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THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF GALION OR IT’S SUCCESSORS. GALION 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.

Operator’s Manual

A566 & A606 Motor Grader

S/n 10505 & 02974 & Up

GA-O-A566+

CAUTION DO NOT OPERATE THIS MACHINE UNLESS YOU ARE QUALIFIED TO DO SO. OSHA SEC. 1926.20(b)(4)

INSPECT THIS MACHINE PRIOR TO EACH USE AND DURING USE TO MAKE SURE IT IS IN SAFE OPERATING CONDITION. OSHA SEC.1926.550(a)(5)

READ AND UNDERSTAND THE OPERATOR'S MANUAL & SAFE OPERATING RULES.

NOTE: BEFORE STARTING THE UNIT, READ AND UNDERSTAND THE OPERATOR'S MANUAL THOROUGHLY. COMPLY WITH ALL MAINTENANCE AND SERVICE INSTRUCTIONS FOR PROPER OPERATION OF MACHINE.

1. UNDERSTAND proper Grader operation and application. 2. KNOW your work area. Use extra caution on uneven terrain. 3. WALK around machine to check condition of machine before beginning

work. 4. MAKE SURE Grader is operating properly and in good repair. 5. IF machine is unsafe or being repaired, do not operate. Attach warning

tag. 6. USE STEPS AND HAND HOLDS for on and off machine. 7. TEST all control s, brakes and steering before starting work. Adjust

brakes as needed. 8. DO NOT carry personnel. 9. DO NOT get on or off a moving vehicle.

10. USE proper fueling procedures. 11. ALWAYS have ALL controls in neutral, parking brake set, moldboard.

lowered to ground, Operator to be seated at controls, sound horn, . before starting Grader. BLOCK wheels when parking on an incline.

12. ALWAYS remove key when leaving Grader. 13. ALWAYS look before reversing. Ba·ck-up alarm or signalman must be

used. 14. NEVER coast downhill in neutral, always maintain control of Grader,

do not ride brakes. 15. BE AWARE of existing traffic pattern. 16. DO NOT GUESS, know total weight of Grader and dimensions for

operation. 17. USE LIGHTS, directional signals, when applicable.

" 18. NEVER allow grease or other debris to gather on Operator's platform.

KEEP Grader clean. KEEP floor free of tools, etc. 19. NEVER repair or service Grader when in motion. ALWAYS block wheels

before repairing or servicing Grader. 20. BE AWARE of all moving parts.

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TABLE OF CONTENTS CAUTION • . . . I NTRODUC T I ON

Message to the Operator • General Specifications

OPERATING INSTRUCTIONS

Preparation for Use •

Operation Under Usual Conditions Control Console. Control Valve Levers Transmission Control Console Foot Controls. Console Release Lever •• Hour Meter Saddle Pin Release Button Operators' Seat.

. . . All Wheel Drive Test Button & Control Box. Instrument Panel Gauges Push Starting & Towing Before Starting Engine Engine Starting • Engine Harm-Up While Warmed-Up - Engine Runnning Above Idle Engine Shutdown • After Shutting Engine Down

Operation Under Unusual Conditions Operation in Extreme Cold Cold Weather Starting Aid • Operation in Extreme Heat. Operation in Dusty or Sandy Areas Operation in Rainy or Humid Conditions Operation in Salt Water Areas. Operation at High Altitudes. Daily Operational Checks - All Wheel Drive

All Wheel Drive Troubleshooting ••

APPLICATION

General Description. Use of All Wheel Drive

Leaning \Jheels Articulation Banksloping •

45° Extended Reach - Right 90° Banksloping - Right • 45° Extended Reach -Left • 90° Banksloping - Left

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1 2

4

5 5 6 7 8 9 9 9

10 • • • 10

• • 11 • 12 • 14

14 14 15 15

• • 15 15

• • • 16 16

• • 17 18 19 19 20 20 21 21

28 • 29

• • • 30 31

• • 32 32 32

• 33 33

t·1AINTENANCE INSTRUCTIONS Lubrication Instructions Periodic Service Chart Periodic Service Table Fluid Specifications Fuel Specifications ••

Daily/lO Hour Service. Weekly/50 Hour Service . . .

. . .

• 150 Hour Service 250 Hour Service 500 Hour Service

. .. . 1,000 Hour Service 2,000 Hour Service

General Torque Values.

Specific Torque Values Locator Photographs •

Fuel System • Fuel Fuel

Tank. Filter Replacement.

. . .

Electrical System. • • ••• Electrical Wiring Diagram.

•

· . · . . . . . · . .

· . . · . . . . . · . . · . . · .

· . . . . · . · .

All Wheel Drive Additional Wiring Diagram •• · . Coo 1 i ng Sys tem

Engine Cooling System. • ••• Torque Converter Oil Cool er •

•

Converter & Transmission Oil Temperature Final Drive •

Lubricating Oil Filters.

· . · . .

· . Care of Hydraul ic System

Hydraulic Oil Filter · . . .

Air Inta ke System • Engine Air System •• Air Cleaner Element Servicing.

CHECKS AND ADJUSTMENTS Rim Centering •• Self-Adjusting Brakes •• Tire Matching. • • •

. . . . · . · . · . .

. . · .

· . . . · . . · .

.. . •

•

· . · . . . . .

· . · .

· . · . •

· .

•

•

• · . Ball & Socket Adjustment Parking/Emergency Brake Adjustment Maintenance of Powershift Transmission

. . •

DECALS Deca 1 Loca -,: '; ons

STORIilJG • SH~?PI!JG

•

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•

·

·

•

•

•

•

•

•

· •

·

·

•

·

•

· 34

· 35 • 36

· 38

· 42

• 43 • 45 • 48 • 49 • 51 · 52

· 52

· 53

· 54 55

• 60 60

· 61

62 • 63

64

· 65 65

· 66 66

· 66

67

• 68 69

· 70 70

· 71

74 • 75

75 • 75

76 .77

78

• 80

• 81

MESSAGE TO THE OPERATOR

Prior to the initial start-up of your GALION Grader, take the time to read and understand the Operator's Manual •. It has been prepared in order to hel p you operate and maitain your Grader properly. After you have familiarized youself with the contents of this manual, retain it on the Grader, so you can refer to it when needed in the future.

The information contained herein is IMPORTANT and will assist in ensuring that your GALION Grader gives you many hours of dependable, economical and trouble­free service.

In the event repair parts are needed or correspondence \.,ith your GALION dealer is required, furnish the Grader MODEL and SERIAL NUMBER and all other related component serial numbers.

A THIS CAUTION SYMBOL IS USED IN THIS MANUAL TO ATTRACT YOUR YOUR ATTENTION TO CERTAIN PROCEDURES THAT MUST BE FOLLOWED FOR PROPER OPERATION, SAFETY AND USE OF THIS EQUIPMENT.

Established and approved safety rules for operation and use of this equipment must be followed.

NOTE: CHECK THE SERIAL NUr-1BER STAMPED ON THE L. H. SIDE OF FRAME TO ENSURE, THAT IT MATCHES THE NUMBER ON THE TAG, LOCATED ON THE L. H. SIDE OF THE SEAT BOX CONSOLE.

DATE RECEIVED

GRADER MODEL & SERIAL NUMBER , ----_._------------ --------------------

ENGINE MODEL & SERIAL NUMBER _________________ , __________________ _

TRANSMISSION MODEL & SERIAL NUt~BER ________________ , ___________________ _

TIRE SIZE & PLY RATING ________________ . __________ , __________________ _

OPTIONS & ACCESSORIES , .-------------.----------- -------.--------------

---------------,------------------,----------------------------.-----, ---------------,-----------------

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GEN ERAL SPECIFICATIONS

DIMENSIONS - A556/A606

Overall Length Overall Width Overa 11 Hei ght Wheelbase Turning Radius Ground Clearance

TRAVEL SPEEDS - A556

27' 9" (8.46 m) 8' 0" (2.44 m)

10' 10" (3.30 m) 21' 11 1/2"{6.69 m) 24' 4" (7.42 m)

23" (584.20 mm)

INTERNATIONAL HARVESTER & DETROIT DIESEL DT-466 4-53T

First* 0 - 3.8 mph (0 - 6.1 kmph) Second* 0 - 7.0 mph (O - 11.3 kmph) Thi rd* 0 - 11. 9 mph (0 - 19.2 kmph) Fourth** 0 - 23.3 mph (0 - 37.5 kmph)

* FORWARD & REVERSE ** FORHARD ONLY

TRAVEL SPEEDS - A606

INTERNATIONAL HARVESTER DT-466

DETROIT DIESEL 6V71N

First* 0 - 3.4 mph (0 - 5.4 kmph) Second* 0 - 6.2 mph (0 - 10.0 kmph) Third* 0 - 10.5 mph (0 - 16.9 kmph) Fourth** 0 - 20.5 mph (0 - 33.0 kmph)

o - 3.7 mph (0 - 6.0 kmph)

* FORWARD & REVERSE ** FORHARD ONLY

OPERATING WEIGHT - A-556

On Front 'tlheel s On Rear Uheels Total

8,900 Lbs. ( 4,040 kg) 21,200 Lbs. ( 9,888 kg) 30,700 Lbs. (13,925 kg)

OPERATING WEIGHT - A-606

On Front Wheel s On Rea r vlhee 1 s Total

8,900 Lbs. ( 4,040 kg) 22,300 Lbs. (10,115 kg) 31,200 Lbs. (14,152 kg)

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o - 6.7 mph (O - 10.8 kmph) o - 11.4 mph (0 - 18.3 kmph) o - 22.3 mph (O - 35.9 kmph)

. :: .. ,:

ENGINE SPECIFICATIONS - A556

DETROiT DIESEL 4 ... 53T",

Gross Horsepower .. : .

'" .. .~ .

," . .... , .... ,.

@ 2500 RPM " 175 . Bore & Stroke - In. 3.875 X 4.50,

- mm ' 98xl14 No. of Cyl i nders,.4, ,,' Displacement - Cu. In. 212 '

- liters ,3.48 Cool ing System - Gal s. 8

- 1 Hers 30 Crankcase with Filter - Gals. 5.S ','

- 1 Hers ' ~l '

ENGINE SPECIFICATIONS - A606

Gross Horsepower

DETROIT DIESEL , 6Y71N

. ~'.. . "

INTERNATIONAL HARVESTER ',,; DT-466

. ...... " ..

160 4.30 x 5.35 109 x 136

6 466.1

7.64 9.50

36 5

19

INTERNATIONAL HARVESTER DT-466

@ 2300 RPM 200 4.25 x 5 108 x 127

6

@ 2500 RPM 186 4.30 x 5.35

109 x 136 6

466.1 7.64 9.50

36

Bore & Stroke - In. - mm

No. of Cylinders Oi s pl acement - Cu. In.

- liters Cooling System - Gals.

- 1 Hers Crankcase with Filter - Gals.

- liters

APPROXIMATE CAPACITIES

',~: Fuel Tank Hydraul ic Tank Hydraulic System Rear Axl e ' Transmission

,<::, Tandem Case "}Master Brake Cyl inder

Front Wheel Gear Box (each)

TIRE PRESSURES*

426 6.99

12.5 47 4.5

17

71 Gals. (269 liters) 16 Gals. ( 61 liters) 31 Gals. (117 liters) 9 Gals. (34 1 Hers) 8 Gals. ( 30 liters) 8 Gals. ( 30 liters) 1 Pt. (0.47 liters) 1 Gal. (3.81Hers)

5 19

Standard Optional

14:00 x 24- 10 ply 10" rims 30 psi (0.21 MPa) 14:00 x 24 - 12 ply 10" rims 35 psi (0.24 MPa) 17.5 x 25 - 12 ply 14" rims 35 psi (0.24 MPa)

*May be increased 50% for work or travel on paved surfaces.

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OPERATING INSTRUCTIONS PREPARATION FOR USE

After initial delivery or following transportation of machine from one job site to another, it is recommended that the following inspection and report be conducted.

Before unloading the Grader, check it thoroughly for any damage during shi pment. Inspect instruments, power unit and control s. If damage is found, contact the carrier or his agent and report the extent of damage or pil ferage. Have this noted on the transportation document.

Contact your GALION distributor to advise him of the damage. He will assist you to obtain the necessary repairs and to expedite any claim you might have against the transportation company.

Check. for tags wired to the unit. These tags wJl1indicate whether the radiator is drained, filled with water orpermanent-typean-tifreeze solution in which case should be checked for proper protection against ambient temperatures.

Remove dirt and/or grease from exposed parts and. particularly cylinder piston rods.

Service the Grader fully in accordance with both the Daily and 50 Hour Periodic Service schedule, located on pages 35 and 36 of thts manual.

A READ THIS MANUAL TO BECOME FAMILIAR tHTH THE OPERATION OF THE GALION MOTOR GRADER.

MACHINE DAf~AGE AND PERSortAL INJURY CAN BE PREVENTED BY A THOROUGH UNDERSTANDING OF THE PROPER OPERATING PROCEDURES.

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OPERATION UNDER USUAL CONDITIONS

CONTROL CONSOLE

The Operator's console is designed for maximum comfort and operating ease.

The control console, located directly in front of the Operator's seat, may be equipped with the following indicators ( pi lot 1 i g hts ) •

1. PANEL LIGHT - self-explanatory.

2. ARTICULATION INDICATOR -indicates whether the REAR MODULE is ARTICULATED LEFT, RIGHT or CENTERED.

3. HORN BUTTON - self-explanatory.

4. A.W.D. SWITCH - Top = AGGRESSIVE "on"; Middle = NORMAL "on"; Bottom = "OFF" •

5. PILOT LIGHT - A.W.D. "ON" (GREEN) -Lights WHEN THE A.W.D. SHITCH (4) is operated in either the TOP/MIDDLE "ON" pos iti ons.

6. PILOT LIGHT - HYDRAULIC OIL TEMPERATURE (RED) - Indicates HYDRAULIC OIL TEtWERATURE is either TOO HOT or TOO LOU.

7. PILOT LIGHT - TORQUE CONVERTER OIL PRESSURE (RED) - Lights when TRANS­MISSION OIL PRESSURE is TOO LOH.

8. PILOT LIGHT - TORQUE CONVERTER OIL TEMPERATURE (RED) - Lights when TRANS­MISSION OIL TEMPERATURE is TOO HIGH.

9. PILOT LIGHT - TRANSMISSION OIL FILTER (RED) - Indicates that PERHAPS the TRANSMISSION OIL FILTER REQUIRES ATTENTION/REPLACEMENT.

10. PILOT LIGHT - PARKING BRAKE (RED) - Indicates that PARKING BRAKE is APPLIED.

11. PILOT LIGHT - ENGINE WATER TEMPERATURE (RED) - Lights when WATER TEMPERA­TURE is TOO HOT/COOLANT is TOO LOH.

12. PILOT LIGHT - ENGINE OIL PRESSURE (RED) - Lights when there is a LOSS OF OIL PRESSURE or when OIL LEVEL is LOH.

These pilot (warning) lights work in conjunction with gauges on the instrument panel. The Operator should monitor machine pressures on the instrum~nt panel along with pilot lights. These lights will only give the Operator an indication that there is a problem.

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CONTROL VALV'E LEVERS

Located on either side of the Opera-tor's console are nine (standard) con­trol valve levers. They are:

1. TURN SIGNALS & EMERGENCY FLASHERS LEVER - pushing the lever upward activates the R.H. turn signal; pulling downward activates the L.H. turn signal. Moving the lever stop, in either direction, acti­vates the hazard warning signals.

2. l. H. BLADE LIFT - pulling control L. H. side of blade is raised; push­ed L. H. side of blade is lowered.

3. SCARIFIER (accessory) - pulling raises the scarifier; pushing lowers the scarifier.

4. CIRCLE ROTATION - pulling moves the circle clockwise; pushing moves the circle counterclockwise.

5. BLADE TILT (optional) - pulling moves the blade rearward; pushing moves blade forward.

6. VACANT - for installation of option or accessory (ie: snow wing or bulldozer).

7. BLADE SHIFT - pulling noves moldboard to the right; pushing moves the moldboard to the left.

8. WHEEL LEAN - pulling moves front wheels right; pushing moves the wheels 1 eft.

9. CIRCLE SHIFT - pulling the control shifts circle drawbar to the right; pushing shifts the circle to the left.

the

10. ARTICULATION - by pulling this lever, the rear module moves from the center to the right, assisting in a R. H. turn; pushing the lever, the rear module moves ~rom the center to the left, assisting in a L. H. turn.

11. R. H. BLADE LIFT - by pulling this control lever, the R. H. side of blade is raised; pushed the R. H. side of blade is lowered.

MOLDBOARD FLOAT To obtain a moldboard float condition: with Grader ready to plow snow, push the L.H. and R.H. blade lift controls (both 2 and 11) all the way forward into their detent positions.

GRADER SHOULD BE SITTING STILL AND NOT MOVING. BLADE WILL DRIFT A TO THE ROAD SURFACE. t1AKE CERTAIN NOTHING IS UNDERNEATH THE BLADE.

t10LDBOARD FLOAT 140RKS- BEST ON HARD (ASPHALT) SURFACES. CAUTION t1UST BE EXCERC ISED OU SOFT (NON-ASPHALT) MATERIAL.

MOLDBOARD TILT

Blade pitch (moldboard tilt) may be changed as desired to accomodate snow removal, etc. Moldboard tilt is a factory installed option.

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.,.