M-215-99R* Operation, Maintenance, Safety

M-215-99R* Operation, Maintenance, Safety
M-215-99R
REPLACES M-215-99
Serial Numbers K5536, K5573-75
K5649-92, K5695-5722, K5726-66,
K5770-80,K5784-88
Variable
Hopper
Chipspreader
R
Operation Maintenance and Safety Manual
E. D. ETNYRE & Co.,Oregon, Illinois 61061
M-215-99R
REPLACES M-215-99
Serial Numbers K5536, K5573-75
K5649-92, K5695-5722, K5726-66, K5770-80,K5784-88
Computerized Variable Hopper
CHIPSPREADER
Operation, Maintenance and Safety Manual
for Hydrostatic Drive Units with Variable Hopper
WARRANTY
E. D. Etnyre & Co. warrants to the original Purchaser, it’s new product to be free from defects in material and workmanship for a period of twelve (12) months after date of delivery to original Purchaser. The obligation of the Company
is limited to repairing or replacing any defective part returned to the Company and will not be responsible for consequential damages or any further loss by reason of such defect.
The company excludes all implied warranties of merchantability and fitness for a particular purpose. There are no
warranties, express or implied, which extend beyond the description of the goods contained in this contract.
This warranty does not obligate the Company to bear the cost of machine transportation in connection with the replacement or repair of defective parts, nor does it guarantee repair or replacement of any parts on which unauthorized
repairs or alterations have been made or for components not manufactured by the Company except to the extent of the
warranty given by the original Manufacturer.
This warranty does not apply to:
(1)
Normal start-up services, normal maintenance services or adjustments usually performed by
the selling dealer, factory service representative or customer personnel.
(2)
Any product manufactured by E. D. Etnyre & Co. purchased or subjected to rental use.
(3)
Any product or part thereof which shows improper operation, improper maintenance, abuse,
neglect, damage or modification after shipment from factory.
(4)
Any product or part thereof damaged or lost in shipment. Inspection for damage should be
made before acceptance or signing any delivery documents releasing responsibility of the de
livering carrier.
This warranty and foregoing obligations are in lieu of all other obligations and liabilities including negligence and all
warranties of merchantability or otherwise, express or implied in fact or by law.
HOW TO ORDER PARTS
To assure prompt delivery when ordering parts, please furnish the following information: 1) Complete name and
address of consignee. 2) Method of shipment preferred. 3) Is shipment to be prepaid or collect? 4) Serial numbers of
units to which parts apply. 5) Complete part numbers and descriptions. 6) Any special instructions. Part numbers beginning with 9250000 are category numbers and must include descriptive term to complete the order (such as, length, color,
etc.). These items when listed in the parts manual will indicate what information must be included.
SPECIFY UNIT SERIAL NUMBER WHEN ORDERING PARTS!
E. D. ETNYRE & CO., Oregon, Illinois 61061-9778
1333 South Daysville Road Phone: 815/732-2116 Fax: 815-732-7400
1
Safety Precautions,
Hazard Seriousness Level
You will find safety information boxes throughout
this manual. These boxes contain information
alerting you to situations or actions to avoid.
Signal words (DANGER, WARNING and CAUTION) are used to identify levels of hazard seriousness. Their selection is based on the likely consequence of human interaction with a hazard. Definitions of hazard levels are as follows.
WARNING
Do not use this machine for any
operation which is not described in this
manual.
If you have any questions about
operation of this machine, contact the
Etnyre Service Department at
1-800-995-2116 or 1-815-732-2116.
Operations that are not approved could
cause serious injury or death.
DANGER - Immediate hazards which
will result in severe personal injury or death.
WARNING - Hazards or unsafe practices which could result in severe personal
injury or death.
CAUTION - Hazards or unsafe practices which could result in minor personal
injury or product or property damage.
CALIFORNIA
Proposition 65 WARNING
Diesel engine exhaust and some of its constituents are known to the State of California
to cause cancer, birth defects, and other
reproductive harm.
Please note this warning and remember Always start and operate the engine in a
well ventilated area;
If in an enclosed area, vent the exhaust to
the outside;
Do not modify or tamper with the exhaust
system.
WARNING
Fluoroelastomer Handling
Some O-rings and seals used in this vehicle
are made from fluoroelastomers, When used
under design conditions, fluoroelastomers do
not require special handling. However, when
fluoroelastomers are heated to temperatures
beyond their design temperature (around 600º
Fahrenheit), decomposition may occur with the
formation of hydrofluoric acid. Hydrofluoric acid
can be extremely corrosive to human tissue if
not handled properly.
A degraded seal may appear as a charred or
black sticky mass, Do not touch either the seal
or the surrounding equipment without wearing
neoprene or PVC gloves if degradation is
suspected. Wash parts and equipment with
10% lime water (calcium hydroxide solution) to
neutralize any hydrofluoric acid.
If contact with the skin occurs, wash the
affected areas immediately with water. Then
rub a 2.5 calcium gluconate gel into the skin
until there is no further irritation, while seeking
prompt medical attention.
Note to Physicians: For advice or treatment of
HF burns, call the DuPont Medical Emergency
number, 1-800-441-3637
2
TABLE OF CONTENTS
General Identification ........................................................ 4
Introduction ....................................................................... 5
Reporting Safety Defects .................................................. 5
Check Out ......................................................................... 5
Attaching Hopper to Unit ................................................... 6
Figure 1 ............................................................................. 6
Figure 2 ............................................................................. 6
Figure 3 Install Conveyor Hoods ....................................... 7
Identification and Function of Controls .............................. 7
Power/Ignition Switch. ....................................................... 7
Mode Selector-Drive/Park ................................................. 8
Figure 4 Control Panel Identification ................................. 8
Speed Set Toggle Switch .................................................. 8
Aggregate Size Switch. ..................................................... 9
Application Rate Switch. ................................................... 9
Fuses. ............................................................................... 9
Computer Display Screen. ................................................ 9
Operator Screens .............................................................. 9
Screen Scroll Switch ....................................................... 11
Speed/Direction Control Handle (Figure 6) ..................... 11
Figure 5 Throttle Lever .................................................... 12
Figure 6 Speed/Direction Control Handle ....................... 12
Gate/Spread Roll Switch. (Figures 4 & 6) ....................... 12
Turn Signal Selector and Indicators. (Figure 8) .............. 13
Hazard Flasher Switch (Figure 8) ................................... 13
Figure 7 Ground Speed Pickup ....................................... 13
Headlight Switch. (Figure 9) ............................................ 13
Seat Shift Switch. (Figure 8) (Optional) .......................... 13
Hitch Release Pushbutton. (Figure 8) ............................. 13
Figure 8. Control Panel ................................................... 13
Hand Throttle Lever. (Figure 5) ....................................... 14
Application Rate Computer. (inside control panel) .......... 14
Right Conveyor Selector (Figure 4) ................................ 14
Left Conveyor Selector. (Figure 4) .................................. 14
Hitch Height Switch. (Figure 4) ....................................... 14
Left Gate Override Switch (Figure 4) .............................. 14
Right Gate Override Switch (Figure 4) ............................ 14
Left Hopper Position Switch (Figure 4) ........................... 14
Right Hopper Position Switch (Figure 4) ......................... 14
Left Gate Power Switch (Figure 4) .................................. 14
Left Spread Roll Switch (Figure 4) .................................. 15
Right Hopper Power Switch (Figure 4) ........................... 15
Right Spread Roll Switch (Figure 4) ................................ 15
Left Auger Selector (Figure 4) ......................................... 15
Right Auger Selector (Figure 4) ...................................... 15
Memory Selector Buttons (Figure 4) ............................... 15
Memory Save Button ...................................................... 15
Calibrate Switch (Figure 4) ............................................. 15
Optional Individual Gates Master Switch ........................ 15
Left Hopper Gate Selector Switches ............................... 15
Right Hopper Gate Selector Switches ............................ 15
Horn (Figure 4) ................................................................ 15
Strobe Beacon Switch (Figure 4) .................................... 15
Warning Light (Figure 4) ................................................. 16
Brake Pedal (Figure 8) .................................................... 16
Figure 10. Auger Auto On/Off Switch .............................. 16
Left Hopper Switch (Figure 11) ....................................... 16
Right Hopper Switch (Figure 11) ..................................... 16
Left Conveyor Switch (Figure 11) .................................... 16
Right Conveyor Switch (Figure 11) ................................. 16
Hitch Release Pushbutton (Figure 11) ............................ 16
Left Auger Switch (Figure 11) .......................................... 16
Right Auger Switch (Figure 11) ....................................... 16
Left Gate Override Switch (Figure 11)............................. 16
Right Gate Override Switch (Figure 11) .......................... 16
Figure 11. Front Operator’s Control Panel ...................... 17
Automatic Conveyor Control (Figure 4) .......................... 19
Figure 12. Conveyor Diaphragm Switches ..................... 19
Figure 13. Belt Speed Controls ....................................... 19
Belt Speed Controls ........................................................ 19
Backup Alarm .................................................................. 19
Hydraulic Powered Seat ................................................. 19
Individual Gates (Figure 14) ............................................ 19
Figure 14. Individual Gates ............................................. 20
Appendix A Maintenance Adjustments............................ 22
Hopper Spread Roll Wear Plate Adjustment (Fig. 15) ..... 22
Hopper Gate Wear Plate Adjustment (Fig. 16) ................ 22
Figure 15. Spread Roll Wear Plate ................................. 22
Figure 16 Hopper Gate Wear Plate ................................. 22
Conveyor Belt Adjustment ............................................... 22
Figure 17 Conveyor Tail Pulley ....................................... 23
Figure 18 Conveyor Head Pulley Adjustment ................. 23
Towing Instructions ......................................................... 23
Appendix B Computer Set Up ......................................... 24
Appendix C Computer Service Screens ......................... 27
Appendix D Systems Startup And Adjustments .............. 32
Hydrostatic System Startup ............................................ 32
Figure 19 Hydrostatic Pump ........................................... 32
Figure 20. Engine Left Side ............................................ 32
Figure 21 Suction Filters ................................................. 33
Variable Hopper Gate Transducer Adjustment ................ 33
Figure 22 Gate Solenoids ............................................... 34
Figure 23 Left Hopper Transducer .................................. 34
Air System Pressure Settings ......................................... 34
Figure 24 Air System (Individual Gate System Only) ...... 34
Pressure Adjustments ..................................................... 35
Pressure Settings For Hydrostatic Drive Pump) ............. 35
Figure 25 POR Setting .................................................... 35
Figure 26 High Pressure Relief Setting ........................... 35
Setting the Charge Pressure ........................................... 36
Figure 27 Charge Pressure Adjustment .......................... 36
Pressure Settings For Auxiliary Pump(s) ........................ 36
High Pressure Relief Valve (first pump) .......................... 36
Figure 28 Conveyor Block ............................................... 37
Figure 29 Pumps ............................................................ 37
High Pressure Relief Valve (second pump) .................... 37
Standby Pressure (first pump) ........................................ 37
Standby Pressure (second pump) .................................. 38
Figure 30 Auger Manifold ............................................... 38
Pressure/Flow Settings For Actuator Valving .................. 38
Gate Cylinder Relief Valves ............................................ 38
Figure 31 Hopper Block .................................................. 38
Hopper Extend/Retract Relief Valve ................................ 38
Spreadroll Speed Adjustment ......................................... 39
Figure 32 Conveyor & Right Spreadroll Manifold ............ 39
Conveyor Speed Adjustment .......................................... 39
Auger Speed Adjustment ................................................ 39
Fixed Displacement Auxiliary Pump ................................ 39
Main Relief Pressure (MP) .............................................. 40
Figure 33 Hydraulic Control Assembly ............................ 40
Pilot Pressure (PP) .......................................................... 40
Reduced Pressure (RP) .................................................. 40
Truck Hitch Arrangement ................................................ 41
Lubrication ...................................................................... 42
Caution And Instruction Plates ........................................ 43
3
GENERAL IDENTIFICATION
Qty
1
1
1
1
1
2
2
1
1
3
1
1
1
1
2
2
2
1
AR
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
AR
Description
Conveyor Drive
Hydraulic Oil Cooler
Front Drive Line
Hydrostatic Pump
Front Drive Axle
Power Steering Cylinder
Return Filter
Tank Breather
Hydraulic Reservoir
Implement Pump
Rear Drive Axle
Rear Drive Line
Rear Drive Motor
Hitch Height Cylinder
Suction Filter
Lights
Conveyor Hood
Front End Man Controls
Engine Covers and Deck
Conveyor Control Valve
Air Filter
Control Console
Operator Seat
Rear Deck Covers
Receiving Hopper
Truck Hitch
Fuel Tank
Left Spread Hopper
Left Gate Transducer
Left Gate Actuating Cylinder
Right Spread Hopper
Right Gate Transducer
Right Gate Actuating Cylinder
Hitch Release Cylinder
Engine Radiator
Individual Gate Cylinders
31
33
1
Ref
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
32
7
9
5
6
4
10
8
11
2
14
35
6
30
3
29
15
13
17
12
20 (inside)
18
16
19
19
22
3101247
21
23
24
25
3390681
WA
3101717
RN
ING
3390683
3390681
3390682
3190505
WARN
Remain
moving clear
ING
of
Entangleparts.
cause
or
ment
serious may
death.
injury
3390681
LUBRI
CATIO
N
3100716
36
1. MAKE
CERTAIN
STARTING
EVERYONE
ENGINE
2. ALWAYS
OR
USE
3. REMAIN
OPERATION.
IS
OF
PLATFORMS
OF
HAVE
AND
MOVING
OR
SHIELDS,
NOT
IN
HOPPER
IN
OF
WAR
BEFORE
NING
THE
FUEL
OF
TANK
THE
CROSS IS PART
NOT
DRILL
WALK.
OR
DO
AREA. WELD
IN
GUAARDS
FRONT
GATES.
PROVIDED.
PARTS.
AND
STAND
GAGE
MACHINE
HANDRAILS
ROTATING
COVERS
5. DO
CLEAR
STEPS,
CLEAR
4. ALWAYS
OPERATING.
PLACE
WHEN
HOPPER
TO
THIS
ENGAGE
AND
DISEN-
3100716
WAR
3101247
NING
THE
FUEL
OF
TANK
THE
CROSS IS PART
NOT
DRILL
WALK.
OR
DO
AREA. WELD
IN
THIS
3101247
28
R
27
26
34
4
INTRODUCTION
The Etnyre Variable Hopper Hydrostatic
ChipSpreader has been designed to improve the accuracy of chip spreading while improving productivity.
This has been done by incorporating Application Rate
capabilities using precise gate opening control and speed
feedback in closed loop controls, and the ability to do
most roads in a single pass.
It is especially important from the safety standpoint
that this manual be thoroughly read and understood
before performing any operational or maintenance function.
The information contained in this manual will enable you to better understand the operation and performance of the machine and thus better utilize it to obtain maximum performance from your ChipSpreader.
hoppers if at all possible. Added weight in either the
front hoppers or the rear hopper increases stopping distance, and weight in the front hopper decreases available traction at the rear wheels.
8. After changing filters or working on the hydrostatic system, be sure to follow hydrostatic start up procedure to reduce the potential for damage to the hydrostatic system.
9. Always install locking control box cover & chock
wheels when leaving machine unattended as protection
against vandalism and accidental movement.
10. Before operating the ChipSpreader, do an inspection of the machine for condition of the tires, fluid leaks,
fluid levels, fuel level, loose bolts, improper hose routings etc. Be sure that the machine is in a safe condition
to operate.
WARNING
Unsafe operation of equipment may
cause injury. Read, understand and follow
the manuals when operating or performing
maintenance
IMPORTANT
1. The front hoppers should be fully closed up and
latched using the safety chains on the left side of the
machine when the unit is traveling between job sites to
avoid possible damage to the outer ends of the hoppers.
2. Keep machine on road or relatively uniform surface at all times to avoid loss of traction and/or possible damage to the front hoppers or rear of conveyors.
3. Place truck gearshift in neutral as soon as the truck
is connected to the spreader.
4. Under most operating conditions the ChipSpreader
should be allowed to tow the truck. However, certain
steep upgrade or downgrade conditions may require the
truck to assist the ChipSpreader. The ChipSpreader must
pull the truck even while the truck is assisting. Do not
attempt to push the ChipSpreader with the truck.
5. Do not tow or push the ChipSpreader before reading the towing instructions contained in this manual as
this may damage the hydraulic motors.
6. Never use the ChipSpreader to dislodge a truck or
other equipment which has become stuck in mud or
soft shoulder conditions as this may cause damage to
the hitch, which could fail later in normal operation.
7. Avoid roading the machine with material in the
CAUTION
The front hoppers should be fully closed up
and latched using the safety chains at the left
side of the machine when the unit is traveling
between job sites to avoid possible damage
to the outer ends of the hoppers.
REPORTING SAFETY DEFECTS
If you believe that your vehicle has a defect which
could cause a crash or could cause injury or death you
should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying E. D. Etnyre & Co.
If NHTSA receives similar complaints, it may open
an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and
remedy campaign. However, NHTSA cannot become
involved in individual problems between you, your
dealer, and E. D. Etnyre & Co.
CHECK OUT
1. The following accessories are shipped with each
ChipSpreader: extra linkage rods for shortened truck
hookup, parts book and operation, maintenance and
safety manual, wiring and hydraulic diagrams, and engine parts and operator’s manual.
2. Best performance for most operating conditions
is achieved when tire pressures are set to 55 to 60 PSI
5
in front and 60 to 65 PSI in rear. However, various operating speeds, road bed conditions, truck pulling arrangements and other operating conditions may require
different tire pressures.
5. Connect all hopper hoses per the parts book diagram. Use caution to wipe each half of each connector
clean before connecting. Dirt and contaminants can
cause major damage to the hydraulic systems.
6. Install hoods and connect electrical connections
WARNING
Never exceed the maximum inflation
pressures indicated on the tire’s sidewall.
3. Grease all fittings and check all reservoir oil levels in accordance with the ChipSpreader Lubrication
Chart on the side of the tool box prior to operation.
4. Check engine coolant and oil levels prior to operation. Refer to engine operator’s maintenance manual
for complete engine service requirements.
(Figure 3)
7. Connect the transducer electrical connectors the
other connectors for the auto features and headlights.
8. Hopper gate adjustment and spread roll straightness are established at the factory. However, to be sure
adjustments or straightness were not altered during shipment and storage, the following gate and spread roll
adjustment checks should be performed prior to operation:
3
4
ATTACHING HOPPER TO UNIT
Before lifting hopper, check to ensure that adequate
clearance will be maintained between the lifting machine and overhead electrical lines. you must maintain
at least 10 feet of clearance.
1
1
SAFETY PRECAUTIONS:
2
3
Ensure that the hopper is well secured and rigged
before starting any lifting operation.
Ensure that the area around the hopper is clear of
personnel and equipment and only trained personnel
are used to assist in installing the hopper.
Never let anyone go under the hopper while it is suspended.
Figure 1
1. Latch Arm
2. Carry Shaft
3. Rear Lifting Eye
4. Front Lifting Eye
Ensure that hands and feet are kept clear of the hopper and potential pinch points on front of the
ChipSpreader during installation.
1
3
Attaching Hopper to Unit
1. By hooking a lifting sling into the two rear lifting
eyes, the hopper can be tilted forward while being
raised, allowing the hopper carrying shafts to engage
the hopper carrying arms on the ChipSpreader. (Figure
1 & 2) Lower hopper slowly until lifting sling can be
disconnected.
2. Attach lifting device to front lifting attachment
and raise hopper to vertical position.
2
Figure 2
1. Latch Pin
2. Carry Arms (2)
3. Pin Catch
3. Install hopper pins, in front of latch arms, through
pin catch.
4. Always install latch pin lock pins and snap down
rings properly prior to releasing the lifting device.
6
Figure 3 Install Conveyor Hoods
5. When operating with the truck, in some cases, such
as on steep downgrades, the truck should assist in braking. The truck should always set its own brakes after
stopping, regardless of whether the combination is
stopped on a downgrade, upgrade or level. The braking
effort must be a coordinated effort when required. It is
therefore important to have a clearly understood means
of communication between the ChipSpreader and truck.
This may be done by radio, hand signals, horns etc.
Each truck driver should know who is to give signals,
where to look for the signal and the meaning of each
signal.
Check that each gate opening cylinder rod clevis is
fully screwed onto its respective cylinder rod.
WARNING
With the hopper on the machine, start the engine and
run it at a minimum of 2000 rpm and extend the hoppers fully. Depress and hold the left and right gate override push button switches until the gate position is at
full opening. Release push button switches and gate
position will return to full close. There should be 1/16"
clearance between the gate and the spread roll. If this
clearance is not constant across the full width of the
hopper, it indicates that either the gate and/or the spread
roll is not straight. Contact the factory for straightening instructions.
Stay off hopper while machine is moving.
Machine movements could cause a fall
resulting in injury or death.
Identification and Function of Controls
Refer to figure 4 for identification of described features.
1. Power/Ignition Switch.
IMPORTANT
1. Since the ChipSpreader is designed to operate on
new sealcoat surfaces, all dynamic braking is being done
by the hydrostatic system. With abrupt control inputs it
is possible to “scuff” the road surface during starting
or stopping. However, with smooth application of control, inputs very precise accelerations and decelerations
can be made, giving the ability to outperform a conventional clutch/brake/gear combination.
2. Friction characteristics on both new sealcoat surfaces and other surfaces vary considerably. Therefore
stopping distances must be watched carefully, particularly when towing a truck, going downhill or in stopping from higher travel speeds.
3. The larger the truck or steeper the grade, the longer
the stopping distance.
4. Traveling with the front hoppers loaded removes
weight from the rear wheels thus reducing the braking
effectiveness of the rear wheels while the additional
weight increases the braking forces required. Carrying
material in the rear hopper also increases the braking
forces required and consequently increases the required
stopping distance from a given speed. It is therefore
highly recommended to travel or “road” the machine
in an empty condition.
Rotating from “off” to “on” supplies electric power
to all systems and controls. Rotating the switch further
to the right against the spring will engage the starter.
When the engine runs, release the key and the switch
will remain in the “on” position. Note the engine will
not start with the control joystick removed from the
neutral position. It is recommended the “park/drive”
switch be in the park position during startup also.
SINCE ALL FUNCTIONS EXCEPT POWER
STEERING, AND REAR BRAKES ARE ELECTRICALLY CONTROLLED, TURNING THE
KEY TO “OFF” RESULTS IN AN EMERGENCY
STOP.
WARNING
Turning ignition switch to “off” results in
emergency stop
SHUT MACHINE OFF AND WAIT FOR ALL
MOVEMENT TO STOP BEFORE LEAVING
OPERATOR’S SEAT OR SERVICING
FAILURE TO DO SO COULD RESULT IN UNEXPECTED MOVEMENT AND CAUSE SERIOUS INJURY OR DEATH
7
2. Mode Selector-Drive/Park
WARNING
A two position switch selects either “drive” or “park”
position.
Selecting “park” while the chipspreader
is moving results in an emergency stop.
In “Park” mode, the “speed/direction handle”, (9) is
disabled and the parking brake is applied. The parking
brake is applied when the chipspreader is stopped regardless of the position of the “Drive/park” switch.
CAUTION! ALWAYS PLACE THE MODE SELECTOR SWITCH IN THE “PARK” POSITION
WHEN THE CHIPSPREADER IS STOPPED TO
AVOID ACCIDENTAL MOVEMENT OF THE
MACHINE.
In the “Drive” position, the parking brake will release when the “speed/direction handle”, (9) is moved
from the neutral position resulting in forward or reverse
motion of the chipspreader.
3. Speed Set Toggle Switch
Since engaging “park” disables “speed/direction
handle” and applies the parking brake, selecting
park while the chipspreader is moving will result in
an emergency stop. Do not select “park” unless the
chipspreader is at a full stop.
LEFT
WARNING
When in the “Drive” position, this switch provides
the command signal (or set point) to the computer. This
switch is used to set the desired ChipSpreader speed in
feet per minute. Pushing the toggle switch up will in-
37
RIGHT
RIGHT HOPPER
OUTER
41
12
13
INNER
OPEN
CLOSE
2
1
MEMORY
3
4
33
CONVEYORS
7
5
T
H
R
O
T
T
L
E
25
RIGHT
OFF
OUT
AUTO
14
21
20
FRONT
CAL
SAVE
Steer
Wheel
Post
15
TURN SIGNAL
AUGERS
LEFT
SIZE
34 35 8 4
26
27
IN IN
24
RATE
SPEED
5
28
3
GATE POWER
RIGHT
LEFT
ON
OUT
GATE OVERRIDE
23
RIGHT
SCROLL
HOPPERS
RIGHT
LEFT
ON
LIGHTS
OUTER
CLOSE
18
FLASHER
INNER
OPEN
36
LEFT
38
INDIVIDUAL GATES
LEFT HOPPER
GATE MASTER
OFF
29
SPREADROLL
ON
OFF
30
OFF
AUTO
31
11
32
FRONT
ON
FUSES
HORN
HITCH
RELEASE
39
OFF
GATES
HORN
6
STROBE/BEACON
MOTORS
6
ON
START
1
IGNITION
LIGHTS
CONVEYORS
SEAT
POSITION
L
DRIVE
R
ACC
6
40
17
HITCH HEIGHT
22
CONTROLLER
16
PARK
2
Figure 4 Control Panel Identification
1. Power/Ignition Switch
4. Aggregate Size Switch
7. Computer Display Screen
12. Left Turn Signal Indicator
15. Headlight Switch
18. Throttle Lever
21. Left Conveyor Control Selector
24. Right Gate Override Switch
27. Left Gate Power Switch
30. Right Spreadroll Switch
33. Memory Selector Buttons
36. Individual Gate Master Switch
39. Horn Button
2. Mode Selector-Drive/Park
5. Application Rate Switch
8. Screen Scroll Switch
13.Right Turn Signal Indicator
16. Seat Shift Switch
19. Computer (inside panel)
22. Hitch Height Switch
25. Left Hopper Position Switch
28. Left Spreadroll Switch
31. Left Auger Control Selector
34. Memory Save Button
37. Left Hopper Gate Selector Switches
40. Strobe/Beacon Switch
3. Speed Set Toggle Switch
6. Fuses
11. Turn Signal Selector
14. Hazard Flasher Switch
17. Hitch Release Pushbutton
20. Right Conveyor Control Selector
23. Left Gate Override Switch
26. Right Hopper Position Switch
29. Right Gate Power Switch
32. Right Auger Control Selector
35. Calibrate Switch
38. Right Hopper Gate Selector Switches
41. Warning Light
8
crease the speed set point, while pushing the switch
down will decrease the speed set point. The computer
display screen will display the set point until the control handle is moved out of neutral, and then it will
display the actual speed. Once the speed is set, the
ChipSpreader will repeat that speed any time the control handle is pushed fully forward. The “Speed Set
Toggle Switch” can be pushed to either increase or decrease the set point while the ChipSpreader is moving.
When this is done, the ChipSpreader will smoothly transition to the new set point, and the display will display
the set point rather than the actual speed. When the
switch is released, the display will switch back to the
actual speed.
If the engine cannot maintain the ChipSpreaders
speed on a steep hill, bring the control handle rearward
toward neutral to slow the ChipSpreader down so that
the engine can recover to high idle rpm, and when the
steepness of the hill decreases, or the truck lightens up,
push the control handle fully forward again to return to
the set speed.
override, hitch release, hitch height, and seat position
functions.
*These fuses are powered from the accessory post
on the ignition switch and lose voltage when starter is
engaged.
Horn fuse: Supplies power to the horn and the front
control box.
Gate fuse: Supplies power to the joystick and individual gates when required.
Motors: Supplies power to the speed pickup and all
relays.
*These fuses are powered from the ignition post on
the ignition switch and maintain voltage while starter
is engaged.
The computer is fused with an in-line, 20 amp fuse
and is powered from the accessory post on the ignition
switch.
7. Computer Display Screen.
OPERATOR SCREENS
4. Aggregate Size Switch.
This switch (4) selects the size of the aggregate to
be spread. The size should be set to the size of the aggregate to be spread before setting the application rate
and doing any calibrating of material.
The choices of aggregate size are: Sand, 1/4” Chips,
3/8” Chips, 3/8” Gravel, 5/8” Chips, and 1” Chips.
The amount of aggregate applied on the ground (application rate) is a function of the front hopper gate
opening. The gate opening is determined by the selected aggregate (i.e. 3/8 chips) and the chipspreader
speed. The computer controls the gate opening to maintain the application rate (i.e. 20.0 lbs/yd2).
5. Application Rate Switch.
This switch sets the position to which the gates will
open, by increasing or decreasing the setpoint. The set
point is the application rate, in lbs/ yd2, that will be
delivered when the Gate/Spread Roll switch (10) is
activated. Pushing the switch up will increase the set
point while pushing the switch down will decrease the
set point. The set point can be changed at any time
whether spreading aggregate or not.
6. Fuses.
Light fuse: Supplies power to all lights except brake
lights.
Conveyor fuse: Supplies power to conveyors and
augers
Controller: Supplies power to hopper in/out, gate
20.0
3/8
400
lb/yd2
Chip
fpm
The screen shown above is displayed when power is
turned on to the computer. This screen shows the application rate set point, aggregate size, and the speed
set point while at a stand still. These values can all be
changed depending on the application as described in
earlier sections. When the chipspreader is powered
down, the values currently on the screen are saved and
returned the next time power is turned on.
The speed setpoint is displayed while the
chipspreader is not moving. Once the chipspreader is
in motion, the actual speed is displayed. The speed
feedback is generated by a magnetic pickup mounted
on the motor output shaft which generates pulses which
the computer displays as feet per minute (FPM).
Different configurations of these three values can be
saved in one of five memory presets. The memory presets store an application rate set point, an aggregate,
and a speed set point in one of the memory locations.
The memory pushbutton then restores the information
stored in that location to the screen when activated. This
allows the operator to switch between stored combinations with the push of a button as opposed to having to
scroll the individual values.
It is important to understand that the memory functions simply restore the selected values to the operators screen. If one of the values is changed while oper9
ating, such as the speed setpoint, the speed will change.
The values stored in the memory will not change. Pressing the memory pushbutton will restore the saved values and overwrite the changed speed setpoint.
to arrive at the pounds per square yard. On a variable
hopper machine, this will need to be done for the left
and right hopper. do this a minimum of 3 times and
average the values before making any changes.
To save information in a memory, adjust the application rate set point, the aggregate size, and the speed
set point to values that will be commonly used together.
When the values displayed on the screen are set to the
desired values, press the save pushbutton. Activating
the save pushbutton will change the display to read “Select location 1, 2, 3, 4 or 5”. Select the location, or
memory, the information is to be stored in by pressing
the corresponding memory pushbutton (i.e. memory 1).
The display will return to the main operator screen depicted above when this has been done. As a check,
press the memory pushbutton the information was saved
to prompting the display to read “Restoring memory
1”. The display will then show the values saved in
memory 1.
Compare the measured values against the application rate setpoint on the display to determine calibration required for each hopper. As an example, assume
the left hopper weighed in at 23.5 lbs and the right hopper weighed 18.0 lbs. Press the cal switch up or down
to access the calibration screens. The screen will now
read:
Certain material conditions could require a calibration of the computer to insure the application rate set
point is equal to the actual application on the ground.
It is important to understand that the aggregate is being
calibrated and not the memory. For example, if 3/8
chips are saved in memory 1 with an application rate
setpoint of 20.0 lb/yd2 and also in memory 2 with an
application rate of 8 lb/yd2, a calibration of 3/8 chips
will update both memory locations. The memory functions serve as a means to quickly change between frequently used operating parameters.
If the set point on the display is dramatically different from the application on the ground it is possible the
incorrect aggregate has been selected. Assuming this
is not the case, the following procedure should be used
to calibrate the aggregate to correct the application rate
information stored in the computer.
Before calibrating a material, verify that both spread
rolls are turning at 96 rpm. The aggregate to be calibrated needs to be selected on the display (i.e. 3/8 chips).
Set the application rate setpoint to the desired value
(i.e. 20 lb/yd2). The speed setpoint should be set around
300 FPM. Using the canvas supplied, place on a flat
surface leaving plenty of room for the chipspreader to
get up to speed. With the control handle in the full
forward position to assure constant speed, maneuver
chipspreader towards the canvas. Actuate the gate
thumbswitch about 10 feet before the material will hit
the canvas to insure the gate is in the correct position.
Deactivate the gate thumbswitch once the canvas is
covered. Weigh the material and the canvas with the
scale provided. Empty the canvas and weigh it empty.
Subtract the empty canvas weight from the total weight
0.0
lb/yd
95.6%
2
RIGHT CAL
The right hopper measured 18.0 lbs and the setpoint
is 20.0 lbs, meaning the right hopper is 2 lbs light. Press
and hold the cal switch up (+) until the lb/yd2 reads 2.0.
The RIGHT CAL value will decrease as the rate is increased, and increase as the rate is decreased. The
RIGHT CAL value is a density factor that serves as a
reference to keep track of the calibration. Press the save
pushbutton to store the calibration for the right hopper.
This process will increase the output of the right hopper by 2.0 lbs making the output equal to the application rate setpoint. The screen will reset to zero once
the save pushbutton is activated.
Press the scroll switch down (-) to access the calibration screen for the left hopper which displays the
following:
0.0
lb/yd
95.6%
2
LEFT CAL
The left hopper weighed 23.5 lbs at the application
rate setpoint of 20.0 lbs/yd2. The measured weight is
3.5 lbs heavy compared to the setpoint. Press and hold
the cal switch down (-) until the lb/yd2 reads -3.5. The
LEFT CAL value will decrease as the rate is increased,
and increase as the rate is decreased. The LEFT CAL
value is a density factor that serves as a reference to
keep track of the calibration. Press the save pushbutton
to store the calibration for the left hopper. This process
will decrease the output of the left hopper by 3.5 lbs
making the output equal to the application rate setpoint.
The screen will reset to zero once the pushbutton is
activated.
The calibration for the left and right hoppers is now
complete. To exit the calibration screens, press the scroll
switch up (+) two times to return to the main operators
screen. The calibration screens can be exited at any
time by pressing the scroll switch without changing the
10
calibration. The calibration is changed only by pressing the save pushbutton. The calibration process may
need to be repeated depending on the accuracy desired.
For very accurate calibrations (± 2.0 lbs) it will be necessary to weigh at least three samples to get an average
material weight to use in the calibration process.
The calibration process will correct both hoppers to
spread very close to the application rate setpoint. While
chipping it may become evident that one side appears
heavier or lighter than the other. This can be fine tuned
using the calibration process explained above while
chipping. If the left hopper appears lighter than the
right, press the cal switch and scroll to the left calibration screen. Toggle the cal switch up (+) to raise the
0.0 to 1 or 2 lbs and press the save pushbutton. This
will increase the output of the left hopper without effecting the right. The change will take effect as soon as
the save pushbutton is activated and should be noticeable on the ground. This process can be repeated until
the left and right hoppers appear the same.
The calibration process is permanent, meaning when
the machine is powered down the changes will be saved
for the next time the machine is put to use.
To move to the next screen, press the scroll switch
down (-).
100°F
60 PSI
15%
WATER
OIL
FUEL
This screen shows the engine coolant temperature
on the left, the engine oil pressure in the center, and the
fuel remaining in the fuel tank on the right. To move to
the next screen, press the scroll switch down (-).
100°F
2200 RPM
13.8 V
HYD OIL
ENGINE
BATTERY
This screen shows the hours on the machine on the
left side, and the feet chipped on the right side. When
the ignition key is turned on but the engine is not running, the hours will not accumulate since the hourmeter is started and stopped by an oil pressure switch. If
the engine is shut down after running less than 6 minutes, the hourmeter will not increase, as it counts up in
6 minute increments. Once the engine is started, the
hours will start to accumulate. The feet chipped will
accumulate as long as the gate thumbswitch is activated.
Distance will not accumulate when traveling and not
chipping. To reset to 0, press the cal switch up or down.
You must push the scroll switch up to return to each
previous screen, eventually returning to the top screen.
A series of alarm functions are built into the computer. If an item sensed by the computer reaches its
programmed alarm condition, the appropriate item will
appear and flash on the screen, regardless of what screen
is currently displayed. In addition, an output is sent to
the beeper and also to the warning light mounted in the
upper part of the control box. For instance, the normal
use will be to have the first screen displayed (FPM &
LBS/SQ. YD) - this will automatically be displayed on
starting the engine. If the fuel level gets down to the
alarm level (approximately 10% or 7 gallons), the words
“low fuel” will flash, the beeper will sound and the
warning light below the steering wheel will come on.
The same is true for any of the items monitored which
have alarm points. The alarm points are as follows:
low oil pressure
5 PSI
high water temperature 240 F
low fuel
10%-7 Gal.
high hydraulic oil temp. 180 F.
low voltage
11 volts
high voltage
15 volts
8. Screen Scroll Switch
This screen shows the hydraulic oil temperature on
the left, the engine rpm in the center, and the system
voltage on the right side. The right side will display
battery voltage when the ignition is on but the engine is
not running. The voltage will increase to 13.5 to 15.0
volts as the output of the alternator supplies voltage to
the system. To move to the next screen, press the scroll
switch down (-).
120.8
7550 FT
ENGINE
CHIPPED
This switch is used to scroll the screen from the first
to the fourth screen. You scroll down one screen each
time you push the switch down. Upon reaching the last
screen, you must push the scroll switch up to return
through the screens to the first screen.
9. Speed/Direction Control Handle (Figure 6)
The control handle controls both direction (forward,
neutral, reverse) and rate of speed.
Full reverse movement will give 100% of the preset
speed in reverse, up to 1300 fpm. In order to back up
faster, you must increase the speed setting. After backing up, you must reselect the appropriate memory but11
ton to reset the speed to your chipping speed. Full forward movement will give 100% of the selected speed
set point. Speed can be slowed down at any time by
pulling the handle back towards neutral and resumed
by pushing the handle fully forward at any time. The
control handle controls the rate of acceleration and deceleration. If the handle is moved quickly, the
ChipSpreader will respond quickly. If the control handle
is moved slowly, the ChipSpreader will respond slowly.
The control handle also incorporates a neutral safety
start switch, automatic application of the brake lights
and parking brake, when placed in neutral, and activation of the backup alarm. The handle has a detent in the
neutral position and an adjustable friction drag for holding at any desired position other than neutral.
point speed and the computer will maintain the set
speed. If the set speed is 200 fpm, the handle must be
moved fully forward to obtain 200 fpm. If the set speed
is 500 fpm, the handle must be fully forward to reach
500 fpm. The rate of acceleration, to the set speed, is
controlled by how fast the handle is moved from neutral to the full forward position. Adjustments to the set
point speed are made using the “Speed” toggle switch.
A change in the speed setpoint may be made at any
time using the “Speed” toggle switch. The speed may
10
PARKING BRAKE MEETS SAE J1472
PARKING BRAKE MAY NOT HOLD ON
GRADES STEEPER THAN 15%
1
9
Figure 6 Speed/Direction Control Handle
9. Control Handle
10. Gate/Spread Roll Switch
be decreased at any time by moving the handle rearward toward neutral without changing the set point and
then be brought back up to the set point by moving the
handle fully forward again. The Aggregate Application
rate is automatically maintained when either of these
methods is used to adjust the travel speed.
Figure 5 Throttle Lever
1. Throttle Lever
Decelerating is always accomplished by moving the
handle toward neutral. Upon reaching the neutral position of the handle, the parking brake will be automatically applied, after the speed sensor reads “0” speed.
The control handle will operate as follows: moving
the handle rearward out of the neutral position approximately 3 degrees will activate the backup alarm and
release the brakes. Moving the handle further rearward
will increase the reverse speed proportionate to the
handle movement until full set speed is achieved with
the handle in the full reverse position. Moving the
handle forward out of the neutral position approximately
3 degrees will release the brakes and begin to increase
the forward speed until at the full forward position of
the handle the ChipSpreader will be at 100% of the set
Stopping is always accomplished by returning the
handle to neutral.
10. Gate/Spread Roll Switch. (Figures 4 & 6)
This rocker switch (10) activates the spread roll and
also the command circuit for the gates. The gate opening is set by the rate switch (5) to the desired opening.
The gates are then opened or closed with the gate/spread
roll switch. Depressing the left side of the switch closes
the gates, while depressing the right side opens the gates.
When used this way the gates will go from closed to
the required opening for the speed and application rate
or from the required opening to closed.
The gate opening will vary, depending on the forward speed of the ChipSpreader, to maintain the set
application rate. The gate switch may be turned on at
any time. If the speed is too slow for the size aggregate
the computer display will read “CAUTION: Speed Too
12
Slow” in place of the speed, but the gates will be open
to an opening dependent on the speed, and as the speed
increases, the gates will continue to open further to
maintain the selected Application Rate . When the speed
has become high enough to exceed the minimum opening for the aggregate selected, the display will return to
showing the actual speed. If the speed is increased or
decreased using either the “Speed Toggle Switch” or
the control handle, the gates will open or close as necessary to maintain the set application rate. When the
ChipSpreader has come to a halt, depress the left side
of the rocker switch to close the gates. The gates will
close automatically when the ChipSpreader’s speed is
less than 30 fpm even if the switch is left on and will
remain closed in neutral without being turned off, however, if they were not turned off, they will immediately
begin to open whenever the forward or reverse speed
exceeds 30 fpm.
11, 12, 13. Turn Signal Selector and
Indicators. (Figure 8)
Push the switch to the right to signal a right turn,
and to the left to signal a left turn.
CAUTION
Turn signals are not self canceling
WARNING
Check local regulations and codes to
determine the lighting and marking
requirements for your usage.
16. Seat Shift Switch. (Figure 8) (Optional)
Hold the switch right or left to move the seat to the
desired position. The moving seat is meant to be an
operator convenience during chipping.
17. Hitch Release Pushbutton. (Figure 8)
Push the hitch release pushbutton to disengage the
ChipSpreader from the supply truck. There must be
some “slack” in the hitch (between the ChipSpreader
and supply truck) in order for the latch to release. While
pushing the hitch release pushbutton, one should momentarily pull the control handle rearward slightly to
slow the ChipSpreader. This will cause the required
“slack”. The control stick should then be pushed forward again, while still depressing the hitch release pushbutton. Once the truck has separated from the
ChipSpreader, the hitch release pushbutton can be released. A second hitch release pushbutton is provided
at the front operator’s controls.
12
14. Hazard Flasher Switch (Figure 8)
Push up for “on” and push down for “off”.
13
14
2
15
11
43
16
1
17
3
Figure 8. Control Panel
Figure 7 Ground Speed Pickup
1. Magnetic Pickup
2. Motor
3. Gear
15. Headlight Switch. (Figure 9)
Pull out for “on” and push in for “off”.
11. Turn Signal Selector
14. Hazard Flasher Switch
12. Lt Turn Signal Ind
15. Headlight Switch
13. Rt Turn Signal Ind
16. Seat Shift Switch (optional)
17. Hitch Release Pushbutton 52. Brake Pedal
It is possible to stop with no “slack” in the hitch (between the ChipSpreader and supply truck). If this happens, the ChipSpreader must be backed up slightly to
create the necessary “slack” and then driven forward
while pushing the hitch release pushbutton.
In order to hook up to a supply truck, momentarily
depress the hitch release pushbutton to open the hitch
if it is not already open, and back into the truck. The
13
hitch automatically closes and locks when it contacts
the back of the truck.
18. Hand Throttle Lever. (Figure 5)
Push forward and up to decrease engine RPM, pull
back and downward to increase RPM. Under certain
conditions it may be desired to have an intermediate
RPM setting, however the hydrostatic system is designed to be run with the engine running at full governed RPM. Therefore whenever chipping at normal
spreads (i.e. anything over 80 FPM) the engine should
be run at governed RPM.
19. Application Rate Computer. (inside
control panel)
The speed pickup (Figure 7) feeds a pulse speed signal to the computer. The gate position feedback transducer feeds a gate position signal to the computer. The
computer compares the speed feedback signal to the
set point and sends the appropriate signal to the pump
to maintain the set speed. The computer also calculates
the required gate opening for the set application rate
and opens and closes the gates to maintain the application rate.
Normal spreading would be done as follows:
a) Place the control handle in neutral.
b) Set the desired speed using the Speed Toggle
Switch (3).
c) Turn the gate/spread roll switch (10) “off”.
d) Set the desired application rate using the Rate
Switch (5), or select the appropriate memory by pushing the appropriate memory button.
e) Push the speed/direction handle (9) forward
smoothly to the full forward position to accelerate to
the speed set point.
f) Upon reaching the starting line of spreading, depress the right side of the gate/spread roll switch (10)
fully to turn the gates “on”.
g) Upon reaching the ending line, center or depress
the left side of the gate/spread roll switch fully (10) to
shut the gates “off”.
h) Return the control handle to neutral.
Speed changes may be made while moving by using
the Speed Toggle Switch to set a new speed. The
ChipSpreader will change speed to the new speed. The
application rate will remain the same as long as the
ChipSpreader is within the limits of gate opening for
the particular aggregate selected.
If a speed is reached which requires a gate opening
greater than that available for the aggregate selected,
or than the hopper has available, the message “CAU-
TION: Speed Too High” will appear in the display. The
gates will remain open but the ChipSpreader will not
be able to maintain the set application rate.
20. Right Conveyor Selector (Figure 4)
In the bottom position, the conveyor is turned “On”.
In the next position from the bottom power is supplied to the front operator’s “on/off” selector switch
allowing the front operator to turn the conveyors “on”
or “off”.
In the 2nd position from the top, power is supplied
to the auto diaphragm switch mounted below and along
the inboard side of the conveyor hood. (See fig. 12)
When this switch is tripped by material moving the
paddle, the conveyor will shut off and conversely when
it is untripped by a lack of material it will start the conveyor attempting to fill the hopper.
In the upper position, the conveyor is turned “Off”
21. Left Conveyor Selector. (Figure 4)
Same operation as above except for left conveyor
and left conveyor auto diaphragm switch.
Since both conveyors are independently controlled,
it is possible to run one conveyor in one mode of control while running the other conveyor in a totally different mode if so desired.
22. Hitch Height Switch. (Figure 4)
Push up to raise the hitch, push down to lower the
hitch. When the switch is released, the cylinder will
hold the hitch at a given height, about which it is free
to float up and down on a spring to provide vertical
articulation between the ChipSpreader the truck.
23. Left Gate Override Switch (Figure 4)
Depress to momentarily fully open the left hopper
gate to clear a jam. Upon releasing the pushbutton, the
gate will return to its original set point.
24. Right Gate Override Switch (Figure 4)
Depress to momentarily fully open the right hopper
gate to clear a jam. Upon releasing the pushbutton, the
gate will return to its original set point.
25. Left Hopper Position Switch (Figure 4)
Push left to extend the left hopper and push right to
retract the left hopper.
26. Right Hopper Position Switch (Figure 4)
Push right to extend the right hopper and push left to
retract the right hopper.
27. Left Gate Power Switch (Figure 4)
This switch connects or disconnects the left hopper’s
14
gate to the “gate/spread roll” switch (Item 10). When
connected, the hopper is then turned “on” or “off” using the “gate/spread roll” switch.
28. Left Spread Roll Switch (Figure 4)
Since both augers are independently controlled, it is
possible to run one auger in one mode of control while
running the other auger in a totally different mode if so
desired.
This switch connects or disconnects the left hopper’s
spread roll to the “gate/spread roll” switch (Item 10).
When connected, the spread roll is then turned “on” or
“off” using the “gate/spread roll” switch. This switch
is only supplied with the optional individual gates.
33. Memory Selector Buttons (Figure 4)
29. Right Hopper Power Switch (Figure 4)
This button is used to save the preset combination
once it has been set to the desired parameters. See the
section on Material Calibration and saving in a preset
location.
This switch connects or disconnects the right
hopper’s gate to the “gate/spread roll” switch (Item 10).
When connected, the hopper is then turned “on” or “off”
using the “gate/spread roll” switch.
30. Right Spread Roll Switch (Figure 4)
This switch connects or disconnects the right
hopper’s spread roll to the “gate/spread roll” switch
(Item 10). When connected, the spread roll is then turned
“on” or “off” using the “gate/spread roll” switch. This
switch is only supplied with the optional individual
gates.
31. Left Auger Selector (Figure 4)
In the bottom position, the left auger is turned “On”.
In the next position from the bottom, power is supplied to the front operator’s “on/off” switch allowing
the front operator to turn the left auger “on” or “off”.
In the 2nd position from the top, power is supplied
to the auto switch located at the outboard end of the
left hopper (See fig. 10). When this switch is tripped
by material against the diaphragm, the auger will shut
off and conversely when it is untripped by a lack of
material, it will start the auger attempting to fill the
outer end of the hopper. In the upper position, the auger is turned “Off”.
32. Right Auger Selector (Figure 4)
In the bottom position, the right auger is turned “On”.
In the next position from the bottom, power is supplied to the front operator’s “on/off” switch allowing
the front operator to turn the right auger “on” or “off”.
In the 2nd position from the top, power is supplied
to the auto switch located at the outboard end of the
right hopper (See fig. 10). When this switch is tripped
by material against the diaphragm, the auger will shut
off and conversely when it is untripped by a lack of
material, it will start the auger attempting to fill the
outer end of the hopper. In the upper position, the auger is turned “Off”.
These switches select which of the 5 preset aggregate combinations of speed, application rate, size and
material is to be spread.
34. Memory Save Button
35. Calibrate Switch (Figure 4)
This switch is used to calibrate the material before
use. See the section on Material Calibration and saving
in a preset location.
36. Optional Individual Gates Master Switch
This switch connects the selected individual gates
to the Thumb Switch on the top of the control stick so
that the selected gates will open when the Thumb Switch
is turned on. A more detailed description of how the
gate operates is located in the section on the Individual
Gates.
37. Left Hopper Gate Selector Switches
These switches select which gates on the left hopper
will be opened when the Thumb Switch is turned on.
Once the hopper is spreading, these switches are used
to control individual gates on the left hopper, turning
them on or off as the spread requires. A more detailed
description of how the gate operates is located in the
section on the Individual Gates.
38. Right Hopper Gate Selector Switches
These switches select which gates on the right hopper will be opened when the Thumb Switch is turned
on. Once the hopper is spreading, these switches are
used to control individual gates on the right hopper,
turning them on or off as the spread requires. A more
detailed description of how the gate operates is located
in the section on the Individual Gates.
39. Horn (Figure 4)
This button is used to operate the Chipspreader’s horn
for signalling the truck or warning of danger.
40. Strobe Beacon Switch (Figure 4)
This switch is used to turn the optional strobe or
warning lights on or off.
15
41. Warning Light (Figure 4)
This light will be activated whenever one of the
monitored functions reaches its alarm point. As in high
oil temperature, high engine coolant temperature, low
engine oil pressure, low voltage, and low fuel. The function which has reached its alarm point will be described
in the computer’s digital display.
52. Brake Pedal (Figure 8)
The brake pedal can be used to assist the hydrostatic
braking. For instance, the parking brake is applied when
the computer sees the chipspreader is stopped. On a
grade, the chipspreader may roll back, since it did not
come to a complete stop and apply the parking brake.
The foot brake will hold the chipspreader on the grade
until the parking brake is set.
WARNING
When the driver has selected “front” on the left conveyor selector switch (22) this switch will turn the left
conveyor “on” or “off”.
46. Right Conveyor Switch (Figure 11)
When the driver has selected “front” on the right
conveyor selector switch (20) this switch will turn the
right conveyor “on” or “off”.
47. Hitch Release Pushbutton (Figure 11)
Push the hitch release pushbutton to disengage the
supply truck from the ChipSpreader. (See item 17
“Hitch Release Pushbutton, operator’s control panel)
48. Left Auger Switch (Figure 11)
When the driver has selected “front” on the left auger selector (38), this switch will turn the left auger
“on” or “off”.
49. Right Auger Switch (Figure 11)
Auger may start automatically at any time!
Do not attempt to clear any jam with the
engine running.
When the driver has selected “front” on the right
auger selector (40), this switch will turn the right auger
“on” or “off”.
50. Left Gate Override Switch (Figure 11)
2
1
Depress to momentarily fully open the left hopper
gate to clear a jam. Upon releasing the pushbutton, the
gate will return to its original set point.
51. Right Gate Override Switch (Figure 11)
Depress to momentarily fully open the right hopper
gate to clear a jam. Upon releasing the pushbutton, the
gate will return to its original set point..
WARNING
Figure 10. Auger Auto On/Off Switch
1. Switch
2. Auger
Unsafe operation of equipment may cause
injury. Read, understand and follow the
manuals when operating or performing
maintenance.
ITEMS 43 THRU 51 ARE LOCATED IN THE
FRONT OPERATOR’S CONTROL BOX (Figure
11)
43. Left Hopper Switch (Figure 11)
Push left to extend the left hopper and push right to
retract the left hopper.
44. Right Hopper Switch (Figure 11)
Push right to extend the right hopper and push left to
retract the right hopper.
45. Left Conveyor Switch (Figure 11)
16
HOPPERS
43
LEFT
IN
44
RIGHT
IN
OUT
LEFT CONV
ON
OUT
HITCH
RELEASE RIGHT CONV
ON
46
45
OFF
OFF
RIGHT AUGER
LEFT AUGER
ON
48
50
47
ON
49
OFF
OFF
LEFT GATE
OVERRIDE
RIGHT GATE
OVERRIDE
3101974
51
Figure 11. Front Operator’s Control Panel
43. Lt Hopper Switch
48. Lt Auger Switch
44. Rt Hopper Switch
49. Rt Auger Switch
45. Left Conveyor Switch
50. Left Gate Override
46. Right Conv Switch
51. Right Gate Override
47. Hitch Release Pushbutton
17
OPERATION
WARNING
Unsafe operation of equipment may cause
injury. Read, understand and follow the
manuals when operating or performing
maintenance.
spread roll or gate and rear of hopper. The
gate could move at any time and cause
severe injury.
Do not travel with the seat unlatched. Seat
movement could occur causing disorientation
and possible loss of control.
CAUTION
Always install locking control box cover and
chock wheels when leaving machine
unattended as protection against vandalism
and accidental movement.
IMPORTANT
Do not tow the ChipSpreader before reading
the towing instructions contained in this
manual. Improper towing may damage the
hydraulic motors.
WARNING
Remain clear of all moving parts.
CAUTION
Before operating the ChipSpreader, make an
inspection of the machine to be sure that the
machine is in a safe condition to operate.
WARNING
Always use steps, platforms and handrails
provided.
Always have shields, covers and guards in
place when operating.
Make certain everyone is clear of machine
before starting or operating the machine.
Since all functions except power steering and
brakes are electrically controlled, turning the
ignition key to “off” results in an emergency
stop.
Keep loose clothing away from conveyor
area when operating the conveyors.
Unsafe operation of equipment may cause
injury. Read, understand and follow the
manuals when operating or performing
maintenance.
Never put hands in between gate and spread
roll or gate and rear of hopper. The gate
could move at any time and cause severe
injury.
Remain clear of all moving parts.
Should a piece of foreign material become lodged in
the gates, push the gate override pushbutton (Ref. 23
or 24, Fig. 4) to open the appropriate gate above the set
point to allow the piece to pass. Releasing the override
will return the gates to the previously set position.
Adjust ChipSpreader hitch height as necessary to
accommodate different individual trucks.
Operate the conveyor belt switches so as to maintain an even distribution of aggregate in the front hopper.
The machine is equipped with conveyor belt speed
controls. The rear conveyor gates should be set to deliver as much material as possible into the conveyor
without spillage and then the conveyor speed should
be adjusted to deliver slightly more aggregate to the
front hopper than the amount being spread. When properly adjusted, the conveyors should run approximately
80% of the time with the hopper at maximum width
and the ChipSpreader traveling at maximum speed for
the particular job.
18
Automatic Conveyor Control (Figure 4)
locked at the desired speed with the lock ring.
In the 2nd position from the top, power is supplied
to the auto diaphragm switch mounted below and along
the inboard side of the conveyor hood. When this switch
is tripped by material moving the paddle, the conveyor
will shut “off” and conversely when it is untripped by
lack of material it will start the conveyor attempting to
fill the hopper. (Fig. 12)
This feature is particularly useful in doing shoulder
work or in operations requiring less than full hopper
width. It is also useful in trying to smooth out delivery
of material to match the rate being spread. (Fig.13)
When properly adjusted, the conveyors should run approximately 80% of the time with the hopper at maximum width and the ChipSpreader traveling at maximum speed for the particular job.
CAUTION
Keep loose clothing away from conveyor
area when operating conveyors.
2
Backup Alarm
The electric backup alarm is automatically actuated
when the speed/direction control handle (Fig. 6) is
pulled to the rear of neutral.
1
OPTIONAL EQUIPMENT
Figure 12. Conveyor Diaphragm Switches
1. Right Diaphragm Switch
2. Left Diaphragm Switch
3
4
1
2
WARNING
Unsafe operation of equipment may cause
injury. Read, understand and follow manuals
when operating or performing maintenance.
Hydraulic Powered Seat
An hydraulically powered seat positioner is operated
by a spring centered toggle switch (Fig 8). The seat
may be positioned wherever it is desired for operation.
Individual Gates (Figure 14)
Figure 13. Belt Speed Controls
1. Rt Conv Solenoid Valve
2. Lt Conv Solenoid Valve
3. Rt Speed Control Valve
4. Lt Speed Control Valve
The individual gates are located at the outer ends of
each hopper as described below.
hopper lgth
9
10
11
12
Belt Speed Controls
gates/side
4
4
5
5
This feature allows the operator located on the right
catwalk to vary the speed of each conveyor independently to provide a uniform distribution of material to
the front hopper. Valves for this operation are incorporated in the integrated circuit block under cover between
the conveyors. Each valve has an adjustment knob and
a locking ring.
lgth inside gate 5’
6’
6’
7’
With the knob screwed fully out, the conveyor will
run at its highest speed. Screwing the knob clockwise
to its full in position will slow the conveyor down. The
knob may be positioned anywhere in between and
These gates are turned on or off by air cylinders.
The air cylinders either keep the gate closed, or when
turned on, they open the gate up against the hydraulically positioned buss bar. The computer controls the
position of buss bar according to the gate opening required. The buss bar is turned on/off by using the gate/
19
spread roll thumb switch. For opening of all of the gates,
the left and right gate power switches should be turned
on and the left and right spread roll switches should be
turned on. For normal operation, the Gate Master switch
is turned on, and the switches for the individual gates
are all turned on. When operated in this manner, the
entire left and right hoppers will open across their full
width. If the hoppers are fully extended, turning off individual switches on the outboard end will turn off 1
foot increments until getting to the inboard gate which
will shut off 4 or more feet depending on hopper size
and extension. The inboard gate will always shut off
that side from the centerline of the ChipSpreader to the
1st 1 foot gate.
As an example, assume a 10 ft variable hopper is
fully closed up. There are 4 1 ft gates and a single 6 ft
gate on each side. When the hopper is fully closed up
the 6 ft gate has only 1 ft exposed beyond the centerline. This is the same on the other side. The hopper will
operate as a 10 ft hopper with 10 individual 1 ft gates
across its length. If the left hopper were extended 2 ft
out and the right hopper were also extended 2 ft out,
you would have a 14 ft hopper with gates of
1,1,1,1,3,3,1,1,1, and 1 ft widths. When the hopper is
fully extended to 20 ft the gates would be
1,1,1,1,6,6,1,1,1,1.
2
1
4
3
Figure 14. Individual Gates
1. Air Cylinder
2. Hydr Cylinder
3. Buss Bar
4. Inside Gate Air Cylinder
The normal operation would be to turn on the Master gate switch and also all of the individual switches.
The gates would then be turned on or off from the thumb
switch on the control handle. If it is desired to turn the
gates off instantly in some operations, the Gate Master
switch can be turned off before the thumb switch, and
then the thumb switch turned off.
Be sure to turn the Gate Master Switch back on again
before opening the thumb switch or no gates will open
with the buss bar.
If it is desired to spread a couple of feet at the end of
a hopper for either shoulder work or patching, it is recommended that the spread roll for the hopper be turned
off to avoid unnecessary wear on the portion of the
spread roll that is turning against the closed gates. If
the spread roll is turned off, the application rate will be
less than with the spread roll on, so it will be necessary
to increase the application rate or gate opening to get
the same amount of material.
20
21
APPENDIX A
MAINTENANCE ADJUSTMENTS
1
WARNING
When two people are required to perform
adjustments or maintenance operations or
two people are simultaneously performing
different operations, the work must be
coordinated between the two people to avoid
possible injuries.
4
3
2
WARNING
Figure 15. Spread Roll Wear Plate
When two people are performing
maintenance adjustments, do not start
engine without assuring that the other
person is clear of moving parts and out from
under the machine. Be sure that the mode
selector is in park and the control stick is in
neutral before attempting to start engine.
(View from top of Hopper Looking Down)
1. Auger
3. Spread Roll Wear Plate
2. Agitator (optional)
4. Hold Down Bolts
Hopper Spread Roll Wear Plate Adjustment
(Figure 15)
WEAR PLATE
Turn the spread rolls and conveyors “off”.
1. Loosen all spread roll wear plate hold down bolts
and adjust the wear plate until a nominal 1/16" clearance exists between the wear plate and the spread roll
for the entire hopper width.
2. Re tighten all the hold down bolts.
3. When one side of a plate has worn excessively it
is possible to turn the plate over and use the opposite
side.
Hopper Gate Wear Plate Adjustment (Fig. 16)
Turn spread roll and conveyors “off”.
1. Loosen wear plate hold down bolts and extend
the plate 1/32" past the gate edge along the entire gate
width.
2. Tighten hold down bolts.
3. As plate wear occurs, additional adjustment will
be necessary.
4. When one side of a plate has been worn away it is
possible to turn the plate over and use the opposite side.
Figure 16 Hopper Gate Wear Plate
WARNING
Conveyor must be running during this
procedure. To avoid personal injury, be sure
to remain clear of moving belt.
Conveyor Belt Adjustment
1. If the conveyor belt tends to move towards one
side of the conveyor, tighten tail pulley adjustment on
that side until the belt is running in the center.
2. Should it be impossible to obtain centered belt
operation by adjusting the tail pulley (Fig. 17) it will
then be necessary to adjust the head pulley as outlined
below. (Fig. 18)
For the right hand conveyor:
a) Loosen the four bolts holding the left hand side
head pulley bearing.
b) Loosen adjusting bolt jam nuts.
22
c) Start conveyor at this time.
ment should be necessary to center conveyor belts.
d) If belt runs to the right hand side of the conveyor,
loosen the adjusting screws until the belt is centered on
the head pulley.
e) If belt runs to the left hand side of the conveyor,
tighten the adjusting screws until the belt is centered
on the head pulley.
f) Re tighten adjusting screw jam nuts.
g) Stop the conveyor belt.
h) Tighten head pulley bearing bolts.
3. Conveyor belts should be sufficiently tight to prevent head pulley slippage when the belts are loaded
and operating at full governed speed. It should be noted,
however, that excessive belt tightness will result in
shortened belt and pulley bearing life. It may be necessary to tighten the belts several times during the first
few weeks of operation until most of the initial belt
stretch has been removed. When doing so it is necessary to tighten each side equally to keep the belt running centered.
WARNING
WARNING
The fuel tank is part of the crosswalk. Do not
drill or weld in this area.
Remain clear of all moving parts.
CAUTION
To avoid potential damage to electrical
components, disconnect batteries before
welding
1
Figure 17 Conveyor Tail Pulley
1
3
4
1. Conveyor Belt Tail Pulley Adjustment Bolt (4 Places)
For left hand conveyor:
a) Loosen the four bolts holding the right hand side
head pulley bearing.
3
2
b) Loosen the adjusting bolt jam nuts.
c) Start conveyor at this time.
WARNING
Remain clear of all moving parts.
d) If belt runs to the right side of the conveyor, tighten
the adjusting screws until the belt is centered on the
head pulley.
e) If belt runs to the left side of the conveyor, loosen
the adjusting screws until the belt is centered on the
head pulley.
f) Re tighten adjusting screw jam nuts.
Figure 18 Conveyor Head Pulley Adjustment
1. Left Conveyor
2. Jam Nut
3. Adjusting Screw
4. Bearing Bolts
IMPORTANT
Do not tow the chipspreader before reading
the towing instructions contained in this
manual. Improper towing may damage the
hydraulic motors and brakes.
g) Stop the conveyor belt.
Towing Instructions
h) Tighten head pulley bearing bolts.
Disconnect driveline assembly at front axle. On a
4WD machine, also disconnect the driveline on the rear
axle
NOTE: Only a small amount of head pulley adjust-
23
APPENDIX B
COMPUTER SETUP
COMPUTER SET UP
The computer must be set up and the various sensors calibrated for the particular ChipSpreader that the
computer is installed in. This is normally done at the
factory, and the settings are retained in the computer’s
non volatile memory. Normally an entire set up does
not have to be done in the field, but if a joystick or a
gate transducer is replaced, that particular item would
have to be re- calibrated. In the case of a gate transducer, it should be mechanically set using the procedure described under “Hopper Gate Transducer Adjustment” before re calibrating the computer. In order to
do that, you must enter the set up screens and follow
through the various screen as described below. If an
item is already properly set, you can just scroll by it to
the next item, until you get to the one that needs to be
re-calibrated. If any one item is changed, you must save
it using the procedure described at the end of the various screens.
SET UP SCREENS
The following screens are entered by holding the cal
switch either up or down while turning the ignition key
on.
IMPORTANT: The setup of the computer should be
performed with the ignition key on, but the engine not
running, except for calibrating the gates and the speed.
CAUTION
Always place the mode selector switch in the
“park” position when the chipspreader is
stopped to avoid accidental movement of the
machine.
These screens are used to configure the computer to
the particular ChipSpreader and to calibrate the speed
pickup, control stick, gates, and application rate. The
first screen will appear when the ignition key is released
from the start position.
Push the “scroll” switch down to move to the next
screen.
SETUP: ENGINE
CUMMINS
This screen shows which engine is in the machine
and sets the tach input for that manufacturers engine.
Use the “cal” switch to toggle between Cummins and
Caterpillar engines. Push the “scroll” switch down to
move to the next screen.
SETUP: DRIVE
4 WHEEL
This screen is used to set the type of drive in the
machine. Either 2 wheel or 4 wheel drive. Use the “cal”
switch to toggle between 2 and 4 wheel drive. Push the
“scroll” switch down to move to the next screen.
SETUP: MOTOR SIZE
107 CC
This screen is used to set the motor displacement.
Use the “cal” switch to toggle between 107 CC and
160 CC. If the machine is a 2WD this must be set to
160 CC. If it is a 4WD, this must be set to 107 CC
(standard) or 160 CC depending on the size of the motors. When this has been properly set, push the “scroll”
switch down to move to the next screen.
SETUP: HOPPER
VARIABLE
This screen is used to set the type of hopper installed
on the machine. Use the “cal” switch to toggle between
fixed and variable hoppers. When this set for your machine, push the “scroll” switch down to move to the
next screen.
SETUP: FIRMWARE
SETUP: UNITS
Version 2.XX
ENGLISH
This screen shows the version of firmware which is
loaded in the machine. (version 2.53 for example)
This screen is used to set the display units to either
english or metric. Use the “cal” switch to toggle be24
tween english and metric units. When this set for your
machine, push the “scroll” switch down to move to the
next screen.
This screen is used to set the threshold current to the
forward solenoid on the hydrostatic pump. This value
should be set to 0.450 amps, using the “cal” switch.
When it is set to this value, push the “scroll” switch to
move to the next screen.
SETUP: JOYSTICK
Actual
0.0%
This screen is the entry screen for calibrating the
joystick. It should say 0.0% with the stick in neutral. If
the stick is pushed full forward, the reading should
change to 100% and if it pulled fully back into reverse,
the reading should change to -100%. If it does not at
any of these positions, place the stick in neutral. Be
sure it is in neutral and then push the “cal” switch. Once
you have pushed the “cal” switch you must complete the sequence or you will have lost the existing
calibration of the joystick. When you push the “cal”
switch, the screen will change to
SETUP: JOYSTICK
Neutral
0.0 volts
Push the “cal” switch to calibrate the neutral position. The display will change to
SETUP: THRESHOLDS
Reverse:
0.350 amps
This screen is used to set the threshold current to the
reverse solenoid on the hydrostatic pump. This value
should be set to 0.350 amps, using the “cal” switch.
When it is set to this value, push the “scroll” switch to
move to the next screen.
SETUP: RIGHT NULL
Actual:
0.00 inches
This screen is used to set the actual closed position
of the right gate. Be sure that the gate is actually closed.
This number should read 0.00 inches, if this number is
not 0.00, set it to 0.00 using the “cal” switch. When it
is set to this value, push the “scroll” switch to move to
the next screen.
SETUP: JOYSTICK
SETUP: RIGHT SCALE
forward
Actual:
0.0 volts
Push the stick full forward, the reading should change
to approximately 4.8 or 4.9 volts. When you have the
stick fully forward, push the “cal” switch to calibrate
the full forward position of the control stick. The display will change to
SETUP: JOYSTICK
reverse
0.0 volts
Pull the stick to the full reverse position, the reading
should change to approximately 4.8 or 4.9 volts. When
you have the stick fully rearward, push the “cal” switch
to calibrate the full reverse position of the control stick.
The display will change to
SETUP: JOYSTICK
Actual
0.0%
When you have finished calibrating the joystick, push
the “scroll” switch to change to the next screen.
SETUP: THRESHOLDS
Forward:
0.450 amps
0.00 inches
This screen is used to set the actual open position of
the right gate. The number will read 0.00 inches until
the right gate override is actuated. While holding the
right gate override the number should read 4.00 inches.
If it does not read 4.00, first visually verify that the
gate is actually fully open. After verification, while
holding the right gate override, press the CAL switch
to set the value to 4.00 inches. When the right gate override is released, the number on the screen should go
back to 0.00.
SETUP: LEFT NULL
Actual:
0.00 inches
This screen is used to set the actual closed position
of the left gate. Be sure that the gate is actually closed.
This number should read 0.00 inches, if this number is
not 0.00, set it to 0.00 using the “cal” switch. When it
is set to this value, push the “scroll” switch to move to
the next screen.
SETUP: LEFT SCALE
Actual:
0.00 inches
This screen is used to set the actual open position of
25
the left gate. The number will read 0.00 inches until the
left gate override is actuated. While holding the left
gate override the number should read 4.00 inches. If it
does not read 4.00, first visually verify that the gate is
actually fully open. After verification, while holding
the left gate override, press the CAL switch to set the
value to 4.00 inches. When the left gate override is released, the number on the screen should go back to 0.00.
SETUP: RIGHT OPEN
0.900 amps
Use the “cal” switch to adjust the current up or down
to increase or decrease the speed at which the right gate
opens.
SETUP: RIGHT CLOSE
1.200 amps
WARNING
Never put hands in between gate and spread
roll or gate and rear of hopper to clear
obstruction. The gate could move at any time
and cause severe injury.
Use the “cal” switch to adjust the current up or down
to increase or decrease the speed at which the right gate
closes.
SETUP: LEFT OPEN
0.975 amps
SETUP: Front Motor
0 fpm 0.400 amp
This screen is used to set the threshold current to the
front motor. The threshold current normally does not
need to be changed. It only might need to be changed if
the ChipSpreader is to be operated at extremely slow
speeds -well under 100 fpm. Operate the chipspreader
at 300 fpm. While the chipspreader is running at 300
fpm, increase the threshold current until a change in
speed is felt, and then back it down until there is no
speed change. The normal threshold current setting from
the factory is 0.400 amps. When it is set to this value,
push the “scroll” switch to move to the next screen.
SETUP: Rear Motor
0 fpm 0.400 amp
This screen is used to set the threshold current to the
rear motor of a 4WD ChipSpreader. The threshold current normally does not need to be changed. It only might
need to be changed if the ChipSpreader is to be operated at extremely slow speed -well under 100 fpm.
Operate the chipspreader at 300 fpm. While the
chipspreader is running at 300 fpm, increase the threshold current until a change in speed is felt, and then back
it down until there is no speed change. The normal
threshold current setting from the factory is 0.400 amps.
When it is set to this value, push the “scroll” switch to
move to the next screen.
Use the “cal’ switch to adjust the current up or down
to increase or decrease the speed at which the left gate
opens.
SETUP: LEFT CLOSE
0.900 amps
Use the “cal” switch to adjust the current up or down
to increase or decrease the speed at which the left gate
closes.
SETUP: RIGHT GATE HOLD
DISTANCE:
0.0 inches
This screen is used to set the delay of the right gate
on a variable hopper. This value should be set to 0.0
except special units. If the number is changed to 10.0,
for example, the computer would wait until the
chipspreader travels 10 inches before the right gate
would open. The left gate is not affected by changing
this number.
SETUP: SAVE AND EXIT
Press Save to Exit
Press the “Save” button to save any changes that were
made or press the “Scroll” switch down to exit without
saving.
The calibration done in these setup screens is to adjust the open and close thresholds on the proportional
valves controlling the gate cylinders. These thresholds
determine the speed at which the gates open and close
and allow the operator to adjust them independently
form side to side to make them open and close at the
same speed.
26
APPENDIX C
COMPUTER SERVICE SCREENS
SERVICE SCREENS
The service screens are entered by holding the
“scroll” switch either up or down while turning the ignition key on. The first four screens are the same as the
“Operator Screens” described under “OPERATOR
SCREENS” but will be repeated here.
CAUTION: When in the service screens, all interlocks are disabled and it is possible to open the gates in
the manual mode while standing still.
20.0
lb/yd
2
3/8
400
Chip
fpm
This screen shows the application rate set point, aggregate preset and the speed set point when standing
still.
This is the screen that will come up when the ignition is turned on and the engine is started, while holding the “scroll” switch either up or down. To move to
the next screen, push the scroll switch down.
100ºF
WATER
60 PSI
OIL
15%
FUEL
This screen shows the engine coolant temperature
on the left, the engine oil pressure in the center, and the
fuel remaining in the fuel tank on the right. To move to
the next screen, push the scroll switch down.
100ºF
2200 RPM
13.8 V
HYD OIL
ENGINE
BATTERY
This screen shows the hydraulic oil temperature on
the left, the engine rpm in the center, and the system
voltage on the right side. To move to the next screen,
push the scroll switch down.
120.8
7550 FT
ENGINE
CHIPPED
left side, and the feet chipped on the right side. To move
to the next screen, push the scroll switch down to move
to the first real service screen
SERVICE:
RIGHT NULL
Actual:
0.0 inches
This screen shows the actual position of the right
gate. Push the scroll switch down to move to the next
screen.
SERVICE:
LEFT NULL
Actual:
0.0 inches
This screen shows the actual position of the left gate.
Push the scroll switch down to move to the next screen.
SERVICE: Aggre. Last
Status: De-activated
This screen shows the position of the “Size” switch.
Push the” Size” switch up and the display should change
to Activated until the switch is released. Push the scroll
switch down to move to the next screen.
SERVICE: Aggre. Next
Status: De-activated
This screen shows the position of the “Size” switch.
Push the “Size” switch down and the display should
change to Activated until the switch is released. Push
the scroll switch down to move to the next screen.
SERVICE: Appl RateStatus: De-activated
This screen shows the position of the “Rate” switch.
Push the “Rate” switch down and the display should
change to Activated until the switch is released. Push
the scroll switch down to move to the next screen.
This screen shows the hours on the machine on the
27
SERVICE: Appl Rate+
SERVICE: L.GATE OVER
Status: De-activated
Status: De-activated
This screen shows the position of the “Rate” switch.
Push the “Rate” switch up and the display should change
to Activated until the switch is released. Push the scroll
switch down to move to the next screen.
SERVICE: Cal RateStatus: De-activated
This screen shows the position of the “Cal” switch.
Push the “Cal” switch down and the display should
change to Activated until the switch is released. Push
the scroll switch down to move to the next screen.
SERVICE: Cal Rate+
Status: De-activated
This screen shows the position of the “Cal” switch.
Push the “Cal” switch up and the display should change
to Activated until the switch is released. Push the scroll
switch down to move to the next screen.
Be sure the “Park /Drive” Mode Switch is in the
park position before performing the next sequence
of checks.
SERVICE: L.GATE SEL
Status: De-activated
This screen shows the position of the “Left Gate
Selector” switch. Put the “Left Gate Select” switch up,
depress the right side of the “Thumb” switch and push
the joystick out of neutral. The display should change
to Activated. Check that it is deactivated with each of
the following switches. Put the joystick in neutral. It
should become deactivated. Push the joystick out of
neutral, it should become activated again. With the joystick still out of neutral, center the “Thumb” switch and
it should become deactivated. Turn the “Thumb” switch
back on again. With the joystick still out of neutral,
push the “Left Gate Select” switch down and the display should change to deactivated. Push the scroll switch
down to move to the next screen.
This screen shows the position of the “Left Gate
Override” switch. Push the left gate override button
down and the display should change to activated as long
as the button is held down and return to deactivated
when the button is released. Push the scroll switch down
to move to the next screen.
SERVICE: R.GATE SEL
Status: De-activated
This screen shows the position of the “Right Gate
Selector” switch. Put the “Right Gate Select” switch
up, depress the right side of the “Thumb” switch and
push the joystick out of neutral. The display should
change to Activated. Check that it is deactivated with
each of the following switches. Put the joystick in neutral. It should become deactivated. Push the joystick
out of neutral, it should become activated again. With
the joystick still out of neutral, center the “Thumb”
switch and it should become deactivated. Turn the
“Thumb” switch back on again. With the joystick still
out of neutral, push the “Right Gate Select” switch down
and the display should change to deactivated. Push the
scroll switch down to move to the next screen.
SERVICE: R.GATE OVER
Status: De-activated
This screen shows the position of the “Right Gate
Override” switch. Push the “Right Gate Override” button down and the display should change to activated as
long as the button is held down and return to deactivated when the button is released. Push the scroll switch
down to move to the next screen.
SERVICE: Save
Status: De-activated
This screen shows the position of the “Save” Button. Push the “Save” button down and the display should
change to Activated as long as the button is held down.
Push the scroll switch down to move to the next screen.
SERVICE: Setup #1
Status: De-activated
28
This screen shows the position of the “Memory 1”
Button. Push the “Memory 1” button down and the display should change to Activated as long as the button is
held down. Push the scroll switch down to move to the
next screen.
Switch. Push the “Speed” switch down and the display
should change to Activated as long as the switch is held
down. Push the scroll switch down to move to the next
screen.
SERVICE: VEH. SPEED+
SERVICE: Setup #2
Status: De-activated
Status: De-activated
This screen shows the position of the “Memory 2”
Button. Push the “Memory 2” button down and the display should change to Activated as long as the button is
held down. Push the scroll switch down to move to the
next screen.
This screen shows the position of the “Speed”
Switch. Push the “Speed” switch up and the display
should change to Activated as long as the switch is held
up. Push the scroll switch down to move to the next
screen.
SERVICE: RELEASE
SERVICE: Setup #3
Status: De-activated
Status: De-activated
This screen shows the position of the “Memory 3”
Button. Push the “Memory 3” button down and the display should change to Activated as long as the button is
held down. Push the scroll switch down to move to the
next screen.
This screen shows the position of the “Brake Release” Switch. With the “Park/Drive” Mode selector in
the park position and the engine not running, push the
control stick out of neutral. The display should change
to activated until the control stick is returned to neutral. Push the scroll switch down to move to the next
screen.
SERVICE: Setup #4
Status: De-activated
SERVICE: BATTERY
Status: 12.3 volts
This screen shows the position of the “Memory 4”
Button. Push the “Memory 2” button down and the display should change to Activated as long as the button is
held down. Push the scroll switch down to move to the
next screen.
SERVICE: Setup #5
Status: De-activated
This screen shows the position of the “Memory 5”
Button. Push the “Memory 5” button down and the display should change to Activated as long as the button is
held down. Push the scroll switch down to move to the
next screen.
This screen shows the condition of the battery and
charging system. With the engine not running the battery voltage will be displayed. When the engine is running, the display will show the output voltage of the
alternator. Push the scroll switch down to move to the
next screen.
SERVICE: OIL PRESSURE
Status: 4.80 volts
This screen shows the voltage being measured in the
oil pressure sender circuit. Push the scroll switch down
to move to the next screen.
SERVICE: VEH. SPEED-
SERVICE: WATER TEMP
Status: De-activated
Status: 4.80 volts
This screen shows the position of the “Speed”
This screen shows the voltage being measured in the
water temperature sender circuit. Push the scroll switch
29
down to move to the next screen.
SERVICE: Right Gate
Status: 0.00 Volts
SERVICE: Engine Speed
Status: 0 Hertz
This screen shows the frequency being measured in
the engine tachometer circuit. Push the scroll switch
down to move to the next screen.
This screen shows the voltage being measured in the
right gate feedback circuit. Push the scroll switch down
to move to the next screen.
SERVICE: Joystick
Status: 0.00 Volts
SERVICE: Fuel Level
Status: 2.80 Volts
This screen shows the voltage being measured in the
fuel level circuit. Push the scroll switch down to move
to the next screen.
SERVICE: Hyd Oil Temp
Status: 8.82 Volts
This screen shows the voltage being measured in the
hydraulic oil temperature circuit. Push the scroll switch
down to move to the next screen.
SERVICE: Front Speed
Status: 0 Hertz
This screen shows the frequency being measured in
the front motor speed feedback circuit. Push the scroll
switch down to move to the next screen.
SERVICE: Rear Speed
Status: 0 Hertz
This screen shows the frequency being measured in
the rear motor speed feedback circuit. Push the scroll
switch down to move to the next screen.
SERVICE: Left Gate
Status: 0.00 Volts
This screen shows the voltage being measured in the
left gate feedback circuit. Push the scroll switch down
to move to the next screen.
This screen shows the voltage being measured in the
joystick circuit. 0.0 volts is the neutral position with
+4.8 volts and -4.8 volts being the full forward and full
reverse positions respectively. Push the scroll switch
down to move to the next screen.
SERVICE: Forward
Status: 0.00 Amps
This screen shows the current to the forward solenoid of the pump. Push the scroll switch down to move
to the next screen.
SERVICE: Reverse
Status: 0.00 Amps
This screen shows the current to the reverse solenoid of the pump. Push the scroll switch down to move
to the next screen.
SERVICE: Front Motor
Status: 0.00 Amps
This screen shows the current to the front motor in
either a 2WD or a 4WD machine. Push the scroll switch
down to move to the next screen.
SERVICE: Rear Motor
Status: 0.00 Amps
This screen shows the current to the rear motor in a
4WD machine. Push the scroll switch down to move to
the next screen.
30
SERVICE: Left Close
Status: 0.00 Amps
This screen shows the current to the left gate closing
solenoid. Push the scroll switch down to move to the
next screen.
SERVICE: Left Open
Status: 0.00 Amps
This screen shows the current to the left gate open
solenoid. Push the scroll switch down to move to the
next screen.
SERVICE: Right Close
Status: 0.00 Amps
This screen shows the current to the right gate closing solenoid. Push the scroll switch down to move to
the next screen.
SERVICE: Right Open
Status: 0.00 Amps
This screen shows the current to the right gate open
solenoid. Push the scroll switch down to move to the
next screen.
2 hrs
0 ft
ENGINE
CHIPPED
From this screen, scrolling down will bring you back
into the service screens, while scrolling up 3 times will
take you back to the top operating screen.
31
APPENDIX D
SYSTEMS STARTUP AND ADJUSTMENTS
Hydrostatic System Startup
with the gate valve closed. This will block the flow to
the pumps and cause cavitation.
After any work has been done on the hydrostatic
ground drive system which involved opening up the
circuit in any way, the following startup procedure
should be used.
1. Jack the machine up and securely support on stands
with all four wheels off the ground.
2. Disconnect the fuel solenoid wire at the engine,
so that the engine can only be cranked and cannot be
started. (Fig. 20)
CAUTION! DO NOT CRANK ENGINE WITH
GATE VALVE CLOSED. DOING SO WILL
CAUSE DAMAGE TO THE HYDRAULIC
PUMPS.
6. Turn ignition key “on” and retard throttle to idle.
Turn key to “start” and crank engine with starter until
seeing at least 40 to 60 psi on the charge pressure gage.
3. Disconnect pump stroker at the pump.
WARNING
DO NOT CRANK FOR MORE THAN 30 SECONDS.
Be certain that machine is securely
supported on stands. Wheels will be rotating
under power & if they contact the ground or
debris becomes lodged between the wheels
& ground, the chipspreader could drive off
the stands.
Wait at least 2 minutes before cranking again. If no
pressure reading can be obtained after 2 or 3 attempts,
the starter may not be cranking the engine fast enough
to develop charge pressure.
4. Remove 1/4" plug (Fig. 27) on the hydrostatic
drive pump and insert a 600 psi gage with the necessary adapters to hook to a 04MB port.
8. Turn ignition key to “start” and release, letting
engine run at idle. Observe the charge pressure for a
reading within 30 seconds. Once a reading is seen, allow the engine to idle for about 10 minutes.
7. Hook up fuel solenoid valve.
2
2
3
1
1
Figure 19 Hydrostatic Pump
1. Hydrostatic Pump
3. 1st Implement Pump
2. Fwd & Rev Solenoids
Figure 20. Engine Left Side
1. Fuel Solenoid
5. Make sure the gate valve, (Fig. 21) in the suction
tube is turned fully open (counterclockwise) with sleeve
and handle installed. Do not attempt to start the engine
During filling of all lines and components, the charge
pressure can surge between 50 and 500 psi. As the sys32
tem fills, surging will decrease and the charge pressure
should settle down to a steady reading.
gate is fully opened, press the CAL switch down while
holding the override to set the opening to 4.00” When
the gate override is released, the display should go back
to 0.00”
WARNING
5. Scroll down to the next screen, LEFT GATE
NULL. Follow the procedure outlined above to set the
null and the scale for the left gate.
Be certain that machine is securely
supported on stands. Wheels will be rotating
under power.
2
3
1
6. Once both gates have been set, scroll down to the
last screen of the set up screens and press the save pushbutton to save any changes that were made.
The procedure described above is very effective for
making adjustments to the gate potentiometers and it is
recommended to try and set the gates using the computer set up screens prior to physically making any adjustments to the potentiometer itself. If the gates cannot be set using the set up screens, or a new gate potentiometer is to be installed, the following procedure
should be used.
1. Place the Drive/Park selector in “PARK”.
2. Disconnect the connector from each solenoid of
both gate valves.
3. Start the engine and run it at about 1000rpm.
Figure 21 Suction Filters
1. Suction Filters
2. Suction Gage
3. Gate Valve
9. Shut down engine, remove all gages and replace
all plugs or caps. Recheck fluid levels after 15 minutes
and add as necessary to bring to level of sight eyes in
each tank.
VARIABLE HOPPER GATE TRANSDUCER
ADJUSTMENT
1. Place the Drive/Park selector in “PARK”
2. Hold the CAL switch down and start the engine.
Release the CAL switch once the computer beeps three
times. This will access the computer set up screens.
3. Scroll down until the display reads RIGHT GATE
NULL. This value should be around 0.0. If it is not,
verify that the right gate is closed. There should be
1/16” between each gate and the spreadroll. If necessary, disconnect the connectors from the right gate valve
and power the gate shut using the manual override. Once
the gate is shut, press the CAL switch down to set the
closed value (null).
4. Once the null is set, scroll down to the next screen,
RIGHT GATE SCALE. Hold the right gate override
pushbutton down and monitor the display. The display
should show 4.00” while the override is activated. If it
does not, verify that the gate is fully open. Once the
4. Extend both hoppers approximately 2 feet each.
5. Using the manual overrides on each gate solenoid
valve, close the gates fully. There should be 1/16” between each gate and its spread roll.
6. Shut the engine off and reconnect the connectors
to each solenoid of the gate valves.
7. Disconnect the 3-pin connector at the right gate
transducer. Measure the resistance between the orange
and green wires. The value should be approximately
250-280 ohms. Next, check the resistance between the
black and green wires. This value should be between
950 and 1200 ohms.
8. Follow the same procedure for the left gate transducer.
9. If the values measured in steps 7 and 8 are not
within the specified tolerance, remove the cover on each
hopper that needs adjusting.
10. Loosen the locking bolt on the gate shaft until
the pin plate can be rotated against the position feedback pot.
11. Rotate the pin against the position feedback pot
to obtain a reading within the range and retighten the
locking bolt.
12. Recheck the reading. Once it is within the range,
reconnect the connector and reinstall each transducer
cover.
33
13. Upon completion, access the computer set up
screens and set the gate null as described above.
Air System Pressure Settings
(Individual Gate System Only)
1. Set the main pressure regulator at 90 psi. (Fig.24)
WARNING
Never put hands in between gate and spread
roll or gate and rear of hopper to clear an
obstruction. The gate could move at any time
and cause severe injury.
2. Set the left inside gate open regulator (Fig. 24) to
35 to 40 psi.
3. Set the right inside gate open regulator (Fig. 24)
to 35 to 40 psi.
15
1
12 13
4
1
7
2
6
5
14
2 3
8
Figure 22 Gate Solenoids
1. Gate Solenoid Valves
2. Hopper Solenoid
16 9
10 17 11
Figure 24 Air System
(Individual Gate System Only)
4
1
3
1. Main Regulator
2. Left Inside Gate Regulator
3. Rt Inside Gate Regulator 4. Reservoir
5. Left Valve Bank
6. Right Valve Bank
7. Quick Couplers
8. Left 1 FT Gate Cylinders
9. Left Inner Gate Cylinder
10. Right Inner Gate Cylinder
11. Rt 1 FT Gate Cylinders
12. Water Separator
13. Air Oiler
14. Compressor
15. Main Pressure Gage
16. Lt Inner Gate Pressure Gage
17. Rt Inner Gate Pressure Gage
2
Figure 23 Left Hopper Transducer
1. Transducer
2. Pin Plate
3. Nut
4. Bearing
34
PRESSURE ADJUSTMENTS
Pressure Settings For Hydrostatic Drive
Pump (Rexroth AA4VG125 Pump)
The pressure settings consist of two (2) high pressure cross port relief valves (forward and reverse) and
the pressure override (pressure cutoff) for the
AA4VG125 pump. The adjustment procedure is as
follows:
1) Install 10,000 psi pressure gages in ports MA and
MB located on the topside of the pump as installed. These
ports are -04 SAE O-ring.
ter deck cover below the operator’s station. Of the three
solenoids on this manifold, it is the small single coil
located to the front of the manifold. Disabling this circuit will insure the chipspreader will not move while
checking pressures. Once parking brake release has
been disabled, apply foot pedal brake and push joystick forward developing maximum system pressure.
Check reading on gage in port MA for forward high pressure. Should the pressure need adjusting, remove the
protective plastic cover located above the high pressure port on the street side of the pump. Turn adjusting
screw in (clockwise) to increase relief setting. This
adjustment requires a 5mm allen wrench and a 17mm
box wrench. Once forward cross-port relief valve (relief valve A) has been set to 7000 psi, repeat above
procedure for reverse (relief valve B). Adjustment for
this relief is located above the curb side high pressure
port.
Figure 25 POR Setting
2) The pressure override (POR) should be turned all
the way IN to be able to obtain the highest possible
pressure cutoff setting. Turn screw in (clockwise) until resistance is encountered. Do not force the adjustment past this point. The POR adjustment is located
below the curb side high pressure port. The adjustment will require a 4mm allen wrench and a 13mm box
wrench. The protective plastic cover will need to be
removed to gain access to the POR adjustment.
3) Set the forward and reverse high pressure crossport relief valves (Relief valves A & B) to approximately
7,000 psi. To do this, first disable the parking brake
release circuit by disconnecting the weatherpack connector at the parking brake release solenoid. This solenoid is located on the hydraulic manifold under the cen-
Figure 26 High Pressure Relief Setting
CAUTION
When setting the two high pressure crossport relief valves DO NOT leave the pump on
stroke for more than a few seconds at a time.
The flow is being short circuited from the
pump inlet and a lot of heat is being
generated.
The Correct procedure is to:
Put the pump on stroke and see where the relief valve
pressure setting is at but not leaving the pump on stroke
for more than a few seconds
35
Put the pump to neutral
Make an adjustment to the relief valve
Put the pump on stroke again and see where the pressure level is at
Repeat the above process as many times as necessary until the correct pressure level is obtained.
4) Once the two high pressure relief valves set correctly for forward and reverse, set the Pressure Override Valve to 6500 psi. To do this, adjust the POR screw
out (counter clockwise) until the pressure reads 6500
psi. The POR adjustment is the same screw that was
turned in full in step 2. There is only one setting for
this relief that controls forward and reverse.
CAUTION
When making the pressure override
adjustment, the pump should be put on
stroke only for a few seconds at a time until
you are sure that the pressure cutoff setting
is Below the setting of the two high pressure
cross-port relief valves.
Once the pressure override setting is below that of
the two high pressure cross-port relief valves, the pump
can be left on stroke without any problems as there will
be no flow across the high pressure cross-port relief
valves.
Setting the Charge Pressure
der operator’s station. The gage will require a size 04
female JIC end to plumb to the gage port. With engine
at low idle, the charge pressure should read 400 psi.
2) If the pressure is below 380 or above 420, an
adjustment should be made to the charge pressure relief valve. To access the relief valve adjustment, remove the protective plastic cap located on the topside
of the pump beside the port marked “G”. Using a 17mm
box wrench with a 5mm allen wrench, loosen the jam
nut and turn set screw clockwise if the pressure is low.
If the pressure is high, loosen the jam nut and turn set
screw counterclockwise. One turn is equal to 55 psi.
Pressure Settings For Auxiliary Pump(s)
(Rexroth A10VO74 Pump)
The variable hopper chipspreader utilizes two variable displacement pumps to supply flow to hydraulic
functions. These pumps are mounted piggyback on the
through drive of the hydrostatic drive pump. Flow for
both conveyors and the right spreadroll is supplied by
the first pump. The second pump supplies flow for
both augers, the left spreadroll, the hopper extend/retract cylinders, and the gate cylinders. These pumps
have an internal high pressure relief setting and a
standby or margin pressure setting. The high pressure
relief should be set to 3000 psi, and the standby pressure set to 300 psi for both pumps.
High Pressure Relief Valve
Setting the first pump (conveyors)
1) Install a 5000 psi gage in the port marked “GLS”
on the conveyor manifold located on top of the hydraulic reservoir. This port is SAE 04 and requires a 3/16
allen wrench to remove the plug. Remove the pressure
hose plumbed to the left conveyor at the manifold and
cap the adapter in the port marked “LP” with a 1/2”
(08) JIC hydraulic cap.
2) With engine running at high idle, turn on left conveyor and monitor gage pressure. If the pressure reading is below 2800 psi or above 3050 psi an adjustment
can be made.
Figure 27 Charge Pressure Adjustment
1) Install 600 PSI gage at gage port on front side of
hitch manifold located below center deck section un-
3) To make an adjustment, use a 17mm wrench to
remove protective cap from relief set screw located to
the rear of the pump on the curbside of the chipspreader.
Of the two adjustments at this location, the high pres36
sure relief is the forward most one of the two (Figure
29, Ref 1). If pressure is low, loosen jam nut and turn
set screw clockwise using a 5mm allen wrench. If pressure is high, loosen jam nut and turn set screw counterclockwise. Replace protective cover once correct pressure is set.
3
1
cap (Fig 30 Ref 2).
2) With engine running at high idle, turn on left auger and monitor gage pressure. If the pressure reading
is below 2800 psi or above 3050 psi an adjustment can
be made.
3) To make an adjustment, use a 17mm wrench to
remove protective cap from relief set screw located to
the rear of the pump on the curbside of the chipspreader.
Of the two adjustments at this location, the high pressure relief is the forward most one of the two (Fig 29,
Ref 2). If pressure is low, loosen jam nut and turn set
screw clockwise using a 5mm allen wrench. If pressure is high, loosen jam nut and turn set screw counterclockwise. Replace protective cover once correct pressure is set.
2
CAUTION
Figure 28 Conveyor Block
1. “GLS” Port
2. “LP” Port and Fitting
3. “G” Port
Do not set pressure above 3000 psi. The
hydraulic components are rated for 3000 psi.
Failure of these components could occur to
at system pressures above 3000 psi.
Standby Pressure
3
5
Setting the first pump (conveyors)
4
1
2
Figure 29 Pumps
1. Conveyor Relief Valve
2. Front Hopper Relief Valve
3. Main Hydrostatic Pump
4. Conveyor Standby Pressure
5. Hopper Standby Pressure
Setting the second pump (front hopper
functions)
1) Install a 5000 psi gage in the port marked “GLS”
on the auger manifold located on the front hopper (Fig
30 Ref 1). This is the rear most manifold of the two.
This port is SAE 04 and requires a 3/16 allen wrench to
remove the plug. Remove the pressure hose plumbed
to the left auger at the manifold and cap the adapter in
the port marked “LP” with a 1/2” (08) JIC hydraulic
1) Install a 600 psi gage in the port marked “G” on
the conveyor manifold located on top of the hydraulic
reservoir (Fig 28 Ref 3). This port is SAE 04 and requires a 3/16 allen wrench to remove the plug.
2) Make sure the left and right conveyor switches
are in the “off” position and the thumb switch on the
control handle is in the center position before starting
the engine. Failure to do so could result in a blown
gage. Start the engine and run at high idle and monitor
the gage pressure. If the pressure is below 285 psi or
above 315 psi, an adjustment should be made.
3) To make an adjustment, use a 17mm wrench to
remove protective cap from set screw. The standby
pressure adjustment is rear most adjustment of the two
adjustments at the rear of the pump (Fig 29 Ref 4). The
1/4” load sense hydraulic line is plumbed into the “X”
port in the side of the set screw housing. If pressure is
low, loosen jam nut and turn set screw clockwise using
a 5mm allen wrench. If pressure is high, loosen jam
nut and turn set screw counterclockwise. Replace protective cover once correct pressure is set.
37
Setting the second pump (front hopper
functions)
1) Install a 600 psi gage in the port marked “G” on
the auger manifold located on the front hopper (Fig 30
Ref 3). This port is SAE 04 and requires a 3/16 allen
wrench to remove the plug.
2) Disconnect electrical connectors from gate valves.
Make sure the left and right auger switches are in the
“off” position and the thumb switch on the control
handle is in the center position before starting the engine. Failure to do so could result in a blown gage.
Start the engine and run at high idle and monitor the
gage pressure. If the pressure is below 285 psi or above
315 psi, an adjustment should be made.
3) To make an adjustment, use a 17mm wrench to
remove protective cap from set screw. The standby
pressure adjustment is rear most adjustment of the two
adjustments at the rear of the pump (Fig 29 Ref 5). The
1/4” load sense hydraulic line is plumbed into the “X”
port in the side of the set screw housing. If pressure is
low, loosen jam nut and turn set screw clockwise using
a 5mm allen wrench. If pressure is high, loosen jam
nut and turn set screw counterclockwise. Replace protective cover once correct pressure is set.
3
2
1
6
5
4
Gate Cylinder Relief Valves
The relief setting for the gate cylinder relief valves
(left and right) should be set to 1200 psi.
1) Install 2000 psi gage in “G” port of hopper cylinder manifold located to the front left of the hopper (Fig
31 Ref 1). This port is SAE 04 MB and requires a 3/16
allen wrench to remove the plug.
3
2
1
Figure 31 Hopper Block
1. “G” Port
2. Gate Relief Valves
3. Hopper Extend/Retract Relief Valve
2) With engine at high idle, depress and hold the
left gate override push-button and monitor pressure. If
pressure is below 1100 or above 1300, an adjustment
should be made.
3) To adjust pressure, use 3/4” box wrench to loosen
jam nut on set screw located on sandwich valve mounted
under the directional control valve for gate cylinder (Fig
31 Ref 2). If pressure is low, turn set screw clockwise.
If pressure is high, turn set screw counterclockwise.
4) Repeat above procedure for the right gate relief
valve.
Figure 30 Auger Manifold
1. “GLS” Port
2. “LP” Port
3. “G” Port
4. Lt Auger Speed Control
5. Lt Spreadroll Speed Cont
6. Rt Auger Speed Control
Hopper Extend/Retract Relief Valve
The relief setting for the hopper extend/retract valve
should be set to 2000 psi.
Pressure/Flow Settings For Actuator
Valving
1) Install a 3000 psi gage in “G” port of hopper
cylinder manifold located to the front left of the hopper
(Fig 31 Ref 1). This port is SAE 04 MB and requires a
3/16 allen wrench to remove the plug.
(Functions supplied by pressure compensating auxiliary pump)
2) With engine at high idle, extend or retract hopper
fully (left or right) to bottom out cylinder. Hold cylinder in this position and monitor gage pressure. If pressure is below 1900 psi or above 2100 psi an adjustment
Note: Other than individual circuits which require
reduced pressure for mechanical purposes, the main
system relief is set at the pump.
38
should be made.
Left Spreadroll
3) To adjust pressure, use a 3/4” box wrench to
loosen jam nut (Fig 31 Ref 3). If pressure is low, turn
set screw clockwise using a 1/4” allen wrench. If pressure is high, turn set screw counterclockwise. This relief valve regulates pressure for both left and right extend/retract functions.
Spreadroll Speed Adjustment
The spreadrolls are each to be set at 96 rpm.
Right Spreadroll
1) Insure park/drive switch is in the park position
and the right gate and right spreadroll power switches
are on. With engine at high idle, push joystick slightly
out of neutral and depress right side of thumb switch
engaging the right gate/spreadroll circuit. Time the
spreadroll with a stopwatch or a low speed tachometer
to determine the revolutions per minute.
4
2
3
1
Figure 32 Conveyor & Right Spreadroll Manifold
1. Left Conv Speed Control
2. Rt Spreadroll Speed Control
3. Rt Conv Speed Control
4. Gage Port
2) To adjust the speed, loosen the jam nut on the
spreadroll flow control valve using a 3/4” box wrench.
This valve is located on the conveyor manifold on the
hydraulic reservoir and is the center of the three adjustments. Using a 1/4” allen wrench, turn set screw clockwise to decrease the speed of the spreadroll, or counterclockwise to increase the speed.
1) Insure park/drive switch is in the park position
and the left gate and left spreadroll power switches are
on. With engine at high idle, push joystick slightly out
of neutral and depress right side of thumb switch engaging the left gate/spreadroll circuit. Time the
spreadroll with a stopwatch or a low speed tachometer
to determine the revolutions per minute.
2) To adjust the speed, loosen the jam nut on the
spreadroll flow control valve using a 3/4” box wrench.
This valve is located on the auger manifold on the front
hopper and is the center of the three adjustments (Fig
30 Ref 5). Using a 1/4” allen wrench, turn set screw
clockwise to decrease the speed of the spreadroll, or
counterclockwise to increase the speed.
Conveyor Speed Adjustment
The conveyors should be set to a speed that allows
the aggregate to fall into the front hoods. Running the
conveyors faster than this does not increase the amount
of aggregate delivered to the front hopper but does cause
premature wear of the hood frames and create unnecessary noise.
1) To adjust the speed of the conveyor (left or right)
loosen jam nut by hand on the flow control valve for
the conveyor to be changed. The adjustments are located on the conveyor manifold on the hydraulic reservoir (Fig 32 Ref 1& 3). Turn the aluminum knob attached to the set screw clockwise to decrease conveyor
speed or counterclockwise to increase speed. Hand
tighten jam nut once speeds are set.
Auger Speed Adjustment
1) To adjust the speed of the auger (left or right)
loosen jam nut by hand on the flow control valve for
the auger to be changed. The adjustments are located
on the auger manifold on the front hopper (Fig 30 Ref
4 & 6). Turn the aluminum knob attached to the set
screw clockwise to decrease conveyor speed or counterclockwise to increase speed. Hand tighten jam nut
once speeds are set.
Fixed Displacement Auxiliary Pump
The fixed displacement pump (gear pump) is
39
mounted to the back of the pressure compensating auxiliary pump. This pump supplies flow for the power
steering and hitch functions. The gear pump does not
have an internal relief and relies on external valving to
govern relief pressure.
Pressure Settings For Actuator Valving
Supplied By Fixed Displacement Pump
Main Relief Pressure (MP)
Brake Pressure
Steering Return
Steering Pressure
Pilot Pressure (PP)
The pilot pressure should be set to 250 psi. The hitch
raise/lower function operates at this pressure.
1) Install 600 psi gage in port marked “PP” on steering/hitch manifold (Fig 32 Ref 4). This port is SAE 06
MB and requires a 1/4” allen wrench to remove plug.
2) With engine at or above 1000 rpm, monitor pressure.
The main relief pressure should be set to 2000 psi.
The steering motor operates at this pressure.
To Front Motor
Charge Pressure
sure is high, adjust set screw counterclockwise.
3) If the pressure is low, remove cap from top of
relief valve (Fig 32 Ref 3) using vise grips ) and adjust
set screw clockwise using a 1/4” allen wrench. If pressure is high, adjust set screw counterclockwise.
5
3
Note: Engine must not be running to adjust set
screw. When cap is removed, oil will flow through
valve and spray out top of valve.
Reduced Pressure (RP)
Pressure from
Rear Pump
To Cooler
6
1
2
4
UP
DO
WN
CL
O
OP SED
EN
Figure 33 Hydraulic Control Assembly
1. Main Pressure Relief Valve
2. Main Pressure Pressure Check Port
3. Pilot Pressure Relief Valve
4. Pilot Pressure Check Port
5. Hitch Release Pressure Reducing Valve
6. Reduced Pressure Check Port
1) Install 3000 psi gage in port marked “MP” on
steering/hitch manifold located under center deck cover
below operators station (Fig 32 Ref 2). This port is
SAE 06 MB and requires a 1/4” allen wrench to remove plug.
2) With engine at or above 1000 rpm, turn front
wheels full left or right until steering cylinder is fully
stroked. Hold wheels in this position and monitor pressure.
The reduced pressure should be set to approximately
120 psi. This can vary due to back pressure in the return line to the reservoir. The hitch release function
operates at this pressure.
1) Install 600 psi gage in port marked “RP” on steering/hitch manifold (Fig 32 Ref 6). On 2WD units, this
port has a 1/4” JIC hydraulic tee installed with a 1/4”
JIC cap. Remove cap to access the reduced pressure.
This will require a 1/4” female JIC adapter on the gage.
On 2WD units, the port is plugged. This port is SAE
06 MB and requires a 1/4” allen wrench to remove plug.
2) Once gage is installed, run engine at or above
1000 rpm and monitor pressure.
3) If pressure is low loosen jam nut on reducing
valve (Fig 32 Ref 5), with 3/4” box wrench and turn set
screw clockwise using 1/4” allen wrench. If pressure
is high, turn counterclockwise. If pressure can not be
set down to 120 psi, back set screw full out (counterclockwise) and turn back in 10-15 psi.
Note: Engine must not be running to adjust set
screw. When cap is removed, oil will flow through
valve and spray out top of valve.
3) If the pressure is low, remove cap from top of
relief valve (Fig 32 Ref 1) using vise grips and adjust
set screw clockwise using a 1/4” allen wrench. If pres40
41
LUBRICATION
23
24
17
19
20
28
18
6
25
7
5
2
21
11
3100716
15
3
4
1. MAKE
CERTAIN
STARTING
2. ALWAYS
EVERYONE
ENGINE
IS
OR
USE
CLEAR
OPERATION. OF
STEPS,
3. REMAIN
MACHINE
THE
HANDRAILS
OF
TANK
CROSS
NOT
IN
OF
HOPPER
TO
OR
THIS
IN
FRONT
GATES.
PART
WALK.
DRILL
GUAARDS
STAND
HOPPER
IS
THE
PROVIDED.
PARTS.
AND
NOT
ING
FUEL
AND
ROTATING
COVERS
5. DO
WARN
BEFORE
PLATFORMS
CLEAR
4. ALWAYS
OF
MOVING
HAVE
OR
OPERATING.
SHIELDS,
GAGE
DO
WELD
WARN IN
FUEL
ING
TANK
AREA.
PLACE
3100716
WHEN
ENGAGE
3101247
THE
OF
AND
IS
THE
CROSS
DISEN-
NOT
PART
WALK.
DRILL
THIS
OR
AREA.
DO
WELD
IN 3101247
1
R
12
26
10
13 22
14
26
27
9
Interval
5
6
8
Weekly 9
10
1
12
13
When IndicatorTurns Red
21
22
Yearly
Point
1
2
3
4
Grease-#2 Molub-Alloy Grease
Gear Lube-SAE 90 API GL-5/MIL-L-2105 B Gear Lube
Hydraulic Oil-ISO VG 46 Hydraulic Oil
Lube Oil-#10 Non-Detergent Oil
16
8
Identification
No. of
Points
Lubricant
Quantity
14
Bearing-Spreadroll (Both Ends)
Bearing-Auger (Both Ends)
Bearing-Hopper Gate (Both Ends)
Bearing-Individual Gates (Optional)
Bearing-Agitator (Optional)
Flange Bearing-Conveyors
Flange Bearing-Return Idler
Bearing-Tail Pulley
Bearing-Hitch Levers
Bearing-Truck Hitch
Shaft-Front Axle Pivot
Spindle-Front Axle
Tie Rod-Front Axle
Universal Joints-Drive Line
15
16
17
18
19
Bearing-Slack Adjuster (2wd only)
Bearing-Camshaft (2wd only)
Hydraulic Reservoir
Hydraulic Oil Cooler
Engine Oil
20
Filter-Engine Air Intake
23
24
Filter-Return•
Filter-Suction•
Magnet-Hydraulic Reservoir (In Tank) 1 - Clean A/R
Breather-Hydraulic Reservoir
221
-
Filter Element
25
Differential Housing**
26
Planetary Wheel End**
27
28
Hub-Rear Axle (2wd only)**
Roller Chain-Power Seat (Optional)
1-2wd
2-4wd
2-2wd
4-4wd
2
2
Gear Lube
Gear Lube
Gear Lube
Gear Lube
Gear Lube
Lube Oil
Fill
Fill
Fill
Fill
Fill
Sparingly
7
1
4
Grease
Sparingly
4
Grease
Sparingly
4
Grease
Sparingly
A/R
Grease
Sparingly
4
Grease
Sparingly
4
Grease
Sparingly
4
Grease
Sparingly
4
Grease
Sparingly
4
Grease
Sparingly
4
Grease
Sparingly
2
Grease
Sparingly
4
Grease
Sparingly
6
Grease
Sparingly
2-2wd
Grease
Sparingly
4-4wd Grease
Sparingly
2
Grease
Sparingly
4
Grease
Sparingly
Hydraulic Oil Add When Low
Clean A/R
1
Engine
Engine
Original Manual
1
Filter Element
Filter Element
Filter Element
* On new machines change filter elements after first two weeks of operation. After initial change (two weeks) replace elements on an annual basis
unless hydraulic system has been worked on and contamination introduced into the system. Change elements anytime it is possible that
contamination has been introduced to the system.
** On new machines drain lubricant from axles after first 50 hours of operation and fill with SAE 90
API GL-5/MIL-L-2105 B gear lube. After initial change (50 hours) change lube on an annual basis.
42
CAUTION AND INSTRUCTION PLATES
2
74
21
01
3
9
7
3
3190505
NG
RNI
WA
3390682
3390681
4
3390683
3101717
5
2
ION
CAUTeveryone
EC
certain
Make of machine
engine
3390682
is clearstarting
.
before
CO
or
operation
ION
CAUTeveryone
certain
Make of machine
engine
3390682
is clearstarting
.
before
operation
or
7
2
3101717
74
21
01
3
6
3390682
3390682
7
4
4
R
2 54 3 7
5
3390681
10
11
6
6
2
3390678
WAR
NING
3101759
AUTO-
3390682
TION
CAU
everyone
3390681
NING
TION
CAU
WAR
3390683
clear
TION
CAU
3101652
NING
WAR
3190505
Stay
off
while
hopper
is moving.
fall
Machine a
or
cuse
could in injury
have
Always
in place
ng
shields
operati
Remain
of
parts.
moving
ent
Entanglem
serious
cause
or
Make
certain
of machine
engine
is clear
starting
before
or
START
BEFORE
MAY
DOWN
TIME!
AUGER ANY
SHUT
AT
AREA TO
THIS
ATTEMPT 3190505
ENGINE
NOT
WORKINGDO
WITH
ENGINE. JAM
ANY
THIS
MATICALLYIN
CLEAR
RUNNING!
3390682
operation.
may
injury
3390681
death.
3390683
when
machine movements
3101717
resulting
death.
6
LEFT
LEFT
OUT
OUT
ING
RN
WA
IS
PART
IN
WELD
HOPPERS
HOPPERS
3101247
RIGHT
RIGHT
IN
IN
HITCH
ON
LEFT
CONV
ON
OUT
IN
IN
LEFT CONV
DO
WALK.
TANK
FUEL CROSSOR
THE THE
DRILL
OF
AREA.
NOT
THIS
HITCH
RELEASE
OUT
RIGHT CONV
RELEASE
LEFT AUGER
OFF
LEFT ON
AUGER
OFF ON
ON
RIGHT
CONV
ON
RIGHT AUGER
OFF
RIGHTONAUGER
LEFT GATE
LEFT
GATE
OVERRIDE
OFF
OVERRIDE
OFF
OFF ON
RIGHT GATE
RIGHT
GATE
OVERRIDE
OFF
OVERRIDE
OFF
3101974
3101974
2
5
1
9
4
286
0 93
3
2
3
4 5
67
3
7
7
8
WA
RNI
3101717
NG
3390683
3390681
3390681
3390682
3190505
7
3390681
LUBRI
CATIO
N
3100716
6
4
1. MAKE
CERTAIN
STARTING
EVERYONE
ENGINE
2. ALWAYS
15
OR
USE
3. REMAIN
OPERATION.
IS
OF
PLATFORMS
OF
HAVE
AND
MOVING
OR
SHIELDS,
IN
PLACE
CROSS
IS
PART
WALK.
OR
DO
AREA. WELD
IN
DRILL
THIS
ENGAGE
AND
TANK
THE
NOT
WHEN
HOPPER
TO
NING
FUEL
OF
IN
OF
THE
GUAARDS
FRONT
GATES.
WAR
BEFORE
PROVIDED.
PARTS.
AND
STAND
HOPPER
MACHINE
HANDRAILS
ROTATING
COVERS
NOT
CLEAR
STEPS,
CLEAR
4. ALWAYS
OPERATING.
5. DO
GAGE
DISEN-
WAR
3100716
FUEL
OF
THE
NOT
3101247
NING
THE
TANK
CROSS
IS
PART
DRILL
THIS
WALK.
OR
DO
AREA. WELD
IN
3101247
12
7
13
3
093
186
R
6
10
6
10,14
11
REF PART NO. QTY
1
2
3
4
5
6
7
8
3390678
3101717
3390682
3390681
3390683
3101652
3190505
6000758
1
10
3
6
4
7
9
1
DESCRIPTION
Decal: WARNING, “Read Manuals”
Label: WARNING Hopper (STAY OFF)
Decal: CAUTION, Before Starting
Decal: WARNING, Remain Clear
Decal: CAUTION, Shields
Plate-Hydro Towing Warning
Plate-WARNING, Auger
Emblem-Vehicle, Slow Moving
REF PART NO. QTY
9
10
11
12
13
14
15
4421557
3101247
3101999
3102000
3102026
3100716
3360180
3100689
2
3
2
2
1
1
1
1
DESCRIPTION
Placard-Shafts, Grease Daily
Plate-WARNING, No Drill or Weld
Decal-Chips, FWD
Decal-Chips, Quad
Decal-Lube Chart, Var Hop
Plate-CAUTION, General
Plate-Fill W/Diesel Fuel Only
Plate Name-Chipspreader, Brass
43
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