Bomag Mph 362 364-2 Recycler And Stabilizer Workshop Service Repair Manual – PDF DOWNLOAD

MPH362_364-2 0852738 CVR

1/16/06

3:13 PM

Page 1

Instructions For Repair

MPH 362/364-2 S/N 901B23001601> Cummins QSM 11 360HP

Soil Stabiliz er/Asphalt Recycler

Printed in U.S.A.

BOMAG Americas, Inc. 2000 Kentville Rd. Kewanee, IL 61443

Catalog number

0852738

01/01/06

MPH 362-2 - MPH 364-2 RECYCLER - STABILIZER DANGER:

08/05

If the machine was received with the Roll Over Protective Structure (ROPS) or Roll Over/Falling Object Protection System (ROPS/FOPS) and Operator Restraint (Seat Belt) NOT installed, both MUST be installed BEFORE the machine is operated. Use the installation instructions drawing included with the installation kit and/or the illustration below.

In the event of a machine roll over, serious injury, or death, can occur due to the failure to correctly install the Roll Over Protective Structure (ROPS) or Roll Over/Falling Object Protection System (ROPS/FOPS) and the Operator Restraint (Seat Belt).

DANGER:

DO NOT operate machine with Roll Over Protective Structure (ROPS) or Roll Over/Falling Object Protection System (ROPS/FOPS) and/or Operator Restraint (Seat Belt) NOT properly installed.

i

ii

08/05

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

DANGER:

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

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

08/05

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 information, and/or clarification details, which are used in conjunction with previously presented information.

iii

Safety Regulations SAFETY SAFETY REGULATIONS

•

INTRODUCTION The following safety regulations apply to all personnel engaged in the operation, maintenance or repair of this machine.

Intended Use The machine is available in both Recycler and Stabilizer configurations. As a Recycler, the machine is intended for use in recycling bituminous surfaced roadways and paved surfaces using recycling teeth mounted on the rotor. When configured as a Stabilizer the machine is intended to stabilize soil, using paddles mounted on the rotor. Only authorized and trained personnel can operate this machine.

The potential for damage to the machine or injury to personnel exists if this machine is used for purposes other than those for which it was designed, or if it is used by personnel not familiar with information contained in this manual.

General

•

Make certain you are familiar with all controls and accessories on the machine.

•

Do not operate the machine unless you are trained on all operating and control features and know how the machine functions.

•

Familiarize yourself with the work area including surface and subsurface conditions, vegetation, water tables and other indications of conditions that may be encountered during operation.

•

Use the machine only for the purpose for which it is intended.

•

Wear protective clothing such as safety helmet, protective shoes, noise protection and eye protection.

•

Original parts and accessories have been specifically designed for this machine. Unauthorized conversions and alterations to the machine or its component parts or assemblies are prohibited as they may endanger safe operation.

iv

The factory has not tested or authorized any component parts or special equipment not supplied by the factory. The installation or use of unauthorized products can have an adverse effect on design characteristics and influence active or passive operating safety.

The manufacturer expressly excludes any liability for damages, actual or consequential, resulting from the use of non-factory approved parts or accessories on this machine.

•

Should the machine contact high voltage power lines: – Move the machine out of the danger zone, if at all possible.

– Do not leave the operator’s platform.

– Alert and warn others to move away from the machine.

– Request electric utility shut down electrical power.

DANGER:

Use EXTREME caution whenever anyone is working inside the wheels on the steering (front) axle.

Serious, or fatal, injuries can result from the wheels being turned while a worker is inside this area. NEVER turn the steering wheel, release the brakes, or engage the hydrostatic drive(s) while someone is working in this area.

DANGER:

Exhaust fumes are dangerous.

Ensure an adequate supply of fresh air when starting up in enclosed spaces or vent the vehicle exhaust outside through an approved exhaust system.

08/05

Safety Regulations SAFETY Prior to Starting

Operation

•

Review operating instructions before starting the engine.

•

•

Press the Emergency Stop push button immediately in emergencies and potentially dangerous situations.

Check the machine and controls for obvious faults.

•

The machine may only be operated from the operator’s seat.

Do not drive or operate the machine with damaged instruments, control lights or control elements or systems.

•

Before starting work, check that controls, lighting and horn are operating properly.

•

Before starting or resuming work, you must make sure no one is in the danger area surrounding the machine.

• •

All protective devices must be properly secured in their locations.

•

Do not leave any loose objects such as tools or personal items such as lunch boxes lying about.

Secure or store such objects in a safe manner.

•

Keep the machine free from all oily or combustible materials.

•

Before climbing onto the machine, make sure there are no persons or obstacles near or under the machine.

– You must give a warning signal.

– Stop work immediately if persons remain in the danger area despite the warning.

•

When driving in reverse, make sure that no one or any obstacles are in the way.

•

Control the speed of the machine to working conditions.

•

Keep the machine away from edges and embankments.

•

When driving under a flyover, bridge, power lines, through a tunnel, etc. make sure there is sufficient clearance.

Starting

•

Use lighting whenever visibility is poor.

•

Ensure all controls are in the “neutral” position when starting the engine.

•

•

Only start and operate the machine from the operator’s seat.

If a slope must be traversed, drive very carefully and always drive directly up or down the slope (never on an angle). Select the lower travel speed range whenever approaching a slope.

•

Check all indicators after start-up to ensure all systems are operating correctly.

•

Soil conditions and weather influences reduce the ability of the machine to climb or descend grades.

•

Never leave a machine unattended while the engine is running.

•

•

For emergency starting using jumper cables from an external power source, connect positive to positive and negative to negative. Always connect the ground wire (negative) last and disconnect the ground wire first. This is a 24 volt sytem.

Wet and loose soils considerably reduce machine ground traction on grades. It also increases the danger of accidents.

•

Never climb on the machine while it is in motion.

•

The machine may never be used as a transport for personnel, or equipment.

•

Use care when climbing onto the machine.

Always use the steps and handrails provided.

•

Adjust the seat before starting the engine.

•

Always use the seat belt provided on machines with ROPS/FOPS or ROPS structures.

08/05

v

Safety Regulations SAFETY •

All handrails, steps and platforms are to be kept free of grease, oil, fuel, dirt, snow and ice.

•

Should the machine develop an unusual noise or generate smoke while operating the machine, stop the engine, trace the cause, and have any faults corrected.

•

Never adjust the operator’s seat while the machine is in motion.

•

Do not use the emergency stop push button as an operating brake.

Parking

•

Before leaving the machine, set the Travel Direction Control Lever (FNR) to “neutral”, apply the parking brake and stop the engine.

•

Park the machine on level and firm ground.

•

Never jump off the machine. Use the access steps and hand rails.

•

If you must park on an incline, set wedges in front of, or behind, the tires.

Maintenance

•

For repairs and maintenance work, place the machine on firm and level ground.

•

Do not perform any adjustments while the engine is running or machine is being driven.

•

Keep unauthorized persons away from the machine whenever performing maintenance work.

•

Identify a machine with problems by attaching a warning sign to the steering wheel.

•

Before starting engine, check that the battery disconnect switch is in the ON position.

•

Whenever refueling or working with the fuel system: – Only refuel while the engine is stopped.

– Observe cleanliness.

– Do not spill any fuel.

•

Petrol-diesel mixtures (winter fuel) are as flammable as standard diesel fuel mixtures.

•

Do not refuel in enclosed spaces.

•

Place used filters in a specially marked container and dispose of them in an approved manner to prevent pollution.

•

During maintenance work, collect oils and fuels and dispose of them carefully to prevent pollution. Be aware there is a danger of scalding when working with hot oil.

•

Do not heat oil to a temperature over 320°F (160°C) otherwise oil, or oil vapor, may ignite.

•

Wipe away any fuel, or oil, which has been spilled.

•

Never smoke when filling the fuel tank or checking acid level of the batteries.

•

Never check acid level of the batteries or fuel level with an open flame.

Loading and Transport

•

Use only strong and stable loading ramps when loading the machine. Make sure no one is endangered in the event the unit accidentally turns over or slips during the loading process.

•

Ramp incline must be lower than the machine’s ability to climb or gradability.

•

Secure the machine on the transport vehicle using the attachment points provided. (See Transportation Data – Section 3.) This action will guard against the machine rolling, slipping or turning over.

• •

vi

Do not step or stand under lifted loads. This constitutes a danger to life.

Do not stand in danger areas of the machine during operation, demonstrations or loading. This constitutes a danger to life.

08/05

Safety Regulations SAFETY •

Dispose of used batteries carefully to prevent pollution.

•

Never perform cleaning work with the engine running.

•

Use caution when working with cleansing agents.

Gasoline, or other easily flammable substances, must never be used for cleaning purposes.

•

Cover electric parts with watertight insulating material when using a steam cleaner. Never subject these parts to a direct water jet.

•

Visually inspect hydraulic hoses at regular intervals.

•

Check to ensure hydraulic lines are depressurized before disconnecting them. Hydraulic oil, escaping under pressure, can penetrate your skin and cause serious injury.

•

When performing adjustments to the hydraulic system, never step behind or in front of the machine.

• • •

Never attempt to adjust pressure relief valves.

These are factory set.

While the system is depressurized, check all connections and fittings for leaks when all maintenance work has been completed.

Refit all protective devices when all maintenance work has been completed.

Repair

•

Repairs to this machine may only be performed by skilled and trained personnel.

•

Use only Bomag Americas approved repair procedures.

•

Observe any special welding instructions when performing welding work.

ROPS/FOPS or ROPS Structure Inspection

•

The machine frame must not be bent, deformed or cracked in the area of the ROPS/FOPS or ROPS installation.

•

The ROPS/FOPS or ROPS structure must not show rust, damage, hairline cracks or open fractures.

•

The ROPS/FOPS or ROPS structure must not rattle when the machine is being driven.

•

All screw connections must be in accordance with manual specifications and must be secure (observe tightening torques).

•

Screws and nuts must not be damaged, bent or deformed.

•

No additional parts may be welded or screwed, and no additional holes may be drilled without the approval of the manufacturer. Unauthorized alterations may influence stability and safe operation.

NOTE: Following the lubrication and maintenance schedules, and the operating instructions will help to ensure that your machine has a long service life and is always fully operational.

08/05

vii

Safety Regulations SAFETY

viii

08/05

Section 1 INTRODUCTION

TABLE OF CONTENTS

PAGE

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 NAMEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

08/05

1-1

Section 1 INTRODUCTION GENERAL INFORMATION. This manual contains OPERATING procedures for BOMAG Recyclers & Stabilizers. (See Figure 1-1).

• • •

TECHNICAL DATA. Standard Equipment.

• • • • • • • • • • • •

Hydrostatic rotor drive with engine load control Hydrostatic travel system Rear axle - hydraulic motors/planetary gearbox with Spring Applied Hydraulically Released (SAHR) brakes - each wheel ASC (electronic traction control) Selectable hydrostatic front drive axle (MPH 364-2 ONLY) Hydraulic power steering Hydrodynamic service brakes Single lever control travel and steer assist braking 24V electrical system with manual battery disconnect Dual element engine air filter Warning horns Emergency stop

• • • • •

Back-up alarm Gauges - Rotor drive pressure - Travel drive pressure PowerView Monitoring and Display System - Fuel level - Hour meter - Voltmeter - High engine coolant temperature - High hydraulic oil temperature - Low engine oil pressure - Low rotor charge pressure - Engine inlet air - restriction - Hydraulic oil filters - restriction - Engine tachometer (RPM) - Feet per minute (FPM)/Speedometer (MPH) Visual warning indicators - Brakes applied Audible warning buzzers - Sounded in conjunction with PowerView monitoring and display system ROPS/FOPS with seat belt, or ROPS with seat belt Adjustable operator’s seat Adjustable tilt steering wheel

FIGURE 1-1. BOMAG RECYCLER – WITH ROPS/FOPS. 1-2

08/05

Section 1 INTRODUCTION SPECIFICATIONS.

NAMEPLATE (SEE FIGURE 1-2).

See Section 2 – SPECIFICATIONS in this manual for specifications of major systems used on the machine.

The nameplate is found in the operator’s control station on the firewall plate near the engine throttle control.

OPERATING INSTRUCTIONS. Read, understand and follow ALL operating instructions given in Section 3 – OPERATION in this manual - and in the Cummins QSM11 “Operation and Maintenance Manual”, supplied with the machine.

BOMAG TYPE

MAINTENANCE PROCEDURES. See Section 4 – MAINTENANCE, in this manual, for maintenance schedules and procedures that are required for the major systems of this machine.

Follow ALL maintenance schedules and procedures given in this manual and in the Cummins QSM11 “Operation and Maintenance Manual”, supplied with the machine.

08/05

BETRIEBSGEWICHT OPERATING WEIGHT POIDS DE SERVISE 39,000 lbs (17706 kg)

NO

Only authorized personnel, who are fully trained in the machine operation procedures, can operate the BOMAG Recycler or Stabilizer.

Follow all instructions given in this manual and written on the “Machine Operation and Warning” decals, found on the machine.

MPH364R

901B2301601

KG

MAX. GEWICHT MAX. WEIGHT POIDS MAX.

KG

MANUFACTURED BY

BOMAG Americas KEWANEE, ILLINOIS, USA MANUFACTURED UNDER ONE OR MORE OF THE FOLLOWING U.S. PATENTS: 5645370, 5248216, 5797699

30100007

FIGURE 1-2. NAMEPLATE. The nameplate shows the machine manufacturing plant code, model number code and serial number.

The nameplate must stay fastened to the machine at all times. If the nameplate is lost or damaged, it must be replaced immediately.

Consult your nearest BOMAG Distributor to obtain a replacement nameplate and install it immediately.

1-3

Section 1 INTRODUCTION SERIAL NUMBER (See Figures 1-2 and 1-3 and Table 1-1).

•

The manufacturing plant code, machine model number code, and serial number are found stamped on the nameplate located in the cockpit. (See Figure 1-2). The complete machine serial number is, also, stamped at two other locations on the machine (See Figure 1-3).

To help ensure correct information, or parts, are obtained for the BOMAG Recyclers and Stabilizers, ALWAYS supply the complete model number and the serial number whenever requesting ANY information, or ordering ANY machine parts.

•

On top of the frame, beneath the bolt on cover for the front ballast compartment.

The top of the frame rail in the engine compartment on the right hand side of the unit.

SERIAL NUMBER LOCATIONS TOP OF CROSS PIECE ON BALLAST - BENEATH FRONT COVER

TOP OF FRAME RAIL ON THE UNIT S/N PLATE IN THE COCKPIT

FIGURE 1-3. STAMPED SERIAL NUMBER LOCATIONS.

901

PLANT OF MANUFACTURE CODE

B230

UNIT CODE

1601

MACHINE SERIAL NUMBER

TABLE 1-1. SERIAL NUMBER DESIGNATIONS.

1-4

08/05

Section 2 SPECIFICATIONS

TABLE OF CONTENTS

PAGE

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 TABLE 2-1. ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 TABLE 2-2. ENGINE INLET AIR FILTRATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 TABLE 2-3. ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 TABLE 2-4. TRANSMISSION AND FINAL DRIVE SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .2-4 TABLE 2-5. BRAKE SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 TABLE 2-6. STEERING SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 TABLE 2-7. ROTOR SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 TABLE 2-8. DIMENSION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8 TABLE 2-9. WEIGHT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 TABLE 2-10. CAPACITY SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

08/05

2-1

Section 2 SPECIFICATIONS GENERAL INFORMATION. This section provides specification tables for major systems of the BOMAG Recycler or Stabilizer.

Dimensions, weights and performance specifications are also provided.

TABLE 2-1. ENGINE SPECIFICATIONS. ITEM

MPH 362-2 - 364-2

ENGINE

2-2

Manufacturer

Cummins

Model

QSM11- Turbocharged & charge air cooled

Cooling

Water

Type

4 Cycle Diesel

Number of Cylinders

6

Firing Order

1-5-3-6-2-4

SAE Net Horsepower

360 hp (268.3 kW) @ 2100 RPM

Torque

900 ft•lbs (1220 N•m) @ 2100 RPM

Fuel

Diesel

Fuel Viscosity

1.3 cSt

Fuel Consumption Rate

19.2 Gal/hr (72.7L/hr) @ 2100 RPM

Compression Ratio

16.3 : 1

Displacement

660 C.I.D. (10.8 liters)

Bore

4.921 in (125 mm)

Stroke

5.787 in (147 mm)

Crankshaft Rotation (Viewed from engine front)

Clockwise

High Idle Speed w/o Load

2100 RPM, Loaded, 2300 RPM not loaded

Low Idle Speed

850 RPM

08/05

Section 2 SPECIFICATIONS TABLE 2-2. ENGINE INLET AIR FILTRATION SPECIFICATIONS. ITEM

MPH 362-2 - 364-2

AIR CLEANER Type

Dry, cycloflow w/secondary element & evacuator valve

Manufacturer

Donaldson

Model

FVG 16-0587

RESTRICTION INDICATOR Type

Electrical / visual resetable

Manufacturer

Donaldson

Model

Electrical Indicator / Informer

TABLE 2-3. ELECTRICAL SPECIFICATIONS. ITEM

MPH 362-2 - 364-2

BATTERY Number per Machine

2

CCA Rating

1,000 CCA @ 0°F

Voltage

24 VDC System (Two 12 Volt batteries in series)

BCI Group

Group 4D-P

ALTERNATOR Manufacturer

See alternator plate for manufacturer and part number

Voltage

24 Volts, negative ground

Maximum Charge Rate

70 Amps

STARTER

08/05

Manufacturer

See starter plate for manufacturer and part number

Voltage

24 Volt

2-3

Section 2 SPECIFICATIONS TABLE 2-4. TRANSMISSION AND FINAL DRIVE SPECIFICATIONS. ITEM

MPH 362-2 - 364-2

TRACTION SYSTEM Type

Hydrostatic (closed loop)

Traction Pump

Variable displacement, axial piston

Traction Motors

Rear: Variable, bent axis piston Front: Radial piston(MPH 364-2 ONLY)

TRANSMISSION (FRONT AXLE MPH 364, MPH 364 WIDE ONLY) Manufacturer

Fluidrive

FINAL DRIVE Manufacturer and Type

L&S - GFT 40 T2 9000

Travel Speed Range 1 (Working)

2.1 MPH (3.4 km/h) = 171 FPM (52.1 m/min)

Range 2 (Transport ONLY)

11.0 MPH (17.7 km/h)

Tire Size (Front)

14.9 x 24 8 PR R-1

Tire Inflation Pressure (Front)

35 psi (2.41 bar) cold

Wheel Nut Torque (Front)

400 ft•lbs (542 N•m)

Tire Size (Rear)

28 LR x 26-165LI

Tire Inflation Pressure (Rear)

35 psi (2.41 bar) cold

Wheel Nut Torque (Rear)

426 ft•lbs (578 N•m)

ITEM

MPH362RW-2-364SW-2 MPH362SW-2-364-SW-2

Travel Speed

2-4

Range 1 (Working)

2.1 MPH (3.4 km/h) = 171 FPM (52.1 m/min)

Range 2 (Transport ONLY)

11.0 MPH (17.7 km/h)

Tire Size (Rear)

26.5 x 25 20PR E-2/L-2+2

Tire Inflation Pressure (Rear)

50 psi (3.44 bar) cold

08/05

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

MPH 362-2 - 364-2

SERVICE BRAKE Type

Hydrodynamic, through hydrostatic travel drive

PARKING BRAKE Type

SAHR (Spring Applied Hydraulically-Released)

EMERGENCY BRAKE Type

SAHR (Spring Applied Hydraulically-Released)

TABLE 2-6. STEERING SYSTEM SPECIFICATIONS. ITEM

MPH 362-2 - 364-2

STEERING SYSTEM

08/05

Type

Axle pivot

Method

Hydraulic, through orbitol

Steering Angle

+/- 30 Degrees

Inside Turning Radius

252 in (6401 mm)

2-5

Section 2 SPECIFICATIONS TABLE 2-7. ROTOR SYSTEM SPECIFICATIONS. ITEM

MPH 362-2 - 364-2

ROTOR SYSTEM Type

Hydraulic, closed loop

Pump Quantity

1

Pump Type

Variable displacement, axial piston

Motor Quantity

2

Motor Type

Radial piston

ROTOR

2-6

Recycler

Stabilizer

Rotor Diameter (Outer)

30 in (762 mm)

30 in (762 mm)

Rotor Circle Diameter (Outside Cutting Teeth)

44 in (1118 mm)

48 in (1219mm) 59.5 in (1511 mm) - Deep Mix

Cutting Width

79 in (2007 mm)

79 in (2007 mm)

Maximum Cutting Depth

12 in (381 mm)

14 in (356 mm) 21 in (533 mm) - Deep Mix

Rotor Speed

I = 135

I = 135

II = 150

II = 150

Sense of Rotation

Up-cut

Up-cut, or down-cut

Type of Cutting Teeth

Carbide tipped bullet tooth knock in/knock out

Carbide faced paddle knock in/knock out

Quantity of Teeth

168

70

Height of Cutting Tooth

7 in (178mm)

9 in (229 mm)

Rotor Hood Width

101 in (2565 mm)

101 in (2565 mm)

Cutting Chamber Width

83.75 in (2127 mm)

83.75 in (2127 mm)

08/05

Section 2 SPECIFICATIONS TABLE 2-7. ROTOR SYSTEM SPECIFICATIONS (CONTINUED).

ITEM

MPH362RW-2-364SW-2 MPH362SW-2-364-SW-2

ROTOR SYSTEM Type

Hydraulic, closed loop

Pump Quantity

1

Pump Type

Variable displacement, axial piston

Motor Quantity

2

Motor Type

Radial piston

ROTOR

08/05

Recycler

Stabilizer

Rotor Diameter (Outer)

34 in (864 mm)

34 in (864 mm)

Rotor Circle Diameter (Outside Cutting Teeth)

48 in (1219 mm)

48 in (1219 mm)

Cutting Width

96 in (2438 mm)

96 in (2438 mm)

Maximum Cutting Depth

15 in (381 mm)

15 in (381 mm)

Rotor Speed

I = 135

I = 135

II = 150

II = 150

Sense of Rotation

Up-cut

Up-cut, or down-cut

Type of Cutting Teeth

Carbide tipped bullet tooth knock in/knock out

Carbide faced paddle knock in/knock out

Quantity of Teeth

196

82

Height of Cutting Tooth

7 in (178mm)

7 in (178mm)

Rotor Hood Width

118 in (2997 mm)

118 in (2997 mm)

Cutting Chamber Width

100.75 in (2559 mm)

100.75 in (2559 mm)

2-7

Section 2 SPECIFICATIONS TABLE 2-8. DIMENSION SPECIFICATIONS. ITEM

MPH 362-2 - 364-2

Dimensions (see Figure 2-1) A. Overall Length

331 in (8407 mm)

B. Overall Width

115 in (2921 mm)

C. Overall Height – With ROPS or ROPS/FOPS

138 in (3505 mm)

D. Overall Height - With Cab

138 in (3505 mm)

E. Height To Top Of Exhaust Pipe

136 in (3454 mm)

F. Height To Top Of Cockpit Handrail

111 in (2819 mm)

G. Wheelbase

129 in (3277 mm)

H. Ground Clearance

19 in (483 mm)

I. Working Width - Rotor

79 in (2007 mm)

I. Working Width - Rotor With Wide Rotor Option

96 in (2438 mm)

C/D

E F

H G

I A

B

FIGURE 2-1. BOMAG MPH 362-2 AND 364-2 RECYCLER/STABILIZER – DIMENSIONS.

2-8

08/05

Section 2 SPECIFICATIONS TABLE 2-9. WEIGHT SPECIFICATIONS. ITEM

MPH 362-2

MPH 364-2

Weights Operating Weight

39,000 lbs. (17,706 kg.)

39,000 lbs. (17,706 kg.)

Axle Load – Front

10,920 lbs. (4,958 kg.)

10,920 lbs. (4,958 kg.)

Axle Load – Rear

28,080 lbs. (12,749 kg.)

28,080 lbs. (12,749 kg.)

% Weight Distribution – Front/Rear

25% / 75% - Approximate

25% / 75% - Approximate

ITEM

MPH362RW-2-364SW-2 MPH362SW-2-364-SW-2

Weights Operating Weight

45,300 lbs. (20,540 kg.)

Axle Load – Front

12,005 lbs. (5,445 kg.)

Axle Load – Rear

34,294 lbs. (15,101 kg.)

% Weight Distribution – Front/Rear

25% / 75% - Approximate

TABLE 2-10. CAPACITY SPECIFICATIONS. ITEM

MPH 362-2 - 364-2

Capacities

08/05

Fuel

260 Gal. (984 liters), Total capacity (BOTH tanks full)

Hydraulic Oil

90 Gal. (341 liters), Reservoir only

Engine Oil

9.8 Gal. (37.4 liters)- including engine mounted filter

Engine Coolant

78.0 Quarts (74 Liters), Total system

2-9

Section 3 OPERATIONS TABLE OF CONTENTS PAGE OPERATING FEATURES AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3 MACHINE INSPECTION UPON RECEIPT FROM CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 MANUAL CODE DESIGNATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 PERSONAL SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 CONSOLE MOUNTED CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 SWITCH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7 IGNITION PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11 ALARM PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17 OPERATOR CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18 STEERING WHEEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20 AUXILIARY PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20 BACKUP TRAVEL CONTROL (FNR) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22 TRAVEL/LOAD CONTROLLER LED STATUS OR ERROR LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . .3-23 CHECKS WITH THE ENGINE STOPPED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24 PREPARING THE MACHINE FOR STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24 MOUNTING AND DISMOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25 POWERVIEW MULTIFUNCTION MONITORING SYSTEM - SUPPORTED . . . . . . . . . . . . . . . . . . . . . . . . . . .

INFORMATION ACCESS AND NAVIGATION WITHIN THE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25 POWERVIEW OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26 POWERVIEW MENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26 FIRST TIME STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26 MAIN MENU NAVIGATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26 STORED FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27 ENGINE CONFIGURATION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27 FAULTS AND WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28 AUXILIARY GAUGE FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28 ACTIVE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29 SHUTDOWN CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29 BACK LIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30 CONTRAST ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31 SELECT UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31 SETUP 1-UP DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32 USE DEFAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32 CUSTOM SETUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33 AUTOMATIC SCAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33 SETUP 4-UP DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34 UTILITIES (INFORMATION AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35 (continued)

08/05

3-1

Section 3 OPERATIONS TABLE OF CONTENTS (continued) PAGE CHECKS WITH ENGINE RUNNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37 OPERATING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37 PREPARATION FOR WORK OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39 STARTING TRACTION (TRANSPORT OPERATION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39 STOPPING TRACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40 ASPHALT PULVERIZATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40 WORK OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40 STARTING ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43 BASIC OPERATION INFORMATION AND GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43 ZERO ADJUSTMENT OF DEPTH INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45 CALIBRATION OF THE DEPTH INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45 STOPPING ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46 BRAKING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46 PRIMARY BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46 SECONDARY(EMERGENCY/PARKING) BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46 STEER BRAKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46 PARKING AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47 STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47 BACKUP TRAVEL CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47 TOWING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-48 TRANSPORTATION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-50

3-2

08/05

Section 3 OPERATIONS OPERATING FEATURES AND CONTROLS.

GENERAL INFORMATION.

The BOMAG Recycler is a hydrostatically driven machine, which is used for breaking and/or reclaiming, pulverizing and reducing, blending and thoroughly mixing additives accurately into asphalt mats and other road surfaces.

This section covers operating instructions for the BOMAG Recycler or Stabilizer. (See Figure 3-1.)

The BOMAG Recycler is designed to meet all the requirements of in-place asphalt recycling.

The BOMAG Stabilizer, like the Recycler, is a hydrostatically driven machine but is intended for soil rehabilitation and improvement.

An electronic control system, used on the machine, assures the rotor maintains constant rotation, while the traction travel speed varies with the hardness of the material being processed.

The Recycler includes flared carbide cutting tips for high abrasive, high impact application, as in most asphalt materials. The Stabilizer has carbide faced paddles, which are used to rehabilitate and improve soils.

The BOMAG Model MPH 362-2 Recycler, or Stabilizer provides two wheel traction. The BOMAG Model MPH 364-2 Recycler, or Stabilizer, provides either two, or four, wheel traction.

08/05

Read, understand and follow all instructions given on the machine “Operating Instructions” and “Warning Decals and written in this manual, before starting or operating the machine.

DANGER:

Failure to observe the “Operating And Warning Instructions,” given in this manual and decals on the machine can cause serious INJURY, or DEATH. Only authorized personnel, who are fully trained in the machine operating procedures, can operate the BOMAG Recycler, or Stabilizer.

Keep the machine in GOOD mechanical condition at ALL times.

Do NOT operate a machine in need of repair. Attach an information tag on the steering wheel that reads “DO NOT OPERATE.” Remove the ignition key from the ignition switch. Repair ALL damage at once. Operating a damaged machine can result in serious injury and/or major machine damage.

3-3

Section 3 OPERATIONS MACHINE INSPECTION UPON RECEIPT FROM CARRIER. Thoroughly inspect the machine for damage and/or loss in transit, or evidence of either, the responsibility for which rests entirely on the carrier. Note any adverse results of this inspection on the shipping papers to substantiate your claim against the carrier.

Compare the shipment received with the packing list to confirm shortages from your purchase order and notify your BOMAG Distributor if any shortages are found.

of the machine before starting operations. Read the operation and maintenance manual. Ask your supervisor questions until you are aware of all limitations that affect the operation of this machine.

Be sure you have performed checks of all controls, in a safe area, before starting to work. (See this section).

The following are general safety comments that apply to all equipment. Review them often as safety reminders.

MANUAL CODE DESIGNATIONS. PERSONAL SAFETY INFORMATION. “Front” as used in this manual is the engine radiator/oil cooler-end of the machine. “Right” and “Left” are established by facing the normal direction of travel (forward) from the operator’s platform [See Figure 3-1].

SAFETY PRECAUTIONS. Your safety, and the safety of those around you, depends upon you using care and judgment in the operation of this equipment.

Know the position and function of all controls before operating this machine.

All equipment has its limitations. Understand the speed, braking, steering and stability characteristics

1. Avoid loose clothing, particularly cuffs and scarves.

2. Know what safety equipment is required on this machine, and what equipment may be required in specific applications. A hard hat, safety glasses, reflector-type vests, respirators, and earplugs are the types of equipment you may need.

3. Do not rush.

4. Know the hand signals used on the job and who has the responsibility for signaling.

5. If operating the machine on the road, know what warnings must be placed on the machine and if you will have an escort.

FIGURE 3-1. BOMAG RECYCLER/STABILIZER. 3-4

08/05

Section 3 OPERATIONS CONTROLS [See Figures 3-2 and 3-2A].

CONSOLE MOUNTED CONTROLS.

T RO

GAUGE

E

GREEN LIGHT

PRE S S UR OR

GREEN LIGHT

EL AV TR PRESS UR E

GAUGE

LIGHT

SWITCH

AUTO

ENGINE LOAD CONTROL

MAN.

ASC

F

N

R

LEFT RIGHT

FIGURE 3-2. OPERATOR’S CONTROL STATION - MPH 362-2 R/S. 08/05

3-5

3-6

GAUGE

E

GREEN LIGHT

PRE S S UR OR

GREEN LIGHT

T RO

LIGHT SWITCH

PRESS UR E

GAUGE

EL AV TR

AUTO

ENGINE LOAD CONTROL MAN.

ASC

R

N

F

LEFT

RIGHT

Section 3 OPERATIONS

FIGURE 3-2A. OPERATOR’S CONTROL STATION - MPH 364-2 R/S.

08/05

Section 3 OPERATIONS SWITCH PANEL [See Figure 3-3 and Table 3-1].

T RO

PRE S S UR OR

E

EL AV TR

GAUGE

GREEN LIGHT

PRESS UR E

T RO

PRE S S UR OR

GAUGE

E

GAUGE

ENGINE LOAD CONTROL

GREEN LIGHT

MAN.

GREEN LIGHT

EL AV TR

PRESS UR E

GAUGE

GREEN LIGHT

AUTO

ENGINE LOAD CONTROL MAN.

MPH 362-2 R/S

AUTO

MPH 364-2 R/S

FIGURE 3-3. SWITCH PANEL – SIDE DASH PANEL. ID 1

Description Rotor Pressure

Table 3-1 – Switch Panel Type Function Analog Gauge Indicates hydraulic pressure in the rotor drive sytem.

Typical pressure is dependent on the selected Rotor R PRE S SU Speed Range. Do NOT operate the unit if the presTO RE O R sure remains above 4000 psi continuously. Maximum pressure is 5000 psi. Do NOT operate the unit in a surging or unsteady cyclic mode, as damage to the hydraulic pump(s) will occur. See this section for the typical pressure for each rotor speed range.

Analog Gauge Indicates hydraulic pressure in the travel drive system. Typical pressure will range from 3000 to E L PRESSU RE AV TR 4000 psi, depending upon operating conditions.

Maximum pressure is 6000 psi. Do NOT operate the unit if the hydraulic pressure is in a surging or unsteady cyclic mode. Operating the machine in this condition may damage the hydraulic pumps.

Two Position On: Turns the rear mounted optional work lights Selector Switch On. Off: Turns the rear mounted optional work lights Off. NOTE: Work lights can be turned on without the ignition switch in the “ON” position.

Work lights are optional. The unit is provided with the work light switches and wiring as standard items.

Three Position OFF (left) - All lights are turned off.

Selector Switch PARK (center) - Front and rear amber parking lights are “ON”.

ON (right) Front and rear amber parking lights are “ON”. Front headlights “ON”.

PARK and ON - Tachometer, speedometer and 5 of the electronic gauges (except hourmeter) are illuminated.

NOTE: All lights can be turned on without the ignition switch in the “ON” position.

GAUGE

2

Travel Pressure

GAUGE

3

Work Lights

4

Head Lights/Parking Lights Off / Park / On

08/05

3-7

Section 3 OPERATIONS Table 3-1 – Switch Panel Type Function Two Position “0”: Turns OFF electronic traction control.

Selector Switch “I”: Turns ON electronic traction control.

Traction control “active”, red light ON. ASC NOTE: If theere is a problem with the traction control system, red light will “flash” a “blink code”.

ID 5

Description Traction Control

6

Four Way Flasher/Hazard

Optional Two Position Selector Switch

Left: Off Right: Red Hazard will flash.

NOTE: If less than three bulbs are functional, the switch will not flash red.

Lights can be turned on without the ignition switch in the “ON” position.

7

Turn Signals

Optional Three Position Selector Switch

Left: Left-hand turn signals are on and switch flashes green.

Center: Directional signals are off.

Right: Right-hand turn signals are on and switch flashes green.

NOTE: If either front or rear bulb is out, the switch will not flash green.

8

Horn

Push button

Press: Controls both front and rear horns.

Press to sound both front and rear horns.

NOTE: Horn will sound without the ignition switch in the “ON” position.

9

3-8

Four Wheel Drive Two Position Select Selector Switch Front Assist [MPH 364-2 R/S ONLY]

Up: Four Wheel Drive Select Front Assist “ON”.

- Works in Low Range only.

- In Low Range, Shift On & Off while moving.

Down: Two Wheel Drive Select.

08/05

Section 3 OPERATIONS

ID 10

08/05

Description Engine Load Control

Table 3-1 – Switch Panel Type Function Two Position MAN: TRANSPORT – In this mode the automatic Selector Switch engine load control is disabled. The travel speed is controlled directly by the Directional ENGINE LOAD CONTROL Control Lever (FNR). Use this mode when AUTO MAN. unit is in transport.

MAN: WORKING - If using the MAN mode while performing recycling or stabilizing operations, remember that the automatic engine load control is OFF. In this mode, the Travel Direction Control Lever (FNR) alone controls the travel speed. You must manually slow down, or speed up, the forward travel speed using the Travel Direction Control Lever (FNR) to maintain desired engine speed. If the forward travel speed is too great, the engine, or rotor, can slow down and/or stall.

NOTE: In order to maintain the selected rotor speed, the engine must not go below 2100 RPM AUTO: WORKING - Fully automatic engine load control, for working the unit. In this mode, the pressure in the rotor drive system is monitored to determine the load on the engine.

As the load increases and decreases, due to changes in the material being recycled, the forward travel speed is adjusted automatically. Travel sped is limited to 70% of full speed in AUTO mode.

The Travel Direction Control Lever (FNR) should be pushed all the way forward to maximize productivity. In order to maintain the selected rotor speed, the engine must not be operated below 2100 RPM. Use this mode only when unit is working.

Do NOT use automatic load control mode for unit transport. Change to MAN mode for unit transport.

3-9

Section 3 OPERATIONS

ID 11

Description Low Gear Range High Gear Range

Table 3-1 – Switch Panel Type Function Two Position General: Only LOW range is used for working. HIGH Switch range is for transport.

LOW: LOW RANGE – Axle travel motors are (Turtle) locked in full displacement.

Front assist, four wheel drive is enabled, if selected (MPH 364-2 R/S only).

HIGH: HIGH RANGE – Axle travel motors are (Rabbit) unlocked.

The motors are allowed to vary in displacement between maximum and minimum, depending on the load.

Speed: ONLY CHANGE SPEED RANGES WHEN THE MACHINE IS STOPPED ON LEVEL GROUND. Locking Push On: Push to engage Emergency Stop. Pressing Button button will lock it in the engaged position.

When the Emergency Stop push button is engaged, all systems, except the engine, are immediately disabled. The engine, however, will continue to operate until it is shut off with the ignition switch.

Off: Rotate button clockwise (CW) to release the Emergency Stop.

NOTE: The Emergency Stop push button must be OFF to start the engine. When the Emergency Stop push button is released, the FNR hand lever MUST be returned to NEUTRAL (N) to reset the travel controller.

GREEN LIGHT

` 12

Emergency Stop

GREEN LIGHT

LEASE RE

RN TO TU

3-10

08/05

Section 3 OPERATIONS IGNITION PANEL [See Figure 3-4 and Table 3-2].

FIGURE 3-4. IGNITION PANEL (RIGHT HAND DASH).

ID 13

Description Fuel Level

Table 3-2 – Gauge and Light Panel Type Function PowerView When accessed using “arrow buttons, menu and Display enter keys, the PowerView display screen will show available fuel contained inboth tanks, as a percentage, with 100% as full (see “access procedures” in THIS section).

Amber Warning LED

Red Shutdown /Derate LED

Display

Menu Key

14

Engine Hours

Arrow Keys

Enter Key

PowerView Display Amber Warning LED

Red Shutdown /Derate LED

When accessed using “arrow buttons, menu and enter keys, the PowerView display screen will show accumulated hours the engine has been running (see “access procedures” in THIS section).

Display

Menu Key

15

Charge Voltage

Arrow Keys

Enter Key

PowerView Display Amber Warning LED

Red Shutdown /Derate LED

Display

Menu Key

16

Engine Coolant Temperature

Arrow Keys

Enter Key

PowerView Display Amber Warning LED

Red Shutdown /Derate LED

Display

Menu Key

08/05

Arrow Keys

When accessed using “arrow buttons, menu and enter keys, the PowerView display screen will show charge voltage from the alternator. Voltage should register between 22 and 30 VDC (see “access procedures” in THIS section).

Enter Key

When accessed using “arrow buttons, menu and enter keys, the PowerView display screen will show engine coolant temperature (see “access procedures” in THIS section). Anytime the 212° F (100° C) limit is exceeded, the PowerView display screen will show an “active fault code” and “WARNING” icon. The audible alarms will sound and the amber warning light will come on. When the PowerView display receives a “severe fault code”, a “SHUTDOWN” icon will be shown onthe screen. The alarms will sound and the red shutdown/derate light will come on. CAUTION: Ignoring active FAULT codes could result in engine damage!

3-11

Section 3 OPERATIONS

ID 17

Description Hydraulic System Oil Temperature

Table 3-2 – Ignition Panel Type Function PowerView When accessed using “arrow buttons, menu and Display enter keys”, the PowerView display screen will show the hydraulic system oil temperature (see “access procedures” in THIS section). Should oil temperature exceed 180o F , the PowerView display screen will show an “active fault code” and “WARNING” icon.

The audible alarms will sound and the amber warning light will come on. Should oil temperature exceed 190o F , the PowerView display screen will show a “severe fault code” and “SHUTDOWN” icon.

The audible alarms will sound and the red shutdown/ derate light will come on.

CAUTION: Ignoring active FAULT codes could result in hydraulic system damage!

Amber Warning LED

Red Shutdown /Derate LED

Display

Menu Key

18

Engine Oil Pressure

Arrow Keys

Enter Key

PowerView Display Amber Warning LED

Red Shutdown /Derate LED

Display

Menu Key

19

Rotor System Hydraulic Charge Oil Filter Condition

Arrow Keys

Enter Key

PowerView Display Amber Warning LED

Red Shutdown /Derate LED

Display

Menu Key

3-12

Arrow Keys

Enter Key

When accessed using “arrow buttons, menu and enter keys, the PowerView display screen will show the engine oil pressure (see “access procedures” in THIS section). Anytime the minimum allowable oil pressure is reached, the PowerView display screen will show an “active fault code” and “WARNING” icon.

The audible alarms will sound and the amber warning light will come on. If the fault condition continues, the PowerView display will show a “severe fault code” and “SHUTDOWN” icon, on the screen. The audible alarms will sound and the red shutdown/derate light will come on.

CAUTION: Ignoring active FAULT codes could result in engine damage!

The PowerView display screen will indicate if the rotor charge oil filter has reached its maximum holding capacity and must be changed (see Section 4 MAINTENANCE). Anytime the filters maximum holding capacity is reached, the PowerView display screenwill show an “active fault code” and “WARNING” icon. The audible alarms will sound and the amber warning light will come on. If the fault condition still exists, after 2 minutes, the PowerView display receives a “severe fault code” and a “SHUTDOWN” icon will be shown on the screen. The audible alarms will sound continuously and the red shutdown/derate light will come on.

CAUTION: Ignoring active FAULT codes could result in rotor hydraulic system damage!

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Section 3 OPERATIONS

ID 20

Description Travel System Hydraulic Charge Oil Filter Condition

Table 3-2 – Ignition Panel Type Function PowerView The PowerView display screen will indicate if the Display travel charge oil filter has reached its maximum holding capacity and must be changed (see Section 4 MAINTENANCE). Anytime the filter’s maximum holding capacity is reached, the PowerView display screenwill show an “active fault code” and “WARNING” icon. The audible alarms will sound and the amber warning light will come on. If the fault condition still exists, after 2 minutes, the PowerView display receives a “severe fault code” and a “SHUTDOWN” icon will be shown, on the screen.

The audible alarms will sound continuously and the red shutdown/derate light will come on.

CAUTION: Ignoring active FAULT codes could result in travel hydraulic system damage!

PowerView The PowerView display screen will indicate if the Display steer/auxiliary systems oil filter has reached its maximum holding capacity and must be changed (see Section 4 - MAINTENANCE). Anytime the filter’s maximum holding capacity is reached, the PowerView display screenwill show an “active fault code” and “WARNING” icon. The audible alarms will sound and the amber warning light will come on. If the fault condition still exists, after 2 minutes, the PowerView display receives a “severe fault code” and a “SHUTDOWN” icon will be shown, on the screen.

The audible alarms will sound continuously and the red shutdown/derate light will come on.

CAUTION: Ignoring active FAULT codes could result in steer/auxiliary hydraulic systems damage!

PowerView The PowerView display screen will indicate if the Display air flow, to the engine, has a restricted condition and must be cleared (see Section 4 MAINTENANCE). Anytime the air flow has a restricted condition, the PowerView display screen will show an “active fault code” and “WARNING” icon. The audible alarms will sound and the amber warning light will come on. If the fault condition still exists, after 2 minutes, the PowerView display receives a “severe fault code” and a “SHUTDOWN” icon will be shown, on the screen. The audible alarms will sound continuously and the red shutdown/derate light will come on. Also, check the visual restriction indicator located on top of the engine air inlet tube, between the air cleaner outlet and turbocharger air inlet. If indicator is between 20 and 25 inches H20, do NOT operate the unit until the restriction is cleared.

CAUTION: Ignoring active FAULT codes could result in engine damage!

Amber Warning LED

Red Shutdown /Derate LED

Display

Menu Key

21

Steer/Aux Systems Hydraulic Return Oil Filter Condition

Arrow Keys

Amber Warning LED

Enter Key

Red Shutdown /Derate LED

Display

Menu Key

22

Engine Inlet Air Flow Restriction

Arrow Keys

Amber Warning LED

Enter Key

Red Shutdown /Derate LED

Display

Menu Key

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Arrow Keys

Enter Key

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Section 3 OPERATIONS

ID 23

Description Low Rotor Drive System Hydraulic Charge Oil Pressure

Table 3-2 – Ignition Panel Type Function PowerView The PowerView display screen will indicate that there Display is low rotor hydraulic charge oil pressure, in the rotor drive system, when pressure drops below 200 psi.

Anytime the rotor charge oil pressure drops below 200psi, the PowerView display screen will show an “active fault code” and “WARNING” icon.

The audible alarms will sound and the amber warning light will come on. If the fault condition still exists, after 2 minutes, the PowerView SHUTDOWN” icon will be shown, on the screen. The audible alarms will sound continuously and the red shutdown/derate light will come on.

CAUTION: Ignoring active FAULT codes could result in rotor hydraulic system damage!

Stop engine immediately and find and correct cause of low charge oil pressure.

PowerView When accessed using “arrow buttons, menu and Display enter keys”, the PowerView display screen will provide a digital readout of the over-the -ground speed of the machine (see “access procedures” in THIS section). The travel speed will shown in feet per minute (FPM) up to a speed of 1 MPH (1.61 kph) and miles per hour (MPH) for all speeds above 1 MPH (1.61 kph).

Amber Warning LED

Red Shutdown /Derate LED

Display

Menu Key

24

Machine Travel Speed

Arrow Keys

Amber Warning LED

Enter Key

Red Shutdown /Derate LED

Display

Menu Key

25

Engine Speed (RPM)

Arrow Keys

Enter Key

PowerView Display Amber Warning LED

Red Shutdown /Derate LED

Display

Menu Key

26

Throttle (Engine Speed Increase/Decrease)

Arrow Keys

Enter Key

Three Position Momentary Switch (Center Returning)

When accessed using “arrow buttons, menu and enter keys”, the PowerView display screen will provide digital readout of engine revolutions per minute (RPM) (see “access procedures” in THIS section). While the machine is working, the engine RPM should not be allowed to operate continuously below 2,100 RPM. Typically, while working, the engine should run at 2,100-2,300 RPM. Low idle is 850 RPM.

Left: Right: Center:

Decrease (DEC) engine speed (RPM).

Increase (INC) engine speed (RPM).

Return position.

NOTE:

Rotor will operate only when engine is at HIGH idle.

Do NOT drive the unit at LOW idle, or damage to the travel hydraulic system can occur.

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Section 3 OPERATIONS

ID 27

Description Brake - Left Light

Table 3-2 – Ignition Panel Type Function Indicator Lamp Engage Brake – Left: When lit, this red lamp indicates that the left rear brake is engaged. During normal BRAKE operations this will occur whenever: 1. The Brake Switch (See 29) is turned on.

RIGHT LEFT 2. The left brake is momentarily toggled ON using the 0 I momentary switch located on top of the Travel Direction Control Lever (FNR).

RED LIGHT

28

Brake - Right Light

RED LIGHT

Indicator Lamp BRAKE RED LIGHT

RED LIGHT

RIGHT

LEFT 0

29

Brake Switch

I

Two Position Selector Switch BRAKE RED LIGHT

RED LIGHT

RIGHT

LEFT 0

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I

Engage Brake – Right: When lit, this red lamp indicates that the right rear brake is engaged. During normal operations this will occur whenever: 1. The Brake Switch (See 29) is turned on.

2. The right brake is momentarily toggled ON using the momentary switch located on top of the Travel Direction Control Lever (FNR).

Used to set the rear axle SAHR brakes while engine is running.

Off: When in the “0” position, brake is released provided engine is running and the E-Stop switch is released. When the brake switch is turned “off” (“0” position), the FNR lever MUST be returned to NEUTRAL (N) to reset the travel controller.

On: Rotating the switch to the “I” position will cause both the right and left SAHR brakes on the rear axle to be set and any travel input signal is defeated (unit can NOT drive against the brakes). This will cause both right and left red brake lights to be illuminated. All power to the Travel/Load Controller is off.

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Section 3 OPERATIONS

ID 30

Description Ignition

Table 3-2 – Ignition Panel Type Function Five Position The five position key switch has the following Key switch functionality: Function Label Position [NOT USED] P OFF O P Left of vertical Not used.

I ON II III

31

Rotor - On/Off

Two Position Selector Switch 0

32

Rotor Speed

ROTOR

|

Two Position Selector Switch

I

3-16

[NOT USED] START

II

O

Vertical

Off position (Key may be removed).

I

Right of vertical IGNITION ON position.

Provides power to all systems.

II

Right of vertical Not used.

III

Right of vertical Ignition START position.

Spring loaded; returns to “I” (ON) when released.

Rotor On/Off – Used to turn the rotor ON or OFF. “O” Position: Rotor OFF “I” Position: Rotor ON NOTE: Engine must be at full throttle (2,100 RPM), or switch will be disabled.

Speed I / II – Used to select speed of rotor.

I: 135 RPM Rotor Speed II: 150 RPM Rotor Speed NOTE: Engine must be at full throttle (2,100 RPM), or rotor will not operate.

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Section 3 OPERATIONS ALARM PANEL [See Figure 3-5 and Table 3-3].

FIGURE 3-5. ALARM PANEL (LEFT HAND DASH).

ID 33

Description Engine Systems Diagnostic Information

34

Warning Alarms

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Table 3-3 – Alarm Panel Type Function 4 Light Each of 4 lights (STOP - WARNING - MAINT - WAIT) Gauge monitor engine systems and are lighted as a diagnostic message if a engine malfunction is detected. The engine systems diagnostic information, on the 4 light gauge, works in conjunction with the PowerView monitoring system. The light will only activate if a engine fault is noted. The PowerView monitoring system may, or may not, recognize the fault. If the PowerView monitoring system does not recognize the fault, NO warning buzzers will sound.

Electrical Alarms (2)

High and low tone warning alarms work in conjunction with the PowerView monitoring system.

Both alarms will sound if any monitored system malfunction, warning or fault code is detected bt the PowerView monitoring system.

Touch the top of the dash mounted warning alarm to cancel the alarm. After cancelled, both alarms will sound, again, if any monitored system continues to have a malfunction, warning, or fault code which is detected by the PowerView monitoring system. The warning alarmswill continue to sound until the cause of the malfunction and/or warning, or fault codes is corrected.

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Section 3 OPERATIONS OPERATOR CONTROL PANEL [See Figure 3-6 and Table 3-4].

F

N

R

LEFT

RIGHT

FIGURE 3-6. OPERATOR CONTROL PANEL.

ID 35

Description Travel Direction (FNR) And Speed Control Lever

Table 3-4 – Operator Control Panel Type Function Lever Travel direction (FNR) and speed control.

Forward: Engages hydrostatic drive forward (F).

F Neutral: Places hydrostatic drive in neutral (N).

Reverse: Engages hydrostatic drive reverse (R).

N The Travel Direction Control Lever (FNR) is used to control the forward/reverse direction of travel, travel speed and dynamic braking. Motion of the R Travel Direction Control Lever (FNR), forward and reverse, will set the direction and speed of travel.

When Travel Direction Control Lever (FNR) is set to reverse (R) direction, the backup alarm will sound.

Pulling, or pushing, the Travel Direction Control Lever (FNR) towards the center, or neutral, (N) position causes dynamic braking to occur.

LEFT

RIGHT

ALWAYS move the Travel Direction Control Lever (FNR) to NEUTRAL and allow the machine to come to a FULL AND COMPLETE STOP before moving the Travel Direction Control Lever (FNR) in the opposite direction (e.g. Forward to Reverse).

3-18

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Section 3 OPERATIONS ID 36

Description Left/Right Independent Brake Switch

Table 3-4 – Throttle Control Type Function Three Position Lever Mounted Momentary Center Returning Switch – Momentary Switch Right: Rear Brake Right engage (Center Returning) Left: Rear Brake Left engage The momentary center-returning switch is used to engage and disengage the SAHR brakes, on the right or left side of the rear axle. This will assist in control of the direction of travel (steering). Braking either wheel allows more traction to be applied to the opposite rear wheel. When switch is used to apply either right or left brake the corresponding brake indicator lamp, on the Ignition Panel, will be lit.

Three Position Momentary Center Returning Switch – Momentary Switch Down: Lower Rotor (Center Returning) Up: Raise Rotor Used to adjust the height of the rotor head and depth of cut. The actual depth of cut is shown on the large CENTER indicator located on the right rear side of the frame, behind the operator.

BRAKE ROCKER SWITCH

F

N

BRAKE APPLICATION

R

LEFT

37

Rotor Lift

38

Rear Rotor Door

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RIGHT

Three Position Momentary Center Returning Switch – Momentary Switch Down: Close (lower) Rear Rotor Hood Door.

(Center Returning) Up: Open (raise )Rear Rotor Hood Door.

The height of the rear door on the rotor hood is shown by the position on the lower LEFT indicator located on the right rear side of the frame, behind the operator.

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Section 3 OPERATIONS STEERING WHEEL ADJUSTMENT [See Figure 3-7 and Table 3-5].

FIGURE 3-7. STEERING WHEEL ADJUSTMENT.

ID 39

Description Steering Wheel Tilt

Table 3-5 – Steering Wheel Adjustment Type Function Lever Used to adjust the vertical angle of the steering wheel.

AUXILIARY PANEL [See Figure 3-8 and Table 3-6].

FIGURE 3-8. AUXILIARY PANEL (UNDER DASH).

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Section 3 OPERATIONS

ID 40

Description Travel Pump Threshold Calibration

41

FNR Override Control (ON/OFF) (Used With ITEM 43)

Table 3-6 – Auxiliary Panel Type Function Momentary The travel pump electronic dieplacement control Push Button EDC) threshold values, in theTRAVEL/LOAD CONTROLLER, can be set by using the Threshold Calibrate Switch.

If travel pump threshold adjustment is required, it MUST be done by authorized, trained service personnel, using Bomag MPH 362, 364 Instructions For Repair Manual, catalog number 0852680.

Two position Selector Switch I

Activates the backup travel control system.

Switch in OFF (0) position places override system in OFF (NORMAL unit operating) condition.

Switch in ON (I) position places override system in Override condition. The unit can now be moved using the BACKUP FNR SWITCH (ITEM 43).

O

42

Engine Load Control Setpoint

Potentiometer

–

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+

Adjusts the engine load control setting.

Functions when the ENGINE LOAD CONTROL SWITCH (ITEM 10) is in AUTO position. This Potentiometer (POT) is factory adjusted for full engine load with travel speeds from 5 to 40 fpm.

Turning the POT + (clockwise) increases load on the engine (engine rpm decreases and rotor drive pressure increases).

Turning the POT - (counterclockwise) decreases load on the engine (engine rpm increases and rotor drive pressure decreases).

If the engine load control set point adjustment is required, it SHOULD be done by authorized, trained service personnel, using Bomag MPH 362, 364 Instructions For Repair Manual, catalog number 0852680.

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Section 3 OPERATIONS BACKUP TRAVEL CONTROL (FNR) SYSTEM [See Figure 3-9 and Table 3-7].

FIGURE 3-9. BACKUP TRAVEL CONTROL (FNR) SYSTEM.

ID 43

Table 3-7 – BACKUP TRAVEL CONTROL SYSTEM Description Type Function Backup Travel Momentary Limited travel control system is for transporting unit Control (FNR) Three Position if there is a problem with the FNR, travel controller, (Used With ITEM 41) Switch or wiring.

Do NOT use this mode for “working” the unit.

F N

R

3-22

Backup FNR switch is activated when FNR override switch (ITEM 41) is in the ON position. Forward, or reverse, travel speed is limited to 0.75 mph (66 fpm) in LOW speed range and 3.0 mph (4.8 kph) in HIGH speed range, at FULL throttle (high idle).

Backup FNR switch controls direction of travel and braking of unit. Smooth operation of the unit will not be possible, as proportional control is not available Adjust engine throttle speed to vary travel speed, if required Move the FNR switch out of neutral, into FORWARD (F) position, (away from operator) to move the unit in FORWARD. Release the FNR switch to slow down, returning to NEUTRAL (N) to stop.

Move the FNR switch out of neutral, into REVERSE (R) position, (toward operator) to move the unit in REVERSE. Release the FNR switch to slow down, returning to NEUTRAL (N) to stop.

ALWAYS move the FNR switch to neutral, and allow the unit to come to a STOP, before changing direction of travel. See ITEM 11 for gear range selection procedures.

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Section 3 OPERATIONS TRAVEL/LOAD CONTROLLER LED STATUS OR ERROR LIGHTS [See Figure 3-10 and Table 3-8].

FIGURE 3-10. TRAVEL/LOAD CONTROLLER LED STATUS OR ERROR LIGHTS.

ID 44

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Table 3-8. TRAVEL/LOAD CONTROLLER LED STATUS OR ERROR LIGHTS DESCRIPTION TYPE FUNCTION Controller LED 4 LED Lamps The controller operates both the travel system and Status Or Error the engine load control system. If either the Lights emergency stop or the brake switches are turned on, the brakes will apply and any travel input signal is defeated. All power to the controller is OFF. When the emergency stop and the brake switches are released (turned OFF) the FNR control lever MUST be returned to NEUTRAL (N), to reset the controller.

Four (4) LED lamps are visible, to the operator, through the clear dash mounted cover. The lights indicate controller status, or if faults (error) were detected. Viewed through cover, from left to right, they are: POWER - Green SYSTEM - Green MODE - Yellow STATUS - Red Controller “LED Status” (For normal operation) Green - POWER ON Green - SYSTEM ON Yellow - MODE - should flash every 2 seconds Red - STATUS - should be OFF If any of the LED lamps are NOT as described, above, the controller has detected a “fault”.

If all of the LED lamps are correct, except, the RED STATUS lamp, a fault has been detected and the cause of the fault must be diagnosed and corrected by authorized, trained, service personnel using Bomag MPH 362, 364 Instructions For Repair Manual, catalog number 0852680.

3-23

Section 3 OPERATIONS CHECKS WITH THE ENGINE STOPPED.

Prior to starting the engine, ALSO read the CUMMINS "Operation and Maintenance Manual - QSM 11 Engine” furnished with the machine. Two types of engines are covered by the Cummins manual, Marine and Industrial models. Only material which references "Industrial" model applies to the machine's engine.

1. Before starting the engine, perform normal engine checks including:

• Engine Oil Level • Engine Coolant Level • Fan Inspection • Belt Inspection 2. Open the hood access door on right hand side of engine. Set the Battery Disconnect Switch to the “ON” position and close the hood access door.

NOTE: The Battery Disconnect Switch is used to remove ALL electrical power provided by the batteries when machine is not in use.

3. Check the tightness of the rotor hood skid bolts before and during work operation. Tighten as required.

Failure to keep the skid bolts tight can result in rotor hood damage.

PREPARING THE MACHINE FOR STARTING [See Figures 3-11 and 3-12].

1. Report and correct any apparent machine damage. Do not operate the Recycler or Stabilizer until all corrections have been satisfactorily completed.

2. Note all work-site hazards and obstructions such as ditches, overhead electrical wires, blocks at wheels, etc.

3. Clean machine floor decks if cluttered or slippery.

4. Ensure proper ventilation, or provide exhaust venting if starting indoors.

5. Remove all loose objects stored on, or near, the machine.

6. Remove all items that should not be on the rotor hood or the rotor areas.

Be particularly careful if the Recycler or Stabilizer is not a machine that you normally operate.

MOUNTING AND DISMOUNTING 1. Always walk - never run.

2. Make sure that steps and grab irons are free of mud and other debris.

3. Stop the engine if the machine is to be left unattended for any reason.

4. Remove, or secure, all maintenance or personal items such as lunch boxes, chains, shovels, etc.

4. Always secure, all equipment and attachments before dismounting.

5. Secure all caps and filler plugs for fuels, oils, fluids, battery covers and radiator.

5. Apply brakes and park in a clear, authorized area before leaving machine. Whenever possible, only park on a flat, or near level grade.

6. Check the fluid levels of coolant, lubricating oil and fuel prior to starting engine (See Section 4 MAINTENANCE).

6. Never jump off of the machine.

7. Verify that all access doors and compartment covers are closed. Warn all personnel in the area that you will be starting the engine, especially those who may have been servicing the machine, and personnel in its path.

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Section 3 OPERATIONS STARTING THE ENGINE [See Figures 3-11 and 3-12].

1. Verify that no one, other than the operator, is on or near the machine during start up.

2. Go to the Operator’s Control Station, sit down, adjust the seat position, as necessary, and fasten seat belt.

DANGER:

The seat belt must be worn if the machine is equipped with the ROPS, or ROPS/FOPS.

3. Set the following switches to their prestart positions:

• Set the Rotor On/Off Switch to the Off (Left)

7. As soon as engine starts, check oil pressure shown on PowerView display panel. If within 15 seconds, the engine fails to register oil pressure on the panel, STOP THE ENGINE IMMEDIATELY. Consult the Cummins “Engine Operation and Maintenance Manual. Oil pressure should be at least 10 psi at 850 RPM (Low Idle), or 35 psi at 2100 RPM (High Idle). Oil pressure will run higher during normal operation.

Operating the engine for longer than 15 seconds without oil pressure will result in serious damage to the engine.

8. Idle the engine three to five minutes at approximately 1,000 RPM prior to attempting to operate under load.

position.

• Place the Travel Direction Control Lever • • •

(FNR) to the Neutral (N) position.

Set the Engine Load Control selector switch to MAN (Manual).

Set the Emergency Stop button to the OFF (released) position. Rotate button to release.

Set the Brake Switch to ON.

NOTE: The left and right brake lights will be “ON” regardless of whether or not the Brake Switch is ON whenever the engine is not running. Double-check to ensure the brake switch is in the ON position.

4. Set throttle control switch to approximately 25% of the full throttle position.

5. Insert the key into the key switch on the bottom of the Right Hand Operator’s Panel. The key should be in the vertical position when inserted.

6. Rotate the switch to the “START” position and hold until engine starts. Release the switch and allow the spring-loaded switch to return to the “I” (Ignition On) position.

Do not crank the engine more than four, 30 second periods. If engine does not start, consult the Cummins “Engine Operation and Maintenance Manual” furnished with the machine.

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9. If starting a cold engine, increase engine speed (RPM) slowly to provide adequate lubrication to the bearings and allow oil pressure to stabilize.

Do not idle engine too long.

Consult the Cummins “Engine Operation and Maintenance Manual.”

10. Run engine at partial throttle and no-load until it is fully warmed-up. Run the engine at maxmum speed only after engine and hydraulic oil are at operating temperature to prevent damage to the engine and other machine systems compnents.

POWERVIEW MULTIFUNCTION MONITORING SYSTEM - SUPPORTED INFORMATION ACCESS AND NAVIGATION WITHIN THE SYSTEM. The PowerView multifunction monitoring system provides electronic instrumentation and monitoring of the machine’s engine, hydraulic travel, steering and rotor systems. The PowerView is a multifunction system that allows the equipment operator and service personnel to view supported engine and hydraulic systems parameters and service codes.

The Powerview display is a backlit LCD display. It can show either a single parameter, or a quadrant display showing 4 parameters simultaneously, as well as fault codes - with text - for the most common fault conditions. Use the following information to access and navigate within the PowerView menus.

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Section 3 OPERATIONS

3-36

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Section 3 OPERATIONS CHECKS WITH THE ENGINE RUNNING. [See Figures 3-11 and 3-12].

Before testing steering, check to see that no personnel are inside of the front wheels/frame pinch area, or in harms way adjacent to the area that will be covered by the rotation of the front wheels during the steering test. Check both sides of machine.

1. Test steering, both right and left, while moving slowly.

2. Test the Forward, Reverse and Neutral positions of the hydrostatic transmission to be sure the machine direction can be controlled. Listen carefully to the engine and gear components while moving slowly to determine if there are noises that may indicate possible damage.

Verify that backup alarm sounds when in reverse.

OPERATING PRECAUTIONS. [See Figures 3-11 and 3-12].

Make sure that the following cautions are observed when operating the BOMAG Recycler or Stabilizer.

To prevent injury to personnel and/or damage to the machine, ALWAYS observe ALL of the following “Operating Precautions.”

1. READ, UNDERSTAND and FOLLOW ALL information shown on the “Operating Instructions” and “Warning” decals, found on the machine [see Figures 3-11 and 3-12] and the instructions written in THIS manual.

DANGER:

3. Operate all machine controls, observing the feel of controls and the smooth response of the machine.

NOTE: The rotor will not operate unless the engine is running at high idle speed, 2,100 RPM. NOTE: Rotor motion is permitted while in high gear as it allows hydraulic fluid to recirculate and cool.

4. Observe the exhaust stack.

• White smoke indicates water leakage to engine;

• Black smoke indicates improper fuel control or blocked air flow.

• Periodic backfire, puffs of smoke, etc., accompanied by poor power indicates an engine in need of repair.

5. Check function of safety devices, lights, backup alarm, and emergency stop, etc.

FAILURE to observe the following precautions and/or the machine “OPERATION AND WARNING INSTRUCTIONS” given in this section and decals on the machine can cause serious INJURY, or DEATH. Only authorized personnel, who are fully trained in the machine operating procedures, can operate the BOMAG Recycler or Stabilizer.

2. USE a SLOW SPEED [work range] and ADDITIONAL CAUTION when nearing, or operating, the machine close to a slope and/or when traveling down a slope.

3. ALWAYS shift the transmission into LOW range - on LEVEL ground - BEFORE traveling up or down any slope (see THIS Section).

DANGER:

Do NOT shift the transmission while the machine is moving on ANY slope. Loss of hydrostatic braking will occur when the transmission is in neutral or anytime it is shifted.

4. USE extra CAUTION when operating the machine near personnel and/or other objects or machines.

5. Do NOT operate a machine in need of repair.

Report ANY needed repairs and have the machine repaired IMMEDIATELY. 6. Keep ALL personnel CLEAR of the rotor and hood area at ALL times, during operation, or service, of the machine.

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3-37

Section 3 OPERATIONS 7. The operator must remain seated, at all times, during machine operation. Keep hands and feet INSIDE the operator’s control station at ALL times. Allow NO riders on the machine at ANY time.

8. Do NOT suddenly stop the machine during operation.

9. Report any problem with the machine, noted during operation, and have it repaired immediately.

10. Observe the PowerView display information and other gauges frequently.

11. Keep throttle at HIGH idle while working the machine.

During operation do NOT slow travel, or rotor speed, by lowering the engine speed. Use only the Travel Direction Control Lever (FNR) to slow the machine.

12. Do not work under overhangs, electric wires, or where there is danger of a slide.

13. Use extra caution in crossing side hills, ridges, logs, ditches, etc.

14. Maintain ground speed consistent with ground conditions. Do NOT coast.

15. Know and understand the traffic flow patterns of your job, and obey flagmen, road signs, or signals.

NOTE: The Oil Pressure, Water Temperature and Hydraulic Oil Temperature readings are shown on the PowerView display panel, located on the right-hand operator’s panel. If the established temperatures are exceeded, fault codes will be displayed and the audible alarms will sound.

18. Never introduce dirt, or other contaminants, into the fuel or hydraulic tanks whenever refilling.

When adding hydraulic oil to the tank, always filter oil through a minimum 6 micron filter.

19. Never allow engine to run at LOW IDLE for prolonged periods of time.

20. Never move the hydrostatic drive Directional Control Lever (FNR) from forward (F) to reverse (R), or reverse (R) to forward (F), without coming to a complete stop first. Always stop the machine in the NEUTRAL (N) position prior to changing direction of travel.

21. Rotor rotation is allowed in high gear, provided the rotor has been raised above the surface being cut. Attempting to operate the machine while the Recycler/Stabilizer is in high gear and moving will cause hydraulic pump and/or system damage.

22. Do not operate a machine NOT having the “Operating Instructions” 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.

Understand the machine’s limitations and keep it under control at all times. Do NOT try to do too much work - too fast.

16. BEFORE getting off the machine, put the directional/speed control handle (FNR) in the “NEUTRAL” (N) position. Set the Brake switch to ON. Stop the engine.

17. Visually check gauges and information accessed on the PowerView display panel. Do NOT let water temperature go above 210° F and oil temperature above 195° F. 3-38

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Section 3 OPERATIONS PREPARATION FOR WORK OPERATIONS. 1. Consult the engineer in charge of work site for specifications as to depth and width of cut, degree of mixing, additive quantity, and other relevant information.

2. Inspect the condition of the cutting teeth in relation to the job to be performed. Replace cutting teeth as required, to help prolong rotor life.

Make sure that ALL personnel stay well clear of the machine when the rotor hood does NOT cover the rotor teeth, at all times.

Failure to replace worn teeth will result in premature wear of the sockets and/or end segments.

STARTING TRACTION (TRANSPORT OPERTION) [See Figures 3-11 and 3-12].

1. If not previously done, start the engine.

2. Raise the rotor and rotor hood a completely UP. 3. Move the tailgate control to close the tailgate.

Be certain that the cutting teeth and hood are sufficiently above the ground level to clear ALL terrain over which the machine will travel. Raise the rotor and rotor hood completely UP. 4. Turn the Rotor ON/OFF switch to the OFF position.

• LOW RANGE – Axle travel motor is locked in full displacement. Front assist -4WD (MPH 364) is enabled, if so equipped and selected.

• HIGH RANGE – Axle travel motor is unlocked and allowed to vary in displace ment between maximum and minimum depending on the load.

Only change speed ranges when the machine is STOPPED, on LEVEL ground.

To shift gears:

• STOP machine on LEVEL ground.

• Move the Travel Direction Control Lever (FNR) to neutral (N).

• Actuate the shift switch to select the desired gear.

DANGER:

Never attempt to travel in the reverse direction with the rotor in the ground. Never put the transmission in neutral (N), or shift the transmission, when the machine is on a slope. The machine MUST be STOPPED, on LEVEL ground, BEFORE shifting the transmission.

Use the Travel Direction Control Lever (FNR) ONLY for slowing down the machine. Never use the throttle lever to slow down the machine. Using the throttle lever to slow down can result in personal injury.

5. Set the Engine Load Control to MAN (Manual).

6. Release brake by rotating the brake switch to the OFF position.

7. Select High, or LOW, travel gear, using the two position selector switch on the console for the desired over-the-ground speed range. Only LOW Range is to be used for working. High Range is for transport, but low range can be used if desired.

08/05

3-39

Section 3 OPERATIONS STOPPING TRACTION. 1. Bring the Travel Direction Control Lever (FNR) gradually to the neutral (N) position.

2. With machine stopped, engage parking brake by placing the brake switch ON (applied), with the application indicator light then being illuminated.

3. Slowly move the rotor position control switch to the “lower” position. Gently lower rotor and rotor hood to the ground, but do NOT apply down pressure.

ASPHALT PULVERIZATION INFORMATION [See Figures 3-11 and 3-12].

DANGER:

Never lower rotor directly into non-scarified pavement. This is dangerous as cutting into a nonscarified surface may cause the machine to move suddenly backwards without warning. First cut across pavement by either lowering rotor into non-paved edge, or scarify pavement at start area.

All handles, steps, walkways and platforms must be kept free of grease, oils, fuels, mud, snow and ice.

When the machine is used for asphalt and lime applications, it is possible small particles of asphalt and lime may become embedded in the engine radiator and hydraulic oil and lubrication oil cooler(s). Watch for this condition.

Periodically clean the coolers using solvent. This will prevent a buildup of asphalt, lime or dust on the cooling fins of these components, which decreases their efficiency.

3-40

OPERATING INSTRUCTIONS [See Figures 3-11 and 3-12].

The following instructions assume that you are thoroughly familiar with the location, the settings and the operation of ALL machine controls.

DANGER:

Failure to observe the “Operating and Warning Instructions,” given in this manual and the decals on the machine can result in INJURY, or DEATH. Only authorized personnel, fully trained in BOMAG Recycler, or Stabilizer, operating procedures, are allowed to operate this machine.

The high-speed range of the traction transmission is provided to reduce transit time between jobs, or for interim movements within a job site. Only LOW range is used for working.

The high-speed range (Rabbit) is NEVER to be used when the rotor is performing work operations.

Attempting to perform a cut using the rotor while the BOMAG Recycler, or Stabilizer, is in the high transmission range CAN result in damage to the rotor, the rotor drives and/or the hydrostatic traction drive.

WORK OPERATION [See Figures 3-11, 3-12 and Table 3-9].

If not previously done, prepare the machine for work operations (See Preparation for Work Operations).

1. Raise the rotor using the manual control switch on the armrest mounted operator control prior to starting the rotor.

2. Start rotation of the rotor by selecting the desired rotor speed (I or II) and turning the Rotor ON/OFF switch to the ON position.

08/05

Section 3 OPERATIONS

OPERATING INSTRUCTIONS ! WA R N I N G :

Read the Operating Manual. Inspect machine before use (See Operating Manual).

STARTING 1.

2.

3.

4.

5.

6.

Release emergency stop button.

Switch brake to ON position.

Move travel direction control lever to “N” (NEUTRAL).

Turn the rotor switch to OFF. Move engine throttle to slightly above LOW idle. Never more than 25% throttle (<1200 RPM).

Turn key switch to START engine. Never crank starter more than 30 seconds.

OPERATING DO NOT operate above half throttle UNTIL hydraulic temperature is over 100 F (38 C).

! WA R N I N G :

Check machine function AND BRAKE OPERATION before use (See Operating Manual).

1. Shift speed range switch to LOW (turtle) for working. Shift to HIGH (hare) for transporting.

(CAUTION: SHIFT ONLY ON LEVEL GROUND. COME TO A COMPLETE STOP BEFORE SHIFTING. HIGH RANGE IS FOR TRANSPORTING ONLY.) 2. Advance engine throttle to FULL. 3. Switch brake to OFF position.

4. Move the travel direction control lever in direction of travel. Move lever away from “N” to increase speed. Move lever toward “N” to slow or stop. Bring machine to a full stop before reversing direction.

5. To start rotor, select rotor speed. Turn the rotor switch to ON. Note: Engine throttle must be at FULL for rotor to turn on.

6. Press the rotor lift switch to lower or raise the rotor and adjust depth of cut. Do not attempt to move in the reverse direction while rotor is in the ground.

7. Use the rear rotor door switch to open or close the rear door and adjust door position.

8. Use the front rotor door switch to open or close the front door and adjust door position (OPTIONAL).

9. Use rocker switch on top of travel direction control lever to engage left or right brake to assist steering when needed. (WARNING: REDUCE SPEED BEFORE APPLYING LEFT OR RIGHT BRAKE.)

! C AU T I O N :

Do not operate in a surging or unsteady cyclic mode.

Maximum production and smooth operation is achieved by adjusting travel speed and rotor door opening.

Surging or unsteady cycling of machine indicates that these settings are not correct. Severe damage to hydraulics will result if operated in a surging mode.

NORMAL STOPPING 1.

2.

3.

4.

Move the travel direction control lever to “N”.

Use the rotor lift switch to raise the rotor out of the ground.

Turn the rotor switch to OFF. Switch brake to ON position. (CAUTION: Apply brake only when machine has come to a complete stop.)

! WA R N I N G :

Transmission will NOT hold parked machine.

5. Move throttle to LOW idle. (CAUTION: ALLOW ENGINE TO RUN AT LOW IDLE 3-5 MINUTES AFTER OPERATING AT FULL LOAD TO COOL DOWN THE ENGINE AND HYDRAULICS.) 6. Turn key switch to OFF.

EMERGENCY STOP 1. Press EMERGENCY STOP button.

2. Move the travel direction control to “N”.

PN 0938339

FIGURE 3-11. OPERATING INSTRUCTIONS DECAL. 08/05

3-41

Section 3 OPERATIONS

FIGURE 3-12. WARNING DECAL. 3-42

08/05

Section 3 OPERATIONS STARTING ROTOR [See Figures 3-12 and 3-13].

1. Set the engine throttle to the “HIGH” idle (Full Throttle).

Engine must be at full throttle for rotor operation. Anything other than full throttle will cause rotation to cease.

2. Select the desired Rotor Speed on the Operator’s right hand panel.

Table 3-9 – Rotor RPM Settings Setting I II

MPH 362-2 & 364-2 Rotor RPM 135 150

NOTE: Table speeds are LOADED (working) rotor speeds. No load (freewheeling) cutting speeds will be higher.

It will be necessary to change rotor speed from time to time as recycling conditions vary. Each time the Rotor Speed switch position changes, a ten second “rampup” or “ramp-down” time is built into the speed change process to allow for smooth transition through the hydraulic drive motors. The actual speed selected will be obtained ten seconds after speed selection. The operator is cautioned against rapidly changing rotor speeds as damage can occur to the hydraulic rotor drive.

3. Turn the Rotor ON/OFF switch located on the Ignition Panel to ON.

Engine must be at full throttle for rotor operation. Anything other than full throttle will cause rotor rotation to cease.

08/05

4. Wait at least ten seconds for the rotor to rampup to speed, and then lower the rotor until it just touches the surface to be recycled. Check the depth indicator. A reading of zero (0) or approximately zero should be indicated. If not, adjust the depth indicator to read zero (0) (See “Calibration Of Depth Indicator, in this section).

BASIC OPERATION INFORMATION AND GUIDELINES. The following information serves as “operation basics and general guidelines” for maximum productivity and optimum engine/rotor load control management.

Operate with the 4WD (FRONT ASSIST SWITCH) in the ON position (MPH 364-2 only). Only operate in LOW TRAVEL GEAR when WORKING. Always use the LOWEST rotor speed range possible for the application. The lowest rotor speed should be used for the heavy loads such as full depth recycling. The highest rotor speed is for the lightest loads such as mixing. In general, rotor speed also, effects the gradation (sizing of the material) and productivity (travel speed). The lower the rotor speed, the higher the productivity, but worse gradation (larger size). The higher the rotor speed, the lower the productivity, but with improved gradation (smaller size).

In order to maximize productivity, the unit should be operated, so that, the engine is at full load.

Typically the engine will vary between full load and no load. In order to maintain the selected rotor speed, while the unit is working under load, the engine should NEVER be allowed to operate continuously below the rated full engine load RPM. Always stop the machine and shift to Low Gear (Turtle) prior to lowering the rotor for a cut. Once the desired depth of cut has been achieved, begin forward motion by moving the Travel Direction Control Lever (FNR) to the forward (F) position.

The ROTOR PRESSURE gauge indicates hydraulic pressure in the rotor drive system. The pressure is dependent on the selected ROTOR SPEED RANGE and is an indication of the engine/rotor load.

3-43

Section 3 OPERATIONS MPH 362-2/364-2 -

FULL LOAD: Rated full load engine speed 2,100 RPM Typical engine speed 2,100 to 2,300 RPM.

Rotor speed I – 4,000 psi rotor pressure, maximum

lever alone controls the travel speed. The operator must manually slow down, or speed up, the forward travel speed with the FNR lever to maintain the engine speed and rotor pressure at full load (see above values). If the forward travel speed is too great the engine, or rotor, can slow down and/or stall.

Rotor speed II – 3,600 psi rotor pressure, maximum Adjust the opening of the rotor hood Rear Door, or tailgate. The Rear Door, or tailgate, is used to strike off and level the material. In general, the rear door position will affect the gradation (sizing of material) and productivity (travel speed). Opening the door results in higher productivity, but poorer gradation (larger size). Closing the door results in lower productivity, but improved gradation).

Adjust the opening of the Rear Door, or tailgate, using the rocker switch in the lower right-hand corner of the armrest control. Tailgate position is indicated on the lower left-hand side of the depth gauge, located on the right rear frame, behind the operator (Figure 3.14 – 2) NOTE: Width of cut is indicated by the RED stripes on the frame, located forward of the front tires.

Speed of advance, or forward motion, depends on the depth and material being cut. The speed of advance will generally not exceed 187 fpm (57.0 m/min).

There are 2 modes of operation. Manual and automatic mode. These are selected with the ENGINE LOAD CONTROL (MAN / AUTO) SWITCH. In the MANUAL mode, the automatic engine load control system is disabled. In this mode the FNR

3-44

In AUTO mode, the pressure in the rotor drive system is monitored to determine the load on the engine. As the load increases and decreases, due to changes in the material being recycled, the travel speed is adjusted automatically. Initially, the FNR lever should be slowly pushed all the way FORWARD (F) to maximize productivity.

Optimum range of operation is at travel speeds from 5 to 40 fpm. Depending on the application, the FNR lever may have to be pulled back from the maximum forward (F) position in order to limit the forward travel speed.

Two possible application exceptions are as follows: 1. Shallow depths of cut under varying material conditions where the engine load has large variations. For example, 5" depth of cut at speeds of 80 fpm that varies from 60 to 120 fpm. This may be too wide of a travel speed range for the load control to compensate accurately. Pull the FNR lever back part of the way toward neutral (N) to limit the maximum travel speed to a steady 70 to 80 fpm. An alternative would be to adjust the load control set point to reduce the amount of power the rotor drive can absorb (see following).

2. Heavy engine loads at a steady, but high travel speed of 60 to 80 fpm. At this speed, with heavy loads, the rotor drive may consume more power than the engine can deliver. Pull the FNR lever back part of the way toward neutral (N) to a steady 40 to 50 fpm, limiting the load on the engine. An alternative would be to adjust the load control set point to reduce the amount of power the rotor drive can absorb (see following).

08/05

Section 3 OPERATIONS Under these circumstances, the LOAD SETPOINT POTENTIOMETER (pot) can be adjusted to match the application. The pot adjusts the engine load control setting. The pot is factory adjusted for full engine load with travel speeds from 5 to 40 fpm.

cm

in

0

0

5 10

2

15

4 6

20 8

25

Turning the pot + (CW) increases the load on the engine. This will cause the engine RPM to decrease and the rotor drive pressure to increase.

Turn the pot - (CCW) to decrease load on the engine. This will cause the engine RPM to increase and the rotor drive pressure to decrease.

Small amounts of adjustment (1/8 turn) will make large changes in the load control setting.

Do NOT operate outside of the engine speed and rotor pressure ranges listed in the above information.

If the set point adjustment is required, it SHOULD be done by authorized, trained service personnel using Bomag MPH 362, 364 Instructions For Repair Manual, catalog number 0852680.

ZERO ADJUSTMENT ON DEPTH INDICATOR [See Figure 3-13].

Lower the machine rotor to ground level with the teeth installed in the rotor. Back off adjusting knob and position indicator arm to read zero (“0”) and lock it into position using the same knob.

CALIBRATION OF THE DEPTH INDICATOR. 1. To allow for differences in road surface, soil condition, and cutting tooth wear, it is suggested that initial and periodic depth calibration checks be made at the job site. This can be accomplished by making a short “pass” between “blue top”, or other reference stakes, with the rotor set to indicated depth required. Check the actual depth of cut after this “pass.” Adjust the indicated depth by loosening the knob holding the depth indicator arm, repositioning the arm, and tighten the knob [Figure 3-13].

08/05

10

30 35

12

40 14 16

MPH 362-2 - MPH 364-2 R/S FIGURE 3-13. DEPTH INDICATOR.

The “step 1” practice should be repeated for different depths, as required, to meet job requirements. Since tooth wear can reduce the cutting depthup to one inch and soil density may vary, calibration or allowance for tooth wear must be considered periodically.

2. Select the correct rotor speed as determined by the jobsite requirement. Adjust the rear door (tailgate) to allow smooth strike off of material as the machine moves through the material being processed.

During calibration do NOT slow travel, or rotor speed, by lowering the engine speed. In the Manual Operation Mode, Use only the Travel Direction Control Lever (FNR) to slow the machine.

3-45

Section 3 OPERATIONS 3. Move the machine forward, so that the travel speed is sufficient to produce the best depth of cut possible, which should match the depth of cut being shown on the indicator. Adjust the rear door (tailgate) to allow smooth strike off of material as the machine moves through the material being processed. Record the depth shown on the indicator.

4. Next, check the actual depth of the cut, made in step 2, by physically measuring the depth of recycled material. Readjust and set the depth indicator, on the rear of the machine frame as necessary to match the measured depth. The machine is now calibrated for this job.

STOPPING ROTOR. 1. Turn the Rotor ON/OFF switch, found on the Operatorâ&#x20AC;&#x2122;s right hand panel, to OFF.

Never put the engine throttle at LOW idle before turning the Rotor ON/OFF switch to OFF. The rotor ON/OFF switch must be in the OFF position BEFORE lowering the engine speed to low idle.

BRAKING SYSTEMS. PRIMARY BRAKE.

Changes in surface or soil conditions and/or tooth wear will require subsequent depth indicator recalibration.

The primary brake is set using the switch located on the Ignition Panel (right-hand side) directly below the BRAKE indicator lamps. Rotating the switch engages and disengages the SAHR brakes on the rear axle as indicated by the lamps.

SECONDARY (EMERGENCY/PARKING) BRAKE.

cm

in

0

0

5 10 15

2 4 6

20 8

25 10

30 35

The SAHR brakes on the rear wheels are set whenever the engine is turned off. The brakes are released only when the engine is restarted and hydraulic pressure is applied.

12

40

STEER BRAKING.

14 16

The right or left-hand rear axle SAHR brake can be applied momentarily independent of the Primary Brake switch. The selected brake is applied using the center returning toggle switch located on top of the Travel Direction Control Lever (FNR).

2

MPH 362-2 - MPH 364-2 R/S

Pressing the switch to the right or left side engages the selected brake. Applying the brake in this situation assists you in correcting slippage.

FIGURE 3-14. DOOR HEIGHT INDICATORS.

3-46

08/05

Section 3 OPERATIONS PARKING AND STORAGE.

BACKUP TRAVEL CONTROL SYSTEM [See Figures 3-15 and 3-16].

1. Gently lower the rotor to the ground before retiring the machine for overnight or extended, parking periods.

This is a limited travel control system for moving the unit. Do NOT use this mode for “working” the unit.

Should the unit become COMPLETELY disabled, and not able to be moved in the forward or reverse travel direction, use the following information to enable the unit to be moved from the work site to a repair area.

2. If the machine is parked on a slope, take care to also block the wheels.

Do NOT apply down pressure with the rotor; which can apply undue loading to front tires. Securely block the wheels with solid blocking.

3. Stopping at the end of any job or work period, requires that ALL operating systems and components be shut down.

4. The entire machine should be frequently and regularly cleaned of any additives adhering to it.

STOPPING THE ENGINE [See Figures 3-12 and 3-13].

1. Be certain that the hydrostatic drive control is in “NEUTRAL” and that the rotor has been lowered to the ground.

The ”Backup Travel Control System” is intended to provide transportation of the unit if there is a problem with the FNR control, travel controller, or wiring using the following information.

1. Keep the engine running. Put the FNR override switch in the ON (I) position (see figure 3-15).

Put the throttle at the full throttle [HIGH IDLE] speed.

NOTE: The Backup FNR Switch is activated when FNR override switch is in the ON (I) position.

2. Put the throttle at a speed slightly less than onehalf full throttle. Allow the engine to run at this speed for about five minutes (except when ANY system problem is noted).

2. Clear ALL personnel from the potential forward or reverse unit path.

3. Put the throttle at the “LOW IDLE”speed.

DANGER:

4. Turn the ignition switch to “OFF” and remove the key (if desired).

ALL personnel MUST be cleared from the potential forward or reverse unit path BEFORE moving the unit.

Failure to perform Step “4”leaves all instruments operative and can drain the battery charge.

5. Open the hood access door on right hand side of engine. Set the Battery Disconnect Switch to the “OFF” position and close the hood access door.

FIGURE 3-15. FNR OVERRIDE (ON/OFF) SWITCH.

08/05

3-47

Section 3 OPERATIONS 3. Slowly move the FNR switch out of neutral, into the FORWARD position, (away from operator) to move the unit in FORWARD. Adjust engine throttle speed to vary travel speed. If needed, release the FNR switch to slow down, stop and return to NEUTRAL. Slowly move the FNR switch out of neutral, into REVERSE position, (toward operator) to move the unit in REVERSE. Adjust engine throttle speed to vary travel speed. If needed release the FNR switch to slow down, stop and return to NEUTRAL (see figure 3-16).

TOWING INSTRUCTIONS [See Figures 3-17 and 3-18].

Do NOT tow the machine unless all of the following procedures have been completed. Should the machine become COMPLETELY disabled, and the engine CANNOT be started, use the following procedures to develop sufficient pressure to release the SAHR brakes on the rear axle.

4. Select the low or high travel gear range by following ALL range selection (shifting) procedures given in THIS Section.

Smooth operation of the unit will NOT be possible; proportional control is NOT available.

Adjust engine throttle speed to vary travel speed, if required.

ALWAYS move the FNR switch to neutral and allow the unit to come to a STOP before changing direction of travel.

Forward or reverse travel speed is limited to 0.75 mph (66 fpm) in LOW speed range and 3.0 mph (4.8 kph) in HIGH speed range, at FULL throttle (high idle).

5. When the unit is at the repair site, put the FNR override switch in the OFF (0) (normal operation) position. Put the throttle at low idle speed and run the engine for 3-5 minutes. Stop the engine. Repair the unit before attempting further use.

Perform this procedure ONLY if the transmission system or engine can NOT be operated and BEFORE attempting to move the machine.

1. A Portable Hydraulic Power Unit capable of providing 500 psi [+/- 100 psi] pressure to the SAHR brake system is necessary to release the brakes in the axle assembly; left and right ends.

Do NOT use a portable hydraulic unit that has an “oil supply” other than CLEAN, FILTERED hydraulic oil, using the same type of oil as contained in the hydraulic oil reservoir of the machine.

2. Place wooden blocks both behind and in front of all four tires.

DANGER:

Securely block the wheels with solid blocking.

3. Look under the right-hand side of the machine’s frame and find the brake valve assembly and the release system connection fitting and cap (Figure 3-17 – Item 1). Removing the right-rear plate from the deck of the operator’s compartment can also expose the brake valve.

FIGURE 3-16. BACKUP FNR CONTROL SWITCH.

3-48

08/05

Section 3 OPERATIONS DANGER: 1

2 3

NEVER allow ANYONE to stand in the path of ANY potential machine motion, FORWARD or BACKWARD, as pressure is applied using the portable hydraulic unit.

As the SAHR brakes are RELEASED, on the rear axle, there is the potential for machine MOTION if the blocks placed in front of and behind the wheel are UNABLE to stop machine motion.

Place BOTH of the towing bypass valves in the “TOW” (OPEN) position BEFORE the machine is moved.

8. Go to the transmission pump, found installed on the rear of the rotor pump. Find the two multifunction valves that are installed into the hydraulic transmission pump (See Figure 3-18).

FIGURE 3-17. BRAKE VALVE. 4. Wipe the fitting cap clean using a CLEAN cloth.

Remove the cap from the connection fitting.

5. Carefully connect and then tighten the Portable Hydraulic Power Unit connection hose fitting to the brake valve assembly connection on top of the valve assembly.

6. Locate the two needle valves [2] on the brake valve (Figure 3-17 – Items 2 and 3). Turn both knobs to the CLOSED [CW] position.

7. Standing back away from the wheels of Recycler or Stabilizer, pump the Portable Hydraulic Power Unit handle back and forth.

Moving the handle will cause the Portable Hydraulic Power Unit to produce sufficient hydraulic pressure in the brake system to release the spring-applied hydraulic-release (SAHR) brakes. The brakes should release at a pressure of 300 psi.

08/05

HOLD OPEN 3 TURNS

LARGE NUT FORWARD MULTI-FUNCTION VALVE

MIDDLE NUT CLOSED

REVERSE MULTI-FUNCTION VALVE

FIGURE 3-18. MULTI_FUNCTION VALVES ON TRANSMISSION PUMP.

3-49

Section 3 OPERATIONS 9. Put a 1-1/16 inch open end wrench on the MIDDLE sized [2nd] hex nut of the FORWARD direction multifunction valve cartridge. Put a 1-1/4 inch open-end wrench on the LARGE sized [3rd] hex nut of the FORWARD direction multifunction valve cartridge.

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

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

11. REPEAT the procedures given in steps 9, 10 and the preceding CAUTION on the reverse direction multifunction valve cartridge.

12. Securely fasten a large capacity towing strap, cable, or chain to the Recycler or Stabilizer and the towing vehicle or winch, and tighten fully.

CAREFULLY remove the wood blocking from under the four tires. CAREFULLY and SLOWLY, tow the machine to a repair area, or move the machine onto a truck or trailer and fasten securely.

Do not tow the machine on any grade. Tow on level terrain ONLY. TOW the machine the LEAST possible distance. Do NOT tow the machine at speeds in excess of ONE (1) mile per hour with the axle in HIGH speed range, or 0.4 mile per hour (35 feet per minute) in LOW speed range. Do NOT tow for a period in excess of FIVE minutes; damage to travel system hydraulic components can occur.

13. After the machine has been towed or transported, the brake system must be reapplied. Turn the pressure release handle on the Portable Hydraulic Power Unit to the “Pressure Release” position. This will release the pressure from the SAHR brake system applying the brakes.

NOTE: Turning the “pressure release handle” to the “release position” will allow the pressure in the brake system to be released from the system. The springapplied brakes are then APPLIED. It requires five to ten seconds for the pressure to be released from the brake system into the Portable Hydraulic Power Unit and for the brakes to be fully applied.

14. Locate the two needle valves [2] on the brake valve (Figure 3-17– Items 2 and 3). Turn both knobs to the OPEN (counterclockwise) position.

15. Carefully disconnect the Portable Hydraulic Power Unit from the fitting on the brake valve assembly.

16. Install the cap onto the brake valve assembly and tighten securely.

Do not overtighten the cap onto the brake release system fitting.

18. AFTER the secondary/parking brakes are APPLIED, close both the forward and reverse direction bypass valves by turning the MIDDLE sized [2nd] hex nut THREE [3] revolutions in the CLOCKWISE [CW] direction with the 1-1/16 inch open end wrench, until the hex nut is seated against the LARGE sized [3rd] hex nut.

Tighten the MIDDLE sized [2nd] hex nut to a torque of 30 ft. lbs. [41 N.m].

BOTH bypass valves must be returned to the CLOSED position.

NOTE: Initially there will be resistance in the hydrostatic transmission system. This is caused by static system oil in the transmission system, and will continue until the transmission motor has turned approximately 1/3 revolution. The machine will then move more easily.

3-50

08/05

Section 3 OPERATIONS TRANSPORTATION DATA [See Figure 3-19].

NEVER attempt to load the machine onto a Tilt Bed trailer.

NEVER attempt to load the machine by yourself.

1. CAREFULLY move the machine onto the transporting trailer.

4. Slow, then stop the engine as described in engine shut off procedures.

5. Place SOLID wood blocks on both sides at the front and rear of each tire.

6. Connect the four tie-down chains between the trailer bed and the machine at the locations indicated in the following drawing. Tighten each tiedown load-binding device to securely hold the machine in position during transport.

2. Apply the brake by setting the brake switch on the operatorâ&#x20AC;&#x2122;s console.

The machine MUST be securely held to the trailer. Be sure the tiedown chains and load binding devices are correctly connected and tightened securely, per manufacturer instructions, for use.

3. Lower the rotor and rotor hood gently until it is resting on blocks placed on the surface of the trailer.

CHAIN

CHAIN BLOCKS BLOCKS

FIGURE 3-19. TRANSPORTATION DATA.

08/05

3-51

Section 3 OPERATIONS NOTES

3-52

08/05

Section 4 MAINTENANCE TABLE OF CONTENTS PAGE GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12 PREVENTIVE MAINTENANCE SERVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12 PREVENTIVE MAINTENANCE OF MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12 REPAIR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12 ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14 HYDRAULIC FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14 MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14 ENGINE LUBRICATION OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14 CHECKING ENGINE LUBRICATION OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14 CHANGING ENGINE LUBRICATION OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15 CHANGING ENGINE LUBRICATION OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16 ENGINE FUEL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16 DAILY FUEL FILTER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16 CHANGING ENGINE FUEL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17 FUEL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17 ADDING FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17 ENGINE AIR FILTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18 ENGINE INLET AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19 CHANGING THE PRIMARY AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18 CHANGING THE SECONDARY AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19 ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19 CHECKING COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20 ADDING COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20 ENGINE COOLANT FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21 CHANGING ENGINE COOLANT FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21 CLEANING ENGINE RADIATOR, HYDRAULIC OIL AND CHARGE AIR COOLERS . . . . . . . . . . . . .4-22 HYDRAULIC SYSTEM OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23 CHECKING HYDRAULIC SYSTEM OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23 ADDING HYDRAULIC SYSTEM OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23 SAMPLING AND ANALYZING HYDRAULIC SYSTEM OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23 CHANGING OIL IN HYDRAULIC SYSTEM TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23 HYDRAULIC TANK BREATHER FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24 TRAVEL, STEERING/AUXILIARY AND ROTOR SYSTEMS HYDRAULIC OIL FILTERS . . . . . . . . . .4-24 CHANGING THE STEERING/AUXILIARY SYSTEMS HYDRAULIC OIL FILTER . . . . . . . . . . . . . .4-25 CHANGING THE ROTOR SYSTEM HYDRAULIC OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25 CHANGING THE TRAVEL SYSTEM HYDRAULIC OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26 ALTERNATOR AND FAN DRIVE BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26 CHECKING BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26 CHECKING AND TIGHTENING THE ENGINE COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . .4-26 (continued)

08/05

4-1

Section 4 MAINTENANCE TABLE OF CONTENTS (continued) PAGE BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26 CHECKING ELECTROLYTE LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27 CLEANING BATTERIES AND CABLE CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27 CHECKING AND TIGHTENING HOLD-DOWN CLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28 FRONT TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28 CHECKING FRONT TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28 APPLYING TORQUE TO FRONT WHEEL MOUNTING NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28 REAR TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29 CHECKING REAR TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29 APPLYING TORQUE TO REAR WHEEL MOUNTING NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30 BELT REPLACEMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30 ROLL OVER OR ROLL OVER / FALLING OBJECT PROTECTION STRUCTURE . . . . . . . . . . . . . . .4-31 CHECKING MOUNTING FASTENERS TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31 INSPECTING FOR CRACKS, RUST AND WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31 DISPLAY PANEL AND GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31 TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31 CHECKING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31 REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31 LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32 DYNAMIC BRAKES (SERVICE BRAKE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33 CHECKING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33 REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34 CHECKING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34 REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34 CHECKING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34 REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34 BACKUP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35 CHECKING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35 REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35 ROTOR SYSTEM ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35 PLANETARY WHEEL ENDS OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35 CHECKING PLANETARY WHEEL ENDS OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35 ADDING OIL TO PLANETARY WHEEL ENDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36 FUEL TANK BREATHER CAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36 CHANGING FUEL TANK BREATHER CAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36 (continued)

4-2

08/05

Section 4 MAINTENANCE TABLE OF CONTENTS (continued) PAGE ELECTRICAL SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36 FUSE ASSIGNMENTS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37 ELECTRICAL RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-38 RELAY ASSIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-38 ELECTRICAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-39 HEADLIGHTS / PARKING LIGHTS / WORKING LIGHTS OPTION . . . . . . . . . . . . . . . . . . . . . . . . .4-39 TURN SIGNALS AND FOUR WAY HAZARD LIGHTS OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-39 STOP LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-39 MISCELLANEOUS INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-39 ROTOR HOOD PITCH ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-39 RECOMMEND FIELD WELDING PROCEDURES FOR ONE PIECE SOCKET TO RECYCLER . . . . . .

ROTOR TUBE - MPH 362-2R AND MPH 364-2R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-40 WELDING INSTRUCTIONS - RECYCLER END SEGMENTS SOCKETS TO MILD STEEL . . . . . . . . .

(MPH 362-2 AND MPH 364-2 RECYCLERS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-41 RECOMMENDED FIELD WELDING PROCEDURES TO TINE PLATE AND/OR SOCKET TO ....

STABILIZER ROTOR TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-42 WINTERIZATION PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43 PREPARING THE MACHINE FOR STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43 BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43 FUEL TANKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43 AIR CLEANER, EXHAUST AND OTHER OPENINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43 TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43 EXPOSED COMPONENT RUST PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-44 REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-44 TORQUE SPECIFICATIONS FOR METRIC FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-44 TORQUE SPECIFICATIONS FOR STANDARD INCH FASTENERS . . . . . . . . . . . . . . . . . . . . . . . .4-45 STANDARD INCH FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46

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4-3

Section 4 MAINTENANCE GENERAL INFORMATION. This section provides the necessary procedures for the proper maintenance of the BOMAG Recycler or Stabilizer. Perform ALL required maintenance as listed on the MAINTENANCE SCHEDULE using the described maintenance.

Always refer to the Cummins Diesel QSM11 Engine "Operation and Maintenance Manual", provided with this machine, for manufacturer approved engine maintenance information.

The Cummins Manual provided references two (2) types of engines. The engine used by the BOMAG Recycler, or Stabilizer, is the “QSM11- INDUSTRIAL” model.

Where a variation is referenced, in the CUMMINS Manual, use only those procedures that apply to the “INDUSTRIAL” engine.

“Maintenance” is a planned program that includes periodic machine lubrication and inspection procedures.

The “Maintenance” program is performed based on the machine “operating hours” that are shown on the PowerView display panel, or on the periodic schedule at times as specified such as weekly, monthly or annually.

NOTE: If the machine is operated less than eight hours per day, follow the “Hour” schedule. If the machine is operated more than eight hours per day, follow the periodic schedules where they apply.

The maintenance program is divided into two subsections; the “Maintenance Schedule” as described in Table 4-1 and the “Maintenance Procedures” which follow Table 4-1.

NOTE: Adjustments of a general or common sense nature to components or assemblies not included in this manual are explained on attached decals and plates on the machine and/or will become apparent upon examination of the component or assembly.

FIGURE 4-1. BOMAG RECYCLER OR STABILIZER - WITH ROPS/FOPS. 4-4

08/05

Section 4 MAINTENANCE MAINTENANCE SCHEDULE. KEY:

A/C

= = = =

*

=

**

=

***

=

C

INSPECT/CHECK CLEAN CHANGE OBTAIN AND ANALYZE OIL SAMPLE - WITH CARE. CHANGE OIL BASED ON RESULTS OF OIL ANALYSIS. REFER TO CURRENT QSM11 ENGINE “OPERATION AND MAINTENANCE MANUAL” PUBLISHED BY CUMMINS ENGINE COMPANY SUPPLIED WITH EACH MACHINE. UNDER VERY DUSTY OR SEVERE OPERATING CONDITIONS, MORE FREQUENT SERVICING MAY BE REQUIRED. SEE DECAL ADJACENT TO THE HYDRAULIC RESERVOIR FILL TUBE.

NOTE: If the machine is operated less than eight hours per day, follow the “Hour” schedule. If the machine is operated more than eight hours per day, follow the periodic schedules where they apply.

Keep an accurate record of maintenance performed in a machine logbook, both scheduled and unscheduled.

TABLE 4-1. MAINTENANCE SCHEDULE. FIG. 4-2 ITEM NO. 1

ITEM

8 HRS OR DAILY

50 HRS OR 1 WK

250 500 1000 HRS HRS HRS OR OR OR 6 MO 1 YR 1 YR

ENGINE OIL

9 Gal (34 L)

*

2

3

ENGINE OIL FILTER

*

ENGINE FUEL FILTERS

*

4

FUEL LEVEL (See Gauge on Dash)

5

ENGINE INLET AIR FILTER (PRIMARY & SECONDARY ELEMENTS)

08/05

2000 2000 HRS HRS QTY OR OR 1 YR 2 YRS

TYPE/REMARKS

Drain diesel engine lubrication oil and replace with new.

1

Change at each engine oil change. Use approved filter only.

2

Drain both filters of water daily, if so equipped.

Change filters at interval shown. Use approved filters only.*

240 #1D or #2D Diesel Fuel.

Gal (908 L) Both **

Check visual restriction indicator, on air intake system, daily. Always monitor PowerView display, on dash, for indication of air restriction within system. Change both elements as indicated. Use APPROVED elements ONLY. See this section.

4-5

Section 4 MAINTENANCE TABLE 4-1. MAINTENANCE SCHEDULE. FIG. 4-2 ITEM NO. 6

7

8

4-6

ITEM

8 HRS OR DAILY

50 HRS OR 1 WK

250 500 1000 HRS HRS HRS OR OR OR 6 MO 1 YR 1 YR

ENGINE COOLING SYSTEM

*

ENGINE COOLANT FILTER

*

Engine Radiator Hydraulic OIL CHARGE AIR - COOLERS

2000 2000 HRS HRS QTY OR OR 1 YR 2 YRS

*

78 Qt. (74 L)

1

C

All Three

TYPE/REMARKS

Check coolant level. Fill as required with 50% mixture (approximately) of drinking water and ethylene glycol base antifreeze, with rust inhibitors and antirust qualities. Add one can of “cooling system conditioner” having rust inhibitor properties.

See this section.

Remove and replace coolant filter with new.

Use APPROVED filter ONLY. See this section.

Clean and inspect the Radiator, Hydraulic Oil and Charge Air Coolers at the start of each shift.

Inspect for blockage by dirt or other contaminates.

See this section.

08/05

Section 4 MAINTENANCE TABLE 4-1. MAINTENANCE SCHEDULE. FIG. 4-2 ITEM NO. 9

ITEM

HYDRAULIC SYSTEM OIL

8 HRS OR DAILY

50 HRS OR 1 WK

250 500 1000 HRS HRS HRS OR OR OR 6 MO 1 YR 1 YR

2000 2000 HRS HRS QTY OR OR 1 YR 2 YRS A/C ***

90 Gal. (341L)

TYPE/REMARKS

Check hydraulic oil level on the reservoir sight gauge.

Add hydraulic oil as required. Use ONLY MOBIL - 423, TEXACO -TDH or EQUIVALENTS. Obtain and analyze oil sample one time for EACH 2,000 hours of machine operation or every two years. Change oil if analysis shows change is required.

Use the CORRECT OIL ONLY. See this section.

9a

HYDRAULIC TANK BREATHER FILTER (INSIDE HYDRAULIC TANK FILL CAP)

1

Replace complete fill cap assembly.

See Parts Catalog for correct parts.

10

TRAVEL SYSTEM AND STEERING/ AUXILIARY SYSTEM HYDRAULIC OIL FILTERS

2

Check condition indicator on filters daily. Change filter elements when hydraulic oil is changed, when the filters condition, monitored by PowerView system, shows a fault code or after repairs within the hydraulic system.

Check after hydraulic system oil has reached operating temperature. Use Bomag APPROVED filter elements ONLY. See MACHINE PARTS catalog for CORRECT replacement elements.

See this section.

08/05

4-7

Section 4 MAINTENANCE TABLE 4-1. MAINTENANCE SCHEDULE. FIG. 4-2 ITEM NO.

ITEM

8 HRS OR DAILY

11

ROTOR HYDRAULIC SYSTEM OIL FILTER

12

ALTERNATOR AND FAN DRIVE BELTS

*

ENGINE COOLING FAN

*

13

14

4-8

BATTERIES

50 HRS OR 1 WK

250 500 1000 HRS HRS HRS OR OR OR 6 MO 1 YR 1 YR

2000 2000 HRS HRS QTY OR OR 1 YR 2 YRS

TYPE/REMARKS

1

Check condition indicator on filter daily. Change filter element every 2,000 hours or two years, or whenever hydraulic oil is changed, when the filter condition, monitored by the PowerView system, shows a fault code or after repairs within the hydraulic system. Check after hydraulic system oil has reached operating temperature. Use Bomag APPROVED filter element ONLY. See MACHINE PARTS catalog for CORRECT replacement element.

See this section.

All

Check belts for wear or damage. Check belts for correct tension or deflection.

Check fan for damage.

Check the fan to make sure it is securely mounted.

Tighten the capscrews if necessary.

2

Batteries ARE NOT maintenance free. Check electrolyte level in each battery. Clean batteries and cable connectors. Check hold down clamps for tightness. Service as required.

See this section.

08/05

Section 4 MAINTENANCE TABLE 4-1. MAINTENANCE SCHEDULE. FIG. 4-2 ITEM NO.

ITEM

8 HRS OR DAILY

50 HRS OR 1 WK

250 500 1000 HRS HRS HRS OR OR OR 6 MO 1 YR 1 YR

2000 2000 HRS HRS QTY OR OR 1 YR 2 YRS

TYPE/REMARKS

15

FRONT TIRES

2

Check pressure when tires are in a “cold” condition.

Set at correct pressure (35 psi [2.4 bar]).

See this section.

16

REAR TIRES

2

Check pressure when tires are in a “cold” condition.

Set at correct pressure (35 psi [2.4 bar]).

See this section.

17

TORQUE ON FRONT WHEEL MOUNTING NUTS

All 10 per wheel

Check at first 50 hrs. initially. Check wheel mounting nuts for correct torque. Tighten nuts as needed.

(400 ft•lbs. [543 N•m]).

See this section.

18

TORQUE ON REAR WHEEL MOUNTING NUTS

All 16 per wheel

Check at first 50 hrs. initially. Check wheel mounting nuts for correct torque. Tighten nuts as needed.

(426 ft•lbs. [578 N•m]).

See this section.

19

LUBRICATION POINTS

All

Lubricate EACH point through provided grease zerk fitting with multipurpose grease.

See this section.

20

SAFETY DECALS

All

Check condition.

Replace with new as needed.

21

SEAT BELT

Set

Check condition.

Replace belt with new as needed.

See this section.

08/05

4-9

Section 4 MAINTENANCE TABLE 4-1. MAINTENANCE SCHEDULE. FIG. 4-2 ITEM NO.

ITEM

8 HRS OR DAILY

50 HRS OR 1 WK

250 500 1000 HRS HRS HRS OR OR OR 6 MO 1 YR 1 YR

2000 2000 HRS HRS QTY OR OR 1 YR 2 YRS

22

ROLL OVER OR FALLING OBJECT / ROLL OVER PROTECTION STRUCTURE

23

GAUGES HORNS LIGHTS

All

Check operation. Repair or replace as needed.

24

DYNAMIC BRAKES

Transmission System

Check operation. Repair as needed.

25

SECONDARY PARKING BRAKE

Rear Axle Brakes

Check operation. Repair as needed.

26

STEERING

Steering System

Check operation. Repair or replace as needed.

27

BACKUP ALARM

Alarm System

Check operation. Repair as needed.

4-10

Structure

TYPE/REMARKS

Inspect ALL of the capscrews that fasten the structure to the machine. Capscrews MUST remain tightened to the correct torque (800 ft•lbs.

[1,085 N•m]).

• Carefully INSPECT ALL welds that fasten the structure components together.

• Examine for cracks or breakage in the weld.

• Inspect where welds join the metal of the steel component for severe rust or other weld related problems.

If any damage is found in the above inspection, IMMEDIATELY contact your nearest Distributor and/or Bomag Americas for information and assistance.

See this section.

08/05

Section 4 MAINTENANCE TABLE 4-1. MAINTENANCE SCHEDULE. FIG. 4-2 ITEM NO.

ITEM

28

ROTOR MOTOR SEAL LUBE CAVITIY

29

PLANETARY WHEEL ENDS OIL

30

FUEL TANK CAP BREATHER (Inside fuel tank fill cap)

8 HRS OR DAILY

50 HRS OR 1 WK

250 500 1000 HRS HRS HRS OR OR OR 6 MO 1 YR 1 YR

2000 2000 HRS HRS QTY OR OR 1 YR 3 YRS 1

2 Places 135 Oz. ea.

(4.0 L ea.)

**

TYPE/REMARKS

See MPH 362, 364 Instructions For Repair Manual for correct procedures.

Change at first 50 hrs initially. Rotate plug on wheel to 3 or 9 o’clock position. Fill to bottom edge of hole. Use EP 80W90 oil when adding oil.

See this section.

2

See Parts Catalog for correct element.

**

31

REAR AXLE MOUNTING

8

Tighten rear axle mounting capscrews. Torque to 735 ft•lbs. (997 N•m.).

32

MUFFLER

1

Once daily, remove plug at bottom of muffler. Drain water. Install and securely tighten plug.

CHECK ENGINE lubrication oil level with the engine “STOPPED” and the oil “COOL.” Check HYDRAULIC SYSTEM oil level with the engine “STOPPED” and the hydraulic oil at “OPERATING” temperature.

08/05

4-11

Section 4 MAINTENANCE MAINTENANCE. GENERAL INFORMATION. The following MAINTENANCE PROCEDURES give instructions for performing required machine maintenance checks and lubrication.

1. Inspect the rotor cutting teeth or paddles and plates for evidence of wear and/or damage.

Replace as required.

2. Check the hydraulic oil level in the hydraulic oil reservoir.

3. Check to make sure the skid bolts on the rotor hood are tight.

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 may, also, include some items NOT shown in the table, or on the decal.

PREVENTIVE MAINTENANCE SERVICES.

REPAIR MAINTENANCE. GENERAL INFORMATION. Refer to the Maintenance Manual (Publication No. 0852680) for service, repair and replacement procedures not described in this manual.

DANGER:

During “Preventive Maintenance Services” perform the listed inspection and change procedures to prevent avoidable deterioration of system components.

DANGER:

The machine must be parked on level terrain with the engine stopped and parking brake “ON” before performing ANY lubrication services or maintenance checks and inspections.

The rotor hood must be in the RAISED and LOCKED position with BOTH lock pins installed before performing ANY lubrication services or maintenance checks and inspections.

Perform all lubrication services and inspections at the intervals as listed in Table 4-1.

PREVENTIVE MAINTENANCE OF MAJOR COMPONENTS.

The machine must be parked on level terrain with the engine stopped and parking brake “ON” before performing ANY lubrication services or maintenance checks and inspections.

The rotor hood must be in the RAISED and LOCKED position with BOTH lock pins installed before performing ANY lubrication services or maintenance checks and inspections.

Tanks, containers or reservoirs MUST be COMPLETELY DRAINED prior to removal.

Verify that a component of a fluid drive is ISOLATED prior to its removal. Isolate the component either by closing the proper valves or, by draining the entire fluid drive line.

DANGER:

Do NOT weld on tanks containing combustible fluids.

Explosion and/or fire danger exists.

Perform the following general checks during daily preventive maintenance inspection of the unit prior to starting. Correct any adverse conditions identified.

4-12

08/05

FIGURE 4-2. MPH 362-2 R/S AND MPH 364-2 R/S MAINTENANCE DECAL.

Section 4 MAINTENANCE

08/05

4-13

Section 4 MAINTENANCE ENGINE MAINTENANCE. The primary source of information on the engine is the CUMMINS "Operation and Maintenance Manual for QSM11 Engines". A copy of this manual is supplied with the machine and should be your PRIMARY SOURCE for referenced engine maintenance and repair procedures.

For additional, very specific, ENGINE maintenance information, see the current QSM11 ENGINE “OPERATION AND MAINTENANCE MANUAL" published by Cummins Engine Company Incorporated that is supplied with the machine.

ENGINE LUBRICATION OIL. CHECKING ENGINE LUBRICATION OIL LEVEL.

The Cummins Manual provided references two (2) types of engines. The engine used by the BOMAG Recycler, or Stabilizer, is the “QSM11- INDUSTRIAL” model.

Where a variation is referenced in the CUMMINS Manual, reference only those procedures that apply to the “INDUSTRIAL” engine.

Prior to checking the oil, make sure the engine is at normal operating temperature.

1. Stop the engine.

2. Allow ten minutes for oil to drain to the oil pan.

3. Remove the dipstick located on the right hand side of the engine and wipe clean.

HYDRAULIC FILTERS. Follow a good maintenance program to assure the hydraulic system remains clean. The filters must be changed after the first 50 hours of machine operation.

AFTER the first 50 hours of machine operation, ALL initial lubrication and service procedures, as listed on the “Maintenance/Lubrication Decal” found on the machine, MUST be performed.

OIL DIPSTICK

FIGURE 4-3. ENGINE OIL DIPSTICK. After the initial 50-hour change, perform a weekly check of filter conditions. Anytime a hydraulic filter fault, or warning, code is shown on the PowerView display; or the filter head mounted element condition indicator slide bar is in the "change zone", change the indicated filter.

MAINTENANCE PROCEDURES. GENERAL INFORMATION. The following ENGINE maintenance information will cover the engine general maintenance procedures most often performed.

4-14

4. Reinsert the dipstick.

5. Remove and check oil level. Oil should be between the high (“H”) and low (“L”) marks on dipstick (see Figure 4-3).

6. If dipstick indicates additional oil is required (below the “L” mark) add oil as necessary.

(Cummins recommends SAE 15W-40 for most typical operating conditions.)

7. Add only enough oil to bring the oil level within the “H” and “L” marks on the dipstick. DO NOT OVERFILL the engine with oil.

08/05

Section 4 MAINTENANCE STOP the engine before checking the engine lubrication oil level. If the engine is left running there is the possibility that hot engine oil can be thrown from the dipstick tube causing serious burns or injury to the service provider.

5. Replace oil filter during EACH oil change. (See Changing Engine Oil Filter before proceeding.)

6. Clean the oil drain plug threads and seal.

7. Replace the oil drain plug.

8. Tighten the oil drain plug securely.

Machine must be on level ground for an accurate reading.

NOTE: See Cummins QSM11 Engine "Operation and Maintenance Manual" provided with the machine.

9. Replace with clean fresh oil. Oil capacity is nine gallons (34 liters). Cummins recommends SAE 15W-40 for most operating conditions. (See Cummins QSM11 engine manual for exceptions for low temperature operation.)

CHANGING ENGINE LUBRICATION OIL. Change engine lubrication oil every 250 hours or six months.

1. Run the engine until the indicated water temperature reaches 140°F (60°C).

2. Place a container under the oil drain plug.

3. Carefully remove the oil drain plug from the BOTTOM of the oil pan (see Figure 4-4).

ENGINE OIL FILTER

FIGURE 4-5. ENGINE LUBRICATION OIL FILTER. CHANGING ENGINE LUBRICATION OIL FILTER. 1. With the oil drained, clean the area around the lubrication oil filter head.

OIL DRAIN PLUG

FIGURE 4-4. LUBRICATION OIL DRAIN PLUG. 4. Drain the oil immediately to make sure all the oil and suspended contaminants are removed.

08/05

2. Remove the screw-on filter (see Figure 4-5). If necessary, a filter wrench may be used to loosen the old filter. Check the filter head to make sure there is no remnant of the old filter’s gasket seal.

3. Clean the gasket surface of the filter head.

4. Use ONLY the correct Combination Full Flow/Bypass Lube Filter.

4-15

Section 4 MAINTENANCE 5. Fill the new oil filter with clean, correct, lubricating oil before installing it on the engine. A lack of engine lubrication oil while the filter is being pumped full of oil will harm the engine.

6. Apply a light film of lubricating oil to the gasketsealing surface before installing the new filter.

7. Screw the replacement filter, filled with fresh oil, onto the lubricating oil filter head in a clockwise direction. Hand tighten ONLY. 8. Continue to tighten the filter element until the filter is hand tight and the seal on top of the filter element has been compressed forming a tight seal.

DIESEL FUEL IS VERY FLAMMABLE. USE EXTRA CAUTION. Do NOT change the fuel filter elements in an area near open flame.

Do NOT change the fuel strainer or fuel filter elements with the unitâ&#x20AC;&#x2122;s engine running.

Do NOT smoke while changing the fuel strainer or fuel filter elements.

Try NOT to spill fuel. If spilled, clean up fuel spills during strainer cleaning or element change before starting engine.

DAILY FUEL FILTER MAINTENANCE. Do not use any mechanical devices for tightening the oil filter. Mechanical overtightening can distort the threads on the lubricating oil filter head or damage the filter element seal.

At the bottom of each of the two fuel filters are water drains (see Figure 4-6). Prior to starting the engine each day, open the drains at the bottom each of the two filters and drain any collected water.

Verify the drains are firmly closed prior to starting the engine.

8. Complete the oil change procedure from Step 6 in Changing Engine Lubrication Oil procedure above, and start the engine. Carefully inspect the oil filter to make sure there are no leaks.

Check the oil pressure reading, shown on the PowerView display, (see Section 3) to confirm proper engine oil pressure exists.

FUEL SYSTEM. ENGINE FUEL FILTERS. The Cummins engine uses two fuel filter elements to ensure a clean fuel supply. Located inside the left-hand engine compartment door, both filters are readily accessible and may require service prior to the start of work each day. Reference the Cummins QSM11 Engine "Operation and Maintenance Manual" provided with the machine.

4-16

FUEL FILTERS WATER DRAINS

FIGURE 4-6. FUEL FILTERS LOCATION AND WATER DRAINS

08/05

Section 4 MAINTENANCE CHANGING ENGINE FUEL FILTERS. [See Figure 4-6].

Change fuel filters every 250 hours or, six months.

1. Clean the area around both fuel filters.

2. Place a container under the fuel filters.

3. Remove both filters using a filter wrench if necessary.

4. Carefully inspect and clean the gasket surface of the filter head.

5. Select the proper fuel filter for this engine.

6. Lubricate the filter seals using clean oil.

7. Fill the new filters with clean fresh fuel. Use same fuel as currently being used in the engine.

8. Install the filter as directed by the filter manufacturer. See filter manufacturer instructions, located on the filterâ&#x20AC;&#x2122;s packing box. Tighten the filter until the seal is compressed.

Mechanical overtightening of the filters can distort the threads or damage the filter element seal.

ALL fuels for internal combustion engines are flammable.

Fill the fuel tank ONLY in designated areas with good ventilation. Have a fire extinguisher handy whenever refueling.

NEVER allow anyone on the machine while fuel is being added to the fuel tanks.

NEVER permit smoking in any area where fueling is being performed.

NEVER fill the fuel tanks near an open flame, or near equipment that can create sparks.

Never check the fuel level with an open flame.

Try NOT to spill fuel. If fuel is spilled, clean the spill immediately and before starting the unitâ&#x20AC;&#x2122;s engine.

ADDING FUEL. 1. Move machine to the designated refueling area.

STOP the engine.

2. Remove the fuel fill cap from one of the two fuel tanks.

FUEL LEVEL. Check the fuel level once each day by reading the fuel level indicated on the PowerView display.

Refuel if necessary. Fill the tanks until the PowerView display reads 100%. The unit should be refueled prior to shutting the machine down at the end of the day and before the machine is stored for the night.

NOTE: The purpose of filling fuel tanks prior to shutting the machine down for the night is to prevent condensation from forming in empty, or near empty fuel tanks.

A full fuel tank eliminates air, which is the primary source of condensation in fuel tanks.

08/05

FIGURE 4-7. FUEL FILL CAP.

4-17

Section 4 MAINTENANCE 3. Fill the fuel tank.

ENGINE INLET AIR FILTER.

4. Replace the fuel fill cap with breather on the fuel tank.

The Air Cleaner is a Donaldson Dry, Cycloflow with secondary element and evacuator valve.

Replacement is ONLY to be with:

5. Remove the fuel fill cap from the other fuel tank MODEL FVG 16-0587 6. Fill the second fuel tank.

7. Replace the fuel fill cap with breather on the second fuel tank.

CHANGING THE PRIMARY AIR FILTER ELEMENT. [See Figure 4-8].

1. Open the left-hand side engine door.

8. Clean up any fuel spills.

ENGINE AIR FILTRATION.

2. Unscrew the wing nut holding the Primary Air Filter in place.

The Bomag Recycler or Stabilizer is equipped with a Donaldson Cycloflow Two-Stage Air Filtration unit.

The quantity of air flow is monitored in two places.

•

A fault code on the PowerView display indicating there is a restriction in the flow of air being drawn into the engine.

•

There is, also, an Air Restriction Indicator mounted on top of the outflow pipe from the air filtration unit. Check this indicator every 250 hours, or six months. Maximum intake air restriction is 25.0 inches H2O (64 cm H2O.) Check the condition shown on the restriction indicator. Replace the elements when the restriction indicator shows needed. Manually reset the restriction indicator.

Inspect the intake piping for cracked hoses, loose clamps or punctures, which can damage the engine.

Replace parts and tighten clamps as required.

Tighten, or replace, parts as necessary to make sure the air intake system does not leak.

Check for corrosion of the intake system piping under the clamps and hoses. Corrosion can allow corrosive products and dirt to enter the intake system. Disassemble and clean as required.

FIGURE 4-8. PRIMARY AIR FILTER ELEMENT. 3. Once the wing nut is released, pull the Primary Air Filter Element out using a slight rotating motion to remove the element.

4. Wipe the inside of the filter clean with a clean dry cloth.

5. Remove and replace the secondary element.

(See “Changing the Secondary Air Filter Element.”)

6. Replace the primary Air Filter element.

4-18

08/05

Section 4 MAINTENANCE 7. Insert the primary element over the secondary element and push in until the seating rod is visible.

8. Complete procedure by returning to Step 7 of the “Changing the Primary Air Filter Element” procedure.

8. Hand-tighten the wing nut, to secure the primary element in place.

ENGINE COOLING SYSTEM.

CHANGING THE SECONDARY AIR FILTER ELEMENT. [See Figure 4-9].

1. After the Primary Air Filter Element has been removed, the Secondary Air Filter Element is exposed.

FIGURE 4-9. SECONDARY AIR FILTER ELEMENT. 2. Remove the cotter pin visible in the center of the rod that supports the secondary element.

The engine is cooled using a cooling package that contains the engine coolant radiator. The package, also, includes one Hydraulic Oil Cooler and one Charge Air Cooler. The engine coolant radiator is mounted on the front of the cooling package. The grill in front of the radiator is ducted upwards to help reduce the amount of dust, dirt and foreign matter stirred up while operating the machine on the worksite (see Figure 4-10).

Do NOT check the system coolant level or ANY component, with the engine “running.” The engine MUST be “STOPPED.” Serious injury can result from being struck or caught by the fan, belts or moving parts. Do NOT check the system coolant level, or any component, when the system is at operating temperature and the coolant is under pressure. Hot coolant, under pressure, can cause severe injury. Check the coolant level ONLY when the filler cap is cool enough to touch with the hand. Remove the filler cap slowly.

3. Using a rotating motion, remove the secondary element.

4. Clean the inside of the filter with a clean, dry cloth.

5. Replace the secondary element.

6. Insert the secondary filter element into the air cleaner assembly.

7. Secure the secondary filter element using the cotter pin on the end of the assembly.

FIGURE 4-10. RADIATOR AND COOLERS ASSEMBLY GRILL.

08/05

4-19

Section 4 MAINTENANCE CHECKING COOLANT LEVEL. 1. Check the coolant level at least once every eight hours of machine operation, or daily.

2. Keep the coolant, in the expansion tank, at a level at the bottom of the expansion tank filler neck, when the cooling system is “cool.” Fill the expansion tank ONLY when the system is “cool.” Fill the expansion tank as needed using a 50/50 (approximate) mixture of ethylene glycol type antifreeze and CLEAN water. Add one can of “cooling system conditioner” having rust inhibitor properties.

3. Drain, flush and fill the cooling system, with NEW coolant, every 2,000 hours of operation, or every two years.

NOTE: The expansion tank sight gauge must always be full of coolant.

4. Check the expansion tank cap gasket each time the expansion tank cap is removed. The expansion tank cap gasket MUST seal on the expansion tank filler neck surface. If the rubber face of the cap valve is damaged, or cracked, replace the expansion tank cap with a new cap of the same capacity immediately.

5. Check the expansion tank overflow tube for restriction, or damage. A restricted, or damaged overflow tube can prevent the expansion tank cap from releasing extra system pressure and system failure can occur.

6. With the engine stopped, inspect the radiator and hydraulic oil cooler and charge air cooler cooling fin areas EACH time the system coolant level is checked. Use a bright light, placed on the inside of the radiator fin area. Light must be clearly seen when looking through the radiator and oil and charge air coolers from the outside of the fin area.

The engine MUST be “STOPPED” before checking and/or cleaning the radiator or oil and charge air coolers fin areas. Serious injury can result from being struck or caught by the fan, belts or moving engine parts.

4-20

NOTE: If a restricted fin condition is noted in the radiator or the hydraulic oil cooler or charge air cooler cooling fin areas, clean the fins using low pressure compressed air.

The compressed air supply MUST have a pressure BELOW 30 psi. (2 bar) Wear safety glasses and protective clothing.

Do not damage the radiator, hydraulic oil cooler or charge air cooler cooling fins during cleaning.

Clean the fin areas with the compressed air blown in the OPPOSITE direction of normal airflow during operation.

Bent cooling fins can be carefully straightened. Use a radiator fin comb to straighten the bent fins after cleaning.

NOTE: Severe restrictions, or accumulations of dirt which were not removed by using compressed air, MUST be removed by using standard steam cleaning or pressure washing. Use a mixture of 50% white vinegar and 50% clean water to neutralize lime, or other additives. Spray the solution on the components and allow to soak. Steam clean, or pressure wash, through the radiator, the hydraulic oil cooler and charge air cooler cooling fins in the direction OPPOSITE the direction of “normal” air flow during operation.

ADDING COOLANT. 1. Fill the expansion tank ONLY when the system is “cool.”

2. Fill the expansion tank as needed using a 50/50 (approximate) mixture of ethylene glycol type antifreeze and CLEAN water, to a level at the BOTTOM of the expansion tank filler neck.

08/05

Section 4 MAINTENANCE NOTE: The expansion tank sight gauge must always be full of coolant.

Cooling System Capacity -39 Quarts (37 liters) of Ethylene Glycol Type Antifreeze -39 Quarts (37 liters) of CLEAN Water 3. Add one can of “cooling system conditioner” having rust inhibitor properties.

4. Check the expansion tank cap gasket. If the rubber face of the cap valve is damaged or cracked, replace the expansion tank cap with a new cap of the same capacity immediately.

CHANGING ENGINE COOLANT FILTER.

Do not remove the expansion tank cap when the expansion tank and coolant are hot. Hot steam will cause serious personal injury.

Remove the coolant expansion tank pressure cap and close the coolant filter head shut off valve before removing the coolant filter.

Failure to do so can result in personal injury from heated coolant spray.

1. Turn the coolant shut off valve to the “OFF” position.

ENGINE COOLANT FILTER. 2. Remove the coolant filter (See Figure 4-11).

Change the engine coolant filter at every oil change and coolant filter change interval.

3. Clean the coolant filter gasket surface.

The coolant filter is located inside the right-hand engine cowling, left of the engine oil filter. This filter is to be replaced every 250 hours, or six months.

4. Apply a light film of lubricating oil to the gasketsealing surface before installing the new coolant filter.

5. Install the filter as specified by the filter manufacturer.

Mechanical overtightening can distort the threads or damage the filter head.

ENGINE COOLANT FILTER

FIGURE 4-11. ENGINE COOLANT FILTER. A manual shut off valve is provided to prevent coolant leakage while changing the coolant filter.

With the valve in the vertical position, the coolant flows to and from the coolant filter. In the horizontal position, the coolant flow is cut off to and from the coolant filter. Replace with factory approved coolant filter.

08/05

4-21

Section 4 MAINTENANCE CLEANING ENGINE RADIATOR, HYDRAULIC OIL AND CHARGE AIR COOLERS [See Figure 4-12].

1. With the engine stopped, inspect the radiator and hydraulic oil and charge air coolers cooling fin areas. Use a bright light, placed on the inside of the radiator fin area. Light must be clearly seen when looking through the radiator and hydraulic oil and charge air coolers from the outside of the fin area.

The engine MUST be “STOPPED” before checking and/or cleaning the radiator, hydraulic oil or charge air coolers fin areas.

Serious injury can result from being struck or caught by the fan, belts or moving engine parts.

NOTE: If a restricted fin condition is noted in the radiator, hydraulic oil cooler or charge air cooler fin areas, clean the fins using low pressure compressed air.

Do not damage the radiator, hydraulic oil cooler or charge air cooler cooling fins during cleaning.

Clean the fin areas with the compressed air blown in the OPPOSITE direction of normal airflow during operation.

Bent cooling fins can be carefully straightened. Use a radiator fin comb to straighten the bent fins after cleaning.

NOTE: Severe restrictions, or accumulations of dirt which were not removed by using compressed air, MUST be removed by using standard steam cleaning or pressure washing. Use a mixture of 50% white vinegar and 50% clean water to neutralize lime, or other additives. Spray the solution on the components and allow to soak. Steam clean, or pressure wash, through the radiator, hydraulic oil cooler and charge air cooler in the direction OPPOSITE the direction of “normal” air flow during operation.

The compressed air supply MUST have a pressure BELOW 30 psi. (2 bar) Wear safety glasses and protective clothing.

RADIATOR

HYDRAULIC OIL COOLER

CHARGE AIR COOLER

FIGURE 4-12. ENGINE RADIATOR, HYDRAULIC OIL AND CHARGE AIR COOLERS.

4-22

08/05

Section 4 MAINTENANCE HYDRAULIC SYSTEM OIL. Hydraulic system oil is drawn from a reservoir located directly behind the seat in the operator’s control station. The reservoir holds 90 gallons (341 liters) of hydraulic fluid, which is used to provide hydraulic fluid for the steering, the hydrostatic travel and rotor drive systems.

CHECKING HYDRAULIC SYSTEM OIL LEVEL. [See Figure 4-13].

At the beginning of each day’s operation, check the level of fluid in the hydraulic reservoir using the sight glass located directly behind the operator’s seat.

ADDING HYDRAULIC SYSTEM OIL.

SAMPLING AND ANALYZING HYDRAULIC SYSTEM OIL. The hydraulic fluid should be sampled and tested by an oil analysis service every 2000 hours, or two years, of operation.

If analysis shows the hydraulic fluid needs replacement, drain the reservoir completely and replace with fresh fluid.

The TOTAL hydraulic system contains 120 gallons (454 liters) of fluid.

CHANGING OIL IN HYDRAULIC SYSTEM TANK. 1. Connect a drain hose to the drain valve located directly beneath the oil tank on the left-hand side (See Figure 4-14).

1. If a drop in hydraulic fluid level occurs, find and correct the cause of the fluid loss. Fill the reservoir with clean fresh oil until the sight glass registers the correct amount.

2. The type of fluid added should be the same as that used to initially fill the reservoir. Keep a record of the type of Hydraulic System Oil used.

Recommended Hydraulic Fluid Types: -

Mobil 423 Texaco – TDH Recognized equivalents to above.

FIGURE 4-14. HYDRAULIC TANK DRAIN VALVE. 2. Obtain two 55 gallon drums.

3. Place hose in one of the 55 gallon drums.

4. Open the valve and drain the hydraulic oil until the drum is filled. Shut off the valve when drum is nearly full.

FIGURE 4-13. HYDRAULIC OIL RESERVOIR.

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4-23

Section 4 MAINTENANCE 5. Move drain hose to second 55 gallon drum.

6. Open valve and drain the remaining hydraulic fluid into the second drum.

On Models MPH 362 R/S and MPH 364 R/S Clockwise from the front left filter, they serve the following functions: 1. Steering/Auxiliary System Oil Filter

7. When the tank is empty close valve, remove the drain hose and seal the drums containing the drained hydraulic fluid. Dispose of the fluid as prescribed by federal, state and/or local statutes.

2. Rotor System Charge Oil Filter 3. Travel System Charge Oil Filter See Figures 4-16.

8. Fill the hydraulic tank with approximately 90 gallons (341 liters) of fresh, clean and filtered hydraulic fluid. Do not mix types, or brands, of hydraulic fluid.

HYDRAULIC TANK BREATHER FILTER. Replace the Hydraulic Tank Breather Cap every 2,000, hours or two years. A filter is contained within the breather cap that loses its effectiveness after two years. Check the Parts Catalog for the proper part number.

2

1

3

FIGURE 4-16. MPH 362-2 R/S AND MPH 364-2 R/S FILTER DESIGNATIONS.

TRAVEL, STEERING/AUXILIARY AND ROTOR SYSTEMS HYDRAULIC OIL FILTERS (See Figure 4-15).

Remove the panel directly behind the boarding ladder underneath the operatorâ&#x20AC;&#x2122;s platform to reveal the hydraulic system oil filters. There are three filters on the Models MPH 362-2 R/S and MPH 364-2 R/S.

FIGURE 4-15. MPH 362-2 R/S AND MPH 364-2 R/S HYDRAULIC SYSTEMS OIL FILTERS.

4-24

08/05

Section 4 MAINTENANCE CHANGING THE STEER/AUXILIARY SYSTEM OIL FILTER (See Figure 4-16).

CHANGING THE ROTOR SYSTEM HYDRAULIC OIL FILTER (See Figure 4-16).

1. Stop the engine and allow time for the hydraulic fluid to cool.

1. Stop the engine and allow time for the hydraulic fluid to cool.

2. Wipe the filter head clean using a clean lint free cloth.

2. Wipe the filter head clean using a clean lint free cloth.

3. Use a filter element wrench to loosen the filter element. Remove and discard the filter element.

3. Use a filter element wrench to loosen the filter element. Remove and discard the filter element.

4. Be sure that the old filter element, rubber gasket is removed and discarded before the new filter element is installed.

4. Be sure that the old filter element, rubber gasket is removed and discarded before the new filter element is installed.

5. Apply clean hydraulic oil on the NEW filter element rubber gasket. Fill the element with the correct, new and filtered hydraulic oil.

5. Apply clean hydraulic oil on the NEW filter element rubber gasket. Fill the element with the correct, new and filtered hydraulic oil.

6. Carefully install the new filter element onto the filter head. Tighten the filter element onto the filter head as directed by the manufacturer.

6. Carefully install the new filter element onto the filter head. Tighten the filter element onto the filter head as directed by the manufacturer.

Do NOT overtighten the new filter element onto the filter head. Hand tighten only.

Do NOT overtighten the new filter element onto the filter head. Hand tighten only.

7. Start the engine using the procedures outlined in Section 3.

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7. Start the engine using the procedures outlined in Section 3.

4-25

Section 4 MAINTENANCE CHANGING THE TRAVEL SYSTEM HYDRAULIC OIL FILTER (See Figure 4-16).

1. Stop the engine and allow time for the hydraulic fluid to cool.

2. Wipe the filter head clean using a clean lint free cloth.

3. Use a filter element wrench to loosen the filter element. Remove and discard the filter element.

4. Be sure that the old filter element, rubber gasket is removed and discarded before the new filter element is installed.

5. Apply clean hydraulic oil on the NEW filter element rubber gasket. Fill the element with the correct, new and filtered hydraulic oil.

6. Carefully install the new filter element onto the filter head. Tighten the filter element onto the filter head as directed by the manufacturer.

Do NOT overtighten the new filter element onto the filter head. Hand tighten only.

7. Start the engine using the procedures outlined in Section 3.

ALTERNATOR AND FAN DRIVE BELTS.

If the fan assembly is found loose and requires tightened, loosen and remove the four (4) capscrews and nuts which fasten the LEFT half of the fan guard assembly to the right half of the fan guard.

Loosen and remove the four (4) capscrews that fasten the LEFT fan guard to the cooling package and remove the guard.

Using a 3/8 drive torque wrench and a correct sized socket, tighten each fan mounting bolt to a torque of 22 ft. lbs. ( 30 N.m).

Put the LEFT fan guard in place against the right guard and align all mounting holes. Install the four (4) capscrews and nuts which fasten the LEFT half of the fan guard assembly to the right half of the fan guard, and tighten.

Install the four (4) capscrews which fasten the LEFT half of the fan guard assembly to the cooling package. If needed, adjust the LEFT fan guard vertically and horizontally to have adequate fan assembly clearance and securely tighten each capscrew.

BATTERIES [See Figure 4-17].

The unit is equipped with a 24 VDC battery system.

Two batteries, connected in series, are located in the front left compartment of the ballast container.

Perform basic maintenance procedures to help ensure long-life and successful starts.

CHECKING BELTS. See CUMMINS QSM11 ENGINE Operation and Maintenance Manual, for suggested procedures.

CHECKING AND TIGHTENING THE ENGINE COOLING FAN. Stop the engine. Visually inspect the fan for apparent looseness, or damage daily.

The engine MUST be â&#x20AC;&#x153;STOPPEDâ&#x20AC;? before checking and/or tightening the fan. Serious injury can result from being struck or caught by the fan, belts or moving engine parts.

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FIGURE 4-17. BATTERIES.

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Section 4 MAINTENANCE CHECKING ELECTROLYTE LEVEL.

CALIFORNIA Proposition 65.

Battery posts, terminals and related accessories contain lead and lead compounds.

Wash hands after handling.

Every 250 hours, or six months, check the electrolyte in the batteries.

Never check the batteries while someone is smoking in the area.

Fumes given off by the batteries are highly flammable. When checking the batteries, make certain you are not in an area where there are open flames or sparks.

Electrolyte contains sulfuric acid.

Wear appropriate clothing including safety goggles and gloves whenever working with electrolyte.

Also, see CUMMINS QSM11 engine "Operation and Maintenance Manual", supplied with the machine, for suggested procedures.

1. Remove the caps from the batteries.

2. Check the fluid level in each opening.

3. If the plates are not covered by electrolyte, add sufficient distilled water to cover the plates. Be careful not to overfill the battery. The electrolyte level should be sufficient to cover the plates, but not reach the bottom of the openings in the top of the battery case.

4. Replace the caps on all the openings in the battery.

CLEANING BATTERIES AND CABLE CONNECTORS. Batteries and cable connectors must be kept clean.

Use the following procedure to ensure batteries are kept clean and free of corrosive deposits.

A battery explosion can occur if the battery is short-circuited.

Always disconnect the NEGATIVE (-) battery cable from the NEGATIVE (-) terminal of the battery first. Then disconnect the POSITIVE (+) battery cable from the POSITIVE (+) terminal of the battery before cleaning the battery terminals and cables.

NEVER short-circuit the positive and negative terminals of the battery.

Always connect the POSITIVE (+) battery cable to the POSITIVE (+) terminal of the battery first. Then connect the NEGATIVE (-) battery cable to the NEGATIVE (-) terminal of the battery after cleaning battery terminals and cables.

1. Disconnect the negative and then the positive battery cables from the terminals of the battery.

2. Clean the positive and negative terminals of the battery using a battery cable cleaning brush, and a solution of baking soda and clear water.

Dry the terminals using a soft clean lint free cloth.

3. Clean the cable connectors using a battery cable cleaning brush and a solution of baking soda and clear water. Dry the cable connectors using a soft clean lint free cloth.

4. Connect the positive and then the negative battery cables to the terminals of the battery.

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4-27

Section 4 MAINTENANCE CHECKING AND TIGHTENING HOLD-DOWN CLAMPS. 1. Clean the battery clamps using a battery cable cleaning brush, and a solution of baking soda and clear water.

2. Tighten the hold-down clamps using a socket set with the appropriate size socket for the nut.

FRONT TIRES. CHECKING FRONT TIRE PRESSURE (See Figure 4-18).

VALVE STEM AND CAP

FIGURE 4-18. CHECKING THE FRONT TIRES. 1. Check the front tires for signs of excessive wear, cuts or other potential damage.

DANGER:

Repair or replace any tire showing serious damage immediately.

2. Check the tires while they are cold. Never check the tires when they are warm. This will provide false readings.

3. Remove the tire valve cap from the tire inflation valve. Check the inflation pressure of each of the front tires using an accurate tire pressure gauge. The Recycler, or Stabilizer, correct pressure is 35 psi (2.41 bar) for the front tires.

4. Inflate, or deflate, the tire to maintain the specified tire pressure.

ALWAYS use remote inflation equipment consisting of an extension hose, with a clip-on filling chuck, and a gauge or preset pressure regulator.

Whenever inflating a tire, ALL personnel MUST keep clear of the tire and rim.

Do not overinflate the tires. Overinflated tires are more likely to cut, snag or puncture.

Do not under-inflate the tires.

Under-inflated tires will be too soft and deflect whenever en countering ruts or other typical hazards of road construction sites. Under-inflated tires can cause a buildup of excessive heat and cause breaks in the tire body cords.

ALWAYS replace tire valve caps onto the tire valve stems after checking and adjusting tire pressure.

APPLYING TORQUE TO FRONT WHEEL MOUNTING NUTS (See Figure 4-21).

1. Check and adjust the torque of the front wheel mounting nuts every 50 hours, or once a week.

2. Place wooden blocks in front and in back of the rear wheels.

3. Jack up the front end of the Recycler or Stabilizer under the wheel so it is just touching the ground. Place wooden bracing under the frame in the event the jack slips.

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Section 4 MAINTENANCE 4. Loosen all nuts and using a torque wrench, retighten each nut to the specified torque (400 ft. lbs. [542 N.m]). Follow a â&#x20AC;&#x153;starâ&#x20AC;? pattern to even the tension on the wheel as the nuts are tightened to the specified torque.

1. Check the rear tires for signs of excessive wear, cuts or other potential damage.

DANGER:

Repair or replace any tire showing serious damage immediately.

2. Check the tires while they are cold. Never check the tires when they are warm. This will provide false readings.

3. Remove the tire valve cap from the tire inflation valve. Check the inflation pressure of each of the rear tires using an accurate tire pressure gauge. The Recycler, or Stabilizer, correct pressure is 35 psi (2.41 bar) in both rear tires.

TIGHTEN FRONT WHEEL MOUNTING NUTS IN A STAR PATTERN

4. Inflate, or deflate, the tire to maintain the specified tire pressure.

FIGURE 4-19. APPLYING TORQUE TO FRONT WHEEL NUTS. 5. Lower the wheel and repeat the procedure for the wheel on the opposite side.

REAR TIRES.

ALWAYS use remote inflation equipment consisting of an extension hose, with a clip-on filling chuck, and a gauge or preset pressure regulator.

Whenever inflating a tire, ALL personnel MUST keep clear of the tire and rim.

CHECKING REAR TIRE PRESSURE (See Figure 4-20).

VALVE STEM AND CAP

Do not overinflate the tires. Overinflated tires are more likely to cut, snag or puncture.

Do not under-inflate the tires.

Under-inflated tires will be too soft and deflect whenever en countering ruts or other typical hazards of road construction sites. Under-inflated tires can cause a buildup of excessive heat and cause breaks in the tire body cords.

ALWAYS replace tire valve caps onto the tire valve stems after checking and adjusting tire pressure.

FIGURE 4-20. CHECKING THE REAR TIRES.

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Section 4 MAINTENANCE APPLYING TORQUE TO REAR WHEEL MOUNTING NUTS (See Figure 4-21).

4. Loosen each nut and using a torque wrench, retighten each nut to the specified tension (426 ft. lbs [578 N.m]). Follow a “star” pattern to even the tension on the wheel as the nuts are tightened to the specified torque.

5. Lower the wheel and repeat the procedure for the wheel on the opposite side.

SAFETY DECALS. 1. Check condition.

2. Replace as necessary.

SEAT BELT.

TIGHTEN REAR WHEEL MOUNTING NUTS IN A STAR PATTERN

FIGURE 4-21. APPLYING TORQUE TO REAR WHEEL NUTS.

1. Check and adjust the torque of the rear wheel mounting nuts every 50 hours or once a week.

1. Check condition 2. Replace as necessary.

BELT REPLACEMENT PROCEDURE. Reference ROPS/FOPS, or ROPS and Seat Belt “Insert Page” in the front of this manual.

2. Place wooden blocks in front and in back of the front wheels.

3. Jack up the back end of the Recycler, or Stabilizer under the wheel so it is just touching the ground. Place wooden bracing under the frame in the event the jack slips.

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08/05

Section 4 MAINTENANCE ROLL OVER OR ROLL OVER / FALLING OBJECT PROTECTION STRUCTURE. CHECKING MOUNTING FASTENERS TORQUE. 1. Inspect the ROPS/FOPS, or ROPS, structure each day prior to starting the engine to ensure that all mounting bolts are in place and tightened to the correct torque.

2. Every 250 Hours, or six months, torque the ROPS/FOPS, or ROPS, structure mounting bolts using a torque wrench.

3. Tighten ALL structure mounting bolts to the correct torque of 800 ft•lbs (1085 N•m).

INSPECTING FOR CRACKS, RUST AND WEAR.

Inspect the entire ROPS/FOPS or ROPS assembly for signs of deterioration at the specified intervals. If any signs of deterioration are present, place the machine off limits and replace the ROPS/FOPS or ROPS assembly prior to resuming work.

1. Inspect the entire ROPS/FOPS, or ROPS, assembly. Signs of danger include:

• • • • •

DISPLAY PANEL AND GAUGES. The ignition panel contains the PowerView multifunction display panel, with access arrows and menu keys. The system monitors selected engine and hydraulic system parameters (see Section 3).

Two gauges, showing rotor system pressure and travel system pressure, are mounted on the switch panel, found on the operator’s console.

CHECKING OPERATION. After the engine is started and when accessed, the PowerView display will provide information about the engine or hydraulic system parameter selected (see Section 3).

The two gauges are a function of external inputs and should be monitored closely upon engine startup and when initially moving, or working, the machine.

A part of each day’s checking operation should include monitoring of the above gauges to ensure their proper function and monitoring of the systems.

REPAIR. See Instructions for Repair Manual, contact your Distributor, or Bomag Americas.

Rust Loose, or missing, bolts Cracks Separation at seams Flaking of paint

2. If any of the above signs are apparent, do not use the machine until the structure is repaired or replaced. Remove the ignition key. Place a Red Warning Tag on the machine's steering wheel describing the problem and stating "Do NOT Operate".

3. Contact your Distributor, or Bomag Americas, for assistance prior to repair, or replacement, of the structure.

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Section 4 MAINTENANCE LUBRICATION POINTS. LUBRICATION (See Figure 4-22 and Table 4-2).

E

D

A

B F

A

D G

C

E

FIGURE 4-22. LUBRICATION POINTS.

TABLE 4-2. LUBRICATION POINTS. LOC. A B C D E F

LUBRICATION FRONT STEERING AXLE HINGES MAIN PIVOT TUBE ROTOR LIFT CYLINDERS PITCH BRACE BEARINGS TAILGATE ROTOR HOOD

APPLY GREASE GREASE GREASE GREASE GREASE GREASE

PERIOD EVERY 50 EVERY 50 EVERY 50 EVERY 50 EVERY 50 EVERY 50

HOURS HOURS HOURS HOURS HOURS HOURS

LUBE POINTS 7 ZERKS 11 ZERKS 2 ZERKS 4 ZERKS 4 ZERKS 2 ZERKS

NOTE: Use Multi-Purpose grease for lubrication.

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Section 4 MAINTENANCE DYNAMIC BRAKES (SERVICE BRAKE).

Dynamic braking is a function of the hydrostatic drive. During machine operation, as the Travel Direction Control Lever is moved from the forward, or reverse, position toward the neutral (N) position, the travel pressure gauge should show a corresponding increase in pressure due to increased load on the system (dynamic braking).

4. After moving a short distance, move the Travel Direction Control Lever (FNR) towards the neutral position. The machine must slow in immediate response to lever inputs. As the lever is set to neutral (N), the machine must come to a complete stop in a reasonably short distance.

5. Repeat the procedure for the reverse direction.

REPAIR.

The machine then slows and can be brought to a complete halt in response to the neutral (N) position of the Travel Direction Control Lever .

It is important to note that while Dynamic Braking is extremely effective, it is not as immediate as applying a mechanical brake.

Allow sufficient distance for machine braking to occur.

CHECKING OPERATION.

The machine should perform as described. If â&#x20AC;&#x153;Dynamic Brakingâ&#x20AC;? does not occur as described, do NOT operate the machine. Contact your Distributor, or Bomag Americas.

DO NOT OPERATE the machine if ANYproblem with Dynamic Braking is noted. Put a tag reading "DO NOT OPERATE" on the steering wheel, of the machine. REMOVE the ignition key and place in storeage.

1. Prior to beginning work each day, lay out a short course where the machine can be run for a short distance to check the operation of various components.

2. Put the throttle at HIGH idle (2300 RPM - no load).

3. Move the Travel Direction Control Lever (FNR) forward. The Travel Pressure should show an increase, and the machine will start to move in the forward direction.

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Section 4 MAINTENANCE PARKING BRAKE.

(c)

The parking brake is a spring activated – hydraulically released (SAHR) type brake on the rear axle.

The brake is engaged whenever there is an absence of hydraulic pressure to keep the brake released.

CHECKING OPERATION. During typical operations, the parking brake is controlled by the position of the Brake Switch located on the Ignition Panel.

When the Emergency Stop push button is pressed and left in the locked (down) position. Pressing the Emergency Stop switch down disables the ability of the system to release the SAHR brakes. The brakes will remain engaged as long as the Emergency Stop switch is in the down and locked position.

REPAIR. See Instructions for Repair Manual, contact your Distributor, or Bomag Americas.

1. To engage the parking brake, set the switch to the right-hand (I) position.

DO NOT OPERATE the machine if ANY problem with the Parking Brake System is noted. Put a tag reading "DO NOT OPERATE" on the steering wheel, of the machine. REMOVE the ignition key and place in storeage.

2. As the brake is set, both red lamps directly above the switch should be illuminated.

3. To release the brake, set the switch to the lefthand (0) position.

4. As the brake is released, both red lamps directly above the switch should go out.

STEERING. CHECKING OPERATION.

NOTE: In addition to the above procedure for setting the SAHR brakes, they are, also, set under three other conditions:

(a)

The parking brakes (SAHR) are on (applied) whenever the engine is OFF. Therefore, when the ignition switch is in the run position and the engine is off, both of the red brake lamps will be on.

(b)

Using the rocker switch, located on top of the handle of the Travel Direction Control Lever (FNR), is used to engage either the right, or left, SAHR brake as an aid to steering. As either brake is engaged using this switch, the corresponding brake light should light up and remain lit until the rocker switch is released.

The steering system is an Axle Pivot type system, powered hydraulically through the orbitol.

Prior to the start of each day’s operation, check the steering system with the machine motionless, and also with the machine running at a slow speed that can be controlled in the event of a steering failure.

Test steering to both the right and left. The front axle should allow for a 30° turn in either direction.

REPAIR.

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See Instructions for Repair Manual, contact your Distributor, or Bomag Americas.

DO NOT OPERATE the machine if ANY problem with the Parking Brake System is noted. Put a tag reading "DO NOT OPERATE" on the steering wheel, of the machine. REMOVE the ignition key and place in storeage.

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Section 4 MAINTENANCE BACKUP ALARM. CHECKING OPERATION (See Figure 4-23).

As the throttle is increased to full (rabbit) and the travel direction control lever is moved in the Reverse direction, the system is fitted with an electrical Backup Alarm horn. Prior to the start of each day’s operation check the function of this horn in a safe manner, as follows.

HIGH pressure is present in the rotor system accumulator assembly and the lines connected to it.

Do NOT attempt to check and/or adjust the system accumulatorprecharge pressure before being informed by Bomag Americas service personnel and/or through the above publication and understanding completely all information provided. The rotor system’s accumulatorp recharge pressure is 300 psi +/- 5 psi (20.68 bar +/0.3 bar).

PLANETARY WHEEL ENDS OIL. CHECKING PLANETARY WHEEL ENDS OIL LEVEL. 1. Rotate the INSPECTION plug to the 3:00 o’clock position. The plug is located on the end of the planetary (See Figure 4-24 – 1).

2. Remove inspection plug.

3. A small amount of oil should flow from the planetary wheel end when the plug is removed.

FIGURE 4-23. BACKUP ALARM. Prior to checking the operation of this alarm, warn your coworkers that you will be testing the backup alarm and ensure that no one is directly behind the rotor. This is an area where the operator’s vision may be obscured. Wherever possible have an assistant watch the back of the machine during testing to ensure no one accidentally walks in the path of the machine, and, also, to verify that the alarm can be heard from various distances.

4. If no oil flows, add oil as described in the following information.

5. If oil is present, replace plug. Tighten it securely.

Do not overtighten the plug stripping the threads.

REPAIR. See Instructions for Repair Manual, contact your Distributor, or Bomag Americas.

ROTOR SYSTEM ACCUMULATOR. Use the information contained in the Instructions for Repair Manual, p.n. 0852680, or supplied by Bomag Americas service personnel, to check and if needed, adjust rotor system precharge system pressure.

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4-35

Section 4 MAINTENANCE ADDING OIL TO PLANETARY WHEEL ENDS.

FUEL TANK BREATHER CAP. (See Figure 4-25).

Remove the FILL plug, found at the 12:00 o'clock position (See Figure 4-24 â&#x20AC;&#x201C; 2). Use a funnel to add oil to the planetary wheel ends through the fill plug hole. Use EP 80W90 when adding oil, until oil flows from the INSPECTION plug hole. Replace both plugs and tighten securely.

CHANGING FUEL TANK BREATHER CAPS. Each of the two 120 gallon fuel tanks is fitted with a breather cap (see figure 4-25). The breather should to be changed every 2,000 hours, or each year.

BREATHER

2 1

FIGURE 4-24. PLANETARY WHEEL ENDS INSPECTION AND FILL PLUGS.

FIGURE 4-25. FUEL TANK CAP. Replace BOTH fuel tank breather caps each year, or every 2,000 hours of operation, or MORE OFTEN if the machine operates in a dusty environment.

Reference the Spare Parts Catalog for the appropriate part number and order through your Distributor.

ELECTRICAL SYSTEM MAINTENANCE. The following charts show the assignments for each of the fuses used on this machine. Reference these charts when it is suspected that a fuse is responsible for an electrical problem.

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Section 4 MAINTENANCE FUSE ASSIGNMENTS AND SPECIFICATIONS. (See Tables 4-3, 4-4, 4-5, 4-6, 4-7 and 4-8).

TABLE 4-3. FUSE BOX 1 (FB-1) POWER APPLIED WHEN

POSITION

USAGE

FUSE

STD/OPT

When Ignition Switch is “ON”

1

15 Amp

Standard

When Ignition Switch is “ON”

2

15 Amp

Standard

When Ignition Switch is “ON”

3

15 Amp

Standard

When Ignition Switch is “ON” When Ignition Switch is “ON” When Ignition Switch is “ON”

4 5 6

Brakes Circuit Brake Lights Circuit Shift Lights Circuit Shift Relays Circuit 2 Speed Shift Circuit Front Assist Circuit (used MPH 364-2 only) Speedometer Circuit Rotor Lift and Door Circuit Control Circuit Rotor Control Circuit Backup Alarm Circuit Travel and Load Control Circuit

10 Amp 15 Amp 10 Amp

Standard Standard Standard

FUSE

STD/OPT

5 Amp 5 Amp 15 Amp 10 Amp 15 Amp 10 Amp

Standard Standard Standard Standard Optional Standard

FUSE

STD/OPT

TABLE 4-4. FUSE BOX 2 (FB-2) POWER APPLIED Always “ON” When Ignition When Ignition When Ignition When Ignition When Ignition

Switch Switch Switch Switch Switch

is is is is is

POSITION “ON” “ON” “ON” “ON” “ON”

1 2 3 4 5 6

USAGE Ignition Switch Circuit Alarm & Warning Lights ASC/ Monitoring System PowerView and Alarm Relay Turn Signals Circuit Stop Lamp Relay Circuit Neutral Relay Circuit

TABLE 4-5. FUSE BOX 3 (FB-3) POWER APPLIED Always Always Always Always Always Always

“ON” “ON” “ON” “ON” “ON” “ON”

POSITION 1 2 3 4 5 6

USAGE Horn Circuit Empty Empty 4-Way Hazard Lights Circuit Work Lights Circuit Park/Head Lights Circuit

15 Amp --15 Amp 20 Amp 20 Amp **

Standard --Optional Optional Optional

** FUSE IS STANDARD

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Section 4 MAINTENANCE TABLE 4-5. FUSE BOX 3 (FB-4)* POWER APPLIED When When When When When When

Ignition Ignition Ignition Ignition Ignition Ignition

Switch Switch Switch Switch Switch Switch

is is is is is is

“ON” “ON” “ON” “ON” “ON” “ON”

POSITION

USAGE

FUSE

STD/OPT

1 2 3 4 5 6

Water Spray System ALPS 4.0 System Rotary Beacon Empty Empty Empty

20 Amp 20 Amp 15 Amp

Optional Optional Optional

FUSE

STD/OPT

10 Amp 10 Amp

Standard Standard

FUSE

STD/OPT

125 Amp 125 Amp 10 Gauge

Standard Standard Standard

TABLE 4-6. FUSE BOX - ENGINE (FB-E-1) POWER APPLIED Always “ON” Always “ON”

POSITION 1 2

USAGE Engine Unswitched Power Engine Unswitched Power

TABLE 4.7. FUSIBLE LINKS POWER APPLIED Always “ON” Always “ON” Always “ON”

POSITION

USAGE

FL3 Power Panel FL1 Power Panel FL2 Alternator

Cab, Heater, A/C Vehicle Electrical System Alternator Charging Cir.

ELECTRICAL RELAYS The following chart lists the functions of the electrical relays used on this unit.

RELAY ASSIGNMENT (See Table 4-8).

TABLE 4-8. RELAYS ID K-1 K-3 K-4 K-6 K-7 K-8 K-9 K-10

USAGE Ignition Relay Start Relay (On engine) Flasher Relay (On Firewall) Stop Light Relay R.H. Brake Relay Rotor Relay L.H. Brake Relay Cab, Heater, A/C (On Engine)

NOTE Power Relay Power Relay (Optional) (Optional)

NOTE: Items listed as optional are available upon request. All machines are wired to accept the listed option, although if not originally installed, the option components are not included.

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Section 4 MAINTENANCE ELECTRICAL OPTIONS.

MISCELLANEOUS INFORMATION.

HEADLIGHTS / PARKING LIGHTS / WORKING LIGHTS OPTION.

ROTOR HOOD PITCH ADJUSTMENT PROCEDURE (See Figure 4-26).

Switches and wiring are built into the dash panels and wiring is included in the main harnesses.

Installation requires installing the lights and plugging into the existing wire harnesses. Installation of an additional fuse for the working lights is required.

1. Park the machine on a smooth, level surface BEFORE making adjustments. Apply the parking brake and STOP the engine.

TURN SIGNALS AND FOUR WAY HAZARD LIGHTS OPTION. Wiring for this option is included in the main wiring harnesses. Switches need to be added to the dash panels. A jumper harness plugs into the main harness and is used to connect to the newly mounted switches. Fuses for the turn signals and the hazard lights need to be installed. Install a flasher relay (Table 4-8 -ID – K-4). The relay connects to an existing plug in the main harness.

STOP LIGHTS. A neutral switch, relay and wiring are built into the main harnesses. Install and plug the light into existing harness.

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2. Loosen the locknut on the hood pitch adjusting screw. Turn the adjusting screw counterclockwise (CCW) for REDUCTION of the hood pitch.

Turn the adjusting screw clockwise (CW) for an INCREASE of the hood pitch.

3. After the pitch adjustment has been made, and verified as correct, tighten the locknut.

NOTE: The normal hood pitch for asphalt reclamation or pulverization is 2” (5.08 mm) ABOVE ground level.

For soil stabilization, the front of the rotor hood should be set at a pitch 4” (10.16 mm) ABOVE ground level (See Figure 4-26).

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Section 4 MAINTENANCE DANGER: LOCKNUT

HOOD PITCH

ADJUSTING SCREW

GROUND LINE

FIGURE 4-26. ROTOR HOOD PITCH ADJUSTMENT PROCEDURE. RECOMMENDED FIELD WELDING PROCEDURES FOR ONE PIECE SOCKET TO RECYCLER ROTOR TUBE - MPH 362-2R AND MPH 364-2R (See Figures 4-27 and 4-28).

The machine must be parked on level terrain, with the parking brake “ON,” before starting ANY weld procedures. The rotor hood MUST be in the RAISED and LOCKED position, with BOTH lock pins installed before starting the welding procedures. Lock the rear rotor door open.

Do NOT attach the ground cable to the rotor arms, frame or hood when welding the socket to the rotor tube. Ground must be made through the rotor tube. Bearings can be damaged when the ground is made through areas other than the rotor tube. Turn the battery disconnect switch to OFF, to help protect electrical components.

1. Clean the rotor tube, removing oil and asphalt, in the area where the socket will be welded.

When replacing, grind off ALL original weld material from the rotor and/or socket surfaces.

2. Position and then “tack weld” the socket to the rotor tube. Remove weld slag from the “tack welds.”

NOTE: ALL sockets, except the two on the center of the rotor, MUST angle OUTWARD from the rotor center 2° - 3°. The two sockets on the center of the rotor will be straight with NO angle.

FIGURE 4-27. RECYCLER SOCKET. 3. Preheat the socket and rotor tube base material to a temperature of 400-450° F (151-170°C).

The base material and socket must retain this temperature for entire welding of each socket.

4. Use a low hydrogen electrode (AWS E 7018, E7028) to weld the socket to the rotor tube surface. Make several “passes” to achieve the required weld size.

4-40

08/05

Section 4 MAINTENANCE 5. Deposit weld four sides of socket as shown, with multiple weld passes (3 to 4 passes each) to achieve a 0.50 overall fillet weld as outlined in the following steps. Work in groups of five sockets allowing socket to cool by welding adjacent sockets in order to avoid possible stress cracking due to heat in affected zone.

NOTE: Avoid concentration of weld heat.

6. Begin by making a single weld pass, front and back, on a group of five sockets. Repeat process ONE PASS ONLY, front and back, until all sockets in group are welded.

7. Next, make a single weld pass on one side only, returning to the first socket welded until all sockets in group have one weld pass on one side.

Then make a single weld pass on the second side until all sockets in the group have one weld pass on second side. Repeat process, one pass at a time, and one side at a time, alternating sides, until all sockets in the group are welded.

Remove the weld slag AFTER each weld “pass” before making the next “pass.” Weld three to four passes on all FOUR sides of the base as shown in Figure 4-29 to achieve a 1/2” overall fillet weld.

The tack welds MUST be “remelted” during welding. Vertical “down” welding is prohibited.

[SEE WELD NOTE BELOW] 0.50

0.50

2¡-3¡

0.50

FIGURE 4-28. RECOMMENDED FIELD WELDING PROCEDURES FOR SOCKET TO RECYCLER ROTOR TUBE.

NOTE: For socket replacement, make sure all signs of original weld are ground off the rotor surface.

WELDING INSTRUCTIONS - RECYCLER END SEGMENTS SOCKETS TO MILD STEEL (MPH 362-2 AND MPH 364-2 RECYCLERS).

1. Segment plate surface must be clean at socket location.

3. After sockets are tack welded in position preheat the segment plate and socket to 400°F450°F prior to welding. Maintain this temperature while welding of each socket.

4. Use cutting tool to locate sockets.

5. Several passes of weld bead can be used in place of a spacer bar to position sockets.

6. Slow cool finished weldment under controlled conditions.

7. For socket replacement, make sure all signs of original weld are ground off the segment plate surface.

08/05

4-41

Section 4 MAINTENANCE RECOMMENDED FIELD WELDING PROCEDURES TO TINE PLATE AND/OR SOCKET TO STABILIZER ROTOR TUBE (See Figure 4-29).

2. Position and then “tack weld” the tine plate to the rotor tube. If the sockets are being replaced, position and then “tack weld” the socket to the tine plate (See Figure 4-29). Remove weld slag from ALL “tack welds.”

DANGER:

3. Preheat the tine plate, socket and rotor tube to a temperature of 125° F (151-170° C) minimum.

The machine must be parked on level terrain, with the parking brake “ON,” before starting ANY weld procedures. The rotor hood MUST be in the RAISED and LOCKER position, with BOTH lock pins installed, before starting to do the welding procedures. Lock the rear rotor door open.

Do NOT attach the ground cable to the rotor arms, frame or hood when welding the socket to the rotor tube. Ground must be made through the rotor tube. Bearings can be damaged when the ground is made through areas other than the rotor tube. Turn the battery disconnect switch to OFF, to help protect electrical components.

1. Clean the rotor tube, removing oil and asphalt in the base area where the tine plate will be welded. For tine plate or socket replacement, grind off ALL “original” weld from the rotor tube and/or tine plate and/or socket surfaces.

4. Use a low hydrogen electrode (AWS E70 XX class) or equivalent to weld the tine plate to the rotor tube surface and/or the socket to the tine plate (see Figure 4-29). Make several “passes” to achieve the required weld size.

Remove the weld slag AFTER each weld “pass” before making the next “pass.” Weld three to four passes on ALL FOUR sides of the tine plate as shown in Figure 4-29 to achieve a 1/2” overall fillet weld. Weld as needed on ALL FOUR (4) sides of the socket to the tine plate as shown in Figure 4-29 to achieve a 3/8” overall fillet weld. The tack welds MUST be “remelted” during welding.

Vertical “down” welding is prohibited.

.63 .38 .38

TYP

SOCKET

TINE PLATE

TYP

.31 .31

.50

TYP

TINE PLATE PREHEAT TINE PLATE AND SOCKET TO 125˚ F MINIMUM PRIOR TO WELDING

ROTOR TUBE

PREHEAT TINE PLATE AND BASE TO 125˚ F MINIMUM PRIOR TO WELDING. USE AWS E 70 XX CLASS ELECTRODE ( LOW HYDROGEN ) OR EQUIVALENT

FIGURE 4-29. RECOMMENDED FIELD WELDING PROCEDURES FOR TINE PLATE AND/OR SOCKET TO STABILIZER ROTOR TUBE.

4-42

08/05

Section 4 MAINTENANCE WINTERIZATION PROCEDURES.

Do NOT store the batteries on a concrete surface. Store the batteries on a WOOD surface ONLY. Be sure that the batteries electrolyte will NOT freeze.

PREPARING THE MACHINE FOR STORAGE. Use the following information as a “general guide” ONLY to prepare the machine for storage.

Manufacturers of components used on the machine can also be contacted for specific information about the components that they manufacture.

ENGINE.

FUEL TANKS. Fill both fuel tanks COMPLETELY before placing in storage. Use only CLEAN fuel of the RECOMMENDED TYPE.

CUMMINS ENGINE COMPANY, manufacturer of the engine used on this machine, has information available on Storage for Engines Out of Service. If the engine is to be out of service for six months or longer, contact your nearest Cummins Authorized Repair Location, or refer to the QSM11 Engine "Operation and Maintenance Manual" for information concerning engine storage procedures.

Do NOT leave the fuel tanks partially filled. Moisture will condense inside the fuel tanks while in storage. This can cause fuel system component damage during storage and/or when the machine is placed back in service.

COOLING SYSTEM. The entire cooling system MUST be protected from freezing. Completely drain the cooling system of water and leave empty, OR install an ethylene glycol-based antifreeze and water solution. The antifreeze and water MUST be of the CORRECT mixture ratio to protect the cooling system. This mixture ratio should protect to a temperature BELOW the lowest expected freezing temperature for the area where the machine is to be stored.

NOTE: Also see the Cummins QSM11 Engine "Operation and Maintenance Manual” provided with the machine for additional cooling system maintenance information from the ENGINE manufacturer.

AIR CLEANER, EXHAUST AND OTHER OPENINGS. Place 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.

Remove the drain fitting installed into the bottom of the muffler.

TIRES. Check and adjust air pressure in all of the tires to the correct cold pressure. CAREFULLY lift BOTH sides of the frame assembly, so that the rear tires are lifted ABOVE the ground a small amount, and so that the tires do NOT support the weight of the machine. Place solid wood blocks under both sides of the frame and under the rotor hood. Cover the tires to keep direct sunlight off them.

BATTERIES. Repeat this procedure for the front tires.

If the machine is to be stored for a period of MORE than 30 days, remove the batteries BEFORE being placed in storage. Charge the batteries once for every 30 days in which they are stored. Keep the batteries stored in a cool, dry place.

08/05

Block the frame support areas SECURELY using SOLID wood blocking.

4-43

Section 4 MAINTENANCE EXPOSED COMPONENT RUST PREVENTION. Put a heavy grease, or equivalent, onto ANY exposed area of ALL hydraulic cylinder rods and/or control valve spools.

Use a rust prevention oil (such as L.P.S.#s 2 or 3) on ALL control linkages, control cable ends, hinges or other moving parts. Put ALL covers and access plates in their CORRECT positions and secure in place.

REFERENCE. TORQUE SPECIFICATIONS FOR METRIC FASTENERS. (See Table 4-9).

TABLE 4-9. TORQUE SPECIFICATIONS FOR METRIC FASTENERS. BOLT DIMENSIONS M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30

TIGHTENING TORQUE FT•LBS / N•m 8.8 2 ft•lbs/3 N•m 4 ft•lbs/6 N•m 7 ft•lbs/10 N•m 18 ft•lbs/25 N•m 37 ft•lbs/50 N•m 65 ft•lbs/88 N•m 101 ft•lbs/137 N•m 156 ft•lbs/211 N•m 213 ft•lbs/290 N•m 304 ft•lbs/412 N•m 413 ft•lbs/560 N•m 524 ft•lbs/711 N•m 774 ft•lbs/1050 N•m 1047 ft•lbs/1420 N•m

10.9 3 ft•lbs/5 N•m 7 ft•lbs/10 N•m 11 ft•lbs/15 N•m 26 ft•lbs/35 N•m 55 ft•lbs/75 N•m 91 ft•lbs/123 N•m 145 ft•lbs/196 N•m 221 ft•lbs/300 N•m 303 ft•lbs/412 N•m 426 ft•lbs/578 N•m 559 ft•lbs/785 N•m 738 ft•lbs/1000 N•m 1092 ft•lbs/1480 N•m 1482 ft•lbs/2010 N•m

NOTE: The above table represents the strength class for capscrews with untreated, non-lubricated surfaces.

The quality designation of the capscrews is marked on the screw head.

12.9 4 ft•lbs/5 N•m 7 ft•lbs/10 N•m 13 ft•lbs/18 N•m 33 ft•lbs/45 N•m 61 ft•lbs/83 N•m 108 ft•lbs/147 N•m 173 ft•lbs/235 N•m 264 ft•lbs/358 N•m 361 ft•lbs/490 N•m 513 ft•lbs/696 N•m 695 ft•lbs/942 N•m 885 ft•lbs/1200 N•m 1308 ft•lbs/1774 N•m 1770 ft•lbs/2400 N•m The values result in a 90% utilization of the capscrews yield point at a coefficient of friction of µ total = 0.14.

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

4-44

08/05

Section 4 MAINTENANCE TORQUE SPECIFICATIONS FOR STANDARD INCH FASTENERS. (See Table 4-10 and Figure 4-30).

TABLE 4-10. TORQUE SPECIFICATIONS FOR STANDARD INCH FASTENERS.

20 UNC 28 UNC 18 UNC 24 UNF

SAE GRADE 5 CAPSCREWS TORQUE TORQUE (Ft•lbs) (N•m) Dry Lubed Dry Lubed 8 6 11 9 10 7 13 10 17 13 24 18 19 14 26 20

SAE GRADE 8 CAPSCREWS TORQUE TORQUE (Ft•lbs) (N•m) Dry Lubed Dry Lubed 12 9 16 12 14 10 19 14 25 18 33 25 27 20 37 28

16 UNC 24 UNF 14 UNC 20 UNF

31 35 49 55

23 26 37 41

42 47 67 75

31 36 50 56

44 49 70 78

33 37 52 58

59 67 95 105

44 50 71 79

13 UNC 20 UNF 12 UNC 18 UNF

75 85 110 120

57 64 82 91

100 115 145 165

77 86 110 125

105 120 155 170

80 90 115 130

145 165 210 230

110 120 155 175

11 UNC 18 UNF 10 UNC 16 UNF

150 170 265 295

115 130 200 225

205 230 360 405

155 175 270 300

210 240 375 420

160 180 280 315

285 325 510 570

215 245 380 425

9 UNC 14 UNF 8 UNC 14 NF

430 475 645 720

320 355 485 540

580 640 875 980

435 480 655 735

605 670 910 1020

455 500 680 765

820 905 1230 1380

615 680 925 1040

7 UNC 12 UNF 7 UNC 12 UNF

795 890 1120 1240

595 670 840 930

1080 1210 1520 1680

805 905 1140 1260

1290 1440 1820 2010

965 1080 1360 1500

1750 1960 2460 2730

1310 1470 1850 2050

6 UNC 12 UNF 6 UNC 12 UNF

1470 1670 1950 2190

1100 1250 1460 1650

1990 2270 2640 2970

1490 1700 1980 2230

2380 2710 3160 3560

1780 2040 2370 2670

3230 3680 4290 4820

2420 2760 3210 3620

NOM. SIZE

THREAD SERIES

1/4 5/16

3/8 7/16

1/2 9/16

5/8 3/4

7/8 1

1-1/8 1-1/4

1-3/8 1-1/2

Tables 4-9 and 4-10 list torque values for standard hardware and are intended as a guide for average application involving typical stresses and machined surfaces.

08/05

Values are based on physical limitations of clean, plated and lubricated hardware. In all cases, when an individual torque value is specified, it should be followed instead of values given in this table. Replace original equipment with hardware of equal grade.

4-45

Section 4 MAINTENANCE STANDARD INCH FASTENERS.

GRADE 5

GRADE 8

PLACEBOLT

SOCKET HEAD CAPSCREW

12 POINT CAPSCREW

FIGURE 4-30. STANDARD INCH FASTENERS.

4-46

08/05

Section 5 FRAME, SEAT AND PROTECTIVE STRUCTURE TABLE OF CONTENTS PAGE GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 SEAT AND SEAT BELT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 SEAT BELT REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 RETRACTOR MECHANISM SIDE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 BUCKLE SIDE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 ROLL OVER/FALLING OBJECT PROTECTIVE STRUCTURE (ROPS/FOPS). . . . . . . . . . . . . . . . . . . . . .5-4 CHECKS AND SERVICE PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 COUNTERWEIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

08/05

5-1

Section 5 FRAME, SEAT AND PROTECTIVE STRUCTURE GENERAL INFORMATION.

SEAT AND SEAT BELT.

This section describes the frame, seat and protective structure used on the BOMAG Model MPH 3622 and MPH 364-2 Recyclers and Stabilizers.

Procedures are included for removal and replacement of the Seat, Seat Belt, Protective Structure and the Counterweights. In addition, inspection and maintenance of the Protective Structure is also described in this section.

The Seat is securely attached to a platform in the cockpit. A Seat Belt System is included with the Protective Structure to restrain the operator in the event of the machine tipping. Carefully inspect the Seat Belt for the following:

The frame is a one-piece welded assembly that serves as a sturdy-mounting platform. The Rotor Assembly is attached to the rear of the frame and the Counterweights are attached at the front of the frame. The Protective Structure can be either a Roll Over Protective Structure/Falling Object Protective Structure (ROPS/FOPS) or a Roll Over Protective Structure (ROPS). The Seat Belt is securely attached to the Seat Base.

FRAME. The Counterweights are located inside an enclosure at the front of the vehicle and is large enough to offset the weight of the Rear Rotor Assembly. When a supply truck is used, the Traction Drive System is powerful enough to operate the vehicle, and push the supply truck at the same time so that both can travel at the same forward speed. Handrails are located so the operator can grasp them to step up or step down from the vehicle but do not provide protection in the event of a rollover.

5-2

1. The Belt Latch must catch and release correctly.

2. The belt material must be clean and not torn, rotted or damaged.

3. The Belt Anchor Eyebolts must remain tightened securely to the Seat Base at a correct torque of 40 ftâ&#x20AC;˘lbs (54.2 Nâ&#x20AC;˘m).

Never operate a machine having a worn, damaged or malfunctioning seat belt. Repair or replace a defective seat belt immediately.

Always use the seat belt provided on machines with ROPS/FOPS or ROPS structures.

08/05

Section 5 FRAME, SEAT AND PROTECTIVE STRUCTURE

FIGURE 5-1. VEHICLE OVERVIEW.

08/05

5-3

Section 5 FRAME, SEAT AND PROTECTIVE STRUCTURE SEAT BELT REPLACEMENT. RETRACTOR MECHANISM SIDE [See Figure 5-2].

1. Remove bolt, (Figure 5-2 – 1), washer (2) and nut (3) securing the Retractor Mechanism (4) to the left side of the Seat Base.

2. Attach replacement Retractor Mechanism (4) with bolt (1) washer (2) and nut (3).

3. Torque nut (3) to 40 ft•lbs (54.2 N·m).

BUCKLE SIDE [See Figure 5-2].

1. Remove bolt (Figure 5-2 – 5) washer (6) and nut (7) securing the buckle (8) to the right side of the Seat Base.

2. Attach replacement buckle (8) with bolt (5) washer (6) and nut (7).

ROLL OVER/FALLING OBJECT PROTECTIVE STRUCTURE (ROPS/FOPS).

The steel components of the Roll Over/Falling Object Protective Structure (ROPS/FOPS) are welded together using material and weld practices that produce a strong integrated structure.

The Protective Structure is fastened to the machine on each side of the Rear Frame Weldment by six Grade 8 capscrews (12 total) at a torque of 800 ft•lbs (1084.7 N•m).

Check torque values and inspect ROPS/FOPS as described in Section 4 of this manual.

An improperly mounted or damaged Protective Structure may not provide operator protection in the event of a machine tipover. Follow the inspection procedures below.

3. Torque nut (7) to 40 ft•lbs (54.2 N•m).

CHECKS AND SERVICE PROCEDURES. Check the Protective Structure components for breakage or other damage during maintenance or at overhaul.

FIGURE 5-2. SEAT BELT.

1. Inspect the twelve Grade 8 capscrews that fasten the Protective Structure to the machine. The capscrews must remain tightened to a value of 800 ft•lbs (1084.7 N•m). If capscrew replacement is needed, remove the capscrew, clean the threaded portion with a wire-brush. Install and then tighten any capscrew found damaged, or lost, to the correct torque specification, with correct replacement fasteners having an equivalent rating. Check the capscrew torque, and tighten the capscrews using a large capacity torque wrench.

If the Protective Structure has been removed from the machine and is being installed again, inspect each capscrew for wear or damage. Replace all worn or damaged capscrews with new. Install and then tighten each capscrew to the correct amount of torque.

Never replace the capscrews with fasteners that carry a “grade rating” of less than Grade 8.

5-4

08/05

Section 5 FRAME, SEAT AND PROTECTIVE STRUCTURE

FIGURE 5-3. ROPS/FOPS.

08/05

5-5

Section 5 FRAME, SEAT AND PROTECTIVE STRUCTURE 2. Carefully inspect ALL welds for cracks, severe rust, or breakage in the weld and/or where the weld joins the metal of the structural steel components.

If any damage is found, contact your distributor or BOMAG Americas immediately for replacement or repair instructions. Do not use the machine until contact is made and the directed repairs or protective structure replacement have been completed. Do not add anything to the protective structure. Never “heat”, weld or drill additional holes for any “add on” item onto the structure area. This practice can weaken the structural integrity of the complete structure.

Do not operate a machine after a rollover has occurred. If a rollover has occurred, remove the Protective Structure from the machine only after contact has been made with the distributor and/or BOMAG Americas Instructions for 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.

3. If surface rust on components, loose bolts, cracks, separation at seams or flaking of paint is found, do not use the machine until assembly is repaired or replaced. Place a Red Warning Tag on the unit’s steering wheel describing the problem.

If ROPS/FOPS is damaged, proceed as follows to remove and install the ROPS/FOPS.

REMOVAL [See Figure 5-3].

1. Provide sufficient support for the ROPS/FOPS weldment (Figure 5-3 – 1).

2. Remove the twelve bolts (2) and twelve washers (3), (six on each side).

3. Lift the ROPS/FOPS (1) from the vehicle.

INSTALLATION [See Figure 5-3].

NOTE: Decals must be installed when a new ROPS/FOPS weldment is installed. Also sound absorbing foam must be installed when a FOPS is replaced.

1. When a FOPS is being installed, install sound absorbing foam (Figure 5-3 – 4) and (5) into top of FOPS weldment. Tuck corners under plate.

2. Install the nineteen caps (6) in the foam.

3. Lift ROPS/FOPS weldment (1) and align the 12 mounting holes with the holes in the frame.

4. Secure the ROPS/FOPS weldment (1) to the frame with the twelve bolts (2) and twelve washers (3), (six on each side).

5. Torque the twelve bolts (2) to 800 ft•lbs [1084.7 N•m].

6. Install the Seat Belt Warning Decal (8) centered on the inside of the right vertical rollbar.

7. Install the Seat Belt Decal (9) centered on the inside of the right vertical rollbar.

8. Install the Bolt Torque Specification Decal (10) on ROPS. 9. For ROPS units only, install the Mounting Direction Decal (11) on ROPS. 10. Install Certification Decal (12) on ROPS.

5-6

08/05

Section 5 FRAME, SEAT AND PROTECTIVE STRUCTURE COUNTERWEIGHTS [See Figure 5-4].

5. Remove two nuts (4) and plates (5).

The counterweights are located under a cover at the front of the vehicle. These counterweights must be secured properly. To check or replace the counterweights or attaching hardware, proceed as follows:

6. Slide two threaded rods (7) out and remove counterweights (6).

1. Remove nine screws (Figure 5-4 – 1) and nine washers (2) securing front cover (3).

7. Remove two nuts (9) and plates (8) from threaded rod (7).

8. Check hardware for any damage to threads of rod or nuts.

2. Remove cover (3).

3. If counterweights are to be removed proceed with step 4. If only mounting hardware is to be retightened, torque nuts (9) to 330–340 ft•lbs (447.4–461.0 N•m).

4. Support the three counterweights (6) through center hole.

9. Install a plate (5) and nut (4) on back end of each rod (7).

Be sure rod extends through nut between 0.25–0.50 inch (6.35–12.7 mm).

10. Insert two rods (7) through rear of frame.

11 Install three counterweights (6) onto rods (7).

12. Secure counterweights (6) with plates (8) and nuts (9).

13. Torque nuts (9) to 330–340 ft•lbs (447.4–461.0 N•m).

08/05

5-7

Section 5 FRAME, SEAT AND PROTECTIVE STRUCTURE

FIGURE 5-4. COUNTERWEIGHTS.

5-8

08/05

Section 6 ENGINE, COOLING, EXHAUST, FUEL SYSTEM, THROTTLE TABLE OF CONTENTS PAGE GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4 RIGHT SIDE FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5 LEFT SIDE FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5 THROTTLE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8 CHARGE AIR COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10 RADIATOR/OIL COOLING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12 INSTALLING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18 ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18

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6-1

Section 6 ENGINE, COOLING, EXHAUST, FUEL SYSTEM, THROTTLE GENERAL INFORMATION. This section contains information about the Cummins QSM11 engine used on the MPH 362 and MPH 364-2 Recycler and Stabilizer, the Exhaust System, the Fuel System and the Throttle.

3. Remove four capscrews (6), and washers (7), attaching Muffler (5) and Thermal Pad (8) to hood.

4. Remove Muffler (5) and Thermal Pad (8).

5. Loosen clamp (9) and remove elbow (4).

NOTE: The Cummins Operation and Maintenance manual for the QSM11 is provided with the MPH 362 and MPH 364-2.

For Engine Operation, Service, Troubleshooting and general Maintenance procedures, see the engine Operation and Maintenance Manual.

EXHAUST SYSTEM.

6. Loosen clamp (10) and remove Flex Tube (11).

7. Loosen V-band clamp (12) and remove Elbow (13) from engine.

INSTALLATION [See Figures 6-1 and 6-2].

1. Install Elbow (Figure 6-1 - 13) on engine and secure with V-band clamp (12).

The Exhaust system includes the Muffler, Tailpipe, Flex Tube, and Thermal Mat. The exhaust system is mounted on the right side of the vehicle.

NOTE: Install Flex Tube (Figure 6-2 - 3) in a relaxed state. Do not stretch, compress or twist Flex Tube during assembly.

REMOVAL [See Figure 6-1].

2. Install Flex Tube (Figure 6-2 - 3) on Elbow (1).

Secure with clamp (2). Be sure clamp is oriented so that threaded stud is toward engine.

Exhaust system may be hot if vehicle has recently been in service. Be sure Exhaust system components have cooled down before removing.

1. Loosen screws on clamp, (Figure 6-1 - 1) and remove Tailpipe (2).

2. Loosen screws on clamp (3) securing Elbow (4) to Muffler (5).

6-2

3. Install Flex Tube (3) on elbow (5) and secure with clamp (4). Be sure clamp is oriented so that threaded stud is toward engine.

NOTE: Install Thermal Mat (Figure 6-1 - 8) on hood with folded/taped edge up.

4. Peel backing from adhesive strips and attach to hood, centering holes in mat (Figure 6-1 - 8) over holes in hood.

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Section 6 ENGINE, COOLING, EXHAUST, FUEL SYSTEM, THROTTLE

12 13 10

11

5

9 4 3

6 6,7 1

2

7

5

FIGURE 6-1. EXHAUST SYSTEM. NOTE: Muffler (5) must be positioned so that exhaust tube can pass through engine compartment hood with adequate clearance on all sides.

8. Install Tailpipe (Figure 6-1 - 2) on Muffler (5) and secure with clamp (1).

INTERNAL LINER

5. Attach Muffler (5) to Thermal Pad (8) and hood with four capscrews (6) and washers (7).

9"

6. Torque capscrews (6) to 70 ft.•lb. (94.9 N•m).

7. Attach elbow (4) to Muffler (5) with clamp (3).

Orient clamp (3) so that attaching screw is located 30° counterclockwise from straight down.

NOTE: Flex Tube (Figure 6-2 - 3) should be about 9 inches (22.9 cm) in length.

Maintain horizontal alignment along centerline of items 1, 2, 3, 4, and 5.

Readjust as necessary to prevent "humping" of Flex Tube.

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5 1

2

3

4

FIGURE 6-2. FLEX TUBE INSTALLATION.

6-3

Section 6 ENGINE, COOLING, EXHAUST, FUEL SYSTEM, THROTTLE FUEL SYSTEM.

RIGHT SIDE FUEL TANK.

The Fuel system consists of two Fuel Tanks, Check Valve, Drain Valve, and the Fuel Filters that are part of the Engine. One Fuel Tank is located on the right side of the vehicle and the other Fuel Tank is located on the left side of the vehicle. Each Fuel Tank has a capacity of 124 gallons (469.4 liters). The Check Valve is located at the output of the Fuel Filters. The Fuel Filters are part of the engine and are located on the left side of the engine. The Drain valve is connected through a TEE connector at the bottom of the left Fuel Tank and is connected by hose to the right Fuel Tank. Both tanks are drained from the one Drain Valve. The tee connection keeps the fuel level the same in both tanks. The fuel line from the top of the left Fuel Tank is connected to the Fuel Filter Input. The fuel return line from the engine is also connected at the top of the left Fuel Tank.

REMOVAL [See Figure 6-3].

The right side Fuel Tank is attached via three straps.

1. Drain the fuel system.

2. Disconnect the hose (Figure 6-3 - 1), from the tank fitting (2).

3. Support the Fuel Tank (3) and remove the three cap screws (4) and nuts (5), securing the Strap Assemblies (6) and bracket (7).

4. Remove the Fuel Tank (3) from the vehicle.

5. If strap (6) is to be replaced, remove lower locknut and remove strap.

7 6 4

5

2

1

3

FIGURE 6-3. FUEL TANK MOUNTING.

6-4

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Section 6 ENGINE, COOLING, EXHAUST, FUEL SYSTEM, THROTTLE INSTALLATION [See Figure 6-3].

1. If strap (6) has been removed, attach the bottom of the strap to the bracket with the nut, making sure at least 6 threads are exposed.

7. Remove the four capscrews (Figure 6-6 - 5), washers (6), and flanged locknuts (7) attaching ladder (8) to fuel tank (4).

8. Remove ladder (8).

2. Position Fuel Tank (3) on bracket and wrap strap (6) around Fuel Tank.

9. Remove six capscrews (1), washers (2) attaching platform (3) to Fuel Tank (4).

3. Attach three straps (6) with brackets (7) to frame with capscrews (4) and locknuts (5).

10. Remove platform (3).

4. Torque capscrews (4) to 212 ft.•lbs.

(287.4 N•m).

11. Support the Fuel Tank (Figure 6-4 - 7) and remove the three cap screws (8) and nuts (9), securing the Strap Assemblies (10) and bracket (11).

NOTE: If installing a new Fuel Tank, a fitting must be installed on bottom of tank.

12. Remove the Fuel Tank (7) from the vehicle.

5. Using pipe thread sealant, connect fitting (2) on bottom of fuel tank, then attach Hose Assembly (1) to fitting.

6. Close drain (Figure 6-4 - 13) on bottom of the left Fuel Tank.

7. Refill Fuel Tanks and check for leaks.

LEFT SIDE FUEL TANK. The left side Fuel Tank is mechanically attached via three straps and has three hose connections. In addition, brackets welded to the tank support the cockpit ladder.

13. If strap (10) is to be replaced, remove lower locknut and remove strap.

INSTALLATION [See Figures 6-4, 6-5 and 6-6].

NOTE: If installing a new Fuel Tank, fittings must be installed on both the top and bottom of Tank.

1. If strap (Figure 6-4 - 10) has been removed, attach the bottom of the strap to the bracket with the nut, making sure at least 6 threads are exposed.

2. Position Fuel Tank (7) on bracket and wrap the three straps (10) around Tank.

REMOVAL [See Figures 6-4, 6-5 and 6-6].

1. Drain the fuel system.

3. Attach three straps (10) with brackets (11) to frame with capscrews (8) and locknuts (9).

2. Disconnect the hose (Figure 6-4 - 1), from the tank fitting (12).

4. Torque capscrews (8) to 189 ft.•lbs.

(256.6 N•m).

3. Disconnect the hose (3), from the tank fitting (4).

5. Using pipe thread sealant, install fitting (2) on bottom of tank (7).

4. Disconnect the hose (5), from the tank fitting (6).

5. Remove four capscrews (Figure 6-5 - 1), washers (2) and flange locknuts (3) securing right handrail (4) to the ladder (5).

6. Remove four capscrews (6), washers (7) and flange locknuts (8) securing left handrail (9) to the ladder (5).

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6. Using pipe thread sealant, install fitting (12) to fitting (2).

7. Using pipe thread sealant, install drain fitting (13) to fitting (2).

8. Using pipe thread sealant, install fitting (4) on top of Tank (7).

6-5

Section 6 ENGINE, COOLING, EXHAUST, FUEL SYSTEM, THROTTLE

3

5

6

7

4 1 2

10 8

9

2

11 13 12

FIGURE 6-4. FUEL TANK MOUNTING.

6-6

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Section 6 ENGINE, COOLING, EXHAUST, FUEL SYSTEM, THROTTLE 9. Using pipe thread sealant, install fitting (6) on top of Tank (7).

17. Attach left handrail (Figure 6-5 - 9) to the ladder (5) with four capscrews (6), washers (7) and flange locknuts (8).

10. Attach hose assembly (1) to fitting (12).

18. Torque capscrews (6) to 95 ft.•lbs. (128.8 N•m).

11. Attach hose assembly (3) to fitting (4).

12. Attach hose assembly (5) to fitting (6).

19. Attach right handrail (4) to ladder (5) with four capscrews (1), washers (2) and flange locknuts (3).

13. Attach ladder (Figure 6-6 - 8) to tank (4) with the four capscrews (5), washers (6), and flanged locknuts (7).

20. Torque capscrews (1) to 95 ft.•lbs. (128.8 N•m).

14. Torque capscrews (5) to 95 ft.•lbs. (128.8 N•m).

15. Attach platform (3) to tank (4) with six capscrews (1), washers (2).

21. Close drain (Figure 6-4 - 13) on bottom of Tank on left side of vehicle.

22. Refill Fuel Tanks, then check for leaks.

16. Torque capscrews (1) to 35 ft.•lbs. (47.5 N•m).

9

4 3

8

8

2

1

5

5 6,7,8

7

1,2,3 6

FIGURE 6-5. HANDRAILS.

4

4

FIGURE 6-6. LADDER AND PLATFORM.

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6-7

Section 6 ENGINE, COOLING, EXHAUST, FUEL SYSTEM, THROTTLE THROTTLE CONTROL.

REMOVAL [See Figure 6-9].

An Electronic Control Module (ECM) (Figure 6-7 - 1) which is mounted on the engine controls the throttle.

The ECM is connected to the control panel by a wiring harness. A connector is used to join the ECM harness to the control panel harness. A switch (Figure 6-8) on the cab control panel is used to increase and decrease engine speed (RPM).

1. Cut the plastic ties (Figure 6-9 - 1) securing the ECM wiring harness to the control panel wiring harness.

2. Disconnect the connector (2) and move the harness clear of the ECM. INSTALLATION [See Figure 6-9].

1. Connect the ECM wiring harness to the control panel wiring harness connector (Figure 6-9 - 2).

2. Using plastic ties secure the wiring harness to prevent movement during operation (1).

FIGURE 6-7. ELECTRONIC CONTROL MODULE (ECM).

FIGURE 6-9. ECM WIRING HARNESS.

FIGURE 6-8. THROTTLE CONTROL.

6-8

08/05

Section 6 ENGINE, COOLING, EXHAUST, FUEL SYSTEM, THROTTLE CHARGE AIR SYSTEM [See Figure 6-10].

The Charge Air System cools fresh air after it is drawn through the air cleaner assembly and before it enters the engine intake. The Charge Air System includes the charge air tubes and hoses that route the air through the intercooler; the intercooler is an integral part of the radiator and uses radiator coolant and the engine-cooling fan to cool the air.

The Charge Air System provides cooler intake air, increased horsepower, lower emissions, increased fuel mileage, and prolonged engine life. Obtaining these benefits is dependent upon Charge Air System maintenance. The charge air tubes must be

completely sealed from outside air entering the system. Hose clamps must be checked and tightened on a regular basis. Charge air tubes and hoses must be inspected on a regular basis.

The charge air intercooler can be removed as part of the radiator (See the paragraph entitled Cooling System for information of radiator removal and installation.)

The charge air tubes and hoses can be removed by loosening the hose clamps and removing the tube u-clamps (See Figure 6-10).

FIGURE 6-10. CHARGE AIR COOLING SYSTEM.

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6-9

Section 6 ENGINE, COOLING, EXHAUST, FUEL SYSTEM, THROTTLE COOLING SYSTEM.

11. Remove capscrew (14) and washer (15) to separate hanger (16) from shroud (10).

The Radiator/Oil Cooler Assembly for the MPH 362/364 includes the Coolant Radiator for the engine, the Hydraulic Oil Cooler, Charge Air Cooler, and the Fan Assembly.

RADIATOR/OIL COOLING ASSEMBLY. The complete Radiator/Oil Cooling Assembly can be removed as a unit or the individual Coolant Radiator and Oil Coolers can be removed as necessary.

REMOVAL [See Figures 6-11, 6-12 and 6-13].

1. Open the two petcocks (Figure 6-11 - 1) on the lower radiator hose assembly and drain coolant.

2. Drain hydraulic system.

3. Loosen four clamps (2) and remove short charge air hoses (3) at top fan shroud (4).

4. Loosen four clamps (6) and remove short coolant hoses (7) at bottom of Radiator.

FIGURE 6-11. RADIATOR OIL COOLER ASSEMBLY.

5. Remove three bolts (Figure 6-12 - 1) and three washers (2) attaching Oil Cooler connection access plate (3) on the upper right of the Cooling Assembly.

6. Disconnect and label the two hoses from upper right side of Oil Cooler. Immediately plug hose ends and oil cooler ports to prevent contamination of the hydraulic system.

7. Remove three bolts (4) and washers (5) and the Oil Cooler connection access plate (6) on the lower left of the Cooling Assembly.

8. Disconnect and label the two hoses from lower left side of Oil Cooler. Immediately plug hose ends and oil cooler ports to prevent contamination of the hydraulic system.

9. Remove the four capscrews (7) and four washers (8) attaching the right fan guard (9) to the front shroud (10).

10. Remove the four capscrews (11) and four washers (12) attaching the left fan guard (13) to the front shroud (10).

FIGURE 6-12. FAN GUARDS.

6-10

08/05

Section 6 ENGINE, COOLING, EXHAUST, FUEL SYSTEM, THROTTLE 12. Remove sixteen front shroud plate mounting bolts (17) and remove front shroud (10).

13. Attach a hoist to the Coolant Radiator and Oil Cooling Assembly.

14. Remove capscrew (Figure 6-13 - 1) plate (2) and bottom part of rubber mount (3) for each of the four rubber mounts.

15. Carefully hoist the Radiator/Oil Cooler Assembly off the vehicle frame.

16. Remove the top part of the rubber mounts (3) from vehicle frame.

INSTALLATION [See Figures 6-11, 6-12, and 6-13].

8. Loosely attach the right fan guard (9) to the shroud (10) with four capscrews (7) and four washers (8).

9. Loosely attach the left fan guard (13) to the shroud (10) with four capscrews (11) and four washers (12).

10. Center the left fan guard (13) and right fan guard (9) horizontally on fan then torque the eight mounting bolts to 25 ft.•lbs. (33.9 N•m).

11. Attach the hanger (16) to the shroud (10) with capscrew (14) and washer (15).

12. Remove plugs and connect the two fittings on upper right side of Oil Cooler Assembly. Match hose label to corresponding fitting label.

1. Install the top part of the four rubber mounts (Figure 6-13 - 3) on vehicle frame.

The Radiator/Oil Cooler Assembly weighs approximately 650 pounds (294.84 kg), use proper lifting equipment.

2. Carefully hoist the Radiator/Oil Cooler Assembly onto the vehicle frame and position on top of rubber mounts (3).

NOTE: Lower part of rubber mount (3) must be positioned as shown in illustration.

3

3. Place thread lock on capscrew (1).

4. Install bottom part of rubber mount (3) against bottom of frame, and then install plate (2) and capscrew (1).

FRAME 3 2 1

5. Torque capscrew (1) to 190 ft.•lbs. (257.6 N•m).

6. Loosely attach the front shroud (Figure 6-12 10) to the Radiator/Oil Cooler Assembly with the sixteen front shroud plate mounting bolts (17).

FIGURE 6-13. RADIATOR/OIL COOLER ASSEMBLY RUBBER MOUNTS.

7. Center the shroud (10) vertically on fan then torque the sixteen mounting bolts (17) to 25 ft.•lbs. (33.9 N•m).

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6-11

Section 6 ENGINE, COOLING, EXHAUST, FUEL SYSTEM, THROTTLE 13. Install the Oil Cooler connection access plate (3) on the upper right of the Cooling Assembly using three bolts (1) and three washers (2).

14. Remove plugs and connect the two hoses to fittings on the lower left side of Oil Cooler Assembly. Match hose label to corresponding fitting label.

15. Install the Oil Cooler connection access plate (6) on the lower left of the Cooling Assembly.

Secure plate with three bolts (4) and washers (5).

16. Install short coolant hoses (Figure 6-11 - 7) at bottom of Radiator and secure with two clamps (6).

17. Install short charge air hoses (3) at top of Radiator and secure with two clamps (2).

NOTE: At this point all coolant and oil lines should be connected to the Radiator/Oil Cooler Assembly.

18. Close the two petcocks (1) on the lower radiator hose assembly and fill the Radiator with coolant mixture. (See Section 4 - MAINTENANCE).

19. Check for leaks at all coolant and oil line connections.

ENGINE. This section contains information about the Cummins QSM11 engine used on the MPH 362 and MPH 364 Recycler and Stabilizer and provides information of the removal and installation of the engine.

For engine operation and general manufacturer maintenance procedures, see the CUMMINS Operation and Maintenance Manual, which is supplied with each machine.

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

6-12

REMOVAL [See Figures 6-11, 6-12 and 6-14 through 6-24].

Insure that engine temperature is "cold".

1. Drain the engine oil from the engine (See Section 4 - MAINTENANCE).

2. Loosen the band clamp that fastens the 90 air inlet elbow from the Inlet Air Flange on the Turbocharger and Air Cleaner Assemblies.

Move the elbow away from the Turbocharger Air Inlet and Air Cleaner Outlet.

3. Loosen the muffler clamp that holds the flexible exhaust tube to the Turbocharger Outlet elbow and move the flexible exhaust tube away from the Turbocharger Outlet.

4. Loosen and remove the negative (-) battery cable from the negative (-) post of the battery FIRST, and then loosen and remove the positive (+) battery cable from the positive (+) post of the battery. Disconnect both cables.

Battery explosion can occur if the battery terminals are shorted.

Always disconnect the negative battery cable from the battery first.

Do not smoke or cause a spark while removing the battery cables from the battery.

5. Place a container under the Radiator and drain the complete cooling system of coolant, including the Engine Cylinder Block (See Section 4 MAINTENANCE).

Do not drain the cooling system of coolant while the system is hot.

Drain when cool only. Hot coolant can cause serious injury.

08/05

Section 6 ENGINE, COOLING, EXHAUST, FUEL SYSTEM, THROTTLE 6. Disconnect the radiator hoses from their engine connection points.

10. Disconnect the fuel supply and return lines from the engine. Put a cap or plug into each line and onto each engine fitting.

7. Disconnect the short charge air hoses (Figure 611 - 3) from the top of the radiator and the engine. Remove charge air tubes, hoses, and all clamps from the engine.

11. Remove the Hydraulic Travel Pump (See Section 8 - HYDRAULICS).

12. Remove the Hydraulic Rotor Pumps (See Section 13 - ROTOR HYDRAULIC SYSTEM).

8. Remove the four capscrews (Figure 6-12 - 7) and four washers (8) attaching the right fan guard (9) to the front shroud (10) and remove the right fan guard.

13. Remove four bolts (Figure 6-14 - 1), on the left side, securing upper door weldment (2) to frame.

9. Remove the four capscrews (11) and four washers (12) attaching the left fan guard (13) to the front shroud (10) and remove the left fan guard.

2 4 3 1

6

5

FIGURE 6-14. MACHINE DOORS AND COVERS.

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6-13

Section 6 ENGINE, COOLING, EXHAUST, FUEL SYSTEM, THROTTLE 14. Support the upper door weldment (Figure 6-15 1) and remove the gas shock (2), by removing bracket (3), which is attached to the upper door weldment (1) by capsscrews (4) and washers (5).

1 4,5 3

2

FIGURE 6-15. DOOR GAS SHOCK. 15. Remove bolts (Figure 6-16 - 1), disks (2) and clamping pieces (3) securing two hinges (4) to door weldment (5) and upper hood weldment (6).

Remove two hinges (4) and door weldment (5).

16. Disconnect hoses (Figure 6-17 - 1) connected to surge tank.

17. Remove surge tank mounting bolts (2).

1 2

4

1 2

5

6 3 1

FIGURE 6-16. DOOR HINGE.

6-14

FIGURE 6-17. SURGE TANK.

08/05

Section 6 ENGINE, COOLING, EXHAUST, FUEL SYSTEM, THROTTLE 18. Remove screws (Figure 6-14 - 3) and remove hood weldment (4).

2

1

19. Remove right door weldment (5) and right panel (6).

20. Remove two capscrews (Figure 6-18 - 1) , nuts (3), and washers (2) from each side of the air cleaner (4) and support bracket assembly (5).

FIGURE 6-19. BATTERY DISCONNECT. 25. Label and disconnect the hydraulic hoses from the priority valve on the left side of the engine and position the hoses clear of the engine.

Immediately plug hoses and valve ports to prevent contamination of the hydraulic system.

26. Remove the priority valve (Figure 6-20 - 1) with the bracket (2) by removing the two capscrews (3).

1 2

FIGURE 6-18. AIR CLEANER ASSEMBLY. 3

21. Using a lifting device, remove the air cleaner assembly and support bracket from the engine compartment.

22. Disconnect the main wiring harness on the left side of the engine. Cut and remove all plastic ties securing the chassis harness to the engine.

FIGURE 6-20. PRIORITY VALVE.

23. Disconnect the starter to chassis ground cable on the left side of the engine at the starter.

24. Disconnect the red battery wire (Figure 6-19 - 1) from the disconnect switch (2) located on the right side of the engine.

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6-15

Section 6 ENGINE, COOLING, EXHAUST, FUEL SYSTEM, THROTTLE 27. Disconnect and label wiring harness (Figure 621) at the Electronic Control Module from the left side of the engine.

FIGURE 6-21. ELECTRONIC CONTROL MODULE (ECM).

28. Remove any other hose clamps, which may be attached to the engine and check that all hoses are clear of engine.

NOTE: At this time, all hydraulic hoses, water hoses, fuel lines and electrical connections should be disconnected from the engine and the engine should be clear for removal.

FIGURE 6-22. LIFT EYE AND BRACKET. 30. Remove two lower tube support bracket mounting capscrews, lock washers, and bracket.

31. Position the lift eye on the top rear of the engine (Figure 6-23 - 3) and secure with two mounting capscrews (1) and washers (2). Tighten capscrews to 30 ft.•lbs. (41 N•m).

29. Remove two mounting capscrews (Figure 6-22 1), lock washers (2), and left front lifting eye (3) from the tube support bracket.

FIGURE 6-23. ENGINE REAR LIFT EYE INSTALLED. 32. Attach a lifting device capable of supporting the weight of the engine to the lifting eyes on the engine.

6-16

08/05

Section 6 ENGINE, COOLING, EXHAUST, FUEL SYSTEM, THROTTLE 33. Using the lifting device, lift the engine enough to remove engine weight from the motor mounts.

34. Remove two front engine mounts by removing nut (Figure 6-24 - 1) from on top of the engine, then removing capscrew (2), washer (3), round plate with hole (4), and bottom half of engine mount (5) from the bottom of the mount.

1

ENGINE (REF)

10

6

7

11

12 9

8 14

5 15

4

3

2

FRONT ENGINE MOUNT

13

FRAME (REF)

REAR ENGINE MOUNT

FIGURE 6-24. ENGINE MOUNTS. 08/05

6-17

Section 6 ENGINE, COOLING, EXHAUST, FUEL SYSTEM, THROTTLE NOTE: Spacer (9), upper half of engine mount (7) and washer (6) will be removed after the engine is lifted.

35. Remove two rear engine mounts by removing flange bolt (10), washer (11), and top half of rear engine mounts (12).

NOTE: Engine should be free to lift at this time.

Use care to prevent damage to any hoses or other components the engine may come in contact with while being lifted out. While removing engine, check for additional wires, clamps, and hoses attached to the engine and other components.

36. Carefully lift engine out of machine.

37. Remove lower rear mounts (13) from rear mount weld (14).

38. Remove spacer (15) from lower rear mounts (13).

39. Remove upper front mounts (7) from front mount weld (8).

40. Remove spacer (9) from upper front mount (7).

41. Remove washer (6).

INSTALLING ENGINE. ENGINE INSTALLATION [See Figures 6-18 through 6-25].

1. Attach lifting device, capable of supporting engine weight, to the lifting eyes on the engine.

Front and rear engine mounts are identical except for color. Front engine mount is green and white.

Rear engine mount is blue and white. When installing engine mounts be sure that mounts are correctly oriented as shown in Figure 6-24.

6-18

2. For both front engine mounts, install spacer (Figure 6-24 - 9) into top half of engine mount (7). Install top half of engine mount (7) and round plate with hole (6) on top of front mount weld (8). Be sure engine mount is correct color and correctly oriented.

3. For both rear engine mounts, install spacer (15) into lower half of rear engine mounts (13). Install lower half of engine mounts (13) over holes in frame. Be sure engine mount is correct color and correctly oriented.

4. Using the lifting device, position on the motor mounts for installation.

5. On front engine mounts, install from under the frame, capscrew (2), tightening washers (3), washer (4), lower part of front engine mount (5).

Be sure engine mount is correct color and correctly oriented.

6. Slide capscrew (2) up through front engine mount (7), washer (6), engine mount weldment and install nut (1).

7. On rear engine mounts, from top of engine mount weldment, install top of engine mount (12), and round plates with hole (11) on rear engine mount weldments (14). Be sure engine mount is correct color and correctly oriented.

8. Coat capscrew (10) with thread lock and install through engine mount.

9. Torque capscrew (10) to 212 ft.•lbs.

(287.4 N•m).

10. Position charge air tube bracket and secure with two capscrews, nuts and flat washers. Tighten nuts to 30 ft.•lbs. (41 N•m).

11. Remove the lifting eye from the top rear of the engine (Figure 6-23 - 3) and install on tube support bracket using two capscrews (1) and lock washers (2). Tighten capscrews to 30 ft.•lbs.

(41 N•m).

08/05

Section 6 ENGINE, COOLING, EXHAUST, FUEL SYSTEM, THROTTLE 12. Using a lifting device, position the air cleaner assembly and support bracket at the rear of the engine. Secure the air cleaner assembly (Figure 6-18 - 4) to the support bracket(s) with two capscrews (1), nuts (2), and washers (3) on each side. Tighten capscrews to 75 ft.•lbs. (101 N•m).

NOTE: Install gas shock with rod end down.

13. Install the priority valve (Figure 6-20 - 1) with the bracket (2) and secure with two capscrews (3).

27. Torque capscrews (4) to 20 ft.•lbs. (27.1 N•m).

14. Torque capscrews (3) to 12 ft.•lbs. (16.3 N•m).

15. Remove plugs and connect the hydraulic hoses to the priority valve.

16. Using labels, connect wiring harness at the Electronic Control Module (ECM) to the left side of the engine (Figure 6-21).

26. Install gas shock (Figure 6-15 - 2), with bracket (3), using capscrews (4) and washers (5).

Lubricate ball studs on gas shock with heavyduty lubricant.

28. Install four bolts (Figure 6-14 - 1), on the left side, securing upper door weldment (2) to the frame.

29. Torque bolts (1) to 35 ft.•lbs. (47.5 N•m).

30. Loosely attach the right fan guard (Figure 6-25 3) to the shroud (4) with four capscrews (1) and four washers (2).

17. Install right door weldment (Figure 6-14- 5) and right panel (6).

18. Install hood weldment (4) and secure with screws (3).

19. Torque screws (3) to 35 ft.•lbs. (47.5 N•m).

20. Position surge tank for installation and secure with mounting bolts (1) (Figure 6-17 - 2).

21. Connect hoses to surge tank.

22. Install the Hydraulic Rotor Pump(s) (See Section 13 - ROTOR HYDRAULIC SYSTEM).

23. Install the Hydraulic Travel Pump (See Section 8 - HYDRAULICS).

NOTE: Hinges must be installed with zerk fitting pointing up-hill. Adjust all hinged doors to allow free/smooth movement throughout the full range of the hinges.

FIGURE 6-25. FAN GUARD.

24. Install the left door weldment (Figure 6-16 - 5) by attaching the hinges (4) to the left door weldment (5) and upper hood weldment (6) with the bolts (1), disks (2) and clamping pieces (3).

25. Torque bolts (1) to 37 ft.•lbs. (50.2 N•m).

08/05

6-19

Section 6 ENGINE, COOLING, EXHAUST, FUEL SYSTEM, THROTTLE 31. Loosely attach the left fan guard (7) to the shroud (4) with four capscrews (5) and four washers (6).

42. Disconnect the red battery wire (Figure 6-21 - 1) from the disconnect switch (2) located on the left side of the engine.

32. Center the left fan guard (7) and right fan guard (3) horizontally on fan then torque the eight mounting bolts to 18 ft.•lbs. (24.4 N•m).

43. Connect the positive (+) battery cable to the positive (+) post of the battery. Connect the negative (-) battery cable to the negative (-) post of the battery.

33. Connect the Fuel Supply and return lines from the engine.

34. Connect the radiator hoses to their engine connection points.

35. Connect the air inlet elbow to the inlet air flange on the turbocharger and tighten the band clamp that fastens the 90° air inlet elbow to the inlet air flange on the Turbocharger and Air Cleaner Assemblies.

36. Place the chassis to starter ground cable on the starter motor stud and secure with nut and washer.

37. Connect the exhaust tube to the turbocharger outlet elbow and tighten the muffler clamp that holds the flexible exhaust tube to the turbocharger outlet elbow.

44. Connect electrical cable connections to engine and install any necessary cable clamps.

45. Fill cooling system with coolant mixture. (See Section 4 - MAINTENANCE).

46. Add engine oil (See Section 4 MAINTENANCE).

47. Add hydraulic oil (See Section 4 MAINTENANCE).

48. Set battery disconnect switch on left side of engine to the ON position.

49. Perform the operational check described in Section 3 - OPERATIONS.

38. Install charge air tubes and hoses to the engine and top of the radiator (Figure 6-11).

Battery explosion can occur if the battery terminals are shorted.

Always disconnect the negative battery cable from the battery first.

Do not smoke or cause a spark while removing the battery cables from the battery.

6-20

08/05

Section 7 ELECTRICAL TABLE OF CONTENTS PAGE GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4 ELECTRICAL SYSTEM MAJOR COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4 STARTER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4 ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4 BATTERY DISCONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4 SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4 KEY SWITCH (IGNITION SWITCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4 FOUR WHEEL DRIVE SELECT FRONT ASSIST SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4 ENGINE LOAD CONTROL MAN/AUTO SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5 2-SPEED LOW/HIGH SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5 EMERGENCY STOP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5 BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5 ROTOR ON/OFF SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6 ROTOR SPEED SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6 THROTTLE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6 TRAVEL DIRECTION (FNR) AND SPEED CONTROL LEVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6 LEFT/RIGHT INDEPENDENT BRAKE SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6 ROTOR LIFT SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6 REAR ROTOR DOOR SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6 BACKUP TRAVEL CONTROL (FNR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7 TRAVEL PUMP THRESHOLD CALIBRATION PUSHBUTTON SWITCH. . . . . . . . . . . . . . . . . . . . . . . .7-7 FNR OVERRIDE CONTROL ON/OFF SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7 ENGINE LOAD CONTROL SETPOINT POTENTIOMETER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7 WORK LIGHTS SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7 HEADLIGHTS/PARKING LIGHTS OFF/PARK/ON SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7 TRACTION CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8 FOUR-WAY FLASH/HAZARD SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8 TURN SIGNAL SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8 HORN PUSHBUTTON SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8 FUSES AND FUSIBLE LINKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8 RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9 IGNITION POWER RELAY K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9 START RELAY K3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9 FLASHER RELAY K4 - OPTIONAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9 STOP LIGHT RELAY K6 - OPTIONAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9 RIGHT-HAND BRAKE RELAY K7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9 ROTOR RELAY K8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9 LEFT-HAND BRAKE RELAY K9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9 CAB RELAY K10 - OPTIONAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9 (continued)

08/05

7-1

Section 7 ELECTRICAL PAGE SOLENOIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9 FRONT ASSIST SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9 TWO-SPEED SHIFT SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9 RIGHT-HAND BRAKE SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10 LEFT-HAND BRAKE SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10 ROTOR LIFT SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10 REAR ROTOR DOOR SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10 SENDING UNITS AND PRESSURE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10 COOLANT TEMPERATURE SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10 COOLANT LEVEL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10 OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10 OIL PRESSURE SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10 THROTTLE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10 FUEL LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11 STEERING/AUX RETURN FILTER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11 TRAVEL PUMP FILTER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11 ROTOR PUMP FILTER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11 AIR FILTER RESTRICTION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11 HYDRAULIC OIL TEMPERATURE SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11 LOW ROTOR CHARGE PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11 MACHINE TRAVEL SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11 POWERVIEW MONITORING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12 POWERVIEW DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12 FUEL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12 ENGINE HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12 CHARGE VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12 ENGINE COOLANT TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12 HYDRAULIC SYSTEM OIL TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12 ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12 ROTOR SYSTEM CHARGE FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12 TRAVEL SYSTEM CHARGE FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12 STEERING/AUX RETURN FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13 ENGINE INLET AIR FLOW RESTRICTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13 LOW ROTOR CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13 MACHINE TRAVEL SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13 ENGINE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13 GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13 ROTOR PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13 TRAVEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13 4-LIGHT DIAGNOSTIC GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13 WARNING ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14 (continued)

7-2

08/05

Section 7 ELECTRICAL PAGE EXTERNAL LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14 STOP LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14 HEADLIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14 PARKING LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14 TURN/HAZARD LIGHTS - OPTIONAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14 WORKLIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14 HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14 BACKUP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14 CABLES AND WIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15 CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15 WIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15 COMPUTER TRAVEL AND LOAD CONTROLLER COMPUTER SYSTEM AND MANUAL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15 ROTOR SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15 TRAVEL SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15 AUTO CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15 GENERAL TROUBLE ANALYSIS INFORMATION AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . .7-16 VOLTAGE MEASUREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17 CONTINUITY (RESISTANCE) MEASUREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17 CURRENT MEASUREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17 TRAVEL SYSTEM FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18 TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19

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Section 7 ELECTRICAL GENERAL INFORMATION.

ALTERNATOR.

This section describes the operation of the electrical system and contains descriptions of the items included in the system used on the MPH362 and MPH364 Recyclers and Stabilizers.

The 70 amp alternator is used to covert mechanical energy into electrical energy. It is mounted on the engine. The alternator supplies electrical current to the electrical circuits and keeps the battery “charged” when the engine is running.

Electrical system “Trouble Analysis” is found at the end of this section.

ELECTRICAL SYSTEM MAJOR COMPONENT DESCRIPTION [See Figure 7-1].

The following information describes the MAJOR electrical components used in the electrical system of the Model MPH362 and MPH364 Recyclers and Stabilizers.

BATTERY DISCONNECT. The battery disconnect switch is on the right hand side (RHS) of the engine and has two positions, ON/OFF. In the OFF position the POSITIVE (+) terminal of the battery is disconnected from the machines electrical circuits. The switch must be in the ON position for the machine to operate.

SWITCHES.

NEVER smoke or cause a spark near and battery. Always loosen and remove the NEGATIVE (-) battery cable from the NEGATIVE (-) battery post BEFORE loosening and removing the POSITIVE (+) battery cable from the POSITIVE (+) battery post. NEVER cause a shorted circuit condition in ANY CIRCUIT. USE EXTRA CAUTION when checking ANY circuit using ANY electrical testing instrument.

BATTERY. The battery supplies direct current to crank the engine and operate electrical circuits until the alternator is able to supply current. Two 12-volt batteries are connected in series to provide 24 volts. Each battery is rated at 320 AMPS MINIMUM RESERVE CAPACITY/1000 CCA@ 0°F and is a “maintenance free” battery.

STARTER MOTOR. The starter motor is used to convert electrical energy into mechanical energy to crank and start the engine. One (1) 24 volt, negative ground starter motor is used in the start circuit.

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NOTE: For information on the location of switches refer to SECTION 3 of THIS MANUAL unless otherwise indicted.

KEY SWITCH (IGNITION SWITCH).

The key switch is a five (5) position switch with the following positions.

P

Left of vertical and is not used.

0

Vertical position. This is the OFF position (key may be removed).

I

Right of vertical is the ignition ON (RUN) position and powers all of the systems.

II

Right of vertical and is not used.

III Right of vertical is the ignition START position.

This momentary position is to start engine and returns to “I” (ON) when released.

FOUR WHEEL DRIVE SELECT FRONT ASSIST SWITCH. The Four Wheel Drive Front Assist switch is a two position selector switch located on the switch panel of the MPH364 recycler. This option is not available on the MPH362. The switch works in the LOW travel gear only, and allows 4WD to be shifted on or off while moving.

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Section 7 ELECTRICAL ENGINE LOAD CONTROL MAN/AUTO SWITCH.

EMERGENCY STOP SWITCH.

The ENGINE LOAD CONTROL MAN/AUTO switch is a two-position selector switch located on the Switch Panel.

The EMERGENCY STOP (E-STOP) switch is a locking push button switch located on the switch panel. The button must be pushed to turn ON which will lock it in the engaged position. Rotate button clockwise and release to return to the OFF position.

Any time the E-STOP button is pressed, all systems except the engine are immediately disabled. The engine will continue to operate until turned off with the ignition switch. The E-STOP switch must be OFF to start the engine. When the E-STOP push button is released, the Travel Direction Control Lever (FNR) must be returned to neutral (N) to reset the travel controller.

The MAN mode is used for transporting or working.

In this mode the automatic engine load control system is disabled. The FNR lever alone controls the travel speed. If this mode is used for WORKING, the operator must manually slow down the forward travel speed with the FNR lever to keep the engine speed at the desired value. If the forward travel speed is too great the engine or rotor can slow down and/or stall. In order to maintain the selected rotor speed the engine must not be operated below 2150 RPM. The AUTO mode is used only for working, providing fully automatic engine load control. In this mode the pressure in the rotor drive system is monitored to determine the load on the engine. As the load increases and decreases due to changes in the material being recycled, the rotor speed remains constant whereas the travel speed is automatically adjusted higher or lower, therefore maintaining a constant load. Travel speed is limited to 70% of full speed in AUTO mode. The FNR lever should be slowly pushed all the way forward to maximize productivity.

2-SPEED LOW/HIGH SWITCH The 2-Speed Low/High Switch is a two position switch located on the switch panel. LOW range is used for working and HIGH range is used for transport. In LOW range, pilot pressure is routed to the axle motor X1 port by energizing the coil of the 2speed selector valve, locking the motor in full displacement. In HIGH range the motor is unlocked.

The 2-speed selector valve coil is not energized.

BRAKE SWITCH. The BRAKE switch is a two-position selector switch located on the ignition panel. The switch is used to engage and disengage the spring applied hydraulic released (SAHR) brakes on the right or left side of the rear axle while the engine is running.

Anytime the BRAKE switch is in the “I” position the brakes are applied and any travel input signal is defeated (unit can not drive against the brakes).

Both red brake lights are illuminated and all power to the travel controller is off. When the brake switch is in the “0” position, the brake is released provided engine is running, and the E-STOP switch is released. When the brake switch is in the “0” position, the Travel Direction Control Lever (FNR) must be returned to neutral (N) to reset the travel controller.

The 2-speed Low/High Switch must be in the LOW position for current to be available at the Controller (Digital Input). When placed in the ON position the ASC Off/On Switch sends a signal thru the 2-Speed Low/High Switch to the ASC Controller (SX Computer). The ASC Controller (SX Computer) also activates a light on the ASC Off/On switch indicated that Traction control is activated.

The vehicle must be stopped on level ground and the Travel Direction Control Lever (FNR) must be in NEUTRAL for the speed range to be changed.

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7-5

Section 7 ELECTRICAL ROTOR ON/OFF SWITCH. The ROTOR ON/OFF switch is a two position selector switch located on the ignition panel. This switch is used to turn the rotor ON or OFF. In the “0” position, the rotor is OFF. In the “I” position the rotor is ON. The engine must be at full throttle (2100 RPM) for the rotor to function.

When the FNR lever is moved out of neutral (N) into reverse (R), or toward the operator, the unit moves backward. The farther the FNR lever is moved, the faster the unit travels. Moving the FNR lever back towards neutral (N) slows the unit down and applies dynamic braking. Moving the FNR control lever to neutral (N) causes the machine to stop. Whenever the FNR is moved into reverse, the BACKUP ALARM sounds.

ROTOR SPEED SWITCH. The Rotor Speed switch is located on the ignition panel.

The FNR lever must be in neutral (N) to start the engine. When the E-STOP or BRAKE switches are released, the FNR lever must be returned to neutral (N) to reset the travel controller.

The MPH362 and MPH364 recycler and stabilizer use a two position selector switch with the following positions to select the speed of the rotor.

LEFT/RIGHT INDEPENDENT BRAKE SWITCH.

–

I – 135 RPM Rotor Speed

–

II – 150 RPM Rotor Speed

Engine must be at full throttle (2100 RPM) for the rotor to function. The Rotor Speed Range can be selected on the fly, however, only change one speed range at a time. There is a 10-second ramp time when the rotor speed range is changed.

THROTTLE SWITCH. The Throttle switch is a three-position momentary switch located on the ignition panel. The “DEC” position causes a decrease in engine speed (RPM).

The “INC” position causes a increase in engine speed (RPM).

TRAVEL DIRECTION (FNR) AND SPEED CONTROL LEVER. The Travel Direction (FNR) and Speed Control Lever is located on the operator control panel. The FNR and Speed Control Lever controls the direction of travel, speed, and dynamic braking of the unit.

When the FNR lever is moved out of neutral (N) into forward (F), or away from the operator, the unit moves forward. The farther the FNR lever is moved, the faster the unit travels. Moving the FNR lever back towards neutral (N) slows the unit down and applies dynamic braking. Moving the FNR control lever to neutral (N) causes the machine to stop.

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This is a three position momentary switch (center returning) located on the top of the FNR lever located on the Operator Control Panel. The switch is used to engage and disengage the spring applied hydraulic released (SAHR) brakes on the right or left side of the rear axle. This will assist in control of the direction of travel (steering). During operation of the unit, braking either wheel allows more traction to be applied to the opposite rear wheel. The right-hand or left-hand red brake indicator light on the ignition panel will illuminate as the corresponding brake is applied.

ROTOR LIFT SWITCH. The Rotor Lift Switch is a three-position momentary switch (center returning), located on the Operator Control Panel. The “Down” position lowers the rotor.

The “Up” position raises the Rotor. This switch adjusts the height of the rotor head and depth of cut. The actual depth of cut is shown on the large CENTER indicator on the Indicator Panel located on the right rear side of the frame, behind the operator, on all models.

REAR ROTOR DOOR SWITCH. The Rear Rotor Door Switch is a three-position momentary switch (center returning) located on the Operator Control Panel. The “Down” position closes (lowers) the Rear Rotor Hood Door. The “Up” position opens (raises) the Rear Rotor Hood Door.

The height of the Rear Rotor Hood Door is shown by the lower left-hand position indicator on the Indicator Panel located on the right rear side of the frame, behind the operator, on all models.

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Section 7 ELECTRICAL BACKUP TRAVEL CONTROL (FNR).

FNR OVERRIDE CONTROL ON/OFF SWITCH.

The Backup Travel Control (FNR) is a three-position momentary switch located on the Operator’s Control Station directly behind the steering wheel.

This is a two position selector switch located on the Auxiliary Panel under the dash. This switch activates the Backup Travel Control System. Switch in the “0” (OFF) position places the override system in OFF (normal unit operating) condition. Switch in “I” (ON) position places override system in Override condition. The unit can now be moved using the Backup Travel Control (FNR).

The limited Travel Control System is for transporting the unit if there is a problem with the FNR, Travel Controller, or wiring. Do not use this mode for “working” the unit. The backup FNR Switch is activated when the FNR override switch is in the ON position.

Forward or reverse travel speed is limited to 0.75 mph (66 fpm) in low speed range and 3.0 mph (4.8 kph) in HIGH speed range, at FULL throttle (high idle).

The switch controls the direction of travel and braking of the unit. Smooth operating of the machine will not be possible as proportional control is not available. The engine throttle can be used to vary the travel speed, if required. The Backup Travel Control must be returned to neutral, and the machine must come to a full stop, before changing direction of travel.

Move the FNR switch out of neutral, into FORWARD (F) position, (away from operator) to move the unit in FORWARD. Relase FNR switch to slow down, returning the NEUTRAL (N) to stop. Move the FNR switch out of neutral, into REVERSE (R) position, (toward operator) to move the unit in REVERSE. Release the FNR switch to slow down, returning to NEUTRAL (N) to stop.

TRAVEL PUMP THRESHOLD CALIBRATION PUSHBUTTON SWITCH. This is a Momentary Pushbutton Switch located on the Auxiliary Panel under the dash. The Travel Pump Electronic Displacement Control (EDC) threshold values in the Travel Controller (SX) computer can be manually set by the Threshold Calibrate Switch. This procedure determines the amount of current required to start the unit moving (turn the wheels). The default value is 15 milliamps.

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ENGINE LOAD CONTROL SETPOINT POTENTIOMETER. This Potentiometer is located on the Auxiliary Panel under the dash. This is a one turn Potentiometer (POT) used to adjust the engine load control setting.

This Potentiometer only functions when the Engine Load Control Switch is in the AUTO position. This POT is factory adjusted for full engine load. Turn the POT (+) or clockwise (CW) to increase load (engine RPM decreases, rotor drive pressure increases).

Turn the POT (-) or counterclockwise (CCW) to decrease load (engine RPM increases, rotor drive pressure decreases). Small adjustments (1/8 turn) makes large changes in the load control setting.

WORK LIGHTS SWITCH. The Work Lights Switch is a two (2) position selector switch located on the Switch Panel. In the “ON” position the switch turns the rear mounted (optional) Work Lights on. In the “OFF” position, the switch turns the rear mounted (optional) Work Lights off.

The Work Lights can be turned on without the ignition switch in the “ON” position.

HEADLIGHTS/PARKING LIGHTS OFF/PARK/ON SWITCH. The Headlights/Parking Lights Off/Park/On Switch is a three position selector switch located on the Switch Panel. In the OFF (left) position, all lights are turned off. In the PARK (center) position, front and rear amber Parking Lights are “ON”. In the “ON” (right) position, the front and rear amber Parking Lights are “ON” and the front headlights are “ON”. In the “PARK” and “ON” positions, all gauges (except hourmeter), are illuminated. All lights can be turned on without the ignition switch in the “ON” position.

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Section 7 ELECTRICAL TRACTION CONTROL SWITCH. This is a two position selector switch controlling the electronic traction control. In the “0” (left) position, the electronic traction control is turned off. In the “I” (right) position, the electronic traction control is turned on. When the electronic traction control is on a red light will illuminate.

FOUR-WAY FLASH/HAZARD SWITCH. This is an optional two position selector switch located on the Switch Panel. In the “OFF” (left) position, the Flasher/Hazard Lights are off. In the “ON” (right) position, the red Hazard Lights will flash. Lights can be turned on without the ignition switch in the “ON” position. If less than three bulbs are functional, the switch will not flash red.

TURN SIGNAL SWITCH. This is an optional three position selector switch located on the Switch Panel. In the left position, the left-hand directional turn signals are on and the switch flashes green. In the center position, the directional signals are off. In the right position, the right-hand directional turn signals are on and the switch flashes green. If either front or rear bulb is out, the switch will not flash green.

HORN PUSHBUTTON SWITCH. This is a Pushbutton Switch on the Switch Panel.

When the switch is pressed, both the front and rear Horns will sound. The Horn will sound without the ignition switch in the “ON” position.

FUSES AND FUSIBLE LINKS. The Fuses are located in four Fuse Boxes (FB-1, FB-2, FB-3, and FB-4) that are on the Electrical Panel Assembly located on the right side of the operator’s cab, and one additional Fuse Box (FB-E) located on the engine. The rating and function of each fuse is as shown in the following chart.

A fusible link for the optional engine cab heater, air conditioner is rated at 125 amps.

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FUSE POSITION

FUNCTION

RATING (AMPS)

FUSE BOX 1 (FB-1) 1 Brakes, Brake Lights, 15 Brake Relays 2 2-Speed Shift, Shift 15 Lights, Front Assist 3 Rotor Lift and Door 15 Control 4 Rotor Control 10 5 Backup Alarm, Stop 15 Lamp 6 Travel and Load 10 Control FUSE BOX 2 (FB-2) 1 Ignition Switch 5 2 Alarm and Warning 5 Lights 3 ASC/Monitoring System 15 4 PowerView and Alarm 10 Relay 5 Turn Signals* 15 6 Stop Lamp Relay, 10 Neutral Relay FUSE BOX 3 (FB-3) 1 Horn 15 2 Empty 3 Empty 4 4-Way Hazard Lights* 15 5 Work Lights* 20 6 Park/Head Lights** 20 FUSE BOX 4 (FB-4)* 1 Water Spray System* 20 2 ALPS 4.0 System* 20 3 Rotary Beacon* 10 4 Empty 5 Empty 6 Empty FUSE BOX ENGINE (FB-E) 1 Engine Unswitched 10 Power 2 Engine Unswitched 10 Power FUSIBLE LINK FL1 Eng. Vehicle Elect. System 125 FL2 Alt. Alternator Charge Wire 10 Ga. FL3 Eng. Cab, Heater, A/C** 125 *Optional Equipment **Optional Equipment (Fuse is standard)

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Section 7 ELECTRICAL RELAYS.

ROTOR RELAY K8.

IGNITION POWER RELAY K1.

The Rotor Relay, K8, is mounted on the Electrical Panel Assembly located on the right side of the Operator’s Platform. This is a single pole double throw (SPDT) relay that is energized when the Rotor Lift Switch, located on the Operator Control Panel is in the “Up” position.

The Ignition Power Relay, K1, is located on the Electrical Panel Assembly which is on the right side of the Operator’s Platform. This relay connects battery voltage to the operating system when the ignition switch is in the “RUN” position and the EMERGENCY STOP ON/OFF switch is the OFF position. This is a single pole-single throw (SPST) relay.

START RELAY K3.

The Start Relay, K3, is mounted on the Power Disconnect Switch Assembly at the left side of the engine. This is a single pole single throw (SPST) relay which when the relay is energized and the BATTERY DISCONNECT ON/OFF switch is in the ON position, battery voltage is routed to the starter solenoid to start the engine. The relay is energized when the Ignition Switch is in the START position.

FLASHER RELAY K4 - OPTIONAL. The optional Flasher Relay, K4, is located on the fire wall. This relay is used to operate the left and right directional flashers and is controlled by the optional three-position Turn Signals Selector Switch on the Switch Panel.

STOP LIGHT RELAY K6 - OPTIONAL. The optional Stop Light Relay, K6, is located on the Electrical Panel Assembly which is on the right side of the operator’s platform. This is a single pole double throw (SPDT) relay that routes DC voltage from the Ignition Power Relay to the stop light, through the Auxiliary Neutral Switch in the Travel Control Lever. This causes the stop light to illuminate when the Travel Control Lever is in the “N” neutral position.

RIGHT-HAND BRAKE RELAY K7.

LEFT-HAND BRAKE RELAY K9.

The Left-Hand Brake Relay, K9, is located on the Electrical Panel Assembly which is on the right side of the Operator’s Platform. The Left-Hand Brake Relay is energized when the Left/Right Independent Brake Switch on the Travel Control Lever is switched to the left-hand (LH) position. This is a single pole double throw (SPDT) relay that routes DC voltage to Left-Hand Brake Solenoid.

CAB RELAY K10 - OPTIONAL. The Cab Relay, K10, is located on the engine. The Cab Relay is a single pole single throw (SPST) relay which is used in the operation of cab heating and A/C equipment.

SOLENOIDS. FRONT ASSIST SOLENOID. The Front Assist Solenoid is only used on the MPH364. The solenoid is located on the Front Axle.

The solenoid is energized when the four wheel drive Front Assist Switch is in the UP position placing the machine in low speed range. The solenoid can be operated on the fly.

TWO-SPEED SHIFT SOLENOID. The Axle Two-Speed Shift Solenoid located on the 2-Speed Valve Assembly is energized when the 2Speed Shift Low Range Relay is energized placing the machine in the low speed range. The 2-Speed Shift Low Range Relay is energized when the 2Speed High/Low Switch is in the LOW position.

The Right-Hand Brake Relay, K7, is located on the Electrical Panel Assembly which is on the right side of the Operator’s Platform. The Right-Hand Brake Relay is energized when the Left/Right Independent Brake Switch on the Travel Control Lever is switched to the right-hand (RH) position. This is a single pole double throw (SPDT) relay that routes DC voltage to Right-Hand Brake Solenoid.

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7-9

Section 7 ELECTRICAL RIGHT-HAND BRAKE SOLENOID.

SENDING UNITS AND PRESSURE SWITCHES.

The Right-Hand Brake Solenoid is located on the Brake Valve. The Brake Solenoid is energized when the Brake Switch on the Ignition Panel Assembly is in the “I” position and the Left/Right Independent Brake Switch on the Travel Control Lever is switched to the right-hand (RH) position. The RightHand Brake Relay is energized when the Left/Right Independent Brake Switch is switched to the righthand (RH) position.

COOLANT TEMPERATURE SENDER. The Coolant Temperature Sender is located on the engine and is a variable resistor type unit used to monitor the engine water temperature. The sender sends a variable voltage signal to the Monitoring Controller. The PowerView display will show the coolant temperature when accessed. This component is covered in detail in the Cummins QSM11 Operation and Maintenance Manual.

LEFT-HAND BRAKE SOLENOID. COOLANT LEVEL SWITCH. The Left-Hand Brake Solenoid is located on the Brake Valve. The Brake Solenoid is energized when the Brake Switch on the Ignition Panel Assembly is in the “I” position and the Left/Right Independent Brake Switch on the Travel Control Lever is switched to the left-hand (LH) position. The LeftHand Brake Relay is energized when the Left/Right Independent Brake Switch is switched to the lefthand (LH) position.

ROTOR LIFT SOLENOID. The Rotor Lift Solenoid is located on the lower frame in front of the operators platform. The Rotor Lift Solenoid is energized when the Rotor Lift Switch, located on the Operator Control Panel is in the “Up” position (raises rotor) or “Down” position (lowers rotor).

REAR ROTOR DOOR SOLENOID. The Rear Rotor Door Solenoid is located on the lower frame in front of the Operators Platform. The Rear Rotor Door Solenoid is energized when the Rear Rotor Door Switch, located on the Operator Control Panel is in the “DOWN” position to close (lowers) the Rear Rotor Door or in the “UP” position to open (raise) the Rear Rotor Door.

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The Coolant Level Switch monitors the coolant level and outputs a variable voltage signal to the engine ECM. Voltage varies from 0.5 volts (max.) to 4.0 volts (min.) when the switch probe is in the fluid and from 4.0 volts (min.) to 0.5 volts (max.) when the switch probe is out of the fluid.

OIL PRESSURE SWITCH. This component is covered in detail in the Cummins QSM11 Operation and Maintenance Manual.

OIL PRESSURE SENDER. The Oil Pressure Sender is located on the engine and is a variable resistor type unit used to monitor the engine oil pressure. The sender sends a variable voltage signal to the Monitoring Controller. The PowerView display will show the oil pressure when accessed. This component is covered in detail in the Cummins QSM11 Operation and Maintenance Manual.

THROTTLE SWITCH. The Throttle Switch is mounted on the engine. This switch closes when the engine is at full throttle (2,100 RPM) DC voltage is routed from the engine ECM to the coil of the Rotor Relay (K8), energizing the relay. When the Rotor Relay (K8) is energized voltage is routed to the Rotor Speed Control Board to allow rotor operation. This component is covered in detail in the Cummins QSM11 Operation and Maintenance Manual.

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Section 7 ELECTRICAL FUEL LEVEL SENDER.

HYDRAULIC OIL TEMPERATURE SENDER.

The Fuel Level Sender is a variable resistor type unit located on the Fuel Tank and used to monitor fuel level. The sender sends a variable voltage signal to the Monitoring Controller. Voltage varies from 1.0 volts when the tank is empty to 4.0 volts when the tank is full. The PowerView display will show the fuel level when accessed.

The Hydraulic Oil Temperature Sender is located on the Case Manifold Assembly. The Hydraulic Oil Temperature Sender is a variable resistor type unit used to monitor the hydraulic oil temperature. The sender sends a constant signal to the Monitoring Controller. The PowerView display will show the hydraulic oil temperature when accessed.

STEERING/AUX RETURN FILTER SWITCH.

LOW ROTOR CHARGE PRESSURE SWITCH.

The Steering/Aux Return Filter Switch monitors the pressure in the Steering/Aux Return Filter. When the pressure exceeds 18 psid the switch closes and sends a signal to the Monitoring Controller. This iniates a visual and/or audible signal from the PowerView display indicating the filter needs to be changed.

The Low Rotor Charge Pressure Switch is located in port GA of the Rotor Loop Flushing Valve to monitor Rotor Charge Pressure. This switch is normally closed and opens at 200 psi. When closed (pressure less than 200 psi) this switch sends a signal to the Monitoring Controller. This iniates a visual and audible signal from the PowerView display indicating the Rotor Charge Pressure has dropped below 200 psi.

TRAVEL PUMP FILTER SWITCH. The Travel Pump Filter Switch monitors the pressure in the Travel Pump Filter. When the pressure exceeds 18 psid the switch closes and sends a signal to the Monitoring Controller. This iniates a visual and/or audible signal from the PowerView display indicating the filter needs to be changed.

ROTOR PUMP FILTER SWITCH.

MACHINE TRAVEL SPEED TRANSDUCER. The Machine Travel Speed Transducer is located on the Rear Drive Control Valve and converts hydraulic flow to a variable voltage signal. The transducer sends the variable voltage signal to the Travel and Load Controller. The PowerView display will show the machine travel speed when accessed.

The Rotor Pump Filter Switch monitors the pressure in the Rotor Pump Filter. When the pressure exceeds 16 psid the switch closes and sends a signal to the Monitoring Controller. This iniates a visual and/or audible signal from the PowerView display indicating the filter needs to be changed.

AIR FILTER RESTRICTION SWITCH. The Air Filter Restriction Switch is located on the air filter. This switch closes at a pressure of 20 in. H2O. When the pressure exceeds a pressure of 20 in.

H2O the switch closes and sends a signal to the Monitoring Controller. This iniates a visual and/or audible signal from the PowerView display indicating the air filter is restricted.

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Section 7 ELECTRICAL POWERVIEW MONITORING SYSTEM. POWERVIEW DISPLAY. The PowerView Display is located on the Ignition Panel (Right-hand dash). The PowerView multifunction monitoring system provides electronic instrumentation and monitoring of the machine’s engine, hydraulic travel, steering and rotor systems.

FUEL LEVEL. When accessed using the arrow buttons, menu and enter keys, the PowerView display screen will show available fuel contained in both tanks, as a percentage, with 100% indicating full condition.

will show a “severe fault code” and “SHUTDOWN” icon. The audible alarms will sound and the red shutdown/derate light will come on.

ENGINE OIL PRESSURE. When accessed using the arrow buttons, menu and enter keys, the PowerView display screen will show the engine oil pressure. Anytime the minimum allowable oil pressure is reached, the PowerView display screen will show an “active fault code” and “WARNING” icon. The audible alarms will sound and the amber warning light will come on. If the fault condition continues, the PowerView display will show a “severe fault code” and “SHUTDOWN” icon, on the screen. The audible alarms will sound and the red shutdown/derate light will come on.

ENGINE HOURS. ROTOR SYSTEM CHARGE FILTER. When accessed using the arrow buttons, menu and enter keys, the PowerView display screen will show accumulated hours the engine has been running.

CHARGE VOLTAGE. When accessed using the arrow buttons, menu and enter keys, the PowerView display screen will show charge voltage from the alternator.

ENGINE COOLANT TEMPERATURE. When accessed using the arrow buttons, menu and enter keys, the PowerView display screen will show the engine coolant temperature. Anytime the 212° F (100° C) limit is exceeded, the PowerView display screen will show an “active fault code” and “WARNING” icon. The audible alarms will sound and the amber warning light will come on. When the PowerView display receives a “severe fault code”, a “SHUTDOWN” icon will be shown on the screen.

The alarms will sound and the red shutdown/derate light will come on.

HYDRAULIC SYSTEM OIL TEMPERATURE. When accessed using the arrow buttons, menu and enter keys, the PowerView display screen will show the hydraulic system oil temperature. Should oil temperature exceed 180°F , the PowerView display screen will show an “active fault code” and “WARNING” icon. The audible alarms will sound and the amber warning light will come on. Should oil temperature exceed 190° F , the PowerView display screen

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The PowerView display screen will indicate if the rotor charge oil filter has reached its maximum holding capacity and must be changed. Anytime the filters maximum holding capacity is reached, the PowerView display screen will show an “active fault code” and “WARNING” icon. The audible alarms will sound and the amber warning light will come on. If the fault condition still exists, after 2 minutes, the PowerView display receives a “severe fault code” and a “SHUTDOWN” icon will be shown on the screen. The audible alarms will sound continuously and the red shutdown/derate light will come on.

TRAVEL SYSTEM CHARGE FILTER. The PowerView display screen will indicate if the travel charge oil filter has reached its maximum holding capacity and must be changed. Anytime the filter’s maximum holding capacity is reached, the PowerView display screen will show an “active fault code” and “WARNING” icon. The audible alarms will sound and the amber warning light will come on. If the fault condition still exists, after 2 minutes, the PowerView display receives a “severe fault code” and a “SHUTDOWN” icon will be shown, on the screen. The audible alarms will sound continuously and the red shutdown/derate light will come on.

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Section 7 ELECTRICAL STEERING/AUX RETURN FILTER.

MACHINE TRAVEL SPEED.

The PowerView display screen will indicate if the steer/auxiliary systems oil filter has reached its maximum holding capacity and must be changed.

Anytime the filter’s maximum holding capacity is reached, the PowerView display screen will show an “active fault code” and “WARNING” icon. The audible alarms will sound and the amber warning light will come on. If the fault condition still exists, after 2 minutes, the PowerView display receives a “severe fault code” and a “SHUTDOWN” icon will be shown, on the screen. The audible alarms will sound continuously and the red shutdown/derate light will come on.

When accessed using the arrow buttons, menu and enter keys, the PowerView display screen will provide a digital readout of the over-the-ground speed of the machine. The travel speed will shown in feet per minute (FPM) up to a speed of 1 MPH (1.61 kph) and miles per hour (MPH) for all speeds above 1 MPH (1.61 kph).

ENGINE SPEED. When accessed using the arrow buttons, menu and enter keys, the PowerView display screen will provide digital readout of engine revolutions per minute (RPM).

ENGINE INLET AIR FLOW RESTRICTION. GAUGES. The PowerView display screen will indicate if the air flow, to the engine, has a restricted condition and must be cleared. Anytime the air flow has a restricted condition, the PowerView display screen will show an “active fault code” and “WARNING” icon.

The audible alarms will sound and the amber warning light will come on. If the fault condition still exists, after 2 minutes, the PowerView display receives a “severe fault code” and a “SHUTDOWN” icon will be shown, on the screen. The audible alarms will sound continuously and the red shutdown/derate light will come on. Also, check the visual restriction indicator located on top of the engine air inlet tube, between the air cleaner outlet and turbocharger air inlet. If indicator is between 20 and 25 inches H20, do NOT operate the unit until the restriction is cleared.

LOW ROTOR CHARGE PRESSURE. The PowerView display screen will indicate that there is low rotor hydraulic charge oil pressure, in the rotor drive system, when pressure drops below 200 psi. Anytime the rotor charge oil pressure drops below 200 psi, the PowerView display screen will show an “active fault code” and “WARNING” icon.

The audible alarms will sound and the amber warning light will come on. If the fault condition still exists, after 2 minutes, the PowerView SHUTDOWN” icon will be shown, on the screen. The audible alarms will sound continuously and the red shutdown/derate light will come on.

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ROTOR PRESSURE. The Rotor Pressure gauge indicates hydraulic pressure in the rotor drive sytem. Typical pressure is dependent on the selected Rotor Speed Range.

Maximum pressure is 5000 psi.

TRAVEL PRESSURE. The Travel Pressure gauge indicates hydraulic pressure in the travel drive system. Typical pressure will range from 3000 to 4000 psi, depending upon operating conditions. Maximum pressure is 6000 psi.

4-LIGHT DIAGNOSTIC GAUGE. The 4-Light Diagnostic gauge is located on the Alarm Panel (left-hand dash). Each of 4 lights (STOP - WARNING - MAINT - WAIT) monitor engine systems and are lighted as a diagnostic message if a engine malfunction is detected. The engine systems diagnostic information, on the 4 light gauge, works in conjunction with the PowerView monitoring system. The light will only activate if a engine fault is noted. The PowerView monitoring system may, or may not, recognize the fault. If the PowerView monitoring system does not recognize the fault, NO warning buzzers will sound.

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Section 7 ELECTRICAL WARNING ALARM.

TURN/HAZARD LIGHTS - OPTIONAL.

The Warning Alarm is located on the Alarm Panel (left-hand dash). High and low tone warning alarms work in conjunction with the PowerView monitoring system. Both alarms will sound if any monitored system malfunction, warning or fault code is detected by the PowerView monitoring system. Touch the top of the dash mounted warning alarm to cancel the alarm. After cancelled, both alarms will sound, again if any monitored system continues to have a malfunction, warning, or fault code which is detected by the PowerView monitoring system. The warning alarms will continue to sound until the cause of the malfunction and/or warning, or fault codes is corrected.

The optional right and left Turn/Hazard Lights are located on the front and the rear of the machine.

These lights are controlled by the three position turn signal switch on the Switch Panel and the two position four way Flasher/Hazard Switch on the Switch Panel. When the four way Flasher/Hazard Switch is turned to the right “ON”, the Red Hazard Lights will flash. If less than three bulbs are functional, the switch will not flash red.

EXTERNAL LIGHTS. STOP LIGHT. The Stop Light on the rear of the machine is turned on when the Stop Light Relay, K6, is energized.

This relay is energized only when the Travel Control Lever is in neutral “N” position.

HEADLIGHTS. The right and left Headlights are located on the front of the machine. These lights are turned on when the LIGHTS OFF/PARK/ON switch is in the ON position.

When the Headlights or Parking Lights are turned on, voltage is also routed to illumination input on the Tachometer, Speedometer and all other gauges on the Gauge and Light Panel, except the Hourmeter, to illuminate the gauges. The Headlights can be turned on regardless of Ignition Switch Position.

The Turn Signal Switch has a left-center-and right position. In the center position the turn signals are off. In the left position the left turns signals flash and the switch flashes green. In the right position the right turns signals flash and the switch flashes green.

The Turn/Hazard Llights can be turned on, regardless of Ignition Switch position.

WORKLIGHTS. The right and left Worklights are located on the rear of the machine. These lights are turned on when the WORKING LIGHTS ON/OFF switch is in the ON position. The Worklights can be turned on regardless of Ignition Switch Position.

HORN. Horns are located on both the front and the rear of the machine. When the Horn Button is pressed battery voltage is routed through the HORN switch to activate both horns. The Horn will operate regardless of Ignition Switch position.

PARKING LIGHTS.

BACKUP ALARM.

The right and left amber Parking Lights are located on the front and the rear of the machine. These lights are turned on when the LIGHTS OFF/PARK/ON switch is in the PARK (center) position. When the Headlights or Parking Lights are turned on, voltage is also routed to illumination input on the Tachometer, Speedometer and on the Gauge and Light Panel, except the Hourmeter, to illuminate the gauges. The Headlights can be turned on, regardless of Ignition Switch position.

The Backup Alarm is located on the rear of the machine. When the Travel Control Lever is moved to the reverse position, a reverse switch in the Control Lever closes and routes DC voltage to the Backup Alarm. The alarm will sound during the time the Travel Control handle is in the reverse position.

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Section 7 ELECTRICAL CABLES AND WIRES. CABLES. The positive (+) and negative (-) Battery Cables connect the positive (+) post of the battery to the Engine Starter Motor through the Disconnect Switch Assembly and the negative (-) post of the battery to system ground at the engine. These cables carry high amperage electrical current for the Engine Starter Motor and current from the alternator to the battery.

WIRES. The Wires used in the Electrical System connect the components and form the circuits through which the electrical current flows. The Wire Assemblies contain different size (gauge) Wires, Connector Terminals, and Plug Assemblies. The Wire Assemblies are covered with a protective PVC coated nylon woven loom, and/or are shielded.

COMPUTER TRAVEL AND LOAD CONTROLLER COMPUTER SYSTEM AND ROTOR SPEED CONTROL BOARD. The Computer Travel and Load Control System and Rotor Speed Control System consist of the Rotor Speed Control Board, the Travel and Load Controller SX Computer, the Travel Pump, the Rotor Pump, a Pressure Transducer, an Engine Load Control Setpoint Potentiometer, and several Control Switches.

MANUAL CONTROL. When the ENGINE LOAD CONTROL MAN/AUTO Switch on the Switch Panel is in the MAN (MANUAL) position, the Travel Load Controller Computer is disabled. The rotor speed is controlled by the Rotor 2-Speed Switch, and the ROTOR ON/OFF Switch. For rotor operation the engine must be operating at full throttle. The travel speed is controlled by the Travel Direction Control (FNR) Lever.

ROTOR SPEED. The Rotor 2-Speed Switch can be set to 135 rpm (position I) or 150 rpm (position II). The ROTOR ON/OFF Switch must be in the On position. Battery

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voltage is applied through the ROTOR ON/OFF Switch, then through the Rotor Relay that is only energized when at full throttle. From the Rotor Relay, the voltage is applied to the (+) Power in on the Rotor Speed Control Board providing operating voltage to the board. The Rotor 2-Speed Switch sets the voltage at the VOLT input on the Rotor Speed Control Board. The MN and MAX pots on the Rotor Speed Control Board are adjusted for the desired speed. Speed for position I is set by the MN pot and the speed for position II is set by the MAX pot. The output from the control board at (+) coil and (-) coil are applied to the EDC coil on the rotor pump to control the rotor speed.

TRAVEL SPEED. Travel Speed is controlled by the Directional Control (FNR) Lever. The Potentiometer in the FNR Lever is connected across a +5 VDC sensor voltage output from the Travel and Load Controller. The wiper arm is positioned by moving the FNR Lever and can select a voltage level from 0.5 VDC to 4.5 VDC. This voltage is applied to the analog 0 (propel) input to the Travel and Load Controller Computer. Voltage levels between 0.5 to 2.5 VDC cause an output at Valve Drive 1 (reverse travel). The amount of drive current depends on the actual voltage level. This voltage is applied to the reverse EDC Coil on the Travel Pump to control reverse speed. The 0.5 VDC level from the FNR Controller will provide maximum speed. The 2.5 VDC Lever is the neutral position and provides no drive output. Voltage levels between 2.5 to 4.5 VDC cause an output at valve drive 0 (forward travel). The amount of drive current depends on the actual voltage level. This voltage is applied to the forward EDC Coil on the Travel Pump to control forward speed. The 4.5 VDC level from the FNR Controller will provide maximum speed.

AUTO CONTROL. The rotor speed operation is the same in both MAN and AUTO operation. In AUTO operation, the Travel and Load Controller Computer is enabled and the Load Controller Computer adjusts the travel speed by monitoring the pressure in the Rotor Hydraulic System. As the pressure increases, the computer reduces the travel speed. When using the AUTO System, the direction control FNR must be set to the maximum forward position to provide maximum productivity.

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Section 7 ELECTRICAL When the ENGINE LOAD CONTROL MAN/AUTO Switch is set to the AUTO position, +24 VDC battery voltage is routed through the switch and applied to the Travel and Load Controller Computer as digital in 0 (auto/manual), enabling the computer. The Travel Pump Electronic Displacement Control (EDC) threshold value in the Travel and Load Controller Computer is set using the EDC Threshold Calibrate Switch on the Auxiliary Panel. When switched on, the switch routes 24 VDC to the digital 2 input (EDC threshold calibrate) on the computer for calibration.

The Directional (FNR) Controller should be set to maximum forward position. This provides a 4.5 VDC input to the computer at analog input 0 (propel input). In addition, the pressure transducer from the Rotor Hydraulic System provides a 0.5 to 4.5 VDC (depending on pressure) to the analog input 2 (pressure transducer signal). An additional input to the computer is the output from the Engine Load Control Setpoint Potentiometer. This is an adjustable voltage level applied to the computer at analog input 1 (set point signal). The Engine Load Control Setpoint Potentiometer allows control of the load on the rotor. Turning the control clockwise (cw) increases the load and turning the control counterclockwise (ccw) decreases the load.

The computer uses these signals to control the output at valve drive 1 (forward propel). This output is applied to the EDC Forward Coil on the Travel Pump and regulates the forward speed as the load on the rotor changes.

NOTE: Computer programming should only be performed by authorized, trained, service personnel. Fault analysis must be diagnosed and corrected by authorized, trained, service personnel using Bomag MPH362/364 Instructions For Repair Manual, catalog number 0852680.

The Travel and Load Controller has four LED lamps that are visible to the operator, through the clear dash mounted cover. The lights indicate controller status, or if faults (errors) were detected. Viewed through the cover, from left to right, the LEDs are as follows:

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Green – POWER ON Green – SYSTEM ON Yellow – MODE- should flash every 2 seconds Red – STATUS – should be OFF If any of the LED lamps are not as described above, the controller has detected a “fault”.

If all of the LED lamps are correct, except the RED STATUS lamp, a fault has been detected and the cause of the fault must be diagnosed and corrected by authorized, trained, service personnel.

GENERAL TROUBLE ANALYSIS INFORMATION AND PROCEDURES. ALWAYS follow the FOUR basic principles of GOOD systematic troubleshooting.

1. KNOW the system.

2. DETERMINE the symptoms.

3. LIST the possible causes.

4. TAKE THE CORRECT action.

NEVER smoke or cause a spark near ANY battery. ALWAYS loosen and remove the NEGATIVE (-) battery cable from the NEGATIVE (-) battery post BEFORE loosening and removing the POSITIVE (+) battery cable from the POSITIVE (+) battery post. NEVER cause a shorted circuit condition in any circuit. USE EXTRA CAUTION when checking ANY circuit using ANY electrical testing instrument.

When troubleshooting ANY system circuit problem, FIRST determine IF the problem noted is confined to ONLY that system circuit OR common to ALL system circuits.

IMPROPER troubleshooting methods waste time and can cause further system problems, or damage.

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Section 7 ELECTRICAL Use STANDARD voltage, ohms and continuity testing instruments to aid in troubleshooting of non-computer controller monitored system circuit problems. For CORRECT test instrument use and procedures, follow the entire testing instrument MANUFACTURERS written instructions, supplied with the test instruments.

VOLTAGE MEASUREMENTS. Most voltage measurements will be made with the negative side of the voltmeter connected to chassis ground and the positive side connected to a positive (+) point in the circuit. The voltage level will normally be battery voltage of about 24 vdc and the computer sensor voltages, which are about 5 vdc. When the voltmeter has manual range selection, always use a range on the voltmeter that allows a normally reading to be near mid-scale. Voltage readings are made with the circuit in normal operation.

CONTINUITY (RESISTANCE) MEASUREMENTS. A continuity test is actually a resistance test, looking for a resistance usually at almost 0 ohms.

Continuity tests can only be performed on a circuit that is not connected to a voltage. When making continuity checks, always disconnect the battery.

The ohmmeter has a built in voltage supply for operation. If the ohmmeter is connected across an external voltage, the meter may be severely damaged.

Always set the ohmmeter to the lowest possible scale.

CURRENT MEASUREMENTS. Current measurements normally require the meter to be placed in series with the circuit. There are some types of current meters that can be clamped around a wire, but in most cases, the meter must be connected into the circuit. This requires the circuit to be de-energized, usually by disconnecting the battery or setting the disconnect switch to the OFF position. The circuit is then opened (wire disconnected) and the current meter connected between the wire and the point the wire had been attached to. When the battery is reconnected or the disconnect switch set to ON, and the circuit energized, the current flowing in the wire will now flow through the current meter, indicating the amount of current.

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Do NOT use ANY testing instrument BEFORE reading ALL manufacturers instructions for the instrument AND procedures to be used to troubleshoot the circuit problem. SERIOUS injury and/or system circuit damage can occur if correct procedures are not followed.

The travel and load controller computer used on the Model MPH362/364 recyclers/stabilizers, has built in â&#x20AC;&#x153;DIAGNOSTICâ&#x20AC;? capability (see this section).

ALL electrical CONTROL system CIRCUITS used on the Model MPH362/364 are EXTREMELY sensitive to having CORRECT voltage SUPPLIED to, and within, them.

ALWAYS be sure that the correct voltage is available to the entire electrical system BEFORE further troubleshooting any circuit.

INCORRECT voltage (LOW), or (HIGH) can cause circuit malfunctions and/or component failures.

If a noted problem is confined to ONLY ONE system circuit, the troubleshooting thought process and procedures should be confined to ONLY the circuits and components which affect THAT system circuit.

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, Hydraulic or some combination of any of these.

Only after the CAUSE of the problem has been determined can the SPECIFIC damaged circuit component be repaired, or replaced.

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Section 7 ELECTRICAL TRAVEL SYSTEM FAULTS. Some travel controller faults can be determined by observing the red STATUS light on the travel controller computer. This light should be OFF for normal operation. If the light is flashing, a fault is indicated as described in the following chart.

NOTE: In this chart a ¡ = short duration flash and a - = a long duration flash.

Fault Code

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Flash Bit Sequence

Device at Fault

Cause of Fault

1

*-**

FNR Potentiometer

Voltage signal out of range

2

--**

Setpoint Trim Potentiometer

Voltage signal out of range

3

*--*

Pressure Sensor

Voltage signal out of range

4

-*-*

Valve Coil

Valve voltage out of range or uncalibrated

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Section 7 ELECTRICAL TROUBLESHOOTING CHART.

NOTE: In the following troubleshooting chart, possible defective components are listed or incorrect switch settings are listed. If these components have been checked and found not to be defective and switches are in the proper position, check plug connections and perform continuity checks on wires to determine if a wire is open.

SYMPTOM ALL SYSTEMS INOPERATIVE

NEITHER HEADLIGHT OPERATES ONE HEADLIGHT IS ON AND THE OTHER IS OFF WORKLIGHTS DO NOT OPERATE

ONE WORKLIGHT IS ON AND THE OTHER WORKLIGHT IS OFF PARKING LIGHTS AND GAUGE LIGHTS DO NOT ILLUMINATE WHEN LIGHT SWITCH IS IN PARK OR ON POSITIONS NEITHER FRONT OR REAR HORNS OPERATE

ONE BUT NOT BOTH HORNS OPERATE MACHINE OPERATES BUT BACKUP ALARM DOES NOT SOUND WHEN FNR CONTROL IS IN REVERSE

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TROUBLESHOOTING CHART CAUSE Battery disconnect switch in OFF position.

Battery not charged.

Battery disconnect switch in OFF position.

Light switch not turned ON. Fuse "6" on fuse box FB-3 blown.

Light switch defective.

Off light is defective.

REMEDY Install battery.

Charge battery.

Set switch to ON position.

Turn switch to ON position.

Replace fuse.

Replace switch.

Replace defective light.

Working light switch not turned ON. Fuse "5" on fuse box FB-3 blown.

Light switch defective.

Off light is defective.

Turn switch to ON position.

Defective light switch.

Fuse "6" on fuse box FB-3 blown.

Replace light switch.

Replace fuse.

Fuse "1" on fuse box FB-3 defective.

Horn switch defective.

Both horns defective.

Defective horn.

Replace fuse.

Fuse "5" on fuse box FB-1 blown.

Defective backup alarm.

Defective reverse switch in directional FNR control lever.

Replace fuse.

Replace switch.

Replace defective light.

Replace horn switch.

Replace horns.

Replace horn.

Replace fuse.

Replace alarm.

Replace FNR control lever.

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Section 7 ELECTRICAL

SYMPTOM MACHINE DOES NOT CRANK WHEN IGNITION SWITCH IS IN POSITION 3 (START)

TROUBLESHOOTING CHART CAUSE Battery disconnect ON/OFF switch not in the ON position.

Battery damaged (dead).

Battery cables are corroded.

Fuse "1" on fuse box FB-2 blown.

Start power relay, K3, not operating.

Starter solenoid damaged.

E-stop ON/OFF switch in ON position or defective.

Brake ON/OFF switch not in ON position or switch is defective.

Rotor ON/OFF switch not in OFF position or switch is defective.

ENGINE CRANKS SLOWLY AND WILL NOT START

ENGINE CRANKS AT NORMAL SPEED BUT WILL NOT START POWERVIEW DISPLAY DOES NOT FUNCTION POWERVIEW HOURMETER DOES NOT INDICATE HOURS AS ENGINE OPERATES POWERVIEW HOURMETER INDICATES ERRATIC HOURS POWERVIEW TACHOMETER DOES NOT OPERATE OR INDICATES INCORRECT RPM

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Directional FNR control lever not in "Neutral" position.

Neutral switch in FNR control lever defective.

Ignition switch damaged.

Diode 4 on diode block DB-3 shorted.

Starter motor winding shorted.

Battery not fully charged.

Engine has internal damage.

Fuel shut-off solenoid not energized.

Engine has internal damage or engine ignition system is defective.

PowerView display defective.

Fuse "4" on fuse box FB-2 blown.

PowerView display defective.

Oil pressure switch on engine defective.

PowerView display defective.

PowerView display defective.

Engine speed magnetic pickup is defective.

REMEDY Set switch to the ON position.

Replace battery.

Clean or replace battery cables.

Replace fuse.

Replace relay, K3.

Replace solenoid.

Place switch in OFF position or replace as necessary.

Set brake ON/OFF switch to ON position or replace switch as necessary.

Set Rotor ON/OFF switch to OFF position or replace switch as necessary.

Place FNR in "Neutral" position.

Replace FNR control lever.

Replace ignition switch.

Replace diode.

Repair or replace starter motor.

Charge battery.

Repair or replace engine.

Check for voltage across solenoid. If voltage is present, replace solenoid. If voltage is not present, check for shorted diode 1 on diode block DB-3 or defective ignition switch.

Repair or replace as necessary.

Replace Replace Replace Replace

PowerView. fuse.

PowerView. oil pressure switch.

Replace PowerView.

Replace PowerView.

Replace engine speed magnetic pickup.

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Section 7 ELECTRICAL

SYMPTOM POWERVIEW DISPLAY NOT INDICATINGCORRECT OIL PRESSURE OR INDICATING NO OIL PRESSURE POWERVIEW DISPLAY DOES NOT INDICATE ENGINE COOLANT TEMPERATURE POWERVIEW DISPLAY NOT INDICATING CORRECT VOLTAGE OR NO VOLTAGE AT ALL POWERVIEW DISPLAY NOT INDICATING CORRECT FUEL LEVEL OR NO FUEL LEVEL AT ALL POWERVIEW DISPLAY DOES NOT INDICATE CORRECT OIL TEMPERATURE OR NO INDICATION AT ALL POWERVIEW DISPLAY DOES NOT INDICATE AN ENGINE INLET AIR RESTRICTION CONDITION

BATTERY IS BEING OVERCHARGED BATTERY IS NOT BEING CHARGED

TROUBLESHOOTING CHART CAUSE Oil pressure sender defective.

REMEDY Replace sender.

PowerView display defective.

Replace PowerView.

Coolant temperature sender defective.

PowerView display defective.

Replace sender.

Replace PowerView.

PowerView display defective.

Fuse "4" on fuse box FB-2 defective.

PowerView display defective.

Fuel level sender on fuel tank defective.

Fuel tank empty.

Temperature sender unit defective.

PowerView display defective.

Replace PowerView.

Replace fuse.

System operating normally.

PowerView display defective.

Faulty light.

Air filter restriction switch faulty.

Open ground at switch or bulb.

Engine ECU malfunction.

NO service needed.

Replace PowerView.

Replace light.

Replace switch.

Correct as necessary.

Refer to Engine Manual QSM11.

Replace regulator.

Replace PowerView.

Replace fuel level sender.

Fill fuel tank.

Replace temperature sender unit.

Replace PowerView.

Voltage regulator in alternator damaged.

Voltage regulator in alternator Replace alternator. damaged.

Alternator not producing voltagage. Repair or replace alternator.

E-STOP/PARKING BRAKE RELEASE SYSTEM

E-STOP/PARKING BRAKE RELEASE SYSTEM NOT RELEASING BRAKES E-STOP/PARKING BRAKE WILL NOT APPLY

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Section 7 ELECTRICAL TROUBLESHOOTING CHART CAUSE REMEDY ENGINE THROTTLE SPEED CONTROL CIRCUIT ENGINE THROTTLE SPEED Engine ECU malfunction.

Refer to Engine Manual WILL NOT CHANGE FROM LOW QSM11.

TO HIGH IDLE OR WILL NOT CHANGE FROM HIGH TO LOW IDLE TRANSMISSION SYSTEM CONTROL CIRCUIT Caution: The transmission system control circuit used on the MPH362/364 is EXTREMELY sensitive to having the correct voltage supplied to the circuit. Always check the supplied voltage to the circuit before further troubleshooting.

TRANSMISSION SYSTEM DOES E-Stop brake system control Place switch in released NOT OPERATE IN EITHER switch is in applied position. position.

DIRECTION IN MAN POSITION E-Stop switch defective.

Replace switch.

OF AUTO/MAN SWITCH Travel and load controller Replace computer. computer defective.

FNR controller lever defective.

Replace FNR controller lever.

Defective EDC coils on travel Replace coils. pump.

Defective travel pump.

Replace pump.

TRANSMISSION SYSTEM Travel and load controller Replace computer.

OPERATES IN ONE DIRECTION computer defective.

ONLY IN MAN POSITION OF FNR controller lever defective.

Replace FNR controller lever.

AUTO/MAN SWITCH Defective EDC coil on travel pump. Replace defective EDC coil.

Defective travel pump.

Replace pump.

IN AUTO POSITION OF Defective AUTO/MAN switch.

Replace AUTO/MAN switch.

AUTO/MAN SWITCH, Defective pressure transducer.

Replace pressure transducer.

TRANSMISSION SYSTEM DOES NOT CHANGE SPEED AS LOAD CHANGES IN AUTO POSITION OF Defective engine load control set Replace potentiometer.

AUTO/MAN SWITCH, point potentiometer.

TRANSMISSION SYSTEM Travel and load controller Replace computer.

ENGINE LOAD SET POINT CAN computer defective.

NOT BE CHANGED SYMPTOM

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08/05

Section 7 ELECTRICAL TROUBLESHOOTING CHART CAUSE REMEDY TRANSMISSION SYSTEM CONTROL CIRCUIT (CONTINUED) FNR OVERRIDE SYSTEM DOES Defective FNR override switch.

Replace defective switch.

NOT OPERATE BUT NORMAL Defective FNR backup switch.

Replace switch.

FNR OPERATION IS OK EDC THRESHOLD CALIBRATION Defective EDC threshold calibrate Replace switch.

DOES NOT WORK switch.

Travel and load controller Replace computer. computer defective.

4WD MPH364 ONLY MACHINE DOES NOT SWITCH 2-Speed High/Low switch not in Set switch to LOW position.

FROM 2-WHEEL DRIVE TO LOW position.

4-WHEEL DRIVE 4WD OFF/ON switch not in ON Set switch to ON position. position.

4WD switch defective.

Replace defective switch.

Diode "5" on diode block DB-1 Replace diode. shorted.

Front assist solenoid defective.

Replace solenoid.

ROTOR CONTROL SYSTEM ROTOR DOES NOT ROTATE IN 15-Amp fuse "4" on fuse box FB-1 Replace fuse.

ANY POSITION blown.

Rotor ON/OFF switch in OFF Set rotor ON/OFF switch to ON position. position.

Rotor ON/OFF switch defective.

Replace defective switch.

FNR speed control lever not set to Set FNR lever for maximum maximum speed. speed.

Throttle switch on engine does not Replace switch. close when FNR is set to maximum speed.

Rotor relay, K8, defective.

Replace relay.

Defective rotor speed controller Replace defective rotor speed board. control board.

Rotor pump EDC coil defective.

Replace EDC coil.

Rotor pump defective.

Replace rotor pump.

ROTOR SPEED DOES NOT Rotor 2-speed or 3-speed switch Replace switch.

CHANGE WHEN ROTOR defective.

2-SPEED IS CHANGED Defective rotor speed controller Replace defective rotor speed board. control board.

SYMPTOM

08/05

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Section 7 ELECTRICAL TROUBLESHOOTING CHART CAUSE ROTOR HOOD AND DOOR CIRCUITS ROTOR DOES NOT RAISE OR 15-Amp fuse "3" on fuse box FB-1 LOWER blown.

Rotor UP/DOWN switch defective.

Rotor lift/lower cylinder defective.

REAR DOOR DOES NOT OPEN 15-Amp fuse "3" on fuse box FB-1 OR CLOSE blown.

Rear door OPEN/CLOSE switch defective.

Rear rotor door open/close cylinder defective.

SYMPTOM

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REMEDY Replace fuse.

Replace switch.

Replace cylinder.

Replace fuse.

Replace switch.

Replace cylinder.

08/05

Section 8 HYDRAULICS TABLE OF CONTENTS PAGE GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2 HYDRAULIC SUPPLY AND RETURN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2 CLEANLINESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2 CASE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4 TANK MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5 THERMAL BYPASS ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7 HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10 HYDRAULIC DRIVE TRAVEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11 TRAVEL CHARGE FILTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12 TRAVEL MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13 REAR TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-14 FRONT TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-15 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-15 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-15 TRAVEL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-16 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-16 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-17 INSPECTION AND PRESSURE CHECK PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-18 SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-23

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8-1

Section 8 HYDRAULICS GENERAL INFORMATION.

3. All gaskets and O-rings should be replaced.

This section provides a description of the main components of the Hydraulic Supply and Return system and the Hydraulic Drive Travel system. Instructions for Removal, Installation, Disassembly and Assembly procedures are provided. Figure 8-16 at the end of the chapter is a complete hydraulic schematics.

4. Lightly lubricate all O-rings with hydraulic oil prior to assembly.

5. Whenever a hose is disconnected, immediately cap the fitting and plug the hose to prevent contamination. If multiple hoses are disconnected or removed, mark and tag connection points to insure proper reassembly.

DESCRIPTION. HYDRAULIC SUPPLY AND RETURN SYSTEM [See Figure 8-1].

The Hydraulic Supply and Return system consists of the following main components: Hydraulic Tank Assembly Case Manifold Assembly Tank Manifold Assembly Thermal Bypass Assembly The Hydraulic Tank Assembly (Figure 8-1 â&#x20AC;&#x201C; 1) is located behind the cockpit and provides the hydraulic oil for all hydraulic systems. The Case Manifold Assembly (2) receives hydraulic oil from the Pump Case Drains, the Rotor Loop Flushing Valve, the Travel Pump Case Drain and the Travel Motor Case Drain. The Hydraulic Oil is sent to the Thermal Bypass Assembly (3). The Case Manifold Assembly (2) contains a test port and a Hydraulic Oil Temperature Sender. The Tank Manifold Assembly (4) receives the hydraulic oil from the Hydraulic Oil Cooler and from the Thermal Bypass Assembly (3) and returns the hydraulic oil to the Hydraulic Tank Assembly (1). The Thermal Bypass Assembly (3) receives the hydraulic oil from the Case Manifold Assembly (2) and routes the hydraulic oil to the Tank Manifold Assembly (4) or to the Oil Cooler Assembly. Information on the Oil Cooler Assembly is provided in SECTION 10.

CLEANLINESS. When servicing the hydraulic system, it is very important to do the following: 1. Clean surfaces, fittings, and hoses at the point of disconnection.

2. Protect all exposed sealing surfaces from damage and foreign material.

8-2

08/05

Section 8 HYDRAULICS

FIGURE 8-1. HYDRAULIC SUPPLY AND RETURN SYSTEM. 08/05

8-3

Section 8 HYDRAULICS CASE MANIFOLD. The Rotor Pump has a single Pump Case Drain connected to the Case Manifold. The Case Manifold has inputs from the Travel Motor Drain and the Travel Pump Drain as well as a Test Port, and Hydraulic Oil Temperature Sender. The outputs from the Case Manifold Assembly are connected to the Thermal Bypass Assembly.

REMOVAL [See Figure 8-2].

Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all vertical cylinders, discharge any accumulators, and block any load whose movement could generate pressure.

NOTE: Plug and cap all lines and ports to prevent entry of dirt into the system.

1. Place a container under the Case Manifold Assembly to catch any oil when the hydraulic lines are disconnected.

2. Disconnect and label the hydraulic line from the Travel Pump Case Drain connected to fitting (Figure 8-2 – 1).

3. Disconnect and label all hydraulic lines to the Case Manifold Assembly.

4. Disconnect and label the wires from the Hydraulic Oil Temperature Sender (6).

5. Remove the four capscrews (7), and two washers (8) and flanged locknuts (9) attaching the Case Manifold Assembly to the frame and remove the Case Manifold Assembly.

6. Remove test port (10) and all fittings from the Case Manifold.

7. Inspect fittings and discard any fitting that is damaged.

8-4

FIGURE 8-2. CASE MANIFOLD REMOVAL AND INSTALLATION. INSTALLATION [See Figure 8-2].

1. Install fittings (Figure 8-2 – 3 through 5) in manifold. Be sure fitting (5) is positioned at 30° as illustrated.

2. Install Hydraulic Oil Temperature Sender (6) in end of manifold.

3. Install fitting (11) in manifold then install test coupling (10) to fitting (11).

4. Install the two fittings (12) into the Case Manifold.

5. Attach the Case Manifold Assembly to the frame with the four capscrews (7), four washers (8) and four flanged locknuts (9).

6. Torque the locknuts (9) to 44 ft•lbs (59.6 N•m).

NOTE: A container should be placed under the Case Manifold Assembly to catch any oil when the hydraulic lines are reconnected.

7. Connect the hydraulic lines from the Travel Pump Case Drain to fitting (1) and the Travel Motor Case Drain.

08/05

Section 8 HYDRAULICS 8. Connect the hydraulic lines from the Thermal Bypass Assembly to fittings (3).

9. Connect the hydraulic line from the Rotor Pump Case Drain.

10. Connect the hydraulic line from the Rotor LoopFlushing Valve to fitting (3).

11. Connect the wires to the Hydraulic Oil Temperature Sender (6).

12. Check hydraulic oil level and add oil as necessary.

13. Perform a pressure check on the system as described in the paragraph INSPECTION AND PRESSURE CHECK PROCEDURE at the end of this chapter.

FIGURE 8-3. TANK MANIFOLD ASSEMBLY. TANK MANIFOLD. The MPH 362/364 has two inputs from the Hydraulic Oil Cooler and two inputs from the Thermal Bypass Assembly. The MPH 362/364 also has an output from the Tank Manifold Assembly to the Hydraulic Tank. All other openings in the Tank Manifold are sealed with plugs.

REMOVAL [See Figure 8-3].

3. Remove the four capscrews (7), four washers (8) and four flanged locknuts (9) attaching the Tank Manifold Assembly to the frame and remove the Tank Manifold Assembly.

4. Remove all fittings from the tank manifold.

5. Inspect fittings and discard any fitting that is damaged.

INSTALLATION [See Figure 8-3].

Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all vertical cylinders, discharge any accumulators, and block any load whose movement could generate pressure.

NOTE: Plug and cap all lines and ports to prevent entry of dirt into the system.

1. Install fittings (Figure 8-3 – 1 through 6) in manifold. Be sure fitting (2) is positioned at 30° as illustrated.

2. Install fittings (10).

3. Attach the Tank Manifold Assembly to the frame with the four capscrews (7), four washers (8) and four flanged locknuts (9).

4. Torque the locknuts (9) to 44 ft•lbs (59.6 N•m).

1. Place a container under the Tank Manifold Assembly to catch any oil when the hydraulic lines are disconnected.

2. Disconnect and label the hydraulic lines from the Hydraulic Oil Cooler connected to fittings (Figure 8-3 – 1 and 2), and the Thermal Bypass Assembly connected to fittings (3), and to the Hydraulic Tank, connected to fitting (6).

08/05

8-5

Section 8 HYDRAULICS NOTE: A container should be placed under the Tank Manifold assembly (Figure 8-3) to catch any oil when the hydraulic lines are reconnected.

5. Connect the hydraulic line that leads to the hydraulic tank to fitting (6).

6. Connect the hydraulic lines from the Hydraulic Oil Cooler to fittings (1 and 2), and the Thermal Bypass Assembly to fitting (3).

7. Check hydraulic oil level and add oil as necessary.

THERMAL BYPASS ASSEMBLIES. Hydraulic Oil from the Case Manifold Assembly is sent to the input of the Thermal Bypass Assembly.

The Thermal Bypass Assembly then routes the hydraulic oil to either the Oil Cooler for cooling or to the Tank Manifold Assembly to be returned to the Hydraulic Tank. There are two Thermal Bypass Assemblies.

REMOVAL [See Figure 8-4].

Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all vertical cylinders, discharge any accumulators, and block any load whose movement could generate pressure.

NOTE: Plug and cap all lines and ports to prevent entry of dirt into the system.

1. Place a container under the Thermal Bypass Assembly to catch any oil when the hydraulic lines are disconnected.

2. Disconnect and label all hydraulic lines.

3. Remove the two capscrews (Figure 8-4 â&#x20AC;&#x201C; 4), two washers (5) and two flanged locknuts (6) attaching the Thermal Bypass Assembly to the frame and remove the Thermal Bypass Assembly.

FIGURE 8-4. THERMAL BYPASS ASSEMBLY.

8-6

08/05

Section 8 HYDRAULICS 4. Remove all fittings (1, 2 and 3) from the Thermal Bypass Assembly.

5. Inspect fittings and discard any fitting that is damaged.

4. Connect all hydraulic lines.

5. Check hydraulic oil level and add oil as necessary.

HYDRAULIC TANK.

INSTALLATION [See Figure 8-4].

1. Install fittings (Figure 8-4 – 1, 2, and 3) in Thermal Bypass. Be sure fitting (1) is positioned in line with the other two fittings and is pointing in the direction of the tank fitting (2).

2. Attach each Thermal Bypass Assembly to the frame with the two capscrews (4), two washers (5) and two flanged locknuts (6).

3. Torque the capscrews (4) to 44 ft•lbs (59.6 N•m).

NOTE: A container should be placed under the Thermal Bypass Assembly to catch any oil when the hydraulic lines are reconnected.

The Hydraulic Tank Assembly is located directly behind the cockpit. This tank assembly provides hydraulic oil for steering, the Hydrostatic Travel and the Rotor Drive systems of the machine. The tank has a capacity of 90 gallons (340.7 liters). The top of the tank has a Filler Breather Assembly that includes a strainer. An Oil Level Gauge is located on the left side of the tank. A Ball Valve is attached to the bottom of the tank for draining. Diffusers are located at all three return input locations. Suction strainers are located at all five suction outlets.

Refer to Figure 8-5 for hydraulic hose connections and routing.

FIGURE 8-5. HYDRAULIC TANK ASSEMBLY HOSE CONNECTIONS.

08/05

8-7

Section 8 HYDRAULICS REMOVAL [See Figure 8-6].

Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all vertical cylinders, discharge any accumulators, and block any load whose movement could generate pressure.

11. Disconnect and label the Hydraulic Hoses from the Rotor Motor Case Flushing and the Steer/Aux Filter connected to fitting (16).

12. Disconnect and label the Hydraulic Hoses from the Tank Manifold Assembly connected to fitting (17).

The hydraulic tank is heavy and requires a harness or lift for removal.

NOTE: Plug and cap all lines and ports to prevent entry of dirt into the system.

13. Attach a harness or lift to the Hydraulic Tank.

1. Place a container under the Hydraulic Tank Assembly to catch any oil when the hydraulic lines are disconnected.

14. Remove the six capscrews (18), and then lift Hydraulic Tank off of machine. Three capscrews are located along each side of the Hydraulic Tank attaching the tank to the frame.

2. Disconnect and label the Hydraulic Hose from fitting (Figure 8-6 â&#x20AC;&#x201C; 1). The hose is connected to the Travel Pump.

3. Disconnect and label the hydraulic hose(s) from fitting (2). The hose goes to the Tandem Gear Pump Brake section.

NOTE: If the tank weldment is to be replaced, proceed with step 15 for removal of all parts.

15. Remove all fittings from strainers and diffusers.

16. Remove diffuser (19) and two diffusers (23).

4. Disconnect and label the Hydraulic Hose from fitting (3). This hose is connected to the Tandem Gear Pump Steer/Aux Assembly.

5. Disconnect and label the Hydraulic Hose from fitting (4). This hose is connected to the righthand Rotor Pump.

17. Remove four strainers (21) and one suction strainer (22).

18. Remove two bolts (24), fluid level gauge (25) and two rubber washers (26).

19. Remove fitting (30) from ball-valve (29).

6. Disconnect and label the Hydraulic Hose from the Priority Flow Divider Valve connected to fitting (6).

20. Remove bolt (27) and nut (28), then remove ball-valve (29).

7. Disconnect and label the Hydraulic Hose from the Relief Valve Return Flow connected to fitting (7).

NOTE: Items (32 through 37) are part of item (31).

8. Disconnect and label the Hydraulic Hose from the Brake Valve connected to fitting (8).

9. Disconnect and label the Hydraulic Hose from the Front Axle Case Drain connected to fitting (11).

10. Disconnect and label the Hydraulic Hose from the 2-speed Valve connected to fitting (12).

8-8

21. Remove cover (32).

22. Remove six bolts (33).

23. Remove filler neck (34), gasket (35), strainer (36), and gasket (37).

24. Remove two plugs (41).

25. Remove eighteen capscrews (38) and remove weldment cover (39) and gasket (40).

08/05

Section 8 HYDRAULICS

FIGURE 8-6. HYDRAULIC TANK ASSEMBLY COMPONENTS.

08/05

8-9

Section 8 HYDRAULICS INSTALLATION [See Figure 8-6].

NOTE: If the tank weldment is being replaced, proceed with step 1 for installation of all parts. If Hydraulic Tank Assembly with all parts already attached is being installed, proceed with step 17.

13. Install six capscrews (18) to secure Hydraulic Tank to machine frame. Three capscrews are located along each side of the Hydraulic Tank.

14. Torque capscrews to 95 ft•lbs (128 N•m) 15. Install diffuser (19) and two diffusers (23).

16. Install plug (42) in diffuser (23).

NOTE: Items (32 through 37) are part of subassembly (31).

1. Install two plugs (Figure 8-6 – 41) in cover weldment (39).

2. Apply adhesive sealant to the eighteen capscrews (38).

3. Install weldment cover (39) and gasket (40) and secure with eighteen capscrews (38).

17. Install fittings (14 and 17) on remaining two diffusers.

18. Install remaining fittings, (6-13, 15, 16 and 18) onto fitting (14).

19. Install four strainers (21) and one suction strainer (22).

20. Install fittings (1 through 5) in strainers as shown in Figure 8-6.

4. Torque capscrews (38) to 15 ft•lbs (20.3 N•m).

21. Attach hose from the travel pump to fitting (1).

5. Install gasket (37), strainer (36), and gasket (35).

6. Install filler neck (34) with locking tab toward front of tank.

22. Attach hose from Tandem Gear Pump Brake section to fitting (2) .

23. Connect hose from Tandem Gear Pump Aux/Steering section to fitting (3).

7. Install six bolts (33).

8. Install cover (32).

24. Connect hose from right-hand Rotor Pump to fitting (4).

9. Install ball-valve (29) and secure handle with capscrew (27) and locknut (28).

25. Connect remaining Hydraulic Hoses to Hydraulic Tank Assembly.

10. Install fitting (30) in ball-valve (29).

11. Install fluid level gauge (25) with two bolts (24) and two rubber washers (26). Lubricate washers (26) before installing.

NOTE: Do not over tighten bolts (24). These bolts are hollow and allow fluid to flow through fluid level gauge.

12. Torque bolts (24) to 5.8 ft•lbs (7.9 N•m).

8-10

08/05

Section 8 HYDRAULICS HYDRAULIC DRIVE TRAVEL SYSTEM [See Figure 8-7].

The Hydraulic Drive Travel system consists of the following main components: Travel Charge Filter Assembly Travel Motor Assemblies Travel Pump Assembly

The rear axle uses travel motors on the left and right planetary drive assemblies. The MPH 364 uses travel motors on the left and right front drive axle.

The flow output to the front and rear travel motor assembly is supplied through a Tee connector. The Travel Charge Filter is connected to ports “D” and “E” on the Travel Pump Assembly. The hydraulic oil flows out of port “D” to the Travel Charge Filter. The return filtered oil flows into port “E”.

FIGURE 8-7. HYDRAULIC DRIVE TRAVEL SYSTEM.

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8-11

Section 8 HYDRAULICS TRAVEL CHARGE FILTER ASSEMBLY.

1. Install fittings (Figure 8-8 – 1 and 2) on filter being sure not to damage the O-rings.

The Travel Charge Filter Assembly is connected to the Travel Pump Assembly at ports “D” and “E”. The filter is located on the left side of the machine, attached to the frame under the cockpit.

Replacement of the filter element is covered in Section 4 - MAINTENANCE. If it is necessary to remove the complete filter assembly, refer to REMOVAL below:

Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all vertical cylinders, discharge any accumulators, and block any load whose movement could generate pressure.

REMOVAL [See Figure 8-8].

NOTE: Plug and cap all lines and ports to prevent entry of dirt into the system.

1. Place a container under the Filter Assembly (See Figure 8-7) to catch any oil when the hydraulic lines are disconnected.

2. Disconnect and label the hydraulic lines from the Filter Assembly.

3. Disconnect the electrical wires from the Filter Assembly.

4. Remove the four capscrews (Figure 8-8 – 3), and four washers (4) attaching the Filter Assembly to the frame and remove the Filter Assembly.

FIGURE 8-8. TRAVEL CHARGE FILTER ASSEMBLY. 2. Install sensor in Filter Assembly.

3. Position the Filter Assembly on underside of frame with flow arrows on filter pointing toward rear of machine and align mounting holes.

4. Apply threadlock to the four capscrews (3).

5. Remove fittings (1 and 2) from the filter.

5. Secure Filter Assembly to frame with the four capscrews (3) and four washers (4).

6. Inspect fittings and discard any fitting that is damaged.

6. Torque capscrews (3) to 44 ft•lbs (59.6 N•m).

7. Remove sensor from the Filter Assembly.

INSTALLATION [See Figure 8-8].

NOTE: Use new O-rings when installing fittings.

8-12

NOTE: Hydraulic hoses should be positioned at a 30° angle from the horizontal.

7. Connect the hydraulic lines from Port “D” on Travel Pump to fitting (2) on Filter Assembly.

08/05

Section 8 HYDRAULICS 8. Connect the hydraulic lines from Port â&#x20AC;&#x153;Eâ&#x20AC;? on Travel Pump to fitting (6) on Filter Assembly.

9. Connect the electrical wire to the Filter Assembly.

10. Add hydraulic oil, if required.

TRAVEL MOTORS. The MPH 362 uses two Travel Motors to drive the rear wheels. The MPH 364 has two additional Travel Motors to drive the front wheels.

REAR TRAVEL MOTOR. FIGURE 8-9. REAR AXLE ASSEMBLY. Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all vertical cylinders, discharge any accumulators, and block any load whose movement could generate pressure.

REMOVAL [See Figures 8-9, 8-10, and 8-11].

NOTE: Plug and cap all lines and ports to prevent entry of dirt into the system.

1. Place blocks in front of and in back of the front wheels.

2. Support the machine with appropriate support stands raising the wheels slightly off the ground.

5. Remove the axle cover, exposing the rear travel motor.

6. Thoroughly clean the travel motor, especially the area surrounding the hydraulic fittings.

7. Release the hydraulic and brake fluid pressure.

8. Drain the hydraulic and brake lines.

9. Disconnect the wiring harness at the travel motor connector.

10. Disconnect the brake hose (Figure 8-10 - 4) from the fitting on the gearbox.

7

4

1, 2

Support the machine with approved jack stands. Do not work underneath a raised vehicle without proper support.

3. Using the information in Section 10 - REAR DRIVE AXLE ASSEMBLY, FRONT STEERING AXLE ASSEMBLY, WHEEL AND TIRES, remove the tire and wheel assembly.

4. Remove two capscrews (Figure 8-9 - 1) and two washers (2) from the axle cover (3).

5

3

6

FIGURE 8-10. REAR TRAVEL MOTOR.

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8-13

Section 8 HYDRAULICS 11. Disconnect and label the flange halfs at ports A (5) and B (6) on the travel motor. Immediately plug the hose and motor ports to prevent contamination.

3. Remove the installed wheel bolt (7) that was secured to the lifting device.

4. Using labels created during removal, connect the case drain hose at the gearbox fitting (3).

5. Install a new o-ring on hoses for travel motor ports A (5) and B (6). Using labels created during removal, remove plugs and position hoses in ports A (5) and B (6). Secure hoses with flanges halfs.

6. Connect the brake hose (4) to the fitting on the gearbox.

7. Connect the wiring harness to the travel motor connector.

FIGURE 8-11. REAR GEARBOX. 12. Disconnect the case drain hose (3) at the travel motor fitting. Immediately plug the hose and motor port to prevent contamination.

13. Insert a previously removed wheel bolt (7) into the empty bolt hole at the 12 o’clock position on the tire assembly.

14. Secure a lifting device to the wheel bolt (7) and secure the assembly.

The travel motor weighs more than 500 pounds. Use a lifting device to support the travel motor.

15. Use a lifting device to support the travel motor assembly. Remove 17 capscrews (1) and washers (2) and then remove the travel motor and gearbox assembly.

8. Position the axle cover (Figure 8-9 - 3) on the axle and over the travel motor. Secure the cover with two washers (2) and capscrews (1).

9. Using information in Section 4 MAINTENANCE, replace hydraulic filter.

10. Add hydraulic oil as needed.

11. Using information in Section 10 - REAR DRIVE AXLE ASSEMBLY, FRONT AXLE ASSEMBLY, WHEEL AND TIRES, remove the tire and wheel assembly.

12. Perform a pressure check on the system as described in the paragraph INSPECTION AND PRESSURE CHECK PROCEDURE at the end of this chapter.

NOTE: The travel motor and gearbox must be removed as an assembly.

INSTALLATION [See Figures 8-9, 8-10, and 8-11].

1. Position the travel motor and gearbox assembly so it is within the axle assembly. Secure with 17 capscrews (Figure 8-10 - 1) and washers (2).

Tighten capscrews to 110 ft.•lbs. (149 N•m) torque.

2. Remove the lifting device from the assembly.

8-14

08/05

Section 8 HYDRAULICS FRONT TRAVEL MOTORS.

Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all vertical cylinders, discharge any accumulators, and block any load whose movement could generate pressure.

5. Disconnect and label hydraulic lines from port L (4) and R (5) on the travel motors. Immediately plug the hoses and drive motor ports to prevent contamination.

6. Disconnect and label the case drain hose from the travel motor assembly.

7. Use a lifting device to support the gearbox and drive motor assembly.

REMOVAL [See Figure 8-12].

1. Place blocks in front of and behind rear wheels.

2. Using the information in Section 10 - REAR DRIVE AXLE ASSEMBLY, FRONT STEERING AXLE ASSEMBLY, WHEEL AND TIRES, remove the tire and wheel assembly.

Support the machine with approved jack stands. Do not work underneath a raised vehicle without proper support.

3. Thoroughly clean the travel motor, especially the area surrounding the hydraulic fittings.

The travel motor and gearbox assembly weighs over 225 pounds. Use a lifting device to support the gearbox and travel motor during removal.

8. Remove eight capscrews and washers (6) from the gearbox mounting.

9. Remove the gearbox and travel motor assembly and place on the floor or a sturdy workbench.

10. If replacing the travel motor remove the hydraulic fittings from the travel motor and install on replacement motor.

INSTALLATION [See Figure 8-12].

4. Remove two capscrews, washers, and clamp (Figure 8-12 - 1) from the axle assembly.

Remove rubber packing (2) and (3) from around the hydraulic tubes.

1. Using a lifting device, position the travel motor and gearbox assembly in the front axle mounting (Figure 8-12). Secure the assembly with eight capscrews and washers (6). Tighten the capscrews to 426 ft.â&#x20AC;˘lbs. (577 Nâ&#x20AC;˘m) torque.

2. Using label created during removal, remove plugs and connect case drain hose at the travel motor.

3. Assemble the tubing clamps on ports L (4) and R (5). Align the hydraulic lines using labels created during removal. Connect the hydraulic lines at ports L (4) and R (5).

4. Install rubber packing (2) and (3) around the hydraulic tubes and secure with clamp and two capscrews with washers.

5. Using the information in Section 10 - REAR DRIVE AXLE ASSEMBLY, FRONT STEERING AXLE ASSEMBLY, WHEEL AND TIRES, install the tire and wheel assembly.

FIGURE 8-12. FRONT TRAVEL MOTOR. 08/05

8-15

Section 8 HYDRAULICS TRAVEL PUMP ASSEMBLY [See Figure 8-13].

The Travel Pump Assembly is mounted on the Rotor Pump Assembly that is attached to the Engine Drive Shaft. The MPH 362 has an output fitting arrangement that provides hydraulic oil flow to the Rear Axle Travel Motors only. The MPH 364 has a tee output fitting arrangement which provides a split hydraulic oil flow to both the Rear Axle and the Front Axle travel motors.

Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all vertical cylinders, discharge any accumulators, and block any load whose movement could generate pressure.

2. Place a container under the Travel Pump Assembly to catch any oil when the hydraulic lines are disconnected.

3. Label and disconnect the hydraulic hoses going to the Rear Travel Motors connected to fitting (Figure 8-12 - 1) and (15).

4. On MPH 364 only, label and disconnect the hydraulic hose going to the Front Travel Motors connected to fitting (1) and (15).

5. Label and disconnect the hydraulic hoses going to fittings (2) through (6). Immediately plug hoses and cap Travel Pump ports.

The travel pump assembly weighs over 100 pounds. Support the travel pump assembly before removing the mounting screws.

REMOVAL [See Figure 8-14].

NOTE: Plug and cap all lines and ports to prevent entry of dirt into the system.

1. Thoroughly clean the Travel Pump especially the area surrounding the hydraulic fittings.

6. Support the Travel Pump Assembly, then remove the four capscrews (7) and hardened washers (8).

7. Lift the Travel Pump Assembly out of the machine and remove the O-ring between the Travel Pump and Rotor Pump Assemblies.

FIGURE 8-13. TRAVEL PUMP ASSEMBLY. 8-16

08/05

Section 8 HYDRAULICS INSTALLATION [See Figure 8-14].

When a new Travel Pump is to be installed, fittings need to be installed on the Travel Pump. Proceed with step 1 to install fittings. If the same Travel Pump is being reinstalled, check that all fittings are in place, then proceed with step 7.

in place with clamps (10), capscrews (11) and lockwashers (12). Connector (1) should be positioned so that it is pointing up at 45° to the horizontal. Repeat for identical fitting (15) at port “B” on other side of Travel Pump Assembly.

2. Torque capscrews (11) to 52 ft•lbs (70.5 N•m).

1. Lubricate O-ring (Figure 8-12 - 9), then install O-ring (9) with fitting (1) into port “A” and secure

FIGURE 8-14. TRAVEL PUMP ASSEMBLY.

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8-17

Section 8 HYDRAULICS 3. Install fitting (2) in port “L2”. Fitting (2) should be positioned so that it is pointing up at 45° to the horizontal.

4. Install fittings (3) through (5) into their respective ports.

5. Install O-ring and tee fitting (14) on top of the Travel Pump Assembly.

12. On MPH 364, remove plugs and caps, and connect the hydraulic hose from the Front Travel Motors to fitting (1) at port “A” and fitting (15) at port “B”.

13. Remove plugs and caps and connect the hydraulic hoses to fittings (2) through (6).

14. Using information in Section 4 MAINTENANCE, replace the hydraulic filter.

6. Install fitting (6) and test coupling (13).

15. Add hydraulic oil as needed.

The Travel Pump Assembly weighs over 100 pounds. Use a proper lifting device when installing the Travel Pump Assembly into the machine.

NOTE: A new Rotor Pump is provided with a cover that has an O-ring between the cover and the Rotor Pump Housing.

When the cover is removed to install the Travel Pump Assembly, this O-ring must be retained and is used between the Rotor Pump Housing and the Travel Pump Housing.

7. Lubricate, then reinstall O-ring (provided with Rotor Pump Cover), between the Rotor Pump and Travel Pump.

8. Lift the Travel Pump and engage the splined input shaft to the Rotor Pump Coupling. Align the four mounting holes on the Travel Pump with the four mounting holes on the Rotor Pump Assembly.

9. Attach the Travel Pump Assembly to the Rotor Pump Assembly with the four capscrews (7) and hardened washers (8).

10. Torque the four capscrews (7) to 100 ft.•lbs.

(135.6 N•m).

11. Remove plugs and caps, and connect the hydraulic hose from to the Rear Travel Motors to fitting (1) at port “A” and fitting (15) at port “B”.

8-18

16. Perform a pressure check on the system as described in the paragraph INSPECTION AND PRESSURE CHECK PROCEDURE at the end of this chapter.

INSPECTION AND PRESSURE CHECK PROCEDURE. The Load Control Unit (LCU) board referred to in the following procedures is located on the Electrical Panel Assembly on the right side of the Instrument Panel Assembly as shown in Figure 8-13.

1. Warm up the engine, run at idle speed of 8001000 for 5 minutes.

2. Adjust engine speed (measure off crankshaft only): Low idle: 850-900 rpm High idle (no load): 2300 +0/-25 rpm High idle (full load): 2150 rpm (nonadjustable) 3. In order to warm up the unit to operating temperature (step 4), the rotor speed II must be initially adjusted for full speed of 180 rpm. For rotor pressure adjustment (step 7), the rotor speed I must be initially adjusted for 40-60 rpm.

This procedure is for temporary adjustment only.

See rotor speed (step 8) for final adjustments. a. Turn the RAMP, MIN, and MAX potentiometers (pots) located on the LCU board CCW all the way. These are 10 turn pots so listen carefully for the quiet clicking sound to indicate when the pot is all the way CCW.

08/05

Section 8 HYDRAULICS b. Start the engine, raise the throttle to FULL, switch to rotor speed II, and turn the rotor ON. The two red lights on the LCU board should be ON. c.

Turn the MIN and MAX pots CW about 3 full turns or until the rotor begins to turn. Switch the rotor speed between I and II. The rotor should turn in both speeds (0-30 rpm).

4. Warm unit to operating temperature. With throttle at FULL, run rotor at full speed (rotor speed II) for 10 minutes. Stop rotor and lower rotor to the ground and lift the rear wheels. With 4WD switch (MPH364 only) in the OFF position, run travel in forward and reverse for a total of 15 minutes. Raise rotor to full up position and again run at full speed (rotor speed II) for 10 minutes. Unit should now be at operating temperature. The hydraulic gauge on the dash or a temperature probe in the case manifold should read at least 125°F (51.7°C).

NOTE: The thermal bypass valves begin to open at 120°F (48.9°C) and are fully shifted to full cooler flow at 145°F (62.8°C). Maintain these temperatures through all of the tests.

5. Install a 100 psi gauge on the test port on the case manifold (RHS under cockpit floorplate, right in front of the hydraulic tank). Record case pressure at high idle. Typically this is 10 psi. All of the following charge pressures are based on 10 psi case pressure.

6. Travel System: Install 7500 psi gauges on A and B test ports on rear travel motors. Note that there is a forward pressure gauge on the dash.

Install a 600 psi gauge on the charge pressure test port on pump (back of remote filter port).

All pressures are at full throttle unless listed.

Travel charge pressure: 350 psi minimum (340 psi + case) at high idle, pump in neutral 425 psi (415 psi + case) at high idle cold, pump in neutral 300 psi minimum (290 psi + case) at Iow idle, pump stroked, brakes released and wheels turning a. To test forward and reverse: shift to LOW gear, turn 4WD to OFF position (MPH 364 only), put brake switch in OFF position, disconnect both Hirshmann connectors C21 (BLACK) and C22 (GREY) to lock brakes on. Move FNR and drive slowly against brake.

Travel Forward (A)/Reverse (B): 6000 +/- 100 psi at high idle Front assist (4WD) case flushing (MPH364 only): 2-3 gpm to AXLE @ temperature (non-adjustable) 7. Rotor System: Install a 7500 psi gauge on the pump high pressure test port “A”. Note that there is a rotor high pressure gauge on the dash. Install a 3000 psi gauge on the pump Iow pressure test port “B”. Install a 600 psi gauge on the charge pressure test port on the pump (back of remote filter port).

All pressures are at full throttle unless listed.

Unit must be at temperature listed in warm up procedure (step 4). Follow procedure only (see steps 3 and 4). Use rotor speed I at 40-60 rpm minimum for testing. On the rotor loop flushing valve, turn the adjusting screw on the relief cartridge clockwise (CW) all the way so there is no loop flushing flow.

Rotor charge pressure (pump in neutral): 425 ±10 psi (415 psi + case) at high idle.

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8-19

Section 8 HYDRAULICS Rotor Forward (digging drive pressure): 5000 ±100 psi (pump stroked, rotor chained, and at high idle). Pump-port “A”.

Rotor Reverse (stopping pressure): 2300 +0/-1000 psi No adjustment required as pump is preset by manufacturer. Pump-port “B”.

Rotor charge pressure flushing (pumps stroked, rotor not chained, free wheeling, and at high idle): 400 psi (390 psi + case) with 6-7 gpm loop flushing OR approximately 20-30 psi less than neutral. Pressure measured at pump charge pressure test port. Flow measured in drain hose between flushing manifold and tank manifold. Must use a 15 gpm flow meter for this step.

Verify Iow rotor charge pressure switch: 200 psi decreasing (non-adjustable).

Rotor motor case flushing: 1.8 gpm per motor (COLD). This is nonadjustable.

8. Rotor Speeds: These are measured with a tack pickup or strobe only!

I speed - 162 ±4 rpm (no load high idle) II speed = 180 +0/-4 rpm (no load high idle, full pump stroke) NOTE: Actual digging speeds with engine at full load are 135 and 150 rpm. These are not used for rotor speed adjustment. a. Turn the RAMP, MIN, and MAX potentiometers (pots) located on the LCU board CCW all the way. These are 10 turn pots so listen carefully for the quiet clicking sound to indicate when the pot is all the way CCW.

c.

Turn the MIN and MAX pots CW about 3 full turns or until the rotor begins to turn. Switch the rotor speed between I and II. The rotor should turn in both speeds (0-30 rpm).

d. Switch between I and II and note the rotor speeds. Rotor speed II should be higher than rotor speed I (example I = 40 rpm and II = 75 rpm). e. Turn the RAMP pot on the LCU board CW all the way. This is a 10 turn pot so listen carefully for the quiet clicking sound to indicate when the pot is all the way CW. f.

Apply red sealant to all 3 pots to indicate they are factory set.

9. Travel Speed Adjustment: On the rear travel motors, turn the displacement limiter out 4 turns (CCW) to increase travel speed. Turn 4WD OFF (MPH 364 only) and check the travel speed in HIGH gear for 10.50 ±0.25 mph.

10. Steering/Aux System (all pressures at 1500 rpm engine speed): a. Install a 3000 psi gauge on the test port at the inlet to the L.S. priority valve (LHS of unit to the rear of the LH engine mount).

Steering pressure: 2000 ±100 psi Auxiliary pressure (rotor lift and door control spool valve): 1500 ±25 psi b. Install 3000 psi gauges on the two (2) test ports at the rotor lift counterbalance valves (LHS of unit, at the rear, under the hydraulic tank).

Rotor lift counterbalance valves: 1500 psi (both should read the same pressure)

b. Start the engine, raise the throttle to FULL, switch to rotor speed II, and turn the rotor ON. The two red lights on the LCU board should be ON.

8-20

08/05

Section 8 HYDRAULICS 11. Brake Release System: Install a 3000 psi gauge on the test port at the inlet to the brake valve (RHS under the cockpit floorplate, right in front of the hydraulic tank).

Brake pressure: 1600 ±100 psi (Iow and high idle, cold or hot, pressures must remain in the ±100 psi range) Verify brake Iow pressure switch: 1300 psi decreasing (non-adjustable) 12. Tire Pressure: 35 psi front and rear 13. Depth of Cut: MPH 362/MPH 364 R (recycler) = 12” (304.8 mm) MPH 362/MPH 364 S (stabilizer) = 14” (355.6 mm) MPH362/MPH 364 S-DM (deep mix stabilizer) = 21” (533.4 mm) 14. Speedometer: 15 ±2 fpm and 50 ±4 fpm (check accuracy, gauge is non-adjustable, sensor gap is adjustable).

15. Tachometer: 2100 ±10 rpm and 2300 ±10 rpm (check accuracy, gauge is non-adjustable, sensor gap is adjustable).

16. Hydraulic Oil Sample: ISO 18/13 particle count or better.

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8-21

Section 8 HYDRAULICS

FIGURE 8-15. ELECTRICAL PANEL ASSEMBLY. 8-22

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Section 9 AUXILIARY HYDRAULICS TABLE OF CONTENTS PAGE GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2 CLEANLINESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2 COUNTERBALANCE VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5 AUXILIARY FUNCTION(S) - DOUBLE SPOOL VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6 ROTOR LIFT CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-8 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-9 SEAL REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-9 ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-9 REAR DOOR CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-12 SEAL REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-12 ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-13 AUXILIARY HYDRAULICS PRESSURE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-14

08/05

9-1

Section 9 AUXILIARY HYDRAULICS GENERAL INFORMATION.

CLEANLINESS.

This section describes the Auxiliary Hydraulics used on the BOMAG models MPH 362-2 and MPH 364-2 Recycler and Stabilizer. Procedures are included for removal and replacement of the Counterbalance Valve Assembly, Double Spool Valve Assembly, Rotor Lift Cylinder, Rear Door (Tailgate) Cylinder, and Front Door Cylinder.

When servicing the Hydraulic System, it is very important to do the following:

Figure 9-1 shows the location of the Auxiliary Hydraulic components for both models. Figure 9-2 is the Auxiliary Hydraulic Schematic for both models

1. Clean surfaces, fittings, and hoses at the point of disconnection.

2. Protect all exposed sealing surfaces from damage and foreign material.

3. All gaskets and O-rings should be replaced.

4. Lightly lubricate all O-rings with hydraulic oil prior to assembly.

5. Whenever a hose is disconnected immediately cap the fitting and plug the hose to prevent contamination.

9-2

08/05

Section 9 AUXILIARY HYDRAULICS

FIGURE 9-1. AUXILIARY HYDRAULICS OVERVIEW.

08/05

9-3

Section 9 AUXILIARY HYDRAULICS

FIGURE 9-2. AUXILIARY HYDRAULICS SCHEMATIC MPH 362-2 AND MPH 364-2.

9-4

08/05

Section 9 AUXILIARY HYDRAULICS COUNTERBALANCE VALVE. The Counterbalance Valve is mounted on the right side of the frame near the Spool Valves. The Counterbalance Valve controls the flow of hydraulic oil to the hydraulic cylinders used to set the depth of the rotor. Port “C2” is connected to the rod end of the cylinders (rotor down) and port “C1” is connected to the piston end of cylinders (rotor up).

Hydraulic oil from port “A” on the rotor section of the Spool Valve is applied to input port “V1”. Hydraulic oil from port “B” on the rotor section of the Spool Valve is applied to input port “V2”.

REMOVAL [See Figure 9-3].

Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all Vertical Cylinders, discharge any Accumulators, and block any load whose movement could generate pressure.

INSTALLATION [See Figure 9-3].

NOTE: Replace all O-rings when installing fittings.

1. Install fittings (Figure 9-3 – 1 through 12) in Counterbalance Valve Assembly. Be sure fittings (1, 4, and 9) are positioned at 45°, and fitting (2) is positioned at 30°.

2. Attach the Counterbalance Valve to the frame with the two capscrews (13), and two washers (14).

3. Torque the capscrews (13) to 12 ft•lbs (16 N•m).

NOTE: A container should be placed under the Counterbalance Valve to catch any oil when the hydraulic lines are reconnected.

4. Connect the four hydraulic lines to the Counterbalance Valve.

5. Add hydraulic oil, if necessary.

NOTE: Plug and cap all lines and ports to prevent entry of dirt into the system.

1. Place a container under the Counterbalance Valve to catch any oil when the hydraulic lines are disconnected.

6. Perform an Auxiliary Hydraulics Pressure Check as described in the paragraph AUXILIARY HYDRAULICS PRESSURE CHECKS.

2. Disconnect and label all hydraulic lines attached to the Counterbalance Valve.

3. Remove the two capscrews (Figure 9-3 – 13) and washers (14) securing the Counterbalance Valve to left side of the frame.

4. Remove all fittings (1 through 12).

FIGURE 9-3. COUNTERBALANCE VALVE.

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9-5

Section 9 AUXILIARY HYDRAULICS AUXILIARY FUNCTION(S) - DOUBLE SPOOL VALVE.

3. Disconnect and label all hydraulic lines connected to the Valve Assembly.

The solenoid-operated Double Spool Valve Assembly (Figure 9-4) is located on the lower frame in front of the operator’s platform. One section of the Spool Valve Assembly controls the up/down movement of the Rotor. The other section controls the opening and closing of the Rear (Tailgate) Door.

4. Remove the two capscrews (2) securing the right side of the Valve Assembly to the frame.

Hydraulic oil from port “EF” on the priority Flow Divider Valve Assembly is applied at port “P”. Pilot pressure from port “M3” on the Travel Pump Assembly is applied at port “X”. Hydraulic oil from port “T” is routed to the Steering/Auxiliary Filter inlet then returned to the Hydraulic Tank. Ports “A” and “B” on the two valve sections are connected as follows:

5. Remove the capscrew (3), washer (4) and locknut (5) securing the left side of the Valve Assembly to the frame, then remove Valve Assembly.

INSTALLATION [SEE FIGURE 9-4].

NOTE: REPLACE ALL O-RINGS WHEN INSTALLING FITTINGS. 1. Install new fittings in Double Spool Valve Assembly.

Rotor port “A”

To bottom of Counterbalance Valve Port “V1” (Rotor Up)

2. Align the Valve Assembly with the mounting holes on the frame.

Rotor port “B”

To top of Counterbalance Valve Port “V2” (Rotor Down)

Rear Door port “A”

To piston end of cylinder (Closes Door)

3. Coat capscrews (Figure 9-4 – 2 and 3) with threadlock, p.n. 0318702, and secure the right side of the Valve Assembly to frame with capscrews (2).

Rear Door port “B”

To rod end of cylinder (Opens Door)

All solenoids operate from 24 VDC.

4. Install capscrew (3), washer (4) and flanged locknut (5).

5. Torque the capscrews (2) and (3) to 44 ft•lbs (59.6 N•m).

REMOVAL [See Figure 9-4].

Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all Vertical Cylinders, discharge any Accumulators, and block any load whose movement could generate pressure.

NOTE: Plug and cap all lines and ports to prevent entry of dirt into the system.

NOTE: A container should be placed under the Valve Assembly to catch any oil when the hydraulic lines are reconnected.

6. Connect all hydraulic lines to the Valve Assembly.

7. Connect electrical wires to the solenoids.

8. Add hydraulic oil, if necessary.

9. Perform an Auxiliary Hydraulics Pressure Check as described in the paragraph AUXILIARY HYDRAULICS PRESSURE CHECKS.

1. Label and disconnect wire from the four solenoids (Figure 9-4 – 1).

2. Place a container under the Double Spool Valve Assembly to catch any oil when the hydraulic lines are disconnected.

9-6

08/05

Section 9 AUXILIARY HYDRAULICS

FIGURE 9-4. AUXILIARY FUNCTION(S) - DOUBLE SPOOL VALVE. ROTOR LIFT CYLINDER. The two 5 inch bore Rotor Lift Cylinders are mounted on the rear of the machine. One end is attached to the machine frame and the other end is attached to the rotor support. The Spool Valve Assembly controls operation of the cylinder. When the piston extends, the rotor is moved up, and when the piston is retracted, the rotor is moved down.

Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all vertical cylinders, discharge any accumulators, and block any load whose movement could generate pressure.

REMOVAL [See Figure 9-5].

NOTE: Plug and cap all lines and ports when disconnected to prevent entry of dirt into the system.

1. Place a container under the cylinder to catch any hydraulic oil when the lines are disconnected.

2. Disconnect and label the two hoses connected to fittings (Figure 9-5 â&#x20AC;&#x201C; 1 and â&#x20AC;&#x201C; 2).

Rotor lift cylinder(s) weigh in excess of 100 lbs. and will require auxiliary support for removal/installation.

3. Remove the pivot bolt (3), spacer (4) and nut (5), securing cylinder to frame.

4. Remove the pivot bolt (6), and nut (7), securing cylinder to rotor support.

5. Remove cylinder from machine.

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9-7

Section 9 AUXILIARY HYDRAULICS INSTALLATION [See Figure 9-5].

1. Install fittings (1 and 2) on rotor cylinder(s).

2. Install lubrication fitting (8) in end of pivot bolts (3 and 6).

NOTE: During reassembly, always use new nuts (5) and (7) and discard previously used nuts.

3. Insert barrel end of cylinder into frame support and attach cylinder with pivot bolt (3) spacer (4) and nut (5). Nut (3) and spacer (4) should be on outside of frame. Tighten nut (5) to attain solid contact between the frame and the washer face of the nut.

4. Insert rod end of cylinder into rotor support and attach cylinder with pivot bolt (6) and nut (7).

Nut (7) should be on outside of support. Tighten nut (7) to attain solid contact between the frame and the washer face of the nut. Set torque at 250 ft. lbs. (338 Nâ&#x20AC;˘m).

5. Connect the two hydraulic hoses.

6. Add hydraulic oil, if necessary.

7. Perform an Auxiliary Hydraulics Pressure Check as described in the paragraph AUXILIARY HYDRAULICS PRESSURE CHECKS.

FIGURE 9-5. ROTOR LIFT CYLINDER.

9-8

08/05

Section 9 AUXILIARY HYDRAULICS DISASSEMBLY [See Figure 9-6].

1. When servicing a cylinder, clamp it in a softjawed vise with a cloth between the jaws and part being clamped. Clamp on the nut on the end of a rod or the outer ear of the cylinder.

NOTE: Never use a vise to clamp on the cylinder barrel or on the cylinder rod-sealing surface. The surface or internal components could be damaged.

2. Use a spanner wrench to remove the cylinder packing head (Figure 9-6 – 10).

3. Remove the packing head (10), piston (5), and piston rod (7) as one unit.

4. Remove the piston (5) from the piston rod (7) using a spanner wrench. Remove the packing head (10).

SEAL REMOVAL AND INSTALLATION [See Figure 9-6].

1. Note the location and direction of the seals during the removal process. Before removing any seal, be sure there is a matching seal in the seal kit for each seal removed from the cylinder.

The seals removed should be nearly identical in terms of overall dimensions, however, the substitute seals may have different material, color or lip design.

2. Place the packing head (9-6 – 10) in a softjawed vise with a cloth inserted between the jaws and the packing head. Do not clamp on any threads. Remove rod wiper (8), rod seal (9), backup ring (11), and O-ring (12).

3. Inspect the packing head (10) grooves for nicks, burrs, scratches and rust. Minor nicks, burrs, scratches and rust can be removed with an emery cloth or approved solvent. If the deformity cannot be removed, replace the damaged packing head. Be sure to check the packing head threads to verify that they are not damaged.

Remove all forms of contamination from the packing head with a clean cloth before the new seals are installed.

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4. Install the new rod seal (9) into the packing head (10). Form the rod seal into a kidney shape and press the seal carefully into the groove. Snap the wear rings into place while making sure that they have a proper fit.

5. Turn the packing head over. Install the rod wiper (8) by forming the rod wiper into a kidney shape and pressing it into the groove.

6. Install the back-up ring (11) and O-ring (12) carefully over the threads of the packing head.

7. Place the piston (5) in a soft-jawed vise with a cloth inserted between the jaws and the piston.

Pry up the piston seals (3) and remove them.

8. Remove O-ring (6).

Do not scratch the seal groove.

9. Inspect the piston grooves for nicks, burrs, scratches, dirt or rust. Minor imperfections may be removed with an emery cloth or an approved solvent. Make sure that the piston threads have not been damaged. Remove all forms of contamination from the piston by using a clean cloth before the new seals are installed.

10. Install the piston seals (3) and O-ring (6).

ASSEMBLY [See Figure 9-6].

1. Double-check all components to make sure they are all free of contamination.

2. Lightly lubricate the inside diameter of the packing head (9-6 – 10) with hydraulic fluid. Slide the packing head (10) carefully onto the piston rod (7).

3. Install the piston (5) onto the piston rod (7) and secure the piston (5) in place with a setscrew (4).

9-9

Section 9 AUXILIARY HYDRAULICS 4. Clamp the cylinder in a soft-jawed vise by gripping an outer ear of the cylinder barrel or the pivot on the Piston Rod Assembly. Lightly lubricate the outside diameter of the piston (5), packing head (10) threads, and threads on the inside diameter of the cylinder wall with hydraulic fluid.

5. While being extremely careful to not damage the piston seals, load the piston (5), piston rod (7) and packing head (10) as one unit. Screw on the packing head while being cautious when tightening the O-ring (12) and back-up ring (11) against the Cylinder Barrel Assembly.

6. Torque the packing head to 250 to 300 ftâ&#x20AC;˘lbs (338.9 to 406.7 Nâ&#x20AC;˘m).

FIGURE 9-6. ROTOR LIFT CYLINDER.

9-10

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Section 9 AUXILIARY HYDRAULICS REAR DOOR CYLINDER. The Rear Door (Tailgate) Cylinder is mounted on the top rear of the hood. One end is attached to the hood and the other end is attached to the rear door.

The auxiliary function(s) Spool Valve Assembly controls operation of the cylinder. When the piston extends, the door is closed, and when the piston is retracted, the door is opened.

Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all vertical cylinders, discharge any accumulators, and block any load whose movement could generate pressure.

REMOVAL [See Figure 9-7].

NOTE: Plug and cap all lines and ports when disconnected to prevent entry of dirt into the system.

1. Place a container under the cylinder to catch any hydraulic oil when the lines are disconnected.

2. Disconnect and label the two hoses connected to fittings (Figure 9-7 – 1 and 2).

3. Remove the locknuts (3), and capscrews (4), securing cylinder to the hood and to the rear door.

4. Remove cylinder from machine.

INSTALLATION [See Figure 9-7].

1. Install fittings (Figure 9-7 – 1 and 2) on rear door cylinder.

2. Coat two capscrews (4) with threadlock, p.n.

0318702.

3. Insert piston end of cylinder into door bracket and attach cylinder with capscrew (4) and nut (3).

4. Insert cylinder end of cylinder into hood bracket and attach cylinder with capscrew (4) and locknut (3).

5. Torque the capscrews (4) to 200 ft•lbs (270 N•m).

6. Lubricate mounting hardware.

7. Connect the two hydraulic hoses.

8. Add hydraulic oil, if necessary.

9. Perform an Auxiliary Hydraulics Pressure Check as described in the paragraph AUXILIARY HYDRAULICS PRESSURE CHECKS.

FIGURE 9-7. REAR DOOR CYLINDER. 08/05

9-11

Section 9 AUXILIARY HYDRAULICS DISASSEMBLY [See Figure 9-8].

1. When servicing a cylinder, clamp it in a softjawed vise with a cloth between the jaws and part being clamped. Clamp on the nut on the end of a rod or the outer ear of the cylinder.

NOTE: Never use a vise to clamp on the cylinder barrel or on the cylinder rod-sealing surface. The surface or internal components could be damaged.

2. Use a spanner wrench to remove the cylinder packing head (Figure 9-8 â&#x20AC;&#x201C; 9).

3. Remove the packing head (9), piston (3), and piston rod (11) as one unit.

4. Remove nut (2) from piston rod (11).

5. Remove the piston (3) from the piston rod (11).

Remove the packing head (9).

SEAL REMOVAL AND INSTALLATION [See Figure 9-8].

1. Note the location and direction of the seals during the removal process. Before removing any seal, be sure there is a matching seal in the seal kit for each seal removed from the cylinder.

The seals removed should be nearly identical in terms of overall dimensions, however, the substitute seals may have different material, color or lip design.

2. Place the packing head (Figure 9-8 â&#x20AC;&#x201C; 9) in a soft-jawed vise with a cloth inserted between the jaws and the packing head. Do not clamp on any threads. Remove rod seal (7), rod wiper (10), and O-ring (8).

3. Inspect the packing head (9) grooves for nicks, burrs, scratches and rust. Minor nicks, burrs, scratches and rust can be removed with an emery cloth or an approved solvent. If the deformity cannot be removed, replace the damaged packing head. Be sure to check the packing head threads to verify that they are not damaged. Remove all forms of contamination from the packing head with a clean cloth before the new seals are installed.

4. Install the new rod seal (7) into the packing head (9). Form the rod seal into a kidney shape and press the seal carefully into the groove.

Snap the wear rings into place while making sure that they have a proper fit.

5. Turn the packing head over. Install the rod wiper (10) by forming the rod wiper into a kidney shape and pressing it into the groove.

6. Install the O-ring (8) carefully over the threads of the packing head.

7. Place the piston (3) in a soft-jawed vise with a cloth inserted between the jaws and the piston.

Pry up the piston seals (4) and remove them.

8. Remove O-ring (5).

Do not scratch the seal groove.

9. Inspect the piston grooves for nicks, burrs, scratches, dirt or rust. Minor imperfections may be removed with an emery cloth or an approved solvent. Make sure that the piston threads have not been damaged. Remove all forms of contamination from the piston by using a clean cloth before the new seals are installed.

10. Install the piston seals (4) and O-ring (5).

9-12

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Section 9 AUXILIARY HYDRAULICS ASSEMBLY [See Figure 9-8].

1. Double-check all components to make sure they are all free of contamination.

2. Lightly lubricate the inside diameter of the packing head (Figure 9-8 – 9) with hydraulic fluid.

Slide the packing head (9) carefully onto the piston rod (11).

3. Install the piston (3) onto the piston rod (11) and secure the piston (3) in place with a nut (2).

4. Torque nut (2) to 65 to 75 ft•lbs (88.1 to 101.7 N•m).

5. Clamp the cylinder in a soft-jawed vise by gripping an outer ear of the cylinder barrel. Lightly lubricate the outside diameter of the piston (3), packing head (9) threads, and threads on the inside diameter of the cylinder barrel with hydraulic fluid.

6. While being extremely careful to not damage the piston seals, load the piston (3), piston rod (11) and packing head (9) as one unit. Screw on the packing head while being cautious when tightening the O-ring (8) against the Cylinder Barrel Assembly.

7. Torque the packing head to 250 to 300 ft•lbs (338.9 to 406.7 N•m).

FIGURE 9-8. REAR DOOR CYLINDER.

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9-13

Section 9 AUXILIARY HYDRAULICS AUXILIARY HYDRAULICS PRESSURE CHECKS. 1. Steering/Aux System (all pressures at 1500 rpm engine speed): NOTE: Unit must be fully warmed up before making pressure checks. a. Install a 3000 psi gauge on the test port at the inlet to the LS Priority Valve (left-hand side of unit to the rear of the left-hand engine mount).

Steering pressure: 2000 Âą100 psi Auxiliary pressure (rotor lift and door control spool valve: 1500 Âą25 psi) b. Install 3000 psi gauges on the two (2) test ports at the Rotor Lift Counterbalance valves (left-hand side of unit, at the rear, under the Hydraulic Tank).

Rotor Lift Counterbalance Valves: 1500 psi (both should read the same).

NOTE: Refer to Section 12, page 12-5, Figure 12-3. Item 9 is the test port location.

9-14

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Section 10 REAR DRIVE AXLE ASSEMBLY, FRONT STEERING AXLE ASSEMBLY, WHEELS AND TIRES TABLE OF CONTENTS PAGE GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2 CLEANLINESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2 REAR DRIVE AXLE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-5 FRONT STEERING AXLE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-6 WITHOUT FRONT WHEEL ASSIST [MPH 362]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-6 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-6 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-8 WITH FRONT WHEEL ASSIST [MPH 364-2]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-9 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-9 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11 WHEELS AND TIRES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-12 FRONT WHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-12 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-12 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-12 REAR WHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-13 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-13 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-13

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10-1

Section 10 REAR DRIVE AXLE ASSEMBLY, FRONT STEERING AXLE ASSEMBLY, WHEELS AND TIRES GENERAL. This section provides a description of the following system components:

5. Whenever a hose is disconnected, immediately cap the fitting and plug the hose to prevent contamination.

REAR DRIVE AXLE ASSEMBLY.

Rear Drive Axle Assembly Front Steering Axle Assembly Wheels and Tires CLEANLINESS. When servicing the hydraulic system, it is very important to do the following: 1. Clean surfaces, fittings, and hoses at the point of disconnection.

2. Protect all exposed sealing surfaces from damage and foreign material.

The Rear Axle Assembly includes the ASC Valve assembly, left and right gear boxes, left and right travel motors, and axle assembly. The axle is bolted to the rear of the frame.

Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all vertical cylinders, discharge any accumulators, and block any load whose movement could generate pressure.

3. All gaskets and O-rings should be replaced.

4. Lightly lubricate all O-rings with hydraulic oil prior to assembly.

FIGURE 10-1. REAR AXLE ASSEMBLY. 10-2

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Section 10 REAR DRIVE AXLE ASSEMBLY, FRONT STEERING AXLE ASSEMBLY, WHEELS AND TIRES REMOVAL [See Figures 10-1, 10-2, 10-3, and 10-4].

NOTE: Clean area wherever a line is to be opened, then plug and cap any open lines and ports to prevent entry of dirt into the system.

Rear axle weights over 2,050 lbs (930 Kilograms). Be sure axle is supported before removing attaching hardware.

1. Using information in Section 4 MAINTENANCE, drain the hydraulic tank.

2. Place wooden blocks in front of and in back of the front wheels.

9. Disconnect and label the hydraulic fitting at the tee mounted below the ASC valve (3). This hose connects to the traction pump port A. Immediately plug the hose and cap the tee to prevent contamination.

10. Disconnect and label the hydraulic fittings at port L2 (Figure 10-4 - 3) on both rear travel motors. These are case drain hoses that connect to the hydraulic return manifold.

Immediately plug the hoses and cap the travel motor ports to prevent contamination. Remove the hoses from the axle assembly.

11. Disconnect and label the hydraulic fitting at port X3 tee (Figure 10-2 - 4) on the ASC valve. This hose connects to the travel pump at port M3 and the brake valve at port P. Immediately plug the hose and cap the ASC port to prevent contamination.

3. Remove the rear wheels as described in the paragraph REAR WHEEL. 4. With the vehicle jacked up and wooden supports under the frame, support the rear axle on both sides.

5. Remove two capscrews and washers (Figure 10-1) attaching the axle covers to the axle assembly. Remove the covers.

6. Disconnect the hydraulic fittings at port X1 (Figure 10-4 - 4) on both rear travel motors.

These hoses connect to the two-speed selector valve. Immediately plug the hoses and motor ports to prevent contamination. Disconnect the hoses at the tee mounted below the ASC valve (Figure 10-2 - 1) and remove the hoses from the axle assembly.

7. Disconnect and label the flange half's and hydraulic hose at port P on the ASC valve (7).

This hose connects to the travel pump at port B. Immediately plug the hose and cap the ASC valve port to prevent contamination.

8. Disconnect and label the hydraulic fitting at port L on the ASC valve (8). This hose connects to the hydraulic return manifold. Immediately plug the hose and cap the ASC valve to prevent contamination.

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FIGURE 10-2. ASC VALVE. 12. Disconnect and label the wiring harness connectors at the ASC valve solenoids (5).

13. Disconnect and label the wiring harness connectors at both travel motors.

14. Remove wiring harness and hold down clamps from the axle assembly.

10-3

Section 10 REAR DRIVE AXLE ASSEMBLY, FRONT STEERING AXLE ASSEMBLY, WHEELS AND TIRES 15. Disconnect and label the hydraulic brake hoses (Figure 10-4 - 5) from the gearbox fittings.

Immediately plug the hoses and gearbox port to prevent contamination. Remove the hoses from the axle assembly.

17. Carefully lower the axle assembly to floor level.

16. Remove four capscrews (Figure 10-3 - 1), nuts (2) and washers (3) from both sides of the axle mounting.

NOTE: If rear axle is replaced, remove the ASC valve, hoses, and travel motors for mounting on the replacement axle.

18. Remove the spacer plates between the axle mounting plates (4) and the frame.

19. Disconnect and label hydraulic fittings at port A (Figure 10-2-2) and port B (6) on the ASC valve (1). These hoses connect to port A on the right side travel motor and port B on the left side travel motor. Immediately plug the hoses and cap the ASC valve to prevent contamination.

20. Remove two capscrews and lock washers securing the ASC valve to the axle mounting plate. Remove the ASC valve.

FIGURE 10-3. REAR AXLE MOUNTING.

FIGURE 10-4. REAR TRAVEL MOTORS. 10-4

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Section 10 REAR DRIVE AXLE ASSEMBLY, FRONT STEERING AXLE ASSEMBLY, WHEELS AND TIRES 21. Disconnect and label the flange half's at port A and port B (Figure 10-4 - 6 & 7) on the travel motors. Immediately plug the hoses and travel motor ports to prevent contamination. Remove the hoses from the axle assembly.

7. Tighten the capscrews to 37 ft.•lbs. (50 N•m) torque.

NOTE: The travel motor and gearbox assemblies weigh over 500 pounds. Use a lifting device for support when removing the mounting bolts and washers.

9. Using labels created during removal, insert the case drain hoses in the axle assembly. Remove plugs and connect the hoses at port L2 (Figure 10-4-4) on the travel motors.

22. While using a lifting device to support the travel motors and gearboxes, remove the 17 capscrews (Figure 10-4 - 1) and washers (2) securing the travel gearboxes to the axle assembly.

Carefully remove the travel motor and gearbox assemblies from the axle assembly.

23. Inspect hoses and hydraulic fittings for wear and damage. Replace worn or damaged fittings and hoses.

INSTALLATION [See Figure 10-1, 10-2, 10-3, and 10-4].

8. Using labels created during removal, remove plugs and connect hydraulics hoses at port A (2) and port B (6) on the ASC valve.

10. Using a lifting device, position the axle under the vehicle aligned with the frame mounting holes.

11. Insert the spacer plates (Figure 10-3 - 4) between the axle mounting plates and the frame.

12. Carefully lift the axle and align the capscrew holes.

13. Insert four capscrews (1) through the frame spacer plates and axle mounting plates (4).

Secure the capscrews with washers (3) and nuts (2).

1. Using a lifting device, position the gearboxes on the axle assembly and secure with 17 capscrews (Figure 10-4 - 1) and washers (2).

14. Tighten capscrews to 738 ft.•lbs. (1000 N•m) torque.

2. Tighten the gearbox mounting capscrews to 426 ft.•lbs. (578 N•m) torque.

15. Install the wiring harness into the axle assembly.

Secure the harness with hold down clamps.

3. Replace the o-rings on the hoses for travel motors port A (6) and B (7).

16. Using labels created during removal, connect the wiring harness connectors to the travel motors and the ASC valve (Figure 10-2 - 5).

4. Position the hoses in the axle assembly and at the travel motor ports (Figure 10-4 - 6 & 7).

Secure hoses with flange half's and four capscrews and washers.

17. Position the axle covers on the axle assemblies above the travel motors. Secure the plates with two capscrews and washers on each side.

5. Using labels created during removal, insert the brake hoses in the axle assembly. Remove plugs and connect the hoses to the gearbox fittings (5).

18. Tighten the capscrews to 44 ft.•lbs. (59 N•m).

6. Position the ASC valve (Figure 10-2 - 1) on the axle mounting plate. Secure the valve with two capscrews and washers.

20. Perform system pressure check as described in the paragraph SYSTEM PRESSURE CHECKS.

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19. Attach rear wheels as described in the paragraph REAR WHEEL.

10-5

Section 10 REAR DRIVE AXLE ASSEMBLY, FRONT STEERING AXLE ASSEMBLY, WHEELS AND TIRES FRONT STEERING AXLE ASSEMBLY. The Front Steering Axle for the MPH 362 does not have Front Wheel Assist. The Front Steering Axle for the MPH 364-2 has Front Wheel Assist. Steering for both type axles is controlled by the steering wheel in the cockpit and is operated by left side and right side steering cylinders. A tie rod is connected between the left and right side to assure proper tracking. Maximum steering angle is 30 degrees.

The front axle is attached to the frame using a single pivot pin.

WITHOUT FRONT WHEEL ASSIST [MPH 362].

NOTE: The engine must be raised to remove the pivot pin securing the front axle to the frame. See Section 6 - ENGINE, COOLING, EXHAUST, FUEL SYSTEM, THROTTLE for instructions on engine removal.

5. Using Section 6 - ENGINE, COOLING, EXHAUST, FUEL SYSTEM, THROTTLE as a guide, loosen the engine mounts.

6. Using a lifting device, lift the engine just enough to remove the pivot pin (Figure 10-5 - 2).

7. Remove the two flange screws (1).

Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all vertical cylinders, discharge any accumulators, and block any load whose movement could generate pressure.

NOTE: Shims and thrust washers will fall free when axle pivot pin (2) is removed.

8. Slide out axle pivot pin (2). Thrust washers (3) and shims (4 and 5) should fall free.

REMOVAL [See Figure 10-5].

9. Carefully lower the front axle and remove from vehicle.

NOTE: Clean area wherever a line is to be opened, then plug and cap all lines and ports to prevent entry of dirt into the system.

10. If front axle is to be serviced, refer to "Manufacturers Service Information Drawing" p.n. 0933484.

Front axle is very heavy. Be sure axle is supported before removing attaching hardware.

1. Place wooden blocks in front of and in back of the rear wheels.

2. Remove steering cylinders from front axle as described in Section 12 - STEERING, Paragraph STEERING CYLINDER. 3. Remove the front wheels as described in the paragraph FRONT WHEEL.

FIGURE 10-5. FRONT AXLE.

4. With the vehicle jacked up and wooden supports under the frame, support the front axle on both sides.

10-6

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Section 10 REAR DRIVE AXLE ASSEMBLY, FRONT STEERING AXLE ASSEMBLY, WHEELS AND TIRES

FIGURE 10-6. STEERING AXLE DIMENSION LOCATION.

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10-7

Section 10 REAR DRIVE AXLE ASSEMBLY, FRONT STEERING AXLE ASSEMBLY, WHEELS AND TIRES INSTALLATION [See Figures 10-5 and 10-6].

NOTE: The number of shims required for mounting the axle must be calculated.

1. Calculate the number of shims required for axle mounting as follows: a. Observe the number "A" (Figure 10-6) stamped on top of the steering axle. b. Subtract this number from the number "B" stamped on top of the axle mount on the frame. c.

Subtract 0.515 from the remainder.

6. Load shims (5) (as required), thrust washers (3) and shims (4) on the axle pivot pin. Grease both sides of the thrust washer (3) with multipurpose grease. Be sure shims (4 and 5) are distributed equally on both sides of the thrust washer (3) using the remaining one-half of the calculated number of shims.

7. Slide the axle pivot pin (2) the remainder of the way through the axle mount.

8. Apply thread lock to the two flange screws (1) securing the axle pivot pin (2) and torque to 104 ft.•lbs. (141 N•m).

9. Using Section 6 - ENGINE, COOLING, EXHAUST, FUEL SYSTEM, THROTTLE as a guide, lower the engine and tighten the engine mounts.

d. Divide the number by 0.010. e. Round your answer DOWN to the nearest whole number. For example 7.875 is 7, 9.375 is 9. f.

This is the number of shims required for axle mounting.

NOTE: Shims should be distributed evenly on both sides of the axle pivot tube.

Minimum of two shims required. One shim on each side of pivot tube.

10. Install the front wheels as described in the paragraph FRONT WHEEL. 11. Install steering cylinders on front axle as described in Section 12 - STEERING, Paragraph STEERING CYLINDER. 12. Bleed the steering system to remove any trapped air.

13. Perform a steering system pressure check as described in the paragraph STEERING SYSTEM PRESSURE CHECKS.

2. Slide the front axle under the vehicle and align the axle pivot tube with the frame axle mount.

3. Start the axle pivot pin (Figure 10-5 - 2) through the axle mount on the frame.

4. Load shims (5) (as required), thrust washers (3) and shims (4) (as required) on the axle pivot pin. Grease both sides of the thrust washer (3) with multipurpose grease. Be sure shims (4 and 5) are distributed equally on both sides of the thrust washer (3) until one-half the calculated number of shims are used.

5. Pass the pivot pin (2) through the axle pivot tube.

10-8

08/05

Section 10 REAR DRIVE AXLE ASSEMBLY, FRONT STEERING AXLE ASSEMBLY, WHEELS AND TIRES WITH FRONT WHEEL ASSIST [MPH 364-2].

Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all vertical cylinders, discharge any accumulators, and block any load whose movement could generate pressure.

REMOVAL [See Figures 10-5, 10-7, and 10-8].

NOTE: Clean area wherever a line is to be opened, then plug and cap any open lines and ports to prevent entry of dirt into the system.

Front axle is very heavy. Be sure axle is supported before removing attaching hardware.

1. Place wooden blocks in front of and in back of the rear wheels.

3. Disconnect and label the forward high-pressure hose from fitting (Figure 10-7 - 1). Immediately plug the hose and Front Assist Selector/Traction Valve port to prevent contamination.

4. Disconnect and label the reverse high-pressure hose from fitting (2). Immediately plug the hose and Front Assist Selector/Traction Valve port to prevent contamination.

5. Disconnect and label the electrical wire from stud (3). Disconnect the wiring from the front assist/traction valve and move the harness away from the axle assembly.

6. Remove the front wheels as described in the paragraph FRONT WHEEL. 7. With the vehicle still jacked up and wooden supports under the frame, support the front axle on both sides.

NOTE: The engine must be raised to remove the pivot pin securing the front axle to the frame. See Section 6 - ENGINE, COOLING, EXHAUST, FUEL SYSTEM, THROTTLE for instructions on engine removal.

2. Remove steering cylinders from front axle as described in Section 12 - STEERING, Paragraph STEERING CYLINDER.

FIGURE 10-7. FRONT AXLE, VALVE, AND MOTORS.

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10-9

Section 10 REAR DRIVE AXLE ASSEMBLY, FRONT STEERING AXLE ASSEMBLY, WHEELS AND TIRES 8. Using Section 6 as a guide, loosen the engine mounts.

9. Using a lifting device, lift the engine just enough to remove the pivot pin (Figure 10-5 - 2).

10. Remove the two flange screws (1).

NOTE: Shims and thrust washers will fall free when axle pivot pin (2) is removed.

11. Slide axle pivot pin (2) out. Thrust washers (3) and shims (4 and 5) should fall free.

12. Carefully lower the front axle and remove from vehicle.

NOTE: If front axle is replaced, remove the front assist selector valve, traction control valve, hoses, and travel motors for mounting on the replacement axle.

13. Remove two capscrews, washers, and clamp (Figure 10-8-1) from both sides of the axle assembly. Remove rubber packing (2) and (3) from around the hydraulic tubes.

14. Disconnect and label hydraulic lines from port L (Figure 10-8 - 4) and R (5) on the travel motors.

Immediately plug the hose and travel motor ports to prevent contamination.

15. Disconnect and label the case drain hose from the travel motors. Immediately plug the hose and Front Assist travel motor ports to prevent contamination.

The travel motors are very heavy.

Be sure motor is supported before removing attaching hardware.

16. Use a lifting device to support the gearbox and travel motor assemblies.

17. Remove eight capscrews and washers (6) from both gearbox mountings.

18. Remove the gearbox and travel motor assembly.

19. Disconnect and label the hydraulic hoses from the Front Assist Selector/Traction Valve (Figure 10-7). Remove the hoses from the axle assembly.

20. Remove two capscrews and washers securing the valve to the mounting plate. Remove the valve from the axle.

21. Remove the protective cover and inspect hoses and hydraulic fittings for wear and damage.

Replace worn or damaged fittings and hoses.

22. If front axle is to be serviced, refer to "Manufacturers Service Information Drawing" p.n. 0933484.

FIGURE 10-8. FRONT AXLE DRIVE.

10-10

08/05

Section 10 REAR DRIVE AXLE ASSEMBLY, FRONT STEERING AXLE ASSEMBLY, WHEELS AND TIRES INSTALLATION [See Figures 10-5, 10-6, 10-7, and 10-8].

1. Position the Front Assist Selector/Traction Valve on the axle mounting plate (Figure 10-7).

Secure the valve with two washers and capscrews.

2. Using the labels created during removal, remove plugs and connect hoses to the Front Assist Selector/Traction Valve (Figure 10-7).

3. Install hoses in the protective cover. Using a lifting device, position the gearbox and travel motor assemblies in place on the axle. Secure the assembly with eight capscrews and washers (Figure 10-8 - 6). Tighten the capscrews to 605 ft.•lbs (820 N•m).

4. Using labels created during removal, remove plugs and connect the case drain hoses to the travel motor fittings on both travel motors.

5. Assemble the tubing clamps on ports L and R (Figure 10-8 - 4 and 5). Align the hydraulic lines using labels created during removal. Connect the hydraulic lines at ports L and R. Secure the clamps with two capscrews and washers.

NOTE: The number of shims required for mounting the axle must be calculated.

6. Calculate the number of shims required for axle mounting as follows: a. Observe the number "A" (Figure 10-6) stamped on top of the steering axle. b. Subtract this number from the number "B" stamped on top of the axle mount on the frame. c.

Subtract 0.515 from the remainder.

d. Divide the number by 0.010.

NOTE: Shims should be distributed evenly on both sides of the axle pivot tube.

Minimum of two shims required. One shim on each side of pivot tube.

7. Slide the front axle under the vehicle and align the axle pivot tube with the frame axle mount.

8. Start the axle pivot pin (Figure 10-5 - 2) through the axle mount on the frame.

9. Load shims (5) (as required), thrust washers (3), and shims (4) (as required) on the axle pivot pin. Grease both sides of the thrust washer (3) with multipurpose grease. Be sure shims (4 and 5) are distributed equally on both sides of the thrust washer (3) until one-half the calculated number of shims are used.

10. Pass the pivot pin (2) through the axle pivot tube.

11. Load shims (5) (as required), thrust washers (3) and shims (4) on the axle pivot pin. Grease both sides of the thrust washer (3) with multipurpose grease. Be sure shims (4 and 5) are distributed equally on both sides of the thrust washer (3) using the remaining one-half of the calculated number of shims.

12. Slide the axle pivot pin (2) the remainder of the way through the axle mount.

13. Apply thread lock to the two flange screws (1) securing the axle pivot pin (2) and torque to 104 ft.•lbs. (141 N•m).

14. Using Section 6 - ENGINE, COOLING, EXHAUST, FUEL SYSTEM, THROTTLE as a guide, lower the engine and tighten the engine mounts.

15. Install the front wheels as described in the paragraph FRONT WHEEL. 16. Connect the forward high-pressure hose to fitting (Figure 10-7 - 1).

e. Round your answer DOWN to the nearest whole number. For example 7.875 is 7, 9.375 is 9.

17. Connect the reverse high-pressure hose to fitting (2).

f.

18. Connect the electrical connection at stud (3).

08/05

This is the number of shims required for axle mounting.

10-11

Section 10 REAR DRIVE AXLE ASSEMBLY, FRONT STEERING AXLE ASSEMBLY, WHEELS AND TIRES 19. Install steering cylinders on front axle as described in Section 12 - STEERING Paragraph STEERING CYLINDER. 20. Bleed the hydraulic system to remove any trapped air.

When installing front wheels, make sure the tire treads are oriented as shown in Figure 10-9. The front wheels are driven on the MPH 364-2 and are not driven on the model MPH 362. The tire tread on the 362 is the reverse of the tire tread on the 364-2.

21. Perform a system pressure check as described in the paragraph SYSTEM PRESSURE CHECKS. WHEELS AND TIRES. FRONT WHEEL. The rim and tire combinations used on the front wheel depend on the vehicle model. The MPH 362 uses 0938468 rim and tire combination on the righthand side and 0938467 rim and tire combination on the left-hand side. The MPH 364-2 uses 0936340 rim and tire combination on the right-hand side and 0936341 rim and tire combination on the left-hand side.

REMOVAL [See Figure 10-9].

1. Place wooden blocks in front of and in back of the rear wheels.

2. Jack up the wheel to be removed until it just touches the ground.

3. Place wooden supports under the frame in case the jack slips.

4. Remove ten nuts (Figure 10-9-1) securing the wheel (2) to the gearbox. Remove wheel.

5. Using a wire brush clean the lug nut studs.

INSTALLATION [See Figure 10-9].

NOTE: Be sure tires are mounted on the rim with proper tread orientation as shown in Figure 10-9. The orientation for Model MPH 364-2 is the reverse of Model MPH 362.

FIGURE 10-9. FRONT WHEEL. 1. Slide the front wheel (2) onto the axle with the tire oriented as shown in Figure 10-9.

2. Secure the wheel with ten nuts (1), with flat side of nut toward the rim.

10-12

08/05

Section 10 REAR DRIVE AXLE ASSEMBLY, FRONT STEERING AXLE ASSEMBLY, WHEELS AND TIRES 3. Using a torque wrench, tighten nuts in a star pattern as follows:

When installing rear wheels mount the wheels with the tire tread oriented as shown in Figure 10-10.

a. For model MPH 362, tighten nuts to 280 ft.•lbs. (379.6 N•m).

1. Slide the rear wheel (2) onto the axle with the tire oriented as shown in Figure 10-10.

b. For model MPH 364-2, tighten nuts to 400 ft.•lbs. (542.3 N•m).

2. Secure the wheel with sixteen lug bolts and washers.

4. Lift the wheel and remove wooden supports.

Lower wheel to the ground.

3. Using a torque wrench, tighten the lug bolts in a star pattern to 460 ft.•lbs. (623.7 N•m).

5. Check tire pressure as described in Section 4 MAINTENANCE.

4. Lift the wheel and remove the wooden supports.

Lower the wheel to the ground.

REAR WHEEL.

5. Check tire pressure as described in Section 4 MAINTENANCE.

The tires used on the rear wheels are the same for all models.

2

REMOVAL [See Figure 10-10].

1. Place wooden blocks in front of and in back of the front wheels.

2. Jack up the wheel to be removed until it just touches the ground.

3. Place wooden supports underneath the frame in case the jack slips.

4. Remove sixteen lug bolts and washers (Figure 10-10 - 1) securing the rear wheel (2) to the gearbox. Remove wheel.

5. Using a wire brush clean the lug bolts.

INSTALLATION [See Figure 10-10].

2

NOTE: Be sure tires are mounted on the rim with proper tread orientation as shown in Figure 10-9. The tread is reversed from side to side.

1 FRONT OF MACHINE

FIGURE 10-10. REAR WHEEL.

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10-13

Section 11 BRAKE AND 2-SPEED TABLE OF CONTENTS PAGE DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2 BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2 TWO-SPEED SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2 CLEANLINESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2 BRAKE VALVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-6 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-6 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-6 2-SPEED VALVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-7 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-7 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-7

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11-1

Section 11 BRAKE AND 2-SPEED DESCRIPTION.

TWO-SPEED SYSTEM.

The main components of the brake and 2-speed circuits are as follows:

The 2-Speed Selector Valve is mounted on the right side of the machine. The valve controls the flow of hydraulic oil to the rear drive motors shifting port "X1". Hydraulic oil is routed from the Travel Pump into port "P" on the 2-Speed Selector Valve. The 2Speed Selector Valve is solenoid operated and controls the flow of oil to the rear drive motors shift port, through ports "X1". When activated by the 2-Speed Low/High Switch the solenoid valve shifts position allowing pump pressure to flow to the motors port "X1" forcing the motor into the high flow position (Low speed). When the 2-Speed Low/High Switch is placed in the OFF position the 2-Speed Selector Valve shifts position blocking oil flow to motors port "X1" and allowing flow through selector valve port "T" to the hydraulic return manifold. The motors are now unlocked and in High Speed Range.

Brake Valve Assembly Priority Valve Assembly Two-Speed Valve Assembly BRAKE SYSTEM. These components are located as shown in Figure 11-1. The Tandem Gear Pump Assembly is a twosection Gear Pump located on the left side of the engine. The rear section is used in the Brake System and the front section is used in the Steering System. Hydraulic oil from the Hydraulic Tank is routed to the input port on the outer pump. The pressure port of the pump is connected to the IN port on the Priority Valve Assembly. The output from the control flow (CF) port is connected to the Brake Valve Assembly. The output from the Excess Flow (EF) port is connected to a Relief Valve and to the Gearbox Oil Pump/Motor Assembly. The Brake Valve Assembly is solenoid operated and controls the flow to the brakes on the left and right drive motors, through ports “C1” and “C2”. Excess flow is returned to the Hydraulic Tank through port “T”. The brakes function at 1400 psi with a maximum system pressure set at 1600 psi.

The vehicle must be stopped on level ground and the Travel Direction Control Lever (FNR) must be in NEUTRAL for the speed range to be changed.

CLEANLINESS. When servicing the hydraulic system, it is very important to do the following: 1. Clean surfaces, fittings, and hoses at the point of disconnection.

2. Protect all exposed sealing surfaces from damage and foreign material.

3. All gaskets and O-rings should be replaced.

4. Lightly lubricate all O-rings with hydraulic oil prior to assembly.

5. Whenever a hose is disconnected, immediately cap the fitting and plug the hose to prevent contamination.

11-2

08/05

Section 11 BRAKE AND 2-SPEED

FIGURE 11-1. COMPONENT LOCATION.

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11-3

Section 11 BRAKE AND 2-SPEED REAR DRIVE AXLE LH SAHR BRAKE

RH SAHR BRAKE

REAR DRIVE GEARBOX LH

REAR DRIVE GEARBOX RH

C1

C2

H 1

BRAKE DRIVE

PRIORITY FLOW CONTROL VALVE

3

2

P

T

P=95 PSI IN 1

3 CF

1.5 GPM PRIORITY

2 EF

20

21

1.5 X ENGINE SPEED ENGINE HIGH IDLE: 2100 RPM FULL LOAD HIGH IDLE: 2300 RPM NO LOAD LOW IDLE: 850 RPM

TRAVEL (SHT 1)

ALPS/WATER OPTION

ROTOR (SHT 1)

ROTOR (SHT 1)

54 STD

61

STD

HIGH FLOW

STD

HIGH FLOW

HYD. TANK

FIGURE 11-2. BRAKE SYSTEM SCHEMATIC.

11-4

08/05

Section 11 BRAKE AND 2-SPEED REAR AXLE TWO SPEED SELECTOR VALVE T

P 2A

C

TO AUX. VALVE PILOT PRESSURE PORT

CYL

*

(HIGHEST CASE PORT) L2 A REAR DRIVE GEARBOX R.H.

Vg min.

FROM PORT "M3" ON TRAVEL PUMP

RATIO 59.1:1 T3

4060 PSI PRESS. COMP.

B

X1

FROM PORT "A" ON ASC VALVE

FROM PORT "A" ON TRAVEL PUMP

M2 M3

L1

M4

REAR TRAVEL MOTOR

R.H. AXLE MOTOR A = FORWARD B = REVERSE (HIGHEST CASE PORT) L2 A REAR DRIVE GEARBOX L.H.

Vg min.

RATIO 59.1:1 T3

FROM PORT "B" ON ASC VALVE

X1

4060 PSI PRESS. COMP.

B

M2 M3

L1

M4

REAR TRAVEL MOTOR

L.H. AXLE MOTOR B = FORWARD A = REVERSE

FIGURE 11-3. 2-SPEED SYSTEM SCHEMATIC.

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11-5

Section 11 BRAKE AND 2-SPEED BRAKE VALVE ASSEMBLY. The Brake Valve Assembly is mounted on the right side of the frame. The Brake Valve is solenoid operated and controls the flow of hydraulic oil to the left and right rear axle SAHR brakes. The valve also contains the pressure switches for operating the brake lights. The assembly includes the brake valve, seven fittings, two pressure switches, and a test port.

REMOVAL [See Figure 11-4].

INSTALLATION [See Figure 11-4].

NOTE: Check all fittings for damage. Do not use any parts that show wear or damage.

1. Install fitting (Figure 11-4 –1 through 7 and 11) on Brake Valve Assembly.

2. Secure the brake valve assembly to the frame with the two screws (9), and two washers (10).

3. Torque screws (9) to 12 ft.•lbs. (16.3 N•m).

Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all vertical cylinders, discharge any accumulators, and block any load whose movement could generate pressure.

NOTE: Plug and cap all lines when disconnected to prevent entry of dirt into the system. Place a container under the hydraulic fittings to be disconnected to catch any hydraulic oil.

4. Connect the hydraulic lines to the Brake Valve Assembly.

5. Connect the electrical connections to solenoids SV1 and SV2.

6. Connect the electrical connections to the pressure switches (8).

7. Bleed the braking system to remove any trapped air.

8. Perform a System Pressure Check as described in the INSPECTION AND PRESSURE CHECK PROCEDURE in chapter 8.

1. Disconnect and label all hydraulic line to the Brake Valve Assembly.

3

2. Disconnect and label the electrical connections to solenoids SV1 and SV2.

4

3. Disconnect and label the electrical connections to the pressure switches (Figure 11-4 – 8).

10

4. Remove the two screws (9), and two washers (10), attaching the Brake Valve Assembly to the frame, then remove Brake Valve Assembly.

11

9

5

5. Remove all fittings (1 through 7 and 11) from the Brake Valve Assembly.

7,6 1

C1

C2

NOTE: If brake valve is to be serviced, call BOMAG service and refer to Part Number 0936400.

2

9

10

8

FIGURE 11-4. BRAKE VALVE ASSEMBLY.

11-6

08/05

Section 11 BRAKE AND 2-SPEED 2-SPEED VALVE ASSEMBLY. The 2-Speed Valve Assembly located on the right side of the machine, controls the flow of hydraulic oil to the Axle Shift Cylinder. Hydraulic oil is routed from the Travel Pump into port “P” on the 2-Speed Valve Assembly. The 2-Speed Valve Assembly is solenoid operated and controls the flow to the Axle Shift Cylinder, through ports “C1” and “C2”. Excess flow is returned to the Hydraulic Tank through port “T”. The solenoids on the 2-Speed Valve Assembly are controlled by the three-position momentary contact Low Gear Range - High Gear Range switch with a spring-loaded center return. Travel speed change can only be performed when the vehicle is stopped and the Travel Direction Control (FNR) is in NEUTRAL. The assembly includes the 2-Speed Valve, five fittings, and two solenoids.

REMOVAL [See Figure 11-5].

INSTALLATION [See Figure 11-5].

NOTE: Check all fittings and O-rings for damage. Do not use any parts that show wear or damage.

NOTE: Use new O-rings when installing fittings.

1. Install fitting (Figure 11-5 – 1 through 4) on the 2-speed valve Assembly.

NOTE: If a new 2-Speed Valve is being installed, the solenoids must be rotated 180°.

2. Torque nut on solenoid to 4-6 ft.•lbs. (5.4-8.1 N•m) 3. Attach the 2-Speed Valve Assembly to the frame, with the two screws (5), and two washers (6).

4. Torque screws (5) to 44 ft.•lbs. (59.7 N•m).

Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all vertical cylinders, discharge any accumulators, and block any load whose movement could generate pressure.

5. Connect the hydraulic lines to the 2-Speed Valve Assembly.

6. Connect the electrical connections to the two solenoids.

7. Bleed the 2-Speed System to remove any trapped air.

NOTE: Plug and cap all lines when disconnected to prevent entry of dirt into the system. Place a container under the hydraulic fittings to be disconnected to catch any hydraulic fluid.

2

6 5 1

CYL

T

1. Disconnect and label the hydraulic lines to the 2-Speed Valve Assembly.

2. Disconnect and label the electrical connections to the two solenoids.

4. Remove all fittings (1 through 4) from the 2Speed Valve.

NOTE: If 2-Speed Valve assembly is to be serviced, call BOMAG service and refer to Part Number 0937380.

08/05

P

3. Remove the two screws (Figure 11-5 – 5), and two washers (6), attaching the 2-speed valve assembly to the frame, then remove the 2Speed Valve Assembly.

6

3

5

4

FIGURE 11-5. 2-SPEED VALVE ASSEMBLY.

11-7

Section 12 STEERING TABLE OF CONTENTS PAGE GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2 SYSTEM OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2 CLEANLINESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2 PRIORITY VALVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-5 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-5 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-6 STEERING CONTROL ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-6 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-6 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-7 FILTER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-8 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-8 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-9 STEERING CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-9 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-9 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-10 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-10 SEAL REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-11 ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-12 TANDEM GEAR-PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-12 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-12 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13 STEERING WHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13 STEERING COLUMN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13 HYDRAULIC TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13 STEERING SYSTEM PRESSURE CHECKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13

08/05

12-1

Section 12 STEERING GENERAL.

SYSTEM OPERATION.

This section provides a description of the main components of the Steering System including Removal, Installation, Disassembly and Assembly procedures.

Trouble analysis for the Steering System is found at the end of this section.

The hydraulic oil from the Hydraulic Tank is passed through the Filter Assembly then routed to the engine driven Tandem Gear Pump Assembly. The front section of the Tandem Gear Pump Assembly pumps the hydraulic oil to the Priority Flow Divider Valve Assembly. The Steering Control Assembly is mounted on the Steering Column and controlled by the Steering Wheel. The Steering Control Assembly controls the flow of hydraulic oil to the left and right Steering Cylinders. Excess hydraulic oil is returned to the hydraulic tank. The Steering Cylinders pivot the spindle area of the steering axle.

DESCRIPTION (Figure 12-1).

The Steering System is an Axle Pivot type system, powered hydraulically and manually controlled with the steering wheel. The location of major components are shown in Figure 12-1 and the steering system schematic is shown in Figure 12-2. The major components of the steering system are as follows: Tandem Gear Pump Assembly Valve Assembly-Priority Flow Divider Steering Control Assembly Filter Assembly Hydraulic Steering Cylinders Steering Column Steering Wheel Hydraulic Tank

NOTE: When turning left, hydraulic oil is supplied to the rod end of the left Steering Cylinder and to the base end of the right Steering Cylinder. When turning right, hydraulic oil is supplied to the rod end of the right Steering Cylinder and to the base end of the left Steering Cylinder.

CLEANLINESS. When servicing the Hydraulic System, it is very important to do the following: 1. Clean surfaces, fittings, and hoses at the point of disconnection.

2. Protect all exposed sealing surfaces from damage and foreign material.

3. All gaskets and O-rings should be replaced.

4. Lightly lubricate all O-rings with hydraulic oil prior to assembly.

5. Whenever a hose is disconnected immediately cap the fitting and plug the hose to prevent contamination.

12-2

08/05

Section 12 STEERING

FIGURE 12-1. STEERING SYSTEM.

08/05

12-3

Section 12 STEERING TO AUX HYD. SPOOL VALVE

STEERING/AUX RETURN FILTER

ALL FLOW GOES EF EXCEPT ON L.S. SIGNAL

P=18±2 PSI NO

EF

P=40 PSI

P

LOAD SENSING PRORITY VALVE

CF LS

*

P=25 PSI B

2-3 GPM TO FRONT AXLE TRAVEL MOTORS CASE FLUSHING (MPH364 ONLY)

T

5 GPM AVAILABLE AT LOW IDLE L.S. HAS PRIORITY UP TO 14 GPM

2000 PSI

A

*

5-6 GPM TO ROTOR MTR CASE FLUSHING

STEERING CONTROL ANTI-KICK BACK CHECK VALVE

LOAD SENSING STEERING ORBITROL T

LS P

STEERING/AUX PUMP 1.0 X ENGINE SPEED ENGINE HIGH IDLE: 2150 RPM FULL LOAD HIGH IDLE: 2300 RPM NO LOAD LOW IDLE: 850 RPM R

L ALPS/WATER OPTION

STEERING CYLINDERS

STD

STD

HIGH FLOW

STD

HIGH FLOW

HYD. TANK

FIGURE 12-2. STEERING SYSTEM SCHEMATIC.

12-4

08/05

Section 12 STEERING PRIORITY VALVE ASSEMBLY.

Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all vertical cylinders, discharge any accumulators, and block any load whose movement could generate pressure.

REMOVAL [See Figure 12-3].

NOTE: Plug and cap all lines and ports when disconnected to prevent entry of dirt into the system.

1. Stop the engine. Wash the Valve Assembly and the area around the Valve Assembly with allpurpose degreaser, p.n. 178297, and dry with compressed air.

2. Place a container under the Valve Assembly to catch any oil when the hydraulic lines are disconnected.

3. Disconnect and label all hydraulic lines to the Priority Valve Assembly.

4. Remove the two screws, (Figure 12-3 â&#x20AC;&#x201C; 10), attaching the Valve Assembly to the right side of the frame below the control console frame and remove the Valve Assembly.

FIGURE 12-3. VALVE ASSEMBLY.

5. Remove and separate the nine fittings (1 through 9) from the Valve Assembly.

Discard all O-rings. Replace the Orings or the complete fitting, if damaged, with new parts during assembly.

6. Inspect fittings and replace any fitting that is damaged.

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12-5

Section 12 STEERING INSTALLATION [See Figure 12-3].

1. Remove ignition key.

1. Install all nine fittings (Figure 12-3 – 1 through 9) and position as shown in Figure 12-3.

2. Disconnect electrical supply by turning Master Power switch (in engine compartment) to OFF position.

2. Position Valve Assembly on right side of frame.

Be sure port “P” is toward front of vehicle and ports “T” and “LS” are toward top.

3. Secure Valve Assembly to frame with two screws (10).

3. Remove the seven screws attaching the right hand panel (Figure 12-4 – 1) located next to the steering wheel (2) and lay panel aside.

4. Remove horn cap (Figure 12-5 – 1) to gain access to steering wheel nut (2).

4. Torque screws (10) to 12 ft•lbs (16.3 N•m).

5. Connect all hydraulic lines to the Priority Valve.

6. Bleed the Steering System to remove any trapped air.

7. Perform a steering system pressure check as described in the paragraph STEERING SYSTEM PRESSURE CHECKS. STEERING CONTROL ASSEMBLY. The Steering Control Assembly is attached to the Steering Wheel through the Steering Column. The Steering Control Assembly is accessible by removal of the riser cover plate. Removal requires the removal of the Steering Wheel and the Steering Column.

REMOVAL [See Figures 12-4, 12-5 and 12-6].

Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all vertical cylinders, discharge any accumulators, and block any load whose movement could generate pressure.

NOTE: Plug and cap all lines and ports when disconnected to prevent entry of dirt into the system. Place a container under the steering unit to catch any hydraulic oil when the lines are disconnected.

12-6

5. Remove large steering wheel nut (2) that attaches the steering wheel (3) to the splined steering column shaft and remove steering wheel (3).

NOTE: Install a steering wheel puller and remove the steering wheel if the wheel can not be removed by hand.

6. Reaching through opening created by removing the right hand panel, remove the two capscrews (4), washers, (5), and nuts (6), attaching release lever (7) with vinyl cap (8), to steering column (9) and remove release lever (7).

7. Disconnect and label the five hydraulic hoses connected to fittings (10 through 14) on the Control Steering Assembly (15).

8. While supporting the Control Steering Assembly (15), remove the four nuts (16), attaching the steering column (9) and the Control Steering Assembly (15) to the steering support plate (17).

9. Maneuver the Control Steering Assembly (15) out through the right hand panel opening.

10. Remove the steering column (9) and bushing (19).

11. Remove the four rods (18) from the control steering assembly.

12. Remove the fittings (Figure 12-6 – 1 through 7) from the Control Steering Assembly.

08/05

Section 12 STEERING INSTALLATION [See Figures 12-4, 12-5 and 12-6].

NOTE: When installing a new Steering Control Assembly (15), the rods and fittings must be installed on the assembly.

1. Install the four rods (18) on the Control Steering Assembly (15) using adhesive sealant, p.n.

0264134.

Discard all O-rings. Replace the Orings or the complete fitting with new parts during assembly.

2. Install the fittings (Figure 12-6 – 1 through 7) as shown.

FIGURE 12-4. STEERING SYSTEM COMPONENT ACCESS.

3. Position the Control Steering Assembly (Figure 12-5 – 15) under the Steering Support Plate (17), with the ports facing toward the right. Align the rods in the Control Steering Assembly with the four holes in the Steering Support Plate.

4. Install bushing (19) on top of steering support plate (17).

5. Install steering column (9) and attach steering column and Control Steering Assembly (15) to steering support plate (17) with four nuts (16).

6. Torque nuts (16) to 44 ft•lbs (59.7 N•m).

7. Insert release lever (7) with vinyl cap (8), through opening in panel and attach release lever (7) to steering column (9) with two capscrews (4), washers (5), and nuts (6).

8. Torque capscrews (4) to 12 ft•lbs (16.3 N•m).

9. Position boot on steering column (9) so that two bellows are above console and two bellows are below console.

10. Connect the five hydraulic hoses fittings(10 through 14) to the Control Steering Assembly (15).

11. Install the steering wheel (3) on to the splined shaft on the steering column (9).

FIGURE 12-5. STEERING SYSTEM COMPONENTS. 08/05

12. Secure steering wheel with the steering wheel nut (2).

12-7

Section 12 STEERING 13. Torque steering wheel nut (2) to 60 ft•lbs (81.3 N•m).

14. Install horn cap (1) on steering wheel.

15. Attach the right hand panel (Figure 12-4 – 1) with the seven screws.

FILTER ASSEMBLY. The filter assembly is located under the cockpit floor plate on the right side of the vehicle. Replacement of the filter element is covered in Section 4, MAINTENANCE. If it is necessary to remove the complete filter assembly, refer to REMOVAL below.

16. Set Master Power switch to ON position.

17. Bleed the Steering System to remove any trapped air.

18. Perform a Steering System pressure check as described in the paragraph STEERING SYSTEM PRESSURE CHECKS.

Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all vertical cylinders, discharge any accumulators, and block any load whose movement could generate pressure.

REMOVAL [See Figure 12-7].

NOTE: Plug and cap all lines and ports to prevent entry of dirt into the system.

1. Place a container under the Filter Assembly to catch any oil when the hydraulic lines are disconnected.

2. Disconnect and label the hydraulic line from the spool valve connected to fitting (Figure 12-7 – 2).

3. Disconnect and label the hydraulic line from the cockpit floor plate port “T” connected to fitting (3).

FIGURE 12-6. CONTROL STEERING ASSEMBLY.

4. Disconnect and label the hydraulic line from the hydraulic tank connected to fitting (5).

5. Disconnect and label the hydraulic line from the rotor motor case flushing connected to fitting (6).

6. Disconnect and label the hydraulic line from the front axle case flushing connected to fitting (8).

7. Remove the four screws (9), attaching the Filter Assembly to the cockpit floor and remove the Filter Assembly.

8. Remove and separate the eight fittings (1 through 8) from the filter.

9. Inspect fittings and discard any fitting that is damaged.

12-8

08/05

Section 12 STEERING 8. Connect the hydraulic line from the hydraulic tank connected to fitting (5).

9. Connect the hydraulic line from the rotor motor case flushing connected to fitting (6).

10. Connect the hydraulic line from the front axle case flushing connected to fitting (8).

11. Bleed the steering system to remove any trapped air.

STEERING CYLINDER. The two Steering Cylinders are mounted on the front axle and attached by ball joints to a bracket on the axle and to a bracket on the wheel spindle area.

FIGURE 12-7. STEERING/AUXILIARY FILTER. INSTALLATION [See Figure 12-7].

Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all vertical cylinders, discharge any accumulators, and block any load whose movement could generate pressure.

REMOVAL [See Figure 12-8].

Discard all O-rings. Replace the Orings or the complete fitting, if damaged, with new parts during assembly.

1. Install fittings (Figure 12-7 – 1, 2, and 3) to inlet side of filter and position as shown.

2. Install fittings (4, 5, 6, 7, and 8) to output side of filter and position as shown.

3. Position filter on underside of cockpit floor plate with fittings facing toward inside of frame.

NOTE: Plug and cap all lines and ports when disconnected to prevent entry of dirt into the system. Place a container under the cylinders to catch any hydraulic oil when the lines are disconnected.

1. Disconnect and label the hose connected to fitting (Figure 12-8 – 1).

2. Disconnect and label the hose connected to fitting (2).

4. Place thread lock on the four screws (9).

3. Disconnect and label the hose connected to fitting (3).

5. Secure filter to cockpit floor plate with four screws (9).

4. Remove the cotter pin (4) and locknut (5), securing ball joint (8) to the wheel spindle area.

6. Connect the hydraulic line from the spool valve connected to fitting (2).

5. Remove ball joint from wheel spindle area.

7. Connect the hydraulic line from the cockpit floor plate port “T” connected to fitting (3).

08/05

6. Remove the cotter pin (4) and locknut (5) securing ball joint (8) to the axle bracket.

7. Remove ball joint from axle bracket.

12-9

Section 12 STEERING 8. With cylinder completely retracted, measure assembled length of cylinder at centerline of ball joints. Record this dimension for reference when assembling replacement cylinders.

NOTE: Cylinder fitting should be on the bottom of the cylinder and facing toward the center of the axle.

5. Connect the hose to fitting (1).

9. Remove nut (6) and screw (7), then remove the two ball joints (8) from steering cylinder.

6. Connect the hose to fitting (2).

10. Remove fitting (1) from steering cylinder.

7. Connect the hose to fitting (3).

11. Remove fittings (2 and 3) from steering cylinder.

8. Bleed the Steering System to remove any trapped air.

INSTALLATION [See Figure 12-8].

DISASSEMBLY [See Figure 12-9].

Discard all O-rings. Replace the Orings or the complete fitting, if damaged, with new parts during assembly.

1. Install fitting (1) on steering cylinder and align as shown.

2

Remove fittings (Figure 12-8 â&#x20AC;&#x201C; 2 and 3) on steering cylinder and align as shown.

NOTE: Leave 3/4 inch of thread exposed below ball joint when assembling ball joint to cylinder. Thread exposure must be equal for all ball joints.

3. Attach the ball joints (8) to steering cylinder.

Align ball joints so that the ball joints and the steering cylinder fittings are both pointing down.

Secure ball joint with screw (7) and nut (6).

1. When servicing a cylinder, clamp it in a softjawed vise with a cloth between the jaws and part being clamped. Clamp on the nut on the end of a rod or the outer ear of the cylinder when possible.

NOTE: Never use a vise to clamp on the cylinder wall or on the cylinder rod-sealing surface. The surface or internal components could be damaged.

2. Use a spanner wrench to remove the cylinder pack head (Figure 12-9 â&#x20AC;&#x201C; 7).

3. Remove the pack head (7), piston (8), and piston rod (1) as one unit.

4. Remove the piston (8) from the piston rod (1) using a spanner wrench. Remove the pack head (7).

4. Secure the ball joints to the brackets on the front axle and the wheel spindle area with lock nuts (5) and cotter pins (4).

FIGURE 12-8. STEERING CYLINDER. 12-10

08/05

Section 12 STEERING SEAL REMOVAL. 1. Note the location and direction of the seals during the removal process. Before removing any seal, be sure there is a matching seal in the seal kit for each seal removed from the cylinder.

The seals removed should be nearly identical in terms of overall dimensions, however, the substitute seals may have different material, color or lip design.

2. Place the pack head (7) in a soft-jawed vise with a cloth inserted between the jaws and the pack head to remove the rod seal (10), O-ring (12) and back-up ring (11). Do not clamp on any threads. Remove rod seal (10) and O-ring (12).

3. Turn pack head over and remove rod wiper.

4. Inspect the pack head (7) grooves for nicks, burrs, scratches and rust. Minor nicks, burrs, scratches and rust can be removed with an emery cloth or an approved solvent. If the deformity cannot be removed, replace the damaged pack head. Be sure to check the pack head threads to verify that they are not damaged.

Remove all forms of contamination from the pack head with a clean cloth before the new seals are installed.

5. Install the new rod seal (10) into the pack head (7). Form the rod seal into a kidney shape and press the seal carefully into the groove. Snap the wear rings into place while making sure that they have a proper fit.

6. Turn the pack head over. Install the rod wiper (9) by forming the rod wiper into a kidney shape and pressing it into the groove.

7. Install the back-up ring (11) and O-ring (12) carefully over the threads of the pack head.

8. Place the piston (8) in a soft-jawed vise with a cloth inserted between the jaws and the piston.

Pry up the piston seals (14) and remove them.

9. Remove O-ring (13).

Do not scratch the seal groove.

10. Inspect the piston (8) grooves for nicks, burrs, scratches, dirt or rust. Minor imperfections may be removed with an emery cloth or an approved solvent. Make sure that the piston threads have not been damaged. Remove all forms of contamination from the piston by using a clean cloth before the new seals are installed.

11. Install the piston seals (14) and O-ring (13).

FIGURE 12-9. STEERING CYLINDER. 08/05

12-11

Section 12 STEERING ASSEMBLY [See Figure 12-9].

TANDEM GEAR-PUMP.

1. Double-check all components to make sure they are all free of contamination.

The Tandem Gear Pump is driven by the engine and is located on the left side of the engine. The front section is used to supply the hydraulic oil to the steering system and the rear section is used in the Braking System. Both sections are removed as a single unit. The input oil supply to the pump is direct from the hydraulic tank. The pump output at the pressure port is connected to the Priority Flow divider Valve in the Steering System.

2. Assemble the Piston Rod Assembly (1). Lightly lubricate the inside diameter of the pack head (7) with hydraulic fluid. Slide the pack head (7) carefully onto the piston rod (1).

3. Install the piston (8) onto the piston rod (1) and secure the piston (8) in place with a new nut (15).

4. Install the piston rod (1) into the cylinder wall (3). Clamp the cylinder in a soft-jawed vise by gripping an outer ear of the cylinder wall or the nut on the piston rod assembly. Lightly lubricate the outside diameter of the piston (8), pack head (7) threads, and threads on the inside diameter of the cylinder wall with hydraulic fluid.

5. While being extremely careful to not damage the piston seals, load the piston (8), piston rod (1) and pack head (7) as one unit. Screw on the pack head while being cautious when tightening the O-ring (12) and back-up ring (11) against the cylinder wall assembly. Torque the pack head assembly to the cylinder wall with 250 to 300 ft•lbs (339 to 406.8 N•m).

REMOVAL [See Figure 12-10].

Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all vertical cylinders, discharge any accumulators, and block any load whose movement could generate pressure.

NOTE: Plug and cap all lines when disconnected to prevent entry of dirt into the system. Place a container under the tandem pump to catch any hydraulic oil when the lines are disconnected.

1. Disconnect and label the hydraulic line going to the hydraulic tank from fitting (Figure 12-10 – 1).

2. Disconnect and label the pressure line going to the Steering Valve Assembly from fitting (2).

3. Disconnect and label the hydraulic line going to the hydraulic tank from fitting (3).

4. Disconnect and label the pressure line going to the Brake Priority Valve Assembly from fitting (4).

5. Remove the two bolts (6) and two washers (5) securing the Tandem Pump Assembly to the engine.

6. Slide the shaft of the Tandem Pump out of the engine.

12-12

08/05

Section 12 STEERING 11. Perform a steering system pressure check as described in the paragraph STEERING SYSTEM PRESSURE CHECKS. STEERING WHEEL. The procedure for the removal of the Steering Wheel is described in the STEERING CONTROL ASSEMBLY paragraph.

STEERING COLUMN. Procedures for the removal of the steering column are described in the STEERING CONTROL ASSEMBLY paragraph. The Steering Wheel must be removed but no hydraulic hoses need to be disconnected.

HYDRAULIC TANK. FIGURE 12-10. TANDEM PUMP ASSEMBLY. INSTALLATION [See Figure 12-10].

1. Lubricate the spline on the Tandem Pump Assembly with motor oil or white grease assembly lubricant.

2. Insert the spline into the engine and align the two mounting holes.

3. Apply thread lock to the two capscrews (6).

4. Attach the Tandem Pump Assembly to the engine with the two capscrews (6) and two washers (5).

The procedures for the removal installation and servicing the Hydraulic Tank are described in Section 8.

STEERING SYSTEM PRESSURE CHECKS. 1. Steering/Aux System (all pressures at 1500 rpm engine speed): NOTE: Unit must be fully warmed up before making pressure checks. a. Install a 3000 psi gauge on the test port at the inlet to the L.S. priority valve (LHS of unit to the rear of the LH engine mount).

5. Torque capscrews (6) to 44 ft•lbs (59.7 N•m).

Steering pressure: 2000 +/- 100 psi

6. Connect the hydraulic line going to the hydraulic tank to fitting (1).

TROUBLESHOOTING.

7. Connect the pressure line going to the Steering Valve Assembly to fitting (2).

8. Connect the hydraulic line going to the hydraulic tank to fitting (3).

Most steering problems can be corrected if the problem is properly defined. The entire steering system should be evaluated before removing any components. The steering control unit is generally not the cause of most steering problems. Table 12-1 is a list of steering problems along with possible causes and suggested corrections.

9. Connect and label the pressure line going to the Brake Priority Valve Assembly to fitting (4).

10. Bleed the steering system to remove any trapped air.

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12-13

Section 12 STEERING TABLE 12-1. TROUBLESHOOTING STEERING PROBLEMS. PROBLEM

PROBABLE CAUSE

REMEDY

Slow steering, hard steering.

Worn or malfunctioning pump.

Confirm and replace pump.

Tendency of vehicle to wander.

Air in the system due to low level of oil, cavitating pump, leaky fitting, pinched hose, etc.

Correct condition and add oil.

Worn mechanical linkage.

Repair or replace.

Bending of linkage or cylinder rod. Repair or replace.

Loose cylinder rod.

Repair or replace.

Severe wear in steering control unit.

Replace steering control unit.

Drift - Deviation of vehicle path, without operator input, from normally expected continuing course.

Worn or damaged steering linkage.

Replace linkage and align.

Slip - slow movement of steering wheel fails to cause any movement of steered wheels.

Leakage of cylinder piston seals.

Replace seals.

Worn steering control unit meter.

Replace steering control unit.

Erratic steering.

Air in system due to low level of oil, cavitating pump, leaky fitting, pinched hose, etc.

Correct condition and add fluid.

Loose cylinder piston.

Replace cylinder.

Sticking flow control spool.

Replace flow control valve.

Air in hydraulic system.

Most likely air trapped in cylinders or lines.

Bleed air out of system.

Low fluid level.

Add fluid and check for leaks.

Steering column upper shaft is loose or damaged.

Tighten steering wheel nut.

Lower splines of column may be disengaged or broken.

Repair or replace column.

Steering control unit meter has a lack of oil. This can happen on start-up, after repair, or long periods of non-use.

Usually starting engine will cure problem.

Low fluid level.

Add fluid and check for leaks.

Ruptured hose.

Replace hose.

â&#x20AC;&#x153;Spongyâ&#x20AC;? or soft steering.

Free wheeling - Steering wheel turns freely with no feeling of pressure and no action on steered wheels.

12-14

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Section 12 STEERING TABLE 12-1. TROUBLESHOOTING STEERING PROBLEMS (continued).

PROBLEM

PROBABLE CAUSE

REMEDY

Free wheeling - Steering wheel turns with slight resistance but results in little or no steered wheel action.

Piston seal blown out.

Determine cause. Correct and replace seal.

Excessive free play at steering wheel.

Loose steering wheel nut.

Steering column shaft worn or damaged. Should be little free play in unit.

Repair or replace steering connection or column.

Excessive free play at steered wheels.

Broken or worn linkage between cylinder and steered wheels.

Check for loose fitting bearings and anchor points in steering linkage between cylinder and steered wheel.

Leaky cylinder seals.

Replace cylinder seals.

Large particles in meter section.

Clean the unit.

Severe wear in steering unit.

Replace unit.

Lines connected to wrong cylinder ports.

Reconnect lines correctly.

Steering unit lock up.

Steering wheel turns in wrong direction when operator activated steering wheel.

08/05

12-15

Section 12 STEERING NOTES

12-16

08/05

Section 13 ROTOR HYDRAULIC SYSTEM TABLE OF CONTENTS PAGE GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-2 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-2 CLEANLINESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-2 ROTOR CHARGE FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-4 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-4 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-4 FLUSHING VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-5 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-5 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-6 ROTOR PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-7 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-7 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-8

08/05

13-1

Section 13 ROTOR HYDRAULIC SYSTEM GENERAL INFORMATION.

CLEANLINESS.

This section provides a description of the main components of the Hydraulic Rotor Drive System.

Instructions for Removal, Installation, Disassembly and Assembly procedures are provide. Trouble analysis for the Hydraulic Rotor Drive System is found at the end of this section.

When servicing the Hydraulic System, it is very important to do the following:

DESCRIPTION. The Hydraulic Rotor Drive System, Figure 13-1, consists of the following main components.

Hydraulic Rotor Drive Rotor Charge Filter Rotor Pump

1. Clean surfaces, fittings, and hoses at the point of disconnection.

2. Protect all exposed sealing surfaces from damage and foreign material.

3. All gaskets and O-rings should be replaced.

4. Lightly lubricate all O-rings with hydraulic oil prior to assembly.

5. Whenever a hose is disconnected, immediately cap the fitting and plug the hose to prevent contamination.

Flushing Valve Accumulator

13-2

08/05

Section 13 ROTOR HYDRAULIC SYSTEM

FIGURE 13-1. ROTOR HYDRAULIC SYSTEM.

08/05

13-3

Section 13 ROTOR HYDRAULIC SYSTEM ROTOR CHARGE FILTER. The Rotor Charge Filter Assembly is connected to the Rotor Pump Assembly at ports “D” and “E”. The filter(s) are located on the left side of the machine, attached to the frame under the cockpit.

Replacement of the filter element is covered in Section 4, MAINTENANCE. If it is necessary to remove the complete filter assembly, refer to REMOVAL below:

Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all vertical cylinders, discharge any accumulators, and block any load whose movement could generate pressure.

REMOVAL [See Figure 13-2].

NOTE: Plug and cap all lines and ports to prevent entry of dirt into the system.

1. Remove the panel directly behind the boarding ladder underneath the operators platform to gain access to the hydraulic oil filters.

2. Place a container under the Filter Assembly (Figure 13-2) to catch any oil when the hydraulic lines are disconnected.

3. Disconnect and label the two hydraulic lines from Ports “D” and “E” on the top of the Rotor Pump Assembly connected to fittings (1) and (2), for the filter to be replaced.

4. Remove the four capscrews (3), and four washers (4) attaching the Filter Assembly to the frame and remove the Filter Assembly.

FIGURE 13-2. ROTOR CHARGE FILTER ASSEMBLY. INSTALLATION [See Figure 13-2].

NOTE: Use new O-rings when installing fittings.

1. Install fittings (Figure 13-2 – 1 and 2) on filter being sure not to damage the O-rings. Position fitting (1) to point 30° down and position fitting (2) to point 45° down.

2. Position Filter Assembly on underside of frame with fittings pointing toward center of machine and arrow pointing towards rear of machine, then align filter with mounting holes.

3. Apply threadlock 242 to the four capscrews (3).

5. Remove fittings (1 and 2) from the filter.

6. Inspect fittings and discard any fitting that is damaged.

4. Secure Filter Assembly to frame with the four capscrews (3) and four washers (4).

5. Torque capscrews (3) to 44 ft•lbs (59.7 N•m).

NOTE: Hydraulic hoses should be positioned at a 30° angle for attachment to fittings (1) and 45° angle for attachment to fitting (2).

13-4

08/05

Section 13 ROTOR HYDRAULIC SYSTEM 6. Connect the hydraulic lines from the Rotor Pump Assembly ports “D” and “E” to fitting (2 and 1) respectively.

7. Add hydraulic oil, if required.

8. Run unit to check for possible leaks.

9. Replace filter area cover panel.

FLUSHING VALVE. The Flushing Valve Assembly is located near the right rear of the frame. All “A” ports are low pressure and all “B” ports are high pressure.

Connections to the ports on the Flushing Valve Assembly are as follows.

A1

To Rotor Pump Port B

A2

To R.H. Rotor Arm Top Bulkhead Fitting

A3

To L.H. Rotor Arm Top Bulkhead Fitting

A4

Plugged

A5

To port “R”

B1

To Rotor Pump Port A

B2

To Right Hand Rotor Arm Bottom Bulkhead Fitting.

B3

To L.H. Rotor Arm Bottom Bulkhead Fitting.

GA

Low Charge Pressure Switch

GB

Pressure Transducer for Load Control

GC

Plugged

R

To Port “A5” and to Case Manifold

08/05

REMOVAL [See Figure 13-3].

Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all vertical cylinders, discharge any accumulators, and block any load whose movement could generate pressure.

NOTE: Plug and cap all lines when disconnected to prevent entry of dirt into the system. Place a container under the hydraulic fittings to be disconnected to catch any hydraulic oil.

1. Disconnect and label all hydraulic lines to the Flushing Valve Assembly.

2. Disconnect and label the electrical connections.

3. Remove the three screws (Figure 13-3 – 1) and three washers (2), attaching the Flushing Valve Assembly (3) to the frame, then remove Flushing Valve Assembly.

4. Remove all fittings (1 through 7 and 11) from the Flushing Valve Assembly.

13-5

Section 13 ROTOR HYDRAULIC SYSTEM INSTALLATION [See Figure 13-3].

NOTE: Check all fittings and O-rings for damage. Do not use any parts that show wear or damage.

1. Install all fittings on Flushing Valve Assembly.

The fitting at port "R" is positioned up at 20° from horizontal.

2. Secure the Flushing Valve Assembly to the frame with the three screws (Figure 13-3 – 1) and three washers (2).

4. Connect the hydraulic lines to the Flushing Valve Assembly.

5. Connect the electrical connections to the pressure switches (8).

6. Refill hydraulic tank to proper level.

7. Bleed the Hydraulic System to remove any trapped air.

8. Perform a system pressure check as described in the paragraph INSPECTION AND PRESSURE CHECK PROCEDURE in Section 8.

3. Torque screws (1) to 44 ft•lbs (59.7 N•m).

FIGURE 13-3. FLUSHING VALVE ASSEMBLY.

13-6

08/05

Section 13 ROTOR HYDRAULIC SYSTEM ROTOR PUMP. The Rotor Pump is attached to the Engine Crankshaft through an Adapter Plate. The pump can be removed without removing the Adapter Plate.

The pump rotates clockwise and has a displacement of 15.25 cubic inches/rev (250 CC/rev). Ports “A” and “B” have pressure limiters. The charge pump displacement is 2.87 cubic inches/rev (47 CC/rev). High Pressure setting for port “A” is 4640 psi (320 bar). High Pressure setting for port “B” is 1885 psi (130 bar). Charge pressure setting is 410 psi (28 bar).

Rotor Pump weights approximately 340 lbs (154 kg). Use a sling or other appropriate support when removing the rotor pump

4. Label and disconnect all electrical wires connected to the Rotor Pump Assembly and the Travel Pump Assembly.

NOTE: Support the rotor pump before removing mounting capscrews.

5. Remove the four capscrews (Figure 13-5 – 1), and four spring washers (2) attaching Rotor Pump Assembly (3) to Adapter Plate Assembly (4) and remove Rotor Pump Assembly.

6. Remove all fittings from the Rotor Pump Assembly.

7. If Rotor and Travel Pumps have been removed as a unit, remove Travel Pump from Rotor Pump.

REMOVAL [See Figure 13-4 and 13-5].

Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all vertical cylinders, discharge any accumulators, and block any load whose movement could generate pressure.

NOTE: The Travel Pump is attached to the Rotor Pump and can be removed before removing the Rotor Pump, or the Tandem Travel Pump and Rotor Pump can be removed as one unit then disassembled.

NOTE: Plug and cap all lines when disconnected to prevent entry of dirt into the system. Place a container under the hydraulic fittings to be disconnected to catch any hydraulic oil.

1. Turn battery disconnect switch to the OFF position to remove all machine electrical power.

2. Remove the Travel Pump (see SECTION 8) or if Travel and Rotor Pump are to be removed as a unit, proceed with step 3.

3. Label and disconnect all hydraulic hoses connected to the Rotor Pump Assembly and the Travel Pump Assembly.

08/05

FIGURE 13-4. ROTOR PUMP ASSEMBLY. 13-7

Section 13 ROTOR HYDRAULIC SYSTEM 5. Attach hose to port “A” using O-ring (13-4 – 5), two flanges (2), four capscrews (3) and four washers (4).

6. Torque capscrews (3) to 52 ft•lbs (70.5 N•m).

7. Attach all remaining hydraulic hoses to Rotor Pump Assembly.

8. Attach electrical connections to Rotor Pump Assembly.

9. Refill hydraulic oil tank to proper level.

10. Bleed the Hydraulic System to remove any trapped air.

11. Perform a system pressure check as described in the paragraph INSPECTION AND PRESSURE CHECK PROCEDURE in Section 8.

FIGURE 13-5. ROTOR PUMP MOUNTING TO ADAPTER PLATE. INSTALLATION [See Figures 13-4 and 13-5].

NOTE: Check all fittings and O-rings for damage. Do not use any parts that show wear or damage.

1. Install all fittings on Flushing Valve Assembly.

The fitting (Figure 13-4 – 1) at port “L1” is positioned pointing down at 45° from horizontal.

2. Coat capscrews (Figure 13-5 – 1) with Loctite 242.

3. Secure the Rotor Pump Assembly (3) to the adapter plate (4) with the four capscrews (1) and four spring washers (2).

4. Torque capscrews (1) to 200 ft•lbs (271.2 N•m).

13-8

08/05

Section 14 ROTOR SYSTEM TABLE OF CONTENTS PAGE GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-2 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-2 CLEANLINESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-2 ROTOR HOOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-4 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-4 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-5 ROTOR LIFT CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-8 REAR DOOR (TAILGATE) CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-8 ROTOR AND ARMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-8 ROTOR REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-8 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-8 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-12 ROTOR DOOR AND DEPTH INDICATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-13 REAR DOOR INDICATORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-13 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-13 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-14 DEPTH INDICATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-16 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-16 ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-16 ROTOR DEPTH PIVOT SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-16 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-16 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-16

08/05

14-1

Section 14 ROTOR SYSTEM GENERAL.

CLEANLINESS.

This section provides a description of the main components of the Rotor System including Removal, Installation, Disassembly and Assembly procedures.

When servicing the Hydraulic System, it is very important to do the following:

DESCRIPTION [See Figure 14-1].

The Rotor System uses Hydraulic Motors to drive the Rotors. The Recycler Rotor contains 168 teeth and the Stabilizer Rotor contains 70 teeth. The Hood on the Recycler includes a Rear Door that is operated by a Hydraulic Cylinders. The Hood on the Stabilizer includes a Rear Door that is operated by a Hydraulic Cylinder. The Hood also has a Rotor Depth and a Door Position Indicator. The major components of the Rotor System are as follows: Rotor Hood

1. Clean surfaces, fittings, and hoses at the point of disconnection.

2. Protect all exposed sealing surfaces from damage and foreign material.

3. All gaskets and O-rings should be replaced.

4. Lightly lubricate all O-rings with hydraulic oil prior to assembly.

5. Whenever a hose is disconnected, immediately cap the fitting and plug the hose to prevent contamination.

Rotor Lift Cylinder Rear Door (Tailgate) Cylinder Rotor and Arms Rotor Door Indicator Depth Indicator

14-2

08/05

Section 14 ROTOR SYSTEM

FIGURE 14-1. ROTOR SYSTEM. 08/05

14-3

Section 14 ROTOR SYSTEM ROTOR HOOD. The Rotor Hood Assembly for the Recycler has a hydraulically operated rear door and has a breaker bar. The Rotor Hood Assembly for the Stabilizer has a hydraulically operated rear door and does not have the breaker bar.

Before opening any circuit connection, make certain that power is off and the system pressure has been released. Lower all vertical cylinders, discharge any accumulators, and block any load whose movement could generate pressure. Be sure rear of hood is on the ground.

REMOVAL [See Figures 14-2 and 14-3].

NOTE: Plug and cap all lines and ports to prevent entry of dirt into the system.

1. Place a container under the hydraulic component to be disconnected to catch any oil when the hydraulic lines are disconnected.

2. Disconnect and remove the Tailgate Cylinder (Figure 14-2 â&#x20AC;&#x201C; 1) hydraulic hoses. Unclamp hoses and position away from Rotor Hood. (See Section 9.)

NOTE: Unless bushing (3) is being replaced, it does not require removal.

8. Remove self-aligning bushing (3), if required.

9. Remove nut (4) and spec bolt (5) on right side of the assembly.

NOTE: Unless bushing (6) is being replaced, it does not require removal.

10. Remove self-aligning bushing (6), if required.

11 Carefully lift Hood Assembly from machine.

12. If pitch brace (7) needs to be removed from left side of hood proceed as follows: a. Remove nut (8), special bolt (9), and spacer (10) on left side of hood.

NOTE: Unless bushing (11) is being replaced, it does not require removal. b. Remove self aligning bushing (11), if required, then remove pitch brace (7).

13. If pitch brace (15) needs to be removed from right side of hood proceed as follows: a. Remove nut (12), special bolt (13), and spacer (14) on right side of hood.

3. Disconnect the cable (3) to the depth indicator.

4. Remove clamps (4) attaching cable to hood.

5. Remove right-hand and left-hand guard weldment from either side of hood. Six capscrews and six washers retain the guards to either side of the Rotor Hood. (See Figure 14-1).

NOTE: Unless bushing (16) is being replaced, it does not require removal. b. Remove self aligning bushing (16) if required, then remove pitch brace (15) on right side of hood.

6. Attach lifting equipment to hood at lifting eyes.

7. Support the hood and remove nut (Figure 14-3 â&#x20AC;&#x201C; 1) and spec bolt (2) on left side of the assembly.

14-4

08/05

Section 14 ROTOR SYSTEM INSTALLATION [See Figures 14-2 and 14-3].

1. If pitch brace (14-3 – 7) needs to be installed on left side of hood, proceed as follows: a. Install self aligning bushing (11), if removed for inspection or replacement into pitch brace (7). b. Install lube fitting (17) in special bolt (9). c.

Secure pitch brace (7) to hood with nut (8), special bolt (9), and spacer (10).

d. Tighten special bolt (9) and nut (8) till secure against ears of hood area.

2. If pitch brace (15) need to be installed on right side of hood proceed as follows: a. Install self aligning bushing (16), if removed for inspection or replacement, into pitch brace (15). b. Install lube fitting (17) in special bolt (13). c.

Secure pitch brace (15) to hood with nut (12), special bolt (13), and spacer (14).

d. Tighten special bolt (13) and nut (12) till secure against ears of hood area.

3. Attach lifting equipment to hood at lifting eyes.

4. Carefully lift Hood Assembly and place over rotor aligning the pitch braces (7 and 15) with the mounting holes on the machine.

5. Install pitch brace (7) on left side of machine as follows: a. Install self aligning bushing (3), if removed for inspection or replacement, into pitch brace (7).

6. Install pitch brace (15) on right side of machine as follows: a. Install self aligning bushing (6), if removed for inspection or replacement, into pitch brace (15). b. Install lube fitting (17) in special bolt (5). c.

Secure pitch brace (15) to machine with nut (4), special bolt (5).

d. Tighten special bolt (5) and nut (4) till secure against ears of frame area.

7. Place a container under the hydraulic component to be reconnected to catch any oil when the hydraulic lines are connected.

8. Install the Tailgate Cylinder (Figure 14-2 – 1) hydraulic hoses. (See Section 9.)

9. Install right-hand and left-hand guard weldments (Figure 14-1) to either side of Rotor Hood. Six capscrews and six washers retain the guards to either side of the Rotor Hood.

NOTE: The following steps assume that the Depth Indicator and Door Position Indicators are mounted and installed.

10. Route the rear door cable (Figure 14-2 – 3) over the hood and connect to Rear Door Position Indicator. Install cable clamps (4) as necessary.

11. Adjust Rotor Hood pitch. (See Section 4-MAINTENANCE.) 12. Adjust Door Position Indicators and Depth Indicator.

b. Install lube fitting (17) in special bolt (2). c.

Secure pitch brace (7) to machine with nut (1), special bolt (2).

d. Tighten special bolt (2) and nut (1) till secure against ears of frame area.

08/05

14-5

Section 14 ROTOR SYSTEM

FIGURE 14-2. HOOD ATTACHMENTS. 14-6

08/05

Section 14 ROTOR SYSTEM

FIGURE 14-3. HOOD MOUNTING.

08/05

14-7

Section 14 ROTOR SYSTEM ROTOR LIFT CYLINDER. Information on the removal, installation, disassembly, and assembly of the Rotor Lift Cylinder is provided in Section 9.

6. Label and disconnect the hydraulic hoses and remove Port Block Assembly as follows: a. Remove the four hoses attached to each Hydraulic Motor (Figure 14-5 â&#x20AC;&#x201C; 1 through 4).

REAR DOOR (TAILGATE) CYLINDER. Information on the removal, installation, disassembly, and assembly of the Tailgate Cylinder is provided in Section 9.

b. Remove four capscrews (9) and hardend washers (10) which mount Port Block Assembly (11) to Rotor Motor(s). c.

ROTOR AND ARMS. ROTOR REMOVAL.

Before breaking any circuit connection, make certain that power is off and the system pressure has been released. Lower all vertical cylinders and block any load whose movement could generate pressure. Be sure rear of Hood is on the ground.

Carefully remove Port Block Assembly (11), accounting for all sealing rings.

NOTE: Mark location of hardened washers before removing capscrews.

7. Remove the twelve capscrews (7) and four hardened washers (8) attaching the Hydrostatic Motor to the left Rotor Arm. 8. Remove the twelve capscrews (7) and four hardened washers (8) attaching the Hydrostatic Motor to the right Rotor Arm.

REMOVAL [See Figures 14-4, 14-5 and 14-6].

NOTE: Plug and cap all lines and ports to prevent entry of dirt into the system.

1. Place a container under the hydraulic component to be removed to catch any oil when the hydraulic lines are disconnected.

2. Remove the Hood Assembly. (See this section.)

3. Remove 10 flange capscrews (Figure 14-4 â&#x20AC;&#x201C; 3) from left-hand Rotor Arm Covers and remove covers.

4. Remove 10 flange capscrews (3) from righthand Rotor Arm Covers and remove covers.

5. Support both left and right Rotor Arms.

14-8

08/05

Section 14 ROTOR SYSTEM

FIGURE 14-4. ROTOR LIFT ARM COVERS. 08/05

14-9

Section 14 ROTOR SYSTEM 9. Remove Rotor Assembly from Rotor Arms.

Rotor Arm may have to be carefully deflected away from Rotor Motor pilot area for Rotor removal.

NOTE: Motor assemblies weigh approximately 1118 lbs (507.1 kg).

10 Support Motor Assemblies.

11. Remove twelve capscrews (Figure 14-6 â&#x20AC;&#x201C; 1) and twelve washers (2) attaching motor mounting ring (3) and end segment (4) (recycler), or end plate (5) (stabilizer) to Rotor Assembly (6).

Remove end segments from rotor.

12. To remove Motor Assembly from Rotor Assembly (Figure 14-6), remove four capscrews (9) and hardened disc (10) attaching motor mounting rings (3) to Rotor Assembly (6) and slide Motor Assembly (11) out of Rotor Assembly (6).

13. Remove eight capscrews (21) securing port block adapter (20) to motor mounting face.

Secure all sealing O-rings.

14. Remove capscrews (12) and hardened discs (13) and remove mounting ring (3) from Motor Assembly (11).

NOTE: For welding or replacing tine plates and/or sockets on a Stabilizer or for welding or welding one piece sockets on recyclers, refer to Section 4 MAINTENANCE.

FIGURE 14-5. HYDROSTATIC MOTOR ASSEMBLY.

14-10

08/05

Section 14 ROTOR SYSTEM

FIGURE 14-6. ROTOR ASSEMBLY. 08/05

14-11

Section 14 ROTOR SYSTEM INSTALLATION [See Figures 14-4, 14-5 and 14-6].

NOTE: Tighten all case drains in Motor Assembly before assembling to Rotor.

1. Coat capscrews (12) with Loctite 271.

2. Attach mounting ring (3) to each Motor Assembly (11) with ten capscrews (12) and ten hardened discs (13).

3. Torque capscrews (12) to 426 ft•lbs (578 N•m).

Motor Assemblies weight approximately 1118 lbs (507.1 kg), use appropriate lifting equipment.

4. Insert Motor Assembly (11) into Rotor Assembly (6) aligning mounting holes in motor mounting ring (3) with mounting holes in Rotor Assembly. a. Rotate left side motor so that port “A” is facing up. b. Rotate right side motor so that port “B” is facing up.

5. Secure motor mounting ring (3) to Rotor Assembly with four capscrews (9) and four hardened discs (10).

6. Torque capscrews (9) to 342 ft•lbs (464 N•m).

7. Coat capscrews (1) with Loctite 271.

8. Secure motor mounting ring (3) and end segment (4) (Recycler) or end plate (5) (Stabilizer) to Rotor Assembly (6) with twelve capscrews (1) and twelve washers (2).

NOTE: Hardened washers (Figure 14-5 – 8) must be installed only at mounting holes marked during disassembly.

13. Coat capscrews (7) with Loctite 271.

14. Secure the Hydrostatic Motor to the left Rotor Arm with the ten capscrews (7) and plate washers (8).

15. Secure the Hydrostatic Motor to the right Rotor Arm with the ten capscrews (7) and plate washers (8).

16. Torque capscrews (7) to 342 ft•lbs (464 N•m).

17. Using new sealing O-rings, carefully install the Port Block Assembly.

18. Place a container under the hydraulic component to be installed to catch any oil when the hydraulic lines are reconnected.

19. Connect the four hydraulic hoses (Figure 14-5 – 1 through 4) to both the left and right Hydrostatic Motors.

20. Check the rotor motor seal lube oil. (See Section 4 MAINTENANCE.) 21. Check that no leaks are present.

22. Install the left-hand and right-hand Rotor Arm Covers using 10 flange capscrews (Figure 14-4 – 3) on each side.

23. Torque capscrews (3) to 31 ft•lbs (42 N•m).

24. Install the Hood Assembly. (See this section.)

9. Torque capscrews (1) to 500 ft•lbs (678 N•m).

10. Install Port Block Adapter (20) to motor mounting face with ten capscrews (21), using new sealing O-rings.

11. Torque ten capscrews (21) to 426 ft•lbs (578 N.m).

12. Apply loctite 242 to six capscrews (16) and torque capscrews to 375 ft•lbs (508 N.m).

14-12

08/05

Section 14 ROTOR SYSTEM ROTOR DOOR AND DEPTH INDICATOR. The Rotor Door Position and Depth Indicator Displays are located on the frame behind the cockpit and is visible to the operator. The Rotor Depth Indicator is present on all machines. The Depth Indicator must be aligned to provide accurate information. The Door Indicator is used to indicate the position of the door. The plate supporting the indicator is welded to the frame and is not removable.

REAR DOOR INDICATORS. REMOVAL [See Figures 14-7 and 14-8].

The Indicator Plate (Figure 14-7) is welded to the frame. The cables and indicator arms can be replaced.

1. Hydraulically close the rear door.

2. Remove nut (6), flange screw (7) and two washers (8) to disconnect spherical rod end (9) from indicator arm (10).

3. Remove flange screw (11), washer (12), and two bevel washers (13). Note position stack for washers.

NOTE: Bushings (14) only require removal if replacing.

4. Slide off spacer (17), indicator arm (10) and two bushings (14), if required.

5. Remove flange screw (15) and pin (16).

08/05

14-13

Section 14 ROTOR SYSTEM INSTALLATION [See Figures 14-7 and 14-8].

9. Torque flange screw (Figure 14-8 – 7) to 7 ft•lbs (11 N•m).

NOTE: Insure unit Rotor and Hood are on solid level surface for adjustment accuracy.

1. Lubricate pin (16) with grease or anti-seize before installing then secure pin (16) with flange screw (15).

2. Torque flange screw (15) to 17 ft•lbs (23 N•m).

3. Insert indicator arm (10) into slots on indicator plate (18), then slide indicator arm (10), two bushings (14), if removed and spacer (17) on pin (16).

4. Secure indicator arm (10) to pin (16) with flange screw (11), washer (12), and two bevel washers (13). Note stack detail.

5. Torque flange screw (11) to 17 ft•lbs (23 N•m).

6. Check that the rear door is closed.

7. Loosen nut (Figure 14-7 – 5) and adjust spherical rod end (6) on cable (7) so that indicator arm (8) is at bottom of slot with front door closed. Tighten nut (5).

8. Connect spherical rod end (Figure 14-8 – 9) to indicator arm (10) with nut (6), flange screw (2) and two washers (8).

FIGURE 14-7. ROTOR DEPTH AND DOOR INDICATOR ASSEMBLY.

14-14

08/05

Section 14 ROTOR SYSTEM

FIGURE 14-8. INDICATOR ARM ASSEMBLY.

08/05

14-15

Section 14 ROTOR SYSTEM DEPTH INDICATOR.

ROTOR DEPTH PIVOT SHAFT.

The Depth Indicator (pointer) is connected by linkage rod to the pivot crossmember weldment and indicates the Rotor depth on the depth plate. When the Rotor height is changed, the pointer is moved by the linkage rod and indicates Rotor depth. The position of the pointer can be adjusted so that the pointer is pointing to “0” when the Rotor is sitting at ground level.

The rotor depth pivot shaft is located on the pivot shaft depth plate and links the pointer to the lever depth indicator weldment.

DISASSEMBLY [See Figure 14-9].

2. Unscrew the knob (5) and remove the knob from the lever depth indicator weldment (17).

1. The pointer can be replaced by removing knob (Figure 14-9 – 5), washer (4), washer (6) and pointer (1).

REMOVAL [See Figure 14-9].

1. Disconnect the linkage rod (Figure 14-9 – 2) from the lever depth indicator weldment (17).

3. Remove washers (4 and 6).

4. Remove pointer (1).

2. The linkage rod can be replaced by removing washer (8) and nut (9) at both ends of linkage rod (2) and disengaging linkage rod.

5. Remove nut (18).

6. Remove washers (13 and 14).

ASSEMBLY [See Figure 14-9].

1. If a new linkage rod is being installed proceed as follows:

7. Remove lever depth indicator weldment (17) with bushing (16), spacer (15) and washer (19).

INSTALLATION [See Figure 14-9].

a. Assemble nut (Figure 14-9 – 10) and ball joint (11) to ends of new linkage rod. Adjust linkage rod length with ball joints attached to be the same length (10.38 inch centerline to centerline) as linkage rod is removed.

1. Place grease on bushing (Figure 14-9 – 16).

2. Install washer (19) on lever depth indicator weldment (17).

b. Lock ball joints (11) in place by tightening nuts (10).

3. Install bushing (16) into rotor depth plate housing.

c.

4. Place spacer (15) on lever depth indicator weldment (17) and insert weldment through the rotor depth plate (7) from the underside.

Attach linkage rod (2) to crossmember weldment (3) with washer (8) and nut (9).

d. Attach linkage rod (2) to depth lever (12) with washer (8) and nut (9). e. With Rotor sitting on the ground, loosen knob (3), then position pointer (1) to read “0”. f.

Tighten knob (3) to lock pointer (1) in position.

2. If a new pointer (1) is being installed, proceed as follows:

5. Install washers (13 and 14) on shaft (17).

6. Install nut (18) on shaft (17) 7. Install pointer (1) and washers (6 and 4) on shaft.

8. Screw knob (5) on shaft.

9. Connect the linkage rod (2) to the shaft (17).

a. Install pointer (1), washer (6), washer (4), and knob (5). b. With rotor sitting on the ground, loosen knob (5), then position pointer (1) to read “0”. c.

14-16

10. With rotor sitting on the ground, loosen knob (5), then position pointer (1) to read “0”.

11. Tighten knob (5) to lock pointer in position (1).

Tighten knob (5) to lock pointer in position (1).

08/05

Section 14 ROTOR SYSTEM

FIGURE 14-9. ROTOR DEPTH ASSEMBLY (SHEET 1 OF 2).

08/05

14-17

Section 14 ROTOR SYSTEM

FIGURE 14-9. ROTOR DEPTH ASSEMBLY (SHEET 2 OF 2).

14-18

08/05

Section 15 OPTIONS TABLE OF CONTENTS PAGE WATER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-2 SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-2 WATER SYSTEM FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-2 MPH ALPS 4.0 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-5 SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-5 MPH ALPS 4.0 SYSTEM FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-5

08/05

15-1

Section 15 OPTIONS WATER SYSTEM.

OPERATION [See Figure 15-2].

SYSTEM DESCRIPTION [See Figure 15-1].

1. Make sure flow control knob (3), spraybar toggle switch (2) and water spray system switch (1) is in the off position.

A hydrostatic pump drives a hydraulic motor, which is connected, to a centrifugal water pump with a 7” impeller. A water tanker truck is connected to the MPH by a push boom and a 3” water hose. The centrifugal water pump draws water from the tanker and delivers the water to the spraybar located above the rotor hood. The spray nozzles on the spraybar inject water directly into the mixing chamber while the machine is working. The water piping system in which the water is delivered to the spraybar is located along the right hand side of the machine and includes a flow meter and an electric shut-off valve.

The operator controls are located directly behind the FNR lever in a control panel. The operator can turn the water spray system on/off, spraybar on/off, control amount of flow, and see flow rate/total amount of water used. A hydraulic filter indicator light is also located on the control panel to indicate if the hydrostatic pumps filter is in need of a servicing.

WATER SYSTEM FEATURES.

• Water pump, centrifugal with 7” impeller, 3” • • • • • • • • • • •

15-2

2. Make sure display (5) is in flow rate mode. Zero totals if desired.

3. Turn water spray system switch (1) on.

4. Toggle spraybar switch (2) on.

5. Adjust flow control knob (3) to desired flow, reading flow rate on the display (5).

6. To stop flow from spraybar and maintain the flow rate setting, toggle spraybar switch (2) off and turn water spray system switch (1) off. To start again turn water spray system switch (1) on and toggle spraybar switch (2) on. Flow will start at previous flow rate setting.

7. To stop flow from spraybar without maintaining the flow rate setting (shuts off faster), turn flow control knob (3) to off, and toggle spraybar switch (2) off. To start again toggle spraybar switch (2) on, and adjust flow control knob (3) to desired flow.

X 2.5” size, dewatering type capable of 3/8” solids.

Water pump drive. Closed circuit hydraulic system with axial piston pump and motor.

Electrical operated servo flow control.

17 nozzles with 3/8” effective orifice.

4.5” nozzle spacing.

Individual shutoff valves at each nozzle to vary width of coverage.

0-350 gpm (1325 l/min).

3” system, 4” flow meter, 4” strainer with 5/32” (.156”) perforations.

Turbine flow meter with +/- 2% accuracy over entire range.

Manual water flow control.

Digital display for flow rate and totalizer. Flow rate displayed in either gpm or l/min. Total volume pumped displayed in either gallons or liters.

All electric controls allow flow stopped and started with out readjusting flow rate.

Includes push boom, quick couplers, and an additional set of nozzles with 1/4” orifice.

08/05

Section 15 OPTIONS

FIGURE 15-1. WATER SYSTEM COMPONENTS. 08/05

15-3

Section 15 OPTIONS

FIGURE 15-2. CONTROL PANEL.

15-4

08/05

Section 15 OPTIONS MPH ALPS 4.0 SYSTEM. SYSTEM DESCRIPTION [See Figure 15-1].

A hydrostatic pump drives a hydraulic motor, which is connected, to a sliding vane asphalt pump (See Figure 15-3). An emulsion tanker truck is connected to the MPH by a push boom and a 3” asphalt hose.

The asphalt pump draws emulsion from the tanker and delivers the emulsion to the spraybar located above the rotor hood. The spray nozzles on the spraybar (See Figure 15-4) inject emulsion directly into the mixing chamber while the machine is working. The emulsion piping system in which the emulsion is delivered to the spraybar is located along the right hand side of the machine and includes a flow meter and additional piping for putting the system in recirculation mode when system is idle so emulsion won’t set-up in piping system.

The operator controls are located to the right of the FNR lever in a control panel (See Figure 15-5). The operator can select the mode of operation (manual mode, auto mode, or manual back-up mode), put the system in run mode or hold mode, turn the spraybar on/off, go into set-up mode, and zero totals. A hydraulic filter indicator light is also located on the control panel to indicate if the hydrostatic pumps filter is in need of servicing.

MPH ALPS 4.0 SYSTEM FEATURES.

• Pump- Asphalt, Sliding Vane Type with relief set at

• • • • •

• •

75 psi, 640 rpm max. pump speed, 240·F max. temp., l.h. rotation when viewed from shaft end, 21/2” NPT inlet flange, 2” NPT outlet flange.

Asphalt pump drive. Closed circuit hydraulic system with axial piston pump and gearotor motor.

Electrical operated servo flow control.

21 nozzles – two types: type A (low flow require ment) 0 – 50 gpm (0 – 189 lpm), and type B (high flow requirement) 40 – 130 gpm (151 – 492 lpm).

4.5” nozzle spacing.

Nozzles can be Individually shutoff to vary width of coverage.

3 modes of operations: - Auto mode: programmable application flow rates, 0.1 – 9.9 gallons per square yard (0.5 – 41.0 liters per square meter) - Manual mode: 3.5 – 130 gpm (13.5 – 492 lpm) - Manual Back Up mode: 3.5 – 130 gpm (13.5 – 492 lpm) Application width – 96 inches (2.4 meters) Emulsion source – tank truck pushed by MPH series recycler during application.

NOTE: For operating and maintenance instructions refer to the BOMAG Operating, Maintenance Instruction/Parts Catalog ALPS 4.0 System For MPH Series Recyclers.

08/05

15-5

Section 15 OPTIONS

FIGURE 15-3. ASPHALT PUMP.

FIGURE 15-4. SPRAYBAR.

15-6

08/05

Section 15 OPTIONS

FIGURE 15-5. CONTROL PANEL.

08/05

15-7

08/05

FIGURE 7-1. MPH 362/364 ELECTRICAL SCHEMATIC (SHEET 1 OF 12).

7-25/26

Section 7 ELECTRICAL

08/05

FIGURE 7-1. MPH 362/364 ELECTRICAL SCHEMATIC (SHEET 2 OF 12).

7-27/28

Section 7 ELECTRICAL

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FIGURE 7-1. MPH 362/364 ELECTRICAL SCHEMATIC (SHEET 3 OF 12).

7-29/30

Section 7 ELECTRICAL

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FIGURE 7-1. MPH 362/364 ELECTRICAL SCHEMATIC (SHEET 4 OF 12).

7-31/32

Section 7 ELECTRICAL

08/05

FIGURE 7-1. MPH 362/364 ELECTRICAL SCHEMATIC (SHEET 5 OF 12).

7-33/34

Section 7 ELECTRICAL

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FIGURE 7-1. MPH 362/364 ELECTRICAL SCHEMATIC (SHEET 6 OF 12).

7-35/36

Section 7 ELECTRICAL

08/05

FIGURE 7-1. MPH 362/364 ELECTRICAL SCHEMATIC (SHEET 7 OF 12).

7-37/38

Section 7 ELECTRICAL

08/05

FIGURE 7-1. MPH 362/364 ELECTRICAL SCHEMATIC (SHEET 8 OF 12).

7-39/40

Section 7 ELECTRICAL

08/05

FIGURE 7-1. MPH 362/364 ELECTRICAL SCHEMATIC (SHEET 9 OF 12).

7-41/42

Section 7 ELECTRICAL

08/05

FIGURE 7-1. MPH 362/364 ELECTRICAL SCHEMATIC (SHEET 10 OF 12).

7-43/44

Section 7 ELECTRICAL

08/05

FIGURE 7-1. MPH 362/364 ELECTRICAL SCHEMATIC (SHEET 11 OF 12).

7-45/46

Section 7 ELECTRICAL

08/05

FIGURE 7-1. MPH 362/364 ELECTRICAL SCHEMATIC (SHEET 12 OF 12).

7-47/48

Section 7 ELECTRICAL

08/05

FIGURE 8-16. MPH 362/364 HYDRAULIC SCHEMATIC (SHEET 1 OF 4).

8-23/24

Section 8 HYDRAULICS

08/05

FIGURE 8-16. MPH 362/364 HYDRAULIC SCHEMATIC (SHEET 2 OF 4).

8-25/26

Section 8 HYDRAULICS

08/05

FIGURE 8-16. MPH 362/364 HYDRAULIC SCHEMATIC (SHEET 3 OF 4).

8-27/28 3

Section 8 HYDRAULICS

08/05

FIGURE 8-16. MPH 362/364 HYDRAULIC SCHEMATIC (SHEET 4 OF 4).

8-29/30

Section 8 HYDRAULICS