660 BeltLoader Maint - Amazon Web Services...CD397-28Maint 2 - 1 - 5 May 2019 (Rev C) Chapter 2...

CD397-Maint 2 - 1 - 1May 2019 (Rev C)

Chapter 2 Mobile Belt Loader Model 660-28Section 1 Maintenance Manual

Chapter2:MaintenanceandRepair

Section 1: Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1-31.1 Safety Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1-31.2 Pre-Operation Checks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1-3

Section 2: Preventive Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2-12.1 Periodic Maintenance/Service Schedules and Checklists - - - - - - - - - - - - - - - - - 2-2-1

Section 3: Maintenance Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3-13.1 Safety Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3-13.2 Jacking Instructions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3-13.3 Fluid Level Checks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3-23.4 Adjustment Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3-4

Section 4: Troubleshooting- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4-14.1 Engine and Transmission - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4-14.2 Brakes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4-24.3 Park Brake - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4-34.4 Steering - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4-44.5 Conveyor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4-54.6 Hydraulic System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4-54.7 Electrical - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4-9

Section 5: Electrical and Hydraulic Layouts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5-15.1 Electrical Layouts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5-25.2 Hydraulic Layouts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5-14

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THIS PAGE INTENTIONALLY BLANK

Mobile Belt Loader Model 660-28 Chapter 2Maintenance Manual Section 1

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Chapter2:MaintenanceandRepairSection1:IntroductionPreventive maintenance is regularly performed maintenance that will lessen the likelihood of equipmentfailure. Preventive maintenance is performed while the equipment is still operating properly, so that it doesnot break down unexpectedly.

The following sections provide information on how to maintain the vehicle to ensure optimal equipmentperformance.

1.1SafetyPrecautionsAll operators and mechanics should refer to the information located in the Safety section, and to theWarnings, Cautions, and Notes throughout this manual.

It is recommended that in addition to mechanical irregularities one should check for the presence andquality of exterior reflector markings. To ensure continued safe operation, any noted deficiencies shouldbe corrected immediately.

1.2Pre-OperationChecksThe following items must be checked before putting the belt loader 660 into service:

1. Unit exterior for cleanliness and/or damage.

2. Tires:

• Air pressure tires: when applicable, inflate tires to 45 psi (3.1 bar).

• Condition of tires: cuts, breaks, or excessive wear.

3. Torque on wheel lug nuts: ensure torque is 125 ft-lb (169.5 N-m).

4. Brakes:

• Test service brake pedal for firmness and braking effectiveness.

• Test park brake.

5. Under unit for signs of leaking of the following:

• engine oil

• transmission fluid• coolant (hoses, and cleanliness of the radiator’s exterior)

• hydraulic fluid, air intake system (soot marks around coupling hardware indicates leakage)

• fuel system (hoses, lines, fittings and linkage)If significant leaks are found, repair them as soon as possible. Do NOT use the equipment until repaired.

CAUTION: Every operator and mechanic/technician involved with this equipment must readand abide by the Safety sections.

WARNING: ALWAYS SET THE PARK BRAKE ON PRIOR TO SHUTTING OFF THE UNIT OREXITING THE VEHICLE.

NOTE: With the unit turned OFF, the park brake should hold the unit in place on a 8% grade.Propert

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6. Fluid levels. When applicable, top off when necessary:

• engine oil level• engine coolant level

• transmission oil level• hydraulic fluid level (including brake fluid)

• fuel level7. That all controls are in good working order.

8. Operator seat settings. Adjust as needed.

9. Seat belt and restraining devices for proper operation.

1.2.1EngineandTransmissionChecks

1. Inspect the engine compartment for loose hardware, loose wires, and leaking lines or fittings.

2. Check for condensation under the engine oil fill cap and ensure engine oil does not have a milky appearance.

a. When moisture is found on the oil fill cap and/or the engine oil has a milky appearance,per form an engine oil and filter service.

b. After the engine oil and filter service, drive the unit at operating temperature 213°F(100.3°C), under load for at least 30 minutes.

c. Ensure the unit is driven at operating temperature for a minimum of 30 minutes every 50hours thereafter.

3. Check radiator coolant mixture level at the coolant recovery tank.

NOTE: As an optional safety feature, the vehicle is inoperable until the seat is activated. The seat isactivated when the operator is securely seated.

CAUTION: Never use a sealing additive to stop leaks in the cooling system. This can result incooling system plugging and inadequate coolant flow, causing the engine to over-heat.

NOTE:Milky oil is a sign of water in the oil and the tractor should be serviced immediately. This maynot indicate a mechanical problem, but instead an engine that is not running long enough toreach operating temperature.

NOTE:

Due to natural environmental conditions, condensation will deposit moisture inside theengine crankcase. This moisture will be vaporized when the motor oil reaches an operatingtemperature above 213°F (100.3°C). Operations with short driving distances may not pro-vide the engine with enough time for the engine oil to exceed 213°F (100.3°C), resulting inan accumulation of moisture in the engine oil, causing the engine oil to have a milky appear-ance. To prevent this, all engines should be brought to operating temperature, and drivenunder load, for a minimum of 30 minutes every 50 hours.

NOTE:If coolant is needed, ensure radiator drain valve is closed. Then add an mixture of anti-freeze, coolant additive, and water at the coolant recovery tank. Some radiators have two(2) fill necks, of which both must be filled when the cooling system is drained.

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CD397-28Maint 2 - 1 - 5May 2019 (Rev C)


4. Check transmission cooling lines for proper connections.

5. Start the engine.

6. With the service brake pedal depressed, cycle the transmission through all gears and allow trans-mission to reach 150°F (66°C).

7. Return to neutral and check the transmission’s oil level and add oil as required without overfilling.

1.2.2FuelSystem1. Check all fuel line connections to ensure they are properly connected.

2. Ensure cell drain valve is closed.

3. Fill fuel tank with correct fuel.

1.2.3SteeringSystemPlace one hand on the steering wheel and turn left to right.

NOTE:This check is to determine if there is fluid in the transmission. If any fluid shows on the dip-stick, do not add transmission fluid until it is checked after the engine has reached normaloperating temperature.

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2 - 1 - 6 CD397-28MaintMay 2019 (Rev C)



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Section2:PreventiveMaintenanceRoutine maintenance is essential if the vehicle is to be an efficient materials handling unit. Lack ofmaintenance will result in costly repairs and interruptions in daily operations.

2.1PeriodicMaintenance/ServiceSchedulesandChecklistsThe unit should be maintained in accordance with periodic schedules. Maintain the unit by performing theperiodic maintenance procedures as listed in this chapter.

During the periodic maintenance of the unit, follow the instructions for service/adjustment of thecomponents and systems as described in this chapter, the manufacturers’ service instructions andmanuals.

Perform maintenance at whichever interval occurs first. At each scheduled maintenance interval, performall previous maintenance checks that are due for scheduled maintenance.

The required maintenance schedules are as follows:

• Daily or every 10 hours of operation

• Weekly or every 50 hours of operation

• Monthly or every 200 hours of operation

• Bi-annual or every 1200 hours of operation and/or

• Annual or every 2400 hours of operation

The following tables detail required periodic maintenance.

2.1.1DailyMaintenanceSchedule

NOTE:

If the system is operating in ambient temperatures below -18°C [0°F] or above 38°C [100°F],perform maintenance at shorter intervals.

Shorter maintenance intervals are also required if the system is operated in abnormallysevere conditions (i.e. sand, dust, salt-air, ice, snow, etc.) or if frequent stops are made.

WARNING: DO NOT CHANGE A PNEUMATIC TIRE FOR A CUSHION TIRE OR VICE VERSAWITHOUT FIRST CONSULTING TEXTRON SPECIALIZED VEHICLES.

CAUTION:The recommended tire pressure listed in these tables are for tires that are standardfor the Mobile Belt Loader 660-28. Non-TUG tires should be inflated according to thetire manufacturer specifications.

Table2-2-1:DailyMaintenanceSchedule

No. Component DailyCheck/Action

1 Exterior Inspect the unit exterior for cleanliness and damage.

2 Fire Extinguisher (Optional)

Ensure fire extinguisher(s) is/are in place and fully charged, if equipped.

3 Controls Check that all controls are in good working order. Report any faulty controls and do not use until repaired.

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4 Battery Check battery charge level and charge as required.

5 Fuel Level Check fuel level and fill as required.

6 Engine Oil Check engine oil and fill as required.

7 Hydraulic SystemCheck hydraulic system for leaks, include hoses and fittings to the remote hydraulic fluid cooler.

Check hydraulic fluid level, add fluid as required.

8 Radiator Coolant/Water Level Check the coolant level/water level and fill as required.

WARNING: EYE PROTECTION MUST BE WORN WHEN USING PRESSURIZED AIR. DO NOTINFLATE TIRES OVER THEIR RATED PRESSURE. DOING SO CAN RUPTURE OREXPLODE A TIRE AND CAUSE PERSONAL INJURY OR EQUIPMENT DAMAGE.

DO NOT CHANGE A PNEUMATIC TIRE FOR A CUSHION TIRE OR VICE VERSAWITHOUT FIRST CONSULTING TEXTRON SPECIALIZED VEHICLES.

CAUTION: The recommended tire pressure listed in these tables are for tires that are stan-dard for the Mobile Belt Loader 660-28. Non-TUG tires should be inflated accord-ing to the tire manufacturer specifications.

9 Tires

Check the tire pressure and ensure tire pressure is:• Front Tires: 45 psi (3.1 bar)

• Rear Tires 75 psi (5.2 bar).

Check tire treads for damage and remove any foreign objects.

10 Lights

Check the operation and aiming of the headlights.

Check the operation of the following components:• front & rear turn signals

• tail lights

• stop lights

11 Cab

If so equipped, check the operation of Cab:• marker lights

• heater

• defogger fan

• windshield wipers

• fan

• light

12 Horn Sound the horn.

13 E-Stop Operation Check/Test E-Stop operation and report if not working.

Table2-2-1:DailyMaintenanceSchedule(Continued)


WARNING

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2.1.2WeeklyorEvery50HoursMaintenanceSchedule

14 Seat Belts Check seat belts, report any faulty belts and do not use until repaired.

15 Windshield Wipers Check windshield wiper blades (if equipped) and fluid level. Change worn wiper blades and add fluid if necessary.

WARNING:

LUG NUTS MUST BE RE-TIGHTENED TO 125 FT-LB (169.5 NM) AFTER THEFOLLOWING REASONS:

• AFTER ANY CHANGE OF A WHEEL

• ANYTIME LUG NUTS HAVE BEEN LOOSENED

• AT THE INTERVALS SPECIFIED IN THIS PERIODIC MAINTENANCE SECTION.

Table2-2-2:WeeklyorEvery50HoursMaintenanceSchedule

No. Component Weekly/50HoursCheck

1 Lug Nuts Ensure wheel lug nuts are tightened to 125 ft-lb (169.5 N-m).

NOTE: Only the initial check is required at 50 hours, check every month or 200 hours there after.

2 Brake Fluid Level Check brake fluid level in the master cylinder. If low, top off master reservoir with a high quality brake fluid, DOT 3 or better.

3 Conveyor Belt

Check conveyor belt for proper tension and alignment.

Check belt drive chain adjustment.

Check rear finger guard adjustment.

Lubricate belt drive chain.

4 AxlesEnsure drive axle mounting bolts are tightened to a torque of 75 ft-lbs (101.69 N-m).

Check for drive axle fluid level and fill as required.

5 Battery Check battery charge level and charge as required.

6 Transmission Fluid With engine running and at operating temperature, check transmis-sion level and fill as required.

7 Ball Joints Check ball joints for looseness.

8 Exhaust System Check exhaust system for leaks and holes, report/repair as neces-sary.

9 Neutral Safety Switch Check neutral safety switch, adjust as necessary.

10 Oil and Filter Change oil and filter only if new unit (first week or first 50 hours)

Table2-2-1:DailyMaintenanceSchedule(Continued)


WARNING

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2 - 2 - 4 CD397-28MaintMay 2019 (Rev C)


2.1.3MonthlyorEvery200HourMaintenanceSchedule

2.1.4Bi-MonthlyorEvery400HoursMaintenanceSchedule

11 Crankcase Ventila-tion (PCV) system

Check crankcase ventilation (PCV) system, report/repair as neces-sary.

Table2-2-3:MonthlyorEvery200HoursMaintenanceSchedule

No. Component Bi-weekly/100HoursCheck

1 Brake System

Check the park brake and adjust as required. The park brake needs adjustment when the unit rolls on a 8% or less grade with the park brake engaged.

Check and lube park brake lever points.

Check, lube and/or adjust service brake pedal pivot.

Check brake pads/shoes and replace if pads are less than 1/8 in (3.175 mm).

2 Accelerator Pedal Check accelerator pedal for proper operation.

3 AxleCheck and lube steer axle, king pins and tie rod ends.

Check and lube drive shaft joints.

4 Lubrication Lube the adjusting slides beneath the operator’s seat.

5 Conveyor BeltCheck and lube conveyor belt roller bearings.

Check and lube conveyor side and handrail pivots.

6 Lubrication Check and lube all grease fittings.

7 Air Filter Clean the air filter, if necessary replace air filter.

8 Cooling System Check radiator hoses and replace as required.

Clean exterior of radiator, replace as necessary.

9 Engine/Engine Components Check fan and alternator belts, tighten as needed.

Table2-2-4:Every2MonthsorEvery400HoursMaintenanceSchedule

No. Item EveryTwo(2)Months/400HoursCheck

1 Hydraulic System Replace hydraulic filter.

2 Cooling SystemCheck for dirt or rust.

Check cooling system thermostat, adjust/replace as necessary.

Table2-2-2:WeeklyorEvery50HoursMaintenanceSchedule(Continued)

No. Component Weekly/50HoursCheck

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CD397-28Maint 2 - 2 - 5May 2019 (Rev C)


2.1.5Bi-AnnuallyorEvery1200HoursMaintenanceSchedule

2.1.6AnnuallyorEvery2400HoursMaintenanceSchedule

3 Wheel Bearings Inspect front wheel bearings, clean and repack.

4 Tie Rods Check tie rod end for looseness and adjust as needed.

6 Spark Plugs Clean the spark plugs and test.

Table2-2-5:Bi-AnnuallyorEvery1200HoursMaintenanceSchedule

No. Item Bi-Annually/1200HoursCheck

1 Fuel System Check fuel filter and replace as required.

2 LPG filter (optional) Check LP filter and replace as required.

3Spark Plug

Check spark plug and replace as required.

4 Check spark plug coil resistance and replace as required.

5 PCV Valve Check PCV valve and replace as required.

Table2-2-6:AnnuallyorEvery2400HoursMaintenanceSchedule

No. Item Annually/2400HoursCheck

1 Axles Drain and refill the drive axle.

2 Hydraulic System

Drain and refill the transmission fluid and replace the filter as neces-sary.

Drain, flush and refill the hydraulic brake system.

Bleed wheel cylinders on the service brake system.

Drain, flush and refill the hydraulic steering system.

Table2-2-4:Every2MonthsorEvery400HoursMaintenanceSchedule

No. Item EveryTwo(2)Months/400HoursCheck

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2 - 2 - 6 CD397-28MaintMay 2019 (Rev C)


2.1.7MaintenanceChecklist

Table2-2-7:PeriodicMaintenanceChecklist

Serial Number: Date:

Manufacture Date: ID Number:

Service Requirement in Hours Daily 50 100 200 400 600 800 1000 1200 2400

Check for working controls

Check fuel level

Check engine oil level

Check hydraulic oil level / check for leaks

Check radiator coolant/water level Check tire pressure and condition

Check ammeter for charging

Check all lights/cab equipment (if equipped)

Check horn operation

Check conveyor belt tension/alignment

Check belt drive chain adjustment

Lube belt drive chain

Check rear finger guard adjustment

Check lug nut tightness

Check brake fluid level in master cylinder

Check battery charge and fluid level

Check/Tighten drive axle mounting bolts

Check transmission fluid level

Check critical torque values of all nuts and bolts

Check drive axle oil level

Check underneath for oil leaks and dam-age

Check ball joints

Check exhaust system

Check crankcase ventilationCheck neutral safety switch adjustment

Check engine oil and filter

Check conveyor belt tension/alignment

Change engine oil and filter (see note below)

Check service brake operation

Check park brake operation

Check fan/alternator belts

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CD397-28Maint 2 - 2 - 7May 2019 (Rev C)


Notes:

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2 - 2 - 8 CD397-28MaintMay 2019 (Rev C)


Table2-2-7:PeriodicMaintenanceChecklist

Serial Number: Date:

Manufacture Date: ID Number:

Service Requirement in Hours Daily 50 100 200 400 600 800 1000 1200 2400

Check hoses / clean radiator exterior

Check brake pads and shoes

Check air filter

Lube service brake pedal linkage pivots

Lube park brake lever pivots

Lube all grease fittings

Lube throttle linkage

Lube conveyor side/hand rail pivots

Lube motor access cover hinges

Lube seat slide

Lube drive shaft joints

Lube steer axle and king pins

Lube all grease fittings

Change hydraulic oil filter

Check cooling system and thermostat

Check/Adjust injector pump timing diesel units

Check/Adjust idle RPM

Check/Clean/Adjust/Test spark plugs gasoline unitsInspect/Clean/Repack front wheel bearings

Check Tie rod ends looseness

Check cylinder compression

Check spark plug coil resistance gasoline units

Check/Tighten intake manifold bolts

Change fuel filter

Change spark plugs gasoline Units

Change PCV valve gasoline units

Adjust automatic transmission bands

Change transmission fluid and filter

Change drive axle oil

Drain/Flush/Refill/Bleed hydraulic brake sys-tem

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CD397-28Maint 2 - 2 - 9May 2019 (Rev C)


Notes:

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CD397-28Maint 2 - 3 - 1May 2019 (Rev C)


Section3:MaintenanceProceduresThe following procedure outline the steps and precautions to take when servicing the unit for maintenanceor repair.

3.1SafetyPrecautions

All operators and mechanics should refer to the information located in the Safety section, and to thewarnings, Cautions, and Notes throughout this manual.

It is recommended that in addition to mechanical irregularities one should check for the presence andquality of exterior reflector markings. To ensure continued safe operation, any noted deficiencies shouldbe corrected immediately.

3.2JackingInstructions

1. Engage the parking brake.

2. Chock wheels.

3. Position jack under front or rear bumper.

4. Raise the unit.

5. Position jack stands under the bumper.

6. Lower unit onto jack stands.

Figure2-3-1:JackingPoints(UndersideView)

WARNING: ALWAYS REVIEW SAFETY PRECAUTIONS PRIOR TO PERFORMING ANY WORKON THIS EQUIPMENT.

CAUTION: Every operator and mechanic/technician involved with this equipment must readand abide by the Safety sections.

WARNING:

TO AVOID INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT, ALWAYS USELIFTING EQUIPMENT, JACK STAND, AND CHAINS WITH A SAFE MINIMUMCAPACITY OF ONE AND A HALF (1.5) TIMES THE WEIGHT OF THE VEHICLEBEING LIFTED.

ALWAYS SET THE PARK BRAKE ON PRIOR TO SHUTTING OFF THE UNIT OREXITING THE VEHICLE.

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2 - 3 - 2 CD397-28MaintMay 2019 (Rev C)


3.3FluidLevelChecksLubrication should be completed as part of the periodic maintenance schedule. See Table 2.1.2 Weekly orEvery 50 Hours Maintenance Schedule and Table 2.1.3 Monthly or Every 200 Hour Maintenance Schedulefor schedule information.

Figure2-3-2:ChassisLubrication

Brake

Pedal

Front

Lift Arm

Pin

Lubricate

Tie Rod

Lubricate

Tie Rod

Lubricate

Steering

Linkage

Parking

Brake

Lever

Repack

Front Wheel

Bearings

Engine Lubrication

(see engine servicing)

Transmission

Universal

Joint FittingsDifferential

Plug

Rear Lift

Arm Pin

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CD397-28Maint 2 - 3 - 3May 2019 (Rev C)


3.3.1LubricationProcedurePressure zerks locations are detailed in the following table Table 2-3-1, “Lubrication Locations,” . Refer toFigure 2-3-3 Lubrication - Top View, and Figure 2-3-4 Lubrication - Side View for locations..

Figure2-3-3:Lubrication-TopView

Figure2-3-4:Lubrication-SideView

Table2-3-1:LubricationLocations

Item ZerkLocation NumberofZerks

1 Ball Joints, Upper and Lower 4

2 Tie Rod Ends 2

3 Hydraulic Lift Cylinders 4

4 Steering Cylinder Tie Rod Ends 2

5 Conveyor Belt Roller Bearings 8

Belt Roller Bearings (4)Belt Drive Chain

Compartment Hinges

Belt Roller Bearings (4)

Conveyor Side/Hand RailPivot Points (8)

Seat Slide

Hydraulic Cylinder PivotPoints (Upper & Lower)

Hydraulic Cylinder PivotPoints (Upper & Lower)

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2 - 3 - 4 CD397-28MaintMay 2019 (Rev C)


3.4AdjustmentProcedures3.4.1TransmissionLinkageAdjustment

1. Place shifter in neutral.

2. Remove swivel from transmission shift lever.

3. Back off lockout from swivel.

4. Place transmission in neutral.

5. Rotate shift lever fully counterclockwise.

6. Rotate shift lever clockwise to third position from fully counterclockwise for three speed transmis-sion.

7. Tighten or loosen swivel one turn at a time until it is perfectly aligned with the hole in the shift lever.

8. Reinstall swivel in shift lever.

9. Tighten lockout until it is firmly engaged with swivel.

3.4.2ServiceBrakePedalForceSetting/AdjustmentAdjustment and or setting the amount of brake pedal force necessary to shift gears to be the same as theamount of pedal force necessary to turn on the brake lights.

3.4.2.1AdjustmentProcedure1. Park the unit on level ground

2. Turn ignition key/master switch to “OFF” position

3. Apply park brake

4. Chock rear wheels

5. Locate the shift inhibit brake pressure switch. See Figure 2-3-5 Hydro-boost & shift Inhibit Brake Pressure Switch.

6. Locate the adjustment screw on the shift inhibit.

7. Turn ignition key/vehicle master switch to the start/ON position and let vehicle idle.

8. One (1) person must carefully depress the service brake pedal until the brake lights just turn on.

9. Hold the pedal in this position without depressing the pedal further.

10. Using a 516” Allen wrench, a second (2) person turns the adjustment screw on the shift inhibit pressure switch counterclockwise until the shift light on the vehicle dash turns on (lights up).

CAUTION: The transmission linkage must be properly adjusted to prevent damage andmaintain safe operation.

NOTE: The hydro-boost is mounted to the frame near the driver compartment and front lift cylinder.

NOTE: Often covered by blue plastic.

NOTE: This procedure is easiest to complete with at least 2 people.

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CD397-28Maint 2 - 3 - 5May 2019 (Rev C)


11. Release the service brake pedal, and slowly depress again.

Figure2-3-5:Hydro-boost&shiftInhibitBrakePressureSwitch

3.4.3ParkBrakeAdjustmentWhen properly adjusted, the parking brake will prevent the belt loader from rolling when parked or while inneutral on an 8% grade. The Parking brake utilizes the brake shoes on the rear axle.

3.4.3.1AdjustmentProcedure1. If parking brake hand lever is equipped with a locking set screw, loosen the set screw.

2. To tighten the park brake, turn the knurled knob at the end of the hand brake lever clockwise.

3. To loosen the park brake, turn the knurled knob at the end of the hand lever counterclockwise.

4. If parking brake hand lever is equipped with a locking set screw, tighten the set screw.

NOTE:

The shift light on the dash should turn on at the same time as the vehicle brake lights. If theydo not turn on at the same time, adjust the shift inhibit pressure switch again until they do.

Turning the screw counterclockwise makes the shift light turn on with less brake pressure,turning the screw clockwise makes the shift light turn on with more brake pressure.

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2 - 3 - 6 CD397-28MaintMay 2019 (Rev C)


3.4.4BleedingtheBrakeSystem1. Brakes can be bled either manually or with pressure bleeding equipment.

2. Check the master cylinder reservoir.

3. Fill the master cylinder reservoir with the appropriate brake fluid, within 1/8 in. of the top.

3.4.4.1ManualBleedingManual bleeding requires two people: one to pump the brake pedal and another to operate the bleedervalves.

1. Ensure the master cylinder is full of required Brake Fluid.

2. Begin at the farthest wheel from the driver.

3. Locate the bleeder screw at the rear of the caliper body (or drum brake wheel cylinder).

4. Remove the rubber cap from the bleeder screw.

5. Place the box-end wrench over the bleeder screw.

6. Place one end of the plastic tubing over the nipple of the bleeder screw.

7. Place other end of tubing into the disposable bottle.

8. Instruct assistant to pump the brakes three times and on the third pump, hold the brake pedal down and respond with “Applied.”

9. Instruct assistant not to release the brakes until told to do so.

CAUTION: Fluid which is drained, flushed, or bled out of a vehicle’s brake system should bediscarded. It is not safe for reuse for any purpose.

NOTE:If the caliper was removed for overhaul, or if the brake hose or steel line was disconnectedfor any other reason, it is necessary to bleed all air from the calipers and connecting lines.

Table2-3-2:BrakeBleedingSupplies

Item Tool/Supplies

1 Box-end wrench

2 Extra brake fluid

3 12-inch (30.5 cm) long clear plastic tubing sized to fit snugly over the bleeder screw

4 Disposable bottle for used fluid

5 Brake cleaner

NOTE: While the actual sequence is not critical to the bleed performance it is easy to remember thesequence as the farthest to the closest. The recommended sequence is: right rear, left rear,right front, and left front.

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10. Loosen the bleeder screw 1/4 turn to release fluid into the waste line.

11. Gently close the bleeder screw.

12. After the bleeder screw is closed, have the assistant release the brake pedal and respond with “Released.”

13. Inspect the fluid in the waste line for bubbles.

14. Continue the process, with previous steps (#7 - #11) until air bubbles are no longer present.

15. Be sure to check if the master cylinder is full after each wheel is finished. Fill if necessary.

16. Move systematically toward the driver - right rear, left rear, right front, and driver side and repeat the bleeding process at each wheel.

17. Using brake cleaner, spray the bleeder screw and any other parts that have been moistened with brake fluid AFTER all four (4) wheelshave been bled.

18. Wipe the sprayed parts with a clean rag.

19. Test the brake pedal for a firm feel.

20. Inspect the bleeder screws and other fittings for signs of leakage.

21. Correct any loose fittings or bleeder screw.

22. Properly dispose of the used fluid.

3.4.4.2InspectBrakes1. Check brake pedal for sponginess or hard pedal.

2. Drive vehicle slowly and make several slow speed stops.

3. Check all brake fluid line fittings and caliper areas for fluid leakage.

4. Correct any discrepancies before returning vehicle to normal service.

NOTE: The brake pedal will “fall” to the floor as the bleeder screw is opened. Assistant should holdthe brake down until told to do otherwise.

NOTE: Only pull on the wrench with a little force. Usually a quick tug will be sufficient.

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3.4.5HydraulicValvePressureAdjustment

Adjust the hydraulic valves in the order listed.See 3.3.4.6 System Pressure Settings

Figure2-3-6:MainTwoLeverHydraulicControlValve

WARNING: ALWAYS REVIEW SAFETY PRECAUTIONS PRIOR TO PERFORMING WORK ONTHIS EQUIPMENT.

NOTE:All pressure checks and settings are to be made when the engine is at normal operatingtemperature at normal idle speed.

Main Two Lever Control Valve

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CD397-28Maint 2 - 3 - 9May 2019 (Rev C)


3.4.6SystemPressureSettings3.4.6.1GeneralInformation

1. Ensure the lock nut is released first before making any adjustments to pressures.

2. After setting the correct pressure, reset the lock nut.

3. After setting the lock nut ensure the pressure setting did not change.

4. Clean up any hydraulic fluid residues that occur.

WARNING:

FOLLOW SAFETY PRECAUTIONS AT ALL TIMES, WEAR SAFETY GLASSES,MAKE SURE NO LOOSE CLOTHING OR LONG HAIR CAN BE CAUGHT IN MOVINGMACHINERY.

ENSURE ALL ENGINE EMISSIONS ARE EXTRACTED AND NOT ALLOWED TOPOLLUTE THE WORK AREA.

NOTE:

Cleanliness is vital. Dirt contamination will cause field failure.

All pressure checks and settings are to be made when engine and hydraulic system are atnormal operating temperatures.

Always follow the sequence of adjusting valves in the order they are listed in this procedure.

Refer to the manifold drawing to identify which valve to adjust and where to fit the pressuregauge.

Table2-3-3:ToolsNeeded

Item Tool Description

1 Hex Key Sizes3/16 in. (4.76 mm)

5/64 in. (1.98 mm)

2 Combination Wrench Sizes

3/4 in. (19.05mm) or 3/4 in. (19.05 mm) deep well socket

9/16 in. (14.29 mm) or 9/16 in. (14.29 mm) deep well socket

3 Hydraulic Gauge Part number 660-2-2815

Two 0 - 3,000 psi (0 - 206.8 bar) fitted with 12 in.(30.48 cm) hose Prop

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3.4.6.2PressureSettingBefore making any adjustments,

1. Lower the conveyor into its lowest position

2. Ensure the hydraulic fluid tank is filled and the tank cap is in place.

Bring the hydraulic system to normal operating temperature by:

• Lowering the conveyor to its lowest position front and rear

• Running the conveyor belt with a high engine idle speed for 10 minutes.

PressureSettingProcedure:1. Remove the seat plate to access the hydraulic manifold. Refer to Figure 2-3-7 Hydraulic Manifold.

2. With engine OFF, install a 3,000 psi (206.8 bar) pressure gauge on the manifold at position G (refer to Figure 2-3-7 Hydraulic Manifold).

3. With engine OFF install a 3,000 psi (206.8 bar) pressure gauge on the manifold at position BB (refer to Figure 2-3-7 Hydraulic Manifold).

4. Start the engine and make sure no hydraulic fluid is leaking from the gauge fittings.

5. Set the Main Pressure Relief Valve by loosening lock nut 3B Main Pressure Relief Valve (refer to Figure 2-3-7 Hydraulic Manifold).

6. Raise the conveyor rear end and observe the pressure gauge.

7. Adjust the pressure using the 3/16 in. (4.76 mm) hex key to limit at 1,500 psi (103.4 bar) when the rear cylinder is fully extended.

NOTE:Retain the plugs and keep them clean as they will be re-installed at the end of the proce-dure.

NOTE: Clockwise increases pressure and counterclockwise decreases pressure.

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8. Tighten lock nut 3B and make sure the pressure setting remains at 1,500 psi (103.4 bar).

Figure2-3-7:HydraulicManifold

9. While raising the conveyor rear end, observe the pressure gauge and adjust the pressure using the hexagonal 5/16 in. (7.94 mm) key to limit pressure to 1,500 psi (103.4 bar) when the rear cyl-inder is fully extended.

10. Set the Front Cylinder Down Pressure Relief Valve by loosening the lock nut 3C (refer to Figure 2-3-7 Hydraulic Manifold).

11. While lowering the conveyor from the fully raised position, observe the pressure gauge and adjust the pressure to about 900 psi (62.05 bar) when the front cylinder is fully extended.

12. Tighten lock nut 3C and make sure the pressure setting remains at 900 psi (62.05 bar).

13. Set the Steering Pressure Relief Valve by loosening lock nut 3A (refer to Figure 2-3-7 Hydraulic Manifold).

14. While turning the steering wheel to the full turn left position and hold there, observe the pressure gauge and adjust the pressure to read 1,000 psi (69 bar).

15. Tighten lock nut 3A and make sure the pressure setting remains at 1,000 psi (69 bar).

16. Ensure pressure settings are set correctly.

17. Raise the rear conveyor end and the pressure should be 1,450 psi (99.97 bar) to 1,550 psi (106.9 bar).

18. Lower the front of the conveyor and the pressure should be 850 psi (58.6 bar) to 950 psi (65.5 bar).

NOTE:If the pressure is below 850 psi (58.6 bar) or above 950 psi (65.5 bar), then adjust the pres-sure using the 3/16 in. (4.76 mm) hex key so that it reads 900 psi (62.05 bar).

NOTE:If the pressure is below 950 psi (65.5 bar) or above 1,050 psi (72.4 bar), then adjust thepressure using the 3/16 in. (4.76 mm) hex key so that it reads 900 psi (62.05 bar).Prop

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19. Put the steering wheel full left or full right turn, hold it there and pressure should be from 950 psi (65.5 bar) to 1,050 psi (72.4 bar).

20. Turn off the engine, remove the pressure gauge, and replace the plugs where they were originally fitted.

21. Restart the engine and make sure no hydraulic fluid is weeping into the hydraulic fender.

22. Turn off the engine.

23. Replace the seat plate.

3.4.7ConveyorBeltTrackingInstructionsThis procedure provides instructions for aligning the conveyor belt to the center of the rollers.

Figure2-3-8:AdjustingConveyorTracking

3.4.8ConveyorBeltTrackingIntroductionBasics of conveyor belt alignments:

• Moving the rear idler roller using the jack screw to the rear on one side of the conveyor tightens that side of the belt causing the belt to move to the other side.

• Moving the rear idler roller using the jack screw to the front on one side loosens that side of the conveyor belt, causing it to move to that side.

• Moving a crowder roller end toward the large end roller will tighten that side of the conveyor belt forcing the belt to the other side of the end roller.

• Moving a crowder roller end toward the center of the conveyor will loosen that side of the conveyor belt allowing it to move to that side of the end roller.

NOTE: If any of the pressure settings are above or below the allowed pressure, then reset them andthen re-check all of the pressures.

WARNING: KEEP HANDS AND CLOTHING AWAY FROM ROLLERS WHILE CONVEYOR ISRUNNING.

REAR IDLER ROLLER ADJUSTERBELT

DRIVER ROLLER

FRONT CROWDER ADJUSTING ROLLER

REAR CROWDER ADJUSTING ROLLER

FRONT ENDOF CONVEYOR

REAR IDLER

REAR ENDOF CONVEYOR

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These conveyor alignment basics hold true for both ends of the conveyor.

3.4.9AdjustmentProcedureUse this procedure to align/adjust the conveyor belt.

1. Check the roller end bearings for failure.

2. Check the front driver and rear idler roller bearings and collar set screws.

3. Raise the front of the conveyor and make sure the front crowder roller is centered and that the bearing collar set screws are tight.

Figure2-3-9:SetScrewLocation

4. Make any necessary adjustments.

NOTE:

Adjust the front crowder roller only when the belt is running in the reverse direction. Adjustthe rear crowder roller only when the belt is running forward.

It is necessary to work from end to end when tracking a belt since adjustment at one end willaffect the other end.

When tracking, make small adjustments and allow the belt to run enough to settle betweenadjustments.

Normal time for an experienced mechanic to track a belt is 45 minutes to one hour.

NOTE: Refer to the safety chapter prior to any maintenance task. Observe all applicable precau-tions.

NOTE: There are two (2) set screws in a collar that positions each roller in the frame. Ensure therollers are centered and that the set screws are tight. If either roller is not centered, loosenthe set screws, pry the roller into position and re-tighten the set screws.

SET SCREWS(2) EACH

SET SCREWS(2) EACH

SET SCREWS(2) EACH SET SCREWS

(2) EACH

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5. Raise the rear of the conveyor and ensure the rear crowder roller is centered and the bearing col-lar is tight.

Figure2-3-10:RearCrowderRoller

6. Make any necessary adjustments.

REAR OF CONVEYOR

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7. Raise the front of the conveyor to approximately 4 ft (122 cm) high and the rear to about 3 ft. 6 in. (99.1 cm) high.

Figure2-3-11:FrontCrowderRoller

8. Position the front crowder roller in its adjusted slots as shown in Figure 2-3-11 Front Crowder Roller.

9. Position the rear crowder roller in its adjusting slots as shown in Figure 2-3-10 Rear Crowder Roller.

10. Adjust the rear idler roller at the jack screw nuts to tension the belt.

11. Adjust the rear idler roller so that it is equidistant from the rear end of the conveyor on both sides.

NOTE: Correct tension is achieved when 4 in. to 6 in. (10.16 cm to 15.24 cm) of the belt can berolled up at the center of the conveyor.

FRONT OF CONVEYOR

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2 - 3 - 16 CD397-28MaintMay 2019 (Rev C)


Figure2-3-12:IdlerAdjustment

12. With the belt running in the reverse direction, observe the position of the belt at the front of the conveyor and correct as follows:

a. To adjust belt in direction, move the left side (as viewed from rear) of the crowder rollertoward the front driver roller, both bolts, until the belt tracks on center. Move 1/8 in. (3.175mm) at a time.

b. To adjust the belt in the opposite direction, move the right side (as viewed from the rear) ofthe front crowder roller forward the front driver roller, both bolts, until the belt tracks oncenter. Move 1/8 in. (3.175 mm) at a time.

c. To adjust the belt in the direction shown in Figure 2-3-13 Conveyor Front End View, movethe right side (as viewed from the rear) of the front crowder roller toward the front driveroller, until the belt tracks on center. Move 1/8 in. (3.175 mm) at a time.

WARNING: KEEP HANDS AND CLOTHING AWAY FROM ROLLERS WHILE CONVEYOR ISRUNNING.

CAUTION: Stop the conveyor any time the left side front crowder roller is being adjusted.

ACCESS TO IDLERADJUSTMENT.(BOTH SIDES)

IDLER ROLLER ADJUSTMENT:GAP TO SAME DISTANCE ONBOTH SIDES.

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CD397-28Maint 2 - 3 - 17May 2019 (Rev C)


Figure2-3-13:ConveyorFrontEndView

d. To adjust the belt in the opposite direction, move the left side (as viewed from the rear) ofthe front crowder roller toward the front driver roller, until the belt tracks on center. Move1/8 in. (3.175 mm) at a time.

13. Continue to make adjustments until the belt runs at the center of the front roller.

14. Continue to run the conveyor in reverse while adjusting the rear jack screw nuts to center the belt on the rear idler roller.

15. Repeat previous steps until both ends of the belt are centered and running true, then shift the belt in the forward direction.

16. Adjust the rear crowder roller to center the belt on the rear idler roller.

17. When belt is running on center, reverse the belt direction and observe alignment.

18. Once belt is tracked, shut off motor and securely tighten all adjusting bolts.

NOTE: If the belt alignment is still satisfactory in reverse, shift belt direction back to forward. Thebelt should stay within 1/2 in.(12.7 mm) in both directions at both ends. If it does not, repeatsteps as often as necessary to track belt.

LEFT FRONT SIDEOF CONVEYOR

FRONT ENDOF CONVEYOR

ROTATION

CROWDERADJUSTMENT

THIS DIRECTION

ADJUST BELT

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2 - 3 - 18 CD397-28MaintMay 2019 (Rev C)


19. Adjust the finger guard at the rear of the conveyor by loosening the two fastener screws.

20. Slide the guard towards the crowder roller without touching the roller.

21. Secure the two fastener screws.

Figure2-3-14:BeltCentering-ConveyorRearEndView

ROTATION

LOOSEN LOCK NUT(WRENCH HANDLEDOWN TO LOOSEN)

ADJUST BELT

REAR ENDOF CONVEYOR

THIS DIRECTION

MOVE WRENCH HANDLEUP TO MOVE IDLERROLLER TO THE REARUNTIL BELT IS CENTERED.(TIGHTEN LOCK NUT WHENADJUSTMENT IS COMPLETE)

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CD397-28Maint 2 - 3 - 19May 2019 (Rev C)


3.4.10Toe-InAdjustmentThe toe-in adjustment must be performed on both the rear and front sides of tires. A level stretch ofpavement that is flat and smooth for at least 30 ft. (m) is required for this adjustment.

3.4.10.1FrontSideofTires1. Place the toe-in gauge in front of the front tires and between the outside edges of the tires.

2. Ensure that the gauge is placed halfway up the tire sidewall (aligned with center of wheel).

3. Observe the number the needle is pointing to on the gauge.

4. Loosen the tie rod sleeve nuts and adjust tie rod length as needed to achieve the #2 (1/ 8" or 3.175mm) toe-in.

5. Tighten the tie rod sleeve bolts once #2 (1/8" or 3.175mm) toe-in is achieved.

6. Set toe-in gauge to 0 (90°).

7. Repeat all the steps starting from rear side to the front side of tires.

3.4.10.2RearSideofTiresIn order to properly adjust the rear toe-in, perform the same steps as the front toe-in adjustment on therear tires.

3.4.11CabDoorAdjustment1. Loosen the bolds on the hinges.

2. Hold the door in desired position and secure by tightening the bolts.

3.4.12HeadlightAdjustment3.4.12.1Vertical

1. Loosen the nut on the horizontal bolt.

2. Aim headlight in desired direction.

3. Tighten the nut.

3.4.12.2Horizontal1. Loosen the nut on the vertical shaft that holds the entire headlight assembly to the rail.

2. Aim headlight in desired direction.

3. Tighten the nut.

NOTE:The needle should be pointing to #2 (1/8") on the toe-in side of the gauge. If it is, the toe-indoes not need any adjustment. If not, then continue to next step.

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CD397-28Maint 2 - 4 - 1May 2019 (Rev C)


Section4:TroubleshootingThe following troubleshooting tables provide information for diagnosis and correcting problems withMobile Belt Loader 660-28.

4.1EngineandTransmission

Table2-4-1:EngineandTransmissionTroubleshooting

No. Symptom PossibleCause PossibleCorrection

1 Engine will not start

Loose or corroded battery cables

Clean and tighten cable connections

Undercharged battery Charge or replace battery

Defective starter relay Replace starter relay

Loose or broken cable to starter Tighten or replace cables

Loose or open wiring through neutral switch Repair, adjust, or replace

Defective starter Repair or replace

E-Stop depressed Reset E-Stop

2 Engine will not start - Starter spins

Defective starter Remove starter, inspect for broken or worn drive

Defective flywheel ring gearInspect ring gear teeth.Replace flywheel and ring gear if necessary

3 Will not start in Neutral Defective Neutral safety switch Adjust or replace

4 Transmission cannot be shifted into or out of gear

Loose or disconnected cable end Tighten cable ends

Improper cable or lever adjustment Adjust cable or lever

Snow or ice obstructing movement Remove obstacle

Transmission controller not operating

Check fuses, replace if necessary

Disconnect transmission controller and verify pins are secure

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2 - 4 - 2 CD397-28MaintMay 2019 (Rev C)


4.2Brakes

5Excess binding transmission selector or hand throttle

Lack of lubrication Clean and lubricate

Foreign object or excessive dirt or corrosion in lever housing

Clean and lubricate

Kinked or mashed cable housing Repair or replace

Throttle or transmission linkage binding Inspect and repair

Table2-4-2:BrakesTroubleshooting


1 Excessive pedal travel or pedal goes to floor

Low brake fluid level Add fluid, bleed system, and check for leaks

Hydraulic system Check master cylinder

Drum brakes out of adjustment or worn Adjust or replace

Loose or improper attachment of pedal, pedal support booster, and/or master cylinder

Repair or replace

Misaligned anchor plate Repair misaligned disc brake anchor plate

2Brake pedal feels spongy when fully applied

Low brake fluid level Add brake fluid, bleed system, check for leaks

Brakes out of adjustment Adjust brakes

Front wheel bearing out of adjustment Adjust front wheel bearings

Disc brakes caliper attachment loose Replace or tighten

Worn or damaged self-adjusters Remove brake drum and check lining for proper adjustment

Table2-4-1:EngineandTransmissionTroubleshooting(Continued)


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CD397-28Maint 2 - 4 - 3May 2019 (Rev C)


4.3ParkBrake

3Noise at wheels when brakes are applied - squeaks or chatters

Worn or scored brake drums and lining or rotors and pads Inspect, repair, or replace

On disc brakes - missing or damaged brake pad insulators Repair disc brake pads

Burrs or rust on caliper that would obstruct seating of shoe to caliper Clean or deburr caliper

Dirty, greased, or glazed linings Clean or replace

4 Brakes pull to one side

Unequal air pressure in tires Inflate all tires to correct pressure

Grease or fluid on brake lining Clean, sand, and/or replace linings

Loose or missing disc brake caliper attaching bolts

Replace missing bolts and tighten to proper torque

Restricted brake lines or hoses Repair or replace

5 Brake warning light on

Low brake fluid level Add brake fluid, bleed system, and check for leaks

Worn or damaged brake warning switch Replace switch

Worn or damaged master cylinderPerform master cylinder diagnosis test. Repair or replace.

Table2-4-3:ParkBrakeTroubleshooting


1 Park brake will not hold

Park brake cable out of adjustment Adjust Park brake cable

Rear brakes out of adjustment Adjust rear brakes

Park brake linkage, release lever, clevis, and ratchet binding Repair or replace linkage

Table2-4-2:BrakesTroubleshooting(Continued)


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4.4Steering

2 Park brake will not release or fully return

Manual release brake control components binding or damaged

Repair or replace manual Park brake control

Park brake linkage and cable binding Repair or replace

Worn or damaged rear brake components

Check rear brake shoe retracting springs and Park brake levers. Repair

3 Park brake lever hard to pull up

Brake handle out of adjustment Adjust or repair

Frozen or damaged brake cable

Light taps with a mallet may free cable and brakes. If not, apply warm air from a ground equipment heater

Table2-4-4: SteeringTroubleshooting


1 Steering is difficult

Lack of lubrication on axle Lubricate

Low fluid in hydraulic reservoir Fill

Steering column bent or bearings are damaged

Check steering column. Replace if necessary

Low hydraulic pressure Adjust hydraulic pressure

Damaged CharLynn valve Replace

2 Front wheel appears to wobble

Loose/worn studs or king pins Tighten or replace

Worn or damaged bearings and/or hubs Repair or replace

Table2-4-3:ParkBrakeTroubleshooting(Continued)


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CD397-28Maint 2 - 4 - 5May 2019 (Rev C)


4.5Conveyor

4.6HydraulicSystemThe hydraulic system is comprised of the following components:

1. Conveyor Hydraulics

2. Hydraulic Steering

3. Hydraulic Braking

4.6.1ConveyorHydraulics

Table2-4-5:ConveyorTroubleshooting


1 All hydraulics not functioning

Low fluid level in reservoir Add fluid

Hydraulic line leaking or disconnected Replace or reconnect line

Pump inlet ball valve closed Open pump inlet ball valve

Faulty pump Replace hydraulic pump

Hydraulic pressure low Verify hydraulic pressure settings per the instructions in this manual

2

For CE Option: Conveyor lift/belt actuation not functioning

Check park brake switch Set or renew park brake switch

Check electrical connections Qualify electrical connections

Solenoid coil voltage Press switch and test for voltage. Replace solenoid coil if necessary

Table2-4-6:ConveyorHydraulicsTroubleshooting


1Front/Rear hydraulic cylinder has insufficient lifting or lowering force

Hydraulic line leaking or disconnected Replace or reconnect line

Incorrect relief valve Adjust setting

Slipping pump belt Replace pump belt or tensioner

Faulty pump Replace pump

Faulty cylinder Replace cylinder

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2

Front/Rear hydraulic cylinder has insufficient lifting or lowering speed

Hydraulic line leaking Check hydraulic connections. Tighten or replace


Blocked line Locate and clear or replace line or component



Faulty holding valve Replace holding valve

3 Front/rear cylinder will not move

Low fluid level in reservoir Add fluid to reservoir

Hydraulic line leaking Check hydraulic connections. Tighten or replace


Blocked line Locate and clear or replace line or component



Faulty holding valve Replace holding valve

4 Noise when front/rear cylinder raised/lowered

Cavitation/aeration of pump Low fluid level - add fluid

Relief valve setting Adjust relief valve according to procedure

Pump slipping Replace pump belt and/or tensioner


5 Cylinders drift down when no valve action

Internal cylinder leak Repair or replace cylinder

Faulty holding valve Repair or replace holding valve

Table2-4-6:ConveyorHydraulicsTroubleshooting(Continued)


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CD397-28Maint 2 - 4 - 7May 2019 (Rev C)


6Conveyor has insufficient forward/reverse speed


Blockage Locate and clear or replace line or component

Slipping conveyor belt Adjust belt tension or replace belt


Faulty conveyor motor Replace conveyor motor

Counterbalance valve setting off

Adjust counterbalance valve setting

Incorrect relief valve adjustment Adjust relief valve setting

7

Conveyor has insufficient forward/reverse load carrying capability


Slipping conveyor belt Adjust belt tensioner or replace belt if worn

Faulty hydraulic pump Replace hydraulic pump

Faulty conveyor motor Replace conveyor motor

8Conveyor fails to move when forward/reverse button(s) pressed

Electrical connection at control box or control solenoid

Check electrical connections at control box, control relays, control solenoid.

Sticking solenoid valveMake sure solenoid valve operates freely. If necessary, dislodge control valve manually

Faulty coil or solenoid on control valve

If signal is received at solenoid connections and still no valve actuation, replace control valve

9Conveyor fails to come to a stop when stop button(s) are pressed

Bad electrical connection at control box or control solenoid

Check electrical connections at control box, control relays, control solenoid.

Sticking solenoid valveMake sure solenoid valve operates freely. If necessary, dislodge control valve manually.

Faulty coil or solenoid on control valve

If signal is received at solenoid connections and still no valve actuation, replace control valve.



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2 - 4 - 8 CD397-28MaintMay 2019 (Rev C)


4.6.2HydraulicSteering

10Conveyor drifts when loaded but not in motion

Hydraulic line leaking Locate and repair leak points.

Counterbalance valve not set Adjust counterbalance valve

Conveyor motor internal leakage Replace conveyor motor

11 Noise when conveyor is set in motion

Incorrect relief valve setting Adjust relief valve

Slipping conveyor belt Adjust or replace conveyor belt

Cavitating conveyor motor Check fluid level

Table2-4-7:HydraulicSteeringTroubleshooting


1 Steering effort too high

Incorrect relief setting Adjust relief setting

Incorrect flow divider setting Adjust flow divider setting

Faulty steer cylinder Repair or replace steer cylinder

Faulty steering valve Repair or replace steering valve

2 Steering effort too high in one direction only


Faulty steering valve Repair or replace steer valve

3 Steering makes noise

Steer system leakage Locate and repair source of leakage

Low fluid level in reservoir Add fluid

Incorrect relief setting Adjust relief setting

Incorrect flow divider Adjust flow divider setting



4

Steering will not actuate quickly enough for emergency maneuvers

Steer system leakage Locate and repair source of leakage

Incorrect flow divider setting Adjust flow divider setting






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CD397-28Maint 2 - 4 - 9May 2019 (Rev C)


4.6.3HydraulicBraking

4.7Electrical

5 Slow response Internal cylinder leak Repair of replace cylinder

6 Tight spot in steeringFaulty steer cylinder Repair or replace steer cylinder


7 System steers on its own Faulty steering valve Repair or replace steer valve

Table2-4-8:HydraulicBrakingTroubleshooting

No. Symptom PossibleCauses PossibleCorrections

1 Braking system force insufficient

Improperly bleed brake Properly bleed brake system

Improper relief setting Re-set relief setting

Faulty brake assist valve Repair or replace brake assist valve

2 Braking system dragging or locked

Blocked brake booster return line Locate and clear or replace line

3 Hard pedal Blocked brake booster return line Locate and clear or replace line

4 Pedal does not retract Blocked brake booster return line Locate and clear or replace line

Table2-4-9:ElectricalTroubleshooting


1Battery does not stay charged - engine starts OK

Worn or damaged battery Test battery, replace if necessary

Loose or worn alternator belt Adjust or replace belt

Worn or damaged wiring or cables Clean, repair as necessary

Defective alternator or regulator

Perform general charging system test. Repair or replace as necessary

Other vehicle electrical system malfunction

Check other systems for current draw. Repair as necessary

Table2-4-7:HydraulicSteeringTroubleshooting(Continued)


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2 - 4 - 10 CD397-28MaintMay 2019 (Rev C)



2 Alternator noisy


Bent pulley flanges Replace pulley

Defective alternator Perform alternator tests. Replace as necessary

3Charge indicator gauge shows steady charge

Worn or damaged battery Check battery. Replace as necessary

Poor regulator ground Make sure regulator is properly grounded

Loose wiring connection Tighten all wiring connections


Perform general charging systems test. Repair or replace as necessary

4Charge indicator gauge shows discharge


Worn or damaged wiringCheck battery-to-alternator wiring for ground or open. Repair as necessary


Perform general charging systems test. Repair or replace as necessary

Defective charge indicator gauge wiring and connections

Repair as necessary

Worn or damaged gauge Replace gauge

Other vehicle electrical system malfunction Check and repair as necessary

Table2-4-9:ElectricalTroubleshooting(Continued)


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Section5:ElectricalandHydraulicLayoutsThis section contains electrical schematics, wiring diagrams, and hydraulic system schematics for the Mobile Belt Loader 660-28. These schematics will assist maintenance personnel in maintaining and troubleshooting this unit.

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2 - 5 - 2 CD397-28MaintMay 2019 (Rev C)


5.1ElectricalLayouts

Figure2-5-1:MobileBeltLoader660-28(WRG-660-STD-28-109_B)WiringSchematic1of5

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CD397-28Maint 2 - 5 - 5May 2019 (Rev C)



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CD397-28Maint 2 - 5 - 7May 2019 (Rev C)


Figure2-5-6:PowerstowBeltLoader660-28(WRG-660-28-182_6-PST36A)WiringSchematic1of6

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CD397-28Maint 2 - 5 - 9May 2019 (Rev C)



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CD397-28Maint 2 - 5 - 11May 2019 (Rev C)



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Figure2-5-12:MobileBeltLoader660-28(WRG-660-110)WiringHallControls

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Introduction - 5 - 14 CD397-28Maint

Mobile Belt Loader Model 660-28 2Maintenance Manual Section 5

5.2HydraulicLayouts

Figure2-5-13:MobileBeltLoader660-28(HYD-660-HSC_E)HydraulicSchematic1of4

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Introduction - 5 - 16 CD397-28Maint

Mobile Belt Loader Model 660-28 2Maintenance Manual Section 5


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CD397-28Maint 2 - 5 - 17May 2019 (Rev C)



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2 - 5 - 18 CD397-28MaintMay 2019 (Rev C)



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660 BeltLoader Maint - Amazon Web Services...CD397-28Maint 2 - 1 - 5 May 2019 (Rev C) Chapter 2...

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Transcript of 660 BeltLoader Maint - Amazon Web Services...CD397-28Maint 2 - 1 - 5 May 2019 (Rev C) Chapter 2...