Home

80-743 - Allied Systems Company

1. Fig 6 4 Fill Cap Location The oil level should be checked with the hoist cylinder ex tendeded down The oil level should be at or near the H high mark on the dipstick Fill with approved hydraulic fluid as required see Lubricant Specifications Chart page 6 4 Do not overfill Engine Coolant Level Daily inspection of the coolant level is recommended Cooling systems using anti aeration baffles restrict vi sual observation of the true coolant level Although the coolant can be seen the system may not be full To gain a true fill add water slowly up to the bottom of the fill neck and allow a 30 second settling period Remember to compensate for the loss of antifreeze when adding water WARNING Never remove the radiator cap if the engine is hot The coolant will be under pres sure and could flash to steam with explosive force causing severe burns Remove the radia tor cap only when the engine is cool NOTE If the engine is hot the coolant will be higher than when it is cold Inspect the radiator daily for restriction caused by leaves paper or bent fins Inspect the radia tor cap houses and connectors for any signs of leakage or damage 6 11 Alied Wagner E Accumulator The pre charge needs to be checked periodically If the accumulator needs to be recharged fill with pure dry nitrog
2. 1 6 457mm Ground Clearance Differential 1 8 508mm H Turning Radius Outside Bucket 27 10 8484mm J Turning Radius Centerline Mach 19 0 5791mm Maximum Dump Height esses 4 2 1270mm L Maximum Height in Dump Position 17 8 5385mm OPTIONAL EQUIPMENT Standard and special options available Contact your Wagner dealer for details Weights and Functions Unit Weight Hydroflation 83 400 Ibs 37 800kg Bogie End Hydroflation 49 200 Ibs 22 300kg Chassis End Hydroflation 34 200 Ibs 15 500kg Dump Angle at Maximum Height eene 60 Bucket Push amp Carry Capacity CHD 60 cu yd 45 8cu m Bucket Lift amp Carry Capacity CHD 30 cu yd 22 9 cu m Bucket Push amp Carry Capacity CD 30 cu yd 22 9 cu m Bucket Lift amp Carry Capacity CD 15 cu yd 11 4 cu m fme 38 each way eroi M EE 15 each way Maximum Bucket Forward 78 Silde Tilt Optional 6 each way from horizontal 1 6 General Section 1 Air Intake Power Unit Engine
3. 6 11 2 6 11 Before Starting 6 11 After Starting 6 12 Maintenance amp Lubrication Points 6 13 6 14 Operator 6 14 ENOM 6 14 Transmission 6 14 Wet Disk Brake 6 14 Hydraulic System sss 6 15 Electrical 6 15 6 15 Maintenance Specifications s 6 16 Hydraulic Pressure Relief Settings 6 16 Wheel Lug 2 6 16 Component Capacities amp Lubrications 6 16 Tire Inflation 6 16 6 16 Recomended Overhaul Schedule 6 17 Recomended Drivetrain Overhaul Intervals 6 17 Section 1 General Figure 1 1 Wagner Dozer 1 1 Introduction This manual is your guide to correct operation of the Wag ner Dozer series Become familiar with it understand it and use it Read all instructions carefully prior to operation They will help you understand the unit its capabilities and its limitations As an operator it s
4. COLD HAND THROTTLE FRESH START THROTTLE UP DOWN CLUTCH AIR f N T 9 Ed as Io y 22 23 24 25 Fig 3 6 Lower Left Console Controls Items 22 25 22 Cold Start Control This control supplies a measured amount of ether to the intake manifold to aid cold engine starting 23 24 25 Hand Throttle Over rides foot throttle To engage flip switch into the on position Adjust RPM s up or down using adjacent switch NOTE For engine warm up only Declutch Control If the control is ON the declutch system automatically shifts the transmission into neutral when you apply the service brakes This allows you to perform all hydraulic functions at any rom smoothly without causing con verter stall or other unnecessary strains on the brake or drivetrain components If downgrades are encountered the control may be turned to the OFF position and the transmission will remain in gear when the brakes are applied This control should be left in the ON position for normal operations Fresh Air Cab Pressurizer Brings filtered fresh air from outside into the cab 3 4 Implement Controls 27 MM of f b BUCKET P FLOAT A EX 5 OPTION all 9 gt J DUMP ROLL BACK LH TILT RH TILT JL HOIST V UP Fig 3 7 Implement Controls Items 26 27 3 4 26 27 3 5 28 29 30 Instruments a
5. See Lubricant Specifications Page 6 4 Some engines require additional coolant treatment See engine Operation and Maintenance Manual for specific information NOTE The specifications shown is this manual are based on information available at the time of publication and are subject to change without notice or obligation 6 16 Maintenance and Lubrication section 6 6 16 Recommended Overhaul Schedule To maximize efficiency and minimize downtime and costly failures Allied Systems Company recommends the follow ing overhaul chart to be used When followed closely your equipment will last longer with less unexpected downtime Contact your local Wagner dealer for Must do Kits including all the bearings seals and gaskets necessary to overhaul your drivetrain components or allow your dealer to overhaul the components for you They are authorized to overhaul and test your components Extreme duty is defined as continuous dozing on slopes or in either poor or excellent traction conditions An example of poor traction conditions would be pine chips where an ex ample of an excellent traction condition would be hog fuel It is recommended that some components be overhauled at the same time even if they might have some time before their required rebuild to minimize downtime Many components may have to be removed in order to gain access to others so the parts should all be rebuilt together This will save you from ha
6. Alied Wagner 101 FM BL Joo c ccc 36 WIPER WIPER FAN LIGHT LIGHT LIGHT LIGHT LIGHT REAR FRONT DEF STROBE AUX AUX REAR FRONT DIMMER STRG BRK IMPL RET Fig 3 10 Overhead Controls 3 7 Overhead Controls 34 Windshield Wash Switch Two position R Off F 35 Rear Windshield Wiper ON OFF Switch Three position Off L H 36 Front Windshield Wiper ON OFF Switch Three position Off L H 37 Defroster Fan Switch window mounted fan Three position Off L H A second switch is located on the fan 38 Fan Switch Optional defroster fan behind operator 39 Strobe Light Switch ON OFF switch for front ROPS mounted lights 40 Auxiliary Light Switch Optional Auxiliary light is mounted on the ROPS 41 Auxiliary Lights Switch Optional ON OFF switch for rear ROPS mounted lights 42 Rear Light Switch Chassis mounted rear lights 43 Front Light Switch Cab mounted front lights 44 Panel Lights Dimmer Control Dims and brightens rocker switch and filter indicator lamps on the instrument and control panels 45 Steering System High Pressure Filter Indicator Lights 46 Brake System High Pressure Filter Indicator Lights 47 Implement High Pressure Filter Indicator Lights 48 Hydraulic System Return Filter Indicator 3 6 Items 34 49 These lights indicate the
7. Low coolant level Check coolant level Engine oil pressure low Transmission Converter SYMPTOM Low oil level Check oil level Oil leaks Tighten connections Contaminated Oil PROBABLE CAUSE Change oil and filters CORRECTIVE ACTION Transmission or converter over heats Low oil level Fill to proper level Oil cooler restricted Remove restriction Lack of power Wet Disk Brake System SYMPTOM Low engine rpm at coverter stall PROBABLE CAUSE Have engine checked governor CORRECTIVE ACTION Brakes won t release Loss of oil See service manual 80 513 Have maintenance check system Loss of braking efficiency Air in hydraulic brake system Check pump See Service Manual 80 513 Section 4 1 6 14 Loss of accumulator pressure Have maintenance check system Low system pressure Wait for system pressure to recharge Also see manufacturer s Operation and Maintenance Manual for additional information Maintenance and Lubrication section 6 Hydraulic System SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION No response to controls Closed tank shutoff valve Open valve Low oil level Implement controls switch off Fill tank to proper level Turn switch to on Sluggish operation or response to controls Hydraulic oil cold Allow adequate warm up time Low oil level Fill tank to proper leve
8. Place the shift lever into the forward or reverse posi tion Moving the lever not only selects the direction of travel but also shifts the transmission from neutral to in gear Depress the throttle pedal slowly and smoothly Avoid sudden or jerky starts Depress the pedal just enough to begin moving slowly CAUTION Always brake to a full stop when changing directions Drivelines are not strong enough to withstand the forces created when tons of vehicle and load are reversed suddenly Keep the speed low until you feel comfortable with the machine Steering With the operator facing the front steering the wheel clockwise will turn the machine right while turning the wheel counterclockwise will turn the machine left Practice moving the machine around the yard Make several practice stops to develop a feel for the brakes Practice driving and steering in forward and reverse Always use the brakes to slow and stop the machine never gear down NOTE It is recommended that you keep the declutch in the ON position for normal operation If a downgrade is encountered the De clutch control may be placed in the OFF position and the transmission will remain in gear while braking If it becomes necessary to use the dozer for pickup and carry such as for cleanup the de clutch should be in the ON position O pe rat i section 5 INCDRRECT 5 6 Dozing on the Level 1 To obtain maximum load retri
9. 24 Volt Negative Ground 24 Volt Start Alternator i nU Dn 100 AMP Circuit Breakers lights 0 30 Circuit Breakers 20 AMP Batteries 2 12 Volt 8D 205 AMP Hr each Torque Converter Clark 8000 Series Single Stage 3 Elements Stall Torque Ratio 2 292 1 Transmission Clark 8000 Series Power Shift 4 SpeedsFwd Rev Range Ratio Speed Unladen BIOTA 4 1 mph 6 6 km h NECI BT A 7 2 mph 11 5 km h e AA SHE E 1 29 1 12 2 mph 19 6 km h duc uL UG OTA 21 1 mph 33 9 km h Cab Cowl Bogie Tower Dump Cylinder Bucket Hoist Cylinder Axles tpi eed de Model Spin with Brake Model Bogie Posi Torque TYPO weeds Planetary Brakes ene Spring Actuated Sump Cooled Wet Disc Carrier Ratio ii eterni prm 4 857 1 Planetary Ratio 5 368 1 Total alee 26 072 1 Tires OZO M 29 50 x 29 Radial All Tires Are Hydroflated Hydraulic System Implement 58 GPM Q 1800 Engine RPM Steering 58 GPM 1800 Engine RPM
10. As a part of the DDM s boot up procedure the DDM must claim a network address for its use If an error occurs during this procedure an error code is displayed on the LCD Error Code 1 Line 1 ACP Err Line 2 No Addr This error occurs if the DDM is not able to claim an address either the default address or one from its range of addresses 43 127 Error Code 2 Line 1 ACP Err Line 2 Bus EP This error occurs if the DDM encounters a Controller Area Network CAN bus error The Bus EP means the DDM is in an Error Passive EP mode The Er ror Passive state is a result of the DDM not having a partner on the CAN bus or the DDM is attached to the CAN bus with the CAN HI and CAN LO reversed Error Code 3 Line 1 ACP Err Line 2 BusError This error occurs if the DDM has transitioned through the Error Passive mode and has continued to en counter CAN bus errors The BusError mode is a result of catastrophic errors on the CAN bus Some possible causes include CAN Hl or CAN LO or both are shorted to electri cal ground or to the battery voltage One or more nodes on the CAN bus is transmitting at a non standard baud rate This type of error is generally non recoverable and will require a skilled service person to help sort out the possible error causes Run Time Bus Errors After the DDM has claimed a network address it enters its run time mode of operation If a bus error occurs during thi
11. The DDM can display the engine configuration data stored Press the UP and DOWN buttons simultaneously to select in the engine ECM electronic control module To select the Engine Configuration menu The DDM will display the the Engine Configuration Menu press the UP or DOWN engine configuration data If the Engine Configuration menu button The following label is displayed on the LCD is unavailable the LCD will display NOTE The parameters displayed on the DDM will vary E ng n e Co nfi g u ratio n depending on the engine make and model Menu Configuration Data Continued To exit the Eng Conf Display menu Press BOTH keys at ANY time Fig 3 17 Engine Configuration Data 3 11 Alied Wagner DDM Internal Error Codes EEPROM Errors The DDM performs a read write test of the EEprom on power up If this test fails the error message EE Error is displayed and the functions of the DDM are stopped at that point Address Claim Procedure Errors ACP Err
12. The way you operate your new engine during the first 50 100 hours will have an important effect on its service life Its moving parts are closely fitted and even though most diesel engines are dynamometer run before leaving the factory an additional period may be required before uniform oil films are established between mating surfaces Generally speaking proceed with a new engine as follows 1 Operate most of the time at one half to three quarters full throttle Do not operate at maximum horsepower for more than five or ten minutes at a time 2 Don t idle the engine for long periods This may cause cylinder wall glazing resulting in excessive oil consump tion and loss of power 3 Keep a close watch on the instruments Reduce rpm if water temperature reaches 200 F 4 Operate in a gear low enough so that you can accelerate under any condition 5 Study and follow the engine s operation manual for specific information The operator must assume the responsibility for the engine during operation This is an important job and one that will determine to a large extent the success of the operation Premature engine failures are very expensive because of lost productivity and the high cost of engine repairs or replace ment Protect your company s investment 5 1 Alied Wagner 5 3 Start and Stop Procedures Before operating this machine the operator must have re ceived operator training a familiarity with this man
13. WARNING When removing battery terminals always disconnect the negative cable first When installing battery terminals always con nect the negative cable last This procedure can prevent a spark at the battery which could cause an explosion When possible always make the last cable connection away from the 6 battery such as on the engine block Use care to keep the cables clear of the fan or any other moving parts 7 5 5 Moving Stopping and Steering 1 Make sure that the area is clear of obstructions and or personnel It is possible for several people to stand un der or near the machine out of sight of the operator It is recommended that you sound the horn before moving the machine CAUTION This machine cannot be stopped instantly The stopping distance varies depend ing on load and speed To avoid collisions be sure to allow ample stopping distance 8 2 Release the hand throttle CAUTION Never attempt to operate with the hand throttle instead of the foot throttle The hand throttle is to be used for warm up only 3 Place the De clutch control in the ON position 4 Liftthe bucket if required to clear any obstructions you might encounter 5 Release the parking brake and put the transmission range selector into 1st gear CAUTION It is recommended that you operate in 1st gear only until you develop a feel for the machine and become familiar with all of its operating characteristics
14. Hydraulic Steering iet A aes Hoist Dump amp Tilt rit 4 5 Electrical 00122 Section 5 Operation 5 1 niina Safety First irt Material 2 5 2 Breakin Period iiis eret an 5 3 Start and Stop Engine Oil Hydraulic Oil 2 Transmission Oil Engine 24 Engine Start p ic ccce inti eei Cold Weather Starting Procedure Temperatures below 32 F 0 Temperatures below 0 F 18 Engine Shut Using Booster Moving Stopping and Steering 00 1 Dozing on the Level eec Cutting on a Reclaiming iioii tnis 5 9 Knocking Down 5 10 Cutting on the Edge of a 5 5 11 Familiarize 5 5 12 Getting the Job 5 5 13 C
15. a charge valve to an accumulator From there oil is supplied through the parking brake solenoid and brake pedal valve to the brakes 4 2 Functional Description Section 4 The parking brake solenoid will allow oil flow to the brake pedal valve when energized parking brake released From there oil will flow directly to the brakes releasing them if the brake pedal is not depressed If the parking brake is set or electrical power to the solenoid has failed oil to the brake pedal valve will be shut off and the brakes will automatically apply Electrical power to the solenoid must be restored to release them Adequate oil and pressure is stored in the ac cumulator for some time in order to release the brakes after the engine is shut off or an oil supply failure has occurred The brake pressure valve is a variable pressure reducing valve Upon depression supply oil to the brakes is shut off and oil pressure in the brakes is modulated down applying the brakes and returning the brake oil back to the hydraulic tank A check located in the valve will allow oil to flow out of the brakes activating the brakes if the oil to the supply valve is cut off QUICK FLOW REF Hoist Dump amp Tilt The hoist and tilt system is what makes the Dozer capable of doing work It allows the bucket to be raised tilted forwards backwards to the right or to the left This allows the operator to move the desired load to the desired location with min
16. and is an important ingredient to the overall success of a preventive maintenance program Shift Maintenance Checklist A recommended checklist is given here as an aid in develop ing a practical shift maintenance program if one has not been developed by your company A shift maintenance report based on the checklist should be used to report defects found when making maintenance checks at the beginning of each shift Your company may have a different reporting method how ever it is usually a requirement that this form be filled out at the end of each shift Accurate shift maintenance reports can help your company anticipate maintenance problems and take action to prevent costly failures Using the Checklist The reference numbers in the left hand column of the checklist indicate the physical location of each check point or lubrication point as it appears on the shift maintenance diagram Circled reference numbers on the diagram indicate lubrication points Boxed numbers indicate maintenance check points Shift maintenance details are provided in section 6 10 Main tenance Procedures These procedures consist of checks that can be preformed by the operator 6 5 Scheduled Maintenance Periodic scheduled maintenance is intended to be performed in a complete maintenance facility by trained mechanics The timely scheduling and completion of these periodic inspec tions by the maintenance department will determine the length of downtime
17. blade has been set at the factory for the correct loading angle or rake Position the machine as far back as possible and headed toward the dump area This will give you time to fill the bucket and feel the control action without being in a hurry As you become familiar with the feel of the controls and the action of the bucket during different loading actions you will recognize the advantages and where to use the procedure of tilting the bucket forward to gain additional cutting pressure 5 12 Getting the Job Done 1 Lower the bucket until it is resting flat on the ground Se lecting first gear and forward direction proceed at about one half 1 2 the throttle and observe the material flow into the bucket At this point if the material appears not to be flowing fast enough apply slight down pressure This will immediately increase the flow and the material will appear to boil As this occurs release the down pressure and maintain the boil until the bucket becomes full and the engine begins to lose RPM s Slowly apply throttle to maintain boil being careful not to spin the wheels With a little practice you will be able to perceive this before it occurs Now you are ready for the feel of weight transfer and a real surprise Apply slight up pressure return to neutral as soon as engine RPM s pick up or spinout is avoided You will immediately notice an increase of material boiling into the bucket Maintain this until th
18. clean up any spills e Shut off the engine and electrical equipment while fill ing the fuel tank Use extra caution when fueling a hot engine Always ground the fuel nozzle against the filler neck to avoid sparks e Handle all solvents and dry chemicals according to pro cedures identified on manufacturers containers Work in a well ventilated area Make sure you know where fire extinguishers are kept and how to use them e Avoid spilling fuel If a spill occurs wipe it up immedi ately e Always ensure that excess grease and oil accumulation including spillage is cleaned up immediately e Inspect the machine daily for potential fire hazards and make any necessary repairs immediately e Maintain the engine cooling system to avoid overheat ing e Check all the electrical wiring and connections for de fects and repair or replace as necessary Keep battery terminals clean and tight e Never perform welding operations until the entire ma chine has undergone a thorough cleaning In addition cover rubber hoses and have at least a fire extinguisher at hand e Hydraulic fluid is flammable Do not weld on or near pipes tubes or hoses that are filled with fluid e Store flammable starting aids in a cool well ventilated location Remember there is always a risk of fire Fire Fighting Equipment All Wagner units built after November 1 2004 are supplied with a hand held fire extinguisher If your unit is not so eq
19. different engine parameters as well as engine service codes The DDM gauge includes a two line eight character backlit LCD display The top line displays data labels e g OilPress while the bottom line displays appropri ate units of measure e g 80 psi for oil pressure Two push buttons are used for scrolling through parameters and viewing menus Two LEDs are used to announce active fault messages received by the DDM See Section 3 9 for more information regarding the operation of the DDM Transmission Pressure Gauge Displays the oil pressure that the transmission clutches use Clutch pressure should be between 190 and 215 psi at engine idle speed The pressure should not vary more than 5 psi between the four speed ranges 3 Engine Coolant Temperature Gauge Displays engine coolant temperature If the temperature holds steady at 200 F or higher discontinue operation allow the engine to idle for 3 to 5 minutes and shut it down Determine the cause before continuing operation If a coolant hose failure occurs shut the engine down immediately 4 Transmission Circuit Temperature Gauge Displays converter oil temperature This gauge should read below 250 F If the temperature exceeds the maximum allowance discontinue operation and report to appropriate service personnel 5 Engine Oil Pressure Gauge Displays engine lubricating oil pressure Determines pressure only not amount EN A Caumon CAUTION Should thi
20. in vested in making your machine a safe product The dividend from this investment is YOUR PERSONAL SAFETY However it must be realized that no power driven equipment can be any safer than the person behind the controls If you don t operate and maintain your Dozer safely our efforts will have been in vain The safety instructions and warnings as documented in this manual and shipped with the machine provide the most reliable procedures for the safe operation and maintenance of your Dozer It s your responsibility to see that they are carried out The following terms define the various precautions and no tices in this manual NOTE Whenever information exists that requires ad ditional emphasis beyond the standard text the term NOTE is used IMPORTANT Whenever information exists that requires special attention to procedures or to ensure proper opera tion of the equipment or to prevent its possible failure the term IMPORTANT is used CAUTION CAUTION Whenever potential damage to equipment exists requiring correct procedures for prevention the term CAUTION is used 2 1 Alied Wagner WARNING WARNING Whenever potential personal in jury or death situations exist requiring correct procedures or practices for prevention this WARNING symbol is used This safety alert symbol indicates important safety messages in this manual When you see this symbol care fully read the messa
21. indicated location of engine filters fuel oil coolant may not be exact Consult your specific engine service manual for exact locations 6 13 Alied Wagner 6 14 Operator Troubleshooting The following table lists the most common problems that may be encountered by operators If the problem cannot be solved using the corrective actions listed in this table notify maintenance personnel Engine SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION Engine turns over but fails to start Fuel filter blocked Replace filter Fuel tank empty Fill tank Fuel shutoff valve at tank closed Open valve Engine fails to turn over Battery disconnect switches open Close switches Transmission not in neutral Place lever in neutral Battery Low Have charging system checked Battery terminals corroded or loose Clean and tighten terminals Bucket float on Turn off bucket float Engine runs unsteady and power output low Insufficient fuel supply Clean fuel strainers replace filter fill tank tighten fuel lines Contaminated fuel Drain tank lines clean strainers and re place fuel Wrong fuel Drain tank and fill with proper fuel Air intake restricted Remove restriction Exhaust smokes badly Too much oil in sump Drain to proper level Air intake restricted Remove restriction Engine overheats Radiator fins restricted Clean fins
22. numbers at your fingertips when requesting parts service or operation information of any kind It is from these numbers that our service department creates a unit file in which a complete history of your machine is maintained General Section 1 A typical lubrication plate is shown in Fig 1 3 These plates are securely fastened to the cab superstructure on the right side The lubrication plate lists the time intervals specifica tions temperature limits and viscosity requirements of lubri cating oils and greases For further lubrication information see Section 6 of this manual LUBRICATION CHART The below specifications and viscosities for each unit are the manufacturer s recommenda tions for the temperatures shown Consult your lubricant supplier for products meeting these specifications and viscosities for temperature below or for above or below those shown If supplier cannot furnish contact your Wagner Dealer INTERVAL SPECIFICATION TEMP AMBIENT PLANITARY GEARS CHECK OIL LEVELS WEEKLY DRAIN AN amp DIFFERENTIALS REFILL EACH 500 OPERATING HOURS HYDRAULIC SYSTEM UNIVERSAL JOINTS NLGI GRADE 2 AVY DUTY LUBRICATE WEEKLY FOR NORMAL SER eee core VICE DAILY IF WORKING MORE THAN MULTEPUAPOSE d NORMAL EIGHT H E CATED POINTS COLOURS GREASE O F TO 100 Fig 1 3 Lubrication Plate 1 3 Alied Wagner 1 4 Specifications CHD100 CD1000 4 Dimensions A Overall
23. real invest ment in working equipment and efficient use of man hours Valuable benefits can be realized all of which mean savings in time and resources Preventive Maintenance Promotes Safety properly maintained equipment is better able to operate within its design specifications and react positively to the operator s control Improves Equipment Availability by minimizing the chances of breakdown Reduces Unexpected Downtime unexpected down time is expensive and detracts from normal scheduled maintenance Allows Planning Daily Production by knowing the condition of available equipment Allows Planning of Maintenance Man Hours by distribution of duties and necessary lead time for parts ordering Provides Complete History Equipment based performance frequency and type or repairs and actual man hours expended on maintenance 6 2 Establishing a Preventive Maintenance Program The key to an effective prevention maintenance program is diligence in following a maintenance schedule set at regular planned intervals Such intervals should be made compat ible with the nature of operation of the equipment and with the capabilities of the maintenance facility In any event the intervals and inspection requirements must be planned regular and consistent Specific maintenance should be completed using the follow ing intervals 10 Hours each shift or daily 50 Hours weekly 250 Hou
24. the control backwards to shift down SEE IMPORTANT Always let up on the throttle slightly when on shifting speed ranges This will significantly reduce shock UE loads to drivetrain components during shift Also you 12 QO 13 should always reduce engine rpm when downshifting mj as you can over speed the engine Ens In 15 Key Switch Start 3 6 The key switch is used to start and stop the engine and to turn the accessories on and off This is a four position switch ACC OFF RUN and START When turning the 1 LI key clockwise from the center or OFF position the first position to the right is RUN The second is START The START position is spring loaded and will return the key to the RUN position when released ACC is to the left Fig 3 3 Left Hand Console Items 10 15 of OFF this position is used for accessories operation only 10a Engine Warning Light yellow This light indicates a non fatal engine control monitor ECM error Engine will derate and shutdown may be ECM TR Gay approaching PP 9 10a gc 10b Engine Stop Light red This light comes whenever engine oil pressure drops men 19 SES 2 below a safe operating level or when engine temperature REV D CLTOH RADIO USER is excessive On some model
25. the output of the steering control unit With this system it is possible to combine the steering and working hydraulics The priority valve ensures that the steer ing has first priority on oil flow from the hydraulic pump The oil flow not used for steering is then sent via the EF line excess flow to the working hydraulics If the steering wheel is not turned the entire oil flow is directed to the working hydraulics with minimal pressure loss The principle applied to the controlled operation of this system is called load sensing As the name suggests it is a system in which the load is sensed or registered The sensed signal is used in this example to control the priority valve in the flow amplifier valve so that oil flow and oil pressure precisely match momentary demands Brakes The reverse modulated wet disc brake system is a spring applied hydraulic release brake system incorporating the durability of an oil immersed enclosed brake with the positive stopping action achieved by spring applied force Each brake is both a service brake and a parking brake In the event of loss of hydraulic power immediate application of braking ac tion occurs Oil pressure is required to release the brakes It is not required to apply them The system begins with the hydraulic tank oil flow to a load sense pressure compensated pump The pump sends oil to a high pressure filter After the high pressure filter oil is sent through
26. the pile will be much lower making an uneven cut See Fig 5 11 Fig 5 11 5 9 Alied Vagnier 3 Cut down the hump in dozing path If you have a build up or mound of mate rial in the path in which you are dozing you will need to cut the mound out or you will continue to loose material when dozing over it Thus increasing the size of the mound with each pass See Fig 5 12 7 Fig 5 12 4 Cutat different angles This will make the job of knocking down a discharge pile much easier See Fig 5 13 Figure 5 13 5 10 O pe rat i section 5 4 10 Cutting on the Edge of a Pile 1 When cutting on the edge of a pile be certain to leave at least a 2 foot berm There are safety as well as practical reasons for this procedure See Fig 5 14 Fig 5 14 You can back blade with the bucket tilted forward with no damage to the machine See Fig 5 15 H 5 gum KE Building a road off a pile Fig 5 16 Alied Wagner 5 11 Familiarize Yourself 1 During the familiarization period we suggest your passes be made on relatively level terrain This will acquaint you with the true feel of the controls and machine handling while loading Start your pass with the bucket rolled back against the stops The angle of the cutting
27. the speed at which the machine is traveling just before that point would be the maximum speed of the vehicle The transmission is a full power shift full reversing unit Full power shift means that the transmission can be shifted from one range to the next either up or down When shifting down the engine rpm must be reduced sufficiently to prevent over speeding the engine when the lower range engages Important Never shift the range selector up or down without momentarily relaxing the throttle pedal Severe damage to the drivetrain could result Full reversing means that you have approximately the same speeds forward and reverse in all speed ranges CAUTION Always brake to a full stop when changing directions Drivelines are not strong enough to withstand the forces created when tons of vehicle and load are reversed sud denly The transmission uses constant mesh gearing in all ranges forward and reverse All gears are engaged by means of hydraulically controlled multiple disc clutches through the control valve actuated by the shift lever in the cab 4 1 Alied Wagner Drivelines Drivelines transmit the engine torque after being multiplied by the converter and transmission to the drive axles Differential The differential is what converts the rotational energy from the engine into rotational energy that drives the wheels In order to do this a series of gears is used to transfer the motion from being perpendic
28. tion and maintenance requirements Oil samples from engine transmission axles and hydraulic system should be taken when oil is hot and well mixed to ensure an accurate analysis Contact your Wagner dealer for complete information and assistance in establishing a scheduled oil sampling analysis program for your equipment 6 3 Alied Wagner 6 7 LUBRICANT SELECTION amp SPECIFICATIONS The efficiency and useful life of mechanical equipment is as dependent on proper lubrication as on proper engineering design The importance of proper lubrication is increased because of the greater loads and pressures imposed on present day mobile heavy equipment For this reason we are vitally interested in promoting widespread usage of the best possible lubricants for Allied Systems Company products Our purpose in compiling these specifications is to provide a guide to aid in the selection of a lubricant that will give the most satisfactory service Because many brands of fluid are available it is not practical to test each one Selecting the correct fluid should be done with the help of a reputable oil supplier who is responsible for the quality of the fluid Our lubricant recommendations are based on commercial products that have given satisfactory results in normal operation In all cases the lubricant supplier assumes all responsibility for the performance of his product and for product liability When changing fluids use the following guide
29. your responsibility to make certain that your Dozer operates at maximum efficiency with the greatest possible safety It is also your responsibility to keep it in top operating condition through proper operating techniques and correct operator maintenance Remember safe and efficient operation is up to you the operator The Wagner Dozers are designed and developed specifi cally to move material faster further and at less cost than a traditional machine It is unique in that it can carry a load and doze at the same time thus greatly increasing its efficiency The weight of the carried load adds to the traction needed to doze a volume comparable to the bucket load Rugged construction and ease of service contribute to the Dozer s long life and low maintenance And the Dozer s superior visibility and responsive controls result in a fast efficient and safe operation Alied Wagner If you require information not found in this manual please contact your local Wagner dealer If you are not sure who your local dealer is then contact Allied Systems Company 2300 Oregon Street Sherwood Oregon 97140 USA Phone 503 625 2560 1 2 Intended Use Statement This machine is designed for the transportation of raw mate rials Use in any other way is considered as contrary to the intended use Compliance with and strict adherence to the conditions of operation service and repair as specified also constitute essential elements of the inte
30. 38 2 cu m Bucket Push amp Carry Capacity CD 40 cu yd 30 6cu m Bucket Lift amp Carry Capacity CD 20 cu yd 15 3 cu m 40 each OscillatiOni cect sds secco rette Bede n 15 each way Maximum Bucket Forward Silde Tilt Optional on 80 yd bucket 6 each way from horizontal Note The specifications shown in this manual are based on information available at the time of publication and are sub ject to change without notice or obligation 1 4 General Section 1 Air Intake Power Unit Engine Radiator Converter Pumps Transmission TID Est Chassis Rear Chassis Axle With Brake Engine Cummins QSX 15 Max 525 2100 RPM Torque seen 1800 Ft Lbs 1400 RPM Bore and 0 5 4 x 6 7 No of Cylinders cis iini ecrire rhet 6 Displacement iisisti 915 15 liters Engine Caterpillar C 15 Electronic Max Horsepower nana 525 2100 RPM rei 1700 Ft Lbs 1500 RPM Bore and Stroke 5 4 x 6 5 Cylinders ine Ee c o ea 6 Displacement irprun 893 Cu In 15 liters Air Donaldson Two Stage Dry Type Electrical System Type
31. 6 e recede 3 2 3 3 Operation 3 3 3 4 Implement Controls siisii 3 4 3 5 Air 8 3 5 3 6 Seat uud iode trier esis 3 5 3 7 Overhead Controls sse 3 6 9 8 Safety Controls cedi eres 3 6 3 9 Display and Diagnostic Module Gauge Operation 3 8 Ee 3 8 Engine 3 8 Operating 3 9 Viewing Engine Data Parameters 3 10 Selecting amp Exiting 3 10 Changing Units of 3 10 Viewing Engine Configuration Data 3 11 DDM Internal Error 3 12 Address Claim Procedure Errors ACP Err 3 12 Run Time Bus 3 12 Section 4 Functional Description 4 1 1 4 1 4 2 Power Unit cere esten ies 4 1 4 1 Torque 4 1 Air Intake 4 1 4 3 Drivetraln 1 4 1 Transmission 4 1 4 2 Differential 4 2 Planet Assembly 4 2 Chassis amp 4 2 4 4
32. 9 3 km h 1 385 1 10 0 mph 16 0 km h P NERONE 0 774 1 17 0 mph 27 0 km h Cab Cowl Bogie Tower Dump Cylinder Bucket Hoist Cylinder Axles Qi Clark Model Spin with Brake Model Bogie irre Posi Torque De Planetary Brak68 eei Spring Actuated Sump Cooled Wet Disc Carrier Ration 2 6 286 1 Planetary ascii eel eas 4 667 1 Total FRedUctiOn seinen beer rre eere RR Pete rS 29 330 1 Tires SIZO M 29 5 x 25 Radial All Tires Are Hydroflated Hydraulic System Implement 70 GPM 2200 Engine RPM Steering 70 GPM Q 2200 Engine RPM Brake 12 GPM 2200 Engine RPM Tilt Brake Cooling Pump if equipped 13 GPM 2200 Engine RPM Steering Cylinder 2 5 x 24 127mm x 610mm Dump Cylinder 2 5 x 37 12mm x 940mm Hoist Cylinder 2 8 x 36 203mm x 915mm 1 7 Alied Wagner Intentionally Blank Section 2 Safety 2 1 Safety Is Your Business Why Because SAFETY based on knowledge technical skill and years of experience has been carefully built into your Wagner Dozer Time money and effort have been
33. Brake Pum pers tiet 33 GPM 1800 Engine RPM Steering Cylinder 2 6 x 32 152mm x 813mm Dump Cylinder 2 6 x 36 152mm x 2718mm Hoist Cylinder 2 9 x 41 229mm x 1041mm Service Refill Capacities Fuel Tank s iecit cti ett 295 Gals 1117 liters Hydraulic Oil 2 22 2 1 160 Gals 606 liters Cooling 22 5 Gals 85 liters 1 5 Alied Wagner 1 5 Specifications CHD 60 CD600 1 i x 5 i D E F I 7T HJ JH JH JH I H 0 M iN Y m 1 Y gt 4 J Dimensions Overall Length esses 33 2 10109mm B Wheelbase erii titer nee den 12 5 3785mm C Height to Top Of 1210 3912mm D Outside Chassis Width Tires 10 4 3150mm E Outside Bogie Width 10 4 3150mm Bucket Width sessin 13 4 4064mm G Ground Clearance
34. Check for adjustment and wear e au RADIATOR amp OIL COOLER Are fins clean and unobstructed m E WHEELS amp TIRES Check condition and pressure ___ LUBRICATE CHASSIS Refer to lube chart Z WALK AROUND INSPECTION of structure welds leaks damaged components etc C ____ FIRE SAFETY CHECK Check for accumulated debris in engine compartment etc e After Starting Engine Check The Following ENGINE Does it sound normal INSTRUMENTS Check for normal readings CJ CJ CONTROLS Check for normal operation CJ CJ EXHAUST SYSTEM Check for leaks and excessive smoke CJ ub AIR INTAKE SYSTEM Check for leaks and damage CJ CJ TRANSMISSION After warming to operation temp Check oil level check for leaks 1 CJ Note Anything Abnormal or in Need of Repair LIGHTS DEFROSTER REVERSE WARNING HORN HORN WINDSHIELD WHIPPERS HEATER AIRCONDITIONER OPERATOR SUPERVISOR DATE MODEL SERIAL NUMBER HOUR METER Alied Wagner 6 11 Lubrication Points 10 HOURS REF FITTINGS 9 STEERING CYLINDER PINS 4 15 HOIST CYLINDER PINS 2 DUMP CYLINDER PINS 4 SIDE TILT CYLINDER PINS 2 LIFT ARM TO BUCKET PINS 2 6 HINGE PIN UPPER 1 HINGE PIN LOWER 1 50 HOURS DRIVELINE CONV TO TRANS DRIVELINE TRANS TO REAR AXLE DRIVELINE TRANS TO SWIVEL DRIVELINE SWIVEL FRONT AXLE DRIVELINE SUPPORT BEARING SWIVEL BEARING 996990 N Use handgun or lower pressure adaptor l
35. Fig 6 6 This provides an additional aid in locating each check point Before Starting Engine Engine Oil Level The oil level should be checked prior to starting the engine Make sure that the area around the dipstick is clean and the machine is sitting on level ground NOTE A 15 minute drain back time is recommended if the engine has been running The oil level must be maintained between the L low mark and the H high mark but as close to the H mark as possible CAUTION CAUTION Never operate the engine with the oil level below the L mark or above the mark Refer to the engine s Operation and Maintenance manual for detailed engine service information Use only approved engine oil see Lubricant Specifications Chart page 6 4 Do not overfill Check engine for leaks Hydraulic Oil Level Always check the hydraulic oil level prior to operation The fill cap is located on the RH chassis deck to the right of the operator s cab Oil poured into the fill cap is directed through the return filters before entering the tank to keep your oil as clean as possible CAUTION CAUTION Always open the tank breather petcock located on the breather pipe before removing the dipstick filler cap or in tank filter cover plate Failure to vent tank can result in injury or a substantial oil spill Be sure to close the petcock before operating the machine RILEY PIPE
36. Length 36 10 11227mm B Wheelbase 14 10 4521mm C Height to Top of Cab 12 9 3886mm D Outside Chassis Width 10 10 3302mm E Outside Bogie Width Tires 10 8 3251mm E Bucket Width 17 0 5182mm G Ground Clearance Chassis 1 10 559mm Ground Clearance Differential 2 0 610mm Turning Radius Outside Bucket 28 4 8941mm Turning Radius Centerline Mach 18 2 5537mm Maximum Dump Height 4 0 1219 mm L Maximum Height in Dump Position 18 4 5588mm OPTIONAL EQUIPMENT Standard and special options are available Contact your Wagner dealer for details ZS g L x AN VG Weights and Functions approximate Unit Weight Hydroflation Bogie End Hydroflation Chassis End Hydroflation 93 300 Ibs 42 358 kg 56 550 Ibs 25 674 kg 36 750 Ibs 16 685 kg Dump Angle at Maximum 54 Bucket Push amp Carry Capacity CHD 80 cu yd 61 cu m Bucket Lift amp Carry Capacity CHD 40 cu yd 30 6 cu m Bucket Push amp Carry Capacity CHD 100 cu yd 76 5 cu m Bucket Lift amp Carry Capacity CHD 50 cu yd
37. Operator s Manual CHD100 CHD60 CHIPDOZER COALDOZER CD1000 CD600 Ali Wagner 80 743 09 04 Printed in USA CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm This operator s manual should be regarded as part of the machine Suppliers of both new and second hand machines are advised to retain documentary evidence that this manual was provided with the machine Contents Section 1 General 1 1 1 2 Intended Use 1 2 1 8 Machine 1 2 1 4 Specifications CHD100 CD1000 1 3 1 5 Specifications CHD 60 CD600 1 5 Section 2 Safety 2 1 Safety Is Your 442 2 2 1 2 2 Operation 2 2 2 3 Rollover Protection Structure ROPS 2 2 What is a Rollover Protection Structure 2 2 ef Meri cm 2 3 Avoiding Rollovers 2 3 Replacing your 5 2 3 2 4 Maintenance 5 2 3 2 5 2 4 Section 3 Instruments and Controls 3 1 3 1 9 2
38. Radiator Converter Pumps Transnission Chassis Rear Chassis Axle With Brake Engine Cummins N14 360 Max 44 22 360 1800 RPM 1215 Ft Lbs 1400 RPM Bore and Stroke uice nere tette is 5 5 x 6 0 of Cylinders redit eee 6 855 In 14 0 L Engine Caterpillar 3406 Max 360 2100 RPM Max Iotque rrr tine 1120 Ft Lbs 1200 RPM Bore and SOKE nere itti 5 4 x 6 5 No of Cylinders ioo Janes cecus nte ree teet e ger leer 6 Displacetrient 21 haves Aided Rte 893 Cu In Air Farr Air Filter and Donaldson Precleaner Electrical System Type 24 Volt Negative Ground 24 Volt Start Altern ltor i eee eene eee 100 AMP Circuit Breakers 30 AMP Circuit Breakers 17 AMP Batteries 2 12 Volt 8D 205 AMP Hr each Torque Converter Clark 68612 5 siet ec o e Stall Ratio 2 54 1 Transmission Clark 6422 Modulated 4 Speeds Fwd Rev Range Ratio Speed Unladen dou ptu UL 4 393 1 3 0 mph 4 8 km h EREE Ii 2 454 1 5 8 mph
39. a functional or operable condition at all times Avoiding Rollovers A rollover can occur on any topography given the right circum stances All operators should be provided with information on rollover hazards they are likely to encounter and must be supervised until they are competent to work on their own Facility managers and operators should take measures to reduce the possibility of rollover hazards For example 1 Restricting the places where the machine is to be used 2 Restricting the speed at which the machine is to be operated 3 Restricting the use of the machine on the basis of opera tor competence 4 Usinga different machine or equipment better suited for the given task Replacing your ROPS It is the position of Allied Systems Company that repair of a modified or damaged ROPS is not possible the effects of modifications or damage to the strength of steel or on the adequacy of the attachment systems cannot be predicted The ROPS including attachment hardware must be replaced if any of the following has occurred 1 When visible damage has been sustained such as cracks tears dents or bends in any member or weld 2 Amachine fire where the fire burned in close proximity to the ROPS 3 Anytime the machine has rolled over 4 Modifications have been made to any part of the ROPS A ROPS must be correctly installed Installation instructions must be followed It is crucial that the specified installation
40. age electrical wires Failure to do so may result in injury or death and may cause damage to the equipment 2 3 Rollover Protection Structure ROPS Your Dozer has been designed to minimize the potential for a rollover accident Should a rollover accident occur Wag ner Dozers are fitted with a Rollover Protection Structure ROPS What is a Rollover Protection Structure The ROPS is a structure and attachment system designed to meet specific standards and serves the purpose of reducing the possibility of an operator being injured should the machine roll over In case of a roll over the protective struc ture is designed to absorb energy deform permanently and maintain a zone of protection for the operator Safety Section 2 The ROPS frame must pass a series of static and dynamic crush tests These tests examine the ability of the ROPS to withstand various loads to verify that the protective zone around the operator station remains intact in an overturn The tests are extensive and destroy the rollover protective structure Seatbelts The ROPS and cab provide a degree of safety during over turns but operators need more protection All operators must wear seatbelts Use of a seatbelt ensures that the operator remains securely in the zone of protection Seat belts restrain and keep the operator from being thrown against the frame through a window or out the door Seatbelts and seatbelt anchors must be maintained and kept in
41. and clothing away from power driven parts Keep off equipment while operating unless seat or operator s platform is provided Keep all oth ers off Make certain everyone is clear of equipment before operating This machine is not designed for lifting mov ing of persons Safety Section 2 2 5 Fire Safety EN wanno WARNING Diesel fuel and hydraulic oil are flammable Never smoke while handling fuel or working on the fuel system The fumes in an empty fuel container are explosive Never cut or weld on fuel lines tanks or containers Keep open flames and sparks away from the machine Avoiding Fire and Explosion Hazards e Keep the machine free of oil grease chips and trash accumulations Regular pressure washing and or steam cleaning is recommended for fire prevention and general safety Use an approved solvent to clean machine parts Never use gasoline or diesel fuel e Inspect for and remove all combustable materials from engine area before starting the machine and periodically throughtout the workshift as required These materials build up in tight corners and are highly combustible To do a thorough job remove the access panels e Remove any debris from the operator s compartment after each work shift e Inspect the driveshaft and brakes for debris and remove as necessary e Never overfill the fuel or hydraulic tanks Any overflow could cause a fire Immediately repair any hydraulic or fuel leaks and
42. ating the machine FITTING Fig 5 3 The oil level should be checked with the hoist cylinder ex tended The oil level should be at or near the H high mark on the dipstick or sight glass Fill with approved hydraulic fluid as required See Lubricant Specifications Chart Section 6 Do not overfill Transmission Oil Level Always check the transmission oil level prior to starting the engine to be sure there is oil in the sump The safe opera tion level should be checked after engine warm up with the transmission at normal operating temperature The fill tube is located at the front of the transmission by the output shaft Always check the level with the engine running at operating temperature with the transmission in neutral The oil level should be between the H high and L low marks Fill with approved fluid only See Lubricant Specification Chart Section 6 Walk Around Inspection Perform a walk around inspection looking for leaks loose or missing fasteners damaged hoses structural cracks or damage etc DO NOT operate the machine until all problems have been corrected Tires Visually inspect the tires for low air pressure and damage to the tread and side walls If a tire appears suspect appropri ate maintenance personnel should thoroughly check it prior to operation Engine PreStart 1 sure that oil and coolant levels have been checked before attempting to start the
43. ause permanent wear within the machine limiting the service life dramatically Scale numbers which represent what is called the ISO 4406 code are used to represent the cleanliness of your oil They allow you to study current contamination levels and set goals for the future Refer to figure 6 2 to help you better under stand this rating scale The system works by giving a 3 part code which represents the number of particles per milliliter mL of oil depending on particle size The first number is representative of particles greater or equal to 4um the second and the third 14um So an oil with the rating 12 17 9 would represent that there are between 20 to 40 4um sized particles per ml 640 to 1300 6um sized particles per ml and 2 5 to 5 particles 14m sized particles per ml present in that particular oil NOTE The used in the code in no way represents a ratio in the scale It is used only as a divider between numbers NOTE The ISO 4406 code was changed in 1999 to ISO 4406 1999 At times the old standard may still be used so be sure you know what version of the code you are deal ing with ISO 4406 1987 old had only two numbers and different sizes for particles represented by each number In that code the first number represented particles 5um and the second number was for particles 15 There are many ways oil can become contaminated including but not limited to poor care at the refinery in transport at your s
44. cle must be shut down and power off before lining wear can be checked The brake must be applied to make wear indicator check This means all hydraulic pressure to the brake must be off as the brakes are applied with spring pressure 1 Thoroughly clean the area around the wear indicator 2 Push wear indicator pin against reaction plate In most cases you must tap the pin lightly with a hammer until it bottoms out 3 When wear indicator pin is flush with indicator nut face the friction and lining disk must be replaced Fig 6 3 RICTION OISCS AND LINING WEAR INDICATOR FRICTION DISC LINING SAFE FRICTION DISCS TO BE REPLACED WEAR INDICATOR PIN FLUSH WITH NUT FACE ERICTION DISCS TO BE REPLACED Fig 6 3 Wet Disk Brake Test 6 6 Maintenance and Lubrication section 6 6 10 Shift Maintenance Checklist EVERY 10 HOURS OR DAILY Note general vehicle condition Clear away all collected debris steam clean if necessary Check for mechanical damage and loose or leaking components Report all faults to maintenance department Before Starting the Engine Check The Following REF ITEM OK NO ADD ENGINE Check oil level check for leaks E lt HYDRAULIC TANK Check oil level check for leaks RADIATOR Check coolant level check for leaks e AIR CLEANER Check indicator clean or change element as required E E empty dust cup ENGINE BELTS
45. commended Cooling systems using anti aeration baffles restrict visual observation of the true coolant level Even if the coolant can be seen the system may not be full To gain a true fill add water slowly up to the bottom of the fill neck and allow a 30 second settling period Remember to compensate for the loss of antifreeze when adding water NOTE If the engine is hot the coolant level will be higher than when it is cold Inspect the radiator daily for restric tion caused by leaves paper or other foreign material Inspect the radiator cap hoses and connectors for any signs of leakage or damage WARNING Never remove the radiator cap if the engine is hot The coolant will be under pressure and could flash to steam with explo sive force causing severe burns Remove the radiator cap only when engine is cool Hydraulic Oil Level Always check the hydraulic oil level prior to operation The plug is located on the right hand chassis deck to the right of the operator s cab See Fig 5 2 Important See warning on facing page for tank venting procedure HYDRAULIC OIL FILL Fig 5 2 Hydraulic Oil Fill Location 5 2 O pe rat section 5 WARNING Always open the tank breather pet cock located on the breather pipe before re moving the filler cap or in tank filter cover plate Failure to vent tank can result in personal injury a substantial oil spill Be sure to close the petcock before oper
46. condition of the high pressure supply filters With the machine running and at operation temperature the green lights should be on If the red light s come on and stay on filter service is required immediately NOTE In cold operating conditions these lights may come on and flicker until oil reaches operating tempera ture This is normal 49 Stereo Cassette optional AM FM Radio and cassette player or CD player 50 DomeLight Switch Not Shown ON OFF switch mounted on light 3 8 Safety Controls IN CASE OF FIRE 1 REMOVE SAFETY PIN 2 STRIKE BUTTON Fig 3 11 Fire Supression System Shown with Automatic Detection and Activation System Item 51 Instruments and Controls section 3 51 Fire Suppression System CAUTION Two fire suppression system actuators are provided Either one will set off the system One is located to the CAUTION If any arc welding is to be carried right of the steering column mounted to the right hand out on the machine s structure it is extremely wall of the cab The other is mounted on the chassis important that the disconnect switch is OFF at ground level just to the left of the right side boarding If the switch is left on severe damage to the ladder Memorize the location of each Many machines electrical system can result are equipped with an optional automatic fire detection and activation system as shown in figure 3 11 NOTE On machines equipped with a fire suppression sys
47. e bucket is full At this time you can raise the bucket to the planning position advancing up and down as necessary to maintain load without losing or boiling material With a little practice on this phase of operation you will discover how easy it is to maintain a smooth work area This is very important to fast cycle times particularly on return runs Learning to spread to an even smooth depth is perhaps the most difficult phase of operating As with any machine you have operated soon with familiarity and understand ing you will find yourself making all the correct moves automatically Take a good look at the bucket cutting edge Notice how it projects below the bucket hinge pin as it tilts forward during the dump cycle First it is ever so slight continu ing to increase at a very fast rate as the bucket rolls out until the total projection is about 12 to 18 depending on the model With the projection below the grade so to speak you realize if the bucket is not raised this amount during dump or roll out you would actually start to dig at a time when you were ready to dump This of course would not only cause you to stall or spinout but would leave a very rough or washboard dump area as you attempt to raise the bucket after the digging started With this in mind you know as you start to roll the bucket out to dump you must hoist or raise the bucket the amount of the projection below grade Because the hoist control and th
48. e rollout control lever are on the same lever the dump and hoist function is relatively easy to coordinate at this critical moment Here again the usual practice makes perfect clich is a fact Understanding this requirement it soon becomes automatic for perfect grade and dump control Remember you only have to hoist 12 to 18 for clearance when dumping and maintaining grade However the thinner you spread the slower you roll out the bucket This is because dumping the material too fast reduces the traction weight and more material is dumped in front of the bucket than can be pushed with an empty machine Thin spread requires constant practice and precise control Once achieved this skill is very useful for stocking out where compaction is so important 5 13 Conveyor Chute Operation 1 Side casting or dozing out from discharge pile usually is a matter of moving high volumes of material in a relative short period of time This requires picking up a full load in a short space and dozing it out 300 to 800 feet Because traction is so important try to keep loose mate rial from building up in the area where you are dozing and filling the bucket You can do this by starting back from the base of the pile lowering the bucket to ground level without digging or picking up material Approach the pile at an angle to penetrate it with approximate one third to one half the width of the bucket As the bucket fills and spin out appears immine
49. em e Take the extinguisher and proceed to the source of the fire calmly 2 6 Though the manufacturer s instructions may vary nor mally aim at the base of the fire Even when the fire seems to be out stand by with the extinguisher until the fire area is dead cool Check this by removing any panels and looking for hot spots Locate the cause of the fire and correct it before restart ing the machine Thoroughly inspect the entire machine and recharge or replace the extinguishers and fire suppression system before returning to work Section 3 Instruments and Controls Fig 3 1 Operator s Platform 3 1 General Become thoroughly familiar with the location and use of all during operation to assure proper care through prompt detec instruments and controls before operating this machine tion of irregularities If any of the instruments do not register Check all instruments immediately upon starting again after properly stop the engine and have the problem corrected reaching operating temperatures and at frequent intervals as soon as practical 3 1 Alied Wagner 3 2 Instruments 12 3 45 6 7 e e e Qe 8 9 Fig 3 2 Instrument Panel Items 1 9 DDM Gauge The Display and Diagnostic Module DDM Gauge is a multi function gauge that enables the operator or service personnel to view many
50. en only Air Cleaner The air cleaner is a Donaldson two stage dry air filter A service indicator shows the condition of the filter The indicator will show in the green zone when the filter is clean The indicator will show red if the filter is restricted If red appears in the indicator window clean or change the element and press the reset button on the indicator Engine Belts Check the tension of the drive belts by pressing with the thumb halfway between pulleys The belts should not deflect more than the values shown in the table Fig 6 5 If any belt is loose or worn report to maintenance for corrective action Belt Deflection Inches mm Cummins 3 8 to 5 8 9 5 to 15 9 Cat 1 2 to 3 4 13 to 19 Fig 6 5 Belt Deflection Wheels and Tires Visually inspect the tires for low air pressure and dam age Also check the wheel assemblies for cracks loose or missing lug nut broken studs etc Report any prob lems to maintenance Structural Inspection Steam clean the machine and inspect for structurally cracks If cracks are present repair before resuming operation Refer to WSBO0369 for information on how to properly weld structural cracks 6 12 After Starting Engine 17 Engine g After starting check that the engine runs and sounds normal It should come up to operating temperature within a few minutes after starting If you notice unusual noises or excessive smoke have maintenance check it out In
51. engine Sit in your normal operating position and adjust the seat for your personal comfort Wear your seat belt Check for emergency parking brake engagement Push the knob to ensure the brake is set Place the transmission range selector the neutral position N on the gear quadrant with the bucket float switch in the off position if so equipped NOTE All current Wagner units are equipped with a neutral start switch which prevents the engine from start ing unless the transmission is in neutral Give warning that you going to start the engine Make sure that all personnel are clear of the machine as you may not be able to see them from the cab Be sure that the area around the machine is clear of all obstructions WARNING WARNING Do not start the engine if the key switch has been tagged with a Do Not Start or red tag 6 Turn the key switch to the ON position The parking brake light and panel lights should come on Engine Start up 1 Turn the key switch to the START position Release the switch to the RUN position as soon as the engine starts CAUTION CAUTION If the engine does not start within 30 seconds allow the starter to cool for at least 2 minutes before re engagement Alied Wagner 2 After the engine starts let it idle Do not accelerate Remember high rpm and full load conditions on cold oil can severely damage the engi
52. es contain sulfuric acid which can cause severe burns Avoid contact with skin eyes or clothing Batteries produce explosive gases Keep sparks flame and cigarettes away Ventilate when charging or servic ing in an enclosed space Always shield your eyes when working near batteries When removing battery cables always turn the battery disconnect switch es OFF first then disconnect the negative cable When installing a battery always connect the positive cable first This procedure will help to prevent a spark which could cause an explosion Before making adjustments to the engine or chassis elec trical system disconnect the battery An electrical spark could cause a fire explosion or severe burns It is essential to personnel safety that safe ladders per sonnel lifts and or scaffolding be used while servicing this machine Always use safety tread walks and hand holds to reach lubrication points or to inspect or adjust the machine These areas can be dangerously slick under conditions of rain frost or oil smears CAUTION Before operating Know your machine Read the Operator s Manual Operate at low speeds in crowded areas or soft terrain Avoid abrupt changes in hoist direction Do not drop load Lower hydraulic equipment before leaving position Shut power off before lubricating or making equipment adjustment unless otherwise speci fied in the Operators Manual Keep hands feet
53. eval of chip dozer start doze on as level a grade as possible Lower the bucket and move into the pile See Figure 5 4 2 Fill the bucket gradually 3 one slot only keep the pile as level as possible See Figure 5 5 4 Tilt the bucket slightly forward to in crease the cut when working in com pacted material This will reduce the drag on the bottom of the bucket See Fig 5 6 5 7 Alied Vagnier 5 7 Cutting on a Knoll When cutting on a knoll or a steep grade tilt the bucket slightly This allows the bucket to load more freely See Fig 5 7 Fig 5 7 5 8 Reclaiming Start to hoist and dump a load approximately 20 feet from the reclaim in feed or the edge of the pile Spending less time at the re claim will increase the cycle time This will also reduce the chance of slipping into the reclaim See Fig 5 8 Fig 5 8 5 8 O pe rat i section 5 5 9 Knocking Down a Cone WARNING Never place your self or dozer under the over hang Fig 5 9 Approach from 4 the outside of the overhang with the bucket a 1 Ifit becomes necessary to knock down an overhang use the following proce dure as shown in Fig 5 10 2 Do not cut into a cone with the bucket too high If you enter the pile with the bucket too high the wheel opposite
54. from the engine for service person nel to use at a later time Controls Many of the operator s controls are electronic in nature The transmission control stick must send electronic information to the transmission the implement stick does the same for the hydraulic system The throttle controls both hand and foot are also part of the electrical system Lights Standard and optional external lighting groups enhance safety by providing illumination of surroundings during night time and adverse weather conditions Similarly interior lighting pro vides the operator with a visual reference of machine controls and instrumentation Exterior lighting has the added benefit of equipment visibility to ground based personnel Automatic Fire Suppression System Optional The automatic detection on your fire suppression system uses an independent electrical system to detect a fire and to deploy the system If the automated electrical system fails there is a manual override the operator can use to deploy the system if needed The system consists of an automatic detection wire an automatic control module a squib nitrogen cartridges and two manual actuators The automatic detection wire has two spring steel conductors separated by a heat sensitive insulator When the insulator melts the two conductors make contact tripping the system The squib is an electrically actu ated component When heated the squib detonates a tiny explosive charge c
55. ge that follows and be alert to the possibility of personal injury or death NOTE All possible safety hazards cannot be foreseen so as to be included in this manual Therefore the opera tor must always be alert to possible hazards that could endanger personnel or damage the equipment lt 2 Operation Warnings You must be trained in the operation of this machine prior to operation Be extremely careful if you do not normally operate this machine Reorient yourself to the machine before starting and then proceed slowly However you must not operate it without having previously received proper training Know your company s safety rules Some have site spe cific directions and procedures The methods outlined in this manual provide a basis for safe operation of the dozer Because of special conditions your company s procedures may be somewhat different from those shown in this manual Always face the ladder when going up and down ladders Maintain three points of contact Never jump on or off the machine All walking surfaces steps ladders etc must be free of ice grease oil or other materials that could cause or contribute to a slip or fall The only person required on the machine is the operator Never allow anyone to ride on the machine or its attach ments Do not operate this machine if you know of any malfunc tions missing parts and or mis adjustments These situations can cause or contribute to an acc
56. hardware be used A ROPS should never be modified by drilling cutting welding or by any other means Modifica tions to a ROPS may seriously weaken the structure and cause it to fail during an overturn Modifications of any kind will void the certification For questions or concerns please contact your local dealer or Allied Systems Company Service Department at 503 625 2560 2 4 Maintenance Warnings Maintenance lubrication and repair of this machine can be dangerous unless performed properly Each person must satisfy himself that he has the necessary skills and informa tion proper tools and equipment and that his work method is safe correct and meets his own company s requirements Do not attempt to make adjustments or perform main tenance or service unless you are authorized and qualified to do so e Unless specified in service procedures never attempt maintenance or lubrication procedures while the ma chine is moving or the engine is running e Keep hands feet long hair and clothing away from power driven parts Do not wear loose fitting clothing or jewelry while performing maintenance and lubrication in these areas Always perform all maintenance and lubrication proce dures with the machine on level ground parked away from traffic lanes e Before performing maintenance or service under the machine Move the machine to a level surface engage the parking brake and stop the engine Tag the
57. ident or damage to the machine Stop the machine immediately if problems arise after starting 2 2 e Do not operate the machine before disconnecting hy draulic tank or engine block heaters e hydraulic tank heater and or engine block heater use a 110 or 220VAC external power source An elec trical shock could be fatal e electrical cables and connectors must be in good condition Use caution in wet weather to avoid danger from electric shock Extension cords to the hydrau lic tank and or engine block heater must be properly grounded e Do not start the engine if the key has been tagged with a DO NOT START or RED tag e Never operate of the cab controls from anywhere other than the operator s seat Sound the horn to alert personnel in the area before starting the engine and make sure everyone is clear Be sure that all controls are in neutral before starting the engine e Lower the bucket before leaving the cab or shutting down the engine e High voltage electricity can discharge to ground through the machine without direct contact with the machine s structure Minimum clearances from en ergized power lines or other power sources must be maintained If electrical energy does discharge through the machine REMAIN IN THE CAB AVOID CONTACT WITH METAL SURFACES DO NOT PER MIT ANYONE TO COME INTO CONTACT WITH THE MACHINE S STRUCTURE WARNING Remain at least 25 feet from high volt
58. imal loss of material Every time the bucket is moved this system is being used Declutch The Declutch system when engaged automatically shifts the transmission into neutral when the brakes are applied This allows more power to be provided to the implements hoist dump tilt etc Because the power is not being unnecessar ily shared it allows the machine to be more productive It is controlled by a pressure switch in the brake line which sends an electronic signal to the transmission The transmission then shifts into neutral yv COLLECTION MANIFOLD IMPLEMENT PUMP STEER PUMP EXCESS PRIORITY STEER FLOW BRAKE PUMP BRAKES Fig 4 3 Hydraulic Flow Chart 4 3 Alied Wagner 4 5 Electrical System Batteries Your Wagner s electrical system is powered by two 12 volt lead acid batteries connected in series At 0 F these bat teries supply 1300 cranking amps They are 20 75 x 11 x 9 63 and weigh approximately 130 Ibs Ignition The ignition system uses an electric starting motor acti vated with a key switch much like the one on your personal vehicle Gauges The gauges in your vehicle are powered through the electri cal system They must receive an electrical signal to provide a reading The DDM is a little more complex This instrument displays a variety of information to the operator This gauge will also display vital information
59. ion 5 4 Using Booster Batteries WARNING Batteries produce explosive gases Keep sparks flame and cigarettes away Ven tilate when charging or using in an enclosed space Always shield your eyes when working with batteries If the batteries on the machine are weak or discharged use booster batteries to start the engine Never try to start the en gine by towing or pushing Use the following procedures 1 Make sure that the parking brake is applied and that all electrical loads are shut off 2 To prevent damage to the alternator use care not to reverse the battery connections Immediate damage to the alternator can be caused by making an incorrect connection during the starting procedure WARNING Batteries contain sulfuric acid which can cause severe burns Avoid contact with skin eyes or clothing 3 Connect one jumper cable to the positive terminal of the booster battery Connect the other end of the same cable to the positive terminal on the machine s bat tery 4 Connect the jumper cable to negative terminal of the booster battery Connect the other end of this cable to good ground connection on the machine s frame away from the battery This procedure will prevent a spark near the battery that could cause an explosion 5 Start the engine in the normal manner 6 After engine has been started disconnect the negative cable first then remove the positive cable 5 5 Alied Wagner
60. ite or within the machine its self New oil is not necessarily going to be as clean as desired and may need to be filtered before adding it to the tank Filtration storage and handling procedures are the most crucial elements to providing clean oil for your machinery A few important steps in a oil cleanliness program are Test your current oil cleanliness levels so you know what to compare your cleaned oil to Carefully evaluate your handling and storage practices Set goals for your company for cleanliness standards Start improvements in filtration storage and handling practices Observe and record your progress and return on invest ment Number of Particles Per 1 mL of Fluid Maximum 0 02 0 04 0 08 0 16 0 32 0 64 1 3 1 3 2 5 2 5 5 5 10 10 20 40 160 160 320 640 1300 2500 5000 10000 20000 40000 80000 160000 320000 640000 1300000 2500000 Fig 6 2 ISO 4406 1999 Fluid Cleanliness Codes 1 2 3 4 5 7 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 8 6 5 Alied Wagner Recirculating filtration systems can greatly help you achieve and maintain your cleanliness goals For smaller jobs a cart mounted system used on strategic intervals is acceptable for this propose These units can also be used to filter new oil before it is ever put into a machine At times with larger jobs a permanently installed system may be required to meet your needs Cartridge type filters are com
61. key switch with a DO NOT START sign and or remove the key Block the tires to keep the machine from roll ing e Never rely on the hydraulic system to support any part of the machine during maintenance or lubrication Never stand under a component that is supported only by the hydraulics Make sure it is resting on its mechanical stops If necessary support components with appropri ate safety stands e Use caution when working around hot fluids Always allow lubricating and hydraulic oils to cool before drain ing Burns can be severe 2 3 Alied Wagner Use extreme caution when using compressed air to blow parts dry The pressure should not exceed 30 psi 208 kPa at the nozzle Never use air to blow yourself off Air pressure penetrating your skin can be fatal Engine exhaust fumes can cause death If it is neces sary to run the engine in an enclosed space remove the exhaust fumes from the area with an exhaust pipe extension Use ventilation fans and open shop doors to provide adequate ventilation DO NOT remove the radiator cap when the engine is hot The coolant will be under pressure and can flash to steam with explosive force causing severe burns To prevent burns remove the radiator cap only when the engine is cool Before disconnecting hydraulic lines be sure to lower all loads and relieve all hydraulic pressure The load could fall on you or escaping hydraulic oil could cause severe personal injury Batteri
62. l Suction leak Correct suction leak Plugged tank breather Replace breather Restriction in circuit Remove restriction check filters Pump speed too slow Check engine speed Excessive noise Cavitation Aeration Eliminate restriction in suction line Replace tank breather Fill tank to proper level Correct suction leak Tubing vibration Tighten mounting clamps Hydraulic system overheating Electrical System SYMPTOM Low oil level Fill tank to proper level Operating over pressure reliefs PROBABLE CAUSE Correct operating procedure CORRECTIVE ACTION Engine fails to turn over Battery disconnect switch open Close switch Neutral start switch open Place transmission shift lever in neutral Battery low Have start charge system tested Battery terminals corroded or loose Clean and tighten terminals Other connections loose Tighten connections Voltmeter indicates discharge Alternator drive belt slipping Tighten or replace belt Loose or corroded battery connec tions Clean and tighten terminals 6 15 Alied Wagner 6 15 Maintenance Specifications Hydraulic Pressure Relief Settings Pump all three pumps set the same Stand by Pressure 400 psi Implement Valve Using Implement Pump Load Sense Relief 2 100 psi max adjustment not used Main Relief Hoist Dump and Tilt 2 900 psi Circuit Relief Hoist Du
63. l list the menu items Changing Units of Measure The DDM can display engine data in either English or Metric units To select English or Metric the Units menu must be selected To select the Units menu press the UP or DOWN button until the display shows the following label Press the UP and DOWN buttons simultaneously to select the Units menu Figure 3 16 shows the steps for selecting the desired units of measure Two options are available 1 Press both buttons to retain the current unit designa tion 2 Press either the UP or DOWN button to toggle the unit selection then press both buttons to select the desired unit of measure Line 1 shows the current units designation M Metric E English Line 2 shows the current units designation full text Units Sub Menu Current Units Screen displays the current units designation Line 1 shows the current units designation M Metric E English Line 2 shows the alternate units Press BOTH keys to select current units and exit sub menu selection Line 1 shows the current units designation M Metric E English Line 2 shows the alternate units selection Fig 3 16 Setting Units of Measure Instruments and Controls section 3 Viewing Engine Configuration Data
64. lines e Add only filtered fluids e If adding lubricants other than what is currently in the reservoir a warranty of compatibility should be obtained from the oil supplier e When the fluid is changed due to changes in ambient temperatures the system should be completely drained and the fluid replaced Listed below are the lubricants used for initial factory fill ENGINE Caterpillar amp Cummins Mobil Delvac 1300 Super 15W 40 TRANSMISSION CONVERTER Mobilfluid 424 DRIVE AXLES Mobilube HD 85W 140 Clark Posi Torque Bogie Axle Lubrizol 6178 Additive HYDRAULIC SYSTEM Mobilfluid 424 GENERAL CHASSIS LUBRICATION Mobilgrease Special No 2 The above lubricants will be used on all WAGNER Dozer units unless the unit is to be operated in extreme climatic conditions Allied Systems Company requires that lubricants meet or exceed the specifications of the oils listed above to avoid component failure and for warranty consideration If across reference to Mobil Oil Corporation specifications is required please consult your local lubricant dealer Maintenance and Lubrication section 6 6 8 Hydraulic Oil Cleanliness Oil is a vital part of any machine s service life but the cleanli ness of that oil may be more important than you think When using clean oil low ISO code component life expectancy can increase dramatically Dirty oil can cause more damage to your machine than you may think Dirt in the oil can c
65. mon in this type sys tem so make sure to change them and thoroughly clean the system between lubricants to avoid cross contamination CAUTION CAUTION DO NOT use the filters on the machine to initially clean your oil Doing so will result in unfiltered oil contaminating your system before it can be filtered Achange in storage and handing techniques is often the most cost effective way to help with the cleanliness of your oil To help prevent moisture from entering the storage drum during the breathing process contain the temperature in your stor age area to asmall range Providing a storage space free of dirt and moisture will also help with this Another simple step is to buy cleaner oil Your company can specify the cleanliness of the oil you purchase It will likely be more expensive but with the increase in machinery life it is worth the cost If this is the way your company decides to get clean oil make sure to test it upon arrival to make sure you are actually receiving what you are paying for Allied Systems recommends that oil with minimum cleanli ness 21 19 16 be used in your Wagner when changing and topping off fluids After an overhaul it is recommended that a cleanliness of at least 25 22 16 be used Exceeding these levels could cause damage to your machine 6 9 Wet Disk Brakes Spring applied hydraulically released liquid cooled brake friction disk lining wear check procedure NOTE The machine vehi
66. mp and Tilt 2 700 psi Steering Flow Amplifier Relief 2 550 psi Pump all three pumps set the same Pressure Compensator 2 500 psi NOTE Hydraulic pressures should be set at 1500 rpm NOTE Set main reliefs with engine at 1500 rpm and double checked at maximum rpm Override should Set Circuit reliefs with engine at 1000 rpm or less not be over 50 100 psi on control valves Check or set see Service Bulletin WSBO0370 for setting procedure pressures in sequence shown when hydraulic oil is hot above 120 F Calibrate your gauge periodically Tire inflation Pressure Wheel Lug Torque Front 29 5 29 65 PSI Max 448 kPa ETOD 315 Ib ft 232 Nm Rear 29 5 x 29 55 PSI Max 380 kPa ROAM ciu dert ets 315 Ib ft 232 N m Component Capacities amp Lubrications COMPONENT OF SYSTEM U S GALLONS LITERS LUBRICATION TYPE Engine crackcase See Engine Service Manual Engine Oil Fuel Tank CHD 100 CD 1000 295 1117 Diesel Fuel CHD 60 CD 600 180 681 Diesel Fuel Cooling System CHD 100 CD 1000 22 5 85 Water Antifreeze CHD 60 CD 600 14 5 Water Antifreeze Hydraulic System CHD 100 CD 1000 Hydraulic Oil CHD 60 CD 600 Hydraulic Oil Transmission System Transmission Oil Differential Gear Lube Planetary Hubs Each 5 Gear Lube Chassis Freeze Fittings As required As required Chassis Grease
67. n System 1 Pull the safety pin on the actuator and strike the button Fire retardant will be released the engine will shut down and the batteries will be disconnected from the electrical system Fig 5 17 Fire Suppression Actuator LEAVE THE VEHICLE After the system has dis charged watch carefully for flare ups and spot fires Call the Fire Department and or service personnel as soon as possible Any time the system is discharged the system must be refilled and recharged before resuming operation Refer to the Service Manual for complete maintenance procedures IMPORTANT Each unit is equipped with two actuators One is located in the operator s cab to the right of the operator s seat in front of the door The other is located on the chassis near ground level This way the system may be actuated by either the operator or by ground personnel NOTE Some models are equipped with a fire detection system that will automatically discharge the system in the event of a fire See the Service Manual for details and additional operator information Inspect for and remove all combustable materials from engine area before starting the machine and periodically throughtout the workshift as required These materials build up in tight corners and are highly combustible To do a thorough job remove the access panels See Section 2 5 for fire
68. nd Controls section 3 Hoist Dump and Tilt Control Single lever mono stick control for hoist and dump Use buttons for side tilt Push the lever forward to lower the bucket Pull the lever back to raise the bucket Push the lever left to dump the bucket Push the lever right to roll it back Push the top left button to tilt the bucket left Push the top right button to tilt the bucket right Implement Conirol Shut Off Switch Place this switch in the OFF position when there is any danger of inadvertently moving the implement control levers during service or repair while the engine is run ning With the switch in the OFF position the implement controls are shut off including optional bucket float feature Lifting the seat control module will also shut off the controls Cab Environmental Controls OS 7 SOOO 9999 52 Fig 3 8 A C System Items 28 30 Circulation Fan Switch Variable position knob controls fan speed Choose off low medium or high Heater Air Conditioner Selection Knob with off heat and air conditioning positions Thermostat Cab temperature control knob 3 6 Seat Controls 31 51 55 Fig 3 9 Seat Controls Items 31 33 Seat Height Adjustment Control Lift the seat and controls to lock into one of three posi tions Seat Controls Forward and Aft Seat Rotate Adjustment Locks seat in forward position and allows rotation for operator ingress and egress
69. nded use The machine should be operated serviced and repaired only by persons who are familiar with its particular characteristics and who understand the relevant safety procedures Accident prevention regulations and all other generally rec ognized regulations on safety and occupational medicine must be observed at all times Any arbitrary modifications carried out on this machine may relieve the Allied Systems Company and your dealer of any liability resulting from damage or injury 1 3 Machine Identification The model and serial number of your vehicle provide Allied Systems with a way to keep record of each machine Each Wagner Dozer has the S N stamped into the chassis on the left side of the machine in the front as shown in Fig 1 2 Ad ditionally the nameplate mounted on the front right side of the cab provides the model and serial number of your vehicle t G g CHD 100 wagner NOSE _ We IO Nl CHD 100 RIDERS 73 Fig 1 2 Machine Identification 1 2 NOTE The importance of the machine s model and se rial numbers cannot be overstated Always have these
70. ne transmission and hydraulic system If engine oil pressure fails to rise sufficiently after approxi mately 40 seconds of running the engine may automatically shut down IMPORTANT Your Dozer is equipped with an audiovisual engine protection system If oil pressure drops below a safe level coolant temperature becomes excessive or coolant level drops too low the engine warning light will come on With some models if the condition continues the engine will shut down automatically If your unit is not equipped to shut down automatically it is vitally important that you immediately shut down the engine if the light comes on 3 Ifa rise in oil pressure of the engine or transmission is not observed within 5 seconds shut down the engine and have maintenance determine the cause of the problem Do not operate the machine until the problem has been corrected 4 Check that transmission is in neutral and that the parking brake is applied Using the hand throttle continue to warm the engine at 1000 rpm until the engine tempera ture reaches at least 130 F 5 Release the hand throttle Meanwhile observe the gauges for proper readings and operation Also check the operation of all safety equipment and accessories Cold Weather Starting Procedure In cold weather it may be necessary to use cold weather starting procedures Note Cummins Engine Only 1 Depress cold start switch and hold This fills the chamber with a metered amoun
71. ngine start up Temperatures below 0 F 18 C If the machine will be shut down for several hours or longer with ambient temperatures below 32 F 0 C the hydraulic tank heater should be plugged in as soon as the machine is shut down This will help to maintain hydraulic oil tempera ture 5 4 O pe rat section 5 WARNING The hydraulic tank heater uses a 220 or 110 VAC external power source Be sure to connect the heater to the proper source with correct voltage An electrical shock could be fatal Don t forget to disconnect the heater cable before beginning operation All electri cal cables and connectors must be in good condition Use caution in wet weather to avoid danger from electric shock All connections to the heater must be properly grounded Let the engine idle for approximately 10 minutes before put ting any load on the engine Check all gauges for normal readings In extremely cold temperatures allow sufficient warm up time Engine Shut down 1 Move the throttle to idle speed and let the engine idle for 5 minutes in order to normalize internal engine tem peratures CAUTION Except in emergencies never shut the engine down immediately after operation Allow the engine to idle for at least five min utes Failure to do this could cause engine damage 2 Meanwhile place all controls in neutral and set the emergency brake 3 To stop the engine turn the key switch to the OFF posi t
72. nt apply lift or hoist pressure only as needed to prevent tire slippage and steer slightly away from the pile This will also give ad ditional relief to the engine RPM s and tire slippage 5 12 O pe rat section 5 3 While this type operation makes it difficult to completely fill the off corner the excess amount in the full corner usually will offset the low corner The average volume moved each pass far exceeds the straight or U blade type machine In addition you must remember the ma terial picked up in the bucket each pass remains there until you selectively dump it Several passes from each side will aid in obtaining maximum loads and keeping a smooth level grade 4 Continued dozing from one side and the occasional sloughing of the pile will sometimes cause an undesir able slope to the grade This can easily be straightened out by moving away from the pile approximately one half the machine width for one pass This allows one half the bucket on the high side to cut out to the lowest level thus leveling to the original grade 5 know of no one who has read a How Do instruc tions and become an expert in one try however we are confident that after you have read these instructions and familiarized yourself with the concepts and capabilities of this unique Dozer you will know how to start and with practice become an efficient operator 5 14 In Case of Fire Units With Optional Fire Suppressio
73. of a particular machine Therefore maintenance scheduling becomes a critical fac tor in the effective use of man hours and the availability of serviceable equipment Scheduled Maintenance Checklist Actual operating environment governs the maintenance schedule Some checks should be performed more often under severe conditions such as heavy dust extreme tem peratures or extremely heavy loads These maintenance checklists are designed to be used as a guide until adequate experience is obtained in establishing a schedule to meet your specific needs A detailed list of component checks is provided with a sug gested schedule basis given in hours of operation or calendar time The engine manufacturers operation and maintenance manual should be consulted for additional engine related checks A maintenance schedule should be established using these checklists as a guide The result will be a maintenance pro gram to fit your specific operation Using the Checklist Although specific maintenance is identified in these check lists location and procedure references are not provided in the columns Scheduled maintenance is normally carried out by trained mechanics who are knowledgeable of the equipment systems and component locations Scheduled maintenance proce dures can be found by referring to the appropriate section of the service manual 6 6 Scheduled Oil Sampling Use scheduled oil sampling SOS to monitor machine condi
74. ontrols section 3 NOTE When first powered up some unused parameters Operating Instructions The DDM Main Menu Tree first displays engine data parameters followed by menu entry points Parameters LCD Display Main Menu Tree NOTE The parameters displayed on the DDM will vary depending on the engine make and model w A A Keys Both Up Parameters Continued Fig 3 15 DDM Main Menu Tree To Eng Conf From Eng Conf may be displayed by the DDM These parameters will be automatically removed from the display after the initialization cycle is complete 3 9 Alied Wagner Viewing Engine Data Parameters To read any of the engine parameters press either the UP or DOWN button until the top line of the display shows the desired information Selecting amp Exiting Menus Press either the UP or DOWN button until the top line of the display shows the label of the desired menu Then press the UP and DOWN buttons simultaneously This action will select the menu and the next screen on the display wil
75. onveyor Chute 5 5 14 In Case of Fire Section 6 Maintenance and Lubrication 6 1 REM 6 2 Safety Precautions iiciin Use Safe Ladders Scaffolding Contents 6 3 Preventive 6 2 Benefits of Preventive Maintenance 6 2 Preventive 6 2 Establishing a Preventive Maintenance Program 6 2 Maintenance Record Keeping 6 2 6 4 Shift 6 3 Shift Maintenance Checklist 6 3 Using the 0 21 6 3 6 5 Scheduled 6 3 Scheduled Maintenance Checklist 6 3 Using the 6 3 6 6 Scheduled Oil 6 3 6 7 Lubricant Selection amp Specifications 6 4 6 8 Hydraulic Oil 2 22 2 6 5 6 9 Wet Disk Brakes incer eterne nene 6 6 6 10 Shift Maintenance Checklist 6 7 6 11 Lubrication Points inen 6 8 6 12 Maintenance 6 9 6 13 Maintenance
76. ransmission oil and filters OK ADD 3 Clean and flush cooling system OK ADD 4 Check pins and bushings for wear OK REPLACE 5 Steam clean machine inspect for structural cracks OK NO EVERY 2000 HOURS OR ANNUALLY 1 Repeat the 1000 hour check OK NO 2 Drain flush and fill differential OK ADD 3 Drain flush and fill planetaries OK ADD 4 Change hydraulic oil and filters OK ADD Normal drain period and filter change intervals for average environmental and duty cycle conditions Severe or sub stained high operating temperatures or very dusty atmospheric conditions will cause accelerated deterioration and contamination Change intervals should be adjusted according to the results of oil sampling analysis Consult your Wagner dealer for assistance in establishing an oil sampling program for your equipment IMPORTANT Consult the engine manufacturers Operation and Maintenance Manual for additional engine related checks and or details Repairs Problem Parts Mechanic Hours Labor Operator Supervisor Machine Model Equipment No Date Shift Hour Meter 6 10 Maintenance and Lubrication section 6 6 13 Maintenance Procedures General The following maintenance procedures should be performed at the beginning of each work shift The number before each maintenance procedure corresponds with the numbers given in the Maintenance and Lubrication Chart
77. reating enough pressure to puncture the seal in the nitrogen cartridge Nitrogen cartridges provide the pressure required to actuate the system The actuators can also be operated manually by pulling the safety pin and strik ing the button which punctures the nitrogen cartridge seal Options amp Accessories The electrical system is not only necessary to operate and protect the machine but it is also used to make it a comfort able piece of equipment to operate The A C and heater unit requires the power from the electrical system to control the temperature inside the cab The optional stereo system also uses it to play your favorite music while you work 4 4 Section 5 Operation 5 1 Introduction You the operator have a key position in your company s material handling operation Skill and attentiveness on your part are essential for maximum productivity as well as the safety of yourself and those around you The operating instructions in this manual are intended to help you get the maximum use of your Dozer with the greatest possible safety Become completely familiar with all of the instruments and controls Learn the machine its capabilities and limitations Study the operating techniques given so that through experience you can develop additional techniques of your own and contribute to the success of your team Safety First Your coworkers depend on you to operate safely Before operating the machine read and obse
78. rs monthly 500 Hours quarterly 1000 Hours semiannually e 2000 Hours annually Each successive schedule e g weekly monthly quarterly etc builds on the former and is accumulative in nature For example when performing weekly maintenance the mechan ic will first take note of the shift maintenance and in addition will perform the checks specified in the weekly schedule Maintenance Record Keeping The importance of good record keeping cannot be overem phasized Each scheduled maintenance form should be checked off as the inspections and service is performed Quantities of replenished lubricants should be recorded as well as hydraulic pressure readings All discrepancies should be recorded whether remedied or pending Opera tors and mechanics should sign off forms and return them to the maintenance supervisor for approval and retention in an equipment unit life Maintenance and Lubrication section 6 6 4 Shift Maintenance Shift Maintenance is where preventive maintenance begins The operator normally completes this inspection It consists of the routine servicing and lubrication of the machine s major systems On a daily basis the operator is in a position to identify remedy and or record potential problem areas and is able to quickly recognize any change in the performance of the machine The comments he or she records on the shift maintenance report become a valuable tool to the main tenance department
79. rve the safety precau tions given in this manual BE A SAFE OPERATOR A good safety record can be rewarding Material Handling The Wagner Carry Dozer was developed for fast cycle times in pushing light to medium bulk materials distances of 200 to 800 feet Cycle times and volumes under 200 feet are limited by the distance required to load the bucket and the time required for bucket roll out and dump In comparing the Carry Dozer bucket to the conventional straight or U type dozer blade four unique and basic ideas are engineered into the Carry Dozer bucket 1 The bucket retains all the original material within the confines of the bucket throughout the dozing cycle 2 Thebucket will retain all of the material as it may become necessary to lift the bucket slightly to reduce a break in traction and maintain maximum speed 3 bucket in addition to carrying a full load will push half again as much in front of the bucket thus produc ing more volume per hour than a conventional Dozer of the same size This capability is possible because the material weight within the bucket is transferred to the drive wheels producing maximum traction throughout the dozing cycle 4 The bucket permits dozing maximum bucket loads around turns with minimal spill from the sides 5 2 Break in Period The initial break in period for your unit is limited to the engine The hydraulic system and other components are ready for full operation
80. s 4 Stop the Engine Before performing any maintenance or lubrication re move the key from the switch or tag the key switch DO NOT START to ensure that the engine is not inadver tently started 5 Install Swivel Locking Pin All four wheel drive units are equipped with these pins Always install this pin when working in the area of the swivel hinge The machine must be on a level surface A single swivel locking pin can be installed with the bogie turned left or right Both pins can be used to lock the bogie in a straight line with the dozer CAUTION Never operate the dozer with the locking pins in the locked position Damage to the machine could result Fig 6 1 Bogie Locking Pin In Storage Hole 6 1 Alied Wagner 6 Use Safe Ladders Scaffolding Due to the height of the upper lube points it is essential to personnel safety that safe ladders personnel lifts and or scaffolding be used while servicing These areas can be dan gerously slick under conditions of rain frost or oil smears 6 3 Preventive Maintenance Preventive maintenance is a system that is designed to detect problem areas and prevent equipment failure and maximize machine availability The system is based on a series of maintenance checks and servicing points To be effective a preventive maintenance program demands strict adherence to a planned schedule Benefits of Preventive Maintenance Time spent making required periodic checks is a
81. s mode one of the following error codes will be displayed Error Code 1 Line 1 EP Line 2 No Data EP is Error Passive For some reason the DDM has lost contact with the network and no longer has a communications partner or partners This may have been caused by a connector separating or the network wires being severed Error Code 2 Line 1 BO Line 2 No Data BO means Bus Off Please refer to ACP Err Code 3 Error Code 3 Line 1 BR Line 2 No Data BR means Bus Reset This error code is similar to ACP Err Code 3 The DDM has encountered CAN bus errors that have caused it to transition through EP Error Passive and BO Bus Off In this state the DDM is resetting the CAN interface in an attempt to re establish connection to the network 3 12 Section 4 Functional Description 4 1 Introduction Wagner carry dozers provide the capability to move large amounts of material at low cost and in a short period of time When operated properly the machine can doze a load of close to the same size as the load contained in the bucket The functions and capabilities of the dozer are the result of several systems working together Power Unit Drivetrain Hydraulic system and Electrical system 4 2 Power Unit Engine The engine is the heart of the machine These units are equipped with diesel engines carefully selected for the in tended use of the
82. s the engine will shut down automatically if the problem continues NUR 20 TUE The light is activated when the ignition switch is turned fee NR LIGHT BAR ON This ensures that the system is working m JOYSTICK 15 LIGHTING 29 11 Instrument Panel Lights Dimmer Control PANEL IZN Dims and brightens the lights on the instrument pan HANES E 80 els 22 Fig 3 4 Circuit Breakers 12 Parking Brake Indicator Light red Item 16 If the key switch is ON and the parking brake is ON this light will be ON 16 Fuses and Circuit Breakers Electrical Protection Push to reset Circuit breakers 13 Parking Brake Control are located on the side panel of the left hand console To apply the parking brakes push the button in To release the brakes pull the button out Fuse amperage is noted on decal 3 3 Alied Wagner 17 18 19 20 21 Fig 3 5 Steering and Pedals Items 17 21 Accelerator Pedal Foot controlled engine accelerator pedal Steering Wheel and Column Telescopic and Tilt Steering Column To move telescopic wheel in or out pull lever up to re lease the lock To tilt steering wheel push lever down Horn Button on Steering Column Center hub of steering wheel contains horn button Depress to sound horn Brake Pedal Will also declutch the transmission if the declutch switch item 24 is ON
83. s pressure drop below that required by the manufacturer s specifications during operation STOP THE ENGINE IMMEDI ATELY AND DETERMINE THE CAUSE 6 Voltmeter The voltmeter indicates the voltage condition of the elec trical system whether the alternator is or isn t charging The numbers indicate volts acceptable range is 20 28 volts 7 Fuel Level Gauge The fuel level gauge indicates how much fuel is remain ing in the tank 8 Tachometer An electrical tachometer indicating engine revolutions per minute rpm To read multiply the indicated number by 100 Example 20 x 100 2000 rpm 9 Low Brake Pressure Warning Light A warning light on the dash signals the operator if the accumulator is under 1600 psi or if a low actuator pressure condition exists It is normal for the light to come on when starting the machine but it should go off within 10 seconds If the warning light stays on there is a problem in the charge circuit and the system needs to be checked A warning will also sound if the brake actuator pressure falls below 1600 psi 3 2 Instruments and Controls section 3 3 3 Operation Controls i 14 Transmission Direction and Range Control Push forward to the F position to engage in forward SEE Center in the position to engage into neutral FIG Pull back to the R position to engage in reverse 3 2 Twist the control forward to shift up Twist
84. safety information Alied Wagner Section 6 Maintenance and Lubrication 6 1 General A machine that receives regular care from its operators and mechanics generally rewards them with decreased down time and greater reliability With the help of the information in this section you should be able to maintain your dozer at top operating efficiency The maintenance and lubrication procedures given here can be performed with a minimum amount of shop tools 6 2 Safety Precautions Before performing any maintenance or lubrication review the following safety procedures They re intended for your protection 1 Read This Manual Be sure you understand the procedures outlined in this manual before attempting to carry them out Pay par ticular attention to any safety warnings presented If you have any questions don t hesitate to ask your Wagner dealer 2 Perform Maintenance on Level Ground The machine should be on level ground and clear of traf fic lanes whenever possible The parking brake should be set and the wheels blocked 3 Remove Loads The machine should be unloaded with the bucket down WARNING Never rely on the hydraulic sys tem to support any part of the machine during maintenance or lubrication NEVER stand un der a component that is supported only by the hydraulic system Make sure it is resting on its mechanical stops or safety stands If nec essary support components with appropriate safety stand
85. struments Check all instruments for normal readings immediately after starting engine Make sure that pressures and tem peratures are within acceptable limits Also check that all controls function properly They should be smooth and responsive Air intake system Inspect all connections for damage loose clamps and air leaks Look for damaged fittings and loose connec tions Do not operate the machine if leaks are present Dirt could enter the engine intake and cause severe damage Exhaust System Check for leaks Make sure that exhaust gases are not entering the operator s cab Mounting brackets must be in place and all connections tight Check for excessive smoke Transmission Oil Level The level should be checked after engine warm up with 180 to 200 showing on the transmission temperature gauge The dipstick and fill tubes are located on the chassis deck directly above the transmission Check oil level with engine running at idle at operating tem perature and with the transmission in neutral The level should be between the H high and L low marks Fill with approved fluid only See Lubricant Specifications Maintenance and Lubrication section 6 Circled numbers indicate Boxed numbers indicate Lubrication points Maintenance checks Fig 6 6 MAINTENANCE AND LUBRICATION CHART NOTE Due to variations in engine types and models the
86. t of ether 2 Crank the engine then release cold start switch This injects the metered amount of ether into the engine intake manifold 3 As the engine starts repeat only if necessary to keep the engine running Note For maximum engine protection and easier start ing e Keep the batteries fully charged e Keep the fuel clean and free of water e Change the engine oil to the recommended viscosity for the air temperature CAUTION CAUTION Excessive amounts of starting fluid when cranking engine will cause engine dam WARNING WARNING Starting fluid is extremely flam mable and toxic Never smoke while using starting fluid Never make a hole in the starting fluid container Do not use near an open flame or put the container into a fire Use only small amounts of starting fluid Never store starting fluid in a hot area or in the operator s cab Temperatures below 32 F 0 C 1 Let the engine idle for approximately 15 to 20 minutes before putting any load on the engine Check all gauges for normal readings N After the engine is warm move the machine to full work capacity slowly until the hydraulic oil is at operating temperature CAUTION CAUTION If the temperature of the hydraulic oil is below its pour point do not start the engine The high oil viscosity could cause immediate pump cavitation resulting in severe damage The oil in the hydraulic tank must be heated prior to e
87. tem the batteries are automatically disconnected In case of fire pull the safety pin on the actuator strike whenever the system is actuated the button and LEAVE THE VEHICLE Fire retardant will be released the engine will shut down and the bat teries will be disconnected from the electrical system After the system has discharged watch carefully for flare ups and spot fires Notify the Fire Department and or service personnel as soon as possible Battery Disconnect Switch SIGHT GAUGE Fig 3 13 Air Filter Indicator F Item 53 Fig 3 12 Battery Disconnect Switch Location Item 52 53 Air Filter Indicator Standard location is mounted on the air cleaner housing 52 Battery Disconnect Switch It indicates air filter restriction by showing red zone This switch isolates the batteries from the electrical the element must be serviced as soon as possible To circuits and should be set to off when the machine is reset the indicator press the button on top not in use or during maintenance and repair to prevent unauthorized starting or electrical shorts Turn the switch counterclockwise to disconnect the battery NOTE Allow 30 seconds between ignition key off and battery disconnect off events to avoid erroneous ECM fault code on electronic engines 3 7 Alied Wagner 3 9 Display and Diagnostic Module Ga
88. ual and a complete understanding of all the procedures and functions that may be performed with this machine Planned maintenance and inspections are to be performed after the machine has been delivered and prior to each shift The operator should be aware of these procedures and be able to perform spot checks during operation NOTE These inspections may be performed by main tenance personnel or by the operator In either case it is the operator s responsibility to see that the machine is ready for operation prior to starting Refer to the planned maintenance chart in section 6 for a complete list of the daily checks that are to be performed Engine Oil Level The oil level should be checked prior to starting the engine NOTE A 15 minute drainback time is recommended if the engine has been running to obtain an accurate reading Fig 5 1 Typical Dipstick The oil level must be maintained between the amp low or ADD mark and the high or full mark Maintain the oil level as close to the H or full mark as possible CAUTION Never operate the engine with the oil level below the L low mark or above the H high mark Refer to the engine s Operation and Maintenance manual for detailed engine service information CAUTION Use only approved engine oil see Lubricant Specifications Chart Section 6 Do not overfill Engine Coolant Level Daily inspection of the coolant level is re
89. ubricate sparingly 250 HOURS FAN DRIVE BEARING not all engines 1 Maintenance and Lubrication section 6 6 12 Maintenance Checklist EVERY 50 HOURS OR WEEKLY 1 Repeat the 10 hour check OK NO 2 Check for fluid leaks oil fuel water OK REPAIR 3 Check wear indicator on wet disk brakes See page 6 6 OK REPAIR 4 Check wheel lug nuts and studs mechanically OK REPAIR 5 Check battery electrolyte level OK ADD 6 Lubricate chassis refer to Lubrication chart OK NO 7 Record engine rpm High Stall 8 Check for structural damage inspect chassis amp attachments for bending cracking amp broken welds OK Repair 1 Repeat the 50 hour check OK NO 2 Change engine oil amp filters OK ADD 3 Take engine oil sample for analysis OK NO 4 Check axle differential oil level OK ADD 5 Check axle planetary oil level OK ADD 6 Change cooling system filter OK 7 Check all hydraulic pressure and record OK NO 8 Check fire suppression actuator OK NO 9 Inspect brake components check wear indicator OK REPAIR 1 Repeat the 250 hour check OK NO 2 Change fuel filters OK REPLACE 3 Change Hydraulic filters OK REPLACE 4 Change Transmission filters OK REPLACE 5 Take oil samples from transmission axle and hydraulic system for analysis OK NO 6 Check Accumulator pressure OK NO 6 9 Alied Wagner EVERY 1000 HOURS OR SEMI ANNUALLY 1 Repeat the 500 hour check OK NO 2 Change t
90. uge Operation Description The Display and Diagnostic Module DDM Gauge is a mal function detection tool that enables the operator or service personnel to view many different engine parameters and engine service codes The DDM gauge includes a two line eight character backlit LCD display The top line displays data labels e g OilPress while the bottom line displays appropriate units of measure e g 80 psi for oil pressure Two push buttons UP and DOWN are used for scrolling through parameters and viewing menus Two LEDs amber and red are used to announce active fault messages received by the DDM Engine Parameters The following are some of the engine parameters displayed by the DDM in English or Metric units when applicable Engine Hours Engine RPM System Voltage Engine Load at the current RPM Coolant Temperature Oil Pressure Fuel Economy Throttle Position Manifold Air Temperature 10 Current Fuel Consumption 11 Active Service Codes 12 Stored Service Codes from the engine 13 Display Units may be changed from English to Metric and vice versa at any time 14 Engine Configuration Parameters NO DIGITAL DISPLAY MODULE 400 PSI TRANS OIL PRESS DASH PANEL DISPLAY 100 PSI OIL Fig 3 14 Digital Display Module and Dash Panel Display 3 8 Instruments and C
91. uiped Allied Systems Company recommends that an ap propriately rated fire extinguisher be installed A 20 pound ABC rated extinguisher is the minimum size recommended Install it within easy reach of the operator in a position that protects it from damage Use only a quick release type of mount e Keep your fire extinguisher s and fire suppression sys tem if so equiped fully charged and in good working order Know how to use them Read and understand the instructions printed on the canister and learn how to operate them Learn how to remove the canisters from their mounting brackets in the shortest amount of time e Service the extinguisher and the fire suppression system according to the manufacturer s specifications Service after every use no matter how short a time and never operate the machine without both in full working order e Fire prevention features provided by the manufactur ers should be maintained in operational condition and should be used to suppliment the operator s fire preven tion efforts In no case should the features be used or assumed as replacement for diligent operator efforts at preventing fires 2 5 Alied Wagner Fire Suppression Do not panic e Stop the machine and turn off the engine in the clearest area available e Lower the bucket e fyourmachine is equiped with a fire suppression system and that system has not automatically been activated manually activate the syst
92. ular to that of the wheels into motion that powers the wheels These gears reduce the number of rotations from the engine to the wheels and allows the wheels on each side of the vehicle to spin at different rates necessary to make turns Planet Assembly The planet assembly is the final gearing reduction between the engine and the wheels It is located at the end of the axles mounting flush with the hub The planet has three planet gears which are driven by a sun gear attached to the axle shaft The planet assembly is bolted to the hub causing it to spin much slower than the original input speed from the differential Planet Gear Fig 4 2 Planet Assembly Chassis amp Bogie The chassis provides a mounting for the rear axle The bogie provides a mounting for the front axle The chassis amp bogie assembly is fully articulated hinged for steering and can swivel to negotiate rough terrain Steering is accomplished by hydraulic cylinders 4 4 Hydraulic System Steering The steering system consists of the steering control unit and a flow amplifier valve When the steering unit is activated a controlled oil flow is directed to the flow amplifier valve This oil flow is amplified and the total flow is directed to the steering cylinders The steering unit provides a fixed displacement of oil per revolution of the steering wheel and the amplification factor of the flow divider valve is 8 Therefore total oil output is eight times
93. vehicle They will provide the power needed for operation Almost every system on the vehicle depends on the engine It provides the power for the drive train hydraulic system and electrical system Fig 4 1 Engine Torque Converter Located between the engine and transmission the torque converter allows the engine and transmission to spin inde pendently by using a chamber filled with oil That oil is spun by a centrifugal pump attached to the engine putting the oil into motion That motion is then captured by a turbine attached to the transmission causing it to spin This allows the vehicle to be stopped without shutting off the engine or depressing a clutch pedal Air Intake System The air intake system is critical to the life of the engine it prevents dust and debris from entering the engine air system causing premature engine wear and possible failure When a two stage dry type cleaner is used both the outer and inner elements are required to fully protect the engine from contamination 4 3 Drivetrain Transmission The transmission changes the gearing from the engine to the wheels It allows the machine to move forward run in neutral or to move in reverse It also allows the vehicle to move at a faster speed because it shifts into different gears allowing the engine to run at a lower rpm yet spin the wheels faster An engine can only spin a certain rpm before damage is done Without being able to change gears
94. ving to tear the machine down again a few thousand operation hours later During the overhaul process make sure all parts are thor oughly cleaned before installation Parts that do not receive this cleaning can cause the lubricant to become contami nated which leads to much shorter service life The schedule assumes proper maintenance and lubrication and genuine Wagner filters are used Recomended Drivetrain Overhaul Intervals Hours Engine UAE mi pear 3000 2000 80 000 20 000 6 17 Alied Wagner

80-743 - Allied Systems Company

Contents

Download Pdf Manuals

Related Search

Related Contents