Bomag BW 124D, BW124PD, BW124 PDB Single drum rollers Instructions for repair Manual 0852636 - PDF

BW 124D, BW124PD, BW124 PDB Single drum rollers Instructions for repair Catalog number 0852636 - 06/96

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 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 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 FALLING OBJECT/ ROLL OVER PROTECTION STRUCTURE ............................................................................................ 5-1.

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

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

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

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

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

SECTION 11 - VIBRATION SYSTEM ...................................................................................................... 11-1.

SECTION 12 - CONTROL SYSTEMS ..................................................................................................... 12-1.

SECTION 13 - OPTIONAL EQUIPMENT ................................................................................................ 13-1.

SECTION 14 - SPECIAL TOOLS ............................................................................................................ 14-1.

6/96

i

Section 1 INTRODUCTION

TABLE OF CONTENTS PAGE GENERAL INFORMATION ............................................................................................................................ 1-2 SPECIFICATIONS .......................................................................................................................................... 1-2 OPERATING INSTRUCTIONS ....................................................................................................................... 1-2 MAINTENANCE PROCEDURES ................................................................................................................... 1-4 REPAIR PROCEDURES ................................................................................................................................ 1-4 NAME PLATE / SERIAL NUMBER PLATE ................................................................................................... 1-4 SERIAL NUMBER .......................................................................................................................................... 1-4

11/95

1-1

Section 1 INTRODUCTION GENERAL INFORMATION.

OPERATING INSTRUCTIONS.

This manual contains SPECIFICATION, OPERATION and MAINTENANCE procedures for the BOMAG Model BW124D, BW124PD and BW124PDB Single Drum Rollers [See figures 1-1,1-2 and 1-3].

Read, understand and follow ALL operating instructions given in Section 3 - OPERATION, of this manual.

SPECIFICATIONS. See Section 2 - SPECIFICATIONS, of this manual, for specifications on major systems used on the BOMAG Model BW124D, BW124PD and BW124PDB Single Drum Rollers.

WARNING: Only authorized personnel, who are fully trained in the machine operation procedures, can operate the BOMAG Model BW124D, BW124PD and BW124PDB Single Drum Rollers.

Follow ALL operating instructions given in this manual and written on the “Warning” decals, found on the machine.

FIGURE 1-1. BOMAG MODEL BW124D SINGLE SMOOTH DRUM ROLLER.

1-2

11/95

Section 1 INTRODUCTION

FIGURE 1-2. BOMAG MODEL BW124PD SINGLE PAD DRUM ROLLER.

FIGURE 1-3. BOMAG MODEL BW124PDB SINGLE PAD DRUM ROLLER - WITH BLADE. 11/95

1-3

Section 1 INTRODUCTION MAINTENANCE PROCEDURES. 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.

REPAIR PROCEDURES. Major machine component repair procedures are found in the “System Repair Procedure” sections of Instructions For Repair Manual pn. 0852636.

CAUTION: For correct machine component repair procedures, use Instructions For Repair Manual pn. 0852636 or other referenced written materials.

FIGURE 1-4. NAME PLATE/SERIAL NUMBER PLATE LOCATION.

NAME PLATE/SERIAL NUMBER PLATE [See Figure 1-4].

The combination name plate/serial number plate is found on the left hand outer side of the control console. The plate must stay fastened to the machine at all times.

If the plate is lost, or damaged, it must be replaced immediately. Contact your nearest Distributor to obtain a replacement nameplate and install it immediately.

SERIAL NUMBER [See Figures 1-4, 1-5 and Table 1-1].

The serial number indicates the design series, manufacturing location, serial number and year of shipment [see table 1-1]. The serial number is found on the name plate/serial number plate [see figure 1-4].

The serial number is also stamped into the top flat area of the right front frame [see figure 1-5].

1-4

FIGURE 1-5. SERIAL NUMBER LOCATION ON FRONT FRAME.

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Section 1 INTRODUCTION A219

C

1535

R

BW124D BW124PD BW124PDB

KEWANEE

SERIAL NUMBER

YEAR SHIPPED

TABLE 1-1. MACHINE SERIAL NUMBER DESIGNATIONS.

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1-5

Section 1 INTRODUCTION NOTES

1-6

11/95

Section 2 SPECIFICATIONS

TABLE OF CONTENTS

PAGE GENERAL INFORMATION ..................................................................................................................... 2-2.

TABLE 2-1. FRAME AND HITCH SPECIFICATIONS ............................................................................ 2-2.

TABLE 2-2. ENGINE SPECIFICATIONS ................................................................................................ 2-2.

TABLE 2-3. ELECTRICAL SPECIFICATIONS ....................................................................................... 2-5.

TABLE 2-4. TRANSMISSION SYSTEM SPECIFICATIONS .................................................................. 2-6.

TABLE 2-5. BRAKE SYSTEM SPECIFICATIONS ................................................................................. 2-8.

TABLE 2-6. STEERING AND LEVELING BLADE SYSTEMS SPECIFICATIONS ................................ 2-8.

TABLE 2-7. DRUM, VIBRATION, AND SCRAPER SPECIFICATIONS ............................................... 2-10.

TABLE 2-8. TIRE SPECIFICATIONS ................................................................................................... 2-12.

TABLE 2-9. CONTROL AND INDICATOR SPECIFICATIONS ............................................................ 2-13.

TABLE 2-10. OPTIONAL EQUIPMENT SPECIFICATIONS................................................................. 2-14.

TABLE 2-11. DIMENSION SPECIFICATIONS ..................................................................................... 2-15.

TABLE 2-12. MACHINE WEIGHT SPECIFICATIONS ......................................................................... 2-17.

TABLE 2-13. PERFORMANCE SPECIFICATIONS ............................................................................. 2-18.

TABLE 2-14. MACHINE SYSTEM CAPACITY SPECIFICATIONS...................................................... 2-18.

TABLE 2-15. COMPONENT WEIGHTS................................................................................................ 2-19.

TABLE 2-16. TORQUE SPECIFICATIONS FOR STANDARD METRIC FASTENERS ................................................................................................... 2-21.

TABLE 2-17. TORQUE SPECIFICATIONS FOR STANDARD INCH FASTENERS ........................................................................................................ 2-22.

TABLE 2-18. LUBRICATION OILS, HYDRAULIC OILS AND COOLANT SPECIFICATIONS ........................................................................................ 2-23.

TABLE 2-19. ADHESIVE THREAD LOCKING SPECIFICATIONS...................................................... 2-23.

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2-1

Section 2 SPECIFICATIONS GENERAL INFORMATION. This section gives specification tables for each major machine system of the BOMAG Model BW124D, BW124PD and BW124PDB Single Drum Rollers.

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

TABLE 2-1. FRAME AND HITCH SPECIFICATIONS. ITEM

DESIGN DATA

FRAME and HITCH Material And Construction

Plate steel unitized, allwelded 2 section

HITCH Oscillation

+/- 6.5˚- up or down, from center, 13˚ total

Articulation

+/- 30˚- right or left turn, from center, 60˚ total

TABLE 2-2. ENGINE SPECIFICATIONS. ITEM

DESIGN DATA

ENGINE

2-2

Model and Manufacturer

F3L1011, Deutz

Type

4 Stroke diesel

Number of Cylinders

Three [3]

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Section 2 SPECIFICATIONS TABLE 2-2. ENGINE SPECIFICATIONS [continued].

ITEM

DESIGN DATA

ENGINE [continued] Bore

3.58 in. [91 mm]

Stroke

4.13 in. [105 mm]

Displacement

125.1 in3 [2 049 cm3]

Rated Brake Horsepower - per SAE J 1349

38 HP [28.3 kW] @ 2,500 RPM

Compression Ratio

18.5:1

Firing Order

1-2-3

Low Idle Speed

1,100 RPM

High Idle Speed

2,500 RPM [governed]

Engine Oil Capacity, W/Filter

6.3 qts. [6.0 liters]

Engine Oil Type

Texaco Ursa Super Plus SAE 15W40, or equivalent, premium motor oil meeting CD/SF standards

ENGINE COOLING

11/95

Cooling Method

Air cooled, blower forced

Cooling Blower Belt Tension

With thumb pressure on belt midway between the blower and crankshaft pulleys, belt deflection of 0.40-0.60 in. [10-15 mm]

2-3

Section 2 SPECIFICATIONS TABLE 2-2. ENGINE SPECIFICATIONS [continued].

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 [Also see Deutz FL 1011 Operating Manual] The fuel MUST have a MINIMUM cetane number of 35. Heavier oil is generally preferable because of its higher energy content

Fuel Capacity

10 Gallons [38 liters]

Rate of Fuel Consumption [at maximum engine H.P. at 100% load conditions]

1.8 Gallons per hour [6.8 liters per hour]* *Operating conditions, that vary, can cause different fuel consumption amounts than those given

FUEL FILTER Fuel Filter

Pressure line, replaceable “spin-on” element

FUEL PUMP Type

2-4

CAV, distributor type

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

DESIGN DATA

BATTERY Number per Machine

One [1]

Ampere Hour Rating

580 CCA hours

Voltage

12 Volts

ALTERNATOR

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Voltage, Type and Manufacturer

12 Volt, negative ground, Bosch

Output Amperage

60 Amps

2-5

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

DESIGN DATA

TRANSMISSION SYSTEM System Type

Hydrostatic

System Oil Capacity.

8.0 Gallons [30.3 liters]

NOTE: Also supplies steering, vibration and leveling blade [BOMAG Model BW124PDB] systems. .

Oil Type

MOBIL 423, TEXACO TDH, or equivalent, having JDM - JDA specifications

Transmission System Charge Oil Filter - Type

One [1] pressure line replaceable "spin on" element

CAUTION: Use ONLY approved filter, see Machine Parts Catalog.

Oil Cooler Type

Aluminum, full flow

TRANSMISSION HYDRAULIC PUMPS Quantity And Type

Two [2], variable displacement, axial piston [one [1] supplies wheel drive oil flow , one [1] supplies drum drive oil flow]

Charge Relief Valve Pressure - At Hydraulic Oil Filter Neutral

2-6

290 psi. [20 bar] MINIMUM - gauge 375 psi. [26 bar] MAXIMUM - gauge

11/95

Section 2 SPECIFICATIONS TABLE 2-4. TRANSMISSION SYSTEM SPECIFICATIONS [continued].

ITEM

DESIGN DATA

HYDRAULIC TRAVEL [WHEEL] MOTORS Type

Radial piston, fixed displacement, with integral SAHR brake

Number Per Machine

Two [2]

HYDRAULIC DRUM DRIVE MOTOR Type

Radial piston, fixed displacement

Number Per Machine

One [1]

TRANSMISSION SYSTEM PRESSURES

NOTE: Pressures given are with hydraulic oil at operating temperature of 100-150˚F. [38-66˚ C] with the engine throttle speed at HIGH idle.

ALL given pressures apply to both wheel and drum drive motor[s] systems.

Neutral Charge

290 psi. [20 bar] MINIMUM - gauge 375 psi. [26 bar] MAXIMUM - gauge

System Relief Forward

5,000 psi. [345 bar] - gauge

Reverse

5,000 psi. [345 bar] - gauge

Pump Case

11/95

43.5 psi. [30 bar] Cold/intermittent ONLY - gauge

2-7

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

DESIGN DATA

Service Brake Type

Hydrodynamic, through hydrostatic Transmission system

Secondary/Parking Brake Type

Spring applied/Hydraulically released [SAHR], multi-disc, integral within each travel [wheel] motor

BRAKE SYSTEM

System Pressures Secondary/ Parking Brake Release System

290-375 psi. [20-26 bar] - gauge

TABLE 2-6. STEERING AND LEVELING BLADE SYSTEMS SPECIFICATIONS. ITEM

DESIGN DATA

STEERING SYSTEM System

Oscillating, articulated, center joint

Method

Hydraulic

STEERING CONTROL UNIT Type

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

STEERING RELIEF VALVE Relief Pressure and Rate

1,850 psi [128 bar] @ 5.2 GPM [20 LPM] - gauge, @ 2500 RPM

BLADE SYSTEM RELIEF VALVE [Model BW 124PDB] Relief Pressure and Speed

2-8

2,500 psi [172.5 bar] - gauge, @ 2500 RPM

11/95

Section 2 SPECIFICATIONS TABLE 2-6. STEERING AND LEVELING BLADE SYSTEMS SPECIFICATIONS [continued].

ITEM

DESIGN DATA

HYDRAULUIC PUMP Type

Gear pump, rear section of two [2] section pump [Also supplies transmission pump[s] charge oil and blade system oil flow [Model BW124PDB]]

STEERING CYLINDER Type

Double acting

Number per Machine

One [1]

LEVELING BLADE CYLINDER [MODEL BW 124PDB] Type

Double acting

Number per Machine

One [1]

STEERING PERFORMANCE Steering Time Stop to Stop Right to Left

3.0 Seconds

Left to Right

3.5 Seconds

Total Number of Wheel Turns

11/95

Left To Right

5 Revolutions

Right To Left

4 Revolutions

Inside Turning Radius

120.1 in. [3 050 mm]

Total Steering [articulation]

60˚ - 30˚ each side of center

2-9

Section 2 SPECIFICATIONS TABLE 2-7. DRUM, VIBRATION AND SCRAPER SPECIFICATIONS. ITEM

DESIGN DATA BW124D

BW124PD

BW124PDB

Width

47.0 in.

[1200 mm]

47.0 in.

[1200 mm]

47.0 in.

[1200 mm]

Diameter

30.0 in.

[750 mm]

31.0 in.

[790 mm]

31.0 in.

[790 mm]

Wrapper Thickness

0.48 in.

[12 mm]

0.40 in.

[10 mm]

0.40 in.

[10 mm]

Number

-----

70

70

Contact Area [per foot]

-----

12.6 in2 [81 cm2]

12.6 in2 [81 cm2]

2.3 in.

[58.4 mm]

2.3 in.

[58.4 mm]

65.5 PLI [29.8 kg/mm]

428 PSI [295 bar] on EACH foot having ground contact

428 PSI [295 bar on EACH foot having ground contact

3,097 lbs.

[1 405 kg]

3,131 lbs.

[1 420 kg]

3,131 lbs.

[1 420 kg]

DRUM

Tamping Feet

Foot Height

Pounds Per Lineal Inch [PLI] OR Pounds Per Square Inch [PSI] of Contact Area With Drum Vibrator “OFF” Drum Weight Drum With Vibrator Assy, Motor, Drum Drive Motor and Isolators

2-10

11/95

Section 2 SPECIFICATIONS TABLE 2-7. DRUM, VIBRATION AND SCRAPER SPECIFICATIONS [continued].

ITEM

DESIGN DATA

VIBRATION SYSTEM Type

Eccentric, single weight, hydraulic motor driven

HYDRAULIC VIBRATOR PUMP Type

Gear pump, front section of two [2] section pump

Pump Output Rate and Speed

5.2 GPM [20 lpm] @ 2500 RPM

HYDRAULIC VIBRATOR MOTOR Type

Gear, fixed displacement

Motor Input Rate

5.2 GPM [20 lpm] @ 4000 psi. [276 bar]

CONTROL VALVE Type

Single spool - open center, electrically controlled

Relief Valve Pressure Setting

4000 psi. [276 bar] - gauge

VIBRATION ISOLATION Type

Rubber buffer

Quantity

11/95

Left [Vibrator Motor]

4

Right [Drum Drive Motor]

8

2-11

Section 2 SPECIFICATIONS TABLE 2-7. DRUM, VIBRATION AND SCRAPER SPECIFICATIONS [continued].

ITEM

DESIGN DATA BW124D

BW124PD/BW124PDB

VIBRATION PERFORMANCE Centrifugal Force

10,060 lbs.

[4 573 kg] @ 2,480 VPM

10,060 lbs.

[4 573 kg] @ 2,480 VPM

Frequency

2,480 VPM [41.3 Hz]

2,480 VPM [41.3 Hz]

Amplitude [nominal] Zero To Peak

0.064 in.

[1.6 mm]

0.064 in.

[1.6 mm]

Type Scraper

Full width, bolt on type

Full width, bolt on type

Number Scrapers Per Machine and Material

Two [2] non-reversible, bolt on, synthetic element

Twelve [12] non-reversible, bolt on, steel

Scraper To Drum Clearance

Against drum

0.25 in. [6.4 mm]

SCRAPERS

TABLE 2-8. TIRE SPECIFICATIONS. ITEM

DESIGN DATA BW124D

BW124PD/BW124PDB

DRIVE WHEEL TIRES

2-12

Size

7.50 x 16

7.50 x 16

Tread Design

Open faced diamond

Bar

Inflation Pressure

26 psi.

[1.8 bar]

28 psi.

[2.0 bar]

11/95

Section 2 SPECIFICATIONS TABLE 2-9. CONTROL AND INDICATOR SPECIFICATIONS. ITEM

DESIGN DATA

FUNCTION

TYPE

CONTROL Direction of Machine Travel

Travel control lever, mechanical linkage to transmission pumps

Engine Speed

Throttle lever and lock, mechanical linkage to fuel injector pump

Steering Control

Steering wheel, hydraulic steering control unit and system

Brake-Service

Travel control lever, mechanical linkage to transmission pumps, hydrostatic through transmission system

Brake-Secondary/ Parking

Hand lever, seat riser mounted

Engine Start, Run and Stop

Electrical key switch, control panel installed

Vibration System “ON-OFF”

Push button switch, travel control lever contained

Horn

Button switch, control panel installed

Optional Operation Lighting System

Rotary switch, control panel installed

Leveling Blade Control [Model BW124PDB]

Pedal control acts to control position of leveling blade. The leveling blade control pedal has four [4] positions: “I” - LIFTING leveling blade “0” - STOP position “II” - LOWERING leveling blade “III” - FLOAT leveling blade - with lock

11/95

2-13

Section 2 SPECIFICATIONS TABLE 2-9. CONTROL AND INDICATOR SPECIFICATIONS [continued].

ITEM

DESIGN DATA

FUNCTION

TYPE

INDICATOR/GAUGE Engine Hours

Hourmeter, electrical, control panel installed

Engine Lubrication Oil Pressure

Oil pressure Indicator light, electrical, control panel installed

Engine Inlet Air Restriction

Air restriction Indicator light, electrical, control panel installed

Fuel Level

Low fuel level indicator light, electrical, control panel installed

High Engine Lubricating Oil Temperature

High engine lubricating oil temperature indicator light, electrical, control panel installed

Charging System Voltage

Low charging voltage indicator light, electrical, control panel installed

Secondary/Parking Brake System Condition Indicator [“ON-OFF”]

“ON” indicator light and buzzer, electrical, control panel installed

TABLE 2-10. OPTIONAL EQUIPMENT. ITEM

DESIGN DATA

LIGHTING SYSTEM Type and quantity and Control

2-14

12 volt, halogen, adjustable, two [2] per machine - one [1] front and one [1] rear mounted, rotary switch controlled

11/95

Section 2 SPECIFICATIONS TABLE 2-11. DIMENSION SPECIFICATIONS [See Figures 2-1, 2-2 and 2-3]. .

ITEM DESIGN DATA BW124D

BW124PD

BW124PDB

A. Overall Height To Top of FOPS/ROPS

91.0 in.

[2 311 mm]

91.5 in.

[2 324 mm]

91.5 in.

[2 324 mm]

B. Height - To Top Of Steering Wheel

59.0 in.

[1 490 mm]

59.0 in.

[1 490 mm]

59.0 in.

[1 490 mm]

C. Overall Width

55.0 in.

[1 390 mm]

55.0 in.

[1 390 mm]

56.0 in.

[1 422 mm]

D. Overall Length

117.0 in.

[2 970 mm]

117.0 in.

[2 970 mm]

130.4 in.

[3 312 mm]

E. Wheel Base

65.0 in.

[1 660 mm]

65.0 in.

[1 660 mm]

65.0 in.

[1 660 mm]

F. Ground Clearance

10.0 in.

[260 mm]

10.0 in.

[260 mm]

8.6 in.

[219 mm]

G. Drum Diameter

30.0 in.

[750 mm]

31.0 in.

[790 mm]

31.0 in.

[790 mm]

H. Drum Width

47.0 in.

[1 200 mm]

47.0 in.

[1 200 mm]

47.0 in.

[1 200 mm]

I. Frame Overhang Each Side

4.0 in.

[95 mm]

4.0 in.

[95 mm]

4.5 in.

[114.3 mm]

J. Drum Wrapper Thickness

0.48 in.

[12 mm]

0.40 in.

[10 mm]

0.40 in.

[10 mm]

K. Leveling Blade Width [ModelBW124PDB ONLY]

---------

---------

55.0 in.

[1 390 mm]

L. Leveling Blade [Model BW124PDB ONLY] Max. Depth Below Ground Level - W/ Foot Penetration

---------

---------

2.5 in.

[63.5 mm]

M. Leveling Blade [Model BW124PDB ONLY] Bottom Blade to Ground With Blade “RAISED” W/O Foot Penetration

---------

---------

15.9 in.

[405 mm]

DIMENSIONS

11/95

2-15

Section 2 SPECIFICATIONS

I

I

A

B G J

F E

H C

D

FIGURE 2-1. BOMAG MODEL BW124D - MACHINE DIMENSIONS.

I

I

A

B G J

F E D

H C

FIGURE 2-2. BOMAG MODEL BW124PD - MACHINE DIMENSIONS.

2-16

11/95

Section 2 SPECIFICATIONS

I

A I B

G L

F E

C K

D

FIGURE 2-3. BOMAG MODEL BW124PDB - MACHINE DIMENSIONS.

TABLE 2-12. MACHINE WEIGHT SPECIFICATIONS. ITEM

DESIGN DATA BW124D

BW124PD

BW124PDB

WEIGHTS

11/95

Operating Weight

5,957 lbs.

[2 702 kg]

5,990 lbs.

[2 717 kg]

5,990 lbs.

[2 717 kg]

Shipping Weight

5,717 lbs.

[2 593 kg]

5,750 lbs.

[2 608 kg]

5,750 lbs.

[2 608 kg]

Drum End [Front] Weight

2,727 lbs.

[1 238 kg]

2,760 lbs.

[1 253 kg]

2,760 lbs.

[1 253 kg]

Tire End [Rear] Weight

2,990 lbs.

[1 356 kg]

2,990 lbs.

[1 356 kg]

2,990 lbs.

[1 356 kg]

Drum Static Linear Load

63.1 lbs./in.

[11.3 kg/cm]

-------------

-------------

2-17

Section 2 SPECIFICATIONS TABLE 2-13. PERFORMANCE SPECIFICATIONS. ITEM

DESIGN DATA BW124D

BW124PD

BW124PDB

Forward or Reverse

0-5.6 MPH [0-9.0 km/h]

0-5.6 MPH [0-9.0 km/h]

0-5.6 MPH [0-9.0 km/h]

EFFECTIVE COVERAGE [Per Pass]

47.0 in.

[1 200 mm]

47.0 in.

[1 200 mm]

47.0 in.

[1 200 mm]

TRAVEL SPEEDS

TABLE 2-14. MACHINE SYSTEM CAPACITY SPECIFICATIONS. ITEM

DESIGN DATA

SYSTEM CAPACITIES

2-18

Fuel

10 Gallons [38 liters]

Engine Lubrication Oil W/ Filter

6.3 Quarts [6.0 liters]

Hydraulic Oil Reservoir

8.0 Gallons [30.3 liters]

Drive Tires Inflation Pressure

26 psi [1.8 bar] - DIAMOND tread, COLD and 28 psi [2.0 bar] - BAR tread, COLD

11/95

Section 2 SPECIFICATIONS TABLE 2-15. 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 BW124D

BW124PD

BW124PDB

FRONT FRAME Bare

1,700 lbs.

[773 kg]

1,700 lbs.

[773 kg]

1,375 lbs.

[624 kg]

With Drum, Drum Drive Motor, All Vibration System Components [And Blade - BW124PDB]

2,727 lbs.

[1 238 kg]

2,760 lbs.

[1 253 kg]

2,760 lbs.

[1 253 kg]

Bare

740 lbs.

[336 kg]

740 lbs.

[336 kg]

740 lbs.

[336 kg]

With Engine and Drive Components

2,990 lbs.

[1 356 kg]

2,990 lbs.

[1 356 kg]

2,990 lbs.

[1 356 kg]

REAR FRAME

OTHER COMPONENTS Engine

11/95

Dry

450 lbs. [205 kg]

With Pumps Installed

700 lbs. [318 kg]

Battery

40 lbs. [18 kg]

Transmission Hydraulic Pumps

55 lbs. [25 kg], each

Drum Drive Hydraulic Motor

75 lbs. [34 kg]

2-19

Section 2 SPECIFICATIONS TABLE 2-15. COMPONENT WEIGHTS [continued].

ITEM

DESIGN DATA

OTHER COMPONENTS [continued]

2-20

Hydraulic Pump Charge/Steering/Vibration

25 lbs. [11 kg]

Steering Control Unit

30 lbs. [14 kg]

Steering Cylinder

25 lbs. [11 kg]

Machine Drive Tire/Wheel Assembly

70 lbs. [32 kg], Each

Drum Vibrator Hydraulic Motor

10 lbs. [5 kg]

Drum Vibrator Assembly

125 lbs. [57 kg]

Falling Object/ Roll Over Protection Structure [FOPS/ROPS]

400 lbs. [181 kg]

Leveling Blade Assembly [BOMAG Model BW124PDB]

325 lbs. [148 kg]

Leveling Blade Control Valve

5 lbs. [2.3 kg]

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Section 2 SPECIFICATIONS TABLE 2-16 TORQUE SPECIFICATIONS FOR METRIC FASTENERS. BOLT DIMENSIONS

TIGHTENING TORQUE - FT. LBS. / Nm. 8.8

10.9

12.9

M4

2 ft. lbs. / 3 Nm

3 ft. lbs. / 5 Nm

4 ft. lbs. / 5 Nm

M5

4 ft. lbs. / 6 Nm

7 ft. lbs. / 10 Nm

7 ft. lbs. /10 Nm

M6

7 ft. lbs. / 10 Nm

11 ft. lbs. / 15 Nm

13 ft. lbs. / 18 Nm

M8

18 ft. lbs. / 25 Nm

26 ft. lbs. / 35 Nm

33 ft. lbs. / 45 Nm

M10

37 ft. lbs. / 50 Nm

55 ft. lbs. / 75 Nm

61 ft. lbs. / 83 Nm

M12

65 ft. lbs. / 88 Nm

91 ft. lbs. / 123 Nm

108 ft. lbs. / 147 Nm

M14

101 ft. lbs. / 137 Nm

145 ft. lbs. / 196 Nm

173 ft. lbs. / 235 Nm

M16

156 ft. lbs. / 211 Nm

221 ft. lbs. / 300 Nm

264 ft. lbs. / 358 Nm

M18

213 ft. lbs. / 290 Nm

303 ft. lbs. / 412 Nm

361 ft. lbs. / 490 Nm

M20

304 ft. lbs. / 412 Nm

426 ft. lbs. / 578 Nm

513 ft. lbs. / 696 Nm

M22

413 ft. lbs. / 560 Nm

559 ft. lbs. / 785 Nm

695 ft. lbs. / 942 Nm

M24

524 ft. lbs. / 711 Nm

738 ft. lbs. / 1000 Nm

885 ft. lbs. / 1200 Nm

M27

774 ft. lbs. / 1050 Nm

1092 ft. lbs. / 1480 Nm

1308 ft. lbs. / 1774 Nm

M30

1047 ft. lbs. / 1420 Nm

1482 ft. lbs. / 2010 Nm

1770 ft. lbs. / 2400 Nm

NOTE: Strength class for capscrews with untreated, non-lubricated surface.

The quality designation of the capscrews is marked on the screw head: 8.8 = 8G 10.9 = 10K 12.9 = 12K The values result in a 90% utilization of the capscrews yielding point at a coefficient of friction of u total = 0.14.

Use a torque wrench to tighten capscrews to the CORRECT torque. The above given torques do NOT apply when using lubricants.

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2-21

Section 2 SPECIFICATIONS TABLE 2-17. TORQUE SPECIFICATIONS FOR STANDARD INCH FASTENERS.

GRADE 5

GRADE 8

PLACEBOLT

SOCKET HEAD CAPSCREW

12 POINT CAPSCREW

FIGURE 2-4. STANDARD HARDWARE

2-22

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Section 2 SPECIFICATIONS TABLE 2-18. LUBRICATION OILS, HYDRAULIC OILS AND COOLANT SPECIFICATIONS.

TABLE 2-19. ADHESIVE THREAD LOCKING SPECIFICATIONS.

264159

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2-23

Section 2 SPECIFICATIONS

2-24

NOTES

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Section 3 OPERATION

TABLE OF CONTENTS

PAGE GENERAL INFORMATION ..................................................................................................................... 3-2 OPERATING CONTROLS AND INDICATORS ....................................................................................... 3-2 CHECKS WITH THE ENGINE STOPPED .............................................................................................. 3-11 STARTING THE ENGINE ....................................................................................................................... 3-11 CHECKS WITH THE ENGINE RUNNING ............................................................................................. 3-13 OPERATING PRECAUTIONS ............................................................................................................... 3-14 OPERATING THE MACHINE ................................................................................................................ 3-16 DYNAMIC BRAKING OF THE MACHINE ............................................................................................. 3-17 STOPPING THE ENGINE ...................................................................................................................... 3-18 MACHINE TOWING ............................................................................................................................... 3-18 TRANSPORTING THE MACHINE ........................................................................................................ 3-20

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3-1

Section 3 OPERATION GENERAL INFORMATION.

OPERATING CONTROLS AND INDICATORS.

This section gives the operating instructions for the BOMAG Model BW124D, BW124PD and BW124PDB Single Drum Rollers.

The BOMAG Model BW124D, BW124PD and BW124PDB Roller operating controls and indicators are shown on Figure 3-1. and are listed in Table 3-1.

Read, understand and follow ALL instructions given on the machine "Operating Instruction and Warning" decals and written in this manual, BEFORE starting, or operating the machine [see figure 3-2].

DANGER: Failure to observe the "Operating And Warning Instructions", given in this manual and found on the decals affixed to the machine can cause serious INJURY, or DEATH. Only authorized personnel, who are fully trained in the machine operating procedures, can operate Model BW124D, BW124PD and BW124PDB Single Drum Rollers.

WARNING: Do NOT start, or operate, a Model BW124D, BW124PD or BW124PDB Roller BEFORE reading, understanding and following ALL information given in this section and shown on the machine "Operating Instruction and Warning Decals", found on the machine. The operator MUST read about and understand thefunction of ALL controls and indicators BEFORE starting the engine.

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 ignition key from the ignition switch. Repair ALL damage at once. Operation of a machine with damage can result serious injury and/or major machine damage.

3-2

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

DESCRIPTION

TYPE

FUNCTION

IGNITION SYSTEM CONTROL

Key Operated Interlock Switch Three [3] Position

Controls engine starting”, “running” and “stopping”.

NO. 0 POSITION: “OFF” condition.

Removes ALL electrical current from circuits.

NO. I POSITION: “ON” condition.

Applies electrical current to ALL circuits. This position also is a “lock out” position and prevents accidental engagement of the starter motor when the engine is in a “run ning” condition. The ignition key MUST be rotated back past this position, to the NO. 0 [OFF] position, before the starter motor can be energized again [start position].

NO. II POSITION: “START” position.

Applies electrical current the starter motor to crank the engine. Switch spring returns key to the NO.1 “ON/RUN” position when the key is released.

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3-3

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

DESCRIPTION

TYPE

FUNCTION

2

TRAVEL CONTROL

Travel Lever

Controls forward/reverse movement of the machine.

Travel control lever in “CENTER” position transmission in “NEUTRAL”.

Travel control lever in “FORWARD” position transmission in “FORWARD”.

Travel control lever in “REARWARD” position transmission in “REVERSE”.

3

ENGINE THROTTLE SPEED

Throttle LeverTwo [2] Position

Controls engine throttle speed.

Move the throttle lever “BACKWARD” to “HIGH” engine idle speed position.

Move the throttle lever “FORWARD” to “LOW” idle engine speed position position.

4

STEERING SYSTEM

Manually Operated Wheel

Provides machine turning control.

Turn the steering wheel in the direction the machine is desired to steer.

5

SECONDARY/ PARKING BRAKE SYSTEM

Manually Controlled Valve - Two [2] Position

Manually controls secondary/parking brake system application and release.

Handle placed in “OFF” position RELEASES the brake system.

Handle placed in “ON” position APPLIES the brake system.

3-4

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Section 3 OPERATION TABLE 3-1. MACHINE OPERATING CONTROLS AND INDICATORS. ITEM NO. [SEE FIG’ 3-2] 6

DESCRIPTION

DRUM VIBRATOR “ON/OFF”

TYPE

FUNCTION

Electrical Push Button Switch Two [2] Position Travel Control Lever Mounted

“On/Off” control of vibration system.

“PRESS” button IN WARD and release system STARTS. “PRESS” button IN WARD, again, and release - system STOPS.

7

ENGINE OPERATION HOURS

Electrical hourmeter

Indicates total hours engine has been in operation.

Operates when ignition key switch is switched “on” and the engine engine is “running”.

8

LOW ENGINE OIL PRESSURE

Indicator Light

Electrical Indicator light monitors engine lubrication oil pressure.

Electrical Indicator light is lighted when ignition switch [ITEM 1] is switched "on", or if low engine lubrication oil pressure exists.

Light must NOT remain lighted after engine has started and is “running”.

CAUTION: STOP the engine IMMEDI ATELY if the light remains lighted, or lights, when the engine is "running".

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3-5

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

DESCRIPTION

TYPE

FUNCTION

9

ELECTRICAL CHARGING SYSTEM

Indicator Light

Electrical Indicator light monitors electrical charging system.

Electrical Indicator light is lighted when ignition switch [ITEM 1] is switched "on" or if battery is NOT being charged.

Light must NOT remain lighted after engine has started and is “running”.

CAUTION: STOP the engine IMMEDI ATELY if the light remains lighted, or lights, when the engine is "running".

10

SECONDARY/ PARKING BRAKE SYSTEM

Indicator Light/buzzer

Electrical Indicator light and warning buzzer monitors application condition of secondary/ parking brake system.

With secondary/parking brake system lever in "on" position, electrical Indicator light is lighted and warning buzzer sounds when ignition switch [ITEM 1] is switched "on" or if charge pressure is lost.

Light must NOT remain lighted after engine has started and is “running” with brake system lever in "off" position.

3-6

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

DESCRIPTION

11

HORN

TYPE

Electrical Push button

FUNCTION

Operates acoustic horn.

Switch Operates when ignition key switch is “on” position and when the engine is “running”.

Push horn button to sound horn.

12

FUSE BOX

Covered Fuse Box

Electrical fuse box contains fuses for standard and optional electrical systems.

Electrical power is supplied to the fuse box when ignition switch [ITEM 1] is switched “on”.

13

HIGH ENGINE OIL TEMPERATURE

Indicator light

Electrical Indicator light Light monitors engine lubrication oil temperature Electrical Indicator light is lighted when ignition switch [ITEM 1] is switched “on” or if high engine lubrication oil temperature exists.

Light must NOT remain lighted after engine has started and is “running”.

CAUTION: STOP the engine IMMEDIATELY if the light remains lighted, or lights, when the engine is “running”.

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3-7

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

DESCRIPTION

TYPE

FUNCTION

14

ENGINE INLET AIR PATH

Indicator Light

Electrical Indicator light monitors engine inlet air path.

Electrical Indicator light is lighted when ignition switch [ITEM 1] is switched "on" or if engine inlet air path is restricted.

Light must NOT remain lighted after engine has started and is “running”.

CAUTION: STOP the engine IMMEDI ATELY if the light remains lighted, or lights, when the engine is "running".

15

LOW FUEL LEVEL

Indicator Light

Indicator light monitors fuel level contained within fuel tank.

Electrical Indicator light is lighted when ignition switch [ITEM 1] is switched "on" when a "low" fuel condition exists.

3-8

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

DESCRIPTION

TYPE

16

VANDAL GUARD

Movable, Lockable Guard

FUNCTION

Helps stop unauthorized machine use and/or damage to instrument panel area.

Install over controls and indicators on instrument panel to help stop possible damage and/or unauthorized use. Secure in position with a padlock. Remove lock and move guard back from panel for authorized start and operation of machine.

17

LIGHT SYSTEM [Optional]

Rotary Switch

Turns light system “On” and “Off”.

Turn switch knob to 1st position to turn parking light system “on”.

Turn switch knob to 2nd position to turn operation lighting system “on”.

18

LEVELING BLADE SYSTEM [BOMAG Model BW124PDB Only]

Foot Pedal Four [4] Positions

Control of leveling blade system.

During machine operation, control leveling blade by foot pedal movement.

1 - LIFT blade position.

0 - STOP/HOLD blade position.

2 - LOWER blade position.

3 - FLOAT and LOCK blade position.

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3-9

Section 3 OPERATION

FIGURE 3-1. MODEL BW124D, BW124PD AND BW124PDB "OPERATING INSTRUCTION" DECAL.

3-10

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Section 3 OPERATION CHECKS WITH THE ENGINE STOPPED. With the engine “STOPPED”, inspect the machine BEFORE use, and AFTER every eight [8] hours of operation, or daily, as directed in Section 4 MAINTENANCE - in this manual.

Park the machine on level and firm terrain. Check, or inspect, the following items: Fuel level.

Engine lubrication oil level.

Condition of engine cooling fan/alternator drive belt.

Hydraulic system oil level.

Fluid leaks from engine, fuel system or hydraulic system.

Drum scraper system.

Inflation air pressure of the drive tires.

Operation of the horn.

Condition of the seat belt set.

Falling object and roll over protection structure [FOPS/ROPS] to machine mounting capscrews torque and overall structure condition.

b. If installed, unlock and then move the vandal guard [ITEM 19] from the instrument panel and to the stowed position. Keep the secondary/parking brake system “ON” [APPLIED] by leaving the secondary/ parking brake system handle [ITEM 5] in the “ON” position.

WARNING: The machine must NOT move, at ANY time, when the secondary/parking brake system handle is in the “ON” [APPLIED] position.

Do NOT operate the machine, if the machine will move when the secondary/parking brake system is “ON” [APPLIED], until the fault is corrected.

c. Put the transmission system in “NEUTRAL” by positioning the travel control lever [ITEM 2] in the “NEUTRAL” [CENTER] position. Keep the travel control mounted drum vibrator “ON/OFF” switch [ITEM 6] “OFF”.

NOTE: The transmission system MUST be in "NEUTRAL" before the engine can be started.

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

WARNING: Do NOT start, or operate, a BOMAG ModelBW124D, BW124PD or BW124PDB Roller BEFORE reading, understanding and following ALL information given in this section and shown on the machine “Operating Instruction and Warning decals”, found on the machine.

The operator MUST read about, and understand, the function of ALL controls and indicators BEFORE starting the engine.

Serious INJURY, or DEATH, can result if these procedures are NOT followed.

d. If so equipped, keep the leveling blade lowered to the ground by leaving the system control foot pedal [ITEM 18] in the blade “LOWER” [#2] position. e. Keep the engine throttle speed lever [ITEM 3] in the “LOW” idle speed position.

CAUTION: Do NOT put the engine throttle speed lever in the “HIGH” idle speed position, at this time. Engine damage can occur.

a. 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, by pulling on the loose end of the belt.

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3-11

Section 3 OPERATION

FIGURE 3-2. MACHINE CONTROLS AND INDICATORS MODEL BW124D, BW124PD AND BW124PDB SINGLE DRUM ROLLERS.

3-12

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Section 3 OPERATION f .Turn the ignition key [ITEM 1] to the number [II] [START] position. Crank and start the engine. Release the ignition key when the engine as the engine starts.

CAUTION: Make a note of the amount of continuous cranking time. Do NOT crank the engine MORE than twenty [20] seconds continuously.

If the engine is NOT started within the above time, put the ignition key in the number [0] [OFF] position. Wait one [1] minute. This will allow the starter motor time to cool. Repeat step “f” until the engine is started. After the engine has started, Do NOT increase the engine speed, above “LOW” idle, for a period of two - three [2-3] minutes to allow the engine and hydraulic systems to warm.

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 machine operation, or daily, as directed in Section 4 - MAINTENANCE in this manual.

Check or inspect the following items: Operation of the secondary/parking brake system. a. Keep the secondary/parking brake system lever in the “ON” [APPLIED] position. SLOWLY move the travel control lever one fourth [1/4] of the full forward or reverse travel distance. Note that the brake system keeps the machine from ANY movement. Repeat the procedure for the opposite direction of travel.

Move the travel control lever to the “NEUTRAL” [CENTER] position.

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WARNING: Keep ALL personnel clear of the machine and travel path when checking the secondary/parking brake system operation.

The machine must NOT move, at ANY time, when the secondary/parking brake system is “ON” [APPLIED].

Do NOT operate the machine, if the machine will move when the secondary/parking brake system lever is in the “ON” [APPLIED] position, until the fault is corrected.

Operation of the steering system. a. Turn the steering wheel to the left, or right, turn position a SMALL amount. Note that the machine turned smoothly in the same direction in which the steering wheel was turned and that the steering system operated correctly.

DANGER: Keep ALL personnel clear of the hitch area. The clearance between the front and rear frames, at the hitch, closes when the machine is turned in either direction. Serious INJURY, or DEATH, can occur if caught between the frames.

WARNING: Do NOT operate the machine if the steering system did NOT operate correctly. Repair the system immedi ately, before ANY machine operation.

Operation of the transmission system, in BOTH directions of travel, and operation of the back up alarm system in the REVERSE direction of travel. a. Move the secondary/parking brake system lever to the “OFF” [RELEASED] position. Move the travel control lever toward the forward direction of travel position, a SMALL amount. Note that the transmission system functioned and the machine moved forward. Move the travel control lever to the forward neutral position.

3-13

Section 3 OPERATION b. Move the travel control lever toward the reverse direction of travel position, a SMALL amount. Note that the transmission system functioned, that the back up ALARM sounded and the machine moved rearward. Move the travel control hand lever to “NEUTRAL”. Put the secondary/parking brake system lever to the “ON” [APPLIED] position.

DANGER: Check the operation of the transmission system ONLY when the machine is in an area clear of personnel and other machines.

Keep ALL personnel CLEAR of the machine and the travel path when checking the transmission system operation.

WARNING: Do NOT operate the machine if the transmission system did NOT operate correctly. Repair the system immediately, before ANY machine operation.

Do NOT operate the machine if there is a malfunction in the back up ALARM SYSTEM. Repair the system IMMEDIATELY. Keep the alarm, clean and free of mud, dirt and other debris at ALL times. After cleaning or removal of these items, ALWAYS test the alarm system, for CORRECT operation, by using the ABOVE procedures.

CAUTION: Do NOT check the operation of the drum vibration system, UNLESS the drum of the machine is on a SOFT surface, such as loose dirt or “old” tires. Damage to the drum and/or machine can occur if the drum vibration system operation is checked on a HARD surface.

Operation of ALL instruments and indicator lights. a. Note that the hourmeter and ALL indicator lights are operating correctly.

3-14

CAUTION: Do NOT operate the machine if the hourmeter, or indicator lights, do NOT operate correctly. Repair the system fault immediately, before ANY machine operation.

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 and the instructions written in this manual.

DANGER: Failure to observe the following “Operating Precautions”, and/or the machine “Operation And Warning Instruc tions”, given in this section and found on the “Operating Instruction and Warning Decals” affixed to the machine, can cause serious INJURY, or DEATH. Only authorized personnel, who are fully trained in the machine operation, can operate Model BW124D, BW124PD and BW124PDB Single Drum Rollers .

a. Drive at a SLOW speed when nearing a slope.

Drive at a SLOW speed and use additional CAUTION when operating the machine close to a slope and/or when traveling “up” or “down” a slope. b. Do NOT travel “across” a slope. When on a slope, TRAVEL in a “UP” or “DOWN” direction ONLY. Keep AWAY from “edges” and/or “embankments”.

Use extra CAUTION when operating the machine on “wet” or “loose” soil. c. Use extra CAUTION when operating the machine near personnel and/or other machines. MATCH the machine operating speed to area and working conditions.

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Section 3 OPERATION d. Do NOT operate a machine in need of repair.

Report and repair ANY damage and/or operation with faults IMMEDIATELY. e. Keep CLEAR of the hitch area at ALL times during operation of, or service to, the machine.

DANGER: Keep ALL personnel CLEAR of the hitch area. Clearance between the front and rear frames CLOSES when the machine is turned in either direction.

Serious INJURY, or DEATH, can occur if caught between the frames.

WARNING

WARNING P/N 918141

FASTEN SEAT BELT!

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

FIGURE 3-3. OPERATION AND SEAT BELT WARNING DECALS - MODEL BW124D, BW124PD AND BW124PDB SINGLE DRUM ROLLERS .

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3-15

Section 3 OPERATION f. IMMEDIATELY after becoming 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 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, ALWAYS do the following procedures: 1. Stop drum vibration. If so equipped, LOWER the leveling blade to the ground by using the leveling blade control foot pedal [ITEM 18].

2. Put the secondary/parking brake system lever [ITEM 5] in the “ON” [APPLIED] position.

3. Put the travel control lever [ITEM 2] in “NEUTRAL”.

4. STOP the engine and remove the ignition key.

WARNING: ALWAYS apply the secondary/parking brake system when the machine is parked. The transmission system will NOT keep the parked machine “STOPPED” at ANY time. The secondary/parking brake system MUST be used to keep the machine “STOPPED” at ALL times.

i. Do NOT operate the machine, if the machine will move when the secondary/parking brake system is “ON” [APPLIED], until the fault is corrected.

WARNING: The machine must NOT move, at ANY time, when the secondary/parking brake system lever [ITEM 5] is in the “ON” [APPLIED] position.

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 AFTER it has been started and 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 fully against the body, by pulling on the loose end of the belt. b. Release the secondary/parking brake system, by putting the secondary/parking brake system lever [ITEM 5] in the “OFF” [RELEASED] position. c. If in a confined area, near personnel, or near other machines, keep the engine throttle lever [ITEM 3] at “LOW” idle. If so equipped, raise the leveling blade from the ground by moving the leveling blade control foot pedal [ITEM 18] to the “RAISE” [#1] position.

WARNING: Do NOT put the engine throttle lever to the “HIGH” idle if the machine is in confined area, near personnel or near other machines.

CAUTION: When operating the machine on the work surface, the engine throttle MUST be at “HIGH” idle. When on the work surface, put he throttle lever [ITEM 3] in “HIGH” idle.

d. SLOWLY move the travel control lever [ITEM 2] TOWARD the direction the machine is desired to travel, a SMALL amount.

j. Do NOT operate a machine NOT having the “Operating Instruction and 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 [See Machine Parts Manual].

3-16

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Section 3 OPERATION WARNING: The machine will MOVE when the travel control lever is moved in EITHER direction [forward or back ward] from NEUTRAL. PUSHING the lever FORWARD selects the FORWARD direction of machine travel.

PULLING the lever BACKWARD selects the REVERSE direction of machine travel.

BEFORE moving the travel control lever, from neutral, be SURE that the machine path is CLEAR.

g. If so equipped, use the leveling blade [Model BW124PDB only] to move fill, as desired, while operating the compactor in the forward or reverse direction of travel.

CAUTION: When changing travel direction, during machine operation, hold the travel control lever in NEUTRAL for a short time, BEFORE moving the lever to the opposite travel direction position.

Change the travel direction ONLY while the machine is STOPPED.

CAUTION: When the machine is parked, ALWAYS lower the leveling blade to the ground.

e. When the machine is in a clear area and away from personnel and other machines, if desired, SLOWLY move the travel control lever [ITEM 2] further forward, or backward, to the full travel position.

NOTE: Full travel lever movement will give FULL machine travel speed. The machine travel speed is proportional to the mount of the travel lever movement in either direction.

f. When on the work surface, if desired, start the drum vibration system by pressing INWARD, and then releasing, the vibrator “ON/OFF” push button [ITEM 6] which is installed into the end of the travel control lever handle [ITEM 2].

DANGER: When compacting the work surface near buildings, check the effect of the vibratory forces on the structures.

STOP work IMMEDIATELY if structure damage is noted.

CAUTION: Operate the vibration system ONLY with the engine throttle [ITEM 3] at “HIGH” idle.

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DANGER: Do NOT use the leveling blade to lift or transport personnel.

Serious INJURY, or DEATH, can occur.

Do NOT move other machines or vehicles with the leveling blade.

Serious INJURY, or DEATH, to personnel in the area can occur.

NOTE: Use the leveling blade system control foot pedal [ITEM 18] to control the operation of the leveling blade: Position “1” - LIFT the blade.

Position “0” - STOP and HOLD the blade.

Position “2” - LOWER the blade.

Position “3” - FLOAT and LOCK the blade.

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

On LEVEL terrain, slowing of the machine is done by moving the travel control lever [ITEM 2] TOWARD NEUTRAL. Complete stopping of the machine is done by moving the travel control lever [ITEM 2] further TO NEUTRAL.

WARNING: When nearing a slope FIRST slow the machine by moving he travel control lever TOWARD NEUTRAL. SLOW the machine further, or STOP the machine, on a slope by moving the travel control lever to the direction of travel position that is OPPOSITE the direction that the machine is traveling.

The secondary/parking brake system MUST be used to hold a stopped, or parked, machine at ALL times. The transmission system, used for DYNAMIC braking, will NOT hold a stopped, or parked, machine at ANY time.

3-17

Section 3 OPERATION CAUTION: BEFORE machine movement stops, stop the vibration system by pressing the vibrator “ON/OFF” push button [ITEM 6] INWARD, and then releasing the button.

STOPPING THE ENGINE [See Figure 3-2 and Table 3-1]. a. SLOW, and then STOP, the machine by using DYNAMIC braking through the transmission system [see procedure above]. LEAVE the travel control lever [ITEM 2] in NEUTRAL.

CAUTION: BEFORE machine movement stops, stop the vibration system by pressing the vibrator “ON/OFF” push button [ITEM 6] INWARD, and then releasing the button.

b. Put the secondary/parking brake system lever [ITEM 5] in the “ON” [APPLIED] position. c. If so equipped, lower the leveling blade [ Model BW124PDB only] to the ground by using the leveling blade control foot pedal [ITEM 18]. d. Move the throttle control lever [ITEM 3] “DOWNWARD” to the “LOW” idle position. Run the engine for a period of three - five [3-5] minutes, at the LOW idle speed, BEFORE stopping the engine.

CAUTION: Do NOT stop the engine BEFORE running at the “LOW” idle speed.

Serious engine damage can occur if the engine is stopped BEFORE waiting the three - five [3-5] minute period.

e. Turn the ignition switch key [ITEM 1] to “OFF” and stop the engine. Remove the key from the ignition switch [ITEM 1]. Move the vandal guard [ITEM 16], into position over the instrument panel and secure with a padlock, if desired.

3-18

MACHINE TOWING [See Figures 3-4, and 3-5].

Should the machine become completely disabled or the engine is not able to be started, use the following procedures to release the secondary/parking brake system on each tire drive motor: a. Put SOLID wood blocks behind, and in front of, BOTH drive tires.

DANGER: Block securely with SOLID block BEFORE releasing the secondary/ parking brake system. Machine movement can occur if the machine is NOT “blocked”.

CAUTION: To prevent machine damage, Do NOT tow the machine unless ALL of the following procedures have been followed.

b. Go to either tire drive motor. Locate the motor housing and brake release piston. Find the plastic protection plug that is snapped into the tapped hole of the brake release piston. Remove the plug [see figure 3-4]. c. Place the brake release device [Item 3] over the tire drive motor housing [Item 5]. Install the capscrew [Item 1] into the tapped hole [4] in the brake release piston until the final stop nut [2] is loosened. d. Turn the nut [2] until contact with the release device [3]. Use a wrench to turn the nut [2] further inward approximately one [1] complete revolution. The secondary/parking brake, on the tire drive motor, is now released and the drive wheel must turn freely.

Leave the release mechanism [1] in place at this time. e. Go to the second tire drive motor. Repeat steps "b", "c" and "d" to release the secondary/parking brake on the tire drive motor. f. Use a solid towing pin to connect a tow bar to the towing eye [Item 1], found on the rear, of the machine. Use a towing pin to connect the tow bar to a towing vehicle, having a pulling capacity larger than the weight of the machine [see figure 3-5].

11/95

Section 3 OPERATION h. After the machine has reached the repair area, put SOLID wood blocks behind, and in front of, BOTH drive tires. Remove the tow bar from the machine and towing vehicle.

DANGER: Block securely with SOLID blocks BEFORE removing the tow bar from the machine, or towing vehicle. Machine movement can occur if the machine is NOT “blocked”.

After the machine has been towed, the secondary/parking brake system on the tire drive motors MUST be applied.

FIGURE 3-4. SECONDARY/PARKING BRAKE RELEASING LOCATION - ON TIRE DRIVE MOTORS.

i. Go to either tire drive motor. Turn the nut [Item 2], found on the release device [Item 1], figure 3-4, until the nut is away from the release device. The secondary/parking brakes, in the tire drive motor, are now APPLIED. Install the protection plug into the tapped hole in the brake release piston. j. Go to the second tire drive motor and repeat step "i". Put the “brake release devices” in the storage compartment.

FIGURE 3-5. TOW BAR CONNECTION TO MACHINE.

g. Remove ALL blocking from the wheels. Have a driver be seated. Use the towing vehicle to SLOWLY tow the machine to a near by service area while the driver steers the machine.

DANGER: Tow the machine on LEVEL terrain.

Do NOT tow the machine at a speed above 0.62 MPH [1 km/h] Do NOT tow the machine further than a MAXIMUM of 0.3 miles [500 m].

NOTE: Manual steering of the machine, during towing, is required. Steering system control effort is increased due to NO hydraulic assist.

11/95

3-19

Section 3 OPERATION TRANSPORTING THE MACHINE [See Figures 3-6, 3-7 and 3-8]. a. Put the engine throttle control lever [ITEM 3] at “LOW” idle. CAREFULLY and SLOWLY load the machine onto the transporting truck or trailer.

DANGER: Use only strong and stable loading ramps to load the machine.

Keep ALL personnel, except the operator, CLEAR of the area while loading the machine.

Do NOT endanger any person through machine tipping and/or roll over. b. Put the secondary/parking brake lever [ITEM 5] “ON” [APPLIED]. Put the travel control lever [ITEM 2] in NEUTRAL. c. Place the machine in a “straight ahead” position.

Slow, and then stop, the engine using the CORRECT procedures given in this section. d. Move the transport lock [Item 1] into position from its stored position [see figure 3-6]. Align the through holes, in the lock, with the through hole in the locking eye on the rear frame. Install the large lock pin [Item 2] through the bores and secure the lock pin with the spring pin [Item 3].

e. Put SOLID wood blocks under EACH drive tire, at both the front and the rear. Put SOLID wood blocks under the drum, on BOTH sides, at both the front and the rear [see figure 3-7]. f. Connect the four [4] tie-down chains, with shackles, between the truck or trailer bed and the machine, at the locations given in the following “DANGER”.

Tighten the tie-down load binding device to hold the machine securely in position for transportation [see figure 3-7].

DANGER: For CORRECT transportation of the machine, FOUR [4] tie-downs MUST be used to secure the machine to the truck or trailer bed to prevent machine rolling, slipping or roll over. One [1] tiedown lug is found behind EACH rear tire, on the outside of the frame and fender. One [1] tie-down cutout is found in EACH side of the front frame, behind the front cross beam.

ALWAYS use shackles, at the machine tie-down points, with the chains and load binding devices. If lifting, and then loading the machine, use the same [4] areas, referenced above, as “lifting eyes” [see Figure 3-8].

ALWAYS use shackles on the lifting points for lifting the machine. See Section 2 - SPECIFICATIONS, for machine weight specifications.

Do NOT stand, or step, under the machine when being lifted.

g. After machine transport, move the transport lock into the stored position and secure with the lock pin and spring pin.

FIGURE 3-6. TRANSPORTATION LOCK INSTALLATION.

3-20

11/95

Section 3 OPERATION

FIGURE 3-7. MACHINE TRANSPORT TIE-DOWN LOCATIONS.

FIGURE 3-8. MACHINE LIFTING LOCATIONS. 11/95

3-21

Section 3 OPERATION NOTES

3-22

11/95

Section 4 MAINTENANCE TABLE OF CONTENTS PAGE GENERAL INFORMATION ................................................................................................................... 4-4.

MAINTENANCE .................................................................................................................................... 4-4.

GENERAL INFORMATION ............................................................................................................... 4-4.

MAINTENANCE SCHEDULE ........................................................................................................... 4-4.

GENERAL INFORMATION ............................................................................................................ 4-4.

TABLE 4-1. MAINTENANCE SCHEDULE ........................................................................................... 4-6.

MAINTENANCE PROCEDURES .......................................................................................................... 4-12.

GENERAL INFORMATION ............................................................................................................... 4-12.

ENGINE MAINTENANCE ................................................................................................................. 4-12.

GENERAL INFORMATION ............................................................................................................ 4-12.

ENGINE LUBRICATION OIL ......................................................................................................... 4-12.

CHECKING THE ENGINE LUBRICATION OIL LEVEL ............................................................. 4-12.

CHANGING THE ENGINE LUBRICATION OIL ......................................................................... 4-12.

CHANGING THE ENGINE LUBRICATION OIL FILTER ............................................................ 4-13.

FUEL SYSTEM ............................................................................................................................... 4-14.

FUEL TANK ................................................................................................................................ 4-14.

ENGINE FUEL FILTER ............................................................................................................... 4-15.

ENGINE AIR FILTRATION ............................................................................................................ 4-16.

AIR CLEANER. ........................................................................................................................... 4-16.

11/95

4-1

Section 4 MAINTENANCE PAGE COOLING SYSTEM ................................................................................................................... 4-17.

CLEANING THE COOLING FINS AND THE HYDRAULIC OIL COOLER ............................. 4-17.

HYDRAULIC SYSTEM ...................................................................................................................... 4-19.

GENERAL INFORMATION ............................................................................................................ 4-19.

CHECKING THE HYDRAULIC OIL LEVEL AND ADDING HYDRAULIC OIL TO THE HYDRAULIC OIL RESERVOIR ....................................................... 4-19.

CHANGING THE HYDRAULIC OIL ............................................................................................... 4-19.

HYDRAULIC PRESSURE OIL FILTER ELEMENTREMOVAL AND REPLACEMENT............................................................................................... 4-22.

ALTERNATOR AND COOLING FANS DRIVE BELT INSPECTION AND REPLACEMENT PROCEDURES .................................................................. 4-23.

ELECTRICAL SYSTEM .................................................................................................................... 4-24.

CHECKING THE BATTERY "CONDITION" AND SERVICING OF RELATED ITEMS ............................................................................................. 4-24.

ELECTRICAL WIRING INSPECTION ............................................................................................ 4-24.

DRIVE TIRES .................................................................................................................................... 4-26.

INSPECTION, AIR PRESSURE CHECK AND ADJUSTMENT .................................................... 4-26.

MISCELLANEOUS MAINTENANCE INFORMATION ..................................................................... 4-27.

GREASE LUBRICATION ............................................................................................................... 4-27.

HITCH BEARINGS ...................................................................................................................... 4-27.

LEVELING BLADE BEARINGS - MODEL BW124PDB ............................................................. 4-27.

SCRAPER ASSEMBLIES ........................................................................................................... 4-27.

OPERATOR RESTRAINT [SEAT BELT, FALLING OBJECT AND ROLL OVER PROTECTION STRUCTURE [FOPS/ROPS] ........................................................ 4-29.

4-2

11/95

Section 4 MAINTENANCE PAGE PREPARING THE MACHINE FOR STORAGE ............................................................................. 4-30.

ENGINE PRESERVATION .......................................................................................................... 4-30.

BATTERY .................................................................................................................................... 4-30.

FUEL TANK ................................................................................................................................ 4-31.

AIR CLEANER, EXHAUST AND OTHER OPENINGS .............................................................. 4-31.

DRIVE TIRES .............................................................................................................................. 4-31.

EXPOSED COMPONENT RUST PREVENTION ........................................................................ 4-31.

11/95

4-3

Section 4 MAINTENANCE GENERAL INFORMATION.

MAINTENANCE SCHEDULE.

THIS section gives the necessary procedures for CORRECT MAINTENANCE of the BOMAG Model BW124D, BW124PD and BW124PDB Single Drum Rollers.

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 BOMAG Model BW124D, BW124PD and BW124PDB Single Drum Rollers.

Follow ALL 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”.

14

15

5

1

9

17

10 18 6

13

4

20

7

21

19 16

11 2 12

8

3

FIGURE 4-1. MACHINE MAINTENANCE POINTS .

4-4

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Section 4 MAINTENANCE

11

5

12

9

1

15 13

6 4 7

14

10

8

3

2

FIGURE 4-2. MACHINE MAINTENANCE DECAL. 11/95

4-5

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

4-6

ITEM

8/ DAY

250/ 3 MO

1

ENGINE OIL

X

2

ENGINE OIL FILTER

3

ENGINE FUEL FILTER

4

FUEL LEVEL - IN TANK

X

5

ENGINE INLET AIR FILTER ELEMENT

X

6

ENGINE COOLING SYSTEM

X

500/ 1 YR

1000/ 1 YR

QUAN.

TYPE/REMARKS

C*

6.3 Qts. [6.0 L]

All temperature Texaco - “URSA” SUPER PLUS 15W40, or equivalent premium motor oil meeting CD/ SF standards.*

C*

1

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

1

Change at interval shown.

Use APPROVED filter ONLY.*

10.0 Gal. [38 L]

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

1

Check condition indicator light.

Change element as needed.**

Air Path

Check cooling air path. If required clean total cooling air path as needed.*

C*

C**

2000/ 2 YR

11/95

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

ITEM

8/ DAY

HYDRAULIC SYSTEM OIL ***

X

250/ 3 MO

500/ 1 YR

1000/ 1 YR

2000/ 2 YR

QUAN.

TYPE/REMARKS

A/C+

8.0 Gal. [30.3 L]

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

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

11/95

HYDRAULIC SYSTEM PRESSURE OIL FILTER

X

C

1

Check filter condition indicator, on filter head, daily. Change 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, shows needed.

Use APPROVED filter element ONLY. See Machine Spare Parts Catalog for CORRECT replacement element.

4-7

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

ITEM

9

ALTERNATOR & COOLING FAN DRIVE BELT

10

BATTERY

11

SECONDARY/ PARKING BRAKE SYSTEM

4-8

8/ DAY

50/ 1 WK

100/ 2 WK

X*

X

X

1000/ 1 YR

2000/ 2 YR

QUAN.

TYPE/REMARKS

1

Check belt for wear or damage.

Check belt for CORRECT adjustment.* Replace belt, with NEW, and adjust if needed [see ENGINE manual].

1

The battery requires minimum service.

Check the charge and electrolyte level of battery one [1] time for each 100 hours of machine operation, or every 2 weeks. Clean battery and battery cable connectors.

Check the 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.

11/95

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

ITEM

8/ DAY

50/ WK

1000/ 1 YR

2000/ 2 YR

QUAN.

TYPE/REMARKS

2

Check inflation pressure each 50 hours, or weekly with tires "COLD".

Adjust pressure as needed [see this section].

12

DRIVE TIRES

13

SAFETY DECALS

X

All

Check condition.

Replace if needed.

See Machine Spare parts Catalog.

14

SEAT BELT

X

1 Set

Check condition.

Replace set if damaged. See Machine Spare parts Catalog.

15

GAUGES HORN LIGHTS

X X X

All

Check operation.

Repair or replace as needed.

16

DYNAMIC BRAKES

X

Trans.

System

Check operation.

Repair IF needed.

See Section 3.

17

STEERING

X

Steering System

Check operation.

Repair if needed.

18

BACK UP ALARM

X

Alarm System

Check system operation.

If needed, repair system BEFORE machine operation.

19

HITCH BEARINGS

All Fittings

Lubricate ALL bearings through grease fittings with multipurpose grease one [1] time for each 50 hours of machine operation, or weekly.

11/95

X

500/ 1 YR

C

4-9

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

ITEM

19

HITCH BEARINGS

20

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

21

LEVELING BLADE BEARINGS

4-10

8/ DAY

50/ WK

C

X

C

500/ 1 YR

1000/ 1 YR

2000/ 2 YR

QUAN.

TYPE/REMARKS

All Fittings

Lubricate ALL bearings through grease fittings with multipurpose grease one [1] time for each 50 hours of machine operation, or weekly.

Structure

Inspect ALL metric M20 - grade 10.9 capscrews, nuts and washers that fasten the structure to the machine. They MUST remain tightened to the torque of 221 ft.lbs. [300 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 your nearest Distributor immediately.

All Fittings

Lubricate ALL bearings through grease fittings with multipurpose grease one [1] time for each 50 hours of machine operation, or weekly.

11/95

Section 4 MAINTENANCE

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

A/C= OBTAIN OIL SAMPLE, WITH CARE, AND ANALYZE. CHANGE OIL BASED ON RESULTS OF OIL ANALYSIS - IF REQUIRED

* = Refer to current “Operation Manual - FL 1011 Diesel Engine ” published by Deutz Engine Company, 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.

11/95

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 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.

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.

ENGINE MAINTENANCE. GENERAL INFORMATION. The following ENGINE maintenance information will cover engine maintenance procedures most often done.

For additional ENGINE maintenance information, see the “Operation Manual - FL 1011 Series Diesel Engine” published by Deutz Engine Company, which is supplied with the machine.

FIGURE 4-3. DEUTZ DIESEL ENGINE LUBRICATION OIL LEVEL CHECK AND FILL LOCATIONS. 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 “bottom” mark but NOT above the “top” mark on the engine lubrication oil dipstick.

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

CHANGING THE ENGINE LUBRICATION OIL [See Figure 4-4].

The engine lubrication oil MUST be changed after EACH 250 hours of machine operation or according to the interval given in the diesel engine “Operation Manual - FL 1011 Series Diesel Engine” published by Deutz Engine Company and supplied with the machine.

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 required engine lubrication oil change schedule.

11/95

Section 4 MAINTENANCE 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 start the engine BEFORE changing the engine lubrication oil filter. Follow the procedures given in THIS section, and in the engine “Operation Manual - FL 1011 Series Diesel Engine” published by Deutz Engine Company.

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 filler cap BEFORE removing the dipstick or oil filler cap.

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 on the engine oil pan. b. Place a container, having a capacity greater than 7 qts. [6.6 L], directly under the engine lubrication oil drain plug. c. CAREFULLY remove the engine lubrication oil drain plug. d. Drain ALL of the engine lubrication oil into the container. e. Clean, install and CAREFULLY tighten the lubrication oil drain plug.

CAUTION: Do NOT overtighten the drain plug.

This action could cause damage to unit. f. Fill the engine to the CORRECT oil level, with the CORRECT engine lubrication oil.

NOTE: See THIS section for the CORRECT amount and type of lubrication oil.

g. Wash the oil filler cap and dry with compressed air. Install the oil filler cap and the engine lubrication oil dipstick.

11/95

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

CHANGING THE ENGINE LUBRICATION OIL FILTER [See Figure 4-5].

The engine lubrication oil filter MUST be changed after EACH 250 hours of machine operation, 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.

4-13

Section 4 MAINTENANCE With the engine “STOPPED” 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.

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

CAUTION: STOP the engine IMMEDIATELY if no, or low, OIL pressure is indicated or any oil leaks are seen. CORRECT any problem noted BEFORE starting the engine, again.

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. 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 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 Manual - FL 1011 Series Diesel Engine” published by Deutz Engine Company., BEFORE the engine is started.

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

4-14

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

FUEL SYSTEM. FUEL TANK [See Figure 4-6].

The low fuel level light is lighted when the amount of fuel in the tank is "low". Check for a low fuel amount ONE [1] time EACH day and fill the fuel tank to “FULL”, as needed. 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.

11/95

Section 4 MAINTENANCE WARNING: DIESEL FUEL IS VERY FLAMMABLE. USE EXTRA CAUTION. Do NOT change the fuel filter element in an area near open flame.

Do NOT change the fuel filter filter element with the machine running.

Do NOT smoke while changing the fuel filter element.

Do NOT spill fuel.

a. STOP the engine. Close the fuel supply valve. b. Put a container under the fuel filter, BEFORE removing the filter element. c. Wipe the area around the fuel filter element and the element mounting head, using a CLEAN lint free cloth.

FIGURE 4-6. FUEL TANK FILL CAP AND SPOUT.

WARNING: The operator MUST be off 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 the fuel level, or check for leaks with an open flame.

d. Use a filter removal wrench to loosen and remove the element, by turning the element in a COUNTER-CLOCKWISE direction. Drain and discard the removed element. e. Wipe the inside area of the filter head with a CLEAN “lint free” cloth. Fill the “NEW” fuel filter element COMPLETELY FULL of the CORRECT and CLEAN fuel. Put CLEAN oil on the element rubber gasket.

ENGINE FUEL FILTER [See Figure 4-7].

The fuel filter element MUST be replaced one [1] time for EACH 500 hours of machine operation, or each year.

Replace the fuel filter element using the following “GENERAL” procedures and those given in the engine “Operation Manual - FL 1011 Series Diesel Engine” published by Deutz Engine Company, and supplied with the machine.

FIGURE 4-7. FUEL FILTER LOCATION - DEUTZ DIESEL ENGINE. 11/95

4-15

Section 4 MAINTENANCE f. Install the “NEW” fuel filter element onto the filter head, until the gasket is seated against the filter head. Tighten the element one half [1/2] additional turn by the HAND only.

ENGINE AIR FILTRATION. AIR CLEANER [See Figure 4-8].

The engine inlet air cleaner assembly uses two [2] replaceable filter elements.

CAUTION: Do NOT overtighten the fuel filter element onto the filter head.

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

g. Open the fuel supply valve. 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.

WING NUT INNER AIR FILTER ELEMENT

RUBBER SEAL BOOT CLAMP

AIR CLEANER BODY

VACUUM SWITCH

RUBBER SEAL

FITTING

RUBBER SEAL WING NUT CLIP RUBBER SEAL CLAMP END CUP OUTER AIR FILTER ELEMENT VACUATOR VALVE

WING NUT

ENGINE INLET AIR SUPPLY HOSE

FIGURE 4-8. AIR CLEANER ASSEMBLY - EXPLODED VIEW.

4-16

11/95

Section 4 MAINTENANCE CAUTION: The air cleaner filter elements 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 elements while the engine is running.

j. Install the air cleaner end cup onto the air cleaner body. k. Install the rubber seal over the threaded end cup and air filter element retaining rod. Install and tighten the wing nut, which holds the end cup onto the air cleaner body. l. 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 “OFF” and that the engine inlet air path is NOT being restricted.

Use the following procedures to service the air cleaner elements: COOLING SYSTEM. a. Loosen the wing nut which retains the end cup.

Remove the end cup from the air cleaner body. b. Remove the wing nut, rubber seal and end cup from the air cleaner body. c. Remove the outer air filter element from inside the air cleaner body and DISCARD. d. Loosen and remove the wing nut and rubber seal which retains the inner air filter element. Remove the inner air filter element and DISCARD. e. Clean the inside of the air cleaner body with a clean cloth. f. Inspect ALL hose clamps for tightness and the condition of the engine inlet air supply hose from the air filter assembly to the engine air intake.

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

CLEANING THE COOLING FINS AND THE HYDRAULIC OIL COOLER [See Figure 4-9].

WARNING: Do NOT clean the system with the engine running. Serious injury can result from being caught or struck by the cooling fans, belt or moving engine parts.

NOTE: Also see the engine “Operation Manual FL 1011 Series Diesel Engine” published

by Deutz Engine Company, and supplied with the machine.

Dirt, particularly in the form of spilled oil and/or fuel on the engine cooling fins and hydraulic oil cooler, reduces the cooling performance.

If oil or fuel leakage in the area of the cooling blower, cylinders or oil cooler is noted, immediately find and repair the leak source.

g. Carefully install the NEW inner air filter element into the air cleaner body. h. Install the rubber seal over the threaded air filter element retaining rod. Install and tighten the wing nut, which holds the inner air filter element into the air cleaner body. i. Carefully install the NEW outer air filter element over the inner air filter element and into the air cleaner body.

11/95

4-17

Section 4 MAINTENANCE 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 hydraulic oil cooler cooling fins during cleaning.

Clean the fin area with the compressed air blown in the OPPOSITE direction of “normal” air flow during operation.

FIGURE 4-9. ENGINE COOLING FINS CLEANING LOCATION.

NOTE: If remaining contamination is oily, spray the engine with a cold cleansing agent and flush with water after an adequate “soaking time”. Also see the engine “Operation Manual - FL 1011 Series Diesel Engine” published by Deutz Engine Company, and supplied with the machine.

After repair of the leak source, clean the cooling fins using the following information.

e. Put the engine cooling air cowl in position on the engine and snap both retaining locks closed.

a. Keep the engine STOPPED.

f. Start the engine and allow the engine to warm for a short period to help prevent corrosion.

b. Unsnap and remove the engine cooling air cowling. c. Using a suitable brush, remove dry dirt from the engine cooling fins.

NOTE: Also use the brush to remove dry dirt from hydraulic oil cooler at this time.

d. Use low pressure compressed air to blow dust from the engine cooling fins.

NOTE: Also use compressed air to remove dry dirt from hydraulic oil cooler at this time.

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Section 4 MAINTENANCE HYDRAULIC SYSTEM.

CHANGING THE HYDRAULIC OIL [See Figures 4-10, 4-11 and 4-12].

GENERAL INFORMATION. The transmission, vibration, steering and leveling blade [Model BW124PDB] 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 4-10].

CHECK the hydraulic oil reservoir oil level, one [1] time EACH day, using the dipstick in the reservoir filler cap. Check the oil level when the hydraulic oil is at “NORMAL” operating temperature.

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.

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. Use the equipment furnished, and follow the directions given, by the oil analysis service. CHANGE the hydraulic oil IF the oil analysis results indicate a change is needed.

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.

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.

The hydraulic reservoir oil level MUST be at the "MAX" [top] line on the dipstick. If the hydraulic oil level is BELOW the MAX" line, the CORRECT, FILTERED hydraulic oil MUST be added to the hydraulic oil reservoir UNTIL the oil level is at the CORRECT level.

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. The hydraulic oil reservoir can have a low pressure in it at system operating temperatures.

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FIGURE 4-10. HYDRAULIC OIL RESERVOIR AND OIL LEVEL CHECK DIPSTICK.

4-19

Section 4 MAINTENANCE Use the following procedures to change the hydraulic oil: a. STOP the engine. Allow the hydraulic oil to cool, until it is at a WARM temperature. Wipe the oil filler cap, and surrounding area with a clean cloth.

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. Go to the lower area of the hydraulic oil reservoir. Wipe the oil drain plug, and surrounding area with a clean cloth. Place an empty container, having a capacity of approximately 10 gallons [39 liters], under the hydraulic reservoir drain plug. Carefully remove the oil drain plug. Allow all of the oil to drain into the container. Install and securely tighten oil drain plug.

c. Go to the top area of the hydraulic oil reservoir.

Remove the capscrews and washers that fasten the hydraulic reservoir access cover to the top of the reservoir. Carefully remove the access cover from the reservoir.

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 gasket with NEW when the cover is installed back onto the reservoir, if damaged.

d. 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.

CAP

SCREW CAP RETAINER

GASKET COVER GASKET CAP SCREW

STRAINER FILLER NECK

WASHER

GASKET

FIGURE 4-12. HYDRAULIC OIL RESERVOIR ACCESS COVER AND RELATED PARTS LOCATIONS. FIGURE 4-11. HYDRAULIC OIL RESERVOIR DRAIN PLUG LOCATION.

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Section 4 MAINTENANCE e. If removed, install a new gasket onto the hydraulic oil reservoir access opening area. Install the access cover over the gasket and onto the hydraulic oil reservoir. Install the retaining capscrews, with washers, into the tapped reservoir bores and tighten securely.

h. Install the hydraulic oil reservoir filler cap onto the reservoir filler neck and tighten securely.

f. CAREFULLY remove the cloth from the hydraulic oil reservoir fill tube opening.

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 eye, get IMMEDIATE medical attention.

NOTE: Also change the one [1] hydraulic pressure oil filter element at this time.

See THIS section for service procedures.

CAUTION: Do NOT fill the hydraulic oil reservoir with NEW hydraulic oil UNTIL the pressure filter element in the ABOVE “NOTE” has been serviced.

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.

i. Start the engine using the correct procedures given in Section 3 - OPERATION - of THIS manual.

CHECK the hydraulic system for ANY leaks.

CAUTION: STOP the engine IMMEDIATELY if ANY hydraulic leak is noted.

Do NOT start the engine UNTIL any problem noted has been corrected.

g. Fill the hydraulic oil reservoir with NEW, CORRECT and FILTERED hydraulic oil to the "MAX" level [top mark] on the dipstick .

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 is at the "MAX" level on the dipstick.

Do NOT overfill the hydraulic oil reservoir with oil.

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4-21

Section 4 MAINTENANCE HYDRAULIC PRESSURE OIL FILTER ELEMENT REMOVAL AND REPLACEMENT [See Figure 4-13].

Check the condition of the hydraulic pressure oil filter element EACH day. The filter element MUST be changed when the change indicator, found on the filter head, indicate an element change is required.

Also change the filter element with EACH hydraulic oil change.

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.

FIGURE 4-13. HYDRAULIC PRESSURE OIL FILTER ELEMENT LOCATION.

NOTE: When the hydraulic oil is “COLD” and at machine “START UP” the filter condition indicator WHITE sliding bar can show a HIGHER amount of filter element restriction.

WARNING: Do NOT loosen, or remove, the hydraulic pressure 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 COLD temperature.

Use the following procedure to remove and replace the hydraulic pressure oil filter element: a. STOP the engine. Allow the hydraulic oil to reach a WARM or COOL temperature.

CAUTION: Be sure that the old filter element rubber gasket was removed and discarded, BEFORE the new filter element is Installed.

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.

CAUTION: Do NOT overtighten the NEW filter element. Tighten by hand ONLY.

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 filterx element. Drain and then discard the removed filter element.

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Section 4 MAINTENANCE 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 and pressure oil filter element given in THIS section BEFORE starting the engine.

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.

ALTERNATOR AND COOLING FANS DRIVE BELT INSPECTION ADJUSTMENT AND REPLACEMENT PROCEDURES [See Figure 4-14].

Inspect the single drive belt one [1] time for EACH 50 hours of machine operation, or every two [2] weeks, and replace the belt if needed.

The belt is kept under tension by an adjustable tension mechanism.

Use the following procedures to inspect and adjust or inspect, replace and then adjust the drive belt:

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FIGURE 4-14. ALTERNATOR AND COOLING FANS DRIVE BELT LOCATION.

a. STOP the engine.

WARNING: Do NOT inspect or adjust the drive belt when the engine is running. The engine MUST be STOPPED before inspecting and/or adjusting the drive belt. Serious injury can result from being caught or struck by the cooling fans, belt or other moving engine parts.

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 0.406-0.593in. [10-15 mm] with thumb pressure on the belt. Replace the belt, with NEW, if any cracks or other damage is noted.

NOTE: If the belt requires replacement with NEW, also see the engine “Operation Manual - FL 1011 Series Diesel Engine” published by Deutz Engine Company, and supplied with the machine.

4-23

Section 4 MAINTENANCE ELECTRICAL SYSTEM. CHECKING THE BATTERY “CONDITION” AND SERVICING OF RELATED ITEMS [See Figure 415].

WARNING: Do NOT attempt to open the battery case, except the filler caps. 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.

Place NO tools on the battery.

Wear eye protection.

WARNING: BATTERY EXPLOSION CAN OCCUR IF THE BATTERY IS SHORTED. ALWAYS disconnect the NEGATIVE [-] battery cable FIRST, and then disconnect the POSITIVE [+] battery cable, BEFORE cleaning the terminals or cables. NEVER make a shorted circuit between the positive [+] terminal and negative [-] terminal of the battery.

ALWAYS connect the POSITIVE [+] battery cable to the POSITIVE battery terminal FIRST, and then connect the NEGATIVE [-] battery cable to the NEGATIVE [-] battery terminal LAST. Do NOT place ANY tools on a battery at ANY time.

Remove the battery fill covers and check the acid level in the battery one [1] time for EACH 100 hours of machine operation, or every two [2] weeks. If needed, fill the battery to the "full" level with clean distilled water. Install the fill covers after checking.

Remove the battery and clean the battery compartment with baking soda and flush with clean water.

Clean the outside of the battery with baking soda and flush with clean water.

Install and tighten the battery hold down assembly.

The battery MUST be kept from ANY movement in the machine.

Use a battery cable cleaning brush, baking soda and clear water to clean the battery terminals and cables. Put petroleum jelly on both posts and cables AFTER the cables are connected.

FIGURE 4-15. BATTERY MAINTENANCE ITEM LOCATIONS.

ELECTRICAL WIRING INSPECTION [See Figure 4-16].

During engine and other system maintenance inspections, check the electrical wiring for correct routing and support. Inspect the wires for loose terminal connections, cracks or wear in the wiring insulation and for corrosion. Wires and connections MUST be free of oil, dirt or grease.

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Section 4 MAINTENANCE

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4-25

Section 4 MAINTENANCE WARNING: BATTERY EXPLOSION CAN OCCUR IF A BATTERY IS SHORTED. ALWAYS disconnect BOTH the positive [+] AND the negative [-] battery cables from a battery, BEFORE ANY repair procedures are done to the electrical wiring or components.

ALWAYS use APPROVED practices when performing electrical system diagnosis procedures and doing repairs.

NEVER make a shorted circuit between the positive [+] terminal and the negative [-] terminal of a battery.

Do NOT place ANY tools on a battery at ANY time.

CAUTION: Do NOT use a wire smaller than the size of the original factory installed wires in the electrical system. If due to wear or damage wires are replaced with new, use wire being replaced.

DRIVE TIRES. INSPECTION, AIR PRESSURE CHECK AND ADJUSTMENT [See Figure 4-17].

Check each tire for the correct inflation pressure one [1] time for each 50 hours of machine operation or weekly.

Also, inspect each tire for cuts or other serious damage at this time.

If tire damage is found, use an authorized tire service to remove the tire/wheel assembly, repair, or replace, the damaged tire and install the tire/wheel assembly onto the machine.

a. Remove the tire valve cap from the tire inflation valve. Check the inflation pressure of the tire, using an accurate tire pressure gauge. Check the second drive tire inflation pressure. Install BOTH valve caps.

WARNING: ALWAYS use remote inflation equipment consisting of an extension hose, with clip-on filling chuck, and a gauge or preset pressure regulator. When adding inflation air to the drive tires, ALL personnel MUST keep clear of the tire and rim.

Serious injury can occur if a tire is released from the wheel.

CAUTION: The pressure indicated, on the tire pressure gauge, must be 26 psi. [1.8 bar], for open faced diamond tread tires, or 28 psi. [2.0 bar] for bar tread tires with the drive tires “cool”.

Adjust the air pressure until the pressure indicated is correct.

Do NOT overinflate the drive tires.

The drive tires will NOT absorb shocks to the machine. Over inflated tires also are more likely to cut, snag or be punctured.

Do NOT under inflate the drive tires.

The drive tires will be too soft and will over deflect. This condition can build excess heat and can cause breaks in the tire body cords.

ALWAYS install a tire valve cap, onto the tire valve stem, after checking and/or adjusting the drive tire inflation pressure.

NOTE: Do NOT check the drive tire pressure when the tires are warm. Check the tire inflation pressure only when the drive tires are “cool”.

Check each drive tire inflation pressure and adjust as needed, using the following procedures:

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Section 4 MAINTENANCE

FIGURE 4-17. DRIVE WHEEL TIRE, INFLATION AIR PRESSURE CHECK, AND FILL LOCATIONS.

FIGURE 4-18. HITCH BEARINGS - LUBRICATION LOCATIONS.

MISCELLANEOUS MAINTENANCE INFORMATION.

LEVELING BLADE BEARINGS - MODEL BW124PDB [See Figure 4-19].

GREASE LUBRICATION.

a. Park the machine on a level surface. Put the secondary/parking brake system “ON” [APPLIED].

STOP the engine.

Use the following information to lubricate the given locations on the machine with LITHIUM HIGH PRESSURE GREASE one time for each 50 hours of machine operation, or weekly.

HITCH BEARINGS [See figure 4-18]. a. Park the machine on a level surface. Put the secondary/parking brake system “ON” [APPLIED].

STOP the engine.

b. Go to the front center of the machine. Find the leveling blade cylinder, two [2] leveling blade cylinder bearings and bearing lubrication grease zerks. c. Wipe the two [2] cylinder bearing lubrication grease zerks with a CLEAN cloth. d. Give each zerk approximately five [5] grease gun pumps to lubricate the bearing.

b. Go to the hitch area. Wipe the three [3] hitch bearing lubrication grease zerks with a CLEAN cloth. c. Give each grease zerk approximately five [5] grease gun handle pumps to lubricate the bearing.

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4-27

Section 4 MAINTENANCE NOTE: On Model BW124D, loosen the one [1] capscrew which fastens the adjustable cleaner bar to the frame at each end.

Adjust the cleaner bar to contact the drum surface. Tighten the capscrews to a torque of 65 ft. lbs. [88 N.m]. On Models BW124PD and BW124PDB, loosen the capscrews that fasten the scrapers to the cross member. Center EACH scraper BETWEEN the drum feet and adjust EACH scraper to drum surface clearance to 0.25 in. [7 mm]. Tighten all capscrews to a torque of 91 ft. lbs. [123 N.m].

FIGURE 4-19. LEVELING BLADE BEARINGS LUBRICATION LOCATIONS.

SCRAPER ASSEMBLIES [See Figures 4-20 and 4-21].

Check for broken or loose scraper components one [1] time for each 50 hours of machine operation, or weekly. Replace broken or missing parts as required. Keep all mounting fasteners correctly tightened at all times.

BOLT

FIGURE 4-20. SCRAPER ASSEMBLIES - MODEL BW124D ROLLER.

WARNING: Scrapers can become very sharp, on the lower edge when worn.

Serious injury can occur if contact is made with a sharp edge.

CAUTION: Do NOT operate a machine having missing or damaged scraper components. Replace ALL missing or damaged scraper components IMMEDIATELY.

4-28

FIGURE 4-21. SCRAPER ASSEMBLIES MODEL BW124PD AND BW124PDB ROLLERS.

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Section 4 MAINTENANCE OPERATOR RESTRAINT [SEAT BELT], FALLING OBJECT AND ROLL OVER PROTECTION STRUCTURE [FOPS/ROPS] SYSTEMS [See Figure 4-22].

One [1] time for each eight [8] hours of machine operation, or daily check the condition of the operator restraint [seat belt] system.

DANGER: If ANY structure damage is found during the inspection process, do NOT operate the machine. Remove the ignition key and place a tag on the steering wheel saying; “DO NOT OPERATE”. Contact your nearest Distributor and/or Compaction America, Kewanee, Illinois, USA, for repair or replacement instructions.

The anchor end of each half belt MUST be securely fastened [bolted] to the machine. Securely tighten any retaining bolt, found to be in a loosened condition, to a torque of 37 ft. lbs. [50 N.m].

Each retaining bolt MUST be in a good condition and NOT be rusted, broken or otherwise damaged.

If needed, replace, and then securely tighten the bolt, with NEW of the SAME type and strength [grade], that shows ANY damage.

Each belt half MUST be in good condition. The belt material must NOT be cut, rotted or torn. Carefully inspect the latch/release mechanism for full and correct latch engagement and release actions.

Replace the COMPLETE operator restraint [seat belt] SET, with NEW, if ANY damage or malfunction is noted.

One [1] time for each eight [8] hours of machine operation, or daily check the condition of the falling object and roll overprotection structure [FOPS/ROPS] to machine retaining capscrews and nuts.

Each of the structure retaining capscrew and nut MUST remain FULLY tightened to the CORRECT torque of 221 ft.lbs. [300 N.m] at ALL times.

Each retaining capscrew MUST be in a good condition and NOT be rusted, broken or otherwise damaged. Replace, and then securely tighten, ANY capscrew, with NEW of the SAME type and strength [M16 - grade 10.8], that shows ANY damage.

Tighten ALL capscrews and nuts to a CORRECT torque of 221 ft.lbs. [300 N.m], AFTER replacement.

At the SAME time, also inspect ALL of the CRITICAL structural members [Uprights, Cross members, Tubes or Gussets] for broken welds, severe rust and/or damage to the materials.

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4-29

Section 4 MAINTENANCE

FIGURE 4-22. OPERATOR RESTRAINT [SEAT BELT], FALLING OBJECT/ROLL OVER PROTECTION STRUCTURE [FOPS/ROPS] SYSTEM COMPONENTS.

PREPARING THE MACHINE FOR STORAGE.

BATTERY.

Use the following information as a “general guide” ONLY to prepare the machine for storage. If desired, Manufacturers of component parts, used on the machine, can also be contacted for specific information about components manufactured by them.

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.

Service the battery as required [see THIS Section].

Fully charge the battery BEFORE it is placed into storage. Charge the battery, again, one [1] time for every 30 days which the battery is stored.

ENGINE PRESERVATION. See the engine “Operation Manual - FL1011 Series Diesel Engine” published by Deutz Engine Company, and supplied with the machine for engine storage preservation procedures that are suggested by the engine manufacturer.

4-30

Keep the battery stored in a wood surface in a COOL and DRY storage area.

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.

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Section 4 MAINTENANCE FUEL TANK.

EXPOSED COMPONENT RUST PREVENTION.

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

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: 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.

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.

DRIVE TIRES. Check and adjust the air pressure of the drive tires to the CORRECT cold pressure [see this section].

Us e a jack, having a capacity of 5 tons [4.5 t] to carefully lift BOTH sides of the machine REAR frame assembly enough, so that BOTH drive tires are ABOVE the ground a SMALL amount. Put solid wood blocks under BOTH sides of the REAR frame, to keep the machine drive tires above the ground.

Lower the machine onto the blocks. Remove the jack. Cover the drive tires to keep direct sun light from them.

WARNING: Keep CLEAR of the jack, frame and blocks while lifting, blocking and lowering the machine. Serious injury can occur if caught by the above items. Block the rear machine frame SECURELY using solid wood blocking.

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4-31

Section 4 MAINTENANCE NOTES

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Section 5 FRAME, HITCH and FALLING OBJECT/ ROLL OVER PROTECTION STRUCTURE

TABLE OF CONTENTS PAGE GENERAL INFORMATION ........................................................................................................................... 5-2 DESCRIPTION OF THE FRAMES AND THE HITCH ................................................................................... 5-2 REMOVAL OF THE HITCH ASSEMBLY ....................................................................................................... 5-3 INSTALLATION OF THE HITCH ASSEMBLY ............................................................................................... 5-5 FALLING OBJECT/ROLL OVER PROTECTION STRUCTURE [FOPS/ROPS] .......................................... 5-7 CHECKS AND SERVICE PROCEDURES .................................................................................................... 5-7 TROUBLE ANALYSIS FOR THE FRAME AND HITCH .............................................................................. 5-10

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5-1

Section 5 FRAME, HITCH and FALLING OBJECT/ ROLL OVER PROTECTION STRUCTURE GENERAL INFORMATION. This section describes the FRAMES, HITCH and FALLING OBJECT/ROLL OVER PROTECTION STRUCTURE [FOPS/ROPS] used on Model BW 124D, BW 124PD, and BW 124PDB Single Drum Rollers [see figure 5-1].

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

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

DESCRIPTION OF THE FRAMES AND THE HITCH [See Figures 5-1 and 5-2].

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 a VERTICAL support, which gives a total of, 60 degrees of machine steering, full left to full right.

The HORIZONTAL joint cross shaft gives the machine a total of 13 degrees oscillation between the FRONT and REAR frames. Frame and hitch loads are held on bushing and thrust bearing assemblies.

The VERTICAL hitch coupling is made of the following items: two [2] pillow blocks each installed onto the rear frame weldment by four [4] hex bolts, four [4] discs, and four [4] hex nuts. Two [2] bearing covers attached to the outside surface of each pillow block casting by [6] hex bolts. One [1] hitch support has an upper assembly and a lower assembly. The upper assembly consisting of the following items: one [1] sealing ring, one [1] spherical bearings, three [3] supporting discs, one [1] internal circlip, and one [1] external circlip.

FRONT WELDMENT

REAR WELDMENT

OSCILLATION HITCH

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

5-2

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Section 5 FRAME, HITCH and FALLING OBJECT/ ROLL OVER PROTECTION STRUCTURE The lower assembly consisting of the following items: one [1] sealing ring, one [1] spherical bearings, two [2] supporting discs, and one [1] internal circlip. Also used are; two [2] grease nipples. One grease nipple is installed on the front of each pillow block.

c. Go to the steering cylinder to hitch connection point. Remove the cotter pin from the steering cylinder to hitch gudgeon. Remove the pin and move the steering cylinder away from the hitch.

The HORIZONTAL hitch coupling is made of the following items: one [1] bearing housing, one [1] joint cross shaft, two [2] tapered roller bearings, two [2] sealing rings, one [1] supporting disc, one [1] belleville spring, and one [1] tension nut.

e. While insuring that both the front and rear frame weldments are supported on all four [4] corners, remove the eight [8] hex bolts attaching the bearing housing to the front weldment.

Also used are, one [1] cylinder loop attached to the rear of the hitch support by six [6] hex bolts, and six [6] discs. One [1] cylinder attached to the cylinder loop by two [2] supporting discs, one [1] spherical bearing, one [1] disc, one [1] gudgeon, one [1] screw plug, and one cotter pin. The rear of the cylinder is attached to the cylinder bearing by two [2] supporting discs, one [1] spherical bearing, one [1] disc, one [1] gudgeon, one [1] screw plug, and one cotter pin. The cylinder support is mounted through the plate of the rear frame by four [4] hex bolts, eight [8] tightening washers, and four [4] hex nuts.

d. Support the hitch assembly with a mobile jack.

f. Go to the rear frame weldment, locate both the upper and lower pillow blocks. Remove the four [4] hex bolts while holding the hex nuts with a wrench from each of the pillow blocks. Set aside the hex bolts, discs, and hex nuts. g. Balance the hitch while removing. Lift the hitch assembly to an appropriate work place. h. Locate the bearing cover on the upper pillow block and remove the six [6] hex bolts and set aside.

Remove the bearing cover and set aside. Remove the external circlip and the supporting disc. i. Locate the bearing cover on the lower pillow block and remove the six [6] hex bolts and set aside.

Remove the bearing cover and set aside.

REMOVAL OF THE HITCH ASSEMBLY [See Figures 5-1 and 5-2].

Use the following procedure for removal of the hitch assembly. a. Support BOTH the front and rear frames, under ALL four [4] corners of each frame, with SOLID wood blocks.

WARNING: Block SECURELY under ALL four [4] corners of BOTH the FRONT and REAR frame sections. The frame halves will NOT balance and MUST be supported under ALL four corners of EACH frame section. b. Completely clean the hitch and frame areas, with All-Purpose Degreaser, part number 178297, and permit to air dry.

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NOTE: Discard all spherical bearings and sealing rings. Contact an authorized distributor and purchase replacement bearings, sealing rings, and any other components showing wear and/or damage. If severe wear or damage is noted in all major components (bearing housing, cylinder support, joint cross shaft), replace the complete hitch assembly with new.

j. Use a puller and remove both pillow blocks from the vertical support. Remove the seal ring and support disc from each pillow block. Remove the internal circlips and supporting disc from each pillow block. k. Use a suitable mandrel to press the spherical

5-3

Section 5 FRAME, HITCH and FALLING OBJECT/ ROLL OVER PROTECTION STRUCTURE SPERICAL BEARING

BEARING COVER PILLOW BLOCK GREASE NIPPLE

EXTERNAL CIRCLIP SUPPORTING DISC SPERICAL BEARING SUPPORTING DISC INTERNAL CIRCLIP SUPPORTING DISC

CYLINDER BEARING

SEALING RING CYLINDER JOINT CROSS SHAFT CYLINDER LOOP

SUPPORT

TAPER ROLLER BEARING

SEALING RING SUPPORTING DISC INTERNAL CIRCLIP SUPPORTING DISC SPERICAL BEARING PILLOW BLOCK

BEARING HOUSING BEARING COVER GREASE NIPPLE

TAPER ROLLER BEARING BELLEVILLE SPRING

SUPPORTING DISC

TENSION NUT SEALING RING FIGURE 5-2. COMPONENTS OF THE HITCH ASSEMBLY.

5-4

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Section 5 FRAME, HITCH and FALLING OBJECT/ ROLL OVER PROTECTION STRUCTURE bearing out of each pillow block. l. Secure the hitch support to allow parts removal from the horizontal hitch assembly. Locate and remove the sealing ring found on the back side of the bearing housing. m. Use a pin wrench to remove the tension nut from the jointed cross shaft. n. Remove and set aside, the Belleville spring. o. Use a puller to pull the bearing housing from its seat and remove it. p. Pull the tapered roller bearing inner race and the supporting disc, from the jointed cross shaft. q. Drive the inner race and both outer races of the tapered roller bearing, out of the bearing housing. r. Check the condition of the jointed cross shaft for wear and/or damage. If necessary, detach and set aside both the jointed cross shaft, sealing ring and the cylinder loop from the vertical support. s. Go to the steering cylinder and remove the screw plug, cotter pin, grudgeon, spherical bearing, disc, and two [2] supporting discs located at the rear of the cylinder and set them aside. Place the cylinder in a secure position.

b. Slide a NEW sealing ring and new supporting disk onto the jointed cross shaft. Fit a new tapered roller bearing and press it on until the final stop. Fill the bearing well with lithium-soaped high pressure grease. c. Press both outer races of the bearing into the bearing housing until final stop. d. Carefully fit the bearing housing over the cross shaft; when doing so, insert the inner seal ring into the bearing housing. e. Fill the outer tapered roller bearing with lithiumsoaped high pressure grease and fit it in position. f. Fit the Belleville spring with the convex side facing inwards. g. Screw on a new tension nut with the large outer diameter facing inwards and tighten it with a pin wrench until the dimension 11.4 [± 0.1 mm] is obtained [SEE FIGURE 5-3].

NOTE: Measurement is made through the inner bores in the tension nut. When tightening, rotate the jointed cross shaft to ensure that the individual rollers support the load equally.

CAUTION: Ensure the cylinder will not damage other internal components.

11.4 +/- 0.1 mm t. Examine all components for wear and/or damage. Discard all spherical bearings and sealing rings. Contact an authorized distributor and purchase replacement bearings, sealing rings, and any other components showing wear and/or damage.

INSTALLATION OF THE HITCH ASSEMBLY [See Figures 5-1 and 5-2]. a. If necessary, attach the jointed cross shaft to the vertical support.

FIGURE 5-3. DIMENSION MEASUREMENT LOCATION. 6/96

5-5

Section 5 FRAME, HITCH and FALLING OBJECT/ ROLL OVER PROTECTION STRUCTURE h. Secure the set tension nut by striking twice with a punch at opposite sides. i. Place the sealing ring into the bearing housing, over the tension nut. j. Install the internal circlip and then the supporting disc into both pillow blocks. k. Press a spherical bearing into each pillow block, until the final stop. l. Lubricate all parts with a lithium-soaped high pressure grease. m. Install the sealing ring, onto each vertical support pin located on the cylinder support. n. Press the pillow blocks onto the upper and lower vertical support pins, install support disc and external circlip onto the upper and lower vertical support pins. o. Fill bore in the bearing cover with a lithiumsoaped high pressure grease. Install the bearing cover on both the upper and lower pillow blocks with six [6] hex bolts each. Torque each of the hex bolts to 30 ft. lbs. [45 N.m].

s. Install the two [2] hex bolts with discs through the left center and right center holes of the bearing housing, and then into the threaded holes in the front frame. t. Install the six [6] hex bolts with discs through both the upper and lower: left, center, and right holes of the bearing housing, and then into the threaded holes in the front frame. u. Tighten all hex bolts connecting the bearing housing to the front frame to a torque of 221 ft. lbs.

[300 N.m]. v. Move the steering cylinder into position to be mounted onto the cylinder support. Press one [1] spherical bearing into the cylinder support. Install one [1] supporting disc on each side of the spherical bearing. Place the steering cylinder onto the cylinder support and install one [1] gudgeon through the top of the cylinder eyelet, place one [1] supporting disc onto the gudgeon. Put one [1] cotter pin through the gudgeon pin and bend the cotter pin. Install the screw plug into the top of the gudgeon.

p. Place the hitch assembly onto the mobile jack in such a position as to allow mobility and support the articulated joint. Return the hitch assembly to the rear frame. Raise the hitch and align the through holes of the lower pillow block with the through holes located on the rear frame.

w. Move the steering cylinder into position to be mounted onto the cylinder loop. Place one [1] spherical bearing into of the cylinder loop. Install one [1] supporting disc on each side of the cylinder loop. Place the steering cylinder onto the cylinder loop and install one [1] gudgeon through the top of the cylinder eyelet, place one [1] supporting disc onto the gudgeon. Put one [1] cotter pin through the gudgeon pin and bend the cotter pin. Install the screw plug into the top of the gudgeon.

q. Install the four [4] hex bolts through both the lower pillow block and the rear frame. Place the four [4] discs and the four [4] hex bolts while, and tighten the hex bolts while holding the hex nuts with a wrench.

x. Use a hydraulic jack, having a capacity MORE than 5,000 lbs. [2270 kg], to lift the frame near each block. Carefully remove ALL support blocking from under the machine and lower the machine. Go to the remaining blocked areas and remove the blocking.

r. Install the four [4] hex bolts through both the upper pillow block and the rear frame. Place the four [4] discs and the four [4] hex nuts, and tighten the hex bolts while holding the hex nuts with a wrench.

After installation, the hex bolts on both pillow blocks must be torqued to 221 ft. lbs. [300 N.m].

5-6

WARNING: Keep CLEAR of the jack, frame area and blocking while lifting the machine, removing the blocking and lowering the machine to the ground.

Serious injury can occur if caught by the above items.

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Section 5 FRAME, HITCH and FALLING OBJECT/ ROLL OVER PROTECTION STRUCTURE y. Start the engine and check the hitch for function.

DANGER: KEEP CLEAR of the hitch area. Clearance closes between the front and rear frames during a right or left turn of the machine.

Serious INJURY, or DEATH, can occur if caught between the frames at the hitch area.

a. Inspect ALL hardware that fastens the STRUCTURE to the machine. They MUST remain tightened to a torque of 221 ft. lbs. [300 N.m]. If replacement hardware is needed, select the correct item having the SAME specifications. Install and then tighten the hex bolts and nuts to the CORRECT torque using a large capacity torque wrench.

The steel components of the FALLING OBJECT/ ROLL OVER PROTECTION STRUCTURE [FOPS/ ROPS] are welded together using material welding practices that produce a strong integrated structure.

WARNING: If the protective structure has been removed from the machine and isbeing installed again, Inspect each piece of mounting hardware for wear or damage. Replace worn, or damaged, hardware items with NEW. Install, and then tighten, all mounting hardware as directed in step "a" above.

NEVER replace any mounting hardware item with an item NOT having equal, or better, rating.

The protection structure with brackets is fastened to the machine on EACH side of the REAR frame by a total of twelve [12] hex bolts, twenty-four [24] tightening washers, and twelve [12] hex nuts.

b. Carefully inspect ALL welds for cracks, severe rust, breakage in the weld and/or where the weld joins the metal of the structure steel components.

FALLING OBJECT/ROLL OVER PROTECTION STRUCTURE [FOPS/ROPS] [See Figure 5-4].

DANGER: An improperly mounted, or damaged, structure may not provide operator protection in the event of a machine tip over. Follow the inspection procedures below.

CHECKS AND SERVICE PROCEDURES [See Figure 5-4].

Use the following information to check the ROLL OVER PROTECTION STRUCTURE components for breakage or other damage and correct tightening at LEAST one [1] time for each eight [8] hours of machine operation, or daily and to do minor surface rust removal and painting on the structure.

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WARNING: If ANY damage is found, contact your nearest Distributor IMMEDIATELY for replacement or repair instructions.

Do NOT use the machine until contact and the directed repairs, or protective structure replacement, has been done.

Do NOT add anything to the protective structure. NEVER "heat" or weld any "add on" item onto the structure.

Do NOT operate a machine AFTER a roll over situation HAS occurred. If a roll over situation has occurred, REMOVE the protective structure from the machine only AFTER contact has been made with your nearest Distributor and/or Compaction America. Assistance in the repair, or replacement, of the system will be offered.

NEVER weld on, or replace, a protective structure component BEFORE obtaining instructions, per the ABOVE information.

5-7

Section 5 FRAME, HITCH and FALLING OBJECT/ ROLL OVER PROTECTION STRUCTURE c. If surface rust on components is found, remove rust from ALL welds and structure components. Apply paint primer and top coat paint to the complete protective structure, as directed by the paint manufacturer. d. A seat belt system is included with the protective structure to help restrain the operator in the event of machine tipping. Carefully inspect the seat belt. The latch MUST catch and release correctly.

The belt material MUST be clean and not torn, rotted or damaged. The belt anchor bolts MUST remain tightened securely, to the seat riser, at a CORRECT torque of 37 ft. lbs. [50 N.m]. Replace the COMPLETE belt SET, with NEW, if ANY damage is found.

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

NEVER operate a machine having a worn, damaged or malfunctioning seat belt. Repair or replace the seat belt IMMEDIATELY.

5-8

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Section 5 FRAME, HITCH and FALLING OBJECT/ ROLL OVER PROTECTION STRUCTURE

ROPS

HEX BOLT

TIGHTENING WASHER CONSOLE LEFTHAND

CONSOLE RIGHTHAND HEX NUT HEX BOLT TIGHTENING WASHER

FIGURE 5-4. FALLING OBJECT/ROLL OVER PROTECTIVE STRUCTURE [FOPS/ROPS] AND OPERATOR RESTRAINT - MAJOR COMPONENT LOCATIONS

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5-9

Section 5 FRAME, HITCH and FALLING OBJECT/ ROLL OVER PROTECTION STRUCTURE TROUBLE ANALYSIS FOR THE FRAME AND HITCH TROUBLE

CAUSE

NOISE IN HITCH AREA DURING OSCILLATION AND/OR TURN

Worn or damaged parts in the hitch assembly

Disassemble hitch. Inspect parts for wear or damage.

Replace parts, with NEW, as found needed.

STEERING ACTION NOT SMOOTH

Binding of the upper and/or lower pin on the vertical support

Disassemble hitch. Inspect parts for wear or damage.

Replace parts, with NEW, as found needed.

Worn or damaged spherical bearing[s] in the hitch

Disassemble hitch. Inspect parts for wear or damage.

Replace parts, with NEW, as found needed.

5-10

CORRECTIVE ACTION

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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 ............................................................................................ 6-4

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6-1

Section 6 ENGINE GENERAL INFORMATION.

REMOVAL OF THE ENGINE [See Figure 6-2].

This section contains information about the DEUTZ diesel engine used in the Model BW 124D, BW 124PD, and BW 124 PDB Single Drum Rollers.

a. Remove the side covers, from the side of the engine compartment. Remove the air inlet hose assembly from the engine inlet air connection point.

Remove the lift shockfrom it's location at the fender mount. Remove the engine hood assembly retaining nuts, washers and cap screws. Disconnect the backup alarm harnes from alarm and remove harnes from hood. Remove the hood assembly from the machine.

This section also contains REMOVAL and INSTALLATION information about the engine.

DESCRIPTION. The Model BW 124D, BW 124PD, and BW 124 PDB Single Drum Rollers are powered by the DEUTZ Model F3L 1011, oil and air cooled engine [see figure 6-1].

For engine OPERATION and general manufacturer MAINTENANCE procedures, see the DEUTZ Model F3L 1011 “OPERATION and MAINTENANCE MANUAL”, which is supplied with EACH machine.

For major engine repair requirements contact the nearest DEUTZ Engine Dealer for assistance about major repair procedures, in dealer shop repairs and/ or engine parts.

FIGURE 6-1. DEUTZ Model F3L 1011 Engine.

6-2

b. FIRST remove the NEGATIVE [-] battery cable from the NEGATIVE [-] terminal of the battery, and then remove the POSITIVE [+] battery cable from the POSITIVE [+] terminal of the battery. Disconnect BOTH the NEGATIVE [-] and the POSITIVE [+] battery cables from their connections to the engine. Remove the battery from the machine and place in a suitable location.

CAUTION: Do NOT place the battery on a concrete surface. Store the battery on a WOOD surface ONLY.

WARNING: BATTERY EXPLOSION CAN OCCUR IF A BATTERY IS SHORTED. Remove the NEGATIVE [-] battery cable FIRST. Do NOT smoke OR cause a spark while removing the battery cables from the battery.

BATTERY MAY CONTAIN EXPLOSIVE GAS. ALWAYS use APPROVED practices when performing electrical system diagnosis procedures and doing repairs.

NEVER make a shorted circuit between the positive [+] terminal and the negative [-] terminal of a battery.

Do NOT place ANY tools on a battery at ANY time.

c. Loosen the clamp at the exhaust pipe to flexible exhaust tube. Remove the exhaust pipe from the flexible exhaust tube.

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Section 6 ENGINE d. Disconnect the fuel supply AND return lines from the engine. Put a cap or a plug into EACH line AND onto EACH engine fitting. e. Detach the throttle cable from the engine. Disconnect the choke cable from the engine. f. Disconnect the transmission system direction control cable from the transmission pumps control lever. g. Put an identification tag on EACH hose and EACH fittingof the transmission pumps, steering/vibration pump, or if so equipped, the steering/vibration/leveling blade system pump. Then disconnect ALL hydraulic supply and return hoses from the hydraulic oil cooler. Put caps or plugs in ALL hoses and on ALL fittings IMMEDIATELY after the hoses are disconnected. h. Disconnect the governor [throttle] control cable from the engine governor control lever and anchor bracket.

l. Install one [1] engine lifting eye into each tapped lifting inset hole, located on top of engine. SECURELY fasten a chain and a lifting device, having a capacity MORE than 1,000 lbs. [454 kg], to the two [2] engine lifting eyes. Tighten the lifting device.

WARNING: Use a lifting device and chain capable of lifting at LEAST a weight of 1,000 lbs. [454 kg].

Fasten SECURELY.

m. Remove the cap screws, nuts and washers which hold the engine to the frame weldment at ALL FOUR [4] connection points.

NOTE: The DEUTZ diesel engine is mounted into the frame at a TOTAL of four [4] engine mount to frame connection points [two [2] FRONT and two [2] REAR].

i. Disconnect ALL hydraulic supply and return hoses from the hydraulic oil cooler. Put caps or plugs in ALL hoses and on ALL fittings IMMEDIATELY after the hoses are disconnected. Remove the fan gaurd from the hydraulic oil cooler. Remove the hydraulic oil cooler from the machine and place component away from the machine.

n. 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.

j. Put an identification tag on EACH electrical wire and EACH electrical wire connection terminal on the engine. Loosen and remove ALL electrical wires which are connected to the engine.

CAUTION: Do NOT remove the engine assembly before loosening and removing ALL items connected to the engine, or fastened to any component being removed with the engine.

k. Put an oil drain pan under the engine lubrication oil drain plug. Wipe the area around the drain plug, using a clean cloth. 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.

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.

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6-3

Section 6 ENGINE o. CAREFULLY and SLOWLY lift the engine, clear of the frame, a SMALL amount. Move the engine assembly “back” and toward the REAR of the machine, a SMALL amount. CAREFULLY and SLOWLY continue to lift the engine assembly, “UPWARD” and “OUT” of the frame, UNTIL the engine assembly is away from the frame and machine.

INSTALLATION OF THE ENGINE ASSEMBLY [See Figure 6-2]. a. If needed install one [1] engine lifting eye into each tapped lifting insert hole located on top of ingine. SECURELY fasten a chain and a lifting device, having a capacity MORE than 1,000 lbs. [454 kg], to the engine lifting eyes.

WARNING: KEEP CLEAR of the engine assembly while it is being lifted and removed from the frame. Serious injury can occur if caught between the engine and frame areas.

WARNING: Use a lifting device and chain having a capacity larger than 1,000 lbs.

[454 kg].

Fasten SECURELY.

p. CAREFULLY lower the engine onto an engine stand or other engine support device.

b. CAREFULLY and SLOWLY lift the engine assembly a SMALL amount.

WARNING: KEEP CLEAR of the engine assembly while being lowered after removal from the frame. Serious injury can occur if caught between the engine and support device.

c. CAREFULLY and SLOWLY lift the engine assembly to a position ABOVE the frame. SLOWLY begin to lower the engine assembly “DOWNWARD” toward the frame. Align ALL the engine mount holes with the holes located in the frame weldment, 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.

d. Install ALL four [4] of the engine mount to frame retaining cap screws - with washers, into the frame and engine mount holes. Install one [1] washer and one [1] nut onto each capscrew. Tighten each engine mount weldment to frame retaining capscrew to a torque of 65ft. lbs. [88 N.m] or until rubber is compressed. Remove the chain from the engine lifting eyes. Remove the lifting eyes from the engine. e. Fill the engine with NEW engine lubrication oil [see Section 4 - MAINTENANCE]. Install the hydraulic oil resevoir, battery support, and battery.

6-4

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Section 6 ENGINE

TORQUE TO 37ft. lbs.[50 n.m] TORQUE COUPLER CAPSCREW TO 45ft. lbs.[ 61 n.m] TORQUE TO 43ft. lbs. [59 n.m]

ENGINE MOUNT

ENGINE MOUNT

FUEL TANK FRAME

FIGURE 6-2. DEUTZ DIESEL ENGINE - INSTALLATION INTO FRAME. f. CAREFULLY connect ALL electrical wires, EXCEPT the POSITIVE [+] and NEGATIVE [-] battery cables, to the CORRECT engine wire connection terminal, as shown by the identification tags, and tighten securely.

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

Serious injury can occur if a "shorted" electrical condition is caused during component connection and installation.

g. Connect the governor [throttle] control cable to the engine governor and anchor bracket. h. Connect the transmission direction control cable to the transmission pump control lever. Adjust the direction control cable linkage if needed [see Section 8 - TRANSMISSION for the procedure].

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i. Remove ALL caps and plugs from ALL the hoses and fittings which fasten to, or are on, the transmission pump, steering/vibration pump, or if so equipped, the steering/vibration/leveling blade systems pump and the vibrator pump. Install EACH hose onto the CORRECT fitting of the above pumps as shown by the identification tags. Securely tighten each hose onto each fitting. j. Remove ALL caps and plugs from ALL hoses and fittings which fasten to, or are on, the hydraulic oil cooler. Install EACH hose onto the CORRECT oil cooler fitting and securely tighten each hose fitting. k. Remove the caps and plugs from the fuel supply and return hoses and engine fittings. Connect the fuel supply and return hoses to the engine fittings.

Securely tighten each hose fitting. Install the fan gaurd onto the hydraulic oil cooler. l. Remove ALL caps and plugs from ALL the hoses and fittings which fasten to, or are on, the hydraulic oil reservoir assembly, ONE [1] at a time. Install EACH hose onto the CORRECT fitting of the hydraulic reservoir as shown by the identification tags. Securely tighten EACH hose onto EACH fitting.

6-5

Section 6 ENGINE m. Add NEW, CLEAN and FILTERED hydraulic oil to the hydraulic oil reservoir UNTIL the oil level is at the proper level on the dipstick [see Section 4 MAINTENANCE].

s. Carefully connect the POSITIVE [+] battery cable terminal 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.

CAUTION: Do NOT start the engine UNTIL ALL of the transmission system start up procedures have been completed.

Be SURE the charge pump has FILLED with oil and IS developing charge pressure BEFORE the engine is started [See section 8 - TRANSMISSION SYSTEM - for the CORRECT procedures].

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 terminals to the battery.

BATTERY MAY CONTAIN EXPLOSIVE GAS.

n. Connect BOTH the POSITIVE [+] and the NEGATIVE [-] battery cables to their connections on the engine. o. Carefully install the hood assembly - with air cleaner onto the machine. Install the hood retaining cap screws, washers and nuts. Securely tighten all cap screws and nuts. Install the wiring harness insulated clamps and harness onto the rear cowl, inside the service access area. Connect ALL electrical wires to the back up alarm and the hydraulic oil temperature sender as indicated by the identification tags. Install the lift cylinders to the fender mounts. p. Connect the air intake hose assembly onto the engine inlet air connection point. Install and securely tighten the retaining band clamp.

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

t. Inspect ALL hose, line, wire and cable connections for CORRECT connection locations and tightness. Check for ANY leak of fuel, oils or coolant, at this time. u. AFTER making sure, AGAIN, that the transmission system start procedures have been completed, 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 machine system does NOT have CORRECT operation.

Do NOT start the engine again UNTIL the system problem has been corrected.

q. Install new exhaust pipe to exhaust manifold gaskets. Install exhaust pipe to engine exhaust minifold. Install exhaust pipe to muffler and place exhaust clamps into position. Tighten clamps to securely. r. Install the engine side shields. Install the side shields retaining cap screws, washers and nuts. Securely tighten all cap screws and nuts.

6-6

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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 GENERATOR ........................................................................................................................................... 7-2 SWITCHES ............................................................................................................................................... 7-2 RELAYS AND CIRCUIT BREAKERS ...................................................................................................... 7-3 INSTRUMENTS AND INDICATOR LIGHTS ............................................................................................ 7-4 INSTRUMENTS .................................................................................................................................. 7-4 INDICATOR LIGHTS .......................................................................................................................... 7-4 CABLES AND WIRES .............................................................................................................................. 7-5 CABLES ............................................................................................................................................. 7-5 WIRES ................................................................................................................................................ 7-5 CIRCUITS ...................................................................................................................................................... 7-5 START - STOP ( PRIMARY CIRCUIT) ..................................................................................................... 7-5 SECONDARY CIRCUITS ......................................................................................................................... 7-5 CHARGING CIRCUIT .......................................................................................................................... 7-9 VIBRATION CIRCUIT .......................................................................................................................... 7-9 FUEL SUPPLY CIRCUIT ................................................................................................................... 7-11 WARNING CONTROL INDICATOR LIGHT CIRCUIT ...................................................................... 7-11 TROUBLE ANALYSIS INFORMATION AND PROCEDURES ................................................................... 7-13 TROUBLE ANALYSIS FOR THE ELECTRICAL SYSTEM ........................................................................ 7-15

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7-1

Section 7 ELECTRICAL GENERAL INFORMATION.

GENERATOR.

This section describes the OPERATION of the electrical system and contains DESCRIPTIONS of the items included in the system used on the Model BW124D, BW124PD, and BW 124PDB Single Drum Rollers.

The 60 amp generator 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”.

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

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.

SYSTEM DESCRIPTION [See Figures 7-1, 7-2 and 7-3].

The electrical system contains the following major components: 1. BATTERY. 2. STARTER MOTOR. 3. GENERATOR. 4. SWITCHES. 5. SOLENOID CONTROLS [of fuel system and vibration system control valves].

6. RELAYS and CIRCUIT BREAKERS 7. INSTRUMENT and INDICATOR LIGHTS. 8. CABLES and WIRES.

SWITCHES. a. Ignition Key Switch.

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 BW124D, BW124PD, and BW124PDB Single Drum Rollers.

BATTERY. The battery supplies direct current to crank the engine and operate electrical circuits until the generator is able to supply current. One [1] 12 volt, 580 CCA hour battery, is used in the electrical system for this purpose.

STARTER MOTOR.

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.

7-2

The ignition key switch is the main control switch for ALL electrical 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] hand lever and the transmission system is NOT in “NEUTRAL”. One [1] neutral start switch is used in the engine start circuit. c. Low Engine Oil Pressure Switch.

The oil pressure switch is used to close the electrical circuit between the ignition switch and the oil pressure control light indicator. The switch is normally open when the engine has been started and is "running". If the switch is closed it also activates the warning buzzer failure indicator.

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Section 7 ELECTRICAL d. High Engine Oil Temperature Switch.

The oil temperature switch is used to close the electrical circuit between the ignition switch and the oil temperature control light indicator. The switch is normally open when the engine has been started and is "running". If the switch is closed it also activates the warning buzzer failure indicator. e. Engine Air Cleaner Vacuum Switch.

The engine inlet air restriction indicator switch is used to complete the electrical GROUND circuit if the engine inlet air flow path becomes restricted.

One [1], normally open, vacuum closed, switch is used in the electrical circuit of the engine inlet air system. f. Horn Button Switch.

The horn button switch is used to close the electrical circuit and supply electrical current to the horn. One [1], normally open, dash installed button switch is used in the electrical circuit of the warning horn system. g. Low Fuel Level Switch The fuel level switch is used to complete the circuit and electrically indicate a low fuel level exists within the fuel tank. One [1] low fuel level switch, having a float assembly, mechanically closes the circuit ground to the machine frame. When the circuit ground is closed, the low fuel level indicator light, on the dash, is lighted, indicating a low fuel level exists in the tank.

RELAYS AND CIRCUIT BREAKERS. a. Neutral Start Relay.

The neutral start relay is used to supply electrical current from the neutral start switch to the starter solenoid. When the transmission system is in "NEUTRAL", electrical current is supplied to the relay from the neutral start switch. Current then closes the relay and flows through the relay to the starter solenoid and energizes the solenoid to allow the starter to crank and start the engine. b. Back Up Alarm Relay.

The back up alarm relay is used to supply electrical current to the back up alarm. When the transmission is in "REVERSE", electrical current is supplied to the relay from the back up alarm switch. Current then closes the relay and flows to the back up alarm and sounds the alarm. c. Vibrator System Relay.

The vibrator system relay is used to supply electrical current from the vibrator "On/Off" control switch to the vibrator solenoid. When the vibrator system "On/ Off" switch is in the "ON" position, current flows from the "On/Off" switch to the relay. Current flows through the relay to the vibrator solenoid on the vibrator control valve. The solenoid then moves the flow control spool, in the valve body, and directs high pressure hydraulic oil flow to the vibrator motor.

h. Vibrator System On/Off Switch The vibrator system on/off solenoid is energized when the control lever installed vibrator “on/off” switch is in the “ON” position. The solenoid moves the oil flow control spool, in the vibrator valve body, and permits high pressure oil to flow to the hydraulic vibrator motor.

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7-3

Section 7 ELECTRICAL d. Ten [10] Amp Circuit Breakers.

Ten [10], 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: electrical charging system indicator light, engine hourmeter, and the generator.

The second circuit breaker is used in the circuit which supplies current to the: high engine oil temperature control light, high engine oil temperature switch.

The third circuit breaker is used in the circuit which supplies current to the: relay warning buzzer failure indicator, buzzer.

INSTRUMENTS, AND INDICATOR LIGHTS. 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 ignition key switch is “on” and/or when the engine is “running”.

INDICATOR LIGHTS. a. Engine Inlet Air Restriction Indicator Light.

The forth circuit breaker is used in the circuit which supplies current to the: oil pressure switch - brake, secondary/parking brake system condition 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 “on” and with the engine "running " and the inlet air route restricted.

The fifth circuit breaker is used in the circuit which supplies current to the: low engine oil pressure switch - engine, and the low engine oil pressure light.

b. Secondary/Parking Brake System Condition Indicator Light.

The sixth circuit breaker is used in the circuit which supplies current to the: horn switch, and the horn.

The seventh circuit breaker is used in the circuit which supplies current to the: drum vibrator toggle switch (on/off), and the vibration relay.

The eighth circuit breaker is used in the circuit which supplies current to the: air cleaner vacuum switch and the air cleaner restriction control light.

The ninth circuit breaker is used in the circuit which supplies current to the: low fuel control light, and the low fuel level switch.

The tenth circuit breaker is used in the circuit which supplies current to the: backup alarm proximity switch, backup alarm relay, and the backup alarm buzzer. e. One half [1/2] Amp Circuit Breaker.

One [1], one half [1/2] amp circuit breaker is used in the electrical system. The circuit breaker supplies current to the low fuel level switch and is supplied current from the ninth, ten [10] amp circuit breaker within the same circuit.

7-4

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]. c. High Engine Oil Temperature Light The engine oil temperature light is lighted if the oil temperature exceeds safe conditions. The red lens covered light can also be lighted when the ignition key switch is “on”, and at machine “start up”. d. Low Engine Oil Pressure Light The engine oil pressure light is lighted if the oil pressure is below the minimal limit. The red lens covered light can also be lighted when the ignition key switch is “on”, and at machine “start up”. e. Low Fuel Level Indicator Light The low fuel level indicator light is lighted if the fuel level is low enough to activate the low fuel level switch located at the fuel tank. The red lens covered light can also be lighted when the ignition key switch is “on”, and at machine “start up”.

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Section 7 ELECTRICAL f. Electrical Charging System Indicator Light The electrical charging system indicator light is lighted if the battery is not being charged by the generator system. The red lens covered light can also be lighted when the ignition key switch is “on”, and at machine “start up”.

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 generator to the battery.

WIRES.

A SECONDARY circuit is an electrical circuit dependent upon a PRIMARY circuit for electrical current.

The electrical system consists of the following circuits: 1. START - STOP (PRIMARY CIRCUIT) A. POWER CIRCUIT B. CONTROL CIRCUIT a. OFF [STOP] b. START c. ON - [RUN].

2. SECONDARY CIRCUITS A. CHARGING. B. VIBRATION. C. FUEL SUPPLY. D. WARNING.

START - STOP CIRCUIT [See Figures 7-1, 7-2 and 7-3].

The START - STOP circuit contains two [2] separate circuits within it, the POWER circuit and the CONTROL circuit.

a. Circuit Wires.

A. POWER CIRCUIT 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.

CIRCUITS. The components of the electrical system is a combination of CIRCUITS, each of which is composed of one, or more, of the following: wiring, switches, control relays, fuses, indicator lights, and other electrical components.

The electrical system is comprised of both a PRIMARY circuit and a variety of SECONDARY circuits.

The PRIMARY circuit is an electrical CIRCUIT not dependent upon another circuit for power. A PRIMARY circuit may, or may not, feed current to SECONDARY circuits.

The battery, cables, generator, and engine starter motor make up the POWER circuit.

B. CONTROL CIRCUIT The CONTROL circuit includes the ignition switch, neutral start switch, starter relay, starter motor solenoid, and the wires which carry the electrical current in the circuit.

In the CONTROL CIRCUIT, constant current is supplied to the ignition switch by current running from the positive battery post into the positive battery cable.

The positive [+] battery cable is connected to the battery positive [+] post, and connects to position thirty [30] on the starter motor solenoid. Current then flows from position thirty [30] on the starter motor solenoid to pin position eight [8] on connector block X21.

Current flows from pin position eight [8], on the X21

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7-5

Section 7 ELECTRICAL connector block, to pin position two [2], on the X21 connector block. Current then flows from pin position two [2], on the X21 connector block, to pin position three [3], on the X21 connector block. Current flows from pin position three [3], on the X21 connector block, to position 30, on the ignition switch.

The ignition key switch has three [3] positions: a. “OFF” [STOP]. b. “START”. c. “ON” [RUN].

Each of the three [3] positions will be discussed separately: a. OFF [STOP] POSITION. With the ignition key switch in the OFF position current flow to ALL SECONDARY circuits is terminated. With the ignition key switch in the ON position current flows to ALL SECONDARY circuits requiring power during running and/ or starting conditions from the PRIMARY circuit.

When the ignition switch key is turned to “OFF”, electrical current no longer will flow from the “ignition” terminal of the ignition switch, through pin position one [1], on the X21 connector block.

Current then flows through the wire, which loops to pin position four [4], on the X21 connector block.

Current flows from pin position four [4], on the X21 connector block, into the wire connected to the solenoid of the fuel shut-off valve, found on the engine.

The lack of electrical current permits the fuel shut-off valve spool to “close”, stopping the fuel flow through the engine fuel system.

NOTE: If the directional control lever is not in neutral, current will NOT travel through the neutral start switch and the machine will not start.

Current flows from terminal BLACK [BK] to the X11 connector block. Current flows from the X11 connector block to pin position one [1], on the X20 connector block. Current flows from pin position one [1,] on the X20 connector block, to pin position four [4], on the X20 connector block. Current flows from pin position four [4], on the X20 connector block, to terminal 85, located on the neutral starter relay.

When current is present in terminal 85, of the neutral start relay, the current closes the relay and allows current to flow through the relay from position three [3], on the X21 connector block, to terminal 30 of the starter relay.

Current flows through terminal 87, located on the neutral start relay, into pin position seven [7], on the X20 connector block. Current flows from pin position seven [7], on the X20 connector block, to pin position six [6], on the X20 connector block. Current flows from pin position six [6], on the X20 connector block to terminal 50, on the starter solenoid. Current energizes the starter solenoid and allows the starter to crank and start the engine. c. ON [RUN] POSITION. 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: See each SECONDARY circuit for information about each individual circuit.

b. START POSITION. When the ignition switch key is turned to the “START” position, electrical current flows from position 50, on the ignition switch, to pin position two [2], on the X21 connector block.

2. SECONDARY CIRCUITS [See Figures 7-1, 7-2 and 7-3].

Current then flows from pin position two [2], on the X21 connector block, to pin position three [3,] on the X21 connector block. Current then flows from pin position three [3], on the X21 connector block, to pin position six [6], on the X21 connector block.

Current flows from pin position six [6] to pin position seven [7], on the X21 connector block, to pin position seven [7] on the X21 connector block. Current then continues to flow through the BLACK wire to the X11 connector block. Current flows from the X11 connector block to the BROWN [BR] terminal, on the neutral start switch, found above the displacement control of the transmission pump assembly.

With the transmission in "neutral", current flows through the neutral start switch and into terminal BLACK [BK],

7-6

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Section 7 ELECTRICAL

t u O d l o ! !

F ! ! ! e ! g ! ! a P E R 2 E E H US line y e K

FIGURE 7-1. ELECTRICAL SYSTEM SCHEMATIC.

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7-7

Section 7 ELECTRICAL

t u O d l o ! !

F ! ! ! e ! g ! ! a P E R 2 E E eH S U lin y e K

FIGURE 7-2. ELECTRICAL SYSTEM WIRE IDENTIFICATION GAGE SIZES, COLORS AND LENGTHS.

7-8

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Section 7 ELECTRICAL Most SECONDARY circuits receive current through the fuse block located on the instrument panel assembly. The main power connection for the fuse block is the "B" block (see FIGURE 7-2). You can determine the position by examining the instrument either from the UNDERSIDE, or the TOPSIDE. From the UNDERSIDE of the Instrument panel, with the fuse block located in the upper RIGHT hand corner, position "A" is the top far RIGHT, up to, and including "F", which is the top far LEFT. Position "1" is the bottom far RIGHT, up to, and including "6", which is the bottom far LEFT. From the TOPSIDE of the instrument panel, with the fuse block located in the upper LEFT hand corner, position "A" is the top far LEFT, up to, and including, "F" , which is the top far RIGHT. Position "1" is the bottom far LEFT, up to, and including, "6", which is the bottom far RIGHT. A. CHARGING CIRCUIT [See Figures 7-1, 7-2 and 7-3].

After the engine has started and is “running”, the generator output voltage increases above the battery voltage.

Current to the generator is supplied from terminal position 15/54, on the ignition switch, to pin position one [1], on the X21 connector block.

Current then flows to pin position 4, on the X21 connector block, to the ten [10] amp fuse [F2], in the fuse block, located on the instrument panel assembly.

Current then flows from the ten [10] amp fuse, in the fuse block, into the charge control indicator light.

The charge control indicator light has two [2] wires leading from it.

The first wire supplies current to the hourmeter through the positive terminal.

The second wire supplies current through the diode into pin position eight [8], on the X20 connector block.

The current then flows from pin position eight [8], on the X20 connector block, to pin position five [5].

Current flows from pin position five [5] to pin position

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two [2], on the X30 connector block.

Then the current travels from pin position two [2] on the X30 connector block to the D+ terminal on the generator.

Current then flows from the B [+] terminal, located on the generator, down to terminal 30, on the starter solenoid. From terminal 30, on the starter solenoid, the generator output current flows through the positive [+] battery cable to the positive [+] terminal of the battery.

B. VIBRATION CIRCUIT [See Figures 7-1, 7-2 and 7-3].

The vibration circuit electrically controls the machine vibration system by turning the system on and off.

The vibration system relay has a constant current supplied from the terminal position 15/54, on the ignition switch, to pin position one [1], on the X21 connector block.

Current is then routed to pin position 4 on the X21 connector block to the ten [10] amp fuse [F3] in the fuse block located on the instrument panel assembly.

The current then travels from the ten [10] amp fuse [F3] in the fuse block located on the instrument panel assembly to terminal 30 on the vibration system toggle relay.

Current then flows from terminal 30, on the vibration system toggle relay, to terminal 56, on the vibration system toggle relay.

If the vibration system toggle relay is grounded, current flows through the relay to terminal 56b.

Current flows from terminal 56b to pin position two [2], on the X20 connector block.

Current then flows from pin position two [2,] on the X20 connector block, to pin position three [3], on the X20 connector block.

Current is then routed from pin position three [3], on the X20 connector block, to terminal one [1], on the solenoid of the vibration valve. The solenoid is

7-9

Section 7 ELECTRICAL

FIGURE 7-3. INSTRUMENT AND CONTROL PANEL ELECTRICAL WIRING DIAGRAM.

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7-10

Section 7 ELECTRICAL grounded through terminal two [2], on the vibration valve.

The vibrator "on/off" control switch, found on the travel control lever, completes the ground for the vibration circuit.

When the "on/off" control switch is "off", the ground is not complete. When in the "off" position, the vibration system toggle relay is NOT supplied current.

When the "on/off" control switch is "on", the ground is completed, and closes the toggle relay.

This ground is achieved by having a closed circuit through the "on/off" control switch. The ground connection leads from terminal S, on the vibrator system toggle relay, to pin position three [3], on the X20 connector block.

The solenoid moves the control valve spool to the “open” position and high pressure hydraulic oil flow is sent to the vibrator motor.

C. FUEL SUPPLY CIRCUIT. When the ignition switch key is turned to “ON”, electrical current flows from the “ignition” terminal of the ignition switch. Current flows to pin position one [1], on the X21 connector block, through the wire that loops to pin position four [4], on the X21 connector block. Current flows from pin position four [4], on the X21 connector block, into the wire connected to the solenoid, of the fuel shut-off valve found on the engine.

Electrical current permits the fuel shut-off valve spool to “open”, allowing fuel to flow through the engine fuel system.

D. WARNING CONTROL INDICATOR LIGHT The ground is continued from pin position three [3], CIRCUITS See Figures 7-1, 7-2 and 7-3]. on the X20 connector block, to pin position two [2], on the X20 connector block. A WHITE wire lead runs a. SECONDARY/PARKING BRAKE CIRCUIT from pin position two [2], on the X20 connector block, to the X12 connector block.

The secondary/parking brake electrical circuit is a warning system that indicates activity by a warning The WHITE wire connecting to the X12 connector indicator light mounted upon the instrument panel block is connected to the GREEN wire. assembly The ground continues through the "on/off" control switch into a second GREEN wire and back to second position, on the X12 connector block.

When the ignition switch is “on”, current flows from the 15/54 terminal, on the ignition switch to pin position one [1], on the X21 connector block.

A BROWN wire leads from the X12 connector block connection to the frame of the machine and completes the circuit ground.

Current is then routed to pin position four [4], on the X2 connector block, to the ten [10] amp fuse [F2], in the fuse block, located on the instrument panel assembly.

When the ground is completed, current flows through the vibrator system toggle relay, as discussed earlier.

When the vibrator system relay system is supplied current, is grounded and is closed, current flows into wire BS. Current flows to the vibrator system solenoid, on the vibrator system control valve block.

NOTE: The vibrator system "on/off" switch must be toggled to the "ON" to operate the vibration system.

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The current then flows from the ten [10] amp fuse, in the fuse block, into the secondary/parking brake control indicator light.

The secondary/parking brake control indicator light will illuminate when the ground is complete. The ground is complete when the secondary/parking brake lever is move into the “on” position. When in the “on” position, the lever manually toggles the oil pressure switch-brake. The switch then grounds itself to the machine frame.

7-11

Section 7 ELECTRICAL b. BACKUP ALARM CIRCUIT The backup alarm circuit has a constant current supplied from the terminal position 15/54, on the ignition switch, to pin position one [1], on the X21 connector block.

Current is then routed to pin position four [4], on the X21 connector block, to the ten [10] amp fuse [F5], in the fuse block, located on the instrument panel assembly.

The current then travels from the ten [10] amp fuse [F5], in the fuse block located on the instrument panel assembly. Current flows to terminal 30, on the backup alarm relay, and pin position four [4], on the X22 connector block. Current then flows to pin position one [1], on the X22 connector block and to the BN [brown] terminal, on the backup alarm proximity switch at the same time.

The backup alarm relay is dependent upon the backup alarm proximity switch for actuation. When the backup alarm proximity switch is activated, by placing the directional control switch in the "reverse" position, it allows current to flow from the BL [black] terminal to pin position two [2], on the X22 connector block. Current flows to pin position three [3,] on the X22 connector block, from pin position three [3], on the X22 connector block, to terminal 85, on the backup alarm relay.

When current is supplied through terminal 85, on the backup alarm relay, the circuit is activated through terminal 87A, on the backup alarm relay.

The current then flows from terminal 85 to pin position six [6], on the X22 connector block, to pin position seven [7], on the X22 connector block.

Current flows from pin position seven [7], on the X22 connector block, to the X1 connector and then from the X1 connector to the positive terminal, of the backup alarm buzzer.

The ground circuit is then completed through the negative terminal of the backup alarm buzzer to the X6 connector. Ground continues from the X6 connector to pin position eight [8], on the X22 connector block, to pin position five [5], on the X22 connector block. Ground continues from pin position five [5], on the X22 connector block, to terminal 86, on the backup alarm relay.

7-12

Ground continues from terminal 86 to pin position two [2], on the X22 connector block, to pin position three [3], on the X22 connector block. From pin position three [3] on the X22 connector block, ground continues to both the BL [BLUE] terminal, on the backup alarm proximity switch to the machine frame ground. c. HORN CIRCUIT The horn circuit has a constant current supplied from the terminal position 15/54, on the ignition switch to pin position one [1], on the X21 connector block.

Current is then supplied to pin position four [4], on the X21 connector block, to the ten [10] amp fuse [F4], in the fuse block located on the instrument panel assembly.

The current then travels from the ten [10] amp fuse [F4], in the fuse block located on the instrument panel assembly, to terminal 4, on the push button horn.

When the horn push button is depressed it allows current to flow through terminal 3, on the horn push button, to pin position eight [8], on the X21 connector block to pin position five [5], on the X21 connector block, to the positive [+] terminal, on the horn.

The ground circuit is completed by a frame ground from the negative [-] terminal, located on the horn. d. LOW FUEL WARNING CIRCUIT The low fuel warning circuit has a constant current supplied from the terminal position 15/54, on the ignition switch, to pin position one [1], on the X21 connector block.

Current is then routed to pin position four [4], on the X21 connector block, to the ten [10] amp fuse [F2], in the fuse block located on the instrument panel assembly.

The current then travels from the ten [10] amp fuse [F2], in the fuse block located on the instrument panel assembly, to positive [+] terminal, on the low fuel indicator light. Current flows from the negative [-] terminal to pin position one [1], on the X23 connector block, to pin position four [4], on the X23 connector block, from pin position four [4], on the X23 connector block to the [F10] 1/2 amp in-line fuse.

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Section 7 ELECTRICAL The in-line fuse is used to reduce the current flowing into the low fuel level switch positive [+] terminal.

TROUBLE ANALYSIS INFORMATION AND PROCEDURES.

The low fuel indicator light will illuminate when the ground circuit is completed by the frame ground. The low fuel level switch consists of a float assembly, which mechanically moves.

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.

When a low fuel level status exists in the tank, the float assembly completes the circuit ground.

The circuit ground is completed from the negative terminal of the low fuel level switch, to the X5 connector and from the X5 connector to the machine frame. e. AIR SUPPLY WARNING CIRCUIT Current flows from the ten [10] amp fuse [F2,] in the fuse block located on the instrument panel assembly, to positive [+] terminal, on the air cleaner restriction control light. Current then flows from the negative [-] terminal to pin position one [1], on the X22 connector block, to pin position four [4], on the X22 connector block. From pin position four [4,] on the X22 connector block, current flows to the air cleaner vacuum switch, positive [+] terminal.

The air cleaner restriction control light will illuminate when the ground circuit is completed by a frame ground. The vacuum will occur, at the air cleaner vacuum switch, if the air flow is obstructed. When this occurs the switch is toggled, and closes the circuit ground.

The circuit ground goes from the negative [-] terminal of the air cleaner vacuum switch to the machine frame.

ALWAYS follow the four basic principles of GOOD systematic trouble shooting: 1. KNOW the system; 2. DETERMINE the symptoms; 3. LIST the possible causes; AND 4. 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.

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.

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7-13

Section 7 ELECTRICAL 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.

WARNING: Do NOT use ANY testing instrument BEFORE reading ALL manufactures 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 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.

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.

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.

7-14

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Section 7 ELECTRICAL TROUBLE ANALYSIS FOR THE ELECTRICAL SYSTEM. [See Figures 7-1, 7-2 and 7-3].

PRIMARY CIRCUIT PROBLEM

CAUSE

CORRECTION

ENGINE WILL NOT CRANK

Battery is damaged [dead] - G1

Charge or replace battery.

Initiator [neutral start] switch not in closed position - B10

Adjust, or replace, switch See Section 8]

Damaged ignition switch - SO

Replace ignition switch.

Damaged starter relay - K5

Replace relay.

Damaged starter solenoid - M1

Replace starter solenoid.

Damaged circuit wire -10/11/5/6/7

Repair, or replace, wire.

Damaged battery cables - 5/6/7

Clean, or replace, battery cables.

Damaged starter motor - M1

Repair, or replace, starter motor.

Battery not fully charged - G1

Charge battery.

Low ambient temperatures

Warm area around machine.

Incorrect engine lubrication oil in engine

Remove oil and replace with correct oil.

Fuel shut-off solenoid not energized - on engine assembly

Check current flow. Repair, or replace, fuel shut-off 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.

ENGINE CRANKS SLOWLY

ENGINE CRANKS BUT WILL NOT START

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7-15

Section 7 ELECTRICAL TROUBLE ANALYSIS FOR THE ELECTRICAL SYSTEM. [See Figures 7-1, 7-2 and 7-3].

SECONDARY CIRCUITS PROBLEM

CAUSE

BATTERY IS OVERCHARGED

Voltage regulator in generator damaged - G2

Replace regulator, or generator.

BATTERY IS NOT CHARGED

Voltage regulator in generator damaged - G2

Replace regulator, or generator.

Damaged generator G2

Repair or replace generator.

Damaged wire[s] in circuit - 2/3

Repair, or replace, wires.

Generator not suppling current to the hourmeter - G2

Check for current output. Repair, or replace, generator.

Damaged wire[s] in circuit - 1/2

Check circuit for current flow.

Correct problem as needed.

Damaged hourmeter- PO

Replace hourmeter.

HOURMETER INDICATES ERRATIC HOURS

Meter circuit in hourmeter is "open"- PO

Replace hourmeter.

ENGINE LOW LUBRICATION OIL PRESSURE INDICATOR LIGHT DOES NOT ILLUMINATE

Low oil pressure closing switch damaged - B6

Replace low oil pressure closing switch with new.

Damaged bulb in light - H9

Replace bulb with new.

Damaged circuit fuse - F2

Replace fuse with new.

No current flowing to indicator light in circuit - 18

Check circuit for current flow.

Correct problem as needed.

Damaged wire[s] in circuit - 18

Repair, or replace, wire[s] as needed.

HOURMETER DOES NOT INDICATE HOURS AS ENGINE OPERATES

7-16

CORRECTION

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Section 7 ELECTRICAL TROUBLE ANALYSIS FOR THE ELECTRICAL SYSTEM. [See Figures 7-1, 7-2 and 7-3].

SECONDARY CIRCUITS PROBLEM

CAUSE

CORRECTION

HIGH ENGINE TEMPERATURE INDICATOR LIGHT DOES NOT ILLUMINATE

High temperature closing switch damaged - B30

Replace high temperature closing switch with new.

Damaged circuit fuse - F2

Replace fuse with new.

Damaged bulb in light - H4

Replace bulb with new.

No current flowing in indicator circuit - 12

Check circuit for current flow. light Correct problem as needed.

Damaged wire[s] in circuit - 12

Repair, or replace, wire[s] as needed.

Damaged bulb in light - H8

Replace bulb with new.

Damaged circuit fuse - F2

Replace fuse with new.

Damaged wire[s] in circuit - 1

Repair, or replace, wire[s] as needed.

Generator damaged - G2

Repair, or replace, generator.

Damaged bulb in light - H24

Replace bulb with new.

Damaged circuit fuse[s] - F2/F10

Replace fuse[s] with new.

Damaged fuel sending unit - S53

Replace fuel sending unit.

Damaged wire[s] in circuit - 24

Repair, or replace, wire[s]

Damaged bulb in light - H1

Replace bulb with new..

Brake system oil closed switch damaged - B5

Replace switch with new.

Damaged circuit fuse - F2

Replace fuse with new.

Damaged wire[s] in circuit - 17

Repair, or replace, wire[s]

Damaged wire[s] in circuit - 17

Repair, or replace, wire[s].

Warning system buzzer relay damaged - K33

Replace relay with new.

Buzzer damaged - H10

Replace buzzer with new.

LOW GENERATOR VOLTAGE INDICATOR LIGHT DOES NOT ILLUMINATE

LOW FUEL LEVEL INDICATOR LIGHT DOES NOT ILLUMINATE

SECONDARY/PARKING BRAKE SYSTEM CONDITION INDICATOR LIGHT DOES NOT ILLUMINATE WHEN SYSTEM IS "ON"

SECONDARY/PARKING BRAKE SYSTEM WARNING BUZZER DOES NOT SOUND WHEN SYSTEM IS "ON"- INDICATOR LIGHT ILLUMINATES

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7-17

Section 7 ELECTRICAL TROUBLE ANALYSIS FOR THE ELECTRICAL SYSTEM. [See Figures 7-1, 7-2 and 7-3].

SECONDARY CIRCUITS PROBLEM ENGINE INLET AIR RESTRICTION INDICATOR LIGHT DOES NOT ILLUMINATE

VIBRATION SYSTEM DOES NOT OPERATE WITH "ON/OFF" BUTTON IN "ON" POSITION

BACKUP ALARM DOES NOT SOUND WHEN MACHINE IN REVERSE DIRECTION OF TRAVEL

CAUSE Damaged bulb in light - H15

Replace bulb with new.

Damaged circuit fuse - F2

Replace fuse with new.

Damaged vacuum switch - B3

Replace switch with new.

No current flowing in circuit - 22

Check circuit for current flow.

Correct problem as needed.

Damaged wire[s] in circuit - 22

Repair, or replace, wire[s] as needed.

Damaged circuit fuse - F3

Replace fuse with new.

Damaged wire[s] in circuit - 20/21

Repair, or replace, wire[s] as needed.

Damaged relay - K4

Replace relay with new.

No ground in circuit - 20/21

Check circuit for ground.

Correct problem as needed.

Damaged push button switch S13

Replace switch with new.

Damaged solenoid valve - Y7

Replace solenoid valve with new.

Damaged circuit fuse - F5

Replace fuse with new.

Damaged wire[s] in circuit - 26/27

Repair, or replace, wire[s] as needed.

Replace switch with new.

Damaged proximity switch - B32

7-18

CORRECTION

No ground in circuit - 26/27

Check circuit for ground.

Correct problem as needed.

Damaged relay- K26

Replace relay with new.

Damaged alarm - H14

Replace alarm with new.

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Section 7 ELECTRICAL TROUBLE ANALYSIS FOR THE ELECTRICAL SYSTEM. [See Figures 7-1, 7-2 and 7-3].

SECONDARY CIRCUITS PROBLEM HORN DOES NOT SOUND WHEN BUTTON IS PUSHED

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CAUSE

CORRECTION

Damaged circuit fuse - F4

Replace fuse with new.

Damaged wire[s] in circuit - 13/19 needed.

Repair, or replace, wire[s] as

Damaged horn button switch - S3

Replace switch with new.

No ground in circuit - 13/19

Check circuit for ground. ßCorrect problem as needed.

Damaged horn assembly - B11

Replace horn with new.

7-19

Section 7 ELECTRICAL NOTES

7-20

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Section 8 TRANSMISSION SYSTEM TABLE OF CONTENTS

PAGE GENERAL INFORMATION ...................................................................................................................... 8-3 EXCHANGING THE TRAVEL PUMP ASSEMBLY .................................................................................. 8-3 EXCHANGING THE TRAVEL PUMP COUPLING ................................................................................... 8-6 SEPARATING THE TRAVEL PUMPS ...................................................................................................... 8-7 TRAVEL PUMPS ...................................................................................................................................... 8-8 GENERAL NOTES FOR REPAIRS ...................................................................................................... 8-8 SEALING THE TRAVEL PUMP DRIVE SHAFT .................................................................................. 8-9 SEALING THE MOUNTING FLANGE AND PIVOT FOR 1ST TRAVEL PUMP ................................. 8-10 SEALING THE MOUNTING FLANGE AND PIVOT FOR 2ND TRAVEL PUMP ................................ 8-11 SEALING THE TRAVEL PUMP VALVES .......................................................................................... 8-12 REMOVING AND INSTALLING THE DRIVE ...................................................................................... 8-13 REMOVING THE DRIVE ................................................................................................................ 8-13 INSTALLING THE DRIVE .............................................................................................................. 8-16 EXCHANGING THE DRUM MOTOR ...................................................................................................... 8-16 EXCHANGING THE TIRE DRIVE TRAVEL MOTORS ........................................................................... 8-17 REPAIRING THE TRAVEL MOTOR - WITH AND WITHOUT BRAKE .................................................. 8-18 TRAVEL MOTOR WITH BRAKE - DISMANTLING THE BRAKE ...................................................... 8-18 DISMANTLING THE TRAVEL MOTOR - WITH/WITHOUT BRAKE .................................................. 8-22

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8-1

Section 8 TRANSMISSION SYSTEM PAGE

FILLING THE HYDRAULIC SYSTEM .................................................................................................... 8-30 FLUSHING OF THE DRUM DRIVE TRAVEL CIRCUIT - GENERAL INFORMATION .......................... 8-32 FLUSHING OF THE DRUM DRIVE TRAVEL CIRCUIT ...................................................................... 8-34 INSTALLING THE FLUSHING SYSTEM ............................................................................................. 8-34 BLEEDING ........................................................................................................................................... 8-35 FLUSHING THE LINES FOR THE FRONT DRUM MOTOR ............................................................... 8-36 FLUSHING THE DRUM MOTOR ......................................................................................................... 8-36 FLUSHING THE WHEEL DRIVE TRAVEL CIRCUIT ............................................................................. 8-37 GENERAL INFORMATION .................................................................................................................. 8-37 FLUSHING OF THE WHEEL DRIVE TRAVEL CIRCUIT .................................................................... 8-39 INSTALLING THE FLUSHING SYSTEM ............................................................................................. 8-39 BLEEDING ........................................................................................................................................... 8-40 FLUSHING THE LINES FOR THE REAR TRAVEL MOTORS ........................................................... 8-41 FLUSHING THE LEFT-HAND AND RIGHT-HAND TRAVEL MOTORS ............................................. 8-41 FUNCTIONAL CHECK ............................................................................................................................ 8-42 MAINTENANCE OF THE FLUSHING FILTER UNIT .............................................................................. 8-42 PRESSURES IN THE WHEEL AND DRUM DRIVE TRAVEL CIRCUITS .............................................. 8-42 CHECKING THE PRESSURES IN THE WHEEL DRIVE CIRCUIT ..................................................... 8-42 CHECKING THE PRESSURES IN THE DRUM DRIVE CIRCUIT ....................................................... 8-43 HIGH PRESSURE TEST OF TRAVEL PUMPS .................................................................................. 8-44 TRAVEL PUMP, WHEEL DRIVE ..................................................................................................... 8-44 TRAVEL PUMP, DRUM DRIVE ....................................................................................................... 8-44 TROUBLE ANALYSIS FOR THE TRANSMISSION SYSTEM .............................................................. 8-45

8-2

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Section 8 TRANSMISSION SYSTEM GENERAL INFORMATION. This section gives information about the TRANSMISSION system (Fig. A) used on the machine.

1. Detach the lever for the parking brake (Fig. 1/1 ). Unscrew the bolts (Fig. 1/2) for the brake actuation valve. Unscrew the bolts and nuts for the console (Fig. 1/3), and pull the console to the front.

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 drum drive motor.

“Trouble Analysis” for the TRANSMISSION system is found at the rear of this section.

EXCHANGING THE TRAVEL PUMP ASSEMBLY. CAUTION: Remove the complete pump assembly from the machine, only after correctly and fully checking the pumps. Use pressure check and flow rate test procedures that will indicate internal component damage which require the pumps be removed for repair, or replacement.

Major transmission repairs will effect warranty. See your nearest Distributor and refer to the "Policies and Procedures" before removing the transmission pumps, or doing major repair procedures to the pumps.

NOTE: The transmission pump is an assembly with the vibration and steering/ charge pump. After pump installation, and BEFORE starting the engine, do the following: Flush and bleed the transmission circuit completely.

Flush and bleed the vibration circuit completely.

Perform ALL pre-charge procedures.

After start up, perform ALL high pressure checks [refer to respective sections for procedures].

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FIGURE 1.

FIGURE 2.

2. Detach the travel actuation cable (Fig. 2/1 ) from the travel lever.

NOTE: For Installation check and set the travel actuation cable, see troubleshooting chart.

3. Unscrew all mounting screws (Fig. 3/2) from the backstop (Fig. 3/1), remove the backstop with attached travel actuation cable and place it to one side.

8-3

Section 8 TRANSMISSION SYSTEM

FIGURE A. HYDRAULIC SYSTEM SCHEMATIC.

8-4

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Section 8 TRANSMISSION SYSTEM

FIGURE 3.

4. Unscrew the cap nuts (Fig. 4) of the hydraulic oil hoses from the connections, and immediately plug the connections and hydraulic oil hoses.

FIGURE 5.

6. Unscrew all bolts (Fig. 5/1 ) from the bell housing (Fig. 5/2).

7. Carefully pull the travel pump to the front.

CAUTION: Collect the hydraulic oil and dispose of it so as to prevent pollution.

WARNING: Risk of inquiry.

NOTE: For Installation, fit the coupling hub (Fig. 6/1 ) of the travel pump into the coupling flange (Fig. 6/2).

FIGURE 4.

5. Attach lifting tackle to the pump.

CAUTION: Weight is approximately 50 kg.

FIGURE 6.

8. Place wooden beams under the travel pump so as to prevent accidents and then lower the travel pump.

9. Remove the lifting tackle, move it to the front of the crosspiece and place it around the pump again.

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8-5

Section 8 TRANSMISSION SYSTEM 10. Lift out the travel pump assembly.

11. To exchange the pump, detach both travel levers (Fig. 7/1 and 2) with rod (Fig. 7/3).

EXCHANGING THE TRAVEL PUMP COUPLING. 1. Remove the travel pump assembly, [see THIS section].

2. Pull off the coupling element (Fig. 1/1 ).

FIGURE 7.

FIGURE 1.

12. Detach the coupling hub (Fig. 8/1 ).

3. Remove the coupling bolts (Fig. 1/2) by unscrewing them.

NOTE: For Installation, Torque 50 Nm.

4. Loosen the clamping screws (Fig. 2/1) of the coupling hub (Fig. 2/2) and pull the coupling hub from the pump shaft.

5. Fit the coupling flange and coupling hub, install the travel pump and perform a trial run.

FIGURE 8.

13. Unscrew the bolts (Fig. 8/2) and remove the bell housing (Fig. 8/3).

14. Unscrew all the double-end unions.

FIGURE 2.

8-6

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Section 8 TRANSMISSION SYSTEM SEPARATING THE TRAVEL PUMPS.

5. Unscrew the bolts (Fig. 3/1) on both sides and separate the travel pumps.

1. Remove the travel pumps [see THIS section].

2. Detach the coupling from the travel pump [see THIS section].

3. Detach the bell housing. To do so, unscrew the bolts (Fig. 1/1 ) and lift off the bell housing.

FIGURE 1.

NOTE: For Installation, fit a new O-ring (Fig. 4/1) into the groove and apply a thin coat of grease. Grease the pivot (Fig. 4/2) and insert it.

FIGURE 3.

4. Detach both travel levers (Fig. 2/1 and 2) with rod (Fig. 2/3).

FIGURE 4.

FIGURE 2.

6. To detach the intermediate flange, unscrew the Allen screws and remove the flange (Fig. 5/1 ).

NOTE: For Installation, use a new O-ring (Fig. 6/1 ). Fit the dowel pins (Fig. 6/2) into the bores in the cover (Fig. 6/3).

Ensure that the coupling element (Fig. 6/4) is fitted correctly.

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8-7

Section 8 TRANSMISSION SYSTEM GENERAL NOTES FOR REPAIRS. CAUTION: To help insure cleanliness and obtain acceptable service life after repair, ALWAYS observe the following notes when repairing hydraulic components.

1. Close ALL ports on hydraulic components [see figure 1].

FIGURE 5.

FIGURE 1.

2. Remove and discard ALL seals and gaskets.

Replace with NEW during assembly [see figure 2 ].

FIGURE 6.

TRAVEL PUMPS. The travel pump assembly contains the following items, which can be resealed, or removed and replaced, as a "minor repair": 1. Drive shaft seal.

2. Mounting flange and pivot [both pumps].

3. Travel pump valves [both pumps].

CAUTION: Opening the travel pumps for "major repairs" causes loss of warranty and/or policy adjustment claims.

NOTE: The following repair procedures follow economical and technical guidelines.

Repairs, other than those given, are NOT recommended.

8-8

FIGURE 2.

3. Examine ALL sealing and sliding surfaces for wear or damage [see figure 3].

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Section 8 TRANSMISSION SYSTEM SEALING THE TRAVEL PUMP DRIVE SHAFT. 1. Remove the circlip (Fig. 1/1) and press off the locking ring (Fig. 1/2).

NOTE: For Installation, check that the circlip is fitted correctly.

FIGURE 3.

2. Remove the radial seal (Fig. 1/4).

4. Fill the hydraulic components with NEW, filtered hydraulic oil before system start up [see figure 4].

3. Check the groove and O-ring (Fig. 1/3) of the cover; check the condition of the drive shaft (Fig. 1/5) and the housing bore.

4. Press the new radial seal with suitable sleeve into the cover so it is positioned correctly.

NOTE: For Installation, before assembling the cover, grease the dust and sealing lips.

FIGURE 4.

1 CIRCLIP 2 LOCKING RING 3 O-RING 4 RADIAL SEAL 5 DRIVE SHAFT

5 4 3 2 1

FIGURE 1.

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8-9

Section 8 TRANSMISSION SYSTEM SEALING THE MOUNTING FLANGE AND PIVOT FOR 1ST TRAVEL PUMP.

6. To remove the pivot (Fig. 1/12), remove the circlip (Fig. 1/8).

1. Mark the mounting flange (Fig. 1/1 ) and detach it.

NOTE: For installation, check that the circlip is fitted correctly.

2. Check the condition of the groove and the contact face of the connecting plate (Fig. 1/7) or mounting flange (Fig. 1/1 ).

7. Press off the locking ring (Fig. 1/10)

3. Remove the sealing washer (Fig. 1/5).

8. Remove the O-rings (Fig. 1/9 and 1/11 ).

4. Check the condition of the bushing (Fig. 1/3), the running face of the coupling element (Fig. 1/4) and both sides of the sealing washer.

9. Check the condition of the running face of the pivot, the sealing face of the housing (Fig. 1/13) and the grooves of the locking ring.

5. Exchange defective parts; use new O-rings.

NOTE: For installation, grease the O-rings before installation.

NOTE: For installation, grease the O-ring before installation.

1

2

8

6

5

4

2

3

7

9 10 12 11 13 1 MOUNTING FLANGE 2 O-RING 3 BUSHING 4 COUPLING ELEMENT 5 SEALING WASHER 6 PIN 7 CONNECTING PLATE

8 CIRCLIP 9 O-RING 10 LOCKING RING 11 O-RING 12 PIVOT 13 HOUSING

FIGURE 1.

8-10

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Section 8 TRANSMISSION SYSTEM SEALING THE MOUNTING FLANGE AND PIVOT FOR 2ND TRAVEL PUMP.

NOTE: For installation, check that the circlip is fitted correctly.

1. Mark the cover (Fig. 1/1 ) and detach it.

6. Press off the locking ring (Fig. 1/10).

2. Check the condition of the groove and the contact face of the connecting plate (Fig. 1/7) and cover (Fig. 1/1 ).

7. Remove the O-rings (Fig. 1/2 and 1/9).

8. Check the running face of the pivot, the sealing face of the housing (Fig. 1/13) and the O-rings and grooves of the locking ring.

3. Check the condition of the bushing (Fig. 1/3).

4. Exchange defective parts, use new O-rings.

NOTE: For installation, grease the O-rings before installation.

NOTE: For installation, grease the O-rings before installation.

5. To remove the pivot (Fig. 1/12), remove the circlip (Fig. 1/8).

1 7

8

2

3

2

9 10 12 11 1 COVER 2 O-RING 3 BUSHING 7 CONNECTING PLATE 8 CIRCLIP

9 0-RING 10 LOCKING RING 11 O-RING 12 PIVOT 13 HOUSING

FIGURE 1.

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8-11

Section 8 TRANSMISSION SYSTEM SEALING THE TRAVEL PUMP VALVES.

NOTE: For installation, stick the valve cone and spring together with grease before assembly.

1. Unscrew the screw plug (Fig. 1/4) of the charge pressure relief valve with spring (Fig. 1/6) and unscrew the O-ring (Fig. 1/5).

3. Remove the two charge valves (Fig. 1/1 ).

NOTE: For installation, wind adhesive tape around the thread of the screw plug before fitting the new O-ring in order to prevent damage to the seal ring.

4. Use new O-rings (Fig. 1/2 and 1/3).

NOTE: For installation, wind adhesive tape around the thread of the charge valves before fitting the new O-rings in order to prevent damage to the seal rings.

2. Remove the valve cone (Fig. 1/7).

1 2

4 5

3

6 7

1 CHARGE VALVE 2 O-RING 3 O-RING 4 SCREW PLUG

5 O-RING 6 SPRING 7 VALVE CONE

FIGURE 1.

8-12

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Section 8 TRANSMISSION SYSTEM 6. Check the condition of the locating pin, bore and contact face of the valve plate, as well as the Oring (Fig. 1/5), seal ring (Fig. 1/6) and grooves in the housing.

REMOVING AND INSTALLING THE DRIVE. REMOVING THE DRIVE. 1. Mark the position of the cover (Fig. 1/1), mounting flange (Fig. 1/13) and valve plate (Fig. 1/3) relative to the housing (Fig. 1/11). Disassemble the parts, see appropriate section.

7. Detach the locking ring (Fig. 1/10), see appropriate section.

8. Swivel the pump housing until the cylinder (Fig. 1/8) with the piston and pullback device (Fig. 3/6) slip out.

2. Remove the coupling element (Fig. 1/2).

3. Detach the valve plate (Fig. 1/3).

9. Place the parts on a soft, clean base.

4. Lift off the valve plate.

5. Lift off the control plate (Fig. 1/7), paying attention to the locating pin (Fig. 1/4) and bore in the timing disc.

10. Remove the locking ring (Fig. 2/1) from the drive shaft (Fig. 2/2).

11. Drive out the drive shaft.

b 1 3

12

5 4 7 10

8 a 6

13 2

9 11 1 COVER 2 COUPLING ELEMENT 3 VALVE PLATE 4 LOCATING PIN 5 O-RING 6 SEAL RING 7 CONTROL PLATE 8 CYLINDER

9 PISTON 10 LOCKING RING 11 HOUSING 12 O-RING 13 MOUNTING FLANGE a 1ST TRAVEL PUMP b 2ND TRAVEL PUMP

FIGURE 1.

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8-13

Section 8 TRANSMISSION SYSTEM 12. Remove the drive shaft with cylinder roller bearing (Fig. 2/4).

17. Check the condition of the toothing and running faces of the drive shaft and exchange the drive shaft if necessary.

13. Remove the pivot (Fig. 2/8).

14. Press off the upper bearing (Fig. 2/6) with the bearing cup (Fig. 2/5).

15. Remove the screw plug (Fig. 2/3) and press off the lower bearing (Fig. 2/6) with bearing cup (Fig. 2/7).

CAUTION: Thoroughly clean all parts and put them down, so that they cannot be damaged.

NOTE: Fits must have no rust. The drive shaft must not show any run-in marks from the radial seal.

18. Check the condition of the bushing (see THIS section), exchange if necessary and fit new O-rings.

19. Check the condition of the sliding races, running faces and sliding face of the pivots (Fig. 2/ 8). They must not show any signs of scoring; if necessary exchange the pivots.

16. Exchange all bearings/bearing cups.

8 5

6

9 4 6 7

2 3 1

1 LOCKING RING 2 DRIVE SHAFT 3 SCREW PLUG 4 CYLINDER ROLLER BEARING 5 UPPER BEARING CUP

6 BEARING 7 LOWER BEARING CUP 8 PIVOT 9 CIRCLIP

FIGURE 2.

8-14

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Section 8 TRANSMISSION SYSTEM 20. Check the condition of the pullback device (Fig. 3/6) with ball (Fig. 3/5). If one of these parts is worn, both parts must be exchanged together.

21. Check the condition of the piston (Fig. 3/7), cylinder (Fig. 3/2) and control plate (Fig. 3/1 ).

NOTE: The pullback device and ball must not show any signs of scoring or run-in marks.

NOTE: The piston running faces must not show any signs of scratches or metal inclusions. The cylinder toothing must not be damaged. Cylinder bores and cylinder slide faces must not show any signs of scoring or inclusions. If there are signs of wear always exchange piston and control plate.

1 2 3 4 5 6 8

7

1 CONTROL PLATE 2 CYLINDER 3 SHIM 4 BELLEVILLE SPRING 5 BALL 6 PULL-BACK DEVICE 7 PISTON 8 SLIPPER PAD

FIGURE 3.

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8-15

Section 8 TRANSMISSION SYSTEM INSTALLING THE DRIVE.

EXCHANGING THE DRUM MOTOR.

1. Heat the cylinder roller bearing (Fig. 2/4) to 80˚ C, slide it on and secure with a circlip (Fig 2/9).

Installation Weight: Drum motor approx. 80 kg 1. Remove the drum, see corresponding section.

NOTE: Check that the circlip is fitted correctly.

2. Detach the console (Fig. 1/7) from the drum motor (Fig. 1/9).

2. Fit the bearings (Fig. 2/6) and bearing cups (Fig. 2/5 and 2/7).

3. Fit the pivot (Fig. 2/8) and press in the drive shaft (Fig. 2/2).

4. Fit the locking ring (Fig. 2/1) with new radial seal and new O-ring, (see THIS section).

5. Preassemble the cylinder assembly (Fig. 3/2,3, 4, 5, 6 and 7), ensuring that the Belleville springs (Fig. 3/4) and shim (Fig. 3/3) are fitted correctly.

3. Attach the drum motor to the lifting tackle.

Weight approx. 80 kg.

4. Unscrew the nuts (Fig. 1/8) from the rubber buffers.

5. Pull the drum motor with attached drive disc (Fig. 1/3) from the rubber buffers.

NOTE: Check the condition of all rubber buffers and exchange if necessary.

6. Oil the slipper pad (Fig. 3/8).

7. Insert the cylinder assembly into the housing, and engage the toothing by turning the drive shaft slightly.

8. Grease the new O-rings (Fig. 1/5 and 1/12) and insert into the grooves.

9. Stick the control plate (Fig. 3/1 ) onto the valve plate (Fig. 1/3) using grease.

6. To exchange the drum motor, unscrew the bolts (Fig. 1/5) and remove the drive disc from the drum motor.

NOTE: For installation, before connecting the hydraulic oil hoses into the opening of the double-end union (Fig. 2) for the leakage hose, pour in oil until the level no longer drops and remains at the upper edge.

NOTE: Ensure that the control plate and locating pin are fitted correctly.

10. Oil the cylinder slide face (Fig. 3/2), and fit the valve plate (Fig. 1/3) in accordance with the marking.

CAUTION: Fill the hydraulic system and flush, otherwise the new units may be destroyed (see THIS section).

11. Fit the coupling element (Fig. 1/2).

12. Fit the cover/mounting flange with new O-rings.

13. Fit the pivot locking ring.

8-16

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Section 8 TRANSMISSION SYSTEM

4

7

2

1 WASHER 2 WASHER 3 DRIVE DISC 4 ALLEN SCREW 5 ALLEN SCREW 6 HEXAGON NUT 7 CONSOLE 8 HEXAGON NUT 9 DRUM MOTOR

3 6

1 5

9 8 2

FIGURE 1.

EXCHANGING THE TIRE DRIVE TRAVEL MOTORS. Installation Weight: Approx. 50 kg Tools: Jack, wooden block 1. Loosen the wheel bolts, on the side in of the machine having the motor removed.

2. Jack up the rear of the machine until the wheel is free.

FIGURE 2.

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DANGER: Support the machine, so as to prevent accidents (Fig. 1).

8-17

Section 8 TRANSMISSION SYSTEM 5. Attach lifting tackle to the travel motor. Weight approx. 50 kg.

6. Unscrew the mounting screws (Fig. 2/2) and pullout the travel motor.

REPAIRING THE TRAVEL MOTOR - WITH AND WITHOUT BRAKE. 1. Remove the travel motor (see THIS section).

FIGURE 1.

3. Unscrew the wheel bolts and remove the wheel.

4. Mark the hydraulic oil lines (Fig. 2/1 ). Unscrew the cap nuts from the connections, and plug the connections and hydraulic oil lines.

2. Remove the plugs from the connection bores of the hydraulic hoses and drain the oil.

NOTE: For installation, pour in oil via the filler bore (Fig. 1/1 ) until at the lower edge and fit plugs (Fig. 1/arrow).

CAUTION: Collect the draining hydraulic oil so as to prevent pollution.

NOTE: For Installation, pour oil into the connection socket for the leakage hose until the level no longer drops but remains at the upper edge.

CAUTION: Fill the hydraulic system and flush it, otherwise the new units may be destroyed (see THIS section).

FIGURE 1.

TRAVEL MOTOR WITH BRAKE - DISMANTLING THE BRAKE. 1. Remove the circlip (Fig. 2/65) and washer (Fig. 2/52).

2. Remove the cylinder head screws (Fig. 3/62) from the stop ring and remove the parts.

FIGURE 2.

8-18

NOTE: For Installation, tighten the bolts crosswise. Align the openings (Fig. 3/arrows) to each other.

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Section 8 TRANSMISSION SYSTEM 4. Use a brass mandrel to loosen the brake piston (Fig. 5/51) from its seat and remove the piston from the stop ring (Fig. 5/47).

FIGURE 2.

FIGURE 5.

NOTE: For installation, use new O-rings (Fig. 6/59 and 6/57).

FIGURE 3.

3. Drive the drive (Fig. 4/48) out of the stop ring (Fig. 4/67).

FIGURE 6.

5. Remove the Belleville spring (Fig. 7/64), O-ring (Fig. 7/56) and washer (Fig. 7/50) from the drive (Fig. 7/48).

NOTE: For installation, fit a new O-ring (Fig. 7/56) into the inner groove (Fig. 7/arrow).

FIGURE 4.

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8-19

Section 8 TRANSMISSION SYSTEM

FIGURE 7.

6. Remove the spacer (Fig. 8/55), shaft (Fig. 8/49), plates (outer) (Fig. 8/53) and plates (inner) (Fig. 8/54).

FIGURE 9.

8. Remove the disc (Fig. 10/34).

NOTE: For installation, 14 plates (outer), 13 plates (inner). Fit parts, beginning with plate (outer). Measure spacer, see Figs.

11 and 12.

FIGURE 10.

FIGURE 8.

7. Unscrew the cylinder head screws (Fig. 9/62) and remove the base plate (Fig. 9/45).

8-20

NOTE: For installation, the disc must fit flush.

Measure the spacers; to do this, place the drive (Fig. 11/48) on the plate assembly (14 outer plates, 13 inner plates) (Fig. 11/53 and 11/54) and disc (Fig. 11/34). Measure height.

Dimension “a” Nominal value 49.3 mm - Dimension “a” 48.0 mm = remainder 1.3 mm Measure the spacers (Fig. 12/55) and fit 1.3 mm thick spacers when installing the plates (Fig. 10).

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Section 8 TRANSMISSION SYSTEM

FIGURE 11.

FIGURE 13.

DISMANTLING THE TRAVEL MOTOR - WITHOUT BRAKE. 1. Unscrew the Allen screws (Fig. 14/36) and remove the cover plate (Fig. 14/35).

NOTE: For installation, Use a new O-ring (Fig. 14/31).

FIGURE 12.

9. Remove the radial seal (Fig. 13/61) from the groove.

NOTE: For installation, use a new o-ring.

FIGURE 14.

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8-21

Section 8 TRANSMISSION SYSTEM DISMANTLING THE TRAVEL MOTOR - WITH/ WITHOUT BRAKE.

2. Use an M5x20 bolt (Fig. 17/a) to pull the stop pin (Fig. 17/23) out of its seat.

NOTE: After detaching the brake, or cover plate, further assembly operations are the same.

NOTE: For installation, use a new O-ring (Fig. 17/29).

1. Unscrew the socket-head cap screws (Fig.15/33) and completely remove the rear housing (Fig. 15/21).

FIGURE 17.

FIGURE 15.

3, Use a brass mandrel of dia. 8 mm to press the distributor ring (Fig. 18) out of the rear housing (Fig. 18/21).

NOTE: For Installation, fit the connections (Fig. 16/a) of the housing so that they point to the type plate and type number (Fig. 16/b). Use a new O-ring (Fig. 16/33).

FIGURE 18.

FIGURE 16.

8-22

4. Fit the distributor ring (Fig. 19/22) with the narrower groove (Fig. 19/a) pointing to the bore for the stop pin (Fig. 19/23).

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Section 8 TRANSMISSION SYSTEM

FIGURE 19.

FIGURE 21.

5. Remove the springs (Fig. 20/24) from the bores of the distributor ring (Fig. 20/22).

FIGURE 22.

FIGURE 20.

6. Exchange the seals (Fig. 21/26, 27 and 28).

7. Completely remove the cylinder block (Fig.22/15) from the front housing (Fig. 22/2).

8. Completely remove the rollers (Fig. 23/16) and piston (Fig. 23/17) from the cylinder block (Fig. 22/15).

NOTE: For installation, check the parts (Fig. 23/16 and 17) and use new parts if necessary. a = bearing cup b = piston c = piston ring 6/96

FIGURE 23.

8-23

Section 8 TRANSMISSION SYSTEM 9. Remove the cam housing (Fig. 24/19).

NOTE: For installation, use a new O-ring (Fig. 24/32). Fit the cam housing so that the type plate (Fig. 24/a) is aligned with the stamped-in numbers (Fig. 24/b).

NOTE: For installation, measure the bearing pretension. Fit the disc (Fig. 26/9) and circlip (Fig. 26/10).

Use a feeler gauge to measure dimension “a”.

Determine the thickness of the spacers, dimension “a” + 0.1 mm pretension = thickness of spacers.

Measure the spacers and fit them during installation.

FIGURE 24.

10. Remove the circlip (Fig. 25/10) and remove the disc (Fig. 25/3) and spacer (Fig. 25/9).

FIGURE 26.

11. Press the shaft (Fig. 27/1 ) out of the bearings.

FIGURE 25.

FIGURE 27.

NOTE: For installation, fit the preassembled shaft (Fig. 28/1 ) into the preassembled front housing (Fig. 28/2), then fit the shaft bearing (Fig. 28/7).

8-24

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Section 8 TRANSMISSION SYSTEM

FIGURE 28.

FIGURE 30.

12. Drive out the bearing cups (Fig. 29/7 and 6) and radial seal (Fig. 29/12).

FIGURE 31.

FIGURE 29.

14. Check all parts for wear, replace damaged parts and all seal rings.

13. Pull the shaft bearing (Fig. 30/6) and sealing flange (Fig. 30/11 ) from the shaft.

NOTE: For installation, first fit the sealing flange (Fig. 31/11), then the shaft bearing (Fig. 31/6).

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8-25

Section 8 TRANSMISSION SYSTEM 19

2 11 1

16 17

15

10 3 9

a 6

12 e 7

b 21

c

i 32

33 f

55 j

69

47

39 24 54

60

53

50

34

52

22

h

65 70 56 61

49 57

48

26

51 23 27

29

45 62

28

59 64

63

k l

FIGURE A.

8-26

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Section 8 TRANSMISSION SYSTEM

LEGEND a) Grease labyrinth region b) Grease bearing c) Fill gap between lips with grease Note: Use lithium-based grease (e.g. BP Energrease L.2) suitable for vehicles e) Use appropriate distance ring so that the bearing has a pretension of 0...0.1. f) Torque 117...122 Nm h) Make sure that disc SK 1960 is fitted in order to limit piston movement (from the chamber to the drive). i) Use appropriate spacer to obtain the necessary assembly height. j) Assembly height k) Torque 47...51Nm l) Torque 23...27 Nm Front housing subassembly, consisting of parts 1... 12.

1 Shaft 2 Front housing 3 Washer 6 Front bearing 7 Rear bearing 9 Spacer 0.1 10 Circlip 11 Gasket,flat 12 Radial seal Rotating subassembly,consisting of parts 15...17 15 Cylinder block 16 Roller 17 Piston subassembly. consisting of Piston Support Piston ring 19 Cam Rear housing subassembly, consisting of parts 21...29

21 Rear housing 22 Distributor ring 23 Stop pin 24 Spring 26 Seal 27 Seal 28 Seal 29 O-ring 32 O-ring 33 Socket-head cap screw 34 Washer 39 Transport plug 45 Base plate 47 Stop ring 48 Drive 49 Shaft 50 Washer 51 Brake piston 52 Washer 53 Plate, outer 54 Plate, inner 55 Spacer 56 O-ring 57 O-ring 59 O-ring 60 Seal 61 Radial seal 62 Cylinder head screw 63 Cylinder head screw 64 Belleville spring 65 Circlip 69 Transport plug 70 Transport plug

LEGEND TO FIGURE A. 6/96

8-27

Section 8 TRANSMISSION SYSTEM 2

19

11 1

16 15

17

10 3 g

a 6

12

b

c 21

e

7

32

33

39 24 35 34 22

31 26

36 23 27

29

g

28

FIGURE B.

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Section 8 TRANSMISSION SYSTEM

LEGEND a) Grease labyrinth region b) Grease bearing c) Fill gap between lips with grease Note: Use lithium-based grease (e.g.BP Energrease L.2) suitable for vehicles e) Use appropriate distance ring so that the bearing has a pretension of 0...0.1. g) Torque 40....45Nm Front housing subassembly, consisting of parts 1...12.

1 Shaft 2 Front housing 3 Washer 6 Front bearing 7 Rear bearing 9 Spacer 0.1 10 Circlip 11 Gasket,flat 12 Radial seal Rotating subassembly,consisting of parts 15...17 15 Cylinder block 16 Roller 17 Piston subassembly, consisting of Piston Support Piston ring 19 Cam Rear housing subassembly, consisting of parts 21...29 21 Rear housing 22 Distributor ring 23 Stop pin 24 Spring 26 Seal 27 Seal 28 Seal 29 O-ring 31 O-ring 32 O-ring 33 Socket-head cap screw (torque 117...122 Nm) 34 Washer 35 Cover plate 36 Allen screw 39 Transport plug

LEGEND TO FIGURE B. 6/96

8-29

Section 8 TRANSMISSION SYSTEM FILLING THE HYDRAULIC SYSTEM.

NOTE: Using the filling and flushing unit to fill the hydraulic system ensures that all hydraulic components are filled and bled with clean hydraulic oil.

1. The travel motors and drum motor must be filled with hydraulic oil.

2. Detach the pressure hose (Fig. 1/1) from the vibration valve and connect to the pressure hose of the filling and flushing unit.

3. Plug the vibration valve connection.

FIGURE 2.

4. Hold the other hose of the filling and flushing unit in the bag filled with clean hydraulic oil or in a filled oil container.

FIGURE 3.

FIGURE 1.

8. Jack up the vehicle at the front and rear, so that the drums can rotate freely.

5. Loosen the cap nuts (Fig. 2) and (Fig. 3) of the high-pressure hoses on the drum motor and travel motors.

DANGER: Do NOT stand under loads which are being lifted. Risk of injury.

6. Switch on the filling and flushing unit and ensure that the pressure has been set to at least 25 bar (read off from the built-in pressure gauge).

9. Connect a pressure gauge to the chargepressure test connection on the travel pump (Fig. 4).

7. Do not tighten the cap nuts (Fig. 2) and (Fig. 3) until oil emerges at the appropriate point.

Proceed in the same way with the remaining cap nuts.

CAUTION: Collect the hydraulic oil and dispose of it so as to prevent pollution.

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6/96

Section 8 TRANSMISSION SYSTEM

FIGURE 4.

FIGURE 6.

10. Move the travel lever to neutral and the throttle lever to the stop position. Actuate the ignition switch, taking care that the engine does not start.

Actuate the starting switch for 10 seconds, at intervals of 10 seconds. Repeat this process until the charge pressure shown on the pressure gauge is reached (Fig. 4).

13. Start the engine and let it idle until hydraulic oil flows out of both Minimess hoses without bubbles (Fig. 6).

11. Detach the pressure gauge.

12. Connect a Minimess hose to each of the M inimess connections MB and MA (Fig. 5) and run the other ends into the hydraulic oil container (Fig. 6).

CAUTION: Collect the hydraulic oil and dispose of it so as to prevent pollution.

14. Carefully move the travel lever in both directions until no more air emerges from the two Minimess hoses.

15. Lower the machine onto the drums.

16. Move the travel lever to neutral and turn the steering several times from one final stop to the other with the engine idling.

17. Check the hydraulic oil level during and after filling. Unscrew the cover with dipstick (Fig. 7) from the hydraulic oil tank, wipe it with a clean, lint-free cloth and insert it again until it bottoms. The oil level must lie between the two marks “”MIN”’ and “”MAX”.

If the oil level is lower than these marks, top up with oil.

FIGURE 5.

FIGURE 7.

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8-31

Section 8 TRANSMISSION SYSTEM FLUSHING OF THE DRUM DRIVE TRAVEL CIRCUIT - GENERAL INFORMATION (FIG. 1).

CAUTION: Always flush the closed circuit after changing a unit. Otherwise, any particles remaining in the circuit may quickly lead to further unit failure.

With strong oil contamination (scurf).

NOTE: The flushing filter must be fitted in the pump return line on the low-pressure side. This results in the travel pump moving forwards.

Flushing the hoses.

1. Remove the travel motor from the circuit; connect the high pressure lines for this purpose.

1. Open and clean the remaining units.

Flushing the entire system.

2. Exchange the high pressure hoses.

1. Connect the travel motor and relieve the load on the drum for flushing.

3. Also flush the wheel drive travel circuit and vibration circuit.

Before flushing.

1. Exchange the hydraulic oil filter

Bleeding.

1. Always bleed the hydraulic circuit when the lines in the closed circuit are removed or connected.

2. Clean the hydraulic oil tank.

3. Filter the hydraulic oil.

NOTE: Use the flushing unit to filter the oil.

Pump away the contents of the tank through a 6uJ filter into the oil bag or a container.

CAUTION: Collect the hydraulic oil and dispose of it so as to prevent pollution.

NOTE: Change oil if there is strong contamination, if oil is discolored if oil change intervals are almost reached.

Filter installation (Fig. 1).

1. Filter output “OUT” to the pump.

2. Filter input “IN” to the hose from the front travel motor.

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6/96

Section 8 TRANSMISSION SYSTEM

5

7 1 4

7 6 3

1 Junction socket 16 S 2 Flushing filter 3 Reducer 25 S/16 S (2x) 4 Drum motor

5 Travel pump (tandem pump) 6 Junction socket 16 S 7 Flushing hose

2

FIGURE 1.

6/96

8-33

Section 8 TRANSMISSION SYSTEM FLUSHING THE DRUM DRIVE TRAVEL CIRCUIT. INSTALLING THE FLUSHING SYSTEM. 1. Detach the engine hood, battery (Fig. 1/1) and retaining plate (Fig. 1/2). Remove the hydraulic oil tank cover (Fig. 1/3) and transfer the contents of the hydraulic oil tank with a filter unit into a clean container or oil bag.

CAUTION: Collect the hydraulic oil and dispose of It so as to prevent pollutlon.

FIGURE 2.

2. Clean the hydraulic oil tank.

CAUTION: Before installing the flushing filter, check the hoses and connections for dirt and clean THEM IF NECESSARY.

3. Detach the upper high pressure hose on the rear travel pump for the drum drive (Fig. 3/1 ) from the side.

1

2

FIGURE 1.

CAUTION: Detach the rod (Fig. 2/1) between the pump control lever.

FIGURE 3.

4. Connect the flushing hose from the “IN” connection of the flushing filter with the hose of the drum motor (Fig. 4/1 ), 5. Connect the flushing hose (Fig. 4/2) from the ”OUT” connection of the flushing filter to the open connection of the travel pump,

8-34

6/96

Section 8 TRANSMISSION SYSTEM

FIGURE 4.

FIGURE 6.

6. Detach the high pressure hoses from the drum motor and connect them to the junction socket (Fig. 5).

8. Connect a 60-bar pressure gauge (Fig. 7) to the charge pressure test connection and let the engine idle for max. 15 seconds. Repeat the procedure after 30 seconds until the pressure gauge shows a constant pressure of 14 -16 bar.

FIGURE 5.

FIGURE 7.

BLEEDING. 7. Connect the test hose to the charge-pressure test point (Fig. 6) and run the open end into a container.

CAUTION: Crank the diesel engine with the starter for max. 10 seconds. Repeat the cranking process after waiting one minute. Then repeat the process as often as necessary until oil emerges from the test hose.

Collect the hydraulic oil and dispose of it so as to prevent pollution.

6/96

8-35

Section 8 TRANSMISSION SYSTEM 9. Perform all these measures with the travel pump at neutral. Bleeding can be started as soon as the charge pressure is present. For bleeding, move the travel lever to the front by hand (Fig. 8).

CAUTION: Move the travel lever only in travel direction “forwards”.

NOTE: Perform bleeding without loading the pump or motor. Pressures over 100 bar must be avoided at all costs.

10. After 1 - 2 minutes running time with the diesel engine idling, wait for approx. 1 minute. This waiting period is necessary to allow air bubbles to escape via the pump's leakage oil return line or via the flushing unit. Repeat this process until the charge pressure indicated on the low-pressure gauge (Fig, 7) drops immediately to ) when the diesel engine is shut down. When this happens, the travel circuit has been fully bled.

2. Move the trave lever forwards by hand (fig. 8).

CAUTION: Move the travel lever only in travel direction "forwards".

3. Flush for approximately 15 minutes with the diesel engine running at different speeds. Shut down the diesel engine.

FLUSHING THE DRUM MOTOR. 1. Lift, or jack, the machine at the front until the drum can rotate freely (Fig. 9).

DANGER: Risk of injury.

FIGURE 9.

FIGURE 8.

2. Secure the rear wheels with wedges.

3. Repeat bleeding.

FLUSHING THE LINES FOR THE FRONT DRUM MOTOR. 1. Start the diesel engine and let it idle at approximately 1400 rpm.

8-36

4. Start the diesel engine and let it idle.

5. Move the travel lever in the direction "forwards".

CAUTION: Move the travel lever only in travel direction “forwards”.

6/96

Section 8 TRANSMISSION SYSTEM 6. Flush for approximately 15 minutes with the diesel engine running at different speeds.

7. Shut down the diesel engine.

FLUSHING THE WHEEL DRIVE TRAVEL CIRCUIT. GENERAL INFORMATION. CAUTION: Always flush the closed circuit after changing a unit. Otherwise, any particles remaining in the circuit may quickly lead to further unit failure.

Filter installation (Fig. 1).

1. Filter output “OUT” to the pump.

2. Filter input “IN” to the hoses from the travel motors.

NOTE: The flushing filter must be fitted in the pump return line on the low-pressure side. This results in the travel pump moving forwards.

Flushing the hoses.

With strong oil contamination (scurf).

1. Open and clean the remaining units.

1. Remove the travel motors from the circuit one after the other; connect the high pressure lines for this purpose.

2. Exchange the high pressure hoses.

Flushing the entire system.

3. Always flush the vibration circuit.

1. Connect the travel motors and relieve the load on the wheels for flushing.

Before flushing.

1. Exchange the hydraulic oil filter.

2. Clean the hydraulic oil tank.

Bleeding.

1. Always bleed the hydraulic circuit when the lines in the closed circuit are removed or connected.

3. Filter the hydraulic oil.

NOTE: Use the flushing unit to filter the oil.

Pump away the contents of the tank through a 6 u filter into the oil bag or a container.

CAUTION: Collect the hydraulic oil and dispose of it so as to prevent pollution.

NOTE: Change oil if there is strong contamination if oil is discoloured if oil change intervals are almost reached.

6/96

8-37

Section 8 TRANSMISSION SYSTEM 1

3

1

4

1 Junction socket 2 Filter 3 Travel motor,right 4 Travel motor,left 5 Travel pump (tandem pump) 6 Junction socket 16 S 7 Flushing hose 8 Reducer 25 S /16 S (2x)

7

5 6

8 7

8 2

FIGURE 1.

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Section 8 TRANSMISSION SYSTEM FLUSHING THE WHEEL DRIVE TRAVEL CIRCUIT. INSTALLING THE FLUSHING SYSTEM. 1. Detach the engine hood, battery (Fig. 1/1) and retaining plate (Fig. 1/2). Remove the hydraulic oil tank cover (Fig. 1/3) and transfer the contents of the hydraulic oil tank with a filter unit into a clean container or oil bag.

CAUTION: Collect the hydraulic oil and dispose of it so as to prevent pollution.

FIGURE 2.

2. Clean the hydraulic oil tank.

CAUTION: Before installing the flushing filter, check the hoses and connections for dirt and clean them if necessary.

1

4. Connect the flushing hose from the “IN” connection of the flushing filter with the hose to the travel motors (Fig. 3/1 ).

5. Connect the flushing hose (Fig. 3/2) from the “OUT”” connection of the flushing filter to the open connection of the travel pump.

2

FIGURE 1.

3. Detach the upper high pressure hose on the front travel pump (Fig. 2/1 ) from the side.

6/96

FIGURE 3.

8-39

Section 8 TRANSMISSION SYSTEM 6. Disconnect the high-pressure hoses from the two rear travel motors and connect them to the junction socket. Seal the openings (Fig. 4).

9. Connect 60-bar pressure gauge (Fig. 6) to the charge pressure test connection and let the engine idle for max. 15 seconds. Repeat the procedure after 30 seconds until the pressure gauge shows a constant pressure of 14... 16 bar.

10. Perform all these measures with the travel lever at neutral! Bleeding can be started as soon as the charge pressure is present. For this purpose move the pump control lever in travel direction “‘forwards” by hand.

CAUTION: Move the pump control lever only in travel direction “forwards”. Perform bleeding without loading the pump and motors. Pressures over 100 bar must be avoided at all costs.

FIGURE 4.

BLEEDING. 7. Connect the test hoses to the high pressure test points (Fig. 5) and run the open ends into a container.

8. Start the diesel engine with the starter for max.

10 . Repeat the starting process after waiting one minute. Then repeat the process as often as necessary until oil emerges from the test hose.

CAUTION: Collect the hydraulic oil and dispose of it so as to prevent pollution.

FIGURE 6.

11. After 1 - 2 min running time with the diesel engine idling, wait for approx. 1 minute. This waiting period is necessary to allow air bubbles to escape via the pump’s leakage oil return line, or via the flushing unit. Repeat this process until the charge pressure indicated on the low-pressure gauge (Fig. 6) drops immediately to "0" when the diesel engine is shut down. When this happens, the travel circuit has been fully bled.

FIGURE 5.

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6/96

Section 8 TRANSMISSION SYSTEM FLUSHING THE LINES FOR THE REAR TRAVEL MOTORS. 1. The travel circuit has been bled.

CAUTION: The rod must have been unhooked.

2. Start the diesel engine and let it idle.

3. Move the pump control lever in travel direction ”forwards” by hand (Fig. 7).

CAUTION: Move the pump control lever only in travel direction “forwards”.

4. Flush for approx. 15 min with the diesel engine running at different speeds.

5. Shut down the diesel engine, 6. Reconnect the high pressure hoses to the lefthand travel motor

FIGURE 8.

FLUSHING THE LEFT-HAND AND RIGHT-HAND TRAVEL MOTORS. 1. Lift or jack up the rear of the machine until the left-hand wheel can turn freely (Fig. 9).

DANGER: Risk of accidents.

2. Secure the drum with wedges.

3. Start the diesel engine and let it idle.

4. Move the pump control lever by hand in travel direction “forwards”’.

CAUTION: Move the pump control lever only in travel direction “forwards”.

FIGURE 7.

7. The high pressure hoses on the right-hand travel motor remain connected with each other (Fig. 8).

CAUTION: Collect the hydraulic oil and dispose of it so as to prevent pollutlon.

FIGURE 9.

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8-41

Section 8 TRANSMISSION SYSTEM 5. Flush for approx. 15 minutes with the diesel engine running at different speeds.

6. Shut down the diesel engine.

7. Reconnect the high pressure hoses of the right-hand travel motor (Fig. 10).

8. Raise up the rear of the machine and support the frame so there is no danger of accidents.

DANGER:

3. Reattach the pump control lever. Check that the travel lever is at neutral. Lower the machine.

4. Perform a test run; when doing so, load the travel drive during forwards and reverse travel, e.g. by hill driving, or starting on slopes.

5. Recheck the hydraulic connections for leaks (visual inspection).

MAINTENANCE OF THE FLUSHING FILTER UNIT. Risk of accidents.

1. Exchange the flushing filter element if the red control pin of the contamination indicator is pressed out.

9. Flush the right-hand travel motor in the same way as the left-hand one.

NOTE: Also possible with very cold oil.

10. Remove the flushing filter and reconnect the high pressure hoses to the travel pump. Repeat bleeding.

CAUTION: Collect the hydraulic oil and dispose of it so as to prevent pollution.

2. Clean the hoses and connections and keep the flushing filter system in a protected place to prevent it being contaminated.

3. Exchange the filter cartridge of the filter unit if the red control pin of the contamination indicator is pressed out.

PRESSURES IN THE WHEEL AND DRUM DRIVE TRAVEL CIRCUITS. CHECKING THE PRESSURES IN THE WHEEL DRIVE CIRCUIT. Tools: Two, 600 bar pressure gauges, 60-bar pressure gauge, test hoses.

1. Connect the 60-bar pressure gauge to the charge pressure test connection of the hydraulic oil filter (Fig. 1 ).

FIGURE 10.

FUNCTIONAL CHECK. 1. Check the hydraulic oil level in the tank and top up if necessary.

2. Check all connections for leaks with the diesel engine running (visual inspection).

8-42

6/96

Section 8 TRANSMISSION SYSTEM CHECKING THE PRESSURES IN THE DRUM DRIVE CIRCUIT. 1. Connect a 600 bar pressure gauge to each of MA and MB on the rear travel pump.

2. Secure the drum/wheels by means of wedges.

3. Start the diesel engine and move the travel lever a short distance.

4. Read off the value on the pressure gauge.

FIGURE 1.

2. Connect a 600 bar pressure gauge to each port MA and MB on the front travel pump (Fig. 2).

NOTE: Nominal value; Charge pressure 14 - 16 bar. High pressure approx. 300 - 320 bar

DANGER: Do not stand in the machine’s articulation area.

3. Secure the drum/wheels by means of wedges.

4. Start the diesel engine and move the travel lever a short distance.

NOTE: Measurement evaluation; If the pressures are not reached, perform troubleshooting in accordance with the troubleshooting chart.

5. Read off the value on the pressure gauge.

NOTE: Nominal value; Charge pressure 14 -16 bar. High pressure approx. 300 - 320 bar

DANGER: Do not stand in the machine’s articulation area.

FIGURE 2.

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8-43

Section 8 TRANSMISSION SYSTEM HIGH PRESSURE TEST OF TRAVEL PUMPS (2 per pump).

TRAVEL PUMP, DRUM DRIVE.

TRAVEL PUMP, WHEEL DRIVE.

1. Detach the T-pieces from connections A and Band plug pump connections A and B (Fig. 2).

Tools: Two, 600 bar pressure gauges, two, test hoses and two, plugs.

CAUTION: Pressure test max. 3 seconds.

1. Detach the T-pieces from connections A and B and plug pump connections A and B (Fig. 1 ).

2. Repeat pressure test.

CAUTION: Pressure test max. 3 seconds.

2. Repeat the pressure test.

NOTE: Measurement evaluation; If the pressures are not reached, perform troubleshooting in accordance with the troubleshooting chart.

NOTE: Measurement evaluation; If the pressures are not reached, perform troubleshooting in accordance with the troubleshooting chart.

FIGURE 2.

FIGURE 1.

8-44

6/96

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

6/96

CAUSE

CORRECTION

Pumps not in neutral [stroked]

Check linkage at pump[s] displacement control for correct fork to arm alignment.

Adjust control cable if needed.

Pumps mechanical neutral (0) position NOT correct

Check the mechanical neutral position [see this section.

Pumps hydraulic (0) position NOT correct

Check the hydraulic neutral position [see this section].

Displacement control has damage

Replace displacement control with new.

Transmission pumps worn or damaged

Replace transmission pumps with new.

Secondary/parking brake system "on".

Release brake system.

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.

Control linkage damaged or linkage not connected to the transmission pumps.

Repair or replace control Connect linkage to the transmission pump.

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.

8-45

Section 8 TRANSMISSION SYSTEM TROUBLE ANALYSIS FOR THE TRANSMISSION SYSTEM TRANSMISSION PUMP PROBLEM

CAUSE

CORRECTION

MACHINE WILL NOT OPERATE IN EITHER DIRECTION [continued]

High pressure relief valves in "open" position

Remove, inspect clean, adjust or replace and adjust valves.

Wheel drive and drum drive motors damaged

Remove, repair or replace motors.

Transmission pumps linkage has damage

Check control system for connection, binding or missing parts. Correct and adjust as needed.

Displacement control valves damaged

Replace valves with new.

One charge pressure check valve damaged

Identify check valve. Remove, clean or replace as needed.

Wheel and drum 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.

Pumps control linkage has damage

Check control system for connection, binding or missing parts. Correct and adjust as needed.

Displacement control valves damaged

Replace valves with new.

Both pumps displacement control cylinder not adjusted correctly, or is damaged

Adjust control cylinders or replace and adjust cylinders as needed.

Hydraulic system oil level "low"

Check oil level in reservoir. Add oil. Find and correct cause of low oil level.

"Stopped" pressure oil filter element

Replace filter element with new.

System being operated at a pressure over "high" relief

Eliminate cause of excessive pressure, or adjust "high" relief pressure setting.

MACHINE OPERATES IN ONE DIRECTION ONLY

NEUTRAL POSITION DIFFICULT OR NOT ABLE TO BE FOUND

SYSTEM OPERATES IN A "HOT" CONDITION

8-46

6/96

Section 8 TRANSMISSION SYSTEM TROUBLE ANALYSIS FOR THE TRANSMISSION SYSTEM TRANSMISSION PUMP PROBLEM SYSTEM OPERATES IN A "HOT" CONDITION [continued]

CAUSE Pumps have internal leakage

CORRECTION Remove, inspect, repair or replace pumps.

CAUTION: Clean the entire hydraulic system AFTER a failure.

TRANSMISSION PUMPS 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.

Pumps have internal wear or damage

Remove, repair or replace pumps.

CAUTION: Clean the entire hydraulic system AFTER a failure.

MACHINE ACCELERATION AND/OR DECELERATION SLOW

6/96

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 steering/charge pump and then adjust, if needed.

Displacement control valves orifice partially "stopped"

Remove displacement control valve. Remove, clean or replace orifice. Install control valve.

Pumps have internal wear or damage

Remove and repair or replace pumps as needed.

8-47

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

CAUSE

CORRECTION

WHEEL DRIVE MOTORS AND DRUM DRIVE MOTOR WILL NOT ROTATE IN EITHER DIRECTION

Secondary/parking brake system "on"

Release brake system.

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 pumps

See "Machine Will Not Operate In Either Direction" - in the Transmission Pumps "Trouble Analysis".

Secondary/parking brakes on wheel drive motors not releasing.

Check brake release hydraulic pilot pressure. Check release piston operation on wheel drive motors. Repair, or replace, components as needed.

Wheel drive motors and drum drive motor have damage

Remove, repair or replace motors with new as needed.

CAUTION: Clean the entire hydraulic system AFTER a failure.

8-48

6/96

Section 8 TRANSMISSION SYSTEM TROUBLE ANALYSIS FOR THE TRANSMISSION SYSTEM TRANSMISSION MOTORS PROBLEM WHEEL DRIVE MOTORS AND DRUM DRIVE MOTOR WILL ROTATE IN ONE DIRECTION ONLY

WHEEL DRIVE MOTORS AND/OR DRUM DRIVE MOTOR OPERATING IN A "HOT" CONDITION

CAUSE

CORRECTION

Pumps displacement control linkage not adjusted correctly or is damaged

Adjust control linkage or replace damaged linkage and then adjust correctly.

Displacement controls valve have damage

Replace control valves with new.

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

Reduce system loading.

Low oil flow reaching wheel drive and/or drum drive motor[s] from transmission pumps.

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.

6/96

8-49

Section 8 TRANSMISSION SYSTEM

WHEEL DRIVE MOTORS MULTI-DISC BRAKES PROBLEM BRAKES WILL NOT RELEASE

BRAKES WILL NOT APPLY

BRAKES WILL NOT APPLY

8-50

CAUSE

CORRECTION

No charge pressure available within system

Check charge pressure. Correct cause of low ,or no, charge pilot pressure to brake valve as needed.

Secondary/parking brake system control valve damaged

Remove and replace valve 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 from brake valve. Correct cause of low, or no, charge pressure, from brake valve, as needed.

Brake release pistons, or seals, worn, or damaged

Remove motors. Disassemble and inspect brake parts. Replace worn or damaged parts as needed.

Brake release valve damaged spool in open flow position

Remove and replace valve with new.

Charge pilot pressure being supplied to brake release pistons at all times

Check for correct brake release oil supply hose routing. Change routing if needed.

Multi-disc brakes worn or damaged

Replace ALL discs with new.

Brake release pistons remaining in

Remove release pistons.

Replace damaged parts, with new.

Belleville [brake application] washers have reduced tension, or other damage

Remove washers and replace with new.

6/96

Section 8 TRANSMISSION SYSTEM TROUBLE ANALYSIS FOR THE TRANSMISSION SYSTEM WHEEL DRIVE MOTORS MULTI-DISC BRAKES PROBLEM BRAKES WILL NOT HOLD MACHINE WHEN APPLIED

6/96

CAUSE

CORRECTION

Multi-disc brakes worn or damaged

Replace ALL discs with new.

Brakes not shimmed correctly

Shim brakes to correct specifications.

Belleville [brake application] washers have reduced tension, or other damage

Remove washers 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.

8-51

Section 8 TRANSMISSION SYSTEM NOTES

8-52

6/96

Section 9 BRAKE SYSTEM

TABLE OF CONTENTS

PAGE GENERAL INFORMATION ....................................................................................................................... 9-2 DYNAMIC BRAKING ................................................................................................................................ 9-3 BASIC OPERATION .............................................................................................................................. 9-3 SECONDARY/PARKING BRAKE SYSTEM ............................................................................................ 9-3 BASIC OPERATION ............................................................................................................................. 9-3 REMOVING AND REPLACING THE SECONDARY/PARKING BRAKE SYSTEM HYDRAULIC SYSTEM CONTROL VALVE ASSEMBLY ....................................................................... 9-4

-

6/96

9-1

Section 9 BRAKE SYSTEM GENERAL INFORMATION [See Figure 1].

THIS section describes the operation of the DYNAMIC [hydrodynamic, through the transmission system] and the SECONDARY/PARKING [spring applied, hydraulically released, [SAHR] braking systems.

SECONDARY/PARKING BRAKE components are included within each wheel drive motor.

Repair procedures for the SECONDARY/PARKING BRAKE system components, within the wheel drive motors, are included in Section 8 - TRANSMISSION SYSTEM. Trouble analysis information for the secondary/ parking brake system is found in Section 8 TRANSMISSION for the wheel drive motor assembly contained components.

FROM CHANGE PUMP

MOTOR BRAKE RELEASE PRESS BRAKE SYSTEM CONTROL VALVE BRAKE RELEASE PRESS

MOTOR

TO TANK

FIGURE 1. SECONDARY/PARKING BRAKE SYSTEM - RELEASE OIL FLOW PATH.

9-2

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Section 9 BRAKE SYSTEM DYNAMIC BRAKING.

SECONDARY/PARKING BRAKE SYSTEM.

BASIC OPERATION.

BASIC OPERATION [See Figure 1].

During operation, SLOWING, or STOPPING, of the machine is done by using the TRANSMISSION system. Control of the transmission system is through the travel control lever, found to the right side of the seat. During machine operation, moving the lever FROM either the FORWARD, or REVERSE, position TOWARD 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.

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 “APPLIED” if the machine has a loss of hydraulic system charge pressure or if there is a stoppage of the engine.

WARNING: When approaching, and then traveling down, a slope use a SLOW speed. ADDITIONAL slowing of the machine is done by moving the travel control lever 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].

Control of the SECONDARY/PARKING brake system is accomplished by using the secondary/parking brake system control handle found on the left side of the machine.

Putting the brake system control valve handle at the “ON” [APPLIED] position, will cause the manually moved spool, found in the brake valve, to stop the flow of release oil to the multi-disc brake release piston in the each wheel drive motor. The application pressure plate will then APPLY the one set of multidisc brakes contained within each wheel drive motor.

WARNING: The machine MUST NOT move, at ANY time, when the secondary/ parking brake system 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.

Putting the secondary/parking brake system control valve handle at the “OFF” [RELEASED] position, will cause the manually moved spool, found in the brake valve, to permit the supply of charge pressure oil to the multi-disc brake release piston in each wheel drive motor, RELEASING the multi-disc secondary/ parking brakes.

6/96

9-3

Section 9 BRAKE SYSTEM REMOVING AND REPLACING THE SECONDARY/ PARKING BRAKE SYSTEM HYDRAULIC SYSTEM CONTROL VALVE ASSEMBLY [See Figure 1].

Use the following information to remove and replace the brake system hydraulic control valve assembly.

1. Stop the engine. Open the engine hood and the access panel above the brake system hydraulic control valve assembly. Wash the control valve and hose and fitting areas to remove dirt accumulations.

2. Put an identification tag on each hose and each valve fitting. Remove each hose from each control valve fitting. Immediately put a cap on each valve fitting and a plug in each hose fitting.

NOTE: For installation, remove the plug from each hose fitting and the cap from each control valve fitting. Install and tighten each hose onto each correct valve fitting per the identification tags.

3. Disconnect the two [2] electrical wires at the connection points, below the brake system condition indicator pressure actuated switch.

4. Remove the brake valve handle retaining capscrew and remove the handle from the valve actuation shaft.

NOTE: For installation, install handle onto the valve actuation shaft. Install and tighten the handle retaining capscrew.

5. Remove the brake valve assembly to panel retaining capscrew and remove the valve assembly from the machine. Remove one [1] fitting at a time, from the removed valve assembly. Clean the threaded area of the fitting. Put teflon tape on the threaded area of the fitting. Exchange the fitting to the SAME port in the new control valve assembly.

Transfer the remaining fittings, using the above information.

NOTE: For installation, install brake valve into the machine and position it against the panel. Install the valve retaining capscrews and washers and tighten the retaining capscrews.

6. Start the engine. Check the secondary/parking brake valve operation.

NOTE: For installation, connect the two [2] electrical wires at the connection points.

CONTROL VALVE

BRAKE VALVE HANDLE (ON VALVE ACTUATION SHAFT)

PANEL ACCESS PANEL

HOSE

HOSE HOSE HOSE ELECTRICAL WIRES

FIGURE 1.

9-4

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Section 10 STEERING SYSTEM

TABLE OF CONTENTS

PAGE GENERAL INFORMATION ...................................................................................................................... 10-2 DESCRIPTION ......................................................................................................................................... 10-2 SYSTEM OPERATION ............................................................................................................................. 10-3 EXCHANGING THE STEERING, CHARGING AND VIBRATION PUMP ............................................... 10-3 REPAIRING THE STEERING, CHARGING AND VIBRATION PUMP.................................................... 10-3 EXCHANGING THE CONTROL VALVE ................................................................................................. 10-6 REMOVING AND INSTALLING THE STEERING UNIT ......................................................................... 10-6 DISMANTLING THE STEERING CONTROL UNIT ................................................................................ 10-9 DISMANTLING THE DOUBLE SHOCK VALVES .............................................................................. 10-9 DISMANTLING THE PRESSURE RELIEF VALVE ........................................................................... 10-11 DISMANTLING THE PRESSURE RELIEF VALVE (CARTRIDGE) .................................................. 10-11 ASSEMBLING THE STEERING CONTROL UNIT ................................................................................ 10-12 ASSEMBLING THE O-RING/KIN RING ............................................................................................. 10-13 ASSEMBLING THE TWO REFILL VALVES ..................................................................................... 10-13 ASSEMBLING THE PRESSURE RELIEF VALVE ............................................................................ 10-14 ASSEMBLING THE DOUBLE SHOCK VALVES ............................................................................. 10-14 REMOVING AND INSTALLING THE STEERING CYLINDER ............................................................ 10-14 REPAIRING THE STEERING CYLINDER ........................................................................................... 10-16 DISMANTLING .................................................................................................................................. 10-16 ASSEMBLY ........................................................................................................................................ 10-16 CHECKING AND SETTING THE STEERING PRESSURE ................................................................ 10-17 TROUBLE ANALYSIS FOR THE STEERING SYSTEM ....................................................................... 10-18

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10-1

Section 10 STEERING SYSTEM Trouble analysis for the STEERING SYSTEM is found at the rear of THIS section.

GENERAL INFORMATION. THIS section contains a description of the steering system operation.

Removal, disassembly, inspection, assembly, installation and pressure check procedures, for the selected system components are also found in THIS section.

DESCRIPTION [See Figure 1] The steering system is a hydraulic operated, manually controlled system with provisions for manual steering IF the engine is in a stopped condition. The steering system has a natural feel to the operator by providing a direct relationship between the steering wheel and the drum of the machine.

STEERING UNIT

STEERING CYLINDER

FILTER

TO VIBRATION MOTOR FROM VIBRATION MOTOR

CONTROL VALVE

CHARGE/STEERING/VIBRATION PUMP

ENGINE

FROM VIBRATION MOTOR BREATHER FILTER TANK

FIGURE 1. STEERING SYSTEM - HYDRAULIC SCHEMATIC.

10-2

6/96

Section 10 STEERING SYSTEM MAJOR steering system components are: a. Steering/charging and vibration gear pump [see THIS section].

When NO steering function, using the steering control unit, is being used the oil flow entering the unit passes through the unit and is directed to the return oil [low pressure] side of the steering system and returns back to the hydraulic oil reservoir.

b. Steering control unit, with integral relief valve. c. Steering cylinder, double acting. d. Hoses and fittings.

NOTE: Return oil from the steering cylinder is directed through the steering control unit, to the return oil [low pressure] side of the steering system.

SYSTEM OPERATION [See Figure 1].

The engine mounted steering, charging and vibration pump assembly contains the gear pump that supplies the steering, transmission and vibration systems with hydraulic oil. The hydraulic oil is drawn from the hydraulic oil reservoir.

The oil is then pulled into, and through, the pump gear section. The pump section generates hydraulic oil flow for the steering, transmission and vibration systems.

Hydraulic oil flows from the pump gear section and through steering, transmission charging and vibration pump.

Oil for the steering system flows from the steering, charging and vibration pump through the pressure oil filter and to the steering control unit.

When any steering function, using the steering control unit, is required [ANY turning of the machine to either the left, or right] the oil flow entering the steering control unit is directed internally through the unit to the steering cylinder supply hose.

The steering cylinder supply hose then supplies the cylinder with oil. Oil is supplied to the ROD end of the cylinder to turn the machine to the RIGHT turn direction, and the BASE end of the cylinder to turn the machine to the LEFT turn direction.

6/96

EXCHANGING THE STEERING, CHARGING AND VIBRATION PUMP. 1. Open the engine hood.

NOTE: For Installation, check the hydraulic oil level and engine oil level and top up.

2. Remove the battery.

3. Unscrew the cap nuts (Fig. 1/3) of the hydraulic oil hoses from the connections and immediately plug the connections and hydraulic oil hoses.

4. Unscrew four mounting screws (Fig. 1/2) from the pump (Fig. 1/1 ) and remove the latter.

CAUTION: Collect the draining oil and dispose of It so as to prevent pollution.

NOTE: For installation, place a new O-ring (Fig. 2/3) over the collar of the pump.

10-3

Section 10 STEERING SYSTEM NOTE: For installation, use a new O-ring (Fig. 3/3). Check the hydraulic oil level and engine oil level and top up, as needed.

FIGURE 1.

5. To exchange the pump, unscrew the nut (Fig. 2/2) and pull off the pinion (Fig. 2/1 ).

FIGURE 3.

REPAIRING THE STEERING, CHARGING AND VIBRATION PUMP. Special Tools: Centering plate.

1. Remove the steering, charging and vibration pump and detach the control valve, see appropriate section.

2. Mark the two covers (Fig. 1/1 and 7) relative to the pump housing and unscrew the mounting screws (Fig. 1/13).

FIGURE 2.

NOTE: For installation, align the cover on the drive side with the centering plate and tighten the two mounting screws.

6. Unscrew the bolts (Fig. 3/2) and remove the flanged connector (Fig. 3/1 ).

10-4

6/96

Section 10 STEERING SYSTEM

7 1 Housing cover 2 Pump housing 4 Radial seal 5 Circlip (inner) 6 Seal ring 7 Housing cover 8 Supporting ring 9 Seal ring 10 Gear wheel 11 Gear wheel 12 Spring washer 13 Allen screw 14 Woodruff key 15 Spring washer 16 Hexagon nut 17 Protection cap 18 Plug 19 Bearing bush 20 Bearing bush

6

12

13

9

8

2

18

17

19 10 14

20 6 8

20

9 1 5 16

11

4 19

15

FIGURE 1.

4. Remove the seal rings (Fig. 1/9), supporting rings (Fig. 1/8) and seal rings (Fig. 1/6) from the housing (Fig. 1/2).

NOTE: For installation, fit new seal rings (Fig. 1/9 and 1 16) into the grooves of the engine housing. Fit supporting rings (Fig. 1/8) onto the inserted seal rings (Fig. 1/6) with the smooth side facing upwards.

6/96

5. Pull the gear wheels (Fig. 1/10 and 11) out of the bearing bushes.

NOTE: For installation, check the condition of the tooth profiles and running faces and exchange gear wheels if necessary.

10-5

Section 10 STEERING SYSTEM 6. Check the condition of the running face of the bearing bushes (Fig. 1/19 and 20) and exchange the latter if necessary.

5. To exchange the control valve, unscrew the bolts (Fig. 2/1). Remove the connecting block (Fig. 2/2).

7. Remove the circlip (Fig. 1/5) from the groove in the cover (Fig. 1/1 ). Press out the radial seal (Fig. 1/4).

NOTE: For installation, grease a new radial seal and press it in with the sealing lip facing outwards.

EXCHANGING THE CONTROL VALVE. 1. Raise up the engine hood.

NOTE: For Installation, Check the hydraulic oil level and top up.

2. Detach the electrical plug (Fig. 1/1 ).

3. Unscrew the hydraulic hoses (Fig. 1/2, 3 and 4) from the connections and immediately plug the connections and hydraulic oil hoses.

FIGURE 2.

REMOVING AND INSTALLING THE STEERING UNIT. 1. Disconnect the battery.

2. Detach the front cover plate.

4. Unscrew both mounting screws (Fig. 1/5) and remove the control valve.

3. Unscrew the bolts (Fig. 1) from the instrument panel. Remove the instrument panel and swing it down.

FIGURE 1.

10-6

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Section 10 STEERING SYSTEM 5. Unscrew four bolts (Fig. 3) for the steering unit.

FIGURE 1.

4. Mark the hydraulic oil hoses and detach them from the connections (Fig. 2) on the steering unit.

Immediately plug the steering unit connections and the hydraulic oil hoses.

CAUTION: Collect the hydraulic oil and dispose of it so as to prevent pollution.

FIGURE 2.

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FIGURE 3.

6. Remove the steering unit from the steering column.

NOTE: For installation, the grooved toothing (Fig. 4) must engage in the steering unit.

FIGURE 4.

10-7

Section 10 STEERING SYSTEM 7. To exchange, remove the banjo fittings (Fig. 5/6).

5 6 6

5

6 3

4

1

6 2

1 Hose 2 Hose 3 Hose 4 Hose 5 Socket 6 Banjo fitting

FIGURE 5.

8. To remove the steering column, remove the cap (Fig. 6/1) from the steering wheel.

10. Remove the steering column, from below.

9. Unscrew the mounting nut (Fig. 6/2) from the steering wheel and pull off the latter.

NOTE: For installation, the brackets (Fig. 7), on the steering column, must fit in the recesses.

11. Check the steering column and drum shell; exchange the complete steering column, if necessary.

FIGURE 6.

FIGURE 7.

10-8

6/96

Section 10 STEERING SYSTEM DISMANTLING THE STEERING CONTROL UNIT.

DISMANTLING THE DOUBLE SHOCK VALVES.

Special Tools: Assembly tool for drive shaft - No. 079 942 01 Assembly tool for dust seal ring - No. 079 942 03 Assembly tool for O-ring/kin ring No. 079 942 02

1. Unscrew the plugs (Fig. 1/34), for the double shock valves, using a 6 mm Allen key.

1. Remove the steering unit (See this section).

3. Measure the screw-in depth, on the two (2) set screws (Fig. 3/3. Note the setting dimension (Fig. 2).

2. Unscrew the bolts in the cover (Fig. 1/26).

3. Remove the cover, from the side.

4. Lift the gear set (Fig. 1/22), possibly with spacer ring, from the unit. Remove the two (2) O-rings (Fig. 1/25).

5. Remove the drive shaft (Fig. 1/18).

6. Remove the distributor plate (Fig. 1/21).

2. Remove the two sealing washers (Fig. 3/4).

4. Unscrew the set screws, using a 6 mm Allen Key. NOTE: Shake out the two (2) springs (Fig. 3/1) and two (2) balls (Fig. 3/2) into your hand.

The valve seats con NOT be removed, since they are fixed in the housing.

Figure 3 shows the double shock valved completely dismantled.

7. Unscrew the threaded bush, from over the check valve.

8. Remove the O-ring (Fig. 1/20).

9. Remove the check valve ball, the pins (Fig. 1/1 ) and the balls (Fig. 1/35) of the refill valve.

10. Hold the pin (Fig. 1/15) horizontally in the outer and inner sliders. The pin is visible through the open end of the inner slider (Fig. 1/5). Press the inner slider inwards. Then remove the outer slider (Fig. 1/6), ring (Fig. 1/14), sliding discs (Fig. 1/12) and needle cage (Fig. 1/13) from the housing.

11. Remove the ring, sliding discs and needle cage from the inner/outer sliders. The outer (thin) sliding disc may “stick” in the housing. Check whether it has been removed.

12. Press out the pin; to do so, use the dowel pin bolt with dowel pin (Fig. 1/29) from the cover.

13. Carefully press the inner slider out of the outer slider.

14. Press the neutral adjustment springs (Fig. 1/16) out of the slot in the inner slider.

15. Remove the dust sealing ring and O-ring/kin ring.

6/96

10-9

Section 10 STEERING SYSTEM

2 1 Pin 2 Dust sealing ring 3 Set of seals for bearing 4 Housing 5 Slider, inner 6 Slider,outer 7 Ball 8 Threaded Bush 9 O-ring 10 Kin ring 11 Bearing 12 Sliding disc 13 Needle cage 14 Ring 15 Pin 16 Set of springs 17 Spring 18 Shaft 19 Spacer 20 O-ring 21 Distributor plate 22 Gear set 23 Rotor 24 Housing 25 O-ring 27 Cover 28 Dowel pin 29 Dowel pin bolt 30 Allen screw 31 Type plate 32 Self-tapping screw 33 Pressure relief valve 34 Double shock valve 35 Ball

34 33 18 4

7

35

19

1

20

9 10

8

21

12 11

13 23

12 14

5

3

22

25 24

6 25 28 26 15 16

27

17

27

29

30 31 32

FIGURE 1.

10-10

6/96

Section 10 STEERING SYSTEM

FIGURE 2.

FIGURE 4.

FIGURE 3.

FIGURE 5.

DISMANTLING THE PRESSURE RELIEF VALVE.

4. Pressure relief valve completely dismantled (Fig, 5).

1. Unscrew the plug using an 8 mm Allen key.

Remove the seal ring (Fig. 5/1 ) (Fig. 4).

2. Unscrew the set screw (Fig. 5/2) using an 8 mm Allen key.

DISMANTLING THE PRESSURE RELIEF VALVE (CARTRIDGE).

3. Shake out spring (Fig. 5/3) and piston (Fig. 5/4). The valve seat cannot be removed since it is fixed in the housing.

1. Unscrew the pressure relief valve (Fig. 1/33) using an 8 mm Allen key. Remove the sealing ring.

The valve must be exchanged if it is defective.

2. Carefully clean all parts in Shellsol K, or similar.

3. Use new seals and washers. Carefully check all parts for damage and wear.

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10-11

Section 10 STEERING SYSTEM ASSEMBLING THE STEERING UNIT.

3. Align the set of springs.

NOTE: Assembly pattern and color code for neutral adjustment springs for steering units (Fig. 6).

Standard springs (grey) 2 x straight, grey plate springs, 4 x curved, grey plate springs.

Before assembly, all parts must be lubricated with hydraulic oil.

4. Insert the inner slider (Fig. 1/5) into the outer slider (Fig. 1/6).

5. Press the spring ends together and press the neutral adjustment springs into position in the outer slider.

6. Align and center the springs.

7. Guide the ring down over the outer slider.

NOTE: The ring must be able to turn freely of the springs.

8. Slide the pin (Fig. 1/15) into the slider assembly.

9. Fit the sliding disc (Fig. 1/12) and needle cage (Fig. 1/13).

FIGURE 6.

1. Fit the two flat neutral adjustment springs (Fig. 7/2) into the slot.

2. Fit the curved springs (Fig. 7/1 ) between the flat springs and slide them into place (see assembly pattern Fig. 6).

10. Assembly pattern for standard bearings Outer sliding disc (Fig. 8/1 ) or (Fig. 1/12) Needle cage (Fig. 8/2) or (Fig. 1/13) Inner sliding disc (Fig. 8/3) or (Fig. 1,,’12). inner slider (Fig. 8/4), or (Fig. 1/5) Outer slider (Fig. 8/5), or (Fig. 1/6).

11. The chamfer of the inner sliding disc must face the inner slider.

FIGURE 8.

FIGURE 7.

10-12

6/96

Section 10 STEERING SYSTEM ASSEMBLING THE O-RING/KIN RING. 1. Turn the steering unit around so that the bore is horizontal. Insert the outer part of special tool No. 079 942 02 into the bore for the slider assembly.

4. Fit the distributor plate so that the duct bores are aligned with the corresponding bores in the housing.

5. Insert the drive shaft into the bore so that the slot is parallel with the connecting flange.

2. Lubricate the O-ring (Fig. 1/9) and kin ring (Fig. 1/10) with hydraulic oil and place on special tool No. 079 942 02.

6. Slide assembly fork No. 079 942 01 below the toothing of the drive shaft.

3. Hold the outer part of special tool No. 079 942 02 into the bottom of the steering unit housing and insert the inner part of special tool No. 079 942 02 completely into the base.

7. Oil the two O-rings with mineral oil (viscosity: 500 cSt at 20˚C) and fit them into the two grooves of the gear ring. Fit the gear wheel and gear ring onto the drive shaft.

4. Press and turn the O-ring/kin ring until they are in position in the housing.

5. Pull the inner and outer parts of special tool No. 079 942 02 out of the bore in the steering unit so that the guide of the inner part remains.

6. Insert the inner and outer sliders into the bore using gentle turning movements.

CAUTION: Fit the gear wheel (rotor) and drive shaft so that the gear tooth base of the rotor is fitted in relation to the groove of the shaft (Fig. 9). Turn the gear ring so that the seven continuous bores for the bolts align with the seven bores In the housing.

NOTE: Fit the slider assembly so that the pin is held horizontally.

7. The guide of special tool No. 079 942 02, which is still in the housing, is pressed out by the slider assembly. The O-ring and kin ring are in their positions.

8. Turn the steering unit around, again, so that the bore is vertical. Fit the ball of the check valve into the bore.

FIGURE 9.

9. Screw the threaded bush slightly into the bore of the check valve. The upper part of the bush must be just below the surface of the housing.

8. Fit the spacer ring (if present).

ASSEMBLING THE TWO REFILL VALVES.

9. Fit the cover.

1. Place a ball into each of the bores.

2. Fit a pin into each of these bores.

3. Lubricate the O-ring with mineral oil (viscosity: 500 cSt at 20˚ C) and insert the O-ring into the groove.

6/96

10-13

Section 10 STEERING SYSTEM 10. Fit a washer to the dowel pin bolt (Fig. 1/29) and screw the bolt into the bore (Fig. 10).

11. Fit washers to the six other bolts and screw these in. Torque all seven bolts to 30.0 + 6.0 Nm, tightening crosswise.

3. Screw in the two set screws (Fig. 3/3) using a 6 mm Allen key and set to the dimension noted when the screws were removed. See this section “Dismantling the double shock valves”.

4. Screw the plug (Fig. 1/34) with sealing washers (Fig. 3/4) into the two shock valves and torque to 3 +/- 0 daNm using a 6 mm Allen key.

5. Fit the dust sealing ring (Fig. 1/2) with the open side facing upwards.

6. Drive the dust sealing ring into the housing using special tool No. 079 942 03 and a plastic hammer.

7. If necessary, press plastic plugs into the connection openings. Do not use a hammer.

FIGURE 10.

ASSEMBLING THE PRESSURE RELIEF VALVE.

8. To set the pressure for the pressure relief valve, fit the steering unit and connect the hydraulic oil hoses.

9. For pressure setting procedures, refer to “Checking and setting the steering pressure”, in this section.

1. Insert the piston (Fig. 5/4) 2. Fit the spring (Fig. 5/3).

3. Screw in the set screw (Fig. 5/2) using an 8 mm Allen key. Set the pressure at the test stand, or at the machine.

4. Screw the plug with seal ring (Fig. 5/1) into the housing using an 8 mm Allen key.

NOTE: Torque 5 +/- 1 daNm.

ASSEMBLING THE DOUBLE SHOCK VALVES. 1. Place a ball (Fig. 3/2) into each of the bores.

2. Fit a spring (Fig. 3/1 ) and a valve disc onto each of the two balls.

10-14

REMOVING AND INSTALLING THE STEERING CYLINDER. 1. Turn the steering to the right-hand stop.

DANGER: Do NOT stand in the roller’s articulation area when the engine is running. The clearance in this area closes when the machine is turned to the right, or the left.

2. Disconnect the hydraulic oil hoses from the steering cylinder connections and plug the connections (Fig. 1/21 and 22).

CAUTION: Collect the hydraulic oil and dispose of It so as to prevent pollution.

6/96

Section 10 STEERING SYSTEM NOTE: For installation, check the hydraulic oil level and top up if necessary. To bleed the steering cylinder, let the engine idle and turn the steering several times to the left-hand and right-hand stops.

3. Pull the cotter pin out of the steering cylinder bearing gudgeon (Fig. 1/7 and 17) and drive out the gudgeon. Remove the washers (Fig. 1/8 and 14).

4. Completely remove the steering cylinder.’

5. If necessary, detach the connection fittings from the steering cylinder (Fig. 1/19).

NOTE: For installation, check the seal rings (if present) and use new ones if necessary.

NOTE: For installation, fit washers on both sides of the self-aligning bearings. Grease the parts.

1 Rod end bearing 2 Hexagon nut 3 Washer 4 Cylinder bearing 5 Washer 6 Cotter pin 7 Gudgeon 8 Washer 9 Rod and bearing 10 Hexagon bolt 11 Hexagon nut 12 Washer 13 Cylinder bearing 14 Washer 15 Washer 16 Cotter pin 17 Gudgeon 18 Screw plug 19 Socket 20 Angular fitting

6. Check the rod end bearing (Fig. 1/1) in the cylinder bearings (Fig. 1/4 and 1/13) and install with new, if necessary.

21 Hose 22 Hose 23 Steering cylinder

14 9 13 18

11 12 12

2 3

17

14 23

10

18

15 16

7 4

19

8 1

20

19 5

20 6

22

21

8

FIGURE 1.

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10-15

Section 10 STEERING SYSTEM REPAIRING THE STEERING CYLINDER.

ASSEMBLY.

DISMANTLING.

1. Insert new parts: guide rings (Fig. 1/8), seal (Fig. 1/7), guide ring (Fig. 1/6), scraper (Fig. 1/5), loop ring (Fig. 1/9) and seal ring (Fig. 1/1) into the guiding bush (Fig. 1/4) in the same position as before removal.

1. Unscrew the cylinder cover (Fig. 1/4) with a grooved nut wrench.

2. Pull the piston rod out of the cylinder tube.

2. Fit the loop ring (Fig. 1/12) into the piston.

3. Unscrew the nut (Fig. 1/13) from the piston rod (Fig. 1/2).

3. FIT THE SEAL (Fig. 1/11).

4. Pull the piston (Fig. 1/10) and cylinder tube (Fig. 1/3) from the piston rod.

4. Oil the parts with clean hydraulic oil.

5. Note, or mark, the position of the individual seal 6. Check the parts for wear and exchange if necessary.

1 Seal ring 2 Piston rod 3 Cylinder tube 4 Guiding bush 5 Scraper 6 Guide ring 7 Seal 8 Guide ring 9 Loop ring 10 Piston

11Seal 12 Loop ring 13 Nut

9 1 4 8

5

6

7

2

3 13 11 10 12

FIGURE 1.

10-16

6/96

Section 10 STEERING SYSTEM CHECKING AND SETTING THE STEERING PRESSURE.

6. Unscrew the plug and turn the set screw accordingly (Fig. 2).

1. Connect a 600 bar pressure gauge to the steering pressure test connection (Fig. 1 ).

FIGURE 1.

FIGURE 1.

NOTE: Turning the screw in, increases the pressure. Turning the screw out, lowers the pressure.

2. Start the diesel engine.

3. Turn the steering to the final stop.

DANGER: Do NOT stand in the roller’s articulation area when the engine is running. The clearance in this area closes when the machine is turned to the right, or the left.

4. Read off the value on the pressure gauge.

7. Screw the plug back in and fit the cover plate.

NOTE: If the pressure cannot be set, perform troubleshooting in accordance with the troubleshooting chart.

8. Check the steering, charging and vibration pump, see Section 11 - DRUM AND VIBRATION.

NOTE: Nominal value: 90 -106 bar.

Measurement evaluation: If the nominal value is not reached, perform the following setting.

5. Detach the cover plate.

6/96

10-17

Section 10 STEERING SYSTEM TROUBLE ANALYSIS FOR THE STEERING SYSTEM PROBLEM

CAUSE

CORRECTION

STEERING CONTROL UNIT NO response when steering wheel is turned.

No flow from pump.

Control unit has damage.

Steering cylinder has damage.

Check for pump output. Repair, or replace, pump or other parts of the pump as needed.

Remove unit. Repair or replace as needed.

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].

Steering control unit sleeve and spool worn.

Remove unit, remove replace spool and sleeve.

Steering control unit metering gear worn.

Remove unit, remove and replace metering gear.

Charge/steering/vibration pump damaged.

See charge/steering/vibration pump in this section.

Manual steering check ball off its seat.

Remove unit, remove and replace check ball. Inspect seat.

Steering wheel does NOT center.

Steering control unit has broken centering springs.

Remove unit, remove and replace centering springs.

Steering wheel rotation is continuous.

Steering control unit has broken centering springs.

Remove unit, remove and replace centering springs.

Steering control unit has burr on sleeve and/or spool.

Remove unit. Remove, repair or replace spool and/or sleeve as needed.

Slow or hard steering.

10-18

6/96

Section 10 STEERING SYSTEM TROUBLE ANALYSIS FOR THE STEERING SYSTEM 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, align metering star to slot in shaft in CORRECT position.

NO pressure OR flow from valve.

Relief valve has internal damage.

Remove steering control unit.

Repair, or replace, with NEW [see THIS section].

System pressure low.

Relief valve not set to correct specifications.

Remove steering control unit.

Repair, or replace, [see THIS section].

System pressure high.

See above information.

See above information.

System pressure NOT steady - varies.

Relief valve has damaged parts.

Remove steering control unit.

Repair, or replace, [see THIS section].

Wrong steering response to steering wheel command.

STEERING CYLINDER NO motion from steering cylinder.

Slow motion from steering cylinder.

6/96

NO oil being supplied to steering cylinder.

Check the system for damaged pump, or relief valve, steering control unit, 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.

10-19

Section 10 STEERING SYSTEM TROUBLE ANALYSIS FOR THE STEERING SYSTEM PROBLEM

CAUSE

CORRECTION

STEERING CYLINDER Action of cylinders 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.

Excessive lost motion at cylinder.

Damaged relief valve in steering control unit.

Remove and replace relief valve, or unit, as needed.

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 end.

Remove cylinder, repair or replace as needed.

CAUSE

CORRECTION

PROBLEM

CHARGE/STEERING/ VIBRATION PUMP NO flow from pump.

LOW flow from pump.

10-20

Low oil level in hydraulic oil reservoir.

Add oil as needed. Find and correct cause of low oil level.

Pump flex drive plate has damage.

See Section 8 “Pump Drive Plate Trouble Analysis”.

Gear pump has internal damage.

Remove pump and repair or replace as needed.

Low oil level in hydraulic oil reservoir.

Add oil as needed. Find and correct cause of low oil level.

Restricted inlet suction hose.

Drain hydraulic oil reservoir.

Remove, clean, or replace, hose.

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Section 10 STEERING SYSTEM TROUBLE ANALYSIS FOR THE STEERING SYSTEM PROBLEM

CAUSE

CORRECTION

CHARGE/STEERING/ VIBRATION PUMP LOW flow from pump [continued].

Pump makes noise.

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Air being drawn into hydraulic system.

Check connections. Tighten as needed.

Pump has internal leakage.

Remove pump. Disassemble, repair, or replace, as needed.

Pump NOT being supplied enough oil, due to low oil level.

Check oil level and add oil as needed. Find and correct cause of low oil level.

Restricted inlet suction hose.

Remove, clean, or replace, hose.

Pump has internal damage.

Remove, repair, or replace, pump as needed.

10-21

Section 10 STEERING SYSTEM NOTES

10-22

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Section 11 DRUM AND VIBRATION SYSTEM TABLE OF CONTENTS PAGE GENERAL INFORMATION ..................................................................................................................... 11-2 COMPONENTS OF THE SYSTEM ......................................................................................................... 11-2 DRUM AND VIBRATION ......................................................................................................................... 11-2 BASIC OPERATION ................................................................................................................................ 11-3 REMOVING AND INSTALLING THE DRUM .......................................................................................... 11-4 EXCHANGING THE RUBBER BUFFERS .............................................................................................. 11-6 LEFT HAND RUBBER BUFFERS ....................................................................................................... 11-6 RIGHT HAND RUBBER BUFFERS ..................................................................................................... 11-6 REPAIRING THE DRUM ......................................................................................................................... 11-7 EXCHANGING THE VIBRATION MOTOR ............................................................................................. 11-9 GENERAL NOTES FOR REPAIRS .................................................................................................... 11-11 REPAIRING THE VIBRATION MOTOR ............................................................................................. 11-12 VIBRATION CIRCUIT FLUSHING ......................................................................................................... 11-14 INSTALLING THE FLUSHING SYSTEM ............................................................................................ 11-15 FLUSHING THE LINES FOR THE VIBRATION CIRCUIT ................................................................. 11-16 FLUSHING THE VIBRATION MOTOR ............................................................................................... 11-16 FUNCTIONAL CHECK ....................................................................................................................... 11-16 MAINTENANCE OF THE FLUSHING FILTER ................................................................................... 11-17 CHECKING THE VIBRATOR SHAFT SPEED ...................................................................................... 11-17 CHECKING THE CHARGING/STEERING/VIBRATION PUMP PRESSURE ....................................... 11-17 CHECKING THE VIBRATION PUMP HIGH PRESSURE ..................................................................... 11-18 CHECKING THE VIBRATION VALVE .................................................................................................. 11-18 TROUBLE ANALYSIS FOR THE DRUM AND VIBRATION SYSTEMS .............................................. 11-19

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11-1

Section 11 DRUM AND VIBRATION SYSTEM GENERAL INFORMATION.

COMPONENTS OF THE SYSTEMS.

THIS section describes the major COMPONENTS and the basic OPERATION of the drum and vibration systems used on the Model BW124D, BW124PD and BW124PDB Rollers.

DRUM AND VIBRATION [See Figures 1 and 2].

PROCEDURES for removal, disassembly, inspection, assembly and installation, of these components are also given, or indicated where to be found, in THIS section.

TROUBLE ANALYSIS, if it applies, is given at the END of THIS section.

The single front mounted drum and the vibration system it contains, has the following major components: 1. Drum weldment, smooth [BW124D] or footed [BW124PD and BW124PDB] - complete.

2. Left and right rubber buffers.

FIGURE 1. VIBRATION SYSTEM - HYDRAULIC SCHEMATIC.

11-2

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Section 11 DRUM AND VIBRATION SYSTEM 3. Charge/steering/vibrator gear pump assembly.

4. Vibrator gear motor.

5. Electrical solenoid moved spool in “control valve”.

6. Vibration control valve.

7. System control switch [See Section 7 - ELECTRICAL].

8. Hydraulic oil reservoir [SAME supply as for ALL hydraulic systems].

9. Drum drive motor assembly [See Section 8 TRANSMISSION SYSTEM].

BASIC OPERATION [See Figure 1].

The drum carries the front machine weight. It also serves to transmit the vibratory forces generated by the vibration mechanism, inside the drum, to the work surface being compacted.

The same vibratory forces are kept from being transmitted into the frame sides through the use of the left and right rubber buffers.

The drum assembly is mounted between the two [2] side frames and uses a total of eight [8 ] rubber buffers, the drum drive motor mount console and the bearing housing on the right side and four [4] rubber buffers and two stand off consoles, on the left side.

The drum weight is carried by the outer bearing at the outer end of the vibration mechanism and the idler assembly and the drum drive motor.

The vibration system supplies the vibratory forces the machine uses for vibratory compaction of the work surface through the use of BOTH hydraulic and mechanical methods.

The hydraulic charge/steering/vibrator pump is driven by the engine. The pump charges the transmission pumps with oil and supplies the steering and vibratory systems with oil flow.

The oil is directed from the pump to the vibration system control valve.

Putting the vibration system “start/stop” travel control mounted push button switch in the “START” position, will electrically energize the vibration system solenoid, found on the vibration system control valve [see Section 7 - ELECTRICAL].

The electrical solenoid moves the spool valve to the open [FLOW] position.

Oil from the hydraulic pump is now permitted to flow to the hydraulic gear motor, which drives the vibration mechanism.

The flow of oil turns the internal gears of the motor and the output shaft at the end of the motor. The hydraulic gear motor output shaft is used to turn the mechanical weight found in the vibration mechanism.

The hydraulic oil returning from the hydraulic gear motor flows back to the hydraulic oil reservoir.

NOTE: The vibration system “ON” pressure relief valve, found on the vibratory system control valve is adjustable. Check and adjust, if needed, using the procedures found in THIS section. The “ON” relief valve will function if the pressure in the system reaches a pressure MORE than the MAXIMUM pressure it is set to permit DURING system start-up, and/or during operation.

When the vibration system is in the “STOP”, or “OFF”, condition, NO electrical current is directed to the vibration system electrical solenoid, found on the “control valve”, and the spool valve remains in the closed [NO flow] position.

Oil flow from the charge/steering/vibrator systems pump will be directed back to the hydraulic oil reservoir.

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11-3

Section 11 DRUM AND VIBRATION SYSTEM REMOVING AND INSTALLING THE DRUM.

CAUTION: Remove the COMPLETE drum assembly ONLY after making sure a COMPLETE inspection and evaluation indicates it is necessary.

NOTE: Installation Weight: 500 kg.

1. Attach lifting tackle to the front of the front frame and lift the front frame up until the rubber buffers are relieved (Fig. 1 ). Weight approx. 150 kg.

2. Unscrew the mounting screws of the bridge (Fig. 1/2) for the hydraulic oil hoses on the left and right.

3. Remove the mounting screws (Fig. 1/1 ) from the front frame.

4. Carefully lower the front frame onto the ground and remove the intermediate plates.

NOTE: For installation, the same number of intermediate plates must be fitted as were removed; screw an M12x40 bolt into the centre threaded bore in the console.

Press down the console until the intermediate plate can be inserted (Fig. 2).

Unscrew the bolt again. If the drum has been exchanged, determine the thickness of the intermediate plates again; to do so, screw the right hand side of the engine console to the front frame.

Measure the distance between the front frame and the console on the left hand side (Fig. 3).

The distance measured corresponds to the thickness of the intermediate plates.

Thicknesses of 1 mm and 2 mm are available.

Always round the thickness upwards; if, for example, the distance measured is 1.5 mm, insert an intermediate plate of 2 mm.

DANGER: Keep away from below the front frame when It is being lowered.

FIGURE 2.

FIGURE 1.

FIGURE 3.

11-4

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Section 11 DRUM AND VIBRATION SYSTEM 5. Remove the mounting screws (Fig. 4/2) from the vibration motor cover (Fig. 4/1); remove the motor cover with attached vibration motor from the bearing cover and place it to one side.

7. Unscrew the cap nuts (Fig. 6) of the hydraulic oil hoses from the connections on the drum motor and immediately plug the connections and hydraulic oil hoses.

CAUTION: Collect the hydraulic oil and dispose of it so as to prevent pollution.

NOTE: For installation, check the condition of the O-rings in the hydraulic oil hose connections and insert new ones if necessary.

FIGURE 4.

6. Pull the coupling sleeve (Fig. 5) from the coupling pinion.

NOTE: For installation, check the toothing of the coupling sleeve for wear and use a new sleeve, if necessary.

FIGURE 6.

8. Attach lifting tackle to the right hand and left hand sides of the drum (Fig. 7) and lift it out of the front frame.

NOTE: Weight approx. 500 kg.

FIGURE 5.

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DANGER: Do NOT stand under the drum when it Is being lifted. When the drum has been lowered, secure it to prevent It rolling away.

11-5

Section 11 DRUM AND VIBRATION SYSTEM 3. Unscrew the rubber buffers from the bearing cover using the mounting jig (Fig. 2).

NOTE: For installation, torque the rubber buffers to 165 Nm.

FIGURE 7.

EXCHANGING THE RUBBER BUFFERS. Tools: Mounting jig No. 007 130 02.

FIGURE 2.

LEFT HAND RUBBER BUFFERS. RIGHT HAND RUBBER BUFFERS. 1. Lower the front frame (see “Removing The Drum “ in this section).

2. Remove the mounting screws (Fig. 1/2) of the console (Fig. 1/1) from the rubber bluffers and remove the console.

4. Remove the drum motor, see SECTION 8 TRANSMISSION. 5. Unscrew the rubber buffers from the drum using the mounting jig (Fig. 3).

NOTE: For installation, torque the rubber buffers to 165 Nm.

FIGURE 1.

FIGURE 3.

11-6

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Section 11 DRUM AND VIBRATION SYSTEM REPAIRING THE DRUM. Tools: Puller No. 007 130 04.

1. Remove the drum, see THIS section.

2. Stand the drum vertically, so that the left-hand side (vibration motor) is at the top.

3. Unscrew the mounting screws (Fig. 1/16) of the bearing supporting ring (Fig. 1/19) and remove them.

4. Pull the coupling sleeve (Fig. 1/22) from the coupling.

NOTE: For installation, check the toothing of the coupling sleeve for wear and fit a new sleeve if necessary.

NOTE: For installation, with the toothing facing upwards, drive the coupling half (Fig. 1/21) onto the vibrator shaft until the final stop.

Measure the vibrator shaft clearance; to do so, measure and note from the top edge of the bearing housing (Fig. 1/5) to the top edge of the coupling half, dimension ‘“a’” e.g. 19.7 mm.

Screw an eye bolt into the vibrator shaft and pull the vibrator shaft upwards until the final stop.

Remeasure and note the distance from the top edge of the bearing housing (Fig. 1/5) to the top edge of the coupling half, dimension “b” e.g. 18.2 mm. Deduct dimension “b”’ from “a”.

19.7 mm - 18.2 mm 1.5 mm = vibrator shaft clearance.

The clearance must be 0.6 - 1.8 mm.

5. Pull the bearing cover (Fig. 1/15) from the bearing housing.

6. Remove the ball bearing (Fig. 1/13) and Nilos ring (Fig. 1/14) from the bearing cover.

NOTE: For installation, fit the Nilos ring with the convex side facing downwards. Drive in a new ball bearing, as far as it will go, and fill by up to 1/3 with lithium-soaped high pressure grease.

7. Remove the spacer ring (Fig. 1/18).

NOTE: For installation, fit the spacer ring with the flat side facing downwards.

8. Attach the puller to the inner coupling half (Fig. 1/21 ) and pull the latter from the vibrator shaft.

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11-7

Section 11 DRUM AND VIBRATION SYSTEM

1 Cylinder roller bearing 2 Allen screw 3 Washer 4 Circlip (inner) 5 Bearing housing 6 Threaded pin 7 Drum 8 Nilos ring 9 Supporting disc 10 Fitting key 11 Spacer ring 12 Vibrator shaft 13 Grooved ball bearing 14 Nilos ring 15 Bearing cover 16 Allen screw 17 Washer 18 Spacer ring 19 Ring 20 Allen screw 21 Coupling 22 Coupling sleeve 23 Bearing housing 24 Allen screw 25 Motor cover

17

6

23

24

1

4 11

8

9 12 10

7 9 8 11 4 15 14

16

13 19

22

15 3 2 18

21

20 25

FIGURE 1.

9. Unscrew the mounting screws (Fig. 1/2) from the bearing housing.

10. Use pulling screws to press the bearing housing (Fig. 1/5) off the drum and lift it out.

11. Remove the circlip (Fig. 1/4) from the groove in the bearing housing.

12. Pull the roller bearing (Fig. 1/1) out of the bearing housing.

NOTE: For installation, drive in a new roller bearing until the final stop and fill by up to 1/3 with lithium-soaped high-pressure grease.

NOTE: For installation, the whole of the circlip must lie in the groove.

11-8

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Section 11 DRUM AND VIBRATION SYSTEM 13. Screw an eye bolt into the vibrator shaft (Fig. 1/12) and pull the latter out of the drum.

NOTE: For installation, carefully insert the vibrator shaft into the lower roller bearing.

14. Remove the fitting key (Fig. 1/10) from the groove.

15. Pull off the inner race of the bearing on both sides of the vibrator shaft (Fig. 1/12) and remove the spacers, Nilos rings and supporting discs.

NOTE: For installation, before screwing in the threaded pins, coat the threads with Hylomar.

21. Screw the pulling screws into the bearing housing and thereby press out the roller bearing.

NOTE: For installation, fit a new roller bearing, drive it in until the final stop and fill by up to 1/3 with lithium soaped high pressure grease.

EXCHANGING THE VIBRATION MOTOR. NOTE: For installation, perform the following operations on both sides of the vibrator shaft in the same way. Slide the supporting disc (Fig. 1/9) onto the shaft.

Slide on the Nilos ring (Fig. 1/8) so that the angled collar faces outwards.

Slide the spacer ring onto the shaft.

Heat the inner race of the bearing up to around 80 ˚C and, with the collar first, slide it on until the final stop.

1. Unscrew the mounting screws (Fig. 1/3) from the bridge (Fig. 1/1) for the hydraulic oil hoses (Fig. 1/2) and remove the bridge.

16. Lay the drum horizontally and secure it from rolling away.

17. Unscrew the mounting screws (Fig. 1/24) from the bearing housing (Fig. 1/23).

18. Use pulling screws to press the bearing housing off the drum and remove it.

19. Remove the circlip (Fig. 1/4) from the groove in the bearing housing.

NOTE: For installation, the whole of the circlip must lie in the groove.

FIGURE 1.

2. Unscrew the mounting screws (Fig. 2/2) from the motor cover (Fig. 2/1 ).

3. Pull off the motor cover with attached vibration motor.

20. Unscrew the threaded pins (Fig. 1/6) from the bearing housing.

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11-9

Section 11 DRUM AND VIBRATION SYSTEM

FIGURE 2.

4. Check the toothing (Fig. 3) of the coupling sleeve for wear and exchange the sleeve if necessary.

FIGURE 3.

5. Unscrew the cap nuts (Fig. 4) of the hydraulic oil hoses from the connection sockets.

FIGURE 4.

6 To exchange the vibration motor, unscrew the nut (Fig. 5/1 ) in front of the coupling pinion (Fig. 5/2) and pull off the latter.

FIGURE 5.

7. Unscrew the mounting screws (Fig. 6) from the motor cover and remove the latter.

CAUTION: Collect the hydraulic oil and dispose of it so as to prevent pollutlon.

11-10

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Section 11 DRUM AND VIBRATION SYSTEM

FIGURE 6.

FIGURE 1.

8. Unscrew the mounting screws (Fig. 7/1 ) from the angular flange sockets (Fig. 7/2) and remove the latter.

2. Renew all seals and gaskets (Fig. 2).

NOTE: For installation, fit a new O-ring (Fig. 7/3) into the groove of the respective angular flange socket.

FIGURE 2.

FIGURE 7.

GENERAL NOTES FOR REPAIRS.

CAUTION: Observe the following notes when repairing hydraulic components.

1. Close all openings on hydraulic components (Fig. 1).

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11-11

Section 11 DRUM AND VIBRATION SYSTEM 3. Examine all sealing and sliding surfaces for signs of wear (Fig. 3).

2. Mark both covers (Fig. 1/3 and 7) relative to the motor housing and unscrew the mounting screws (Fig. 1/14).

NOTE: For Installation, Align the cover on the drive side to the centering plate and tighten both mounting screws.

3. Remove both covers.

4. Remove the seal rings (Fig. 1/10), supporting rings (Fig. 1/8) and seal rings (Fig. 1/6) from the housing (Fig. 1/2).

FIGURE 3.

4. Fill hydraulic components with hydraulic oil before commissioning (Fig. 4).

NOTE: For Installation, Fit new seal rings (Fig. 1/10) into the grooves of the motor housing.

Insert new seal rings (Fig. 1/6) into the grooves of the motor housing.

Fit supporting rings (Fig. 1/8) onto the inserted seal rings (Fig. 1/6) with the smooth surface facing upwards.

5. Pull the gear wheels (Fig. 1/11 and 12) out of the bearing bushes.

NOTE: For Installation, Check the condition of the tooth profiles and running faces and exchange the gear wheels if necessary.

HYDRAULIC 0IL

6. Check the condition of the running face of the bearing bushes (Fig. 1/19) and exchange the bearing bushes if necessary.

FIGURE 4.

REPAIRING THE VIBRATION MOTOR.

7. Remove the circlip (Fig. 1/5) from the groove of the cover (Fig, 1/3). Press out the radial seal (Fig. 1/4).

Special Tools: Centering plate.

1. Remove the vibration motor, see THIS section.

11-12

NOTE: For installation, grease a new radial seal and press it in with the sealing lip facing outwards.

If needed, exchange/repair the charge/ steering/vibration pump assembly, see Section 10 - STEERING.

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Section 11 DRUM AND VIBRATION SYSTEM

7 1 14 1 Protection cap 2 Pump housing 3 Housing cover 4 Radial seal 5 Circlip (inner) 6 Seal ring 7 Housing cover 8 Supporting ring 9 Pin 10 Seal ring 11 Gear wheel 12 Gear wheel 13 Spring washer 14 Allen screw 15 Woodruff key 16 Spring washer 9 17 Hexagon nut 18 Protection cap 19 Bearing bush

13 2

18

10 8 6

19

18 12 15 19

19

3 11

4

9

5 19

6

16 17

8 10

FIGURE 1.

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11-13

Section 11 DRUM AND VIBRATION SYSTEM Before flushing:

VIBRATION CIRCUIT FLUSHING (see Fig. 1).

CAUTION: Always flush the open circuit after changing a unit. Otherwise particles remaining In the circuit will quickly lead to further unit failure.

1. Exchange the hydraulic oil filter.

2. Clean the hydraulic oil tank.

3. Filter the hydraulic oil.

With strong oil contamination (scurf):

NOTE: Use the flushing unit to filter the oil.

Pump the contents of the tank through a 61J filter into the oil bag, or a container.

Also fit the filter unit when filling.

1. Open and clean the remaining units.

2. Exchange the high pressure hoses.

CAUTION: Change oil if there is strong contamination if oil is discolored if oil change intervals are almost reached.

CAUTION: Collect the hydraulic oil and dispose of It so as to prevent pollution.

1 Steering unit 2 Vibration pump 3 Reducer 16S/15L 4 Flushing hose 5 Reducer 25S/16S 6 Reducer 25S/15L 7 Filter 8 Connection piece 15L 9 Vibration motor 10 Vibration control valve

1

2

3

8 4

4 9 8 10 6

5 7

FIGURE 1.

11-14

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Section 11 DRUM AND VIBRATION SYSTEM Filter installation (see Fig. 1): 1. Filter input “IN” with flushing hose at vibration pump output.

2. Filter output “OUT” with hose to the vibration valve.

INSTALLING THE FLUSHING SYSTEM. 1. Detach the engine hood, battery (Fig. 1/1) and retaining plate (Fig. 1/2). Remove the hydraulic oil tank cover (Fig. 1/3) and pour the contents of the hydraulic oil tank, with filter unit, into a clean container, or oil bag.

CAUTION: Collect the hydraulic oil and dispose of it so as to prevent pollutlon.

FIGURE 2.

4. Unscrew the hose (Fig. 3/1 ) from the vibration valve.

2. Clean the hydraulic oil tank.

CAUTION: Before installing the flushing filter, check that the hoses and connections are clean, and clean them if necessary.

FIGURE 3.

5. Connect the hose (Fig. 3/1 ) with reducer to filter input “IN”.

6. Connect the flushing hose with reducer to the valve and the other end with reducer to filter output “OUT” (Fig. 4).

FIGURE 1.

3. Unscrew the high pressure hoses from the vibration motor (Fig. 2). Connect high pressure hoses to junction socket and plug the connections.

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11-15

Section 11 DRUM AND VIBRATION SYSTEM

FIGURE 4.

FLUSHING THE LINES FOR THE VIBRATION CIRCUIT. 1. Start the diesel engine and run it at maximum speed.

2. Switch on the vibration and flush for 15 minutes. During flushing, switch the vibration on, and off, at intervals of 30 seconds.

3. Shut down the diesel engine.

FIGURE 5..

5. Switch on the vibration and flush for 15 minutes. During flushing, switch the vibration on ‘and off at intervals of 30 seconds.

6. Shut down the diesel engine.

7. Refit the vibration motor.

FUNCTIONAL CHECK. 1. Check the hydraulic oil level in the tank and top up if necessary using the filter unit.

FLUSHING THE VIBRATION MOTOR. 1. Reconnect the high pressure hoses and leakage lines to the vibration motor.

CAUTION: Collect the hydraulic oil and dispose of it so as to prevent pollution.

2. Move the machine so that the drum is resting on a flexible base (used tires).

3. Switch on the vibration with the diesel engine running and check the vibration pressures and frequency.

4. Check all hydraulic connections for leaks (visual inspection).

2. Unscrew the mounting screws (Fig. 5/’2) from the motor cover (Fig. 5/1 ).

3. Pull the vibration motor out of the coupling.

4. Start the diesel engine and run it at maximum speed.

11-16

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Section 11 DRUM AND VIBRATION SYSTEM MAINTENANCE OF THE FLUSHING FILTER UNIT.

2. Start the diesel engine and set the throttle lever to max. speed.

1. Exchange the flushing filter element if the red control pin of the contamination indicator is pressed out.

3. Measure the speed; when doing so, rest the meter on your thumb (Fig. 2).

4. Switch on the vibration.

NOTE: Also possible with very cold oil.

2. Clean the hoses and connections and keep the flushing filter system in a protected place to prevent it being contaminated.

NOTE: Nominal value: min. 2280 vpm (38 Hz).

Measurement evaluation: If the nominal value is not reached, troubleshooting must be performed in accordance with the troubleshooting chart.

3. Exchange the filter cartridge of the filter unit if the red control pin of the contamination indicator is pressed out.

CHECKING THE VIBRATOR SHAFT SPEED. Tools: Vibration reed frequency meter.

CAUTION: Perform measurement at operating temperature of (40˚ C).

1. Drive the machine so that the drum rests on a flexible base (rubber tires) (Fig. 1 ).

FIGURE 2.

CHECKING THE CHARGING/STEERING AND VIBRATION PUMP PRESSURE. Tools: 600 bar pressure gauge, test hose CAUTION: Perform measurement at operating temperature (40˚ C).

1. Connect the 600 bar pressure gauge (Fig. 1) to the steering pressure test connection.

2. Move the throttle lever to stop position.

FIGURE 1.

3. Crank the diesel engine using the starter only (press engine shut-off); move the steering to the final stop.

DANGER: Do not stand In the machlne’s articulation area. Clearance closes.

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11-17

Section 11 DRUM AND VIBRATION SYSTEM 4. Read off the pressure gauge.

CHECKING THE VIBRATION VALVE. NOTE: Nominal value: 90 - 100 bar.

Measurement evaluation: If the nominal value is not reached, troubleshooting must be performed using the troubleshooting chart.

Tools: 600 bar pressure gauge, test hose.

CAUTION: Perform measurement at operating temperature (40˚ C).

1. Unscrew the high pressure hose (Fig. 1 ) from the vibration motor and seal with steel plugs.

FIGURE 1.

CHECKING THE VIBRATION PUMP HIGH PRESSURE.

FIGURE 1.

2. Connect the 600 bar pressure gauge (Fig. 2).

Tools: 600 bar pressure gauge, test hose

3. Crank the diesel engine using the starter only and switch on the vibration.

CAUTION: Perform measurement at operating temperature (40˚ C).

4. Read off the value on the pressure gauge (Fig. 2).

1. Move the drum onto rubber tires.

2. Connect the 600 bar pressure gauge (Fig. 1).

3. Run the diesel engine at max. speed.

NOTE: Nominal value: approx. 200 bar.

Measurement evaluation: If the nominal value is not reached, troubleshooting must be performed in accordance with the troubleshooting chart.

4. Switch on the vibration and read off the value on the pressure gauge.

NOTE: Nominal value: Starting pressure approx.

180 bar. Operating pressure approx. 60 bar (depends on ground below drum).

Measurement evaluation: If the nominal value is not reached, troubleshooting must be performed using the troubleshooting chart.

FIGURE 2.

11-18

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Section 11 DRUM AND VIBRATION SYSTEM TROUBLE ANALYSIS FOR THE DRUM AND VIBRATION SYSTEMS. PROBLEM

CAUSE

CORRECTION

DRUM AND VIBRATION NO drum vibration when system is in “on” condition.

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“START/STOP” push button switch damaged.

Remove and replace switch.

Electrical circuit has damage.

Inspect and check circuit.

Repair as needed [see Section 7].

Low oil level in hydraulic oil reservoir.

Add oil as needed. Find and correct cause of low oil level.

Charge/steering/vibration pump NOT being driven.

Check operation. Repair or replace as needed [see Section 10 ].

Charge/steering/vibration pump has internal damage.

Check operation. Remove, repair, or replace, as needed [see Section 10].

Low or no charge oil flow to or through “vibration valve”.

Check charge oil flow and pressure [see THIS section].

Check operation of electrical solenoid for vibration spool movement [see Section 7].

No oil flow from vibration valve to vibrator motor.

Check for oil flow. Remove, and replace valve as needed.

Oil supply hose[s] are in stopped condition.

Check hose[s] for stoppage.

Remove and clean or replace as needed.

Vibrator motor has internal damage.

Remove, repair, or replace, motor as needed.

Drive coupling, connecting vibrator motor to driven vibration mechanism, broken or has damage.

Remove and replace. Find, and correct, cause of breakage or damage.

Vibration mechanism has internal damage.

Remove, repair, or replace, and install as needed.

Low oil level in hydraulic oil reservoir.

Add oil as needed. Find and correct cause for low oil level.

11-19

Section 11 DRUM AND VIBRATION SYSTEM TROUBLE ANALYSIS FOR THE DRUM AND VIBRATION SYSTEMS. PROBLEM

CAUSE

CORRECTION

DRUM AND VIBRATION Drum vibration NOT to specification.

Vibration control valve has internal damage.

Remove, repair or replace control valve as needed.

Low oil flow from control valve to gear motor.

Check oil flow. Remove, repair, or replace, valve as needed.

Oil supply hose[s] are in a partially stopped condition.

Check hose[s] for stoppage.

Remove and clean, or replace, as needed.

Vibration gear motor has internal damage.

Remove, repair, or replace, motor as needed.

Vibration mechanism or bearings have damage.

Remove, repair, or replace, and install as needed.

Vibration from drum transmitting into machine frame.

Rubber buffers have damage.

Replace buffers, as needed.

Excessive drum movement between the frame sides.

Rubber buffers have damage.

Replace buffers, as needed.

GEAR PUMP

NO flow from pump.

LOW flow from pump.

11-20

Low oil level in hydraulic oil reservoir.

Add oil as needed. Find, and correct, cause of low oil level.

Pump drive gear has damage.

Remove pump and repair, or replace, as needed.

Gear pump has internal damage.

Remove pump and repair, or replace, as needed.

Low oil level in hydraulic oil reservoir.

Add oil as needed. Find, and correct, cause of low oil level.

Restricted inlet suction hose.

Drain hydraulic oil reservoir.

Remove, clean, or replace, hose.

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Section 11 DRUM AND VIBRATION SYSTEM TROUBLE ANALYSIS FOR THE DRUM AND VIBRATION SYSTEMS. PROBLEM

CAUSE

CORRECTION

GEAR PUMP LOW flow from pump [continued].

Air being drawn into hydraulic system.

Check all hose to fitting connections. Tighten as needed.

Pump has internal leakage.

Remove pump. Disassemble, repair, or replace, as needed.

Pump makes noise.

Pump NOT being supplied enough oil, due to low oil level.

Check oil level and add oil as needed. Find and correct cause of low oil level.

Restricted inlet suction hose.

Remove, clean, or replace, hose.

Pump has internal damage.

Remove, repair, or replace, pump as needed.

GEAR MOTOR NO output shaft rotation from gear motor.

LOW output shaft rotation speed from gear motor.

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NO flow from gear pump.

See “Gear Pump Trouble Analysis” in THIS Section.

No flow from vibration control valve to vibrator motor.

Check flow path. Remove, disassemble, repair, or replace, control valve as needed.

Oil supply hose[s] are in a stopped condition

Check hose[s] for stoppage.

Remove and clean, or replace, as needed.

Vibrator motor has internal damage.

Remove, repair, or replace, as needed.

LOW oil flow from the vibration pump.

See “Gear Pump Trouble analysis” in THIS Section.

LOW oil flow from vibration control valve to vibrator motor.

Check flow path. Remove, disassemble, repair or replace control valve as needed.

11-21

Section 11 DRUM AND VIBRATION SYSTEM TROUBLE ANALYSIS FOR THE DRUM AND VIBRATION SYSTEMS. PROBLEM

CAUSE

CORRECTION

GEAR MOTOR Oil supply hose[s] are in a partially stopped condition.

Check hose[s] for stoppage.

Remove and clean or replace as needed.

Vibrator motor has internal damage.

Remove, repair, or replace, as needed.

Vibrator “high pressure” relief valve can NOT be adjusted and/or will NOT keep relief pressure, as set.

Relief valve cartridge assembly damaged.

Remove and replace relief valve cartridge. Check and adjust relief pressure of valve as needed.

System pressure NOT Correct at system “start” and/or system “run”.

Vibrator relief valve NOT adjusted to correct pressure.

Check and adjust high pressure relief setting as needed.

LOW output shaft rotation speed from gear motor [continued].

SCRAPERS Drum NOT being cleaned correctly by front and/or rear scraper.

Scraper support and/or scraper loose due to loss of mounting capscrews, or not adjusted correctly.

Replace mounting capscrews as needed. Adjust scraper to drum face as required and tighten mounting capscrews to correct torques [see Section 4].

Scrapers hit drum face in one area as it rotates.

Scrapers are damaged, or are NOT adjusted correctly.

Inspect scrapers for damage.

Remove, repair or replace as needed. Adjust scraper to drum face as required and tighten mounting capscrews to correct torques [see Section 4].

11-22

6/96

Section 12 CONTROL SYSTEMS

TABLE OF CONTENTS

PAGE GENERAL INFORMATION ...................................................................................................................... 12-2 GENERAL DESCRIPTION - GOVERNOR CONTROL ........................................................................... 12-2 SYSTEM COMPONENTS ..................................................................................................................... 12-2 OPERATION ......................................................................................................................................... 12-2 GOVERNOR CONTROL CABLE ASSEMBLY REMOVAL AND REPLACEMENT............................. 12-4 GOVERNOR CONTROL CABLE TRAVEL ADJUSTMENT ................................................................ 12-4 GENERAL DESCRIPTION - TRAVEL CONTROL ................................................................................. 12-5 SYSTEM COMPONENTS ..................................................................................................................... 12-5 OPERATION ......................................................................................................................................... 12-5 TRAVEL CONTROL CABLE ASSEMBLY REMOVAL AND REPLACEMENT.................................... 12-5 TRAVEL CONTROL CABLE MOVEMENT ADJUSTMENT ................................................................ 12-7 TROUBLE ANALYSIS FOR THE CONTROL SYSTEMS ....................................................................... 12-9

6/96

12-1

Section 12 CONTROL SYSTEMS GENERAL INFORMATION.

OPERATION [See Fig. 1].

THIS section contains information about the governor control [engine throttle speed] and travel [transmission system] control [F-N-R] used on the Model BW124D, BW124PD and BW124PDB Rollers.

The engine governor control lever is found to the right hand side of the operator's seat. The lever mechanically moves the governor control cable wire, inside the control cable outer casing.

THIS section also includes procedures for the removal and replacement of the control cables and the adjustments which can be required after such replacements.

Trouble analysis for the systems is found at the rear of THIS section.

The control cable wire is fastened to the movement arm of the lever assembly by the ball anchor. The outer casing of the control cable assembly is held in an adjusted position by the hex nut on the cable and is tightened against the throttle housing.

The other end of the governor control cable is hooked, through the extension spring, to the actuation arm of the engine governor mechanism.

GENERAL DESCRIPTION - GOVERNOR CONTROL [See Fig. 1].

The outer casing of the control cable assembly, at this end, is also held in an adjusted position by two [2] lock nuts on the cable, which tighten against the ball joint in the throttle bracket, on the engine.

The governor control system adjusts the engine speed from “LOW” to “HIGH” idle. It acts as a mechanical linkage between the engine governor control lever and the engine governor. The governor acts to control the speed of the engine.

Movement of the governor control lever moves the governor control cable wire inside of the outer governor control cable casing.

SYSTEM COMPONENTS [See Fig. 1].

The following MAJOR components are used in the governor control system: a. Governor control lever and mounting hardware. b. Governor control cable assembly, including extension spring, jam nuts and hardware.

The control cable wire moves the extension spring, which moves the governor actuation arm. The arm moves the internal components of the governor. At high idle, the governor keeps the engine at the “HIGH” idle speed, selected by the operator, until a load is placed upon the engine.

When load is placed upon the engine, the governor will permit the engine speed to drop a maximum manufacturer determined percent “full” load condition. When engine load is decreased, the governor will then permit the engine speed to increase back to the high idle speed, again.

c. Engine governor control cable mounting bracket. d. Miscellaneous tie straps, plates and hardware.

When the engine is being slowed to the “LOW” idle speed the control cable inside the outer governor control cable assembly casing is moved and stops pull on the extension spring.

The lack of pull allows the governor actuation arm and internal governor components to return to the “LOW” idle speed position, again, through internal governor spring tension.

12-2

6/96

Section 12 CONTROL SYSTEMS

GOVERNOR CONTROL CABLE ASSEMBLY

SAFETY NUT PLUG

DISC

HOUSING

HEX NUT WIRE

SPRING WASHER HEX BOLT TAPPET

HEX NUT

LEVER ARM

EYE BOLT ROCKER ARM (REF.) HEX NUT

SPRING

SHAFT BOOT

TIE

BRACKET

HEX NUT (2 PLCS.) WASHER (2 PLCS.) BUSHING

HEX NUT

HEX BOLT (2 PLCS.) CABLE ASSEMBLY

FIGURE 1. ENGINE GOVERNOR CONTROL SYSTEM .

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12-3

Section 12 CONTROL SYSTEMS GOVERNOR CONTROL CABLE ASSEMBLY REMOVAL AND REPLACEMENT [See FIG. 1].

GOVERNOR CONTROL CABLE TRAVEL ADJUSTMENT [See Fig. 1].

Use the following procedures to remove and replace the governor control cable assembly with new:

Use the following procedures to adjust the amount of the governor control cable wire travel between the control lever and the engine governor.

a. STOP the engine. Go to the engine governor area. Unhook and remove the extension spring from the governor control eyebolt on the governor actuation arm. Loosen the two [2] lock nuts that hold the control cable casing against the ball joint at the throttle bracket. Move the control cable wire and casing assembly away from the governor actuation arm and throttle bracket. b. Go to the throttle control lever area. Loosen the cable to throttle control housing hex nut. c. Remove the nut, and disc, from the bolt which fastens the tappet into the throttle control housing. d. Move the tappet outward and clear of the housing. Lift the control wire ball from its seat in the tappet. Move the control cable wire and casing assembly away from the lever arm and mounting bracket.

a. STOP the engine. Check to be sure the control cable assembly casing is fully anchored at the governor control LEVER end by the lock nut being tightened against the housing. b. Go to the engine governor area. Hook the extension spring into the governor control eyebolt on the governor actuation arm, so that the spring is NOT bound and swivels freely. Put the governor control lever in the LOW idle position. c. Loosen both hex nuts, on the throttle cable, that holds the cable housing in the adjusted position against the ball joint in the throttle bracket. Turn the hex nuts inward, or outward and adjust the cable, so that the extension spring does NOT have any pull (tension) on it with the hook end of the extension spring hooked in the hole in the control eyebolt, on the engine governor throttle lever arm.

e. Loosen all cable clamps and tie straps that hold the cable and casing to the machine frame and/or other cables or hoses. Carefully remove the COMPLETE governor control cable and casing assembly from the machine.

d. Tighten both hex nuts, on the throttle cable, against the ball joint in the throttle bracket. Note that the engine governor control lever is contacting the LOW idle stop screw.

f. Remove the extension spring and all jam and lock nuts from the control cable assembly, just taken from the machine.

CAUTION: Be SURE the governor control lever does NOT move while doing step “c and d”.

g. Install the extension spring, all jam and lock nuts onto the NEW control cable assembly. Carefully install the NEW governor control cable and casing assembly into the machine in the SAME position at which the original cable assembly was in when removed. Replace ALL cable ties with NEW and install and tighten all cable clamps, if used. h. Finish installation and adjust the governor control cable travel using the procedures given in THIS section, as needed.

e. Put the governor control lever in the HIGH idle position. Note that the engine governor control lever contacts the HIGH idle stop screw. f. Start the engine and check the engine governor control system for CORRECT operation from “LOW” to “HIGH” engine idle speed and back to “LOW” engine idle speed by moving the governor control lever.

WARNING: Keep the HANDS and CLOTHING CLEAR of the engine at ALL times.

12-4

6/96

Section 12 CONTROL SYSTEMS GENERAL DESCRIPTION - TRAVEL CONTROL [See Fig. 1].

The transmission control system permits the selection, and control, of direction [F-N-R] and speed, up to maximum, of machine travel. It acts as a mechanical linkage between the travel control lever and the transmission pumps.

SYSTEM COMPONENTS [See Fig. 1].

The following MAJOR components are used in the travel control system: a. Travel control lever, [F-N-R] assembly and mounting hardware. b. Travel control cable assembly with adjustable ball joint, with lock nut on ends.

Movement of the travel control [F-N-R] lever moves the control cable wire inside of the outer cable casing.

The control cable wire moves the second transmission pump actuation arm from the center [NEUTRAL] position to the forward, or reverse, travel position. Further control lever movement, in forward or reverse, increases machine travel speed up to maximum.

The first transmission pump actuation arm is moved exactly the SAME amount, from the center [NEUTRAL] position to the forward, or reverse, travel position by a linkage assembly, having ball joints and a threaded link rod.

This linkage arrangement connects the first and second transmission pump actuation arms and controls equal pump stroking, in either travel direction.

c. Control cable mounting brackets. d. Miscellaneous tie straps and related hardwares.

OPERATION [See Fig. 1].

The travel control lever [F-N-R] is found to the right hand side of the operator's seat. The lever mechanically moves the travel control cable wire, inside the control cable outer casing.

The control cable wire is fastened to the movement arm of the lever assembly by the angular joint and safety nut. The outer casing of the control cable assembly is held in an adjusted position by the two [2] hex nuts on the cable, tightened against the ball joint at the mounting bracket.

The other end of the control cable is fastened to the actuation arm of the second transmission pump assembly by the clevis and pin.

The outer casing of the control cable assembly, at this end, is held in an adjusted position by two [2] hex nuts on the cable, tightened against the ball joint in the first transmission pump mounting bracket.

6/96

TRAVEL CONTROL CABLE ASSEMBLY REMOVAL AND REPLACEMENT [See FIG. 1].

Use the following procedures to remove and replace the travel control cable assembly with new: a. STOP the engine. Go to the area of the transmission pumps. Remove the capscrew and nut, from through the ball joint and the second transmission pump actuation arm. Move the ball joint away from the arm. b. Loosen the two [2] jam nuts, on the direction control cable, at the mount bracket on the first transmission pump. Move the control cable assembly away from the mount bracket. c. Go to the travel control lever area. Lift the hinged seat and access panel. Remove the tie strap holding the small electrical wire assembly to the travel control cable. d. Go to the lower side of the travel control assembly. Loosen the cable housing to pipe joint lock nut.

12-5

Section 12 CONTROL SYSTEMS

TRAVEL CONTROL ASSEMBLY

CABLE ACTUATION RACK PIPE JOINT LOCK NUT

JAM NUT DISCS

LOCK NUT JAM NUT

JAM NUT CONTROL CABLE ASSEMBLY

BALL JOINT ASSEMBLY

NUT DISC DISC CAPSCREW

FIGURE 1. TRAVEL CONTROL SYSTEM.

12-6

6/96

Section 12 CONTROL SYSTEMS e. Use the hands to turn the complete control cable assembly counterclockwise until the assembly is free to be removed from the travel control assembly. Move the control cable assembly away from the travel control assembly and from the machine.

m. Put the small electrical wire assembly in position against the travel control cable and install a new tie strap. Adjust the travel control cable, using the procedures given in THIS section, as needed.

NOTE: Turning the control cable assembly releases the threaded cable from the cable actuation rack, inside the travel control assembly.

TRAVEL CONTROL CABLE MOVEMENT ADJUSTMENT [See Fig. 1].

f. Measure and write down the position of the hex hut found on the threaded end of the cable which was installed into the cable actuation rack. Measure and write down the position of the ball joint assembly on the threaded end of the cable which connects to the second transmission pump actuation arm. g. Remove the nut, ball joint assembly, and all lock nuts and discs from the control cable assembly just taken from the machine. h. Install the discs, lock nuts, ball joint assembly and nut onto the NEW control cable assembly at the SAME positions noted in step "f". i. Carefully install the threaded end of the NEW control cable assembly into the travel control assembly. j. Use the hands to turn the complete control cable assembly clockwise, until the nut on the threaded cable end is tightened against cable actuation rack, inside the travel control assembly. Tighten the cable housing to pipe joint lock nut securely. k. Put the control cable assembly into the mount bracket, on the first transmission pump assembly.

Tighten each jam nut against the discs and notched bracket.

NOTE: Put one [1] disc and one [1] jam nut on each side of the notched bracket.

l. Put the ball joint in position at the second transmission pump actuation arm. Install the capscrew through the ball joint and the actuation arm. Install nut onto the capscrew and securely tighten.

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Use the following procedures to adjust the amount of travel control cable wire movement between the control lever and the second transmission pump actuation arm. a. STOP the engine. Install the steering lock bar.

Lift the machine and support both the front [drum end] and the rear [tire end] clear of the floor with solid wood blocking.

DANGER: Block securely using SOLID wood blocking. Keep CLEAR of the machine while lifting, blocking and lowering the machine.

b. Go to the transmission pump area. Remove the capscrew and nut, from through the ball joint and the second transmission pump actuation arm. c. Go to the travel control lever area. Put the travel control lever in the exact NEUTRAL position. d. Go to the transmission pump area. Loosen the one [1] jam nut, on the cable assembly that is against the adjustable ball joint sleeve. Hold the ball joint in position directly above the second transmission pump lever arm. Turn the sleeve inward, or outward, a small amount, to position the center of the ball joint exactly EVEN with the center of the through hole in the pump actuation arm.

CAUTION: Be SURE the travel control lever does NOT move while doing step “d ”.

e. Tighten the one [1] jam nut against the adjustable ball joint sleeve, while holding the sleeve. Install the capscrew, from the top side, through the ball joint and the actuation arm. Install nut onto the capscrew and securely tighten.

12-7

Section 12 CONTROL SYSTEMS f. Go to the travel control lever and note that both transmission actuation arms move to the FULL stroked position when the travel control lever is moved from “NEUTRAL” to “FULL FORWARD” and from “NEUTRAL” to “FULL REVERSE” positions. g. Start the engine. Keep the travel control lever in the NEUTRAL position. Keep the engine throttle at LOW idle. Release the secondary/parking brake system. Note that NO drum, or tire, rotation occurs.

DANGER: Keep ALL personnel CLEAR of the machine, at ALL times, during the operation check.

h. Check the transmission control system for CORRECT operation from “NEUTRAL” to “FORWARD” and “NEUTRAL” to “REVERSE” control lever positions. i. STOP the engine. Lift the machine and remove the blocking from under both the front [drum end] and the rear [tire end] and lower the machine to the floor. Remove the steering lock bar.

DANGER: Keep CLEAR of the machine while lifting, removing blocking and lowering the machine.

NOTE: If the tire drum and tires rotated during step "g", repeat steps "b" through "g", again, until NO movement is noted.

12-8

6/96

Section 12 CONTROL SYSTEMS TROUBLE ANALYSIS FOR THE CONTROL SYSTEMS PROBLEM

CAUSE

CORRECTION

THROTTLE CONTROL SYSTEM Governor control Lever does NOT move governor.

Governor control lever moves governor, but NOT easily.

Engine high idle speed can NOT be reached.

Engine speed does NOT return to low idle, after being above low idle speed.

6/96

Cable not connected at lever or extension spring to engine governor eye bolt.

Correct where loose.

Control cable seized.

Remove control cable and replace NEW. Adjust as/if needed.

Control assembly seized.

Remove, free as needed, or replace with new, and install.

Engine governor assembly has internal damage.

Remove, repair, or replace, as needed.

Control cable partially seized in casing.

Remove and free, or replace with new, as needed.

Control assembly sticking

Remove lever, free as needed and install.

Engine governor has internal damage.

Remove and repair, or replace, as needed.

Governor control cable travel NOT adjusted correctly.

Adjust control cable travel using CORRECT procedures.

Governor stop not adjusted correctly.

Adjust governor stop using CORRECT procedures.

Engine governor has internal damage.

Remove and repair, or replace, as needed.

Engine has internal, or system damage.

Evaluate and repair as needed.

Governor control cable sticking.

Remove, free, or replace, as needed.

Governor control cable travel NOT adjusted correctly.

Adjust control cable travel using CORRECT procedures.

Engine governor has internal damage.

Remove, repair, or replace, as needed.

Engine has internal, or system, damage.

Evaluate and repair as needed.

12-9

Section 12 CONTROL SYSTEMS TROUBLE ANALYSIS FOR THE CONTROL SYSTEMS PROBLEM

CAUSE

CORRECTION

TRAVEL CONTROL SYSTEM Travel control lever does NOT move second transmission pump actuation arm.

Travel control lever moves second transmission pump actuation arm, but NOT easily.

Full forward and/or reverse position can NOT be reached.

Transmission pump[s] does NOT return to neutral, after being at full forward and/or reverse position.

12-10

Cable not connected at hand lever, or at transmission actuation arm.

Connect where not connected.

Control cable seized.

Remove control cable and replace with NEW. Adjust as needed.

Control assembly seized.

Remove, free as needed and install.

Displacement control assembly has internal damage (seized).

Remove and replace, with NEW.

Control cable partially seized in casing.

Remove and free, or replace, as needed.

Control assembly sticking

Remove lever, free as needed and install.

Transmission pump has internal damage.

Remove and repair, or replace, as needed.

Transmission control cable travel NOT adjusted correctly.

Adjust control cable travel using CORRECT procedures.

Transmission pump[s] Displacement control damaged.

Remove and replace control[s]. See Section 8 TRANSMISSION.

Transmission pump[s] has major internal damage.

Remove and replace pump[s].

See Section 8 - TRANSMISSION.

Travel control cable sticking.

Remove, free, or replace, as needed.

Travel control cable travel NOT adjusted correctly.

Adjust control cable travel using CORRECT procedures.

Transmission pump[s] displacement control damaged.

Remove and replace control[s]. See Section 8 TRANSMISSION.

Transmission pump[s] has major internal damage.

Remove and replace pump[s].

See Section 8 - TRANSMISSION. 6/96

Section 13 OPTIONAL EQUIPMENT TABLE OF CONTENTS PAGE GENERAL INFORMATION ...................................................................................................................... 13-2 LEVELING BLADE SYSTEM ...................................................................................................................13-2 DESCRIPTION ......................................................................................................................................... 13-2 SYSTEM ITEM DESCRIPTION AND OPERATION .................................................................................13-3 LEVELING BLADE SYSTEM HYDRAULIC PUMP.................................................................................. 13-3 LEVELING BLADE CONTROL VALVE ...................................................................................................13-3 LEVELING BLADE CYLINDER ............................................................................................................... 13-3 SYSTEM CONTROL FOOT PEDAL AND LINKAGE .............................................................................. 13-3 LEVELING BLADE CONTROL VALVE ...................................................................................................13-4 REMOVAL ............................................................................................................................................. 13-4 INSTALLATION .................................................................................................................................... 13-4 PRIORITY VALVE ................................................................................................................................... 13-5 REMOVALAND INSTALLATION ......................................................................................................... 13-5 LEVELING BLADE CYLINDER ............................................................................................................... 13-6 REMOVAL ............................................................................................................................................ 13-6 DISASSEMBLY .................................................................................................................................... 13-6 CLEANING AND INSPECTION ........................................................................................................... 13-7 ASSEMBLY .......................................................................................................................................... 13-8 INSTALLATION .....................................................................................................................................13-8 LEVELING BLADE SYSTEM RELIEF PRESSURE CHECK AND ADJUSTMENT................................. 13-8 LEVELING BLADE ASSEMBLY ........................................................................................................... 13-10 REMOVAL AND INSTALLATION ...................................................................................................... 13-10 REMOVAL ....................................................................................................................................... 13-10 INSTALLATION ............................................................................................................................... 13-10 LEVELING BLADE CONTROL FOOT PEDAL AND LINKAGE ........................................................... 13-12 LINKAGE CHECK AND ADJUSTMENT PROCEDURE .................................................................... 13-12 OPTIONAL LIGHTING SYSTEM ........................................................................................................... 13-13 CHECKS AND ADJUSTMENT ........................................................................................................... 13-14 TROUBLE ANALYSIS FOR THE LEVELING BLADE SYSTEM .......................................................... 13-15 6/96

13-1

Section 13 OPTIONAL EQUIPMENT GENERAL INFORMATION. THIS section contains a description and service information about the leveling blade system, used on the Model BW124PDB footed drum Roller, and optional operation lighting system available for the Model BW124D, BW124PD and BW124PDB Rollers.

The leveling blade system provides a method to move and level fill material as the machine is operated in either direction of travel.

The manual/hydraulic control system permits the leveling blade to be placed in one [1] of four [4] positions, which can be changed at any time during machine operation.

LEVELING BLADE SYSTEM. DESCRIPTION [Fig. 1].

The leveling blade system is standard on the Model BW124PDB footed drum Roller.

TO FILTER

TO STEERING UNIT

21 POS. 01 10 18 19 20 21

DESCRIPTION TANK ENGINE STEERING PUMP PRIORITY FLOW DIVIDER BLADE VALVE BLADE CYLINDER

19 M5 18

TO VIBRATION PUMP 10

20

13 TITLE M5

01

MAX. PRESSURE (BAR) 172 BLADE

OPTIONAL EQUIPMENT

FIGURE 1. OPTIONAL LEVELING BLADE SYSTEM - HYDRAULIC SCHEMATIC.

13-2

6/96

Section 13 OPTIONAL EQUIPMENT The FOUR [4] leveling blade positions are: 1. RAISE leveling blade.

0. HOLD leveling blade.

2. LOWER leveling blade.

3. FLOAT and LOCK leveling blade.

The leveling blade system contains the following MAJOR items which are used within the system: 1. One [1] FLOW REGULATOR VALVE assembly.

2. One [1] LEVELING BLADE CONTROL VALVE assembly.

The valve is supplied oil flow the flow regulator valve and has the control spool moved through the system foot pedal control, and linkage.

The valve will react to the movement of the foot pedal in any of the FOUR [4] positions. Oil flow is directed through the control valve when the foot pedal is placed in position 1, or 2. Oil flow is then directed to the leveling blade cylinder. The leveling blade cylinder rod then is moved by the flow of oil supplied through, and from, the control valve to the position selected by the operator moved foot pedal.

When NO leveling blade system oil flow needs are present, [position 0 and 3] oil flow supplied to the control valve is directed from the control valve to the steering control unit and back to the hydraulic oil reservoir.

3. One [1] LEVELING BLADE CYLINDER. 4. One [1] LEVELING BLADE assembly [contains blade weldment WITH bolt on blade edges].

5. One [1] system CONTROL FOOT PEDAL assembly [includes ALL brackets, rods, joints and related hardware].

LEVELING BLADE CYLINDER. The leveling blade cylinder is of the double acting type.

6. Miscellaneous ADDITIONAL ITEMS [hoses, fittings, frame brackets and related hardware].

When required, the cylinder is supplied oil flow from the “A” or “B” outlet ports of the leveling blade control valve.

SYSTEM ITEM DESCRIPTION AND OPERATION [See Fig. 1].

Oil returning from the cylinder is directed back to the leveling blade control valve. It then flows through the valve, to the steering control unit and back to the hydraulic oil reservoir.

LEVELING BLADE SYSTEM HYDRAULIC PUMP. The LEVELING BLADE system uses oil flow produced by the charging/steering/vibration pump assembly. System oil is routed from the pump assembly to, and then through, the flow regulator valve.

The machine steering system has "priority" for use of oil flow at any time both the steering and leveling blade systems are being used at the SAME time.

LEVELING BLADE CONTROL VALVE. The LEVELING BLADE CONTROL VALVE is a single spool, four [4] way, four [4] position valve with one [1] externally adjusted relief valve.

6/96

SYSTEM CONTROL FOOT PEDAL AND LINKAGE. The system control foot pedal, and linkage, contains the foot pedal, threaded rod, fork joint, link connector, mounting brackets, and miscellaneous hardware.

The assembly serves as a mechanical link between the foot pedal and the spool of the leveling blade control valve. Movement of the foot pedal is mechanically relayed to the control valve spool by the assembly. When the assembly is correctly adjusted, the movement of the spool is to the CORRECT position, so that the leveling blade will also be in the CORRECT position, and match the foot pedal position selected by the operator.

13-3

Section 13 OPTIONAL EQUIPMENT LEVELING BLADE CONTROL VALVE.

INSTALLATION [See Fig.1].

REMOVAL [See Fig. 1].

Use the following procedures to install the leveling blade control valve:

Use the following procedures to remove the leveling blade control valve for replacement:

WARNING: Be SURE the blade rests on the ground.

Do NOT service the blade system or components with the blade raised from the ground.

1. Lower the blade to the ground. Stop the engine.

Remove the access cover from the leveling blade control valve mounting area, inside the control panel riser. Wash the leveling blade control valve area, where the valve is mounted, and ALL hose connection fittings with steam, and dry using compressed air.

2. Remove cotter key from the cross pin connecting the link connector to control valve spool. Remove the connector from the spool end.

3. Put an identification tag on EACH hose and fitting. Remove All hoses from the leveling blade control valve. Put plugs in ALL hoses and put caps on ALL fittings.

4. Hold the valve in position. Loosen and remove all castle nuts and washers from the hex bolts that fasten the valve to the riser. Carefully move the valve away from the riser and out of the machine.

CAUTION: Do NOT permit the valve to fall while being removed.

1. Put the NEW leveling blade control valve in position inside the riser. Install the hex bolts. Install the washers and castle nuts onto the bolts and tighten the nuts securely.

2. Remove the cap from each fitting in the valve.

Remove the plug from each hose. Put each hose onto the correct control valve fitting as indicated by the identification tags put on the hoses and fittings during removal. Tighten the hose fittings securely onto the control valve fittings.

3. Align the holes in the link connector and valve spool. Install the cross pin through the holes in the link connector and valve spool. Put the cotter pin through the cross pin and bend.

4. Check the hydraulic oil level of the hydraulic oil reservoir. ADD oil IF needed [See Section 4 MAINTENANCE].

5. Follow ALL “pre-start” procedures given in Section 8 - TRANSMISSION SYSTEM. 6. Check, and if needed, adjust the leveling blade system relief pressure and/or valve actuation linkage, using the procedures given in THIS section.

7. Start the engine and check the system for CORRECT operation.

CAUTION: STOP the engine IMMEDIATELY if ANY system problem is noted and repair.

HOSE

BLADE CONTROL VALVE

NOTE: At this time, NO internal valve parts are serviced. Remove and replace the valve with NEW.

HEX BOLT (2 PLCS)

CASTLE NUT (2 PLCS) HOSE

WASHER (2 PLCS)

HOSE HOSE

HOSE

FIGURE 1.

13-4

6/96

Section 13 OPTIONAL EQUIPMENT PRIORITY VALVE.

Use the following procedures to remove and install the priority valve:

6. Put the priority valve and bracket assembly in position on the floor plate . Align the notched bracket slots with the through holes in the floor plate. Install the hex bolts from the top side. Install the washers and castle nuts onto the bolts and tighten the nuts securely.

WARNING: Be SURE the blade rests on the ground.

Do NOT service the blade system or components with the blade raised from the ground.

7. Remove the cap from each fitting in the valve.

Remove the plug from each hose. Put each hose onto the correct control valve fitting as indicated by the identification tags put on the hoses and fittings during removal. Tighten the hose fittings securely onto the control valve fittings.

REMOVAL AND INSTALLATION [See Fig. 1].

1. Lower the blade to the ground. Stop the engine.

Remove the access cover from the priority valve mounting area, inside the control panel riser. Wash the priority valve area, where the valve is mounted, and ALL hose connection fittings with steam, and air dry.

2. Put an identification tag on EACH hose and fitting. Remove both hoses from the priority valve.

Put plugs in both hoses and put caps on both fittings.

3. Hold the valve in position. Loosen and remove the castle nuts and washers from the hex bolts that fasten the valve mounting bracket to the floor plate .

Carefully move the valve and bracket away from the floor plate and out of the machine.

8. Install the access cover onto the control panel riser. Install the retaining capscrews and tighten securely.

9. Check the hydraulic oil level of the hydraulic oil reservoir. ADD oil IF needed [See Section 4 MAINTENANCE].

10. Follow ALL “pre-start” procedures given in Section 8 - TRANSMISSION SYSTEM. 12. Start the engine and check the steering and blade systems for CORRECT operation.

DANGER: Keep Clear of the rollers articulation area during the steering check.

Clearance in this area closes when the machine is turned to the right, or the left.

CAUTION: Do NOT permit the valve to fall while being removed.

4. Hold the bracket in a vise. Loosen and remove the castle nuts and washers from the hex bolts that fasten the valve to the mounting bracket. Move the valve away from the bracket.

CAUTION: STOP the engine IMMEDIATELY if ANY system problem is noted and repair.

HEX BOLT WASHER

HEX NUT WASHER

FLOW DIVIDER VALVE HOSE

HOSE

NOTE: NO internal valve parts are serviced.

Remove and replace the valve with NEW.

5. Hold the bracket in a vise. Put the NEW valve in position against the mounting bracket. Align the through holes in the valve and bracket. Install the hex bolts through the bracket and valve, from the outer side. Install the washers and the castle nuts onto the hex bolts and tighten securely.

6/96

BRACKET

FLOOR PLATE

HEX NUT

HEX BOLT

FIGURE 1.

13-5

Section 13 OPTIONAL EQUIPMENT LEVELING BLADE CYLINDER. REMOVAL [See Fig.1].

Use the following procedures to remove the blade cylinder for repair, or replacement.

PIN UPPER CYLINDER MOUNT ARM SPACER SPACER

1. Put the leveling blade "DOWN" onto the ground.

Stop the engine. Wash the leveling blade cylinder, hoses and the area where it connects with CLEAN diesel fuel and dry using compressed air.

WARNING: Be SURE the blade rests on the ground.

Do NOT service the blade system, or components, with the blade raised from the ground.

2. Put an identification tag on EACH hose and cylinder fitting. Loosen and remove the cylinder oil supply and return hose fitting at EACH cylinder fitting. Put a plug in EACH hose fitting end and a cap on EACH cylinder fitting.

3. Go to the upper cylinder mount arm. Remove one [1] cotter pin from the cylinder retaining pin.

Remove the cylinder retaining pin, spacers and washer from the cylinder and mount arm.

4. Go to the cylinder lower cylinder mount arm.

Remove one [1] cotter pin from the cylinder retaining pin. Remove the cylinder retaining pin, spacers and washer from the cylinder and the lower cylinder mount arm.

5. CAREFULLY remove the leveling blade cylinder from the machine.

WARNING: HOLD the cylinder SECURELY. Do NOT permit the cylinder to fall from the machine.

6. Inspect the spherical bushing in the upper and lower cylinder mount arms. If worn or damaged, remove the bushing[s] and replace with new.

HOSE WASHER

CYLINDER

COTTER PIN

PIN

LOWER CYLINDER MOUNT ARM

HOSE

SPACER SPACER

WASHER

COTTER PIN

FIGURE 1.

DISASSEMBLY [See Figure 1] .

1. Wash the cylinder with All purpose degreaser, part number 178297, and allow to air dry.

2. Put the cylinder in a vise, with the shell area held securely by the jaws. Put the cylinder rod in the extended position.

CAUTION: Do NOT crush the shell area of the cylinder.

3. Remove the two [2] capscrews that fasten the steel rod end cap to the packing gland assembly.

Remove the end cap from the cylinder shell and from against the packing gland assembly. Move the end cap downward on the cylinder rod.

4. Push the packing gland assembly inward. Use a plier, or a screw driver to carefully remove the packing gland retaining wire from the groove in the cylinder shell.

WARNING: Safety glasses must be worn during wire removal.

5. Carefully move the packing gland assembly outward from inside the cylinder shell and slide it downward on the cylinder rod.

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Section 13 OPTIONAL EQUIPMENT CLEANING AND INSPECTION [See Figure 1] .

1. Wash all cylinder parts with All purpose degreaser, part number 178297, and allow to air dry.

2. Inspect each part for wear or damage. Replace worn or damaged parts with new.

3. Inspect the gland assembly and the piston assembly for wear or damage. Replace either, or both, items if worn or damaged.

5. Inspect the inside of the cylinder shell for wear, nicks, burrs, scratches, rust or other damage.

Replace e the shell if worn or damaged.

6. Inspect the cylinder rod for wear or damage to the chrome surface. Replace the rod if worn or damaged, bent or if has a nicked, rusted, scratched or pitted chrome surface.

NOTE: Slight damage can be removed with fine sandpaper, or emery cloth.

FIGURE 1.

6. Pull on the cylinder rod and carefully remove the piston/rod assembly from the cylinder shell bore.

7. Put the cylinder rod end clevis in a vise and tighten the vise to hold the clevis securely.

8. Remove the large locknut on the piston.

9. Remove the piston from the cylinder rod.

Remove both piston seals from the piston. Remove the one [1] static seal from the groove in the cylinder rod.

CAUTION: Do NOT sand all chrome plating from the outside of the rod. If there is any doubt about chrome plating having been removed from the rod, check by applying copper sulfate to the .

The rod will discolor where chrome has been removed. If this condition is noted, replace the cylinder rod or complete cylinder assembly.

Wash the cylinder rod after the above damage repair has been done, and air dry the rod.

10. Move the packing gland assembly up the cylinder rod and off of the rod.

11. Remove the cylinder rod wiper from the inner bore of the gland assembly. Remove the rod sealing o-ring and back up ring from the inner bore of the gland assembly. Remove the gland to shell sealing o-ring and back up ring from the groove in the outer diameter of the gland assembly.

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13-7

Section 13 OPTIONAL EQUIPMENT ASSEMBLY [See Figure 1].

CAUTION: ALL cylinder parts MUST be very clean. The assembly area MUST be clean. Dirt , of any type, can cause damage to the cylinder and/or other hydraulic system components and repeat failure can occur.

1. Put CLEAN hydraulic oil on ALL cylinder parts.

Put the cylinder rod in a vise, with the clevis end through mounting holes between the vise jaws.

Tighten the vise to securely hold the rod. Put tape over the threaded area on the rod.

2. Install the new rod wiper, rod seal, back up ring and o-ring into the inner bore of the gland assembly.

Install the NEW back up ring and o-ring into the groove at the outside diameter of the gland assembly. If removed, install the rod end cap over the end of the cylinder rod and move downward. Put the gland assembly over the end of the cylinder rod end and carefully slide the assembly towards the end of the rod.

3. Install a new cylinder rod static o-ring seal into the cylinder rod groove.

4. Carefully install the new piston seals onto the piston. Install the piston onto the cylinder rod.

5. Remove the tape from the threaded area on the rod. Install the locknut onto the threaded rod. Tighten the locknut to a torque of 250 - 300 ft. lbs. [350 - 420 N.m].

6. Carefully compress the piston seals, with the fingers, while sliding the piston/rod assembly into the cylinder shell bore.

7. Carefully compress the o-ring and back up ring, on the outside diameter of the gland assembly, with the fingers. Keep the rings compressed and carefully move the gland assembly into the cylinder shell.

8. Push the gland assembly fully into the shell, so that the gland retaining wire groove, in the cylinder shell, is seen. Use a plier, or screw driver, to carefully install the gland retaining wire fully into the groove.

WARNING: Eye protection MUST be worn during wire installation.

9. Move the cylinder rod end cap upward on the cylinder rod and into position on the cylinder shell.

Align the two [2] holes in the end cap with the tapped holes in the gland assembly. Install the two [2] end cap retaining capscrews into the tapped holes and tighten securely.

10. Fill the cylinder with NEW approved and filtered hydraulic oil. Close the ports on the blade cylinder with plugs. Install the cylinder back onto the machine.

INSTALLATION. Reverse the removal procedures to install the leveling blade cylinder [See CYLINDER REMOVAL procedures and Fig. 1].

NOTE: Check the hydraulic oil level after installing the leveling blade cylinder, top up if necessary. To bleed the leveling blade cylinder run the engine at idling speed and fully raise and lower the leveling blade.

Check the operation of the leveling blade system after cylinder installation.

DANGER: Keep ALL personnel CLEAR OF the leveling blade. Clearance CLOSES between the blade and ground when the leveling blade is raised and then lowered. Serious INJURY, or DEATH, can occur if caught between the blade and ground.

LEVELING BLADE SYSTEM RELIEF PRESSURE CHECK AND ADJUSTMENT [See Fig. 1].

Use the following procedures to check and, if needed, adjust the leveling blade system relief pressure: 1. STOP the engine. Find the steering/leveling blade systems pressure check port fitting at the top of the steering pump. Wipe the check port area with a CLEAN cloth.

2. Loosen and remove the cap from the pressure check fitting. Install a 5,000 psi. [345 bar] pressure gauge, on a hose, onto the pressure check port fitting and tighten securely.

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Section 13 OPTIONAL EQUIPMENT 3. Check the hydraulic oil level in the hydraulic oil reservoir. ADD oil IF needed [See Section 4 MAINTENANCE].

6. Keep the engine in the STOPPED condition.

Wipe the relief valve cartridge assembly and control valve housing area using a CLEAN lint FREE cloth.

4. Put the secondary/parking brake system in the “ON” [APPLIED] condition. Start the engine. Put the engine throttle in the HIGH idle position. Move the leveling blade foot pedal to the LOWER position and make the leveling blade reach, and then put pressure on, the ground. NOTE the HIGHEST pressure indicated on the pressure gauge. Put the engine throttle in the LOW idle position and run the engine for a period of 3-5 minutes. STOP the engine.

7. Loosen the pressure adjusting screw locknut a SMALL amount.

WARNING: Keep CLEAR of the leveling blade assembly during the pressure check procedure. The blade MUST be lowered onto the ground.

CAUTION: The leveling blade system RELIEF pressure MUST be 1,850 +/- 50 psi.

[124 +/- 35 bar] to be CORRECT. ANY pressure ABOVE , or BELOW, this pressure MUST be changed by external adjustment of the relief valve assembly, found on the bottom of the leveling blade control valve.

NOTE: IF the pressures indicated were correct, NO system relief pressure adjustment is required. DO step “5”, given below, at THIS time. If the pressure indicated was NOT correct do NOT do step “5” at THIS time. See the “CAUTION” following step “5”.

5. Loosen and remove the hose and pressure gauge from the pressure check port fitting. Install and tighten the cap onto the pressure check port fitting.

CAUTION: IF the relief pressure] was NOT correct, ADJUST the leveling blade system RELIEF pressure using the following ADDITIONAL procedures:

8. Adjust the system relief pressure by turning the pressure adjusting screw a SMALL amount.

CAUTION: Turn the adjusting screw ONLY a SMALL amount inward or outward.

Turning the adjusting screw CLOCKWISE will INCREASE the system relief pressure. Turning the adjusting screw COUNTER CLOCKWISE will DECREASE the system relief pressure.

9. Hold the pressure adjusting screw in position and tighten the locknut.

CAUTION: Do NOT move the pressure adjusting screw.

10. Check the system relief pressure AGAIN using the procedures given in step “4” and ALL “NOTES”, “CAUTIONS” and “WARNINGS”. If the pressure is CORRECT, do step “5” at THIS TIME.

NOTE: If the relief pressure is still NOT correct, REPEAT the steps “7” through “10” UNTIL the relief pressure is CORRECT, then do step “5”.

BLADE VALVE

PRESSURE ADJUSTING SCREW

LOCKNUT

ALLEN WRENCH

FIGURE 1.

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Section 13 OPTIONAL EQUIPMENT LEVELING BLADE ASSEMBLY. REMOVAL AND INSTALLATION. USE the following procedures to remove and install the COMPLETE leveling blade assembly. The procedure also includes steps to remove and replace the bushing found on EACH side of the frame at the point where the leveling blade arms fasten to the frame.

REMOVAL [See Fig. 1].

NOTE: IF only the bushing[s] are being replaced, lower the leveling blade arms down. Remove the bushing[s] from the blade arm bore[s]. Replace the bushing[s] with NEW.

6. If complete leveling blade assembly removal is required, carefully lift the assembly a small amount and move it away from the frame and machine.

WARNING: Keep CLEAR of the leveling blade assembly while being lifted and moved.

1. Put the leveling blade assembly in the DOWN position and onto the ground. STOP the engine.

WARNING: Be SURE the blade rests on the ground.

Do NOT service the blade system, or components, with the blade raised from the ground.

2. Wash the COMPLETE leveling blade assembly and mounting area with steam, and air dry.

3. Go to the cylinder rod end. Remove the rod end from the mounting ear [see this section].

4. Fasten a chain, having a capacity more than 1,000 lbs. [454 kg], to EACH leveling blade arm at a point near the frame to arm area. Fasten a hoist, having a capacity more than 1,000 lbs. [454 kg], to the chains and apply ONLY enough lifting pressure to keep the chains tight.

5. Loosen and remove the center retaining capscrew and large washer found at the outer side of EACH blade mounting bracket. Loosen and remove the two [2] clamping capscrews found at EACH end of the flat ridge steel. Remove the blade arm mounting pin. Repeat the procedure on the OPPOSITE side of the machine.

WARNING: Keep the hands clear of the pin bore to arm and mounting bracket area during pin removal. A pinch area can exist if the blade arms move.

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NOTE: Inspect the two [2] shoe weldments, which are fastened to the underside of the leveling blade, for excessive wear or damage. Replace as needed. Inspect the bolt on reversible blade cutting edges for wear or damage. Reverse, or replace, as needed at THIS time.

INSTALLATION [See Fig. 1].

1. Use a CLEAN cloth to remove ANY oil or grease from the bushing bore in the leveling blade arm.

CAREFULLY lift the leveling blade assembly and move it into position, so that the pin bore in each leveling blade arms bushing is in alignment with the mounting bracket bores, on EACH side of the frame.

WARNING: Keep CLEAR of the leveling blade assembly while being lifted and moved into position.

2. Keep the leveling blade arms in position, so that the bushing bore is aligned with the mounting bracket bores. Put multipurpose grease on each mounting pin. Carefully install the mounting pin through the outer side of the mounting bracket, through the bushing bore, in the leveling blade arm, and into the other side bore in the mounting bracket.

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Section 13 OPTIONAL EQUIPMENT 3. Put the pin in position from the outer side of the mounting bracket. Put Loctite #242 on the threaded area of the two [2] capscrews that fasten pin into to the bracket. Install and securely tighten the capscrews .

7. Start the engine and check for correct operation of the leveling blade assembly.

WARNING: Keep CLEAR of the leveling blade during the check of operation.

4. Go to the opposite of the machine and repeat step "3".

5. Put the leveling blade cylinder rod end. Connect the cylinder rod end to the mounting ear [see this section]

PIN HEX BOLT

HEX BOLT

BUSHING DETACHED BLADE ARM

FIGURE 1.

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Section 13 OPTIONAL EQUIPMENT LEVELING BLADE CONTROL FOOT PEDAL AND LINKAGE. LINKAGE CHECK AND ADJUSTMENT PROCEDURE [See Fig. 1].

CAUTION: Check the leveling blade system control linkage adjustment AFTER the control foot pedal, threaded rod or other linkage items have been removed, replaced and installed again.

Use the following procedures to check and, if needed, adjust the threaded rod linkage between the control foot pedal and the leveling blade system control valve: 1. Lower the leveling blade onto the ground. STOP the engine.

WARNING: Be SURE the blade rests on the ground.

Do NOT service the blade system, or components, with the blade raised from the ground.

2. Go to the underside area below the foot pedal arm. Loosen the hex nut, which keeps the fork joint in the “adjusted” position.

3. Put the foot pedal control in the EXACT center of the “LOWER” [#2] position. d. Go to the leveling blade control valve and make SURE the control valve spool, and control linkage threaded rod are in the “BLADE DOWN” position. e. Go to the underside area below the foot pedal, again. Remove the cross pin and washer from the fork joint to pedal lever. Turn the fork joint inward, or outward, and adjust the position of the joint, so that the through hole in the fork joint is in the EXACT same position as the through hole in the pedal lever.

When the adjustment is correct, tighten the hex nut against the adjustable fork joint.

13-12

CAUTION: Do NOT adjust the fork joint outward to the point that LESS than 1/2 inch [12.7 mm] of the rod threads remain in the fork joint to meet the condition described in step “e” above.

NOTE: If LESS than 1/2 inch [12.7 mm] of threaded rod end would remain in the adjustable fork joint, GO to the CONTROL VALVE end of the threaded bar. Remove the cotter pin from the cross pin to valve spool cross pin. Loosen the hex nut from against the link connector.

Turn the joint outward, so that the available link center hole to control valve spool center hole length is INCREASED. Install the cross pin through the link connector and valve spool bores. Put the cotter pin through cross pin and bend. Tighten the hex nut against the fork joint. Repeat step “e” from above.

CAUTION: Do NOT adjust the link outward to the point that LESS than 1/2 inch [12.7 mm] of the threaded rod threads remains in the link connector.

f. Install the cross pin, and washer, through the link connector and pedal lever from the inner side. Install the cotter pin through the cross pin and bend. g. Start the engine. Check the operation of the leveling blade system in EACH position.

WARNING: Keep CLEAR of the leveling blade, cylinder and leveling blade arms during the check of system operation.

CAUTION: The leveling blade MUST go to the SAME position at which the control foot pedal is positioned for EACH of the FOUR [4] leveling blade positions.

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Section 13 OPTIONAL EQUIPMENT

CONTROL VALVE

CROSS PIN LINK CONNECTOR FORK JOINT

NUT COTTER PIN WASHER THREADED ROD

CROSS PIN

COTTER PIN WASHER PEDAL LEVER

FIGURE 1.

OPERATION LIGHTING SYSTEM. The operation lighting system is used to enable machine operation under dark conditions.

When the control switch is put in the “ON” position current will flow through the switch to the dash gauge and instrument illumination light harness, the front light harness and the rear light harness.

The lighting system is available as a factory installed option, or can be added to the machine by the nearest Distributor.

Current then flows through the harnesses to and through the lights to ground.

The system contains light assembly supply wiring harnesses, 10 amp fuse, securing clamps and ties one [1] front headlight light assembly and one tail light assembly.

NOTE: Also see Section 7 - ELECTRICAL SYSTEM - for additional system information.

When the ignition key switch is in the “ON” position, system electrical current is supplied from the connection terminal F06 of the circuit bridge to the system control switch.

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13-13

Section 13 OPTIONAL EQUIPMENT CHECKS AND ADJUSTMENT. The front head light assembly 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. Replace any component that has damage, as needed.

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.

FIGURE 1.

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Section 13 OPTIONAL EQUIPMENT TROUBLE ANALYSIS FOR THE LEVELING BLADE SYSTEM PROBLEM

CAUSE

CORRECTION

BLADE CONTROL VALVE

No leveling blade action when control foot pedal placed in ANY of the four [4] positions.

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Control linkage connection at foot pedal, or at valve, NOT installed

Replace missing connection part and correctly adjust control linkage

NO oil flow being supplied to system from steering pump

Check for oil flow from steering pump

Leveling blade system relief pressure set too LOW for system to operate

Check relief pressure and adjust as needed

Leveling blade system relief valve has damage [will NOT permit system to develop ANY pressure]

Remove and replace relief valve with NEW. Check system relief pressure and adjust if needed

Leveling blade control valve has internal damage

Remove and replace valve

Oil supply and/or return hoses from and back to control valve plugged or damaged [NO oil reaches and/or returns from leveling blade cylinder]

Check hose[s]. Clean, or replace, as needed

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Section 13 OPTIONAL EQUIPMENT TROUBLE ANALYSIS FOR THE LEVELING BLADE SYSTEM PROBLEM

CAUSE

CORRECTION

BLADE CONTROL VALVE NOT all four [4] leveling blade actions operate when control foot pedal is placed in the correct position.

Leveling blade control foot pedal to control valve linkage NOT adjusted correctly

Check linkage and adjust as needed

Control valve spool NOT moving to correct location to port oil flow correctly

Remove and replace valve with NEW

Leveling blade arms being restricted in their movement by an obstruction

Find and remove obstruction. Check leveling blade action

Leveling blade system relief pressure set too LOW [functions needing high pressure NOT working]

Check pressure. Adjust relief pressure to CORRECT specification

BLADE CYLINDER NO motion from leveling blade cylinder.

Slow motion from the leveling blade cylinder.

13-16

No oil being supplied to blade cylinder

Check system for oil flow from blade system pump to control valve and/or control valve and the cylinder. Correct cause of NO oil supply as needed

Cylinder has internal damage

Remove, disassemble, clean, inspect and repair as needed. Install cylinder

Low oil supply to the cylinder

Check as indicated above

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Section 13 OPTIONAL EQUIPMENT TROUBLE ANALYSIS FOR THE LEVELING BLADE SYSTEM PROBLEM

CAUSE

CORRECTION

BLADE CYLINDER Action of cylinders 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

Excessive lost motion at cylinder.

Bent or deformed cylinder piston or rod

Remove cylinder, repair or replace as needed

Bushing[s] at blade cylinder to blade mount or anchor worn

Remove and replace bushing[s] as needed

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13-17

Section 13 OPTIONAL EQUIPMENT NOTES

13-18

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Section 14 SPECIAL TOOLS

TABLE OF CONTENTS

PAGE GENERAL INFORMATION ..................................................................................................................... 14-2 SPECIAL EQUIPMENT AND TOOLS ..................................................................................................... 14-2

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14-1

Section 14 SPECIAL TOOLS GENERAL INFORMATION. The following "Special Tool List" includes the equipment, or tool, description and part number assigned to the equipment, or tool.

3. Mounting jig for exchanging the rubber buffers (Fig. 3): Part no.: 007 130 02

SPECIAL EQUIPMENT AND TOOLS. 1. Vibration read frequency meter (Fig. 1): Part no.: 300 120 80

FIGURE 3.

4. Centering jig for vibration motor cover (Fig. 4): Part no.: 007 130 05

FIGURE 1.

2. Filling and filtering unit with oil bag (Fig. 2: Part no.: 007 610 01

FIGURE 4.

5. Puller for coupling half on vibrator shaft (Fig. 5: Part no.: 007 130 04 FIGURE 2.

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Section 14 SPECIAL TOOLS

FIGURE 5.

6. Pin wrench for screwing tension nut on and off the articulated joint (Fig. 6): Part no.: 007 122 01

FIGURE 6.

FIGURE 7.

8. Centering plate for drive shaft (Fig. 8): Part no.: 079 942 01

FIGURE 8.

7. Centering plate for cover on steering, charging and vibration pump (Fig. 7): Part no.: 007 130 06

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14-3

Section 14 SPECIAL TOOLS 9. Mounting tool for dust sealing ring (Fig. 9): Part no.: 079 942 03

FIGURE 11.

FIGURE 9.

13. Hydraulic test case (Fig.12): Part no.: 007 610 03

10. Mounting tool for O-ring/kin ring (Fig. 10): Part no.: 079 942 02

FIGURE 12.

FIGURE 10.

14. Test hose, 1m long (fig. 13): Part no.: 079 930 02

11. Flushing filter - travel circuit (Fig. 11): Part no.: 007 000 01 12. Filter element: Part no.: 079 930 01

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Section 14 SPECIAL TOOLS

FIGURE 13.

15. Flushing hose, 16S connection (Fig. 14): Part no.: 055 513 72

FIGURE 14.

FIGURE 15.

17. Flushing hose, 15L connection (Fig. 16): Part no.: 055 510 09

FIGURE 16.

16. Reducing socket, 25S/16S (Fig. 15): Part no.: 055 423 27

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Section 14 SPECIAL TOOLS

18. Electrical test kit (Fig. 17): Part no.: 057 505 70

FIGURE 17.

19. Junction socket, 16S (Fig. 18): Part no.: 055 459 43

FIGURE 19.

21. Flushing filter, vibration circuit (Fig. 20): Part no.: 079 930 29 22. Filter element Part no.: 079 930 14 23. Double end union, R 3/4" - 15L Part no.: 055 40 89

FIGURE 18.

20. Junction socket, 15L (Fig. 19): Part no.: 055 459 32 FIGURE 20.

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Section 14 SPECIAL TOOLS

24. Threaded bar, M 16, with eye (Fig. 21): Part no.: 007 122 21

FIGURE 21.

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Section 14 SPECIAL TOOLS NOTES

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