300 Pacer & Super Power Graders

Transcription

1 Austin-Western Service Manual 300 Pacer & Super Power Graders Service Manual THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF AUSTIN-WESTERN OR IT S SUCCESSORS. AUSTIN-WESTERN AND IT S SUCCESSORS ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL. TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS. AW-S-300P&SGDR

2 CLQRK EQUIPMENT - OPERATOR'S AND SERVICE MANUAL NO. 482-A MODEL 300 PACER & SUPER POWER GRADERS' This Manual applies to machines numbered serially from No and up. AW-S-300P&SGDR CLARK EBUIPMENT COMPANY AUSTIN-WESTERN DIVISION AURORA, ILLINOIS U.S.A. ' Printed in U.S.A.

3 AUSTIN-WESTERN DIVISION ~ rmdritmm SECTION I MAJOR MACHINE SPECIFICATIONS TOPIC PAGE Location of 300 Pacer Components Pacer 300 Specifications... Location of 300 Super Components Super 300 Specifications A Section I

4 en 51 o ::I FUEL AND HYDRAULIC TAN J MAIN HYDRAULIC PIPING II, HIGH LIFT CYLINDER ENGINE COMPARTMENT BLADE LIFT CYLINDER, PROPELLER SHAFT ]I FRONT AXLE -' SCARIFIER CYLINDER J:a C UJ -t I\) 2 I e m UJ -t m JI 2 C - c: "-REAR AXLE-PACER UJ - o 2 CLUTCH PROPELLER SHAFT I -,-REAR AXLE DRAWBAR FRONT AXLE MAINFRAME THROTTLE CONTROL LINKAGE TRANSFER CASE ~ CD I\) :J,. PACER 300 GRADER.(.,.,

5 AUSTIN-WESTERN DIVISION SECTION" LUBRICATION TOPIC PAGE Recommended Lubrication Specifications... 2 Pacer 300 Lubrication Chart... 3 Super 300 Lubrication Chart... 4 Lubrication Chart Key A Section 2

6 ... ;,... AU STI N -WE STE R N SECTION III DIVISION m:m ~ GET IT GOING, KEEP IT GOING Machine Preparation, Safety, and Preveri-tiv~,iJ'~i~tenance Procedures 'j. TOPIC PAGE General Description Inspection... 2 Unloading Grader... 3 Safe Operating Practices Get It Going, Keep It Going Preventive Maintenance In Operation... 4 CONTROL COMPONENTS Operator's Controls... 5 Shifting Instrument' 'Panel -~"... 6 ENGINES and COMPONENTS Starting & Stopping Cummins Diesel Starting & Stopping GMC Diesel Cold Weather Starting Operating Engine Engine Maintenance Air Cleaner Maintenance Oil Bath Dry Type " General Precautions Electrical System Preparation Storage Batteries Cooling System Fan Fan Belt Tension... _ Radiator Cleanliness Radiator Cap Hoses Draining and Refilling , Fuel Tank and Lines HYDRAULIC SYSTEM Preparation for Operation Tank Breather Return Line Filter... : Hoses and Piping TIRE CARE Matching Factory-Equip Tires...' Matching Used Tires Inflation Charts Over - and Under-inflation Bleeding Tires Overloading Repai r Chains PREPARING GRADER FOR BLADE OPERATION Moldboard Operation Field Lubrication Procedures Adjusting Blade Tilting Links Checking Front and Rear Steering Angles... '.' A Section 3

7 Dry Type (Standard on Cummins, Optional on GMC) (Refer to Fig. 9) The dry-type air cleaner used with the Cummins engine is similar in many respects to the air cleaner used in the average automobile in that both filter the air through coated paper cartridges and, under normal operating circumstances, neither require as frequent a schedule of major maintenance as does the oil bath air cleaner. Frequency of service with a dry type air cleaner can range from 4 to 120 hours. Daily inspection is recommended, however; more often if dust conditions warrant, as the dry type air cleaner will not function properly when dust deposits build up past a 2" level in the dust cup (14).-A tight, positive seal must be made between dust cup and cleaner body (9) after every servicing, as leakage at this point will increase dust loading and make it necessary to service the filter cartridge more often. Because of the normal frequency of dust cup servicing --and the possibility of O-ring damage, it is recommended that several replacement O-rings (2, 8, and 12) be kept in stock at all times. Excessive exhaust smoke and/or loss of power may also indicate the need for filter cartridge service. AUSTIN-WESTERN DIVISION r.mm mal Unscrew wing bolt (3) which holds cartridge (6) in position, and lift cartridge from cleaner. Considerable dust can be dislodged by slapping the side or bottom rim of the cartridge with the palm of the hand. WARNING: DO NOT BANG BOTTOM RIM OF CART RIDGE AGAINST ANY HARD SURFACE. Thi.<; may damage the rim and affect the seal when unit is rea.<; sembled. If compressed air at 100 PSI or less is available, blow out cartridge from clean air side. An even, bright light pattern seen through the cartridge when a light is held inside means that the cartridge is clean. We recommend having several spare cartridges on hand to minimize down-time. With both filter cartridge and dust cup removed, inspect tubes by looking through with a bright light. Remove dust deposits with stiff fiber brush. WASHING In addition to tapping and use of air, it is practical to wash the filter cartridge with any good, non-sudsing household detergent. Warm water ( F) is recommended. Flush unit with gentle water stream until drain water is clear. Air dry thoroughly before using; inspect cartridge after each cleaning for ruptures or other damage. ASSEMBLY Before replacing cartridge, wipe out any dust which may be at the bottom of the cartridge chamber. Check top and bottom gaskets (2 and 12), filter cartridge gasket (7) and restriction tap plug (10) to insure that all are seated, undamaged, and leak-free. Lower cartridge (6) into position and secure with wing nut (3) so that unit cannot be rotated. Be sure that rubber-metal washer (4) is in place under the wing nut (3), and that it is in good condition. After insuring cover gaskets are in good condition, cover shoul!1 fit -into position smoothly, without forcing. If not, it may not be properly seated. Check and try again. - For operation's sake, the filter should be replaced after 1000 hours of use. While the cartridge may function sufficiently for a longer period, the small savings gained does not justify the risk. Figure 9. Dry type air cleaner. CLEANING Stop engine, then wipe cover and upper portion of air cleaner. Loosen clamps (11) and remove cover (1). 482-A GENERAL PRECAUTIONS-ALL AIR CLEANERS As an added precaution ag,ainst dirt getting into the engine, frequently inspect the rubber-flexible hose connection between the air cleaner and the cleaner pipe. Should it show any sign of deterioration, replace it. Also check the clamps periodically and tighten when necessary. Failure to perform maintenance as outlined above may result in unnecessary dust entering the engine, causing rapid premature wear to the internal engine parts such as piston and sleeve groups and also valves and the crankshaft assembly. These costs must be borne by the owner, including labor for the parts installation. Section 3

8 AUSTIN-WESTERN DIVISION ~ I1IiaI SECTION IV GRADER OPERATION TOPIC PAGE All-Wheel Drive... 2 All-Wheel Steer... 2 Manipulating the Controls... 3 Grading on a Slope... 3 Starting a New Ditch Making a Second Pass in a New Ditch, or Cleaning an Old Ditch Cleaning or Cutting a Wet Ditch... 6 Windrow Move-over, or Third Pass... 7 Grading the Outslope of a Low-Banked Ditch... 8 Grading a High-Banked Slope... 9 Heavy Grading on Flat Ground Conventional Maintenance Grading Close to an Immovable Object Fine Grading Grading Around Curves Wide Reach or Resloping Grade Shoulders Grading in Reverse Cutting a Flat-Bottom Ditch...-: Grading Between Forms... : Cutting High and Filling Low Places NOTE: Instructions governing the use of various optional accessories available for use on the Austin-Western Power Grader will be found listed under headings of the individual accessories in Section 6, Machine Options. 482-A Section 4

9 AUSTIN-WESTERN DIVISION GRADER MAINTENANCE AND REPAIR mmt!i IilIiII PART I-MAIN HYDRAULIC SYSTEM Topic Page General Information Oil Terminology... 1 Oil Function... 1 Handling Hydraulic Oil Handling Bulk Oil... 1 Draining Hydraulic System... 1 Refilling Hydraulic System... 1 Troubleshooting and Preventive Maintenance Limits of Hydraulic System Preventive Maintenance Troubleshooting... '3,' General Information... 3 Troubleshooting Charts Excessive Noise Excessive Heat.... Incorrect Flow.... Incorrect Pressure.... Faulty Operation.... Diagnosis and Correction of Aeration and Cavitation.... Aeration.... Causes.... Avoiding Aeration.... Cavitation.... Causes.... Avoiding Cavitation.... Conclusion.... Main System Components.... Basic Hydraulic Piping Diagram and Flow Chart.... Main Hydraulic Pump.... Specifications.... Description and Location... :..'.... Disassembly..._.... Inspection and Repair... :.... Reassembly.... Troubleshooting.... Valve Group.... Piping Diagrams.... Relief Valve... :.... Specifications.... Principle of Operation.... Service and Repair.... Proportional Flow Divider.... Specifications... : ,.... Principle of Operation. _... _... _.... Service and Repair.... Priority Valve.... Specifications.... Principle of Operation.... Service and Repair... "... ".... Main Hydraulic Reservoir... ".... Specifications ""... "... ".... Integral Filter Data... "... "... :.... Description and Servicing... "... " A A Section 5

10 - r.mrn!i Main Hydraulic Oil Filter.... Specifications.... Location and Servicing.... Main Valve Bank.... Description.... Leakage.... Lubrication.... Control Plunger Maintenance.... Disassembly.... Inspection and Repair.... Reassembly.... AUSTIN-WESTERN DIVISION Topic Page PART 11-THE BLADE General Information Drawbar and Circie Location and Description.... Adjusting Circle Shim Groups.... Adjusting Horizontal Circle Play.... Adjusting Play at Forward Ball Joint.... Ram Ball Joints.... Worm Gear Circle Motor.... Specifications.... Torque.... Mounting.... Disassembly.... Inspection and Repair.... Reassembly.... Filtration.... Shaft Alignment.... Troubleshooting.... Worm Gear Circle Drive.... Specifications.... Location and Description.... Disassembly.... Maintenance and Repair.... Reassembly.... (Includes preloading procedures for bearings) Tooth Contact Pattern Adjustment Swivel Valve..'.... Location and Description... :.... Service.... Blade Lift Check Valve.... Specifications...'.... Principle of Operation... ~.... Service...,.... Blade Ram Cylinders.... General Information.... Blade Lift Ram... : :. :. Specifications.... Location and Description.... Disassembly.... Inspection and Repair.... Reassembly.... Blade Side Shift Ram.... Specifications.... Location and Description.... Disassembly.... Inspection and Repair.... Reassembly Section 5 B 482-A

11 AUSTIN -WESTERN DIVISION Topic Blade High Lift Ram.... Specifications.... Location and Description.... Disassembly.... Inspection and Repair.... Reassembly.... Setting the High-Lift Mechanism.... Right-hand High Lift...,.... Left-hand High Lift.... Moldboard and Extensions...,.... r.mrn!i miiii Page PART 111-THE GRADER POWER TRAIN The Distribution System Engines Clutches and Torque C,?!!yerters Clutches General Information.... Clutch Abuse.... CI utch Lubrication.... Clutch Adjustment.... Adjusting Linkage.... Clutch Brake... Adjusting Clutch Brake.... Oil Clutch.... Specifications.... Principles of Operation.... Adjustments and Tolerances (Figure 44).... Oil Clutch Pump.... Specifications.... Location and Description.... Maintenance... Disassembly... ".... Inspection and Repair.... Reassembly.... Oil Clutch Line Filter.... Specifications.... Location... Servicing.... Oil Clutch Relief Valve.... Specifications.... Location and Description.... Servicing.... Oil Clutch Breather Cap.... Specifications.... Location and Description.... Servicing.... Torque Converter Clutch...' '.... Specifications... '.'.... Location and Description.... Clutch Removal.... Checking Clutch Plate Alignment.... Repair and Maintenance.... Adjusting Tolerances.... Reassembly...,... " General Information Cross References Torque Converter A c Section 5

12 mmt!i II1II AUSTIN-WESTERN DIVISION Topic Page Description Location Function Lubrication Oil Pressure Tail Shaft Governor Specifications Description Location Operation Lubrication Adjusting Linkage Checking Action Engine Surging Replacing Drive Belt Transmission an<:i. Transfer C,!~.e Removal and Repair Preparation Removal of Combined Units From Machine Disassembly and Repair of Transfer Case Location and Description Disassembly Inspection and Repair Reassembly Transmission Repair and Maintenance Description Inspecting Shift Rails Transmission Disassembly Inspection and Repair Reassembly Troubleshooting Brake Systems Disc Service Brake Specifications Performance Location Removal of Major Components Self-retracting Piston...:.: Principle of Operation... :... : Adjustment and Replacement... -:: Master Brake Cylinder Specifications Principle of Operation Disassembly Inspection and Repair Reassembly Brake Pedal Adjustment Troubleshooting Disc Parking Brake Specifications... '.'..._ Location, Access and Removal... : Propeller Shafts General Information Main Power Train Propeller Shaft Front Propeller Shaft, Front Section Front Propeller Shaft, Center Section Front Propeller Shaft, Rear Section Rear Axle Propeller Shaft, "Pacer" Machines Rear Axle Propeller Shaft, "Super" Machines..., Wheels and Axles General Information...; 79 Steering Rams Section 5 D 482-A

13 AUSTIN.WESTERN DIVISION Topic mm lili'iii Page Front Steering Ram-All Front Axles.... Specifications.... Access and Location.... Disassembly.... Inspection and Repair.... Reassembly.... Rear Steer Ram-Pacer.... Specifications.... Location and Description.... Removal. Disassembly and Repair.... Remounting.... Rear Steer Rams-Super.... Specifications.... Access and Location.... Disassembly.... Inspection- and Repair.... Reassembly.... Outer Wheel and Axle Subassemblies All Front and Pacer Rear Wheels Wheel Removal and Reassembly Removal Inspection and Repair Reassembly Removal and Replacement of Steering Joint and Axle Shaft Steering Joint Disassembly and Assembly Pacer Front Axl&-Rzeppa Joint Disassembly Pacer Rear Axle/Super Front Axle-Cardan Joint Disassembly Inspection and Repair-All Joints Reassembly-All Joints Timing Cardan Joints Wheel Steering Knuckles Disassembly Inspection and Repair Reassembly...,., Wheel Pivot Bearing Adjustment... :_ Super Rear Tandem Unit General Information Chain Inspection and Removal.... Drive Axle Removal and Reassembly... :.... Removal.... Inspection and Repair.... Reassembly.... Removing Pivot Case From Axle Housing.... Removal Inspection and Repair.... Reassembly.... Removing and Replacing Stub Axles.... Removal.... Inspection and Repair.... Reassembly.... Drive Chain Installation.... Drive Chain Adjustment.... Axle Assemblies Preparation for Disassembly 482-A E Section 5

14 r.mm ami AU STI N-WESTE R N DIVISION Topic Removal and Reinstallation of Axle Assemblies from Frame...,.... All Front Axles.... Pacer Rear Axles.... Super Rear Axle and Tandem Unit.... Removing Gear Carriers From Axle Housings.... All Front Gear Carriers.... Pacer Rear Gear Carriers.... Super Rear Gear Carrier.... Gear Carrier Disassembly and Reassembly (All front and rear axles).... Disassembly.... Inspection and Repair.... Reassembly.... Remounting Gear Carriers in Housings.... All Front Axles.... Pacer Rear: Axles.... Super Rear Axle... -~":.... Bevel Gear.:and Pinion Adjustment.... Checking tooth Contact.... Tire Mounting and Demounting.... Precautions With Tubeless Tires.... Mounting Procedures (All tire types).... Demounting Procedures (All tire types).... Page Section 5 F 482-A

15 with the O-ring against the housing (22). Install the seven cap screws (C) and tighten to a torque of 300 inch-ibs. Replace the O-ring seal (21B) on the outside of the spacer plate. AUSTIN-WESTERN DIVISION SPLINE TOOTH mmt!i IIiIII not to disengage the geroler from the splines on the drive. Step 10. Install the seven cap screws (D) in the motor and tighten them finger tight. Using a torque wrench, tighten all bolts to 50 in.-ib., then 125, 175, 225, 275, and 300 inch-pounds in turn. Step 11. Remount the assembled motor back onto the grader drawbar with four bolts (A), and reconnect hydraulic lines, making sure that they are mounted to the same port from which they were disconnected. Test motor thoroughly before returning grader to regular service. No special pre-conditioning or run-in time is necessary; testing, however, insures against leaks, bad joints, or faulty parts or workmanship. CAUTION It is not advisable to start the motor with no oil in the bearing housings. Therefore, prior to starting a motor after repair or replacement and installation, if necessary to do so, disconnect one of the hydraulic lines to the motor and manually add hydraulic fluid until it begins to flow back out of the port. Reconnect the hydraulic line and tighten. SPLINED t-i SHAFT UJOIH.,--r-- MAR K (ON SHAFT SPLINE) FILTRATION It is especially important that hydraulic fluid used to drive this motor is filtered and clean. Contaminated fluids cause wear on the bearings, geroler star and rolls, and on the drive splines, reducing the motor's operating life and increasing the likelihood of breakdown. SHAFT ALIGNMENT Figure 24. Timing the circle motor. Step 8. Make a mark on the shaft spline which lies in line with the forward valving slot, then align the mark with an imaginary centerline which extends up and bisects the two ports, as shown in Figure 24. Insert the splined drive into the shaft in the housing with the splines in the position shown. CA UTION: This is very important as rotating the spline ONE tooth will change the direction of shaft rotation. Place the geroler in the position shown. With this orientation, the shaft will rotate as shown in the lower views with the ports pressurized as shown. Step 9. Place the spacer. (Item 3, Fig. 22) inside the geroler star, then replace the O-ring seal (21C) in the end cap (1) and place the end cap in position. Realign the holes for the mounting screws (D), being careful Poor installation practices which may lead to misaligned shafts should be -avoided. This motor is adequately designed to withstand sufficient side and thrust loads, but to impose an unnecessary continuous force on the motor shaft can accelerate wear and reduce the work life of the motor. T~OUBLESHOOTING In the event that difficulties arise which affect the operation of the worm gear circle motor, their possible causes and corrective measures are listed on the following page. WORM GEAR CIRCLE DRIVE MAKE: Austin-Western Gear Ratio, Motor-to-Worm: 38-1 Gear Ratio, Worm-to-Pinion: Total Motor-to-Pinion Ratio: The worm gear circle drive mechanism is located on top of the grader drawbar, immediately forward of the swivel valve. The circle is driven by a hydraulic motor 482-A Section 5

16 AUSTIN-WESTERN DIVISION TABLE OF CONTENTS SECTION VI ~ ImIJII OPTIONAL ACCESSORIES Topic Page AUTOMATIC BACK-UP WARNING SYSTEM Specifications... 7 Description and Location... 7 Installation... 7 Alarm Unit... 7 Trip Switch... 7 Balance of System..., 7 BULLDOZER Specifications... 8 Description and Location Installation... 8 Installation. of BullqQ;ler Mount Blade Installation Bit Replacement... 8 Operating Bulldozer., Earthmoving Stumping RegularGrading CAB CLIMATE-CONTROL ACCESSORIES Windshield Wipers Specifications, Front Wipers Specifications, Rear Wipers Description and Locations Service, Repair and Replacement... ' 13 Defroster Fans Specifications Descri ption and Locations Principle of Operation Maintenance and Repair Cab Heater Specifications Description and Location Maintenance and Repair... ''-' '.' GAUGES AND METERS... : Electric Fuel Gauge... ~ Specifications Description and Location... '.' Installation Hourmeter... '._,..., 17 Specifications..._..., 17 Description Installation Odometers Specifications Location and Description... '.'... :_. '.' Installation Service LIGHTS Descriptions and Locations Wiring and Mounting Diagrams Running Lights Combinations Headlights Tail and Stop Lights... " 23 Directional Lights... _ Clearance and Identification Lights..."... ' A 1 Section 6

17 m:m 118 AUSTIN-WESTERN DIVISION ~~ P~ Safety Lights Flasher Lights Revolving Beacons Alarm Lights Moldboard Lights Back-up Lights Spotlights " 36 Miscellaneous Lights MOLDBOARD OPTIONS POWER-TI L T MOLDBOARD Description and Location Installation Reworking Circle Reworking Blade Cylinder Shield Modifying Tilt Arm Assembly and Installing New Tilt Arm... '_'.' Mainframe Modifications Additional Frame and Cab Modifications Required with Tiller Bar Steer Additional Frame and Cab Modifications Required with Orbitrol Steer Cab Valve Installation On Orbitrol Steer Machines On Tiller Bar Machines Service and Repair Valves Hydraulic Tilt Rams Specifications Access and Location Disassembly Inspection and Repair Reassembly FLOATING MOLDBOARD Description and Location Installation Modifying Valve Support Plate Piping Float Valves :... Specifications... Description Service ORBITROL STEERING Description Specifications... ' Location and Access Piping... ' Troubleshooting Service ' Functional Check Before You Start... ' Disassembly... ' Inspection and Repair Reassembly RADIATOR SHUTTERS Specifications Description and Location Principle of Operation Field Installation Service Section A

18 AUSTIN-WESTERN DIVISION m:m IIaI Topic Page Control Housing Shutters and Linkage General..., Engine Running Too Hot Engine Running Too Cold Removing Slack From Linkage ROLL-OVER PROTECTIVE STRUCTURE Description..,,...,..,..., Installation...,..., Accessory Modifications..."..., ROTO-PAMIC AIR CLEANER...,..., Specifications...,..,', Description,...,... " Principle of Operation Maintenance '...,.,.. ' SCARIFIER...,.,...,., Description.,.',., --."...,,..,...,... :.., Specifications,... ".,..., Description of Parts.. ',...,...,...,,..., Operation.,,,,...,,...,...,... ' 78 Principle of Operation ",..., Field Operation ".,.,... " Field Lubrication."... "...,...,...,. 80 Disabling for Plow or Bulldozer Operation Unit Maintenance and Repair..,,..., Removal of Scarifier Assembly Remounting of Scarifier Assembly Auxiliary Parts ".. ".. " Scarifier Ram.'...,...,..., Specifications...,... " Disassembly..., Inspection and Repair Reassembly..., Check Valve..., Specifications..., Description and Location, Service.,...,...,83 SNOW-REMOVAL EQUIPMENT Introduction Moldboard Plowing Snow-Removal Lights GIANT V-PLOW Specifications Principle of Operation Installing the Giant V-Plow Mount Mounting the Plow on the Installation Settings Lubrication..., Replacing Worn or Damaged Parts Using the Giant V-Plow :.: REVERSIBLE SNOW PLOW Specifications PrinCiple of Operation Installation Installing the Reversible Plow Mount Mounting the Reversible Plow Mounting the Control Valve Reversible Plow Hydraulic Data Control Valve Disassembly '....' Inspection and Repair... ' A \ 3 Section 6

19 r.mm I11III AUSTIN-WESTERN DIVISION Topic Page Reassembly Reversing Ram Specifications Access and Removal Disassembly Inspection and Repair Reassembly Cushion Valve Specifications Description and Location... '.' Service Adjustable Plow Shoes Operating the Reversible Plow SNOW WING Specifications Principle of Operation Installation... '.~~.' Install i ng Safety Eyes....' Mounting Front Mast Assembly Mounting Rear Mast Assembly Mounting Control Apparatus Modifications Necessary with Roll Bar Snow Wing Hydraulic System Relief Valve Control Valve Specifications Description and Location Disassembly Inspection and Repair Reassembly Front Lift Ram Specifications Description & Location Access and Removal Disassembly Inspection 'and Repair... '.' Reassembly Sheave Maintenance Rear Lift Ram Specifications Descri ption and Location Access and Removal Servicing Blade Arm Lift Ram Specifications Description and Location Access and Removal Servicing Mounting the Snow Wing Front-end Push Tubes Lift Cable Operating the Snow Wing Controls Lubrication Road Clearance Working the Wing on the Road... " 115 Transporting Mounted Wing Section A /..

20 o o o Topic TIRE PUMP Specifications Mounting Operation Service AUSTIN.WESTERN DIVISION o r:mm am. Page NOTES 482-A 5 Section 6