TS14F Operation - Safety - Maintenance
WHEN RE-ORDERING THIS HANDBOOK, SPECIFY - PART NUMBER 15272933
TECHNICAL PUBLICATIONS DEPARTMENT TEREX EQUIPMENT LIMITED MOTHERWELL, SCOTLAND ML1 5RY Ref No. OHE 772 Rev 1 Nov 1999
CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, bir th defects, and other reproductive harm.
SPARE PARTS STATEMENT When carrying out repairs, alterations or fitting attachments, it is important that only genuine spare parts are used to ensure the operating safety of the machine is not impaired. It is only by using genuine parts that the technical requirements stipulated by the manufacturer can be maintained. If a General Operating Approval is issued for this machine, it may be considered null and void if non-genuine parts are used.
CONTENTS 1. INTRODUCTION Introduction ........................................ 1-2 Safety Precautions ............................ 1-2 Machine Identification ........................ 1-4 Theft Deterrent Practices .................. 1-5 2. SAFETY PRECAUTIONS General .............................................. 2-2 Twin Hitch Safety Precautions .......... 2-3 Preventing Fire Hazards .................... 2-4 Mounting and Dismounting ................ 2-6 Pre-Starting ........................................ 2-7 Starting ............................................... 2-7 Operating ........................................... 2-8 Roading .............................................. 2-9 Lubrication and Servicing ................ 2-11 Wheels and Tyres ............................ 2-12 Avoid Tyre Explosion Hazard .......... 2-13 3. CONTROLS AND OPERATING Controls and Instruments .................. 3-3 Basic Data ......................................... 3-4 Indicator/Warning Lights ................ 3-4 Instruments .................................... 3-6 Switches ......................................... 3-8 Controls ........................................ 3-11 Heater .......................................... 3-12 Air Conditioner ............................. 3-12 Operator's Seat - Air Suspension 3-13 Seat Belt ...................................... 3-14 Machine Controls ............................. 3-15 Braking ......................................... 3-15 Service Brake ........................... 3-15 Park/Emergency Brake ............ 3-15 Engine .......................................... 3-16 Electronic Foot Pedals ............. 3-16
HEUI Electronic Management System ..................................... 3-16 Description ............................... 3-18 Operation ................................. 3-19 Steering ........................................ 3-32 Transmission ................................ 3-33 System Components ............... 3-35 General Transmission Operation 3-37 Power-Locking Differential ........... 3-38 Hydraulic System Controls .......... 3-39 Twin-Hitch Control (Optional) ...... 3-40 4. OPERATING THE SCRAPER Pre-Starting Inspection ...................... 4-2 Component Checks - Tractor ............ 4-3 Component Checks - Scraper ........... 4-5 Engine Operation ............................... 4-7 Starting the Engines .......................... 4-8 Tractor Engine ............................... 4-8 Scraper Engine ............................ 4-10 Low Ambient Temperatures ........ 4-12 Starting the Engine with Jumper Cables ..................... 4-13 Pre-Operating Checks ..................... 4-14 Brake Function Checks ................... 4-14 Driving and Stopping ....................... 4-16 Stopping the Engines ...................... 4-18 Parking ............................................. 4-20 5. WORKING THE SCRAPER Standard Functions ........................... 5-2 Loading Self Loading ................................... 5-3 Push Loading ................................. 5-4 Hauling ............................................... 5-6 Spreading ........................................... 5-7
Returning To The Cut ........................ 5-9 Working Special Materials ................. 5-9 Sand ............................................... 5-9 Coal .............................................. 5-10 Gravel ........................................... 5-10 Wet and Sticky Material ............... 5-10 Loading Large Objects ................ 5-11 Blade Arrangements ........................ 5-12 Twin Hitch Loading (Optional Attachment) .................. 5-13 Types Of Cuts .................................. 5-15 Cutting Through Hills ................... 5-15 Cutting Banks .............................. 5-15 Stripping Topsoil .......................... 5-15 Starting A Ditch ............................ 5-16 Types Of Fills ................................... 5-16 Finishing And Grading ..................... 5-17 6. ROADING Roading ................................................ 6-2 General ............................................ 6-2 Preparation Prior to Roading ........... 6-2 In Case Of Trouble .......................... 6-4 7. MOVING DISABLED SCRAPER Moving Disabled Scraper .................... 7-2 8. LUBRICATION AND SERVICING Safety Precautions .............................. 8-2 Lubrication and Servicing .................... 8-3 Tractor Lubrication and Service Chart ............. 8-5 Remote Lubrication Points .................. 8-8 Additional Miscellaneous Servicing Information ....................... 8-9 Recommended Lubricants ................ 8-13
1-1
CONTENTS - Continued 8. LUBRICATION AND SERVICING (Cont) Scraper Lubrication& Service Chart .............. 8-16 Remote Lubrication Points .............. 8-19 Additional Miscellaneous Servicing Information ................... 8-20 Recommended Lubricants .............. 8-23 Temperature Conversions ............... 8-24 9. TECHNICAL DATA 10. SYMBOL IDENTIFICATION
INTRODUCTION This Handbook is provided as a guide to familiarize the operator and serviceman with the controls, recommended inspections, start-up, operating, shutdown and parking procedures for TS14F Scrapers. Look for this symbol to point out important safety precautions. It means: ATTENTION! BECOME ALERT! YOUR SAFETY AND THE SAFETY OF OTHERS IS INVOLVED!
Safety Precautions The machine should be properly operated and maintained to keep it in safe, efficient operating condition. Be sure that all controls are free of mud, grease, or other matter that might cause slips hazardous to the operator, serviceman, or other personnel or equipment. Report all malfunctions to those responsible for maintenance, and, do not operate the equipment until corrected. Normal service or maintenance performed as required can prevent unexpected and unnecessary downtime.
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This Handbook describes general inspections, servicing and operation with the normal safety precautions required for normal servicing and operating conditions. It is not a guide however, for other than normal conditions or situations, and therefore, servicemen and operators must be safety conscious and alert to recognize potential servicing or operating safety hazards at all times, and take, necessary precautions to assure safe servicing and operation of the machine. READ the CIMA Safety Manual supplied with this machine. All information, illustrations and specifications contained in this publication are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice. Continuing improvement and advancement of the design may cause changes to your machine which may not be included in this publication. Each publication is reviewed and revised, as required, to update and include these changes in later editions. This Handbook contains lubrication and routine servicing instructions, most of which can be performed in the field. Maintenance manuals containing repair/ rebuild procedures can be obtained from your dealer.
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Machine Identification While reading this handbook you will notice references to controls and equipment which may not be found on all machines. It is important that you know your machine and its equipment and how to operate it properly. Information regarding the machine model, code and chassis serial number is found on the unit serial number plates on the front left hand side of the tractor and rear right hand side of the scraper. The machine model and serial number should always be referenced in any correspondence with your dealer or factory. There is a dealer serving every part of the world where these products are sold. Your dealer is ready to provide you with any additional information needed and should be consulted for additional publications for this machine.
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Theft Deterrent Practices General The owner/operator should take the following precautions to discourage theft, to aid in the recovery in the event that the machine is stolen, or to reduce vandalism. Actions to Discourage Theft and Vandalism Remove all keys any time the machine is left unattended. At night lock all doors and attach, secure or lock all anti-vandalism and anti-theft devices on the machine. Immobilize the machine by removing a critical electrical or starting system device. Upon receipt of a machine, record the machine serial number and the serial numbers of all major components and attachments. Keep this list up to date and filed in a safe location for fast retrieval. Place a decal or notice on the machine that all serial numbers are recorded. Discourage the thief! Inspect the gates and fences of the machinery storage yard or construction site. Keep machines in well-lit areas and ask the local law enforcement authorities to make frequent checks around the storage yard or work site. Establish liaison with neighbours and ask them to watch equipment left at job sites and to report any suspicious activities to the local law enforcement authorities. Make frequent inventories of machines to promptly detect losses or vandalism.
1-5
Actions to Aid in Recovery of Stolen Machines In the event of theft, immediately notify the law enforcement authorities having jurisdiction. Provide the investigating officer with name, type of equipment, chassis and serial numbers of major attachments and components. It is helpful to show the investigating officer an Operator’s Handbook, photographs, and advertising, to familiarize him with the appearance of the machine. Report the theft to the insurance company. Provide the model and all serial numbers. Report the model and serial numbers of the stolen machine to a dealer handling the respective line of equipment. Request that the dealer forward this same information to the equipment manufacturer.
1-6
2 - Safety Precautions 2-1
SAFETY PRECAUTIONS General
2-2
*
Read this Operator’s Handbook and learn the operating characteristics and limitations of the machine. Know what operating clearances the machine requires.
*
Read the CIMA Safety Manual and follow the recommended safety precautions.
*
Know clearances of all side and overhead obstructions such as wires, bridges, etc., for operating safely.
*
Always know all traffic rules, signs, flags and hand signals used on the job and know who has the responsibility for signalling.
*
Be aware of operating hazards that weather changes can create on the job. Know proper procedures to follow when a severe rain or electrical storm strikes.
*
Never attempt to operate or work on a machine when not feeling physically fit.
*
Know what safety equipment is required and use it. Such equipment may be: Hard hat, safety glasses, reflector type vests, respirators and ear plugs.
*
Never wear loose clothing, rings, watches etc., that might catch levers and controls and cause loss of control.
*
Keep hands and controls free from water, grease and mud to assure nonslip control.
*
Handle fuels and lubricants carefully and clean up spills to avoid fire and slipping hazards.
*
Clean any mud, grease or oil from controls, handrails, ladders and decks. Lash necessary tools securely and remove all loose items before operating machine.
*
Never carry passengers on the machine.
WARNING The protection offered by the roll over and falling object protective structure may be impaired if it has been subjected to any modification or damage.
Twin Hitch Safety Precautions *
Do not operate machine with the bail down, except when coupled to another machine, as this results in a dozing action, bending the bail and causing unnecessary damage to hitch assembly and machine.
*
Never park or leave the machine with the bail in the raised position. Bail can be dropped by accidental control lever movement, or loss of cylinder air pressure, and could be dangerous to any personnel in the area of the bail. If the machine is being parked for an extended period of time, or being serviced with the air supply (engine) shut off, the bail, if left in the raised position, will eventually drop to the lowered position of its own weight. Always lower the bail when dismounting the machine for any reason. Note: Holes are provided in the side plates of the push plate assembly for propping the bail in the raised position with a pin, for servicing procedures.
*
Twin hitch scrapers are designed to operate in pairs of the same size and type. Twin hitch operations with unequal size scrapers, three or more scrapers in train or push tractor assistance could seriously impair the service life of the machines.
2-3
*
Never turn the machine when hitched to another machine. The machines must remain in a straight line while hooked together as turning of either machine will damage the bail of the rear machine.
*
Keep bowl as low as possible, but high enough to clear objects in the haul road, as this increases ground clearance of hitch push plate and bail assembly on the front of the machine.
*
Scraper team should alternate pushing and pulling functions during loading cycles to equalize wear of the attachments on both machines.
Preventing Fire Hazards General Fire Precautions * Make sure machine has a fire extinguisher and that it is accessible and fully charged. (Not furnished with machine).
2-4
*
Never use an open flame as a light anywhere on, or around, the machine.
*
Clean all dirt, oil, grease and other fluids from systems and components to minimize fire hazards and aid in spotting loose or leaking lines, fittings etc..
*
Check the engine compartment for rubbish, oily rags or other debris that could cause fires before starting the engine.
*
Don’t let greasy, oily rags or similar hazards accumulate in the cab.
*
If the machine has been operated with an under inflated tyre. Make sure that the tyre has cooled sufficiently before parking and leaving the machine unattended.
Flammable Fluid Precautions * Do not use diesel fuel or other flammable fluids for cleaning purposes. Use approved, nonflammable solvents. *
Make sure all fluid system caps, drain cocks, valves, fittings, lines etc., are secure and leak free.
*
Never use an open flame (match, lighter etc.) when checking fuel, lubricant, coolant and battery fluid levels or when checking for fluid leaks. Use a flashlight or other safe lighting only.
*
Shut off engine and use extra caution if engine is hot when refuelling. Ground the hose spout to prevent sparks when spout is touched to fuel tank filler tube.
*
Never smoke while checking or adding fuel or other fluids or handling fluid containers and lines.
*
Use care and do not stand downwind when adding fuel or other flammable fluids to tanks and reservoirs to avoid fluids being blown or splashed onto clothing.
*
Close fuel tank shut-off valves, if used, before servicing fuel system.
*
When preparing machines or components for storage, seal and tape all openings and close containers tightly to seal in all volatile inhibitor fluids and compounds used.
*
Follow manufacturer’s recommendations when handling and using enginestarting fluids and disposing of spent containers. Do not puncture or burn empty containers. These fluids are explosive and highly flammable.
2-5
Electrical Hazard Precautions * Never smoke or allow open flames or sparks near batteries. *
Leave battery box open when charging batteries in machine for adequate ventilation of explosive gas (hydrogen) produced.
*
Always disconnect batteries before repairing electrical system to avoid danger of fire-causing sparks. Disconnect battery ground cable first and reconnect last.
*
Always disconnect battery equalizer, batteries, ECU electrical connections and alternator leads before carrying out any welding on the machine. Disconnect ground cables first and reconnect last.
*
Never check battery charge by placing metal objects across battery posts to avoid sparks at battery posts.
*
Use jumper cables only as recommended. Improper use can result in battery explosion or unexpected machine motion.
*
Never operate engine starter for more than 30 seconds and allow two minutes between cranking periods for cooling. An overheated starter could cause a fire.
*
If electric coolant or lubricant heaters are used, be sure to follow heater manufacturer’s recommendations for use to avoid electrical and/or fire hazards.
Mounting and Dismounting *
2-6
Only use steps and hand holds provided to mount or dismount machine. Do not grasp steering wheel.
*
Always face the access system and maintain at least three points of support to mount or dismount the machine.
*
Always use care when mounting machine with oil covered, frosted, or iced fenders, decks, hand holds or steps.
*
Never mount or dismount a moving machine. Never jump off the machine.
Pre-Starting *
If engine is to be started and run indoors, ensure proper ventilation to remove deadly exhaust gases.
*
Always perform 'Pre-Starting Inspection' instructions described on page 4-2 to ensure the machine is ready for operation.
*
Always walk around the machine to make sure no-one is working on, underneath or close to the machine before starting the engine or operating the machine.
*
Adjust, secure and latch the seat and fasten the seat belt before starting the machine.
*
Sound horn before starting the engine or beginning to move the machine; two blasts for forward and three blasts for reverse.
Starting *
Do not start the engine or operate any control if there is a 'DO NOT OPERATE' or similar warning sign attached to any control.
*
Use jumper cables only as recommended. Improper use can result in battery explosion or unexpected machine motion.
2-7
*
Always obey 'Starting the Engines' instructions described on page 4-8.
*
Do not bypass the machine’s neutral-start system. The neutral-start system must be repaired if it malfunctions.
*
Start and operate the machine only from the operator’s cab.
Operating
2-8
*
Ensure all cab glass, mirrors and light lenses are clean during machine operation for maximum visibility.
*
Always keep cab floor clear of anything that could restrict full operation of pedals.
*
Always make sure all gauges, warning/indicator lights and controls are working properly before operating machine.
*
Always perform 'Pre-Operating Checks' described on page 4-14 to ensure the machine is ready for operating.
*
Always wear seat belts when operating the machine.
*
Do not operate if exposed personnel enter the immediate work area.
*
Sound horn before starting engine or beginning to move machine; two blasts for forward and three blasts for reverse.
*
Watch for ground crew and other personnel on foot. Sound horn as a warning before setting machine in motion and when approaching ground crew.
*
Never release the parking brake or move the machine until the needle in the air pressure gauge is in, or approaching the centre of the green zone.
Roading WARNING Be extra cautious at raised rail crossings, other raised portions of roads and overpasses to make sure the scraper and raised bowl will clear as it passes. Personal injury or property damage may result if the bowl is not adjusted properly and clearance is not significant. 709
Raise Bowl Fully
*
Fully raise bowl so as to clear any obstacle in the path of the scraper. If in doubt as to clearance, stop the machine and check clearance.
*
Always try to face or look in the direction the machine is travelling.
*
Slow down when moving in congested areas. Do not race with other machines. Stop in authorized areas only, except in emergency.
*
Use extreme caution and turn on lights at night or when fog, dust or similar hazards limit visibility. Do not overdrive your headlights.
*
Know clearances of all side and overhead obstructions such as wires, bridges, etc., for operating safely.
*
Always know all traffic rules, signs, flags and hand signals used on the job and know who has the responsibility for signalling.
*
Be alert for soft ground conditions, espescially when working on slopes, near drop-offs or excavations or fill material, which could lead to sudden tipping of the machine.
*
Be aware of operating hazards that weather changes can create on the job. Know proper procedures to follow when a severe rain or electrical storm strikes.
2-9
2-10
*
Observe instruments frequently. Report any defects or unusual noises in machine during operation.
*
Stop at appropriate intervals to inspect the machine and allow the tyres to cool. Tyre air pressure will rise during operation. Do not reduce tyre pressure. Excess speed will cause tyres to heat up. Reduce your travel speed, not tyre pressure.
*
Always shut off the engine when leaving the machine unattended. Apply the parking brake, place the shift lever in the 'Neutral' position, lower the bowl to the ground, place the battery master switch in the 'Off' position and block all road wheels.
*
Match speed to road conditions.
*
Yield the right of way when required. Always give loaded machines the rightof-way when your machine is empty. On narrow or hilly roads, loaded machines should stay next to the high wall. Obey the rules of the road.
*
Always be sure the bowl is in a travel position high enough to clear any obstacles in its path. If in doubt as to clearance, stop the machine and check clearance.
*
Brake firmly in one application. Frequent and repeated light applications may exhaust air from reservoir faster than it can be replaced by the compressor. Never operate the machine if a warning light or gauge indicates low air pressure.
*
Stay in gear when driving downhill. Do not coast with transmission in neutral. Select the proper gear and maintain safe speed with the service brakes or/ and retarder. Always maintain safe speeds for haul road operating conditions for maximum control. Reduce speed before turning.
*
Always operate straight up or down slopes whenever possible, side hill operation can cause sideslip and possible roll-over. If the machine starts slipping sideways, turn down-hill immediately.
*
Stay as close to the side of the road as possible. Pass other equipment only when the road is clear and enough room and reserve power are available.
*
Use accessory lights and devices at night or in poor visibility. Carry a flare kit. Do not overdrive your headlights.
Lubrication and Servicing *
Do not allow unauthorized personnel to service or maintain this machine. Study the Operator’s Handbook and Maintanance Manual before starting, operating or servicing this machine. Always follow procedures and safety precautions detailed in the Maintanance Manual.
*
Never allow anyone to work on the machine while it is moving.
*
Make sure no one is on the machine before working on it.
*
Do not work under or near any unblocked or unsupported linkage, part or machine.
*
Always shut down machine according to the procedure under 'Stopping The Engine', described on page 4-18, and turn off the master switch before cleaning, lubricating or servicing the machine except as called for in this Handbook or Maintanance Manual.
*
Always deflate tyre before attempting to remove any embedded objects or removing the tyre and rim assembly from the machine.
*
Always use a self-attaching chuck with a long airline and stand to one side while the tyre is inflating.
*
Always relieve pressure before servicing any pressurized system.
*
Always attach a 'DO NOT OPERATE' or similar warning sign to ignition switch or a control before cleaning, lubricating or servicing the machine.
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Wheels and Tyres If tyres on a machine were inflated at the factory with dry nitrogen gas, the tyre walls will be marked 'N' and the following factory installed decal will be found mounted on the fenders. NOTICE TYRES ON THIS MACHINE ARE FACTORY INFLATED WITH DRY NITROGEN. IT IS RECOMMENDED THAT DRY NITROGEN BE USED EXCLUSIVELY FOR ALL TYRE PRESSURE ADJUSTMENTS AS WELL AS INFLATION OF REPLACEMENT TYRES. Nitrogen gas improves tyre pressure retention, increases tyre life by reducing carcass oxidation from within, minimizes rim rust, and has no known detrimental effect on the tyre. It also reduces the potential of a tyre explosion because it is an inert gas and will not support combustion inside the tyre. The same tyre inflation pressure used for air inflation should be used for nitrogen inflation. Refer to Section 160-0050, 'NITROGEN INFLATION OF TYRES' of machine Maintanance Manual for recommended procedures for inflating and pressure adjusting tyres with dry nitrogen gas. Only proper nitrogen charging equipment operated by personnel trained in its use should be used.
2-12
WARNING Never mix components of one manufacturer’s rims with those of another. Using the rim base of one manufacturer with the lock ring of another or vice versa is dangerous. The lock ring of one may not fully engage with the lock ring groove of the other. Always consult the rim manufacturers for proper matching, assembly and safety instructions. Also, use and servicing of damaged, worn out or improperly assembled rim assemblies is a very dangerous practice. Failure to comply with the above warnings could result in an explosion from tyre pressure causing serious property damage and serious personnel injury or death.
Avoid Tyre Explosion Hazard 50 m (15 ft)
WARNING
460 m (1 500 ft)
460 m (1 500 ft)
460 m (1 500 ft)
460 m (1 500 ft)
Whenever a machine’s tyre(s) is (are) exposed to excessive heat such as a machine fire or extremely hot brakes, the hazard of a subsequent violent tyre explosion must be recognized. All nearby persons must avoid approaching the machine so as not to be physically endangered in the event of an explosion of the tyre and rim parts. The machine should be moved to a remote area, but only when this can be done with complete safety of the operator operating or towing the machine. All other persons should stay clear of the machine. The fire or overheated brakes, wheel etc., should be extinguished or cooled from a safe distance. Do not attempt to extinguish the fire or cool the machine by use of hand-held fire extinguishers. If it is absolutely necessary to approach a machine with a suspect tyre, approach only from the front or the back. Stay at least 15 m (50 ft) from the tread area. Keep observers out of the area and at least 460 m (1 500 ft) from the tyre sidewall. Refer to the accompanying sketch. The tyre(s) should be allowed at least eight (8) hours cooling time after the machine is shut down or the fire extinguished before approaching closer.
50 m (15 ft) 710
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3 - Controls and Operating 3-1
1
2
3
4
5
6
7
8
9
10
11
12
13
14 15 33
16 17
32
27
31
26
25 18 19
28
30
29
24
23
22 21 20
3-2
1291
CONTROLS AND INSTRUMENTS 1. Windscreen Demister 2. Face Vent 3. Warning Lights 4. Tachometer/Hourmeter 5. Transmission Oil Temperature Gauge (Tractor) 6. Air Pressure Gauge 7. Transmission Oil Temperature Gauge (Scraper) 8. Gear/Diagnostic Display Unit 9. Warning Lights 10. Face Vent 11. Windscreen Demister 12. Side Window Demister 13. Switches 14. Park/Emergency Brake Control 15. Gear Shift Selector 16. Bowl Control Lever 17. Apron Control Lever 18. Ejector Control Lever 19. Side Window Demister
20. Heater Control 21. Temperature Control 22. Blower Control 23. Accelerator Pedal (Tractor) 24. Accelerator Pedal (Scraper) 25. Engine Start Key Switch (Scraper) 26. Ignition and Starter Key Switch 27. Accessory Lamp Socket 28. Steering Wheel 29. Service Brake Pedal 30. Power-Locking Differential Pedal (Optional) 31. Headlight Dipper, Direction Indicator, Windscreen Wiper/Washer, Horn Control 32. Fuse Box Cover 33. Radio/Cassette Player 33. Interior Light (Not Shown). Located above RH dash panel. 34. Emergency Exit Hammer (Not Shown). Located on RH cab pillar. 35. Cup Holder (Not Shown). Located on LH cab pillar.
3-3
BASIC DATA Indicator/Warning Lights
1
3
5
7
SERVICE ENGINE SOON
1. Tractor Engine Check Light (Amber) - When the 'Check Engine' light comes on, the computer has detected a fault in the engine. The fault should be diagnosed and corrected at the earliest opportunity. STOP
2. Tractor Engine Stop Light (Red) - When the 'Stop Engine' light comes on, the computer has detected a major malfunction in the engine that requires immediate attention. It is the operators responsibility to shut down the engine to avoid serious damage. An alarm also sounds. 3. Engine Service Light (Red) - Illuminates when the engine is due to be serviced. Both engines should be serviced at the earliest opportunity. 4. Tractor Transmission Oil Pressure (Red) - Illuminates if pressure is low. Illuminates when the ignition is turned on and should go out when the engine starts. If the light illuminates during operation, stop the engine and investigate the cause. Light flickering when gear shifting is permissible. 5. Converter Indicator Light - Illuminates to indicate when the transmission is in torque converter drive. 6. Tractor Transmission Oil Filter Restriction (Amber) - Illuminates when the filter is restricted, indicating that a filter change is required. 7. Headlight Main Beam (Blue) - Illuminates when headlights are operated on main beam. 8. Alternator Charging (Red) - Illuminates to indicate when the alternator is not charging.
3-4
2 1283
4
6
Left Hand Panel
8
9
11
13
9. Bowl Suspension Indicator Light (Red) - Illuminates to indicate when the bowl suspension switch is in operation.
15
10. Direction Indicator (Green) - Flashes when the indicator lights are operating. 11. Low Air Pressure Warning Light - Illuminates when there is a loss of air pressure in the following circuits: STOP
10
12
14
16
a. Front service circuit air pressure falls below 4.1 bar (60 lbf/in²). b. Rear service circuit air pressure falls below 4.1 bar (60 lbf/in²). c. Park/emergency brake circuit air pressure falls below 5.5 bar (80 lbf/in²).
1284
Right Hand Panel
12. Scraper Transmission Oil Filter Restriction (Amber) - Illuminates when the filter is restricted, indicating that a filter change is required. 13. Scraper Transmission Oil Temperature - Illuminates when the transmission oil temperature rises above the safe operating temperature. 14. Scraper Transmission Oil Pressure (Red) - Illuminates if pressure is low. Illuminates when the ignition is turned on and should go out when the engine starts. If the light illuminates during operation, stop the engine and investigate the cause. Light flickering when gear shifting is permissible. 15. Scraper Engine Check Light (Amber) - When the 'Check Engine' light comes on, the computer has detected a fault in the engine. The fault should be diagnosed and corrected at the earliest opportunity. 16. Scraper Engine Stop Light (Red) - When the 'Stop Engine' light comes on, the computer has detected a major malfunction in the engine that requires immediate attention. It is the operators responsibility to shut down the engine to avoid serious damage. An alarm also sounds.
3-5
Instruments 1. Tachometer/Hourmeter - Driven from the alternator, the tachometer indicates the number of engine crankshaft revolutions per minute. The needle shows variations in engine operating speed. Never accelerate the engine to speeds indicated by the red zone on the dial face. A digital hourmeter is incorporated in the tachometer to record total hours of engine operation. The readings can be used for operating and service records. 2. Transmission Oil Temperature Gauge (Tractor) - Indicates converter and transmission oil operating temperature. This gauge should read in the green zone at all times. Stop the engine immediately if the needle goes into the red zone until the fault is corrected. 3. Air Pressure Gauge - Indicates air reservoir pressure. During normal operation, the needle in this gauge should be showing in the centre of the green zone. Do not operate if the needle remains in the red zone.
3-6
3
2
1
4
15 10 RPM x100 20 5
25 30
0
120
50
TRANS OIL
120
140 50
150
SERVICE ENGINE SOON
AIR STOP
1286
WARNING Never release the parking brake or move the machine until the needle is at least approaching the centre of the green zone.
TRANS OIL
TEMP
140 150
TEMP
SERVICE PRESS STOP
4. Transmission Oil Temperature Gauge (Scraper) - Indicates converter and transmission oil operating temperature. This gauge should read in the green zone at all times. Stop the engine immediately if the needle goes into the red zone until the fault is corrected.
5. Air Cleaner Restriction Gauge - Indicates the degree of air cleaner element restriction as the red band rises in the gauge window. The filter elements must be cleaned or replaced if the red band locks in place when the engine is shut down. Reset the restriction gauge by pushing the plunger at the top of the gauge with the engine running.
890
5
3-7
Switches
1
1. Tractor Engine Diagnostic Request Switch - Operates as a diagnostic request switch when: a. - the engine is not running and ignition is 'On'. Pressing and releasing the switch will flash out the engine codes. Pressing the switch a second time will stop the engine codes flashing. Note: Active codes are displayed initially, followed by inactive codes. Refer to pages 21 to 31 for fault code details.
HAZARD
1287
2. Hazard Warning Light - Press bottom of switch to make turn indicators flash simultaneously as hazard warning lights. The direction indicator warning light on the instrument panel will flash. To switch hazard lights off; press the top of the switch. 3. Sidelight and Headlight - Press bottom of switch to the first position to operate side, tail and panel lights. The lights in the other switches will illuminate. Press switch to the second position to operate the headlights. To switch lights off; press the top of the switch. 4. Cutting Edge Light Switch - Press bottom of switch to operate the flood lights to illuminate the bowl. To switch off; press top of switch.
3-8
2
3
4
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TEST
1288
7
8
9
5. Rear Windscreen Wiper and Washer Switch - Press bottom of switch to operate the rear windscreen wiper. Press the switch again for wash. To switch off; press top of switch. 6. Warning Light Test Switch - Pressing the switch with the ignition switched on will illuminate the warning lights to provide a bulb and system check. Note: All warning/indicator lights, with the exception of the main beam, direction indicators, alternator charging, 'Stop' engine, 'Check' engine and service engine soon, will illuminate to provide a bulb and system check when the ignition is on and the test switch is pressed. 7. Bowl Suspension Switch - Press bottom of switch to operate the bowl suspension system. This will allow movement and provide the operator with a smoother ride. Note: Bowl suspension system should only be operated when travelling, never while loading the scraper. 8. Bowl Drop Switch - Press bottom of switch to lower the bowl to the ground. Press top of switch to stop bowl lowering. Note: The bowl drop switch is for use only when the bowl cannot be lowered using the normal hydraulic control. 9. Scraper Engine Diagnostic Request Switch - Operates as a diagnostic request switch when: a. - the engine is not running and ignition is 'On'. Pressing and releasing the switch will flash out the engine codes. Pressing the switch a second time will stop the engine codes flashing. Note: Active codes are displayed initially, followed by inactive codes. Refer to pages 21 to 31 for fault code details.
3-9
10. Ignition and Starter Key Switch - The combined switch operates the ignition and starter motor. The key can only be withdrawn from position '0'. '0' - Ignition switched off. All electrical systems are inoperative. This position also cuts off fuel to shut down both the engines.
START
'1' - Ignition switched on, instruments, gauges and warning lights register as appropriate. All electrical systems are operative. The key must remain in this position whilst operating the machine. '2' - Front starter motor operates. The key when released will return to position '1'.
10
11
1289
11. Scraper Engine Starter Switch - Press switch and hold to crank the engine. Release the switch when the engine starts. Note: Never crank the engine more than 30 seconds continuously. Allow starter at least 2 minutes cooling time between cranking periods to avoid overheating. To prevent serious starter motor damage, do not press the starter switch again after the engine has started. Note: Scraper engine cannot be started unless tractor engine is running. 12. Battery Master Switch - Located on the front right hand side of the tractor frame, adjacent to the battery box. Turn key clockwise to connect the batteries to the electrical circuits. Switch key off and remove when leaving machine unattended.
1126
12
1290
13
13. Diagnostic Test Points - Plug in connector for diagnostic data reader (DDR). There are two diagnostic test points located on the right hand side of the fuse box, under the dash panel. The front most test point is for the tractor engine and the rear test point is for the scraper engine.
3-10
Controls Headlight Dipper, Direction Indicator, Windscreen Wiper/Washer and Horn
340
1
342
3
1. Headlight Dipper and Flasher: Control downwards = Main Beam Neutral Position = Dipped Beam Control Upwards = Headlight Flash 2. Direction Indicator: Control rearwards = Left Indicators Control forwards = Right Indicators 3. Windscreen Wiper/Washer: Position J = Intermittent Wash/ Wipe Position 0 = Neutral Position Position 1 = Wiper Slow Speed Position 2 = Wiper Fast Speed Ring Pushed = Windscreen Wash
341
2
343
4
4. Horn: Button pushed in = Horn Sounds
3-11
Heater
1 2
Blower control (1) is rotated to select one of three blower speeds. Temperature control (3) is rotated to vary heater output temperature. Heater output air is unheated with the control turned fully anticlockwise and heated by turning clockwise. Heater/air conditioner outlets (4) may be adjusted to control air flow output by opening and closing the control flaps. Air direction can be adjusted by rotating complete outlet.
MED
HI
LO
LO OFF
3
OFF HI
AIR
TEMP
1292
Air Conditioner 4
Keep all windows and vents closed. Blower control (1) is rotated to select one of three blower speeds. The air conditioning will not operate if the blower control is not switched on. Temperature control (2) adjusts the air conditioner output temperature. Rotating the control right provides maximum cooling. Heater/air conditioner outlets (4) may be adjusted to control air flow output by opening and closing the control flaps. Air direction can be adjusted by rotating complete outlet.
3-12
4
4 4
1293
Operator's Seat - Air Suspension The air seat only reacts when the driver sits on the seat. When unoccupied, the seat sinks to the lowest position to allow easier access. The incorporated suspension block out maintains the seat in position for driving.
8
The following is the list of controls to adjust the seat: 6
1. Height and slope adjustment, front. 2. Height and slope adjustment, rear. 3
3. Backrest angle adjustment. 4. Weight adjustment.
2
5. Horizontal adjustment (sliderails).
1
7
6. Lumber support adjustment (5 positions). 7. Seat belt anchorage.
4
5 1097
Operators Seat - Air Suspension
8. Armrest adjustment. WARNING Do not attempt to adjust the seat or seat belt while the machine is moving. Loss of control may result. Stop the machine; apply the brakes; then adjust.
3-13
Seat Belt A retractable seat belt is installed on the operators seat. The seat belt requires no external adjustment and allow freedom of movement for proper manipulation of all controls.
WARNINGS Always wear seat belt when operating the machine. Always check condition of seat belts and mounting hardware before operating the machine. Any signs of looseness or wear should be reported to your Service Department or Dealer for repair or replacement immediately. Replace seat belt at least once every three years, regardless of appearance. Do not attempt to adjust the seat or seat belt while the machine is moving. Loss of control may result. Stop the machine; apply the brakes; then adjust.
3-14
495
Typical Retractable Seat Belt
MACHINE CONTROLS Braking
896
Service Brake Pedal
The dual safety brake system installed on this machine is applied using the service brake pedal or park/emergency brake control lever, or automatically should the air pressure drop below 5.2 bar (75 lbf/in²) to slow or stop the machine. For effective braking, the air system pressure gauge should read around the centre of the green zone 7.2 - 8.6 bar (105 - 125 lbf/in²). If the gauge indicates a pressure drop for extended periods or the Low Air Pressure warning light illuminates, the machine should be shut down until the fault is corrected. Service Brake This is a floor mounted pedal operated by the left foot. Depress the pedal as required by speed, load and road conditions to slow or stop the machine. Release the pedal as the machine slows until, when stopped, the pedal is depressed just enough to hold it stationary. Do not 'FAN' the pedal, as this needlessly wastes the air supply in the reservoirs.
1294
WARNING Never release the park/ emergency brake or move the machine until the needle is at least approaching the centre of the green zone.
Park/Emergency Brake This is a modulated brake control valve, located on the right hand dash panel. When the lever is moved towards the 'PARK' position, there is a gradual increase in brake application until the lever is fully back in the 'PARK' position and the brakes are fully applied. The brake lights are automatically applied. To release the brakes, move the lever forward to the 'RELEASE' position. Note: Moving the lever to the 'PARK' position will apply the brakes to stop the machine, but this should be done only in emergencies; never for normal braking. For normal braking the service brake pedal should be used. WARNING Always apply the park/emergency brake before leaving the operator's seat.
3-15
Engine Electronic Foot Pedals There are two electronic foot pedals mounted on the cab floor. The electronic foot pedals provide an electrical signal to the engine's fuel control system in proportion to the degree of pedal actuation. The right hand pedal operates the tractor engine and the left hand pedal operates the scraper engine. The right hand (tractor) accelerator pedal can be operated individually when only the tractor engine is running, however, when both engines are running, it is recommended that both pedals are depressed at the same time to provide equal power to both engines. This action is obtained by depressing the left hand accelerator pedal which, by means of a linking bar, also depresses the right hand pedal. Note: The electronic controlled engine will override the electronic foot pedal position until the engine is warmed up to the correct operating temperature. The engine MUST be started with the foot 'OFF' the electronic foot pedal. HEUI Electronic Management System This machine is equipped with the HEUI electronic management system which continually monitors the engine and warns the operator when a problem develops. The system also takes action to prevent damage to the engine and, provides the serviceman with diagnostic capabilities so that problems can be corrected quickly and easily.
WARNING When turning, depress only the tractor accelerator pedal. If both pedals are depressed, the scraper engine will continue to power forward in the original direction, forcing the tractor unit to tilt over.
3-16
1295
WARNING Before any welding is done on a machine equipped with the HEUI electronic management system, disconnect the following in this order: Battery earth cable, battery supply cable, alternator earth cables, alternator supply cables, front & rear transmission ECU connectors (located behind access door below cab door) and front & rear engine ECU connectors (located on LH side of engine). Turn off battery master switch before disconnecting any components. After welding connect all of the above in the reverse order.
SERVICE ENGINE SOON
7 6 STOP
3
1,2 8 HAZARD
4
9 5
1 - Electronic Control Module (ECM) 2 - Programmable Read Only Memory (PROM) 3 - HEUI Fuel System Injectors 1312
4 - Batteries 5 - Electronic Foot Pedals 6 - Stop Light
7 - Check Light 8 - Diagnostic Switch 9 - Diagnostic Test Points
3-17
HEUI Electronic Management System - Description 1. Electronic Control Module (ECM) - Receives electronic inputs from the driver as well as from sensors that provide information electronically, such as oil pressure and temperature and intake manifold pressure. This information is used to control both the quantity of fuel injected and injection timing. 2. Programmable Read Only Memory (PROM) - Located in the ECM and encoded with the operating software. Additional information is programmed into the EEPROM. This information controls the horsepower rating, torque curve, maximum engine speed and engine protection devices. The ECM processes this information and sends electronic signals to the Electronic Fuel System Injectors where the precise amount of fuel is injected into the engine. 3. Electronic Fuel System Injectors - The injector is a lightweight, compact unit that injects diesel fuel directly into the combustion chamber. The amount of fuel injected and the beginning of injection timing is determined by the ECM. The ECM sends a command pulse which activates the injector solenoid. The injector performs four functions: a - Creates the high fuel pressure required for efficient injection. b - Meters and injects the exact amount of fuel required to handle the load. c - Atomizes the fuel for mixing with the air in the combustion chamber. d - Permits continuous fuel flow for component cooling. Electronic fuel system injectors are self compensating and virtually eliminate engine tune-ups. Note: Never apply 12 or 24 volts directly to terminals on the injector or engine sensors as they will burn out. Before removing injectors, the fuel passages must be blown out to prevent fuel flow from entering the cylinder head.
3-18
HEUI Electronic Management System - Operation When either 'Stop' engine light on the dash panel illuminates, the computer has detected a major malfunction in the respective engine that requires immediate attention. It is the operators responsibility to shut down the engine to avoid serious damage. The machine is equipped with an engine protection system, which records fault codes when an out-of-range conditions is found. The stop engine and check engine lights illuminate when the engine protection system is initiated. If a fault occurs within the tractor engine, resulting in a loss of power and speed, then the scraper engine will rampdown in accordance, as a safety feature, allowing the operator to maintain full control of the vehicle. The operator MUST shut down the engine, at the first safe opportunity, to avoid serious damage. The engine should not be restarted after it has been shut down after activation of the engine protection derate system unless the problem has been diagnosed and corrected. Conditions that will cause the Stop Engine light to come on are; Low coolant level, High coolant temperature, Low oil pressure and High oil temperature. Whenever the Check Engine light or Stop Engine light comes on, the Electronic Management System computer will determine where the problem is and will store this information in its memory. If the malfunction is intermittent, the lights will come on and go off as the computer senses the changing engine condition.
3-19
The operator can check for fault codes by turning the ignition key switch to the 'OFF' position, pressing the diagnostic request switch 'ON' and holding it down, turning the ignition key switch to position '1' and then releasing the diagnostic request switch. Do NOT start the engine. To retrieve any active or inactive (historic) codes recorded, press the diagnostic request switch. The fault codes flash in the following sequence: the red Stop light flashes once, then there is a pause where both lights are off. Then the numbers of the recorded fault code flash in amber (Check light). There is a pause between each number. When the number is done, the red light flashes again. e.g. red flashes once - pause - amber flashes twice - pause - amber flashes three times - pause - amber flashes five times - pause - red flashes once, indicates fault code 235. If the red light flashes once again, this indicates that there are more active codes recorded. If code 111 is flashed, no faults have been detected. All of the active codes will be displayed first. Once all the active codes have been displayed, the red Stop light will flash twice, indicating the start of the inactive code transmission. These are displayed in the same manner as the active codes. On completion of the inactive code transmission, the red Stop light will flash three times. Refer to 'Electronic Fuel System Diagnostic Codes' tables for fault code descriptions. A special diagnostic data reader (DDR) is available that can be plugged into the engine computer memory to extract information related to the cause of the problem. Once the malfunction has been corrected, the Electronic Management System will return the engine to normal operation. The fault code recorded in the ECM memory will remain until it is erased by a technician.
3-20
ELECTRONIC MANAGEMENT SYSTEM DIAGNOSTIC CODES Code
Description
Fault Lamp
Additional Actions Taken
None
1. None. 2. Engine cannot be started.
112
Detectable problems may be present, but do not have a dedicated code: 1. No faults. 2. TRS signal problem not identified with Code 143, 144, 145 or 612. 3. Fan control or transmissionrelay circuit may not be functioning properly. 4. Simultaneously energizing PTO control pins 36 & 37. 5. Main power relay may not be functioning properly. A voltage more than 28V was provided to the ECM.
None
113
A voltage less than 6V was provided to the ECM.
None
114
CTS signal less than 0.127V for more than 0.1 seconds.
Check
115
CTS signal more than 4.6V for more than 0.1 seconds.
Check
121
MAPS signal more than 4.9V for more than 0.1 seconds.
Check
122
MAPS signal less than 0.39V for more than 0.1 seconds.
Check
123
MAPS signal more than 16.7 lb/in² (115 kPa) at low idle.
Check
111
3. Functionality will be degraded. 4. PTO control will be disabled. 5. None - functionality may be affected. Intermittent voltage gives inactive code. Continuous supply causes power down. Intermittent voltage gives inactive code. Continuous supply causes power down. ECM will ignore CTS signal & assume a coolant temp of -29°F (-34°C) for start & 180°F (82°C) for engine operation. Fan control feature is disabled, fan is kept on all the time. ECM will ignore CTS signal & assume a coolant temp of -29°F (-34°C) for start & 180°F (82°C) for engine operation. Fan control feature is disabled, fan is kept on all the time. ECM will ignore MAPS signal & operate engine using program default values. ECM will ignore MAPS signal & operate engine using program default values. ECM will ignore MAPS signal & operate engine using program default values.
3-21
ELECTRONIC MANAGEMENT SYSTEM DIAGNOSTIC CODES
3-22
Code
Description
124
IPS signal less than 0.039V for more than 1 second.
Fault Lamp Check
125
IPS signal more than 4.9V for more than 1 second.
Check
131
TPS signal less than 0.146V for more than 0.5 seconds.
Check
132
TPS signal more than 4.55V for more than 0.5 seconds.
Check
133
TPS & IVS signals disagree. Code caused by an intermittent condition.
Check
134
TPS & IVS signals disagree. Either TPS or IVS is varying: TPS & IVS signal are varying or ECM cannot determine fault/code in allotted time. Code caused by intermittent condition.
Check
135
IVS signal is varying, while TPS signal is constant. Code caused by intermittent condition.
Check
141
Test voltage across VSS too low for more than 0.5 seconds.
None
Additional Actions Taken ECM will ignore IPS signal & use open loop strategy (ECM uses calibrated value based on engine load, speed & temp to estimate it). ECM will ignore IPS signal & use open loop strategy (ECM uses calibrated value based on engine load, speed & temp to estimate it). Engine speed reduced to low idle setting, LO-IDLE-SPEED while code active. Engine speed reduced to low idle setting, LO-IDLE-SPEED while code active. ECM assumes TPS is the conflict source. Engine speed reduced to low idle setting, LO-IDLE-SPEED. Code remains active until engine is shutdown & restarted. Will not recover without cycling the ignition switch. Engine speed reduced to low idle speed settting, LO-IDLE-SPEED. Code remains active until engine is shutdown & restarted. Will not recover without cycling the ignition switch. Engine speed reduced to 50% of throttle requested. Code remains active until engine is shutdown & restarted. Will not recover without cycling the ignition switch. ECM will disable, cruise control, PTO operation, fast idle control & road speed limiting, if enabled and limites engine speed in all gears.
ELECTRONIC MANAGEMENT SYSTEM DIAGNOSTIC CODES Code
Description
142
Test voltage across VSS too high for more than 0.5 seconds.
None
143
None None Check
If condition persists, engine may stop running. Code will cause a not start condition.
151
23 wide-window TRS signals were not received between two narrow signals. TRS signal has detected a voltage spike. Inactive TRS, during cranking when ICP pressure is sufficient to start engine. BAPS signal more than 4.95V for more than 1 seconds.
ECM will disable, cruise control, PTO operation, fast idle control & road speed limiting, if enabled and limites engine speed in all gears. If condition persists, engine will stop running.
None
152
BAPS signal less than 1.0V for more than 1 seconds.
None
154
ATS signal less than 0.127V for more than 0.2 seconds.
None
155
ATS signal more than 4.6V for more than 0.2 seconds.
None
211
OPS signal less than 0.39V for more than 0.1 seconds.
None
ECM uses MAPS signal generated at low idle to determine barometric pressure, calculate altitude & adjust fuel quantity & timing to optimise engine operation and smoke control. If MAPS signal is bad, sea level is assumed. ECM uses MAPS signal generated at low idle to determine barometric pressure, calculate altitude & adjust fuel quantity & timing to optimise engine operation and smoke control. If MAPS signal is bad, sea level is assumed. ECM will ignore ATS signal & assume air temp is 77°F (-25°C). Fan control feature is disabled, fan is kept on all the time. ECM will ignore ATS signal & assume air temp is 77°F (-25°C). Fan control feature is disabled, fan is kept on all the time. ECM will ignore OPS signal & disable oil press warning & critical level alerts of engine warning & protection feature, with an active code.
144 145
Fault Lamp
Additional Actions Taken
3-23
ELECTRONIC MANAGEMENT SYSTEM DIAGNOSTIC CODES
3-24
Code
Description
212
OPS signal more than 4.9V for more than 0.1 seconds.
Fault Lamp Check
213
Secondary throttle device signal is/was less than 0.25V.
None
214
Secondary throttle device signal is/was more than 4.5V.
None
215
VSS signal frequency is/was more than 4,365Hz.
None
216 221
HPS signal voltage less than 0.39V for more than 0.1 seconds. Speed adjustment switch signal is different than ECM expected.
None None
222
Brake switch status signals at pins 44 and 43 differ.
None
224 225
Flash memory fault. OPS signal is/was more than 40lb/in², when key was ON and the engine was OFF.
None None
226 231
HPS voltage signal is/was more than 4.9V for more than 0.1 sec. ECM can't communicate with data link: data link wiring and/or connector fault; interference on data bus; or faulty ECM (eg. dash or WTEC controller).
None None
Additional Actions Taken ECM will ignore OPS signal & disable oil warning & critical level alerts of engine warning & protection feature, with an active code. Device will be disabled. Engine speed will return to idle speed setting. Device will be disabled. Engine speed will return to idle speed setting. ECM will disable, cruise control, PTO operation, fast idle control & road speed limiting, if enabled and limites engine speed in all gears. HPG is disabled when active. ECM will disable, cruise control, PTO operation & fast idle control. TPS position will be used when this code is active. All features using brake signal inputs will be disabled, when this code is active (ie. cruise control, fast idle, HPG, PTO control, CAP & idle shutdown). ECM will ignore OPS signal & disable oil press warning & critical level alerts of engine warning & protection feature, with an active code. HPG is disabled when active. Devices requiring information from data link won't function, including DDR, speedo, tacho etc. Use diagnostic data switch to retrieve codes.
ELECTRONIC MANAGEMENT SYSTEM DIAGNOSTIC CODES Code
Description
241
Injection pressure regulator failed the output circuit check, during the key ON engine OFF standard diagnostic test (ie. voltage drop across pins 17 & 37 was not between 5 - 20 Ohms). Main power relay failed the output circuit check, during key ON engine OFF standard diagnostic test. Transmission relay failed the output circuit check, during key ON engine OFF standard diagnostic test (ie. relay resistance was not between 80 - 120 Ohms as measured across pins 85 & 86). Fan control relay failed the output circuit check, during key ON engine OFF standard diagnostic test. Radiator shutter relay failed the output circuit check, during key ON engine OFF standard diagnostic test. SIL lamp failed the output circuit check, during the key ON engine OFF standard diagnostic test (ie. voltage is not between 0.62 and 12/24V). SEL lamp failed the output circuit check, during the key ON engine OFF standard diagnostic test (ie. voltage is not between 0.62 and 12/24V). Vehicle retarder relay failed the output circuit check, during key ON engine OFF standard diagnostic test. The check lamp circuit failed the output circuit failed the output circuitcheck, during the key ON, engine OFF standard diagnostic test(i.e., voltage is not between .62 and 12/24V). The OTS signal is/was less than 0.2V for more than 0.1 seconds.
243 244
246 256 262
263
265 266
311
Fault Lamp
Additional Actions Taken
None
Engine will not run when this code is active.
None
None.
None
None.
None
None.
None
None.
None
Engine will not run when this code is active.
None
Engine will not run when this code is active.
None
None.
None
None.
Check
The ECM will ignore the OTS signal and use the CTS signal. If both sensors are dysfunctional, the ECM will assume the oil temperature is 29°F(-2°C) for starting and 212°F (100°C) otherwise.
3-25
ELECTRONIC MANAGEMENT SYSTEM DIAGNOSTIC CODES Code
Description
312
The OTS signal is/was less than 4.78V for more than 0.1 seconds.
Check
313
Engine oil pressure is/was below one of the warning limits [5Ib/in² @ 700r/min, 10Ib/in² @ 1400r/min, 20 Ib/in² @ 2000r/min].
Stop
314
The engine oil pressure is/was below one of the warning limits [2Ib/in² @ 700r/min, 5Ib/in² @ 1400r/min, 12 Ib/in² @ 2000r/min].
Stop
315
The engine speed was/is above 3 000 r/min.
Check
316
The ECM was not able to warm the coolant temperature to a satisfactory level within 120 min of operation ,using Cold Ambient Protection strategy (ie. 142°F (61°C) for manual transmissions, 106°F (41°C) for automatic transmissions). The engine coolant temperature is/was above the warning limit [109.0°C (228.2°F)].
None
321
3-26
Fault Lamp
Stop
Additional Actions Taken The ECM will ignore the OTS signal and use the CTS signal. If both sensors are dysfunctional, the ECM will assume the oil temperature is 29°F (-2°C) for starting and 212°F (100°C) otherwise. To avoid irreparable damage to the engine do not continue to operate the engine when this code is active, unless it is unsafe to shut it down. To avoid irreparable damage to the engine do not continue to operate the engine when this code is active, unless it is unsafe to shut it down. This code event is stored as a permanent record in the ECM; it can not be erased with a DDR or the DRB. The last two events will be recorded with an engine hour and mileage stamp.
To avoid irreparable damage to the engine, do not continue to operate the engine when this code is active, unless it is unsafe to shut it down. Note: If the coolant temperature drops below 109°C (228.2°F), Code 321 it will become inactive.
ELECTRONIC MANAGEMENT SYSTEM DIAGNOSTIC CODES Code
Description
322
The engine coolant temperature is/was above the warning limit [112.5°C(234.5°F)].
Stop
323
The engine coolant level is/was below the critical limit [98% of Drawdown].
Stop
324
The engine was shutdown in compliance with the Idle Shutdown Control feature settings. Coolant Temperature Compensation Control is activated.
Stop
325
Fault Lamp
None
331
The IPS signal is/was greater than 3675 Ib/in² (2.5 MPa) for 1.5 seconds.
Check
332
The IPS signal was higher than expected during the standard test (ie. IPS signal was greater than 1.625 V [1160 lb/in² (8 MPa)]).
Check
333
The IPS signal within 362 Ib/in² (2.5 MPa) of the expected value for a period of more than 7 seconds.
Check
Additional Actions Taken To avoid irreparable damage to the engine, do not continue to operate the engine when this code is active, unless it is unsafe to shut it down, Note: If the coolant temperature drops below 112.5°C (234.5°F), Code 322 will become inactive. To avoid irreparable damage to the engine, do not continue to operate the engine when this code is active, unless it is unsafe to shut it down. After the coolant tank has been filled to the proper level, code 323 will switch from active to inactive status, and the event will be recorded and the total number of occurrences will be incremented. Engine is shutdown. Engine power is reduced at a rate of 6% for each degree Celsius above 224.6°F (107°C), due to high coolant temperature. ECM ignores the IPS signal and attempts to control the engine with the desired values (vs. measured). The ECM will ignore the IPS signal and use open loop strategy (i.e., The ECM will use a calibrated value based on engine load, engine speed, and temperature to estimate it). The ECM will ignore the IPS signal and use open loop strategy (i.e., The ECM will use a calibrated value based on engine load, engine speed, and temperature to estimate it).
3-27
ELECTRONIC MANAGEMENT SYSTEM DIAGNOSTIC CODES Code
Description
334
421
The actual injection control pressure differs from the desired pressure by more than 1300Ib/in² (9MPa) for more than 3 secs. (ie. the pressure didn’t get to the commanded pressure within the allocated time frame). The ICP signal was insufficient during cranking speed is at least 130 r/min. (ie. less than 725 Ib/in² (5 MPa) for more than 8 to 10 seconds, varying based on temperature). The HPG control pressure didn’t get to the commanded pressure within the allocated time frame. Injector solenoid #1 circuit fault: High side to low side is open.
422
Injector solenoid #2 circuit fault: High side to low side is open.
Stop
423
Injector solenoid #3 circuit fault: High side to low side is open.
Stop
424
Injector solenoid #4 circuit fault: High side to low side is open.
None
425
Injector solenoid #5 circuit fault: High side to low side is open.
None
426
Injector solenoid #6 circuit fault: High side to low side is open.
None
431
Injector solenoid #1 circuit fault: High side shorted to low side.
None
432
Injector solenoid #2 circuit fault: High side shorted to low side.
None
433
Injector solenoid #3 circuit fault: High side shorted to low side.
None
434
Injector solenoid #4 circuit fault: High side shorted to low side.
None
335
336
3-28
Fault Lamp None
Additional Actions Taken
None
The ECM will ignore the IPS signal and use open loop strategy (i.e., The ECM will use a calibrated value based on engine load, engine speed, and temperature to estimate it). Starting difficulty.
None
HPG is disabled when active.
Stop
The ECM will compensate for engine misfire to keep the engine running. The ECM will compensate for engine misfire to keep the engine running. The ECM will compensate for engine misfire to keep the engine running. ECM will compensate for engine misfire to keep engine running. ECM will compensate for engine misfire to keep engine running. ECM will compensate for engine misfire to keep engine running. ECM will compensate for engine misfire to keep engine running. ECM will compensate for engine misfire to keep engine running. ECM will compensate for engine misfire to keep engine running. ECM will compensate for engine misfire to keep engine running.
ELECTRONIC MANAGEMENT SYSTEM DIAGNOSTIC CODES Code
Description
435
Injector solenoid #5 circuit fault: High side shorted to low side.
Fault Lamp None
436
Injector solenoid #6 circuit fault: High side shorted to low side.
None
451
Injector solenoid #1 circuit fault: High side shorted to ground.
None
452
Injector solenoid #2 circuit fault: High side shorted to ground.
None
453
Injector solenoid #3 circuit fault: High side shorted to ground.
None
454
Injector solenoid #4 circuit fault: High side shorted to ground.
None
455
Injector solenoid #5 circuit fault: High side shorted to ground.
None
456
Injector solenoid #6 circuit fault: High side shorted to ground.
None
461 462 463 464 465 466
Injector #1 failed the contribution test. Injector #2 failed the contribution test. Injector #3 failed the contribution test. Injector #4 failed the contribution test. Injector #5 failed the contribution test. Injector #6 failed the contribution test.
None None None None None None
Additional Actions Taken ECM will compensate for engine misfire to keep engine running. ECM will compensate for engine misfire to keep engine running. ECM will disable an entire bank of cylinders, this includes faulty solenoid & other two on the same pigtail (ie. #1, #2, #3). ECM will disable an entire bank of cylinders, this includes faulty solenoid & other two on the same pigtail (ie. #1, #2, #3). ECM will disable an entire bank of cylinders, this includes faulty solenoid & other two on the same pigtail (ie. #1, #2, #3). ECM will disable an entire bank of cylinders, this includes faulty solenoid & other two on the same pigtail (ie. #4, #5, #6). ECM will disable an entire bank of cylinders, this includes faulty solenoid & other two on the same pigtail (ie. #4, #5, #6). ECM will disable an entire bank of cylinders, this includes faulty solenoid & other two on the same pigtail (ie. #4, #5, #6).
3-29
ELECTRONIC MANAGEMENT SYSTEM DIAGNOSTIC CODES Code
Description
513
Low side to Bank #1 (cylinders 1, 2 & 3) is open.
Check
514
Low side to Bank #2 (cylinders 4, 5 & 6) is open.
Check
515
Bank #1 (cylinders 1, 2 & 3) has a low side short to ground. (ie. excessive current draw).
Check
521
Bank #2 (cylinders 4, 5 & 6) has a low side short to ground. (ie. excessive current draw).
Check
525 612
Injector driver circuit fault has been detected. ECM does not recognise the signal generated by timing disk and TRS, or incorrect TRS installed. The engine family rating code and ECM configuration do not match. Programmable parameters for ECM were never changed from the manufacturing defaults. Programmable parameters for ECM were never changed from the field rating defaults. The engine family rating code and ECM strategy configuration do not match. Programmable parameters for ECM were never changed from the field parameter defaults.
None Check
The drivers for cylinders 1, 2 & 3 are disabled. The ECM will compensate for misfire to keep engine running. The drivers for cylinders 4, 5 & 6 are disabled. The ECM will compensate for misfire to keep engine running. The drivers for cylinders 1, 2 & 3 are disabled. The ECM will compensate for misfire to keep engine running. The drivers for cylinders 4, 5 & 6 are disabled. The ECM will compensate for misfire to keep engine running. Starting difficulty. Engine won't start.
Check
Starting difficulty or low power.
Check
Engine will produce only 25 hp.
Check
Intermittent power loss through main power relay.
None
Engine will produce lowest power in its class. Features won't function. Modify parameters. Starting difficulty or low power. Reprogram ECM. Engine will produce lowest power in its class. Features won't function. Attempt to reprogram the ECM. Main power relay is reset. ECM will power down. Operation will be erratic in a power down/reboot loop.
614 621 622 623 624
626
3-30
Fault Lamp
Check None
Additional Actions Taken
ELECTRONIC MANAGEMENT SYSTEM DIAGNOSTIC CODES Code
Description
626
Intermittent power loss through main power relay.
Fault Lamp None
631 632 655
Self-test ROM fault. Self-test RAM fault. Incompatible programmable parameters list.
Check None None
661
Programmable parameter memory (RAM) content is corrupt.
None
664
Incompatible software calibration level.
None
665
Programmable parameter memory (ROM) content is corrupt.
None
Additional Actions Taken Main power relay is reset. ECM will power down. Operation will be erratic in a power down/reboot loop. Replace ECM. Replace ECM. Starting difficulty or low power. Features will not function. Starting difficulty or low power. Features will not function. Replace ECM. Starting difficulty or low power & features will not function. Attempt to reprogram ECM. Starting difficulty or low power & features will not function. Attempt to reprogram ECM.
3-31
Steering Full hydraulic type steering is provided by two single stage, double acting steering cylinders. To steer the front wheels, rotate the steering wheel in the desired direction to the required radius of turn. The front wheels will turn only as the steering wheel is turned and at a rate of turning directly proportional to steering wheel speed. The front wheels will stop and hold position when the steering wheel is stopped. To return the front wheels to the straight ahead position or to the opposite direction, turn the steering wheel in the opposite direction. Allow sufficient room when turning, to avoid scuffing the tyres against kerbs or other obstacles. Turn wide enough to avoid other vehicles parked near intersections. If possible, avoid any debris on the road to prevent unnecessary abuse of the tyres.
WARNINGS Improper steering control unit repair or hose connections can cause sudden and forceful steering wheel movement when engine is started. Keep hands off steering wheel and ensure area around the scraper is clear when starting the engine. When turning, depress only the tractor accelerator pedal. If both pedals are depressed, the scraper engine will continue to power forward in the original direction, forcing the tractor unit to tilt over.
3-32
1296
Steering Wheel Rotation
Transmission This machine is fitted with a Funk DF158 Powershift transmission equipped with the Funk DF158 Electronic Control Unit (ECU), to operate the transmission. Upshifting and downshifting are the main functions of the ECU. Another function of the ECU is the capability to communicate with a panel mounted gear/diagnostic display unit.
WARNING Before any welding is done on the machine, disconnect battery cables from terminal posts (ground cables first) and electrical connections at the ECU to avoid damage to electrical components. Turn off the battery master switch before disconnecting any components. General Theory of Operation The transmissions performance is determined by the various inputs to the ECU. Based upon these inputs the ECU commands the transmission so that maximum performance can be achieved under the present operating conditions. All functions of the ECU are under software control. Switching the vehicle's ignition to the 'On' position supplies power to the ECU and related system components from the batteries, through the transient voltage protection (TVP) module. At this point the ECU begins to monitor all inputs and outputs. If a known conflict in inputs or a fault condition is detected, the ECU will command the transmission to stay in Neutral regardless of the shift lever position. A flashing error code will be displayed on the gear/diagnostic display unit, and will remain displayed until the error has been corrected and the shift lever cycled back through the Neutral position. If no error conditions are detected, the ECU will calculate a speed ratio between the engine speed (derived from the engine speed MPU signal) and the transmission output speed (derived from the transmission output speed MPU). Based upon this speed ratio and the combination of inputs from the shift lever and any other
3-33
applicable inputs, the ECU will select the proper transmission gear and command the transmission to shift to this gear. The gear/diagnostic display unit will show the actual gear selected. The transmission uses electrohydraulic valves to control the operation of the transmission. The solenoids controlling the transmission clutches (solenoids A through D and 1 through 4) are driven by a pulse width modulated (PWM) signal that produces proportional pressure/flow changes. This is achieved by pulsing the solenoid at a constant frequency and varying the 'on time' of each cycle. The ratio of 'on time' to cycle time is called duty cycle. These transmission solenoids are driven with a maximum duty cycle considerably less than this and ramped up to full on. The initial duty cycle is dependant upon several factors and is not a preset value. The process of modulating these clutches greatly enhances shift quality.
3-34
System Components Description and Operation 1. Electronic Control Unit (ECU) - There are two electronic control units located beneath the cab. The ECU is the brain of the system. It is responsible for the logic, computation, and decision making processes and the control of the transmission based on these calculations. How the ECU performs is determined by software programmed into the ECU's memory. The ECUs application is specific, therefore ECUs from different vehicles are not interchangeable. 2. Transient Voltage Protection (TVP) Module - The TVP module is responsible for supplying electrical power to the system and protecting the systems electrical components. It provides 40 volt limiting during an electrical load dump malfunction and protection from reverse battery connection. Protection is provided only while the ignition is switched on, thus energizing an internal relay which provides an electrical connection between vehicle power and the protection device inside the module. 3. Engine Speed Magnetic Pickup (MPU) - The engine speed MPU is located in the input housing of the transmission. The MPU provides a signal to the ECU which represents engine speed. This signal is of a sinusoidal nature, varying in amplitude and frequency relative to engine speed. The ECU conditions this signal and converts it into pulses. It then measures the width of these pulses in microseconds, and based on a preprogrammed value in the ECU which represents the number of pulses per revolution of the engine, calculates the engine speed. 4. Transmission Output Speed MPU - The transmission output speed MPU is located in the rear housing of the transmission and provides a signal to the ECU which represents transmission output speed. This signal is of a sinusoidal nature, varying in amplitude and frequency relative to output speed. The ECU conditions this signal and converts it into pulses. It then measures the width of these pulses in microseconds, and based on a preprogrammed value in the ECU which represents the number of pulses per revolution of the transmission output, calculates output speed.
3-35
5. Gear Shift Lever - The transmission provides seven forward ranges, one reverse gear and a neutral position. The lever is detented in the Forward, Neutral and Reverse positions with a positive lock only in the Neutral position. To move out of the Neutral position, the operator must pull up on the collar.
F N R
The gear shift lever is spring loaded to the centre position. 'Bumping' the shift lever to the upshift or downshift direction sends a corresponding signal to the ECU.
WARNING Do not allow the vehicle to coast in Neutral. This practice can result in severe transmission damage. When Reverse is selected an audible alarm sounds. This feature warns personnel to the immediate rear of the machine that the operator has shifted the transmission to Reverse.
WARNING Always select Neutral and apply the parking brake before leaving the operator’s seat. 6. Wiring Harness - The wiring harness consists of the various wires needed to provide electrical connections between the components of the system. All connectors in the system are sealed to protect the connections from the environment and to prevent corrosion of the contacts, which would eventually result in a failure.
3-36
1297
Gear Shift Lever
7. Gear/Diagnostic Display Unit - A dash mounted gear/diagnostic display unit provides the operator with information about the system. Under normal operating conditions the display shows the actual forward or reverse transmission gear and the state of the disconnect. 120
50
TRANS OIL
16 18
140 0 150
OIL
TEMP
AIR
1298
25 TRANS PRESS
SERVICE PRESS
Gear/Diagnostic Display Unit
When an error has occurred, the display will flash an error code indicating that a problem has been detected in the system. This error code will continue to flash until the shift lever has been placed in Neutral. Once the ECU has detected a legal Neutral condition, the error will clear and 'NEU' will be displayed. Once the shift lever is moved out of Neutral the error will once more begin to flash. This condition will continue until the error has been corrected and the shift lever cycled through Neutral again. If the error is related to the Neutral signal making it impossible for the ECU to see a legal Neutral signal, the error will continue to flash even in the Neutral position until it is resolved. 8. Diagnostic Test Points - The diagnostic test points for the tractor and scraper transmissions are located at the front of the fuse box, under the dash panel.
GENERAL TRANSMISSION OPERATION Watch for wide deviations from normal readings on the transmission oil temperature gauge during machine operation. If the transmission oil temperature gauge shows oil temperature consistently rising above the green zone under normal operating conditions; check for external causes. If none are evident shift to Neutral (N) and operate the engine at 1 200 - 1 500 rev/min. If the transmission oil temperature does not decrease into the green zone within 2 or 3 minutes, the cause of the overheating should be corrected before the machine is operated further. Watch the oil temperature gauge when operating on upgrades, also. If the oil temperature goes into the yellow zone, select the range which will limit upshifts to the highest range in which the transmission will operate closest to the normal temperature range (green zone). If upshifting must be consistently limited to ranges lower than normal for the loads and the grades encountered to prevent overheating the transmission oil, the causes should be determined and corrected.
3-37
Power-Locking Differential (Optional) The power-locking differential allows the operator to increase traction on slippery surfaces where normal differential action between drive wheels is not desirable. Note: Continued wheel spinning without the Power Locking Differential applied will result in rapid wear of pinion bushings and tyres. If one wheel spins on a slippery spot with the other wheel on firm footing, decelerate the engine until the spinning wheel stops then depress the power-locking differential pedal. This provides a locking action between the axles, wheels and differentials. 876
Precautions Note: The following precautions should be observed when using the power-locking differential. Failure to adhere to these practices amounts to abuse of the equipment. 1. The power-locking differential may only be used in first gear. 2. Always apply the power-locking differential before engaging in a potential wheel spinning situation (except in a turn). 3. Never apply the power-locking differential while in a turn or when steering is required. 4. Never apply the power-locking differential with one wheel spinning rapidly on a slippery spot. Decelerate the engine until the spinning wheel stops before locking the differential. 5. Never apply the power-locking differential at speeds in excess of maximum speed attainable in first gear and engine at wide open throttle. For maximum utilisation of the power-locking differential, it is suggested that it be applied when entering the cut and left on until leaving the cut, wherever possible. Apply power-locking action only as required for added traction to prevent bogging down in soft footing either before starting to move, or when momentum has been lost.
3-38
Hydraulic System Controls
1 4
2 3
1299
Hydraulic System Controls
Located to the right hand side of the operator's seat are three hydraulic control levers. The front lever operates the bowl, centre lever the apron and the rear lever the ejector. Operation of these controls are as follows: 1. Bowl - Pull the control lever to raise the bowl and push to lower. The control lever will return to the 'Neutral' (centralised) position when released. The bowl can also be lowered by pressing bowl drop switch (4), but this should only be used in an emergency, when the bowl cannot be lowered using the bowl control lever. 2. Apron - Pull the control lever to raise the apron and push to lower. The control lever will return to the 'Neutral' (centralised) position when released. 3. Ejector - Pull the control lever to raise the ejector and push to return. A detent will hold the control lever in the return position until travel is complete. Controlling the bowl, apron and ejector with these levers is simple and easy as the operator is merely moving the valve spools to which they are connected, to direct hydraulic oil to the appropriate cylinders. For maximum cylinder operating efficiency, the engine should be operated at maximum rated speed, and control levers moved to their extreme positions. Note: Do not use two levers at one time. To do so will cause the component whose control plunger precedes the other in the line to operate, while the other receives no hydraulic pressure. e.g. When unloading, pulling the apron and ejector levers at the same time will allow the ejector to raise while the apron remains down.
3-39
Twin-Hitch Control (Optional) The twin-hitch attachment is optional and permits the operators of two scrapers to assist each other in loading. A bail is attached to the front end of the tractor and a bail to the rear bumper of the scraper. The bail at the front end is raised and lowered by an air operated cylinder controlled by a valve in the operators compartment. To connect the two scrapers for loading, position the rear tractor twin hitch push plate against the rear bumper of the scraper ahead, with its bail in the 'Raised' position. Be sure that the scrapers are aligned end-to-end in a straight line. Move the bail control lever on the rear scraper to the 'Lower' position and lower the bail over the front scraper bumper hook. To disconnect the scrapers, move the rear scraper bail control lever to the 'Raise' position. The bail operating cylinders will lift the bail clear of the front scraper hook as soon as any forward pulling force exerted on the bail by the front scraper hook is released.
WARNING Never park or leave a scraper with the bail in the raised position. The bail can be dropped by accidental lever movement or loss of air pressure, which could be dangerous to personnel in the area.
3-40
915
Twin Hitch Control Lever
4 - Operating The Scraper 4-1
OPERATING THE SCRAPER Pre-Starting Inspection * Before the engine is started, ensure the machine is ready for operation. * The machine should be in a level position to permit accurate checking of fluid quantities in the engine and other components. * Make sure the parking brake is applied and block wheels securely to prevent accidental movement of the machine while checking component levels. * Test all lights, warning signals, controls and instruments for proper operation. * Walk around the machine and carry out the Inspections and Component Checks described in the drawing opposite and on the following pages.
OPERATORS COMPARTMENT AND LADDERS Check for cleanliness. Check seat belt. TYRES Check condition and inflation. DIFFERENTIAL Check for leaks. PIVOT AREA Check for debris. STEERING CYLINDERS Check for debris and damage.
BOWL CUTTING EDGES Check for wear or damage.
HYDRAULIC SYSTEM Check oil level. Check for leaks. RIDE CYLINDERS Check for debris and damage. WHEEL PLANETARIES Check for leaks. TRANSMISSION Check for leaks.
BOWL AND APRON CYLINDERS Check for debris and damage. REMOTE FILTERS Check for leaks.
EJECTOR CYLINDER Check for debris and damage.
FUEL TANKS Check fuel level.
DIFFERENTIAL Check for leaks.
WHEEL PLANETARIES Check for leaks
4-2
RADIATOR Check coolant level. Check for leaks and debris in the fins.
761
TRANSMISSION Check for leaks.
RADIATOR Check coolant level. Check for leaks and debris in the fins.
Component Checks - Tractor 1. Engine - With the engine off, check the oil level. Oil should be above the 'Low' mark but not over the 'Full' mark. Add oil if low. 2. Fuel Strainer - Drain sediment and water from sump until fuel runs clear. 762
1
4
890
3. Radiator - Check coolant level. Add if low. WARNING Press button in centre of cap to bleed pressure before removing cap completely. Fill to bottom of filler neck.
763
2
5
041
In subfreezing temperatures, be sure that the coolant contains sufficient antifreeze. 4. Air Cleaner Restriction Gauge Check air cleaner restriction gauge, replace elements if required. 5. Tyres - Carefully inspect all tyres for cuts, bruises, or other damage and proper inflation for the loads to be carried. Inflate all tyres to the recommended pressure while cold.
764
3
766
Typical Air Tank Drain Cock
6
6. Air Tanks - Make sure all drain cocks are securely closed.
4-3
7. Hydraulic Tank - Cold Oil Level The oil should be at the 'Cold Level' mark on the sight gauge. Add oil, if low. Note: Remove filler cap slowly to bleed any air from the hydraulic tank. 8. Transmission - Cold Oil Level This check is made only to determine if the transmission contains sufficient oil for safe starting. Remove cover to access dipstick and make sure there is some oil showing on the dipstick before starting the engine. Add oil if low.
904
7
1096
9
903
8
472
10
9. Fuel Tank - Check fuel level. Tank should be filled at end of each shift to prevent condensation. 10. Seat and Seat Belts - Adjust the seat position and lap belt as required to allow complete machine control at all times with minimum fatigue. Make sure the seat belt does not restrict movement for proper machine operation. Note: Firmness control will not operate until air pressure has built up.
4-4
Component Checks - Scraper 1. Engine - With the engine off, check the oil level. Oil should be above the 'Low' mark but not over the 'Full' mark. Add oil if low. 2. Fuel Strainer - Drain sediment and water from sump until fuel runs clear.
1
762
4
890
3. Radiator - Check coolant level. Add if low. WARNING Press button in centre of cap to bleed pressure before removing cap completely. Fill to bottom of filler neck.
763
Typical Fuel Filter Drain
2
5
041
In subfreezing temperatures, be sure that the coolant contains sufficient antifreeze. 4. Air Cleaner Restriction Gauge Check air cleaner restriction gauge, replace elements if required. 5. Tyres - Carefully inspect all tyres for cuts, bruises, or other damage and proper inflation for the loads to be carried. Inflate all tyres to the recommended pressure while cold.
764
3
766
Typical Air Tank Drain Cock
6
6. Air Tank - Make sure drain cock is securely closed.
4-5
7. Transmission - Cold Oil Level - This check is made only to determine if the transmission contains sufficient oil for safe starting. Remove cover to access dipstick and make sure there is some oil showing on the dipstick before starting the engine. Add oil if low.
903
7
1096
8
8. Fuel Tank - Check fuel level. Tank should be filled at end of each shift to prevent condensation.
4-6
Engine Operation Do not place engine under FULL LOAD at FULL SPEED IMMEDIATELY after starting. ALWAYS allow the engine to fully circulate lubricant and warm up gradually before operating at full speed and full load. Operate engine at top rated speed when maximum power is needed for the load. Operation of the engine below top rated speed can occur during gear shifting due to the difference of ratios between transmission gears, but engine operation MUST NOT be sustained more than 30 seconds at full throttle below top rated speed. Under normal operating conditions, both engines should be accelerated equally to apply equal power to both the tractor and scraper wheels by depressing both engine accelerators at the same time. In a sharp turn however, use only front engine power, because the scraper wheels tend to push the tractor sideways. NEVER idle the engine more than 5 minutes at a time; shut it off. If any gauge operates outwith its normal operating range or a warning light illuminates, shut engine down immediately and report to service or maintenance personnel. WARNING Never start the engine indoors unless proper exhaust ventilation is provided to remove deadly exhaust gases. Once the engine is running, move the machine outdoors as soon as possible. Exhaust gases are hazardous and can cause unconsciousness and death. Operating the engine beyond high idle speed can cause severe engine damage. The engine speed must not exceed 2 400 rev/min under any circumstances. When descending a steep grade, use a combination of transmission gears, retarder and service brakes to control the vehicle and engine speed.
4-7
STARTING THE ENGINES F N R
Above 0° C (32° F) Attention to the warning lights and instruments when starting the engine, and operating, will help the operator monitor the machine systems and components. Note: Always start the tractor engine before starting the scraper engine, as the air compressor and alternator are driven by the tractor engine.
1300
1
1302
4
1141
2
314
5
1301
3
Tractor Engine 1. Make sure the park/emergency brake control lever is in the 'Park' position. 2. Turn the master switch to the 'On' position. 3. Make sure the scraper control levers are in the 'Neutral' position. 4. Make sure the transmission shift selector is in the 'Neutral' position. 5. Press horn control to sound horn. Note: Always sound horn before starting engine or operating any control.
4-8
6. Turn key switch to clockwise to the first position 'IGN'. Press the warning light test switch to test operation of the warning lights.
0 1
Turn the key further clockwise against spring pressure to crank the engine. Release the key as soon as the engine starts firing.
2
Note: Never crank the engine more than 30 seconds continuously. Allow starter at least 2 minutes cooling time between cranking periods to avoid overheating.
6
249
7. The amber 'Check Engine' and red 'Stop Engine' lights should come on, and then go out after 6 - 10 seconds. If the amber 'Check Engine' light does not go out, have the system checked out as soon as possible. If the red 'Stop Engine' light does not go out after 6 - 10 seconds, or illuminates during operation, stop the engine immediately.
SERVICE ENGINE SOON
STOP
1303
7 8. Do not release the parking brake until the air pressure gauge registers a pressure of 6.2 bar (90 lbf/in²) or more.
379
8
4-9
Scraper Engine F N R
Attention to the warning lights and instruments when starting the engine, and operating, will help the operator monitor the machine systems and components. Note: Always start the tractor engine before starting the scraper engine, as the air compressor and alternator are driven by the tractor engine.
1300
1
3
1302
1. Make sure the park/emergency brake control lever is in the 'PARK' position. START
2. Make sure the scraper control levers are in the 'Neutral' position. 3. Make sure the transmission shift selector is in the 'Neutral' position. 4. Press engine start switch and start the engine. Release the switch as soon as the engine starts firing.
4-10
Note: Never crank the engine more than 30 seconds continuously. Allow starter at least 2 minutes cooling time between cranking periods to avoid overheating. To prevent serious starting motor damage, do not press the start switch again after the engine has started.
1301
2
1304
4
5. The amber 'Check Engine' and red 'Stop Engine' lights should come on, and then go out after 6 - 10 seconds. If the amber 'Check Engine' light does not go out, have the system checked out as soon as possible. If the red 'Stop Engine' light does not go out after 6 - 10 seconds, or illuminates during operation, stop the engine immediately. STOP
1305
5
4-11
Starting the Engine at Low Ambient Temperatures (Below 0° C (32° F) Follow steps 1 through 6 for 'Above 0° C (32° F)' described on page 4-8 then proceed as follows: 1. Fill starting aid reservoir if required. To fill, raise the cover of the reservoir and push the filler can, head downwards, firmly over the filler valve of the reservoir. Fill the transparent reservoir up to, but not over the 'MAXI' mark. 2. Turn key switch clockwise to position '1'. Press warning light test switch to test operation of warning lights. Turn key further clockwise against spring pressure to position '2' to crank the engine. When cranking has commenced, operate the starting pilot pump. When the engine starts and runs, release starter key and stop pumping. If necessary, further short applications can be made in order to keep the engine running. DO NOT use excessive starting fluid during starting or after the engine is running. 3. Follow normal starting procedures but limit engine speed to 1 200 rev/min and run for two to five minutes, depending on the temperature. Before moving, operate the hydraulic controls to circulate warm oil throughout the hydraulic systems.
4-12
WARNING Starting fluid is poisonous and flammable. Breathing vapours or repeated contact with skin can cause personal injury. Use only in well ventilated areas. Use with care to avoid fires. Do not smoke when changing cylinders. Do not store cylinders in the operators compartment, living areas, in direct sunlight or at temperatures above 490 C (1020 F). Discard cylinders properly. Do not puncture or burn cylinders. Keep cylinders out of the reach of unauthorized personnel.
Starting the Engine with Jumper Cables WARNING Hazardous hydrogen gas and sulphuric acid. Check for required voltage and polarity connections to discharged batteries. Excessive booster voltage and/or incorrect jumper cable connections, open flame, lighted cigar, or other ignition source can cause battery explosion/fire. Keep all sources of ignition away from batteries. Do not lean over batteries, and wear eye protection at all times to prevent personal injury. Do not jump start a vehicle by using arc welding equipment. Currents and voltages are dangerously high and cannot be sufficiently reduced to make the method safe. Note: Be sure machines are not touching each other. Use cables that are equal to cable size on the machine, for example (1/0) or (2/0). If jumper cables are used to start an engine, be sure to follow this procedure: Connect one end of a jumper cable, usually coloured red, to the discharged battery 'POSITIVE' (+) post. Connect the other end of the same cable to the 'POSITIVE' (+) post on the booster or charged battery. Connect one end of the second cable, usually coloured black, to the 'NEGATIVE' (-) post of the booster battery. Connect the other end of the 'NEGATIVE' (-) cable to machine frame for grounding so that if a spark occurs, it is away from battery fumes (explosive hydrogen). Check for cause of failure on the dead battery.
4-13
Pre-Operating Checks Make sure all cab glass, mirrors and lights are clean. Test all controls to ensure they are functioning properly. Check all gauges and stop the engine immediately if any gauge is operating outwith its recommended operating range. Select 'REVERSE' momentarily on the transmission shift selector to make sure the reverse alarm sounds. 1. Transmission (Tractor and Scraper) - Hot Oil Level - Adjust bowl height to level the transmission, apply the parking brake and securely block the road wheels. With the engine idling, transmission in 'Neutral' and at normal operating temperature, the oil level should be up to, but not over, the 'FULL' mark on the dipstick. Add oil if low. Do not overfill.
903
1
912
2
2. Hydraulic Tank - Hot Oil Level - With the scraper on a level surface, operate the bowl, apron and ejector controls several times to warm the hydraulic oil and fill all hydraulic lines and cylinders. With the bowl on the ground, apron down and ejector returned, shut off the engine and allow thirty seconds for ride cylinders to retract and steering accumulator to discharge oil back to the tank. Check the oil level in the hydraulic tank sight gauge. If oil level is below the 'Cold' level, loosen the filler cap slowly to release any pressure developed in the tank. Remove filler cap and add oil until oil level is between the 'Cold' and 'Hot' marks.
BRAKE FUNCTION CHECKS In addition to the above checks, the following brake function checks can be carried out to determine if both the service and park/emergency brake systems are functional before operating the machine.
4-14
WARNING Make sure the area around the machine is clear of personnel and obstructions before carrying out these checks.
WARNING If the machine moves during these checks, stop the machine, apply the parking brake and do not operate until the fault is corrected. Note: The following checks are NOT intended to measure maximum brake holding ability. If NEW brake pads are fitted, they MUST be burnished as per the manufacturers recommendations before carrying out the checks. Service Brake Holding Ability Check With the bowl in the 'Fully Raised' position, depress service brake pedal and select 1st gear on the transmission shift selector. Move the park/emergency control lever to the 'Release' position. Depress front engine accelerator control and accelerate engine to 1 350 rev/min. The machine should not move. Decelerate the engine, shift transmission to 'Neutral' and apply the park/ emergency brake before releasing the service brake. Park/Emergency Brake Holding Ability Check With the bowl in the 'Fully Raised' position, move the park/emergency control lever to the 'Park' position and select 1st gear on the transmission shift selector. Depress front engine accelerator control and accelerate engine to 1 350 rev/min. The machine should not move. Decelerate the engine, shift transmission to 'Neutral' and move the park/emergency control lever to the 'Park' position. Note: Brake holding effort required to hold a machine static at a specific engine speed, can vary from machine to machine due to differences in engine performance, powertrain efficiency, etc., as well as differences in brake holding ability. Note: As an indication of system deterioration, engine speed at which point the machine moved, with the service or park/emergency brakes applied, can be compared against engine speed your machine was able to hold to on a previous check.
4-15
Driving and Stopping Before driving off observe all instruments and warning lights. All instruments should operate in their normal range and all warning lights should be out. Make sure the area around the machine is clear of personnel and obstructions before driving off. In the first few minutes of travel, check carefully for the required steering, braking, engine and transmission power response for maximum operating safety. 709
Raise Bowl Fully
1
1. Make sure the bowl is fully raised and the hydraulic control levers are in the 'Neutral' position. 2. Apply the service brake and release the park/emergency brake. 3. Select the driving direction required.
2
1306
F N R
4-16
1307
3
4. Sound the horn; two blasts for forward and three blasts for reverse. F N R
314
792
793
4
5
6
1308
1300
WARNING There is no mechanical connection between the engine and wheels on machines with converter transmissions. The parking brake must always be applied when the engine is switched off.
5. Release the service brake, apply equal power to both the tractor and scraper wheels by depressing both engine accelerators at the same time and move off.
7
8
6. To stop the machine release the accelerator pedals and depress the service brake pedal. Release the service brake as the machine slows until, when stopped, the pedal is depressed just enough to hold the machine stationary. Do not 'Fan' the brake pedal as this needlessly wastes the air supply in the air reservoirs. 7. When the machine has stopped, shift the transmission to 'Neutral', apply the park/emergency brake and release the service brake. 8. If the service brake does not stop the machine. Apply the park/ emergency brake. This should only be applied to stop the machine in an emergency.
4-17
Stopping the Engines 1. Lower the bowl to the ground, lower the apron and return the ejector. Place all control levers in the 'Neutral' position. 2. Make sure the park/emergency brake control lever is in the 'PARK' position. 1301
1
380
4
1300
2
281
5
3
1140
6
3. Make sure the transmission is in 'NEUTRAL'. Note: Test the application of the brake shoes by momentarily shifting the transmission to 1st gear and accelerating the engine sufficiently to determine that the brake shoes are locked in the 'Applied' position. Return transmission shift lever to the 'Neutral' position. 4. Allow the engine to idle 3 to 5 minutes after a full load operation before shutting it off. This allows the engine to cool gradually and uniformly.
F N R
5. Turn the ignition key switch to the 'OFF' position to shut off fuel and stop engine.
4-18
6. Turn the battery master switch to the 'OFF' position.
1302
Parking When parking the machine overnight, or for an extended period, the following procedure in addition to that given in 'Stopping the Engine' will help maintain it in good condition for subsequent use: 1096
1
3
797
1. Fill the fuel tanks completely, to prevent condensation. If security kit is supplied, keep it locked. 2. Always park the machine on level ground where possible. If the machine must be parked on a grade, position the machine at right angles to the grade and block the wheels securely.
796
2
766
Typical Air Tank Drain Cock
4
3. Place the transmission in 'Neutral' and lower the bowl and apron and return ejector completely. Note: If the scraper is to be parked for an extended period, it is good practice to place planks or timbers under the bowl edges to keep the edges off the ground. 4. Open the drain cocks on all air tanks and leave open so that all condensation will drain completely. This is especially important in cold weather operation.
4-19
5. If below freezing temperatures are expected, make sure the cooling system has sufficient antifreeze to prevent the coolant freezing. If antifreeze cannot be added to the cooling system, drain the cooling system completely. 6. Check all tyres, hoses, wiring, tubing and fittings for cuts, ply separation, abrasion, fraying, or other damage or deterioration. Inspect for structural damage to the cab, body and chassis. Attach warning signs to the steering wheel or to a control to alert others if lubricant has been drained, batteries removed etc.. 7. Clean dirt, mud or other matter from steering, bowl, apron and ejector cylinders, particularly from the piston rods. Take care not to damage polished surfaces. 8. Lubricate grease points at the intervals and points specified and with grease specified in Section 8, Lubrication and Servicing, in this handbook. Note: The above grease points must be lubricated at the proper intervals without fail.
4-20
5 - Working The Scraper 5-1
WORKING THE SCRAPER Standard Functions 1. Before entering the cut, raise the apron. Upon entering the cut, lower the scraper bowl until the blades reach the desired depth of cut. 2. When the bowl is filled, lower the apron. Raise the bowl sufficiently to clear the dirt that has accumulated in front of the bowl.
714
1
716
3
715
2
717
4
3. Raise the scraper bowl to the desired travelling height and proceed to the fill. 4. At the fill, lower the scraper bowl to the desired depth of fill. Raise the apron no higher than is necessary to clear the load being dumped then use the ejector to finish dumping the load. Lower the apron, return ejector and raise the scraper bowl to the travel height.
5-2
Loading Self Loading 1. When self loading, apply the power locking differential (if fitted). 2. Raise the apron 300 - 600 mm (1 - 2 ft) above the scraper blades. 876
1
1269
3
3. Lower the scraper bowl until the cut depth is reached. 4. During loading, adjust the apron opening to prevent dirt from piling up in front of the scraper bowl. The opening should be large enough to allow the material to enter the bowl, but not so large as to allow the material to enter and then fall out. The apron opening varies for each type of material being loaded.
1268
2
721
4
5-3
5. After the scraper is fully loaded, raise the scraper bowl until the blades are 25 - 50 mm (1 - 2 in) above the ground. Continue to travel out of the cut with the scraper bowl at this height until the dirt that has accumulated in front of the scraper is dispersed. 6. Disengage the power-locking differential (if fitted). Note: If trouble is encountered in fully closing the apron, the operator will find that moving the apron lever to the lower position shortly before the bowl is completely loaded will allow the dirt flowing into the bowl to push against the apron and close it immediately when the bowl is raised.
1270
5
876
6
Self-Loading Hints When opening a pit, the operator should take the first few cuts to shave the pit, making it as flat as possible so a good working surface is available. At this time also, the cuts should be made to afford good drainage in the right direction. Subsequent scraper loads can then be obtained in the fastest manner without having to worry about the contour of the pit and drainage problems. As the operator proceeds through the cut, he will find that inequalities in the surface, over which the machine is moving, and soil conditions make it necessary for the operator to raise and lower the scraper blades to maintain the same depth of cut. The good operator will learn to raise or lower the blade just enough to allow these variations and to maintain a uniform speed. A common mistake is 'Overcontrol'; that is lifting the blade too high, which allows the machine to move forward at an excessive speed, or dropping the blade too low, which stops the machine completely. Overcontrol may be avoided by using snappy , quickly repeated movements of the scraper bowl control lever. This brings the blade to the proper level necessary without overcontrol and causing the surface being cut to become rough or scalloped.
5-4
Push-Loading BACKTRACK LOADING
When push-loading hard, rocky or frozen material, apply only enough power to front scraper tractor to operate the hydraulic system.
CHAIN LOADING
724
Push-loading a scraper with a crawler tractor is recommended for loading most materials, because of the extra traction of a crawler tractor.
SHUTTLE LOADING
Backtrack loading is usually used where the cut is fairly short and it is impractical to load both ways. Chain loading is usually used where the cut is fairly long, making it possible to pick up two or more scraper loads without backtracking. Shuttle loading is usually used for short cuts where it is practical to load both ways. In many cases a combination of any two of the above can be used to great advantage for increasing production. Push-Loading Hints 1. Eliminate lost time by keeping pusher tractor at a minimum. To do this, the scraper should pull alongside the pusher tractor when it is loading another machine so the scraper will be readily available when it is its turn to load.
725
2. Use fast loading methods. A good example of this is step loading in wide cuts. To step load, a cut is taken on both sides of a scraper wide strip leaving a step in the middle where a third machine can be loaded quickly. 3. Use proper blade combinations for the type of cut and soil. 4. Always load and unload DOWNHILL where possible. This greatly reduces the amount of tractive power required. 5. Eliminate all unnecessary turns. When working a job with a cut on each side of the fill, the figure 8 loading and hauling cycle can be used to great advantage. This cycle eliminates one turn per load.
726
6. When working on a job with a series of cuts and fills, the 'S' layout can be used to great advantage in eliminating turns. In using either method, remember to always cut on the DOWNHILL travel.
5-5
Hauling After the machine is fully loaded and has reached the haul road, the operator should raise the bowl to the travel height and proceed to the fill or dumping area in the highest gear range practicable. The bowl travel height should be no higher than necessary to clear any obstacles that might be on the haul road. A low bowl height permits the operator better control of the machine by keeping its centre of gravity low and prevents the loss of time necessary to lower the bowl as the machine approaches the fill area. The best bowl travel height, if possible, is the height at which the bowl must be when the load is spread.
716
When travelling over a slippery haul road, keep the blades as close to the road as possible. Doing this allows the operator to drop the bowl and help stop the machine in case of an emergency. Shift to first gear and engage the power locking differential (if fitted) as required to maintain good traction enroute, unless steering is required. Do not engage at speed in excess of speed attainable in first gear and engine at wide open throttle. While travelling over the haul road, avoid holes and large obstacles which may damage the machine's tyres. When making a sharp turn, do not cut the corner too close but allow for the scraper length so as not to pull the scraper wheels off the road. 876
5-6
Watch Bowl Height
Spreading 1. On approaching the fill area, the operator should lower or raise the scraper bowl to the depth of fill desired. The speed of the machine must also be adjusted to this depth - a relatively high speed for a thin spread, or a slower speed for a deep spread.
717
Adjust Speed and Bowl Height
1
To start spreading, raise the apron by pulling the apron control lever to allow the dirt to fall out of the bowl. The size of the apron opening depends on two factors; the depth of the spread and the type of material being spread. A thin layer of free-flowing material, such as sand, will require only a small apron opening and high machine speed, while a larger opening and slower machine speed will be necessary for a thin spread of gummy material, such as wet clay. 2. After the apron opening has been adjusted, the ejector must be activated to finish unloading the scraper bowl when the dirt flow through the apron opening lessens. To permit an even spread, activate the ejector immediately when the dirt flow lessens.
728
Apron and Ejector Actions
2 3. When the bowl is empty, move the ejector to return. The lever will stay in detent until fully retracted.
1271
3
5-7
4. Raise the scraper bowl to travel height and place the control lever in 'Neutral'.
1270
4
1272
5
5. Lower the apron and place the control lever in 'Neutral'.
Spreading Hints 1. Keep the machine moving while unloading. Stopping during the unloading operation on a soft fill will cost production time by needless shifting and possible bogging down of the machine. Apply the power locking differential as needed on the fill. 2. Always make an even spread so the next trip will not be rough.
5-8
3. If possible when travelling out of a fill, pass back over the area you have just filled in order to compact it with the large tyres.
RETURNING TO THE CUT While returning to the cut, it is good practice to occasionally grade the haul road with the scraper blade. By watching the road, the operator can vary the cutting action of the blades to cut off small rises and carry the dirt to depressions while travelling. When returning to the cut and not grading the haul road, carry the scraper bowl high enough to avoid any haul road obstacles, yet low enough for good handling. Carrying the bowl low will allow quick slowing of the machine by lowering the cutting edge to the ground if necessary. Allow plenty of room for the scraper wheels to avoid obstacles when making tight turns, and maintain a safe speed for the condition of the haul road.
WORKING SPECIAL MATERIALS Sand
730
Sand Buildup Ahead of Bowl
Sand, being a free-flowing material, has a tendency to float ahead of the scraper blade when being loaded. To load the scraper completely and to avoid being bogged down by the sand, it is necessary to 'Pump Load'. To do this, enter the cut in the usual manner with the apron open approximately 1 m (3 ft) and the scraper blade lowered into the ground. Continue through the cut until the bowl is approximately half-full or the machine starts to stall. When this happens, lower the apron into the sand that has piled up in front of the scraper blade and raise the bowl 50 - 75 mm (2 - 3 in). Continue through the cut alternately dropping and raising the bowl 75 - 100 mm (3 - 4 in) at a time. Do not completely close the apron or drop the bowl deep enough to stall the machine. This 'Pump Loading' will ordinarily allow the scraper to obtain a full load.
731
Lower Apron and Raise Bowl
When spreading sand, always spread it as thin as possible and keep the machine moving in the fill. A thin spread will allow better compaction and will make travelling over the fill easier. In many cases, reduced tyre pressures will greatly aid the loading and spreading operations in loose sand.
5-9
Coal Coal stockpiling with a scraper accomplishes two things; it compacts the coal with the tyres, and it affords a fast and efficient method of handling coal when it must be moved around the stockpile. Loose coal is loaded from the stockpile with a smooth cut, to avoid drainage problems. Care should be taken not to drop the bowl too deep as this will stall the machine. Spread a load of coal in thin equal layers of approximately 150 mm (6 in) thick. After spreading, travel back over the freshly spread coal if possible, to allow the tyres to compact the coal. This is important as it eliminates air holes, lessening the chances of spontaneous combustion.
732
Spreading Coal
733
Back Up to Release Stones
734
Bowl High/Apron Open Wide
Gravel To obtain a complete load when loading gravel, it may be necessary to 'Pump Load' it in the same manner as previously described for sand. Some difficulty may be experienced in closing the apron due to large stones being caught between it and the scraper blade. To overcome this, back up slightly with the blade still in the ground while closing the apron. This will ordinarily force the stones out and allow the apron to close completely. To prolong tyre life, avoid spinning the wheels and hitting sharp rocks. The tyres should be kept at the proper inflation pressure as recommended by your local tyre dealer for the particular machine and tyres involved.
Wet and Sticky Material The greatest difficulty with handling these particular materials is during the unloading process. This may be overcome by using a few precautions. When unloading, do not attempt to spread the material too thin and always keep the bowl high enough to allow the material to flow back under the scraper.
5-10
Attempting to spread the material too thin and/or keeping the bowl too low will cause the material to pack against the scraper blade and inside the bowl, making it impossible to eject the load. If the material is so sticky that it will not flow out of the bowl, bring the ejector forward, and alternately power-down and raise the apron, slicing off sections of the material.
Loading Large Objects 735
Power Down Apron
Proper manoeuvring of the machine will enable the scraper to pick up large objects that the tractor can not pass over. Approach the object with the apron and scraper bowl raised to their full heights. Bring the tractor past the object until the drive wheels are slightly beyond it. Pivot the tractor sharply towards the object. This will enable the tractor to bypass the object and bring the scraper blade into position to load it.
736
Approaching the Object
When the tractor reaches its sharpest angle of turn, bring the scraper blade close to the object. Lower the scraper blade and load in the usual manner. To completely close the apron after the object has been loaded, a little dirt may have to be picked up to push it back into the scraper bowl. To unload the object, it may be necessary to extend and return the ejector a few times to move it around so it will fall out. If necessary, more dirt can be loaded to position the object for unloading. After the object has been unloaded, turn the machine sharply so that the scraper may go around it.
737
Pivoting the Tractor
5-11
BLADE ARRANGEMENTS The scraper cutting edges (blades) and scraper blade base are designed so that one type of edge can be used for various edge arrangements. In addition, the edges are reversible which prolongs the useful life of the edges. The use of the proper edge arrangement for certain types of cut or soil conditions can save a great deal of money in edge replacement and labour. Scraper edges should never be allowed to wear to the point where the blade base is doing the cutting. The 100 mm (4 in) drop centre arrangement is recommended for hard, rock-free soils when a maximum drop centre and centre heaped loads is required. To renew this arrangement after one edge is worn, reverse all edges and interchange the outer pair of edges with the inner pair. The straight edge arrangement is recommended whenever a level cut or a level fill is required. To renew this arrangement after one edge is worn, reverse all edges and interchange the outer pair of edges with the inner pair.
100 mm (4 in)
738
DIRECTION OF CUT
739
The maximum overhang arrangement is recommended for fast, easy loading in rock-free soils and for maximum edge wear life. When working in rocky soils, the minimum overhang edge arrangement is recommended. For beginning scraper cuts on side slopes or to crown a scraper cut, the one side cutting edge is recommended. These three edge arrangements cannot be renewed by reversing the edge when one edge is worn, however, the edges can be used with the 100 mm (4 in) drop centre and straight edge arrangements.
5-12
100 mm (4 in) Drop Centre
Straight Edge
One Side Cutting Edge 50 mm (2 in)
740
Maximum Overhang
50 mm (2 in)
Minimum Overhang
50 mm (2 in)
TWIN HITCH LOADING (Optional Attachment) TRACTOR
SCRAPER
Twin Hitch loading uses two scrapers hooked together, end to end, to assist each other in the loading operation. Two scrapers enter the cut aligned bumper to bumper. The front scraper begins its cut in first gear and the drag created by the cutting action of the blade slows the scraper allowing the rear scraper to catch up. The rear scraper, with bail raised, contacts the front scraper's rear bumper. Cushions mounted behind the push plate on the rear scraper absorb the shock of impact and make the contact smoother.
741
TRACTOR
SCRAPER
Note: When using the Twin Hitch, use scrapers of the same size and equipped with the same size of tyres. Using scrapers of different sizes can cause excessive stresses within each machine which can result in reduced life. As the rear scraper begins to push the front scraper, the rear scraper operator shifts the bail control lever to the 'Lower' position. This lowers the bail over the rear bumper hook of the front scraper and positions it for the remaining operation.
742
TRACTOR
SCRAPER
The rear scraper continues pushing the front scraper until it is filled. At this point, usually on a signal from the operator of the rear scraper, the bowl of the first scraper is raised. The rear scraper should continue pushing until the front scraper's bowl is raised and it can accelerate and pull away from the rear scraper. The hook of the front scraper then catches in the bail of the rear scraper. When the operator of the rear scraper feels the front scraper pulling, the rear scraper bowl is lowered and the cut is continued. While the front scraper is pulling, the operator of the rear scraper shifts the bail control lever to the 'Raise' position, but the two scrapers will remain together as long as the front scraper continues pulling.
743
Note: When scrapers are hooked together they must remain in a straight line,
5-13
as turning of either scraper will damage the bail of the rear scraper. If for any reason the front scraper should become turned at an angle to the rear scraper while pulling, the operator of the front scraper should decrease pulling power and correct the angle.
TRACTOR
When the rear scraper is full, the operator raises the bowl slightly off cut, shifts to second gear range and accelerates, overtaking the front scraper. As the rear scraper accelerates and overtakes the front scraper, the pulling force of the front scraper on the bail of the rear scraper is released, allowing the bail to raise. When the operator of the front scraper feels the bump of the rear scraper, the operator knows that the rear scraper is full and it all right to shift to a higher gear range and pull away. As the machines proceed to the dump area, the rear scraper should steer away from the front scraper before beginning to turn to avoid damaging the front scraper.
744
Note: When hauling, lower the bowl as much as possible to raise the nose of the tractor and increase ground clearance of the hitch. Scraper teams with Twin Hitches should alternate pushing and pulling operations as much as possible to equalize wear of attachments on both machines. It is also recommended that the front portion of the Twin Hitch attachments be removed from the scrapers when operations will not involve the use of Twin Hitch, thus reducing the chance of accidental damage to the attachments.
WARNING Never park or leave a scraper with the bail in the raised position. The bail can be dropped by accidental movement or loss of air pressure, which could be dangerous to personnel in the area.
5-14
745
SCRAPER
TYPES OF CUTS Cutting Through Hills To cut out the centre of a hill, the first cut should be taken at stakes 'A'. Work across the hill taking cuts until stakes 'B' are reached. The next cut should be taken one scraper width from the first cut, forming a step. Take cuts across the hill until one scraper width from Stakes 'B' is reached.
746
Cutting Through Hills
This will form a step at stakes 'B' side of the hill. All cuts should be made with the centre of the cut higher than both ends of the cut. Repeat this procedure until the required depth is reached. The steps can be smoothed out with a grader if the slope is gentle, or a crawler if the slope is steep.
STAKE
Cutting Banks When cutting down a bank, the first cut should be made at the stakes and then cuts should be made as shown by the numbered sequence shown in the illustration. This method will keep the scraper level, or leaning toward the bank, and prevent the possibility of the scraper slipping down the bank. A grader or crawler can then smooth out the bank slope after the cuts have been made. 747
Cutting Banks
Stripping Topsoil The cuts should proceed across the cutting area, using the step method of loading. To step load, a cut is taken on both sides of a scraper wide strip leaving a step in the middle where a third cut can be quickly loaded.
748
Stripping Topsoil
5-15
Starting A Ditch To start a ditch, take several cuts along the ditch grade stakes until the cut is deep enough to allow the scraper cutting edge to approximate the slope required. Place one set of wheels in the cut, the other on the bank and cut the ditch at the required angle. To finish the ditch, use a scraper equipped with a straight cutting edge arrangement.
749
Starting Ditch
750
Starting Fill
751
Building Fill
TYPES OF FILLS To start a fill, spread the first loads a few feet away from the fill and grade stakes. This practice compensates for the dirt being pushed out by the scraper and tractor wheels as the fill deepens. If the first loads are spread in line with the stakes, the machine's wheels will push the dirt beyond these stakes resulting in unnecessary bulldozing work to clean up the fill.
When building a fill, the outside edges or shoulders should be kept higher than the centre. This allows the scraper to spread close to the edge without danger of sliding over it. The fill slope can be built at the proper angle, reducing the bulldozer work required to back-finish it.
5-16
Spread equal layers at the fill site, keeping the centre lower than the sides. When the shoulders reach grade level, it is very easy to finish the fill by filling the centre. At the end of the work day or when the fill is to be left for a time, always fill in the centre for better drainage.
752
Spread Equal Layers
Where the fill must meet specific compactation requirements, the load must be spread in thin, equal thicknesses, or 'Lifts'. To accomplish this, set the bowl to give the desired lift before entering the fill. As the load is spread, the scraper wheels pull up on the freshly spread material and raise the height of the bowl from the ground. To compensate for this, lower the bowl to maintain the same lift. If the bowl is not lowered, the spread will be much thicker at the end than it was at the beginning.
753
Allow for Lift
FINISHING AND GRADING The scraper can be used to finish level ground and moderate slopes, by using a straight edge blade arrangement. If it is necessary to carry dirt from one spot to another, load in the usual manner; however, for grading work, carry the apron high and ejector forward to produce the same effect as a bulldozer/grader blade.
754
Grading Arrangement
When finishing a slope, DO NOT attempt to load as the dirt will fall to the lower side of the bowl, resulting in this side cutting deeper than the high side. Always keep tyres at the same inflation pressure. A low tyre pressure on one side will cause the blade to cut deeper on that side.
5-17
5-18
6 - Roading 6-1
ROADING WARNING These machines are equipped with cylinders containing compressed nitrogen gas. Transportation of these machines by any method may require a special permit from the appropriate authority of the country involved. Consult your Dealer for details.
General 'Roading' (operating a scraper over public highways) requires special care and attention. Scrapers, because of their large size, are slower and less manoeuvrable than most other machines encountered on the road. Yet, while on the road, they must be operated for extended periods of time at, or near, maximum speeds. Before 'Roading' a scraper for an extended distance between jobs, or between widely scattered sections of a job, the machine must be properly equipped and in good condition. It is also recommended to carry a 'Warning Triangle'. The operator must use extra care while on the public highways and remain constantly alert, especially for overhead cables and low bridges. Necessary permits must be obtained from the proper authorities before the machine is 'Roaded' on public highways.
Preparation Prior to Roading Lubrication Thoroughly lubricate and service all components and systems as described under 'LUBRICATION AND SERVICING' in this handbook and/or Maintanance Manuals for this machine.
6-2
Inspection Perform all pre-starting and post-starting checks described in this Handbook. Pay particular attention to the function of all instruments and lights, and make any repairs necessary. Note: Improper tyre inflation during over-the-road operation can cause rapid tyre deterioration by overheating. Tyre pressures increase with heat. Always check pressures while tyre is cold. Consult your tyre dealer for proper pressures and tyre speed limits for roading. Check the inflation pressures of all tyres, while cold, with an accurate tyre pressure gauge. Inflate tyres if necessary, while cold, to the recommended pressure for 'Roading'. Inspect all tyres thoroughly and carefully for stones or other debris embedded in the treads or carcasses. Inspect for cuts, bruises, burned beads abnormal wear and damaged wheels rims. Replace any damaged or excessively worn tyres. Check all hoses, drain cocks, fuel level check cocks, and other potential sources of air or fluid leaks. Make sure that all leaks are repaired and that all drain cocks are sufficiently tightened to avoid subsequent loosening. Make sure that all warning flags, oversize load signs etc. are in place and secure. Clean all glass and adjust the seat for proper operation of all controls. Check the lights, horn, windscreen wipers, heater, defroster, headlight dip control, and all controls for proper operation. Make sure the scraper bowl is empty and in a fully raised position and the ejector fully retracted. Make sure the apron is lowered completely. Remove the planetary flange covers from the scraper wheels, pull out the axle shafts and reinstall the gaskets and planetary flange covers to keep dust and dirt out of the planetary gears and gear oil in. Make sure all hydraulic control levers are in the 'Hold' position. 098
6-3
In Case of Trouble If trouble develops enroute, move machine off the road at the first safe parking place, and shut off the engine. Carefully note as many of the symptoms of the trouble as possible, such as rough engine operation with loss of power and overheating, or loss of speed and transmission clutch pressure with normal engine operation etc.. If the area in which the trouble occurs requires that the machine be left unattended while the trouble is reported by phone, disconnect a battery cable and apply security locks, if so equipped, before leaving the parked machine. Make sure bowl is completely lowered, if it has not been blocked up in the travel position, and the parking brake is applied. Report the following data as soon as possible: 1. Exact location. 2. Destination. 3. The nature of the trouble (with as many details as possible) and the time and conditions under which it happened. 4. The telephone number at which the machine operator can be reached. Note: Do not attempt to restart or operate the machine unless instructed to do so. An engine, pump, transmission or other component that develops a minor defect can be completely destroyed in just a few extra minutes of unnecessary operation.
6-4
7 - Moving Disabled Scraper 7-1
MOVING DISABLED SCRAPER Any unusual powertrain noises noted while operating the scraper should be reported to those responsible for maintenance. Should the powertrain, air, hydraulic or electrical systems fail, the machine should be stopped and shut down immediately until suitable repairs can be made. If the failure is in the powertrain and the scraper must be moved to a service area or workshop to make required repairs, remove the planetary flange covers from the tractor and scraper wheels and pull out the axle shafts. This will prevent any possible additional damage which may be caused by the drive wheels turning the powertrain as the machine is towed. Replace the covers on the drive wheels to retain lubricant and prevent entry of dirt. If possible, start the engine to provide the required air and hydraulic pressure for steering and braking. Never allow riders on a machine being towed without sufficient hydraulic pressure for safe steering and braking. If the nature of the trouble prevents engine operation, repairs must be made on the site of the breakdown, or special arrangements made for towing the machine safely to the repair area without braking and steering power.
WARNING Uncontrolled machine movement hazard. There is no mechanical connection between the machine wheels and the engine when the parking brake is released. Before releasing the parking brake, make sure the machine wheels are secured with chock blocks to prevent or restrict unexpected machine movement. When moving the machine with insufficient air and hydraulic pressure, for safe braking and steering, use extreme caution to ensure personnel and property safety.
7-2
098
If the safety or parking brake has been applied and the engine cannot be started, the air tanks must be recharged by an external source to release the brakes before the scraper can be moved.
WARNING When using a chain or cable, be sure it is strong enough for the expected load and properly secured. When pulling, take up the slack slowly to avoid jerking. A chain or cable which fails under load can cause serious injury. Stand clear. Do not pull through a kinked chain or cable. Do not pull or tow unless the operator's compartment is guarded against, or out of reach of, a whipping chain or cable. Attach only to the towing hook. Failure to follow these instructions could cause serious injury or death.
7-3
7-4
8 - Lubrication and Servicing 8-1
SAFETY PRECAUTIONS Do not allow unauthorized personnel to service or maintain this machine. Study the Operator’s Handbook and Maintanance Manual before starting, operating or servicing this machine. Always follow procedures and safety precautions detailed in the Maintanance Manual. Never allow anyone to work on the machine while it is moving. Make sure no one is on the machine before working on it. Do not work under or near any unblocked or unsupported linkage, part or machine. Always shut down machine according to the procedure under 'Stopping The Engine', described on page 4-14. Turn off the master switch before cleaning, lubricating or servicing the machine except as called for in this Handbook or Maintanance Manual. Always deflate tyre before attempting to remove any embedded objects or removing the tyre and rim assembly from the machine. Always use a self-attaching chuck with a long airline and stand to one side while the tyre is inflating. Always relieve pressure before servicing any pressurized system. Always attach a 'DO NOT OPERATE' or similar warning sign to ignition switch or a control before cleaning, lubricating or servicing the machine.
8-2
LUBRICATION AND SERVICING Lubrication is an essential part of preventive maintenance. It is important that the instructions regarding types of lubricants and the frequency of their application be followed to prolong the useful life of the machine. Periodic lubrication of moving parts reduces to a minimum the possibility of mechanical failures. Thoroughly clean all fittings, caps, plugs etc., to prevent dirt from entering the system while servicing. Lubricants must be at operating temperature when draining. Do not operate any system unless oil level is within the operating range as indicated on oil level dip stick, sight gauge or level plug. Small circles on the following illustrations represent points at which lubrication or servicing must take place, at the intervals indicated on the left-hand side of the lubrication chart. The numbered circles on the illustrations contain reference numbers which correspond to the 'Ref. Points' column of the chart. All change and service periods are recommendations based on average operating conditions. Lubricants showing evidence of excessive heat, oxidation or dirt should be changed more frequently to prevent these conditions. Lubricant change and service periods must be established on the basis of individual job conditions.
8-3
8-4
1310
Lubrication Points - Tractor
LUBRICATION AND SERVICE CHART - Tractor Interval Hours
10
50
150
Ref. Points Identification 1 2 -
Engine Transmission Hydraulic Oil Tank Coolant Level Fuel Tank Fuel Filter/Water Separator Cooling Fan Drive Belts Air Reservoirs Air Cleaner Restriction Air/Water Separator Tyres
-
Controls and Instruments General Inspection
3 4 5 7 8 9 10 11 12 13 -
Service Instructions
No. of Points
Lubricant Service/Quantities
Check oil level. Add if low Check oil level. Add if low Check oil level. Add if low Check coolant level. Add if low Drain water Drain water and sediment Visually inspect for debris & damage Visually inspect all belts Drain all air tanks Check gauge. Replace element if reqd Drain water Check condition. Check pressures when tyres are cold Check for proper operation Check for leaks and damaged parts. Repair/replace as required
1 1 1 1 1 1 1 3 1 1 2
EO HTF HO Antifreeze -
As required As required As required As required See page 10 Sec. 160-0050, Main.Man.
-
-
Steering Frame Pins Steering Cylinder Pins Reversing Valve Rollers Remote Lubrication Points - Basic
Lube Lube Lube Lube
2 4 2 3
EP, NLGI EP, NLGI EP, NLGI EP, NLGI
See Note 1 See Note 1 See Note 1 See Note 1 & Page 8
Cooling System Planetary Assemblies Differential Driveline Slip Joints Universal Joints Brake Cam Shafts Brake Shoe Anchor Pins Steering Gear Differential Breather Remote Lubrication Points - Brakes
Check antifreeze concentration Check oil level. Add if low Check oil level. Add if low Lube Lube Lube Lube Lube Clean Lube
2 1 2 4 2 4 1 1 1
EPL EPL EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI
Ref. Engine Manual As required As required See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 & Page 8
-
8-5
LUBRICATION AND SERVICE CHART - Tractor (Continued) Interval Hours
Service Instructions
No. of Points
Lubricant Service/Quantities
250
-
Trans. Input Flange/Yoke
Lube
1
300
1
Engine Lube Oil Filters Engine
Replace Drain oil and refill
1
EO
Ref. Engine Manual 24.6 litres (6.5 US gal)
500
EP, NLGI See Page 11
-
Transmission Oil Filter
Replace
1
-
-
-
Fuel Filters and Strainer Drive Belts Hydraulic Filter Hydraulic Tank Breather Air Compressor Governor Coolant Inhibitor
Replace filters and clean housings Check tension. Adjust if required Change filter element Clean Clean or replace filters Replenish
1 1 1
-
Ref. Engine Manual Ref. Engine Manual
900
-
Engine Coolant Filter
Replace filter/conditioner element
1
-
1 000
2 -
Transmission Transmission Oil Filter
Drain oil and refill Replace
1 1
HTF -
48.5 litres (12.8 US gal) -
6 7 8 -
Engine Power Takeoff Drain oil and refill Engine Air Cleaner Clean inlet hood and tubes Engine Crankcase Breather Replace element Planetary Assemblies Drain oil and refill Differential Drain oil and refill Cooling System Drain coolant and refill
1 1 2 1 1
EPL EPL EPL Antifreeze
See Page 11 43 litres (11.4 US gal)
1 800
-
Hydraulic System Hydraulic Oil Tank Screen
Drain oil and refill Remove and clean
1
HO -
204 litres (54 US gal) -
2 000
-
Air Drier
Replace dessicant cartridge.
1
-
-
2 400
-
Engine Cooling System
Drain coolant and refill. Replace filters
-
-
Ref. Engine Manual
600
1 200
8-6
Ref. Points Identification
-
Note: Capacities given are approximate, work to dipstick, sight gauges or level plugs. Use chart in conjunction with 'Recommended Lubricants' table. Note 1 - Lubricate slowly until excess lube is seen. EO
- Engine Oil. Refer to 'Recommended Lubricants' table.
*
- Refer to 'Recommended Lubricants' table.
EPL
- Extreme Pressure Gear Lubricant spec. MIL-L-2105D.
HTF
- Hydraulic Transmission Fluid Type C-4. Refer to 'Recommended Lubricants' table.
HO
- Hydraulic Transmission Oil. Refer to 'Recommended Lubricants' table.
EP, NLGI - Extreme Pressure Lithium No. 2 Grease. Refer to 'Recommended Lubricants Table'.
8-7
Remote Lubrication Points For improved accessibility, remote lube lines are run to manifold blocks mounted on the front right hand side engine cover and the front left hand side of the bowl. These lines should be inspected periodically for damage. Apply sufficient grease into each nipple until there is clear evidence of grease emerging from one or two of the clearly visible connected bearing points.
FRONT LHS OF BOWL TRACTOR
1 STEERING CYLINDER PIN 2 LEVER MOUNTING PIN 3 STEERING CYLINDER PIN 4 BOWL CYLINDER MOUNTING PIN 5 BOWL CYLINDER MOUNTING PIN (Lower) 6 LIFT ROD MOUNTING PIN (Upper) 7 BOWL CYLINDER MOUNTING PIN (Lower) 8 LIFT ROD MOUNTING PIN (Upper) 9 BOWL CYLINDER MOUNTING PIN (Lower) 10 LIFT ROD MOUNTING PIN (Upper)
1 3 5 7 9
1 BRAKE CAM SHAFT 2 DRIVE BEARING 3 BRAKE SAFETY CHAMBER 4 BRAKE SAFETY CHAMBER 5 BRAKE SHOE ANCHOR PIN 6 BRAKE SHOE ANCHOR PIN 7 BRAKE SHOE ANCHOR PIN 8 BRAKE SHOE ANCHOR PIN 9 PLUGGED 10 BRAKE CAM SHAFT
C
2 4 6 8 10
A 1 3 5 7 9
2 4 6 8 10
Do not over grease the brake system. When a component is lubricated, the general condition of the component should also be visually checked. Look for cracked parts, loose fasteners, excessive wear, or improper clearance as applicable to the component being lubricated. Follow procedures detailed in Section 300-0020 of the Maintenance Manual.
1 LEVER MOUNTING PIN 2 BOWL CYLINDER MOUNTING PIN 3 LEVER MOUNTING PIN 4 APRON CABLE ROLLER 5 BOWL CYLINDER MOUNTING PIN 6 LOWER KING PIN 7 LIFT ROD MOUNTING PIN (Upper) 8 LIFT ROD MOUNTING PIN (Lower) 9 LIFT ROD MOUNTING PIN (Lower) 10 LOWER KING PIN 11 PLUGGED 12 PLUGGED
D 1 3 5 7 9 11
2 4 6 8 10 12
1 ROLLER 2 STEERING FRAME PIN 3 ROLLER 4 STEERING FRAME PIN 5 STEERING CYLINDER PIN 6 STEERING FRAME PIN 7 PLUGGED 8 STEERING CYLINDER PIN
B 1 3 5 7
2 4 6 8
FRONT RHS ON ENGINE COVER TRACTOR
8-8
1335A
ADDITIONAL MISCELLANEOUS SERVICING INFORMATION WHEN REQUIRED Seat Belts -
Inspect for damage. Replace if required.
Windscreen Wipers And Washers -
Replace wiper blades and top up reservoirs.
EVERY 10 HOURS OF OPERATION (DAILY) Walk Around Inspection - Inspect machine (As per Section 4). Engine -
Visually check engine for damage, loose or frayed belts and listen for any unusual noises.
Engine Air Cleaner -
Change air cleaner element only when air restriction gauge locks up in the red. Service dust cup daily. Note: Service air cleaners more often when operating under extremely dusty conditions.
Engine Crankcase -
Check oil level and add oil if low. With the engine off, the oil should be between the 'Low' and 'Full' marks on the dipstick, up to the 'Full' mark is preferable.
Transmission -
Adjust bowl height to level the transmission and, with the engine running and oil at normal operating temperature, check oil level. Add oil if the level is below the 'FULL' line on the dipstick. Do not overfill.
Hydraulic Tank -
With the bowl on the ground, apron down, ejector returned and the engine off, check oil level. Oil level should be between the 'Cold' and 'Hot' marks on the sight gauge. Add oil if low.
Cooling System -
Check coolant level, add if low. Add coolant to the top of the filler neck.
8-9
AFTER FIRST 50 HOURS OF OPERATING NEW OR REBUILT COMPONENTS Transmission Drain oil, replace filter and refill. AFTER FIRST 150 HOURS OF OPERATING NEW OR REBUILT COMPONENTS Differential Drain oil and refill. Planetaries -
Drain oil and refill.
EVERY 150 HOURS OF OPERATION
8-10
General Inspection -
Check entire scraper for leaks, loose bolts and nuts or damaged parts. Examine the scraper, particularly the chassis, for cracks or broken welds. Repair where necessary.
Drive Belts -
Visually check the belts and replace if they are cracked or frayed. Adjust belts that have a glazed or shiny surface which indicates belt slippage. Correctly installed and tensioned belts will show even pulley and belt wear. Refer to 'Engine Operation and Maintenance Manual' for drive belt tension and adjustment of new and used belts. Note: The fan belt is maintained to the correct belt tension by a spring loaded idler arm, therefore, there is no need to adjust belt tension.
Oil Can Points -
Oil brake treadle rollers, hinges and other working parts with engine oil.
EVERY 250 HOURS OF OPERATION Transmission Input Flange/Yoke -
Cooling Fan -
Remove the breather and lubricate through the lube fitting with a hand grease gun until grease exits the breather hole. Do not over grease. Reinstall breather. Note: Failure to lubricate with a No. 2 Consistency grease could cause premature failure of the input bearing. Visually check fan for cracks, loose rivets, and bent or loose blades. Check fan mounting and tighten if required. Replace any fan that is damaged.
EVERY 600 HOURS OF OPERATION Coolant Inhibitor -
Check and replenish coolant inhibitor as described in Engine 'Operation and Maintenance Manual'.
EVERY 1 200 HOURS OF OPERATION Hydraulic Oil Tank -
Drain tank, remove and clean filter screen assembly and discard filter element. Reinstall filter screen, new filter element and refill with clean hydraulic oil. Refer to Section 235-0040, HYDRAULIC TANK in the Maintanance Manual.
Engine Power Takeoff -
Drain and refill. Remove bottom pipe plug in PTO cover and drain oil into a suitable container. Reinstall pipe plug and refill to level of check cock.
8-11
ENGINE AND TRANSMISSION All information contained in the 'Lubrication and Service Chart' was extracted from the relevant manufacturers Operators Manual and was correct at time of publication. User should ensure that information contained in this chart, regarding the Engine and Transmission, reflects the information shown in the relevant manufacturers Operators Manuals, supplied with the machine. Maintenance procedures should be carried out in conjunction with any additional procedures contained in the relevant manufacturers 'Operation and Maintenance Manual', at the intervals specified.
8-12
RECOMMENDED LUBRICANTS COMPONENT
LUBRICANT
Engine
Engine oil with 1.00% sulphated ash is recommended. Sulphated ash must not exceed 1.85% limit.
API Classification Military Specifications SAE Grade Transmission
VISCOSITY (See Note 1) The use of low viscosity oils, such as 10W or 10W-30, can be used to aid in starting the engine and providing sufficient oil flow at ambient temperatures below -5°C (23°F). Continuous use of low viscosity oils can CG-4 or CF-4 decrease engine life due to wear. MIL-L-2104E 15W-40
Hydraulic Transmission Oil, Type C-4. See Note 3.
Ambient
Recommendation
-30° to 30° C -25° to 30° C -15° to 30° C -10° to 30° C -5° to 50° C 0° to 50° C
SAE 0W-20 (Arctic) DEXRON-III SAE 10W SAE 15W SAE 30 SAE 40
8-13
RECOMMENDED LUBRICANTS (Continued) COMPONENT
LUBRICANT
VISCOSITY (See Note 1)
Differential, Planetary Gears, Power Takeoff, Steering Gear
Multipurpose Extreme Pressure type gear oil meeting MIL-L-2105C Specifications (No Zinc Additive).
SAE 80W-90 at ambient temperatures of -18° to 32° C
Grease Fittings
Multipurpose Extreme Pressure Lithium Grease with a typical melting point of 190° C.
No. 2 Consistency
Cooling System
Antifreeze, Ethylene Glycol
Fuel Tank
Diesel Fuel Oil with maximum sulphur 0.5%
DIN EN590
Hydraulic System
Hydraulic Transmission Oil meeting MIL-L-2104C Specifications or API Service Code CC or CD/SC
SAE 10W at ambient temperatures of -18° to 32° C
Drivelines, Steering Column
Multipurpose Extreme Pressure Lithium Grease (without 'Molybdenum'), with a typical melting point of 190° C.
No. 2 Consistency
Note - For temperature conversions to degrees Fahrenheit (°F) refer to table on page 8-24. Note 1 - Consult your lubricant supplier for the correct viscosity of lubricant to use when ambient temperatures are consistently above or below those listed. Note 2 - Detroit Diesel does not recommend any specific brand of engine oil but the use of oils that meet API categories. Detroit Diesel recommends use of only the multi-graded viscosity oils shown for the various ambient temperatures listed. Note 3 - Preheat is required below minimum temperatures shown. Operation below the minimum temperatures listed for the oil used without proper preheat or warm-up results in greatly reduced transmission life. Proper warm-up requires 20 minutes minimum operation in neutral (with engine at part throttle) before operating the transmission in gear. Hydraulic Transmission Oil meeting Specification EMS19058 may also conform to the Allison C-4 requirements. Consult your lubricant supplier for confirmation.
8-14
1311
Lubrication Points - Scraper
8-15
LUBRICATION AND SERVICE CHART - Scraper Interval Hours
10
50
Ref. Points
Identification
Service Instructions
1 2 -
Engine Transmission Coolant Level Fuel Tank Fuel Strainer Fuel/Water Separator Cooling Fan Drive Belts Air Reservoirs Air Cleaner Restriction Tyres
-
General Inspection
Check oil level. Add if low Check oil level. Add if low Check coolant level. Add if low Drain water Drain water and sediment Drain water and sediment Visually inspect for debris and damage Visually inspect all belts Drain all air tanks Check gauge. Replace element if reqd. Check condition. Check pressures when tyres are cold Check for leaks and damaged parts. Repair/replace as required
3 4 5 6 7 8 9 10 11 12 13 -
150
8-16
14 15
No. of Points
Lubricant Service/Quantities
1 1 1 1 1 1 1 1 1 2
EO HTF Antifreeze -
-
-
Ejector Lever Roller Pin Lube Lower Kingpin Thrust Bearing Lube Lower Kingpin Bushing Lube Upper Kingpin Lube Lever Mounting Pins Lube Bowl Cylinder Mounting Pins Lube Lift Rod Mounting Pins Lube Apron Sheave Pin Lube Apron Cable Roller Lube Pull Yoke Ball Joint Lube Ejector Lever Mounting and Lube Ejector Cylinder Pins Remote Lubrication Points Lube - Basic
1 1 1 1 3 6 4 1 2 2 3
EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI
1
EP, NLGI See Note 1 & Page 19
Cooling System Planetary Assemblies Differential
2 1
Check antifreeze concentration Check oil level. Add if low Check oil level. Add if low
EPL EPL
As required As required As required See page 21 Sec. 160-0050, Main.Man. See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1
Ref. Engine Manual As required As required
LUBRICATION AND SERVICE CHART - Scraper (Continued) Interval Hours
Ref. Points
No. of Points Lubricant Service/Quantities
Identification
Service Instructions
16 17 18 19 -
Driveline Slip Joints Universal Joints Brake Cam Shafts Brake Shoe Anchor Pins Differential Breather Remote Lubrication Points - Brakes
Lube Lube Lube Lube Clean Lube
250
-
Trans. Input Flange/Yoke
300
1
Engine Oil Lube Filter Engine
500
-
Transmission Oil Filter
600
-
Coolant Inhibitor Fuel Filters and Strainer Drive Belts
900
-
Engine Coolant Filter
Replace filter/conditioner element
1
-
1 000
2 -
Transmission Transmission Oil Filter
Drain oil and refill Replace
1 1
HTF -
49 litres (12.9 US gal) -
14 15 -
Engine Power Takeoff Engine Air Cleaner Engine Crankcase Breather Planetary Assemblies Differential Fuel Tank
Drain oil and refill Clean inlet hood and tubes Replace element Drain oil and refill Drain oil and refill Clean filler neck screen
1 1 2 1 1
EPL EPL EPL -
See Page 22 -
-
Cooling System
Drain coolant and refill. Replace filters
-
150
1 200
4 000
2 4 2 4 1 1
EP, NLGI EP, NLGI EP, NLGI EP, NLGI EP, NLGI
See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 & Page 19
Lube
1
EP, NLGI See Page 21
Replace Drain oil and refill
1 1
EO
24.6 litres (6.5 US gal)
Replace
1
-
-
Replenish Replace filters and clean housings Check tension. Adjust if required
1 -
-
Ref. Engine Manual Ref. Engine Manual -
Antifreeze 42 litres (11.1 US gal)
8-17
Note: Capacities given are approximate, work to dipstick, sight gauges or level plugs. Use chart in conjunction with 'Recommended Lubricants' table. Note 1 - Lubricate slowly until excess lube is seen. EO
- Engine Oil. Refer to 'Recommended Lubricants' table.
*
- Refer to 'Recommended Lubricants' table.
EPL
- Extreme Pressure Gear Lubricant spec. MIL-L-2105D.
HTF
- Hydraulic Transmission Fluid Type C-4. Refer to 'Recommended Lubricants' table.
HO
- Hydraulic Transmission Oil. Refer to 'Recommended Lubricants' table.
EP, NLGI - Extreme Pressure Lithium No. 2 Grease. Refer to 'Recommended Lubricants Table'.
8-18
Remote Lubrication Points REAR LHS SCRAPER ENGINE COVER
For improved accessibility, remote lube lines are run to a manifold block mounted on the rear right hand side of the engine cover. These lines should be inspected periodically for damage. 10 8 6 4 2
9 7 5 3 1
E
1 BRAKE SAFETY CHAMBER 2 BRAKE SHOE ANCHOR PIN 3 PLUGGED 4 BRAKE SHOE ANCHOR PIN 5 BRAKE SHOE ANCHOR PIN 6 BRAKE CAM SHAFT 7 BRAKE SAFETY CHAMBER 8 DRIVE BEARING 9 BRAKE SHOE ANCHOR PIN 10 BRAKE CAM SHAFT
Apply sufficient grease into each nipple until there is clear evidence of grease emerging from one or two of the clearly visible connected bearing points. Do not over grease the brake system. When a component is lubricated, the general condition of the component should also be visually checked. Look for cracked parts, loose fasteners, excessive wear, or improper clearance as applicable to the component being lubricated.
6 4 2
1 EJECTOR CYLINDER 2 EJECTOR LEVER ROLLER PIN 3 EJECTOR CYLINDER MOUNTING PLATE 4 EJECTOR CYLINDER (Lower) 5 PLUGGED 6 PLUGGED
Follow procedures detailed in Section 300-0020 of the Maintenance Manual.
5 3 1
F
1335B
8-19
ADDITIONAL MISCELLANEOUS SERVICING INFORMATION EVERY 10 HOURS OF OPERATION (DAILY) Walk Around Inspection - Inspect machine (As per Section 4). Engine -
Visually check engine for damage, loose or frayed belts and listen for any unusual noises.
Engine Air Cleaner -
Change air cleaner element only when air restriction gauge locks up in the red. Service dust cup daily. Note: Service air cleaners more often when operating under extremely dusty conditions.
Engine Crankcase -
Check oil level and add oil if low. With the engine off, the oil should be between the 'Low' and 'Full' marks on the dipstick, up to the 'Full' mark is preferable.
Transmission -
Adjust bowl height to level the transmission and, with the engine running and oil at normal operating temperature, check oil level. Add oil if the level is below the 'FULL' line on the dipstick. Do not overfill.
Cooling System -
Check coolant level, add if low. Add coolant to the top of the filler neck.
AFTER FIRST 50 HOURS OF OPERATING NEW OR REBUILT COMPONENTS Transmission -
Drain oil, replace filter and refill.
AFTER FIRST 150 HOURS OF OPERATING NEW OR REBUILT COMPONENTS Differential Drain oil and refill.
8-20
Planetaries -
Drain oil and refill.
EVERY 150 HOURS OF OPERATION General Inspection -
Check entire scraper for leaks, loose bolts and nuts or damaged parts. Examine the scraper, particularly the chassis, for cracks or broken welds. Repair where necessary.
Oil Can Points -
Oil brake treadle rollers and other working parts with engine oil.
Drive Belts -
Visually check the belts and replace if they are cracked or frayed. Adjust belts that have a glazed or shiny surface which indicates belt slippage. Correctly installed and tensioned belts will show even pulley and belt wear. Refer to 'Engine Operation and Maintenance Manual' for drive belt tension and adjustment of new and used belts. Note: The fan belt is maintained to the correct belt tension by a spring loaded idler arm, therefore, there is no need to adjust belt tension.
EVERY 250 HOURS OF OPERATION Transmission Input Flange/Yoke -
Cooling Fan -
Remove the breather and lubricate through the lube fitting with a hand grease gun until grease exits the breather hole. Do not over grease. Reinstall breather. Note: Failure to lubricate with a No. 2 Consistency grease could cause premature failure of the input bearing. Visually check fan for cracks, loose rivets, and bent or loose blades. Check fan mounting and tighten if required. Replace any fan that is damaged.
8-21
EVERY 600 HOURS OF OPERATION Coolant Inhibitor -
Check and replenish coolant inhibitor as described in Engine 'Operation and Maintenance Manual'.
EVERY 1 200 HOURS OF OPERATION Hydraulic Oil Tank -
Drain tank, remove and clean filter screen assembly and discard filter element. Reinstall filter screen, new filter element and refill with clean hydraulic oil. Refer to Section 235-0040, HYDRAULIC TANK in the Maintanance Manual.
Engine Power Takeoff -
Drain and refill. Remove bottom pipe plug in PTO cover and drain oil into a suitable container. Reinstall pipe plug and refill to level of check cock.
ENGINE AND TRANSMISSION All information contained in the 'Lubrication and Service Chart' was extracted from the relevant manufacturers Operators Manual and was correct at time of publication. User should ensure that information contained in this chart, regarding the Engine and Transmission, reflects the information shown in the relevant manufacturers Operators Manuals, supplied with the machine. Maintenance procedures should be carried out in conjunction with any additional procedures contained in the relevant manufacturers 'Operation and Maintenance Manual', at the intervals specified.
8-22
RECOMMENDED LUBRICANTS COMPONENT
LUBRICANT
Engine
Engine oil with 1.00% sulphated ash is recommended. Sulphated ash must not exceed 1.85% limit.
API Classification Military Specifications SAE Grade Transmission
VISCOSITY (See Note 1) The use of low viscosity oils, such as 10W or 10W-30, can be used to aid in starting the engine and providing sufficient oil flow at ambient temperatures below -5°C (23°F). Continuous use of low viscosity oils can CG-4 or CF-4 decrease engine life due to wear. MIL-L-2104E 15W-40
Hydraulic Transmission Oil, Type C-4. See Note 3.
Ambient
Recommendation
-30° to 30° C -25° to 30° C -15° to 30° C -10° to 30° C -5° to 50° C 0° to 50° C
SAE 0W-20 (Arctic) DEXRON-III SAE 10W SAE 15W SAE 30 SAE 40
8-23
RECOMMENDED LUBRICANTS (Continued) COMPONENT
LUBRICANT
VISCOSITY (See Note 1)
Differential, Planetary Gears
Multipurpose Extreme Pressure type gear oil meeting MIL-L-2105C Specifications (No Zinc Additive).
SAE 80W-90 at ambient temperatures of -18° to 32° C
Grease Fittings Ejector Rollers
Multipurpose Extreme Pressure Lithium Grease with a typical melting point of 190° C.
No. 2 Consistency
Cooling System
Antifreeze, Ethylene Glycol
Fuel Tank
Diesel Fuel Oil with maximum sulphur 0.5%
DIN EN590
Drivelines
Multipurpose Extreme Pressure Lithium Grease (without 'Molybdenum'), with a typical melting point of 190° C.
No. 2 Consistency
Note 1 - Consult your lubricant supplier for the correct viscosity of lubricant to use when ambient temperatures are consistently above or below those listed. Note 2 - Detroit Diesel does not recommend any specific brand of engine oil but the use of oils that meet API categories. Detroit Diesel recommends use of only the multi-graded viscosity oils shown for the various ambient temperatures listed. Note 3 - Preheat is required below minimum temperatures shown. Operation below the minimum temperatures listed for the oil used without proper preheat or warm-up results in greatly reduced transmission life. Proper warm-up requires 20 minutes minimum operation in neutral (with engine at part throttle) before operating the transmission in gear. Hydraulic Transmission Oil meeting Specification EMS19058 may also conform to the Allison C-4 requirements. Consult your lubricant supplier for confirmation. Temperature Conversions
8-24
° Celsius
-32
-30
-27
-25
-20
-18
-15
-10
-5
0
10
15
25
32
35
38
50
93
° Fahrenheit
-26
-22
-17
-13
-4
0
5
14
23
32
50
59
77
90
95
100 122 200
9 - Technical Data 9-1
3 440 (11-3.5) Max. Width
3 060 (10-0.5) 2 260 (7-5) 1 460 (4-9.5)
3 060 (10-0.5) 2 260 1 460 (7-5) (4-9.5)
3 150 (10-4) to ground
3 810 (12-6)
3 250 (10-8)
2 770 (9-1)
7 040 (23-1)
2 590 (8-6)
12 400 (40-8) All vertical dimensions with bowl at 300 mm (12 in) carry position. Unit empty.
9-2
1309
Dimensions in mm (ft-in)
Dimensions in mm (ft-in)
TS14F TECHNICAL DATA DIMENSIONS Apron opening ..................................... 2 100 mm (6 ft 11 in) Width of Bowl and Cutting Edge ............ 2 910 mm (9 ft 7 in) Width of cut .......................................... 3 000 mm (9 ft 10 in) Depth of cut - maximum ............................ 305 mm (1 ft 0 in) Depth of spread - maximum ..................... 685 mm (2 ft 3 in) Clearance under drive axle ..................... 585 mm (1 ft 11 in) Clearance under bowl - maximum .......... 585 mm (1 ft 11 in) Overall length with optional Twin Hitch Bail Raised ............................................ 13.6 m (44 ft 7 in) Bail Lowered ........................................ 14.04 m (56 ft 8 in) Note: All vertical measurements are with bowl at 300 mm (12 in) carry position. Unit empty. ENGINE Tractor Engine Series ................................ Detroit Diesel Series 40E Type ...................................... 4 Cycle Diesel, Turbocharged, Electronic Management Gross power at 2 200 rev/min ..................... 134 kW (180 hp) Net power at 2 200 rev/min ......................... 121 kW (162 hp) Note: Gross power rated to SAE J1995 June 90. Engine emission meets USA EPA/CARB MOH 40 CFR 89 and EU NRMM (non-road mobile machinery) directive. Maximum Torque .......... 720 Nm (531 lbf ft) at 1 600 rev/min Number of cylinders/configuration ............................ 6, Inline
Bore x Stroke ........................ 109 x 136 mm (4.30 x 5.35 in) Total Displacement ................................... 7.6 litres (466 in³) Air cleaner ....................................................... Dry, Aspirated Starting ....................................................................... Electric Maximum Speed (No load) .............................. 2 450 rev/min Maximum Speed (Full load) ............................. 2 200 rev/min Idle Speed ........................................................... 700 rev/min Safe Operating Angle ................................... 30°/57% Grade Scraper Engine Series ................................ Detroit Diesel Series 40E Type ...................................... 4 Cycle Diesel, Turbocharged, Electronic Management Gross power at 2 200 rev/min ..................... 119 kW (160 hp) Net power at 2 200 rev/min ......................... 109 kW (146 hp) Note: Gross power rated to SAE J1995 June 90. Engine emission meets USA EPA/CARB MOH 40 CFR 89 and EU NRMM (non-road mobile machinery) directive. Maximum Torque .......... 644 Nm (475 lbf ft) at 1 600 rev/min Number of cylinders/configuration ............................ 6, Inline Bore x Stroke ........................ 109 x 136 mm (4.30 x 5.35 in) Total Displacement ................................... 7.6 litres (466 in³) Air cleaner ....................................................... Dry, Aspirated Starting ....................................................................... Electric Maximum Speed (No load) .............................. 2 450 rev/min Maximum Speed (Full load) ............................. 2 200 rev/min Idle Speed ........................................................... 700 rev/min Safe Operating Angle ................................... 30°/57% Grade
9-3
TRANSMISSION Make/Model .................................... Funk DF158 Powershift, counter-shaft type transmission with integral torque converter. Seven speeds forward and one reverse. Automatic lockup in the top six forward gears. Manual, electric shifting and downshift inhibitor. Rear transmission is equipped with an alarm to warn the operator in the event of transmission malfunction. Stall Speed ...................................................... 1 885 rev/min Torque Converter Ratio (front and rear) ................... 2.408:1 SPEEDS WITH STANDARD DIFFERENTIAL Forward Gear 1 2 3 4 5 6 Ratio 5.72 4.05 2.90 2.03 1.45 1.03 km/h 5.9 8.3 11.5 16.5 23.1 32.5 mile/h 3.6 5.1 7.2 10.2 14.3 20.2 Reverse Ratio 4.05 km/h 8.3 mile/h 5.1
7 0.74 49.7 30.9
AXLES Heavy duty axles with fully-floating axle shafts, single reduction bevel gear differential and planetary reduction in each wheel. A NoSpin differential is standard in the rear
9-4
axle for improved traction in difficult conditions. A pedal controlled power-locking differential is optional in the front axle, operational in first gear only. Ratios: Differential ............................................................... 4.11:1 Planetary ................................................................. 5.33:1 Total Reduction ..................................................... 21.91:1 BRAKES Full air operated drum brakes with automatic application on loss of air pressure. Secondary system can also be manually applied. Parking by mechanical locking of service brakes. Air dryer standard. Braking Lining: Diameter ....................................................... 508 mm (20 in) Shoe Width ..................................................... 152 mm (6 in) Lining Thickness .......................................... 19 mm (0.75 in) Lining Area - Each Axle .......................... 3 355 cm² (520 in²) Air Compressor Capacity ............. 374 litre/min (13.2 ft³/min) WHEELS AND TYRES Wheel Rim Width .......................................................... 25 in Tyres: Standard ................................................ 29.5 R25** Radial Optional ............................................... 29.5-25 (28PR) E3 Note: Consult tyre manufacturers for optimum tyre selection and correct t-km/h (ton-mileh) capacity for application.
STEERING SYSTEM Full hydraulic type provided by two interchangeable single stage, double acting steering cylinders. Steering cylinders are mounted below the gooseneck to aid stability. System Pressure ................................ 135 bar (1 950 lbf/in²) at 1 500 rev/min Steering Cylinder: Bore and Stroke ................... 140 x 145 mm (5.5 x 17.5 in) Pump: Type ........................................................................... Gear Drive ................................. In tandem with hydraulic pump Capacity at 2 200 rev/min .. 147 litre/min (38.7 US gal/min) Steering Angle to either side ............................................ 90° Vehicle clearance circle (SAE) ........................... 10 m (33 ft) HYDRAULICS AND CONTROLS Hydraulic system is filtered and has one reservoir supplying a triple section gear pump for steering and scraper hydraulics. Scraper Functions: Capacity at 2 200 rev/min .. 270 litre/min (71.2 US gal/min) System Pressure at 1 500 rev/min ........................... 103 bar (1 500 lbf/in²) Servo Control Functions: Capacity at 2 200 rev/min .... 43 litre/min (11.3 US gal/min) System Pressure at 1 500 rev/min ................................ 17 bar (250 lbf/in²) Steering Pump ..................................... See Steering System Three fingertip servo assisted control levers allow independent operation of the bowl, apron and ejector.
BOWL High strength alloy steel used in sides and floor for increased strength and life. Low, wide design aids loading ability. Bowl employs two single stage, double acting cylinders to exert positive down pressure on the cutting edge to help penetrate hard material and load faster. Cylinders are interchangeable. Cylinder Bore and Stroke .... 203 x 460 mm (8.00 x 18.12 in) Maximum Hydraulic Force at Cutting Edge with Bowl Empty ............. 214 kN (21 822 kgf) (48 000 lbf) APRON Gravity closed, semi-radial design, power closing apron operated by one single stage, single acting cylinder with apron arms mounted outside the bowl. Apron and ejector cylinders are interchangeable. Cylinder Bore and Stroke ...... 233 x 635 mm (9.17 x 25.0 in) EJECTOR Positive roll-out type operated by one single stage, single acting cylinder. Cylinder Bore and Stroke ...... 233 x 635 mm (9.17 x 25.0 in) CUTTING EDGE Four section hardened cutting edge with drop centre capability. All edges are interchangeable and reversible. Dimensions (Each) ................................. 25 x 406 x 724 mm (1.0 x 16.0 x 28.5 in)
9-5
ELECTRICAL SYSTEM Type ............................................. 24 volt, Negative Ground. Battery ......................................... Two, 12 Volt, 165 Ah each Accessories ................................................................ 24 Volt Alternator .................................................................. 70 Amp
VOLUMES Struck (SAE) ............................................. 10.7 m³ (14.0 yd³) Heaped 3:1 ............................................... 12.2 m³ (16.0 yd³) Heaped 2:1 ............................................... 13.0 m³ (17.0 yd³) Heaped 1:1 (SAE) ..................................... 15.3 m³ (20.0 yd³)
SERVICE CAPACITIES Tractor Cooling System .................................. 43 litres (11.4 US gal) Fuel Tank .......................................... 378 litres (100 US gal) Engine Crankcase (with filters) ......... 24.6 litres (6.5 US gal) Transmission and Converter ........... 48.5 litres (12.8 US gal) Hydraulic System ................................ 204 litres (54 US gal) Drive Axle ............................................. 17 litres (4.5 US gal)
VEHICLE WEIGHTS
Scraper Cooling System .................................. 42 litres (11.1 US gal) Fuel Tank ............................................ 303 litres (80 US gal) Engine Crankcase (with filters) ......... 24.6 litres (6.5 US gal) Transmission and Converter .............. 49 litres (12.9 US gal) Drive Axle ............................................. 17 litres (4.5 US gal)
9-6
Standard Vehicle
%
kg
lb
58.5 41.5
16 560 11 710
36 510 25 815
Net Vehicle Weight
28 270
62 325
Rated Payload
21 770
48 000
26 020 24 020
57 370 52 955
50 040
110 325
Net Weight Distribution Tractor Axle Scraper Axle
Gross Weight Distribution Tractor Axle Scraper Axle Gross Vehicle Weight
52.0 48.0
10 - Symbol Identification
SYMBOL IDENTIFICATION These pages explain the meaning of symbols that may appear on your machine.
10-2
Basic Warning Symbol
Switch 'Off'
Hourmeter
Unlock
Pressurised Compartment
Negative Ground
Fast
Basic Engine
Master Switch
Ammeter
Slow
Engine Starter
Switch 'On'
Circuit Breaker
Lock
Engine Rev/Min
Engine 'Off'
Basic Transmission
Transmission Converter Lockup
Minimum or Low
Emergency Engine Shut Off
Transmission Oil
Air Pressure
Maximum or High
Engine Oil
Transmission Oil Pressure
Air Filter or Restriction
Basic Hydraulic Oil Symbol
Engine Oil Pressure
Transmission Oil Temperature
Starter Air Pressure
Hydraulic Oil Filter
Engine Oil Filter
Transmission Oil Filter
Oil Level
Hydraulic Oil Filter Pressure
10-3
10-4
Hot Hydraulic Oil
Heating
Light Flood
Horn
Coolant Temperature
Fuel Gauge or Fill Tube
Light Low Beam
Windshield Wiper
Coolant 'Cold'
Fuel Filter
Light High Beam
Windshield Defroster
Coolant 'Hot'
Fuel Shut-Off
Instrument Panel Light
Windshield Washer
Cooling
Basic Lights Symbol
Lamp Test
Blower Fan
Heater
Parking Brake
Low Steering Pressure
Body 'Hold'
Air Conditioner
Brake Oil Temperature
High Speed or Level
Body 'Lower'
Inside Air Circulation
Turn Left
Low Speed or Level
Body 'Float'
Outside Air Circulation
Turn Right
Body Up
Dumptruck 'Retarder'
Parking Brake
Tilt Steering Column
Body 'Raise'
Neutral
10-5
Lift Point
Clutch 'Disengage'
Do Not Lift
Brake Applied Clutch Engaged
Forward
Brake Applied Clutch Disengaged
Reverse
Clutch 'Engaged'
10-6
Notes 10-7
NOTES
10-8
NOTES
10-9
NOTES
10-10