Chipspreader

Chipspreader
M-213-12
w/ RC 36 Controller
Serial Numbers K6747 Thru K6981
Updated November 2, 2015
R
FIXED HOPPER Series
Chipspreader
M-213-12
Computerized Fixed Hopper
CHIPSPREADER
Operation, Maintenance and Safety Manual
Serial #’s K6747 thru K6981
WARRANTY
E. D. Etnyre & Co. warrants to the original Purchaser, its 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 startup services, normal maintenance services or adjustments usually performed by the selling dealer, factory service representative or customer personnel.
(3)
Any product or part thereof which shows improper operation, improper maintenance, abuse, neglect, damage or modification after shipment from factory.
(2)
(4)
Any product manufactured by E. D. Etnyre & Co. purchased or subjected to rental use.
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 delivering 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!
R
E. D. ETNYRE & CO., Oregon, Illinois 61061-9778
1333 South Daysville Road Phone: 815/732-2116 Fax: 815-732-7400
1
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.
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
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.
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.
Table Of Contents
WARRANTY....................................................................... 1
List Of Figures.................................................................... 4
GENERAL
General Identification......................................................... 5
Introduction......................................................................... 6
Reporting Safety Defects.............................................. 6
Check Out..................................................................... 6
Attaching Hopper To Unit Safety Precautions:............... 7
Attaching Hopper to Unit............................................... 7
OPERATION (cont)
Operation......................................................................... 19
Automatic Conveyor Control........................................ 20
Ultrasonic Sensors...................................................... 20
Backup Alarm.............................................................. 20
Individual Gates (Figure 11)........................................ 20
Towing Instructions...................................................... 21
Hydraulic Powered Seat Assembly............................. 21
Extra Agitator .............................................................. 21
OPERATION
Identification and Function of Controls......................... 9
Power/Ignition Switch ................................................... 9
Mode Selector-Drive/Park............................................. 9
Speed Set Toggle Switch............................................... 9
Aggregate Size Switch................................................ 10
Application Rate Switch............................................... 10
Circuit Breakers........................................................... 11
Computer Display Screens.......................................... 11
Operator Screens....................................................11
Screen Scroll Switch................................................... 14
Speed/Direction Control Handle (Figure 6)................. 14
Gate/Spread Roll Switch. (Figure 6)............................ 14
Turn Signal Selector and Indicators. (Figure 7)........... 15
Hazard Flasher Switch (Figure 7)................................ 15
Headlight Switch (Figure 7) ........................................ 15
Seat Shift Switch. (Figure 7) (Optional)....................... 15
Hitch Release Pushbutton (Figure 7).......................... 15
Strobe (Optional)......................................................... 15
Application Rate Computer.......................................... 15
Right Conveyor Selector............................................. 16
Left Conveyor Selector ............................................. 16
Hitch Height Switch .................................................... 16
Gate Override Switch.................................................. 16
Memory Selector Buttons............................................ 16
Memory Save Button................................................... 16
Calibrate Switch.......................................................... 16
Horn............................................................................. 17
Batwing Switch............................................................ 17
Warning Light ............................................................. 17
Filter Indicator.............................................................. 17
Traction Control Switch............................................... 17
Throttle Run/Idle Switch.............................................. 17
Throttle Increase/Decrease Switch.............................. 17
Auxiliary 12 Volt Power................................................ 17
Engine Diagnostics On/Off Switch............................... 17
Engine Diagnostics Stop Light.................................... 17
Engine Diagnostics Warning Light............................... 17
Vibrator Auto Select Switch (Optional)........................ 17
Vibrator Manual On/Off Switch (Optional)................... 17
Emergency Stop Switch.............................................. 17
Computer Reset Switch............................................... 17
Individual Gates Master Switch................................... 18
Left Hopper Gate Selector Switches........................... 18
Right Hopper Gate Selector Switches......................... 18
Traction Boost Switch (Optional)................................. 18
Hopper Height Switch . ............................................... 18
Brake Pedal (Figure 7)................................................ 18
Left Conveyor Pushbutton (Figure 10)........................ 18
Right Conveyor Pushbutton (Figure 10)...................... 18
Hitch Release Pushbutton (Figure 10)............................. 18
MAINTENANCE
APPENDIX A.................................................................... 22
MAINTENANCE ADJUSTMENTS............................... 22
Hopper Spread Roll Wear Plate Adjustment.......... 22
Hopper Gate Wear Plate Adjustment .................... 22
Conveyor Belt Adjustment...................................... 23
APPENDIX B.................................................................... 24
COMPUTER SETUP................................................... 24
Computer Set Up.................................................... 24
Set Up Screens.......................................................24
APPENDIX C.................................................................... 27
COMPUTER SERVICE SCREENS............................. 27
APPENDIX D.................................................................... 31
SYSTEMS STARTUP AND ADJUSTMENTS.............. 31
Hydrostatic System Startup..................................... 31
Gate Transducer Adjustment................................... 32
Air Pressure Adjustments........................................ 33
Pressure Settings For Hydrostatic Drive Pump
(Rexroth AA4VG125 Pump)............................... 33
Setting the Charge Pressure................................... 35
Pressure Settings For Auxiliary Pump
(Rexroth A10VO74 Pump).................................. 35
Relief Valve Settings................................................ 35
Pressure/Flow Settings For Actuator Valving.......... 36
Gate Cylinder Relief Valve....................................... 36
Spreadroll Speed Adjustment.................................. 37
Fixed Displacement Auxiliary Pump........................ 37
Pressure Settings For Actuator Valving Supplied
By Fixed Displacement Pump .......................... 37
Main Relief Pressure (MP)...................................... 37
Pilot Pressure (PP).................................................. 37
Fan Valve Pressure Setting..................................... 38
Reduced Pressure (RP).......................................... 38
Pressure Setting for Traction Boost Circuit............. 39
Traction Boost Pressure.................................... 39
Engine Belt Routing........................................... 39
Truck Hitch Arrangement.................................................. 40
Caution And Instruction Plates......................................... 41
Lubrication........................................................................ 42
COMMENT FORM............................................................43
3
List Of Figures
Figure 1. Front Of Chipspreader........................................ 7
Figure 2. Rear Of Hopper................................................... 7
Figure 3. Hopper................................................................ 8
Figure 4. Hopper Gates...................................................... 8
Figure 5. Control Console Identification........................... 10
Figure 6. Speed/Direction Control Handle........................ 14
Figure 7. Control Panel.................................................... 15
Figure 8. Ground Speed Pickup....................................... 16
Figure 9. Conveyor Diaphragm Switches......................... 16
Figure 10. Front Operator’s Control Panel....................... 18
Figure 11. Individual Gates............................................... 20
Figure 12. Seat Position Switch....................................... 21
Figure 13. Spread Roll Wear Plate................................... 22
Figure 14. Gate Wear Plate.............................................. 22
Figure 15. Hopper Gates.................................................. 22
Figure 16. Conveyor Tail Pulley........................................ 23
4
Figure 17. Conveyor Head Pulley Adjustment.................. 23
Figure 18. Hydrostatic Pump............................................ 31
Figure 19. Engine Left Side.............................................. 31
Figure 20. Gate Valve....................................................... 32
Figure 21. Hopper Transducer......................................... 33
Figure 22. Air System....................................................... 33
Figure 23. POR Setting.................................................... 34
Figure 24. High Pressure Relief Setting........................... 34
Figure 25. Charge Pressure Adjustment.......................... 35
Figure 26. Pumps............................................................. 35
Figure 27. Conveyor Manifold.......................................... 36
Figure 28. Gate Relief Valve............................................. 37
Figure 29. Hydraulic Control Assembly............................ 38
Figure 30. Fan Valve........................................................ 39
Figure 31. Traction Boost Relief Valve............................. 39
Figure 32. Engine Belt Routing........................................ 39
14
21
GENERAL
General Identification
1
2
19
1
Ref
Qty
1
2
2
1
3
1
4
2
5
AR
6
2
7
1
8
1
9
1
10
1
11
1
12
2
13
2
14
2
15
1
16
1
17
3
18
1
19
2
20
1
21
1
22
2
23
2
24
1
25
2
26
2
27
2
28
1
29
1
30
1
31
AR
32
AR
33
2
34
1
35
4
36
1
37
1
38
AR
39
1
40
2
41
1
42
10
43
1
44
1
3
Description
Conveyor Drive Motors
ManifoldConveyor/Spreadroll/Auger
Conveyor Switch
Gate Transducer
Gates
Rear Hopper Flow Gate
Front Axle Drive
Rear Motor Access Panel
Front Hydraulic Motor
20
Rear Hydraulic Motor
5
4
Rear Axle Drive (4WD Shown)
7
Hitch Position Linkage
Tail Pulley Asm
Head Pulley Asm
Hitch Release Cylinder
Manifold-Hitch/Pwr Steer/Brake
Hydraulic Pumps
Radiator
Return Filter
42
Gate Actuating Cylinder
Manifold-Gate/Hopper
23
22
Conveyor Hood
23
Head Light
Hopper Asm
Hopper Latch Pin
33
Rough Tread Step
Tail Light
Back Up Alarm
Fuel Tank
Hitch
Rear Lining
Flashing
Material Separator
Slow Moving Emblem
Handrails
Seat Assembly
Control Console Asm
25
24
Rough Tread
Air Intake Asm
26
Conveyor Belt
Hitch Release
Engine/Conveyor Covers/Decking
44
Horn
Hydraulic Reservoir
18
17
16
12
9
43
13
11
40
10
15
13
41
39
38
37
36
35
34
27
6
32
31
27
29
28
8
30
5
GENERAL
Introduction
The Etnyre Computer Controlled Hydrostatic
Chipspreader has been designed to improve the accuracy of chip spreading while improving productivity
and simplifying the operation. This has been done by
incorporating Application Rate capabilities using precise gate opening control and speed feedback in closed
loop controls.
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.
WARNING
Unsafe operation of equipment may cause
injury. Read, understand and follow the
manuals when operating or performing
maintenance
Important
1. The optional front hopper segregation screen
should be up when the unit is traveling between job
sites to avoid possible damage to the screen.
2. Keep the Chipspreader on the road or relatively
uniform surface at all times to avoid loss of traction
and/or possible damage to the front hopper 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
6
hoppers if at all possible. Added weight in either hopper
increases stopping distance.
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.
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.
To contact NHTSA, you may either call the Auto
Safety Hotline toll-free at 1-800-424-9393 (or 3660123 in Washington, D.C. area) or write to: NHTSA,
US. Department of Transportation, Washington, D.C.
20696. You can also obtain other information about
motor vehicle safety from the hotline.
Check Out
1. The following accessories are shipped with each
Chipspreader: extra linkage rods for shortened truck
hookup, agitator disconnect bolt, 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
in front and 60 to 65 PSI in rear. However, various
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.
5. Uncouple spread roll hoses and couple to hopper
drive motor hoses. Use caution to wipe each half of
each connector clean before connecting. Dirt and contaminants can cause major damage to the hydraulic
systems.
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:
4. Check engine coolant and oil levels prior to operation. Refer to engine operator’s maintenance manual for
complete engine service requirements.
Attaching Hopper To Unit Safety Precautions:
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.
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. Front Of Chipspreader
1. Carrying Arms
3. Latch Pin Lock Pin
2. Hopper Pin
Ensure that hands and feet are kept clear of the hopper
and potential pinch points on front of the Chipspreader
during installation.
Attaching Hopper to Unit
1. By hooking a lifting sling into the rear lifting eye,
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 the hopper slowly until the lifting sling can be
disconnected.
2. Attach the lifting device to the front lifting attachment and raise the hopper to vertical position.
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.
Figure 2. Rear Of Hopper
1. Carry Shaft
2. Latch Arms (2)
3. Hopper
4. Front Lifting Eye
7
GENERAL
operating speeds, road bed conditions, truck pulling arrangements and other operating conditions may require
different tire pressures.
GENERAL
1. Check that the gate opening cylinder rod clevis is
fully screwed onto the cylinder rod.
2. With the hopper on the machine, start the engine
and run it at a minimum of 2000 rpm.
1. Hydraulic Cylinder
2. Air Cylinder
3. Air Valve
4. Buss Arm
Figure 3. Hopper
5. Gate Open Stop
6. Gate Close Stop
7. Gate
3. Depress and hold the gate override push button
until the gates are at the full open position. Release
the pushbutton and the gates will return to the closed
position. There should be 1/16” clearance between the
gates and the spread roll. If this clearance is not constant
across the full width of the hopper, it indicates that the
wear plates may need to be adjusted or the spread roll
is not straight. Contact the factory for straightening
instructions.
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 hopper 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
8
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.
1. Gates
Figure 4. Hopper Gates
2. Adjustment Bolts
3. Spread Roll
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.
WARNING
Stay off hopper while machine is moving.
Machine movements could cause a fall
resulting in injury or death.
Refer to figure 5 for identification of described
features.
1. Power/Ignition Switch
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 “park/drive” switch in the drive position.
It is also recommended that the control joystick be in
the neutral position during startup. If started without
the control joystick in neutral, the Chipspreader will
not move until the joystick has been returned to the
neutral position .
Since all functions except power steering and rear
brakes are electrically controlled, turning the key to
“off” results in a violent stop.
WARNING
Turning ignition switch to “off” results in a
violent 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
2. Mode Selector-Drive/Park
A two position switch selects either “Drive” or
“Park” position.
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 by
returning the speed/direction handle to neutral, regardless of the position of the “Drive/Park” switch.
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.
Since engaging “Park” disables “Speed/direction
handle” and applies the parking brake, selecting park
while the chipspreader is moving will result in a violent
stop. Do not select “Park” unless the chipspreader is
at a full stop.
Auxiliary computer power is routed through the
Park/Drive switch/ When the engine is not running,
place the switch in the Park position to avoid draining
the batteries.
The “Park/Drive” switch must be in the park position after the computer has been turned on for the
Chipspreader to be movable. If the computer is reset
with the “Park/Drive” switch in drive, it must be moved
to park first and then back to drive to resume normal
operation. Similarly, the control joystick must be returned to the neutral position after a computer restart
to resume normal operation.
WARNING
Selecting “park” while the chipspreader is
moving results in an emergency stop.
CAUTION
Always place the mode selector switch in the
“Park” position when the chipspreader is
stopped to avoid accidental movement of the machine.
3. Speed Set Toggle Switch
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
increase 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 Chipspreader’s
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.
9
OPERATION
Identification and Function
of Controls
4. Aggregate Size Switch
This switch 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.
5. Application Rate Switch
This switch sets the position to which the gates will
open by increasing or decreasing the set point. 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.
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).
42
43
lEfT gATES
OuTER
mASTER
SWiTcH
iNNER
12
13
lEfT
44
WARNiNg
gATE cONTROlS
37
RigHT
filTER
iNDicATOR
STOP
RigHT gATES
35
WAiT TO
START
DiAg / Wif
mEmORY
ON
2
1
mEmORY
3
4
5
OuTER
3150826
24
25
SAVE
26
cAl
Off
29
30
ENgiNE
DiAgNOSTicS
36
000 00 0 0 00 000 0 0 0 00 0 00 0 0 00
000 00 0 0 00 000 0 0 0 00 0 00 0 0 00
7
ON
AuTO
RATE
5
ON
ScROll
+
+
- 8
SiZE
-
-
Off
Off
SPEED
+
cONVEYORS
4
gATE
OVERRiDE
+
-
3
23
bATWiNg
28
VibRATORS
38
WARNiNg
flASHER
14
cOmPuTER Do not reset computer while cOmPuTER
RESET
RESET
chipspreader
is in motion.
Park/Drive Switch
must
Violent
stop will
occur to
be in PARK
position
causing
serious
injury
or
reset computer.
death.
41
41
27
31
Off
HORN
failure to place Park/Drive
switch in park position
when shutting down will
discharge batteries.
ciRcuiT bREAKERS
Off
HORN
gATES
6
STRObE
18
mOTORS
ON
ON
20
21
HiTcH
RElEASE
SEAT
POSiTiON
HiTcH
HEigHT
l
17
START
Acc
Off
22
THROTTlE
ERgENc
m
R
34
10
9
STOP
16
40
DRiVE
RuN
TRAcTiON
bOOST
igNiTiON
ligHTS
cONVEYORS
cONTROllER
3150875
1. Power/Ignition Switch
2. Mode Selector-Drive/Park
3. Speed Set Toggle Switch
4. Aggregate Size Switch
5. Application Rate Switch
6. Circuit Breakers
7. Computer Display Screen
8. Screen Scroll Switch
9. Joystick 10. Gate Switch
11. Turn Signal Switch
12. Left Turn Signal Indicator
13. Right Turn Signal Indicator
14. Hazard Flasher Switch
15. Headlight Switch
16. Seat Shift Switch
1
iDlE
32
33
PARK
17. Hitch Release Pushbutton
18. Strobe
19. Computer (inside panel)
20. Right Conveyor Control Selector
21. Left Conveyor Control Selector
22. Hitch Height Switch
23. Gate Override Switch
24. Memory Selector Buttons
25. Memory Save Button
26. Calibrate Switch
27. Horn Button
28. Batwing Switch
29. Warning Light
30. Filter Indicator
31. Traction Control
32. Throttle Run/Idle Switch
Figure 5. Control Console Identification
10
45
Y
ON
11
46
cAuTiON
TRAcTiON
cONTROl
AuTO
39
ON
ligHTS
15
TuRN SigNAl
HOPPER
HEigHT
E
OPERATION
The choices of aggregate size are: Sand, 1/4” Chips,
3/8” Chips, 3/8” Gravel, 5/8” Chips, and 1” Chips.
2
33. Throttle Increase / Decrease Switch
34. Auxiliary 12VDC Power
35. Engine Diagnostics On / Off Switch
36. Engine Stop Indicator Light
37. Engine Warning Light
38. Vibrator Auto Select Switch
39. Vibrator On / Off Switch
40. Emergency Stop Switch
41. Computer Reset Switch
42. Gate Master Switch
43 Left Side Gate Switches
44 Right Side Gate Switches
45 Traction Boost
46 Hopper Height
These circuit breakers are powered from the
accessory post on the ignition switch and lose voltage
when starter is engaged.
Light circuit breaker: Supplies power to all lights
except brake lights.
Conveyor circuit breaker: Supplies power to conveyor and auger switches.
Controller circuit breaker: Supplies power to the
joystick, display, hitch functions, hopper functions, seat
position, batwings, and gate override.
These circuit breakers are powered from the ignition
post on the ignition switch and maintain voltage while
starter is engaged.
Horn circuit breaker: Supplies power to the horn,
input switches, and front control box.
Gate circuit breaker: Supplies power to the gate
power switches, the spreadroll power switches, and the
individual gates when required.
Motor circuit breaker: Supplies power to the brake
lights, speed sensor, and traction control switch.
The computer is fused with an in-line, 30 amp fuse
and is powered from the accessory post on the ignition
switch.
7. Computer Display Screens
Operator Screens
20.0
3/8
lbs/yd2Chip
400
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 operating
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 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.
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 the spread
roll is turning at 100 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
the chipspreader towards the canvas. Actuate the gate
thumbswitch about 10 feet before the material will hit
11
OPERATION
6. Circuit Breakers
OPERATION
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
to arrive at the pounds per square yard. Do this a minimum of 3 times and average the values before making
any changes.
Compare the measured values against the application
rate setpoint on the display to determine calibration
required for the hopper. As an example, assume the
hopper weighed in at 23.5 lbs. Press the cal switch up
or down to access the calibration screens. The screen
will now read:
0.0
lb/yd 2
95.6%
RIGHT CAL
The program is universal for variable and fixed hoppers. The fixed hopper uses the left hopper screens for
calibration, so you must scroll past the right hopper
screen.
Press the scroll switch down (-) to access the calibration screen for the left hopper which displays the
following:
0.0
95.6%
lb/yd LEFT CAL
2
The 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 hopper 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 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
12
weigh at least three samples to get an average material
weight to use in the calibration process.
The calibration process will correct the hopper to
spread very close to the application rate setpoint. While
chipping it may become evident that the material is less
than actually desired. This can be fine tuned using the
calibration process explained above while chipping. If
the hopper appears lighter than desired, 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 hopper without effecting the displayed rate on
the screen. 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
material appears as desired.
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 (-).
Left Conv
0%
Right Conv
0%
This screen shows how fast the conveyors are moving. The speed of the conveyors can be varied independently to provide a uniform distribution of material
to the front hopper. With the percentage set to 99% the
conveyor will run at its highest speed. With the percentage set to 10% the conveyor will run at its slowest
speed. To change the speed of the conveyors press the
CAL switch up or down. The screen will now show
the set percentage of the left conveyor.
Left Conv
85%
Pressing the cal switch up (+) will increase the left
conveyor speed by 5%. Pressing the cal switch down
(-) will decrease the left conveyor speed by 5%. Pressing the scroll switch down (-) will show the screen for
changing the right conveyor speed.
Right Conv
85%
Pressing the cal switch up (+) will increase the right
conveyor speed by 5%. Pressing the cal switch down
(-) will decrease the right conveyor speed by 5%. Pressing the scroll switch up (+) will show the screen for
changing the left conveyor speed. Pressing the scroll
switch up (+) again will show the actual speed of both
conveyors. The conveyor speed percentage can be
Adjusting the speed of the conveyors 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. 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.
To move to the next screen, press the scroll switch
down (-).
Left Auger Right Auger
0%
0%
This screen shows how fast the augers are moving.
The speed of the augers can be varied independently to
provide a uniform distribution of material in the front
hopper. With the percentage set to 99% the auger will
run at its highest speed. With the percentage set to 10%
the auger will run at its slowest speed. To change the
speed of the augers press the CAL switch up or down.
The screen will now show the set percentage of the
left auger.
Left Auger
85%
Pressing the cal switch up (+) will increase the left conveyor speed by 5%. Pressing the cal switch down (-)
will decrease the left auger speed by 5%. Pressing the
scroll switch down (-) will show the screen for changing
the right auger speed.
Right Auger
85%
Pressing the cal switch up (+) will increase the right
auger speed by 5%. Pressing the cal switch down (-)
will decrease the right auger speed by 5%. Pressing the
scroll switch up (+) will show the screen for changing
the left auger speed. Pressing the scroll switch up (+)
again will show the actual speed of both augers. The
auger speed percentage can be changed at any time
whether or not the augers are moving.
To move to the next screen, press the scroll switch
down (-).
15%
100ºF 60 PSI
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, push the scroll switch down (-).
100ºF HYD OIL 2200 RPM
13.8 V
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. 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, push the scroll
switch down (-).
120.8 ENGINE
8240 FT
CHIPPED
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. 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
travelling 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 word
“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:
high water temperature
240 F
high hydraulic oil temp.
180 F.
low fuel
low voltage
high voltage
10%-7 Gal.
12 volts
15 volts
13
OPERATION
changed at any time whether or not the conveyors are
moving.
8. Screen Scroll Switch
This switch is used to scroll the screen from the first
to the sixth screen. Pressing the switch down will change
to the next screen. Pressing the switch up will change to
the previous screen.
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
OPERATION
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 button 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 parking brake
and brake lights 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.
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.
WARNING
Parking Brake Meets SAE J1472
Parking Brake may not hold on grades steeper
than 15%
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 point speed and the computer
will maintain the set speed. If the set speed is 200 fpm,
14
Figure 6. Speed/Direction Control Handle
9. Control Handle
10. Gate/Spread Roll Switch
500 fpm. The rate of acceleration, to the set speed,
is always 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 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 .
Stopping is always accomplished by returning
the handle to neutral.
10. Gate/Spread Roll Switch. (Figure 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 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 desired
application rate of material will not flow out of the hop-
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.
OPERATION
per, 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. 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 7)
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
14. Hazard Flasher Switch (Figure 7)
Pull up for “on” and push down for “off”.
15. Headlight Switch (Figure 7)
Pull out for “on” and push in for “off”.
WARNING
Check local regulations and codes to
determine the lighting and marking
requirements for your usage.
16. Seat Shift Switch. (Figure 7) (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 7)
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
Figure 7. Control Panel
11. Turn Signal Selector
17. Hitch Release
12. Lt Turn Signal Ind
22. Hitch Height
13. Rt Turn Signal Ind
29. Warning Indicator
14. Hazard Flasher Switch 30. Filter Indicator
15. Headlight Switch
47. Brake Pedal
16. Seat Shift Switch (optional)
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
hitch automatically closes and locks when it contacts
the back of the truck.
18. Strobe (Optional)
Push the switch up to turn on the optional strobe or
beacon and down to turn it off.
19. Application Rate Computer
The speed pickup (Figure 8) 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.
15
OPERATION
At any point, regardless of the position of the Right
Conveyor Selector, the front operator can momentarily
turn on the right conveyor using the pushbutton switch
in the front control box.
Figure 8. Ground Speed Pickup
1. Magnetic Pickup
Normal spreading operation in auto speed and auto
gate would be done as follows:
a) Place the control handle in neutral.
Figure 9. Conveyor Diaphragm Switches
1. Left Ultrasonic Switch
2. Right Switch (not shown)
b) Set the desired speed using the Speed Toggle
Switch (3).
21. Left Conveyor Selector
d) Set the desired application rate using the Rate
Switch (5), or select the appropriate memory by pushing the memory switch up.
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.
c) Turn the gate/spread roll switch (10) “off”.
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.
Same operation as above except for left conveyor
and left conveyor auto switch.
22. Hitch Height Switch
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 and the truck.
23. Gate Override Switch
Depress to momentarily fully open the hopper gate
to clear a jam. Upon releasing the pushbutton, the gate
will return to its original set point.
24. Memory Selector Buttons
These switches select which of the 5 preset aggregate
combinations of speed, application rate, size and material is to be spread.
20. Right Conveyor Selector
25. Memory Save Button
In the middle position, power is supplied to the auto
switch mounted on top of the conveyor hood (See fig.
9). When this switch senses material, the conveyor will
shut off and conversely when no material is sensed it
will start the conveyor attempting to fill the hopper.
26. Calibrate Switch
In the bottom position, the conveyor is turned
“On”.
In the upper position, the conveyor is turned “Off”.
16
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.
The switch is used to calibrate the material before
use. See the section on Material Calibration and saving
in a preset location.
This button is used to operate the Chipspreader’s horn
for signalling the truck or warning of danger.
28. Batwing Switch
This switch is used to operate the batwing hopper.
Push up to raise the batwings, and down to lower.
29. Warning Light
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.
30. Filter Indicator
This light indicates that the charge pressure filter is
clogged when lit.
31. Traction Control Switch
This switch transfers torque to the front axle. The
joystick must be in neutral to engage this switch. If a rear
wheel spins, position the joystick in neutral and move
the traction control switch to the on position. Move the
joystick out of neutral and drive the chipspreader into
an area with better traction. The chipspreader speed is
limited to 200 fpm while the switch is engaged. When
this switch is moved to the off position, the machine
will resume set point speed.
32. Throttle Run/Idle Switch
The engine should be started with the switch in the
idle position. The engine will run at low idle when the
switch is in this position. When the switch is in the run
position, the engine will run at high idle. The hydrostatic system is designed to run at high idle, therefore
the switch should be in this position to perform any
work.
33. Throttle Increase/Decrease Switch
Press the switch up to increase the engine RPM
and down to decrease the engine RPM. The minimum
recommended engine speed is 900 RPM.
34. Auxiliary 12 Volt Power
A “Cigarette Lighter” style 12 volt power supply.
This supply is on when the ignition switch is in the on
position or the accessory position.
35. Engine Diagnostics On/Off Switch
With the ignition switch in the on position (engine
not running) position the diagnostic switch in the on
position to access the engine fault codes. The stop light
(Ref 36) will flash a series of times corresponding to a
particular fault code. The warning light (Ref 37) will
light when the code is finished. If more than one fault
code is present, use the throttle increase/decrease switch
to scroll through the active fault codes. The throttle
switch functions in this manner only when the engine
diagnostics switch is in the on position, otherwise it
functions as the throttle switch.
36. Engine Diagnostics Stop Light
When the stop light is lit, shut down the engine. Access the fault code and call your Cummins dealer.
37. Engine Diagnostics Warning Light
The warning light indicates something is wrong with
the engine and should be looked into soon.
38. Vibrator Auto Select Switch (Optional)
This switch places the vibrators, if so equipped, in
the auto mode. The vibrators will cycle on with activation of the gate/spreadroll switch for the set time and
then shutoff. The on time is adjustable from 1 to 10
seconds on the timer inside the control panel.
39. Vibrator Manual On/Off Switch (Optional)
This switch will turn on the vibrators when held
in the up position and automatically returns to the off
position when released.
40. Emergency Stop Switch
The emergency stop switch will bring the chipspreader to a controlled stop when activated, regardless of the
joystick position. The switch stops the engine while
maintaining electrical power, insuring a predictable
stop. To restart the engine, the switch must be reset by
turning the knob clockwise. The foot pedal service brake
is active with the emergency stop switch and can be used
to bring the chipspreader to a quicker stop.
41. Computer Reset Switch
warning
Do not reset computer while chipspreader is
in motion. Violent stop will occur which could
cause a fall resulting in injury or death.
When activated simultaneously, the computer reset
switches will reset the computer. Activating a single
switch will have no effect on the computer. In the
event of an alarm that limits the speed of the machine,
the computer can be reset without turning off the engine. Bring the machine to a stop before pressing the
17
OPERATION
27. Horn
OPERATION
Computer Reset buttons. A violent stop will occur if
the buttons are pressed while the machine is in motion.
The park/drive switch must be placed in the park position, and the joystick must be in the neutral position
while resetting the computer. The chipspreader will not
respond to the joystick until both the park/drive switch
has been placed in the park position and the joystick
has been placed in the neutral position.
47. Brake Pedal (Figure 7)
42. Individual Gates Master Switch
When the chipspreader is in motion and the brake
pedal is applied, a pressure switch in the brake line sends
a 12 volt signal to the computer, which destrokes the
pump. The chipspreader will decelerate as long as the
brake pedal is applied until it comes to a stop, regardless of the joystick position. To resume operation, the
joystick must be returned to center. If the brake pedal
is released during deceleration, the speed at that instant
will become the new speed set point. For example, if
the chipspreader is traveling at 1000 FPM and the brake
pedal is applied, the chipspreader will begin to decelerate. If the brake pedal is then released at 500 FPM, this
will be the new speed set point. When the joystick is
returned to center, the speed set point will return back
to the original 1000 FPM.
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.
43. 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.
44. 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.
45. Traction Boost Switch (Optional)
This switch activates a cylinder which pushes up
on the hitch. When attached to a truck this function
increases traction on the chipspreader’s rear tires. This
switch should only be activated while attached to a truck
and there will be no increase in traction while disconnected from a truck. The hitch release switch will not
function while traction boost switch is active.
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.
Items 48 thru 50 are located in the front
operator’s control box (figure 10)
48. Left Conveyor Pushbutton (Figure 10)
Pressing switch will turn left conveyor on independent of Left Conveyor Selector. Releasing switch will
transfer conveyor switch control back to Left Conveyor
Selector.
49. Right Conveyor Pushbutton (Figure 10)
Pressing switch will turn right conveyor on independent of Right Conveyor Selector. Releasing switch
will transfer conveyor switch control back to Right
Conveyor Selector.
50. Hitch Release Pushbutton (Figure 10)
Push the hitch release pushbutton to disengage the
supply truck from the Chipspreader.
Caution
Traction Boost may reduce braking efficiency
of truck.
49
48
46. Hopper Height Switch
This switch is used to change the height of the hopper. Push up to raise the hopper and down to lower
hopper.
18
50
Figure 10. Front Operator’s Control Panel
48. Left Conveyor Switch
50. Hitch Release Button
49. Right Conveyor Switch
Operation
Unsafe operation of equipment may cause
injury. Read, understand and follow the
manuals when operating or performing
maintenance.
WARNING
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.
WARNING
Do not travel with the seat unlatched. Seat
movement could occur causing disorientation
and possible loss of control.
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 a violent stop.
Keep loose clothing away from conveyor area
when operating the conveyors.
CAUTION
Always install locking control box cover
and chock wheels when leaving machine
unattended as protection against vandalism
and accidental movement.
OPERATION
WARNING
IMPORTANT
Do not tow the Chipspreader before reading
the towing instructions contained in this
manual. Improper towing may damage the
hydraulic motors.
WARNING
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 to clear
obstruction. 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 switch (Ref. 23, Fig. 5)
to open the 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.
Conveyor flow deflectors should be used to achieve
the desired material distribution in the front hopper.
Conveyor hoods should be used to adjust the distribution to the front hopper, primarily to control the amount
of material in the front hopper in the area in front of
the conveyor. The amount of material in front of the
conveyor will affect when the auto conveyor switch is
tripped to shut off the conveyor. Generally, the larger
the stone, the further forward the hood should be positioned. Approximately 1 1/2” gap is a good starting
point for 3/8” to 1/2” chips.
19
OPERATION
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 spreading full width and
the Chipspreader traveling at maximum speed for the
particular job.
The operator may wish to disengage the front hopper agitator while spreading clean dry aggregate. This
operation is performed by removing the agitator disconnect bolt. This will prevent unnecessary wearing
of the agitator.
Automatic Conveyor Control
In the middle position, power is supplied to the auto
switch mounted on the outside of the spread hopper.
When this switch senses material, the conveyor will
shut “off” and conversely when it no longer senses
material it will start the conveyor attempting to fill the
hopper. (Fig. 9)
Ultrasonic Sensors
The switching point of the ultrasonic switches can be
changed to optimize flow of rock in hopper and hood.
To change the switching point distance:
1) Turn key to the ON position and corresponding
selector switch to AUTO position.
2) Hold A1 button until red light flashes.
Backup Alarm
The electric backup alarm is automatically actuated
when the speed/direction control handle (Fig. 6) is
pulled to the rear of neutral.
Individual Gates (Figure 11)
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/spread roll
thumb switch. 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 hopper will open across the full width. Turning off individual switches will turn off 6 inch incre.
ments for the outer 2 feet and 1 foot after that
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.
3) Place object desired distance from switch.
4) Press A1 button to save.
5) Repeat steps 2-4 for A2 button.
Caution
Setting switching point to close or changing
mode from desired setting may cause
automatic switches to function improperly.
CAUTION
Keep loose clothing away from conveyor area
when operating conveyors.
20
Figure 11. Individual Gates
1. Air Cylinder
3. Buss Arm
2. Buss Bar
Install a chain or strap around the front hydrostatic
motor and parking brake assembly and secure the assembly to the front engine crossmember. Remove the
four 16mm bolts that secure the parking brake to the
front axle and pull the parking brake and motor assembly away from the front axle to disengage the spline.
On a 4WD machine secure the rear motor to the frame
crossmember and remove the motor in the same manner. The chipspreader should be towed to an area where
it can be loaded onto a trailer. It is not recommended
to tow the chipspreader for long distances. When the
chipspreader is placed back in service, verify that the
axle differential housings are filled with gear lube to
the full level.
Important
Do not tow the chipspreader before reading the
towing instructions contained in this manual.
Improper towing may damage the hydraulic
motors and brakes.
Optional Equipment
WARNING
Unsafe operation of equipment may cause
injury. Read, understand and follow manuals
when operating or performing maintenance.
Hydraulic Powered Seat Assembly
A hydraulically powered seat positioner is operated
by a spring centered toggle switch (Fig. 12). The seat
may be positioned wherever it is desired for operation.
Extra Agitator
When sand or other small aggregate is being spread,
an optional second agitator may be placed in the hopper
so as to greatly reduce the possibility of bridging. This
agitator should be disengaged normally and only used
when bridging has been experienced.
Figure 12. Seat Position Switch
21
OPERATION
Towing Instructions
APPENDIX A
MAINTENANCE ADJUSTMENTS
Hopper Gate Wear Plate Adjustment
MAINTENANCE
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.
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.
WARNING
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.
Figure 14. Gate Wear Plate
Hopper Spread Roll Wear Plate Adjustment
Turn spread roll 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.
1. Spread Roll
Figure 13. Spread Roll Wear Plate
1. Hold Down Bolts
22
2. Spread Roll Wear Plate
Figure 15. Hopper Gates
2. Gates
3. Adjustment Bolts
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. 16) it will
then be necessary to adjust the head pulley as outlined
below. (Fig. 17)
For the right hand conveyor:
b) Loosen adjusting bolt jam nuts.
c) Start conveyor at this time.
Figure 16. Conveyor Tail Pulley
1. Conveyor Belt Tail Pulley Adjustment Bolt (4 Places)
MAINTENANCE
a) Loosen the four bolts holding the right hand side
head pulley bearing.
WARNING
Conveyor must be running during this
procedure. To avoid personal injury, be sure to
remain clear of moving belt.
WARNING
Remain clear of moving parts.
d) If belt runs to the right hand side of the conveyor,
tighten the adjusting screws until the belt is centered
on the head pulley.
e) If belt runs to the left hand side of the conveyor,
loosen 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.
For left hand conveyor:
a) Loosen the four bolts holding the right hand side
head pulley bearing.
b) Loosen the adjusting bolt jam nuts.
c) Start conveyor at the time.
d) If belt runs to the right side of the conveyor, loosen
the adjusting screws until the belt is centered on the
head pulley.
e) If belt runs to the left 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.
Figure 17. Conveyor Head Pulley Adjustment
1. Left Conveyor
2. Jam Nut
3. Adjusting Screw
4. Bearing Bolts
5. Hood Adjustment
6. Hood Adjustment Set Screws
NOTE: Only a small amount of head pulley adjustment should be necessary to center conveyor belts.
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
The fuel tank is part of the crosswalk. Do not
drill or weld in this area.
CAUTION
To avoid potential damage to electrical
components, disconnect batteries before
welding
23
APPENDIX B
COMPUTER SETUP
MAINTENANCE
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.
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.
SETUP: FIRMWARE
Version 1.xx
This screen shows the version of firmware which is
loaded in the machine. (version 1.01 for example)
Push the “scroll” switch down to move to the next
screen.
24
SETUP: WORK MODE
SETUP: ENGINE
This screen is used to set the machine in ship mode
or work mode. In ship mode the speed setpoint is
fixed at 300 FPM. Work mode allows the operator to
adjust the speed setpoint in the main operator screen.
Use the “cal” switch to toggle between work and ship
mode. Push the “scroll” button down to move to the
next screen.
ELECTRONIC
This screen shows how the engine communicates
with the computer. With an electronic engine the
computer reads the data from the engine ECU. With a
mechanical engine the computer reads engine data from
external sensors attached to the engine. Use the “cal”
switch to toggle between electronic and mechanical
engine. 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
160 CC
This screen is used to set the motor displacement. Use
the “cal” switch to set the motor displacement to 160
CC. When this has been properly set, push the “scroll”
switch down to move to the next screen.
SETUP: HOPPER
FIXED
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: UNITS
ENGLISH
This screen is used to set the display units to either
english or metric. Use the “cal” switch to toggle between english and metric units. When this set for your
machine, push the “scroll” switch down 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 2.3 volts
Push the “cal” switch to calibrate the neutral position.
The display will change to
SETUP: JOYSTICK
Forward
4.3 volts
Push the stick full forward, the reading should change
to approximately 4.4 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
0.7 volts
SETUP: JOYSTICK
Actual
SETUP: GATE OPENING
Maximum:
4.00 inches
This screen is used to set the maximum gate opening
for the front hopper. Standard machines have a 4 inch
gate opening and big chippers have a 5 inch gate opening. If the maximum gate opening is set incorrectly for
the machine the application rate will be off. Use the
“cal” switch to toggle between 4 inch and 5 inch gate
opening. When this is set for the machine, push the
“scroll” switch down to move to the next screen.
SETUP: RIGHT NULL
Actual:
0.00 inches
This screen is not used for a fixed hopper. Push the
“scroll” switch to move to the next screen.
SETUP: RIGHT SCALE
Actual:
0.00 inches
This screen is not used for a fixed hopper. Push the
“scroll” switch to move to the next screen.
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.
For a fixed hopper, the computer uses the left
gate settings.
Pull the stick to the full reverse position, the reading
should change to approximately 0.7 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: LEFT SCALE
Actual:
0.00 inches
This screen is used to set the actual open position of
the gate. The number will read 0.00 inches until the left
gate override is actuated. While holding the 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.
0.0%
When you have finished calibrating the joystick, push
the “scroll” switch to change to the next screen.
25
MAINTENANCE
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.
MAINTENANCE
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.
The calibration done in these setup screens is to adjust the open and close thresholds on the proportional
valves controlling the gate cylinder. These thresholds
determine the speed at which the gates open and
close.
The right gate is not used on a fixed hopper. Push
the scroll switch down to scroll past the right gate setup
screens.
SETUP: RIGHT OPEN
1.200 amps
This screen is not used for a fixed hopper. Push the
“scroll” switch to move to the next screen.
26
SETUP: RIGHT CLOSE
1.200 amps
This screen is not used for a fixed hopper. Push the
“scroll”
switch to move to the next screen.
SETUP: LEFT OPEN
1.000 amps
Use the “cal” switch to adjust the current up or down
to increase or decrease the speed at which the gate
closes. Adjusting this value too high will cause the gates
to hunt around the desired gate opening. Adjusting this
value too low will cause a delay of the gate opening.
SETUP: LEFT CLOSE
1.000 amps
Use the “cal” switch to adjust the current up or down
to increase or decrease the speed at which the gate
closes. Adjusting this value too high will cause the gates
to hunt around the desired gate closing. Adjusting this
value too low will cause a delay of the gate closing.
SETUP: GATE OPEN 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 on 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 begin to open. The left gate is not affected by
changing this number.
SETUP: GATE SHUT 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 on 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 begin to close. 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.
APPENDIX C
COMPUTER SERVICE SCREENS
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
3/8
400
lb/yd Chip
fpm
2
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 15%
OIL FUEL
100ºF 2200 RPM
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.
HYD OIL
ENGINE
13.8 V
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
ENGINE
7550 FT
CHIPPED
This screen shows the hours on the machine on the
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 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 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: Aggre. Next
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: 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.
SERVICE: Appl Rate+
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.
27
MAINTENANCE
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.
SERVICE: Cal Rate-
Status: 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
MAINTENANCE
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 to the computer. Put the “Left Gate
Power” switch up, and depress the “Thumb” switch.
The display should change to Activated. Check that
it is deactivated with each of the following scenarios.
Depress the “Thumb” switch to turn the “Gates Active” light off. The display should become deactivated.
Turn the “Thumb” switch back on. Push the “Left Gate
Power” switch down and the display should change to
deactivated. Push the scroll switch down to move to
the next screen.
SERVICE: L.GATE OVER
Status: De-activated
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 to the computer. Put the “Right Gate
Power” switch up, and depress the “Thumb” switch.
The display should change to Activated. Check that
it is deactivated with each of the following scenarios.
28
Depress the “Thumb” switch to turn the “Gates Active”
light off. The display should become deactivated. Turn
the “Thumb” switch back on. Push the “Right Gate
Power” 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: BRAKE INPUT
Status: De-activated
This screen shows the position of the “Service Brake”
pedal. Push the “Service Brake” pedal down and the
display should change to “Activated” as long as the
pedal is held down. 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
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.
SERVICE: Setup #2
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.
SERVICE: Setup #3
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.
SERVICE: Setup #4
Status: De-activated
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.
SERVICE: VEH. SPEED Status: De-activated
This screen shows the position of the “Speed”
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 +
Status: De-activated
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
Status: De-activated
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: BATTERY
Status: 12.3 volts
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: 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: 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.
SERVICE: Right Gate
Status: 0.00 Volts
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
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. 29
MAINTENANCE
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
MAINTENANCE
This screen shows the current to the rear motor in a
4WD machine. Push the scroll switch down to move
to the next screen.
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.
30
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
ENGINECHIPPED
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.
APPENDIX D
SYSTEMS STARTUP AND ADJUSTMENTS
CAUTION
Hydrostatic System Startup
1. Jack the machine up and securely support on stands
with all four wheels off the ground.
2. Disconnect the 50 pin connector at the engine,
so that the engine can only be cranked and cannot be
started. (Fig. 19)
3. Disconnect pump stroker at the pump.
WARNING
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.
4. Insert a 600 psi gage (with a size 10 male boss
end) in port “G” on the drive pump (Fig. 25).
Do not crank engine with gate valve closed.
Doing so will cause damage to the hydraulic
pumps.
6. Turn ignition key “on” and place the throttle switch
in the “idle” position. Turn key to “start” and crank
engine with starter until seeing at least 40 to 60 psi on
the charge pressure gage.
DO NOT CRANK FOR MORE THAN 30 SECONDS.
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.
7. Hook up the 50 pin connector.
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.
Figure 18. Hydrostatic Pump
1.
Hydrostatic Pump
3. 1st Implement Pump
2. Fwd & Rev Solenoids
5. Make sure the gate valve, (Fig 20) in the suction
tube is turned fully open (counterclockwise) with sleeve
and handle installed. Do not attempt to start the engine
with the gate valve closed. This will block the flow to
the pumps and cause cavitation.
Figure 19. Engine Left Side
1. 50 Pin Connector
During filling of all lines and components, the charge
pressure can surge between 50 and 500 psi. As the system fills, surging will decrease and the charge pressure
should settle down to a steady reading.
31
MAINTENANCE
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.
WARNING
Be certain that machine is securely supported
on stands. Wheels will be rotating under power.
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. Start the engine and run it at about 1000 rpm.
MAINTENANCE
3. Check that the gate switch is turned off and the
gates appear to be closed and then shut the engine off.
4. To insure that the gates are fully closed, swap the
connectors on the gate open and close valve and restart
the engine. Depress the gate override button which will
fully close the gates. While holding the override button down shut off the engine. There should be 1/16”
between each gate and the spread roll.
5. Replace the connectors in their correct positions.
Figure 20. Gate Valve
1. 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 the sight eye
in the tank.
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 LEFT GATE
NULL. Note that on a fixed hopper the right gate
is not used. This value should be around 0.0. If it is
not, verify that the gate is closed. There should be
1/16” between each gate and the spreadroll. 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,
LEFT GATE SCALE. Hold the 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 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”
It is recommended to try and set the gates using the
computer set up screens prior to physically making
32
6. Enter the Set up access screens by holding the
“Cal” switch down while turning the key on. Do not
start the engine. Scroll down to the left gate null setting,
and set the null to zero by depressing the “Cal” switch.
The screen should change to 0.0. Then scroll down to
the save screen and save the value.
7. Using needle probes on a digital voltmeter, measure the voltage between the red and black wires at the
gate transducer. The value should be 5.0 volts DC. Next,
check the voltage between the blue and black wires. This
value should be between 0.5 and 1.5 volts DC.
8. If the value measured in step 7 is not within the
specified tolerance, remove the transducer cover on
the hopper.
9. Loosen the transducer mounting bolts and rotate
the transducer as necessary to get the 0.5-1.5 volt DC
reading.
10. Retighten the mounting bolts.
11. Recheck the reading.
12. Start the engine and depress the gate override
button to fully open the gates. While depressing the
override button, shut the engine off. The gates should
remain fully open. Turn the key back on and measure the
voltage between the blue and black wires. The voltage
should be 3.5 to 4.5 volts DC. Restart the engine and
let the gates close and recheck that the closed value is
still within the specified range of 0.5 -1.5 volts.
If it is, enter the set up screens while starting the
engine and scroll down to the appropriate gate scale
screen.
13. Depress the override button to fully open the
gates and then depress the cal switch. The reading
should change to 4.00.
14. Release the override button and scroll up to the
“Gate Null” screen to check the reading. If it is no longer
at ”0”, depress the override button and scroll down to
the “Gate Scale” screen. Depress the override button
and while depressing the override button, depress the
“Cal” button to set the scale.
Air Pressure Adjustments
1. Set the main pressure regulator at 80 psi. (Fig 22)
5
6
4
3
2
15. Repeat these two steps as required until the
readings get to “0” and “4” or until they no longer
change.
16. Upon completion, scroll to the save screen and
exit set up by depressing the “Save” button.
7
1
WARNING
8
MAINTENANCE
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.
Figure 22. Air System
1. Compressor
3. Air Oiler
5. Main Regulator 7. Valve Bank
2. Reservoir
4. Water Separator
6. Main Pressure Gage
8. 1 FT Gate Cylinders
Pressure Settings For Hydrostatic Drive
Pump (Rexroth AA4VG125 Pump)
Figure 21. Hopper Transducer
1. Drive Pin
3. Transducer
The pressure settings consist of two (2) high pressure
cross port relief valves (forward and reverse) and the
pressure over-ride (pressure cut-off) for the AA4VG125
pump. The adjustment procedure is as follows:
2. Lever Arm
4. Bearing
33
1) Install 10,000 psi pressure gages in ports MA and
MB located on the top side of the pump. These ports are
-04 SAE O-ring. The pressure gages should be installed
with enough hose to see the gage without getting under
the machine.
warning
MAINTENANCE
Do not go under the machine while the engine
is running. The machine could move causing
severe injury or death.
mA
the rear wheels from turning. Disconnect the two rear
drive hoses at the drive pump and install 16MB caps
on the adapters and 16MB plugs in the hose ends. Once
the parking brake release has been disabled, unhook
the brake pressure switch, if equipped. The switch is
located on the hose coming from the foot pedal. 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, you may have to 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.
mb
mA
mb
POR
Figure 23. POR Setting
2) The pressure over-ride (POR) should be turned
all the way IN to be able to obtain the highest possible
pressure cut-off 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 may have 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 center deck
cover below the operator’s station. The brake release
solenoid is the forward most coil towards the curbside
of the machine. Disabling this circuit will insure the
chipspreader will not move while checking pressures.
On 4WD units, the rear hoses must be capped to prevent
34
Figure 24. 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:
1) 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.
2) Put the pump to neutral.
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 high pressure reads
6500 psi. The POR. adjustment is the same screw that
was turned in fully in step 2. There is only one setting
for this relief that controls forward and reverse.
CAUTION
1) Install 600 PSI gage in the “CGP” port on the hitch
manifold (Fig 29, Ref 1). The gage will require a size 04
male boss 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, you may
have to remove the protective plastic cap located on
the top side of the pump beside the port marked “G”
(Fig 25). 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.
Remove the gage.
When making the pressure over-ride
adjustment, the pump should be put on stroke
only for a few seconds at a time until you are
sure that the pressure cut-off setting is Below
the setting of the two high pressure cross-port
relief valves.
Once the pressure over-ride 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.
Remove the gages.
Setting the Charge Pressure
g
Pressure Settings For Auxiliary Pump
(Rexroth A10VO74 Pump)
This pump is stacked on the back of the drive pump.
Flow for the left and right conveyors, the spreadroll, and
the gate cylinder is supplied by this pump on a fixed
hopper chipspreader. The pump has 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 400 psi.
Relief Valve Settings
1) Install a 1000 psi gage, with a shutoff valve in
the port marked “TP” on the conveyor manifold located
on top of the hydraulic reservoir (Fig 27 Ref 2). This
port is SAE 04 and requires a 9/16 wrench to remove
the plug.
5
2
4
3
1
Figure 26 Pumps
1. Front Pump Relief Valve
2. Rear Pump Relief Valve
3. Main Hydrostatic Pump
4. Front Standby Pressure
5. Rear Standby Pressure
Figure 25. Charge Pressure Adjustment
2) Disconnect the electrical connectors from gate
valve. 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
35
MAINTENANCE
3) Make an adjustment to the relief valve.
the engine. Make sure the shutoff valve is shut. Failure
to do so could result in a blown gage. Start the engine
and run at low idle and monitor the gage pressure. The
standby pressure should be 400 psi.
MAINTENANCE
3) To make an adjustment, use a 17mm wrench to
remove protective cap from set screw. The standby
pressure adjustment is the higher adjustment of the
two adjustments at the rear of the pump (Fig 26, Ref
3). Loosen the jam nut on the rear pump and turn the
set screw until the pressure reads 400 psi on the gage.
Replace protective cover once correct pressure is set.
Tighten the jam nut. Shut the engine off.
4) Install a 5000 psi gage in the port marked “TP” on
the conveyor manifold located on top of the hydraulic
reservoir (Fig 27, Ref 2). Remove the pressure hose
plumbed to the left conveyor at the manifold and cap
the adapter in the port marked “A2” with a 1/2” (08)
JIC hydraulic cap.
5) With engine running at half throttle, turn on left
conveyor and monitor gage pressure. If the pressure
reading is below 2950 psi or above 3050 psi an adjustment should be made.
6) 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 lower one of the two. 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 the correct pressure is set.
7) Reinstall the hose removed in step 1 and remove
gage.
8) Remove gage and reinstall the 1000 psi gage with
the shutoff closed. Restart engine and let it idle. Open
the shutoff valve and verify that the standby pressure
is still at 400 psi and adjust if necessary.
9) Reconnect the electrical connectors on the gate
valve and remove the gage.
1. “LS” Port
Figure 27. Conveyor Manifold
2. “TP” Port
CAUTION
Do not set pressure above 3000 psi. The
hydraulic components are rated for 3000 psi.
Failure of these components could occur at
system pressures above 3000 psi.
Pressure/Flow Settings For Actuator Valving
(Functions supplied by pressure compensating auxiliary pump)
Note: Other than individual circuits which require
reduced pressure for mechanical purposes, the main
system relief is set at the pump.
Gate Cylinder Relief Valve
The relief setting for the gate cylinder relief valve
should be set to 1500 psi.
1) Install 2000 psi gage in “TP” port of gate cylinder
manifold located just behind conveyor manifold on
hydraulic reservoir (Fig 28). This port is SAE 04 MB
and requires a 9/16 wrench to remove the plug.
2) With engine at high idle, depress and hold the
gate override push-button and monitor pressure. If
pressure is below 1450 or above 1550, an adjustment
should be made.
36
3) To adjust pressure, use 9/16” box wrench to loosen
jam nut on set screw located on the gate manifold on
top of the reservoir (Fig 28). If pressure is low, turn
set screw clockwise. If pressure is high, turn set screw
counterclockwise.
4) Remove gage.
Pressure Settings For Actuator Valving
Supplied By Fixed Displacement Pump
Main Relief Pressure (MP)
The main relief pressure should be set to 2000 psi.
The steering motor operates at this pressure.
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.
Figure 28. Gate Relief Valve
1. “TP” Port
2. Gate Relief Valve
Spreadroll Speed Adjustment
The spreadroll should be set at 100 rpm.
1) With engine at high idle and park/drive switch in
park position, push joystick slightly out of neutral and
depress right side of thumb switch engaging the 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 9/16” box wrench.
This valve is located on the gate manifold on the hydraulic reservoir. Using a 1/4” allen wrench, turn set
screw clockwise to decrease the speed of the spreadroll,
or counterclockwise to increase the speed.
Fixed Displacement Auxiliary Pump
The fixed displacement pump (gear pump) is 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.
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. Shut the engine off
before proceeding to make any adjustment.
3) If the pressure is low, remove cap from top of
relief valve using vise grips (Figure 29, Ref 1) and adjust
set screw clockwise using a 1/4” allen wrench. If pressure is high, adjust set screw counterclockwise.
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. 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.
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. Shut the engine off
before proceeding to make any adjustment.
3) If the pressure is low, remove cap from top of
relief valve using vise grips (Figure 29, Ref 3) and adjust
set screw clockwise using a 1/4” allen wrench. If pressure is high, adjust set screw counterclockwise.
37
MAINTENANCE
1) Install 3000 psi gage in port marked “MP” on
steering/hitch manifold located under center deck cover
below operators station. This port is SAE 06 MB and
requires a 1/4” allen wrench to remove plug. (Figure
29, Ref 2)
Reduced Pressure (RP)
Fan Valve Pressure Setting
MAINTENANCE
charge
Pressure
To Parking
brake
Steering Pressure
Steering Return
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.
3) To adjust the pressure turn off engine and adjust
relief set screw on fan valve. A 9/16” box wrench is
required to loosen the jam nut and a 5/32” allen wrench
is required to adjust the set screw. If the pressure is low
turn the set screw clockwise. If pressure is high turn
the setscrew counterclockwise.
To cooler
Rt. bottom
4) Restart the engine and monitor pressure. Repeat
step 3 as necessary to adjust the pressure in the range
of 1900 psi to 2100 psi.
3 4
1
HO
R
HU
PS
R
P
PS
BP
DY
P
L
gear Pump
BW
R
HC
G
CP
AT
SE
BW
MP
SE
AT
L
HD
R
5
Figure 29. Hydraulic Control Assembly
1. Charge Pressure Check Port
2. Pilot Pressure Check Port
3. Main Pressure Relief Valve
4. Pilot Pressure Relief Valve
5. Main Pressure Check Port
1) Install 600 psi gage in port marked “RP” on steering/hitch manifold. 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 4WD 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 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.
38
1) Remove hose from “M” port on the fan valve
located behind the cooler (Fig 30). Cap the end of the
hose and install a 3000 psi gage into port “M” on the
fan valve. This port is an SAE 16 and requires a 1 1/2”
wrench for the hose and cap.
2) With engine at high idle, unplug connector at the
fan valve, monitor pressure. If the pressure is below
1900 psi an adjustment should be made.
2
4) Remove gauge.
The fan valve relief should be set to 2000 psi. The
fan motor operates at this pressure.
5) Shut engine off. Remove gage, reinstall hose and
reconnect electrical connection on fan valve.
Pressure Setting for Traction Boost Circuit
Traction Boost Pressure
The relief pressure of the traction boost circuit should
be set at 1000 psi. The traction boost circuit operates
at this pressure.
1) Install a 3000 psi gage in the hydraulic tee of the
port marked “1” on the relief valve located between the
conveyors below the operator station (Fig 31 & 31A).
3) If the pressure is below 900 psi or above 1100
psi an adjustment should be made. A 3/8” wrench is
required to loosen the jam nut on the relief valve and
a 1/8” allen wrench is required to adjust the set screw.
If the pressure is low turn the set screw clockwise until
the gage pressure reads 1000 psi. If the pressure is high
turn the set screw counterclockwise until the gage pressure reads 1000 psi.
Figure 31. Traction Boost Relief Valve
MAINTENANCE
2) With engine at high idle, turn traction boost switch
to the on position, monitor pressure.
4) Turn engine off. Remove gage and replace cap
on tee.
Figure 31A.
Figure 30. Fan Valve
Figure 32. Engine Belt Routing
39
MAINTENANCE
Truck Hitch Arrangement
40
Caution And Instruction Plates
11
2a
2m
2h
MAINTENANCE
1b
1c
2e
1a
2k
2f,2g
4
7
10
2d
2m
2h
2n,8
2c
9 1d 2j 7
REF PART NO. QTY
1
2
3102066
3102066-A
3102066-B
3102066-C
3102066-D
3102065
3102065-A
3102065-B
3102065-C
3102065-D
3102065-E
3102065-F
3102065-G
3102065-H
3102065-J
1
1
2
1
1
1
1
1
1
1
1
1
2
2
2
DESCRIPTION
7
2j
2f,2g
2f,2g 4
Decal Set, Chips Hopper Std.
Caution: Shields,Warning: Clear
Caution: Shields,Warning: Clear
Notice: Hose Disconnect
Lubrication Chart
Decal Set, Chipspreader Body
Warning: Injury, Read, Brake
Warning: Fuel Tank, Fill
Warning: No Drill
Warning: No Shift
Anti-Freeze
Proposition 65 Warning
Warning: No Drill, Caution: Towing
Warning: Clear, Caution: Towing
Warning: Hydraulic Tank
7
2L
REF PART NO. QTY
2
3
4
5
6
7
8
9
10
11 3102065-K
3102065-L
3102065-M
3102065-N
3101268
3102000
3101999
3102000
3100689
6000758
3102176
3103394
3102205
3102268
3190516
1
1
2
1
1
2
2
2
1
1
4
1
2
1
1
DESCRIPTION
Warning: Clear, Caution: Shields
Caution: Towing
Grease Daily
Caution: Valve
Plate-Hyd Hitch Release
Decal-Chipspreader, Quad
Decal-Chipspreader, FWD
Decal-Chipspreader, QUAD
Nameplate-Chipspreader, Brass
Emblem-Vehicle, Slow Moving
Decal-Warning, Pinch Point
Notice-Emission Control Information
Warning-No Passengers, No Handrails
Warning-Ignition Switch
Caution-Traction Boost
41
Lubrication
4
4
17
16
5
2
26
6
19,20
23
10
11
MAINTENANCE
3
1
1
13
8
24
12
24
25
Point
15
21,22
14
7
Interval
18
Grease-#2 Molub-Alloy Grease
Lube Oil-#10 Non-Detergent Oil
9
Hydraulic Oil-ISO VG 46 Hydraulic Oil
Gear Lube-SAE 90 API GL-5/MIL-L-2105 B Gear Lube
Identification
Points
No. of
Lubricant
Quantity
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Cartridge Bearing (Both Ends)
Bearing Disconnect
Front Hopper Gates
Baffle Shaft (Both Hoods)
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
Bearing-Slack Adjuster (2WD only)
Bearing-Camshaft (2wd only)
Hydraulic Reservoir
Hydraulic Oil Cooler
Engine Oil
4
1
A/R
2
4
4
4
4
4
2
4
6
2
4
1
Grease
Grease
Grease
Grease
Grease
Grease
Grease
Grease
Grease
Grease
Grease
Grease
Grease
Grease
Hydraulic Oil
Engine Original
Sparingly
Sparingly
Sparingly
Sparingly
Sparingly
Sparingly
Sparingly
Sparingly
Sparingly
Sparingly
Sparingly
Sparingly
Sparingly
Sparingly
Add When Low
Clean A/R
Engine Manual
When Indicator turns red
18
Filter-Engine Air Intake
1
-
Filter Element
Yearly
19
20
21
22
23
Filter-Return*
Filter-Suction*
Magnet-Hydraulic Reservoir
Breather-Hydraulic Reservoir
Differential Housing**
Planetary Wheel End**
25
26
Hub-Rear Axle (2wd only)**
Roller Chain-Power Seat
Gear Lube
Gear Lube
Gear Lube
Gear Lube
Gear Lube
Lube Oil
Filter Element
Filter Element
Clean A/R
Filter Element
24
2
2
1
1
1-2wd
2-4wd
2-2wd
4-4wd
2
2
Weekly
Fill
Fill
Fill
Fill
Fill
Sparingly
(1) 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.
(2) 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
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K-525-01
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