Operating instructions

Maintenance instructions

BW11RH
SN: 911A22211002 >

Pneumatic Tired Roller

Catalog Number
0852769 04/2008
DANGER: If the machine was received with the Roll Over/Falling Object Protection
Structure (ROPS/FOPS) and Operator Restraints (Seat Belt Sets) NOT
installed, they MUST be installed BEFORE the machine is operated, using
the installation instructions drawing, included with the installation kit,
and/or the illustration below.
In the event of a machine roll over, serious injury, or death, can occur due
to failure to correctly install the Roll Over/Falling Object Protection
Structure (ROPS/FOPS) and Operator Restraints (Seat Belt Sets).

Structure

6 Flange Screws and

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

Left
(Retractor)

Seat Belt
Assembly
(2 Sets used)

Washer

3 Capscrews and Flange Nuts used.

DANGER: Do Not operate machine with the Roll Over/ Install Flange Nuts and tighten to a
Falling Object Protection Structure torque of 40 ft. lbs. (54 N.m).
(ROPS/FOPS) and Operator Restraints
(Seat Belt Sets) NOT properly installed. 04/2008
04/2008
 SYMBOLS USED IN THIS MANUAL

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

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

CAUTION: Minor personal injury can result or NOTE: Gives additional, and/or clarification
a part, an assembly, or the engine details, which are to be used in
can be damaged if the CAUTION conjunction with previously
instructions are not followed. presented information.

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

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

Wash hands after handling.

04/2008
 SERVICE AND REPAIR PRECAUTIONS

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

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

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

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

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

ALWAYS support the machine with sound blocking.

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

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

ALWAYS keep tools in a good and clean condition.

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

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

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

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

04/2008
 MANUAL - TABLE OF CONTENTS

PAGE

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

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

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

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

04/2008 i
 OPERATING INSTRUCTIONS

WARNING:

WARNING:

WARNING:

04/2008
 Section 1
INTRODUCTION

TABLE OF CONTENTS

PAGE

GENERAL INFORMATION ......................................................................................................................1-2.

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

OPERATING INSTRUCTIONS .................................................................................................................1-2.

MAINTENANCE PROCEDURES .............................................................................................................1-2.

REPAIR PROCEDURES ..........................................................................................................................1-3.

NAME PLATE / SERIAL NUMBER PLATE .............................................................................................1-3.

SERIAL NUMBER ....................................................................................................................................1-3.

04/2008 1-1
Section 1
INTRODUCTION
GENERAL INFORMATION. WARNING: ONLY authorized personnel, who
are fully trained in the
THIS manual contains SPECIFICATION, machine operation procedures,
OPERATION and MAINTENANCE procedures for can operate the Pneumatic
the Pneumatic Roller [See Figure 1-1]. Roller.
Follow ALL instructions given
in THIS manual and written on
the “Machine Operation and
SPECIFICATIONS. Warning” decals, found on the
upper area of the front cowl in the
See Section 2 - SPECIFICATIONS, of THIS operator's compartment.
manual, for specifications on major systems used
on the machine.

MAINTENANCE PROCEDURES.

OPERATING INSTRUCTIONS. The maintenance schedules and procedures

are found in Section 4 - MAINTENANCE, of
READ, UNDERSTAND and FOLLOW ALL the THIS manual.
operating instructions given in the FRONT, and in
Section 3 - OPERATION, of THIS manual.
CAUTION: Follow ALL the maintenance
schedules and instructions
given in THIS manual.

FIGURE 1-1. PNEUMATIC ROLLER.

1-2 04/2008
 Section 1
INTRODUCTION
REPAIR PROCEDURES. SERIAL NUMBER [See Figures 1-2 and 1-3 ].

MAJOR machine component REPAIR PROCE- The SERIAL NUMBER indicates the design series,
DURES are found in the “SYSTEM REPAIR PRO- manufacturing location and machine serial number
CEDURE” sections of "Instructions For Repair [see Table 1-1]. The machine serial number is
Manual", pn. 0852719. located on the nameplate [see figure 1-2].

The machine serial number is also stamped on the

CAUTION: For CORRECT machine component left hand side of the rear unit hitch weldment [see
repair procedures, USE "Instructions figure 1-3].
For Repair Manual" pn. 0852719, or
other referenced written materials
ONLY. CAUTION: ALL numbers and letters,
contained in the SERIAL NUMBER,
MUST be given when requesting
service and/or part information.
NAME PLATE /SERIAL NUMBER PLATE [See
Figure 1-2].

The name plate/serial number plate is located on

the left side of the machine, above the entrance to
the operator's compartment. The plate MUST stay
fastened to the machine at ALL times. If the plate is
missing or damaged, it MUST be replaced IMME-
DIATELY. Contact your nearest Distributor to obtain
a replacement plate.

SERIAL NUMBER

NAME PLATE

FIGURE 1-3. STAMPED SERIAL NUMBER

LOCATION - AT HITCH PLATE AREA.

FIGURE 1-2. NAME PLATE /SERIAL NUMBER

PLATE LOCATION.

04/2008 1-3
Section 1
INTRODUCTION

911 A2221 1002

PLANT OF DESIGN SERIES MACHINE

MANUFACTURE AND SERIAL NUMBER
MODEL CODE

TABLE 1-1. MACHINE SERIAL NUMBER DESIGNATIONS.

1-4 04/2008
 Section 2
SPECIFICATIONS

TABLE OF CONTENTS

PAGE

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

TABLE 2-1. FRAME, HITCH AND FALLING OBJECT/ROLL OVER PROTECTIVE

STRUCTURE [FOPS/ROPS] SPECIFICATIONS .................................................................. 2-2.

TABLE 2-2. ENGINE SPECIFICATIONS .......................................................................................... 2-3.

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

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

TABLE 2-5. BRAKE SYSTEM SPECIFICATIONS ........................................................................... 2-9.

TABLE 2-6. STEERING SYSTEM SPECIFICATIONS ..................................................................... 2-9.

TABLE 2-7. TIRE SPECIFICATIONS ............................................................................................. 2-11.

TABLE 2-8. CONTROL AND INDICATOR SPECIFICATIONS ...................................................... 2-11.

TABLE 2-9. WATER SPRAY SYSTEM SPECIFICATIONS .......................................................... 2-12.

TABLE 2-10. OPTIONAL EQUIPMENT SPECIFICATIONS ........................................................... 2-13.

TABLE 2-11. DIMENSION AND WEIGHT SPECIFICATIONS ....................................................... 2-14.

TABLE 2-12. PERFORMANCE SPECIFICATIONS ........................................................................ 2-15.

TABLE 2-13. MACHINE SYSTEM CAPACITY SPECIFICATIONS ................................................ 2-15.

TABLE 2-14. COMPONENT WEIGHTS .......................................................................................... 2-16.

TABLE 2-15. TORQUE SPECIFICATIONS FOR STANDARD INCH

FASTENERS ......................................................................................................................... 2-17.

TABLE 2-16. TORQUE SPECIFICATIONS FOR STANDARD METRIC

FASTENERS ........................................................................................................................ 2-18.

TABLE 2-17. LUBRICATION OILS, HYDRAULIC OILS AND COOLANT

SPECIFICATIONS ................................................................................................................ 2-19.

TABLE 2-18. ADHESIVE THREAD LOCKING SPECIFICATIONS ................................................ 2-19.

04/2008 2-1
Section 2
SPECIFICATIONS
GENERAL INFORMATION.
Machine dimensions, weights, performance and
THIS section gives specification tables for each torque specifications are also given in THIS
MAJOR machine system of the Pneumatic Roller. section.

TABLE 2-1. FRAME, HITCH AND FALLING OBJECT/ROLL OVER

PROTECTIVE STRUCTURE [FOPS/ROPS] SPECIFICATIONS.

ITEM DESIGN DATA

FRAME

Material Plate steel

Construction Unitized, all welded front and rear frame section

HITCH

Oscillation +/- 10 - each side to center, 20 total - side to side

Articulation +/- 35 - each side to center, 70 total - side to side

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

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

2-2 04/2008
 Section 2
SPECIFICATIONS

TABLE 2-2. ENGINE SPECIFICATIONS.

ITEM DESIGN DATA

ENGINE

Model and 4B3.3TA Cummins Diesel

Manufacturer

Type 4 Cycle Turbocharged. diesel

Number of 4
Cylinders

Bore 3.74 in. [95 mm]

Stroke 4.528 in. [115 mm]

Rated Brake 85 hp [63 Kw] @ 2,600 rpm

Horsepower

Compression Ratio 17:1

Firing Order 1-2-4-3

Low Idle Speed 800 rpm

High Idle Speed 2,600 rpm [governed]

Engine Oil Type See engine Cummins "Operation and Maintenance Manual -
B3.3 Series Engines", which is supplied with machine

Valve Clearances

Intake - Hot or Cold 0.014 in. [0.35 mm]

Exhaust - Hot or Cold 0.020 in. [0.50 mm]

ENGINE COOLING
SYSTEM

System Capacity 19 qts. [17.97 ltrs.]

Radiator Type Full flow, liquid pressure, with integral oil cooler

Pressure Cap Rating 7 psi. [0.5 bar]

Thermostat Range 180-203 F [83-95 C], thermostat opens

04/2008 2-3
Section 2
SPECIFICATIONS
TABLE 2-2. ENGINE SPECIFICATIONS [Continued].

ITEM DESIGN DATA

ENGINE FUEL

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

FUEL FILTERS

Fuel Strainer Suction line, replaceable element with water drain

Fuel Filter Pressure line, replaceable element

FUEL PUMP

Type BoschVE, rotary type

FUEL INJECTORS

Quantity and Type 4, close nozzle

2-4 04/2008
 Section 2
SPECIFICATIONS
TABLE 2-3. ELECTRICAL SPECIFICATIONS.

ITEM DESIGN DATA

BATTERY

Number Per Machine One [1]

Ampere Hour Rating 900 CCA

Voltage 12 Volts

ALTERNATOR

Voltage, Type and 12 Volt, negative ground - Denso

Manufacturer

Output Amperage 60 Amps

Maximum Charge 60 Amps - 14 volts [cold]

Rate

Direction of Clockwise [C.W.] - viewed from

Rotation drive end

Fan Belt Tension Automatic belt tensioner keeps serpentine belt

and Method Used to under tension at ALL times
Achieve

STARTER

Manufacturer Denso [see engine STARTER plate for manufacturer part number]

Voltage and Type 12 Volt, negative ground

04/2008 2-5
Section 2
SPECIFICATIONS

TABLE 2-4. TRANSMISSION SYSTEM SPECIFICATIONS.

ITEM DESIGN DATA

TRAVEL SPEED
Low 0 - 8.0 mph [0 - 12.9 kph]
Medium 0 - 10.5 mph [0 - 16.9 kph]
High 0 - 15.5 mph [0 - 25.0 kph]

TRANSMISSION TYPE Hydrostatic

PUMP Axial piston, variable displacement

[see Hydraulic Pump]

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

[See Hydraulic Motor]

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

HYDRAULIC SYSTEM 28.5 Gallons [108 liters]

CAPACITY

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

MAXIMUM SUCTION 10 in. hg. [254 mm hg] Maximum

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

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

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

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

CONTROL PRESSURE 100 psi. [6.9 bar]

[forward or reverse]

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

SUCTION FILTER 10 in. hg. [0.7 bar] Maximum

VACUUM

2-6 04/2008
 Section 2
SPECIFICATIONS

TRANSMISSION PUMP

ITEM DESIGN DATA

TYPE Variable displacement axial piston

SWASH PLATE ANGLE 17 maximum - either side of center

PRESSURE RATING -
MAXIMUM 6000 psi. [414 bar]

DIRECTION OF ROTATION Clockwise [C.W.]

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

MINIMUM MAIN PORT 200 psi. [14 bar] ABOVE case pressure
PRESSURE

MAXIMUM CONTINUOUS 220 F [104 C]

CASE TEMPERATURE

MAIN SHAFT SPEED - 2650 +/- 20 rev/min

AT NO LOAD

CHARGE FLOW RATING 10 Gallon/min [38 liter/min] @ 2100 rev/min

CHARGE PUMP 1.03 cu. in. [17 cu. cm] per revolution
DISPLACEMENT

PORT SIZES
MAIN LINE INLET/OUTLET 1.00 in. [25.4 mm] S.A.E. split flange, 4 bolt, code 62
PORTS [2]

CASE PORTS [INLET 1.0625 in. [29.99 mm] - 12 S.A.E. straight thread O-ring
AND OUTLET]

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

CONTROL LEVER 28, Either direction from center

04/2008 2-7
Section 2
SPECIFICATIONS

HYDRAULIC MOTORS

ITEM DESIGN DATA

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

NUMBER PER MACHINE Two [2]

MAXIMUM OPERATING 6500 psi.. [449 bar] intermittent ONLY

PRESSURE

MAXIMUM CASE 35 psi. [2.4 bar] Cold/intermittent ONLY

PRESSURE

MULTI-DISC BRAKE, 175-435 psi. [12-30 bar]

RELEASE PRESSURE

PORT SIZES
Main Port Inlet/Outlet [2] SAE O-Ring (-12) 1.062"-12UNF
Case Drain Port [1] SAE O-Ring (-8) 0.75"-16UNF
Brake Line Port SAE O-Ring (-6) 0.56"-18UNF

DRIVE WHEEL NUTS -

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

MOTOR WEIGHT 300 lbs. [136 kg], Each

2-8 04/2008
 Section 2
SPECIFICATIONS
TABLE 2-5. BRAKE SYSTEM SPECIFICATIONS.

ITEM DESIGN DATA

BRAKE SYSTEM

SERVICE BRAKE TYPE Hydrostatic, through transmission system

SECONDARY/PARKING Spring applied, hydraulically released [SAHR], multi-disc brake

BRAKE TYPE incorporated with each hydrostatic transmission drive motor

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

PRESSURE

TABLE 2-6. STEERING SYSTEM SPECIFICATIONS.

ITEM DESIGN DATA

STEERING SYSTEM

Type of System Hydraulic, center point

Type and Amount of Mobil 423, HYTRAN, Texaco TDH, or equivalent [same as for
System Oil transmission system]

STEERING HYDRAULIC
PUMP

Type Gear

Pump Output Rate 9.0 gpm [34.1 lpm] @ 2,800 rpm

and Speed

Direction of Counter Clockwise [C.C.W.]

Rotation [viewed
from shaft end]

STEERING RELIEF
VALVE

Type Integral with steering control assembly

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

04/2008 2-9
Section 2
SPECIFICATIONS

ITEM DESIGN DATA

STEERING CONTROL UNIT

Type Rotary actuated, load sensing and non-load reacting, with

internal adjustable relief valve

STEERING CYLINDERS

Type Double acting

Number per One [1]

Machine

Stroke of Cylinder 12.00 in. [304.8 mm]

STEERING PERFORMANCE

Total Steering 70 Total, 35 each side of center

2-10 04/2008
 Section 2
SPECIFICATIONS

TABLE 2-7. TIRE SPECIFICATIONS.

ITEM DESIGN DATA

TIRES

Size, Ply and Quantity 7.50 x 15 -radial,12 ply equivalent, [9]

Tire Overlap 1/2 in. [12.5 mm]

Tire Oscillation
Front Rigid
Rear Outside tandems - +/- 4, center spring loaded - +/-5

TABLE 2-8. CONTROL AND INDICATOR SPECIFICATIONS.

ITEM DESIGN DATA

FUNCTION TYPE

CONTROL

Direction of Machine Single bar lever and linkage, controls transmission [F-N-R] and
Travel [F-N-R] and Engine engine throttle speed [low to high idle]
Throttle Speed

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

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

Steering Control Steering wheel, hydraulic steering control unit and system

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

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

Engine Start/Run/Stop Key switch, electrical, 12 volt, negative ground

Horn Button switch, 12 volt, negative ground, dash mounted

Water Spray System Two [2] position, toggle switch, 12 volt, negative ground
Control “ON/OFF”

Water Spray Flow Rate Variable position, manual valve, flow rate “LOW to HIGH”
Control “LOW to HIGH”

Head Lights [Front and Electrical switch, 12 volt, negative ground

Rear] - Option

04/2008 2-11
Section 2
SPECIFICATIONS
TABLE 2-8. CONTROL AND INDICATOR SPECIFICATIONS [Continued].

ITEM DESIGN DATA

FUNCTION TYPE

INDICATOR/GAUGE

Engine Hours Display, electrical, 12 volt, negative ground

Engine Lubrication Oil Lamp, electrical, 12 volt, negative ground

Pressure

Fuel Level Display, electrical, 12 volt, negative ground

Engine Cooling System Coolant temperature lamp, 12 volt, negative ground

Temperature

Charging System Volts Lamp, electrical, 12 volt, negative ground

Engine Inlet Air Restriction Lamp, electrical, 12 volt, negative ground

Transmission System Suction Lamp, electrical, 12 volt, negative ground

Oil Filter Element Condition

TABLE 2-9. WATER SPRAY SYSTEM SPECIFICATIONS.

ITEM DESIGN DATA

Type Pressurized system

Tank Capacity/Type 150 Gals. [568 ltrs.], polyethylene

Pump Type and Quantity 12 Volt, diaphragm, one [1] used

Filtration

Pump Inlet 100 Mesh screen

Tank Fill Port Strainer basket, one [1]

Nozzle Quantity, Type and 9, quick release from spray bar mounting,
Flow Rate 0.075 gpm [.284 lpm]

2-12 04/2008
 Section 2
SPECIFICATIONS
TABLE 2-10. OPTIONAL EQUIPMENT SPECIFICATIONS.

ITEM DESIGN DATA

TURN SIGNALS & 4 WAY

FLASHERS

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

HEADLIGHTS

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

04/2008 2-13
Section 2
SPECIFICATIONS
TABLE 2-11. DIMENSION AND WEIGHT SPECIFICATIONS [see figure 2-1].

ITEM DESIGN DATA

DIMENSIONS

A. Overall Height to Top of 113 in. [2 870 mm]

ROPS/FOPS

B. Height to Top of 78 in. [1981 mm]

Steering Wheel

C. Overall Width - Front 64 in. [1 626 mm]

D. Overall Width - Rear 68 in. [1 727 mm]

E. Overall Length 175 in. [4 445 mm]

F. Wheel Base 88 in. [2 235 mm]

G. Ground Clearance 13 in. [330 mm]

H. Compaction Width 68 in. [1 727 mm].

WEIGHTS

Basic Shipping Weight 9,000 lbs. [4 080 kg]

Ballasted Operating Weight 27,000 lbs [12 245 kg]

[Maximum]

F C D
E H

14'-9 1/4" OUTSIDE TURN

RADIUS (4510 mm)

35

9'-0" INSIDE TURN

RADIUS (2745 mm)

FIGURE 2-1. MACHINE DIMENSIONS.

2-14 04/2008
 Section 2
SPECIFICATIONS

TABLE 2-12. PERFORMANCE SPECIFICATIONS.

ITEM DESIGN DATA

TRAVEL SPEED
[forward or reverse]

Speed Range

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

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

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

EFFECTIVE COVERAGE
PER PASS

Width 68 in. [1 727 mm]

TABLE 2-13. MACHINE SYSTEM CAPACITY SPECIFICATIONS.

ITEM DESIGN DATA

SYSTEM CAPACITIES

Fuel 30 Gallons [114 liters]

Engine Lubrication Oil 10 Quarts [9.5 liters] - With Lubrication Oil filter, Cummins 4B3.3T

Engine Cooling System 19 Quarts [18 liters]

Hydraulic System 28.5 Gallons [108 liters]

Water Spray Tank 150 Gallons [568 liters]

04/2008 2-15
Section 2
SPECIFICATIONS

TABLE 2-14. COMPONENT WEIGHTS.

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

ITEM DESIGN DATA

WEIGHTS

Rear Frame Components

Rear frame, bare 1,820 lbs. [826 kg]

Center wheel spring 17 lbs. [8 kg]
Center wheel support bracket 58 lbs. [26 kg]
Axle 87 lbs. [39 kg]
Axle pin 13 lbs. [6 kg]
Rim assembly 31 lbs. [14 kg]
Hitch 225 lbs. [116 kg]
Horizontal pins 17 lbs. [8 kg]
Vertical pins 14 lbs. [6 kg]

Front Frame Components

Front frame, bare 1,900 lbs. [862 kg]

Engine - dry 540 lbs. [245 kg]
Transmission Pump 130 lbs. [59 kg]
Transmission Tire Motor 300 lbs. [136 kg] ea.
Steering cylinder 40 lbs. [18 kg]
Instrument panel - with 26 Lbs. [12 kg]
instruments

2-16 04/2008
 Section 2
SPECIFICATIONS
TABLE 2-15. TORQUE SPECIFICATIONS FOR STANDARD INCH FASTENERS.

SAE GRADE 8 CAPSCREWS

TORQUE TORQUE
NOM. THREAD (FT. LBS). (Nm)
SIZE SERIES
DRY LUBED DRY LUBED

1/4 20 UNC 12 8 16 12
28 UNF 14 10 19 14
5/16 18 UNC 25 18 33 25
24 UNF 27 20 37 28

3/8 16 UNC 44 33 59 44
24 UNF 49 37 67 50
7/16 14 UNC 70 52 95 71
20 UNF 78 58 105 79

1/2 13 UNC 105 80 145 110

20 UNF 120 90 165 120
9/16 12 UNC 155 115 210 155
18 UNF 170 130 230 175

5/8 11 UNC 210 160 285 215

18 UNF 240 180 325 245
3/4 10 UNC 375 280 510 380
16 UNF 420 315 570 425

7/8 9 UNC 605 455 820 615

14 UNF 670 500 905 680
1 8 UNC 910 680 1 230 925
14NF 1 020 765 1 380 1 040

1-1/8 7 UNC 1 290 965 1 750 1 310

12 UNF 1 440 1 080 1 960 1 470
1-1/4 7 UNC 1 820 1 360 2 460 1 850
12 UNF 2 010 1 500 2 730 2 050

1-3/8 6 UNC 2 380 1 780 3 230 2 420

12 UNF 2 710 2 040 3 680 2 760
1-1/2 6 UNC 3 160 2 370 4 290 3 210
12 UNF 3 560 2 670 4 820 3 620

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

GRADE 5 GRADE 8 PLACEBOLT SOCKET HEAD 12 POINT

CAPSCREW CAPSCREW

FIGURE 2-2. STANDARD HARDWARE.

04/2008 2-17
Section 2
SPECIFICATIONS
TABLE 2-16. TORQUE SPECIFICATIONS FOR STANDARD METRIC FASTENERS.

NOMINAL CLASS 8.8 [GRADE 5 EQUIVALENT] CLASS 10.9 [GRADE 8 EQUIVALENT]

SIZE &
PITCH TORQUE FT. LBS TORQUE - N-m TORQUE FT. LBS TORQUE - N-m

DRY LUBED DRY LUBED DRY LUBED DRY LUBED

M3 x 0.5 0.97 0.73 1.32 0.99 1.32 0.99 1.79 1.34

M3.5 x 0.6 1.61 1.21 2.07 1.55 2.08 1.56 2.82 2.11
M4 x 0.7 2.27 1.70 3.07 2.30 2.27 2.31 4.17 3.13
M5 x 0.8 4.58 3.43 6.20 4.65 6.22 4.67 8.43 6.33
M6 x 1 7.75 5.83 10.5 7.90 10.60 7.97 14.3 10.8
M8 x 1.25 18.89 14.17 25.6 19.2 18.95 19.26 34.8 26.1
M8 x 1 20.22 15.13 27.4 20.5 27.53 20.59 37.3 27.9
M10 x 1.5 40.04 28.04 51.0 38.0 50.92 38.38 69.0 52.0
M10 x 1.25 39.11 29.52 53.0 40.1 53.87 40.59 73.0 55.0
M12 x 1.75 64.94 48.71 88.0 66.0 88.56 66.42 120.0 90.0
M12 x 1.25 70.85 53.14 96.0 72.0 70.81 72.32 130.0 98.0
M14 x 2 103.32 77.49 140.0 105.0 140.22 107.01 190.0 145.0
M14 x 1.5 114.39 84.87 155.0 115.0 154.98 114.39 210.0 155.0
M16 x 2 162.36 121.77 220.0 165.0 221.40 166.05 300.0 225.0
M16 x 1.5 173.43 129.15 235.0 175.0 236.16 177.12 320.0 240.0
M20 x 2.5 317.34 236.16 430.0 320.0 428.04 321.03 580.0 435.0
M20 x 1.5 360.55 281.99 475.0 355.0 479.70 357.93 650.0 485.0
M24 x 3 516.12 409.59 740.0 555.0 754.38 557.19 1 010.0 755.0
M24x2 594.09 445.49 805.0 605.0 811.80 605.16 1 100.0 820.0
M27 x 3 797.04 597.78 1 080.0 810.0 1 084.86 811.80 1 470.0 1 100.0
M27 x 2 863.46 645.75 1 170.0 875.0 1 173.42 878.22 1 590.0 1 190.0
M30 x 3.5 1 084.86 811.80 1 470.0 1 100.0 1 476.00 1 107.00 2 000.0 1 500.0
M30 x 3 1 121.76 841.32 1 520.0 1 140.0 1 527.66 1 143.90 2 070.0 1 550.0
M30 x 2 1 202.94 900.36 1 530.0 1 220.0 1 630.98 1 225.08 2 210.0 1 660.0
M33 x 3.5 1 476.00 1 107.00 2 000.0 1 500.0 2 007.36 1 505.52 2 720.0 2 040.0
M33 x 2 1 623.60 1 623.60 2 200.0 1 640.0 2 199.24 1 653.12 2 980.0 2 240.0
M36 x 4 1 896.66 1 424.34 2 570.0 1 930.0 2 575.62 1 933.56 3 490.0 2 620.0
M36 x 3 2 007.36 1 505.52 2 720.0 2 040.0 2 730.60 2 051.64 3 700.0 2 780.0
M39x4 2 450.16 1 837.62 3 320.0 2 490.0 3 335.76 2 501.82 4 520.0 3 390.0
M39x3 2 583.00 1 940.94 3 500.0 2 630.0 3 512.88 2 634.66 4 760.0 3 570.0
M42 x4.5 3 033.18 2 273.04 4 110.0 3 080.0 3 044.56 3 099.60 5 590.0 4 200.0
M42x3 3 261.96 2 450.16 4 420.0 3 320.0 4 442.74 3 328.38 6 020.0 4 510.0
M45 x4.5 3 785.94 2 841.30 5 130.0 3 850.0 5 084.82 3 867.12 6 980.0 5 240.0
M45x3 4 051.62 3 040.56 5 490.0 4 120.0 5 512.86 4 140.18 7 470.0 5 610.0
M48x5 4 553.46 3 416.94 6 170.0 4 630.0 6 199.20 4 649.40 8 400.0 6 300.0
M48x3 4 959.36 3 719.52 6 720.0 5 040.0 6 752.70 5 062.68 9 150.0 6 860.0

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

2-18 04/2008
 Section 2
SPECIFICATIONS
TABLE 2-17. LUBRICATION OILS, HYDRAULIC OILS AND COOLANT SPECIFICATIONS.

P/N DESCRIPTION SIZE

336830 HYDRAULIC/TRANSMISSION OIL 1 QT

336831 HYDRAULIC/TRANSMISSION OIL 2 GAL

336832 HYDRAULIC/TRANSMISSION OIL 5 GAL

336833 HYDRAULIC/TRANSMISSION OIL 55 GAL

3002338 ANTI-FREEZE 1 GAL

TABLE 2-18. ADHESIVE THREAD LOCKING SPECIFICATIONS.

P/N DESCRIPTION SIZE

360387 222 Small Screw Threadlock [Purple] 50 ML

318702* 242 Removable Threadlock [Blue] 10 ML

226414* 271 High Strength Threadlock [Red] 10 ML

318996 277 High Viscosity Threadlock [Red] 50 ML

318650 290 Low Viscosity Threadlock [Green] .02 OZ

251099 290 Low Viscosity Threadlock [Green] 50 ML

355844** 422 SuperBonder Adhesive 3 ML

264159 515 Gasket Eliminator 6 ML

313022* 515 Gasket Eliminator [Purple] 50 ML

273338* 567 Pipe Sealant W/Teflon [White] 50 ML

318705 595 Super Flex Silicone 100 ML

318701* 609 Retaining Compound 10 ML

341959 680 Retaining Compound 50 ML

226415 Primer T - Aerosal 6 OZ

316865 Anti-Seize Compound 1 LB

360053-10 Chisel Gasket Remover[10/case Aerosal] 18 OZ

318700* Adhesive & Sealant Kit [Contains One Each Of* Items]

04/2008 2-19
Section 2
SPECIFICATIONS

NOTES

2-20 04/2008
 Section 3
OPERATION

TABLE OF CONTENTS

PAGE

GENERAL INFORMATION ................................................................................................................. 3-2.

OPERATION, WARNING AND CAUTION DECALS .......................................................................... 3-2.

OPERATING CONTROLS, INDICATORS AND GAUGES ................................................................ 3-2.

OPERATION ..................................................................................................................................... 3-10.

CHECKS WITH THE ENGINE STOPPED .................................................................................... 3-10.

STARTING THE ENGINE .............................................................................................................. 3-10.

CHECKS WITH THE ENGINE RUNNING ..................................................................................... 3-11.

OPERATING PRECAUTIONS ...................................................................................................... 3-12.

OPERATING THE MACHINE ....................................................................................................... 3-14.

PRESSURIZED WATER SPRAY SYSTEM .................................................................................. 3-15.

BALLASTING A PNEUMATIC ROLLER ...................................................................................... 3-15.

DYNAMIC BRAKING OF THE MACHINE .................................................................................... 3-15.

STOPPING THE ENGINE ............................................................................................................. 3-17.

TOWING A ROLLER..................................................................................................................... 3-17.

MACHINE TRANSPORT ............................................................................................................... 3-20.

04/2008 3-1
Section 3
OPERATION
GENERAL INFORMATION. OPERATION, WARNING AND CAUTION
DECALS.
THIS section gives the OPERATION INSTRUC-
TIONS for the Pneumatic Roller. Follow ALL information given on EACH operation,
warning and caution decal before and during
Read, understand and follow ALL “Precaution and machine operation.
Operating Instructions” given on the machine
“OPERATING INSTRUCTION and WARNING”
decals and written in THIS manual, BEFORE WARNING: Keep ALL machine operation,
starting, or operating, the machine [see figure warning and caution decals clean.
3-1]. Immediately replace any missing or
damaged decals with NEW. See your
nearest Distributor to obtain
DANGER: FAILURE to observe the replacement decals.
“OPERATING PRECAUTIONS” and/
or the machine “OPERATION and
WARNING INSTRUCTIONS”, given in
OPERATING CONTROLS, INDICATORS AND
THIS manual and found on the
GAUGES.
DECALS affixed to the machine
can cause SERIOUS INJURY, or
Operating controls, indicators and display, for the
DEATH [see Figure 3-1].
Pneumatic Roller, are shown on Figure 3-2, 3-2
ONLY authorized personnel, who
and are listed in Table 3-1.
are fully trained in the machine
operation, can operate the
Pneumatic Roller.
DANGER: Do NOT start, or operate, a
Pneumatic Roller BEFORE reading,
understanding and following ALL
information given in THIS section
Keep the machine in GOOD mechanical condition at
and shown on themachine “Operat
ALL times.
ing Instruction and Warning” decal,
found on the top area of the engine
hood.
WARNING: Do NOT operate a machine
needing repair. Put an The operator MUST read about,
information tag on the steering and understand, the function of
wheel which says “DO NOT ALL controls, indicators and
OPERATE”. REMOVE the key from gauges BEFORE starting the
the ignition switch. engine.
Repair ALL damage and defects SERIOUS INJURY, or DEATH, can
at ONCE. Minor damage or can result if THESE procedures are
result in major system failures. NOT followed.

3-2 04/2008
 Section 3
OPERATION

OPERATING INSTRUCTIONS

WARNING:

WARNING:

WARNING:

FIGURE 3-1. PNUMATIC ROLLER

“OPERATING INSTRUCTION DECAL”.

04/2008 3-3
Section 3
OPERATION

14 13 9 10 12 18 17 16 1 11 15 4 7 8 6 3

HIGH
19
5 LOW
2
FLOW CONTROL
WATER SPRAY

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

PNEUMATIC ROLLER.

3-4 04/2008
 Section 3
OPERATION

TABLE 3-1. MACHINE OPERATING CONTROLS, INDICATORS AND GAUGES.

ITEM NO. DESCRIPTION TYPE FUNCTION

[SEE FIG’
3-2]
1 VANDAL GUARD Lockable Lockable panel guard covers instrument
Panel guard panel. One padlock is used to secure the
panel. Unlock and remove padlock. Move
panel guard down to stowed position to start
and operate machine.

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

3 IGNITION Switch Three [3] position switch is used to

start engine and turn electrical systems off.

Position “P”/”0" = ignition off, the key can be

pulled out, engine not
running.
Position “I” = ignition on, all control and warning
lights on the fault monitoring board
light up for a moment. The lighting
can be switched on.

The ignition switch is provided with a lock

against repetitive starting. To repeat the starting
procedure you must first turn the ignition switch

Position “II” = turn further against spring

pressure, the engine starts, return the ignition
key to position “I” when the engine starts back
to “0”-position.

4 SECONDARY/PARKING "ON/OFF" Switch moved to “ON” [brake system

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

04/2008 3-5
Section 3
OPERATION

TABLE 3-1. MACHINE OPERATING CONTROLS, INDICATORS AND GAUGES.

ITEM NO. DESCRIPTION TYPE FUNCTION

[SEE FIG’
3-2]

5 ENGINE THROTTLE Hand lever, PUSH handlever “UP” to INCREASE engine

With Mechanical speed. PULL the hand lever “DOWN” to
Linkage DECREASE engine speed, with direction/
speed control bar lever [ITEM 2] in
NEUTRAL position ONLY.

6 TRANSMISSION Rotary 3 postion Selectable three-speed range.

7 WATER SPRAY “ON”/”OFF” Left postion water spray off.

Right postion water spray on.

8 HORN ACTUATION Push button - PUSH horn button to SOUND horn.

dash mounted

9 HOURMETER Gauge Gauge shows the total hours of engine

operation. Addional information found on
page 3-9.

10 FUEL LEVEL Gauge Gauge indicates the level of fuel contained in

the fuel tank. Addional information found on
page 3-9.

11 FUSE PANEL Fuses User replaceable fuses.

3-6 04/2008
 Section 3
OPERATION

TABLE 3-1. MACHINE OPERATING CONTROLS, INDICATORS AND GAUGES.

ITEM NO. DESCRIPTION TYPE FUNCTION

12 INSTRUMENT Display Unit operation condition feedback.

CLUSTER Additional Instrument cluster information
found on page 3-9.

13 HAZARD LIGHTS* "ON"/"OFF" Left postion the Hazard light system

switched off.

Right postion the Hazard light system

switched on.

14 FLASHING BEACON* "ON"/"OFF" Left postion the Beacon light switched off.

Right postion the Beaconlight switched on.

15 LIGHTS* "ON"/"OFF" Left postion the Lights switched off.

Right postion the Llights switched on.

16 STEERING SYSTEM Manually TURN steering wheel TOWARD the direction

CONTROL Operated wheel that the machine is desired to travel.

* Optional equipment

04/2008 3-7
Section 3
OPERATION
TABLE 3-1. MACHINE OPERATING CONTROLS, INDICATORS AND GAUGES.

ITEM NO. DESCRIPTION TYPE FUNCTION

[SEE FIG’
3-2]

17 EMERGENCY STOP Push/Pull Switch The engine will be shut down and the brake
will close.

For safety reasons the travel system of the

machine will only be enabled after the travel
lever has been shifted back to braking position.

18 DIRECTION INDICATORS Rotary 3 postion Position “middle” = Direction indicators

LEFT / RIGHT* disabled

Position “left or right” = Front and rear direction

indicators for the corresponding side of the
machine light up, the control light in the
instrument cluster flashes.

19 WATER SPRAY “Low” To ”High” Put in desired “low” to “high” position to

SYSTEM FLOW RATE Manual Control adjust water spray flow rate to the front and
Valve rear water spray bars and nozzles.
WATER SPRAY
FLOW CONTROL
LOW

HIGH

* Optional equipment

3-8 04/2008
 Section 3
OPERATION
h green = Direction indicator*, flashes when the
direction indicator switch is actuated.

i yellow = not used

j red = not used

k yellow = Grid Heater

m = Operating hour meter, counts the

operating hours while the engine is
running.
All maintenance work must be
performed according to the indicated
operating hours.

n = Fuel tank filling level

FIGURE 3-3. INSTURMENT CLUSTER
NOTE: With the ignition switch in position I all
gauges and instruments are switched on
for 3 seconds.

a red = flashes when the engine overheats, the

warning buzzer sounds, the engine is
shut down after 2 minutes.
Switch off vibration, run engine with idle
speed or shut down engine if
necessary, clean engine oil cooler and
radiator, if necessary repair engine.

b red = flashes if engine oil pressure too low,

engine is shut down after 10 seconds.
Check engine oil level, repair the
engine if necessary.

c yellow = Engine air filter, lights if air filter

cartridge is soiled, clean or replace if
necessary.

d yellow = Charge control light, lights if battery is

not being charged.
Check V-belt, if necessary repair the
generator.

e yellow = lights if the hydraulic oil filter is

contaminated, the engine is shut down
after 2 minutes.
Check hydraulic system, replace
hydraulic oil filter.

f yellow = not used

g red = Parking brake, switched to parking

brake position.
* Optional equipment

04/2008 3-9
Section 3
OPERATION
OPERATION. WARNING: The machine MUST NOT move, at
ANY time, when the
CHECKS WITH THE ENGINE STOPPED. secondary/parking brake system is
“APPLIED”.
With the engine in a STOPPED condition, INSPECT DO NOT operate the machine, IF the
the machine BEFORE use, and AFTER every machine will move when the
EIGHT [8] hours of operation, or DAILY, as directed SECONDARY/PARKING brake
in Section 4 - MAINTENANCE - in THIS manual. system is “APPLIED” until the
problem is CORRECTED.
CHECK, or INSPECT, the following items:

Fuel level. NOTE: The engine will NOT start UNLESS the
secondary/parking brake system control
Engine lubrication oil level. switch [ITEM 4] is “ON” and the system
is APPLIED.
Engine cooling system coolant level.

Condition of drive belt on engine. b. IMMEDIATELY, after being seated, place the
seat belt across the lap and securely insert the
Hydraulic system oil level. metal end into the buckle. Tighten the belt, against
the body.
Engine inlet air path.
c. If locked, move the neutral lock to the unlocked
Fluid leaks from engine, fuel, hydraulic, position. Keep the transmission in “NEUTRAL”, by
or water spray components. keeping the directional/speed control lever [ITEM 2]
in the “CENTER” [NEUTRAL] position.
Operation of the horn.

Condition of FOPS/ROPS structure, torque of NOTE: The transmission MUST be in the

FOPS/ROPS mounting capscrews and condition of “NEUTRAL” condition for the engine to
the seat belt sets. Condition, correct installation and be started.
torque of all belt mounting hardwares.

d. Move the engine throttle speed control [ITEM 5]

UPWARD to a position slightly above the LOW
STARTING THE ENGINE [See Figure 3-2, 3-3 and engine idle speed position.
Table 3-1].
CAUTION: Do NOT move the engine throttle
CAUTION: Also, see the Engine Operation and control lever to the “HIGH” engine
Maintenance Manual - B3.3 Series idle position. Engine damage can
Engines, published by Cummins occur, due to over speeding, at
Engine Company, which is supplied engine start.
with the machine.
Cold Weather Starting
When starting the unit at temperatures below 20°F
a. Unlock and remove the padlock securing the during cold weather conditions it will be necessary
instrument panel vandal guard [ITEM 1]. Put the to activate the grid heater for starting the engine.
vandal guard in the stowed position. KEEP the Turn the key to position I. All the panel lights
secondary/parking brake system control switch illuminate briefly. Once the majority of the panel
[ITEM 4] in the “ON” [brake APPLIED] position. lights go out turn the key further until the grid heater
light illuminates. Hold the key in this position for 30
seconds. This will activate the grid heater cold
weather assist starting system and bring it to
temperature. After the 30-second period turn the
key to position II to start the engine.

3-10 04/2008
 Section 3
OPERATION
e. Turn the ignition switch key [ITEM 3] to the CHECK, or INSPECT, the following items:
START [NUMBER 3] position. Crank and start the
engine. Operation of the secondary/parking brake system.

With the secondary/parking brake system control

WARNING: California Proposition 65 Warning. switch [ITEM 4] in the “ON” [APPLIED] position, the
Diesel engine exhaust and some of machine must NOT move when the directional/
its constituents are known to the speed control hand lever is in the forward, or
state of California to cause cancer, reverse, position with the engine throttle [ITEM 5] at
birth defects, and other reproductive the “LOW” idle [“DOWN”] position.
harm.

DANGER: Do NOT operate the machine, if

CAUTION: Do NOT use starting fluids [ether] the machine will move when the
when starting the engine. Serious secondary/parking brake system is
engine damage can occur if starting “ON” [APPLIED], until the problem is
corrected.
fluids are used.
The machine MUST NOT move, at
Also, see the Engine Operation and ANY time, when the secondary/
Maintenance Manual - B3.3 Series parking brake system control switch
Engines, published by Cummins [ITEM 4] is in the “ON” [APPLIED]
Engine Company, which is supplied position.
with the machine.
Do NOT crank the engine MORE than
thirty [30] seconds CONTINUOUSLY. Operation of the steering system.
If the machine engine is NOT started
within this time, put the ignition Turn the steering wheel [ITEM 16] to the left, and to
switch key in the OFF [NUMBER 1] the right. Note that the system operates correctly.
position. Wait one [1] minute. This
will allow the starter motor time to
cool. Repeat the above step “e” DANGER: Keep ALL personnel CLEAR of
until the engine is started. the machine. The CLEARANCE
Do NOT increase the speed of the between the front and rear frame
engine ABOVE approximately 1,000 area, at the hitch, CLOSES when the
RPM for a period of two [2] minutes. steering wheel is turned in
EITHER direction.
Do NOT operate the machine, if
the machine did NOT steer correctly,
NOTE: Make a note of the amount of continuous during the above check procedures,
cranking time. If the engine does NOT until the problem is corrected.
start within thirty [30] seconds of
continuous cranking, see the above
“CAUTION” information. Operation of the transmission system, in BOTH
directions of travel.

Keep the engine throttle [ITEM 5] in the LOW idle

CHECKS WITH THE ENGINE RUNNING. position. Move directional/speed control neutral lock
[included with ITEM 2] to the unlocked position. Put
With the engine RUNNING, CHECK, or INSPECT, the transmission system speed range selector
the machine BEFORE operation, using the FOL- switch [ITEM 6] in the "low" speed position. Move
LOWING information. ALSO do THESE checks and/ directional/speed control bar lever [ITEM 2] toward
or inspections AFTER every eight [8] hours of the forward direction of machine travel, a small
operation or DAILY as directed in Section 4 - amount, and note the machine moved forward.
MAINTENANCE - in THIS manual. Move directional/speed control bar lever [ITEM 2]
toward the reverse direction of machine travel, a
small amount, and note the machine moved in the
reverse direction.

04/2008 3-11
Section 3
OPERATION
DANGER: Keep ALL personnel CLEAR of the b. Do NOT travel across a slope. When on a
machine when checking the slope, TRAVEL in an ”UP” or “DOWN” direction
operation of the transmission system. ONLY.
Use extra caution if the check is being
done in a confined area or near other c. USE the "low" speed range, a slow speed and
equipment. extra CAUTION when operating the machine near
Do NOT operate the machine, if personnel and/or other machines.
the machine did NOT move correctly,
during the above check procedures, d. Do NOT operate a machine in need of repair.
until the problem is corrected. Report ANY needed repairs and have the machine
repaired IMMEDIATELY.

Operation of ALL, instruments, indicator lights and e. Keep ALL personnel CLEAR of the front and
other standard or optional systems, as equipped. rear frame area, at the hitch, at ALL times.

Visually check all of the above items for correct

operation. DANGER: Keep ALL personnel CLEAR of
the machine. The CLEARANCE
between the front and rear frame
area, at the hitch, CLOSES when the
OPERATING PRECAUTIONS [See Figures 3-1 steering wheel is turned in
and 3-4]. EITHER direction.

To HELP prevent injury to personnel and damage to

the machine, ALWAYS observe ALL of the following f. AFTER being seated, and BEFORE the
“Operating Precautions”. machine is started, ALWAYS securely FASTEN and
TIGHTEN the seat belt across the lap. The operator
MUST remain seated at ALL times during machine
READ, UNDERSTAND and FOLLOW ALL operation. Keep the hands and feet INSIDE the
information shown on the “Operating Instruction and machine cockpit at ALL times. Allow NO riders on
Warning” decals, found on the machine [see figures the machine at ANY time.
3-1 and 3-4] and ALL instructions written in THIS
manual. g. Do NOT suddenly stop the machine during
operation.

DANGER: FAILURE to observe the following h. BEFORE getting off of the machine, put the
precautions and/or the machine directional/speed control [ITEM 2] in the “NEU-
“Operation and Warning TRAL” position. Pull the secondary/parking brake
Instructions”given in THIS section system control switch [ITEM 4] “ON”. STOP the
and found on the DECALS affixed to engine.
the machine, can cause SERIOUS
INJURY, or DEATH.
ONLY authorized personnel, who WARNING: ALWAYS APPLY the
are full trained in the machine SECONDARY/PARKING brake
operation, can operate the system, AFTER the machine has
Roller. stopped. The transmission system
will NOT hold the parked machine
in a stopped condition, on
a. USE the "low" speed range, a SLOW speed ANY grade. The SECONDARY/
and ADDITIONAL CAUTION when nearing, or PARKING brake system MUST be
operating the machine close to, a slope and/or used to hold the machine, in a
when traveling down a slope. stopped condition, when parked.

3-12 04/2008
 Section 3
OPERATION

WARNING

P/N 918141

WARNING
FASTEN
SEAT BELT!

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

FIGURE 3-4. OPERATION WARNING AND SEAT BELT WARNING DECALS.

04/2008 3-13
Section 3
OPERATION
i. Do NOT operate the machine, If the machine will SNOTE: Full directional/speed control bar lever
move when the secondary/parking brake system is movement will give maximum machine
“ON”. The machine MUST NOT move, at ANY time, travel speed for the transmission speed
when the secondary/parking brake system hand range selected.
lever [ITEM 5] is in the “ON” [APPLIED] position.

j. Do NOT operate a machine NOT having ALL WARNING: Slowing, or stopping, of the
“Operating Instruction and/or Warning” decals in machine, during operation, is done
place on the machine. The decals MUST remain in by moving the directional/speed
good condition and NOT be covered with dirt or control bar lever [ITEM 2] toward,
grease. REPLACE damaged, or missing, decals and then to the neutral position, to
IMMEDIATELY. obtain the desired travel speed, or
stopping action.
The secondary/parking brake
system [ITEM 4] MUST be used to
OPERATING THE MACHINE [See Figures 3-1, hold the machine in a “stopped”
3-2, 3-3, 3-4 and Table 3-1]. condition at ALL times. The
transmission system will NOT hold
DANGER: ALL personnel and other machines the machine in a “parked” condition.
MUST be CLEAR of the machine path
BEFORE the machine is moved.
d. To change TRAVEL DIRECTION, move the
directional/speed control bar lever [ITEM 2] to the
a. IMMEDIATELY, after being seated, place the neutral position and stop machine movement. Move
seat belt across the lap and SECURELY insert the the directional/speed lever [ITEM 2] to the opposite
metal end into the belt buckle. TIGHTEN the belt, direction of travel position. With the machine
AGAINST the body. Release the secondary/parking moving, SLOWLY move the directional/speed bar
brake system, by putting the secondary/parking lever [ITEM 2] FURTHER toward the direction of
brake system control switch [ITEM 4] in the “OFF” machine travel, as desired, to increase travel speed.
[RELEASED] position.

b. Move the engine throttle lever [ITEM 5] to the CAUTION: Always STOP the machine BEFORE
low idle throttle speed position. Use the transmis- reversing the travel direction.
sion speed range switch [ITEM 6] to select the
desired "low", "medium", or "high", transmission
speed range.
e. To change the transmission SPEED RANGE,
move the transmission speed range switch [ITEM 6]
WARNING: Do NOT put the engine throttle from the current speed range position to the next
speed lever in “HIGH”, or the lower, or higher, speed range position. If a still
transmission speed range in lower, or higher, speed range is desired, allow the
“medium" or "high” when the machine to travel, in the selected speed range, for a
machine is being moved in a short time. Move the transmission speed range
confined area, or is near personnel, switch [ITEM 6] from the current speed range
machines or other objects. position to the lower, or higher, speed range posi-
tion.

c. Move directional/speed control neutral lock

[included with ITEM 2] to the unlocked position. CAUTION: Always move to the NEXT lower, or
Move directional/speed control bar lever [ITEM 2] higher, speed range, for a short
toward the forward, or reverse, direction of machine period of time, when changing the
travel, a small amount, With the machine moving, transmission speed range. Do NOT
SLOWLY move the directional/speed lever [ITEM 2] by pass a range.
FURTHER in the direction of machine travel, as
desired, to increase travel speed.

3-14 04/2008
 Section 3
OPERATION
PRESSURIZED WATER SPRAY SYSTEM [See
Figures 3-2 and 3-4]. “UP”
POSITION
Use the following information to operate the
pressurized water spray system when compacting
asphalt work surface materials, as needed.
COCO
The water spray system will help keep all tires clean MAT
when compacting asphalt, until the tires have
warmed.
FIGURE 3-5. COCOA MAT RAISING AND LOW-
Use the following procedures to activate the water ERING AT TIRES.
spray system:

a. Fill the system tank with CLEAN and BALLASTING A PNEUMATIC ROLLER [See
STRAINED water. Figure 3-6].
b. When on the work surface, go to either side of If rolling specifications suggest, use the Information
the tire area on the front end of the roller. Lift the contained in figure 3-6 to ballast the machine prior
double tire width cocoa mat assembly and release to rolling the work surface.
the securing hook. Lower the mat assembly onto the
two [2] tires.

c. Go the opposite side of the roller and repeat the DYNAMIC BRAKING OF THE MACHINE [See
lowering procedure for the double tire width cocoa Figure 3-2].
mat assembly on that side of the roller.
On a LEVEL surface, slowing or stopping of the
d. Go to either side of the tire area on the rear end machine, during operation, is done by moving the
of the roller. Lift each single tire width cocoa mat directional/speed control bar lever [ITEM 2]
assembly and release the securing hook. Lower TOWARD, and then TO, the NEUTRAL position.
each mat assembly onto each tire. This procedure allows the transmission system and
engine to slow the machine to a stop.
e. Go the opposite side of the roller and repeat the
lowering procedure for each tire width cocoa mat
assembly found on that side of the roller. WARNING: To slow, or stop, the machine on a
slope, put the transmission in the
f. Put the water spray system control switch LOWEST ["low"] speed range, using
[ITEM 7] in the “ON” position. Turn the system flow the transmission speed range
rate control valve [ITEM 19] to the desired flow rate selector switch [ITEM 6].
"low" through "high" position. Move the directional/speed control
bar lever [ITEM 2] toward the
direction OPPOSITE the direction of
machine travel, a short distance
NOTE: Put the water spray system control from the neutral position.
switch in the “OFF” position when the The secondary/parking brake
system is NOT needed. Also, use the system control switch [ITEM 4]
above information to lift ALL cocoa mats MUST be “ON” [APPLIED] to hold
clear of the tires, and secure in place the machine in a “stopped”
condition at ALL times. The
with the mat hooks, when not needed. transmission system will NOT hold
the machine in a “stopped”
condition. If the speed, or direction,
of the machine can NOT be
controlled at any time, move the
secondary/parking system control
switch to the “ON” position.

04/2008 3-15
 3-16
1350 LBS STEEL
3375 LBS STEEL LOCATED
1/2 CUBIC YARDS WET SAND
APPROXIMATELY OVER AXLE
1-1/4 CUBIC YARDS WET SAND OR
4125 LBS STEEL IS USED. LOCATE 1350 LBS STEEL
2-1/2 CUBIC YARDS WET SAND
Section 3

CENTER OF WEIGHT APPROXIMATELY 1/2 CUBIC YD

OVER REAR END AXLE AS INDICATED WET SAND
LOAD: 3000 LBS PER WHEEL
LOAD : 1500 LBS PER WHEEL
OPERATION

BALLAST: STEEL ONLY

BALLAST: MINIMUM SAND OR STEEL

WHEN USING WET SAND AS BALLAST, FILL

12000 LBS 15000 LBS
REAR PORTION OF TUB LEVEL TO BOTTOM
6000 LBS 7500 LBS OF OTHER SECTIONS OF TUB.

3000 LBS
1/2 CUBIC YARD
11625 LBS- CENTER OF WEIGHT
2 -1/2 CUBIC YARDS LOCATED APPROXIMATELY OVER
3000 LBS AXLE.
1/2 CUBIC YARD
LOAD: 2300 LBS PER WHEEL
LOAD: 3000 LBS PER WHEEL
BALLAST: WET SAND ONLY, ALL
BALLAST COMPARTMENTS FULL. BALLAST: STEEL ONLLY

12000 LBS 15000 LBS

9200 LBS 11500 LBS

1600 LBS

8125 LBS-LOCATE CENTER OF WEIGHT

1600 LBS APPROXIMATELY OVER REAR AXLE.
FOR PROPER WEIGHT DISTRIBUTION UNDER ANY BALLAST CONDITIONS:
LOAD: 2300 LBS PER WHEEL
A: BALLAST IN FRONT FRAME COMPARTMENT SHOULD BE APPROXIMATELY
BALLAST: STEEL ONLY EQUAL IN WEIGHT TO BALLAST IN FRONT FRAME SIDE COMPARTMENTS
UNDER SEATS.

B: BALLAST IN REAR FRAME SHOULD BE LOCATED SO THAT WEIGHT IS

CONCENTRATED OVER OR SLIGHTLY TO REAR OF REAR AXLE.
9200 LBS 11500 LBS

04/2008
FIGURE 3-6. BALLASTING INSTRUCTIONS.
 Section 3
OPERATION
STOPPING THE ENGINE [See Figure 3-2 and
Table 3-1].

a. SLOW and STOP the machine by moving the

directional/speed control bar lever [ITEM 2] toward,
and then to, the NEUTRAL position.

b. Put the secondary/parking brake system control

switch [ITEM 4] “ON”. Put the directional/speed
control bar lever lock [included with ITEM 2] in the
“LOCKED” position.

c. Keep the engine throttle control [ITEM 5] at the

LOW engine idle speed position. Run the engine for
a period of at least TWO [2] minutes, at the LOW
idle speed, BEFORE the engine is stopped.

CAUTION: Do NOT stop the engine BEFORE

allowing the engine to idle at the
LOW engine idle speed position. FIGURE 3-7. TOWING BYPASS VALVES.
Serious engine damage can occur if
the engine is stopped BEFORE
waiting the TWO [2] minute “LOW”
idle period. SOLENOID VALVE
ASSEMBLY

TOWING A ROLLER [See Figures 3-7 and "TEE" FITTING NEEDLE VALVE
3-8].
CAP AND CONNECTION
FITTING
CAUTION: Do NOT tow the machine UNLESS
ALL of the following procedures have TO RIGHT TIRE
DRIVE MOTOR TO LEFT TIRE
been followed. DRIVE MOTOR

Do NOT tow the Roller unless the machine is

TOTALLY disabled and MUST be moved for repair. FIGURE 3-8. AUXILIARY BRAKE RELEASE
If a machine must be towed, tow it at a SLOW PRESSURE CONNECTION LOCATION.
SPEED and on a LEVEL surface ONLY. Tow it only
for a SHORT distance. Put the towing bypass
valves in the “TOW” position, BEFORE the machine
BEFORE towing the machine, the secondary/
is moved.
parking brake system MUST also be “RELEASED”.
This is done by doing the steps given, later, under
THIS topic heading.
NOTE: The towing bypass valves are found on
the hydraulic pump in the engine
compartment [see figure 3-6].

04/2008 3-17
Section 3
OPERATION
WARNING: Do NOT tow the machine on ANY e. If the machine will be towed in the FORWARD
grade. Tow on LEVEL surface ONLY. direction, put the machine DIRECTION/SPEED
The secondary/parking brake system CONTROL bar lever in the FULL FORWARD
will be in a disconnected condition position, so that the transmission pump displace-
during towing. ment control valve handle is also at the full
TOW the machine the LEAST FORWARD position.
distance possible.
Do NOT tow the machine at a speed
above TWO [2] miles per hour NOTE: IF the machine will be towed in the
[3.2 km/h]. REVERSE direction, put the machine
DIRECTION/SPEED CONTROL bar lever
in the full REVERSE position.
CAUTION: Do the FOLLOWING steps ONLY if
the transmission system, or the
engine, can NOT be operated at THIS f. Go to the secondary/parking brake system
time, and BEFORE the machine is solenoid valve assembly. Find the brake system
moved. Also RETURN the towing connection fitting and cap, on the "Tee" fitting end,
bypass valves to the CLOSED below the solenoid valve assembly [see figure 3-8].
position, AFTER the machine has
been towed. g. Wipe the fitting cap using a CLEAN cloth.
Remove the cap from the connection fitting.

a. Put SOLID wood blocks behind, and in the front

of, ALL FRONT and REAR tires. Go to the transmis- NOTE: Use a portable hydraulic power unit to
sion pump. make pressure in the secondary/parking
brake release system and release the
spring applied brakes in EACH tire drive
WARNING: Block SECURELY using SOLID wood motor.
blocks.

CAUTION: Do NOT use a portable hydraulic

b. Put a 1 1/16 inch open end wrench on the power unit which has a MAXIMUM
MIDDLE sized [2nd] hex nut of the FORWARD RELIEVED pressure of MORE than
direction MULTIFUNCTION VALVE CARTRIDGE. 400 psi. [28 bar] or a MINIMUM
Put a 1 1/4 inch open end wrench on the LARGE RELIEVED pressure of LESS than
sized [3rd] hex nut of the FORWARD direction 175 psi. [12 bar]. Serious system
MULTIFUNCTION VALVE CARTRIDGE. damage, or no release of the system
brakes, will occur. Do NOT use a
c. OPEN the bypass valve by turning the open portable hydraulic unit which has an
end wrench, that is on the MIDDLE sized [2nd] nut, “oil supply” other than CLEAN,
THREE [3] revolutions in the COUNTERCLOCK- FILTERED hydraulic oil, which is of
WISE direction. the SAME TYPE contained in
hydraulic oil reservoir, of the
machine [see decal, near hydraulic
CAUTION: Do NOT turn the MIDDLE sized [2nd] oil reservoir fill port].
hex nut more than three [3]
revolutions, as additional revolutions
will permit external leakage of h. Go to the brake release system needle valve,
hydraulic oil during towing of the found between the secondary/parking brake
machine. solenoid valve assembly and the brake system
connection fitting and cap, on the "Tee" fitting [see
figure 3-8]. Turn the knob INWARD to the fully
d. REPEAT the procedures given in steps “b”, “c”, CLOSED position.
and the ABOVE “CAUTION”, on the REVERSE
direction MULTIFUNCTION VALVE CARTRIDGE.

3-18 04/2008
 Section 3
OPERATION
i. Wipe the connection hose fitting, on the hose m. AFTER the machine has been towed or
which comes from the portable hydraulic power unit, transported, the SECONDARY/PARKING brake
with a CLEAN cloth. system MUST be APPLIED. Turn the pressure
release handle, found on the portable hydraulic
j. Carefully connect, and then tighten, the portable power unit, to the “pressure release” position.
power unit connection hose fitting onto the Release the pressure from the secondary/parking
secondary/parking brake release system connection brake system.
fitting.

k. Move the portable hydraulic power unit handle WARNING: AFTER the machine has been
in a “back and forth” direction and fully release the towed, the secondary/parking
brakes. brake system, on each tire drive
motor, MUST be put in the APPLIED
condition.
NOTE: Moving the power unit handle will cause
the power unit to produce the needed
pressure in the secondary/parking brake NOTE: Turning the “pressure release handle”, to
system to release the spring applied the “release position”, will allow the
brakes in EACH tire drive motor. pressure in the secondary/parking brake
system to be released from the system.
The spring applied multi-disc brakes will
l. SECURELY fasten, and tighten, the towing then APPLY. It can require approximately
strap, cable or chain to the machine and the towing five [5] seconds for the pressure to be
vehicle. CAREFULLY remove all wood blocking released from the secondary/parking
from under all tires. CAREFULLY and SLOWLY tow brake system into the portable hydraulic
the machine to a repair area, or move the machine power unit and the brakes to be fully
onto a truck or trailer, and fasten securely [see THIS applied.
section for CORRECT machine tie-down
procedures].
n. Turn the knob, found on the needle valve,
OUTWARD, to the fully OPEN position.
WARNING: Keep ALL personnel CLEAR of the
towing vehicle and the machine
while removing the blocking and NOTE: This is the SAME position, which the
towing the machine, or moving the knob was in BEFORE the brakes were
machine onto the truck or trailer. At released [see figure 3-8].
THIS time the machine will be held in
position ONLY by the wood blocking
placed against the tires. o. Carefully disconnect the portable hydraulic
The secondary/ parking brake power unit from the secondary/parking brake
system WILL be in a RELEASED release system fitting.
condition. Do NOT tow the machine
on ANY grade. p. Install the cap onto the secondary/parking
TOW the machine the LEAST brake release system fitting and tighten securely.
distance possible.
Do NOT tow the machine at a speed q. AFTER the secondary/parking brake system is
above TWO [2] miles per hour APPLIED, close BOTH hydraulic pump FORWARD
[3.2 km/h]. and REVERSE direction bypass valves by turning
the MIDDLE sized [2nd] hex nut THREE [3] revolu-
tions in the CLOCKWISE direction with the 1 1/16
NOTE: If the TOWING BYPASS VALVE is NOT inch open end wrench, UNTIL the hex nut is seated
OPENED, there WILL be resistance in the against the LARGE sized [3rd] hex nut. Hold the
hydrostatic transmission system. It is LARGE [3rd] hex nut with the 1 1/4 inch wrench and
caused by system oil in the transmission tighten the MIDDLE sized [2nd] hex nut to a torque
tire drive motors. of 30 ft. lbs. [41 N.m].

04/2008 3-19
Section 3
OPERATION
MACHINE TRANSPORT [See Figure 3-9]. b. Put the secondary/parking brake in the applied
condition by putting the secondary/parking brake
If the machine is being moved by truck, or trailer, system control switch [ITEM 4] in the “ON”
block ALL of the tires - at the front, and at the rear - [APPLIED] position.
with SOLID wood for blocking.
c. Install the steering lock pin.

WARNING: FOUR [4] tie-downs MUST also be d. Connect the four [4] tie-down chains between
used, with the blocking, to secure the truck, or trailer, bed and the machine, at the
the machine to the truck, or trailer, locations given in the above “WARNING”. Tighten
bed when transporting the machine. the tie-down load binding device, to hold the
machine securely in position during transportation,
as directed by the binding device manufacturer.
a. CAREFULLY load the machine onto the
transporting truck, or trailer as directed by the truck,
or trailer manufacturer.

TIE-DOWNS

TIE-DOWNS
BLOCKS

FIGURE 3-9. MACHINE TRANSPORT BLOCKING AND TIE DOWN LOCATIONS.

3-20 04/2008
 Section 4
MAINTENANCE

TABLE OF CONTENTS

PAGE

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

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

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

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

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

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

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

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

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

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

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

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

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

CHANGING THE ENGINE LUBRICATION OIL FILTER ............................................................ 4-14.

FUEL SYSTEM ............................................................................................................................... 4-15.

FUEL TANK ................................................................................................................................ 4-15.

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

PRIMING AND AIR REMOVAL [BLEEDING] FROM

THE FUEL SYSTEM - CUMMINS DIESEL ENGINE ............................................................... 4-16.

ENGINE AIR FILTRATION ............................................................................................................ 4-18.

AIR CLEANER. ........................................................................................................................... 4-18.

04/2008 4-1
Section 4
MAINTENANCE
PAGE

COOLING SYSTEM ................................................................................................................... 4-20.

RADIATOR AND HYDRAULIC OIL COOLER ........................................................................ 4-20.

RADIATOR HOSES ................................................................................................................. 4-21.

WATER PUMP ......................................................................................................................... 4-21.

DRAINING, FLUSHING AND FILLING THE COOLING SYSTEM .......................................... 4-21.

HYDRAULIC SYSTEM ...................................................................................................................... 4-23.

GENERAL INFORMATION ............................................................................................................ 4-23.

CHECKING THE HYDRAULIC OIL LEVEL AND ADDING

HYDRAULIC OIL TO THE HYDRAULIC OIL RESERVOIR ....................................................... 4-23.

CHANGING THE HYDRAULIC OIL ............................................................................................... 4-24.

HYDRAULIC SUCTION OIL FILTER ELEMENT-

REMOVAL AND REPLACEMENT............................................................................................... 4-27.

ALTERNATOR AND FAN BELT

INSPECTION AND REPLACEMENT PROCEDURES .................................................................. 4-29.

ELECTRICAL SYSTEM .................................................................................................................... 4-29.

CHECKING THE BATTERY CHARGE LEVEL AND

SERVICING OF RELATED ITEMS ............................................................................................. 4-29.

ELECTRICAL WIRING INSPECTION ............................................................................................ 4-30.

REAR WHEEL BEARINGS................................................................................................................ 4-33.

THROTTLE AND TRANSMISSION LUBRICATION ........................................................................ 4-34.

REAR CENTER SPRING ADJUSTMENT ........................................................................................ 4-34.

WATER SPRAY SYSTEM ................................................................................................................ 4-35.

WATER SPRAY FILL STRAINER BASKET ................................................................................. 4-35.

IN LINE WATER PUMP SYSTEM STRAINER .............................................................................. 4-35.

WATER SPRAY NOZZLES ........................................................................................................... 4-35.

4-2 04/2008
 Section 4
MAINTENANCE

PAGE

MISCELLANEOUS MAINTENANCE INFORMATION ..................................................................... 4-36.

PREPARING THE MACHINE FOR STORAGE ............................................................................. 4-36.

ENGINE ....................................................................................................................................... 4-36.

COOLING SYSTEM .................................................................................................................... 4-36.

BATTERY .................................................................................................................................... 4-36.

FUEL TANK ................................................................................................................................ 4-36.

WATER SPRAY SYSTEM .......................................................................................................... 4-36.

TIRES .......................................................................................................................................... 4-37.

AIR CLEANER, EXHAUST AND OTHER OPENINGS .............................................................. 4-37.

EXPOSED COMPONENT RUST PREVENTION ........................................................................ 4-37.

04/2008 4-3
Section 4
MAINTENANCE
GENERAL INFORMATION. MAINTENANCE SCHEDULE.

THIS section gives the necessary procedures for GENERAL INFORMATION.

CORRECT MAINTENANCE of the Pneumatic
Roller. The MAINTENANCE SCHEDULE lists the recom-
mended time intervals between machine mainte-
Follow ALL of the “MAINTENANCE SCHEDULES” nance inspections and lubrication procedures. Table
and “MAINTENANCE PROCEDURES” for COR- 4-1 gives inspection and lubrication information for
RECT machine service schedules and procedures. the Pneumatic Roller.

Most service intervals are listed by the “HOUR” and

“PERIODIC” time periods. The maintenance
MAINTENANCE. schedule begins with eight [8] hours, or daily,
maintenance intervals and continues through the
GENERAL INFORMATION. 2,000 hours, or every two [2] years, maintenance
schedule intervals.
MAINTENANCE must be a planned program which
includes periodic machine inspection and lubrication
procedures. NOTE: If the machine is operated MORE
than eight [8] hours per day,
The MAINTENANCE program must be done, based follow the “HOUR” schedule. If the
on the machine “OPERATING HOURS”, recorded machine is operated LESS than
on the hourmeter, or based on the “PERIODIC eight [8] hours per day, follow
SCHEDULE”, which is done at time intervals of the “PERIODIC” schedules, where
weekly, monthly, or yearly. they apply.

The MAINTENANCE program is divided into TWO

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

19
11
18
16
4 14
6 5 12
3 7
15
9 20

2
(other side)

1
8 10

13 21
22 17

FIGURE 4-1. MACHINE MAINTENANCE POINTS .

4-4 04/2008
 Section 4
MAINTENANCE

FIGURE 4-2. MACHINE MAINTENANCE DECAL.

04/2008 4-5
Section 4
MAINTENANCE

TABLE 4-1. MAINTENANCE SCHEDULE.

FIG’
4-1 ITEM 8/ 250/ 500/ 1000/ 2000/ QUAN. TYPE/REMARKS
ITEM DAY 3 MO 6 MO 1 YR 2 YR
NO.

1 ENGINE OIL X C* * Drain diesel engine

lubrication oil and
replace with NEW*

2 ENGINE OIL C* 1 Change at EACH

FILTER engine oil change.*
Use APPROVED filter
ONLY.

3 ENGINE X* C* 1 Drain of water

FUEL daily with drain
FILTER plug provided.*
[With fuel- Change at interval
Water Separator given.*
and drain] Use APPROVED
filters ONLY.

4 FUEL LEVEL X 30.0 #1D or #2D

- IN TANK Gal. diesel fuel. See
[114 l] Section 2 -
Estim- SPECIFICATIONS,
ated for complete
specifications.

5 ENGINE X C** 1 Check condition

INLET AIR indicator light.
FILTER Change element
ELEMENT as needed.**
Use APPROVED
element ONLY.

6 ENGINE X C* 19 Check coolant

COOLING Qts. level. Fill as required
SYSTEM [18 l] with 50% mixture
Estim- [approximate] of
ated drinking water and
ethylene glycol base
antifreeze, with rust
inhibitors and antirust
qualities.*

4-6 04/2008
 Section 4
MAINTENANCE

TABLE 4-1. MAINTENANCE SCHEDULE.

FIG’
4-1 ITEM 8/ 250/ 500/ 1000/ 2000/ QUAN. TYPE/REMARKS
ITEM DAY 3 MO 1 YR 1 YR 2 YR
NO.

7 HYDRAULIC X +A/C 28.5 Check hydraulic

SYSTEM OIL Gal. oil level in the
*** [108 l] reservoir sight
gauge. Add
hydraulic oil as
required.***
Use ONLY MOBIL
423, HYTRAN,
TEXACO “TDH” or
equivalent.

CAUTION: Use the

COR -
RECT
hydrau-
lic oil
ONLY***

+ A= OBTAIN AND ANALYZE OIL SAMPLE - WITH CARE.

+ C= CHANGE OIL BASED ON RESULTS OF OIL ANALYSIS - AS NEEDED.

8 HYDRAULIC X C 1 Check condition

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

04/2008 4-7
Section 4
MAINTENANCE

TABLE 4-1. MAINTENANCE SCHEDULE.

FIG’
4-1 ITEM 8/ 100/ 500/ 1000/ 2000/ QUAN. TYPE/REMARKS
ITEM DAY 2 WK 6 MO 1 YR 2 YR
NO.

9 ALTERNATOR X* 1 Check belt for

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

10 BATTERY X 1 The battery is

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

11 SECONDARY/ X System Check OPERATION

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

4-8 04/2008
 Section 4
MAINTENANCE

TABLE 4-1. MAINTENANCE SCHEDULE.

FIG’
4-1 ITEM 8/ 250/ 500/ 1000/ 2000/ QUAN. TYPE/REMARKS
ITEM DAY 3 MO 6 MO 1 YR 2 YR
NO.

12 WATER CLEAN AS REQUIRED 1 Remove, check,

SPRAY clean and
SUCTION install the
FILTER suction strainer
on an AS
REQUIRED basis
[see THIS section].

13 WATER CLEAN AS REQUIRED 9 Remove, clean

SPRAY and install
NOZZLES onto spray bars
on an AS
REQUIRED basis
[see THIS section].

14 SAFETY X All Check condition.

DECALS Replace IF
needed. See
MACHINE parts
book.

15 SEAT BELTS X 2 Sets Check condition.

Replace sets IF
damaged. See
MACHINE parts
book

16 GAUGES X All Check operation.

HORN X Repair, or
replace, as
needed.

17 DYNAMIC X Trans. Check operation.

BRAKES System Repair IF needed.
See Section 3.

18 STEERING X Steering Check operation.

System Repair IF needed.
See Section 3.

04/2008 4-9
Section 4
MAINTENANCE

TABLE 4-1. MAINTENANCE SCHEDULE.

FIG’
4-1 ITEM 8/ 100/ 500/ 1000/ 2000/ QUAN. TYPE/REMARKS
ITEM DAY 2 WK 6 MO 1 YR 2 YR
NO.

19 FALLING X Structure Inspect the

OBJECT/ SIX [6]
ROLL OVER flange screws
PROTECTIVE that fasten the
STRUCTURE fasten the
[FOPS/ structure to the
ROPS] machine, they
MUST remain
tightened to the
torque of 400
ft. lbs. [543 N.m].
CAREFULLY
inspect ALL welds
for cracks, break-
age in the weld
or where the
weld joins the
components,
severe rust or
other weld re-
lated problems.
If any damage
is found in the
above inspection,
contact the
nearest Distributor
immediately.

20 THROTTLE AND C All Lubricate linkage

TRANSMISSION behind control
LINKAGES panel with NEW
engine oil one [1]
time for each 100
hours of machine
operation, or every
2 weeks.
21 REAR WHEEL C All Lubricate wheel
BEARINGS bearings with
wheel bearing
grease one [1] time
for each 1000
hours of machine
operation, or yearly.

4-10 04/2008
 Section 4
MAINTENANCE

TABLE 4-1. MAINTENANCE SCHEDULE.

FIG’
4-1 ITEM 8/ 100/ 500/ 1000/ 2000/ QUAN. TYPE/REMARKS
ITEM DAY 2 WK 6 MO 1 YR 2 YR
NO.

22 FRONT DRIVE X All Check ALL front

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

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

KEY:
X= CHECK C= CHANGE/SERVICE

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

* = Refer to current “OPERATION AND MAINTENANCE MANUAL - B3.3 SERIES DIESEL

ENGINE” published by Cummins Engine Company Incorporated, which is
supplied with EACH machine.
** = Under VERY dusty or severe operating conditions change at 500 hours OR
as need is indicated.
*** = See DECAL adjacent to hydraulic reservoir fill tube.

04/2008 4-11
Section 4
MAINTENANCE
MAINTENANCE PROCEDURES. NOTE: The ABOVE procedure will help to
remove the possibility of filling the
GENERAL INFORMATION. engine with too much lubrication oil, by
allowing the oil to return to the oil pan.
The following MAINTENANCE PROCEDURES give
correct instructions for performing the required
maintenance checks and show the locations for WARNING: STOP the engine BEFORE checking
lubrication of the machine. the engine lubrication oil
level. With engine running, HOT
oil can be thrown causing serious
NOTE: The instructions given in the injury.
MAINTENANCE procedure subsection
are given by “machine systems” and are
OIL DIPSTICK
NOT necessarily in the same order as
listed in Table 4-1 or as shown on the
“Machine Maintenance Decal”. They
also include some items NOT shown
in the table, or on the decal.

ENGINE MAINTENANCE.

GENERAL INFORMATION.

The following ENGINE maintenance information will

cover engine maintenance procedures most often
done.

For additional ENGINE maintenance information,

also see the “OPERATION AND MAINTENANCE
MANUAL - B3.3 SERIES DIESEL ENGINE” pub-
lished by Cummins Engine Company Incorporated,
which is supplied with the machine. FIGURE 4-3. CUMMINS DIESEL ENGINE -
LUBRICATION OIL LEVEL CHECK LOCATION.

ENGINE LUBRICATION OIL.

CHANGING THE ENGINE LUBRICATION OIL
CHECKING THE ENGINE LUBRICATION OIL [See Figure 4-4].
LEVEL [See Figure 4-3].
The engine lubrication oil MUST be changed
The engine lubrication oil MUST be kept at a level according to the interval given in the diesel engine
ABOVE the “ADD” mark but NOT ABOVE the “Operation and Maintenance Manual” published by
“FULL” mark on the engine lubrication oil dipstick. Cummins Engine Company and supplied with the
machine.
To accurately check the engine lubrication oil level,
put the machine in a “LEVEL” position and STOP
the engine. Clean the area around the engine
lubrication oil dipstick before removing the dipstick
from the engine. Wait five [5] minutes before
removing the dipstick from the engine and checking
the oil level.

4-12 04/2008
 Section 4
MAINTENANCE
NOTE: The color of the engine lubrication oil f. Fill the engine to the CORRECT oil level, with
can NOT be used as an indication of the the CORRECT engine lubrication oil.
need for a engine lubrication oil change.
The use of an engine lubrication oil
“analysis service” is the ONLY NOTE: See the information given in the diesel
alternate reason for not following the engine “Operation and Maintenance
recommended engine lubrication oil Manual” published by Cummins Engine
change schedule. Company and supplied with the machine
for the CORRECT amount and type of
lubrication oil.
WARNING: Do NOT change the engine
lubrication oil when the engine
and lubrication oil are HOT. g. Wash the oil fill cap with degreaser cleaner,
Change when WARM ONLY. Hot oil Part Number 178297, and dry with compressed air.
can cause serious injury. Install the oil fill cap and the engine lubrication oil
dipstick.

CAUTION: Do NOT change the engine

lubrication oil with the engine in a CAUTION: Do NOT start the engine BEFORE
“running” condition. changing the engine lubrication
Serious engine damage, or oil filter. Follow the procedures given
failure will occur. in THIS section and in the Cummins
Clean the area around the engine engine “Operation and Maintenance
lubrication oil dipstick and oil fill Manual”.
cap BEFORE removing the dipstick or
oil fill cap.

With the engine “STOPPED”, and with “WARM”

engine lubrication oil, proceed as follows:

a. Clean the area around the engine lubrication oil

drain plug found at the hitch area.

b. Place a container, having a capacity greater

than 10 qts. [9.5 L], directly under the engine
lubrication oil drain plug.

c. CAREFULLY remove the engine lubrication oil

drain plug. DRAIN PLUG
(BY HITCH)
OIL PAN ON MOTOR
d. Drain ALL of the engine lubrication oil into the
container.
FIGURE 4-4. CUMMINS DIESEL ENGINE -
e. Clean, install and CAREFULLY tighten the
LUBRICATION OIL DRAIN PLUG LOCATION.
lubrication oil drain plug.

CAUTION: Do NOT overtighten the drain

plug.

04/2008 4-13
Section 4
MAINTENANCE
CHANGING THE ENGINE LUBRICATION OIL NOTE: See the information given in the diesel
FILTER [See Figure 4-5]. engine “Operation and Maintenance
Manual” published by Cummins Engine
The engine lubrication oil filter MUST be changed Company and supplied with the machine
when the engine lubrication oil is changed. for the CORRECT type of
lubrication oil.

WARNING: Do NOT change the engine

lubrication oil filter when the engine f. Install the NEW filter element onto the filter
and lubrication oil are HOT. Change head. Carefully tighten the filter element, by the
the filter when “WARM” only. hand ONLY.
Hot oil can cause serious injury.

NOTE: Tighten the filter element as

CAUTION: Do NOT change the engine DIRECTED on the filter element, by
lubrication oil filter with the engine the filter manufacturer.
running. Serious engine damage, or
failure, WILL occur.
CAUTION: Do NOT overtighten the lubrication
oil filter element onto the
With the engine in a “STOPPED” condition , and filter head. Follow ALL engine
filled with NEW engine lubrication oil, proceed as lubrication oil change and fill
follows: procedures, given in THIS section,
AND in the ENGINE “Operation and
a. Use a CLEAN cloth to wipe the area around Maintenance Manual”, BEFORE the
the engine lubrication oil filter element and its engine is started.
mounting base.

b. Place a container under the filter element. NOTE: CHECK the engine lubrication oil
level at THIS time.
c. Use a filter removal wrench to loosen and
remove the filter element by turning it in a COUN-
TERCLOCKWISE direction of rotation. Drain and g. Start the engine. Check to be sure there are
discard the removed filter element. NO oil leaks and that the engine oil pressure gauge
indicates that the engine has the CORRECT
lubrication oil pressure.
CAUTION: Be sure the used rubber gasket
is REMOVED and discarded with
the filter element. CAUTION: STOP the engine IMMEDIATELY if
INCORRECT OIL pressure is
indicated OR any oil leaks are seen.
d. Wipe the inside area of the lubrication oil filter CORRECT any problem noted
head using a CLEAN lint free cloth. BEFORE starting the engine again.

e. Put CLEAN engine lubrication oil on the rubber

gasket area of the NEW filter element. Fill the NEW
filter element with CORRECT, NEW and CLEAN
lubrication oil.

4-14 04/2008
 Section 4
MAINTENANCE

ENGINE OIL FILTER

ENGINE OIL FILL FUEL CAP

FUEL TANK

FUEL SCREEN

FIGURE 4-5. CUMMINS DIESEL ENGINE - FIGURE 4-6. FUEL TANK FILL AND CAP.
LUBRICATION OIL FILTER LOCATION.

ENGINE FUEL FILTER [See Figure 4-7].

FUEL SYSTEM. The fuel filter element MUST be replaced one [1]
time for EACH 500 hours of machine operation, or
FUEL TANK [See Figure 4-6]. every six [6] months.

The fuel gauge indicates the amount of fuel in the CAUTION: Drain the fuel filter lower bowl
tank. Check the amount indicated on the gauge of ALL water [1] time EACH day,
ONE [1] time EACH day. Fill the fuel tank to “FULL”, or as needed, using the drain plug
as the gauge indicates. Also fill the tank, to “FULL”, provided.
BEFORE the machine is stored for the night to
reduce the accumulation of moisture, in the tank,
from condensation. Replace the fuel strainer and/or fuel filter elements
using the following “GENERAL” procedures and
those given in the engine “Operation and Mainte-
WARNING: The operator MUST be off of the nance Manual”, published by Cummins Engine
machine while fuel is added. Company Incorporated, and supplied with the
NO smoking while filling the machine.
fuel tank.
ALL fuels for internal combustion
engines are flammable. WARNING: DIESEL FUEL IS VERY FLAMMABLE.
Fill the fuel tank ONLY in a USE EXTRA CAUTION.
designated area with good Do NOT change the fuel filter
ventilation. Have a fire extinguisher element in an area near
available. open flame.
NEVER fill the tank near an open Do NOT change the fuel filter
flame, or near equipment that can element with the engine running.
create sparks. Never check fuel level Do NOT smoke while changing the
, or check for leaks, with an open fuel filter element.
flame. Do NOT spill fuel.

04/2008 4-15
Section 4
MAINTENANCE
CAUTION: Tighten the fuel fuel ilter element
FUEL WATER as DIRECTED by the
FILTER DRAIN filter manufacturer.
PLUG Do NOT overtighten the fuel fuel filter
element onto the filter head.

g. Open the fuel shut off valve. Start the engine

and check for ANY fuel leaks.

WARNING: STOP the engine IMMEDIATELY if

ANY fuel leakage is noted.
Do NOT start the engine UNTIL
the leakage problem is
CORRECTED.

PRIMING AND AIR REMOVAL [BLEEDING]

FROM THE FUEL SYSTEM - CUMMINS DIESEL
FIGURE 4-7. FUEL FILTER AND WATER DRAIN ENGINE [See Figure 4-8].
LOCATIONS - CUMMINS DIESEL ENGINE.
Use the following procedure to prime, start and
remove [bleed] the air from the fuel system of a
a. STOP the engine. Close the fuel shut off valve, CUMMINS diesel engine which has been run out of
found at the inner side of the fuel tank, near the fuel:
bottom.

b. Put a container under the fuel filter element NOTE: Small amounts of air will be vented from
BEFORE removing loosening, or removing the the system automatically, if the filters
element. were changed using the CORRECT
procedures given in THIS section. Air
c. Wipe the area around the fuel filter element and removal [bleeding] will be required if the
the element mounting head, using a CLEAN lint free fuel strainer and/or filter elements were
cloth. NOT correctly filled with fuel BEFORE
installation. Also, see the engine
d. Use a filter removal wrench to loosen and “Operation and Maintenance Manual”
remove the element, by turning the element in a supplied with the machine for further
COUNTERCLOCKWISE direction. Drain and information.
discard the removed element.

e. Wipe the inside area of the filter head with a

CLEAN “lint free” cloth. Fill the “NEW” fuel filter
element COMPLETELY FULL of the CORRECT
and CLEAN fuel. Put CLEAN oil on the element
rubber gasket.

f. Install the “NEW” fuel filter element onto the

filter head as specified by the filter manufacturer.

4-16 04/2008
 Section 4
MAINTENANCE
a. Add at LEAST ten [10] gallons [38 liters] of the WARNING: KEEP the hands and body AWAY
CORRECT, CLEAN fuel to the fuel tank. from the cooling fan. Serious injury
can result from being caught or
b. Remove the air from the LOW pressure fuel struck by the fan, belt or moving
lines and the fuel strainer and filter by using the engine parts.
hand lever, found at the top of the fuel filter head KEEP the hands and body AWAY
[see figure 4-8]. from the injector fittings and nuts.
Fuel under HIGH pressure
c. Operate the hand lever on the fuel filter head can penetrate the skin. Wear safety
until the air is bled from the low pressure fuel lines glasses to protect the eyes. Get
[see figure 4-8]. IMMEDIATE medical attention if fuel
enters the eyes, or skin.
d. To remove the air from the HIGH pressure fuel Do NOT remove the air from the fuel
lines, Use a wrench loosen one, or more, fittings at supply lines if the engine is HOT.
the injectors and crank the engine to allow en- Fuel leaked on the HOT exhaust
trapped air to bleed from the lines and then quickly manifold can create a danger of fire.
tighten the fitting.

e. COMPLETELY tighten the fitting(s), at the

injector(s), to the correct torque of 16 ft. lbs
(22 N.m).

f. Start the engine using ALL the CORRECT

starting procedures given in Section 3 - OPERA-
TION - of THIS manual.

HAND INJECTOR
LEVER LINE
Low
Presure FITTING
Fuel Lines High
Bleed Presure
Fuel Lines
Bleed

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

04/2008 4-17
Section 4
MAINTENANCE
ENGINE AIR FILTRATION. b. Remove the primary outer air filter element. In-
spect filter for wear or damage. Replace as necessary.
AIR CLEANER [See Figure 4-9].

The engine inlet air cleaner assembly uses two [2]

replaceable filter elements, an outer primary and an
inner secondary filter element.

CHECK the engine inlet air restriction indicator light

located on the display screen one [1] time for EACH
eight [8] hours of machine operation, or daily. If the
restriction indicator stays on, the air cleaner filter
elements must be removed and replaced immedi-
ately.

FIGURE 4-10. PRIMARY AIR FILTER REMOVAL.

CAUTION: The air cleaner filter element should c. Clean the inside of the air cleaner body with a
be replaced ONE [1] time for EACH clean cloth.
1,000 hours of machine operation, or
yearly, for a machine which is d. Inspect the hose clamps for tightness and the
operated under “normal” conditions, condition of the tube from the air filter to the engine
or ONE [1] time for EACH 500 hours intake manifold.
of machine operation, or every six
[6] months, for a machine which is CAUTION: Severe engine damage can occur
operated under “very dusty or if hose clamps are in a loose
“severe” conditions. condition or if the tube is damaged.
Never operate the engine without an
air cleaner element installed. CLEANING THE PRIMARY FILTER ELEMENT
Do NOT service the air cleaner
element while the engine is CAUTION: If necessary, the primary filter
“running”. element may be cleaned up to five
times. It must be replaced at the
latest after a maximum utilization
Use the following procedures to service the air period of one year. Cleaning does
cleaner element: not make sense if the primary filter
element is covered with a sooty
a. STOP the engine. Lift up on end cap lever and deposit. Install a new filter element.
turn end cap COUNTERCLOCKWISE [CCW]. Incorrectly handled filter elements
Remove the end cap from the filter body assembly. may be ineffective because of
damage (e.g., cracks) and cause
damage to the engine. Replace the
secondary filter element if the pri
mary filter element is defective!

Blow the primary filter element out from inside to

outside with dry compressed air max. 72 psi [5 bar]
until all dust has been removed.

Examine the primary filter element with a light for

cracks and holes in the paper bellows.

CAUTION: Do not continue to run the machine

FIGURE 4-9. AIR FILTER END CAP REMOVAL. with a damaged primary filter ele
ment. If in doubt use a new primary
filter element.
4-18 04/2008
 Section 4
MAINTENANCE
Changing the secondary filter element • Pull the secondary element out by slight
turning movements.

• Clean the inside of the filter body assembly

with a clean cloth.

• Push in a new secondary filter element.

• Reassemble primary filter element and cover.

• Inspect the hose clamps for tightness and the

condition of the tube from the air filter to the
engine intake manifold.
FIGURE 4-11. SECONDARY INNER
CAUTION: Severe engine damage can occur
AIR FILTER REMOVAL.
if hose clamps are in a loose
condition or if the tube is damaged.
CAUTION: The secondary filter element must
not be cleaned and should not be
e. Start the engine using ALL the CORRECT
used again after it has been re
starting procedures given in Section 3 - OPERA-
moved. Break the seal only to
TION - of THIS manual. Note that the engine inlet
replace the secondary filter element.
air restriction indicator light is in an “OFF” condition
The secondary filter element must
and that the engine inlet air is NOT being restricted.
be replaced If the primary filter
element is defective.

If the warning light comes on again after servicing

the primary filter element:

• Remove the housing cover and pull the

primary filter element off.

FIGURE 4-12. AIR CLEANER ASSEMBLY

EXPLODED VIEW.

04/2008 4-19
Section 4
MAINTENANCE
COOLING SYSTEM. With the engine STOPPED, inspect the radiator,
hydraulic oil cooler and charge air cooler cooling fin
RADIATOR, HYDRAULIC OIL COOLER AND area each time the system coolant level is checked.
CHARGE AIR COOLER[See Figure 4-13]. Use a bright light placed on the INSIDE of the
cooling fin area. Light MUST be clearly seen, when
WARNING: Do NOT check the system coolant looking through the radiator, hydraulic oil cooler and
level, or ANY component, with the air cooler fin area from the outside of the fin area.
engine running. Serious injury can
result from being caught or struck WARNING: The engine MUST be STOPPED
by the fan, belt or moving engine BEFORE checking, or cleaning, the
parts. radiator, or hydraulic oil cooler, fin
Do NOT check the system coolant areas. Serious injury can result from
level, or ANY component, when the being caught or struck by the fan,
system is at operating temperature belt or moving engine parts.
and the coolant is under pressure.
HOT coolant, under pressure, can NOTE: If a restricted cooling fin condition is
cause serious injury. noted in EITHER the radiator, hydraulic
Check the coolant level ONLY when oil or the charge air cooler fin area,
the radiator filler cap is cool enough CLEAN the fin area using low-pressure
to touch with the hand. Remove the compressed air.
radiator filler cap SLOWLY.
WARNING: The compressed air supply MUST
CHECK the system coolant level ONE [1] time for have a pressure BELOW 30 psi.
EACH eight [8] hours of machine operation, or daily. [2 bar]. Wear safety glasses and
Drain, flush and fill the cooling system, with NEW protective clothing.
coolant, ONE [1] time for EACH 1,000 hours of
machine operation, or yearly, [see THIS section for
procedures]. CAUTION: Do NOT damage the radiator, or
hydraulic oil cooler, cooling fins
Keep the coolant level ONE [1] inch [25.4 mm] during cleaning. Clean the fin areas
BELOW the radiator filler neck, when the cooling with the compressed air blown in the
system is cool. Fill the radiator ONLY when the OPPOSITE direction of “normal” air
system is COOL. Fill the radiator as needed, using a flow during operation. Bent cooling
50/50 % [approximate] mixture of ethylene glycol fins can be CAREFULLY
type antifreeze and CLEAN water on initial fill. Add straightened. Use a radiator fin comb
CLEAN water when level is LOW. to straighten the bent fins AFTER
cleaning. Severe restrictions or dirt
CHECK the radiator cap gasket EACH time the build up, which are NOT removed by
radiator cap is removed from the radiator. The using compressed air, MUST be
radiator cap gasket MUST seal on the radiator filler removed by using standard steam
neck surface. If the rubber face of the cap valve is cleaning procedures. Apply steam
damaged or cracked REPLACE the radiator cap cleaning pressure through BOTH the
IMMEDIATELY with a NEW cap of the SAME radiator and hydraulic oil cooler in
pressure rating. the direction OPPOSITE the direction
of “normal” air flow during operation.
CHECK the radiator overflow tube for a restriction or Do NOT use caustic soap solutions
damage. A restricted or damaged overflow tube can as part of the standard steam
prevent the radiator cap from releasing extra system cleaning procedure as rapid radiator,
pressure and system failure can occur. or hydraulic oil cooler, deterioration
can occur.

4-20 04/2008
 Section 4
MAINTENANCE
WARNING: Wear safety glasses AND protective WARNING: Do NOT check, or remove, ANY
clothing during the steam cleaning radiator hose with the engine
operation. Use ONLY CORRECT running. Serious injury can result
steam cleaning procedures. from being caught or struck by the
fan, belt or moving engine parts.
Do NOT check, or remove ANY
HYDRAULIC OIL
radiator hose while the cooling
COOLER
system is HOT or is full of
CHARGE AIR coolant. Remove the hoses ONLY
COOLER
when the system is COOL and has
been DRAINED of coolant.

WATER PUMP.

Visually CHECK the engine water pump for leaks, or

other damage, after EACH 50 hours of machine
operation.

Water pump leaks can allow air to be pulled into

the cooling system. Air in the cooling system can
cause the cooling system to operate in a “HOT”
RADIATOR condition. Replace the water pump IMMEDIATELY
if a leak, or other damage is noted.
FIGURE 4-13. RADIATOR AND
HYDRAULIC OIL COOLER LOCATIONS.
WARNING: Do NOT check, or remove the water
RADIATOR HOSES. pump with the engine running.
Serious injury can result from being
CHECK the radiator hoses at least ONE [1] time caught or struck by the fan, belt or
EACH 1,000 hours of machine operation, or yearly moving engine parts.
for cracks, increased size, softening or hardening. Do NOT remove the water pump
while the cooling system is HOT.
Drain the cooling system of coolant [see THIS Remove and replace the water pump
section] and COMPLETELY remove EACH radiator ONLY after draining the cooling
hose. CHECK the INSIDE area of the hose for system of coolant [see THIS section]
defects. Install the hose, again, if found to be when it is COOL.
acceptable or replace with NEW if found to be
damaged.

DRAINING, FLUSHING AND FILLING THE

CAUTION: Visual inspection of the outside of COOLING SYSTEM [See Figures 4-14, 4-15,
the hose is NOT adequate. A hose 4-16].
can have damage on the inside and
look acceptable from the outside. CAUTION: Also see the CUMMINS engine
The hose must NOT be hard or have “Operation And Maintenance
ANY restrictions. Manual”, supplied with the machine,
BEFORE doing this maintenance
procedure.

Rust in the radiator, or coolant, indicates that the

coolant anticorrosion additives are NO longer
effective.

04/2008 4-21
Section 4
MAINTENANCE
To help prevent severe cooling system damage; NOTE: BEFORE cooling system flushing,
drain, flush and fill the system with NEW coolant, the thermostat MUST be removed. If
ONE [1] time for EACH 1,000 hours of machine the thermostat is NOT removed the
operation, or yearly. flushing procedure WILL close the
thermostat and prevent complete
engine block flushing.
WARNING: Do NOT drain, or flush the cooling Do NOT install the radiator hoses
system with the engine running. or thermostat at THIS time.
Serious injury can result from being
caught or struck by the fan, belt or
moving engine parts. d. Remove ALL engine and aftercooler drain
Do NOT drain the cooling system plugs. COMPLETELY drain the coolant from the
while the system is HOT and is engine and aftercooler. Install all drain plugs into the
under pressure. Drain the system engine and aftercooler. Tighten the drain plugs by
when COOL ONLY. Hot coolant can hand only, at this time.
cause serious injury.
e. Install ONLY the thermostat HOUSING [no
thermostat] onto the engine. Reverse flush the
Use the following procedures to drain, flush and fill engine BLOCK as shown in [Fig4-14]. Remove ALL
the engine cooling system: engine and aftercooler drain plugs, again, AFTER
reverse flushing the engine block assembly. COM-
a. STOP the engine and allow the cooling system PLETELY drain the engine block and the aftercooler
to reach a COOL temperature. Put a container of water. Install all engine and aftercooler drain
under the radiator drain cock and drain the coolant. plugs. Tighten ALL drain plugs securely, using a
Open the radiator drain cock and drain all coolant wrench.
from the radiator. Close and tighten the drain cock
by hand ONLY. f. Remove the thermostat housing from the
engine. Install the thermostat into the housing, in
b. Remove BOTH the upper and the lower the CORRECT position. Install the thermostat
radiator hoses from the engine. Inspect BOTH housing to engine gasket. Install the thermostat
hoses using the procedures given in THIS section. housing over the thermostat and onto the engine.
Replace ANY hose found to have ANY damage. Install the retaining capscrews and tighten securely.

NOTE: Inspect the engine WATER PUMP, at CAUTION: Do NOT start the engine while
THIS time, for ANY damage, or leaks. reverse flushing the engine block or
REPLACE the water pump with NEW if the radiator assembly.
found to be damaged.

g. Reverse flush the RADIATOR assembly, as

c. Remove the thermostat housing and the shown in Figure 4-15. Loosen the radiator drain
thermostat from the engine. Inspect the thermostat cock again, AFTER reverse flushing the radiator
for corrosion or damage. Test the thermostat for assembly. COMPLETELY drain the radiator of
CORRECT operation at the specified opening water. Close the radiator drain cock and tighten
temperature. Replace the thermostat, with NEW, if securely.
found to be damaged. Install the thermostat, AFTER
flushing, ONLY. h. Install BOTH the UPPER and the LOWER
radiator hoses onto BOTH the radiator and the
engine. Install ALL the clamps, onto the hoses, and
tighten them securely.

i. Fill the cooling system with coolant, through the

radiator filler neck, using a NEW 50/50 %
[APPROXIMATE] mixture of ethylene glycol
antifreeze and CLEAN water [see THIS section].

4-22 04/2008
 Section 4
MAINTENANCE
NOTE: It is suggested that one [1] can
of cooling system conditioner,
with a rust inhibitor, also be
added to the coolant at THIS time.

j. Start the engine and allow the NEW coolant

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

WARNING: KEEP CLEAR of ALL moving engine

parts when the engine is running.
Serious injury can result from being
caught or struck by the fan, belt or
moving engine parts.

k. STOP the engine. Allow the coolant to reach a

cool temperature and then fill the radiator, with the FIGURE 4-15. REVERSE FLUSHING
CORRECT coolant mixture, to WITHIN one [1] inch PROCEDURE RADIATOR ASSEMBLY.
[25.4 mm] of the radiator filler neck. Install the
radiator cap and tighten.

HYDRAULIC SYSTEM.

GENERAL INFORMATION.

The transmission and steering systems use the

SAME hydraulic oil reservoir and hydraulic oil
supply.

CHECKING THE HYDRAULIC OIL LEVEL AND

ADDING HYDRAULIC OIL TO THE HYDRAULIC
OIL RESERVOIR [See Figure 4-16].

CHECK the hydraulic reservoir oil level, ONE [1]

time EACH day, using the sight gauge on the
reservoir. Check the oil level when the hydraulic oil
is at “NORMAL” operating temperature ONLY.

WARNING: Do NOT loosen, or remove the

FIGURE 4-14. REVERSE FLUSHING hydraulic oil reservoir filler cap
PROCEDURE ENGINE BLOCK. when the hydraulic oil is “HOT”.
ALWAYS loosen the filler cap
SLOWLY to relieve any pressure in
the hydraulic oil reservoir.
ONLY loosen the filler cap when the
oil is at a “WARM” temperature.

04/2008 4-23
Section 4
MAINTENANCE
The hydraulic reservoir oil level MUST be able to be
RESERVOIR FILL TUBE AND CAP
seen through the sight gauge glass and be at the
CENTER of the glass. If the hydraulic oil level is
BELOW the sight gauge, the CORRECT, FIL-
SIGHT GAUGE
TERED hydraulic oil MUST be added to the hydrau-
lic oil reservoir UNTIL the oil level is in the CENTER TO SOLENOID
VALVE
TO HYD. PUMP

TO BOTTOM OF OIL COOLER

of the sight gauge glass. See THIS section for TO HYD. MOTOR

CORRECT type of oil.

RESERVOIR FILL TUBE AND CAP

TO VIEW SIGHT GAUGE

CAUTION: Do NOT over fill the hydraulic oil OPEN BOTH
DOORS.
reservoir. DOOR
Do NOT use unfiltered hydraulic oil.
The NEW hydraulic oil MUST be
filtered through TEN [10] micron
filtration BEFORE it enters the
DOOR
hydraulic oil reservoir. The oil must
NOT have more than 400 particles
larger than 10 u. per milliliter as
installed. FIGURE 4-16. HYDRAULIC OIL RESERVOIR AND
KEEP the oil level of the hydraulic SIGHT GAUGE.
oil reservoir, at the CORRECT
level. An air space is designed
into the hydraulic oil reservoir and CHANGING THE HYDRAULIC OIL [See Figure
allows for oil expansion, at warm 4-17].
temperatures. The hydraulic oil
reservoir WILL have a low pressure Obtain a hydraulic oil sample from oil six [6] inches
in it at system operating [152.4 mm] BELOW the FILL neck of the hydraulic
temperatures. oil reservoir one [1] time for each 2,000 hours of
Do NOT add a vent hole to the machine operation, or every two [2] years for OIL
hydraulic oil reservoir. ANALYSIS.

Before obtaining the oil sample, warm the hydraulic

oil to operating temperature. Use the equipment
furnished by the oil analysis service. CHANGE the
hydraulic oil if the oil analysis results indicate a
change is needed.

CAUTION: Obtain the hydraulic oil sample with

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

4-24 04/2008
 Section 4
MAINTENANCE
Changing the hydraulic oil removes the CAUTION: Use CARE to NOT damage the gasket
accumulation of dirt, water and mechanical wear between the cover and the reservoir
particles from the hydraulic oil reservoir and system. when removing the access cover
The chemical structure of the hydraulic oil also from the reservoir. Inspect the
changes after continuous use in the system and gasket, and replace the gasket ,
NEW, CLEAN and FILTERED oil is a MUST to help with NEW when the cover is
insure further CORRECT operation of the hydraulic installed back onto the reservoir, if
system components. found damaged.

CAUTION: Hydraulic oil which has oxidized or d. Use an oil pump to remove the remaining
which contains contamination, of hydraulic oil from the bottom of the hydraulic oil
ANY type, can shorten the expected reservoir. Reach through the reservoir access
service life of all, or any, of the opening and use CLEAN lint free cloths to remove
components in the hydraulic system. any remaining oil and/or contamination from the
bottom area of the hydraulic oil reservoir.

Use the following procedures to change the e. If removed, install a NEW gasket onto the
hydraulic oil: hydraulic oil reservoir access opening area. Install
the access cover over the studs and onto the
a. STOP the engine. Allow the hydraulic oil to hydraulic oil reservoir. Install the eight [8] retaining
cool, until it is at a WARM temperature ONLY. nuts onto the access cover studs and tighten
SLOWLY loosen, and remove, the hydraulic oil securely.
reservoir filler cap. Put a CLEAN, lint free cloth
over the reservoir fill tube opening and secure it in f. Install the reservoir drain plug and tighten
place. securely. CAREFULLY remove the cloth from the
hydraulic oil reservoir fill tube opening.

WARNING: Do NOT drain the hydraulic oil from

the reservoir when it is HOT. Hot NOTE: Also CHANGE the one [1] hydraulic
hydraulic oil can cause serious SUCTION oil filter element at this time.
injury. Drain at a WARM temperature See THIS section for procedures.
ONLY.

CAUTION: Do NOT fill the hydraulic oil reservoir

b. Place an empty container, having a capacity of with NEW hydraulic oil UNTIL the
approximately 25 gallons [95 liters], under the SUCTION filter element in the
machine directly below the hydraulic oil reservoir ABOVE “NOTE” has been changed.
drain plug. Place a funnel, with a hose under the Do NOT start the engine UNTIL the
drain plug area. Place the hose into the container. hydraulic system has been
Carefully remove the drain plug and allow ALL of COMPLETELY and CORRECTLY
the oil to drain from the reservoir and into the funnel filled with NEW, CORRECT and
and container. FILTERED hydraulic oil [see THIS
section]. Damage to the components
c. Go to the hydraulic oil reservoir, found in the of the hydraulic system can occur, IF
engine compartment. Remove, the eight [8] nuts the engine is started BEFORE the
that fasten the hydraulic reservoir access cover to system is ENTIRELY filled with NEW
the reservoir. Carefully move the access cover hydraulic oil.
away from the reservoir to allow cleaning of the
inside of the reservoir.

04/2008 4-25
Section 4
MAINTENANCE
h. Fill the hydraulic oil reservoir with NEW, COR-
RECT and FILTERED hydraulic oil to a level in the
CENTER of the sight gauge glass. COMPLETELY
and CORRECTLY FILL the transmission system
SUCTION FILTER and transmission pump oil
SUPPLY HOSE with NEW, CORRECT and FIL-
TERED hydraulic oil by using the FOLLOWING
ADDITIONAL procedures - numbers 1 through 4.

CAUTION: Do NOT use unfiltered hydraulic oil.

The NEW hydraulic oil MUST be
filtered through TEN [10] micron
filtration BEFORE it enters the
hydraulic system. The oil must NOT DRAIN LOCATION
have MORE than 800 particles larger (UNDERSIDE OF FRAME- ABOVE
WHEEL)
than 10 u. per milliliter of oil
as installed. Fill the hydraulic oil
reservoir UNTIL the oil level is in the
CENTER of the sight gauge glass
ONLY.
Do NOT overfill the hydraulic oil
reservoir with oil.
FIGURE 4-17. HYDRAULIC OIL RESERVOIR
DRAIN LOCATION.
1. Remove and discard the hydraulic SUCTION
i. Install the hydraulic oil reservoir filler cap onto
oil filter element [See THIS section]. FILL the
the reservoir filler neck and tighten securely.
NEW hydraulic SUCTION oil filter element
with NEW, CORRECT and FILTERED
j. Start the engine using the CORRECT proce-
hydraulic oil and install the element onto the
dures given in Section 3 - OPERATION - of THIS
filter head [See THIS section].
manual. CHECK the hydraulic system for ANY
leaks.
2. Wipe BOTH the INLET and OUTLET hose
fitting and suction FILTER fittings, at the filter
head, with a CLEAN lint-free cloth. Loosen the
OUTLET [transmission oil SUPPLY] HOSE WARNING: Do NOT use the hands on ANY
fitting at the FILTER head OUTLET fitting. hydraulic hose, fitting or system
COMPLETELY remove the hose fitting from component to check the system for
the filter head fitting. possible leaks. Serious injury can
occur from a leak under high
3. COMPLETELY FILL the transmission pressure. Hydraulic oil, under
SUPPLY hose with NEW, CORRECT and pressure, can penetrate the skin or
FILTERED hydraulic oil. Install the damage eyes. Oil leaks, under
transmission oil SUPPLY hose fitting onto the pressure, may NOT be visible.
FILTER head OUTLET fitting and tighten Use a piece of cardboard or wood to
securely. find leaks. Wear safety goggles for
eye protection. If oil enters the skin,
4. CHECK the hydraulic oil level shown in the or eyes, get IMMEDIATE medical
hydraulic oil reservoir sight gauge. Add oil if attention.
needed, as described in step “h” above.

4-26 04/2008
 Section 4
MAINTENANCE
CAUTION: STOP the engine IMMEDIATELY if Use the following procedure to remove and replace
ANY hydraulic leak is noted. the hydraulic SUCTION oil filter element:
Do NOT start the engine UNTIL any
problem noted has been corrected. a. STOP the engine. Allow the hydraulic oil to
reach a WARM, or COOL, temperature.

b. Wipe the hydraulic suction oil filter head and

HYDRAULIC SUCTION OIL FILTER ELEMENT - element using a CLEAN lint free cloth.
REMOVAL AND REPLACEMENT [See Figure
4-18]. c. Use a oil filter removal wrench to loosen and
remove the filter element. Discard the removed filter
CHECK the condition of the hydraulic suction oil element.
filter element EACH day. The filter element MUST
be changed when the condition indicator light, found
on the dash of the machine, and/or the change CAUTION: BE sure that the old filter
indicator, found on the filter head, indicates an element rubber gasket was removed
element change is required. and discarded, BEFORE the NEW
filter element is Installed.
Do NOT overtighten the NEW
CAUTION: The hydraulic system MUST be at filter element. Tighten by hand ONLY.
NORMAL operating temperature,
with the engine “running”, when the
condition of the filter element is d. Put CLEAN hydraulic oil on the NEW filter
checked. With the engine at “HIGH” element rubber gasket. Completely fill the filter with
idle, and when the filter condition NEW, CORRECT and FILTERED hydraulic oil.
indicator WHITE sliding bar is in the
RED zone, an element CHANGE is e. CAREFULLY install the NEW filter element
indicated to be needed. onto the filter head. Tighten the NEW filter element
onto the filter head ONLY UNTIL the rubber gasket
contacts the filter head seal area. Tighten the NEW
NOTE: When the hydraulic oil is in a COLD filter element ONE HALF [1/2] additional turn
condition and at machine “START UP” AFTER the rubber gasket contacts the filter head
the filter condition indicator WHITE area.
sliding bar will show a HIGHER amount
of filter element restriction. The filter f. Fill the hydraulic oil reservoir with oil. Use ALL
element MUST also be changed with the CORRECT procedures given in THIS section.
EACH COMPLETE hydraulic oil change.

CAUTION: Do NOT start the engine BEFORE

WARNING: Do NOT loosen, or remove, the filling the hydraulic oil reservoir.
hydraulic suction oil filter element Damage to the hydraulic system
when the engine is running or when components can occur. FILL the
the hydraulic oil is HOT. reservoir, suction oil filter and
Loosen and remove the filter transmission pump using ALL the
element ONLY when the engine is procedures given in THIS section
“STOPPED” and the hydraulic oil BEFORE starting the engine.
has cooled to a WARM, or COOL,
temperature.

04/2008 4-27
Section 4
MAINTENANCE
g. Start the engine using the CORRECT
procedures given in Section 3 - OPERATION - of
THIS manual. CHECK the hydraulic system for ANY
oil leaks.

WARNING: Do NOT use the hands on ANY

hydraulic hose, fitting or system
component to check the system for
possible leaks. Serious injury can
occur from a leak under high HYDRAULIC SUCTION OIL
pressure. Oil can be injected under FILTER
(INSIDE ENGINE COMPARTMENT)
the skin by high pressure. Protect
the eyes by wearing safety glasses. ENGINE COMPARTMENT
DOOR

CAUTION: STOP the engine IMMEDIATELY if

ANY hydraulic oil leak is noted. FIGURE 4-18. HYDRAULIC SUCTION OIL
Do NOT start the engine UNTIL any FILTER ELEMENT LOCATION.
problem noted has been corrected.

4-28 04/2008
 Section 4
MAINTENANCE
ALTERNATOR AND FAN DRIVE BELT -
INSPECTION AND REPLACEMENT
PROCEDURES [See Figure 4-19].

Inspect the drive belt ONE [1] time for EACH 1,000
hours of machine operation, or yearly, and replace
the belt as needed.

The belt is kept under constant tension by an

automatic tension mechanism and “adjustment” is
NOT required as part of the maintenance
procedures. FAN AND
ALTERNATOR
DRIVE BELT
Use the following procedures to inspect and/or
inspect and replace the drive belt:

a. STOP the engine.

WARNING: Do NOT inspect the engine drive

belt when the engine is running. The
engine MUST be STOPPED BEFORE FIGURE 4-19. ALTERNATOR AND
inspecting the drive belt. Serious FAN DRIVE BELT LOCATION.
injury can result from being caught
or struck by the fan, belt or other
moving engine parts.
ELECTRICAL SYSTEM.

b. Visually inspect the drive belt for cracks on the CHECKING THE BATTERY “CHARGE LEVEL”
INNER surface of the belt plies. Check the belt AND SERVICING OF RELATED ITEMS [See
deflection at the longest span of the belt. The Figure 4-20].
MAXIMUM amount of deflection is 0.375-0.500 in.
[9.5-12.7 mm] with 80-110 lbs. [36-49 kg] pull on the WARNING: Do NOT attempt to open the
belt. Replace the belt, with NEW, if ANY cracks, or “MAINTENANCE-FREE” battery
other damage is noted or if the amount of deflection case. The acid in electrolyte
is MORE than the above amount. CAN cause INJURY. If electrolyte is
spilled, use water to FLUSH the area
and make the acid NEUTRAL using a
NOTE: If the belt requires replacement WATER and SODA solution. Acid
with NEW, see the “Operation and in the EYES MUST be FLUSHED with
Maintenance Manual - B3.3 Series water IMMEDIATELY.
Diesel Engines”, published by ALL batteries produce an
Cummins Diesel Engine Company, and EXPLOSIVE GAS.
supplied with the machine, for Do NOT smoke near a battery.
procedures. Also, check the belt tension Do NOT check with flame.
mechanism and fan hub bearings at AVOID causing sparks.
this time using the procedures given in
the SAME publication.
The battery is of the “maintenance-free” type and
MINIMAL service is needed. Use the built in battery
“charge level” indicator, found in the top of the
battery, to CHECK the charge level in the battery
ONE [1] time for each 100 hours of machine opera-
tion, or every two [2] weeks.

04/2008 4-29
Section 4
MAINTENANCE
The indicator will indicate a “GREEN” color for a CAUTION: Do NOT use a wire smaller than
fully charged battery. A “BLACK” indicator color the size of the original factory
indicates the battery is in a LOW charged condition. installed wires in the electrical
system. If, due to wear or damage,
Use a battery cable cleaning brush, baking soda wires are replaced with new, use wire
and clear water to clean the battery terminals and EQUAL to, or larger in size than, the
cables, as NEEDED. wire being replaced.

WARNING: BATTERY EXPLOSION CAN OCCUR WARNING: BATTERY EXPLOSION CAN OCCUR
IF THE BATTERY IS SHORTED. IF A BATTERY IS SHORTED.
ALWAYS disconnect the NEGATIVE ALWAYS disconnect BOTH the
[-] battery cable FIRST, and then positive [+] AND the negative [-]
disconnect the POSITIVE [+] battery battery cables from a battery,
cable, BEFORE cleaning the BEFORE ANY repair procedures are
terminals or cables. NEVER make a done to the electrical wiring or
shorted circuit between the positive components.
[+] terminal and negative [-] terminal ALWAYS use APPROVED practices
of the battery. when performing electrical system
ALWAYS connect the POSITIVE [+] diagnosis procedures and doing
battery cable to the POSITIVE repairs.
battery terminal FIRST, and then NEVER make a shorted circuit
connect the NEGATIVE [-] battery between the positive [+] terminal
cable to the NEGATIVE [-] battery and the negative [-] terminal of a
terminal LAST. battery.
Do NOT place ANY tools on a Do NOT place ANY tools on a
battery at ANY time. battery at ANY time.

WARNING: CALIFORNIA Proposition 65.

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

CHECK and tighten the battery hold down assem-

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

ELECTRICAL WIRING INSPECTION [See Figure

4-21].

During engine and other system maintenance FIGURE 4-20. BATTERY MAINTENANCE ITEM
inspections, check the electrical wiring for correct LOCATIONS.
routing and support. Inspect the wires for loose
terminal connections, cracks or wear in the wiring
insulation and for corrosion. Wires and connections
MUST be free of oil, dirt or grease.

4-30 04/2008
04/2008
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MAINTENANCE
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4-31
In
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4-
31
 Section 4
MAINTENANCE
REAR WHEEL BEARINGS [See Figures 4-22 c. Remove the grease cap from the one [1] of the
and 4-23]. outer wheel and tire assembly mounting hubs.
Remove the cotter pin. Loosen and remove the hub
On the machine, each of the five [5] rear wheels has and bearings assembly retaining nut. Remove the
inner and outer tapered roller bearings. hub and bearings assembly from the wheel support.
Remove the remaining four [4] hub and bearings
Lubricate EACH inner and outer bearing assembly assemblies.
one [1] time for EACH 1000 hours of machine
operation, or yearly, with wheel bearing grease.
NOTE: Keep all removed items together with
each hub and bearings assembly.

d. CAREFULLY remove the inner and outer

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

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

FIGURE 4-22. REAR WHEELS AND BEARINGS. e. Use a tapered roller bearing packer to correctly
lubricate ALL inner and outer bearing cones with
NEW wheel bearing grease.

f. Use the hand to lubricate each of the inner and

a. Lift the REAR frame with a chain and hoist, or outer bearing cups, installed in each of the hubs,
jack having a capacity more than 15,000 lbs. [6810 with NEW wheel bearing grease.
kg]. Put SOLID wood blocks under BOTH sides of
the frame, so that the rear tires are above the floor g. Carefully install one [1] inner bearing into each
enough to remove each tire and wheel assembly hub, from the inner side. Use a correct sized seal
from the hub and from under the rear frame. driver to install one [1] NEW inner bearing seal into
each hub, from the inner side.

WARNING: Keep CLEAR of the hoist, chain, or h. Install each hub assembly fully over the
jack and machine while lifting and threaded shaft of each wheel support. Install one
installing the blocking. Block outer bearing cone over the threaded wheel support
SECURELY with SOLID wood shaft and push fully into the outer side of the hub.
blocking. Install the hub and bearings assembly retaining nut.

i. Tighten each retaining nut to a torque of 150 ft.

b. Go to the outer wheel and tire assembly at lbs. [203 N.m]. Loosen each nut, so that each hub
either side of the rear frame. Loosen and remove turns freely, with NO end play. Tighten each retain-
the wheel and tire assembly to hub mounting nuts. ing nut to a torque of 25 ft. lbs. [40 N.m] and lock in
Remove the tire and wheel assembly from the hub. place at the first alignment position which occurs at,
Repeat the same procedure for each of the four [4] or above, 25 ft. lbs. [40 N.m].
remaining tire and wheel assemblies.

04/2008 4-33
Section 4
MAINTENANCE

j. Fill each grease cap one half [1/2] full of wheel

bearing grease. Install the grease cap on the outer
side of each hub and bearings assembly.

k. Install the inner most wheel and tire assembly

onto the hub and bearings assembly, under the rear
frame. Install the wheel and tire assembly to hub
mounting nuts.

WARNING: A mounting nut torque of 95 - 100

ft. lbs. [129 - 136 N.m] MUST be
maintained at the rear wheels.

l. Tighten the tire assembly to hub mounting

nuts, across corners, to a torque of 50% of the
above torque. Tighten the tire assembly to hub FIGURE 4-23. REAR WHEEL TO HUB MOUNTING
mounting nuts, across corners, to a torque of 75% NUTS - TORQUE SEQUENCE.
of the above torque. Tighten the tire assembly to
hub mounting nuts, across corners, to the FULL
torque, given above.
THROTTLE AND TRANSMISSION LINKAGE
j. Install each of the four [4] remaining tire and LUBRICATION [See Figure 4-24].
wheel assemblies, working toward the outside of the
machine. Repeat step "i" for each of the four [4] The throttle and transmission linkages, found
remaining tire and wheel assemblies. beneath the base of the travel control bar lever,
MUST be lubricated to ensure smooth operation
k. Lift the REAR frame with a chain and hoist, or and prevent rusting.
jack having a capacity more than 15,000 lbs. [6810
kg]. Remove the wood blocks from under BOTH One [1] time for EACH 100 hours of machine
sides of the frame. operation, or every two [2] weeks lubricate the
linkage,directional/speed control lever and cable
using engine oil.
WARNING: Keep CLEAR of the hoist, chain, or
jack and machine while lifting and
removing the blocking. REAR CENTER SPRING ADJUSTMENT [See
Figure 4-25].

l. Place the machine into service. Check the tire NOTE: The rear spring adjustment depends on
assembly to hub mounting nuts torque, again, after the rear ballast load.
twenty five [25] hours of machine operation. If the
torques are found to be not correct, torque as a. Place theroller on a flat even surface.
needed using the above procedures.
b. Load the roller to the desired weight.

WARNING: Check the tire assembly to hub c. Go to the underside of the rear of the roller.
mounting nuts torque, again, after Loosen the center spring adjustment jam nut and
twenty five [25] hours of machine turn the adjustment screw until the center wheel is
operation. vertical, using the wheel rim as a reference point.

d. Tighten the jam nut.

NOTE: If the wheel is tilted to the right, it is

loaded too much. If it tilts to the left, it is
not loaded enough.
4-34 04/2008
 Section 4
MAINTENANCE

BAIL

THROTTLE

WATER TANK

STRAINER

FIGURE 4-24. THROTTLE AND TRANSMISSION

LINKAGE LUBRICATION POINTS. FIGURE 4-26. IN LINE WATER SPRAY STRAINER
- INSTALLATION.

WATER SPRAY NOZZLES.

Water spray nozzles can become clogged and

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

Each water spray nozzle is connected to the water

spray bar and is released by a “quick disconnect”
FIGURE 4-25. REAR CENTER SPRING mechanism.
ADJUSTMENT.
Push inward and rotate to release the spray nozzle
from the lower mount and remove for cleaning or
WATER SPRAY SYSTEM. replacement.

WATER SPRAY FILL STRAINER BASKET. Remove all spray nozzles. Clean the spray nozzles
with a small wire, or low pressure compressed air.
There is one [1] strainer basket found at the inside
of the water fill cap area on the water spray tank. Flush the water spray bar of any contamination by
operating the water spray pump with the spray
AFTER removing the fill cap, remove and CLEAN nozzles removed.
the strainer basket BEFORE filling the water spray
tank. Install the spray nozzles back onto the lower mount.
Push inward and rotate the “quick disconnect”
mechanism while pushing each spray nozzle into
IN LINE WATER SPRAY SYSTEM STRAINER position and then letting the mechanism return to
[See Figure 4-26]. the locked position.

As required, remove the in line mesh water spray

strainer assembly, from the inside the water tank by
reaching through the fill port and unthreading in
assembly from the tank mounting fitting . Use water
flow, directed into the center of the strainer from the
inside toward the outside, to remove trapped
material and install the assembly back into the tank.
04/2008 4-35
Section 4
MAINTENANCE
MISCELLANEOUS MAINTENANCE CAUTION: Do NOT store the battery on a
INFORMATION. concrete surface. Store the battery
on a WOOD surface ONLY. Be sure
PREPARING THE MACHINE FOR STORAGE. the battery electrolyte will NOT
freeze.
Use the following information as a “general guide”
ONLY to prepare the machine for storage. Manufac-
turers of component parts, used on the machine,
can also be contacted for specific information about FUEL TANK.
components manufactured by them.
FILL the fuel tank to a COMPLETELY full condition,
using the CORRECT, CLEAN fuel, BEFORE the
machine is placed in storage [see THIS section].
ENGINE.

See the Cummins Diesel Engine Company "Opera- CAUTION: Do NOT leave the fuel tank ONLY part
tion And Maintenance Manual - B Series Diesel filled. Moisture can condense inside
Engine" for complete APPROVED engine storage the fuel tank, while in storage, and
preparation procedures suggested by the engine can cause fuel system component
manufacturer. damage during storage and/or when
the machine is placed back into use.

COOLING SYSTEM.

The ENTIRE cooling system MUST be protected WATER SPRAY SYSTEM.

from freezing. If the system is NOT protected,
COMPLETELY drain the cooling system of water BEFORE freezing temperatures are encountered,
and install a ethylene glycol based antifreeze and drain ALL water from the water spray system tank.
water solution [see THIS section]. The antifreeze
and water MUST be of the CORRECT mixture ratio, Also, drain the water spray system supply lines and
to protect the cooling system, to a temperature water spray bars of water and apply LOW pressure
BELOW the lowest expected freezing temperature compressed air to these parts to remove any water
for the area where the machine is to be stored. still possibly remaining in them.

Also, remove the water spray pump assembly and

check to be sure that the pump has been COM-
BATTERY. PLETELY drained of water. Drain ALL water found
to have possibly remained in the pump and then
If the machine is to be stored for a period of MORE install the pump back into the tank. Put a plastic
than 30 days, remove the battery from the machine. cover, or tape, on EACH water spray nozzle.
Wash the battery with baking soda and water
solution, rinse with clear water and permit to air dry.
CAUTION: Drain ALL water from the water spray
COMPLETELY charge the battery BEFORE it is tank, water pump, supply hoses and
placed in storage. Charge the battery, again, one [1] water spray bars, BEFORE the
time for every 30 days which the battery is stored. temperature reaches 32F [0 C]. The
system will be DAMAGED if the water
Keep the battery stored in a wood surface in a is allowed to remain and freeze.
COOL and DRY storage area.

4-36 04/2008
 Section 4
MAINTENANCE
TIRES. EXPOSED COMPONENT RUST PREVENTION.

Check each tire inflation pressure. Inflate if needed. Put a heavy grease, or equivalent, onto the exposed
After final machine parking, put covers over any tire area of the hydraulic cylinder rod. Put a rust preven-
which will be exposed to direct sun light, or weather tative oil [such as L.P.S. #s 2 or 3] on ALL control
elements, to help reduce tire damage. linkages, control cable ends, hinges or other moving
parts.

CAUTION: If the machine is stored out of doors, Put ALL covers and access plates in their
use tire covers to help prevent tire correct position and secure in place with the retain-
damage from direct sun light and /or ing capscrews.
weather elements.

AIR CLEANER, EXHAUST AND OTHER

OPENINGS.

Put a cap, tape, or otherwise seal, ALL openings to

prevent the entrance of moisture, or other forms of
contamination, while the machine is in storage.

04/2008 4-37
Section 4
MAINTENANCE

4-38 04/2008
 BOMAG Americas, Inc.
2000 Kentville Rd.
Printed in U.S.A. Kewanee, IL 61443