Bomag Bw 11rh Pneumatic Tired Roller Service Repair Workshop Manual Download by www.heydownloads.com

BW 11RH Pneumatic tired roller Instructions for repair Catalog number 0852645 11/00

BW11RH DANGER: If the machine was received with the Roll Over/Falling Object Protection Structure (ROPS/FOPS) and Operator Restraints (Seat Belt Sets) NOT installed, they MUST be installed BEFORE the machine is operated, using the installation instructions drawing, included with the installation kit, and/or the illustration below. In the event of a machine roll over, serious injury, or death, can occur due to failure to correctly install the Roll Over/Falling Object Protection Structure (ROPS/FOPS) and Operator Restraints (Seat Belt Sets).

Structure

6 Flange Screws and Nuts used. Apply Loctite #242 to each Flange Screw. Install Nuts and tighten to a torque of 400 ft. lbs. (542 N.m).

Right (Buckle)

Left (Retractor)

Seat Belt Assembly (2 Sets used)

Washer

DANGER: Do Not operate machine with the Roll Over/ Falling Object Protection Structure (ROPS/FOPS) and Operator Restraints (Seat Belt Sets) NOT properly installed.

3 Capscrews and Flange Nuts used. Install Flange Nuts and tighten to a torque of 40 ft. lbs. (54 N.m).

March 2000

SYMBOLS USED IN THIS MANUAL The following symbols have been used in THIS Manual to help communicate the intent of instructions. When one of the symbols appears, it conveys the meaning defined below:

DANGER: Serious personal injury, death and/or extensive property damage can result if the DANGER instructions are not followed.

WARNING: Serious personal injury and/or extensive property damage can result if the WARNING instructions are not followed.

CAUTION: Minor personal injury can result or a part, an assembly, or the engine can be damaged if the CAUTION instructions are not followed.

NOTE: Gives additional, and/or clarification details, which are to be used in conjunction with previously presented information.

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm.

CALIFORNIA Proposition 65 Warning Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the state of California to cause cancer, birth defects, and other reproductive harm. Wash hands after handling.

SERVICE AND REPAIR PRECAUTIONS

ALWAYS inspect all slings, chains, or cables when lifting components, be sure that they are properly tied, fastened and balanced before lifting. Be sure that the lifting device is capable of retaining the weight to be lifted.

NEVER attempt to lift heavy parts by hand when a lifting device should be used.

ALWAYS wear safety glasses when performing any maintenance or repair work on the machine.

NEVER attempt to remove or repair any component, on the machine, while the engine is running.

NEVER leave the machine and/or heavy parts in an unstable position during repair.

ALWAYS support the machine with sound blocking.

ALWAYS keep the machine and work area clear of lubricants and dirt.

ALWAYS use the correct tools for the repair procedures being done on the machine,

ALWAYS keep tools in a good and clean condition.

ALWAYS use approved parts, that are designed for the machine being repaired. This helps to ensure maximum service life of the machine.

ALWAYS be sure that all necessary nuts, bolts, snap rings, and other fastening devices, are removed before using force to remove components.

ALWAYS attach a sign in the machine operator’s area, stating “DO NOT OPERATE” when the machine is being repaired.

ALWAYS observe ALL WARNING AND CAUTION statements given in the Operating Manual and Service Manual and found on the machine decals.

MANUAL - TABLE OF CONTENTS

PAGE SECTION 1 - INTRODUCTION ......................................................................................................... 1-1.

SECTION 2 - SPECIFICATIONS ...................................................................................................... 2-1.

SECTION 3 - OPERATION .............................................................................................................. 3-1.

SECTION 4 - MAINTENANCE .......................................................................................................... 4-1.

SECTION 5 - FRAME, HITCH AND FOPS/ROPS .................................................................................. 5-1.

SECTION 6 - ENGINE ............................................................................................................................. 6-1.

SECTION 7 - ELECTRICAL .................................................................................................................... 7-1.

SECTION 8 - TRANSMISSION SYSTEM ............................................................................................... 8-1.

SECTION 9 - BRAKE SYSTEM .............................................................................................................. 9-1.

SECTION 10 - STEERING SYSTEM ...................................................................................................... 10-1.

SECTION 11 - WATER SPRAY SYSTEM .............................................................................................. 11-1.

2/98

OPERATING INSTRUCTIONS WARNING:

WARNING:

Section 1 INTRODUCTION

TABLE OF CONTENTS

PAGE GENERAL INFORMATION ......................................................................................................................1-2. SPECIFICATIONS ....................................................................................................................................1-2. OPERATING INSTRUCTIONS .................................................................................................................1-2. MAINTENANCE PROCEDURES .............................................................................................................1-2. REPAIR PROCEDURES ..........................................................................................................................1-3. NAME PLATE / SERIAL NUMBER PLATE .............................................................................................1-3. SERIAL NUMBER ....................................................................................................................................1-3.

11/00

1-1

Section 1 INTRODUCTION GENERAL INFORMATION. THIS manual contains SPECIFICATION, OPERATION and MAINTENANCE procedures for the Model BW11RH Roller [See Figure 1-1].

SPECIFICATIONS. See Section 2 - SPECIFICATIONS, of THIS manual, for specifications on major systems used on the machine.

WARNING: ONLY authorized personnel, who are fully trained in the machine operation procedures, can operate the Model BW11RH Roller. Follow ALL instructions given in THIS manual and written on the “Machine Operation and Warning” decals, found on the upper area of the front cowl in the operator's compartment.

MAINTENANCE PROCEDURES. OPERATING INSTRUCTIONS. READ, UNDERSTAND and FOLLOW ALL the operating instructions given in the FRONT, and in Section 3 - OPERATION, of THIS manual.

The maintenance schedules and procedures are found in Section 4 - MAINTENANCE, of THIS manual.

CAUTION: Follow ALL the maintenance schedules and instructions given in THIS manual.

FIGURE 1-1. MODEL BW11RH ROLLER.

1-2

11/00

Section 1 INTRODUCTION REPAIR PROCEDURES.

SERIAL NUMBER [See Figures 1-2 and 1-3 ].

MAJOR machine component REPAIR PROCEDURES are found in the “SYSTEM REPAIR PROCEDURE” sections of "Service Manual", pn. 0852462.

The SERIAL NUMBER indicates the design series, manufacturing location and machine serial number [see Table 1-1]. The machine serial number is located on the nameplate [see figure 1-2].

CAUTION: For CORRECT machine component repair procedures, USE "Service Manual" pn. 0852462, or other referenced written materials ONLY.

NAME PLATE /SERIAL NUMBER PLATE [See Figure 1-2].

The machine serial number is also stamped on the left hand side of the rear unit hitch weldment [see figure 1-3].

CAUTION: ALL numbers and letters, contained in the SERIAL NUMBER, MUST be given when requesting service and/or part information.

The name plate/serial number plate is located on the left side of the machine, above the entrance to the operator's compartment. The plate MUST stay fastened to the machine at ALL times. If the plate is missing or damaged, it MUST be replaced IMMEDIATELY. Contact your nearest Distributor to obtain a replacement plate.

NAME PLATE SERIAL NUMBER

FIGURE 1-3. STAMPED SERIAL NUMBER LOCATION - ON RIGHT INSTRUMENT PANEL COWL.

FIGURE 1-2. NAME PLATE /SERIAL NUMBER PLATE LOCATION.

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1-3

Section 1 INTRODUCTION A222

BW11RH * *H = HYDROSTATIC

KEWANEE

1505

CONSECUTIVE SERIAL NUMBER

YEAR OF SHIPMENT

109

PLANT OF MANUFACTURE

A222

BW11RH * *H = HYDROSTATIC

01850

MACHINE SERIAL NUMBER

TABLE 1-1. MACHINE SERIAL NUMBER DESIGNATIONS.

1-4

11/00

Section 2 SPECIFICATIONS

TABLE OF CONTENTS PAGE GENERAL INFORMATION ............................................................................................................... 2-2. TABLE 2-1. FRAME, HITCH AND FALLING OBJECT/ROLL OVER PROTECTIVE STRUCTURE [FOPS/ROPS] SPECIFICATIONS .................................................................. 2-2. TABLE 2-2. ENGINE SPECIFICATIONS .......................................................................................... 2-3. TABLE 2-3. ELECTRICAL SPECIFICATIONS ................................................................................. 2-5. TABLE 2-4. TRANSMISSION SYSTEM SPECIFICATIONS ............................................................ 2-6. TABLE 2-5. BRAKE SYSTEM SPECIFICATIONS ........................................................................... 2-9. TABLE 2-6. STEERING SYSTEM SPECIFICATIONS ..................................................................... 2-9. TABLE 2-7. TIRE SPECIFICATIONS .............................................................................................. 2-11. TABLE 2-8. CONTROL AND INDICATOR SPECIFICATIONS ....................................................... 2-11. TABLE 2-9. WATER SPRAY SYSTEM SPECIFICATIONS ........................................................... 2-12. TABLE 2-10. OPTIONAL EQUIPMENT SPECIFICATIONS ............................................................ 2-13. TABLE 2-11. DIMENSION AND WEIGHT SPECIFICATIONS ........................................................ 2-14. TABLE 2-12. PERFORMANCE SPECIFICATIONS ........................................................................ 2-15. TABLE 2-13. MACHINE SYSTEM CAPACITY SPECIFICATIONS ................................................ 2-15. TABLE 2-14. COMPONENT WEIGHTS .......................................................................................... 2-16. TABLE 2-15. TORQUE SPECIFICATIONS FOR STANDARD INCH FASTENERS ......................................................................................................................... 2-17. TABLE 2-16. TORQUE SPECIFICATIONS FOR STANDARD METRIC FASTENERS ......................................................................................................................... 2-18. TABLE 2-17. LUBRICATION OILS, HYDRAULIC OILS AND COOLANT SPECIFICATIONS ................................................................................................................. 2-19. TABLE 2-18. ADHESIVE THREAD LOCKING SPECIFICATIONS ................................................ 2-19.

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2-1

Section 2 SPECIFICATIONS GENERAL INFORMATION. THIS section gives specification tables for each MAJOR machine system of the Model BW11RH Roller.

Machine dimensions, weights, performance and torque specifications are also given in THIS section.

TABLE 2-1. FRAME, HITCH AND FALLING OBJECT/ROLL OVER PROTECTIVE STRUCTURE [FOPS/ROPS] SPECIFICATIONS. ITEM

DESIGN DATA

FRAME Material

Plate steel

Construction

Unitized, all welded front and rear frame section

HITCH Oscillation

+/- 10˚ - each side to center, 20˚ total - side to side

Articulation

+/- 35˚ - each side to center, 70˚ total - side to side

ROLL OVER/FALLING OBJECT [ROPS/FOPS] STRUCTURE - WITH OPERATOR RESTRAINT SYSTEM Type and Description

2-2

Bolt on, welded single post steel structure and two [2] seat belt sets, for operator restraint, conform to SAE recommended practice J-1040C, J231 and J-386; and CSA B352 (Canada)

07/01

Section 2 SPECIFICATIONS TABLE 2-2. ENGINE SPECIFICATIONS. ITEM

DESIGN DATA

ENGINE Model and Manufacturer

4B3.9 Cummins Diesel

Type

4 Cycle N.A. diesel

Number of Cylinders

Bore

4.02 in. [102 mm]

Stroke

4.72 in. [120 mm]

Rated Brake Horsepower

80 hp [59.7 Kw] @ 2,500 rpm

Compression Ratio

16.5:1

Firing Order

1-3-4-2

Low Idle Speed

800 - 850 rpm

High Idle Speed

2,650 +/- 20 rpm [governed]

Engine Oil Type

See engine Cummins "Operation and Maintenance Manual - B Series Engines", which is supplied with machine

Valve Clearances Intake - Cold

0.010 in. [0.25 mm]

Exhaust - Cold

0.020 in. [0.51 mm]

ENGINE COOLING SYSTEM System Capacity

19 qts. [17.97 ltrs.]

Radiator Type

Full flow, liquid pressure, with integral oil cooler

Pressure Cap Rating

7 psi. [0.5 bar]

Thermostat Range

180-190˚ F [82-88˚ C], thermostat opens

07/01

2-3

Section 2 SPECIFICATIONS ITEM

DESIGN DATA

ENGINE FUEL Type Used

Use ONLY distillate fuels [A.S.T.M. No.1 or No.2 fuel oil or No.1D or No. 2D diesel fuel are EXAMPLES]. The fuel MUST have a MINIMUM cetane number of 35. Heavier oil is generally preferable because of its higher energy content

Rate of Fuel Consumption [@ normal engine H.P. @ 40% load]

1.3 Gallons per hour [4.9 liters per hour]*

*Operating conditions, that vary, can cause different fuel consumption amounts than those given FUEL FILTERS Fuel Strainer

Suction line, replaceable element

Fuel Filter

Pressure line, replaceable element

FUEL PUMP Type

Bosch, distributor type

FUEL INJECTORS Quantity and Type

2-4

4, close nozzle

07/01

Section 2 SPECIFICATIONS TABLE 2-3. ELECTRICAL SPECIFICATIONS. ITEM

DESIGN DATA

BATTERY Number Per Machine

One [1]

Ampere Hour Rating

900 CCA

Voltage

12 Volts

ALTERNATOR Voltage, Type and Manufacturer

12 Volt, negative ground - Bosch

Output Amperage

62 Amps

Maximum Charge Rate

62 Amps - 14 volts [cold]

Direction of Rotation

Clockwise [C.W.] - viewed from drive end

Fan Belt Tension and Method Used to Achieve

Automatic belt tensioner keeps serpentine belt under tension at ALL times

STARTER Manufacturer

Delco Remy [see engine STARTER plate for part number]

Voltage and Type

12 Volt, negative ground

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2-5

Section 2 SPECIFICATIONS TABLE 2-4. TRANSMISSION SYSTEM SPECIFICATIONS. ITEM

DESIGN DATA

TRAVEL SPEED Low Medium High

0 - 8.0 mph [0 - 12.9 kph] 0 - 10.5 mph [0 - 16.9 kph] 0 - 15.5 mph [0 - 25.0 kph]

TRANSMISSION TYPE

Hydrostatic

PUMP [see Hydraulic Pump]

Axial piston, variable displacement

MOTORS [See Hydraulic Motor]

Radial piston, variable displacement, with integral multi-disc brake

APPROVED OILS

Texaco TDH, Mobil 423, or equivalent oil meeting J20A specification

HYDRAULIC SYSTEM CAPACITY

28.5 Gallons [107.91 liters]

SUCTION FILTER

7 Micron [nominal, Beta ten of 3.86 average - 3.10 minimum

MAXIMUM SUCTION

10 in. hg. [254 mm hg] Maximum

SYSTEM PRESSURES [At normal operating temperatures, with the engine running @ 1500-2000 RPM, EXCEPT charge pressure checks which are taken @ LOW engine IDLE speed]

2-6

NEUTRAL CHARGE

350 psi. [24 bar] Minimum, 400 psi., [28 bar] Maximum

STROKED CHARGE

15-30 psi. [1.0-2.0 bar], below neutral charge

HIGH PRESSURE

6200 +/- 100 psi. [428 +/- 6.9 bar]

CONTROL PRESSURE [forward or reverse]

100 psi. [6.9 bar]

CASE PRESSURE

40 psi. [2.8 bar] Continuous, 75 psi. [5.2 bar] Intermittent

SUCTION FILTER VACUUM

10 in. hg. [0.7 bar] Maximum

07/01

Section 2 SPECIFICATIONS TRANSMISSION PUMP ITEM

DESIGN DATA

TYPE

Variable displacement axial piston

SWASH PLATE ANGLE

17˚ maximum - either side of center

PRESSURE RATING MAXIMUM

6000 psi. [414 bar]

DIRECTION OF ROTATION

Clockwise [C.W.]

CASE PRESSURE

75 psi. [5.2 bar] Maximum cold start intermittent ONLY 40 psi. [2.8 bar] continuous warm

MINIMUM MAIN PORT PRESSURE

200 psi. [14 bar] ABOVE case pressure

MAXIMUM CONTINUOUS CASE TEMPERATURE

220˚ F [104˚ C]

MAIN SHAFT SPEED AT NO LOAD

2650 +/- 20 rev/min

CHARGE FLOW RATING

10 Gallon/min [38 liter/min] @ 2100 rev/min

CHARGE PUMP DISPLACEMENT

1.03 cu. in. [17 cu. cm] per revolution

PORT SIZES MAIN LINE INLET/OUTLET PORTS [2]

1.00 in. [25.4 mm] S.A.E. split flange, 4 bolt, code 62

CASE PORTS [INLET AND OUTLET]

1.0625 in. [29.99 mm] - 12 S.A.E. straight thread O-ring

CHARGE PUMP INLET

1.312 in. [29.99 mm] - 12 S.A.E. straight thread O-ring

CONTROL LEVER

28˚, Either direction from center

07/01

2-7

Section 2 SPECIFICATIONS HYDRAULIC MOTORS ITEM

2-8

DESIGN DATA

TYPE

Radial piston,variable displacement, with multi-disc brake

NUMBER PER MACHINE

Two [2]

MAXIMUM OPERATING PRESSURE

6500 psi.. [449 bar] intermittent ONLY

MAXIMUM CASE PRESSURE

35 psi. [2.4 bar] Cold/intermittent ONLY

MULTI-DISC BRAKE, RELEASE PRESSURE

175-435 psi.. [12-30 bar]

PORT SIZES Main Port Inlet/Outlet [2] Case Drain Port [1] Brake Line Port

0.75 in. [19 mm] - Code 62 M22x1.5 M16x1.5

DRIVE WHEEL NUTS TORQUE

188 ft. lbs. [255 N.m] - tighten across corners

MOTOR WEIGHT

300 lbs. [136 kg], Each

07/01

Section 2 SPECIFICATIONS TABLE 2-5. BRAKE SYSTEM SPECIFICATIONS. ITEM

DESIGN DATA

BRAKE SYSTEM SERVICE BRAKE TYPE

Hydrostatic, through transmission system

SECONDARY/PARKING BRAKE TYPE

Spring applied, hydraulically released [SAHR], multi-disc brake incorporated with each hydrostatic transmission drive motor

SYSTEM RELEASE PRESSURE

175-435 psi. [12-30 bar]

TABLE 2-6. STEERING SYSTEM SPECIFICATIONS. ITEM

DESIGN DATA

STEERING SYSTEM Type of System

Hydraulic, center point

Type and Amount of

Mobil 423, HYTRAN, Texaco TDH, or equivalent [same as for transmission system]

System Oil STEERING HYDRAULIC PUMP Type

Gear

Pump Output Rate and Speed

9.0 gpm [34.1 lpm] @ 2,800 rpm

Direction of Rotation [viewed from shaft end]

Clockwise [C.W.]

STEERING RELIEF VALVE Type

Integral with steering control assembly

Relief Pressure

2,200 psi. [110 bar] @ 2650 rpm

07/01

2-9

Section 2 SPECIFICATIONS ITEM

DESIGN DATA

STEERING CONTROL UNIT Type

Rotary actuated, load sensing and non-load reacting, with internal adjustable relief valve

STEERING CYLINDERS Type

Double acting

Number per Machine

One [1]

Stroke of Cylinder

12.00 in. [304.8 mm]

STEERING PERFORMANCE Total Steering

2-10

70˚ Total, 35˚ each side of center

07/01

Section 2 SPECIFICATIONS TABLE 2-7. TIRE SPECIFICATIONS. ITEM

DESIGN DATA

TIRES Size, Ply and Quantity Standard Optional

7.50 x 15 -12 ply, [9] 7.50 x 15 -14 ply, [9]

Tire Overlap

1/2 in. [12.5 mm]

Tire Oscillation Front Rear

Rigid Outside tandems - +/- 4˚, center spring loaded - +/-5˚

TABLE 2-8. CONTROL AND INDICATOR SPECIFICATIONS. ITEM

DESIGN DATA

FUNCTION

TYPE

CONTROL Direction of Machine Travel [F-N-R] and Engine Throttle Speed

Single bar lever and linkage, controls transmission [F-N-R] and engine throttle speed [low to high idle]

Engine Throttle

Hand lever controls engine throttle speed [low to high idle] ONLY when FNR bar lever is in neutral position. Engine throttle linkage operates with FNR bar lever in "forward" or "reverse"

Transmission Speed Range

Three [3] position switch - with position lock collar, 12 volt, negative ground, selects "low", "medium" or "high" transmission speed range

Steering Control

Steering wheel, hydraulic steering control unit and system

Brake - Service

Single bar lever [F-N-R], over dash mounted

Brake - Secondary/ Parking

Two [2] position toggle switch, 12 volt, negative ground, controls release and application of system and transmission pump neutral

Engine Start/Run/Stop

Key switch, electrical, 12 volt, negative ground

Horn

Button switch, 12 volt, negative ground, dash mounted

Water Spray System Control “ON/OFF”

Two [2] position, toggle switch, 12 volt, negative ground

Water Spray Flow Rate Control “LOW to HIGH”

Variable position, manual valve, flow rate “LOW to HIGH”

Head Lights [Front and Rear] - Option

Electrical switch, 12 volt, negative ground

Turn Signals and 4 Way Flashers - Option

Electrical switch and actuation assembly, 12 volt, negative ground

07/01

2-11

Section 2 SPECIFICATIONS ITEM

DESIGN DATA

FUNCTION

TYPE

INDICATOR/GAUGE Engine Hours

Hourmeter, electrical, 12 volt, negative ground

Engine Lubrication Oil Pressure

Oil pressure gauge, electrical, 12 volt, negative ground

Fuel Level

Fuel gauge, electrical, 12 volt, negative ground

Engine Cooling System Temperature

Coolant temperature gauge, 12 volt, negative ground

Charging System Volts

Voltmeter, electrical, 12 volt, negative ground

Hydraulic System Oil Temperature

Temperature gauge, electrical, 12 volt, negative ground

Engine Inlet Air Restriction

Red lensed indicator light, 12 volt, negative ground

Transmission System Suction Oil Filter Element Condition

Red lensed indicator light, 12 volt, negative ground

TABLE 2-9. WATER SPRAY SYSTEM SPECIFICATIONS.

ITEM

DESIGN DATA

Type

Pressurized system

Tank Capacity

150 gals. [568 ltrs.]

Pump Type and Quantity

12 Volt, diaphragm, one [1] used

Filtration Pump Inlet

100 Mesh screen

Tank Fill Port

Strainer basket, one [1]

Nozzle Quantity, Type and Flow Rate

2-12

9, quick release from spray bar mounting, 0.075 gpm [.284 lpm]

07/01

Section 2 SPECIFICATIONS TABLE 2-10. OPTIONAL EQUIPMENT SPECIFICATIONS. ITEM

DESIGN DATA

TURN SIGNALS & 4 WAY FLASHERS Type and Quantity

12 Volt turn signal switch - with 4 way flasher switch. 4 turn signal/4 way flasher assemblies - 2 front and 2 rear

HEADLIGHTS Type and Quantity

12 Volt lighting system with dash mounted control switch, 4 halogen, adjustable headlight assemblies; two [2] front and two [2] rear]

TIRES Type and Quantity

07/01

7.50 x 15 - 14 ply; nine [9]

2-13

Section 2 SPECIFICATIONS TABLE 2-11. DIMENSION AND WEIGHT SPECIFICATIONS [see figure 2-1]. ITEM

DESIGN DATA

DIMENSIONS A. Overall Height to Top of ROPS/FOPS

113 in. [2 870 mm]

B. Height to Top of Steering Wheel

78 in. [1981 mm]

C. Overall Width - Front

64 in. [1 626 mm]

D. Overall Width - Rear

68 in. [1 727 mm]

E. Overall Length

175 in. [4 445 mm]

F. Wheel Base

88 in. [2 235 mm]

G. Ground Clearance

13 in. [330 mm]

H. Compaction Width

68 in. [1 727 mm].

WEIGHTS Basic Shipping Weight

8,000 lbs. [3 632 kg] - Approximate/calculated, @ this printing

Ballasted Operating Weight [Maximum]

25,200 lbs [11 430 kg] - Approximate/calculated, @ this printing

(4510 mm)

FIGURE 2-1. MACHINE DIMENSIONS.

2-14

07/01

Section 2 SPECIFICATIONS TABLE 2-12. PERFORMANCE SPECIFICATIONS. ITEM

DESIGN DATA

TRAVEL SPEED [forward or reverse] Speed Range Low

0 - 8.0 mph [0 - 12.9 km/h]

Medium

0 - 10.5 mph [0 - 16.9 km/h]

High

0 - 15.5 mph [0 - 25.0 km/h]

EFFECTIVE COVERAGE PER PASS Width

68 in. [1 730 mm]

TABLE 2-13. MACHINE SYSTEM CAPACITY SPECIFICATIONS. ITEM

DESIGN DATA

SYSTEM CAPACITIES Fuel

30 Gallons [114 liters]

Engine Lubrication Oil

10 Quarts [9.5 liters] - With Lubrication Oil filter, Cummins 4B3.9

Engine Cooling System

19 Quarts [18 liters]

Hydraulic System

28.5 Gallons [30 liters]

Water Spray Tank

150 Gallons [568 liters]

07/01

2-15

Section 2 SPECIFICATIONS TABLE 2-14. COMPONENT WEIGHTS.

NOTE: The following list of component weights is APPROXIMATE and is given as a guide ONLY for selecting sling and lifting equipment used in machine servicing.

ITEM

DESIGN DATA

WEIGHTS Rear Frame Components Rear frame, bare Center wheel spring Center wheel support bracket Axle Axle pin Rim assembly Hitch Horizontal pins Vertical pins

1,820 lbs. [826 kg] 17 lbs. [8 kg] 58 lbs. [26 kg] 87 lbs. [39 kg] 13 lbs. [6 kg] 31 lbs. [14 kg] 225 lbs. [116 kg] 17 lbs. [8 kg] 14 lbs. [6 kg]

Front Frame Components Front frame, bare Engine - dry Transmission Pump Transmission Tire Motor Steering cylinder Instrument panel - with instruments

2-16

1,900 lbs. [862 kg] 600 lbs. [272 kg] 130 lbs. [59 kg] 300 lbs. [136 kg] ea. 40 lbs. [18 kg] 26 Lbs. [12 kg]

07/01

Section 2 SPECIFICATIONS TABLE 2-15. TORQUE SPECIFICATIONS FOR STANDARD INCH FASTENERS. SAE GRADE 8 CAPSCREWS

NOM. SIZE

1/4 5/16

3/8 7/16

1/2 9/16

5/8 3/4

7/8 1

1-1/8 1-1/4

1-3/8 1-1/2

TORQUE (FT. LBS).

THREAD SERIES

TORQUE (Nm)

DRY

LUBED

DRY

LUBED

20 UNC 28 UNF 18 UNC 24 UNF

12 14 25 27

8 10 18 20

16 19 33 37

12 14 25 28

16 UNC 24 UNF 14 UNC 20 UNF

44 49 70 78

33 37 52 58

59 67 95 105

44 50 71 79

13 UNC 20 UNF 12 UNC 18 UNF

105 120 155 170

80 90 115 130

145 165 210 230

110 120 155 175

11 UNC 18 UNF 10 UNC 16 UNF

210 240 375 420

160 180 280 315

285 325 510 570

215 245 380 425

9 UNC 14 UNF 8 UNC 14NF

605 670 910 1 020

455 500 680 765

820 905 1 230 1 380

615 680 925 1 040

7 UNC 12 UNF 7 UNC 12 UNF

1 290 1 440 1 820 2 010

965 1 080 1 360 1 500

1 750 1 960 2 460 2 730

1 310 1 470 1 850 2 050

6 UNC 12 UNF 6 UNC 12 UNF

2 380 2 710 3 160 3 560

1 780 2 040 2 370 2 670

3 230 3 680 4 290 4 820

2 420 2 760 3 210 3 620

WARNING: THESE TABLES LIST TORQUE VALUES FOR STANDARD FASTENERS AND ARE INTENDED AS A GUIDE FOR AVERAGE APPLICATION INVOLVING TYPICAL STRESSES AND MACHINED SURFACES. VALUES ARE BASED ON THE PHYSICAL LIMITATIONS OF CLEAN, PLATED AND LUBRICATED FASTENERS. IN ALL CASES, WHEN AN INDIVIDUAL TORQUE IS SPECIFIED, IT SHOULD BE FOLLOWED INSTEAD OF VALUES GIVEN IN THIS TABLE. REPLACE ORIGINAL EQUIPMENT WITH FASTENERS OF EQUAL GRADE.

GRADE 5

GRADE 8

PLACEBOLT

SOCKET HEAD CAPSCREW

12 POINT CAPSCREW

FIGURE 2-2. STANDARD HARDWARE.

07/01

2-17

Section 2 SPECIFICATIONS TABLE 2-16. TORQUE SPECIFICATIONS FOR STANDARD METRIC FASTENERS. NOMINAL SIZE & PITCH

M3 x 0.5 M3.5 x 0.6 M4 x 0.7 M5 x 0.8 M6 x 1 M8 x 1.25 M8 x 1 M10 x 1.5 M10 x 1.25 M12 x 1.75 M12 x 1.25 M14 x 2 M14 x 1.5 M16 x 2 M16 x 1.5 M20 x 2.5 M20 x 1.5 M24 x 3 M24x2 M27 x 3 M27 x 2 M30 x 3.5 M30 x 3 M30 x 2 M33 x 3.5 M33 x 2 M36 x 4 M36 x 3 M39x4 M39x3 M42 x4.5 M42x3 M45 x4.5 M45x3 M48x5 M48x3

CLASS 8.8 [GRADE 5 EQUIVALENT]

CLASS 10.9 [GRADE 8 EQUIVALENT]

TORQUE FT. LBS

TORQUE - N-m

TORQUE FT. LBS

TORQUE - N-m

DRY

LUBED

DRY

LUBED

DRY

0.97 1.61 2.27 4.58 7.75 18.89 20.22 40.04 39.11 64.94 70.85 103.32 114.39 162.36 173.43 317.34 360.55 516.12 594.09 797.04 863.46 1 084.86 1 121.76 1 202.94 1 476.00 1 623.60 1 896.66 2 007.36 2 450.16 2 583.00 3 033.18 3 261.96 3 785.94 4 051.62 4 553.46 4 959.36

0.73 1.21 1.70 3.43 5.83 14.17 15.13 28.04 29.52 48.71 53.14 77.49 84.87 121.77 129.15 236.16 281.99 409.59 445.49 597.78 645.75 811.80 841.32 900.36 1 107.00 1 623.60 1 424.34 1 505.52 1 837.62 1 940.94 2 273.04 2 450.16 2 841.30 3 040.56 3 416.94 3 719.52

1.32 2.07 3.07 6.20 10.5 25.6 27.4 51.0 53.0 88.0 96.0 140.0 155.0 220.0 235.0 430.0 475.0 740.0 805.0 1 080.0 1 170.0 1 470.0 1 520.0 1 530.0 2 000.0 2 200.0 2 570.0 2 720.0 3 320.0 3 500.0 4 110.0 4 420.0 5 130.0 5 490.0 6 170.0 6 720.0

0.99 1.56 2.31 4.67 7.97 19.26 20.59 38.38 40.59 66.42 72.32 107.01 114.39 166.05 177.12 321.03 357.93 557.19 605.16 811.80 878.22 1 107.00 1 143.90 1 225.08 1 505.52 1 653.12 1 933.56 2 051.64 2 501.82 2 634.66 3 099.60 3 328.38 3 867.12 4 140.18 4 649.40 5 062.68

1.79 2.82 4.17 8.43 14.3 34.8 37.3 69.0 73.0 120.0 130.0 190.0 210.0 300.0 320.0 580.0 650.0 1 010.0 1 100.0 1 470.0 1 590.0 2 000.0 2 070.0 2 210.0 2 720.0 2 980.0 3 490.0 3 700.0 4 520.0 4 760.0 5 590.0 6 020.0 6 980.0 7 470.0 8 400.0 9 150.0

LUBED 0.99 1.55 2.30 4.65 7.90 19.2 20.5 38.0 40.1 66.0 72.0 105.0 115.0 165.0 175.0 320.0 355.0 555.0 605.0 810.0 875.0 1 100.0 1 140.0 1 220.0 1 500.0 1 640.0 1 930.0 2 040.0 2 490.0 2 630.0 3 080.0 3 320.0 3 850.0 4 120.0 4 630.0 5 040.0

1.32 2.08 2.27 6.22 10.60 18.95 27.53 50.92 53.87 88.56 70.81 140.22 154.98 221.40 236.16 428.04 479.70 754.38 811.80 1 084.86 1 173.42 1 476.00 1 527.66 1 630.98 2 007.36 2 199.24 2 575.62 2 730.60 3 335.76 3 512.88 3 044.56 4 442.74 5 084.82 5 512.86 6 199.20 6 752.70

LUBED 1.34 2.11 3.13 6.33 10.8 26.1 27.9 52.0 55.0 90.0 98.0 145.0 155.0 225.0 240.0 435.0 485.0 755.0 820.0 1 100.0 1 190.0 1 500.0 1 550.0 1 660.0 2 040.0 2 240.0 2 620.0 2 780.0 3 390.0 3 570.0 4 200.0 4 510.0 5 240.0 5 610.0 6 300.0 6 860.0

2-18

07/01

Section 2 SPECIFICATIONS TABLE 2-17. LUBRICATION OILS, HYDRAULIC OILS AND COOLANT SPECIFICATIONS. P/N

DESCRIPTION

SIZE

336830

HYDRAULIC/TRANSMISSION OIL

1 QT

336831

HYDRAULIC/TRANSMISSION OIL

2 GAL

336832

HYDRAULIC/TRANSMISSION OIL

5 GAL

336833

HYDRAULIC/TRANSMISSION OIL

55 GAL

3002338

ANTI-FREEZE

1 GAL

TABLE 2-18. ADHESIVE THREAD LOCKING SPECIFICATIONS. P/N

DESCRIPTION

SIZE

360387

222 Small Screw Threadlock [Purple]

50 ML

318702*

242 Removable Threadlock [Blue]

10 ML

226414*

271 High Strength Threadlock [Red]

10 ML

318996

277 High Viscosity Threadlock [Red]

50 ML

318650

290 Low Viscosity Threadlock [Green]

.02 OZ

251099

290 Low Viscosity Threadlock [Green]

50 ML

355844**

422 SuperBonder Adhesive

3 ML

264159

515 Gasket Eliminator

6 ML

313022*

515 Gasket Eliminator [Purple]

50 ML

273338*

567 Pipe Sealant W/Teflon [White]

50 ML

318705

595 Super Flex Silicone

100 ML

318701*

609 Retaining Compound

10 ML

341959

680 Retaining Compound

50 ML

226415

Primer T - Aerosal

6 OZ

316865

Anti-Seize Compound

1 LB

360053-10

Chisel Gasket Remover[10/case Aerosal]

18 OZ

318700*

Adhesive & Sealant Kit [Contains One Each Of* Items]

07/01

2-19

Section 2 SPECIFICATIONS NOTES

2-20

07/01

Section 3 OPERATION

11/00

3-1

Section 3 OPERATION GENERAL INFORMATION. THIS section gives the OPERATION INSTRUCTIONS for the Model BW11RH Roller. Read, understand and follow ALL “Precaution and Operating Instructions” given on the machine “OPERATING INSTRUCTION and WARNING” decals and written in THIS manual, BEFORE starting, or operating, the machine [see figure 3-1].

DANGER: FAILURE to observe the “OPERATING PRECAUTIONS” and/ or the machine “OPERATION and WARNING INSTRUCTIONS”, given in THIS manual and found on the DECALS affixed to the machine can cause SERIOUS INJURY, or DEATH [see Figure 3-1]. ONLY authorized personnel, who are fully trained in the machine operation, can operate the Model BW11RH Roller.

Keep the machine in GOOD mechanical condition at ALL times.

WARNING: Do NOT operate a machine needing repair. Put an information tag on the steering wheel which says “DO NOT OPERATE”. REMOVE the key from the ignition switch. Repair ALL damage and defects at ONCE. Minor damage or can result in major system failures.

3-2

OPERATION, WARNING AND CAUTION DECALS. Follow ALL information given on EACH operation, warning and caution decal before and during machine operation.

WARNING: Keep ALL machine operation, warning and caution decals clean. Immediately replace any missing or damaged decals with NEW. See your nearest Distributor to obtain replacement decals.

OPERATING CONTROLS, INDICATORS AND GAUGES. Operating controls, indicators and gauges, for the Model BW11RH Roller, are shown on Figure 3-2 and are listed in Table 3-1.

DANGER: Do NOT start, or operate, a Model BW11RH Roller BEFORE reading, understanding and following ALL information given in THIS section and shown on the machine “Operating Instruction and Warning” decal, found on the top area of the engine hood. The operator MUST read about, and understand, the function of ALL controls, indicators and gauges BEFORE starting the engine. SERIOUS INJURY, or DEATH, can result if THESE procedures are NOT followed.

11/00

Section 3 OPERATION

OPERATING INSTRUCTIONS WARNING:

WARNING:

FIGURE 3-1. MODEL BW11RH ROLLER “OPERATING INSTRUCTION DECAL”.

11/00

3-3

Section 3 OPERATION 12

18 17 3

FIGURE 3-2. MACHINE OPERATING CONTROLS, INDICATORS AND GAUGES MODEL BW11RH ROLLER.

3-4

11/00

Section 3 OPERATION TABLE 3-1. MACHINE OPERATING CONTROLS, INDICATORS AND GAUGES. ITEM NO. [SEE FIG’ 3-2]

DESCRIPTION

TYPE

FUNCTION

VANDAL GUARD

Lockable Panel guard

Lockable panel guard covers instrument panel. One padlock is used to secure the panel. Unlock and remove padlock. Move panel guard down to stowed position to start and operate machine.

DIRECTIONAL/ SPEED CONTROL & NEUTRAL LOCK

Bar - lever with neutral lock

Move neutral lock to lock, or unlock, bar lever. The bar lever MUST be in the center [“NEUTRAL”] position for engine to start. To travel, move lever slowly toward the direction of desired machine travel. The lever position controls the travel speed. FULL lever movement [forward OR reverse] gives HIGHEST speed of machine travel for the "1st", "2nd" or "3rd", speed range selected by the transmission speed range selector switch [ITEM 6].

IGNITION

Switch

Three [3] position switch is used to start engine and turn electrical systems off. POSITION NUMBER 1: The “OFF” position removes all power from the electrical circuits [EXCEPT the horn circuit]. POSITION NUMBER 2: The “ON” [RUN] position applies power to the electrical circuits. POSITION NUMBER 3: The key in the “START” position engages the engine starter. When the key is released, the switch will return to the “ON” [RUN] position.

11/00

SECONDARY/PARKING BRAKE

"ON/OFF" control switch

Switch moved to “ON” [brake system APPLIED] position puts system “ON”. Switch moved to “OFF” [brake system RELEASED] position puts the system “OFF”.

3-5

Section 3 OPERATION TABLE 3-1. MACHINE OPERATING CONTROLS, INDICATORS AND GAUGES. ITEM NO. [SEE FIG’ 3-2]

DESCRIPTION

TYPE

FUNCTION

ENGINE THROTTLE

Hand lever, With Mechanical Linkage

PUSH handlever “UP” to INCREASE engine speed. PULL the hand lever “DOWN” to DECREASE engine speed, with direction/ speed control bar lever [ITEM 2] in NEUTRAL position ONLY.

TRANSMISSION SPEED RANGE

Toggle Switch Three [3] Position, With Position Lock Collar

Lift position lock collar. Put switch “DOWN” for “LOW” speed range. Release lock collar. Lift position lock collar. Put switch “CENTER” for “MEDIUM” speed range. Release lock collar. Lift position lock collar. Put switch “UP” for “HIGH” speed range. Release lock collar.

WATER SPRAY SYSTEM

“ON”/”OFF” switch

Put switch in “ON” position to turn spray system “ON”. PUT switch in “OFF” position to turn spray system “OFF”.

HORN ACTUATION

Push button dash mounted

PUSH horn button to SOUND horn.

HOURMETER

Indicator

Indicator shows the total hours of engine operation.

FUEL LEVEL

Gauge

Gauge indicates the level of fuel contained in the fuel tank.

HYDRAULIC SYSTEM OIL TEMPERATURE

Gauge

Gauge indicates the temperature of oil in the transmission system. During NORMAL operation, the needle will be in the area between 120˚ F [49˚ C] and 180˚ F [82˚ C].

CAUTION: STOP the engine IMMEDIATELY if the gauge pointer moves to the RED zone of the gauge.

3-6

11/00

Section 3 OPERATION TABLE 3-1. MACHINE OPERATING CONTROLS, INDICATORS AND GAUGES. ITEM NO. [SEE FIGâ&#x20AC;&#x2122; 3-2]

DESCRIPTION

ENGINE COOLANT TEMPERATURE

TYPE

Gauge

FUNCTION

Gauge indicates the temperature of the coolant circulating through the engine. During NORMAL operation, the needle will be in the CENTER of the of the green zone.

CAUTION: STOP the engine IMMEDIATELY if the gauge pointer moves to the RED zone of the gauge.

ENGINE OIL PRESSURE

Gauge

Gauge indicates the pressure of the engine lubrication oil. Operates when engine is "running". Can indicate a high pressure [LARGE symbol] when engine is first started. Pressure indicated will lower to "NORMAL" [MIDDLE sized symbol] as engine warms.

CAUTION: STOP the engine IMMEDIATELY if there is NO, or LOW, oil pressure sure indicated on the oil pressure gauge.

VOLTMETER

Instrument

Indicates alternator output voltage. Can be in RED [DISCHARGE] zone on instrument at LOW engine idle, BUT will move to GREEN [CHARGE] zone on instrument when engine speed is increased.

LIGHTS

Push-Pull Switch

Pull switch to FIRST detent position to ILLUMINATE control panel lights, and if so equipped, the optional front headlights. Pull the switch to SECOND detent to ILLUMINATE all four [4] optional headlights, if so equipped.

STEERING SYSTEM CONTROL

Manually Operated wheel

TURN steering wheel TOWARD the direction that the machine is desired to travel.

11/00

3-7

Section 3 OPERATION TABLE 3-1. MACHINE OPERATING CONTROLS, INDICATORS AND GAUGES. ITEM NO. [SEE FIG’ 3-2]

DESCRIPTION

TYPE

FUNCTION

ENGINE INLET AIR CONDITION

Electrical Light, Red Lens Covered

Indicates “RED” lighted condition ONLY when engine inlet air flow is restricted. When lighted, IMMEDIATE service of air cleaner assembly is required BEFORE further machine operation.

TRANSMISSION SYSTEM SUCTION OIL FILTER ELEMENT CONDITION

Electrical Light, Red Lens Covered

Indicates “RED” lighted condition condition when transmission system SUCTION oil filter element has reached maximum holding capacity and MUST be changed before further machine operation.

CAUTION: Hydraulic system MUST be at "NORMAL OPERATING" temperature for CORRECT system light indications. Indicator light can be "lighted" when the hydraulic oil is at a temperature LOWER than "normal operating" temperature. 19

WATER SPRAY SYSTEM FLOW RATE

“Low” To ”High” Manual Control Valve

Put in desired “low” to “high” position to adjust water spray flow rate to the front and rear water spray bars and nozzles.

WATER SPRAY FLOW CONTROL LOW

HIGH

3-8

11/00

Section 3 OPERATION OPERATION. CHECKS WITH THE ENGINE STOPPED. With the engine in a STOPPED condition, INSPECT the machine BEFORE use, and AFTER every EIGHT [8] hours of operation, or DAILY, as directed in Section 4 - MAINTENANCE - in THIS manual.

WARNING: The machine MUST NOT move, at ANY time, when the secondary/parking brake system is “APPLIED”. DO NOT operate the machine, IF the machine will move when the SECONDARY/PARKING brake system is “APPLIED” until the problem is CORRECTED.

CHECK, or INSPECT, the following items: Fuel level. Engine lubrication oil level.

NOTE: The engine will NOT start UNLESS the secondary/parking brake system control switch [ITEM 4] is “ON” and the system is APPLIED.

Engine cooling system coolant level. Condition of drive belt on engine. Hydraulic system oil level.

b. IMMEDIATELY, after being seated, place the seat belt across the lap and securely insert the metal end into the buckle. Tighten the belt, against the body.

Engine inlet air path. Fluid leaks from engine, fuel, hydraulic, or water spray components.

c. If locked, move the neutral lock to the unlocked position. Keep the transmission in “NEUTRAL”, by keeping the directional/speed control lever [ITEM 2] in the “CENTER” [NEUTRAL] position.

Operation of the horn. Condition of FOPS/ROPS structure, torque of FOPS/ROPS mounting capscrews and condition of the seat belt sets. Condition, correct installation and torque of all belt mounting hardwares.

STARTING THE ENGINE [See Figure 3-2 and Table 3-1].

CAUTION: Also, see the Engine Operation and Maintenance Manual - B Series Engines, published by Cummins Engine Company, which is supplied with the machine.

NOTE: The transmission MUST be in the “NEUTRAL” condition for the engine to be started.

d. Move the engine throttle speed control [ITEM 5] UPWARD to a position slightly above the LOW engine idle speed position.

CAUTION: Do NOT move the engine throttle control lever to the “HIGH” engine idle position. Engine damage can occur, due to over speeding, at engine start.

a. Unlock and remove the padlock securing the instrument panel vandal guard [ITEM 1]. Put the vandal guard in the stowed position. KEEP the secondary/parking brake system control switch [ITEM 4] in the “ON” [brake APPLIED] position.

11/00

3-9

Section 3 OPERATION e. Turn the ignition switch key [ITEM 3] to the START [NUMBER 3] position. Crank and start the engine.

WARNING: California Proposition 65 Warning. Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm.

CAUTION: Do NOT use starting fluids [ether] when starting the engine. Serious engine damage can occur if starting fluids are used. Also, see the Engine Operation and Maintenance Manual - B Series Engines, published by Cummins Engine Company, which is supplied with the machine. Do NOT crank the engine MORE than thirty [30] seconds CONTINUOUSLY. If the machine engine is NOT started within this time, put the ignition switch key in the OFF [NUMBER 1] position. Wait one [1] minute. This will allow the starter motor time to cool. Repeat the above step “e” until the engine is started. Do NOT increase the speed of the engine ABOVE approximately 1,000 RPM for a period of two [2] minutes.

NOTE: Make a note of the amount of continuous cranking time. If the engine does NOT start within thirty [30] seconds of continuous cranking, see the above “CAUTION” information.

CHECKS WITH THE ENGINE RUNNING. With the engine RUNNING, CHECK, or INSPECT, the machine BEFORE operation, using the FOLLOWING information. ALSO do THESE checks and/ or inspections AFTER every eight [8] hours of operation or DAILY as directed in Section 4 MAINTENANCE - in THIS manual.

3-10

CHECK, or INSPECT, the following items: Operation of the secondary/parking brake system. With the secondary/parking brake system control switch [ITEM 4] in the “ON” [APPLIED] position, the machine must NOT move when the directional/ speed control hand lever is in the forward, or reverse, position with the engine throttle [ITEM 5] at the “LOW” idle [“DOWN”] position.

DANGER: Do NOT operate the machine, if the machine will move when the secondary/parking brake system is “ON” [APPLIED], until the problem is corrected. The machine MUST NOT move, at ANY time, when the secondary/ parking brake system control switch [ITEM 4] is in the “ON” [APPLIED] position.

Operation of the steering system. Turn the steering wheel [ITEM 16] to the left, and to the right. Note that the system operates correctly.

DANGER: Keep ALL personnel CLEAR of the machine. The CLEARANCE between the front and rear frame area, at the hitch, CLOSES when the steering wheel is turned in EITHER direction. Do NOT operate the machine, if the machine did NOT steer correctly, during the above check procedures, until the problem is corrected.

Operation of the transmission system, in BOTH directions of travel. Keep the engine throttle [ITEM 5] in the LOW idle position. Move directional/speed control neutral lock [included with ITEM 2] to the unlocked position. Put the transmission system speed range selector switch [ITEM 6] in the "low" speed position. Move directional/speed control bar lever [ITEM 2] toward the forward direction of machine travel, a small amount, and note the machine moved forward. Move directional/speed control bar lever [ITEM 2] toward the reverse direction of machine travel, a small amount, and note the machine moved in the reverse direction. 11/00

Section 3 OPERATION DANGER: Keep ALL personnel CLEAR of the machine when checking the operation of the transmission system. Use extra caution if the check is being done in a confined area or near other equipment. Do NOT operate the machine, if the machine did NOT move correctly, during the above check procedures, until the problem is corrected.

b. Do NOT travel across a slope. When on a slope, TRAVEL in an ”UP” or “DOWN” direction ONLY.

Operation of ALL gauges, instruments, indicator lights and other standard or optional systems, as equipped.

e. Keep ALL personnel CLEAR of the front and rear frame area, at the hitch, at ALL times.

Visually check all of the above items for correct operation.

DANGER: Keep ALL personnel CLEAR of the machine. The CLEARANCE between the front and rear frame area, at the hitch, CLOSES when the steering wheel is turned in EITHER direction.

OPERATING PRECAUTIONS [See Figures 3-1 and 3-3]. To HELP prevent injury to personnel and damage to the machine, ALWAYS observe ALL of the following “Operating Precautions”.

READ, UNDERSTAND and FOLLOW ALL information shown on the “Operating Instruction and Warning” decals, found on the machine [see figures 3-1 and 3-3] and ALL instructions written in THIS manual.

DANGER: FAILURE to observe the following precautions and/or the machine “Operation and Warning Instructions”given in THIS section and found on the DECALS affixed to the machine, can cause SERIOUS INJURY, or DEATH. ONLY authorized personnel, who are full trained in the machine operation, can operate the Model BW11RH Roller.

a. USE the "low' speed range, a SLOW speed and ADDITIONAL CAUTION when nearing, or operating the machine close to, a slope and/or when traveling down a slope.

11/00

c. USE the "low" speed range, a slow speed and extra CAUTION when operating the machine near personnel and/or other machines. d. Do NOT operate a machine in need of repair. Report ANY needed repairs and have the machine repaired IMMEDIATELY.

f. AFTER being seated, and BEFORE the machine is started, ALWAYS securely FASTEN and TIGHTEN the seat belt across the lap. The operator MUST remain seated at ALL times during machine operation. Keep the hands and feet INSIDE the machine cockpit at ALL times. Allow NO riders on the machine at ANY time. g. Do NOT suddenly stop the machine during operation. h. BEFORE getting off of the machine, put the directional/speed control [ITEM 2] in the “NEUTRAL” position. Pull the secondary/parking brake system control switch [ITEM 4] “ON”. STOP the engine.

WARNING: ALWAYS APPLY the SECONDARY/PARKING brake system, AFTER the machine has stopped. The transmission system will NOT hold the parked machine in a stopped condition, on ANY grade. The SECONDARY/ PARKING brake system MUST be used to hold the machine, in a stopped condition, when parked.

3-11

Section 3 OPERATION

WARNING

P/N 918141

WARNING FASTEN SEAT BELT!

IF MACHINE TIPS: DO NOT JUMP! P/N 918142

FIGURE 3-3. OPERATION WARNING AND SEAT BELT WARNING DECALS.

3-12

11/00

Section 3 OPERATION i. Do NOT operate the machine, If the machine will move when the secondary/parking brake system is “ON”. The machine MUST NOT move, at ANY time, when the secondary/parking brake system hand lever [ITEM 5] is in the “ON” [APPLIED] position.

NOTE: Full directional/speed control bar lever movement will give maximum machine travel speed for the transmission speed range selected.

j. Do NOT operate a machine NOT having ALL “Operating Instruction and/or Warning” decals in place on the machine. The decals MUST remain in good condition and NOT be covered with dirt or grease. REPLACE damaged, or missing, decals IMMEDIATELY.

WARNING: Slowing, or stopping, of the machine, during operation, is done by moving the directional/speed control bar lever [ITEM 2] toward, and then to the neutral position, to obtain the desired travel speed, or stopping action. The secondary/parking brake system [ITEM 4] MUST be used to hold the machine in a “stopped” condition at ALL times. The transmission system will NOT hold the machine in a “parked” condition.

OPERATING THE MACHINE [See Figures 3-1, 3-2, 3-3 and Table 3-1].

DANGER: ALL personnel and other machines MUST be CLEAR of the machine path BEFORE the machine is moved.

a. IMMEDIATELY, after being seated, place the seat belt across the lap and SECURELY insert the metal end into the belt buckle. TIGHTEN the belt, AGAINST the body. Release the secondary/parking brake system, by putting the secondary/parking brake system control switch [ITEM 4] in the “OFF” [RELEASED] position. b. Move the engine throttle lever [ITEM 5] to the low idle throttle speed position. Use the transmission speed range switch [ITEM 6] to select the desired "low", "medium", or "high", transmission speed range.

WARNING: Do NOT put the engine throttle speed lever in “HIGH”, or the transmission speed range in “medium" or "high” when the machine is being moved in a con fined area, or is near personnel, machines or other objects.

c. Move directional/speed control neutral lock [included with ITEM 2] to the unlocked position. Move directional/speed control bar lever [ITEM 2] toward the forward, or reverse, direction of machine travel, a small amount, With the machine moving, SLOWLY move the directional/speed lever [ITEM 2] FURTHER in the direction of machine travel, as desired, to increase travel speed. 11/00

d. To change TRAVEL DIRECTION, move the directional/speed control bar lever [ITEM 2] to the neutral position and stop machine movement. Move the directional/speed lever [ITEM 2] to the opposite direction of travel position. With the machine moving, SLOWLY move the directional/speed bar lever [ITEM 2] FURTHER toward the direction of machine travel, as desired, to increase travel speed.

CAUTION: Always STOP the machine BEFORE reversing the travel direction.

e. To change the transmission SPEED RANGE, lift the selector switch position lock collar. Move the transmission speed range switch [ITEM 6] from the current speed range position to the next lower, or higher, speed range position and release the lock collar. If a still lower, or higher, speed range is desired, allow the machine to travel, in the selected speed range, for a short time. Lift the selector switch position lock collar, again. Move the transmission speed range switch [ITEM 6] from the current speed range position to the lower, or higher, speed range position and release the lock collar.

CAUTION: Always move to the NEXT lower, or higher, speed range, for a short period of time, when changing the transmission speed range. Do NOT by pass a range.

3-13

Section 3 OPERATION PRESSURIZED WATER SPRAY SYSTEM [See Figures 3-2 and 3-4].

“UP” POSITION

Use the following information to operate the pressurized water spray system when compacting asphalt work surface materials, as needed. The water spray system will help keep all tires clean when compacting asphalt, until the tires have warmed. Use the following procedures to activate the water spray system:

COCO MAT

FIGURE 3-4. COCOA MAT RAISING AND LOWERING AT TIRES.

a. Fill the system tank with CLEAN and STRAINED water.

BALLASTING A PNEUMATIC ROLLER [See Figure 3-5].

b. When on the work surface, go to either side of the tire area on the front end of the Roller. Lift the double tire width cocoa mat assembly and release the securing hook. Lower the mat assembly onto the two [2] tires.

If rolling specifications suggest, use the Information contained in figure 3-5 to ballast the machine prior to rolling the work surface.

c. Go the opposite side of the Roller and repeat the lowering procedure for the double tire width cocoa mat assembly on that side of the Roller.

DYNAMIC BRAKING OF THE MACHINE [See Figure 3-2].

d. Go to either side of the tire area on the rear end of the Roller. Lift each single tire width cocoa mat assembly and release the securing hook. Lower each mat assembly onto each tire.

On a LEVEL surface, slowing or stopping of the machine, during operation, is done by moving the directional/speed control bar lever [ITEM 2] TOWARD, and then TO, the NEUTRAL position. This procedure allows the transmission system and engine to slow the machine to a stop.

e. Go the opposite side of the Roller and repeat the lowering procedure for each tire width cocoa mat assembly found on that side of the Roller. f. Put the water spray system control switch [ITEM 7] in the “ON” position. Turn the system flow rate control valve [ITEM 19] to the desired flow rate "low" through "high" position.

NOTE: Put the water spray system control switch in the “OFF” position when the system is NOT needed. Also, use the above information to lift ALL cocoa mats clear of the tires, and secure in place with the mat hooks, when not needed.

3-14

WARNING: To slow, or stop, the machine on a slope, put the transmission in the LOWEST [low] speed range, using the transmission speed range selector switch [ITEM 6]. Move the directional/speed control bar lever [ITEM 2] toward the direction OPPOSITE the direction of machine travel, a short distance from the neutral position. The secondary/parking brake system control switch [ITEM 4] MUST be “ON” [APPLIED] to hold the machine in a “stopped” condition at ALL times. The transmission system will NOT hold the machine in a “stopped” condition. If the speed, or direction, of the machine can NOT be controlled at any time, move the secondary/parking system control switch to the “ON” position.

11/00

1600 LBS

1/2 CUBIC YARD

9200 LBS

1600 LBS

9200 LBS

1/2 CUBIC YARD

6000 LBS

BALLAST: WET SAND ONLY, ALL BALLAST COMPARTMENTS FULL.

LOAD: 2300 LBS PER WHEEL

2 -1/2 CUBIC YARDS

WHEN USING WET SAND AS BALLAST, FILL REAR PORTION OF TUB LEVEL TO BOTTOM OF OTHER SECTIONS OF TUB.

12000 LBS

3000 LBS

12000 LBS

15000 LBS

BALLAST: STEEL ONLLY

LOAD: 3000 LBS PER WHEEL

11625 LBS- CENTER OF WEIGHT LOCATED APPROXIMATELY OVER AXLE.

BALLAST: STEEL ONLY

LOAD: 3000 LBS PER WHEEL

2-1/2 CUBIC YARDS WET SAND

3375 LBS STEEL LOCATED APPROXIMATELY OVER AXLE

B: BALLAST IN REAR FRAME SHOULD BE LOCATED SO THAT WEIGHT IS CONCENTRATED OVER OR SLIGHTLY TO REAR OF REAR AXLE.

A: BALLAST IN FRONT FRAME COMPARTMENT SHOULD BE APPROXIMATELY EQUAL IN WEIGHT TO BALLAST IN FRONT FRAME SIDE COMPARTMENTS UNDER SEATS.

FOR PROPER WEIGHT DISTRIBUTION UNDER ANY BALLAST CONDITIONS:

3000 LBS

1/2 CUBIC YD WET SAND

1350 LBS STEEL

1350 LBS STEEL 1/2 CUBIC YARDS WET SAND

FIGURE 3-5. BALLASTING INSTRUCTIONS.

BALLAST: STEEL ONLY

LOAD: 2300 LBS PER WHEEL

8125 LBS-LOCATE CENTER OF WEIGHT APPROXIMATELY OVER REAR AXLE.

11500 LBS

7500 LBS

BALLAST: MINIMUM SAND OR STEEL

LOAD : 1500 LBS PER WHEEL

1-1/4 CUBIC YARDS WET SAND OR 4125 LBS STEEL IS USED. LOCATE CENTER OF WEIGHT APPROXIMATELY OVER REAR END AXLE AS INDICATED

Section 3 OPERATION

3-15

Section 3 OPERATION STOPPING THE ENGINE [See Figure 3-2 and Table 3-1]. a. SLOW and STOP the machine by moving the directional/speed control bar lever [ITEM 2] toward, and then to, the NEUTRAL position. b. Put the secondary/parking brake system control switch [ITEM 4] “ON”. Put the directional/speed control bar lever lock [included with ITEM 2] in the “LOCKED” position. c. Keep the engine throttle control [ITEM 5] at the LOW engine idle speed position. Run the engine for a period of at least TWO [2] minutes, at the LOW idle speed, BEFORE the engine is stopped.

CAUTION: Do NOT stop the engine BEFORE allowing the engine to idle at the LOW engine idle speed position. Serious engine damage can occur if the engine is stopped BEFORE waiting the TWO [2] minute “LOW” idle period.

TOWING A ROLLER HAVING THE STANDARD SECONDARY/PARKING BRAKE RELEASE SYSTEM [See Figures 3-6 AND 3-7].

CAUTION: Do NOT tow the machine UNLESS ALL of the following procedures have been followed.

Do NOT tow the Roller unless the machine is TOTALLY disabled and MUST be moved for repair. If a machine must be towed, tow it at a SLOW SPEED and on a LEVEL surface ONLY. Tow it only for a SHORT distance. Put the towing bypass valves in the “TOW” position, BEFORE the machine is moved.

FIGURE 3-6. TOWING BYPASS VALVES.

SOLENOID VALVE ASSEMBLY

"TEE" FITTING

NEEDLE VALVE

CAP AND CONNECTION FITTING TO RIGHT TIRE DRIVE MOTOR

TO LEFT TIRE DRIVE MOTOR

FIGURE 3-7. AUXILIARY BRAKE RELEASE PRESSURE CONNECTION LOCATION.

BEFORE towing the machine, the secondary/ parking brake system MUST also be “RELEASED”. This is done by doing the steps given, later, under THIS topic heading.

NOTE: The towing bypass valves are found on the hydraulic pump in the engine compartment [see figure 3-6].

3-16

11/00

Section 3 OPERATION WARNING: Do NOT tow the machine on ANY grade. Tow on LEVEL surface ONLY. The secondary/parking brake system will be in a disconnected condition during towing. TOW the machine the LEAST distance possible. Do NOT tow the machine at a speed above TWO [2] miles per hour [3.2 km/h].

CAUTION: Do the FOLLOWING steps ONLY if the transmission system, or the engine, can NOT be operated at THIS time, and BEFORE the machine is moved. Also RETURN the towing bypass valves to the CLOSED position, AFTER the machine has been towed.

a. Put SOLID wood blocks behind, and in the front of, ALL FRONT and REAR tires. Go to the transmission pump.

WARNING: Block SECURELY using SOLID wood blocks.

b. Put a 1 1/16 inch open end wrench on the MIDDLE sized [2nd] hex nut of the FORWARD direction MULTIFUNCTION VALVE CARTRIDGE. Put a 1 1/4 inch open end wrench on the LARGE sized [3rd] hex nut of the FORWARD direction MULTIFUNCTION VALVE CARTRIDGE. c. OPEN the bypass valve by turning the open end wrench, that is on the MIDDLE sized [2nd] nut, THREE [3] revolutions in the COUNTERCLOCKWISE direction.

CAUTION: Do NOT turn the MIDDLE sized [2nd] hex nut more than three [3] revolutions, as additional revolutions will permit external leakage of hydraulic oil during towing of the machine.

d. REPEAT the procedures given in steps “b”, “c”, and the ABOVE “CAUTION”, on the REVERSE direction MULTIFUNCTION VALVE CARTRIDGE. 11/00

e. If the machine will be towed in the FORWARD direction, put the machine DIRECTION/SPEED CONTROL bar lever in the FULL FORWARD position, so that the transmission pump displacement control valve handle is also at the full FORWARD position.

NOTE: IF the machine will be towed in the REVERSE direction, put the machine DIRECTION/SPEED CONTROL bar lever in the full REVERSE position.

f. Go to the secondary/parking brake system solenoid valve assembly. Find the brake system connection fitting and cap, on the "Tee" fitting end, below the solenoid valve assembly [see figure 3-7]. g. Wipe the fitting cap using a CLEAN cloth. Remove the cap from the connection fitting. NOTE: Use a portable hydraulic power unit to make pressure in the secondary/parking brake release system and release the spring applied brakes in EACH tire drive motor. CAUTION: Do NOT use a portable hydraulic power unit which has a MAXIMUM RELIEVED pressure of MORE than 400 psi. [28 bar] or a MINIMUM RELIEVED pressure of LESS than 175 psi. [12 bar]. Serious system damage, or no release of the system brakes, will occur. Do NOT use a portable hydraulic unit which has an “oil supply” other than CLEAN, FILTERED hydraulic oil, which is of the SAME TYPE contained in hydraulic oil reservoir, of the machine [see decal, near hydraulic oil reservoir fill port].

h. Go to the brake release system needle valve, found between the secondary/parking brake solenoid valve assembly and the brake system connection fitting and cap, on the "Tee" fitting [see figure 3-7]. Turn the knob INWARD to the fully CLOSED position.

3-17

Section 3 OPERATION i. Wipe the connection hose fitting, on the hose which comes from the portable hydraulic power unit, with a CLEAN cloth. j. Carefully connect, and then tighten, the portable power unit connection hose fitting onto the secondary/parking brake release system connection fitting. k. Move the portable hydraulic power unit handle in a “back and forth” direction and fully release the brakes. NOTE: Moving the power unit handle will cause the power unit to produce the needed pressure in the secondary/parking brake system to release the spring applied brakes in EACH tire drive motor.

l. SECURELY fasten, and tighten, the towing strap, cable or chain to the machine and the towing vehicle. CAREFULLY remove all wood blocking from under all tires. CAREFULLY and SLOWLY tow the machine to a repair area, or move the machine onto a truck or trailer, and fasten securely [see THIS section for CORRECT machine tie-down procedures].

m. AFTER the machine has been towed or transported, the SECONDARY/PARKING brake system MUST be APPLIED. Turn the pressure release handle, found on the portable hydraulic power unit, to the “pressure release” position. Release the pressure from the secondary/parking brake system.

WARNING: AFTER the machine has been towed, the secondary/parking brake system, on each tire drive motor, MUST be put in the APPLIED condition. NOTE: Turning the “pressure release handle”, to the “release position”, will allow the pressure in the secondary/parking brake system to be released from the system. The spring applied multi-disc brakes will then APPLY. It can require approximately five [5] seconds for the pressure to be released from the secondary/parking brake system into the portable hydraulic power unit and the brakes to be fully applied.

n. Turn the knob, found on the needle valve, OUTWARD, to the fully OPEN position.

WARNING: Keep ALL personnel CLEAR of the towing vehicle and the machine while removing the blocking and towing the machine, or moving the machine onto the truck or trailer. At THIS time the machine will be held in position ONLY by the wood blocking placed against the tires. The secondary/ parking brake system WILL be in a RELEASED condition. Do NOT tow the machine on ANY grade. TOW the machine the LEAST distance possible. Do NOT tow the machine at a speed above TWO [2] miles per hour [3.2 km/h].

NOTE: If the TOWING BYPASS VALVE is NOT OPENED, there WILL be resistance in the hydrostatic transmission system. It is caused by system oil in the transmission tire drive motors.

3-18

NOTE: This is the SAME position, which the knob was in BEFORE the brakes were released [see figure 3-7].

o. Carefully disconnect the portable hydraulic power unit from the secondary/parking brake release system fitting. p. Install the cap onto the secondary/parking brake release system fitting and tighten securely. q. AFTER the secondary/parking brake system is APPLIED, close BOTH hydraulic pump FORWARD and REVERSE direction bypass valves by turning the MIDDLE sized [2nd] hex nut THREE [3] revolutions in the CLOCKWISE direction with the 1 1/16 inch open end wrench, UNTIL the hex nut is seated against the LARGE sized [3rd] hex nut. Hold the LARGE [3rd] hex nut with the 1 1/4 inch wrench and tighten the MIDDLE sized [2nd] hex nut to a torque of 30 ft. lbs. [41 N.m]. 11/00

Section 3 OPERATION TOWING A ROLLER HAVING THE OPTIONAL SECONDARY/PARKING BRAKE RELEASE SYSTEM [See Figures 3-6, 3-7 and 3-8].

c. OPEN the bypass valve by turning the open end wrench, that is on the MIDDLE sized [2nd] nut, THREE [3] revolutions in the COUNTERCLOCKWISE [CCW] direction.

CAUTION: Do NOT tow the machine unless ALL of the following procedures have been followed. Should the machine become COMPLETELY disabled, and the engine is NOT able to be started, use the following procedure to develop enough secondary/parking brake system pressure to release the brakes. Put BOTH of the g bypass valves in the “TOW” [OPEN] position BEFORE the machine is moved.

CAUTION: Do NOT turn the MIDDLE sized [2nd] hex nut more than three [3] revolutions. Additional revolutions will permit external leakage of hydraulic oil during towing of the machine.

NOTE: The towing bypass valves are found on the hydraulic transmission pump [see figure 3-6]. CAUTION: DO the FOLLOWING steps ONLY if the transmission system, or engine, can NOT be operated and BEFORE the machine is moved. RETURN the towing bypass valves to the “OPERATE” [CLOSED] position, AFTER the machine has been moved.

a. Put SOLID wood blocks behind, and in the front of, ALL FRONT and REAR tires. Go to the transmission pump. Find the two [2] towing bypass valves that are installed into the hydraulic transmission pump [see figure 3-6].

d. REPEAT the procedures, given in steps “b”, “c”, and the above “CAUTION” on the REVERSE direction multifunction valve cartridge. e. If the machine will be towed in the FORWARD direction, put the DIRECTION/SPEED CONTROL handlever in the FULL FORWARD position, so that the transmission pump displacement control valve handle is, also, at the full forward position. NOTE: If the machine will be towed in the REVERSE direction, put the DIRECTION/ SPEED CONTROL handlever in the full reverse position.

SMALL LEVER HANDLE HOSE

b. Put a 1 1/16 inch open end wrench on the MIDDLE sized [2nd] hex nut of the FORWARD direction multifunction valve cartridge. Put a 1 1/4 inch open end wrench on the LARGE sized [3rd] hex nut of the FORWARD direction multifunction valve cartridge. HAND PUMP ASSEMBLY

PUMP HAND LEVER

FIGURE 3-8. OPTIONAL SECONDARY/PARKING BRAKE RELEASE SYSTEM - HAND PUMP INSTALLED ABOVE ENGINE FLYWHEEL HOUSING. 11/00

3-19

Section 3 OPERATION f. Go to the brake release system REMOTE flow control valve. Turn the knob to the fully CLOSED [remote supply] position [see figure 3-7]. NOTE: The brake release system needle valve, is found at the bottom the secondary/ parking brake solenoid valve assembly and the brake system release pressure supply hose, on the “solenoid stack valve”.

g. Go to the secondary/parking brake system release hand pump assembly, which is installed on a plate above the engine flywheel housing [see figure 3-8]. Turn the “small” lever handle “UPWARD”. Move the hand pump lever “back and forth”. NOTE: Moving the hand pump lever approximately twenty [20] times will make approximately 175 psi. [12 bar] MINIMUM to 400 psi. [28 bar] MAXIMUM of pressure in the secondary/parking brake release system and release the brakes.

H. Securely fasten a large capacity towing strap, cable or chain to the Roller and the towing vehicle, or winch, and tighten fully. CAREFULLY remove the wood blocking from under the drive tires. CAREFULLY and SLOWLY tow the machine to a repair area or move the machine onto a truck, or trailer, and fasten securely [see this section for CORRECT machine tie-down procedures]. WARNING: Do NOT tow the machine on ANY grade. Tow on LEVEL terrain ONLY. The secondary/parking brake system will be RELEASED during towing. TOW the machine the LEAST distance possible. Do NOT tow the machine at a speed above TWO [2] miles per hour [3.2 Km/h].

NOTE: There will be resistance in the hydrostatic transmission system. It is caused by static system oil in the transmission wheel motors, until the motors have turned approximately one third [1/3] revolution. The machine will then roll more easily.

i. AFTER the machine has been towed or transported, the SECONDARY/PARKING brake system MUST be APPLIED. Turn the “small” lever handle, found on the brake system release pump, “DOWNWARD” to apply the secondary/parking brakes. NOTE: Turning the lever handle downward, will allow the pressure in the secondary/ parking brake system to be released from the system. The spring applied multi-disc brake will then APPLY. It will require approximately five [5] seconds for the pressure to be released from the secondary/parking brake system and the brakes to be fully applied.

j. Turn the knob, found on the REMOTE flow control valve, OUTWARD, to the fully OPEN position [see figure 3-7]. NOTE: This is the SAME position, which the knob was in BEFORE the brakes were released [see figure 3-7].

k. AFTER the secondary/parking brakes are APPLIED, close both the forward and reverse direction bypass valves by turning the MIDDLE sized [2nd] hex nut THREE [3] revolutions in the CLOCKWISE [CW] direction with the 1 1/16 inch open end wrench, UNTIL the hex nut is seated against the LARGE sized [3rd] hex nut. Hold the LARGE [3rd] hex nut with the 1 1/4 inch wrench and tighten the MIDDLE sized [2nd] hex nut to a torque of 30 ft. lbs. [41 N.m] [see figure 3-6]. CAUTION: BOTH bypass valves MUST be returned to the CLOSED position.

3-20

11/00

Section 3 OPERATION MACHINE TRANSPORT [See Figure 3-8]. If the machine is being moved by truck, or trailer, block ALL of the tires - at the front, and at the rear with SOLID wood for blocking.

b. Put the secondary/parking brake in the applied condition by putting the secondary/parking brake system control switch [ITEM 4] in the “ON” [APPLIED] position. c. Install the steering lock pin.

WARNING: FOUR [4] tie-downs MUST also be used, with the blocking, to secure the machine to the truck, or trailer, bed when transporting the machine.

d. Connect the four [4] tie-down chains between the truck, or trailer, bed and the machine, at the locations given in the above “WARNING”. Tighten the tie-down load binding device, to hold the machine securely in position during transportation, as directed by the binding device manufacturer.

a. CAREFULLY load the machine onto the transporting truck, or trailer as directed by the truck, or trailer manufacturer.

FIGURE 3-8. MACHINE TRANSPORT BLOCKING AND TIE DOWN LOCATIONS.

11/00

3-21

Section 3 OPERATION NOTES

3-22

11/00

Section 4 MAINTENANCE

07/01

4-1

Section 4 MAINTENANCE PAGE COOLING SYSTEM ................................................................................................................... 4-19. RADIATOR AND HYDRAULIC OIL COOLER ........................................................................ 4-19. RADIATOR HOSES ................................................................................................................. 4-20. WATER PUMP ......................................................................................................................... 4-20. DRAINING, FLUSHING AND FILLING THE COOLING SYSTEM .......................................... 4-20. HYDRAULIC SYSTEM ...................................................................................................................... 4-22. GENERAL INFORMATION ............................................................................................................ 4-22. CHECKING THE HYDRAULIC OIL LEVEL AND ADDING HYDRAULIC OIL TO THE HYDRAULIC OIL RESERVOIR ....................................................... 4-22. CHANGING THE HYDRAULIC OIL ............................................................................................... 4-23. HYDRAULIC SUCTION OIL FILTER ELEMENTREMOVAL AND REPLACEMENT............................................................................................... 4-26. ALTERNATOR AND FAN BELT INSPECTION AND REPLACEMENT PROCEDURES .................................................................. 4-28. ELECTRICAL SYSTEM .................................................................................................................... 4-28. CHECKING THE BATTERY CHARGE LEVEL AND SERVICING OF RELATED ITEMS ............................................................................................. 4-28. ELECTRICAL WIRING INSPECTION ............................................................................................ 4-29. REAR WHEEL BEARINGS................................................................................................................ 4-31. THROTTLE AND TRANSMISSION LUBRICATION ........................................................................ 4-32. REAR CENTER WHEEL SPRING ADJUSTMENT ......................................................................... 4-32. WATER SPRAY SYSTEM ................................................................................................................ 4-33. WATER SPRAY FILL STRAINER BASKET ................................................................................. 4-33. IN LINE WATER PUMP SYSTEM STRAINER .............................................................................. 4-33. WATER SPRAY NOZZLES ........................................................................................................... 4-33.

4-2

07/01

Section 4 MAINTENANCE PAGE MISCELLANEOUS MAINTENANCE INFORMATION ..................................................................... 4-34. PREPARING THE MACHINE FOR STORAGE ............................................................................. 4-34. ENGINE ....................................................................................................................................... 4-34. COOLING SYSTEM .................................................................................................................... 4-34. BATTERY .................................................................................................................................... 4-34. FUEL TANK ................................................................................................................................ 4-34. WATER SPRAY SYSTEM .......................................................................................................... 4-34. TIRES .......................................................................................................................................... 4-35. AIR CLEANER, EXHAUST AND OTHER OPENINGS .............................................................. 4-35. EXPOSED COMPONENT RUST PREVENTION ........................................................................ 4-35.

07/01

4-3

Section 4 MAINTENANCE GENERAL INFORMATION.

MAINTENANCE SCHEDULE.

THIS section gives the necessary procedures for CORRECT MAINTENANCE of the Model BW11RH Roller.

GENERAL INFORMATION. The MAINTENANCE SCHEDULE lists the recommended time intervals between machine maintenance inspections and lubrication procedures. Table 4-1 gives inspection and lubrication information for the Model BW11RH Roller.

Follow ALL of the “MAINTENANCE SCHEDULES” and “MAINTENANCE PROCEDURES” for CORRECT machine service schedules and procedures.

Most service intervals are listed by the “HOUR” and “PERIODIC” time periods. The maintenance schedule begins with eight [8] hours, or daily, maintenance intervals and continues through the 2,000 hours, or every two [2] years, maintenance schedule intervals.

MAINTENANCE. GENERAL INFORMATION. MAINTENANCE must be a planned program which includes periodic machine inspection and lubrication procedures.

NOTE: If the machine is operated MORE than eight [8] hours per day, follow the “HOUR” schedule. If the machine is operated LESS than eight [8] hours per day, follow the “PERIODIC” schedules, where they apply.

The MAINTENANCE program must be done, based on the machine “OPERATING HOURS”, recorded on the hourmeter, or based on the “PERIODIC SCHEDULE”, which is done at time intervals of weekly, monthly, or yearly. The MAINTENANCE program is divided into TWO [2] subsections: The MAINTENANCE SCHEDULE and the MAINTENANCE PROCEDURES.

The maintenance checks, given in Table 4-1, are also listed on the “Machine Maintenance Decal”, found on the machine [See Figure 4-2]. Figure 4-1 shows the location of the “machine maintenance points”.

19 11 18

4 14

5 7

15 20

2 (other side) 1 8

3 22

FIGURE 4-1. MACHINE MAINTENANCE POINTS .

4-4

07/01

Section 4 MAINTENANCE MAINTENANCE INFORMATION

FIGURE 4-2. MACHINE MAINTENANCE DECAL.

07/01

4-5

Section 4 MAINTENANCE TABLE 4-1. MAINTENANCE SCHEDULE. FIGâ&#x20AC;&#x2122; 4-1 ITEM NO.

4-6

ITEM

8/ DAY

ENGINE OIL

ENGINE OIL FILTER

ENGINE FUEL FILTERS [Primary and Secondary]

FUEL LEVEL - IN TANK

ENGINE INLET AIR FILTER ELEMENT

ENGINE COOLING SYSTEM

250/ 3 MO

500/ 6 MO

1000/ 1 YR

2000/ 2 YR

QUAN.

TYPE/REMARKS

Drain diesel engine lubrication oil and replace with NEW*

Change at EACH engine oil change.* Use APPROVED filter ONLY.

Drain PRIMARY of EACH water daily with drain plug provided.* Change at interval given.* Use APPROVED filters ONLY.

30.0 Gal. [114 l] Estimated

#1D or #2D diesel fuel. See Section 2 SPECIFICATIONS, for complete specifications.

C**

Check condition indicator light. Change element as needed.** Use APPROVED element ONLY.

19 Qts. [18 l] Estimated

Check coolant level. Fill as required with 50% mixture [approximate] of drinking water and ethylene glycol base antifreeze, with rust inhibitors and antirust qualities.*

07/01

Section 4 MAINTENANCE TABLE 4-1. MAINTENANCE SCHEDULE. FIG’ 4-1 ITEM NO. 7

ITEM

HYDRAULIC SYSTEM OIL ***

8/ DAY

250/ 3 MO

500/ 1 YR

1000/ 1 YR

2000/ 2 YR

+A/C

QUAN.

28.5 Gal. [108 l]

TYPE/REMARKS

Check hydraulic oil level in the reservoir sight gauge. Add hydraulic oil as required.*** Use ONLY MOBIL 423, HYTRAN, TEXACO “TDH” or equivalent.

CAUTION: Use the COR RECT hydraulic oil ONLY*** + A= OBTAIN AND ANALYZE OIL SAMPLE - WITH CARE. + C= CHANGE OIL BASED ON RESULTS OF OIL ANALYSIS - AS NEEDED. 8

07/01

HYDRAULIC SYSTEM SUCTION OIL FILTER [Trans’ System]

Check condition indicator lights daily. Change filter element when hydraulic oil is changed, and/or one [1] time for every 2,000 hours of machine operation, or when filter element condition indicator, on filter head, and/or indicator light shows needed. Use APPROVED filter element ONLY. See MACHINE PARTS book for CORRECT replacement element.

4-7

Section 4 MAINTENANCE TABLE 4-1. MAINTENANCE SCHEDULE. FIG’ 4-1 ITEM NO.

ITEM

ALTERNATOR & FAN DRIVE BELT

BATTERY

SECONDARY/ PARKING BRAKE SYSTEM

4-8

8/ DAY

100/ 2 WK

500/ 6 MO

1000/ 1 YR

2000/ 2 YR

QUAN.

TYPE/REMARKS

Check belt for wear or damage. Check belt for CORRECT deflection.* Replace belt with NEW if needed [see Cummins ENGINE manual].

The battery is of the “maintenance free” type. Check the built in “test indicator” for indication of battery condition. If fully charged, should indicate “GREEN” condition. Clean battery AND battery cable connectors AND check hold down clamp for tightness. Service as required. See THIS section.

System Check OPERATION and APPLICATION condition of SECONDARY/ PARKING BRAKE SYSTEM, one [1] time for every eight [8] hours of machine operation, OR daily, using the procedures given in THIS section.

07/01

Section 4 MAINTENANCE TABLE 4-1. MAINTENANCE SCHEDULE. FIGâ&#x20AC;&#x2122; 4-1 ITEM NO.

ITEM

8/ DAY

250/ 3 MO

500/ 6 MO

1000/ 1 YR

2000/ 2 YR

QUAN.

TYPE/REMARKS

WATER SPRAY SUCTION FILTER

CLEAN AS REQUIRED

Remove, check, clean and install the suction strainer on an AS REQUIRED basis [see THIS section].

WATER SPRAY NOZZLES

CLEAN AS REQUIRED

Remove, clean and install onto spray bars on an AS REQUIRED basis [see THIS section].

SAFETY DECALS

All

Check condition. Replace IF needed. See MACHINE parts book.

SEAT BELTS

2 Sets

Check condition. Replace sets IF damaged. See MACHINE parts book

GAUGES HORN

X X

All

Check operation. Repair, or replace, as needed.

DYNAMIC BRAKES

Trans. System

Check operation. Repair IF needed. See Section 3.

STEERING

Steering System

Check operation. Repair IF needed. See Section 3.

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4-9

Section 4 MAINTENANCE TABLE 4-1. MAINTENANCE SCHEDULE. FIGâ&#x20AC;&#x2122; 4-1 ITEM NO.

ITEM

8/ DAY

FALLING OBJECT/ ROLL OVER PROTECTIVE STRUCTURE [FOPS/ ROPS]

THROTTLE AND TRANSMISSION LINKAGES

4-10

REAR WHEEL BEARINGS

100/ 2 WK

500/ 6 MO

1000/ 1 YR

2000/ 2 YR

QUAN.

TYPE/REMARKS

Structure

Inspect the SIX [6] flange screws that fasten the fasten the structure to the machine, they MUST remain tightened to the torque of 400 ft. lbs. [543 N.m]. CAREFULLY inspect ALL welds for cracks, breakage in the weld or where the weld joins the components, severe rust or other weld related problems. If any damage is found in the above inspection, contact the nearest Distributor immediately.

All

Lubricate linkage behind control panel with NEW engine oil one [1] time for each 100 hours of machine operation, or every 2 weeks.

All

Lubricate wheel bearings with wheel bearing grease one [1] time for each 1000 hours of machine operation, or yearly.

07/01

Section 4 MAINTENANCE TABLE 4-1. MAINTENANCE SCHEDULE. FIG’ 4-1 ITEM NO. 22

ITEM

FRONT DRIVE WHEEL NUTS

8/ DAY

100/ 2 WK

500/ 6 MO

1000/ 1 YR

2000/ 2 YR

QUAN.

All

TYPE/REMARKS

Check ALL front drive wheel nuts for correct torque one [1] time for each 100 hours of machine operation, or every 2 weeks. Maintain a torque of 188 ft. lbs. [255 N.m] across corners.

CAUTION: CHECK ENGINE lubrication oil level with the engine in the “OFF and COLD” condition. CHECK HYDRAULIC system oil level with the engine in the “OFF” condition and the hydraulic oil at the “OPERATING” temperature. KEY: X= CHECK

C= CHANGE/SERVICE

A/C= OBTAIN OIL SAMPLE, WITH CARE, AND ANALYZE. CHANGE OIL BASED ON RESULTS OF OIL ANALYSIS - IF REQUIRED * = Refer to current “OPERATION AND MAINTENANCE MANUAL - B SERIES DIESEL ENGINE” published by Cummins Engine Company Incorporated, which is supplied with EACH machine. ** = Under VERY dusty or severe operating conditions change at 500 hours OR as need is indicated. *** = See DECAL adjacent to hydraulic reservoir fill tube.

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4-11

Section 4 MAINTENANCE MAINTENANCE PROCEDURES. GENERAL INFORMATION. The following MAINTENANCE PROCEDURES give correct instructions for performing the required maintenance checks and show the locations for lubrication of the machine.

NOTE: The instructions given in the MAINTENANCE procedure subsection are given by “machine systems” and are NOT necessarily in the same order as listed in Table 4-1 or as shown on the “Machine Maintenance Decal”. They also include some items NOT shown in the table, or on the decal.

NOTE: The ABOVE procedure will help to remove the possibility of filling the engine with too much lubrication oil, by allowing the oil to return to the oil pan.

WARNING: STOP the engine BEFORE checking the engine lubrication oil level. With engine running, HOT oil can be thrown causing serious injury.

ENGINE MAINTENANCE. GENERAL INFORMATION. The following ENGINE maintenance information will cover engine maintenance procedures most often done. For additional ENGINE maintenance information, also see the “OPERATION AND MAINTENANCE MANUAL - B SERIES DIESEL ENGINE” published by Cummins Engine Company Incorporated, which is supplied with the machine.

FIGURE 4-3. CUMMINS DIESEL ENGINE LUBRICATION OIL LEVEL CHECK LOCATION.

ENGINE LUBRICATION OIL. CHECKING THE ENGINE LUBRICATION OIL LEVEL [See Figure 4-3]. The engine lubrication oil MUST be kept at a level ABOVE the “ADD” mark but NOT ABOVE the “FULL” mark on the engine lubrication oil dipstick.

CHANGING THE ENGINE LUBRICATION OIL [See Figure 4-4]. The engine lubrication oil MUST be changed according to the interval given in the diesel engine “Operation and Maintenance Manual” published by Cummins Engine Company and supplied with the machine.

To accurately check the engine lubrication oil level, put the machine in a “LEVEL” position and STOP the engine. Clean the area around the engine lubrication oil dipstick before removing the dipstick from the engine. Wait five [5] minutes before removing the dipstick from the engine and checking the oil level.

4-12

07/01

Section 4 MAINTENANCE NOTE: The color of the engine lubrication oil can NOT be used as an indication of the need for a engine lubrication oil change. The use of an engine lubrication oil “analysis service” is the ONLY alternate reason for not following the recommended engine lubrication oil change schedule.

WARNING: Do NOT change the engine lubrication oil when the engine and lubrication oil are HOT. Change when WARM ONLY. Hot oil can cause serious injury.

CAUTION: Do NOT change the engine lubrication oil with the engine in a “running” condition. Serious engine damage, or failure will occur. Clean the area around the engine lubrication oil dipstick and oil fill cap BEFORE removing the dipstick or oil fill cap.

f. Fill the engine to the CORRECT oil level, with the CORRECT engine lubrication oil.

NOTE: See the information given in the diesel engine “Operation and Maintenance Manual” published by Cummins Engine Company and supplied with the machine for the CORRECT amount and type of lubrication oil.

g. Wash the oil fill cap with degreaser cleaner, Part Number 178297, and dry with compressed air. Install the oil fill cap and the engine lubrication oil dipstick.

CAUTION: Do NOT start the engine BEFORE changing the engine lubrication oil filter. Follow the procedures given in THIS section and in the Cummins engine “Operation and Maintenance Manual”.

With the engine “STOPPED”, and with “WARM” engine lubrication oil, proceed as follows: a. Clean the area around the engine lubrication oil drain plug found at the hitch area. b. Place a container, having a capacity greater than 10 qts. [9.5 L], directly under the engine lubrication oil drain plug. c. CAREFULLY remove the engine lubrication oil drain plug.

DRAIN PLUG (BY HITCH)

d. Drain ALL of the engine lubrication oil into the container. e. Clean, install and CAREFULLY tighten the lubrication oil drain plug.

OIL PAN ON MOTOR

FIGURE 4-4. CUMMINS DIESEL ENGINE LUBRICATION OIL DRAIN PLUG LOCATION.

CAUTION: Do NOT overtighten the drain plug.

07/01

4-13

Section 4 MAINTENANCE CHANGING THE ENGINE LUBRICATION OIL FILTER [See Figure 4-5]. The engine lubrication oil filter MUST be changed when the engine lubrication oil is changed.

WARNING: Do NOT change the engine lubrication oil filter when the engine and lubrication oil are HOT. Change the filter when “WARM” only. Hot oil can cause serious injury.

CAUTION: Do NOT change the engine lubrication oil filter with the engine running. Serious engine damage, or failure, WILL occur.

With the engine in a “STOPPED” condition , and filled with NEW engine lubrication oil, proceed as follows: a. Use a CLEAN cloth to wipe the area around the engine lubrication oil filter element and its mounting base. b. Place a container under the filter element. c. Use a filter removal wrench to loosen and remove the filter element by turning it in a COUNTERCLOCKWISE direction of rotation. Drain and discard the removed filter element.

CAUTION: Be sure the used rubber gasket is REMOVED and discarded with the filter element.

d. Wipe the inside area of the lubrication oil filter head using a CLEAN lint free cloth.

NOTE: See the information given in the diesel engine “Operation and Maintenance Manual” published by Cummins Engine Company and supplied with the machine for the CORRECT type of lubrication oil.

f. Install the NEW filter element onto the filter head. Carefully tighten the filter element, by the hand ONLY.

NOTE: Tighten the filter element as DIRECTED on the filter element, by the filter manufacturer.

CAUTION: Do NOT overtighten the lubrication oil filter element onto the filter head. Follow ALL engine lubrication oil change and fill procedures, given in THIS section, AND in the ENGINE “Operation and Maintenance Manual”, BEFORE the engine is started.

NOTE: CHECK the engine lubrication oil level at THIS time.

g. Start the engine. Check to be sure there are NO oil leaks and that the engine oil pressure gauge indicates that the engine has the CORRECT lubrication oil pressure.

CAUTION: STOP the engine IMMEDIATELY if INCORRECT OIL pressure is indicated OR any oil leaks are seen. CORRECT any problem noted BEFORE starting the engine again.

e. Put CLEAN engine lubrication oil on the rubber gasket area of the NEW filter element. Fill the NEW filter element with CORRECT, NEW and CLEAN lubrication oil.

4-14

07/01

Section 4 MAINTENANCE FUEL CAP

FUEL TANK

FUEL SCREEN

FIGURE 4-5. CUMMINS DIESEL ENGINE LUBRICATION OIL FILTER LOCATION.

FIGURE 4-6. FUEL TANK FILL AND CAP.

ENGINE FUEL FILTERS [See Figure 4-7]. FUEL SYSTEM. FUEL TANK [See Figure 4-6]. The fuel gauge indicates the amount of fuel in the tank. Check the amount indicated on the gauge ONE [1] time EACH day. Fill the fuel tank to “FULL”, as the gauge indicates. Also fill the tank, to “FULL”, BEFORE the machine is stored for the night to reduce the accumulation of moisture, in the tank, from condensation.

WARNING: The operator MUST be off of the machine while fuel is added. NO smoking while filling the fuel tank. ALL fuels for internal combustion engines are flammable. Fill the fuel tank ONLY in a designated area with good ventilation. Have a fire extinguisher available. NEVER fill the tank near an open flame, or near equipment that can create sparks. Never check fuel level , or check for leaks, with an open flame.

07/01

The fuel strainer [PRIMARY] and the fuel filter [SECONDARY] elements MUST be replaced one [1] time for EACH 500 hours of machine operation or every six [6] months.

CAUTION: Drain the PRIMARY fuel strainer lower bowl of ALL water [1] time EACH day, or as needed.

Replace the fuel strainer and/or fuel filter elements using the following “GENERAL” procedures and those given in the engine “Operation and Maintenance Manual” published by Cummins Engine Company Incorporated and supplied with the machine.

NOTE: Also remove and replace the fuel prefilter assembly, found in the fuel line ahead of the fuel lift pump, one [1] time for EACH 500 hours of machine operation, or every six [6] months.

4-15

Section 4 MAINTENANCE WARNING: DIESEL FUEL IS VERY FLAMMABLE. USE EXTRA CAUTION. Do NOT change the fuel strainer, or fuel filter, element in an area near open flame. Do NOT change the fuel strainer, or fuel filter, element with the machine running. Do NOT smoke while changing the fuel strainer, or fuel filter, element. Do NOT spill fuel.

e. Wipe the inside area of the filter head with a CLEAN “lint free” cloth. Fill the “NEW” fuel strainer, or fuel filter, element COMPLETELY FULL of the CORRECT and CLEAN fuel. Put CLEAN oil on the element rubber gasket. f. Install the “NEW” fuel strainer, or fuel filter, element onto the filter head. CAREFULLY tighten the element by HAND ONLY.

CAUTION: Tighten the fuel strainer, or the fuel filter, element as DIRECTED on the filter element, by the filter manufacturer. Do NOT overtighten the fuel strainer, or fuel filter, element onto the filter head.

g. Start the engine and check for ANY fuel leaks.

WARNING: STOP the engine IMMEDIATELY if ANY fuel leakage is noted. Do NOT start the engine UNTIL the leakage problem is CORRECTED.

FIGURE 4-7. FUEL STRAINER, WATER DRAIN AND FUEL FILTER LOCATIONS - CUMMINS DIESEL ENGINE.

PRIMING AND AIR REMOVAL [BLEEDING] FROM THE FUEL SYSTEM - CUMMINS DIESEL ENGINE [See Figure 4-8]. Use the following procedure to prime, start and remove [bleed] the air from the fuel system of a CUMMINS diesel engine which has been run out of fuel:

a. STOP the engine. b. Put a container under the fuel strainer, or the fuel filter, element BEFORE removing either element. c. Wipe the area around the fuel strainer, or the fuel filter, element and the element mounting head, using a CLEAN lint free cloth. d. Use a filter removal wrench to loosen and remove the element, by turning the element in a COUNTERCLOCKWISE direction. Drain and discard the removed element.

4-16

NOTE: Small amounts of air will be vented from the system automatically, if the filters were changed using the CORRECT procedures given in THIS section. Air removal [bleeding] will be required if the fuel strainer and/or filter elements were NOT correctly filled with fuel BEFORE installation. Also see the engine “Operation and Maintenance Manual” supplied with the machine for further information.

07/01

Section 4 MAINTENANCE a. Add at LEAST ten [10] gallons [38 liters] of the CORRECT, CLEAN fuel to the fuel tank. b. Remove the air from the LOW pressure fuel lines and the fuel strainer and filter by opening the air bleed screw, found at the manifold above the fuel filter [see figure 4-8]. c. Operate the hand lever on the fuel lift pump until the flow of fuel from the manifold fitting is continuous and FREE of air bubbles [see figure 4-8]. d. COMPLETELY tighten the air bleed screw and stop the operation of the lift pump hand lever. e. Start the engine using ALL the CORRECT starting procedures given in Section 3 - OPERATION - of THIS manual.

f. With the engine running at LOW idle speed, CAREFULLY use a wrench to loosen the fuel supply line to injector retaining nuts a SMALL amount, ONE [1] at a time. Let the fuel flow from EACH line until there is NO indication of air bubbles present at ANY line connection point. CAREFULLY use the wrench to tighten EACH fuel supply line nut at the injector fittings [see figure 4-8].

WARNING: KEEP the hands and body AWAY from the cooling fan. Serious injury can result from being caught or struck by the fan, belt or moving engine parts. KEEP the hands and body AWAY from the injector fittings and nuts. Fuel under HIGH pressure can penetrate the skin. Wear safety glasses to protect the eyes. Get IMMEDIATE medical attention if fuel enters the eyes, or skin. Do NOT remove the air from the fuel supply lines if the engine is HOT. Fuel leaked on the HOT exhaust manifold can create a danger of fire.

FIGURE 4-8. FUEL PRIMING AND AIR REMOVAL LOCATIONS.

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4-17

Section 4 MAINTENANCE ENGINE AIR FILTRATION.

f. CAREFULLY install the NEW air filter element into the air cleaner body assembly.

AIR CLEANER [See Figure 4-9]. The engine inlet air cleaner assembly uses a replaceable filter element.

g. Install the baffle assembly over the end of the air filter element. Install and tighten the wing nut, which holds the baffle assembly and air filter element into the air cleaner body assembly.

CHECK the engine inlet air restriction indicator light DAILY. If the restriction indicator light is “ON”, the air cleaner filter element MUST be removed and replaced with NEW IMMEDIATELY.

h. Install the air cleaner end cap onto the air cleaner body. Snap the spring clamps over the end cap.

CAUTION: The air cleaner filter element should be replaced ONE [1] time for EACH 1,000 hours of machine operation, or yearly, for a machine which is operated under “normal” conditions, or ONE [1] time for EACH 500 hours of machine operation, or every six [6] months, for a machine which is operated under “very dusty or “severe” conditions. Do NOT service the air cleaner element while the engine is “running”.

i. Start the engine using ALL the CORRECT starting procedures given in Section 3 - OPERATION - of THIS manual. Note that the engine inlet air restriction indicator light is in an “OFF” condition and that the engine inlet air is NOT being restricted.

SPRING CLAMPS (TYPICAL)

Use the following procedures to service the air cleaner element: a. STOP the engine. Release the spring clamps which hold the end cup assembly onto the air cleaner body. Remove the end cup from the air cleaner body. b. Remove the wing nut and baffle assembly from inside the air cleaner body. c. Remove the air filter element from inside the air cleaner body and DISCARD.

FIGURE 4-9. AIR CLEANER ASSEMBLY EXPLODED VIEW.

d. Clean the inside of the air cleaner body with a clean cloth. e. Inspect the hose clamps for tightness and the condition of the tube from the air filter to the engine intake manifold.

CAUTION: Severe engine damage can occur if hose clamps are in a loose condition or if the tube is damaged.

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07/01

Section 4 MAINTENANCE COOLING SYSTEM. RADIATOR AND HYDRAULIC OIL COOLER [See Figure 4-10].

WARNING: Do NOT check the system coolant level, or ANY component, with the engine running. Serious injury can result from being caught or struck by the fan, belt or moving engine parts. Do NOT check the system coolant level, or ANY component, when the system is at operating temperature and the coolant is under pressure. HOT coolant, under pressure, can cause serious injury. Check the coolant level ONLY when the radiator filler cap is cool enough to touch with the hand. Remove the radiator filler cap SLOWLY.

CHECK the system coolant level ONE [1] time for EACH eight [8] hours of machine operation, or daily. Drain, flush and fill the cooling system, with NEW coolant, ONE [1] time for EACH 1,000 hours of machine operation, or yearly, [see THIS section for procedures]. Keep the coolant level ONE [1] inch [25.4 mm] BELOW the radiator filler neck, when the cooling system is cool. Fill the radiator ONLY when the system is COOL. Fill the radiator as needed, using a 50/50 % [approximate] mixture of ethylene glycol type antifreeze and CLEAN water on initial fill. Add CLEAN water when level is LOW. CHECK the radiator cap gasket EACH time the radiator cap is removed from the radiator. The radiator cap gasket MUST seal on the radiator filler neck surface. If the rubber face of the cap valve is damaged or cracked REPLACE the radiator cap IMMEDIATELY with a NEW cap of the SAME pressure rating. CHECK the radiator overflow tube for a restriction or damage. A restricted or damaged overflow tube can prevent the radiator cap from releasing extra system pressure and system failure can occur.

07/01

With the engine STOPPED, inspect the radiator and the hydraulic oil cooler cooling fin area EACH time the system coolant level is checked. Use a bright light placed on the INSIDE of the radiator fin area. Light MUST be clearly seen, when looking through the radiator and hydraulic oil cooler fin area FROM the outside of the fin area.

WARNING: The engine MUST be STOPPED BEFORE checking, or cleaning, the radiator, or hydraulic oil cooler, fin areas. Serious injury can result from being caught or struck by the fan, belt or moving engine parts.

NOTE: If a restricted fin condition is noted in EITHER the radiator, or the hydraulic oil cooler, fin area, CLEAN the fin area using LOW pressure compressed air.

WARNING: The compressed air supply MUST have a pressure BELOW 30 psi. [2 bar]. Wear safety glasses and protective clothing.

CAUTION: Do NOT damage the radiator, or hydraulic oil cooler, cooling fins during cleaning. Clean the fin areas with the compressed air blown in the OPPOSITE direction of “normal” air flow during operation. Bent cooling fins can be CAREFULLY straightened. Use a radiator fin comb to straighten the bent fins AFTER cleaning. Severe restrictions or dirt build up, which are NOT removed by using compressed air, MUST be removed by using standard steam cleaning procedures. Apply steam cleaning pressure through BOTH the radiator and hydraulic oil cooler in the direction OPPOSITE the direction of “normal” air flow during operation. Do NOT use caustic soap solutions as part of the standard steam cleaning procedure as rapid radiator, or hydraulic oil cooler, deterioration can occur.

4-19

Section 4 MAINTENANCE WARNING: Wear safety glasses AND protective clothing during the steam cleaning operation. Use ONLY CORRECT steam cleaning procedures.

RADIATOR FILL CAP

WARNING: Do NOT check, or remove, ANY radiator hose with the engine running. Serious injury can result from being caught or struck by the fan, belt or moving engine parts. Do NOT check, or remove ANY radiator hose while the cooling system is HOT or is full of coolant. Remove the hoses ONLY when the system is COOL and has been DRAINED of coolant.

WATER PUMP. Visually CHECK the engine water pump for leaks, or other damage, after EACH 50 hours of machine operation.

OIL OIL COOLER COOLER

DRAIN COCK

FIGURE 4-10. RADIATOR AND HYDRAULIC OIL COOLER LOCATIONS.

RADIATOR HOSES. CHECK the radiator hoses at least ONE [1] time EACH year for cracks, increased size, softening or hardening. Drain the cooling system of coolant [see THIS section] and COMPLETELY remove EACH radiator hose. CHECK the INSIDE area of the hose for defects. Install the hose, again, if found to be acceptable or replace with NEW if found to be damaged.

CAUTION: Visual inspection of the outside of the hose is NOT adequate. A hose can have damage on the inside and look acceptable from the outside. The hose must NOT be hard or have ANY restrictions.

Water pump leaks can allow air to be pulled into the cooling system. Air in the cooling system can cause the cooling system to operate in a “HOT” condition. Replace the water pump IMMEDIATELY if a leak, or other damage is noted.

WARNING: Do NOT check, or remove the water pump with the engine running. Serious injury can result from being caught or struck by the fan, belt or moving engine parts. Do NOT remove the water pump while the cooling system is HOT. Remove and replace the water pump ONLY after draining the cooling system of coolant [see THIS section] when it is COOL.

DRAINING, FLUSHING AND FILLING THE COOLING SYSTEM [See Figures 4-10, 4-11, 4-12].

CAUTION: Also see the CUMMINS engine “Operation And Maintenance Manual”, supplied with the machine, BEFORE doing this maintenance procedure.

Rust in the radiator, or coolant, indicates that the coolant anticorrosion additives are NO longer effective.

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07/01

Section 4 MAINTENANCE To help prevent severe cooling system damage; drain, flush and fill the system with NEW coolant, ONE [1] time for EACH 1,000 hours of machine operation, or yearly.

WARNING: Do NOT drain, or flush the cooling system with the engine running. Serious injury can result from being caught or struck by the fan, belt or moving engine parts. Do NOT drain the cooling system while the system is HOT and is under pressure. Drain the system when COOL ONLY. Hot coolant can cause serious injury.

Use the following procedures to drain, flush and fill the engine cooling system: a. STOP the engine and allow the cooling system to reach a COOL temperature. Put a container under the radiator drain cock and drain the coolant. Close the radiator drain cock and tighten by hand ONLY [see figure 4-10]. b. Remove BOTH the upper and the lower radiator hoses from the engine. Inspect BOTH hoses using the procedures given in THIS section. Replace ANY hose found to have ANY damage.

NOTE: Inspect the engine WATER PUMP, at THIS time, for ANY damage, or leaks. REPLACE the water pump with NEW if found to be damaged.

c. Remove the thermostat housing and the thermostat from the engine. Inspect the thermostat for corrosion or damage. Test the thermostat for CORRECT operation at the specified opening temperature. Replace the thermostat, with NEW, if found to be damaged. Install the thermostat, AFTER flushing.

NOTE: BEFORE cooling system flushing, the thermostat MUST be removed. If the thermostat is NOT removed the flushing procedure WILL close the thermostat and prevent complete engine block flushing. Do NOT install the radiator hoses or thermostat at THIS time.

d. Loosen and remove ALL engine block drain plugs. COMPLETELY drain the coolant from the engine block. Install ALL engine block drain plugs into the engine block. Tighten the drain plugs by hand ONLY, at THIS time. e. Install ONLY the thermostat HOUSING [NO thermostat] onto the engine. Reverse flush the ENGINE BLOCK assembly as shown in figure 4-11. Remove ALL engine block drain plugs again, AFTER reverse flushing the engine block assembly. COMPLETELY drain the engine block of water. Install ALL engine block drain plugs. Tighten the drain plugs securely, using a wrench. f. Remove the thermostat housing from the engine. Install the thermostat into the housing, in the CORRECT position. Install the thermostat housing to engine gasket. Install the thermostat housing over the thermostat and onto the engine. Install the retaining capscrews and tighten securely.

CAUTION: Do NOT start the engine while reverse flushing the engine block or the radiator assembly.

g. Reverse flush the RADIATOR assembly, as shown in Figure 4-12. Loosen the radiator drain cock again, AFTER reverse flushing the radiator assembly. COMPLETELY drain the radiator of water. Close the radiator drain cock and tighten securely. h. Install BOTH the UPPER and the LOWER radiator hoses onto BOTH the radiator and the engine. Install ALL the clamps, onto the hoses, and tighten them securely. i. Fill the cooling system with coolant, through the radiator filler neck, using a NEW 50/50 % [APPROXIMATE] mixture of ethylene glycol antifreeze and CLEAN water [see THIS section].

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4-21

Section 4 MAINTENANCE NOTE: It is suggested that one [1] can of cooling system conditioner, with a rust inhibitor, also be added to the coolant at THIS time.

j. Start the engine and allow the NEW coolant mixture to circulate through the cooling system. Inspect the COMPLETE system for ANY coolant leakage. STOP the engine IMMEDIATELY and correct ANY leakage problem noted, BEFORE further engine operation.

WARNING: KEEP CLEAR of ALL moving engine parts when the engine is running. Serious injury can result from being caught or struck by the fan, belt or moving engine parts.

k. STOP the engine. Allow the coolant to reach a cool temperature and then fill the radiator, with the CORRECT coolant mixture, to WITHIN one [1] inch [25.4 mm] of the radiator filler neck. Install the radiator cap and tighten.

FIGURE 4-12. REVERSE FLUSHING PROCEDURE RADIATOR ASSEMBLY.

HYDRAULIC SYSTEM. GENERAL INFORMATION. The transmission and steering systems use the SAME hydraulic oil reservoir and hydraulic oil supply.

CHECKING THE HYDRAULIC OIL LEVEL AND ADDING HYDRAULIC OIL TO THE HYDRAULIC OIL RESERVOIR [See Figure 4-13]. CHECK the hydraulic reservoir oil level, ONE [1] time EACH day, using the sight gauge on the reservoir. Check the oil level when the hydraulic oil is at “NORMAL” operating temperature ONLY.

FIGURE 4-11. REVERSE FLUSHING PROCEDURE ENGINE BLOCK.

4-22

WARNING: Do NOT loosen, or remove the hydraulic oil reservoir filler cap when the hydraulic oil is “HOT”. ALWAYS loosen the filler cap SLOWLY to relieve any pressure in the hydraulic oil reservoir. ONLY loosen the filler cap when the oil is at a “WARM” temperature.

07/01

Section 4 MAINTENANCE The hydraulic reservoir oil level MUST be able to be seen through the sight gauge glass and be at the CENTER of the glass. If the hydraulic oil level is BELOW the sight gauge, the CORRECT, FILTERED hydraulic oil MUST be added to the hydraulic oil reservoir UNTIL the oil level is in the CENTER of the sight gauge glass. See THIS section for CORRECT type of oil.

RESERVOIR FILL TUBE AND CAP

SIGHT GAUGE TO SOLENOID VALVE

TO HYD. PUMP

TO BOTTOM OF OIL COOLER TO HYD. MOTOR

CAUTION: Do NOT over fill the hydraulic oil reservoir. Do NOT use unfiltered hydraulic oil. The NEW hydraulic oil MUST be filtered through TEN [10] micron filtration BEFORE it enters the hydraulic oil reservoir. The oil must NOT have more than 400 particles larger than 10 u. per milliliter as installed. KEEP the oil level of the hydraulic oil reservoir, at the CORRECT level. An air space is designed into the hydraulic oil reservoir and allows for oil expansion, at warm temperatures. The hydraulic oil reservoir WILL have a low pressure in it at system operating temperatures. Do NOT add a vent hole to the hydraulic oil reservoir.

RESERVOIR FILL TUBE AND CAP

TO VIEW SIGHT GAUGE OPEN BOTH DOORS. DOOR

DOOR

FIGURE 4-13. HYDRAULIC OIL RESERVOIR AND SIGHT GAUGE.

CHANGING THE HYDRAULIC OIL [See Figure 4-14]. Obtain a hydraulic oil sample from oil six [6] inches [152.4 mm] BELOW the FILL neck of the hydraulic oil reservoir one [1] time for each 2,000 hours of machine operation, or every two [2] years for OIL ANALYSIS. Before obtaining the oil sample, warm the hydraulic oil to operating temperature. Use the equipment furnished by the oil analysis service. CHANGE the hydraulic oil if the oil analysis results indicate a change is needed.

CAUTION: Obtain the hydraulic oil sample with the engine running and the hydraulic oil at operating temperature. Obtain the oil sample from a stream of oil originating from the LOW pressure side of the hydraulic system, such as "case drain" from pumps or motors.

07/01

4-23

Section 4 MAINTENANCE Changing the hydraulic oil removes the accumulation of dirt, water and mechanical wear particles from the hydraulic oil reservoir and system. The chemical structure of the hydraulic oil also changes after continuous use in the system and NEW, CLEAN and FILTERED oil is a MUST to help insure further CORRECT operation of the hydraulic system components.

CAUTION: Use CARE to NOT damage the gasket between the cover and the reservoir when removing the access cover from the reservoir. Inspect the gasket, and replace the gasket , with NEW when the cover is installed back onto the reservoir, if found damaged.

CAUTION: Hydraulic oil which has oxidized or which contains contamination, of ANY type, can shorten the expected service life of all, or any, of the components in the hydraulic system.

d. Use an oil pump to remove the remaining hydraulic oil from the bottom of the hydraulic oil reservoir. Reach through the reservoir access opening and use CLEAN lint free cloths to remove any remaining oil and/or contamination from the bottom area of the hydraulic oil reservoir.

Use the following procedures to change the hydraulic oil:

e. If removed, install a NEW gasket onto the hydraulic oil reservoir access opening area. Install the access cover over the studs and onto the hydraulic oil reservoir. Install the eight [8] retaining nuts onto the access cover studs and tighten securely.

a. STOP the engine. Allow the hydraulic oil to cool, until it is at a WARM temperature ONLY. SLOWLY loosen, and remove, the hydraulic oil reservoir filler cap. Put a CLEAN, lint free cloth over the reservoir fill tube opening and secure it in place.

WARNING: Do NOT drain the hydraulic oil from the reservoir when it is HOT. Hot hydraulic oil can cause serious injury. Drain at a WARM temperature ONLY.

b. Place an empty container, having a capacity of approximately 25 gallons [95 liters], under the machine directly below the hydraulic oil reservoir drain plug. Place a funnel, with a hose under the drain plug area. Place the hose into the container. Carefully remove the drain plug and allow ALL of the oil to drain from the reservoir and into the funnel and container. c. Go to the hydraulic oil reservoir, found in the engine compartment. Remove, the eight [8] nuts that fasten the hydraulic reservoir access cover to the reservoir. Carefully move the access cover away from the reservoir to allow cleaning of the inside of the reservoir.

4-24

f. Install the reservoir drain plug and tighten securely. CAREFULLY remove the cloth from the hydraulic oil reservoir fill tube opening.

NOTE: Also CHANGE the one [1] hydraulic SUCTION oil filter element at this time. See THIS section for procedures.

CAUTION: Do NOT fill the hydraulic oil reservoir with NEW hydraulic oil UNTIL the SUCTION filter element in the ABOVE â&#x20AC;&#x153;NOTEâ&#x20AC;? has been changed. Do NOT start the engine UNTIL the hydraulic system has been COMPLETELY and CORRECTLY filled with NEW, CORRECT and FILTERED hydraulic oil [see THIS section]. Damage to the components of the hydraulic system can occur, IF the engine is started BEFORE the system is ENTIRELY filled with NEW hydraulic oil.

07/01

Section 4 MAINTENANCE h. Fill the hydraulic oil reservoir with NEW, CORRECT and FILTERED hydraulic oil to a level in the CENTER of the sight gauge glass. COMPLETELY and CORRECTLY FILL the transmission system SUCTION FILTER and transmission pump oil SUPPLY HOSE with NEW, CORRECT and FILTERED hydraulic oil by using the FOLLOWING ADDITIONAL procedures - numbers 1 through 4.

CAUTION: Do NOT use unfiltered hydraulic oil. The NEW hydraulic oil MUST be filtered through TEN [10] micron filtration BEFORE it enters the hydraulic system. The oil must NOT have MORE than 800 particles larger than 10 u. per milliliter of oil as installed. Fill the hydraulic oil reservoir UNTIL the oil level is in the CENTER of the sight gauge glass ONLY. Do NOT overfill the hydraulic oil reservoir with oil.

1. Remove and discard the hydraulic SUCTION oil filter element [See THIS section]. FILL the NEW hydraulic SUCTION oil filter element with NEW, CORRECT and FILTERED hydraulic oil and install the element onto the filter head [See THIS section]. 2. Wipe BOTH the INLET and OUTLET hose fitting and suction FILTER fittings, at the filter head, with a CLEAN lint-free cloth. Loosen the OUTLET [transmission oil SUPPLY] HOSE fitting at the FILTER head OUTLET fitting. COMPLETELY remove the hose fitting from the filter head fitting. 3. COMPLETELY FILL the transmission SUPPLY hose with NEW, CORRECT and FILTERED hydraulic oil. Install the transmission oil SUPPLY hose fitting onto the FILTER head OUTLET fitting and tighten securely. 4. CHECK the hydraulic oil level shown in the hydraulic oil reservoir sight gauge. Add oil if needed, as described in step “h” above.

07/01

DRAIN LOCATION (UNDERSIDE OF FRAME- ABOVE WHEEL)

FIGURE 4-14. HYDRAULIC OIL RESERVOIR DRAIN LOCATION.

i. Install the hydraulic oil reservoir filler cap onto the reservoir filler neck and tighten securely. j. Start the engine using the CORRECT procedures given in Section 3 - OPERATION - of THIS manual. CHECK the hydraulic system for ANY leaks.

WARNING: Do NOT use the hands on ANY hydraulic hose, fitting or system component to check the system for possible leaks. Serious injury can occur from a leak under high pressure. Hydraulic oil, under pressure, can penetrate the skin or damage eyes. Oil leaks, under pressure, may NOT be visible. Use a piece of cardboard or wood to find leaks. Wear safety goggles for eye protection. If oil enters the skin, or eyes, get IMMEDIATE medical attention.

4-25

Section 4 MAINTENANCE CAUTION: STOP the engine IMMEDIATELY if ANY hydraulic leak is noted. Do NOT start the engine UNTIL any problem noted has been corrected.

HYDRAULIC SUCTION OIL FILTER ELEMENT REMOVAL AND REPLACEMENT [See Figure 4-15]. CHECK the condition of the hydraulic suction oil filter element EACH day. The filter element MUST be changed when the condition indicator light, found on the dash of the machine, and/or the change indicator, found on the filter head, indicates an element change is required.

CAUTION: The hydraulic system MUST be at NORMAL operating temperature, with the engine “running”, when the condition of the filter element is checked. With the engine at “HIGH” idle, and when the filter condition indicator WHITE sliding bar is in the RED zone, an element CHANGE is indicated to be needed.

NOTE: When the hydraulic oil is in a COLD condition and at machine “START UP” the filter condition indicator WHITE sliding bar will show a HIGHER amount of filter element restriction. The filter element MUST also be changed with EACH COMPLETE hydraulic oil change.

WARNING: Do NOT loosen, or remove, the hydraulic suction oil filter element when the engine is running or when the hydraulic oil is HOT. Loosen and remove the filter element ONLY when the engine is “STOPPED” and the hydraulic oil has cooled to a WARM, or COOL, temperature.

4-26

Use the following procedure to remove and replace the hydraulic SUCTION oil filter element: a. STOP the engine. Allow the hydraulic oil to reach a WARM, or COOL, temperature. b. Wipe the hydraulic suction oil filter head and element using a CLEAN lint free cloth. c. Use a oil filter removal wrench to loosen and remove the filter element. Discard the removed filter element.

CAUTION: BE sure that the old filter element rubber gasket was removed and discarded, BEFORE the NEW filter element is Installed. Do NOT overtighten the NEW filter element. Tighten by hand ONLY.

d. Put CLEAN hydraulic oil on the NEW filter element rubber gasket. Completely fill the filter with NEW, CORRECT and FILTERED hydraulic oil. e. CAREFULLY install the NEW filter element onto the filter head. Tighten the NEW filter element onto the filter head ONLY UNTIL the rubber gasket contacts the filter head seal area. Tighten the NEW filter element ONE HALF [1/2] additional turn AFTER the rubber gasket contacts the filter head area. f. Fill the hydraulic oil reservoir with oil. Use ALL the CORRECT procedures given in THIS section.

CAUTION: Do NOT start the engine BEFORE filling the hydraulic oil reservoir. Damage to the hydraulic system components can occur. FILL the reservoir, suction oil filter and transmission pump using ALL the procedures given in THIS section BEFORE starting the engine.

07/01

Section 4 MAINTENANCE g. Start the engine using the CORRECT procedures given in Section 3 - OPERATION - of THIS manual. CHECK the hydraulic system for ANY oil leaks.

WARNING: Do NOT use the hands on ANY hydraulic hose, fitting or system component to check the system for possible leaks. Serious injury can occur from a leak under high pressure. Oil can be injected under the skin by high pressure. Protect the eyes by wearing safety glasses.

CAUTION: STOP the engine IMMEDIATELY if ANY hydraulic oil leak is noted. Do NOT start the engine UNTIL any problem noted has been corrected.

07/01

HYDRAULIC SUCTION OIL FILTER (INSIDE ENGINE COMPARTMENT)

ENGINE COMPARTMENT DOOR

FIGURE 4-15. HYDRAULIC SUCTION OIL FILTER ELEMENT LOCATION.

4-27

Section 4 MAINTENANCE ALTERNATOR AND FAN DRIVE BELT INSPECTION AND REPLACEMENT PROCEDURES [See Figure 4-17]. Inspect the drive belt ONE [1] time for EACH 1,000 hours of machine operation, or yearly, and replace the belt as needed. The belt is kept under constant tension by an automatic tension mechanism and “adjustment” is NOT required as part of the maintenance procedures. Use the following procedures to inspect and/or inspect and replace the drive belt: a. STOP the engine.

WARNING: Do NOT inspect the engine drive belt when the engine is running. The engine MUST be STOPPED BEFORE inspecting the drive belt. Serious injury can result from being caught or struck by the fan, belt or other moving engine parts.

FIGURE 4-16. ALTERNATOR AND FAN DRIVE BELT LOCATION.

ELECTRICAL SYSTEM. b. Visually inspect the drive belt for cracks on the INNER surface of the belt plies. Check the belt deflection at the longest span of the belt. The MAXIMUM amount of deflection is 0.375-0.500 in. [9.5-12.7 mm] with 80-110 lbs. [36-49 kg] pull on the belt. Replace the belt, with NEW, if ANY cracks, or other damage is noted or if the amount of deflection is MORE than the above amount.

NOTE: If the belt requires replacement with NEW, see the “Operation and Maintenance Manual - B Series Diesel Engines”, published by Cummins Diesel Engine Company, and supplied with the machine, for procedures. Also, check the belt tension mechanism and fan hub bearings at this time using the procedures given in the SAME publication.

CHECKING THE BATTERY “CHARGE LEVEL” AND SERVICING OF RELATED ITEMS [See Figure 4-17].

WARNING: Do NOT attempt to open the “MAINTENANCE-FREE” battery case. The acid in electrolyte CAN cause INJURY. If electrolyte is spilled, use water to FLUSH the area and make the acid NEUTRAL using a WATER and SODA solution. Acid in the EYES MUST be FLUSHED with water IMMEDIATELY. ALL batteries produce an EXPLOSIVE GAS. Do NOT smoke near a battery. Do NOT check with flame. AVOID causing sparks.

The battery is of the “maintenance-free” type and MINIMAL service is needed. Use the built in battery “charge level” indicator, found in the top of the battery, to CHECK the charge level in the battery ONE [1] time for each 100 hours of machine operation, or every two [2] weeks.

4-28

07/01

2 -2 9&

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E -

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Section 4 MAINTENANCE

4-29

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Section 4 MAINTENANCE

FIGURE 4-18. ELECTRICAL SYSTEM SCHEMATIC.

4-30

07/01

Section 4 MAINTENANCE REAR WHEEL BEARINGS [See Figures 4-19 and 4-20]. On the machine, each of the five [5] rear wheels has inner and outer tapered roller bearings. Lubricate EACH inner and outer bearing assembly one [1] time for EACH 1000 hours of machine operation, or yearly, with wheel bearing grease.

c. Remove the grease cap from the one [1] of the outer wheel and tire assembly mounting hubs. Remove the cotter pin. Loosen and remove the hub and bearings assembly retaining nut. Remove the hub and bearings assembly from the wheel support. Remove the remaining four [4] hub and bearings assemblies.

NOTE: Keep all removed items together with each hub and bearings assembly.

OUTER BEARING

INNER BEARING

FIGURE 4-19. REAR WHEELS AND BEARINGS.

a. Lift the REAR frame with a chain and hoist, or jack having a capacity more than 15,000 lbs. [6810 kg]. Put SOLID wood blocks under BOTH sides of the frame, so that the rear tires are above the floor enough to remove each tire and wheel assembly from the hub and from under the rear frame.

WARNING: Keep CLEAR of the hoist, chain, or jack and machine while lifting and installing the blocking. Block SECURELY with SOLID wood blocking.

b. Go to the outer wheel and tire assembly at either side of the rear frame. Loosen and remove the wheel and tire assembly to hub mounting nuts. Remove the tire and wheel assembly from the hub. Repeat the same procedure for each of the four [4] remaining tire and wheel assemblies.

07/01

d. CAREFULLY remove the inner and outer bearing cones and inner bearing seal from each hub assembly . Discard each inner bearing seal. Wash the bearing cups and cones using CLEAN diesel fuel and dry with compressed air. Inspect all bearing cups, cones, hubs and other parts for wear, or damage, and replace as needed.

CAUTION: Replace each inner bearing with NEW at assembly, after all bearings are cleaned and lubricated with wheel bearing grease.

e. Use a tapered roller bearing packer to correctly lubricate ALL inner and outer bearing cones with NEW wheel bearing grease. f. Use the hand to lubricate each of the inner and outer bearing cups, installed in each of the hubs, with NEW wheel bearing grease. g. Carefully install one [1] inner bearing into each hub, from the inner side. Use a correct sized seal driver to install one [1] NEW inner bearing seal into each hub, from the inner side. h. Install each hub assembly fully over the threaded shaft of each wheel support. Install one outer bearing cone over the threaded wheel support shaft and push fully into the outer side of the hub. Install the hub and bearings assembly retaining nut. i. Tighten each retaining nut to a torque of 150 ft. lbs. [203 N.m]. Loosen each nut, so that each hub turns freely, with NO end play. Tighten each retaining nut to a torque of 25 ft. lbs. [40 N.m] and lock in place at the first alignment position which occurs at, or above, 25 ft. lbs. [40 N.m].

4-31

Section 4 MAINTENANCE j. Fill each grease cap one half [1/2] full of wheel bearing grease. Install the grease cap on the outer side of each hub and bearings assembly. k. Install the inner most wheel and tire assembly onto the hub and bearings assembly, under the rear frame. Install the wheel and tire assembly to hub mounting nuts.

WARNING: A mounting nut torque of 95 - 100 ft. lbs. [129 - 136 N.m] MUST be maintained at the rear wheels.

l. Tighten the tire assembly to hub mounting nuts, across corners, to a torque of 50% of the above torque. Tighten the tire assembly to hub mounting nuts, across corners, to a torque of 75% of the above torque. Tighten the tire assembly to hub mounting nuts, across corners, to the FULL torque, given above. j. Install each of the four [4] remaining tire and wheel assemblies, working toward the outside of the machine. Repeat step "i" for each of the four [4] remaining tire and wheel assemblies. k. Lift the REAR frame with a chain and hoist, or jack having a capacity more than 15,000 lbs. [6810 kg]. Remove the wood blocks from under BOTH sides of the frame.

WARNING: Keep CLEAR of the hoist, chain, or jack and machine while lifting and removing the blocking.

l. Place the machine into service. Check the tire assembly to hub mounting nuts torque, again, after twenty five [25] hours of machine operation. If the torques are found to be not correct, torque as needed using the above procedures.

FIGURE 4-20. REAR WHEEL TO HUB MOUNTING NUTS - TORQUE SEQUENCE.

THROTTLE AND TRANSMISSION LINKAGE LUBRICATION [See Figure 4-21]. The throttle and transmission linkages, found beneath the base of the travel control bar lever, MUST be lubricated to ensure smooth operation and prevent rusting. One [1] time for EACH 100 hours of machine operation, or every two [2] weeks lubricate the linkage,directional/speed control lever and cable using engine oil.

REAR CENTER SPRING ADJUSTMENT [See Figure 4-22].

NOTE: The rear spring adjustment depends on the rear ballast load. a. Place theroller on a flat even surface. b. Load the roller to the desired weight.

WARNING: Check the tire assembly to hub mounting nuts torque, again, after twenty five [25] hours of machine operation.

c. Go to the underside of the rear of the roller. Loosen the center spring adjustment jam nut and turn the adjustment screw until the center wheel is vertical, using the wheel rim as a reference point. d. Tighten the jam nut.

NOTE: If the wheel is tilted to the right, it is loaded too much. If it tilts to the left, it is not loaded enough.

4-32

07/01

Section 4 MAINTENANCE BAIL THROTTLE

WATER TANK

STRAINER

FIGURE 4-21. THROTTLE AND TRANSMISSION LINKAGE LUBRICATION POINTS.

FIGURE 4-23. IN LINE WATER SPRAY STRAINER - INSTALLATION.

WATER SPRAY NOZZLES.

JAM NUT

Water spray nozzles can become clogged and cause a reduced flow from the nozzle. Remove, clean and install the nine [9] water spray nozzles, found on both the FRONT [ four [4] total] and REAR [five [5] total] water spray bars, as required.

ADJUSTING SCREW

FIGURE 4-22. REAR CENTER SPRING ADJUSTMENT. WATER SPRAY SYSTEM. WATER SPRAY FILL STRAINER BASKET. There is one [1] strainer basket found at the inside of the water fill cap area on the water spray tank. AFTER removing the fill cap, remove and CLEAN the strainer basket BEFORE filling the water spray tank.

IN LINE WATER SPRAY SYSTEM STRAINER [See Figure 4-23].

Each water spray nozzle is connected to the water spray bar and is released by a “quick disconnect” mechanism. Push inward and rotate to release the spray nozzle from the lower mount and remove for cleaning or replacement. Remove all spray nozzles. Clean the spray nozzles with a small wire, or low pressure compressed air. Flush the water spray bar of any contamination by operating the water spray pump with the spray nozzles removed. Install the spray nozzles back onto the lower mount. Push inward and rotate the “quick disconnect” mechanism while pushing each spray nozzle into position and then letting the mechanism return to the locked position.

As required, remove the in line mesh water spray strainer assembly, from the inside the water tank by reaching through the fill port and unthreading in assembly from the tank mounting fitting . Use water flow, directed into the center of the strainer from the inside toward the outside, to remove trapped material and install the assembly back into the tank. 07/01

4-33

Section 4 MAINTENANCE MISCELLANEOUS MAINTENANCE INFORMATION. PREPARING THE MACHINE FOR STORAGE. Use the following information as a “general guide” ONLY to prepare the machine for storage. Manufacturers of component parts, used on the machine, can also be contacted for specific information about components manufactured by them.

CAUTION: Do NOT store the battery on a concrete surface. Store the battery on a WOOD surface ONLY. Be sure the battery electrolyte will NOT freeze.

FUEL TANK. FILL the fuel tank to a COMPLETELY full condition, using the CORRECT, CLEAN fuel, BEFORE the machine is placed in storage [see THIS section].

ENGINE. See the Cummins Diesel Engine Company "Operation And Maintenance Manual - B Series Diesel Engine" for complete APPROVED engine storage preparation procedures suggested by the engine manufacturer.

CAUTION: Do NOT leave the fuel tank ONLY part filled. Moisture can condense inside the fuel tank, while in storage, and can cause fuel system component damage during storage and/or when the machine is placed back into use.

COOLING SYSTEM. The ENTIRE cooling system MUST be protected from freezing. If the system is NOT protected, COMPLETELY drain the cooling system of water and install a ethylene glycol based antifreeze and water solution [see THIS section]. The antifreeze and water MUST be of the CORRECT mixture ratio, to protect the cooling system, to a temperature BELOW the lowest expected freezing temperature for the area where the machine is to be stored.

BATTERY. If the machine is to be stored for a period of MORE than 30 days, remove the battery from the machine. Wash the battery with baking soda and water solution, rinse with clear water and permit to air dry. COMPLETELY charge the battery BEFORE it is placed in storage. Charge the battery, again, one [1] time for every 30 days which the battery is stored. Keep the battery stored in a wood surface in a COOL and DRY storage area.

4-34

WATER SPRAY SYSTEM. BEFORE freezing temperatures are encountered, drain ALL water from the water spray system tank. Also, drain the water spray system supply lines and water spray bars of water and apply LOW pressure compressed air to these parts to remove any water still possibly remaining in them. Also, remove the water spray pump assembly and check to be sure that the pump has been COMPLETELY drained of water. Drain ALL water found to have possibly remained in the pump and then install the pump back into the tank. Put a plastic cover, or tape, on EACH water spray nozzle.

CAUTION: Drain ALL water from the water spray tank, water pump, supply hoses and water spray bars, BEFORE the temperature reaches 32˚F [0˚ C]. The system will be DAMAGED if the water is allowed to remain and freeze.

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Section 4 MAINTENANCE TIRES.

EXPOSED COMPONENT RUST PREVENTION.

Check each tire inflation pressure. Inflate if needed. After final machine parking, put covers over any tire which will be exposed to direct sun light, or weather elements, to help reduce tire damage.

Put a heavy grease, or equivalent, onto the exposed area of the hydraulic cylinder rod. Put a rust preventative oil [such as L.P.S. #s 2 or 3] on ALL control linkages, control cable ends, hinges or other moving parts.

CAUTION: If the machine is stored out of doors, use tire covers to help prevent tire damage from direct sun light and /or weather elements.

Put ALL covers and access plates in their correct position and secure in place with the retaining capscrews.

AIR CLEANER, EXHAUST AND OTHER OPENINGS. Put a cap, tape, or otherwise seal, ALL openings to prevent the entrance of moisture, or other forms of contamination, while the machine is in storage.

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4-35

Section 4 MAINTENANCE NOTES

4-36

07/01

Section 5 FRAME, HITCH AND FOPS/ROPS

TABLE OF CONTENTS

PAGE GENERAL INFORMATION ...................................................................................................................... 5-2 DESCRIPTION OF THE FRAMES ........................................................................................................... 5-2 CENTER POINT HITCH ............................................................................................................................ 5-2 GENERAL .............................................................................................................................................. 5-2 HITCH REMOVAL ................................................................................................................................. 5-4 HITCH INSTALLATION ......................................................................................................................... 5-4 FALLING OBJECT/ROLL OVER PROTECTION STRUCTURE (FOPS/ROPS) ..................................... 5-6 SEAT BELTS ............................................................................................................................................ 5-6 CHECKS AND SERVICE PROCEDURES ............................................................................................... 5-6 TROUBLESHOOTING .............................................................................................................................. 5-8

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5-1

Section 5 FRAME, HITCH AND FOPS/ROPS GENERAL INFORMATION [See Figure 5-1].

CENTER POINT HITCH [See Figure 5-2].

This section describes the frames, hitch and falling object/roll over protective structure used of the Model BW11RH Roller.

GENERAL.

Hitch removal and disassembly, inspection of components, assembly, installation and shimming information are given in this section.

The centerpoint hitch between the front and rear frames consists of a vertical coupling to provide 35 degrees of centerpoint steering and a horizontal coupling for 20 degrees of oscillation between the frames.

Information about inspection and maintenance of the falling object/roll over protection structure is, also, found in this section.

The horizontal coupling consists of one large pivot which turns in a self-lubricating bearing with a thrust washer on each side.

DESCRIPTION OF THE FRAMES [See Figure

The vertical coupling consists of two [2] pins and two [2] spherical bearings, but only one thrust washer is used with each pin. The washers are located on the top side of the upper bushing and on the bottom side of the lower bushing to carry thrust loads.

5-1]. The machine uses a front frame and a rear frame weldment. The front and rear frame weldments are connected by the hitch assembly. The hitch assembly permits movement of the two [2] frames. The hitch includes two [2] vertical pins, which give a total of 70 degrees of machine steering (35 degrees each side of center), full left to full right. Oscillation is 10 degrees each side of center.

REAR FRAME

FRONT FRAME

HITCH

FIGURE 5-1. LOCATIONS OF THE HITCH AND FRAMES.

5-2

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Section 5 FRAME, HITCH AND FOPS/ROPS FLANGE SCREW COVER

GASKET

FRONT FRAME

CAPSCREW WASHER SNAP RING PIN

BEARING HITCH

FLANGE SCREWS

SHIM

BEARING HOUSING

THRUST WASHER

FLANGE SCREWS

REAR FRAME

BEARING WASHER

CAPSCREW

BEARING FLANGE SCREWS

THRUST WASHER SHIM

HITCH PLATE

FIGURE 5-2. HITCH.

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5-3

Section 5 FRAME, HITCH AND FOPS/ROPS HITCH REMOVAL [See Figure 5-2]. a. Loosen and remove the negative [-] battery cable from the negative [-] post of the battery FIRST, and then loosen and remove the positive [+] battery cable from the positive [+] post of the battery.

WARNING: Battery explosion can occur if the battery terminals are shorted. ALWAYS disconnect the NEGATIVE battery cable from the battery FIRST. Do NOT smoke or cause a spark while removing the battery cables from the battery.

b. Block both ends of the front and rear frames.

WARNING: Blocking of both ends of each half is necessary because varying ballast distribution may cause the ends to tip either direction. c. Remove the driver compartment floor plate. d. Remove the steering cylinder mounting pin and free the cylinder from the hitch.

m. Support the bearing housing and remove the capscrew and washer securing the bearing housing to the lower vertical pin. Remove the bearing housing. n. Inspect the upper and lower vertical pins. If necessary, remove the screws securing the upper and lower vertical pins to the front frame. Remove the pins with a drift and hammer or a hydraulic jack. o. Inspect the upper vertical bearing in the hitch. If necessary, remove the snap ring. Using a tube with the same outer diameter as the vertical bearing and a hydraulic jack, drive the vertical bearings from the hitch.

WARNING: Eye protection MUST be worn during the snap ring removal.

p. Inspect the lower vertical bearing in the bearing housing. Using a tube with the same outer diameter as the vertical bearing and a hydraulic jack, drive the vertical bearings from the bearing housing. q. Inspect the horizontal bearing in the rear frame. If necessary, drive the horizontal bearing from the rear frame.

e. Remove the ten [10] screws securing the hitch plate and remove the hitch plate, shims and thrust washer.

HITCH INSTALLATION [See Figure 5-2].

f. Using an overhead crane or a PortaPower, separate the two halves far enough so that the hitch can be removed.

a. If removed, press upper vertical bearing into hitch until it bottoms. Insert snap ring with smooth surface facing out.

g. Remove the remaining thrust washer and shims from the hitch.

WARNING: Eye protection MUST be worn during the snap ring installation.

h. Support the hitch with blocks. i. Remove the four [4] screws securing the cover to the top of the hitch. Remove the cover and gasket.

b. If removed, press lower vertical bearing into bearing housing until centered.

j. Remove the capscrew securing the washer to the top vertical pin.

c. If removed, apply adhesive, pn 340419, to the vertical pins. Align mounting holes, press the pins into the front frame. Apply adhesive, pn 340419, to the mounting screws. Install and tighten the mounting screws to a torque of 105 ft. lbs. [143 N.m].

k. Remove the eight [8] screws securing the hitch to the bearing housing. l. Remove the hitch from the upper vertical pin.

5-4

d. Lubricate the upper and lower vertical pins.

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Section 5 FRAME, HITCH AND FOPS/ROPS e. Position the hitch on the rear of the front frame and over the top vertical pin. f. Position bearing housing over the bottom vertical pin and secure to the hitch with the eight [8] screws and thread lock, pn 318702. Tighten the screws to a torque of 105 ft. lbs. [143 N.m]. g. Secure washers to the upper and lower vertical pins with the capscrews. Tighten the capscrews to a torque of 280 ft. lbs. [382 N.m].

CAUTION: Allow the adhesive on the vertical pins to set up for 4 hours before applying torque to the capscrews. h. Drive horizontal bearing into rear frame until flush. i. Determine the number of shims required for the horizontal pivot as follows: 1. Observe the number stamped on the rear frame near the hitch bore. Subtract this number from the number stamped on the hitch. 2. Measure the thickness of both thrust washers and subtract the measurement. 3. Divide by 0.020 and round your answer off to nearest whole number. Example: 2.351 is 2, 2.734 is 3. Use this number of shims. j. Determine shim location as follows: 1. 2 SHIMS REQ'D: Locate one shim on each side of rear frame member. 2. 3 SHIMS REQ'D: Locate one shim on front side of rear frame member and two shims rear side of rear frame member.

k. Load one shim, thrust washer and second shim, if required, onto hitch. l. Lubricate the ID of the horizontal bearing. m. Using an overhead crane or a PortaPower, move the two halves of the machine together so the hitch passes through the horizontal bearing. n. Load third shim, if required, thrust washer, and fourth shim, if required, onto the hitch on the rear side of the rear frame. o. Install the hitch plate and secure with the ten [10] screws and thread lock, pn 318702. Tighten the screws to a torque of 105 ft. lbs. [143 N.m]. p. Reconnect the steering cylinder to the hitch. q. Install the driver compartment floor plate. r. Remove the blocking from the front and rear frames. s. CAREFULLY connect the POSITIVE [+] battery cable to the POSITIVE [+] terminal of the battery and tighten FIRST. Then CAREFULLY connect the NEGATIVE [-] battery cable to the NEGATIVE [-] terminal of the battery and tighten.

WARNING: Do NOT connect the NEGATIVE [-] battery cable to the NEGATIVE [-] terminal of the battery BEFORE connecting the POSITIVE [+] battery cable to the POSITIVE [+] terminal of the battery. Do NOT smoke or cause a spark while connecting the battery cable terminal to the battery. BATTERY MAY CONTAIN EXPLOSIVE GAS.

3. 4 SHIMS REQ'D: Locate two shims on each side of rear frame member.

2/98

5-5

Section 5 FRAME, HITCH AND FOPS/ROPS FALLING OBJECT/ROLL OVER PROTECTION STRUCTURE (FOPS/ROPS)

CHECKS AND SERVICE PROCEDURES [See Figure 5-3].

[See Figure 5-3]. Machines include the structure as a standard item for the machine. The steel components of the falling object/roll over protection structure are welded together, using materials and practices that produce a strong integrated structure. The falling object/roll over protection structure is fastened to the machine on the top of the front frame by six [6] grade 8 flange screws and six [6] grade 8 flange nuts.

WARNING: An improperly mounted, or damaged, protection structure may NOT provide operator protection in the event of a machine tip over. Follow the checks and service information which follows.

SEAT BELTS [See Figure 5-3]. Machines include a seat belt as a standard item for the machine to help restrain the operator, in the event of a machine roll over.

Use the following information to check the falling object/roll over protection structure components for breakage, or other damage, at least one time each eight [8] hours of machine operation or daily, and to do minor surface rust removal and painting on the structure. a. Inspect the six [6] grade 8 flange screws and nuts that fasten the falling object/roll over protection structure to the machine. They must remain tightened to the correct torque of 400 ft. lbs. [546 N.m]. Check each flange screw torque and tighten as needed using a large capacity torque wrench and torque multiplier assembly.

WARNING: If the falling object/roll over protection structure has been removed from the machine and is being installed again, inspect each flange screw for wear or damage. Replace ALL worn, or damaged, flange screws with NEW. Put thread lock, pn 318702, on the threaded area of each flange screw. Install and then tighten each flange screw to the above amount of torque. NEVER replace the flange screws with flange screws that carry a â&#x20AC;&#x153;grade ratingâ&#x20AC;? less than GRADE 8.

WARNING: IMMEDIATELY after becoming seated, FASTEN and TIGHTEN the seat belt, BEFORE starting the engine. During machine operation, if the machine tips, do NOT jump.

5-6

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Section 5 FRAME, HITCH AND FOPS/ROPS

FOPS/ROPS

SEAT BELT DECAL

FLANGE BOLT SEAT BELT

FLANGE NUT TORQUE INFO PLATE

FIGURE 5-3. FALLING OBJECT/ROLL OVER PROTECTION STRUCTURE AND SEAT BELTS.

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5-7

Section 5 FRAME, HITCH AND FOPS/ROPS b. CAREFULLY inspect ALL welds which fasten the structure components together for cracks, breakage in the weld and/or where the weld joins the metal of the steel component, severe rust or other weld related problems.

DANGER: Do NOT operate a machine AFTER a roll over situation has occurred. If a roll over situation has occurred, REPLACE the falling object/roll over protection structure only AFTER contact has been made with your nearest Distributor and/or Compaction America, Inc. Assistance in the repair, or replacement, of the system will be offered. NEVER weld on, or replace, a CRITICAL structural component BEFORE obtaining additional instructions, per the ABOVE information.

WARNING: One [1] time for each eight [8] hours of machine operation, or daily, carefully inspect ALL welds which fasten the critical structure components together for cracks, breakage in the weld and where the weld joins the metal of the steel components. Carefully inspect the welds and adjoining critical structure metal areas for rust or other related problems. If ANY damage is found during the above described inspections, contact the Compaction America, Inc. or your nearest Distributor IMMEDIATELY. Do NOT use the machine until contact and the directed repairs or structure replacement have been done. NEVER “heat” or weld any “add on” item onto ANY structure area. This practice can weaken the structural integrity of the complete structure. Do NOT add ANYTHING to the structure.

5-8

c. If rust on components is found, remove rust from ALL welds and structure components. Apply paint primer and top coat paint to the complete falling object/roll over protection structure as directed by the paint manufacturer. d. One [1] time for EACH eight [8] hours of machine operation, or daily, CAREFULLY inspect the restraint system [two [2] seat belt sets] used with the falling object/roll over protection system. The belt latches MUST catch and release correctly. The belt material MUST be clean and NOT torn, rotted or damaged. The belt anchors MUST remain tightened securely to the machine at a CORRECT torque of 40 ft. lbs. [55 N.m]. REPLACE the complete belts SETS, with new, if ANY damage is found [see MACHINE parts manual, which is supplied with the machine].

DANGER: NEVER operate a machine having a worn, damaged or malfunctioning operator restraint system. Replace the system, with new, IMMEDIATELY.

TROUBLESHOOTING. Table 5-1 is a trouble analysis check for the hitch and frame assemblies. This table list the most common troubles that may be encountered, the probable causes of the trouble, and the corrective action that should be taken to restore the unit to normal operating condition.

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Section 5 FRAME, HITCH AND FOPS/ROPS Table 5-1. TROUBLE ANALYSIS FOR THE FRAME AND HITCH [See Figures 5-1 and 5-2] TROUBLE

CAUSE

CORRECTIVE ACTION

NOISE IN MACHINE HITCH AREA DURING OSCILLATION AND/OR TURN

Worn, or damaged, parts in the hitch assembly.

Remove, inspect, replace worn, or damaged, parts as needed and assemble.

STEERING ACTION NOT SMOOTH

Binding of the vertical hitch shafts in the spherical bearings.

Remove, inspect, replace worn, or damaged, parts as needed and assemble.

Worn, or damaged, spherical bearings in hitch.

Remove, inspect, replace worn, or damaged, parts as needed and assemble.

2/98

5-9

Section 5 FRAME, HITCH AND FOPS/ROPS NOTES

5-10

2/98

Section 6 ENGINE

TABLE OF CONTENTS

PAGE GENERAL INFORMATION ...................................................................................................................... 6-2 DESCRIPTION ......................................................................................................................................... 6-2 REMOVAL OF THE ENGINE ASSEMBLY.............................................................................................. 6-2 INSTALLATION OF THE ENGINE ASSEMBLY ..................................................................................... 6-6

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6-1

Section 6 ENGINE GENERAL INFORMATION. This section contains information about the Cummins diesel engine used in the Model BW11RH Roller. This section also contains REMOVAL and INSTALLATION information about the engine.

DESCRIPTION. The Model BW11RH Roller is powered by the Cummins Model 4B3.9 liter, water cooled diesel engine [see figures 6-1]. For engine OPERATION and general manufacturer MAINTENANCE procedures, see the Cummins â&#x20AC;&#x153;Operation and Maintenance Manual - B Series Diesel Enginesâ&#x20AC;?, which is supplied with each machine. For major engine repair requirements contact the nearest Cummins, Engine Dealer for assistance about major repair procedures, in-shop dealer repairs and/or engine parts.

REMOVAL OF THE ENGINE ASSEMBLY. To remove the engine, do the following:

CAUTION: Put caps or plugs in all removed hoses and on all fittings immediately after the hoses are disconnected to help keep the system free of dirt.

a. Loosen and remove the negative [-] battery cable from the negative [-] post of the battery FIRST, and then loosen and remove the positive [+] battery cable from the positive [+] post of the battery.

b. Open the L.H. and R.H. hood doors. c. Remove the hardware securing the shock absorbers to the doors and remove the shock absorbers. d. Remove the hardware securing the L.H. and R.H. hood doors to the center hood and remove the doors. e. Disconnect exhaust clamp connecting the muffler to the engine. Lift muffler and attached exhaust tube (stack) out the top of the center hood. f. Disconnect the air cleaner elbow clamp connecting the air cleaner elbow to the engine. g. Remove screws securing the air cleaner to the center hood and remove the air cleaner with piping. h. Remove screws securing center hood and lift hood from machine.

FIGURE 6-1. CUMMINS MODEL 4B3.9 DIESEL ENGINE.

6-2

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Section 6 ENGINE i. If so equipped, disconnect wiring for head lights and remove wiring that passes through the support. j. Drain the complete cooling system of coolant [see Section 4 - MAINTENANCE].

o. Trace upper oil cooler hose back to the steering control and disconnect the hose from the control. Put a cap or a plug into hose and onto steering control fitting. p. Free the oil cooler hoses from any clamps and secure them to the radiator cowl.

WARNING: Do NOT drain the cooling system of coolant while the system is HOT. Drain when COOL ONLY. Hot coolant can cause serious injury.

k. Completely drain the hydraulic reservoir of oil.

WARNING: Do NOT drain the hydraulic oil while the oil is HOT. Drain the hydraulic oil when it is warm or cool ONLY. Hot oil can cause serious injury.

l. Put an oil drain pan under the engine lubrication oil drain plug. Wipe the area around the drain plug, using a clean cloth. Loosen and remove the drain plug and drain the engine of lubrication oil. Replace and tighten the drain plug after the engine is completely drained of oil. Remove the oil drain hose from its connection onto the frame mounted fitting. Put a plug in the engine lubrication oil drain hose. [See Figure 6-2]

WARNING: Do NOT drain the engine lubrication oil while the oil is HOT. Drain the oil ONLY when WARM or COOL. Hot oil can cause serious injury. m. Loosen the radiator hose clamps at the engine connection and disconnect the upper and lower radiator hoses from the engine.

q. Remove the screws and washers securing the radiator shroud to the radiator. Free the shroud from the radiator and rest it on the fan.

CAUTION: The blower fan is fragile. Be careful not to damage fan when moving radiator and shroud. r. Fasten a sling and a hoist, having a capacity more than 500 lbs. [227 kg], to the radiator cowl so that it will be balanced when lifted. s. Loosen, but DO NOT REMOVE, nuts securing radiator cowl to frame. Gently lift radiator cowl up and away from the front frame and remove the shims. Remove the radiator shroud from the fan. t. Loosen the clamps and disconnect the fuel supply line from the fuel filter located on the rear of the engine and the return line from the left side of the engine. Put a cap or a plug into each line and onto each engine fitting. Free the lines from any clamps on the engine. u. Disconnect the transmission direction control cable from the transmission pump control lever and free the cable from the bracket [See Figure 6-3]. v. Disconnect the governor [throttle] control cable from the engine governor control lever [See Figure 6-3].

n. Trace lower oil cooler hose back to the hydraulic tank and disconnect the hose from the tank. Put a cap or a plug into hose and onto the hydraulic tank fitting.

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6-3

Section 6 ENGINE

FRAME MOUNTED FITTING

ADAPTER FITTING FRONT MOUNT

HOSE ASSEMBLY

DRAIN PLUG REAR MOUNT

FIGURE 6-2. ENGINE OIL DRAIN AND ENGINE MOUNTS.

6-4

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Section 6 ENGINE GOVERNOR CONTROL CABLE

TO THROTTLE

y. SECURELY fasten a chain and a lifting device, having a capacity larger than 1,500 lbs. [685kg], to the engine lifting eyes.

WARNING: Use a lifting device and chain capable of lifting at LEAST a weight of 1,500 lbs. [681kg]. Fasten SECURELY. z. Loosen and remove the four [4] retaining nuts, screws and large washers from the front and rear isolators, two [2] on each side [See Figure 6-2]. aa. Check, AGAIN, to be sure that ALL the hoses, lines and electrical wire and cable connections have been disconnected and removed from the engine. Also check for removal of these items from other components being removed with the engine, as an assembly.

CABLE BRACKET

TRANSMISSION PUMP CONTROL CABLE

CAUTION: Do NOT remove the engine assembly before disconnecting ALL items connected to the engine, or any component, being removed with the engine. ab. CAREFULLY and SLOWLY lift the engine assembly “UP” and “OUT” of the frame, until the engine assembly is away from the frame.

WARNING: KEEP CLEAR of the engine assembly while it is being lifted and removed from the frame.

FIGURE 6-3. GOVERNOR AND TRANSMISSION. w. Put an identification tag on each electrical wire and each electrical wire connection terminal on the engine or items mounted on the engine. Remove all electrical wires or wire harnesses which are connected to the engine or items mounted on the engine. x. Put an identification tag on each hose and each fitting of the transmission pump and the steering pump. Disconnect all hoses from both the transmission pump and the steering pump. Put caps, or plugs, in ALL hoses and on ALL fittings IMMEDIATELY after the hoses are disconnected.

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CAUTION: Use CARE to NOT damage the transmission pump which is mounted to the engine as the engine is removed from the frame. ac. CAREFULLY lower the engine onto an engine stand or other engine support device.

WARNING: KEEP CLEAR of the engine assembly while being lowered after removal from the frame. Do NOT allow anyone under the engine while it is being lowered. Make sure the engine and support will NOT tip.

6-5

Section 6 ENGINE INSTALLATION OF THE ENGINE ASSEMBLY. a. If necessary, install the front and rear engine mounts to the engine. Tighten the front screws to a torque of 78 ft. lbs. [107 N.m]. Tighten the rear screws to a torque of 59 ft. lbs. [81 N.m] b. SECURELY fasten a chain and a lifting device, having a capacity larger than 1,500 lbs. [681 kg], to the engine lifting eyes.

WARNING: Use a chain and lifting device capable of lifting at LEAST a weight of 1,500 lbs. [681 kg]. Fasten SECURELY.

c. CAREFULLY and SLOWLY lift the engine assembly and move into position ABOVE the frame. d. SLOWLY begin to lower the engine assembly DOWN and toward the frame. Align ALL capscrew holes in both the front and rear engine mount isolators and frame as the engine assembly reaches the frame.

WARNING: KEEP CLEAR of the engine assembly while it is being installed. Lower the engine assembly SLOWLY into the frame. Check for ANY interference between components at ALL times during engine installation.

CAUTION: Do NOT permit the transmission pump assembly to contact the hydraulic oil filter as the engine and transmission pump assembly is installed. e. Position the rubber mounts on the front and rear engine mounts and install the four [4] screws, large washers and retaining nuts [See Figure 6-2]. Tighten the screws to a torque of 120 ft. lbs. [164 N.m]. f. Route and connect the engine oil drain hose to its connection of the frame. Check that the oil drain plug is properly installed.

6-6

g. Fill the engine with NEW engine lubrication oil at this time [see the Cummins "Operation and Maintenance Manual - B Series Diesel Engines", which is supplied with each machine, for the CORRECT amount and type]. h. Remove ALL caps and plugs from ALL the hoses and fittings which fasten to, or are on, the transmission pump and the steering pump. Install EACH hose onto the CORRECT fitting of the transmission pump and the steering pump as indicated by the identification tags installed before removal. Securely tighten each hose onto each fitting. i. CAREFULLY connect ALL electrical wires, EXCEPT the positive [+] and negative [-] battery cables, to the correct engine wire connection terminal and items mounted onto the engine, as indicated by the identification tags installed before removal, and tighten securely.

WARNING: Do NOT connect EITHER battery cable to the battery, at THIS time.

j. Remove the caps, or plugs, from each fuel supply line and return line and from each engine fitting. Connect the fuel supply hose to the fuel filter located on the rear of the engine and the return line to the left side of the engine and tighten securely. k. Connect the governor [throttle] control cable to the engine governor [See Figure 6-3]. Check and adjust the governor [throttle] control cable, if needed [see TRANSMISSION Section for the CORRECT procedure]. l. Connect the transmission direction control cable to the transmission pump control lever [See Figure 6-3]. Adjust the direction control cable linkage, if needed [see TRANSMISSION Section for the CORRECT procedure]. m. Put the fan shroud in position around the fan.

CAUTION: The blower fan is fragile. Be careful not to damage fan when mounting radiator and shroud.

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Section 6 ENGINE n. Fasten a sling and a hoist, having a capacity more than 500 lbs. [227 kg], to the radiator cowl so that it will be balanced when lifting. CAREFULLY and SLOWLY lift the assembly and move into position above the frame.

t. Add NEW, CLEAN and FILTERED hydraulic oil to the hydraulic oil reservoir until the oil is in the center of the sight gauge [see Section 4 - MAINTENANCE- for the CORRECT amount and type of hydraulic oil].

o. Position the radiator cowl, on frame and over retaining studs. After cowl is properly positioned, install shims that were originally removed. Tighten nuts on retaining studs. Remove the sling and hoist.

CAUTION: Do NOT start the engine UNTIL ALL of the transmission system start up procedures have been completed [See the TRANSMISSION section for the CORRECT procedures].

p. Position the fan shroud against the radiator. Install the retaining capscrews. Adjust the fan shroud for the correct EQUAL fan blade to fan shroud clearance. Tighten the capscrews, which hold the fan shroud onto the radiator assembly, securely.

CAUTION: The blower fan is fragile. Be careful not to damage blower fan when moving radiator and shroud. Keep the fan shroud in the correct position while tightening the retaining capscrews. Clearance must be kept between the blades of the fan and the fan shroud at all points around the shroud.

u. Connect BOTH the upper and lower radiator hoses to their engine connection points. Tighten the retaining clamps securely. Tighten ALL engine block coolant drain plugs securely. Fill the cooling system with coolant [see Section 4 - MAINTENANCE].

CAUTION: Fill the cooling system with the CORRECT antifreeze/water mixture to protect the system from freezing [see Section 4 - MAINTENANCE].

v. Replace center hood and secure with retaining capscrews. w. Position air cleaner under center hood and secure with retaining screws.

q. If so equipped, install wiring that passes through the support. Connect wiring for the lights. r. Route the upper oil cooler hose back to the steering control. Remove all caps and plugs from the hose and the steering control fitting. Install the hose onto the correct fitting of the steering control. s. Route the lower oil cooler hose back to the hydraulic tank. Remove all caps and plugs from the hose and the hydraulic tank fitting. Install the hose onto the correct fitting of the hydraulic tank.

x. Connect the engine air inlet hose onto the engine air intake assembly. Install and tighten the hose retaining band clamps to a torque of 50 in. lbs. [5.7 N.m].

CAUTION: Tighten the retaining band clamp to the CORRECT torque. Loose clamps can permit contaminated air to enter, and damage, the engine. y. Install the exhaust pipe to the engine exhaust manifold. Install and tighten the retaining clamp securely to the exhaust pipe and the exhaust manifold. z. Install the L.H. and R.H. hood doors the center hood.

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6-7

Section 6 ENGINE aa. Position the shock absorbers between the center hood and hood doors. Secure with mounting hardware.

ac. Inspect all hose, lines wire and cable and linkages for correct connection. Check for any leak of fuel, oils or coolant at this time.

ab. CAREFULLY connect the POSITIVE [+] battery cable to the POSITIVE [+] terminal of the battery and tighten FIRST. Then CAREFULLY connect the NEGATIVE [-] battery cable to the NEGATIVE [-] terminal of the battery and tighten.

ad. Prime the hydraulic system with oil, using the pre-start procedures given in Section 8 - TRANSMISSION Section, at THIS time.

CAUTION: Tighten the retaining band clamps to the CORRECT torque. Loose clamps can permit contaminated air to enter, and damage, the engine.

6-8

CAUTION: Do NOT start the engine UNTIL the pre-start procedures have been completed. Hydraulic system component damage can occur.

ae. Start the engine, using the CORRECT engine starting procedures given in Section 3 - OPERATION. Check ALL machine systems for correct operation and function.

CAUTION: STOP the engine IMMEDIATELY if ANY system of the machine does NOT have CORRECT operation. Do NOT start the engine again UNTIL the system problem has been corrected.

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Section 7 ELECTRICAL

TABLE OF CONTENTS PAGE GENERAL INFORMATION ...................................................................................................................... 7-2 SYSTEM DESCRIPTION ......................................................................................................................... 7-2 DESCRIPTION - ELECTRICAL SYSTEM MAJOR COMPONENTS ...................................................... 7-2 BATTERY ............................................................................................................................................. 7-2 STARTER MOTOR .............................................................................................................................. 7-2 ALTERNATOR ..................................................................................................................................... 7-2 SWITCHES ........................................................................................................................................... 7-2 SENDING UNITS .................................................................................................................................. 7-7 SOLENOID CONTROLS ...................................................................................................................... 7-7 CIRCUIT BREAKERS .......................................................................................................................... 7-7 INSTRUMENTS AND GAUGES .......................................................................................................... 7-8 INSTRUMENTS ............................................................................................................................... 7-8 GAUGES ......................................................................................................................................... 7-8 INDICATOR AND GAUGE LIGHTS .................................................................................................... 7-8 CABLES AND WIRES ......................................................................................................................... 7-9 CABLES .......................................................................................................................................... 7-9 WIRES ............................................................................................................................................. 7-9 CIRCUITS ................................................................................................................................................. 7-9 START - STOP CIRCUIT ..................................................................................................................... 7-9 ON [RUN] CIRCUIT .............................................................................................................................. 7-11 CHARGING CIRCUIT ........................................................................................................................... 7-12 SECONDARY/PARKING BRAKE CIRCUIT ........................................................................................ 7-12 TRANSMISSION SPEED RANGE CIRCUIT ....................................................................................... 7-12 ACCESSORY CIRCUIT ....................................................................................................................... 7-13 OPTIONAL OPERATION LIGHTING SYSTEM ...................................................................................... 7-13 CHECKS AND ADJUSTMENTS .......................................................................................................... 7-14 OPTIONAL TURN SIGNALS AND FOUR WAY FLASHERS ................................................................. 7-14 TROUBLE ANALYSIS INFORMATION AND PROCEDURES ............................................................... 7-15 TROUBLE ANALYSIS FOR THE ELECTRICAL SYSTEM .................................................................... 7-17

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7-1

Section 7 ELECTRICAL GENERAL INFORMATION.

STARTER MOTOR.

This section describes the OPERATION of the electrical system and contains DESCRIPTIONS of the items included in the system used on the Model BW11RH Roller.

The starter motor is used to convert electrical energy into mechanical energy to crank and start the engine. One [1] 12 volt, negative ground starter motor is used in the start circuit.

“TROUBLE ANALYSIS” for the electrical system is found at the rear of this section.

SYSTEM DESCRIPTION [See Figures 7-1, 7-2 and 7-3]. The electrical system contains the following major components: BATTERY. STARTER MOTOR. ALTERNATOR. SWITCHES. SENDING UNITS. SOLENOID CONTROLS [of fuel system and hydraulic valves]. RELAYS and CIRCUIT BREAKERS INSTRUMENTS, GAUGES and INDICATOR LIGHTS. CABLES and WIRES.

ALTERNATOR. The 62 amp alternator is used to convert mechanical energy into electrical energy. It supplies electrical current to the electrical circuits and keeps the battery “charged” when the engine is “running”.

WARNING: NEVER smoke, or cause a spark, near ANY battery. ALWAYS loosen and remove the NEGATIVE [-] battery cable from the NEGATIVE [-] battery terminal BEFORE loosening and removing the POSITIVE [+] battery cable from the POSITIVE [+] battery terminal. NEVER cause a shorted circuit condition in ANY CIRCUIT. USE EXTRA CAUTION when checking ANY circuit using ANY electrical testing instrument. BATTERY MAY CONTAIN EXPLOSIVE GAS.

DESCRIPTION - ELECTRICAL SYSTEM MAJOR COMPONENTS [See Figures 7-1, 7-2, and 7-3]. The following information describes the MAJOR electrical components used in the electrical system of the Model BW11RH Roller.

BATTERY. The battery supplies direct current to crank the engine and operate electrical circuits until the alternator is able to supply current. One [1] 12 volt, 900 CCA hour battery, is used in the electrical system for this purpose.

7-2

SWITCHES. a. Ignition Key Switch. The ignition key switch is the main control switch for ALL electrical circuits [except the horn and lighting circuits]. The switch is a three [3] position switch which permits the engine to be started, put in a “running” condition and stopped. One [1] ignition key switch is used in the electrical system. b. Neutral Start Switch. The neutral start switch is used to stop the engine from being started when the travel control [F-N-R] bar lever and the transmission system is NOT in “NEUTRAL”. One [1] neutral start switch is used in the engine start circuit.

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Section 7 ELECTRICAL

7-3 . gs p E US

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RE E H ILE F T U DO L FO 4 &7

! !!!!

7-3

Section 7 ELECTRICAL

7-3 . gs p E US

7-4

RE E H ILE F UT O LD O F -4 7 &

! !!!!

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Section 7 ELECTRICAL

YYY

BBB E

R-1

DD TAPE BACK IF NOT USED (USED FOR TURN SIGNAL OPT.) AUX

BAT

AUX

BAT

AUX

BAT

XXX

CC PP

LLL

P EE

BATT

ACC 1 4

B G R D

RRR

3 6

IGN

XXX

LLL

WIRE

COLOR

B E G L N P Q R U Z CC DD EE FF JJ PP XX ZZ BBB LLL RRR XXX YYY

BLACK BROWN BLACK ORANGE BLUE YELLOW YELLOW RED WHITE GREEN BLUE RED RED BROWN YELLOW ORANGE YELLOW BROWN LT GREEN PURPLE ORANGE YELLOW ORANGE

GAGE 10 14 16 14 16 12 10 14 12 10 14 14 14 14 14 14 14 14 14 14 14 12 16

Q PP

10 AMP CIRCUIT BREAKER

GROUND

BATT YYY

G TO 10 AMP CIRCUIT BREAKER USED FOR TURN SIGNAL OPT.

TO MAIN UNIT WIRING HARNESS

B L EE N LLL G Z R

10 AMP CIRCUIT BREAKER

AUX N P

BATT L

YYY

AIR OIL FILTER FILTER INDICATOR INDICATOR

AUX BBB E

BBB

30 AMP CIRCUIT BREAKER BATT XXX

GROUND

AUX FF

DD RRR ZZ

3 SPEED SWITCH

RRR R P P

LIGHT SWITCH

WATERSPRAY SWITCH

U CC PP RRR DD XX ZZ

GRD

XXX B

YYY

BATT

IGN

ACC

IGNITION SWITCH

EE 6

HORN

BBB

LLL

BRAKE SWITCH

TO MAIN UNIT WIRING HARNESS

1 BRAKE INDICATOR

FIGURE 7-2. CONTROL PANEL WIRING DIAGRAM AND SCHEMATIC.

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7-5

Section 7 ELECTRICAL

FIGURE 7-3. GAUGE PANEL WIRING DIAGRAM AND SCHEMATIC.

7-6

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Section 7 ELECTRICAL SENDING UNITS. a. Engine Lubrication Oil Pressure Sending Unit. The engine lubrication oil pressure sending unit is used to electrically indicate the pressure of the oil flowing within the engine lubrication oil system. One [1] sending unit, with a flexible internal diaphragm, sends a varied amount of electrical current to the engine lubrication oil pressure gauge. The gauge indicates the pressure of the engine lubrication oil flowing through the engine. b. Engine Coolant Temperature Sending Unit. The engine coolant temperature sending unit is used to electrically indicate the temperature of the coolant flowing within the engine cooling system. One [1] sending unit, having a “bimetal” temperature sensor, sends a varied amount of electrical current to the engine coolant temperature gauge. The gauge indicates the engine coolant temperature. c. Fuel Level Sending Unit. The fuel level sending unit is used to electrically indicate the level of fuel contained within the fuel tank. One [1] sending unit, having a float assembly, mechanically moves a variable resistance type sending mechanism. The sending unit supplies a varied amount of electrical current to the fuel gauge, which indicates the amount of fuel contained in the tank.

b. Secondary/Parking Brake System Release Solenoid. The secondary/parking brake system release [brake] solenoid is electrically energized when the ignition key switch is “on” and the secondary/parking brake system switch is “OFF” [BRAKES RELEASED]. The solenoid is used to move the secondary/parking brake system release spool from the brakes “applied” position to the brakes “released” position. This action permits the brakes, found in each of the drive motors, to be released by hydraulic pressure. c. Transmission System Speed Range Solenoids. The transmission system speed range solenoids are electrically energized by the transmission system range switch. When the transmission system range switch is in the "MEDIUM" position with the engine "running", the LH transmission speed range solenoid is energized, moving the flow control spool to direct hydraulic oil to the LH drive motor, where the displacement is changed, causing "medium" speed range. When the transmission system range switch is in the "HIGH" position with the engine "running", both the LH and RH transmission speed range solenoids are energized, moving both flow control spools to direct hydraulic oil to both drive motors, where the displacement is changed in both drive motors, causing "high" speed range.

CIRCUIT BREAKERS. a. Ten [10] Amp Circuit Breakers.

SOLENOID CONTROLS. a. Engine Fuel Shut-Off Solenoid. The engine fuel shut-off solenoid is used to control the flow of fuel to the engine. One [1], normally open solenoid, when electrically energized, in the “start” and “run” ignition key switch positions, will open the fuel shut-off valve and permit fuel flow within the fuel system.

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Three [3] ten [10] amp circuit breakers are used in the electrical system. The first circuit breaker is used in the circuit which supplies current to the brake switch and the water spray system. The second circuit breaker supplies current to all electrical gauges, except the hourmeter, and to the transmission speed range control switch. The third circuit breaker is used in the circuit which supplies current to the optional turn signal and 4 way flasher system, if so equipped.

7-7

Section 7 ELECTRICAL b. Thirty [30] Amp Circuit Breaker. One [1] thirty [30] amp circuit breaker is used in the electrical system. The circuit breaker is used in the circuit, which supplies current to the horn button switch, standard gauge and instrument lights [except hourmeter] and optional front and rear headlights and the third ten [10] amp circuit breaker. The 30amp circuit breaker is supplied by wire XXX from the BAT terminal on the ignition switch.

the engine. The gauge will operate when the ignition key switch is “on” and the engine is “running”. The gauge has a face scale ranging from a “low” to a “high” symbol. c. Engine Coolant Temperature. The engine coolant temperature gauge indicates the temperature of the coolant circulating through the engine cooling system. The gauge will operate when the ignition key switch is “on”. The gauge has a scale ranging from “white” [100o F - 38o C] to “green” [140o F- 60o C] to “red” [230o F - 110o C].

INSTRUMENTS AND GAUGES. d. Hydraulic System Oil Temperature.

INSTRUMENTS. a. Engine Hourmeter. The engine hourmeter indicates the amount of time the engine has operated and is given in time divisions of tenths, units, tens, hundreds and thousands of hours. The engine hourmeter is “on” when the engine is “running” and the engine lubrication oil pressure closed switch has been by closed, permitting electrical current to flow through the circuit. b. Voltmeter. The voltmeter indicates the voltage in the electrical system and will give an indication of battery or alternator voltage, which ever currently is the highest. The voltmeter has a scale ranging from plus [+] 10 volts to plus [+] 16 volts of direct current [D.C.].

GAUGES. a. Fuel Gauge. The fuel gauge indicates the level of fuel contained in the fuel tank. The gauge will operate when the ignition key switch is "on". The gauge has a face scale ranging from “empty” to “full” symbol. b. Engine Lubrication Oil Pressure. The engine lubrication oil pressure gauge indicates the pressure of the lubrication oil circulating through

7-8

The hydraulic system oil temperature gauge indicates the temperature of the hydraulic oil flowing in the system. The gauge will operate when the ignition key switch is “on”. The gauge has a colored scale ranging from “green” [100o F - 38o C] to “yellow” [180o F- 82o C] then to “red” [220o F - 104o C].

INDICATOR AND GAUGE LIGHTS. a. Hydraulic System Suction Oil Filter Element Condition Indicator Light. The suction oil filter element condition indicator light is lighted when the oil filter element has reached the maximum holding capacity and MUST be changed. The red lens covered light will also be lighted when the ignition key switch is in the “start” position and show that the bulb and circuit is working. The bulb will go out when the switch returns to the “run” position. The red lens covered light can also be lighted with the hydraulic oil at a “cold” temperature at machine “start up”. b. Engine Inlet Air Restriction Indicator Light. The engine inlet air restriction indicator light is lighted if the engine inlet air route is restricted. The red lens covered light will be lighted when the ignition key switch is in the “start” position and show that the bulb and circuit is working. The bulb will go out when the switch returns to the “run” position. The red lens covered light will be lighted with the engine "running " and the inlet air route restricted.

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Section 7 ELECTRICAL c. Secondary/Parking Brake System Condition Indicator Light. With the ignition key switch “on”, the secondary/ parking brake system condition indicator red lens covered light is lighted when the secondary/parking brake system is "on" [applied].

CIRCUITS. The electrical system consists of the following major circuits: START/STOP. ON - [RUN].

d. Gauge Lights. CHARGING. The voltmeter, fuel gauge, engine lubrication oil pressure gauge, engine coolant temperature and hydraulic system oil temperature gauge all have individual illumination lights. The lights are lighted when the light switch is placed in the "on" position. The hourmeter is not lighted.

SECONDARY/PARKING BRAKE. TRANSMISSION SPEED RANGE [High/Medium/ Low]. ACCESSORY.

CABLES AND WIRES. CABLES. a. Positive [+] and Negative [-] Battery Cables. The positive [+] and negative [-] battery cables connect the positive [+] and negative [-] terminals of the battery to the engine starter motor and the system ground at the engine. The cables carry high amperage electrical current for the engine starter motor and current from the alternator to the battery.

START - STOP CIRCUIT [See Figures 7-1 and 7-4]. The START - STOP circuit contains two [2] separate circuits within it, the POWER circuit and the CONTROL circuit. The battery, cables and engine starter motor make up the POWER circuit. The CONTROL circuit includes the ignition switch, starter motor solenoid, fuel shut-off solenoid and the wires which carry the electrical current in the circuit.

WIRES.

The ignition key switch has three [3] positions:

a. Circuit Wires.

“OFF” [STOP]. “ON” [RUN]. “START”.

The wires used in the electrical system connect the components and form the circuits which the electrical current flows through. The wire assemblies contain different size [gauge] wires and connection terminals. The wire assemblies are covered with a protective plastic tape, which is wound around the wires of the assembly, to form the wire harness.

When the ignition switch key is turned to the “START” position, electrical current flows from the ignition switch into wire Q. Electrical current continues through wire Q to the secondary/parking brake system control switch. With the secondary/parking brake system control switch "on", current flows through the switch and into wire Z. Current in wire Z flows to the neutral start switch, found on the displacement control of the transmission pump assembly.

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7-9

Section 7 ELECTRICAL B.S. NEUTRAL START SWITCH

BATTERY

STARTER BRAKE SWITCH

Q HORN BUTTON

HORN

PP LIGHT SWITCH VOLT ENGINE WATER XSMN OIL METER OIL TEMP TEMP PRESSURE

IGNITION SWITCH L

GAUGE LIGHTS

FUEL LEVEL

K XXX

FUEL SHUTOFF SOLENOID

30 AMP CIRCUIT BREAKER

FIGURE 7-4. ELECTRICAL SYSTEM START/STOP CIRCUIT.

With the transmission in "neutral", current flows through the neutral start switch and into wire S.

NOTE: The secondary/parking brake system control switch MUST be in the "on" [applied] position and the directional speed control hand lever MUST be in the "neutral" position for the engine to be started.

Current in wire S flows to the S terminal of the starter solenoid, and energizes the starter solenoid and allows the starter to crank and start the engine.

7-10

When the engine has been started, and the ignition key is released, the ignition switch will return to the “on” [RUN] position by spring pressure.

NOTE: If the battery is “charged”, current is flowing to the “battery” terminal of the ignition switch, through wire B, at ALL times. The HORN and LIGHTING circuits have current supplied to them at ALL times from the “battery” terminal, of the ignition switch, through wire XXX to the thirty [30] amp circuit breaker and wires FF and JJ.

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Section 7 ELECTRICAL The normally open fuel shutoff valve is energized in the "start" and "run" ignition switch positions through wires L and K. In these positions the fuel shutoff valve opens, allowing fuel flow within the fuel system. When the ignition switch key is turned to “OFF”, electrical current no longer will flow from the “ignition” switch terminal, through wires L and K, to the solenoid of the engine fuel shutoff valve. The lack of electrical current permits the fuel shutoff valve spool to “close”, stopping the fuel flow through the engine fuel system.

ON [RUN] CIRCUIT [See Figures 7-1]. When the engine has been started and is “running”, electrical current flows from the “IGNITION” terminal on the ignition switch through wire L to the ignition terminal on the engine oil pressure switch. Electrical current is, also, supplied to wire K of fuel shutoff valve. Electrical current is, also, applied to one of the 10 AMP circuit breakers through wire L. Current is applied from the circuit breaker to the air filter indicator light and the hydraulic oil filter indicator on the control panel. When the Ignition switch is turned to the “START” position, a ground is applied from the ignition switch ground [GRD] terminal to two diodes, then through wire XX to the oil filter indicator light and through wire ZZ to the air filter indicator light causing the lights to come “ON”. When the switch is released, the lights will go out. This is an indication that the bulbs in the lights are working. If the engine inlet air route is in a restricted condition, a ground is applied at the air restriction indicator on the engine through wire ZZ from the engine to the air filter indicator light. The indicator light will be lighted indicating that the engine air filter element MUST be changed. When the hydraulic suction oil filter element has reached the maximum holding capacity, a ground is applied by the hydraulic oil filter indicator switch through wire XX to the hydraulic oil filter indicator light. The indictor light will be lighted, indicating that the hydraulic suction filter element MUST be changed.

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When the engine is "running", current flows through the engine oil pressure closed switch and into wires M and H. Current in wire M then flows through a diode to the #1 terminal of the alternator. Current in wire H flows to the “input” terminal of the hourmeter. The hourmeter operates whenever the engine is "running". With the ignition switch in the “RUN” position, current will flow through the ACCESSORY terminal of the ignition switch, through wire YYY to the 10 AMP circuit breaker. Current flows from the 10 amp circuit breaker through wire N to terminal N of the hydraulic system oil temperature gauge, water temperature gauge, engine lubrication oil pressure gauge, voltmeter and fuel level gauge. Current then flows from the hydraulic oil temperature gauge through wire J to the transmission temperature sending unit, which monitors the hydraulic oil in the transmission and steering system. From the water temperature gauge, current flows through wire C to the water temperature sending unit on the engine. From the engine oil pressure gauge, current flows through wire D to the oil pressure switch on the engine. From the fuel level gauge, current flows through wire WWW to the fuel level sensing unit at the fuel tank. Current flows from the same 10 AMP circuit breaker on wire P to the three speed switch [see transmission speed range circuit for description]. The three speed switch controls the two [2] two position solenoids through wires R and RRR. One solenoid controls the RH side two speed drive motor and the second solenoid controls the LH side two speed drive motor. Current flows from the second 10 AMP circuit breaker on wire E to the water spray switch, on the control panel. When the water spray control switch is placed in the “ON” position, current will flow through wire U to the water spray pump, to pump water to the spray bars. Current flows from the second 10 AMP circuit breaker and into wire BBB to the secondary/parking brake system control switch.

7-11

Section 7 ELECTRICAL With the secondary/parking brake system control switch in the "ON" [brakes APPLIED] position current flows into the supply wire to the brake indicator light, and it is lighted. Current, also, flows into wire Z. Current in wire Z flows to the transmission neutral start switch. Current will not flow from the switch, into wire LLL, UNTIL the switch is placed in the “OFF” [brakes RELEASED] position. Current will then flow from the switch through wire LLL to the brake release solenoid and energize the solenoid. No current is supplied to the brake indicator light, at this time. Current flows from a third 10 AMP circuit breaker into wire DD to the optional turn signals/warning flashers switch [if so equipped] on the steering column.

CHARGING CIRCUIT [See Figures 7-1]. After the engine has started and is “running”, the alternator output voltage increases ABOVE the battery voltage. The alternator current then flows through wire A to the large stud terminal on the starter solenoid. From the large stud connection terminal, on the starter solenoid, the alternator current flows through the POSITIVE [+] battery cable to the POSITIVE [+] terminal of the battery. The voltmeter, found on the gauge panel of the machine, will indicate EITHER battery OR alternator voltage in the charging system, which ever is the highest at the time.

SECONDARY/PARKING BRAKE CIRCUIT

control switch in the “ON” [UP] position, NO electrical current is sent from the switch to the brake system release solenoid. With the secondary/parking brake system control switch in the "ON" [brakes APPLIED] position current flows into the supply wire to the brake indicator light, and it is lighted. Current, also, flows into wire Z. Current in wire Z flows to the transmission neutral start switch. When the brake system is in the “RELEASED” [OFF] condition, with the secondary/parking brake system control switch in the “OFF” [DOWN] position, electrical current is sent from the switch through wire LLL to the brake release solenoid. No current is supplied to the brake indicator light, at this time. The electrical current energizes the solenoid, which moves the brake release valve spool, in the solenoid valve body to the “open” position. When the brake release valve spool is in the “open” position, hydraulic oil can then flow to the spring applied disc brake assemblies and releases the brakes.

TRANSMISSION SPEED RANGE CIRCUIT [See Figures 7-1]. The transmission three speed range electrical system electrically controls the speed range change from “low”, to "medium", to “high” range. Electrical current is supplied to the speed range selection switch, through wire P, from a ten [10] amp circuit breaker. When the transmission speed range selector switch is in “LOW” position, electrical current does NOT flow through wires R, or RRR, to the transmission speed range selector valve solenoids and the solenoids are NOT energized.

[See Figures 7-1]. The secondary/parking brake electrical circuit controls the RELEASING of the brake system. Electrical current is supplied from the ignition key switch, through the 10 AMP circuit breaker to the secondary/parking brake system control switch through wire BBB. When the brake system is in the “APPLIED” [ON] condition, with the secondary/parking brake system

7-12

When the transmission speed range selection switch is in “MEDIUM” [CENTER] position, electrical current will flow through the toggle switch, through wire R to the outside transmission two speed range selector valve solenoid. When the solenoid is energized, the LH side two speed drive motor is switched to high speed. With one drive motor operating in the high speed range and the other drive motor operating in the low speed range, the vehicle operating speed is between the "high" and "low" speed.

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Section 7 ELECTRICAL When the transmission speed range selection switch is in “HIGH”, electrical current will flow through the toggle switch, through wires R and RRR to both the outside and center transmission two speed range selector valve solenoids. With both solenoids energized, both motors operate at "high" speed.

e. Circuit Breakers and Miscellaneous Electrical Items. Three [3] ten [10] amp circuit breakers, one [1] thirty [30] amp circuit breaker, one [1] electric horn, optional equipment, connecting wire assemblies, cables, and water spray pump.

ACCESSORY CIRCUIT [See Figures 7-1]. OPTIONAL OPERATION LIGHTING SYSTEM The accessory circuit includes the following listed items and is “ON” when the ignition key switch is in the “ON” [RUN] position, EXCEPT the horn button switch and light switch which will complete the horn and light circuit at ALL times. Current is supplied to the items in the circuit through the wires connected to the “IGNITION” and “ACCESSORY” terminals of the ignition key switch.

[See Figures 7-1 and 7-5]. The operation lighting system is used to enable machine operation under dark conditions. The lighting system is available as a factory installed option or can be added to the machine by your nearest Distributor.

b. Sender Units and Switches.

The system contains the standard control panel lighting system control switch, control panel gauge and instrument illumination light wiring harness and bulbs, light assembly supply wiring harnesses, circuit breaker, securing clamps and ties and four [4] halogen seal beam light assemblies. Two [2] adjustable light assemblies are mounted one on each side, of the front frame and two [2] light assemblies are mounted on the rear frame.

Engine lubrication oil pressure sender, engine coolant temperature sender, fuel level sender, hydraulic system oil temperature sender, ignition key switch, engine lubrication oil pressure closed switch, transmission neutral start switch, transmission system speed range control switch, secondary/ parking brake system control switch, water spray system “on/off” switch, light switch, turn signal switch [OPTIONAL system] and the horn button switch.

The light switch is a three [3] position, pull type switch. When it is pushed “IN”, all lights are “OFF”. When the switch is pulled to the first detent position, the front two [2] optional head lights and the lights in the hydraulic oil temperature gauge, engine coolant temperature gauge, fuel gauge, voltmeter and engine lubrication oil pressure gauge are “lighted”. By pulling the switch to the second detent, the rear two [2] optional head lights are, also, “lighted” along with the previously listed lights, if so equipped.

c. Electrical Solenoids.

Voltage is constantly applied to the light switch from the battery through the BATTERY terminal on the IGNITION switch and through wire XXX to the 30 AMP circuit breaker. [See figure 7-1]. From the circuit breaker, voltage flows through wire FF to the light switch.

a. Indicators and Gauges. Engine hourmeter, engine lubrication oil pressure gauge, engine coolant temperature gauge, fuel level gauge, hydraulic system oil temperature gauge, and voltmeter.

Secondary/parking brake system release solenoid, transmission system speed range control solenoid and starter solenoid [included on engine starter]. d. Lights. Instrument lights five [5], front and rear head lights four [4] [OPTIONAL system] and front and rear turn signal lights four [4] [OPTIONAL system] with 4 way flashers.

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When the switch is pulled to the first detent, voltage flows through wire PP to the FRONT lights and the five [5] indicators on the dash gauge panel. When the switch is pulled to the second detent, voltage then flows through wire CC from the switch to the REAR lights, illuminating all of the lights.

7-13

Section 7 ELECTRICAL

FIGURE 7-5. OPTIONAL OPERATION LIGHTING SYSTEM, TURN SIGNALS, AND FOUR WAY FLASHERS - COMPONENT DETAIL. Four [4] turn signal lights are optional. Two [2] turn signal lights are mounted one on each side, of the front cowl and two [2] light assemblies are mounted on the rear frame.

CHECKS AND ADJUSTMENT [See Figure 7-5]. Each of the operation light assemblies is able to be adjusted to aim the beam of light as desired. Loosen the retaining nut on the mounting bracket to light assembly through bolt. Adjust the light assembly as desired and tighten the nut on the through bolt to secure the light in the desired adjusted position. Check the operation of the system each time the machine is started to be sure the system is without faults, which can cause the system to not operate correctly when needed. Immediately replace any component that has damage.

OPTIONAL TURN SIGNALS AND FOUR WAY FLASHERS [See Figures 7-1 and 7-5]. Directional turn signals and four way flashers are an OPTIONAL item. The direction lighting system is available as a factory installed OPTION or can be added to the machine by your nearest Distributor. The direction lighting system contains a steering column mounted signal switch, light assembly supply wiring harnesses, circuit breaker, four way flasher, circuit breaker, securing clamps and ties and four [4] light assemblies. The two [2] rear directional lights are mounted on the rear frame next to the rear operational lights, if so equipped. The two [2] front directional lights are mounted on each side of the cowl, with the two [2] front operational lights mounted on the front covers, if so equipped.

CAUTION: Replace a damaged component with the same type or sized item. NEVER use a wire having a smaller gauge than the wire being replaced. Use ONLY EQUAL, or LARGER, size wire.

7-14

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Section 7 ELECTRICAL Voltage to operate the directional lights comes from the ACCESSORY terminal of the ignition switch. The ignition switch must be “ON” to operate the directional lights and four way flasher. Voltage flows through wire YYY from the ACCESSORY terminal to the third ten [10] amp circuit breaker. From the circuit breaker, voltage flows through wire DD to the turn signal switch. Move the turn signal switch lever up for a right turn. Voltage will flow through wire GG to both the front and rear right turn lights. Move the turn signal switch lever down for a left turn. Voltage will flow through wire HH to both the front and rear left turn lights.

TROUBLE ANALYSIS INFORMATION AND PROCEDURES. The following “TROUBLE ANALYSIS” information tables are about the individual electrical circuits used on the machine. The tables give the most common problems that can be found, the probable cause of the problem and the usual corrective action that should restore the machine to a normal operating condition. Always follow the four basic principles of good systematic trouble shooting: KNOW the system; DETERMINE the symptoms;

When the ignition switch is “ON”, voltage is, also, applied to the four way flasher through wire DD and a fuse. When the hazard warning button, found at the base of the turn signal lever, is pushed “IN”, both, the left and right turn circuits are supplied current and voltage will flow through the flasher and through wires GG and HH, causing all four directional lights to flash. To release the hazard warning button, move the turn signal lever, a small amount, either way and the hazard warning button will be released, turning the four way flashing system “OFF”. Check the operation of the system each time the machine is started to be sure the system is without faults, which can cause the system to not operate correctly when needed. Immediately replace any component that have damage.

CAUTION: Replace a damaged component with the same type or sized item. NEVER use a wire having a smaller gauge than the wire being replaced. Use ONLY EQUAL, or LARGER, size wire.

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LIST the possible causes; AND TAKE the CORRECT ACTION.

WARNING: NEVER smoke, or cause a spark, near ANY battery. ALWAYS loosen and remove the NEGATIVE [-] battery cable from the NEGATIVE [-] battery terminal BEFORE loosening and removing the POSITIVE [+] battery cable from the POSITIVE [+] battery terminal. NEVER cause a shorted circuit condition in any circuit. USE EXTRA CAUTION when checking ANY circuit using ANY electrical testing instrument. BATTERY MAY CONTAIN EXPLOSIVE GAS.

CAUTION: IMPROPER trouble shooting methods waste time and can cause further system problems.

7-15

Section 7 ELECTRICAL When trouble shooting any system circuit problem, first determine if the problem noted is confined to only that system circuit or common to all system circuits.

If the problem is confined to ONLY one system circuit, the trouble shooting thought process and procedures should be confined to ONLY the circuits and components which affect that system circuit.

Use standard voltage, ohms and continuity testing instruments to aid in trouble shooting all system circuit problems. For correct test instrument use and procedures follow all of the testing instrument MANUFACTURES written instructions, which are supplied with the above test instruments.

If the problem affects ALL system circuits, then the problem must be caused by malfunctions in circuits, or components, COMMON to ALL system circuits and the thought process and procedures should be related to those areas.

WARNING: Do NOT use any testing instruments BEFORE reading ALL manufacturers instructions for the instrument and procedures to be used to trouble shoot ANY circuit problem. Serious injury and/or system circuit damage can occur if instructions are not followed.

7-16

Determine WHICH system factor, where they apply, is causing the problem: Electrical, Mechanical or Hydraulic. Only after the cause of the problem has been determined can the specific damaged circuit item be removed, repaired, or replaced.

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Section 7 ELECTRICAL TROUBLE ANALYSIS FOR THE ELECTRICAL SYSTEM. [See Figures 7-1, 7-2, 7-3, 7-4 and 7-5]. STARTING CIRCUIT PROBLEM ENGINE WILL NOT CRANK

CAUSE

CORRECTION

Battery is damaged [dead]

Charge or replace battery.

Neutral start switch not in closed position

Adjust or replace neutral start switch.

Secondary/parking brake switch in Place switch in "on" position. "off" position

ENGINE CRANKS SLOWLY

ENGINE CRANKS BUT WILL NOT START

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Neutral start switch damaged

Replace switch.

Secondary/parking brake system control switch damaged

Replace switch.

Ignition switch damaged

Replace ignition switch.

Starter solenoid damaged

Replace starter solenoid.

Loose or broken wire in circuit

Tighten or replace wire.

Battery cables have corrosion

Clean or replace battery cables.

Starter motor windings shorted

Repair or replace starter motor.

Battery not fully charged

Charge battery.

Low ambient temperatures

Warm area around machine.

Incorrect engine lubrication oil in engine

Remove oil and replace with correct oil.

Fuel shutoff solenoid not energized

Check current flow. Repair or replace fuel shutoff solenoid and/or valve.

No fuel in tank

Add correct fuel.

Fuel pre-cleaner, strainer and/or filter "plugged"

Replace pre-cleaner, strainer and/or filter with new.

Air in fuel supply system

"Bleed" air from system.

Damaged fuel pump

Replace pump.

Incorrect injector pump timing

Set timing.

Damaged injector pump

Replace pump.

7-17

Section 7 ELECTRICAL TROUBLE ANALYSIS FOR THE ELECTRICAL SYSTEM. [See Figures 7-1, 7-2, 7-3, 7-4 and 7-5]. CHARGING CIRCUIT PROBLEM

CAUSE

CORRECTION

BATTERY IS OVERCHARGED

Voltage regulator, in alternator, damaged

Replace regulator or alternator.

BATTERY IS NOT CHARGED

Voltage regulator, in alternator, damaged

Replace regulator or alternator.

Alternator not producing voltage

Repair or replace alternator.

Engine oil pressure closed switch damaged

Replace oil pressure switch.

Damaged wire[s] in circuit

Repair or replace wires.

ACCESSORY CIRCUIT PROBLEM HOURMETER DOES NOT INDICATE HOURS AS ENGINE OPERATES

CAUSE Engine oil pressure closed switch not closing circuit

CORRECTION Replace oil pressure switch.

Meter circuit in hourmeter shorted Replace hourmeter. No current flowing to hourmeter

Check circuit for current flow. Correct problem as needed.

HOURMETER INDICATES ERRATIC HOURS

Meter circuit in hourmeter is “open”

Replace hourmeter.

ENGINE LUBRICATION OIL PRESSURE GAUGE DOES NOT INDICATE ANY PRESSURE

Oil pressure sender damaged

Replace oil pressure sender.

No current flowing to gauge

Check circuit for current flow correct problem as needed.

Damaged wire[s] in circuit

Repair or replace wire[s] as needed.

Oil pressure sender damaged

Replace oil pressure sender.

Gauge damaged

Replace oil pressure gauge.

Damaged wire[s] in circuit

Repair or replace wire[s] as needed.

ENGINE LUBRICATION OIL PRESSURE GAUGE NOT INDICATING CORRECT OIL PRESSURE

7-18

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Section 7 ELECTRICAL TROUBLE ANALYSIS FOR THE ELECTRICAL SYSTEM. [See Figures 7-1, 7-2, 7-3, 7-4 and 7-5]. ACCESSORY CIRCUIT PROBLEM ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE TEMPERATURE

VOLTMETER NOT INDICATING CORRECT VOLTAGE OR NO VOLTAGE AT ALL

FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT FUEL LEVEL OR NO FUEL LEVEL AT ALL

CAUSE

CORRECTION

Coolant temperature sender damaged

Replace temperature sender.

No current flowing to gauge

Check circuit for current flow. Correct problem as needed.

Damaged wire[s] in circuit

Repair or replace wire[s] as needed.

Coolant temperature gauge damaged

Replace temperature gauge.

Meter circuit, in voltmeter, is "open"

Replace voltmeter.

Meter circuit in, voltmeter, is "shorted"

Replace voltmeter.

Damaged wire[s] in circuit

Repair or replace wire[s] as needed.

Alternator damaged

Replace alternator.

No current flowing to gauge

Check circuit for current flow correct problem as needed.

Fuel sending unit, in tank, damaged

Replace fuel sending unit.

Damaged wire[s] in circuit

Repair or replace wire[s] as needed.

Meter circuit, in fuel gauge, "open" Replace fuel gauge. HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT OIL TEMPERATURE, OR SHOWS NO INDICATION AT ALL

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No current flowing to gauge

Check circuit for current flow correct problem as needed.

Temperature sender unit damaged

Replace temperature sender unit.

Meter circuit, in temperature gauge, "open" or "shorted"

Replace temperature gauge.

Damaged wire[s] in circuit

Repair or replace wire[s] as needed.

7-19

Section 7 ELECTRICAL TROUBLE ANALYSIS FOR THE ELECTRICAL SYSTEM. [See Figures 7-1, 7-2, 7-3, 7-4 and 7-5]. ACCESSORY CIRCUIT PROBLEM SECONDARY/PARKING BRAKE SYSTEM CONDITION INDICATOR LIGHT DOES NOT ILLUMINATE - SYSTEM OPERATES NORMALLY

HYDRAULIC SUCTION OIL FILTER CONDITION INDICATOR LIGHT DOES NOT ILLUMINATE

ENGINE INLET AIR RESTRICTION CONDITION INDICATOR LIGHT DOES NOT ILLUMINATE

7-20

CAUSE

CORRECTION

Brake system control switch damaged

Replace control switch.

Bulb damaged

Replace bulb.

Light socket not grounded

Check circuit for ground correct problem as needed.

Damaged wire to light

Repair or replace wire.

No current flowing to light from the ten [10] amp circuit breaker

Check circuit for current flow correct problem as needed.

Bulb damaged

Replace bulb.

Closing switch in filter head damaged

Replace closing switch.

No circuit ground being completed between closing switch and indicator light

Check circuit for ground correct problem as needed.

Light socket not grounded

Check circuit for ground correct problem as needed.

Damaged wire to light

Repair or replace wire.

System operating normally

NO service needed.

No current flowing to light from the ten [10] amp circuit breaker

Check circuit for current flow correct problem as needed.

Bulb damaged

Replace bulb.

Vacuum closing switch damaged

Replace vacuum closing switch.

No circuit ground being completed between vacuum closing switch and indicator light

Check circuit for ground correct problem as needed.

Light socket not grounded

Check circuit for ground correct problem as needed.

Damaged wire to light

Repair or replace wire.

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Section 7 ELECTRICAL TROUBLE ANALYSIS FOR THE ELECTRICAL SYSTEM. [See Figures 7-1, 7-2, 7-3, 7-4 and 7-5]. SYSTEM CONTROL CIRCUITS PROBLEM TRANSMISSION SPEED RANGE SOLENOIDS DO NOT ENERGIZE

WATER SPRAY ELECTRICAL SYSTEM DOES NOT OPERATE

SECONDARY/PARKING BRAKE SYSTEM RELEASE SOLENOID DOES NOT ENERGIZE

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CAUSE

CORRECTION

No current flowing to range selector switch from ten [10] amp circuit breaker

Check circuit for current flow. Correct problem as needed.

Ten [10] amp circuit breaker damaged

Replace circuit breaker.

Range selector switch damaged

Replace switch.

Damaged wire[s] in circuit

Repair or replace wire[s] as needed.

One, or both, electrical solenoids damaged

Replace electrical solenoid(s).

No current flowing to master on/off control switch from ten [10] amp circuit breaker

Check circuit for current flow Correct problem as needed.

Ten [10] amp circuit breaker damaged

Replace circuit breaker.

System on/off switch damaged

Replace switch.

Damaged wire[s] in circuit

Repair or replace wire[s] as needed.

System pump damaged

Replace pump.

No current flowing to secondary/ parking brake system control switch from the ten [10] amp circuit breaker and /or ignition key switch

Check circuit for current flow - correct problem as needed.

Ten [10] amp circuit breaker damaged

Replace circuit breaker.

Secondary/parking brake system control switch damaged

Replace control switch.

Damaged wire[s] in circuit

Repair or replace wire[s] as needed.

Brake electrical solenoid damaged

Replace electrical solenoid.

7-21

Section 7 ELECTRICAL TROUBLE ANALYSIS FOR THE ELECTRICAL SYSTEM. [See Figures 7-1, 7-2, 7-3, 7-4 and 7-5]. OPTIONAL OPERATION LIGHTING SYSTEM PROBLEM NO LIGHTS ILLUMINATE

CAUSE

CORRECTION

Open in circuit current supply

Check for battery voltage at ignition switch and 30 amp circuit breaker- repair or replace parts as necessary.

Open wire

Check, repair as needed.

Damaged switch

Replace switch.

Damaged light [sealed beam]

Replace light [sealed beam] with NEW.

Open wire

Check and repair as needed.

Open wire

Check and repair as needed.

Damaged switch

Replace as needed.

Damaged lights [sealed beams]

Replace lights [sealed beams] with NEW.

Open wire

Check and repair as needed.

Damaged lights [sealed beams]

Replace lights [sealed beams] with NEW.

GAUGE LIGHTS DO NOT ILLUMINATE - FRONT LIGHTS ILLUMINATE

Open wire[s]

Check and repair as needed.

Damaged lights [bulbs]

Replace lights [bulbs] with NEW.

ONE GAUGE LIGHT NOT ILLUMINATED

Open wire

Check and repair as needed.

Damaged bulb

Replace bulb with NEW.

ONE LIGHT DOES NOT ILLUMINATE

REAR LIGHTS DO NOT ILLUMINATE

FRONT LIGHTS DO NOT ILLUMINATE - GAUGE LIGHTS ILLUMINATE

7-22

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Section 7 ELECTRICAL TROUBLE ANALYSIS FOR THE ELECTRICAL SYSTEM. [See Figures 7-1, 7-2, 7-3, 7-4 and 7-5]. OPTIONAL TURN SIGNALS AND FOUR WAY FLASHERS PROBLEM NO TURN SIGNALS ILLUMINATE

CAUSE

CORRECTION

Open in circuit current supply

Check for battery voltage at ignition switch 30 amp circuit breaker- repair or replace parts as needed.

Damaged circuit breaker

Replace with NEW.

ONE TURN SIGNAL LIGHT DOES NOT ILLUMINATE

Damaged bulb, or light

Replace with NEW.

RIGHT TURN LIGHTS DO NOT ILLUMINATE - LEFT TURN LIGHTS ILLUMINATE

Open wire

Check and repair.

Damaged switch

Replace with NEW.

LEFT TURN LIGHTS DO NOT ILLUMINATE - RIGHT TURN LIGHTS ILLUMINATE

Open wire

Check and repair.

Damaged switch

Replace with NEW.

HAZARD WARNING SYSTEM DOES NOT FUNCTION

Damaged fuse

Replace with NEW.

Open power wire

Check and repair as needed.

Flasher damaged

Replace with NEW.

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7-23

Section 7 ELECTRICAL NOTES

7-24

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Section 8 TRANSMISSION SYSTEM TABLE OF CONTENTS

PAGE GENERAL INFORMATION .................................................................................................................... 8-4 FLEX DRIVE PLATE ........................................................................................................................... 8-4 REMOVAL ........................................................................................................................................... 8-4 INSPECTION ....................................................................................................................................... 8-5 INSTALLATION ................................................................................................................................... 8-6 HYDRAULIC SYSTEM ........................................................................................................................... 8-8 GENERAL INFORMATION ................................................................................................................. 8-8 TRANSMISSION SYSTEM ..................................................................................................................... 8-8 GENERAL INFORMATION ................................................................................................................. 8-8 TRANSMISSION PUMP ASSEMBLY .................................................................................................... 8-9 OPERATION ........................................................................................................................................ 8-9 TRANSMISSION PUMP CIRCUITS AND COMPONENTS .................................................................... 8-10 CHARGE PUMP AND CIRCUIT .......................................................................................................... 8-10 DISPLACEMENT CONTROL AND CIRCUIT ...................................................................................... 8-11 CHARGE RELIEF VALVE ................................................................................................................... 8-11 MULTI FUNCTION VALVE ASSEMBLIES .......................................................................................... 8-12 CHARGE CHECK VALVES ................................................................................................................. 8-12 PRESSURE LIMITER VALVES ........................................................................................................... 8-12 HIGH PRESSURE RELIEF VALVES ................................................................................................... 8-13 BY-PASS VALVES .............................................................................................................................. 8-14 TRANSMISSION PUMP CASE DRAIN CIRCUIT ................................................................................ 8-14 TRANSMISSION SYSTEM FILTRATION ............................................................................................ 8-14 REMOVAL, REPAIR OR REPLACEMENT OF COMPONENTS OF THE TRANSMISSION PUMP ....................................................................................................................... 8-14 GENERAL INFORMATION ................................................................................................................. 8-14 GEROTOR CHARGE PUMP ............................................................................................................... 8-15 REMOVAL/DISASSEMBLY .............................................................................................................. 8-15 INSPECTION ..................................................................................................................................... 8-15 ASSEMBLY/INSTALLATION ........................................................................................................... 8-16

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8-1

Section 8 TRANSMISSION SYSTEM PAGE MULTI-FUNCTION VALVES .................................................................................................................. 8-17 REMOVAL, INSPECTION AND INSTALLATION ............................................................................... 8-17 CHARGE CHECK VALVES .................................................................................................................... 8-18 REMOVAL, INSPECTION, CLEANING AND INSTALLATION .......................................................... 8-18 MANUAL DISPLACEMENT CONTROL VALVE .................................................................................... 8-18 REMOVAL AND REPLACEMENT ...................................................................................................... 8-18 NEUTRAL START SWITCH ................................................................................................................... 8-20 REMOVAL AND REPLACEMENT ...................................................................................................... 8-20 ADJUSTMENT ..................................................................................................................................... 8-20 PRESSURE LIMITER VALVES .............................................................................................................. 8-21 REMOVAL, INSPECTION AND INSTALLATION ............................................................................... 8-21 TRANSMISSION PUMP SHAFT SEAL .................................................................................................. 8-21 REMOVAL, INSPECTION AND INSTALLATION .............................................................................. 8-21 COMPLETE TRANSMISSION PUMP ASSEMBLY ................................................................................ 8-23 REMOVAL ........................................................................................................................................... 8-23 INSTALLATION ................................................................................................................................... 8-23 ADJUSTMENT OF THE TRANSMISSION DIRECTION CONTROL CABLE ........................................ 8-23 ADJUSTMENT OF THE THROTTLE CONTROL LINKAGE ................................................................. 8-24 TRANSMISSION PUMP PRESSURES .................................................................................................. 8-25 CHECKING AND ADJUSTMENT PROCEDURES .............................................................................. 8-25 CHARGE PRESSURE ......................................................................................................................... 8-26 PRESSURE LIMITER SYSTEM AND HIGH PRESSURE RELIEF VALVE PRESSURE CHECK AND ADJUSTMENT ............................................................................................................. 8-27 SHUTTLE [FLUSHING] VALVE FLOW .............................................................................................. 8-29 DRIVE MOTOR/BRAKE ASSEMBLIES ................................................................................................. 8-31 DESCRIPTION ..................................................................................................................................... 8-31 OPERATION ........................................................................................................................................ 8-31 REMOVAL .......................................................................................................................................... 8-34 DISASSEMBLY .................................................................................................................................. 8-34 INSPECTION ...................................................................................................................................... 8-36 ASSEMBLY ........................................................................................................................................ 8-37 INSTALLATION .................................................................................................................................. 8-40

8-2

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Section 8 TRANSMISSION SYSTEM PAGE DRIVE MOTOR PRESSURE AND FLOW CHECKS .............................................................................. 8-41 CHECKING PROCEDURES ................................................................................................................. 8-41 CASE PRESSURE ............................................................................................................................... 8-41 CASE DRAIN FLOW AMOUNT ........................................................................................................... 8-42 LOW TO HIGH RANGE PILOT PRESSURE ....................................................................................... 8-43 BRAKE SYSTEM RELEASE PILOT PRESSURE ............................................................................... 8-44 CLEANING THE HYDRAULIC SYSTEM ............................................................................................... 8-46 HYDRAULIC SYSTEM PRE-START PROCEDURES ............................................................................ 8-47 HYDRAULIC SYSTEM START UP PRESSURE CHECKS .................................................................... 8-48 TROUBLE ANALYSIS FOR THE TRANSMISSION SYSTEM ............................................................. 8-49

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8-3

Section 8 TRANSMISSION SYSTEM GENERAL INFORMATION. This section gives information about the transmission system used on the Model BW11RH Roller. This section also includes information for removal, disassembly, inspection, assembly and installation of the major transmission system components, including the secondary/parking brake components, which are integral with the drive motors.

"Trouble Analysis" for the transmission system is found at the rear of this section.

FLEX DRIVE PLATE [See Figure 8-1].

b. Wash the pump and flywheel housing area with clean diesel fuel and permit to air dry.

The flex drive plate assembly is used to send rotary torque from the engine flywheel to the transmission pump. The flex drive plate assembly is fastened to the engine flywheel by eight [8] capscrews and rotates with the flywheel. The flex plate, and splined sleeve, drive the input shaft of the transmission pump. As the flex drive plate turns with the engine flywheel, it and the splined sleeve rotate the transmission pump input shaft.

REMOVAL. NOTE: Remove the flex drive plate assembly ONLY if there is damage to the splined sleeve or other parts of the plate. BEFORE removal of the flex drive plate, the hydraulic pump MUST be disconnected and removed as an assembly [see this section].

8-4

c. Disconnect and remove the direction control cable from the transmission pump control lever. d. Put identification tags on each electrical wire and each electrical connector terminal on the transmission pump. Disconnect all electrical wires which are connected to the transmission pump. e. Put identification tags on each hydraulic hose and each fitting on the transmission pump. Disconnect all hoses from the transmission pump. Put plugs and caps on ALL hoses and fittings IMMEDIATELY after the hoses are disconnected. f. Fasten a sling and hoist, having a capacity MORE than 250 lbs. [114 kg], around the circumference of the transmission pump body. Use the hoist to apply tension to the sling to keep the pump assembly in a level position when the retaining capscrews are loosened and removed.

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Section 8 TRANSMISSION SYSTEM

FIGURE 8-1. FLEX DRIVE PLATE ASSEMBLY - CROSS SECTION.

g. Loosen and remove the four [4] pump retaining flange screws. Remove the transmission pump from the pump mounting plate at the rear of the flywheel housing. Lower the pump assemblies to a flat surface and remove the sling and hoist.

WARNING: Do NOT get under the pump assembly while moving and lowering.

h. Loosen and remove the twelve [12] capscrews which fasten the pump mounting plate to the flywheel housing. Remove the pump mounting plate from the housing.

INSPECTION [See Figure 8-1]. a. Wash the flex drive plate and splined sleeve with CLEAN diesel fuel and dry using compressed air. b. CAREFULLY inspect the center splined area of the drive plate for damaged splines, cracks or other damage. Inspect the area around the through holes for cracks or other damage. Replace the flex drive plate with NEW if ANY damage is noted. CAREFULLY inspect the splined sleeve for wear or damage. Replace the sleeve with NEW if worn or damaged.

i. Remove the splined sleeve from the drive plate. Loosen and remove the eight [8] capscrews that fasten the flex drive plate to the flywheel. CAREFULLY remove the plate from the flywheel. Put the plate on a CLEAN flat work surface.

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8-5

Section 8 TRANSMISSION SYSTEM INSTALLATION [See Figure 8-1]. a. Put the flex drive plate into position on the engine flywheel. b. Put thread lock, pn 318702, on thread area of the retaining capscrews. Install the retaining capscrews through the holes in the flex drive plate and thread them into the tapped holes in the engine flywheel. Tighten the capscrews to a torque of 33 ft. lbs. [45 N.m]. c. Put white grease on the external and internal splines of the splined sleeve. Install the splined sleeve into the center splined area of the flex drive plate. Put the pump mounting plate into position on the flywheel housing. Put the twelve [12] plate retaining capscrews through the holes in the pump mounting plate and turn them into the tapped holes in the housing. Tighten the capscrews to a torque of 33 ft. lbs. [45 N.m]. d. Fasten a sling and a hoist, having a capacity more than 250 lbs. [114 kg], to the transmission pump assembly. Lift the pump and put the transmission pump input shaft in a position, so that it is in alignment with the center splined sleeve in the flex drive plate. CAREFULLY install the splined input shaft into the splined sleeve. e. Put thread lock, pn 318702, on the thread area of the four [4] capscrews that fasten the transmission pump to the pump mounting plate. Install the pump retaining capscrews and tighten to a torque of 80 ft. lbs [108 N.m]. f. Remove the caps from ALL fittings and the plugs from ALL hoses. Install EACH hose onto the CORRECT pump fittings as indicated by the identification tags installed before removal. Tighten EACH hose securely onto EACH fitting or install and tighten the flange retaining capscrews. g. Connect the direction control cable to the transmission pump control lever. Adjust the control cable travel, if needed, using the procedures given in THIS section. h. CAREFULLY connect ALL electrical wires, EXCEPT the positive [+] and negative [-] battery cables, to the correct transmission pump wire connection terminal, as indicated by the identification tags installed before removal, and tighten securely.

8-6

i. CAREFULLY connect the POSITIVE [+] battery cable to the POSITIVE [+] terminal of the battery and tighten FIRST. Then CAREFULLY connect the NEGATIVE [-] battery cable to the NEGATIVE [-] terminal of the battery and tighten.

j. Add hydraulic oil, as needed, to the hydraulic oil reservoir using the procedures given in Section 4 MAINTENANCE. Follow ALL pre-start procedures given in THIS section BEFORE starting the engine.

CAUTION: Do NOT start the engine BEFORE the hydraulic oil level, in the reservoir, is at the CORRECT level. Do NOT start the engine until ALL pre-start procedures have been done. Damage to the components of the hydraulic system WILL occur.

k. Start the engine. Check for CORRECT operation of ALL systems. Check for ANY fluid leaks.

WARNING: Do NOT use the hands on ANY hydraulic hose, fitting or system component to check the system for possible leaks. Serious injury can occur from a leak under high pressure.

CAUTION: STOP the engine IMMEDIATELY if ANY fluid leak is noted. Do NOT start the engine UNTIL any problem noted has been corrected.

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FIGURE 8-2. HYDRAULIC SYSTEM SCHEMATIC - MODEL BW11RH ROLLER.

Section 8 TRANSMISSION SYSTEM

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8-7

Section 8 TRANSMISSION SYSTEM HYDRAULIC SYSTEM. GENERAL INFORMATION [See Figure 8-2]. The closed hydraulic system is made of two [2] subsystems. These subsystems are: HYDROSTATIC TRANSMISSION system. STEERING system. Both subsystems use the same hydraulic oil and reservoir. See Section 4 - MAINTENANCE - for the CORRECT hydraulic oil type and amount. THIS section describes the TRANSMISSION system and the removal, disassembly, inspection, assembly and installation of MOST major parts of the system. See Section 10 - STEERING SYSTEM for information about the STEERING system.

TRANSMISSION SYSTEM. GENERAL INFORMATION [See Figure 8-2]. The MAJOR transmission system components are as follows: a. One [1] transmission hydraulic pump. b. Two [2] transmission drive motors . c. Transmission control linkage and cable. d. Hoses. e. Hydraulic oil reservoir. f. Hydraulic suction filter. g. Shuttle [Flushing] valve. h. Solenoid [Stack] valve. The hydrostatic transmission permits infinite control of the machine speed, up to the maximum speed, in either the FORWARD or REVERSE direction of travel.

8-8

Control of the transmission system variable displacement, axial piston pump is important to machine performance. The axial piston pump is equipped with two [2] pressure limiter sensing valves, which are contained in the two [2] multi-function valve cartridge assemblies. Control of the variable displacement, axial piston pump is through movement of the directional control [F-N-R] handlever to either the FORWARD or REVERSE direction of travel position. Movement of the handlever, also, moves the control cable. The control cable end is fastened to the lever arm of the pump manual displacement control on the transmission pump. Movement of the manual displacement control lever arm in either the FORWARD, or REVERSE, direction moves the control spool in the transmission pump displacement control. The spool movement permits "control oil" to flow to, and from, the hydraulic pump control [servo] cylinders. The "control oil", under pressure, causes the servo piston to move and tilt the pump swashplate from 0 degree of angle. Tilting the swashplate from 0 degree of angle causes the pistons to stroke in and out of the cylinder block bores as it is rotated. Increasing the angle of the swashplate, up to the MAXIMUM, in the FORWARD, or REVERSE, direction of machine travel varies the piston stroke and, therefore, the amount of high pressure oil being displaced [pumped] to the transmission drive motors. ANY change in the amount of oil flowing to the drive motors causes a change in the output speed of the drive motors. Tilting the swashplate in the OPPOSITE direction, from 0 degree of angle, REVERSES the oil flow to the transmission drive motors and, therefore, the direction of their rotation. Loss of control pressure, or charge pressure, will cause the pump swashplate to return to the neutral position because EACH servo control cylinder is spring loaded toward the NEUTRAL position.

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Section 8 TRANSMISSION SYSTEM The swashplate will also be AUTOMATICALLY moved toward the neutral [destroked] position IF the HIGH pressure, in the transmission system, goes above the MAXIMUM allowable pressure as sensed by the two [2] pump pressure limiter sensing valves.

TRANSMISSION PUMP ASSEMBLY [See Figure 8-3]. The variable displacement transmission pump assembly contains the following MAJOR parts: a. Body casting. b. Drive shaft. c. Cylinder block assembly. d. Swashplate. e. Valve bearing plate. f. Displacement control valve.

FIGURE 8-3. TRANSMISSION PUMP. The transmission pump will be in the NEUTRAL condition when the swashplate is at 0 degree of angle and NO forward, or reverse, movement of the machine will occur.

g. Servo cylinders and pistons. h. Gerotor charge pump assembly. i. Multi-function valve cartridge assemblies two [2], that contain the charge check valves, pressure limiter valves, adjustable high pressure relief valves and the bypass valves.

OPERATION. The transmission pump drive shaft is fitted to the center of the cylinder block. The cylinder block assembly contains nine [9] pistons. The pump drive shaft, cylinder block and pistons are in rotation together when the engine is in a running condition.

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Moving the direction control [F-N-R] handlever, found on the rear of the operator's compartment, to EITHER the forward, or reverse, direction position will cause the servo control circuit to apply pressure to one [1] servo piston. The servo piston will tilt the swashplate from the 0 degree of angle position [positive displacement]. Tilting the swashplate toward EITHER side FROM center causes the nine [9] pistons to move [stroke] in their bores as they contact the thrust plate. The degree of swashplate tilt angle controls the volume [displacement] of hydraulic oil moved by each cylinder piston. Each cylinder piston strokes in its cylinder EACH revolution of the cylinder block when the swashplate is tilted.

8-9

Section 8 TRANSMISSION SYSTEM The valve bearing plate contains ports which are in contact with the cylinder block. The opposite side of the valve bearing plate mates with the pump end cap. Two [2] ports in the pump end cap are connected to the high pressure hoses. When a piston moves past the inlet ports, in the valve bearing plate, it moves "out" of the block and pulls low pressure oil into the cylinder. This is the intake stroke of the piston. Further rotation of the cylinder block moves the oil filled cylinder toward the high pressure ports in the valve bearing plate. The pistons are pushed into the cylinder block by the tilted swashplate and thrust plate. Hydraulic oil, now under high pressure, is directed to the outlet high pressure port in the end cap through the valve bearing plate. With the pump swashplate tilted to ONE side of the center position, the machine will travel in the forward direction of travel and one [1] hose will carry high pressure oil through a Tee'd connection at the pump to BOTH drive motors. The other hose will carry low pressure [return] oil back to the pump. The opposite tilt of the pump swashplate will REVERSE the high pressure and return function of the hoses from, and to, the pump AND the machine direction of travel. The main ports of the pump are connected by hydraulic hoses through a Tee'd fitting at the pump, to the two [2] drive motors. Hydraulic oil flows from the pump to the drive motors and back to the pump in a CLOSED circuit. EITHER hydraulic hose will carry HIGH pressure. The position of the pump swashplate determines which hydraulic hose carries the HIGH pressure oil and the direction of HIGH pressure oil flow.

CHARGE PUMP

FIGURE 8-4. CHARGE PUMP.

TRANSMISSION PUMP CIRCUITS AND COMPONENTS. CHARGE PUMP AND CIRCUIT [See Figures 8-2 and 8-4]. A fixed displacement [GEROTOR type] charge pump is mounted on the rear of the variable displacement transmission pump and is driven by the main pump shaft. The charge pump supplies cool hydraulic oil to the system, keeps the system charged with oil and supplies the control system with oil. Charge pressure, with the pump in neutral [0 flow] is limited by a relief valve which is normally factory set at a pressure of 270-350 psi. [19-24 bar] ABOVE case pressure. Since either of the main hydraulic lines can be the high pressure line, two [2] charge check valves are used to direct the charge supply into the LOW pressure line. The check valves are contained in the multi-function valves, that are installed in the left side of the charge pump section.

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Section 8 TRANSMISSION SYSTEM The gerotor charge pump draws hydraulic oil from the hydraulic oil reservoir. Charge oil is cleaned by a 7 micron SUCTION filter BEFORE going through the charge pump and BEFORE it enters the LOW pressure side of the main circuit.

DISPLACEMENT CONTROL AND CIRCUIT [See Figures 8-2 and 8-5]. The pump manual displacement control valve is mounted to the top of the variable displacement transmission pump. It provides a control of the transmission pump output [displacement], in either direction, that is approximately proportional to the angular movement of the control handlever on the operator's compartment.

CAUTION: Do NOT use ANY displacement control other than those designed for the "90 SERIES" hydrostatic pumps. Displacement controls for THIS series of hydrostatic pumps are designed to be used ONLY in conjunction with the PRESSURE LIMITER system.

MANUAL DISPLACEMENT CONTROL VALVE

The charge pump provides oil, under pressure, to the hydraulic pump control valve for transmission pump output control. When the directional control handlever is moved to either the FORWARD, or REVERSE, position the displacement control valve directs control oil, under pressure to one [1] swashplate control servo, which applies pressure to the servo piston. The servo piston is moved, and, thereby, moves the pump swashplate, providing pump output flow [displacement]. The manual displacement control valve has an orifice for controlling maximum acceleration or powered deceleration [control responses]. The orifice matches the machine response desired and the orifice size must NOT be changed. The manual displacement control valve, also, contains a NEUTRAL start switch, so that the engine can ONLY be started when the control is in the "NEUTRAL" position. The switch provides an electrical interrupt, of the starting circuit, UNLESS the displacement control is in the NEUTRAL position.

CHARGE RELIEF VALVE [See Figure 8-6]. The charge relief valve is located in the top of the charge pump section. Charge pressure, with the transmission pump in neutral [0 flow], is limited by the charge relief valve which is normally factory set at a pressure of 350 psi. [24 bar] MINIMUM, 400 psi. [28 bar] MAXIMUM above case pressure. When charge pressure is MORE than the above pressures, the charge relief valve will open and permit oil to flow from the relief valve and back to the hydraulic oil reservoir.

FIGURE 8-5. MANUAL DISPLACEMENT CONTROL VALVE LOCATION.

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8-11

Section 8 TRANSMISSION SYSTEM

CHARGE RELIEF VALVE

Two [2] charge check valves are needed because EITHER line can supply HIGH, or LOW, pressure. When the transmission pump is stroked, and is producing oil flow, the charge check valve sensing HIGH pressure will be held in a CLOSED position by high pressure and NO charge oil can flow into the line. The charge check valve sensing LOW pressure will be in the OPEN position and permit charge oil to enter the LOW pressure side of the cylinder block assembly to maintain adequate oil in the system.

FIGURE 8-6. CHARGE RELIEF VALVE LOCATION.

MULTI-FUNCTION VALVE ASSEMBLIES [See Figure 8-7]. The transmission pump uses two [2] multi-function valve cartridge assemblies. Both cartridge assemblies are installed into the left side of the charge pump section. EACH multi-function valve cartridge assembly contains a main system loop check valve, a high pressure relief valve, a pressure limiter valve and a bypass valve. The following information describes the basic function of EACH of the items contained in the multifunction valve cartridge assemblies.

MULTI-FUNCTION VALVES

FIGURE 8-7. MULTI-FUNCTION VALVE LOCATIONS. When the transmission pump is in the neutral condition, BOTH of the charge check valves will be in the OPEN position and permit oil, under charge pressure, to lubricate and charge BOTH sides of the pump cylinder block and system.

PRESSURE LIMITER VALVES CHARGE CHECK VALVES [See Figure 8-7].

[See Figures 8-7 and 8-8].

The two [2] charge check valves are contained in the multi-function valves. The check valves are used to send filtered charge oil to the LOW pressure side of the system when the transmission pump is in the FORWARD, or REVERSE, output condition.

The two [2] pressure limiter valves are contained in the multi-function valves.

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The pressure limiter system is a fast responding control which LIMITS MAXIMUM pump output pressure to a preset level, WITHOUT significant energy dissipation.

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Section 8 TRANSMISSION SYSTEM

FIGURE 8-8. PRESSURE LIMITER SYSTEM - SCHEMATIC. The system destrokes the pump swashplate [REDUCES displacement] whenever the MAXIMUM preset system HIGH pressure has been reached, and then maintains that pressure.

HIGH PRESSURE RELIEF VALVES [See Figure 8-7]. The two [2] high pressure relief valves are contained in the multi-function valves. They have been factory preset to a pressure of 6,200 +/- 100 psi. [428 +/- 6.9 bar] and EACH can be externally adjusted at the end of EACH multi-function valve cartridge assembly. During STROKED transmission pump operation the high pressure relief valve, exposed to HIGH system pressure, can act as the control to limit and maintain the MAXIMUM system HIGH pressure. When system pressure ABOVE the preset MAXIMUM high pressure is sensed, the valve will IMMEDIATELY send a small amount of HIGH pressure oil DIRECTLY to the OPPOSITE servo piston of that which has control pressure applied to it from the displacement control valve.

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This small amount of HIGH pressure oil moves the servo piston TOWARD the DESTROKE position, a SMALL amount. The moving piston is fastened to the pump swashplate and moves the swashplate TOWARD the DESTROKE [neutral] position. At the same time, control oil from the OPPOSITE servo is also IMMEDIATELY released from behind the servo piston and permitted to flow back into the low pressure circuit.

NOTE: The action of the pressure limiter system is VERY FAST in response time. The system can port high pressure to and from EITHER servo piston and maintain the MAXIMUM HIGH system pressure WITHOUT the need to act through the pump displacement control valve.

This procedure LOWERS the MAXIMUM HIGH pressure in the system to the preset pressure. The high pressure relief valve CONTINUES to SENSE and MAINTAIN the MAXIMUM system HIGH pressure as long as the machine continues to be operated in the SAME direction of travel.

NOTE: Reversing the direction of machine travel will cause the OPPOSITE valve sensing HIGH pressure to function in the SAME way as described previously for THAT direction of machine travel.

8-13

Section 8 TRANSMISSION SYSTEM BY-PASS VALVES. The two [2] by-pass valve are contained in the multifunction valves and are used ONLY for towing of the machine [See Section 3 OPERATION in this manual].

TRANSMISSION PUMP CASE DRAIN CIRCUIT. The transmission pump uses the case drain circuit to remove hot hydraulic oil from the pump and thereby cool the pump during operation. The circuit also removes oil, from the pump case, which has leaked by pistons and other internal pump parts during operation. During transmission pump operation HOT hydraulic oil, having a pressure less than 40 psi. [3 bar], flows from the top case drain port of the pump case to the hydraulic oil reservoir.

TRANSMISSION SYSTEM FILTRATION. When the engine has started, and is "running", hydraulic oil is pulled by the transmission charge pump from the hydraulic reservoir. Hydraulic oil then flows through the SUCTION filter [See Figure 8-9]. The transmission system oil is then drawn into the charge pump and flows, under pressure into the pump system [See THIS Section].

FIGURE 8-9. HYDRAULIC OIL SUCTION FILTER LOCATION.

REMOVAL, REPAIR OR REPLACEMENT OF COMPONENTS OF THE TRANSMISSION PUMP. GENERAL INFORMATION. The following components CAN be removed, repaired, or replaced, WITHOUT canceling the pump warranty. See your nearest Distributor for a copy of "Service Policy and Procedures", which describes COMPLETE warranty information. a. Gerotor charge pump.

Transmission system inlet vacuum MUST NOT be ABOVE 10 in hg. [254 mm hg]. See Section 4 MAINTENANCE - for correct SUCTION filter service procedures.

b. Displacement control valve assembly. c. Shaft seal. d. Charge pressure relief valve. e. Multi-function valve cartridge assemblies.

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Section 8 TRANSMISSION SYSTEM If the transmission pump has failed, or test results indicate that service to components, other than those listed above are needed, it is intended major repairs be done, ONLY, by Sauer-Sundstrand, Authorized Service Centers, or the pump be replaced with a new, or remanufactured, pump.

b. Put an identification tag on EACH hose connected to the transmission pump fittings. Loosen and remove EACH hose from BOTH pump fittings. Put a plug in EACH hose and a cap on EACH fitting.

CAUTION: See your nearest BOMAG Distributor for a copy of the "Service Policy and Procedure Manual", which describes complete warranty information. Major repairs are those which require the removal of the pump end cap, or side cover. Major repairs are intended to be done, ONLY, by SauerSundstrand, Authorized Service Centers.

d. CAREFULLY remove the retainer and the charge pump cover. Note the orientation of the gerotor.

c. Remove the six [6] capscrews holding the charge pump cover retainer.

e. Remove the charge pump shaft and charge pump drive key. f. Remove the charge pump gerotor assembly. g. Remove the outer eccentric ring and alignment pin. h. Remove the inner port plate.

The following components CAN be removed from the pump WITHOUT removing the complete pump from the machine. a. Gerotor charge pump assembly.

CAUTION: Do NOT drop the internal parts as they are removed. Put the parts on a CLEAN lint free cloth.

b. Displacement control valve assembly. c. Charge pressure relief valve.

i. Put a paper cover over the opening in the charge pump housing and tape in position to keep dirt out.

d. Multi-function valve cartridge assemblies. Use the following procedures to remove, inspect and install the above components of the transmission pump and to remove and replace the complete transmission pump assembly if needed.

GEROTOR CHARGE PUMP.

INSPECTION [See Figure 8-10]. a. Wash the parts with CLEAN diesel fuel and dry using compressed air. b. Inspect the charge pump parts for wear, damage or foreign material. Replace parts if worn or damaged.

REMOVAL/DISASSEMBLY [See Figure 8-10]. CAUTION: Clean the charge pump mounting area of the pump body with diesel fuel and dry with compressed air.

a. Loosen and remove the oil inlet and case drain hoses from the charge pump. QUICKLY put a plug in EACH hose to stop oil from draining from the reservoir.

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CAUTION: ANY visible scoring, cracks or heavy wear in the charge pump gerotor areas or plate indicate that ALL internal charge pump parts MUST be discarded and replaced with NEW. The outer valve plate, the gerotor assembly and the inner valve plate MUST be replaced as a COMPLETE assembly.

8-15

Section 8 TRANSMISSION SYSTEM ASSEMBLY/INSTALLATION [See Figure 8-10]. a. BEFORE installation of ANY new parts, put CLEAN petroleum jelly to the I.D., O.D. and side faces of the gerotor assembly. b. Remove the paper cover from the opening in the charge pump housing. c. CAREFULLY install the inner port plate and the gerotor assembly outer ring. d. Install the alignment pin to properly orient the port plate and outer eccentric ring for corresponding pump rotation. e. Install the gerotor assembly. f. Install the charge pump drive key into the charge pump shaft and retain with petroleum jelly. g. Install the charge pump shaft. The internally splined end of the shaft must engage the main pump shaft.

h. CAREFULLY remove the alignment pin from the housing cavity, WITHOUT moving the position of the aligned parts. Put petroleum jelly on the end of the alignment pin and place the pin into the hole in the charge pump cover. i. Put petroleum jelly on the NEW charge pump cover o-ring. Install the NEW o-ring into the groove in the charge pump cover. j. CAREFULLY install the charge pump cover and alignment pin, into, and over, the aligned parts inside the charge pump housing cavity.

CAUTION: Use CAUTION to NOT move the position of the aligned parts inside the housing cavity. Do NOT damage the o-ring during charge pump cover installation.

k. Install the charge pump cover retainer and the six capscrews. Tighten the capscrews to a torque of 10 ft. lbs. [13.5 N.m].

FIGURE 8-10. TRANSMISSION CHARGE PUMP COMPONENTS.

8-16

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Section 8 TRANSMISSION SYSTEM l. QUICKLY remove the plug from the charge pump oil inlet hose and the cap from the pump fittings. Install and tighten the hose onto the charge pump fitting. Remove the plug from the case drain hose and the cap from the pump fitting. Install and tighten the hose onto the fitting. m. Check the hydraulic oil level in the reservoir and add oil if needed [See Section 4 - MAINTENANCE].

CAUTION: NO repair of the multi-function valve cartridges is possible. The cartridges can ONLY be removed, cleaned and installed OR removed and replaced with NEW. Replace the o-rings with NEW when the new or inspected multi-function valve cartridge is installed into the main pump body.

CAUTION: Follow ALL Transmission System pre-start and start-up procedures BEFORE the engine is started. Damage to the transmission pump can occur if the engine is started without doing the procedures.

MULTI-FUNCTION VALVES. REMOVAL, INSPECTION AND INSTALLATION [See Figure 8-11 and 8-12]. NOTE: The multi-function valve cartridge assemblies incorporate the system check valve, the pressure limiter valve, the high pressure relief valve and the bypass valve. One [1] cartridge controls these functions for the FORWARD direction and one [1] cartridge controls these functions for the REVERSE direction.

MULTI-FUNCTION VALVES

FIGURE 8-11. MULTI-FUNCTION VALVE LOCATIONS.

a. STOP the engine. Clean BOTH multi-function valves and the main pump area where they are installed with clean diesel fuel and dry with compressed air. b. Put a 1.25 in. [32 mm] wrench on the LARGEST hex of the multi-function valve cartridge being removed. Loosen and remove the multi-function valve from the main pump body. Scribe the position [LEFT or RIGHT] on the hex cartridge nut, after the cartridge is removed. If needed, remove and identify the second cartridge assembly. c. Remove the o-rings from the cartridge. Wash the cartridge assembly with CLEAN diesel fuel and dry using compressed air. Inspect the multi-function valve cartridge assembly for ANY damage to the parts.

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FIGURE 8-12. MULTI-FUNCTION VALVE CARTRIDGE ASSEMBLY.

8-17

Section 8 TRANSMISSION SYSTEM d. Put petroleum jelly on the NEW cartridge o-rings and install the o-rings onto the cartridge assembly. Install the cartridge assembly into the CORRECT main pump cartridge location. Tighten the cartridge assembly to a torque of 66 ft. lbs. [89 N.m]. If removed, install the second cartridge assembly using the same procedures.

CAUTION: If installing a cleaned and inspected cartridge assembly, install the cartridge into the SAME main pump body location from which it was REMOVED. Check the system HIGH pressure relief setting of BOTH multifunction valves, using the procedures given in THIS section.

CHARGE CHECK VALVES. REMOVAL, CLEANING, INSPECTION AND INSTALLATION [See Figure 8-13]. a. STOP the engine. Clean multifunction valves and the main pump area where they are installed with clean diesel fuel and dry with compressed air. b. Before removing the multifunction valves, mark the installation position in the pump on them [Top or BOTTOM], so as to maintain the original installation location when installing. c. Remove the multifunction valves from the pump, using a 1 1/4 [32 mm] wrench. d. Remove the o-ring from the cartridge Wash parts with CLEAN diesel fuel and dry using compressed air. Inspect the poppet and mating seat for damage, or foreign material. Assemble the multifunction valve assembly [see this section].

CAUTION: NO repair of the charge check valve is possible. The multifunction valves can ONLY be removed, cleaned and installed OR removed and replaced with NEW. Replace the o-ring with NEW when the new, or inspected multifunction valves are installed.

8-18

MULTI-FUNCTION VALVES

FIGURE 8-13. CHARGE CHECK VALVE LOCATIONS [MULTIFUNCTION VALVES]. e. Install the multifunction valves into the pump housing, as indicated by the position markings made at removal, and torque to 66 ft. lbs. [89 N.m].

MANUAL DISPLACEMENT CONTROL VALVE. REMOVAL AND REPLACEMENT [See Figure 8-14].

CAUTION: There are NO adjustable items in the manual displacement control valve assembly, Except for adjustment of the neutral start switch. ALL functions are FACTORY set by the pump manufacturer.

a. Wash the displacement control valve and the area where it is mounted to the pump housing with clean diesel fuel and dry using compressed air. b. Loosen and remove the control cable from the displacement control handle.

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Section 8 TRANSMISSION SYSTEM MANUAL DISPLACEMENT CONTROL VALVE

f. Remove any gasket material from the control valve and the mating area on the main pump body. g. Inspect the control orifice and spring for damage. Replace the control orifice with one of the SAME size if damaged. h. Remove the paper cover from the opening in the pump body opening. CAREFULLY put the spring and control orifice in position in the control valve housing. Put a NEW gasket on the control valve housing.

CAUTION: Make sure that the spring and control orifice are in, and remain in, the proper position in the pump body.

FIGURE 8-14. MANUAL DISPLACEMENT CONTROL VALVE LOCATION. c. Loosen and remove the six [6] retaining capscrews from the control valve. CAREFULLY swing the control valve away from the main pump housing.

NOTE: The control valve is sealed to the main pump body by the use of a gasket.

CAUTION: Do NOT permit the control orifice or spring to fall into the main pump housing. Keep the control orifice and spring in the control valve housing.

i. Put the pin on the control valve link INTO the mating hole in the link fastened to the swashplate. j. CAREFULLY move the control valve into position against the pump body and hold in position. Align the holes in the control valve with the holes in the gasket and pump body.

NOTE: Check proper engagement of the control linkage pin. Proper engagement will be indicated by centering torque as the control valve arm is moved away from the center position in EITHER direction. NO noted torque indicates the pin is NOT engaged in the swashplate link. Remove the control valve and repeat steps "i and j" if NO torque is noted.

d. Complete removing the control valve by disengaging the pin in the control link FROM the link fastened to the swashplate. CAREFULLY remove the control orifice and spring from the control valve housing.

k. CAREFULLY install the six [6] retaining capscrews through the control valve and into the tapped holes in the pump body. Tighten the capscrews to a torque of 12 ft. lbs. [16 N.m].

e. Cover the area in the main pump body where the control valve was removed with paper to stop dirt from entering the pump.

NOTE: Check the neutral start switch adjustment at THIS time using the procedures given in THIS section.

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8-19

Section 8 TRANSMISSION SYSTEM NEUTRAL START SWITCH. REMOVAL AND REPLACEMENT

NEUTRAL START SWITCH

[See Figure 8-15].

NOTE: Removal and replacement of the neutral start switch can be done WITH the displacement control valve on the pump, and the pump still installed in the machine.

WARNING: Do NOT disturb ANY locknuts or adjustments on the neutral start switch other than those described in THIS procedure. Disturbing other components CAN result in the engine of the machine starting in a position other than when the pump is in the neutral [0 flow] position.

a. Clean the neutral start switch and the area around the switch with CLEAN diesel fuel and dry using compressed air. b. Put an identification tag on EACH wire fastened to the neutral start switch. Loosen and remove the two [2] wires that fasten to the switch.

FIGURE 8-15. NEUTRAL START SWITCH INSTALLED IN DISPLACEMENT CONTROL VALVE.

ADJUSTMENT [See Figure 8-16].

c. Hold the switch in place with one 1.125 in. [29 mm] wrench and CAREFULLY loosen the locknut with another 1.125 in. [29 mm] wrench.

a. Put the control lever arm in the EXACT center of the neutral position. Fasten the leads of a continuity checker to the two [2] screws on the end of the neutral switch.

CAUTION: Do NOT turn the switch when loosening the locknut. Turning the switch can change other critical switch adjustments.

b. Keep the control lever arm in the EXACT neutral position. Turn the switch in a CLOCKWISE [CW] direction until electrical continuity is broken, then turn the switch counterclockwise [CCW] until electrical continuity is obtained. Turn the switch an additional 1/4 turn (90o) more in the same direction after the continuity has been obtained.

d. CAREFULLY remove the switch from the control valve by turning the switch in a COUNTERCLOCKWISE [CCW] direction of rotation. e. CAREFULLY install the NEW switch by turning the switch in a CLOCKWISE [CW] direction of rotation UNTIL finger tight. Leave the locknut loose at THIS time.

CAUTION: Check the neutral start switch ADJUSTMENT using the following procedures at THIS time.

8-20

c. Hold the switch in this position with one [1] 1.125 in. [29 mm] wrench and tighten the locknut with another 1.125 in. [29 mm] wrench to 20 ft. lbs. [27 N.m]. d. Leave the continuity checker attached to the switch and move the control lever arm in each direction to assure continuity is broken when the control is NOT in the neutral position.

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Section 8 TRANSMISSION SYSTEM TRANSMISSION PUMP SHAFT SEAL. REMOVAL, INSPECTION AND INSTALLATION [See Figure 8-17]. The transmission pump assembly MUST be loosened and moved away from the pump mounting plate and flex drive plate, or be removed from the machine [see THIS section for procedures], BEFORE the shaft seal can be removed and replaced with NEW.

CAUTION: ALL shaft seal parts MUST be replaced with NEW after removal. FIGURE 8-16. NEUTRAL START SWITCH ADJUSTMENT.

e. Remove the continuity checker from the switch and connect the two [2] wires to the switch per the identification tag fastened on each wire.

a. With the INPUT shaft end of the pump assembly moved away from the pump mounting plate and the shaft splines fully disengaged from the flex drive plate OR the pump assembly removed from the machine, position the pump with the shaft facing up.

PRESSURE LIMITER VALVES.

NOTE: If the pump is positioned horizontally when the shaft is removed, the cylinder block could move out of place, making shaft installation difficult.

REMOVAL, INSPECTION AND INSTALLATION [See Figure 8-12].

b. Remove the three [3] capscrews that hold the retainer plate to the main pump body.

EACH pressure limiter valve is contained in the multi-function valve cartridge assembly and is serviced through the removal, cleaning, inspection and installation of the cartridge assembly [See THIS section].

CAUTION: Check the adjustment of the pressure limiter valves, using the information found in THIS section. See the "PRESSURE LIMITER AND HIGH PRESSURE RELIEF VALVE PRESSURE CHECK AND ADJUSTMENT" procedure.

c. CAREFULLY move the retainer plate.

NOTE: The seal carrier is held in place by the friction of the o-ring on its outside diameter. An outward spring force on the input shaft will tend to overcome the friction from the o-ring on the seal carrier and push the seal carrier outward. If the seal carrier does NOT move from its bore after removal of the capscrews, CAREFULLY pry the carrier toward the end of the shaft UNTIL the o-ring is free, using two [2] screw drivers against the outside of the housing.

CAUTION: Do NOT damage the cover OR pump body bore during removal. Do NOT remove the input shaft. After the seal cover is removed, the shaft will be in a free condition and can be removed or fall from the pump body.

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8-21

Section 8 TRANSMISSION SYSTEM RETAINING PLATE

SCREW

SEAL CARRIER

ROLLER BEARING ASSEMBLY

RETAINING RING SEAL

O-RING

FIGURE 8-17. TRANSMISSION PUMP SHAFT SEAL INSTALLATION. d. Remove the o-ring from the seal carrier. e. Place the seal cover in an arbor press and remove the old seal from the cover. f. Wash the parts in CLEAN diesel fuel and dry with compressed air. Inspect the seal carrier, the NEW seal and o-ring for ANY damage or nicks.

NOTE: The outside diameter of the seal may be lightly coated with a sealant (such as Loctite High Performance Sealant #59231) prior to installation. This aids in preventing leaks caused by damage to the seal bore in the seal carrier. g. Using the arbor press, CAREFULLY install the new shaft seal into the seal carrier.

CAUTION: Do NOT damage the seal during installation.

8-22

h. Inspect the sealing area on the input shaft for rust, wear or contamination. If the shaft is not being replaced, proceed to step "l". i. Remove shaft and roller bearing assembly from the pump. The bearing assembly can be transferred to the new shaft. j. Remove the retaining ring that secures roller bearing assembly with a snap ring pliers. Remove the roller bearing assembly. k. Place roller bearing assembly on new shaft and secure with the retaining ring. l. Put thin plastic film, or equivalent, around the input shaft splined area to protect the sealing lip on the seal during installation.

CAUTION: Do NOT install ANY shaft seal parts over the input shaft BEFORE covering the shaft with the protective film.

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Section 8 TRANSMISSION SYSTEM m. Put petroleum jelly on the sealing lip and seal carrier o-ring. CAREFULLY put the seal carrier and seal over the input shaft and into the pump bore.

CAUTION: Hold the seal carrier in position. The seal carrier will have a small spring load at this time due to the outward spring force on the input shaft.

INSTALLATION [See Figure 8-18]. Install the transmission pump by using the procedures given in THIS section [see FLEX DRIVE PLATE INSTALLATION].

ADJUSTMENT OF THE TRANSMISSION DIRECTION CONTROL CABLE [See Figure 8-19].

n. Install the retainer plate and capscrews and tighten to a torque of 12 ft. lbs. [16 N.m]. o. CAREFULLY remove the plastic film from around the input shaft. Install the transmission pump splined input shaft into the splined drive sleeve and position the pump against the pump mounting plate. Install the four [4] pump retaining capscrews and tighten to a torque of 80 ft. lbs. [108 N.m].

COMPLETE TRANSMISSION PUMP ASSEMBLY. REMOVAL [See Figure 8-18]. CAUTION: Remove the COMPLETE pump assembly, from the machine, ONLY after correctly and fully checking the pump. Use pressure check and flow rate test procedures, that will indicate internal component failures which REQUIRE the pump be removed for repair or replacement. MAJOR transmission pump repair procedures WILL effect warranty. See your nearest Distributor and refer to the "Warranty Policies and Procedures" before removing a transmission pump assembly and/or having major repair done to the transmission pump assembly.

Remove the transmission pump by using the procedures given in THIS section [see FLEX DRIVE PLATE REMOVAL].

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Use the following procedure to adjust the transmission direction control cable, after the pump has been removed, repaired or replaced and installed back into the machine. a. STOP the engine. Keep the engine in the "OFF" condition. Put the direction control [F-N-R] handlever in the CENTER of the NEUTRAL position.

WARNING: NEVER adjust the transmission direction control cable with the engine in a "running" condition.

NOTE: Be sure the rod end is in the CENTER of the cable threads and the locknut is tightened against the rod end.

b. Put the transmission control lever, found on the displacement control valve, in the CENTER of the NEUTRAL position and at a position 90o to the control cable axis. c. Adjust the ball joint, found on the transmission pump end of the direction control cable, so that the threaded ball stud of the ball joint aligns with the through hole in the transmission lever and tighten the jam nut.

CAUTION: There should be NO tension on the ball joint when the pump lever and the control handlever are BOTH in the NEUTRAL position.

d. Check the neutral start switch for correct operation when the transmission pump is in the neutral condition [see THIS Section].

8-23

Section 8 TRANSMISSION SYSTEM ADJUSTMENT OF THE THROTTLE CONTROL LINKAGE [See Figure 8-19]. CAUTION: To help avoid possible transmission pump damage, with the throttle control linkage correctly adjusted, the engine MUST reach 1200 RPM BEFORE the pump starts to stroke in either direction.

Use the following procedure to adjust the throttle control linkage, after the pump has been removed, repaired or replaced and installed back into the machine. a. Center the directional control lever using the neutral lock. The auxiliary throttle lever should be at the lowest possible setting. FIGURE 8-18. TRANSMISSION PUMP ASSEMBLY - INSTALLED IN THE MACHINE.

e. Pre-charge the hydraulic systems using the procedures given in THIS section.

CAUTION: Do NOT start the engine UNTIL after ALL pre-start procedures have been completed.

b. Cables should be installed in the position as shown in figure 8-19. c. While holding the distance between the threads on the throttle cable and the top of the bracket to 0.25 - 0.75" [see figure 8-19], adjust the bracket in the slots so that the slack is removed evenly from both cables attached to the directional control lever. Tighten bracket's mounting hardware at this position.

NOTE: Some slack may be present in the cables. f. Start the engine. Check the transmission system for CORRECT operation.

WARNING: Keep ALL personnel, except the operator, CLEAR of the machine while checking the system operation.

d. Adjust the ball joint on the engine throttle so that no slack is present in the cables with throttle at low idle.

NOTE: At full stroke forward or reverse, engine throttle spring should stretch to account for over stroke.

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Section 8 TRANSMISSION SYSTEM AUXILIARY THROTTLE LEVER

0.25 TO 0.75

LUBRICATE BOTH ENDS WITH MULTIPURPOSE GREASE TO HYD. PUMP

BRACKET TO THROTTLE

INJECTOR PUMP LEVER

FIGURE 8-19. TRANSMISSION CONTROL CABLE AND THROTTLE CONTROL LINKAGE ADJUSTMENT.

TRANSMISSION PUMP PRESSURES. CHECKING AND ADJUSTMENT PROCEDURES. The following information describes the different pressure check locations, gauge sizes needed, correct pressures and suggested methods for changing an incorrect system pressure. Capped system gauge ports are provided for the various pressure checks usually needed to be made.

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WARNING: Keep ALL personnel, except the operator and an assistant - when needed, CLEAR of the machine during pressure checking procedures. Use ONLY the CORRECT gauge, on a hose, for each pressure check.

CAUTION: The hydraulic system oil MUST be at "NORMAL OPERATING" temperature and at the correct level BEFORE any pressure check is taken. The engine throttle MUST be in the "HIGH IDLE" condition for ALL pressure checks. The SECONDARY/PARKING brake system control switch MUST be in the "ON" condition for ALL pressure checks.

8-25

Section 8 TRANSMISSION SYSTEM CHARGE PRESSURE [See Figure 8-20]. The capped CHARGE pressure check port is located on the left side of the transmission pump. Check and, if needed, adjust THIS pressure as follows: FORWARD HIGH PRESSURE CHECK PORT

SOLENOID [STACK] VALVE NEEDLE VALVE

BRAKE PILOT PRESSURE CHECK POINT

REVERSE HIGH PRESSURE CHECK PORT

CHARGE PRESSURE CHECK PORT

FIGURE 8-20. PRESSURE CHECK PORT LOCATIONS. a. Put the secondary/parking brake system control switch "ON" [APPLIED]. STOP the engine. b. Close the needle valve located below the solenoid valve [See Figure 8-21].

c. Wipe the charge pressure check port cap and the area around it with a CLEAN cloth.

FIGURE 8-21. BRAKE NEEDLE VALVE LOCATION f. Put the auxiliary throttle in the "HIGH" idle position and the secondary/parking brake system control switch "OFF" position. Leave the transmission direction control handlever in the NEUTRAL position. Have an assistant note the neutral charge pressure indicated on the pressure gauge. The CORRECT NEUTRAL charge pressure is 350 psi. [24 bar] MINIMUM to 400 psi. [28 bar] MAXIMUM. g. Slow the engine to "LOW" idle speed and run for a period of 3-5 minutes. STOP the engine.

NOTE: The charge relief pressure MUST be adjusted IF the charge pressure noted was NOT as given ABOVE. Use the following ADDITIONAL information. Low charge pressure, at LOW IDLE and at HIGH IDLE, can also indicate possible internal charge pump leakage, which requires removal, repair or replacement of the gerotor charge pump assembly.

d. Remove the cap from the charge pressure check port. Install a 600 psi. [41 bar] gauge, on a short hose, onto the check port fitting and tighten securely.

1. Keep the engine in the "OFF" condition. Clean the area of the charge pump section where the charge relief valve assembly is installed [See Figure 8-22].

e. With the secondary/parking brake system control switch "OFF" position and unit in high speed range, test brakes by stroking the transmission direction control handlever to full stroke in both directions. Brakes must stall full motor torque in high speed range.

2. Loosen the lock nut with a 1-1/16 in. wrench and turn the adjustment plug with a large screwdriver. Clockwise rotation of the plug increases the setting, and counterclockwise rotation decreases the setting [at a rate of approximately 50 psi. [3.5 bar] per turn].

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Section 8 TRANSMISSION SYSTEM PRESSURE LIMITER SYSTEM AND HIGH PRESSURE RELIEF VALVE PRESSURE CHECK AND ADJUSTMENT [See Figure 8-20]. CHARGE RELIEF VALVE

The two [2] capped high system pressure check ports are found on right side of the transmission pump.

NOTE: The ONE [1] pressure check port is for HIGH pressure check in the FORWARD direction and the other pressure check port is for HIGH pressure check in the REVERSE direction of travel.

a. Put the secondary/parking brake system control switch "ON" [APPLIED]. STOP the engine. FIGURE 8-22. CHARGE RELIEF VALVE LOCATION. 3. While holding the plug with the screwdriver, torque the lock nut to 38 ft. lbs. [52 N.m]. 4. Check the charge pressure, again, using the ABOVE procedures. Repeat the adjustment procedure UNTIL the pressure indicated is CORRECT. h. STOP the engine. Loosen and remove the gauge and hose assembly from the pressure check port. Install and tighten the check port cap. i. Put the secondary/parking brake system control switch "ON" [APPLIED]. j. Open the needle valve located below the solenoid valve [See Figure 8-21].

b. Close the needle valve located below the solenoid valve [See Figure 8-21].

NOTE: The brakes are now set in the drive motors and can not be released with the switch on the dash unless the needle valve is manually opened [CCW]. This condition is necessary to accurately set up and inspect the unit. c. Clean BOTH high pressure check port caps and the area around them with a CLEAN cloth. d. Remove BOTH of the caps from the two [2] high pressure check ports. Use two [2] 10,000 psi. [690 bar] pressure gauges, connected to hoses that will reach the operator's compartment. Place BOTH gauges in a position in the operator's compartment, so that they can be clearly seen during the "high pressure check" procedure.

WARNING: Except for the OPERATOR, Keep ALL personnel CLEAR of the MACHINE and the surrounding AREA during THIS "pressure check" procedure. Maximum high system pressure will be developed during THIS pressure check procedure.

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8-27

Section 8 TRANSMISSION SYSTEM e. Start the engine. Put the transmission speed range control switch in the "LOW" position. Put the engine throttle in the "HIGH" idle position. SLOWLY move the direction control handlever from the NEUTRAL position toward the full FROWARD direction of machine travel position. Watch the gauge indicating "HIGH" pressure for THIS direction, and note the HIGHEST pressure indicated. Return the direction control handlever to the NEUTRAL position. Move the handlever from the neutral position toward the full REVERSE direction of machine travel position. Watch the gauge indicating "HIGH" pressure for this direction, and note the HIGHEST pressure indicated. Return the direction control handlever to the NEUTRAL position. Put the throttle in the "LOW" idle position and run the engine 3-5 minutes to cool the engine and components. STOP the engine.

CAUTION: The correct "HIGH" pressure noted in both directions MUST be 6200 +/- 100 psi. gauge pressure. This is the pressure where the pressure limiter sensing valve for each direction of travel will begin to open and destroke the pump. ANY pressure indicated, in either or both directions, which is NOT correct will require that the pressure limiter sensing /pressure relief valve for THAT direction be adjusted. If either, or both relief pressures, were NOT correct use the following additional information to adjust the pressure limiter sensing/pressure relief valve assemblies.

NOTE: Adjustment of the pressure limiter system and the high pressure relief valve settings for both is accomplished by using the same procedure, at each multifunction valve cartridge assembly. The FORWARD direction pressure limiter/ high pressure relief adjusting screw is found at the end of the UPPER multifunction valve cartridge assembly [See Figure 8-23]. The REVERSE direction pressure limiter/high pressure relief adjusting screw is found at the end of the LOWER multi-function valve cartridge assembly [See Figure 8-23].

8-28

FIGURE 8-23. MULTI-FUNCTION VALVE ADJUSTMENT. 1. Put the transmission speed range control toggle switch in the "LOW" position.

DANGER: To be able to correctly make the HIGH pressure relief valve adjustments, an assistant is required and the transmission system MUST reach MAXIMUM system pressure. The secondary/parking brake system, and the additional wooden blocking, MUST assure that the machine is kept from ANY movement during this adjustment procedure.

NOTE: A plastic dust plug is installed in the adjusting screw.

2. Loosen locking nut [smallest hex on multifunction valve] with a 19 mm wrench on the multi-function valve to be adjusted.

NOTE: The FORWARD direction pressure limiter/ high pressure relief adjusting screw is found at the end of the UPPER multifunction valve cartridge assembly [See Figure 8-23]. The REVERSE direction pressure limiter/high pressure relief adjusting screw is found at the end of the LOWER multi-function valve cartridge assembly [See Figure 8-23].

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Section 8 TRANSMISSION SYSTEM 3. Insert a 5 mm internal hex wrench into the pressure adjusting screw. Turn the adjusting screw, a small amount, to change the pressure.

NOTE: Clockwise [CW] rotation of the pressure adjusting screw will INCREASE the relief pressure setting. Counterclockwise [CCW] rotation of the pressure adjusting screw will DECREASE the relief pressure setting. Each complete rotation of the pressure adjusting screw changes the pressure setting by approximately 1,350 psi. [93 bar].

6. Have the operator slow the engine to "LOW" engine idle and move the transmission direction control handlever to the NEUTRAL position. 7. If required, adjust the opposite direction setting in the same manner. f. STOP the engine. Loosen and remove both gauge and hose assemblies from the "HIGH" pressure check ports. Install and tighten the port cap onto each fitting. g. Put the secondary/parking brake system control switch "ON" [APPLIED]. h. Open the needle valve out [CCW] to its stop.

4. To verify the actual pressure setting, keep the transmission speed range selector toggle switch in the "LOW" position. Start the engine, and then put the engine throttle in the "HIGH" idle position. Put the transmission direction control handlever in the direction being adjusted. Note the pressure indicated on the pressure gauge.

DANGER: ONLY allow the operator and the person making the pressure adjustments near the machine. ALL other personnel MUST be kept CLEAR of the area around the machine.

NOTE: The pressure limiter system and high pressure relief valve pressures are reached when the pressure remains STEADY at the CORRECT pressure level.

5. While still watching the pressure gauge, CAREFULLY hold the adjusting screw in the SAME position where the relief pressure is CORRECT. CAREFULLY tighten the lock nut while keeping the adjusting screw in the SAME position, so that the pressure gauge indicates the CORRECT relief pressure. Torque the lock nut to 12 ft. lbs. [16 N.m].

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SHUTTLE [FLUSHING] VALVE FLOW [See Figure 8-24].

DANGER: SERIOUS INJURY, or DEATH, can occur if the shuttle valve is NOT adjusted correctly and causes a loss of correct machine directional control. CORRECT adjustment of the hydrostatic transmission system shuttle valve is critical to correct machine performance, and efficiency of the cooling system. Always use the information given below to correctly adjust the shuttle valve after service to, or replacement of, the valve.

a. Put the secondary/parking brake system control switch "ON". STOP the engine.

8-29

Section 8 TRANSMISSION SYSTEM c. Wipe the case drain RETURN oil hose fitting and the 90 degree fitting it connects to, at the shuttle valve, with a CLEAN cloth. d. Loosen the RETURN oil hose at the 90o fitting at the control shuttle valve. Remove the hose from the 90o fitting. Install a 0-5 GPM flowmeter [flow direction is from the shuttle valve to the transmission pump]. e. Start the engine. With the secondary/parking brake system control switch "OFF", put the auxiliary throttle in the "HIGH" idle position. f. Slowly stroke the transmission direction control handlever in the FORWARD direction until the transmission begins to drive against the brake. DO NOT operate under these conditions for more than a few seconds. Note the shuttle flow indicated on the flowmeter. FIGURE 8-24. SHUTTLE [FLUSHING] VALVE.

b. Close the needle valve located below the solenoid valve [See Figure 8-25].

SOLENOID [STACKED] VALVE NEEDLE VALVE

BRAKE PILOT PRESSURE CHECK POINT

g. Put the transmission direction control handlever in the NEUTRAL position and then slowly stroke the transmission direction control handlever in the REVERSE direction until the transmission begins to drive against the brake. DO NOT operate under these conditions for more than a few seconds. Again, note the shuttle flow indicated on the flowmeter.

NOTE: Both flow readings MUST be 4.25 +/-0.25 GPM.

h. Slow the engine and allow to run at "LOW" idle speed for a period of 3-5 minutes. STOP the engine.

NOTE: The shuttle valve MUST be adjusted if the flows noted were not as given above. Use the following ADDITIONAL information.

1. Keep the engine in the "OFF" condition. Clean the area of the shuttle valve where the adjusting valve is installed. 2. Loosen the lock nut. Using a large screwdriver, turn the adjustment plug inward [CW], toward the valve body, or outward [CCW], away from the valve body a small amount.

FIGURE 8-25. BRAKE NEEDLE VALVE LOCATION

8-30

3. Recheck the shuttle valve flow.

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Section 8 TRANSMISSION SYSTEM 4. After adjusting the shuttle valve flow, check the charge pressure in the forward and reverse direction, using the procedures given in this section. The minimum charge pressure under load must be 350 psi. The maximum charge pressure at no load high idle must not exceed 400 psi. If necessary, adjust the charge pressure using the procedures given in this section. Then recheck the shuttle valve flow. i. STOP the engine. Remove the flowmeter and reconnect the hose to the shuttle valve. j. Put the secondary/parking brake system control switch "ON" [APPLIED]. k. Open the needle valve out [CCW] to its stop.

DRIVE MOTOR/BRAKE ASSEMBLIES. DESCRIPTION [See Figures 8-26]. The two [2] LOW speed - HIGH torque drive motors are a two [2] speed multi-lobe radial piston type, with a multi-disc brake system integral inside each drive motor. Each drive motor contains two drive flanges containing the mounting studs. Two wheels are mounted on each drive motor.

FIGURE 8-26. DRIVE MOTOR/BRAKE.

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Each drive motor contains the following five [5] MAJOR parts: Front bearing support assembly. Cylinder block assembly, with ten [10] pistons. Cam ring, having eight [8] lobes. Valving assembly, with a two [2] speed change pool. Brake assembly.

OPERATION [See Figure 8-27]. In the forward, or reverse, direction of machine travel, HIGH pressure oil from the transmission pump flows to the drive motors. Selecting the "LOW" speed range, using the control switch found on the console, keeps both transmission low/high range solenoids in the, spring applied, low range position. The high pressure oil enters each drive motor at the valving [oil distributor] assembly. High pressure oil then is distributed to the ten [10] pistons and uses ALL eight [8] cam ring lobes as "power lobes" for the "LOW" speed range, FULL displacement, of the drive motors. Selecting the "HIGH" speed range, using the control switch found on the console, energizes both transmission low/high range solenoids, moving the spools to the high range position. The high pressure oil is distributed to the ten [10] pistons, ONE HALF of the time in each revolution, and, thereby, uses ONLY four [4] cam ring lobes as "power lobes". This will put the drive motors at ONE HALF displacement and is the "HIGH" speed range. Selecting the "MEDIUM" speed range, using the control switch found on the console, energizes the LH transmission low/high range solenoid, moving the spool to the high range position. The RH transmission low/high range solenoid will remain in the low range position. This will put the LH drive motor at ONE HALF displacement and the RH drive motor will remain at FULL displacement. Because the supply for the two drive motors are teed together, the mixed displacement causes a "MEDIUM" speed range.

8-31

Section 8 TRANSMISSION SYSTEM

2 3 1

8 5 7

15 14 16

26 33

28 38 29 30

40 42

19 35

1 39

12 11

10 13 17 23 25

22 32

47 45

1. PISTON 2. KIT, SEALING 3. PISTON 4. CAM 5. O-RING 6. VALVING COVER 7. SCREW 8. GASKET 9. SCREW 10. SEAL 11. VALVING/DIST. 12. SEAL KIT 13. SPRING 14. VALVE SPOOL 15. WASHER 16. SNAP RING

17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32.

SPRING SEAL SHAFT SPACER SLEWING RING RING BEARING SUPPORT SEAL RING SCREW SHIM SET HUB WASHER SCREW STUD O-RING

33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48.

THRUST RING O-RING RING BEARING SEAL DEFLECTOR DISC DISC SHIM SET O-RING O-RING O-RING BRAKE PISTON SUPPORT SPRING SCREW

FIGURE 8-27. TRANSMISSION DRUM DRIVE MOTOR - FULL SECTIONED VIEW.

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Section 8 TRANSMISSION SYSTEM Energizing a transmission low/high range solenoid moves the spool in the solenoid valve. The spool movement permits oil, at charge pressure, to flow to the HIGH speed port on its drive motor valving assembly. The oil flow moves a pilot spool in the center of the valving assembly, which lowers the "used" displacement of that drive motor. EACH of the ten [10] pistons will have HIGH pressure applied to the back of the piston and begin to move outward in its bore just after it passes the HIGH pressure ports. EACH piston pushes the piston and roller assembly against the cam ring. This action causes the COMPLETE cylinder block assembly to rotate and turn the splined drive and brake shaft. The profile of the cam ring is calculated to create a constant angular displacement of the drive motor as each piston and roller assembly moves by the high pressure port, in the valve block assembly. The distribution of the pistons make them balanced for smooth torque. As the piston and roller assemblies continue to follow the curved contour of the cam ring, the curving shape causes the assemblies to move inward again. This action causes the roller assembly to push the piston inward. This inward movement of the piston is timed with the piston passing the "LOW" pressure port, of the valve block assembly, for that piston in that direction. The oil, which now is under low pressure, enters the "LOW" pressure port of the valve block assembly and is directed to the "LOW" pressure hose which is fastened to the top of the valve housing. The oil, now under "LOW" pressure, flows from each drive motor. The "LOW" pressure oil then flows to the LOW pressure side of the transmission pump in the "closed loop" system. Changing the direction of machine travel will only reverse the direction that the oil, under HIGH and LOW pressures, will flow. This change will cause the drive motors to turn in the opposite direction of rotation, but in the same method as described above.

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Oil from any drive motor internal leakage flows from the case port of each drive motor to a "tee" fitting. From the "tee" fitting the oil flows to a point in the oil return line where it joins the return oil from the transmission pump. The secondary/parking brake system is a integral assembly on each drive motor. The multi-disc, spring applied and hydraulically released brake uses hydraulic oil, at a pressure of 175 psi. [12 bar] minimum to 435 psi. [30 bar] maximum, to release the spring applied disc brakes on both drive motors. When the secondary/parking brake system control switch is placed at "ON" [BRAKES APPLIED], the release piston, in each drive motor, is stopped from having oil pressure applied to it. The multi-disc brakes in each drive motor are applied by spring pressure and the brake shaft is stopped from turning.

NOTE: LACK of hydraulic pressure, against the release piston from ANY cause, WILL permit the multi-disc brakes to be applied by spring pressure.

When the secondary/parking brake system control switch is placed at "OFF" [BRAKES RELEASED], electrical current will energize the "brake release" solenoid. The solenoid moves a spool found in the "solenoid valve" which permits oil, at approximately "charge pressure", to flow from the outlet of the "solenoid valve" to each drive motor brake release pressure port. The oil enters the release port and is directed internally to the pressure side of the multidisc brake release piston of each drive motor. The hydraulic pressure moves the release piston. The piston releases the multi-disc brakes by overcoming the pressure of the twenty one [21] brake apply springs. The brake shaft, which is splined to the drive motor cylinder block assembly, is then free to turn with the cylinder block assembly.

8-33

Section 8 TRANSMISSION SYSTEM REMOVAL [See Figure 8-26]. CAUTION: Remove a drive motor assembly from the machine only after correctly and fully checking the drive motor. Use pressure check and flow rate test procedures that will indicate internal component failures which require the drive motor be removed, disassembled, and inspected.

a. Install SOLID wooden blocks in the front and rear of the rear tires.

WARNING: Block SECURELY.

b. Use a floor jack, having a capacity more than 10,000 lbs. [4540 kg], to carefully lift each side of the front frame, so that the tires just is clear of the floor. Put SOLID wood blocks, or jack stands, under each side of the front frame.

e. Fasten a sling and hoist, having a capacity MORE than 500 lbs. [227 kg], around the circumference of the drive motor. Use the hoist to apply tension to the sling to keep the drive motor in position when the retaining screws and nuts are removed. f. Loosen and remove the eight [8] flange screws and flanged locknuts, that hold the drive motor to the front frame. g. Check to be completely sure that all hoses requiring disconnection have been disconnected from the drive motor and all hoses and fittings are correctly capped or plugged. h. CAREFULLY lower the drive motor from the machine and move the motor to a CLEAN surface, in a clean work area.

WARNING: Do NOT get under the drive motor while moving or lowering the drive motor.

DISASSEMBLY [See Figure 8-27]. WARNING: Block securely under the machine frame area, with SOLID wood blocks or jack stands. Keep clear of the frame sides, blocks or stands and jacks. When lifting, blocking and lowering the machine.

CAUTION: Clean the area around the hydraulic components BEFORE loosening and removal of the hoses.

c. Remove the inner and outer tires from the drive motor to be removed. d. Put identification tags on all hydraulic hoses that are connected to the drive motor being removed. Disconnect and remove all of the hoses which fasten to the drive motors. Put plugs and caps on all hoses and fittings.

CAUTION: ALL capscrews used to fasten the components are of the "METRIC SIZE", and always must be replaced and tightened to torques accordingly. ALL components [seals, bearings, springs etc.'] are also "METRIC SIZED" and must never be replaced with "standard sized" replacement parts.

a. Clean the drive motor again to remove any remaining dirt. Place the drive motor assembly in a VERTICAL position with the brake assembly end, of the drive motor, at the bottom. b. Put a scribed VERTICAL reference line on the side of all external bolted together assemblies.

NOTE: BE sure the line is clear for CORRECT position of assemblies during assembly.

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Section 8 TRANSMISSION SYSTEM c. Loosen and remove the four screws (30) that fasten the washer (29) to the end of the shaft (19) and remove the washer. d. Remove hub (28), o-ring (34) and shims (27) from the shaft (19). Discard the o-ring. Do not discard the shims.

q. Remove and discard the o-ring (5) from the slewing ring (21). r. Carefully remove the cylinder block (1) and spacer (20). Put the cylinder block on a clean surface for further disassembly and inspection later, If needed.

e. Remove the thrust ring (33) from the shaft (19) and remove the o-ring (32) from the inside of the thrust ring. Discard the o-ring.

s. Disassemble the secondary/parking brake using the following additional procedures.

f. Using a press, press the shaft (19) out of the drive motor.

WARNING: The support (46) and slewing plate (21) are under spring pressure. Use care when removing the screws (48).

g. Remove the 10 screws (26) securing the bearing support (24) and remove the support. h. Remove the bearing (23) and seal ring (25) from the inside of the bearing support (24).

1. Turn the assembly over and remove twelve [12] screws (48) secure support (46) to slewing plate (21).

i. Remove the spring (17) and the valve spool (14) from valving cover (6).

2. Remove support (46) and twenty one [21] springs (47).

j. Remove the two o-rings (10 and 18) from the valving cover (6). Discard the o-rings.

3. Remove the seal (37), bearing (36) and seal ring (35) from support (46).

k. Remove the twelve [12] screws (7) securing valving cover (6) and remove the valving cover.

4. CAREFULLY remove the brake piston (45) from the slewing plate (21), by applying a small amount or air pressure through the brake release oil supply port.

CAUTION: Ensure that valve block (11) does not drop out of valving cover (6) when removed.

l. If disassembly, inspection and/or replacement of valve block seals is needed, use a permanent marker to mark the position of the valve block (11) in relation to the valving cover (6).

WARNING: Keep clear of the brake piston during removal procedures. Do NOT use an air supply having more than 30 psi. [2 bar] of pressure. Use ONLY a small burst of air to move the brake piston outward from the bore.

m. Remove the valve block (11) from the valving cover (6).

5. Remove the two [2] o-rings (42 and 43) from the brake piston (45).

n. Remove and discard the seals (12) from the inside of the valving cover (6).

6. Remove the internal and external brake discs (39 and 40) alternately from the splined cavity of the slewing plate (21).

o. Remove and discard the o-ring (5) from the end of the valving cover (6). p. Remove cam ring (4).

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NOTE: Keep the internal and external brake discs in the same order in which they were installed for easier assembly later.

8-35

Section 8 TRANSMISSION SYSTEM INSPECTION [See Figure 8-27]. a. Carefully wash ALL bearings, housings and other LARGE components in clean diesel fuel and dry with compressed air.

CAUTION: Do NOT wash the SMALLER components at the same time as when washing LARGER components. Items such as internal and external brake discs MUST be kept in the order of removal and need to be cleaned in a method that will keep that order. Clean and dry these parts separately and place back in the SAME position as they were in, before cleaning, for CORRECT assembly position later.

c. Inspect the outer surface of the rollers, which contact the cam ring "lobe area", for wear or damage. Replace ALL roller assemblies, with NEW, if ANY are found to have wear, or damage. Inspect the roller segments. Replace All segments, with NEW, if ANY are found to have wear or damage.

CAUTION: ALWAYS replace the roller guide rings, with NEW, if the rollers are replaced with new.

d. CAREFULLY inspect the roller cam area, of the cam ring (4), for wear, or damage. The area of the roller cams are induction hardened and must NOT show evidence of "flaking" or of pieces of metal eroded from the roller cam surfaces. Replace the COMPLETE assembly IF worn, or damaged.

b. If removed, inspect EACH piston and EACH bore for wear, seizure or damage. Replace any piston that is found to be worn, seized or damaged with NEW. Replace the complete cylinder block (1) with NEW if ANY piston bore is found to be worn or damaged.

e. CAREFULLY inspect the valving [distributor] block (11) for any damage which can be noted visually. Inspect the mating surfaces of the distributor block (11) and cylinder block (1) for damage or scratches. Remove any scratches by polishing OR replace a part found to be severely damaged.

CAUTION: A COMPLETE failure of the drive motor will usually result in severe wear, or damage, to ALL pistons, rings and piston bore areas. REPLACE the COMPLETE cylinder block assembly, with new, if the above wear and/or damage is noted.

f. Inspect the condition of the drive shaft (19) and its splined areas. There must be NO wear that is able to be felt with the fingernail on ANY smooth surface where the seals mate the drive shaft. The splines must NOT indicate fretting, breakage, twisting or other damage. Replace the drive shaft (19) if worn or damaged as noted above. g. CAREFULLY inspect the inner AND outer roller bearings (23 and 36) for wear, or damage. BOTH bearings MUST turn freely without ANY binding or roughness being noted. Replace a bearing found to be worn, or damaged, with a NEW bearing during assembly of the drive motor.

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Section 8 TRANSMISSION SYSTEM h. CAREFULLY, visually inspect the condition of the internal AND external brake discs (39 and 40). The discs must NOT show evidence of heavy wear, or be cracked, chipped or broken. Replace ALL discs with NEW and keep the SAME order in which they were removed, if ANY are found to be worn, or damaged.

NOTE: The internal and external discs MUST, ALSO, be further checked for correct TOTAL thickness. The TOTAL thickness of ALL the discs must NOT be LESS than 2.047 in. [52 mm] including the 11.7 mm shim (41). Replace ALL of the internal and external discs IF the disc thickness is LESS than the ABOVE figure.

ASSEMBLY [See Figures 8-27]. CAUTION: ALL capscrews used to fasten the components are "METRIC SIZE", and always must be replaced and tightened to torques accordingly. ALL components [seals, bearings etc.'] are also "METRIC SIZED" and must never be replaced with "standard sized" replacement parts.

a. Stand the shaft (19) on end on a CLEAN work surface. Place the slewing plate (21), upside-down, on the shaft in order to align and center the discs. b. Oil all the discs.

CAUTION: If the multi-disc brake did NOT hold the machine, during operation, BEFORE the drive motor was removed, replacement of ALL of the INTERNAL and EXTERNAL brake discs is a MUST. Do NOT add shims to compensate for wear to the internal and external brake discs.

i. CAREFULLY, visually inspect the twenty one [21] brake apply springs (47) for damage or lack of tension due to "over heat" conditions. Replace ALL springs with NEW if ANY are found to be damaged or show a loss of tension. j. CAREFULLY inspect the brake release piston (45) for damage. Replace the piston with NEW if any damage was noted.

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c. Install the 11.7 mm shim (41), then starting with an external brake disc, install the external and internal brake discs (39 and 40) alternately over the shaft (38) and into the slewing plate (21). d. Put the brake release piston (45), WITHOUT the o-rings (42 and 43), on the top of the brake discs. e. Use a press to apply pressure to the piston and compress the brake discs. Measure the distance from the top of the brake release piston (45) to the mounting surface of the slewing plate (21) as shown in Figure 8-28.

NOTE: A force of 220 lbs. [100 kg] is required to properly compress the assembly for measurement.

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Section 8 TRANSMISSION SYSTEM f. Write the measurement found in step "e" on a paper and SUBTRACT the amount of 0.535 inches [13.6 mm]. Make a shim pack EQUAL to the amount found, AFTER the subtraction. g. Release the pressure being applied to the piston and discs by the press. Remove the piston from the brake housing bore.

o. Apply grease in the area between the seals (35 and 37) the bearing (36). p. Grease and install a new o-ring (44) on bearing support (46). q. Place the twenty one [21] springs (47) on the piston (45). r. Position the bearing support (46) on the slewing plate (21) and install screws (48). Tighten the screws to a torque of 48 ft. lbs. [5.5 N.m]. s. Put the drive shaft into position, so that it will install into the front bearing support (46) from the outer side. Use a press to CAREFULLY install the drive shaft into the front bearing support housing.

FIGURE 8-28. DETERMINING SHIM PACK.

h. Insert the shim pack made in step "f", on top of the last brake disc in the multi-disc stack. i. Put clean hydraulic oil on the NEW o-rings (42 and 43) to be installed on the brake release piston (45). Install the o-rings onto the piston. CAREFULLY install the brake release piston into the slewing plate (21). j. Remove the shaft (19) from the brake assembly. k. Place the bearing cup (36) in the bearing support (46). Use an arbor press and a sleeve, having an outside diameter of 5.83 inches [148 mm], to install the bearing cup into the bearing support. l. CAREFULLY place the new shaft seal (35) in the bearing support (46) and install using a seal installation tool. m. Pack the bearing cone (36) with wheel bearing grease and place in bearing cup (36).

CAUTION: Be SURE the bearing cone is fully "packed" with grease, as NO other lubrication is available to the bearing at this location.

n. CAREFULLY place the new lip seal (37) in the bearing support (46) and install using a seal installation tool.

8-38

CAUTION: Do NOT damage the OUTER and INNER shaft seals (35 and 37) as the splines pass through them. Put tape around the area of the splines to help stop possible damage to the seal lips, and remove it AFTER the assembly of the drive shaft into the bearing support housing is complete.

t. Mount the spacer (20) after coating with Molybdenum Disulfide grease. u. Install the assembled cylinder block (1). v. Grease and install a new o-ring (5) in the groove of slewing plate (21). w. Install the cam (4) ensuring alignment of the marks made during disassembly. x. Lightly grease the seal grooves in the valving cover (6). y. Install the seals (12) in their respective grooves using minimum deformation. z. Grease and install the springs (13) in the bore of valve block (11). aa. Oil the seal surfaces of valve block (11) and insert in valving cover (6) ensuring alignment of the marks made during disassembly.

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Section 8 TRANSMISSION SYSTEM ab. Gease and install a new o-ring (5) in the groove of valving cover (6). ac. Install valving cover (6) aligning the marks made during disassembly. ad. Insure that the brake port, the two speed port and the case drain port are all aligned vertically with each other. ae. Install and tighten the twelve [12] screws (7) to a torque of 215 ft. lbs. [30 N.m]. af. Place the bearing cup (36) over the shaft (19) and position it against the valving cover (6). ag. Pack the bearing cone (36) with wheel bearing grease and place in bearing cup (36). Using a press, preload the bearing (36) with a 20,000 lb. force.

CAUTION: Be SURE the bearing cone is fully "packed" with grease, as NO other lubrication is available to the bearing at this location.

an. Determine the thickness of the shim pack (27) using the following additional procedures. 1. Replace the 0.118 in. [3.0 mm] shim pack (29) with a piece of standard resin core solder. 2. Reinstall the hub, washer and old screws. Torque the screws to 116 ft. lbs. [158 N.m]. 3. Remove one screw (30). Using a caliper through this screw hole, measure from the top of the shaft (19) to the top of the washer (29). Record this measurement. 4. Remove the three remaining screws (30), the washer (29) and the hub (28). 5. Measure and record the thickness of the solder. 6. Add 0.008 in. [0.20 mm] to the dimension determined in step 5. This is the amount of shims (27) to be used. ao. Place the shim pack determined above onto the thrust ring (33).

ah. Mount the shaft seal (25) in bearing support (24). ai. Position bearing support against the valving cover (6). Install the ten [10] screws (26) and torque to 215 ft. lbs. [30 N.m]. aj. Install the new o-ring (32) inside thrust ring (33).

ap. Place the o-ring (34) around the ledge of hub (31). The o-ring will be rolled back into position later. aq. Install the hub (31), the washer (29) and the old screws (30). Torque the screws to 116 ft. lbs. [158 N.m].

al. Install the thrust ring (33) onto the shaft (19) and press the thrust ring into the bearing support (24) by hand.

ar. Remove two screw (30) [opposite each other]. Using a caliper through these screw holes, measure from the top of the shaft (19) to the top of the washer (29). This measurement should be the same as the measurement recorded earlier. If not, repeat steps "am" through "ar".

am. Seat the thrust ring (33) using the following additional procedures.

as. Install two new screws (30) and torque to 107 ft. lbs. [146 N.m].

ak. Seal ring (22) should still be in place around outside of the thrust ring (33).

1. Temporary install a 0.118 in. [3.0 mm] shim pack (29) on top of thrust washer (33). 2. Install hub (28) on the shaft (19). Install the washer (29) and secure with the old screws (30). Torque the screws to 57 ft. lbs. [78 N.m].

at. Remove the two remaining old screws ( 30), install two new screw and torque to 107 ft. lbs. [146N.m]. au. Roll the o-ring (34) off of hub (28) to cover the space between the hub and thrust ring (33).

3. Remove the screws (30), washer (29) and the hub (28).

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8-39

Section 8 TRANSMISSION SYSTEM INSTALLATION [See Figure 8-26]. a. Fasten a sling and a hoist, having a capacity more than 500 lbs. [114 kg], to the drive motor. CAREFULLY lift the drive motor and move it into installation position on the front frame.

WARNING: Do NOT get under the drive motor while lifting, or lowering the drive motor.

b. CAREFULLY put the brake end of the drive motor toward the center of the machine and position the mounting flange against the inner surface of the front frame. c. CAREFULLY align the eight [8] holes in the front frame with the same holes of the drive motor.

WARNING: Keep the hands CLEAR of the area between the drive motor mounting flange and the front frame.

d. Put thread lock, pn 318702, on the threaded area of the eight [8] drive motor mounting screws. Install the screws through the drive motor and front frame into the flange nuts. Tighten the capscrews into the nuts to a torque of 375 ft. lbs. [512 N.m]. e. Remove ALL plugs and caps from the hoses and fittings. Fasten the brake release pressure, low to high range and case drain hoses to their fitting port connections on the drum drive motor, as shown by the identification tags, and tighten securely.

g. Install the inner and outer tires onto the drive motor and torque the nuts to 188 ft. lbs. [257 N.m]. h. Follow ALL hydraulic system "pre-start and start up" procedures as given in THIS section BEFORE starting the engine.

CAUTION: Both drive motor cases MUST be filled with oil BEFORE the engine is started. Loosen each air removal [bleed] screw on each drive motor and allow each drive motor to be COMPLETELY filled with oil as the air is removed. Close each screw when oil appears and is free of air bubbles. i. Check the hydraulic oil level of the reservoir and add oil if needed [see Section 4 - MAINTENANCE]. j. AFTER ALL system pre-start procedures have been followed, start the engine and check the machine for correct transmission AND secondary/ parking brake system function.

WARNING: Keep ALL personnel, except the operator, CLEAR of the machine and the surrounding area during the initial system checks. Be prepared to STOP the engine if a system malfunction is noted. IF a problem is noted, Do NOT start the engine again until it has been corrected.

k. Check the hydraulic oil level of the reservoir AGAIN and add oil, if needed [see Section 4 MAINTENANCE].

f. Remove the caps or plugs from the two [2] high pressure hoses and the fitting caps from flange connection ports on the drum drive motors. Connect the high pressure hoses to the CORRECT outlets on the drum drive motors, as shown by the identification tags, and tighten the flange retaining bolts securely.

8-40

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Section 8 TRANSMISSION SYSTEM DRIVE MOTOR PRESSURE AND FLOW CHECKS. CHECKING PROCEDURES. The following information describes the different drive motor pressure check locations, pressure gauge sizes needed and correct pressures.

b. Wash the area around the straight fitting on the drive motor, where EACH drive motor RETURN oil hose is connected, with CLEAN diesel fuel and dry with compressed air. MOTOR CASE PRESSURE CHECK

CAUTION: The hydraulic system oil MUST be at "NORMAL OPERATING" temperature and at the correct level BEFORE ANY pressure check or flow rate is taken. The engine throttle is to be in the "HIGH" idle position for ALL checks.

CASE PRESSURE [See Figure 8-30]. The case PRESSURE of the drive motors can be checked by using the following procedures: a. Close the needle valve located below the solenoid valve [See Figure 8-29].

NOTE: The brakes are now set in the drive motors and can not be released with the switch on the dash unless the needle valve in manually opened [CCW]. This condition is necessary to accurately setup and inspect the unit.

SOLENOID [STACKED] VALVE NEEDLE VALVE

BRAKE PILOT PRESSURE CHECK POINT

FIGURE 8-30. DRIVE MOTOR CASE PRESSURE CHECK LOCATION. c. Loosen, and then remove, the drive motor case drain hose at the straight fitting installed in the drive motor case. Install a correct size "tee" fitting, having a #4 gauge port, between the case drain hose fitting and the straight fitting installed into the drive motor case. Connect a 100 psi. [7 bar] pressure gauge, on a long hose, to the #4 fitting on the "tee" and tighten securely. Place the gauge in the operator's compartment, so that the operator can note the pressure indicated, during the pressure check procedures.

DANGER: Keep ALL personnel, except the operator, CLEAR of the MACHINE and the surrounding AREA during the "pressure check" procedures. Maximum system pressures will be developed.

d. Start the engine. Put the TRANSMISSION RANGE selector switch in the "LOW" range position. Put the engine throttle lever in the "HIGH" idle position. Move the direction control handlever to the FULL FORWARD position and note the highest case pressure indicated on the pressure gauge. FIGURE 8-29. BRAKE NEEDLE VALVE LOCATION.

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8-41

Section 8 TRANSMISSION SYSTEM e. Move the direction control handlever to the FULL REVERSE position and note the highest case pressure indicated on the pressure gauge for this direction. Move the direction control handlever to the NEUTRAL position. Slow and then stop the engine.

CAUTION: The case pressure indicated should be the SAME in BOTH directions. The MAXIMUM allowable pressure is 20 psi. [1.4 bar]. The NORMAL pressure during operation, with the system at operating temperature is 10 psi. [0.7 bar].

NOTE: A case pressure ABOVE the given MAXIMUM pressure can be an indication of drive motor internal high pressure leakage due to worn, or damaged, parts which can reduce the efficiency of the drive motor. A further check of the drive motor case flow AMOUNT, using the procedure given in THIS section, and "overall" machine performance can confirm the loss of efficiency. Repeat the process for the other drive motor.

f. If the pressures were CORRECT, loosen and remove the pressure gauge, and hose from its connection to the hose coming from the drive motor. Loosen and remove the "tee" fitting. Connect the case drain RETURN oil hose to the straight fitting and then tighten securely. g. Check the oil level in the hydraulic oil reservoir. Add oil, if needed [see Section 4 - MAINTENANCE]. h. Put the secondary/parking brake system control switch "ON" [APPLIED]. i. Open the needle valve out [CCW] to its stop.

a. Close the needle valve located below the solenoid valve [See Figure 8-29].

NOTE: The brakes are now set in the drive motors and can not be released with the switch on the dash unless the needle valve is manually opened [CCW]. This condition is necessary to accurately setup and inspect the unit. b. Wash the area around the straight fitting on the drive motor, where EACH drive motor RETURN oil hose is connected, with CLEAN diesel fuel and dry with compressed air. MOTOR CASE FLOW CHECK

FIGURE 8-31. DRUM DRIVE MOTOR CASE FLOW CHECK LOCATION. c. Loosen the drive motor case drain RETURN oil hose and remove it from the fitting. Put a plug in the hose fitting. Install a short hose onto the straight fitting and tighten securely.

WARNING: Keep ALL personnel, except the operator, CLEAR of the MACHINE and the surrounding AREA during the "flow check" procedures.

CASE DRAIN FLOW AMOUNT [See Figure 8-31]. Use the following procedures to check the amount of case drain flow from the drive motors.

8-42

CAUTION: NEVER seal the case drain port in a drive motor. SEVERE drive motor damage can result if case flow and pressure are NOT permitted an OUTLET path.

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Section 8 TRANSMISSION SYSTEM d. Put the OPEN end of the short installed hose into a measuring container.

NOTE: A flow meter can be installed into the line between the straight motor fitting and the case drain return oil hose as an alternate method of checking the flow amount.

e. Start the engine. Put the transmission RANGE selector switch in the "LOW" range position. Put the engine throttle in the "HIGH IDLE" position. f. Move the direction control handlever to the FULL FORWARD position for a period of FIFTEEN [15] seconds. Move the direction control handlever back to the NEUTRAL position and put the throttle in the "LOW IDLE" position. g. CAREFULLY measure the AMOUNT of hydraulic oil held in the measuring container.

i. To check case drain flow for the second drive motor repeat steps "a" through "h". j. Loosen, and then remove the hose installed onto the straight fitting. Remove the plug from the case drain return oil hose. Install, and then tighten, the drive motor RETURN oil hose onto the straight fitting.

NOTE: If installed, loosen and then remove, the flow meter from the line between the motor straight fitting and the return oil hose. Install, and then tighten, the return oil hose onto the straight fitting.

k. Check the oil level in the hydraulic oil reservoir. Add oil, IF needed [see Section 4 - MAINTENANCE]. l. Put the secondary/parking brake system control switch "ON" [ APPLIED]. m. Open the needle valve out [CCW] to its stop.

CAUTION: While under load for a fifteen [15] second time period, the MAXIMUM amount of case drain oil from ONE drive motor must NOT be MORE than ONE [1] quart [.95 liter].

h. Empty the collected oil from the container. Put the hose back into the container. Repeat steps "f" and "g", with the directional control handlever in the FULL REVERSE position. Move the direction control handlever back to the NEUTRAL position and put the throttle in the "LOW IDLE" position and run the engine for a period of 3-5 minutes. STOP the engine.

NOTE: The amount of case drain oil collected should be the SAME as that collected in the forward direction. Combined case flow amounts ABOVE the MAXIMUM flow amount can be an indication of drive motor internal high pressure oil leakage due to worn or damaged parts which can reduce the efficiency of the drive motor. A further check of the flow amount of EACH drive motor and the "overall" machine performance can confirm the loss of efficiency.

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LOW TO HIGH RANGE PILOT PRESSURE [See Figure 8-32]. Hydraulic oil pressure is needed to move the pilot spool, in EACH of the drive motor valving blocks. This will reduce, by one half, the "usable" displacement of the drive motors and thereby causes the "HIGH" speed range mode. Use the following procedures to check the high range pilot pressure supply to EACH drive motor. a. Put the secondary/parking brake system control switch "ON". Stop the engine. b. Close the needle valve located below the solenoid valve [See Figure 8-29].

8-43

Section 8 TRANSMISSION SYSTEM c. Wash the area around the straight fitting on the drive motor, where the pilot oil supply hose is connected, with CLEAN diesel fuel and dry with compressed air.

f. Note the pressure indicated on the pressure gauge. Put the engine throttle lever in the "LOW" idle position and run the engine for a period of 3-5 minutes. Stop the engine.

d. Loosen and remove the pilot oil supply hose from the fitting. Install and tighten a CORRECT type "tee fitting" onto the open fitting. Install and tighten the pilot oil supply hose onto one [1] port of the installed "tee fitting". Install and tighten a 600 psi. [41 bar] pressure gauge, on a long hose, onto the remaining port of the "tee fitting".

NOTE: The charge pressure indicated on the pressure gauge MUST be a minimum of 270-350 psi. [19-24 bar]. This pressure will move the pilot spool and permit complete shift in range from "LOW" to "HIGH".

HIGH RANGE PILOT PRESSURE CHECK

g. Loosen and remove the pressure gauge supply hose from the "tee" fitting. Loosen and remove the pilot oil supply hose from the "tee" fitting. Remove the "tee" fitting. Install and tighten the pilot oil supply hose onto the fitting installed into the drive motor. h. Check the oil level in the hydraulic oil reservoir. Add oil, if needed [see Section 4 - MAINTENANCE]. i. Put the secondary/parking brake system control switch "ON" [APPLIED]. j. Open the needle valve out [CCW] to its stop.

FIGURE 8-32. DRIVE MOTOR HIGH RANGE PILOT PRESSURE CHECK LOCATION.

BRAKE SYSTEM RELEASE PILOT PRESSURE [See Figure 8-33].

e. Start the engine. Put the transmission speed range switch in the "HIGH" range position. Put the engine throttle lever in the "HIGH" idle position.

The hydraulic oil pressure needed to move the brake release piston and release the multi-disc brakes, in BOTH drive motors, can be checked using the following procedures:

NOTE: NO pilot oil will flow from the high range port, on the drive motor, IF the transmission speed range switch is in the "LOW" range position. NO pressure will be indicated on the pressure gauge.

8-44

DANGER: Keep ALL personnel, except the operator, CLEAR of the area around the machine while checking the brake system holding capacity. DO NOT operate, or check, a machine IF it can be moved forward, or backward, WHILE the brake system is in the "ON" [APPLIED] condition. Repair the malfunction IMMEDIATELY.

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Section 8 TRANSMISSION SYSTEM The capped brake system release pilot pressure check port is located below the needle valve located below the "solenoid [stacked] valve". a. Place the machine on a LEVEL surface. Put the secondary/ parking brake system control switch "ON" [APPLIED]. Stop the engine. b. Clean the capped brake system release pilot pressure check port with CLEAN diesel fuel and dry with compressed air. c. Remove the cap fitting from the tee fitting and install and tighten a 600 psi. [41 bar] pressure gauge, on a long hose. SOLENOID [STACKED] VALVE NEEDLE VALVE

BRAKE PILOT PRESSURE CHECK POINT

FIGURE 8-33. BRAKE SYSTEM RELEASE PILOT PRESSURE CHECK LOCATION.

d. Put SOLID wood blocks in the front, and at the rear, of the drive tires. Start the engine. Keep the direction control handlever in the NEUTRAL position. Put the throttle in the "LOW IDLE" position. Put the secondary/parking brake system control switch in the "OFF" [RELEASED] position. Note the pressure indicated on the pressure gauge.

WARNING: Block SECURELY with SOLID wood blocks. The blocks MUST hold and keep the machine from ANY movement.

NOTE: NO brake release oil will flow from the outlet port of the "solenoid [stack] valve" IF the secondary/parking brake system control switch is in the "ON" [APPLIED] position. NO pressure will be indicated on the pressure gauge. The hydraulic oil pressure needed to FULLY release the multi-disc brakes, in the drive motors, MUST be above 175 psi. [12 bar] MINIMUM and below 435 psi. [30 bar] MAXIMUM.

e. Put the secondary/parking brake system control switch in the "ON" [APPLIED] position. CAREFULLY remove the blocks from in front, and at the rear, of the drive tires. Put the direction control handlever in the FULL FORWARD position. Note that the machine can NOT be moved against the brake system. Repeat this procedure with the machine direction control in the FULL REVERSE position, and note the SAME brake system performance. Put the engine throttle lever in the "LOW IDLE" position and run the engine for a period of 35 minutes. Stop the engine. f. Loosen and remove the pressure gauge supply hose from the "tee" fitting. Reinstall the plug fitting. g. Check the oil level in the hydraulic oil reservoir. Add oil, if needed [see Section 4 - MAINTENANCE].

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8-45

Section 8 TRANSMISSION SYSTEM CLEANING THE HYDRAULIC SYSTEM [See

9. Oil suction filter.

Figure 8-2]. 10. Oil cooler assembly. 11. "Shuttle [flushing] valve".

CAUTION: Dirt of ANY type WILL shorten the service life of the transmission, and steering system components or cause the components to fail. If a failure occurs in the transmission or steering system, it is BEST to DISASSEMBLE, CLEAN and then ASSEMBLE the ENTIRE hydraulic system.

NOTE: See the Section, in THIS manual, which covers EACH major component for removal, disassembly, inspection assembly and installation information.

Use the following procedures to CLEAN the ENTIRE hydraulic system IF a component failure HAS occurred:

CAUTION: Replace ALL components with the SAME type and part number IF replacement is needed. ALWAYS replace the suction oil filter element, with NEW, BEFORE filling the oil reservoir with NEW, CLEAN AND FILTERED hydraulic oil.

a. Drain the hydraulic oil reservoir of oil [see Section 4 - MAINTENANCE].

WARNING: Drain when warm or cool ONLY. Hot oil can cause serious injury.

c. Fill the hydraulic oil reservoir with NEW, CLEAN and FILTERED hydraulic oil [see Section 4 - MAINTENANCE].

b. Remove, disassemble, CLEAN, repair, assemble or replace and install the following system components AFTER a component failure:

CAUTION: Also, fill the suction filter and hose between filter and pump [see Section 4 - MAINTENANCE].

1. Hydraulic oil reservoir. 2. Transmission pump assembly.

d. Precharge the hydraulic system using the "HYDRAULIC SYSTEM PRE-START PROCEDURES" found in THIS Section.

3. Transmission drive motors. 4. Steering pump assembly. 5. Steering control unit. 6. Steering cylinder. 7. "Solenoid [Stack] valve" assembly. 8. ALL pressure AND return hose assemblies and fittings.

8-46

CAUTION: Do NOT start the engine UNTIL ALL pre-start procedures have been followed. Any dirt or contamination remaining in the hydraulic system can cause a repeat failure in the system. Partial, or incomplete, cleaning is NOT good enough. COMPLETE system disassembly, and FULL cleaning is the ONLY acceptable method of hydraulic system service.

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Section 8 TRANSMISSION SYSTEM HYDRAULIC SYSTEM PRE-START PROCEDURES [See Figure 8-2]. Use the following pre-start procedures to help to insure that ALL components are full of hydraulic oil BEFORE the engine is started. Use these procedures ANY time the system has been "opened" and a component has been removed and installed back into the system.

CAUTION: Do NOT permit the engine to be started UNTIL ALL pre-start procedures have been followed and it is certain ALL hydraulic system components have been FILLED with oil. Severe damage to system components can occur IF filling has NOT been completed.

a. Check ALL hydraulic hose to fitting connections to be sure they are tightened correctly. Tighten again as needed. b. Fill the hydraulic oil reservoir with NEW, CLEAN and FILTERED hydraulic oil [see Section 4 - MAINTENANCE]. c. Disconnect the electrical wire FROM the engine fuel shut off solenoid. Put electrical tape on the terminal of the wire, removed from the solenoid, to prevent it from touching the engine and ground.

NOTE: DISCONNECTING the wire from the fuel shut off solenoid will keep the engine fuel shut off valve in the "OFF" position when the engine is cranked. Cranking the engine will rotate the hydraulic pumps to develop oil flow and fill the hoses and other system components with oil.

d. Wipe the charge pressure check port cap with a CLEAN cloth. Loosen and remove the cap from the charge pressure check port fitting. Install and tighten a 600 psi. [41 bar] pressure gauge, on a short hose, onto the pressure check port fitting.

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e. Put the secondary/parking brake system control switch in the "ON" [APPLIED] position. Put the direction control handlever in the "NEUTRAL" position. Put the engine throttle in the "LOW IDLE" position. f. Crank the engine, while an assistant watches the charge pressure being indicated on the pressure gauge. Continue to crank the engine UNTIL there IS charge pressure of 100 psi. [7 bar] MINIMUM indicated on the pressure gauge. Stop cranking the engine.

CAUTION: Do NOT crank the engine for more than 30 seconds continuously. Wait one [1] minute between engine cranks to allow the starter motor time to cool.

NOTE: THIS procedure WILL "precharge" the hydraulic system with oil BEFORE the engine is started.

g. Loosen the hose fitting, that connects to the secondary/parking brake port fitting of ONE [1] drive motor, a SMALL amount. Hydraulic oil MUST be present and "leak" at the fitting. If oil was present at the fitting, securely tighten the hose fitting onto the secondary/parking brake port fitting. Repeat the SAME procedure at the SECOND drive motor.

CAUTION: If NO oil was present, check the oil level in the hydraulic oil reservoir. Add oil IF needed. REPEAT the TOTAL "precharge" procedure to produce the needed oil filling of ALL components.

h. Check the oil level in the hydraulic oil reservoir. Add oil as needed [see Section 4 - MAINTENANCE].

NOTE: Leave the pressure gauge and hose connected to the charge pressure check port UNTIL the "after start" pressure check of the charge pressure is complete. Then remove the hose and pressure gauge assembly, from the pressure check port, and install and tighten the cap onto the fitting.

8-47

Section 8 TRANSMISSION SYSTEM i. Remove the electrical tape from the electrical wire that fastens to the engine fuel shut off solenoid. Install the wire onto the solenoid terminal and tighten the nut securely.

HYDRAULIC SYSTEM START UP PRESSURE CHECKS.

d. Put the engine throttle in the "LOW" idle position and run the engine for a period of 3-5 minutes. STOP the engine. Loosen and remove the cap from the pressure check port fitting, found on the steering pump located on the LH side of the engine. Install and tighten a 3,000 psi. [210 bar] pressure gauge, on a short hose, onto the pressure check port for steering.

Use the following information to check the different system pressures at "hydraulic system start up" and help to determine IF a system is operating at the CORRECT pressure.

DANGER: Keep ALL personnel CLEAR of the area between the front and the rear frames. Clearance CLOSES in ANY turn.

WARNING: Keep ALL personnel, except the operator, CLEAR of the MACHINE and the surrounding AREA during the "pressure check" procedures.

e. Start the engine. Put the engine throttle in the "HIGH" idle position. Turn the steering wheel to the left or right position and have an assistant note the steering pressure at relief, indicated on the pressure gauge. Put the throttle in the "LOW" idle position and run the engine for a period of 3-5 minutes. Stop the engine.

a. Close the needle valve located below the solenoid valve [See Figure 8-33].

b. Install the steering lock pin at the steering cylinder. c. Start the engine. Put the engine throttle in the "HIGH" idle position. Check the NEUTRAL charge pressure indicated on the pressure gauge. Check for ANY hydraulic system leaks.

CAUTION: The pressure indicated on the pressure gauge MUST be between 350-400 psi. [24-28 bar]. STOP the engine IMMEDIATELY if NO or LOW charge pressure OR any system leaks are noted. Do NOT start the engine again UNTIL any problem noted has been corrected.

8-48

CAUTION: The pressure indicated on the gauge must NOT go above a MAXIMUM pressure of 2,250 +/-50 psi. when the system relief pressure was noted. IF an incorrect pressure is noted [See Section 10 - STEERING SYSTEM in this manual]. f. Remove the hose and pressure gauge from the pressure check port fitting and install and tighten the cap onto the check port fitting. g. Check the high system pressure in BOTH the forward and reverse directions of machine travel using the procedures given in THIS Section [see "Pressure Limiter And High Pressure Relief Valve Pressure Check And Adjustment", found under the transmission pump pressure check information]. h. Open the needle valve [CCW] to its stop.

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Section 8 TRANSMISSION SYSTEM TROUBLE ANALYSIS FOR THE TRANSMISSION SYSTEM TRANSMISSION PUMP PROBLEM MACHINE DRIVES WITH TRAVEL CONTROL LEVER IN NEUTRAL

MACHINE WILL NOT OPERATE IN EITHER DIRECTION

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CAUSE

CORRECTION

Pump not in neutral [stroked]

Check linkage at pump displacement control for correct fork to arm alignment. Adjust control cable if needed.

Pump mechanical neutral (0) position NOT correct

Check the mechanical neutral position.

Pump hydraulic (0) position NOT correct

Check the hydraulic neutral position.

Displacement control has damage

Replace displacement control with new.

Transmission pump worn, or damaged

Replace transmission pump with new.

Secondary/parking brake system "on".

Release brake system.

Secondary/parking brake system needle valve closed

Open needle valve [CCW] to its stop.

Solenoid coil not energized, or is damaged

Check electrical circuit for current flow. Repair circuit, if needed. Check solenoid for operation. Replace with new, if damaged.

Hydraulic system oil level low

Check oil level in reservoir. Add oil. Find and correct cause of low oil level.

Pump control linkage damaged or linkage not connected to the transmission pump.

Repair, or replace, control linkage

Both transmission charge pressure check valves in "open" position.

Remove, inspect, clean or replace as needed.

Air being drawn into the system

Check all fittings and hoses for correct tightness. Tighten as needed.

Cold, or wrong oil in system

Permit system to warm. See Section 4 for correct oil.

8-49

Section 8 TRANSMISSION SYSTEM TROUBLE ANALYSIS FOR THE TRANSMISSION SYSTEM TRANSMISSION PUMP PROBLEM MACHINE WILL NOT OPERATE IN EITHER DIRECTION [continued]

MACHINE OPERATES IN ONE DIRECTION ONLY

NEUTRAL POSITION DIFFICULT OR NOT ABLE TO BE FOUND

SYSTEM OPERATES IN A "HOT" CONDITION

8-50

CAUSE

CORRECTION

Both "multi-function valves in open position

Remove, inspect clean, adjust or replace and adjust valves.

Drive motors damaged

Remove, repair, or replace, motors.

Transmission pump linkage has damage

Check control system for connection, binding or missing parts. Correct and adjust as needed.

Displacement control valve damaged

Replace valve with new.

One charge pressure check valve [in multi-function valve] damaged

Identify check valve. Remove, clean, or replace, as needed.

Drive motors damaged

Remove motors. Repair, or replace as needed.

Hoses carrying "high" pressure in a "stopped" condition

Locate "stopped" hose. Remove, clean, or replace, as needed.

Pump control linkage has damage

Check control system for connection, binding or missing parts. Correct and adjust as needed.

Displacement control valve damaged

Replace valve with new.

Transmission pump displacement control cylinder not adjusted correctly or is damaged

Adjust control cylinder or replace and adjust cylinder as needed.

Hydraulic system oil level "low"

Check oil level in reservoir. Add oil. Find and correct cause of low oil level.

"Stopped" suction oil filter element

Replace filter element with new.

System being operated over at a pressure over "high" relief

Eliminate cause of excessive pressure or adjust "high" relief pressure setting.

2/98

Section 8 TRANSMISSION SYSTEM TROUBLE ANALYSIS FOR THE TRANSMISSION SYSTEM TRANSMISSION PUMP PROBLEM SYSTEM OPERATES IN A "HOT" CONDITION [continued]

CAUSE Pump has internal leakage

CORRECTION Remove, inspect, repair or replace pump.

CAUTION: Clean the entire hydraulic system AFTER a failure. TRANSMISSION PUMP AND SYSTEM NOISY DURING OPERATION

Hydraulic system oil level low

Check oil level in reservoir. Add oil. Find and correct cause of low oil level.

Hose or fitting loose, allowing air to be drawn into the system

Check all fittings and hoses for correct tightness. Tighten as needed.

Pump has internal wear or damage

Remove, repair or replace pump

CAUTION: Clean the entire hydraulic system AFTER a failure.

MACHINE ACCELERATION AND/OR DECELERATION SLOW

2/98

Hoses not correctly insulated from vibration or not positioned as needed

Check hose routings. They must not touch any metal that can increase natural hydraulic system "hum".

Air being drawn into system

See " System Noisy During Operation - Air In System".

Low charge pressure

Adjust charge pressure to correct amount. Disassemble, repair or replace charge pump and then adjust, if needed.

Displacement control valve orifice partially "stopped"

Remove displacement control valve. Remove, clean or replace orifice. Install control valve.

Pump has internal wear or damage

Remove and repair or replace pump as needed.

Machine being operated in "HIGH" transmission speed range

Put switch in "LOW" range position.

8-51

Section 8 TRANSMISSION SYSTEM TROUBLE ANALYSIS FOR THE TRANSMISSION SYSTEM TRANSMISSION PUMP PROBLEM MACHINE ACCELERATION AND/OR DECELERATION IS SLOW [continued]

CAUSE

CORRECTION

Engine not operating at correct speed - low RPM

Set engine at correct "high" idle RPM.

High pressure relief valve open or damaged

Remove, inspect, clean or replace valve as needed. Check pressure adjustment.

TRANSMISSION MOTORS PROBLEM DRIVE MOTORS WILL NOT ROTATE IN EITHER DIRECTION

CAUSE

CORRECTION

Secondary/parking brake system "on"

Release brake system.

Secondary/parking brake system needle valve closed

Open needle valve [CCW] to its stop.

Wires to secondary/parking brake system switch reversed

Check wire connections and change as needed.

Hydraulic system oil level low

Check oil level in reservoir. Add oil. Find and correct cause of low oil level.

No output from transmission pump

See "Machine Will Not Operate In Either Direction" - in the Transmission Pump "Trouble Analysis".

Secondary/parking brakes on drive motors NOT releasing

Check brake release hydraulic pilot pressure. Check release piston operation on motors. Repair or replace components as needed. Repair or replace components needed.

Drive motors have damage

Remove, repair or replace motors with new as needed.

CAUTION: Clean the entire hydraulic system AFTER a failure.

8-52

2/98

Section 8 TRANSMISSION SYSTEM TROUBLE ANALYSIS FOR THE TRANSMISSION SYSTEM TRANSMISSION MOTORS PROBLEM DRIVE MOTORS WILL ONLY ROTATE IN ONE DIRECTION ONLY

DRIVE MOTORS OPERATING IN A "HOT" CONDITION

CAUSE

CORRECTION

Pump displacement control linkage not adjusted correctly, or is damaged

Adjust control linkage or replace damaged linkage and then adjust correctly.

Displacement control valve has damage

Replace control valve with new.

Both motors have internal damage

Remove, repair or replace motors with new.

Hoses carrying "high" pressure oil for direction NOT rotating "stopped"

Remove hoses. Clean or replace as needed.

Excessive loading of hydraulic system - operating in "HIGH" range

Reduce system loading. Put speed range switch in "LOW".

Low oil flow reaching drive motor[s] from transmission pump

See "TRANSMISSION PUMP" - "System Operates In A Hot Condition".

Incorrect type oil used in hydraulic system

Drain and flush system. Fill with correct type oil [see Section 4].

Motor[s] have internal damage

Remove motor[s] and repair, or replace, with new as needed.

CAUTION: Clean the entire hydraulic system AFTER a failure. DRIVE MOTORS WILL NOT CHANGE FROM LOW TO MEDIUM AND/OR HIGH TRANSMISSION SPEED RANGE

2/98

Speed range electrical control circuit has no current flow

Check circuit for current flow. Correct electrical circuit problems as needed [see Section 7 - ELECTRICAL].

Speed range selector switch damaged

Remove and replace switch with new.

Valve solenoid(s) damaged

Remove and replace solenoid(s) with new.

8-53

Section 8 TRANSMISSION SYSTEM TROUBLE ANALYSIS FOR THE TRANSMISSION SYSTEM TRANSMISSION MOTORS PROBLEM DRIVE MOTOR WILL NOT CHANGE FROM LOW TO MEDIUM AND/OR HIGH TRANSMISSION SPEED RANGE [continued]

CAUSE

CORRECTION

Low or no charge pilot pressure flowing to the drive motor

Check charge pilot pressure to, and from, speed range selector valve. Correct cause of low or no charge pressure as needed.

Speed range change spool, in drive motor, "stuck" or damaged

Remove motor. Clean and free spool or replace spool with new.

DRIVE MOTORS MULTI-DISC BRAKES PROBLEM

CAUSE

BRAKES WILL NOT RELEASE

Electrical circuit has no current flow

Check circuit for current flow and repair as needed [see Section 7 - ELECTRICAL].

Secondary/parking brake system needle valve closed

Open needle valve [CCW] to its stop.

Secondary/parking brake system control switch damaged

Remove and replace switch with new.

Brake valve solenoid damaged

Remove and replace solenoid.

Low, or no, charge pilot pressure flowing from brake valve to brake release pistons

Check charge pilot pressure to, and from, brake valve. Correct cause of low or no charge pressure as needed.

Brake release pistons, or seals, worn or damaged

Remove motor. Disassemble and inspect brake parts. Replace worn or damaged parts as needed.

Secondary/parking brake system control switch shorted

Remove and replace switch with new.

Charge pilot pressure being supplied to both brake release pistons at all times

Check for correct brake release oil supply hoses routing. Change routing if needed.

Brake release valve damaged spool in open flow position

Remove and replace valve with new.

Multi-disc brakes worn or damaged

Replace ALL discs with new.

BRAKES WILL NOT APPLY

8-54

CORRECTION

2/98

Section 8 TRANSMISSION SYSTEM TROUBLE ANALYSIS FOR THE TRANSMISSION SYSTEM DRUM DRIVE MOTORS MULTI-DISC BRAKES PROBLEM BRAKES WILL NOT APPLY [continued]

BRAKES WILL NOT HOLD MACHINE WHEN APPLIED

2/98

CAUSE

CORRECTION

Brake release pistons remaining in release position

Remove release pistons. Inspect seals and pistons. Replace parts as needed.

Brake application springs have reduced tension or other damage

Remove springs and replace with new.

Multi-disc brakes worn or damaged

Replace ALL discs with new.

Brakes not shimmed correctly

Shim brakes to correct specifications.

Brake application springs have reduced tension or other damage

Remove springs and replace with new.

Brake release pistons not fully returning to the retracted position when brakes are applied

Remove motors. Disassemble and inspect pistons and seals. Replace damaged parts with new.

8-55

Section 8 TRANSMISSION SYSTEM NOTES

8-56

2/98

Section 9 BRAKE SYSTEM

TABLE OF CONTENTS

PAGE GENERAL INFORMATION ...................................................................................................................... 9-2 DYNAMIC BRAKING ............................................................................................................................... 9-2 OPERATION ......................................................................................................................................... 9-2 SECONDARY/PARKING BRAKE SYSTEM ............................................................................................ 9-2 OPERATION ......................................................................................................................................... 9-2 SECONDARY/PARKING BRAKE SYSTEM SOLENOID VALVE .......................................................... 9-4 REMOVAL AND REPLACEMENT ....................................................................................................... 9-4

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9-1

Section 9 BRAKE SYSTEM GENERAL INFORMATION [See Figure 9-1]. This section describes the operation of the "dynamic" [hydrodynamic, through the transmission system] and the "secondary/parking" [spring applied in each drive motor] braking systems. "Secondary/parking" brake components are included in each drive motor assembly. Repair procedures for the "secondary/parking" brake system components are included in the drive motor disassembly, inspection and assembly procedures found in Section 8 TRANSMISSION SYSTEM, of this manual. Removal and replacement of the "secondary/ parking" brake system solenoid valve is described in this Section. Trouble analysis for the "secondary/parking" brake system is found in the rear of Section 8 - TRANSMISSION SYSTEM, of this manual.

WARNING: When approaching, and then traveling down, a slope use a slow speed with the transmission speed range control switch in the low speed range. Additional slowing of the machine is done by moving the directional control [F-N-R] handlever past neutral, to the direction OPPOSITE the direction of machine travel. The secondary/parking brake system MUST be used to hold the machine in a “stopped” condition at all times. The transmission system, used for the “dynamic” braking of the machine, WILL NOT hold and keep the machine in a “stopped” condition.

NOTE: Repair of the "dynamic" braking system is done through service to the transmission system [See Section 8 - TRANSMISSION SYSTEM].

DYNAMIC BRAKING. OPERATION.

SECONDARY/PARKING BRAKE SYSTEM.

During operation, slowing, or stopping, of the machine is done by using the "dynamic" transmission system. Control of the transmission system is through the directional control [F-N-R] handlever, found on the rear of the operator's compartment. During machine operation, moving the handlever from either the forward, or reverse, position to the neutral position causes the oil flow through the transmission system to be reduced and/or then stopped. This slows, and then stops, the machine.

OPERATION [See Figure 9-1].

9-2

The "secondary/parking" brake system is used to hold the machine in a “stopped” condition after it has been stopped through the use of "dynamic" braking. During machine operation the system will, also, be in an “applied” condition if the machine has a loss of transmission system charge and/or control pressure, loss of electrical current or if there is a stoppage of the engine.

2/98

Section 9 BRAKE SYSTEM TO OIL RESERVOIR SECONDARY/ PARKING BRAKE SOLENOID TRANSMISSION LOW/HIGH RANGE SOLENOIDS

FROM CHARGE PUMP

RH DRIVE MOTOR

LH DRIVE MOTOR

FIGURE 9-1. SECONDARY/PARKING BRAKE SYSTEM - RELEASE OIL FLOW PATH. Control of the secondary/parking brake system is accomplished by using the secondary/parking brake control switch found on the control console. Putting the secondary/parking brake control switch in the “ON” [APPLIED] position will cause a spring to move the spool in the solenoid valve, releasing the charge pressure oil at the release piston in each drive motor. Oil from each brake release piston is then directed to the hydraulic oil reservoir. The large application washers will then put the multi-disc brakes in the “ON” [APPLIED] condition.

WARNING: The machine MUST NOT move, at ANY time, when the secondary/ parking brake control switch is in the “ON” position. DO NOT operate the machine, if the machine will move when the secondary/parking brake system is in an “ON” [APPLIED] condition. Notify repair personnel and repair the machine IMMEDIATELY.

2/98

Putting the secondary/parking brake system control switch in the “OFF” [RELEASED] position will cause the solenoid to move the spool in the solenoid valve, permitting the supply of charge pressure oil to the secondary/parking brake release piston in each drive motor. The brake release piston will move outward, compressing the large application washer and release the multi-disc brakes on each drive motor.

NOTE: Inspection, and repair as needed, of the secondary/parking brake system MUST be done when the drive motors are removed from the machine. Remove, inspect and replace secondary/ parking brake parts, as needed, using the information given under the drive motor “Repair procedures”, in the TRANSMISSION SYSTEM Section, at that time. See Section 7 - ELECTRICAL - for secondary/parking brake system electrical circuit operation descriptions.

9-3

Section 9 BRAKE SYSTEM SECONDARY/PARKING BRAKE SYSTEM SOLENOID VALVE.

c. Loosen and remove the solenoid retaining nut, found at the top of the solenoid.

REMOVAL AND REPLACEMENT [See Figure

d. CAREFULLY lift the solenoid from the valve body.

9-2]. Use the following procedure to remove and replace the secondary/parking brake system solenoid, found on the solenoid valve.

e. CAREFULLY install the NEW solenoid onto the valve body. f. Install and tighten the solenoid retaining nut to securely hold the solenoid to the body.

NOTE: Use the SAME procedure, as given below, to remove and replace the L.H. and R.H. transmission low/high range solenoid, which also is found on the solenoid valve. All three solenoids are the same and are able to be exchanged.

CAUTION: Do NOT overtighten the retaining nut.

a. Stop the engine. Wash the solenoid and valve body with CLEAN diesel fuel and dry with compressed air.

h. Start the engine. Check for correct system operation.

b. CAREFULLY remove the single wire from the solenoid being removed and replaced.

LH TRANSMISSION LOW/HIGH RANGE SOLENOID

g. CAREFULLY connect the single wire to the solenoid.

WARNING: Keep ALL personnel, except the operator, CLEAR of the area of the machine during the operation check. RH TRANSMISSION LOW/HIGH RANGE SOLENOID RETAINING NUT

SECONDARY/PARKING BRAKE SYSTEM SOLENOID

FIGURE 9-2. SECONDARY/PARKING BRAKE SYSTEM SOLENOID VALVE ASSEMBLY.

9-4

2/98

Section 10 STEERING SYSTEM

TABLE OF CONTENTS

PAGE GENERAL ................................................................................................................................................. 10-3 OPERATION ............................................................................................................................................. 10-5 POWER OPERATION ........................................................................................................................... 10-5 MANUAL OPERATION ......................................................................................................................... 10-5 HYDRAULIC POWER STEERING PUMP ................................................................................................ 10-5 REMOVAL ............................................................................................................................................. 10-5 DISASSEMBLY ..................................................................................................................................... 10-5 CLEANING AND INSPECTION ............................................................................................................. 10-7 ASSEMBLY ........................................................................................................................................... 10-7 INSTALLATION ..................................................................................................................................... 10-8 POWER STEERING CONTROL ............................................................................................................... 10-8 GENERAL .............................................................................................................................................. 10-8 REMOVAL ............................................................................................................................................. 10-8 INSTALLATION ..................................................................................................................................... 10-9

2/98

10-1

Section 10 STEERING SYSTEM PAGE STEERING CYLINDER ............................................................................................................................. 10-9 REMOVAL ............................................................................................................................................. 10-9 DISASSEMBLY ..................................................................................................................................... 10-10 CLEANING AND INSPECTION ............................................................................................................. 10-10 ASSEMBLY ........................................................................................................................................... 10-10 INSTALLATION ..................................................................................................................................... 10-12 REMOVING AIR FROM [BLEEDING] THE SYSTEM .............................................................................. 10-12 CHECKING AND ADJUSTING STEERING SYSTEM PRESSURE ........................................................ 10-13 TROUBLESHOOTING .............................................................................................................................. 10-14

10-2

2/98

Section 10 STEERING SYSTEM GENERAL [See Figure 10-1].

Components of the steering system are:

This section contains a description of the steering system operation and overhaul instructions for selected major components. Overhaul instructions include removal, disassembly, inspection, assembly, installation and pressure check procedures.

Engine mounted hydraulic oil supply pump.

Specifications are given in Section 2 and troubleshooting guide, for the selected system components, is found in this section.

One [1] double acting hydraulic steering cylinder.

Dashboard mounted steering control and steering column.

The steering system has a neutral feel to the operator by providing a direct relation between the steering wheel position and the position of the steering cylinder.

Steering wheel. Hydraulic oil reservoir [common with the transmission hydraulic reservoir]. Hydraulic lines and fittings.

TEST COUPLING

FITTING

FLANGE SCREWS

PRESSURE HOSE CAPSCREW AND WASHER

STEERING CONTROL

STEERING WHEEL

STEERING COLUMN

NUT

CAP

SUPPLY HOSE

OIL COOLER

FLOOR PLATE GASKET STEERING PUMP

FITTING STRAINER

STEERING CYLINDER

FIGURE 10-1. STEERING SYSTEM COMPONENTS.

2/98

10-3

Section 10 STEERING SYSTEM

FIGURE 10-2. STEERING SYSTEM HYDRAULIC SCHEMATIC.

10-4

2/98

Section 10 STEERING SYSTEM OPERATION [See Figure 10-2].

REMOVAL [See Figure 10-1].

POWER OPERATION.

Use the following procedures to remove the steering pump from the engine.

With no turning force yet applied, hydraulic oil is drawn through a strainer located in the hydraulic reservoir to the power steering pump. This gear pump circulates oil through the primary control valve of the power steering control (dashboard mounted). Return oil is then directed through the oil cooler and back to the reservoir. When steering action is initiated by rotation of the steering wheel, the control spool is rotated, thereby allowing fluid to be fed to the power steering control metering section. This section meters out only the amount of oil required to make the turn indicated by the steering wheel position. The fluid is then ported to feed the proper actuator control port and thus the correct steering cylinder end. The alternate actuator port is simultaneously coupled to return displaced fluid from the opposite end of the cylinder through the oil cooler and back to the hydraulic reservoir. Once the correct amount of fluid is measured out, the control valve is repositioned by a spring to its open center, neutral setting, hence causing a rotary followup action in the steering wheel. The spool then maintains pressure in the steering cylinder for the desired turn until steering action is again initiated.

MANUAL OPERATION. In manual operation, the fluid metering section becomes a rotary pump and directs fluid to move the spool in either direction when the steering wheel is manually rotated. A check valve within the unit develops a closed circuit between the hydraulic cylinder and the metering area.

a. Open the LH hood side door. b. Wash the steering pump and the hoses fastened to it with CLEAN diesel fuel and dry using compressed air. c. Put an identification tag on each hose and each fitting of the steering pump. Disconnect all hoses from the steering pump. Put caps, or plugs, in all hoses and on all pump fittings IMMEDIATELY after the hoses are disconnected. d. Remove the capscrews which fasten the steering pump to the engine. Carefully remove the pump from the engine.

CAUTION: Do not permit the pump to fall when being removed from the engine.

e. Remove the pump to engine sealing gasket from the pump mounting area on the engine. Put a clean paper cover over the pump mounting area on the engine and secure with tape.

DISASSEMBLY [See Figure 10-3]. Use the following procedures to disassemble a steering pump which was removed for inspection and/or replacement of the internal parts.

CAUTION: Disassemble the pump only on a CLEAN work surface, in a CLEAN work area.

HYDRAULIC POWER STEERING PUMP [See Figures 10-1] The hydraulic steering pump is a gear type with a constant rate of delivery per revolution and is mounted directly to the left hand side of the engine.

a. Wash the pump with CLEAN diesel fuel to remove ALL dirt not previously removed. Dry the pump by using compressed air.

The pump supplies a flow of hydraulic fluid for operation of the power steering system.

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10-5

Section 10 STEERING SYSTEM e. Remove the end plate.

b. Make a scribed line down the full length of the pump to help align sections during assembly. Support the pump between the jaws of a vise.

f. Remove the two [2] gears. g. Remove the gear plate.

CAUTION: Do NOT tightly clamp the pump in a vise for disassembly. Use the vise to only support the pump. Clamping the pump will cause damage to the body and internal parts.

c. Loosen and remove the four [4] capscrews that fasten the end plate to the pump body.

h. Remove the wear plates from the pump body and end plate. i. Remove the pre-load seals and the load seals from the pump body and end plate. j. CAREFULLY remove the seal from the pump body.

d. Remove the two [2] o-rings from the inlet and outlet ports on the pump body.

CAUTION: Do NOT pry the components apart. Use a SOFT plastic hammer to tap on the components until they separate.

NOTE: ONLY the thrust plate, wear plate and seal kit are available to service the pump. REPLACE the pump, with NEW, if damage to parts not serviced is found during the following inspection procedures.

PLUG BODY

CAPSCREW

GEARED BEARING SHAFT SEAL BEARING SEAL RETAINER BEARING SEAL RING

END PLATE O - RING GEARED SHAFT

FIGURE 10-3. STEERING PUMP - EXPLODED VIEW.

10-6

2/98

Section 10 STEERING SYSTEM CLEANING AND INSPECTION [See Figure 10-3].

c. Carefully install the shaft seal into the pump body.

Use the following procedures and guidelines to inspect the disassembled pump parts to help determine if a part should be used again or be replaced with new.

CAUTION: Do NOT damage the seal during installation.

a. Wash ALL parts with CLEAN diesel fuel and dry using compressed air.

d. Put bearing grease on all pre-load and load seals.

CAUTION: Discard all o-rings and seals. Replace the o-rings and seals with NEW during assembly. These parts are contained in the seal "kit".

e. Carefully install the pre-load seal and the load seal into the pump body. Carefully install the pre-load seal and the load seal into the end plate.

b. Inspect the pump components for wear or damage. Replace components with new as needed.

CAUTION: Install the load seal against the wear plate in both the pump body and end plate. Use extreme caution when installing the seals. Install the seals in a "square" relationship to the seal bores.

CAUTION: If components are NOT smooth, the pump shows unusual wear or the pump did not meet specified flow and pressure requirements, replace the pump with new.

f. Install the wear plates.

ASSEMBLY [See Figure 10-3]. Use the following procedures to assemble the steering pump after component inspection.

CAUTION: Be sure all parts of the steering pump are CLEAN. Assemble the pump only on a CLEAN work surface in a CLEAN work area. Use only CLEAN lint free cloth during pump assembly. a. If needed, polish all cover and housing machined surfaces, which mate together, using a carborundum stone. Wash all parts, again, and dry using compressed air. Put CLEAN hydraulic oil on ALL parts BEFORE the pump assembly begins. Put all parts on CLEAN lint free cloth. b. Carefully install the bearings into the pump body and end plate.

2/98

CAUTION: Install the wear plates, so that the brass surface of the wear plate is TOWARD the pump gears.

g. Install the dowel pins into the pump body. h. Put CLEAN hydraulic oil on the seal ring. Install the seal ring into the groove in the body. i. Put bearing grease on the gear shafts. Install the gears into the gear plate.

CAUTION: Do NOT damage the shaft seal when installing the gears. Place a drive shaft installation sleeve over the shaft when installing the shaft through the shaft seal. The sleeve wall thickness should be approximately 0.010 inch [0.25 mm].

10-7

Section 10 STEERING SYSTEM j. Lubricate the seal ring with CLEAN hydraulic oil. Install the seal ring into the end plate. k. Carefully align the scribe line on the pump body and the end plate. Install the end plate. Install the four [4] capscrews. Tighten the capscrews to a torque of 34 - 38 ft. lbs.[ 46-51 N.m].

CAUTION: Rotate the drive shaft while tightening the capscrews. Tighten the capscrews evenly to avoid distortion of the pump body and end plate.

l. Install NEW o-rings on the housing inlet and outlet ports.

g. Prime the system using the "Pre-Start Procedures" given in Section 8 - TRANSMISSION SYSTEM, before the engine is started. h. Start the engine. Check the steering system for correct operation.

DANGER: Keep ALL personnel CLEAR of the hitch area. Clearance CLOSES when the machine is turned in either direction.

POWER STEERING CONTROL. GENERAL.

m. Fill the pump with APPROVED, CLEAN and FILTERED hydraulic oil. Put a cap on each fitting.

The dashboard-mounted power steering control meters the oil flow to the steering cylinder. Provisions are also made for manual operation. For operation, see OPERATION in this section.

INSTALLATION [See Figure 10-1]. REMOVAL [See Figure 10-1]. Use the following procedures to install the steering pump onto the engine. a. Remove the paper cover from the pump mounting area on the engine. Put anti-seize on the spline area of the pump shaft. b. Put a new pump to engine sealing gasket in place on the pump mount area of the engine. Carefully put the steering pump in position on the pump mount area. c. Align the two [2] through holes in the steering pump mounting flange with the tapped holes in the engine. d. Install the two [2] capscrews and washers through the holes in the mounting flange and thread into the tapped holes in the engine. Tighten the capscrews to a torque of 39 ft. lbs. [53 N.m]. e. Remove the plugs from the hoses and the caps from the pump fittings. Connect each hose to the CORRECT pump fitting and tighten securely.

a. Stop the engine. b. Pry out the steering wheel center hub. c. Remove steering wheel jam nut and use a puller to remove steering wheel. d. Put an identification tag on each hose and each fitting of the steering control. Disconnect all hoses from the steering control. Put caps, or plugs, in all hoses and on all control fittings IMMEDIATELY after the hoses are disconnected. e. While supporting the control unit, remove the two [2] screws securing the steering control and the steering column to the mounting bracket. f. Remove the control unit and the steering column.

NOTE: The power steering control unit is serviced through removal and replacement with NEW.

f. Check the oil in the hydraulic oil reservoir. Add oil as needed [see Section 4 - MAINTENANCE].

10-8

2/98

Section 10 STEERING SYSTEM INSTALLATION [See Figures 10-1].

STEERING CYLINDER.

Use the following procedures to install the new steering control unit.

REMOVAL [See Figure 10-4].

a. Fill the new control with APPROVED, CLEAN and FILTERED hydraulic oil.

Use the following procedures to remove the steering cylinder for repair, or replacement. a. Stop the engine.

b. Position the steering column in through the mounting plate. c. Put the steering control in position on the steering column. Install and tighten the retaining capscrews. d. Remove the plugs from the hoses and the cap from all fittings. CAREFULLY connect EACH hose to the CORRECT steering control fitting as indicated by the identification tags installed before removal. e. Install the steering wheel onto the splined steering column. Install and tighten the wheel retaining nut. f. Install the steering wheel center hub.

b. Remove the floor plate from the operator's compartment. c. Wash the steering cylinder, hoses and the area where it connects, with CLEAN diesel fuel and dry using compressed air. d. Put an identification tag on EACH hose that fastens to the cylinder. Loosen and remove BOTH hoses from the cylinder. Put plugs in EACH hose and caps on EACH fitting. e. Remove the bolts securing the eyebolts to the steering cylinder and remove the eyebolts and mounting pins. f. Remove the steering cylinder.

WARNING: Do NOT put the hands or the arms through the steering wheel spoke area. A malfunction in the steering control or hoses not being connected correctly can cause the steering wheel to rotate with a force that can cause serious injury.

CAUTION: Do NOT start the engine UNTIL all system prestart procedures have been completed [See Section 8 TRANSMISSION SYSTEM].

FITTING STEERING CYLINDER TO PORT "R" ON STEERING CONTROL TO PORT "L" ON STEERING CONTROL

FITTING EYEBOLT MOUNTING PIN LOCK PIN (STORED POSITION)

FIGURE 10-4. STEERING CYLINDER - INSTALLED IN THE MACHINE.

2/98

10-9

Section 10 STEERING SYSTEM DISASSEMBLY [See Figure 10-5].

CLEANING AND INSPECTION [See Figure 10-5].

Use the following procedures to disassemble the steering cylinder for inspection and replacement of internal parts, as needed.

a. Wash ALL cylinder parts with CLEAN diesel fuel and dry using compressed air.

a. Wash the cylinder AGAIN with CLEAN diesel fuel and dry using compressed air.

NOTE: ALL seals are available in the repair "kit". Replace ALL items contained in the "kit".

b. Put the cylinder in a vise, with the shell area held VERY securely by the jaws. Put the cylinder rod in the mid range position.

b. Inspect the inside of the cylinder shell for wear, nicks, burrs, scratches, rust or other damage.

CAUTION: Do NOT crush the shell area of the cylinder.

c. Inspect the cylinder rod for wear or damage to the chrome surface. Replace the rod IF damaged, bent or if it has a nicked, rusted, scratched or pitted chrome surface.

c. Loosen and remove the two capscrews securing the cap.

NOTE: SLIGHT defects can be removed with FINE sandpaper or emery cloth.

d. Slide the cap up the rod. Using a soft drive, carefully tap the sleeve into the shell far enough to expose the lockwire. e. Remove the lockwire from the shell. f. Carefully pull the rod from the shell of the cylinder. g. Protect the cylinder rod with a cloth. CAREFULLY put the cylinder rod end in a vise, having SOFT jaws, and tighten the vise to hold the rod end securely.

CAUTION: Do NOT sand chrome plating off the outside of the rod. IF there is ANY doubt about chrome plating being removed from the rod, check by applying copper sulfate to the area. The rod will discolor where chrome is removed. If this condition is seen re chrome or replace the cylinder rod. Wash the cylinder rod AFTER defect removal, using CLEAN diesel fuel and dry with compressed air.

CAUTION: Do NOT damage the cylinder rod.

ASSEMBLY [See Figure 10-5].

h. Loosen and remove the piston locknut.

Use the following procedures to assemble the cylinder.

i. Remove the piston locknut and remove the piston, o-ring and the sleeve from the rod. j. Remove the piston seal from the piston. k. Remove the o-ring and the back-up ring from the OD of the sleeve. l. Remove the rod seal from the ID of the sleeve.

CAUTION: ALL parts of the cylinder MUST be VERY clean. The work surface, where the cylinder is being assembled MUST also be CLEAN and be in a CLEAN area. Dirt of ANY type can cause damage to the cylinder and/or steering system and a repeat failure can occur.

a. Put CLEAN hydraulic oil on ALL cylinder parts.

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Section 10 STEERING SYSTEM

SHELL

ROD

CAP

O-RING

BACK-UP LOCK RING WIRE SLEEVE PISTON SEAL

CAPSCREW

LOCKNUT

O-RING SEAL ROD SEAL

PISTON

FIGURE 10-5. STEERING CYLINDER - EXPLODED VIEW.

b. Install the new rod seal in the ID of the sleeve. c. Install the new o-ring and the back-up ring on the OD of the sleeve. The back-up ring must be installed, so that, it will be closest to the rod eye when installed. d. Install the new rod seal on the OD of the piston. e. Put a CLEAN cloth on the cylinder rod area. Put the cylinder rod in a vise. Tighten the vise to securely hold the rod. Put tape over the threaded area on the rod. f. Install the cap and sleeve on the piston rod. Slide them downward towards the middle of the rod.

i. CAREFULLY install the assembled piston rod into the open end of the cylinder shell, while compressing the back-up ring, o-ring and piston seal with the fingers. j. Slide the cap up the rod. Using a soft drive, carefully tap the sleeve into the shell far enough to expose the lockwire groove. k. Install the lockwire in the groove of the cylinder shell. l. Position the cap against the cylinder shell. Install the two [2] capscrews and tighten securely. m. Fill the cylinder with CLEAN, FILTERED hydraulic oil and install caps on EACH fitting.

g. Remove the tape from the threaded area on the rod. h. Install the o-ring and piston on the end of the piston rod. Install the locknut and tighten to a torque of 250-300 ft. lbs. [350-420 N.m].

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10-11

Section 10 STEERING SYSTEM INSTALLATION [See Figure 10-4]. Use the following procedures to install the repaired, or replacement, steering cylinder onto the machine. a. CAREFULLY put the steering cylinder into position, so that the shell end is in position on the front frame and the rod end is in position on the ear of the hitch. b. Liberally coat the mounting pins with anti-seize compound. Install the two [2] mounting pins and secure with the eyebolts and flange screws. Tighten the flange screws to a torque of 105 ft. lbs. [143 N.m]. c. Remove the caps from the fittings in the cylinder and the plugs from the hoses. Connect EACH steering hose to the CORRECT cylinder fitting. Tighten the hoses securely onto the fittings. d. Check the oil level in the hydraulic oil reservoir. Add oil, IF needed, using the procedures given in Section 4 - MAINTENANCE. e. Prime the system using the "Pre-Start Procedures" given in Section 8 - TRANSMISSION SYSTEM, before the engine is started.

CAUTION: Do NOT start the engine BEFORE performing the "Pre-Start Procedures" given in Section 8 - TRANSMISSION SYSTEM and the following AIR REMOVAL procedures.

f. Start the engine. Check for correct steering cylinder and system function.

DANGER: Keep ALL personnel CLEAR of the hitch area. Clearance CLOSES when the machine is turned in either direction.

Remove the air [bleed] from the system using the following information: a. Fill the hydraulic oil reservoir to the CORRECT oil level [see Section 4 - MAINTENANCE]. b. Start the engine and put the throttle in the LOW idle position for approximately ONE [1] minute.

WARNING: DO NOT put the hands or the arms through the steering wheel spoke area. A malfunction in the steering control unit or hoses not being connected correctly can cause the steering wheel to rotate with a force that can cause serious injury.

c. Increase the engine speed to approximately 1000 RPM and turn the steering wheel in ONE [1] direction UNTIL the steering cylinder reaches its limit. Quickly reverse the steering wheel rotation to cause pressure to build in the opposite end of the steering cylinder.

DANGER: Keep ALL personnel CLEAR of the hitch area. Clearance CLOSES when the machine is turned in either direction.

NOTE: This will permit the large air bubbles to leave the system.

d. Continue to rotate the steering wheel left and right, from stop to stop, UNTIL the steering functions are normal and correct. Slow and stop the engine.

NOTE: If the steering functions fail to be normal, air can be entering the system at the suction side of the pump. Check and tighten ALL hoses to fitting connections. Also check system pressure using the procedures given in THIS section.

REMOVING AIR FROM [BLEEDING] THE SYSTEM. Air can become trapped in the system when the system is opened and a component is removed and replaced. An aerated system is indicated by jerky or spongy operation when the steering wheel is turned.

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Section 10 STEERING SYSTEM CHECKING AND ADJUSTING STEERING SYSTEM PRESSURE [See Figure 10-1]. Use the following procedures to check the steering system relief pressure. The relief pressure is checked at the pressure check port located at the steering pump.

NOTE: Under most normal conditions, the steering system relief pressure should be found within the correct pressure range, during this pressure check. Therefore, no steering system relief pressure adjustment will be required.

a. Check the oil level in the hydraulic reservoir. Add APPROVED oil if needed using the procedures given in Section 4 - MAINTENANCE.

g. Put the throttle in the "HIGH" idle position. Turn the steering wheel either to the left or the right, while reading the relief pressure indicated on the pressure gauge. Put the engine throttle switch in the "LOW" idle position and run the engine for a period of 3-5 minutes. Stop the engine.

CAUTION: The correct relief pressure is 2250 +/-50 psi [155 +/-3 bar]. An indicated relief pressure that is above or below the above pressure will need correction by adjustment of the steering system relief valve assembly contained in the steering control unit.

h. If needed, adjust the relief pressure using the following information. 1. Keep the engine STOPPED.

b. Install the steering lock pin at the hitch. c. STOP the engine. Clean the fitting and pressure check area with a CLEAN lint free cloth. d. Loosen and remove the pressure check cap from the fitting. e. Install and tighten a 3000 psi. [210 bar] pressure gauge, on a long hose that will reach the cockpit area, onto the pressure check port fitting and tighten securely. f. Put the secondary/parking brake system control toggle switch in the "ON" [APPLIED] position. Start the engine and allow the hydraulic system to reach normal operating temperature.

CAUTION: Do NOT hold the system over relief pressure for a period longer than TWENTY [20] seconds. Pump damage can occur.

2. Go to the dashboard area, just below the steering column. Find and remove the plastic hole plug which is installed into the pressure adjustment access hole in the dashboard. 3. If not previously done, alter a 3/16 Allen wrench by grinding the short end of the wrench away to a length approximately one half of the original length.

NOTE: Reducing the length of the short end of the wrench will allow the wrench to fit into the pressure adjusting screw.

4. Install the short end of the Allen wrench through the access hole in the dash and into the steering relief pressure adjusting screw. Change the pressure by turning the adjusting screw INWARD or OUTWARD a SMALL amount. Remove the ALLEN wrench.

NOTE: Turning the adjusting screw INWARD [CLOCKWISE] will INCREASE the steering relief pressure. Turning the adjusting screw OUTWARD [COUNTERCLOCKWISE] will DECREASE the steering relief pressure.

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10-13

Section 10 STEERING SYSTEM 5. Start the engine. Check the steering relief pressure, AGAIN, using the procedures given above. IF needed, adjust the pressure, AGAIN, using the above information.

TROUBLESHOOTING.

6. AFTER the steering relief pressure is found to be correct, install the plastic plug into the dashboard. Do steps "i" through "k" below.

These tables list the most common troubles that may be encountered, the probable causes of the trouble, and the corrective action that should be taken to restore the unit to normal operating condition.

Table 10-1 is a trouble analysis check chart for the steering system components.

i. Remove the hose and pressure gauge from the check port and install and tighten the cap onto the check port fitting. j. Remove the steering lock pin. k. Start the engine and check the steering system for correct operation.

DANGER: Keep ALL personnel CLEAR of the hitch area. Clearance CLOSES when the machine is turned in either direction.

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Section 10 STEERING SYSTEM TABLE 10-1. TROUBLE ANALYSIS FOR THE STEERING SYSTEM PROBLEM

CAUSE

CORRECTION

STEERING PUMP NO FLOW FROM PUMP

LOW FLOW FROM PUMP

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Low oil level in reservoir

Check oil level and add oil as needed. Find and correct cause of low oil level.

Pump NOT being driven.

Check drive gear on engine. Repair as needed

Steering pump has internal damage

Remove, repair or replace pump.

Pump NOT priming air entering system

Check ALL hose and fittings for tightness and tighten as needed.

Fluid outlet from reservoir in a restricted condition

Remove clean or replace strainer and/or hose.

Incorrect hydraulic oil in system

COMPLETELY drain the system of oil. Flush ENTIRE system and fill with NEW, CLEAN and FILTERED oil [see Section 4 - MAINTENANCE].

Low oil level in reservoir

Check oil level and add oil as needed. Find and correct cause of low oil level.

Restricted inlet suction strainer and/or hose

Remove, clean and replace as needed.

Air being drawn into system

Check ALL hose to fitting connections. Tighten as needed.

Pump has internal leakage.

Worn and/or damaged parts in pump. Remove, repair or replace, as needed.

10-15

Section 10 STEERING SYSTEM TABLE 10-1. TROUBLE ANALYSIS FOR THE STEERING SYSTEM (CONT.) PROBLEM

CAUSE

CORRECTION

STEERING PUMP PUMP MAKES NOISE

10-16

Pump NOT being supplied enough oil

Check oil level and add oil as needed. Find and correct cause of low oil level.

Restricted inlet suction strainer and/or hose

Remove, clean and replace as needed.

Pump has internal damage

Remove, repair or replace pump.

Air being drawn into system.

Check ALL hose and fitting connections. Tighten as needed.

Dirt in pump and system

Drain and flush system. Remove pump, disassemble and inspect pump. Repair, or replace, pump as needed and install.

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Section 10 STEERING SYSTEM TABLE 10-1. TROUBLE ANALYSIS FOR THE STEERING SYSTEM (CONT.) PROBLEM

CAUSE

CORRECTION

STEERING CONTROL UNIT No flow from pump

Check for pump output. Repair, or replace, pump as needed.

Control unit has damage

Remove unit. Replace with NEW.

Steering cylinder has damage

Remove cylinder. Repair or replace as needed.

Low system oil level

Add oil as needed. Find and correct cause of low oil level.

Hose[s] in system in a stopped condition

Remove, clean or replace hose[s].

Dirt in system

Check suction strainer. Clean or replace as needed. Clean COMPLETE hydraulic system, if needed [see section 8 - TRANSMISSION SYSTEM].

Steering control unit sleeve and spool worn

Remove unit, replace with NEW.

Steering control unit metering gear worn

Remove unit, replace with NEW.

Steering pump damaged

Remove, repair or replace pump.

Manual steering check ball off its seat.

Remove unit, replace with NEW.

STEERING WHEEL DOES NOT CENTER

Steering control unit has broken centering springs

Remove unit, replace with NEW.

STEERING WHEEL ROTATION IS CONTINUOUS

Steering control unit has broken centering springs

Remove unit, replace with NEW.

Steering control unit has burr on sleeve and/or spool

Remove unit, replace with NEW.

NO RESPONSE WHEN STEERING WHEEL IS TURNED

SLOW OR HARD STEERING

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10-17

Section 10 STEERING SYSTEM TABLE 10-1. TROUBLE ANALYSIS FOR THE STEERING SYSTEM (CONT.) PROBLEM

CAUSE

CORRECTION

STEERING CONTROL UNIT Steering supply hoses NOT correctly connected to unit and/or cylinders

Check for CORRECT connection locations and change as needed.

Steering control unit metering star to shaft slot NOT aligned correctly

Remove unit, replace with NEW.

NO PRESSURE OR FLOW FROM VALVE

Relief valve has internal damage

Remove steering control unit. Replace with NEW [see THIS section].

SYSTEM PRESSURE LOW

Relief valve not set to correct specifications

Adjust relief pressure [see THIS section].

SYSTEM PRESSURE HIGH

See above information.

SYSTEM PRESSURE NOT STEADY - VARIES

Relief valve has damaged parts

Remove steering control unit. Replace wth NEW [see THIS section].

WRONG STEERING RESPONSE TO STEERING WHEEL COMMAND

STEERING CYLINDER NO MOTION FROM STEERING CYLINDER

SLOW MOTION FROM STEERING CYLINDER

10-18

NO oil being supplied to steering cylinder

Check the system for damaged pump, relief valve, steering control unit, or hose[s]. Check oil level. Repair as needed. See THIS "Trouble Analysis".

Cylinder has internal damage

Remove cylinder, repair or replace as needed.

LOW oil supply to cylinder

Check as above.

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Section 10 STEERING SYSTEM TABLE 10-1. TROUBLE ANALYSIS FOR THE STEERING SYSTEM (CONT.) PROBLEM

CAUSE

CORRECTION

STEERING CYLINDER ACTION OF CYLINDER IS JERKY

Air in system

Check oil level in reservoir. Add oil as needed. Find and correct cause for low oil level. Check for loose hose to fitting connections. Tighten as needed. Remove air [bleed] [See this section].

EXCESSIVE LOST MOTION AT CYLINDER

Bent or deformed cylinder piston, or rod

Remove cylinder, repair or replace as needed.

Bushings at steering cylinder to machine worn.

Remove and replace bushings as needed.

Loose cylinder anchor pin, retainer pin and/or anchor capscrew

Inspect and tighten nut the CORRECT specification as needed.

Cylinder yoke worn/broken at rod and/or anchor ends

Remove cylinder, repair or replace as needed.

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10-19

Section 10 STEERING SYSTEM NOTES

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Section 11 WATER SPRAY SYSTEM

TABLE OF CONTENTS

PAGE GENERAL INFORMATION ...................................................................................................................... 11-2 DESCRIPTION ......................................................................................................................................... 11-2 STRAINER ................................................................................................................................................ 11-2 SPRAY NOZZLES .................................................................................................................................... 11-2 WATER SPRAY PUMP AND MOTOR .................................................................................................... 11-3 GENERAL ............................................................................................................................................. 11-3 REMOVAL ............................................................................................................................................. 11-3 DISASSEMBLY ..................................................................................................................................... 11-3 ASSEMBLY ........................................................................................................................................... 11-3 INSTALLATION .................................................................................................................................... 11-5 TROUBLESHOOTING ............................................................................................................................. 11-5

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11-1

Section 11 WATER SPRAY SYSTEM GENERAL INFORMATION. 10 AMP CIRCUIT BREAKER

This section contains a description of the water spray system for the Model BW11RH Roller. Design specifications, are presented in Section 2 and a troubleshooting guide is presented at the end of this section.

DESCRIPTION [See Figure 11-1].

WATER TANK

WATER SPRAY SWITCH

WATER PUMP

WATER SPRAY PUMP MOTOR

Water spray system is fed by a pump. The water pump, which is controlled by an electrical “on/off” switch on the dash, supplies water to the manifolds, when the system control switch is in the “ON” position. When the system control switch is placed in the “ON” position, the amount of water being supplied to both water spray manifolds is regulated by the flow control valve. The flow control valve is found behind the cover on the back wall of the operator's compartment. The water spray system consists of a tank, solenoid valve, pump, motor, spray manifold and spray nozzles. The tank features an access cover for cleaning the tank, an inlet screen and a sump strainer. A drain plug is located in the bottom of the tank for flushing or draining the tank.

WATER SPRAY BAR

FIGURE 11-1. WATER SPRAY BLOCK DIAGRAM.

STRAINER. Maintenance procedures for the water spray system strainer is given in Section 4 - MAINTENANCE - in THIS manual.

SPRAY NOZZLES. Maintenance procedures for the water spray nozzles are given in Section 4 - MAINTENANCE - in THIS manual.

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Section 11 WATER SPRAY SYSTEM WATER SPRAY PUMP AND MOTOR. GENERAL. The water spray pump and motor is located behind the cover on the back wall of the operator's compartment. The pump and motor is a single assembly, combining an electric motor with a small pump.

REMOVAL [See Figure 11-2]. a. Put the water spray system “on/off” control switch in the “OFF” position and STOP the engine. b. Remove the cover on the back wall of the operator's compartment. c. Disconnect the electrical wires from the water spray pump.

b. Remove the pump housing from the diaphragm assembly. c. Remove the check valve assembly from the pump housing. d. Remove the two [2] screws that hold the cover and diaphragm assembly to the motor body. Align the set screw with a slot in the pump cover. Loosen the set screw with an Allen wrench just enough to slide the diaphragm and cover assembly off the motor drive shaft as a unit. e. Remove the two [2] screws that attach the cam/ bearing to the diaphragm. Remove the diaphragm and cover.

NOTE: The screws that hold the cam/bearing, the cam/bearing diaphragm, cover and check valve are all included in the pump "repair kit".

d. Put an identification tag on each hose connected to the water pump fittings. Loosen the retaining clamps and remove hoses from the water spray pump fitting.

CAUTION: Do NOT mix old and new "repair kit" parts. Install all NEW parts.

e. Remove the four [4] retaining nuts from the four [4] mounting bracket studs. Remove the pump assembly.

ASSEMBLY [See Figure 11-3].

f. Put the water spray pump assembly on a CLEAN work surface. If needed, disassemble the pump by using the following ADDITIONAL repair information.

a. Install the new set screw in the new cam/bearing, a small amount. Install the two [2] new screws into the new cam/bearing, through the cover and into the new diaphragm assembly. Tighten the screws securely.

DISASSEMBLY [See Figure 11-3].

b. Slide the diaphragm and cover assembly onto the motor drive shaft and tighten the set screw securely against the drive shaft.

CAUTION: A “repair kit” is available and permits the water spray pump assembly and the drive motor to be serviced SEPARATELY. In some cases the pump damage can require the complete water spray pump assembly to be replaced with NEW. a. Remove the four [4] screws and lock washers from the pump housing.

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c. Install the two [2] screws, that hold the cover and diaphragm assembly, to the motor body. Tighten the screws securely. d. Install the new check valve assembly into the pump head. e. Install the pump head and check valve assembly, onto the cover assembly. Align the four [4] mounting screw holes and install the mounting screws. Tighten the screws securely.

11-3

Section 11 WATER SPRAY SYSTEM CAP MANIFOLD PIPE COLLAR

BRACKET

PUMP

NOZZLE

COLLAR

MANIFOLD PIPE CLAMP GROMMET

CAP

CAPSCREW, NUT

WATER TANK STRAP

CLAMP

FLANGE SCREWS

CLAMP VALVE

CLAMP VIEW A-A CLAMP STRAINER

CLAMP

FIGURE 11-2. WATER SPRAY SYSTEM COMPONENT LOCATIONS.

11-4

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Section 11 WATER SPRAY SYSTEM f. Fill the water tank with enough water to check the water spray system operation.

INSTALLATION [See Figure 11-2]. a. Position the water spray pump on the four [4] mounting studs, so that the pump is in the correct position for connection of the lines. b. Install the four [4] retaining nuts on the mounting studs. Tighten the four [4] retaining nuts to a torque of 5 ft. lbs. [6.8 N.m].

CAUTION: Do NOT overtighten the retaining nuts.

g. Turn the ignition key switch in the “ON” [RUN] position. Put the water spray system control switch in the “ON” position and check the water spray system for CORRECT operation [See Section 3 OPERATION in this manual].

TROUBLESHOOTING. Table 11-1 is a trouble analysis check chart for the water pump assembly.

c. Install the hoses onto the water spray pump fittings and tighten the clamps securely. d. Connect the electrical wire harness plug to the pump harness connection plug fitting.

This table lists the most common troubles that may be encountered, the probable causes of the trouble, and the corrective action that should be taken to restore the unit to normal operating condition.

e. Install the cover on the back wall of the operator's compartment.

MOTOR

PUMP

COVER SET SCREW DIAPHRAM KIT CHECK VALVE SCREW

HOUSING

CAM SEARING

CONNECTOR CONNECTOR SCREW SCREW

GOMMENT PLATE

FIGURE 11-3. WATER SPRAY PUMP - EXPLODED VIEW.

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11-5

Section 11 WATER SPRAY SYSTEM Table 11-1. TROUBLE ANALYSIS FOR THE WATER SPRAY SYSTEM. PROBLEM PUMP MOTOR WILL NOT OPERATE

CAUSE

CORRECTION

Open circuit in on/off control toggle switch

Remove and replace switch.

Circuit breaker in electrical system NOT resetting - damaged

Remove and replace breaker.

Contaminate in pump

Clean pump.

Motor brushes worn excessively or motor has total failure damage

Remove pump and motor assembly. Replace pump and motor assembly with new. Install pump and motor assembly.

PUMP MOTOR WILL NOT SHUT OFF

On/off toggle control switch damaged

Remove and replace switch.

PUMP OPERATES BUT HAS LITTLE, OR NO, SPRAY PATTERN

Insufficient liquid in water tank

Replenish liquid supply.

Strainer plugged

Remove, clean strainer and install. Clean tank.

Pump housing cracked from freezing

Replace pump.

Spray nozzles plugged

Remove, clean nozzles and manifolds and install.

One or more spray nozzles plugged

Remove nozzles, clean and install.

Charging system has damage. (low voltage to water spray pump motor

Check charging system. Repair system as needed.

SPRAY PATTERN NOT COMPLETELY COVERING TIRE

11-6

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Section 11 WATER SPRAY SYSTEM NOTES

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11-7