CHAPTER 2 TABLE OF CONTENTS

Maintenance SECTION PAGE

I.

SERVICING ............................................................................................................................................. 1 A. B. C. LUBRICATION INSTRUCTIONS ................................................................................................... 1 CHASSIS LUBRICATION DIAGRAM ............................................................................................. 2 BODY LUBRICATION DIAGRAMS ................................................................................................ 3

II.

TROUBLESHOOTING ............................................................................................................................ 1 A. B. C. D. E. ENGINE/TRANSMISSION ............................................................................................................. 1 BRAKES ........................................................................................................................................ 3 PARK BRAKE ................................................................................................................................ 5 CONVEYOR HYDRAULICS ........................................................................................................... 6 ELECTRICAL ............................................................................................................................... 10

III.

REMOVAL/INSTALLATION .................................................................................................................... 1 A. B. C. D. E. F. G. H. ENGINE/TRANSMISSION REMOVAL ........................................................................................... 1 ENGINE/TRANSMISSION INSTALLATION ................................................................................... 2 REAR AXLE REMOVAL ................................................................................................................. 2 REAR AXLE INSTALLATION ......................................................................................................... 3 FRONT AXLE REMOVAL .............................................................................................................. 3 FRONT AXLE INSTALLATION ...................................................................................................... 3 CONVEYOR REMOVAL ................................................................................................................ 4 CONVEYOR INSTALLATION ........................................................................................................ 4

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SECTION I. J. K. L. M. N. 0. P. Q. R. S. T. U. V. W. X.

PAGE BELT DRIVE MOTOR REMOVAL .................................................................................................. 4 CONVEYOR BELT DRIVE MOTOR INSTALLATION .................................................................... 5 CONVEYOR BELT CONTROL VALVE REMOVAL ........................................................................ 6 CONVEYOR BELT CONTROL VALVE INSTALLATION ................................................................ 6 HOLDING VALVE REMOVAL ........................................................................................................ 6 HOLDING VALVE INSTALLATION ................................................................................................ 7 LIFT CYLINDERS CONTROL VALVE REMOVAL ......................................................................... 7 LIFT CYLINDERS CONTROL VALVE INSTALLATION ................................................................. 7 FRONT LIFT CYLINDER REMOVAL ............................................................................................. 7 LIFT CYLINDER INSTALLATION .................................................................................................. 8 LIFT CYLINDER REMOVAL .......................................................................................................... 8 REAR LIFT CYLINDER INSTALLATION ........................................................................................ 9 HYDRAULIC PUMP REMOVAL ..................................................................................................... 9 HYDRAULIC PUMP INSTALLATION ............................................................................................. 9 ALTERNATOR REMOVAL ........................................................................................................... 10 INSTALLATION .............................................................................................................................. 10

IV.

BELT TRACKING INSTRUCTIONS ........................................................................................................ 1

V.

SYSTEM PRESSURE SETTINGS AND METHODS ............................................................................... 1

VI.

TRANSMISSION LINKAGE ADJUSTMENT ........................................................................................... 1

VII.

PARKING BRAKE ADJUSTMENT ........................................................................................................... 1 A. B. DISCUSSION ................................................................................................................................. 1 PROCEDURE ................................................................................................................................. 1

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VIII. ACCELERATOR CABLE AND MECHANICAL MODULATOR ADJUSTMENT ..................................... 1 A. B. ACCELERATOR ............................................................................................................................ 1 MODULATOR (CUMMINS/ONAN AND PERKINS 4.135) ................................................................. 1

IX.

INSTRUCTIONS FOR JACKING AND POSITIONING VEHICLE ........................................................... 1

X.

HOOF GOVERNOR ADJUSTMENT (GASOLINE ENGINE) ...................................................................... 1 A. B. ADJUSTING SCREW ADJUSTMENT ............................................................................................ 1 SECONDARY SCREW ADJUSTMENT. ........................................................................................ 1

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I.

SERVICING A complete preventive maintenance checklist is included in Chapter 5 of this manual (Appendices). See section 5-1. A. LUBRICATION INSTRUCTIONS

1.

Periodic lubrication should be performed (check service plate at drivers seat for service intervals and types of lubricant).

2.

Use grease at pressure zerks in the following locations as equipped: (a) (b) (c) (d) (e) Ball joints, Upper & Lower Tie Rod Ends Hydraulic Lift Cylinders Steering Cylinder Tie Rod Ends Conveyor roller bearings (4) (2) (4) (2) (8)

3.

Oil The Following Items: (a) (b) (c) (d) (e) Parking brake lever pivot points. Conveyor side and handrail pivot points. Belt drive chain. Motor access cover hinges. Seat slide.

4.

Use appropriate high quality gear oil: (a) (b) Drive reduction gear box Belt reduction gear box

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B.

CHASSIS LUBRICATION DIAGRAM

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C.

BODY LUBRICATION DIAGRAMS

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II.

TROUBLESHOOTING A. ENGINE/TRANSMISSION

COMPLAINT 1. Engine will not crank. (a)

CAUSE Loose or corroded battery cables. Undercharged battery. Starter Relay Loose or broken cable to starter. Loose or open wiring through neutral switch. Starter motor. (a)

CORRECTION Clean & tighten cable connections. Charge or replace battery. Replace starter relay. Tighten or replace cables.

(b) (c) (d)

(b) (c) (d)

(e)

(e)

Repair, adjust or replace.

(f)

(f)

Repair or replace.

2.

Engine will not crank starter spins

(a)

Starter motor.

(a)

Remove starter, inspect for broken or worn drive Inspect ring gear teeth. Replace fly wheel & ring gear if necessary. Adjust or replace.

(b)

Flywheel ring gear.

(b)

3.

No start in N.

(c)

Adjust or replace.

(c)

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A.

ENGINE/TRANSMISSION CAUSE CORRECTION

COMPLAINT

4.

Transmission cannot be shifted into or out of forward, neutral, or reverse gear range.

(a)

Loose or disconnected cable end. Improper cable or lever adjustment. Snow or ice obstructing movement

(a)

Tighten cable ends.

(b)

(b)

Adjust cable or lever.

(c) . 5. Excess binding transmission selector or hand throttle. (a) (b)

(c)

Remove obstacle

Lack of lubrication. Foreign object or excessive dirt or corrosion in lever housing. Kinked or mashed cable housing. Carburetor or transmission linkage binding.

(a) (b)

Clean & lubricate. Clean & lubricate.

(c)

(c)

Repair or replace.

(d)

(d)

Inspect and repair.

6.

Engine speed too high with hand throttle in idle position.

(a)

Hand throttle linkage out of adjustment. Choke or idle speed is out of adjustment.

(a)

Adjust or repair linkage

(b)

(b)

Inspect and adjust

7.

Engine speed too low at maximum speed position of hand throttle.

(a)

Linkage or cable loose or disconnected.

(a)

Adjust or repair linkage.

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B.

BRAKES CAUSE CORRECTION

COMPLAINT

1.

Excessive pedal travel or pedal goes to floor consistently.

(a)

Low fluid level

(a)

Add fluid, bleed system, check for leaks. Refer to master cylinder. Repair or replace as required. Repair or replace as required.

(b) (c)

Hydraulic system. Drum brakes out of adjustment, worn. Loose or improper attachment of pedal, pedal support booster & master cylinder. Misaligned anchor plate.

(b) (c)

(d)

(d)

(e)

(e)

Refer misaligned disc brake anchor plate diagnosis.

2.

Brake pedal feels spongy when fully applied.

(a)

Low fluid level

(a)

Add fluid, bleed system, check for leaks. Adjust brakes. Adjust front wheel bearings Replace or tighten as required. Remove drum & check lining for proper adjustment.

(b) (c)

Brakes out of adjustment. Front wheel bearing out of adjustment. Disc brake caliper attachment loose. Worn or damaged selfadjusters.

(b) (c)

(d)

(d)

(e)

(e)

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B.

BRAKES (CONT.) CAUSE CORRECTION

COMPLAINT

3.

Noise at wheels when brakes are appliedsqueaks or chatter.

(a)

Worn or scored brake drums & lining or rotors & pads. On disc brakes- missing or damaged brake pad insulators Burrs or rust on caliper that would obstruct seating of shoe to caliper. Dirty, greased or glazed linings.

(a)

Inspect, repair or replace as required.

(b)

(b)

Replace disc brake pads.

(c)

(c)

Clean or deburr caliper.

(d)

(d)

Clean or replace.

4.

Brakes pull to one side.

(a)

Unequal air pressure in tires. Grease or fluid on lining.

(a)

Inflate tires to correct pressure. Clean, sand &/ or replace linings. Replace missing bolts. Tighten to proper torque.

(b)

(b)

(c)

Loose or missing disc brake caliper attaching bolts. Restricted brake lines or hoses.

(c)

(d)

(d)

Repair or replace as required.

5.

Brake warning light on. (a) Low fluid level (a) Add fluid, bleed system & check for leaks. Replace switch.

(b)

Worn or damaged brake warning switch. Worn or damaged master cylinder.

(b)

(c)

(c)

Perform master cylinder diagnosis test. Repair or replace as required.

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C.

PARK BRAKE CAUSE CORRECTION

COMPLAINT

1.

Parking brake will not hold.

(a)

Parking.brake cable out of adjustment. Rear brakes out of adjustment. Parking brake linkage, release lever,clevis & rachet binding.

(a)

Adjust parking brake cable. Adjust rear brakes.

(b)

(b)

(c)

(c)

Repair or replace linkage as reqd.

2.

Parking brake will not release or fully return.

(a)

Manual release brake control components binding or damaged. Parking brake linkage & cable binding. Worn or damaged rear brake components.

(a)

Repair or replace manual parking brake control.

(b)

(b)

Repair or replace as required. Check rear brake shoe retracting springs & parking brake levers. Repair as required. Adjust or repair.

(c)

(c)

3.

Parking brake lever hard to pull up.

(a)

Brake handle out of adjustment. Frozen or damaged brake cable.

(a)

(b)

(b)

Light taps with a mallet may free cable & brakes, other- wise apply warm air from a ground equipment heater.

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D.

CONVEYOR HYDRAULICS CAUSE CORRECTION

COMPLAINT

1.

The front & rear lift arms will not raise conveyor.

(a)

Low oil level due to leak in system.

(a)

Service hydraulic tank locate & repair leak. Recheck system Replace and/or adjust.

(b)

Hydraulic pump drive belt slipping or broken. Defective hydraulic pump Relief valve set too low. Lift control valve defective. Pump belt slipping. Internal valve leak. Internal cylinder leak. Low oil level in tank. Worn hydraulic pump. System relief valve too low. Relief valve leaking internally.

(b)

(c) (d) (e)

(c) (d) (e)

Repair or replace. Adjust or repair. Replace or repair.

2.

Conveyor raises too slowly.

(a) (b) (c) (d) (e) (f)

(a) (b) (c) (d) (e) (f)

Adjust. Repair or replace. Repair or replace. Add oil. Repair or replace. Adjust.

(g)

(g)

Repair or replace.

3.

Conveyor creeps down with control valve in the OFF position.

(a)

Internal leak in cylinder or valve.

(a)

Repair or replace.

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D.

CONVEYOR HYDRAULICS CAUSE CORRECTION

COMPLAINT

1.

Conveyor belt will not run in either direction, when controls are actuated.

(a) (b)

Defective control valve. Belt drive chain broken or too loose. Belt drive shaft key missing. Defective hydraulic motor. Optional shifter-brake interlock out of adjustment with parking brake.

(a) (b)

Repair or replace. Adjust or replace.

(c)

(c)

Replace.

(d) (e)

(d) (e)

Repair or replace. Adjust or replace.

2.

Forward belt speed too low.

(a) {b) (c) (d)

Low oil level in tank. Pump drive belt slipping. Loose conveyor belt. Too much load on conveyor &/or conveyor angle too steep.

(a) (b) (c) (d)

Add oil. Adjust. Adjust rear take-up. Basic capacity is 2000 lbs. At conveyor angles exceeding 15 , the capacity must be reduced below 2000 lbs. Adjust, lubricate, repair or replace.

(e)

Binding in belt drive or rollers.

(e)

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D.

CONVEYOR HYDRAULICS CAUSE CORRECTION

COMPLAINT

3.

Reverse belt speed too fast.

(a)

Belt drive motor holding valve out of adjustment.

(a)

Repair or replace.

4.

Belt will go forward only.

(a)

Belt drive motor holding valve out of adjustment. Relief valve set too low or defective.

(a)

Adjust or replace.

(b)

(b)

Adjust, repair or replace.

5.

Drive chain is noisy.

(a)

Chain is out of adjustment.

(a)

Adjust & lubricate.

6.

Belt does not track properly.

(a)

Rollers are out of adjustment.

(a)

Adjust.

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D.

CONVEYOR HYDRAULICS CAUSE CORRECTION

COMPLAINT

7.

Conveyor belt will not run in either direction when controls are actuated.

(a)

Defective control box, circuit or solenoid control valve. Optional shifter brake interlock out of adjustment with parking brake. Defective neutral/start switch or circuit breaker. Open wiring or stop button stuck in open circuit.

(a)

Repair or replace.

(b)

(b)

Adjust or replace.

(c)

(c)

Check by stopping & restarting engine. Inspect circuit & repair.

(d)

(d)

8.

Belt will not continue to run after push button is released.

(a)

Defective R1 or R2 belt control relay or open wiring.

(a)

Repair or replace.

9.

Belt will not stop when "stop" button is pushed.

(a)

Short to ground bypassing "STOP" button. Short circuit across ineffective "STOP" button.

(a)

Repair.

(b)

(b)

Repair or replace.

10.

Belt will only run forward.

(a)

Open electrical circuit or defective solenoid.

(a)

Repair or replace.

11.

Belt stops running although engine continues to run & stop button has not been pressed.

(a)

Defective control relay, solenoid or 15 ampere circuit breaker.

(a)

Replace

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E.

ELECTRICAL CAUSE CORRECTION

COMPLAINT

1.

Battery does not stay charged- engine starts O.K.

(a)

Worn or damaged battery.

(a)

Test battery, replace if necessary. Adjust or replace belt.

(b)

Loose or worn alternator belt. Worn or damaged wiring or cables. Alternator or regulator.

(b)

(c)

(c)

Clean, repair as required.

(d)

(d)

Perform general charging systems test. Repair or replace as required. Check other systems for current draw. Repair as required. Adjust or replace belt.

(e) 2. Alternator noisy

Other vehicle electrical systems.

(e)

(a)

Loose or worn alternator belt. Bent pulley flanges. Alternator defective.

(a)

(b) 3. Charge indicator gauge shows steady charge. (c)

(b) (c)

Replace pulley. Perform alternator tests. or replace as required. Check battery, replace if necessary. Assure good ground.

(a)

Worn or damaged battery.

(a)

(b)

Poor regulator ground.

(b)

(c)

Loose wiring connection.

(c)

Tighten all wiring connections. Perform general charging systems test.

(d)

Alternator or regulator.

(d)

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E.

ELECTRICAL CAUSE CORRECTION

COMPLAINT

4.

Charge indicator gauge shows discharge.

(a)

Loose or worn alternator belt. Warn or damaged wiring.

(a)

Adjust or replace belt.

(b)

(b)

Check battery to alternator wiring for ground or open Repair if necessary. Perform general charging system test. Repair or replace as required.

(c)

Alternator or regulator.

(c)

(d)

Charge indicator gauge wiring & connections. Worn or damaged gauge. Other vehicle electrical systems malfunction.

(d)

Repair as required.

(e) (f)

(e) (f)

Replace gauge. Check & repair as required.

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III.

REMOVAL/INSTALLATION The following procedures for removal and installation of vehicle components outline the steps and precautions to take when removing items for replacement or repair. WARNING: ALWAYS REVIEW SAFETY PRECAUTIONS PRIOR TO PERFORMING WORK ON THIS EQUIPMENT. A. ENGINE/TRANSMISSION REMOVAL 1. 2. Disconnect battery. Remove conveyor assembly (see specific section). Remove engine hood. (a) (b) (c) 3. Unlatch hood. Remove attaching hardware, at frame and hood, for hood support. Remove attaching hardware at hood hinge point.

Remove exhaust system. (a) (b) (c) Disconnect flange at exhaust manifold. Disconnect tail pipe at hanger at rear of frame. Remove muffler and connecting exhaust pipe.

4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Disconnect drive shaft at transmission universal. Disconnect water temperature connections at sender. Disconnect transmission selector cable at transmission selector lever. Disconnect battery and alternator wiring. Disconnect wiring at ignition coil and oil pressure sender. Disconnect fuel line at fuel pump. Drain radiator and engine block coolant system. Disconnect coolant hoses to engine at radiator. Disconnect transmission oil cooler lines at radiator. Remove radiator.

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III.

REMOVAL/INSTALLATION A. ENGINE/TRANSMISSION REMOVAL (CONT) 14. 15. 16. 17. Disconnect speedometer cable at transmission. Attach lifting sling to engine. Remove engine frame mounting bolts. Remove hydraulic pump and bracket (and alternator) and swing aside (do not disconnect oil lines). Hoist engine slowly, insuring all lines, cables, wires, etc. are disconnected, and clear as engine is raised.

18.

B.

ENGINE/TRANSMISSION INSTALLATION Installation of engine/transmission is performed by reversing the order of steps A.1 through A.13, preceding. WARNING: DO NOT CONNECT BATTERY UNTIL ALL ALTERNATOR WIRING IS CONNECTED. LEAD-ACID BATTERIES GENERATE EXPLOSIVE GASES. KEEP SPARKS, FLAME, AND SMOKING MATERIALS AWAY FROM BATTERIES. DO NOT SMOKE IN THE VICINITY OF THE BATTERY. DO NOT SHORT BATTERY TERMINALS. BEFORE REMOVING OR INSTALLING BATTERY REMOVE METAL BRACKETS, WRISTWATCH BANDS, RINGS, ETC. POSITIVE MUST BE DISCONNECTED FIRST TO PREVENT SPARKS FROM ACCIDENTAL GROUNDING. ALWAYS WEAR EYE PROTECTION AROUND BATTERIES. WASH HANDS OR CLOTHING IMMEDIATELY IF ACCIDENTLY IN CONTACT WITH ELECTROLYTE. CAUTION: INSURE OIL, TRANSMISSION OIL AND COOLANT SYSTEM HAVE BEEN SERVICED BEFORE STARTING ENGINE. ADJUST TRANSMISSION SELECTOR CONTROLS FOR PROPER DETENT OPERATION. INSURE THAT FAN IS FREE TO ROTATE NOTE: ADJUST ALTERNATOR BELT FOR PROPER TENSION. NOTE: CHECK FOR PROPER ENGINE OIL PRESSURE DURING INITIAL ENGINE RUN.

C.

REAR AXLE REMOVAL 1. Jack up the rear frame of the mobile conveyor and place jack stands under the frame forward of the rear axle. Disconnect drive shaft at rear axle universal. Disconnect hydraulic brake line mounted on rear axle.

2. 3.

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CAUTION: WIPE CONNECTION CLEAN BEFORE OPENING BRAKE SYSTEM. CAUTION: CAP OR PLUG ALL OPEN PORTS OR LINES NOTE: USE BACK UP WRENCHES ON ALL MATING PARTS.

4.

Use a transmission jack to support the axle. WARNING: DO NOT LIFT VEHICLE OFF JACK STANDS.

5. 6.

Remove U-bolts attaching axle to frame. Lower transmission jack and roll axle out to the rear.

D.

REAR AXLE INSTALLATION Installation of the rear axle is performed by reversing the order of steps C.1 through C.6, preceding. WARNING: BLEED AIR FROM BRAKE SYSTEM UPON COMPLETION OF INSTALLATION.

E.

FRONT AXLE REMOVAL 1. Jack up the front frame of the mobile conveyor and place jack stands under the frame rearward of the front axle. Disconnect hydraulic brake lines from front disc brake assemblies. CAUTION: WIPE CONNECTION CLEAN BEFORE OPENING BRAKE SYSTEM. CAUTION: CAP OR PLUG ALL OPEN PORTS OR LINES. NOTE: USE BACK UP WRENCHES ON ALL MATING PARTS. 3. Use a transmission jack to support the axle. DO NOT LIFT VEHICLE FRAME OFF JACK STANDS. 4. 5. Remove U-bolts attaching axle to frame. Lower transmission jack and roll axle out to the rear.

2.

F.

FRONT AXLE INSTALLATION Installation of the front axle is performed by reversing the order steps E.1 through E.6, preceding.

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III.

REMOVAL/INSTALLATION F. FRONT AXLE INSTALLATION (CONT) WARNING: BLEED AIR FROM BRAKE SYSTEM UPON COMPLETION OF INSTALLATION.

G.

CONVEYOR REMOVAL 1. Raise conveyor hydraulically, both front and rear, high enough to remove hardware from pivot points. WARNING: ALWAYS USE SAFETY PROP WHEN WORKING UNDER CONVEYOR. 2. Block up rear end of conveyor between vehicle frame and conveyor cross member, or support with sling and hoist. Disconnect electrical control cable (between Frame and conveyor when equipped) at terminal block in enclosure mounted on cross member at rear of conveyor. Disconnect hydraulic lines (between rear lift frame and conveyor) at hose to tube connection at rear lift frame. CAUTION: WIPE CONNECTION CLEAN BEFORE OPENING BRAKE SYSTEM. CAUTION: CAP OR PLUG ALL OPEN PORTS OR LINES. NOTE: USE BACK UP WRENCHES ON ALL MATING PARTS. 5. 6. 7. Loosen nut on cam follower pivot bolt, and allow the follower plate to swing downward. Remove pivot bolt, nut and washer from rear lift frame and conveyor pivot. Using proper lifting gear of 2,000 pound minimum capacity, lift conveyor from pivot attaching points. WARNING: HOIST AND SLING CAPACITY SHALL BE 2,000 POUNDS MINIMUM.

3.

4.

H.

CONVEYOR INSTALLATION Installation of conveyor is performed by reversing the order of steps G.1 through G.7, preceding.

I.

BELT DRIVE MOTOR REMOVAL WARNING: ALWAYS USE SAFETY PROP WHEN WORKING UNDER CONVEYOR. WARNING: KEEP HANDS AND CLOTHING AWAY FROM CONVEYOR BELT AND BELT DRIVE WHILE BELT IS IN MOTION.

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1.

Drive belt slowly, until drive chain master link is visible in the area just behind the drive pulley. WARNING: DO NOT CONNECT BATTERY UNTIL ALL ALTERNATOR WIRING IS CONNECTED. LEAD-ACID BATTERIES GENERATE EXPLOSIVE GASES. KEEP SPARKS, FLAME, AND SMOKING MATERIALS AWAY FROM BATTERIES. DO NOT SMOKE IN THE VICINITY OF THE BATTERY. DO NOT SHORT BATTERY TERMINALS. BEFORE REMOVING OR INSTALLING BATTERY REMOVE METAL BRACKETS, WRISTWATCH BANDS, RINGS, ETC. POSITIVE MUST BE DISCONNECTED FIRST TO PREVENT SPARKS FROM ACCIDENTAL GROUNDING. ALWAYS WEAR EYE PROTECTION AROUND BATTERIES. WASH HANDS OR CLOTHING IMMEDIATELY IF ACCIDENTLY IN CONTACT WITH ELECTROLYTE.

2. 3.

Stop belt and engine and disconnect battery. Slacken chain. (a) (b) Loosen four (4) bolts on face of motor mounting plate. Turn adjusting screw (located on rear face of take-up) clockwise to slacken chain.

4.

Remove drive chain. (a) (b) Remove chain master link. Disengage chain from drive sprocket.

5.

Disconnect hydraulic lines from motor. CAUTION: WIPE ALL CONNECTIONS CLEAN PRIOR TO OPENING SYSTEM CAUTION: CAP OR PLUG ALL OPEN PORTS AND LINES. NOTE: USE BACK UP WRENCHES ON ALL MATING FITTINGS.

6.

Remove hydraulic motor. (a) (b) Remove motor mounting bolts. Pull motor straight out. Sprocket will pass through motor mounting hole.

J.

CONVEYOR BELT DRIVE MOTOR INSTALLATION Installation of the drive motor is performed by reversing the order of steps I.l through I.5, preceding.

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III.

REMOVAL/INSTALLATION (CONT): K. CONVEYOR BELT CONTROL VALVE REMOVAL WARNING: ALWAYS USE SAFETY PROP WHEN WORKING UNDER CONVEYOR. 1. 2. 3. Raise Conveyor. Position conveyor support prop. Tag and disconnect hydraulic lines. CAUTION: WIPE ALL CONNECTIONS CLEAN Prior TO OPENING SYSTEM CAUTION: CAP OR PLUG ALL OPEN PORTS. NOTE: USE BACK UP WRENCHES ON ALL MATING FITTINGS. 4. 5. Tag and Disconnect solenoid wires (electric belt control only). Remove hardware and valve.

L.

CONVEYOR BELT CONTROL VALVE INSTALLATION Installation of the control valve is performed by reversing the order of steps K.1 through K.5, preceding.

M.

HOLDING VALVE REMOVAL WARNING: Disconnecting Hydraulic LINES FROM A CONVEYOR CYLINDER HOLDING VALVE Will RESULT IN LOWERING OF THE CONVEYOR NOT OTHERWISE SUPPORTED.

1.

Tag and disconnect hydraulic hoses and tube fittings at the valve. CAUTION: WIPE ALL CONNECTIONS CLEAN PRIOR TO OPENING SYSTEM. CAUTION: CAP OR PLUG ALL OPEN PORTS AND LINES. NOTE: USE BACK UP WRENCHES ON ALL MATING FITTINGS. WARNING: USE SAFETY PROP WHENEVER WORKING UNDER CONVEYOR.

2.

If removing the front lift cylinder holding valve, raise the front of the conveyor and support with the safety prop. If removing the rear lift cylinder holding valve, raise and block up the rear of the conveyor.

3.

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4.

Remove attaching hardware and valve.

N.

HOLDING VALVE INSTALLATION Installation of the holding valve is performed by reversing the order of steps M.1 and M.2, preceding.

0.

LIFT CYLINDERS CONTROL VALVE REMOVAL 1. 2. 3. Remove seat and seat plate. Remove cotter pins from hand lever to valve linkage and remove hand levers. Tag and disconnect hydraulic tube fittings. CAUTION: WIPE ALL CONNECTIONS CLEAN PRIOR TO OPENING SYSTEM. CAUTION: CAP OR PLUG ALL OPEN PORTS AND LINES. NOTE: USE BACK UP WRENCHES ON ALL MATING FITTINGS. 4. Remove attaching hardware and valve.

P.

LIFT CYLINDERS CONTROL VALVE INSTALLATION Installation of the control valve is performed by reversing the order of Steps 01 through 03, preceding. WARNING: STAND CLEAR OF CONVEYOR UNTIL AIR IS BLED FROM SYSTEM. CAUTION: DO NOT OVER TORQUE ATTACHMENT HARDWARE. OVER TORQUING MAY DISTORT VALVE BODY AND CAUSE BINDING OF VALVE SPOOLS. PERFORM OPERATIONAL CHECK OF HYDRAULIC SYSTEM.

Q.

FRONT LIFT CYLINDER REMOVAL 1. Elevate front of belt conveyor either hydraulically or with a hoist and sling (while holding lift cylinder control valve open). Position conveyor support prop under conveyor lift arms (cylinder attaching point). Disconnect hydraulic hoses from holding valve (mounted on cylinder). CAUTION: WIPE ALL CONNECTIONS CLEAN PRIOR TO OPENING SYSTEM.

2. 3.

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III.

REMOVAL/INSTALLATION Q. FRONT LIFT CYLINDER REMOVAL (CONT): CAUTION: CAP OR PLUG ALL OPEN PORTS AND LINES. NOTE: USE BACK UP WRENCHES ON ALL MATING FITTINGS. WARNING: DISCONNECTING HYDRAULIC LINES FROM A CONVEYOR LIFT CYLINDER HOLDING VALVE WILL RESULT IN LOWERING OF THE CONVEYOR IF NOT OTHERWISE SUPPORTED 4. 5. 6. 7. Disconnect hydraulic tube fittings at each end of cylinder and remove holding valve. Remove nut and pivot bolt from cylinder rod end. Remove nut and pivot bolt from cylinder base end. Remove cylinder with portable hoist or equal.

WARNING: DO NOT BUMP CONVEYOR OR SUPPORT FRAME WITH HOIST OR CYLINDER AXLE REMOVING FRONT LIFT CYLINDER. R. LIFT CYLINDER INSTALLATION 1. Using a portable hoist or equal, position cylinder with cylinder base mount aligned with frame mounting bracket. WARNING: DO NOT BUMP CONVEYOR OR SUPPORT FRAME WITH HOIST OR CYLINDER WHILE INSTALLING FRONT LIFT CYLINDER. 2. 3. 4. 5. 6. Install bolt and nut in cylinder base mounting hole. Replace holding valve and connect hydraulic line to base of cylinder. Start engine and hydraulically extend cylinder rod to lift frame attaching point. Install bolt and nut. Connect hydraulic line to rod end of cylinder. WARNING: STAND CLEAR OF CONVEYOR UNTIL AIR HAS BEEN BLED FROM SYSTEM. 7. Start engine, raise conveyor and stow conveyor support prop.

S.

LIFT CYLINDER REMOVAL 1. Raise rear of conveyor and block up lift frame to prevent it from lowering.

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2.

Tag and disconnect hydraulic hoses to holding valve. CAUTION: WIPE ALL CONNECTIONS CLEAN PRIOR TO OPENING SYSTEM. CAUTION: CAP OR PLUG ALL OPEN PORTS AND LINES. NOTE: USE BACK UP WRENCHES ON ALL MATING FITTINGS.

3. 4. 5. 6.

Disconnect hydraulic lines at each end of cylinder and remove holding valve. Remove nut and bolt from rod end of cylinder. Remove nut and bolt from base of cylinder. Remove cylinder.

T.

REAR LIFT CYLINDER INSTALLATION Installation of the rear lift cylinder is performed by reversing the order of Steps Sl through S6, preceding. WARNING: STAND CLEAR OF CONVEYOR UNTIL AIR HAS BEEN BLED FROM SYSTEM.

U.

HYDRAULIC PUMP REMOVAL 1. Raise front of conveyor and position conveyor support prop under lift frame cross member.

WARNING: ALWAYS USE SAFETY PROP WHEN WORKING UNDER CONVEYOR. 2. 3. Raise engine cover. Disconnect hydraulic lines from pump. CAUTION: WIPE ALL CONNECTIONS CLEAN PRIOR TO OPENING SYSTEM. CAUTION: CAP OR PLUG ALL OPEN PORTS AND LINES. NOTE: USE BACK UP WRENCHES ON ALL MATING FITTINGS. 4. 5. 6. Loosen pump mounting hardware and remove belt from pulley. Remove pulley mounted on pump shaft with set screw. Remove mounting hardware (2 bolts), spacer and pump.

V.

HYDRAULIC PUMP INSTALLATION 1. Installation of the hydraulic pump is performed by reversing the order of steps Ul through

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III.

REMOVAL/INSTALLATION V. HYDRAULIC PUMP INSTALLATION (CONT): U6, preceding. 2. Adjust hydraulic pump drive belt tension.

W.

ALTERNATOR REMOVAL WARNING: DO NOT CONNECT BATTERY UNTIL ALL ALTERNATOR WIRING IS CONNECTED. LEAD-ACID BATTERIES GENERATE EXPLOSIVE GASES. KEEP SPARKS, FLAME, AND SMOKING MATERIALS AWAY FROM BATTERIES. DO NOT SMOKE IN THE VICINITY OF THE BATTERY. DO NOT SHORT BATTERY TERMINALS. BEFORE REMOVING OR INSTALLING BATTERY REMOVE METAL BRACKETS, WRISTWATCH BANDS, RINGS, ETC. POSITIVE MUST BE DISCONNECTED FIRST TO PREVENT SPARKS FROM ACCIDENTAL GROUNDING. ALWAYS WEAR EYE PROTECTION AROUND BATTERIES. WASH HANDS OR CLOTHING IMMEDIATELY IF ACCIDENTLY IN CONTACT WITH ELECTROLYTE. 1. 2. Remove battery ground cable. Disconnect wiring from: (a) (b) c) (d) Alternator Input. Auxiliary Field Terminal Ground Terminal CAUTION: IF FIELD TERMINAL (WIRE) IS GROUNDED WITH THE BATTERY STILL CONNECTED. THE VOLTAGE REGULATOR WILL BE BURNED OUT. 3. 4. 5. 6. Remove adjusting bolt at top flange of alternator housing. Loosen pivot bolt at bottom flange of alternator housing. Rotate alternator towards engine and remove drive belt. Remove pivot bolt and alternator.

X.

INSTALLATION 1. 2. Insure battery ground cable is disconnected. Position alternator at mount and install pivot bolt, washer and nut hand tight.

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3. 4.

Install alternator drive belt. If worn or cracked, install a new belt. Install adjusting bolt finger tight through slotted adjusting brace and through hole in alternator flange. Adjust alternator drive belt tension. Connect all disconnected alternator wires at their correct positions. WARNING: DO NOT CONNECT BATTERY UNTIL ALL ALTERNATOR WIRING IS CONNECTED. LEAD-ACID BATTERIES GENERATE EXPLOSIVE GASES. KEEP SPARKS, FLAME, AND SMOKING MATERIALS AWAY FROM BATTERIES. DO NOT SMOKE IN THE VICINITY OF THE BATTERY. DO NOT SHORT BATTERY TERMINALS. BEFORE REMOVING OR INSTALLING BATTERY REMOVE METAL BRACKETS, WRISTWATCH BANDS, RINGS, ETC. POSITIVE MUST BE DISCONNECTED FIRST TO PREVENT SPARKS FROM ACCIDENTAL GROUNDING. ALWAYS WEAR EYE PROTECTION AROUND BATTERIES. WASH HANDS OR CLOTHING IMMEDIATELY IF ACCIDENTLY IN CONTACT WITH ELECTROLYTE.

5. 6.

7.

Connect battery.

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IV.

BELT TRACKING INSTRUCTIONS The following procedure is offered as a guide for aligning the cargo belt to the center of the rollers in a minimum length of time. WARNING: KEEP HANDS AND CLOTHING AWAY FROM ROLLERS WHILE CONVEYOR IS RUNNING.

Figure 1 A. DISCUSSION Basic fundamentals of belt alignment are as follows: 1. Moving the rear idler roller to the rear on one side with the jack screw tightens that side of the belt, causing the belt to move to the other side. Moving the rear idler roller to the front on one side with the jack screw loosens that side of the belt, causing the belt to move to that side. 2. Moving a crowder roller end toward the large end roller will tighten that side of the belt and force the belt to the other side of the end roller. Moving a crowder roller end toward the center of the conveyor will loosen that side of the belt and allow the belt to move to that side of the end roller. These fundamentals hold true on both ends of the conveyor. Adjust the front crowder roller only when the belt is running in the reverse direction. Adjust the rear crowder roller only when the belt is running forward. 3. It is necessary to work from end to end when tracking a belt as adjustment at one end will affect the other end. When tracking, make small adjustments and allow the belt to run and settle in between adjustments. Normal time for an experienced mechanic to track a belt is 45 minutes to one hour.

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BELT TRACKING INSTRUCTIONS B. PROCEDURE NOTE: REFER TO SAFETY CHAPTER PRIOR TO PERFORMING ANY MAINTENANCE TASK ON THIS EQUIPMENT AND OBSERVE ALL APPLICABLE PRECAUTIONS. 1. 2. Check the roller end bearings for failure. Check the front driver and rear idler roller bearings and collar set screws. There are two set screws in a collar that positions each roller in the frame. Insure that the rollers are centered and that the set screws are tight. If either roller is not centered, loosen the set screws, pry the roller into position and secure the set screws. See figure 2 for locations.

Figure 2

3.

Raise the front of the conveyor and insure that the front crowder roller is centered and that the bearing collar set screws are tight. Make any necessary adjustments as in step 2 above. Raise the rear of the conveyor and insure that the rear crowder roller is centered and that the bearing collar set screws are tight. Make any necessary adjustments as in step 2 above. Raise the front of the conveyor to approximately 4 feet high and the rear to about 3 feet, 6 inches high. Position the front crowder in its adjusting slots as shown in figure 3. Figure 3

4.

5.

6.

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7.

Position the rear crowder roller in its adjusting slots as shown in figure 4. Adjust the rear idler roller at the jack screw nuts to tension the belt. Adjust the rear idler roller so that it is equidistant from the rear end of the conveyor on both sides. Correct tension is achieved when 4 to 6 inches of the belt can be rolled up at the center of the conveyor. (See figure 5) Figure 4 WARNING: KEEP HANDS AND CLOTHING AWAY FROM ROLLERS WHILE CONVEYOR IS RUNNING.

8.

Figure 5

9.

With the belt running in the reverse direction, observe the position of the belt at the front of the conveyor and correct as follows: (a) To adjust belt in direction shown in figure 6, move left side (as viewed from rear) of the front crowder roller toward the front driver roller, both bolts, until the belt tracks on center. Move 1/8 inch at a time.

Figure 6

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IV.

BELT TRACKING INSTRUCTIONS B. PROCEDURE (CONT) WARNING: STOP CONVEYOR ANY TIME THE LEFT SIDE FRONT CROWDER ROLLER IS ADJUSTED! (b) To adjust belt in opposite direction, move right side (as viewed from rear) of the front crowder roller forward the front driver roller, both bolts, until the belt tracks on center. Move 1/8 inch at a time.

Figure 7

(c)

To adjust belt in direction shown in figure 7, move right side (as viewed from rear) of the front crowder roller toward the front driver roller, until the belt tracks on center. Move 1/8 inch at a time. To adjust belt in opposite direction, move left side (as viewed from rear) of the front crowder roller toward the front driver roller, until the belt tracks on center. Move 1/8 inch at a time.

(d)

10. 11.

Continue to make adjustments until the belt runs at the center of the front roller. Continue to run the conveyor in reverse while adjusting the rear jack screw nuts to center the belt on the rear idler roller. Repeat steps 9 through 11 until both ends of the belt are centered and running true, then shift belt into forward direction. Adjust the rear crowder roller to center the belt on the rear idler roller. When belt is running on center, reverse belt direction and observe alignment. If belt alignment is still satisfactory in reverse, Shift belt direction back to forward. The belt should stay within 1/2 inch in both directions at both ends. If it does not, go back to step 9 and repeat steps as often as necessary to track belt. Once belt is tracked, shut off motor and securely tighten all adjusting bolts.

12.

13. 14.

15.

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V.

SYSTEM PRESSURE SETTINGS AND METHODS A. Adjust the following valves in the order in which they are listed. All pressure checks and settings are to be made when the engine is at normal operating temperature, choke open and at normal idle speed. WARNING: ALWAYS REVIEW SAFETY PRECAUTIONS PRIOR TO PERFORMING WORK ON THIS EQUIPMENT. B. If not already installed, install a 0-3000 PSI hydraulic gauge in the tee fitting which is located behind the left front wheel and approximately six inches in front of the axle. 1. Main two-lever control valve. (a) (b) Pressure relief valve setting is 1500 PSI. The main system pressure valve is located in the left side of the two-lever valve under the seat. While observing the pressure gauge, move the rear cylinder lever down and hold in the down position, dead-heading the pump. Pressure should read 1500 +50 PSI. To adjust, turn the valve screw clockwise to raise pressure or counter-clockwise to reduce pressure. Access is provided by hole in the plate beside the valve levers. Loosening or tightening the lockout may require removing the seat and plate. 2. Pilot Operated Check Valve, Reverse Direction Only (a) (b) Pressure relief valve setting is 850-900 PSI. The blue Racine holding valve is approximately 4" x 5" x 1.5" in size and is located under the front of the conveyor. While observing the pressure gauge, run the conveyor in the reverse direction. Pressure should read 850-900 PSI. WARNING: ALWAYS USE SAFETY PROP WHEN WORKING UNDER CONVEYOR. To adjust, turn off the engine and remove the allen socket plug from the rear of the valve. Insert the allen wrench into the valve and turn clockwise to raise pressure or counter-clockwise to reduce pressure. One full turn will change the pressure setting by approximately 75 PSI. Replace the plug and recheck the pressure setting. 3. Pressure Relief Valve, Front Cylinder Down (a) (b) Pressure relief valve setting is 900 +50 PSI. The blue Racine relief valve is approximately 3" x 3" x 1.5" in size and is located under the seat. Access can be gained through the opening in the left frame rail beside the seat.

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V.

SYSTEM PRESSURE SETTINGS AND METHODS 3. Pressure Relief Valve, Front Cylinder Down (Cont) (c) While observing the pressure gauge, lower the front of the conveyor from the fully raised position. Pressure should read 900 +50 PSI. To adjust, turn the knob on the valve clockwise to raise pressure or counterclockwise to reduce pressure.

(d)

4.

Pressure Relief Valve, Steering (a) (b) Pressure relief valve setting is 1000 +50 PSI. The blue Racine relief valve is approximately 3" x 3" x l.5" in size and is located behind the left front wheel against the left frame rail. While observing the pressure gauge, turn the steering wheel to full left and hold. Pressure should read 1000 +50 PSI. To adjust, turn the knob on the valve clockwise to raise pressure or counterclockwise to reduce pressure.

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VI.

TRANSMISSION LINKAGE ADJUSTMENT NOTE: THE TRANSMISSION LINKAGE MUST BE PROPERLY ADJUSTED TO PREVENT DAMAGE AND MAINTAIN SAFE OPERATION. A. B. C. Place shifter in neutral position. Remove swivel from transmission shift lever and back off lockout from swivel. Place transmission in neutral. 1. 2. Rotate shift lever fully counter clockwise. Rotate shift lever clockwise to second position from full counter clockwise for 2-speed transmission (gasoline engine) or third position from full counter clockwise for three 3speed transmission (diesel engine).

D.

Tighten or loosen swivel on turn at a time until it is perfectly aligned with the hole in the shift lever, then reinstall swivel in shift lever. Tighten lockout until it is firmly engaged with swivel.

E.

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VII.

PARKING BRAKE ADJUSTMENT A. DISCUSSION When properly adjusted, the parking brake will prevent the loader from rolling when parked on a 15% grade. Since the parking brake is on the drive shaft and brakes through the reduction in the differential, engaging a properly adjusted parking brake should not require an excessive amount of force, however some slight resistance will be present when engaging. B. PROCEDURE 1. 2. 3. 4. If parking brake hand lever is equipped with a locking set screw, loosen the set screw. To tighten parking brake, turn knurled knob at the end of the hand lever clockwise. To loosen parking brake, turn knurled knob at the end of the hand lever counter-clockwise. If parking brake hand lever is equipped with a locking set screw, tighten the set screw.

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VIII.

ACCELERATOR CABLE AND MECHANICAL MODULATOR ADJUSTMENT A. ACCELERATOR

1.

Ensure that the throttle pull springs and throttle pull rod are properly installed and the accelerator cable is attached to the accelerator pedal and the throttle. Loosen the fastener(s) on the accelerator linkage clamp. Position the accelerator cable such that the accelerator pedal is all he way up and the throttle pull springs are relaxed. Tighten the fastener(s) on the accelerator linkage clamp.

2. 3.

B.

MODULATOR (CUMMINS/ONAN AND PERKINS 4.135) NOTE: MODULATORS ELIMINATED IN ALL NEW BELTLOADERS EFFECTIVE MARCH 1999. 1. 2. 3. With the accelerator cable properly adjusted, fully depress the accelerator pedal. Measure the cable travel. Travel should be 1.5 inches. Adjust as necessary by loosening the fasteners on the cable clamp, positioning the cable and tightening the fasteners.

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IX.

INSTRUCTIONS FOR JACKING AND POSITIONING VEHICLE WARNING: IMPROPER JACKING CAN RESULT IN DAMAGE TO THE LOADER AND/OR PERSONAL INJURY AND POSSIBLE DEATH. A. B. C. Engage the parking brake and chock the wheels. Position jack under front or rear bumper and raise the loader. Position jack stands under the bumper and lower the loader onto the jack stands.

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X.

HOOF GOVERNOR ADJUSTMENT (GASOLINE ENGINE) A. ADJUSTING SCREW ADJUSTMENT 1. Remove welch plug covering the adjusting screw by drilling the plug with a 1/16-inch drill. Insert a 1/16-inch rod in drilled hole and pry off welch plug. Remove brass lock washer. Use an engine tachometer to read engine speed at full throttle. Adjust speed to 2400 to 2600 R.P.M. NOTE: USE A SCREWDRIVER TO TURN THE ADJUSTING SCREW AS NEEDED ON THE HOUSING TO INCREASE OR DECREASE ENGINE SPEED. 4. Seal adjusting screw by replacing the brass lock washer in the screw slot and reinstall the welch plug. Tap lightly using a flat punch.

2. 3.

B.

SECONDARY SCREW ADJUSTMENT. The secondary adjusting screw in this governor has been factory set to cover a wide range of engine speeds. In setting governor to desired road or engine speed, use the main adjusting screw only. If governor control is too sharp or not sharp enough, adjust using instructions below. NOTE: ONLY IN RARE INSTANCES WILL THE SECONDARY ADJUSTMENT NEED TO BE CHANGED. 1. Remove welch plug covering the secondary adjusting screw by drilling the plug with a 1/ 16-inch drill. Insert a 1/16-inch rod in drilled hole and pry off welch plug. If governor control is too sharp, causing surging or hunting, turn the secondary adjusting screw clockwise 1/4 turn at a time. NOTE: IT WILL BE NECESSARY TO TURN THE MAIN ADJUSTING SCREW COUNTER-Clockwise APPROXIMATELY ONE TURN TO COMPENSATE FOR EVERY 1/4 TURN OF CLOCKWISE SECONDARY SCREW ADJUSTMENT. 3. If governor control is not sharp enough, causing too great a variation in speed between load and no-load conditions, turn the secondary adjusting screw counter-clockwise 1/4 turn at a time. NOTE: IT WILL BE NECESSARY TO TURN THE MAIN ADJUSTING SCREW CLOCKWISE APPROXIMATELY ONE TURN TO COMPENSATE FOR EVERY 1/4 TURN OF COUNTER-CLOCKWISE SECONDARY SCREW ADJUSTMENT. 4. Seal secondary adjusting screw by replacing the brass lock washer in the screw slot and reinstall the welch plug. Tap lightly using a flat punch.

2.

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X.

HOOF GOVERNOR ADJUSTMENT (GASOLINE ENGINE) B. SECONDARY SCREW ADJUSTMENT. (CONT) CAUTION: TOO SHARP A BLOW TO THE WELCH PLUG MAY UPSET THE SECONDARY ADJUSTMENT SCREW ADJUSTMENT.

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