Volvo G700B Series, G720B, G710B, G740B, G746B Operator's Manual

...

Foreword

G700B

OPERATOR’S MANUAL

This Operator’s Manual is intended as a guide for the correct use and maintenance of the machine. Therefore, study it carefully before starting and operating the machine, or before carrying out any preventive maintenance.

Keep the manual in the manual box in the cab so that it is always at hand. Replace it immediately if it is lost.

NOTE: The manual describes the applications for which the machine is primarily intended, and is written to apply for all markets. We therefore ask you to disregard the sections that are not applicable to your machine or to the work for which you use your machine.

Many hours are spent on design and production to make a machine that is as efficient and safe as possible. The accidents that occur in spite of this are mostly caused by the human factor. A safety-conscious person and a well maintained machine make a safe, efficient and profitable combination. Therefore, read the safety instructions and follow them.

Every new Volvo Motor Grader is shipped with a CIMA Grad- er Safety Manual published by the Construction Industry Manufacturers’ Association. Read it carefully before operating or servicing your grader.

We continually strive to improve our products and to make them more efficient through changes to their design. We retain the right to make these changes without committing ourselves to introducing these improvements on products that have already been delivered.

We also retain the right to change data and equipment, as well as instructions for service and maintenance, without prior notice.

Contents

Presentation

Instrument panels

Controls

Operating instructions

Operating techniques

SAFETY REGULATIONS

It is the operator’s obligation to know and follow the applicable national and local safety regulations. The safety instructions in this manual only apply to cases when there are no national or local regulations.

WARNING!

The symbol above appears at various points in the manual together with warning text. It means – Warning, be alert! Your safety is involved. It is the obligation of the operator to make sure that all warning decals are in place on the machine and that they are readable. Accidents may otherwise occur.

Know the capacity and limits of your machine!

This manual applies to Serial Number 35000 and up.

Safety when servicing

Service and maintenance

Specifications

Alphabetical index

Ref. No.: 21 1 434 4006

Printed in Canada

Foreword

State the PIN number of the machine (serial number) below. Always state this information when contacting the manufacturer and when ordering spare parts. It is also a good idea to note the serial number of the components.

Manufacturer Volvo Motor Graders Limited

160 Maitland Road,

Goderich, Ontario, Canada N7A 3Y6

The PIN number of the machine (serial number)

Engine

Transmission

Final drive

Foreword

Operation and maintenance of the machine 3

Operation and maintenance of the machine

Volvo Motor Graders Limited is only responsible if:

n the machine has been used in a correct way and has been maintained

in accordance with the instructions in the Operator’s Manual and Service Manual.

n prescribed service and prescribed inspections have been carried out

at the stated points of time.

n the recommended lubricants according to the manual have been

used.

n no security seals have been broken other than by authorized persons.

n all modifications and repairs have been carried out and methods have

been used in the way prescribed by Volvo Motor Graders Limited.

n only genuine Volvo spare parts/accessories, or genuine spare parts/

accessories that meet Volvo’s requirements, have been used.

WARNING!

The operator of a motor grader must have sufficient knowledge and instructions before he/she operates the machine. Untrained operators may cause severe injuries or even fatalities. Therefore, it is important that you read and follow the instructions of this Operator’s Manual. Never use a motor grader that has no Operator’s Manual available. Learn and understand the safety signs and symbols on the machine and the operator instructions before you begin to use the machine.

Foreword

4 Communication equipment, installation

Communication equipment, installation

IMPORTANT!

All installations of electronic communication equipment must be performed by trained professionals and in accordance with Volvo Construction Equipment instructions applicable to the specified machine.

Protection from electromagnetic interference

The Volvo Motor Grader is equipped with multiple ECUs that were tested for Electro Magnetic Compliance. This means that the ECUs are immune to electromagnetic interference at the levels prescribed in the international standards. However, if improper installation and use of communication equipment exceed the limits of these components, the machine may malfunction. Therefore, it is very important that all non-approved electronic accessories, such as communication equipment, be tested before the machine is put into service.

Mobile telephones

To obtain the best functionality, mobile telephones should be permanently installed in the electrical system of the grader with a permanently fixed antenna on the cab, installed as advised by the manufacturer.

If a portable mobile telephone is used, note that it can constantly transmit information to its base station, even when the telephone is not used. For this reason, it should not be located beside electronic equipment in the machine, such as directly on a control panel, etc.

Guidelines

The following guidelines must be followed during installation:

– The antenna placement must be chosen to give good adaptation to

the surroundings.

– The antenna cable must be of the coaxial type. Be careful to ensure

the cable is undamaged, that the sheath and braid are not split at the ends, and the braid covers the connector ferrules and has good galvanic contact with them.

– The mating surface between the antenna mounting bracket and the

bodywork must have clean metal surfaces, with all dirt and oxide removed. Protect the mating surfaces against corrosion after installation to maintain good galvanic contact.

– Remember to separate interfering and interfered cables physically. In-

terfering cables consist of the communication equipment’s supply cables and antenna cable. Interfered cables are those which are connected to electronic devices in the machine. Install the cables as close as possible to grounded sheet metal surfaces, since the metal has a shielding effect.

Contents

Foreword.................................................................1

Operation and maintenance of the machine ......................3

Communication equipment, installation..............................4

Contents..................................................................5

Presentation ...........................................................7

General...............................................................................7

CE Marking and Declaration of Conformity ......................10

Plates and decals .............................................................12

Service .............................................................................16

General Information..........................................................17

Instrument panels ................................................21

General.............................................................................21

Center instrument panel ...................................................22

Pedestal instrument panel................................................28

Side console instrument panel .........................................45

All Wheel Drive control panel ...........................................52

Other ................................................................................54

Controls ................................................................55

Operator controls..............................................................55

Operator comfort ..............................................................57

Hydraulic controls .............................................................64

Other controls ...................................................................71

Operating instructions.........................................73

Introduction.......................................................................73

Running-in period .............................................................74

Safety and responsibility ..................................................75

Before operating ...............................................................80

Ignition switch ...................................................................83

Starting the engine ...........................................................85

Shifting gears ...................................................................87

Steering ............................................................................93

Braking .............................................................................95

Differential lock .................................................................97

After operating ..................................................................98

Towing............................................................................101

Transporting the machine...............................................103

Manual release of parking brake ....................................106

Moveable Blade Control System ....................................107

Scarifier ..........................................................................115

Ripper.............................................................................116

Windrow eliminator .........................................................117

Dozer blade/V-plow ........................................................119

One way plow.................................................................120

Hydraulic snow wing.......................................................121

Operating techniques ........................................123

Introduction.....................................................................123

Moldboard ......................................................................124

Turning around using articulation ...................................125

Making a three point turn................................................126

Contents

Grading around an object.............................................. 127

Grading on an ‘S’ curve shoulder .................................. 128

Right-hand leveling........................................................ 130

Left-hand leveling .......................................................... 131

Road construction.......................................................... 132

Scarifier and ripper operation ........................................ 143

Safety when servicing ...................................... 145

Introduction.................................................................... 145

Service position ............................................................. 146

General ......................................................................... 148

Fire prevention measures.............................................. 152

Hydraulic system ........................................................... 156

Electrical system............................................................ 159

Tires............................................................................... 160

Air conditioning unit ....................................................... 161

Fuel handling ................................................................. 162

Service and maintenance ................................. 163

Fuel system ................................................................... 165

Turbocharger ................................................................. 169

Engine air cleaner.......................................................... 170

Radiators and coolers.................................................... 172

Engine cooling system................................................... 174

Drive belt tension........................................................... 178

Electrical system............................................................ 179

Transmission ................................................................. 185

Engine clutch ................................................................. 187

Final drives .................................................................... 188

Tandems........................................................................ 190

Brake system................................................................. 191

Hydraulic system ........................................................... 193

All Wheel Drive .............................................................. 195

Tires............................................................................... 196

Climate control system .................................................. 197

Miscellaneous ................................................................ 200

Maintenance schedule................................................... 201

Grease points ................................................................ 202

Symbol key, lubrication and service chart ..................... 203

Lubrication and service chart......................................... 204

Specifications.................................................... 217

Recommended lubricants.............................................. 217

Capacities...................................................................... 219

Intervals between changes ............................................ 219

Engine ........................................................................... 221

Fuel system ................................................................... 223

Cooling system .............................................................. 224

Electrical system............................................................ 225

Power transmission ....................................................... 227

Brake system................................................................. 229

Hydraulic/Steering system ............................................. 230

Critical mounting torques ............................................... 231

Dimensional drawing ..................................................... 233

Noise and vibration levels.............................................. 234

Alphabetical index ......................................................... 235

Presentation

General 7

General

Intended use

The machine is intended to be used under normal conditions for the operations described in the Operator’s Manual. If it is used for other purposes or in potentially dangerous environments, for example, an explosive atmosphere, areas with dust containing asbestos, etc., special safety regulations must be followed and the machine must be equipped for such use. Contact the manufacturer or dealer for further information.

Engine

The engine is a four stroke cycle, in line six cylinder, turbocharged diesel with overhead valves and air-to-air charge air cooler. These engines are of the low emission type and all models have VHP (Variable horsepower).

VHP

All Volvo grader models have engines that provide 2 different power levels depending on the gear selected by the operator.

– For non-All Wheel Drive equipped graders, forward gears 1,

2, and reverse 1, have reduced power to minimize wheel slip. In forward gears 3 through 8, and reverse gears 2 through 4, engine power is automatically increased.

– For All Wheel Drive equipped models with the All Wheel Drive

system turned OFF, the function of the VHP is the same as above.

– For All Wheel Drive equipped models with the All Wheel Drive

turned ON, the engine power is increased for all gears.

– There is no operator selectable control over the VHP system.

Presentation

8 General

Electrical system

The electrical system is a 24VDC, negative-ground system. Power is supplied by two 12VDC batteries connected in series. Battery charging is accomplished using a standard 75 amp alternator and an optional 100 amp alternator. Electrical power can be disconnected using a ground isolation switch.

Clutch

A multiple wet disc clutch is mounted to the engine flywheel and connected to the transmission with a driveshaft. The clutch must be used when starting to move or when changing direction.

Transmission

The transmission has eight forward and four reverse speeds. It is a fully sequential, direct drive, powershift unit utilizing a countershaft design.

Final drive/tandems

Final drives are single reduction in models G710B to G746B and double reduction in the G780B. Each has an operator controlled lock/unlock differential. Rear axles are case hardened, full floating design, supported on double row spherical roller bearings. Tandem wheels are chain-driven.

Brakes

Hydraulically actuated, oil disc service brakes are located at the four tandem drive wheels. The crossover dual braking circuits provide even braking on both sides of the grader.

If the engine stalls, or hydraulic boost pressure becomes unavailable, full braking capability is available through a reserve system. An electric motor supplies the power required to bring the grader to a safe stop.

The parking brake is a spring apply/hydraulic release, disc-type brake. It is driveline-mounted to the transmission output shaft. An accumulator in the circuit stores system pressure allowing the brakes to remain released in the event of system pressure loss for about 15 minutes.

Steering

The steering system is a closed-center dynamic signal load sensing system. The hydraulic steering system incorporates two steering cylinders. The leaning wheel feature and articulated frame can be used to decrease turning radius. There is no manual steering.

Cab and frame

Both the canopy and fully-enclosed cab are equipped according to the ROPS standard. FOPS approved structures are optional. Enclosed cabs are also provided with air conditioning and/or heating systems as options. All controls are housed in the fully adjustable steering pedestal and the right-hand side console. Ergonomic seating and hydraulic control lever placement ensure operator comfort and efficiency. The frame articulates 22° to the left or to the right and uses anti-drift lock valves to ensure stable operation.

Presentation

General 9

MBCS (Moveable Blade Control System)

Blade mobility permits steep ditch cutting angles and back sloping outside of overall machine width. The circle is held in place by adjustable clamp plates and guide shoes. Bearing surfaces are DURAMIDE™-faced to maximize service life. Hardened teeth are cut on the outside of the circle. Oil is directed to the two drive cylinders by a circle timing valve. The cylinders are arranged 90° out of phase to ensure consistent power. The moldboard is provided with replaceable cutting edge and end-bits. The drawbar is a narrow “T” design for optimum visibility to the work area.

Hydraulic system

The closed-center hydraulic system uses a pressure and flow compensated (load-sensing) variable displacement piston pump. The pump supplies oil to the implements, the steering and the engine cooling fan system.

The cooling fan is driven by a fixed displacement vane-type motor. Fan speed is variable and is determined by various cooling requirements. The fan operates between pre-determined minimum and maximum speeds. The fan remains at its minimum speed until there is a demand for cooling. Fan speed will automatically increase with the demand for cooling.

Lock valves (counterbalance valves) are incorporated into the blade lift, moldboard tilt, circle shift, wheel lean and articulation circuits to prevent cylinder drift. The control levers are short throw, feathering type located on an adjustable steering pedestal.

All Wheel Drive

G726B and G746B are All Wheel Drive models. The system operates in gears 1 through 7. It is powered by two electronically controlled, variable displacement hydraulic pumps in a closed loop system. Each pump supplies one front wheel motor.

Front wheel motors are two-speed, high torque, radial piston, cam lobe type. Each wheel motor has a separate speed sensor.

The system has a 16-speed aggression control dial.

Equipment and attachments

The circle, drawbar and moldboard equipment is fully maneuverable using hydraulic cylinders. Optional attachments include:

– Dozer blade

– Rear-mounted ripper-scarifier

– Mid-mounted scarifier

– Front-mounted scarifier

– Windrow eliminator

– Push block (counterweight for ripper)

– One-way plow

–V-plow

– Hydraulic snow wing (high and low bench)

– A-frame (used with V-plow and One-way plow only)

Presentation

10 CE Marking and Declaration of Conformity

CE Marking and Declaration of Conformity

(Only applies to machines marketed within the EU/EEA).

This machine is CE marked. This means that when delivered the machine meets the applicable “Essential Health and Safety Requirements”, which are given in the EU Machinery Safety Directive.

If changes are made that affect the safety of the machine, the person carrying out the changes is responsible for the same.

As proof that the requirements are met, the machine is supplied with an EU Declaration of Conformity, issued by Volvo Motor Graders Limited for each separate machine. This EU Declaration also covers attachments made by Volvo Motor Graders Limited. This documentation is a valuable document, which should be kept safe and retained for at least 10 years. The document should always accompany the machine when it is sold.

If the machine is used for other purposes or with other attachments than described in this manual, safety must at all times and in each separate case be maintained. The person carrying out such action is also responsible for the action that, in some cases, may require a new CE marking and the issue of a new EU Declaration of Conformity.

EU EMC Directive

The electronic equipment of the machine may in some cases cause interference to other electronic equipment, or suffer from external electromagnetic interference, which may constitute safety risks.

The EU EMC directive on “Electromagnetic conformity” provides a general description of what demands can be made on the machine out of a safety point of view, where permitted limits have been determined and given according to international standards.

A machine or device, which meets the requirements, should be CE marked. Our machines have been tested particularly for electromagnetic interference. The CE marking on the machine and the declaration of conformity also covers the EMC directive.

If other electronic equipment is fitted to this machine, the equipment must be CE marked and tested on the machine as regards to electromagnetic interference.

Presentation

CE Marking and Declaration of Conformity 11

Modifications

Modifications of any kind to this product including the fitting of unauthorized attachments, accessories, assemblies or parts could affect the integrity of the product and/or the ability of the product to perform as designed or intended.

It is policy that no modification of any kind is to be made to this product unless officially approved by Volvo Motor Graders. A modification includes, but is not restricted to, the use of attachments, accessories, assemblies and parts not approved by Volvo Motor Graders and/or not installed in a factory approved manner.

Modifications are officially approved if at least one of the following conditions is met:

1 The attachment, accessory, assembly or part is manufactured

or distributed by Volvo and installed in a factory approved manner as described in the publications available from Volvo; or

2 The modification has been approved in writing by the Engineer-

ing Department of Volvo Motor Graders.

Volvo Motor Graders disclaims responsibility for any situation that may arise as a result of a non-approved modification. If any person or organization modifies or contributes in any way to a nonapproved modification, the person or organization will be deemed to have assumed all the risks associated with such a modification, including but not limited to, product failure, product damage, property damage, loss of production, injury or death.

If any claims result from a non-approved modification, Volvo Motor Graders will protect its interest by taking whatever action is appropriate.

Volvo Motor Grader warranty shall not apply to any product or part which fails or is damaged by, or whose functioning or operation is adversely affected by non-approved modification.

Unauthorized modifications of the ROPS (Roll Over Protective Structure)

Never make any unauthorized alterations to the ROPS such as lowering the height of the ceiling, drilling or welding to it.

Such unauthorized modifications will affect the structural limits of the ROPS cab and will void the certification.

The ROPS has been approved after testing and meets the standard according to ISO 3471 1994 and SAE 1040 APR 88.

An optional cab has also been tested and approved according to the FOPS (Falling Object Protective Structure) standard as defined by ISO 3449 1992, SAE J231 JAN 81 and meets the requirements for “Overhead guards for high-lift rider trucks” ISO 6055 1979 and “Operator seat belt requirements” SAE J386 JUN 93.

All planned alterations must be reviewed in advance by our Engineering Department to determine whether the alteration can be made within the limits of the certifying tests.

It is important that all persons in your organization, including management, be made fully aware of these rules involving the ROPS. Whenever anyone sees a machine ROPS with unauthorized alterations, both the customer and manufacturer should be notified in writing.

Presentation

12 Plates and decals

Plates and decals

Product plates

The following illustrations and text show which product plates are installed on the machine. These numbers are recorded at the factory.

Always quote the motor grader Model Number and the Product Identification Number when ordering spare parts, and in all telephone inquiries or correspondence.

1 Engine

The engine serial numbers are found on a plate on the left-hand side of the engine on models G710B to G730B. G740B, G746B and G780B models have the serial number stamped into the righthand side of the engine block.

2 Cab

The ROPS and FOPS serial number plates are found inside the cab on the left-hand post behind the operator’s seat. The ROPS plate states the model and serial number, specification, maximum machine mass, and bolt torque. The FOPS plate states the model, serial number and specification.

3 Product identification plate

This plate is found on the right-hand side of the frame in front of the cab. It has the Model Number and PIN (Product Identification Number) stamped on it. The Model Number is broken down as follows: the first digit designates G700 Models; the next two digits indicate weight and horsepower range.

The Model Number and PIN must be used in conjunction with the Parts Catalog to order correct replacement parts.

4 Product identification plate (EU/EEA countries)

In addition to the above information, this plate shows machine weight, engine power, year of manufacture and has a space for the CE mark. It also is positioned on the right-hand side of the frame in front of the cab.

Presentation

Plates and decals 13

5 Product identification plate for TUV (Germany)

This plate is found on the right-hand side of the frame in front of the cab.

6 Transmission

The transmission serial number is located on the lower front of the housing.

7 Final drive

The final drive serial number is found on the right-hand side on the rear of the final drive on models G710B to G746B. On G780B models it is found on the top of the center housing.

Presentation

14 Plates and decals

Information and warning plates

The following illustrations and text show which safety signs can be found on the machine. The operator of the machine must know and follow warnings and information given on safety signs.

Safety signs that have been damaged, painted over, disappeared, or for any other reason are no longer legible, must be replaced immediately.

The part number of the respective safety sign can be found in the Parts Catalog.

Presentation

Plates and decals 15

Item Description Location

1 Warning! Hot components. Right-hand side, under the door latch of the engine compart-

ment door.

2 Warning! Never Short across starter

terminals.

3 24V Start On the starter, inside the engine compartment, right-hand side.

4 Warning! Hot pressurized coolant. On the top of the engine hood.

5 Warning! Crush zone. Both sides of the cab.

6 Parking brake decal Right-hand side of pedestal.

7 Warning! Wear seat belt when operat-

ing machine.

7 Warning! Read the operator’s manual

first!

8 Warning! Accumulator contents under

pressure.

9 Warning! Use only petroleum base fluid

in brake reservoir.

10 Warning! Crush zone. Both sides below the engine compartment door.

11 Differential lock operating instructions On the front windshield.

12 Anti-freeze coolant tag. On the steering wheel.

On the starter, inside the engine compartment, right-hand side.

Front of the pedestal.

Over the barrel of the accumulator (if equipped).

Rear right-hand side of cab.

13 Warning! Use no ether. On the engine hood beside the air intake.

14 Warning! Explosive gases. Inside the battery box, left-hand tandem case.

15 24V Start Inside the battery box, left-hand tandem case.

16 Safety instructions: Use handholds and

steps.

17 Warning! Keep clear of moldboard. On the left, right and rear faces of the drawbar.

18 Lubrication and service chart Left-hand side under the cab on the frame.

19 Warning! Rotating components. Right-hand side below engine compartment door. Both sides

20 Warning! Rotating fan. Inside of the rear radiator cowling door.

21 Sound decal

(Statement of exterior noise measurement of the machine)

Both sides of the cab.

inside the cooling compartment door.

On the right-hand side of the frame in front of the cab. (TUV, EU/EEA countries only.)

Presentation

16 Service

Service

If the machine is to operate as economically as possible, it must be properly maintained. Intervals of maintenance and lubrication apply to the machine under normal environmental and operating conditions. The maintenance work described in this manual can be carried out by the operator. For further adjustments and repairs, the machine should be taken to an authorized dealer.

Delivery inspection

Before the machine left the factory it was tested and adjusted. In addition to this, your dealer has carried out a further check – the “Delivery Inspection” – according to our instructions before the machine was handed over to you.

Inspection

It is especially important, however, that during the first period of operation, the machine is subjected to further checks. Retightening of bolts, checking adjustments and other minor measures have to be carried out. Carry out this inspection within 100 operating hours.

Maintenance service

Condition Test and Maintenance Programs

In addition to the maintenance listed in the Maintenance Schedule in this manual, your authorized dealer offers a maintenance system based on tests which give an indication of the general condition of your machine. Further information about this maintenance system can be obtained from your nearest authorized dealer.

Presentation

General Information 17

General Information

The USA federal clean air act

The Federal Clean Air Act Section 203 (a) (3) states that the removal of air pollution control devices or the modification of an EPA-certified non road engine to a non certified configuration.

The Federal regulations implementing the Clean Air Act for nonroad engines, 40 C.F.R. section 89.1003(a)(3)(i) reads as follows:

The following acts and the causing thereof are prohibited: For a person to remove or render inoperative a device or ele-

ment of design installed on or in a non road engine vehicle or equipment in compliance with regulations under this part prior to its sale and delivery to the ultimate purchaser or for a person knowingly to remove or render inoperative such a device or element of design after the sale and delivery to the ultimate purchaser.

The law provides a penalty of up to $2,500 for each violation.

An example of a prohibited modification is the recalibration of the fuel system so that the engine will exceed the certified horsepower or torque.

You should not make a change to an EPA-certified non-road engine that would result in an engine that does not match the engine configuration certified to meet the Federal Standards.

Customer assistance

Volvo Construction Equipment wishes to assure that the Emission Control System Warranty is properly administered. In the event that you do no receive the warranty service to which you believe you are entitled under the Emission Control System Warranty, you should contact your nearest Volvo Construction Equipment Regional office for assistance.

Presentation

18 General Information

Normal non-road engine use

The Maintenance Instructions are based on the assumption that this conventional machine will be used as designated in the Operator's Instruction Manual and operated only with the specified fuel and lubrication oils.

Non-road engine maintenance

The non-road engine is of conventional design and any local dealer may perform the necessary non-road engine emission control maintenance defined in this manual.

Volvo recommends that the purchaser use the service program for the non-road engine, known as Preventative Maintenance, including the recommended engine emission control maintenance.

In order to document that the proper regular maintenance has been performed on the non-road engine, Volvo recommends that the owner keep all records and receipts of such maintenance. These records and receipts should be transferred to each subsequent purchaser of the non-road engine.

Service performed by your local dealer

Your local dealer is best qualified to give you good, dependable service since he has trained service technicians and is equipped with genuine original manufacturer's parts and special tools, as well as the latest technical publications. Discuss your servicing and maintenance requirements with your local dealer. He can tailor a maintenance program for your needs.

For regular scheduled service or maintenance, it is advisable to contact your local dealer in advance to arrange for an appointment to ensure availability of the correct equipment and service technician to work on your machine. This will aid your local dealer in efforts to decrease service time on your machine.

Presentation

General Information 19

Preventive maintenance program

To retain the dependability, noise level and exhaust emission control performance originally built into your conventional non-road engine, it is essential that the non-road engine receive periodic service, inspections, adjustments and maintenance.

Fuel system

Fuel Recommendations:

The fuel used must be clean, completely distilled, stable and noncorrosive. Distillation range, cetane level and sulfur content are most important when selecting fuel for optimum combustion and minimum wear.

Engine working conditions and ambient temperature influence the selection of the fuel with respect to cold handling properties and cetane levels.

In cold weather conditions, below 32 ºF (0 ºC), the use of lighter distillate or higher cetane level fuel are recommended. (Final boiling point max. 660 ºF (349 ºC) and cetane min 45.)

To avoid excessive deposit formation and to minimize the emissions of sulfur dioxide into the ambient air, the sulfur content of the fuel should be the lowest available. The diesel fuels recommended for use in Volvo engines should meet ASTM designation: D 975 No. ID (C-B) or No. 2D (T-T); with a cetane level above 42 and sulfur content not exceeding 0.5 percent by weight.

Check for fuel leaks (with the engine running at fast idle):

n Visually check unions and hose connections.

Check the condition of the fuel hoses for:

n Ageing

n Cracks

n Blisters

n Scuffing

Check the condition of the fuel tank:

n Drain water condensation.

n Check for cracks.

n Check for leaks.

n Check the mounting.

Check the turbocharger:

n Visually check for leaks in the intake hoses and exhaust pipe

of the turbocharger.

Presentation

20 Notes

Instrument panels

General 21

Instrument panels

General

WARNING!

Do not operate the machine until you are thoroughly familiar with the position and function of the various instruments and controls. Read this manual carefully. Your safety is involved!

Glance at the instruments now and then. Doing so will alert you to any abnormal readings and allow necessary action to prevent serious damage.

If any warning lamps or buzzers energize, park the machine and shut down the engine immediately. Report the problem to your supervisor.

The battery isolation switch must be in the ON (I) position and the ignition switch in the “I” position (running position) when checking the function of the instruments and warning devices.

1 Center instrument panel (display unit, control lamps, gauges) 2 Pedestal head instrument panel (switches, warning lights, gauges) 3 Side console instrument panel (switches, warning lights/buzzers) 4 All Wheel Drive control panel (switches, warning/information lights, aggression dial)

Instrument panels

22 Center instrument panel

Center instrument panel

1 Information (amber) 12 High beams

2 Central warning (red) 13 Turn signal indicator

14 Differential locked

3 Charging battery 15 Engine preheat

4 High Hydraulic oil temperature 16 Secondary steering

5 Low transmission oil pressure

6 Brake warning 17 Display unit (speedometer optional)

7 Blade control system unlocked 18 Engine oil pressure

8 Parking brake applied 19 Engine coolant temperature

9 Engine air filter restriction 20 Fuel level

10 Filter bypass warning

11 Primary steering system 21 (not used)

22 Hydraulic oil level

23 (not used)

General

If red control lamps light up – stop the machine immediately! If amber lamps light up – an abnormal condition exists and mea-

sures may be required depending on the function concerned. The remaining lamps – indicate that the respective function is

engaged/connected.

Instrument panels

Center instrument panel 23

1 Information (amber)

The amber central warning lamp flashes when system errors occur for less critical warnings. It informs the operator that a function is engaged/disengaged or that a function needs to be kept under observation (for example low fuel). It is accompanied by another warning lamp and/or message display to clarify the warning/error.

2 Central warning (red)

The central warning lamp flashes when critical warnings or errors occur. It is accompanied by a buzzer, another indicator lamp and/ or message on the display unit. It informs the operator that immediate attention is required.

Buzzer

The buzzer sounds at the same time the red central warning lamp illuminates if any of the following faults are indicated:

– Low engine oil pressure

– Low transmission oil pressure

– Low parking/service brake pressure

– Parking brake (if applied in gear)

– Low hydraulic oil level

– Low steering system pressure

– High engine coolant temperature

– High hydraulic oil temperature

3 Battery charge warning (red)

This lamp is energized if the alternator is not charging. A message is shown on the display unit if the electrical system voltage drops below 21 volts or rises above 31 volts.

Instrument panels

24 Center instrument panel

4 Hydraulic oil temperature warning (red)

(optional)

This lamp indicates the hydraulic oil temperature in the reservoir is too high. It is accompanied by the red central warning lamp, buzzer, and display message.

Fluid temperature must be kept within acceptable limits in order to retain its viscosity and other properties necessary for satisfactory operation between oil change intervals. Refer to Service and maintenance, Hydraulic system page 193 for further information.

5 Transmission pressure warning (red)

This lamp indicates low transmission oil pressure. It is accompanied by the red central warning lamp, buzzer, and display message.

6 Service brake warning (red)

This lamp indicates low brake system pressure or one of the brake circuits is not functioning. It is accompanied by the red central warning lamp, buzzer, and display message.

WARNING!

If the brake warning lamp and alarm energize during grader operation, the brake system is faulty and must be repaired by a qualified service technician. Do not drive the grader.

Instrument panels

Center instrument panel 25

7 MBCS status lamp (amber)

The lamp indicates the MBCS (Moveable Blade Control System) lock is disengaged.

107.

8 Parking brake applied (red)

This lamp indicates the parking brake is applied. If the brake is applied when the transmission is in gear, the lamp is accompanied by the red central warning lamp, buzzer, and display message.

9 Engine air filter restriction (amber)

This lamp indicates restricted air flow through the engine air filter and is accompanied by the amber central warning lamp. If this lamp lights up, service or clean the engine air filter. Refer to Service and maintenance, Engine air filter elements page 170.

Refer to Moveable Blade Control System page

WARNING!

Operate the system only long enough to make a steering correction – maximum two minutes.

10 Filter bypass warning (amber)

(optional)

This lamp indicates either the transmission or hydraulic filter is clogged. It is accompanied by a message in the display panel identifying which filter is bypassing and the amber central warning lamp.

11 Primary steering system (red)

(Secondary steering option only)

This lamp indicates low steering system hydraulic pressure. It is accompanied by the red central warning, buzzer, and display message.

The Secondary steering option is an auxiliary hydraulic system that allows the operator to make steering corrections more easily in the event of loss of hydraulic flow to the steering unit. The ignition key must be in the “I” (running) position for this system to function. The system will also turn on when the test switch is activated, see below.

Secondary steering system check

Refer to Secondary steering system test switch page 42.

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26 Center instrument panel

12 High beam (blue)

The blue control lamp is on when the high beam lights are on. Refer to the Directional indicator/High beam/Horn button page 43.

13 Directional indicators (green)

This lamp flashes when the directional indicator lever is moved for turning left or right and when the 4-way hazard flasher switch is activated.

14 Differential lock status (amber)

This lamp energizes when the differential lock is in the LOCK position.

15 Engine preheat (amber)

This lamp indicates the engine preheating element is on. Refer to Side console instrument panel, Engine preheat switch page 49.

After 10 to 50 seconds (the time depends on the coolant temperature) the preheating element will be disconnected and the lamp extinguished.

For cold starting instructions, refer to Starting the engine page 85.

16 Secondary steering system status (amber)

(Secondary steering option only)

This lamp will energize simultaneously with the Primary steering system lamp. It indicates the secondary steering system has been activated.

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Center instrument panel 27

17 Display unit

For display information, refer to the Pedestal head instruments, Keypad, display unit page 30.

18 Engine oil pressure gauge

The pointer displays the current engine oil pressure. If the pointer enters the red sector, the lamp beside the gauge will illuminate along with the red central warning, buzzer, and display message.

19 Engine coolant temperature gauge

The pointer displays the current engine coolant temperature. If the pointer enters the red sector, the lamp beside the gauge will illuminate along with the red central warning, buzzer, and display message.

20 Fuel gauge

The gauge shows the current level in the fuel tank. Check your fuel supply when the grader is on level ground. If the pointer moves into the red area, the warning lamp will illuminate indicating the machine should be refuelled. In this situation, there is approximately 17% of fuel capacity left. Refuel the machine to avoid air entering the system.

If the tank has been run empty, see Bleeding the fuel system page 168

under Service and maintenance.

Fill the tank at the end of each shift. This reduces the chance of condensation forming in the fuel tank.

For the capacity of the fuel tank, see Specifications, Capacities page 219.

21 (not used)

22 Hydraulic oil level (red)

(optional)

This lamp illuminates when the hydraulic oil level is too low in the reservoir. It is accompanied by the red central warning lamp, buzzer, and display message.

23 (not used)

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28 Pedestal instrument panel

Pedestal instrument panel

1 Transmission gear display 7 Secondary steering system test

2 Articulation indicator gauge 8 Directional indicator/ High beam/Horn

3 Keypad, display unit 9 Float valves power switch

4 Four-way hazard flasher 10 Float valves system indicator lights

5 Differential lock switch 11 Parking brake switch

6 MBCS lock pin

Code Meaning

.8.8 LCD (Liquid Crystal Display) test

7.8 ECU (Electronic Control Unit) identification

8.4 ECU identification (All Wheel Drive)

1 Last gear memorized* (example)

1 Transmission gear display

The transmission gear display is located in the top left-hand side of the pedestal. It displays the transmission gear selected.

With the shift lever in the FORWARD position, the display shows the number of the forward gear, for example ‘3’.

With the shift lever in the REVERSE position, the display shows a negative number, for example ‘-2’.

Refer to Shifting gears page 87.

The gear display can also provide other information:

n It indicates a Start code sequence on start-up.

n It shows an error code if there is a fault in the transmission or

All Wheel Drive electrical system.

-1 Opposite gear* (example)

* Alternating display while in neutral

Start code sequence

When you start the engine, the transmission gear display will show a series of codes called the Start code sequence.

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Pedestal instrument panel 29

Error codes

The transmission ECU (electronic control unit) continuously monitors the transmission and the AWD (All Wheel Drive) electrical system. In the event of a malfunction in either of these systems, an error code is shown in the gear display. Record any error

codes and have the electrical system repaired by a qualified service technician. For further information on Error Codes, see the Service manual.

Transmission error codes

If a malfunction occurs in the transmission electrical system, the gear display shows the letter ‘E’ followed by a two-digit numeric code. Multiple error codes are possible. The ECU disables the transmission shifter and places the transmission in NEUTRAL. The display alternates between ‘E’ and the code until the operator returns the shift lever to the NEUTRAL position.

n “1.0” series error codes indicate insufficient power available

for transmission solenoids. The transmission will not operate until this problem has been resolved.

n “2.0” or “3.0” series error codes indicate either an open or

short circuit in a transmission solenoid. An alternate gear can be selected by returning the transmission to NEUTRAL. This will allow the grader to be moved.

n “2.8” or “3.8” series error codes indicate either an open or

short circuit in the parking brake solenoid. The grader will not operate until this problem has been resolved.

n “4.2” error code indicates the fault may be corrected by plac-

ing the shifter in NEUTRAL then back into gear.

n “4.4” error code indicates a multiple shift command error.

More than one proximity switch has been energized simultaneously. The circuit board must be replaced to correct this

problem.

n “4.6” error code indicates there is a problem with the shift le-

ver. The shift lever is out of neutral with no signal to the forward or reverse solenoids.

n “P” series error codes indicate a malfunction in the parking

brake electrical system.

AWD (All Wheel Drive) error codes

The transmission ECU continuously monitors the AWD electrical system. It is able to detect abnormal conditions and alert the operator of a problem by displaying a code that will aid in correcting the problem.

If a malfunction occurs:

1 The transmission gear display shows the letter “E” followed by

a 2-digit alphanumeric code. Multiple error codes are possible.

2 The display alternates between “E” and the error code until the

malfunction is corrected. The transmission is not disabled.

Record the error codes and have the AWD electrical system repaired by a qualified service technician. Some error codes will disable the AWD system.

NOTE! “L1”, “L2” and “L4” Series error codes indicate a serious problem with hydraulic oil temperature, level or pressure. Shut the grader down immediately and correct the problem.

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30 Pedestal instrument panel

2 Articulation indicator gauge

The indicator needle displays the degree the grader frame is articulated. The frame is straight with the needle in the center position.

3 Keypad, display unit

The keypad allows access to information in different areas of the grader. The information is organized into systems (function groups).

Engine

Engine speed, Coolant temperature, Oil pressure, Air inlet temperature, Boost temperature, Boost pressure, Fuel temperature, Fuel pressure (G740B, G746B and G780B only), Coolant level.

1Engine 7 Arrow down

2Transmission 8Setup

3Hydraulics 9Select

4 Hourmeter 10 Auxiliary 2

5 Electrical system 11 Auxiliary 1

6 Arrow up 12 Esc

Transmission

Transmission oil pressure, Filter bypass (optional), VHP status

Hydraulics

Brake pressure, Hydraulic filter bypass (optional), Hydraulic oil temperature (optional), Hydraulic oil level (optional).

Electrical system

System voltage

AUX1 (Grader information)

Model, Tire size, Distance (only with speedometer option), Instantaneous fuel consumption, Average fuel consumption, Total fuel consumption, Time to next service, Next service interval.

AUX2 (Trip measurement information)

Fuel used, Time, Fuel/hour, Distance, Average speed, Fuel/distance, Reset (changes fuel, time and distance values to zero).

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Pedestal instrument panel 31

The following functions can be controlled from the keypad:

– Selecting function group by direct selection (function key)

– Browsing within a function group (the arrow keys)

– Activating/deactivating functions (on/off)

– Setting to zero/acknowledge (time/distance/cycles)

– Numerical settings (the arrow keys)

– Alpha-numerical settings (the arrow keys)

– Simpler settings (e.g. increase/reduce)

Engine, Transmission, Hydraulics, Hourmeter, Electrical, Auxiliary 1 and Auxiliary 2 keys, display information about the

respective function group.

SETUP key displays the menu for making changes to units and language. Refer to Setup, language and units page 34.

Arrow Up and Arrow Down keys are used to scroll in a function group menu. Select key is used to change and confirm settings.

ESC key returns the display to “Operating display”, regardless of which menu is showing.

When in the SETUP mode, pressing ESC will bring you back to the top of the selected menu.

Refer to Setup, language and units page 34.

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32 Pedestal instrument panel

Display unit

Starting sequence (initial display)

(Ignition key in the “I” position)

The starting sequence takes about 4 to 5 seconds. At this time, a test program runs to verify the system.

The progress of this test is indicated on the display unit by the appearance of black squares from 1 to 7.

During the first part of the test, the control lamps will light up and the gauges will indicate (at twelve o’clock).

Displayed information

The display unit provides information to the operator. This information is divided into three groups:

1 Operating information, etc.

2 Warning displays (low pressure etc.)

Operating information display

3 ERROR displays (sensor and control device check)

1 Engine speed 2 Machine hours 3 Travel speed (optional) 4 Units for travel speed

Operating information display

n This is the default display.

n Obtain different information – engine, transmission, hydrau-

lics, hourmeter, electrical, auxiliary 1 and auxiliary 2 – by selecting buttons on the keypad.

Warning display

n Alerts the operator to a malfunction in machine systems (en-

gine, hydraulics, transmission, etc.).

n Applies to various areas of the grader.

Error display

n Alerts the operator to malfunction in the monitoring system.

n Applies to various areas of the grader.

Operating information (default display)

– Operating Information will be displayed after starting (unless

the operator had another display screen showing when the power was switched off).

– At a speed above 20 km/h (12.4 mph) the Operating Informa-

tion will show the current travel speed (even if another display screen was selected).

– If a display screen other than the Operating Information was

selected, the system will revert to that display screen when the travel speed drops below 20 km/h (12.4 mph).

– Changing the display screen using the keyboard is only pos-

sible if the travel speed is below 20 km/h (12.4 mph).

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Pedestal instrument panel 33

Changing display screen

Move from one function group to another using the keys on the keypad. When changing function group, the first menu of that group will be displayed. To return to the Operating Information display, press the ESC key.

Setup Settings of language and units are done in Setup, language

and units page 34.

Display classes

The information shown on the display for the operator is organized into the following classes:

Class 1: WARNING

Shown regardless of which display is selected. “WARNING” display is shown for 2 seconds, then the previous display for 3 seconds. This is repeated for as long as the malfunction remains.

Generally, the red central warning lamp flashes while the alarm text is shown.

Class 2: INFORMATION

Shown regardless of which display is selected. “INFO” display is shown for 2 seconds, then the previous display for 3 seconds. This is repeated until the info display has been shown 3 times.

Generally, the amber central warning lamp flashes while the info display is shown.

The next time the machine is started, the info display is repeated if it is still active.

Class 3: ERROR

Shown regardless of which display is selected. “ERROR” display is shown for 2 seconds, then the previous display for 3 seconds. This is repeated as long as the malfunction remains.

Generally, the amber central warning lamp flashes while the error display is shown.

Class 4: SERVICE INFO

Shown regardless of which display is selected. “SERVICE INFO” display is shown for 2 seconds, then the previous display for 3 seconds. This is repeated until acknowledged by “reset”.

Generally, the amber central warning lamp flashes while the service info display is shown.

Multi-info/warning/error display:

If several info/warning/error displays are active simultaneously, they are shown one after the other.

Machines with the optional speedometer

At vehicle speeds greater than 20 km/h (12.4 mph), the info/warning/error display is shown first, then “Operating info” is shown, then the next info/warning/error display, etc. At speeds less than 20 km/h (12.4 mph), the display information follows the sequence described in its class, with the “previous” display shown between the alternating multiple displays.

For machines not equipped with a speedometer, the information displayed follows the sequence described in its class above, with the “previous” display shown between the alternating multiple displays.

Instrument panels

34 Pedestal instrument panel

Setup, language and units

Language

– Depress the SETUP key, then depress the SELECT key to

– Select the required language with up or down arrow keys. – After the language has been chosen, press SELECT. If no

Units

– By pressing the SELECT key, the display will change from the

– Choose the required units with the arrow keys and press SE-

– Press ESC to return to the main menu.

To cancel a setting, press ESC. The SETUP menu will appear. Press ESC again to return to the main menu.

show the language menu. Available languages are English, French, Spanish, Swedish, and German.

change of the setting is required, just press SELECT.

language menu to the menu for “Units”.

LECT. If no change of the setting is required, just press

SELECT.

Information display screens

Function groups

Each function group consists of one or more display screens. If there is more than one screen for each function group, an arrow pointing downward will be displayed in the bottom, right-hand corner of the display. Arrows pointing upward and downward indicate there are screens above and below the current one.

To browse within a function group, press the down or up arrow

keys. NOTE! If “Er” is shown for a value in any display screen, it in-

dicates an error in the signal monitoring that information.

x = Engine speed (revolutions per minute).

y = Engine coolant temperature, units are °C or °F. Shown down

to 0 °C, below that shown as < 0 °C or < 0 °F.

z = Engine oil pressure, units are in bar or psi.

x = Intake air temperature, units are °C or °F. Indicates actual

temperature down to 0 °C, below that shown as < 0 °C or < 0 °F.

y = Charge air temperature, units are °C or °F. Indicates actual

temperature down to 0 °C, below that shown as < 0 °C or < 0 °F.

z = Charge air pressure, units are in bar or psi.

x = Fuel temperature, units are °C or °F. Indicates actual tem-

perature down to 0 °C, below that shown as < 0 °C or < 0 °F.

y = Fuel pressure, units are bar and psi.

z = Coolant level (normal or low).

Instrument panels

Pedestal instrument panel 35

x = Transmission oil pressure (indicates normal or low). y = Transmission oil filter (indicates normal, clogged).

z = VHP status (indicates ON or OFF).

x = Brake system pressure (indicates normal or low).

y = Hydraulic oil filter (indicates normal or clogged).

z = Hydraulic oil temperature (indicates normal or high).

x = Time in hours, up to 99999.9.

x = Electrical system voltage (real time) in volts DC.

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36 Pedestal instrument panel

x = Machine model

y = Tire size designation

y = Distance travelled, units in km or mi. Shown up to

NOTE! Values for distance are only shown if the speedometer option is installed on the machine.

x = Current fuel consumption, shown in L/h or g/h (liters per

y = Average fuel consumption per hour, shown in L/h or g/h (li-

z = Total fuel consumption, calculated up to 9999999 liters or

999,999 km or 621,372 miles.

hour or US gallons per hour).

ters per hour or US gallons per hour). Calculated by dividing total fuel consumed by engine hours.

2641720 US gal, in one unit increments.

x = Time remaining to next service interval.

y = Service interval, shown as 250, 500, 1000, 2000. When 8

hours remain to next service, display shows “Time for service”.

To acknowledge and remove information, press SELECT.

The bars indicate the total time left until the next service interval.

Each one represents 25 hours.

When 8 hours remain to next service, the display shows “Time to

change engine oil”.

To acknowledge and remove information, press SELECT.

x = Fuel consumption since resetting, in liters or US gal up to

999,999 liters or 264,200 US gal.

y = Time since resetting in hours up to 9999.9

z = Fuel consumption per hour since resetting, up to 99.9 L/h or

26.4 US gal/hr.

NOTE! To reset, see Trip information reset to follow.

x = Total distance since resetting in km (or mi) up to 9999.9 km

(6213.6 mi), alternatively –

y = Average speed since resetting up to 99.9 kmh (62.1 mph)

shown in kmh (kilometre/hour) or mph (miles/hour), alternatively –

z = Fuel consumption per unit distance since resetting, up to

99.9 in L/km or US mi/gal, alternatively –

NOTE! Values based on distance only available with speedometer option. If speedometer not available, value displays as “n/a”.

Instrument panels

Pedestal instrument panel 37

Trip information reset:

– Press AUX 2, display shows “TRIP INFORMATION 1”.

– Press the down arrow, display shows “TRIP

INFORMATION 2”.

– Press the down arrow, display shows “TRIP RESET”.

– Press SELECT to reset. The display shows “TRIP RESET –

RESETTING”.

– Trip data is now set to zero.

Warning displays

The following alarm texts may appear on the display unit.

ENGINE, warning and information displays

XXXX = PPID, PID, or SID YYY = Numeric value 1 - 999

TRANSMISSION, warning and information displays

Instrument panels

38 Pedestal instrument panel

HYDRAULICS, warning and information displays

ELECTRICAL SYSTEM, warning and information displays

WARNING DISPLAYS, other

Instrument panels

Pedestal instrument panel 39

ERROR DISPLAYS, sensor and actuator switches, engine

XXXX = PPID, PID, or SID YYY = Numeric value 1 - 999

Instrument panels

40 Pedestal instrument panel

ERROR DISPLAYS, sensor and actuator switches, transmission

ERROR DISPLAYS, sensor and actuator switches, hydraulics

ERROR DISPLAYS, sensor and actuator switches, other

Instrument panels

Pedestal instrument panel 41

4 4-way hazard flasher switch

Depress the top of the rocker switch to turn on the 4-way flashers. Depress the bottom of the switch to turn them off.

The directional indicator lamp in the center display will flash when the 4-way flashers are activated. The red indicator lamp on the switch will flash when the flashers are activated.

5 Differential lock/unlock switch

The top of the rocker switch is depressed to activate the differential lock; the bottom of the switch is depressed to deactivate.

The differential lock status lamp in the center display panel and the lamp on the switch energize when the differential lock is in the LOCK position.

Put the control switch in the LOCK position for normal grading operations when maximum traction is required. Put the control switch in the UNLOCK position when differential action is required. This will reduce the turning radius and decrease tire scuffing when operating on paved surfaces.

WARNING!

Lock or unlock the differential ONLY when driving at slow speeds, in a straight line or if the grader is stopped. Do not lock or unlock the differential while making a turn or when the tandem wheels on one side are spinning. Damage to the differential could result.

Instrument panels

42 Pedestal instrument panel

6 MBCS (Moveable Blade Control System)

lock pin switch

The switch has a secondary release to activate it and prevent involuntary release of the MBCS lock pin. Push up on the secondary release and the top of the rocker switch to retract the pin. The MBCS status lamp in the center display energizes to indicate that the lock pin is retracted.

Push the bottom of the switch to engage the MBCS lock pin.

Directional indicator

Move the turn signal switch lever UP to activate the right-hand turn signal. Move the turn signal switch lever DOWN to activate the left-hand turn signal.

High beam

Pull the lever back towards the operator to change the headlights from low beam to high beam and back. A blue lamp illuminates in the display panel to indicate high beam.

Horn button

Push in on the end of the lever to sound the horn.

Instrument panels

44 Pedestal instrument panel

9 Float valves power switch

The float valve switch arms the float system for the moldboard and attachments. This is a momentary style switch.

Push the power switch up to activate the system; push down to deactivate. Lights mounted on the front of the pedestal indicate that the system is activated. See below.

WARNING!

Do not use float control to lower moldboard. Loss of control of grader could result.

10 Front float valves system indicator lights

(control lamp amber)

These indicator lamps are mounted on the front right-hand side of the pedestal. They illuminate when the Front float valve system is active. If the option is not installed on the grader, the lamp will not illuminate.

NOTE! If the valve is already in the float position (4th position detent), and the floats have not been activated, move the lever out of the float position in order to activate the system.

11 Parking brake switch

Push in the knob to apply the parking brake; pull out to release it. The switch must be pushed in (parking brake applied) to start the grader.

Instrument panels

Side console instrument panel 45

Side console instrument panel

1 Heater/air conditioner fan speed switch 12 Ignition switch

2 Air conditioner switch 13 Engine preheat switch

3 Heater/air conditioner temperature control 14 Amber revolving beacon switch

4 Front defroster fan switch 15 Blue revolving beacon switch

5 Rear defroster fan switch 16 Wing lights switch

6 Heated mirrors switch 17 Tire pump switch

7 Headlights and parking light switch 18 Moldboard lights switch

8 Extra headlights or EEC headlights and parking lights switch 19 Rear flood lights switch

9 Lower windows wiper/washer 20 Fuse and relay center access panel

10 Front windshield wiper/washer 21 Socket for service display unit

11 Rear windshield wiper/washer 22 Instrument lighting level

23 24V Remote electrical receptacle (not

shown)

Instrument panels

46 Side console instrument panel

1 Heater air conditioner fan speed switch

(optional)

Turn the knob to increase or decrease the heater air/conditioner fan speed.

0 = System off

1 = Low fan speed

2 = Medium fan speed

3 = High fan speed

2 Air conditioner switch

(optional)

The air conditioning system is turned on and off using the rocker switch. Depress the top of the switch to turn the system on. Depress the bottom of the switch to turn it off. An indicator lamp in the switch illuminates when the switch is activated.

3 Heater/air conditioner temperature control

(optional)

Turn the knob clockwise to raise the air temperature (warmer). Turn it counterclockwise to lower the air temperature (cooler).

Instrument panels

Side console instrument panel 47

4 Front defroster fan switch

(optional)

This is a three position switch. Depress the top of the switch to position two to activate low speed. Depress the top of the switch again to position three to activate high fan speed. Depress the bottom of the switch to turn it off.

5 Rear defroster fan switch

(optional)

6 Heated mirrors switch (optional)

Depress the top of the switch to activate the heated external cab mirrors. An indicator lamp in the switch illuminates to show the switch has been activated. Depress the bottom of the switch to turn them off.

7 Headlights, EEC headlights and parking

lights switch

This is a three position rocker switch. Depress the top of the switch to position two to turn on the parking lights only. Depress the top of the switch to position three to turn on the front headlights along with the parking lights. If the high beam lights are on, the blue control lamp in the center display panel will be on.

8 Extra headlights switch

(optional)

This switch is used for extra headlights. Depress the top of the rocker switch to turn on these lights. Depress the bottom of the switch to turn them off.

Instrument panels

48 Side console instrument panel

9 Lower windows wiper/washer

(optional)

The wiper switch has three positions. Move it clockwise one indexed position for normal speed. Move it two indexed positions for fast speed. The windshield washer activates when the switch is pushed (spring return). See also Windshield washer fluid reser- voir, front and rear windows page 200

10 Front windshield wiper/washer

(optional)

11 Rear windshield wiper/washer

(optional)

Instrument panels

Side console instrument panel 49

12 Ignition switch

The Ignition switch has four positions.

O Turned off R Radio position I Running position and preheating position II (not used) III Starting position

14 and 15 Amber and blue revolving beacon light

switches

(optional)

Depress the top end of the rocker switch to turn on the revolving beacon. Depress the bottom end of the rocker switch to turn it off. An indicator lamp on the switch illuminates when the switch is activated.

16 Wing lights switch (optional)

Depress the top end of the rocker switch to turn on the wing lights. Depress the bottom of the switch to turn them off. An indicator lamp on the switch illuminates when the switch is activated.

17 Tire pump switch (optional)

Depress the top end of the rocker switch to activate the tire pump. Depress the bottom of the switch to turn it off. An indicator lamp on the switch illuminates when the switch is activated.

Instrument panels

50 Side console instrument panel

18 Moldboard lights switch

(optional)

Depressing the top of the rocker switch turns on the moldboard work lights. Depress the bottom of the switch to turn them off. An indicator lamp on the switch illuminates when the switch is activated.

19 Rear flood lights switch

(optional)

Depressing the top of the rocker switch turns on the floodlights on the rear of the machine. Depress the bottom of the switch to turn them off. An indicator lamp on the switch illuminates when the switch is activated.

Instrument panels

Side console instrument panel 51

20 Fuse and relay center access panel

The fuse panel is installed inside the console cover and contains circuit breakers, fuses, relays, and the directional indicator flasher unit. See Basic Preventive maintenance, Electrical system, Circuit breakers and fuses page 183, for additional information.

If an electrical overload occurs:

n The button of the applicable circuit breaker extends to the

open position.

n The element of the applicable automotive blade-type fuse

melts.

To reconnect the electrical circuit:

n Press the circuit breaker button into the closed position.

n Find and discard the fuse with the broken element. Install a

new fuse having the same amperage rating.

NOTE! If the problem persists, have it repaired by a qualified service technician.

21 Socket for service display unit

The service socket is positioned on the side console beside the fuse access panel.

Contact an authorized dealer workshop.

22 Instrument lighting level

This control is used for regulating the intensity of the instrument lighting (gauges and control lamps).

Turning the control to the right increases the light intensity.

NOTE! Switch 7 (Headlight switch) must be on.

23 24V Remote electrical receptacle

(Not shown in main overview illustration)

A remote 24 volt electrical receptacle is located on the front panel of the right-hand side console.

Instrument panels

52 All Wheel Drive control panel

All Wheel Drive control panel

General

The All Wheel Drive control panel is mounted on the right-hand side of the cab in the door post. It contains all the controls and warning lamps needed to operate the All Wheel Drive system.

The All wheel Drive System is activated by a rocker switch on the front of the control panel (7).

Green lamps indicate system (1) and Creep mode activation (4). The control panel has additional lamps that warn of excessive oil temperature (5), low charge pressure (6), low oil level (2) and clogged filter (3). These lamps alert you that a problem exists. Low oil level and low charge pressure lamps are accompanied by an audible alarm.

At the bottom of the control panel is the All Wheel Drive 16-position aggression dial (9). This dial allows the operator to adjust the power applied to the front wheels in comparison to the rear. For further information on the operation of the All Wheel Drive system, refer to Operating instructions, All Wheel Drive models page 91.

1 System activation lamp (green)

2 Low oil level lamp (red)

3 Oil filter clogged lamp (amber)

4 Creep mode activation lamp (green)

5 High oil temperature lamp (red)

6 Low oil pressure lamp (red)

7 System activation switch

8 Creep mode activation switch

9 All Wheel Drive aggression dial

Warning lamps

These warning lamps indicate a malfunction with the system. If any of these lamps energize during normal operation of the All Wheel Drive system and remain on, perform the following:

n Turn the system off.

n Stop the grader and report the malfunction.

n Investigate the cause.

n Have the system repaired by qualified service personnel.

n Do not attempt to use the All Wheel Drive system until the fault

is repaired.

1 System activation lamp

This lamp indicates the All Wheel Drive system is activated.

2 Low oil level lamp

This warning lamp will energize, the buzzer will sound and the system automatically shuts down when the oil level in the hydraulic oil reservoir is too low.

3 Oil filter clogged lamp

This warning lamp will energize when the filter becomes clogged. It may also energize during a cold start but will correct itself when the oil temperature increases.

Instrument panels

All Wheel Drive control panel 53

4 Creep mode activation lamp

Indicates the Creep Mode has been activated.

5 High oil temperature

If the oil temperature increases above an acceptable level, the high temperature warning lamp energizes and the system automatically shuts down.

6 Low oil pressure

If the All Wheel Drive hydraulic system charge pressure drops below a safe value, the charge pressure warning lamp energizes, the buzzer sounds and the system automatically shuts down.

7 System activation switch

All Wheel Drive is available in gears 1 to 7. Push the top of the rocker switch to engage the All Wheel Drive system. To deactivate it, depress the bottom of the switch. For more information on the use and function of the All Wheel Drive system, structions, All Wheel Drive models page 91.

see Operating in-

8 Creep mode activation switch

Creep Mode is used for low speed, fine grading using the front wheel drive only. It will operate at speeds from 0 to 3,2 km/h (0 to 2 mph) in forward and reverse. Creep mode is activated by depressing the top of the spring return rocker switch. It is deactivated by pressing the top of the switch again. For more information on the use and function of the All Wheel Drive system, see Operating instructions, All Wheel Drive models page 91.

9 All Wheel Drive aggression dial

Different tractive conditions can be encountered by the front and the rear of the machine. This will only occur when grading under diverse conditions with the All Wheel Drive system engaged. The 16-position manual dial control is used to fine tune speed differences that may occur between the front and the rear wheels.

n A lower setting slows the front wheel rotational speed com-

pared to the rear; a higher setting increases the front wheel rotational speed in comparison to the rear.

Instrument panels

54 Other

Other

21 Dome light switch

The dome light switch is located on the right-hand door post. Depress the top of the rocker switch to turn on the interior dome light. Depress the bottom of the switch to turn it off.

22 Cigar lighter

The electric power to the glow coil is connected when the cigar lighter is pushed in. When the right temperature is reached, the lighter will be pushed out automatically.

The cigar lighter may also be used as a 12 V DC (15 A) power socket.

23 Hourmeter

(not shown in main overview illustration)

The Hourmeter is located next to the heater vent on the right-hand side of the cab. It displays the hours of engine operation.

Operator controls 55

Controls

Operator controls

Controls

1 Clutch pedal 7 Operator seat and seat belt

2 Brake pedal 8 Pedestal tilt pedal

3 Accelerator/decelerator pedal 9 Steering wheel tilt lever

4 Hand throttle lever 10 Climate control system

5 Transmission shift lever 11 Hydraulic controls

6 Steering wheel 12 Auxiliary hydraulic controls (optional)

Controls

56 Operator controls

1 Clutch pedal

Use the clutch pedal when you are starting from a complete stop or changing directions. Do not start to move the grader in any forward gear higher than 4th or any reverse gear higher than -2nd. Refer to Shifting gears page 87.

2 Brake pedal

3 Accelerator/decelerator pedal

n Depress the pedal toe to increase rpm. n Release the pedal to decrease engine rpm. n Use the pedal to override the hand throttle setting. n Depress the pedal heel to decrease engine rpm when the hand

throttle is set.

n When you remove your foot from the pedal, the engine speed

will return to the preset hand throttle position. Refer to Hand throttle.

NOTE! If the engine is started with the hand throttle above low idle position, the accelerator will not function. Move the hand throttle lever to low idle position to obtain accelerator response.

4 Hand throttle

The hand throttle provides a fixed engine speed control during grading.

NOTE! Do not use the hand throttle when roading the grader.

The hand throttle is self-locking in any position. Moving the throttle handle releases the locking mechanism and allows free movement of the lever. When starting the engine, the hand throttle lever must be in the low idle position (pulled back towards you) to achieve accelerator function.

5 Transmission shift lever

The transmission shift lever is mounted in the console on the operator’s right-hand side. The shift lever is equipped with a neutral lock button. The shift lever may only be moved to the FORWARD or REVERSE position if the neutral lock button on the shift lever knob is depressed. NEUTRAL may be selected without depressing the neutral lock button. The alarm will sound if the transmission FORWARD or REVERSE mode is selected when the parking brake is applied. A digital display is incorporated into the pedestal to show you which gear the transmission is in. See Transmission gear display page 28.

Refer to Shifting gears page 87.

6 Steering wheel

The steering wheel is used to steer the grader. Refer to Operating instructions, Steering page 93.

Controls

Operator comfort 57

Operator comfort

7 Operator seat and seat belt

Adjust the seat before starting the grader. Ensure the parking brake is applied.

Weight adjustment

Adjust the seat for the operator’s weight by turning the weight adjuster knob with the seat empty. The indicator shows the set weight.

To prevent injury, you must check and adjust the operator’s weight setting before driving the machine.

Height adjustment

You can adjust the seat height at several settings. Raise the seat to the required height until it audibly latches into place. When the seat is raised above the highest setting (endstop), it drops back down to the lowest position.

Fore/aft adjustment

You can adjust the fore/aft setting by lifting the locking bar or lever (depending on your model).

The locking bar or lever must latch securely into the desired position. It should not be possible to move the seat into another position when it is locked.

Controls

58 Operator comfort

Seat pan angle adjustment

You can adjust the seat pan angle by lifting the handle on the front left-hand side of the seat (refer to the illustration).

Exert pressure on or off the seat pan to move it to the desired angle position.

Seat cushion depth adjustment

You can adjust the depth of the seat cushion by lifting the handle on the front right-hand side of the seat (refer to the illustration).

Move the seat cushion backwards or forwards until you reach the desired seating position.

Armrest adjustment

You can change the inclination of the armrests by turning the adjustment knob (arrow).

Controls

Operator comfort 59

Armrests

You can fold and adjust the height of the armrests individually if required. To adjust the armrest height, remove the round plastic cap to expose a hexagon nut (see arrow). Loosen the nut (size 13 mm). Adjust the armrest to the desired position, retighten the nut and install the round plastic cap.

Lumbar support

You can adjust both the height and curvature of the backrest cushion individually by turning the adjustment knob (arrow) to the left or right. This helps to increase seating comfort and operator efficiency.

Dirt can impair the function of the seat. Make sure you keep your seat clean!

Upholstery can be quickly and simply removed from the seat frame for easy cleaning or replacement. Take care when removing upholstery from the backrest frame. The frame may jerk forward and cause injury! When cleaning the upholstery, make sure the material is not soaked through. Use a standard commercially available upholstery or plastics cleaning agent. Test first for

compatibility on a small, concealed area.

Controls

60 Operator comfort

Seat belt

Adjust the seat and fasten the seat belt. The seat belt must fit snug and low around your hips. The holding strap must be free of slack.

n Hold the clasp end of the seat belt with your left hand.

n Pull the right side of the belt out from the seat with your right

hand until there is enough slack to reach across your lap to the clasp.

n Insert the belt into the clasp. Check that it is secure.

n Allow the belt to retract when fastened to fit snug and low

around your hips. The seat belt must be free of slack.

WARNING!

Wear seat belt when operating machine.

8 Pedestal tilt pedal

To move the pedestal forwards or backwards:

n Grasp the steering wheel.

n Push down on the pedal located at the bottom of the pedestal

column.

n Move the pedestal to the desired position and release the

pedal.

Controls

Operator comfort 61

9 Steering wheel tilt lever

Pull up on this lever to tilt the steering wheel and pedestal head. Releasing the lever locks the steering wheel in one of the four positions.

To tilt the steering wheel and control head assembly:

n Grasp the steering wheel and lift the lever located on the up-

per right-hand side of the pedestal column.

n Move the steering wheel and control head to one of the four

positions.

n Release the lever and ensure it latches securely.

1 Fan speed switch 2 Air conditioner on/off switch 3 Temperature control switch 4 Front defroster fan switch 5 Rear defroster fan switch

10 Climate control system

Heating, ventilation and air conditioning controls

The controls for the heating, ventilation and air conditioning systems are located on the side console. Filtered, fresh air is supplied to the cab through upper, mid and lower level vents.

Cab air temperature is controlled using the fan and temperature controls. Refer to Side console instrument panel page 45. Turn the switch knobs to increase or decrease the temperature and regulate the fan speed. The air conditioning system is switched on and off using the rocker switch (2). The defroster fans (4 and 5) are used to remove condensation and defrost the front and rear windshields.

General information

n Keep doors and windows closed to provide efficient heating

and air conditioning in an enclosed cab.

n Direct air flow away from unprotected skin.

n Adjust the fan speed until the air flow in the cab feels comfo-

ratable.

n For service information on the fresh air filter(s) and recircula-

tion vent/screen, refer to Climate control system page 197.

Provide good ventilation Do not operate the machine with the doors and windows closed for extended periods of time without the ventilation fan running. Lack of fresh air can cause drowsiness.

Controls

62 Operator comfort

Cab air distribution

Upper level vents

These vents are mounted in the upper door posts. The high profile cab has three louvers, one facing forward and two facing center/ rearward. The low profile cab has two louvers, one facing forward and one facing center/rearward. All louvers close in the downward position.

1 Upper vent louvers 2 Rear defroster fan

1 Mid level vents 2 Floor level vents 3 Recirculation vent and screen

Mid level vents

These vents are mounted on the seat floor. Both of these vents face rearward and close towards the outside of the cab.

If the left-hand side console option is installed, the left-hand louver is mounted on the inner facing console wall. The louver closes in the upward position.

Floor level vents

These vents are mounted in the seat riser panel, one per side. The two louvers for the floor level vents close towards the outside of the cab.

Recirculation vents and screen

The recirculation vents and screen provide an intake for cab air to be recirculated through the evaporator and heater cores. The vent below the seat has a washable foam filter mounted in the inlet screen.

Air can also be recirculated through the intake tube vents on the left-hand door post. With the vents closed, more outside air is drawn into the cab. This position is used for normal winter and summer operation. With the vents open, intake air is a mix of inside and outside air. This allows more cab air to be recirculated through the evaporator and cool the cab quicker.

1 Fan speed switch 2 Air conditioner on/off switch 3 Temperature control switch 4 Front defroster fan switch 5 Rear defroster fan switch

Controls

Operator comfort 63

Adjusting heating and ventilation

These instructions are only basic recommendations and each operator should experiment to achieve the best possible working environment in an enclosed cab.

For maximum warmth:

n Ensure heater shut off taps at engine are open

n Open all vent louvers.

n Turn the temperature control switch (3) fully clockwise.

n Turn the fan speed switch (1) to position 3.

n When a comfortable level is reached, turn the temperature

switch (3) until the required temperature is maintained. Turn the fan speed switch (1) to position 1 or 2.

For a comfortable working temperature:

n Turn the temperature control knob (3) counterclockwise until

a comfortable temperature is reached.

n Reduce the fan speed (1) to 1 or 2.

To defrost or demist the front and rear windshields:

n Turn on the defroster fan switches (4 and 5).

n Adjust the upper front facing louvers and the lower vent lou-

vers towards the side windows.

Cab ventilation

n The cab can also be ventilated by opening the doors. Secure

the doors in the open position by pushing them all the way open until they latch against the stop on the side of the cab.

n Release the door by pulling the release lever beside the seat.

Adjusting air conditioning

For maximum cooling:

n Turn the fan speed switch (1) to the maximum position.

n Turn on the air conditioning switch (2).

n Turn the temperature control switch counterclockwise to the

minimum position.

n Open the two recirculation vents in the back of the left-hand

door post.

n When the temperature has dropped to the required level, turn

the fan speed switch to 1 or 2. Adjust the temperature control to a comfortable level.

For a comfortable working temperature:

n Turn the temperature control knob (3) clockwise until a com-

fortable temperature is reached.

n Reduce the fan speed (1) to 1 or 2.

Controls

64 Hydraulic controls

Hydraulic controls

1 Left-hand blade lift lever 6 Right-hand blade lift lever

2 Moldboard slide shift lever 7 Control lever for scarifier, ripper or windrow eliminator

3 Circle turn lever 8 Articulation lever

4 Circle shift lever 9 Moldboard tilt lever

5 Front wheel lean lever 10 A-frame attachments lever

11 Hydraulic controls

1 and 6

Left-hand and right-hand blade lift

n Push forward on both levers at the same time to lower the

moldboard.

n Pull back on both levers at the same time to raise the mold-

board.

Controls

Hydraulic controls 65

n Push forward on the lever for the side you wish to lower.

n Pull back on the lever for the side you wish to raise.

Electric float valves

n On graders equipped with optional blade float, push forward

on the lever until it locks in the detent (see figure). Pull backward on the lever to return it to the normal operating position.

WARNING!

Do not use the float control to lower the moldboard. Loss of control of the grader could result.

1 Float detent position

1 Float valves power switch 2 Front float valve system indicator lamps

Front float valve system operation

Graders equipped with float valves allow the moldboard and/or Aframe attachment to ‘float’ along the ground by following the surface contours. For snow wing float, refer to Hydraulic snow wing page 121.

Either or both blade lift cylinders can be put into float to allow independent control of each end of the moldboard.

Use moldboard float to remove snow, move loose material on hard-packed surfaces or to level loose material to a hard surface. (Float only the moldboard end contacting the hard surface.)

n The float valves power switch is located on the right-hand side

of the pedestal.

n Ensure the levers are in the non-float detent position.

n Push the power switch up to activate the system. This is a mo-

mentary style switch. Indicator lamps mounted on the front right-hand side of the pedestal indicate that the system is activated.

n The ignition key must be in the “I” position to activate the sys-

tem using the float valves power switch.

n Push the float valves power switch down to de-activate the

system. The system also de-activates when you turn the ignition key to the OFF position.

Controls

66 Hydraulic controls

Moldboard slide shift lever

This lever is the third lever in from the extreme left. It controls the left-to-right sliding action of the moldboard.

n Push forward on the moldboard slide shift lever to slide the

blade out to the left-hand side of the grader.

n Pull back on the lever to slide the blade to the right-hand side

of the grader.

Circle turn lever

This lever is the fifth lever in from the extreme left. It controls the clockwise and counterclockwise rotation of the circle and moldboard assembly.

n Push forward on the circle turn lever to rotate the circle coun-

terclockwise.

n Pull back on the lever to rotate the circle clockwise.

WARNING!

Keep clear when engine is running or moldboard is off ground.

Controls

Hydraulic controls 67

Circle shift lever

This lever is the fifth lever in from the extreme right. It controls the circle shift function.

n Push forward on the circle shift lever to move the circle and

moldboard assembly to the left.

n Pull back on the lever to move the assembly to the right.

Front wheel lean lever

This lever is the third lever in from the extreme right. It controls the lean of the front wheels to the left or right for a reduced turning radius and improved machine stability while grading.

n Push forward on the wheel lean lever to lean the front wheels

to the left.

n Pull back on the lever to lean the wheels to the right.

Controls

68 Hydraulic controls

Control lever for scarifier, ripper or windrow elimi-

nator

This lever is the second lever in from the extreme right. The attachments lever normally controls the scarifier function. The lever also controls either a ripper or windrow eliminator if the grader is not equipped with a scarifier.

n Push forward on the control lever to lower the attachment.

n Pull back on the lever to raise the attachment.

Articulation lever

This lever is located fourth from the extreme right. The articulation lever controls the direction of the articulation function.

NOTE! Remove the articulation lock pins before attempting to articulate the grader.

n Push forward on the control lever to articulate the grader to the

left.

n Pull back on the lever to articulate the grader to the right.

n The indicator gauge in the pedestal displays the amount of

frame articulation.

Refer to Steering using articulation page 93.

WARNING!

Do not articulate the grader when operating on steep slopes or when roading the machine. Grader could roll over. Severe personal injury or death could result. Always articulate the grader prior to moving onto the slope.

Controls

Hydraulic controls 69

Moldboard tilt lever

This lever is located fourth from the extreme left. Use the moldboard tilt feature to ensure that the grading material rolls freely off the blade.

n Push forward on this lever to tilt the moldboard forward.

n Pull back on this lever to tilt the moldboard rearward.

A-frame attachments lever

This lever is the second lever in from the extreme left. It controls the raising and lowering action of the front-mounted dozer blade/ scarifier or other attachment.

n Push the lever forward to lower the attachment.

n Pull the lever back to raise the attachment.

On motor graders equipped with optional front lift float capabilities, operate the lever to select the detent position. Refer to Front float valve system operation page 65 for further information.

n For float action, push forward on the lever until it locks in the

detent.

n Pull backward on the lever to return it to the normal operating

position.

Controls

70 Hydraulic controls

12 Auxiliary hydraulic controls

(optional)

Controls levers for additional attachments such as a rear ripper, windrow eliminator or snow wing as equipped are placed to the right of the operator’s seat.

n Push forward on the control lever to lower the attachment.

n Pull back on the lever to raise the attachment.

For further information on attachments, see Operating instructions Scarifier page 115, Ripper page 116, Windrow eliminator page 117, Dozer blade/V-plow page 119, One way plow page 120, and Hydraulic snow wing page 121.

1 Extra hydraulic circuits 2 Snow wing front mast 3 Snow wing rear mast slide/ripper/windrow elimi-

nator 4 Extra hydraulic circuits 5 Snow wing lift

Controls

Other controls 71

Other controls

(not shown in main overview illustration)

Accumulators

Some graders are equipped with blade lift and circle shift accumulators. The accumulators absorb shock loads and protect the system from impact damage when the grader is working in severe applications.

In fine grading operations where a high degree of blading tolerance is needed, the accumulators can be isolated from the hydraulic system. This is done using shut-off valves. Shut-off valve handles are found in the toolbox located on the right-hand tandem case for this purpose. Turn the handle clockwise to disconnect the accumulator from the hydraulic system.

Turn the handle counterclockwise to connect the accumulator to the hydraulic system.

Radio/tape player

A factory-installed radio/tape player is available as an option. The radio console is mounted in the headliner to the left behind the operator. Twin speakers are installed in the upper rear corners of the cab. Refer to the instructions supplied in the package of manuals.

Battery isolation switch

The battery isolation switch is located inside the engine compartment on the left-hand side of the grader. The switch cuts off electricity between the batteries and the grader’s electrical system.

n Turn the switch OFF to the (O) position and all electrical de-

vices are inoperative.

n Turn the switch ON to the (I) position to reconnect the electri-

cal system.

NOTE! Do not bypass the battery isolation switch. Have the switch repaired if it is not working properly.

Notes

Operating instructions

Introduction 73

Operating instructions

Introduction

This chapter contains rules which must be followed to make working with the machine safe. However, these rules do not relieve the operator from following laws or other national regulations for traffic safety, industrial safety, and labor welfare.

Alertness, judgement and respect for applicable safety regulations are conditions necessary to avoid the risk of accidents.

Operating instructions

74 Running-in period

Running-in period

NOTE! Check oil pressure and temperature often.

During the running-in period or the first 50 hours, the machine must be operated with a certain amount of care.

The following instructions and intervals apply during the runningin period.

Engine

The engine oil should be changed and the filters replaced after 100 hours of operation. Other new engine commissioning operations to be performed at this time are:

– Replace fuel filter cartridge

– Drain and check fuel filter/water separator.

– Check engine mounts (retighten as necessary)

– Check V-belts (retighten as necessary)

– Inspect engine for leaks

Filters

Change the following filters after the initial 100 hours. Refer to Recommended lubricants page 217

– Change the hydraulic oil filter after the first 100 hours, then ev-

ery 500 hours thereafter. See Hydraulic system filter element page 194.

– Change the transmission filter after the first 100 hours, then

every 500 hours thereafter. See Transmission filter element page 186.

for further instructions.

Lubricants

Change the following lubricants after the initial 100 hours.

– Change the final drive lubricant and clean the magnetic plug,

see Final drives page 188.

– Change the All Wheel Drive gearbox oil (if equipped), refer to

All Wheel Drive, Gearbox oil, changing page 195.

Other checks

Re-torque the final drive to frame bolts and the final drive to tandem bolts. See Critical mounting torques page 231.

Hand signals for on-site traffic control 1Back-up 2 Clearance 3Stop 4 Change direction

Operating instructions

Safety and responsibility 75

Safety and responsibility

Operator duties

The operator should know and pay attention to the specific requirements and risks at the worksite and when travelling on public roads. The operator should therefore read the rules stated below to learn how to avoid serious personal injuries and property damage.

Operator precautions

n Avoid loose fitting clothing, loose or uncovered long hair, jew-

elry and loose personal articles. These can be caught in moving parts. Jewelry may also ground a live electrical circuit.

n Know and use the protective equipment that is to be worn

when operating or servicing the grader. Hard hats, protective glasses, protective shoes, gloves, reflector type vests, respirators and hearing protection are types of equipment that may be required.

n Do not rush. Walk, do not run.

n Keep the steps, handholds, operator’s platform, seat, pedals

and controls in good condition. Keep them clean and clear of debris, mud, ice and grease.

n Do not dismount from the grader with the engine running. Be-

fore leaving the operator’s cab, place the transmission in neutral, lower the moldboard and all attachments to the ground. Apply the parking brake. Shut down the engine. Remove and retain the ignition key.

n Know and use the hand signals required for particular jobs.

Know who has the responsibility for signaling. Ensure the lights are working properly at all times.

n Clean the grader regularly. Keep windows, mirrors and lights

clean. Replace all broken windows and mirrors.

n Ensure the back-up alarm and back-up lights work properly.

Never disconnect the back-up alarm or lights.

n Ensure that your grader is properly equipped for emergencies.

Equipment such as a fire extinguisher, first aid kit, flares may be required. Locate and know how to use this equipment.

n It is the responsibility of the machine user to determine the ex-

istence of special hazards such as toxic gases, ground conditions, etc. that require special precautions. Take the necessary actions to eliminate the hazards.

WARNING!

Do not coast downhill. Excess speed could cause serious transmission damage and loss of control of grader. Severe personal injury or death could result.

n Select a gear that will prevent excessive speed when going

downhill.

Operating instructions

76 Safety and responsibility

n When operating close to electrical lines, underground cables,

n Know and understand the job site traffic flow patterns and

n Watch for bystanders and never allow anyone to be under or

water mains or gas lines, contact the responsible authority and request assistance. Contact with a buried pipeline or cable could result in serious injury or death due to fire or explosion.

obey flagmen, road signs and signals. Signal before turning.

to reach into the grader and its attachments while operating.

WARNING!

Sudden loss of any fluid indicates a serious malfunction. Stop grader and consult a qualified service technician.

WARNING!

Do not use float control to lower moldboard. Loss of control of grader could result.

SMV Plate (slow moving vehicle)

Mounting and dismounting

n Face the cab when climbing in or out of the grader. Use the

handholds and steps provided. Maintain three points of support. For example, two hands and one foot or one hand and two feet.

n Do not mount or operate the grader with wet or greasy hands,

muddy shoes or boots.

n Do not jump from the grader at any time.

n Never try to mount or dismount the grader while it is moving.

Know and use the hand signals required for particular jobs. Know who has the responsibility for signaling.

Driving on a roadway

n Understand and obey traffic laws, road signs and signals.

n Keep both ends of the moldboard high and within the width of

the grader.

n Use extra caution at all intersections.

n Be aware of traffic behind you. If necessary, pull over to the

side of the road and allow the vehicles to pass safely.

n Stop and look both ways at railway crossings. Proceed when

clear.

n Ensure your grader is properly equipped for roading. Such

equipment as lights, flashing beacon, turn signals and warning devices such as flags and a slow moving vehicle sign may be required. Check the local traffic laws for the correct traveling requirements.

n Ensure the articulation lock pins are installed when roading

the grader.

n Drive cautiously when entering or leaving the shoulder of the

road to avoid a rollover.

n Do not use the hand throttle when roading the grader.

Operating instructions

Safety and responsibility 77

Job site precautions

n Know and understand the job site traffic flow patterns and

obey flagmen, road signs and signals.

n When moving the grader backwards, have a flagman direct

you and the traffic around you. If a flagman is not available, look around and behind the grader to ensure the area is clear before moving.

n When scarifying or ripping across a slope, keep the mold-

board parallel with the front axle, centered to the frame and lowered close to the ground to provide protection against rolling over.

n Do not dismount from the grader with the engine running. Be-

fore leaving the operator’s cab, place the transmission in NEUTRAL, lower the moldboard and all the attachments to the ground. Apply the parking brake. Shut down the engine. Remove and retain the ignition key.

n Use the clutch pedal when starting, stopping, or when chang-

ing direction.

WARNING!

Do not articulate the grader when operating on steep slopes. Grader could roll over. Severe personal injury or death could result.

Night operation

n Ensure the grader is properly equipped for night operation.

Equipment such as worklights, headlights, beacons and a slow moving vehicle sign may be required.

n Ensure the worklights are properly aimed. Dim the headlights

for approaching traffic.

n When stopping at night near traffic areas, drive the grader off

to the side of the road and set out flares or reflectors.

Snow removal

n Snow removal presents unique hazards due to weather con-

ditions, poor visibility, slippery road surfaces, high operating speed, and other traffic. Be sure your grader is in good condition and that you have been properly trained before doing this work.

n Ensure your grader has the proper attachments before plow-

ing snow. Equipment such as tire chains, warning lights, additional beacons and markings may be required.

n Keep your windshield and other window areas clean and clear

for the best possible visibility. Use the windshield wipers and the window defrosters.

n Be alert for any obstructions covered by snow. Obstructions

such as manhole covers, curbs, bridge abutments, embankments and fire hydrants, etc. may be hazardous.

n Ensure the snow wing is fully raised when not in use and se-

cured with the proper chains.

Operating instructions

78 Safety and responsibility

Special hazards

n Do not stop or turn the grader around on curves or at the crest

n Be alert when grading haul roads as normal rules of the road

n Use extra care when grading against oncoming traffic. Pre-

n Do not operate the grader in areas where volatile gases may

Fire

n Remove dust and combustible debris from the grader regular-

n Inspect the grader daily for potential fire hazards such as

n Ensure that excess oil, grease or fuel is cleaned up immedi-

n Ensure the grader is properly equipped for grading in dry or

of hills.

might not be observed.

cautions such as flags, barricades, flashing lights, and flagmen may be needed to alert traffic.

be present. Explosion could result. If you encounter an area where volatile gases may be present, shut down the grader and leave the area immediately.

ly.

damaged electrical wires. Have necessary repairs made immediately.

ately.

forested areas. Equipment such as a spark arrestor may be required.

When there is a risk of overturning

ROPS

The cab is for the protection of the operator and meets the requirements for Roll Over Protective Structure according to the adopted standard (ROPS). A precondition for the protection is that the operator uses the seat belt and remains in the cab. Therefore, hold on to the steering wheel if the machine should roll over. Do not

jump!

FOPS

The cab is designed to meet the requirements for objects falling onto the cab roof according to given testing methods for Falling Object Protective Structure (FOPS). A precondition for the protection is that the operator uses the seat belt and remains in the cab. Therefore, hold to the steering wheel if the machine should roll over. Do not jump!

Emergency exit

The left-hand door opening is the most commonly used entrance.

The right-hand door opening can be used as the EXIT in case of an emergency.

Models equipped with a snow wing are supplied with an emergency hammer located inside the left-hand door post. It can be used to break the glass in case of a rollover.

Operating instructions

Safety and responsibility 79

Towing

n When it is necessary to tow the grader, do not exceed 8 km/h

(5 mph).

n Be sure the towing machine has sufficient braking capacity to

stop the towed load.

n If the towed grader cannot be braked, a tow bar or two towing

machines must be used – one in front pulling and one at the rear to provide braking. Do not tow over long distances.

n Use the tow hitch when using the grader for towing. If a cable

or chain is used, keep people away from the towline.

n Shielding of the operator(s) against towline breakage must be

provided. Refer to Operating instructions, To wing page 101.

WARNING!

Improper towing methods or equipment could result in severe personal injury or death. Read and understand the towing instructions and precautions in this manual.

Transporting

n Exercise safety and follow all local laws when loading, unload-

ing or transporting the grader. Refer to Operating instructions, Safety and responsibility, Transporting the machine page 103.

Operating instructions

80 Before operating

Before operating

General rules

n Do not operate the grader unless you are a qualified operator.

n Read and understand the entire Operator’s Manual. Before

you operate the grader, understand its performance characteristics, capabilities and limitations, and become thoroughly familiar with all controls and instruments.

n Consult your supervisor if you do not understand the Opera-

tor’s Manual.

n Read and obey all safety signs on the grader. Ensure they are

kept clean and in good condition. Replace the safety signs if they are damaged, missing or illegible. Refer to Plates and de- cals page 12.

n Never drive or operate the grader while you are under the in-

fluence of alcohol or drugs.

n Know and follow your safety program rules.

n For specific safety requirements, potential work area hazards

and the necessary precautions, consult your supervisor.

n Before operating the grader, ensure it is properly equipped.

Consult your supervisor or your Volvo Dealer for details.

n Do not permit riders in or on the grader. Ensure all doors, pan-

els, inspection covers and the battery box cover are in place and secure.

n Remove or secure loose objects in the cab such as lunch box-

es, tools, etc. Remove all objects which do not belong in or on the grader.

n Before backing up, use extra care to ensure all persons and

vehicles are clear of the grader.

n Adjust the seat and fasten the seat belt. The seat belt must fit

snug and low around your hips. The holding strap must be free of slack.

n Ensure the snow wing is fully raised when not in use and se-

cured with the proper chains.

n Before operating your grader, test the brakes, steering, trans-

mission, clutch and all controls and functions. Perform the test in an area where the safety of personnel and property will not be in jeopardy.

n If a malfunction is observed, park the grader and place a ‘DO

NOT OPERATE’ or similar warning tag on the steering wheel

and/or battery isolation switch. Be sure to remove the ignition key. Report the problem and have it repaired before operating the grader.

n If a failure occurs that causes loss of control such as steering,

service brakes or engine, stop the grader as quickly as possible. Keep the grader securely parked until the malfunction is corrected or the grader can be safely towed.

n Understand the grader’s limitations and keep the grader under

control.

n Drive the grader with care and at speeds compatible with con-

ditions. Use extra caution when operating over rough ground, on slopes, when ditching and when turning the grader.

Operating instructions

Before operating 81

n Know your stopping distance at any speed. Regulate the

speed of your grader accordingly.

n Note and avoid all hazards and obstructions such as over-

hangs, ledges, slide areas, electrical lines, underground cables, water mains, gas lines, etc.

Daily pre-start checks

Before making any checks, ensure the grader is in the Service position. Refer to Service position page 146.

Carry out daily maintenance, see Service and maintenance, Daily (every 10 hours) page 205.

Conduct a daily inspection of your grader every 4 to 24 hours of operation or at the beginning of each work shift.

Perform the following general walk-around inspection before climbing into the cab. Report any faults.

1 Look for oil and coolant leaks. Report all tire damage, pinched

hoses, loose bolts or worn cutting edges. Have them repaired or replaced.

2 Clear away any debris from the moldboard or circle turn area.

3 Check that the moldboard slide rails and circle top surface are

clean.

4 Ensure the safety signs are clean and in good condition. Re-

place them if damaged, missing or illegible.

5 Check for ‘DO NOT OPERATE’ or similar warning tags.

6 Clean the cab glass.

7 Check adjustment of all rearview mirrors.

8 Before starting the grader, remove all tools and other loose ob-

jects from the machine.

9 Ensure the lights, back-up alarm and other warning and safety

devices are clean and working properly.

10 Warn all personnel who may be servicing the grader or are in its

path prior to starting. Do not start the engine until all personnel are clearly away from the grader.

11 Secondary steering system check. If your grader has this option

installed, perform this check once a week or every 50 hours before you start the engine. Refer to Secondary steering system test switch page 42.

Operating instructions

82 Before operating

Procedures before starting the machine

Before starting the grader, check for ‘DO NOT OPERATE’ or sim- ilar warning tags. Turn the battery isolation switch on.

n Perform the ‘Pre-start checks’ in this manual before starting

the grader.

n Start and operate the grader only from the operator’s seat.

n Adjust the seat and fasten the seat belt. The seat belt must fit

snug and low around your hips. The holding strap must be free of slack.

n Know how to shut the engine down before attempting to start

it.

n Check the transmission shift lever to ensure it is in NEUTRAL

before starting the engine.

n Ensure the parking brake is applied.

n Sound the horn before starting the engine.

n Do not operate the engine in an enclosed area without ade-

quate ventilation.

n Do not bypass the battery isolation switch. Have the switch re-

paired if it is not working properly.

n Use jumper cables only in the recommended manner. Improp-

er use can result in battery explosion or unexpected movement of the grader. Refer to Starting with jumper cables: page

182.

n After the engine has started, check all gauges and indicators

for proper readings. Shut down the engine immediately if any improper readings or energized warning lamps are observed. Refer to Instrument panels page 21.

n Ensure that the lights work properly.

n Check that the hydraulic controls function properly.

n Check that the parking and service brakes function properly.

Refer to Braking page 95.

n Check that the engine hand throttle and accelerator function

properly.

n Listen for unusual noises.

n Look around and behind the grader before moving it.

n Check that the left-hand steering and right-hand steering func-

tion properly.

Operating instructions

Ignition switch 83

Ignition switch

The ignition switch has four positions:

NOTE! Position II is not used.

O Turned off

R Radio position

I Running position and preheating position

III Starting position

O (OFF position)

In the “O” position, the engine stops immediately and the electrical system is turned off.

NOTE! With the parking brake released and the ignition key in the I position, the brake will be automatically applied if the switch is moved to the R or O positions.

R (Radio position)

When the ignition key is in the “R” position:

– Current is supplied to some electrical equipment

– The engine is off in this position

NOTE! With the parking brake released and the ignition key in the I position, the brake will be automatically applied if the switch is moved to the R or O positions.

I (Running position and preheat position)

In the “I” position:

– The electrical system is turned on

– Engine preheating can be engaged

– The engines runs in this position

III (Start position)

The starter will be engaged with the ignition key in the “III” position.

Operating instructions

84 Ignition switch

Checking instruments and control lamps

Turn the ignition key to the “I” position (running position). The following control lamps should illuminate.

Red lamps

Red central warning

Battery charge warning

Hydraulic oil temperature warning

Transmission pressure warning

Service brake warning

Parking brake applied

Primary steering system warning

Hydraulic oil level warning

Hydraulic oil pressure warning

Amber lamps

Central warning

Differential lock engaged

MBCS lock disengaged

Engine air filter restriction

Hydraulic filter bypass

Secondary steering system

Engine preheat status

Green lamps

Turn signal indicator lights

Blue lamps

High beam lights

If any of these lamps do not light up, either the lamp is faulty or there is a fault in the electrical system. Have this problem corrected before start-up. All lamps should be extinguished when the grader starts up (unless there is a message in the display panel stating otherwise).

Operating instructions

Starting the engine 85

Starting the engine

WARNING!

Keep clear of the articulation joint when the engine is running. There is a risk of crushing.

IMPORTANT! After starting the engine, run it at low idle

speed for at least 30 seconds. This is to ensure proper lubrication pressure.

IMPORTANT! Do not hold the key in the starting (III) position for more than 20 seconds. This could seriously damage the starting system. Wait 2 minutes, then try to start the engine again.

1 Push in the parking brake switch to apply parking brake.

2 Place the transmission shifter in neutral.

3 Place the hand throttle lever in the low idle position.

4 Insert the ignition key in the switch and rotate the key clockwise

to position “III” (start position).

5 Release the key when engine starts.

If the engine does not start:

6 Wait until the engine has stopped completely. 7 Turn the key back to the “O” position before a new starting at-

tempt is made.

A Control lamp, preheating element B Switch, preheating element

Starting a cold engine

Engine preheating should be used when the engine temperature is below 0° C (32° F).

WARNING!

Do not use starting aids (ether, etc.) when preheating the engine. Serious engine damage could result.

1 Turn the ignition key to position “I” (Running position and preheat

position).

2 Momentarily depress the Preheat element switch beside the igni-

tion switch on the side console. The preheat now remains engaged for up to 50 seconds and the control lamp will illuminate.

3 When the control lamp goes out, turn the ignition key clockwise to

position “III” (start position). Release the key when the engine starts. Making a starting attempt during the preheat cycle will cancel the preheat.

NOTE! The use of an immersion heater to warm the oil in the engine is highly recommended or, if possible, store the grader inside a heated facility.

4 After starting, the lamp may come on for a short period of time

indicating post heat.

NOTE! If the control lamp stays on after a 50 second period, the preheating element is still connected. Check the function of the element as there is a risk of overheating.

Operating instructions

86 Starting the engine

Cold weather operation

During the cold season or at temperatures below 0°C (32°F) note the following points:

– Make sure the freezing point of the coolant corresponds to the

weather conditions, according to Coolant with anti-freeze and corrosion protection page 174.

– Use recommended lubricating oil for winter use. See Recom-

mended lubricants page 217.

– Fill the fuel tank after work has finished for the day. This will

counteract condensation water in the fuel tank.

– When the engine has started, run it at low speed and light

loading until the oil in the engine, transmission, hydraulic system and final drive have warmed up and become more fluid to provide proper lubrication.

NOTE! When it is very cold (below – 15°C = 5°F) the machine must not be put to hard work immediately after the engine is started. Allow the engine to run just above idle at 1000 to 1100 rpm with the transmission in neutral for 10 to 15 minutes.

NOTE! To start with booster cables, see Starting with jumper cables: page 182.

Lubricant requirements for transmission and hydraulic systems

When operating in temperatures below –10° C (14° F), store the grader inside a heated facility or use immersion heaters in the transmission case and the hydraulic tank. You can use the recommended oils provided the following conditions are met (refer to Recommended lubricants page 217):

a) Before start up, the oil is preheated to a temperature above the minimum value for the indicated oil and viscosity range.

b) The operating temperature stays above the minimum value in the applicable range.

Failure to comply with these requirements may result in a malfunction or reduced life of the transmission or hydraulic components.

Cold weather start-up – Hydraulic system

If oil in the hydraulic circuit is cold, hydraulic functions may move slowly. Do not attempt grader operations until the hydraulic oil is warmed up. If you do not follow the proper warm up procedure, hydraulic pump damage may result.

a) Run the engine at approximately 1000 rpm for five minutes. Do not put load on the hydraulic system.

b) Cycle all hydraulic cylinders through their working range several times until the hydraulic functions operate normally.

1 Clutch pedal 2 Brake pedal 3 Accelerator/decelerator pedal

Operating instructions

Shifting gears 87

Shifting gears

Use the clutch pedal when you are starting from a complete stop or changing directions.

NOTE! Do not start to move the grader in any forward gear higher than 4th or any reverse gear higher than -2nd.

Starting out

n Raise the moldboard and all attachments off the ground. Re-

fer to Hydraulic controls page 64.

n If roading the grader, position the moldboard inside the tires.

Steer the front wheels to make sure they do not strike the moldboard.

n Depress the clutch and brake pedals.

n Pull out the parking brake switch to release the parking brake.

n Depress the neutral lock button and move the shift lever into

the FORWARD or REVERSE position.

n Select the starting gear by nudging the shift lever to the right

or to the left. A digital display is incorporated into the pedestal to tell you which gear the transmission is in.

n Release the brake pedal, then slowly release the clutch pedal

and accelerate as required.

NOTE! Do not rest your feet on the clutch or brake pedals when driving the grader. This can cause unnecessary wear and premature failure.

AForward B Reverse C Neutral lock button

Operating instructions

88 Shifting gears

Changing gears

Once the grader is in motion, you do not have to use the clutch pedal to change gears.

n To shift to a higher gear, nudge the shift lever to the right and

release it.

n To shift to a lower gear, nudge the shift lever to the left and

release it.

When not using the moldboard or attachments, lower the engine rpm as you upshift.

NOTE! Do not shift to a lower gear at maximum engine rpm. Damage to the transmission could result.

A Shift to higher gear B Shift to lower gear

Memory Gear Feature

Changing directions

NOTE! Stop the grader to change directions.

1 Depress the clutch pedal and bring the grader to a complete

stop using the service brakes.

2 Select an appropriate gear for starting depending on your work-

ing conditions. Starting in too high a gear may cause the engine to stall.

3 Depress the neutral lock button and move the shift lever forward

for forward travel or backward for reverse travel.

4 Release the brake pedal, then slowly release the clutch pedal

and accelerate as required.

AForward B Reverse C Neutral lock button

Table A Default gear combinations

Forward

gear

1– 2

2– 2

3– 2

4– 2

5– 3

6– 3

7– 3

8– 4

Reverse

gear

Operating instructions

Shifting gears 89

Memory gear feature

The “smart shift” memory gear feature allows the operator to customize the shift patterns of the transmission to suit the job. Tab le A shows the default shift pattern before the operator uses the memory gear function.

To obtain different shift patterns, such as FORWARD 2 and REVERSE 1, you must manually shift the transmission to that gear.

The memory feature remembers the selected gear that was last used in either FORWARD or REVERSE, and upon returning to that direction the controller automatically selects that gear. You only have to select the required gears in either FORWARD or REVERSE, no other programming action is needed. Refer to Table B for the allowable memory gear selections.

Once you have obtained a valid memory gear combination, you can ‘shuttle-shift’ between FORWARD and REVERSE. However, you must still use the engine clutch.

If a selected combination of FORWARD and REVERSE gears is not valid (see Table B), the transmission ECU (electronic control unit) automatically selects the closest appropriate gear.

When the shift lever is in NEUTRAL, the display always indicates the FORWARD and REVERSE gears available.

An upshift or downshift of the shift lever while in NEUTRAL cancels the memory gear function and returns the transmission shift pattern to the default settings (see Tab l e A).

Operating instructions

90 Shifting gears

You must make a complete shift sequence (i.e., F-N-R or R-N-F) to use the memory gear function. If you make an incomplete shift sequence (i.e., F-N-F or R-N-R), the transmission returns to the previous FORWARD and REVERSE gear selection.

Table B Valid gear combinations

Forward to Reverse Reverse to Forward

1 – 1

– 2

2 – 1

– 2

3 – 1

– 2 – 3

4 – 2

– 3

5 – 2

– 3

6 – 3

7 – 3

8 – 4

– 1 1

2 3

– 2 1

2 3 4 5

– 3 3

4 5

– 4 5

All Wheel Drive models using Creep Mode

Forward to Reverse Reverse to Forward

C – 1 – C 1

– 2 2

Memory gear feature – All Wheel Drive models

With the All Wheel Drive system engaged, switching to Creep Mode will eliminate any previously selected memory gear combination.

The memory gear feature allows you to shift between normal All Wheel Drive and Creep Mode. Upshifting or downshifting the transmission while in Creep Mode, places it in normal All Wheel Drive. For example, shift between Creep Mode forward and second gear reverse.

1 System activation lamp 2 All Wheel Drive on/off switch

Operating instructions

Shifting gears 91

All Wheel Drive models

AWD (All Wheel Drive) is an optional hydrostatic drive system used to increase tractive effort and steering control at the front wheels during slippery conditions. Two electronically controlled, variable-displacement hydraulic pumps power the system in a closed loop circuit. Each pump supplies one front wheel motor. The wheel motors are a 2-speed, high torque, radial piston, cam lobe type. Each wheel motor has a separate speed sensor. AWD responds in forward gears 1 to 7 and all reverse gears.

All Wheel Drive applications

Side loading

You can counteract the side loads encountered when working across a slope or when grading heavy material by using All Wheel Drive. Driving the front wheels against the side loads maintains directional control.

Traction and steering control

When traction is poor and the rear wheels of the grader are slipping, use All Wheel Drive to transfer power to the front wheels. By counteracting rear wheel slip, All Wheel Drive allows the grader to carry a greater load on the blade, reduces rear tire wear and reduces shock loads on the primary drivetrain. All Wheel Drive can also give you better steering control on low traction surfaces by supplying full power to both front wheels during turns.

System operation

The system is activated by depressing the rocker switch on the AWD control panel (2). All Wheel Drive capability is available in gears 1 to 7 forward, and all reverse gears. Refer to Instrument panels, All Wheel Drive control panel page 52.

n If AWD is switched on when the grader is moving, the grader

must be slowed below 4th gear for the system to engage. The indicator lamp will flash until the system engages.

n When upshifting, the system automatically switches to tan-

dem drive only in 8th gear, and back to AWD in 7th gear when downshifted.

IMPORTANT! Do not allow the grader to coast (freewheel) downhill in NEUTRAL with the AWD System engaged. Damage to components may result.

System deactivation

The AWD system automatically deactivates under the following

conditions: 1 AWD rocker switch is placed in the OFF position.

2 Transmission shifter is placed in neutral.

3 Transmission shifter is placed in eighth gear forward.

4 Clutch or brake pedal are depressed.

5 Hydraulic oil temperature in the reservoir is above normal oper-

ating range.

6 Oil level in the hydraulic tank is too low.

7 Charge pressure is too low.

Operating instructions

92 Shifting gears

Creep mode

Creep mode uses hydrostatic front wheel drive to power the grader from 0 to 3.2 km/h (0 to 2 mph). The rear wheels are not driving when Creep Mode is activated.

NOTE! Selecting Creep Mode eliminates any memory gear combination previously used.

n With the AWD system engaged, the grader stopped and the

transmission in neutral, switch to Creep Mode using the rocker switch on the control panel (2). The transmission gear display will alternate between “C” and “-C” while in neutral until a gear is selected.

n Place the transmission shifter in the forward or reverse posi-

tion as desired. The display will indicate “C” for forward movement and “-C” for reverse.

n Increase engine speed above 1000 rpm to start moving. Use

engine rpm to adjust to desired ground speed.

n To stop the grader or change direction, depress the clutch

pedal and reduce the engine speed below 1000 rpm.

n Using the clutch and upshifting the transmission will place the

system into normal AWD mode. Shift between a normal AWD gear combination and Creep Mode.

n After turning Creep Mode off, the transmission will default to

the closest gear.

1 Creep mode activation lamp 2 Creep mode on/off switch 3 All Wheel Drive Aggression dial

AWD Aggression

Graders often have different tractive conditions encountered by the front and the rear of the machine. The 16-position manual dial control is used to fine tune rotational speed differences that may occur between the front and the rear wheels when grading under diverse conditions with the All Wheel Drive system engaged.

n A dial setting at '7' matches the front wheel speed evenly with

the rear wheel speed.

n A lower setting slows the front wheel rotational speed com-

pared to the rear; a higher setting increases the front wheel rotational speed in comparison to the rear.

1 Articulation lever

2 Wheel lean lever

Operating instructions

Steering 93

Steering

The grader has a hydraulic steering system. Turn the steering

wheel to steer the grader to the left or right.

WARNING!

The steering system only operates when engine is running. If engine stalls, stop the grader.

If the engine stalls, stop the grader. Place transmission in NEU-

TRAL and apply the parking brake. Start the engine, if possible. If

the engine cannot be started, refer to Stopping the machine page

98. Have the engine repaired by a qualified Volvo service techni-

cian.

Front wheel lean

You can reduce the turning circle of your grader by leaning the

front wheels. Lean the wheels in the direction you will turn. Posi-

tion the front wheels vertically again after completing the turn. Do

not use wheel lean at high speeds. Reaction is quick.

Refer to Front wheel lean lever page 67.

1 Articulation lock pin

Steering using articulation

WARNING!

Use the articulation lever to further reduce the grader’s turning cir-

cle. Before articulating, remove the articulation lock pins. Install

the lock pins when not using the articulation function. Do not use

at high speeds. Reaction is quick.

Refer to Articulation lever page 68.

n Ensure the articulation lock pins are installed when roading

the grader.

Operating instructions

94 Steering

n Bolt-on shims may be removed from the articulation hinge to

increase the articulation angle. The shims prevent interference between the tandem tires and cab when larger than standard tires are fitted. Interference with larger tires only occurs during full tandem oscillation and full frame articulation.

n Ensure the control switch for locking the differentials is in the

UNLOCK position before turning the grader. This reduces strain on the final drive and reduces tire scuffing. Put the switch in the LOCK position for normal grading. Refer to Dif- ferential lock page 97.

Secondary steering system

(optional)

This auxiliary hydraulic system allows the operator to make steering corrections more easily in the event of loss of hydraulic flow to the steering unit. The ignition key must be in the “I” position to operate the system.

A Control lamp (red) primary steering system B Control lamp (amber) secondary steering

system C Message display D Central warning lamp (red)

WARNING!

Do not operate the supplementary steering system longer than two minutes. Equipment damage will result.

Operate the system long enough only to make a steering correction - maximum two minutes.

In the event of low steering oil pressure, the Primary steering system warning lamp (A) and the Secondary steering system status lamp (B) will illuminate, accompanied by a buzzer, message display (C), and the red central warning lamp (D).

To test the Secondary steering system:

n Insert and turn the ignition key to the “I” position (running po-

sition).

n Do not start the engine.

n Depress and hold the Secondary steering test button located

on the pedestal.

n The Secondary steering warning lights and alarm should en-

ergize.

n Check the system by turning the steering wheel. If it does not

turn easily, there is a fault in the system. Have the system repaired by a qualified Volvo service technician.

n Depress and hold the Secondary steering test button only

long enough only to check the system.

n Start the engine. The warning lights and alarm will de-

energize, indicating the system is ready if the engine stalls.

n If the warning lights and alarm remain energized with the en-

gine running, do not drive the grader. The system is faulty and must be repaired by a qualified service technician.

A Service brake pedal

B Central warning lamp (red)

C Service brake warning lamp (red)

D Display message

Operating instructions

Braking 95

Braking

Service brakes

Push down on the brake pedal to apply the service brakes.

WARNING!

In case of faulty brakes, do not continue to operate. Have a qualified service technician repair the brake system immediately.

The service brake system has two separate brake circuits. The system provides reduced braking capability in the event of a brake line rupture or other failure in one circuit.

Each of the two circuits function on one front and opposite rear tandem wheel. Should one circuit fail, braking remains effective on all tandem wheels through the tandem chains.

In the event of service brake system failure, the warning lamp (C) will illuminate accompanied by the red central warning lamp (B), a display panel message (D), and a buzzer.

A supplementary power source automatically supplies hydraulic power assist in the event of an engine failure or any situation where hydraulic oil flow is interrupted to the service brake system.

Reduced braking capability is still available when the engine is not running, or the key is not inserted in the ignition switch. Supplementary power source will engage when the brake pedal is depressed with the key either on or off.

This reserve system provides power assisted braking capability at a reduced level and automatically resets when hydraulic oil flow is restored.

IMPORTANT! Do not rest your foot on the brake pedal with

the ignition key in the off position. This may damage the supplementary brake system.

Stopping the machine

n Depress the brake pedal to apply the service brakes.

n Reduce engine speed.

n Slowly depress and hold down the clutch and brake pedals.

Depressing the clutch pedal only may not stop the grader.

n Use brake pedal to hold grader when transmission is in gear,

clutch pedal depressed and engine is running.

n Move the shift lever into the NEUTRAL position.

n Apply the parking brake.

n Release the clutch and brake pedals.

n Lower the moldboard and all attachments to the ground.

n Shut down the engine.

Brake adjustment

Refer to the Service Manual for information on adjusting the brakes.

Operating instructions

96 Braking

A Parking brake switch B Parking brake applied warning lamp (red) C Central warning lamp (red) D Display message

Parking brake

NOTE! Only apply the parking brake when the machine has stopped. Always apply the brake if the machine is to be left unattended.

NOTE! When the parking brake is applied, the transmission cannot be shifted out of neutral.

When the parking brake is applied, the red indicator lamp (B) illuminates. If the brake is applied while the transmission is in gear, it is accompanied by the red central warning lamp (C), a buzzer, and a display message (D).

NOTE! With the ignition key in the I position and the parking brake released, the brake will be automatically applied if the switch is moved to the R or O positions.

In the event of a loss of system pressure (e.g. engine stall), the parking brake will not immediately apply itself. The brake has an accumulator that stores energy in the circuit allowing the operator to bring the machine to a stop safely.

Once the stored pressure is depleted, the parking brake will be applied automatically. When hydraulic pressure is restored, the brake can be released.

To manually release the parking brake, refer to Manual release of parking brake page 106.

The parking brake is self-adjusting, see Parking brake page 191 for specifications.

Emergency brake

In an emergency situation, the parking brake may be used as an emergency brake.

WARNING!

The parking brake must be inspected by a qualified service technician after being used in an emergency situation.

A Differential lock/unlock switch

B Differential lock indicator lamp (amber)

C Differential lock operating instructions decal

(on windshield)

Operating instructions

Differential lock 97

Differential lock

WARNING!

The lock/unlock differential control switch (A) is mounted in the pedestal on the upper right-hand side. An amber lamp (B) illuminates when the lock is engaged.

n Put the control switch in the ‘UNLOCK’ position when differen-

tial action is required. This will reduce the turning radius and decrease tire scuffing when operating on paved surfaces. The indicator lamp will de-energize.

n Put the control switch in the ‘LOCK’ position for normal grad-

ing operations when maximum traction is required. The indicator lamp will energize.

n The DIFF UNLOCK warning light “OFF” means the lock/un-

lock mechanism is DISENGAGED.

n Do not engage the final drive lock/unlock mechanism while

the tandem wheels are spinning, under load, or the machine is turning.

Operating instructions

98 After operating

After operating

WARNING!

When you are entering and leaving the machine, always face the machine and use the steps or handholds to avoid slipping. Always use the three-point stance, i.e. two hands and one foot or two feet and one hand when climbing up or descending from the machine. Do not jump!

General

When the machine is left unattended:

1 Apply the parking brake and when required (on a slope), block

the wheels so that the machine cannot roll.

2 Lower the moldboard and all attachments to the ground. Do not

apply down pressure.

3 Remove the ignition key.

4 Close the windows and lock the doors.

5 Turn off the battery isolation switch.

Stopping the machine

The machine is stopped as follows:

1 Release the accelerator to reduce engine speed.

2 Depress the clutch and brake the grader. (Depressing the clutch

only may not stop the machine.)

3 Move the transmission shift lever to neutral.

4 Apply the parking brake.

Use the brake pedal to hold the grader when transmission is in gear with clutch pedal depressed and engine is running.

NOTE! Only apply the parking brake when the machine has stopped. Always apply the brake if the machine is to be left unattended.

Stopping the engine

NOTE! Run the engine at low idle for a few minutes before stopping it to safeguard lubrication of the turbocharger.

1 Turn the ignition key counter-clockwise to the “O” position to

shut down the engine.

NOTE! If the machine is to be left for any length of time, turn off the battery isolation switch.

Operating instructions

After operating 99

Parking

To park the grader:

n Always park the grader on a level surface.

n Stop the grader using the service brakes, then place the trans-

mission in NEUTRAL.

n Apply the parking brake.

n Lower the moldboard and all attachments to the ground. Do

not apply down-pressure.

n Shut down the engine.

n Remove and retain the ignition key.

n Turn the battery isolation switch OFF.

Long-term parking

When a grader is taken out of service for more than 30 days, you must ensure that it is protected from exposure to the elements. An enclosed structure will protect the grader from rapid temperature changes and decrease the amount of condensation that forms in fluid reservoirs, e.g., engine oil pan, fuel tank, hydraulic oil tank, etc.

After you have parked the grader and shut down the engine, per-

form the following steps: 1 Inspect for leaks and other defects. Correct as necessary.

2 Thoroughly wash the grader. Be sure to rinse off any caustic

residue.

3 Touch up any areas where the paint has worn away.

4 Clean or replace air filter elements.

5 Open the drain valve at the bottom of the fuel tank and drain 1

liter (approx. 1 US quart) of fuel to remove any water accumulation.

6 Replace engine fuel filters.

7 Add the recommended amount of fuel stabilizer and corrosion

inhibitor to the fuel tank.

8 Start and run the engine at 1400 rpm to 1600 rpm with no load

for approximately four minutes.

9 Change the engine oil and replace the engine oil filter.

10 Properly seal the engine exhaust and air intake openings.

11 If tires are to be left on, raise the grader and place it on blocks

to keep the tires off the ground. Deflate and cover the tires.

12 Turn off the battery isolation switch. Remove batteries and store

them in a cool, clean, dry and well-ventilated area where the temperature is be-tween 0°C and 21°C (32°F and 70°F). Be sure batteries are fully charged.

13 Coat all machined and unpainted surfaces (including mold-

board) with grease to prevent rust forming.

14 Coat all exposed chrome plated surfaces on hydraulic cylinder

piston rods with a thin layer of grease.

15 Grease all door hinges.

Operating instructions

100 After operating

Preparing for operation after long-term parking

Perform the following steps before putting the grader back into service:

1 Inspect for leaks and other defects which may have occurred

during storage.

2 Thoroughly wash the grader. Remove all grease and coatings

installed as Long term parking steps 13 and 14 on the previous page.

3 Remove any seals from the engine exhaust and air intake open-

ings.

4 Lubricate all grease points. See Grease points page 202.

5 Install fully charged batteries. Turn on the battery isolation

switch.

6 Inflate the tires to the correct pressure. Refer to Maximum tire

pressures page 196. Lower the grader from the storage blocks.

7 Perform all appropriate pre-start checks. Refer to Daily pre-start

checks page 81.

8 Start and run the engine at 1400 rpm to 1600 rpm with no load

for approximately four minutes. If any warning lamps and the alarm energize or gauges show abnormal readings, shut down the engine. Report the problem and have it repaired by a qualified service technician.

Volvo G700B Series, G720B, G710B, G740B, G746B Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Foreword

SAFETY REGULATIONS

Ref. No.: 21 1 434 4006

Printed in Canada

Operation and maintenance of the machine

Volvo Motor Graders Limited is only responsible if:

IMPORTANT!

Protection from electromagnetic interference

Mobile telephones

Guidelines

Contents

Presentation

General

Intended use

Engine

Electrical system

Clutch

Transmission

Final drive/tandems

Brakes

Steering

Cab and frame

MBCS (Moveable Blade Control System)

Hydraulic system

All Wheel Drive

Equipment and attachments

CE Marking and Declaration of Conformity

EU EMC Directive

Modifications

Unauthorized modifications of the ROPS (Roll Over Protective Structure)

Plates and decals

Product plates

1 Engine

2 Cab

3 Product identification plate

4 Product identification plate (EU/EEA countries)

5 Product identification plate for TUV (Germany)

6 Transmission

7 Final drive

Information and warning plates

Service

Delivery inspection

Inspection

Maintenance service

General Information

The USA federal clean air act

Customer assistance

Normal non-road engine use

Non-road engine maintenance

Service performed by your local dealer

Preventive maintenance program

Fuel system

Instrument panels

General

Center instrument panel

General

Buzzer

Secondary steering system check

Pedestal instrument panel

Start code sequence

Error codes

Transmission error codes

AWD (All Wheel Drive) error codes

Engine

Transmission

Hydraulics

Electrical system

AUX1 (Grader information)

AUX2 (Trip measurement information)

The following functions can be controlled from the keypad:

Display unit

Starting sequence (initial display)

Displayed information

1 Operating information, etc.

2 Warning displays (low pressure etc.)

3 ERROR displays (sensor and control device check)