GT-3600 Trimmer/Paver Owner/Operator's Manual G21 / Apitech: The Worldwide Leader in Concrete Paving Technology

The Worldwide Leader in Concrete Paving Technology
GT-3600
Trimmer/Paver
Owner/Operator’s
Manual
G21 / Apitech
GOMACO CORPORATION
A Division of
GODBERSEN-SMITH CONSTRUCTION COMPANY
WARRANTY
All equipment manufactured by Gomaco Corporation ("GOMACO") and delivered new to the initial purchaser and user, and all parts
manufactured by GOMACO and contained in that equipment, and all parts manufactured by GOMACO and delivered new to the initial
purchaser are sold under and are subject to the following warranty and limitations:
FOR A PERIOD OF SIX MONTHS AFTER DELIVERY TO THE INITIAL PURCHASER AND USER, GOMACO will replace, f.o.b. its
factory, any part manufactured by GOMACO (whether contained in equipment manufactured and delivered by GOMACO or delivered separately)
having defects in materials or workmanship, all without charge except for shipping and installation costs and transportation expense of those
involved in the installation of such parts. GOMACO will make no allowances for repairs or alterations to such equipment or such parts unless
the same are authorized in writing by GOMACO.
EXCEPT AS MAY BE OTHERWISE AND EXPRESSLY PROVIDED HEREIN, SUCH REPLACEMENT OR REPAIR OF
DEFECTIVE PARTS MANUFACTURED BY GOMACO SHALL BE THE EXCLUSIVE REMEDY OF THE INITIAL PURCHASER AND
USER AND ANY OTHER PERSON TO WHOM THIS WARRANTY MAY EXTEND.
NO AFFIRMATION OF FACT OR PROMISE, AND NO DESCRIPTION, AND NO SAMPLE OR MODEL MADE OR PRESENTED BY
ANY PERSON WITH RESPECT TO EQUIPMENT OR PARTS MANUFACTURED BY GOMACO SHALL CONSTITUTE A WARRANTY
UNLESS EXPRESSLY AUTHORIZED OR CONFIRMED BY GOMACO IN WRITING. NO STATEMENT BY ANY PERSON SHALL CHANGE
THE TERMS OR SCOPE OF THE WARRANTY, LIMITATIONS AND DISCLAIMERS IN THIS INSTRUMENT UNLESS AUTHORIZED OR
CONFIRMED IN WRITING BY GOMACO.
ALL WARRANTIES PROVIDED HEREUNDER OR OTHERWISE SHALL CEASE TO EXIST UPON (i) THE MAKING OF UNAUTHORIZED
REPAIRS OR ALTERATIONS, (ii) IMPROPER OPERATION, (iii) OPERATION IN A MANNER EXCEEDING OPERATING LIMITATIONS, (iv)
USE FOR A PURPOSE EXCEEDING CAPABILITIES, (v) OR ABUSE, MISUSE, NEGLIGENCE OR ACCIDENT, AND IN ANY EVENT, (vi)
UPON EXPIRATION OF SIX MONTHS AFTER DELIVERY TO INITIAL PURCHASER AND USER.
THE WARRANTIES PROVIDED FOR HEREIN SHALL NOT EXTEND TO ANY PERSON, EXCEPT FOR BODILY INJURY, OTHER
THAN THE INITIAL PURCHASER AND USER OF EQUIPMENT AND PARTS MANUFACTURED BY GOMACO.
EXCEPT FOR THE WARRANTIES EXPRESSLY AND SPECIFICALLY MADE HEREIN, GOMACO MAKES NO OTHER
WARRANTIES, EXPRESS OR IMPLIED, AND DISCLAIMS ALL OTHER IMPLIED WARRANTIES OF MERCHANTABILITY AND ALL
IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE FOR WHICH THE EQUIPMENT OR PARTS ARE REQUIRED.
Any parts, accessories, subassemblies, engines, motors and other items not manufactured by GOMACO but furnished with or constituting
a part of the equipment sold by GOMACO ARE NOT COVERED BY ANY OF THE WARRANTIES HEREIN, AND WITH RESPECT TO ANY
SUCH ITEM, GOMACO MAKES NO WARRANTY OF ANY KIND WHATEVER, EXPRESS OR IMPLIED, AND DISCLAIMS ALL IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. No affirmation of fact or promise, and no description,
and no sample or model, and no express warranty of any type, has been authorized by GOMACO or by any other person with respect to any
such item, and any affirmation, statement or description as to any such item constitutes merely an opinion or commendation.
GOMACO SHALL NOT BE LIABLE UNDER ANY CIRCUMSTANCES FOR, AND DISCLAIMS ANY LIABILITY FOR, ANY INCIDENTAL
OR CONSEQUENTIAL DAMAGES, INCLUDING LOST OR DUPLICATED TIME OR EXPENSE, ACCRUING FOR ANY REASON TO THE
OWNER OR USER OF ANY PRODUCTS SOLD BY GOMACO, WHETHER CLAIM IS MADE IN CONTRACT OR IN TORT OR UNDER ANY
WARRANTY OR IN NEGLIGENCE OR OTHERWISE, AND IN ANY EVENT, GOMACO SHALL NOT BE LIABLE FOR ANY DAMAGES FOR
ANY REASON IN EXCESS OF THE PURCHASE PRICE OF THE EQUIPMENT OF THE EQUIPMENT SUBJECT TO THIS WARRANTY.
GOMACO reserves the right to make changes in its products without incurring any obligation to incorporate such improvements in any
products previously sold or in service.
GOMACO CORPORATION
G. L. Godbersen
PRESIDENT & CEO
GT-3600
TRIMMER/PAVER
OWNER/OPERATOR
MANUAL
MACHINE SERIAL NUMBER:__________________________
ENGINE SERIAL NUMBER:___________________________
GOMACO Corporation
HIGHWAYS 59 & 175
Ida Grove, Iowa 51445
Telephone: 712-364-3347
Fax # (712) 364-3986 Form No. H-36NG0606API-C1
Version 1.2
Printed in USA
Copyright 2006 GOMACO
GT-3600 New Generation
TO THE CUSTOMER
Your new GOMACO GT-3600 was carefully designed and manufactured to give years of dependable
service. To keep it running efficiently, read the instructions in this manual thoroughly. It contains
detailed descriptions and instructions for the efficient operation and maintenance of your GT-3600.
Each section is clearly identified so you can easily find the information that you need. Read the
Table of Contents to learn where each section is located. All instructions are recommended
procedures only.
Throughout this manual you will come across “Caution”, “Warning” or “Danger” statements which
will be carried out in bold type and preceded by one of the following symbols. Be certain to carefully
read the message that follows to avoid the possibility of personal injury or machine damage.
A “Danger” statement is of utmost importance and

! DANGER! ! signals severe injury or high probability of death to
the user if proper precautions are not taken.
A “Warning” statement is customarily used to

! WARNING! ! indicate a potential hazard which could result in
serious personal injury.
A “Caution” statement usually indicates a hazard

! CAUTION! ! that could result in minor injury, or damage to
equipment.
You will also come across “Notice” statements which will be carried out in bold type. A “Notice”
statement usually indicates a precaution or procedure to take to prevent personal injury, property
damage or an unsatisfactory finished product.
Right hand and left hand sides are determined by facing the direction the GT-3600 will travel during
paving operations. The two track end of the GT-3600 is referred to as the “front” and single track
end is referred to as the “rear”.
There are a variety of special applications which the GT-3600 may be used on. This manual covers
the use of the GT-3600 for standard low profiles, and side-mounted barrier. For special applications,
consult your nearest GOMACO Distributor.
Record your GT-3600 serial numbers in the appropriate spaces provided on the title page. Your
GOMACO dealer needs this information to give you prompt, efficient service when you order parts.
It pays to rely on an authorized GOMACO Distributor for your service needs. For the location of the
Distributor nearest you, contact GOMACO.
NOTE: It is GOMACO’s policy to constantly strive to improve GOMACO products. The

information, specifications, and illustrations in this publication are based on the information in
effect at the time of approval for printing and publishing. GOMACO therefore reserves the right
to make changes in design and improvements whenever it is believed the efficiency of the
machine will be improved without incurring any obligation to incorporate such improvements in
any machine which has been shipped or is in service. It is recommended that users contact an
authorized GOMACO Distributor for latest revisions.
1-2
Table of Contents
CHAPTER I ........................................................................................................................................................... 1-1
To the Customer ..................................................................................................................................... 1-2
Table of Contents ................................................................................................................................... 1-3
Quick Reference Parts List ................................................................................................................... 1-6
Safety Section ........................................................................................................................................ 1-8
Safety Decal Locations .........................................................................................................................1-11
CHAPTER II CONTROLS AND GAUGES ........................................................................................................... 2-1

01 Content of Chapter ........................................................................................................................... 2-1
02 Standard Engine Controls and Gauges ......................................................................................... 2-1
03 Cummins Tier II and Tier III Engine Controls and Gauges ........................................................... 2-3
04 Hydraulic Gauges and Control Valves ........................................................................................... 2-5
05 Control Switches .............................................................................................................................. 2-9
Electric travel and steering controls .......................................................................................... 2-12
06 G21 control system ........................................................................................................................ 2-15
Faceplate controls and gauges ................................................................................................. 2-15
G21 displays ............................................................................................................................. 2-17
Sensitivity displays .................................................................................................................... 2-19
Calibrate Displays ..................................................................................................................... 2-20
Control Knob Calibration Displays ............................................................................................ 2-22
Propel Valve Displays ............................................................................................................... 2-23
Service Displays ........................................................................................................................ 2-23
Optional Service Display Access ............................................................................................... 2-25
Set displays ............................................................................................................................... 2-25
Test Displays ............................................................................................................................. 2-27
System Operation ..................................................................................................................... 2-28
System Diagnostics ................................................................................................................... 2-29
Fault History Displays ............................................................................................................... 2-31
07 Moving the machine ....................................................................................................................... 2-32
CHAPTER III STANDARD SETUP ....................................................................................................................... 3-1

02 Curb and Gutter Form Preparation ................................................................................................. 3-1
03 Sidewalk Form Preparation ............................................................................................................. 3-6
04 Positioning the Legs ........................................................................................................................ 3-8
05 Preparing and Mounting the Conveyor ........................................................................................ 3-12
06 Trimmerhead Preparation .............................................................................................................. 3-13
Positioning the Trimmerhead Lift Mounts .................................................................................. 3-13
Changing Trimmerhead Width .................................................................................................. 3-14
Left Hand Discharge Trimmerhead Assembly ........................................................................... 3-16
Positioning and Mounting the Trimmerhead .............................................................................. 3-18
07 Mounting the Slipform Mold .......................................................................................................... 3-19
Hook and Go Attachment .......................................................................................................... 3-21
08 Mounting the Sensors ................................................................................................................... 3-22
Standard Sensor Arms .............................................................................................................. 3-22
Split Sensor Arms ...................................................................................................................... 3-24
Sensor Installation ..................................................................................................................... 3-29
Left Side Grade Control/Right Side Slope Control .................................................................... 3-31
09 Preliminary Adjustments ............................................................................................................... 3-31
24 Inch (61 cm) Radius Setup with 12 Inch (30 cm) Grade and Steering Offset ...................... 3-37
1-3
10 Final Adjustments .......................................................................................................................... 3-41

11 Pouring Operations ........................................................................................................................ 3-42
12 Center Mount Form Installation .................................................................................................... 3-50
Center Mount Assembly up to 8 feet (2.44 meter) .................................................................... 3-51
Field Installation of auxiliary vibrator and auger control valves ................................................. 3-53
Center Mount Assembly up to 10 feet (3.05 meters) ................................................................. 3-54
CHAPTER IV SIDE MOUNTED BARRIER SETUP ............................................................................................. 4-1

02 Form Preparation ............................................................................................................................. 4-1
03 Positioning the Legs ........................................................................................................................ 4-4
04 Installing the Side Mount Assembly ............................................................................................... 4-4
05 Mounting the Slipform Mold ............................................................................................................ 4-7
06 Preparing and Mounting the Conveyor .......................................................................................... 4-9
07 Mounting the Sensors ..................................................................................................................... 4-9
Center Mount Stringline .............................................................................................................. 4-9
Left Stringline ............................................................................................................................ 4-10
08 Preliminary Adjustments ............................................................................................................... 4-12
09 Final Adjustments .......................................................................................................................... 4-16
10 Pouring Operations ........................................................................................................................ 4-18
Lubrication and Maintenance Service Interval Chart ...................................................................................... 5-1
CHAPTER V MAINTENANCE ............................................................................................................................. 5-3

02 Fuels .................................................................................................................................................. 5-3
03 Lubricants ......................................................................................................................................... 5-3
Engine Lubrication Oil ................................................................................................................. 5-3
Hydraulic Oil ................................................................................................................................ 5-3
Gear Case Oils ............................................................................................................................ 5-3
Grease ........................................................................................................................................ 5-3
04 Ten Hour or Daily Service ................................................................................................................ 5-4
05 Fifty Hour or Weekly Service ........................................................................................................... 5-6
06 150 Hour or Monthly Service ......................................................................................................... 5-10
07 250 Hour .......................................................................................................................................... 5-12
08 500 Hour Service ............................................................................................................................ 5-13
09 600 Hour or Annual Service .......................................................................................................... 5-14
10 Servicing Air Cleaner ..................................................................................................................... 5-18
11 Battery Service ............................................................................................................................... 5-18
12 Alternator, Regulator and Starter Service .................................................................................... 5-19
13 Adjusting Servo Valves .................................................................................................................. 5-20
14 Adjusting Pressures ...................................................................................................................... 5-20
Trimmerhead Pressure .............................................................................................................. 5-20
Sequence Valve Flow Adjustment ............................................................................................. 5-21
Conveyor Pressure ................................................................................................................... 5-21
Tractive Pressure ...................................................................................................................... 5-22
Main Vibrator Relief ................................................................................................................... 5-22
Vibrator Variable Relief .............................................................................................................. 5-23
Lift Pressure .............................................................................................................................. 5-23
Calibrating the Control Knob Thresholds .................................................................................. 5-23
15 Calibrating the Steering Systems ................................................................................................. 5-25
16 Calibrating the Slope Sensors ...................................................................................................... 5-26
17 High Pressure Wash System Service ........................................................................................... 5-27
CHAPTER VI DIAGNOSTICS ............................................................................................................................. 6-1

1-4
02 Engine Diagnostics .......................................................................................................................... 6-1

03 Hydraulic Reservoir Diagnostics .................................................................................................... 6-1
04 Conveyor Hydraulic Diagnostics .................................................................................................... 6-4
05 Trimmer Hydraulic Diagnostics ...................................................................................................... 6-8
06 Tractive Hydraulic Diagnostics ..................................................................................................... 6-12
Hydraulic description with standard motors .............................................................................. 6-12
07 Track Hydraulic Diagnostics with Two Speed Motors ................................................................ 6-18
Hydraulic description with two speed motors ............................................................................ 6-18
High/Low Travel Speed ............................................................................................................. 6-19
08 Tractive Electrical Diagnostics ...................................................................................................... 6-26
09 Vibrator Hydraulic Diagnostics ..................................................................................................... 6-36
10 Vibrator Electrical Diagnostics ..................................................................................................... 6-42
11 Mold Hold Down Hydraulic Diagnostics ...................................................................................... 6-45
12 Auxiliary Hydraulic Diagnostics ................................................................................................... 6-47
13 Grade Hydraulic Diagnostics ........................................................................................................ 6-53
14a Grade and Slope Electrical Schematic ................................................................................... 6-58
14 Grade and Slope Electrical Diagnostics ...................................................................................... 6-59
Elevation or Dual Elevation Operation ...................................................................................... 6-59
Slope Operation ........................................................................................................................ 6-60
15 Steer Hydraulic Diagnostics ......................................................................................................... 6-69
16a Steer Electrical Schematic ....................................................................................................... 6-74
16 Steer Electrical Diagnostics .......................................................................................................... 6-75
17a Emergency Stop Electrical System Schematic ...................................................................... 6-90
17 Emergency Stop Electrical Diagnostics ...................................................................................... 6-91
18a Cummins 4BT3.9 Elite Engine Electrical Schematic ............................................................. 6-97
18a John Deere 4045T Engine Electrical Schematic .................................................................... 6-98
18 Engine Electrical Systems Diagnostics ........................................................................................ 6-99
John Deere Engine Electrical Description ................................................................................. 6-99
Cummins Engine Electrical Description .................................................................................... 6-99
19a Cummins QSB-110 Engine Electrical Schematic ................................................................. 6-104
19 Cummins QSB-110 Engine Electrical Diagnostics .................................................................... 6-105
Engine start circuit ................................................................................................................... 6-105
CHAPTER VII STRINGLINE SETUP .................................................................................................................. 7-1

02 Setting Straight Line ........................................................................................................................ 7-1
03 Setting Line for Radii ....................................................................................................................... 7-4
04 Positioning Stringline for Cross Slope Changes .......................................................................... 7-5
05 Setting the Line Under the Machine ............................................................................................... 7-6
06 Setting Radius Wheels .................................................................................................................... 7-7
1-5
Quick Reference Parts List

Engine Oil Filters
Cummins 4BT3.9 .............................................................................................. 210-46A29
John Deere 4.5L ............................................................................................... 210-50D45
Cummins QSB 110 ........................................................................................... 210-46A29
Cummins QSB 3.9-30-TAA .............................................................................. 210-51K93
Engine Primary Fuel Filters

Cummins 4BT3.9 .............................................................................................. 210-46A30
John Deere 4.5L ............................................................................................... 210-50D44
Cummins QSB 110 ........................................................................................... 210-46A30
Cummins QSB 3.9-30-TAA .............................................................................. 210-51K92
Engine Secondary Fuel Filters

Cummins 4BT3.9 .............................................................................................. 210-46A31
Cummins QSB 110 ........................................................................................... 210-46A31
Engine Air Filter

Cummins 4BT3.9 or John Deere 4.5L .............................................................. 210-46B41
Cummins QSB 3.9 -30-TAA Primary ................................................................ 210-51Y99
Cummins QSB 3.9-30-TAA Safey .................................................................... 210-52A01
Hydraulic
Main Hydraulic Filter Element ........................................................................... 110-10C51
High Pressure Lift Circuit Filter Element ........................................................... 110-45Q53
Sump Filter ....................................................................................................... 110-46F19
Sump Filter Access Cover Gasket .................................................................... GT62-194
Access Cover Bolt Rubber Seal Washer .......................................................... 420-30A96
G21 control system
Grade/Steering Sensor ..................................................................................... 500-46D83
Slope Sensor .................................................................................................... 500-46Y35
Smart Steer Cylinder ........................................................................................ GT10-421
S2X ................................................................................................................... 500-49J69
Pancon Controller ............................................................................................. 500-49Y71
Display Switch Assembly (Main Control Panel Module) ........................ B-GT61-555-D
Individual Control Meter Module ....................................................................... 500-48L54
Vertical Switch Assembly (Elevation Control) ........................................ B-GT61-555-B

Horizontal Switch Assembly (Steering Control) ..................................... B-GT61-555-C
1-6
Sensor Coil Cord (10 ft.) ................................................................................... 520-48D39

Sensor Coil Cord (20 ft.) ................................................................................... 520-48D40
Servo Valve (5 gpm) ......................................................................................... 125-45N30

Servo Valve Mounting O-rings (4 required) ................................................. 160-10F22
Grade Sensor Wand (Complete) ...................................................................... 500-15A77

Sensor Wand (Tube Only) .................................................................... 500-15A80
Thumb Screw for Grade Wand ............................................................. 500-10P87
O-ring for Thumb Screw on Grade Wand ............................................. 500-10P88
Steering Sensor Wand ..................................................................................... 500-15A69

Thumb Screw for Steering Wand ......................................................... 500-10F65
0-3000 psi (0-207 bar) Pressure Gauge ........................................................... 700-35A46
Ignition Key Switch ........................................................................................... 210-46K14
Vibrator ............................................................................................................. GT11-046
Relief Cartridges
Vented Main Relief Valve Cartridge (RVEA LAN) ............................................ 125-10C47
Vibrator Vented Main Relief Valve Cartridge (RVEA LAN) ............................... 125-10C47
Vibrator Variable Relief Valve Cartridge (RVGA LHN) ..................................... 125-45Q87
Lift Lock Check Valve/Thermal Relief (CBCA LHN) ......................................... 125-45N98
Solenoid Valves
Vibrator Solenoid Valve Assembly (N/O) .......................................................... 125-50G57
E-stop Solenoid Valve Assembly (N/O) ............................................................ 125-50G57
Tractive Brake Solenoid Valve Assembly (N/O) ............................................... 125-50G57
Solenoid Valve Coil Only ............................................................................. 125-49F28
Servo Lock Solenoid Valve Assembly .............................................................. 125-45R91

Servo Lock Solenoid Coil Only .................................................................... 125-45R94
Differential Lock Solenoid Valve Assembly ...................................................... 125-45R91

Differential Lock Solenoid Coil Only ............................................................ 125-45R94
Circuit Breakers
8 Amp ............................................................................................................... 525-10S43
10 Amp ............................................................................................................. 525-10S44
20 Amp ............................................................................................................. 525-10S45
Quick Coupler O-Rings

1/4 inch ............................................................................................................. 160-10Y41
3/8 inch ............................................................................................................. 160-10J99
1/2 inch ............................................................................................................. 160-10K03
3/4 inch ............................................................................................................. 160-10K01
Conveyor Discharge Chute .............................................................................. RC64-028
Trimmer Teeth (Carbide Tip) ............................................................................ 730-45J82

1-7
SAFETY SECTION WARNING SIGNS AND DECALS

The safety section lists basic safety precautions. In
addition, this section identifies the text and locations of There are several specific safety signs or decals on
warning labels used on the machine. your machine. Please take the time to familiarize
631012 yourself with the safety signs.
Read and understand the basic precautions listed in 631016
the safety section before operating or performing Make sure that you can read all safety signs. Clean or
lubrication, maintenance and repair on this equipment. replace these if you cannot read the words or see the
631013 pictures. When cleaning the labels use a cloth, water
WARNING: DO NOT OPERATE THIS EQUIPMENT and soap. Do not use solvents, gasoline, etc., to clean
UNTIL YOU HAVE READ AND THOROUGHLY safety signs. The use of solvents, gasoline, etc., could
UNDERSTOOD THE OPERATORS MANUAL. loosen the sign’s adhesive and cause the sign to fall
FAILURE TO FOLLOW THIS PROCEDURE MAY off.
RESULT IN INJURY OR DEATH. 631017
631014 You must replace a label if it is damaged, missing or
DANGER: DO NOT ALTER OR MODIFY THIS cannot be read. If a label is on a part that is replaced,
PRODUCT WITHOUT THE EXPRESS WRITTEN make sure a new label is installed on the replaced
CONSENT OF THE MANUFACTURER. part. Contact your GOMACO dealer for new labels.
UNAUTHORIZED MODIFICATION MAY RESULT IN 631018
SERIOUS INJURY OR DEATH. HIGH PRESSURE WATER
631015
GENERAL SAFETY STATEMENTS High pressure water can cause personal injury. When
using high pressure water for cleaning, wear a
1. The GT-3600 should only be operated by responsible protective face shield, protective clothing and
persons who have thoroughly read the operators protective shoes. Wear eye protection at all times
manual and have been properly instructed to do so. when cleaning the machine. Pressurized water could
Do not allow unnecessary persons on the machine. cause debris and/or water to be blown and result in
631001 personal injury. Do not aim the nozzle at any part of
2. Be certain all shields and guards are kept in place. the body.
631002 631019
3. Be certain that the trimmerhead or auger is free of FLUID LEAKS
debris before engaging the control valve.
631003 Always use a board or cardboard when checking for a
4. Keep hands, feet and clothing free of moving parts. leak. Escaping fluid under pressure, even a pin-hole
Do not wear loose fitting clothing or jewelry that can size leak, can penetrate body tissue, causing serious
catch on controls or other parts of the machine. injury, and possible death.
631004 631020
5. Use steps and hand rail to mount and dismount from If fluid is injected into your skin, it must be treated by a
the GT-3600. doctor familiar with this type of injury immediately.
631005 631021
6. Be certain that the engine is shut off before performing Do not kink or strike high pressure lines. Do not install
service or maintenance on the GT-3600. bent or damaged lines, tubes or hoses.
631006 631022
7. Place the tractive brake in the "on" position before Repair any loose or damaged fuel and oil lines, tubes
loading or unloading the machine or while traveling and hoses. Leaks can cause fires.
down steep enbankments. 631023
631007 Inspect all lines, tubes and hoses carefully. Do not
8. Stop the trimmer wheel or auger rotation and shut the use your bare hands to check for leaks. Tighten all
engine off before removing debris. connections securely.
631008 631024
9. Be certain that all hydraulic control valves and Check for the following:
electrical controls are in the "off" position before
starting the engine. -End fittings damaged or leaking.
631009 -Outer covering chafed or cut and wire reinforcing
10. Wear a hard hat, protective glasses and other exposed.
protective equipment as required by job conditions. -Outer covering ballooning locally.
631010
-Evidence of kinking or crushing of the flexible part of
11. Report all needed repairs.
631011
1-8
the hose. FIRE OR EXPLOSION PREVENTION

-End fittings displaced.
631025 All fuels, most lubricants and some coolant mixtures
BURN PREVENTION are flammable.
631040
Do not touch any part of an operating engine. Allow Diesel fuel is flammable. Gasoline is flammable. The
the engine to cool before any repairs are performed on mixture of diesel and gasoline fumes are extremely
the engine. explosive.
631026 631041
Do not touch any hydraulic tank, valve or hose when at Do not smoke in areas where batteries are charged, or
operating temperature. Allow the hydraulic oil to cool where flammable materials are stored.
before performing any service on the hydraulic circuits. 631042
631027 Keep all fuels and lubricants stored in properly marked
Relieve all pressure in oil, fuel or cooling systems containers and away from all unauthorized persons.
before any lines, fittings or related items are 631043
disconnected or removed. Store all oily rags or other flammable material in a
631028 protective container, in a safe place.
COOLANT 631044
Do not weld or flame cut the frame, pipes or tubes that
At operating temperature, the engine coolant is hot contain flammable fluids without prior authorization
and under pressure. The radiator and all lines to the and instruction from GOMACO or a GOMACO
engine contain hot coolant. When pressure is relieved authorized dealer. Do not weld on the machine with
rapidly, this hot coolant can turn into steam. the battery connected. Disconnect the battery
631029 negative (-) ground cable to prevent damage to the
Any contact with hot coolant or steam can cause electrical system and /or explosion.
severe burns. 631045
631030 Remove all flammable materials such as fuel, oil and
Check the coolant level only after the engine has been other debris before they accumulate on the engine or
stopped and the filler cap is cool enough to remove other components of the machine.
with your bare hand. 631046
631031 Do not expose the engine or hydraulic components to
Remove the cooling system filler cap slowly to relieve flames if at all possible.
pressure. 631047
631032 Have a fire extinguisher available and know how to
Cooling system additive contains alkali. To prevent use it. Inspect and have it serviced as recommended
personal injury, avoid contact with the skin and eyes on it instruction plate.
and do not drink. 631048
631033 When starting from an external source, always
Allow cooling system components to cool before connect the positive (+) jumper cable to the POSITIVE
draining. (+) terminal of the battery of the engine to be started.
631034 631049
BATTERIES To prevent potential sparks from igniting combustible
gases produced by some batteries, attach the negative
Battery electrolyte contains acid and can cause injury. (-) boost ground cable last, to the starter NEGATIVE
Avoid contact with the skin and eyes. (-) terminal (if equipped) or to the engine block.
631035
631050
Wash hands after touching batteries and connectors. Clean and tighten all electrical connections. Check
Use of gloves is recommended. daily for loose or frayed electrical wires. Have all
631036
loose or frayed electrical wires tightened, repaired or
Batteries give off flammable fumes which can explode.
631037 replaced before operating the machine.
631051
Do not smoke when observing the battery electrolyte
CRUSHING OR CUTTING PREVENTION
levels.
631038
Support equipment and attachments properly when
Always wear protective glasses when working with
working beneath them.
batteries.
631052
631039
1-9
Never attempt adjustments while the engine is running

unless otherwise specified in this manual.
631053
Stay clear of all rotating and moving parts. Guards
should be in place whenever maintenance is not being
performed.
631054
Were protective glasses when striking objects to avoid
injury to your eyes.
631055
Chips or other debris can fly off objects when stuck.
Make sure no one can be injured by flying debris
before striking any object.
631056
MOUNTING AND DISMOUNTING
Do not jump off the machine. Always use steps and

handholds when mounting and dismounting.
631057
Clean steps, handholds and areas of the machine you
will be working on or around.
631058
PREPARING TO START THE MACHINE
Be sure that all protective guards and covers are

installed if the machine must be started to make
adjustments or checks. To help prevent an accident
caused by parts in rotation, work carefully around
them.
631059
Inspect the machine for potential hazards.
631060
Make sure no one is working on, or close to the
machine before starting or moving it.
631061
1-10
1-11
REPLACEMENT ELEMENT DECAL AS PER

MACHINE SERIAL NUMBER
Cummins QSB Engine Only
1-12
1-13
1-14
CHAPTER II CONTROLS AND GAUGES

01 Content of Chapter
This chapter describes engine, hydraulic, and

electrical controls. It also gives the basic operating
procedures for the GT-3600. Read this chapter
thoroughly to identify the controls and operations.
Only qualified personnel should be allowed to operate
the GT-3600. Pay particular attention to all safety
statements.
02 Standard Engine Controls and Gauges
Engine Gauges
360171
! WARNING! !
DIESEL FUEL IS FLAMMABLE. WHEN REFUELING
THE MACHINE, STOP THE ENGINE. DO NOT
SMOKE WITHIN 50 FEET (15 M) OF THE MACHINE.
DO NOT ALLOW ANY HOT OR BURNING
MATERIALS NEAR THE FUEL FILL LOCATION.
SEVERE BURN MAY OCCUR IF THE FUEL WERE
TO IGNITE.
Fuel Gauge: Monitors the amount of diesel fuel in the

reservoir. “4/4” indicates a full reservoir. Refill the
Air Filter Restriction Indicator
360390 reservoir when the gauge indicates “0”; or slightly
Air Filter Restriction Indicator: Monitors the amount above. The fuel tank capacity is 44 gallons (166.6
of engine air intake restriction. As the air intake liters).
restriction increases, the line will move on the
indicator. When the engine is stopped, the line will Voltage Meter: Indicates voltage in the electrical
lock in place. When the shows in the service indicator circuits. Normal indication is a 13-14 volt charge at
window the air filter requires replacement. Push in on 2250 rpm.
the button in the bottom and release it to reset the
indicator. Engine Water Temperature: Indicates operating
temperature of engine coolant. Normal operating
temperature is approximately 190 to 200° F (88 to
93.4° C) for Cummins engines, depending on ambient
air temperature. If the temperature rises above 220° F
(104.4° C), locate the cause and correct.
Engine Oil Pressure: Indicates engine oil pressure.

Normal operating pressure is 65 psi (4.5 bar) at 2250
rpm for Cummins engines. Refer to the appropriate
engine operators manual for additional instructions.
Tachometer and Hour Meter: Electrically operated

and registers engine rpm and hours of operation.
Driven by alternator. Normal operating speed is 2250
rpm (maximum).
G21 09/02/2003
2-1
Hydraulic Oil Temperature Gauge: Monitors the

hydraulic fluid temperature. Normal operating
temperature is 140° to 180° F (60° to 82.2° C)
depending on the ambient temperature. If hydraulic
fluid temperature rises above 195° F (90.5° C), locate
the cause of the overheating. Overheating can be
caused by excessive load on all systems on a warm
day, air flow through the oil cooler restricted and/or by
a system that is constantly exceeding relief pressure.
The overheating can be corrected by reducing the load
on all systems on a warm day, cleaning the oil cooler
fins, and/or by reducing the load on the various
systems to maintain pressure below relief setting.
Note: Excessive oil temperature may cause

serious damage to components.
Ignition Switch
360393
Ignition switch: Turn the key to the start ( ) position
to start the engine. After the engine starts, allow the
switch to return to the on ( ) position.
The on position supplies electrical power to the

electronic controls and the engine fuel solenoid. Turn
the switch to the off ( ) position to stop the engine.
STOP
Throttle
360389
! CAUTION! !
CONTINUOUS EXPOSURE TO ENGINE AND
MACHINE NOISE CAN CAUSE HEARING INJURY.
DO NOT OPERATE THE MACHINE WITHOUT
ADEQUATE HEARING PROTECTION.
Throttle: The engine speed can be adjusted with this Master disconnect switch
360371
control in one of two ways. First, by turning the control
counterclockwise (out) to increase rpm and clockwise
(in) to decrease rpm. Second, by pushing in on the
! CAUTION! !
center button and pulling out on the control to increase WHEN SERVICING THE ELECTRICAL SYSTEM OR
rpm and pushing in on the control to decrease rpm. WELDING ON THE MACHINE, ALWAYS
Normal engine operating speed is 2250 rpm DISCONNECT THE GROUND STRAP FROM THE
(maximum). Do not increase engine speed above BATTERY(S) TO PREVENT DAMAGE TO THE
1000 rpm until engine oil pressure has increased, MACHINE ELECTRICAL SYSTEMS.
especially in turbocharged engines.
Master Disconnect Switch: The master disconnect
switch is used to disconnect the ground side of the
electrical system from the negative post of the battery.
G21 09/02/2003
2-2
With the switch in the “off” position, ground to all An active fault code will be indicated as follows: The
electrical circuits is disconnected and the circuits will yellow warning lamp will flash followed by a 1 or 2
not operate. When the switch is turned to the “on” second pause. The red stop lamp will flash the
position, a ground is provided to the electrical circuits, number of times that corresponds to the first number
allowing them to operate. The switch must be in the followed by a 1 or 2 second pause. The cycle will be
“on” position during normal operation. repeated for each number. When the three digit
number has finished flashing in red, the yellow warning
03 Cummins Tier II and Tier III Engine Controls lamp will appear again. Each recorded fault code will
and Gauges repeat a second time before moving to the next fault
code number.
Note: Control panels may differ according to
engine make and model installed in the machine. Contact the nearest engine dealer with the fault code
numbers, engine serial number and engine model
number for diagnostic and service information.
Note: Refer to the LCD diagnostic gauge for more

additional diagnostic information.
Next (↑↑↓)Fault Switch: Each fault code is flashed

two times before advancing to the next code. To skip
to the next fault code sooner, move the next fault
switch in the (↑) position. To go to the previous fault
code, move the switch in the (↓) position.
Engine Diagnostic Gauge: The LCD display

indicates engine operating parameters and diagnostic
trouble codes. Depress the up or down arrows to
scroll through the various functions that are monitored
by the engine computer. When service codes or
stored service codes is indicated, depress the up and
Tier II engine controls
down arrows simultaneously to access the SPN FMI
360416 diagnostic codes for the engine. The amber LED light
Ignition Switch: Turn the key to the start ( ) position will illuminate when an active diagnostic service code
to crank the engine. After the engine starts, allow the is indicated for the engine. The red LED light indicates
switch to return to the on ( ) position. an engine shutdown. The following table lists some of
the engine parameters displayed in English or Metric
The on position supplies electrical power to the units (when applicable).
electronic controls and the engine fuel solenoid. Turn
the switch to the off ( ) position to stop the engine.
STOP 1. Engine hours.
2. Engine RPM.
Engine Throttle Switch: Controls the engine speed. 3. System Voltage.
Depressing the switch in the “up” position will cause 4. % Engine Load at the current RPM.
the engine rpm to increase. Depressing the switch in 5. Coolant Temperature.
the “down” position will cause the engine rpm to 6. Oil Pressure.
decrease. Releasing the spring loaded switch will lock 7. Fuel Economy.
the throttle in any given position. Normal operating 8. Throttle Position.
engine speed is 2250 rpm (maximum throttle). 9. Manifold Air Temperature.
10. Current Fuel Consumption.
Diagnostic Fault On Switch: Turn the key switch to 11. Active Service Codes.
the on ( ) position without starting the engine. 12. Stored Service Codes from the engine.
Depress and hold the diagnostic switch in the on (↑) 13. Set the Units for display.
position. If no active faults are recorded, the warning 14. View the Engine Configuration Parameters.
lamp and the stop lamp will illuminate and will stay on.
If active fault codes are recorded, the warning and Gauge Circuit Breaker Reset: A three amp circuit
stop lamps will illuminate momentarily, then begin to breaker with a manual reset button provides 12 volt
flash the code of the recorded fault(s). power supply to the engine gauges on the control
G21 09/02/2003
2-3
panel. The circuit breaker will interrupt power supply if Most electronic fault codes will light a lamp when they
the reset button is extended. If the reset button is are active. There are three lamps that may be
extended, depress the button to reset the circuit illuminated during an active fault. The yellow warning
breaker. Consult the engine troubleshooting section in lamp indicates the need to repair the fault at the first
chapter 6 if the button will not remain depressed. available opportunity. The red stop lamp indicates the
need to stop the engine as soon as it can be safely
Tachometer and Hour Meter: Electrically operated done. The engine should remain shut down until the
and registers engine rpm and hours of operation. fault is repaired. The maintenance lamp will illuminate
Driven by alternator. Normal operating speed is 2250 when an engine maintenance function is required.
rpm (maximum).
Engine Oil Pressure: Indicates engine oil pressure.

Normal operating pressure is 70 psi (4.8 bar) at 2250
! WARNING! !
rpm for Cummins engines. Refer to the appropriate DIESEL FUEL IS FLAMMABLE. WHEN REFUELING
engine operators manual for additional instructions. THE MACHINE, STOP THE ENGINE. DO NOT
SMOKE WITHIN 50 FEET (15 M) OF THE MACHINE.
Engine Water Temperature: Indicates operating DO NOT ALLOW ANY HOT OR BURNING
temperature of engine coolant. Normal operating MATERIALS NEAR THE FUEL FILL LOCATION.
temperature is approximately 190 to 200° F (88 to SEVERE BURN MAY OCCUR IF THE FUEL WERE
93.4° C) for Cummins engines, depending on ambient TO IGNITE.
air temperature. If the temperature rises above 220° F
(104.4° C), locate the cause and correct.
360416J
Fuel Gauge: Monitors the amount of diesel fuel in the
Engine diagnostic lamps reservoir. “4/4” indicates a full reservoir. Refill the
360422A reservoir when the gauge indicates “0”; or slightly
above. The fuel tank capacity is 44 gallons (166.6
! DANGER! ! liters).
DO NOT USE ETHER. INTAKE MANIFOLD FLAME
HEATER STARTING AID HAS OPEN FLAME.
ETHER MAY CAUSE EXPLOSION AND SEVERE
INJURY.
Engine Diagnostic Lamps: This gauge contains four

lamps which illuminate during initial starting of the
engine or when faults occur. The blue wait lamp is
illuminated when cold-weather preheating time takes
place. The engine should not be cranked until the wait
lamp is extinguished to minimize cranking time during
cold-weather starting.
G21 09/02/2003
2-4
04 Hydraulic Gauges and Control Valves
ECM power disconnect switch

360410
ECM disconnect switch: Disconnects power supply Circuit Selector Valve and Gauges
to the engine electronic control module (ECM) in the 360170
“off” position. The on position supplies power to the Lift Pressure Gauge: Monitors the amount of
ECM. hydraulic pressure available for machine grade
(elevation) and steering control. Normal lift pressure is
1600 psi (110 bar).
Note: If lift pressure drops below 1000 psi (69

bar), the machine control may become slow.
Circuit Selector Valve and Pressure Gauge: Valve

and pressure gauge are used to check the pressure of
the trimmer, tracks, vibrator and conveyor. To check
the pressure on any of the systems, turn the selector
arrow to the desired circuit and observe the gauge in
the center. The gauge will show the working pressure
of the system being checked. When the selector
arrow is turned to “T”, pressure on the gauge will drop
to zero.
Hydraulic Filter Pressure Gauge: Monitors the

amount of pressure required to force the hydraulic oil
Engine pre-heater switch through the main hydraulic filter. Normal operating
360632 pressure is below 25 psi (1.7 bar). During cold
Engine pre-heater switch: Connects power to an weather start up, the filter pressure may exceed 25 psi
engine pre-heater for Cummins tier III engines. (1.7 bar). The filter must be changed when the gauge
Placing the switch in the “on” position will operate the registers in the replace area with the hydraulic fluid at
pre-heater. Placing the switch in the “off” position will operating temperature.
stop the operation of the pre-heater.
Notice: Before starting in cold weather, place the

engine pre-heater switch in the “on” position for
10 to 20 minutes. To prevent excessive battery
drain, place the pre-heater switch in the “off”
position before starting the engine.
G21 09/02/2003
2-5
“forward” or “reverse”, the faster the conveyor will run.

When cleaning the conveyor, clean the visible side of
the belt and then turn it 1/2 turn to clean the opposite
side. Do not allow the conveyor to run continuously
when cleaning.
Control Valves
360564
! DANGER! ! 360378
Vibrator Variable Control Valves
TO PREVENT SERIOUS INJURY OR DEATH, BE Vibrator Variable Control Valves: Used to

CERTAIN THAT THE TRIMMERHEAD AREA IS individually control the vibration output of each
CLEAR BEFORE STARTING THE hydraulic powered concrete vibrator in the slipform
TRIMMERWHEEL. STAY CLEAR OF THE mold. Controls vibrator output from 0 to 10,500
TRIMMER WHEEL AND DISCHARGE AUGER vibrations per minute. Rotating each control knob
WHEN THE ENGINE IS RUNNING. STOP THE counterclockwise increases vibration and clockwise
ENGINE BEFORE PERFORMING ANY SERVICE decreases the vibration in the corresponding vibrator.
WORK ON THE WHEEL UNLESS OTHERWISE Turning the knob all the way clockwise stops the
INSTRUCTED. vibrator attached to that circuit.
Trimmerhead Control Valve: Controls the direction

of the trimmer wheel rotation. “Forward” position
rotates the trimmer wheel in a direction opposed to
machine forward travel. “Off” position stops the wheel
rotation. “Reverse” position rotates the wheel in a
reverse direction to free it of debris.
! WARNING! !
TO AVOID SERIOUS INJURY, DO NOT STAND ON
THE CONVEYOR ANY TIME THAT THE ENGINE IS
RUNNING, IN CASE IT IS ACCIDENTLY STARTED.
ROTATE THE CONVEYOR 1/2 TURN AT A TIME
AND STOP IT WHEN CLEANING THE MACHINE.
KEEP HANDS, FEET AND CLOTHING AWAY FROM
ROTATING BELT, PULLEYS AND ROLLERS.
STOP THE CONVEYOR BEFORE CLEANING THE Stack Valves
360379
BELT, PULLEYS OR ROLLERS.
Drawbar Hold Down Control Valve: Controls the
Conveyor Directional Control Valve: Controls the hydraulic cylinder used to hold the front of the slipform
direction and speed of the charging conveyor. When mold down in firm contact with the concrete. “Up”
the control valve is moved towards the “forward” raises the front of the slipform mold and “down” will
position, the conveyor runs in the charging direction. lower it onto the concrete. Center position will stop the
The “off” position stops the conveyor. “Reverse” is form in a given position, but will not necessarily hold it
used mainly for cleaning the belt. The more the in that position. The valve is used in conjunction with
control valve is moved from the “off” position, towards the drawbar hold-down pressure control valve and
G21 09/02/2003
2-6
must be operated in the “down” position during pouring

operations.
Hold Down Control Valve: Controls the hydraulic

cylinder used to hold the rear of the slipform mold
down in firm contact with the concrete. “Up” raises the
rear of the slipform mold and “down” will lower it onto
the concrete. Center position will stop the form in a
given position, but will not necessarily hold it in that
position. The valve is used in conjunction with the
hold-down pressure control valve and must be
operated in the “down” position during pouring
operations.
Conveyor Lift Control Valve: Controls the vertical

movement of the receiving hopper end of the conveyor
to allow easier concrete discharge from supply trucks.
“Up” will raise the receiving end of the conveyor and Conveyor Shift Control Valve
“down” will lower it. The conveyor will maintain its 360181
vertical position when the valve is allowed to return to Conveyor Shift Control Valve: Controls the
center. Be certain to remove the pin from the two longitudinal movement of the conveyor assembly to
piece tube under the conveyor mount. The pin can be allow the conveyor easier access to the slipform mold
placed through the inner tube to limit the downward hopper in any of its positions. Moving the control valve
travel of the conveyor. to the “up” position, will cause the conveyor frame to
shift up towards the slipform mold and will cause it to
Right Front Leg Shift Control Valve: Controls the shift down when moved to the “down” position.
lateral movement of the right front leg from flush with Remove the retaining pin in the conveyor shift frame
the side of the machine to 24 inches to the right. The while shifting the frame and replace it when finished to
right front leg can be positioned anywhere in this area. maintain the new position.
Moving the lever to the “left” position will move it left
and moving the lever to the “right” position will cause it
to move right. The leg will maintain its lateral position
when the valve is allowed to return to center.
Rear Leg Shift Control Valve: Controls the lateral

repositioning of the rear leg assembly from centered at
the rear of the machine to 40 inches to the left.
Moving the control valve to the “left” position, will
cause the leg to shift to the left and will cause it to shift
right when moved to the “right” position. The leg will
maintain its lateral position when the valve is allowed
to return to center.
Selector Valve
360380
Auxiliary Travel/Vibrator Selector Valve: Directs
hydraulic fluid flow from the vibrator pump to the
vibrator circuit when in the “vibrator” position (knob
pushed in) or to the tractive system when in the
“auxiliary travel” position (knob pulled out).
G21 09/02/2003
2-7
Note: The auxiliary travel/ vibrator selector valve

will only be used on machines equipped with the
single speed track drive motors.
Servo Valve Overrides

216
Manual Override Control Levers: Used for
troubleshooting the steering and grade systems to
determine if the fault is electrical or hydraulic. By
moving the manual control lever on the top of the
servo valve, the system controlled by that valve should
respond as follows:
Pressure Control Valves and Gauges 1. Left Front Steer: By moving the manual control
214 lever left, the front of the corresponding track
Drawbar Hold Down Pressure Control Valve: Used should turn left and should turn right when the
to adjust the amount of pressure holding the front of lever is moved to the right.
the slipform mold down on the concrete. Adjustable
from 30 to 600 psi (2.1 to 41.4 bar) by turning the 2. Rear and Right Front Steer: By moving the
control knob clockwise to increase pressure and manual control lever left, the front of the right
counterclockwise to decrease pressure. track should turn right and should turn left when
the lever is moved to the right.
Hold Down Pressure Control Valve: Used to adjust
the amount of pressure holding the rear of the slipform 3. Left Front, Right Front and Rear Grade: By
mold down on the concrete. Adjustable from 30 to 600 moving the manual control lever left, the corre-
psi (2.1 to 41.4 bar) by turning the control knob sponding leg should raise and should lower
clockwise to increase pressure and counterclockwise when the lever is moved to the right.
to decrease pressure.
Note: The Auto-Manual switch on the control loop
Draw Bar Pressure Gauge: Monitors the amount of of the system being checked should be in the
pressure applied to the hydraulic cylinder holding the manual mode. The servo lock switch must be in
front of the slipform mold down in contact with the the ( ) position.
concrete.
Form Hold Down Pressure Gauge: Monitors the

amount of pressure applied to the hydraulic cylinder
holding the rear of the slipform mold down in contact
with the concrete.
G21 09/02/2003
2-8
05 Control Switches
Trimmer lift switches

360556
Trimmer Lift Switches (Left and Right): Controls
the vertical movement of the trimmerhead up to 12
inches (30 cm). The trimmerhead can be positioned
anywhere in this area. Moving the switches to the “up”
position will cause the trimmerhead to raise and
moving the switches to the “down” position will cause it
Travel Override Control to lower.
360567
Travel Manual Override Control: Used for
Trimmerhead Shift Switch: Controls the lateral
troubleshooting the travel circuit to determine if the
positioning of the trimmerhead up to 48 inches (1.22
fault is electrical or hydraulic. When the lever is
m) to the left side of the machine. The trimmerhead
moved up or down, the track drives should move in the
can be positioned anywhere in this area. Moving the
forward or reverse directions.
switch to the “left” position will cause the trimmerhead
to shift left and moving the switch to the “right” position
will cause it to shift right.
Mold Shift Switch: Controls the lateral positioning of

the slipform mold up to 48 inches (1.22 m) to the left
side of the machine. The slipform mold can be
positioned anywhere in this area. Moving the switch to
the “left” position will cause the slipform mold to shift
left and moving the switch to the “right” position will
cause it to shift right.
Left Front Leg Pivot Switch: Controls the lateral

movement of the left front leg from straight ahead to
21 inches to the left and 12 inches to the right. The
left front leg can be positioned anywhere in this area.
Moving the switch to the “left” position will move it to
the left and moving the switch to the “right” position will
cause it to move right.
Two Speed Switch (Optional): Controls a solenoid

valve coil used to shift the track drive motors into high
Relief Valves speed transport travel. When the switch is in the “off”
360060
position, the track drive motors are operated at low
Pressure Relief Valves: Used to individually control
speed with high torque. When the switch is placed in
the maximum pressure settings of the trimmer, tracks,
the “on” position, the solenoid coil is energized causing
vibrators and conveyor systems. If any of the systems
the track motors to shift into high speed with low
should stall, the pressure relief valve for that system
torque. The switch should be in the “off” position for
will open, bypassing hydraulic fluid back to the
normal paving operation.
pressure tank. If one of the valves should open, it will
in no way affect the operation of the other valves. The
valve cartridges are interchangeable with any of the
other valves for troubleshooting purposes.
G21 09/02/2003
2-9
! WARNING! !
TO PREVENT SERIOUS INJURY OR DEATH, BE
SURE THAT ALL CONTROLS ARE IN THE
“NEUTRAL” OR “OFF” POSITION BEFORE
RESETTING THE EMERGENCY STOP SYSTEM.
MAKE CERTAIN ALL PERSONNEL ARE AWAY
FROM THE MACHINE BEFORE RESETTING THE
EMERGENCY STOP SYSTEM. MAKE CERTAIN
ALL EMERGENCY STOP BUTTONS ARE IN
WORKING CONDITION PRIOR TO OPERATING
Tractive brake switch THE MACHINE.
360226B
! WARNING! ! Emergency Stop Reset Switch: Resets the

emergency stop system after one of the emergency
THE TRACTIVE BRAKE SWITCH MUST BE IN THE stop buttons is depressed.
“ON” POSITION WHILE LOADING AND
UNLOADING THE MACHINE. DO NOT ATTEMPT If the emergency stop light is on, make sure all
TO LOAD OR UNLOAD THE MACHINE ON METAL emergency stop buttons are pulled out, that all controls
RAMPS, ON WET RAMPS OR IN RAINING are in the “off” or “neutral” position, and that everyone
WEATHER. SEVERE INJURY OR DEATH CAN is away from the machine. Move the reset switch to
OCCUR IF THE MACHINE IS ALLOWED TO FREE the up position to reset the emergency stop system.
WHEEL OR SLIDE OFF THE TRAILER OR DOWN A The emergency stop light will go out and the tracks,
STEEP EMBANKMENT. trimmer, conveyor, and vibrators will operate normally.
Tractive Brake Switch: Controls a solenoid valve in Notice: All emergency stop buttons must be in the
the return line of the tractive system which acts as a out position to operate the machine. Check the
hydraulic brake to prevent the machine from “free operation of each emergency stop button every
wheeling” off of a trailer or down steep embankments. day before beginning operation: make certain all
“Off” position deactivates the solenoid valve to an emergency stop buttons are reset and that the
open position. “On” position activates the solenoid check E-stop light is out. Depress any of the
valve to a closed position, thus creating a back emergency stop buttons. If the check E-stop light
pressure against the tractive hydraulic system. does not come on after depressing any emergency
stop button, check the system for faults and
correct before operating the machine. Repeat the
check with the remaining emergency stop buttons.
E-Stop Commanded: RESET

Emergency stop light and reset switch
TURN OFF ALL Pots!
360224E
Emergency Stop Indicator Light: Alerts the operator 031-0170
when the emergency stop system has been activated
(when the engine is started or when an emergency E-Stop commanded display
031-0170
stop button is depressed or disconnected). When the When the emergency stop light illuminates, the G21
emergency stop light is on, the tracks, trimmer, controller screen flashes “E-Stop Commanded:
conveyor, and vibrators will not operate. RESET” in the first line and “TURN OFF ALL Pots!” in
the second line.
G21 09/02/2003
2-10
Emergency stop button

360059
! WARNING! !
TO PREVENT SERIOUS INJURY OR DEATH, BE Front sensor selector switch
360558
SURE THAT ALL CONTROLS ARE IN THE
Front sensor selector switch: When the machine is
“NEUTRAL” OR “OFF” POSITION BEFORE
being used to pour a tight left (outside) radius, two sets
MOVING THE EMERGENCY STOP RESET SWITCH
of front sensors are mounted to the machine. The
TO THE UP POSITION. MAKE SURE ALL
front set (sensor 1) is mounted next to the trimmer
PERSONS ARE AWAY FROM THE MACHINE
mold board and the rear set (sensor 2) is mounted
BEFORE RESETTING THE EMERGENCY STOP
back towards the middle of the mold. As the mold
SYSTEM.
enters a tight radius, move the front sensor selector
Emergency Stop Button: Used to stop the operation switch from the front set of sensors to the middle set
of the trimmer, track, conveyor and vibrator hydraulic so the machine can follow the stringline through the
systems. Depressing any one of the emergency stop radius.
buttons located around the machine will cause a
Place the front sensor selector switch in the front
vented relief to open in the trimmer, conveyor, track
position when pouring on straight stringline or radii
and vibrator hydraulic systems. This will dump all oil
down to 10 feet (3 M). Place the front sensor selector
supply for each of the systems back to the pressure
switch in the rear position when pouring left (outside)
tank. To reset the system, place the trimmer, track,
radii less than 10 feet (3 M).
conveyor and vibrator hydraulic controls in the off
position. Turn either the remote variable speed Note: Sensor 1 position is used when pouring
control knob or the console variable speed control right (inside) radii.
knob counterclockwise to the off position. Pull the
depressed emergency stop button out and depress the Computer Restart Switch: Controls the interruption
emergency stop reset switch. of power to the G21 controller. The switch must be in
the "on" position for normal operation of the controller.
The switch is used to restart the computer when
parameters have been changed in the software. It
eliminates the need to restart the engine when using
the ignition switch to restart the controller.
G21 09/02/2003
2-11
All Jog Switch: Raises or lowers all legs at the same

↑) position to raise all of
time. Hold the switch in the (↑
↓) position to lower all
the legs. Hold the switch in the (↓
of the legs.
Note: The all jog switch temporarily overrides

automatic G21 control of leg elevation. If any of
the leg elevation control modules are in automatic
(A), and the G21 controller is in run mode, control
of leg elevation returns to sensor control when the
all jog switch is released to the center position.
Vibrator auto/off switch Servo lock switch: Locks all grade and steering
360226A
Vibrator auto/off switch: Turns off the vibrators systems in a given position. Place the switch in the
when moving the machine around the jobsite. Place locked ( ) position to lock the grade and steering
the switch in the “off” position to stop vibrator cylinders in position. Place the switch in the unlock
operation. Place the switch in the “auto” position to ( ) position to unlock the grade and steering cylinders.
allow the vibrators to be controlled by the travel/neutral The servo lock switch must be in the “off” position
switch, the forward/reverse switch, and the travel during normal pouring operations.
variable speed control knob.
Servo lock warning light: Notifies the operator when
When the vibrator auto/off switch is in the “auto” the servo lock switch is in the locked position ( ). The
position, the vibrators will operate whenever the travel/ servo lock warning light comes on when the servo lock
neutral switch is in the “travel” position, the forward/ switch is in the locked position ( ). The light goes out
reverse switch is in the “forward” position, and the when the servo lock switch is placed in the unlocked
travel variable speed control knob is rotated clockwise position ( ). The warning light should be out during
past the “off” position. When the vibrator auto/off normal pouring operations.
switch is in the “auto” position, the vibrators will stop
whenever the forward/reverse switch is in the “reverse” Electric travel and steering controls
position, the travel/neutral switch is in the “neutral”
position, or whenever the travel variable control knob
is rotated counterclockwise to the “off” position. ! CAUTION! !
The vibrator auto/off switch must be in the “auto” PLACE THE TRAVEL VARIABLE CONTROL
position during pouring operations. KNOBS ON THE CONSOLE AND ON THE TRAVEL/
STEER REMOTE IN THE “OFF” POSITION BEFORE
CONNECTING OR DISCONNECTING THE TRAVEL/
STEER REMOTE BULKHEAD.
All jog switch

360225
G21 09/02/2003
2-12
Note: The G21 controller must be in run mode to

allow operation of the travel control systems.
All Travel Pots

TURN OFF ALL Pots & FNRs
360394
All travel pots display

360394
The display above may be indicated after initial start of
the machine or after an emergency stop button has
been depressed. If the G21 controller main screen
indicates as shown above, the travel variable control
knob on the console is not turned to the off position. If
the travel/steer remote is connected, then the remote
Remote travel variable control knob travel variable control knob is not turned to the off
360555
position. If the appropriate travel variable control knob
is turned off, look for an electrical fault in the
appropriate knob or in the cords to the G21 controller.
Console travel variable control knob

031-0157E
Travel variable control knob: Controls the travel
speed of the machine in either forward or reverse. If
the travel/steer remote is plugged in, the knob on the Travel/neutral switch
remote will operate, but the knob on the console will 031-0157F
not. Travel/neutral switch: Controls track drive system

and the vibrators. Place the switch in the “neutral”
Rotate the control knob counterclockwise to the “off” position to stop the track drive system and the
position to stop the track drive system. Rotate the vibrators. Place the switch in the “travel” position to
control knob clockwise away from the “off” position to start the vibrators and move the machine.
start moving the track drive system. The more the
control knob is turned clockwise, the faster the The travel variable speed knob must be rotated
machine will travel. clockwise past the “1” position before the machine will
move. The vibrator auto/off switch must be in the
The travel variable control knob also starts and stops “auto” position, the forward/reverse switch must be in
the vibrators when the vibrator auto/off switch is in the the “forward” position, and the vibrator variable
“auto” position and the forward/reverse switch is in the controls must be turned counterclockwise before the
forward (F) position. When the travel variable control vibrators will start.
knob is rotated away from the “off” position, all
vibrators start immediately. The tracks will not begin Note: The G21 controller must be in run mode to
moving until the knob reaches the “1” position. When allow operation of the travel control systems.
the knob is rotated to the “off” position, the vibrators
stop.
G21 09/02/2003
2-13
Forward/reverse switch Manual steer knob

031-0157G 031-0157D
Forward/reverse switch: Notifies the G21 controller Manual steer knob: Turns the tracks when the steer
whether the machine will be travelling forward or select knob is in any of the four manual positions. If
backwards. The switch must be in the correct position the travel/steer remote is plugged in, the knob on the
before operating the machine along a stringline or the remote will operate, but the knob on the console will
controller will steer the tracks in the wrong direction. not.
Place the switch in the forward (F) position to move
the machine forward. Place the switch in the reverse When the indicator on the manual steer knob is
(R) position to move the machine backwards. The centered, the tracks turn straight ahead. As the knob
vibrators will not operate when the forward/reverse is turned either direction from center, the tracks will
switch is in the reverse (R) position. turn accordingly. The more the knob is turned, the
more the tracks will turn. The manual steer knob has
Note: The G21 controller must be in run mode to no affect on the steering when the steer select switch
allow operation of the travel control systems. is in the stringline steer ( ) position. To use the
manual steer knob and the steer select knob, the G21
controller must be in run mode and all three steering
modules must be in automatic (A) (see Section 05 G21
control system for more information).
Steer select knob

031-0157B
Remote manual steer knob
360555 Steer select knob: selects one of the following
steering modes:
G21 09/02/2003
2-14
steering control knob is in the center position, all tracks

are straight ahead. If the knob is turned left or right
from the center position, the rear track turns in the
corresponding direction and the front tracks remain
straight ahead.
06 G21 control system
Faceplate controls and gauges
031-0137A
Stringline steer
031-0137A
Place the knob in the stringline steering position ( ) to
steer the tracks with the steering sensors or with the
steering jog switches. When the knob is in the
stringline steering position the main screen shows
“STRING” steer and the manual steer knob is
disabled.
When the steer select switch is in the coordinated

steer position ( ), the steering control knob steers the
tracks and the main screen shows “COORD” steer.
When the steering control knob is in the center
position, the tracks are straight ahead. If the knob is
turned left or right from the center position, the leading
tracks will turn in the corresponding direction and the
trailing track(s) will turn in the opposite direction to give
minimum turning radius.
When the steer select switch is in the crab steer

position ( ), the steering control knob steers the
tracks and the main screen shows “CRAB” steer.
When the steering control knob is in the center
G21 control panel
position, the tracks are straight ahead. If the knob is 031-0146
turned left or right from the center position, all tracks The G21 control panel contains three individual leg
turn in the corresponding direction to walk the machine modules, a main screen, two slope setpoint switches,
to the side. a run/standby switch, twelve service switches, and a
warning light.
When the steer select switch is in the front steer only
position ( ), the steering control knob steers the front
tracks, the rear track is locked straight ahead, and the
main screen shows “FRONT” steer. When the
steering control knob is in the center position, all tracks
are straight ahead. If the knob is turned left or right
from the center position, the front tracks turn in the
corresponding direction and the rear track remains
straight ahead.
When the steer select switch is in the rear steer only

position ( ), the steering control knob steers the rear
track, the front tracks are locked straight ahead, and
the main screen shows “REAR” steer. When the
G21 09/02/2003
2-15
grade deviation indicator on each leg module displays

grade or slope sensor positions. If a steering or grade
sensor is centered, the deviation indicator forms a
straight line. If a steering sensor moves to the left or
right, the deviation indicator forms an arrow pointing to
the left or right. If a grade sensor moves up or down,
the deviation indicator forms an arrow pointing up or
down. The more the grade or steering sensor moves,
the larger the arrow becomes.
LED lights at the top of each leg module show whether

the control modules for the grade and steering are in
automatic (A) or manual (M). For example, if the
steering control module for the right front leg is in
manual, the LED light below the “M” will be on in the
steering deviation indicator for the right front leg. If the
steering control module for the right front leg is in
automatic, the LED light below the “A” will be on in the
steering deviation indicator for the right front leg
module.
Three switches next to each deviation indicator control

Individual leg module the grade or steering module for the corresponding
360557
Individual leg module: Each leg module contains leg. The vertically positioned switches control the
two deviation indicators, two grade jog switches, two grade module and the horizontally positioned switches
steering jog switches, one grade A/M switch, and one control the steering module.
steering A/M switch.
Each leg module displays information and controls the

leg from the corresponding location on the machine
frame when facing forward. The left front module is for
the left front leg, the right front module is for the right
front leg, and the rear module is for the rear leg.
A/M switches
360557
A/M switches: The automatic/manual (A/M) switch in
the center sets the grade or steering module for
LED deviation indicators automatic or manual operation. In automatic, the
031-0150B
corresponding leg responds to signals from the
The LED steering deviation indicator on each leg
sensor. In manual, the corresponding leg will not
module displays steering sensor positions. The LED
respond to signals from the sensor.
G21 09/02/2003
2-16
Jog switches: The jog switches have arrows pointing standby. The main screen shows “Stdby” for standby,
to the left and right (for steering) or up and down (for or “Run” for run. In standby, all automatic signals to
elevation), and can raise and lower or steer the the servo valves are turned off and none of the legs
corresponding leg at any time whether a control will respond to sensor signals. In run, the legs
module is in automatic or manual (the jog switches respond to sensor signals if their grade and steering
override the sensor signals when the control module is control modules are in automatic. The G21 controller
in automatic). The jog switches also operate when must be in run before the machine can be moved in
with the G21 controller main screen is in run or forward or reverse.
standby. The jog switches also increase or decrease
sensitivity when required (see below).
Warning light
031-0143A
G21 controller main screen Warning Light: If a fault exists in one or more of the
031-0157I
G21 controller main screen: The G21 controller individual control modules, the G21 controller is in run,
main screen at the bottom of the G21 control panel and the individual module is in automatic, the light will
displays letters, numbers and symbols in two lines of remain on. The light flashes on and off any time the
up to 24 characters each. The display shows system, G21 controller is in standby. The light goes out if a
calibration, service and testing information. The fault does not exist in the system and the G21
display is backlit for low light and night viewing. controller is in run.
Slope setpoint switches

031-0144A
Last/Next/Clear switches
Slope setpoint switches: The slope setpoint 031-0149
switches next to the G21 controller main screen Last/Next/Clear switches: Depress the NEXT switch
change the cross slope of the machine frame. If slope to move forward through the G21 displays (described
control is on the right side, depress the switch with the below). Depress the LAST switch to move backwards
arrow pointing to the left to raise the right side of the through the displays. The clear switch clears data
machine. Depress the switch with the arrow pointing entered in some of the displays (such as the job total
to the right to lower the right side of the machine. feet/meters), and has no effect on other displays (such
as slope or sensitivity).
Depress and release either setpoint switch to change
the slope setting in 0.05% increments. G21 displays
Run/standby switch: Depress and release the run/ Below is a description of the separate displays that
standby switch to place the G21 controller in run or can be accessed in the G21 controller main screen
G21 09/02/2003
2-17
after it is started up (depress the NEXT or LAST normal operating display also shows the current slope
switches to scroll through the displays): setting for the machine (for example, “1.51”).
The first word of the bottom line of the normal

operating display shows the position of the travel
forward/reverse switch or the travel/neutral switch
GT 3600 Oct 4 2002
(“Fwd”, “Neu”, or “Rev”). The second word of the
Software # S0492010 bottom line of the normal operating display shows the
position of the steer select knob: “String” is stringline
360349 steer, “Coord” is coordinated steer, “Crab” is crab
Power up display steer, “Front” is front steering, and “Rear” is rear
360349 steering. The third word and number of the bottom
Power up display: When the G21 controller is line of the normal operating display shows the position
started, the power up display appears for a few of the front sensor selection switch (Sensor 1 or
seconds in the main screen. The G21 controller Sensor 2).
checks the programming for faults while the power up
display is visible. If a fault is found, the display panel
will show it. The power up display shows the machine
type (GT 3600), the date the G21 software was
created (Oct 4 2002), and the serial number of the JOB TOTAL AVERAGE
software (# S0492010). The exact dates and numbers 0ft 0ft 0f/m
in this display will change if the G21 controller is
reprogrammed. Note the date and serial number 031-0171
before discussing G21 troubleshooting with GOMACO
Job distance display
personnel. 031-0171
Job distance display: The job distance display is not
Note: On later software updates, a Kernal (knl) currently operational on the GT-3600.
number will be added to the display. The Kernal
number represents the computer operating
software. The software number indicated above
represents the machine model software for the Propel Drv, Vibr
GT-3600. It is very important to match the Kernal
0 OFF
operating software with the machine model
software for proper operation of the controller.
360351
Contact GOMACO for more information prior to
downloading new software. Propel drive display
360351
Propel drive display: The propel drive display shows
the percentage of total drive that the G21 controller is
sending to the travel proportional control valve. The
Stdby LGrd RSlope= 0.00 drive signal ranges from 0 to 100 percent and may be
Neu Coord Sensor 1 monitored at any time the G21 controller is in “Run”.
360350
Normal operating display example

360350
Normal operating display: The normal operating
display appears after the power up display. The exact
appearance of the display may be different from the
example shown above. The top line of the normal
operating display shows whether the G21 controller is
in standby (Stdby) or run mode and whether the G21
controller is configured for left grade, right slope (LGrd
RSlope) or Leica stringless operation (see the
“Calibrate displays” section, below, to configure the
G21 controller for a specific machine layout). The
G21 09/02/2003
2-18
Sensitivity displays
Sensitivity switches
031-0148A
The sensitivity switches allow the sensitivity settings to
be changed in the displays shown below:
Sensitivity display on the individual leg modules
031-0055B
Depress the up jog switch next to any of the individual
leg modules to increase the sensitivity for an individual
ELEVATION SENSITIVITY
elevation control module. Depress the down jog
Use Next/Last switch next to any of the individual leg modules to
decrease the sensitivity for an individual elevation
031-0175 control module. The sensitivity will change one setting
Initial elevation sensitivity display each time either jog switch is depressed. The
031-0175 minimum elevation sensitivity is “1” and the maximum
Depress and release the ELEV sensitivity switch to elevation sensitivity is “19”. To exit the elevation
show the initial elevation sensitivity display on the sensitivity display, depress and release the ELEV
main screen. Depress the NEXT switch to show the switch.
following display:
STEERING SENSITIVITY
LF:10 RF:09 REAR:15 Use Next/Last
Use Jog Switch to Adjust
031-0177
360634
Initial steering sensitivity display
Elevation sensitivity display 031-0177
360634 Depress and release the STEER sensitivity switch to
Elevation sensitivity display: The elevation show the initial steering sensitivity display on the main
sensitivity display shows the elevation sensitivity screen. Depress the NEXT switch to show the
settings for all three legs on the main screen and on following display:
the individual leg modules.
LF:10 RF:09 REAR:15

Use Jog Switch to Adjust
360634
Steering sensitivity display

360634
Steering sensitivity display: The steer sensitivity
display shows the steering sensitivity settings for all
G21 09/02/2003
2-19
three legs on the main screen and on the individual leg

modules.
SYSTEM CAL., Last/Next
*Cycle Power To Enable*
031-0179
System calibration display

031-0179
System calibration display: Depress the CALIB
switch to show the system calibration display on the
main screen. Depress the NEXT and LAST switches
to scroll through the calibration displays shown below.
Use the calibration displays to set up the G21
controller for specific machine applications. The
flashing words in each calibration display show the
setting that can be changed. Depress the + and -
slope switches to change the settings. To exit the
calibration displays at any time, depress and release
the CALIB switch.
Sensitivity display on the individual leg modules
031-0055B
Note: The ignition switch or computer restart
Depress the right jog switch below any of the individual
switch must be turned off and back on before any
leg modules to increase the sensitivity for an individual
changes to the calibrate displays will be enabled.
steering control module. Depress the left jog switch
below any of the individual leg modules to decrease
the sensitivity for an individual steering control module.
The sensitivity will change one setting each time either
jog switch is depressed. The minimum steering Grade Mode Cycle Power!
sensitivity is “1” and the maximum steering sensitivity LGrd RSlope , +/- Adjust
is “19”. To exit the steering sensitivity display, depress
and release the STEER switch. 360352
Calibrate Displays Grade display

360352
Grade display: The Grade display sets the type of
sensor control the machine will use for a particular job
situation. The upper line displays “Grade Mode Cycle
Power!” and the lower line displays the current setting,
for example, “LGrd RSlope , +/- Adjust”. Depress and
release the +/- switches to change elevation display
settings to any of the following:
Grade Mode Cycle Power!

Calibrate switch
LGrd RSlope , +/- Adjust
031-0148B
Calibrate switch: Depress the CALIB switch to 360352
access the displays described below.
Left grade/right slope
360352
G21 09/02/2003
2-20
Notice: The Key codes are different for each G21

control box. When purchasing a 3D control
system, record the controller serial number (S/N)
and date code from the controller name plate
Leica , +/- Adjust inside the G21 control box. Contact a GOMACO
distributor or GOMACO for additional information
360353
and the key codes.
Leica
360353
Turn the ignition switch or computer restart switch to
the “off” position, then back to the “on” or “start”
position to save any changes to the elevation displays. Grade Wands Cycle Power!
PUSH +/- Adjust
031-0187
Alarm Mode Cycle Power! Grade wand display
LAMP , +/- Adjust 031-0187
Grade wand display: The upper line reads “Grade
Wands Cycle Power!”. If the grade sensor wands will
031-0184 be mounted behind the grade sensor hubs, the lower
Alarm display line must read “PULL +/- Adjust”. If the grade sensor
031-0184 wands will be mounted ahead of the grade sensor
Alarm display: The lamp is the only alarm system hubs, the lower line must read “PUSH +/- Adjust”. If
available on the machine for troubleshooting purposes. the display is not correct, depress the +/- switches to
An audible alarm is not currently operational on the change it. Turn the ignition switch or computer restart
GT-3600. switch to the “off” position, then back to the “on” or
“start” position to save any changes to the grade
wands push/pull mode.
Units Cycle Power! Note: All grade sensor wands on the machine
ENGLISH, +/- Adjust must face the same direction.
031-0185
English/metric display LF All Jog Cycle Power

031-0185
English/metric display: The English/metric display is Curr = 200mA +/- Adjust
not currently operational on the GT-3600.
031-0191
All jog display

031-0191
Feature Encryption All jog displays: The all jog displays allow
(+) Key to Enter adjustment of the signal to each elevation servo valve
so all three legs move up evenly when the all jog
951310 switch is held in the up position. Depress and release
the NEXT switch to select the three all jog milliampere
Feature Key Encryption (mA) displays. The upper line of the first display reads
951210
Depressing and releasing the NEXT switch will select “LF All Jog Cycle Power” and the lower line reads
the feature encryption mode on the main screen. This “Curr = 200mA +/- Adjust”.
mode is used to activate key codes for hidden
When the all jog switch is held in the up position, all
software in the G21 control system. When a 3D
three legs should raise the machine at the same
stringless control system has been acquired for use on
speed. If one of the legs is too fast or too slow,
the machine, numbers are entered into the controller,
depress the NEXT or LAST switch to select the leg
under feature encryption, to unlock the additional
“LF” (left front), “RF” (right front), or “Rear” and
operating and diagnostic displays required for use with
depress the +/- switches to adjust the setting.
the system.
G21 09/02/2003
2-21
Increase the setting if the leg is too slow or decrease switch or computer restart switch to the “off” position,
the setting if the leg is too quick. The setting for each then back to the “on” or “start” position to save any
leg should normally be adjusted from 150 to 250 mA changes to the forward steer authority mode.
(milliamperes).
Turn the ignition switch or computer restart switch to

the “off” position, then back to the “on” position to save
Rev Str Auth Cycle Power
any changes to the all jog milliampere modes. Check
the operation of the all jog switch. If the up or down
FULL +/- Adjust
speed is not correct, readjust and recheck.
031-0190
Note: The all jog milliampere setting has no affect
Reverse steer authority display
on the automatic control output signals. 031-0190
Reverse steer authority display: The upper line
reads “Rev Str Auth Cycle Power” and the lower line
will read either “FULL +/- Adjust” or “HALF +/- Adjust”.
Steer Wands Cycle Power! When reverse steer authority is set to HALF, the drive
signal sent to the steering servo valves is decreased
PUSH +/- Adjust
by 50% when the machine is traveling in reverse. The
reverse steer authority should be set to half if the
031-0188 machine is not backing up on the stringline correctly.
Steer wand display If the reverse steer authority is not set correctly
031-0188 depress the +/- switches to change it. Turn the ignition
Steer wand display: The upper line reads “Steer switch or computer restart switch to the “off” position,
Wands Cycle Power!” If the steer sensor wands will then back to the “on” or “start” position to save any
be mounted behind the steer sensor hubs, the lower changes to the reverse steer authority mode.
line must read “PULL +/- Adjust”. If the steer sensor
wands will be mounted ahead of the steer sensor Control Knob Calibration Displays
hubs, the lower line must read “PUSH +/- Adjust”. If
the display is not correct, depress the +/- switches to
change it. Turn the ignition switch or computer restart
switch to the “off” position, then back to the “on” or
Propel = 0 Press
“start” position to save any changes to the steer wand
select mode.
Thres = 32 Store
Note: All steering sensor wands on the machine 360395

must face in the same direction.
Propel = 0 Press
Rev Thres = 32 Store
Fwd Str Auth Cycle Power
FULL +/- Adjust 360396
031-0189 Control knob threshold calibration

360395 & 360396
Forward steer authority display Depress and hold the Calibrate button while
031-0189 depressing the Engine button one time to access the
Forward steer authority display: The upper line control knob calibration mode. Depress the NEXT or
reads “Fwd Str Auth Cycle Power” and the lower line LAST switch to scroll through the threshold displays.
reads either “FULL +/- Adjust” or “HALF+/- Adjust”. The propel calibration displays are used to adjust the
When forward steer authority is set to HALF, the drive start, or threshold; of track movement. The control
signal sent to the steering servo valves is decreased knob is typically turned 25% of full rotation to begin
by 50% when the machine is traveling forward. this movement when applied to the tracks and usually
Normally the forward steer authority should be set to requires a factory adjustment of 32 for a stored
FULL. If the forward steer authority is not set correctly threshold value. A threshold value for forward and
depress the +/- switches to change it. Turn the ignition reverse rotation is stored for each track threshold
G21 09/02/2003
2-22
direction. Refer to the Maintenance chapter for

complete instructions.
Propel Valve Displays S61 SERVICE ROUTINES

LAST or NEXT for More
031-0192
Propel Valve Type Initial service display
= Apitech 031-0192
Initial service display: Depress the SERVICE switch
to show the initial service display on the main screen.
360561
Depress the NEXT or LAST switch to scroll through
the available service displays described below. To exit
the service mode, depress and release the SERVICE
Propel Valve Type switch.
= Modular
360562
Common Switch Test ESTOP
Propel Valve Type ENGINE OFF
360361 & 360362
Depress and hold the Calibrate button while
depressing the Engine button one time to access the 031-0193
control knob calibration mode. Depress the NEXT or
Common switch test display
LAST switch to scroll to the propel valve display. The 031-0193
propel valve used in the track drive system can be a Common switch test display: The common switch
Modular proportional manifold or an Apitech test display shows the function of the display switches
proportional valve. If an older machine is retrofitted located directly above the main screen, including the
with a G21 control system, this allows the system to run/standby and slope setpoint switches. Depress the
control either valve type. Depress the + or - switch to appropriate switch and the main screen will show
choose the correct valve type used on the machine. which switch was depressed. For example, if the steer
sensitivity switch is depressed, the main screen will
Note: The ignition switch or computer restart read:
Service Displays
Common Switch Test ESTOP
STEER SENSITIVITY OFF
031-0194
Common switch test

031-0194
If the display does not show which of the switches is
being depressed, the switch or the wiring connection
may be defective. Refer to the diagnostic chapter for
more information.
Engine, hydraulic and service switches

031-0147
Engine and hydraulic switches: The ENG and HYD
switches are not currently operational. Deviation Meter Test
Check ALL Dots!
031-0195
Deviation meter test

031-0195
G21 09/02/2003
2-23
Deviation meter test: The deviation meter test steer A/M switch. Depress the appropriate switch and
alternates the LED lights on the individual leg modules the main screen should show which switch is
to show if any of the lights are defective. If any of the depressed. If the main screen does not show which
LED lights do not come on, the display is defective and steer switch is depressed, the switch or the wiring
may require replacement. Refer to the diagnostic connection may be defective. Refer to the diagnostic
chapter for more information. chapter for more information.
The display also indicates the function of the manual

steer select switch. Rotate the control knob and the
bottom line of the main screen should change to show
Grade Switch, AllJog
the corresponding position of the switch. If the
LF ELEV JOG DOWN Jg DN corresponding position is not indicated, the switch or
the wiring connection may be defective. Refer to the
360354 diagnostic chapter for more information.
Elevation switch test
360354
Grade switch test: The grade switch test display
shows the function of an individual elevation jog
switch, elevation A/M switch, or the all jog switch. Propel Pot, FNR,
Depress the appropriate switch and the display should 2.50 Volts Fwd
show which switch is depressed. If the main screen
does not show which elevation switch is depressed, 360355
the switch or the wiring connection may be defective. Travel pot test
Refer to the diagnostic chapter for more information. 360355
Travel pot test: The travel pot test display shows the
function of the variable travel control knob on the
console or on the travel/steer remote (if it is plugged
in). Rotate the variable travel knob and the display
Manual Steer Pot
should indicate the voltage output of the knob from
2.45 Volts 0.21 to 5.00 Volts. If the main screen does not show
an increase or decrease in voltage, the control knob or
031-0198 the wiring connection may be defective.
Manual steer pot test
031-0198 The bottom line of the travel pot test also shows the
Manual steer pot test: The manual steer pot test position of the forward/reverse and the travel/neutral
display shows the function of the manual steer control switches. If the main screen does not show “NEU”
knob on the console or on the travel/steer remote (if it when the travel/neutral switch is in the neutral (N)
is plugged in). Rotate the manual steer knob and the position, “FWD” when the forward/reverse switch is in
main screen should indicate the voltage output of the the forward (F) position and the travel/neutral switch is
knob. If the voltage in the main screen does not in the “travel” position or “REV” when the forward/
increase or decrease as the knob is rotated, the reverse switch is in the reverse (R) position and the
control knob or the wiring connection may be travel/neutral switch is in the “travel” position, one or
defective. Refer to the diagnostic chapter for more both switches or the wiring connection may be
information. defective. Refer to the diagnostic chapter for more
information.
Steer Switch, Steer Mode

LF STEER JOG LEFT Strin
031-0197
Steer switch test

031-0197
Steer switch test: The steer switch test display
shows the function of an individual steer jog switch or
G21 09/02/2003
2-24
Optional Service Display Access Set displays
Hit +/- To Adjust

Slope Comp. = ON
950999
Slope Compensation access

950999
Depress and hold the SERVICE button while
depressing the + and - slope adjustment switches Set and store switches
simultaneously. Depress the NEXT switch to display 031-0142A
the slope compensation on/off display. When the Set and store switches: Depress the SET switch to
slope compensation display indicates the “OFF” enter the set displays. The display below will appear:
position, all displays pertaining to the operation of the
slope compensation programming will be hidden.
Depressing the + or - switches will adjust the display to
the “ON” position, which will allow the operation of the STORE to Save Slope Null
slope compensation programming. The operator must & Feedback Pot. Points.
cycle the power before any changes are enabled.
031-0200
Initial set display

031-0200
Hit +/- To Adjust The set displays are used to change the null positions
Slope Tran. = ON of the smart cylinders and the slope sensor. Depress
the NEXT or LAST switches to select the display for
951000 the appropriate smart cylinder or the slope sensor.
Depress the STORE switch to enter a new null value
Slope transition access for the smart cylinder or slope sensor. Depress and
951000
Depress the NEXT switch to display the slope release the SET switch to exit the set displays at any
transition on/off display. When the slope transition time. The exact procedures for setting the null points
display indicates the “OFF” position, all displays for the slope sensor and smart cylinders is described
pertaining to the operation of the slope transition below.
programming will be hidden. Depressing the + or -
switches will adjust the display to the “ON” position, Centering the Slope Sensor: Before centering the
which will allow the operation of the slope transition slope sensor, level the machine frame from side.
programming. The operator must cycle the power When the machine frame is level, turn off the engine.
before any changes are enabled. Turn the ignition switch to the “on” position to start the
G21 controller. After the power up display disappears,
Note: An operation manual for the automatic depress the SET switch. The initial set display shown
slope transition system is available from below appears.
GOMACO. Order form number H-050105ATGC
from a GOMACO distributor or GOMACO.
STORE to Save Slope Null

& Feedback Pot. Points.
031-0202
Initial set display

031-0202
Depress the NEXT switch until the slope sensor stored
null display appears:
G21 09/02/2003
2-25
Front Slope = 2.44 V Jog LF Leg Left & Store

Stored Null = 2.50 V 3.84 V Stored: 3.84 V
031-0201 031-0203
031-0203
Front slope sensor calibration display The top line of the display describes the calibration
031-0201
The top line of the stored null display shows the procedure. The bottom line shows the voltage that the
voltage that the G21 controller is receiving from the G21 controller is receiving from the smart cylinder on
sensor. The lower line shows the previously stored the left front leg and the previously stored null voltage
null voltage of the sensor. of the smart cylinder.
If the top line of the display does not read between Use the jog switch for the left front leg to turn the track
2.40 and 2.60 Volts, loosen the slope sensor mount as far to the left as required to prevent the track from
and rotate the sensor until the top line voltage reads contacting obstacles on the machine or the jobsite.
between 2.40 and 2.60 Volts. Tighten the mounting Depress the STORE switch to store the new left turn
screws securely. Depress the STORE switch to store null point for the left front leg. Depress the NEXT
the new null point. Refer to the Maintenance chapter switch to make the display below appear:
for more information.
Calibrating the smart cylinders: The calibration

procedure described below sets the left, center, and Center LF Leg & Store
right null points for the smart cylinder on each leg. 2.56 V Stored: 2.56 V
Calibrate the center null point for each smart cylinder
so that the G21 controller steers the tracks precisely
031-0204
straight whenever a steering sensor calls for straight
031-0204
steering. Calibrate the left and right null points for Jog the track to the straight ahead position and adjust
each smart cylinder to prevent the G21 controller from it carefully until the square leg tube is parallel to the
turning the track too far and contacting an obstacle on leg mount. Depress the STORE switch to store the
the machine or on the jobsite. new center null point for the left front leg. Depress the
NEXT switch to make the display below appear:
To calibrate the smart cylinders, start the engine. After
the power up display disappears from the main screen,
depress the SET switch. The initial set display shown
below appears.
Jog LF Leg Right & Store
1.29 V Stored: 1.29 V
STORE to Save Slope Null 031-0205

031-0205
& Feedback Pot. Points. Use the right jog switch for the left front leg to turn the
track as far to the right as required to prevent the track
031-0200 from contacting obstacles on the machine or the
Initial set display jobsite. Depress the STORE switch to store the new
031-0200 right turn null point for the left front leg.
Depress and release the NEXT switch repeatedly until
the display for the left front (LF) leg appears: Depress the NEXT switch and repeat the procedure
above to calibrate the left, center, and right null points
on the right front (RF) and rear (Rr) legs.
Note: When tight radius work is required, make

sure that the left and right null points on each leg
do not prevent the track from turning enough to
complete the radius.
G21 09/02/2003
2-26
Test Displays Power supply ................... 9.0 to 16.0

LED supply ...................... 4.75 to 5.25
Sensor supply .................. 4.75 to 5.25
Sensor output .................. 1.2 to 3.8
Slope sensor output ........ 0.75 to 4.25
Feedback Pot .................. 1.0 to 4.0
Elevation Valve ................ 0.0 to +/-4.10
Steer Valve ...................... 0.0 to +/-4.10
Circuit voltage range table: The circuit voltage

range table shows the normal voltage range for each
G21 component. Any voltage above or below the
Test switch normal ranges is an indication of a faulty circuit and
031-0142B
Test switch: Depress the test switch to enter the test should be repaired or replaced.
displays. The initial test display, shown below, will
appear:
LF BPwr SPwr GdWnd GdVlv

15.09V 5.01V 2.86V-0.38V
Test Mode Displays
LAST or NEXT for more 360356
Elevation power test display

031-0206 360356
Elevation test displays: The elevation test displays
Initial test display show, from left to right, the corresponding S2X
031-0206
controller power supply voltage (BPwr), the sensor
The test displays show the voltages coming to and
power supply voltages (SPwr), the voltage coming
from the G21 control devices such as sensors and
from the grade sensors (GdWnd), and the voltage
valves. Depress the NEXT or LAST switches to scroll
going out to the grade servo valves (GdVlv).
through the test displays shown below. To exit the test
mode, depress and release the TEST switch. The first elevation test display shows information for
the left front (LF) leg. The voltage from the elevation
sensor for the left front leg are from the front grade
sensor mounted at the front of the slipform mold with
BtPwr SPwr LEDPwr the front sensor selection switch in the sensor 1
14.06 V 5.01 V 4.97 V position (the voltages from the front grade sensor
mounted at the middle of the mold can be seen by
031-0207 placing the front sensor selection switch in the sensor
2 position). Depress the NEXT switch again to scroll
Main power test display to the elevation test display for the right front (RF) and
031-0207
Main power test display: The main power test rear leg.
display shows, from left to right, the voltage available
from the battery, the voltage available to power the
manual steering knob on the control panel or the travel/
steer remote (SPwr), and the power available for the LF FdbkPot StrWnd StrVlv
LED lights on the individual control module displays. 2.40V 2.52V 0.00V
002-2760
Steering test displays

002-2760
Steering test displays: The steering test displays
show, from left to right, the voltage from the smart
cylinders (Fdbk), the voltage from the steer sensor
G21 09/02/2003
2-27
(StrWnd), and the voltage going out to the steer servo

valves (StrVlv).
The first steering test display shows information for the

left front (LF) leg. The voltage from the steer sensor
for the left front (LF) and right front (RF) legs are from
the front steer sensor mounted at the front of the
slipform mold with the front sensor selection switch in
the sensor 1 position (the voltages from the front steer
sensor mounted at the middle of the mold can be seen
by placing the front sensor selection switch in the
sensor 2 position). Depress the NEXT switch to scroll
to the steering test display for the right front (RF) leg.
Depress the NEXT switch again to scroll to the
steering test display for the rear (Rr) leg.
Front Slope Control modules in manual mode

2.86V 031-0141A
Manual operation: When no sensors are connected
360357 to the machine, any leg on the machine can be raised
or lowered with the main control module in standby
Front slope test display (Stdby) or run mode, or with the grade control modules
360357
Slope test display: The slope test display shows the in manual (M) or automatic (A). If the sensors are not
voltage from the slope sensor. Depress the NEXT connected, a fault will be indicated on the display if the
switch again to return to the main power test display. system is in the run mode with the control loops in
automatic. To raise or lower the leg, depress and hold
System Operation the up or down jog switch next to the appropriate
control module. When the machine is at the desired
height, release the switch.
To use the jog switches to raise or lower any leg on

Stdby LGrd RSlope= 0.00 the machine with the sensors connected, the main
Neu Coord Sensor 1 control module must be in standby (Stby), or the grade
control modules must be in manual (M) if the G21
360350 controller is in run mode.
Normal operating display
360350 All leg elevations on the machine can be controlled
When the machine is started, the G21 display panel with the all jog switch. Hold the all jog switch to the up
will show the normal operating display after the power position to raise all three legs. Hold the all jog switch
up display disappears. The letters “Stdby” on the left to the down position to lower all three legs.
end of the upper line show that the G21 controller is in
standby. To hold the machine frame level, place the main
control module in run mode, and the right front slope
control module in automatic (A). Use the +/- switch to
adjust the slope setpoint to “0.00%”. This will cause
the frame to automatically remain level while moving
the machine around. Decrease the sensitivity for the
slope control module if the machine becomes
unstable.
To individually steer any track, place the G21

controller in standby (Stdby), then depress and hold
the left or right jog switch on the appropriate control
module.
G21 09/02/2003
2-28
connect them to the correct bulkheads. Mount the

steering and grade sensors so that the center of their
hubs are near the correct steering and grade offset.
System Diagnostics
The G21 controller is capable of system diagnostics. It

will detect the following conditions:
1. Low battery voltage

2. Incorrect sensor signals
3. Shorts in wiring
031-0137B 4. Off stringline
5. Location of faults
Smart steer in manual mode 6. Program faults
031-0137B
To manually steer the machine using the steering knob 7. Servo valve drive faults
(with or without the sensors connected), depress the
run/standby switch to place the G21 controller in run mod The display will show the type of fault and the current
and place all three steering control modules in voltage reading for the failed circuit. If there is more
automatic (A). Place the forward/reverse switch in the than one fault at any time, the main screen will
forward (F) or reverse (R) position, and turn the steer alternate between faults, giving an overall view of the
select switch to one of the four manual positions. Turn fault. The fault messages are described below.
the manual steer knob on the console or the remote to
the left or right to turn the tracks.
Automatic Operation: The machine can be operated Master Sensor Power

with a stringline on the left side or under the machine. OUT OF RANGE
Before operating the machine automatically along a
stringline, follow the instructions in the “calibrate
031-0217
displays” section to set up the G21 controller for left
stringline. Master sensor power fault
031-0217
Master sensor power fault: If the supply voltage to
the travel or steer knobs on the console or the remote
drops below 4.75 volts or increases above 5.25 volts
Stdby LGrd RSlope= 0.00 the display will alternate the message “Master Sensor
Neu Coord Sensor 1 Power OUT OF RANGE” with the normal operating
display. The machine can be steered with the manual
360350 override controls only.
Left grade, right slope display
360350
For example, if the G21 controller is calibrated for left
grade/right slope, the controller will assign grade Left Front Steer Wand
control to the left front and rear legs and slope control
SHORT TO 0V
to the right front leg.
360359
Short to 0.0 Volts

360359
Run LGrd RSlope= 0.00 Short to 0 Volts: If the output voltage from a sensor
Fwd String Sensor 1 or a smart cylinder drops below 1.2 volts (or 0.75 for a
slope sensor), the top line of the display shows the
360358 location and type of sensor or feedback pot. The
bottom line shows “SHORT TO 0 V”. The message
G21 controller in automatic with slope
360358 alternates with the normal operating display. The
To set the control system for automatic control, mount output voltage to the corresponding servo valve shuts
the sensors to the correct side of the machine and
G21 09/02/2003
2-29
down, holding the appropriate grade or steering

cylinder in position. This fault will not appear unless
the appropriate control module is in automatic (A) and
Left Front Steer Wand
the G21 controller is in run mode.
VALUE TO HIGH
360360
Left Front Grade Wand Sensor signal short to power

360360
OFF STRINGLINE VALUE TOO HIGH — This message refers to a direct
short between the power supplied to the sensors and
360362 the sensor signal returning to the S2X controller. If
Off stringline sensor signal voltage increases above 3.8 volts the
360362 main screen will indicate the location of the fault. The
Off stringline: If the output voltage signal from a message “VALUE TOO HIGH” will alternate with the
grade sensor drops below 1.5 volts or increases above normal operating display. The output voltage drive to
3.5 volts, the display shows the location and the type the corresponding servo valve will shut down, holding
of the sensor. The bottom line shows “OFF the appropriate cylinder in position.
STRINGLINE”. The message alternates with the
normal operating display. The output voltage drive to
the corresponding servo valve shuts down, holding the
appropriate grade cylinder in position. This fault will
LF Grade Servo
not appear unless the appropriate control module is in
automatic (A) and the G21 controller is in run mode
VALUE OUT OF RANGE
To correct this fault, place the grade sensor wand(s)
back on the stringline. 360363
Servo valve fault

360363
Servo valve OUT OF RANGE — If the wiring in or to
a servo valve shorts out or becomes disconnected, the
Rear Steer FdBk main screen shows where the fault is. The message
VALUE TO LOW will alternate with the normal operating display.
031-0220
Value too low

031-0220 SA=6 Propel Valve
VALUE TOO LOW: The “VALUE TOO LOW”
FAULT
message appears if the power supply to a sensor from
a S2X controller falls below 4.75 volts. This will affect
the voltage output from the sensor, causing it to drop 031-0223
below the minimum operating range recognized by the Travel valve fault
G21 control system. Refer to the circuit voltage range 031-0223
table, in the Test Display section of this chapter, for Travel valve fault — If the wiring in or to the travel
typical voltage ranges of the various sensors . The top valve shorts out or becomes disconnected, the main
line of the main screen shows the location of the fault. screen will show the S2X address (SA=6) and the
The message will alternate with the normal operating name of the valve. The message will alternate with
display. The output voltage drive to the corresponding the normal operating display.
servo valve shuts down, holding the appropriate
cylinder in position.
Rear Slave
NO RESPONSE
360361
S2X controller not responding

360361
G21 09/02/2003
2-30
NO RESPONSE — If an S2X controller fault occurs, controller and the last time occurred at the 8 hour
the main screen will indicate the location of the S2X. actual run time of the controller. The following table
The message NO RESPONSE will alternate with the indicates the fault number code and the explanation of
normal operating display. This message occurs when the code:
a S2X controller is not communicating with the main
control panel. A power fault or a defective S2X 11 .................................... Value at Five Volts
controller may be the cause. 12 .................................... Value too High
13 .................................... No Response
Fault History Displays 14 .................................... Value at Mid Volts
15 .................................... Value too Low
Depress and hold the SERVICE switch and depress 16 .................................... Value at Zero Volts
the NEXT and LAST switches simultaneously. The 17 .................................... Not Calibrated
display below will appear. 18 .................................... Just Calibrated
19 .................................... Value Out of Range
Note: Fault History displays are available with 21 .................................... Generic Fault
software updates on earlier model machines 22 .................................... No Signal
equipped with a G21 controller. 23 .................................... User Fault 1
24 .................................... User Fault 2
25 .................................... User Fault 3
26 .................................... User Fault 4
Fault History Display 27 .................................... User Fault 5
Press NEXT to view 28 .................................... Time Out
29 .................................... No Data Available
031-0567 31 .................................... Invalid Setup
32 .................................... Min Cal too low
Fault history display 33 .................................... Min Cal too high
031-0567
All G21 controller faults are recorded and stored. The 34 .................................... Max Cal too low
fault history may be used to review faults that have 35 .................................... Max Cal too high
occurred since the last time the fault history was
cleared. By clearing past faults and returning to the Continue to depress the NEXT switch to review all
fault history displays, any active faults will again be stored faults. The following display will appear after all
stored. Once past faults have been cleared, they will stored faults have been reviewed.
be erased permanently from the memory of the
controller. Depress the NEXT switch to review all
stored faults.
No More Faults Stored
Press CLEAR to delete
Left Rear Elev. Wa16# 3 031-0560

1st- 6 HR Last- 8 HR
Fault history clear display
031-0560
031-0564 Depress the CLEAR switch to delete all of the stored
faults from the history displays. A confirmation screen
History display for left rear elevation wand “Clear Fault History?–Press CLEAR to accept” will
031-0564
Each display indicates the type of fault on the top line appear. Press the CLEAR switch again to delete the
of the display (Left Rear Elevation Wand), a history displays. A screen “Fault History Cleared” will
corresponding number code for the fault (16#) and the confirm the history displays are permanently deleted.
number of occurrences (3) since the fault codes were New faults will be stored at the time they occur.
last cleared. The bottom line of the display indicates
the “1st” occurrence of the fault was at the “6” hour To refuse to delete the history displays, depress the
(HR) controller operating clock time and the “Last” NEXT switch to return to the first fault history display
occurrence of the fault was at the “8” hour (HR) clock or depress the SERVICE switch two times to return to
time. To clarify, the left rear elevation wand fault the normal operating display.
(Value at Zero Volts) occurred three different times.
The first time was at the 6 hour actual run time of the
G21 09/02/2003
2-31
Note: Current software allows the capability to Increase engine speed to 1500 rpm and allow the
clear the fault history. Future releases of software engine to warm up for 10 to 15 minutes.
will allow distributors or GOMACO personnel the
access required to clear the fault history. When the engine is warm, depress the CALIB switch.
Follow the directions in the “calibrate displays” section,
07 Moving the machine above, to check the machine settings and change
them if necessary. Select the appropriate elevation
Before starting the engine, check all oil and coolant mode, alarm mode, sensor push/pull, and steer
levels. Grease the machine as specified in the authority. Once the settings are made, they are stored
maintenance chapter. Place all hydraulic controls and in the controller and are recalled after each shut down.
switches in the “neutral” or “off” position and place the
servo lock switch in the locked ( ) position.
! WARNING! !
! DANGER! ! THE TRACK BRAKE SWITCH MUST BE “ON” ANY
TIME THE MACHINE IS LOADED OR UNLOADED
DO NOT USE ETHER. MACHINES EQUIPPED OR MOVING UP OR DOWN STEEP
WITH AN INTAKE MANIFOLD FLAME HEATER EMBANKMENTS.
STARTING AID HAS OPEN FLAME. ETHER MAY
CAUSE EXPLOSION AND SEVERE INJURY. To move the machine, or to load or unload it, increase
engine speed to maximum (2250 rpm). Place the
To start the engine, turn the throttle open servo lock switch in the unlocked position ( ). Place
(counterclockwise) three or four turns. Make sure the the track brake switch in the “on” position. Using the
travel variable control knobs on the console and the all jog switch, raise the machine high enough to clear
remote are in the “off” position. Turn the ignition key to obstacles.
the start ( ) position.
Note: To hold the machine frame level, place the
servo lock switch in the unlocked ( ) position.
! CAUTION! ! Adjust the slope setpoint to “0.0%” of slope by
depressing the +/- switches. Place the slope
CONTINUOUS EXPOSURE TO ENGINE AND control module in automatic (A) and the G21
MACHINE NOISE CAN CAUSE HEARING INJURY. controller in run mode. The machine frame will
DO NOT OPERATE THE MACHINE WITHOUT automatically remain level from side to side while
ADEQUATE HEARING PROTECTION. moving the machine. It may be necessary to
reduce the sensitivity if the machine overreacts.
Notice: To prevent damage to the starter motor,
do not crank the engine for more than 30 seconds
at a time. Allow the starter to cool for 2 to 3
minutes between starting attempts. ! WARNING! !
MOVE SLOWLY ANY TIME THE MACHINE IS
Crank the engine until it starts. Release the key and LOADED OR UNLOADED OR WHEN MOVING UP
allow it to return to the on ( ) position. After the OR DOWN STEEP EMBANKMENTS.
engine starts, do not increase speed above 1000 rpm
for one minute to allow engine oil pressure to increase.
Note: The travel variable control knobs on the

console and the remote must be rotated to the
“off” position before the engine will crank. When
the engine starts, the ignition switch must remain
in the on ( ) position for the electronic controls to
function.
Depress the emergency stop reset switch to energize

the emergency stop system. When the emergency
stop light goes out, the machine is ready for operation.
If the light stays on, make sure all of the emergency
stop buttons are pulled out.
G21 09/02/2003
2-32
the “travel” position. To start the machine in motion,

slowly rotate the travel variable control knob on the
console or the travel/steer remote clockwise. The
more the control knob is turned clockwise, the faster
the machine will travel.
031-0137B
Select a manual steer mode
031-0137B
Place the manual steer selector in one of the manual
steer positions and the G21 controller in run mode.
Place each of the control loops in automatic mode for
steering the machine. Rotate the manual steer knob
to steer the tracks. Make sure the tracks are correctly
positioned before moving the machine.
Note: The servo lock switch must be in the

unlocked ( ) position to steer the tracks.
Shipped components
360646 & 2075
Banded to the conveyor is the ladder for boarding the
machine, 2 sensor arm assemblies, 4 sensor arm
braces, the rubber discharge chute for the conveyor
and miscellaneous other parts. Cut the bands and lay
Controls set to move the machine all parts off to one side for installation later.
360284
Remove the sensors, steering wands, grade wands

! WARNING! ! and miscellaneous other parts from the tool box on the
left front leg extension. Lay them off to the side out of
BEFORE MOVING THE MACHINE, MAKE SURE
the way until needed.
THAT THE AREA IS CLEAR. MOVE THE MACHINE
SLOWLY WHEN LOADING OR UNLOADING. USE
CAUTION WHEN TRAVELING DOWN
EMBANKMENTS TO AVOID TILTING. BE CERTAIN
THAT THE AREA AROUND THE MACHINE IS
CLEAR BEFORE TURNING.
Place the forward/reverse switch in the forward (F) or

reverse (R) position. Place the travel/neutral switch in
G21 09/02/2003
2-33
CHAPTER III STANDARD SETUP 02 Curb and Gutter Form Preparation
This chapter covers instructions for the preparation of

the machine, trimmerhead and the various slipform
molds used for standard types of pouring. Also
covered are instructions for mounting the attachments
to the machine and pouring operations. At the end of
the chapter are instructions for cleaning the machine
at the end of the pour. Some procedures apply to
machines that are being assembled for the first time,
while others pertain to machines that may have been
in service for some time. All adjustments are
recommended procedures only. Pay particular
attention to all Safety statements.
Adjust Stainless
301
NOTICE Stainless Trowel Adjustment: Adjust the stainless
trowel section of the slipform mold so the leading edge
WARNING! is approximately 1/8 inch (3 mm) above the rear edge
DO NOT OPERATE THIS EQUIPMENT UNTIL
YOU HAVE READ AND THOROUGHLY
of the main pan. Make the adjustment at both sides of
UNDERSTAND THE OPERATORS MANUAL. the mold. Tighten the adjustment nuts securely.
FAILURE TO FOLLOW THIS PROCEDURE MAY
RESULT IN INJURY OR DEATH.
DANGER!
DO NOT ALTER OR MODIFY THIS PRODUCT
WITHOUT THE EXPRESS WRITTEN CONSENT
OF THE MANUFACTURER.
UNAUTHORIZED MODIFICATION MAY RESULT
IN SERIOUS INJURY OR DEATH.
DCAL-058
! CAUTION! ! 302
Measure With Straight Edge
CONTINUOUS EXPOSURE TO ENGINE NOISE CAN Place a 4 feet (1.22 m) straight edge from the rear of
CAUSE HEARING INJURY. DO NOT OPERATE the stainless trowel section, up into the main form.
ENGINE WITHOUT ADEQUATE HEARING Adjust the rear of the stainless until there is a 1/8 inch
PROTECTION. (3 mm) gap between the rear edge of the main form
and the straight edge. Tighten the adjustment nuts
securely.
G21 06/01/04
3-1
hopper section prior to attachment of the slipform

mold. Also for easier access, sideshift the mold
sideshift beam to the left if the split hopper is mounted
on the drawbar. Measure the slipform profile to be
used and transfer these measurements to the split
hopper section for approximate mounting position(s) of
the vibrator(s).
GOMACO TIP: It will be much easier to install the

vibrators if the hopper is attached to the drawbar
on the machine and raised above grade for easy
access.
Note: Any slipform mold within 6 to 32.75 inches

Adjust Curb Profile (15.2 to 83.2 cm) wide and up to 20.5 inches (52
303 cm) in height can be attached to the universal
Place the straight edge in the top of the curb profile. hopper included with the machine (measurements
Adjust the rear of the curb profile stainless until there include slump allowance). Any slipform mold that
is a 1/8 inch (3 mm) gap between the rear edge of the does not fit within these measurements will require
main form and the straight edge. Tighten the an integral hopper built for the individual mold.
adjustment nuts securely. Check the sides of the curb
profile to be certain that the leading edge of the
stainless is not protruding inside the dimensions of the
main form. If so, slightly bend the leading edge of
stainless trowel as necessary.
By adjusting the stainless trowel section in this manner

assures that as concrete slips from the main form, the
leading edge of the stainless will not catch and tear the
surface. It also assures that the rear of the stainless
will push down slightly on the concrete to give it a
troweled surface.
Note: When adjusting the stainless trowel section

on curb and gutter forms, it is normally easier to
roll the form over on its top.
Install Vibrator
305
Vibrator Installation: Vibrator placement in a barrier
type curb (no gutter section) is with the lower vibrator
in an underslung (horizontal) position, centered in the
curb. The tip should be 6 inches (15 cm) above the
bottom of the form. The top vibrator should be in an
overslung (vertical) position, centered in the curb
opening and tipped back slightly. The tip should be 6
to 8 inches (15 to 20 cm) below the top of the opening.
Tighten the vibrator attaching bolts and setscrews
securely. Tighten the adjustable vibrator mount
assemblies securely in position.
Hopper Mounted to Machine
304
Vibrator and Slipform Mold Installation: The split
hopper design is a separate assembly to which the
slipform mold is attached with four clamps. For ease
of installation, the vibrators will be installed in the split
G21 06/01/04
3-2
When the vibrator(s) have been installed in the hopper

section, move the machine next to the slipform profile
to be used and lower the machine until it is 1 to 2
inches (2.54 to 5 cm) above the profile. Align the
flange on the bottom of the hopper with the opening on
the top of the slipform profile. Carefully lower the
machine until firm contact is made around the
perimeter of the two halves. Place the hook of each
clamp in the catch on the profile and snap the clamp
into its locked position. Hold the clamp in position with
a hair pin. Adjust the set screw on the clamp as
necessary to create a tight seal between the hopper
and the profile. Place bolts through each of the holes
in the flange between to the halves of the slipform
mold. Secure with lock washers and nuts and tighten
Install Curb Vibrator securely.
306
When installing vibrators in a standard curb and gutter Note: The clamps are temporary and should not
form, place one vibrator in the overslung (vertical) be used to hold the slipform profile to the hopper
position, centered in front of the curb opening. The tip during pouring operations.
should be tilted back slightly and 6 to 8 inches (15 to
20 cm) below the top of the opening. The gutter
vibrator should be underslung (horizontal)
approximately 4 to 6 inches (10 to 15 cm) from the
outer edge of the gutter with the tip centered in the
concrete thickness. Tighten the vibrator attaching
bolts and setscrews securely. Tighten the adjustable
vibrator mount assemblies securely in position.
To install vibrators in a drive over type or a valley curb

and gutter form, position both vibrators in the
underslung (horizontal) position, approximately 4 to 6
inches (10 to 15 cm) in from each edge. The tip
should be centered in the concrete thickness. Tighten
the vibrator attaching bolts and setscrews securely.
Tighten the adjustable vibrator mount assemblies
securely in position.
Hold Down Attached
309
Note: It may be necessary to position the Lower the hold down cylinder to the hold down bar on
vibrators to one side of the recommended position the rear of the profile. Attach the lug clamp under the
to allow steel bars to be fed into any of the forms hold down bar and attach the clamp to the hold down
previously described. On forms of 3 feet (91 cm) cylinder with two bolts and lock washers. Tighten
wide or over, it may be necessary to add an securely.
additional vibrator in the center of the form.
Check the position of the vibrator(s) from the rear of
the mold. Make certain that the tip of the curb vibrator
in the overslung position does not extend more than 6
to 8 inches (15 to 20 cm) below the top of the curb
opening and is centered in the opening. Make certain
that the vibrator in the gutter section (if needed) is
centered in the opening. Adjust as necessary.
When installing vibrators in a solid hopper design

mold, the previous measurements may be used
Bolt flanges together referring to the type of mold. The vibrators may be
308
installed while the mold is attached to the machine (as
G21 06/01/04
3-3
in the split hopper design) or, using a suitable lifting Set the driveway cutter assembly in place on the
device, the mold may be tipped forward to rest on the square tubes at the top of the form. Insert the
front of the hopper when it is detached from the mounting bolts and tighten securely. Extend the
machine. cylinder to the maximum, making certain the blade
enters the slot in the top of the gutter profile. Check
Refer to Section 8, Mounting the Slipform Mold, for the gum rubber hose seals on each side of the blade
installation instructions of other mold profiles. to be sure they are snug to prevent grout from leaking
out.
Note: If a slot has not been cut in top of curb

profile, order GOMACO brochure number
H-0476-02 for complete installation instructions.
California Style Blockout Driveway Cutter Blade

310
312
Driveway Cutter Installation: There are two Look under the slipform mold and note the angle of the
assemblies available for cutting driveways, the bottom edge of the blade. It may be necessary to cut
California style driveway depressor and the guillotine the bottom of the blade to get the desired angle.
cutter. It is recommended that the California style
driveway depressor be installed at the factory while the Note: If blade angle is to be changed, do not
driveway cutter can be field installed. The guillotine remove an excess of material. Remove material
driveway cutter can be interchanged with other molds, in small amounts and check performance after
with minor changes, while the California style driveway each such removal.
depressor is built for an individual mold and cannot be
interchanged.
Install Sideplates
313
Driveway Cutout Installing Sideplates: On forms that are designed to
311
be used for pouring against the edge of the existing
roadway (scab-on), a removable sideplate is available.
G21 06/01/04
3-4
The sideplate may be installed so that the form may be be necessary to loosen each of the clamp plates on
used for pouring free standing curb and gutter. Bolt the sideplate guide tubes.
the sideplate to the side of the form and tighten the
attaching bolts securely. When the form is used for Measure from the bottom of the sideplate to the top of
scab on operations, the plate is removed and the the gutter face just ahead of the stainless section.
guide plates are installed in its place. This measurement should be 3/8 inch (10 mm) more
than the actual height of the gutter to allow for slump.
Raise or lower the sideplate as necessary with the
adjustment bolt and tighten securely. It may be
necessary to loosen each of the clamp plates on the
sideplate guide tubes.
Measure from the top of the sideplate to the bottom of

the angle iron on the side of the form, in line with the
rear adjustment bolt. Measure from the top of the
sideplate to the bottom of the angle iron on the side of
the form, in line with the front adjustment bolt. Adjust
the front of the sideplate until the measurement is the
same as the rear. Adjust the front of the sideplate in
the same manner on both sides of the form.
Note: Sideplate measurements may vary

Stainless Trowel Section
314 depending on the height of the curb and concrete
The stainless trowel sections must be changed to mix designs.
match the type of pour. Loosen the adjustment nuts
on the four stainless adjustment bolts. Remove the
cotter keys and pins from the adjustment bolt clevis
and remove the stainless section. Insert the proper
stainless section into place and install the pins and
cotter keys. Adjust the stainless trowel section as
previously described.
Hydraulic adjusted sideplates

001-2559
Hydraulic Sideplates: An optional pressure
compensated sideplate assembly can be installed on
the form. Hydraulic pressure is used to hold the
sideplates down in firm contact with the grade. Hang
the control box on the top of the guard rail on the left
Adjustable sideplates
001-2560 side of the machine.
Adjustable Sideplates: On forms equipped with
adjustable sideplates, it will be necessary to adjust the Connect the pressure and return hoses from the
sideplates for the proper height. Raise the form off the control valve to the quick couplers hanging down
ground. Measure from the bottom of the sideplate to under the machine near the pump suction lines. Route
the top of the curb form just ahead of the stainless the hoses from the sideplate cylinders over the top of
section. This measurement should be 5/8 inch (16 the slipform mold to the control box on the left guard
mm) more than the actual height of the curb to allow rail. Connect the hoses from the cylinder to the
for slump. Raise or lower the sideplate as necessary respective hoses in the control box. Be certain to
with the adjustment bolt and tighten securely. It may place the protective covers over/in the quick couplers
G21 06/01/04
3-5
when they are disconnected to keep dirt from entering

the hydraulic system.
During pouring operations, place the control valve

handles in the “down” position and adjust the pressure
holding the front and rear of each sideplate on the
grade to approximately 300 psi (20.7 bar). To adjust
the pressure, loosen the jam nut on the adjusting
screw and turn the screw in to increase pressure, or
out to decrease pressure. Before raising the slipform
mold, place the control valves in the center (neutral) Remove Bolts Between Sections
316
position. Move the valve handles to the “up” position Remove the bolts from the adjoining ends of the
to raise the sideplates. stainless trowel section. Remove the bolts from the
back of the form and the hopper where it is to be split.
Note: It may be necessary to operate the two
If an insert section is to be removed, remove the bolts
front sideplate cylinders in the “neutral” position if
at each side of the section and lift the section clear.
running on soft subbase to prevent the sideplate
Push the sections together and insert the bolts
from digging into the subbase material.
previously removed. If a section is to be added, use a
03 Sidewalk Form Preparation suitable lifting device and lift one side of the form away
from the other section enough to insert the section of
Note: Maximum width of the sidewalk form is 5 desired width. Insert the bolts through each end of the
feet (1.52 M) when the simultaneous trimming and added section. Do not tighten bolts at this point.
pouring method is used.
Straighten Bottom of Form

317
Using a suitable lift device, align the bottom edge of
the form where the section(s) adjoin. Place a straight
edge across the front and the rear of the main form to
check for flatness. If the profile needs adjusting, it
may be necessary to shim the insert sections of the
Sectional Form main form. Tighten all bolts securely.
315
Changing Sectional Form Widths: When changing
the width of the sectional sidewalk mold, it should be
removed from the machine. Place adequate support
blocking under the form on each side of the joint where
the form is to be split.
Note: If a section is to be removed, place

blocking to each side of, but not under the section.
Stainless Adjustment
318
Stainless Trowel Adjustment: Adjust the stainless
trowel section of the slipform mold so the leading edge
is approximately 1/8 inch (3 mm) above the rear edge
of the main pan. Make the adjustment at both edges
G21 06/01/04
3-6
and at each center adjustment location. Tighten the desired location and mark the holes. Drill 3/8 inch (10
adjustment nuts securely. mm) holes at each marked location and then install the
blockout.
Place a 4 feet (1.2 M) straight edge from the rear of
the stainless trowel section, up into the main form. Bolt the edger into place on the stainless trowel
Adjust the rear of the stainless, at each adjustment section. Place a straight edge along the side of the
location, until there is 1/8 inch (3 mm) gap between the blockout and adjust the front of the edger so it is 1/8
edge of the main form and the straight edge. Tighten inch (3 mm) outside the rear edge of the blockout.
the adjustment nuts securely. Adjust the rear of the edger in, or out, so there is a 1/8
inch (3 mm) gap between the rear edge of the blockout
and the straight edge. Tighten the attaching bolts
securely.
Note: If holes are not in stainless trowel section,

position edger in proper location and mark holes.
Drill a 3/8 inch (10 mm) hole at each of the marked
locations and attach the edger.
Straightedge on Stainless
319
Place a straight edge across the rear edge of the
sidewalk portion of the stainless trowel to check for
flatness. If the profile needs adjusting, it may be
necessary to adjust the center rear of the main form
also.
Hopper Installation
321
Install the rear half of the false end into the proper end
of the slipform hopper and secure it to the rear of the
hopper. Install the front half and secure it to the front
of the hopper. Fasten the two halves together in the
center. Attach both halves to the bottom of the
blockout and tighten all mounting bolts securely.
Blockout Installation
320
Blockout Installation: If the width of the standard
sidewalk or gutter portion of the slipform mold must be
made smaller, it will be necessary to install a blockout
assembly. Tilt the form up until it is resting on the front
of the hopper. Hold the bottom portion of the blockout
in place and secure it with the bolts, nuts and lock Sidewalk Vibrators
322
washers provided. Tighten the bolts securely. If the Vibrator Installation: Install a vibrator 4 to 6 inches
holes are not provided in the main form, it will be (10 to 15 cm) in from the edge of the sidewalk portion
necessary to drill holes. Secure the blockout in the of the form in the underslung (horizontal) position. The
G21 06/01/04
3-7
top of the vibrator tip should be even with the bottom should be placed in the same vertical position,
of the form pan. On 3 to 5 feet (0.9 to 1.5 M) wide provided the tracks are all operating on subgrade that
forms, a third vibrator should be positioned in the is parallel to and at approximately the same elevation
center of the form. The center vibrator(s) should be as the concrete subgrade. Also, the machine frame
installed in the underslung (horizontal) position, with cross slope should be at the same slope as the grade
the top(s) even with the bottom of the form pan. the machine is operating on.
Normally the track mounts are all placed in position

number one when pouring curb and gutter or sidewalk
requiring a straight grade profile. The mounts are
usually placed in the highest position for barrier wall
(#3) when pouring under the machine, or in the lowest
position (#1) when pouring side mount barrier or
bridge parapet.
If the cross slope of the machine frame is different

Depth Extensions than the slope of the grade the machine is operating
323
on, it may be necessary to adjust one or more of the
Installing Depth Extensions: If the thickness of the
legs vertically. Adjust the leg(s) to positions two or
sidewalk must be increased, bolt on extensions are
three as necessary to keep the hydraulic grade control
available for the bottom of the form sides. Bolt the
cylinders extended near the center of stroke during
extensions into place and tighten securely. If no holes
normal pouring operations.
are provided in the bottom angles of the form, clamp
the extensions in place and mark the location of the
holes. Drill the holes, using a 1/2 inch (13 mm) drill bit.
Fasten the extensions in place and tighten the
mounting bolts securely.
04 Positioning the Legs
Leg Mounts Numbered

349
If the left front track is running on the same grade
elevation as the concrete subgrade, but the right front
and rear tracks are running on grade that is lower than
the concrete subgrade, it may be necessary to adjust
the right and rear track mounts vertically to position the
Leg Positions cylinders near the center of their stroke. If the left front
348
Vertical Positioning: The vertical positioning of the track is running on a grade elevation that is a lower
track mounts will be determined by the difference in elevation than the right front or rear tracks, it can be
elevation between the subgrade on which each track adjusted vertically to position the cylinders near the
runs and the concrete subgrade. The positioning is center of their stroke.
also affected by the slope of the machine frame in
relation to the slope of the grade the machine is
operating on and by the type of profile. It is
recommended to adjust the track mounts so that the
leg is extended near the center of stroke during normal
pouring operations. The track mounts are adjustable
in 4 inch (10 cm) increments. All three track mounts
G21 06/01/04
3-8
Note: It is advisable to place a wooden block

! CAUTION! ! between the track yoke and the track and place a
chain around the outer guide tube and top of the
IT IS ADVISABLE THAT AT LEAST THREE frame mount to help stabilize the assembly.
PERSONS PERFORM THE REPOSITIONING
OPERATION. ONE TO OPERATE THE MACHINE Make certain that the water tank is empty before
AND “JOG” SWITCHES, ONE TO STABILIZE THE adjusting the position of the right leg. It is advisable to
TRACK MOUNT AND ANOTHER TO REMOVE AND place a chain around the outer guide tube and the top
REPLACE THE ATTACHING BOLTS. of the frame mount to aid in stabilizing the track mount.
Place adequate blocking or a support under the right
When adjusting the vertical position of the track leg extension tube or support it with a lifting device.
mounts, the rear track should be as near the center of Using the jog switch for the right front grade, lower the
the machine as possible. Using the “jog” switches on machine onto the support system until all weight is
the appropriate control loop, raise the machine frame removed from the track. Remove the eight mounting
to maximum height then adjust the right front leg to bolts. Using the jog switch, lower the track guide tube
level the machine frame. until the proper holes in the guide tube align with the
holes in the frame mount. Replace the bolts and
tighten securely. Lift the machine high enough to
remove the support system.
Place adequate blocking or support under the rear of

the machine frame or support it with a lifting device.
Do not place blocking under the rear track positioning
cylinder or under the hydraulic tank drain plugs. Using
the jog switch for the rear grade, lower the machine
frame onto the support system until all weight is
removed from the track. Remove the eight mounting
cap screws. Using the jog switch, lower the track
guide tube until the proper holes in the guide tube
align with the holes in the frame mount. Replace the
cap screws and tighten securely. Be certain that the
lock washers are in place on the cap screws. Lift the
Leg Prepared for Removal
350 machine high enough to remove the support system.
! WARNING! !
WHEN ADJUSTING THE POSITION OF THE LEG,
DO NOT GET UNDER THE MACHINE, OR THE LEG.
DO NOT PLACE FINGERS IN HOLES TO CHECK
FOR ALIGNMENT. SEVERE INJURY, OR
AMPUTATION, COULD OCCUR IF THE LEG WERE
TO MOVE OR FALL.
Place adequate blocking or a support under the left

front leg extension or support it with a lifting device.
Place the servo lock switch in the “off” position. Using
the jog switch for the left front grade, lower the
machine frame onto the support system until all weight
is removed from the track. Remove the eight
mounting bolts. Using the jog switch, lower the track
guide tube until the proper holes in the guide tube
align with the holes in the frame mount. Replace the
bolts and tighten securely. Lift the machine high
enough to remove the support system.
G21 06/01/04
3-9
Position Rear Track

351
The rear track assembly should normally be positioned
so enough clearance exists between the front of the Left Front Leg Positions
352
track and the rear of the slipform mold to allow the
The pivoting left front track extension can be adjusted
track to turn without running into the concrete when
to position the left front track from straight ahead
doing radius work. It can be adjusted from centered
(aligned with the outside of the main frame) to 21
on the machine frame up to 40 inches (101.6 cm) to
inches (53.3 cm) to the outside (left) of the frame, or
the left, or flush with the left side of the frame. Move
12 inches (30.5 cm) to the inside (right) of the frame.
the rear shift control lever to either the “left” or “right” to
Remove the left front turnbuckle between the machine
position the rear track as desired. It is advisable that
frame and the left front pivot arm. Move the left front
the machine be moving during positioning operations.
leg pivot switch in either the “left” or “right” direction to
position the track in the desired position.
G21 06/01/04
3-10
Install left front pivot turnbuckle

360013
Once the left front leg has been pivoted to the desired
position it will be necessary to install the turnbuckle
between the lugs on the left front leg pivot arm and the
mount bracket on the front of the machine frame.
Install the mount bracket to the front of the machine
frame with the clamps, bolts, lock washers and nuts
provided and tighten securely. Insert the turnbuckle
between the mount bracket on the machine frame and
one of the two lugs that are welded to the pivot arm.
Insert the pins in each end of the turnbuckle and
secure with hair pins. Tighten the turnbuckle to
remove any excess movement in the pivot arm.
Tighten the lock nut securely.
Note: Properly tighten the turnbuckle by screwing

the threads into the barrel of the turnbuckle.
Right Front Leg Positions
Notice: The turnbuckle is installed to remove 353
excess movement in the left front leg pivot while The right front track extension can be adjusted to
pouring. An unsatisfactory finished product may position the right front track from flush with the outside
result if it is not installed. of the main frame to 24 inches (61 cm) to the outside
(right) of the frame. To position the track, start the
machine traveling in either the forward or reverse
direction. Move the right front frame extension control
valve in the “left” or “right” direction to position the
track in the desired position. The track can be
positioned anywhere in its range of movement. It may
be necessary to loosen the right front leg clamps
before attempting to move the leg. Tighten the clamps
securely when the leg is in its’ final position for the
pour.
G21 06/01/04
3-11
05 Preparing and Mounting the Conveyor
Install Discharge Chute

360641
Turn the discharge chute over and slide the rubber
Conveyor Shipping Position
354 discharge chute into place on the conveyor discharge
The conveyor is usually shipped attached to the ring. Two and preferably three channel locks or
machine. In special cases the conveyor will be locking pliers (vise grips) are the best tools for
removed for shipment. installing the rubber discharge chute to the ring. Place
the ring clamp around the rubber chute. To assemble
the ring clamp, use a clamp to pull the two ends of the
ring clamp together. Insert the bolt and tighten the
clamp securely. Be certain that the end of the rubber
chute is 2 to 3 inches (5 to 7 cm) above the top metal
ring on the discharge chute and the ring clamp is just
above the bottom ring.
Parts Banded to Conveyor

355
Several component parts are banded to the conveyor
for shipment. Cut the bands and remove all the parts
from on top of conveyor and lay them to one side until
required.
Mount Conveyor Cam Follower Assembly to Machine frame

357
Raise the conveyor cam follower assembly, with the
pivot arm and conveyor lift cylinder assembly attached,
into position above the frame mount attached to the
front of the machine frame. Carefully lower the
conveyor cam follower assembly and start the pivot
arm into the frame mount. Lower the conveyor cam
follower assembly until it is supported by the frame
mount. Raise the yoke end of the conveyor lift cylinder
assembly and attach it to the lower end of the pivot
arm. Install the bolt and tighten. Connect the
G21 06/01/04
3-12
conveyor lift hoses (1/4 inch (6 mm) hoses) to the Connect the conveyor motor hose quick couplers to
conveyor lift cylinder. Be certain the lift cylinder is the conveyor bulkheads on the side of the operators
positioned below the two piece tube. console. Start the engine and move the conveyor
control valve to the “forward” position. The conveyor
Note: The mounting bracket for the conveyor shift should run in a direction that would bring concrete up
valve should be closer to the discharge end of the the belt. If the belt runs the wrong direction, reverse
conveyor. the hoses on the drive motor.
Adjust the conveyor belt tension and adjust the

alignment of the belt following the instruction in the
Maintenance chapter.
06 Trimmerhead Preparation
Positioning the Trimmerhead Lift Mounts
Mounting Conveyor to Conveyor Cam Follower Assembly

359
! WARNING! !
DO NOT GET BENEATH CONVEYOR DURING
ASSEMBLY. IF THE CONVEYOR WERE TO FALL,
SERIOUS INJURY CAN OCCUR.
Position the conveyor frame over the conveyor cam

follower assembly. Align the bottom slotted hole in the
conveyor cam follower assembly with the first hole
below the conveyor insert section. Insert the four
bolts, flat washers (on slotted holes only), lock
washers and nuts on both sides of the conveyor frame Trimmerhead Lift Mounts Installed
324
and tighten securely. The standard position for the left and right
trimmerhead lift assembly, when pouring curb and
gutter or sidewalk, is to align the bottom of the
mounting flange on the lift assembly with the bottom of
the frame mounting flange. The lift assembly is
equipped with 12 inches (30.4 cm) of cylinder stroke to
accommodate most elevation adjustments. However,
the lift assembly may be lowered on the frame mount
flange an additional 6 inches (15.2 cm) to
accommodate a bi-level subgrade. The left lift mount
also has two horizontal mounting positions and should
be mounted closest to the outside (left) of the frame for
maximum coverage of the slipform mold when fully
side shifted to the left. Insert the bolts, lock washers
and nuts and tighten securely.
Conveyor Quick Couplers
362
G21 06/01/04
3-13
Note: If the left lift assembly is mounted to the

inboard position and the trimmerhead is side
shifted fully to the left, the trimmerhead may not
cover the full width of the mold when it is side
shifted to its maximum left extension. The inboard
mounting holes allow the trimmerhead to retract
flush with the left side of the machine frame for
minimum road travel width.
Thoroughly clean the quick couplers on the

trimmerhead lift hoses. Connect the lift hoses to their
respective quick couplers on the trimmerhead lift
cylinders. Whenever the trimmerhead lift is removed,
always place the protective covers over/in the quick
coupler to prevent dirt from entering the hydraulic
system.
Trimmerhead Removed from Machine
360654
Changing Trimmerhead Width It is recommended to remove the trimmerhead from
the machine when changing the width of the
trimmerwheel assembly. Disconnect all hydraulic
hoses from the trimmerhead and place the protective
covers over/in the quick coupler to prevent dirt from
entering the hydraulic system. Place a cap over the
case drain line fitting to prevent dirt from entering the
hydraulic system. Lower each of the trimmerhead lift
legs to allow easy access to all fittings. Place blocking
under the left front corner of the trimmerhead to
support it during removal from the machine.
Notice: Do not place a quick coupler in the case

drain line. Excess back pressure will cause
damage to the trimmer gearbox seal.
Standard Trimmer
325
The minimum width of the trimmerhead is 30 inches
(76 cm), consisting of a 15 inches (38 cm) drive
! CAUTION! !
shroud section and a 15 inches (38 cm) idler shroud MAKE CERTAIN ALL PERSONNEL ARE CLEAR OF
section. Shroud inserts are available in 12 inches THE MACHINE AND/OR ARE AWARE THAT THE
(30.4 cm), 18 inches (45.7 cm) and 30 inches (76.2 MACHINE IS MOVING.
cm) sections. Maximum grade width of the
trimmerhead should not exceed 66 inches (1.67 M). It
is recommended that the trimmer width should be at
least 6 inches (15 cm) wider than the pouring width.
G21 06/01/04
3-14
Trimmerhead removed from machine

3029a
Remove the bolts from the trimmerhead shroud prior
to laying the trimmerhead over on to the rear of the
shroud.
Remove bolts from left trimmer slide

360207
Remove eight bolts from the left shift mount attached
to the trimmerhead shroud.
Trimmer on Back
330
Lay the trimmerhead over on it’s back. Remove the
bolts, nuts and lock washers connecting the trimmer
wheel to the idler shaft. It is recommended to support
the trimmer wheel on the discharge end with blocking
to prevent damage to the gearbox guideplate on the
opposite end of the trimmer wheel. With all bolts, nuts
and lock washers removed from the shroud, separate
the sections of the trimmer to allow insertion or
removal of sections as required.
Remove bolts from right trimmer slide
360208 Note: The 26-7/8 inch (68.3 cm) main drive wheel
Remove eight bolts from the slide clamps which are section must remain attached to the drive gearbox.
over the I-beam shift assembly on the right side of the
trimmerhead. Remove the shim plates and clamps.
Raise the machine high enough to clear the
trimmerhead assembly. Move the machine away from
the trimmerhead while watching for clearance of all
obstacles.
Position Inserts
331
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3-15
Position the insert shroud(s) next to the drive shroud

and attach with bolts, nuts and lock washers and
tighten securely. With the tooth mounts forming a
continuous spiral, connect the trimmer wheel insert(s)
to the end of the trimmer wheel and tighten the bolts
securely.
Note: Make certain that the trimmer width is at

least 6 inches (15 cm) wider than the pouring
width.
Trimmerhead Removed
360654
To change the trimmerhead to left hand discharge,
remove the trimmerhead assembly from the machine
following the description in the preceding section on
changing trimmer width.
Install Trimmer Wheel

332
Move the idler shroud and shaft into position. Align
the idler shaft flange with the trimmer wheel and bolt
both the shroud and trimmer wheel flanges together.
Tighten securely. Using a suitable lifting device, raise
the trimmer assembly into an upright position and
support the front of the shroud with blocking.
Left Hand Discharge Trimmerhead Assembly
Note: A right discharge trimmerhead is standard

equipment. If left hand discharge is required, a left
hand discharge trimmerhead conversion must be
ordered.
Gearbox Removed
GOMACO Tip: It is typically recommended to 337
order a complete left-hand discharge trimmerhead

minus the gearbox and motor. This reduces down
time, when changing from right discharge to left
! WARNING! !
KEEP HANDS AND FEET CLEAR OF THE
discharge, to the amount of time required to
TRIMMER GEARBOX. SERIOUS INJURY CAN
change the gearbox and motor from one trimmer
OCCUR IF THE TRIMMER GEARBOX DROPS ON
assembly to the other.
FEET OR HANDS WHEN REMOVED FROM THE
The following procedures describe changing of a right TRIMMER WHEEL.
hand discharge trimmerhead to a left hand discharge
Unscrew the adjustment bolt from the drive mount
trimmerhead with the least amount of purchased parts.
plate and remove the bolt from the drive shroud.
The purchased parts will determine the number of
Remove the two main hydraulic hoses from the drive
assembly procedures needed to complete the
motor and place protective covers in the ends of the
assembly. Follow only those required.
hoses to prevent dirt from entering the hydraulic
circuit. Remove the two fittings in the hydraulic motor
and place protective covers in the motor ports to
G21 06/01/04
3-16
prevent dirt from entering the hydraulic circuit.

Remove the front and rear guides from either side of
the drive mount plate. Remove the 1/2 inch (13 mm)
bolts connecting the drive mount plate to the gearbox
and remove the drive mount plate. Remove the
tapered nuts connecting the gearbox to the trimmer
wheel. Remove the gearbox from the trimmer wheel.
LH Trimmerwheel
341
Attach the front and rear guides in position on either
side of the drive mount plate. Insert eight bolts and
lock washers (flat washers are always placed over
slotted holes when needed). Remove the two set
Gearbox Assembled screws from the right hand trimmer drive shroud and
340
Using a suitable lifting device, insert the drive motor insert them into the left hand drive shroud. Screw
and gearbox assembly into the 26 7/8 inch (68 cm) left them tight against the slotted guide. Tighten all bolts
hand discharge trimmer wheel. Attach the eight securely.
tapered nuts and tighten securely. Attach the drive
mount plate to the gearbox (the motor ports, when Note: The trimmer wheel should be adjusted for
mounted in the trimmerhead should point towards proper height when mounted on the machine.
forward direction of travel and at a slight angle
Thoroughly clean the hydraulic fittings and insert them
upward). Insert nine bolts and lock washers and
into the gearbox drive motor. Tighten securely. Attach
tighten securely. Use a suitable lifting device and
the hose fittings to the motor fittings and tighten
place the gearbox and trimmer wheel assembly into
securely. The drive hoses will need to be switched so
position in the trimmer drive shroud.
that the trimmer wheel rotates in the correct direction
when the trimmer valve is in the “forward” position.
After assembly is completed, raise the trimmerhead to

set it upright using a suitable lifting device. Place
blocking under the front corner of the trimmerhead to
hold it in an upright position.
Attach the trimmerhead mount assembly to the

trimmerhead in the same manner as it was removed.
Refer to the Maintenance chapter for instructions on
adjusting the trimmer wheel height.
G21 06/01/04
3-17
Positioning and Mounting the Trimmerhead
Trimmerhead Positioned
364
Attach Rear Mounting Bracket
Mounting the Trimmerhead: It is advisable to 366
position the trimmerhead on a relatively flat area when Slowly raise or lower the rear of the machine until it is
mounting it to the machine. While moving the machine possible to slide the rear mounting bracket onto the
over the trimmerhead, use the left front leg pivot switch rear mounting bar. Secure with flat washer, lock
and the right frame extension control valve to position washer and bolt. Tighten securely.
the tracks in their full outboard positions. This will
enable driving over the trimmerhead. Move the Note: It will be necessary to position the
machine until the slots in the front mounts line up with trimmerhead laterally after the mold has been
the front mounting bars across the top of the installed. This is done with the trimmer shift
trimmerhead. Be certain that the left side of the switch.
trimmerhead is mounted flush with the left side of the
machine frame for transport width restrictions.
Trimmerhead hooks
365
Slowly lower the machine and make sure the front Connect Quick Couplers
360188
mounting bars slide completely into the front mounting
slots. When the mounting bars have slid all the way
into the slots, place the latch bolts under the front bar
! DANGER! !
and secure it by tightening the nuts securely. The TO PREVENT SERIOUS INJURY, OR DEATH, BE
front bar should be pulled into the slots of the front CERTAIN THAT THE TRIMMERHEAD AREA IS
mount. CLEAR BEFORE STARTING THE
TRIMMERWHEEL. STAY CLEAR OF THE
TRIMMERWHEEL WHEN THE ENGINE IS
RUNNING. STOP THE ENGINE BEFORE
PERFORMING ANY SERVICE WORK ON THE
TRIMMERWHEEL UNLESS OTHERWISE
INSTRUCTED.
G21 06/01/04
3-18
Thoroughly clean the quick couplers on the trimmer

drive hoses and on the bulkhead to prevent dirt from
entering the hydraulic system. Connect the trimmer
drive hoses to their respective quick couplers on the
bulkhead. Whenever the trimmerhead is removed,
couplers to prevent dirt from entering the hydraulic
system.
Connect Trimmer Sideshift Hoses

360199
Thoroughly clean the quick couplers on the trimmer
sideshift hoses and on the bulkhead to prevent dirt
from entering the hydraulic system. Connect the
trimmer sideshift hoses to their respective quick
couplers. Whenever the trimmerhead is removed,
couplers to prevent dirt from entering the hydraulic
Connect Case Drain Line system.
360155
Clean all dirt from the case drain line fittings. Connect 07 Mounting the Slipform Mold
the case drain line from the trimmer to the machine
case drain line. Whenever the trimmerhead is
removed, always place the protective covers over/in
the case drain line connections to prevent dirt from
entering the hydraulic system.
Notice: Do not place quick couplers in the case

drain line. Excessive back pressure, caused by
quick couplers may cause trimmer gearbox seal
failure.
Position Mold
370
Place the slipform mold on a relatively flat spot. Coil
the vibrator hoses and place them in the mold hopper.
Extend the mold sideshift so that the drawbar is
beyond the frame of the machine. Move the machine
into position next to the slipform mold. It may be
necessary to swing the left front track back to its
straight ahead position. Be sure that the mold is far
enough forward, so that when the machine is lowered,
the drawbar will clear the drawbar plates on the mold.
G21 06/01/04
3-19
On slipform molds of 4 feet (1.22 M) or wider, it will be

necessary to shift the mold side shift to the center of
the slipform mold drawbar. Install a drawbar pin
through the hole in each end of the slipform mold
drawbar.
Align Drawbar
371
Lower the machine far enough to align the machine
drawbar with the drawbar plates on the back of the
mold hopper. It may be necessary to lower the
machine drawbar, by loosening the limiting nuts and
lowering the drawbar hold down cylinder, if the trimmer
prevents the machine from being lowered enough.
Slowly drive the machine forward and make sure the
machine drawbar slips in between the drawbar plates Hold-down Connected
373
on the mold. Normally the mold is mounted as far to
Using the form hold down control valve, extend (lower)
the left as possible for clearance reasons.
the hold down cylinder until the mounting plate
contacts the hold down bar on the rear of the form. It
may be necessary to loosen the hold down cylinder
mounting bracket and slide it left or right on the mold
sideshift beam to center the cylinder on the mold hold
down bar. Place the locking lug under the hold down
bar and tighten securely. It may be necessary to turn
the adjustment nuts on the hold down limiting rods, to
the end of the rods, to allow the hold down cylinder to
extend enough.
Insert Two Drawbar Pins

372
! WARNING! !
DO NOT INSERT FINGERS INTO THE HOLES TO
CHECK FOR ALIGNMENT AS SEVERE INJURY
COULD OCCUR IF THE MACHINE OR THE
SLIPFORM MOLD WERE TO MOVE.
Align the holes in the mold drawbar plates with the

appropriate holes in the drawbar. Insert two drawbar
pins.
G21 06/01/04
3-20
Connect Driveway Cutter

375
The driveway cutter, or depressor (if so equipped) is
normally powered by the rear shift control valve.
Position the rear track to the necessary operating
position and disconnect the quick couplers from the
rear shift cylinder. Clean all the dirt from the quick
couplers and connect them to the quick couplers on
the driveway cutter. When the hoses are
disconnected, place the protective covers over/in them
to prevent dirt from entering the system.
Hook and Go Attachment

Connect Vibrator Quick Couplers
374 Position the slipform mold as indicated previously.
Thoroughly clean the quick couplers on the vibrator Extend the mold sideshift so that the drawbar is
drive hoses and the bulkhead quick couplers to beyond the frame of the machine. Move the machine
prevent dirt from entering the hydraulic system. into position next to the slipform mold.
Connect the vibrator drive hoses to the vibrator outlet
quick couplers. It is recommended that the vibrators
be connected in a consecutive order beginning with
number 1 from top to bottom on the bulkheads. Any
vibrator bulkhead that does not have a vibrator
attached to it, must have the loop hoses connected.
When the vibrators are disconnected, place the

protective covers over the quick couplers or connect
couplers to keep dirt from entering the hydraulic
system.
Align drawbar
360586
Lower the machine far enough to align the machine
drawbar with the drawbar plates on the back of the
mold hopper. It may be necessary to lower the
machine drawbar, by loosening the limiting nuts and
lowering the drawbar hold down cylinder, if the trimmer
prevents the machine from being lowered enough.
G21 06/01/04
3-21
Slowly drive the machine forward and make sure the 08 Mounting the Sensors
machine drawbar slips in between the drawbar plates
on the mold. The alignment pin should fit between the Standard Sensor Arms
lower guides on the machine drawbar.
Adjust Sensor Arms Parallel
Sensor arms parallel on

left side of machine frame
Right side
of machine
frame
Front sensor arm
Rear sensor arm
3600DWG2
Adjust sensor arms parallel

3600SWG2
Initial setup of the sensor mount tubes requires
adjusting the outer sensor mount tubes parallel with
Drawbar fully engaged each other. Using a straight edge placed against the
360594
right side of the machine frame and aligned with the
Advance the machine travel until the drawbar
front sensor mount tube, measure distance “A”
alignment pin is fully engaged.
between the left end of the outer tube and the straight
edge. Record this measurement. Place the straight
against the right side of the machine frame and align it
with the rear sensor mount tube. Measure distance
“B” between the left end of the rear outer tube and the
straight edge. Compare this measurement with the
front tube. If the measurements are not equal, loosen
the clamps holding the rear outer tube stationary to the
machine frame and adjust the rear outer tube left or
right until the front and rear measurements are equal.
Tighten the clamps on the rear sensor mount tube
securely.
Note: The left ends of the front and rear outer

sensor mount tubes can now be used when
measuring the machine frame for parallel to the
guideline.
Lower the hold down cylinder
360591
Loosen the limit nuts on the hold down cylinder
assembly and extend the cylinder until it contacts the
mount bar on the rear of the slipform mold as shown
above.
To raise the slipform mold off the ground, evenly

retract the drawbar and hold down cylinders.
G21 06/01/04
3-22
rear of the angle mount bracket with two bolts, lock

washers and flat washers (flat washers are only
required on slotted holes). Tighten securely. Repeat
the procedures for the front grade jack.
Angle Mount Bracket Installed

376
Loosen the set screws on the sensor mount tubes and
slide the two tubes out and away from the side of the
machine frame to the approximate offset distance
needed to reach the guideline. With assistance, lift the
angle mount bracket in position so that the slots in the
two vertical hangers are aligned with the mounting
brackets on the ends of the sensor mount tubes.
Insert four bolts, lock washers, flat washers, nuts and
tighten securely. Grade Jack Mounted in Second Position
378
Note: The amount that the sensor mount tubes The front grade jack has two mounting positions. The
need to be moved out and away from the machine front position, near the trimmerhead moldboard,
frame is determined by the distance the slipform should be used if radii of 10 feet or more are going to
mold is shifted from under the frame. be poured during the day. The second position with
the slotted hole located at the leading edge of the
stainless steel section of the slipform mold, should be
used if radii of 10 feet or less are going to be poured
during the day.
Three Grade Sensor Positions

CG030404-13
Grade Jacks Mounted The machine is equipped with a switch to allow
377
changing from the front grade sensor (number 1), near
To mount the grade jacks, remove the L-shaped
the trimmerhead moldboard, to the second position
sensor bracket from the bottom of the jack and install
grade sensor (number 2) at the leading edge of the
the grade jack mount (if not attached) around the
stainless steel section of the slipform mold. It is
barrel of the jack. Attach the L-shaped sensor bracket
necessary to mount all three grade jacks and sensors
in its original position with the bolt and lock washer.
to complete a radius that is smaller than 10 feet.
Attach the grade jack mount to the two holes at the
G21 06/01/04
3-23
for the jobsite conditions. Install the sensor arm pivot

mount to the end of the front sensor arm extension
tube using two bolts, clamp bars, lock washers and
nuts. The sensor arm pivot mount is slotted to allow
vertical movement of the entire sensor arm assembly.
Adjust the vertical positioning of the sensor arms so
they will match the position of the stringline as
necessary to position the slipform mold on grade.
Tighten the bolts securely.
Install the sensor arm pivot (number 1 in diagram

360148) to the base of the sensor arm pivot mount.
Tighten the sensor pivot securely. Install the steer
offset jack assembly (number 2 in diagram 360148)
into the pivot mount. The steer offset jack should be
perpendicular to the machine frame. Adjust the steer
Steer Sensor Mount Bracket
380 offset jack to the midpoint of its stroke to allow for
Attach three steer sensor mount brackets to the adjustment in either direction during final adjustments.
bottom of the angle mount bracket in the remaining
holes and slots with bolts, lock washers, and flat Note: It may be necessary to extend or retract the
washers. Turn the steering sensor adjustment screws sensor arm extension tube depending upon offset
in or out until each sensor mount is at the midpoint of distance and mold shift extension.
the adjustment screw.
Split Sensor Arms
Three versions of split sensor arms have been

manufactured. Follow the installation instructions
which match the assemblies supplied with the
machine.
3
4
Front sensor arm
360150
Insert the parallel sensor arm tube (number 3 in
1 2 diagram 360148) into the steer offset jack assembly.
The end of the tube should extend to the rear of the
trimmerhead. Install the elevation jack assembly
(number 4 in diagram 360148) on the end of the
parallel sensor arm tube and tighten securely. The
sensor mounting position should be located in-line with
the trimmer moldboard cutting blade (as shown in
previous photo). Tighten all adjustment screws
securely.
360148
Front sensor arm
360148
Assembly 1:
The sensor arm pivot mount is provided in two

different lengths to allow shorter or longer vertical
adjustment. Choose the most appropriate pivot mount
G21 06/01/04
3-24
is positioned in line with the hold down mounting bar

on the slipform mold. Tighten all clamps securely.
3
4 5 Note: The number two steer and elevation sensor
mounts are only required for radius paving of 10
feet or less.
Assembly 2
2 1

Right side
of machine
frame
360147 Front sensor arm
Rear sensor arm

360147 A
Clamp the sensor arm pivot mount to the end of the
rear sensor arm extension tube using two bolts, clamp Rear sensor arm
bars, lock washers and nuts. Tighten securely.

B
Install the sensor arm pivot (number 1 in diagram

360147) to the base of the sensor arm pivot mount. 3600DWG2
Tighten the sensor pivot securely. Install the steer Adjust the front and rear sensor arms parallel as
offset jack assembly (number 2 in diagram 360147) indicated earlier in this section on page 31.
into the pivot mount. The steer offset jack should be
perpendicular to the machine frame. Adjust the steer
offset jack to the midpoint of its stroke to allow for
adjustment in either direction during final adjustments.
Attach sensor pivots

360589
Rear sensor arm Extend the front and rear sensor mount tubes. Attach
360149 the front and rear sensor pivot mounts to the lowest
Insert the parallel sensor arm tube (number 3 in set of holes shown above. The front pivot mount
diagram 360147) into the steer offset jack assembly. should be attached to the front side of the sensor
The end of the tube should extend to the rear of the mount tube so clearance exists to shift the
slipform mold. Install the number 2 elevation jack trimmerhead left or right. The rear pivot mount (shown
assembly (number 4 in diagram 360147) on the end of above) should be mounted to the rear side of the
the parallel sensor arm tube and slide forward until the sensor mount tube so clearance exists to shift the
elevation jack aligns with the leading edge of the drawbar left or right. Tighten the bolts securely.
slipform mold stainless. Install the rear elevation jack
assembly (number 5 in diagram 360147) on the end of The sensor pivot may be attached to the top or bottom
the parallel sensor arm tube. Slide the assembly of the pivot mount to compensate for guideline
forward until the mounting position for the steer sensor location. Note the guideline location and attach the
sensor pivot as necessary for proper extension on the
G21 06/01/04
3-25
sensor elevation jacks. Adjust the sensor pivot so that

it is perpendicular to the side of the machine frame as
shown above.
Top
View
Front Rear
sensor Sensor
arm Arm
Front jack assemblies
360599 & CG-050501-02
Insert the front square tube into the front sensor arm
360598 pivot mount. The end of the square tube should be
Steer sensor jack even with the rear of the trimmerhead shroud. The
360598 square tube should be parallel to the side of the
Insert the front and rear steer sensor jacks. A slight machine frame. Tighten the setscrews securely.
angle of the arms may be required (as shown above)
to allow better support of the sensor assemblies and Place an elevation jack and clamp assembly for the
allow proper positioning of the sensors in relation to number 1 steer and grade sensors on to the front
the rear of the slipform mold. Loosen and adjust the square tube. Slide the assembly forward until the
assemblies as necessary. After proper placement is mounting position for the elevation sensor is
determined, tighten all bolts securely. positioned in line with the trimmer moldboard blade.
Tighten the setscrews securely.
360599
Front and rear jack assemblies
360599
Rear jack assemblies

CG050501-03
Insert the rear square tube into the rear sensor arm
pivot mount. The end of the square tube should be
extended 6 to 12 inches (150 to 300 mm) beyond the
hold down mounting bar at the rear of the slipform
mold. The square tube should be parallel to the side
of the machine frame. Tighten the setscrews securely.
G21 06/01/04
3-26
Select the number 2 elevation jack assembly equipped

with a small screw jack on the steer sensor mount.
1
The number 2 elevation jack should be adjusted so the
steer sensor wand is 18.5 inches ahead of the rear
steer sensor wand. The rear elevation jack should be
adjusted so the rear steer sensor wand is aligned with
the rear edge of the stainless trowel surface. 4 2
Place an elevation jack and clamp assembly for the 3

360614
rear steer and grade sensors on to the rear square
tube. Slide the assembly forward until the mounting
position for the steer sensor is positioned in line with
the hold down mounting bar on the slipform mold.
Tighten the setscrews securely.
Assembly 3

Right side
of machine
frame
Front sensor arm
A
Attach steer screw jack assembly
360614 & 360619
Rear sensor arm Extend the front and rear sensor mount tubes an equal
B
distance from the machine frame. Attach each
adapter mount tube (number 1 in previous drawing) to
the end of the sensor mount tubes. Slide the front and
3600DWG2
rear steer screw jack assemblies (number 2 in
Adjust the front and rear sensor arms parallel as previous drawing) into the adapter mount tube on the
indicated earlier in this section on page 31. front and rear sensor mount tubes. Adjust the steer
screw jack assemblies for approximate offset distance
from the reference point of the slipform mold in use.
Tighten all bolts and setscrews securely. Locate the
mounting clamp (number 3 in previous drawing) and
four bolts with flat washers, lock washers and nuts.
Attach the mounting clamp to the bottom (as shown
above) or to the top of the steer screw jack assembly.
G21 06/01/04
3-27
Sensor arm with riser extension

360621
An 8 inch riser extension (number 4 in previous
drawing) is provided to mount to the top or bottom of
the sensor steer jack assembly. The riser extension is Front sensor assemblies
used when necessary to adjust for guideline location. CG040613-01A
When mounting the riser to the top of the steer jack, Attach three elevation jack assemblies to the
the clamp is attached on the top of the riser. When aluminum tubes. The front number 1 elevation jack
mounting the riser to the bottom of the steer jack, the should align with the trimmerhead moldboard cutting
clamp is attached on the bottom of the riser. blade. Typical placement of the number 1 sensor
assembly is shown above. If clearance between the
trimmerhead and the number 1 sensors is a problem,
the number 1 sensors may be mounted forward of the
trimmerhead.
Attach sensor assemblies (view of left side)

360613 & 360622
Slide an aluminum rectangular tube between the
clamp and steer jack at the front and rear steer jack
assemblies. The front aluminum tube should extend to
the rear of the trimmerhead shroud. Rear sensor assemblies
CG040613-01B
Select the number 2 elevation jack assembly equipped
with a small screw jack on the steer sensor mount.
The number 2 elevation jack should be adjusted so the
number 2 steer sensor wand is 18.5 inches ahead of
the rear steer sensor wand. The rear elevation jack
should be adjusted so the rear steer sensor wand is
G21 06/01/04
3-28
aligned with the rear edge of the stainless trowel

surface as shown in photo CG010613-01B.
Note: It is only necessary to attach the number 2

steer and elevation jack if radii of 10 feet or less
are going to be poured during the day.
Sensor Installation
Grade Sensor Mounted

CG090504-05
Mount a sensor for elevation control to the mount on
the adjustable grade jack with the mounting bolt facing
forward and the sensor hub away from the side of the Steer Sensor Mounted
360512
machine. Mount the sensor so the top of it is level and Mount a sensor for steering control to the adjustable
tighten the mounting bolt securely. The grade sensors mount with the mounting bolt towards the machine and
are all mounted in the same manner. the sensor hub towards the front. Mount the sensor
with the top level and tighten the mounting bolt
The grade sensor wand is mounted with the round
securely. Mount all three steer sensors in the same
tube towards either the front of the machine (same
manner.
side as mounting bolt) and pointing away from the side
of the machine or; toward the rear of the machine The steering sensor wand should be attached to the
(same side as the cord) and pointing away from the sensor hub, so that when the pin in the shaft is
side of the machine. The wand should be attached, so centered between the stops on the sensor, the wand is
that when the stop pin in the sensor shaft is centered at a 90° angle to the mounting bolt (vertical). Tighten
between the stops on the sensor, the wand is parallel the attaching “thumbscrew” securely.
to the mounting bolt (horizontal). Tighten the attaching
“thumbscrew” securely.
Note: All grade sensors and wands must be

installed in the same manner. If one sensor or
wand is facing the wrong direction according to the
calibrate settings in the G21 controller, it will work
backwards (see later).
G21 06/01/04
3-29
Adjust the spring tension on the sensor hubs to hold

the wands firmly in contact with the guideline, but not
tight enough to deflect the line. Check for correct
spring tension after the machine has been adjusted to
the line. Remove all wands and check each steer and
grade sensor pair for proper spring tension. Only one
grade wand and one steer wand should be in contact
with the stringline during this testing procedure.
Note the position of the line on the grade sensor wand.

Pull the steering sensor wand away from the line and
note movement of the line on the grade wand. If
movement exceeds 1/8 inch (3 mm), the steering
sensor spring tension is too tight. Loosen tension
slightly. Note the position of the line on the steering
sensor wand. Pull the grade sensor wand down, away
Sensors Connected to Bulkhead from the line and note movement of the line on the
360023
Connect the sensors to their respective plugs on the steering wand. If the movement exceeds 1/8 inch (3
bulkhead. Steering to the “steer” plugs, and grade mm), the grade sensor spring tension is too tight.
sensors to the “grade” plugs. Loosen the tension slightly. Pull the line away from
both sensor wands. The steering wand should move
Notice: When the sensors are disconnected, place out towards the line until the stop pin in the sensor hub
the dust caps over the electrical plugs to keep contacts the stop pin in the side of the sensor. If not,
moisture and dirt out. tighten the spring slightly. The grade wand should
move up towards the line, until the stop pin in sensor
hub contacts the stop pin in the side of the sensor. If
not, tighten the spring slightly. If the sensor wands
deflect the line more than 1/8 inch (3 mm), but the stop
pins in the sensor and hub will not contact one another
when the line is pulled away, suspect that the line is
inadequately tensioned. Adjust the line as necessary.
Repeat the procedure for each pair of sensors,
removing the previously checked wands from the
stringline.
Note: When checking sensor wand spring

Two Counterweight Washers Removed tension, it should be done half way between
386
It is normally recommended to remove two of the stations so line holders do not interfere. The
counterweight washers from the rear of the grade control system should be in the “standby” mode or
wand, so only two remain. the servo lock switch must be in the “on” position
when checking the sensor spring tension.
Notice: An unsatisfactory product will occur if the

guideline is not adequately tensioned. This is
especially important on the GT-3600 due to the
close proximity of the sensor wands applying
pressure to the guideline.
Adjust Spring Tension

387
G21 06/01/04
3-30
Left Side Grade Control/Right Side Slope Control procedures. The operator must cycle the power
before any changes are enabled.
The left front leg elevation is controlled by the front

grade sensor connected to the left front grade plug,
Grade Wands Cycle Power!
and the left front elevation control loop. The rear leg
PUSH +/- Adjust elevation is controlled by the rear grade sensor,
connected to the rear grade plug, and the rear
002-2809 elevation control loop. The right front leg elevation is
Grade sensor mode selection controlled by a slope sensor, located in the battery
002-2809
Depress the calibrate switch on the service panel and box, and the right front elevation control loop. The
use the NEXT switch to scroll forward to the grade steering of both front tracks is controlled by the front
sensor mode. Use the slope adjust switches (+ or -) to steer sensor connected to the front steer plug and the
change the mode to “GRADE WANDS = PULL” if the front steer control loops. The steering of the rear track
round tube of the grade wand is on the same side as is controlled by the rear steer sensor connected to the
the cord. If the round tube of the grade wand is on the rear steer plug and the rear steer control loop.
same side as the mounting bolt, change the mode to
09 Preliminary Adjustments
“GRADE WANDS = PUSH”.
Steer Wands Cycle Power!

PUSH +/- Adjust
002-2812
Steer sensor mode selection
002-2812
Using the NEXT switch, scroll forward to the steer
sensor mode. Use the slope adjust switches (+ or -) to
change the mode to “STEER WANDS = LEAD” if the
round tube of the steer wand is facing forward. If the
round tube of the steer wand is facing towards the rear
of the machine change the mode to “STEER WANDS Level Machine
= TRAIL”. 389
To adjust the trimmerhead and the slipform mold for
the proper height, park the machine on a flat, level
area. Level the machine from front to back and across
the cross frame using the elevation jog switches. Stop
the engine.
Determine what offsets will be used with the slipform
360352 mold that is attached. These may vary with the
G21 display for left grade, right slope minimum steering offset being 6 inches (15.24 cm).
360352
Also determine if any obstacles require the slipform
To operate the machine with left hand grade control
mold to be fully retracted under the machine or
and right side slope control, depress the calibrate
extended partially or fully. Shifting the mold and
switch. Scroll through the various displays until the
trimmerhead fully to the left will allow the machine to
elevation mode is displayed. Use the slope adjust
turn a tighter radius. Shift the slipform mold to the left
switches (+ or -) to change the mode to “L GR/R
as required.
SLOPE”. After the appropriate grade and steering
mode settings are selected, depress the calibrate
switch to return to the main control display. Adjust the
desired amount of cross slope with the appropriate
switch on the main control display. Refer to the
Preliminary Adjustments section for final adjustment
G21 06/01/04
3-31
This measurement (A and B) should be equal on the

front and rear sensor arm extension tubes. If not,
adjust the extension tubes in or out as necessary to
maintain the offset distance. When the front and rear
sensor arm extension tubes are extended equally and
the offset measurement is correct, tighten the sensor
arm extension tubes securely.
Measure the offset distance

398
Adjust the steer sensor mount assembly in or out to
the approximate offset distance. Measure the offset Angle Mount Bracket Level With Machine Frame
391
distance between the slipform mold and the center of Place a level on the angle mount bracket. Adjust the
the steer sensor hub. This measurement should be angle mount bracket so that it is level from front to rear
equal to the offset distance. the same as the machine frame.
If the machine is equipped with split sensor arms,

place a level between the front and rear sensor arm
left side of machine frame extension tubes. Determine if the front and rear tubes
are parallel to the machine frame. If a difference
exists, make a spacer of the appropriate size to use
Front sensor arm
when measuring from the extension tubes down to the
A stringline. Make certain the sensor arm extension
tubes are tightened securely for accuracy of the
Rear sensor arm measurement.
B
3600DWG3
Machine steered parallel to stringline

CG090504-04
Move the machine to a parallel position along side the
guideline and crab steer the machine towards the
Sensor mount tube measurement guideline until the steering wands make contact.
3600DWG3 & 360609
Measure from the left end of the front and rear sensor Depress each of the steering control loop A/M
arm outer tubes to the end of the inner extension tube. switches so that “A” (auto) is displayed in each of the
G21 06/01/04
3-32
displays. Turn the steer select switch to the 2 sensor screw in or out until the number 2 centering
“stringline” position. Make certain that the forward/ signal is equal to the number 1 centering signal.
reverse switch is in the “forward” position and the Depress the TEST switch to return to the normal
sensor select switch is in the number “1” position. operating display. Depress the run/standby switch
Drive the machine forward until all steering sensors again to place the G21 controller in the “run” mode.
are located between two guideline stakes and the
tracks have been adjusted automatically to the straight
ahead position. Stop the machine travel.

Front sensor arm
Guideline Correct Position of Guideline on Wands

Rear sensor arm 393
Note the position of the guideline on the steer wands.
B
When the machine is set for final grade the guideline
should be approximately 12 to 16 inches (30 to 41 cm)
from the steer sensor hub. Adjust the sensor arm
3600DWG4
assembly up or down as necessary. Make certain the
Machine Parallel to Guideline angle mount bracket remains parallel to the machine
3600DWG4
Place a straight edge vertically against the back side frame as adjusted previously.
of the guideline near the front sensor mount tube.
Measure from the guideline to the outer sensor mount
tube and record this measurement (A). Repeat this
procedure at the rear sensor mount tube (B).
Compare the two measurements. If they are not equal
it will be necessary to adjust the steer sensor screws
in or out. One full turn on the steer sensor screws is
equal to 1/8 inch (3 mm). Move the machine forward
until the tracks are straight ahead with the steer
sensors located between two guideline stakes and
repeat the procedure until both measurements are
equal. Tighten the locking nuts on the steer sensor
adjustment screws securely.
LF FdbkPot StrWnd StrVlv

2.40V 2.52V 0.00V
002-2760
Test mode to set the #2 steer sensor
002-2760
Machine Frame Parallel to Guideline
Depress the run/standby switch to place the G21 394
controller in the standby “S” mode. Depress the TEST Place each of the grade wands under the guideline.
switch on the G21 controller. Select the left front Adjust the grade jacks up or down until each one is
steering control loop by depressing the steering A/M extended approximately half way. Loosen the set
switch. Note the number 1 steering sensor voltage screws holding the grade jack and raise or lower each
signal. Place the sensor select switch in the number jack until the grade wand is in a parallel position to the
“2” position. Compare the number 2 centering signal guideline. Tighten the set screws securely. Place
with the number 1 centering signal. Adjust the number each of the elevation controls loops in the auto mode.
G21 06/01/04
3-33
Measure from the guideline to the angle mount bracket subbase will be lower than the grade the tracks are
at the front and rear. Compare the two operating on, the trimmerhead can be lowered up to
measurements. If they are not equal it will be 12 inches (30.5 cm) hydraulically and an additional 6
necessary to adjust the grade jacks up or down until inches (15 cm) of manual adjustment on the machine
the two measurements are equal. One full turn on the frame. Make certain in either case, that 10 to 18
grade jack is equal to 1/8 inch (3 mm). inches (25.4 to 45.7 cm) of inner leg tube is exposed
to allow adequate adjustment over uneven terrain.
Refer back to the leg positioning section of this chapter
for additional adjustments if necessary. With the
LF BPwr SPwr GdWnd GdVlv machine frame level left to right, place a level across
15.09V 5.01V 2.86V-0.38V the trimmerhead lift mounts. Raise or lower the
individual mounts until the lift mounts are level. Lower
the limiting nuts for each lift mount and tighten
360356
securely. The limiting nuts prevent the trimmerhead
Test mode to set the #2 grade sensor from going any lower than what was set and allows the
360356
If the number 2 grade sensor is mounted for radii 10 operator to raise the trimmerhead for obstacles and
feet (3 meters) or less, it will be necessary to center return to the previous setting.
the voltages between the number 1 and number 2
grade sensors. Depress the run/standby switch to
place the G21 controller in the standby “S” mode.
Depress the TEST switch on the G21 controller.
Select the left front grade control loop by depressing
the steering A/M switch. Note the number 1 grade
sensor voltage signal. Place the sensor select switch
in the number “2” position. Compare the number 2
centering signal with the number 1 centering signal.
Adjust the number 2 sensor jack up or down until the
number 2 centering signal is equal to the number 1
centering signal. Depress the TEST switch to return to
the normal operating display. Depress the run/standby
switch again to place the G21 controller in the “run”
mode.
Note: Adjust the number 2 grade and steer

sensors as shown in the radius setup section of
this chapter.
Check Machine Frame For Proper Slope

396
If the slipform mold is not built with the required slope,
it will be necessary to set the machine frame for the
proper slope. Depress the slope set point switch
pointing to the left to rotate the frame to the left.
Depress the slope set point switch pointing to the right
to rotate the frame to the right. Check the machine
frame for proper slope with a level placed across the
front of the machine frame.
Level Trimmerhead Lift Mounts
395
The trimmerhead should be sideshifted to the correct
position. If the trimmed subbase will be even with the
grade the tracks are operating on, the trimmerhead
can be adjusted so that 10 to 18 inches (25.4 to 45.7
cm) of inner leg tube on each of the grade legs is
exposed while the machine is pouring. If the trimmed
G21 06/01/04
3-34
Measure Subgrade
397
Place the trimmer control valve in the “forward”
position and begin moving forward. If no grade is
being trimmed, raise the front and rear grade jacks an Clamps on mold sideshift
equal amount of turns until the trimmer begins cutting 360175
grade. Measure the trimmed subgrade behind the The slipform mold should be shifted to the correct
machine and compare it to final subgrade. It is position according to the preset offset distance. Plumb
recommended that the subgrade be left approximately a level vertically against the guideline and measure to
one inch (25 mm) high prior to final trimming and the proper reference point on the slipform mold (Back
pouring to minimize loss of concrete due to low of curb, face of curb or face of gutter). Adjust the mold
subgrade. sideshift as necessary and tighten sideshift clamps
securely.
! DANGER! !
CONTACT WITH MOVING TRACKS OR
TRIMMERWHEEL CAN CAUSE SERIOUS INJURY
OR DEATH. BE CERTAIN THAT NO ONE IS NEAR
THE TRIMMERWHEEL BEFORE ENGAGING THE
CONTROL VALVE. BE CERTAIN THAT NO ONE IS
NEAR THE TRACKS BEFORE MOVING THE
MACHINE. KEEP HANDS, FEET AND LOOSE
CLOTHING AWAY FROM MOVING PARTS TO
PREVENT SEVERE PERSONAL INJURY.
Drawbar Cylinder Lowered

3100
Adjust the slipform mold for proper height, in relation to
the trimmed subgrade. The drawbar can be lowered
up to 12 inches (30 cm) hydraulically and an additional
6 inches (15 cm) of manual adjustment on the
machine frame. Place the drawbar and hold down
valves in the down position and lower the drawbar and
the hold down cylinders until the bottom of the slipform
mold contacts the subgrade. Reduce the drawbar and
hold down pressure to 50-75 psi (3.5-5.25 bar). If the
drawbar does not lower evenly it may be necessary to
loosen the drawbar clamps. It may also be necessary
Measure for Proper Offset Distance
to raise the limiting nuts on the drawbar and hold down
398 to allow the slipform mold to contact the subgrade.
G21 06/01/04
3-35
Drawbar Clamps
3101
Place a level across the drawbar and check that the
drawbar is parallel to the machine frame. Adjust the Drawbar stabilizer adjustments
drawbar as necessary for parallel, lower the limiting 360592
nuts and tighten securely. If the drawbar is going to After the drawbar has been measured parallel with the
remain in this position for the duration of the pour it is machine frame, adjust each of two drawbar stabilizer
recommended to tighten the drawbar clamps securely. bolts in firm contact with the top of the drawbar
If the drawbar is going to be raised and lowered it is weldment. Tighten the jam nuts securely. The
recommended that the drawbar clamps be tightened stabilizer bolts prevent the mold from tipping left or
enough to remove any excess movement in the right when the drawbar assembly is raised or lowered
drawbar assembly but still allow the drawbar to raise during a pour.
or lower.
Note: Earlier model drawbars are not be
equipped with drawbar stabilizer bolts.
Secure drawbar bolts

3071
Securely tighten each of the drawbar hinge bolts
(shown in right side of photo above) to help prevent
tipping of the slipform mold if it is raised or lowered
during the pour to avoid obstacles.
Measure Slipform Mold for Proper Draft
3102
Plumb a level from the guideline and over the rear of
the slipform mold. Measure from the level to the
horizontal frame tube of the slipform mold at both the
front and rear of the mold. The rear of the slipform
mold should be 1/8 inch (3 mm) lower than the front of
the mold. Adjust the hold down limiting nuts as
necessary and tighten securely.
G21 06/01/04
3-36
Swing the conveyor discharge chute over the slipform 24 Inch (61 cm) Radius Setup with 12 Inch (30 cm)
mold hopper and tighten the retainer bolt. If the chute Grade and Steering Offset
does not drop into the center of the hopper it will be
necessary to shift the conveyor frame. The following procedures allow adjustment of the
GT-3600 for a 24 inch (61 cm) outside radius using the
top, back of the curb profile as the reference point for
grade and steering control. Precise adjustment as
indicated is required for trouble-free turning of radii.
Tight Radius Offset

Stringline
12 in.
30 cm
12 in. 12 in.
30 cm 30 cm
Connect Conveyor Shift Valve Hub

3103
Connect the conveyor shift cylinder hoses to the Radius
conveyor shift valve. The operator on the conveyor Center Point
360521.eps
shift valve can activate the cylinder and release the
pressure on the retainer pin. Offset measurements
360521
The steer offset measurement used for the guideline
Remove the hair pin and retainer pin and shift the
setup is 12 inches (30 cm) from the back of curb. The
conveyor frame up or down to center the discharge
elevation offset used for the guideline setup is 12
chute over the slipform mold hopper. Place the
inches (30 cm) above top of curb. Adjust stringline
retainer pin in the nearest set of holes and connect the
setup to conform to these measurements. Use of
hair pin.
fiberglass rod, pvc pipe or radius wheels is highly
Start the engine and increase rpm to maximum. Push recommended to reduce setup time.
the vibrator-auxiliary travel valve in to the “vibrator”
position. Place the vibrator auto/off switch in the
“auto” position. Rotate the variable speed control dial
in the increase direction just enough to start the
vibrators without moving the machine. Rotate each
vibrator variable control valve, that has a vibrator
attached, counterclockwise to the maximum position.
Do Not operate a vibrator out of a cooling
substance (water or concrete) for periods longer
than 30 seconds. The vibrator should begin to rotate
to full speed. If necessary, test the individual vibrators Left front leg pivot turnbuckle
360014
with a vibratach to measure the amount of vibration
Remove the turnbuckle from the left front leg pivot arm
each of the vibrators is capable of producing. If a
and adjust the left front leg to the maximum right pivot
vibrator does not produce a minimum of 9000
position. Reinstall the turnbuckle and tighten the
vibrations per minute (VPM) at maximum engine
barrel of the turnbuckle by hand until tight. It may be
speed and maximum oil flow, it will be necessary to
necessary to move or swing the conveyor frame
replace the vibrator with a new or rebuilt unit.
further to the right to allow the maximum extension of
Note: Testing vibration levels should be done the left front leg pivot to the right.
daily prior to pouring concrete. Allow enough time
Notice: The left and right smart steer cylinder
to replace a vibrator prior to concrete arrival.
limits must be set to allow the tracks maximum left
and right steer capability. Refer to the
Maintenance chapter for adjustment procedures.
G21 06/01/04
3-37
elevation offset measurements in relation to the back

of the curb profile and top of the curb profile.
Extend mold shift

360510
After the curb profile is attached to the drawbar and
hold down assemblies, use the mold shift control Attach the grade and steer sensors
switch to extend the slipform mold to the maximum left 360513
position. Tighten the mold shift clamps securely. Attach a grade sensor to each of the elevation
adjustment jacks with the mounting bolt facing towards
Note: The slipform mold must be extended to the the rear of the machine and the sensor hub and shaft
maximum left position to allow the machine to turn facing towards the guideline. The sensor housing
a 24 inch (61 cm) outside radius. should be mounted in a level position. Tighten the
mounting bolt securely. It may be necessary to
Note the job conditions and extend the drawbar and remove the sensor mounting bracket from the end of
hold down cylinders to conform to the job. Adjust the the elevation sensor jack and position it as shown in
limit bolts on the drawbar and hold down cylinder so photo number 360513. Each grade sensor is mounted
the curb profile is parallel to the machine frame front to in the same manner.
rear.
Attach a grade wand to the grade sensor hub. Hold
the sensor hub and shaft in a centered position
between the two stops on the sensor housing and
attach the sensor wand in a parallel position with the
sensor mount bolt. The wand should face in the
forward (push) direction. Tighten the wand thumb
screw securely.
Attach sensor arm

360508
Adjust the machine frame to a level position from front
to rear. Extend the front and rear sensor mount tubes
and attach the sensor arm in a level position to match
the machine frame. Tighten the mounting bolts Rotate number 2 grade sensor
360517
securely. Adjust the sensor arm and sensor mount
Adjust the number 2 grade sensor mount bracket so
tubes as necessary to approximate the steer and
that the grade sensor wand is angled towards the
G21 06/01/04
3-38
guideline as shown in photo 360517. This allows the

number 2 grade wand to stay in contact with the
guideline as the outside radius is turned.
Measure steer position

360514
Measure the center to center distance between the
mounting bolts for the rear steer sensor mount
assembly and the number 2 steer sensor mount
assembly. The distance should be 18.5 inches (470
mm). Adjust the number 2 steer sensor mount to the
correct measurement by loosening the mounting bolt
and sliding the mount forward or backward. Tighten
the mounting bolt securely.
Note: The distance between the number 2 steer

wand and the rear steer wand should be the same
measurement used between the mounting bolts.
When using one of the split sensor arm assemblies,

measure the center to center distance between the
Attach steer sensors
360512 steer wands.
Attach a steer sensor to each of the steer adjustment
jacks with the mounting bolt facing towards the
machine and the sensor hub and shaft facing the
forward direction of travel. Tighten the sensor
mounting bolt securely.
Attach a steer wand to each steer sensor hub. Hold

the sensor hub and shaft in a centered position
between the two stops on the sensor housing and
attach the steer wand in a perpendicular position to the
sensor mount bolt. Tighten the wand thumb screw
securely.
The rear steer sensor wand placement should be in

alignment with the hold down cylinder mount. The
photo above shows a double stainless section.The
rear grade sensor wand and steer wand should be in
alignment with the hold down cylinder mount.
G21 06/01/04
3-39
360518
Required Pre-Trimming for Tight Radius

Pre-trimming area
Radius Wheel
Stringline
Adjust steer wand placement on stringline Machine Direction of Travel

360507
Adjust the height of the sensor arm in relation to the Curb Area of Coverage by Trimmerwheel
3600DWG1
guideline so that each steer sensor wand is located on
the guideline as shown in the photo above. The Required pre-trimming for tight radii
3600DWG1
guideline should contact the steer wand approximately
Pre-trimming tight radii is recommended since the
3 inches (76 mm) from the tip of the wand. Remember
trimmerhead will not cover the full radius as shown in
to maintain the sensor arm in a parallel position (front
photo 360518. It is also recommended that the area
to rear) with the machine frame when the arm is raised
not covered by the trimmerwheel, be trimmed below
or lowered for adjustment. This can be accomplished
final subgrade a minimum of 1/2 inch (13 mm) low. If
with a level as indicated earlier in this chapter and
pre-trimming is not completed, the side of the slipform
makes it easier to make final elevation adjustments.
mold will collect and drag material around the radius
It may be necessary to adjust the extension of the causing the mold to tilt at an angle as the radius is
elevation jacks so that the null position of the grade poured. Make certain that the width of trimmed area
sensor wand is aligned with the guideline contact point around the radius is equal to, or longer than; the length
on the steer wand. The rear grade sensor wand and of the mold since the mold will travel sideways around
steer wand should be in alignment with the hold down the tight radius.
cylinder mount.
Make certain all leg clamps and mold shift clamps are
tightened securely.
G21 06/01/04
3-40
10 Final Adjustments
Check Slope With Level

3105
Place a level in the gutter portion of the slipform mold
at the rear of the main form. Raise the lower end of Check Subgrade with Level
the level until it is plumb. Measure the distance 3106
between the form side of the level and the top of the
form to determine the amount of slope. If the amount ! DANGER! !
of slope is incorrect, adjust the slope setting on the
CONTACT WITH MOVING TRACKS OR
machine until the desired amount of slope is attained.
Note: When checking the slope on a curb and OR DEATH. BE CERTAIN THAT NO ONE IS NEAR
gutter form, be sure to allow for edge slump, which THE TRIMMERWHEEL BEFORE ENGAGING THE
may be 1/4 to 3/8 inch (6 to 9 mm). CONTROL VALVE. BE CERTAIN THAT NO ONE IS
When checking the cross slope of a sidewalk form, MACHINE. KEEP HANDS, FEET AND LOOSE
place a level across the rear of the main form. Raise CLOTHING AWAY FROM MOVING PARTS TO
the lower end of the level, until it is plumb. Measure PREVENT SEVERE PERSONAL INJURY.
the distance between the level and the top of the form.
If the amount of slope is incorrect, adjust the slope Hold a level, plumbed horizontally, above or below the
setting on the machine until the desired amount of guideline and extended over the trimmed grade.
slope is attained. Measure from the guideline side of the level down to
the trimmed grade directly below the reference point
(top of back of curb, gutter line, etc.). If the
measurement is incorrect, adjust the grade sensors
equally as required. Moving the sensors up, lowers
the grade and moving the sensors down, raises the
grade. One turn of the grade jack crank changes the
grade approximately 1/8 inch (3 mm). After a grade
adjustment has been made, move the machine
forward 20 or 30 feet (6 to 9 M) and recheck the
grade. Readjust as necessary.
Note: If the grade must be lowered, it will be

necessary to have the machine moving forward
slowly.
When adjusting the grade for pouring against an

existing roadway, raise or lower the machine until the
edge of the slipform is even with the roadway.
G21 06/01/04
3-41
If the product is being poured on a smooth surface (no Note: Make certain the form is parallel to the
trimmerhead), such as concrete or asphalt, the grade guideline when checking the offset.
is normally adjusted so that the bottom of the form
clears any high spots in the grade by at least 1/8 inch When adjusting the offset for pouring against an
(3 mm). Adjust the grade sensors up or down as existing roadway, adjust the steering until the lip on the
necessary. Be certain that the bottom of the form is edge of the form (if so equipped) is approximately 1/8
parallel to the machine frame when changing grade. inch (3 mm) from the roadway edge.
11 Pouring Operations
After the machine has been set to line and grade, it will
be necessary to move it back to the start of the job.
Set the forward/reverse switch to the “reverse”
position. Place the front and rear elevation control
loops in the manual mode. Using the jog switches on
the front or rear elevation loops, raise the machine
high enough so the trimmerhead and slipform mold will
clear all obstacles. If the drawbar and hold down
cylinders are in a lowered position for pouring, it is
recommended to leave the front and rear elevation
control loops in the “Auto” mode and raise just the
trimmerhead and the slipform mold rather than the
whole machine. While backing the machine to the
start of the pour with the elevation control loops in the
“manual” mode, raise or lower the front or rear of the
machine as necessary to keep the steering wands
Check Steering Offset with Level from coming off the line or to keep the trimmerhead or
3107 slipform mold from striking an obstacle.
! DANGER! ! Note: It may be necessary to manually steer the

machine to the start of the pour when pouring
CONTACT WITH MOVING TRACKS OR scab on.
OR DEATH. BE CERTAIN THAT NO ONE IS NEAR
THE TRIMMERWHEEL BEFORE ENGAGING THE
! DANGER! !
NEAR THE TRACKS BEFORE MOVING THE CONTACT WITH MOVING TRACKS OR
MACHINE. KEEP HANDS, FEET AND LOOSE TRIMMERWHEEL CAN CAUSE SERIOUS INJURY
CLOTHING AWAY FROM MOVING PARTS TO OR DEATH. BE CERTAIN THAT NO ONE IS NEAR
PREVENT SEVERE PERSONAL INJURY. THE TRIMMERWHEEL BEFORE ENGAGING THE
Set a level, plumbed vertically against the guideline, in NEAR THE TRACKS BEFORE MOVING THE
line with the machine drawbar. Measure the distance MACHINE. KEEP HANDS, FEET AND LOOSE
between the guideline side of the level and the CLOTHING AWAY FROM MOVING PARTS TO
reference point (top of back of curb, gutter line, etc.) PREVENT SEVERE PERSONAL INJURY.
on the slipform mold. This measurement should be
the required offset distance. If not, adjust the front and Back the machine approximately 15 to 20 feet (4.6 to
rear steering sensors evenly as necessary. Moving 6 m) beyond the starting point of the pour if possible
the sensors towards the guideline, increases the and stop the machine. Place the forward-reverse
distance between the line and the form. Moving the switch in the “forward” position. Lower the
sensors away from the guideline, decreases the trimmerhead and slipform mold if they were raised.
distance between the form and line. After each Using the jog switches on the front or rear elevation
adjustment, move the machine forward 20 to 30 feet control loops, lower the machine until the trimmerhead
(6 to 9 M) and recheck the offset. and the slipform mold are resting on the grade. Move
the trimmerhead control valve to the “forward” position.
Place the grade sensor wands under the guideline and
G21 06/01/04
3-42
the steering sensor wands, if necessary, on the necessary to clear a small amount of material next to
machine side of the line. Notice the position of the the existing curb and gutter or sidewalk that the
display arrows on the elevation loops. If either, or trimmer could not remove.
both, of the LED lights are centered or an arrow is
pointing up, place the corresponding control loop in the Notice: Be certain to tighten the clamps on the
“Auto” mode. If an arrow is indicated pointing down, mold sideshift beam before attempting to pour. An
start the machine slowly moving forward. Using the unsatisfactory finished product could result if the
left front elevation jog switch, lower the front of the clamps are not tightened.
machine slowly until the LED lights are centered or an
arrow is pointing up. Place the control loop in the Note: The slipform mold will not fit over the
“Auto” mode. Do the same with the rear grade. Move product that was poured with it at a previous time.
the machine forward until the starting point of the pour Concrete slump causes the product to expand
is lined up with a point approximately 2 feet (61 cm) to wider than the slipform profile.
the rear of the slipform hopper.
! CAUTION! !
! CAUTION! ! DO NOT PLACE OIL ON THE OPERATORS
DO NOT ALLOW ENTIRE WEIGHT OF MACHINE PLATFORM, OR THE BOARDING LADDER, AS IT
TO REST ON THE SLIPFORM MOLD AS IT COULD MAY CAUSE THEM TO BECOME VERY SLIPPERY.
BE DAMAGED. INJURY MAY RESULT IF SLIPPAGE OCCURS.
It is advisable to coat the inside and outside of the

form and the machine frame below the conveyor with
form oil. The conveyor frame, receiving hopper and
the discharging hopper should also be coated. Avoid
placing oil on the inside surface of the belt as it could
cause slippage.
GOMACO Tip: Place plastic or burlap over the

machine frame directly below the conveyor to aid
in clean up at the end of the day.
Pour Started from Existing Curb

3108
If the pour is to start from an existing product, it will
first be necessary to be certain that the grade at the
end of the existing product is correct. The grade at the
end of the existing product to a point at least 10 feet (3
m) beyond the end must be on grade to 1/2 inch (13
mm) low. Back the machine to the start of the pour, as
previously described, until the rear of the slipform mold
is against the existing curb and gutter.
It may also be possible on various job sites to sideshift Concrete Vibrated Back to Existing Slab
the mold and the trimmerhead to the right and back 3109
the machine so that the rear of the trimmerhead will

clear the existing curb and gutter or sidewalk. Lower
and sideshift the trimmerhead into trimming position.
Trim and move the machine forward until the rear of
the slipform mold will clear the existing curb and gutter
or sidewalk. Sideshift and lower the slipform mold into
pouring position on the trimmed grade. It may be
G21 06/01/04
3-43
movement. Adjust the travel speed and vibration as

! DANGER! ! required.
KEEP HANDS, FEET AND CLOTHING AWAY FROM As soon as the concrete begins to slip from the rear of
MOVING CONVEYOR BELT AND ROLLERS. BE the form, move the hold-down control valve to the
CERTAIN THAT NO ONE IS NEAR THE CONVEYOR “down” position. Adjust the hold-down pressure, by
BEFORE STARTING IT. SERIOUS INJURY OR turning the hold-down pressure control valve clockwise
DEATH MAY RESULT IF ENTANGLED. DO NOT to increase pressure, or counterclockwise to decrease
STAND BEHIND THE CONCRETE SUPPLY TRUCK pressure, to hold the form in firm contact with the
WHEN IT IS BACKING INTO POSITION. SERIOUS concrete. If the hold-down pressure is too high, the
INJURY OR DEATH MAY OCCUR IF STRUCK BY top surfaces will appear to “puff up” as the concrete
THE MOVING TRUCK. slips from under the form. If the hold-down pressure is
too low, the stainless trowel section will appear to
Move the conveyor directional control valve to the “leave” the concrete, causing the top surfaces to
“forward” position and push the vibrator-auxiliary travel appear streaked. If the stainless trowel section will not
valve in to the “vibrator” position. Rotate each vibrator touch the concrete surface with the pressure high,
variable control valve, that has a vibrator attached, loosen the limit bolts. Adjust the travel speed and
counterclockwise to the maximum position. Place the vibration as required.
vibrator auto/off switch in the “auto” position.
Discharge concrete onto the conveyor belt from the
supply truck. Fill the hopper of the slipform mold at
least 75% full. Rotate the variable speed control dial
in the increase direction just enough to start the
vibrators without moving the machine. Allow the
vibrators to force the concrete back into the form until
they can force no more into it. Keep the slipform
hopper at least 75% full by starting and stopping the
conveyor as necessary.
GOMACO Tip: By spraying the underside of the

form and the grade with water, before dumping
concrete into the form, it may be possible to fill the
form more fully. It may also help to spray a small
amount of water onto the first amount of concrete
in the hopper to help it slip into the form more
easily.
Check cross slope of product
3111
After pouring 15 to 20 feet (4.6 to 6 m) check the
finished product for proper slope, line and grade. If
adjustments are needed, make them in small
increments over a great distance. For example, if the
grade requires a change of 1/4 inch (6 mm) adjust it
1/8 inch (3 mm) every 5 feet (1.5 m) or more. To
check the cross slope, place a level in the gutter
section, or across the surface of a sidewalk and raise
the lower end until the level is plumb. Measure from
the bottom of the level to the top surface of the
concrete. Adjust the slope setting of the machine as
necessary.
Adjust hold-down pressure
3110
When the form is completely full, rotate the variable
speed control dial in the “increase” direction to position
number 30, or above, to start the machine forward
G21 06/01/04
3-44
concrete line must move closer to the line, move the

sensors away from the line.
Check Grade of Product

3112
To check the grade, place a level above or below the
guideline and plumb it out over the edge of the finished Good Product
product. Measure from the guideline side of the level 3114
down to the reference point on the concrete (top back Production rate (or travel speed) is determined by
of curb, flow line, etc.). Adjust the front and rear grade many factors, of which a few are:
sensors, up or down, evenly to get the proper
measurement. If the grade must be raised, lower the 1. Delivery rate of the concrete mix. If the concrete
sensors. If the grade must be lowered, raise the mix cannot be readily discharged from the
sensors. supply truck, the production rate will be lowered.
The size of the slipform mold will have a direct
Note: When checking the grade to the top back of affect on how far each load of concrete will go.
curb, be certain that the curb has not slumped
down too far by measuring the back side of the 2. Amount of pressure required to turn the
curb for the correct measurement. trimmerhead. A narrow width trimmerhead,
trimming a small amount of material, will operate
at low pressure, allowing for higher production
rate. A wide trimmerhead, trimming a large
amount of material, will operate at high pres-
sure, reducing the production rate. Ideally, the
subgrade to be trimmed during pouring opera-
tions should be 1/2 inch to 1 inch (13 to 25 mm)
high.
3. How wet or dry the concrete mix is (slump). With

high slump (wet) concrete, the travel speed can
be increased, which in turn will increase the
production rate. With low slump (dry) concrete,
the travel speed must be decreased, which in
turn will decrease the production rate. The
recommended concrete slump, for curb and
gutter or sidewalk, is 1-1/2 to 2 inches (38 to 51
mm).
Check offset of product
3113 4. Amount of hand work to be done behind the
To check the offset, plumb the level vertically along the machine. If pouring a curb which requires the
side of the line. Measure the distance between the cutting of many driveway openings, it is impor-
guideline side of the level and the concrete reference tant that the machine not get too far ahead. If
point (top back of curb, flow line, etc.). Adjust the front the machine were to get too far ahead, it would
and rear steering sensors evenly, right or left as allow the concrete to begin to set, making the
necessary. If the concrete line must be moved away cutting of each driveway opening progressively
from the line, move the sensors towards the line. If the more difficult.
G21 06/01/04
3-45
Hump caused by running vibrators

3117
During paving operations, it occasionally becomes
Wet Concrete necessary to stop and start the machine travel. When
3115 stopping, rapidly move the variable speed control dial
When the concrete mix becomes too wet (high slump), in the “decrease” direction to the stop. This causes
it may be necessary to increase travel speed and/or the vibrators to stop at the same instant as the
decrease vibration to avoid a “puffy” surface. If the machine travel ceases. When starting the machine
concrete is extremely wet, the edges or curb may travel, rapidly move the variable speed control dial in
slump excessively or even fall over. The solution the “increase” direction to position number 30 or
would then be to get the concrete mix drier or refuse to above. This will start the vibrators at the same instant
accept it. as the machine travel begins. After the machine is
moving, adjust the travel speed as necessary.
Dry Concrete
3116 Hump caused by bumping line
3118
When the concrete mix becomes too dry (low slump),
it may be necessary to decrease travel speed and/or During pouring operations, it is important that nothing
increase vibration to eliminate “voids” in the concrete comes in contact with the guideline. Be certain there
surface. If the concrete is extremely dry, large “voids” is no debris against the guideline which could become
may appear in the surface, or the concrete may pull entangled in the sensor wands. Be certain that
apart completely. The solution would then be to add persons working around the machine do not come in
water to the concrete mix, or if necessary, refuse to contact with the line.
accept it.
G21 06/01/04
3-46
Trimming excessive grade

3119
! DANGER! !
IF THE TRIMMER WHEEL IS FULL OF MATERIAL Low grade boil out
3120
THAT MUST BE CLEARED BY HAND OR When low spots are present in the subgrade, it is
MATERIAL MUST BE REMOVED FROM THE advisable to fill them with fill material prior to pouring
SUBGRADE, THE TRIMMERWHEEL MUST BE operations. Enough fill should be added so that when
STOPPED AND THE ENGINE MUST BE SHUT OFF it is compacted the grade is 1/2 to 1 inch (13 to 25
BEFORE CLEARING THE MATERIAL OR SERIOUS mm) high. Low areas can cause the top line of the
INJURY, OR DEATH, CAN RESULT. FOR finished product to sag, especially if the hold-down
ADDITIONAL SAFETY, REMOVE THE KEY FROM limiters are not used. It is recommended to spot check
THE IGNITION SWITCH. BE CERTAIN THAT for high and low grade spots.
PERSONNEL ARE CLEAR OF THE
TRIMMERWHEEL BEFORE STARTING THE Pouring on low grade can cause severe loss of
ENGINE. KEEP HANDS, FEET AND LOOSE concrete yield. For example, with the grade 1/2 inch
CLOTHING CLEAR OF TRIMMERWHEEL WHILE IN (13 mm) low over a width of 3 feet (0.91 m), an
OPERATION. additional cubic yard (0.764 m) would be required for
every 216 feet (65.8 m) poured.
During trimming and pouring operations, it is normally
recommended to trim no more than 1 to 1-1/2 inches
(25 to 38 mm). If more than 2 inches (51 mm) of
material must be removed, it is best to remove it with a
motorized blade or scraper. If an attempt is made to
remove the excessive amount of material with the
trimmerhead, it could cause frequent stalling of the
trimmerhead drive system. This would reduce the
production rate. Also, if the rear track is running on
the windrow created by excessive trimming, it could
cause a build up in the track, which could cause track
damage. The leg may also bottom out while running
on the windrow created by excessive trimming,
causing loss of grade control.
Trimmer Position on Radius
Note: If a motorized blade or scraper is not 3121
available, the grade can be pre-trimmed by raising For tight radius work, it will be necessary to remove
the machine 1 inch (25 mm). After the grade is excess subgrade material before attempting to pour.
pre-trimmed, back the machine to the start of the The trimmerwheel will not follow the same path as the
pour, lower it the 1 inch (25 mm) and begin rear of the slipform mold and will not remove any
pouring operations. The windrow from pre- material in this area. Using grading equipment,
trimming should be removed in some manner. remove the excess material so that it is on or just
below final grade. This should be done around the
G21 06/01/04
3-47
complete radius and extended up to 10 feet (3 m) corresponding sensor(s). Continue to pour forward
beyond the ends of the radius. until the rear sensors are to the obstacle. Repeat the
procedure for the rear sensors.
When entering a tight radius the slipform mold hopper
should be full of concrete so that it is not necessary to Note: If several obstacles are apparent, it may be
stop the machine in the middle of the radius. When less time consuming to readjust the guideline in
pouring around a tight radius it may be necessary to order to avoid the obstacle.
slow the travel of the machine at the beginning of the
radius to allow the front tracks to make the initial turn.
It may also be necessary to reduce the speed of the
vibrators to prevent the concrete from pumping out the
back of the slipform mold. Adjust the speed of the
machine travel and the vibrators to prevent an
unsatisfactory finished product.
Occasionally, obstacles are situated between the

guideline and the finished product. If clearance is
possible, remove just the sensors or the grade jack. It
may be necessary to loosen and slide the angle mount
bracket or split sensor arm assembly towards the
machine frame, or remove it to clear the obstacle.
When the front sensors get to the obstacle, stop the
machine, place the control loop in the “Man” mode for
the corresponding sensor(s). Mark the position of the
sensors and the other mounts that need to be cleared. Pour Ending Against an Obstacle
3123
Proceed as necessary to clear the path.
If the end of the pour is up against an existing curb
and gutter or sidewalk, stop the machine forward travel
when the left front track or if possible the trimmerhead,
is up against the end of the existing product. Raise
and/or sideshift the trimmerhead to clear the existing
curb and gutter or sidewalk and place the trimmerhead
control valve in the “off” position. Move the machine
forward until the front of the slipform mold is against
the existing curb and gutter or sidewalk. Place the
conveyor directional control valve in the “off” position.
Pull the auxiliary travel vibrator selector valve out to
the “auxiliary travel” position. Place the grade control
loops in the “Man” mode and the manual steer select
switch in one of the manual steer positions. Raise the
machine using the all jog switch and move the
machine to an area where it can be cleaned.
If the pour is to be stopped in an open area, it is

advisable to trim forward an additional 20 to 30 feet (6
to 9 M) past the stopping point. By doing this, when
the pour is continued, the subgrade is already trimmed
for the machine setup. To continue trimming past the
Machine Past Obstacle end of the pour, stop the conveyor and vibrators.
3122 Place the hold-down control valve in the “neutral”
Move the machine forward until the obstacle is past (center) position and continue to trim forward the
the sensor mount. Reattach the parts that were desired amount. When the desired amount has been
removed and align them to their previous positions. trimmed, raise the machine and move it to an area to
Tighten securely. Place the grade wand under the line be cleaned.
and the steering wand on the machine side of the line.
Place the control loop in the “Auto” mode for the
G21 06/01/04
3-48
Water Pump Hydraulic Hose Quick Couplers

3126
Mark sensor location
3124
The sensors should be removed before washing the ! WARNING! !
machine. It is advisable to mark the sensor location PLACE ALL CONTROL VALVES ON THE
on the mounts prior to their removal. This will speed OPERATOR CONTROL CONSOLE IN THE
setup time if the pour is continued at a later date. Be NEUTRAL POSITION TO PREVENT THE WASH
certain to place protective dust caps over the electrical HOSE OR OPERATOR FROM GETTING CAUGHT
plugs to keep moisture and dirt out. IN A MOVING PART.
The water pump is operated by a vibrator circuit. Hook

the hoses from the pump hydraulic drive motor to a
vibrator circuit. Turn on that circuit to the maximum
position and turn off any circuit that has a vibrator
attached. Place the vibrator auxiliary travel selector
valve in the “vibrator” position. Place the travel/neutral
switch in the “travel” position and the forward/reverse
switch in the “forward” position. Rotate the variable
speed control dial in the increase direction enough to
run the vibrator circuit without turning the tracks. Allow
the engine to run at 1500 rpm.
Uncoil the hose from the hose hanger on the side of

the tank and wash the concrete off of the machine. It
is recommended that the underside of the form be
washed off first. Clean the underside of the form
thoroughly, as any concrete left to dry on the
Fill Port on Top of Tank underside will affect the final concrete finish when the
3125
pour is resumed.
The machine should be cleaned as soon as possible
after pouring operations have ended. It is advisable to
fill the water tank on the machine (if so equipped) at
the start of the pour, so water for cleaning purposes is
available at the end of the pour. Remove the lid from
the top opening of the tank and insert a fill hose.
When the tank is full, replace the lid.
G21 06/01/04
3-49
!
¶031-03-0480
DANGER! !
TO PREVENT SEVERE INJURY OR DEATH, DO
NOT OPERATE THE AUGER, CONVEYOR,
TRIMMER, OR TRACKS WHEN CLEANING THE
MACHINE. PLACE ALL CONTROL VALVES ON
THE OPERATOR CONTROL CONSOLE IN THE
NEUTRAL POSITION TO PREVENT THE WASH
HOSE AND THE OPERATOR FROM GETTING
CAUGHT IN MOVING PARTS.
! WARNING! !
Vibrator Hoses Hooked to Power Wash Bulkheads THE HIGH PRESSURE WASH SYSTEM USES HIGH
3127
PRESSURE WATER. DO NOT AIM THE NOZZLE
If the machine is equipped with the optional power
AT ANY PART OF THE BODY, AS SERIOUS
washer, it will be necessary to disconnect two of the
INJURY CAN OCCUR. WEAR PROPER EYE
vibrators from the bulkheads and connect the male
PROTECTION WHEN CLEANING THE MACHINE.
quick couplers into the power wash bulkheads. This
will provide 8 gal./minute (30.3 liters/minute) at full Remove the power wand and uncoil the hose from the
engine rpm, with the vibrator variables rotated fully on, hose hanger on the side of the tank and wash the
to the hydraulic motor operating the power washer. concrete off of the machine. It is recommended that
the underside of the form be washed first. Clean the
To operate the power washer, place the travel/neutral
underside of the form thoroughly, as any concrete left
switch in the “neutral” position. Place the vibrator
to dry on the underside will affect the final concrete
auto/off switch in the “auto” position. If equipped,
finish when the pour is resumed.
place the auxiliary travel vibrator selector valve in the
“vibrator” position. Rotate the variable speed control 12 Center Mount Form Installation
dial just enough to operate the vibrator circuit. Rotate
the two vibrator variables connected to the power Two different assemblies are available for the GT-
washer circuit to the on position. Make sure the 3600, one assembly is for up to 8 feet (2.44 meters)
remaining vibrator variables are turned off. Run the \width and the other assembly is for up to 10 feet (3.05
engine at 1500 rpm. meters) width. Refer to the appropriate procedures for
the type of center mount assembly being installed.
Notice: Severe damage to the high pressure
washer pump can occur if no water is provided to
it. Cease operation before the tank is run
completely dry.
! WARNING! !
NEVER USE FINGERS TO CHECK ALIGNMENT OF
BOLT HOLES. MACHINE PARTS MAY SHIFT
CAUSING AMPUTATION OF FINGERS. ALWAYS
USE AN ALIGNMENT PIN TO LINE UP BOLT
HOLES.
Note: When installing either conversion, it must

be done on the jobsite. Once installed, the
machine will be too wide for transport.
Power Washer Wand

3128
G21 06/01/04
3-50
Center Mount Assembly up to 8 feet (2.44 meter)
3
5
4
6
Remove trimmer mounts
360001
Using a suitable lifting device, remove the
trimmerhead and trimmer lift assembly from the
machine frame. 360262
8 feet (2.44 meter) center mount assemblies
360262
Remove hold down cylinder

360004 Install rear leg frame extension
Disconnect the hydraulic lines from the hold down 360054
cylinder. Be certain to place protective caps or plugs

over or in the quick disconnects to prevent foreign ! DANGER! !
material from entering the hydraulic system. Using a TO PREVENT SERIOUS INJURY OR DEATH, USE
suitable lifting device, remove the hold down cylinder ADEQUATE BLOCKING UNDER THE FRAME
assembly from the machine frame and set aside for DURING THE FOLLOWING ASSEMBLY
storage. PROCEDURES.
Place suitable blocking under the rear of the machine.

Lower and remove the machine weight from the rear
leg. Mark the hydraulic lines for the rear leg,
disconnect and cap the lines to prevent foreign
material from entering the hydraulic system.
Disconnect the cord from the feedback pot. Using a
suitable lifting device, remove the rear leg from the
machine frame and set aside temporarily. Remove the
rear leg mounting flange and the rear leg shift cylinder
and set aside for storage. Using a suitable lifting
G21 06/01/04
3-51
device, attach the rear leg mount beam (number 2 in Attach the hold down mount plate to the bottom left
drawing 360262) to the rear of the machine frame hand clamp for the rear leg mount beam. Tighten the
using the clamps (number 3 in drawing 360262) bolts securely.
provided. Adjust the left mount plate and clamp to the
left edge of the machine frame and tighten securely. Note: Make certain that the proper clamp is
Attach the hose hanger (number 1 in drawing 360262) installed on the bottom left hand clamp of the rear
to the top mount clamp. Attach the rear leg to the mount beam to allow the hold down tube to be
mounting flange on the rear leg mount beam and attached.
tighten securely. Install the 48 inch (1.22 meter)
hydraulic line extensions and reconnect the hydraulic
lines to the appropriate positions on the leg.
Reconnect the cord to the feedback pot. Raise the
machine and remove the blocking.
Install the hold down mount tube

360271
Attach the turnbuckle mount tube (number 4 in
drawing 360262) to the tapped mounting holes on the
right rear corner of the machine frame and to the hold
down mount plate using the clamp and bolts provided.
Install the drawbar Tighten all bolts securely.
360270
Using a suitable lifting device, attach the drawbar
assembly (number 6 in drawing 360262) to the
mounting flanges for the trimmerhead lift cylinders on
the machine frame and tighten the bolts securely.
Install the slipform mold

360270
Place the slipform mold on a flat level surface. Raise
the machine frame high enough to clear all obstacles.
Move the machine until the front of the slipform mold
hopper is directly behind the drawbar mount on the
Left hand hold down mount plate machine frame. Lower the machine frame until the
360255a
drawbar mount flanges are aligned and move the
machine in reverse to engage the mounts. Insert the
G21 06/01/04
3-52
drawbar pins (number 5 in drawing 360262) through Note: If the welded lugs do not exist on the
both mount flanges. slipform mold frame tubes, it will be necessary to
add them.
Note: The center mount form is connected at the
front of the hopper. If the form is not equipped Using a 4 foot (1.22 meter) level, adjust the machine
with the drawbar on the front of the hopper, it will frame to a level position from front to rear. Place the
be necessary to install it. same level on the slipform mold , front to rear, and
adjust the hold down turnbuckles until the slipform
mold is 1/8 inch (3 mm) lower at the rear of the form in
the 4 foot (1.22 meter) length of the level. Tighten the
turnbuckle jam nuts securely.
Field Installation of auxiliary vibrator and auger

control valves
For machines that are not equipped with six vibrator

controls, an optional auxiliary vibrator console is
provided. If an auger is required in the slipform mold,
the auxiliary console may also be equipped with an
auger control valve.
Install the hold down turnbuckles

360052
Place three lug clamps around the turnbuckle mount
tube. One of the clamps should be placed in the
center and the other two should be placed in alignment
with the outside edges of the slipform mold. Align the
lug clamps directly behind the mounting holes in the
angled hopper brace weldments on the slipform mold
and tighten securely. Install the turnbuckles between
the lug on the turnbuckle mount tube and the
corresponding angled hopper brace weldment on the
rear of the slipform mold hopper using cylinder pins
and retaining pins. Turn the barrel of the turnbuckle Place auxiliary console over guard rail
braces by hand, turning the threads into the barrel, 360103
until snug and tighten the barrel jam nuts securely. Attach the auxiliary vibrator/auger console over the
guard rail near the operators station. Secure the
Note: If the mounting holes in the angled hopper console using the U-bolt provided. Connect the large
brace weldments do not exist on the slipform quick couplers to the trimmer hydraulic lines to supply
mold, it will be necessary to add them. pressure and return hydraulic flow to the auxiliary
console. Connect the remaining vibrator quick
Place three lug clamps around the turnbuckle mount couplers to the appropriate control knob connections
tube. One of the clamps should be placed near the on the auxiliary console and connect the auger drive
center of the slipform mold and directly above the motor to the quick couplers on the auger control valve.
welded lug on the slipform mold frame tubes. The
other two clamps should be placed in alignment with Note: The trimmer control valve must be engaged
the welded lug mounts on the outside frame tubes of in the forward direction to allow operation of the
the slipform mold. Tighten the lug clamps securely. auger and vibrator controls on the auxiliary
Insert the turnbuckle brace between the lugs on the console.
slipform mold and the turnbuckle mount tube using the
cylinder pins and retaining pins.
G21 06/01/04
3-53
Center Mount Assembly up to 10 feet (3.05 meters)
! WARNING! !
NEVER USE FINGERS TO CHECK ALIGNMENT OF
BOLT HOLES. MACHINE PARTS MAY SHIFT
CAUSING AMPUTATION OF FINGERS. ALWAYS
USE AN ALIGNMENT PIN TO LINE UP BOLT
HOLES.
2
4
3
5 6 Attach the left front frame extension beam

360141
7 Using a suitable lifting device, attach the left front
8 frame extension beam (number 4 in drawing 360263)
to the front of the machine frame as shown. Make
9 10 11 certain to position the extension beam so that all
twelve bolts are used when the beam is attached to
the machine frame. Tighten all bolts securely.
360263.eps
10 feet (3.05 meter) center mount assemblies
360263.eps
Attach left front leg pivot

Remove the left front leg and pivot assembly 360249
360014
Determine placement of the left front leg pivot
according to job site restrictions. If a wider width of the
! DANGER! ! tracks is needed, move the left front leg pivot further
TO PREVENT SERIOUS INJURY OR DEATH, USE left on the extension beam. Using a suitable lifting
ADEQUATE BLOCKING UNDER THE FRAME device, reattach the left front leg pivot to the mounting
DURING THE FOLLOWING ASSEMBLY flange on the extension beam. Make certain to use all
PROCEDURES. eight bolts when attaching the left front leg pivot to the
extension beam. Tighten all bolts securely. Using a
Place suitable blocking under the left front corner of suitable lifting device, reattach the left front leg to the
the machine frame and lower the machine to remove pivot arm. Tighten all bolts securely. Install 20 inch
the weight from the left front leg. Mark the hydraulic (0.51 meter) hydraulic line extensions and reconnect
lines for the left front leg, disconnect and cap the lines the hydraulic lines to the appropriate positions on the
to prevent foreign material from entering the hydraulic leg. Reconnect the cord to the feedback pot. Shift the
system. Disconnect the cord from the feedback pot. left front leg as necessary to clear any obstacles on
Using a suitable lifting device, remove the left front leg the jobsite. Insert the turnbuckle brace between the
and the left front leg pivot from the machine frame and extension beam lug and the left front leg pivot lug.
set it aside temporarily. Secure the turnbuckle with cylinder pins and retaining
G21 06/01/04
3-54
pins. Turn the barrel of the turnbuckle brace by hand,

turning the threads into the barrel until snug. Tighten
the brace jam nut securely. Raise the machine and
remove the blocking from under the frame.
Rear frame extension beam

360143
Using suitable blocking under the rear of the machine
frame, lower the rear leg until all weight is removed
from the rear track. Mark the hydraulic lines for the
Drawbar mount rear leg, disconnect and cap the lines to prevent
360253 foreign material from entering the hydraulic system.
Using a suitable lifting device, attach each drawbar Disconnect the cord from the feedback pot. Using a
mount (number 1 in drawing 360263) to the mounting suitable lifting device, remove the rear leg from the
flanges for the trimmerhead lift cylinders on the machine frame and set aside temporarily. Disconnect
machine frame and leave bolts slightly loose to allow the rod end of the rear leg shift cylinder from the shift
easy alignment of the drawbar beam. The left drawbar assembly and support the cylinder temporarily. Using
mount must be aligned with the right side of the left a suitable lifting device, remove the rear leg side shift
mounting flange on the machine frame. assembly from the machine frame and set aside for
storage. Using a suitable lifting device, remove the
tool box and guard rail assembly and set aside
temporarily. Using a suitable lifting device, attach the
rear leg mount beam (number 8 in drawing 360263) to
the rear of the machine frame with the clamps (number
7 in drawing 360263) provided and tighten all bolts
securely.
Drawbar beam
360252
Using a suitable lifting device, align the drawbar beam
mount plates (number 2 in drawing 360263) with the
plates on the drawbar mounts and tighten all bolts
securely in the drawbar mounts and drawbar beams.
G21 06/01/04
3-55
Left hand hold down mount plate Attach rear leg

360255a 360142
Attach the hold down mount plate to the bottom left Using a suitable lifting device, attach the rear leg to the
hand clamp for the rear leg mount beam. Tighten the mounting flange on the rear leg mount beam. Tighten
bolts securely. all bolts securely. Install 48 inch (1.22 meter)
hydraulic line extensions and reconnect the hydraulic
Note: Make certain that the proper clamp is lines to the appropriate positions on the leg.
installed on the bottom left hand clamp of the rear Reconnect the cord to the feedback pot.
mount beam to allow the hold down mount plate to
be attached.
Attach tool box and guard rail

360134
Rear shift cylinder Using a suitable lifting device, attach the tool box and
360240 guard rail assembly to the clamp flanges on the rear
Connect the rod end of the rear shift cylinder to the lug leg mount beam with the clamps provided. The tool
on the rear leg mount beam. Insert the pin and secure box may be shifted left or right along the clamping
with retaining pins. flange to align the tool box guard rail with the left side
of the access opening to the operators station.
Note: The rear leg must be shifted to the left side Tighten the clamps securely. Reattach the tool box
of the slipform mold for track steering clearance guard rail and tighten the nuts securely if removed
during paving. Adjust the rear leg mount beam as during disassembly.
necessary to clear the slipform mold.
G21 06/01/04
3-56
Rear extension tube

360244
Using a suitable lifting device, attach the rear
extension beam to the mounting flange on the rear leg
mount beam. Tighten all bolts securely.
Right front stiffener beam

360232
Extend the right front leg mounting flange to allow
track steering clearance during paving. Insert the right
front stiffener beam between the rear extension beam
and the right front inner telescoping tube. The stiffener
beam prevents the inner telescoping tube from twisting
when the right front leg is raised with the weight of the
machine frame. Tighten the clamps securely.
Right front inner telescoping tube
360234
Using a suitable lifting device, attach the right front leg
Place suitable blocking under the right front corner of
to the mounting flange on the right front telescoping
the machine frame. Retract the right front leg until the
tube. Tighten all bolts securely. Install 48 inch (1.22
track is off the ground. Extend the right front inner
meter) hydraulic line extensions and reconnect the
telescoping tube fully to the right. Mark the hydraulic
hydraulic lines to the appropriate positions on the leg.
lines for the right front leg, disconnect and cap the
Reconnect the cord to the feedback pot.
lines to prevent foreign material from entering the
hydraulic system. Disconnect the cord from the
feedback pot. Using a suitable lifting device, remove
the water tank assembly from the right front leg and
set aside temporarily. Using a suitable lifting device,
remove the right front leg from the machine and set
aside temporarily. Remove the clamps from the front
and bottom of the right front inner telescoping tube.
Disconnect the rod end of the right front extend
cylinder and remove the right front inner telescoping
tube from the machine frame. Insert the longer inner
telescoping tube (number 6 in drawing 360263) into
the machine frame. Connect the right front extend
cylinder and reattach the clamps to the front and
bottom side of the machine frame for the inner
telescoping tube. Adjust the clamps as instructed in
the Maintenance chapter.
G21 06/01/04
3-57
Attach turnbuckle mount tube

360235
Attach the turnbuckle mount tube between the
mounting plate on the left and the vertical mount tube
on the right using the clamps and bolts provided.
Attach hold down vertical mount tube Measure and record the distance between the
360231
turnbuckle mount tube and the rear leg mount beam at
Attach the hold down vertical mount tube to the
the left mount plate. Adjust the hold down vertical
mounting flange on the stiffener beam using the clamp
mount tube up or down until the same measurement
plate and bolts provided. Tighten snugly until a
exists on the right side of the turnbuckle mount tube.
measurement can be taken for the hold down
Tighten all bolts securely.
turnbuckle mount tube.
Attach turnbuckle braces

360257
Place three lug clamps around the turnbuckle mount
tube. One of the clamps should be placed in the
center and the other two should be placed in alignment
with the outside edges of the drawbar mount beam.
Align the lug clamps directly behind a mounting hole
on the drawbar mount beam and tighten securely.
Left hand hold down mount plate Insert the turnbuckle brace between the drawbar
360255 mount beam and lug on the turnbuckle mount tube.
Attach the hold down mount plate to the bottom left Secure with cylinder pins and retaining pins. Turn the
hand clamp for the rear leg mount beam. Tighten the barrel of the turnbuckle, pulling the threads into the
bolts securely. barrel until hand tight. Tighten the barrel jam nut
securely.
G21 06/01/04
3-58
same level on the slipform mold; front to rear, and

adjust the hold down turnbuckles until the slipform
mold is 1/8 inch (3 mm) lower at the rear of the form in
the 4 foot (1.22 meter) length of the level. Tighten the
barrel jam nuts securely.
Attach slipform mold

360252 Attach grade and steer sensors
360049
Raise the machine high enough to clear the slipform
Attach the sensor arm and sensors in the same
mold. After the machine has been moved to straddle
manner used for curb and gutter setup.
the slipform mold, lower the machine frame until the
drawbar is centered with the drawbar mount on the
slipform mold. Make certain that proper clearance
exists for steering the tracks without contacting the
mold or the concrete slab. Install the drawbar pins to
secure the slipform mold to the machine.
Attach grade ski and dual grade sensor

360052
Attach hold down turnbuckles A grade ski may be used on the right side of the
360245 slipform mold to allow the form to follow the trimmed
Place three lug clamps around the turnbuckle mount subgrade more closely. Connect the sensor into the
tube. One of the clamps should be placed near the bulkhead in the back of the control panel for right front
center of the slipform mold and directly above one of grade control. The G21 control system will need to be
the slipform mold frame tubes. The other two clamps calibrated for dual grade control instead of left grade
should be placed in alignment above the outside frame with right slope control.
tubes of the slipform mold. Tighten the lug clamps
securely. Attach the turnbuckle lugs to the slipform
frame tubes and tighten securely. Insert the
turnbuckle brace between the lugs on the slipform
mold and the turnbuckle mount tube.
Using a 4 foot (1.22 meter) level, adjust the machine

frame to a level position from front to rear. Place the
G21 06/01/04
3-59
CHAPTER IV SIDE MOUNTED BARRIER

SETUP
This chapter covers the instructions necessary for the

preparation of the machine and slipform mold for
pouring barrier wall on the left side of the machine.
The instructions for mounting the attachments and
pouring operations are also included. At the end of the
chapter are instructions for cleaning the machine at
the end of the pour. Some procedures pertain to
machines that are being assembled for the first time,
while others pertain to machines that may have been Adjust rear of sideplate
in service for some time. Disregard procedures that 001-1912
do not apply. All adjustments are recommended If the back of the barrier form is a straight edge
procedures only. Pay particular attention to all (parapet), measure the amount of exposed sideplate
Safety statements. below the main portion of the form on the front side,
after it has been set for the proper amount of exposed
02 Form Preparation surface. Adjust the sideplate on the back side of the
form until the amount of exposed sideplate below the
main portion of the form is the same as the front.
Make the measurement in line with the adjustment
bolts.
Adjust rear of sideplate

001-1911
Adjusting Standard Sideplates: Adjust the rear of
the sideplate on each side of the form to give the
proper amount of exposed vertical surface. Measure
Adjust front of sideplate
from the angled transition bend line to the bottom of 001-1913
the sideplate. Adjust the sideplate up or down with the Measure from the top of the sideplate to the bottom of
rear adjustment bolt. Lock the adjustment in place the angle iron on the side of the form, in line with the
when the proper measurement is attained. Make the rear adjustment bolt. Measure the distance from the
measurement in line with the adjustment bolt. top of the sideplate to the bottom of the angle iron on
the side of the form, in line with the front adjustment
Note: Sideplate adjustment is normally easier bolt. Adjust the front of the sideplate until the
with the form attached to the machine and raised measurement is the same as the rear.
off the ground.
Note: If pressure compensated sideplates are
installed on the form, refer to the Final Adjustment
section (section 09) for adjustment procedures.
G21 09/08/03 4-1

Adjust Top Plate Adjust top at center

001-1916 001-1918
Adjusting the Top Plate: Place a straight edge, from Note the measurement at the rear of the form between
side to side, below the bottom rear edge of the the straight edge and the top plate. Move the straight
sideplates. Measure from the straight edge to the rear edge forward to the center set of adjusting bolts.
edge of the stainless top cap. This measurement Adjust the center of the top plate until it is
should be the same as the required height of the wall, approximately 1/4 inch (6 mm) above the rear of the
plus approximately 3/4 inch (19 mm) allowance for plate. Move the straight edge forward to the front set
slump. of adjusting bolts. Adjust the front of the plate until it is
approximately 1/2 inch (13 mm) above the rear of the
plate. Tighten all of the adjusting nuts securely.
Tighten the attaching bolts on both sides of the form
securely.
Adjust top of wall to proper slope

001-1917
To adjust the top plate, loosen the attaching bolts on
both sides of the form. Adjust the rear edge of the top
plate up or down with the adjusting bolts until the wall
is the correct height. Lock the nuts on the adjusting
bolts securely. Place a straight edge across the two
square tubes on the top of the form directly over the
rear of the top plate. Measure from the straight edge
down to the flat portion of the plate on each side. Adjust side stainless
001-1920
These measurements should normally be even. If not,
Stainless Trowel Adjustment: Adjust the stainless
adjust one side or the other as necessary.
trowel section on each side of the slipform mold so the
leading edge is approximately 1/8 inch (3 mm) outside
of the rear edge of the main form. Make the
adjustment at all adjustment points. Tighten the
adjustment nuts securely.
Place a 4 feet (1.2 m) straightedge from the rear of the

stainless trowel section, up into the main form in line
G21 09/08/03 4-2

with one of the adjusting bolts. Adjust the rear of the

stainless until there is a 1/8 inch (3 mm) gap between
the rear edge of the main form and the straight edge.
Tighten the adjustment nuts securely. Do the same at
each set of adjustment bolts.
Install second vibrator

001-1923
If the wall is of the straight back (parapet) design, the
second vibrator is positioned in the underslung
Install vibrator in parapet wall base
(horizontal) manner when pouring over cage steel.
001-1921 The vibrator should be positioned in the back of the
Vibrator Installation: The first vibrator is installed in wall, as low as possible and still clear the steel by 1
the underslung (horizontal) manner with the tip inch (25 mm) (provided there is enough space).
centered in the width of the wall base if pouring
straight back (parapet) wall. Place the vibrator to one
side if pouring over cage steel making certain that
there is at least 1 inch (25 mm) of clearance between
the steel and the vibrator.
Install vibrators in barrier wall base Install third vibrator

001-1922 001-1924
If the wall is of the standard design, a second vibrator The third vibrator is installed in the underslung
can be installed in the right side of the form. The (horizontal) manner when pouring over cage steel.
vibrator should be installed in the underslung The vibrator should be positioned to the right (machine
(horizontal) manner. Position the left and right side) of the center vertical portion of the wall. The
vibrators with their tips 6 to 8 inches (150 to 200 mm) vibrator should be mounted in a higher position in
in from their respective sides. The tips should be relation to the second vibrator. The vibrator should
positioned 4 to 6 inches (100 to 150 mm) off the grade. clear the steel by a minimum of 1 inch (25 mm). If no
steel is being inserted into the wall, the vibrator can be
Place the vibrator to one side if pouring over cage installed with the tip pointing into the center of the
steel making certain that there is at least 1 inch (25 vertical portion of the wall.
mm) of clearance between the steel and the vibrator.
G21 09/08/03 4-3

Refer to the vertical leg positioning section of the

standard setup chapter for instructions for
repositioning the track mounts vertically.
Install top vibrator

001-1925
The top vibrator is installed in the overslung (vertical)
manner with the tip tilted rearward slightly when
pouring over cage steel. The vibrator should be
centered in the throat opening of the wall top. Be Lateral leg position
certain that the tip will clear the steel by a minimum of 351
1 inch (25 mm). The top vibrator is installed in the Lateral Positioning: When pouring side mounted
same manner if no steel is being inserted. Tighten the barrier wall, the right front leg should normally be
mounting bolts and setscrews securely on all vibrators. extended to the maximum right (out) position. The left
front leg is normally positioned in the straight ahead
03 Positioning the Legs (center) position. The rear leg should be repositioned
as far to the left as possible. Refer to chapter 3 for
lateral positioning procedures.
04 Installing the Side Mount Assembly
When installing the side mounted barrier package it

will be necessary to remove the trimmerhead and
trimmerhead lift assembly. It will also be necessary to
remove the hold down assembly and the drawbar
assembly from the mold side shift beam.
Vertical leg position

349
! WARNING! !
WHEN ADJUSTING THE POSITION OF THE LEG,
DO NOT GET UNDER THE MACHINE, OR THE LEG,
DO NOT PLACE FINGERS IN HOLES TO CHECK
FOR ALIGNMENT. SEVERE INJURY, OR
AMPUTATION, COULD OCCUR IF THE LEG WERE
TO MOVE OR FALL. Disconnect Hydraulic Hoses
325
Vertical Positioning: The vertical positioning of the Notice: Do not place quick couplers in the case
track mounts will be determined by the height of the drain line. Excessive back pressure, caused by
wall. Normally, for side mounted barrier wall, the track quick couplers may cause trimmer gearbox seal
mounts are placed in the lowest position (position #1). failure.
G21 09/08/03 4-4

To remove the trimmerhead, disconnect all hydraulic Note: It may be necessary to pivot the left front
hoses from the trimmerhead and place the protective leg and the right front leg to allow enough side
covers over/in the quick couplers to prevent dirt from clearance when backing away from the
entering the hydraulic system. Place a cap over the trimmerhead.
case drain line fitting to prevent dirt from entering the
hydraulic system. Lower each of the trimmerhead lift
legs enough to allow easy removal of the retainer nuts
on the J-bolts. Place blocking under the left front
corner of the trimmerhead and under the right hand
side of the trimmerhead mount assembly to support it
during removal from the machine.
Remove Trimmer Lift Mounts

360001
The trimmerhead lift mounts will need to be removed.
J-Bolt Removed Disconnect the hydraulic hoses and place the
327
protective covers over/in the quick couplers to prevent
dirt from entering the hydraulic system. Using a
suitable lifting device, remove the trimmerhead lift
mounts.
Rear Mount Removed

328
! WARNING! !
MAKE CERTAIN ALL PERSONNEL ARE CLEAR OF
THE MACHINE AND/OR ARE AWARE THAT THE
MACHINE IS MOVING. Remove Hold Down Assemblies
360004
Disconnect the hydraulic hoses and place the
Remove the J-bolts from the front mount bar on the
protective covers over/in the quick couplers to prevent
trimmerhead mount assembly. Remove the retainer
dirt from entering the hydraulic system. Using a
bolt, lock washer and flat washer from the rear mount
suitable lifting device, remove the hold down cylinder
and remove it from the rear mount bar on the
assembly from the side shift beam and set it aside, as
trimmerhead mount assembly. It may be necessary to
it will not be used in the side mount barrier set up.
raise or lower the rear leg of the machine a small
Remove the eight bolts attaching the hold down
amount to allow easy removal of the rear mount.
cylinder mounting bracket to the side shift beam and
Raise the machine high enough to clear all obstacles
set the mounting bracket aside.
and back away from the trimmerhead.
G21 09/08/03 4-5

1 8
4
2
5
7
6
360268
Sidemount barrier assembly kit
360268 the trimmerhead lift mounting flanges on the machine
frame. Insert 3/4 X 2-1/2 inch (19 x 64 mm) bolts, lock
washers and nuts and tighten securely. Flat washers
are required on the slotted hole side of each hole.
Front Side Mount Bracket

360002
Using a suitable lifting device, raise the front mount Rear Side Mount Bracket
beam (number 1 in drawing 360268) and attach it to 360006
G21 09/08/03 4-6

Using a suitable lifting device, lift the rear side mount 05 Mounting the Slipform Mold
beam (number 2 in drawing 360268) into place on the
mold side shift beam. Placing a flat washer over each
of the slotted holes, insert a 1/2 X 1-3/4 inch (13 x 45
mm) bolt, lock washer and nut and tighten securely. A
90 degree steel plate (number 3 in drawing 360268) is
attached to the front of the mold side shift beam above
the drawbar. Remove the appropriate mounting bolts
from the drawbar assembly and attach the mounting
plate to align with the bracket on the rear side mount
beam. Insert the bolts and tighten securely.
Note: It is not necessary to remove the drawbar

assembly from the mold side shift beam.
Mounting Barrier Form

360012
Mounting the Form: Place the slipform mold on a
relatively flat area. Coil the vibrator hoses and place
them into the form hopper. Move the machine into
position along side of the slipform mold. Raise, or
lower one side of the machine or the other so that the
mounts on the machine are parallel to the mounts on
the form. The top of the machine mounts should be
Front Barrier Side Mount Plate
360009 slightly lower than the top of the form mounts.
Using a suitable lifting device, attach the barrier side
mount plate (number 4 in drawing 360268) to the front
side mount bracket. Insert a 3/4 X 2 inch (19 x 51
mm) bolt, flat washer, lock washer and nut through
each of the slotted holes and tighten securely. Flat
washers are required on the slotted hole side of each
hole.
Attach the barrier side mount plate to the rear side

mount bracket. Insert a 3/4 X 2 inch (19 x 51 mm)
bolt, flat washer, lock washer and nut through each of
the slotted holes and tighten securely.
The barrier side mount plates should be parallel to

each other on the frame of the machine. Measure
between the barrier side mount plate and the side of
the machine frame. The measurement on the front
should be the same as the measurement on the rear Insert bolts in front mount
360013
mount. If not, adjust as necessary. The top of the
Slowly drive the machine forward, making sure that the
barrier side mount plates should also be parallel to
flange at the top of the form mount captures the
each other. Tighten all locking clamps securely.
machine mount. Continue moving the machine
forward until contact is made at the stop plate on the
front of the form mount to align the mounting holes.
Install the bolts, flat washers, lock washers and nuts
and tighten securely (flat washers go on slotted hole
side) on the front mount.
G21 09/08/03 4-7

Install front stabilizing turnbuckle

360018
Install the front stabilizing turnbuckle between the lug
on the bottom of the front side mount bracket and the
lug on the front of the form, near the bottom.
Insert bolts in rear mount

360016
Install the bolts, flat washers, lock washers and nuts
on the rear mount and tighten securely (flat washers
go on slotted hole side).
Connecting Vibrator Quick Couplers

374
Thoroughly clean the quick couplers on the vibrator
drive hoses and bulkhead quick couplers to prevent
dirt from entering the hydraulic system. Connect the
vibrator drive hoses to the vibrator outlet quick
Install rear stabilizing turnbuckle couplers. It is recommended that the vibrators be
360017
Install the rear stabilizing turnbuckle (number 5 in connected in a consecutive order beginning with
drawing 360268) between the lug on the rear side number one at the top. Any vibrator outlet that does
mount bracket and the lug on the rear of the form, near not have a vibrator attached to it, must have the loop
the bottom. hose connected.
G21 09/08/03 4-8

Attach the pivot mount to the pivot mount bracket

using a bolt and lock washer. Rotate the pivot mount
in the direction that the sensor arm will be facing.
Attach the rear pivot mount bracket and pivot mount in
the same manner.
Slide a sensor arm assembly into the pivot mount at

the front and rear of the machine. The front grade and
steer sensors should be aligned with the front of the
slipform mold. The rear grade and steer sensors
should be aligned near the stainless trowel section of
the mold. The number 2 grade and steer sensors are
not required for barrier or parapet wall operations.
Hydraulic Sideplate Hoses Connected Note: The grade sensors should never be located
360097
Connect the hydraulic sideplate control valve hoses (if to the right side of the slope sensor mounting
equipped) on the machine. Be sure to thoroughly location. The slope sensor is located in the
clean the quick couplers to prevent dirt from entering battery box on early model machines and is
the hydraulic system. located above the main hydraulic filter on current
model machines. The G21 controller will not
Notice: When removing the slipform mold, do not properly control the machine elevation when the
connect the hoses on the machine for the grade sensors are mounted to the right side of the
hydraulic sideplates together, or loss of lift slope sensor.
pressure will result.
Notice: Allow turning clearance for the track when
06 Preparing and Mounting the Conveyor positioning the sensors. Make certain that the
track can make a full turn without coming in
Refer to Chapter 3 Standard Setup for adjustment contact with the sensors or sensor arm. Severe
procedures to follow when preparing and mounting the damage can occur if contact is made.
conveyor.
07 Mounting the Sensors
Center Mount Stringline
Install pivot mount and bracket

360071
Attach the pivot mount bracket by clamping it around
the front sensor mount tube located under the machine
frame. The mount bracket may be adjusted closer to
either the left or right sides of the machine as required
for the guideline location. Tighten the bolts securely.
G21 09/08/03 4-9

rear steering sensors are mounted in the same

manner.
The steering sensor wand should be attached to the

sensor hub, so that when the stop pin in the sensor
shaft is centered between the stops on the sensor, the
wand is at a 90° angle to the mounting bolt (vertical).
Tighten the attaching “thumbscrew” securely.
Note: All steer sensors and wands must be

Left Stringline
360022
Mount a sensor for elevation control to the mount on
the adjustable grade jack with the mounting bolt facing
forward or reverse and the sensor hub facing towards
the guideline. Mount the sensor so the top of it is level Left stringline sensor mount
360075
and tighten the mounting bolt securely. The front and Attach the pivot mount bracket by clamping it around
rear grade sensors are mounted in the same manner. the rear sensor arm extension tube. The extension
tube can be adjusted as needed to provide support to
the sensor arm to prevent flexing of the arm. Tighten
tube facing towards either the front of the machine and
the bolts securely. Attach the pivot mount to the pivot
pointing towards the guideline or; toward the rear of
mount bracket using a bolt and lock washer. Rotate
the machine and pointing towards the guideline. The
the pivot mount in the direction that the sensor arm will
wand should be attached, so that when the stop pin in
be facing. Attach the front pivot mount bracket and
the sensor shaft is centered between the stops on the
pivot mount in the same manner.
sensor, the wand is parallel to the mounting bolt
(horizontal). Tighten the attaching “thumbscrew” Slide a sensor arm assembly into the pivot mount at
securely. the front and rear of the machine. The front grade and
steer sensors should be aligned with the front of the
slipform mold. The rear grade and steer sensors
should be aligned near the stainless trowel section of
the mold. The number 2 grade and steer sensors are
not required for barrier or parapet wall operations.
Mount a sensor for steering control to the square tube

mount with the mounting bolt facing away from the
stringline and the sensor hub towards either the front
or the rear. Mount the sensor so the top of it is level
and tighten the mounting bolt securely. The front and
G21 09/08/03 4-10

Note: All steer sensors and wands must be

Sensors Connected to Bulkhead

385
Grade Sensor Mounted Connect the sensors to their respective plugs on the
360074
Mount a sensor for elevation control to the mount on bulkhead. Steering to the “steer” plugs, and grade
the adjustable grade jack with the mounting bolt facing sensors to the “grade” plugs.
forward and the sensor hub away from the side of the
machine. Mount the sensor so the top of it is level and Notice: When the sensors are disconnected, place
tighten the mounting bolt securely. The front and rear the dust caps over the electrical plugs to keep
grade sensors are mounted in the same manner. moisture and dirt out.

tube facing towards either the front of the machine
(same side as mounting bolt) and pointing towards the
side mounted form or; toward the rear of the machine
(same side as the cable) and pointing towards the side
mounted form. The wand should be attached, so that
when the stop pin in the sensor shaft is centered
between the stops on the sensor, the wand is parallel
to the mounting bolt (horizontal). Tighten the attaching
“thumbscrew” securely.

installed in the same manner. If one sensor or Remove Counterweights and Adjust Spring Tension
387
It is normally recommended to remove two of the
counterweight washers from the rear of the grade
wand, so only two remain.
Mount a sensor for steering control to the square tube
mount with the mounting bolt facing towards the
guideline and the sensor hub towards either the front
or the rear. Mount the sensor so the top of it is level Grade Wands Cycle Power!
and tighten the mounting bolt securely. The front and PUSH +/- Adjust
rear steering sensors are mounted in the same
manner. 031-0187
Grade sensor mode selection
The steering sensor wand should be attached to the 031-0187
sensor hub, so that when the stop pin in the sensor Depress the calibrate switch on the service panel and
shaft is centered between the stops on the sensor, the use the NEXT switch to scroll forward to the grade
wand is at a 90° angle to the mounting bolt (vertical). sensor mode. Use the slope adjust switches (+ or -) to
Tighten the attaching “thumbscrew” securely. change the mode to "GRADE WANDS = PULL" if the
round tube of the grade wand is on the same side as
the cable. If the round tube of the grade wand is on
G21 09/08/03 4-11

the same side as the mounting bolt, change the mode tracks is controlled by the front steer sensor connected
to "GRADE WANDS = PUSH". to the front steer plug and the front steer control loops.
The steering of the rear track is controlled by the rear
Test the operation of the grade sensor wands by steer sensor connected to the rear steer plug and the
placing the sensors in automatic control on the G21 rear steer control loop.
controller. When the wand is moved above the
centered position, the machine should raise. If the 08 Preliminary Adjustments
machine operates in the wrong direction, change the
grade wand calibration to the opposite mode.
Steer Wands Cycle Power!

PUSH +/- Adjust
031-0188
Steer sensor mode selection
031-0188
Using the NEXT switch, scroll forward to the steer
sensor mode. Use the slope adjust switches (+ or -) to
change the mode to "STEER WANDS = PUSH" if the Leveling Mold with Machine Frame
round tube of the steer wand is facing forward. If the 360019
round tube of the steer wand is facing towards the rear Place a level across the frame of the machine (left to
of the machine change the mode to "STEER WANDS right). Using the grade or slope jog switches, manually
= PULL". level the machine from side to side. Stop the engine
or place the “servo lock” switch in the “on” position.
Place the level across the square tubes at the top of
the open front extension shroud. Adjust the front
stabilizing turnbuckle until the top front of the form is
Grade Mode Cycle Power! level. Secure the turnbuckle in place with the jam nut.
LGrd RSlope , +/- Adjust Place the level across the square tubes near the rear
of the form. Adjust the rear stabilizing turnbuckle until
360352 the top of the form is level. Secure the turnbuckle in
G21 panel for left grade, right slope place with the jam nut.
360352
To operate the machine with left hand grade control, Note: If the form does not have the open front
and right side slope control, depress the calibrate extension shroud, place the level on the top of the
switch. Scroll through the various displays until the front of the hopper to adjust the front turnbuckle.
elevation mode is displayed. Use the slope adjust
switches (+ or -) to change the mode to "L GR/R
SLOPE". After the appropriate grade and steering
mode settings are selected, depress the calibrate
switch to return to the main control panel display.
Note: The ignition switch or computer restart

The left front leg elevation is controlled by the left front

grade sensor connected to the left front grade plug,
and the left front elevation control loop. The rear leg
elevation is controlled by the rear grade sensor,
connected to the left rear grade plug, and the rear
elevation control loop. The right front leg elevation is Machine Set Over Cage Steel
001-1973
controlled by the slope sensor, and the right front
elevation control loop. The steering of both front
G21 09/08/03 4-12

! WARNING! !
CONTACT WITH MOVING TRACKS CAN CAUSE
SERIOUS INJURY. BE CERTAIN THAT NO ONE IS
NEAR THE TRACK BEFORE MOVING IT. KEEP
HANDS, FEET AND LOOSE CLOTHING AWAY
FROM MOVING PARTS TO PREVENT SEVERE
INJURY.
If control of the machine is being taken from a

guideline on the left side, refer to the preliminary
Adjustment section of the Standard Set-Up chapter. If
the guideline is under the machine, move the machine
into position over the guideline. Steer the front or rear
of the machine left or right as necessary, until
approximately the same distance exists between the
guideline and the front of the form and the guideline
and the rear of the form. If pouring over cage steel,
the form should be parallel to and centered over the
steel. Steer the front and rear tracks to the straight
G21 Sensors on Guideline
ahead position. 360021
It is advised to screw the steering adjustment crank, in
the end of the sensor arm assembly, out (clockwise) 3
to 4 inches (76 to 100 mm) before making sensor
adjustments. Adjust the grade jack out the same
amount. This will allow for minor steering and grade
adjustments if needed. Place the grade sensor wands
under the guideline and the steering sensor wands on
the left side of the guideline. Turn the sensor mount
brackets until the shaft through each of the steering
sensors is parallel to the guideline and the shaft
through each of the grade sensors is at a 90° right
angle to the guideline.
Lower form to grade

001-1961 LF FdbkPot StrWnd StrVlv
Insert the required slope setting into the G21 controller
2.40V 2.52V 0.00V
by depressing the slope setpoint switches until the
proper setting is reached. Place the slope control loop
002-2760
in the “Auto” mode. Depress the “run-standby” switch
on the G21 controller to place it in the “Run” mode. Steer Sensor Reading at 2.50 volts
002-2760
Lower the machine using the front and rear elevation Depress the test switch under the service panel. To
“jog” switches until the bottom of the slipform mold is select the front steering sensor, depress the steer A/M
lightly resting on the grade. Be sure the frame is switch on the left front control loop. Adjust the steering
approximately the same distance above the guideline sensor left or right (in or out) until the steer sensor test
at the front and rear. Be certain that the tracks are display reading is “2.50 ” volts. If a large amount of
straight ahead and stop the engine. Leave the ignition adjustment, 1 inch (25 mm) or more, is necessary to
switch in the “on” position. center the sensor reading, loosen the setscrews in the
sensor pivot mount and adjust the sensor arm
assembly in or out as needed (save crank adjustment
for fine adjustments). Depress the A/M switch for the
rear steering control loop and adjust the rear steer
sensor as described above.
G21 09/08/03 4-13

Depress the A/M switch for the left front grade control
loop. Adjust the front grade sensor up or down until
the grade sensor test display reading is “2.50” volts. If
a large amount of adjustment is necessary to center
the sensor reading, loosen the setscrews in the grade
sensor jack and raise or lower the jack as needed.
Tighten the setscrews securely. Depress the A/M
switch for the rear grade control loop and adjust the
rear grade sensor as described above.
Adjust Spring Tension

387
Adjust the spring tension on the sensor hubs to hold
the wands firmly in contact with the guideline, but not
tight enough to deflect the line. Check for the correct
spring tension after the machine has been adjusted to
the line. Note the position of the line on the grade
wand. Pull the steering wand away from the line and
note the movement of the line on the grade wand. If
the movement exceeds 1/8 inch (3 mm), the steering
spring tension is too tight. Loosen the tension slightly.
Note the position of the line on the steering wand. Pull
the grade wand down, away from the line and note the
movement of the line on the steering wand. If the
movement exceeds 1/8 inch (3 mm), the grade sensor
spring tension is too tight. Loosen the tension slightly.
Pull the line away from both sensor wands. The
steering wand should move left towards the line until
the stop pin in the sensor hub contacts the stop pin in
the side of the sensor. If not, tighten the spring
slightly. The grade wand should move up towards the
line, until the stop pin in the sensor hub contacts the
stop pin in the side of the sensor. If not, tighten the
spring slightly. If the sensor wands deflect the line
Adjust Sensors on Guideline more than 1/8 inch (3 mm), but the stop pin in the
360022
sensor and the hub will not contact one another,
Loosen the L-shaped clamp bolt in the grade jack
suspect that the line has inadequate tension. Adjust
bracket and slide the jack left or right until the grade
the line as necessary.
sensor wand is centered beneath the guideline.
Tighten the clamp bolt securely. Loosen the setscrew Note: When checking the sensor wand spring
in the steering sensor square tube mount and slide the tension, it should be done half way between
sensor assembly up or down until the line crosses the stations so the line holders do not interfere. The
wand 12 to 16 inches (300 to 410 mm) from the pivot control system should be in the “standby” mode or
point. Tighten the setscrew securely. the servo lock switch must be in the “on” position
when checking the sensor spring tension.
G21 09/08/03 4-14

! WARNING! !
INJURY.
Start the engine and depress all A/M switches on the

control loops so they are in the “Auto” mode. Place
the steering selector switch in the “Stringline” position.
Depress the run-standby switch on the G21 controller
to place it in the “Run” mode. Place the forward/
reverse switch in the “forward” position. Place the Measure to guideline (front)
servo lock switch in the “off” position. Increase the 360024
engine speed to maximum and slowly rotate the travel Place a straight edge against the side of the machine
variable control dial in the increase direction to start frame, just to the rear of the front form mount, and
the machine moving. Move the machine forward 20 to extend it down to the stringline height. Measure the
30 feet (6 to 9 m) and stop the machine. distance between the machine side of the straight
edge and the guideline. Record this measurement.
Place a straight edge against the side of the machine

frame, just to the front of the rear form mount, and
extend it down to the stringline height. Measure the
distance between the machine side of the straight
edge and the guideline. This measurement should be
within 1/4 in (6 mm) of the front measurement. If not,
adjust the steering sensors left or right.
! WARNING! !
Measure to Guideline (rear) NEAR THE TRACK BEFORE MOVING IT. KEEP
001-1954 HANDS, FEET AND LOOSE CLOTHING AWAY
Measure from the bottom of the machine frame down FROM MOVING PARTS TO PREVENT SEVERE
to the guideline at the front. Record this INJURY.
measurement.
After adjusting the sensors, move the machine forward
Measure from the bottom of the machine frame down 20 to 30 feet (6 to 9 m) to allow the steering system to
to the guideline at the rear. This measurement should correct itself and recheck the measurements.
be within 1/4 inch (6 mm) of the front measurement. If
not, adjust the grade sensors up or down and recheck Note: The barrier or parapet mold must be
the measurement. parallel to the frame of the machine when
measuring the steering offset.
Note: It is advisable to raise the low end of the
machine, rather than lower the high end.
G21 09/08/03 4-15

09 Final Adjustments
Check offset (left guideline)

001-1959
Adjust slope (parapet) When the guideline is on the left side of the machine,
001-1957 plumb a level vertically against the guideline, in line
Adjust the slope of the straight back barrier form by with the rear of the slipform hopper. Measure the
holding a level against the straight side of the form. distance between the guideline side of the level and
Plumb the level vertically and adjust the slope setting the reference point (center of top, edge of base, etc.)
on the machine until the batter of the back of the wall on the slipform mold. This measurement should be
is correct. the required offset distance. If not, adjust the front and
rear steering evenly as necessary. Moving the
sensors towards the guideline (left), increases the
distance between the line and form. Moving the
sensors away from the guideline (right) decreases the
distance between the line and form. After each
adjustment, move the machine forward 20 to 30 feet (6
to 9 m) and recheck the offset.
Adjust slope (barrier)

001-1960
To adjust the slope of a standard barrier, locate the
center of the top of the wall. Locate the center of the
base of the wall. Hold a level in line with these two
marks. Adjust the slope setting until the wall is at the
desired slope.
Check offset
001-1970
When the guideline is under the machine, plumb a
level vertically against the guideline, in line with the
rear of the slipform hopper. Measure the distance
between the guideline side of the level and the
reference point (center of top, edge of base, etc.) on
the slipform mold. This measurement should be the
required offset distance. If not, adjust the front and
rear steering evenly as necessary. Moving the
sensors towards the guideline (left), increases the
distance between the line and form. Moving the
G21 09/08/03 4-16

sensors away from the guideline (right) decreases the Note: Be certain to allow for top slump when
distance between the line and form. After each checking grade.
adjustment, move the machine forward 20 to 30 feet (6
to 9 m) and recheck the offset.
Check pressure compensated setting

001-2617
Check stationary sideplate clearance After the machine has been set to grade, move the
001-1961 hydraulic sideplate control valves to the down position.
If the barrier form is equipped with standard sideplates Lower the sideplates until they are resting on the
and the wall is being poured on a smooth surface such grade front and rear. Adjust each pressure control
as concrete or asphalt, the grade is normally adjusted valve so that there is 300 psi ±50 psi (21 bar ±3 bar)
so that the bottom of the form clears any high spots in indicated on the gauges. To adjust the pressure,
the grade by at least 1/8 inch (3 mm). Adjust the loosen the jam nut and turn the adjusting screw in to
grade sensors up or down evenly as necessary and increase pressure, or out to decrease pressure.
recheck measurement. Tighten the jam nut securely. The valves are normally
adjusted to the same pressure.
Note: The are between the mold and the

sideplates should be well lubricated with grease to
provide continuous operation during the pour and
prevent concrete buildup between the mold and
sideplates.
Check final elevation

001-1962
If the barrier form is equipped with pressure
compensated hydraulic sideplates and the wall is
being poured on a smooth surface such as concrete or
asphalt, hold a level, plumbed horizontally, above or
below the guideline and extended over to the rear of
the form. Measure from the guideline side of the level
to the top of the rear of the form. If the measurement Check cage steel clearance
001-1964
is incorrect, adjust both grade sensors up or down If the barrier wall is to be poured over cage steel, it is
equally as required. Moving the sensors up, lowers recommended to dry run the length of the job, if
the grade and moving the sensors down raises the possible. Make certain that the steel is properly set
grade. One turn of the grade jack crank changes the and the vibrators clear it by a minimum of 1 inch (25
grade approximately 1/8 inch (3 mm). mm).
G21 09/08/03 4-17

over it until it is approximately 1-1/2 feet (46 cm) from

! WARNING! ! the rear of the form hopper. Stop the machine. Place
the forward/reverse steer switch in the “forward”
CONTACT WITH MOVING TRACKS CAN CAUSE position and the travel/neutral switch in the “travel”
SERIOUS INJURY. BE CERTAIN THAT NO ONE IS position. Be certain that the control system is in
NEAR THE TRACK BEFORE MOVING IT. KEEP "automatic" and the servo lock switch is in the "off"
HANDS, FEET AND LOOSE CLOTHING AWAY position. Move the control valves for the pressure
FROM MOVING PARTS TO PREVENT SEVERE compensated sideplates to the down position to lower
INJURY. the sideplates on to the grade.
After the machine has been set to line and grade, it will
be necessary to move it back to the start of the job.
Set the forward/reverse switch to the “reverse”
! CAUTION! !
position. Place the travel/neutral switch in the “travel” DO NOT PLACE OIL ON THE OPERATORS
position. Move the travel variable control knob in the PLATFORM OR THE BOARDING LADDER, AS IT
“increase” direction to move the machine to the start of MAY CAUSE THEM TO BECOME VERY SLIPPERY.
the pour. It may be necessary to raise the machine or INJURY MAY RESULT IF SLIPPAGE OCCURS.
the hydraulic sideplates a small amount to prevent the
form from catching on any obstacles. It is advisable to coat the inside and outside of the
form and the machine frame below the conveyor with
10 Pouring Operations form oil. The conveyor frame, receiving hopper and
the discharge hopper should also be coated. Avoid
placing oil on the inside surface of the belt as it could
cause slippage.
GOMACO Tip: Place plastic or burlap over the

machine frame, directly below the conveyor to aid
in clean up at the end of the day.
Starting Header
001-1965
! WARNING! !
Starting from header
HANDS, FEET AND LOOSE CLOTHING AWAY 001-1966
FROM MOVING PARTS TO PREVENT SEVERE Move the conveyor directional control valve to the
INJURY. “forward” position and pull the vibrator-auxiliary travel
valve out to the “vibrator” position. Rotate each
Starting Pour from Header: When first beginning the vibrator variable control valve, that has a vibrator
barrier wall pour, it is recommended that a template attached, counterclockwise to the maximum position.
header form be used to start from. The header form Place the vibrator auto/off switch in the “auto” position.
should be at least 1/2 inch (13 mm) smaller than the Discharge concrete onto the conveyor from the supply
wall on the top and both sides. Set the header form at truck. Fill the hopper of the slipform mold at least
the beginning point of the pour and brace it adequately three-fourths full. Rotate the variable speed control
as there will be an extreme amount of pressure dial in the “increase” direction just enough to start the
against it when the concrete is first vibrated against it. vibrators without moving the machine. Allow the
After the header form is set, slowly back the machine vibrators to force the concrete back into the form
G21 09/08/03 4-18

around the header, until it is completely full. Keep the the form. Begin pouring forward as previously
slipform hopper a minimum of three-fourths full by described. By filling the form in this manner, a majority
starting and stopping the conveyor as necessary. of the hand work needed to complete the joint is
eliminated.
When the form is completely full around the header
form, rotate the variable speed control dial in the
“increase” direction to position 30 to start machine
forward movement. After the concrete begins to slip
from the form, adjust the travel speed and vibration as
required.
Check for proper slope

001-1969
After pouring 15 to 20 feet (4.6 to 6 m) check the final
product for proper slope, line and grade. If
adjustments are needed, make them in small
increments over a great distance. For example, if the
Top cover plate in form grade requires a change of 1/4 inch (6 mm), adjust it
001-1967 1/8 inch (3 mm) every 5 feet (1.5 m) or more. To
check the slope of a straight backed barrier (parapet),
! WARNING! ! plumb a level vertically along the back of the wall and
check for the correct amount of batter. To check the
slope of a standard barrier, plumb a level vertically
along the edge of the wall base and measure over to
the center of the wall. Adjust the slope setting as
necessary.
INJURY.
Continuing the Pour From an Existing Wall: If the

pour is to start or continue, from an existing wall, it is
necessary that the grade at the end of the existing wall
is correct. Back the machine to the start of the pour,
as previously described, until the rear of the slipform
mold is against the existing wall.
Note: The slipform mold will not fit over the

product that was poured with it at a previous time.
Concrete slump causes the product to expand
wider than the slipform profile.
Set all controls for pouring as previously described.

Check for proper offset
Remove the cover plate from the top of the form. 001-1970
Begin filling the form and vibrating the concrete back To check the offset, plumb a level vertically along the
into the form. Insert a stinger type vibrator into the side of the guideline. Measure the distance between
opening in the top of the form and “work” the concrete the guideline side of the level and the concrete
to the rear of the form. Continue to “work” the reference point (center of top, edge of base, etc.).
concrete until the form is completely full. Stop the Adjust the front and rear steering sensors evenly, left
main vibrators on the machine and withdraw the or right as necessary.
stinger vibrator. Reinstall the cover plate on the top of
G21 09/08/03 4-19
optimum performance, it may be necessary to

increase or decrease the sensitivity. Sensitivity
settings can be made in the standby or run mode. For
final setup instructions, refer to the setup chapter.
Check for proper elevation

001-1971
To check the grade, lightly place a level on the top of
the wall and plumb it over, or under, the guideline.
Measure the distance between the concrete side of the
level and the guideline. Adjust the front and rear Good product
033-3020
grade sensors up or down, evenly, to get the proper
Continuing the Pour: Production rate (or travel
measurement.
speed) is determined by many factors, of which a few
are:
! WARNING! !
MACHINE. KEEP HANDS, FEET AND LOOSE
CLOTHING AWAY FROM MOVING PARTS. DO
NOT STAND BEHIND THE CONCRETE SUPPLY
TRUCK WHEN IT IS BACKING INTO POSITION.
1. Delivery rate of the concrete mix. If the concrete mix

cannot be readily discharged from the supply truck,
the production rate will be lowered. The size of the
slipform mold will have a direct affect on how far each
Sensitivities on control loop load will go.
031-0055b
Adjust the sensitivity level on each grade and steer GOMACO Tip: If the concrete redi-mix truck is
control loop to prevent the machine from reacting too equipped with secondary discharge fins, it is
fast or too slow. Sensitivity settings can be checked recommended to remove them to aid in the
by depressing and releasing either the elevation or discharge of the low slump concrete mix.
steer sensitivity switches under the service panel. The
settings will be shown on the individual control loops 2. How dry the concrete mix is (slump). The drier the
by the number displayed. Minimum sensitivity is one concrete, the slower the travel speed will be, resulting
and maximum sensitivity is nineteen. The sensitivity in a lower production rate. The recommended
can be set at any place in between. Individual control concrete slump is 1 inch ±1/4 inch (25 mm ±6 mm).
loop sensitivities can be increased by depressing the
up switch, or decreased by depressing the down
switch for elevation or depressing the left and right
switch for steer. For each depression of either switch,
the sensitivity will change one setting. Initial setting for
the sensitivity on the grade, slope and steering control
loops is typically between ten and fifteen. For
G21 09/08/03 4-20
Cage steel centered in front of form

001-1973 Dry concrete mix
When pouring over cage steel, it is important that the 001-1908
steel be set straight and even. Observe the steel When the concrete mix becomes too dry (low slump),
going into the front of the form to be sure there is it may be necessary to decrease travel speed and/or
equal clearance on all sides. Adjust steel or machine increase vibration to eliminate “voids” in the concrete
as necessary. Be certain that the steel is securely tied surface. If the concrete is extremely dry, large “voids”
and braced to prevent movement. may appear in the surface, or the concrete may even
pull apart. The solution would then be to add water to
the concrete mix, or if necessary, refuse to accept it.
Wet concrete mix

001-1974
When the concrete mix becomes too wet (high slump),
it may be necessary to increase the travel speed and/ Hump caused by vibrators
033-3022
or decrease the vibration to avoid a “puffy” surface. If During pouring operations, it occasionally becomes
the concrete is extremely wet, the top of the wall may necessary to stop and start the machine travel. When
slump excessively, or even fall over. When pouring stopping, smoothly rotate the “variable speed control”
over cage steel, wet concrete may cause the bars of dial in the “decrease” direction to the “off” position.
steel to reflect in the concrete surface. A vibrator This causes the vibrators to stop at the same instance
touching the cage steel can also cause the steel to as the machine travel ceases. When starting the
reflect. Adjust the vibrator to prevent contact with the machine travel, smoothly rotate the “variable speed
steel. If the concrete is the problem, the solution control” dial in the “increase” direction to position 30 or
would be to get the concrete mix drier, or refuse to above. This will start the vibrators at the same
accept it. instance as the machine travel begins. After the
machine is moving, adjust the travel speed as
necessary. Another possible solution is to use the
travel/neutral switch. The travel/neutral switch will
simultaneously start and stop the travel and the
vibrators when used.
G21 09/08/03 4-21

GOMACO Tip: When it is necessary to stop for a

short period of time, it is recommended to rotate
the “variable speed control” dial just clear of the off
position of the switch to start the vibrators
operating. Allow the vibrators to operate for 5 to
10 seconds before moving the machine to shake
the concrete free in the form. This will help
eliminate the possibility of the wall tearing when
the machine moves forward. It may also be
advisable to turn all the vibrator variables to the
maximum position
Example of something hitting guideline

CG-110404-08
During pouring operations, it is important that nothing,
or no one bumps the guideline. Be sure there is no
debris against the guideline which could become
entangled in the sensor wands. Be certain that
persons working around the machine do not come in
contact with the line.
Waiting too long for concrete delivery
001-1976
The photo above shows what will occur if the machine
sits in one position for too long and the concrete sets
up in the mold. When it becomes necessary to wait for
concrete delivery, it is recommended to have the
hopper completely full when the last truck departs,
especially if the temperature is extremely warm.
Slowly move the machine forward approximately 12
inches (300 mm) every 5 to 10 minutes. It is
recommended to set the vibrators to maximum before
moving the machine, after it has set for a period of
time. If the concrete begins to pull and crack at the
rear of the mold, stop the machine travel and allow the
vibrators to work the concrete in an attempt to loosen it
from the mold. Slowly move forward until the concrete Installation of repair forms
001-1973
slips freely from the mold. Resume normal speed and
When the top of the wall needs to be repaired due to
adjust the operating speed of the vibrators as
any of the preceding causes, it is recommended to
necessary.
install forms on each side. Clamp the forms in place
so the ends are even with the top of the good sections
of wall. Fill the forms with concrete and finish as
necessary.
G21 09/08/03 4-22

Example of concrete slump variance

001-1977
Small variations of concrete slump can cause the top Bridge parapet expansion joint
of the product to vary up or down during pouring cg050537-21
operations. Maintaining a constant concrete slump will The expansion joint above was securely wired into the
help eliminate the variance in the top of the wall. To cage steel of a bridge parapet. The support structure
check, a 10 or 12 foot (3.0 to 3.7 m) straight edge may of the expansion joint should be strong enough to
be used when placed lightly on top of the wall. Repair withstand the force of the concrete as the mold passes
any fluctuation greater than 1/8 inch (3 mm) as over. The frame work should measure a minimum of
necessary. 1/2 inch smaller then the opening of the slipform mold
on all sides. Finish around the expansion joint as
required after the machine has poured over it.
Finishing wall
001-1979
Apply any finishing practices to the wall as may be
necessary such as a broom finish. Cut any necessary
control joints. After all finishing is completed, apply
curing compound as necessary.
Formed expansion joint
001-2647
Expansion Joints: Where expansion joints are In the example above, two metal hand forms are
required in barrier walls and bridge parapets, there placed on each side of the barrier wall. A space
are various methods used to either hand form or between each pair of forms will allow a saw to cut
slipform the joint into the wall. In either case, make open the joint while the concrete is still plastic.
certain that the method is approved and meets or
exceeds the local specifications. The saw can be made from a long strip of plywood
with handles cut on either end. Teeth are cut into the
bottom edge of the plywood to form the saw. After the
concrete has set up enough to remove the forms, hand
finishing will be required to complete the joint.
G21 09/08/03 4-23

Spray the wall with cure End of pour over header

001-2620 001-1981
Cover the wall with wet burlap or spray with a curing When ending the pour, stop the conveyor. Continue to
compound as required to prevent excessive moisture move the machine forward until all of the concrete has
evaporation. slipped from under the form. Push the auxiliary travel/
vibrator selector valve in to the “auxiliary travel”
position. Place the vibrator auto/off switch in the “off”
position. Depress the “A/M” switch on each elevation
control loop to place the grade control system in
"manual". Select a manual steer mode with the steer
select switch. Raise the machine using the all jog
switch and move the machine to an area where it can
be cleaned.
The sensors should be removed before washing the

machine. It is advisable to mark the sensor location
on the mounts prior to their removal. This will speed
setup time if the pour is to be continued at a later date.
Be sure to place protective dust caps over the
End of pour header form electrical plugs to keep moisture and dirt out.
001-1980
If pouring over cage steel, it is possible to set a
template header form to pour over at the end of the
pour. The header form should be cut at least 1/2 inch
(13 mm) smaller than the wall on the top and both
sides. Set the header form at the end of the pour and
brace it adequately, as there will be an extreme
amount of pressure against it as the concrete in the
hopper, being vibrated, goes over it. As the header
form begins to go into the front of the form, be certain
that it does not catch on the sides or top.
Clean machine
3125
The machine should be cleaned as soon as possible
after pouring operations have ended. It is advisable to
G21 09/08/03 4-24

fill the water tank on the machine (if so equipped) at

the start of the pour, so water for cleaning purposes is
available at the end of the pour. Remove the lid from
the top opening of the tank and insert a fill hose.
When the tank is full, replace the lid.
Vibrator hoses connected to high pressure wash bulkheads

3127
If the machine is equipped with the optional high
pressure washer, it will be necessary to disconnect
two of the vibrators from the bulkheads and connect
the male quick couplers into the high pressure wash
bulkheads. This will provide 8 gal./minute (30.3 liters/
minute) at full engine rpm, with the vibrator variables
Water Pump Hydraulic Hose Quick Couplers rotated fully on, to the hydraulic motor operating the
3126
high pressure washer.
! CAUTION! ! To operate the high pressure washer, place the travel/

PLACE ALL CONTROL VALVES ON THE neutral switch in the “travel” position. Place the
OPERATOR CONTROL CONSOLE IN THE vibrator auto/off switch in the “auto” position. If
NEUTRAL POSITION TO PREVENT THE WASH equipped, place the auxiliary travel vibrator selector
HOSE OR OPERATOR FROM GETTING CAUGHT valve in the “vibrator” position. Rotate the variable
IN A MOVING PART. speed control dial just enough to operate the vibrator
circuit. Rotate the two vibrator variables connected to
The water pump is operated by a vibrator circuit. the high pressure washer circuit to the maximum
Connect the hoses from the pump hydraulic drive position. Make sure the remaining vibrator variables
motor on the pump to a vibrator circuit. Turn on that are turned “off”. Run the engine at 1500 rpm.
circuit to the maximum position and turn off any circuit
that has a vibrator attached. Place the vibrator Notice: Severe damage to the high pressure
auxiliary travel selector valve in the “vibrator” position. washer pump can occur if no water is provided to
Place the vibrator auto/off switch in the "auto" position. it. Cease operation before the tank is run
Rotate the variable speed control dial in the increase completely dry.
direction enough to run the vibrator circuit without
turning the tracks. Allow the engine to run at 1500 rpm.
Uncoil the hose from the hose hanger on the side of

the tank and wash the concrete off of the machine. It
is recommended that the underside of the form be
washed off first. Clean the underside of the form
thoroughly, as any concrete left to dry on the
underside will affect the final concrete finish when the
pour is resumed.
High pressure wash wand

3128
G21 09/08/03 4-25

!
¶031-03-0480
DANGER! !
TO PREVENT SEVERE INJURY OR DEATH, DO
NOT OPERATE THE AUGER, CONVEYOR,
TRIMMER, OR TRACKS WHEN CLEANING THE
MACHINE. PLACE ALL CONTROL VALVES ON
THE OPERATOR CONTROL CONSOLE IN THE
NEUTRAL POSITION TO PREVENT THE WASH
HOSE AND THE OPERATOR FROM GETTING
CAUGHT IN MOVING PARTS.
! WARNING! !
THE HIGH PRESSURE WASH SYSTEM USES HIGH
PRESSURE WATER. DO NOT AIM THE NOZZLE
AT ANY PART OF THE BODY, AS SERIOUS
INJURY CAN OCCUR. WEAR PROPER EYE
PROTECTION WHEN CLEANING THE MACHINE.
Remove the high pressure wand and uncoil the hose

from the hose hanger on the side of the tank and wash
the concrete off of the machine. It is recommended
that the underside of the form be washed first. Clean
the under side of the form thoroughly, as any concrete
left to dry on the underside will affect the final concrete
finish when the pour is resumed.
G21 09/08/03 4-26

Lubrication and Maintenance Service Interval Chart

Item 10 Hour 50 Hour 250 Hour 500 Hour 600 Hour
Check E-stop operation •
Check engine oil level •
Clean engine compartment •
Check hydraulic fluid level •
Fill fuel tank •
Grease trimmer gearbox •
Check engine coolant level •
Grease trimmer discharge bearing •
Grease conveyor bearings •
Grease steering cylinder pins •
Check track drive gearbox oil level •
Check pump drive gearbox oil level •
Check battery electrolyte level •
Check alternator and fan belts •
Adjust conveyor belt tension •
Replace belt wiper •
Adjust trimmer wheel height •
Replace trimmer teeth • • • •
Service or replace engine air filter • •
Check engine air intake fittings •
Replace engine oil filter •
Grease inner guide tubes •
Grease leg lower guide tube bearing •
Grease leg upper guide tube bearing •
Grease track yoke pivot pin •
Grease Front Swinging Leg Pivot Pin •
G21 08/13/03 5-1

Lubrication and Maintenance Service Interval Chart

Item 10 Hour 50 Hour 250 Hour 500 Hour 600 Hour
Replace fuel filters •
Replace hydraulic oil filter •
Replace high pressure lift filter •
Clean sump filters •
Change oil in track drive gearbox •
Change oil in pump drive gearbox •
Check oil level in track rollers •
Check oil level in track idler •
Check battery electrolytes •
Adjust servo pilot valves •
Adjust pressure relief valves •
Clean power washer pump inlet screens •
Check power washer gearcase oil level •
G21 08/13/03 5-2

CHAPTER V MAINTENANCE 2. Use of 10W30 in temperatures below 14° F (-10°

C.).
3. The lubricant shall meet the performance
This chapter contains detailed instructions for the requirements shown in service classifications
lubrication and adjustments necessary for trouble free CC/CD (equivalent to MIL-L-45199B).
operation of the GT-3600. The services listed for the
engine are basic services only. Refer to the engine 4. A maximum sulfated ash content of 1.85% by
service manual for more detailed instructions. It is weight. Refer to the Cummins engine operators
advisable to perform all lubrication checks and manual for further information.
services prior to initial machine setup.
Instructions for the servicing of the battery, charging HYDRAULIC OIL CONVERSION CHART
system, fuel system, engine cooling system, engine AMOCO MOBIL
lubrication system and the machine hydraulic systems AMOCO AW 46 DTE 25
are included in this chapter. Also included are RYKON OIL #46
PHILLIPS
instructions for adjusting the pressures of the various ARCO *
hydraulic circuits and instructions for adjusting the MAGNUS A OIL 46
ARCO DURO AW 46
steering and slope systems. Pay particular attention SHELL
to all safety statements. CHEVRON
TELLUS 46
EP HYD OIL 46
02 Fuels STANDARD OIL (OHIO)
CITIES SERVICE
INDUSTRON 48
The quality of fuel oil used for high speed diesel PACEMAKER XD46
SUN
engine operation is a very important factor in obtaining CONOCO
satisfactory engine performance, long engine life and SUNVIS 747
SUPER HYD OIL 46 SUNVIS 821 WR
acceptable exhaust.
EXXON TEXACO
Fuel oil should be kept clean and free of NUTO 46 RANDO OIL HD 46
contamination. Storage tanks should be inspected
GULF UNION 76
regularly for dirt, water or water emulsion sludge and
cleaned if contaminated. Storage instability of the fuel
HARMONY 46AW UNAX AW 46
can lead to the formation of varnish or sludge in the KENDALL * GOMACO Standard Oil
tank. To keep the fuel system in its most efficient 047 EP

condition, keep all dirt, water and other foreign matter M-D-999-007
out of the fuel and avoid storing fuel for a long period
of time. Hydraulic oil chart
Hydraulic Oil
Refer to the engine manual for further information and
specifications. GOMACO recommends any anti-wear hydraulic oil
with an I.S.O. viscosity rating of 215 at 100° F (37.8°
03 Lubricants C) such as Arco Duro AW-46, which is installed in the
machine at the factory. The oil is non-foaming and
Effective use of the proper lubricating oils and grease
has anti-wear additives in it. Refer to the chart for
is perhaps the most important step towards low
equivalent oils.
upkeep cost, long machine life and satisfactory
service. Use only lubricants specified in this section. Gear Case Oils
Apply them at the intervals and according to the
instructions in the lubrication section. Use SAE 90 gear oil with EP additives in the various
gear drives unless otherwise instructed. Use of other
Engine Lubrication Oil types of oils will not give satisfactory service and may
result in eventual damage.
Cummins Engine recommends the use of multigrade
oils in their engines, using the following requirements: Grease
1. Use of 15W40 or 20W40 in temperatures above Use any multipurpose lithium soap grease for all
14° F. (-10° C.). grease fittings. Application of grease as instructed in
G21 08/13/03 5-3

this chapter will provide proper lubrication and will

keep contamination out of bearings.
Notice: Use only high grade lubricants which have

been stored in clean containers. Wipe away all
grease and dirt before removing filler caps or
plugs. Wipe grease fittings clean before
lubricating.
04 Ten Hour or Daily Service
Check E-stop light Check engine oil level

360217
360224e
Check engine crankcase oil level with the bayonet
! WARNING! ! gauge. Do not operate the engine with oil level below
the bottom mark. Check the oil level ten minutes after
A DEFECTIVE EMERGENCY STOP SYSTEM MAY stopping the engine. If the oil level is low, add the
CAUSE SEVERE INJURY OR DEATH. DO NOT proper grade of oil through the oil fill opening until the
OPERATE THE MACHINE WITH AN INOPERATIVE oil level is to the full mark on the bayonet gauge.
EMERGENCY STOP SYSTEM. CHECK THE
EMERGENCY STOP SYSTEM FOR PROPER
WORKING ORDER BEFORE BEGINNING PAVING
OPERATIONS.
Check the operation of each emergency stop button

every day before beginning operation. Make certain
that all emergency stop buttons are pulled out and that
the check E-stop light on the panel is out. Depress
each emergency stop button, one at a time.
Grease steering cylinder pins
Depressing any one emergency stop button should 001-1746
cause the check E-stop light to illuminate. If the check Grease the cylinder pins and bushings on each
E-stop light does not illuminate after depressing any steering cylinder until grease is expelled from between
individual emergency stop button, check the system the bushing and the pin.
for faults and correct before operating the machine.
Clean engine compartment

360095
Check and clean the engine compartment, radiator
core and oil cooler core if necessary. The engine
compartment should be cleaned by blowing it out with
G21 08/13/03 5-4

compressed air or by washing it out with a pressure Refill the fuel tank at the end of each day with clean,
washer (maximum pressure 100 psi; 6.9 bar). Allow fresh fuel. Keeping the fuel tank full, reduces
the engine to cool before washing the compartment. condensation to a minimum.
The radiator and oil cooler cores can also be cleaned
with compressed air or a pressure washer (maximum
pressure 100 psi; 6.9 bar). The cores should be
cleaned from the inside to the outside.
Check air filter restriction indicator

360390
Check hydraulic fluid level Check the air filter restriction indicator. If the red line
503
Check the hydraulic oil level by observing the oil level is in the window, the air filter element must be
in the reservoir sight glass. Oil level should be to the replaced. Refer to the air filter service section for
full mark with the oil cold. Do not operate the machine replacement instructions. To reset the restriction
when oil is not visible in the sight glass. Fill to the full indicator, push in on the button on the bottom of the
mark with the proper grade of hydraulic oil. Oil needs indicator and release it.
to be changed only if contaminated.
Grease trimmer gearbox

505
! DANGER! !
TO PREVENT SERIOUS INJURY, OR DEATH, KEEP
Fill fuel tank
504 HANDS, FEET AND CLOTHING CLEAR OF
ROTATING TRIMMERWHEEL. IT IS
! WARNING! ! RECOMMENDED TO HAVE SOMEONE AT THE
OPERATORS STATION TO STOP THE
DIESEL FUEL IS FLAMMABLE. WHEN REFUELING TRIMMERWHEEL IN CASE OF EMERGENCY.
THE MACHINE, STOP THE ENGINE. DO NOT
SMOKE WITHIN 50 FEET (15 M) OF THE MACHINE. Note: A grease fitting will not be present if the
DO NOT ALLOW ANY HOT OR BURNING trimmerwheel is equipped with the optional direct
MATERIALS NEAR THE FUEL FILL LOCATION. drive piston motor.
SEVERE BURNS MAY OCCUR IF THE FUEL WERE
TO IGNITE.
G21 08/13/03 5-5

With the engine idling and the trimmer wheel rotating

slowly, inject grease into the fitting next to the drive
motor, until grease is expelled from around the large
trimmerhead gearbox mounting flange seal
(approximately 20 pumps). It is recommended that a
multipurpose, high temperature grease be used in this
location.
Note: Under dry, dusty or sandy conditions, it is

recommended to grease the fitting next to the
drive motor more frequently (2 or 4 times a day).
Grease trimmer discharge bearing

360091
! DANGER! !
TO PREVENT SERIOUS INJURY, OR DEATH, DO
NOT ATTEMPT TO GREASE THE BEARING ON
THE DISCHARGE END OF THE TRIMMERWHEEL
WITH THE WHEEL ROTATING. STOP THE WHEEL
Check engine coolant level AND SHUT OFF THE ENGINE BEFORE GREASING.
512
! WARNING! ! With the trimmerwheel stopped, grease the bearing on

the auger shaft end of the trimmerhead until resistance
IF NECESSARY TO ADD COOLANT TO THE is felt against the grease gun handle (1 or 2 pumps).
SYSTEM WHEN THE ENGINE IS HOT AND/OR HAS Do not over grease as seal damage could result.
OVERHEATED, USE CARE TO AVOID BEING
SCALDED. ALLOW THE ENGINE TO COOL Note: Under dry, dusty or sandy conditions, it
BEFORE REMOVING THE RADIATOR CAP. may be necessary to grease the trimmer auger
PLACE A RAG OVER THE RADIATOR CAP AND shaft bearing more frequently.
TURN IT SLOWLY TO THE FIRST STOP, WHICH
ALLOWS STEAM TO ESCAPE THROUGH THE
OVERFLOW TUBE.
Check the coolant level in the engine radiator. Open

the access door to reach the radiator cap. The coolant
level should be no more than 1 inch (25 mm) down
from the bottom of the filler neck. See the appropriate
engine manual for further coolant system instructions.
Refer to the specification chapter for coolant system
capacities.
05 Fifty Hour or Weekly Service
Perform all ten hour lubrication and periodic services.
Grease conveyor bearings

360279
G21 08/13/03 5-6

! WARNING! ! ! WARNING! !
TO PREVENT SERIOUS INJURY, DO NOT MOVING TRACKS CAN CAUSE SERIOUS INJURY
ATTEMPT TO GREASE THE BEARINGS ON THE OR DEATH. BE CERTAIN THAT NO ONE IS NEAR
CONVEYOR WITH THE CONVEYOR OPERATING. THE TRACKS BEFORE MOVING THE MACHINE.
STOP THE CONVEYOR AND STOP THE ENGINE KEEP HANDS, FEET AND LOOSE CLOTHING
BEFORE GREASING. AWAY FROM MOVING PARTS.
Grease the conveyor drive pulley (upper end) bearing, Check the gear oil level in the track drive gearboxes.
on the side opposite of the drive motor, until resistance Rotate the box until the fill/drain plug is on the top.
is felt against the grease gun handle (1 or 2 pumps). Remove the check plug from the center of the
Do not over grease as seal damage could result. gearbox. Gear oil should flow from the opening. If
not, add EP-90 gear oil until it begins to flow from the
check plug opening.
Note: If hydraulic oil flows from the check plug

hole, suspect that the shaft seal on the hydraulic
drive motor has failed. It will be necessary to
remove the drive motor and replace the seal.
Grease conveyor idler pulley bearings Check pump drive gearbox oil level
360377 510
Grease bearings on each side of the conveyor idler Check the gear oil level in the pump drive gearbox on
pulley (lower end) until resistance is felt against the the rear of the engine. Remove the hex plug from the
grease gun handle (1 or 2 pumps). Do not over side of the gear box, oil should be at the level of the
grease as seal damage could result. plug. If not, add EP-90 through the filler hole on top of
the gearbox until oil is visible in the sight gauge.
Note: If the gear oil level is above the top of the

hex plug, or oil is being expelled from the breather,
suspect that the shaft seal on one of the hydraulic
pumps has failed. It will be necessary to remove
one, or possibly all, of the pumps to find and
replace the defective seal.
Check track drive gearbox oil level

509
Check battery electrolyte level

513
G21 08/13/03 5-7

! CAUTION! !
BATTERIES CONTAIN SULFURIC ACID AND
NORMALLY PRODUCE EXPLOSIVE GASES
WHICH CAN CAUSE SERIOUS INJURY.
THEREFORE, DO NOT ALLOW FLAMES OR
SPARKS TO COME NEAR THE BATTERY. WHEN
CHARGING OR WORKING NEAR A BATTERY,
ALWAYS SHIELD YOUR FACE AND PROTECT
YOUR EYES. IN CASE OF ACID CONTACT WITH Adjust conveyor belt tension
515
SKIN OR EYES, FLUSH IMMEDIATELY WITH
WATER FOR A MINIMUM OF 15 MINUTES AND
GET PROMPT MEDICAL ATTENTION. IF ACID IS ! WARNING! !
SWALLOWED, CALL A PHYSICIAN IMMEDIATELY. KEEP HANDS, FEET, TOOLS AND CLOTHING
AWAY FROM MOVING CONVEYOR BELT AND
Check the level of the electrolyte (acid and water
ROLLERS. SERIOUS INJURY OR DEATH MAY
solution) in each of the cells of the battery. Use
RESULT IF ENTANGLED.
distilled water or any clean water that is fit to drink and
does not have a high mineral content to fill the cells to Check the conveyor belt tension and alignment. If the
the bottom of the filler necks. belt tension is insufficient (apparent by drive pulley
slippage), tighten the belt by adjusting the position of
Note: Do not add water in freezing weather
the idler pulley evenly on both sides.
unless the engine is to be ran two or three hours,
or the battery is to be charged for a minimum of
one hour, to thoroughly mix the water and
electrolyte.
Check alternator and fan belts

514
! WARNING! !
516
Train Belt to Center of Pulley
DO NOT ATTEMPT TO CHECK THE BELTS WITH To align the belt, start the engine and allow it to run at
THE ENGINE RUNNING. SEVERE INJURY WILL 1000 rpm. Move the conveyor directional control valve
OCCUR IF CAUGHT IN MOVING BELTS. to the “forward” position and allow the belt to rotate.
Observe the belt to see which side it is running to.
Check the belts for any sign of wear. Replace belts
Turn the idler pulley adjuster nut, in small increments,
that are cracked or frayed Refer to the engine manual
on the side the belt is running to. Allow the belt to
for further instructions.
rotate five or six complete revolutions before making
more adjustments to allow time for belt to center itself.
Secure adjuster nut with jam nut.
G21 08/13/03 5-8

Adjust trimmer wheel height

519
! DANGER! !
Belt wiper (current) HANDS, FEET AND CLOTHING CLEAR OF
360382
Inspect the belt wipers on the underside of the ROTATING TRIMMERWHEEL. IT IS
conveyor just inside of the discharge hopper. The RECOMMENDED TO HAVE SOMEONE AT THE
wiper blades should be replaced when the blue portion OPERATORS STATION TO STOP THE
of the blade is worn down to the support assembly or TRIMMERWHEEL IN CASE OF EMERGENCY.
has been severely damaged so it does not wipe the
The trimmer wheel is properly adjusted when the teeth
belt clean. Release the spring tension on the wiper
are 1/4 inch to 3/8 inch (6 to 10 mm) below the cutting
assembly. Remove the two bolts, lockwashers and
edge of the moldboard.
nuts from each wiper blade. Reverse the disassembly
instructions to attach the new wiper blades. Tighten One way to adjust the trimmer wheel is to position the
the bolts securely. machine on a flat, level, concrete or asphalt surface.
Place a 6 inch x 6 inch x 3/8 inch (150 mm x 150 mm x
10 mm) steel plate under each end of the trimmerhead
moldboard. Lower the machine until the moldboard
rests on the plate. Make certain the machine frame is
parallel to the surface it is setting on. Stop the engine.
Disconnect the trimmerhead pressure and return quick
couplers and loop the trimmerhead hydraulic drive
motor hoses together. Rotate the trimmerwheel by
hand.
If the trimmerwheel teeth do not strike the surface, it

will be necessary to adjust the trimmerwheel down.
Slightly loosen the cap screws securing the guide
plates at each end of the trimmerhead. Adjust the
Tension belt wiper trimmer wheel down with the adjusting bolts until the
360383
Adjust the wiper spring tension until there is enough teeth lightly strike the concrete or asphalt surface.
tension against the conveyor belt to wipe the belt Tighten all cap screws and setscrews securely.
clean.
Note: The belt wiper must be thoroughly cleaned

at the end of each day to maintain its'
effectiveness.
G21 08/13/03 5-9

The trimmer wheel can also be adjusted during

trimming operations by observing the finished grade
behind the machine. When trimming, teeth marks
should be slightly visible in the subgrade. If teeth are
set more than 3/8 inch (10 mm) below the moldboard,
excessive loose material will be left on the subgrade.
If the teeth are set above the moldboard, increased
tractive pressure will result as well as a poorly finished
subgrade. If the teeth are set above the moldboard, it
can cause the machine to “kick” sideways, creating
steering problems. Adjust the trimmer wheel height as
previously described.
Trimmed Grade
521
Replace trimmer teeth

522
! DANGER! !
TO PREVENT SERIOUS INJURY, OR DEATH, BE
Wheel Set too Deep CERTAIN THAT THE ENGINE IS STOPPED
521a
BEFORE WORKING ON THE TRIMMERWHEEL. IT
IS RECOMMENDED TO REMOVE THE KEY FROM
THE IGNITION SWITCH TO KEEP THE ENGINE
FROM BEING ACCIDENTALLY STARTED. WEAR
EYE PROTECTION WHEN REMOVING AND
REPLACING THE TEETH.
If the carbide tip breaks off of the tooth, it will allow the
remaining portion to wear off rapidly. It will be
necessary to replace the tooth to prevent the holder
from wearing also. Stop the engine. Place a punch
against the rear of the tooth shank and drive it out from
the rear. Set a new tooth in place in the holder and
Wheel Set too Shallow place the special driver tool (GOMACO part number
521b
GT80-119) over the tip. Tap the new tooth into place.
! DANGER! ! Be certain the flat spot on the shank of the tooth is on
the same side as the flat area on the holder before
TO PREVENT SERIOUS INJURY, OR DEATH, KEEP driving the tooth into place.
HANDS, FEET AND CLOTHING CLEAR OF
ROTATING TRIMMERWHEEL. IT IS 06 150 Hour or Monthly Service
RECOMMENDED TO HAVE SOMEONE AT THE
Perform all 10 and 50 hour lubrication and periodic
OPERATORS STATION TO STOP THE
services.
TRIMMERWHEEL IN CASE OF EMERGENCY.
G21 08/13/03 5-10

Notice: The wear bars should be equally

tensioned on all four sides of each leg. This must
be done to maintain the inner leg tube in the center
of the upper leg assembly. Excessive tube wear or
jamming of the leg can result if the tube is
adjusted to one side of center.
Lubricate inner guide tubes

523
Using the control loop “jog” switches, raise the
machine to maximum up position. Apply a thin layer of
grease to the four sides of the inner guide tube.
Upper Guide Tube Grease Fittings

528
Grease the guide plate at the upper end of each track
guide tube. Give each of the four grease fittings, on
each guide tube, 5-6 pumps of grease.
Loosen the jam nuts and turn the setscrews in snug

against the retainer blocks on the top of the upper
guide tube plate. Tighten the jam nuts securely.
Loosen the jam nuts and turn the setscrews in tight
against the side of the square guide tube. Tighten the
jam nuts securely. Repeat the procedure on all three
legs.
Lower Guide Tube Grease Fittings

527
Grease the bronze bearing at the lower end of each
track guide tube. Give each of the four grease fittings,
on each guide tube, 5-6 pumps of grease.
Loosen the jam nuts on the adjustment setscrews on

the bottom of each leg, and turn the setscrews in snug
against the wear bar to eliminate any looseness
between the inner and outer guide tubes. Tighten the
jam nuts securely. Repeat the procedure on all three
legs.
When proper tension is adjusted, the track should turn

within 1 inch of steer cylinder stroke in either direction.
The elevation leg will not move up or down if the wear
bars are tightened too much.
Grease track yoke pivot pin
531
G21 08/13/03 5-11

Grease the track pivot yoke pin, on each track, through Change the engine oil by removing the cap from the
the bottom of each guide tube and track frame yoke drain hose and allowing the oil to drain into a
until grease is expelled from between the guide tube container. Oil should be drained at the end of a work
and the yoke. day while it is still warm. This will allow the oil to drain
faster and all contamination suspended in the oil will
drain with it.
Grease Front Swinging Leg Pivot Pins

532
Grease the front and rear pivot pins in the swinging left
Replace oil filter
front extension assembly until grease is expelled from 525
between the pins and the bushings. Remove the engine oil filter element and discard the
oil filter and the oil properly. Make certain that all of
07 250 Hour the old gasket is removed and clean any dirt from the
filter base. When installing the new engine oil filter,
Perform all 10 hour, 50 hour and 150 hour lubrication coat the gasket with a light coat of engine oil. Fill the
and periodic services. filter with clean engine oil and install it. Hand tighten
the filter element 3/4 turn after the gasket contacts the
base.
Drain engine oil

524
! WARNING! ! 526
Fill engine with oil
Replace the drain cap and refill the engine with the
USE CARE WHEN REMOVING THE DRAIN PLUG
proper grade of oil in accordance with the instructions
TO PREVENT CONTACT WITH THE HOT OIL. HOT
given in the lubricating oil specification section of the
OIL CAN CAUSE SEVERE BURNS.
G21 08/13/03 5-12

appropriate engine manual. Start the engine and

inspect the oil filter canister for leaks.
08 500 Hour Service
Perform all 10 hour, 50 hour and 250 hour lubrication

and periodic services.
John Deere fuel filter

360185
In-line fuel filter

360191
Replace the in-line fuel filter element by sliding each of
the spring clamps away from either side of the filter.
Pull the fuel lines off of each nipple extension on the
filter and dispose of the filter in an environmentally
correct manner. Place the new filter between the fuel
lines. Make certain that the direction of flow arrow on
the filter is pointing in the correct direction. Return the
spring clamps into position on the fuel lines to retain
the filter.
Cummins fuel filters
533
Note: The in-line filter is a screen type filter. Do Remove the engine fuel filter elements and discard the
not replace it with a paper filter type. fuel filters properly. Make certain that all of the old
gasket is removed and clean any dirt from the filter
Notice: The in-line fuel filter may require servicing bases. Tighten the new filter elements 3/4 of a turn
more often depending upon fuel quality and after the gasket contacts the base. Loosen the air
working conditions. bleed screw and use the manual fuel pump to force all
air from the fuel system. Tighten the bleed screw.
Refer to the appropriate Diesel Engine Manual for
further fuel system service.
Note: Drain the water from the bottom of the front

fuel filter at least once a week. Turn the drain plug
out approximately 2 turns and allow a small
amount of fuel and any water to drain. Tighten the
drain fitting securely. Refer to the appropriate
engine manual for further instructions.
G21 08/13/03 5-13

09 600 Hour or Annual Service
Perform all 10 hour, 50 hour, 150 hour, 250 hour and

500 hour lubrication and periodic services.
It will be necessary to lower the hydraulic oil level

when changing the hydraulic filters. Locate the drain
plug under the vertical surge tank and remove the
drain plug. Allow the oil to drain into a clean container
of approximately 55 gallons (208 L) until the oil level is
below the bottom of the access plate on the rear of the
vertical surge tank. Place thread sealer on the drain
plug and install it. Tighten the plug securely.
Note: It is recommended to service all hydraulic

filters before replacing the hydraulic oil that was
drained.
Replace High Pressure Lift Filter
Remove the cover over the main filter. Remove the 360186
filter cap by removing the capscrews and lifting the Replace the high pressure lift filter. Unscrew the filter
cover off. Notches are provided on each side of the canister from the base and discard the old filter
cap to pry it off if necessary. element properly. Clean the inside of the filter canister
thoroughly. Install a new filter element in the canister
and replace the assembly. Tighten the canister
securely.
Note: The high pressure lift filter element should

be replaced after the first 50 to 100 hours of
operation and then annually, or whenever the filter
pressure indicator on the filter head is popped up
with the hydraulic oil at operating temperature.
Remove Retainer Spring

536
Remove the retainer spring, relief valve assembly and
the filter element from the filter. Discard the old
element properly and replace it with a new one. Be
certain the element is centered over the guide in the
bottom of the filter canister. Replace the relief valve
assembly (spring end down) and then the retainer
spring. Check the o-ring on the cover and replace it if
necessary. Bolt the filter cap in place and replace the
cover. Replace the hydraulic oil which was drained
from the system if no other filters are to be replaced.
Note: The main filter element should be replaced Remove sump filter access cover
537
after the first 50 to 100 hours of operation and Remove and clean the sump filters. Drain the
then annually, or whenever the filter pressure hydraulic oil level down as previously described.
indicator is in the replace zone, with the hydraulic Remove the access cover from the rear of the surge
oil at operating temperature. tank. Reach down into the tank and unscrew the
sump filters and remove them. Remove all gasket
G21 08/13/03 5-14

material from the sump tank opening and from the Note: It is recommended that a hydraulic oil
access cover. sample should be taken at least once a year to
check for contamination. Send the sample to an
accredited laboratory for testing. A good
preventive maintenance program usually requires
multiple samples during the year.
Remove sump filters

538
After the filter elements are removed, wash the
elements in clean solvent or diesel fuel. Blow the
elements dry and reinstall the filters. Hand tighten the
elements only. Replace the access cover gasket (part
#GT62-194) and reinstall the cover. Replace the
rubber seal washers (part #420-30A96) on the cover
cap screws if damaged. Replace the hydraulic oil
which was drained from the system if no other filters
Change oil in torque hub gearbox
are to be replaced.
Note: The sump filters should be cleaned any

time that the main filter elements are replaced.
! WARNING! !
The sump filters need to be replaced only if MOVING TRACKS CAN CAUSE SERIOUS INJURY
damaged. OR DEATH. BE CERTAIN THAT NO ONE IS NEAR
THE TRACK BEFORE MOVING IT. KEEP HANDS,
FEET AND LOOSE CLOTHING AWAY FROM
MOVING PARTS.
Drain the gear oil from the track drive gearboxes and
discard the oil properly. Refill with clean new EP-90
gear oil. To drain the oil, rotate the fill plug to the
bottom.
Note: It is recommended to change the EP-90

gear oil in the torque hub gearboxes after the first
50 to 100 hours of machine operation.
Hydraulic oil drain plugs
539
The hydraulic oil needs to be changed only if it is
contaminated. The oil is contaminated when the main
filters need frequent changing, or when water or diesel
fuel has gotten into the system. To drain, remove the
drain plugs from the bottom of each tank. Wash the
magnetic drain plugs off and place sealer on the
threads before replacing the plugs. Discard the
hydraulic oil properly. Refill the hydraulic system with
the proper hydraulic oil. The hydraulic reservoir
capacity is 105 gallons (397 liters).
Dual Pump Drive Gearbox Drain Plug
540
Drain the gear oil from the pump drive gearbox on the
rear of the engine and discard the oil properly. Refill
G21 08/13/03 5-15

with clean new EP-90 gear oil. To drain, remove the

drain plug located in the bottom of the gearbox.
Note: It is recommended to change the EP-90

gear oil in the torque hub gearboxes after the first
50 to 100 hours of machine operation.
Check oil level in track rollers Contact surfaces on wear bar

542 360398
Check the oil level of the lower track idler rollers.
Remove the rock guard from the outside of the track
assembly. Rotate the rollers until the check plug is in
the horizontal position and remove the plug. Oil
should flow from the check opening. If not, inject
EP-90 gear oil into the roller with a pump type oil can
until the oil flows from the check opening. Replace the
plug. Do all the rollers the same on each track.
Note: The check plugs require a 6 mm hex

wrench to remove them.
Check wear bars on right front leg

360397
Loosen and remove the right front extension tube
frame clamp and wear bar. A 1/4 inch (6 mm) raised
contact surface is placed against the top and bottom of
the inner extension tube. If this contact surface no
Check oil level in track idler longer exists, the wear bar must be replaced. There
543
Check the oil level of the front track idler roller. Rotate should also be a minimum of 1/16 inch (1.5 mm) space
the front idler roller until the check plug is to the front (as indicated in photo 360397) between the steel
and in the horizontal position and remove the plug. Oil adjustment plate and the front of the machine frame if
should flow from the check opening. If not, inject the wear bar is good. If excessive movement is
EP-90 gear oil into the roller with a pump type oil can apparent after adjustment, remove and replace the
until oil flows from the check opening. Replace the wear bar as necessary on the right front leg extension
plug. Do the front idler on all tracks the same. tube.
Note: The check plug requires a 6 mm hex

wrench to remove it.
Notice: Some track idler rollers may be equipped

with a sealed bearing. A permanent oil is used and
does not require service.
G21 08/13/03 5-16

Check wear bars on trimmer lift Measure wear bars for replacement
002-2301 360400
Adjust the trimmer lift wear bars to remove any Loosen the wear bar adjustment bolts under the mold
excessive movement from the trimmer lift tubes. shift extension tube and remove the wear bar
There should be a minimum of 1/16 inch (1.5 mm) of assemblies. Measure the depth of the remaining moly
brass bar remaining on the steel adjustment plate if wear bar. A new wear bar will measure 1-1/2 inches
the wear bar is good. Remove and replace the wear (38 mm) in depth. The wear bar should measure no
bars and brass screws as necessary on each of the less than 3/4 inch (19 mm). If the wear bar measures
trimmer lift assemblies. less than previously indicated or, the metal backing
plate in the wear bar is excessively worn or, the bolts
have worn through the metal backing plate; replace
the wear bar assembly. When proper tension is
adjusted, the top of the inner extension tube should
contact the top of the outer tube.
Check wear bars for replacement

360175
Check leg wear bars for replacement

360288
Loosen the wear bar adjustment bolts and remove the
wear bar assemblies. Measure the depth of the
remaining moly wear bar. A new wear bar will
measure 1 inch (25 mm) in depth. The wear bar
should measure no less than 5/8 inch (15 mm). If the
wear bar measures less than previously indicated or,
the metal backing plate in the wear bar is excessively
G21 08/13/03 5-17

worn or, the bolts have worn through the metal

backing plate; replace the wear bar assembly. When
proper tension is adjusted, the track should turn within
1 inch of steer cylinder stroke in either direction. The
elevation leg will not move up or down if the wear bars
are tightened too much.
Notice: The wear bars should be equally

tensioned on all four sides of each leg. This must
be done to maintain the inner leg tube in the center
of the upper leg assembly. Excessive tube wear or
jamming of the leg can result if the tube is
adjusted to one side of center. Air Filter Connections
548
10 Servicing Air Cleaner Be sure all connections between the air filter assembly
and the engine are tight.
11 Battery Service
Remove the air filter

544
To remove the air cleaner filter element, remove the
access cover from the engine console. Loosen the
Battery
clamp ring screw and remove the air cleaner cover. 549
Remove the filter retaining screw and pull the element The GOMACO GT-3600 uses one 12 volt battery. The
from the filter canister. When servicing the air cleaner, battery is an Exide 24-900 with 900 cold cranking
check all connections from the air cleaner to the amps. The electrical system is a 12 volt, negative
engine. Connections should be air tight at all times. ground system. Keep all sparks and flames away from
the battery as electrolyte gas is highly explosive.
When the element must be serviced in the field, pat
the side of the element gently near the end with the
palm of the hand while rotating the element. Do not ! WARNING! !
tap the element against a hard surface as this may
dent or rupture the element.
Wipe out the inside of the air cleaner shell before WHICH CAN CAUSE SERIOUS INJURY.
installing the new element. Install the element and THEREFORE, DO NOT ALLOW FLAMES OR
secure with the wing nut and the seal washer. Install SPARKS TO COME NEAR THE BATTERY(S).
the dust collector cap with the rubber unloading valve WHEN CHARGING OR WORKING NEAR A
down and tighten the clamp ring screw finger tight. BATTERY, ALWAYS SHIELD YOUR FACE AND
Install the engine console access cover. PROTECT YOUR EYES. IN CASE OF ACID
CONTACT WITH SKIN OR EYES, FLUSH
IMMEDIATELY WITH WATER FOR A MINIMUM OF
15 MINUTES AND GET PROMPT MEDICAL
ATTENTION. IF ACID IS SWALLOWED, CALL A
PHYSICIAN IMMEDIATELY.
G21 08/13/03 5-18

Be sure to keep the battery filled and fully charged

during cold weather to keep it from freezing. Freezing
weather has little affect on a fully charged battery.
! WARNING! !
DO NOT ATTACH THE END OF THE NEGATIVE (-)
CABLE OPPOSITE THE BOOSTER BATTERY TO
THE NEGATIVE (-) POST OF THE DEAD BATTERY.
A SPARK COULD OCCUR AND CAUSE AN
EXPLOSION OF GASES NORMALLY PRESENT
AROUND THE BATTERY.
Badly pitted battery terminal
052-0226 When connecting a booster battery, if necessary for
cold weather starting, connect one end of the first
! CAUTION! ! jumper cable to the positive (+) terminal of the dead
battery and the other end to the positive (+) terminal of
WHEN SERVICING THE ELECTRICAL SYSTEM OR the booster battery. Connect one end of the second
WELDING ON THE MACHINE, ALWAYS jumper cable to the negative (-) terminal of the booster
DISCONNECT THE GROUND STRAP FROM THE battery and the other end to the frame of the machine
BATTERY(S) TO PREVENT DAMAGE TO THE with the dead battery.
MACHINE ELECTRICAL SYSTEMS.
12 Alternator, Regulator and Starter Service
Before connecting the battery, make certain all
electrical switches and accessories are turned off. Be
certain that the terminals and battery posts are
thoroughly cleaned and that the battery cable
terminals are tight, as dirty or loose connections can
create high electrical resistance and permit arcing,
which will quickly burn and pit terminals and posts.
Note: The electrical system is a negative ground

system. Connect the starter cable to the positive
(+) post of the battery. Connect the ground cable
to the negative (-) post of the battery. It is
advisable to disconnect the negative cable first
and connect it last. Reversed polarity can damage
the electrical system.
Use a battery hydrometer to check the specific gravity

of the electrolyte in each battery cell. A fully charged
battery will have a specific gravity of 1.260. Charge Alternator
360387
the battery if the reading is below 1.215. The alternator supplies electrical current for charging
the battery and ample electrical power to the electronic
Keep the battery clean by washing it off whenever dirt
controls. The built-in regulator in the alternator
build up is excessive. If corrosion is present around
controls the voltage output. If for any reason the wires
terminal connections, remove them and wash with
must be disconnected from the alternator, mark them
ammonia solution or a solution consisting of 1/4 lb.
so that they can be reconnected properly. Use the
(0.11 kg) baking soda added to one quart of warm
following precautions to prevent damage to the
water. Make certain the vent caps are tight to prevent
alternator and/or regulator:
solution from entering the cells. After cleaning, pour
clean water over the battery and surrounding area to 1. An alternator is never to be polarized. Never
wash the solution away. Check vent cap breather ground any alternator terminals or circuits.
openings to make sure they are open.
G21 08/13/03 5-19

2. Always disconnect the battery before 1. Place the circuit to be adjusted in the manual
disconnecting or connecting the alternator. Never mode. Run the engine at 1500 rpm. Remove the
disconnect the alternator with it operating. Be access plug to gain access to the adjustment
certain the wiring is properly connected before screw.
connecting the battery.
2. Turn the servo centering screw on the proper
3. Always connect a booster battery in the proper servo valve until the corresponding cylinder stops
polarity. Negative to negative and positive to moving in one direction and begins to move in the
positive. opposite direction. Mark the position of the
adjusting hex wrench on the servo valve.
3. Turn the servo centering screw back the opposite

direction until the cylinder begins to move in the
original direction. Mark the position of the
adjusting hex wrench on the servo valve. Turn the
centering screw to the center position between the
two marks.
14 Adjusting Pressures
Starter
360184
The starter is used to crank the engine. If for any
reason the wires must be disconnected from the
starter, mark them so that they can be reconnected
properly.
13 Adjusting Servo Valves
Relief Valves
360060
Trimmerhead Pressure
! CAUTION! !
Servo Valve Adjustment Access Plug DO NOT STALL A SYSTEM WITH AN UNKNOWN
552 RELIEF PRESSURE SETTING. IF THE PRESSURE
The grade servo pilot valves need only be adjusted if SETTING IS TOO HIGH, SERIOUS MACHINE
the grade cylinders slowly “creep” up or down with the DAMAGE MAY OCCUR. WHEN CHECKING A
engine running and the system in the “manual” mode. RELIEF PRESSURE SETTING, TURN THE
The steering servo pilot valves need only be adjusted ADJUSTMENT SCREW OUT 3 OR 4 TURNS
if the tracks slowly “drift” left or right with the system in BEFORE STALLING THE SYSTEM.
the “manual” mode. The hydraulic oil should be at
operating temperature before adjusting the servos. The main relief pressure for the trimmerhead circuit is
Proceed as follows: set at 2350 psi (162 bar) with the hydraulic oil at
G21 08/13/03 5-20

operating temperature. To adjust the trimmerhead adjustment screw in until the trimmer wheel stops
pressure, disconnect the trimmer drive motor hoses at rotation and note the position of the adjustment
the bulkhead quick couplers. It is recommended to wrench. Turn the adjustment screw out until the
turn the pressure adjustment screw on the relief valve trimmer wheel begins to rotate; then turn in to stop the
out 3 or 4 turns before checking the pressure. Start rotation as indicated previously. The wrench position
the engine and run it at 1000 rpm. Slowly move the should be approximately the same. If not, repeat the
trimmerhead control valve towards the “forward” procedure again. When the wrench position is
position and note the increasing pressure on the approximately the same and the trimmer wheel is
corresponding pressure gauge If the pressure stopped, note the standby pressure indicated on the
continues to increase above 2350 psi (162 bar), trimmer pressure gauge and increase this pressure 50
immediately move the control valve back to the center psi (3.5 bar) using the adjustment screw. Hold the
position. Turn the pressure relief adjustment screw adjustment screw in position while tightening the lock
out an additional 3 or 4 turns and recheck. If the nut securely and recheck the pressure reading.
pressure does not increase above 2350 psi (162 bar),
engage the valve the maximum amount and increase Conveyor Pressure
the engine speed to maximum. If adjustment is
necessary to increase the pressure to 2350 psi (162
bar), loosen the jam nut. Turn the adjusting screw in ! CAUTION! !
to increase pressure or out to decrease pressure.
DO NOT STALL A SYSTEM WITH AN UNKNOWN
Tighten the jam nut.
RELIEF PRESSURE SETTING. IF THE PRESSURE
Sequence Valve Flow Adjustment SETTING IS TOO HIGH, SERIOUS MACHINE
DAMAGE MAY OCCUR. WHEN CHECKING A
RELIEF PRESSURE SETTING, TURN THE
ADJUSTMENT SCREW OUT 3 OR 4 TURNS
BEFORE STALLING THE SYSTEM.
The main relief pressure for the conveyor circuit is set

at 2150 psi (148 bar) with the hydraulic oil at operating
temperature. To adjust the main relief pressure,
disconnect both conveyor drive motor hoses at the
appropriate bulkhead quick couplers. It is
recommended to turn the pressure adjustment screw
on the relief valve out 3 or 4 turns before checking the
pressure. Start the engine and run it at 1000 rpm.
Slowly move the conveyor valve towards the “unload”
position and note the increasing pressure on the
corresponding pressure gauge. If the pressure
continues to increase above 2150 psi (148 bar),
immediately move the control valve back to the center
Sequence Valve position. Turn the pressure relief adjustment screw
360165a
out an additional 3 or 4 turns and recheck. If the
! DANGER! ! pressure does not increase above 2150 psi (148 bar),
engage the valve the maximum amount and increase
TO PREVENT SERIOUS INJURY, OR DEATH, KEEP the engine speed to maximum. If adjustment is
HANDS, FEET AND CLOTHING CLEAR OF necessary to increase the pressure to 2150 psi (148
ROTATING TRIMMERWHEEL. bar), loosen the jam nut. Turn the adjusting screw in
to increase pressure, or out to decrease pressure.
To adjust the sequence valve, connect both trimmer Tighten the jam nut.
drive hoses to the appropriate bulkhead quick
couplers. Start the engine and run at maximum rpm.
Place the trimmer control valve in the maximum
“forward” position. Depress the console emergency
stop button and observe the rotation of the trimmer
wheel. The trimmer wheel should completely stop
rotation. If not, slowly turn the sequence valve
G21 08/13/03 5-21

turn the relief valve on the vibrator variable manifold in,

3 to 4 turns. Disconnect one vibrator or loop hose.
Start the engine and run it at 1000 rpm. It is
recommended to turn the pressure adjustment screw
on the main vibrator relief valve out 3 or 4 turns before
checking the pressure.
Track Relief Cartridge

5054
Tractive Pressure
! CAUTION! ! 558
Main Vibrator Relief
DO NOT STALL A SYSTEM WITH AN UNKNOWN Place the vibrator auto/off switch in the “auto” position.
RELIEF PRESSURE SETTING. IF THE PRESSURE Turn the circuit selector gauge to the “vibrator”
SETTING IS TOO HIGH, SERI US MACHINE position. The G21 control screen should indicate “run”
DAMAGE MAY OCCUR. WHEN CHECKING A and the forward/reverse switch should be in “forward”.
RELIEF PRESSURE SETTING, TURN THE Place the vibrator/auxiliary travel valve in the “vibrator”
ADJUSTMENT SCREW OUT 3 OR 4 TURNS position. Rotate the variable control valve that
BEFORE STALLING THE SYSTEM. corresponds to the disconnected circuit to the full
increase position (full counterclockwise). Rotate the
To adjust the tractive pressure to the correct setting, it travel variable speed dial in the “increase” direction a
is necessary to swap the tractive relief cartridge with small amount and note the increasing pressure on the
the conveyor relief cartridge. First, adjust the corresponding pressure gauge. If the pressure
conveyor relief cartridge to 2150 psi (148 bar) as continues to increase above 2150 psi (148 bar),
described previously. Shut off the engine and remove immediately move the travel variable speed dial to the
the filler cap on the hydraulic reservoir to release off position. Turn the pressure relief adjustment screw
residual air pressure. Remove the relief cartridge from on the main vibrator relief out an additional 3 or 4 turns
the tractive system and interchange it with the and recheck. If the pressure does not increase above
cartridge from the conveyor system. Adjust the 2150 psi (148 bar) with the travel variable speed dial
cartridge from the tractive system in the conveyor released, increase the engine speed to maximum. If
system as necessary. adjustment is necessary to increase the pressure to
2150 psi (148 bar), loosen the jam nut on the main
Main Vibrator Relief relief valve adjusting screw. Turn the adjusting screw
in to increase, or out to decrease the pressure. If the
presssure cannot be adjusted, it may be necessary to
! CAUTION! ! turn the relief valve on the variable control manifold in
an additional one to two turns. Tighten the jam nut.
DO NOT STALL A SYSTEM WITH AN UNKNOWN
SETTING IS TOO HIGH, SERIOUS MACHINE
The main relief pressure for the vibrator circuit is set at

2150 psi (148 bar). To adjust the main vibrator relief,
G21 08/13/03 5-22

Lift Pressure
To adjust the lift pressure, run the engine at 2100 rpm

(maximum). Place the servo lock switch in the “on”
position. Place the hold down and drawbar control
valves in the “neutral” or center position. Observe the
pressure reading of the lift pressure gauge. The
reading should be 1600 psi (110 bar). If adjustment is
necessary, turn the adjuster on the pump in to
increase or out to decrease pressure.
Calibrating the Control Knob Thresholds

Vibrator Variable Relief Notice: If it is necessary to replace the G21
559
Vibrator Variable Relief control panel, it will be required to calibrate the
control knob thresholds prior to moving the
machine.
! CAUTION! ! The purpose of this procedure is to adjust the travel
DO NOT STALL A SYSTEM WITH AN UNKNOWN variable control knobs so that movement of the track
RELIEF PRESSURE SETTING. IF THE PRESSURE system begins at or around 25 % rotation of the control
SETTING IS TOO HIGH, SERIOUS MACHINE knob from the off position. This is important on the
DAMAGE MAY OCCUR. WHEN CHECKING A track drive system so that vibration will occur within the
RELIEF PRESSURE SETTING, TURN THE 0 to 25% range of the knob. The vibrators must begin
ADJUSTMENT SCREW OUT 3 OR 4 TURNS operating before track movement when vibrating
BEFORE STALLING THE SYSTEM. through a slipform mold to an existing concrete surface
at the starting point of a pour. It may be necessary to
The vibrator variable relief pressure for the vibrator vibrate the concrete for several seconds before the
circuit is set at 1850 psi (127 bar). To adjust the operator may begin track movement by turning the
vibrator variable relief, first adjust the main relief as control knob above 25% rotation.
described previously. Using the same procedure,
adjust the variable relief by turning the adjusting screw Note: This procedure is only to be used when a
in to increase pressure or out to decrease pressure control problem exists between the track and
until the pressure is at 1850 psi (127 bar). Tighten the vibrator hydraulic systems controlled by the travel
jam nut securely. variable control knob.
The following table indicates typical threshold levels

for each of the systems:
Reverse Propel 29-35

Forward Propel 29-35
Note: Factory adjusted threshold numbers may

vary a small amount for each direction. Factory
thresholds are set using a flow meter at a rate of 2
gpm (7.5 lpm) from the forward or reverse working
ports of the apitech valve. The threshold value
required to reach 2 gpm (7.5 lpm) is stored as
indicated in the following procedures. Flow meter
use is preferred but not a required tool to achieve
a suitable adjustment.
To set the travel threshold, turn the travel variable

Lift Pressure Adjustment control knob counterclockwise. Place the travel/
360368a
neutral switch in the neutral position. Start the
machine and depress the E-stop reset switch. The
G21 08/13/03 5-23

E-stops must be engaged before continuing. Make calibrated. Depress the NEXT switch until the
certain that the hydraulic oil is at normal operating appropriate circuit is displayed:
temperature before proceeding.
To begin the procedure, depress and hold the calibrate

switch and depress the ENG (engine) switch. The
Propel = 0 Press
main screen should read:
Rev Thres = 32 Store
360396
Reverse threshold calibration display
Calibrate Prop Threshold 360395
LAST or NEXT for more Place the travel forward/reverse switch in the "reverse"
position. Slowly turn the control knob clockwise until
002-2839 the machine part begins to move. Note the position of
the control knob.
Calibrate control knob thresholds
002-2839
The main screen indicates "Calibrate Proportional
Threshold" mode and to depress the LAST or NEXT
switches to continue. Depress the NEXT switch and
the main screen will read:
***** WARNING! *****

MOVING MACHINE PARTS!
002-2840
Operator warning display
002-2840
This display serves to warn the operator that machine
parts will move and proper caution should be
exercised to prevent an accident. Depress the NEXT
switch and the instructional displays will read:
Control knob rotation
360392a
If the machine part begins to move before 2.5 on the
control knob, it will be necessary to decrease the
Adjust Pot and Hit STORE stored value displayed on the screen. Rotate the
to Save Thres, But First control knob to decrease the value on the top line of
the screen until it is lower than the value on the bottom
002-2841 line of the screen. Depress the STORE button and
repeat the procedure to check how the new value
affects the rotation of the control knob.
Set FNR Switches to Neut If the machine part begins to move after 2.5 on the
then Select Ftn. to CAL control knob, it will be necessary to increase the stored
value displayed on the screen. Rotate the control
002-2842 knob to increase the value on the top line of the screen
until it is higher than the value on the bottom line of the
Instructional messages
002-2841 & 002-2842 screen. Depress the STORE button and repeat the
The messages instruct the operator to turn the procedure to check how the new value affects the
potentiometer (control knobs) clockwise and depress rotation of the control knob.
the STORE switch to save the selected threshold
value. Before proceeding, place the FNR switches in
the "neutral" position and select which circuit will be
G21 08/13/03 5-24

Note: It is not necessary to exit the Calibrate

procedure to test the new value. Turn the control
knob “off”, after the STORE button was
depressed, and turn the knob “on” to test the new
value. & Feedback Pot. Points.
Repeat the adjustment procedure until the machine 002-2821

part begins movement at or around 2.5 on the control Set mode
002-2821
knob. Depress the NEXT switch and the main screen
Three adjustments are required for each steering
will read:
cylinder: left turn limit, center and right turn limit.
Begin by starting the engine. Depress and release the
SET switch. The main screen will indicate “STORE to
Save Slope Null & Feedback Pot. Points”. To select a
Propel = 0 Press smart steering cylinder for adjustment, depress the
Thres = 32 Store LAST or NEXT switch until the appropriate cylinder
signal is indicated on the main screen (Photo 002-
360395 2823).
Forward threshold calibration display
002-2844 Note: Each of the limits may be calibrated
Place the travel forward/reverse switch in the "forward" separately. It is not necessary to recalibrate all
position. Repeat the previous adjustment procedure three limits if only one limit requires adjustment.
for forward movement of the appropriate control
system with the corresponding display.
Note: FWD does not appear on the forward

threshold display. Jog LF Leg Left & STORE
3.54 V Stored: 3.54 V
002-2823
If Done, hit CALIB Twice
Otherwise, Select an FNR
002-2845
Return to normal operations
002-2845
Depressing the calibrate switch twice will return the
control system to the automatic mode.
15 Calibrating the Steering Systems
Notice: If it is necessary to replace the G21

control panel or a steering cylinder, it will be
required to calibrate the steering systems prior to
moving the machine.
The procedures for adjusting the steering system on

any of the legs is the same. Be certain the setscrews Left limit display
002-2823 & 002-2650
are snug against the wear bar on the bottom of the LEFT LIMIT – Turn the corresponding track as far to
outer guide tube on each leg to eliminate any the left as required to prevent the track from contacting
looseness between the inner and outer guide tubes. obstacles on the jobsite. Depress the STORE switch
Be certain the setscrews are snug against the top to store the left turning limit for the corresponding
guide plate retainer and against the side of the square track. Depress the NEXT switch until the center limit
guide tube. Tighten the jam nuts securely. for the corresponding track is indicated on the main
screen (Photo 002-2824).
G21 08/13/03 5-25

Note: When radius work is required, make certain

that the left limit setting does not prevent the track
from turning enough to complete the radius.
Jog LF Leg Right & STORE
Notice: If the operator turns the track the wrong 1.31 V Stored: 1.31 V
direction to store the left or right limits, the G21
controller will store the voltage but will not operate 002-2825
correctly.
CENTER LIMIT – Turn the track to the straight ahead

position and measure for correct adjustment.
Straighten the track

5062
Set the appropriate track straight ahead by measuring Right limit display
002-2825 & 002-2651
the distance from each side of the square tube at the
RIGHT LIMIT – Turn the track to the right as far as
top of the leg to the mounting flange. The
possible without contacting obstacles on the jobsite.
measurements should be equal. Steer the track left or
Depress the STORE switch. Continue to depress the
right until both measurements are equal.
NEXT switch to repeat the procedure for the other
tracks (if necessary).
Note: When radius work is required, make certain

Center LF Leg & STORE that the right limit setting does not prevent the
2.34 V Stored: 2.32 V track from turning enough to complete the radius.
Notice: If the operator turns the track the wrong

002-2824
direction to store the left or right limits, the G21
Center limit display controller will store the voltage but will not operate
002-2824
When it is adjusted parallel to the machine frame correctly.
depress the STORE switch to store the center limit for
the corresponding track. Depress the NEXT switch 16 Calibrating the Slope Sensors
until the right turn limit for the corresponding track is
indicated on the main screen (Photo 002-2825).
Level Frame of Machine

567
G21 08/13/03 5-26

To level the 3-track machine frame, place a level on

the front cross frame in front of the engine. Use the
jog switch for the right front elevation to raise or lower
the right front leg until the machine frame is level.
Stop the engine, but leave the ignition switch on.

& Feedback Pot. Points.
002-2821
Set mode
002-2821
Depress and release the SET switch. The main
screen will indicate “STORE to Save Slope Null & Parapet wall slope sensor mount position
360027
Feedback Pot. Points”. To select the slope sensor for When parapet wall is poured with the machine, the
adjustment, depress the LAST or NEXT switch until guideline must be set under the machine. If the
the appropriate slope sensor is indicated on the main guideline location is to the right of the slope sensor
screen (Photo 002-2822). location in the battery box, then the slope sensor
should be moved. The slope sensor may be relocated
to the position above the main hydraulic filter. The
guideline must be located to the left of the slope
Front Slope= 2.40 V sensor or directly below it, but should never be located
Stored Null= 2.50 V to the right of the slope sensor mounting position.
002-2822 Notice: Improper operation of the sensor controls

will result if the guideline is located to the right of
Front slope sensor calibration
002-2822 the slope sensor mounting position.
If the top line of the main screen does not read
between 2.40 and 2.60 Volts, loosen the slope sensor 17 High Pressure Wash System Service
and rotate it until the voltage reads between 2.40 and
2.60 Volts. Tighten the mounting screws securely.
Depress the STORE switch to store the new null point.
Factory slope sensor mount position

569
The slope sensor is mounted in the battery location
from the factory and is used when a guideline is Water inlet screen (current)
located to the left side of the slipform mold. Curb and
gutter, sidewalk and barrier wall typically use a If the flow from the wash nozzle slows down, it may be
guideline set to the left side. necessary to remove the filter from the inlet side of the
pump and clean it. Remove the retainer nut and
remove the filter. Wash the filter in water and blow
dry. Inspect the filter and replace it if damaged. Insert
G21 08/13/03 5-27

the clean filter into the opening and replace the

retainer nut.
Check gearcase oil level

360222
Remove the filler plug in the top of the gearcase and
check the oil level with the bayonet gauge. If the oil
Drain the water tank level is low, add 30 weight engine oil through the oil fill
360042
opening until the oil level is to the full mark on the
! CAUTION! ! bayonet gauge. The oil needs to be changed
whenever it is contaminated.
SEVERE DAMAGE WILL RESULT TO THE PUMP IF
IT IS ALLOWED TO FREEZE. BE CERTAIN TO
COMPLETELY DRAIN IT IN FREEZING WEATHER.
IF THE PUMP IS TO REMAIN IN FREEZING
WEATHER, RUN A SMALL AMOUNT OF
ANTIFREEZE THROUGH IT FOR PROTECTION.
If the machine is to be used in an area that freezing

temperatures will be encountered, open the drain
valve on the hose on the bottom of the tank and drain
all water.
Remove the inlet and outlet lines from the pump and
allow all water to drain from the pump and hoses. It is
recommended to remove the water pump from the
machine and store it in a warm place.
G21 08/13/03 5-28

CHAPTER VI DIAGNOSTICS
NOTICE
WARNING!
This chapter gives procedures to follow in the event of DO NOT OPERATE THIS EQUIPMENT UNTIL
a machine failure. Determine which system is faulty YOU HAVE READ AND THOROUGHLY
UNDERSTAND THE OPERATORS MANUAL.
and refer to the corresponding section for diagnostic FAILURE TO FOLLOW THIS PROCEDURE MAY
procedures. Pay particular attention to all safety RESULT IN INJURY OR DEATH.
statements. DANGER!
DO NOT ALTER OR MODIFY THIS PRODUCT
WITHOUT THE EXPRESS WRITTEN CONSENT
OF THE MANUFACTURER.
02 Engine Diagnostics UNAUTHORIZED MODIFICATION MAY RESULT
IN SERIOUS INJURY OR DEATH.
For diagnostic procedures on the engine, refer to the
Cummins engine manual, or contact your nearest DCAL-058
Cummins dealer.
03 Hydraulic Reservoir Diagnostics
Hydraulic Reservoir
Front of Machine
Vibrator &
Conveyor
Pumps
Relief
Manifold
Trimmer &
Lift Pump Track Pumps
Pressure Oil
Dump or Drain
Reservoir
Pressure
Tank
Sump
Filters
Main
Filter
360326
360
G21 08/19/03 6-1

The hydraulic reservoirs are contained within the main Symptom

frame structure. Beginning at the tank on the right
side, the oil flow is routed through two 100 wire mesh Main pumps cavitate or aerate.
sump filters, with magnetic straps, into the suction
ports of the main hydraulic pumps. From the pumps, Corrective Measures
the oil is forced into the various circuits that power the
1. Low hydraulic oil level. Add the proper hydraulic
machine functions. Each circuit contains an individual
oil to bring the level up to the full mark on the
main relief valve set to bypass at a specific pressure.
sight gauge, with the oil warm.
If a circuit were to stall, causing the corresponding
relief valve to open, the bypassed oil is routed back to 2. Sump filters clogged. Remove and clean the
the pressure tank. The opening of one relief valve in filters following the instructions given in the
no way affects the operation of the other relief valves. Maintenance chapter.
From the manifold, the oil is routed out to the various
circuits. The return oil from these circuits is then
dumped back into the pressure tank at the center of
the machine frame. The pressure tank is a sealed
tank. The oil must flow through the main filter to get
out of the pressure tank into the right rear tank on the
right side. The amount of pressure in the pressure
tank will depend on the amount of pressure required to
force the hydraulic oil through the main filter. This
pressure is indicated on the filter pressure gauge.
When the pressure reaches 25 psi (1.7 bar), the filter
relief valve will open, allowing unfiltered oil to be
dumped into the system. From the main filter, the oil
flows into the sump tank to the sump filters where the Connections on pumps
602
cycle is repeated (the hydraulic tank after the main
3. Loose connections between the pumps and the
filter is referred to as the reservoir, or low pressure
hydraulic reservoir. Tighten all fittings and hose
tank).
clamps. It may be necessary to remove the
The main frame tanks are internally baffled to keep all flange fittings and couplings and replace the o-
of the oil flowing to eliminate dead spots and to keep ring seals.
the oil in contact with the outer edges of the tank to aid
Symptom
in dissipating heat. The hydraulic oil reservoir capacity
is 105 U.S. gallons (397.5 L). Oil flowing from the breather cap.
Symptom Corrective Measures
High main filter pressure. The hydraulic reservoir oil level is too high. The oil
level should be at the full mark on the sight gauge with
Corrective Measures
the oil warm.
1. Clogged filter. Remove and replace the main
Symptom
filter element as instructed in the Maintenance
chapter. Hydraulic oil overheats.
2. Contaminated oil. If the filter must be replaced Corrective Measures
frequently, the oil may need to be changed. If
water or diesel fuel has gotten into the oil, it
must be changed. Refer to the Maintenance
chapter for instructions on changing the oil.
! WARNING! !
DO NOT ATTEMPT TO ADJUST BELT TENSION
3. Cold oil. If the hydraulic oil is extremely cold, it WITH THE ENGINE RUNNING. SEVERE
may cause high pressure. Allow oil to warm up PERSONAL INJURY WILL OCCUR IF CAUGHT IN
and recheck pressure. MOVING BELTS.
G21 08/19/03 6-2

1. Air flow through the hydraulic oil cooler 4. Excessive loading with high air temperature.
restricted. Clean the fins of the oil cooler. Reduce the work load on all systems if the air
Check fan belt tension. If the air flow through temperature is excessive.
the oil cooler is restricted, the engine coolant
temperature may increase also. Symptom:
Tracks, conveyor, vibrators and trimmer will not

operate.
Corrective Measures:
! DANGER! !
CHECK FOR ANY PERSONNEL IN OR AROUND
THE AUGER, TRACKS OR TRIMMERWHEEL
PRIOR TO RESETTING THE EMERGENCY STOP
SYSTEM. SEVERE INJURY OR DEATH WILL
OCCUR WHEN CAUGHT IN THE AUGER, TRACKS
OR TRIMMERWHEEL.
Bypass check valve location
603
2. The in-line check valve between the oil cooler 1. Emergency stop system is not reset. Depress
and the trimmerhead control valve is stuck open, the reset switch.
allowing the hydraulic oil to pass directly to the
pressure tank instead of passing through the
cooler. To check, bypass the check valve. If oil
temperature is now corrected, the check valve is
defective and must be replaced.

002-2004a
2. Emergency stop button is depressed or
defective. Refer to the emergency stop
electrical diagnostic section for more
information.
Relief Valve
360164
Note: The emergency stop system will affect all
3. Relief valve open. If a hydraulic system is
hydraulic functions on the machine except for the
constantly stalling out, excessive heat is
lift circuit.
generated. Reduce the load on the system to
keep it from stalling. If a circuit is not being
used, be sure the control valve is in the “off”
(neutral) position or the loop hoses are attached.
If the trimmerhead system should stall, all of the
oil is dumped straight back to the pressure tank
and no oil passes through the oil cooler.
G21 08/19/03 6-3

04 Conveyor Hydraulic Diagnostics
Conveyor Hydraulic System
Pressure
Return
Dump or Drain Circuit selector &
pressure gauge
4-way
control
To pressure valve
tank
Case Drain line added with

To pressure change in motor manufacturer
tank
Belt Conveyor
Cam Driven pump To tank
Rear stage 7 gpm ring
13 gpm (49 lpm) at 2250 rpm
Relief manifold
with emergency stop
Vented relief set
at 2150 psi
Quick
couplers Conveyor
drive
motor
Screw Conveyor
Cam Driven pump
Front stage 11 gpm ring
20.6 gpm (77.9 lpm)
at 2250 rpm
To pressure
tank
360324
360324
The oil flow for the conveyor circuit begins at the rear “forward” direction, the oil flow is routed from the inlet,
stage of the front main pump, which delivers 10 gpm out a work port, through a set of bulkhead mounted
(38 lpm) at 2100 rpm. From the pump, the oil is routed quick couplers and into one of the inlet ports on the
through the relief manifold, past a relief valve set to conveyor drive motor, causing it to turn. As the motor
bypass at 2150 psi (148 bar). A line tapped into the shaft turns, the conveyor belt will move, bringing
relief manifold port is connected to the circuit selector material up the conveyor to charge the slipform mold
valve/pressure gauge assembly, through which the hopper. Return oil from the motor flows out the
system pressure is checked. opposite motor port, back through the opposite quick
couplers, through the control valve, and back to the
With an emergency stop system the oil will be returned pressure tank.
to tank through the relief valve until the emergency
stop solenoid valve is energized. The solenoid valve When the control valve is moved in the “reverse”
closes the pilot line to each of the vented relief valves direction, the oil flow through the valve and the
and stops the return oil flow to the pressure tank. The conveyor drive motor is reversed which causes the
vented relief valve will bypass oil at 2150 psi (148 bar) conveyor belt to travel in reverse. The more the
as described previously. control valve is moved from “off”, towards “forward” or
“reverse”, the faster the conveyor belt will travel.
From the relief manifold, the oil is routed to the inlet of
the control valve. With the valve in the “off” (center) Symptom
position, the oil is routed through the valve and back to
the pressure tank. As the valve is moved in the Conveyor belt will not travel. Normal pressure
indicated.
G21 08/19/03 6-4
Corrective Measures 1. Concrete build up on drive or idler pulleys, or on

troughing or return rollers. Inspect and clean as
necessary.
! WARNING! !
MOVING CONVEYOR BELT AND ROLLERS.
SERIOUS INJURY OR DEATH MAY RESULT IF
ENTANGLED.
1. Insufficient belt tension, allowing the drive pulley

to slip. Adjust the belt tension as instructed in
the Maintenance chapter.
Drive Pulley Square
607
! WARNING! !
MOVING CONVEYOR BELT AND ROLLERS. DO
NOT ATTEMPT TO CLEAN THE ROLLERS OR
PULLEYS WITH THE CONVEYOR OPERATING
ENTANGLED.
2. Troughing rollers, return, or drive pulley out of

alignment. Rollers and drive pulley must be at a
90° angle to the conveyor frame. To adjust,
place a framing square against roller or pulley
and adjust as necessary.
3. Faulty belt splice. Check belt splice for square.

Motor Drive Shaft Defective
606 Splice should be 90° to belt edge. Check with a
2. Key in motor drive shaft or drive coupler, framing square and replace or repair the belt or
defective. Remove the conveyor drive motor splice as needed.
and inspect the motor shaft and the coupler.
Replace as necessary. It will first be necessary Symptom
to loosen the conveyor belt tension as the drive
pulley is supported by the motor bearings on the Conveyor stalls at low pressure.
motor side.
Corrective Measures
Symptom
1. Main relief valve not maintaining 2150 psi (148
Conveyor belt will not remain trained (centered). bar) relief pressure. Refer to the Maintenance
chapter for instructions on how to adjust
Corrective Measures pressure.
2. Hydraulic motor allowing oil to leak past the rotor

! WARNING! ! internally, relieving system pressure.
Disconnect both drive motor hoses at the quick
KEEP HANDS, FEET AND CLOTHING AWAY FROM couplers. Activate the control valve (engine
MOVING CONVEYOR BELT AND ROLLERS. DO running at 2100 rpm). If the pressure gauge
NOT ATTEMPT TO CLEAN THE ROLLERS OR indicates 2150 psi (148 bar), the motor is
PULLEYS WITH THE CONVEYOR OPERATING defective and must be repaired or replaced.
ENTANGLED.
G21 08/19/03 6-5

Symptom Corrective Measures
Conveyor runs slower than normal. Stalls at proper

pressure. ! WARNING! !
Corrective Measures KEEP HANDS, FEET AND CLOTHING AWAY FROM
MOVING CONVEYOR BELT AND ROLLERS. DO
NOT ATTEMPT TO CLEAN THE ROLLERS OR
! CAUTION! ! PULLEYS WITH THE CONVEYOR OPERATING
DO NOT STALL A SYSTEM WITH AN UNKNOWN ENTANGLED.
SETTING IS TOO HIGH, SERIOUS MACHINE 1. Conveyor belt stuck. Inspect drive and idler
DAMAGE MAY OCCUR. WHEN CHECKING A pulleys for concrete build up or other debris and
RELIEF PRESSURE SETTING, TURN THE clean as necessary.
1. Defective pump. Check with a flow meter if

available. A good indication of a defective pump
is to compare system pressure to engine rpm.
To check, disconnect both drive hoses at the
quick couplers. Start the engine and run it at
1000 rpm. Slowly move the conveyor valve
towards the “forward” position and note the Bypass Quick Couplers
608
increasing pressure on the corresponding
2. Quick coupler not fully connected or defective. If
pressure gauge. If the pressure continues to
both are fully connected, disconnect and check
increase above 2150 psi (148 bar), immediately
for debris. Check for a defective quick coupler
move the control valve back to the center
by bypassing the coupler using a pipe coupling,
position. Readjust the pressure relief valve
or a coupler known to be good.
following the instructions in the Maintenance
chapter. If the pressure does not increase Note: A defective or disconnected quick coupler
above 2150 psi (148 bar), engage the valve the may cause the motor shaft seal to rupture. If
maximum amount and increase the engine leakage is evident, repair or replace the motor.
speed to maximum. Gradually reduce the
engine speed while noting the pressure reading 3. Drive motor is defective. Remove the motor
on the gauge. A damaged pump will not from the conveyor and apply pressure to the
maintain relief pressure, but the pressure will motor. If the motor will not run (high pressure
drop rapidly as engine speed is reduced. A indicated), repair or replace as necessary. To
good pump will maintain approximately the remove the motor, it will first be necessary to
same pressure as engine speed decreases. loosen the conveyor belt tension as the drive
Replace or repair the pump if found to be pulley is supported by the motor bearings.
defective.
Symptom:
2. Engine is not operating at maximum speed
(2100 rpm). If the engine speed is low, hydraulic Tracks, conveyor, vibrators and trimmer will not
pump output flow will be low, causing all operate.
hydraulic systems, to operate slower. Increase
engine speed to maximum.
Symptom
Conveyor stalls at high pressure.
G21 08/19/03 6-6

! DANGER! !
OR TRIMMERWHEEL.
1. Emergency stop system is not reset. Depress

the reset switch.

002-2004a
information.

lift circuit.
G21 08/19/03 6-7

05 Trimmer Hydraulic Diagnostics
Trimmer Hydraulic System

Pressure
Return
Dump or Drain
Quick 4-way
control valve Hydraulic
couplers To pressure Oil
tank Cooler
Trimmer drive motor

& gearbox
5 psi
One-way
check valve
142 psi
One-way
check valve
To reservoir To pressure
To pressure Sequence tank
tank Valve
Relief manifold
with emergency stop
Vented relief set
at 2350 psi
Pressure
gauge
Left main pump
Front stage 21 gpm ring
39 gpm (147 lpm)
at 2250 rpm
To pressure
tank
360325
360325
The oil flow for the trimmerhead circuit begins at the from the outlet port. The sequence valve is set at
front stage of the right main pump, which delivers 39 approximately 300 psi. A dump line will bleed off any
gpm (147 lpm) at 2250 rpm. From this pump, the oil is case pressure in the sequence manifold. The
routed through the relief manifold, past a relief valve sequence valve acts as a safety valve to force all oil
set to bypass at 2350 psi (162 bar), and into the inlet through the trimmer vented relief valve when the
of the control valve. A line for the trimmerhead emergency stop system is de-energized.
pressure gauge is tapped into the relief manifold port.
When the control valve is in the “off” (center) position,
With an emergency stop system the oil will be returned the inlet oil is routed directly through the valve to the
to tank through the relief valve until the emergency outlet port. If the control valve is moved to the
stop solenoid valve is energized. The solenoid valve “forward” position, the inlet oil is routed through a work
closes the pilot line to each of the vented relief valves port of the valve, through a set of quick couplers, into
and stops the return oil flow to the pressure tank. The one of the trimmer drive motor ports. As the oil flows
vented relief valve will bypass oil at 2350 psi (162 bar) through the trimmer motor, it causes the motor shaft to
as described previously. turn, driving the trimmer gearbox, which causes the
trimmer wheel to turn in a forward direction. Return oil
As the oil exits the emergency stop relief manifold, it is from the trimmer drive motor flows out the opposite
routed to the inlet of the sequence valve. When inlet motor port, through another set of quick couplers and
pressure overcomes the opposing force of the into the opposite work port of the control valve. From
sequence valve spring, the valve opens permitting flow this work port, oil is routed through the valve to the
G21 08/19/03 6-8

outlet port. When the control valve is moved to the pulling out. Rotate the travel variable speed
“reverse” position, oil flow through the valve and the knob to the "off" position. The reset light should
trimmer drive motor is reversed, causing the trimmer stop illuminating.
wheel to turn in the reverse direction.
From the outlet of the control valve, the oil is routed to hydraulic functions on the machine except for the
the bottom of the hydraulic oil cooler, which is located lift circuit.
in front of the engine radiator. As the oil flows through
the oil cooler, heat is transferred from it to the 2. Main relief valve not maintaining 2350 psi (162
atmosphere. The oil then flows out of the oil cooler bar) relief pressure. Refer to the Maintenance
back into the pressure tank. All of the trimmerhead oil chapter for instructions on how to adjust
is routed through the oil cooler, regardless of the pressure.
control valve position. The only time there would be
no oil going through the oil cooler, would be if the
trimmerhead were to stall, causing the relief valve to ! DANGER! !
open, allowing the oil to dump directly back to the
pressure tank, or if the in-line check valve were to stick
HANDS, FEET AND CLOTHING CLEAR OF
in the open position.
ROTATING TRIMMERWHEEL. IT IS
The purpose of the in-line check valve in the line RECOMMENDED TO HAVE SOMEONE AT THE
between the control valve and the oil cooler is to OPERATORS STATION TO STOP THE
protect the oil cooler from extreme pressure during TRIMMERWHEEL IN CASE OF EMERGENCY.
cold weather operation. If the pressure required to
2. Hydraulic motor allowing oil to leak past rotor
force the hydraulic oil through the oil cooler exceeds
internally, relieving system pressure. To check
145 psi (10 bar), the check valve will open and dump
for excessive internal wear, disconnect the case
the oil directly back to the pressure tank. As the oil
drain line. With the trimmer wheel running freely
warms and the pressure drops below 145 psi (10 bar),
at maximum speed, oil draining from the case
the check valve closes, routing the oil back through the
drain line should not exceed 1/2 gpm (1.6 lpm).
cooler.
If the amount of drain oil is excessive, replace
the motor.
The trimmerhead gearbox is lubricated by internal
leakage from the drive motor draining into the gearbox
Symptom
(no shaft seal on motor). When the gearbox is filled,
excess oil is drained out a case drain line, through a Trimmer wheel runs slower than normal. Stalls at
one way check valve and back into the reservoir tank. proper pressure.
The one way check valve is used to keep the oil in the
reservoir from draining out when the trimmerhead is Corrective Measures
removed.
Symptom ! CAUTION! !
Trimmer wheel stalls at low pressure. DO NOT STALL A SYSTEM WITH AN UNKNOWN
Corrective Measures SETTING IS TOO HIGH, SERIOUS MACHINE
! WARNING! !
CHECK FOR ANY PERSONNEL IN OR AROUND BEFORE STALLING THE SYSTEM.
1. Defective pump. Check with a flow meter if
available. A good indication of a defective pump
is to compare system pressure to engine rpm.
To check, disconnect both drive hoses at the
OR TRIMMERWHEEL.
quick couplers. Start the engine and run it at
1000 rpm. Slowly move the trimmer valve
1. Emergency stop button is depressed. Check all
towards the left position and note the increasing
emergency stop buttons on the machine by
G21 08/19/03 6-9

pressure on the corresponding pressure gauge. and shroud or end plates for debris and clean as
If the pressure continues to increase above necessary.
2350 psi (162 bar), immediately move the
control valve back to the center position. 4. Quick coupler not fully connected or defective. If
Readjust the pressure relief valve following the both are fully connected, disconnect and check
instructions in the Maintenance chapter. If the for debris. Check for a defective quick coupler
pressure does not increase above 2350 psi (162 by bypassing the coupler using a pipe coupling
bar), engage the valve the maximum amount or a different set of quick couplers.
and increase the engine speed to maximum.
Gradually reduce the engine speed while noting 5. Drive motor is defective. Remove the motor
the pressure reading on the gauge. A damaged from the trimmer gearbox and apply pressure to
pump will not maintain relief pressure, but the the motor. If the motor will not run (high
pressure will drop rapidly as engine speed is pressure indicated), repair or replace as
reduced. A good pump will maintain necessary.
approximately the same pressure as engine
6. Damaged gearbox. Generally when the gearbox
speed decreases. Replace or repair the pump if
is internally damaged, it becomes noisy before it
found to be defective.
stops functioning. Remove the gearbox from the
2. Engine is not operating at maximum speed trimmer wheel and examine the internal gears
(2100 rpm). If the engine speed is low, hydraulic and bearings. Replace or repair the gearbox if
pump output flow will be low, causing all damage is evident. Refer to the Overhaul &
hydraulic systems, to operate slower. Increase Parts Manual for the GT17-019 Trimmerhead
engine speed to maximum. Drive Gearbox manual for the necessary
instructions to repair the gearbox (form #
Symptom I0749001E available from GOMACO).
Trimmer wheel stalls at high pressure. Symptom
Corrective Measures Oil leak at gearbox.
1. Trimming an excessive amount at a high rate of Corrective Measures

travel. Reduce the amount being trimmed and/
or reduce the travel speed. Remove the gearbox and replace the ruptured seal.
Before replacing the gearbox, inspect the one way
2. Trimmer teeth worn creating excessive trimmer check valve located in the case drain line. A defective
wheel drag. Replace the teeth as instructed in check valve can cause excessive pressure in the
the Maintenance chapter. gearbox, rupturing the seal. Check the case drain line
from the gearbox to the hydraulic tank to be certain
that it is not restricting the free flow of oil to the tank.
! DANGER! ! Replace the hydraulic line if damaged.
IF THE TRIMMER WHEEL IS FULL OF MATERIAL Grease the gearbox fitting as recommended in the
THAT MUST BE CLEARED BY HAND OR maintenance chapter to prevent dirt from entering the
MATERIAL MUST BE REMOVED FROM THE gearbox and causing the oil seal to rupture.
SUBGRADE, THE TRIMMERWHEEL MUST BE
STOPPED AND THE ENGINE MUST BE SHUT OFF Note: Do not install quick couplers in the case
BEFORE CLEARING THE MATERIAL OR SERIOUS drain line. Excessive back pressure may cause
INJURY, OR DEATH, CAN RESULT. FOR the gearbox seal to rupture.
ADDITIONAL SAFETY, REMOVE THE KEY FROM
THE IGNITION SWITCH. BE CERTAIN THAT Symptom:
PERSONNEL ARE CLEAR OF THE
TRIMMERWHEEL BEFORE STARTING THE
operate.
ENGINE. KEEP HANDS AND FEET CLEAR OF
TRIMMER WHEEL WHILE IN OPERATION.
3. Debris lodged between trimmer wheel and

shroud. Inspect the area between the wheel
G21 08/19/03 6-10

! DANGER! !
OR TRIMMERWHEEL.

the reset switch.

002-2004a
information.

lift circuit.
G21 08/19/03 6-11

06 Tractive Hydraulic Diagnostics
Track Hydraulic System
Left front
track drive
motor
Right front
Flow Divider track drive
motor
To Tank
On/Off Solenoid Valve Rear
One-Way
and One-Way track drive
Check Valve
Check Valve motor
To Tank
From Vibrator/ Variable To Tank

Auxiliary Travel Control
Valve Valve
To Tank
Selector
Gauge
(Standard)
Relief manifold Rear Stage of left main pump Pressure
with emergency stop 26 gpm (98 lpm) at 2250 rpm Return
relief set at 2150 psi Dump or Drain
(With Six Vibrator option) Suction
Front stage of Cam driven pump Static Flow
20.6 gpm (77.9 lpm) at 2250 rpm
360569
360327
Hydraulic description with standard motors vented relief valve will then bypass oil at 2150 psi (148
bar) as described previously.
The oil flow for the tractive circuit begins at the rear
stage of the right main pump, which delivers 26 gpm From the relief manifold, the oil is routed to the inlet of
(98 lpm) at 2250 rpm on a standard machine. If the the variable travel control valve. A line from the
machine is equipped with the six vibrator option, the vibrator/auxiliary travel selector valve is also
front stage of the cam driven pump will deliver 20.6 connected to the inlet port. As hydraulic flow enters
gpm (77.9 lpm) at 2250 rpm to the track hydraulic the inlet of the directional control valve, it is restricted
system. From the pump the oil is routed through the by a reducing-relieving valve. The reducing-relieving
relief manifold, past a relief valve set to bypass at valve begins to increase system pressure until a pilot
2150 psi (148 bar). A line tapped into the relief pressure of 200 psi (14 bar) is created. When pilot
manifold port is connected to the circuit selector/ pressure is reached, hydraulic flow is directed to the
pressure gauge assembly, through which the system control valve return port and back to the high pressure
pressure is checked. reservoir. A pressure differential of 200 psi (14 bar)
should be maintained between the pressure inlet line
With an emergency stop system the oil will be returned and the tank return line.
stop solenoid valve is energized. The solenoid valve Pilot pressure is supplied to two electrically operated
closes the pilot line to each of the vented relief valves proportional pulsar solenoid valves. If track control is
and stops the return oil flow to the pressure tank. The placed in the forward direction, an electric signal is
supplied to one of the pulsar solenoid coils, causing it
to direct pilot pressure against one end of the control
G21 08/19/03 6-12
valve spool. As the control valve spool is shifted, counterbalance valve directs this pressure increase to
pressure oil is directed out one of the work ports. a small shuttle piston in the valve, which shifts, lifting
the check valve off its’ seat. This allows oil from the
If track control is placed in the "reverse" position, the track drive motors to return to the opposite control
opposite pulsar solenoid coil is energized, causing it to valve working port, through the control valve and out to
direct pilot pressure against the opposite end of the the reservoir. When the control valve spool returns to
control valve spool and causing the tracks to rotate in neutral, the check valve in the counterbalance valve
the reverse direction. returns to its’ seat, locking the oil in the drive motors
and preventing rotation.
When the control valve is centered, the hydraulic oil is
bypassed to the tank port at 200 psi (14 bar) plus any The right front and rear outlet ports in the flow divider
additional pressure in the return line. The bypass are connected using a one-way check valve and a
pressure reading indicated on the pressure gauge is normally open solenoid valve. This connection is used
referred to as “standby pressure”. to equalize the differential pressure between the rear
track and the right front track when turning a tight
When the control valve is shifted for forward direction outside (left) radius. When a differential pressure of 5
of travel, hydraulic oil flows from one working port to psi (0.34 bar) is reached between the rear track and
the counterbalance valve manifold port. The oil forces the right front track, hydraulic oil is forced through the
the internal check valve off its’ seat (in the check valve from the rear track into the right front
counterbalance valve) and flows into the flow divider track. This causes the rear track to slow and the right
where the oil is equally divided to each of the outlet front track to increase speed, allowing the machine to
ports. The oil will enter the working port of each drive track more easily around the outside (left) radius.
motor, causing each track to rotate in the forward While pouring straight aways or tracking around an
direction. As the oil exits each drive motor, it is inside (right) radius, the solenoid valve is energized to
recombined before entering the counterbalance valve a closed position by placing the sensor select switch in
manifold. Since the track drive is equipped with the sensor 1 position, preventing oil flow between the
double counterbalance valves, the oil flow is stopped, right front and rear tracks. When the sensor select
causing pressure to build throughout the track drive switch is placed in the sensor 2 position for tight
system and preventing free-wheeling of the tracks outside (left) radii, the solenoid valve is de-energized
when traveling down steep embankments or loading to its normally open position.
ramps in the forward direction. A small port in the
counterbalance valve directs this pressure increase to Symptom
a small shuttle piston in the valve, which shifts, lifting
the check valve off its’ seat. This allows oil from the Track chain frequently breaks or comes off.
track drive motors to return to the opposite control
valve working port, through the control valve and out to Corrective Measures
the reservoir. When the control valve spool returns to
neutral, the check valve in the counterbalance valve
returns to its’ seat, locking the oil in the drive motors ! WARNING! !
IF THE TRACK IS FULL OF MATERIAL THAT MUST
When the control valve is shifted for reverse direction BE CLEARED BY HAND, THE TRACKS MUST BE
of travel, hydraulic oil flows from one working port to STOPPED AND THE ENGINE MUST BE SHUT OFF
the opposite counterbalance valve manifold port. The BEFORE CLEARING THE MATERIAL OR SERIOUS
oil forces the internal check valve off its’ seat (in the INJURY, OR DEATH, CAN RESULT. BE CERTAIN
counterbalance valve) and flows into the opposite work THAT PERSONNEL ARE CLEAR OF THE TRACKS
port of each track drive motor, causing each track to BEFORE STARTING THE ENGINE OR MOVING
rotate in the reverse direction. As the oil exits each THE MACHINE. KEEP HANDS AND FEET CLEAR
drive motor, it is recombined as it enters the flow OF THE TRACKS WHILE IN OPERATION.
divider before returning to the counterbalance valve
1. Debris in track chain. Clean track chain
manifold. Since the track drive is equipped with
thoroughly and check links for hardened
double counterbalance valves, the oil flow is stopped,
concrete.
causing pressure to build throughout the track drive
system and preventing free-wheeling of the tracks 2. Incorrect alignment of the front idler with the rear
when traveling down steep embankments or loading drive sprocket. Securely tighten any lose bolts
ramps in the reverse direction. A small port in the
G21 08/19/03 6-13

and nuts on the track drive gearbox and the “neutral” position. Slowly rotate the travel
sprocket assembly. Check the track frame for variable speed knob in the “increase” direction
damage with a straight edge from front to rear. and note the increasing pressure on the
The front idler should be in alignment with the corresponding pressure gauge. If the pressure
rear drive sprocket. Repair or replace the track continues to increase above 2150 psi (148 bar),
frame if it is damaged. immediately rotate the knob back to the “0”
position. Turn the pressure relief adjustment
Symptom screw out 3 or 4 turns and recheck. Refer to
Section 13 of the Maintenance Chapter for
Tracks run slower than normal, but stall at correct further information on setting the relief pressure
pressure. before continuing. Run the engine at maximum
speed and rotate the travel variable speed knob
Corrective Measures
in the “increase” direction. Note the indicated
pressure and then gradually reduce the engine
speed. A damaged pump will not maintain relief
pressure, but pressure will drop rapidly as
engine speed is decreased. A good pump will
maintain approximately the same pressure
regardless of engine speed. Repair or replace
pump as necessary, if found to be defective.
Readjust the tractive brake pressure as
described in the Maintenance chapter.

(2100 rpm). If the engine speed is low, hydraulic
pump output flow will be low, causing all
Symptom:
Tracks will not operate with electrical controls but will

operate with the manual override lever on the control
valve.
Engine Speed to Pressure Comparison Corrective Measures:

611
Make certain that standby pressure is registering on
! CAUTION! ! the track pressure gauge. This should be
approximately 200 psi. If pressure is not indicated,
DO NOT STALL A SYSTEM WITH AN UNKNOWN remove and check both of the pulsar solenoid valves
RELIEF PRESSURE SETTING. IF THE PRESSURE for proper o-ring installation. Replace o-rings that are
SETTING IS TOO HIGH, SERIOUS MACHINE damaged or missing. If standby pressure is evident,
DAMAGE MAY OCCUR. WHEN CHECKING A refer to the track electrical diagnostic section.
ADJUSTMENT SCREW OUT 3 OR 4 TURNS Symptom:
1. A defective pump can cause the tracks to run operate.
slower, but yet stall at the proper relief pressure.
The pump should be checked with a flow meter
if available. A good indication of a defective
pump is to compare relief pressure to engine
speed. To check, turn the adjustment screw on
the tractive brake relief valve in three or four
turns. Place the tractive brake switch in the “on”
position and the travel directional control valve in
G21 08/19/03 6-14
! DANGER! !
OR TRIMMERWHEEL.

the reset switch.
Pulsar solenoid valve

002-2702
1. Defective o-ring on the pulsar solenoid valve. If
an o-ring is damaged, pilot pressure may be
lost. Remove each pulsar from the valve block
and inspect the o-rings. Replace o-rings that
are visibly damaged or missing. Reinstall the
pulsar solenoid valve and tighten securely.

002-2004a
information.

lift circuit.
Track valve relief
Symptom:
Tracks will not operate. The pressure gauge indicates

zero standby pressure.
Isolate the fault; hydraulic versus electrical. If the

system will not respond to the electrical controls, Pilot pressure valve spool and spring
check the system operation by moving the override 360570
lever on the variable control valve. If the system will 2. Pilot pressure valve is adjusted incorrectly or
respond to the override lever, the fault could be lack of contaminated. Measure the exposed portion of
pilot pressure for electric over hydraulic control. If the the relief valve prior to removal. Remove the
system will not respond to the override lever, the fault valve spool and spring assembly. The spool
is in the hydraulic system. Proceed as follows: must be removed from the plug end of the
G21 08/19/03 6-15

chamber and the spring and washer must be 2. Defective drive motor. To check the motor,
removed from the relief end of the chamber. swap the suspected motor with a good motor
The valve spool should move freely in the from one of the other tracks. If the fault
chamber. Thoroughly clean and inspect the transfers, repair or replace the motor.
valve block chamber and valve spool for debris.
Reinstall the components and check for proper 3. Defective three-stage flow divider. To check,
operation. Replace the complete valve swap hoses on the flow divider. If fault
assembly if operation is not restored. transfers, replace the flow divider.
Notice: Make certain to mark or measure the 4. Defective track drive gearbox. If after swapping
distance between the jam nut and the top of the the motors, or swapping the hoses on the flow
relief cartridge prior to removal of the relief from divider the fault remains on the same track,
the valve block assembly. The adjusted distance suspect the track drive gearbox. Remove the
must be maintained for correct pilot pressure to gearbox and disassemble it. Inspect the gears
operate the pulsar solenoid valves. and bearings and replace as necessary.
Symptom
Tracks stall with high pressure indicated.
Corrective Measures
! WARNING! !
SERIOUS INJURY OR DEATH. IF THE TRACK(S)
IS/ARE FULL OF MATERIAL THAT MUST BE
CLEARED BY HAND, THE TRACKS MUST BE
STOPPED AND THE ENGINE MUST BE SHUT OFF
BEFORE CLEARING THE MATERIAL OR SERIOUS
INJURY, OR DEATH, CAN RESULT. BE CERTAIN
Relief valve THAT PERSONNEL ARE CLEAR OF THE TRACKS
002-2699
BEFORE STARTING THE ENGINE OR MOVING
3. High pressure relief valve is contaminated.
THE MACHINE. KEEP HANDS, FEET AND
Remove and inspect the valve for any
CLOTHING CLEAR OF THE TRACKS WHILE IN
contamination. Inspect and replace any o-rings
OPERATION.
that are damaged. Wash the valve in a
petroleum solvent solution and reinstall in the 1. Inspect tracks for excessive tension caused by a
valve block cavity to the proper measurement. If build up of debris in chain. Remove and clean
the fault remains, replace the relief cartridge. any debris from the track.
Notice: Make certain to mark or measure the 2. Flow divider jammed. If the tracks are free, but
distance between the jam nut and the top of the stall with high pressure indicated, suspect the
relief cartridge prior to removal of the relief from flow divider. Repair or replace the flow divider
the valve block assembly. The adjusted distance as necessary.
must be maintained for correct pilot pressure to
operate the pulsar solenoid valves. Symptom
Symptom One track attempts to run opposite of the other tracks.
One track stalls (forward direction). Corrective Measures
Corrective Measures Drive motor hoses reversed. This fault can occur
when a track or track motor is removed for any reason.
1. Debris in the track. Remove and clean any Switch the hydraulic hoses at the track drive motor that
debris from the track. is operating in the incorrect direction.
G21 08/19/03 6-16

Symptom A motor shaft seal is typically damaged by excessive

back pressure inside the motor housing. Check the
Ripples in finished product approximately 5 inches case drain line for any blockage or pinched lines. If
(12.7 cm) apart. quick couplers are used in the case drain line, make
certain that they are connected and allow fluid to pass
Corrective Measures through. Defective quick couplers will cause
excessive back pressure. Maximum case drain
This fault can be caused by worn track drive
pressure should not exceed 25 psi (1.72 bar) during
sprockets. Check the condition of the track drive
normal operations and should not exceed 75 psi (5.17
sprockets and repair or replace as necessary.
bar) during cold start.
Symptom
Symptom:
Tracks will not move when variable speed control knob
Tracks freewheel one direction when machine is
is turned on (Clockwise).
stopped.
Corrective Measures
With the engine running, determine if the fault is
Contaminated counterbalance valve. Make certain
hydraulic or electrical by moving the manual override
that the machine is parked on a flat level surface.
control. If the tracks begin moving with the manual
Remove and swap the counterbalance valves from the
override lever and a small amount of pilot pressure is
manifold block. If the tracks hold in the noted
indicated on the track pressure gauge, the fault is
direction, but freewheel in the opposite direction,
electrical. Refer to Tractive Electrical Diagnostics for
replace the counterbalance valve.
procedures to follow. If the tracks do not move with
the travel directional control valve in the “forward” or
“reverse” positions, the fault is hydraulic.
1. Defective pump. Refer to the previous

symptom; tracks run slower than normal, but
stall at correct pressure for procedures to follow.
2. Emergency stop system not reset. Pull all

emergency stop buttons out to the reset position
and depress the reset switch on the console.
3. Contaminated main relief cartridge. Swap the

track relief cartridge with the conveyor relief
cartridge. Check for visible contamination and
clean the track relief cartridge prior to installing it
into the conveyor system. Turn the adjustment
screw out until it stops, then readjust the relief
as indicated in the maintenance chapter. If the
conveyor does not operate, replace the relief
cartridge.
Symptom:
Hydraulic fluid is found in one or more of the track

drive gearboxes.
Track drive motor shaft seal is damaged. Remove the

drive motor and repair the shaft seal as shown in the
appropriate manufacturers drive motor repair manual.
G21 08/19/03 6-17

07 Track Hydraulic Diagnostics with Two Speed

Motors
Track Hydraulic System with Two Speed Motors

From Lift Pump
Two-speed manifold
To Tank
Left front
track drive
motor
To Tank
Right front
Flow Divider track drive
motor
To Tank To Tank
On/Off Solenoid Right rear

One-Way
Valve and track drive
Check Valve
One-Way Check motor
Valve
To Tank
To Tank
Counterbalance
Control Valve Valve Assembly To Tank
From Vibrator/
Auxiliary Travel
Valve
To Tank
Selector
Gauge
(Standard)
Rear Stage of left main pump Pressure
Relief manifold 26 gpm (98 lpm) at 2250 rpm Regulated Pressure
with emergency stop Return
relief set at 2150 psi (With Six Vibrator option) Dump or Drain
Front stage of Cam driven pump Suction
20.6 gpm (77.9 lpm) at 2250 rpm Static
360568
360524
Hydraulic description with two speed motors With an emergency stop system the oil will be returned
The track hydraulic system may also be equipped with stop solenoid valve is energized. The solenoid valve
two position variable displacement hydraulic motors as closes the pilot line to each of the vented relief valves
an option. If the machine is equipped with 4 vibrators, and stops the return oil flow to the pressure tank. The
the oil flow for the tractive circuit begins at the rear vented relief valve will then bypass oil at 2150 psi (148
stage of the right main pump and delivers 26 gpm (98 bar) as described previously.
lpm) at 2250 rpm. If the machine is equipped with 6
vibrators, the oil flow for the tractive circuit begins at From the relief manifold, the oil is routed to the inlet of
the front stage of the cam driven pump and delivers the variable travel control valve. A line from the
20.6 gpm (77.9 lpm) at 2250 rpm. vibrator/auxiliary travel selector valve is also
connected to the inlet port. As hydraulic flow enters
From the pump the oil is routed through the relief the inlet of the directional control valve, it is restricted
manifold, past a relief valve set to bypass at 2150 psi by a reducing-relieving valve. The reducing-relieving
(148 bar). A line tapped into the relief manifold port is valve begins to increase system pressure until a pilot
connected to the circuit selector/pressure gauge pressure of 200 psi (14 bar) is created. When pilot
assembly, through which the system pressure is pressure is reached, hydraulic flow is directed to the
checked. control valve return port and back to the high pressure
reservoir. A pressure differential of 200 psi (14 bar)
G21 08/19/03 6-18

should be maintained between the pressure inlet line drive motor, it is recombined as it enters the flow
and the tank return line. divider before returning to the counterbalance valve
manifold. Since the track drive is equipped with
Pilot pressure is supplied to two electrically operated double counterbalance valves, the oil flow is stopped,
proportional pulsar solenoid valves. If track control is causing pressure to build throughout the track drive
placed in the forward direction, an electric signal is system and preventing free-wheeling of the tracks
supplied to one of the pulsar solenoid coils, causing it when traveling down steep embankments or loading
to direct pilot pressure against one end of the control ramps in the reverse direction. A small port in the
valve spool. As the control valve spool is shifted, counterbalance valve directs this pressure increase to
pressure oil is directed out one of the work ports. a small shuttle piston in the valve, which shifts, lifting
the check valve off its’ seat. This allows oil from the
If track control is placed in the "reverse" position, the track drive motors to return to the opposite control
opposite pulsar solenoid coil is energized, causing it to valve working port, through the control valve and out to
direct pilot pressure against the opposite end of the the reservoir. When the control valve spool returns to
control valve spool and causing the tracks to rotate in neutral, the check valve in the counterbalance valve
the reverse direction. returns to its’ seat, locking the oil in the drive motors
When the control valve is centered, the hydraulic oil is
bypassed to the tank port at 200 psi (14 bar) plus any Each drive motor is equipped with its' own case drain
additional pressure in the return line. The bypass line which allows internal leakage to escape from the
pressure reading indicated on the pressure gauge is drive motor case. The internal leakage is used to cool
referred to as “standby pressure”. and lubricate the motor before returning to the
hydraulic reservoir.
When the control valve is shifted for forward direction
of travel, hydraulic oil flows from one working port to The right front and rear outlet ports in the flow divider
the counterbalance valve manifold port. The oil forces are connected using a one-way check valve and a
the internal check valve off its’ seat (in the normally open solenoid valve. This connection is used
counterbalance valve) and flows into the flow divider to equalize the differential pressure between the rear
where the oil is equally divided to each of the outlet track and the right front track when turning a tight
ports. The oil will enter the working port of each drive outside (left) radius. When a differential pressure of 5
motor, causing each track to rotate in the forward psi (0.34 bar) is reached between the rear track and
direction. As the oil exits each drive motor, it is the right front track, hydraulic oil is forced through the
recombined before entering the counterbalance valve check valve from the rear track into the right front
manifold. Since the track drive is equipped with track. This causes the rear track to slow and the right
double counterbalance valves, the oil flow is stopped, front track to increase speed, allowing the machine to
causing pressure to build throughout the track drive track more easily around the outside (left) radius.
system and preventing free-wheeling of the tracks While pouring straight aways or tracking around an
when traveling down steep embankments or loading inside (right) radius, the solenoid valve is energized to
ramps in the forward direction. A small port in the a closed position by placing the sensor select switch in
counterbalance valve directs this pressure increase to the sensor 1 position, preventing oil flow between the
a small shuttle piston in the valve, which shifts, lifting right front and rear tracks. When the sensor select
the check valve off its’ seat. This allows oil from the switch is placed in the sensor 2 position for tight
track drive motors to return to the opposite control outside (left) radii, the solenoid valve is de-energized
valve working port, through the control valve and out to to its normally open position.
the reservoir. When the control valve spool returns to
neutral, the check valve in the counterbalance valve High/Low Travel Speed
returns to its’ seat, locking the oil in the drive motors
and preventing rotation. To achieve a high and low travel speed, the tracks are
equipped with variable speed piston drive motors. For
When the control valve is shifted for reverse direction low speed travel, the drive motor swash plate is
of travel, hydraulic oil flows from one working port to spring-loaded to a maximum displacement position,
the opposite counterbalance valve manifold port. The causing low speed, high torque rotation of the tracks.
oil forces the internal check valve off its’ seat (in the For high speed travel, the two-speed solenoid valve is
counterbalance valve) and flows into the opposite work energized to an open position, causing oil from the lift
port of each track drive motor, causing each track to hydraulic system to flow through a pressure reducing-
rotate in the reverse direction. As the oil exits each relieving valve, reducing the pressure to 300 psi (21
G21 08/19/03 6-19

bar). This pressure is routed to each drive motor Corrective Measures:

where it is directed against the yoke control piston,
causing it to shift in the direction of the spring tension.
As the yoke control piston moves, the swash plate will
tilt to the minimum displacement position, causing high
! DANGER! !
speed, low torque rotation of the tracks. When the
two-speed solenoid valve is de-energized for low
speed travel, the valve spool will shift, draining oil from
each track drive motor yoke control piston back to the
reservoir. Each spring-loaded drive motor swash plate
OR TRIMMERWHEEL.
will return to the low speed travel position.
Symptom 1. Emergency stop system is not reset. Depress

the reset switch.
Track chain frequently breaks or comes off.
Corrective Measures
! DANGER! !
IF THE TRACK IS FULL OF MATERIAL THAT MUST
BE CLEARED BY HAND, THE TRACKS MUST BE
BEFORE CLEARING THE MATERIAL OR SERIOUS
INJURY, OR DEATH, CAN RESULT. BE CERTAIN
THAT PERSONNEL ARE CLEAR OF THE TRACKS
THE MACHINE. KEEP HANDS AND FEET CLEAR
OF THE TRACKS WHILE IN OPERATION.
1. Debris in track chain. Clean track chain

thoroughly and check links for hardened Emergency stop button
002-2004a
concrete. 2. Emergency stop button is depressed or
2. Incorrect alignment of the front idler with the rear
drive sprocket. Securely tighten any lose bolts
information.
and nuts on the track drive gearbox and
sprocket assembly. Check the track frame for Note: The emergency stop system will affect all
damage with a straight edge from front to rear. hydraulic functions on the machine except for the
The front idler should be in alignment with the lift circuit.
rear drive sprocket. Repair or replace the track
frame if it is damaged. Symptom:
Symptom: Tracks will not operate. The pressure gauge indicates

zero standby pressure.
operate. Corrective Measures:
Isolate the fault; hydraulic versus electrical. If the

system will not respond to the electrical controls,
check the system operation by moving the override
lever on the variable control valve. If the system will
respond to the override lever, the fault could be lack of
pilot pressure for electric over hydraulic control. If the
system will not respond to the override lever, the fault
is in the hydraulic system. Proceed as follows:
G21 08/19/03 6-20

chamber and the spring and washer must be

removed from the relief end of the chamber.
The valve spool should move freely in the
chamber. Thoroughly clean and inspect the
valve block chamber and valve spool for debris.
Reinstall the components and check for proper
operation. Replace the complete valve
assembly if operation is not restored.
Notice: Make certain to mark or measure the

distance between the jam nut and the top of the
relief cartridge prior to removal of the relief from
the valve block assembly. The adjusted distance
operate the pulsar solenoid valves.
Pulsar solenoid valve

002-2702
1. Defective o-ring on the pulsar solenoid valve. If
an o-ring is damaged, pilot pressure may be
lost. Remove each pulsar from the valve block
and inspect the o-rings. Replace o-rings that
are visibly damaged or missing. Reinstall the
pulsar solenoid valve and tighten securely.
Relief valve
002-2699
3. High pressure relief valve is contaminated.
Remove and inspect the valve for any
contamination. Inspect and replace any o-rings
that are damaged. Wash the valve in a
petroleum solvent solution and reinstall in the
valve block cavity to the proper measurement. If
the fault remains, replace the relief cartridge.
Track valve relief Notice: Make certain to mark or measure the

distance between the jam nut and the top of the
relief cartridge prior to removal of the relief from
the valve block assembly. The adjusted distance
operate the pulsar solenoid valves.
Symptom
Pilot pressure valve spool and spring Tracks run slower than normal, but stall at correct
360570
2. Pilot pressure valve is adjusted incorrectly or pressure.
contaminated. Measure the exposed portion of
the relief valve prior to removal. Remove the
valve spool and spring assembly. The spool
must be removed from the plug end of the
G21 08/19/03 6-21

Corrective Measures speed and rotate the travel variable speed knob
in the “increase” direction. Note the indicated
pressure and then gradually reduce the engine
speed. A damaged pump will not maintain relief
pressure, but pressure will drop rapidly as
engine speed is decreased. A good pump will
maintain approximately the same pressure
regardless of engine speed. Repair or replace
pump as necessary, if found to be defective.
Readjust the tractive brake pressure as

(2100 rpm). If the engine speed is low, hydraulic
pump output flow will be low, causing all
Symptom
One track stalls (forward direction).
Corrective Measures
Engine Speed to Pressure Comparison 1. Debris in the track. Remove and clean any
611
debris from the track.
! CAUTION! ! 2. Defective drive motor. To check the motor,

DO NOT STALL A SYSTEM WITH AN UNKNOWN swap the suspected motor with a good motor
RELIEF PRESSURE SETTING. IF THE PRESSURE from one of the other tracks. If the fault
SETTING IS TOO HIGH, SERIOUS MACHINE transfers, repair or replace the motor.
3. Defective three-stage flow divider. To check,
swap hoses on the flow divider. If fault
transfers, replace the flow divider.
4. Defective track drive gearbox. If after swapping
1. A defective pump can cause the tracks to run
the motors, or swapping the hoses on the flow
slower, but yet stall at the proper relief pressure.
divider the fault remains on the same track,
The pump should be checked with a flow meter
suspect the track drive gearbox. Remove the
if available. A good indication of a defective
gearbox and disassemble it. Inspect the gears
pump is to compare relief pressure to engine
and bearings and replace as necessary.
speed. To check, turn the adjustment screw on
the tractive brake relief valve in three or four Symptom
turns. Place the tractive brake switch in the “on”
position and the travel directional control valve in Tracks stall with high pressure indicated.
the “neutral” position. Slowly rotate the travel
variable speed knob in the “increase” direction
and note the increasing pressure on the
corresponding pressure gauge. If the pressure
continues to increase above 2150 psi (148 bar),
immediately rotate the knob back to the “0”
position. Turn the pressure relief adjustment
screw out 3 or 4 turns and recheck. Refer to
Section 13 of the Maintenance Chapter for
further information on setting the relief pressure
before continuing. Run the engine at maximum
G21 08/19/03 6-22

Corrective Measures indicated on the track pressure gauge, the fault is

electrical. Refer to Tractive Electrical Diagnostics for
procedures to follow. If the tracks do not move with
! WARNING! ! the travel directional control valve in the “forward” or
“reverse” positions, the fault is hydraulic.
SERIOUS INJURY OR DEATH. IF THE TRACK(S) 1. Defective pump. Refer to the previous
IS/ARE FULL OF MATERIAL THAT MUST BE symptom; tracks run slower than normal, but
CLEARED BY HAND, THE TRACKS MUST BE stall at correct pressure for procedures to follow.
BEFORE CLEARING THE MATERIAL OR SERIOUS 2. Emergency stop system not reset. Pull all
INJURY, OR DEATH, CAN RESULT. BE CERTAIN emergency stop buttons out to the reset position
THAT PERSONNEL ARE CLEAR OF THE TRACKS and depress the reset switch on the console.
THE MACHINE. KEEP HANDS, FEET AND 3. Contaminated relief cartridge. Swap the track
CLOTHING CLEAR OF THE TRACKS WHILE IN relief cartridge with conveyor relief cartridge. If
OPERATION. the track drive will operate. The relief may be
contaminated. Remove the cartridge and wash
1. Inspect tracks for build up of debris in chain. thoroughly in a solvent solution. Check for any
Clean chain as necessary. debris before returning the cartridge to the
manifold. Replace the cartridge if the system
2. Flow divider jammed. If the tracks are free, but does not operate.
stall with high pressure indicated, suspect the
flow divider. Repair or replace the flow divider Symptom:
as necessary.
One or more tracks will not change speed when the
Symptom high/low switch is changed.
One track attempts to run opposite of the other tracks. Corrective Measures:
Corrective Measures If the symptom affects all tracks, locate the two-speed
solenoid valve. Depress the solenoid valve manual
Drive motor hoses reversed. This fault can occur override button and check the travel speed. If the
when a track or track motor is removed and the hoses system operates at high speed, the fault is electrical.
were not labeled. Refer to troubleshooting the track electrical system for
more information. If no change is noticed, the fault is
Symptom hydraulic. Refer to the following measures for
troubleshooting information.
Ripples in finished product approximately 5 in. (12.7
cm) apart. 1. Machine is not stopped when the high/low
switch is changed. To change from high to low
Corrective Measures
speed or; from low to high speed requires that
This fault can be caused by worn track drive sprockets the travel control knob is rotated to the "off"
in the rear track. Check the condition of the track drive position. To prevent pressure spike damage to
sprockets and repair or replace as necessary. the track drive motors, the controller will not
allow "on-the-go" high/low travel speed changes.
Symptom
2. Defective or stuck yoke control piston. If one
Tracks will not move when variable speed control knob track is remaining at the previous speed while
is turned on (Clockwise). the other tracks are attempting to rotate at the
correct speed, then the track drive motor yoke
Corrective Measures control piston may be stuck or contaminated.
Remove the motor from the affected track and
With the engine running, determine if the fault is swap with one of the other tracks. If the fault
hydraulic or electrical by moving the manual override transfers to the other track, the motor is
control. If the tracks begin moving with the manual defective and must be repaired or replaced.
override lever and a small amount of pilot pressure is
G21 08/19/03 6-23

Symptom:
Tracks freewheel one direction when machine is

stopped.
Contaminated counterbalance valve. Make certain

that the machine is parked on a flat level surface.
Remove and swap the counterbalance valves from the
manifold block. If the tracks hold in the noted
direction, but freewheel in the opposite direction,
replace the counterbalance valve.
Pressure reducing valve

002-2917
3. Incorrect pressure adjustment for high/ low
speed. Place the high/low switch in the high
position and check the pressure indicated on the
two speed pressure gauge located under the
front of the engine. The pressure should
indicate 300 psi (21 bar). If not, adjust the
pressure reducing valve in or out until 300 psi
(21 bar) is indicated.
Note: If the pressure adjustment is too high,

damage may occur to the yoke stroking assembly
in the drive motors. The pressure should not
exceed 400 psi (27.5 bar).
Symptom:
Hydraulic fluid is found in one or more of the track

drive gearboxes.
Track drive motor shaft seal is damaged. Remove the

drive motor and repair the shaft seal as shown in the
appropriate manufacturers drive motor repair manual.
A motor shaft seal is typically damaged by excessive

back pressure inside the motor housing. Check the
case drain line for any blockage or pinched lines. If
quick couplers are used in the case drain line, make
certain that they are connected and allow fluid to pass
through. Defective quick couplers will cause
excessive back pressure. Maximum case drain
pressure should not exceed 25 psi (1.72 bar) during
normal operations and should not exceed 75 psi (5.17
bar) during cold start.
G21 08/19/03 6-24

G21 08/19/03
Rear Tractive Electrical Circuits

S2X Controller Travel variable
To Left control knob
STATUS
Front S2X A
––– 10A –––
B Refer to Miscellaneous
POWER 1 Circuit Breaker 5 Wiring Schematic for more information 1
>
2
>
3 2
> J1 Connected to
4
>
Pancon Controller
47Ω
5 Terminal 3 CW
> A1
J1 <A2 Bar (TB) 1000 Ω
<
A3 +5V
Bulkhead <
B1 Trav. Sig.
1
B4
<
B2 2
<
B3 Gnd
3
1
<
C1 4
B4 < 2 <
C2
5
Rem. Flag
<
3
<
C3
6
CAN < < 7
Minifast 4 D1 Steer Sig.
< < 8
J2 <A1 Gnd Connector <
5
<
D2 Trav. Sig.
9
A2 CAN + D3
<
A3
<
E1
10
<
B1
<
E2
11
< < 12 A
J2 Connected to E3 >
<
B2 Shield < B B1
B3 Pancon Controller F1 >
< CAN - < C
A1 F2 >
<
C1 To Rear J2 < < D
C2 A2 F3 >
< Gnd S2X <
A3 < E
>
C3 1 < G1 F
< > B1 < >
D1 2 < G2
< > B2 <
D2 3 < G3
< > <
D3 Gnd 4 <
B3 H1 10K ohm
< > C1 <
E1 Gnd 5 < <
H2 Travel resistor
6-25
< > C2
E2 H3
< <
C3 < FNR switch
E3 < J1
< D1 <
F1 Battery A B < J2 3 Fwd
< ––– 8A ––– D2 < ––– 2
F2 Travel Fwd S2X < CAN + J3 –––
< D3 < 1
F3 Travel Rvs Circuit Breaker < CAN - K1 ––– Rev
< E1 <
To Right < CAN Shield K2
E2 <
K3
Front S2X <
E3 < Travel Neutral
1 <
> F1 travel 3
2 < 2 –––
> F2 A B ––– 1
3 < Battery + ––– 8A –––
> F3 neutral –––
4 < Gnd Circuit Breaker 1
> 6
5 travel –––
> 5
––– 4
neutral –––
Refer to Miscellaneous
Wiring Schematic for see vibrator electrical
A
> <
A Wht more information for more information
B PWM B Blk

> B3 <
C
> <
C Red
D D Grn Remote steer
> <
E
<
E control knob
> 47Ω
F F
> < 1
G G
> < 2
H H
> < 47Ω
I I CW 3 A
> < >
J J 1000 Ω B
> < 8 >
Added in 2005 C
Ω >
Remote travel D
>
E
Vibrator/Aux. Travel variable control knob >
F
3 Valve Coil >
On 1
2 –––
B A –––
––– 20A ––– 1 2
Miscellaneous ––– Used with two 8
Off speed motors Ω 4-way 3-position 47Ω
Circuit Breaker CW 3
Two-Speed Proportional load 1000 Ω
Switch Two Speed sense control valve
Valve Coil 360582.eps
08 Tractive Electrical Diagnostics
The network control system is used to electrically

operate the track hydraulic proportional control valve.
Two controllers are used to operate the track electrical
circuit. The Pancon controller is the main computer on
the machine and is located in the console control box.
It receives the input information from the various
sources and processes that information. In the travel
circuit the input devices are the console travel variable
control knob, the remote travel variable control knob,
the travel FR (forward/reverse) switch and the travel
neutral switch. After processing is completed, the
Pancon controller sends an appropriate response
signal through the CAN communication network to the
rear S2X controller located on the rear access door of
the control console. The S2X controller will receive
the response from the Pancon controller and will send 18 pin and 30 pin connectors on Pancon controller
002-2549
the appropriate output drive signal to the track The forward/reverse switch (F/R) is used to determine
proportional control valve. the direction that the steering sensors will be traveling
on the stringline and the travel direction of the tracks.
The Pancon controller receives a 12 volt power source When placed in either the forward or reverse positions
from an 8 amp circuit breaker (circuit breaker 1 inside with the travel/neutral switch in the travel position, a
control box) and a ground connection from the ground connection is supplied to the Pancon
machine frame. A 10 amp circuit breaker (circuit controller. If a ground connection is received on pin
breaker 5 inside control box) supplies 12 volt power E3 in the 30 pin connector, forward direction of the
through the CAN network cable to the circuit breakers travel circuit is selected. If a ground connection is
at each of the S2X assemblies around the machine. received on pin F1, reverse direction of the travel
The rear S2X controller is supplied 12 volt power from circuit is selected. If a ground is not received on either
a 8 amp circuit breaker, located on the S2X mounting pin E3 or F1, the Pancon controller recognizes that the
assembly, and with a ground connection from the neutral mode has been selected and will not allow an
machine frame. To operate the variable control knobs, output drive signal to either pulsar solenoid valve. The
the Pancon controller supplies sensor power (+5 volts) network controller must be in the Run mode, the circuit
and a ground connection to the terminal bar inside the must be in working order and the emergency stop
control box. The terminal bar is used to distribute the system must be reset before an output signal can be
power and ground connections to the various control sent to the rear S2X controller.
knobs in the remote and in the control box.
The travel/neutral switch may be used as a way to
From the terminal bar, 5 volts is supplied to the start and stop the forward or reverse travel of the
console travel variable control knob on terminal 1 and machine. When placed in the neutral position, the
a ground is provided to terminal 3. A resistor is ground is disconnected to the forward/reverse (F/R)
connected into the ground wire on terminal 3 to create switch causing the control system to stop the travel of
a minimum output voltage of 0.21 volts when the the machine. Placing the travel/neutral switch in the
control knob is turned off. The Pancon controller travel position reconnects the ground through the
recognizes this minimum voltage as the “off” position forward/reverse (F/R) switch causing the machine to
of the control knob. As the control knob is rotated resume travel according to the amount of travel
clockwise, the output voltage will vary from 0.21 volts variable control knob rotation.
to a maximum of 5.00 volts. The control knob output
voltage is routed from terminal 2 to pin B1 on the 30
pin connector attached to the Pancon controller. An
adjustable threshold voltage is preset in the Pancon
controller to begin rotation of the tracks. The threshold
is normally adjusted to begin the rotation of the travel
circuit when the control knob is rotated clockwise to
position 2.5 on the control knob label. Refer to the
Maintenance chapter for this adjustment procedure.
G21 08/19/03 6-26

and depress. If the trimmer, track, conveyor and

vibrator systems operate, the fault is in the emergency
stop electrical system. Refer to Emergency Stop
Propel Drv, Vibr
Electrical Diagnostics for more information. If the
0 OFF hydraulic systems do not operate using the manual
override button, the fault is hydraulic. Refer to the
360351
appropriate Track Hydraulic Diagnostic section` for
Propel output drive signal more information. If the emergency stop system is
002-2571
As the variable control knob output voltage increases, reset, proceed with the following diagnostic
the Pancon controller will send a corresponding signal procedures.
to the rear S2X controller through the CAN network
Symptom:
cable. The signal is processed by the rear S2X
controller and a corresponding output drive signal is
routed from the S2X 18 pin connector through
bulkhead 3 and to the appropriate pulsar solenoid
valve. The output will vary from 0 to 80 percent and Master Sensor Power
corresponds with the amount of variable control knob VALUE OUT OF RANGE
signal.
002-2753
Notice: Make certain to carefully read all
Sensor power short inside control box
diagnostic displays on the main display screen. 002-2579
This will indicate the number of faults that are Master Sensor Power — VALUE OUT OF RANGE is
currently affecting the machine. The general indicated on the main screen.
location of each fault is given on the display and
will help to narrow the fault area. Corrective measures:
Symptom: This is a good indication that sensor power is shorted

inside the control box for the travel variable control
All main hydraulic systems; trimmer, tracks, conveyor knobs. If Master Sensor Power — VALUE OUT OF
and vibrators will not operate. RANGE is indicated on the main display screen, open
the main control box by removing the console cover
Corrective Measures: guide bar above the left side of the control box and
turn the box latch to open.
Manual override button

360211a
Twisted power and ground wires
This is a good indication that the emergency stop 002-2876
system is not engaged to allow operation of the Disconnect the power and ground wires (twisted pairs)
primary hydraulic systems. Open the rear access door for each variable control knob individually until the
to the control console. Locate the manual override display screen does not indicate the value is out of
control button on the emergency stop solenoid valve
G21 08/19/03 6-27

range. The control knob or the wiring connected to the If the voltage reads 0.0 volts, the cable may be
control knob, that was last disconnected, is defective. defective. Check the cables for continuity using
Repair or replace the shorted wiring and/or the control a volt ohm meter. Repair or replace any
knob as necessary. defective cables.
If all wires to the control knobs have been removed 3. Travel neutral switch in neutral or defective.
from the terminal bar and the display still indicates the Place the switch in the travel position. If the
Master Sensor Power — VALUE OUT OF RANGE; propel pot screen above indicates that the FNR
either the wiring between the terminal bar and the 30 switch is in neutral (NEU), the switch may be
pin connector is shorted to ground; or the Pancon defective or the ground connection is corroded
controller is shorted internally. Check the wiring for or loose. Connect a jumper wire between the
damage and good connections and repair as terminals on the back of the travel neutral
necessary. Before replacing the Pancon controller, switch. If the travel system operates, the switch
trying reprogramming the controller. Contact your is defective and must be replaced. If the travel
GOMACO distributor or GOMACO for instructions and system does not operate, connect a jumper wire
procedures to reprogram the controller. Replace the between a frame ground and the center terminal
Pancon controller if reprogramming fails to correct the on the travel neutral switch. If the screen
fault. indicates forward (Fwd) or reverse (Rvs), the
ground connection is corroded or loose.
Symptom: Remove and clean the terminals on either end of
the wire before reconnecting and tighten
The travel circuit will not operate in either direction. securely.
The trimmer and conveyor hydraulic systems operate.
4. Forward reverse switch defective. With the
Corrective Measures: travel neutral switch in the travel position, place
a jumper wire between terminals 1 and 2 or
1. The controller is in the Standby (Stdby) mode.
between terminals 2 and 3 on the forward
Depress the Run/Standby switch to place the
reverse switch. If the propel pot screen above
system in the Run mode.
indicates forward (Fwd) or reverse (Rev) using
2. Defective variable speed control knob. If the the jumper wire, the switch is defective and must
remote variable speed control knob is in use, be replaced.
disconnect the remote and operate the system
5. Pilot pressure in the valve is zero. Check the
with the console variable speed control knob. If
track pressure gauge for standby pressure with
the system operates, the remote variable speed
the travel circuits turned off and the engine
control knob may be defective or the cable
running. If a small amount of pressure is not
between the remote and the control box may be
present, refer to the track hydraulic diagnostic
defective.
section for more information.
Symptom:
Propel Pot, FNR, The travel circuit will not operate in one direction but
2.50 Volts Fwd will operate in the opposite direction.
360355
Variable speed knob voltage
360355
The variable speed control knob may also be
checked for voltage output by depressing the
SERVICE switch and depress the NEXT switch
until the Propel Pot display is indicated. The
voltage should indicate 0.21 volts when the knob
is turned counterclockwise to the off position and
should vary between 0.21 volts to 5.00 volts as
the knob is rotated clockwise to the maximum
position.
G21 08/19/03 6-28

Propel Valve Type

= Apitech
360561
Propel Valve Type

= Modular
360562
Valve Type designation Pulsar solenoid valve packard connectors
360561 & 360562 360560
1. Check for proper designation of control valves. 4. Defective wiring between the S2X controller and
This fault is typical of in field installation of a the travel valve connector. Disconnect and
control system. Select the correct valve type swap the connectors at the travel valve. If the
and try again. fault remains in the same direction, replace the
pulsar solenoid coil. If the fault switches to the
2. Forward reverse switch defective. With the opposite direction, check the cable between the
travel neutral switch in the travel position, place S2X controller and the coil connections for
a jumper wire between terminals 1 and 2 or continuity using a volt ohm meter. Repair or
between terminals 2 and 3 on the forward replace the cable as necessary.
reverse switch. If the machine will travel forward
with the jumper wire between terminals 2 and 3, Note: Do not force the ohm meter leads into the
or reverse with the jumper wire between bulkhead plug pin holes. Expansion of the pin
terminals 1 and 2, the switch is defective and holes can cause intermittent loss of signal.
must be replaced.
5. Defective wiring between bulkhead 3 and the 18
pin connector at the S2X controller. Remove the
18 pin connector from the S2X controller and
disconnect the cable from bulkhead 3. Using an
Propel Drv, Vibr ohm meter, check the wiring for continuity
0 OFF between pin F2 on the 18 pin connector and pin
B in bulkhead 3. Check the wiring for continuity
360351 between pin F3 on the 18 pin connector and pin
Propel drive signal D in bulkhead 3. If continuity does not exist, the
360351
wiring is defective and must be repaired or
3. Defective proportional solenoid. Depress the
replaced. Also check pin A and pin C to the
NEXT switch to display the propel drive screen.
frame ground for loose connections or corrosion
Operate the travel variable speed control knob
and repair as necessary.
and check the propel drive for a variable signal
from 0 to 80. If a propel signal is not present,
check the previous two corrective measures for
defects.
G21 08/19/03 6-29

Propel Pot, FNR,

0.21 Volts Fwd
360403
Service mode
360403
2. Defective variable speed control knob. Depress
the SERVICE switch and scroll to the propel pot
display using the NEXT switch. Correct voltage
should be approximately 0.21 volts when the
variable speed control knob is off. If not,
disconnect the remote and check the operation
of the console travel variable speed control
knob. If the console controls operate normally,
Rear S2X controller mounted to door the remote or the cables to the remote are
360366 defective. Check as follows:
6. Defective S2X controller. Each of the S2X
controllers are programmed the same and are To check the cable between the control box and
interchangeable. Disconnect both connectors the remote bulkhead on the side of the console,
from the S2X controller believed to be defective disconnect the cable from the back of the control
and swap the controller with one of the S2X box. Bypass the cable by connecting the remote
controllers known to be good. Reconnect the bulkhead plug directly into the back of the
wiring and test. If the fault switches to a control box. If normal operation is resumed
different location on the machine, the S2X using the remote variable speed control knob,
controller is defective and must be replaced. the frame cable for the remote is defective and
must be repaired or replaced.
Symptom:
If the remote will not operate the system,
suspect that the remote is defective. The
remote can be checked for ohms of resistance
All Travel Pots using an ohm meter. Place one lead from the
TURN OFF ALL Pots & FNRs ohm meter in pin A on the remote bulkhead plug
and the other lead in pin D. With the remote
360394 travel variable speed knob turned
counterclockwise to the off position, the meter
All travel pots display
360394 should read 48 ohms of resistance and should
All Travel Pots is displayed on main screen. Remote increase to 555 ohms of resistance as the knob
will not operate. is turned to the maximum speed position. If the
reading is incorrect, the remote is defective and
Corrective Measures: must be replaced.
This display indicates that the travel variable speed
knob is defective or not rotated to the off position. The
Travel/neutral switch must also be placed in the
neutral position. Make certain that both the console
and remote travel variable speed knobs are turned off
if the remote is in use.
1. Remote variable speed control knob is not

turned off. Turn the knob counterclockwise to
the off position.
G21 08/19/03 6-30

Symptom:
Propel Pot
SHORT TO 0 V
002-2797
Defective output signal from travel control knob
002-2680
Propel Pot; NOT CALIBRATED or SHORT TO 0 V is
indicated on the display. This indicates that a variable
output voltage is not being received by the Pancon
controller.
Corrective Measures: Minifast connection

360644
1. Defective minifast connector or CAN cable.
Disconnect the CAN cable between the rear
S2X bulkhead connection and the minifast
Propel Pot,FNR,Hi/Low Sw
connector. Swap it to another S2X known to be
0.00 Volts Neu Low good. If the fault switches, replace the cable. If
not, disconnect the minifast connector for the
002-2798 rear S2X and swap it to another S2X known to
Defective travel pot output voltage indicated be good. If the fault switches, replace the
002-2679
To test, depress the SERVICE switch on the control minifast connector.
box. Depress the NEXT switch until the propel pot
display is indicated. The normal voltage range should
be 0.21 volts to 5.00 volts as the travel control knob is
rotated clockwise. If the reading is 0.00 volts, make
certain that 5.00 volts is provided to the control knob
on pin 1 and a good ground connection is provided on
pin 3. Make certain that the output wire between pin 2
on the control knob and pin B1 on the 30 pin connector
is securely connected and check for continuity. If a
good ground and 5.00 volts of power exists, the control
knob is defective and must be replaced.
Symptom:
Rear Slave
NO RESPONSE 18 pin and 30 pin connectors
360369
2. Defective cable harness at the S2X controller.
360361 Remove the 18 pin and 30 pin connectors from
No response indicated on display the S2X believed to be defective. Swap the rear
360361 S2X with one of the other S2X controllers known
The display indicates Rear Slave No Response. to be good. If the fault switches to a different
location on the machine, replace the S2X
controller.
This fault indicates that the rear S2X is not
If the fault remains with the rear slave (S2X), the
communicating through the CAN network to the
CAN network cable connection between the 18
Pancon controller and the other S2X controllers.
G21 08/19/03 6-31

pin connector and the CAN cable bulkhead may

be defective due to corrosion. Disconnect the
18 pin and 30 pin connectors and spray with an
electrical cleaner. Do not use an oil based
lubricant to clean the connections. Reconnect to
the rear S2X. If the fault remains, replace the
cable harness at the rear S2X.
Symptom:
All S2X slaves are indicating NO RESPONSE on the

display.
CAN network minifast connectors and terminator

002-2614
This indicates that the CAN network cables may be
defective. Make certain that the CAN minifast
terminators are in place on the minifast connectors as
indicated in the electrical drawing.
Remove the right bottom cable connector from the end

of the CAN minifast connectors on the front access
door. Remove the CAN cable from bulkhead 4 on the
back of the control box. Check for continuity between
the bulkhead 4 cable and the disconnected CAN
minifast connector on the front access door. If
continuity does not exist, disconnect and recheck each
of the cables in the CAN network wiring harness until
the defective component is located. Repair or replace
the wiring harness as necessary.
If continuity exists in the wiring harness, check

continuity between bulkhead 4 and the 18 pin
connector on the Pancon controller. Repair or replace
the control box wiring as necessary.
G21 08/19/03 6-32

G21 08/19/03
Pressure Oil
Return Oil Vibrator System Note: Front stage of cam drive pump is standard pump
Dump or Drain (Standard Configuration) for vibrator system. Rear stage of cam drive pump is
Static Oil standard pump for conveyor system.
Selector Valve
Push in for Vibrators
Pull out for Aux. Travel
Drawing number 360624
indicates new selector valve
used on current models.
Circuit Selector &
C
Relief manifold
Pressure Gauge B
with emergency stop
relief set at 2150 psi
Vibrator Variable Manifold with

Solenoid Valve and Relief Valve To
Set at 1850 psi Travel
To Pressure Tank Circuit
To
6-33
Pressure
Vibrator Tank
Return
Manifold
To
To Pressure
Pressure Tank
Pressure
Wash Cam driven pump
Tank
Manifold Front Stage with 4 vibrator system

Power Washer or
Water Pump Motor
Note: Pressure Wash hydraulic
is supplied by lift hydraulic system
Vibrator on current models.
To
Pressure
Tank 360329
Pressure Oil
Return Oil Vibrator System Note: Rear stage of the rear main pump
is used to operate vibrators when six vibrator
Dump or Drain (with six vibrator circuit option) option is used on machine. The front
Static Oil stage of the cam driven pump is used
to operate the track drive. Conveyor and trimmer
pumps are not affected by this option.
Selector Valve
Push in for Vibrators
Pull out for Aux. Travel
Drawing number 360624
indicates new selector valve
used on current models.
Circuit Selector &
C
Relief manifold
Pressure Gauge B
with emergency stop
relief set at 2150 psi
Solenoid Valve and Relief Valve
Set at 1850 psi
To
Travel
To Pressure Tank Circuit
To
6-34
Pressure
Vibrator Tank
Return
To
Manifold
Pressure
Tank
To
To Pressure
Pressure Tank
Rear main pump
Tank
Rear stage with 6 vibrator system
Pressure
Wash
Manifold
Power Washer or
Water Pump Motor
G21 08/19/03
To
Pressure
Tank 360625
G21 08/19/03
Pressure Oil
Return Oil Vibrator System Note: Rear stage of cam driven pump is used to
operate vibrators when screw conveyor option
Dump or Drain (with screw conveyor option) is used on machine. Front stage of cam driven
Static Oil pump is used to operate screw conveyor. Track
trimmer pumps are not affected by this option.
Selector Valve
Solenoid de-energized for Vibrators
Energized for Aux. Travel
Circuit Selector &

4 gpm (15 lpm) Relief manifold
Pressure Gauge
added to with emergency stop
compensate for relief set at 2150 psi
smaller rear stage To
pump Travel
Circuit
From Lift
Pump
To Pressure Tank
Solenoid Valve and Relief Valve
To Set at 1850 psi
6-35
Pressure
Vibrator Tank
Return
Manifold
To
To Pressure
Pressure Tank
Tank
Pressure

Wash
Manifold Cam Driven Pump
Power Washer or Rear Stage with 4 vibrator system
Water Pump Motor 13 gpm (49 lpm) at 2250 rpm
To
Pressure
Tank 360624
09 Vibrator Hydraulic Diagnostics de-energized to the closed position, pressure begins to

build in the pilot sense line. If no vibrator variables are
360329
The oil flow for the four vibrator system begins at the opened, this pressure is directed against the pressure
front stage of the cam driven pump which delivers 20 differential valve causing it to open at approximately
gpm (75 lpm) at 2250 rpm. 75 psi (5 bar) spring tension. The oil from the pump is
dumped back to tank at approximately 75 psi (5 bar)
Oil flow for the six vibrator system begins at the rear through the vented relief.
stage of the rear main pump which delivers 26 gpm
(98 lpm) at 2250 rpm. When a vibrator variable is rotated in the increase
direction, pressure begins to increase between the
Oil flow for the vibrator system on a machine equipped variable and the attached vibrator. This pressure
with a screw conveyor begins at the rear stage of the increase is directed against the spring loaded end of
cam driven pump which delivers 13 gpm (49 lpm) at the pressure differential spool (by a small orifice)
2250 rpm. Since this is only enough oil to operate causing it to shift in the direction of the spring tension.
three vibrators, an additional 4 gpm (15 lpm) of oil is As the valve spool shifts, it begins to block off the free
added through a flow control valve from the lift pump. flow of the oil back to the tank by the vented relief
This additional oil is controlled by a solenoid valve and causing the pressure in the system to increase
one way check valve. When the vibrator circuit is sufficiently to operate the vibrator at the preset speed.
energized for operation, the solenoid valve is The unused oil is returned to the tank at a pressure
energized to an open position, allow ing the four approximately 75 psi (5 bar) higher than the pressure
gallons of oil to flow through a one-way check valve required to operate the vibrator. If the vibrator variable
and into a tee fitting at the inlet of the vibrator variable is rotated more in the increase direction, or another
manifold. The check valve prevents the vibrator oil vibrator is turned on, there is a pressure drop in the
from back flowing through the solenoid valve to the lift system. This causes the pressure differential spool to
pump. When the vibrators and the solenoid valve are shift to block the flow of oil to tank, increasing the
de-energized, the oil flow is stopped causing the pressure sufficiently to operate the vibrator at a higher
vibrators to cease operation. speed or to operate additional vibrators. Any unused
oil will be returned to tank. The vibrator pressure
From the pump the oil is routed past a vented relief gauge will indicate the highest pressure required to
valve set to bypass at 2150 psi (148 bar) and to the operate any one of the vibrators.
auxiliary travel-vibrator selector valve. The relief valve
is necessary to protect the pump from pressure spikes If a vibrator should stall, pressure will increase against
when the selector valve position is changed. With the the pressure differential valve spool causing it to shift
selector valve shifted to the “auxiliary travel” position to block the free flow of oil to the tank, increasing the
(valve in), oil is routed out a work port to the inlet of the pressure in the system. When the pressure reaches
travel variable control valve, resulting in increased 1750 psi (121 bar), the vented relief valve will open,
travel speed. dumping any unused oil (including that from the stalled
vibrator) back to the tank at approximately 1850 psi
With an emergency stop system the oil will be returned (127 bar). All other vibrators will continue to operate at
to tank through the relief valve until the emergency normal speed and pressure. A flow control valve on
stop solenoid valve is energized. The solenoid valve the output side of each variable regulates the
closes the pilot line to each of the vented relief valves maximum output for each vibrator to 4 gpm (15.2 lpm).
and stops the return oil flow to the pressure tank. The
vented relief valve will then bypass oil at 2150 psi (148 A solenoid valve in the pilot line between the vented
bar) as described previously. relief valve and the pressure differential valve is used
to automatically start and stop the vibrators. When the
When the selector is set to the “vibrator” position travel variable speed knob is turned off, the low
(valve out), the oil flows out a work port to the inlet of voltage output signal to the Pancon controller indicates
the vibrator variable manifold. With the vibrator that travel has stopped and the vibrators must be
variables all in the off position, pressure begins to build stopped. A signal is output from the Pancon controller
in the system. This pressure increase is directed which energizes the vibrator manifold solenoid to the
through a small orifice in the end of the vented relief open position, draining the pressure oil from the spring
valve. If the solenoid valve in the vented relief pilot loaded (pilot) side of the vented relief valve, which
sense line is energized to the open position, the shifts to open oil flow back to tank under low pressure,
vented relief opens under low pressure and dumps the causing the vibrators to stop. When the travel variable
oil to the return tank. If the solenoid valve is control knob is turned clockwise, the solenoid is de-
G21 08/19/03 6-36

energized by the Pancon controller to the closed operate slower. Increase engine speed to
position blocking the flow of oil from the pilot port. This maximum.
causes pressure to increase on the spring loaded side
of the vented relief, causing it to shift to block the flow 2. Vibrator variable controls turned down. Turn
of oil back to the tank, forcing the vibrators to operate. each variable control knob to increase the
An override switch is provided for stopping the vibrator speed.
vibrators while moving from one place to another. By
placing the switch in the “off” position the solenoid is
held in the energized position, preventing the vibrators
from operating, regardless of the travel variable speed
knob position. When the switch is in the “auto”
position, the starting and stopping of the vibrators is
controlled automatically by the travel variable speed
knob.
By connecting the loop hoses from the vibrators

connected to #3 and #4 vibrator variable controls, to
the bulkheads labeled for the pressure wash system,
oil is routed through a set of quick couplers to the inlet
port of the drive motor. The motor turns either a
standard water pump or an optional high pressure
washer system. The oil is then routed out the outlet
port of the motor, through a set of quick couplers, and
back to the pressure tank.
Symptom:
All vibrators slowly operate when the machine is

stopped.
Engine Speed to Pressure Comparison
622
Corrective Measures: 3. Defective pump stage. The pump should be
checked with a flow meter if available. A good
This is a normal function of the hydraulic system for indication of a defective pump is to compare
vibrator operation. The vented relief is equipped with relief pressure to engine speed. To check,
a spring that requires 50 psi (3.5 bar) to force the relief disconnect all vibrators or loop hoses at the
open and drain the oil back to tank. The residual quick couplers. Place the “vibrator-auxiliary
pressure in the system will cause some vibrators to travel” selector valve in the “vibrator” position,
turn very slowly. This will not damage a vibrator when the “vibrator override” switch in the “off” position
turning at such low speed. and rotate all vibrator variable controls to the
maximum speed. Place the G21 control system
Symptom
in the run mode on the display and place the
All vibrators operate at low speed. travel/neutral switch in the “travel” position and
the forward/reverse switch in “forward”. Rotate
Corrective Measures the travel variable speed knob in the “increase”
direction a small amount to break contact with
the “off” position of the knob and note the
! CAUTION! ! increasing pressure on the corresponding
pressure gauge. If the pressure continues to
CONTINUOUS EXPOSURE TO ENGINE NOISE CAN increase above 1850 psi (127 bar), immediately
CAUSE HEARING INJURY. DO NOT OPERATE move the travel variable speed knob to the “off”
THE MACHINE WITHOUT HEARING PROTECTION. position. Turn the pressure relief adjustment
screw out 3 or 4 turns and recheck. Refer to
1. Engine is not operating at maximum speed Section 13 of the Maintenance Chapter for
(2100 rpm). If the engine speed is low, hydraulic further information on setting the relief pressure
pump output flow will be low, causing all vibrator before continuing. Note the indicated pressure
circuits, as well as all other hydraulic systems, to on the circuit selector gauge. Gradually reduce
G21 08/19/03 6-37

the engine speed. A damaged pump will not

maintain relief pressure, but will drop rapidly as
engine speed is reduced. A good pump will
maintain approximately the same pressure as
the engine speed decreases. Replace or repair
the pump if found to be defective.
4. Vibrator relief valve pressure setting low. Check

and adjust the vibrator relief valve pressure as
Symptom:
Concrete surface is not vibrated in one area. Vibrator

pressure indicates 1850 psi (127 bar).
Remove vibrator relief
1. Defective vibrator. Make certain the vibrator is 360195a
operating. If not, swap the vibrator to another 5. Vibrator relief valve stuck in the open position.
circuit and try again. If the vibrator will not Remove the relief valve cartridge and clean it in
operate, the vibrator is defective and must be clean solvent. Inspect the valve and o-rings for
repaired or replaced. If the vibrator will operate damage or contamination. Replace as
on a different circuit, the quick couplers may be necessary. Using a small screwdriver, attempt
defective. Replace the quick couplers as to depress the inner valve assembly (opposite of
necessary. the adjustment nut) against spring pressure. If
the valve sticks in, or is stuck in the open
2. Quick couplers defective or not fully connected. position, the valve is defective and must be
Check quick couplers by replacing with quick replaced.
couplers known to be good. Replace coupler if
defective.
Note: If a faulty quick coupler is in the return line,

it could cause the shaft seal in the hydraulic motor
to rupture. Replace the seal if necessary.
Symptom
All vibrators will not operate. Low pressure indicated.
Corrective Measures
1. Selector valve in the “auxiliary travel” position. Remove and Inspect Solenoid Valve
Place the selector in the “vibrator” position. 002-2706
6. Solenoid valve stuck open. Remove the valve
2. Vibrator variable off (fully clockwise). Rotate the cartridge and clean it in clean solvent. Inspect
variable control in the increase direction to start the valve and o-rings for damage or
the vibrators operating. contamination. Replace as necessary. Using a
small screwdriver, attempt to depress the inner
3. Vibrator override switch in the “off” position. valve assembly (opposite the coil end) against
Place the switch in the “auto” position. spring pressure. If the valve sticks in, or is stuck
in the open position, the valve is defective and
4. Main relief valve stuck open. Replace the main must be replaced.
relief valve cartridge with the relief valve
cartridge from the conveyor circuit. If the
vibrators now operate, the relief valve cartridge
is defective and must be replaced.
G21 08/19/03 6-38

Symptom: 5. Defective vibrator motor. Check the vibrator

using a vibratach to check vibrations per minute
(VPM). At maximum speed the vibratach should
indicate over 9000 vpm's if the motor is not
bypassing an excessive amount of oil. If the
vibrator is not maintaining 9000 vpm's, refer to
the appropriate vibrator repair manual and repair
or replace the vibrator motor.
Voids in concrete surface

001-1884
Concrete surface is not vibrated properly. Voids
appear in the surface of the concrete. Normal
operating pressure is indicated.
1. Concrete mix is dry. Increase slump of the

concrete mix by adding water in the truck and
mixing for the required time. Vibrator flow control valves
360643
6. Vibrator flow control valve is not adjusted for 4
2. Individual vibrator control knob is not turned up.
gpm (15 lpm). Place a flow meter in the suspect
Rotate the control knob to increase vibration.
individual vibrator circuit and operate at
3. Engine rpm is low. Low rpm will turn the maximum flow using the variable control knob.
hydraulic pump at a slower speed, decreasing If the flow meter indicates a flow of less than
the amount of hydraulic flow available to the 3.75 gpm (14 lpm), adjust the flow control
vibrators as well as the rest of the hydraulic cartridge to a flow setting between 3.75 and 4
systems on the machine. Increase engine rpm gpm (14 and 15 lpm).
to maximum.
Note: Do not increase the hydraulic flow control
4. Vibrator is filled with hydraulic oil. Remove the cartridge setting above 4 gpm (15 lpm) as this will
vibrator and repair or replace the seals as cause the vibrator to overspeed and cause early
necessary. motor failure.
Symptom:
Vibrator pressure gauge indicates 1850 psi (127 bar)

relief pressure. All connected vibrators are operating
normally.
1. Quick couplers are not looped on unused

vibrator circuits. Make certain that all unused
vibrator circuits are looped at the quick couplers
or connected to a vibrator.
To test for a defective circuit, turn all variable

controls off. Operate each individual vibrator
Vibratach testing
Vib trl 035 circuit by turning the variable control on and note
G21 08/19/03 6-39

the pressure gauge reading. If a normal 4. Incorrect adjustment of the pressure differential
pressure is indicated (0 - 1500 psi; 0 - 103 bar), valve or the valve is defective. If adjustment of
the individual circuit tested is good. Continue the pressure differential valve has taken place, it
checking each individual circuit until high will be necessary to readjust the valve. This can
pressure (1850 psi; 127 bar) is indicated on the only be done with a measurement used to adjust
defective circuit. Loop the unused connection or the valve stem screw. Call GOMACO for an
determine if a quick coupler is defective as accurate measurement of the valve stem. If
follows. adjustment has not taken place, the valve may
be defective and must be replaced.
2. Defective vibrator or quick coupler. Make
certain that all vibrators are operating normally. Symptom:
One defective vibrator can cause the vibrator
system to operate at 1850 psi (127 bar). Swap One or more vibrators are frequently filled with
or replace suspected quick coupler with one hydraulic oil.
known to be good. If the fault switches, replace
the coupler. If the fault remains in the same Corrective Measures:
circuit, swap the remaining coupler in the same
1. Overheating vibrators by operating them out of
manner.
concrete. Vibrators dissipate heat build up
through the concrete surrounding the vibrator. If
a vibrator is operated out of concrete for a short
period of time, when the hydraulic oil is at
normal operating temperature, the vibrator motor
will overheat causing bearing and possible seal
failure. Make certain to turn off individual
vibrators as they are exposed from the concrete
at the end of a pour. Refer to the appropriate
vibrator repair manual and repair the vibrator
seals and bearings as necessary.
2. Quick couplers attached to incorrect hydraulic

supply lines during rebuild of a vibrator. Make
certain that the small inlet port of the vibrator
motor is equipped with a female quick coupler.
Replace the vibrator motor shaft seal.
Orifice fitting location under solenoid valve
002-2707 3. Flow restriction on the return line of the vibrator.
3. Pressure differential valve orifice fitting is A defective quick coupler can cause restriction
contaminated. Remove the solenoid coil and against the vibrator motor shaft seal causing the
valve stem from the vibrator manifold. Use an seal to fail. Repair the vibrator and swap the
appropriate sized hex wrench to remove the vibrator to an alternative vibrator circuit.
orifice fitting from the base of the solenoid valve Replace the return quick coupler if the fault
port in the manifold. Check for any continues. If the vibrator continues to
contamination and clean thoroughly. Make experience motor shaft seal failure, the vibrator
certain to count the number of turns when motor may require replacement.
removing the orifice fitting so that it may be
returned to its original position after cleaning.
Return the solenoid valve to its original position
and tighten securely.
Notice: A small amount of hydraulic oil loss will

occur when removing the solenoid valve stem.
Take appropriate steps to prevent contamination
and dispose of the hydraulic oil as required.
G21 08/19/03 6-40

Individual flow control cartridges

360643
4. Defective flow control valve or incorrect 002-2004a
adjustment. Each individual flow control valve is 2. Emergency stop button is depressed or
adjusted for a maximum flow of no more than 4 defective. Refer to the emergency stop
gpm (15 lpm). Insert a flow meter between the electrical diagnostic section for more
pressure and return lines of the suspect information.
individual vibrator circuit. Operate the individual
vibrator circuit at maximum speed and full Note: The emergency stop system will affect all
engine rpm. The flow reading should be hydraulic functions on the machine except for the
between 3.75 and 4.00 gpm (14 and 15 lpm). If lift circuit.
not, loosen the lock nut and adjust the set screw
as necessary. Tighten the lock nut securely
while holding the set screw in position when
adjustment is complete.
If correct adjustment is not possible, the flow

control valve cartridge may be defective.
Replace the valve as necessary.
Symptom:

operate.
! DANGER! !
OR TRIMMERWHEEL.

the reset switch.
G21 08/19/03 6-41

10 Vibrator Electrical Diagnostics
Vibrator Electrical Circuits

Travel Neutral
travel 3
2 –––
––– 1
–––
Console Travel neutral
travel 6
J2 <A1 J1 <
A1 Variable 5
–––
–––
A2 A2 1 4
< < neutral –––
A3 A3
<
B1 Relay <
B1 2
< < 1K
<
B2
B3
K2 <
B2
B3 3 CW
< <
C1 C1
< <
C2 C2
< <
C3 C3
< <
D1 D1
< <
D2 D2
< 30 87 <
D3 ––– ––– D3
< <
E1 E1
< <
E2 E2
< <
E3 E3
< <
F1 F1
< <
F2 F2
< <
F3 F3
< <
G1
<
G2
Circuit <
G3
<
Breaker 2 <
H1
H2
<
B A H3
––– 8A ––– <
Vibrator Circuit Breaker J1
<
J2
<
J3
<
K1
Refer to Miscellaneous <
K2
Wiring Schematic for <
K3
more information <
Inside console control box
Remote steer Bulkhead

control knob B1
47Ω A
1 <
B
2 <
C
47Ω <
CW 3 A D
1000 Ω
> <
B E
> <
C F
> <
Remote travel D
>
E Bulkhead
variable control knob >
F
1
> B5
2
A
B
> <
A
B
Vibrator
47Ω > <
CW
1000 Ω
3 C
> <
C off/auto
D D 3 auto
> < ––– 2
Vibrator E E
1 –––
Screw F
> <
F ––– off
Manifold > <
Conveyor
Solenoid
Only added to machines
with a screw conveyor 360404
360404
The network control system is used to electrically counterclockwise to the off position, the voltage (0.21
operate the vibrator system. The Pancon controller is volts) is recognized by the Pancon controller as the off
the main computer on the machine and is located in position. This will stop the operation of the vibrator
the console control box. It receives the input circuits.
information from the various sources and processes
that information. In the vibrator circuit the input When an increased voltage signal is received from the
devices are the remote and console travel variable remote or console travel variable control knob the
control knobs. Pancon controller will send an electrical signal from
pin C2 in the 18 pin J2 connector to energize relay
Place the G21 control system in the run mode on the K2. When the relay closes its’ contacts, it connects a
display and place the travel/neutral switch in the 12 volt signal to the travel/neutral switch. The travel/
“travel” position and the forward/reverse switch in neutral switch must be in the travel position to allow
“forward”. The travel variable control knobs are used this 12 volt signal to continue to the vibrator off/auto
to signal the Pancon controller that machine switch. If the vibrator off/auto switch is in the “off”
movement is to begin. This same signal is also used position, the vibrators will not operate. If the vibrator
to indicate that the vibrator circuit should begin off/auto switch is in the “auto” position, the 12 volt
operation. When the control knob is turned signal continues through bulkhead 5 to the vibrator
G21 08/19/03 6-42

manifold. The normally open solenoid coil is If the reading does not exist, or is more than 2
energized to a closed position, which allows the ohms higher or lower than the correct reading,
vibrator system to begin building pressure for the solenoid coil is defective and must be
operation of the individual vibrators. replaced.
When the travel variable control knob is turned to the 6. Defective ground wire connection. Check the
“off” position, the Pancon controller de-energizes relay wire between the vibrator solenoid coil and the
K2. The 12 volt signal is disconnected to the vibrator frame of the machine. Repair or replace the
solenoid coil and the vibrator solenoid is de-energized connection as necessary.
to an open position. This causes the hydraulic oil to
be returned to the tank, stopping the vibrators. 7. Defective power wire between bulkhead 5 and
the solenoid coil. Disconnect bulkhead 5 from
Symptom: the rear of the main control box and check
continuity between pin D in bulkhead 5 and the
Vibrators will not operate. Zero pressure is indicated power wire connector on the vibrator solenoid
on the pressure gauge. coil. The wire must be disconnected from the
solenoid coil prior to checking for continuity. If
Corrective Measures: continuity is not indicated, the wiring is defective
and must be repaired or replaced. If continuity
1. Vibrator off/auto switch is in the “off” position.
does exist, check the following for more
Place the switch in the “auto” position.
information.
2. G21 controller is in the standby mode. Depress
8. Defective diode filter between the power and
the run/standby switch to indicate the “run”
ground connections on the solenoid coil. While
mode on the display.
attempting to operate the vibrator system, touch
3. Travel/neutral switch is in the “neutral” position. the diode filter attached between the connectors
The travel/neutral switch will not allow track on the vibrator solenoid coil. If it is extremely
drive movement if it is in the “neutral” position as hot to the touch, the diode is shorted to ground.
well as operation of the vibrators. Place the Make certain that the diode is installed correctly
switch in the “travel” position. between the two terminals on the vibrator
solenoid. The black wire on the diode should be
4. Travel variable control knob is not turned on. connected to the same terminal with the power
Rotate the travel control knob clockwise to begin wire from the control box. The white wire should
operation of the vibrators. be connected to the grounded terminal of the
vibrator solenoid coil. If this is incorrect, swap
the diode end for end and reinstall.
Note: If the wiring is shorted to ground, the circuit

breaker inside the control box will make a
snapping sound as it automatically resets every 3-
5 seconds.
A volt/ohm meter may also be used to check the

diode. Place the meter leads on each of the two
wires exiting the diode (diode must be removed
from the solenoid coil). After checking for
continuity, swap the meter leads on the diode
and test again. If there is continuity in both
directions through the diode, it is defective and
must be replaced. If continuity exists in one
direction only, the diode is good and should be
installed in the correct orientation as previously
Vibrator solenoid coil resistance described.
002-2705
5. The vibrator solenoid coil is defective. Check
9. Defective wiring inside the control box. Check
with a volt/ohm meter for 8.5 ohms of resistance.
for loose terminal connections on the back of the
If the reading is correct the solenoid coil is good.
G21 08/19/03 6-43

vibrator off/auto switch and the travel/neutral

switch. Tighten any loose connections securely.
Check for 12 volts on both terminals of the

circuit breaker. If 12 volts is evident on the
battery side but not the auxiliary side and a
snapping sound is not evident from the circuit
breaker, the circuit breaker is defective and must
be replaced. If a snapping sound is evident from
the circuit breaker, a short to ground is located
between the auxiliary side of the circuit breaker
and the vibrator solenoid coil. Beginning at the
vibrator solenoid coil, eliminate the individual
components one by one until the short is
eliminated. The last component eliminated is
If 12 volts exists on both sides, check at terminal Relay K2

002-2878
30 and terminal 87 on relay K2 for 12 volts when 9. Defective relay K2. Place the G21 control
the relay is energized. If 12 volts is evident on system in the run mode on the display and place
both sides, the relay is good. If 12 volts is the travel/neutral switch in the “travel” position
evident on terminal 30 but not on terminal 87, and the forward/reverse switch in “forward”.
the relay is either defective or is not being With the travel variable control knob turned on,
energized by the Pancon controller. Refer to check for a 12 volt signal on terminal 86. If 12
corrective measure 9 for further diagnostic volts is evident, but 12 volts is not evident on
procedures. terminal 87, the relay is defective and must be
replaced. If 12 volts is not evident, depress the
Check the travel/neutral switch for 12 volts on
Last/Next switches until the propel drive display
terminals 5 and 6 when the switch is in the
is indicated on the controller screen. If the
“travel” position. If 12 volts exists on terminal 5
vibrator signal is “on”, the Pancon controller is
but not on terminal 6, the switch is defective and
defective and must be replaced. If the vibrator
must be replaced. If 12 volts exists on both
signal is “off’, the input signal from the travel
terminals, the switch is good.
variable control knob is defective. This is
Check the vibrator off/auto switches for 12 volts normally indicated on the display screen as “not
on terminals 2 and 3 when the switch is in the calibrated” or “short to 0 volts”. Repair or
“auto” position. If 12 volts exists on terminal 2 replace the components as necessary.
but not on terminal 3, the switch is defective and
Note: Make certain all wiring connectors are
must be replaced. If 12 volts exists on both
connected securely.
terminals, the switch is good.
Check for 12 volts at the vibrator solenoid coil

wiring. If 12 volts does not exist, the wiring
between the vibrator off/auto switch and the
solenoid coil is defective and must be repaired
or replaced. If 12 volts does exist, the vibrator
solenoid coil may be defective. Refer to
corrective measure 4 for more diagnostic
information.
G21 08/19/03 6-44

11 Mold Hold Down Hydraulic Diagnostics
Mold Hold Down Systems

Pressure Control Valve Bank
Gauge
Reducing-Relieving
Valve
To
Pressure
Drawbar Tank
Hold Down
Cylinder
Quick
Couplers
Pressure
Gauge
Reducing-Relieving
Valve
To Lift Pressure
Pressure Manifold
Hold Down Tank
Cylinder
Quick
Couplers Pressure Oil
Return Oil
Dump or Drain
Regulated Pressure
360330
360330
The drawbar hold down and the rear mold hold down down cylinder returns back through a work port of the
circuits operate the same hydraulically. The control valve and back to the pressure tank. A
explanation for one is the same for both circuits. pressure gauge is connected to the line between the
reducing/relieving valve and the hold down cylinder to
The oil for the hold down circuit is supplied by the lift monitor the hold down pressure.
pump. With the control valve in the “neutral” (center)
position, the oil flow is blocked by the valve spool. If the machine should move down, the pressure in the
Moving the valve to the “down” position, directs oil line between the hold down cylinder and the reducing/
through the valve, out a work port, to the inlet of the relieving valve will begin to increase. The reducing/
reducing/relieving valve. The reducing/relieving valve relieving valve senses this increase of the preset
reduces the incoming pressure of 1600 psi (110 bar) pressure and opens to drain excess pressure back to
down to an operator setting of between 30 and 600 psi the pressure tank, maintaining the preset pressure. As
(2 and 41 bar). The oil is routed through the reducing/ the machine begins to raise, the pressure in the line
relieving valve to the piston end of the hold down between the hold down cylinder and the reducing/
cylinder causing it to extend. As the cylinder begins to relieving valve begins to drop. The reducing/relieving
press down on the rear of the slipform mold or the valve senses this pressure drop and opens to add oil
drawbar, pressure begins to build up in the line to the line to maintain the preset pressure.
between the hold down cylinder and the reducing/
relieving valve. When the pressure reaches what the When the control valve is moved to the “up” position,
operator has preset, the flow of oil to the hold down oil is routed through the control valve, out a work port
cylinder is halted. Oil from the rod end of the hold to the rod end of the hold down cylinder causing it to
G21 08/19/03 6-45

retract. The oil from the piston end is forced back Symptom:
through the reducing/relieving valve to the pressure
tank. Hold down cylinder will not raise or lower.
Symptom: Corrective Measures:
Hold down cylinder will retract, but will not extend. 1. Hold down control valve in the “neutral” (center)
position. Move the control valve to the proper
Corrective Measures: position.
Hold down pressure control valve set too low. Turn 2. Low pressure in the lift circuit. Check the
the control valve knob clockwise to increase pressure indicated pressure on the lift circuit pressure
to extend hold down cylinder. gauge. Adjust the lift pressure to 1600 psi (110
bar) if necessary, following the instructions given
Symptom: in the Maintenance chapter.
Cannot maintain constant hold down pressure. Note: If the lift pressure is low, the following
circuits will be affected; all three grade circuits,
Corrective Measures: front and rear steering circuits, auxiliary circuits,
and hold down circuit.
Remove and Inspect Pressure Control Valve

628
1. Hold down pressure control valve dirty or
defective. Remove pressure adjustment
cartridge and clean. Inspect and replace as
necessary.
Check for Defective Cylinder

629
2. Defective hold down cylinder. To check,
disconnect the hose on the rod end of the
cylinder, with it extended completely. Apply
pressure to the piston end (hold down valve in
“down” position). If hydraulic fluid escapes from
the open fitting on the rod end of the cylinder,
the internal piston packing is leaking. Repair or
replace the cylinder as necessary.
G21 08/19/03 6-46

12 Auxiliary Hydraulic Diagnostics
Pressure Oil
Auxiliary Systems Auxiliary Control
Return Oil Valves
Dump or Drain
Conveyor Lift
Cylinder
Right Leg
Shift Cylinder
Lift
Manifold
Rear Leg
Shift Cylinder
Track Tension
Manifold
Conveyor Shift
Control Valve
To Track Tension
Cylinders
Conveyor Shift
Motor (Current Models)
360342a
360342
The auxiliary system is separated into two different oil flow is routed through the valve to one of the work
control circuits. One circuit uses a closed-center ports. The oil forces a check valve off its’ seat as it
control valve assembly which controls the functions of passes through the double acting lock valve (on rear of
the conveyor lift, conveyor shift, rear shift, right front valve) and then out to the piston end of the
leg shift, drawbar hold down cylinder and rear mold corresponding cylinder. Since a check valve in the
hold down cylinder. For more information on drawbar double acting lock valve is blocking the oil flow back to
hold down and rear mold hold down circuits, refer to the control valve from the rod end of the cylinder,
Mold Hold Down Hydraulic Diagnostics in the previous pressure begins to build in the line between the piston
section. The second circuit uses an electrically end of the cylinder and the control valve. This
operated solenoid valve assembly which controls the pressure increase acts against a shuttle piston in the
functions of the trimmerhead lift, mold shift, left front locking valve, which shifts, lifting the check valve on
leg pivot and trimmer shift. the return side off its’ seat, thus allowing the oil from
the rod end of the cylinder to return through the control
The first auxiliary circuit consists of the conveyor lift, valve and back to the pressure tank.
conveyor shift, rear shift and right front leg shift
circuits. The operation of these four circuits is the When the control valve is shifted in the opposite
same, with the end results being the only difference. direction, the oil flows through the check valve, in the
The oil for the auxiliary circuits is supplied by the lift opposite side of the locking valve and out to the rod
pump. When the control valve is in the “neutral” end of the corresponding cylinder. Since a check
(center) position, the oil flow is blocked by the valve valve in the locking valve is now blocking the oil flow
spool. When the valve is moved in one direction, the from the piston end of the cylinder back to the control
valve, pressure begins to build between the rod end of
G21 08/19/03 6-47
the cylinder and the control valve. This pressure Reverse the hoses on the rear of the valve. If
increase works against the shuttle piston in the locking the cylinder will now move in the opposite
valve, which shifts, lifting the check valve on the return direction, the locking valve is defective and must
side off its’ seat, thus allowing the oil from the piston be repaired or replaced.
end of the cylinder to return through the control valve
and back to the pressure tank. The purpose of the 2. Low lift pressure. Check the indicated pressure
double acting lock valve is to keep the corresponding on the lift circuit pressure gauge. Adjust the lift
cylinder from drifting. The diagnostic procedures for pressure to 1600 psi (110 bar) if necessary,
all four auxiliary circuits are the same. following the instructions given in the
Maintenance chapter. If the lift pressure is low,
The conveyor shift circuit is operated by connecting the grade circuits and steering circuits will also
the valve into the pressure and return hoses. To be affected.
supply oil to the valve, it will be necessary for the
operator to hold the conveyor lift valve in the “up” 3. Locking pin through holes in inner and outer
position while the conveyor shift valve is being tubes of conveyor lift or conveyor shift. This will
operated. affect the conveyor lift or conveyor shift only.
Remove pin and install it through the holes in
Symptom inner tube only to limit how far the conveyor can
be lowered or shifted.
Cylinder will extend but not retract; or retract but not
extend.
Corrective Measures
Right Front Leg Clamps

632
4. Clamp on right front leg is tight. Loosen clamp
before attempting to shift the right front leg.
Locking valve
631 5. Tracks are stuck in soft grade. Travel the
1. Locking valve not releasing in one direction. machine while attempting to shift the right front
Check by reversing the hoses on the rear of the or rear legs.
valve. If the cylinder will now move in the
opposite direction, the locking valve is defective Symptom
and must be repaired or replaced.
Cylinder will not hold position.
2. Defective quick coupler. Inspect quick couplers
Corrective Measures
by bypassing couplers with pipe couplings or
with a set of couplers known to be good. 1. Locking valve not holding. Remove the lines
from the defective valve and swap them with the
Symptom
lines from an unaffected valve. If the cylinder
Cylinder will not extend or retract. that was not holding position, now holds
position, the valve is defective and must be
Corrective Measures repaired or replaced.
1. Locking valve not releasing in one direction. If 2. Internal cylinder packing leaking. If swapping
the cylinder is completely extended, or retracted the lines as previously described does not stop
and the locking valve shuttle piston is stuck, it the cylinder from creeping, suspect the internal
will not release in the opposite direction. cylinder piston packing. To check, extend the
G21 08/19/03 6-48

cylinder fully. Remove the line from the rod end

of the cylinder and apply pressure to the piston
end. If oil flows from the open fitting on the rod
end of the cylinder, the internal piston packing is
defective. Repair or replace the cylinder as
necessary.
Symptom
The conveyor shift will not operate.
Corrective Measures
1. Conveyor shift valve not connected to pressure

and return lines. Connect the quick couplers.
2. Conveyor shift retaining pin not removed.

Remove the retaining pin in the conveyor shift
frame. Reinsert the retaining pin to hold the
conveyor shift in position.
3. Screw shaft is siezed with debris. Clean and

lubricate the screw shaft prior to operation of the
conveyor shift. If necessary, place plastic or
burlap over the shaft to prevent debris from
collecting on the shaft. Make certain to remove
the plastic or burlap prior to operation of the
conveyor shift.
4. Defective drive motor. Remove the drive motor

and have it checked by a qualified hydraulic
technician. Repair or replace the motor if
defective.
G21 08/19/03 6-49

Pressure Oil
Auxiliary Systems II
Return Oil
Dump or Drain
To Pressure Tank
Wht Blk
Org Red
Grn Blu
Wht/Blk Blk/Wht
Left Right
Org/Blk Red/Blk
Trimmer Lift Cylinders
Solenoid Stack
Trimmer Shift Cylinder Valve Assembly
Mold Shift Cylinder
Diodes
On-off solenoid
valve with
flow control
From Lift Pump
Left Leg Pivot
Cylinder
Pressure Washer
To
Pressure
Tank 360343
360343
The oil supply for the solenoid controlled auxiliary When the switch is moved to the opposite position, the
circuits is supplied by the lift pump, through the lift opposite valve coil is energized, causing the valve
manifold (refer to the grade circuit, section 10, for lift spool to shift in the opposite direction. Oil flows
pump description). When the solenoid valve coils are through the opposite work port and check valve in the
de-energized, the solenoid valve spool is in the center double lock valve and out to the rod end of the
position, blocking the oil flow. When one of the corresponding cylinder. Since a check valve in the
switches is moved to an energized position, a valve double lock valve is blocking the return oil flow from
coil is energized, causing the valve spool to shift. Oil is the piston end of the cylinder back to the control valve,
then routed out through one of the work ports of the pressure begins to build between the rod end of the
valve into the double lock valve. The oil forces a check cylinder and the control valve. This pressure build up
valve off its’ seat as it passes through the double lock works against a shuttle piston in the lock valve, which
valve and then out to the piston end of the shifts, lifting the check valve on the opposite side off
corresponding cylinder. Since a check valve, in the its’ seat, thus allowing the oil from the piston end of the
double lock valve, is blocking the oil flow back to the cylinder to return through the control valve and back to
control valve from the rod end of the cylinder, pressure the pressure tank. Each circuit operates in the same
begins to build in line between the piston end of the manner.
cylinder and control valve. This pressure build up acts
against a shuttle piston in the double lock valve, which The purpose of the double lock valve is to keep the
shifts, lifting the check valve on the opposite side off corresponding cylinder from drifting.
its’ seat, thus allowing oil from the rod end of the
cylinder to return through the control valve and back to Symptom:
the pressure tank.
Cylinders will not extend or retract.
G21 08/19/03 6-50

1. Low lift pressure. Check the indicated pressure

on the lift circuit pressure gauge. Adjust the lift
pressure to 1600 psi (110 bar) if necessary,
following the instructions given in the
Maintenance chapter. If lift pressure is low, the
grade and steer circuits will also be affected.
Check Solenoid Coil for 5 Ohms

360536
5. Solenoid coil defective. Push in on the manual
override button on each end of the solenoid
valve. If the system responds, the coil is
defective. Replace the coil. A good coil will
register 5 ohms when an ohm meter is
Check for +12 volts on Solenoid Wires
connected to the terminals on the coil (wires
634 removed).
2. Solenoid coil not being energized when control
switch is activated. Remove the color coded 6. Solenoid valve defective. If pushing the manual
wires from the solenoid coil and switch them to override buttons will not activate the system,
another solenoid valve. Activate the control disconnect the hoses from the defective valve
switch, if solenoid energizes, refer to solenoid and connect them to a valve known to be good.
coil defective (step 5). If the solenoid coil is not If the system will not respond when connected to
energized, check for +12 volts at each of the a good solenoid, the cylinder is defective. Repair
solenoid coil wires when the switch is activated. or replace. To check the locking valve, remove
If +12 volts is not available, check for +12 volts the fittings from the ports. Remove the four
being supplied to the center terminal of the locking valve attaching screws. Install the
control switch. If +12 volts is available, removed fittings into the solenoid valve and
separately jump each of the solenoid wires to connect the hoses. Check the system operation.
the center terminal of the switch. If the solenoid If the system will operate, the locking valve is
energizes, the control switch is faulty and should defective. Repair or replace. If the system will
be repaired or replaced. not operate, the solenoid valve is defective and
must be repaired or replaced.
Note: Do not connect the color-coded wires to the
wire that jumps from coil to coil as this is a ground Symptom
wire. Touching them to ground when the control
switch is activated will cause the 20 amp circuit Cylinder will not hold position.
breaker under the control console to trip.
Corrective Measures
3. Ground is not being supplied to solenoid valve
coils. Check loop wire, that jumps from coil to 1. Locking valve not holding. Remove the lines
coil and is connected to the control console. from the defective valve and swap them with the
Make certain all connections are clean and tight. lines from an unaffected valve. If the cylinder
that was not holding position, now holds
4. Defective quick coupler. Inspect quick couplers position, the valve is defective and must be
by bypassing couplers with pipe couplings or repaired or replaced.
with a set of couplers known to be good.
2. Internal cylinder packing leaking. If swapping
the lines as previously described does not stop
G21 08/19/03 6-51

the cylinder from creeping, suspect the internal

cylinder piston packing. To check, extend the
cylinder fully. Remove the line from the rod end
of the cylinder and apply pressure to the piston
end. If oil flows from the open fitting on the rod
end of the cylinder, the internal piston packing is
defective. Repair or replace the cylinder as
necessary.
G21 08/19/03 6-52

13 Grade Hydraulic Diagnostics
Grade Hydraulic Circuits
Servo manifold with

servo valves
Left front grade cylinder
with locking valve
Right front grade cylinder

with locking valve
To pressure
return reservoir
Servo
lock
solenoid
Lift Pump Rear grade cylinder

17.5 gpm at 2150 rpm with locking valve
To Manual Set at 1600 psi
Stack Valves
Distribution
Manifold
To Solenoid
Stack Valves High pressure
lift filter
Pressure Oil
Return Oil
To track
Dump or Drain
tension circuit
To hydraulic
To pressure
sideplates, etc.
360331 return reservoir
360331
The oil flow for the lift circuit begins at the reservoir, The oil is routed from the pump through a non-bypass
where the oil is routed through the two 100 wire mesh 10 micron high pressure lift filter.
sump filters, with magnetic straps, into the suction port
of the pressure compensated lift circuit pump. A case The oil flow is routed from the high pressure lift filter to
drain line protects the case from extreme pressures by the servo lock solenoid. With the servo lock switch in
draining excess oil from the case back to the reservoir. the “on” position, the solenoid is energized to the
Oil flow from the lift circuit pump is 17 gpm (64.6 lpm) closed position, blocking the flow of oil into all servo
at 2100 rpm. valves. When the servo lock switch is placed in the
“off” position, the solenoid is de-energized to the open
The lift circuit and all circuits drawing an oil supply position, allowing oil to pass into all of the servo
from the lift pump are closed center systems. This valves. With the servo valve spool in the centered
means there is a standby pressure in the systems of position, the oil flow is stopped. All of the grade
1600 psi (110 bar), but no flow until a circuit is circuits on the operate the same hydraulically. The
activated. With no circuits activated, the pressure in explanation of one is the same for all.
the systems will build until a sensing device in the
pump senses the pressure is at 1600 psi (110 bar), When the servo valve receives an “up” signal from the
thus causing the pump to stop pumping. As soon as control system, the spool in the servo valve shifts,
the pressure in the system drops, the pump will begin directing the oil out through a port in the manifold to
to pump again, until the pressure returns to the preset the locking valve on the appropriate lift cylinder. The
pressure. oil forces the internal check valve off its’ seat (in the
locking valve) and flows into the piston (top) end of the
G21 08/19/03 6-53

lift cylinder, causing it to extend. The return oil from

the rod (bottom) end of the cylinder flows back to the
opposite port in the servo manifold unrestricted,
through the servo valve and back to the reservoir.
When the servo valve spool returns to neutral, the
check valve in the locking valve goes on its’ seat,
locking the oil in the piston (top) end of the cylinder,
holding it extended.
When the servo valve receives a “down” signal from

the control system, the servo valve spool is shifted in
the opposite direction, routing oil out a manifold port,
to the rod (bottom) end of the lift cylinder. Since the Locking Valve in Cylinder
637
check valve, in the locking valve, on the piston (top)
end of the cylinder is on its’ seat, the cylinder cannot
retract. Pressure begins to increase in the line
! WARNING! !
between the rod (bottom ) end of the cylinder and the BE CERTAIN TO COMPLETELY LOWER THE
servo valve. A small port in the locking valve directs MACHINE, OR REMOVE ALL WEIGHT FROM THE
this pressure increase to a small shuttle piston in the LEG, BEFORE REMOVING THE LOCKING
valve, which shifts, lifting the check valve off its’ seat. CARTRIDGE. IF THE CARTRIDGE IS REMOVED
This allows oil from the piston (top) end of the cylinder WITH THE MACHINE UP, HYDRAULIC OIL WILL BE
to return to the opposite servo manifold port, through EXPELLED RAPIDLY FROM THE CYLINDER AND
the servo valve and out to the reservoir. The purpose THE MACHINE WILL DROP. SEVERE INJURY CAN
of the locking valve is to keep the cylinder from drifting OCCUR IF CONTACT IS MADE WITH FLUID
down when the engine is running and the servo lock ESCAPING UNDER HIGH PRESSURE.
switch is “on”, or overnight when the engine is
stopped. Pressure is required to extend the cylinder 1. Faulty lift check valve. If the machine will raise,
(to lift the machine) and to retract it (because of but not lower, suspect that the shuttle piston in
locking valves). The grade servo valves are the 5 gpm the check valve is defective. Lower the machine
(16.4 lpm) models. The diagnostic procedures for one and stop the engine. Swap the suspected valve
grade hydraulic system is the same for all. with a valve that is operating properly. If the
fault moves to the opposite system, the valve is
Symptom defective and must be replaced.
One grade cylinder inoperative or slow to respond. 2. Inner and outer guide tube binding. Raise the
machine to the maximum and check for binding.
Corrective Measures Adjust the wear plates on the bottom of the legs
as instructed in the Maintenance chapter.
Isolate the fault; hydraulic versus electrical. If the Grease the inner guide tube.
system will not respond to the appropriate jog switch,
check the system operation by moving the override Symptom
lever on the top of the servo valve cover. If the system
will respond to the override lever, the fault is in the All grade circuits inoperative or slow to respond.
electrical system. Refer to Grade and Slope Electrical
Diagnostics for procedures to follow. If the system will Corrective Measures
not respond to the override lever, the fault is in the
hydraulic system. Proceed as follows: Isolate the fault, electrical versus hydraulic. If the
system will not respond to the appropriate jog switch,
check the system operation by moving the override
lever on the top of the servo valve cover. If the system
will respond to the override lever, the fault is in the
electrical system. Refer to Grade and Slope Electrical
Diagnostics for procedures to follow. If the system will
not respond to the override lever, the fault is in the
hydraulic system. Proceed as follows:
G21 08/19/03 6-54

1. Servo lock switch “on”. Place the switch in the decreased. A damaged pump will not hold
“off” position. pressure as engine rpm decreases. The
pressure will drop rapidly. Repair or replace the
2. Lift pressure lower than 1600 psi (110 bar). pump as necessary.
Adjust the lift pressure as necessary following
the procedures in the Maintenance chapter. 5. Excessive internal leakage past servo valve
spools, or auxiliary valve spools. Place the
3. Plugged high pressure lift circuit filter. If the servo lock switch in the “on” position. If the lift
indicator on the top of the high pressure filter is pressure does not increase, disconnect and cap
extended, it may be necessary to replace the the pressure line between the lift manifold and
filter. The filter is of the non-bypass type. If it the auxiliary valve bank. If the pressure
becomes completely clogged, it will not pass any increases, a high pressure internal leak exists
oil. inside one or more of the auxiliary valves. It is
recommended to replace the valve bank as a
unit. If the lift pressure increases when the
servo lock switch is placed in the “on” position,
suspect one or more of the servo valves. It may
be necessary to replace the servo valves one at
a time to check.
Note: It is possible that the amount of leakage in

any one valve is not sufficient to affect the lift
pressure, but the combination of two or more will
affect it. It may be necessary to replace more than
one valve.
6. Auxiliary hoses for hydraulic sideplates

connected together allowing hydraulic oil to
dump directly back to tank. Disconnect the
hoses at the quick couplers.
Symptom
Lift cylinder drifts up, or down, with the servo lock

switch “off”, the engine running and the control system
in the “standby” mode. Will hold position with the
servo lock switch in the “on” position, or the engine
stopped.
Engine Speed to Pressure Comparison (lift) Corrective Measures

638
This is a good indication that the servo valve pilot may

! CAUTION! ! need centering. Adjust the servo pilot centering screw
with a hex wrench as described in the Maintenance
CONTINUOUS EXPOSURE TO ENGINE NOISE CAN
chapter. If the servo valve will not remain centered, it
CAUSE HEARING INJURY. DO NOT OPERATE
may be necessary to replace the valve.
THE MACHINE WITHOUT HEARING PROTECTION.
Symptom
4. Defective lift pump. It is possible that the lift
pump may have failed, reducing the total flow to Gradual swales in grade.
the system. If all grade and steering circuits are
activated simultaneously, it could cause a Corrective Measures
pressure drop in the system, resulting in slow
response. Check the pump output with a flow A sticky servo valve can cause this type of symptom.
meter. A good indication of a defective pump is Sticky valve spools are caused by contaminated oil.
to compare system pressure with engine rpm. A Frequently, sticky valve spools can be freed by rapidly
good pump will hold pressure as engine rpm is moving the manual lever on the servo valve. This
G21 08/19/03 6-55

throws the valve spool rapidly from one extreme to the the opposite system, the valve is defective and
other and the particles, causing the spool to stick, tend must be replaced.
to wash out, thus freeing the spool. A sticky spool can
be detected on the control system display meter by 2. Internal cylinder piston packing leaking. If no oil
two methods: flows from the loosened line or the fault remains
on the same cylinder after swapping the locking
1. If the LED arrow overshoots when it approaches valve cartridge, the fault is in the grade cylinder.
center from an offset. Remove the cylinder and repair or replace it.
2. If the LED arrow tends to hang to one side of

center and won't re-center. This will tend to
happen when approaching center from either
side. It shows that a small amount of electrical
signal to the valve doesn’t have enough physical
power to overcome the resistance of the sticky
spool.
Note: The servo valve being out of adjustment

may also cause the LED arrow to hang to one side
of center during operation. The adjustment of the
servo valve usually does not affect the ability of
the system to hold grade during automatic
operation.
Other causes may be loose guideline, incorrect

tension on the sensor hub spring or the sensitivity is
set too low. Refer to the appropriate chapter for
adjustment procedures.
Symptom
Grade cylinder drifts down overnight and/or with the

engine running with the servo lock switch “on”.
Corrective Measures
! WARNING! !
BE CERTAIN TO COMPLETELY LOWER THE
MACHINE, OR REMOVE ALL WEIGHT FROM THE
LEG, BEFORE REMOVING THE LOCKING
CARTRIDGE. IF THE CARTRIDGE IS REMOVED
WITH THE MACHINE UP, HYDRAULIC OIL WILL BE
EXPELLED RAPIDLY FROM THE CYLINDER AND
THE MACHINE WILL DROP. SEVERE INJURY CAN
OCCUR IF CONTACT IS MADE WITH FLUID
ESCAPING UNDER HIGH PRESSURE.
1. Faulty lift check valve. If the machine slowly

drifts down overnight suspect that the shuttle
piston in the check valve is defective. This can
also occur when the servo lock is “on” while the
engine is in operation. Lower the machine to
remove all weight from the cylinder and stop the
engine. Swap the suspected valve with a valve
that is operating properly. If the fault moves to
G21 08/19/03 6-56

40 4 RF Jog Up A1 J1, J2 and J3 are connected Right Front Sensor Bulkhead
J3 <39
<38
<37
3
2
1
>
>
>
RF A/M Elev
RF Jog Down
J1 <
<
A2
A3 Sensor power +5
to the Pancon Controller
INSIDE Grade and Slope Electrical Circuits J1 <
A1
A2
Sensor power +5V
#1 Grade Signal
A
B
>
<36 > Grd < CONTROL < >
<35 <
B1 J2 <A1
BOX
Right Front S2X <
A3 Sensor Ground C
>
<34 B2 A2 B1 D
< < < >
<33 A3
<32 <
B3 Sensor ground <
B1
STATUS
<
B2 E
>
4 RR Jog Up C1 A B B3 F
<31 > < < ––– 10A ––– < >
<30
3
> RR A/M Elev C2 <
B2 See Miscellaneous POWER
C1 Sensor power +5V
<29
2
> RR Jog Down < B3 Circuit Electrical Drawing Grd
<
<28
1
> Grd <
C3 <
C1 Breaker 5
A1 J2
> <
C2 Spare
<27 <
D1 <
C2 1
A2
> <
C3 Sensor Ground A
>
<26
<
D2 < > Can + A3
> <
D1 B
<25 C3 2 B4 >
<24 <
D3 <
D1 3
> B1
> <
D2 #1 Steer Signal C
>
4 LF Jog Up E1 1 Grd B2 D3 D
<23 3 > < < > < > < >
<22 > LF A/M Elev E2 D2 Can + 4 2 B3 E1 E
2 < < > < > < >
<21 > LF Jog Down E3 D3 Can - 5 3 C1 E2
1 Grd < > < F
<20 > < E1 Can Shield > < >
<19 F1 < 4 C2 E3
< E2 < > <
<18
<
F2 < <
5 Can- C3
> <
F1
<17 E3 3
<16 <
F3 <
F1 2
Sensor 1 ––– D1
> <
F2 Feedback Signal
4 LR Jog Up G1 D2 F3
< 3 > < < ––– 1 > <
<15 > LR A/M Elev F2 Grd D3
Sensor 2 –––
2 G2 < G1
<14 > LR Jog Down < F3 > <
<13
1
> Grd <
G3 < Grd E1
> <
G2
<12 <
H1 E2
> <
G3
<11 H2 E3 H1
10
< 9 < 1 2 3 4 5 6 7 8 9 10 11 12
Terminal > <
< <
H3 Bar (TB) B A
––– 8A –––
F1
> <
H2 #2 Grade Signal
4 >
< 8 3 >
Run/Standby
<
J1
S2X Circuit F2
> <
H3
7 CW Slope
< 6 2 CCW Slope <
J2
Breaker F3
> <
J1 Grade Servo +
<
5 1 > Grd J3 J2 #2 Steer Signal A
< 4 > 4 > < < >
< 3 3 >
Clear <
K1
<
J3 Grade Servo - B
>
<
2 2
Next
Last <
K2
<
K1 Steer Servo + C
>
< 1 1 > Grd
K3 Left Front S2X K2 D
< > < < >
<
K3 Steer Servo -
STATUS
POWER
Shield
Grade Steer
1
Org 2
Grn 3 J3
Red 4
Blk 5
Wht 6
J2
CAN Minifast
Connectors
Left Front Grade Sensor #1 J2 <A1 Grd

A2
<
<
A3 Can +
B1
#1 Left Front <
B2 Grd Rear Sensor Bulkhead
<
Sensor Bulkhead <
B3 1
> A1 Sensor power +5V A A
C1 2 J1 < > <
A
<
A Sensor power +5V A1
> J1
<
C2 3
>
<
A2 Grade Signal B
> <
B
>
B B Grade Signal A2 < > A3 Sensor Ground C C
C
> <
C Sensor Ground A3
>
<
C3 Can - 4
>
<
B1 D
> <
D
> < > D1 5 < > <
D D B1 < > B2 E E
> < > D2 < > <
E E B2 < B3 F F
> < > D3 < > <
F
<
F B3
>
<
E1 Grd Rear S2X <
C1 Sensor power +5V A
>
>
Sensor power +5V C1
>
<
E2 <
C2 Slope Signal B
>
Feedback Sig. C2
>
<
E3 <
C3 Sensor Ground C
>
Sensor Grnd C3 <
STATUS
D1 D
#2 Left Front D1
>
<
F1 A
–––
B
8A ––– POWER
<
<
D2 Steer Signal E
>
>
> F2
Sensor Bulkhead Steer Signal D2 < S2X Circuit D3 F
D3
>
<
F3
Breaker Grd A1 J2
>
<
E1
>
A > A2 <
A E1 > E2
> < > Can + A3 <
B B E2 > E3
> < > B1 <
C C E3 > F1 F A
> < > Grd B2 <

E
D C
B
D D F1 > F2 Feedback Signal

> < > 1 B3 <
E E Feedback Signal F2 < > F3
> < > 2 C1 <
F
F
> < F3
G1
>
<
<
3 Grd C2
>
>
<
G1
G2
Slope Sensor
>
<
4 Can- C3
>
<
G2
> 5 D1 <
G3
1 Shield
Org
Grade Steer
G3 < > H1
> D2 < 2
H1
> Grd D3
>
<
H2 Spare J3 3 Red
Grade Signal H2 > H3 4 Grn
H3
> Grd E1
>
<
J1 Grade Servo + 5 Blk
> E2 < J2
Wht
Grade Servo + J1
> E3
>
<
J2 Spare A
>
6
Steer Signal J2
> B A F1
>
<
J3 Grade Servo - B
>
A Grade Servo - J3 ––– 8A ––– > K1 Steer Servo + C
< > F2 < >
B Steer Servo + K1 S2X Circuit F3
>
<
K2 D
< > >
C K2 Breaker >
<
K3 Steer Servo -
< >
<
D Steer Servo - K3
>
Rear Grade Sensor

Shield 1
Grade Steer
Org 2
Grn 3 J3
Red 4
Blk 5 Left Left Right Right Right Right 360456
Wht 6
J2
Front Front Front Front Rear Rear
Left Front Grade Sensor #2 Steer Grade Steer Grade Steer Grade
6-58
14 Grade and Slope Electrical Diagnostics The power supply and ground connections are routed
through the S2X sensor bulkhead and continue to the
The elevation control systems are responsible for bulkhead circuit board located remotely on the
maintaining the correct elevation on all sides of the machine frame. The circuit board distributes the
machine frame. Each elevation system consists of a common power supply to pin A in each of the two
sensor, a S2X controller, the Pancon Controller in the sensor bulkheads (grade and steer). The circuit board
control box and a servo valve. The left side of the also distributes the common ground connection to pin
machine is controlled by the stringline elevation C in each of the two sensor bulkheads (grade and
sensors and by the setup parameters determined by steer). When the sensor is connected to the
the operator. appropriate bulkhead, it receives +5.0 volt power from
pin A and a ground connection from pin C.
To set the parameters, the operator must depress the
CALIB (calibrate) switch on the main control box. The sensor has a wand attached to its' shaft, which is
Depressing and releasing the NEXT switch will select held against the guideline by spring tension. As the
the elevation mode on the main screen. The elevation machine frame moves up or down, in relation to the
mode is used to designate the type of sensor control guideline, the wand causes the sensor shaft to rotate.
the machine will be using for a job site. Depressing As the shaft rotates, a corrective signal is sent to the
and releasing the +/- switches will scroll through the corresponding S2X control loop. The sensor works
elevation mode settings available (left grade/right within a voltage range of 1.2 volts to 3.8 volts.
slope, Leica). When the appropriate mode is selected,
it will be necessary to restart the G21 controller to When the sensor wand mode (wand is mounted ahead
allow operation of the new parameter. of the sensor) in the Calibrate display, is selected as
"push" and the sensor wand is rotated upward, the
The slope control system is responsible for voltage signal to the S2X will decrease from 2.50 volts.
maintaining the correct cross slope elevation through The S2X will recognize a voltage decrease (with the
adjustment of the right front elevation leg. The slope "push" wand selection) as an up signal, causing the
system consists of a slope sensor and a control loop machine elevation to raise. As the sensor wand is
on an S2X controller which is networked to the other rotated downward, the voltage signal to the S2X will
S2X controllers on the machine, including the Pancon increase (from 2.50 volts), indicating that the machine
Controller in the control box. elevation must go down.
Elevation or Dual Elevation Operation When the sensor wand mode (wand is mounted
behind the sensor) in the Calibrate display, is selected
The description of all elevation systems is identical. as "pull" and the sensor wand is rotated upward, the
The main control module must be in the "run" mode to voltage signal to the S2X will increase from 2.50 volts.
operate the elevation control circuit in the automatic The S2X will recognize a voltage increase (with the
mode. From the individual S2X controllers, common "pull" wand selection) as a up signal, causing the
power (+5.0 VDC) is supplied to the primary sensor machine elevation to raise. As the sensor wand is
bulkhead (#1) from pin A on the J1 connector and to rotated downward, the voltage signal to the S2X will
the secondary sensor bulkhead (#2) from pin C1 on decrease (from 2.50 volts), indicating that the machine
the J1 connector. A common ground is supplied to the must go down.
primary sensor bulkhead (#1) from pin A3 on the J1
connector and to the secondary sensor bulkhead from With the sensor wand centered between the roll pin
pin C3 on the J1 connector. stops, a 2.5 volt signal (center) is returned to the S2X
through pin "B" in the sensor cord. It is routed to the
3600 G21 Frame Cable Connections bulkhead circuit board where the individual sensor
S2X Controller
Circuit Board
To Steer
WHT A A 6 WHT WHT A A +5 Volts
signals must remain separated. The following color
BLK B B BLK B B Pot Input Signal
Sensor RED C JC 5 BLK
GRN
ORG
RED
C C Ground code indicates the wire color and type of signal for
D 2D 4 GRN
D D Grade Input Signal
E
F
E
F 3 RED SHD
E
F
E
F
Steer Input Signal
each wire exiting the bulkhead circuit board.
2 ORG
WHT A A
To Grade BLK 1 SHD
Sensor RED
B
C
B
JC White wire ............................. +5.0 volts supply
D 3D
E E
F F
Black wire ........................ Feedback pot signal
Orange wire ....................... Ground connection
360457
360457.eps
Red wire ..................... Elevation sensor signal
G21 10/21/03
6-59
Green wire ........................ Steer sensor signal indicating that the right side of the machine must go
up. As the sensor is rotated counterclockwise, the
Shield wire ................................. Frame ground voltage signal to the S2X will increase (from 2.5 volts),
As the signal from the elevation sensor is returned to indicating that the right side of the machine must go
the corresponding S2X controller, it is passed to the down.
CAN network connection and routed to the Pancon
controller in the main control box. The Pancon As the signal from the slope sensor is returned to the
controller receives the elevation sensor signal and rear S2X controller, it is passed to the CAN network
processes the information. After processing is connection and routed to the Pancon controller in the
completed, the Pancon controller returns the main control box. The Pancon controller receives the
appropriate response signal to the S2X controller slope sensor signal and processes the information.
through the CAN network connection. The S2X After processing is completed, the Pancon controller
controller will then send a variable voltage signal to the returns the appropriate response signal to the right
corresponding servo valve, causing the elevation front S2X controller through the CAN network
control cylinder to extend or retract. connection. The S2X controller will then send a
variable voltage signal to the corresponding servo
With the “off stringline” feature, the normal working valve, causing the slope control cylinder to extend or
range of the elevation sensor (1.2 volts to 3.8 volts) is retract.
reduced to approximately 1.5 volts to 3.5 volts for
operation purposes. If the sensor output voltage The slope setpoint switches are connected to the
should read between 1.2 volts to 1.5 volts, or between slope control loop to provide a means of adjusting the
3.5 volts to 3.8 volts, it will cause the "off stringline" cross slope of the machine frame. With the slope
feature to activate. When the "off stringline" feature is setting at "0.0%" of slope, a signal is sent to the slope
activated, the drive to the corresponding servo valve is control loop, indicating that the machine frame must be
shut down and the servo valve spool returns to center, level. The control loop receives a signal from the
holding the machine elevation in the position it was in slope sensor indicating the present position of the
when the feature was activated. The system can still machine frame. If the signal from the slope sensor
be operated with the jog switches or by returning the does not match the slope setting signal, the
sensor wand to a centered position. appropriate S2X control loop sends a corrective signal
to the appropriate servo valve, causing the slope
Slope Operation controlled side of the machine to raise or lower until
the slope sensor signal matches the slope setting
A single slope sensor is operated on the GT-3600. signal in the control loop. The machine frame should
The slope sensor is mounted on the machine frame be level, from side to side, at a 0.0% slope setting. If
and will control the right front elevation. The main the slope setting is adjusted to 2% slope, a signal is
control module must be in the "run" mode to operate sent to the slope control loop indicating a change is
the slope control circuit in the automatic mode. From required. The control loop receives a signal from the
the rear S2X controller, common power (+5 volts) is slope sensor and if it does not match the slope setting
supplied to the sensor from pin C1 on the J1 signal, the S2X control loop sends a signal to the
connector. A common ground is supplied to the servo valve to raise or lower the slope side of the
sensors from pin C3 on the J1 connector. The power machine until the two signals match. The frame
supply and ground connections are routed through the should be at the desired 2% slope after the correction
sensor bulkhead on the rear access door and continue is completed.
to the slope sensor. The shaft in the center of the
slope sensor is held stationary by a pendulum weight. When an elevation or slope system is operating in the
As the elevation controlled side of the machine moves automatic mode, the G21 system measures the
up or down, the slope sensor rotates as the machine amount and direction of the signal from the sensor and
tilts. As the sensor rotates, a corrective signal is sent conveys a corrective signal to the appropriate servo
to the rear S2X controller. The sensor works on a valve. The amount of servo valve spool movement is
voltage range of 0.75 volts to 4.25 volts. With the in proportion to the amount of corrective signal. The
sensor in the center position (machine frame level), a sensitivity setting on the control loop affects the input
2.5 volt signal (center) is sent to the rear S2X through signal from the sensor and will change the amount of
pin "B" in the slope sensor cord. As the sensor is servo valve spool movement in relation to the amount
rotated clockwise (viewed from the rear), the voltage of sensor movement. For example, with the sensitivity
signal to the S2X will decrease (from 2.5 volts), adjustment set at number 5, it may be necessary to
move the elevation sensor wand 2 inches (50 mm) in
G21 10/21/03
6-60
either direction, or rotate the slope sensor sensor and the sensitivity setting on the control loop.
approximately 6° (degrees), to get the maximum When the spool shifts, pressure oil is either routed to
amount of servo valve spool movement. However, the piston (top) end of the elevation cylinder causing it
with the sensitivity adjustment set at number 15, it may to extend, or to the rod (bottom) end of the cylinder
be necessary to only move the sensor wand 1 inch (25 causing it to retract. Return oil from the opposite side
mm) in either direction, or rotate the slope sensor of the cylinder flows back through the servo valve to
approximately 3° (degrees), to get the maximum the reservoir. The more the valve spool is shifted, the
amount of servo valve spool movement. The more the faster the machine will raise or lower.
sensor moves off center, the faster the system will
respond. The sensitivity has no affect on the manual When the necessary correction has been made, the
operation of the system. sensor signal is electrically centered, or "nulled" and a
signal is sent to the control loop indicating the
correction has been made. The control loop signal to
the servo valve is stopped, which causes the spool to
shift to the center position. This blocks the flow of oil
to either end of the elevation cylinder, causing the
machine to maintain its' elevation.
LF BPwr SPwr ElWnd ElVlv

12.23V 4.95V 2.50V 0.00V
002-2850
Elevation test display
002-2850
When the test switch is depressed the main screen will
indicate the test mode has been entered and
depressing the LAST or NEXT switches will scroll
through the test displays for each system. The main
screen will change to reflect the voltage from the
corresponding sensors. As the elevation sensor wand
Corrective signal and null indicators is moved, or the slope sensor is rotated, the reading
002-2075
The LED indicator lights on the control loop will on the main screen will vary around a centered voltage
indicate the amount and direction of the signal from reading of "2.50V". The following table indicates the
the sensor. When the lights are centered, it indicates normal voltage range of each circuit displayed in the
that no correction is necessary to the system. When test mode.
the LED lights form an arrow shape, it indicates a
correction is required and it will remain off center until Circuit ...................................... Voltage Range
the necessary correction is made. The larger the Battery Power (BPwr) ..................... 9.0 to 16.0
arrow appears, the faster the system will respond. If
the necessary correction is not made, the machine will Sensor Power (SPwr) ................... 4.75 to 5.25
continue to react until the cylinder is completely
LED Power (LEDPwr) ................... 4.75 to 5.25
extended or retracted or until the "off stringline" feature
is activated. When a jog switch is used for manual Elevation Sensor(ElWnd) ................. 1.2 to 3.8
control, the servo valve spool shifts the full amount
and remains there until the switch is released. The jog Steer Sensor (StrWnd) ..................... 1.2 to 3.8
switches will not affect the LED indicator. From the Slope sensor output ...................... 0.75 to 4.25
control loop, the corrective signal is sent out to the
corresponding servo valve. Feedback Pot (FdbkPot) ................... 1.0 to 4.0
When the servo valve receives a corrective signal from Elevation Valve (ElVlv) ............... 0.0 to +/-4.10
the control loop, the spool in the servo valve will shift. Steer Valve (StrVlv) .................... 0.0 to +/-4.10
The amount of servo valve spool movement will
depend on the amount of corrective signal from the
G21 10/21/03
6-61
If the sensor is not connected, the sensor reading will Determine which sensor is affected by the location
show approximately "0.00V". The arrow on the indicated in the display message: Left Front, Right
corresponding display will also move to center when Front or Rear.
the sensor is disconnected. To exit the test mode,
depress the test switch. The system will return to the
normal operating display.
Symptom:
360352
Elevation mode display
Left Front Grade Wand 360352
OFF STRINGLINE 1. The elevation mode is not selected properly for
the current sensor setup of the machine.
360362 Depress the CALIB (calibrate) switch. Depress
Off stringline display the NEXT/LAST switches until the elevation
360362 mode is selected on the main screen. Select the
"Off Stringline" is displayed on the main screen. appropriate mode for the current setup
configuration of the sensors (Left Grade/Right
Corrective Measures: Slope, Leica).
Determine which sensor is affected by the location 2. Sensor not connected or connected to wrong
indicated in the display message: Left Front, Right bulkhead. Connect the sensor to the
Front or Rear. appropriate bulkhead plug.
This indicates that the elevation sensor wand is off the 3. Defective sensor. Disconnect the cord from the
stringline. Place the wand under the stringline. If the sensor and connect it to a different sensor. If
wand is within the 1.5 to 3.5 volt operating range, the the system will now operate, replace the
sensor will operate normally. When the sensor voltage defective sensor.
reading is between 1.2 to 1.5 volts or 3.5 to 3.8 volts,
the off stringline message is displayed and the G21 4. Defective sensor cord. If the system will not
controller will not send a servo valve drive signal to the work after swapping the sensor, suspect the
appropriate servo valve. cord between the sensor and the bulkhead plug.
Swap the cord between the sensor and the
Symptom: bulkhead plug with the cord from another
sensor. If the system will now work, repair or
replace the cord.
Right Front Elev. Wand

SHORT TO 0 V
002-2889
Front Slope Sensor

SHORT TO 0 V
002-2890
Elevation sensor fault
002-2889 & 002-2890
"Elevation Wand - Short to 0 V" or "Slope Sensor -
Short to 0 V" is displayed on the main screen.
Swap frame cords
360366
G21 10/21/03
6-62
If the elevation system will not work it will be 6. Defective wiring between the bulkhead plugs at
necessary to swap the frame cord with one of the S2X and the J1/J2 connectors on the S2X.
the other two frame cords at the left front or rear Disconnect the J1 and J2 connectors from the
S2X controllers. If the diagnostic display suspect S2X. Remove the S2X from the access
switches locations, the frame cord or the door and swap with one known to be good. If
bulkhead circuit board is defective. Make the fault remains in the same location, repair or
certain sensors remain connected to the replace the wiring. If the fault changes location,
bulkhead circuit board. replace the S2X.
If the fault remains with the same S2X, the CAN

network wiring connection between the J2
connector and the CAN bulkhead may be
defective due to corrosion. Disconnect the J2
and J1 connectors and spray with an electrical
cleaner. Do not use an oil based lubricant to
clean the connections. Reconnect to the S2X.
If the fault remains, replace the wiring harness at
the S2X.
Symptom:
Left Front Sensor Power

VALUE TOO LOW
Swap bulkhead circuit boards
360212 002-2891
Remove the terminal connections on the rear of
Sensor power failure
the suspect bulkhead circuit board and swap 002-2891
with one known to be good. Reconnect the "Sensor Power - Value too low" is displayed on the
sensors. If the diagnostic display indicates the main screen.
fault remained in the original location, the cord is
defective and must be replaced. If the Corrective Measures:
diagnostic display indicates the fault switched to
a different location, replace the bulkhead circuit If the sensor power supply voltage drops below 4.75
board. volts, the message "Sensor Power - Value too low" will
appear on the main screen. This indicates a power
short to ground which may occur in any of the
components supplied with sensor power from an
individual S2X. It is first necessary to narrow the area
in which the power short is located.
Determine which sensors are affected by the location

indicated in the display message: Left Front, Right
Front or Rear.
J1 and J2 connectors
360369
G21 10/21/03
6-63
Reconnect one of the sensor cords to the

bulkhead at the S2X controller. If “value too low”
is indicated, isolate the frame cord between the
S2X and the bulkheads shown in the previous
photo by disconnecting the sensor cords at the
exterior bulkhead. If “value too low” remains on
the screen, replace the sensor cord between the
exterior bulkheads and the S2X controller.
Reconnect any remaining sensor cords at the
S2X controller and check in the same manner.
If “value too low” is not indicated, the sensor

cord or the sensor may be defective. Reconnect
the sensor cord to the bulkhead and disconnect
the sensor cord from the sensor. If “value too
low” is indicated, replace the sensor cord. If
“value too low is not indicated, replace the
Swap sensor cords sensor. Reconnect any remaining sensor cords
360366
1. If the system does not operate, there may be at the bulkheads and check in the same manner.
defective wiring between the sensor bulkhead
on the front access door and the sensors on the Symptom:
machine. The sensors affected on each leg
include the steer sensor, elevation sensor and
linear feedback pot in the steering cylinder. The
slope sensor would be included in the diagnostic Rear Elev. Wand
for the rear S2X. VALUE TO HIGH
To check, disconnect each of the cords labeled 360635
for sensors from the bulkhead at the appropriate
Elevation sensor failure
S2X controller. If the fault goes away, refer to 360635
the following paragraph. If “value too low” "Elevation Wand - Value too High" is displayed on the
remains, the wiring between the S2X controller main screen in the run mode.
and the bulkhead is defective or; the S2X
controller is defective. Remove the J1 Corrective Measures:
connector (larger connector) from the S2X and
check again. If the fault remains, the S2X must If the sensor signal voltage increases above 3.80 volts,
be replaced. the message "Elevation Wand - Value too High" will
appear on the main screen. This indicates a power
short between the sensor power supply and the sensor
signal wiring has occurred. It is first necessary to
narrow the area in which the power short is located.

Front or Rear.
1. Defective sensor cord or sensor. Disconnect the

suspect sensor cord from the bulkhead. If the
main screen indicates "Elevation wand - Short to
0 V" but does not indicate "Elevation wand -
Value too High", then the value too high short is
located in the sensor cord or in a sensor. Swap
the cord with one known to be good and recheck
the main screen after the cord is connected. If
360023 the fault does not exist, replace the cord. If a
good cord is installed and the main screen
G21 10/21/03
6-64
indicates "Elevation wand - Value too High", directions from center. If the machine does not
replace the sensor. respond to the override lever, the fault is in the
hydraulic system. Refer to Grade Hydraulic
2. Defective sensor frame cord. If the main screen Diagnostics for procedures to follow. Depress one of
continues to indicate "Elevation wand - Value the jog switches on the control loop of the affected
too High" after the sensor cord has been system. If the message “Grade Servo Value Out of
disconnected, the sensor frame cord may be Range” appears on the main screen, it is an indication
defective. Swap the suspect sensor frame cord of a bad coil on the servo valve, defective wiring
with one of the other frame cords known to be between the corresponding S2X and the valve, or a
good. If the system now operates correctly, defective S2X controller. Proceed as follows.
repair or replace the sensor frame cord.
1. Bad in the servo valve. Disconnect the leads
3. Defective S2X. Turn the ignition key off. from the primary coil on the suspect servo valve
Disconnect the appropriate J1 and J2 and connect it to the unused secondary leads on
connectors from the S2X. Swap the suspect the same servo valve. Depress the jog switch
S2X with one of the units known to be good. for the suspected system and observe the
Reconnect the J1 and J2 connectors. If “value message on the main screen. If the system
too high” is inidicated in a different location, operates and the message “Grade Servo Value
replace the S2X. Out of Range” does not appear, repair or
replace the servo valve.
network wiring connection between the J2 Note: The leads for elevation control connected to
connector and the CAN bulkhead may be the primary coil may be connected to the
defective due to corrosion. Disconnect the J2 secondary coil to continue operation.
cleaner. Do not use an oil based lubricant to The valve coil can be checked with an ohm
clean the connections. Reconnect to the S2X. meter. Check at the valve terminals (with the
If the fault remains, replace the wiring harness at leads disconnected) for 15.5 ohms on the
the S2X. primary coil and 19.5 ohms on the secondary
coil. To determine which coil is which, look at
4. If “Value too High“ remains in the same location, the point where the wires exit the valve (manual
repair or replace the wiring between the J1 override lever up). The wires on the right are for
connector and the sensor bulkhead at the S2X. the primary coil and the wires on the left are for
the secondary coil. If the resistance readings
Symptom: are incorrect, repair or replace the servo valve.
2. Defective wiring between the S2X controller and

the connectors on the servo valve. Disconnect
LF Grade Servo the servo cord from the bulkhead at the
VALUE OUT OF RANGE corresponding S2X and swap it with one of the
other servo cords known to be good from
360363 another S2X. Depress the jog switch for the
defective system. If one of the elevation legs
Elevation servo fault
360363 will operate with the good cord, repair or replace
"Grade Servo Value Out of Range" is indicated on the the defective servo cord.
main screen in the run mode.
If the servo fault remains in the same location,
Corrective Measures: the wiring between the J1 connector and the
bulkhead may be checked for continuity as
Determine which servo is affected by the location follows:
Front or Rear. J1--J1 ..............................servo bulkhead pin A
Isolate the fault, hydraulic versus electrical. The J1-J3 ............................... servo bulkhead pin B
elevation servos are equipped with a manual override If continuity does not exist, repair or replace the
lever on the valve cover. Move the override lever both wiring as necessary.
G21 10/21/03
6-65
3. Defective S2X controller. Turn the ignition key The CAN cords may also be checked for continuity.
off. Disconnect the J1 and J2 connectors from Check each wire in the CAN cord using an ohm meter.
the suspect S2X controller. Swap the controller If any wire does not indicate continuity, replace the
with one of the other S2X controllers and cord.
reconnect the J1 and J2 connectors. Restart the
G21 controller. Depress the elevation jog Symptom:
switches for all three legs. If the main screen
indicates that the servo fault is in a different No automatic control.
location than previously noted, replace the S2X
controller.
Determine if the fault affects both the manual control
as well as the automatic control by checking the
operation of the system with the jog switches. If the
system will not respond with the jog switches, refer to
the preceding symptom. If the system will respond in
manual, but not in automatic, proceed as follows.
the S2X.
Symptom:
Rear Slave
NO RESPONSE
360361
S2X controller failure
360361
"Slave - No Response" is indicated on the main
screen.
Manual control loop mode
This display indicates that the corresponding S2X 360436
controller is not communicating with the Pancon 1. Control loop in the “manual” mode. Place the
controller (main control box) or with any of the other loop in the “auto” mode by depressing the A/M
S2X controllers on the front access door. switch.
To check, swap the suspect S2X controller with one

that is known to be good. If the fault switches to a
different location corresponding with the suspect S2X
controller, replace the S2X. Make certain that the red
Stdby LGrd RSlope= 0.00
power lamp is illuminated on the S2X controller to Neu Coord Sensor 1
inidicate that power and ground is available for
operation. 360350
Standby mode
360350
If “No Response” remains in the same location after
2. Main screen indicates “Stdby”. Depress the run/
swapping the S2X controllers, the CAN network
standby switch to indicate the “run” mode.
connection may be be defective. Swap the short CAN
cord between the S2X bulkhead and the CAN minifast Symptom:
connector to one of the other S2X cotrollers. If the “No
Response” screen indicates a different location, The main screen or one of the individual LED meter
replace the cord. displays is fogged under the screen.
G21 10/21/03
6-66
Corrective Measures: Although this does not hinder the operation of the G21
system, the main screen should be replaced to prevent
moisture from entering the control box. To replace the
display, open the control box and remove the locking
connector from the rear of the main screen. Loosen
and remove the four screws from the front of the
display. It may be necessary to pry the display from
the control box enclosure to loosen the gasket seals.
Thoroughly clean the area around the opening to
remove all foreign material and gasket. Place two
gasket seals around the new main screen unit and
insert the unit in the proper orientation as compared to
the previous display. Insert and tighten each of the
screws evenly. Do not over tighten the screws as this
will cause the display frame to distort and improper
sealing of the gasket material may occur. Reattach
the locking connector.
Symptom:
LED display replacement
002-2548
Although this does not hinder the operation of the G21 One or all of the switches in a switch pack does not
system, the display should be replaced to prevent operate.
display, open the control box and remove the locking Corrective Measures:
connector from the rear of the appropriate display.
Loosen and remove the four screws from the corners
of the display. It may be necessary to pry the display
from the control box enclosure to break the silicone Grade Switch, AllJog
sealer. Thoroughly clean the area around the opening LF ELEV JOG DOWN Jg DN
to remove all foreign material and excess silicone
sealant. Place a small bead of silicone sealant around 360354
the new LED display unit and insert the unit in the Service mode for testing switches
proper orientation as compared to the existing 360354
displays. Insert and tighten each of the screws Depress the service switch under the service panel.
securely. Reattach the locking connector. Depress the NEXT/LAST switches to scroll to the
appropriate switch test mode. Depress the defective
switches. If a switch is activated and no function is
displayed, the switch may be defective. Open the
control panel and check for any pinched wiring to the
switch pack. If no pinched wiring is visible, disconnect
the suspect switches and swap connectors with
another switch pack known to be good. If the switches
will not operate, the switch pack is defective and must
be replaced.
Main screen replacement

002-2545
G21 10/21/03
6-67
Switch pack replacement

002-2546
To replace the switch pack, open the control box and
disconnect the wiring to the defective switch pack.
Using a flat blade screw driver, place the screwdriver
in the hole behind the switch pack to be removed.
Support the face of the control box cover around the
switch pack and strike the screw driver forcefully to
dislodge the switch pack from the control panel. Peel
the protective backing from the rear of the new switch
pack. Place the switch pack in the proper orientation
and press the switch pack firmly into position.
Connect the wiring to the switch pack and close the
control box. Secure the control panel. Attach the
appropriate switch pack decal to the front of the new
switches.
G21 10/21/03
6-68
15 Steer Hydraulic Diagnostics
Steer Hydraulic Circuits
Left front steer cylinder
Servo manifold with

servo valves
Right front steer cylinder
To pressure
return reservoir
Lift Pump
21 gpm at 2150 rpm
To Manual Set at 1800 psi
Stack Valves
Distribution Rear steer cylinder
Manifold
To Solenoid
Stack Valvesv High pressure
lift filter
Pressure Oil
Return Oil
To track
Dump or Drain
tension circuit
To hydraulic
To pressure
360333 sideplates, etc.
return reservoir
The steering servos draw their oil supply from the main steering cylinder to be reversed, thus turning the front
lift pump. Each track has its’ own servo valve and of the left front track to the right.
steer cylinder for turning left and right. The following
description is for the left front steering hydraulic The following description is for the right front and rear
system. track steering hydraulic system.
The following description of the steering system is with The following description of the steering system is with
the forward/reverse steer switch in the “forward” the forward/reverse steer switch in the “forward”
position. When the servo valve receives a left turn position. When the servo valve receives a left turn
signal from the DC2, the spool in the servo valve will signal from the DC2, the spool in the servo valve will
shift. Oil is routed through the servo valve and out a shift. Oil is routed through the servo valve and out a
port in the manifold to the piston (butt) end of cylinder port in the manifold to the rod end of cylinder causing it
causing it to extend. This will cause the front of the to retract. This will cause the front of the track to turn
track to turn to the left. Oil from the opposite end of to the left. Oil from the opposite end of the cylinder is
the cylinder is routed back through the opposite port in routed back through the opposite port in the manifold
the manifold and back through the same servo valve to and back through the same servo valve to the
the reservoir. reservoir.
When the servo valve receives a right turn signal from When the servo valve receives a right turn signal from
the DC2, the spool in the servo valve will shift in the the DC2, the spool in the servo valve will shift in the
opposite direction. This will cause the oil flow to the opposite direction. This will cause the oil flow to the
G21 10/21/03
6-69
steering cylinder to be reversed, thus turning the front the internal packing in the cylinder is defective.
of the track to the right. Replace or repair the cylinder.
With the forward/reverse steer switch in the “reverse” Note: Be certain that the cylinder being checked
position, the signal from the DC2 to the servo valve is is completely extended before removing the line
reversed. This causes the servo valve spool to shift in from the rod end.
the opposite direction than when in “forward”. When a
left turn signal is received, the spool will shift and oil
will be routed to the steering cylinder, causing the rear
of the corresponding track to turn left.
Each of the tracks follow the sensor in the same

manner (see Steering Electrical Diagnostics). When
the track turns left, or right, an electrical signal is sent
from the smart cylinder on the leg to the S2X indicating
how far the track turns. When the position of the
feedback pot matches the position of the sensor, the
S2X receives a center signal and the servo valve spool
will return to center, causing the track to hold its’
position until another correction is called for.
Symptom
Track Stuck in Loose Material
Steering cylinder inoperative or slow to respond. 663
Corrective Measures
! WARNING! !
Isolate the fault; hydraulic versus electrical. If the CONTACT WITH MOVING TRACKS CAN CAUSE
system will not respond to the corresponding control SERIOUS INJURY. BE CERTAIN THAT NO ONE IS
loop “jog” switch, check the system operation by NEAR THE TRACK BEFORE MOVING IT. KEEP
moving the override lever both directions from center HANDS, FEET AND LOOSE CLOTHING AWAY
on the corresponding servo valve. If the system will FROM MOVING PARTS TO PREVENT SEVERE
respond when moving the override lever, the fault is in INJURY.
the corresponding electrical system. Refer to Steering
Electrical Diagnostics. If the system will not respond 4. Track in a bind. If the track is in loose material,
when moving the override lever, the fault is in the or against an obstruction, it may stop it from
hydraulic system. The possible hydraulic faults are as turning. Move the machine forward or backward
follows: to get the track out of the bind.
1. Servo lock switch in the “on” position. Place the Symptom

switch in the “off” position. If the servo lock
switch is in the “on” position, all steering and Steering cylinder drifts left or right with the engine
grade circuits will be inoperative. running and the main control module in the “standby”
mode or the corresponding control loop in the
2. Low lift pressure. Refer to Grade Hydraulic “manual” mode.
Diagnostics for low lift pressure diagnostic
procedures. Check under the symptom; all Corrective Measures
grade circuits inoperative or slow to respond.
1. This is a good indication that the pilot valve on
3. Internal piston packing leaking in the steering the servo valve needs to be centered. Adjust
cylinder. Extend the appropriate cylinder the the pilot valve as described in the Maintenance
maximum amount with the corresponding jog chapter.
switch. Stop the engine and remove the line
from the rod end of the steering cylinder and cap 2. The servo valve main spool is sticking slightly off
it. Start the engine and apply pressure to the center. To check, swap the servo valve with a
piston (butt) end of the cylinder. If oil flows from valve that is not drifting. If the fault is corrected,
the open fitting on the rod end of the cylinder, the servo valve should be replaced.
G21 10/21/03
6-70
Note: It is normally easier to swap the output

hoses on the rear of the servo manifold from one
servo to the other, than it is to swap the servo
valves. If the hoses are swapped, it will also be
necessary to swap the electrical connectors on the
top of the corresponding servo valves. Be certain
to reconnect the hoses and the electrical
connectors to their original positions after the
testing is complete.
G21 10/21/03
6-71
J1, J2 and J3 are connected
40 A1 J2 <A1 Right Front Sensor Bulkhead
J3 <39
<38
<37
J1 <
<
A2
A3 +5V
to the Pancon Controller
47Ω
<
<
A2
A3
See
Miscellaneous
B
Circuit
A
––– 10A ––– Steer Electrical Circuits J1 <
A1
A2
Sensor power +5V
#1 Grade Signal
A
B
> <
A
B
A
B
>
1 Electrical
<36
<35 4 RF Jog Right
<
B1 1 <
B1
Drawing Breaker 5 Right Front S2X <
A3 Sensor Ground C
> <
C C
>
> < < >
<34 3
2
> RF A/M Steer B2 2 2 <
B2 B1 D
<
D D
>
RF Jog Left < B3 < > < >
<33
<32 1
>
> Grd <
B3 Grd 3 47Ω < STATUS
<
B2 E
>
E E
3 CW C1 < >
<31 <
C1 Steer Sig. 4 1000 Ω
<
C2 1 POWER <
B3 F
> <
F F
>
<30
<29 <
C2 Remote Flag 5 <
C3
>
2 B4 <
C1 Sensor power +5V
<28 <
C3
6 Steer <
D1 3
> Grd A1 J2
> <
C2 Spare
<27 4 RR Jog Right D1 Rem. Steer Sig. < > A2 C3 Sensor Ground A
3 > < 7 control knob D2 Can + 4 > < >
<26
2 > RR A/M Steer D2 Rem. Travel Sig. < > Can + A3 D1 B
<25
1 > RR Jog Left <
D3 8 <
D3 Can - 5
> B1
> <
D2 #1 Steer Signal C
>
<24 > Grd < > < >
<23 E1 9 <
E1 Can Shield 1 Grd B2 D3 D
< E2 3 < > < >
<22
<
E2 10 < Sensor 1 ––– <
2 B3
> <
E1 E
<21 E3 2 >
<20 <
E3 11 <
F1
––– 1 <
3 C1
> <
E2 F
>
4
<19 > LF Jog Right F1 12 < Sensor 2 ––– 4 C2 E3
<18
3
2 > LF A/M Steer
<
F2 <
F2 <
<
5 Can- C3
>
>
<
F1 Smart
<17 > LF Jog Left < Terminal F3 <
<16
1 > Grd <
F3 < D1
> <
F2 Feedback Signal Steer
< <
G1 Bar (TB) D2
> <
F3
<15 G2 Grd D3 G1 Cylinder
<14 < > <
<13 <
G3 A
>
Grd E1
> <
G2
<12 <
H1 B B1 E2
> <
G3
<11
10 H2 C
> E3 H1
< 9 < > <
H3 > B A F1 H2 #2 Grade Signal
< < D ––– 8A ––– > <
4 >
< 8 3 >
Run/Standby
<
J1
E
>
S2X Circuit F2
> <
H3
7 CW Slope
< 6 2 CCW Slope <
J2
F
> Breaker F3
> <
J1 Grade Servo +
<
5 1 > Grd J3 > J2 #2 Steer Signal A
< 4 > 4 > < < >
< 3 3 >
Clear <
K1
<
J3 Grade Servo - B
>
<
2 2
Next
<
K2
<
K1 Steer Servo + C
>
< 1 1 >
Last
Grd
K3 10K ohm K2 D
< > < < >
INSIDE CONTROL BOX resistor <
K3 Steer Servo -
Remote steer
Shield Left Front S2X control knob
Grade Steer
1
Org 2 47Ω
CAN Minifast
Grn 3 J3 STATUS
1 Connectors
Red 4
Blk 5 J2
Front Steer POWER
2
47Ω
Wht 6 CW 3 A
Sensor 1 1000 Ω B
>
>
Remote travel C
A
> D
> Rear Sensor Bulkhead
B
>
variable control knob >
C
> 1
E
> J1 <
A1 Sensor power +5V A
> <
A
D
>
F <
A2 Grade Signal B
> <
B
E
> A3 Sensor Ground C C
2 < > <
> B1 D
F 47Ω D
> CW
< > <
3 B2 E E
Smart 1000 Ω <
<
B3 F
>
>
<
<
F
#1 Left Front Steer Cylinder Rear S2X <
C1 Sensor power +5V A
>
J2 <A1 Grd <
C2 Slope Signal B
>
Sensor Bulkhead <
A2
<
C3 Sensor Ground C
>
A A Sensor power +5V A1 <
A3 Can + STATUS
<
D1 D
>
< > J1 B1
B
>
B Grade Signal A2
> < POWER
<
D2 Steer Signal E
>
C
> <
C Sensor Ground A3 <
B2 Grd Grd A1 J2 <
D3 F
>
> < > B3 1 > E1
D D B1 < > A2 <
> < > C1 2 > E2
E B2 >
E
> < > <
C2 3 Can + A3
>
<
E3
F F B3 < > B1 <
> < > C3 Can - 4 > F1
Sensor power +5V C1
> <
D1 5
> Grd B2 < Shield
Feedback Sig. C2 > F2 Feedback Signal 1
Org
Grade Steer
< > 1 B3 <
> D2 < > F3 2
Sensor Grnd C3 < 2 C1 < Red
#2 Left Front D1
>
<
D3 <
3 Grd C2
>
<
G1 J3 3
4 Grn
> E1 Grd < > G2
Sensor Bulkhead Steer Signal D2
> <
E2
4 Can- C3 < 5 Blk
D3 < > G3 J2
Wht
> < 5 D1 < 6
A A E1 E3 < > H1
> < > < D2 <
B
> <
B E2
> <
F1 A
8A
–––
B
––– Grd D3
>
<
H2 Spare
C F2 > H3
C
> < E3
> < S2X Circuit Grd E1 <
D
> <
D F1
> <
F3
Breaker E2
>
<
J1 Grade Servo +
E
> <
E Feedback Signal F2
> E3
>
<
J2 Spare A
>
F
> <
F F3 B A F1
>
<
J3 Grade Servo - B
> A
G1
> 8A –––
–––
F2
>
<
K1 Steer Servo + C <
> S2X Circuit > > B
G2 K2 D <
F3 < > C
G3
> Breaker >
<
K3 Steer Servo - <
> D
H1 <
> E
Grade Signal H2
>
<
F
H3 <
>
Grade Servo + J1
>
Steer Signal J2
>
<
A Grade Servo - J3
>
<
B Steer Servo + K1
>
C K2
< >
<
D Steer Servo - K3
>
Rear Steer
Shield Sensor
1 Smart
Grade Steer
Org 2
Grn 3 J3 Front Steer Steer Cylinder
Red 4
Blk 5 Sensor 2 Left Left Right Right Right Right
Wht 6
J2
Front Front Front Front Rear Rear 360492
Steer Grade Steer Grade Steer Grade
6-74
16 Steer Electrical Diagnostics pot is connected directly into the primary bulkhead at
the right front S2X controller.
The front and rear steer control systems are
responsible for maintaining the correct distance The steer sensor has a wand attached to its' shaft,
between the finished product and the guideline. Each which is held against the guideline by spring tension.
steering system consists of a sensor, a feedback pot As the machine frame moves left or right, in relation to
(smart steer cylinder), a servo valve and a control loop the guideline, the wand causes the sensor shaft to
on a S2X controller which is networked to the other rotate. As the shaft rotates, a corrective signal is sent
S2X controllers on the machine, including the Pancon to the corresponding S2X control loop. The sensor
controller in the control box. works within a voltage range of 1.2 volts to 3.8 volts.
To set the steer and elevation control parameters, the When the sensor wand position, in the Calibrate mode,
operator must depress the CALIB (calibrate) switch. is selected as “push” and the sensor wand is rotated
Depressing and releasing the NEXT switch will select towards the guideline, the voltage signal to the S2X
the elevation mode on the main screen. The elevation will decrease (from 2.5 volts), indicating that the
mode is used to designate the type of sensor control machine must turn left. As the sensor wand is rotated
the machine will be using for a particular job situation. away from the guideline, the voltage signal to the S2X
Depressing and releasing the +/- switches will scroll will increase (from 2.5 volts), indicating that the
through the elevation mode settings available (left machine must turn right.
grade/right slope and Leica). When the appropriate
mode is selected, it will be necessary to restart the When the sensor wand position, in the Calibrate mode,
G21 controller to allow operation of the new is selected as “pull” and the sensor wand is rotated
parameter. towards the guideline, the voltage signal to the S2X
will increase (from 2.5 volts), indicating that the
The G21 controller must be in the “run” mode to machine must turn left. As the sensor wand is rotated
operate the steering control systems in the automatic away from the guideline, the voltage signal to the S2X
mode. The steer mode select switch on the smart will decrease (from 2.5 volts), indicating that the
steer panel must be in the “string steer” position. From machine must turn right.
each S2X, power (+5 volts) is supplied to pin A in the
primary sensor bulkhead from the J1 connector on pin With the sensor wand centered between the roll pin
A1. A common ground is supplied to the sensors from stops, a 2.5 volt signal (center) is returned to the S2X
the J1 connector on pin A3. through pin “B” in the sensor cord. It is routed to the
bulkhead circuit board where the individual sensor
Power is also supplied to pin A in a secondary sensor signals must remain separated. The following color
bulkhead from the J1 connector on pin C1 and a code indicates the color and type of signal for each
common ground is supplied from the J1 connector on wire exiting the bulkhead circuit board.
pin C3. The power supply and ground connections are
routed through the sensor bulkhead at the S2X and White wire ............................. +5.0 volts supply
continue to the bulkhead circuit board located remotely
on the machine frame. Black wire ........................ Feedback pot signal
The bulkhead circuit board distributes the common Orange wire ....................... Ground connection
power supply to pin A in each of the two sensor
bulkheads (grade and steer). The circuit board also
distributes the common ground connection to pin C in Red wire ..................... Elevation sensor signal
each of the two sensor bulkheads (grade and steer).
When the sensor is connected to the appropriate Green wire ........................ Steer sensor signal
bulkhead, it receives +5.0 volt power from pin A and a
ground connection from pin C. Shield wire ................................. Frame ground
A separate bulkhead is connected into the left front

and rear bulkhead circuit boards to connect the
feedback pot (smart steer cylinder) into the system.
Power is also supplied to pin A and ground to pin C in
the feedback pot bulkhead. The right front feedback
G21 12/30/03
6-75
stop turning. The deviation meter will indicate that the

two signals are matched by returning to center. The
track is held in this position until the sensor wand is
moved, indicating that the track must now turn to a
new position.
When the steering system is operating in the

automatic mode, the G21 controller measures the
amount and direction of the signal from the steer
sensor and conveys a corrective signal to the
appropriate servo valve. The amount of servo valve
spool movement is in proportion to the amount of
corrective signal. The sensitivity setting on the control
loop affects the input signal from the sensor and will
change the amount of servo valve spool movement in
relation to the amount of sensor movement. For
example, with the sensitivity adjustment set with three
Smart steer cylinder (3) indicators showing, it may be necessary to move
002-2622
The smart steer cylinder feedback pot on each track is the steering sensor wand 2 in. (50 mm) at midpoint on
used to control how far the track will turn for a given the wand in either direction to get the maximum
sensor movement. Without the feedback pot, the track amount of servo valve spool movement. However,
would turn the maximum amount if the machine travel with the sensitivity adjustment set with fifteen (15)
were stopped with the sensor sending a very small indicators showing, it may be necessary to only move
amount of corrective signal to the control loop. The the sensor wand 1 in. (25 mm) at midpoint on the
control system sends a corrective signal to the servo wand in either direction to get the maximum amount of
valve, where the spool shifts a small amount, causing servo valve spool movement. The more the sensor
the track to turn. Without the feedback pot, the sensor moves off center, the faster the system will respond.
must return to center before the necessary correction The sensitivity has no affect on the manual operation
can be accomplished in the opposite direction. Since of the system.
the machine must be moving for the sensor wand to
return to center, the servo valve spool will remain in An LED position indicator is used to show steering
the shifted position, causing the track to turn error and elevation error. A centered signal from the
completely, over-steering the system. steering or elevation sensor is indicated by a straight
line of LED indicator lights. As a sensor signal error
The feedback pot measures the position of the track occurs, an arrow will indicate the amount of signal
and sends a continuous signal to the S2X, indicating error. As the arrow increases in size, it corresponds to
the track position. The steer signal and the feedback the amount of signal error that the sensor is outputting.
pot signal are passed to the CAN network where the If the necessary correction is not made, the track will
information reaches the Pancon controller. When the continue to turn until the track is completely turned.
steer sensor signal to the S2X indicates a turn of 1 in.
(2.5 cm) to the left is necessary, the Pancon controller When a jog switch is used for manual control, the
compares the signal from the steer sensor with the servo valve spool shifts the full amount and remains
signal from the feedback pot. If the signal from the there until the switch is released and allowed to return
feedback pot indicates that the track is straight ahead, to center. The jog switches will not affect the LED
the two signals will not match and the Pancon position indicator. From the S2X, the corrective signal
controller will send a corrective signal to the is sent out to the corresponding servo valve.
appropriate S2X. The S2X will produce a signal to the
The sensor must control the leading edge of the tracks
servo valve to turn the track left. The deviation meter
in forward or reverse. When the forward/reverse
will indicate that the two signals do not match and that
switch on the smart steer panel is in “forward”, the
a correction is being called for. When the track has
sensor controls the front portion of the tracks. When a
turned 1 in. (2.5 cm) to the left, the feedback pot signal
left turn is necessary, the servo valve spool shifts,
to the S2X indicates that the track has turned. The
causing the front of the tracks to turn to the left. When
signal from the feedback pot and the sensor now
the forward/reverse steer switch is in the “reverse”
match and the Pancon controller will stop the
position, the output drive to the steering servo valve is
corrective signal to the appropriate S2X causing the
reversed. Now, when a left turn is necessary, the
servo valve spool to move to center and the track will
G21 12/30/03
6-76
servo valve spool shifts, causing the rear of the tracks in the center position, the front tracks will be straight
to turn to the left. ahead. If the knob is turned left or right from the
center position, the two front tracks will turn in the
Manual Steer Operation: The smart steer control corresponding direction and the rear track will remain
system (manual steering) is used for steering the straight ahead. The more the knob is turned in either
tracks when driving the machine around the jobsite. direction, the more the tracks will turn.
The smart steer system consists of a five position
steer mode select switch and a steering control dial. When the steer mode select switch is in the “rear steer
only” position, the steering control knob will control the
turning of the rear tracks and the two front tracks will
be locked straight ahead. When the knob is in the
center position, the rear tracks will be straight ahead.
If the knob is turned left or right from the center
position, the rear tracks will turn in the corresponding
direction and the two front tracks will remain straight
ahead. The more the knob is turned in either direction,
the more the tracks will turn.
Steer mode select switch

031-0157B
The five position steer mode select switch is used to
select the automatic steering mode or one of four
manual steering modes. The “string steer” mode is
selected when steering is to be controlled by the
steering sensors or by the jog switches. When the
system is set to one of the four manual steer modes,
Manual steer knob
all tracks will turn in proportion to the manual steer 002-2067c
knob, in the same way as they turn in proportion to the The manual steer knob is used to turn the tracks in
sensors. any of the four manual modes. When the indicator on
the knob is centered the tracks will be straight ahead.
When the steer mode select switch is in the As the knob is turned either direction from center, the
“coordinated steer” position, the steering control knob tracks will turn accordingly. The more the knob is
will control the turning of the tracks. When the knob is turned, the more the tracks will turn. The manual steer
in the center position, the tracks will be straight ahead. knob has no affect on the steering when the steer
If the knob is turned left or right from the center mode select switch is in the “string steer” position.
position, the leading tracks will turn in the
corresponding direction and the trailing track will turn
in the opposite direction to give minimum turning
radius. The more the knob is turned in either direction,
LF FdbkPot StrWnd StrVlv
the more the tracks will turn.
2.40V 2.52V 0.00V
When the steer mode select switch is in the “crab
steer” position, the steering control knob will control 002-2760
the turning of the tracks. When the knob is in the Steer test display
002-2760
center position, the tracks will be straight ahead. If the
When the test switch is depressed the main screen will
knob is turned left or right from the center position, all
indicate the test mode has been entered and
tracks will turn in the corresponding direction, to walk
depressing the LAST or NEXT switches will scroll
the machine to the side. The more the knob is turned
through the test displays for each system. The main
in either direction, the more the tracks will turn.
screen will change to reflect the voltage from the
When the steer mode select switch is in the “front corresponding sensors. As the steer sensor wand is
steer only” position, the steering control knob will moved, or the smart steer cylinder is extended or
control the turning of the two front tracks and the rear retracted, the reading on the main screen will vary
track will be locked straight ahead. When the knob is around a centered voltage reading of “2.50V”. The
G21 12/30/03
6-77
following table indicates the normal voltage range of correct display is indicated for the direction that
each circuit displayed in the test mode. the track is turned. If the STORE button is
depressed with the track facing the wrong
Circuit ...................................... Voltage Range direction or the incorrect display on the screen,
the track will appear to vibrate rapidly. Reset
Battery Power (BPwr) ..................... 9.0 to 16.0 the steer limit settings correctly.
Sensor Power (SPwr) ................... 4.75 to 5.25
LED Power (LEDPwr) ................... 4.75 to 5.25 Jog LF Leg Left & Store
2.93 V Stored: 2.65 V
Elevation Wand (ElWnd) .................. 1.2 to 3.8
360497
Steer Wand (StrWnd) ....................... 1.2 to 3.8
Slope sensor output ...................... 0.75 to 4.25 Center LF Leg & Store
2.56 V Stored: 2.56 V
Feedback Pot (FdbkPot) ................... 1.0 to 4.0
031-0204
Elevation Valve (ElVlv) ............... 0.0 to +/-4.10
Steer Valve (StrVlv) .................... 0.0 to +/-4.10

2.93 V Stored: 2.49 V
If the sensor is not connected, the sensor reading will
show approximately “0.00V”. The arrow on the
360496
corresponding display will also move to center when
360497 & 031-0204 & 360496
the sensor is disconnected. To exit the test mode, 2. Limits are stored too close to the center position.
depress the test switch. The system will return to the When limiting the steering of the tracks, make
normal operating display. certain that the left and right limits are not set
too close to the straight ahead (center) position.
Symptom:
The tracks will appear to vibrate left and right if
One or more tracks vibrate rapidly left and right. this occurs. Reset the steer limit setting to allow
more movement.
Jog LF Leg Left & Store

3.84 V Stored: 3.84 V
031-0203

1.29 V Stored: 1.29 V
031-0205
031-0203 & 031-0205
1. Incorrect adjustment of the steering limits.
When adjusting the left and right limit settings for
the individual tracks, make certain that the
G21 12/30/03
6-78
small connecting plug and install the

replacement. Reassemble in the reverse order.
3. Defective smart steer cylinder. Swap the

cylinder with one of the other steer cylinder on
the machine. If the problem switches to the
other track, replace the cylinder.
4. Defective cord. Swap the smart cylinder cord

with a cord known to be good. If the problem
switches to the other steering system, replace
the cord.
5. Defective S2X controller. Disconnect the J1 and

J2 connectors at the S2X controller and swap
the controller with one known to be good. If the
problem switches to a different track, replace the
Clamps on leg S2X controller.
360288
3. Loose wear pads or worn cylinder pins and If the fault remains with the same S2X, the CAN
bushings on the leg. Replace worn bushings or network wiring connection between the J2
cylinder pins. Refer to the maintenance chapter connector and the CAN bulkhead may be
for clamp adjustment information. defective due to corrosion. Disconnect the J2
the S2X.
6. Defective frame cord wiring. Swap the cord with

one known to be good. If the problem goes
away, replace the cord.
7. Defective servo valve. Disconnect the two wire

connector at the servo valve while engine is in
operation. If the track continues to vibrate left
and right, replace the servo valve.
Symptom:
Smart cylinder bulkhead plug

360498
4. Internal hydraulic seal leakage in cylinder
LEFT FRONT STEER FDBK
bulkhead plug. Check the smart cylinder
bulkhead for hydraulic oil leakage inside the
SHORT TO 0V
plug. If oil is present, use an electrical cleaning
solvent to clean the bulkhead connection. If the 002-2759
oil returns, replace the bulkhead.
To replace the bulkhead, turn off the engine and

remove four set screws attaching the bulkhead LEFT FRONT STEER WAND
fitting to the cylinder housing. Gently pull the SHORT TO 0V
wires from the cylinder housing to expose the
small connecting plug as shown above. 002-2744
Disconnect the the bulkhead assembly at the Steer sensor fault
002-2759& 002-2744
G21 12/30/03
6-79
“Steer Feedback- Short to 0 V” or “Steer Sensor -

Short to 0 V” is displayed on the main screen.
Determine which sensor is affected by the location

Front or Rear.

360352
Elevation mode display
360352
1. The elevation mode is not selected properly for Swap frame cords
360366
the current sensor setup of the machine. If the steer system will not work it will be
Depress the CALIB (calibrate) switch. Depress necessary to swap the frame cord at the
the NEXT/LAST switches until the elevation appropriate S2X controller. If the diagnostic
mode is selected on the main screen. Select the display switches locations, the frame cord or the
appropriate mode for the current setup bulkhead circuit board is defective. Make
configuration of the sensors (Left Grade/Right certain sensors remain connected to the
Slope, Leica). bulkhead circuit board.
2. Sensor not connected or not connected to the

correct side of the machine. Connect the sensor
to the appropriate bulkhead plug.
3. Defective sensor. Disconnect the cord from the

sensor or smart steer cylinder and connect it to
a different sensor or steer cylinder. If the
system will now operate, replace the defective
sensor.
4. Defective sensor cord. If the system will not

work after swapping the sensor or cylinder,
suspect the cord between the sensor and the
bulkhead plug. Swap the cord between the
sensor or cylinder and the bulkhead plug with
the cord from another sensor or cylinder. If the
system will now work, repair or replace the cord.
Swap bulkhead circuit boards
360212
Remove the terminal connections on the rear of
the suspect bulkhead circuit board and swap
with one known to be good. Reconnect the
sensors. If the diagnostic display indicates the
problem remained in the original location, the
cord is defective and must be replaced. If the
diagnostic display indicates the problem
switched to a different location, replace the
bulkhead circuit board.
G21 12/30/03
6-80
short to ground which may occur in any of the

components supplied with sensor power from an
individual S2X. It is first necessary to narrow the area
in which the power short is located.

Front or Rear.
J1 and J2 connectors
360369
6. Defective wiring between the bulkhead plugs at
the S2X and the J1/J2 connectors on the S2X.
Disconnect the J1 and J2 connectors from the
suspect S2X. Remove the S2X from the access
door and swap with one known to be good. If
the problem remains in the same location, repair
or replace the wiring. If the problem changes
location, replace the S2X. Swap sensor cords
360366
If the fault remains with the same S2X, the CAN 1. If the system does not operate, there may be
network wiring connection between the J2 defective wiring between the sensor bulkhead
connector and the CAN bulkhead may be and the sensors on the machine. The sensors
defective due to corrosion. Disconnect the J2 affected on each leg include the steer sensor,
and J1 connectors and spray with an electrical elevation sensor and linear feedback pot in the
cleaner. Do not use an oil based lubricant to smart steering cylinder. The slope sensor would
clean the connections. Reconnect to the S2X. be included in the diagnostics for the rear S2X.
the S2X. To check, disconnect each of the cords labeled
for sensors from the bulkhead at the appropriate
Symptom: S2X controller. If the problem goes away or
changes to “short to 0 V”, refer to the following
paragraph. If “value too low” remains, the wiring
between the S2X controller and the bulkhead is
defective or; the S2X controller is defective.
LF Front Sensor Power Remove the J1 connector (larger connector)
VALUE TOO LOW from the S2X and check again. If the problem
remains, the S2X must be replaced. If the
002-2761 problem changes to “short to 0 V”, the bulkhead
Sensor power failure wiring must be repaired or replaced.
002-2586
“Sensor Power - Value too low” is displayed on the
main screen in the run mode.
Corrective Measures: connector and the CAN bulkhead may be
If the sensor power supply voltage drops below 4.75 and J1 connectors and spray with an electrical
volts, the message “Sensor Power - Value too low” will cleaner. Do not use an oil based lubricant to
appear on the main screen. This indicates a power clean the connections. Reconnect to the S2X.
G21 12/30/03
6-81
If the fault remains, replace the wiring harness at Symptom:

the S2X.
LEFT FRONT STEER WAND

VALUE TOO HIGH
002-2746
LEFT FRONT STEER FDBK

VALUE TOO HIGH
002-2747
Steer signal failure-Value too high
002-2659
“Steer Wand - Value too High” or “Steer Feedback -
360023 Value too High” is displayed on the main screen.
Reconnect one of the sensor cords to the
bulkhead at the S2X controller. If “value too low” Corrective Measures:
is indicated, isolate the frame cord between the
S2X and the bulkheads shown in the previous If the sensor or the feedback pot signal voltage
photo by disconnecting the sensor cords at the increases above 3.80 volts, the message “Steer Wand
exterior bulkhead. If “value too low” remains on - Value too High” or “Steer Feedback - Value too High”
the screen, replace the sensor cord between the will appear on the main screen. This indicates a
exterior bulkheads and the S2X controller. power short between the sensor power supply and the
Reconnect any remaining sensor cords at the sensor signal wiring has occurred. It is first necessary
S2X controller and check in the same manner. to narrow the area in which the power short is located.
If “value too low” is not indicated, the sensor Determine which sensors are affected by the location
cord or the sensor may be defective. Reconnect indicated in the display message: Left Front, Right
the sensor cord to the bulkhead and disconnect Front or Rear.
the sensor cord from the sensor. If “value too
low” is indicated, replace the sensor cord. If 1. Defective sensor cord or sensor. Disconnect the
“value too low is not indicated, replace the suspect sensor cord from the bulkhead under
sensor. Reconnect any remaining sensor cords the machine frame. If the main screen indicates
at the bulkheads and check in the same manner. “Steer Wand - Short to 0 V” but does not
indicate “Steer Wand - Value too High”, then the
short is located in the sensor cord or in a sensor.
Swap the cord with one known to be good and
recheck the main screen after the cord is
connected. If the problem does not exist,
replace the cord. If the main screen indicates
“Steer Wand - Value too High” or “Steer
Feedback - Value too High”, replace the sensor
or smart steer cylinder.
2. Defective sensor frame cord or bulkhead circuit

board. If the main screen continues to indicate
“Steer Wand - Value too High” after the sensor
cord has been disconnected, the sensor frame
cord may be defective. Disconnect the suspect
sensor frame cord from the bulkhead plug at the
appropriate S2X. If the system indicates “Steer
Wand - Short to 0 V” but does not indicate
G21 12/30/03
6-82
“Steer Wand - Value too High”, then the short is hydraulic system. Refer to Steer Hydraulic
located in the sensor frame cord or the bulkhead Diagnostics for procedures to follow. Depress one of
circuit board. Disconnect and remove the wiring the jog switches on the control loop of the affected
from the terminals on the rear of the suspect system. If the message “Steer Servo Value Out of
bulkhead circuit board. Make certain the Range” appears on the main screen, it is an indication
individual wires do not touch each other or the of a bad coil on the servo valve, defective wiring
machine frame. If the main screen indicates between the corresponding S2X and the valve, or a
“Steer Wand - Value too High”, the frame cord defective S2X controller. Proceed as follows.
must be repaired or replaced. If the main screen
indicates “Steer Wand - Short to 0V”, the 1. Bad coil in the servo valve. Disconnect the lead
bulkhead circuit board is defective and must be from the primary coil on the suspect servo valve
replaced. and connect it to the unused secondary lead on
the same servo valve. Depress the jog switch
3. Defective S2X. Turn the ignition key off. for the suspected system and observe the
Disconnect the appropriate J1 30 pin connector message on the main screen. If the system
from the suspect S2X. If the main screen operates and the message “Steer Servo Value
indicates “Steer Wand - Value too High”, replace Out of Range” does not appear, repair or
the S2X. If the main screen indicates “Steer replace the servo valve.
Wand - Short to 0V”, repair or replace the wiring
between the J2 connector and the sensor Note: The leads for steering control connected to
bulkheads at the S2X. the primary coil may be connected to the
secondary coil to continue operation.
network wiring connection between the J2 The valve coil can be checked with an ohm
connector and the CAN bulkhead may be meter. Check at the valve terminals (with the
defective due to corrosion. Disconnect the J2 leads disconnected) for 15.5 ohms on the
and J1 connectors and spray with an electrical primary coil and 19.5 ohms on the secondary
cleaner. Do not use an oil based lubricant to coil. To determine which coil is which, look at
clean the connections. Reconnect to the S2X. the point where the wires exit the valve (manual
If the fault remains, replace the wiring harness at override lever up). The wires on the right are for
the S2X. the primary coil and the wires on the left are for
the secondary coil. If the resistance readings
Symptom: are incorrect, repair or replace the servo valve.
2. Defective wiring between the S2X controller and

the connectors on the servo valve. Disconnect
the servo cord from the bulkhead at the
LF Steer Servo
corresponding S2X and swap it with one of the
VALUE OUT OF RANGE other servo cords known to be good from
another S2X. Depress the jog switch for the
360495 defective system. If one of the tracks will steer
Steer servo fault with the good cord, repair or replace the
360495
“Steer Servo Value Out of Range” is indicated on the defective servo cord.
main screen.
Corrective Measures: network wiring connection between the J2
Determine which servo is affected by the location defective due to corrosion. Disconnect the J2
indicated in the display message: Left Front, Right and J1 connectors and spray with an electrical
Front or Rear. cleaner. Do not use an oil based lubricant to
Isolate the problem, hydraulic versus electrical. The If the fault remains, replace the wiring harness at
steer servos are equipped with a manual override the S2X.
lever on the valve cover. Move the override lever both
directions from center. If the machine does not If the servo fault remains in the same location,
respond to the override lever, the problem is in the the wiring between the J1 connector and the
G21 12/30/03
6-83
bulkhead may be checked for continuity as inidicate that power and ground is available for
follows: operation.
J1--K1 ............................ servo bulkhead pin C If the fault remains with the same S2X, the CAN
network wiring connection between the J2 connector
J1-K3 ............................. servo bulkhead pin D and the CAN bulkhead may be defective due to
corrosion. Disconnect the J2 and J1 connectors and
If continuity does not exist, repair or replace the spray with an electrical cleaner. Do not use an oil
wiring as necessary. based lubricant to clean the connections. Reconnect
to the S2X. If the fault remains, replace the wiring
3. Defective S2X controller. Turn the ignition key harness at the S2X.
off. Disconnect the J1 and J2 connectors from
the suspect S2X controller. Swap the controller If “No Response” remains in the same location after
with one of the other S2X controllers and swapping the S2X controllers, the CAN network
reconnect the J1 and J2 connectors. Restart the connection may be be defective. Swap the short CAN
G21 controller. Depress the steer jog switches cord between the S2X bulkhead and the CAN minifast
for all three steer systems. If the main screen connector to one of the other S2X cotrollers. If the “No
indicates that the servo fault is in a different Response” screen indicates a different location,
location than previously noted, replace the S2X replace the cord.
controller.
The CAN cords may also be checked for continuity.
If the fault remains with the same S2X, the CAN Check each wire in the CAN cord using an ohm meter.
network wiring connection between the J2 If any wire does not indicate continuity, replace the
connector and the CAN bulkhead may be cord.
Symptom:
cleaner. Do not use an oil based lubricant to No automatic control.
If the fault remains, replace the wiring harness at Corrective Measures:
the S2X.
Determine if the problem affects both the manual
Symptom: control as well as the automatic control by checking
the operation of the system with the jog switches. If
the system will not respond with the jog switches, refer
to the preceding symptom. If the system will respond
Rear Slave in manual, but not in automatic, proceed as follows.
NO RESPONSE
360361
S2X controller failure
360361
“Slave - No Response” is indicated on the main
screen.
This display indicates that the corresponding S2X

controller is not communicating with the Pancon
controller (main control box) or with any of the other
S2X controllers on the front access door.
To check, swap the suspect S2X controller with one

that is known to be good. If the problem switches to a
different location corresponding with the suspect S2X
controller, replace the S2X. Make certain that the red
power lamp is illuminated on the S2X controller to
G21 12/30/03
6-84
Manual control loop mode LED display replacement

360436
002-2548
1. Control loop in the “manual” mode. Place the Although this does not hinder the operation of the G21
loop in the “auto” mode by depressing the A/M system, the display should be replaced to prevent
switch. moisture from entering the control box. To replace the
connector from the rear of the appropriate display.
Loosen and remove the four screws from the corners
Stdby LGrd RSlope= 0.00 of the display. It may be necessary to pry the display
Neu Coord Sensor 1 from the control box enclosure to break the silicone
sealer. Thoroughly clean the area around the opening
360350 to remove all foreign material and excess silicone
Standby mode sealant. Place a small bead of silicone sealant around
360350 the new LED display unit and insert the unit in the
2. Main screen indicates “Stdby”. Depress the run/ proper orientation as compared to the existing
standby switch to indicate the “run” mode. displays. Insert and tighten each of the screws
securely. Reattach the locking connector.
Symptom:
The main screen or one of the individual LED meter

displays is fogged under the screen.
Main screen replacement

002-2545
G21 12/30/03
6-85
Although this does not hinder the operation of the G21

system, the main screen should be replaced to prevent
connector from the rear of the main screen. Loosen
and remove the four screws from the front of the
display. It may be necessary to pry the display from
the control box enclosure to loosen the gasket seals.
Thoroughly clean the area around the opening to
remove all foreign material and gasket. Place two
gasket seals around the new main screen unit and
insert the unit in the proper orientation as compared to
the previous display. Insert and tighten each of the
screws evenly. Do not over tighten the screws as this
will cause the display frame to distort and improper
sealing of the gasket material may occur. Reattach
the locking connector.
Switch pack replacement
002-2546
Symptom: To replace the switch pack, open the control box and
disconnect the wiring to the defective switch pack.
One or all of the switches in a switch pack does not Using a flat blade screw driver, place the screwdriver
operate. in the hole behind the switch pack to be removed.
Support the face of the control box cover around the
switch pack and strike the screw driver forcefully to
dislodge the switch pack from the control panel. Peel
the protective backing from the rear of the new switch
package. Place the switch pack in the proper
Steer Switch, Steer Mode orientation and press the switch pack firmly into
LF STEER JOG LEFT STRIN position. Connect the wiring to the switch pack and
close the control box. Secure the control panel.
002-2765 Attach the appropriate switch pack decal to the front of
Service mode for testing switches the new switches.
002-2764
Depress the service switch under the service panel. Symptom:
Depress the NEXT/LAST switches to scroll to the
appropriate switch test mode. Depress the defective Main Screen indicates the manual steer knob is not
switches. If a switch is activated and no function is calibrated.
displayed, the switch may be defective. Open the
control panel and check for any pinched wiring to the Corrective Measures:
switch pack. If no pinched wiring is visible, disconnect
the suspect switches and swap connectors with
another switch pack known to be good. If the switches
will not operate, the switch pack is defective and must Manual Steering Pot
be replaced. NOT CALIBRATED
002-2755
Not calibrated
002-2765
This display indicates that an output signal is not being
received by the Pancon controller, it will be necessary
to proceed with the following steps.
G21 12/30/03
6-86
Manual Steer Pot

2.55 Volts
002-2766
Service mode
002-2766
Depress the Service button and scroll to the manual
steer pot screen. Rotate the manual steer control
knob fully clockwise. The voltage should change from
0.21 to 4.80 volts. If not, measure across terminals 1
and 3 on the manual steer pot for 900 to 1100 ohms of
resistance. Replace the manual steer control pot if the
resistance is not correct.
Symptom:
Operator remote steer pot does not operate. Console

controls will operate the manual steering.
1. Check the cord for visible signs of damage or

broken wires. Repair any defects and check for
proper operation.
2. Defective remote steer pot. Check to see if the

remote travel control knob will operate the track
drive. If not, refer to Tractive Electrical
Diagnostics for more information.
If the remote travel pot does operate, check the

remote steer pot for ohms of resistance. Place
the leads of the ohm meter in pin A and pin C on
the remote bulkhead plug. A variable reading of
48 ohms to 555 ohms of resistance should be
indicated when rotating the remote steer knob
from left to right. Place the leads of the ohm
meter in pin B and pin C and repeat the
procedure. The same reading should be
indicated when rotating the remote steer knob
from right to left. If the readings are not correct,
repair or replace the operator remote.
3. Defective frame cord. Disconnect the remote

frame cord from bulkhead 1 (B1) on the back of
the main control box and disconnect the remote
from the opposite end of the cord. Check the
individual pins for continuity. Repair or replace
the cord if any of the pins do not indicate
continuity.
G21 12/30/03
6-87
Emergency Stop Electrical System
+
Battery
-
Cold OFF
Hot ON
Starter Master Disconnect
Coil Switch
E-Stop Reset Control Box

A A
> B3 B3 <B
2 1 B Reset Console E-Stop
> <
C C Wht A> A 1 2
E-stop Reset > < B2 B2 <B
D D E-Stop Lamp Blk B>
Switch > < <
C C Emergency Stop
> <
D D Contacts
> <
E-stop Lamp
Power Relay 54 Left Front E-Stop
7 2
A A Spare
> < Ω A A 1 2
21 B B12 B12 <B >
B B7
<
B
> C 3 > <
Ω C < 4 1 C C
> D Spare > < Emergency Stop
A B Aux D < 6 D D Contacts
20A > E Spare > <
E-Stop Batt E 5 8
> <
8 Circuit Power Relay E-Stop Right Front E-Stop
See Miscellaneous Ω Breaker 3
Contacts Relay K1 A A 1 2
> <
Engine Electrical 7 54 2 B B8 B
E-Stop > <
Ω C C Emergency Stop
Drawing for Ignition Valve Coil
3 D
> <
D Contacts
> <
Switch connections. 4 1
J2 <A1 6 Left Rear E-Stop
A B A2 E-Stop Signal 5 8 A A 1 2
20A < > <
Main Circuit A3 B B9 B
Ignition < E-Stop > <
Breaker 1 B1 C C
Switch < Relay K3 Emergency Stop
B2 > <
< D D Contacts
76 B3 > <
Batt Acc Ω <
A C1 Right Rear E-Stop
87 B 20A <
St C2 Vibrator/Auto Float A A 1 2
30 87A Network < > <
Ign Circuit C3 B B10 B
Ignition Relay K1 < > <
(Cummins Tier II Only) Breaker 2 D1 C C
< > < Emergency Stop
D2 D D Contacts
< 2 3 > <
D3
<
E1 Track Brake
<
E2 Switch
1 <
2 E3
3 < Servo
F1 Lock
< AUX.
Left Trimmer F2 Batt (+) Light
< 2 3 Wht A A
Lift F3 Batt (-)
1 < Blk
>
B B5 B5 <B
2
Servo Lock > <
3 Org C C
Wht 5 Left 5 Blk Switch > <
Ω Ω 85 Red D D 8
Right Trimmer Trimmer A B > <
Lift Lift 8A
Ω Grn E E 8 Ω
S2X > < Ω
1 Circuit Breaker 1 87 5 6 2 3 Blu F F 8
Orn 5 Right 5 Red > <
2 8 Ω Tractive Brake
3 Ω Trimmer Ω A 10A
B 30 87A
Travel/Neutral Vibrator Valve Coil
Lift Ω Servo Lock
Control Switch Vibrator Switch Switch 1 Vibrator Valve Coil
Trimmer Shift Circuit Breaker 2
Grn Trimmer Blu Power In On/Off Valve Coil
5 5 A B Differential
1 Ω Shift Ω A A 10A Relay K2
Valve Coil
2 > B11 <B E-Stop Button
3 B (Normally
> < Circuit Breaker 3
Mold Blk/Wht C C Closed
Mold Shift Wht/Blk 5 5 > < A B 5 6
Ω Shift Ω D D 10A Valve)
> < E-Stop Valve
1 E E Sensor 1
2 > < Circuit Breaker 4
3 Left Red/Blk Sensor 2
Orn/Blk 5 5 A B
Ω Front Ω 10A Switch
Left Front Leg CAN Power
Leg Pivot Circuit Breaker 5
360494.eps
6-90
17 Emergency Stop Electrical Diagnostics
Power for the emergency stop system is supplied from

the battery to the power relay. Power is routed from
the battery (Batt) terminal of the power relay to the
battery post on the main circuit breaker. From the
auxiliary post of the main circuit breaker, power is
routed to the battery terminal on the ignition switch and
to terminal 30 of the ignition relay on a Cummins tier II
engine. When the ignition switch is turned to the "on"
position, power is supplied to the battery post (B) on
circuit breaker 2 from the accessory (acc) post on the
ignition switch. Refer to the appropriate Engine
Electrical Schematic in the following section of this
chapter for more wiring information.
From the auxiliary post of circuit breaker 2, power is

routed to terminal 2 on the e-stop reset switch and to E-stop relays K1 and K3
002-2879
bulkhead 11 in the main control box. Bulkhead 11 To allow operation of the hydraulic and electrical
provides a ground between the machine frame and the systems, the travel control knobs must be rotated
ground lug inside the control box. Power is routed counterclockwise to the “off” position. By depressing
through pins B and D in bulkhead 11 to the battery (B) the e-stop reset switch, power is routed to terminal 2
side of each circuit breaker located inside the control on e-stop relay K1, causing it to energize. The contact
box. points will change, connecting terminals 1 and 3 as
well as terminals 8 and 6 together in the relay.
From the auxiliary (A) side of the S2X circuit breaker,
power is supplied to the Pancon controller inside the From terminal 3 on e-stop relay K1, power is routed in-
control box. The auxiliary (A) side of the control switch series through the buttons in the following order:
circuit breaker supplies power to the track brake consolebutton, left front button, right front button, left
switch, the servo lock switch, the sensor 1/sensor 2 rear button and right rear button. If each button is
switch and to terminal 30 on the vibrator on/off relay pulled out, power is returned to terminal 2 on e-stop
K2. The auxiliary (A) side of the e-stop button circuit relay K1. This allows the e-stop buttons to remain
breaker supplies power to terminal 1 on e-stop relay energized after the e-stop reset switch is released. If
K1. The auxiliary (A) side of the e-stop valve circuit any one of the emergency stop buttons is depressed,
breaker supplies power to terminal 8 on e-stop relay contact is broken and e-stop relay K1 is de-energized
K1. Refer to the grade and slope electrical system causing the previously indicated hydraulic systems to
schematic or the steer electrical system schematic for cease operation.
power supply information from the CAN power circuit
breaker.
Upon initial start up of the engine, the e-stop lamp will

be illuminated. Power is supplied to the lamp from e-
stop relay K1 inside the control box. When the relay is
de-energized, terminals 1 and 4 are connected which
supplies power to the lamp. When the lamp is
illuminated, the e-stop valve coil on the relief manifold
is de-energized. Since the e-stop solenoid valve is
normally open the hydraulic oil for the trimmer, track,
vibrator and conveyor systems will dump to tank
through the relief valves at low pressure. Also, the
Pancon controller will not receive a ground signal from
the e-stop system which causes it to shut down
electrical output signals to the track and vibrator
systems.
E-stop power relay

360434
G21 3600 12/11/03

6-91
From terminal 6 on e-stop relay K1, power is routed to

e-stop relay K3 causing it to energize. Power is also
routed from terminal 6 through bulkhead 12 to
energized the power relay coil.
With terminals 1 and 3 connected through e-stop relay

K3, a ground is routed to Pancon controller connector
J2 on pin A2. The ground connection signals the
controller that the e-stop system has been reset and
the travel and vibrator systems will operate electrically.
E-Stop Commanded: RESET

ALL SWITCHES TO NEUTRAL!
002-2768 Jumper wire on E-stop switch

Emergency stop display
WARNING!
002-2768
The controller is also programmed with an additional ! !
safety procedure which requires that all variable
control knobs and FNR switches be returned to the TO PREVENT SERIOUS INJURY OR DEATH, BE
"off" or "neutral" position before the Pancon controller SURE THAT ALL CONTROLS ARE IN THE
will allow operation of the control systems. The screen “NEUTRAL” OR “OFF” POSITION BEFORE
will indicate "E-Stop Commanded: RESET ALL RESETTING THE EMERGENCY STOP SYSTEM.
SWITCHES TO NEUTRAL!" if any of the FNR MAKE CERTAIN ALL PERSONNEL ARE AWAY
switches are not in the neutral position or the variable FROM THE MACHINE BEFORE RESETTING THE
control knobs are not turned off. When all procedures EMERGENCY STOP SYSTEM. MAKE CERTAIN
have been completed, all systems will be operational ALL EMERGENCY STOP BUTTONS ARE IN
and the screen will indicate the normal operating WORKING CONDITION PRIOR TO OPERATING
display. THE MACHINE.
With the power relay energized, power is routed to the 3. Defective E-stop switch. If one of the E-stop
e-stop valve coil causing the solenoid valve to close switches is defective, the system cannot be
causing the hydraulic systems to begin or resume reset. Connect a jumper wire between the
operation. Power is also supplied to the auxiliary terminals on the E-stop switch on the control
hydraulic control switches to allow operation of the panel. If the system can now be reset, the panel
trimmer lift, trimmer shift, mold shift and left front leg E-stop switch is defective and must be replaced.
solenoid valves. If the system does not reset, place a jumper
between the terminals on the left front switch,
Symptom: then the right front switch, followed by the left
rear switch and then the right rear switch (one
Machine controls will not operate. Emergency stop switch at a time). If placing a jumper wire
reset light is illuminated and screen indicates E-Stop between the terminals on any of the switches
Commanded display. will allow the system to be reset, that switch is
4. Defective wiring to one of the emergency stop
1. Emergency stop system not reset. Depress the buttons. The sequence of power supply is as
emergency stop reset switch to reset the follows: K1 relay terminal 3 to pin A console
system. stop button; pin B console stop button to pin A
left front stop button; pin B left front stop button
2. Emergency stop button depressed. Release to pin A right front stop button; pin B right front
each depressed button to the out position before stop button to pin A left rear stop button; pin B
depressing the emergency stop reset switch. left rear stop button to pin A right rear stop
button; pin B right rear stop button to relay K1
G21 3600 12/11/03

6-92
terminal 2. The emergency stop switch, when Symptom:

depressed, will also supply power to relay K1
terminal 2. Machine control will not operate. Emergency stop
reset light is not illuminated. Screen indicates E-Stop
Using a voltage meter or 12 volt test light, Commanded display.
depress and hold the reset switch while testing
the wiring. Disconnect an emergency stop Corrective Measures:
button at the frame cable bulkhead. Check for
12 volt power supply on pins A and B. If 12 volts
is indicated on pin A, the power supply is
reaching this button from terminal 3 on relay K1.
This indicates that all wiring is good ahead of the
button that is being tested. If 12 volts is not
indicated on pin A, then a break in the 12 volt
power is between relay K1 terminal 3 and the
button being tested. If 12 volts is indicated on
pin B, the power supply is reaching this button
from emergency stop reset switch. This
indicates that all wiring is good behind the button
that is being tested. If 12 volts is not indicated
on pin B, then a break in the 12 volt power is
between relay K1 terminal 2 and the button
being tested. Continue testing the wiring at
each button until the defective wiring or button is
located. Repair or replace the defective wiring Manual override button
as necessary. 360211a
Open the rear access door to the control console.
Locate the manual override control button on the
e-stop solenoid valve and depress it. If the hydraulic
systems do not operate, refer to the appropriate
hydraulic system diagnostics for more information. If
the hydraulic systems do operate, refer to the following
procedures for diagnostic information.
1. The console or remote variable speed control

knob has not been returned to the "off" position
or the travel/neutral switch is not in “neutral”.
Rotate travel variable control knobs to the "off"
position and place the travel/neutral switch in
“neutral”.
2. Defective power or ground connection to K3

relay coil. If the K3 relay LED light is not
illuminated, make certain that 12 volts is
Swap K1 and K3 relays available to terminal 2 on relay K3 and a good
002-2879
ground connection is available on terminal 7.
5. Defective K1 relay coil. Remove and swap the
Temporarily use a jumper wire to test the power
K1 relay with the K3 relay. Depress the
and ground connections. Repair damaged
emergency stop reset switch. If the emergency
wiring as necessary.
stop reset light will stop illuminating after
swapping has occurred, replace the defective
relay.
G21 3600 12/11/03

6-93
Swap relays
002-2879
3. Defective K3 relay. To check, place a jumper Check power relay voltage
wire between terminal 1 and terminal 3 on relay 002-2886
K3. If all hydraulic systems operate, replace the 1. Defective power relay. Using a volt meter or test
relay. light, check for 12 volts on the large terminals on
the top of the power relay. Check for a 12 volt
4. Defective ground connection to connector J2 pin connection between the small power and ground
A2 on the controller. Remove the wire from terminals on the top of the power relay. If 12
terminal 1 on relay K3 and momentarily connect volts is indicated on the small terminals but is
it to ground. If the E-Stop Commanded display not indicated on both of the large terminals,
no longer appears on the screen, the ground replace the power relay.
connection through the relay is defective or the
relay base is defective. Repair or replace the 2. Defective wiring between relay K1 and the
relay base or ground wire connection on power relay. If 12 volts is not indicated between
terminal 3 as necessary. the small terminals on the power relay, the
wiring may be defective. Check continuity of the
Symptom: wiring between the small terminals on the relay
to bulkhead 12. If continuity does not exist, the
Travel, conveyor, trimmer and control switches do not wiring is defective and must be repaired or
operate. Emergency stop light is not illuminated. replaced.
If continuity does exist, check the wiring inside

the control box between bulkhead 12 and
terminal 6 on relay K1. If continuity does not
exist, repair or replace the defective wiring.
If continuity does exist, check continuity between

terminals 6 and 8 while the relay is energized. If
continuity does not exist, replace the relay.
G21 3600 12/11/03

6-94
volts are present on the battery side of the

breaker, but not the auxiliary side, the circuit
breaker is defective and must be replaced. If 12
volts are present on both sides, check the
continuity of the wire between the circuit breaker
and the center terminal of the emergency stop
reset switch. If continuity does not exist, repair
or replace the wire.
2. Defective wiring. Open the main control box and

depress the emergency stop reset switch. An
LED light will illuminate inside the K1 relay if the
relay coil is energized. If the LED light does not
illuminate, check the continuity of the wiring
between terminal 2 on the K1 relay and terminal
1 on the emergency stop reset switch. If
continuity does not exist, the wiring must be
Emergency stop circuit breaker repaired or replaced.
002-2615
3. Tripped circuit breaker caused by a short in one
of the emergency stop solenoid coils. 3. Defective K1 relay. Remove and swap the K1
Disconnect both of the wires from the auxiliary relay with the K3 relay. Depress the emergency
side of the 20 amp circuit breaker. Check both stop reset switch. If the emergency stop reset
sides of the circuit breaker for 12 volts. If 12 light will stop illuminating after swapping has
bolts are present on the battery side of the occurred, the relay is defective and must be
breaker, but not the auxiliary side, the circuit replaced.
breaker is defective and must be replaced. If 12
4. Defective K1 relay base. Remove the K1 relay
volts are present on both sides, reconnect one
from the base. Check continuity between each
of the wires from the emergency stop solenoid
screw terminal and the corresponding relay pin
coils. If the circuit breaker now trips, the
in the base. If continuity does not exist in one of
connected wiring or solenoid coil is defective
the pin to terminal checks, the relay base is
and must be repaired or replaced. If the circuit
breaker does not trip, reconnect the wire from
the other emergency stop solenoid coil. If the
circuit breaker now trips, the wiring or solenoid
coil is defective. Replace or repair the wiring or
solenoid coil as necessary.
Symptom:
Emergency stop reset light continues to illuminate

when depressing the reset switch. Main hydraulic
systems do not function.
1. Defective emergency stop reset switch. Using a

test light or volt meter, check the center terminal
of the reset switch for 12 volts. If 12 volts exists,
depress the reset switch and check terminal 1
for 12 volts. If 12 volts does not exist, the switch
is defective and must be replaced.
If 12 volts does not exist on either terminal,

remove the wiring from the auxiliary terminal of
the 10 amp engine circuit breaker. Check both
sides of the circuit breaker for 12 volts. If 12
G21 3600 12/11/03

6-95
Engine Gauge Panel Cummins 4BT3.9 Elite Engine Schematic (G21)
Tachometer
To Fuel Sender
Volt Water Oil Fuel
Meter Temperature L2 Pressure Gauge
L3 L3 L3 L3 Starter
Cold Coil
G G G G G Hot
S I S I S I S I S I
Starter Relay Cold
Hot
Starter
+
Alternator Actuator
Battery
- Master Disconnect
Switch
OFF
Oil Pressure ON
Switch
Temperature Engine
Sender Oil Pressure P
Sender
C NO
Diode
Hold in Coil-Red
Cold
A Fuel
Pull in Coil-Wht Stop
B 21
Hot Ground-Blk Actuator
C
Ω
Fuel Relay Aux
Batt
A B
20A Power Relay
Main Circuit
Breaker 1 Contacts
Ignition Switch
SW4
Batt Acc
A B
Control Box St 20A
E-Stop Circuit
Ign 8 Breaker 3
See Emergency Stop Electrical, Ω
the Steer Electrical or the
Elevation Electrical Schematics E-Stop
Valve Coil To solenoid valve control switches
To E-stop reset switch See Emergency Stop Electrical
A B See Emergency Stop Schematic
8A
S2X Electrical Schematic
Circuit Breaker
A B
10A
Control Switch A A
> <
Circuit Breaker B B11 B
> <
A B C C A B
10A > < 20A
E-Stop Button D D Miscellaneous
> <
Circuit Breaker E E Circuit
> < Breaker 2
A B
10A
E-Stop Valve
Circuit Breaker
A B
10A
CAN Power
Circuit Breaker
360501.eps
6-97
Engine Gauge Panel John Deere 4045T Engine Schematic (G21)
Tachometer
To Fuel Sender
Volt Water Oil Fuel
Meter Temperature L2 Pressure Gauge
L3 L3 L3 L3 Starter
Cold Coil
G G G G G Hot
S I S I S I S I S I
Starter Relay Cold
Hot
Starter
+
Alternator Actuator
Battery
- Master Disconnect
Switch
OFF
Oil Pressure ON
Switch
Temperature Engine
Sender Oil Pressure P
Sender
C NO
Diode
21
Ω
Aux
Batt
A B
20A Power Relay
Main Circuit
Breaker 1 Contacts
A B
20A
Ignition Switch E-Stop Circuit
SW4 8 Breaker 3
Ω
Batt Acc
E-Stop
Control Box St Valve Coil To solenoid valve control switches
Ign
See Emergency Stop Electrical, See Emergency Stop Electrical
the Steer Electrical or the Schematic
Elevation Electrical Schematics
for more information. Fuel Stop
To E-stop reset switch Solenoid
A 8A
B See Emergency Stop
S2X Electrical Schematic
Circuit Breaker 1
A B
10A A A
Control Switch > <
Circuit Breaker 2 B B11 B
> <
A B C C A B
10A > < 20A
E-Stop Button D D Miscellaneous
> <
Circuit Breaker 3 E E Circuit
> < Breaker 2
A B
10A
E-Stop Valve
Circuit Breaker 4
A B
10A
CAN Power
Circuit Breaker 5
360500.eps
6-98
18 Engine Electrical Systems Diagnostics positions. With the engine started, the fuel stop “hold-
in” coil will remain energized, allowing fuel to be
Select the appropriate drawing according to engine supplied to the engine.
model and manufacturer. If the machine is equipped
with the Cummins QSB Tier II engine, refer to section When the ignition switch is turned to the start position,
19 of this chapter for diagnostic procedures. The the ignition switch start “St” terminal supplies power to
electrical systems consist of the engine wiring energize the starter relay and the fuel relay. With the
including the power supply to the circuit breakers. starter relay coil energized, contact is made between
the hot and cold terminals to supply power to the
Power for the engine gauges is supplied through the starter coil causing it to energize to crank the engine.
engine oil pressure switch. The engine must be With the Cummins fuel relay coil energized, the fuel
running for engine oil pressure to increase, causing stop actuator “pull-in coil is energized to allow fuel to
the switch to close, thus supplying the necessary 12 the engine. After the engine is started, the ignition
volts of power to the gauges. When the engine is switch is returned to the "on" position. The starter
stopped, the oil pressure switch opens and power to relay and the fuel relay will de-energize causing the
the gauges is broken. starter to cease operation and the pull-in coil on the
fuel stop to de-energize. The fuel stop hold-in coil will
The electrical systems operate on a 12 volt power remain energized as previously indicated.
supply which begins at the battery. Continuous power
is supplied to the hot terminal on the starter coil and The ignition switch accessory (Acc) terminal supplies
starter relay. Continuous power is also supplied to the power to the miscellaneous circuit breaker (#2) when
hot terminal on the power relay and to the main circuit the switch is in the “on” position only. The
breaker. miscellaneous circuit breaker supplies power to the
fuel gauge and to all circuit breakers in the G21 control
From the 20 amp main circuit breaker, power is box.
supplied to the battery terminal of the ignition switch.
Power relay and emergency stop system
John Deere Engine Electrical Description
The power relay provides power to the emergency
On the John Deere engine, power is supplied from the stop circuit breaker (#3) when the relay coil is
ignition (Ign) terminal to the fuel stop solenoid when energized. From the circuit breaker, power is supplied
the ignition switch is in the “on” and “start” positions. to the solenoid valve control switches and to the
With the fuel stop solenoid coil energized, the fuel emergency stop valve coil. Refer to the emergency
solenoid valve will open allowing fuel to be supplied to stop electrical schematic for more information.
the engine.
Symptom:
When the ignition switch is turned to the start position,
the ignition switch start (St) terminal supplies power to All electronic controls inoperative.
energize the starter relay. When the relay is
energized, contact is made between the hot and cold Corrective Measures:
terminals to supply power to the starter coil causing it
to energize to crank the engine. When the ignition 1. Battery discharged. Recharge as necessary.
switch is released to the “on” position, the starter relay
is de-energized and the starter disengages. 2. Defective ignition switch. Connect a jumper wire
between terminal 15 (Batt) and terminal 75 (Acc)
The ignition switch accessory (Acc) terminal supplies on the rear of the switch. If the controls now
power to the miscellaneous circuit breaker (#2) when respond, the switch is defective and must be
the switch is in the “on” position only. The replaced.
miscellaneous circuit breaker supplies power to the
fuel gauge and to all circuit breakers in the G21 control 3. 20 amp main circuit breaker tripped. Check for
box. 12 volts at each terminal of the circuit breaker. If
12 volts are present on the battery side, but not
Cummins Engine Electrical Description the auxiliary side, the circuit breaker may be
tripped. Disconnect the wires from the auxiliary
On the Cummins engine, power is supplied from the side of the circuit breaker and check again. If 12
ignition (Ign) terminal to the fuel stop actuator “hold-in” volts are not present on the auxiliary side,
coil when the ignition switch is in the “on” and “start” replace the circuit breaker. If 12 volts are
G21 07/28/03
6-99
present on the auxiliary side of the circuit Corrective Measures:

breaker with the ignition switch in the “off”
position, but are not present with the switch “on”
suspect a short in the wiring between the switch
and the fuel stop solenoid or; between the
switch and miscellaneous circuit breaker (#3).
Check wiring and repair or replace as
necessary.
Symptom:
Fuel gauge and G21 controls do not operate.
Tripped miscellaneous circuit breaker caused by a

short circuit in the wiring. Disconnect the wires from
the auxiliary side of the miscellaneous circuit breaker.
Check both sides of the circuit breaker for 12 volts. If
12 bolts are present on the battery side of the breaker, Master disconnect switch
360371
but not the auxiliary side, replace the circuit breaker.
1. Master disconnect switch is “off”. Turn the
If 12 volts are present on both sides, reconnect the switch “on”.
wires individually from bulkhead B11 on the back of
the main control box to the auxiliary terminal of the
circuit breaker. If the circuit breaker now trips, repair ! WARNING! !
or replace the wiring. BATTERIES CONTAIN SULFURIC ACID AND
If the circuit breaker does not trip, reconnect the wire WHICH CAN CAUSE SERIOUS INJURY.
to the fuel gauge. If the circuit breaker now trips, THEREFORE, DO NOT ALLOW FLAMES OR
disconnect the wiring at the fuel gauge. If the circuit SPARKS TO COME NEAR THE BATTERY. WHEN
breaker trips, repair or replace the wiring. If the circuit CHARGING OR WORKING NEAR A BATTERY,
breaker does not trip, replace the fuel gauge. ALWAYS SHIELD YOUR FACE AND PROTECT
YOUR EYES. IN CASE OF ACID CONTACT WITH
Symptom:
Engine will not crank. WATER FOR A MINIMUM OF 15 MINUTES AND
GET PROMPT MEDICAL ATTENTION. IF ACID IS
SWALLOWED, CALL A PHYSICIAN IMMEDIATELY.
2. Discharged battery. Make certain that the

battery is fully charged. The electrical system is
a 12 volt negative ground system. Use a battery
hydrometer to check specific gravity of the
electrolyte in each battery cell. A fully charged
battery will have a specific gravity of 1.260.
Charge the battery if the reading is below 1.215.
Refer to the maintenance chapter in this manual
or to the appropriate engine operators manual
for more information on proper charging
procedures.
G21 07/28/03
6-100
Clean battery cables

360218
3. Battery cables are dirty or loose. Clean and
Check fuel shut-off solenoid for 8 ohms
tighten the cables. 6103
Fuel shut-off solenoid not receiving +12 volts or
4. Defective ignition switch. Momentarily connect a defective. Check the solenoid coil with an ohm meter
jumper wire between the “Bat” (#15) and “Sol” for 8 ohms of resistance with the wires removed. If the
(#50) terminals on the rear of the ignition switch. solenoid coil reading is faulty it should be replaced. If
If the engine cranks, the switch is defective and the coil reads correctly, check for +12 volts from the
must be replaced. wire when the ignition switch is “on”. If +12 volts is not
evident, replace the wiring.
5. Defective wiring between the ignition switch and
the starter relay. Momentarily touch a jumper Symptom:
wire between the hot terminal on the starter
relay and the coil terminal on the starter relay. If Engine gauges will not work.
the starter engages, the wiring is defective and
must be repaired or replaced. Corrective Measures:
6. Defective starter relay. Momentarily touch a

jumper wire between the positive (+) terminal on
the starter solenoid and the small terminal on
the top of the solenoid. If the starter engages,
the starter relay is defective and must be
replaced.
7. Defective starter. Remove the starter and have

it checked and repaired by a qualified service
center.
Symptom:
Engine stops suddenly or will not start but will crank.
Oil pressure switch

360217a
Oil pressure switch not closing to supply 12 volts to the
gauges. Connect the wires on the oil pressure switch
together. If the gauges respond, the switch is
defective and must be replaced, or the pressure in the
G21 07/28/03
6-101
oil system is low. Refer to the Cummins Diesel Engine

Operators Manual for procedures used to check the oil
pressure.
Symptom:
Tachometer indicates engine overspeed at maximum

throttle.
This is an indication that the tachometer may require

adjustment. Run engine at maximum speed. Insert a
small screwdriver through the adjustment hole in the
rear of the tachometer. Turn the adjustment screw
until the tachometer registers the same as the factory
adjustment for maximum rpm listed on the engine data
tag. For most accurate adjustment, check the engine
speed with a strobe or mechanical tachometer and
adjust the machine tachometer accordingly.
Note: Loose fan/alternator drive belts or a

defective alternator can cause faulty tachometer
readings. Adjust the belts as described in the
Maintenance chapter. Remove the alternator and
have it checked and repaired by a qualified service
center if necessary.
638624
G21 07/28/03
6-102
Cummins QSB-110 Engine Electrical Schematic (G21) Fuel Gauge
L1
B1 NC <31 Ignition
NC <30 S I
B1 connects CAN Shield <29 J1-C
Relay K1
CAN + <28 J1-A Throttle
to Engine NC <27 Switch SW1
NC <26 76
wiring harness ISC Decr <25 SW1-1 B1-25 1 Decrease
2 B1-21
Ignition Switch 85 Ω 86
ISC Incr <24 SW1-3 B1-24 3 SW4 87 A 20A
B
Diag Decr <23 SW3-1 Increase B A Circuit
<22
NC 30 87A
Note: Contact an Engine B1-20 20A Breaker 2
Dealer for additional wiring,
Batt - <21 SW1-2 Diagnostic Batt Acc Main Circuit
service and diagnostic information.
Batt + <20 SW4-Batt
Mode SW2 St
Breaker 1 Fuel
Sender
NC <19 B1-10
NC <18 3 Off
2 B1-9
Ign
CAN - <17 J1-B
B1-12 1
NC <16 On PL1-3
NC <15 To E-stop reset switch
31 20
NC <14 Next Diagnostic
30 8 21
Diag Incr <13 SW3-3
Fault SW3 Lamps See Emergency Stop
19 9 Diag On/Off <12 SW2-1 From Hot Terminal Engine Glow Plug Relay
18 2 10 WTS Lamp <11 PL1-2 B1-23 1 Decrease Electrical Schematic
2
29 7 223 Key Start <10 SW4-ST B1-13 3
28
17
6
1
4
11
23
+12 V < 9 SW4-IGN Increase
16 5 12 NC < 8
15 13 NC < 7
27 14 24 NC < 6 123456
26 25
ISC 1 < 5 Grd PL1
Maint Lamp < 4 PL1-5 SW4-Ign
Diag Lamp < 3 PL1-1
WIF Lamp < 2 PL1-5
Stop Lamp < 1 PL1-6
Engine
Coolant Engine Oil
WIF=Water In Fuel Pressure
WTS=Wait To Start Temp Tachometer
A B
6A
Engine Gauge 21
Circuit Ω
Breaker 4 Aux
Batt
Power Relay
C B A C B A C B A
D E F D E F D E F
Contacts
C B A B A
J14 J13 J12 J11 J10 J9
A B
A B C A B C A B C A B C 20A
A B C A B Circuit
F E D F E D F E D F E D
8 Breaker 3
Ω
C B A A B C
D E F J1 F E D
J8 To solenoid valve
E-Stop
B A control switches
B1-17 Databus Module Valve Coil
See Emergency
C Stop Electrical
B1-28 A B B A
B1-29 Schematic
C J2 C A B C D A B C A B C A B C A B C
H G F E F E D F E D F E D F E D
J3 J4 J5 J6 J7
D C B A
E F G H Control Box
A B
8A
S2X
Circuit Breaker 1
A B
10A
Control Switch A A
> <
Circuit Breaker 2 B B11 B
See Emergency Stop Electrical, C
> <
C
Diagnostic A B > <
the Steer Electrical or the 10A
Module E-Stop Button D D
> <
Elevation Electrical Schematics Circuit Breaker 3 E E
> <
for more information. A B
10A
E-Stop Valve
Circuit Breaker 4
A B
10A
CAN Power
Circuit Breaker 5
360499
6-104
19 Cummins QSB-110 Engine Electrical Note: If a “red” stop lamp is indicated on the
Diagnostics engine diagnostic lamp gauge or on the Murphy
diagnostic gauge, the ECM will not crank the
The Cummins QSB tier II electrical schematic includes engine.
the Gomaco wiring harness connected to the
Cummins engine wiring harness at bulkhead plug B1 The power relay provides power to the emergency
and all circuit breakers on the machine. The engine is stop circuit breaker (#3) when the relay coil is
supplied with a battery disconnect switch which must energized. From the circuit breaker, power is supplied
be placed in the “on” position to provide power for all to the solenoid valve control switches and to the
electrical functions. emergency stop valve coil. Refer to the emergency
stop electrical schematic for more information.
Power (+12 volts) is supplied through bulkhead 1 pin
20 (B1-20) to terminal 15 (Batt) on the ignition switch. The throttle switch, diagnostic mode switch and the
Power is also supplied from the hot terminal on the top next fault switch are provided a ground connection
engine glow plug relay, to the battery side (Batt) of the looped between terminal 2 of each switch from the
power relay. From the battery side of the power relay, ECM on bulkhead 1 pin 21 (B1-21). If one of the
power is supplied to the battery post (Batt) of the main switches is depressed, a ground connection is made to
circuit breaker. the ECM in the appropriate direction to increase or
decrease the engine throttle; to activate the diagnostic
From the auxiliary side of the main circuit breaker, lamp mode or to advance to the next or last fault code.
power is routed to terminal 30 on ignition relay K1.
With the ignition switch in the “off” position, power is Symptom:
terminated at both the ignition switch and the ignition
relay. When the ignition switch is turned to the “on” Engine will not crank. Engine gauges do not
position, power is supplied from terminal 30 (Ign) illuminate.
through the 6 amp engine gauge circuit breaker (#4) to
the databus module, providing power to the engine Corrective Measures:
gauges. Power is also supplied to plug 1 terminal 3
(PL1-3) for the engine diagnostic lamp gauge and to
bulkhead 1 pin 9 (B1-9) for engine control module
(ECM) operation.
When the ignition switch is in the “on” position, power

is supplied from terminal 75 (Acc) to terminal 85 on the
ignition relay causing it to energize. With the ignition
relay K1 energized, contact is made between terminals
30 and 87. Power is routed from terminal 87 to the
battery (B) terminal on miscellaneous circuit breaker 2.
From the auxiliary (A) terminal of circuit breaker 2,
power is supplied to terminal “I” on the fuel gauge.
Power is also supplied to bulkhead 11 in the main
control box on pins B and D. Power supply is looped
to each of the control box circuit breakers from
bulkhead 11. A frame ground is supplied through
bulkhead 11 on pins A and C to a ground lug inside Battery disconnect switch
the control box. Power is also supplied to the e-stop 360410
reset switch (refer to the emergency stop electrical 1. Battery disconnect switch in the “off” position.
schematic for more information). Turn the disconnect switch to the “on” position.
The disconnect switch is located on the right
Engine start circuit side of the engine. Remove the engine shroud
door from the right side of the engine
When the ignition switch is turned to the “start” compartment to gain access to the switch.
position, power is supplied from terminal 50 (St) to
bulkhead 1 pin 10 (B1-10) on the engine wiring
harness. The engine control module (ECM) will crank
the engine when power is received.
Network 06/02/04
6-105
! WARNING! !
WHICH CAN CAUSE SERIOUS INJURY.
THEREFORE, DO NOT ALLOW FLAMES OR
SPARKS TO COME NEAR THE BATTERY. WHEN
CHARGING OR WORKING NEAR A BATTERY,
ALWAYS SHIELD YOUR FACE AND PROTECT
YOUR EYES. IN CASE OF ACID CONTACT WITH
WATER FOR A MINIMUM OF 15 MINUTES AND
GET PROMPT MEDICAL ATTENTION. IF ACID IS
SWALLOWED, CALL A PHYSICIAN IMMEDIATELY.
2. Discharged battery. Make certain that the

battery is fully charged. The electrical system is Check voltage at ignition switch
360443
a 12 volt negative ground system. Use a battery 4. Defective ignition switch. Using a test light or
hydrometer to check specific gravity of the volt meter, check for 12 volts on terminal 15
electrolyte in each battery cell. A fully charged (bat) on the ignition switch. If 12 volts are not
battery will have a specific gravity of 1.260. present, check the engine wiring harness for
Charge the battery if the reading is below 1.215. defective wiring and repair or replace as
Refer to the maintenance chapter in this manual necessary. If 12 volts are present, check for 12
or to the appropriate engine operators manual volts on terminal 30 with the ignition switch in
for more information on proper charging the “on” position. If 12 volts are not present, the
procedures. ignition switch is defective and must be
replaced.
Symptom:
No power to the main control box. Fuel gauge does

not operate.
Clean battery cables

360218
3. Battery cables are dirty or loose. Clean and
tighten the cables.
Voltage test at power relay

002-2866
1. No power provided to terminal 30 on the ignition
relay. Use a test light or volt meter to check for
Network 06/02/04
6-106
12 volts at the battery side of the emergency 85 and 86. A volt ohm meter should indicate
stop power relay. If 12 volts are not present, approximately 76 ohms of resistance between
replace the wiring between the engine and the the two terminals. Replace the ignition relay if
power relay. the reading is incorrect.
If 12 volts are present, check for 12 volts on both 4. Defective circuit breaker. Use a volt meter to
sides of the main circuit breaker. If 12 volts are check for 12 volts on both posts of circuit
present on the battery side but not the auxiliary breaker 2. If 12 volts are provided to the battery
side of the circuit breaker, remove the wire from side (B) of circuit breaker 2 but are not present
the auxiliary side and repeat the check. Replace on the auxiliary side of the circuit breaker,
the circuit breaker if the previous check remains remove all wires from the auxiliary side of the
the same. circuit breaker and check again. Replace the
circuit breaker if 12 volts are not present.
Replace the wiring between the main circuit
breaker and the ignition relay if both posts of the 5. Defective wiring. If 12 volts are present, on both
circuit breaker indicate 12 volts are present. sides of the circuit breaker after removing all the
wires from the auxiliary (A) post, reconnect each
2. Defective ignition switch. With the ignition wire until the circuit breaker trips. This indicates
switch in the “on” position, use a test light or volt that a short ciruit is present on the last wire that
meter to check for 12 volts on terminal 75 (Acc) was connected. Trace the wire to its origin and
on the ignition switch. Replace the ignition disconnect thewire teminal or bulkhead cable.
switch if 12 volts are not present but the ignition Reconnect the wire at the circuit breaker.
switch will crank the engine. Replace the wiring if the 12 volts are not
present.
If 12 volts are present, replace the fuel gauge,

e-stop reset switch or the wiring between the
control box circuit breakers and bulkhead 11 as
necessary.
Symptom:
One or more engine gauges do not work with the

engine running.
1. Defective gauge. Remove the gauge panel from

the console. Some of the gauges are connected
to the databus module using 6 pin connectors.
The 6 pin connectors (J4 - J7 and J9 - J12) are
Voltage test at ignition relay interchangeable. Swap the connector from the
002-2896
nonworking gauge to one of the connectors
3. Defective ignition relay. Use a volt meter to
used by a working gauge. If the gauge still does
check for 12 volts at terminal 30 and terminal 87
not operate, it must be replaced. If the gauge
on the ignition relay K1. If 12 volts are present
operates, the connecting plug in the databus
at terminal 30 but are not present at terminal 87,
module may be defective. Connect the gauge
check the following.
into one of the other 6 pin connectors not in use.
Check for 12 volts at terminal 85 on the ignition Mark the defective plug to prevent further use.
relay. If 12 volts are not present, refer to the
2. No power supply to the databus module. If the
preceding corrective measure. If 12 volts are
gauge lights do not work, depress the engine
present, make certain a good ground connection
gauge circuit breaker button if it is extended. If
is provided to the relay coil on terminal 86.
the button pops out immediately, an electrical
The coil may also be checked for ohms of short to ground is present.
resistance by removing the wires from terminals
Network 06/02/04
6-107
Disconnect plug J1 from the databus module.

Reset the circuit breaker. If the reset button
pops out, the circuit breaker may be weak or the
wiring between the circuit breaker and plug J1 is
defective. Repair or replace the wiring or the
circuit breaker.
If the reset button remains depressed, the

databus module or one of the gauges is shorted.
Turn the ignition switch “off”. Disconnect all
gauges and reconnect plug J1 to the databus
module. Turn the ignition switch “on”. If the
circuit breaker reset button pops out, the module
is shorted and must be replaced. If the circuit
breaker reset button remains depressed,
connect each gauge individually until the button
pops out. Replace the gauge that pops out the
circuit breaker reset button.
Symptom:
Engine stops operation. Red diagnostic lamp

illuminated.
If the diagnostic lamp gauge illuminates a red stop

lamp, check either the Murphy diagnostic gauge for
service codes or depress and hold the diagnostic fault
switch to read the flash codes on the diagnostic lamp
gauge. Provide the SPN FMI service code or the flash
code numbers to your local Cummins Service Center
Network 06/02/04
6-108
CHAPTER VII STRINGLINE SETUP Assemble the line holder rods and clamps and place a
rod and clamp on each stake.
Note: This should be done before the stake is
This chapter contains detailed instructions on setting driven, as the head of the stake will spread,
the stringline which the machine follows for straight preventing the placement of the clamp on the
work, radius work and for slope changes. Accurate stake.
placement of the stringline assures maximum control
to meet strictest tolerances. Any deviation in the
stringline will affect final line and grade.
Recommended Offsets
Stringline
0 to 24 in.
0 to 60 cm
12 to 48 in.
30 to 122 cm
Hub
Set stakes behind hub

715-0001
M-D-999-047 801
Drive one stake and rod assembly approximately 1 ft.
Recommended Offsets (30 cm) behind each grade hub, as near vertical as
M-D-999-047
The recommended distance between the stringline possible. Stakes should not be placed over 50 ft.
and the edge of the finished product is 12 to 36 in. (30 (15.2 m) apart, with 25 ft. (7.6 m) intervals
to 91 cm). The recommended distance the stringline recommended. If stakes are not driven as near
should be placed above the top edge of the finished vertical as possible, line will be affected when grade is
product is 0 to 24 in. (0 to 60 cm). The distances will adjusted, or grade will be affected when line is
be determined by job conditions and the mold profile adjusted.
used.
Drive one stake and rod assembly 15 to 20 ft. (4.6 to
Note: Offset distances used in this chapter are 6.1 m) before the first and past the last grade hub, if
referenced from the top back of the curb profile. possible, to allow room to maintain line and grade prior
Reference points may differ according to job to the beginning point and past the finish point of the
conditions. Make certain the reference point is job.
known before proceeding.
02 Setting Straight Line
Set winch
715-0003
Assemble the winches by placing the crank handle on
Assemble line holder rod to stake
715-0002 the drive shaft and securing it in place with the self
locking nut.
G21 09/22/97 7-1

Drive a stake approximately 4 ft. (1.2 m) beyond the Drive a stake at an angle approximately 4 ft. (1.2 m)
first stake. Place the hole in the winch mounting plate beyond the last stake and attach the line. Attach the
down over the stake and fasten the winch in place by line at the same height as the finished line will be. It is
tightening the setscrew. Drive a second stake through recommended that the excess line not be cut loose,
the slot in the mounting plate and secure the winch to unless necessary.
this stake by driving the wedge plate (on the
underside) in tight.
Note: The winch should be set at the same height

as the finished line.
Check line for tension

715-0005
Winch the line tight enough to eliminate any slack that
would affect line and grade. To check, attempt to twist
the line. If it can be twisted more than 45 degrees, it is
too loose.
Attach line to winch drum
715-0015
Attach the end of the stringline to the winch drum.
Winch approximately 5 ft. (1.65 m) of line onto the
drum. Insert a bar into the center of the spool of line
and uncoil as much as is needed. It is recommended
that one winch be used to tension no more than 1000
ft. (305 m) of line.
! CAUTION! !
THE METAL INSERTS IN THE CENTER OF THE
LINE SPOOL MAY CAUSE PERSONAL INJURY IF
THE LINE IS UNCOILED BY PLACING FINGERS IN
CENTER OF SPOOL.
Place line in holder notch
715-0006
Place the line in the notches at the end of each line
holder rod. The hole in the end of the line holder rod is
at a right angle (90°) to the holder. The slot cut down
into the hole is at approximately a 5° angle to the hole.
This provides a hook to hold the line in the hole.
Position the line holder rod at a right angle (90°) to the
stringline so the hooks will hold the line in the hole.
Note: Do not place the line in the holder rod notch

until the line has been winched tight. The line
could catch in the holder rod notch and affect
tension.
Attach line to anchor stake

715-0004
G21 09/22/97 7-2

Plumb line over hub Set line for cuts

715-0007
715-0009
Using a level, plumb up from the locating mark on the To adjust the line for cuts, subtract the required
top of the grade hub and adjust the line in or out as amount of cut from the distance between the line and
needed to position the line directly above the grade the finished product, to give the distance the line is to
hub. Tighten the adjusting screw in the clamp be set above the grade hub. A cut indicates the
securely. finished product will be below the top of the grade hub
by the amount indicated.
For Example: If the line is to be 2 ft. (60 cm)

above the top of the finished product and the
grade stake calls for a cut of 0.25 ft. (7.6 cm), the
distance between the grade hub and the line
would be 1.75 ft. (52.4 cm). This would cause the
finished product to be 0.25 ft. (7.6 cm) below the
top of the grade hub.
Set line for fills

715-0008
Adjust the stringline elevation by measuring up to the
line from the locating mark on the top of the grade hub.
For fills, add the required amount of fill to the distance
between the line and the finished product, to give the
distance the line must be set above the grade hub. A
fill indicates that the finished product will be above the
top of the grade hub by the amount indicated.
For Example: If the line is to be 2 ft. (60 cm) Eyeball line for imperfections
715-0014
above the top of the finished product and the After the line has been completely adjusted, check it
grade stake calls for a fill of 0.50 ft. (15 cm), the by sight to locate any deviations in the line, or to adjust
distance between the grade hub and the line stakes that are set in between grade hub locations.
would be 2.5 ft. (75 cm). This would cause the Adjust the line as necessary.
finished product to be 0.50 ft. (15 cm) above the
grade hub.
G21 09/22/97 7-3

03 Setting Line for Radii

Outside Radius Inside Radius
Stringline
Machine
Stringline
Machine
Pivot Point
Pivot Point
M-D-999-005 814
Comparison of inside and outside radii

M-D-999-005
An outside radius refers to the machine beyond the
radius pivot point and the stringline; an inside radius
indicates the machine is between the pivot point and
the stringline.
Stringline set for radius

715-0010
To set the line for a radius, drive a stake at the radius
hub. Measuring out from this point, drive stakes and
rod assemblies at the correct distance from the radius
hub.
For Example: If a 25 ft. (7.6 m) outside radius is

being set and the finished product line is to be 4 ft.
(1.2 m) from the line, set the stakes at 20 ft. (6.1
m) and the line at 21 ft. (6.4 m) from the radius
point. If a 35 ft. (10.7 m) inside radius is being set
and the finished product line is to be 4 ft. (1.2 m)
from the line, set the stakes 40 ft. (12.2 m) from
the radius point and the line 39 ft. (11.9 m). Plastic pipe in holder
715-0011
To determine the distance to set between the stakes, To make a smooth radius and use less stakes and
divide the radius by ten. Thus in a 25 ft. (7.6 m) rods, use 3/4 in. (2 cm) plastic tube. Drive the radius
radius, the stakes would be placed no more than 2.5 ft. stakes 4 to 5 ft. (1.2 to 1.5 m) apart. Make a special
(76 cm) apart. Place the stringline in the holder rod bracket such as the one shown in figure M-D-999-006
notches and adjust the line and grade as necessary to and slide it over the end of the line holder rod. Place
give a smooth looking radius. the plastic tube into the holder and slide the bracket
onto the holder so the end of the line holder rod will
Note: When paving around a radius, the material hold the tube in the holder. Tighten the setscrew.
line may move towards the radius point. It may be
necessary to “dry run” the paving equipment and
reset the line in, or out, to achieve the correct line.
G21 09/22/97 7-4

section and continue setting the line in the normal

manner.
Note: It may be necessary to tie the two lines

together with small pieces of string or tape, to hold
them both in the notch in the end of the line holder
rod.
To assure sensor wand clearance, drive an offset

stake on either side of the last stake in the first section.
Adjust the offset line holders to hold the line back from
and slightly above the main line.
04 Positioning Stringline for Cross Slope Changes

Start of plastic pipe radius
Drive a stake and line holder rod assembly When setting stringline through a super elevation, or
approximately 4 ft. (1.2 m) before the start of the any location involving a slope change, a correction in
radius. Place the stringline in the notch in the holder the height of the stringline is usually necessary.
and adjust for line and grade as previously described. Stringline elevation correction is directly related to and
Attach the end of the line to an anchor stake, set 1 ft. proportional to the amount of cross slope change and
(30 cm) behind the main line, so the end of the line is the distance the stringline is from the material
slightly higher than the main line. Extend the tubing placement line.
from the beginning of the radius to the stake set ahead
of the starting point. Secure the end of the tube to the Slope/Grade Elevation Change
top of the stringline with tape, so the machine side of
Pivot Point
the tube is even with the side of the stringline. Adjust
the tube so the bottom edge of it is at the same grade
as the stringline and the edge of it is the proper offset
distance from the radius point. Set the finish end of Grade Elevation
the radius in the same manner. Change
Continuing Line Past 1000 Ft. (304.8 M)

M-D-999-045 818
First Section
Second Take-up Slope/grade elevation change
Winch M-D-999-045
Automated trimmers and pavers pivot around the
stringline. The stringline acts as a pivot point when
Off-set Stake
cross slope is changed. As slope is increased or
decreased, grade elevation is affected. At those
First Take-up
Winch locations where slope changes are required, it is
recommended that the stringline height be changed to
compensate. When the stringline is on the left side of
the machine and the amount of slope is increased, the
stringline should be lowered, and the line should be
Second Section raised as the amount of slope is decreased. When the
stringline is set under the machine and the slope is
increased, the line must be raised, and must be
M-D-999-046
lowered when the slope is decreased.
Continuing line past 1000 ft.
M-D-999-046
To continue the stringline past 1000 ft. (305 m), place
a winch assembly between the last two stakes of the
first section, in line with the stakes. Attach the second
section of line to the winch and uncoil the line as
required. Winch the line tight. Place the second line
in the notch of the last line holder rod in the first
G21 09/22/97 7-5

Corrected Stringline
05 Setting the Line Under the Machine
Corrected String Line
Correct Elevation
M-D-999-044
Corrected stringline
M-D-999-044
To determine the amount of grade correction
necessary for a given amount of slope change,
measure the distance from the stringline to the
material placement line. Multiply this distance by the
total amount of slope change. The result is the
amount of grade change necessary. When setting the line for under the machine, when
pouring parapet wall, special holders must be made
For Example: If the stringline is located 3 ft. (91 that will not tip over. There is a variety of ways to
cm) from the concrete line and the total amount of make holders. Some will weld a 12 in. (30 cm) piece
slope change is 4%, multiply as follows: of 3/4 in. (2 cm) shaft to a plate of steel and others will
insert a shaft into a pail of fresh concrete and allow the
Multiply 4% (.04) x 3 ft. (91 cm) concrete to harden. It is recommended to set the line
approximately 8 to 9 in. (20 to 23 cm) above the grade
.04 x 3 ft. (91 cm) = 0.12 ft. (3.64 cm) correction surface.
required.
The line is normally set 5 ft. (1.5 m) from the front face
Raise or lower the stringline as required. If the amount of the wall base. Measure from the reference point
of slope is being increased, the stringline must be and set the line accordingly. After the line is set,
lowered and if the slope is being decreased, the adjust it by sight for any deviations. It is
stringline must be raised. It is recommended to start recommended to draw a line around the base plates,
the stringline adjustment at the beginning of the slope so if they are moved, they can be returned to the exact
transition and make even adjustments at each grade same place.
stake. The maximum amount of stringline adjustment
should be attained at the high point of the transition. PVC Holder bracket 1
4 Wall Min.
For Example: If a slope change of 4% is required
over 100 ft. (30.5 m), adjust the line 1/4 of the total 3 85
amount necessary at each of the four grade 3
112 7
I. D.
stakes in that 100 ft. (30.5 m). The total amount of 16
adjustment would be made at the high point, which

would be 0.12 ft. (3.64 cm). The first stake prior
to, or after, the high point would be adjusted 0.09
ft. (2.37 cm), the second one prior to, or after, the
high point would be adjusted 0.06 ft. (1.82 cm) and
the third one prior to, or after, the high point would
be adjusted 0.03 ft. (0.91 cm). Adjust the line in 5
10 UNC
16
this manner on both sides of the transition high 3
4 Dia. Conduit Clamp
point. M-D-999-006 820
Plastic tube holder drawing

M-D-999-006
G21 09/22/97 7-6

06 Setting Radius Wheels
Note: Other materials such as PVC pipe,

fiberglass rod, or fiberglass bar may be used to
form a smooth radius to guide the machine.
Raise Radius Wheel and Attach Clips

824
Raise the radius wheel up to the approximate height it
will be at for the pour. Tighten two of the set screws
temporarily to hold the wheel in position. Place the
stringline around the radius wheel and clip it in position
using the spring clips provided and tighten the
Placement of Radius Wheel stringline. To check, attempt to twist the line. If it can
822
It will be necessary to find the center of the radius and be twisted more than a 20° angle, it is too loose. It
place the center spoke of the radius wheel over the may be necessary to have another person support the
center point of the radius. Make certain that the radius stringline on the radius wheel while tightening the
wheel is the proper size. Measure from the center of stringline.
the wheel to the outer edge and add the offset that the
machine will be set for. The sum will give the total size Notice: An unsatisfactory product will occur if the
of the radius to be poured. For example, if the radius stringline is not adequately tensioned. This is
wheel measures 4 feet (1.2 m) and the offset is 1 foot especially important on the GT-3600 due to the
(30 cm) to the back of curb, then the total size of the close proximity of the sensor wands applying
radius is 5 feet (1.5 m). Place a stringline stake in the pressure to the stringline.
center spoke of the wheel and drive it as vertical a
possible.
Set Wheel to Grade

825
Adjust the radius wheel elevation by measuring up to
Orientation of radius wheel the bottom side of the wheel from the locating mark on
823 the top of the grade hub. For fills, add the required
Orient the spokes in the radius wheel so that they are amount of fill to the distance between the bottom of the
at a 90° angle in relation to the next radius wheel and/ wheel and the finished product to give the distance the
or the stringline. Drive a stringline stake in each of the wheel must be set above the grade hub. A fill
remaining holders as vertical as possible. indicates that the finished product will be above the top
of the grade hub by the amount indicated.
G21 09/22/97 7-7

To adjust the wheel for cuts, subtract the required

amount of cut from the distance between the bottom of
the wheel and the finished product to give the distance
the wheel is to be set above the grade hub. A cut
indicates the finished product will be below the top of
the grade hub by the amount indicated.
Tighten the set screw(s) securely that is(are) located

nearest to the grade hub used to set the wheel.
Placing a level across the top of the radius wheel,

plumb the wheel to match the same slope (if any) as is
set in the stringline. If another radius wheel is located
nearby, it may be possible to pull a stringline across
the top of the two radius wheels. Adjust the wheels so
that they are parallel to each other.
After the wheel and stringline have been completely

adjusted, check it by sight to locate any deviations in
the line, or to adjust stakes that are set in between
grade hub locations. Adjust the line as necessary.
Contact GOMACO or your nearest authorized

GOMACO dealer for information on the different radius
wheel sizes that are available.
G21 09/22/97 7-8

Percent Inches Inches Inches Inches Inches Inches

Slope Per Per Per Per Per Per
Foot 10 Ft. 11 Ft. 12 Ft. 13 Ft. 14 Ft.
0.13% 1/64" 5/32" 11/64" 13/16" 13/64" 7/32"

0.26% 1/32" 5/16" 11/32" 3/8" 13/32" 7/16"
0.52% 1/16" 5/8" 11/16" 3/4" 13/16" 7/8"
0.78% 3/32" 15/16" 1-1/32" 1-1/8" 1-17/32" 1-5/16"
1.04% 1/8" 1-1/4" 1-3/8" 1-1/2" 1-5/8" 1-3/4"
1.56% 3/16" 1-7/8" 2-1/16" 2-1/4" 1-7/16" 2-5/8"
2.08% 1/4" 2-1/2" 2-3/4" 3" 3-1/4" 3-1/2"
3.13% 3/8" 3-3/4" 4-1/8" 4-1/2" 4-7/8" 5-1/4"
4.17% 1/2" 5" 5-1/2" 6" 6-1/2" 7"

M-D-999-048 821
Relation of Degree and Percent of Slope

7
6
30°
5 50%
25°
4 40%
20°
RISE
3 30%
15°
2 20%
10°
1 10%
5°
1 2 3 4 5 6 7 8 9 10
RUN
M-D-999-049 822
G21 09/22/97 7-9

GT-3600 Trimmer/Paver Owner/Operator's Manual G21 / Apitech: The Worldwide Leader in Concrete Paving Technology

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GT-3600 Trimmer/Paver Owner/Operator's Manual G21 / Apitech: The Worldwide Leader in Concrete Paving Technology

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The Worldwide Leader in Concrete Paving Technology

GODBERSEN-SMITH CONSTRUCTION COMPANY

ENGINE SERIAL NUMBER:___________________________

A “Danger” statement is of utmost importance and

A “Warning” statement is customarily used to

A “Caution” statement usually indicates a hazard

NOTE: It is GOMACO’s policy to constantly strive to improve GOMACO products. The

CHAPTER II CONTROLS AND GAUGES ........................................................................................................... 2-1

CHAPTER III STANDARD SETUP ....................................................................................................................... 3-1

10 Final Adjustments .......................................................................................................................... 3-41

CHAPTER IV SIDE MOUNTED BARRIER SETUP ............................................................................................. 4-1

Lubrication and Maintenance Service Interval Chart ...................................................................................... 5-1

CHAPTER V MAINTENANCE ............................................................................................................................. 5-3

CHAPTER VI DIAGNOSTICS ............................................................................................................................. 6-1

02 Engine Diagnostics .......................................................................................................................... 6-1

CHAPTER VII STRINGLINE SETUP .................................................................................................................. 7-1

Quick Reference Parts List

Engine Primary Fuel Filters

Engine Secondary Fuel Filters

Engine Air Filter

High Pressure Lift Circuit Filter Element ........................................................... 110-45Q53

Sump Filter ....................................................................................................... 110-46F19

Sump Filter Access Cover Gasket .................................................................... GT62-194

Access Cover Bolt Rubber Seal Washer .......................................................... 420-30A96

G21 control system

Grade/Steering Sensor ..................................................................................... 500-46D83

Slope Sensor .................................................................................................... 500-46Y35

Smart Steer Cylinder ........................................................................................ GT10-421

S2X ................................................................................................................... 500-49J69

Pancon Controller ............................................................................................. 500-49Y71

Display Switch Assembly (Main Control Panel Module) ........................ B-GT61-555-D

Individual Control Meter Module ....................................................................... 500-48L54

Vertical Switch Assembly (Elevation Control) ........................................ B-GT61-555-B

Sensor Coil Cord (10 ft.) ................................................................................... 520-48D39

Servo Valve (5 gpm) ......................................................................................... 125-45N30

Grade Sensor Wand (Complete) ...................................................................... 500-15A77

Steering Sensor Wand ..................................................................................... 500-15A69

0-3000 psi (0-207 bar) Pressure Gauge ........................................................... 700-35A46

Ignition Key Switch ........................................................................................... 210-46K14

Vibrator ............................................................................................................. GT11-046

Vented Main Relief Valve Cartridge (RVEA LAN) ............................................ 125-10C47

Vibrator Variable Relief Valve Cartridge (RVGA LHN) ..................................... 125-45Q87

Lift Lock Check Valve/Thermal Relief (CBCA LHN) ......................................... 125-45N98

Servo Lock Solenoid Valve Assembly .............................................................. 125-45R91

Differential Lock Solenoid Valve Assembly ...................................................... 125-45R91

Quick Coupler O-Rings

Conveyor Discharge Chute .............................................................................. RC64-028

Trimmer Teeth (Carbide Tip) ............................................................................ 730-45J82

SAFETY SECTION WARNING SIGNS AND DECALS

the hose. FIRE OR EXPLOSION PREVENTION

Never attempt adjustments while the engine is running

Do not jump off the machine. Always use steps and

Be sure that all protective guards and covers are

REPLACEMENT ELEMENT DECAL AS PER

Cummins QSB Engine Only

CHAPTER II CONTROLS AND GAUGES

This chapter describes engine, hydraulic, and

02 Standard Engine Controls and Gauges

Fuel Gauge: Monitors the amount of diesel fuel in the

Engine Oil Pressure: Indicates engine oil pressure.

Tachometer and Hour Meter: Electrically operated

Hydraulic Oil Temperature Gauge: Monitors the

Note: Excessive oil temperature may cause