BW 11RH

Pneumatic tired roller

Instructions for repair

Catalog number 0852645 11/00
 BW11RH
DANGER: If the machine was received with the Roll Over/Falling Object Protection
Structure (ROPS/FOPS) and Operator Restraints (Seat Belt Sets) NOT
installed, they MUST be installed BEFORE the machine is operated, using
the installation instructions drawing, included with the installation kit,
and/or the illustration below.
In the event of a machine roll over, serious injury, or death, can occur due
to failure to correctly install the Roll Over/Falling Object Protection
Structure (ROPS/FOPS) and Operator Restraints (Seat Belt Sets).

Structure

6 Flange Screws and

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

Left
(Retractor)

Seat Belt
Assembly
(2 Sets used)

Washer

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.
March 2000
 SYMBOLS USED IN THIS MANUAL

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

DANGER: Serious personal injury, death and/or 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.

 SERVICE AND REPAIR PRECAUTIONS

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

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

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

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

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

ALWAYS support the machine with sound blocking.

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

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

ALWAYS keep tools in a good and clean condition.

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

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

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

ALWAYS observe ALL WARNING AND CAUTION statements given in the Operating Manual and
Service Manual and found on the machine decals.
 MANUAL - TABLE OF CONTENTS

PAGE

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

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

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

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

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

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

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

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

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

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

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

2/98 i
 OPERATING INSTRUCTIONS

WARNING:

WARNING:

WARNING:
 Section 1
INTRODUCTION

TABLE OF CONTENTS

PAGE

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

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

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

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

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

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

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

11/00 1-1
Section 1
INTRODUCTION
GENERAL INFORMATION. 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 Model BW11RH
the Model BW11RH 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. MODEL BW11RH ROLLER.

1-2 11/00
 Section 1
INTRODUCTION
REPAIR PROCEDURES. SERIAL NUMBER [See Figures 1-2 and 1-3 ].

MAJOR machine component REPAIR 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 "Service Manual", pn. [see Table 1-1]. The machine serial number is
0852462. 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 "Service figure 1-3].
Manual" pn. 0852462, or other
referenced written materials ONLY.
CAUTION: ALL numbers and letters,
contained in the SERIAL NUMBER,
MUST be given when requesting
NAME PLATE /SERIAL NUMBER PLATE [See service and/or part information.
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.

NAME PLATE
SERIAL NUMBER

FIGURE 1-3. STAMPED SERIAL NUMBER

LOCATION - ON RIGHT INSTRUMENT PANEL
COWL.

FIGURE 1-2. NAME PLATE /SERIAL NUMBER

PLATE LOCATION.

11/00 1-3
Section 1
INTRODUCTION

A222 C 1505 T

BW11RH * KEWANEE CONSECUTIVE YEAR OF

*H = HYDROSTATIC SERIAL NUMBER SHIPMENT

OR

109 A222 01850

PLANT OF BW11RH * MACHINE

MANUFACTURE *H = HYDROSTATIC SERIAL NUMBER

TABLE 1-1. MACHINE SERIAL NUMBER DESIGNATIONS.

1-4 11/00
 Section 2
SPECIFICATIONS

TABLE OF CONTENTS

PAGE

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

TABLE 2-15. TORQUE SPECIFICATIONS FOR STANDARD INCH

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

TABLE 2-16. TORQUE SPECIFICATIONS FOR STANDARD METRIC

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

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

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

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

07/01 2-1
Section 2
SPECIFICATIONS
GENERAL INFORMATION. Machine dimensions, weights, performance and
torque specifications are also given in THIS
THIS section gives specification tables for each section.
MAJOR machine system of the Model BW11RH
Roller.

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 07/01
 Section 2
SPECIFICATIONS
TABLE 2-2. ENGINE SPECIFICATIONS.

ITEM DESIGN DATA

ENGINE

Model and 4B3.9 Cummins Diesel

Manufacturer

Type 4 Cycle N.A. diesel

Number of 4
Cylinders

Bore 4.02 in. [102 mm]

Stroke 4.72 in. [120 mm]

Rated Brake 80 hp [59.7 Kw] @ 2,500 rpm

Horsepower

Compression Ratio 16.5:1

Firing Order 1-3-4-2

Low Idle Speed 800 - 850 rpm

High Idle Speed 2,650 +/- 20 rpm [governed]

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

Valve Clearances

Intake - Cold 0.010 in. [0.25 mm]

Exhaust - Cold 0.020 in. [0.51 mm]

ENGINE COOLING
SYSTEM

System Capacity 19 qts. [17.97 ltrs.]

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

Pressure Cap Rating 7 psi. [0.5 bar]

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

07/01 2-3
Section 2
SPECIFICATIONS
ITEM DESIGN DATA

ENGINE FUEL

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

Rate of Fuel 1.3 Gallons per hour

Consumption [@ [4.9 liters per hour]*
normal engine H.P.
@ 40% load]
*Operating conditions, that vary, can cause different fuel
consumption amounts than those given

FUEL FILTERS

Fuel Strainer Suction line, replaceable element

Fuel Filter Pressure line, replaceable element

FUEL PUMP

Type Bosch, distributor type

FUEL INJECTORS

Quantity and Type 4, close nozzle

2-4 07/01
 Section 2
SPECIFICATIONS
TABLE 2-3. ELECTRICAL SPECIFICATIONS.

ITEM DESIGN DATA

BATTERY

Number Per Machine One [1]

Ampere Hour Rating 900 CCA

Voltage 12 Volts

ALTERNATOR

Voltage, Type and 12 Volt, negative ground - Bosch

Manufacturer

Output Amperage 62 Amps

Maximum Charge 62 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 Delco Remy [see engine STARTER plate for part number]

Voltage and Type 12 Volt, negative ground

07/01 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 [107.91 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 07/01
 Section 2
SPECIFICATIONS

TRANSMISSION PUMP

ITEM DESIGN DATA

TYPE Variable displacement axial piston

SWASH PLATE ANGLE 17˚ maximum - either side of center

PRESSURE RATING -
MAXIMUM 6000 psi. [414 bar]

DIRECTION OF ROTATION Clockwise [C.W.]

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

MINIMUM MAIN PORT 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

07/01 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] 0.75 in. [19 mm] - Code 62
Case Drain Port [1] M22x1.5
Brake Line Port M16x1.5

DRIVE WHEEL NUTS -

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

MOTOR WEIGHT 300 lbs. [136 kg], Each

2-8 07/01
 Section 2
SPECIFICATIONS
TABLE 2-5. BRAKE SYSTEM SPECIFICATIONS.

ITEM DESIGN DATA

BRAKE SYSTEM

SERVICE BRAKE TYPE Hydrostatic, through transmission system

SECONDARY/PARKING 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
transmission system]
System Oil

STEERING HYDRAULIC
PUMP

Type Gear

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

and Speed

Direction of Clockwise [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

07/01 2-9
Section 2
SPECIFICATIONS

ITEM DESIGN DATA

STEERING CONTROL UNIT

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

internal adjustable relief valve

STEERING CYLINDERS

Type Double acting

Number per 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 07/01
 Section 2
SPECIFICATIONS
TABLE 2-7. TIRE SPECIFICATIONS.

ITEM DESIGN DATA

TIRES

Size, Ply and Quantity

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

Turn Signals and 4 Way Electrical switch and actuation assembly, 12 volt,
Flashers - Option negative ground

07/01 2-11
Section 2
SPECIFICATIONS

ITEM DESIGN DATA

FUNCTION TYPE

INDICATOR/GAUGE

Engine Hours Hourmeter, electrical, 12 volt, negative ground

Engine Lubrication Oil Oil pressure gauge, electrical, 12 volt, negative ground
Pressure

Fuel Level Fuel gauge, electrical, 12 volt, negative ground

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

Temperature

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

Hydraulic System Oil Temperature gauge, electrical, 12 volt, negative ground

Temperature

Engine Inlet Air Restriction Red lensed indicator light, 12 volt, negative ground

Transmission System Suction Red lensed indicator light, 12 volt, negative ground
Oil Filter Element Condition

TABLE 2-9. WATER SPRAY SYSTEM SPECIFICATIONS.

ITEM DESIGN DATA

Type Pressurized system

Tank Capacity 150 gals. [568 ltrs.]

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

Filtration

Pump Inlet 100 Mesh screen

Tank Fill Port Strainer basket, one [1]

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

2-12 07/01
 Section 2
SPECIFICATIONS
TABLE 2-10. OPTIONAL EQUIPMENT SPECIFICATIONS.

ITEM DESIGN DATA

TURN SIGNALS & 4 WAY

FLASHERS

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

HEADLIGHTS

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

TIRES

Type and Quantity 7.50 x 15 - 14 ply; nine [9]

07/01 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 8,000 lbs. [3 632 kg] - Approximate/calculated, @ this printing

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

(4510 mm)

FIGURE 2-1. MACHINE DIMENSIONS.

2-14 07/01
 Section 2
SPECIFICATIONS
TABLE 2-12. PERFORMANCE SPECIFICATIONS.

ITEM DESIGN DATA

TRAVEL SPEED
[forward or reverse]

Speed Range

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

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

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

EFFECTIVE COVERAGE
PER PASS

Width 68 in. [1 730 mm]

TABLE 2-13. MACHINE SYSTEM CAPACITY SPECIFICATIONS.

ITEM DESIGN DATA

SYSTEM CAPACITIES

Fuel 30 Gallons [114 liters]

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

Engine Cooling System 19 Quarts [18 liters]

Hydraulic System 28.5 Gallons [30 liters]

Water Spray Tank 150 Gallons [568 liters]

07/01 2-15
Section 2
SPECIFICATIONS
TABLE 2-14. COMPONENT WEIGHTS.

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

ITEM DESIGN DATA

WEIGHTS

Rear Frame Components

Rear frame, bare 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 600 lbs. [272 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 07/01
 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.

07/01 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 07/01
 Section 2
SPECIFICATIONS
TABLE 2-17. LUBRICATION OILS, HYDRAULIC OILS AND COOLANT SPECIFICATIONS.

P/N DESCRIPTION SIZE

336830 HYDRAULIC/TRANSMISSION OIL 1 QT

336831 HYDRAULIC/TRANSMISSION OIL 2 GAL

336832 HYDRAULIC/TRANSMISSION OIL 5 GAL

336833 HYDRAULIC/TRANSMISSION OIL 55 GAL

3002338 ANTI-FREEZE 1 GAL

TABLE 2-18. ADHESIVE THREAD LOCKING SPECIFICATIONS.

P/N DESCRIPTION SIZE

360387 222 Small Screw Threadlock [Purple] 50 ML

318702* 242 Removable Threadlock [Blue] 10 ML

226414* 271 High Strength Threadlock [Red] 10 ML

318996 277 High Viscosity Threadlock [Red] 50 ML

318650 290 Low Viscosity Threadlock [Green] .02 OZ

251099 290 Low Viscosity Threadlock [Green] 50 ML

355844** 422 SuperBonder Adhesive 3 ML

264159 515 Gasket Eliminator 6 ML

313022* 515 Gasket Eliminator [Purple] 50 ML

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

318705 595 Super Flex Silicone 100 ML

318701* 609 Retaining Compound 10 ML

341959 680 Retaining Compound 50 ML

226415 Primer T - Aerosal 6 OZ

316865 Anti-Seize Compound 1 LB

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

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

07/01 2-19
Section 2
SPECIFICATIONS
NOTES

2-20 07/01
 Section 3
OPERATION

TABLE OF CONTENTS

PAGE

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

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

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

OPERATION ........................................................................................................................................... 3-9.

CHECKS WITH THE ENGINE STOPPED .......................................................................................... 3-9.

STARTING THE ENGINE ................................................................................................................... 3-9.

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

OPERATING PRECAUTIONS .......................................................................................................... 3-11.

OPERATING THE MACHINE ........................................................................................................... 3-13.

PRESSURIZED WATER SPRAY SYSTEM ...................................................................................... 3-14.

BALLASTING A PNEUMATIC ROLLER .......................................................................................... 3-14.

DYNAMIC BRAKING OF THE MACHINE ........................................................................................ 3-14.

STOPPING THE ENGINE ................................................................................................................. 3-16.

TOWING A ROLLER HAVING THE STANDARD SECONDARY/PARKING

BRAKE RELEASE SYSTEM ......................................................................................................... 3-16.
TOWING A ROLLER HAVING THE OPTIONAL SECONDARY/PARKING
BRAKE RELEASE SYSTEM ......................................................................................................... 3-19.

MACHINE TRANSPORT .................................................................................................................. 3-21.

11/00 3-1
Section 3
OPERATION
GENERAL INFORMATION. OPERATION, WARNING AND CAUTION
DECALS.
THIS section gives the OPERATION INSTRUC-
TIONS for the Model BW11RH 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 gauges, for the
DEATH [see Figure 3-1].
Model BW11RH Roller, are shown on Figure 3-2
ONLY authorized personnel, who
and are listed in Table 3-1.
are fully trained in the machine
operation, can operate the Model
BW11RH Roller.
DANGER: Do NOT start, or operate, a
Model BW11RH Roller
BEFORE reading, understanding
and following ALL information given
Keep the machine in GOOD mechanical condition at
in THIS section and shown on the
ALL times.
machine “Operating 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 11/00
 Section 3
OPERATION

OPERATING INSTRUCTIONS

WARNING:

WARNING:

WARNING:

FIGURE 3-1. MODEL BW11RH ROLLER

“OPERATING INSTRUCTION DECAL”.

11/00 3-3
Section 3
OPERATION

12 9 11 10 16 8 7 15 6 4

1 18

17

13

14

5 19 2

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

MODEL BW11RH ROLLER.

3-4 11/00
 Section 3
OPERATION
TABLE 3-1. MACHINE OPERATING CONTROLS, INDICATORS AND GAUGES.

ITEM NO. 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 NUMBER 1: The “OFF” position

removes all power from the electrical circuits
[EXCEPT the horn circuit].

POSITION NUMBER 2: The “ON” [RUN]

position applies power to the electrical
circuits.

POSITION NUMBER 3: The key in the

“START” position engages the engine starter.
When the key is released, the switch will
return to the “ON” [RUN] position.

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”.

11/00 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 Toggle Switch - Lift position lock collar. Put switch “DOWN”
SPEED RANGE Three [3] Position, for “LOW” speed range. Release lock collar.
With Position Lift position lock collar. Put switch “CENTER”
Lock Collar for “MEDIUM” speed range. Release lock
collar. Lift position lock collar. Put switch “UP”
for “HIGH” speed range. Release lock collar.

7 WATER SPRAY “ON”/”OFF” Put switch in “ON” position to turn spray

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

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

dash mounted

9 HOURMETER Indicator Indicator shows the total hours of engine

operation.

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

the fuel tank.

11 HYDRAULIC SYSTEM Gauge Gauge indicates the temperature of oil in the

OIL TEMPERATURE transmission system. During NORMAL
operation, the needle will be in the area
between 120˚ F [49˚ C] and 180˚ F [82˚ C].

CAUTION: STOP the engine IMMEDIATE-

LY if the gauge pointer moves
to the RED zone of the gauge.

3-6 11/00
 Section 3
OPERATION

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

ITEM NO. DESCRIPTION TYPE FUNCTION

[SEE FIG’
3-2]

12 ENGINE COOLANT Gauge Gauge indicates the temperature of the

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

CAUTION: STOP the engine IMMEDIATELY

if the gauge pointer moves to
the RED zone of the gauge.

13 ENGINE OIL Gauge Gauge indicates the pressure of the

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

CAUTION: STOP the engine IMMEDIATELY

if there is NO, or LOW, oil
pressure sure indicated on the
oil pressure gauge.

14 VOLTMETER Instrument Indicates alternator output voltage. Can be

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

15 LIGHTS Push-Pull Switch Pull switch to FIRST detent position to

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

16 STEERING SYSTEM Manually TURN steering wheel TOWARD the direction

CONTROL Operated wheel that the machine is desired to travel.

11/00 3-7
Section 3
OPERATION
TABLE 3-1. MACHINE OPERATING CONTROLS, INDICATORS AND GAUGES.

ITEM NO. DESCRIPTION TYPE FUNCTION

[SEE FIG’
3-2]

17 ENGINE INLET AIR Electrical Light, Indicates “RED” lighted condition ONLY
CONDITION Red Lens when engine inlet air flow is restricted.
Covered When lighted, IMMEDIATE service of air
cleaner assembly is required BEFORE
further machine operation.

18 TRANSMISSION Electrical Light, Indicates “RED” lighted condition

SYSTEM SUCTION OIL Red Lens condition when transmission system
FILTER ELEMENT Covered SUCTION oil filter element has reached
CONDITION maximum holding capacity and MUST be
changed before further machine operation.

CAUTION: Hydraulic system MUST be at

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

19 WATER SPRAY “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

3-8 11/00
 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 and engine idle speed position.
Table 3-1].

CAUTION: Also, see the Engine Operation and CAUTION: Do NOT move the engine throttle
Maintenance Manual - B Series control lever to the “HIGH” engine
Engines, published by Cummins idle position. Engine damage can
Engine Company, which is supplied occur, due to over speeding, at
with the machine. engine start.

a. Unlock and remove the padlock securing the

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

11/00 3-9
Section 3
OPERATION
e. Turn the ignition switch key [ITEM 3] to the 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 - B 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.

3-10 11/00
 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 gauges, instruments, indicator e. Keep ALL personnel CLEAR of the front and
lights and other standard or optional systems, as rear frame area, at the hitch, at ALL times.
equipped.

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

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

h. BEFORE getting off of the machine, put the

DANGER: FAILURE to observe the following directional/speed control [ITEM 2] in the “NEU-
precautions and/or the machine TRAL” position. Pull the secondary/parking brake
“Operation and Warning system control switch [ITEM 4] “ON”. STOP the
Instructions”given in THIS section engine.
and found on the DECALS affixed to
the machine, can cause SERIOUS
INJURY, or DEATH. WARNING: ALWAYS APPLY the
ONLY authorized personnel, who SECONDARY/PARKING brake
are full trained in the machine system, AFTER the machine has
operation, can operate the stopped. The transmission system
Model BW11RH Roller. will NOT hold the parked machine
in a stopped condition, on
ANY grade. The SECONDARY/
a. USE the "low' speed range, a SLOW speed and PARKING brake system MUST be
ADDITIONAL CAUTION when nearing, or operating used to hold the machine, in a
the machine close to, a slope and/or when traveling stopped condition, when parked.
down a slope.

11/00 3-11
Section 3
OPERATION

WARNING

P/N 918141

WARNING
FASTEN
SEAT BELT!

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

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

3-12 11/00
 Section 3
OPERATION
i. Do NOT operate the machine, If the machine will NOTE: 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 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,
lift the selector switch position lock collar. Move the
WARNING: Do NOT put the engine throttle transmission speed range switch [ITEM 6] from the
speed lever in “HIGH”, or the current speed range position to the next lower, or
transmission speed range in higher, speed range position and release the lock
“medium" or "high” when the collar. If a still lower, or higher, speed range is
machine is being moved in a con desired, allow the machine to travel, in the selected
fined area, or is near personnel, speed range, for a short time. Lift the selector switch
machines or other objects. position lock collar, again. Move the transmission
speed range switch [ITEM 6] from the current speed
range position to the lower, or higher, speed range
c. Move directional/speed control neutral lock position and release the lock collar.
[included with ITEM 2] to the unlocked position.
Move directional/speed control bar lever [ITEM 2]
toward the forward, or reverse, direction of machine CAUTION: Always move to the NEXT lower, or
travel, a small amount, With the machine moving, higher, speed range, for a short
SLOWLY move the directional/speed lever [ITEM 2] period of time, when changing the
FURTHER in the direction of machine travel, as transmission speed range. Do NOT
desired, to increase travel speed. by pass a range.

11/00 3-13
Section 3
OPERATION
PRESSURIZED WATER SPRAY SYSTEM [See
Figures 3-2 and 3-4]. “UP”
POSITION
Use the following information to operate the
pressurized water spray system when compacting
asphalt work surface materials, as needed.
COCO
The water spray system will help keep all tires clean MAT
when compacting asphalt, until the tires have
warmed.
FIGURE 3-4. 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 3-5].
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 3-5 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 DYNAMIC BRAKING OF THE MACHINE [See
the lowering procedure for the double tire width Figure 3-2].
cocoa 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.

3-14 11/00
11/00
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
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
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
Section 3
OPERATION

FIGURE 3-5. BALLASTING INSTRUCTIONS.

3-15
Section 3
OPERATION
STOPPING THE ENGINE [See Figure 3-2 and
Table 3-1].

a. SLOW and STOP the machine by moving the

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

b. Put the secondary/parking brake system control

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

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

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

CAUTION: Do NOT stop the engine BEFORE

allowing the engine to idle at the
LOW engine idle speed position. FIGURE 3-6. 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 HAVING THE "TEE" FITTING NEEDLE VALVE

STANDARD SECONDARY/PARKING BRAKE
RELEASE SYSTEM [See Figures 3-6 AND 3-7]. CAP AND CONNECTION
FITTING

CAUTION: Do NOT tow the machine UNLESS TO RIGHT TIRE

DRIVE MOTOR TO LEFT TIRE
ALL of the following procedures have DRIVE MOTOR
been followed.

Do NOT tow the Roller unless the machine is FIGURE 3-7. AUXILIARY BRAKE RELEASE
TOTALLY disabled and MUST be moved for repair. PRESSURE CONNECTION LOCATION.
If a machine must be towed, tow it at a SLOW
SPEED and on a LEVEL surface ONLY. Tow it only
for a SHORT distance. Put the towing bypass
valves in the “TOW” position, BEFORE the machine 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].

3-16 11/00
 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 3-7].
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 3-7]. 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.

11/00 3-17
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”,
system to release the spring applied to 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 3-7].
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].

3-18 11/00
 Section 3
OPERATION
TOWING A ROLLER HAVING THE OPTIONAL c. OPEN the bypass valve by turning the open
SECONDARY/PARKING BRAKE RELEASE end wrench, that is on the MIDDLE sized [2nd] nut,
SYSTEM [See Figures 3-6, 3-7 and THREE [3] revolutions in the
3-8]. COUNTERCLOCKWISE [CCW] direction.

CAUTION: Do NOT tow the machine unless ALL CAUTION: Do NOT turn the MIDDLE sized [2nd]
of the following procedures have hex nut more than three [3]
been followed. Should the machine revolutions. Additional revolutions
become COMPLETELY disabled, and will permit external leakage of
the engine is NOT able to be started, hydraulic oil during towing of the
use the following procedure to machine.
develop enough secondary/parking
brake system pressure to release the
brakes. Put BOTH of the g bypass d. REPEAT the procedures, given in steps “b”,
valves in the “TOW” [OPEN] position “c”, and the above “CAUTION” on the REVERSE
BEFORE the machine is moved. direction multifunction valve cartridge.

e. If the machine will be towed in the FORWARD

NOTE: The towing bypass valves are found on direction, put the DIRECTION/SPEED CONTROL
the hydraulic transmission pump [see handlever in the FULL FORWARD position, so that
figure 3-6]. the transmission pump displacement control valve
handle is, also, at the full forward position.

CAUTION: DO the FOLLOWING steps ONLY if

the transmission system, or engine, NOTE: If the machine will be towed in the
can NOT be operated and BEFORE REVERSE direction, put the DIRECTION/
the machine is moved. RETURN the SPEED CONTROL handlever in the full
towing bypass valves to the reverse position.
“OPERATE” [CLOSED] position,
AFTER the machine has been
moved.

a. Put SOLID wood blocks behind, and in the

SMALL LEVER
front of, ALL FRONT and REAR tires. Go to the HANDLE
transmission pump. Find the two [2] towing bypass
valves that are installed into the hydraulic HOSE
transmission pump [see figure 3-6].

b. Put a 1 1/16 inch open end wrench on the

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

HAND PUMP PUMP HAND LEVER

ASSEMBLY

FIGURE 3-8. OPTIONAL SECONDARY/PARKING

BRAKE RELEASE SYSTEM - HAND PUMP -
INSTALLED ABOVE ENGINE FLYWHEEL
HOUSING.

11/00 3-19
Section 3
OPERATION
f. Go to the brake release system REMOTE flow NOTE: There will be resistance in the
control valve. Turn the knob to the fully CLOSED hydrostatic transmission system. It is
[remote supply] position [see figure 3-7]. caused by static system oil in the
transmission wheel motors, until the
motors have turned approximately one
NOTE: The brake release system needle valve, third [1/3] revolution. The machine will
is found at the bottom the secondary/ then roll more easily.
parking brake solenoid valve assembly
and the brake system release pressure
supply hose, on the “solenoid stack i. AFTER the machine has been towed or
valve”. transported, the SECONDARY/PARKING brake
system MUST be APPLIED. Turn the “small” lever
handle, found on the brake system release pump,
g. Go to the secondary/parking brake system “DOWNWARD” to apply the secondary/parking
release hand pump assembly, which is installed on brakes.
a plate above the engine flywheel housing [see
figure 3-8]. Turn the “small” lever handle
“UPWARD”. Move the hand pump lever “back and NOTE: Turning the lever handle downward, will
forth”. allow the pressure in the secondary/
parking brake system to be released
from the system. The spring applied
NOTE: Moving the hand pump lever multi-disc brake will then APPLY. It will
approximately twenty [20] times will require approximately five [5] seconds
make approximately 175 psi. [12 bar] for the pressure to be released from the
MINIMUM to 400 psi. [28 bar] MAXIMUM secondary/parking brake system and the
of pressure in the secondary/parking brakes to be fully applied.
brake release system and release the
brakes.
j. Turn the knob, found on the REMOTE flow
control valve, OUTWARD, to the fully OPEN
H. Securely fasten a large capacity towing strap, position [see figure 3-7].
cable or chain to the Roller and the towing vehicle,
or winch, and tighten fully. CAREFULLY remove the
wood blocking from under the drive tires. NOTE: This is the SAME position, which the
CAREFULLY and SLOWLY tow the machine to a knob was in BEFORE the brakes were
repair area or move the machine onto a truck, or released [see figure 3-7].
trailer, and fasten securely [see this section for
CORRECT machine tie-down procedures].
k. AFTER the secondary/parking brakes are
APPLIED, close both the forward and reverse
WARNING: Do NOT tow the machine on ANY direction bypass valves by turning the MIDDLE
grade. Tow on LEVEL terrain ONLY. sized [2nd] hex nut THREE [3] revolutions in the
The secondary/parking brake CLOCKWISE [CW] direction with the 1 1/16 inch
system will be RELEASED during open end wrench, UNTIL the hex nut is seated
towing. TOW the machine the against the LARGE sized [3rd] hex nut. Hold the
LEAST distance possible. Do NOT LARGE [3rd] hex nut with the 1 1/4 inch wrench and
tow the machine at a speed above tighten the MIDDLE sized [2nd] hex nut to a torque
TWO [2] miles per hour [3.2 Km/h]. of 30 ft. lbs. [41 N.m] [see figure 3-6].

CAUTION: BOTH bypass valves MUST be

returned to the CLOSED position.

3-20 11/00
 Section 3
OPERATION
MACHINE TRANSPORT [See Figure 3-8]. 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.

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

11/00 3-21
Section 3
OPERATION
NOTES

3-22 11/00
 Section 4
MAINTENANCE

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 FILTERS ............................................................................................................ 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.

07/01 4-1
Section 4
MAINTENANCE
PAGE

COOLING SYSTEM ................................................................................................................... 4-19.

RADIATOR AND HYDRAULIC OIL COOLER ........................................................................ 4-19.

RADIATOR HOSES ................................................................................................................. 4-20.

WATER PUMP ......................................................................................................................... 4-20.

DRAINING, FLUSHING AND FILLING THE COOLING SYSTEM .......................................... 4-20.

HYDRAULIC SYSTEM ...................................................................................................................... 4-22.

GENERAL INFORMATION ............................................................................................................ 4-22.

CHECKING THE HYDRAULIC OIL LEVEL AND ADDING

HYDRAULIC OIL TO THE HYDRAULIC OIL RESERVOIR ....................................................... 4-22.

CHANGING THE HYDRAULIC OIL ............................................................................................... 4-23.

HYDRAULIC SUCTION OIL FILTER ELEMENT-

REMOVAL AND REPLACEMENT............................................................................................... 4-26.

ALTERNATOR AND FAN BELT

INSPECTION AND REPLACEMENT PROCEDURES .................................................................. 4-28.

ELECTRICAL SYSTEM .................................................................................................................... 4-28.

CHECKING THE BATTERY CHARGE LEVEL AND

SERVICING OF RELATED ITEMS ............................................................................................. 4-28.

ELECTRICAL WIRING INSPECTION ............................................................................................ 4-29.

REAR WHEEL BEARINGS................................................................................................................ 4-31.

THROTTLE AND TRANSMISSION LUBRICATION ........................................................................ 4-32.

REAR CENTER WHEEL SPRING ADJUSTMENT ......................................................................... 4-32.

WATER SPRAY SYSTEM ................................................................................................................ 4-33.

WATER SPRAY FILL STRAINER BASKET ................................................................................. 4-33.

IN LINE WATER PUMP SYSTEM STRAINER .............................................................................. 4-33.

WATER SPRAY NOZZLES ........................................................................................................... 4-33.

4-2 07/01
 Section 4
MAINTENANCE

PAGE

MISCELLANEOUS MAINTENANCE INFORMATION ..................................................................... 4-34.

PREPARING THE MACHINE FOR STORAGE ............................................................................. 4-34.

ENGINE ....................................................................................................................................... 4-34.

COOLING SYSTEM .................................................................................................................... 4-34.

BATTERY .................................................................................................................................... 4-34.

FUEL TANK ................................................................................................................................ 4-34.

WATER SPRAY SYSTEM .......................................................................................................... 4-34.

TIRES .......................................................................................................................................... 4-35.

AIR CLEANER, EXHAUST AND OTHER OPENINGS .............................................................. 4-35.

EXPOSED COMPONENT RUST PREVENTION ........................................................................ 4-35.

07/01 4-3
Section 4
MAINTENANCE
GENERAL INFORMATION. MAINTENANCE SCHEDULE.

THIS section gives the necessary procedures for GENERAL INFORMATION.

CORRECT MAINTENANCE of the Model BW11RH
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 Model BW11RH 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”.

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

2
(other side)

1
8 10
3
13 21
22 17

FIGURE 4-1. MACHINE MAINTENANCE POINTS .

4-4 07/01
 Section 4
MAINTENANCE

MAINTENANCE INFORMATION

FIGURE 4-2. MACHINE MAINTENANCE DECAL.

07/01 4-5
Section 4
MAINTENANCE
TABLE 4-1. MAINTENANCE SCHEDULE.

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* * Drain PRIMARY of

FUEL EACH water daily with
FILTERS drain plug provided.*
[Primary Change at interval
and given.*
Secondary] 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 07/01
 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.

07/01 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 07/01
 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.

07/01 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 07/01
 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 - B SERIES DIESEL

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

07/01 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
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 - B SERIES DIESEL ENGINE” published
by Cummins Engine Company Incorporated, which
is supplied with the machine. FIGURE 4-3. CUMMINS DIESEL ENGINE -
LUBRICATION OIL LEVEL CHECK LOCATION.

ENGINE LUBRICATION OIL.

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 07/01
 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.

07/01 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 07/01
 Section 4
MAINTENANCE

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 FILTERS [See Figure 4-7].

FUEL SYSTEM.
The fuel strainer [PRIMARY] and the fuel filter
FUEL TANK [See Figure 4-6]. [SECONDARY] elements MUST be replaced one
[1] time for EACH 500 hours of machine operation
The fuel gauge indicates the amount of fuel in the or every six [6] months.
tank. Check the amount indicated on the gauge
ONE [1] time EACH day. Fill the fuel tank to “FULL”,
as the gauge indicates. Also fill the tank, to “FULL”, CAUTION: Drain the PRIMARY fuel strainer
BEFORE the machine is stored for the night to lower bowl of ALL water [1] time
reduce the accumulation of moisture, in the tank, EACH day, or as needed.
from condensation.

Replace the fuel strainer and/or fuel filter elements

WARNING: The operator MUST be off of the using the following “GENERAL” procedures and
machine while fuel is added. those given in the engine “Operation and Mainte-
NO smoking while filling the nance Manual” published by Cummins
fuel tank. Engine Company Incorporated and supplied with
ALL fuels for internal combustion the machine.
engines are flammable.
Fill the fuel tank ONLY in a
designated area with good NOTE: Also remove and replace the fuel pre-
ventilation. Have a fire extinguisher filter assembly, found in the fuel line
available. ahead of the fuel lift pump, one [1] time
NEVER fill the tank near an open for EACH 500 hours of machine
flame, or near equipment that can operation, or every six [6] months.
create sparks. Never check fuel level
, or check for leaks, with an open
flame.

07/01 4-15
Section 4
MAINTENANCE
WARNING: DIESEL FUEL IS VERY FLAMMABLE. e. Wipe the inside area of the filter head with a
USE EXTRA CAUTION. CLEAN “lint free” cloth. Fill the “NEW” fuel strainer,
Do NOT change the fuel strainer, or or fuel filter, element COMPLETELY FULL of the
fuel filter, element in an area near CORRECT and CLEAN fuel. Put CLEAN oil on the
open flame. element rubber gasket.
Do NOT change the fuel strainer,
or fuel filter, element with the f. Install the “NEW” fuel strainer, or fuel filter,
machine running. element onto the filter head. CAREFULLY tighten
Do NOT smoke while changing the the element by HAND ONLY.
fuel strainer, or fuel filter, element.
Do NOT spill fuel.
CAUTION: Tighten the fuel strainer, or the fuel
filter, element as DIRECTED on
the filter element, by the filter
manufacturer.
Do NOT overtighten the fuel strainer,
or fuel filter, element onto the filter
head.

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

WARNING: STOP the engine IMMEDIATELY if

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

PRIMING AND AIR REMOVAL [BLEEDING]

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

b. Put a container under the fuel strainer, or the NOTE: Small amounts of air will be vented from
fuel filter, element BEFORE removing either 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 strainer, or the removal [bleeding] will be required if the
fuel filter, element and the element mounting head, fuel strainer and/or filter elements were
using a CLEAN lint free 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.

4-16 07/01
 Section 4
MAINTENANCE
a. Add at LEAST ten [10] gallons [38 liters] of the f. With the engine running at LOW idle speed,
CORRECT, CLEAN fuel to the fuel tank. CAREFULLY use a wrench to loosen the fuel
supply line to injector retaining nuts a SMALL
b. Remove the air from the LOW pressure fuel amount, ONE [1] at a time. Let the fuel flow from
lines and the fuel strainer and filter by opening the EACH line until there is NO indication of air
air bleed screw, found at the manifold above the bubbles present at ANY line connection point.
fuel filter [see figure 4-8]. CAREFULLY use the wrench to tighten EACH fuel
supply line nut at the injector fittings
c. Operate the hand lever on the fuel lift pump [see figure 4-8].
until the flow of fuel from the manifold fitting is
continuous and FREE of air bubbles
[see figure 4-8]. WARNING: KEEP the hands and body AWAY
from the cooling fan. Serious injury
d. COMPLETELY tighten the air bleed screw and can result from being caught or
stop the operation of the lift pump hand lever. struck by the fan, belt or moving
engine parts.
e. Start the engine using ALL the CORRECT KEEP the hands and body AWAY
starting procedures given in Section 3 - OPERA- from the injector fittings and nuts.
TION - of THIS manual. Fuel under HIGH pressure
can penetrate the skin. Wear safety
glasses to protect the eyes. Get
IMMEDIATE medical attention if fuel
enters the eyes, or skin.
Do NOT remove the air from the fuel
supply lines if the engine is HOT.
Fuel leaked on the HOT exhaust
manifold can create a danger of fire.

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

07/01 4-17
Section 4
MAINTENANCE
ENGINE AIR FILTRATION. f. CAREFULLY install the NEW air filter element
into the air cleaner body assembly.
AIR CLEANER [See Figure 4-9].
g. Install the baffle assembly over the end of the
The engine inlet air cleaner assembly uses a air filter element. Install and tighten the wing nut,
replaceable filter element. which holds the baffle assembly and air filter
element into the air cleaner body assembly.
CHECK the engine inlet air restriction indicator light
DAILY. If the restriction indicator light is “ON”, the h. Install the air cleaner end cap onto the air
air cleaner filter element MUST be removed and cleaner body. Snap the spring clamps over the end
replaced with NEW IMMEDIATELY. cap.

i. Start the engine using ALL the CORRECT

CAUTION: The air cleaner filter element should starting procedures given in Section 3 - OPERA-
be replaced ONE [1] time for EACH TION - of THIS manual. Note that the engine inlet
1,000 hours of machine operation, or air restriction indicator light is in an “OFF” condition
yearly, for a machine which is and that the engine inlet air is NOT being restricted.
operated under “normal” conditions,
or ONE [1] time for EACH 500 hours
of machine operation, or every six
[6] months, for a machine which is
operated under “very dusty or SPRING CLAMPS
(TYPICAL)
“severe” conditions.
Do NOT service the air cleaner
element while the engine is
“running”.

Use the following procedures to service the air

cleaner element:

a. STOP the engine. Release the spring clamps

which hold the end cup assembly onto the air cleaner
body. Remove the end cup from the air cleaner body.

b. Remove the wing nut and baffle assembly from

inside the air cleaner body.

c. Remove the air filter element from inside the air FIGURE 4-9. AIR CLEANER ASSEMBLY
cleaner body and DISCARD. EXPLODED VIEW.

d. Clean the inside of the air cleaner body with a

clean cloth.

e. Inspect the hose clamps for tightness and the

condition of the tube from the air filter to the engine
intake manifold.

CAUTION: Severe engine damage can occur

if hose clamps are in a loose
condition or if the tube is damaged.

4-18 07/01
 Section 4
MAINTENANCE
COOLING SYSTEM. With the engine STOPPED, inspect the radiator and
the hydraulic oil cooler cooling fin area EACH time
RADIATOR AND HYDRAULIC OIL COOLER [See the system coolant level is checked. Use a bright
Figure 4-10]. light placed on the INSIDE of the radiator fin area.
Light MUST be clearly seen, when looking through
WARNING: Do NOT check the system coolant the radiator and hydraulic oil cooler fin area FROM
level, or ANY component, with the the outside of the fin area.
engine running. Serious injury can
result from being caught or struck
by the fan, belt or moving engine WARNING: The engine MUST be STOPPED
parts. BEFORE checking, or cleaning, the
Do NOT check the system coolant radiator, or hydraulic oil cooler, fin
level, or ANY component, when the areas. Serious injury can result from
system is at operating temperature being caught or struck by the fan,
and the coolant is under pressure. belt or moving engine parts.
HOT coolant, under pressure, can
cause serious injury.
Check the coolant level ONLY when NOTE: If a restricted fin condition is noted in
the radiator filler cap is cool enough EITHER the radiator, or the hydraulic oil
to touch with the hand. Remove the cooler, fin area, CLEAN the fin area using
radiator filler cap SLOWLY. LOW pressure compressed air.

CHECK the system coolant level ONE [1] time for WARNING: The compressed air supply MUST
EACH eight [8] hours of machine operation, or daily. have a pressure BELOW 30 psi.
Drain, flush and fill the cooling system, with NEW [2 bar]. Wear safety glasses and
coolant, ONE [1] time for EACH 1,000 hours of protective clothing.
machine operation, or yearly, [see THIS section for
procedures].
CAUTION: Do NOT damage the radiator, or
Keep the coolant level ONE [1] inch [25.4 mm] hydraulic oil cooler, cooling fins
BELOW the radiator filler neck, when the cooling during cleaning. Clean the fin areas
system is cool. Fill the radiator ONLY when the with the compressed air blown in the
system is COOL. Fill the radiator as needed, using OPPOSITE direction of “normal” air
a 50/50 % [approximate] mixture of ethylene glycol flow during operation. Bent cooling
type antifreeze and CLEAN water on initial fill. Add fins can be CAREFULLY
CLEAN water when level is LOW. straightened. Use a radiator fin comb
to straighten the bent fins AFTER
CHECK the radiator cap gasket EACH time the cleaning. Severe restrictions or dirt
radiator cap is removed from the radiator. The build up, which are NOT removed by
radiator cap gasket MUST seal on the radiator filler using compressed air, MUST be
neck surface. If the rubber face of the cap valve is removed by using standard steam
damaged or cracked REPLACE the radiator cap cleaning procedures. Apply steam
IMMEDIATELY with a NEW cap of the SAME cleaning pressure through BOTH the
pressure rating. radiator and hydraulic oil cooler in
the direction OPPOSITE the direction
CHECK the radiator overflow tube for a restriction or of “normal” air flow during operation.
damage. A restricted or damaged overflow tube can Do NOT use caustic soap solutions
prevent the radiator cap from releasing extra system as part of the standard steam
pressure and system failure can occur. cleaning procedure as rapid radiator,
or hydraulic oil cooler, deterioration
can occur.

07/01 4-19
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
RADIATOR radiator hose while the cooling
system is HOT or is full of
FILL CAP
coolant. Remove the hoses ONLY
when the system is COOL and has
been DRAINED of coolant.

WATER PUMP.

Visually CHECK the engine water pump for leaks,

or other damage, after EACH 50 hours of machine
operation.

Water pump leaks can allow air to be pulled into

the cooling system. Air in the cooling system can
OIL
OIL COOLER
COOLER DRAIN COCK cause the cooling system to operate in a “HOT”
condition. Replace the water pump IMMEDIATELY
if a leak, or other damage is noted.
FIGURE 4-10. RADIATOR AND
HYDRAULIC OIL COOLER LOCATIONS.
WARNING: Do NOT check, or remove the water
pump with the engine running.
Serious injury can result from being
caught or struck by the fan, belt or
RADIATOR HOSES.
moving engine parts.
Do NOT remove the water pump
CHECK the radiator hoses at least ONE [1] time
while the cooling system is HOT.
EACH year for cracks, increased size, softening or
Remove and replace the water pump
hardening.
ONLY after draining the cooling
system of coolant [see THIS section]
Drain the cooling system of coolant [see THIS
when it is COOL.
section] and COMPLETELY remove EACH radiator
hose. CHECK the INSIDE area of the hose for
defects. Install the hose, again, if found to be
acceptable or replace with NEW if found to be
DRAINING, FLUSHING AND FILLING THE
damaged.
COOLING SYSTEM [See Figures 4-10, 4-11,
4-12].
CAUTION: Visual inspection of the outside of
CAUTION: Also see the CUMMINS engine
the hose is NOT adequate. A hose
“Operation And Maintenance
can have damage on the inside and
Manual”, supplied with the machine,
look acceptable from the outside.
BEFORE doing this maintenance
The hose must NOT be hard or have
procedure.
ANY restrictions.

Rust in the radiator, or coolant, indicates that the

coolant anticorrosion additives are NO longer
effective.

4-20 07/01
 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. Loosen and remove ALL engine block drain
Do NOT drain the cooling system plugs. COMPLETELY drain the coolant from the
while the system is HOT and is engine block. Install ALL engine block drain plugs
under pressure. Drain the system into the engine block. 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 assembly as shown in figure 4-11.
the engine cooling system: Remove ALL engine block drain plugs again,
AFTER reverse flushing the engine block assembly.
a. STOP the engine and allow the cooling system COMPLETELY drain the engine block of water.
to reach a COOL temperature. Put a container Install ALL engine block drain plugs. Tighten the
under the radiator drain cock and drain the coolant. drain plugs securely, using a wrench.
Close the radiator drain cock and tighten by hand
ONLY [see figure 4-10]. 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 4-12. 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. 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].

07/01 4-21
Section 4
MAINTENANCE
NOTE: It is suggested that one [1] can
of cooling system conditioner,
with a rust inhibitor, also be
added to the coolant at THIS time.

j. Start the engine and allow the NEW coolant

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

WARNING: KEEP CLEAR of ALL moving engine

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

k. STOP the engine. Allow the coolant to reach a FIGURE 4-12. REVERSE FLUSHING
cool temperature and then fill the radiator, with the PROCEDURE RADIATOR ASSEMBLY.
CORRECT coolant mixture, to WITHIN one [1] inch
[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 4-13].

CHECK the hydraulic reservoir oil level, ONE [1]

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

WARNING: Do NOT loosen, or remove the

hydraulic oil reservoir filler cap
when the hydraulic oil is “HOT”.
FIGURE 4-11. REVERSE FLUSHING ALWAYS loosen the filler cap
PROCEDURE ENGINE BLOCK. SLOWLY to relieve any pressure in
the hydraulic oil reservoir.
ONLY loosen the filler cap when the
oil is at a “WARM” temperature.

4-22 07/01
 Section 4
MAINTENANCE
The hydraulic reservoir oil level MUST be able to be
seen through the sight gauge glass and be at the
CENTER of the glass. If the hydraulic oil level is
BELOW the sight gauge, the CORRECT, FIL- RESERVOIR FILL TUBE AND CAP

TERED hydraulic oil MUST be added to the hydrau-

lic oil reservoir UNTIL the oil level is in the CENTER
of the sight gauge glass. See THIS section for SIGHT GAUGE

CORRECT type of oil. TO SOLENOID

VALVE
TO HYD. PUMP

TO BOTTOM OF OIL COOLER

TO HYD. MOTOR

CAUTION: Do NOT over fill the hydraulic oil RESERVOIR FILL TUBE AND CAP

reservoir.
TO VIEW SIGHT GAUGE
Do NOT use unfiltered hydraulic oil. OPEN BOTH
DOORS.
The NEW hydraulic oil MUST be DOOR
filtered through TEN [10] micron
filtration BEFORE it enters the
hydraulic oil reservoir. The oil must
NOT have more than 400 particles
larger than 10 u. per milliliter as DOOR

installed.
KEEP the oil level of the hydraulic
oil reservoir, at the CORRECT FIGURE 4-13. HYDRAULIC OIL RESERVOIR AND
level. An air space is designed SIGHT GAUGE.
into the hydraulic oil reservoir and
allows for oil expansion, at warm
temperatures. The hydraulic oil CHANGING THE HYDRAULIC OIL [See Figure
reservoir WILL have a low pressure 4-14].
in it at system operating
temperatures. Obtain a hydraulic oil sample from oil six [6] inches
Do NOT add a vent hole to the [152.4 mm] BELOW the FILL neck of the hydraulic
hydraulic oil reservoir. oil reservoir one [1] time for each 2,000 hours of
machine operation, or every two [2] years for OIL
ANALYSIS.

Before obtaining the oil sample, warm the hydraulic

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

CAUTION: Obtain the hydraulic oil sample with

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

07/01 4-23
Section 4
MAINTENANCE
Changing the hydraulic oil removes the 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.

4-24 07/01
 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 4-14. HYDRAULIC OIL RESERVOIR
DRAIN LOCATION.
1. Remove and discard the hydraulic SUCTION
oil filter element [See THIS section]. FILL the
NEW hydraulic SUCTION oil filter element
with NEW, CORRECT and FILTERED i. Install the hydraulic oil reservoir filler cap onto
hydraulic oil and install the element onto the the reservoir filler neck and tighten securely.
filter head [See THIS section].
j. Start the engine using the CORRECT proce-
2. Wipe BOTH the INLET and OUTLET hose dures given in Section 3 - OPERATION - of THIS
fitting and suction FILTER fittings, at the filter manual. CHECK the hydraulic system for ANY
head, with a CLEAN lint-free cloth. Loosen the leaks.
OUTLET [transmission oil SUPPLY] HOSE
fitting at the FILTER head OUTLET fitting.
COMPLETELY remove the hose fitting from WARNING: Do NOT use the hands on ANY
the filter head fitting. hydraulic hose, fitting or system
component to check the system for
3. COMPLETELY FILL the transmission possible leaks. Serious injury can
SUPPLY hose with NEW, CORRECT and occur from a leak under high
FILTERED hydraulic oil. Install the pressure. Hydraulic oil, under
transmission oil SUPPLY hose fitting onto the pressure, can penetrate the skin or
FILTER head OUTLET fitting and tighten damage eyes. Oil leaks, under
securely. pressure, may NOT be visible.
Use a piece of cardboard or wood to
4. CHECK the hydraulic oil level shown in the find leaks. Wear safety goggles for
hydraulic oil reservoir sight gauge. Add oil if eye protection. If oil enters the skin,
needed, as described in step “h” above. or eyes, get IMMEDIATE medical
attention.

07/01 4-25
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
4-15]. 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.

4-26 07/01
 Section 4
MAINTENANCE
g. Start the engine using the CORRECT
procedures given in Section 3 - OPERATION - of
THIS manual. CHECK the hydraulic system for ANY
oil leaks.

WARNING: Do NOT use the hands on ANY

hydraulic hose, fitting or system
component to check the system for
possible leaks. Serious injury can
occur from a leak under high 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 4-15. HYDRAULIC SUCTION OIL
Do NOT start the engine UNTIL any FILTER ELEMENT LOCATION.
problem noted has been corrected.

07/01 4-27
Section 4
MAINTENANCE
ALTERNATOR AND FAN DRIVE BELT -
INSPECTION AND REPLACEMENT
PROCEDURES [See Figure 4-17].

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

The belt is kept under constant tension by an

automatic tension mechanism and “adjustment” is
NOT required as part of the maintenance
procedures.

Use the following procedures to inspect and/or

inspect and replace the drive belt:

a. STOP the engine.

WARNING: Do NOT inspect the engine drive

belt when the engine is running. The
engine MUST be STOPPED BEFORE FIGURE 4-16. 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 4-17].
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 - B 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.

4-28 07/01
07/01
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Section 4
MAINTENANCE

4-29
Section 4
MAINTENANCE

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FIGURE 4-18. ELECTRICAL SYSTEM SCHEMATIC.

4-30 07/01
 Section 4
MAINTENANCE
REAR WHEEL BEARINGS [See Figures 4-19 c. Remove the grease cap from the one [1] of the
and 4-20]. 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 4-19. 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.

07/01 4-31
Section 4
MAINTENANCE
j. Fill each grease cap one half [1/2] full of wheel
bearing grease. Install the grease cap on the outer
side of each hub and bearings assembly.

k. Install the inner most wheel and tire assembly

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

WARNING: A mounting nut torque of 95 - 100

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

l. Tighten the tire assembly to hub mounting

nuts, across corners, to a torque of 50% of the
above torque. Tighten the tire assembly to hub FIGURE 4-20. 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 4-21].
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 4-22].

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.
4-32 07/01
 Section 4
MAINTENANCE
BAIL

THROTTLE

WATER TANK

STRAINER

FIGURE 4-21. THROTTLE AND TRANSMISSION

LINKAGE LUBRICATION POINTS. FIGURE 4-23. IN LINE WATER SPRAY STRAINER
- INSTALLATION.

WATER SPRAY NOZZLES.

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 4-22. 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 4-23]. the locked position.

As required, remove the in line mesh water spray

strainer assembly, from the inside the water tank by
reaching through the fill port and unthreading in
assembly from the tank mounting fitting . Use water
flow, directed into the center of the strainer from the
inside toward the outside, to remove trapped
material and install the assembly back into the tank.
07/01 4-33
Section 4
MAINTENANCE
MISCELLANEOUS MAINTENANCE 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.

4-34 07/01
 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.

07/01 4-35
Section 4
MAINTENANCE
NOTES

4-36 07/01
 Section 5
FRAME, HITCH AND FOPS/ROPS

TABLE OF CONTENTS

PAGE

GENERAL INFORMATION ...................................................................................................................... 5-2

DESCRIPTION OF THE FRAMES ........................................................................................................... 5-2

CENTER POINT HITCH ............................................................................................................................ 5-2

GENERAL .............................................................................................................................................. 5-2

HITCH REMOVAL ................................................................................................................................. 5-4

HITCH INSTALLATION ......................................................................................................................... 5-4

FALLING OBJECT/ROLL OVER PROTECTION STRUCTURE (FOPS/ROPS) ..................................... 5-6

SEAT BELTS ............................................................................................................................................ 5-6

CHECKS AND SERVICE PROCEDURES ............................................................................................... 5-6

TROUBLESHOOTING .............................................................................................................................. 5-8

2/98 5-1
Section 5
FRAME, HITCH AND FOPS/ROPS
GENERAL INFORMATION [See Figure 5-1]. CENTER POINT HITCH [See Figure 5-2].

This section describes the frames, hitch and falling GENERAL.

object/roll over protective structure used of the
Model BW11RH Roller. The centerpoint hitch between the front and rear
frames consists of a vertical coupling to provide 35
Hitch removal and disassembly, inspection of degrees of centerpoint steering and a horizontal
components, assembly, installation and shimming coupling for 20 degrees of oscillation between the
information are given in this section. frames.

Information about inspection and maintenance of the The horizontal coupling consists of one large pivot
falling object/roll over protection structure is, also, which turns in a self-lubricating bearing with a thrust
found in this section. washer on each side.

The vertical coupling consists of two [2] pins and two

[2] spherical bearings, but only one thrust washer is
DESCRIPTION OF THE FRAMES [See Figure used with each pin. The washers are located on the
5-1]. top side of the upper bushing and on the bottom side
of the lower bushing to carry thrust loads.
The machine uses a front frame and a rear frame
weldment. The front and rear frame weldments are
connected by the hitch assembly. The hitch assem-
bly permits movement of the two [2] frames. The
hitch includes two [2] vertical pins, which give a total
of 70 degrees of machine steering (35 degrees each
side of center), full left to full right. Oscillation is 10
degrees each side of center.

FRONT REAR
FRAME FRAME

HITCH

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

5-2 2/98
 Section 5
FRAME, HITCH AND FOPS/ROPS

FLANGE
SCREW

COVER

FRONT GASKET
FRAME
CAPSCREW

WASHER
SNAP RING
PIN
BEARING

FLANGE HITCH
SCREWS

PIN SHIM
BEARING THRUST
HOUSING WASHER
FLANGE
SCREWS REAR
FRAME
BEARING

WASHER

CAPSCREW

BEARING

FLANGE
THRUST SCREWS
WASHER

SHIM

HITCH
PLATE

FIGURE 5-2. HITCH.

2/98 5-3
Section 5
FRAME, HITCH AND FOPS/ROPS
HITCH REMOVAL [See Figure 5-2]. m. Support the bearing housing and remove the
capscrew and washer securing the bearing housing
a. Loosen and remove the negative [-] battery cable to the lower vertical pin. Remove the bearing hous-
from the negative [-] post of the battery FIRST, and ing.
then loosen and remove the positive [+] battery cable
from the positive [+] post of the battery. n. Inspect the upper and lower vertical pins. If
necessary, remove the screws securing the upper
and lower vertical pins to the front frame. Remove
WARNING: Battery explosion can occur if the the pins with a drift and hammer or a hydraulic jack.
battery terminals are shorted. AL-
WAYS disconnect the NEGATIVE o. Inspect the upper vertical bearing in the hitch. If
battery cable from the battery FIRST. necessary, remove the snap ring. Using a tube with
Do NOT smoke or cause a spark the same outer diameter as the vertical bearing and
while removing the battery cables a hydraulic jack, drive the vertical bearings from the
from the battery. hitch.

b. Block both ends of the front and rear frames. WARNING: Eye protection MUST be worn during
the snap ring removal.

WARNING: Blocking of both ends of each half is

necessary because varying ballast
distribution may cause the ends to tip p. Inspect the lower vertical bearing in the bearing
either direction. housing. Using a tube with the same outer diameter
as the vertical bearing and a hydraulic jack, drive the
c. Remove the driver compartment floor plate. vertical bearings from the bearing housing.

d. Remove the steering cylinder mounting pin and q. Inspect the horizontal bearing in the rear frame. If
free the cylinder from the hitch. necessary, drive the horizontal bearing from the rear
frame.
e. Remove the ten [10] screws securing the hitch
plate and remove the hitch plate, shims and thrust
washer. HITCH INSTALLATION [See Figure 5-2].

f. Using an overhead crane or a PortaPower, a. If removed, press upper vertical bearing into hitch
separate the two halves far enough so that the hitch until it bottoms. Insert snap ring with smooth surface
can be removed. facing out.

g. Remove the remaining thrust washer and shims

from the hitch. WARNING: Eye protection MUST be worn during
the snap ring installation.
h. Support the hitch with blocks.

i. Remove the four [4] screws securing the cover to b. If removed, press lower vertical bearing into
the top of the hitch. Remove the cover and gasket. bearing housing until centered.

j. Remove the capscrew securing the washer to the c. If removed, apply adhesive, pn 340419, to the
top vertical pin. vertical pins. Align mounting holes, press the pins
into the front frame. Apply adhesive, pn 340419, to
k. Remove the eight [8] screws securing the hitch to the mounting screws. Install and tighten the mount-
the bearing housing. ing screws to a torque of 105 ft. lbs. [143 N.m].

l. Remove the hitch from the upper vertical pin. d. Lubricate the upper and lower vertical pins.

5-4 2/98
 Section 5
FRAME, HITCH AND FOPS/ROPS
e. Position the hitch on the rear of the front frame k. Load one shim, thrust washer and second shim,
and over the top vertical pin. if required, onto hitch.

f. Position bearing housing over the bottom vertical l. Lubricate the ID of the horizontal bearing.
pin and secure to the hitch with the eight [8] screws
and thread lock, pn 318702. Tighten the screws to a m. Using an overhead crane or a PortaPower, move
torque of 105 ft. lbs. [143 N.m]. the two halves of the machine together so the hitch
passes through the horizontal bearing.
g. Secure washers to the upper and lower vertical
pins with the capscrews. Tighten the capscrews to a n. Load third shim, if required, thrust washer, and
torque of 280 ft. lbs. [382 N.m]. fourth shim, if required, onto the hitch on the rear
side of the rear frame.
CAUTION: Allow the adhesive on the vertical
pins to set up for 4 hours before o. Install the hitch plate and secure with the ten [10]
applying torque to the capscrews. screws and thread lock, pn 318702. Tighten the
screws to a torque of 105 ft. lbs. [143 N.m].
h. Drive horizontal bearing into rear frame until
flush. p. Reconnect the steering cylinder to the hitch.

i. Determine the number of shims required for the q. Install the driver compartment floor plate.
horizontal pivot as follows:
r. Remove the blocking from the front and rear
1. Observe the number stamped on the rear frames.
frame near the hitch bore. Subtract this
number from the number stamped on the s. CAREFULLY connect the POSITIVE [+] battery
hitch. cable to the POSITIVE [+] terminal of the battery and
tighten FIRST. Then CAREFULLY connect the
2. Measure the thickness of both thrust washers NEGATIVE [-] battery cable to the NEGATIVE [-]
and subtract the measurement. terminal of the battery and tighten.

3. Divide by 0.020 and round your answer off to

nearest whole number. Example: 2.351 is 2, WARNING: Do NOT connect the NEGATIVE [-]
2.734 is 3. Use this number of shims. battery cable to the NEGATIVE [-]
terminal of the battery BEFORE
j. Determine shim location as follows: connecting the POSITIVE [+] battery
cable to the POSITIVE [+] terminal of
1. 2 SHIMS REQ'D: Locate one shim on each the battery.
side of rear frame member. Do NOT smoke or cause a spark
while connecting the battery cable
2. 3 SHIMS REQ'D: Locate one shim on front terminal to the battery.
side of rear frame member and two shims BATTERY MAY CONTAIN EXPLOSIVE
rear side of rear frame member. GAS.

3. 4 SHIMS REQ'D: Locate two shims on each

side of rear frame member.

2/98 5-5
Section 5
FRAME, HITCH AND FOPS/ROPS
FALLING OBJECT/ROLL OVER CHECKS AND SERVICE PROCEDURES [See
PROTECTION STRUCTURE (FOPS/ROPS) Figure 5-3].
[See Figure 5-3].
Use the following information to check the falling
Machines include the structure as a standard item for object/roll over protection structure components for
the machine. breakage, or other damage, at least one time each
eight [8] hours of machine operation or daily, and to
The steel components of the falling object/roll over do minor surface rust removal and painting on the
protection structure are welded together, using structure.
materials and practices that produce a strong
integrated structure. a. Inspect the six [6] grade 8 flange screws and nuts
that fasten the falling object/roll over protection
The falling object/roll over protection structure is structure to the machine. They must remain tight-
fastened to the machine on the top of the front frame ened to the correct torque of 400 ft. lbs. [546 N.m].
by six [6] grade 8 flange screws and six [6] grade 8 Check each flange screw torque and tighten as
flange nuts. needed using a large capacity torque wrench and
torque multiplier assembly.

WARNING: An improperly mounted, or damaged,

protection structure may NOT provide WARNING: If the falling object/roll over protec-
operator protection in the event of a tion structure has been removed from
machine tip over. Follow the checks the machine and is being installed
and service information which fol- again, inspect each flange screw for
lows. wear or damage. Replace ALL worn,
or damaged, flange screws with NEW.
Put thread lock, pn 318702, on the
SEAT BELTS [See Figure 5-3]. threaded area of each flange screw.
Install and then tighten each flange
Machines include a seat belt as a standard item for screw to the above amount of torque.
the machine to help restrain the operator, in the NEVER replace the flange screws
event of a machine roll over. with flange screws that carry a “grade
rating” less than GRADE 8.

WARNING: IMMEDIATELY after becoming seated,

FASTEN and TIGHTEN the seat belt,
BEFORE starting the engine. During
machine operation, if the machine
tips, do NOT jump.

5-6 2/98
 Section 5
FRAME, HITCH AND FOPS/ROPS

FOPS/ROPS

SEAT BELT
DECAL

FLANGE
BOLT

SEAT BELT

FLANGE
NUT

TORQUE INFO
PLATE

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

2/98 5-7
Section 5
FRAME, HITCH AND FOPS/ROPS
b. CAREFULLY inspect ALL welds which fasten the c. If rust on components is found, remove rust from
structure components together for cracks, breakage ALL welds and structure components. Apply paint
in the weld and/or where the weld joins the metal of primer and top coat paint to the complete falling
the steel component, severe rust or other weld object/roll over protection structure as directed by the
related problems. paint manufacturer.

d. One [1] time for EACH eight [8] hours of machine

DANGER: Do NOT operate a machine AFTER a operation, or daily, CAREFULLY inspect the restraint
roll over situation has occurred. If a system [two [2] seat belt sets] used with the falling
roll over situation has occurred, object/roll over protection system. The belt latches
REPLACE the falling object/roll over MUST catch and release correctly. The belt material
protection structure only AFTER MUST be clean and NOT torn, rotted or damaged.
contact has been made with your The belt anchors MUST remain tightened securely to
nearest Distributor and/or Compac- the machine at a CORRECT torque of 40 ft. lbs. [55
tion America, Inc. Assistance in the N.m]. REPLACE the complete belts SETS, with new,
repair, or replacement, of the system if ANY damage is found [see MACHINE parts
will be offered. manual, which is supplied with the machine].
NEVER weld on, or replace, a CRITI-
CAL structural component BEFORE
obtaining additional instructions, per DANGER: NEVER operate a machine having a
the ABOVE information. worn, damaged or malfunctioning
operator restraint system. Replace
the system, with new, IMMEDIATELY.
WARNING: One [1] time for each eight [8] hours
of machine operation, or daily,
carefully inspect ALL welds which TROUBLESHOOTING.
fasten the critical structure compo-
nents together for cracks, breakage in Table 5-1 is a trouble analysis check for the hitch
the weld and where the weld joins the and frame assemblies.
metal of the steel components.
Carefully inspect the welds and This table list the most common troubles that may be
adjoining critical structure metal encountered, the probable causes of the trouble, and
areas for rust or other related prob- the corrective action that should be taken to restore
lems. the unit to normal operating condition.
If ANY damage is found during the
above described inspections, contact
the Compaction America, Inc. or your
nearest Distributor IMMEDIATELY. Do
NOT use the machine until contact
and the directed repairs or structure
replacement have been done.
NEVER “heat” or weld any “add on”
item onto ANY structure area. This
practice can weaken the structural
integrity of the complete structure.
Do NOT add ANYTHING to the struc-
ture.

5-8 2/98
 Section 5
FRAME, HITCH AND FOPS/ROPS
Table 5-1. TROUBLE ANALYSIS FOR THE FRAME AND HITCH
[See Figures 5-1 and 5-2]

TROUBLE CAUSE CORRECTIVE ACTION

NOISE IN MACHINE Worn, or damaged, parts in the Remove, inspect, replace worn,
HITCH AREA DURING hitch assembly. or damaged, parts as needed
OSCILLATION AND/OR and assemble.
TURN

STEERING ACTION NOT Binding of the vertical hitch Remove, inspect, replace worn,
SMOOTH shafts in the spherical bearings. or damaged, parts as needed
and assemble.

Worn, or damaged, spherical Remove, inspect, replace worn,

bearings in hitch. or damaged, parts as needed
and assemble.

2/98 5-9
Section 5
FRAME, HITCH AND FOPS/ROPS

NOTES

5-10 2/98
 Section 6
ENGINE

TABLE OF CONTENTS

PAGE

GENERAL INFORMATION ...................................................................................................................... 6-2

DESCRIPTION ......................................................................................................................................... 6-2

REMOVAL OF THE ENGINE ASSEMBLY.............................................................................................. 6-2

INSTALLATION OF THE ENGINE ASSEMBLY ..................................................................................... 6-6

2/98 6-1
Section 6
ENGINE
GENERAL INFORMATION. REMOVAL OF THE ENGINE ASSEMBLY.

This section contains information about the To remove the engine, do the following:
Cummins diesel engine used in the Model BW11RH
Roller.
CAUTION: Put caps or plugs in all removed
This section also contains REMOVAL and INSTAL- hoses and on all fittings immediately
LATION information about the engine. after the hoses are disconnected to
help keep the system free of dirt.

DESCRIPTION. a. Loosen and remove the negative [-] battery cable

from the negative [-] post of the battery FIRST, and
The Model BW11RH Roller is powered by the then loosen and remove the positive [+] battery
Cummins Model 4B3.9 liter, water cooled diesel cable from the positive [+] post of the battery.
engine [see figures 6-1].

For engine OPERATION and general manufacturer WARNING: Battery explosion can occur if the
MAINTENANCE procedures, see the Cummins battery terminals are shorted. AL-
“Operation and Maintenance Manual - B Series WAYS disconnect the NEGATIVE
Diesel Engines”, which is supplied with each ma- battery cable from the battery FIRST.
chine. Do NOT smoke or cause a spark
while removing the battery cables
For major engine repair requirements contact the from the battery.
nearest Cummins, Engine Dealer for assistance
about major repair procedures, in-shop dealer
repairs and/or engine parts. b. Open the L.H. and R.H. hood doors.

c. Remove the hardware securing the shock

absorbers to the doors and remove the shock
absorbers.

d. Remove the hardware securing the L.H. and

R.H. hood doors to the center hood and remove the
doors.

e. Disconnect exhaust clamp connecting the

muffler to the engine. Lift muffler and attached
exhaust tube (stack) out the top of the center hood.

f. Disconnect the air cleaner elbow clamp connect-

ing the air cleaner elbow to the engine.

g. Remove screws securing the air cleaner to the

center hood and remove the air cleaner with piping.

h. Remove screws securing center hood and lift

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

6-2 2/98
 Section 6
ENGINE
i. If so equipped, disconnect wiring for head lights o. Trace upper oil cooler hose back to the steering
and remove wiring that passes through the support. control and disconnect the hose from the control.
Put a cap or a plug into hose and onto steering
j. Drain the complete cooling system of coolant control fitting.
[see Section 4 - MAINTENANCE].
p. Free the oil cooler hoses from any clamps and
secure them to the radiator cowl.
WARNING: Do NOT drain the cooling system of
coolant while the system is HOT. q. Remove the screws and washers securing the
Drain when COOL ONLY. Hot coolant radiator shroud to the radiator. Free the shroud from
can cause serious injury. the radiator and rest it on the fan.

CAUTION: The blower fan is fragile. Be careful

k. Completely drain the hydraulic reservoir of oil. not to damage fan when moving
radiator and shroud.

WARNING: Do NOT drain the hydraulic oil while r. Fasten a sling and a hoist, having a capacity
the oil is HOT. Drain the hydraulic oil more than 500 lbs. [227 kg], to the radiator cowl so
when it is warm or cool ONLY. Hot oil that it will be balanced when lifted.
can cause serious injury.
s. Loosen, but DO NOT REMOVE, nuts securing
radiator cowl to frame. Gently lift radiator cowl up
l. Put an oil drain pan under the engine lubrication and away from the front frame and remove the
oil drain plug. Wipe the area around the drain plug, shims. Remove the radiator shroud from the fan.
using a clean cloth. Loosen and remove the drain
plug and drain the engine of lubrication oil. Replace t. Loosen the clamps and disconnect the fuel
and tighten the drain plug after the engine is com- supply line from the fuel filter located on the rear of
pletely drained of oil. Remove the oil drain hose from the engine and the return line from the left side of
its connection onto the frame mounted fitting. Put a the engine. Put a cap or a plug into each line and
plug in the engine lubrication oil drain hose. [See onto each engine fitting. Free the lines from any
Figure 6-2] clamps on the engine.

u. Disconnect the transmission direction control

WARNING: Do NOT drain the engine lubrication cable from the transmission pump control lever and
oil while the oil is HOT. Drain the oil free the cable from the bracket [See Figure 6-3].
ONLY when WARM or COOL. Hot oil
can cause serious injury. v. Disconnect the governor [throttle] control cable
from the engine governor control lever [See Figure
m. Loosen the radiator hose clamps at the engine 6-3].
connection and disconnect the upper and lower
radiator hoses from the engine.

n. Trace lower oil cooler hose back to the hydraulic

tank and disconnect the hose from the tank. Put a
cap or a plug into hose and onto the hydraulic tank
fitting.

2/98 6-3
Section 6
ENGINE

FRAME
MOUNTED
FITTING

ADAPTER FITTING
HOSE ASSEMBLY DRAIN PLUG
FRONT REAR
MOUNT MOUNT

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

6-4 2/98
 Section 6
ENGINE
GOVERNOR
y. SECURELY fasten a chain and a lifting device,
CONTROL CABLE having a capacity larger than 1,500 lbs. [685kg], to
the engine lifting eyes.

TO THROTTLE
WARNING: Use a lifting device and chain ca-
pable of lifting at LEAST a weight of
1,500 lbs. [681kg]. Fasten SE-
CURELY.

z. Loosen and remove the four [4] retaining nuts,

screws and large washers from the front and rear
isolators, two [2] on each side [See Figure 6-2].

aa. Check, AGAIN, to be sure that ALL the hoses,

lines and electrical wire and cable connections have
been disconnected and removed from the engine.
Also check for removal of these items from other
components being removed with the engine, as an
assembly.
CABLE
BRACKET
CAUTION: Do NOT remove the engine assembly
before disconnecting ALL items
TRANSMISSION connected to the engine, or any
PUMP component, being removed with the
CONTROL CABLE
engine.

ab. CAREFULLY and SLOWLY lift the engine

assembly “UP” and “OUT” of the frame, until the
engine assembly is away from the frame.

WARNING: KEEP CLEAR of the engine assembly

while it is being lifted and removed
from the frame.

FIGURE 6-3. GOVERNOR AND TRANSMISSION. CAUTION: Use CARE to NOT damage the
transmission pump which is
w. Put an identification tag on each electrical wire mounted to the engine as the engine
and each electrical wire connection terminal on the is removed from the frame.
engine or items mounted on the engine. Remove all
electrical wires or wire harnesses which are con- ac. CAREFULLY lower the engine onto an engine
nected to the engine or items mounted on the stand or other engine support device.
engine.

x. Put an identification tag on each hose and each WARNING: KEEP CLEAR of the engine assembly
fitting of the transmission pump and the steering while being lowered after removal
pump. Disconnect all hoses from both the transmis- from the frame.
sion pump and the steering pump. Put caps, or Do NOT allow anyone under the
plugs, in ALL hoses and on ALL fittings IMMEDI- engine while it is being lowered.
ATELY after the hoses are disconnected. Make sure the engine and support
will NOT tip.

2/98 6-5
Section 6
ENGINE
INSTALLATION OF THE ENGINE g. Fill the engine with NEW engine lubrication oil at
ASSEMBLY. this time [see the Cummins "Operation and Mainte-
nance Manual - B Series Diesel Engines", which is
a. If necessary, install the front and rear engine supplied with each machine, for the CORRECT
mounts to the engine. Tighten the front screws to a amount and type].
torque of 78 ft. lbs. [107 N.m]. Tighten the rear
screws to a torque of 59 ft. lbs. [81 N.m] h. Remove ALL caps and plugs from ALL the hoses
and fittings which fasten to, or are on, the transmis-
b. SECURELY fasten a chain and a lifting device, sion pump and the steering pump. Install EACH
having a capacity larger than 1,500 lbs. [681 kg], to hose onto the CORRECT fitting of the transmission
the engine lifting eyes. pump and the steering pump as indicated by the
identification tags installed before removal. Securely
tighten each hose onto each fitting.
WARNING: Use a chain and lifting device ca-
pable of lifting at LEAST a weight of i. CAREFULLY connect ALL electrical wires,
1,500 lbs. [681 kg]. Fasten SE- EXCEPT the positive [+] and negative [-] battery
CURELY. cables, to the correct engine wire connection
terminal and items mounted onto the engine, as
indicated by the identification tags installed before
c. CAREFULLY and SLOWLY lift the engine removal, and tighten securely.
assembly and move into position ABOVE the frame.

d. SLOWLY begin to lower the engine assembly WARNING: Do NOT connect EITHER battery
DOWN and toward the frame. Align ALL capscrew cable to the battery, at THIS time.
holes in both the front and rear engine mount
isolators and frame as the engine assembly reaches
the frame. j. Remove the caps, or plugs, from each fuel
supply line and return line and from each engine
WARNING: KEEP CLEAR of the engine assembly fitting. Connect the fuel supply hose to the fuel filter
while it is being installed. Lower the located on the rear of the engine and the return line
engine assembly SLOWLY into the to the left side of the engine and tighten securely.
frame. Check for ANY interference
between components at ALL times k. Connect the governor [throttle] control cable to
during engine installation. the engine governor [See Figure 6-3]. Check and
adjust the governor [throttle] control cable, if needed
[see TRANSMISSION Section for the CORRECT
CAUTION: Do NOT permit the transmission procedure].
pump assembly to contact the
hydraulic oil filter as the engine and l. Connect the transmission direction control cable
transmission pump assembly is to the transmission pump control lever [See Figure
installed. 6-3]. Adjust the direction control cable linkage, if
needed [see TRANSMISSION Section for the
e. Position the rubber mounts on the front and rear CORRECT procedure].
engine mounts and install the four [4] screws, large
washers and retaining nuts [See Figure 6-2]. Tighten m. Put the fan shroud in position around the fan.
the screws to a torque of 120 ft. lbs. [164 N.m].

f. Route and connect the engine oil drain hose to CAUTION: The blower fan is fragile. Be careful
its connection of the frame. Check that the oil drain not to damage fan when mounting
plug is properly installed. radiator and shroud.

6-6 2/98
 Section 6
ENGINE
n. Fasten a sling and a hoist, having a capacity t. Add NEW, CLEAN and FILTERED hydraulic oil
more than 500 lbs. [227 kg], to the radiator cowl so to the hydraulic oil reservoir until the oil is in the
that it will be balanced when lifting. CAREFULLY center of the sight gauge [see Section 4 - MAINTE-
and SLOWLY lift the assembly and move into NANCE- for the CORRECT amount and type of
position above the frame. hydraulic oil].

o. Position the radiator cowl, on frame and over CAUTION: Do NOT start the engine UNTIL ALL
retaining studs. After cowl is properly positioned, of the transmission system start up
install shims that were originally removed. Tighten procedures have been completed
nuts on retaining studs. Remove the sling and hoist. [See the TRANSMISSION section for
the CORRECT procedures].
p. Position the fan shroud against the radiator.
Install the retaining capscrews. Adjust the fan
shroud for the correct EQUAL fan blade to fan u. Connect BOTH the upper and lower radiator
shroud clearance. Tighten the capscrews, which hoses to their engine connection points. Tighten the
hold the fan shroud onto the radiator assembly, retaining clamps securely. Tighten ALL engine block
securely. coolant drain plugs securely. Fill the cooling system
with coolant [see Section 4 - MAINTENANCE].

CAUTION: The blower fan is fragile. Be careful CAUTION: Fill the cooling system with the
not to damage blower fan when CORRECT antifreeze/water mixture to
moving radiator and shroud. Keep protect the system from freezing [see
the fan shroud in the correct position Section 4 - MAINTENANCE].
while tightening the retaining
capscrews. Clearance must be kept
between the blades of the fan and v. Replace center hood and secure with retaining
the fan shroud at all points around capscrews.
the shroud.
w. Position air cleaner under center hood and
secure with retaining screws.
q. If so equipped, install wiring that passes through
the support. Connect wiring for the lights. x. Connect the engine air inlet hose onto the engine
air intake assembly. Install and tighten the hose
r. Route the upper oil cooler hose back to the retaining band clamps to a torque of 50 in. lbs.
steering control. Remove all caps and plugs from [5.7 N.m].
the hose and the steering control fitting. Install the
hose onto the correct fitting of the steering control. CAUTION: Tighten the retaining band clamp to
the CORRECT torque. Loose clamps
s. Route the lower oil cooler hose back to the can permit contaminated air to enter,
hydraulic tank. Remove all caps and plugs from the and damage, the engine.
hose and the hydraulic tank fitting. Install the hose
onto the correct fitting of the hydraulic tank. y. Install the exhaust pipe to the engine exhaust
manifold. Install and tighten the retaining clamp
securely to the exhaust pipe and the exhaust
manifold.

z. Install the L.H. and R.H. hood doors the center

hood.

2/98 6-7
Section 6
ENGINE
aa. Position the shock absorbers between the center ac. Inspect all hose, lines wire and cable and
hood and hood doors. Secure with mounting hard- linkages for correct connection. Check for any leak
ware. of fuel, oils or coolant at this time.

ab. CAREFULLY connect the POSITIVE [+] battery ad. Prime the hydraulic system with oil, using the
cable to the POSITIVE [+] terminal of the battery pre-start procedures given in Section 8 - TRANS-
and tighten FIRST. Then CAREFULLY connect the MISSION Section, at THIS time.
NEGATIVE [-] battery cable to the NEGATIVE [-]
terminal of the battery and tighten.
CAUTION: Do NOT start the engine UNTIL the
pre-start procedures have been
WARNING: Do NOT connect the NEGATIVE [-] completed. Hydraulic system compo-
battery cable to the NEGATIVE [-] nent damage can occur.
terminal of the battery BEFORE
connecting the POSITIVE [+] battery
cable to the POSITIVE [+] terminal of ae. Start the engine, using the CORRECT engine
the battery. starting procedures given in Section 3 - OPERA-
Do NOT smoke or cause a spark TION. Check ALL machine systems for correct
while connecting the battery cable operation and function.
terminal to the battery.
BATTERY MAY CONTAIN EXPLO-
SIVE GAS. CAUTION: STOP the engine IMMEDIATELY if
ANY system of the machine does
NOT have CORRECT operation.
CAUTION: Tighten the retaining band clamps to Do NOT start the engine again UNTIL
the CORRECT torque. Loose clamps the system problem has been cor-
can permit contaminated air to enter, rected.
and damage, the engine.

6-8 2/98
 Section 7
ELECTRICAL

TABLE OF CONTENTS

PAGE

GENERAL INFORMATION ...................................................................................................................... 7-2

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

2/98 7-1
Section 7
ELECTRICAL
GENERAL INFORMATION. STARTER MOTOR.

This section describes the OPERATION of the The starter motor is used to convert electrical
electrical system and contains DESCRIPTIONS of energy into mechanical energy to crank and start the
the items included in the system used on the Model engine. One [1] 12 volt, negative ground starter
BW11RH Roller. motor is used in the start circuit.

“TROUBLE ANALYSIS” for the electrical system is

found at the rear of this section.
ALTERNATOR.

The 62 amp alternator is used to convert mechanical

SYSTEM DESCRIPTION [See Figures 7-1, energy into electrical energy. It supplies electrical
7-2 and 7-3]. current to the electrical circuits and keeps the
battery “charged” when the engine is “running”.
The electrical system contains the following major
components:
WARNING: NEVER smoke, or cause a spark,
BATTERY. near ANY battery.
STARTER MOTOR. ALWAYS loosen and remove the
ALTERNATOR. NEGATIVE [-] battery cable from the
SWITCHES. NEGATIVE [-] battery terminal BE-
SENDING UNITS. FORE loosening and removing the
SOLENOID CONTROLS [of fuel system and POSITIVE [+] battery cable from the
hydraulic valves]. POSITIVE [+] battery terminal.
RELAYS and CIRCUIT BREAKERS NEVER cause a shorted circuit
INSTRUMENTS, GAUGES and INDICATOR condition in ANY CIRCUIT.
LIGHTS. USE EXTRA CAUTION when check-
CABLES and WIRES. ing ANY circuit using ANY electrical
testing instrument.
BATTERY MAY CONTAIN EXPLO-
SIVE GAS.
DESCRIPTION - ELECTRICAL SYSTEM
MAJOR COMPONENTS [See Figures 7-1,
7-2, and 7-3].
SWITCHES.
The following information describes the MAJOR
a. Ignition Key Switch.
electrical components used in the electrical system
of the Model BW11RH Roller.
The ignition key switch is the main control switch for
ALL electrical circuits [except the horn and lighting
circuits]. The switch is a three [3] position switch
which permits the engine to be started, put in a
BATTERY. “running” condition and stopped. One [1] ignition key
switch is used in the electrical system.
The battery supplies direct current to crank the
engine and operate electrical circuits until the b. Neutral Start Switch.
alternator is able to supply current. One [1] 12 volt,
900 CCA hour battery, is used in the electrical The neutral start switch is used to stop the engine
system for this purpose. from being started when the travel control [F-N-R]
bar lever and the transmission system is NOT in
“NEUTRAL”. One [1] neutral start switch is used in
the engine start circuit.

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 Section 7
ELECTRICAL

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ELECTRICAL

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7-4 2/98
 Section 7
ELECTRICAL

BBB R-1 R-1

YYY G N E P L

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

AUX BAT AUX BAT AUX BAT FF

WIRE COLOR GAGE
XXX
P B BLACK 10
CC E BROWN 14
G BLACK 16
L ORANGE 14
PP N BLUE 16
R P YELLOW 12
1 4

U Q YELLOW 10
2 5
R RED 14
3 6 U WHITE 12
B LLL Z GREEN 10
CC BLUE 14
DD RED 14
L G EE RED 14
P FF BROWN 14
EE Z BATT
JJ YELLOW 14
ACC E PP ORANGE 14
N R 1 4
XX YELLOW 14
ST
B JJ ZZ BROWN 14
G 2 5
BBB LT GREEN 14
R
D RRR LLL PURPLE 14
XXX
IGN 3 6
RRR ORANGE 14
XXX YELLOW 12
LLL YYY ORANGE 16
Q
PP U CC

L YYY ZZ FF XX EE Q Z BBB DD RRR ZZ XX

10 AMP 10 AMP AIR OIL 30 AMP

CIRCUIT CIRCUIT FILTER FILTER CIRCUIT 3 SPEED LIGHT WATERSPRAY
GROUND BREAKER BREAKER INDICATOR INDICATOR BREAKER GROUND SWITCH SWITCH SWITCH

BATT AUX BATT AUX BATT AUX

G YYY N P L BBB E ZZ XX XXX FF RRR R P P PP CC JJ U E
TO 10 AMP
CIRCUIT BREAKER
USED FOR TURN DD
SIGNAL OPT.

B U
L CC
EE PP
TO MAIN
TO MAIN N RRR UNIT WIRING
UNIT WIRING HARNESS
HARNESS LLL DD
G XX
Z ZZ
R

Q XXX B L YYY FF EE BBB LLL Q Z

GRD ST BATT IGN ACC 6 5 4 2 3 1

IGNITION SWITCH HORN BRAKE SWITCH BRAKE

INDICATOR

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

2/98 7-5
Section 7
ELECTRICAL

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

7-6 2/98
 Section 7
ELECTRICAL
SENDING UNITS. b. Secondary/Parking Brake System Release
Solenoid.
a. Engine Lubrication Oil Pressure Sending
Unit. The secondary/parking brake system release [brake]
solenoid is electrically energized when the ignition
The engine lubrication oil pressure sending unit is key switch is “on” and the secondary/parking brake
used to electrically indicate the pressure of the oil system switch is “OFF” [BRAKES RELEASED]. The
flowing within the engine lubrication oil system. One solenoid is used to move the secondary/parking
[1] sending unit, with a flexible internal diaphragm, brake system release spool from the brakes “ap-
sends a varied amount of electrical current to the plied” position to the brakes “released” position. This
engine lubrication oil pressure gauge. The gauge action permits the brakes, found in each of the drive
indicates the pressure of the engine lubrication oil motors, to be released by hydraulic pressure.
flowing through the engine.
c. Transmission System Speed Range Sole-
b. Engine Coolant Temperature Sending Unit. noids.

The engine coolant temperature sending unit is used The transmission system speed range solenoids are
to electrically indicate the temperature of the coolant electrically energized by the transmission system
flowing within the engine cooling system. One [1] range switch. When the transmission system range
sending unit, having a “bimetal” temperature sensor, switch is in the "MEDIUM" position with the engine
sends a varied amount of electrical current to the "running", the LH transmission speed range solenoid
engine coolant temperature gauge. The gauge is energized, moving the flow control spool to direct
indicates the engine coolant temperature. hydraulic oil to the LH drive motor, where the
displacement is changed, causing "medium" speed
c. Fuel Level Sending Unit. range. When the transmission system range switch
is in the "HIGH" position with the engine "running",
The fuel level sending unit is used to electrically both the LH and RH transmission speed range
indicate the level of fuel contained within the fuel solenoids are energized, moving both flow control
tank. One [1] sending unit, having a float assembly, spools to direct hydraulic oil to both drive motors,
mechanically moves a variable resistance type where the displacement is changed in both drive
sending mechanism. The sending unit supplies a motors, causing "high" speed range.
varied amount of electrical current to the fuel gauge,
which indicates the amount of fuel contained in the
tank.
CIRCUIT BREAKERS.

a. Ten [10] Amp Circuit Breakers.

SOLENOID CONTROLS.
Three [3] ten [10] amp circuit breakers are used in
a. Engine Fuel Shut-Off Solenoid. the electrical system. The first circuit breaker is used
in the circuit which supplies current to the brake
The engine fuel shut-off solenoid is used to control switch and the water spray system. The second
the flow of fuel to the engine. One [1], normally open circuit breaker supplies current to all electrical
solenoid, when electrically energized, in the “start” gauges, except the hourmeter, and to the transmis-
and “run” ignition key switch positions, will open the sion speed range control switch. The third circuit
fuel shut-off valve and permit fuel flow within the fuel breaker is used in the circuit which supplies current
system. to the optional turn signal and 4 way flasher system,
if so equipped.

2/98 7-7
Section 7
ELECTRICAL
b. Thirty [30] Amp Circuit Breaker. the engine. The gauge will operate when the ignition
key switch is “on” and the engine is “running”. The
One [1] thirty [30] amp circuit breaker is used in the gauge has a face scale ranging from a “low” to a
electrical system. The circuit breaker is used in the “high” symbol.
circuit, which supplies current to the horn button
switch, standard gauge and instrument lights [except c. Engine Coolant Temperature.
hourmeter] and optional front and rear headlights
and the third ten [10] amp circuit breaker. The 30- The engine coolant temperature gauge indicates the
amp circuit breaker is supplied by wire XXX from the temperature of the coolant circulating through the
BAT terminal on the ignition switch. engine cooling system. The gauge will operate when
the ignition key switch is “on”. The gauge has a
scale ranging from “white” [100o F - 38o C] to
“green” [140o F- 60o C] to “red” [230o F - 110o C].
INSTRUMENTS AND GAUGES.
d. Hydraulic System Oil Temperature.
INSTRUMENTS.
The hydraulic system oil temperature gauge indi-
a. Engine Hourmeter. cates the temperature of the hydraulic oil flowing in
the system. The gauge will operate when the ignition
The engine hourmeter indicates the amount of time key switch is “on”. The gauge has a colored scale
the engine has operated and is given in time divi- ranging from “green” [100o F - 38o C] to “yellow”
sions of tenths, units, tens, hundreds and thousands [180o F- 82o C] then to “red” [220o F - 104o C].
of hours. The engine hourmeter is “on” when the
engine is “running” and the engine lubrication oil
pressure closed switch has been by closed, permit-
ting electrical current to flow through the circuit. INDICATOR AND GAUGE LIGHTS.

b. Voltmeter. a. Hydraulic System Suction Oil Filter Element

Condition Indicator Light.
The voltmeter indicates the voltage in the electrical
system and will give an indication of battery or The suction oil filter element condition indicator light
alternator voltage, which ever currently is the is lighted when the oil filter element has reached the
highest. The voltmeter has a scale ranging from plus maximum holding capacity and MUST be changed.
[+] 10 volts to plus [+] 16 volts of direct current The red lens covered light will also be lighted when
[D.C.]. the ignition key switch is in the “start” position and
show that the bulb and circuit is working. The bulb
will go out when the switch returns to the “run”
position. The red lens covered light can also be
GAUGES. lighted with the hydraulic oil at a “cold” temperature
at machine “start up”.
a. Fuel Gauge.
b. Engine Inlet Air Restriction Indicator Light.
The fuel gauge indicates the level of fuel contained
in the fuel tank. The gauge will operate when the The engine inlet air restriction indicator light is
ignition key switch is "on". The gauge has a face lighted if the engine inlet air route is restricted. The
scale ranging from “empty” to “full” symbol. red lens covered light will be lighted when the
ignition key switch is in the “start” position and show
b. Engine Lubrication Oil Pressure. that the bulb and circuit is working. The bulb will go
out when the switch returns to the “run” position.
The engine lubrication oil pressure gauge indicates The red lens covered light will be lighted with the
the pressure of the lubrication oil circulating through engine "running " and the inlet air route restricted.

7-8 2/98
 Section 7
ELECTRICAL
c. Secondary/Parking Brake System Condition CIRCUITS.
Indicator Light.
The electrical system consists of the following major
With the ignition key switch “on”, the secondary/ circuits:
parking brake system condition indicator red lens
covered light is lighted when the secondary/parking START/STOP.
brake system is "on" [applied].
ON - [RUN].
d. Gauge Lights.
CHARGING.
The voltmeter, fuel gauge, engine lubrication oil
pressure gauge, engine coolant temperature and SECONDARY/PARKING BRAKE.
hydraulic system oil temperature gauge all have
individual illumination lights. The lights are lighted TRANSMISSION SPEED RANGE [High/Medium/
when the light switch is placed in the "on" position. Low].
The hourmeter is not lighted.
ACCESSORY.

CABLES AND WIRES.

START - STOP CIRCUIT [See Figures 7-1
CABLES. and 7-4].

a. Positive [+] and Negative [-] Battery Cables. The START - STOP circuit contains two [2] separate
circuits within it, the POWER circuit and the CON-
The positive [+] and negative [-] battery cables TROL circuit.
connect the positive [+] and negative [-] terminals of
the battery to the engine starter motor and the The battery, cables and engine starter motor make
system ground at the engine. The cables carry high up the POWER circuit.
amperage electrical current for the engine starter
motor and current from the alternator to the battery. The CONTROL circuit includes the ignition switch,
starter motor solenoid, fuel shut-off solenoid and the
wires which carry the electrical current in the circuit.

WIRES. The ignition key switch has three [3] positions:

a. Circuit Wires. “OFF” [STOP].

“ON” [RUN].
The wires used in the electrical system connect the “START”.
components and form the circuits which the electri-
cal current flows through. The wire assemblies
contain different size [gauge] wires and connection When the ignition switch key is turned to the
terminals. The wire assemblies are covered with a “START” position, electrical current flows from the
protective plastic tape, which is wound around the ignition switch into wire Q. Electrical current contin-
wires of the assembly, to form the wire harness. ues through wire Q to the secondary/parking brake
system control switch.

With the secondary/parking brake system control

switch "on", current flows through the switch and
into wire Z. Current in wire Z flows to the neutral
start switch, found on the displacement control of
the transmission pump assembly.

2/98 7-9
Section 7
ELECTRICAL

B.S.

NEUTRAL S
BATTERY START
SWITCH

Z
STARTER
BRAKE
SWITCH
Q

Q
B
HORN BUTTON IGNITION
HORN SWITCH
L
GAUGE LIGHTS JJ
PP FF K
LIGHT FUEL
SWITCH
FUEL VOLT ENGINE WATER XSMN XXX SHUTOFF
G
LEVEL METER OIL TEMP OIL SOLENOID
PRESSURE TEMP

30 AMP
CIRCUIT BREAKER

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

With the transmission in "neutral", current flows When the engine has been started, and the ignition
through the neutral start switch and into wire S. key is released, the ignition switch will return to the
“on” [RUN] position by spring pressure.

NOTE: The secondary/parking brake system

control switch MUST be in the "on" NOTE: If the battery is “charged”, current is
[applied] position and the directional flowing to the “battery” terminal of the
speed control hand lever MUST be in the ignition switch, through wire B, at ALL
"neutral" position for the engine to be times. The HORN and LIGHTING circuits
started. have current supplied to them at ALL
times from the “battery” terminal, of the
ignition switch, through wire XXX to the
Current in wire S flows to the S terminal of the thirty [30] amp circuit breaker and wires
starter solenoid, and energizes the starter solenoid FF and JJ.
and allows the starter to crank and start the engine.

7-10 2/98
 Section 7
ELECTRICAL
The normally open fuel shutoff valve is energized in When the engine is "running", current flows through
the "start" and "run" ignition switch positions through the engine oil pressure closed switch and into wires
wires L and K. In these positions the fuel shutoff M and H.
valve opens, allowing fuel flow within the fuel
system. When the ignition switch key is turned to Current in wire M then flows through a diode to the
“OFF”, electrical current no longer will flow from the #1 terminal of the alternator. Current in wire H flows
“ignition” switch terminal, through wires L and K, to to the “input” terminal of the hourmeter. The
the solenoid of the engine fuel shutoff valve. hourmeter operates whenever the engine is "run-
ning".
The lack of electrical current permits the fuel shutoff
valve spool to “close”, stopping the fuel flow through With the ignition switch in the “RUN” position,
the engine fuel system. current will flow through the ACCESSORY terminal
of the ignition switch, through wire YYY to the 10
ON [RUN] CIRCUIT [See Figures 7-1]. AMP circuit breaker. Current flows from the 10 amp
circuit breaker through wire N to terminal N of the
When the engine has been started and is “running”, hydraulic system oil temperature gauge, water
electrical current flows from the “IGNITION” terminal temperature gauge, engine lubrication oil pressure
on the ignition switch through wire L to the ignition gauge, voltmeter and fuel level gauge.
terminal on the engine oil pressure switch. Electrical
current is, also, supplied to wire K of fuel shutoff Current then flows from the hydraulic oil temperature
valve. gauge through wire J to the transmission tempera-
ture sending unit, which monitors the hydraulic oil in
Electrical current is, also, applied to one of the 10 the transmission and steering system. From the
AMP circuit breakers through wire L. Current is water temperature gauge, current flows through wire
applied from the circuit breaker to the air filter C to the water temperature sending unit on the
indicator light and the hydraulic oil filter indicator on engine. From the engine oil pressure gauge, current
the control panel. flows through wire D to the oil pressure switch on
the engine. From the fuel level gauge, current flows
When the Ignition switch is turned to the “START” through wire WWW to the fuel level sensing unit at
position, a ground is applied from the ignition switch the fuel tank.
ground [GRD] terminal to two diodes, then through
wire XX to the oil filter indicator light and through Current flows from the same 10 AMP circuit breaker
wire ZZ to the air filter indicator light causing the on wire P to the three speed switch [see transmis-
lights to come “ON”. When the switch is released, sion speed range circuit for description].
the lights will go out. This is an indication that the
bulbs in the lights are working. The three speed switch controls the two [2] two
position solenoids through wires R and RRR. One
If the engine inlet air route is in a restricted condi- solenoid controls the RH side two speed drive motor
tion, a ground is applied at the air restriction indica- and the second solenoid controls the LH side two
tor on the engine through wire ZZ from the engine to speed drive motor.
the air filter indicator light. The indicator light will be
lighted indicating that the engine air filter element Current flows from the second 10 AMP circuit
MUST be changed. breaker on wire E to the water spray switch, on the
control panel.
When the hydraulic suction oil filter element has
reached the maximum holding capacity, a ground is When the water spray control switch is placed in the
applied by the hydraulic oil filter indicator switch “ON” position, current will flow through wire U to the
through wire XX to the hydraulic oil filter indicator water spray pump, to pump water to the spray bars.
light. The indictor light will be lighted, indicating that
the hydraulic suction filter element MUST be Current flows from the second 10 AMP circuit
changed. breaker and into wire BBB to the secondary/parking
brake system control switch.

2/98 7-11
Section 7
ELECTRICAL
With the secondary/parking brake system control control switch in the “ON” [UP] position, NO electri-
switch in the "ON" [brakes APPLIED] position cal current is sent from the switch to the brake
current flows into the supply wire to the brake system release solenoid.
indicator light, and it is lighted. Current, also, flows
into wire Z. Current in wire Z flows to the transmis- With the secondary/parking brake system control
sion neutral start switch. switch in the "ON" [brakes APPLIED] position
current flows into the supply wire to the brake
Current will not flow from the switch, into wire LLL, indicator light, and it is lighted. Current, also, flows
UNTIL the switch is placed in the “OFF” [brakes into wire Z. Current in wire Z flows to the transmis-
RELEASED] position. Current will then flow from the sion neutral start switch.
switch through wire LLL to the brake release sole-
noid and energize the solenoid. No current is When the brake system is in the “RELEASED”
supplied to the brake indicator light, at this time. [OFF] condition, with the secondary/parking brake
system control switch in the “OFF” [DOWN] position,
Current flows from a third 10 AMP circuit breaker electrical current is sent from the switch through wire
into wire DD to the optional turn signals/warning LLL to the brake release solenoid. No current is
flashers switch [if so equipped] on the steering supplied to the brake indicator light, at this time.
column.
The electrical current energizes the solenoid, which
moves the brake release valve spool, in the solenoid
valve body to the “open” position. When the brake
CHARGING CIRCUIT [See Figures 7-1]. release valve spool is in the “open” position, hydrau-
lic oil can then flow to the spring applied disc brake
After the engine has started and is “running”, the assemblies and releases the brakes.
alternator output voltage increases ABOVE the
battery voltage.

The alternator current then flows through wire A to TRANSMISSION SPEED RANGE CIRCUIT
the large stud terminal on the starter solenoid. From [See Figures 7-1].
the large stud connection terminal, on the starter
solenoid, the alternator current flows through the The transmission three speed range electrical
POSITIVE [+] battery cable to the POSITIVE [+] system electrically controls the speed range change
terminal of the battery. from “low”, to "medium", to “high” range. Electrical
current is supplied to the speed range selection
The voltmeter, found on the gauge panel of the switch, through wire P, from a ten [10] amp circuit
machine, will indicate EITHER battery OR alternator breaker.
voltage in the charging system, which ever is the
highest at the time. When the transmission speed range selector switch
is in “LOW” position, electrical current does NOT
flow through wires R, or RRR, to the transmission
speed range selector valve solenoids and the
SECONDARY/PARKING BRAKE CIRCUIT solenoids are NOT energized.
[See Figures 7-1].
When the transmission speed range selection switch
The secondary/parking brake electrical circuit is in “MEDIUM” [CENTER] position, electrical
controls the RELEASING of the brake system. current will flow through the toggle switch, through
wire R to the outside transmission two speed range
Electrical current is supplied from the ignition key selector valve solenoid. When the solenoid is
switch, through the 10 AMP circuit breaker to the energized, the LH side two speed drive motor is
secondary/parking brake system control switch switched to high speed. With one drive motor
through wire BBB. operating in the high speed range and the other
drive motor operating in the low speed range, the
When the brake system is in the “APPLIED” [ON] vehicle operating speed is between the "high" and
condition, with the secondary/parking brake system "low" speed.

7-12 2/98
 Section 7
ELECTRICAL
When the transmission speed range selection switch e. Circuit Breakers and Miscellaneous Electrical
is in “HIGH”, electrical current will flow through the Items.
toggle switch, through wires R and RRR to both the
outside and center transmission two speed range Three [3] ten [10] amp circuit breakers, one [1] thirty
selector valve solenoids. With both solenoids [30] amp circuit breaker, one [1] electric horn,
energized, both motors operate at "high" speed. optional equipment, connecting wire assemblies,
cables, and water spray pump.

ACCESSORY CIRCUIT [See Figures 7-1].

OPTIONAL OPERATION LIGHTING SYSTEM
The accessory circuit includes the following listed [See Figures 7-1 and 7-5].
items and is “ON” when the ignition key switch is in
the “ON” [RUN] position, EXCEPT the horn button The operation lighting system is used to enable
switch and light switch which will complete the horn machine operation under dark conditions.
and light circuit at ALL times.
The lighting system is available as a factory installed
Current is supplied to the items in the circuit through option or can be added to the machine by your
the wires connected to the “IGNITION” and “AC- nearest Distributor.
CESSORY” terminals of the ignition key switch.
The system contains the standard control panel
a. Indicators and Gauges. lighting system control switch, control panel gauge
and instrument illumination light wiring harness and
Engine hourmeter, engine lubrication oil pressure bulbs, light assembly supply wiring harnesses,
gauge, engine coolant temperature gauge, fuel level circuit breaker, securing clamps and ties and four [4]
gauge, hydraulic system oil temperature gauge, and halogen seal beam light assemblies. Two [2] adjust-
voltmeter. able light assemblies are mounted one on each side,
of the front frame and two [2] light assemblies are
b. Sender Units and Switches. mounted on the rear frame.

Engine lubrication oil pressure sender, engine The light switch is a three [3] position, pull type
coolant temperature sender, fuel level sender, switch. When it is pushed “IN”, all lights are “OFF”.
hydraulic system oil temperature sender, ignition key When the switch is pulled to the first detent position,
switch, engine lubrication oil pressure closed switch, the front two [2] optional head lights and the lights in
transmission neutral start switch, transmission the hydraulic oil temperature gauge, engine coolant
system speed range control switch, secondary/ temperature gauge, fuel gauge, voltmeter and
parking brake system control switch, water spray engine lubrication oil pressure gauge are “lighted”.
system “on/off” switch, light switch, turn signal By pulling the switch to the second detent, the rear
switch [OPTIONAL system] and the horn button two [2] optional head lights are, also, “lighted” along
switch. with the previously listed lights, if so equipped.

c. Electrical Solenoids. Voltage is constantly applied to the light switch from

the battery through the BATTERY terminal on the
Secondary/parking brake system release solenoid, IGNITION switch and through wire XXX to the 30
transmission system speed range control solenoid AMP circuit breaker. [See figure 7-1]. From the
and starter solenoid [included on engine starter]. circuit breaker, voltage flows through wire FF to the
light switch.
d. Lights.
When the switch is pulled to the first detent, voltage
Instrument lights five [5], front and rear head lights flows through wire PP to the FRONT lights and the
four [4] [OPTIONAL system] and front and rear turn five [5] indicators on the dash gauge panel. When
signal lights four [4] [OPTIONAL system] with 4 way the switch is pulled to the second detent, voltage
flashers. then flows through wire CC from the switch to the
REAR lights, illuminating all of the lights.

2/98 7-13
Section 7
ELECTRICAL

FIGURE 7-5. OPTIONAL OPERATION LIGHTING SYSTEM, TURN SIGNALS, AND FOUR WAY
FLASHERS - COMPONENT DETAIL.

Four [4] turn signal lights are optional. Two [2] turn OPTIONAL TURN SIGNALS AND FOUR
signal lights are mounted one on each side, of the WAY FLASHERS [See Figures 7-1 and 7-5].
front cowl and two [2] light assemblies are mounted
on the rear frame. Directional turn signals and four way flashers are an
OPTIONAL item.

The direction lighting system is available as a factory

CHECKS AND ADJUSTMENT [See Figure 7-5]. installed OPTION or can be added to the machine
by your nearest Distributor.
Each of the operation light assemblies is able to be
adjusted to aim the beam of light as desired. Loosen The direction lighting system contains a steering
the retaining nut on the mounting bracket to light column mounted signal switch, light assembly
assembly through bolt. Adjust the light assembly as supply wiring harnesses, circuit breaker, four way
desired and tighten the nut on the through bolt to flasher, circuit breaker, securing clamps and ties and
secure the light in the desired adjusted position. four [4] light assemblies.

Check the operation of the system each time the The two [2] rear directional lights are mounted on
machine is started to be sure the system is without the rear frame next to the rear operational lights, if
faults, which can cause the system to not operate so equipped. The two [2] front directional lights are
correctly when needed. Immediately replace any mounted on each side of the cowl, with the two [2]
component that has damage. front operational lights mounted on the front covers,
if so equipped.

CAUTION: Replace a damaged component with

the same type or sized item. NEVER
use a wire having a smaller gauge
than the wire being replaced. Use
ONLY EQUAL, or LARGER, size wire.

7-14 2/98
 Section 7
ELECTRICAL
Voltage to operate the directional lights comes from TROUBLE ANALYSIS INFORMATION AND
the ACCESSORY terminal of the ignition switch. PROCEDURES.
The ignition switch must be “ON” to operate the
directional lights and four way flasher. Voltage flows The following “TROUBLE ANALYSIS” information
through wire YYY from the ACCESSORY terminal to tables are about the individual electrical circuits used
the third ten [10] amp circuit breaker. From the on the machine. The tables give the most common
circuit breaker, voltage flows through wire DD to the problems that can be found, the probable cause of
turn signal switch. the problem and the usual corrective action that
should restore the machine to a normal operating
Move the turn signal switch lever up for a right turn. condition.
Voltage will flow through wire GG to both the front
and rear right turn lights. Always follow the four basic principles of good
systematic trouble shooting:
Move the turn signal switch lever down for a left
turn. Voltage will flow through wire HH to both the KNOW the system;
front and rear left turn lights.
DETERMINE the symptoms;
When the ignition switch is “ON”, voltage is, also,
applied to the four way flasher through wire DD and LIST the possible causes; AND
a fuse. When the hazard warning button, found at
the base of the turn signal lever, is pushed “IN”, TAKE the CORRECT ACTION.
both, the left and right turn circuits are supplied
current and voltage will flow through the flasher and
through wires GG and HH, causing all four direc- WARNING: NEVER smoke, or cause a spark,
tional lights to flash. To release the hazard warning near ANY battery.
button, move the turn signal lever, a small amount, ALWAYS loosen and remove the
either way and the hazard warning button will be NEGATIVE [-] battery cable from the
released, turning the four way flashing system NEGATIVE [-] battery terminal BE-
“OFF”. FORE loosening and removing the
POSITIVE [+] battery cable from the
Check the operation of the system each time the POSITIVE [+] battery terminal.
machine is started to be sure the system is without NEVER cause a shorted circuit
faults, which can cause the system to not operate condition in any circuit.
correctly when needed. Immediately replace any USE EXTRA CAUTION when check-
component that have damage. ing ANY circuit using ANY electrical
testing instrument.
BATTERY MAY CONTAIN EXPLO-
CAUTION: Replace a damaged component with SIVE GAS.
the same type or sized item. NEVER
use a wire having a smaller gauge
than the wire being replaced. Use CAUTION: IMPROPER trouble shooting methods
ONLY EQUAL, or LARGER, size wire. waste time and can cause further
system problems.

2/98 7-15
Section 7
ELECTRICAL
When trouble shooting any system circuit problem, If the problem is confined to ONLY one system
first determine if the problem noted is confined to circuit, the trouble shooting thought process and
only that system circuit or common to all system procedures should be confined to ONLY the circuits
circuits. and components which affect that system circuit.

Use standard voltage, ohms and continuity testing If the problem affects ALL system circuits, then the
instruments to aid in trouble shooting all system problem must be caused by malfunctions in circuits,
circuit problems. For correct test instrument use and or components, COMMON to ALL system circuits
procedures follow all of the testing instrument and the thought process and procedures should be
MANUFACTURES written instructions, which are related to those areas.
supplied with the above test instruments.
Determine WHICH system factor, where they apply,
is causing the problem: Electrical, Mechanical or
WARNING: Do NOT use any testing instruments Hydraulic.
BEFORE reading ALL manufacturers
instructions for the instrument and Only after the cause of the problem has been
procedures to be used to trouble determined can the specific damaged circuit item be
shoot ANY circuit problem. Serious removed, repaired, or replaced.
injury and/or system circuit damage
can occur if instructions are not
followed.

7-16 2/98
 Section 7
ELECTRICAL
TROUBLE ANALYSIS FOR THE ELECTRICAL SYSTEM.
[See Figures 7-1, 7-2, 7-3, 7-4 and 7-5].

STARTING CIRCUIT

PROBLEM CAUSE CORRECTION

ENGINE WILL NOT CRANK Battery is damaged [dead] Charge or replace battery.

Neutral start switch not in closed Adjust or replace neutral start

position switch.

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

"off" position

Neutral start switch damaged Replace switch.

Secondary/parking brake system Replace switch.

control switch damaged

Ignition switch damaged Replace ignition switch.

Starter solenoid damaged Replace starter solenoid.

Loose or broken wire in circuit Tighten or replace wire.

Battery cables have corrosion Clean or replace battery cables.

ENGINE CRANKS SLOWLY Starter motor windings shorted Repair or replace starter motor.

Battery not fully charged Charge battery.

Low ambient temperatures Warm area around machine.

Incorrect engine lubrication oil Remove oil and replace with

in engine correct oil.

ENGINE CRANKS BUT Fuel shutoff solenoid not Check current flow. Repair or
WILL NOT START energized replace fuel shutoff solenoid
and/or valve.

No fuel in tank Add correct fuel.

Fuel pre-cleaner, strainer and/or Replace pre-cleaner, strainer

filter "plugged" and/or filter with new.

Air in fuel supply system "Bleed" air from system.

Damaged fuel pump Replace pump.

Incorrect injector pump timing Set timing.

Damaged injector pump Replace pump.

2/98 7-17
Section 7
ELECTRICAL

TROUBLE ANALYSIS FOR THE ELECTRICAL SYSTEM.

[See Figures 7-1, 7-2, 7-3, 7-4 and 7-5].

CHARGING CIRCUIT

PROBLEM CAUSE CORRECTION

BATTERY IS OVERCHARGED Voltage regulator, in alternator, Replace regulator or alternator.

damaged

BATTERY IS NOT CHARGED Voltage regulator, in alternator, Replace regulator or alternator.

damaged

Alternator not producing voltage Repair or replace alternator.

Engine oil pressure closed switch Replace oil pressure switch.

damaged

Damaged wire[s] in circuit Repair or replace wires.

ACCESSORY CIRCUIT

PROBLEM CAUSE CORRECTION

HOURMETER DOES NOT Engine oil pressure closed switch Replace oil pressure switch.
INDICATE HOURS AS not closing circuit
ENGINE OPERATES

Meter circuit in hourmeter shorted Replace hourmeter.

No current flowing to hourmeter Check circuit for current flow.

Correct problem as needed.

HOURMETER INDICATES Meter circuit in hourmeter is Replace hourmeter.

ERRATIC HOURS “open”

ENGINE LUBRICATION Oil pressure sender damaged Replace oil pressure sender.
OIL PRESSURE GAUGE
DOES NOT INDICATE No current flowing to gauge Check circuit for current flow -
ANY PRESSURE correct problem as needed.

Damaged wire[s] in circuit Repair or replace wire[s] as

needed.

ENGINE LUBRICATION Oil pressure sender damaged Replace oil pressure sender.
OIL PRESSURE GAUGE
NOT INDICATING Gauge damaged Replace oil pressure gauge.
CORRECT OIL PRESSURE
Damaged wire[s] in circuit Repair or replace wire[s] as
needed.

7-18 2/98
 Section 7
ELECTRICAL

TROUBLE ANALYSIS FOR THE ELECTRICAL SYSTEM.

[See Figures 7-1, 7-2, 7-3, 7-4 and 7-5].

ACCESSORY CIRCUIT

PROBLEM CAUSE CORRECTION

ENGINE COOLANT Coolant temperature sender Replace temperature sender.

TEMPERATURE GAUGE DOES damaged
NOT INDICATE TEMPERATURE
No current flowing to gauge Check circuit for current flow.
Correct problem as needed.

Damaged wire[s] in circuit Repair or replace wire[s] as

needed.

Coolant temperature gauge Replace temperature gauge.

damaged

VOLTMETER NOT Meter circuit, in voltmeter, is Replace voltmeter.

INDICATING CORRECT "open"
VOLTAGE OR NO
VOLTAGE AT ALL Meter circuit in, voltmeter, is Replace voltmeter.
"shorted"

Damaged wire[s] in circuit Repair or replace wire[s] as

needed.

Alternator damaged Replace alternator.

FUEL LEVEL GAUGE No current flowing to gauge Check circuit for current flow -
DOES NOT INDICATE correct problem as needed.
CORRECT FUEL LEVEL
OR NO FUEL LEVEL Fuel sending unit, in tank, Replace fuel sending unit.
AT ALL damaged

Damaged wire[s] in circuit Repair or replace wire[s] as

needed.

Meter circuit, in fuel gauge, "open" Replace fuel gauge.

HYDRAULIC OIL No current flowing to gauge Check circuit for current flow -
TEMPERATURE GAUGE correct problem as needed.
DOES NOT INDICATE
CORRECT OIL Temperature sender unit Replace temperature sender unit.
TEMPERATURE, OR SHOWS damaged
NO INDICATION AT ALL
Meter circuit, in temperature Replace temperature gauge.
gauge, "open" or "shorted"

Damaged wire[s] in circuit Repair or replace wire[s] as

needed.

2/98 7-19
Section 7
ELECTRICAL

TROUBLE ANALYSIS FOR THE ELECTRICAL SYSTEM.

[See Figures 7-1, 7-2, 7-3, 7-4 and 7-5].

ACCESSORY CIRCUIT

PROBLEM CAUSE CORRECTION

SECONDARY/PARKING Brake system control switch Replace control switch.

BRAKE SYSTEM damaged
CONDITION INDICATOR
LIGHT DOES NOT Bulb damaged Replace bulb.
ILLUMINATE - SYSTEM
OPERATES NORMALLY Light socket not grounded Check circuit for ground -
correct problem as needed.

Damaged wire to light Repair or replace wire.

HYDRAULIC SUCTION No current flowing to light from Check circuit for current flow -
OIL FILTER CONDITION the ten [10] amp circuit breaker correct problem as needed.
INDICATOR LIGHT
DOES NOT ILLUMINATE Bulb damaged Replace bulb.

Closing switch in filter head Replace closing switch.

damaged

No circuit ground being Check circuit for ground -

completed between closing correct problem as needed.
switch and indicator light

Light socket not grounded Check circuit for ground -

correct problem as needed.

Damaged wire to light Repair or replace wire.

ENGINE INLET AIR System operating normally NO service needed.

RESTRICTION CONDITION
INDICATOR LIGHT DOES No current flowing to light from Check circuit for current flow -
NOT ILLUMINATE the ten [10] amp circuit breaker correct problem as needed.

Bulb damaged Replace bulb.

Vacuum closing switch damaged Replace vacuum closing switch.

No circuit ground being Check circuit for ground -

completed between vacuum correct problem as needed.
closing switch and indicator light

Light socket not grounded Check circuit for ground -

correct problem as needed.

Damaged wire to light Repair or replace wire.

7-20 2/98
 Section 7
ELECTRICAL
TROUBLE ANALYSIS FOR THE ELECTRICAL SYSTEM.
[See Figures 7-1, 7-2, 7-3, 7-4 and 7-5].

SYSTEM CONTROL CIRCUITS

PROBLEM CAUSE CORRECTION

TRANSMISSION SPEED No current flowing to range Check circuit for current flow.
RANGE SOLENOIDS DO selector switch from ten [10] Correct problem as needed.
NOT ENERGIZE amp circuit breaker

Ten [10] amp circuit breaker Replace circuit breaker.

damaged

Range selector switch damaged Replace switch.

Damaged wire[s] in circuit Repair or replace wire[s] as

needed.

One, or both, electrical solenoids Replace electrical solenoid(s).

damaged

WATER SPRAY ELECTRICAL No current flowing to master Check circuit for current flow -
SYSTEM DOES NOT OPERATE on/off control switch from Correct problem as needed.
ten [10] amp circuit breaker

Ten [10] amp circuit breaker Replace circuit breaker.

damaged

System on/off switch damaged Replace switch.

Damaged wire[s] in circuit Repair or replace wire[s] as

needed.

System pump damaged Replace pump.

SECONDARY/PARKING No current flowing to secondary/ Check circuit for

BRAKE SYSTEM RELEASE parking brake system control current flow - correct
SOLENOID DOES NOT switch from the ten [10] problem as needed.
ENERGIZE amp circuit breaker and /or
ignition key switch

Ten [10] amp circuit Replace circuit breaker.

breaker damaged

Secondary/parking brake Replace control switch.

system control switch damaged

Damaged wire[s] in circuit Repair or replace wire[s] as

needed.

Brake electrical solenoid Replace electrical solenoid.

damaged

2/98 7-21
Section 7
ELECTRICAL

TROUBLE ANALYSIS FOR THE ELECTRICAL SYSTEM.

[See Figures 7-1, 7-2, 7-3, 7-4 and 7-5].

OPTIONAL OPERATION LIGHTING SYSTEM

PROBLEM CAUSE CORRECTION

NO LIGHTS ILLUMINATE Open in circuit current supply Check for battery voltage at
ignition switch and 30 amp circuit
breaker- repair or replace parts as
necessary.

Open wire Check, repair as needed.

Damaged switch Replace switch.

ONE LIGHT DOES NOT Damaged light [sealed beam] Replace light [sealed beam] with
ILLUMINATE NEW.

Open wire Check and repair as needed.

REAR LIGHTS DO NOT Open wire Check and repair as needed.

ILLUMINATE
Damaged switch Replace as needed.

Damaged lights [sealed beams] Replace lights [sealed beams]

with NEW.

FRONT LIGHTS DO NOT Open wire Check and repair as needed.

ILLUMINATE - GAUGE LIGHTS
ILLUMINATE Damaged lights [sealed beams] Replace lights [sealed beams]
with NEW.

GAUGE LIGHTS DO NOT Open wire[s] Check and repair as needed.

ILLUMINATE - FRONT LIGHTS
ILLUMINATE Damaged lights [bulbs] Replace lights [bulbs] with NEW.

ONE GAUGE LIGHT NOT Open wire Check and repair as needed.
ILLUMINATED
Damaged bulb Replace bulb with NEW.

7-22 2/98
 Section 7
ELECTRICAL

TROUBLE ANALYSIS FOR THE ELECTRICAL SYSTEM.

[See Figures 7-1, 7-2, 7-3, 7-4 and 7-5].

OPTIONAL TURN SIGNALS AND FOUR WAY FLASHERS

PROBLEM CAUSE CORRECTION

NO TURN SIGNALS Open in circuit current supply Check for battery voltage at
ILLUMINATE ignition switch 30 amp circuit
breaker- repair or replace parts as
needed.

Damaged circuit breaker Replace with NEW.

ONE TURN SIGNAL LIGHT Damaged bulb, or light Replace with NEW.
DOES NOT ILLUMINATE

RIGHT TURN LIGHTS Open wire Check and repair.

DO NOT ILLUMINATE - LEFT
TURN LIGHTS ILLUMINATE Damaged switch Replace with NEW.

LEFT TURN LIGHTS Open wire Check and repair.

DO NOT ILLUMINATE - RIGHT
TURN LIGHTS ILLUMINATE Damaged switch Replace with NEW.

HAZARD WARNING SYSTEM Damaged fuse Replace with NEW.

DOES NOT FUNCTION
Open power wire Check and repair as needed.

Flasher damaged Replace with NEW.

2/98 7-23
Section 7
ELECTRICAL

NOTES

7-24 2/98
 Section 8
TRANSMISSION SYSTEM

TABLE OF CONTENTS

PAGE

GENERAL INFORMATION .................................................................................................................... 8-4

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

2/98 8-1
Section 8
TRANSMISSION SYSTEM
PAGE

MULTI-FUNCTION VALVES .................................................................................................................. 8-17

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

8-2 2/98
 Section 8
TRANSMISSION SYSTEM
PAGE

DRIVE MOTOR PRESSURE AND FLOW CHECKS .............................................................................. 8-41

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

2/98 8-3
Section 8
TRANSMISSION SYSTEM
GENERAL INFORMATION. a. Loosen and remove the negative [-] battery cable
from the negative [-] post of the battery FIRST, and
This section gives information about the transmission then loosen and remove the positive [+] battery cable
system used on the Model BW11RH Roller. from the positive [+] post of the battery.

This section also includes information for removal,

disassembly, inspection, assembly and installation of WARNING: Battery explosion can occur if the
the major transmission system components, includ- battery terminals are shorted. AL-
ing the secondary/parking brake components, which WAYS disconnect the NEGATIVE
are integral with the drive motors. battery cable from the battery FIRST.
Do NOT smoke or cause a spark
"Trouble Analysis" for the transmission system is while removing the battery cables
found at the rear of this section. from the battery.

b. Wash the pump and flywheel housing area with

FLEX DRIVE PLATE [See Figure 8-1]. clean diesel fuel and permit to air dry.

The flex drive plate assembly is used to send rotary c. Disconnect and remove the direction control
torque from the engine flywheel to the transmission cable from the transmission pump control lever.
pump.
d. Put identification tags on each electrical wire and
The flex drive plate assembly is fastened to the each electrical connector terminal on the transmis-
engine flywheel by eight [8] capscrews and rotates sion pump. Disconnect all electrical wires which are
with the flywheel. connected to the transmission pump.

The flex plate, and splined sleeve, drive the input e. Put identification tags on each hydraulic hose and
shaft of the transmission pump. each fitting on the transmission pump. Disconnect all
hoses from the transmission pump. Put plugs and
As the flex drive plate turns with the engine flywheel, caps on ALL hoses and fittings IMMEDIATELY after
it and the splined sleeve rotate the transmission the hoses are disconnected.
pump input shaft.
f. Fasten a sling and hoist, having a capacity
REMOVAL. MORE than 250 lbs. [114 kg], around the circumfer-
ence of the transmission pump body. Use the hoist to
apply tension to the sling to keep the pump assembly
NOTE: Remove the flex drive plate assembly in a level position when the retaining capscrews are
ONLY if there is damage to the splined loosened and removed.
sleeve or other parts of the plate. BE-
FORE removal of the flex drive plate, the
hydraulic pump MUST be disconnected
and removed as an assembly [see this
section].

8-4 2/98
 Section 8
TRANSMISSION SYSTEM

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

g. Loosen and remove the four [4] pump retaining INSPECTION [See Figure 8-1].
flange screws. Remove the transmission pump from
the pump mounting plate at the rear of the flywheel a. Wash the flex drive plate and splined sleeve with
housing. Lower the pump assemblies to a flat CLEAN diesel fuel and dry using compressed air.
surface and remove the sling and hoist.
b. CAREFULLY inspect the center splined area of
the drive plate for damaged splines, cracks or other
WARNING: Do NOT get under the pump assem- damage. Inspect the area around the through holes
bly while moving and lowering. for cracks or other damage. Replace the flex drive
plate with NEW if ANY damage is noted. CARE-
FULLY inspect the splined sleeve for wear or dam-
h. Loosen and remove the twelve [12] capscrews age. Replace the sleeve with NEW if worn or dam-
which fasten the pump mounting plate to the flywheel aged.
housing. Remove the pump mounting plate from the
housing.

i. Remove the splined sleeve from the drive plate.

Loosen and remove the eight [8] capscrews that
fasten the flex drive plate to the flywheel. CARE-
FULLY remove the plate from the flywheel. Put the
plate on a CLEAN flat work surface.

2/98 8-5
Section 8
TRANSMISSION SYSTEM
INSTALLATION [See Figure 8-1]. i. CAREFULLY connect the POSITIVE [+] battery
cable to the POSITIVE [+] terminal of the battery and
a. Put the flex drive plate into position on the engine tighten FIRST. Then CAREFULLY connect the
flywheel. NEGATIVE [-] battery cable to the NEGATIVE [-]
terminal of the battery and tighten.
b. Put thread lock, pn 318702, on thread area of the
retaining capscrews. Install the retaining capscrews
through the holes in the flex drive plate and thread WARNING: Do NOT connect the NEGATIVE [-]
them into the tapped holes in the engine flywheel. battery cable to the NEGATIVE [-]
Tighten the capscrews to a torque of 33 ft. lbs. [45 terminal of the battery BEFORE
N.m]. connecting the POSITIVE [+] battery
cable to the POSITIVE [+] terminal of
c. Put white grease on the external and internal the battery.
splines of the splined sleeve. Install the splined Do NOT smoke or cause a spark
sleeve into the center splined area of the flex drive while connecting the battery cable
plate. Put the pump mounting plate into position on terminal to the battery.
the flywheel housing. Put the twelve [12] plate BATTERY MAY CONTAIN EXPLOSIVE
retaining capscrews through the holes in the pump GAS.
mounting plate and turn them into the tapped holes in
the housing. Tighten the capscrews to a torque of 33
ft. lbs. [45 N.m]. j. Add hydraulic oil, as needed, to the hydraulic oil
reservoir using the procedures given in Section 4 -
d. Fasten a sling and a hoist, having a capacity MAINTENANCE. Follow ALL pre-start procedures
more than 250 lbs. [114 kg], to the transmission given in THIS section BEFORE starting the engine.
pump assembly. Lift the pump and put the transmis-
sion pump input shaft in a position, so that it is in
alignment with the center splined sleeve in the flex CAUTION: Do NOT start the engine BEFORE the
drive plate. CAREFULLY install the splined input hydraulic oil level, in the reservoir, is
shaft into the splined sleeve. at the CORRECT level.
Do NOT start the engine until ALL
e. Put thread lock, pn 318702, on the thread area of pre-start procedures have been done.
the four [4] capscrews that fasten the transmission Damage to the components of the
pump to the pump mounting plate. Install the pump hydraulic system WILL occur.
retaining capscrews and tighten to a torque of 80 ft.
lbs [108 N.m].
k. Start the engine. Check for CORRECT operation
f. Remove the caps from ALL fittings and the plugs of ALL systems. Check for ANY fluid leaks.
from ALL hoses. Install EACH hose onto the COR-
RECT pump fittings as indicated by the identification
tags installed before removal. Tighten EACH hose WARNING: Do NOT use the hands on ANY
securely onto EACH fitting or install and tighten the hydraulic hose, fitting or system
flange retaining capscrews. component to check the system for
possible leaks. Serious injury can
g. Connect the direction control cable to the trans- occur from a leak under high pres-
mission pump control lever. Adjust the control cable sure.
travel, if needed, using the procedures given in THIS
section.
CAUTION: STOP the engine IMMEDIATELY if
h. CAREFULLY connect ALL electrical wires, ANY fluid leak is noted.
EXCEPT the positive [+] and negative [-] battery Do NOT start the engine UNTIL any
cables, to the correct transmission pump wire problem noted has been corrected.
connection terminal, as indicated by the identification
tags installed before removal, and tighten securely.

8-6 2/98
2/98
FIGURE 8-2. HYDRAULIC SYSTEM SCHEMATIC - MODEL BW11RH ROLLER.

8-7
Section 8
TRANSMISSION SYSTEM
Section 8
TRANSMISSION SYSTEM
HYDRAULIC SYSTEM. Control of the transmission system variable displace-
ment, axial piston pump is important to machine
GENERAL INFORMATION [See Figure 8-2]. performance. The axial piston pump is equipped with
two [2] pressure limiter sensing valves, which are
The closed hydraulic system is made of two [2] contained in the two [2] multi-function valve cartridge
subsystems. These subsystems are: assemblies.

HYDROSTATIC TRANSMISSION system. Control of the variable displacement, axial piston

pump is through movement of the directional control
STEERING system. [F-N-R] handlever to either the FORWARD or
REVERSE direction of travel position.
Both subsystems use the same hydraulic oil and
reservoir. See Section 4 - MAINTENANCE - for the Movement of the handlever, also, moves the control
CORRECT hydraulic oil type and amount. cable. The control cable end is fastened to the lever
arm of the pump manual displacement control on the
THIS section describes the TRANSMISSION system transmission pump.
and the removal, disassembly, inspection, assembly
and installation of MOST major parts of the system. Movement of the manual displacement control lever
arm in either the FORWARD, or REVERSE, direction
See Section 10 - STEERING SYSTEM for informa- moves the control spool in the transmission pump
tion about the STEERING system. displacement control. The spool movement permits
"control oil" to flow to, and from, the hydraulic pump
control [servo] cylinders.

TRANSMISSION SYSTEM. The "control oil", under pressure, causes the servo
piston to move and tilt the pump swashplate from 0
degree of angle. Tilting the swashplate from 0 degree
GENERAL INFORMATION [See Figure 8-2]. of angle causes the pistons to stroke in and out of
the cylinder block bores as it is rotated.
The MAJOR transmission system components are
as follows: Increasing the angle of the swashplate, up to the
MAXIMUM, in the FORWARD, or REVERSE, direc-
a. One [1] transmission hydraulic pump. tion of machine travel varies the piston stroke and,
therefore, the amount of high pressure oil being
b. Two [2] transmission drive motors . displaced [pumped] to the transmission drive motors.
c. Transmission control linkage and cable. ANY change in the amount of oil flowing to the drive
motors causes a change in the output speed of the
d. Hoses. drive motors.
e. Hydraulic oil reservoir. Tilting the swashplate in the OPPOSITE direction,
from 0 degree of angle, REVERSES the oil flow to
f. Hydraulic suction filter. the transmission drive motors and, therefore, the
direction of their rotation.
g. Shuttle [Flushing] valve.
Loss of control pressure, or charge pressure, will
h. Solenoid [Stack] valve. cause the pump swashplate to return to the neutral
position because EACH servo control cylinder is
The hydrostatic transmission permits infinite control spring loaded toward the NEUTRAL position.
of the machine speed, up to the maximum speed, in
either the FORWARD or REVERSE direction of
travel.

8-8 2/98
 Section 8
TRANSMISSION SYSTEM
The swashplate will also be AUTOMATICALLY
moved toward the neutral [destroked] position IF the
HIGH pressure, in the transmission system, goes
above the MAXIMUM allowable pressure as sensed
by the two [2] pump pressure limiter sensing valves.

TRANSMISSION PUMP ASSEMBLY

[See Figure 8-3].

The variable displacement transmission pump

assembly contains the following MAJOR parts:

a. Body casting.

b. Drive shaft.

c. Cylinder block assembly.

d. Swashplate. FIGURE 8-3. TRANSMISSION PUMP.

e. Valve bearing plate. The transmission pump will be in the NEUTRAL

condition when the swashplate is at 0 degree of
f. Displacement control valve. angle and NO forward, or reverse, movement of the
machine will occur.
g. Servo cylinders and pistons.
Moving the direction control [F-N-R] handlever, found
h. Gerotor charge pump assembly. on the rear of the operator's compartment, to
EITHER the forward, or reverse, direction position
i. Multi-function valve cartridge assemblies two [2], will cause the servo control circuit to apply pressure
that contain the charge check valves, pressure limiter to one [1] servo piston. The servo piston will tilt the
valves, adjustable high pressure relief valves and the swashplate from the 0 degree of angle position
bypass valves. [positive displacement].

OPERATION. Tilting the swashplate toward EITHER side FROM

center causes the nine [9] pistons to move [stroke] in
The transmission pump drive shaft is fitted to the their bores as they contact the thrust plate. The
center of the cylinder block. The cylinder block degree of swashplate tilt angle controls the volume
assembly contains nine [9] pistons. The pump drive [displacement] of hydraulic oil moved by each
shaft, cylinder block and pistons are in rotation cylinder piston. Each cylinder piston strokes in its
together when the engine is in a running condition. cylinder EACH revolution of the cylinder block when
the swashplate is tilted.

2/98 8-9
Section 8
TRANSMISSION SYSTEM
The valve bearing plate contains ports which are in
contact with the cylinder block. The opposite side of
the valve bearing plate mates with the pump end cap.
Two [2] ports in the pump end cap are connected to
the high pressure hoses.

When a piston moves past the inlet ports, in the

valve bearing plate, it moves "out" of the block and
pulls low pressure oil into the cylinder. This is the
intake stroke of the piston. Further rotation of the
cylinder block moves the oil filled cylinder toward the
high pressure ports in the valve bearing plate. The
pistons are pushed into the cylinder block by the
tilted swashplate and thrust plate. Hydraulic oil, now
under high pressure, is directed to the outlet high
pressure port in the end cap through the valve
bearing plate.

With the pump swashplate tilted to ONE side of the

center position, the machine will travel in the forward
direction of travel and one [1] hose will carry high CHARGE
PUMP
pressure oil through a Tee'd connection at the pump
to BOTH drive motors.
FIGURE 8-4. CHARGE PUMP.
The other hose will carry low pressure [return] oil
back to the pump. The opposite tilt of the pump
swashplate will REVERSE the high pressure and
return function of the hoses from, and to, the pump TRANSMISSION PUMP CIRCUITS AND
AND the machine direction of travel. COMPONENTS.

The main ports of the pump are connected by CHARGE PUMP AND CIRCUIT
hydraulic hoses through a Tee'd fitting at the pump, to [See Figures 8-2 and 8-4].
the two [2] drive motors. Hydraulic oil flows from the
pump to the drive motors and back to the pump in a A fixed displacement [GEROTOR type] charge pump
CLOSED circuit. EITHER hydraulic hose will carry is mounted on the rear of the variable displacement
HIGH pressure. The position of the pump swashplate transmission pump and is driven by the main pump
determines which hydraulic hose carries the HIGH shaft. The charge pump supplies cool hydraulic oil to
pressure oil and the direction of HIGH pressure oil the system, keeps the system charged with oil and
flow. supplies the control system with oil. Charge pres-
sure, with the pump in neutral [0 flow] is limited by a
relief valve which is normally factory set at a pres-
sure of 270-350 psi. [19-24 bar] ABOVE case
pressure.

Since either of the main hydraulic lines can be the

high pressure line, two [2] charge check valves are
used to direct the charge supply into the LOW
pressure line. The check valves are contained in the
multi-function valves, that are installed in the left side
of the charge pump section.

8-10 2/98
 Section 8
TRANSMISSION SYSTEM
The gerotor charge pump draws hydraulic oil from The charge pump provides oil, under pressure, to
the hydraulic oil reservoir. Charge oil is cleaned by a the hydraulic pump control valve for transmission
7 micron SUCTION filter BEFORE going through the pump output control. When the directional control
charge pump and BEFORE it enters the LOW handlever is moved to either the FORWARD, or
pressure side of the main circuit. REVERSE, position the displacement control valve
directs control oil, under pressure to one [1]
swashplate control servo, which applies pressure to
the servo piston. The servo piston is moved, and,
DISPLACEMENT CONTROL AND CIRCUIT thereby, moves the pump swashplate, providing
[See Figures 8-2 and 8-5]. pump output flow [displacement].

The pump manual displacement control valve is The manual displacement control valve has an orifice
mounted to the top of the variable displacement for controlling maximum acceleration or powered
transmission pump. It provides a control of the deceleration [control responses]. The orifice matches
transmission pump output [displacement], in either the machine response desired and the orifice size
direction, that is approximately proportional to the must NOT be changed.
angular movement of the control handlever on the
operator's compartment. The manual displacement control valve, also, con-
tains a NEUTRAL start switch, so that the engine
can ONLY be started when the control is in the
CAUTION: Do NOT use ANY displacement "NEUTRAL" position. The switch provides an electri-
control other than those designed for cal interrupt, of the starting circuit, UNLESS the
the "90 SERIES" hydrostatic pumps. displacement control is in the NEUTRAL position.
Displacement controls for THIS series
of hydrostatic pumps are designed to
be used ONLY in conjunction with the
PRESSURE LIMITER system. CHARGE RELIEF VALVE [See Figure 8-6].

The charge relief valve is located in the top of the

MANUAL charge pump section. Charge pressure, with the
DISPLACEMENT transmission pump in neutral [0 flow], is limited by
CONTROL the charge relief valve which is normally factory set
VALVE
at a pressure of 350 psi. [24 bar] MINIMUM, 400 psi.
[28 bar] MAXIMUM above case pressure.

When charge pressure is MORE than the above

pressures, the charge relief valve will open and
permit oil to flow from the relief valve and back to the
hydraulic oil reservoir.

FIGURE 8-5. MANUAL DISPLACEMENT

CONTROL VALVE LOCATION.

2/98 8-11
Section 8
TRANSMISSION SYSTEM
Two [2] charge check valves are needed because
EITHER line can supply HIGH, or LOW, pressure.
When the transmission pump is stroked, and is
producing oil flow, the charge check valve sensing
CHARGE HIGH pressure will be held in a CLOSED position by
RELIEF high pressure and NO charge oil can flow into the
VALVE
line. The charge check valve sensing LOW pressure
will be in the OPEN position and permit charge oil to
enter the LOW pressure side of the cylinder block
assembly to maintain adequate oil in the system.

FIGURE 8-6. CHARGE RELIEF VALVE

LOCATION.

MULTI-FUNCTION VALVE ASSEMBLIES

[See Figure 8-7].

The transmission pump uses two [2] multi-function MULTI-FUNCTION

valve cartridge assemblies. Both cartridge assem- VALVES
blies are installed into the left side of the charge
pump section.
FIGURE 8-7. MULTI-FUNCTION VALVE -
LOCATIONS.
EACH multi-function valve cartridge assembly
contains a main system loop check valve, a high
When the transmission pump is in the neutral
pressure relief valve, a pressure limiter valve and a
condition, BOTH of the charge check valves will be in
bypass valve.
the OPEN position and permit oil, under charge
pressure, to lubricate and charge BOTH sides of the
The following information describes the basic func-
pump cylinder block and system.
tion of EACH of the items contained in the multi-
function valve cartridge assemblies.

PRESSURE LIMITER VALVES

CHARGE CHECK VALVES [See Figure 8-7]. [See Figures 8-7 and 8-8].

The two [2] charge check valves are contained in the The two [2] pressure limiter valves are contained in
multi-function valves. The check valves are used to the multi-function valves.
send filtered charge oil to the LOW pressure side of
the system when the transmission pump is in the The pressure limiter system is a fast responding
FORWARD, or REVERSE, output condition. control which LIMITS MAXIMUM pump output
pressure to a preset level, WITHOUT significant
energy dissipation.

8-12 2/98
 Section 8
TRANSMISSION SYSTEM

FIGURE 8-8. PRESSURE LIMITER SYSTEM - SCHEMATIC.

The system destrokes the pump swashplate [RE- This small amount of HIGH pressure oil moves the
DUCES displacement] whenever the MAXIMUM servo piston TOWARD the DESTROKE position, a
preset system HIGH pressure has been reached, SMALL amount. The moving piston is fastened to the
and then maintains that pressure. pump swashplate and moves the swashplate TO-
WARD the DESTROKE [neutral] position. At the
same time, control oil from the OPPOSITE servo is
also IMMEDIATELY released from behind the servo
HIGH PRESSURE RELIEF VALVES piston and permitted to flow back into the low pres-
[See Figure 8-7]. sure circuit.

The two [2] high pressure relief valves are contained

in the multi-function valves. NOTE: The action of the pressure limiter system
is VERY FAST in response time. The
They have been factory preset to a pressure of 6,200 system can port high pressure to and
+/- 100 psi. [428 +/- 6.9 bar] and EACH can be from EITHER servo piston and maintain
externally adjusted at the end of EACH multi-function the MAXIMUM HIGH system pressure
valve cartridge assembly. WITHOUT the need to act through the
pump displacement control valve.
During STROKED transmission pump operation the
high pressure relief valve, exposed to HIGH system
pressure, can act as the control to limit and maintain This procedure LOWERS the MAXIMUM HIGH
the MAXIMUM system HIGH pressure. pressure in the system to the preset pressure. The
high pressure relief valve CONTINUES to SENSE
When system pressure ABOVE the preset MAXI- and MAINTAIN the MAXIMUM system HIGH pres-
MUM high pressure is sensed, the valve will IMME- sure as long as the machine continues to be oper-
DIATELY send a small amount of HIGH pressure oil ated in the SAME direction of travel.
DIRECTLY to the OPPOSITE servo piston of that
which has control pressure applied to it from the
displacement control valve. NOTE: Reversing the direction of machine travel
will cause the OPPOSITE valve sensing
HIGH pressure to function in the SAME
way as described previously for THAT
direction of machine travel.

2/98 8-13
Section 8
TRANSMISSION SYSTEM
BY-PASS VALVES.

The two [2] by-pass valve are contained in the multi-

function valves and are used ONLY for towing of the
machine [See Section 3 OPERATION in this
manual].

TRANSMISSION PUMP CASE DRAIN

CIRCUIT.

The transmission pump uses the case drain circuit to

remove hot hydraulic oil from the pump and thereby
cool the pump during operation. The circuit also
removes oil, from the pump case, which has leaked
by pistons and other internal pump parts during
operation.
FIGURE 8-9. HYDRAULIC OIL SUCTION FILTER -
During transmission pump operation HOT hydraulic
LOCATION.
oil, having a pressure less than 40 psi. [3 bar], flows
from the top case drain port of the pump case to the
hydraulic oil reservoir.
REMOVAL, REPAIR OR REPLACEMENT OF
COMPONENTS OF THE TRANSMISSION
TRANSMISSION SYSTEM FILTRATION. PUMP.

When the engine has started, and is "running", GENERAL INFORMATION.

hydraulic oil is pulled by the transmission charge
pump from the hydraulic reservoir. Hydraulic oil then The following components CAN be removed, re-
flows through the SUCTION filter [See Figure 8-9]. paired, or replaced, WITHOUT canceling the pump
warranty. See your nearest Distributor for a copy of
The transmission system oil is then drawn into the "Service Policy and Procedures", which describes
charge pump and flows, under pressure into the COMPLETE warranty information.
pump system [See THIS Section].
a. Gerotor charge pump.
Transmission system inlet vacuum MUST NOT be
ABOVE 10 in hg. [254 mm hg]. See Section 4 - b. Displacement control valve assembly.
MAINTENANCE - for correct SUCTION filter service
procedures. c. Shaft seal.

d. Charge pressure relief valve.

e. Multi-function valve cartridge assemblies.

8-14 2/98
 Section 8
TRANSMISSION SYSTEM
If the transmission pump has failed, or test results b. Put an identification tag on EACH hose con-
indicate that service to components, other than those nected to the transmission pump fittings. Loosen and
listed above are needed, it is intended major repairs remove EACH hose from BOTH pump fittings. Put a
be done, ONLY, by Sauer-Sundstrand, Authorized plug in EACH hose and a cap on EACH fitting.
Service Centers, or the pump be replaced with a
new, or remanufactured, pump. c. Remove the six [6] capscrews holding the charge
pump cover retainer.

CAUTION: See your nearest BOMAG Distributor d. CAREFULLY remove the retainer and the charge
for a copy of the "Service Policy and pump cover. Note the orientation of the gerotor.
Procedure Manual", which describes
complete warranty information. e. Remove the charge pump shaft and charge
Major repairs are those which require pump drive key.
the removal of the pump end cap, or
side cover. Major repairs are intended f. Remove the charge pump gerotor assembly.
to be done, ONLY, by Sauer-
Sundstrand, Authorized Service g. Remove the outer eccentric ring and alignment
Centers. pin.

h. Remove the inner port plate.

The following components CAN be removed from the
pump WITHOUT removing the complete pump from
the machine. CAUTION: Do NOT drop the internal parts as
they are removed. Put the parts on a
a. Gerotor charge pump assembly. CLEAN lint free cloth.

b. Displacement control valve assembly.

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

d. Multi-function valve cartridge assemblies.

Use the following procedures to remove, inspect and INSPECTION [See Figure 8-10].
install the above components of the transmission
pump and to remove and replace the complete a. Wash the parts with CLEAN diesel fuel and dry
transmission pump assembly if needed. using compressed air.

b. Inspect the charge pump parts for wear, damage

or foreign material. Replace parts if worn or dam-
GEROTOR CHARGE PUMP. aged.

REMOVAL/DISASSEMBLY [See Figure 8-10].

CAUTION: ANY visible scoring, cracks or heavy
wear in the charge pump gerotor
CAUTION: Clean the charge pump mounting areas or plate indicate that ALL
area of the pump body with diesel internal charge pump parts MUST be
fuel and dry with compressed air. discarded and replaced with NEW.
The outer valve plate, the gerotor
assembly and the inner valve plate
a. Loosen and remove the oil inlet and case drain MUST be replaced as a COMPLETE
hoses from the charge pump. QUICKLY put a plug in assembly.
EACH hose to stop oil from draining from the reser-
voir.

2/98 8-15
Section 8
TRANSMISSION SYSTEM
ASSEMBLY/INSTALLATION [See Figure 8-10]. h. CAREFULLY remove the alignment pin from the
housing cavity, WITHOUT moving the position of the
a. BEFORE installation of ANY new parts, put aligned parts. Put petroleum jelly on the end of the
CLEAN petroleum jelly to the I.D., O.D. and side alignment pin and place the pin into the hole in the
faces of the gerotor assembly. charge pump cover.

b. Remove the paper cover from the opening in the i. Put petroleum jelly on the NEW charge pump
charge pump housing. cover o-ring. Install the NEW o-ring into the groove in
the charge pump cover.
c. CAREFULLY install the inner port plate and the
gerotor assembly outer ring. j. CAREFULLY install the charge pump cover and
alignment pin, into, and over, the aligned parts inside
d. Install the alignment pin to properly orient the port the charge pump housing cavity.
plate and outer eccentric ring for corresponding
pump rotation.
CAUTION: Use CAUTION to NOT move the
e. Install the gerotor assembly. position of the aligned parts inside
the housing cavity.
f. Install the charge pump drive key into the charge Do NOT damage the o-ring during
pump shaft and retain with petroleum jelly. charge pump cover installation.

g. Install the charge pump shaft. The internally

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

FIGURE 8-10. TRANSMISSION CHARGE PUMP COMPONENTS.

8-16 2/98
 Section 8
TRANSMISSION SYSTEM
l. QUICKLY remove the plug from the charge CAUTION: NO repair of the multi-function valve
pump oil inlet hose and the cap from the pump cartridges is possible. The cartridges
fittings. Install and tighten the hose onto the charge can ONLY be removed, cleaned and
pump fitting. Remove the plug from the case drain installed OR removed and replaced
hose and the cap from the pump fitting. Install and with NEW. Replace the o-rings with
tighten the hose onto the fitting. NEW when the new or inspected
multi-function valve cartridge is
m. Check the hydraulic oil level in the reservoir and installed into the main pump body.
add oil if needed [See Section 4 - MAINTENANCE].

CAUTION: Follow ALL Transmission System

pre-start and start-up procedures
BEFORE the engine is started.
Damage to the transmission pump
can occur if the engine is started
without doing the procedures.

MULTI-FUNCTION VALVES.

REMOVAL, INSPECTION AND

INSTALLATION [See Figure 8-11 and 8-12].

NOTE: The multi-function valve cartridge assem-

MULTI-FUNCTION
blies incorporate the system check valve, VALVES
the pressure limiter valve, the high
pressure relief valve and the bypass
valve. One [1] cartridge controls these FIGURE 8-11. MULTI-FUNCTION VALVE -
functions for the FORWARD direction LOCATIONS.
and one [1] cartridge controls these
functions for the REVERSE direction.

a. STOP the engine. Clean BOTH multi-function

valves and the main pump area where they are
installed with clean diesel fuel and dry with com-
pressed air.

b. Put a 1.25 in. [32 mm] wrench on the LARGEST

hex of the multi-function valve cartridge being
removed. Loosen and remove the multi-function
valve from the main pump body. Scribe the position
[LEFT or RIGHT] on the hex cartridge nut, after the
cartridge is removed. If needed, remove and identify
the second cartridge assembly.

c. Remove the o-rings from the cartridge. Wash the

cartridge assembly with CLEAN diesel fuel and dry FIGURE 8-12. MULTI-FUNCTION VALVE
using compressed air. Inspect the multi-function CARTRIDGE ASSEMBLY.
valve cartridge assembly for ANY damage to the
parts.

2/98 8-17
Section 8
TRANSMISSION SYSTEM
d. Put petroleum jelly on the NEW cartridge o-rings
and install the o-rings onto the cartridge assembly.
Install the cartridge assembly into the CORRECT
main pump cartridge location. Tighten the cartridge
assembly to a torque of 66 ft. lbs. [89 N.m]. If re-
moved, install the second cartridge assembly using
the same procedures.

CAUTION: If installing a cleaned and inspected

cartridge assembly, install the car-
tridge into the SAME main pump
body location from which it was
REMOVED. Check the system HIGH
pressure relief setting of BOTH multi-
function valves, using the procedures
MULTI-FUNCTION
given in THIS section.
VALVES

CHARGE CHECK VALVES. FIGURE 8-13. CHARGE CHECK VALVE

LOCATIONS [MULTIFUNCTION VALVES].
REMOVAL, CLEANING, INSPECTION AND
INSTALLATION [See Figure 8-13]. e. Install the multifunction valves into the pump
housing, as indicated by the position markings made
a. STOP the engine. Clean multifunction valves and at removal, and torque to 66 ft. lbs. [89 N.m].
the main pump area where they are installed with
clean diesel fuel and dry with compressed air.

b. Before removing the multifunction valves, mark MANUAL DISPLACEMENT CONTROL VALVE.
the installation position in the pump on them [Top or
BOTTOM], so as to maintain the original installation REMOVAL AND REPLACEMENT
location when installing. [See Figure 8-14].

c. Remove the multifunction valves from the pump,

using a 1 1/4 [32 mm] wrench. CAUTION: There are NO adjustable items in the
manual displacement control valve
d. Remove the o-ring from the cartridge Wash parts assembly, Except for adjustment of
with CLEAN diesel fuel and dry using compressed the neutral start switch. ALL func-
air. Inspect the poppet and mating seat for damage, tions are FACTORY set by the pump
or foreign material. Assemble the multifunction valve manufacturer.
assembly [see this section].

CAUTION: NO repair of the charge check valve is a. Wash the displacement control valve and the
possible. The multifunction valves area where it is mounted to the pump housing with
can ONLY be removed, cleaned and clean diesel fuel and dry using compressed air.
installed OR removed and replaced
with NEW. Replace the o-ring with b. Loosen and remove the control cable from the
NEW when the new, or inspected displacement control handle.
multifunction valves are installed.

8-18 2/98
 Section 8
TRANSMISSION SYSTEM
f. Remove any gasket material from the control
MANUAL
DISPLACEMENT valve and the mating area on the main pump body.
CONTROL
VALVE g. Inspect the control orifice and spring for damage.
Replace the control orifice with one of the SAME size
if damaged.

h. Remove the paper cover from the opening in the

pump body opening. CAREFULLY put the spring and
control orifice in position in the control valve housing.
Put a NEW gasket on the control valve housing.

CAUTION: Make sure that the spring and control

orifice are in, and remain in, the
proper position in the pump body.

i. Put the pin on the control valve link INTO the

FIGURE 8-14. MANUAL DISPLACEMENT mating hole in the link fastened to the swashplate.
CONTROL VALVE LOCATION.
j. CAREFULLY move the control valve into position
c. Loosen and remove the six [6] retaining cap- against the pump body and hold in position. Align the
screws from the control valve. CAREFULLY swing holes in the control valve with the holes in the gasket
the control valve away from the main pump housing. and pump body.

NOTE: The control valve is sealed to the main NOTE: Check proper engagement of the control
pump body by the use of a gasket. linkage pin. Proper engagement will be
indicated by centering torque as the
control valve arm is moved away from the
center position in EITHER direction. NO
CAUTION: Do NOT permit the control orifice or noted torque indicates the pin is NOT
spring to fall into the main pump engaged in the swashplate link. Remove
housing. Keep the control orifice and the control valve and repeat steps "i and
spring in the control valve housing. j" if NO torque is noted.

d. Complete removing the control valve by disen- k. CAREFULLY install the six [6] retaining cap-
gaging the pin in the control link FROM the link screws through the control valve and into the tapped
fastened to the swashplate. CAREFULLY remove holes in the pump body. Tighten the capscrews to a
the control orifice and spring from the control valve torque of 12 ft. lbs. [16 N.m].
housing.

e. Cover the area in the main pump body where the NOTE: Check the neutral start switch adjustment
control valve was removed with paper to stop dirt at THIS time using the procedures given
from entering the pump. in THIS section.

2/98 8-19
Section 8
TRANSMISSION SYSTEM
NEUTRAL START SWITCH.
NEUTRAL
START
REMOVAL AND REPLACEMENT SWITCH
[See Figure 8-15].

NOTE: Removal and replacement of the neutral

start switch can be done WITH the dis-
placement control valve on the pump,
and the pump still installed in the ma-
chine.

WARNING: Do NOT disturb ANY locknuts or

adjustments on the neutral start
switch other than those described in
THIS procedure. Disturbing other
components CAN result in the engine
of the machine starting in a position
other than when the pump is in the
neutral [0 flow] position.

a. Clean the neutral start switch and the area FIGURE 8-15. NEUTRAL START SWITCH -
around the switch with CLEAN diesel fuel and dry INSTALLED IN DISPLACEMENT CONTROL
using compressed air. VALVE.

b. Put an identification tag on EACH wire fastened

to the neutral start switch. Loosen and remove the
two [2] wires that fasten to the switch. ADJUSTMENT [See Figure 8-16].
c. Hold the switch in place with one 1.125 in. [29 a. Put the control lever arm in the EXACT center of
mm] wrench and CAREFULLY loosen the locknut the neutral position. Fasten the leads of a continuity
with another 1.125 in. [29 mm] wrench. checker to the two [2] screws on the end of the
neutral switch.

CAUTION: Do NOT turn the switch when loosen- b. Keep the control lever arm in the EXACT neutral
ing the locknut. Turning the switch position. Turn the switch in a CLOCKWISE [CW]
can change other critical switch direction until electrical continuity is broken, then turn
adjustments. the switch counterclockwise [CCW] until electrical
continuity is obtained. Turn the switch an additional
1/4 turn (90o) more in the same direction after the
d. CAREFULLY remove the switch from the control continuity has been obtained.
valve by turning the switch in a COUNTERCLOCK-
WISE [CCW] direction of rotation. c. Hold the switch in this position with one [1] 1.125
in. [29 mm] wrench and tighten the locknut with
e. CAREFULLY install the NEW switch by turning another 1.125 in. [29 mm] wrench to 20 ft. lbs. [27
the switch in a CLOCKWISE [CW] direction of N.m].
rotation UNTIL finger tight. Leave the locknut loose
at THIS time. d. Leave the continuity checker attached to the
switch and move the control lever arm in each
direction to assure continuity is broken when the
CAUTION: Check the neutral start switch AD- control is NOT in the neutral position.
JUSTMENT using the following
procedures at THIS time.

8-20 2/98
 Section 8
TRANSMISSION SYSTEM
TRANSMISSION PUMP SHAFT SEAL.

REMOVAL, INSPECTION AND INSTALLA-

TION [See Figure 8-17].

The transmission pump assembly MUST be loos-

ened and moved away from the pump mounting
plate and flex drive plate, or be removed from the
machine [see THIS section for procedures], BE-
FORE the shaft seal can be removed and replaced
with NEW.

CAUTION: ALL shaft seal parts MUST be re-

placed with NEW after removal.
FIGURE 8-16. NEUTRAL START SWITCH -
ADJUSTMENT.
a. With the INPUT shaft end of the pump assembly
moved away from the pump mounting plate and the
shaft splines fully disengaged from the flex drive
e. Remove the continuity checker from the switch
plate OR the pump assembly removed from the
and connect the two [2] wires to the switch per the
machine, position the pump with the shaft facing up.
identification tag fastened on each wire.
NOTE: If the pump is positioned horizontally
when the shaft is removed, the cylinder
block could move out of place, making
PRESSURE LIMITER VALVES. shaft installation difficult.

REMOVAL, INSPECTION AND INSTALLA- b. Remove the three [3] capscrews that hold the
TION [See Figure 8-12]. retainer plate to the main pump body.

EACH pressure limiter valve is contained in the c. CAREFULLY move the retainer plate.
multi-function valve cartridge assembly and is
serviced through the removal, cleaning, inspection
and installation of the cartridge assembly [See THIS NOTE: The seal carrier is held in place by the
section]. friction of the o-ring on its outside
diameter. An outward spring force on the
input shaft will tend to overcome the
CAUTION: Check the adjustment of the pres- friction from the o-ring on the seal carrier
sure limiter valves, using the infor- and push the seal carrier outward. If the
mation found in THIS section. See seal carrier does NOT move from its bore
the "PRESSURE LIMITER AND HIGH after removal of the capscrews, CARE-
PRESSURE RELIEF VALVE PRES- FULLY pry the carrier toward the end of
SURE CHECK AND ADJUSTMENT" the shaft UNTIL the o-ring is free, using
procedure. two [2] screw drivers against the outside
of the housing.

CAUTION: Do NOT damage the cover OR pump

body bore during removal.
Do NOT remove the input shaft. After
the seal cover is removed, the shaft
will be in a free condition and can be
removed or fall from the pump body.

2/98 8-21
Section 8
TRANSMISSION SYSTEM

RETAINING
PLATE
SCREW

SEAL
CARRIER

ROLLER RETAINING
BEARING RING
ASSEMBLY
SEAL

O-RING

FIGURE 8-17. TRANSMISSION PUMP SHAFT SEAL INSTALLATION.

d. Remove the o-ring from the seal carrier. h. Inspect the sealing area on the input shaft for
rust, wear or contamination. If the shaft is not being
e. Place the seal cover in an arbor press and replaced, proceed to step "l".
remove the old seal from the cover.
i. Remove shaft and roller bearing assembly from
f. Wash the parts in CLEAN diesel fuel and dry the pump. The bearing assembly can be transferred
with compressed air. Inspect the seal carrier, the to the new shaft.
NEW seal and o-ring for ANY damage or nicks.
j. Remove the retaining ring that secures roller
NOTE: The outside diameter of the seal may be bearing assembly with a snap ring pliers. Remove
lightly coated with a sealant (such as the roller bearing assembly.
Loctite High Performance Sealant
#59231) prior to installation. This aids in k. Place roller bearing assembly on new shaft and
preventing leaks caused by damage to secure with the retaining ring.
the seal bore in the seal carrier.
l. Put thin plastic film, or equivalent, around the
g. Using the arbor press, CAREFULLY install the input shaft splined area to protect the sealing lip on
new shaft seal into the seal carrier. the seal during installation.

CAUTION: Do NOT damage the seal during CAUTION: Do NOT install ANY shaft seal parts
installation. over the input shaft BEFORE cover-
ing the shaft with the protective film.

8-22 2/98
 Section 8
TRANSMISSION SYSTEM
m. Put petroleum jelly on the sealing lip and seal INSTALLATION [See Figure 8-18].
carrier o-ring. CAREFULLY put the seal carrier and
seal over the input shaft and into the pump bore. Install the transmission pump by using the proce-
dures given in THIS section [see FLEX DRIVE
PLATE INSTALLATION].
CAUTION: Hold the seal carrier in position. The
seal carrier will have a small spring
load at this time due to the outward ADJUSTMENT OF THE TRANSMISSION
spring force on the input shaft. DIRECTION CONTROL CABLE
[See Figure 8-19].

n. Install the retainer plate and capscrews and Use the following procedure to adjust the transmis-
tighten to a torque of 12 ft. lbs. [16 N.m]. sion direction control cable, after the pump has been
removed, repaired or replaced and installed back into
o. CAREFULLY remove the plastic film from the machine.
around the input shaft. Install the transmission pump
splined input shaft into the splined drive sleeve and a. STOP the engine. Keep the engine in the "OFF"
position the pump against the pump mounting plate. condition. Put the direction control [F-N-R] handlever
Install the four [4] pump retaining capscrews and in the CENTER of the NEUTRAL position.
tighten to a torque of 80 ft. lbs. [108 N.m].

WARNING: NEVER adjust the transmission

direction control cable with the
COMPLETE TRANSMISSION PUMP engine in a "running" condition.
ASSEMBLY.

REMOVAL [See Figure 8-18]. NOTE: Be sure the rod end is in the CENTER of
the cable threads and the locknut is
tightened against the rod end.
CAUTION: Remove the COMPLETE pump
assembly, from the machine, ONLY
after correctly and fully checking the b. Put the transmission control lever, found on the
pump. Use pressure check and flow displacement control valve, in the CENTER of the
rate test procedures, that will indicate NEUTRAL position and at a position 90o to the
internal component failures which control cable axis.
REQUIRE the pump be removed for
repair or replacement. MAJOR trans- c. Adjust the ball joint, found on the transmission
mission pump repair procedures pump end of the direction control cable, so that the
WILL effect warranty. See your threaded ball stud of the ball joint aligns with the
nearest Distributor and refer to the through hole in the transmission lever and tighten the
"Warranty Policies and Procedures" jam nut.
before removing a transmission
pump assembly and/or having major
repair done to the transmission CAUTION: There should be NO tension on the
pump assembly. ball joint when the pump lever and
the control handlever are BOTH in
the NEUTRAL position.
Remove the transmission pump by using the proce-
dures given in THIS section [see FLEX DRIVE
PLATE REMOVAL]. d. Check the neutral start switch for correct opera-
tion when the transmission pump is in the neutral
condition [see THIS Section].

2/98 8-23
Section 8
TRANSMISSION SYSTEM
ADJUSTMENT OF THE THROTTLE CON-
TROL LINKAGE [See Figure 8-19].

CAUTION: To help avoid possible transmission

pump damage, with the throttle
control linkage correctly adjusted,
the engine MUST reach 1200 RPM
BEFORE the pump starts to stroke in
either direction.

Use the following procedure to adjust the throttle

control linkage, after the pump has been removed,
repaired or replaced and installed back into the
machine.

a. Center the directional control lever using the

neutral lock. The auxiliary throttle lever should be at
the lowest possible setting.
FIGURE 8-18. TRANSMISSION PUMP ASSEMBLY
- INSTALLED IN THE MACHINE. b. Cables should be installed in the position as
shown in figure 8-19.

e. Pre-charge the hydraulic systems using the c. While holding the distance between the threads
procedures given in THIS section. on the throttle cable and the top of the bracket to
0.25 - 0.75" [see figure 8-19], adjust the bracket in
the slots so that the slack is removed evenly from
CAUTION: Do NOT start the engine UNTIL after both cables attached to the directional control lever.
ALL pre-start procedures have been Tighten bracket's mounting hardware at this position.
completed.

NOTE: Some slack may be present in the

cables.
f. Start the engine. Check the transmission system
for CORRECT operation.
d. Adjust the ball joint on the engine throttle so that
no slack is present in the cables with throttle at low
WARNING: Keep ALL personnel, except the idle.
operator, CLEAR of the machine
while checking the system operation.
NOTE: At full stroke forward or reverse, engine
throttle spring should stretch to account
for over stroke.

8-24 2/98
 Section 8
TRANSMISSION SYSTEM
AUXILIARY
THROTTLE
LEVER

0.25
LUBRICATE BOTH
TO
ENDS WITH MULTI-
0.75
PURPOSE GREASE
TO HYD. PUMP
BRACKET

TO THROTTLE

INJECTOR PUMP
LEVER

FIGURE 8-19. TRANSMISSION CONTROL CABLE AND THROTTLE CONTROL LINKAGE

ADJUSTMENT.

TRANSMISSION PUMP PRESSURES. WARNING: Keep ALL personnel, except the

operator and an assistant - when
CHECKING AND ADJUSTMENT PROCE- needed, CLEAR of the machine
DURES. during pressure checking proce-
dures.
The following information describes the different Use ONLY the CORRECT gauge, on a
pressure check locations, gauge sizes needed, hose, for each pressure check.
correct pressures and suggested methods for
changing an incorrect system pressure. Capped
system gauge ports are provided for the various CAUTION: The hydraulic system oil MUST be at
pressure checks usually needed to be made. "NORMAL OPERATING" temperature
and at the correct level BEFORE any
pressure check is taken. The engine
throttle MUST be in the "HIGH IDLE"
condition for ALL pressure checks.
The SECONDARY/PARKING brake
system control switch MUST be in
the "ON" condition for ALL pressure
checks.

2/98 8-25
Section 8
TRANSMISSION SYSTEM
CHARGE PRESSURE [See Figure 8-20].
SOLENOID
[STACK]
The capped CHARGE pressure check port is located VALVE
on the left side of the transmission pump. Check NEEDLE
and, if needed, adjust THIS pressure as follows: VALVE

FORWARD HIGH
PRESSURE
CHECK PORT BRAKE PILOT
PRESSURE
REVERSE HIGH
CHECK POINT
PRESSURE
CHECK PORT

FIGURE 8-21. BRAKE NEEDLE

VALVE LOCATION
CHARGE
PRESSURE
CHECK PORT f. Put the auxiliary throttle in the "HIGH" idle
position and the secondary/parking brake system
FIGURE 8-20. PRESSURE CHECK control switch "OFF" position. Leave the transmis-
PORT LOCATIONS. sion direction control handlever in the NEUTRAL
position. Have an assistant note the neutral charge
a. Put the secondary/parking brake system control pressure indicated on the pressure gauge. The
switch "ON" [APPLIED]. STOP the engine. CORRECT NEUTRAL charge pressure is 350 psi.
[24 bar] MINIMUM to 400 psi. [28 bar] MAXIMUM.
b. Close the needle valve located below the sole-
noid valve [See Figure 8-21]. g. Slow the engine to "LOW" idle speed and run for
a period of 3-5 minutes. STOP the engine.
NOTE: The brakes are now set in the drive
motors and can not be released with the NOTE: The charge relief pressure MUST be
switch on the dash unless the needle adjusted IF the charge pressure noted
valve is manually opened [CCW]. This was NOT as given ABOVE. Use the
condition is necessary to accurately set following ADDITIONAL information. Low
up and inspect the unit. charge pressure, at LOW IDLE and at
HIGH IDLE, can also indicate possible
internal charge pump leakage, which
c. Wipe the charge pressure check port cap and requires removal, repair or replacement
the area around it with a CLEAN cloth. of the gerotor charge pump assembly.

d. Remove the cap from the charge pressure check 1. Keep the engine in the "OFF" condition.
port. Install a 600 psi. [41 bar] gauge, on a short Clean the area of the charge pump section
hose, onto the check port fitting and tighten se- where the charge relief valve assembly is
curely. installed [See Figure 8-22].

e. With the secondary/parking brake system control 2. Loosen the lock nut with a 1-1/16 in. wrench
switch "OFF" position and unit in high speed range, and turn the adjustment plug with a large
test brakes by stroking the transmission direction screwdriver. Clockwise rotation of the plug
control handlever to full stroke in both directions. increases the setting, and counterclockwise
Brakes must stall full motor torque in high speed rotation decreases the setting [at a rate of
range. approximately 50 psi. [3.5 bar] per turn].

8-26 2/98
 Section 8
TRANSMISSION SYSTEM
PRESSURE LIMITER SYSTEM AND HIGH
PRESSURE RELIEF VALVE PRESSURE
CHECK AND ADJUSTMENT
[See Figure 8-20].
CHARGE
RELIEF
VALVE The two [2] capped high system pressure check
ports are found on right side of the transmission
pump.

NOTE: The ONE [1] pressure check port is for

HIGH pressure check in the FORWARD
direction and the other pressure check
port is for HIGH pressure check in the
REVERSE direction of travel.

a. Put the secondary/parking brake system control

switch "ON" [APPLIED]. STOP the engine.
FIGURE 8-22. CHARGE RELIEF VALVE
LOCATION. b. Close the needle valve located below the sole-
noid valve [See Figure 8-21].
3. While holding the plug with the screwdriver,
torque the lock nut to 38 ft. lbs. [52 N.m]. NOTE: The brakes are now set in the drive
motors and can not be released with the
4. Check the charge pressure, again, using the switch on the dash unless the needle
ABOVE procedures. Repeat the adjustment valve is manually opened [CCW]. This
procedure UNTIL the pressure indicated is condition is necessary to accurately set
CORRECT. up and inspect the unit.

h. STOP the engine. Loosen and remove the gauge c. Clean BOTH high pressure check port caps and
and hose assembly from the pressure check port. the area around them with a CLEAN cloth.
Install and tighten the check port cap.
d. Remove BOTH of the caps from the two [2] high
i. Put the secondary/parking brake system control pressure check ports. Use two [2] 10,000 psi. [690
switch "ON" [APPLIED]. bar] pressure gauges, connected to hoses that will
reach the operator's compartment. Place BOTH
j. Open the needle valve located below the sole- gauges in a position in the operator's compartment,
noid valve [See Figure 8-21]. so that they can be clearly seen during the "high
pressure check" procedure.

WARNING: Except for the OPERATOR, Keep ALL

personnel CLEAR of the MACHINE
and the surrounding AREA during
THIS "pressure check" procedure.
Maximum high system pressure will
be developed during THIS pressure
check procedure.

2/98 8-27
Section 8
TRANSMISSION SYSTEM
e. Start the engine. Put the transmission speed
range control switch in the "LOW" position. Put the
engine throttle in the "HIGH" idle position. SLOWLY
move the direction control handlever from the
NEUTRAL position toward the full FROWARD
direction of machine travel position. Watch the gauge
indicating "HIGH" pressure for THIS direction, and
note the HIGHEST pressure indicated. Return the
direction control handlever to the NEUTRAL position.
Move the handlever from the neutral position toward
the full REVERSE direction of machine travel posi-
tion. Watch the gauge indicating "HIGH" pressure for
this direction, and note the HIGHEST pressure
indicated. Return the direction control handlever to
the NEUTRAL position. Put the throttle in the "LOW"
idle position and run the engine 3-5 minutes to cool
the engine and components. STOP the engine. FIGURE 8-23. MULTI-FUNCTION VALVE -
ADJUSTMENT.

CAUTION: The correct "HIGH" pressure noted in 1. Put the transmission speed range control
both directions MUST be 6200 +/- 100 toggle switch in the "LOW" position.
psi. gauge pressure. This is the
pressure where the pressure limiter
sensing valve for each direction of DANGER: To be able to correctly make the HIGH
travel will begin to open and destroke pressure relief valve adjustments, an
the pump. ANY pressure indicated, in assistant is required and the trans-
either or both directions, which is mission system MUST reach MAXI-
NOT correct will require that the MUM system pressure. The second-
pressure limiter sensing /pressure ary/parking brake system, and the
relief valve for THAT direction be additional wooden blocking, MUST
adjusted. assure that the machine is kept from
If either, or both relief pressures, were ANY movement during this adjust-
NOT correct use the following addi- ment procedure.
tional information to adjust the
pressure limiter sensing/pressure
relief valve assemblies. NOTE: A plastic dust plug is installed in the
adjusting screw.

NOTE: Adjustment of the pressure limiter

system and the high pressure relief valve 2. Loosen locking nut [smallest hex on multi-
settings for both is accomplished by function valve] with a 19 mm wrench on the
using the same procedure, at each multi- multi-function valve to be adjusted.
function valve cartridge assembly. The
FORWARD direction pressure limiter/
high pressure relief adjusting screw is NOTE: The FORWARD direction pressure limiter/
found at the end of the UPPER multi- high pressure relief adjusting screw is
function valve cartridge assembly [See found at the end of the UPPER multi-
Figure 8-23]. The REVERSE direction function valve cartridge assembly [See
pressure limiter/high pressure relief Figure 8-23]. The REVERSE direction
adjusting screw is found at the end of pressure limiter/high pressure relief
the LOWER multi-function valve car- adjusting screw is found at the end of the
tridge assembly [See Figure 8-23]. LOWER multi-function valve cartridge
assembly [See Figure 8-23].

8-28 2/98
 Section 8
TRANSMISSION SYSTEM
3. Insert a 5 mm internal hex wrench into the 6. Have the operator slow the engine to "LOW"
pressure adjusting screw. Turn the adjusting engine idle and move the transmission
screw, a small amount, to change the pres- direction control handlever to the NEUTRAL
sure. position.

7. If required, adjust the opposite direction

NOTE: Clockwise [CW] rotation of the pressure setting in the same manner.
adjusting screw will INCREASE the relief
pressure setting. Counterclockwise f. STOP the engine. Loosen and remove both
[CCW] rotation of the pressure adjusting gauge and hose assemblies from the "HIGH" pres-
screw will DECREASE the relief pressure sure check ports. Install and tighten the port cap onto
setting. Each complete rotation of the each fitting.
pressure adjusting screw changes the
pressure setting by approximately 1,350 g. Put the secondary/parking brake system control
psi. [93 bar]. switch "ON" [APPLIED].

h. Open the needle valve out [CCW] to its stop.

4. To verify the actual pressure setting, keep
the transmission speed range selector toggle
switch in the "LOW" position. Start the
engine, and then put the engine throttle in the SHUTTLE [FLUSHING] VALVE FLOW
"HIGH" idle position. Put the transmission [See Figure 8-24].
direction control handlever in the direction
being adjusted. Note the pressure indicated
on the pressure gauge. DANGER: SERIOUS INJURY, or DEATH, can
occur if the shuttle valve is NOT
adjusted correctly and causes a loss
DANGER: ONLY allow the operator and the of correct machine directional
person making the pressure adjust- control. CORRECT adjustment of the
ments near the machine. ALL other hydrostatic transmission system
personnel MUST be kept CLEAR of shuttle valve is critical to correct
the area around the machine. machine performance, and efficiency
of the cooling system. Always use
the information given below to
NOTE: The pressure limiter system and high correctly adjust the shuttle valve
pressure relief valve pressures are after service to, or replacement of,
reached when the pressure remains the valve.
STEADY at the CORRECT pressure level.

a. Put the secondary/parking brake system control

5. While still watching the pressure gauge, switch "ON". STOP the engine.
CAREFULLY hold the adjusting screw in the
SAME position where the relief pressure is
CORRECT. CAREFULLY tighten the lock nut
while keeping the adjusting screw in the
SAME position, so that the pressure gauge
indicates the CORRECT relief pressure.
Torque the lock nut to 12 ft. lbs. [16 N.m].

2/98 8-29
Section 8
TRANSMISSION SYSTEM
c. Wipe the case drain RETURN oil hose fitting and
the 90 degree fitting it connects to, at the shuttle
valve, with a CLEAN cloth.

d. Loosen the RETURN oil hose at the 90o fitting at

the control shuttle valve. Remove the hose from the
90o fitting. Install a 0-5 GPM flowmeter [flow direction
is from the shuttle valve to the transmission pump].

e. Start the engine. With the secondary/parking

brake system control switch "OFF", put the auxiliary
throttle in the "HIGH" idle position.

f. Slowly stroke the transmission direction control

handlever in the FORWARD direction until the
transmission begins to drive against the brake. DO
NOT operate under these conditions for more than a
few seconds. Note the shuttle flow indicated on the
flowmeter.

g. Put the transmission direction control handlever

FIGURE 8-24. SHUTTLE [FLUSHING] VALVE. in the NEUTRAL position and then slowly stroke the
transmission direction control handlever in the
REVERSE direction until the transmission begins to
b. Close the needle valve located below the sole- drive against the brake. DO NOT operate under
noid valve [See Figure 8-25]. these conditions for more than a few seconds. Again,
note the shuttle flow indicated on the flowmeter.
NOTE: The brakes are now set in the drive
motors and can not be released with the NOTE: Both flow readings MUST be 4.25 +/-0.25
switch on the dash unless the needle GPM.
valve is manually opened [CCW]. This
condition is necessary to accurately
setup and inspect the unit. h. Slow the engine and allow to run at "LOW" idle
speed for a period of 3-5 minutes. STOP the engine.

SOLENOID
[STACKED]
VALVE
NOTE: The shuttle valve MUST be adjusted if
NEEDLE the flows noted were not as given above.
VALVE Use the following ADDITIONAL informa-
tion.

BRAKE PILOT
PRESSURE 1. Keep the engine in the "OFF" condition.
CHECK POINT Clean the area of the shuttle valve where the
adjusting valve is installed.

2. Loosen the lock nut. Using a large screw-

driver, turn the adjustment plug inward [CW],
toward the valve body, or outward [CCW],
away from the valve body a small amount.

FIGURE 8-25. BRAKE NEEDLE 3. Recheck the shuttle valve flow.

VALVE LOCATION

8-30 2/98
 Section 8
TRANSMISSION SYSTEM
4. After adjusting the shuttle valve flow, check Each drive motor contains the following five [5]
the charge pressure in the forward and MAJOR parts:
reverse direction, using the procedures given
in this section. The minimum charge pressure Front bearing support assembly.
under load must be 350 psi. The maximum
charge pressure at no load high idle must not Cylinder block assembly, with ten [10] pistons.
exceed 400 psi. If necessary, adjust the
charge pressure using the procedures given Cam ring, having eight [8] lobes.
in this section. Then recheck the shuttle valve
flow. Valving assembly, with a two [2] speed change pool.

i. STOP the engine. Remove the flowmeter and Brake assembly.

reconnect the hose to the shuttle valve.

j. Put the secondary/parking brake system control

switch "ON" [APPLIED]. OPERATION [See Figure 8-27].

k. Open the needle valve out [CCW] to its stop. In the forward, or reverse, direction of machine travel,
HIGH pressure oil from the transmission pump flows
to the drive motors.

DRIVE MOTOR/BRAKE ASSEMBLIES. Selecting the "LOW" speed range, using the control
switch found on the console, keeps both transmis-
DESCRIPTION [See Figures 8-26]. sion low/high range solenoids in the, spring applied,
low range position. The high pressure oil enters each
The two [2] LOW speed - HIGH torque drive motors drive motor at the valving [oil distributor] assembly.
are a two [2] speed multi-lobe radial piston type, with High pressure oil then is distributed to the ten [10]
a multi-disc brake system integral inside each drive pistons and uses ALL eight [8] cam ring lobes as
motor. "power lobes" for the "LOW" speed range, FULL
displacement, of the drive motors.
Each drive motor contains two drive flanges contain-
ing the mounting studs. Two wheels are mounted on Selecting the "HIGH" speed range, using the control
each drive motor. switch found on the console, energizes both trans-
mission low/high range solenoids, moving the spools
to the high range position. The high pressure oil is
distributed to the ten [10] pistons, ONE HALF of the
time in each revolution, and, thereby, uses ONLY
four [4] cam ring lobes as "power lobes". This will put
the drive motors at ONE HALF displacement and is
the "HIGH" speed range.

Selecting the "MEDIUM" speed range, using the

control switch found on the console, energizes the
LH transmission low/high range solenoid, moving the
spool to the high range position. The RH transmis-
sion low/high range solenoid will remain in the low
range position. This will put the LH drive motor at
ONE HALF displacement and the RH drive motor will
FIGURE 8-26. DRIVE MOTOR/BRAKE. remain at FULL displacement. Because the supply
for the two drive motors are teed together, the mixed
displacement causes a "MEDIUM" speed range.

2/98 8-31
Section 8
TRANSMISSION SYSTEM

2
3

31 37 36 46 48 44 9 21 6 24 26 31
4
8 15
43 5 7 14 16 33

18

28

38
29
30

40 1 12 10 27

19 42 39 41 20 11 13 17 23 25 22 32 34

35 47 45

1. PISTON 17. SPRING 33. THRUST RING

2. KIT, SEALING 18. SEAL 34. O-RING
3. PISTON 19. SHAFT 35. RING
4. CAM 20. SPACER 36. BEARING
5. O-RING 21. SLEWING RING 37. SEAL
6. VALVING COVER 22. RING 38. DEFLECTOR
7. SCREW 23. BEARING 39. DISC
8. GASKET 24. SUPPORT 40. DISC
9. SCREW 25. SEAL RING 41. SHIM SET
10. SEAL 26. SCREW 42. O-RING
11. VALVING/DIST. 27. SHIM SET 43. O-RING
12. SEAL KIT 28. HUB 44. O-RING
13. SPRING 29. WASHER 45. BRAKE PISTON
14. VALVE SPOOL 30. SCREW 46. SUPPORT
15. WASHER 31. STUD 47. SPRING
16. SNAP RING 32. O-RING 48. SCREW

FIGURE 8-27. TRANSMISSION DRUM DRIVE MOTOR - FULL SECTIONED VIEW.

8-32 2/98
 Section 8
TRANSMISSION SYSTEM
Energizing a transmission low/high range solenoid Oil from any drive motor internal leakage flows from
moves the spool in the solenoid valve. The spool the case port of each drive motor to a "tee" fitting.
movement permits oil, at charge pressure, to flow to From the "tee" fitting the oil flows to a point in the oil
the HIGH speed port on its drive motor valving return line where it joins the return oil from the
assembly. The oil flow moves a pilot spool in the transmission pump.
center of the valving assembly, which lowers the
"used" displacement of that drive motor. The secondary/parking brake system is a integral
assembly on each drive motor. The multi-disc, spring
EACH of the ten [10] pistons will have HIGH pres- applied and hydraulically released brake uses
sure applied to the back of the piston and begin to hydraulic oil, at a pressure of 175 psi. [12 bar]
move outward in its bore just after it passes the minimum to 435 psi. [30 bar] maximum, to release
HIGH pressure ports. EACH piston pushes the piston the spring applied disc brakes on both drive motors.
and roller assembly against the cam ring.
When the secondary/parking brake system control
This action causes the COMPLETE cylinder block switch is placed at "ON" [BRAKES APPLIED], the
assembly to rotate and turn the splined drive and release piston, in each drive motor, is stopped from
brake shaft. having oil pressure applied to it. The multi-disc
brakes in each drive motor are applied by spring
The profile of the cam ring is calculated to create a pressure and the brake shaft is stopped from turning.
constant angular displacement of the drive motor as
each piston and roller assembly moves by the high
pressure port, in the valve block assembly. The NOTE: LACK of hydraulic pressure, against the
distribution of the pistons make them balanced for release piston from ANY cause, WILL
smooth torque. permit the multi-disc brakes to be applied
by spring pressure.
As the piston and roller assemblies continue to follow
the curved contour of the cam ring, the curving
shape causes the assemblies to move inward again. When the secondary/parking brake system control
This action causes the roller assembly to push the switch is placed at "OFF" [BRAKES RELEASED],
piston inward. This inward movement of the piston is electrical current will energize the "brake release"
timed with the piston passing the "LOW" pressure solenoid. The solenoid moves a spool found in the
port, of the valve block assembly, for that piston in "solenoid valve" which permits oil, at approximately
that direction. The oil, which now is under low "charge pressure", to flow from the outlet of the
pressure, enters the "LOW" pressure port of the "solenoid valve" to each drive motor brake release
valve block assembly and is directed to the "LOW" pressure port. The oil enters the release port and is
pressure hose which is fastened to the top of the directed internally to the pressure side of the multi-
valve housing. disc brake release piston of each drive motor.

The oil, now under "LOW" pressure, flows from each The hydraulic pressure moves the release piston.
drive motor. The "LOW" pressure oil then flows to The piston releases the multi-disc brakes by over-
the LOW pressure side of the transmission pump in coming the pressure of the twenty one [21] brake
the "closed loop" system. apply springs. The brake shaft, which is splined to
the drive motor cylinder block assembly, is then free
Changing the direction of machine travel will only to turn with the cylinder block assembly.
reverse the direction that the oil, under HIGH and
LOW pressures, will flow. This change will cause the
drive motors to turn in the opposite direction of
rotation, but in the same method as described
above.

2/98 8-33
Section 8
TRANSMISSION SYSTEM
REMOVAL [See Figure 8-26]. e. Fasten a sling and hoist, having a capacity
MORE than 500 lbs. [227 kg], around the circumfer-
ence of the drive motor. Use the hoist to apply
CAUTION: Remove a drive motor assembly from tension to the sling to keep the drive motor in posi-
the machine only after correctly and tion when the retaining screws and nuts are re-
fully checking the drive motor. Use moved.
pressure check and flow rate test
procedures that will indicate internal f. Loosen and remove the eight [8] flange screws
component failures which require the and flanged locknuts, that hold the drive motor to the
drive motor be removed, disas- front frame.
sembled, and inspected.
g. Check to be completely sure that all hoses
requiring disconnection have been disconnected
a. Install SOLID wooden blocks in the front and rear from the drive motor and all hoses and fittings are
of the rear tires. correctly capped or plugged.

h. CAREFULLY lower the drive motor from the

WARNING: Block SECURELY. machine and move the motor to a CLEAN surface, in
a clean work area.

b. Use a floor jack, having a capacity more than WARNING: Do NOT get under the drive motor
10,000 lbs. [4540 kg], to carefully lift each side of the while moving or lowering the drive
front frame, so that the tires just is clear of the floor. motor.
Put SOLID wood blocks, or jack stands, under each
side of the front frame.
DISASSEMBLY [See Figure 8-27].

WARNING: Block securely under the machine

frame area, with SOLID wood blocks CAUTION: ALL capscrews used to fasten the
or jack stands. Keep clear of the components are of the "METRIC
frame sides, blocks or stands and SIZE", and always must be replaced
jacks. When lifting, blocking and and tightened to torques accordingly.
lowering the machine. ALL components [seals, bearings,
springs etc.'] are also "METRIC
SIZED" and must never be replaced
CAUTION: Clean the area around the hydraulic with "standard sized" replacement
components BEFORE loosening and parts.
removal of the hoses.

a. Clean the drive motor again to remove any

c. Remove the inner and outer tires from the drive remaining dirt. Place the drive motor assembly in a
motor to be removed. VERTICAL position with the brake assembly end, of
the drive motor, at the bottom.
d. Put identification tags on all hydraulic hoses that
are connected to the drive motor being removed. b. Put a scribed VERTICAL reference line on the
Disconnect and remove all of the hoses which fasten side of all external bolted together assemblies.
to the drive motors. Put plugs and caps on all hoses
and fittings.
NOTE: BE sure the line is clear for CORRECT
position of assemblies during assembly.

8-34 2/98
 Section 8
TRANSMISSION SYSTEM
c. Loosen and remove the four screws q. Remove and discard the o-ring (5) from the
(30) that fasten the washer (29) to the end of the slewing ring (21).
shaft (19) and remove the washer.
r. Carefully remove the cylinder block (1) and
d. Remove hub (28), o-ring (34) and shims (27) spacer (20). Put the cylinder block on a clean
from the shaft (19). Discard the o-ring. Do not surface for further disassembly and inspection later,
discard the shims. If needed.

e. Remove the thrust ring (33) from the shaft (19) s. Disassemble the secondary/parking brake using
and remove the o-ring (32) from the inside of the the following additional procedures.
thrust ring. Discard the o-ring.

f. Using a press, press the shaft (19) out of the WARNING: The support (46) and slewing plate
drive motor. (21) are under spring pressure. Use
care when removing the screws (48).
g. Remove the 10 screws (26) securing the bearing
support (24) and remove the support.
1. Turn the assembly over and remove twelve
h. Remove the bearing (23) and seal ring (25) from [12] screws (48) secure support (46) to
the inside of the bearing support (24). slewing plate (21).

i. Remove the spring (17) and the valve spool (14) 2. Remove support (46) and twenty one [21]
from valving cover (6). springs (47).

j. Remove the two o-rings (10 and 18) from the 3. Remove the seal (37), bearing (36) and seal
valving cover (6). Discard the o-rings. ring (35) from support (46).

k. Remove the twelve [12] screws (7) securing 4. CAREFULLY remove the brake piston (45)
valving cover (6) and remove the valving cover. from the slewing plate (21), by applying a
small amount or air pressure through the
brake release oil supply port.
CAUTION: Ensure that valve block (11) does not
drop out of valving cover (6) when
removed. WARNING: Keep clear of the brake piston during
removal procedures.
Do NOT use an air supply having
l. If disassembly, inspection and/or replacement of more than 30 psi. [2 bar] of pressure.
valve block seals is needed, use a permanent Use ONLY a small burst of air to
marker to mark the position of the valve block (11) in move the brake piston outward from
relation to the valving cover (6). the bore.

m. Remove the valve block (11) from the valving 5. Remove the two [2] o-rings (42 and 43) from
cover (6). the brake piston (45).

n. Remove and discard the seals (12) from the 6. Remove the internal and external brake discs
inside of the valving cover (6). (39 and 40) alternately from the splined
cavity of the slewing plate (21).
o. Remove and discard the o-ring (5) from the end
of the valving cover (6). NOTE: Keep the internal and external brake
discs in the same order in which they
p. Remove cam ring (4). were installed for easier assembly later.

2/98 8-35
Section 8
TRANSMISSION SYSTEM
INSPECTION [See Figure 8-27]. c. Inspect the outer surface of the rollers, which
contact the cam ring "lobe area", for wear or dam-
a. Carefully wash ALL bearings, housings and other age. Replace ALL roller assemblies, with NEW, if
LARGE components in clean diesel fuel and dry with ANY are found to have wear, or damage. Inspect the
compressed air. roller segments. Replace All segments, with NEW, if
ANY are found to have wear or damage.

CAUTION: Do NOT wash the SMALLER compo-

nents at the same time as when CAUTION: ALWAYS replace the roller guide
washing LARGER components. Items rings, with NEW, if the rollers are
such as internal and external brake replaced with new.
discs MUST be kept in the order of
removal and need to be cleaned in a
method that will keep that order. d. CAREFULLY inspect the roller cam area, of the
Clean and dry these parts separately cam ring (4), for wear, or damage. The area of the
and place back in the SAME position roller cams are induction hardened and must NOT
as they were in, before cleaning, for show evidence of "flaking" or of pieces of metal
CORRECT assembly position later. eroded from the roller cam surfaces. Replace the
COMPLETE assembly IF worn, or damaged.

b. If removed, inspect EACH piston and EACH bore e. CAREFULLY inspect the valving [distributor]
for wear, seizure or damage. Replace any piston that block (11) for any damage which can be noted
is found to be worn, seized or damaged with NEW. visually. Inspect the mating surfaces of the distributor
Replace the complete cylinder block (1) with NEW if block (11) and cylinder block (1) for damage or
ANY piston bore is found to be worn or damaged. scratches. Remove any scratches by polishing OR
replace a part found to be severely damaged.

CAUTION: A COMPLETE failure of the drive f. Inspect the condition of the drive shaft (19) and
motor will usually result in severe its splined areas. There must be NO wear that is able
wear, or damage, to ALL pistons, to be felt with the fingernail on ANY smooth surface
rings and piston bore areas. RE- where the seals mate the drive shaft. The splines
PLACE the COMPLETE cylinder block must NOT indicate fretting, breakage, twisting or
assembly, with new, if the above wear other damage. Replace the drive shaft (19) if worn or
and/or damage is noted. damaged as noted above.

g. CAREFULLY inspect the inner AND outer roller

bearings (23 and 36) for wear, or damage. BOTH
bearings MUST turn freely without ANY binding or
roughness being noted. Replace a bearing found to
be worn, or damaged, with a NEW bearing during
assembly of the drive motor.

8-36 2/98
 Section 8
TRANSMISSION SYSTEM
h. CAREFULLY, visually inspect the condition of the ASSEMBLY [See Figures 8-27].
internal AND external brake discs (39 and 40). The
discs must NOT show evidence of heavy wear, or be
cracked, chipped or broken. Replace ALL discs with CAUTION: ALL capscrews used to fasten the
NEW and keep the SAME order in which they were components are "METRIC SIZE", and
removed, if ANY are found to be worn, or damaged. always must be replaced and tight-
ened to torques accordingly.
ALL components [seals, bearings
NOTE: The internal and external discs MUST, etc.'] are also "METRIC SIZED" and
ALSO, be further checked for correct must never be replaced with "stan-
TOTAL thickness. The TOTAL thickness dard sized" replacement parts.
of ALL the discs must NOT be LESS than
2.047 in. [52 mm] including the 11.7 mm
shim (41). Replace ALL of the internal a. Stand the shaft (19) on end on a CLEAN work
and external discs IF the disc thickness surface. Place the slewing plate (21), upside-down,
is LESS than the ABOVE figure. on the shaft in order to align and center the discs.

b. Oil all the discs.

CAUTION: If the multi-disc brake did NOT hold
the machine, during operation, c. Install the 11.7 mm shim (41), then starting with
BEFORE the drive motor was re- an external brake disc, install the external and
moved, replacement of ALL of the internal brake discs (39 and 40) alternately over the
INTERNAL and EXTERNAL brake shaft (38) and into the slewing plate (21).
discs is a MUST.
Do NOT add shims to compensate d. Put the brake release piston (45), WITHOUT the
for wear to the internal and external o-rings (42 and 43), on the top of the brake discs.
brake discs.
e. Use a press to apply pressure to the piston and
compress the brake discs. Measure the distance
i. CAREFULLY, visually inspect the twenty one [21] from the top of the brake release piston (45) to the
brake apply springs (47) for damage or lack of mounting surface of the slewing plate (21) as shown
tension due to "over heat" conditions. Replace ALL in Figure 8-28.
springs with NEW if ANY are found to be damaged
or show a loss of tension.
NOTE: A force of 220 lbs. [100 kg] is required to
j. CAREFULLY inspect the brake release piston properly compress the assembly for
(45) for damage. Replace the piston with NEW if any measurement.
damage was noted.

2/98 8-37
Section 8
TRANSMISSION SYSTEM
f. Write the measurement found in step "e" on a o. Apply grease in the area between the seals (35
paper and SUBTRACT the amount of 0.535 inches and 37) the bearing (36).
[13.6 mm]. Make a shim pack EQUAL to the amount
found, AFTER the subtraction. p. Grease and install a new o-ring (44) on bearing
support (46).
g. Release the pressure being applied to the piston
and discs by the press. Remove the piston from the q. Place the twenty one [21] springs (47) on the
brake housing bore. piston (45).

r. Position the bearing support (46) on the slewing

plate (21) and install screws (48). Tighten the screws
to a torque of 48 ft. lbs. [5.5 N.m].

s. Put the drive shaft into position, so that it will

install into the front bearing support (46) from the
outer side. Use a press to CAREFULLY install the
drive shaft into the front bearing support housing.

FIGURE 8-28. DETERMINING SHIM PACK.

CAUTION: Do NOT damage the OUTER and
INNER shaft seals (35 and 37) as the
h. Insert the shim pack made in step "f", on top of splines pass through them. Put tape
the last brake disc in the multi-disc stack. around the area of the splines to help
stop possible damage to the seal lips,
i. Put clean hydraulic oil on the NEW o-rings (42 and remove it AFTER the assembly of
and 43) to be installed on the brake release piston the drive shaft into the bearing
(45). Install the o-rings onto the piston. CAREFULLY support housing is complete.
install the brake release piston into the slewing plate
(21).
t. Mount the spacer (20) after coating with Molyb-
j. Remove the shaft (19) from the brake assembly. denum Disulfide grease.

k. Place the bearing cup (36) in the bearing support u. Install the assembled cylinder block (1).
(46). Use an arbor press and a sleeve, having an
outside diameter of 5.83 inches [148 mm], to install v. Grease and install a new o-ring (5) in the groove
the bearing cup into the bearing support. of slewing plate (21).

l. CAREFULLY place the new shaft seal (35) in the w. Install the cam (4) ensuring alignment of the
bearing support (46) and install using a seal installa- marks made during disassembly.
tion tool.
x. Lightly grease the seal grooves in the valving
m. Pack the bearing cone (36) with wheel bearing cover (6).
grease and place in bearing cup (36).
y. Install the seals (12) in their respective grooves
using minimum deformation.
CAUTION: Be SURE the bearing cone is fully
"packed" with grease, as NO other z. Grease and install the springs (13) in the bore of
lubrication is available to the bearing valve block (11).
at this location.
aa. Oil the seal surfaces of valve block (11) and
insert in valving cover (6) ensuring alignment of the
n. CAREFULLY place the new lip seal (37) in the marks made during disassembly.
bearing support (46) and install using a seal installa-
tion tool.

8-38 2/98
 Section 8
TRANSMISSION SYSTEM
ab. Gease and install a new o-ring (5) in the groove an. Determine the thickness of the shim pack (27)
of valving cover (6). using the following additional procedures.

ac. Install valving cover (6) aligning the marks made 1. Replace the 0.118 in. [3.0 mm] shim pack
during disassembly. (29) with a piece of standard resin core
solder.
ad. Insure that the brake port, the two speed port and
the case drain port are all aligned vertically with each 2. Reinstall the hub, washer and old screws.
other. Torque the screws to 116 ft. lbs. [158 N.m].

ae. Install and tighten the twelve [12] screws (7) to a 3. Remove one screw (30). Using a caliper
torque of 215 ft. lbs. [30 N.m]. through this screw hole, measure from the
top of the shaft (19) to the top of the washer
af. Place the bearing cup (36) over the shaft (19) (29). Record this measurement.
and position it against the valving cover (6).
4. Remove the three remaining screws (30), the
ag. Pack the bearing cone (36) with wheel bearing washer (29) and the hub (28).
grease and place in bearing cup (36). Using a press,
preload the bearing (36) with a 20,000 lb. force. 5. Measure and record the thickness of the
solder.

CAUTION: Be SURE the bearing cone is fully 6. Add 0.008 in. [0.20 mm] to the dimension
"packed" with grease, as NO other determined in step 5. This is the amount of
lubrication is available to the bearing shims (27) to be used.
at this location.
ao. Place the shim pack determined above onto the
thrust ring (33).
ah. Mount the shaft seal (25) in bearing support (24).
ap. Place the o-ring (34) around the ledge of hub
ai. Position bearing support against the valving (31). The o-ring will be rolled back into position later.
cover (6). Install the ten [10] screws (26) and torque
to 215 ft. lbs. [30 N.m]. aq. Install the hub (31), the washer (29) and the old
screws (30). Torque the screws to 116 ft. lbs. [158
aj. Install the new o-ring (32) inside thrust ring (33). N.m].

ak. Seal ring (22) should still be in place around ar. Remove two screw (30) [opposite each other].
outside of the thrust ring (33). Using a caliper through these screw holes, measure
from the top of the shaft (19) to the top of the
al. Install the thrust ring (33) onto the shaft (19) and washer (29). This measurement should be the same
press the thrust ring into the bearing support (24) by as the measurement recorded earlier. If not, repeat
hand. steps "am" through "ar".

am. Seat the thrust ring (33) using the following as. Install two new screws (30) and torque to 107 ft.
additional procedures. lbs. [146 N.m].

1. Temporary install a 0.118 in. [3.0 mm] shim at. Remove the two remaining old screws ( 30),
pack (29) on top of thrust washer (33). install two new screw and torque to 107 ft. lbs.
[146N.m].
2. Install hub (28) on the shaft (19). Install the
washer (29) and secure with the old screws au. Roll the o-ring (34) off of hub (28) to cover the
(30). Torque the screws to 57 ft. lbs. [78 N.m]. space between the hub and thrust ring (33).

3. Remove the screws (30), washer (29) and

the hub (28).

2/98 8-39
Section 8
TRANSMISSION SYSTEM
INSTALLATION [See Figure 8-26]. g. Install the inner and outer tires onto the drive
motor and torque the nuts to 188 ft. lbs. [257 N.m].
a. Fasten a sling and a hoist, having a capacity
more than 500 lbs. [114 kg], to the drive motor. h. Follow ALL hydraulic system "pre-start and start
CAREFULLY lift the drive motor and move it into up" procedures as given in THIS section BEFORE
installation position on the front frame. starting the engine.

WARNING: Do NOT get under the drive motor CAUTION: Both drive motor cases MUST be
while lifting, or lowering the drive filled with oil BEFORE the engine is
motor. started. Loosen each air removal
[bleed] screw on each drive motor
and allow each drive motor to be
b. CAREFULLY put the brake end of the drive COMPLETELY filled with oil as the air
motor toward the center of the machine and position is removed. Close each screw when
the mounting flange against the inner surface of the oil appears and is free of air bubbles.
front frame.
i. Check the hydraulic oil level of the reservoir and
c. CAREFULLY align the eight [8] holes in the front add oil if needed [see Section 4 - MAINTENANCE].
frame with the same holes of the drive motor.
j. AFTER ALL system pre-start procedures have
been followed, start the engine and check the
WARNING: Keep the hands CLEAR of the area machine for correct transmission AND secondary/
between the drive motor mounting parking brake system function.
flange and the front frame.

WARNING: Keep ALL personnel, except the

d. Put thread lock, pn 318702, on the threaded area operator, CLEAR of the machine and
of the eight [8] drive motor mounting screws. Install the surrounding area during the initial
the screws through the drive motor and front frame system checks. Be prepared to STOP
into the flange nuts. Tighten the capscrews into the the engine if a system malfunction is
nuts to a torque of 375 ft. lbs. [512 N.m]. noted. IF a problem is noted, Do NOT
start the engine again until it has
e. Remove ALL plugs and caps from the hoses and been corrected.
fittings. Fasten the brake release pressure, low to
high range and case drain hoses to their fitting port
connections on the drum drive motor, as shown by k. Check the hydraulic oil level of the reservoir
the identification tags, and tighten securely. AGAIN and add oil, if needed [see Section 4 -
MAINTENANCE].
f. Remove the caps or plugs from the two [2] high
pressure hoses and the fitting caps from flange
connection ports on the drum drive motors. Connect
the high pressure hoses to the CORRECT outlets on
the drum drive motors, as shown by the identifica-
tion tags, and tighten the flange retaining bolts
securely.

8-40 2/98
 Section 8
TRANSMISSION SYSTEM
DRIVE MOTOR PRESSURE AND FLOW b. Wash the area around the straight fitting on the
CHECKS. drive motor, where EACH drive motor RETURN oil
hose is connected, with CLEAN diesel fuel and dry
CHECKING PROCEDURES. with compressed air.

The following information describes the different drive MOTOR CASE

motor pressure check locations, pressure gauge PRESSURE
CHECK
sizes needed and correct pressures.

CAUTION: The hydraulic system oil MUST be at

"NORMAL OPERATING" temperature
and at the correct level BEFORE ANY
pressure check or flow rate is taken.
The engine throttle is to be in the
"HIGH" idle position for ALL checks.

CASE PRESSURE [See Figure 8-30].

The case PRESSURE of the drive motors can be

checked by using the following procedures:
FIGURE 8-30. DRIVE MOTOR CASE PRESSURE
a. Close the needle valve located below the sole- CHECK LOCATION.
noid valve [See Figure 8-29].
c. Loosen, and then remove, the drive motor case
drain hose at the straight fitting installed in the drive
NOTE: The brakes are now set in the drive motor case. Install a correct size "tee" fitting, having
motors and can not be released with the a #4 gauge port, between the case drain hose fitting
switch on the dash unless the needle and the straight fitting installed into the drive motor
valve in manually opened [CCW]. This case. Connect a 100 psi. [7 bar] pressure gauge, on
condition is necessary to accurately a long hose, to the #4 fitting on the "tee" and tighten
setup and inspect the unit. securely. Place the gauge in the operator's compart-
ment, so that the operator can note the pressure
indicated, during the pressure check procedures.
SOLENOID
[STACKED]
VALVE DANGER: Keep ALL personnel, except the
NEEDLE operator, CLEAR of the MACHINE
VALVE
and the surrounding AREA during
the "pressure check" procedures.
Maximum system pressures will be
BRAKE PILOT developed.
PRESSURE
CHECK POINT

d. Start the engine. Put the TRANSMISSION

RANGE selector switch in the "LOW" range position.
Put the engine throttle lever in the "HIGH" idle
position. Move the direction control handlever to the
FULL FORWARD position and note the highest
case pressure indicated on the pressure gauge.

FIGURE 8-29. BRAKE NEEDLE

VALVE LOCATION.

2/98 8-41
Section 8
TRANSMISSION SYSTEM
e. Move the direction control handlever to the FULL a. Close the needle valve located below the sole-
REVERSE position and note the highest case noid valve [See Figure 8-29].
pressure indicated on the pressure gauge for this
direction. Move the direction control handlever to the
NEUTRAL position. Slow and then stop the engine. NOTE: The brakes are now set in the drive
motors and can not be released with the
switch on the dash unless the needle
CAUTION: The case pressure indicated should valve is manually opened [CCW]. This
be the SAME in BOTH directions. The condition is necessary to accurately
MAXIMUM allowable pressure is 20 setup and inspect the unit.
psi. [1.4 bar]. The NORMAL pressure
during operation, with the system at b. Wash the area around the straight fitting on the
operating temperature is 10 psi. [0.7 drive motor, where EACH drive motor RETURN oil
bar]. hose is connected, with CLEAN diesel fuel and dry
with compressed air.

NOTE: A case pressure ABOVE the given MAXI- MOTOR CASE

MUM pressure can be an indication of FLOW CHECK
drive motor internal high pressure leak-
age due to worn, or damaged, parts
which can reduce the efficiency of the
drive motor. A further check of the drive
motor case flow AMOUNT, using the
procedure given in THIS section, and
"overall" machine performance can
confirm the loss of efficiency. Repeat the
process for the other drive motor.

f. If the pressures were CORRECT, loosen and

remove the pressure gauge, and hose from its
connection to the hose coming from the drive motor.
Loosen and remove the "tee" fitting. Connect the FIGURE 8-31. DRUM DRIVE MOTOR CASE FLOW
case drain RETURN oil hose to the straight fitting CHECK LOCATION.
and then tighten securely.
c. Loosen the drive motor case drain RETURN oil
g. Check the oil level in the hydraulic oil reservoir. hose and remove it from the fitting. Put a plug in the
Add oil, if needed [see Section 4 - MAINTENANCE]. hose fitting. Install a short hose onto the straight
fitting and tighten securely.
h. Put the secondary/parking brake system control
switch "ON" [APPLIED].
WARNING: Keep ALL personnel, except the
i. Open the needle valve out [CCW] to its stop. operator, CLEAR of the MACHINE and
the surrounding AREA during the
"flow check" procedures.

CASE DRAIN FLOW AMOUNT

[See Figure 8-31]. CAUTION: NEVER seal the case drain port in a
drive motor. SEVERE drive motor
Use the following procedures to check the amount of damage can result if case flow and
case drain flow from the drive motors. pressure are NOT permitted an
OUTLET path.

8-42 2/98
 Section 8
TRANSMISSION SYSTEM
d. Put the OPEN end of the short installed hose into i. To check case drain flow for the second drive
a measuring container. motor repeat steps "a" through "h".

j. Loosen, and then remove the hose installed onto

NOTE: A flow meter can be installed into the line the straight fitting. Remove the plug from the case
between the straight motor fitting and the drain return oil hose. Install, and then tighten, the
case drain return oil hose as an alternate drive motor RETURN oil hose onto the straight fitting.
method of checking the flow amount.

NOTE: If installed, loosen and then remove, the

e. Start the engine. Put the transmission RANGE flow meter from the line between the
selector switch in the "LOW" range position. Put the motor straight fitting and the return oil
engine throttle in the "HIGH IDLE" position. hose. Install, and then tighten, the return
oil hose onto the straight fitting.
f. Move the direction control handlever to the FULL
FORWARD position for a period of FIFTEEN [15]
seconds. Move the direction control handlever back k. Check the oil level in the hydraulic oil reservoir.
to the NEUTRAL position and put the throttle in the Add oil, IF needed [see Section 4 - MAINTENANCE].
"LOW IDLE" position.
l. Put the secondary/parking brake system control
g. CAREFULLY measure the AMOUNT of hydraulic switch "ON" [ APPLIED].
oil held in the measuring container.
m. Open the needle valve out [CCW] to its stop.

CAUTION: While under load for a fifteen [15]

second time period, the MAXIMUM
amount of case drain oil from ONE LOW TO HIGH RANGE PILOT PRESSURE
drive motor must NOT be MORE than [See Figure 8-32].
ONE [1] quart [.95 liter].
Hydraulic oil pressure is needed to move the pilot
spool, in EACH of the drive motor valving blocks. This
h. Empty the collected oil from the container. Put will reduce, by one half, the "usable" displacement of
the hose back into the container. Repeat steps "f" the drive motors and thereby causes the "HIGH"
and "g", with the directional control handlever in the speed range mode.
FULL REVERSE position. Move the direction control
handlever back to the NEUTRAL position and put the Use the following procedures to check the high
throttle in the "LOW IDLE" position and run the range pilot pressure supply to EACH drive motor.
engine for a period of 3-5 minutes. STOP the
engine. a. Put the secondary/parking brake system control
switch "ON". Stop the engine.

NOTE: The amount of case drain oil collected b. Close the needle valve located below the
should be the SAME as that collected in solenoid valve [See Figure 8-29].
the forward direction. Combined case
flow amounts ABOVE the MAXIMUM flow
amount can be an indication of drive NOTE: The brakes are now set in the drive
motor internal high pressure oil leakage motors and can not be released with the
due to worn or damaged parts which can switch on the dash unless the needle
reduce the efficiency of the drive motor. valve is manually opened [CCW]. This
A further check of the flow amount of condition is necessary to accurately
EACH drive motor and the "overall" setup and inspect the unit.
machine performance can confirm the
loss of efficiency.

2/98 8-43
Section 8
TRANSMISSION SYSTEM
c. Wash the area around the straight fitting on the f. Note the pressure indicated on the pressure
drive motor, where the pilot oil supply hose is con- gauge. Put the engine throttle lever in the "LOW" idle
nected, with CLEAN diesel fuel and dry with com- position and run the engine for a period of 3-5
pressed air. minutes. Stop the engine.

d. Loosen and remove the pilot oil supply hose from

the fitting. Install and tighten a CORRECT type "tee NOTE: The charge pressure indicated on the
fitting" onto the open fitting. Install and tighten the pressure gauge MUST be a minimum of
pilot oil supply hose onto one [1] port of the installed 270-350 psi. [19-24 bar]. This pressure
"tee fitting". Install and tighten a 600 psi. [41 bar] will move the pilot spool and permit
pressure gauge, on a long hose, onto the remaining complete shift in range from "LOW" to
port of the "tee fitting". "HIGH".

HIGH RANGE
PILOT PRESSURE g. Loosen and remove the pressure gauge supply
CHECK hose from the "tee" fitting. Loosen and remove the
pilot oil supply hose from the "tee" fitting. Remove
the "tee" fitting. Install and tighten the pilot oil supply
hose onto the fitting installed into the drive motor.

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

Add oil, if needed [see Section 4 - MAINTENANCE].

i. Put the secondary/parking brake system control

switch "ON" [APPLIED].

j. Open the needle valve out [CCW] to its stop.

FIGURE 8-32. DRIVE MOTOR HIGH RANGE PILOT BRAKE SYSTEM RELEASE PILOT PRES-
PRESSURE CHECK LOCATION. SURE [See Figure 8-33].
e. Start the engine. Put the transmission speed The hydraulic oil pressure needed to move the brake
range switch in the "HIGH" range position. Put the release piston and release the multi-disc brakes, in
engine throttle lever in the "HIGH" idle position. BOTH drive motors, can be checked using the
following procedures:
NOTE: NO pilot oil will flow from the high range
port, on the drive motor, IF the transmis- DANGER: Keep ALL personnel, except the
sion speed range switch is in the "LOW" operator, CLEAR of the area around
range position. NO pressure will be the machine while checking the
indicated on the pressure gauge. brake system holding capacity. DO
NOT operate, or check, a machine IF
it can be moved forward, or back-
ward, WHILE the brake system is in
the "ON" [APPLIED] condition.
Repair the malfunction IMMEDI-
ATELY.

8-44 2/98
 Section 8
TRANSMISSION SYSTEM
The capped brake system release pilot pressure d. Put SOLID wood blocks in the front, and at the
check port is located below the needle valve located rear, of the drive tires. Start the engine. Keep the
below the "solenoid [stacked] valve". direction control handlever in the NEUTRAL posi-
tion. Put the throttle in the "LOW IDLE" position. Put
a. Place the machine on a LEVEL surface. Put the the secondary/parking brake system control switch
secondary/ parking brake system control switch in the "OFF" [RELEASED] position. Note the
"ON" [APPLIED]. Stop the engine. pressure indicated on the pressure gauge.

b. Clean the capped brake system release pilot

pressure check port with CLEAN diesel fuel and dry WARNING: Block SECURELY with SOLID wood
with compressed air. blocks. The blocks MUST hold and
keep the machine from ANY move-
c. Remove the cap fitting from the tee fitting and ment.
install and tighten a 600 psi. [41 bar] pressure
gauge, on a long hose.
NOTE: NO brake release oil will flow from the
outlet port of the "solenoid [stack]
SOLENOID
[STACKED]
valve" IF the secondary/parking brake
VALVE system control switch is in the "ON"
NEEDLE [APPLIED] position. NO pressure will be
VALVE indicated on the pressure gauge.
The hydraulic oil pressure needed to
FULLY release the multi-disc brakes, in
BRAKE PILOT the drive motors, MUST be above 175
PRESSURE psi. [12 bar] MINIMUM and below 435
CHECK POINT psi. [30 bar] MAXIMUM.

e. Put the secondary/parking brake system control

switch in the "ON" [APPLIED] position. CARE-
FULLY remove the blocks from in front, and at the
rear, of the drive tires. Put the direction control
handlever in the FULL FORWARD position. Note
FIGURE 8-33. BRAKE SYSTEM RELEASE PILOT that the machine can NOT be moved against the
PRESSURE CHECK LOCATION. brake system. Repeat this procedure with the
machine direction control in the FULL REVERSE
position, and note the SAME brake system perfor-
mance. Put the engine throttle lever in the "LOW
IDLE" position and run the engine for a period of 3-
5 minutes. Stop the engine.

f. Loosen and remove the pressure gauge supply

hose from the "tee" fitting. Reinstall the plug fitting.

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

Add oil, if needed [see Section 4 - MAINTE-
NANCE].

2/98 8-45
Section 8
TRANSMISSION SYSTEM
CLEANING THE HYDRAULIC SYSTEM [See 9. Oil suction filter.
Figure 8-2].
10. Oil cooler assembly.

CAUTION: Dirt of ANY type WILL shorten the 11. "Shuttle [flushing] valve".
service life of the transmission, and
steering system components or
cause the components to fail. If a NOTE: See the Section, in THIS manual, which
failure occurs in the transmission or covers EACH major component for
steering system, it is BEST to DISAS- removal, disassembly, inspection assem-
SEMBLE, CLEAN and then AS- bly and installation information.
SEMBLE the ENTIRE hydraulic
system.
CAUTION: Replace ALL components with the
SAME type and part number IF
Use the following procedures to CLEAN the ENTIRE replacement is needed. ALWAYS
hydraulic system IF a component failure HAS replace the suction oil filter element,
occurred: with NEW, BEFORE filling the oil
reservoir with NEW, CLEAN AND
a. Drain the hydraulic oil reservoir of oil [see FILTERED hydraulic oil.
Section 4 - MAINTENANCE].

c. Fill the hydraulic oil reservoir with NEW, CLEAN

WARNING: Drain when warm or cool ONLY. Hot and FILTERED hydraulic oil [see Section 4 - MAIN-
oil can cause serious injury. TENANCE].

b. Remove, disassemble, CLEAN, repair, assemble CAUTION: Also, fill the suction filter and hose
or replace and install the following system compo- between filter and pump [see Section
nents AFTER a component failure: 4 - MAINTENANCE].

1. Hydraulic oil reservoir.

d. Precharge the hydraulic system using the
2. Transmission pump assembly. "HYDRAULIC SYSTEM PRE-START PROCE-
DURES" found in THIS Section.
3. Transmission drive motors.

4. Steering pump assembly. CAUTION: Do NOT start the engine UNTIL ALL
pre-start procedures have been
5. Steering control unit. followed. Any dirt or contamination
remaining in the hydraulic system
6. Steering cylinder. can cause a repeat failure in the
system. Partial, or incomplete, clean-
7. "Solenoid [Stack] valve" assembly. ing is NOT good enough. COMPLETE
system disassembly, and FULL
8. ALL pressure AND return hose assemblies cleaning is the ONLY acceptable
and fittings. method of hydraulic system service.

8-46 2/98
 Section 8
TRANSMISSION SYSTEM
HYDRAULIC SYSTEM PRE-START PROCE- e. Put the secondary/parking brake system control
DURES [See Figure 8-2]. switch in the "ON" [APPLIED] position. Put the
direction control handlever in the "NEUTRAL"
Use the following pre-start procedures to help to position. Put the engine throttle in the "LOW IDLE"
insure that ALL components are full of hydraulic oil position.
BEFORE the engine is started. Use these proce-
dures ANY time the system has been "opened" and f. Crank the engine, while an assistant watches the
a component has been removed and installed back charge pressure being indicated on the pressure
into the system. gauge. Continue to crank the engine UNTIL there IS
charge pressure of 100 psi. [7 bar] MINIMUM
indicated on the pressure gauge. Stop cranking the
CAUTION: Do NOT permit the engine to be engine.
started UNTIL ALL pre-start proce-
dures have been followed and it is
certain ALL hydraulic system compo- CAUTION: Do NOT crank the engine for more
nents have been FILLED with oil. than 30 seconds continuously. Wait
Severe damage to system compo- one [1] minute between engine
nents can occur IF filling has NOT cranks to allow the starter motor time
been completed. to cool.

a. Check ALL hydraulic hose to fitting connections NOTE: THIS procedure WILL "precharge" the
to be sure they are tightened correctly. Tighten again hydraulic system with oil BEFORE the
as needed. engine is started.

b. Fill the hydraulic oil reservoir with NEW, CLEAN

and FILTERED hydraulic oil [see Section 4 - MAIN- g. Loosen the hose fitting, that connects to the
TENANCE]. secondary/parking brake port fitting of ONE [1] drive
motor, a SMALL amount. Hydraulic oil MUST be
c. Disconnect the electrical wire FROM the engine present and "leak" at the fitting. If oil was present at
fuel shut off solenoid. Put electrical tape on the the fitting, securely tighten the hose fitting onto the
terminal of the wire, removed from the solenoid, to secondary/parking brake port fitting. Repeat the
prevent it from touching the engine and ground. SAME procedure at the SECOND drive motor.

NOTE: DISCONNECTING the wire from the fuel CAUTION: If NO oil was present, check the oil
shut off solenoid will keep the engine fuel level in the hydraulic oil reservoir.
shut off valve in the "OFF" position when Add oil IF needed. REPEAT the
the engine is cranked. Cranking the TOTAL "precharge" procedure to
engine will rotate the hydraulic pumps to produce the needed oil filling of ALL
develop oil flow and fill the hoses and components.
other system components with oil.

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

d. Wipe the charge pressure check port cap with a Add oil as needed [see Section 4 - MAINTENANCE].
CLEAN cloth. Loosen and remove the cap from the
charge pressure check port fitting. Install and tighten
a 600 psi. [41 bar] pressure gauge, on a short hose, NOTE: Leave the pressure gauge and hose
onto the pressure check port fitting. connected to the charge pressure check
port UNTIL the "after start" pressure
check of the charge pressure is com-
plete. Then remove the hose and pres-
sure gauge assembly, from the pressure
check port, and install and tighten the
cap onto the fitting.

2/98 8-47
Section 8
TRANSMISSION SYSTEM
i. Remove the electrical tape from the electrical d. Put the engine throttle in the "LOW" idle position
wire that fastens to the engine fuel shut off solenoid. and run the engine for a period of 3-5 minutes.
Install the wire onto the solenoid terminal and tighten STOP the engine. Loosen and remove the cap from
the nut securely. the pressure check port fitting, found on the steering
pump located on the LH side of the engine. Install
and tighten a 3,000 psi. [210 bar] pressure gauge, on
a short hose, onto the pressure check port for
HYDRAULIC SYSTEM START UP PRESSURE steering.
CHECKS.

Use the following information to check the different DANGER: Keep ALL personnel CLEAR of the
system pressures at "hydraulic system start up" and area between the front and the rear
help to determine IF a system is operating at the frames. Clearance CLOSES in ANY
CORRECT pressure. turn.

WARNING: Keep ALL personnel, except the e. Start the engine. Put the engine throttle in the
operator, CLEAR of the MACHINE and "HIGH" idle position. Turn the steering wheel to the
the surrounding AREA during the left or right position and have an assistant note the
"pressure check" procedures. steering pressure at relief, indicated on the pressure
gauge. Put the throttle in the "LOW" idle position and
run the engine for a period of 3-5 minutes. Stop the
a. Close the needle valve located below the sole- engine.
noid valve [See Figure 8-33].

NOTE: The brakes are now set in the drive CAUTION: The pressure indicated on the gauge
motors and can not be released with the must NOT go above a MAXIMUM
switch on the dash unless the needle pressure of 2,250 +/-50 psi. when the
valve is manually opened [CCW]. This system relief pressure was noted. IF
condition is necessary to accurately an incorrect pressure is noted [See
setup and inspect the unit. Section 10 - STEERING SYSTEM in
this manual].

f. Remove the hose and pressure gauge from the

b. Install the steering lock pin at the steering pressure check port fitting and install and tighten the
cylinder. cap onto the check port fitting.

c. Start the engine. Put the engine throttle in the g. Check the high system pressure in BOTH the
"HIGH" idle position. Check the NEUTRAL charge forward and reverse directions of machine travel
pressure indicated on the pressure gauge. Check for using the procedures given in THIS Section [see
ANY hydraulic system leaks. "Pressure Limiter And High Pressure Relief Valve
Pressure Check And Adjustment", found under the
transmission pump pressure check information].
CAUTION: The pressure indicated on the pres-
sure gauge MUST be between 350-400 h. Open the needle valve [CCW] to its stop.
psi. [24-28 bar]. STOP the engine
IMMEDIATELY if NO or LOW charge
pressure OR any system leaks are
noted. Do NOT start the engine again
UNTIL any problem noted has been
corrected.

8-48 2/98
 Section 8
TRANSMISSION SYSTEM
TROUBLE ANALYSIS FOR THE TRANSMISSION SYSTEM

TRANSMISSION PUMP

PROBLEM CAUSE CORRECTION

MACHINE DRIVES WITH Pump not in neutral [stroked] Check linkage at pump
TRAVEL CONTROL LEVER IN displacement control for correct
NEUTRAL fork to arm alignment.
Adjust control cable if needed.

Pump mechanical neutral (0) Check the mechanical

position NOT correct neutral position.

Pump hydraulic (0) position NOT Check the hydraulic neutral

correct position.

Displacement control has Replace displacement control

damage with new.

Transmission pump worn, or Replace transmission pump

damaged with new.

MACHINE WILL NOT OPERATE Secondary/parking brake system Release brake system.
IN EITHER DIRECTION "on".

Secondary/parking brake system Open needle valve [CCW] to its

needle valve closed stop.

Solenoid coil not energized, or Check electrical circuit for

is damaged current flow. Repair circuit, if
needed. Check solenoid for
operation. Replace with new, if
damaged.

Hydraulic system oil level low Check oil level in reservoir. Add
oil. Find and correct cause of low
oil level.

Pump control linkage damaged or Repair, or replace, control linkage

linkage not connected to the
transmission pump.

Both transmission charge Remove, inspect, clean or

pressure check valves in "open" replace as needed.
position.

Air being drawn into the system Check all fittings and hoses for
correct tightness. Tighten as
needed.

Cold, or wrong oil in system Permit system to warm. See

Section 4 for correct oil.

2/98 8-49
Section 8
TRANSMISSION SYSTEM

TROUBLE ANALYSIS FOR THE TRANSMISSION SYSTEM

TRANSMISSION PUMP
PROBLEM CAUSE CORRECTION

MACHINE WILL NOT OPERATE Both "multi-function valves in Remove, inspect clean, adjust
IN EITHER DIRECTION open position or replace and adjust valves.
[continued]
Drive motors damaged Remove, repair, or replace,
motors.

MACHINE OPERATES IN ONE Transmission pump linkage has Check control system for
DIRECTION ONLY damage connection, binding or missing
parts. Correct and adjust as
needed.

Displacement control valve Replace valve with new.

damaged

One charge pressure check valve Identify check valve. Remove,

[in multi-function valve] damaged clean, or replace, as needed.

Drive motors damaged Remove motors. Repair, or

replace as needed.

Hoses carrying "high" pressure in Locate "stopped" hose. Remove,

a "stopped" condition clean, or replace, as needed.

NEUTRAL POSITION DIFFICULT Pump control linkage has Check control system for
OR NOT ABLE TO BE damage connection, binding or missing
FOUND parts. Correct and adjust as
needed.

Displacement control valve Replace valve with new.

damaged

Transmission pump displacement Adjust control cylinder or

control cylinder not adjusted replace and adjust cylinder as
correctly or is damaged needed.

SYSTEM OPERATES IN A "HOT" Hydraulic system oil level "low" Check oil level in reservoir. Add
CONDITION oil. Find and correct cause of low
oil level.

"Stopped" suction oil filter Replace filter element with new.

element

System being operated over at a Eliminate cause of excessive

pressure over "high" relief pressure or adjust "high" relief
pressure setting.

8-50 2/98
 Section 8
TRANSMISSION SYSTEM

TROUBLE ANALYSIS FOR THE TRANSMISSION SYSTEM

TRANSMISSION PUMP

PROBLEM CAUSE CORRECTION

SYSTEM OPERATES IN A Pump has internal leakage Remove, inspect, repair or

"HOT" CONDITION replace pump.
[continued]
CAUTION: Clean the entire
hydraulic system
AFTER a failure.

TRANSMISSION PUMP AND Hydraulic system oil level low Check oil level in reservoir. Add
SYSTEM NOISY DURING oil. Find and correct cause of low
OPERATION oil level.

Hose or fitting loose, allowing air Check all fittings and hoses for
to be drawn into the system correct tightness. Tighten as
needed.

Pump has internal wear or Remove, repair or replace

damage pump

CAUTION: Clean the entire

hydraulic system
AFTER a failure.

Hoses not correctly insulated from Check hose routings. They must
vibration or not positioned as not touch any metal that can
needed increase natural hydraulic
system "hum".

MACHINE ACCELERATION Air being drawn into system See " System Noisy During
AND/OR DECELERATION Operation - Air In System".
SLOW
Low charge pressure Adjust charge pressure to
correct amount. Disassemble,
repair or replace charge pump
and then adjust, if needed.

Displacement control valve orifice Remove displacement control

partially "stopped" valve. Remove, clean or replace
orifice. Install control valve.

Pump has internal wear or Remove and repair or replace

damage pump as needed.

Machine being operated in "HIGH" Put switch in "LOW" range

transmission speed range position.

2/98 8-51
Section 8
TRANSMISSION SYSTEM

TROUBLE ANALYSIS FOR THE TRANSMISSION SYSTEM

TRANSMISSION PUMP

PROBLEM CAUSE CORRECTION

MACHINE ACCELERATION Engine not operating at correct Set engine at correct "high" idle
AND/OR DECELERATION speed - low RPM RPM.
IS SLOW [continued]

High pressure relief valve open or Remove, inspect, clean or

damaged replace valve as needed. Check
pressure adjustment.

TRANSMISSION MOTORS

PROBLEM CAUSE CORRECTION

DRIVE MOTORS WILL Secondary/parking brake system Release brake system.

NOT ROTATE IN EITHER "on"
DIRECTION
Secondary/parking brake system Open needle valve [CCW] to
needle valve closed its stop.

Wires to secondary/parking brake Check wire connections and

system switch reversed change as needed.

Hydraulic system oil level low Check oil level in reservoir. Add
oil. Find and correct cause of
low oil level.

No output from transmission pump See "Machine Will Not Operate

In Either Direction" - in the
Transmission Pump "Trouble
Analysis".

Secondary/parking brakes on Check brake release hydraulic

drive motors NOT releasing pilot pressure. Check release
piston operation on motors.
Repair or replace components
as needed. Repair or replace
components needed.

Drive motors have damage Remove, repair or replace

motors with new as needed.

CAUTION: Clean the entire

hydraulic system
AFTER a failure.

8-52 2/98
 Section 8
TRANSMISSION SYSTEM

TROUBLE ANALYSIS FOR THE TRANSMISSION SYSTEM

TRANSMISSION MOTORS

PROBLEM CAUSE CORRECTION

DRIVE MOTORS WILL Pump displacement control Adjust control linkage or

ONLY ROTATE IN ONE linkage not adjusted correctly, or replace damaged linkage and
DIRECTION ONLY is damaged then adjust correctly.

Displacement control valve has Replace control valve with new.

damage

Both motors have internal damage Remove, repair or replace

motors with new.

Hoses carrying "high" pressure Remove hoses. Clean or

oil for direction NOT rotating replace as needed.
"stopped"

DRIVE MOTORS OPERATING Excessive loading of hydraulic Reduce system loading. Put
IN A "HOT" CONDITION system - operating in "HIGH" speed range switch in "LOW".
range

Low oil flow reaching drive See "TRANSMISSION PUMP"

motor[s] from transmission pump - "System Operates In A Hot
Condition".

Incorrect type oil used in Drain and flush system. Fill

hydraulic system with correct type oil
[see Section 4].

Motor[s] have internal damage Remove motor[s] and repair, or

replace, with new as needed.

CAUTION: Clean the entire

hydraulic system
AFTER a failure.

DRIVE MOTORS WILL NOT Speed range electrical control Check circuit for current flow.
CHANGE FROM LOW TO circuit has no current flow Correct electrical circuit
MEDIUM AND/OR HIGH problems as needed [see
TRANSMISSION SPEED Section 7 - ELECTRICAL].
RANGE
Speed range selector switch Remove and replace switch
damaged with new.

Valve solenoid(s) damaged Remove and replace solenoid(s)

with new.

2/98 8-53
Section 8
TRANSMISSION SYSTEM
TROUBLE ANALYSIS FOR THE TRANSMISSION SYSTEM

TRANSMISSION MOTORS

PROBLEM CAUSE CORRECTION

DRIVE MOTOR WILL NOT Low or no charge pilot pressure Check charge pilot pressure to,
CHANGE FROM LOW TO flowing to the drive motor and from, speed range selector
MEDIUM AND/OR HIGH valve. Correct cause of low or
TRANSMISSION SPEED no charge pressure as needed.
RANGE [continued]

Speed range change spool, in Remove motor. Clean and free

drive motor, "stuck" or damaged spool or replace spool with new.

DRIVE MOTORS MULTI-DISC BRAKES

PROBLEM CAUSE CORRECTION

BRAKES WILL NOT RELEASE Electrical circuit has no current Check circuit for current flow and
flow repair as needed [see Section
7 - ELECTRICAL].

Secondary/parking brake system Open needle valve [CCW] to

needle valve closed its stop.

Secondary/parking brake system Remove and replace switch

control switch damaged with new.

Brake valve solenoid damaged Remove and replace solenoid.

Low, or no, charge pilot pressure Check charge pilot pressure to,
flowing from brake valve to brake and from, brake valve. Correct
release pistons cause of low or no charge
pressure as needed.

Brake release pistons, or seals, Remove motor. Disassemble

worn or damaged and inspect brake parts.
Replace worn or damaged
parts as needed.

BRAKES WILL NOT APPLY Secondary/parking brake system Remove and replace switch
control switch shorted with new.

Charge pilot pressure being Check for correct brake release

supplied to both brake release oil supply hoses routing. Change
pistons at all times routing if needed.

Brake release valve damaged - Remove and replace valve with

spool in open flow position new.

Multi-disc brakes worn or Replace ALL discs with new.

damaged

8-54 2/98
 Section 8
TRANSMISSION SYSTEM
TROUBLE ANALYSIS FOR THE TRANSMISSION SYSTEM

DRUM DRIVE MOTORS MULTI-DISC BRAKES

PROBLEM CAUSE CORRECTION

BRAKES WILL NOT APPLY Brake release pistons remaining Remove release pistons.
[continued] in release position Inspect seals and pistons.
Replace parts as needed.

Brake application springs Remove springs and replace

have reduced tension or with new.
other damage

BRAKES WILL NOT HOLD Multi-disc brakes worn or Replace ALL discs with new.
MACHINE WHEN APPLIED damaged

Brakes not shimmed correctly Shim brakes to correct

specifications.

Brake application springs Remove springs and replace

have reduced tension or with new.
other damage

Brake release pistons not fully Remove motors. Disassemble

returning to the retracted position and inspect pistons and seals.
when brakes are applied Replace damaged parts with
new.

2/98 8-55
Section 8
TRANSMISSION SYSTEM
NOTES

8-56 2/98
 Section 9
BRAKE SYSTEM

TABLE OF CONTENTS

PAGE

GENERAL INFORMATION ...................................................................................................................... 9-2

DYNAMIC BRAKING ............................................................................................................................... 9-2

OPERATION ......................................................................................................................................... 9-2

SECONDARY/PARKING BRAKE SYSTEM ............................................................................................ 9-2

OPERATION ......................................................................................................................................... 9-2

SECONDARY/PARKING BRAKE SYSTEM SOLENOID VALVE .......................................................... 9-4

REMOVAL AND REPLACEMENT ....................................................................................................... 9-4

2/98 9-1
Section 9
BRAKE SYSTEM
GENERAL INFORMATION [See Figure 9-1]. WARNING: When approaching, and then travel-
ing down, a slope use a slow speed
This section describes the operation of the "dy- with the transmission speed range
namic" [hydrodynamic, through the transmission control switch in the low speed
system] and the "secondary/parking" [spring applied range.
in each drive motor] braking systems. Additional slowing of the machine is
done by moving the directional
"Secondary/parking" brake components are included control [F-N-R] handlever past
in each drive motor assembly. Repair procedures for neutral, to the direction OPPOSITE
the "secondary/parking" brake system components the direction of machine travel.
are included in the drive motor disassembly, inspec- The secondary/parking brake system
tion and assembly procedures found in Section 8 - MUST be used to hold the machine
TRANSMISSION SYSTEM, of this manual. in a “stopped” condition at all times.
The transmission system, used for
Removal and replacement of the "secondary/ the “dynamic” braking of the ma-
parking" brake system solenoid valve is described in chine, WILL NOT hold and keep the
this Section. machine in a “stopped” condition.

Trouble analysis for the "secondary/parking" brake

system is found in the rear of Section 8 - TRANS- NOTE: Repair of the "dynamic" braking system
MISSION SYSTEM, of this manual. is done through service to the transmis-
sion system [See Section 8 - TRANSMIS-
SION SYSTEM].

DYNAMIC BRAKING.

OPERATION. SECONDARY/PARKING BRAKE SYSTEM.

During operation, slowing, or stopping, of the OPERATION [See Figure 9-1].

machine is done by using the "dynamic" transmis-
sion system. Control of the transmission system is The "secondary/parking" brake system is used to
through the directional control [F-N-R] handlever, hold the machine in a “stopped” condition after it has
found on the rear of the operator's compartment. been stopped through the use of "dynamic" braking.
During machine operation, moving the handlever During machine operation the system will, also, be in
from either the forward, or reverse, position to the an “applied” condition if the machine has a loss of
neutral position causes the oil flow through the transmission system charge and/or control pressure,
transmission system to be reduced and/or then loss of electrical current or if there is a stoppage of
stopped. This slows, and then stops, the machine. the engine.

9-2 2/98
 Section 9
BRAKE SYSTEM

TO OIL
RESERVOIR

SECONDARY/
PARKING BRAKE
SOLENOID

TRANSMISSION
LOW/HIGH RANGE
SOLENOIDS FROM CHARGE
PUMP

RH DRIVE
MOTOR

LH DRIVE
MOTOR

FIGURE 9-1. SECONDARY/PARKING BRAKE SYSTEM - RELEASE OIL FLOW PATH.

Control of the secondary/parking brake system is Putting the secondary/parking brake system control
accomplished by using the secondary/parking brake switch in the “OFF” [RELEASED] position will cause
control switch found on the control console. Putting the solenoid to move the spool in the solenoid valve,
the secondary/parking brake control switch in the permitting the supply of charge pressure oil to the
“ON” [APPLIED] position will cause a spring to move secondary/parking brake release piston in each drive
the spool in the solenoid valve, releasing the charge motor. The brake release piston will move outward,
pressure oil at the release piston in each drive compressing the large application washer and
motor. Oil from each brake release piston is then release the multi-disc brakes on each drive motor.
directed to the hydraulic oil reservoir. The large
application washers will then put the multi-disc
brakes in the “ON” [APPLIED] condition. NOTE: Inspection, and repair as needed, of the
secondary/parking brake system MUST
be done when the drive motors are
WARNING: The machine MUST NOT move, at removed from the machine.
ANY time, when the secondary/ Remove, inspect and replace secondary/
parking brake control switch is in the parking brake parts, as needed, using
“ON” position. the information given under the drive
DO NOT operate the machine, if the motor “Repair procedures”, in the
machine will move when the second- TRANSMISSION SYSTEM Section, at that
ary/parking brake system is in an time. See Section 7 - ELECTRICAL - for
“ON” [APPLIED] condition. secondary/parking brake system electri-
Notify repair personnel and repair cal circuit operation descriptions.
the machine IMMEDIATELY.

2/98 9-3
Section 9
BRAKE SYSTEM
SECONDARY/PARKING BRAKE SYSTEM c. Loosen and remove the solenoid retaining nut,
SOLENOID VALVE. found at the top of the solenoid.

REMOVAL AND REPLACEMENT [See Figure d. CAREFULLY lift the solenoid from the valve
9-2]. body.

Use the following procedure to remove and replace e. CAREFULLY install the NEW solenoid onto the
the secondary/parking brake system solenoid, found valve body.
on the solenoid valve.
f. Install and tighten the solenoid retaining nut to
securely hold the solenoid to the body.
NOTE: Use the SAME procedure, as given
below, to remove and replace the L.H.
and R.H. transmission low/high range CAUTION: Do NOT overtighten the retaining
solenoid, which also is found on the nut.
solenoid valve. All three solenoids are
the same and are able to be exchanged.
g. CAREFULLY connect the single wire to the
solenoid.
a. Stop the engine. Wash the solenoid and valve
body with CLEAN diesel fuel and dry with com- h. Start the engine. Check for correct system
pressed air. operation.

b. CAREFULLY remove the single wire from the

solenoid being removed and replaced. WARNING: Keep ALL personnel, except the
operator, CLEAR of the area of the
machine during the operation check.

LH TRANSMISSION RH TRANSMISSION
LOW/HIGH RANGE LOW/HIGH RANGE
SOLENOID SOLENOID

RETAINING
NUT

SECONDARY/PARKING
BRAKE SYSTEM
SOLENOID

FIGURE 9-2. SECONDARY/PARKING BRAKE SYSTEM SOLENOID VALVE ASSEMBLY.

9-4 2/98
 Section 10
STEERING SYSTEM

TABLE OF CONTENTS

PAGE

GENERAL ................................................................................................................................................. 10-3

OPERATION ............................................................................................................................................. 10-5

POWER OPERATION ........................................................................................................................... 10-5

MANUAL OPERATION ......................................................................................................................... 10-5

HYDRAULIC POWER STEERING PUMP ................................................................................................ 10-5

REMOVAL ............................................................................................................................................. 10-5

DISASSEMBLY ..................................................................................................................................... 10-5

CLEANING AND INSPECTION ............................................................................................................. 10-7

ASSEMBLY ........................................................................................................................................... 10-7

INSTALLATION ..................................................................................................................................... 10-8

POWER STEERING CONTROL ............................................................................................................... 10-8

GENERAL .............................................................................................................................................. 10-8

REMOVAL ............................................................................................................................................. 10-8

INSTALLATION ..................................................................................................................................... 10-9

2/98 10-1
Section 10
STEERING SYSTEM

PAGE

STEERING CYLINDER ............................................................................................................................. 10-9

REMOVAL ............................................................................................................................................. 10-9

DISASSEMBLY ..................................................................................................................................... 10-10

CLEANING AND INSPECTION ............................................................................................................. 10-10

ASSEMBLY ........................................................................................................................................... 10-10

INSTALLATION ..................................................................................................................................... 10-12

REMOVING AIR FROM [BLEEDING] THE SYSTEM .............................................................................. 10-12

CHECKING AND ADJUSTING STEERING SYSTEM PRESSURE ........................................................ 10-13

TROUBLESHOOTING .............................................................................................................................. 10-14

10-2 2/98
 Section 10
STEERING SYSTEM
GENERAL [See Figure 10-1]. Components of the steering system are:

This section contains a description of the steering Engine mounted hydraulic oil supply pump.
system operation and overhaul instructions for
selected major components. Overhaul instructions
include removal, disassembly, inspection, assembly, Dashboard mounted steering control and steering
installation and pressure check procedures. column.

Specifications are given in Section 2 and trouble- One [1] double acting hydraulic steering cylinder.
shooting guide, for the selected system components,
is found in this section.
Steering wheel.
The steering system has a neutral feel to the opera-
tor by providing a direct relation between the steering Hydraulic oil reservoir [common with the transmis-
wheel position and the position of the steering sion hydraulic reservoir].
cylinder.
Hydraulic lines and fittings.

TEST FITTING FLANGE

COUPLING SCREWS STEERING
WHEEL
PRESSURE
HOSE STEERING
STEERING COLUMN NUT CAP
CONTROL
CAPSCREW
SUPPLY
AND
HOSE
WASHER

OIL
COOLER

FLOOR
PLATE

GASKET

STEERING
PUMP

FITTING
STRAINER STEERING
CYLINDER

FIGURE 10-1. STEERING SYSTEM COMPONENTS.

2/98 10-3
Section 10
STEERING SYSTEM

FIGURE 10-2. STEERING SYSTEM HYDRAULIC SCHEMATIC.

10-4 2/98
 Section 10
STEERING SYSTEM
OPERATION [See Figure 10-2]. REMOVAL [See Figure 10-1].

POWER OPERATION. Use the following procedures to remove the steering

pump from the engine.
With no turning force yet applied, hydraulic oil is
drawn through a strainer located in the hydraulic a. Open the LH hood side door.
reservoir to the power steering pump. This gear
pump circulates oil through the primary control valve b. Wash the steering pump and the hoses fastened
of the power steering control (dashboard mounted). to it with CLEAN diesel fuel and dry using com-
pressed air.
Return oil is then directed through the oil cooler and
back to the reservoir. When steering action is initiated c. Put an identification tag on each hose and each
by rotation of the steering wheel, the control spool is fitting of the steering pump. Disconnect all hoses
rotated, thereby allowing fluid to be fed to the power from the steering pump. Put caps, or plugs, in all
steering control metering section. This section hoses and on all pump fittings IMMEDIATELY after
meters out only the amount of oil required to make the hoses are disconnected.
the turn indicated by the steering wheel position.
d. Remove the capscrews which fasten the steering
The fluid is then ported to feed the proper actuator pump to the engine. Carefully remove the pump from
control port and thus the correct steering cylinder the engine.
end. The alternate actuator port is simultaneously
coupled to return displaced fluid from the opposite
end of the cylinder through the oil cooler and back to CAUTION: Do not permit the pump to fall when
the hydraulic reservoir. being removed from the engine.

Once the correct amount of fluid is measured out, the

control valve is repositioned by a spring to its open e. Remove the pump to engine sealing gasket from
center, neutral setting, hence causing a rotary follow- the pump mounting area on the engine. Put a clean
up action in the steering wheel. The spool then paper cover over the pump mounting area on the
maintains pressure in the steering cylinder for the engine and secure with tape.
desired turn until steering action is again initiated.

MANUAL OPERATION.
DISASSEMBLY [See Figure 10-3].
In manual operation, the fluid metering section
becomes a rotary pump and directs fluid to move the Use the following procedures to disassemble a
spool in either direction when the steering wheel is steering pump which was removed for inspection
manually rotated. A check valve within the unit and/or replacement of the internal parts.
develops a closed circuit between the hydraulic
cylinder and the metering area.
CAUTION: Disassemble the pump only on a
CLEAN work surface, in a CLEAN
work area.
HYDRAULIC POWER STEERING PUMP [See
Figures 10-1]
a. Wash the pump with CLEAN diesel fuel to
remove ALL dirt not previously removed. Dry the
The hydraulic steering pump is a gear type with a
pump by using compressed air.
constant rate of delivery per revolution and is
mounted directly to the left hand side of the engine.

The pump supplies a flow of hydraulic fluid for

operation of the power steering system.

2/98 10-5
Section 10
STEERING SYSTEM
b. Make a scribed line down the full length of the e. Remove the end plate.
pump to help align sections during assembly. Sup-
port the pump between the jaws of a vise. f. Remove the two [2] gears.

g. Remove the gear plate.

CAUTION: Do NOT tightly clamp the pump in a
vise for disassembly. Use the vise to h. Remove the wear plates from the pump body and
only support the pump. Clamping the end plate.
pump will cause damage to the body
and internal parts. i. Remove the pre-load seals and the load seals
from the pump body and end plate.

c. Loosen and remove the four [4] capscrews that j. CAREFULLY remove the seal from the pump
fasten the end plate to the pump body. body.

d. Remove the two [2] o-rings from the inlet and

outlet ports on the pump body. NOTE: ONLY the thrust plate, wear plate and
seal kit are available to service the pump.
REPLACE the pump, with NEW, if dam-
CAUTION: Do NOT pry the components apart. age to parts not serviced is found during
Use a SOFT plastic hammer to tap on the following inspection procedures.
the components until they separate.

PLUG

BODY CAPSCREW
GEARED BEARING
SHAFT
SEAL

BEARING

SEAL
END
RETAINER BEARING SEAL PLATE
RING
O - RING
GEARED
SHAFT

FIGURE 10-3. STEERING PUMP - EXPLODED VIEW.

10-6 2/98
 Section 10
STEERING SYSTEM
CLEANING AND INSPECTION c. Carefully install the shaft seal into the pump
[See Figure 10-3]. body.

Use the following procedures and guidelines to

inspect the disassembled pump parts to help deter- CAUTION: Do NOT damage the seal during
mine if a part should be used again or be replaced installation.
with new.

a. Wash ALL parts with CLEAN diesel fuel and dry d. Put bearing grease on all pre-load and load
using compressed air. seals.

CAUTION: Discard all o-rings and seals. Replace e. Carefully install the pre-load seal and the load
the o-rings and seals with NEW seal into the pump body. Carefully install the pre-load
during assembly. These parts are seal and the load seal into the end plate.
contained in the seal "kit".

b. Inspect the pump components for wear or CAUTION: Install the load seal against the wear
damage. Replace components with new as needed. plate in both the pump body and end
plate. Use extreme caution when
CAUTION: If components are NOT smooth, the installing the seals. Install the seals in
pump shows unusual wear or the a "square" relationship to the seal
pump did not meet specified flow and bores.
pressure requirements, replace the
pump with new.
f. Install the wear plates.

ASSEMBLY [See Figure 10-3]. CAUTION: Install the wear plates, so that the
brass surface of the wear plate is
Use the following procedures to assemble the TOWARD the pump gears.
steering pump after component inspection.

CAUTION: Be sure all parts of the steering pump g. Install the dowel pins into the pump body.
are CLEAN. Assemble the pump only
on a CLEAN work surface in a CLEAN h. Put CLEAN hydraulic oil on the seal ring. Install
work area. Use only CLEAN lint free the seal ring into the groove in the body.
cloth during pump assembly.
i. Put bearing grease on the gear shafts. Install the
a. If needed, polish all cover and housing machined gears into the gear plate.
surfaces, which mate together, using a carborundum
stone. Wash all parts, again, and dry using com-
pressed air. Put CLEAN hydraulic oil on ALL parts CAUTION: Do NOT damage the shaft seal when
BEFORE the pump assembly begins. Put all parts on installing the gears. Place a drive
CLEAN lint free cloth. shaft installation sleeve over the shaft
when installing the shaft through the
b. Carefully install the bearings into the pump body shaft seal. The sleeve wall thickness
and end plate. should be approximately 0.010 inch
[0.25 mm].

2/98 10-7
Section 10
STEERING SYSTEM
j. Lubricate the seal ring with CLEAN hydraulic oil. g. Prime the system using the "Pre-Start Proce-
Install the seal ring into the end plate. dures" given in Section 8 - TRANSMISSION SYS-
TEM, before the engine is started.
k. Carefully align the scribe line on the pump body
and the end plate. Install the end plate. Install the h. Start the engine. Check the steering system for
four [4] capscrews. Tighten the capscrews to a correct operation.
torque of 34 - 38 ft. lbs.[ 46-51 N.m].

DANGER: Keep ALL personnel CLEAR of the

CAUTION: Rotate the drive shaft while tightening hitch area. Clearance CLOSES when
the capscrews. Tighten the capscrews the machine is turned in either
evenly to avoid distortion of the pump direction.
body and end plate.

l. Install NEW o-rings on the housing inlet and POWER STEERING CONTROL.
outlet ports.
GENERAL.
m. Fill the pump with APPROVED, CLEAN and
FILTERED hydraulic oil. Put a cap on each fitting. The dashboard-mounted power steering control
meters the oil flow to the steering cylinder. Provisions
are also made for manual operation. For operation,
see OPERATION in this section.
INSTALLATION [See Figure 10-1].
REMOVAL [See Figure 10-1].
Use the following procedures to install the steering
pump onto the engine. a. Stop the engine.

a. Remove the paper cover from the pump mounting b. Pry out the steering wheel center hub.
area on the engine. Put anti-seize on the spline area
of the pump shaft. c. Remove steering wheel jam nut and use a puller
to remove steering wheel.
b. Put a new pump to engine sealing gasket in place
on the pump mount area of the engine. Carefully put d. Put an identification tag on each hose and each
the steering pump in position on the pump mount fitting of the steering control. Disconnect all hoses
area. from the steering control. Put caps, or plugs, in all
hoses and on all control fittings IMMEDIATELY after
c. Align the two [2] through holes in the steering the hoses are disconnected.
pump mounting flange with the tapped holes in the
engine. e. While supporting the control unit, remove the two
[2] screws securing the steering control and the
d. Install the two [2] capscrews and washers steering column to the mounting bracket.
through the holes in the mounting flange and thread
into the tapped holes in the engine. Tighten the f. Remove the control unit and the steering column.
capscrews to a torque of 39 ft. lbs. [53 N.m].

e. Remove the plugs from the hoses and the caps NOTE: The power steering control unit is ser-
from the pump fittings. Connect each hose to the viced through removal and replacement
CORRECT pump fitting and tighten securely. with NEW.

f. Check the oil in the hydraulic oil reservoir. Add oil

as needed [see Section 4 - MAINTENANCE].

10-8 2/98
 Section 10
STEERING SYSTEM
INSTALLATION [See Figures 10-1]. STEERING CYLINDER.

Use the following procedures to install the new REMOVAL [See Figure 10-4].
steering control unit.
Use the following procedures to remove the steering
a. Fill the new control with APPROVED, CLEAN cylinder for repair, or replacement.
and FILTERED hydraulic oil.
a. Stop the engine.
b. Position the steering column in through the
mounting plate. b. Remove the floor plate from the operator's
compartment.
c. Put the steering control in position on the steering
column. Install and tighten the retaining capscrews. c. Wash the steering cylinder, hoses and the area
where it connects, with CLEAN diesel fuel and dry
d. Remove the plugs from the hoses and the cap using compressed air.
from all fittings. CAREFULLY connect EACH hose to
the CORRECT steering control fitting as indicated by d. Put an identification tag on EACH hose that
the identification tags installed before removal. fastens to the cylinder. Loosen and remove BOTH
hoses from the cylinder. Put plugs in EACH hose and
e. Install the steering wheel onto the splined steer- caps on EACH fitting.
ing column. Install and tighten the wheel retaining
nut. e. Remove the bolts securing the eyebolts to the
steering cylinder and remove the eyebolts and
f. Install the steering wheel center hub. mounting pins.

f. Remove the steering cylinder.

WARNING: Do NOT put the hands or the arms
through the steering wheel spoke
area. A malfunction in the steering FITTING
control or hoses not being connected STEERING
correctly can cause the steering CYLINDER
wheel to rotate with a force that can TO PORT "R"
FITTING
cause serious injury. ON STEERING
CONTROL EYEBOLT

TO PORT "L" MOUNTING

ON STEERING PIN
CAUTION: Do NOT start the engine UNTIL all CONTROL
system prestart procedures have
LOCK PIN
been completed [See Section 8 - (STORED
TRANSMISSION SYSTEM]. POSITION)

FIGURE 10-4. STEERING CYLINDER - INSTALLED

IN THE MACHINE.

2/98 10-9
Section 10
STEERING SYSTEM
DISASSEMBLY [See Figure 10-5]. CLEANING AND INSPECTION
[See Figure 10-5].
Use the following procedures to disassemble the
steering cylinder for inspection and replacement of a. Wash ALL cylinder parts with CLEAN diesel fuel
internal parts, as needed. and dry using compressed air.

a. Wash the cylinder AGAIN with CLEAN diesel fuel NOTE: ALL seals are available in the repair "kit".
and dry using compressed air. Replace ALL items contained in the "kit".

b. Put the cylinder in a vise, with the shell area held b. Inspect the inside of the cylinder shell for wear,
VERY securely by the jaws. Put the cylinder rod in nicks, burrs, scratches, rust or other damage.
the mid range position.
c. Inspect the cylinder rod for wear or damage to
the chrome surface. Replace the rod IF damaged,
CAUTION: Do NOT crush the shell area of the bent or if it has a nicked, rusted, scratched or pitted
cylinder. chrome surface.

c. Loosen and remove the two capscrews securing NOTE: SLIGHT defects can be removed with
the cap. FINE sandpaper or emery cloth.

d. Slide the cap up the rod. Using a soft drive,

carefully tap the sleeve into the shell far enough to CAUTION: Do NOT sand chrome plating off the
expose the lockwire. outside of the rod. IF there is ANY
doubt about chrome plating being
e. Remove the lockwire from the shell. removed from the rod, check by
applying copper sulfate to the area.
f. Carefully pull the rod from the shell of the cylin- The rod will discolor where chrome is
der. removed. If this condition is seen re
chrome or replace the cylinder rod.
g. Protect the cylinder rod with a cloth. CARE- Wash the cylinder rod AFTER defect
FULLY put the cylinder rod end in a vise, having removal, using CLEAN diesel fuel and
SOFT jaws, and tighten the vise to hold the rod end dry with compressed air.
securely.

CAUTION: Do NOT damage the cylinder rod. ASSEMBLY [See Figure 10-5].

Use the following procedures to assemble the

h. Loosen and remove the piston locknut. cylinder.

i. Remove the piston locknut and remove the

piston, o-ring and the sleeve from the rod. CAUTION: ALL parts of the cylinder MUST be
VERY clean. The work surface, where
j. Remove the piston seal from the piston. the cylinder is being assembled
MUST also be CLEAN and be in a
k. Remove the o-ring and the back-up ring from the CLEAN area. Dirt of ANY type can
OD of the sleeve. cause damage to the cylinder and/or
steering system and a repeat failure
l. Remove the rod seal from the ID of the sleeve. can occur.

a. Put CLEAN hydraulic oil on ALL cylinder parts.

10-10 2/98
 Section 10
STEERING SYSTEM

SHELL

ROD

CAP O-RING
BACK-UP
LOCK RING
WIRE
SLEEVE

PISTON
SEAL CAPSCREW
LOCKNUT
O-RING
SEAL

ROD SEAL

PISTON

FIGURE 10-5. STEERING CYLINDER - EXPLODED VIEW.

b. Install the new rod seal in the ID of the sleeve. i. CAREFULLY install the assembled piston rod
into the open end of the cylinder shell, while com-
c. Install the new o-ring and the back-up ring on the pressing the back-up ring, o-ring and piston seal with
OD of the sleeve. The back-up ring must be installed, the fingers.
so that, it will be closest to the rod eye when in-
stalled. j. Slide the cap up the rod. Using a soft drive,
carefully tap the sleeve into the shell far enough to
d. Install the new rod seal on the OD of the piston. expose the lockwire groove.

e. Put a CLEAN cloth on the cylinder rod area. Put k. Install the lockwire in the groove of the cylinder
the cylinder rod in a vise. Tighten the vise to securely shell.
hold the rod. Put tape over the threaded area on the
rod. l. Position the cap against the cylinder shell. Install
the two [2] capscrews and tighten securely.
f. Install the cap and sleeve on the piston rod. Slide
them downward towards the middle of the rod. m. Fill the cylinder with CLEAN, FILTERED hydrau-
lic oil and install caps on EACH fitting.
g. Remove the tape from the threaded area on the
rod.

h. Install the o-ring and piston on the end of the

piston rod. Install the locknut and tighten to a torque
of 250-300 ft. lbs. [350-420 N.m].

2/98 10-11
Section 10
STEERING SYSTEM
INSTALLATION [See Figure 10-4]. Remove the air [bleed] from the system using the
following information:
Use the following procedures to install the repaired,
or replacement, steering cylinder onto the machine. a. Fill the hydraulic oil reservoir to the CORRECT oil
level [see Section 4 - MAINTENANCE].
a. CAREFULLY put the steering cylinder into
position, so that the shell end is in position on the b. Start the engine and put the throttle in the LOW
front frame and the rod end is in position on the ear idle position for approximately ONE [1] minute.
of the hitch.

b. Liberally coat the mounting pins with anti-seize WARNING: DO NOT put the hands or the arms
compound. Install the two [2] mounting pins and through the steering wheel spoke
secure with the eyebolts and flange screws. Tighten area. A malfunction in the steering
the flange screws to a torque of 105 ft. lbs. [143 control unit or hoses not being
N.m]. connected correctly can cause the
steering wheel to rotate with a force
c. Remove the caps from the fittings in the cylinder that can cause serious injury.
and the plugs from the hoses. Connect EACH
steering hose to the CORRECT cylinder fitting.
Tighten the hoses securely onto the fittings. c. Increase the engine speed to approximately 1000
RPM and turn the steering wheel in ONE [1] direction
d. Check the oil level in the hydraulic oil reservoir. UNTIL the steering cylinder reaches its limit. Quickly
Add oil, IF needed, using the procedures given in reverse the steering wheel rotation to cause pres-
Section 4 - MAINTENANCE. sure to build in the opposite end of the steering
cylinder.
e. Prime the system using the "Pre-Start Proce-
dures" given in Section 8 - TRANSMISSION SYS-
TEM, before the engine is started. DANGER: Keep ALL personnel CLEAR of the
hitch area. Clearance CLOSES when
the machine is turned in either
CAUTION: Do NOT start the engine BEFORE direction.
performing the "Pre-Start Proce-
dures" given in Section 8 - TRANS-
MISSION SYSTEM and the following NOTE: This will permit the large air bubbles to
AIR REMOVAL procedures. leave the system.

f. Start the engine. Check for correct steering d. Continue to rotate the steering wheel left and
cylinder and system function. right, from stop to stop, UNTIL the steering functions
are normal and correct. Slow and stop the engine.

DANGER: Keep ALL personnel CLEAR of the

hitch area. Clearance CLOSES when NOTE: If the steering functions fail to be normal,
the machine is turned in either air can be entering the system at the
direction. suction side of the pump. Check and
tighten ALL hoses to fitting connections.
Also check system pressure using the
procedures given in THIS section.
REMOVING AIR FROM [BLEEDING] THE
SYSTEM.

Air can become trapped in the system when the

system is opened and a component is removed and
replaced. An aerated system is indicated by jerky or
spongy operation when the steering wheel is turned.

10-12 2/98
 Section 10
STEERING SYSTEM
CHECKING AND ADJUSTING STEERING g. Put the throttle in the "HIGH" idle position. Turn
SYSTEM PRESSURE [See Figure 10-1]. the steering wheel either to the left or the right, while
reading the relief pressure indicated on the pressure
Use the following procedures to check the steering gauge. Put the engine throttle switch in the "LOW"
system relief pressure. The relief pressure is checked idle position and run the engine for a period of 3-5
at the pressure check port located at the steering minutes. Stop the engine.
pump.

CAUTION: The correct relief pressure is 2250

NOTE: Under most normal conditions, the +/-50 psi [155 +/-3 bar]. An indicated
steering system relief pressure should be relief pressure that is above or below
found within the correct pressure range, the above pressure will need correc-
during this pressure check. Therefore, no tion by adjustment of the steering
steering system relief pressure adjust- system relief valve assembly con-
ment will be required. tained in the steering control unit.

a. Check the oil level in the hydraulic reservoir. Add h. If needed, adjust the relief pressure using the
APPROVED oil if needed using the procedures given following information.
in Section 4 - MAINTENANCE.
1. Keep the engine STOPPED.
b. Install the steering lock pin at the hitch.
2. Go to the dashboard area, just below the
c. STOP the engine. Clean the fitting and pressure steering column. Find and remove the plastic
check area with a CLEAN lint free cloth. hole plug which is installed into the pressure
adjustment access hole in the dashboard.
d. Loosen and remove the pressure check cap from
the fitting. 3. If not previously done, alter a 3/16 Allen
wrench by grinding the short end of the
e. Install and tighten a 3000 psi. [210 bar] pressure wrench away to a length approximately one
gauge, on a long hose that will reach the cockpit half of the original length.
area, onto the pressure check port fitting and tighten
securely.
NOTE: Reducing the length of the short end of
f. Put the secondary/parking brake system control the wrench will allow the wrench to fit
toggle switch in the "ON" [APPLIED] position. Start into the pressure adjusting screw.
the engine and allow the hydraulic system to reach
normal operating temperature.
4. Install the short end of the Allen wrench
through the access hole in the dash and into
CAUTION: Do NOT hold the system over relief the steering relief pressure adjusting screw.
pressure for a period longer than Change the pressure by turning the adjusting
TWENTY [20] seconds. Pump damage screw INWARD or OUTWARD a SMALL
can occur. amount. Remove the ALLEN wrench.

NOTE: Turning the adjusting screw INWARD

[CLOCKWISE] will INCREASE the steer-
ing relief pressure. Turning the adjusting
screw OUTWARD [COUNTERCLOCK-
WISE] will DECREASE the steering relief
pressure.

2/98 10-13
Section 10
STEERING SYSTEM
5. Start the engine. Check the steering relief TROUBLESHOOTING.
pressure, AGAIN, using the procedures given
above. IF needed, adjust the pressure, Table 10-1 is a trouble analysis check chart for the
AGAIN, using the above information. steering system components.

6. AFTER the steering relief pressure is found These tables list the most common troubles that may
to be correct, install the plastic plug into the be encountered, the probable causes of the trouble,
dashboard. Do steps "i" through "k" below. and the corrective action that should be taken to
restore the unit to normal operating condition.
i. Remove the hose and pressure gauge from the
check port and install and tighten the cap onto the
check port fitting.

j. Remove the steering lock pin.

k. Start the engine and check the steering system

for correct operation.

DANGER: Keep ALL personnel CLEAR of the

hitch area. Clearance CLOSES when
the machine is turned in either
direction.

10-14 2/98
 Section 10
STEERING SYSTEM
TABLE 10-1. TROUBLE ANALYSIS FOR THE STEERING SYSTEM

PROBLEM CAUSE CORRECTION

STEERING PUMP

NO FLOW FROM PUMP Low oil level in Check oil level and
reservoir add oil as needed.
Find and correct
cause of low oil
level.

Pump NOT being Check drive gear on

driven. engine. Repair as
needed

Steering pump has Remove, repair or

internal damage replace pump.

Pump NOT priming - Check ALL hose and

air entering system fittings for tightness
and tighten as needed.

Fluid outlet from Remove clean or replace

reservoir in a restricted strainer and/or hose.
condition

Incorrect hydraulic COMPLETELY drain the

oil in system system of oil. Flush
ENTIRE system and
fill with NEW, CLEAN
and FILTERED oil [see
Section 4 - MAINTENANCE].

LOW FLOW FROM PUMP Low oil level in Check oil level and add oil as
reservoir needed. Find and correct
cause of low oil level.

Restricted inlet suction Remove, clean and replace

strainer and/or hose as needed.

Air being drawn into Check ALL hose to

system fitting connections.
Tighten as needed.

Pump has internal Worn and/or damaged

leakage. parts in pump. Remove,
repair or replace, as needed.

2/98 10-15
Section 10
STEERING SYSTEM
TABLE 10-1. TROUBLE ANALYSIS FOR THE STEERING SYSTEM (CONT.)

PROBLEM CAUSE CORRECTION

STEERING PUMP

PUMP MAKES NOISE Pump NOT being Check oil level and add oil as
supplied enough oil needed. Find and correct
cause of low oil level.

Restricted inlet suction Remove, clean and replace

strainer and/or hose as needed.

Pump has internal damage Remove, repair or replace

pump.

Air being drawn into Check ALL hose and fitting

system. connections. Tighten as
needed.

Dirt in pump and system Drain and flush system.

Remove pump,
disassemble and inspect
pump. Repair, or replace,
pump as needed and install.

10-16 2/98
 Section 10
STEERING SYSTEM
TABLE 10-1. TROUBLE ANALYSIS FOR THE STEERING SYSTEM (CONT.)

PROBLEM CAUSE CORRECTION

STEERING CONTROL UNIT

NO RESPONSE WHEN No flow from pump Check for pump output. Repair,
STEERING WHEEL IS or replace, pump as needed.
TURNED
Control unit has damage Remove unit. Replace with
NEW.

Steering cylinder has dam- Remove cylinder. Repair or

age replace as needed.

SLOW OR HARD STEERING Low system oil level Add oil as needed. Find and
correct cause of low oil level.

Hose[s] in system in a Remove, clean or replace

stopped condition hose[s].

Dirt in system Check suction strainer. Clean or

replace as needed. Clean
COMPLETE hydraulic system, if
needed [see section 8 - TRANS-
MISSION SYSTEM].

Steering control unit sleeve Remove unit, replace with NEW.

and spool worn

Steering control unit metering Remove unit, replace with NEW.

gear worn

Steering pump damaged Remove, repair or replace

pump.

Manual steering check ball Remove unit, replace with NEW.

off its seat.

STEERING WHEEL DOES Steering control unit has Remove unit, replace with NEW.
NOT CENTER broken centering springs

STEERING WHEEL ROTA- Steering control unit has Remove unit, replace with NEW.
TION IS CONTINUOUS broken centering springs

Steering control unit has burr Remove unit, replace with NEW.
on sleeve and/or spool

2/98 10-17
Section 10
STEERING SYSTEM
TABLE 10-1. TROUBLE ANALYSIS FOR THE STEERING SYSTEM (CONT.)

PROBLEM CAUSE CORRECTION

STEERING CONTROL UNIT

WRONG STEERING RE- Steering supply hoses NOT Check for CORRECT con-
SPONSE TO STEERING correctly connected to unit nection locations and change
WHEEL COMMAND and/or cylinders as needed.

Steering control unit metering Remove unit, replace with

star to shaft slot NOT aligned NEW.
correctly

NO PRESSURE OR FLOW Relief valve has internal Remove steering control unit.
FROM VALVE damage Replace with NEW [see THIS
section].

SYSTEM PRESSURE LOW Relief valve not set to correct Adjust relief pressure [see
specifications THIS section].

SYSTEM PRESSURE HIGH See above information. See above information.

SYSTEM PRESSURE NOT Relief valve has damaged Remove steering control unit.
STEADY - VARIES parts Replace wth NEW [see THIS
section].

STEERING CYLINDER

NO MOTION FROM NO oil being supplied to Check the system for dam-
STEERING CYLINDER steering cylinder aged pump, relief valve,
steering control unit, or
hose[s]. Check oil level. Repair
as needed. See THIS "Trouble
Analysis".

Cylinder has internal damage Remove cylinder, repair or

replace as needed.

SLOW MOTION FROM LOW oil supply to cylinder Check as above.

STEERING CYLINDER

10-18 2/98
 Section 10
STEERING SYSTEM
TABLE 10-1. TROUBLE ANALYSIS FOR THE STEERING SYSTEM (CONT.)

PROBLEM CAUSE CORRECTION

STEERING CYLINDER

ACTION OF CYLINDER IS Air in system Check oil level in reservoir.

JERKY Add oil as needed. Find and
correct cause for low oil level.
Check for loose hose to fitting
connections. Tighten as
needed. Remove air [bleed]
[See this section].

EXCESSIVE LOST MOTION Bent or deformed cylinder Remove cylinder, repair or

AT CYLINDER piston, or rod replace as needed.

Bushings at steering cylinder Remove and replace bush-

to machine worn. ings as needed.

Loose cylinder anchor pin, Inspect and tighten nut the

retainer pin and/or anchor CORRECT specification as
capscrew needed.

Cylinder yoke worn/broken at Remove cylinder, repair or

rod and/or anchor ends replace as needed.

2/98 10-19
Section 10
STEERING SYSTEM

NOTES

10-20 2/98
 Section 11
WATER SPRAY SYSTEM

TABLE OF CONTENTS

PAGE

GENERAL INFORMATION ...................................................................................................................... 11-2

DESCRIPTION ......................................................................................................................................... 11-2

STRAINER ................................................................................................................................................ 11-2

SPRAY NOZZLES .................................................................................................................................... 11-2

WATER SPRAY PUMP AND MOTOR .................................................................................................... 11-3

GENERAL ............................................................................................................................................. 11-3

REMOVAL ............................................................................................................................................. 11-3

DISASSEMBLY ..................................................................................................................................... 11-3

ASSEMBLY ........................................................................................................................................... 11-3

INSTALLATION .................................................................................................................................... 11-5

TROUBLESHOOTING ............................................................................................................................. 11-5

2/98 11-1
Section 11
WATER SPRAY SYSTEM
GENERAL INFORMATION.
10 AMP
This section contains a description of the water CIRCUIT
BREAKER
spray system for the Model BW11RH Roller.

Design specifications, are presented in Section 2

WATER
and a troubleshooting guide is presented at the end WATER
TANK SPRAY
of this section. SWITCH

WATER
DESCRIPTION [See Figure 11-1]. WATER SPRAY
PUMP PUMP
MOTOR
Water spray system is fed by a pump.

The water pump, which is controlled by an electrical WATER

“on/off” switch on the dash, supplies water to the SPRAY
BAR
manifolds, when the system control switch is in the
“ON” position.

When the system control switch is placed in the FIGURE 11-1. WATER SPRAY BLOCK DIAGRAM.
“ON” position, the amount of water being supplied to
both water spray manifolds is regulated by the flow
control valve. The flow control valve is found behind
the cover on the back wall of the operator's compart- STRAINER.
ment.
Maintenance procedures for the water spray system
The water spray system consists of a tank, solenoid strainer is given in Section 4 - MAINTENANCE - in
valve, pump, motor, spray manifold and spray THIS manual.
nozzles. The tank features an access cover for
cleaning the tank, an inlet screen and a sump
strainer. A drain plug is located in the bottom of the
tank for flushing or draining the tank. SPRAY NOZZLES.

Maintenance procedures for the water spray nozzles

are given in Section 4 - MAINTENANCE - in THIS
manual.

11-2 2/98
 Section 11
WATER SPRAY SYSTEM
WATER SPRAY PUMP AND MOTOR. b. Remove the pump housing from the diaphragm
assembly.
GENERAL.
c. Remove the check valve assembly from the
The water spray pump and motor is located behind pump housing.
the cover on the back wall of the operator's compart-
ment. The pump and motor is a single assembly, d. Remove the two [2] screws that hold the cover
combining an electric motor with a small pump. and diaphragm assembly to the motor body. Align
the set screw with a slot in the pump cover. Loosen
the set screw with an Allen wrench just enough to
slide the diaphragm and cover assembly off the
REMOVAL [See Figure 11-2]. motor drive shaft as a unit.

a. Put the water spray system “on/off” control switch e. Remove the two [2] screws that attach the cam/
in the “OFF” position and STOP the engine. bearing to the diaphragm. Remove the diaphragm
and cover.
b. Remove the cover on the back wall of the
operator's compartment.
NOTE: The screws that hold the cam/bearing,
c. Disconnect the electrical wires from the water the cam/bearing diaphragm, cover and
spray pump. check valve are all included in the pump
"repair kit".
d. Put an identification tag on each hose connected
to the water pump fittings. Loosen the retaining
clamps and remove hoses from the water spray CAUTION: Do NOT mix old and new "repair kit"
pump fitting. parts. Install all NEW parts.

e. Remove the four [4] retaining nuts from the four

[4] mounting bracket studs. Remove the pump
assembly. ASSEMBLY [See Figure 11-3].

f. Put the water spray pump assembly on a CLEAN a. Install the new set screw in the new cam/bearing,
work surface. If needed, disassemble the pump by a small amount. Install the two [2] new screws into
using the following ADDITIONAL repair information. the new cam/bearing, through the cover and into the
new diaphragm assembly. Tighten the screws
securely.

DISASSEMBLY [See Figure 11-3]. b. Slide the diaphragm and cover assembly onto the
motor drive shaft and tighten the set screw securely
against the drive shaft.
CAUTION: A “repair kit” is available and permits
the water spray pump assembly and c. Install the two [2] screws, that hold the cover and
the drive motor to be serviced diaphragm assembly, to the motor body. Tighten the
SEPARATELY. screws securely.
In some cases the pump damage can
require the complete water spray d. Install the new check valve assembly into the
pump assembly to be replaced with pump head.
NEW.
e. Install the pump head and check valve assembly,
a. Remove the four [4] screws and lock washers onto the cover assembly. Align the four [4] mounting
from the pump housing. screw holes and install the mounting screws. Tighten
the screws securely.

2/98 11-3
Section 11
WATER SPRAY SYSTEM

CAP
MANIFOLD
PIPE
COLLAR

BRACKET

PUMP COLLAR
NOZZLE MANIFOLD
PIPE
CAPSCREW, WATER TANK
CLAMP CAP NUT
GROMMET
CLAMP STRAP

CLAMP FLANGE SCREWS

VALVE

CLAMP
VIEW A-A
CLAMP
STRAINER

CLAMP

FIGURE 11-2. WATER SPRAY SYSTEM COMPONENT LOCATIONS.

11-4 2/98
 Section 11
WATER SPRAY SYSTEM
INSTALLATION [See Figure 11-2]. f. Fill the water tank with enough water to check
the water spray system operation.
a. Position the water spray pump on the four [4]
mounting studs, so that the pump is in the correct g. Turn the ignition key switch in the “ON” [RUN]
position for connection of the lines. position. Put the water spray system control switch
in the “ON” position and check the water spray
b. Install the four [4] retaining nuts on the mounting system for CORRECT operation [See Section 3 -
studs. Tighten the four [4] retaining nuts to a torque OPERATION in this manual].
of 5 ft. lbs. [6.8 N.m].

CAUTION: Do NOT overtighten the retaining TROUBLESHOOTING.

nuts.
Table 11-1 is a trouble analysis check chart for the
water pump assembly.
c. Install the hoses onto the water spray pump
fittings and tighten the clamps securely. This table lists the most common troubles that may
be encountered, the probable causes of the trouble,
d. Connect the electrical wire harness plug to the and the corrective action that should be taken to
pump harness connection plug fitting. restore the unit to normal operating condition.

e. Install the cover on the back wall of the

operator's compartment.

PUMP MOTOR

COVER
SET
SCREW
DIAPHRAM
KIT
CONNECTOR
CHECK
VALVE CAM CONNECTOR
SEARING
SCREW HOUSING SCREW GOMMENT

SCREW PLATE

FIGURE 11-3. WATER SPRAY PUMP - EXPLODED VIEW.

2/98 11-5
Section 11
WATER SPRAY SYSTEM
Table 11-1. TROUBLE ANALYSIS FOR THE WATER SPRAY SYSTEM.

PROBLEM CAUSE CORRECTION

PUMP MOTOR WILL Open circuit in on/off Remove and replace

NOT OPERATE control toggle switch switch.

Circuit breaker in Remove and replace

electrical system NOT breaker.
resetting - damaged

Contaminate in pump Clean pump.

Motor brushes worn Remove pump and motor

excessively or motor assembly. Replace pump
has total failure damage and motor assembly with
new. Install pump and
motor assembly.

PUMP MOTOR WILL On/off toggle control switch Remove and replace
NOT SHUT OFF damaged switch.

PUMP OPERATES - Insufficient liquid in Replenish liquid supply.

BUT HAS LITTLE, water tank
OR NO, SPRAY
PATTERN Strainer plugged Remove, clean strainer
and install. Clean tank.

Pump housing cracked Replace pump.

from freezing

Spray nozzles plugged Remove, clean nozzles

and manifolds and install.

SPRAY PATTERN One or more spray Remove nozzles, clean

NOT COMPLETELY nozzles plugged and install.
COVERING TIRE
Charging system has Check charging system.
damage. (low voltage Repair system as needed.
to water spray pump
motor

11-6 2/98
 Section 11
WATER SPRAY SYSTEM

NOTES

2/98 11-7