits and cutting edge. Hydraulic controls for side shift and blade tilt.

Available sizes: 12 ft - 12 x 24.5 x 0.875 in (3658 x 622 x 22 mm) ............................................................................ optional 13 ft - 13 x 26.4 x 0.875 in (3962 x 671 x 22 mm) ............................................................................ optional 14 ft - 14 x 26.4 x 0.875 in (4267 x 671 x 22 mm) ........................................................................... standard Maximum raise height from ground ................................................................................ 17.5 in (444.5 mm) Maximum bank cutting angle (RH and LH) ............................................................................................. 90º

Blade Reach (Measured Outside Tires), Non-Articulated Frame With circle displacement only Right side .......................................................................................................................... 39.3 in (999 mm) Left side ........................................................................................................................... 43.8 in (1112 mm) With blade displacement only Right side ........................................................................................................................... 59 in (1500 mm) Left side ........................................................................................................................... 53.3 in (1355 mm) With circle and blade displacement Right side ........................................................................................................................ 76.6 in (1945 mm) Left side ........................................................................................................................... 70.2 in (1784 mm) With circle, blade displacement and saddle rotated in hole number one Right side ........................................................................................................................... 85 in (2158 mm) Left side ............................................................................................................................ 77.2 in (1961 mm)

Blade Reach (Measured Outside Tires), Articulated Frame With machine articulated a full 250 to the right and to the left, add 684 mm for all above dimensions.

Hydraulic System Full hydraulic control, supplied by a “Load Sensing” type gear pump. Closed center circuits. Blade raise cylinders mounted over the saddle. Saddle lock system by a hydraulic cylinder controlled by a solenoid valve activated by a switch located on the side console. Relief and check valves for all controls.

Implement pump ....................................................................... 49 gpm (186 l/min) and 2600 psi (179 bar) Steering & brake pump Brake and steering section ..................................................... 11.1 gpm (41.8 l/min) @ 2200 engine rpm Rear axle cooling section ....................................................... 11.1 gpm (41.8 l/min) @ 2200 engine rpm Rear axle diff. lock section (optional) ........................................ 2.3 gpm (8.8 l/min) @ 2200 engine rpm

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168

G200

SPECIFICATIONS Accessories SCARIFIER Parallelogram type, front mounted Weight (5 teeth) ...................................................................... 1256 lbs (570 kg), includes front attachment Width ................................................................................................................................. 46 in (1.168 mm) Number of teeth .................................................................................................................... 5 (11 optional) Maximum raise height from the ground ............................................................................ 20.75 in (527 mm) Maximum ground penetration ........................................................................................... 12.5 in (318 mm) Overall machine length with scarifier .................................................................................. 31 ft (9.449 mm) REAR RIPPER Type ................................................................................................................ parallelogram, rear mounted Weight ................................................................................................................................. 2167 lb (985 kg) Number of teeth ..................................................................................................................... 5 (9, optional) Tooth spacing .................................................................................................................... 20.8 in (530 mm) Maximum Width (viewed from rear) .............................................................................. 92.13 in (2340 mm) Maximum lift above ground (ripper teeth) ........................................................................ 20.38 in (518 mm) Maximum ground penetration (ripper teeth) .................................................................... 17.22 in (437 mm) Machine length with rear ripper .................................................................................... 31 ft 4 in (9550 mm) FRONT BLADE Weight .............................................................................................................................. 2568 lb (1165 kg) Dimensions ................................................................................................. 109 x 37.5 in (2.762 x 953 mm) Maximum penetration .......................................................................................................... 6.5 in (165 mm) Machine length with front blade fully retracted .......................................................... 30 ft 11 in (9.423 mm)

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169

G200

SPECIFICATIONS OPERATING DATA AND DIMENSIONS

D

A B C

A. Wheel tread ....................................................................................................................... 7 ft (2134 mm) B. Outside edges of tires ................................................................................................ 8 ft 8 in (2650 mm) C. Blade width ..................................................................................................... 12 ft (3658 mm) (optional) 13 ft (3962 mm) (optional) 14 ft (4267 mm) (standard) D. ROPS overall height (high profile cab) ................................................................ 10 ft 11.5 in (3340 mm) ROPS overall height (low profile cab) ...................................................................... 10 ft 4 in (3140 mm)

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170

G200

SPECIFICATIONS

N

M

L

J

K

I H

O

E F G

R

Q

P

E. Tandem center to rear end of machine ...................................................................... 5 ft 5 in (1662 mm) F. Distance from front axle and rear end of machine ................................................. 25 ft 10 in (7881 mm) G. Overall length .................................................................................................................. 28 ft (8555 mm) H. Rear axle to rear wheels ........................................................................................... 2 ft 7.5 in (801 mm) I. Tandem wheelbase .................................................................................................... 5 ft 2 in (1594 mm) J. Center articulation to rear axle ................................................................................... 6 ft 5 in (1958 mm) K. Front axle to moldboard blade (blade base) .............................................................. 8 ft 5 in (2562 mm) L. Tire radius ........................................................................................................................... 2 ft (610 mm) M. Lift cylinder height ...........................................................................................................10 ft (3047 mm) N. Height to top of exhaust pipe .............................................................................. 10 ft 10.8 in (3323 mm) O. Wheel base .............................................................................................................. 20 ft 5 in (6219 mm) P. Distance between rear tires and rear ripper ............................................................... 6 ft 8 in (2040 mm) Q. Distance between front tires and front scarifier .......................................................... 5 ft 0 in (1520 mm) R. Distance between front tires and front dozer blade ................................................... 5 ft 5 in (1645 mm) -

Outside tire turning radius ...................................................................................... 23 ft 11 in (7289 mm)

-

Ground clearance (rear axle) ........................................................................................ 14.9 in (380 mm)

-

Ground clearance (front axle) ....................................................................................... 24.5 in (622 mm)

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G200

SPECIFICATIONS

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172

ALPHABETICAL INDEX G170

ALPHABETICAL INDEX A

C

Access Doors ..................................................... 84 Accessories ...................................................... 173 Adding Air to the Tires ........................................ 71 Additional Safety Rules ...................................... 14 Adjustment Circle Guides ................................................ 122 Valve Clearance ........................................... 104 Air Conditioner ................................................... 47 Refrigerant Charge ......................................... 48 Switch ............................................................. 45 Air Filter System ................................................ 96 Air Recirculation Switch ..................................... 45 Alternator and Air Conditioning Belt ................ 120 Articulation, Hydraulic Cylinders and Pivot Joints ................................................ 87 Auxiliary Electrical Current Receptacle ............. 46

Cab .................................................................... 52 Cab Headliner .................................................. 119 Cab Heat Control ............................................... 45 Changing Engine Speeds .................................. 60 Changing the Fuel Filters................................. 103 Checking Circle Turn Gear Box Oil .................. 112 Circle ................................................................ 171 Circle Guides Check and Adjustment .................................. 122 Circle Turn Clearances .................................... 122 Cleaning Air Filter Element ................................ 96 Cleaning Filter Suction Line ............................. 106 Cleaning the Batteries ..................................... 126 Cold Start Switch ............................................... 44 Cold Weather Precautions ................................. 63 Components List .............................................. 141 Console Tilt Pedal .............................................. 42 Cooling System .................................................. 98 Draining and Flushing ..................................... 99 Radiator Cleaning ......................................... 100 Cutting a “V” Ditch ............................................. 65

B Bank or Back Sloping ........................................ 61 Battery Booster Batteries .......................................... 127 Fluid Level .................................................... 126 Safety ........................................................... 125 Service .......................................................... 126 Vents ............................................................. 126 Before Operation ............................................... 11 Before Starting the Engine ................................ 55 Before you Service ............................................ 75 Belt and Tensioner ........................................... 120 Blade ................................................................ 172 Blower Fan Speed Switch .................................. 45 Booster Battery Connections ............................. 59 Brake System ................................................... 105 Oil Change .................................................... 107 Brakes .............................................................. 170 Burn Prevention ................................................. 16

D Damage to the ROPS ...................................... 117 Decals ................................................................ 27 Diesel Fuel System .......................................... 101 Differential Lock Switch ..................................... 41 Diffusers ............................................................. 52 Ditch Cutting on Flat Plain ................................. 66 Dome Light ......................................................... 53 Doors Hinges ................................................... 119 Draining and Flushing the Cooling System ....... 99 Draw Bar .......................................................... 171 Drawbar Ball and Socket ................................... 87 Drawbar Ball Nut Torque Check ...................... 123 Drive Belt and Tensioner Inspection ................ 121

173

G170

ALPHABETICAL INDEX E Electric Diagrams ............................................. 143 Electrical System .................................... 125, 170 Electronic Monitor .............................................. 39 Engine .............................................................. 169 Coolant Temperature gauge ........................... 46 Cooling System .............................................. 98 Crankcase ...................................................... 85 Filter Replacement ......................................... 94 Fuel Filter ........................................................ 86 Hood ............................................................... 78 Lubrication ...................................................... 92 Oil Change ...................................................... 94 Oil Level .......................................................... 94 Oil Pressure Gauge ........................................ 45 Oil Selection ................................................... 92 Engine Control Module Connectors ................. 129 Engine Coolant Level ......................................... 85 Engine Protection System ............................... 132 Engine Stop ..................................................... 132 Error Code Display ............................................ 41 Explosion Prevention ......................................... 17

F Fire Extinguisher ....................................... 16, 119 First Service Intervals ........................................ 57 Floodlights .......................................................... 38 Fluid Levels ........................................................ 85 Fluids and Lubricants ......................................... 80 Frame ............................................................... 171 Front Axle ......................................................... 171 Front Axle Spindle Pivot ..................................... 90 Front Blade Float Switch .................................... 44 Front Console .................................................... 36 Front Floodlight Switch ...................................... 45 Front Wheel Bearings ......................................................... 91 Knuckle ........................................................... 89 Lean Cylinder ................................................. 89 Front Windshield Washer Switch ....................... 45 Front Windshield Wiper Switch .......................... 44 Fuel Conditioner .............................................. 101 Fuel Filters ......................................................... 86 Change ......................................................... 103

174

Fuel Injector Nozzles ....................................... 104 Fuel Level Indicator Gauge ............................... 46 Fuel Storage .................................................... 102 Fuel System ..................................................... 101 Fuel Tank Drain Cock ...................................... 103 Fuse Box ................................................... 42, 131

G Gauge Panel ...................................................... 45 Gauges Engine Coolant Temperature .......................... 46 Fuel Level Indicator ........................................ 46 Transmission Oil Pressure ............................. 46 Gear and Error Code Display ............................ 41 General Safety before you Service .................... 75 Grease Fittings .................................................. 87

H Hand Signals ...................................................... 32 Headlights .......................................................... 38 Heat Control ....................................................... 45 Horn ................................................................... 38 Hoses and Wiring ............................................ 119 Hourmeter ................................................... 39, 76 Hydraulic Diagnostic Panel .............................. 124 Hydraulic System .................................... 105, 172 Oil Change .................................................... 107 Hydraulic Tank ................................................... 86

I Identification Numbers ......................................... 4 Ignition Switch .................................................... 46 Implement Control Levers Left Side ......................................................... 36 Right Side ....................................................... 36 Indicator Lights ................................................ 132 Indicators Air Filter Restriction ........................................ 41 Hydraulic Oil Filter Restriction ........................ 41 Instrument Panel ............................................ 40 Transmission Oil Filter Restriction .................. 41 Warning Flasher ............................................. 41 Inspection of ROPS ......................................... 116

G170

ALPHABETICAL INDEX L

O

Lean Cylinder ..................................................... 89 Levers Articulation ...................................................... 36 Blade Lift .................................................. 36, 37 Blade Pitch ..................................................... 36 Blade Side Shift .............................................. 36 Circle Side Shift .............................................. 36 Circle Turn ...................................................... 36 Front Scarifier, Blade or Ripper ...................... 36 Front Wheel Lean ........................................... 37 Parking Brake ................................................. 51 Throttle Control ............................................... 43 Lift Cylinders Balls ............................................. 87 Limp-Home ...................................................... 128 Limp-Home Switch ............................................. 44 List Fuse and Relay ............................................ 131 Logic Checking for Tier3 Cummins Engine Operation .................................................. 132 Lubrication & Maintenance Chart ...................... 81 Lubrication/Filters/Fluids .................................... 75

Oil Viscosity and Temperature Ranges ............. 93 Operating in Hot Weather .................................. 63 Operating Instructions ........................................ 55 Operating Tips ................................................... 64 Operating Weights ........................................... 171 Operator Manual Storage Compartment ............. 3 Operators Compartment .................................... 35 Operators Manual .............................................. 23 Operators Seat................................................. 118 Optional Air Ride Seat .................................... 49 Standard Seat ................................................. 49

M

R

Machine Components .......................................... 6 Machine Operation ............................................ 12 Machine Storage .............................................. 167 Maintenance ........................................ 18, 20, 79 Air Conditioner ................................................ 47 Maintenance of ROPS ..................................... 116 Master Switch .................................................... 46 Moldboard Antishock Function Switch .............................. 44 Float Switch .................................................... 44 Lift Cylinders Balls .......................................... 87 Tilt Cylinder Pivot ............................................ 88 Tilt Cylinders Balls .......................................... 87 Tilt Pivot .......................................................... 88 Monitor ............................................................... 39

Radiator ............................................................. 85 Radiator Cleaning ............................................ 100 Radio ................................................................ 140 Read Operators Manual .................................... 23 Rear Axle ................................................ 110, 171 End Compartment Oil Level ......................... 111 Oil Change .................................................... 110 Rear Floodlight Switch ....................................... 45 Rear Ripper Pivots and Cylinder ....................... 91 Rear Window Washer Switch ............................ 45 Rear Window Wiper Switch ............................... 45 Removal from Storage ..................................... 167 Ripper / Scarifier Switch .................................... 44 Road Bed ........................................................... 67 Roll-Over Protective Structure .................. 19, 115 ROPS Damage ........................................................ 117 Maintenance and Inspection ......................... 116 ROPS Cab and ROPS Torque Specifications ................................... 116 Run-in ................................................................ 58

N Neutral Lock ....................................................... 43

P Parking Brake ........................................... 51, 115 Parking the Machine and Stopping the Engine .................................. 16 Parking the Motorgrader .................................... 63 Pedal Inching ............................................................ 41 Personel Safety ................................................. 10 Plastic and Resin Parts ...................................... 77

175

G170

ALPHABETICAL INDEX S Safety Decals ..................................................... 23 Safety Rules ........................................... 9, 14, 26 Scarifier ............................................................ 173 Scarifing ............................................................. 63 Seat Optional Air Ride ............................................. 49 Standard ......................................................... 49 Seat Belt ............................................ 51, 57, 116 Secondary Steering Light (Optional) ................. 41 Service Pin ......................................................... 76 Service Specifications Engine ............................................................ 94 Rear axle ...................................................... 110 Swing/Circle Turn Gear Box ......................... 112 Tandem ......................................................... 113 Shut Down ......................................................... 13 Specifications ................................................... 169 Speedometer ..................................................... 39 Start Up .............................................................. 13 Starting the Engine ............................................ 59 Using Booster Batteries ................................ 127 Steering ............................................................ 170 Steering Arm Pivot ............................................. 89 Steering Wheel Console and Pedals ....................................... 37 Tilt Lever ......................................................... 41 Stopping the Engine .......................................... 60 Stopping the Motorgrader .................................. 63 Storage Preparation ......................................... 167 Swing/Circle Turn Gear Box ............................ 112 Symbols used in this Manual ............................. 24 Systemgard Lubrication Analysis Program ....................................... 77, 95

T Tandem ................................................... 113, 170 Central Bearings ............................................. 91 Oil change .................................................... 113 Oil Level Check ............................................ 113 Wheel Nut ..................................................... 113 Wheel Shaft Bearings ..................................... 90 Tandem Wheel Lug Nuts ................................... 72 Terracing - Level Curves .................................... 65 Tire or Rim Service ............................................ 71

176

Tires .......................................................... 69, 170 Adding Air ....................................................... 71 Pressure ......................................................... 72 Pressure Check .............................................. 72 Service ............................................................ 71 Tread Direction ............................................... 71 To the Owner ........................................................ 1 Torque Specifications ROPS Cab and ROPS .................................. 116 Seat and Seat Belts ...................................... 118 Towing ................................................................ 61 Transmission ........................................... 108, 169 Fluid Level ...................................................... 85 Oil Change and Screen Cleaning ................. 109 Oil Filter Change ........................................... 109 Oil Level Check ............................................ 108 Oil Pressure Gauge ........................................ 46 Transmission Auxiliary System ........................ 128 Transmission Control Module Connectors ...... 129 Transport Service Pin ........................................ 76 Troubleshooting Codes .................................... 132 Checking and Interpretation ......................... 134 Turning Signals .................................................. 38 Typical Operation ............................................... 65

U Universal Joint and Drive Shaft ......................... 90 Utility Safety ....................................................... 10

V Valve Clearance Adjustment ............................ 104

W Warning Flasher ................................................. 37 Wear Plate Adjustment .................................... 122 Welding Service on the Machine ..................... 128 Wheel and Tire Maintenance ................................................... 19 Wheel Lean Link ................................................ 89 Wheels ............................................................... 69 Nuts Torque .................................................... 72 Windshield Washer Reservoir ......................... 114 Windshield Wiper ............................................... 52 Work Lights Switch ............................................ 45