Model Year 2005 ROGATOR 418 CATERPILLAR 3056E ENGINE - HYDROSTATIC DRIVE OPERATOR'S MANUAL P/N A

Model Year 2005

R ^O G ^ATOR 418

C ATERPILLAR 3056E E NGINE - H YDROSTATIC D RIVE

O ^PERATOR ' ^S M ^ANUAL

P/N 611871-A

Safety is Your Responsibility

READ AND UNDERSTAND THIS MANUAL BEFORE OPERATING THIS VEHICLE OR ANY OF ITS CONNECTED SYSTEMS.THIS ALSO APPLIES FOR ALL FURTHER MANUALS DELIVERED WITH THIS VEHICLE.

Please contact your Ag-Chem Europe BV Service Centre if the information contained in this manual is not complete or partially incomprehensible or if you have any questions.

Ag-Chem Europe BV cares about safety. This vehicle and its connected systems are designed to provide the maximum possible safety. However, no machine design can prevent operator error or care- lessness.

This operator's manual provides instructions for the safe operation of this vehicle.

Make sure that the vehicle, connected systems and components are in a good condition.

Check the Maintenance Schedule in this manual before operation.

Definition of safety symbols and instructions:

All safety instructions are preceded by the warning symbol.

Carefully read and follow the instructions beside the symbols:

DANGER

!

WARNING

!

CAUTION

!

IMPORTANT: Important instructions to prevent damage to the vehicle , systems and components. This also identifies in- formation worthy of special attention

NOTE: General information about the correct

Notice:

Information, illustrations and specifications in this manual are based on the latest informa- tion available at the time of publication. All rights are reserved to make changes at any time without notice.

Some illustrations may show optional equip- ment. Illustrations may show shields, guards, etc. open or removed for illustration purposes only. All shields, guards, etc. must be in place during operation of this vehicle and systems.

Copyright © 2005

Ag-Chem Europe BV

Horsterweg 66a

5971 NG Grubbenvorst

Netherlands

Tel. (0031)-77-3278400

ii

WARNING

Please note the following:

• Always start and operate the engine in a well-ventilated area.

• Never operate the vehicle’s engine inside a building unless adequate ventilation is pro- vided to safely and properly remove the exhaust fumes.

• NEVER modify or tamper with the exhaust system in any way.

If there are any questions about this manual, don’t take

any risks. Please contact Ag-Chem Europe BV.

SAFETY... 01

Follow Safety Instructions ...01.1 Preparation for Emergencies ...01.1 Emergency Exit from Cabin ...01.1 Safe Operation of the Vehicle ...01.2 Prevent Vehicle Runaway ...01.2 Use of Safety Lights and Safety Devices ...01.3 Operating on Slopes ...01.3 Travelling on Public Roads ...01.3 Stopping and Parking the Vehicle ...01.4 System Boom Safety ...01.4 Avoid Eye Contact with Radar ...01.4 Exhaust Gases ...01.4 Overhead Electrical Power Lines ...01.5 Noise ...01.5 Safe Handling of Fuel - Avoid Fires ...01.5 Stay Clear of Rotating Power Takeoffs and

Moving Parts ...01.6 Towing Other Vehicles ...01.6 Modifications ...01.6 Safety Treads and Grips ...01.6 Chemical Safety...01.7 Maintenance and Service Safety ...01.8 Practice Safe Maintenance ...01.8 Wear Protective Clothing ...01.8 Clean Working Area...01.9 Proper Servicing...01.9 Use of Proper Tools ...01.9 Proper Support of Vehicle ...01.9 Proper Lifting Equipment ...01.9 High-Pressure Fluids ...01.10 Hydraulic Hoses...01.10 Avoid Great Heat Near Pressurized Fluid Lines....01.10 Safe Servicing of Cooling System...01.10 Removal of Paint before Welding or Heating ...01.11 Batteries...01.11 Tyres and Wheels ...01.11 Dispose of Waste Properly...01.12 Mobile Radio Installations ...01.12 Location of Safety and Service Decals Chassis ....01.13 Location of Safety and Service Decals Cabin ...01.15

INTRODUCTION... 02

Before Operating the RoGator 418 ...02.1 Identification...02.2 Serial Number Identification Plates...02.2 Engine Serial Number...02.2 Hydrostatic Drive ...02.3 Traction Control Lever, Pump and Wheel Motors...02.3 Engine...02.3 Low -pressure Pump...02.3 Cooler ...02.3 Tank and Filter...02.3 Break -in Period ...02.4 First 100 Hours of Operation...02.4 Hydraulic System...02.4 Engine Coolant Level...02.4 Wheel Mounting Bolts ...02.4 Maintenance Schedule ...02.4 Chassis and Cab Modifications ...02.4

RoGator towing Procedure ...02.5 Transport...02.5 Mobile Radio... 02.5 Location of Components...02.6

CONTROLS ... ... 03

Operation ...03.1 Turn Signal, Lights and Horn Lever...03.1 Adjustment of the steering wheel ...03.1 Accelerator Pedal...03.1 Traction Control Lever...03.2 Positions of the Traction Control Lever...03.2 (1) Neutral...03.2 (2) Driving Forwards ...03.2 Field Position...03.2 Road Position...03.2 (3) Reversing ...03.2 Field Position...03.2 Road Position...03.2 Adjustment of the Traction Control Lever Position ... 03.3 Brakes (Option) ...03.4 Brake/Inching Pedal...03.4 Parking Brake...03.4 Turning the Controller On and Off...03.4 Engine Speed Governing ...03.4 Engine RPM On/Off switch...03.4 Engine RPM switch...03.4 From inside the cab...03.4 From the remote switch box ... 03.4 Instrument Panel ...03.5 Ignition Switch ...03.6 Suspension ... 03.6 Automatic suspension switch... 03.6 Manual suspension switch ...03.6 Driving in the Field or on the Road...03.6 4-Wheel steering...03.6 4-Wheel steering switch...03.6 4-Wheel steering foot switch... 03.6 Switching the spray computer On/Off ...03.7 Remote Throttle Control ...03.7 Electronic Governing On / Off Switch...03.7 Engine speed switch...03.7 Spraypump On / Of f ...03.7 Res 1 / Res 2...03.7 Control Buttons on Traction Control Lever ...03.7 Master Switch...03.7 Fast Speed Range Switch...03.7 Slow Speed Range Switch...03.7 Lighting and door handling of the cab ...03.8 Door Latch... 03.8 Sun Visor ... 03.8 Cabin light switch...03.8 Seat...03.9 Location of seat controls ...03.9 1 Weight adjustment...03.9 2 Height adjustment ...03.9 3 Fore / aft isolator ...03.9 4 Fore / aft adjustment ...03.9 5 Seat pan angle adjustment... 03.9 6 Seat depth adjustment...03.9

TABLE OF CONTENTS

II

RoGator 418

9 Armrest...03.9 10 Armrest adjustment ...03.9 11 Backrest adjustment...03.9 12 Swivel...03.9 13 absorber ...03.9 External Lighting and Temperature Control Panel in the Cabin ...03.10

Work Light Switch One...03.10 Work Light Switch Two...03.10 Work Light Switch Three...03.10 Work Light Switch Four...03.10 Hazard Warning Light Switch

(Orange Flashing Warning Lights)...03.10 Beacon Light Switch - Option...03.10 Stop lamp ...03.10 Warning / cold start lamp ...03.10 Automatic suspension switch ...03.10 Manual suspension switch...03.10 Temperature Control Knob...03.10 Air Conditioner / Heater Switch...03.10 Blower Speed Switch ...03.10

INSTRUMENT PANEL... 04

Instrument panel dashboard...04.1 Speedometer ...04.2 Fuel level gauge...04.2 Battery voltage gauge ...04.2 High beam ON indicator light...04.2 Parking brake warning light...04.2 Left turn signal light ...04.2 Right turn signal light...04.2 Suction / return line filter and leak oil filter

indicator light...04.2 Boost pressure indicator light...04.2 Hydraulic oil level indicator light...04.2 Oil temperature indicator light ...04.2 Transmission neutral indicator light...04.2 Transmission in first gear indicator light...04.2 Transmission in second gear indicator light ...04.2 Transmission in third gear indicator light ...04.2 All-steer mode indicator light ...04.2 Two-wheel-steer mode indicator light...04.2 Front axle in middle position indicator light...04.2 Rear axle in middle position indicator light...04.2 Reset button speedometer ...04.2 General description GEM ...04.3 Getting started...04.3 General ...04.4 Setting display contrast and lighting ...04.4 Using the soft keys...04.4 The main engine display ...04.4 Engine hours...04.4 Trip engine hours...04.4 The quad display ...04.5 The graph display ...04.6 The quad and graph parameters...04.6 The alarm display screen ...04.7 Pop-up messages and warnings ...04.7 Configuration ...04.8

OPERATION ... 05

Before Starting the Vehicle Engine...05.1

Starting the Engine ...05.2 Restarting a Stalled Engine...05.2 Starting at Low Temperatures ... 05.2 Hydraulic System – Operation at Low Temperatures05.2 Driving the RoGator...05.3

Driving the RoGator with the “Field / Road” Switch in the “Road” Position...05.3 Driving the RoGator with the “Field / Road” Switch in the “Field” Position...05.3 Economic Driving...05.3 Speed Ranges:...05.3 4-Wheel Steering...05.4 Operation... 05.4 Switch for 4-Wheel Steering... 05.4 Automatic ... 05.4 Manual...05.4 4-Wheel Steering Off ...05.4 Driving on Public Roads...05.4 Turning Machine Off with Rear Wheels Steered ... 05.4 Front Axle Suspension ( Option )...05.5 Automatic Position...05.5 Manual Position...05.5 Hydraulic Skid Regulator (option) ...05.5 Switching the skid regulator On/Off ...05.5 Automatic Adjustment of the Track Width ( Option )05.6

Sliding the Axle...05.6 Setting the Track Width ...05.6 Track width 1,50 - 2,00 m (Front axle)...05.7 Track width 1,80 - 2,25 m (Front axle)...05.7 Track width 2,00 - 2,25 m (Front axle)...05.8 Maintenance of the sliding axle... 05.8 Separ ate Ladder...05.9 Motor Platform...05.9 Diesel filling point ...05.9 Remote Throttle Control ...05.9 Electronic Gpverning On / Off Switch...05.9 Engine Speed Switch...05.9 Spraypump On / Off...05.9 Res 1/ Res 2...05.9 Travelling on Public Roads ...05.9

MAINTENANCE ... 06

Maintenance Introduction ...06.1 Lubricants and Fluids ...06.1 Lubricant Filling Reminders...06.1 Maintenance Symbols...06.2 Maintenance Schedule...06.3 Compressed Air System Maintenance ...06.5 Compressed Air System ...06.5 Air Conditioner ...06.5 Engine ...06.5 Checking the Oil Level ...06.5 Changing the Engine Oil and Oil Filter...06.5 Engine Belts...06.6 Engine Coolant...06.6 Supplemental Coolant Additives (SCA’s) ...06.6 Air Cleaner Maintenance ...06.7 Primary Filter Element...06.7 Inner Filter Element ...06.8 Fuel...06.8 Fuel Tank ... 06.8 Fuel Storage...06.8 Fuel Filter... 06.8

Priming of the Fuel System ...06.9 Tyre Maintenance ...06.10

Tyre Mounting...06.10 Tyre Pressure Chart...06.11 Wheel Maintenance ...06.11 Removing the Wheels...06.11 Installing the Wheels ...06.11 Cab Air filter ...06.12 Anti carbide filter ...06.12 Cab Mounting Bolts ...06.12 Windshield Wiper Blade ...06.12 Windshield Washer Reservoir ...06.12 Hydraulic (Hydrostatic) System ...06.13

Replacing Hydraulic Fluid and Filters

in Hydraulic System...06.13 Replacing the Suction and Return Line Filter...06.13 Replacing the Leakage Oil Filter...06.13 Heat Exchanger ...06.14 Electrical System...06.14 Electrical System Safety...06.14 Batteries ...06.14 Fuse Panel...06.15 Jump Starting...06.16 Storage of Vehicle ...06.16 Before Operating the Vehicle after a Long Storage.06.16 Cab Seat Preventative Maintenance ...06.17 Lubricate Adjusters Twice a Year...06.17 Armrest Mechanism...06.17 Paint and Decals...06.17 Safety Treads ...06.17 Maintenance Parts RG618 ...06.17

COLD WEATHER OPERATION ... 07

Minimising the effect of cold weather...07.1 Seasonal viscosity Oil and Proper

coolant concentration...07.1 Idling the engine ...07.1 Engine coolant specification...07.1 Water quality...07.1 Ethylene glycol concentrate...07.1 Supplement coolant additives (SCA's) ...07.1 Diesel Engine Oil recommendations...07.2 Mixing of lubricants...07.2 Grease...07.2 Diesel fuel...07.3 Diesel fuel storage...07.3

LONG TERM STORAGE ... 08

Long Term Storage Preparation ...08.1 Long Term Storage Removal ...08.1

TROUBLESHOOTING... 09

Engine ...9.1 Electrical System...9.2 Hydraulic System...9.3 Brakes ...9.3 Steering...9.3

SPECIFIACTIONS ... 10

Chassis Specifications ...10.1 Engine...10.1 Traction Pump...10.1 Wheel Motors...10.1 Service Brake (Option)...10.1 Parking Brake...10.1 Steering... 10.1 Frame ...10.1 Air Cleaner ... 10.1 Exhaust ... 10.1 Fuel Tank ... 10.1 Electrical System...10.1 Hydraulic System...10.1 Compressed Air System...10.1 Cab...10.1 Turning Radius ...10.1 Tyres ...10.1 Ground Clearnance...10.1 Speed Ranges...10.1 Options... 10.2 Chassis Weights ...10.2 Dimensions ... 10.2

INDEX... INDEX

SAFETY

01.1

11-04 RoGator 418

IMPORTANT: Tampering with the engine is against the law. Any modifications on the vehicle or its sys- tems not authorised by Ag-Chem Europe BV can cre- ate a safety hazard and void the warranty.

This also includes self-repair of malfunctions

Follow Safety Instructions

Never operate the vehicle and/or equipment without proper instruction and/or a complete understanding of control operation!

Carefully read, learn and understand all safety messages and i nformation in this manual and on the vehicle’s safety signs. Keep safety signs in good condition. Replace miss- ing or damaged safety signs. Make sure new equipment components and repair parts i nclude the current safety signs. Replacement safety signs are available from your Ag-Chem Europe BV.

Learn how to operate the vehicle and how to use all con- trols properly BEFORE OPERATION. Do not let anyone operate the vehicle, systems or perform service and maintenance procedures without the proper instruction.

Keep the vehicle, all components and systems in the proper wo rking condition. Modifications unauthorized by Ag-Chem Europe BV to the vehicle may impair the func- tion and/or safety, affects vehicle life, and can void the vehicle warranty.

Preparation for Emergencies

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

In cases of emergency dial 112 or your own national emergency number.

Keep emergency numbers for doctors, ambulance ser- vice, hospital and fire department readily available at all times.

Emergency Exit from Cabin

Familiarise yo urself with the use of the emergency exit at the right-hand side of the cab before operating the

vehicle.

Pull the green tab at the rear right-hand cab window to remove the glass seal.

Push the right-hand window out and exit the vehicle

through this opening.

Safe Operation of the Vehicle

• Wear a seat belt at all times if national law requires.

• Make sure all wheel bolts are torqued to the proper specifications before operating the vehicle.

• Make sure the operator and ladder areas are clean and dry to help prevent personal injuries.

• Warn all personnel in the area before operating the vehicle. Sound the horn before starting the engine.

• Never permit any passengers on or into the vehicle when it is in operation.

• Brake the vehicle firmly and place the Drive Lever in the NEUTRAL position before starting the engine.

• If a malfunction occurs, first turn off the engine and engage the parking brake before starting to

troubleshoot.

• Stop the vehicle immediately if there is a failure in the engine, hydraulic system, or any vehicle system. Do not turn the key switch to the OFF position until the vehicle is stopped and the vehicle is shut down properly.

• Never carry more than the recommended load capacity of the vehicle.

• Never get off a moving vehicle.

• When leaving the vehicle unattended, engage the parking brake and remove the key.

• If you wish to dismount, first lower the ladder, by engaging the parking brake, before shutting off the engine.

• If the machine is turning over, hold the steering wheel and wait until the machine has come to rest. If the left door is obstructed use the emergency exit.

Prevent Vehicle Runaway

Avoid possible injury or death from vehicle runaway.

Never start the engine by shorting across the starter terminals. The engine will start, and the vehicle can move if normal starting circuitry is bypassed.

Never start the engine while standing on the ground.

Start the e ngine only from the operator’s seat with the

seat belt applied, drive lever in the neutral position and

the parking brake e ngaged.

SAFETY

01.3

11-04 RoGator 418

Use of Safety Lights and Safety Devices

Slow moving vehicles can create a hazard when travelling on public roads. Slow moving vehicles and vehicles without lights are difficult to see, especially at night. Avoid possible personal injury or death from a collision with another vehicle.

To increase visibility, use the safety lights and devices provided with the vehicle. Amber rotating beacon are recommended whenever driving on public roads. Keep safety items and features in the proper working order.

Replace any missing or damaged components immediately.

Operation on Slopes

Keep the vehicle in a safe speed when going down slopes. Avoid holes, ditches and obstructions that may cause vehicle roll-over, especially on hillsides. Avoid sharp turns on hills.

When driving parallel on steep slopes beware that the vehicle doesn’t roll-over.

Never drive near the edge of a gully or steep embankment.

Travelling on Public Roads

ALWAYS walk around and visually inspect the vehicle before travelling on public roads. Check for damage and/or faulty components that can fail and create a hazard or unsafe condition. Make sure ALL vehicle systems operate properly including, but not limited to:

front road lights, tail and brake lights, hazard warning lights, safety lights, parking brake, horn, windshield wiper and washer, and rear-view mirrors. Repair or replace any component that is not in proper working order.

Never drive at a speed that causes the vehicle to bounce or cause the loss of control.

Obey all traffic law. Operate the vehicle with the rotating

beacon lights ON, unless prohibited by law. It is the

operator’s responsibility to activate and use the road

lights when travelling on public roads.

Stopping and Parking the Vehicle

Vehicle roll-over, collisions, runaway vehicles, and people being crushed under vehicles can occur when the

vehicle’s operator ignores operation safety procedures.

Signal before stopping, turning or slowing down on public roads, or anywhere it will cause a potential safety hazard.

Pull over to the side of the road before stopping the vehicle.

Be extremely careful when stopping the vehicle on slippery surfaces.

Be extremely careful when towing or stopping with heavy loads.

Always engage the Parking Brake when the vehicle is stopped.

Remove the key to prevent any unauthorized personnel from operating the vehicle.

System Boom Safety

If you have a system with booms, make sure no personnel or objects are ever in the path of the booms before operating them, especially when folding or unfolding them.

Be aware of the location of the booms at all times.

Before driving on public roads fold and lock the booms in transport position.

Avoid Eye Contact with Radar

Radar ground sensors emit a low intensity microwave signal. The microwave signal will not cause any ill effects during normal use. Although the intensity is low, to avoid eye damage, never look directly into the sensor while the sensor is in operation.

Exhaust Fumes

Always work in a properly ventilated area.

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, use the proper equipment to safely remove the exhaust fumes from the working area.

Always open the doors and get fresh outside air into the working area.

Never operate the engine inside a building unless

adequate ventilation is provided to safely and fully

remove the exhaust fumes.

SAFETY

01.5

11-04 RoGator 418

Overhead Electric Power Lines

Never let the vehicle come into contact with overhead power lines. The antenna’s must be turned over and se- cured in place any time overhead electrical power lines are near the vehicle. This can decrease the possibility that the vehicle may come into contact with an overhead power line when in operation or when the vehicle is transported.

Noise

Long periods of exposure to high decibels or loud noise can cause hearing impairment or even loss of hearing.

Wear proper hearing protection during periods of exposure to high decibels or loud noise.

Safe Handling of Fuel – Avoid Fires

Handle fuel with care: it is highly flammable.

Always stop the engine before refuelling the vehicle.

Never refuel the vehicle while smoking.

Add fuel in a safe place, away from open flame or sparks.

Fill the fuel tank only outdoors.

Never fill the fuel tank completely to the top of the fuel tank.

Clean up any spilled fuel immediately.

Never use diesel fuel, kerosene, gasoline or any

flammable solvents for cleaning. NEVER use flammable solvents for cleaning anything.

Prevent fire hazards by keeping the vehicle clean of any accumulated trash, grease and debris.

Always have a multipurpose dry chemical fire

extinguisher filled and available during vehicle operation

and adding fuel. Know how to use it.

Stay Clear of Rotating Power Takeoffs and Moving Parts

Entanglement in rotating power takeoffs or moving components will cause serious injury or death.

Keep all safety guards and shields in place at all times when operating the vehicle.

Turn the key switch to the OFF position. Remove the key from the switch to prevent unauthorized operation of the vehicle before removing any safety guards and shields.

Wear close fitting clothing. Stop the engine and make sure the power takeoffs are stopped before making any adjustments or performing any type of service on the e n- gine or vehicle.

Towing Other Vehicles

Towing of other vehicles without brakes is NOT approved by Ag-Chem Europe b.v.

Modifications

Welding or altering the chassis in any way can cause damage or failure of components and create a safety hazard. Modifications not approved by Ag-Chem Europe b.v. can also void the vehicle or system warranty.

Safety Treads and Grips

Replace worn, damaged or missing safety treads, hand

rails and steps.

SAFETY

01.7

11-04 RoGator 418

Chemical Safety

The cab filter MAY NOT filter out hazardous

chemicals/vapours. Read, understand and follow all instructions and safety precautions the chemical manufacturer recommends.

Never spray hazardous chemicals when the wind is in excess of the chemical manufacturer’s recommendation.

NEVER allow chemicals to contact the skin or eyes.

Always wear APPROVED protective equipment and clothing.

Before leaving the cab, wear personal protective

equipment as required by pesticide use instructions and the chemical manufacturer recommendations. When re- entering the cab, remove protective equipment and store;

either outside the cab in a closed box or another type of sealable container. Inside the cab, use a pesticide resistant container such as a plastic bag or approved container. Clean shoes or boots to remove soil or other contaminated pesticides prior to entering the cab.

Select a safe area to fill, flush, calibrate and decontaminate the vehicle. Select an area where hazardous chemicals will not drift or run off to

contaminate people, animals, vegetation, water supply, etc.

If hazardous chemicals come in contact with the body, wash immediately according to the chemical

manufacturer’s recommendations.

Never place no zzles, tips or other parts to lips to blow out trash or debris. Have spare tips available for

replacement.

Clean the vehicle of hazardous chemicals after use.

Hazardous chemical residue can build up on the inside and outside of the vehicle.

Direct exposure to hazardous chemicals can cause serious injury or death. Potentially hazardous chemicals used with Ag-Chem Europe b.v. equipment include such items as fuel, lubricants, coolants, hydraulic fluid, paints and adhesives.

The Material Safety Data Sheet (MSDS) provides specific details on hazardous chemical products: physical and health hazards, safety procedures and emergency response techniques.

Check the MSDS before starting any project using a hazardous chemical. Know exactly what the risks are and how to do the project safely. Follow procedures and equipment recommendations.

(Contact the chemical manufacturer for Material Safety

Data Sheets on chemical products used with Ag-Chem

Europe b.v. equipment.)

Maintenance and Service Safety

Read the maintenance and safety instructions and understand them before performing any maintenance procedures.

Never perform any maintenance procedures or repairs if the instructions and safety procedures are not fully understood. Only trained and qualified personnel should perform any maintenance procedures or repairs.

Never modify any equipment or add attachments not ap- proved by Ag-Chem Europe b.v.

Practice Safe Maintenance

Never lubricate, service, or adjust the vehicle, any of its systems or components while they are moving.

Never wear a necktie, necklace, scarf or loose clothing when working near machine tools or moving parts.

Tie long hair behind the head and wear a hair net.

Remove rings and other jewellery to prevent electrical shorts or other personal injury when in contact with machine tools or moving parts.

Stop the engine, remove the key, and allow the vehicle to cool.

Keep all parts in good condition and properly installed.

Fix any damaged vehicle, systems or component immediately.

Replace worn, damaged or broken parts immediately.

Remove any accumulation of grease, oil or debris and discard it properly.

Disconnect the electrical system before making adjustments on electrical systems or welding on the vehicle.

Wear Protective Clothing

Wear close-fitting clothes and the proper safety equipment required for the job.

Wear a suitable hearing protection device such as ear protectors or ear plugs to protect against objectionable or uncomfortable noise.

Prolonged exposure to high decibels or loud noise can cause hearing impairment or loss of hearing.

The safe operation of the equipment requires the full

attention of the operator. Never wear headphones to

listen to the radio or music while operating the vehicle.

SAFETY

01.9

11-04 RoGator 418

Clean Working Area

Thoroughly clean the working area, the vehicle, systems, and components before starting a job. Dirty and greasy areas can create a work hazard.

Proper Servicing

Light your working area properly, adequately and safely.

Use proper safety lights with wire safety cages. Naked lights can ignite fluids.

Catch any drained fluids in proper containers.

Never use beverage containers that could mislead personnel to drink from them.

Use of Proper Tools

Make-shift tools and procedures can create safety

hazards. Use only the proper equipment and procedures.

Use power tools only to loosen threaded parts and fasteners, not to tighten the treaded parts.

Use only imperial tools with imperial fasteners and metric tools with metric fasteners.

Proper Support of Vehicle

Never support the vehicle on aerated cement blocks, hollow tiles or supports that can bend or crumble.

Never work under a vehicle that is only supported by a jack. Use axle stands and wheel chocks.

Proper Lifting Equipment

Incorrect lifting can cause severe injury or vehicle damage.

Follow the procedures recommended in the appropriate manual for removal and installation of vehicular

components, systems or assemblies.

High-Pressure Fluids

AVOID CONTACT WITH HIGH-PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin and cause serious injury.

The vehicle must be stopped and cooled before checking fluids. Use caution when removing radiator caps, plugs, grease fittings or pressure taps or fittings.

Never open pressure lines when they are under pressure.

Release all pressure before doing maintenance or repairs on any pressure system.

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of wood or cardboard. Protect hands and body from high pressure fluids. Do not use your hands!

Never open hydraulic lines or fuel lines when they are under pressure. Hydraulic fluid or diesel fuel under

pressure can cut the skin, cause severe burns, eye injury or skin irritation.

If an accident does occur, get medical help immediately if any personnel are injured by hydraulic fluid or fuel.

Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

Doctors unfamiliar with this type of injur y should reference a knowledgeable medical source.

Hydraulic Hoses

Important: Hydraulic hoses have a long working live. By weather influences and use under heavy conditions and normal aging the working live will reduce.

There for is checking of hydraulic hoses by damaging and aging important for good functioning of your machine and the safety of the user and the environment.

Replace immediately damaged and leaking hydraulic hoses.

Avoid Great Heat near Pressurised Fluid Lines

Never create a source of heat by welding, soldering or using a torch near pressurized fluid lines or other flammable materials.

As heat goes beyond the immediate flame area, pressurized fluid lines can so be accidentally cut.

Inflammable spatters can be caused by heat near

pressurized fluid lines, possibly resulting in severe burns.

SAFETY

01.11

11-04 RoGator 418

Safe Servicing of Cooling System

An explosive release of fluids from the cooling system can cause serious burns.

Shut off the engine. Remove the filler cap only when it is cool enough to touch with bare hands. Slowly loosen the filler cap to the first stop to relieve any pressure before removing the cap completely.

Remove Paint before Welding or Heating

Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering or using a cutting torch.

Always work outside in a well-ventilated area. Dispose of paint and solvent properly in an environment-friendly way.

Always remove paint before welding or heating. Wear an approved respirator when grinding off the paint and avoid inhaling the dust.

If a solvent or paint stripper is used, remove the stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from the area. Allow fumes to disperse before welding or heating.

Batteries

A lead acid battery will generate flammable and explosive gases. Keep sparks and flames away from the battery.

Sulphuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed i nto eyes.

If acid contacts eyes, skin or clothing, flush with water immediately. If acid contacts eyes get immediate medical help.

Tyres and Wheels

Never weld on a wheel or rim that has a tyre on it.

Never attempt to mount or remove a tyre without the

proper equipment, tyre safety cage, or instructions. You

should be trained and qualified to perform the work

safely. Failure to follow the correct procedure when

mounting a tire on a wheel or rim may cause it to e x-

plode, resulting in serious injury. Tyre repairs must be

performed by trained and qualified personnel.

Dispose of Waste Properly

Improper disposal of potentially harmful waste can pose a threat to the environment. Potentially harmful waste used with Ag-Chem Europe BV vehicles includes such items as oil, fuel, filters, fluids and batteries.

Use leak-proof containers when draining fluids.

Never pour harmful waste onto the ground, down a drain, or into any water source.

Air conditioning refrigerants escaping into the atmosphere can damage the earth’s atmosphere.

Government regulations require a certified air

conditioning service centre to recover and recycle used air conditioning refrigerants.

Mobile Radio Installations

Under no circumstances should a mobile radio antenna be mounted to the rear of the cab or antenna cable and be routed near harness or electrical system controllers or near operator controls. Failure to follow these precautions could expose the operator to radio frequency energy levels higher than recommended by the European Directive 89/336/EEC: Electro-Magnetic Compatibility, and/or could cause undesirable performance of

electrically controlled systems.

SAFETY

01.13

11-04 RoGator 418

Location of Safety and Service Decals Chassis

WARNING

!

1 Caution - Hot surface (E720604) 7 Use only Diesel specified to EN590 (E552394) 2 Don’t open hood with engine running (E720561) 8 Decal “418” (E558992)

3 Caution - Read operator's manual (E720568) 9 Warning – Stay outside the rotation area of the steps. (E558577)

4 Grease gun (E720569) 10 Decal “RG418” (E558991)

5 Beware of leaking hydraulic lines / hoses (E720709) 11 No clearance for person in the working area of this machine (E720737)

6 System charged with R134A refrigerant (E720742) 12 Warning – Do not ride or stand in this area when machine or booms are in motion (238783) NOTE: Replacement safety signs are available by Ag-Chem Europe BV.

418 ROGATOR 418

Location of Safety and Service Decals Chassis

13 Decal “ROGATOR” (E720506) 16 Caution – Extern hydraulic system is filled with ISO VG 46 Oil (E558586)

14 Warning – Do not put limbs between the wheels and frame when the engine runs. Tires and wheels can move without warning and crush you. You can

17 Caution - The vehicle will swing as a result of the 4- wheelsteering (E558574)

ROGATOR 418

418 ROGATOR

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RPM

RPM

SAFETY

01.15

11-04 RoGator 418

Location of Safety and Service Decals Cabine

18 Warning – Keep booms and all antennas away from power lines. Do not attempt to enter the vehicle if it is in contact with power lines. Electrocution will result.

(E558568)

23 Before starting the engine, first check the oil level of the engine and hydraulic tanks.

(E720735)

19 Caution – WHEEL MOUNTING PROCEDURE (E558638)

24 Emergency Exit (E720738)

20 Serial number and CE plate (E770002) 25 Warning – If you want to fold in or out the steps, be aware that there are no persons inside the rotation area of the steps (E558571) 21 If the machine is tipping over, do not try to jump off, but

hold firmly on the steering wheel. (E720741)

26 Caution – PARKING BRAKE Engage the parking brake before you leave the cab. If you will use the parking brake as a service brake, this will result in damaging the hydraulic system.(E558565)

22 Warning – DO NOT EXCEED TYRE SPEED RATING Tires may overheat and fail causing personal injury or death. When vehicle is loaded, reduce speed further according to the tire chart. (E588530)

27 Decal cabine heater and Fan. (E558989) 18

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RoGator 418

Self-Propelled, Off-Road Agricultural Working Machine

READ AND UNDERSTAND THIS MANUAL

BEFORE OPERATING THE ROGATOR.

This manual contains important information about the safe operation and maintenance of the RoGator. More information is given in the Parts Manual(s). These are also supplied by manufacturers of Ag-Chem Europe BV com- ponents. If there is anything not understand- able, contact Ag-Chem Europe BV before op- erating the vehicle.

When the word "right" or "left" is used in this manual, it refers to the di- rection when the operator is looking out the front windshield.

INTRODUCTION

02.2

11-04

Identification

Serial Number Identification Plates

Write the serial numbers in the spaces provided.

Use these numbers when referring to the RoGator.

Ag-Chem Europe BV identification plate with the serial number is located on the front panel of the compartment in the cabin.

AG-CHEM SERIAL NUMBER

Identification plate with serial number

Engine Serial Number

The engine serial number plate is located on the right-hand side of the engine.

The following information is stamped on the serial number plate:

ENGINE SERIAL NUMBER (1)

APPLICATION DATA OR TYPE (2)

Engine Serial Number Plate

Hydrostatic Drive

CAUTION

!

Accidents or damage can result if you are not used to driving with a hydrostatic drive and re- spond improperly to certain situations.

Traction Control Lever, Pump and Wheel Motors.

Pushing the traction control lever forward or back modulates the swash plate in the pumps, allowing hydraulic oil under pressure to flow to the four wheel motors in a closed system. The traction control lever is connected to the pumps, which control the speed of the vehicle by regulating the amount of oil flowing to the wheel motors. The RoGator has two possible travel mode switch positions:

1. Field position 2. Road position.

When driving with the travel mode switch in the field position, the vehicle speed is not controlled with the engine speed but with the position of the traction control lever. In this situation the hand throttle must be used.

In the road position this lever is moved forward or back as far as possible. The speed of the machine is determined by the accelerator pedal.

Engine

The Diesel engine drives the pumps.

Low-pressure Pump

The low-pressure pump (a part of the traction pump) generates a low pressure for:

1. Flushing the system,

2. Modulating the traction pump.

Combined Cooler

The oil part of the combined cooler cools the flush- ing and leakage oil before it flows back to the hy- draulic oil tank.

Tank and Filter

The complete return oil flows through the suction and return oil filter. A part of the filtered oil flows to the intake line of the low-pressure pumps and the rest goes to the hydraulic tank.

INTRODUCTION

02.4

11-04

Break-in Period

First 100 Hours of Operation

IMPORTANT: Change the engine oil and oil filter after the first 100-150 service hours. This should be done in connection with a 100 to 150 hour maintenance service performed by AG- Chem Europe b.v. after making an appointment with the Service Centre. Refer to the section entitled "Maintenance" for the engine oil and engine oil filter specifications. The running-in instructions can be found in the engine operat- ing and maintenance manual.

Hydraulic System

IMPORTANT: Replace the filter element of the hydraulic suction/return line filter after the first 100 to 150 service hours.

(See "Maintenance" section.)

Check the oil level daily and watch for any possible leaks.

Engine Coolant Level

Check the engine coolant level and watch for any possible leaks.

WARNING

!

Wheel Mounting Bolts

1. Loosen each wheel mounting bolt 1/4 turn every 10 hours during the first 50 hours of operation and then tighten opposite bolts to a torque of 250 Nm.

2. Retighten all bolts, but now to a torque of 515 Nm.

3. Repeat step 2 every 500 service hours. For procedure see P. 6.11.

Maintenance Schedule

Check all items shown under the daily section of the maintenance schedule, every day the machine is in use.

Chassis and Cabin Modifications

IMPORTANT: It is not allowed to modify the vehicle or auxiliary parts not approved by Ag- Chem Europe b.v. or by the manufacturer of the vehicle.

IMPORTANT: To prevent damage to the wiring and hoses, never drill holes into the cabin. Be particularly cautious with vertical pipes.

Towing the RoGator

If there is a problem that cannot be corrected on the spot, transport the vehicle instead of towing it if at all possible.

Towing with Engine Operable

The vehicle may be towed a short distance if nec- essary.

IMPORTANT: When towing, run the engine at idle speed to provide hydraulic power for steer- ing and to release the parking brake. The ball valves must be set at the traction drive mani- fold so that the oil can still circulate without pressure. Do not tow the vehicle at a speed of more than 8 km/h.

Towing with Engine Disabled

IMPORTANT: If the engine can not be run, the parking brake must be released.

Do not exceed a speed of 5 km/h as steering is more difficult.

Also operate the ball cock valves.

IMPORTANT: if there is a problem that can not be corrected in the field, TRANSPORT THE VEHICLE INSTEAD OF TOWING THE VEHICLE IF AT ALL POSSIBLE. Towing the vehicle is not recommended, except in cases of emergency.

CAUTION

!

This can result in personal in- jury.

Therefore always use a tow bar.

RoGator Towing Procedure

1. If at all possible, let the engine run when towing the vehicles to provide sufficient hydraulic power for the brakes. If the engine may NOT run, be sure that there is enough hydraulic power for a LIMITED number of braking.

2. It is recommended to use a tow bar instead of a towing rope.

3. If the engine is NOT running, disengage the parking brake by hand. Do this as follows:

I. Put chocks in front of and behind the wheels to prevent the RoGator from rolling.

II. Remove the rubber plug (Pos. 5) at the rear wheel motors.

III. Place the spacer (60x60x8) (Pos. 9) on the brake (Pos. 2). The spacer should be about 280 mm long. In the centre of the spacer should be a hole with a diameter of 16.5 mm.

IV. Insert a M16 x 120 screw (Pos. 7) through the spacer and turn the screw tightly into the piston. Tighten the M16 nut (Pos. 8) nut until the motor shaft (Pos. 1) can rotate freely.

The parking brake is now disengaged.

4. The vehicle must be in NEUTRAL.

Parking brake disengagement

5. Open the lock valve at the centre of the chassis.

6. The vehicle can be towed.

Lock Valves

The lock valves are closed. Position when driving.

Transport

IMPORTANT: If transporting the vehicle on a truck, put a cover on the engine exhaust pipe to prevent damage to the turbocharger.

WARNING

!

If a machine problem cannot be repaired in the field, it is recommended that the vehicle be trans- ported on another vehicle and not towed.

Mobile Radio

CAUTION

!

IMPORTANT: Avoid the possible influence of the antenna cable on electronic circuitry near the roof. The antenna base must be grounded.

IMPORTANT: Do not tamper with or modify the engine in any way. In case of problems, please contact Ag-Chem Europe b.v.

1. Drive shaft 2. Brake

3. Lock washer 4. Protective cap 5. Plug

6. Piston

7. Screw M16 x 120 8. Nut M16

9. Spacer 60x60x8

INTRODUCTION

02.6

11-04

Location of Components

1. Engine oil dipstick/oil filler opening 2. Engine oil filter

3. Fuel filter

4. Primary and inner air filter elements 5. Coolant reservoir

6. Coolant filler opening

7. Electrical system earth switch 8. Batteries

9. Hydraulic tank

10. Hydraulic tank suction/return line filter 11. Hydraulic tank filler opening

12. Fuel tank

13. Fuel tank filler opening 14 Wheel motor

15. Traction pump 16. Gear pump

17. Compressed air tanks 18. Ladder

19. Fuse panel 20. Cooler 21. Exhaust

22. Leakage oil filter

ROGATOR 418

418 ROGATOR

418 ROGATOR 418

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Operation

Turn Signal, Lights and Horn Lever

Pull the lever forward to turn the right turn signal lever on.

Push the lever back to turn the left turn signal lever on.

Rotate the cap on the lever to switch on the parking lights or the low beam.

Move the lever to the right to switch the lights from high beam to dip beam.

Move the lever to the right to switch from dip beam to high beam.

Press the top of the lever to sound the horn.

Turn Signal, Lights and Horn Lever

1. Turn signal, lights and horn lever

Adjustment of the Steering Wheel

Unlock the steering wheel by rotating the handel (1) on the left side of the steering column. Tilt the steer- ing wheel in the direction you want. Pull the steering wheel out to the desired position. Tighten the handel on the left side of the steering column, to lock the steering wheel in the desired position.

1. Adjustment handel steering column.

Accelerator Pedal

Remark: The accelerator pedal is used mainly whe n driving on public roads. In the field the throttle should be used (field/street switch) in the "field" position. The advan- tage of driving with the throttle is that the engine speed remains much more constant, and this raises the quality of the spraying and spreading.

Pressing on the accelerator pedal increases the engine speed. If the traction control lever is not in neutral position, the ground speed of the machine will increase.

Releasing the right foot from the pedal decreases the engine speed, reducing the ground speed of the

CONTROLS

03.2

11-04

Traction Control Lever

Positions of the Traction Control Lever

Place the lever in the left cut-out to put the vehicle in neutral.

(2) Driving Forwards

Depending upon the position of the field/street switch, two methods are possible:

Field Position:

The machine is being driven with the throttle. Move the lever slowly forward to increase the speed during forward travel.

Move the lever slowly back to reduce the speed dur- ing forward travel.

Road Position:

The machine is being driven with the accelerator pedal. Allow the engine to idle (about 800 rpm).

Move the lever forward as far as possible (to select the direction of travel).

Depress the accelerator pedal to increase the en- gine speed during forward travel. Allow the accelera- tor pedal to come up to decrease the speed.

(3) Reversing

Depending upon the position of the field/street switch, two methods are possible:

Field Position:

The machine is being driven with the throttle. Move the lever slowly back from the neutral position to increase the reversing speed. Move the lever slowly forward to reduce the reversing speed.

Road Position:

The machine is being driven with the accelerator pedal. Allow the engine to idle (about 800 rpm).

Move the lever back as far as possible (to select the direction of travel).

Depress the accelerator pedal to increase the en- gine speed during reversing. Allow the accelerator pedal to come up to decrease the speed. In case the vehicle is not braked fast enough with the trac- tion control lever or the accelerator pedal, it is pos- sible to use the brake/inching pedal (see operation of brake/inching pedal on page 3.5).

Positions of the Traction Control Lever

1. Neutral

2. Driving forward 3. Reversing

CAUTION

!

CAUTION

!

Adjustment of the Traction Control Lever Position:

1. Rotation of the traction control lever: Loosen the lock nut and the knurled nut under the trac- tion control lever. Then turn the traction control lever to the desired position. Subsequently tighten the clamping nut and the knurled nut.

2. Adjusting the traction control lever console:

Loosen the screws beside the armrest, slide the console forward or backwards and retighten the screws.

Adjustment of Traction Control Lever Position

1. Adjustment bolts 1

CONTROLS

03.4

11-04

Brakes (Option)

Brake/Inching Pedal

Braking with the brake/inching pedal proceeds in two stages, namely in inching and braking. If the brake pedal is depressed slightly, the inching func- tion is activated. With this function the speed of the traction pump is reduced, thus reducing the ground speed of the machine.

If the brake pedal is depressed fully, the service brake is activated and the machine is braked with the drum brakes acting on the wheel motors.

Brake/Inching Pedal, accelerator Pedal

1. Brake / Inch Pedal 2. Accelerator Pedal

Parking Brake

PLEASE NOTE: The parking brake may not be used to brake the machine.

The machine is braked with the parking brake if the parking brake switch is in the locked position.

Press the switch out of this locked position to re- lease the parking brake.

The parking brake can not be engaged when the drive lever is not in the neutral position.

When the parking brake is engaged and the drive lever is moved out of neutral, an alarm will sound.

The alarm will stop when the drive lever is moved back into neutral. The parking brake can only be disengaged when the drive lever is in neutral posi- tion.

As soon as the parking brake is engaged the ladder will be lowered. As soon as the parking brake is released the ladder will be raised.

The ladder will not work if the drive lever is out off neutral, the door is opened or the hydraulic enable switch is disabled.

PLEASE NOTE: The ignition must be running in order to be able to release the parking brake.

PLEASE NOTE: When the parking brake is en- gaged the ladder will be lowered. When the parking brake is disengaged the ladder will be raised.

Turning the Controller ON and OFF

The controller power supply is turned on and off with the controller on / off switch. Most often the control- ler is also equipped with an on / off switch.

Engine Speed Governing

Engine RPM On/Off switch

Activates or deactivates electronic speed governing from inside the cab.

Engine RPM switch

Engine rpm can be raised by pressing the + button.

Engine rpm can be lowered by pressing the minus button.

From inside the cab

Put the engine RPM switch in position 1, be sure that the switch on the remote switchbox (see page 3.7) is on 0. Set the engine speed by pushing “+” on the engine RPM switch, or by pushing the foot throt- tle to the desired engine speed and then hit “+” to set the engine speed. When pressing “-“ on the en- gine RPM switch, the engine revs. Are decreased.

When the brake pedal is pushed (option), the en- gine goes back to idle. When pressing “-“ the en- gine goes back to the set engine speed.

When the engine RPM on/off switch is pushed into position 0 the engine goes back to idle.

From the remote switch box

See page 3.7 for the switches on the remote switch box.

Put the throttle switch on the remote switch box on 1, be sure that the engine RPM on/off switch inside the cab is on 0. Set the engine speed by pushing

“+”. When pushing “-“ the engine speed is de- creased. The engine goes back to idle when the remote throttle switch is pushed on 0.

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Instrument Panel

1. Field / Road switch

2. All-wheel-steering On / Off / Auto 3. Regulating computer On / Off switch 4. Engine RPM On/Off switch

5. Engine RPM switch 6. Hydraulic Enable switch 7. Not used

8. Spraypump On / Off switch 9. Dubbel foam switch

10. Differential Lock On / Off switch (Optional) 11. Folding / Unfolding Booms switch

12. Second Fold switch

13. Half Fold switch 14. Purge switch

15. Regulation sprayer Auto / Manual switch 16. Increase / Decrease pressure spray system

switch 17. Not used

18. Power Socket cigaret lighter style.

19. Track width lock switch.

20. Front axle track width switch.

21. Rear axle track width switch.

22. Not used

23. Warning light Green Differential Lock On 23

CONTROLS

03.6

11-04

Ignition Switch

The ignition switch has three positions.

CAUTION

!

0. MACHINE OFF. When the key is in this posi- tion, the machine and the accessories are turned off.

1. ON. This is the normal position for the operation of the vehicle.

2. START. In this position the engine is started with the starter.

PLEASE NOTE: The ignition switch can only be set to START (2) only ONCE. Return the key fully to the OFF position and repeat the start- ing procedure.

Suspension

Automatic Suspension Switch

Operating this switch puts the suspension in the automatic mode.

Manual Suspension Switch

With this switch it is possible to raise or lower the suspension manually.

Driving in the Field or on the Road

For driving on public roads the field / road switch is set to the "road" position, and for working in the field to the "field" position.

When this switch is in the "road" position, the fol- lowing condition applies:

• 4-wheel steering is switched off.

4-Wheel Steering

PLEASE NOTE: The 4-wheel steering can only be selected in the field position.

4-Wheel Steering Switch

With this switch it is possible to select three posi- tions.

Automatic: This is the working position for the 4- wheel steering. When the switch is in this position, the 4-wheel steering can be switched on and off with the foot switch.

Manual: This is the calibration position for the 4- wheel steering.

Zero Position: The 4-wheel steering is now turned off, depressing the foot switch has no effect.

4-Wheel Steering Foot Switch

4-Wheel Steering foot switch

Switching the Spraycomputer On/Off

With the switch Spraycomputer On/Off the com- puter will be supplied with power. The spraycom- puter its self has also an ON/Off switch.

Remote Throttle Control

Remote Throttle Control Box

1. Electronic governing On / Off switch 2. Increase / Decrease motor RPM 3. Spraypump On / Off

4. Res 1 5. Res 2

Electronic Governing On / Off Switch

Engine Speed Switch

The engine speed can be raised or reduced with this switch, if the switch mentioned above is in the on position.

Spraypump on / off

Only in combination with spraypack.

Res 1 / Res 2

Option switches only .in combination with spray- pack

Control Buttons on Traction Control Lever

Control Buttons on the Traction Control Lever

1. High Speed Range Switch 2. Low Speed Range Switch 3. Master Switch

Master Switch

Master switch for the sprayer / spreader.

Fast Speed Range Switch

Push this button to select a higher speed range.

Slow Speed Range Switch

Push this button to select a lower speed range.

LII LI

SI

E558477 SII

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