KOMATSU GD530A-2EY, AW-2EY GD650A-2EY, AW-2EY GD670A-2EY, AW-2EY MOTOR GRADER WITH EMISSIONIZED ENGINE OPERATION & MAINTENANCE MANUAL (SN:210098 & UP) – PDF DOWNLOAD

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KOMATSU GD530A-2EY, AW-2EY GD650A-2EY, AW-2EY GD670A-2EY, AW-2EY MOTOR GRADER WITH EMISSIONIZED ENGINE OPERATION & MAINTENANCE MANUAL (SN:210098 & UP)

KOMATSU GD530A-2EY, AW-2EY GD650A-2EY, AW-2EY GD670A-2EY, AW-2EY MOTOR GRADER WITH EMISSIONIZED ENGINE OPERATION & MAINTENANCE MANUAL (SN:210098 & UP) – PDF DOWNLOAD:

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KOMATSU GD530A-2EY, AW-2EY GD650A-2EY, AW-2EY GD670A-2EY, AW-2EY MOTOR GRADER WITH EMISSIONIZED ENGINE OPERATION & MAINTENANCE MANUAL (SN:210098 & UP)

• Before the initial startup of your grader, take the time to read and understand the “Operation and Maintenance Manual.” The manual is stored in the document holder (arrow), which is located to the left of the operator’s seat. The manual has been prepared to help you operate and maintain your grader properly. After you have familiarized yourself with the contents of this manual, retain it on the grader, so you can refer to it when needed in the future.
• The information contained herein is IMPORTANT and will assist in ensuring that your grader gives you many hours of dependable, economical and trouble-free service. Two types of cross references exist throughout this manual. One type is to a heading in another section. Unless otherwise stated, references will be to the same section. Refer to the contents page at the beginning of the manual for specific page numbers. Some illustrations are of general application of the model and may not show your machine accurately in all details.
• Throughout this manual the use of the terms “left,” “right,” “front,” and “rear” must be understood to avoid confusion when following instructions. Left and right indicate the left and right sides of the machine when facing forward in the operator’s seat. Front and rear indicate the front and rear of the machine when facing forward in the operator’s seat

 TABLE OF CONTENTS:

KOMATSU GD530A-2EY, AW-2EY GD650A-2EY, AW-2EY GD670A-2EY, AW-2EY MOTOR GRADER WITH EMISSIONIZED ENGINE OPERATION & MAINTENANCE MANUAL (SN:210098 & UP)

MAIN MENU................................................................................................................................  0
COVER....................................................................................................................................  1
INTRODUCTION.............................................................................................................................  4
	1. GENERAL...........................................................................................................................  5
	2. PIN LOCATIONS.....................................................................................................................  7
	3. SERIAL NUMBERS (S/N)..............................................................................................................  8
		3.1 ENGINE S/N...................................................................................................................  8
		3.2 TRANSMISSION S/N.............................................................................................................  8
		3.3 CAB S/N......................................................................................................................  8
	4. MACHINE SHIPPING.................................................................................................................. 10
		4.1 LONG-DISTANCE SHIPPING....................................................................................................... 10
			4.1.1 TRUCK.................................................................................................................. 11
			4.1.2 RAILROAD FLATCAR....................................................................................................... 11
			4.1.3 DRIVING................................................................................................................ 11
	5. LIFTING THE MACHINE FOR TRANSPORT................................................................................................. 12
	6. MOVING A DISABLED MACHINE......................................................................................................... 13
		6.1 METHODS OF TOWING............................................................................................................ 13
			6.1.1 METHOD ONE............................................................................................................. 14
			6.1.2 METHOD TWO............................................................................................................. 15
			6.1.3 METHOD THREE........................................................................................................... 16
	7. MACHINE STORAGE................................................................................................................... 17
		7.1 PREPARING FOR STORAGE........................................................................................................ 17
		7.2 SERVICING MACHINE DURING STORAGE............................................................................................. 19
			7.2.1 ONE-MONTH REPETITIVE SERVICE PERIOD.................................................................................... 19
			7.2.2 SIX-MONTH REPETITIVE SERVICE PERIOD.................................................................................... 19
		7.3 PREPARING FOR OPERATION...................................................................................................... 20
	8. ROLLOVER PROTECTIVE STRUCTURE (ROPS).............................................................................................. 20
	9. TABLE OF CONTENTS................................................................................................................. 21
SAFETY................................................................................................................................... 30
	10.  GENERAL PRECAUTIONS............................................................................................................. 31
	11. SOUND AND VIBRATION.............................................................................................................. 33
		11.1 SOUND LEVLE FOR ENCLOSED CAB................................................................................................ 33
		11.2 VIBRATION LEVEL............................................................................................................. 33
	12. OPERATIONAL SAFETY............................................................................................................... 34
		12.1 GENERAL..................................................................................................................... 34
		12.2 BEFORE STARTING THE OPERATION............................................................................................... 35
		12.3 AFTER STARTING THE ENGINE................................................................................................... 35
		12.4 DURING OPERATION............................................................................................................ 36
		12.5 PARKING..................................................................................................................... 38
OPERATION................................................................................................................................ 39
	13. UNIVERAL SYMBOLS................................................................................................................. 40
	14. PREPARATION FOR USE.............................................................................................................. 41
	15. OPERATIONAL CONTROLS AND INSTRUMENTATION......................................................................................... 42
		15.1 OPERATOR'S CAB AND CONTROLS................................................................................................. 43
			15.1.1 BEACON................................................................................................................ 44
			15.1.2 CAB DOORS............................................................................................................. 44
			15.1.3 LOWER OPENING FRONT CAB WINDOWS....................................................................................... 45
		15.2 STEERING WHEEL AND SPINNER KNOB............................................................................................. 46
			15.2.1 HORN BUTTON........................................................................................................... 46
			15.2.2 STEERING WHEEL TILT KNOB.............................................................................................. 47
			15.2.3 TURN SIGNAL LEVER, HAZARD WARNING FLASHER SWITCH AND HEADLIGHT DIMMER BUTTON.......................................... 47
		15.3 CONTROL VALVE LEVERS........................................................................................................ 48
			15.3.1 LEFT HAND CONTROL LEVER BANK.......................................................................................... 49
			15.3.2 RIGHT HAND CONTROL LEVER BANK......................................................................................... 52
		15.4 FOOT CONTROLS............................................................................................................... 54
		15.5 SHIFT CONSOLE AND CONTROLS.................................................................................................. 55
			15.5.1 TRANSMISSION GEAR RANGE LEVER AND ENGINE SPEED CONTROL LEVER.......................................................... 55
			15.5.2 SHIFT CONSOLE CONTROL PANEL........................................................................................... 56
		15.6 STEERING CONSOLE CONTROLS AND GAUGES........................................................................................ 61
			15.6.1 INSTRUMENT PANEL...................................................................................................... 61
		15.7 SPEEDOMETER AND WARNING LIGHT PANEL......................................................................................... 67
		15.8 OPERATOR'S SEAT............................................................................................................. 70
			15.8.1 SUSPENSION SEAT (EUROPEAN)............................................................................................ 70
			15.8.2 SEAT BELT (RETRACTABLE)............................................................................................... 71
		15.9 SUN SHADE................................................................................................................... 71
		15.10 DOME LIGHTS AND FANS....................................................................................................... 72
			15.10.1 FRONT DOME LIGHT..................................................................................................... 72
			15.10.2 FRONT AND REAR FANS.................................................................................................. 72
		15.11 MISCELLANEOUS GAUGES AND VALVES............................................................................................ 73
			15.11.1 HYDRAULIC OIL TANK GAUGE............................................................................................. 73
			15.11.2 PARKING BRAKE RELEASE VALVE.......................................................................................... 73
			15.11.3 FUEL TANK SHUTOFF VALVE.............................................................................................. 73
			15.11.4 BLEED-DOWN VALVES.................................................................................................... 74
			15.11.5 FUEL TANK DRAIN VALVE AND PLUG....................................................................................... 75
		15.12 ACCESS COVERS, HOOD SIDES.................................................................................................. 76
			15.12.1 FUEL TANK AND HYDRAULIC OIL TANK ACCESS COVERS....................................................................... 76
			15.12.2 RADIATOR ACCESS COVER................................................................................................ 76
		15.13 INTERACTING CONTROLS....................................................................................................... 77
	16. PRECAUTIONS...................................................................................................................... 78
		16.1 PUSH STARTING............................................................................................................... 78
		16.2 TOWING...................................................................................................................... 78
			16.2.1 TOWING A GRADER WITH AWD.............................................................................................. 78
		16.3 ENTERING OR LEAVING THE CAB................................................................................................. 79
		16.4 MOUNTED EQUIPMENT OPERATION................................................................................................. 80
		16.5 BEFORE STARTING THE ENGINE.................................................................................................. 80
	17. PREPARATION FOR ROADING OR JOB SITE OPERATION.................................................................................... 85
		17.1 ROADING CONFIGURATION....................................................................................................... 85
		17.2 JOB SITE CONFIGURATION...................................................................................................... 86
		17.3 ENGINE STARTING............................................................................................................. 86
			17.3.1 NORMAL START.......................................................................................................... 87
			17.3.2 COLD WEATHER START USING ETHER INJECTION.............................................................................. 88
			17.3.3 ENGINE WARM-UP........................................................................................................ 89
			17.3.4 ENGINE WARMED-UP AND RUNNING ABOVE IDLE............................................................................... 89
		17.4 PUTTING THE GRADER INTO OPERATION........................................................................................... 89
	18. EMERGENCY STOPPING............................................................................................................... 91
		18.1 PRIMARY AND SECONDARY/EMERGENCY STOPPING SYSTEM............................................................................. 91
			18.1.1 PARKING BRAKE SYSTEM.................................................................................................. 92
	19. PARKING THE GRADER............................................................................................................... 93
		19.1 ENGINE SHUTDOWN............................................................................................................. 93
			19.1.1 AFTER SHUTTING DOWN THE ENGINE........................................................................................ 94
	20. TROUBLESHOOTING GUIDE............................................................................................................ 95
	21. OPERATION UNDER UNUSUAL CONDITIONS...............................................................................................101
		21.1 OPERATION IN EXTREME COLD...................................................................................................101
		21.2 OPERATION IN EXTREME HEAT...................................................................................................102
		21.3 OPERATION IN DUSTY OR SANDY AREAS...........................................................................................103
		21.4 OPERATION IN RAINY OR HUMID CONDITIONS......................................................................................103
		21.5 OPERATION IN SALT WATER AREAS...............................................................................................103
		21.6 OPERATION AT HIGH ALTITUDES.................................................................................................104
	22. APPLICATION......................................................................................................................105
		22.1 LEANING WHEELS..............................................................................................................105
			21.1.1 USE OF LEANING WHEELS IN STEERING.....................................................................................105
			21.1.2 SURFACE WORK..........................................................................................................106
		22.2 ARTICULATION................................................................................................................106
			22.2.1 USE OF ARTICULATION IN STEERING.......................................................................................107
		22.3 BANKS SLOPE OVERVIEW........................................................................................................108
		22.4 SADDLE PIN INDICATORS.......................................................................................................109
			22.4.1 RECOMMENDATION FOR 45 EXTENDED REACH RIGHT............................................................................109
			22.4.2 RECOMMENDATION FOR 90 BANKSLOPE RIGHT.................................................................................110
			22.4.3 RECOMMENDATION FOR 45 EXTENDED REACH LEFT.............................................................................111
			22.4.4 RECOMMENDATION FOR 90 BANKSLOPE LEFT..................................................................................111
		22.5 CIRCLE DRIVE................................................................................................................112
			22.5.1 BLADE ANGLE...........................................................................................................113
			22.5.2 BLADE PITCH...........................................................................................................113
		22.6 DITCHING....................................................................................................................115
			22.6.1 MARKING CUTS..........................................................................................................115
			22.6.2 ADDITIONAL PASSES.....................................................................................................115
			22.6.3 CASTING WINDOWS.......................................................................................................115
		22.7 BANK SLOPING................................................................................................................116
			22.7.1 FINISHING THE INSIDE SLOPE............................................................................................116
		22.8 CUTTING THE FLAT BOTTOM DITCH...............................................................................................116
			22.8.1 MOVING WINDOW FROM THE SHOULDER.......................................................................................117
		22.9 SNOW REMOVAL................................................................................................................117
			22.9.1 RECOMMENDATION........................................................................................................117
MAINTENANCE..............................................................................................................................118
	23. MAINTENANCE......................................................................................................................119
		23.1 PRECAUTIONS.................................................................................................................119
			23.1.1 GENERAL...............................................................................................................119
			23.1.2 DURING MAINTENANCE....................................................................................................120
		23.2 CARE OF HYDRAULIC SYSTEM....................................................................................................121
		23.3 LUBRICATION INSTRUCTION.....................................................................................................122
		23.4 PERIODIC LUBRICATION........................................................................................................123
			23.4.1 PERIODIC SERVICE CHART................................................................................................123
			23.4.2 PERIODIC SERVICE TABLE................................................................................................124
	24. SERVICE PROCEDURE................................................................................................................135
		24.1 EACH SHIFT/10 HOUR SERVICE..................................................................................................135
			24.1.1 DRAWBAR BALL STUD.....................................................................................................135
			24.1.2 CIRCLE SIDE SHIFT CYLINDER ...........................................................................................135
			24.1.3 BLADE PITCH CYLINDER..................................................................................................135
			24.1.4 BLADE PIVOT...........................................................................................................136
			24.1.5 LIFT CYLINDER CAP.....................................................................................................136
			24.1.6 FLUID LEVEL, TRANSMISSION.............................................................................................136
			24.1.7 FLUID FILL, TRANSMISSION..............................................................................................137
			24.1.8 OIL LEVEL, HYDRAULIC OIL TANK.........................................................................................137
			24.1.9 OIL FILL, HYDRAULIC OIL TANK..........................................................................................137
			24.1.10 BLADE SLIDE RAILS....................................................................................................138
			24.1.11 COOLANT LEVEL, ENGINE RADIATOR.......................................................................................138
			24.1.12 FILL, ENGINE COOLANT.................................................................................................138
			24.1.13 FILL, FUEL TANK......................................................................................................139
			24.1.14 FUEL-WATER TRAP......................................................................................................139
			24.1.15 OIL LEVEL, ENGINE....................................................................................................139
			24.1.16 AIR CLEANER SYSTEM...................................................................................................140
			24.1.17 AIR CLEANER SERVICE..................................................................................................141
			24.1.18 AIR FILTER ELEMENT CLEANING..........................................................................................142
			24.1.19 ENGINE FAN BLAD......................................................................................................143
			24.1.20 ENGINE DRIVE BELT....................................................................................................143
			24.1.21 ADJUSTING A/C BELT TENSION...........................................................................................144
			24.1.22 DIFFERENTIAL PUMP BELT TENSION.......................................................................................144
			24.1.23 ALTERNATE METHOD OF DIFFERENTIAL PUMP BELT ADJUSTMENT................................................................144
			24.1.24 CHECKING BELT TENSION/KOMATSU S6D114E-1 AND S6D102E-1................................................................145
		24.2 20 HOUR SERVICE ............................................................................................................146
			24.2.1 TRANSMISSION OIL FILTER...............................................................................................146
		24.3 WEEKLY/50 HOUR SERVICE......................................................................................................147
			24.3.1 SCARIFIER CYLINDERS AND PIVOT.........................................................................................147
			24.3.2 LOCK PIN CYLINDER.....................................................................................................147
			24.3.3 CIRCLE & SHOES........................................................................................................147
			24.3.4 LEANING WHEEL CYLINDER................................................................................................148
			24.3.5 TIE ROD & LEANING WHEEL ROD...........................................................................................148
			24.3.6 UPPER AND LOWER STEERING YOKE.........................................................................................148
			24.3.7 FRONT AXLE PIVOT......................................................................................................149
			24.3.8 STEERING CYLINDERS....................................................................................................149
			24.3.9 LIFT CYLINDER TRUNNIONS...............................................................................................149
			24.3.10 LIFT CYLINDER TRUNNION SHAFTS........................................................................................150
			24.3.11 FRONT BLADE CYLINDERS................................................................................................150
			24.3.12 REAR RIPPER CYLINDER.................................................................................................150
			24.3.13 OIL LEVEL, TANDEM CASES..............................................................................................151
			24.3.14 OIL FILL, TANDEM CASES...............................................................................................151
			24.3.15 OIL LEVEL, FRONT WHEEL GEAR CASE.....................................................................................151
			24.3.16 CONTROL LEVER LINKAGES...............................................................................................152
			24.3.17 CONTROL VALVE LINKAGES...............................................................................................152
			24.3.18 HYDRAULIC OIL FILTER.................................................................................................152
			24.3.19 OIL LEVEL, CIRCLE DRIVE GEAR CASE....................................................................................153
			24.3.20 OIL FILL, CIRCLE DRIVE GEAR CASE.....................................................................................153
			24.3.21 OIL LEVEL AND FILL (OPTION), CIRCLE SLIP CLUTCH......................................................................154
			24.3.22 OIL LEVEL, REAR AXLE.................................................................................................154
			24.3.23 OIL FILL, REAR AXLE..................................................................................................155
			24.3.24 BATTERIES............................................................................................................155
			24.3.25 TANDEM CASE BREATHER.................................................................................................155
			24.3.26 DRAIN, FUEL TANK.....................................................................................................156
			24.3.27 LOCK/UNLOCK REAR AXLE DIFFERENTIAL FILTER............................................................................156
		24.4 100 HOUR SERVICE............................................................................................................156
			24.4.1 FLUID CHANGE, REAR AXLE OIL...........................................................................................156
		24.5 MONTHLY/250 HOUR SERVICE....................................................................................................157
			24.5.1 PARKING BRAKE CALIPER.................................................................................................157
			24.5.2 ARTICULATION JOINT....................................................................................................157
			24.5.3 SUSPENSION ARM PIVOTS (BOTH SIDES)....................................................................................157
			24.5.4 REAR AXLE PIVOTS......................................................................................................158
			24.5.5 TRANSMISSION OIL FILTER...............................................................................................158
			24.5.6 TRANSMISSION BREATHER.................................................................................................158
			24.5.7 CIRCLE DRIVE GEAR CASE BREATHER.......................................................................................159
			24.5.8 COOLANT FILTER/CORROSION RESISTOR CATRIDGE............................................................................159
			24.5.9 AIR CLEANER SYSTEM....................................................................................................159
			24.5.10 COOLANT SYSTEM.......................................................................................................160
			24.5.11 BALL JOINTS..........................................................................................................160
		24.6 3 MONTHS/250 HOUR SERVICE...................................................................................................161
			24.6.1 OIL CHANGE............................................................................................................161
			24.6.2 OIL FILTER CHANGE.....................................................................................................162
		24.7 3 MONTHS/500 HOURS SERVICE..................................................................................................162
			24.7.1 FILL, ENGINE COOLANT..................................................................................................162
			24.7.2 ALL-WHEEL DRIVE FILTER................................................................................................162
			24.7.3 FLUID CHANGE, FRONT WHEEL DRIVE GEAR CASE.............................................................................163
			24.7.4 ENGINE FUEL FILTER....................................................................................................163
			24.7.5 FUEL TANK FILTER (STAINER) SCREEN.....................................................................................163
			24.7.6 PARKING BRAKE LININGS AND ADJUSTMENT..................................................................................164
			24.7.7 INTERNAL WET BRAKE LININGS............................................................................................164
			24.7.8 TANDEM CASE CHAINS....................................................................................................165
			24.7.9 HYDRAULIC ACCUMULATORS................................................................................................167
		24.8 6 MONTHS/1,000 HOUR SERVICE.................................................................................................168
			24.8.1 HYDRAULIC OIL FILTER..................................................................................................168
			24.8.2 FLUID CHANGE, TRANSMISSION............................................................................................168
			24.8.3 TRANSMISSION BREATHER.................................................................................................168
			24.8.4 DRIVE SHAFT...........................................................................................................169
			24.8.5 LOCK/UNLOCK REAR AXLE DIFFERENTIAL FILTER.............................................................................169
			24.8.6 ENGINE ADJUSTMENTS....................................................................................................169
		24.9 YEARLY/2,000 HOUR SERVICE...................................................................................................170
			24.9.1 FRONT WHEEL BEARINGS..................................................................................................170
			24.9.2 FLUID CHANGE, CIRCLE DRIVEGEAR CASE...................................................................................170
			24.9.3 FLUID CHANGE, CIRCLE SLIP CLUTCH......................................................................................170
			24.9.4 FLUID CHANGE, REAR AXLE...............................................................................................171
			24.9.5 LOCK/UNLOCK REAR AXLE DIFFERENTIAL STRAINER...........................................................................171
			24.9.6 DRAIN, HYDRAULIC OIL TANK.............................................................................................171
			24.9.7 FLUID CHANGE, TANDEM CASES............................................................................................172
			24.9.8 FRONT WHEEL DRIVE GEAR CASE BREATHERS.................................................................................172
			24.9.9 DRAIN, ENGINE COOLANT.................................................................................................172
			24.9.10 TORQUE CONVERTER OIL COOLER..........................................................................................173
			24.9.11 BATTERIES............................................................................................................173
			24.9.12 HYDRAULIC OIL TANK FILLER STRAINER...................................................................................173
			24.9.13 HYDRAULIC OIL STRAINER...............................................................................................174
		24.10 BIENNIAL/2,000 HOUR SERVICE................................................................................................174
			24.10.1 ENGINE VIBRATION DAMPER..............................................................................................174
		24.11 NOT SPECIFIED/AS REQUIRED SERVICE..........................................................................................175
			24.11.1 ENGINE RADIATOR......................................................................................................175
			24.11.2 AIR PRESSURIZATION FILTER............................................................................................175
			24.11.3 CAB RECIRCULATION FILTER.............................................................................................175
			24.11.4 REAR AXLE BREATHER...................................................................................................176
	25. OIL CHANGE RECOMMENDATIONS.......................................................................................................177
	26. OIL, FLUIDS AND GREASE...........................................................................................................178
		26.1 ENGINE OIL..................................................................................................................178
		26.2 GEAR LUBRICANT..............................................................................................................178
		26.3 HYDRAULIC TRANSMISSION FLUID................................................................................................178
		26.4 EXTREME PRESSURE GREASE.....................................................................................................179
		26.5 AUTOMATIC TRANSMISSION FLUID................................................................................................179
	27. WEAR LIMITS......................................................................................................................180
	28. FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....................................................................181
		28.1 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS............................................................................181
		28.2 ENGINE OIL SPECIFICATIONS...................................................................................................184
			28.2.1 NORMAL OPERATION......................................................................................................184
			28.2.2 ARCTIC OPERATION......................................................................................................185
		28.3 TRANSMISSION, TORQUE CONVETER AND OIL COOLER, TANDEM DRIVE CASE, FRONT WHEEL DRIVE GEAR CASE, IF EQUIPPED AND HYDRAULIC ....185
		28.4 REAR DRIVE AXLE AND CIRCLE DRIVE BRAKE HOUSING OIL SPECIFICATIONS...........................................................185
		28.5 DIESEL FUEL SPECIFICATIONS..................................................................................................185
		28.6 COOLANT SPECIFICATIONS......................................................................................................186
			28.6.1 GENERAL ..............................................................................................................186
			28.6.2 WATER.................................................................................................................186
			28.6.3 ANTIFREEZE............................................................................................................187
			28.6.4 SUPPLEMENTAL COOLANT ADDITIVES........................................................................................188
		28.7 CIRCLE DRIVE GEAR CASE OIL SPECIFICATIONS...................................................................................193
	29. VENTING AND PRIMING ENGINE.......................................................................................................194
	30. ENGINE CRANKCASE VENTILATION.....................................................................................................194
		30.1 KOMATSU S6D102E-1  AND S6D114E-1 DIESEL ENGINES.............................................................................194
			30.1.1 LOCATION ON THE KOMATSU S6D102E-1 DIESEL ENGINE.......................................................................194
			30.1.2 LOCATION ON THE KOMATSU S6D114E-1 DIESEL ENGINE.......................................................................194
	31. ELECTRICAL SYSTEM................................................................................................................195
		31.1 BATTERIES...................................................................................................................197
			31.1.1 CONVENTIONAL ANTIMONY (LEAD-ACID) BATTERY.............................................................................197
			31.1.2 LOW-MAINTENANCE BATTERY...............................................................................................197
			31.1.3 MAINTENANCE-FREE BATTERY..............................................................................................197
			31.1.4 GENERAL MAINTENANCE...................................................................................................198
			31.1.5 CLEANING THE BATTERIES................................................................................................198
		31.2 BATTERY CHARGING............................................................................................................198
			31.2.1 CHARGING INSTRUCTIONS.................................................................................................199
			31.2.2 CHARGING AND TESTING MAINTENANCE-FREE BATTERIES.......................................................................199
			31.2.3 SLOW CHARGE...........................................................................................................201
			31.2.4 FAST CHARGE...........................................................................................................201
			31.2.5 BATTERY CHARGING GUIDES...............................................................................................202
	32. SPEEDOMETER CALIBRATION..........................................................................................................204
	33. TIRES............................................................................................................................206
		33.1 DIRECTION OF TIRE TREADS....................................................................................................206
			33.1.1 TANDEM DRIVE TIRES....................................................................................................206
			33.1.2 NON-ALL WHEEL DRIVE FRONT AXLE........................................................................................206
			33.1.3 ALL WHEEL DRIVE ( AWD) FRONT AXLE.....................................................................................206
		33.2 RIM CENTERING...............................................................................................................207
		33.3 TIRE INFLATION..............................................................................................................208
		33.4 TIRE MATCHING...............................................................................................................208
		33.5 TIRE SIZES..................................................................................................................209
	34. TURBOCHARGER.....................................................................................................................210
		34.1 PRECAUTIONS.................................................................................................................210
		34.2 PRIMING.....................................................................................................................211
SPECIFICATIONS...........................................................................................................................212
	39. GENERAL DESCRIPTION..............................................................................................................213
		39.1 BLADE SUSPENSION IDENTIFICATION.............................................................................................213
	40.  GENERAL SPECIFICATIONS..........................................................................................................214
		40.1 OVERALL DIMENSIONS..........................................................................................................219
		40.2 APPENDIX A..................................................................................................................223
	41. TORQUE VALUES FOR STANDARD ENGLISH FASTENERS.....................................................................................229
		41.1 BOLT IDENTIFICATION CHART...................................................................................................229
		41.2 TYPE 1, 5 AND 8 NON-PHOSPHATE COATED HARDWARE...............................................................................229
		41.3 TYPE 8 PHOSPATE COATED HARDWARE.............................................................................................230
	42. TORQUE VALUES FOR STANDARD METRIC FASTENERS......................................................................................231
	43. TORQUE VALUES FOR HOSE CLAMPS....................................................................................................232
	44. TORQUE VALUES FOR SPLIT FLANGE CONNECTIONS.......................................................................................232
	45. TORQUE VALUES FOR HYDRAULIC TUBES AND FITTINGS...................................................................................233
	46. SPECIFIC BOLT TORQUES............................................................................................................234
		46.1 RIM TO WHEEL NUTS...........................................................................................................234
			46.1.1 NON-AWD FRONT AXLE....................................................................................................234
			46.1.2 AWD FRONT AXLE........................................................................................................234
		46.2 RIM TO WHEEL NUTS (REAR)....................................................................................................234
			46.2.1 WHEEL TO AXLE NUTS (REAR).............................................................................................234
		46.3 FRONT AXLE TO FRAME PIVOT PIN CAPS..........................................................................................235
		46.4 PLANETARY CARRIER...........................................................................................................235
		46.5 TIE ROD.....................................................................................................................235
		46.6 STEERING CYLINDERS..........................................................................................................236
			46.6.1 ROD END...............................................................................................................236
			46.6.2 BASE END..............................................................................................................236
		46.7 STEERING YOKE TO AXLE.......................................................................................................236
		46.8 LEANING WHEEL CYLINDER & TIE BAR............................................................................................236
		46.9 DRAWBAR TO FRAME............................................................................................................237
		46.10 CIRCLE SHOE BOLTS (FOUR SHOE CIRCLE).......................................................................................237
		46.11 UPPER SLIDE RAIL WEAR PAD BOLTS............................................................................................237
		46.12 BLADE SHIFT CYLINDER.......................................................................................................238
		46.13 LIFT CYLINDER TO YOKE......................................................................................................238
		46.14 YOKE TO SUSPENSION ARM.....................................................................................................238
		46.15 LOCK PIN CYLINDER..........................................................................................................239
		46.16 SUSPENSION ARM TO FRAME....................................................................................................239
		46.17 SUSPENSION ARM TO LINK.....................................................................................................239
		46.18 BLADE PIVOT LOCK NUT.......................................................................................................240
		46.19 BLADE PITCH PIVOT SLOT.....................................................................................................240
		46.20 ARTICULATION CYLINDERS.....................................................................................................240
		46.21 ARTICULATION JOINT.........................................................................................................241
		46.22 CAB MOUNTS.................................................................................................................241
			46.22.1 FRONT (1 EACH SIDE)..................................................................................................241
			46.22.2 REAR (2 EACH SIDE)...................................................................................................241
		46.23 REAR AXLE TO FRAME.........................................................................................................241
		46.24 BEARING HOUSING TO TANDEM CASE.............................................................................................242
		46.25 TANDEM CASE TO AXLE........................................................................................................242
		46.26 DRIVE SHAFT................................................................................................................242
		46.27 PARKING BRAKE DISC TO FINAL DRIVE INPUT YOKE...............................................................................243
		46.28 PARKING BRAKE CALIPER (MICO) TO MOUNTING BRACKET...........................................................................243
		46.29 REAR TRANSMISSION SUPPORT..................................................................................................243
			46.29.1 TRANSMISSION SUPPORT TO FRAME........................................................................................243
			46.29.2 TRNSMISSION SUPPORT TO TRANSMISSION..................................................................................243
		46.30 FRONT ENGINE SUPPORT.......................................................................................................244
			46.30.1 ENGINE SUPPORT TO FRAME..............................................................................................244
			46.30.2 ENGINE SUPPORT TO ENGINE.............................................................................................244
		46.31 ALTERNATOR PULLEY NUT......................................................................................................244
	47. DECALS...........................................................................................................................245
		47.1 DECAL LOCATION..............................................................................................................245
		47.2 DECAL PART NUMBERS..........................................................................................................246
		47.3 INDIVIDUAL DECALS...........................................................................................................247
OPTIONS,  ATTACHMENTS....................................................................................................................252
	49. HEATING AND AIR CONDITIONING ....................................................................................................253
		49.1 HEATER/AIR CONDITIONING CONTROLS............................................................................................253
			49.1.1 CONTROLS IDENTIFIED...................................................................................................253
			49.1.2 CONTROLS DEFINED......................................................................................................253
		49.2 AIR PRESSURIZATION RECICULATION VENTS.......................................................................................254
			49.2.1 NON AIR-CONDITIONED CABS..............................................................................................254
			49.2.2 STANDARD WITH AIR CONDITIONED CABS....................................................................................254
	50. ALL WHEEL DRIVE..................................................................................................................255
		50.1 USE OF ALL WHEEL DRIVE......................................................................................................255
		50.2 AWD CONTROLS AND INDICATOR LIGHTS...........................................................................................255
		50.3 OPERATIONAL CHECKS..........................................................................................................256
	51. BATTERY CHARGING RECEPTICLE......................................................................................................256
	52. COLD-WEATHER STARTING AID........................................................................................................256
		52.1 ETHER STARTING..............................................................................................................256
			52.1.1 STARTING PROCEDURES...................................................................................................257
			52.1.2 PREVENTIVE MAINTENANCE................................................................................................257
		52.2 ENGINE BLOCK HEATER.........................................................................................................258
	53. FIRE EXTINGUISHER................................................................................................................258
	54. HYDRAULIC ACCUMULATOR (DRAWBAR AND CIRCLE OPTION)................................................................................258
	55. HYDRAULIC LOCK/UNLOCK DIFFERENTIAL...............................................................................................259
	56. FRONT BLADE ATTACHMENT...........................................................................................................260
		56.1 OPERATION...................................................................................................................260
		56.2 FRONT BLADE CONTROLS........................................................................................................261
		56.3 INSTALLATION AND STORAGE OF THE SHEATH......................................................................................261
		56.4 FRONT BLADE REMOVAL AND INSTALLATION........................................................................................261
			56.4.1 REMOVAL...............................................................................................................261
			 56.4.2 INSTALLATION.........................................................................................................261
	57. FRONT-MOUNTED SCARIFIER..........................................................................................................262
		57.1 FRONT-MOUNTED SCARFIER SETUP................................................................................................262
		57.2 SCARFIER TOOTH REPLACEMENT..................................................................................................263
		57.3 FRONT-MOUNTED SCARFIER REMOVAL AND INSTALLATION.............................................................................263
			57.3.1 REMOVAL...............................................................................................................263
			57.3.2 INSTALLATION..........................................................................................................264
		57.4 SCARFIER CONTROLS...........................................................................................................265
	58. MASTER SWITCH....................................................................................................................266
	59. REAR-MOUNTED RIPPER..............................................................................................................267
		59.1 REAR-MOUNTED RIPPER SETUP...................................................................................................267
			59.1.1 RIPPER WITH RIPPER SHANKS.............................................................................................267
			59.1.2 RIPPER WITH SCARIFIER SHANKS..........................................................................................268
		59.2 RIPPER CONTROLS.............................................................................................................268
		59.3 RIPPER TOOTH REPLACEMENT....................................................................................................269
		59.4 REAR-MOUNTED RIPPER HITCH PIN...............................................................................................269
			59.4.1 RIPPER HITCH PIN......................................................................................................269
			59.4.2 MAXIMUM PULLING LIMITS................................................................................................269
			59.4.3 RIPPER POSITION WHILE PULLING.........................................................................................270
		59.5 REAR-MOUNTED RIPPER LOCK BAR................................................................................................271
		59.6 REAR-MOUNTED RIPPER REMOVAL AND INSTALLATION................................................................................271
			59.6.1 REMOVAL...............................................................................................................271
			59.6.2 INSTALLATION..........................................................................................................272
	60. SPARE TIRE ......................................................................................................................272
		60.1 OPERATION AND SET UP........................................................................................................272
	61. WHEEL CHOCKS.....................................................................................................................273
	62. WORK LIGHT SOCKET................................................................................................................273
	63. ELECTRIC FLOAT...................................................................................................................274
		63.1 FLOAT SWITCH................................................................................................................274
		63.2 AUXILIARY FLOAT SWITCH......................................................................................................274
	64. AM/FM/WB STEREO RADIO............................................................................................................275
		64.1 CONTROLS....................................................................................................................275
			64.1.1 CONTROLS IDENTIFIED...................................................................................................275
			64.1.2 CONTROLS DEFINED......................................................................................................276
			64.1.3 SETTING THE CLOCK.....................................................................................................277

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