g700b operator’s manual - grader's pro

Safety when servicing

Operating instructions

Controls

Contents

OPERATOR’S MANUAL

Presentation

Instrument panels

Operating techniques

Service and maintenance

Specifications

Alphabetical index

G700BForewordThis Operator’s Manual is intended as a guide for the correct use and maintenance of the machine. Therefore, study it carefully before starting and operating the machine, or be-fore carrying out any preventive maintenance.

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

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

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

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

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

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

SAFETY REGULATIONSIt is the operator’s obligation to know and follow the applica-ble national and local safety regulations. The safety instruc-tions in this manual only apply to cases when there are no national or local regulations.

WARNING!

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

Know the capacity and limits of your machine!

This manual applies to Serial Number 35000 and up.

Ref. No.: 21 1 434 4006

Printed in Canada

Foreword

2

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

Manufacturer Volvo Motor Graders Limited

160 Maitland Road,

Goderich, Ontario, Canada N7A 3Y6

The PIN number of the

machine (serial number)

Engine

Transmission

Final drive

Foreword

Operation and maintenance of the machine 3

Operation and maintenance of the machine

Volvo Motor Graders Limited is only responsible if:

� the machine has been used in a correct way and has been maintained in accordance with the instructions in the Operator’s Manual and Service Manual.

� prescribed service and prescribed inspections have been carried out at the stated points of time.

� the recommended lubricants according to the manual have been used.

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

� all modifications and repairs have been carried out and methods have been used in the way prescribed by Volvo Motor Graders Limited.

� only genuine Volvo spare parts/accessories, or genuine spare parts/accessories that meet Volvo’s requirements, have been used.

WARNING!

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

Foreword

4 Communication equipment, installation

Communication equipment, installationIMPORTANT!

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

Protection from electromagnetic interference

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

Mobile telephones

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

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

Guidelines

The following guidelines must be followed during installation:

– The antenna placement must be chosen to give good adaptation to the surroundings.

– The antenna cable must be of the coaxial type. Be careful to ensure the cable is undamaged, that the sheath and braid are not split at the ends, and the braid covers the connector ferrules and has good gal-vanic contact with them.

– The mating surface between the antenna mounting bracket and the bodywork must have clean metal surfaces, with all dirt and oxide re-moved. Protect the mating surfaces against corrosion after installation to maintain good galvanic contact.

– Remember to separate interfering and interfered cables physically. In-terfering cables consist of the communication equipment’s supply ca-bles and antenna cable. Interfered cables are those which are connected to electronic devices in the machine. Install the cables as close as possible to grounded sheet metal surfaces, since the metal has a shielding effect.

Contents

5

ContentsForeword.................................................................1

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

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

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

Presentation ...........................................................7General...............................................................................7

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Contents

6

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Service and maintenance ................................. 163Fuel system ................................................................... 165

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

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

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

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

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


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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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


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

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

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

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

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

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

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

Presentation

General 7

Presentation

GeneralIntended use

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

Engine

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

VHP

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

– For non-All Wheel Drive equipped graders, forward gears 1, 2, and reverse 1, have reduced power to minimize wheel slip. In forward gears 3 through 8, and reverse gears 2 through 4, engine power is automatically increased.

– For All Wheel Drive equipped models with the All Wheel Drive system turned OFF, the function of the VHP is the same as above.

– For All Wheel Drive equipped models with the All Wheel Drive turned ON, the engine power is increased for all gears.

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

Presentation

8 General

Electrical system

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

Clutch

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

Transmission

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

Final drive/tandems

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

Brakes

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

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

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

Steering

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

Cab and frame

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

Presentation

General 9

MBCS (Moveable Blade Control System)

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

Hydraulic system

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

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

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

All Wheel Drive

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

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

The system has a 16-speed aggression control dial.

Equipment and attachments

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

– Dozer blade

– Rear-mounted ripper-scarifier

– Mid-mounted scarifier

– Front-mounted scarifier

– Windrow eliminator

– Push block (counterweight for ripper)

– One-way plow

– V-plow

– Hydraulic snow wing (high and low bench)

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

Presentation

10 CE Marking and Declaration of Conformity

CE Marking and Declaration of Conformity(Only applies to machines marketed within the EU/EEA).

This machine is CE marked. This means that when delivered the machine meets the applicable “Essential Health and Safety Re-quirements”, which are given in the EU Machinery Safety Direc-tive.

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

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

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

EU EMC Directive

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

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

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

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

Presentation

CE Marking and Declaration of Conformity 11

Modifications

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

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

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

1 The attachment, accessory, assembly or part is manufactured

or distributed by Volvo and installed in a factory approved man-

ner as described in the publications available from Volvo; or

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

ing Department of Volvo Motor Graders.

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

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

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

Unauthorized modifications of the ROPS (Roll Over Protective Structure)

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

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

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

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

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

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

Presentation

12 Plates and decals

Plates and decals

Product plates

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

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

1 Engine

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

2 Cab

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

3 Product identification plate

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

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

4 Product identification plate (EU/EEA countries)

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

Presentation

Plates and decals 13

5 Product identification plate for TUV (Germany)

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

6 Transmission

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

7 Final drive

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

Presentation

14 Plates and decals

Information and warning plates

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

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

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

Presentation

Plates and decals 15

Item Description Location

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

2 Warning! Never Short across starter terminals.

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

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

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

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

6 Parking brake decal Right-hand side of pedestal.

7 Warning! Wear seat belt when operat-ing machine.

Front of the pedestal.

7 Warning! Read the operator’s manual first!

Front of the pedestal.

8 Warning! Accumulator contents under pressure.

Over the barrel of the accumulator (if equipped).

9 Warning! Use only petroleum base fluid in brake reservoir.

Rear right-hand side of cab.

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

11 Differential lock operating instructions On the front windshield.

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

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

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

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

16 Safety instructions: Use handholds and steps.

Both sides of the cab.

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

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

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

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

21 Sound decal (Statement of exterior noise measure-ment of the machine)

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

Presentation

16 Service

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

Delivery inspection

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

Inspection

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

Maintenance service

Condition Test and Maintenance Programs

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

Presentation

General Information 17

General Information

The USA federal clean air act

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

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

The following acts and the causing thereof are prohibited:

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

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

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

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

Customer assistance

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

Presentation

18 General Information

Normal non-road engine use

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

Non-road engine maintenance

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

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

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

Service performed by your local dealer

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

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

Presentation

General Information 19

Preventive maintenance program

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

Fuel system

Fuel Recommendations:

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

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

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

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

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

� Visually check unions and hose connections.

Check the condition of the fuel hoses for:

� Ageing

� Cracks

� Blisters

� Scuffing

Check the condition of the fuel tank:

� Drain water condensation.

� Check for cracks.

� Check for leaks.

� Check the mounting.

Check the turbocharger:

� Visually check for leaks in the intake hoses and exhaust pipe of the turbocharger.

Presentation

20 Notes

Instrument panels

General 21

Instrument panels

General

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

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

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

1 Center instrument panel (display unit, control lamps, gauges)

2 Pedestal head instrument panel (switches, warning lights, gauges)

3 Side console instrument panel (switches, warning lights/buzzers)

4 All Wheel Drive control panel (switches, warning/information lights, aggression dial)

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

Instrument panels

22 Center instrument panel

Center instrument panel

General

If red control lamps light up – stop the machine immediately!

If amber lamps light up – an abnormal condition exists and mea-sures may be required depending on the function concerned.

The remaining lamps – indicate that the respective function is engaged/connected.

1 Information (amber) 12 High beams

2 Central warning (red) 13 Turn signal indicator

14 Differential locked

3 Charging battery 15 Engine preheat

4 High Hydraulic oil temperature 16 Secondary steering

5 Low transmission oil pressure

6 Brake warning 17 Display unit (speedometer optional)

7 Blade control system unlocked 18 Engine oil pressure

8 Parking brake applied 19 Engine coolant temperature

9 Engine air filter restriction 20 Fuel level

10 Filter bypass warning

11 Primary steering system 21 (not used)

22 Hydraulic oil level

23 (not used)

Instrument panels

Center instrument panel 23

1

Information (amber)

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

2

Central warning (red)

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

Buzzer

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

– Low engine oil pressure

– Low transmission oil pressure

– Low parking/service brake pressure

– Parking brake (if applied in gear)

– Low hydraulic oil level

– Low steering system pressure

– High engine coolant temperature

– High hydraulic oil temperature

3

Battery charge warning (red)

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

Instrument panels


4

Hydraulic oil temperature warning (red)

(optional)

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

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

5

Transmission pressure warning (red)

This lamp indicates low transmission oil pressure. It is accompa-nied by the red central warning lamp, buzzer, and display mes-sage.

6

Service brake warning (red)

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

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

Instrument panels


7

MBCS status lamp (amber)

The lamp indicates the MBCS (Moveable Blade Control System) lock is disengaged. Refer to Moveable Blade Control System page 107.

8

Parking brake applied (red)

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

9

Engine air filter restriction (amber)

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

10

Filter bypass warning (amber)

(optional)

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

11

Primary steering system (red)

(Secondary steering option only)

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

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

Secondary steering system check

Refer to Secondary steering system test switch page 42.

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

Instrument panels


12

High beam (blue)

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

13

Directional indicators (green)

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

14

Differential lock status (amber)

This lamp energizes when the differential lock is in the LOCK po-sition.

15

Engine preheat (amber)

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

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

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

16

Secondary steering system status (amber)

(Secondary steering option only)

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

Instrument panels


17

Display unit

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

18

Engine oil pressure gauge

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

19

Engine coolant temperature gauge

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

20

Fuel gauge

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

If the tank has been run empty, see Bleeding the fuel system page 168 under Service and maintenance.

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

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

21

(not used)

22

Hydraulic oil level (red)

(optional)

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

23

(not used)

Instrument panels

28 Pedestal instrument panel

Pedestal instrument panel

1

Transmission gear display

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

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

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

Refer to Shifting gears page 87.

The gear display can also provide other information:

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

� It shows an error code if there is a fault in the transmission or All Wheel Drive electrical system.

Start code sequence

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

1 Transmission gear display 7 Secondary steering system test

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

3 Keypad, display unit 9 Float valves power switch

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

5 Differential lock switch 11 Parking brake switch

6 MBCS lock pin

Code Meaning

.8.8 LCD (Liquid Crystal Display) test

7.8 ECU (Electronic Control Unit) identification

8.4 ECU identification (All Wheel Drive)

1 Last gear memorized* (example)

-1 Opposite gear* (example)

* Alternating display while in neutral

Instrument panels

Pedestal instrument panel 29

Error codes

The transmission ECU (electronic control unit) continuously mon-itors the transmission and the AWD (All Wheel Drive) electrical system. In the event of a malfunction in either of these systems, an error code is shown in the gear display. Record any error codes and have the electrical system repaired by a qualified service technician. For further information on Error Codes, see the Service manual.

Transmission error codes

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

� “1.0” series error codes indicate insufficient power available for transmission solenoids. The transmission will not oper-ate until this problem has been resolved.

� “2.0” or “3.0” series error codes indicate either an open or short circuit in a transmission solenoid. An alternate gear can be selected by returning the transmission to NEU-TRAL. This will allow the grader to be moved.

� “2.8” or “3.8” series error codes indicate either an open or short circuit in the parking brake solenoid. The grader will not operate until this problem has been resolved.

� “4.2” error code indicates the fault may be corrected by plac-ing the shifter in NEUTRAL then back into gear.

� “4.4” error code indicates a multiple shift command error. More than one proximity switch has been energized simulta-neously. The circuit board must be replaced to correct this problem.

� “4.6” error code indicates there is a problem with the shift le-ver. The shift lever is out of neutral with no signal to the for-ward or reverse solenoids.

� “P” series error codes indicate a malfunction in the parking brake electrical system.

AWD (All Wheel Drive) error codes

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

If a malfunction occurs:

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

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

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

malfunction is corrected. The transmission is not disabled.

Record the error codes and have the AWD electrical system re-paired by a qualified service technician. Some error codes will dis-able the AWD system.

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

Instrument panels


2

Articulation indicator gauge

The indicator needle displays the degree the grader frame is artic-ulated. The frame is straight with the needle in the center position.

3

Keypad, display unit

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

Engine

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

Transmission

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

Hydraulics

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

Electrical system

System voltage

AUX1 (Grader information)

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

AUX2 (Trip measurement information)

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

1 Engine 7 Arrow down

2 Transmission 8 Setup

3 Hydraulics 9 Select

4 Hourmeter 10 Auxiliary 2

5 Electrical system 11 Auxiliary 1

6 Arrow up 12 Esc

Instrument panels


The following functions can be controlled from the keypad:

– Selecting function group by direct selection (function key)

– Browsing within a function group (the arrow keys)

– Activating/deactivating functions (on/off)

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

– Numerical settings (the arrow keys)

– Alpha-numerical settings (the arrow keys)

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

Engine, Transmission, Hydraulics, Hourmeter, Electrical, Auxiliary 1 and Auxiliary 2 keys, display information about the respective function group.

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

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

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

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

Refer to Setup, language and units page 34.

Instrument panels


Display unit

Starting sequence (initial display)

(Ignition key in the “I” position)

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

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

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

Displayed information

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

1 Operating information, etc.

2 Warning displays (low pressure etc.)

3 ERROR displays (sensor and control device check)

Operating information display

� This is the default display.

� Obtain different information – engine, transmission, hydrau-lics, hourmeter, electrical, auxiliary 1 and auxiliary 2 – by se-lecting buttons on the keypad.

Warning display

� Alerts the operator to a malfunction in machine systems (en-gine, hydraulics, transmission, etc.).

� Applies to various areas of the grader.

Error display

� Alerts the operator to malfunction in the monitoring system.

� Applies to various areas of the grader.

Operating information (default display)

– Operating Information will be displayed after starting (unless the operator had another display screen showing when the power was switched off).

– At a speed above 20 km/h (12.4 mph) the Operating Informa-tion will show the current travel speed (even if another display screen was selected).

– If a display screen other than the Operating Information was selected, the system will revert to that display screen when the travel speed drops below 20 km/h (12.4 mph).

– Changing the display screen using the keyboard is only pos-sible if the travel speed is below 20 km/h (12.4 mph).

Operating information display

1 Engine speed

2 Machine hours

3 Travel speed (optional)

4 Units for travel speed

Instrument panels


Changing display screen

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

Setup

Settings of language and units are done in Setup, language and units page 34.

Display classes

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

Class 1: WARNING

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

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

Class 2: INFORMATION

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

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

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

Class 3: ERROR

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

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

Class 4: SERVICE INFO

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

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

Multi-info/warning/error display:

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

Machines with the optional speedometer

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

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

Instrument panels


Setup, language and units

Language

– Depress the SETUP key, then depress the SELECT key to show the language menu. Available languages are English, French, Spanish, Swedish, and German.

– Select the required language with up or down arrow keys.

– After the language has been chosen, press SELECT. If no change of the setting is required, just press SELECT.

Units

– By pressing the SELECT key, the display will change from the language menu to the menu for “Units”.

– Choose the required units with the arrow keys and press SE-LECT. If no change of the setting is required, just press SELECT.

– Press ESC to return to the main menu.

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

Information display screens

Function groups

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

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

NOTE! If “Er” is shown for a value in any display screen, it in-dicates an error in the signal monitoring that information.

x = Engine speed (revolutions per minute).

y = Engine coolant temperature, units are °C or °F. Shown down to 0 °C, below that shown as < 0 °C or < 0 °F.

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

x = Intake air temperature, units are °C or °F. Indicates actual temperature down to 0 °C, below that shown as < 0 °C or < 0 °F.

y = Charge air temperature, units are °C or °F. Indicates actual temperature down to 0 °C, below that shown as < 0 °C or < 0 °F.

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

x = Fuel temperature, units are °C or °F. Indicates actual tem-perature down to 0 °C, below that shown as < 0 °C or < 0 °F.

y = Fuel pressure, units are bar and psi.

z = Coolant level (normal or low).

Instrument panels


x = Transmission oil pressure (indicates normal or low).

y = Transmission oil filter (indicates normal, clogged).

z = VHP status (indicates ON or OFF).

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

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

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

x = Time in hours, up to 99999.9.

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

Instrument panels


x = Machine model

y = Tire size designation

y = Distance travelled, units in km or mi. Shown up to 999,999 km or 621,372 miles.

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

x = Current fuel consumption, shown in L/h or g/h (liters per hour or US gallons per hour).

y = Average fuel consumption per hour, shown in L/h or g/h (li-ters per hour or US gallons per hour). Calculated by dividing total fuel consumed by engine hours.

z = Total fuel consumption, calculated up to 9999999 liters or 2641720 US gal, in one unit increments.

x = Time remaining to next service interval.

y = Service interval, shown as 250, 500, 1000, 2000. When 8 hours remain to next service, display shows “Time for ser-vice”.

To acknowledge and remove information, press SELECT.

The bars indicate the total time left until the next service interval. Each one represents 25 hours.

When 8 hours remain to next service, the display shows “Time to change engine oil”.

To acknowledge and remove information, press SELECT.

x = Fuel consumption since resetting, in liters or US gal up to 999,999 liters or 264,200 US gal.

y = Time since resetting in hours up to 9999.9

z = Fuel consumption per hour since resetting, up to 99.9 L/h or 26.4 US gal/hr.

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

x = Total distance since resetting in km (or mi) up to 9999.9 km (6213.6 mi), alternatively –

y = Average speed since resetting up to 99.9 kmh (62.1 mph) shown in kmh (kilometre/hour) or mph (miles/hour), alterna-tively –

z = Fuel consumption per unit distance since resetting, up to 99.9 in L/km or US mi/gal, alternatively –

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

Instrument panels


Trip information reset:

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

– Press the down arrow, display shows “TRIP INFORMATION 2”.

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

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

– Trip data is now set to zero.

Warning displays

The following alarm texts may appear on the display unit.

ENGINE, warning and information displays

XXXX = PPID, PID, or SID

YYY = Numeric value 1 - 999

TRANSMISSION, warning and information dis-plays

Instrument panels


HYDRAULICS, warning and information displays

ELECTRICAL SYSTEM, warning and information displays

WARNING DISPLAYS, other

Instrument panels


ERROR DISPLAYS, sensor and actuator switches, engine

XXXX = PPID, PID, or SID

YYY = Numeric value 1 - 999

Instrument panels


ERROR DISPLAYS, sensor and actuator switches, transmission

ERROR DISPLAYS, sensor and actuator switches, hydraulics

ERROR DISPLAYS, sensor and actuator switches, other

Instrument panels


4

4-way hazard flasher switch

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

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

5

Differential lock/unlock switch

The top of the rocker switch is depressed to activate the differen-tial lock; the bottom of the switch is depressed to deactivate.

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

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

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

Instrument panels


6

MBCS (Moveable Blade Control System) lock pin switch

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

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

See also Moveable Blade Control System page 107.

7

Secondary steering system test switch

(optional)

This is a momentary style switch. Push on the top of the switch to activate and deactivate the system. The switch defaults to the off position.

To test the Secondary steering system:

� Turn the ignition key to the “I” (running) position. Do not start the engine.

� Depress the top of the rocker switch to activate the system. The Red central warning lamp, Primary steering system lamp and the Secondary steering lamp in the center instrument panel will energize accompanied by a buzzer and display message.

Instrument panels


� Check the system by turning the steering wheel.

� If the steering wheel does not turn easily, there is a fault in the system. Have the system repaired by a qualified service tech-nician.

8

Directional indicator/High beam/Horn but-ton

Directional indicator

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

High beam

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

Horn button

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

WARNING!Do not operate the supplementary steering system longer than two minutes. Equipment damage will result.

Instrument panels


9

Float valves power switch

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

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

10

Front float valves system indicator lights (control lamp amber)

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

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

11

Parking brake switch

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

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

Instrument panels

Side console instrument panel 45

Side console instrument panel

1 Heater/air conditioner fan speed switch 12 Ignition switch

2 Air conditioner switch 13 Engine preheat switch

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

4 Front defroster fan switch 15 Blue revolving beacon switch

5 Rear defroster fan switch 16 Wing lights switch

6 Heated mirrors switch 17 Tire pump switch

7 Headlights and parking light switch 18 Moldboard lights switch

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

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

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

11 Rear windshield wiper/washer 22 Instrument lighting level

23 24V Remote electrical receptacle (not shown)

Instrument panels

46 Side console instrument panel

1

Heater air conditioner fan speed switch

(optional)

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

0 = System off

1 = Low fan speed

2 = Medium fan speed

3 = High fan speed

2

Air conditioner switch

(optional)

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

3

Heater/air conditioner temperature control

(optional)

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

Instrument panels


4

Front defroster fan switch

(optional)

This is a three position switch. Depress the top of the switch to po-sition two to activate low speed. Depress the top of the switch again to position three to activate high fan speed. Depress the bot-tom of the switch to turn it off.

5

Rear defroster fan switch

(optional)

This is a three position switch. Depress the top of the switch to po-sition two to activate low speed. Depress the top of the switch again to position three to activate high fan speed. Depress the bot-tom of the switch to turn it off.

6

Heated mirrors switch (optional)

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

7

Headlights, EEC headlights and parking lights switch

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

8

Extra headlights switch

(optional)

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

Instrument panels


9

Lower windows wiper/washer

(optional)

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

10

Front windshield wiper/washer

(optional)

The wiper switch has three positions. Move it clockwise one in-dexed position for normal speed. Move it two indexed positions for fast speed. The windshield washer activates when the switch is pushed (spring return).

11

Rear windshield wiper/washer

(optional)

The wiper switch has three positions. Move it clockwise one in-dexed position for normal speed. Move it two indexed positions for fast speed. The windshield washer activates when the switch is pushed (spring return).

Instrument panels


12

Ignition switch

The Ignition switch has four positions.

O Turned off

R Radio position

I Running position and preheating position

II (not used)

III Starting position

See also Ignition switch page 83.

13

Engine preheat switch

This momentary style switch is used for connecting a heating ele-ment in the intake manifold.

To turn on the preheating element, turn the ignition key to the “I” position. Depress and release the switch. The lamp in the center instrument panel illuminates to indicate the element is connected.

Refer to Starting the engine page 85.

14 and 15

Amber and blue revolving beacon light switches

(optional)

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

16

Wing lights switch (optional)

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

17

Tire pump switch (optional)

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

Instrument panels


18

Moldboard lights switch

(optional)

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

19

Rear flood lights switch

(optional)

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

Instrument panels


20

Fuse and relay center access panel

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

If an electrical overload occurs:

� The button of the applicable circuit breaker extends to the open position.

� The element of the applicable automotive blade-type fuse melts.

To reconnect the electrical circuit:

� Press the circuit breaker button into the closed position.

� Find and discard the fuse with the broken element. Install a new fuse having the same amperage rating.

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

21

Socket for service display unit

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

Contact an authorized dealer workshop.

22

Instrument lighting level

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

Turning the control to the right increases the light intensity.

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

23

24V Remote electrical receptacle

(Not shown in main overview illustration)

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

Instrument panels

52 All Wheel Drive control panel

All Wheel Drive control panel

General

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

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

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

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

Warning lamps

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

� Turn the system off.

� Stop the grader and report the malfunction.

� Investigate the cause.

� Have the system repaired by qualified service personnel.

� Do not attempt to use the All Wheel Drive system until the fault is repaired.

1

System activation lamp

This lamp indicates the All Wheel Drive system is activated.

2

Low oil level lamp

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

3

Oil filter clogged lamp

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

1 System activation lamp (green)

2 Low oil level lamp (red)

3 Oil filter clogged lamp (amber)

4 Creep mode activation lamp (green)

5 High oil temperature lamp (red)

6 Low oil pressure lamp (red)

7 System activation switch

8 Creep mode activation switch

9 All Wheel Drive aggression dial

Instrument panels

All Wheel Drive control panel 53

4

Creep mode activation lamp

Indicates the Creep Mode has been activated.

5

High oil temperature

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

6

Low oil pressure

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

7

System activation switch

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

8

Creep mode activation switch

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

9

All Wheel Drive aggression dial

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

� A lower setting slows the front wheel rotational speed com-pared to the rear; a higher setting increases the front wheel ro-tational speed in comparison to the rear.

Instrument panels

54 Other

Other21

Dome light switch

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

22

Cigar lighter

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

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

23

Hourmeter

(not shown in main overview illustration)

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

Controls

Operator controls 55

Controls

Operator controls

1 Clutch pedal 7 Operator seat and seat belt

2 Brake pedal 8 Pedestal tilt pedal

3 Accelerator/decelerator pedal 9 Steering wheel tilt lever

4 Hand throttle lever 10 Climate control system

5 Transmission shift lever 11 Hydraulic controls

6 Steering wheel 12 Auxiliary hydraulic controls (optional)

Controls

56 Operator controls

1

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

2

Brake pedal

3

Accelerator/decelerator pedal� Depress the pedal toe to increase rpm.

� Release the pedal to decrease engine rpm.

� Use the pedal to override the hand throttle setting.

� Depress the pedal heel to decrease engine rpm when the hand throttle is set.

� When you remove your foot from the pedal, the engine speed will return to the preset hand throttle position. Refer to Hand throttle.

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

4

Hand throttleThe hand throttle provides a fixed engine speed control during grading.

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

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

5

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

Refer to Shifting gears page 87.

6

Steering wheel

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

Controls

Operator comfort 57

Operator comfort

7

Operator seat and seat belt

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

Weight adjustment

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

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

Height adjustment

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

Fore/aft adjustment

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

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

Controls

58 Operator comfort

Seat pan angle adjustment

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

Exert pressure on or off the seat pan to move it to the desired an-gle position.

Seat cushion depth adjustment

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

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

Armrest adjustment

You can change the inclination of the armrests by turning the ad-justment knob (arrow).

Controls

Operator comfort 59

Armrests

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

Lumbar support

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

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

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

Controls

60 Operator comfort

Seat belt

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

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

� Pull the right side of the belt out from the seat with your right hand until there is enough slack to reach across your lap to the clasp.

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

� Allow the belt to retract when fastened to fit snug and low around your hips. The seat belt must be free of slack.

8

Pedestal tilt pedal

To move the pedestal forwards or backwards:

� Grasp the steering wheel.

� Push down on the pedal located at the bottom of the pedestal column.

� Move the pedestal to the desired position and release the pedal.

WARNING!Wear seat belt when operating machine.

Controls

Operator comfort 61

9

Steering wheel tilt lever

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

To tilt the steering wheel and control head assembly:

� Grasp the steering wheel and lift the lever located on the up-per right-hand side of the pedestal column.

� Move the steering wheel and control head to one of the four positions.

� Release the lever and ensure it latches securely.

10

Climate control system

Heating, ventilation and air conditioning controls

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

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

General information

� Keep doors and windows closed to provide efficient heating and air conditioning in an enclosed cab.

� Direct air flow away from unprotected skin.

� Adjust the fan speed until the air flow in the cab feels comfo-ratable.

� For service information on the fresh air filter(s) and recircula-tion vent/screen, refer to Climate control system page 197.

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

1 Fan speed switch

2 Air conditioner on/off switch

3 Temperature control switch

4 Front defroster fan switch

5 Rear defroster fan switch

Controls

62 Operator comfort

Cab air distribution

Upper level vents

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

Mid level vents

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

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

Floor level vents

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

Recirculation vents and screen

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

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

1 Upper vent louvers

2 Rear defroster fan

1 Mid level vents

2 Floor level vents

3 Recirculation vent and screen

Controls

Operator comfort 63

Adjusting heating and ventilation

These instructions are only basic recommendations and each op-erator should experiment to achieve the best possible working en-vironment in an enclosed cab.

For maximum warmth:

� Ensure heater shut off taps at engine are open

� Open all vent louvers.

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

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

� When a comfortable level is reached, turn the temperature switch (3) until the required temperature is maintained. Turn the fan speed switch (1) to position 1 or 2.

For a comfortable working temperature:

� Turn the temperature control knob (3) counterclockwise until a comfortable temperature is reached.

� Reduce the fan speed (1) to 1 or 2.

To defrost or demist the front and rear windshields:

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

� Adjust the upper front facing louvers and the lower vent lou-vers towards the side windows.

Cab ventilation

� The cab can also be ventilated by opening the doors. Secure the doors in the open position by pushing them all the way open until they latch against the stop on the side of the cab.

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

Adjusting air conditioning

For maximum cooling:

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

� Turn on the air conditioning switch (2).

� Turn the temperature control switch counterclockwise to the minimum position.

� Open the two recirculation vents in the back of the left-hand door post.

� When the temperature has dropped to the required level, turn the fan speed switch to 1 or 2. Adjust the temperature control to a comfortable level.

For a comfortable working temperature:

� Turn the temperature control knob (3) clockwise until a com-fortable temperature is reached.

� Reduce the fan speed (1) to 1 or 2.

1 Fan speed switch

2 Air conditioner on/off switch

3 Temperature control switch

4 Front defroster fan switch

5 Rear defroster fan switch

Controls

64 Hydraulic controls

Hydraulic controls

11

Hydraulic controls

1 and 6

Left-hand and right-hand blade lift

� Push forward on both levers at the same time to lower the moldboard.

� Pull back on both levers at the same time to raise the mold-board.

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

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

3 Circle turn lever 8 Articulation lever

4 Circle shift lever 9 Moldboard tilt lever

5 Front wheel lean lever 10 A-frame attachments lever

Controls

Hydraulic controls 65

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

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

Electric float valves

� On graders equipped with optional blade float, push forward on the lever until it locks in the detent (see figure). Pull back-ward on the lever to return it to the normal operating position.

Front float valve system operation

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

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

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

� The float valves power switch is located on the right-hand side of the pedestal.

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

� Push the power switch up to activate the system. This is a mo-mentary style switch. Indicator lamps mounted on the front right-hand side of the pedestal indicate that the system is ac-tivated.

� The ignition key must be in the “I” position to activate the sys-tem using the float valves power switch.

� Push the float valves power switch down to de-activate the system. The system also de-activates when you turn the igni-tion key to the OFF position.

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

1 Float detent position

1 Float valves power switch

2 Front float valve system indicator lamps

Controls


2

Moldboard slide shift lever

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

� Push forward on the moldboard slide shift lever to slide the blade out to the left-hand side of the grader.

� Pull back on the lever to slide the blade to the right-hand side of the grader.

3

Circle turn lever

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

� Push forward on the circle turn lever to rotate the circle coun-terclockwise.

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

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

Controls


4

Circle shift lever

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

� Push forward on the circle shift lever to move the circle and moldboard assembly to the left.

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

5

Front wheel lean lever

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

� Push forward on the wheel lean lever to lean the front wheels to the left.

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

Controls


7

Control lever for scarifier, ripper or windrow elimi-nator

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

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

� Pull back on the lever to raise the attachment.

8

Articulation lever

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

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

� Push forward on the control lever to articulate the grader to the left.

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

� The indicator gauge in the pedestal displays the amount of frame articulation.

Refer to Steering using articulation page 93.

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

Controls


9

Moldboard tilt lever

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

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

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

10

A-frame attachments lever

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

� Push the lever forward to lower the attachment.

� Pull the lever back to raise the attachment.

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

� For float action, push forward on the lever until it locks in the detent.

� Pull backward on the lever to return it to the normal operating position.

Controls


12

Auxiliary hydraulic controls

(optional)

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

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


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

1 Extra hydraulic circuits

2 Snow wing front mast

3 Snow wing rear mast slide/ripper/windrow elimi-nator

4 Extra hydraulic circuits

5 Snow wing lift

Controls

Other controls 71

Other controls(not shown in main overview illustration)

Accumulators

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

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

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

Radio/tape player

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

Battery isolation switch

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

� Turn the switch OFF to the (O) position and all electrical de-vices are inoperative.

� Turn the switch ON to the (I) position to reconnect the electri-cal system.

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


Introduction 73


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

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


74 Running-in period

Running-in periodNOTE! Check oil pressure and temperature often.

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

The following instructions and intervals apply during the running-in period.

Engine

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

– Replace fuel filter cartridge

– Drain and check fuel filter/water separator.

– Check engine mounts (retighten as necessary)

– Check V-belts (retighten as necessary)

– Inspect engine for leaks

Filters

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

– Change the hydraulic oil filter after the first 100 hours, then ev-ery 500 hours thereafter. See Hydraulic system filter element page 194.

– Change the transmission filter after the first 100 hours, then every 500 hours thereafter. See Transmission filter element page 186.

Lubricants

Change the following lubricants after the initial 100 hours.

– Change the final drive lubricant and clean the magnetic plug, see Final drives page 188.

– Change the All Wheel Drive gearbox oil (if equipped), refer to All Wheel Drive, Gearbox oil, changing page 195.

Other checks

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


Safety and responsibility 75

Safety and responsibility

Operator duties

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

Operator precautions

� Avoid loose fitting clothing, loose or uncovered long hair, jew-elry and loose personal articles. These can be caught in mov-ing parts. Jewelry may also ground a live electrical circuit.

� Know and use the protective equipment that is to be worn when operating or servicing the grader. Hard hats, protective glasses, protective shoes, gloves, reflector type vests, respi-rators and hearing protection are types of equipment that may be required.

� Do not rush. Walk, do not run.

� Keep the steps, handholds, operator’s platform, seat, pedals and controls in good condition. Keep them clean and clear of debris, mud, ice and grease.

� Do not dismount from the grader with the engine running. Be-fore leaving the operator’s cab, place the transmission in neu-tral, lower the moldboard and all attachments to the ground. Apply the parking brake. Shut down the engine. Remove and retain the ignition key.

� Know and use the hand signals required for particular jobs. Know who has the responsibility for signaling. Ensure the lights are working properly at all times.

� Clean the grader regularly. Keep windows, mirrors and lights clean. Replace all broken windows and mirrors.

� Ensure the back-up alarm and back-up lights work properly. Never disconnect the back-up alarm or lights.

� Ensure that your grader is properly equipped for emergencies. Equipment such as a fire extinguisher, first aid kit, flares may be required. Locate and know how to use this equipment.

� It is the responsibility of the machine user to determine the ex-istence of special hazards such as toxic gases, ground condi-tions, etc. that require special precautions. Take the necessary actions to eliminate the hazards.

� Select a gear that will prevent excessive speed when going downhill.

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

Hand signals for on-site traffic control

1 Back-up

2 Clearance

3 Stop

4 Change direction


76 Safety and responsibility

� When operating close to electrical lines, underground cables, water mains or gas lines, contact the responsible authority and request assistance. Contact with a buried pipeline or ca-ble could result in serious injury or death due to fire or explo-sion.

� Know and understand the job site traffic flow patterns and obey flagmen, road signs and signals. Signal before turning.

� Watch for bystanders and never allow anyone to be under or to reach into the grader and its attachments while operating.

Mounting and dismounting

� Face the cab when climbing in or out of the grader. Use the handholds and steps provided. Maintain three points of sup-port. For example, two hands and one foot or one hand and two feet.

� Do not mount or operate the grader with wet or greasy hands, muddy shoes or boots.

� Do not jump from the grader at any time.

� Never try to mount or dismount the grader while it is moving. Know and use the hand signals required for particular jobs. Know who has the responsibility for signaling.

Driving on a roadway

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

� Keep both ends of the moldboard high and within the width of the grader.

� Use extra caution at all intersections.

� Be aware of traffic behind you. If necessary, pull over to the side of the road and allow the vehicles to pass safely.

� Stop and look both ways at railway crossings. Proceed when clear.

� Ensure your grader is properly equipped for roading. Such equipment as lights, flashing beacon, turn signals and warn-ing devices such as flags and a slow moving vehicle sign may be required. Check the local traffic laws for the correct travel-ing requirements.

� Ensure the articulation lock pins are installed when roading the grader.

� Drive cautiously when entering or leaving the shoulder of the road to avoid a rollover.

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

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

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

SMV Plate (slow moving vehicle)



Job site precautions

� Know and understand the job site traffic flow patterns and obey flagmen, road signs and signals.

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

� When scarifying or ripping across a slope, keep the mold-board parallel with the front axle, centered to the frame and lowered close to the ground to provide protection against roll-ing over.

� Do not dismount from the grader with the engine running. Be-fore leaving the operator’s cab, place the transmission in NEUTRAL, lower the moldboard and all the attachments to the ground. Apply the parking brake. Shut down the engine. Remove and retain the ignition key.

� Use the clutch pedal when starting, stopping, or when chang-ing direction.

Night operation

� Ensure the grader is properly equipped for night operation. Equipment such as worklights, headlights, beacons and a slow moving vehicle sign may be required.

� Ensure the worklights are properly aimed. Dim the headlights for approaching traffic.

� When stopping at night near traffic areas, drive the grader off to the side of the road and set out flares or reflectors.

Snow removal

� Snow removal presents unique hazards due to weather con-ditions, poor visibility, slippery road surfaces, high operating speed, and other traffic. Be sure your grader is in good condi-tion and that you have been properly trained before doing this work.

� Ensure your grader has the proper attachments before plow-ing snow. Equipment such as tire chains, warning lights, addi-tional beacons and markings may be required.

� Keep your windshield and other window areas clean and clear for the best possible visibility. Use the windshield wipers and the window defrosters.

� Be alert for any obstructions covered by snow. Obstructions such as manhole covers, curbs, bridge abutments, embank-ments and fire hydrants, etc. may be hazardous.

� Ensure the snow wing is fully raised when not in use and se-cured with the proper chains.

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


78 Safety and responsibility

Special hazards

� Do not stop or turn the grader around on curves or at the crest of hills.

� Be alert when grading haul roads as normal rules of the road might not be observed.

� Use extra care when grading against oncoming traffic. Pre-cautions such as flags, barricades, flashing lights, and flag-men may be needed to alert traffic.

� Do not operate the grader in areas where volatile gases may be present. Explosion could result. If you encounter an area where volatile gases may be present, shut down the grader and leave the area immediately.

Fire

� Remove dust and combustible debris from the grader regular-ly.

� Inspect the grader daily for potential fire hazards such as damaged electrical wires. Have necessary repairs made im-mediately.

� Ensure that excess oil, grease or fuel is cleaned up immedi-ately.

� Ensure the grader is properly equipped for grading in dry or forested areas. Equipment such as a spark arrestor may be required.

When there is a risk of overturning

ROPS

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

FOPS

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

Emergency exit

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

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

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



Towing

� When it is necessary to tow the grader, do not exceed 8 km/h (5 mph).

� Be sure the towing machine has sufficient braking capacity to stop the towed load.

� If the towed grader cannot be braked, a tow bar or two towing machines must be used – one in front pulling and one at the rear to provide braking. Do not tow over long distances.

� Use the tow hitch when using the grader for towing. If a cable or chain is used, keep people away from the towline.

� Shielding of the operator(s) against towline breakage must be provided. Refer to Operating instructions, Towing page 101.

Transporting

� Exercise safety and follow all local laws when loading, unload-ing or transporting the grader. Refer to Operating instructions, Safety and responsibility, Transporting the machine page 103.

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


80 Before operating

Before operatingGeneral rules

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

� Read and understand the entire Operator’s Manual. Before you operate the grader, understand its performance charac-teristics, capabilities and limitations, and become thoroughly familiar with all controls and instruments.

� Consult your supervisor if you do not understand the Opera-tor’s Manual.

� Read and obey all safety signs on the grader. Ensure they are kept clean and in good condition. Replace the safety signs if they are damaged, missing or illegible. Refer to Plates and de-cals page 12.

� Never drive or operate the grader while you are under the in-fluence of alcohol or drugs.

� Know and follow your safety program rules.

� For specific safety requirements, potential work area hazards and the necessary precautions, consult your supervisor.

� Before operating the grader, ensure it is properly equipped. Consult your supervisor or your Volvo Dealer for details.

� Do not permit riders in or on the grader. Ensure all doors, pan-els, inspection covers and the battery box cover are in place and secure.

� Remove or secure loose objects in the cab such as lunch box-es, tools, etc. Remove all objects which do not belong in or on the grader.

� Before backing up, use extra care to ensure all persons and vehicles are clear of the grader.

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

� Ensure the snow wing is fully raised when not in use and se-cured with the proper chains.

� Before operating your grader, test the brakes, steering, trans-mission, clutch and all controls and functions. Perform the test in an area where the safety of personnel and property will not be in jeopardy.

� If a malfunction is observed, park the grader and place a ‘DO NOT OPERATE’ or similar warning tag on the steering wheel and/or battery isolation switch. Be sure to remove the ignition key. Report the problem and have it repaired before operating the grader.

� If a failure occurs that causes loss of control such as steering, service brakes or engine, stop the grader as quickly as possi-ble. Keep the grader securely parked until the malfunction is corrected or the grader can be safely towed.

� Understand the grader’s limitations and keep the grader under control.

� Drive the grader with care and at speeds compatible with con-ditions. Use extra caution when operating over rough ground, on slopes, when ditching and when turning the grader.


Before operating 81

� Know your stopping distance at any speed. Regulate the speed of your grader accordingly.

� Note and avoid all hazards and obstructions such as over-hangs, ledges, slide areas, electrical lines, underground ca-bles, water mains, gas lines, etc.

Daily pre-start checks

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

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

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

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

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

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

replaced.

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

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

clean.

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

place them if damaged, missing or illegible.

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

6 Clean the cab glass.

7 Check adjustment of all rearview mirrors.

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

jects from the machine.

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

devices are clean and working properly.

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

path prior to starting. Do not start the engine until all personnel

are clearly away from the grader.

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

installed, perform this check once a week or every 50 hours be-

fore you start the engine. Refer to Secondary steering system

test switch page 42.


82 Before operating

Procedures before starting the machine

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

� Perform the ‘Pre-start checks’ in this manual before starting the grader.

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

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

� Know how to shut the engine down before attempting to start it.

� Check the transmission shift lever to ensure it is in NEUTRAL before starting the engine.

� Ensure the parking brake is applied.

� Sound the horn before starting the engine.

� Do not operate the engine in an enclosed area without ade-quate ventilation.

� Do not bypass the battery isolation switch. Have the switch re-paired if it is not working properly.

� Use jumper cables only in the recommended manner. Improp-er use can result in battery explosion or unexpected move-ment of the grader. Refer to Starting with jumper cables: page 182.

� After the engine has started, check all gauges and indicators for proper readings. Shut down the engine immediately if any improper readings or energized warning lamps are observed. Refer to Instrument panels page 21.

� Ensure that the lights work properly.

� Check that the hydraulic controls function properly.

� Check that the parking and service brakes function properly. Refer to Braking page 95.

� Check that the engine hand throttle and accelerator function properly.

� Listen for unusual noises.

� Look around and behind the grader before moving it.

� Check that the left-hand steering and right-hand steering func-tion properly.


Ignition switch 83

Ignition switchThe ignition switch has four positions:

NOTE! Position II is not used.

O Turned off

R Radio position

I Running position and preheating position

III Starting position

O (OFF position)

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

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

R (Radio position)

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

– Current is supplied to some electrical equipment

– The engine is off in this position

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

I (Running position and preheat position)

In the “I” position:

– The electrical system is turned on

– Engine preheating can be engaged

– The engines runs in this position

III (Start position)

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


84 Ignition switch

Checking instruments and control lamps

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

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

Red lamps

Red central warning

Battery charge warning

Hydraulic oil temperature warning

Transmission pressure warning

Service brake warning

Parking brake applied

Primary steering system warning

Hydraulic oil level warning

Hydraulic oil pressure warning

Amber lamps

Central warning

Differential lock engaged

MBCS lock disengaged

Engine air filter restriction

Hydraulic filter bypass

Secondary steering system

Engine preheat status

Green lamps

Turn signal indicator lights

Blue lamps

High beam lights


Starting the engine 85

Starting the engine

IMPORTANT! After starting the engine, run it at low idle speed for at least 30 seconds. This is to ensure proper lubri-cation pressure.

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

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

2 Place the transmission shifter in neutral.

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

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

to position “III” (start position).

5 Release the key when engine starts.

If the engine does not start:

6 Wait until the engine has stopped completely.

7 Turn the key back to the “O” position before a new starting at-

tempt is made.

Starting a cold engine

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

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

position).

2 Momentarily depress the Preheat element switch beside the igni-

tion switch on the side console. The preheat now remains engaged

for up to 50 seconds and the control lamp will illuminate.

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

position “III” (start position). Release the key when the engine

starts. Making a starting attempt during the preheat cycle will can-

cel the preheat.

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

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

indicating post heat.

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

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

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

A Control lamp, preheating element

B Switch, preheating element


86 Starting the engine

Cold weather operation

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

– Make sure the freezing point of the coolant corresponds to the weather conditions, according to Coolant with anti-freeze and corrosion protection page 174.

– Use recommended lubricating oil for winter use. See Recom-mended lubricants page 217.

– Fill the fuel tank after work has finished for the day. This will counteract condensation water in the fuel tank.

– When the engine has started, run it at low speed and light loading until the oil in the engine, transmission, hydraulic sys-tem and final drive have warmed up and become more fluid to provide proper lubrication.

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

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

Lubricant requirements for transmission and hydraulic systems

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

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

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

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

Cold weather start-up – Hydraulic system

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

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

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


Shifting gears 87

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

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

Starting out

� Raise the moldboard and all attachments off the ground. Re-fer to Hydraulic controls page 64.

� If roading the grader, position the moldboard inside the tires. Steer the front wheels to make sure they do not strike the moldboard.

� Depress the clutch and brake pedals.

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

� Depress the neutral lock button and move the shift lever into the FORWARD or REVERSE position.

� Select the starting gear by nudging the shift lever to the right or to the left. A digital display is incorporated into the pedestal to tell you which gear the transmission is in.

� Release the brake pedal, then slowly release the clutch pedal and accelerate as required.

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

1 Clutch pedal

2 Brake pedal

3 Accelerator/decelerator pedal

A Forward

B Reverse

C Neutral lock button


88 Shifting gears

Changing gears

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

� To shift to a higher gear, nudge the shift lever to the right and release it.

� To shift to a lower gear, nudge the shift lever to the left and release it.

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

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

Changing directions

NOTE! Stop the grader to change directions.

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

stop using the service brakes.

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

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

to stall.

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

for forward travel or backward for reverse travel.

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

and accelerate as required.

Memory Gear Feature

A Shift to higher gear

B Shift to lower gear

A Forward

B Reverse

C Neutral lock button


Shifting gears 89

Memory gear feature

The “smart shift” memory gear feature allows the operator to cus-tomize the shift patterns of the transmission to suit the job. Table A shows the default shift pattern before the operator uses the memory gear function.

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

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

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

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

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

An upshift or downshift of the shift lever while in NEUTRAL can-cels the memory gear function and returns the transmission shift pattern to the default settings (see Table A).

Table A Default gear combinations

Forward gear

Reverse gear

1 – 2

2 – 2

3 – 2

4 – 2

5 – 3

6 – 3

7 – 3

8 – 4


90 Shifting gears

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

Memory gear feature – All Wheel Drive models

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

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

Table B Valid gear combinations

Forward to Reverse Reverse to Forward

1 – 1– 2

– 1 123

2 – 1– 2

– 2 12345

3 – 1– 2– 3

– 3 345

4 – 2– 3

– 4 5

5 – 2– 3

6 – 3

7 – 3

8 – 4

All Wheel Drive models using Creep Mode

Forward to Reverse Reverse to Forward

C – 1 – C 1

– 2 2

3


Shifting gears 91

All Wheel Drive models

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

All Wheel Drive applications

Side loading

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

Traction and steering control

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

System operation

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

� If AWD is switched on when the grader is moving, the grader must be slowed below 4th gear for the system to engage. The indicator lamp will flash until the system engages.

� When upshifting, the system automatically switches to tan-dem drive only in 8th gear, and back to AWD in 7th gear when downshifted.

IMPORTANT! Do not allow the grader to coast (freewheel) downhill in NEUTRAL with the AWD System engaged. Dam-age to components may result.

System deactivation

The AWD system automatically deactivates under the following conditions:

1 AWD rocker switch is placed in the OFF position.

2 Transmission shifter is placed in neutral.

3 Transmission shifter is placed in eighth gear forward.

4 Clutch or brake pedal are depressed.

5 Hydraulic oil temperature in the reservoir is above normal oper-

ating range.

6 Oil level in the hydraulic tank is too low.

7 Charge pressure is too low.

1 System activation lamp

2 All Wheel Drive on/off switch


92 Shifting gears

Creep mode

Creep mode uses hydrostatic front wheel drive to power the grad-er from 0 to 3.2 km/h (0 to 2 mph). The rear wheels are not driving when Creep Mode is activated.

NOTE! Selecting Creep Mode eliminates any memory gear combination previously used.

� With the AWD system engaged, the grader stopped and the transmission in neutral, switch to Creep Mode using the rock-er switch on the control panel (2). The transmission gear dis-play will alternate between “C” and “-C” while in neutral until a gear is selected.

� Place the transmission shifter in the forward or reverse posi-tion as desired. The display will indicate “C” for forward move-ment and “-C” for reverse.

� Increase engine speed above 1000 rpm to start moving. Use engine rpm to adjust to desired ground speed.

� To stop the grader or change direction, depress the clutch pedal and reduce the engine speed below 1000 rpm.

� Using the clutch and upshifting the transmission will place the system into normal AWD mode. Shift between a normal AWD gear combination and Creep Mode.

� After turning Creep Mode off, the transmission will default to the closest gear.

AWD Aggression

Graders often have different tractive conditions encountered by the front and the rear of the machine. The 16-position manual dial control is used to fine tune rotational speed differences that may occur between the front and the rear wheels when grading under diverse conditions with the All Wheel Drive system engaged.

� A dial setting at '7' matches the front wheel speed evenly with the rear wheel speed.

� A lower setting slows the front wheel rotational speed com-pared to the rear; a higher setting increases the front wheel ro-tational speed in comparison to the rear.

1 Creep mode activation lamp

2 Creep mode on/off switch

3 All Wheel Drive Aggression dial


Steering 93

SteeringThe grader has a hydraulic steering system. Turn the steering wheel to steer the grader to the left or right.

If the engine stalls, stop the grader. Place transmission in NEU-TRAL and apply the parking brake. Start the engine, if possible. If the engine cannot be started, refer to Stopping the machine page 98. Have the engine repaired by a qualified Volvo service techni-cian.

Front wheel lean

You can reduce the turning circle of your grader by leaning the front wheels. Lean the wheels in the direction you will turn. Posi-tion the front wheels vertically again after completing the turn. Do not use wheel lean at high speeds. Reaction is quick.

Refer to Front wheel lean lever page 67.

Steering using articulation

Use the articulation lever to further reduce the grader’s turning cir-cle. Before articulating, remove the articulation lock pins. Install the lock pins when not using the articulation function. Do not use at high speeds. Reaction is quick.

Refer to Articulation lever page 68.

� Ensure the articulation lock pins are installed when roading the grader.

WARNING!The steering system only operates when engine is running. If engine stalls, stop the grader.


1 Articulation lever

2 Wheel lean lever

1 Articulation lock pin


94 Steering

� Bolt-on shims may be removed from the articulation hinge to increase the articulation angle. The shims prevent interfer-ence between the tandem tires and cab when larger than standard tires are fitted. Interference with larger tires only oc-curs during full tandem oscillation and full frame articulation.

� Ensure the control switch for locking the differentials is in the UNLOCK position before turning the grader. This reduces strain on the final drive and reduces tire scuffing. Put the switch in the LOCK position for normal grading. Refer to Dif-ferential lock page 97.

Secondary steering system

(optional)

This auxiliary hydraulic system allows the operator to make steer-ing corrections more easily in the event of loss of hydraulic flow to the steering unit. The ignition key must be in the “I” position to op-erate the system.

Operate the system long enough only to make a steering correc-tion - maximum two minutes.

In the event of low steering oil pressure, the Primary steering sys-tem warning lamp (A) and the Secondary steering system status lamp (B) will illuminate, accompanied by a buzzer, message dis-play (C), and the red central warning lamp (D).

To test the Secondary steering system:

� Insert and turn the ignition key to the “I” position (running po-sition).

� Do not start the engine.

� Depress and hold the Secondary steering test button located on the pedestal.

� The Secondary steering warning lights and alarm should en-ergize.

� Check the system by turning the steering wheel. If it does not turn easily, there is a fault in the system. Have the system re-paired by a qualified Volvo service technician.

� Depress and hold the Secondary steering test button only long enough only to check the system.

� Start the engine. The warning lights and alarm will de-energize, indicating the system is ready if the engine stalls.

� If the warning lights and alarm remain energized with the en-gine running, do not drive the grader. The system is faulty and must be repaired by a qualified service technician.

WARNING!Do not operate the supplementary steering system longer than two minutes. Equipment damage will result.

A Control lamp (red) primary steering system

B Control lamp (amber) secondary steering system

C Message display

D Central warning lamp (red)


Braking 95

Braking

Service brakes

Push down on the brake pedal to apply the service brakes.

The service brake system has two separate brake circuits. The system provides reduced braking capability in the event of a brake line rupture or other failure in one circuit.

Each of the two circuits function on one front and opposite rear tandem wheel. Should one circuit fail, braking remains effective on all tandem wheels through the tandem chains.

In the event of service brake system failure, the warning lamp (C) will illuminate accompanied by the red central warning lamp (B), a display panel message (D), and a buzzer.

A supplementary power source automatically supplies hydraulic power assist in the event of an engine failure or any situation where hydraulic oil flow is interrupted to the service brake system.

Reduced braking capability is still available when the engine is not running, or the key is not inserted in the ignition switch. Supple-mentary power source will engage when the brake pedal is de-pressed with the key either on or off.

This reserve system provides power assisted braking capability at a reduced level and automatically resets when hydraulic oil flow is restored.

IMPORTANT! Do not rest your foot on the brake pedal with the ignition key in the off position. This may damage the supplementary brake system.

Stopping the machine

� Depress the brake pedal to apply the service brakes.

� Reduce engine speed.

� Slowly depress and hold down the clutch and brake pedals. Depressing the clutch pedal only may not stop the grader.

� Use brake pedal to hold grader when transmission is in gear, clutch pedal depressed and engine is running.

� Move the shift lever into the NEUTRAL position.

� Apply the parking brake.

� Release the clutch and brake pedals.

� Lower the moldboard and all attachments to the ground.

� Shut down the engine.

Brake adjustment

Refer to the Service Manual for information on adjusting the brakes.

WARNING!In case of faulty brakes, do not continue to operate. Have a qualified service technician repair the brake system immediately.

A Service brake pedal

B Central warning lamp (red)

C Service brake warning lamp (red)

D Display message


96 Braking

Parking brake

NOTE! Only apply the parking brake when the machine has stopped. Always apply the brake if the machine is to be left unattended.

NOTE! When the parking brake is applied, the transmission cannot be shifted out of neutral.

When the parking brake is applied, the red indicator lamp (B) illu-minates. If the brake is applied while the transmission is in gear, it is accompanied by the red central warning lamp (C), a buzzer, and a display message (D).

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

In the event of a loss of system pressure (e.g. engine stall), the parking brake will not immediately apply itself. The brake has an accumulator that stores energy in the circuit allowing the operator to bring the machine to a stop safely.

Once the stored pressure is depleted, the parking brake will be ap-plied automatically. When hydraulic pressure is restored, the brake can be released.

To manually release the parking brake, refer to Manual release of parking brake page 106.

The parking brake is self-adjusting, see Parking brake page 191 for specifications.

Emergency brake

In an emergency situation, the parking brake may be used as an emergency brake.

WARNING!The parking brake must be inspected by a qualified service technician after being used in an emergency situation.

A Parking brake switch

B Parking brake applied warning lamp (red)

C Central warning lamp (red)

D Display message


Differential lock 97

Differential lock

The lock/unlock differential control switch (A) is mounted in the pedestal on the upper right-hand side. An amber lamp (B) illumi-nates when the lock is engaged.

� Put the control switch in the ‘UNLOCK’ position when differen-tial action is required. This will reduce the turning radius and decrease tire scuffing when operating on paved surfaces. The indicator lamp will de-energize.

� Put the control switch in the ‘LOCK’ position for normal grad-ing operations when maximum traction is required. The indi-cator lamp will energize.

� The DIFF UNLOCK warning light “OFF” means the lock/un-lock mechanism is DISENGAGED.

� Do not engage the final drive lock/unlock mechanism while the tandem wheels are spinning, under load, or the machine is turning.

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

A Differential lock/unlock switch

B Differential lock indicator lamp (amber)

C Differential lock operating instructions decal (on windshield)


98 After operating

After operating

General

When the machine is left unattended:

1 Apply the parking brake and when required (on a slope), block

the wheels so that the machine cannot roll.

2 Lower the moldboard and all attachments to the ground. Do not

apply down pressure.

3 Remove the ignition key.

4 Close the windows and lock the doors.

5 Turn off the battery isolation switch.

Stopping the machine

The machine is stopped as follows:

1 Release the accelerator to reduce engine speed.

2 Depress the clutch and brake the grader. (Depressing the clutch

only may not stop the machine.)

3 Move the transmission shift lever to neutral.

4 Apply the parking brake.

Use the brake pedal to hold the grader when transmission is in gear with clutch pedal depressed and engine is running.

NOTE! Only apply the parking brake when the machine has stopped. Always apply the brake if the machine is to be left unattended.

Stopping the engine

NOTE! Run the engine at low idle for a few minutes before stopping it to safeguard lubrication of the turbocharger.

1 Turn the ignition key counter-clockwise to the “O” position to

shut down the engine.

NOTE! If the machine is to be left for any length of time, turn off the battery isolation switch.

WARNING!When you are entering and leaving the machine, always face the machine and use the steps or handholds to avoid slipping. Always use the three-point stance, i.e. two hands and one foot or two feet and one hand when climbing up or descending from the machine. Do not jump!


After operating 99

Parking

To park the grader:

� Always park the grader on a level surface.

� Stop the grader using the service brakes, then place the trans-mission in NEUTRAL.

� Apply the parking brake.

� Lower the moldboard and all attachments to the ground. Do not apply down-pressure.


� Remove and retain the ignition key.

� Turn the battery isolation switch OFF.

Long-term parking

When a grader is taken out of service for more than 30 days, you must ensure that it is protected from exposure to the elements. An enclosed structure will protect the grader from rapid temperature changes and decrease the amount of condensation that forms in fluid reservoirs, e.g., engine oil pan, fuel tank, hydraulic oil tank, etc.

After you have parked the grader and shut down the engine, per-form the following steps:

1 Inspect for leaks and other defects. Correct as necessary.

2 Thoroughly wash the grader. Be sure to rinse off any caustic

residue.

3 Touch up any areas where the paint has worn away.

4 Clean or replace air filter elements.

5 Open the drain valve at the bottom of the fuel tank and drain 1

liter (approx. 1 US quart) of fuel to remove any water accumula-

tion.

6 Replace engine fuel filters.

7 Add the recommended amount of fuel stabilizer and corrosion

inhibitor to the fuel tank.

8 Start and run the engine at 1400 rpm to 1600 rpm with no load

for approximately four minutes.

9 Change the engine oil and replace the engine oil filter.

10 Properly seal the engine exhaust and air intake openings.

11 If tires are to be left on, raise the grader and place it on blocks

to keep the tires off the ground. Deflate and cover the tires.

12 Turn off the battery isolation switch. Remove batteries and store

them in a cool, clean, dry and well-ventilated area where the

temperature is be-tween 0°C and 21°C (32°F and 70°F). Be

sure batteries are fully charged.

13 Coat all machined and unpainted surfaces (including mold-

board) with grease to prevent rust forming.

14 Coat all exposed chrome plated surfaces on hydraulic cylinder

piston rods with a thin layer of grease.

15 Grease all door hinges.


100 After operating

Preparing for operation after long-term parking

Perform the following steps before putting the grader back into service:

1 Inspect for leaks and other defects which may have occurred

during storage.

2 Thoroughly wash the grader. Remove all grease and coatings

installed as Long term parking steps 13 and 14 on the previ-

ous page.

3 Remove any seals from the engine exhaust and air intake open-

ings.

4 Lubricate all grease points. See Grease points page 202.

5 Install fully charged batteries. Turn on the battery isolation

switch.

6 Inflate the tires to the correct pressure. Refer to Maximum tire

pressures page 196. Lower the grader from the storage blocks.

7 Perform all appropriate pre-start checks. Refer to Daily pre-start

checks page 81.

8 Start and run the engine at 1400 rpm to 1600 rpm with no load

for approximately four minutes. If any warning lamps and the

alarm energize or gauges show abnormal readings, shut down

the engine. Report the problem and have it repaired by a quali-

fied service technician.


Towing 101

Towing

General

� The operator must be in the operator’s seat to control steering and braking when towing the grader.

� Do not tow the grader with the engine shut down. Braking and steering capabilities are reduced with the engine shut down.

� To release the parking brake manually, refer to Manual re-lease of parking brake page 106.

� If the engine runs, ensure the transmission shift lever is in NEUTRAL. Tow the grader with the engine running. On All Wheel Drive models, make sure the All Wheel Drive system is switched OFF.

� Some state and local laws prohibit or limit the use of tow chains on highways. Check state and local regulations.

� If the final drive is damaged, do not tow the grader. Do not at-tempt to start the engine by towing. Damage to the transmis-sion will result.

� Provide adequate shielding for the operator against towline breakage.

� Do not tow the grader faster than 8 km/h (5 mph).

� Be sure the vehicle which does the towing is at least as heavy as the machine being towed. This will ensure sufficient engine and braking capabilities to be able to pull and stop both ma-chines on any uphill or downhill slope.

� If the towed grader cannot be braked, a tow bar or two towing machines must be used – one in front pulling and one at the rear to provide braking. Do not tow over long distances.

� Ensure the towline or bar is in good condition and is strong enough for the towing situation. Mark the center of the towline with a flag or brightly colored cloth. Ensure that a ‘slow moving vehicle sign’ is attached to the rear of the grader.

� Ensure the towline angle is less than 20 degrees with respect to the horizontal plane.

� Do not allow the towline to contact any components mounted on the grader.

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

WARNING!If the engine cannot be started, the brake and steering functions will be limited. In this case, towing should be restricted to emergencies only and over the shortest possible distance by knowledgeable personnel. If possible, transport the machine on a trailer.


102 Towing

� Tow the grader from the hole provided in the noseplate.

� Sudden machine movement can cause the towline or tow bar to break. Proceed gradually and smoothly.

� Make sure the parking brake is released.

� Secure the moldboard and all attachments. Use chains or ca-bles that are in good condition.

� Install the articulation lock pins.

� When turning, keep the towing angle and speed to a mini-mum.

� Turn the hazard lights on while towing.

After towing

The following safety measures should be taken before the towbar, chain or wire rope is disconnected after towing:

1 Place the machine on level ground.

2 Apply the parking brake

3 Block the wheels to prevent the machine from rolling.



Transporting the machine 103

Transporting the machine� Use a pressure washer to remove any loose gravel, mud or

debris from the grader moldboard, tires or frame.

� Install both articulation lock pins before loading the grader onto the trailer bed.

� Load and unload the grader on a level surface.

� Ensure the combined height of the trailer bed and the top of the grader cab is lower than local height restrictions or any bridges, overpasses or overhead obstructions expected to be encountered during transport. Refer to Dimensional drawing page 233.

� Ensure the transporting equipment is adequate to hold the weight and size of the grader.

� Place chocks against the truck and trailer wheels.

� Use a ramp or loading dock. Ensure the ramp is strong enough and has a low angle of rise to the height of the trailer bed.

� Do not place tie-down cables or chains over or against hy-draulic tubes, hoses, cylinders or valves, etc. Attach tie-down cables or chains securely to front attachment points.

� Obey all local laws concerning loading, unloading or trans-porting the grader. Wide load permits may be required for graders equipped with tires larger than 14.00.

� Keep the trailer bed clean.

� The rotating beacon can be lowered for increased clearance. Lift and release the pivot rod handle on the left-hand side of the bracket. Grasp the handle at the rear of the bracket. Slightly move the bracket upward, and then allow the bracket to pivot until it reaches the end of its travel limit. Return the piv-ot rod handle to the locked position.

� When loading the grader onto a trailer bed, drive the grader straight and centered with the width of the trailer bed. The cen-terline of the grader must be directly over that of the trailer bed or railcar.


1 Rotating beacon light

2 Pivot rod handle

3 Lowered position

1 Grader centerline

2 Railcar or trailer centerline


104 Transporting the machine

Before securing tie-down cables or chains, position the grader on the trailer bed as follows:

1 Place the transmission in NEUTRAL and apply the parking

brake.

2 Lower the moldboard lengthwise under the grader onto wooden

blocks to protect the trailer bed. Do not apply down pressure. Al-

so, lower any attachments such as a scarifier or ripper.

3 Place grader in the Service position. See Service position page

146.

4 Install chocks at the front and rear tandem wheels. Wedge and

nail the chocks in place.

5 Relieve residual hydraulic pressure by operating all the control

levers.

6 Remove and retain the ignition key. Lock the cab doors.

1 Wooden blocks

1 Wheel chocks


Transporting the machine 105

7 Turn the battery isolation switch off. It is located inside the en-

gine compartment on the left-hand side of the grader.

8 Cover the exhaust opening with heavy gauge plastic and secure

in place to prevent dust and moisture entering the engine. Re-

member to remove the plastic cover before starting the grader.

Lifting arrangement and Tie-down locations1 Exhaust opening

Lifting arrangement

1 15° maximum lifting angle

2 10° maximum lifting angle

Tie-down locations

3 Front and rear tie-down locations

4 Front and rear lifting points


106 Manual release of parking brake

Manual release of parking brakeIf the engine and hydraulic system are inoperable, proceed as fol-lows:

1 If the engine is inoperable, use a hand pump to recharge the

parking brake accumulator through the test port on the top of the

valve. Pressure is limited to 1724 kPa (17 bar)(250 psi) with a

relief valve.

2 Return to cab, and push in the parking brake switch to the ap-

plied position.

3 Cycle the key switch to the crank position (III) momentarily and

release.

4 Pull the parking brake switch out to the release position.

5 If a hand pump is not available, place the machine in the Service

Position (refer to Service position page 146) then remove the

lower driveshaft.

A Lower driveshaft between the transmission and final drive


Moveable Blade Control System 107

Moveable Blade Control System

Moldboard blade lift procedure – Right-hand side

This procedure describes how to maneuver the moldboard into the right-hand side high bank sloping position. The MBCS (Move-able Blade Control System) provides a total blade position range.

� Observe all moving parts to prevent structure fouling when us-ing the MBCS.

� Park the grader and apply the parking brake.

� Place the transmission in NEUTRAL.

� Position the moldboard at 90 degrees to the frame.

� Centralize the circle, drawbar and moldboard with the frame.

� Fully lower the moldboard and all attachments.

� Ensure that there are no persons or vehicles near the grader.

1 Operate the MBCS switch (A) on the console by pushing the

button on the switch to override the interlock. The MBCS status

lamp (B) in the center display energizes to indicate that the lock

pin is retracted. If the warning lamp does not energize, operate

both the right-hand and left-hand blade lift cylinder control le-

vers until the MBCS lock pin fully retracts and the lamp illumi-

nates.

A MBCS lock pin switch

B MBCS lock pin indicator lamp (amber)


108 Moveable Blade Control System

2 Observe the pointer on the bracket and “dimples” on the right-

hand arm. Retract the left-hand blade lift cylinder and extend

the right-hand blade lift cylinder to move the MBCS lockbar to

the right. This action pivots the blade lift arms around their

pins. Pivot the blade lift arms until the final “dimple” on the

right-hand arm aligns with the pointer.

3 Push the MBCS switch until it locks. The MBCS warning lamp

de-energizes to indicate that the lock pin has engaged. If the

warning lamp does not de-energize, operate both the right-

hand and left-hand blade lift cylinder control levers until the

MBCS lock pin fully engages.



4 Use the moldboard slide shift lever to slide the moldboard as

far to the right as possible.

5 Using the circle turn lever, rotate the circle so that the end of

the moldboard is close to the front tire.



6 Retract the right-hand blade lift cylinder approximately 60 cm

(2 feet). Fully extend the left-hand blade lift cylinder and the

circle shift cylinder. Retract the right-hand blade lift cylinder

until the moldboard reaches the desired position. Observe all

moving parts to prevent structure fouling when using the

MBCS.

7 Using the circle turn lever, rotate the circle to allow the end of

the moldboard to clear the ground.

Reverse this procedure to return the moldboard to the normal grading position.



Moldboard blade lift procedure – Left-hand side

� This procedure describes how to maneuver the moldboard into the left-hand side high bank sloping position. This system provides a total blade position range.

� Observe all moving parts to prevent structure fouling when us-ing the MBCS.

� Remove the right-hand moldboard extension if installed.

� Park the grader and apply the parking brake.

� Place the transmission in NEUTRAL.

� Position the moldboard at 90 degrees to the frame.

� Centralize the circle, drawbar and moldboard with the frame.

� Fully lower the moldboard and all attachments.

� Ensure that there are no persons or vehicles near the grader.

1 Operate the MBCS switch (A) on the console by pushing the

button on the switch to override the interlock. The MBCS status

lamp (B) in the center display energizes to indicate that the lock

pin is retracted. If the warning lamp does not energize, operate

both the right-hand and left-hand blade lift cylinder control le-

vers until the MBCS lock pin fully retracts.

A MBCS lock pin switch

B MBCS lock pin indicator lamp (amber)



2 Observe the pointer on the bracket and “dimples” on the left-

hand arm. Retract the right-hand blade lift cylinder and extend

the left-hand blade lift cylinder to move the MBCS lockbar to

the left. This action pivots the blade lift arms around their pins.

Pivot the blade lift arms until the final “dimple” on the left-hand

arm aligns with the pointer.

3 Push the MBCS switch until it locks. The MBCS warning lamp

de-energizes to indicate that the lock pin has engaged. If the

warning lamp does not de-energize, operate both the right-

hand and left-hand blade lift cylinder control levers until the

MBCS lock pin fully engages.



4 Use the moldboard slide shift lever to slide the moldboard as

far to the left as possible.

5 Rotate the circle so that the end of the moldboard is close to

the front tire.



6 Retract the left-hand blade lift cylinder approximately 60 cm (2

feet). Fully extend the right-hand blade lift cylinder and retract

the circle shift cylinder. Retract the left-hand blade lift cylinder

until the moldboard reaches the desired position. Observe all

moving parts to prevent structure fouling when using the

MBCS.

7 Rotate the circle to allow the end of the moldboard to clear the

ground.

Reverse this procedure to return the moldboard to the normal grading position.


Scarifier 115

ScarifierThe scarifier is hydraulically raised and lowered using the control lever on the pedestal. Refer to Control lever for scarifier, ripper or windrow eliminator page 68.

NOTE! The front and mid-mounted scarifiers use the same teeth and shanks.

� Do not skid the teeth along the surface. Always lower the teeth directly into the ground.

� Do not use the scarifier when turning or with the frame articu-lated.

� Scarify downslope whenever possible. Refer to Operating techniques, Scarifier and ripper operation page 143.

Scarifier shank depth adjustment

� Lower the scarifier to within several centimeters of the ground.

� Remove the wedge from each shank.

� The shanks incorporate adjustment notches. Move the shank to the desired depth and engage the appropriate notch with the scarifier box.

� Install the wedge.

Scarifier tooth angle adjustment

� Lower the scarifier to the ground.

� Remove the bolts, lockwashers and nuts that hold the scarifier box arms to the scarifier drawbar.

� Tilt the scarifier box to the desired angle and align the bolt holes. You may have to loosen the ball stud nuts. Install and tighten the bolts.

Scarifier teeth

� The hardened scarifier teeth are replaceable. Use a hammer and drift to force the tooth forward and off the shank.

� Install a new tooth and tap onto the shank.

WARNING!Crushing hazard. Support the attachment before adjusting or servicing it. Hydraulic or mechanical failure could cause attachment to fall resulting in severe personal injury or death.

WARNING!Do not work on graders supported only by moldboard or attachments. Hydraulic or mechanical failure could cause grader to fall resulting in severe personal injury or death.

1 Tooth

2 Shank

3 Scarifier box

4 Wedge

1 Scarifier drawbar

2 Scarifier box arms

3 Bolt


116 Ripper

Ripper� The ripper is hydraulically raised and lowered using the rear

auxiliary control lever located on the right-hand side door grab handle. Some export machines may use the Scarifier Control Lever to raise and lower the ripper. Refer to Control lever for scarifier, ripper or windrow eliminator page 68.

� Push forward on the lever to lower the attachment.


Refer to Scarifier and ripper operation page 143.

Ripper tooth angle adjustment

(See illustration below)

� To adjust the tooth angle, lower the ripper to the ground. Do not apply down pressure.

� Remove the bolts, washers and pins (1) from the control rods (2) and ripper arms (3).

� Carefully raise or lower the ripper to the desired tooth angle.

� Align the appropriate holes in the control rods with the holes in the ripper arms.

� Install the pins and secure them with the bolts and washers.

Ripper shank removal

� Lower the ripper onto a support.

� Remove the cotter pins, flatwashers and pins that hold the shank in the ripper box (4).

� Remove the shanks carefully. They are heavy.

Changing ripper teeth

� To change ripper teeth (5), remove the roll pin (6). Clean the shank and replace the tooth. Install the roll pin.

Clearance position

Move the ripper shanks up into the clearance position (7) by re-moving the lower pin (4). Swing the shank upwards and reinstall the pin (4) in the upper hole (8).

1 Ripper control lever


Windrow eliminator 117

Windrow eliminator� The windrow eliminator is hydraulically raised and lowered us-

ing the rear auxiliary control lever located on the right-hand side door grab handle.

� Push forward on the lever to lower the attachment.


Moldboard height adjustment

� Lower the windrow eliminator to the ground.

� Turn the hand cranks clockwise to increase the spreading height.

� Turn the hand cranks counterclockwise to decrease the spreading height.

Moldboard angle adjustment

� Lower the windrow eliminator to the ground.

� Remove the brace arm pins and the brace arm.

� Loosen the pull tube collar setscrews.

� Maneuver the moldboard assembly to the desired angle.

� Align the appropriate holes in the pull tubes and the pull tube collars.

� Tighten the pull tube collar setscrews.

� Adjust the brace arm length. Remove the linch pin and slide the brace arm tube in or out as required. Replace the linch pin.

� Install the brace arm and secure with the brace arm pins.

1 Windrow eliminator

1 Hand crank

1 Moldboard assembly

2 Brace arm pin

3 Pull tube collar setscrews

4 Linch pin

5 Pull tubes

6 Brace arm

7 Brace arm pin


118 Windrow eliminator

Moldboard position adjustment

� The moldboard can be adjusted to three different positions.


� Remove the brace arm from the pull tube bracket.

� Move the moldboard to the desired position.

� Install the brace arm in the appropriate bracket hole.

� Install the brace arm and secure with the brace arm pins.

Moldboard position adjustment – Right-hand to left-hand grading

� Lower the moldboard to the ground.


� Remove the upper and lower moldboard brackets.

� Position the moldboard to the right or left as required.

� Install the upper and lower moldboard brackets.

� Install the brace arm in the opposite direction and secure with the brace arm pins.

Lift chain adjustment

Both ends of the windrow eliminator should be the same distance from the ground when raised. Adjust the lift chains if they are not.

� Lower the windrow eliminator until the lift chains are slack.

� Vary the number of lift chain links through the lift plates on ei-ther or both sides. Raise the windrow eliminator. Repeat ad-justment as necessary.

1 Moldboard

2 Brace arm pin

3 Brace arm

4 Lower moldboard bracket

5 Pull tube bracket

6 Upper moldboard bracket

1 Lift plate

2 Lift chain

3 Pull tube swivel adjustment


Dozer blade/V-plow 119

Dozer blade/V-plowDozer blade

The dozer blade is hydraulically raised and lowered using a con-trol lever on the pedestal. Blade float capabilities are optional.

It is used for spreading, backfilling and knocking down piles of ma-terial.

Refer to A-frame attachments lever page 69.

V-plow

The V-Plow is hydraulically raised and lowered using a control le-ver on the pedestal. Refer to A-frame attachments lever page 69.

Skid shoe adjustment

Adjust the skid shoes to allow the V-Plow to clear obstacles in the road surface.

� Lower the V-Plow to the desired height and support it ade-quately.

� Adjust the shoes to contact the ground.

1 A-frame

2 Push frame

3 Heel chains


120 One way plow

One way plowThe One way plow is hydraulically raised or lowered using a con-trol lever on the pedestal. Refer to A-frame attachments lever page 69. It has several adjustments and includes a spring loaded safety trip design that allows the blade to lift if it strikes an obsta-cle.

Skid shoe adjustment

Adjust the skid shoes to allow the plow to clear obstacles in the road surface.

� Lower the plow to the desired height and support it adequate-ly.

� Loosen the adjuster setscrews and turn the handles until the shoes contact the ground.

� Tighten the setscrews.

Blade tilt adjustment

� Lower the plow to the ground.

� Release the tension in the safety trip springs by loosening the nuts.

� Remove the pin from the tilt link.

� Tilt the blade to the desired angle and align the appropriate holes.

� Install the pin.

� Apply tension to the safety trip springs by tightening the nuts.

Lift chain adjustment

� Periodically check and adjust the lift chains at the lift spade.

� Lower the plow to the ground.

� Remove any slack in the chains by adjusting the number of chain links passing through the lift spade.

1 Handle

2 Setscrew

3 Skid shoe

1 Blade

2 Tilt link

3 Safety trip spring

4 Lift spade

5 Lift chains

6 Push frame


Hydraulic snow wing 121

Hydraulic snow wing

� The rear mounted hydraulic snow wing is available in high and low benching configurations.

� The snow wing is fully hydraulic and can be used with the moldboard for a wider clearing width per pass. Articulation to either left-hand or right-hand side is not restricted.

Hydraulic snow wing controls

� The snow wing positions are hydraulically controlled using the auxiliary control levers located on the right-hand side door grab handle. Optional electric float valves allow the wing to float along surface contours. With the float option, the valve has no detent and operates off of the Front float valve system switch. Refer to Front float valve system operation page 65.

� The front mast slide lever controls the vertical height of the wing and allows the operator to raise and lower the wing par-allel to the ground. Push forward on the front mast slide lever to lower the wing. Pull back on the front mast slide lever to raise the wing.

� The wing lift lever controls the outboard end of the wing. Push forward on the wing lift lever to lower the outboard end of the wing. Pull back on the wing lift lever to raise the outboard end of the wing. With the optional wing lift float, push the control lever ahead to the detent to allow the outboard end of the wing to float.

� Only high benching configured snow wings are equipped with a rear mast slide. Push forward on the rear mast slide lever to lower the stand-off arms. Pull back on the rear mast slide lever to raise the stand-off arms.

1 Front mast slide

2 Rear mast slide

3 Wing lift

1 Rear mast

2 Wing brace

3 Upper stand-off arms

4 Wing lift cylinder

5 Wing

6 Pitch adjustment

7 Front mast

8 Wing brace


122 Hydraulic snow wing

� Position the wing to catch snow from the moldboard, front mounted V-plow or one-way plow.

Hydraulic snow wing pitch adjustment

Pitch the wing forward enough to roll the snow off the outboard end.

� Lower the wing to the ground.

� Remove the shear pins from the back side of the wing.

� Tilt the wing to the desired pitch, align the appropriate holes and install the shear pins.

Hydraulic snow wing position for roading

� Pull back on the wing lift lever and raise the outboard end of the wing until it reaches the maximum position (parallel with the grader side panels).

� Secure the wing with the chain.

� Operate the front mast slide and raise the inboard end of the wing to clear the top of the right-hand front tandem tire.

WARNING!Ensure the snow wing is fully raised when not in use and secured with the proper chains. Hydraulic or mechanical failure could cause snow wing to fall resulting in severe personal injury or death.


Introduction 123


IntroductionDo not operate the grader until you read and understand the warn-ings and instructions in this manual. Failure to follow the instruc-tions or heed the hazard alerts, safety signs and precautions could result in machine damage, injury or death.

Ensure your grader is properly equipped. Such equipment as lights, flashing beacons, turn signals and warning devices such as flags and a slow moving vehicle sign may be required. Use and position cones and signs to alert traffic while grading highways. Check the local traffic laws for the correct operating requirements.

Operating techniques in this section are basic. Your skills and techniques will develop as you gain knowledge of your grader and its capabilities. This section will help you to understand the oper-ating characteristics of your grader. Read this section carefully. If any questions arise concerning the operation of your grader, con-sult your supervisor.

Volvo motor graders are equipped with an articulated frame. Artic-ulating the grader counteracts side thrust and will help keep the tandem wheels on solid ground during ditching operations for maximum traction while achieving maximum blade reach. Articu-lating the grader while maneuvering around corners also reduces the turning radius.


124 Moldboard

MoldboardMoldboard positioning is very important when grading. The mold-board is usually angled 15 to 75 degrees from the center line of the frame. The greater the moldboard angle, the more material is carried across the moldboard allowing for deeper cuts and heavier grading. The earth moved by the moldboard creates a side thrust on the grader. The operator can counteract this side thrust by leaning the front wheels in the direction the material is moving along the moldboard.

Moldboard pitch is also important. For normal grading, the mold-board should be tilted slightly forward from the vertical position. Tilting the moldboard forwards allows material to roll for spreading or compacting. Tilting the moldboard backwards increases the cutting ability and reduces the rolling action of the material.

Study these illustrations to familiarize yourself with the terms used in this section.

Moldboard toe – The point of the moldboard closest to the front wheels.

Moldboard heel – The point of the moldboard farthest away from the front wheels.

Moldboard angle – The angle of the moldboard as measured from the moldboard toe to the center line of the front frame of the grader.

Typical road section1 Backslope

2 Foreslope

3 Ditch

4 Wearing surface

5 Road surface (travelled way)

6 Shoulder

7 Roadbed

8 Roadway (road right-of-way)

A Left-hand grading

B Right-hand grading

1 Moldboard toe

2 Moldboard heel

3 Moldboard angle

4 Centerline of frame


Turning around using articulation 125

Turning around using articulationWatch for bystanders and never allow anyone to be near the grad-er and its attachments while operating.

Ensure the control switch for the locking differential is in the UN-LOCK position before turning the grader. This reduces strain on the final drive and reduces tire scuffing. Put the switch in the LOCK position for normal grading.

Use the articulation lever to articulate the grader in the direction you wish to turn.

Before articulating, ensure the articulation lock pins are removed and stored appropriately.

� Push forward on the control lever to articulate the grader to the left.

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

The articulation indicator gauge in the pedestal indicates the de-gree of articulation.

Install the lock pins when not using the articulation function, trav-eling in traffic or at roading speeds.

� Fully raise the moldboard and attachments before you turn the grader around.

� Position the moldboard so it will not contact the front or rear tandem tires when articulating as severe damage can occur.

� With the grader moving forward, turn the wheels left and artic-ulate the frame left.

� Upon completing the turn, turn the wheels right and articulate the frame straight.


1 Articulation indicator gauge

2 Differential lock/unlock switch

1 Lock pin


126 Making a three point turn

Making a three point turn� Watch for bystanders and never allow anyone to be under or

to reach into the grader and its attachments while operating.

� Understand and obey the traffic laws, road signs and signals.

� When turning on a narrow road or highway, use your own judgement for the amount of area the grader requires to turn around.

Maneuver 1

� Fully raise the moldboard and attachments before you turn the grader around.

� Lean the wheels slightly in the direction you are turning.

� Travel as far forward as possible.

Maneuver 2:

� Lean and turn the front wheels in the opposite direction.

� Select reverse gear and back up the grader as far as possible.

Maneuver 3:

� Lean and turn the wheels to the new travel direction.

� Straighten the wheels after the turn is completed.

If using the articulation function to help turn the grader, refer to the previous page. Ensure the articulation lock pins are removed be-fore articulating, and install them when not using the articulation function. Position the moldboard so it will not contact the tires when articulating as severe damage can occur.


Grading around an object 127

Grading around an object� Note and avoid all hazards and obstructions such as over-

hangs, ledges, slide areas, electrical lines, underground ca-bles, water mains, gas lines, etc.

� When operating close to electrical lines, underground cables, water mains or gas lines, contact the responsible authority and request assistance.

Maneuver 1

� Reduce your speed.

� Use the accelerator/decelerator to slowly maneuver the mold-board around the object.

� Drive as close as possible to the object to reduce the amount of hand shoveling required.

Maneuver 2

� Use the moldboard slide shift and side shift levers to follow the shape of the object.

Maneuver 3

� Slide the moldboard back to its original position after you have passed the object and continue grading.


128 Grading on an ‘S’ curve shoulder

Grading on an ‘S’ curve shoulder� Slowly approach the first right-hand curve.

� Lean the front wheels slightly to the left to counteract side thrust.

� Turn right and follow the edge of the shoulder nearest the ditch.

� Position the toe of the moldboard behind and outside the front right-hand wheel. Always have the toe of the moldboard posi-tioned on the edge of the shoulder nearest the ditch while grading.

� When finishing the right-hand curve, turn straight.

Lean wheels

1 Moldboard toe

Lean wheels

1 Moldboard toe


Grading on an ‘S’ curve shoulder 129

� As you approach the second curve, follow the edge of the shoulder nearest the ditch and turn left.

� Complete the curve and continue grading.

� If a windrow has been created, make a clean-up pass to re-move the windrow and reshape the shoulder.

� Ensure the articulation lock pins are removed before articulat-ing, and install them when not using the articulation function. Articulate the grader in the direction of the curve and follow the edge of the shoulder nearest the ditch. Slide and position the moldboard as required. Do not allow the moldboard to contact the tires when articulating.

Lean wheels

1 Moldboard toe


130 Right-hand leveling

Right-hand leveling� Use the circle shift lever to offset the circle and drawbar slight-

ly to the left of the frame.

� Position the moldboard horizontally at the desired depth of the cut and deposit the windrow outside the left-hand tandem wheels.

� Lean the front wheels to the left to overcome the side thrust.

� Tilt the moldboard forward until the material constantly rolls off the moldboard.

Articulate the frame to the right. If the drive wheels lose traction, reduce the articulation angle. This will decrease the cutting angle and side thrust allowing the drive wheels to regain traction. Depos-it the windrow between the tandem wheels. Spread the windrow over the new surface until it is smooth.

NOTE! Ensure the articulation lock pins are removed before articulating the grader. Install them when not using the artic-ulation function.

Lean wheels

Lean wheels


Left-hand leveling 131

Left-hand leveling� Use the circle shift lever to offset the circle and drawbar slight-

ly to the right of the frame.

� Position the moldboard horizontally at the desired depth of the cut and deposit the windrow outside the right-hand tandem wheels.

� Lean the front wheels to the right to overcome the side thrust.

� Tilt the moldboard forward until the material constantly rolls off the moldboard.

Articulate the frame to the left. If the drive wheels lose traction, re-duce the articulation angle. This will decrease the cutting angle and side thrust allowing the drive wheels to regain traction. Depos-it the windrow between the tandem wheels. Spread the windrow over the new surface until it is smooth.

NOTE! Ensure the articulation lock pins are removed before articulating, and install them when not using the articulation function.

Lean wheels

Lean wheels


132 Road construction

Road construction

Right-hand ‘V’ ditching

� Place a line of stakes to define where the ditch will be con-structed.

� Position the moldboard with the toe just outside the front right-hand wheel and the moldboard heel just ahead of the left-hand tandem wheels.

� Tilt the moldboard back and raise the heel to carry the material inside the left-hand tandem wheels.

� Lean the front wheels left to counteract side thrust.

� Make the marking pass slowly.

� If using an articulated grader on a firm surface, keep the frame straight.

� If the surface is loose, articulate the frame to keep the drive wheels on firm ground. Remember to remove the articulation lock pins before articulating the grader. If the articulation fea-ture will not be used, install the articulation lock pins.

� Make the second pass with the front right-hand wheel on the bottom of the first cut. Cut a 3 to 1 slope at a slightly higher speed.

� A clean-up pass may be required as the windrow builds up on the roadside. Side shift the circle towards the ditch. Carry the material well inside the toe of the moldboard to prevent spill-age back into the ditch.

� Cut the ditch back slope by using the MBCS system to move the moldboard to the right-hand side of the grader. Rotate the circle counterclockwise and lower the left blade lift cylinder while the circle is rotating. Refer to Moveable Blade Control System page 107.

Lean wheels

1 Raise heel of moldboard


Road construction 133

� Center the moldboard heel in front of the right-hand tandem wheels. Drive the grader with the tandem wheels in the ditch. Deposit the material in the ditch.

� When you have completed the back slope procedure, position the moldboard to complete the clean-up pass. This spreads the windrow created by the back slope, and builds up the road surface.

Repeat these procedures to cut the ditch on the other side of the road.

High bank cutting

� Establish a level platform surface for grader operation.

� If the platform surface is hard, make a pass cutting into the platform. This pass should slope slightly towards the bank to stop the grader from sliding away while cutting into the bank slope.

� Prepare your grader for cutting the bank slope by side shifting the circle and moldboard as far as possible to the side of the grader you will be working with.

� Rotate the circle and moldboard counterclockwise and lower the left blade lift cylinder at the same time. Refer to Moveable Blade Control System page 107.

� Lower or raise the circle shift cylinder to position the heel of the moldboard at the bottom of the bank slope and aligned with the inner edge of the tandem wheels.

� Move the grader slowly towards the bank. Check to see if the moldboard is angled correctly before actually cutting into the bank.

� While cutting the slope, ensure tandem wheels are near the base of the bank slope.

� The depth of cut or degree of slope required can be accom-plished easily by raising or lowering the moldboard, tilting the moldboard, or leaning the front wheels.

� Keep your platform surface clean by moving the windrow after each pass on the bank slope.

Ensure the articulation lock pins are removed before articulating, and install them when not using the articulating function. On the level platform surface articulate the front frame towards the bank slope and allow the front wheels to ride the bank slope and posi-tion the moldboard as required. The tandem wheels must be kept on the level platform surface.



Flat bottom ditching – Gravel roads

If no ‘V’ ditch exists, see Right-hand ‘V’ ditching page 132, and cut a ditch to the desired depth.

� The first step is to cut the ditch foreslope.

� With the frame straight, operate the grader with the right-hand wheels riding at the bottom of the ‘V’ ditch.

� Position the moldboard toe behind the front right-hand wheel, and the heel outside and in front of the left-hand tandem wheels.

� Tilt the moldboard forward.

� Lower the moldboard toe to the bottom of the ditch.

� Raise or lower the heel to the required ditch foreslope and lean the front wheels to the left.

� Deposit the material onto the shoulder.

� Reposition the moldboard to cut a second ‘V’ ditch closer to the road and not as deep as the first ‘V’ ditch cut. Deposit the material onto the shoulder.

� Reposition the moldboard to make a clean-up pass for the ma-terial built up on the road shoulder. Side shift the circle to-wards the ditch. Carry the material well inside the toe of the moldboard to prevent spillage back into the ditch.

� Spread the material to the center of the road to create a crown. Refer to Crowning a road page 136.

First cut

1 Backslope

2 Foreslope

3 Windrow

Second cut

1 Backslope

2 Foreslope

3 Windrow

1 Spread out material

2 Backslope

3 Foreslope

4 Windrow



� If the backslope is insufficient or if you are building a new road, make a pass to cut the backslope. Refer to Right-hand ‘V’ ditching page 132.

� To begin a flat bottom cut, operate the grader with its right-hand side wheels riding in the first ‘V’ ditch cut.

� Position the moldboard toe at the bottom of the ditch backs-lope and the heel at the bottom of the ditch foreslope.

� Tilt and lower the moldboard for the required depth.

� Make a horizontal cut and lean the front wheels to the left.

� Reposition the moldboard to make a cleanup pass to spread the windrow created by the flat bottom cut up onto the shoul-der. Spread this material and finish the final grade.

1 Cut backslope

2 Backslope

3 Foreslope

1 Flat bottom cut

2 Backslope

3 Foreslope

4 Windrow

1 Clean-up pass

2 Spread out material

3 Backslope

4 Foreslope

5 Windrow



Crowning a road

Crowning a road is simply constructing a road surface so that the center of the road is higher than the road edge. This allows water to drain into the ditches as quickly as possible. If the crown is not built properly, water will be trapped and break up the road crust producing potholes and washboards. The amount of crown is the amount of slope on the road. For good drainage, a road should have a crown of 8 mm to 13 mm for very 305 mm (1/3 in. to 1/2 in. for every 12 in.) of width measured from the center of the road to the outside edge where the road meets the shoulder.

� After the ditches have been constructed, grade the excess material to the center of the road, creating a windrow.

� Position the moldboard parallel to the front axle.

� Drive the grader straight down the center of the windrow, keeping the moldboard high on the windrow to feather the ma-terial to both sides of the grader.

� Construct the crown slope by tilting the moldboard forward and position it between a 60 and 75 degree angle. Place the transmission in a higher gear to increase your speed. Raise the heel of the moldboard slightly to allow the material to be feathered. Work both sides of the road constructing the slope at the same time.

� When you reach the shoulders, align the heel of the mold-board with the tandem wheels, to compact the excess materi-al.

Example of road section

A Road surface width

B Lane width

C Crown height

D Edge of road surface

E Shoulder

F Height from edge of road

Moldboard high on windrow

Raise heel and tilt moldboard forward



Cul-de-sac using articulation

Cul-de-sacs are easily constructed with articulated frame graders.

� Start grading at the perimeter of the cul-de-sac in a circular pattern and work the material towards the center. Angle the moldboard to deposit the material outside the tandem wheels.

� Articulate the frame and lean the wheels in the direction you are turning to increase steering control as you approach the center of the cul-de-sac.

� To begin the finished grade of the cul-de-sac, drive the grader opposite to the direction you were previously operating at the outside edge and form a windrow towards the center.

� Tilt the moldboard forward and move the windrow towards the center of the cul-de-sac.

� Check the slope as you grade the windrow towards the center, making the center the highest point.

� When you have completed circling, grade the excess material out the cul-de-sac entrance.



Finishing a gradual slope using articulation

� It is best to start from the top and finish your grading at the bot-tom of the slope, if possible.

� Work back and forth across the slope.

� Always extend the moldboard down slope.

� Ensure the articulation lock pins are removed before articulat-ing and install them when not using the articulating function.

� Articulate the grader. Keep the tandem wheels on the level surface.

� Lean the front wheels vertically and position the uphill front wheel on the edge of the windrow created from the previous pass. This provides stability and allows you to create an even grade.

� Position the toe of the moldboard outside and behind the up-hill wheel so that the heel of the moldboard deposits the ma-terial outside the downhill tandem wheels.

� When you have completed grading the slope, spread the re-maining material to make a smooth finished grade.

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

1 Work across slope

2 Start from the top and finish at the bottom

1 Windrow deposited outside tandem wheels

2 Uphill front wheel

3 Moldboard toe



Road maintenance – Gravel roads

Check the road surface material. If it is dry, using water to dampen it results in a better finished surface.

Washboard road surface or potholes need reshaping because of the effects of weather and traffic. Reshaping involves cutting and re-mixing aggregates and fines.

� Start at the edge of the shoulder and cut the material into a windrow. Deposit the material towards the center of the road and outside the tandem wheels.

� Ensure the circle is centered and the moldboard is angled at 30 degrees to the frame center line.

� Tilt the moldboard back for maximum cutting to remove the ridges and potholes.

� Lean the front wheels towards the heel side of the moldboard as you work towards the center of the road.

� Repeat these procedures for the other side of the road sur-face.

� Generally, tilt the moldboard forward for grading and back for ditching.

� Build the road surface by moving half the windrow towards the shoulder. Feather the material over the road surface as you check the crown, and work towards the shoulder with each pass.

� As you make a final pass at the edge of the shoulder, raise the heel of the moldboard to feather the material and use the tan-dem wheels to compact any remaining material.

Lean wheels

1 Tilt moldboard back

Raise heel of moldboard



Right-hand ditch clean-up

� Position the moldboard toe behind the front right-hand wheel.

� Lower the right-hand blade lift cylinder to position the mold-board to the depth of the ditch.

� Move the left-hand blade lift cylinder to position the heel of the moldboard to deliver the material onto the foreslope between the tandem wheels, without cutting the foreslope.

� Lean the front wheels slightly left to counteract side thrust.

� For the next pass, reposition the moldboard as required to move the material up the foreslope and onto the shoulder.

� On the next pass spread the material to finish the shoulder grade.

Left-hand ditch clean-up

� Position the moldboard toe behind the front left-hand wheel.

� Lower the left-hand blade lift cylinder to position the mold-board to the depth of the ditch.

� Move the right-hand blade lift cylinder to position the heel of the moldboard to deliver the material onto the foreslope be-tween the tandem wheels, without cutting the foreslope.

� Lean the front wheels slightly right to counteract side thrust.

� For the next pass, reposition the moldboard as required to move the material up the foreslope and onto the shoulder.

� On the next pass spread the material to finish the shoulder grade.

1 Moldboard toe



Cleaning a wet ditch

� Ensure the articulation lock pins are removed before articulat-ing, and install them when not using the articulating function.

� Articulate the grader so that the front wheels are in the ditch.

� Keep the tandem wheels on the shoulder to prevent wheel slippage in the wet or soft material of the ditch.

� Side shift the circle and drawbar assembly towards the ditch.

� Tilt and angle the moldboard as required to move the material out of the ditch and to deposit it between the tandem wheels.

� For the next pass, straighten the frame, side shift the circle and drawbar assembly and center it under the frame. Position and angle the moldboard as required to spread the wet mate-rial over the shoulder.



Dragging a shoulder (right-hand side)

� Check the material you will be grading. If it is dry, using water to dampen it will result in a better finished surface.

� Position the right toe of the moldboard in line with the outer edge of the front right-hand wheel.

� Angle the moldboard 30 to 45 degrees from the center line of the frame. Tilt the moldboard forward to drag the material, not to cut it.

� Lean the front wheels to the left to counteract side trust.

� Deposit the material outside the left-hand tandem wheels onto the edge of the road.

� On the next pass, collect the windrow from the edge of the road and feather the material back onto the shoulder surface. Remember to adjust the moldboard to create a gentle slope towards the ditch.

� Ensure you clean up the road surface before allowing traffic to use the road way.

NOTE! Procedures and illustrations shown are for right-hand side grading. For left-hand side grading, lean the front wheels and position the moldboard opposite to the description and illustrations shown.

Lean wheels


Scarifier and ripper operation 143

Scarifier and ripper operation� When operating close to electrical lines, underground cables,

water mains or gas lines, contact the responsible authority and request assistance.

� When scarifying or ripping across a slope, keep the mold-board parallel with the front axle, centered to the frame and lowered close to the ground to provide protection against roll-ing over.

A Volvo scarifier or ripper is useful for breaking up hard surfaces such as asphalt, rocky subgrade and ice to ease grading.

Scarifier

A scarifier is mounted either on the front of the machine or behind the front wheels and is hydraulically operated from inside the cab. Refer to Control lever for scarifier, ripper or windrow eliminator page 68. The mid-mounted scarifier can be used with other front mounted attachments.

The scarifier is equipped with up to eleven teeth that are adjust-able and replaceable. Use the scarifier to break up surfaces that are too hard to cut with the moldboard. For especially hard surfac-es, reduce the number of teeth. Always lower the scarifier teeth into the material slowly while the grader is moving at a low speed. Do not skid the teeth along hard surfaces such as large rocks or pavement. Do not use the scarifier when turning or articulating. This places side loads on the scarifier teeth and may result in equipment damage.

Ripper

The ripper is very useful for dislodging large rocks and tree stumps, and breaking up asphalt pavement. The ripper can be equipped with five ripper teeth or nine scarifier teeth. The ripper is hydraulically operated from inside the cab. Refer to Auxiliary hy-draulic controls page 70.

When using the ripper, lower the teeth into the ground with the grader in motion. If the rear wheels lose traction, raise the ripper until the wheels regain traction. For especially hard surfaces, re-duce the number of teeth. To break old pavement, lower the teeth under the pavement and raise the ripper. Avoid the use of the rip-per when turning, this reduces wear on equipment.


144 Notes


Introduction 145


Introduction

NOTE! This sections deals with general safety rules which should be followed when checking and servicing the ma-chine. Safety rules and warning texts for operating the ma-chine are given in the respective sections in this Operator’s Manual.

Safety concerns everybody

This section is intended as a guide to the correct handling of the machine. Therefore, carefully read these instructions before ser-vicing the machine. Keep the Operator’s Manual in the machine for handy reference.

Many hours have been spent designing and producing the safest and most efficient machine possible. However, this is in vain if the individual who is about to use or service the machine does not read or follow the safety instructions. For example:

– does not re-install guards

– steps on slippery parts of the machine instead of using a lad-der

– grabs hold of hoses instead of handholds

– uses the wrong tool for the job

In order to maintain safe and efficient function, always use Volvo CE genuine spare parts.

Machines rarely cause accidents, whereas incorrect handling of-ten does.

A safe and conscious person and a well maintained machine make a safe, efficient and profitable combination.

WARNING!Any person who does not follow the safety instructions or fails to heed the warnings given in this Operator’s Manual, must make sure that his or her working method is safe. Otherwise there is risk of serious accidents, which could be fatal.


146 Service position

Service position

Before performing any service, maintenance or inspection proce-dure, the grader must be placed in the Service Position as shown below:

1 Park the grader on a level surface.

2 Place the transmission in NEUTRAL and apply the parking

brake.

3 Install both articulation lock pins.

4 Lower the moldboard and all attachments to the ground. Do

not apply down pressure.

5 Shut down the engine.

6 Remove and retain the ignition key.

WARNING!If you have to work on a machine before it has cooled down, beware of hot fluids and components which can cause burns.


Service position 147

7 Install chocks at the front and rear tandem wheels. Wedge the

chocks in place.

8 Fasten a ‘DO NOT OPERATE’ or similar warning tag on the

steering wheel.

9 Turn the battery isolation switch OFF to the (O) position.

10 Allow the engine and hydraulic system to cool before working

in these areas.

11 Be aware of other service personnel in your work area.

If the service procedure includes welding, refer to Welding and electronic components page 150.

If the service procedure includes repair to the hydraulic sys-tem, you must perform the following steps.

All of the hydraulic implements except the moldboard slide have a lock valve between the main control valve and the cylinder.

Moving the main control valve levers will not relieve any pressure that is trapped in the cylinder(s). The only exception is the mold-board slide, which does not have a lock valve in the circuit.

� Carefully loosen the appropriate hydraulic line to allow any trapped oil under pressure to be relieved.

� Connect blade lift accumulators (if installed) to their hydraulic circuits by turning the shut-off handles counterclockwise.

� Relieve residual hydraulic pressure in moldboard slide circuit by operating the control lever.

� Some circuits have electrically activated float valves. To re-lieve pressure in these circuits, turn on the ignition key without starting the engine and place the control lever in the float de-tent position.

For more information on relieving trapped pressure in the hy-draulic system, refer to the Service Manual.

WARNING!� Fluid escaping under pressure can penetrate the skin

causing serious injury. Do not use your hand to check for hydraulic leaks. Use a piece of cardboard. If possible, relieve all pressure before disconnecting hoses.

� Make sure all personnel are clear of moldboard, attachments or components controlled by the hydraulic circuits. Unexpected movement of the component could result in severe personal injury or death.

� Be careful to place the machine in a position that does not allow any external load on the cylinder(s) or circuit(s) to be worked on.

� Properly block the machine or implement to prevent movement. Relieving trapped pressure by loosening a fitting may allow the machine or implement to move unexpectedly.


148 General

General

� Place the grader in the Service Position before performing any service, maintenance or inspection procedure. Refer to Ser-vice position page 146.

� Know and use the proper protective equipment. Equipment such as hard hat, protective glasses, protective shoes, gloves, reflector type vest, respirator and hearing protection may be required.

� Avoid loose fitting clothing, loose or uncovered long hair, jew-elry and loose personal articles. These can get caught in mov-ing parts. Jewelry may also ground or short a live circuit when working on the electrical system.

� Wear gloves to protect hands when handling cable.

� Disconnect the battery cables before working on the electrical system. Remove the negative cable first and install it last.

� Avoid lubrication or mechanical adjustments with the grader in motion or the engine operating. If the engine must be in oper-ation to make certain adjustments, place the transmission in NEUTRAL, apply the parking brake, place the grader in a safe position, lower the moldboard and attachments, securely block the wheels and use extreme caution.

� Ensure that adequate stands or blocks are used to support the grader when servicing.

� Securely block the moldboard or any attachments that may fall before working on them.

� When servicing the grader, fasten a ‘DO NOT OPERATE’ or similar warning tag on the steering wheel. Be sure that the bat-tery isolation switch is in the off position and that you remove and retain the ignition key.

� Ensure the work area is clean, organized and safe.

WARNING!Do not attempt to repair or adjust grader unless you are a qualified service technician. Read and understand the grader service manual, the engine manual and the powertrain manual. Failure to follow the instructions or heed the warnings could result in severe personal injury or death. Proper care is your responsibility. Contact your Dealer or Volvo for replacement parts.

WARNING!Do not work on graders supported only by moldboard or attachments. Hydraulic or mechanical failure could cause grader to fall resulting in severe personal injury or death.


General 149

� When servicing or replacing pins, etc., use a brass drift or oth-er suitable material between the hammer and pin.

� Keep the brakes and the steering systems in good operating condition.

� Safety equipment such as goggles, respirators, and special clothing may be needed.

� Some parts or assemblies of the grader are very heavy. Use suitable lifting equipment.

� Keep your head, body, limbs, feet and hands away from all moving parts. These include: circle and moldboard assem-blies, scarifier, ripper, engine drive belts and drive shafts, etc.

� Before the grader is placed back in service, ensure all doors, panels, inspection covers and the battery box cover are in place and secure.

� After servicing the grader, test it in a safe location.

� Do not allow unauthorized personnel on or around the grader.

� The spray from pressurized coolant can cause serious injury to your eyes and skin. Wait until the engine is cool enough to rest your hand on the cap.

� Avoid burns from direct contact with hot components or splashing hot oil.

WARNING!When using pressurized air for cleaning, wear a face shield and protective clothing. Do not direct the air hose nozzle at yourself or others. Severe personal injury could result.

WARNING!Handle all chemicals carefully and according to manufacturer's instructions. Improper handling can result in burns, poison from fumes, fire or explosion hazards. Severe personal injury or death could result.

WARNING!Rotating components. Keep hands away when engine is running.

WARNING!Structural damage or unauthorized modifications weaken the ROPS cab and reduce protection in a rollover situation. Consult your Volvo Dealer if the ROPS is damaged, has been modified, or if grader has been involved in a rollover incident.


150 General

Welding and electronic components

Before welding on the grader, disconnect the following items:

1 Negative battery cable.

2 Positive battery cable.

3 Power supply and transmission wiring harnesses at the trans-

mission ECU (electronic control unit).

4 Wiring harnesses at the instrument ECU, engine ECU, and fan

ECU.

5 Alternator to battery wiring harness.

6 5 amp 24V-12V convertor (if installed) wiring harness at the fuse

panel.

7 25 amp 24V-12V convertor (if installed) wiring harness at the

battery.

8 Float valve module (if installed) wiring harness at the module.

Connect the arc-welder ground cable as close as possible to the work area. Install the battery box cover. After completing your welding procedures, connect the above items in the reverse order. Ensure you connect the negative battery cable last.

Refer to Fire prevention measures, Welding and grinding work page 153, and Health hazards with paint, plastics and rubber page 154.

WARNING!Explosive gases. No smoking. Keep flames and sparks away from battery.


General 151

Safety when lifting and supporting the machine

� Use only lifting devices with sufficient capacity to safely sup-port the expected weight you are lifting.

� All lifting devices (straps, slings, chains, ratchet blocks, etc.) must comply with applicable regulations and certifications. We can accept no responsibility for the use of sub-standard equip-ment and work practices.

� If you use a jack, the floor or ground must be even and of suf-ficient strength to support the expected load. Prevent the ma-chine from rolling by applying the parking brake and wedge tire blocks in front and behind the tires that remain on the ground.

� Place the jack under the axle of the wheel to be removed. Make sure it is positioned correctly and that it will safely sup-port the expected load.

� Take care to safely position the supports under the machine.

NOTE! The machine must be lowered from the jack to a suit-able secure stand before the wheel is removed. Do not use the jack to support the weight of the machine when removing the wheel.

Safety when handling oil and fuel

� Hot oil can cause painful burns. Use caution when changing the engine, transmission or hydraulic oil.

� Oils and fuel can irritate and damage the eyes, throat and oth-er sensitive skin. Avoid contact.

� Oils and fuel are hazardous to the environment. Take special care not to spill or discharge these fluids. Use approved con-tainers and methods to handle and dispose machine fluids. Use an authorized disposal and recycling company.

� Be aware of the risk of fire.


152 Fire prevention measures

Fire prevention measures� There may always be a risk of fire. Learn the correct type of

fire extinguisher to use, how to use it, and where it is kept.

� A fire extinguisher is available as an option on Volvo motor graders. It is mounted on the right-hand rear post inside the cab.

� Any on-board fire extinguisher must be kept fully charged and in good working order at all times.

� Any on-board fire fighting equipment should be considered as a complement to the operator’s own fire fighting efforts. It is not a replacement.

� Never expose diesel fuel to open flame or smoking materials, especially when refueling or the fuel system is open to the air.

� Never use diesel fuel as a cleaner, use only an approved cleaning solvent.

� Many solvents are flammable and can cause skin rashes or other conditions. Do not inhale solvent vapors.

� Engine starting aids are flammable and should be stored in a cool, well-ventilated location. Never use starting aids when preheating intake air.

� Ensure the grader is properly equipped for grading in dry or forested areas. Equipment such as a spark arrestor may be required.

� At the first sign of a fire, take the following actions if the situa-tion will safely permit:

– Drive the machine away from the danger area.

– Lower the moldboard and other implements and attachments to the ground.

– Shut down the engine with the ignition key switch.

– Leave the cab quickly and safely.

– Turn the battery isolation switch off.

– Begin extinguishing the fire and call for assistance if required.

Cleanliness

� Cleanliness is important to effective machine service. Con-tamination introduced to machine systems can shorten com-ponent service life and cause the machine to malfunction.

� Keep the service area clean. Oil or water on the floor can cre-ate a dangerous work environment, increasing the risk of falls and electrocution. Oily and greasy clothing and shop rags are a fire hazard.


Fire prevention measures 153

� The machine should be inspected daily for the build-up of flammable debris. This will reduce the chance of a fire, and will make it easier to detect loose or leaking parts.

IMPORTANT! Take care when using high pressure water for cleaning, especially around electrical components and insu-lation.

� Take special care to keep machines clean in applications such as coal mines where the risk of fire is greatest. In such appli-cations, suitable equipment to reduce the risk of fire should be installed and maintained.

Electrical system

� Inspect wiring for chafing, breakage, and any routing condition that could expose wiring to damage. This is especially impor-tant for positive electrical wires that could make contact with the frame (ground). Pay special attention to the cables be-tween the batteries, from the batteries to the starter, and be-tween the alternator and starter.

� When reconnecting wires, it is important to connect, route and secure them so they are protected from damage and wear. They must not be routed in contact with fuel or oil hoses.

� If any auxiliary electrical equipment is installed on the ma-chine, wiring must be fused, connected and routed to avoid exposure to wear or damage.

Fuel, hydraulic and brake systems

� Check to make sure fuel, hydraulic and brake hoses are not worn or damaged, and are routed to avoid chafing.

Welding and grinding work

� Move the machine to a clean, safe area before welding, grind-ing or using an oxy/acetylene torch on it. This type of work should only be done in a clean area and not in places that con-tain combustible materials, such as fuel tanks, hydraulic pipes or similar.

� Work with extra care when welding, grinding or torch cutting near flammable objects.

IMPORTANT! Have a fully charged and maintained fire extin-guisher on hand when doing any welding on the machine.

� Welding on painted surfaces releases dangerous fumes and results in a poor weld joint that can result in failure and poten-tial accidents. Always remove paint from areas to be welded.

� See Working on painted surfaces to follow.


154 Fire prevention measures

Health hazards with paint, plastics and rub-ber

Working on painted surfaces

� Welding and gas cutting must not be performed on painted surfaces.

� All paint disintegrates when heated, forming many different compounds that may be irritating or constitute a serious health hazard after long or frequent exposure.

The following safety instructions must be followed:

� Before welding or gas cutting, remove paint by sandblasting at least 10 cm (4 in.) around the area. Sandblasting is the rec-ommended method of paint removal.

� If a sandblasting machine is not available, use a chemical paint stripper. Paint stripper is corrosive and toxic. Use a por-table air extractor, an approved respirator, goggles, and gloves.

� A high-speed grinding machine also heats the paint and must only be used in conjunction with an air extractor. Also use ap-proved breathing protection/respirator.

Rubber and plastics

Certain seals designed to withstand high operating temperatures (for example, in engines, transmissions, axles, brakes, hydraulic motors, and pumps) may be made of fluor rubber.

If a machine or a component of a machine has burned or been ex-posed to intense heat, it should be handled by specially trained personnel. In handling of machines after a fire, wear protective neoprene rubber gloves, goggles, and approved respirator.

The acid may remain on machine parts for a very long time (sev-eral years) after a fire. It cannot be rinsed or washed off the skin, but causes very severe burns that take a very long time to heal. As a rule, injured tissue must be removed surgically.

NOTE! There may be a delay of several hours after contact with the acid before any symptoms appear.

Seek medical attention immediately if swelling, redness or burning sensations appear.

WARNING!Risk of serious corrosive injuries! Heating of hydrogen fluoride rubber to high temperatures (approx. 320°C [600°F]) causes risk of forming hydrogen fluoride gas and hydrofluoric acid. The gas has a strongly corrosive effect on respiratory tracts when inhaled. The acid causes severe burns and is very corrosive.


Fire prevention measures 155

Decontamination

Decontaminate the area around a part that may be made of fluor rubber by thoroughly washing with liberal quantities of lime water (a solution or suspension of calcium hydroxide). When work is completed, wash cleaning materials in lime water and discard.

If a machine has been damaged by fire or been exposed to other intense heat, the safety precautions in the following check list must be followed under all circumstances.

Check list after fire or heat exposure

� As a precaution, all o-rings and seals should be handled as if they were made of fluor rubber. See also “Fluor rubber” in this section.

� Never touch burnt components or parts with your bare hands when there is a risk that you may be exposed to contact with burnt fluor rubber. See section “Rubber and plastics”.

� Wear thick, protective neoprene gloves, goggles, and ap-proved respirator.

� First, wash thoroughly with plenty of lime water (a solution or a suspension of calcium hydroxide, i.e. slaked lime).

� Seek medical attention if skin contact with burnt fluor rubber is suspected. The affected skin should be treated with Hydroflu-oric Acid Burn Jelly or similar.

� Symptoms may not appear until several hours after contact with burnt fluor rubber.

� Wash with lime water, then discard protective gloves, rags and other items that may have contacted burnt fluor rubber.

WARNING!Avoid splashes when washing a machine damaged by fire! Never use a high-pressure washer.


156 Hydraulic system

Hydraulic system� Never adjust a pressure relief valve or other pressure-limiting

device to a higher pressure than specified.

� Replace any hydraulic hose immediately that shows signs of swelling, wear, leaks or damage before it bursts.

� If skin penetration occurs seek medical attention immediately.

� Always wear eye protection when working on the hydraulic system.

� Do not bend or strike high pressure lines, tubes or hoses, or reinstall them in a bent or damaged condition. Leaks can cause a fire hazard.

� Tighten all connections to the specified torque when you in-stall or replace high pressure lines, tubes or hoses. Refer to your Service Manual.

� Residual pressure may remain in the hydraulic system. Re-lieve all pressure before disconnecting hoses. Tighten all con-nections before applying pressure.

� Check valves, lock valves and similar hydraulic components are designed to retain pressure or oil flow. See the Service Manual for specific procedures to relieve residual pressure with these components in a hydraulic circuit.

WARNING!Fluid escaping under pressure can penetrate the skin causing serious injury. Relieve all pressure before disconnecting hoses. Do not use your hand to check for hydraulic leaks. Use a piece of cardboard.


Hydraulic system 157

Accumulators

� Use extreme care when working with hydraulic systems incor-porating accumulators. Relieve the hydraulic system pressure before performing any service.

� Never discard a hydraulic accumulator without first carefully drilling a 3 mm (1/8 in.) hole in the cylinder to eliminate the risk of explosion.

� Ensure the accumulators have the proper precharge before putting the grader back into service. Improper precharge could result in severe personal injury or death. Consult your Volvo Dealer.

All Wheel Drive system

� Do not attempt to repair or adjust the All Wheel Drive System unless you are a qualified service technician.

� Use extra care when working on All Wheel Drive System com-ponents and hoses. A high pressure leak could result in per-sonal injury.

� Only qualified service personnel should test the system.

WARNING!Do not use oxygen or compressed air when precharging accumulators. An explosion can occur if oxygen comes in contact with a spark. Use dry nitrogen.

WARNING!Accumulator contents under pressure. Service by qualified personnel only.

WARNING!Do not bypass or alter any switch or other component in the All Wheel Drive System. Modifications can cause premature engagement or prevent disengagement of the system. Property damage and personal injury can result.

WARNING!Do not operate the All Wheel Drive System with the front wheels off the ground except when testing the system. Wheels may rotate unexpectedly. Keep clear when engine is running.



� Use clean, new oil and the cleanliest possible shop practice when adding oil to the All Wheel Drive System. Small amounts of contamination can cause excessive wear and abrasion to precision components and reduce service life.

� Do not use any hydraulic oil or filter other than those recom-mended by Volvo.

� Keep hose connections clean and tight to prevent contami-nants from entering the hydraulic system.

� Check the hydraulic oil level. Never operate the system with a low oil level. If loss of oil or charge pressure occurs, stop the grader as quickly as possible and shut down the engine. Loss of oil can result in component damage. Report the problem and have it repaired by a qualified service technician.

� Have defective components repaired or replaced immediately. Using defective components may cause serious damage to other parts in the system.

� Turn the All Wheel Drive System OFF and shut down the en-gine before leaving the operator’s cab or when performing maintenance.

� Read and understand Operating instructions, Shifting gears, All Wheel Drive models page 91.


Electrical system 159

Electrical system� Use only test instruments with LED (light-emitting diode) dis-

plays to trace electrical faults. Do not use test equipment that uses light bulbs. The voltage characteristics of light bulbs can destroy sensitive and expensive electronic components.

� When installing a two-way radio, mobile telephone and similar equipment, follow the manufacturer’s installation instructions in order to eliminate interference with the function of the elec-tronic system and components on the machine.

Batteries

� Batteries produce explosive gases. Keep sparks, flames, smoking materials, or other ignition sources away from batter-ies. Use a flashlight to check the electrolyte level.

� Battery electrolyte contains corrosive sulfuric acid. In case of contact with the skin, wash immediately with plenty of water. In case of contact with the eyes or other sensitive part of the body, wash immediately with plenty of water and seek imme-diate medical attention.

� Wear a face shield when working with batteries.

� Never lean over a battery during charging, testing or jump starting operations.

� Be familiar with procedures for charging and testing a battery. Read and follow the manufacturer’s instructions for the bat-tery charger.

� Place a wet cloth over the battery and its vents before charg-ing or jump starting. Ensure that the cloth is not placed near any fan blades, belts or any other moving parts.

� Disconnect the negative cable first when removing a battery. Connect it last when installing a battery.

� Do not let metal objects come in contact with the battery ter-minals.

� Do not charge or jump start a frozen battery. It may explode due to gas trapped in the frozen battery. Allow the battery to warm to 16°C (60°F) before charging or jump starting it.

� For jump starting instructions, refer to Starting with jumper ca-bles: page 182.

WARNING!Explosive gases. No smoking. Keep flames and sparks away from battery.

WARNING!Handle batteries carefully. Battery acid is extremely corrosive and poisonous. Contact with the eyes, skin, or clothing can result in severe burns or other serious personal injury.


160 Tires

TiresTire repair or replacement must be performed by qualified person-nel only. Tires should be visually inspected daily for wear, damage, and correct air pressure. Check the tire pressure weekly with an accurate pressure gauge when the tires are cold.

� Do not overinflate the tires. Refer to Service and mainte-nance, Maximum tire pressures page 196.

� Ensure that all tires and rim parts are undamaged and correct-ly assembled before inflating the tires.

� Never stand beside a tire that is being inflated. Use a self-at-taching air chuck with a hose long enough to be out of the tra-jectory path of the wheel rim when inflating a tire.

� Do not fully inflate spare tires. Use only enough air pressure to keep the rim parts in place.

� Always use an inflation cage, safety cables or chains when in-flating a tire that is not installed on a machine.

� Never mount a tire on a wheel rim that is not clearly recom-mended for that tire.

� Never use wheel parts of different sizes together, and never use damaged or faulty wheel parts.

� Use extreme care if you must use a repaired or reworked wheel rim. Faulty welding, brazing or heating can cause weak areas that can result in failure of the part.

� Remove all rust, dirt and debris from the locking ring groove in the rim before installing the ring.

WARNING!Failure to use a safety cage when inflating tires could result in severe personal injury or death.

WARNING!Do not weld on the rim. The flame and heat can cause an explosion. The weld can cause premature rim failure. Severe personal injury or death could result.


Air conditioning unit 161

Air conditioning unit� The air conditioning system uses R134a refrigerant and PAG

(polyalkyleneglycol) refrigerant oil. Do not use any other type of refrigerant – for example, R12 (Freon®) – in the air condi-tioning system. A mixture of R134a and R12 refrigerants can cause unacceptably high compressor discharge pressures. Mixtures of R134a and R12 cannot be separated and usually have to be disposed of by incineration.

� Do not attempt to repair or adjust the air conditioning system or handle the R134a refrigerant and PAG refrigerant oil unless you are a qualified service technician.

� If R134a refrigerant contacts your skin or eyes seek medical attention immediately. PAG oil produces a mild irritation to the skin. Wash immediately with soap and water.

� Wear protective clothing, impervious gloves and chemical splash goggles while working on the air conditioning system.

� Ensure you handle the R134a refrigerant in a well ventilated area. Inhaling high concentrations of vapor can be harmful.

WARNING!Do not smoke in an area where R134a refrigerant and PAG refrigerant oil are used or stored. Do not allow R134a refrigerant and PAG refrigerant oil to come in contact with an open flame or heated metal. Open flames or heated metal will decompose the refrigerant and produce harmful hydrofluoric acid and toxic fumes.

WARNING!Exercise extreme care when handling R134a refrigerant. Direct contact with skin may cause frostbite.


162 Fuel handling

Fuel handling� Allow the engine to cool before refueling.

� Do not refuel with the engine running.

� Ensure the fueling area is well ventilated.

� Turn off all electrical switches, cab heaters and the battery iso-lation switch.

� Do not smoke while refueling.

� To refuel, use the handholds and step provided to get to the fuel tank. Ensure the handholds, tires, tandems and the tan-dem steps are clean and dry to prevent you from slipping.

� Use care when removing the fuel tank cap.

� To prevent static electricity sparks from igniting the fuel va-pors, make a good ground contact by keeping the fuel nozzle in constant contact with the fuel tank filler neck.

� Do not fill the fuel tank to full capacity. Leave room for fuel ex-pansion.

� Clean up any spilled fuel immediately.

� Do not mix gasoline or any other non-specified material with diesel fuel. Highly combustible vapors may result.

� Install and tighten the fuel tank cap. Should the fuel tank cap be lost, replace it only with the original manufacturer’s ap-proved cap. Using a non-approved cap without proper venting may result in pressurization of the fuel tank.

� Use the correct fuel grade for the operating season.

WARNING!Keep open flames and sparks away from fueling area. Do not smoke. Severe personal injury or death could result.


163


Engine oil level

Check the engine oil level daily with the engine off.

The machine should be parked on level ground to check the en-gine oil. Check the oil when the engine is cold.

The oil filler cap and dipstick are located on the left-hand side of the engine.

– Withdraw the dipstick and check the oil level. The oil level must be between the marks on the dipstick.

– Add engine oil as required. Refer to Specifications, Recom-mended lubricants page 217 for correct oil type.

Check the oil for contaminants or water.

Changing the engine oil

Change the engine oil every 250 hours. Drain the oil when the en-gine is warm. Change the filter(s) at each oil change.

The oil change interval can be increased to 500 hours by closely following the guidelines below. If any of the following conditions cannot be met, the oil should be changed and the filters replaced every 250 hours.

The conditions for the 500 hour interval between oil changes are:

1 The oil filters MUST be replaced each time the oil is changed.

2 The oil filters MUST meet the Volvo CE specifications.

3 The sulphur content of the fuel MUST NOT exceed 0.2% by

weight. See Fuel system page 19.

4 The oil MUST be a quality grade. See Recommended lubricants

page 217.

5 The ambient temperature remains above –10° C (+14° F).

6 The correct oil viscosity for the ambient air temperature is se-

lected according to Recommended lubricants page 217.

Draining

Drain the oil while the engine is still warm.

1 Place a container with a suitable capacity under the oil pan drain

plug.

2 Remove the drain valve dust cap.

3 Take out the drain hose adapter found in the toolbox and con-

nect it to the drain valve to drain oil.

Filling

Fill with oil through the filler pipe. Refer to Recommended lubri-cants page 217 for the correct fluid type.

Oil capacity when changing oil and filter(s):

– G710B to G730B = 32 L (8.5 US gal)

– G740B to G780B = 39.5 L (10.4 US gal)

Take care of waste liquids in an environmentally safe way!

1 Drain hose adapter

2 Draining valve cap

WARNING!Take care when changing oil. Hot oil can cause burns on unprotected skin.


164

Engine oil filter

Change the engine oil filter(s) every 250 hours or when the en-gine oil is changed. The engine lubricating oil filters are the dispos-able type. They cannot be cleaned; they must be replaced.

Removing:

1 Use a filter wrench or suitable tool to remove the filter.

Installing:

2 Fill the filter(s) with clean oil and apply oil to the gasket.

3 Screw on the filter by hand until the gasket just touches the seal-

ing surface.

4 Tighten the filter a further 1/2 turn by hand.

5 Start the engine and check for leaks. If the filters leak, stop the

engine, remove the filters, and check the sealing surface. Usu-

ally it does not help to tighten the filter further.

NOTE! After replacing the oil filters, the engine must run at a low idle for at least one minute to ensure proper lubrication before putting the machine to work.

IMPORTANT! It is very important that the filters are filled with oil before they are installed. This ensures lubrication of the engine immediately when it is started.

Models G710B to G730B

The engine oil filter is located on the left-hand side of the engine.

Models G740B, G746B, and G780B

The engine oil filters are located on the left-hand side of the en-gine. There are three filters – two full flow filters and one bypass filter.


Fuel system 165

Fuel systemFor fuel quality, refer to Fuel system page 19.

Fuel tank

Clean fuel is essential for trouble-free operation of the diesel en-gine.

Carefully clean around the filler cap before removing it. Avoid spill-ing fuel when filling as this attracts dirt.

Refer to Specifications, Capacities page 219 for fuel tank capaci-ty.

� Fill the fuel tank at the end of each day to reduce the chance of condensation and corrosion. Do not fill the fuel tank to ca-pacity. Leave room for fuel expansion.

� Before starting the engine, open the 2 fuel shut-off valves lo-cated on the bottom of the fuel tank. There is one located on the supply line and one on the return line.

� Open the drain valve on the bottom of the sump to drain water or other accumulated contaminants into an appropriate con-tainer.

� Clean up any spilled fuel immediately. Refer to Safety when servicing, Fuel handling page 162.

Fuel filter

Replace the fuel filter every 500 hours.

On G710B to G730B machines, the fuel filter is located inside the engine compartment on the rear left-hand side.

On G740B to G780B machines, it is located inside the engine compartment door on the rear right-hand side.

NOTE! When replacing the fuel filters, close the fuel tank shut off valve. Fuel leakage could occur.

NOTE! The filter is the disposable type that must be replaced. It cannot be cleaned.

Removing:

1 Use a filter wrench or suitable tool to remove the filter.

Installing:

2 Coat the gasket on the new filter with clean diesel fuel.

3 Screw on the filter by hand until the gasket just touches the seal-

ing surface.

4 Tighten the filter a further 1/2 turn.

5 Open the fuel tank shut-off valve.

6 To bleed the fuel system, see Bleeding the fuel system page

WARNING!Keep open flames and sparks away from fueling area. Do not smoke. Severe personal injury or death could result.

Fuel tank sump

1 Sediment bowl on fuel tank

2 Drain valve

3 Fuel shut-off valve

Fuel filter – Models G710B to G730B

Fuel filter – Models G740 to G780B


166 Fuel system

168.

Fuel filter/water separator

The frequency of draining water from the fuel filter/water separator is determined by the contamination level of the fuel. Inspect or drain the collection bowl daily.

Replace the element every 500 hours or if high restriction causes a power loss.

NOTE! Dispose of fuel and contaminants in an environmen-tally safe manner.


The fuel filter/water separator is mounted between the fuel tank and the fuel lift pump. It is located in the right-hand engine com-partment at the front.

To drain water and contaminants:

1 Turn the engine off.

2 Open the vent plug in the filter head.

3 Place a container under the drain valve in the bowl and open the

valve.

4 When all of the contaminates have been drained out of the bowl,

close the drain valve.

5 Close the vent plug and start the engine.

To change the filter element:


2 Close the 2 fuel tank shut-off valves. There is one on the supply

line and one on the return line.

3 Remove the lid screws, lid, spring cassette, and filter element.

4 Install a new filter element and refit the spring cassette.

5 Replace the lid gasket.

6 Fit the lid while checking for correct positioning. Insert the

screws and tighten.

7 Prime the fuel system and check for leaks.


The fuel filter/water separator is mounted between the fuel tank and the fuel lift pump. It is located in the right-hand engine com-partment, at the front. There are two fuel filter/water separators available for the G740B, G746B, and G780B. The standard unit has an integral primer pump in the filter head. The optional unit has a larger capacity with a T-handle on the top for easier service.

Standard fuel filter/water separator (with integral primer)




valve.

3 When all of the contaminates have been drained out of the bowl,

close the drain valve.

1 Vent plug

2 Drain valve


Fuel system 167

To change the filter element:


2 Close the fuel tank shut-off valve.

3 Open the 2 fuel tank shut-off valves.


valve. Drain off some of the fuel.

5 Disconnect the water sensor and heater connectors (if

equipped).

6 Spin the element and bowl off together.

7 Remove the bowl and clean the O-ring gland.

8 Apply a coating of clean fuel or motor oil to the new O-ring and

element seal.

9 Spin the bowl onto the new element, then spin them both onto

the filter head. Tighten by hand ONLY.

10 Connect the water sensor and heater connectors (if equipped).

11 Open the fuel tank feed valve.

12 With the vent plug still loosened, operate the primer pump until

fuel purges at the vent plug.

13 Close the vent plug. Start the engine and check for leaks.

Models G740B to G780B – Optional fuel filter/water separator


1 Shut off the engine.

2 Place a container under the drain valve. (The drain valve is self-

venting.)

3 Open the valve and drain out the contaminates.

4 Close the valve and prime the system if necessary.

To change the filter element

1 Shut off the engine

2 Close the fuel tank feed valve

3 Remove the lid by turning out the T-handle.

4 Remove the element by slowly pulling upward on the molded

handle with a turning motion.

5 Install new element. Apply a coating of clean fuel to the new lid

seal and install.

6 Replace the lid and tighten the T-handle snugly by hand ONLY.

7 Open the fuel tank feed valve and purge the air from the system

by opening the self-venting drain.

8 Start the engine and check for leaks.

1 Primer pump

2 Filter element

3 Filter bowl

4 Drain valve

1 T-handle

2 Drain valve


168 Fuel system

Bleeding the fuel system

The fuel tank is mounted above the fuel filters, therefore minimal bleeding effort is required.

NOTE! Make sure the fuel tank shut-off valve in the fuel tank sump is open.

G710B to G730B Models

A priming pump is located in the engine compartment on the front left-hand side. The fuel filter/water separator is located inside the engine compartment on the front right-hand side.

1 Open the vent plug on the top of the fuel filter/water separator.

2 Operate primer pump by moving the cylinder in and out until all

air is expelled.

3 Close the vent plug.

4 To prime the secondary fuel filter, continue to operate the primer

pump until resistance is felt.


6 Repeat as necessary.

G740B to G780B Models

The priming pump is integral with the standard fuel filter/water separator. A second priming pump is located at the fuel injection pump.

An optional fuel filter/water separator is available with a larger ca-pacity and self-venting drain. With this option, an additional prim-ing pump is located inside the right-hand side access door underneath the fuel tank.

To prime the fuel filter/water separator (with integral primer):

1 Open the vent plug in the filter head.

2 Open the drain on the bottom of the bowl and collect the fuel and

any contaminates into a container. Dispose of them in an envi-

ronmental safe way.

3 Close the drain and operate the priming pump in the filter head

until all the air is purged from the filter.

4 Close the vent plug.


To prime the optional fuel filter/water separator:

1 Place a suitable container under the drain at the bottom of the

canister. (The drain is self-venting.)

2 Drain out the fuel and contaminates and dispose of them in an

environmental safe way.

3 Operate the primer pump until all air is purged.

4 Close the self-venting drain.


For additional priming:

1 Open the bleed valve on top of the filter base.

2 Operate the priming pump at the fuel injection pump until all air

is purged.

3 Close the bleed valve.

Fuel primer pump

1 Primer pump cylinder

(G740B to G780B option shown)


Turbocharger 169

Turbocharger

The turbocharger is lubricated and cooled through the engine lu-bricating system.

An essential condition for trouble-free service from the turbo-charger is that the engine oil and lubricating oil filter are changed at the prescribed intervals.

Maintenance of the air cleaner is also important as are the tight-ness of the exhaust system and lubrication lines.

If any irregular or abnormal noises can be heard, or if the turbo-charger vibrates, it must be reconditioned or changed immediate-ly.

Only authorized workshops may carry out work on the turbo-charger.

Important!Never race the engine immediately after it has been started.Run the engine at low idle speed for two minutes before stopping it to safeguard lubrication and cooling of the turbocharger.

A Exhaust inlet

B To exhaust system

C Air inlet

D Compressed air

Air Oil Exhaust


170 Engine air cleaner

Engine air cleanerCheck the hoses and connections leading from the air cleaner to the engine. Check the exhaust aspirator hose and connections. Look for accumulations of dust, which may indicate leaks, cracked hoses or loose clamps.

Engine air filter elements

Primary filter

When the display unit shows “Clogged Air Filter” or every 1000 hours, the filter should be cleaned or replaced.

If the lamp still lights after the service, the safety filter element must be changed. Refer to Secondary filter page 171. Do not clean the safety filter element.

NOTE! The primary filter may only be cleaned a maximum of three times. Thereafter, it should be replaced. Make a mark on the end of the secondary filter every time the primary filter is cleaned or replaced.

NOTE! Use approved respirator when cleaning filters.

The length of time between filter changes depends entirely on the operating environment of the machine. It may be neces-sary to change the filter more often.

Replacing primary filter

� To service the air cleaner, wipe all the dirt from around the housing end cover.

� Unfasten the latches and remove the end cover.

� Remove the primary element from the housing. Take care not to damage either the primary or secondary filters.

� Do not attempt to clean the primary element by striking it. This can easily damage the element.

1 Air cleaner

2 Hose, exhaust aspirator


Engine air cleaner 171

� Using regulated compressed air at less than 210 kPa (30 psi), clean the primary element. Always direct the pressurized air from inside the element outward and in the opposite direction of the normal air flow. High air pressure can destroy the ele-ment. Hold the air nozzle 25 to 50 mm (1 to 2 in.) away from the filter element.

� Carefully check the element, replace it if it shows any signs of damage. Re-using a damaged element can cause engine contamination.

� Wipe the inside of the housing with a damp cloth and remove any dirt.

Secondary filter

Replace the secondary filter when the primary filter has been replaced 3 times, however no longer than every 2000 hours.

This filter works as a protective secondary filter in case the primary filter should be damaged. If the filter indicator lamp remains on even though the primary filter has been changed or cleaned, the secondary filter has become clogged.

NOTE! The secondary filter should never be cleaned. Replace only.

� Clean the air cleaner housing completely and remove the sec-ondary filter.

� Install a new secondary filter element.

� Install the primary element and end cover.

� Fasten the three latches that hold the end cover in place.

� Check the hoses and connections leading from the air cleaner to the engine. Look for accumulations of dust, which may indi-cate leaks, cracked hoses or loose clamps.

IMPORTANT! Never remove the secondary filter unless it is to be replaced.


1 Primary filter element

1 Secondary filter element


172 Radiators and coolers

Radiators and coolersThe coolers and engine radiator are rear-mounted, cross-flow ra-diators with a hydraulically driven cooling fan. The cooling fan can be driven at variable speeds by hydraulic pump flow based on var-ious system cooling requirements.

Charge air temperature, engine coolant temperature and hydrau-lic system temperature are monitored. The system with the high-est cooling demand will determine fan speed.

Fan speed is relatively proportional to temperature. When a sys-tem operating temperature reaches a specified temperature, the fan will begin to increase in speed. The fan will continue to in-crease in speed if temperature continues to increase.

The minimum fan speed is approximately 500 rpm and the maxi-mum speed is approximately 1750 rpm. A temperature sensor fail-ure will cause the fan to drive at maximum speed.

If the engine temperature becomes too high, even though the coolant level is correct, the radiator should be cleaned.

If the temperature still remains high, contact an authorized dealer for immediate action.

IMPORTANT! Take care not to damage the fins on the radia-tor core.

Engine radiator

Radiator cleaning

Clean the radiator every 500 hours or as needed.

1 Open the rear radiator cowl and side access doors.

2 Remove any debris from the radiator and cooler fins.

3 Check the fan blades.

Blow the radiator clean with compressed air in the opposite direc-

tion of normal air flow.

WARNING!Stop the engine and turn off the battery isolation switch before swinging out the rear radiator cowling door.


1 Cooling fan motor

2 Engine radiator


Radiators and coolers 173

Oil Cooler(s), general

� Open the radiator fan cowling door and side access doors.

� Remove any debris from the radiator and cooler fins.

� Check the fan blades for looseness or cracking.

� Clean the cooler(s) with compressed air in the opposite direc-tion to the normal air flow.

� Drain charge air cooler.

Hydraulic oil cooler

The hydraulic oil cooler is located at the rear right-hand side of the grader.

� Open the rear access door and inspect the oil cooler for clogged or damaged cooler fins.

� Clean the cooler with compressed air. Direct the air in the op-posite direction to the normal air flow.

Charge air cooler drain

1 Hydraulic oil cooler

(G740B, G780B shown)


174 Engine cooling system

Engine cooling systemCoolant

Coolant with anti-freeze and corrosion protection

Anti-freeze

Check the anti-freeze every 250 hours. Use accurate, reliable equipment to measure coolant antifreeze levels.

The engine cooling system is filled at the factory with an antifreeze coolant solution of 60% antifreeze and 40% water. This ensures protection against freezing down to –52° C (–62° F).

If coolant concentration has been diluted, care must be taken to ensure that the antifreeze concentration is a minimum 40% which gives protection down to –25° C (–13° F). If there is a risk that the ambient temperature falls below this, ensure that the concentra-tion is adjusted to provide adequate protection for the anticipated temperature.

Corrosion protection

Anti-freeze contains active anti-corrosion additives in order to pro-tect the engine and radiator. These additives have a limited dura-bility. Therefore, change the coolant every 2000 hours or once a year.

Coolant with corrosion protection only

If the climate conditions are such that anti-freeze is not necessary, an additive should still be used.


Engine cooling system 175

Checking coolant

The expansion tank should be 2/3 full, at the MAX mark when the engine is warm. The control lamp for the coolant level lights up when the level in the expansion tank is too low. Top up when re-quired.

The coolant level must never be below the minimum mark.

Adding coolant

� Add coolant through the reservoir cap located on top of the engine hood beside the air cleaner intake.

� Turn the engine off and fill to the MAX mark on the reservoir.

IMPORTANT! Extreme loss of coolant indicates a leak in the cooling system or a serious engine malfunction. Consult a qualified service technician.

� Do not add cold coolant to a hot engine. Let the engine cool.

� Do not exceed 68% antifreeze. More than 68% antifreeze re-duces freeze protection. The maximum recommended anti-freeze level is 60% which provides freeze protection to –52° C (–62° F). Coolant containing 50% antifreeze provides freeze protection to –37° C (–34° F).

� Do not reuse drained coolant with over concentrated anti-freeze or supplemental coolant additives.

WARNING!Hot pressurized coolant. Remove cap only when engine is cool.

WARNING!Coolant is dangerous to drink.


176 Engine cooling system

Changing coolant

Change coolant every 2000 hours or every 2 years. Refer to Ca-pacities page 219, for the cooling system capacity.

Draining coolant

1 Remove the expansion tank cap.

2 Place a suitable container under the radiator drain valve.

3 Open the drain valve and drain the coolant.

NOTE! To completely drain the cooling system, the engine block must also be drained. Refer to the Service Manual for further details.

Flushing the cooling system

1 Close the drain valve.

2 Refill the system with clean tap water.

3 Start the engine and run at low idle for about 10 minutes.

4 Stop the engine and drain the water.

NOTE! The cooling system is not safeguarded against frost even after draining the complete system. Some pockets of water may still remain.

Refilling the cooling system

Refill the cooling system through the expansion tank.

Use clean water in the radiator, with the addition of anti-corrosion agents and anti-freeze. If the coolant is rusty, rinse the system thoroughly before filling with new coolant.

1 The engine should be off and the heater control set to warm.

2 The cap for the expansion tank should be removed.

3 Fill up to the MAX level in the expansion tank.

4 Take the machine for a test drive to remove all air from the cool-

ing system.

5 Top up the fluid level until the system is completely full.

6 The level should be checked again after the engine has been

run warm then allowed to cool.

IMPORTANT! Never put cold coolant in a warm engine. This can cause cracking in the cylinder block and cylinder head.

Failure to change coolant will cause clogging of the cooling system and risk of the engine seizing.

WARNING!Hot pressurized coolant. Remove cap only when engine is cool.


Radiator drain valve

WARNING!Do not start the engine with the rear radiator cowling door open. The fan motor could start unexpectedly possibly resulting in personal injury.


Engine cooling system 177

Coolant filter, replacing

NOTE! Coolant filter is installed on models G740B, G746B and G780B only.

The filter should be replaced every 1000 hours. To gain access to the filter, open the left-hand engine compartment door. The filter is located towards the fan end of the engine.

Removing

1 Turn the handle on the shut-off valve (1).

2 Loosen the filter with a suitable wrench.

Installing

3 Coat the gasket on the filter with petroleum jelly.

4 Fill the filter with coolant.

5 Screw the filter on until the gasket touches the sealing surface.

Tighten the filter a further 1/2 turn.

6 Open the valve (1).

After installing

7 Wipe around the filter and filter head until dry.

8 Start and run the engine until warm.

9 Stop the engine and check that the gasket on the filter has

sealed. If it has not, remove it and check the sealing surface.

NOTE! Usually it does not help to tighten the filter further.

WARNING!Take care when replacing filter. Hot coolant can cause severe burns on unprotected skin.

1 Shut-off valve


178 Drive belt tension

Drive belt tensionCheck the tension of the drive belts every 500 hours. Use a belt tensioning gauge to achieve the correct tension when belts are warm. Re-tension new belts after 15 minutes of run-in.


Fuel pump drive belt

Adjusting:

� Slacken off bolts 1 and 2.

� Push fuel pump (3) in direction of arrow until correct belt ten-sion is achieved.

� Tighten bolts 1 and 2.

Water pump/fuel pump


WARNING!The engine must be turned off before checking belt tension. Rotating parts can cause severe injuries.

Belt tension New Used

Alternator 356 N (80 lb) 214 N (48 lb)

Air conditioning compressor

356 N (80 lb) 285 N (64 lb)

Bolt torque 21 N�m (150kgf�m)(15 lbf�ft)


10 mm belt 450 N (101 lb) 300 N (67 lb)

13 mm belt 550 N (124 lb) 400 N (90 lb)


Alternator 712 N (160 lb) 498 N (112 lb)

Air conditioning compressor

356 N (80 lb) 285 N (64 lb)



Electrical systemCheck the operation of the travelling lights and control lamps daily.

Battery isolation switch

IMPORTANT! The battery isolation switch must remain on while the engine is running. If it is switched off with the engine running, damage to the alternator or electronic con-trol units may result.

The battery isolation switch is located inside the engine compart-ment on the left-hand side of the grader. Turn the switch on before starting the grader. At the end of the day, turn the switch off for added security.

Do not bypass the battery isolation switch. Have the switch re-paired if it is not working properly.

Batteries

Checking electrolyte level

NOTE! Volvo Motor Graders are supplied with maintenance-free batteries only. The following information is for service-able batteries.

Check the electrolyte level in the batteries every 500 hours. It should be 10 mm (0.4 in.) above the cell plates. At temperatures above +20°C (+68°F), check more often. Batteries are located in-side the battery box mounted on the left-hand tandem case.

� Remove the battery box cover.

� Check the terminals for corrosion and tightness of the cable connectors.

� If the batteries have filler caps, remove the caps and check the level of the electrolyte.

� Add distilled water only. Install the caps.

� Operate the machine after topping up so that the water is mixed with the electrolyte. This is particularly important in cold weather.

� Check that cable terminals and pole studs are clean, well tightened and coated with petroleum jelly or similar.

� Check and tighten the battery hold down clamps and do not let tools or metal objects come in contact with the battery ter-minals.

� Replace the battery box cover.

� An optional battery lifting strap is located in the toolbox. Attach the strap to the battery terminals to lift and carry the battery.

Checking state of charging

The state of charge of the batteries is checked with the aid of an acid tester. When there is risk of frost, it is particularly important that the batteries do not become discharged, as the electrolyte in a flat battery may freeze and thus destroy the battery.

WARNING!Operating with faulty batteries is not recommended. Damage to ECUs could result.


180 Electrical system

Battery problems

To prevent these problems, you must check the battery acid level, inspect the battery casing for leaks and ensure the specific gravity readings are to specification. Check the specific gravity of the bat-tery when you have received your grader. Recheck it every three months. In hot climates recheck it every two months.

Rules for batteries

� If contact with battery acid occurs, seek medical attention im-mediately.

� Wear a face shield when working with batteries.

� Before jump starting the grader, determine why the engine will not crank.

� Remove the batteries and recharge them separately.

� Batteries produce explosive gases. Keep sparks, flames, smoking materials or other ignition sources away from batter-ies. Use a flashlight to check the electrolyte level.

� Do not let metal objects contact the battery terminals.

Shorted Cell When an electrical load is placed on the battery, the cell starts to bubble.

Dead Cell A 50 point spread in the specific gravity reading between the high and low cell readings indicates that the battery has a bad cell. A voltage reading below 10V also indicates that a battery has a bad cell.

Discharged When all cells read below a specific grav-ity reading of 1.230, the battery is dis-charged. The battery should be recharged before an accurate test can be conducted.

Overcharged A voltage reading above 12.6V and a specific gravity reading above 1.265 sig-nifies an overcharged battery.

Open Circuit When an electrical load test is done on the battery and the needle slowly drops off to zero, check for an open circuit.

Sulfated An acid filled battery that has been left to sit without recharging over a long period of time. The end result is that the battery looses capacity and it is difficult to reverse the process.

WARNING!Handle batteries carefully. Battery acid is extremely corrosive and poisonous. Contact with the eyes, skin, or clothing can result in severe burns or other serious personal injury.



Rules for using jumper cables

IMPORTANT! This grader is equipped with 24 volt starting and charging systems.

� Do not charge or jump start a frozen battery. Gas pressure build-up can cause an explosion. Allow the battery to warm to 15°C (60°F) before jump starting or charging.

� Do not lean over batteries during jump starting procedures.

� The booster battery and the discharged battery must be of the same voltage. If they are not, electrical arcing could occur and cause an explosion.

� Ensure the moldboard and all the attachments are lowered to the ground.

� Position the vehicle with the booster battery as close as pos-sible to the grader's discharged battery without touching the grader. Ensure the batteries are close enough to easily con-nect the jumper cables.

� Apply the parking brake of both vehicles and move the trans-mission shift lever of the grader to NEUTRAL. If the other ve-hicle has an automatic transmission, move the lever to PARK. If the vehicle has a manual transmission, move the shift lever to NEUTRAL. Shut down engine. Switch off all unnecessary electrical systems such as lights, heaters, air conditioners, etc. in the grader and the booster vehicle.

� Some batteries have removable vent caps. Remove and clean them. Ensure the vent holes are free of contamination and the caps are installed tightly. Place a wet cloth over the vent caps of each battery. Ensure the cloth is away from fan blades, belts or any other moving parts.

� A wrong connection will cause arcing. Ensure the jumper ca-bles do not contact any moving parts or other metals.

� Warn all personnel who may be around the vehicle or the grader prior to starting the engines. Do not start the engines until all personnel are clearly away from vehicles.



Starting with jumper cables:

1 Turn the battery isolation switch off.

2 Connect a jumper cable between the positive terminal on the

fully charged booster battery and the positive terminal on the

starter motor of the grader with the dead or low batteries.

3 Connect the other jumper cable from the negative terminal on

the booster battery to a frame grounding point on the machine

(a starter mounting bolt or ground strap mounting bolt). Do not

connect the booster battery directly to the discharged battery.

4 Turn on the battery isolation switch.

5 Start the engine of the booster vehicle. Allow the engine to run

for a few minutes.

6 Start the engine of the grader from the operator's seat. Fasten

the seat belt. If the engine does not start within 30 seconds, re-

lease the ignition key and wait two minutes before trying again.

This allows the starter motor to cool. If the engine does not start

on the second or third attempt, stop this procedure. Report the

problem and have it repaired by a qualified service technician.

� Do not dismount from the grader with the engine running. Have a qualified service technician disconnect the jumper ca-bles in the reverse order of connection.

� Allow the grader's engine to run for a few minutes and ensure all controls and instruments are working properly before driv-ing or operating the grader.

Charging batteries

WARNING!When batteries are charging, they give off an explosive mixture of hydrogen and oxygen gases. A short circuit, spark, open flame or cigarette can ignite these gases and cause a powerful explosion. Always turn off the battery charger before disconnecting a charging clip to prevent sparking. If the battery must be charged in a confined space, it must be well ventilated.

WARNING!Battery electrolyte contains corrosive sulfuric acid. In case of contact with the skin, wash immediately with plenty of water. In case of contact with the eyes or other sensitive part of the body, wash immediately with plenty of water and seek immediate medical attention.



Alternator

Sensitivity of alternator

The alternator installation is sensitive to incorrect connection; therefore, always follow the instructions below:

Disconnection

� Battery and alternator cables must not be disconnected while the engine is running. A fault may arise in the alternator and electronics.

� Disconnect and insulate the battery cables before carrying out any work on the alternator equipment.

Battery connection

� The battery terminals must never be confused. Each terminal is clearly marked with a (+) or (–) sign respectively. If the ca-bles are wrongly connected, the alternator rectifier will be de-stroyed immediately.

� When disconnecting batteries, first break the circuit by switch-ing the battery disconnect switch off.

Circuit breakers and fuses

The fuse panel is installed inside the console cover and contains circuit breakers, fuses, relays, and the directional indicator flasher unit. Refer to the decal on the back of the access panel cover for fuse and circuit breaker locations.

If an electrical overload occurs:

� The button of the applicable circuit breaker extends to the open po-sition.

� The element of the applicable automotive blade-type fuse melts.

To reconnect the electrical circuit:

� Press the circuit breaker button into the closed position.

� Find and discard the fuse with the broken element. Install a new fuse having the same amperage rating.

If the problem persists, have it repaired by a qualified service tech-nician.



1 Instrument ECU – 10 A circuit breaker

2 Engine preheat – 5 A circuit breaker

3 Transmission shifter – 3 A circuit breaker

4 Transmission ECU – 7.5 A circuit breaker

5 Ignition switch – 7.5 A circuit breaker

6 Brakes – 5 A fuse

7 Instrument ECU, switched – 10 A fuse

8 Engine ECU, switched – 20 A circuit breaker

9 Radio/heated mirrors – 10 A fuse

10 Climate control condenser fans – 20 A fuse

11 Heater – 25 A fuse

12 Air conditioner – 25 A circuit breaker

13 Headlights – 15 A circuit breaker

14 EEC/Extra headlights – 15 A circuit breaker

15 Directional indicators/horn – 7.5 A circuit breaker

16 Flasher – 7.5 A circuit breaker

17 Floats/differential lock – 7.5 A circuit breaker

18 Sensor feed – 5 A fuse

19 Defroster fans – 7.5 A circuit breaker

20 Tire pump/remote receptacle – 15 A circuit breaker

21 Front wipers – 5 A circuit breaker

22 Rear wipers – 5 A circuit breaker

23 Lower wipers – 7.5 A circuit breaker

24 Rear worklights – 7.5 A circuit breaker

25 Backup lights – 7.5 A circuit breaker

26 Moldboard work lights – 15 A circuit breaker

27 MBCS/beacon – 7.5 A circuit breaker

28 Secondary steering – 3 A fuse

29 All Wheel Drive - 15 A circuit breaker

30 Cigar lighter and 12 V supply - 15 A circuit breaker

31 Electronics relay

32 Neutral start relay

33 Back-up/Alarm lights relay

34 Headlights relay

35 Secondary steering relay

36 EEC and extra headlights relay

37 Directional indicator flasher module

38 Brake no-flow relay

39 Instrument ECU relay

40 Ignition latch relay

A - AM/FM radio/heated mirrors

B - Climate control condenser fans

C - Defroster fans

D - Tire pump/remote receptacle

E - All Wheel Drive

F - Lighter


Transmission 185

TransmissionTransmission oil pressure

The transmission oil pressure is monitored by the machine. If the oil pressure reaches a low level, the Transmission pressure warn-ing lamp in the display panel will light accompanied by the red cen-tral warning lamp, a buzzer, and display message.

Transmission oil level

Check the oil level in the transmission daily.

Check the transmission oil level at operating temperature. The best time is at the end of each shift. The transmission oil level sight glass should be full when the engine is shut down.

To check the oil:

� Park the grader on level ground and place the transmission in NEUTRAL.

� Apply the parking brake and lower the moldboard and all at-tachments to the ground.

� The transmission oil level sight glass is located on the left-hand side of the transmission case. When the engine speed is at idle, the oil level should be at the middle of the sight glass.

To add oil to the transmission:

Refer to Recommended lubricants page 217 for the correct fluid type. The filler tube is found at the back of the cab on the left-hand side.

� If additional oil is required, shut down the engine.

� Remove the cap installed in the filler tube.

� Add transmission oil as required.

� Have an assistant re-check the oil level with the engine idling.

A Transmission pressure warning lamp

B Central warning lamp

C Display message


186 Transmission

Changing the transmission oil

Change the transmission oil every 1000 hours.

The oil drain plug for the transmission is located on the left-hand side of the machine at the bottom of the transmission case.

1 Park the grader on level ground.

2 Place a container with a 38 L (10 US gal) capacity underneath

the drain plug.

3 Remove the filler tube cap located underneath the back of the

cab.

4 Remove the plug and drain the oil.

5 Clean the plug and install it.

6 Fill the transmission with clean fresh oil and install the filler tube

cap. Refer to Recommended lubricants page 217.

7 With the engine running at idle and at operating temperature,

have an assistant check the transmission oil level. It must be in

the middle of the level check sight glass.

Transmission filter element

The transmission hydraulic filter is located beneath the cab on the front right-hand side. The hydraulic filter assembly is installed on a bracket attached to the transmission case.

� Replace it every 500 hours of operation.

� The filter element is a spin-on type and can be removed with a filter wrench.

� Clean any accumulated dirt from the old filter before removing it.

� To install a new filter element, first apply a coating of clean hy-draulic oil to the gasket. Fill the filter element with fresh oil.

� Install the new element on the filter head and tighten it as far as possible by hand only.

� Do not use a filter wrench to tighten the element.

WARNING!Take care when changing oil. Hot oil can cause burns on unprotected skin.



Engine clutch 187

Engine clutchClutch fluid level

The clutch master cylinder is located under the left-hand side of the cab. Use only petroleum based fluid in the clutch master cylin-der. Refer to Recommended lubricants page 217 for the correct fluid type.

� Clean the top of the reservoir.

� Remove the cap. The fluid level should be approximately 13 mm (1/2 in.) from the top.

� Add the correct fluid type as required.

� Clean up spilled fluid immediately.

Clutch slave cylinder and pedal free play

The clutch slave cylinder is located on the right-hand side of the clutch housing.

1 Open the side access door on the right-hand side of the fuel

tank stand. Open the right-hand engine compartment door for

additional access to the clutch housing.

2 Install an appropriate wrench on the bolt retaining the clutch

slave cylinder to the cross shaft arm.

3 Press the cross shaft arm downwards. This will rotate the cross

shaft.

4 Press until a firm resistance is felt. This means that the release

bearing is engaging the lever arms of the clutch.

5 The clutch slave cylinder free play should be 3 mm (1/8 in.).

6 Check the clutch pedal free play by depressing the pedal and

measuring the deflection. This can be done by hand.

7 The clutch pedal free play should be 3 to 6 mm (1/8 to 1/4 in.).

8 Refer to the Service Manual for detail adjustment instructions.

1 Master cylinder

2 Cap


188 Final drives

Final drivesFinal drive oil level, checking


Chock the tires properly.

� The level check/fill plug for the final drive is the top plug on the rear of the final drive case. Clean all dirt from around the plug.

� The oil should be at the level of the hole.

� Add final drive oil as required.

Refer to Recommended lubricants page 217 for the correct oil type.

Model G780B

Chock the tires properly.

� The level check plug for the final drive is located in the right-hand side housing behind the cross shaft cap. Clean all dirt from around the plug.

� Remove the plug. The oil should be at the level of the hole.

� To add more oil, remove the breather cap from the filler tube located on the left-hand side of the engine compartment.


1 Level check plug

1 Level check plug


Final drives 189

Final drive oil, changing

Change the oil in the final drive every 1000 hours.



1 Remove the level check plug

2 Place a container with a capacity of 23 liters (6 US gal) under

the final drive drain plug.


4 Clean and install the drain plug.

5 Refill with clean oil. Fill the final drive until the oil reaches the

bottom of the level check hole.

6 Apply pipe sealant on the threads and install the level check

plug.

Model G780B

1 Remove the level check plug

2 Place a container with a capacity of 34 liters (9 US gal) under

the final drive drain plug.


4 Clean and install the drain plug.

5 Refill with clean oil. Fill the final drive until the oil reaches the

bottom of the level check hole.

6 Apply pipe sealant on the threads and install the level check

plug.


1 Level check plug

2 Drain plug

1 Level check plug

Final drive filler cap


190 Tandems

TandemsTandem oil level

� Ensure the tandems are level for an accurate oil level check.

� Slight oil pressure inside the tandem may give a false oil level indication when the oil level dipstick is first removed. Relieve the pressure by removing the dipstick slowly.

� Remove, clean, then re-insert the dipstick to check the tan-dem oil level.

� The oil level should be between the two bends of the dipstick.

� Check both tandems.


Changing tandem oil

Change the oil in the tandems every 1500 hours.

1 Remove the dipstick from the tandem.

2 Place a container under the tandem drain plug. Refer to Capac-

ities page 219 for correct capacity.

3 Remove the drain plug and drain the oil.

4 Clean and install the plug.

5 Refill with clean oil. The oil level must be between the two bends

on the dipstick.

6 Repeat for the other side.


1 Drain plugs


Brake system 191

Brake system

Parking brake

The parking brake is driveline-mounted to the transmission output shaft. Check the parking brake lining every 1000 hours. Have the brake rebuilt if there is evidence of any fluid leaks, cracked or chipped linings, or the brake lining has reached a minimum thick-ness of 0,8 mm (0.031 in.).

Have the parking brake adjusted if the clearance between the pads and the disc exceeds 1,57 mm (0.062 in.).

With the transmission in third gear, the parking brake should stall the engine when the clutch is released.


192 Brake system

Service brakes master cylinder fluid

Replace the service brake master cylinder fluid every 2000 hours.

Use petroleum base fluid in the master cylinder reservoir.

Refer to Recommended lubricants page 217 for correct fluid type.

Visually check the brake fluid level through the semi-transparent master cylinder reservoir.

� The service brakes master cylinder is located under the right-hand side of the cab.

� Clean the outside of the reservoir.

� The fluid level should be at the reservoir flange and no more than 25 mm (1 in.) from the top of the reservoir cap.

� Add the correct fluid type as required.

� Clean up spilled fluid immediately.

Service brakes warning system, checkingCheck the service brakes warning system as follows:

� Turn the battery isolation switch on to the “I” position.

� Depress the brake pedal until resistance is felt.

� The master cylinder booster pump electric motor should now be working. The Service brake warning lamp (B) should turn on (without alarm buzzer).

� If the electric motor or warning lamp do not energize, the brake system is faulty and must be repaired by a qualified ser-vice technician.

� Release the brake pedal. The electric motor and Service brake warning lamp (B) should turn off.

� Insert the ignition key and turn to the “I” position. Do not start the engine.

� The master cylinder booster pump electric motor should now be working. The Service brake warning lamp (B) should turn on (without alarm buzzer).

� If the electric motor or warning lamp do not energize, the brake system is faulty and must be repaired by a qualified ser-vice technician.

� Start the engine. The Service brake warning lamp should turn off.

� If there is a fault in the brake system when the engine is run-ning, the Service brake warning lamp (B), the Central warning lamp (A) and buzzer will turn on, accompanied by a message in the display panel (C) – “Warning - Service Brake System”.

WARNING!Use only petroleum base fluid in the brake reservoir. Other liquids may cause brake failure. Severe personal injury or death could result.

1 Fluid level

A Central warning lamp (red)

B Service brake warning lamp (red)

C Display message


Hydraulic system 193

Hydraulic systemThis table indicates operating ranges for fluids available for differ-ent ambient temperatures. Refer to Recommended lubricants page 217 for further information.

A constant temperature above the normal acceptable operating range for a specific fluid type may indicate a problem in the hy-draulic system. Have the system repaired by a qualified service technician.

Checking the hydraulic oil fluid level

The hydraulic tank oil filler cap and dipstick are located at the rear of the grader on the left-hand side, inside the rear side door.

� To check the hydraulic oil level, start the engine, centralize the circle and moldboard under the grader and fully lower the blade and all attachments.

� Put the grader in the Service position, refer to Service position page 146.


� Clean any dirt from around the filler cap.

� Remove the cap from the hydraulic tank and wipe the dipstick clean.

� Replace the cap and seat it firmly. Remove it again and check the oil level. The oil level must be at the “FULL” mark on the dipstick and not more than 1/4 in. (6 mm) down.

� Add clean hydraulic oil as necessary through the filler neck. Refer to Specifications, Recommended lubricants page 217 for the correct oil type.

Fluid type

Operating range

Polar Standard Tropical

Normal under 52°C (under 125 °F)

under 77°C (under 170 °F)

under 88°C (under 190 °F)

Caution 52 to 60 °C(125 to 140 °F)

77 to 88 °C(170 to 190 °F)

88 to 99 °C(190 to 210 °F)

Warning over 60 °C(over 140 °F)

over 88 °C(over 190 °F)

over 99 °C(over 210 °F)



Changing the hydraulic oil

Change the hydraulic oil every 2000 hours.

1 Park the grader on a level surface and shut down the engine.

2 Open the tank filler cap.

3 Move all control levers to relieve any pressure remaining in the

hydraulic circuit.

4 Place a container with a capacity of 134 L (35.4 US gal) under

the hydraulic tank drain plug. The drain plug is under the rear of

the grader.



7 Refill with clean oil. Refer to Specifications page 217, for correct

oil type.

8 Remove the case plug in the hydraulic pump (top of case). Fill

the pump case to the top with clean hydraulic oil

Hydraulic system filter element

Replace the hydraulic system filter every 500 hours of operation.

The hydraulic oil filter is located inside the left-hand engine com-partment, next to the radiator shroud. All Wheel Drive systems share the same filter (no additional filter is used).

� The filter element is a spin-on type and can be removed with a filter wrench.

� Clean any accumulated dirt from around the filter and filter head. Make provisions to capture oil that may spill during filter removal.

� Remove the filter.

� To install a new filter element, first apply a coating of clean hy-draulic oil to the gasket. Fill the filter element with fresh oil.

� Install the new element on the filter head and tighten it as far as possible by hand only.

� Do not use a filter wrench to tighten the element.



All Wheel Drive 195

All Wheel Drive

Hoses and fittings

Inspect all hoses and fittings for wear, cracks or leaks.

� Use cardboard or a similar material to check for hydraulic leaks. Fluid escaping under pressure can penetrate the skin causing serious injury. If this occurs, seek medical attention immediately.

All Wheel Drive oil filter

The All Wheel Drive hydraulic system shares the same filter with the main hydraulic system. Refer to Hydraulic system filter ele-ment page 194.

Gearbox oil, checking

With the machine parked on a level surface, check the All Wheel Drive gearbox oil level by looking at the sight glass inside the rear left-hand side door. The oil level must be visible in the middle of the glass.

Gearbox oil, changing

Change All Wheel Drive gearbox oil every 2000 hours.

The drain plug for the All Wheel Drive gearbox is accessible from underneath the grader on the left-hand side, just ahead of the hy-draulic tank.

1 Place a container with a capacity of 3.4 L (3.6 US qt) underneath

the drain plug.



4 Refill the gearbox with clean fresh oil. The oil level must be vis-

ible in the middle of the sight glass. Refer to Recommended lu-

bricants page 217.



196 Tires

TiresCheck the tire pressure weekly with an accurate pressure gauge when the tires are cold.

Improper tire inflation can cause premature tire wear. It can also affect the grader’s ride and handling.

� Visually inspect the tires daily for excessive tread wear, dam-age, and air pressure.

� To reduce ‘gallop’, vary the pressures of adjacent tires plus or minus 35 kPa (5 psi). Make sure the rims are properly installed on the wheel castings.

� Tire repair or replacement must be performed by qualified per-sonnel only.

� Do not stand near the tire while inflating. Ensure you use a self-attaching air chuck with a remote shut-off. Stand behind a safety cage covering the tire. Refer to Safety when servic-ing, Tires page 160.

Maximum tire pressures

Maximum pressures shown are only a guideline for typically equipped machines. Consult your tire manufacturer for further de-tails.

WARNING!Failure to use a safety cage when inflating tires could result in severe personal injury or death.

Bias ply tires Radial tires

Tire size PlyMaximum pressure

Tire sizeMaximum pressure

kpa psi kpa psi

13.00 X 24 12 241 35 13.00R24 310 45

14.00 X 24 12 241 35 14.00R24 310 45

14.00 X 24 16 301 45 16.00 X 24 310 45

15.50 X 25 12 248 36 15.5R25 248 36

16.00 X 24 12 206 30 16.00R24 310 45

16.00 X 24 16 275 40 17.50R25 310 45

17.50 X 25 12 206 30 20.50R25 310 45

20.50 X 25 12 172 25

1 Pressure gauge


Climate control system 197

Climate control system

Routine maintenance

Compressor seals can dry out and leak if the compressor is not used for extended periods of time. To prevent the seals from dry-ing out, operate the air conditioner at least five minutes at each en-gine oil change (or once a month) – even in the winter months.

Perform a visual inspection for:

1 Loose electrical connections

2 Damage to components

3 Damage to refrigerant or coolant hoses

The cab has a standard cab air filter and an optional external filter. The condition of the filters is entirely dependent on the working en-vironment of the machine. Check the filters once a week.

NOTE! The cab filter(s) are only intended to separate dust particles from the air. Any dangerous gases are not trapped by the filter.

NOTE! Use approved respirator when cleaning filters.

Internal cab air filter

This filter is found on the external left-hand side of the cab behind the door. Remove the panel, then turn the wing nuts to open the filter compartment.

To service the internal cab air filter, pull the filter outward.

Clean or replace the filter as required. Check weekly, or more of-ten in dusty environments.

Vacuum the filter area as required, reassemble.

External cab air filter (optional)

The external cab air filter is mounted on the outside of the cab above the left-hand door.

Remove the two grill retainer bolts, lower the grill and remove the filter assembly. Clean, inspect and replace the filter as necessary.

WARNING!R134a refrigerant is moderately hazardous and should be handled accordingly. Air conditioning service should only be performed by a certified technician who is approved to handle refrigerants and is trained in the correct service procedures and equipment operation.


198 Climate control system

Recirculation vent filter

Remove the recirculation vent screen to remove the foam filter. Wash or clean as necessary. Inspect for damage or tears. Replace as necessary.

Drain hose valves

The drain hose valves are located on the bottom of the air condi-tioning unit, accessible from underneath the cab.

Check drain hose valves for restriction, sticking or sealing. Clean or replace the valves and hoses as necessary.

Basic operational checks

Before attempting any service procedure or performance check, follow these operational checks:

� The machine will be operated during system evaluation. En-sure engine fluid levels and condition will support testing.

� Operate the engine to ensure it will reach operating tempera-ture for normal heating system operation.

� Inspect the fresh air filter(s) before proceeding with any oper-ational test to ensure adequate air flow to the cab.

Heater system

1 Ensure the heater shut off taps at the engine are open.

2 Operate blower fans at all speeds; slowly cycle temperature po-

tentiometer from cold to hot to check heater valve operation.

Air conditioning system

1 Perform a thorough visual inspection of air conditioning refriger-

ant system components for signs of refrigerant oil leakage or

physical damage.

2 Operate blower fans at all speeds; slowly cycle the temperature

potentiometer from hot to cold to check heater valve operation.

3 Visually identify compressor clutch engagement. If suction line

(refrigerant return) is not cold to the touch within 1 to 2 minutes

of compressor operation, shut system down to avoid component

damage.

Air conditioning system

Checking performance

IMPORTANT! The following procedures must be performed with the engine running. Take special care when working in close proximity to rotating components. Take care to avoid moving any levers and controls by accident, and make sure to warn persons in the area. Put the machine in the Service Position as standard working practice Refer to Service posi-tion page 146.

Test the system performance at least once a year.

1 Operate the engine to bring it to its normal operating tempera-

ture.


Climate control system 199

2 Park the grader with the cab in the shade and leave the engine

running.

3 Turn on the air conditioning system and check to see that the

compressor clutch engages.

4 With the engine at high idle, operate the system for ten minutes

and measure the temperature of the cooling air at the seat deck

riser vent.

5 At some time during testing, the lower vent temperature should

drop to the range of 1° C to 14° C (34° F to 58° F).

NOTE! The vent temperature will vary with humidity and ambi-

ent temperature readings.

6 Inspect for any evidence of leakage, repairing the system imme-

diately if a leak is found.

NOTE! Shut off the air conditioning system immediately if the clutch engages but the suction line to the compressor is not cold in 1 to 2 minutes. Continued operation in this condition can damage the compressor.

Air conditioner service

The most common air conditioning problems are caused by mois-ture in the refrigerant and refrigerant leakage. Moisture in the re-frigerant will cause ice to form and block the expansion valve preventing the circulation of refrigerant in the system. Working in a clean, dry environment and completing repairs quickly can re-duce the risk of introducing moisture into the system. Store com-pressor PAG oil in a sealed container to prevent it from absorbing moisture. Do not remove plugs and caps from new components until they are ready for connection. Do not clean components with compressed air.

1 Inspect lines and fittings for leakage and external damage.

2 Check the operation of the cab switches and controls.

3 Inspect the electrical connections and wiring for damage and

poor connections.

4 Make sure there is no restriction in the evaporator drain tube.

5 Check to see that the cab air filter is not plugged. Remove the

filter and clean it if necessary. Replace the filter if it is damaged.

6 Carefully inspect all components for damage. Pay special atten-

tion to soldered joints. Replace any bent or cracked pipes, do

not attempt to repair them. If there is evidence that a component

has become contaminated, it must be thoroughly cleaned and

inspected before it is reused.

NOTE! Replace the receiver-dryer unit whenever major re-pairs are made, components are changed, or if there is evi-dence of moisture in the system.

Refer to the Service manual for further information.


200 Miscellaneous

Miscellaneous

Circle adjustment

G710B to G746B

� Adjust the front guide plate(s) to contact the inner face of the circle. Contact should be across the complete width of the guide plate(s).

� Check the backlash of both drive pinions. It should be 2,2 mm (0.090 in.).

� Adjust the clearance of the rear guide plates to 1,0 mm to 2,0 mm (0.040 in. to 0.080 in.) evenly between the guide plates and the circle.

Refer to the Service Manual for G780B and G780B VHP, and fur-ther detailed adjustment instructions. Have the circle adjusted by qualified service personnel.

Tool box

The toolbox is mounted on the right-hand tandem case.

Windshield washer fluid reservoir, front and rear windows

The washer fluid reservoir is located inside the side access door on the left-hand side of the grader.

� Make sure the washer fluid is suitable for temperatures ex-pected when there is the risk of frost.

� Top up when necessary.

1 Guide plates

2 Drive pinion


Maintenance schedule 201

Maintenance scheduleThis schedule shows which measures should be taken at the re-spective hour meter readings.

Example: When the machine has been operated for 1000 hours, the Daily, Weekly, 250, 500 and 1000 hour services should be car-ried out according to the Lubrication and service chart.

Service intervals

NOTE! Daily and Weekly service should always be carried out first.

A 250 hours

B 500 hours

C 1000 hours

D 1500 hours

E 2000 hours

Refer to Lubrication and service chart page 204.


202 Grease points

Grease points

Item Description Points

1 Pivot pin 2

2 Wheel bearings 1 each side

3 Knuckle and king pin 3 each side

4 Tie bar 1 each side

5 Wheel lean cylinder 2 each cylinder

6 Drawbar ball stud 1

7 Blade lift cylinder ball pin 1 each side

8 Stirrup 2 each side

9 Stirrup shaft 2 each side

10 Circle shift cylinder 1 each end

11 Upper and lower driveshafts 3 each shaft

12 Articulation cylinder 2 each side

13 Tandem sleeve thrust plate 1 each side

14 Clutch slave cylinder 2

15 Pump driveshaft splines 1 fitting

16 Wheel lean pivot pins 2 each side

17 All Wheel Drive motor 2 each side

18 Drag link 2 each side, stan-dard;7 heavy duty

19 Steering cylinder 2 each side

20 Circle turn valve 1

21 Circle turn cylinder and crank 4 each side

22 MBCS arm pivot and lockbar 6

23 Blade tilt cylinder, tilt quadrant 2 each cylinder, standard;3 each side, heavy duty

24 Brake and clutch pedal shafts 1 each


Symbol key, lubrication and service chart 203

Grease points, general

Refer to the Lubrication and service chart page 204 for greas-ing intervals.

� Be sure to clean all dirt and accumulated grease from the fit-tings before attaching the grease gun.

� By following the recommended service intervals, one or two strokes of a hand-lever grease gun will supply the parts with enough grease. Do not over-lubricate. Pressure from excess grease can damage the seals.

� Increase greasing frequency in dry or dusty conditions, or if dry joints are apparent.

Symbol key, lubrication and service chartThese standard symbols are used in the Lubrication and service chart on the following pages.

1 Engine

2 Transmission

3 Hydraulic system

4 Brake system

5 Axles

6 Fuel system

7 Battery

8 Coolant

9 Air conditioning

10 Lubrication

11 Oil/liquid

12 Filter

13 Air filter

14 Level check

15 Belt tension

16 Control lamps

17 Drain

18 Tandems

19 Clutch


204 Lubrication and service chart

Lubrication and service chart10 (daily) and 50 hour services


Lubrication and service chart 205

10 (daily) and 50 hour services

Checks and lubrication

Daily (every 10 hours)

Item Measure Page

11 Check control lamps (function)

12 Oil disc brake reservoir level 192

22 Hydraulic oil level 193

23 Coolant level 175

24 Engine oil level 163

27 Fuel level, fuel filter/water separator (optional) 166

29 Transmission oil level. Oil warmed, in neutral at idle. 185

Weekly (every 50 hours)

Item Measure Page

1 Pivot pin - MPG – 2 fittings

2 Wheel bearings - MPG – 1 fitting each side with EP2 grade

3 Knuckle and king pin - MPG – 3 fittings each side

4 Tie bar - MPG – 1 fitting each side

5 Wheel lean cylinder - MPG – 2 fittings each cylinder

6 Drawbar ball stud - MPG – 1 fitting

7 Blade lift cylinder ball pin - MPG – 1 fitting each side

10 Circle shift cylinder - MPG – 1 fitting each end

14 Articulation cylinder - MPG – 2 fittings each side

28 Check cab fresh air filter 197

30 Brake and clutch pedal shafts - MPG – 1 fitting each

34 Circle turn cylinder and crank - MPG – 4 fittings, each side

35 Circle turn valve - MPG – 1 fitting

36 Steering cylinder - MPG - 2 fittings, each side

37 Drag link - MPG – 2 fittings each side, standard,

– 7 fittings, heavy duty

38 All Wheel Drive motor (optional) - MPG - 2 fittings each side

39 Wheel lean pivot pins - MPG – 2 fittings each side

Adjustment checks

Check tire pressure 196



250 hour service



250 hour service – Interval “A”

Checks, oil changes and lubrication

Item Measure Page

8 Stirrup - MPG – 2 fittings each side

9 Stirrup shaft - MPG – 2 fittings each side

13 Upper and lower driveshafts - MPG – 3 fittings each shaft

15 Clutch slave cylinder - MPG – 2 fittingsCheck clutch slave cylinder and pedal free play

187

19 Pump driveshaft - MPG – 1 fitting

20 Check All Wheel Drive pump drive gearbox oil level 195

22 Check antifreeze concentration

23 Engine oil and filter(s)Routine engine oil change intervals performed after the initial commissioning service will be either 250 or 500 hours depending on fuel sulfur content, oil quality, and operating conditions.

163

24 Check final drive oil level 188

29 Inspect clutch reservoir oil level 187

31 Blade tilt cylinder/tilt quadrant - MPG – 2 fittings each cylinder, standard– 3 fittings each side, heavy duty

Adjustment checks

Axle pivot bearing preload

Stirrup bearings

Steering draglink jam nuts

Circle, circle timing

Ball cap

Drawbar ball stud

Inspect Page

Moldboard sliding surfaces

Hydraulic cylinders

Driveshafts/couplings

Transmission mounts 231

Air cleaner and Air intake 170

Radiator 172

Attachment mounting bolts

Throttle linkages



500 hour service



500 hour service – Interval “B”


Item Measure Page

16 Tandem sleeve thrust plate - MPG – 1 fitting each side

17 Check tandem oil level 190

18 Check drive belts and pulleys. 178

21 Change hydraulic filter element 194

25 Check battery 179

26 Change fuel filter, check fuel tank 165

27 Change transmission oil filter 186

Adjustment checks

Wheel toe-in

Blade lift cylinder trunnions

Wheel bearing preload. See Service Manual.

Inspect Page

Pump mounts

Cab and ROPS mounting bolts 231

Wheel rim bolts 231

Articulation lock pins

Torque Page

Steering draglink jam nuts 231



1000 hour service



1000 hour service – Interval “C”


Item Measure Page

22 Change coolant filter – G740B, G746B, G780B only 177

24 Change final drive lubricant 188

27 Change transmission oil. 186

32 MBCS Arm pivot and lockbar - MPG – 6 fittings

40 Check, clean or replace engine primary air filter 170

Adjustment checks

Primary hydraulic relief settings

Steering system pressures

Transmission lubrication lock-up pressures

Inspect Page

Tilt quadrant bolt

Hydraulic oil. Replace if necessary. Clean suction strainer and magnetic

plug as equipped.

194

Fan motor hydraulic hoses

Fan motor mount and bracket bolts

Parking brake linings/adjustment 191

Torque Page

Final drive to frame bolts 231

Final drive to tandem bolts 231



1500 hour service



1500 hour service – Interval “D”


Item Measure Page

17 Change tandem oil 190

Inspect

Engine and turbocharger mounting bolts

Belts and pulleys



2000 hour service



2000 hour service – Interval “E”

As required maintenance


Item Measure Page

12 Change service brakes master cylinder fluid 192

20 Change All Wheel Drive gearbox lubricant 195

21 Change hydraulic fluid 194

22 Change engine coolant 176

Inspect

Vibration damper

Engine belts and pulleys

Checks

Item Measure Page

33 Circle top, clamp and guide bearing surfaces.Moldboard upper and lower slide rails. Keep these bearing surfaces clean.

Wheel rim torque 231

Battery isolation switch 179

Radiator and oil coolers 172

Air cleaner 170


216 Notes

Specifications

Recommended lubricants 217

Specifications

Recommended lubricants

Specifications

218 Recommended lubricants

Grease type

Grease with a lithium base together with EP additives and consis-tency No. NLGI-2 without molybdenum disulphide additive (MoS2).

Fuel Recommendations

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

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

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

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

Specifications

Capacities 219

Capacities

Intervals between changes

Oil and fluid changes

Component Volume

Engine, including filtersG710B to G730BG740B, G746B, G780B

32 L (8.5 US gal)39,5 L (10.4 US gal)

Hydraulic tank 134 L (35.4 US gal)

Hydraulic system 210 L (55.5 US gal)230 L (60.8 US gal) All Wheel Drive models

Tandems (each) 100 L (26.5 US gal) – G710B to G746B105 L (27.7 US gal) – G780B

All Wheel Drive Gearbox 3.4 L (3.6 US qt)

Final Drive 23 L (6 US gal) – G710B to G746B34 L (9 US gal) – G780B

Transmission 38 L (10 US gal)

Cooling systemG710B to G730BG740B, G746B, G780B

28L (7.4 US gal)31L (8.2 US gal)

Fuel TankG710B to G730BG740B, G746B, G780B

370 L (97.7 US gal)460 L (121.5 US gal)

Component Hours Page

Engine 250 163

Coolant 2000 176

Transmission 1000 186

Final drive 1000 189

Tandems 1500 190

Master cylinders – Oil disc brakes 2000 192

Hydraulic oil 2000 194

Specifications

220 Intervals between changes

Filter changes

Engine

Transmission

Hydraulic system

Cab


Oil Filters 250 164

Fuel filter 500 165

Water trap filter 500 166

Primary air filter 1000 170

Secondary air filter As required 171


Oil Filter 500 186


Oil Filter 500 194


Internal cab air filter as required 197

External cab air filter (optional) as required 197

Specifications

Engine 221

Engine


Air cleaner

Make Volvo

Designation D7D

Flywheel output kW (hp) See engine data plate

Number of cylinders 6

Stroke 130 mm (5.118 in.)

Cylinder bore 108.1 mm (4.256 in.)

Cylinder capacity, total 7,2 L (439.4 in3)

Compression ratio 17.5:1

Idling speed, low 800 rpm

Idling speed, high 2400 rpm

Valve clearance, cold engineInletexhaust

0,3 ±0,1 mm (0.0118 ±0.0039 in.)0,5 ±0,1 mm (0.0197 ±0.0039 in.)

Oil pressure, min. at low idling speed (warm engine) 80 kPa (0,8 bar)(11.6 psi)

Oil pressure, min. at high idling speed (warm engine) 200 kPa (2 bar)(29 psi)

Air cleaning in 3 steps Cyclone cleaner – Primary filter – Secondary filter

Specifications

222 Engine


Air cleaner

Make Volvo

Designation D10 GA E2

Flywheel output kW (hp) See engine data plate

Number of cylinders 6

Stroke 140 mm (5.51 in.)

Cylinder bore 121 mm (4.764 in.)

Cylinder capacity, total 9,6 L (586 in3)

Compression ratio 18.0:1

Idling speed, low 800 rpm

Idling speed, high 2300 rpm

Valve clearance, cold engineInletexhaust

0,4 mm (0.16 in.)0,7 mm (0.27 in.)

Oil pressure, min. at low idling speed (warm engine) 60 kPa (0,6 bar)(8.7 psi)

Oil pressure, min. at high idling speed (warm engine) 300 – 500 kPa (3 – 5 bar)(43.5 – 72.5 psi)

Air cleaning in 3 steps Cyclone cleaner – Primary filter – Secondary filter

Specifications

Fuel system 223

Fuel system

Feed pump

G710B to G730B

G740B to G780B

Cold-starting device

Type Rotary pump

Make N/A

Feed pressure 400 – 500 kPa (4 – 5 bar)(58 – 72.5 psi)

Order of injection 153624

Type Piston pump

Make Bosch

Feed pressure 200 – 250 kPa (2 – 2.5 bar)(29 – 36 psi)

Order of injection 153624

Type Coil

Power, preheating element 2 kW

Time relay (integrated), engagement time Variable

Specifications

224 Cooling system

Cooling system

Fan control system

Minimum fan speed is approximately 500 rpm

Maximum fan speed is approximately 1750 rpm.

Fan speeds depend on ambient temperature, duty cycle, and machine model.

Cooling fan has 9 blades.

Thermostat

G710B to G730B

Type Closed system

Thermostat begins to open at 83° C (181° F)

Thermostat fully open at 95° C (203° F)

G740B to G780B

Type Closed system

Thermostat begins to open at 82° C (180° F)

Thermostat fully open at 92° C (198° F)

Specifications


Electrical system

Battery electrolyte density (kg/dm3)

Bulbs

System voltage 24 V

Batteries 2 pcs, 12 V connected in series

Battery voltage 12 V

Battery reserve capacity 160 minutes – G710B195 minutes – G720B to G780B(25 amp @ 27° C/80° F)

Battery capacity 96 Ah – G710B to G730B117 Ah – G740B to G780B

Battery cold cranking amps 660 CCA – G710B to G730B950 CCA – G740B to G780B

Chassis connection Negative terminal

Alternator output 1800 W2400 W (optional)

Current max. 75 amp100 A (optional)

Starter motor output 5.4 kW – G710B to G730B7.5 kW – G740B to G780B

Fully charged battery 1.265

The battery should be charged at 1.230

Watt Socket

Headlamps 75 W/70 W H4

Parking lights 4 W –

Directional indicators 21 W Single contact bayonet

Working lights 75 W/70 W H4

Instrument lighting 1.2 W –

Rotating beacon 70 W H3

Tail lights 5 W Single contact bayonet

Stop lights 21 W Single contact bayonet

Back-up lights 21 W Single contact bayonet

Specifications


FusesSee also Circuit breakers and fuses page 183.

Location Type Rated current Qty

Fuse panel inside console cover Circuit breaker 3 A 2 pcs


Fuse panel inside console cover Circuit breaker 7.5 A 12 pcs

Fuse panel inside console cover Blade fuse 7.5 A 1 pc

Fuse panel inside console cover Blade fuse 10 A 2 pcs


Fuse panel inside console cover Blade fuse 25 A 2 pcs

Specifications

Power transmission 227

Power transmission

Transmission

Speed range

Transmission oil cooler

Make Volvo

Type Fully sequential, direct drive, powershift transmission, with eight forward and four reverse speeds

Designation 8400

Number of gears forward/reverse 8/4

Gear-shifting system Electro-hydraulic

Model G710BG720B, G726B, G730B

G740B, G746B G780B

Engine rpm 2200 2200 2100 2100

Tire size 13.00 X 24 14.00 X 24 14.00 X 24 16.00 X 24

Forward gears km/h mph km/h mph km/h mph km/h mph

1st 3,8 2.4 4,4 2.8 4,2 2.6 3,7 2.3

2nd 5,4 3.3 6,2 3.9 5,9 3.7 5,1 3.2

3rd 7,4 4.6 8,5 5.3 8,2 5.1 7,1 4.5

4th 10,4 6.5 11,9 7.5 11,4 7.1 10,0 6.2

5th 14,7 9.2 16,9 10.5 16,1 10.1 14,1 8.8

6th 20,5 12.8 23,6 14.7 22,5 14.1 19,7 12.3

7th 28,5 17.8 32,7 20.4 31,2 19.5 27,3 17.0

8th 39,8 24.9 45,7 28.5 43,6 27.2 38,1 23.8

Reverse gears

1st 3,8 2.4 4,4 2.8 4,2 2.6 3,7 2.3

2nd 7,4 4.6 8,5 5.3 8,2 5.1 7,1 4.5

3rd 14,7 9.2 16,9 10.5 16,1 10.1 14,1 8.8

4th 28,5 17.8 32,7 20.4 31,2 19.5 27,3 17.0

Type Air to oil cooler

Cooling agent Engine coolant

Specifications

228 Power transmission

Clutch

G710B – 12 springs, 4 plate disc and hub assembly

G720B, G726B, G730B – 15 springs, 4 plate disc and hub assembly

G740B, G746B, G780B – 15 springs, 5 plate disc and hub assembly

Final drivesG710B to G726B

G730B to G746B

G780B

Tandem

Type Wet clutch, 343 mm (13.5 in.) diameter

Make Volvo

Model SR30 – Single reduction

Gear ratio 6.14:1

Differential lock Dog clutch

Differential lock operation Electro-hydraulic

Make Volvo

Model SR40 – Single reduction

Gear ratio 6.14:1



Make Volvo

Model Volvo twin bull gear – Double reduction

Gear ratio 8.97:1



Type Chain drive, single reduction

Specifications

Brake system 229

Brake system

Service brakesThe Service brakes are oil disc hydraulic brakes. The system consists of two independent brake circuits. The circuits are open center with an electric back-up pump.

The first circuit is connected to the master cylinder outlet port of the master cylinder, and to the front right-hand and rear left-hand brake units.

The second circuit connects to the second outlet port, and to the rear right-hand and front left-hand brake units.

Parking brakeThe parking brake an electrically activated, spring applied high pressure caliper disc brake. It is hydraulically released.

Brake booster flow rate 23 L/min (6 gpm)

Brake booster relief setting 6 895 kPa (69 bar)(1000 psi)

Brake master cylinder relief setting 15,1 MPa (152 bar)(2200 psi)

Accumulator manual recharge relief valve 1 724 kPa (17,2 bar)(250 psi)

Accumulator precharge 689 kPa (7 bar)(100 psi)

Intensifier pressure ratio 11.5:1

Minimum brake release pressure 7 929 kPa (79,3 bar)(1150 psi)

Maximum brake pressure 20,7 MPa (207 bar)(3000 psi)

Specifications

230 Hydraulic/Steering system

Hydraulic/Steering systemHydraulic system

Steering system

Type of system Closed center, load sensing system

Standby pressure (varies with fan speed)Fan speed at 500 rpmFan not connected

3447 – 4137 kPa (500 – 600 psi)2413 kPa (350 psi)

Type of hydraulic pump Pressure and flow compensating (load sensing) variable displacement piston pump

Pump displacement 130 cc (7.93 in3) per revolution

Pump flow 284 Lpm (75 gpm) @ 2200 rpm

Maximum system working pressure 17,2 MPa (172 bar)(2500 psi)

Differential pressure setting 2400 kPa (24 bar)(350 psi)

Pressure compensator setting 19 MPa (186 bar)(2700 psi)

External load sense relief valve setting 14,8 MPa (148 bar)(2150 psi)

Fan motor Fixed displacement vane motor

Fan motor displacement 45 cc (2.75 in3) per revolution

Minimum fan speed 550 rpm (nominal)

Maximum fan speed 1750 rpm (nominal)

Hydraulic filter 10 micron absolute – 2 micron nominal

Type of steering system Hydraulic power front wheel steering. Incorpo-rates two steering cylinders. System is:– load sensing – closed center – dynamic signal

Number of steering wheel revolutions 6.5

Steering arc 72°

Wheel lean 18° (15° for All Wheel Drive models)

Front axle pivot 16°

Steering lock (articulated) 2 X 22°

Minimum turning radius using front axle steering, artic-ulation, wheel lean, and unlocked differential

7,4 m (24 ft 4 in.) G726B7,75 m (25 ft - 5 in.) G710B, G780B7,77 m (25 ft - 6 in.) G730B7,80 m (25 ft - 7 in.) G740B, G746B

Specifications

Critical mounting torques 231

Critical mounting torques

1 Wheel rim bolts

All models 623 N�m 64 kgf�m 460 lbf�ft

2 Cab mounting bolts


3 Rops mounting bolts


4 Final drive bolts

To frame 922 N�m 94 kgf�m 680 lbf�ft

To tandem 378 N�m 39 kgf�m 280 lbf�ft

Specifications

232 Critical mounting torques

5 Transmission mount bolts

To frame 230 N�m 24 kgf�m 170 lbf�ft

6 Transmission mount bolts

Housing 136 N�m 14 kgf�m 100 lbf�ft

7 Engine mount bolts

G710B to G730B

275 N�m 28 kgf�m 203 lbf�ft

G740B G746BG780B

149 N�m 15 kgf�m 110 lbf�ft

8 Engine mount bolts


9 Engine mount to frame bolts


10 Front axle draglink nuts


Specifications

Dimensional drawing 233

Dimensional drawing

Model

DimensionG710B G720B

G726BG730B G740B

G746BG780B

A Length 8 890 mm (29’ 2”)

8 915 mm (29’ 3”)

8 915 mm (29’ 3”)

9 068 mm(29’ 9”)

9 119 mm(29’ 11”)

B Width 2 489 mm (8’ 2”)

2 540 mm (8’ 4”)

2 540 mm (8’ 4”)

2 540 mm (8’ 4”)

2 794 mm(9’ 2”)

C Height 3 378 mm (11’ 1”)

3 404 mm (11’ 2”)

3 404 mm (11’ 2”)

3 404 mm (11’ 2”)

3 505 mm(11’ 6”)

Low profile cab 3 073 mm (10’ 1”)

3 099 mm (10’ 2”)

3 099 mm (10’ 2”)

3 099 mm (10’ 2”)

3 200 mm(10’ 6”)

D Wheelbase 6 096 mm (20’ 0”)

6 096 mm (20’ 0”)

6 096 mm (20’ 0”)

6 248 mm(20’ 6”)

6 248 mm(20’ 6”)

E Tread width 2 083 mm (6’ 10”)

2 083 mm (6’ 10”)

2 083 mm (6’ 10”)

2 136 mm(7’ 0”)

2 311 mm(7’ 7”)

F Bladebase(ISO 7134)

2 616 mm (8’ 7”)

2 591 mm (8’ 6”)

2 591 mm (8’ 6”)

2 718 mm(8’ 11”)

2 718 mm(8’ 11”)

Specifications

234 Noise and vibration levels

Noise and vibration levels

Noise levels

Interior operator noise level ranges from 78 to 81 dB(A) per ISO 6394 (enclosed cab).

Vibration levels

Whole body vibration is less than 1.25 m/s2 RMS, measured on the operator’s seat according to ISO 7096.

The operator’s seat in the grader meets the following technical specifications: ISO 6683, ISO 7096 EM4/EM5/EM6/EM7/EM8. The seat meets the requirements for a grader application under EM4.

Alphabetical index 235

Alphabetical indexAccelerator/decelerator pedal . . . . . . . . . . . . . . . . . . 56

Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Adjusting air conditioning . . . . . . . . . . . . . . . . . . . . . 63

Adjusting heating and ventilation . . . . . . . . . . . . . . . 63

A-frame attachments lever . . . . . . . . . . . . . . . . . . . . 69

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

After towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Air conditioner

service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199

switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

system, checking performance . . . . . . . . . . . . .198

unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161

All Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . 9, 29, 195

aggression dial . . . . . . . . . . . . . . . . . . . . . . . . . .53

applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195

system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

Amber and blue revolving beacon light switches . . . 49

Anti-freeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

Armrest adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Armrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Articulation indicator gauge . . . . . . . . . . . . . . . . . . . . 30

Articulation lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

As required maintenance . . . . . . . . . . . . . . . . . . . . 215

Auxiliary hydraulic controls . . . . . . . . . . . . . . . . . . . . 70

AWD Aggression . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159, 179

Battery

charge warning . . . . . . . . . . . . . . . . . . . . . . . . . .23

electrolyte level . . . . . . . . . . . . . . . . . . . . . . . . .179

electrolyte specific gravity . . . . . . . . . . . . . . . . .225

isolation switch . . . . . . . . . . . . . . . . . . .21, 71, 179

problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180

state of charging . . . . . . . . . . . . . . . . . . . . . . . .179

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

Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . 168

Brake

adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

system . . . . . . . . . . . . . . . . . . . . . . . . . . .191, 229

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Cab

air distribution . . . . . . . . . . . . . . . . . . . . . . . . . . .62

and frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . .231

ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

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

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

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

Central warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Change

AWD gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . 195

coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

display screen . . . . . . . . . . . . . . . . . . . . . . . . . . 33

engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

tandem oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

transmission oil . . . . . . . . . . . . . . . . . . . . . . . . 186

Charging batteries . . . . . . . . . . . . . . . . . . . . . . . . . 182

Check list after fire or heat exposure . . . . . . . . . . . 155

Checking instruments and control lamps . . . . . . . . . 84

Cigar lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Circle

adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

system accumulators . . . . . . . . . . . . . . . . . . . . . 71

turn lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Circuit Breakers and Fuses . . . . . . . . . . . . . . . . . . 183

Cleaning a wet ditch . . . . . . . . . . . . . . . . . . . . . . . . 141

Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Clearance position . . . . . . . . . . . . . . . . . . . . . . . . . 116

Climate control system . . . . . . . . . . . . . . . . . . . 61, 197

Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, 187

fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

slave cylinder and pedal free play . . . . . . . . . . 187

Cold weather operation . . . . . . . . . . . . . . . . . . . . . . . 86

start-up – Hydraulic system . . . . . . . . . . . . . . . . 86

Control lever for scarifier, ripper or windrow

eliminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

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

Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

filter, replacing . . . . . . . . . . . . . . . . . . . . . . . . . 177

with anti-freeze and corrosion protection . . . . . 174

with corrosion protection only . . . . . . . . . . . . . 174

Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Creep mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

activation lamp . . . . . . . . . . . . . . . . . . . . . . . . . . 53

activation switch . . . . . . . . . . . . . . . . . . . . . . . . 53

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

Crowning a road . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Cul-de-sac using articulation . . . . . . . . . . . . . . . . . 137

Daily pre-start checks . . . . . . . . . . . . . . . . . . . . . . . . 81

Decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Delivery inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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

lock status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

lock/unlock switch . . . . . . . . . . . . . . . . . . . . . . . 41

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

236 Alphabetical index

Directional indicator . . . . . . . . . . . . . . . . . . . . . . . 26, 43

Directional indicator/High beam/Horn button . . . . . . 43

Display classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27, 32

Displayed information . . . . . . . . . . . . . . . . . . . . . . . . 32

Dome light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Dozer blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

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

Dragging a shoulder . . . . . . . . . . . . . . . . . . . . . . . . 142

Drain hose valves . . . . . . . . . . . . . . . . . . . . . . . . . . 198

Driving on a roadway . . . . . . . . . . . . . . . . . . . . . . . . 76

Electric float valves . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Electrical system . . . . . . . . . . . . . . . . . 8, 153, 159, 179

warning and information displays . . . . . . . . . . . .38

Emergency brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

air filter elements . . . . . . . . . . . . . . . . . . . . . . .170

air filter restriction . . . . . . . . . . . . . . . . . . . . . . . .25

clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187

coolant temperature gauge . . . . . . . . . . . . . . . . .27

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

mount bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . .232

mount to frame bolts . . . . . . . . . . . . . . . . . . . . .232

oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164

oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163

oil pressure gauge . . . . . . . . . . . . . . . . . . . . . . . 27

preheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

preheat switch . . . . . . . . . . . . . . . . . . . . . . . . . . .49

warning and information displays . . . . . . . . . . . 37

Equipment and attachments . . . . . . . . . . . . . . . . . . . . 9

Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Error display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

sensor and actuator switches, engine . . . . . . . .39

sensor and actuator switches, hydraulics . . . . . .40

sensor and actuator switches, other . . . . . . . . . .40

sensor and actuator switches, transmission . . . 40

EU EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

External cab air filter . . . . . . . . . . . . . . . . . . . . . . . . 197

Extra headlights switch . . . . . . . . . . . . . . . . . . . . . . 47

Filter bypass warning . . . . . . . . . . . . . . . . . . . . . . . . 25

Filter changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Final drive

bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231

oil level, checking . . . . . . . . . . . . . . . . . . . . . . .188

oil, changing . . . . . . . . . . . . . . . . . . . . . . . . . . .189

/tandems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Finishing a gradual slope using articulation . . . . . . 138

Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

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

Flat bottom ditching – Gravel roads . . . . . . . . . . . . 134

Float valve – Front, system operation . . . . . . . . . . . . 65

power switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

system indicator lights . . . . . . . . . . . . . . . . . . . . 44

Floor level vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Flushing the cooling system . . . . . . . . . . . . . . . . . . 176

FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

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

Front

axle draglink nuts . . . . . . . . . . . . . . . . . . . . . . . 232

defroster fan switch . . . . . . . . . . . . . . . . . . . . . . 47

wheel lean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

wheel lean lever . . . . . . . . . . . . . . . . . . . . . . . . . 67

windshield wiper/washer . . . . . . . . . . . . . . . . . . 48

float valve system operation . . . . . . . . . . . . . . . 65

Fuel

filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

filter/water separator . . . . . . . . . . . . . . . . 166, 166

gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

recommendations . . . . . . . . . . . . . . . . . . . 19, 218

system . . . . . . . . . . . . . . . . . . . . . . . . . 19, 19, 165

tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Function groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Fuse and relay center access panel . . . . . . . . . . . . 51

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Gearbox oil, changing . . . . . . . . . . . . . . . . . . . . . . 195

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

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

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

Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

points, general . . . . . . . . . . . . . . . . . . . . . . . . . 203

type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Hand throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Headlights, EEC headlights and parking

lights switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Health hazards with paint, plastics and rubber . . . . 154

Heated mirrors switch . . . . . . . . . . . . . . . . . . . . . . . 47

Heater air conditioner fan speed switch . . . . . . . . . . 46

Heater/air conditioner temperature control . . . . . . . . 46

Heating, ventilation and air conditioning controls . . . 61

High bank cutting . . . . . . . . . . . . . . . . . . . . . . . . . . 133

High beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26, 43

Horn button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Hydraulic

controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

oil fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

oil temperature warning . . . . . . . . . . . . . . . . . . . 24

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

snow wing controls . . . . . . . . . . . . . . . . . . . . . 121

snow wing pitch adjustment . . . . . . . . . . . . . . . 122

snow wing position for roading . . . . . . . . . . . . 122

system . . . . . . . . . . . . . . . . . . . . . . . . . 9, 156, 193

system filter element . . . . . . . . . . . . . . . . . . . . 194

Alphabetical index 237

warning and information displays . . . . . . . . . . . .38

Ignition switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 49, 83

Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

and warning plates . . . . . . . . . . . . . . . . . . . . . . .14

display screens . . . . . . . . . . . . . . . . . . . . . . . . . .34

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Instrument lighting level . . . . . . . . . . . . . . . . . . . . . . . 51

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

Internal cab air filter . . . . . . . . . . . . . . . . . . . . . . . . . 197

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

Job site precautions . . . . . . . . . . . . . . . . . . . . . . . . . 77

Keypad, display unit . . . . . . . . . . . . . . . . . . . . . . . . . 30

Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Left-hand and right-hand blade lift . . . . . . . . . . . . . . 64

Left-hand ditch clean-up . . . . . . . . . . . . . . . . . . . . . 140

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

Lifting arrangement . . . . . . . . . . . . . . . . . . . . . . . . . 105

Long-term parking . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Lower windows wiper/washer . . . . . . . . . . . . . . . . . . 48

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

Lumbar support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

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

Maintenance service . . . . . . . . . . . . . . . . . . . . . . . . . 16

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

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

Maximum tire pressures . . . . . . . . . . . . . . . . . . . . . 196

MBCS (Moveable Blade Control System) . . . . . . . . . . 9

lock pin switch . . . . . . . . . . . . . . . . . . . . . . . . . .42

status lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Memory gear feature . . . . . . . . . . . . . . . . . . . . . . . . . 89

Mid level vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124

heel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124

blade lift procedure . . . . . . . . . . . . . . . . . . . . . .107

lights switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

slide shift lever . . . . . . . . . . . . . . . . . . . . . . . . . .66

tilt lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

toe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124

Mounting and dismounting . . . . . . . . . . . . . . . . . . . . 76

Night operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

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

Oil Cooler(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Oil disc brakes reservoir . . . . . . . . . . . . . . . . . . . . . 192

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

Operating information . . . . . . . . . . . . . . . . . . . . . . . . 32

display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

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

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

Operating using differential lock . . . . . . . . . . . . . . . . 97

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

Operator

comfort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

seat and seat belt . . . . . . . . . . . . . . . . . . . . . . . 57

Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

brake . . . . . . . . . . . . . . . . . . . . . . . . . 96, 191, 229

brake applied . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

brake switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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

tilt pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Preparing for operation after long-term parking . . . 100

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

Pre-start checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Primary filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Primary steering system . . . . . . . . . . . . . . . . . . . . . . 25

Procedures before starting the machine . . . . . . . . . 82

Product identification plate . . . . . . . . . . . . . . . . . . . . 12

Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

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

Radio/tape player . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Rear

defroster fan switch . . . . . . . . . . . . . . . . . . . . . . 47

flood lights switch . . . . . . . . . . . . . . . . . . . . . . . 50

windshield wiper/washer. . . . . . . . . . . . . . . . . . . 48

Recirculation vent and screen . . . . . . . . . . . . . . . . . 62

vent filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

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

Refilling the cooling system . . . . . . . . . . . . . . . . . . 176

Replacing primary filter . . . . . . . . . . . . . . . . . . . . . 170

Right-hand ‘V’ ditching . . . . . . . . . . . . . . . . . . . . . . 132

Right-hand ditch clean-up . . . . . . . . . . . . . . . . . . . 140

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

Ripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116, 143

shank removal . . . . . . . . . . . . . . . . . . . . . . . . . 116

teeth, changing . . . . . . . . . . . . . . . . . . . . . . . . 116

tooth angle adjustment . . . . . . . . . . . . . . . . . . 116

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

Road maintenance - Gravel roads . . . . . . . . . . . . . . 39

ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . 231

Rubber and plastics . . . . . . . . . . . . . . . . . . . . . . . . 154

Rules

for batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

for using jumper cables . . . . . . . . . . . . . . . . . . 181

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

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

Safety concerns everybody . . . . . . . . . . . . . . . . . . 145

Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

when handling oil and fuel . . . . . . . . . . . . . . . . 151

when lifting and supporting the machine . . . . . 151

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

238 Alphabetical index

Scarifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115, 143

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

shank depth adjustment . . . . . . . . . . . . . . . . . .115

teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115

tooth angle adjustment . . . . . . . . . . . . . . . . . . .115

Seat

belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

cushion depth adjustment . . . . . . . . . . . . . . . . . .58

pan angle adjustment . . . . . . . . . . . . . . . . . . . . .58

Secondary air filter . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Secondary steering system . . . . . . . . . . . . . . . . . . . . 94

check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

test switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

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

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

brake warning . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Service brakes . . . . . . . . . . . . . . . . . . . . . . . . . 95, 229

master cylinder fluid . . . . . . . . . . . . . . . . . . . . .192

warning system, checking . . . . . . . . . . . . . . . . .192

Service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

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

Setup, language and units . . . . . . . . . . . . . . . . . . . . 34

Shifting gears, All Wheel Drive models . . . . . . . . . . . 91

Shifting gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

Snow removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Socket for service display unit . . . . . . . . . . . . . . . . . . 51

Special hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

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

cooling system . . . . . . . . . . . . . . . . . . . . . . . . .224

electrical system . . . . . . . . . . . . . . . . . . . . . . . .225

engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221

fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . .223

power transmission . . . . . . . . . . . . . . . . . . . . . .227

steering/hydraulic system . . . . . . . . . . . . . . . . .230

Start code sequence . . . . . . . . . . . . . . . . . . . . . . . . . 28

Starting

out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

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

with jumper cables . . . . . . . . . . . . . . . . . . . . . .182

Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, 93

using articulation . . . . . . . . . . . . . . . . . . . . . . . . .93

wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

wheel tilt lever . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Stopping

the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

the machine . . . . . . . . . . . . . . . . . . . . . . . . .95, 98

Suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

fore/aft adjustment . . . . . . . . . . . . . . . . . . . . . . .57

height adjustment . . . . . . . . . . . . . . . . . . . . . . . .57

weight adjustment . . . . . . . . . . . . . . . . . . . . . . . .57

Symbol key, lubrication and service chart . . . . . . . . 204

Tandem oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

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

The USA Federal Clean Air Act . . . . . . . . . . . . . . . . 17

Tie-down locations . . . . . . . . . . . . . . . . . . . . . . . . . 105

Tire pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Tire pump switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160, 196

To stop the grader . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Tool box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79, 101

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, 185

error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

filter element . . . . . . . . . . . . . . . . . . . . . . . . . . 186

gear display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

mount bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

pressure warning . . . . . . . . . . . . . . . . . . . . . . . . 24

shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

warning and information displays . . . . . . . . . . . 37

Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

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

Trip information reset . . . . . . . . . . . . . . . . . . . . . . . . 37

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

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

Unauthorized modifications of the ROPS . . . . . . . . . 11

Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Upper level vents . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Use of FM radios and two-way transmitters . . . . . . . . 4

VHP (Variable Horsepower) . . . . . . . . . . . . . . . . . . . . 7

Vibration levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

V-plow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Warning display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Washer fluid reservoir . . . . . . . . . . . . . . . . . . . . . . 200

Water pump, belt tension . . . . . . . . . . . . . . . . . . . . 178

Welding and electronic components . . . . . . . . . . . 150

Welding and grinding work . . . . . . . . . . . . . . . . . . . 153

Wheel lean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Wheel rim bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

When there is a risk of overturning . . . . . . . . . . . . . 78

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

Wing lights switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Working on painted surfaces . . . . . . . . . . . . . . . . . 154

Ref. no.: 21 1 434 4006 EnglishPrinted in Canada CST

g700b operator’s manual - grader's pro

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