BW266AD-4

BW278AD-4
R1
0852756

Operating instructions
Maintenance instructions

Tandem Vibratory Roller

12-2010
12-2010
 DANGER: If the machine was received with the
Roll Over/Falling Object Protection
Structure [ROPS/FOPS] and Opera-
tor Restraints [Seat Belt Sets] NOT
installed, they MUST be installed
BEFORE the machine is operated,
using the installation instructions
drawing included with the installa-
tion kit and/or the illustration below.
In the event of a machine rollover,
serious injury or death can occur
due to failure to correctly install the
Roll Over/Falling Object Protection
Structure [ROPS/FOPS] and Opera-
tor Restraints [Seat Belt Sets].

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

12-2010
12-2010
 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/ WARNING: Serious personal injury and/or
or extensive property damage can extensive property damage can
result if the DANGER instructions result if the WARNING instructions
are 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 presented
instructions are not followed. information.

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

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

12-2010
 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 maxi-
mum 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 be-
ing repaired.

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

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 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.

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12-2010
 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.

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

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

12-2010 1-1
Section 1
INTRODUCTION
GENERAL INFORMATION. WARNING: ONLY authorized personnel, who
are fully trained in the machine
THIS manual contains SPECIFICATION information operation procedures, can operate
and OPERATION, MAINTENANCE and REPAIR pro- the Tandem Vibratory Roller. Follow
cedures for the Tandem Vibratory Roller [see 1-2 ALL instructions given in THIS
fig1]. manual, and written on the “Machine
Operation and Warning” decal, found
on the flat plate on the right side of,
SPECIFICATIONS. and below, the control panel.

See Section 2 - SPECIFICATIONS, of THIS manual,

for specifications on major systems used on the
MAINTENANCE PROCEDURES.
machine.
The maintenance schedules and procedures are
found in Section 4 - MAINTENANCE, of THIS man-
OPERATING INSTRUCTIONS. ual.

READ, UNDERSTAND and FOLLOW ALL the operat- CAUTION: Follow ALL the maintenance
ing instructions given in the FRONT, and in Section 3 schedules and instructions given
- OPERATION, of THIS manual. in THIS manual.

1-2 Fig1. TANDEM VIBRATORY ROLLER.

1-2 12-2010
 Section 1
INTRODUCTION
REPAIR PROCEDURES. SERIAL NUMBER [See 1-3 Fig2 and 1-4 Fig3].

MAJOR machine component REPAIR PROCEDURES The nameplate shows the machine manufacturing
are found in the “SYSTEM REPAIR PROCEDURE” plant code, model number code and serial number
sections of “Instructions for Repair Manual”. [see 1-4 Table 1-1]. The machine serial number is
located on the nameplate [See 1-3 Fig2]. The serial
CAUTION: For CORRECT machine component number is also stamped on the flat surface of the
repair procedures, USE the REPAIR hitch assembly at the left-hand side of the machine
procedures given in the above [see 1-4 Fig3].
service manual, and/or other
referenced written materials ONLY. CAUTION: ALL numbers and letters, contained
in the SERIAL NUMBER, must be
given when requesting service and/or
part information.
NAMEPLATE/SERIAL NUMBER PLATE
[See 1-3 Fig2].

The nameplate/serial number plate is located on the

left side of front panel. The nameplate shows the ma-
chine manufacturing plant code, model number code
and serial number. The plate MUST stay fastened to
the machine at ALL times. If the plate is missing, or
damaged, it MUST be replaced IMMEDIATELY.
Contact your nearest Distributor to obtain a replace-
ment plate.

1-3 Fig2. NAMEPLATE/SERIAL NUMBER PLATE LOCATION.

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Section 1
INTRODUCTION

XXX X000 00000

PLANT OF DESIGN SERIES MACHINE

MANUFACTURE AND MODEL SERIAL NUMBER
I, O, Q NOT USED CODE

TABLE 1-1. MACHINE SERIAL NUMBER DESIGNATIONS.

1-4 Fig3. SERIAL NUMBER LOCATION - NEAR HITCH ASSEMBLY.

1-4 12-2010
 Section 2
SPECIFICATIONS

TABLE OF CONTENTS

PAGE

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

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

STRUCTURE [ROPS/FOPS] 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 ................................................................................. 2-8.

TABLE 2-6. STEERING SYSTEM SPECIFICATIONS ........................................................................... 2-8.

TABLE 2-7. DRUM, VIBRATION AND CLEANER BAR SPECIFICATIONS ....................................... 2-10.

TABLE 2-8. WATER SPRAY SYSTEM SPECIFICATIONS ................................................................. 2-12.

TABLE 2-9. OPTIONAL EQUIPMENT SPECIFICATIONS .................................................................. 2-13.

TABLE 2-10. DIMENSION SPECIFICATIONS ..................................................................................... 2-14.

TABLE 2-11. PERFORMANCE SPECIFICATIONS ............................................................................. 2-14.

TABLE 2-12. MACHINE SYSTEM CAPACITY SPECIFICATIONS ..................................................... 2-14.

TABLE 2-13. COMPONENT WEIGHTS ............................................................................................... 2-16.

TABLE 2-14. TORQUE SPECIFICATIONS FOR STANDARD METRIC FASTENERS .......................2-18.

TABLE 2-15. TORQUE SPECIFICATIONS FOR STANDARD INCH FASTENERS ............................2-19.

TABLE 2-16. LUBRICATION OILS, HYDRAULIC OILS AND COOLANT SPECIFICATIONS ............2-20.

TABLE 2-17. ADHESIVE THREAD LOCKING SPECIFICATIONS ......................................................2-21.

12-2010 2-1
Section 2
SPECIFICATIONS
GENERAL INFORMATION.

This section gives specification tables for each major

machine system of the Tandem Vibratory Roller.

Machine dimensions, weights, performance and

torque specifications are also given in THIS section.

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

PROTECTION STRUCTURE [ROPS/FOPS] SPECIFICATIONS.

ITEM DESIGN DATA

FRAME

Material Plate steel

Construction Unitized, all welded two [2] section, with bolt-on front and rear weight
plates

HITCH

Oscillation ± 12° - side to side, 24° total

Articulation
   66 Inch Roller Unit ± 33° - right to left [steering] turn, 66° total
   78 Inch Roller Unit ± 31° - right to left [steering] turn, 62° total

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

Type and Description Welded steel structure, bolted to machine for protective system and one
[1] seat belt sets for operator restraint, conforms to SAE recommended
practice J-1040C, J-231 and J-386; and CSA B352 [Canada]

2-2 12-2010
 Section 2
SPECIFICATIONS
TABLE 2-2. ENGINE SPECIFICATIONS.

ITEM DESIGN DATA

ENGINE

Model and Manufacturer QSB4.5 Cummins Diesel

Type 4 Cycle diesel, Turbocharged and Charge Air Cooled

Number of Cylinders Four [4]

Displacement 275 cu in. [4.5 liter]

Bore & Stroke 4.02 in. [102 mm] x 4.72 in. [120 mm]

Rated Brake Horsepower 130 hp [97 kW @2200 rpm]

Compression Ratio 17.2:1

Firing Order 1-3-4-2

Low Idle Speed 1000 rpm

High Idle Speed 2200 ± 10 rpm, NO load

Engine Oil Type See Cummins “Operation and Maintenance Manual - QSB4.5 Engine”
for correct oil type

Turbocharger

Type Holsett

Boost Pressure 23.5 psi [1.63 bar] @ 2200 rpm

ENGINE COOLING SYSTEM

Radiator Type Full flow, liquid pressure, W/O integral oil cooler

System Coolant Capacity 20.5 qts. [19.4 Liters]

Thermostat Range 180 - 199°F [82 - 93° C], thermostat opens

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Section 2
SPECIFICATIONS
TABLE 2-2. ENGINE SPECIFICATIONS (Continued).

ITEM DESIGN DATA

ENGINE FUEL

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

Fuel Capacity
   66 Inch Roller Unit 49.4 gallons [187 liters]
   78 Inch Roller Unit 58 gallons [220 liters]

Rate of Fuel Consumption 4.8 gallons per hour [18.2 liters per hour]*
[at normal engine H.P. at
60% load] *Operating conditions, that vary, can cause different fuel consumption
amounts than those given

FUEL FILTERS

Fuel Filter Pressure line, replaceable “spin-on” element [see Cummins “Operation
and Maintenance Manual - QSB4.5 Engine”]

FUEL PUMP

Type Bosch High Pressure Common Rail (HPCR)

FUEL INJECTORS

Quantity and Type Four [4], close nozzle

2-4 12-2010
 Section 2
SPECIFICATIONS
TABLE 2-3. ELECTRICAL SPECIFICATIONS.

ITEM DESIGN DATA

BATTERY

Number Per Machine One [1], maintenance free

Ampere Hour Rating 900 CCA

Voltage 12 Volts

ALTERNATOR

Voltage 12 Volt, negative ground

Output Amperage 95 Amps

Maximum Charge Rate 95 Amps - 14 volts [cold]

Direction of Rotation Clockwise [CW] - viewed from drive end

Fan Belt Tension and Automatic belt tension mechanism keeps serpentine belt under tension
Method Used to Achieve at ALL times

STARTER

Manufacturer See engine STARTER plate for manufacture and part number

Voltage and Type 12 Volt, negative ground

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

ITEM DESIGN DATA

TRANSMISSION SYSTEM

System Type Hydrostatic

System Oil Capacity 15 gallons [56.8 liters]

[also supplies steering
and vibration systems]

Oil Type See decal, adjacent to hydraulic reservoir fill, for correct type

Oil Cooler Type Aluminum, full flow [separate from radiator]

TRANSMISSION
HYDRAULIC PUMP

Type Variable displacement, axial piston

Swash Plate Angle 0 - 20° maximum, either side of center

Direction of Rotation Counterclockwise [CCW]

Inlet Vacuum 15 in. hg [381 mm hg], maximum

[at charge pump inlet]

Maximum Allowable 210° F [99 ° C]

Case Temperature

TRANSMISSION
HYDRAULIC DRUM
DRIVE MOTORS

Type Radial piston, variable displacement - with spring applied multi-disc brake

Quantity Two [2]

Maximum Operating 6,530 psi. [450 bar] intermittent

Pressure

Maximum Horsepower 94 hp [70 kW] each

at Full Displacement

2-6 12-2010
 Section 2
SPECIFICATIONS
TABLE 2-4. TRANSMISSION SYSTEM SPECIFICATIONS (Continued).

ITEM DESIGN DATA

Maximum Speed - at 150 rpm

Full Displacement

Multi-Disc Brake 175 - 435 psi. [12 - 30 bar] - plus case pressure
Release Pressure

Maximum Braking Torque 13,720 ft. lbs. [18,600 N•m]

TRANSMISSION NOTE: Pressures given are with hydraulic oil at operating

SYSTEM PRESSURES temperature of 100 - 150°F [38 - 66°C] with the engine speed at HIGH
idle.

Neutral Charge 400 psi. [28 bar], plus case pressure, with engine @ high idle

Stroked Charge 350 psi. [24 bar] - minimum, above case pressure, with engine
@ high idle and transmission pump @ full stroke

System High Relief 6,200 psi. [427 bar], forward, or reverse

Pump Case Pressure 40 psi. [2.7 bar], continuous - 75 psi. [5.2 bar], intermittent

Torque Specifications

 ydraulic Drum Drive

H 425 ft. lbs. [578 N•m]
Motor To Motor Carrier

TRANSMISSION See engine STARTER plate for manufacture and part number
PUMP DRIVE PLATE

Type Nylon Flange, with center hub splined

Torque Specifications

Flex Drive Plate 37 ft. lbs. [50 N•m]

To Engine Flywheel

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

ITEM DESIGN DATA

BRAKE SYSTEM

Service Brake Type Through hydrostatic transmission system

Secondary/Parking Spring applied, hydraulically released, [SAHR] multi-disc brake,

Brake Type incorporated with each hydrostatic transmission drum drive motor

TABLE 2-6. STEERING SYSTEM SPECIFICATIONS.

ITEM DESIGN DATA

STEERING SYSTEM

Type of System Hydraulic

System Oil Capacity See transmission system capacity, in THIS Section

Type of System Oil See maintenance decal, for correct type

STEERING HYDRAULIC
PUMP

Type Gear, single section

Pump Output Rate 11 gpm [42 Ipm] @ 2200 rpm

and Speed

Direction of Rotation Counterclockwise [CCW]

[viewed from shaft end]

STEERING RELIEF VALVE

Type Integral with steering control valve

Relief Pressure 2,800 ± 25 psi. [193 ± 1.7 bar], with engine @ high idle

STEERING CONTROL
VALVE

Type Closed center proportional servo valve w/electronic

displacement control.

Port Sizes - Inlet/Outlet SAE - 8 Std thread, o-ring boss

2-8 12-2010
 Section 2
SPECIFICATIONS
TABLE 2-6. STEERING SYSTEM SPECIFICATIONS (Continued).

ITEM DESIGN DATA

STEERING CYLINDERS

Type Double acting

Number per Machine One [1]

Bore of Cylinder 3.5 in. [89 mm]

Stroke of Cylinder 12.00 ± 0.13 in. [305 ± 3 mm]

Rod Diameter 1.25 in. [32 mm]

Retracted Length of 22.25 ± 0.13 in. [565 ± 3 mm]

Cylinder [between pin
bore centers]

Extended Length of 34.25 ± 0.13 in. [870 ± 3 mm]

Cylinder [between pin
bore centers]

STEERING PERFORMANCE

Steering Time - stop to stop

Right To Left Idle 7.6 Seconds
Right To Left High Idle 3.9 Seconds
Left To Right Idle 8.2 Seconds
Left to Right High Idle 3.9 Seconds

66 Inch Roller Unit 78 Inch Roller Unit

Inside Turning Radius 13 ft. 7 in. [4.2 m] 16 ft. 6 in [5.0 m]

Outside Turning Radius 19 ft. 1 in. [5.8 m] 23 ft. [7.0 m]

Total Steering 33° each side of center, 66° total 31° each side of center, 62° total

Torque Specifications

Hydraulic Pump Mount 55 ft. lbs. [75 N•m]

S
 teering Cylinder 200 ft. lbs. [271 N•m]
Piston Retaining Nut

S
 teering Cylinder Anchor 37 ft. lbs. [50 N•m]
End Mounting Cap
Screws

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Section 2
SPECIFICATIONS
TABLE 2-7. DRUM, VIBRATION AND CLEANER BAR SPECIFICATIONS.

ITEM DESIGN DATA

DRUM 66 Inch Roller Unit 78 Inch Roller Unit

Width 66 in. [1,676 mm] 78 in. [1,981 mm]

Diameter 48 in. [1,219 mm] 48 in. [1,219 mm]

PLI - Drum Contact Area

   Hi‑amp @ 3400 vpm 672 pli [118 N/mm] 645 pli [113 N/mm]
   Lo‑amp @ 4000 vpm 621 pli [109 N/mm] 589 pli [103 N/mm]

Drum Approximate Weight - 5,000 lbs. [2,268 kg] 5,524 lbs. [2,506 kg]
With Vibrator Assembly,
Motor and Isolators

Wrapper Thickness 0.70 in. [17.78 mm]

VIBRATION SYSTEM

Type Variable amplitude, two [2] eccentric vibrator weights EACH drum.
One [1] piston pump, for EACH drum, supplies oil flow to one [1] fixed
displacement piston motor, installed at EACH drum

System Hydraulic Oil Same as transmission and steering systems supply

Supply

Hydraulic PRESSURE One [1] filter with replaceable element, rated five [5] micron [nominal]
Oil Filter and Element [Use APPROVED replacement element ONLY - see machine parts manual]

Drum Bearing Lubrication

Oil [inside each drum]

Type See Section 4 - MAINTENANCE for CORRECT type

Amount 10.5 gallons [39.7 liters], each drum

Hydraulic Pump Output Piston pump, variable displacement, two [2]

Rate and Speed 26.0 gpm [98 Ipm] @ 2200 rpm

Direction of Rotation Clockwise [CW]

[as viewed from shaft end]

Hydraulic Motor Type Axial piston, fixed displacement, two [2]

and Quantity

Motor Input Rate 26.0 gpm [98 Ipm] @ 4400 psi. [304 bar]
and Pressure

Motor Maximum Speed 4000 rpm

2-10 12-2010
 Section 2
SPECIFICATIONS
TABLE 2-7. DRUM, VIBRATION AND CLEANER BAR SPECIFICATIONS (Continued).

ITEM DESIGN DATA

Direction of Rotation Bi-directional

[viewed from shaft end]

Case Pressure - Pumps 20 - 35 psi. [1.4 - 2.4 bar]

Relief Valve 4,400 ± 150 psi. [303 ± 10.3 bar], maximum @ 3 gpm [11.4 Ipm]

Pressure Setting and At start-up. After a few seconds, drive pressure should drop to below
Rate - Vibrator “Start/Stop” 3000 psi. [207 bar]

Charge Relief Valve

Pressure Setting

Neutral Charge 350 psi. [24 bar], plus case pressure (typical 420 psi. [29 bar])

VIBRATION PERFORMANCE
66 Inch Roller Unit 78 Inch Roller Unit

Centrifugal Force
High Amplitude@3400 vpm 32,800 lbs. [146 kN] 37,100 lbs. [165 kN]
Low Amplitude@4000 vpm 30,300 lbs. [135 kN] 33,650 lbs. [150 kN]

Frequency Range 2500 - 4000 vpm 2500 - 4000 vpm

Amplitude [nominal]
High Amplitude 0.029 in. [0.74 mm] 0.029 in. [0.74 mm]
Low Amplitude 0.019 in. [0.487 mm] 0.019 in. [0.48 mm]

CLEANER BEAMS AND

CLEANER SCRAPERS

Type Cleaner Beams Full width, bolt-on type

Number Cleaner Beams Four [4] total, two [2] per drum
Per Machine

Number Cleaner Scrapers One [1] adjustable, full width

Per Beam and Type

Adjustment Against drum surface

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Section 2
SPECIFICATIONS
TABLE 2-7. DRUM, VIBRATION AND CLEANER BAR SPECIFICATIONS (Continued).

ITEM DESIGN DATA

TORQUE SPECIFICATIONS

Drum To Frame 431 ft. lbs. [585 N•m]

Mounting Cap screws

Vibration Isolation 157 ft. lbs. [213 N•m]

System Assembly To Drum

Cleaner Beam To Frame 275 ft. lbs. [373 N•m]

Mounting Cap screws

Cleaner Scraper 90 ft. lbs. [122 N•m]

To Cleaner
Beam Mounting
Cap screws

TABLE 2-8. WATER SPRAY SYSTEM SPECIFICATIONS.

ITEM DESIGN DATA

WATER SPRAY SYSTEM

Type Pressurized system

Tank Capacity and Quantity 158 gal. [598 Iiters] each, two [2]

Pump Type and Quantity 12 Volt, diaphragm, one [1] per tank; total two [2] per unit

Filtration Tank Fill Ports Strainer sock, one [1] per tank

Pump Inlet Mesh screen, one [1] per pump assembly

Water Spray Control One [1], rotary switch located on right seat control console. When fully
clockwise [CW], water spray is in the manual position. In the manual
switch position water is controlled by the push button on top of the steer
lever located on the left seat control console. When the rotary switch is
fully counterclockwise [CCW], water spray is automatic and water spray
will only come on when in travel.

Nozzle Quantity 66 Inch Roller Unit 78 Inch Roller Unit

five (5) per roller seven (7) per roller

Flow Rate 29.7 oz/min. 24.8 oz/min.

Type Threaded collar release from spray bar mounting.

2-12 12-2010
 Section 2
SPECIFICATIONS
TABLE 2-9. OPTIONAL EQUIPMENT SPECIFICATIONS.

ITEM DESIGN DATA

LIGHTING SYSTEM

Type, Quantity and Control 12 volt, halogen, ROPS/FOPS positioned, four [4] per machine -
two [2] front and two [2] rear, dash mounted switch controlled

TURN SIGNALS,
4-WAY FLASHERS

Type, Quantity, and 12 volt, - four [4] turn signal/4-way flasher light assemblies, two [2] front
Control and rear.

12-2010 2-13
Section 2
SPECIFICATIONS
TABLE 2-10. DIMENSION SPECIFICATIONS [See 2-15 Fig1].

ITEM DESIGN DATA

DIMENSIONS 66 Inch Roller Unit 78 Inch Roller Unit

A. Overall Height to Top of ROPS/FOPS 111 in. [2,819 mm] 111 in. [2,819 mm]

B. Height - without ROPS/FOPS 81 in. [2,057 mm] 81 in. [2,057 mm]

C. Overall Width 72 in. [1,828 mm] 84.5 in. [2,146 mm]

D. Overall Length 200 in. [5,080 mm] 200 in. [5,080 mm]

E. Wheel Base 120 in. [3,048 mm] 120 in. [3,048 mm]

F. Ground Clearance 15 in. [381 mm] 15 in. [381 mm]

TABLE 2-11. PERFORMANCE SPECIFICATIONS.

ITEM DESIGN DATA

TRAVEL SPEED

TRAVEL [High] Range 0 - 10 mph [0 - 16.1 kmph]

WORK [Low] Range 0 - 5 mph [0 - 8.0 kmph]

EFFECTIVE COVERAGE 66 Inch Roller Unit 78 Inch Roller Unit

Width 66 in. [1,676 mm] 78 in. [1,981 mm]

TABLE 2-12. MACHINE SYSTEM CAPACITY SPECIFICATIONS.

ITEM DESIGN DATA

SYSTEM CAPACITIES 66 Inch Roller Unit 78 Inch Roller Unit

Fuel 49.4 gallons [187 liters] 58 gallons [220 liters]

Engine Lubrication Oil 17 quarts [16 liters] - with Lubrication Oil Filter

Cooling System 20.5 quarts [19 liters]

Hydraulic Oil Reservoir [Supplies 15 gallons [56.7 liters]

All Oil To Transmission, Steering
and Vibration Systems]

Drum Bearing Lubrication Oil 10.5 Gallons [39.7 liters] - each drum

Water Spray - Two [2] Tanks Used 158 Gallons [598 liters] - each tank
Per Machine

2-14 12-2010
 Section 2
SPECIFICATIONS

2-15 Fig1. MACHINE DIMENSIONS.

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Section 2
SPECIFICATIONS
TABLE 2-13. 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 66 Inch Roller Unit 78 Inch Roller Unit

Operating Weight with ROPS/FOPS 24,300 lbs. [11,022 kg] 25,800 lbs. [11,703 kg]

Shipping Weight with ROPS/FOPS 22,450 Ibs. [10,183 kg] 23,900 Ibs. [10,841 kg]

REAR FRAME

With Engine and Drive Components 9,887 lbs. [4,484 kg] 10,345 lbs. [4,692 kg]

FRONT FRAME

With Isolators and Drum

with ROPS/FOPS 12,573 lbs. [5,703 kg] 13,155 lbs. [5,967 kg]

ENGINE

Dry 850 lbs. [386 kg] 850 lbs. [386 kg]

With Pump and All Items Installed 1,100 Ibs. [499 kg] 1,100 Ibs. [499 kg]

OTHER COMPONENTS

Radiator/Oil Cooler 145 Ibs. [66 kg] 145 Ibs. [66 kg]

Battery 49 lbs. [22 kg] 49 lbs. [22 kg]

Transmission Hydraulic Pump 90 lbs. [41 kg] 90 lbs. [41 kg]

Transmission Hydraulic
450 lbs. [205 kg], each 450 lbs. [205 kg], each
Drum Drive Motor - two [2] Used

2-16 12-2010
 Section 2
SPECIFICATIONS
TABLE 2-13. COMPONENT WEIGHTS (Continued).

ITEM DESIGN DATA

OTHER COMPONENTS 66 Inch Roller Unit 78 Inch Roller Unit

Hydraulic Oil Reservoir 102 lbs. [46 kg], empty 102 lbs. [46 kg], empty

Steering Cylinder 28 lbs. [10 kg] 28 lbs. [10 kg]

Hydraulic Pump Vibration 140 lbs. [64 kg] 140 lbs. [64 kg]

Hydraulic Vibrator Motor - 17 lbs. [8 kg] 17 lbs. [8 kg]

Two [2] Used

Drum and Vibrator Assembly 3,362 lbs. [1,525 kg] 3,891 lbs. [1,765 kg]
Complete -Two [2] Used

Machine Cockpit 1,240 lbs. [562 kg] 1,240 lbs. [562 kg]
Assembly Complete

Roll Over/Falling Object 1260 lbs. [571 kg] 1340 lbs. [608 kg]
Protective Structure
[ROPS/FOPS]

Cross Beam Plate - 164 lbs. [74 kg] 193 lbs. [88 kg]
Front & Rear - Two [2] Used

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Section 2
SPECIFICATIONS
TABLE 2-14. TORQUE SPECIFICATIONS FOR METRIC FASTENERS.

BOLT Tightening torque

dimensions FT. lbs. /N•m

8.8 10.9 12.9

M4 2 ft. lbs./3 N•m 3 ft. lbs./5 N•m 4 ft. lbs./5 N•m
M5 4 ft. lbs./6 N•m 7 ft. lbs./10 N•m 7 ft. lbs./10 N•m
M6 7 ft. lbs./10 N•m 11 ft. lbs./15 N•m 13 ft. lbs./18 N•m
M8 18 ft. lbs./25 N•m 26 ft. lbs./35 N•m 33 ft. lbs./45 N•m
M10 37 ft. lbs./50 N•m 55 ft. lbs./75 N•m 61 ft. lbs./83 N•m
M12 65 ft. lbs./88 N•m 91 ft. lbs./123 N•m 108 ft. lbs./147 N•m
M14 101 ft. lbs./137 N•m 145 ft. lbs./196 N•m 173 ft. lbs./235 N•m
M16 156 ft. lbs./211 N•m 221 ft. lbs./300 N•m 264 ft. lbs./358 N•m
M18 213 ft. lbs./290 N•m 303 ft. lbs./412 N•m 361 ft. lbs./490 N•m
M20 304 ft. lbs./412 N•m 426 ft. lbs./578 N•m 513 ft. lbs./696 N•m
M22 413 ft. lbs./560 N•m 559 ft. lbs./785 N•m 695 ft. lbs./942 N•m
M24 524 ft. lbs./711 N•m 738 ft. lbs./1000 N•m 885 ft. lbs./1200 N•m
M27 774 ft. lbs./1050 N•m 1092 ft. lbs./1480 N•m 1308 ft. lbs./1774 N•m
M30 1047 ft. lbs./1420 N•m 1482 ft. lbs./2010 N•m 1770 ft. lbs./2400 N•m

WARNING: Tables 2-14 and 2-15 list torque values for standard hardware and are intended as a guide
for average application involving typical stresses and machined surfaces.
Values are based on physical limitations of clean, plated and lubricated hardware. In
all cases, when an individual torque value is specified, it should be followed instead of
values given in this table. Replace original equipment with hardware of equal grade.

NOTE: The above table represents the strength class for capscrews with untreated, non-lubricated
surfaces. The quality designation of the capscrews is marked on the screw head.
The values result in a 90% utilization of the capscrews, yield point at a coefficient of friction of
µ total = 0.14.
Use a torque wrench to tighten capscrews to the CORRECT above-given torques; do NOT
apply when using lubricants.

2-18 12-2010
 Section 2
SPECIFICATIONS
TABLE 2-15. TORQUE SPECIFICATIONS FOR STANDARD INCH FASTENERS.

SAE GRADE 5 CAPSCREWS SAE GRADE 8 CAPSCREWS

Nom. Thread
size series torque torque torque torque
(FT. LBS.) (N•m) (FT. LBS.) (N•m)
Dry Lubed Dry Lubed Dry Lubed Dry Lubed Dry Lubed
1/4 20 UNC 8 6 11 9 12 9 16 12
28 UNC 10 7 13 10 14 10 19 14
5/16 18 UNC 17 13 24 18 25 18 33 25
24 UNF 19 14 26 20 27 20 37 28

3/8 16 UNC 31 23 42 31 44 33 59 44
24 UNF 35 26 47 36 49 37 67 50
7/16 14 UNC 49 37 67 50 70 52 95 71
20 UNF 55 41 75 56 78 58 105 79

1/2 13 UNC 75 57 100 77 105 80 145 110

20 UNF 85 64 115 86 120 90 165 120
9/16 12 UNC 110 82 145 110 155 115 210 155
18 UNF 120 91 165 125 170 130 230 175

5/8 11 UNC 150 115 205 155 210 160 285 215
18 UNF 170 130 230 175 240 180 325 245
3/4 10 UNC 265 200 360 270 375 280 510 380
16 UNF 295 225 405 300 420 315 570 425

7/8 9 UNC 430 320 580 435 605 455 820 615
14 UNF 475 355 640 480 670 500 905 680
1 8 UNC 645 485 875 655 910 680 1230 925
14 NF 720 540 980 735 1020 765 1380 1040

1-1/8 7 UNC 795 595 1080 805 1290 965 1750 1310
12 UNF 890 670 1210 905 1440 1080 1960 1470
1-1/4 7 UNC 1120 840 1520 1140 1820 1360 2460 1850
12 UNF 1240 930 1680 1260 2010 1500 2730 2050

1-3/8 6 UNC 1470 1100 1990 1490 2380 1780 3230 2420
12 UNF 1670 1250 2270 1700 2710 2040 3680 2760
1-1/2 6 UNC 1950 1460 2640 1980 3160 2370 4290 3210
12 UNF 2190 1650 2970 2230 3560 2670 4820 3620

WARNING: Tables 2-14 and 2-15 list torque values for standard hardware and are intended as a guide
for average application involving typical stresses and machined surfaces.
Values are based on physical limitations of clean, plated and lubricated hardware. In
all cases, when an individual torque value is specified, it should be followed instead of
values given in this table. Replace original equipment with hardware of equal grade.

12-2010 2-19
Section 2
SPECIFICATIONS

STANDARD INCH FASTENERS.

TABLE 2-16. LUBRICATION OILS, HYDRAULIC OILS AND COOLANT SPECIFICATIONS.

P/N DESCRIPTION SIZE

336830 HYDRAULIC/TRANSMISSION OIL 1 QT

836831 HYDRAULIC/TRANSMISSION OIL 2 GAL
336832 HYDRAULIC/TRANSMISSION OIL 5 GAL
336833 HYDRAULIC/TRANSMISSION OIL 55 GAL
3002338 ANTIFREEZE 1 GAL
326457 MULTIPURPOSE GREASE 5 LB

2-20 12-2010
 Section 2
SPECIFICATIONS
TABLE 2-17. 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] 0.02 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

742 SAF-T-LOK

226415 Primer T - Aerosol 6 0Z

316865 Anti-Seize Compound 1 LB

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

318700* Adhesive & Sealant Kit [Contains one each of * items]

12-2010 2-21
Section 2
SPECIFICATIONS

Notes

2-22 12-2010
 Section 3
OPERATION

TABLE OF CONTENTS

page

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

OPERATING CONTROLS, INDICATORS AND GAUGES .................................................................... 3-2.
OPERATION ......................................................................................................................................... 3-13.
CHECKS WITH THE ENGINE STOPPED .................................................................................. 3-13.
STARTING THE ENGINE ........................................................................................................... 3-13.
CHECKS WITH THE ENGINE RUNNING ................................................................................... 3-13.
OPERATION OF THE Park Brake SYSTEM ............................................................... 3-13.
OPERATION OF THE STEERING SYSTEM .................................................................... 3-14.
OPERATION OF THE TRANSMISSION SYSTEM ........................................................... 3-14.
ACTIVE FAULTS AND WARNINGS......................................................................................................3-14.
Changing the LCD-display............................................................................................................3-14.
Switching the middle display over...............................................................................3-14.
Switching the bottom display over..............................................................................3-15.
Activating input mode and changing display fields (brief instructions)...3-15.
Example of changing “Time/Date”...................................................................................3-17.
Switching over the upper display “Time / Coolant Temperature”..................3-19.
Changing the display units to “Metric / Imperial”..................................................3-21.
Setting the day/night brightness of the LCD-display..........................................3-22.
Entering input codes for service.................................................................................3-24.
OPERATING PRECAUTIONS .............................................................................................................. 3-26.
OPERATING THE MACHINE ............................................................................................................... 3-27.
DYNAMIC BRAKING OF THE MACHINE .................................................................................. 3-28.
STOPPING THE ENGINE............................................................................................................ 3-28.
RELEASING THE TOWING BYPASS VALVES AND SECONDARY/PARKING
BRAKE SYSTEM AND TOWING A COMPLETELY DISABLED MACHINE .......................... 3-30.
TRANSPORTING THE MACHINE ........................................................................................................ 3-33.
ESX FAULT CODES ............................................................................................................................. 3-35.

12-2010 3-1
Section 3
OPERATION
GENERAL INFORMATION. OPERATING CONTROLS, INDICATORS
AND GAUGES.
This section gives the OPERATING INSTRUCTIONS
for the Tandem Vibratory Roller. Operating controls and indicators for the Tandem
Vibratory Roller are shown on 3-4 Fig2 and are
Read, understand, and follow all “Precaution and listed in Table 3-1.
­OPERATING INSTRUCTIONS and WARNING” de-
cals and written in THIS manual, BEFORE starting, DANGER: Do NOT start, or operate, the Tandem
or operating, the machine [see 3-3 Fig1]. Vibratory Roller BEFORE reading,
understanding, and following ALL
DANGER: FAILURE to observe the information given in THIS section and
“OPERATING PRECAUTIONS” and/ shown on the machine “Operating
or the machine “OPERATION and Instruction and Warning” decal, found
WARNING INSTRUCTIONS”, given on the Instrument/Control panel
in this manual and found on the protection cover. The operator MUST
DECALS affixed to the machine can read about, and understand the
cause serious injury, or death. function of ALL controls, indicators,
Only authorized personnel, who are and gauges BEFORE starting the
fully trained in the machine operation, engine. SERIOUS INJURY or DEATH,
can operate the Tandem Vibratory can result if THESE procedures are
Roller. NOT followed.

Keep the machine in good mechanical condition at all

times.

WARNING: Do NOT operate a machine needing

repair. Put an information tag on the
steering control, which says “DO
NOT OPERATE”. Remove the key
from the ignition switch. Repair ALL
damage at ONCE. Minor damage can
result in major system failures.

3-2 12-2010
 Section 3
OPERATION

3-3 Fig1. OPERATING INSTRUCTION DECAL FOR TANDEM VIBRATORY ROLLER.

12-2010 3-3
Section 3
OPERATION

3-4 Fig2. MACHINE OPERATING CONTROLS AND INDICATORS.

3-4 12-2010
 Section 3
OPERATION
Table 3-1. MACHINE OPERATING CONTROLS, INDICATORS AND GAUGES.

ITEM NO. DESCRIPTION TYPE FUNCTION

[See 3-4
Fig2]

1 STEER CONTROL Control Lever - Controls left and right steering direction.
Lever Located On Left Lever in CENTER position – steer neutral.
Seat Console Unit will maintain direction of last user input.
Unit will NOT return to a straight direction line
of travel without input from operator.
To steer unit, push or pull steer control lever
towards desired direction of travel. This will
be true regardless of seat position.
Steer control lever also has a manual water
spray push button mounted on top [See item
2].

2 MANUAL H2O Electrical Push MANUAL “START/STOP” control of water

[WATER SPRAY] Button Thumb spray for front and rear rollers. Water saver
“START/STOP” SWITCH Switch On Top manual/automatic selector switch located on
Of Steer Control right control console must be in the manual
Lever position 11.
DEPRESS AND RELEASE switch to start
water spray.
DEPRESS AND RELEASE switch to stop
water spray.

3 AUTO-VIBE SPEED Momentary Rotary Vibration system turns on and off at a

INCREASE/DECREASE Switch selected travel speed.

4 DRUM VIBE MODE Rotary Switch - RIGHT position puts system in “AUTOMATIC
“MAN/AUTO” Two [2] position MODE”. Automatic mode is then set with
the “AUTO-VIBE SPEED” switch [Item 3]
controlling the vibration system to turn on and
off at a selected travel speed.
LEFT position puts system in “MANUAL
MODE”. Manual mode is controlled with
the top left ON/OFF push button [3-11 Fig3
Item 23] located on the right joystick control
lever [Item 11].

12-2010 3-5
Section 3
OPERATION
Table 3-1. MACHINE OPERATING CONTROLS, INDICATORS AND GAUGES (Continued).

ITEM NO. DESCRIPTION TYPE FUNCTION

[See 3-4
Fig2]

5 OPERATOR STATION Electrical LCD Provides machine system information

DISPLAY SCREEN Alpha and for display of operating parameters or
Numeric diagnostics mode. For detailed display
function [see 3-12 Fig4].

6 VIBE DRUM Rotary Switch - Selects drum vibration system(s) location

SELECTION Three [3] Position Front, Both, Rear.
LEFT switch position selects Front drum only.
CENTER switch position selects both Front
and Rear drums.
RIGHT switch position selects Rear drum
only.

7 VIBRATION Rotary Switch - Selects AMPLITUDE mode of BOTH Front

“AMPLITUDE” LOW/ Three [3] Position and Rear drum vibration systems.
OFF/HIGH SWITCH LEFT switch position, puts BOTH front
and rear drum vibration systems in LOW
amplitude mode.
RIGHT switch position, puts BOTH front
and rear drum vibration systems in HIGH
amplitude mode.
CENTER switch position, puts BOTH front
and rear drum vibration systems in OFF.

8 VIBRATOR SYSTEM Rotary Momentary Select desired FREQUENCY [VPM] for high
SPEED (VPM) Switch - Two [2] or low amplitude. Minimum frequency for
position both low and high amplitude is 2500 VPM.
Maximum frequency for low amplitude is
4000 VPM and maximum frequency for high
amplitude is 3400 VPM.
Turn momentary switch to the Left
[counterclockwise] to decrease vibe speed.
Turn momentary switch to the Right
[clockwise] to increase vibe speed.
Initial step increment is in 5 VPM intervals.
Interval will gradually increase the longer the
switch is held in position.

3-6 12-2010
 Section 3
OPERATION
Table 3-1. MACHINE OPERATING CONTROLS, INDICATORS AND GAUGES (Continued).

ITEM NO. DESCRIPTION TYPE FUNCTION

[See 3-4
Fig2]

9 IGNITION SWITCH Three [3] Position Controls STARTING, RUNNING, and

- Key Operated STOPPING the engine.
Interlock Switch NO. 1 Position: “OFF” condition, removes all
electrical power from circuits, except Beacon
and Hazard lights circuits.
NO. 2 Position: “ON” condition. Applies
electrical voltage to all circuits. This position
also is a “lock out” position and prevents
accidental engagement of the starter motor
when engine is in a “running” condition. The
Ignition switch must be rotated back past this
position to the NO. 1 [OFF] position before
the starter motor can be energized again
[start position].
NO. 3 Position: “START” condition. Applies
electrical current to the starter motor to crank
the engine. Switch spring returns to the NO.
2 [ON] position when the key is released.

10 ENGINE SPEED Rotary Switch- Electronically controls engine rpm [LOW,

SELECTION SWITCH Three [3] position ECO and HIGH] idle speed.
switch

12-2010 3-7
Section 3
OPERATION
Table 3-1. MACHINE OPERATING CONTROLS, INDICATORS AND GAUGES (Continued).

ITEM NO. DESCRIPTION TYPE FUNCTION

[See 3-4
Fig2]

11 TRAVEL/BRAKE Joystick Handle Controls park brake, forward/reverse

CONTROL LEVER - Mounted On movement and speed of machine in the
Right Seat Control direction selected.
Console Joystick in CENTER position - transmission
is in NEUTRAL.
Joystick in LEFT or RIGHT position - roller
unit will travel in that direction.
Joystick in CENTER BACK position - PARK
BRAKE is engaged.
Operator must be seated before TRAVEL/
BRAKE control lever will function.
LCD display will show “OPERATOR OUT
OF POSITION”, if seat position switch is not
activated. Item “r” Section 3-12 Figure4.
Full travel distance of [forward or reverse]
joystick position gives the highest travel speed.
The travel/brake control lever is also used to
toggle to other functions on the LCD display
console [see 3-11 Fig3].
Control lever must be in BRAKE POSITION
to start tandem roller unit.
Control handle also has the “MANUAL VIB”
[drum vibrator] push button switch located on
the upper left. [See 3-11 Fig3 Item 23].

12 12-SPEED Toggle Switch Select range of transmission drum speed.

TRANSMISSION - Twelve [12]
“WORK” range is positions 1 through 11 with
RANGE SELECTOR Position.
maximum travel speed 0 - 5 mph.
“TRAVEL” range is position 12 with maximum
travel speed of 10 mph.
NOTE: Vibration system is disabled in
“TRAVEL” range position 12.

3-8 12-2010
 Section 3
OPERATION
Table 3-1. MACHINE OPERATING CONTROLS, INDICATORS AND GAUGES (Continued).

ITEM NO. DESCRIPTION TYPE FUNCTION

[See 3-4
Fig2]

13 EMERGENCY STOP Two [2] Position Emergency stop switch. Out position releases
SWITCH Switch brake and allows engine to be started.
Depressed position sets brake and stops
engine.

14 WORK LIGHT SWITCH Toggle Switch - Controls front and rear work lights.
Two [2] Position

15 NIGHT LIGHT SWITCH Rotary Switch - Control front and rear night work lights.
Two [2] Position Note: Night work lights are optional
equipment.

16 BEACON LIGHT Two [2] position Controls beacon light.

SWITCH Toggle Switch Note: Beacon light is optional
equipment.

12-2010 3-9
Section 3
OPERATION
Table 3-1. MACHINE OPERATING CONTROLS, INDICATORS AND GAUGES (Continued).

ITEM NO. DESCRIPTION TYPE FUNCTION

[See 3-4
Fig2]

17 TURN SIGNAL SWITCH Three [3] Position Switch left to turn on Left directional lights.
LEFT/OFF/RIGHT Rotary Switch
Switch right to turn on Right directional lights.

18 HAZARD LIGHT Rotary Switch - Turn switch clockwise [CW] to turn Hazard/
SWITCH Two [2] Position 4-Way Flashers on.
Turn switch counterclockwise [CCW] to turn
Hazard/4-Way Flashers off.

19 WATER SAVER Rotary Switch- Position 0 is off.

MANUAL/AUTOMATIC Twelve [12] Positions 1 through 10 are AUTOMATIC
SELECTOR SWITCH Position mode. Each position turns water spray ON
and OFF at a different timed interval during
vibration mode.
Position 11 is MANUAL mode and controlled
by depressing push button [Item 2] located
on top of steer control lever [Item 1].

20 HORN SWITCH Push Button Provides activation of the horn. When the horn
Switch - Dash button is pushed, the horn will sound.
Mounted

3-10 12-2010
 Section 3
OPERATION

3-11 fig3. MACHINE OPERATING CONTROLS AND INDICATORS (Continued).

ITEM NO. FUNCTION

[See 3-11 Fig3]

21 Scroll DOWN button reduces the parameter value within the display screen. See Section
3 for details.

22 Scroll LEFT button within a parameter value on display screen. See Section 3 for details.

23 Manual ON/OFF vibration button.

24 Scroll UP button increases the parameter value within the display screen. See Section 3
for details.

25 Scroll RIGHT button within a parameter value on display screen. See Section 3 for
details.

26 Toggles lower display screen to show impacts per foot [IPF], mph for auto vibration
setting, battery voltage, engine oil pressure, hydraulic oil temperature and engine load
percentage.

27 Toggles upper display screen to show hour meter, vibrations per minute [VPM] and fuel
usage [gph].

12-2010 3-11
Section 3
OPERATION
h red = flashes when the coolant [filling] level is too
low. Engine is shut down after 10 seconds.

i yellow = lights if the hydraulic oil filter is contami-

nated. Check hydraulic system, replace hydraulic oil
filter.

j yellow = lights when hydraulic oil temperature is to

high.

k yellow = Charge control light. Lights if the battery

is not being charged. Check V-belt, if necessary re-
pair the generator.

l red = Water separator in fuel pre-cleaner.

Lights when the water proportion in the transparent
section of the fuel filter reaches the contacts.
3-12 fig4. DISPLAY SCREEN m = Function display. Set brightness of display.
Note: With the ignition switch in position 1 all n = Middle display field. Can be switched to display
gauges and instruments are switched on operating hours, vibration frequency or mean fuel
for 3 seconds. consumption by actuating the “Info-button”
a green = flashes when the direction indicator [see 3-11 Fig3 Item 27].
switch is actuated. o = Bottom display field. Can be switched to display
b = Indication of fuel level. impacts per foot [IPF], drum, voltage, hydraulic oil
pressure, hydraulic oil temperature or percent of en-
c = Upper display field. Shows either the time or the gine load by actuating “Info-button” [see 3-11
engine coolant temperature. Fig3 Item 26].

d = Indication of travel speed and pre-selected p = Asphalt temperature gauge.

speed limitation [green ring segment upper region].
Auto Vibe On/Off is indicated in the lower region of q yellow = Swivel seat out of position.
the green ring segment. r yellow = The seat occupation monitoring system
e red = flashes if engine oil pressure too low. En- lights when the seat is not occupied. If the machine is
gine is shut down after 30 seconds. Check engine oil travelling, the warning buzzer will sound. The unit will
level, repair the engine if necessary. stop after 2 seconds.

f red = flashes if the engine overheats [coolant s red = Park brake, with travel lever disengaged.
temperature] the warning buzzer sounds. Switch off t red = Central warning light. Lights if a fault code is
vibration, run engine with idle speed or shut down displayed.
engine if necessary. Clean radiator, if necessary
repair engine. Engine derate starts when the light is u red = Hazard light. Flashes when the hazard light
lit. Maximum derate occurs when a temperature of is activated.
238 degrees Fahrenheit is achieved. You will have
30 seconds until engine shutdown occurs. v = Engine speed display.

g yellow = lights if combustion air filter cartridge is

soiled. Clean or replace if necessary.

3-12 12-2010
 Section 3
OPERATION
OPERATION. e. Put engine speed switch [Item 10] in “LOW” or
“ECO” position.
CHECKS WITH THE ENGINE STOPPED.
CAUTION: Do not put the engine speed switch
With the engine in a STOPPED condition, INSPECT in the HIGH position. Engine damage
the machine BEFORE use and AFTER every eight can occur.
[8] hours of operation or DAILY, as directed in Sec-
tion 4 - MAINTENANCE - in THIS manual. f. Turn the ignition key switch [Item 9] to the
START [Number 3] position. Crank and start the
CHECK or INSPECT the following: engine.
Fuel level. WARNING: CALIFORNIA Proposition 65 Warning:
Engine lubrication oil level. Diesel engine exhaust and some of
Engine cooling system coolant level. its constituents are known to the
Condition of drive belt on engine. state of California to cause cancer,
Hydraulic system oil level. birth defects, and other reproductive
Drum bearing lubrication oil level, in BOTH drums. harm.
Engine inlet air path.
Fluid leaks from engine, fuel, or hydraulic system. CAUTION: Make a note of the amount of
Operation of the Horn. continuous cranking time. Do NOT
Operation of Lights and turn signal. crank the engine MORE than thirty
Safety decals, securely affixed to machine and their [30] seconds CONTINUOUSLY. If the
condition. engine is not started within this time,
Condition and operation of seat belt. put the Ignition switch key in the
ROPS/FOPS overall, condition of structure welds, OFF [Number 1] position. Wait one
and correct tightening torque of all structure mounting [1] minute. This will allow the starter
capscrews. motor time to cool. Repeat step “g”
until the engine is started.
STARTING THE ENGINE [see 3-4 Fig2 and
Table 3-1]. CHECKS WITH THE ENGINE RUNNING.
a. Remove the cover from the center display With the engine “running” CHECK and INSPECT the
console and right seat control console. machine BEFORE operation, using the FOLLOWING
b. Move travel/brake joystick control lever [Item 11] information. Also do these checks and/or inspections
to neutral. AFTER every eight [8] hours of operation, or DAILY,
as directed in Section 4 - MAINTENANCE - in this
c. Pull travel/brake joystick control lever [Item 11] manual. CHECK, or INSPECT, the following items.
back to apply brake.
OPERATION OF THE PARK BRAKE SYSTEM.
DANGER: The machine MUST NOT move, at
any time when the BRAKE is applied. With the travel/brake control lever [see 3-4 Fig2 Item
Do NOT operate the machine, if the 11] in the brake “ON” [APPLIED] position, note that
machine will move when the BRAKE the machine remains stopped.
is in the ON position, until the fault is
corrected. DANGER: Do NOT operate the machine if
the machine moves when the Park
d. Keep the steer control lever [Item 1] in the Center Braking system is in an “ON”
“NEUTRAL” position. [APPLIED] condition, until the fault is
corrected. The machine MUST NOT
NOTE: The transmission and the steering move, at ANY time, when the Park
controls must be in “NEUTRAL” for the Braking system control switch is in
engine to start. the “ON” [APPLIED] position.

12-2010 3-13
Section 3
OPERATION
OPERATION OF THE STEERING SYSTEM. Changing the LCD-display
DANGER: Keep ALL personnel CLEAR of the
Switching the middle display over
hitch area. The CLEARANCE between
the front and rear frames, at the hitch, NOTE: Switching over is possible while machine
CLOSES when the machine is turned is operated.
in EITHER direction.

The steering is controlled by the “STEER” control

lever [Item 1] located on the left seat control console.
Move the “STEER” control lever in the direction of
desired turn. The further the lever is moved, the
faster the machine will turn. Refer to Section 2 -
SPECIFICATIONS for steering turn radius informa-
tion.

OPERATION OF THE TRANSMISSION SYSTEM.

DANGER: Keep ALL personnel CLEAR of
the machine when checking the
operation of the transmission system.

CAUTION: Do NOT check the operation of either

drum vibration system, UNLESS the 3-14 fig54. CONTROL LEVER
drums of the machine are on a SOFT
surface, such as loose dirt, or “old”
tires. Damage to the drums and/or • Press Info-button 1 (3-14 Fig54) (back of travel
machine can occur if the operation of lever).
the drum vibration system is checked
on a HARD surface.

ACTIVE FAULTS AND WARNINGS.

The active ESX fault code will be displayed on the

Operator Display Screen. Please refer to page 3-35.

3-14 fig55. DISPLAY

With each actuation of the button the display cycles

thru operating hours to mean fuel consumption to
VPM (3-14 Fig55).

3-14 12-2010
 Section 3
OPERATION
Switching the bottom display over Activating input mode and changing
display fields (brief instructions)
NOTE: Switching over is possible while machine
is operated NOTE: In input mode the following can be
changed:
   - Display of time/coolant temperature
   - Setting of time / date
   - Metric/imperial units
   - Brightness of display
   - Input codes for service

3-15 fig56. CONTROL LEVER

• Press Info-button 2 (3-15 Fig56).

3-15 fig58. CONTROL LEVER

• Set the travel lever (3-15 Fig58) to braking position

3-15 fig57. DISPLAY

3-15 fig59. CONTROL LEVER
With each actuation of the button the values for 1.
impacts per foot, 2. speed for auto vibe setting, 3.
battery voltage, 4. engine oil pressure, 5. hydraulic oil • Press both Info-buttons simultaneously (3-15
temperature and 6. engine load % are successively Fig59) longer than three seconds to access the
displayed (3-15 Fig57). input mode.

* Optional equipment “CLOCK” appears in the display.

12-2010 3-15
Section 3
OPERATION
Sequence of changeable fields (3-16 Fig61):

Setting of time / date,

upper display changing of time / coolant temperature

Changing units from metric/imperial

Adapting brightness of display,

Entering input codes for service

3-16 fig60. CONTROL LEVER

• Select the desired field with the selection key F3

(3-16 Fig60).

NOTE: With function key F5 you can only jump

back within the display, e.g. from minutes
to hours. It cannot be used to jump from
one field function to the previous one, e.g.
from changing the upper display back to
the time.
3-16 fig62. CONTROL LEVER

• To change the field press keys F2 or F4

(3-16 Fig62).

NOTE: F2 = reduces the value or changes the

display
F4 = increases the value or changes the
display

3-16 fig61. DISPLAY

3-16 fig63. CONTROL LEVER

3-16 12-2010
 Section 3
OPERATION
• To quit the input mode press both Info-buttons
(3-16 Fig63) longer than three seconds or press
the F3-key as often as required to re-establish
normal condition.

Example of changing “Time/Date”

3-17 fig66. CONTROL LEVER

• Set the hours with keys F2 or F4 (3-17 Fig66).

3-17 fig64. CONTROL LEVER

Press both Info-buttons (3-17 Fig64) longer than

3-17 fig67. CONTROL LEVER

• Press key F3 to select “Minutes” (3-17 Fig67) and

set the displayed minutes with keys F2 or F4
(3-17 Fig66).

3-17 fig65. DISPLAY

three seconds to access the input mode.

“CLOCK” appears in the display and the figures rep-

resenting the hours are flashing (3-17 Fig65).

12-2010 3-17
Section 3
OPERATION

3-18 fig68. DISPLAY 3-18 fig70. DISPLAY

The figures representing minutes flash (3-18 Fig68) • Press key F3 to select “Month” (3-18 Fig70) and
set the displayed month with keys F2 or F4
• Set the minutes with keys F2 or F4 (3-17 Fig66). (3-17 Fig66).

3-18 fig69. DISPLAY 3-18 fig71. DISPLAY

• Press key F3 to select “Day” (3-18 Fig69) and set • Press key F3 to select “Year” (3-18 Fig71) and
the display keys F2 or F4 (3-17 Fig66). set the year with keys F2 or F4 (3-17 Fig66).

3-18 12-2010
 Section 3
OPERATION

3-19 fig72. CONTROL LEVER 3-19 fig74. CONTROL LEVER

• To quit the input mode press both Info-buttons • Press selection key F3 (3-19 Fig74) as often as
(3-19 Fig72) longer than three seconds or press required to quit the setting mode for time/date.
the F3-key as often as required to re-establish
normal condition.

Switching over the upper display “Time /

Coolant Temperature”

3-19 fig75. DISPLAY

The display “CLOCK” flashes (3-19 Fig75).

3-19 fig73. CONTROL LEVER

• Press both Info-buttons (3-19 Fig73) longer than

three seconds to access the input mode.

“CLOCK” appears in the display.

12-2010 3-19
Section 3
OPERATION

3-20 fig76. CONTROL LEVER 3-20 fig78. CONTROL LEVER

• Press keys F2 or F4 (3-20 Fig76). Press selection key F3 (3-20 Fig78) once to confirm.

3-20 fig77. DISPLAY 3-20 fig79. CONTROL LEVER

The coolant temperature is displayed (3-20 Fig77). • To quit the input mode press both Info-buttons
(3-20 Fig79) longer than three seconds or press
the F3-key as often as required to re-establish
normal condition.

3-20 12-2010
 Section 3
OPERATION
Changing the display units to “Metric /
Imperial”

3-21 fig82. DISPLAY

The display will show “MET” or “ENG” (3-21 Fig82).

3-21 fig80. CONTROL LEVER

• Press both Info-buttons (3-21 Fig80) longer than

three seconds to access the input mode.

3-21 fig83. CONTROL LEVER

• Press selection key F3 (3-21 Fig83) once to

confirm.
3-21 fig81. CONTROL LEVER

“CLOCK” appears in the display.

• Press selection key F3 (3-21 Fig81) as often as

required to reach the “Metric/Imperial” setting
mode.

12-2010 3-21
Section 3
OPERATION

3-22 fig84. CONTROL LEVER 3-22 fig86. CONTROL LEVER

• To quit the input mode press both Info-buttons • Press selection key F3 (3-22 Fig86) as often as
(3-22 Fig84) longer than three seconds or press required to reach the “Brightness” setting mode.
the F3-key as often as required to re-establish
normal condition.

Setting the day/night brightness of the

LCD-display

3-22 fig87. DISPLAY

The symbol “Lamp” and the brightness value (day) in

percent flashes (3-22 Fig87).

3-22 fig85. CONTROL LEVER

• Press both Info-buttons (3-22 Fig85) longer than

three seconds to access the input mode.

“CLOCK” appears in the display.

3-22 12-2010
 Section 3
OPERATION

3-23 fig88. CONTROL LEVER 3-23 fig90. DISPLAY

• Adjust the value with the keys F2 or F4 The brightness percentage (night) appears flashing
(3-23 Fig88). (3-23 Fig90).

Note: Standard setting for day = 100 %

Standard setting for night = 50 %

3-23 fig89. LIGHT SWITCH

• Switch on the light (3-23 Fig89). 3-23 fig91. CONTROL LEVER

• Adjust the value with the keys F2 or F4 (3-23

Fig91).

12-2010 3-23
Section 3
OPERATION
Entering input codes for service

3-24 fig92. CONTROL LEVER

3-24 fig94. CONTROL LEVER
• Press selection key F3 (3-24 Fig92) once
to confirm.
• Press both Info-buttons (3-24 Fig94) longer than
three seconds to access the input mode.

“CLOCK” appears in the display.

3-24 fig93. CONTROL LEVER

• To quit the input mode press both Info-buttons

3-24 fig95. CONTROL LEVER
(3-24 Fig93) longer than three seconds or press
the F3-key as often as required to re-establish
normal condition. • Press selection key F3 (3-24 Fig95) as often as
required to reach the “Service Codes” setting
mode.

3-24 12-2010
 Section 3
OPERATION

3-25 fig96. DISPLAY 3-25 fig98. CONTROL LEVER

The figures to enter the code are displayed • Select the following code digits with the keys F3
(3-25 Fig96). or F5 (3-25 Fig98) and adjust these with the func-
tion keys F2 or F4 (3-25 Fig97).

3-25 fig97. CONTROL LEVER

• Adjust the value of the first digit with the keys F2

or F4 (3-25 Fig97).

12-2010 3-25
Section 3
OPERATION
OPERATING PRECAUTIONS f. AFTER being seated, and BEFORE the machine
[See 3-3 Fig1, 3-4 Fig2, and 3-29 Fig5]. is started, ALWAYS securely FASTEN and
TIGHTEN the seat belt across the lap. The
To help prevent injury to personnel and/or damage to operator MUST remain seated at ALL times
the machine, ALWAYS observe ALL of the following during machine operation. Keep the hands and
“Operating Precautions”. feet INSIDE the machine cockpit at ALL times.
Allow NO riders on the machine at ANY time.
READ, UNDERSTAND and FOLLOW ALL informa-
tion shown on the “Operating Instruction and Warn- g. Do NOT suddenly stop the machine during
ing” operation, personnel INJURY or machine
decals found on the machine [see 3-3 Fig1 and 3-29 DAMAGE may occur.
Fig5] and the instructions written in THIS manual.
h. BEFORE getting off of the machine. Pull the
DANGER: FAILURE to observe the following Travel/Brake joystick control lever [Item 11] back
precautions and/or the machine to apply brake. Move engine speed switch [Item
“OPERATION and WARNING 10] to “LOW” or “ECO” position. Turn key switch
INSTRUCTIONS”, given in THIS [Item 9] to “OFF”.
section and found on the DECALS
affixed to the machine, can cause WARNING: ALWAYS APPLY the brake AFTER
SERIOUS INJURY, or DEATH. ONLY the machine has stopped. The
authorized personnel, who are fully transmission system will NOT hold
trained in the machine operation, can the parked machine in a stopped
operate the Tandem Vibratory Roller. condition, on ANY grade. The brake
MUST be used to hold the machine, in
a. USE a SLOW SPEED [work range] and a stopped condition, at ALL times.
ADDITIONAL CAUTION when nearing, or
operating, the machine close to a slope and/or i. Do NOT operate the machine, if the machine will
when traveling down a slope. move when the brake is in an “ON” [APPLIED]
position.
b. Do NOT travel across a slope. When on a slope,
TRAVEL in an “UP” or “DOWN” direction ONLY. j. Do NOT operate a machine NOT having the
“Operating Instruction and Warning” decals in
c. USE extra CAUTION when operating the place on the machine. The decals MUST remain
machine near personnel and/or other objects or in good condition and NOT be covered with dirt
machines. Visually check the operation of ALL or grease. REPLACE damaged, or missing,
instruments and display. decals IMMEDIATELY.
d. Do NOT operate a machine in need of repair.
Report ANY needed repairs and have the
machine repaired IMMEDIATELY. All instruments
and the display MUST operate, not be damaged
and be able to be read. Immediately replace any
instrument, having damage, with NEW.

e. Keep ALL personnel CLEAR of the hitch area at

ALL times, during operation, or service, of the
machine.

DANGER: Keep ALL personnel CLEAR of the

hitch area. The CLEARANCE between
the front and rear frames, at the hitch,
CLOSES when the machine is turned
in EITHER direction.

3-26 12-2010
 Section 3
OPERATION
OPERATING THE MACHINE CAUTION: When on the work surface, do not
[See 3-3 Fig1, 3-4 Fig2, 3-29 Fig5 and Table 3-1]. attempt to operate the drum vibration
systems with the “THROTTLE” RUN/
DANGER: ALL personnel and other machines IDLE control switch [Item 10] at
MUST be CLEAR of the machine path “IDLE”. The vibration system will not
BEFORE the machine is moved. operate with the engine at the “IDLE”
a. IMMEDIATELY, after being seated, place the engine speed and/or if the speed
seat belt across the lap and SECURELY insert range selector switch [Item 12] is in
the metal end into the belt buckle to TIGHTEN the “TRAVEL” position.
the belt AGAINST the body. After starting the d. SLOWLY move the Travel/Brake control lever
engine, release the brake system, by putting [Item 11] in the same direction the machine is
the brake system control switch [Item 13] in the desired to travel.
“OFF” [RELEASED] position.
NOTE: MOVING the Travel/Brake control lever
b. Put the transmission range selector switch in the direction of travel will cause the
[Item 12] in the “WORK” [Iow] range position. machine to travel in that direction. The
machine travel speed is proportional to
WARNING: Keep the transmission system in the
the amount of the Travel/Brake control
“WORK” range. Use the “WORK”
lever movement, until full lever travel has
range for machine movement within a
been reached, in either direction. The
confined area, when near personnel,
transmission system will be electrically
or objects, and for ALL vibratory
disengaged and the engine stopped,
applications when on the work
when the E-STOP/Park brake system
surface.
control switch [Item 13] is in the “ON”
[APPLIED] position.
Do NOT put the transmission in the
“TRAVEL” range when the machine is e. When the machine is clear of confinement,
moved within a confined area, is near personnel or objects, slowly move the Travel/
personnel, any object or machine. Brake control lever [Item 11] further toward the
The “TRAVEL” range is for “machine same direction of machine travel. This will give
transport” ONLY. full machine speed for the transmission range
and engine throttle speed, selected.
NOTE: The vibration systems will NOT operate
if the “TRAVEL” [high] transmission NOTE: During normal operation, the machine
range is selected. When the speed range travel speed is proportional to the
selector switch is in the “TRAVEL” amount of the Travel/Brake control lever
(12) position, “LOW” transmission movement, until full handle movement
system torque is available. When the has been reached, in either direction.
“2-SPEED” speed range selector switch
is in the WORK position (1-11), “HIGH” CAUTION: Damage to the drums and/or machine
transmission system torque is available. can occur if the drum vibration
system[s] is/are operated on a HARD
c. When on the work surface, put the engine surface.
“THROTTLE” RUN/IDLE switch [Item 10] in the
“RUN” [high engine speed] or ECO position. f. Turn vibration speed FREQUENCY [vpm] switch
[Item 8] to set the control at the desired drum
WARNING: Do NOT put the engine “THROTTLE” [vpm]. FREQUENCY [vpm] range from 2500-to-
RUN/IDLE control switch [Item 10] 4000.
in the “RUN” [high engine speed]
position when the machine is
being moved in a confined area, or
when near personnel, any object or
machine.

12-2010 3-27
Section 3
OPERATION
NOTE: Put the drum selection switch [Item 6] STOP switch [Item 13] and STOP the
at the desired “FRONT/BOTH/REAR” engine if observed machine operation
position. If operating either drum is NOT normal.
vibration system in the “MANUAL
MODE”, turn the system[s] “ON” and DYNAMIC BRAKING OF THE MACHINE
“OFF” by using the thumb switch [Item [See 3-4 Fig2].
23] located on the top left of travel/brake The TRANSMISSION SYSTEM is the PRIMARY
joystick control lever [Item 11]. In either [DYNAMIC] brake system for the machine.
the AUTOMATIC, or MANUAL mode, the
vibration system[s] will NOT operate with Slowing, and then stopping, of the machine, during
the engine at the “LOW” engine speed operation, is done by moving the TRAVEL/BRAKE
and/or if the travel speed switch is in joystick control lever [Item 11] TOWARD the “NEU-
the TRAVEL position. Adjustment of the TRAL” position.
vibration speed [Item 8] can be done at
any time, while the machine is on, or off, WARNING: When nearing a slope, first slow the
the work surface. When operating in the machine by moving the TRAVEL/
AUTOMATIC vibrator mode, the vibration BRAKE joystick control lever [Item
system[s] will start and stop at the 11] toward the neutral position.
adjusted, preset ON/OFF speed, without To SLOW the machine further,
the use of the thumb switch [Item 23], as or STOP the machine on a slope,
each work surface rolling pass is started move joystick lever rearward to
and then stopped. the PARKING brake position. The
PARKING brake MUST be used to
g. Put the drum selection FRONT/BOTH/REAR hold the machine in a “stopped”
control switch [Item 6] at the desired “FRONT”, condition at ALL times.
“REAR” or “BOTH” position.
STOPPING THE ENGINE [See 3-4 Fig2 and
h. Put the AMPLITUDE “LOW/ HIGH” control switch
Table 3-1].
[Item 7] at the desired LOW or HIGH drum
AMPLITUDE position. a. Move the TRAVEL/BRAKE joystick control lever
[Item 11] to neutral. Pull rearward on joystick to
i. When operating on the work surface, select the apply park brake.
desired water spray mode AUTO/MANUAL by
rotating the WATER SAVER selector switch b. Put the “Engine Speed control switch [Item 10] in
[Item 19] located on the right seat control the “LOW” position. Run the engine for a period
console. “AUTOMATIC” mode is position 1 of at LEAST three - five [3 - 5] minutes, at “LOW”
through 11. Each position is timed incrementally speed, BEFORE the engine is stopped.
turning the water on and off at desired setting.
Position 1 is the shortest and 11 is the longest CAUTION: Do NOT stop the engine BEFORE
time increment. running at the “LOW” engine idle
The “MANUAL” position allows the operator to speed. Serious engine DAMAGE
turn the water on or off as necessary using the can occur if the engine is stopped
thumb switch [Item 2] located on top of the steer BEFORE waiting the three - five [3 - 5]
lever [Item 1]. Turning the water saver selector minute period, to allow the engine to
switch fully counterclockwise [CCW] turns the normalize.
system OFF.
c. Put the ignition key switch [Item 9] at the “OFF”
DANGER: ALWAYS follow ALL “Operating [NUMBER 1] position and allow the engine to
Precautions and Instructions”, stop. Remove the key from the ignition switch
given in this manual and found on and install and lock the vandal guard, if desired.
the decals affixed to the machine.
Failure to follow the “Operating
Precautions and Instructions” can
cause SERIOUS INJURY or DEATH.
Immediately push the EMERGENCY

3-28 12-2010
 Section 3
OPERATION

3-29 fig5. OPERATION WARNING AND SEAT BELT WARNING DECALS.

12-2010 3-29
Section 3
OPERATION
RELEASING THE TOWING BYPASS VALVES h. Securely fasten the towing strap, cable or
AND SECONDARY/PARK BRAKE SYSTEM AND chain to the machine and the towing vehicle.
TOWING A COMPLETELY DISABLED MACHINE Tighten the strap, cable or chain completely.
[See 3-32 Fig6 and Fig7]. CAREFULLY remove the wood blocking from
under the drum. CAREFULLY and SLOWLY
WARNING: Do NOT tow the machine UNLESS tow the machine from the work surface. Tow the
ALL of the following procedures have machine to a truck or trailer. Move the machine
been followed. onto the truck or trailer and fasten securely [see
THIS section for CORRECT machine tie-down
Should the machine become COMPLETELY disabled procedures]. Move the machine for repair using
and the engine can NOT be started and/or the hy- the truck or trailer.
draulic system operated, use the following procedure
to release the BYPASS VALVES and the SECOND- WARNING: Keep ALL personnel CLEAR of the
ARY/PARKING brake system. towing vehicle and the machine
while removing the blocking and
a. Put SOLID wood blocks behind, and in front of, towing the machine, or moving the
the FRONT drum. machine onto the truck or trailer.
At this time, the machine will be
WARNING: Block SECURELY using SOLID wood
held in position ONLY by the wood
blocks. The blocks MUST hold the
blocking placed against the drums.
machine in place when the Park Brake
The secondary/park brake will be in a
system is released.
DISCONNECTED condition.
Do NOT tow the machine on ANY
b. Turn both screws [see 3-32 Fig6 Item1] located
grade. TOW the machine the LEAST
on bypass valves CLOCKWISE [CW] until flush
distance possible, from the work
with nut.
surface.
c. Locate the two [2] “brake release mechanisms”,
found behind the left-hand fuel fill access side Do NOT tow the machine at a speed
door. above TWO [2] miles per hour
[3.2 km/h]. Do NOT tow the machine
d. Take one [1] “brake release mechanism”. Turn to the repair area. ONLY use a truck
the nut onto the capscrew threads until it is near or trailer to move the machine to the
the head of the capscrew by using the fingers. repair area.

e. Go to either drum drive motor. Locate the NOTE: There will be resistance in the hydro-
0.875 in. [22 mm] hole in the frame rail. Install static transmission system. It is caused
the 20 mm capscrew through the frame rail. Turn by system oil in the transmission drum
the capscrew threads into the tapped hole, in drive motors, and will be noted UNTIL
the brake release piston, until the capscrew is the drum assemblies have turned
FULLY engaged in the tapped hole. approximately one third [1/3] revolution.
The machine will then roll more easily.
f. Turn the nut CLOCKWISE [CW], on the
capscrew threads, until the nut is against the WARNING: AFTER the machine has been moved,
frame rail. Hold the capscrew head with a the E-Stop/Parking brake system,
wrench. Use a second wrench to turn the nut on BOTH drum drive motors MUST
further INWARD until the nut will NOT turn be put in the APPLIED condition
any further through the use of the wrench. The using the following ADDITIONAL
secondary/parking brake, on THIS drum drive information.
motor, is now released. LEAVE the release
mechanism in place at THIS time. i. Go to either drum drive motor. Turn the nut,
found on the “brake release mechanism”, in the
g. Go to the SECOND drum drive motor. REPEAT COUNTERCLOCKWISE [CCW] direction until
steps “c” through “f” and release the secondary/ the nut is away from the frame rail. The brakes in
parking brake on that motor, using the SECOND the motor will now be APPLIED.
“brake release mechanism”.

3-30 12-2010
 Section 3
OPERATION
j. Go to the second drum drive motor and REPEAT
step “i”.
NOTE: AFTER the machine has reached
the repair area, both “brake release
mechanisms” MUST be removed. Keep
both “brake release mechanisms” with
the machine for future use.
k. Go to the transmission pump assembly. CLOSE
both the FORWARD, and the REVERSE,
direction bypass valves. Close the bypass valves
by turning the screw out COUNTERCLOCKWISE
[CCW]. until the screw is seated. Tighten nut to a
torque of 30 ft. lbs. [41 N•m].

CAUTION: BOTH bypass valves MUST be

returned to the CLOSED position.

12-2010 3-31
Section 3
OPERATION

3-32 Fig6. TRANSMISSION PUMP.

M16 X 2 X 115 mm
PROP. CLASS 10.9 METRIC
CAPSCREW FULLY TREADED

3-32 Fig7. SECONDARY/PARK BRAKE SYSTEM RELEASE LOCATION.

3-32 12-2010
 Section 3
OPERATION
TRANSPORTING THE MACHINE
[See 3-32 Fig6 and Fig7].

WARNING: FOUR [4] tie-downs MUST be used

to secure the machine to the truck
or trailer bed when transporting the
machine. ONE [1] frame tie-down
cut-out hole is found in EACH side of
the FRONT frame, near the outer end
of the drum. ONE [1] frame tie-down
hole is found in EACH side of the
REAR frame, near the outer end of
the drum.
a. CAREFULLY load the machine onto the
transporting truck or trailer. Put the Travel/brake
control lever [Item 11] in the “ON” [APPLIED]
position. Slow and then stop the engine using the
CORRECT procedures given in THIS section.
b. Install the steering lock pin through the lock pin
bores of the hitch [see 3-34 Fig8].
c. Put SOLID wood blocks under EACH drive drum
at the FRONT, and at the REAR, on BOTH sides
of the machine [see 3-34 Fig9].
d. Put SOLID wood blocks between roller frame
and transport on FRONT and REAR, on BOTH
sides. Connect four [4] tie-down chains between
the truck or trailer bed and the machine, at
the locations given in the above “WARNING”.
Tighten the tie-down load binding device
to hold the machine securely in position for
transportation [see 3-34 Fig9].
WARNING: The machine MUST be securely held
to the truck or trailer bed. Be sure
the tie-down chains and load binding
devices are correctly connected and
tightened securely.

12-2010 3-33
Section 3
OPERATION

3-34 fig8. STEERING LOCK PIN LOCATION.

3-34 fig9. MACHINE TRANSPORT TIE-DOWN LOCATIONS.

3-34 12-2010
 Section 3
OPERATION
ESX FAULT CODES

Selected Fault Reactions of the ESX Control

Reaction Symbol in fault Warning Warning Engine stop
message display
Signal Code output Code output Code output
without buzzer with buzzer with buzzer

Engine oil pressure

(from EMC)

Coolant temperature
(from EMC)

Coolant level

after 5s
Engine air filter

after 5s
hydraulic oil filter
- Main circuit -
after 5s
Hydraulic oil filter
- Steering hydraulics -
after 5s
Hydraulic oil temperature

after 5s
Water separator in fuel filter
TIER III Engines

Seat contact

Seat position

Version: V1.04 / 06.06.07

Autor: Ch. Fondel / TES

12-2010 3-35
Section 3
OPERATION
ESX FAULT CODES

Fault codes of the ESX control

Overview
Fault code Fault description
General faults / warnings / machine tests
Fault in travel system
Fault in steering system
Fault in remote control
Faults in work functions (vibration, attachment plates,
rotor, chip spreader)
Fault in measuring systems
Fault diesel engine
Fault hydraulic system
Fault anti-theft warning system, localization system,
access system, time account, etc.
Input of machine codes
Input of codes for measuring technology
Operating hours, load spectrum, etc.
1
Severe software error
Errors of external IO-nodes (joystick, data collector,
1
Dios module, LC-display, etc.)

1
Not all of these faults are decrypted here, please ask the after sales service for assistance!

Version: V1.04 / 06.06.07

Autor: Ch. Fondel / TES

3-36 12-2010
12-2010
Description of fault reactions
Fault reaction Description of fault reaction
Warning.
Fault code is displayed.
ESX FAULT CODES

Warning.
Fault code is displayed.
Audible signal

Function affected, the faulty function is replaced by an emergency function.

Fault code is displayed.
Audible signal

Partial function faulty, the partial function cannot be overridden by an emergency function.
The machine is stopped if this fault occurs.
The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible.
Fault code is displayed.
Audible signal

Partial function faulty, the partial function cannot be overridden by an emergency function.
 the diesel engine is shut down.
The machine is no longer able to drive, e.g. because parts of the travel system are defective
Fault code is displayed.
Audible signal

Severe fault. The function of the control can no longer be guaranteed.

 Control is switched off.
 the diesel engine is shut down, if possible.
The fault code is displayed, the signal light in the monitoring board is permanently on.
No audible signal!

Note: Errors with error reaction 1 and 2 are only warning messages and are NOT stored in the error log!

Version: V1.04 / 06.06.07

Autor: Ch. Fondel / TES

3-37
OPERATION
Section 3
3-38
Detailed description of fault codes and their possible causes

General
Section 3

Fault Fault description Possible causes Terminal Input Fault

Code code for reaction
diagnose
OPERATION

Driving against brake – warning A corresponding input code has been entered
The function "Driving against brake" is activated 2

Simulated engine run - warning A corresponding input code has been entered
The function "Simulated engine run" is activated 2

Ant- Slip Control (ASC) deactivated - warning A corresponding input code has been entered
The function "Anti Slip Control (ASC)" is deactivated 2

Drum drive deactivated - warning A corresponding input code has been entered
Test mode "Drum drive deactivated" was activated. 2

Axle drive deactivated - warning A corresponding input code has been entered
Test mode "Axle drive deactivated" was activated. 2

Overvoltage 8,5V Connection of voltage level to operating voltage, another voltage X35:23
The voltage level of the 8,5V range is impermissibly potential or control defective 2
exceeded
(see signal description)
Undervoltage 8,5V Connection of voltage level to ground, another voltage potential X35:23
The voltage level of the 8,5V range is impermissibly fallen or control defective 2
short of
(see signal description)
Error "Voltage Override Relay" 2
The voltage level of the 8,5V range is...

Version: V1.04 / 06.06.07

Autor: Ch. Fondel / TES

12-2010
ESX FAULT CODES
12-2010
Brake
Fault Fault description Possible causes Terminal Input Fault
Code code for reaction
diagnose
Brake valve line breakage  The connecting line between output pf control and
The required control power cannot be transmitted to the control solenoid is interrupted. 1001 6
X35:61

ESX FAULT CODES

control solenoid. The solenoid is defective

Brake valve short circuit to ground  The connecting cable has short circuit to ground
Signal outside the valid range (see signal description)  Coil defective X35:61 1001 6

Brake valve short circuit Ub  The connecting cable has short circuit to battery voltage
Signal outside the valid range (see signal description) X35:61 1001 6

Brake valve  The connecting cable has short circuit to ground

Overheating of output driver in ESX  Coil defective X35:61 1001 6

BTS brake / plausibility (BTS=output driver)  Hardware defect on travel lever

Plausibility conflict in evaluation of travel lever X- axis to  Connection between ESX and travel lever interrupted X35:14 5
the brake contact signal X33:3

Backup warning buzzer

Fault Fault description Possible causes Terminal Input Fault
Code code for reaction
diagnose
Relay (K26) for backup warning buzzer, line  The connecting line between output pf control and 3
interrupted relay interrupted.
X35:2
The required control power cannot be transmitted to the  Relay defective.
control solenoid.
Relay (K26) for backup warning buzzer, short circuit to  The connecting cable has short circuit to ground 3
ground  Coil defective X35:2
Signal outside the valid range (see signal description)
Relay (K26) for backup warning buzzer, short circuit to  The connecting cable has short circuit to battery voltage 3
Ub X35:2
Signal outside the valid range (see signal description)

Version: V1.04 / 06.06.07

Autor: Ch. Fondel / TES

3-39
OPERATION
Section 3
3-40
Travel lever
Fault Fault description Possible causes Terminal Input Fault
Code code for reaction
Section 3

diagnose
Travel lever sum error X-axis Internal fault in travel lever -> Replace travel lever.
Error in redundant evaluation of axis CAN 2 3
OPERATION

Travel lever cable breakage X-axis Cable breakage in travel lever -> Replace travel lever.
Signal outside the valid range (see signal description) CAN 2 3

Travel lever parameterization X-axis Internal fault in travel lever -> Replace travel lever.
CAN 2
3
Travel lever direction evaluation X-axis Internal fault in travel lever -> Replace travel lever.
The direction of travel lever movement could not be CAN 2 3
determined
Travel lever difference error X-axis Internal fault in travel lever -> Replace travel lever.
Error in redundant evaluation of travel lever signal CAN 2 3

Travel lever software error X-axis Internal fault in travel lever -> Replace travel lever.
Software does not work fault free CAN 2 3

Fault Fault description Possible causes Terminal Input Fault

Code code for reaction
diagnose
Travel lever sum error Y-axis Internal fault in travel lever -> Replace travel lever.
Error in redundant evaluation of axis CAN 2 3

Travel lever cable breakage Y-axis Cable breakage in travel lever -> Replace travel lever.
Signal outside the valid range (see signal description) CAN 2 3

Travel lever parameterization Y-axis Internal fault in travel lever -> Replace travel lever.
CAN 2
3
Travel lever direction evaluation Y-axis Internal fault in travel lever -> Replace travel lever.
The direction of travel lever movement could not be 3
CAN 2
determined

Travel lever difference error Y-axis Internal fault in travel lever -> Replace travel lever.
Error in redundant evaluation of travel lever signal CAN 2 3

Travel lever software error Y-axis Internal fault in travel lever -> Replace travel lever.
Software does not work fault free CAN 2 3

Version: V1.04 / 06.06.07

Autor: Ch. Fondel / TES

12-2010
ESX FAULT CODES
12-2010
Travel speed range selector switch
Fault Fault description Possible causes Terminal Input Fault
Code code for reaction
diagnose
Travel range selector switch "Ground connection" Cable breakage in ground line, or X23:8
Signal outside the valid range (see signal description) Connecting cable between switch and ground connection has 1040 3
come loose
Travel range selector switch "Supply connection" Cable breakage in connecting line, or X23:5
ESX FAULT CODES

Signal outside the valid range (see signal description) The connecting cable between switch and supply line 1040 3
has come loose
Travel speed range selector switch Higher contact resistances have possibly caused a faulty signal. X23:11
Signal outside the valid range (see signal description) The switch must be replaced. 1040 3

Travel system
Fault Fault description Possible causes Terminal Input Fault
Code code for reaction
diagnose
Output travel pump forward valve The connecting line from the output of the control to the X35:48
The required control power cannot be transmitted to the proportional solenoid is interrupted or the proportional solenoid 4
proportional solenoid. is defective
-> Line interrupted/cable breakage.
Output travel pump forward valve Short circuit of connecting line (control to proportional valve) to X35:48
Supply voltage UB applied to the output to the proportional voltage supply 5
valve.
Output travel pump forward valve - Short circuit of connecting line (control to proportional valve) X35:48
Output to proportional valve shorted to ground. to machine frame or a ground cable. 4
- Proportional valve defective.
Output travel pump forward valve Faults in valve control Check wiring. X35:48
Fault of current regulator forward 4

Output travel pump forward valve Faults in valve control Check wiring. X35:48
Fault of current regulator forward 4

Output travel pump forward valve Internal Software failure X35:48

Output not initialized 4
Output travel pump forward valve Internal Software/Hardware failure X35:48
Output pin error 4

Version: V1.04 / 06.06.07

Autor: Ch. Fondel / TES

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OPERATION
Section 3
3-42
Fault Fault description Possible causes Terminal Input Fault
Code code for reaction
diagnose
Section 3

Output travel pump backward valve The connecting line from the output of the control to the
The required control power cannot be transmitted to the proportional solenoid is interrupted or the proportional solenoid 4
X35:49
proportional solenoid. is defective
-> Line interrupted/cable breakage.
OPERATION

Output travel pump backward valve Short circuit of connecting line (control to proportional valve) to
Supply voltage UB applied to the output to the proportional voltage supply X35:49 5
valve.
Output travel pump backward valve - Short circuit of connecting line (control to proportional valve)
Output to proportional valve shorted to ground. to machine frame or a ground cable. X35:49 4
- Proportional valve defective.
Output travel pump backward valve Faults in valve control Check wiring.
Fault of current regulator forward X35:49 4

Output travel pump backward valve Faults in valve control Check wiring.
Fault of current regulator forward X35:49 4

Output travel pump backward valve Internal Software failure

X35:49
Output not initialized 4
Output travel pump backward valve Internal Software/Hardware failure
X35:49
Output pin error 4

Teaching function travel system

Fault Fault description Possible causes Terminal Input Fault

Code code for reaction
diagnose
Note! Threshold currents for travel pump have NOT been
learned. See 3.2.2 1
Error in teaching the surge current forward Machine mechanically blocked
X35:48
Travel system bypass valves out of adjustment 3
Error in teaching the surge current backward Machine mechanically blocked
X35:49
Travel system bypass valves out of adjustment 3

Version: V1.04 / 06.06.07

Autor: Ch. Fondel / TES

12-2010
ESX FAULT CODES
12-2010
Drum drive motors

Fault Fault description Possible causes Terminal Input Fault

Code code for reaction
diagnose
Valve for front Poclain motor, line interrupted  The connecting line between output of control and 1100 3
ESX FAULT CODES

The required control power cannot be transmitted to the valve interrupted. 1101
X35:20
control solenoid.  Valve coil defective.

Valve for front Poclain motor, short circuit to ground  The connecting cable has short circuit to ground 3
X35:20
Signal outside the valid range (see signal description)  Valve coil defective
Valve front Poclain motor, Short circuit to Ub  The connecting cable has short circuit to battery voltage 3
X35:20
Signal outside the valid range (see signal description)
Speed sensor pulses front travel motor Check connecting lines and plugs on wheel speed sensor, if 1105 4
Incorrect or non-existent signal "Frequency" necessary replace the wheel speed sensor X35:34 1106

Valve for rear Poclain motor, line interrupted  The connecting line between output of control and 1110 3
The required control power cannot be transmitted to the valve interrupted. 1111
X35:21
control solenoid.  Valve coil defective.

Valve for rear Poclain motor, short circuit to ground  The connecting cable has short circuit to ground 3
X35:21
Signal outside the valid range (see signal description)  Coil defective
Valve rear Poclain motor, Short circuit to Ub  The connecting cable has short circuit to battery voltage 3
X35:21
Signal outside the valid range (see signal description)

Seat position sensor, seat contact

Fault Fault description Possible causes Terminal Input Fault

Code code for reaction
diagnose
Seat connect not occupied Cable breakage in signal line, or 2
X35:15
driver's seat not occupied (driver not seated!)
Seat position not OK The seat is not in a permissible driving position or the fault has 2
X35:38
not yet been reset by returning the travel lever to brake
X35:39
engagement position.
Seat position Sensor init Internal software failure 4
X35:38
Inside switch is not initialised
Seat position Sensor init Internal software failure 4
X35:39
Outside switch is not initialised
Seat position Sensor linebreak Cable breakage in signal line from switch, voltage supply or Gnd 4
Inside switch Signal outside the valid range (see signal line X35:38
description)

Version: V1.04 / 06.06.07

Autor: Ch. Fondel / TES

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OPERATION
Section 3
3-44
Fault Fault description Possible causes Terminal Input Fault
Code code for reaction
diagnose
Seat position Sensor linebreak Cable breakage in signal line from switch, voltage supply or Gnd 4
Inside switch Signal outside the valid range (see signal line X35:39
Section 3

description)
OPERATION

Version: V1.04 / 06.06.07

Autor: Ch. Fondel / TES

12-2010
ESX FAULT CODES
12-2010
Steering lever
Fault Fault description Possible causes Terminal Input Fault
Code code for reaction
diagnose
Steering lever sum error X-axis Internal fault of steering lever -> Replace the steering lever. CAN 2
ESX FAULT CODES

Error in redundant evaluation of axis 3

Steering lever cable breakage X-axis Cable breakage inside the steering lever -> Replace the steering CAN 2
Signal outside the valid range (see signal description) lever. 3

Steering lever parameterization of X-axis Internal fault of steering lever -> Replace the steering lever. CAN 2
3
Steering lever direction evaluation X-axis Internal fault of steering lever -> Replace the steering lever. CAN 2
The direction of travel lever movement could not be 3
determined
Steering lever difference error X-axis Internal fault of steering lever -> Replace the steering lever. CAN 2
Error in redundant evaluation of travel lever signal 3

Steering lever software error X-axis Internal fault of steering lever -> Replace the steering lever. CAN 2
Software does not work fault free 3

Fault Fault description Possible causes Terminal Input Fault

Code code for reaction
diagnose
Steering lever sum error Y-axis Internal fault of steering lever -> Replace the steering lever. CAN 2
Error in redundant evaluation of axis 3

Steering lever cable breakage Y-axis Cable breakage inside the steering lever -> Replace the steering CAN 2
Signal outside the valid range (see signal description) lever. 3

Steering lever parameterization Y-axis Internal fault of steering lever-> Replace the steering lever. CAN 2
3
Steering lever direction evaluation Y-axis Internal fault of steering lever-> Replace the steering lever. CAN 2
The direction of travel lever movement could not be 3
determined

Steering lever difference error Y-axis Internal fault of steering lever-> Replace the steering lever. CAN 2
Error in redundant evaluation of travel lever signal 3

Steering lever software error Y-axis Internal fault of steering lever-> Replace the steering lever. CAN 2
Software does not work fault free 3

Version: V1.04 / 06.06.07

Autor: Ch. Fondel / TES

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OPERATION
Section 3
3-46
Steering valves
Fault Fault description Possible causes Terminal Input Fault
Code code for reaction
diagnose
Section 3

Output steering valve right The connecting line from the output of the control to the X35:47 2100 4
The required control power cannot be transmitted to the proportional solenoid is interrupted or the proportional solenoid 2101
proportional solenoid. is defective
OPERATION

-> Line interrupted/cable breakage.

Output steering valve right Short circuit of connecting line (control to proportional valve) to X35:47 5
Supply voltage UB applied to the output to the proportional voltage supply
valve.
Output steering valve right - Short circuit of connecting line (control to proportional valve) X35: 47 4
Output to proportional valve shorted to ground. to machine frame or a ground cable.
- Proportional valve defective.
Output steering valve right Faults in valve control Check wiring. X35: 47 4
Fault current regulator
Output steering valve right Faults in valve control Check wiring. X35: 47 4
Fault current regulator

Output steering valve right Internal Software failure X35: 47 4

Output not initialized
Output steering valve right Internal Software/Hardware failure X35: 47 4
Output pin error
Output steering valve left The connecting line from the output of the control to the X35:46 2102 4
The required control power cannot be transmitted to the proportional solenoid is interrupted or the proportional solenoid 2103
proportional solenoid. is defective
-> Line interrupted/cable breakage.
Output steering valve left Short circuit of connecting line (control to proportional valve) to X35: 46 5
Supply voltage UB applied to the output to the proportional voltage supply
valve.
Output steering valve left - Short circuit of connecting line (control to proportional valve) X35: 46 4
Output to proportional valve shorted to ground. to machine frame or a ground cable.
- Proportional valve defective.
Output steering valve left Faults in valve control Check wiring. X35: 46 4
Fault current regulator
Output steering valve left Faults in valve control Check wiring. X35:46 4
Fault current regulator

Output steering valve left Internal Software failure X35:46 4

Output not initialized
Output steering valve left Internal Software/Hardware failure X35:46 4
Output pin error

Version: V1.04 / 06.06.07

Autor: Ch. Fondel / TES

12-2010
ESX FAULT CODES
12-2010
Vibration front
Fault Fault description Possible causes Terminal Assignment Input Fault
Code AD-4 AM-4 code for reaction
diagnose
Vibration pump front valve (low amplitude on AD) The connecting line between control output and proportional X35:42 X X 3010 4
Line interruption solenoid is interrupted, or 3013
The proportional solenoid is defective
changeover relay / bridge missing
ESX FAULT CODES

Vibration pump front valve(low amplitude on AD) Short circuit of connecting line (control to proportional valve) to X35:42 X X 5
Supply voltage UB applied to the output to the proportional voltage supply
valve.
Vibration pump front valve(low amplitude on AD) • Short circuit of connecting line (control to proportional valve) X35:42 X X 4
Output to proportional valve shorted to ground. to machine frame or a ground cable.
• Proportional valve defective.

Vibration pump front valve(low amplitude on AD) System fault! Replace the control! X35:42 X X 4
Internal system fault.
Vibration pump front valve(low amplitude on AD) System fault! Replace the control! X35:42 X X 4
Internal system fault.
Vibration pump front valve(low amplitude on AD) System fault! Replace the control! X35:42 X X 4
Internal system fault. Init Error.
Vibration pump front valve(low amplitude on AD) System fault! Replace the control! X35:42 X X 4
Internal system fault. Pin Error
Vibration adaptation control front (low amplitude on DH)? • Wear or damage in vibration system hydraulic circuit. X35:42 X X 2
"Frequency adaptation" • Valve sticking/defective.
Adjustment range reached!
(see signal specification)
Vibration adaptation control front (low amplitude on DH)? • Wear or damage in vibration system hydraulic circuit. X35:42 X X 2
"Frequency adaptation" • Valve sticking/defective.
Upper adjustment range reached!
(see signal specification)
Vibration adaptation control front (low amplitude on DH)? • Wear or damage in vibration system hydraulic circuit. X35:42 X X 2
"Frequency adaptation" • Valve sticking/defective.
Lower adjustment range reached!
(see signal specification)
Vibration frequency front (low amplitude on AD) Vibrations frequency exceeded by more than 5Hz. X35:42 X X 4
Frequency/speed to high Emergency shut down to protect bearings.
After replacement of a vibration pump or peripheral equipment in
the vibration circuit this fault may occur as a result of
unfavourable component tolerances.
In this case normal operation can be reached by multiple
activation of the vibration, after the fault has been rectified.
ATTENTION! It must be assured, that the fault has not be
caused by a faulty component (pump, control,
valve.
Vibration pump front valve (low amplitude on AD) Internal Software fault X35:42 X X 3

Version: V1.04 / 06.06.07

Autor: Ch. Fondel / TES

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OPERATION
Section 3
3-48
Fault Fault description Possible causes Terminal Assignment Input Fault
Code AD-4 AM-4 code for reaction
diagnose
Internal system fault. Hysteresis error
Faults in connecting line, incorrect valve coil, or X35:42 X X 3
Section 3

Valve vibration pump front (low amplitude on AD)

"Current range" Connection to another potential (e.g. operating voltage)
The control current is outside the valid range (see signal
specification)
OPERATION

Vibration sensor front "No signal" Check connecting lines and plugs to the front vibration sensor, X35:34 X X 3012 3
The sensor in the front vibration motor does not pick up or
any pulses. replace the sensor in the vibration motor, if necessary.

Fault Fault description Possible causes Terminal Assignment Input Fault

Code AD-4 AM-4 code for reaction
diagnose
Vibration pump front valve (only AD: high amplitude) The connecting line between control output and proportional X35:42 X 3011 4
Line interruption solenoid is interrupted, or 3014
The proportional solenoid is defective
changeover relay / bridge missing
Vibration pump front valve (only AD: high amplitude) Short circuit of connecting line (control to proportional valve) to X35:42 X 5
Supply voltage UB applied to the output to the proportional voltage supply
valve.
Vibration pump front valve (only AD: high amplitude) • Short circuit of connecting line (control to proportional valve) X35:42 X 4
Output to proportional valve shorted to ground. to machine frame or a ground cable.
• Proportional valve defective.
Vibration pump front(only DH: high amplitude) Faults in connecting line, incorrect valve coil, or X35:42 X 4
"Control fault regulating up" Connection to another potential (e.g. operating voltage)
The control current is outside the valid range (see signal
specification)
Vibration pump front(only DH: high amplitude) Faults in connecting line, incorrect valve coil, or X35:42 X 4
"Control fault regulating down" Connection to another potential (e.g. operating voltage)
The control current is outside the valid range (see signal
specification)
Vibration pump front valve (only AD: high amplitude) System fault! Replace the control! X35:42 X 4
Internal system fault. Init Error.
Vibration pump front valve (only AD: high amplitude) System fault! Replace the control! X35:42 X 4
Internal system fault. Pin Error.
Vibration front, adaptation control (only AD: high Wear or damage in vibration system hydraulic circuit. X35:42 X 2
amplitude) Frequency adaptation
Limits of adaptation range exceeded
(see signal specification)
Vibration front, adaptation control (only AD: high • Wear or damage in vibration system hydraulic circuit. X35:42 X 2
amplitude) "Frequency adaptation" • Valve sticking/defective.
Upper adjustment range reached!

Version: V1.04 / 06.06.07

Autor: Ch. Fondel / TES

12-2010
ESX FAULT CODES
12-2010
Fault Fault description Possible causes Terminal Assignment Input Fault
Code AD-4 AM-4 code for reaction
diagnose
(see signal specification)
Vibration front, adaptation control (only AD: high • Wear or damage in vibration system hydraulic circuit. X35:42 X 2
amplitude) "Frequency adaptation" • Valve sticking/defective.
Lower adjustment range reached!
(see signal specification)
ESX FAULT CODES

Vibration frequency front (only AD: high amplitude) Vibrations frequency exceeded by more than 5Hz. X35:42 X 4
Frequency/speed to high Emergency shut down to protect bearings.
After replacement of a vibration pump or peripheral equipment in
the vibration circuit this fault may occur as a result of
unfavourable component tolerances.
In this case normal operation can be reached by multiple
activation of the vibration, after the fault has been rectified.
ATTENTION! It must be assured, that the fault has not be
caused by a faulty component (pump, control,
valve.
Vibration pump front valve (only AD: high amplitude) System fault! Replace the control! X35:42 X 3
Internal system fault. Hysteresis error
Valve vibration pump front(only DH: high amplitude) Faults in control line, or X35:42 X 3
"Current range" Connection to another potential (e.g. operating voltage)
The control current is outside the valid range (see signal
specification)

Vibration rear
Fault Fault description Possible causes Terminal Assignment Input Fault
Code AD-4 AM-4 code for reaction
diagnose
Vibration pump rear valve (low amplitude on AD) The connecting line between control output and proportional X35:43 X X 3020 4
Line interruption solenoid is interrupted, or 3023
The proportional solenoid is defective
changeover relay / bridge missing
Vibration pump rear valve(low amplitude on AD) Short circuit of connecting line (control to proportional valve) to X35:43 X X 5
Supply voltage UB applied to the output to the proportional voltage supply
valve.
Valve vibration pump rear valve(low amplitude on AD) • Short circuit of connecting line (control to proportional valve) X35:43 X X 4
Output to proportional valve shorted to ground. to machine frame or a ground cable.
• Proportional valve defective.
Valve vibration pump rear (low amplitude on AD) Faults in connecting line, incorrect valve coil, or X35:43 X X 4
"Regulate up to compensate control fault" Connection to another potential (e.g. operating voltage)
The control current is outside the valid range (see signal
specification)

Version: V1.04 / 06.06.07

Autor: Ch. Fondel / TES

3-49
OPERATION
Section 3
3-50
Fault Fault description Possible causes Terminal Assignment Input Fault
Code AD-4 AM-4 code for reaction
diagnose
Valve vibration pump rear (low amplitude on AD) Faults in connecting line, incorrect valve coil, or X35:43 X X 4
Connection to another potential (e.g. operating voltage)
Section 3

"Regulate down to compensate control fault"

The control current is outside the valid range (see signal
specification)
Valve vibration pump rear valve(low amplitude on AD) System fault! Replace the control! X35:43 X X 4
OPERATION

Internal system fault. Init Error.

Valve vibration pump rear valve(low amplitude on AD) System fault! Replace the control! X35:43 X X 4
Internal system fault. Pin Error.
Vibration adaptation control rear (low amplitude on DH)? • Wear or damage in vibration system hydraulic circuit. X35:43 X X 2
"Frequency adaptation" • Valve sticking/defective.
Adjustment range reached!
(see signal specification)
Vibration adaptation control rear (low amplitude on DH)? • Wear or damage in vibration system hydraulic circuit. X35:43 X X 2
"Frequency adaptation" • Valve sticking/defective.
Upper adjustment range reached!
(see signal specification)
Vibration adaptation control rear (low amplitude on DH)? • Wear or damage in vibration system hydraulic circuit. X35:43 X X 2
"Frequency adaptation" • Valve sticking/defective.
Lower adjustment range reached!
(see signal specification)
Vibration frequency rear (low amplitude on AD) Vibrations frequency exceeded by more than 5Hz. X35:43 X X 4
Frequency/speed to high Emergency shut down to protect bearings.
After replacement of a vibration pump or peripheral equipment in
the vibration circuit this fault may occur as a result of
unfavourable component tolerances.
In this case normal operation can be reached by multiple
activation of the vibration, after the fault has been rectified.
ATTENTION! It must be assured, that the fault has not be
caused by a faulty component (pump, control,
valve.
Vibration pump rear valve (low amplitude on AD) Internal Software fault X35:43 X X 3
Internal system fault. Hysteresis error
Vibration pump rear valve (low amplitude on AD) Faults in control line, or X35:43 X X 3
"Current range" Connection to another potential (e.g. operating voltage)
The control current is outside the valid range (see signal
specification)
Vibration sensor rear "No signal" Check connecting lines and plugs to the front vibration sensor, X35:35 X X 3022 3
The sensor in the front vibration motor does not pick up or
any pulses. replace the sensor in the vibration motor, if necessary.

Fault Fault description Possible causes Terminal Assignment Input Fault

Code AD-4 AM-4 code for reaction
diagnose

Version: V1.04 / 06.06.07

Autor: Ch. Fondel / TES

12-2010
ESX FAULT CODES
12-2010
Fault Fault description Possible causes Terminal Assignment Input Fault
Code AD-4 AM-4 code for reaction
diagnose
Vibration pump rear "Cable breakage" The connecting line between control output and proportional X35:43 X 3021 4
(only AD: high amplitude) solenoid is interrupted, or 3024
Line interruption The proportional solenoid is defective
changeover relay / bridge missing
Vibration pump rear valve (only AD: high amplitude) Short circuit of connecting line (control to proportional valve) to X35:43 X 5
ESX FAULT CODES

Supply voltage UB applied to the output to the proportional voltage supply

valve.
Vibration pump rear valve (only AD: high amplitude) - Short circuit of connecting line (control to proportional valve) X35:43 X 4
Output to proportional valve shorted to ground. to machine frame or a ground cable.
- Proportional valve defective.
Valve vibration pump rear (only DH: high amplitude) Faults in connecting line, incorrect valve coil, or X35:43 X 3
"Control fault regulating up" Connection to another potential (e.g. operating voltage)
The control current is outside the valid range (see signal
specification)
Valve vibration pump rear (only DH: high amplitude) Faults in connecting line, incorrect valve coil, or X35:43 X 3
"Control fault regulating down" Connection to another potential (e.g. operating voltage)
The control current is outside the valid range (see signal
specification)
Vibration pump rear valve (only AD: high amplitude) System fault! Replace the control! X35:43 X 4
Internal system fault. Init error
Vibration pump rear valve (only AD: high amplitude) System fault! Replace the control! X35:43 X 3
Internal system fault. Pin error
Vibration rear, adaptation control (only AD: high Wear or damage in vibration system hydraulic circuit. X35:43 X 2
amplitude) Frequency adaptation
Limits of adaptation range exceeded
(see signal specification)
Vibration rear, adaptation control (only AD: high • Wear or damage in vibration system hydraulic circuit. X35:43 X 2
amplitude) "Frequency adaptation" • Valve sticking/defective.
Upper adjustment range reached!
(see signal specification)
Vibration rear, adaptation control (only AD: high • Wear or damage in vibration system hydraulic circuit. X35:43 X 2
amplitude) "Frequency adaptation" • Valve sticking/defective.
Lower adjustment range reached!
(see signal specification)
Vibration frequency rear (only AD: high amplitude) Vibrations frequency exceeded by more than 5Hz. X35:43 X 4
Frequency/speed to high Emergency shut down to protect bearings.
After replacement of a vibration pump or peripheral equipment in
the vibration circuit this fault may occur as a result of
unfavourable component tolerances.
In this case normal operation can be reached by multiple
activation of the vibration, after the fault has been rectified.
ATTENTION! It must be assured, that the fault has not be
caused by a faulty component (pump, control,
valve.

Version: V1.04 / 06.06.07

Autor: Ch. Fondel / TES

3-51
OPERATION
Section 3
3-52
Fault Fault description Possible causes Terminal Assignment Input Fault
Code AD-4 AM-4 code for reaction
diagnose
Vibration pump front valve (only AD: high amplitude) System fault! Replace the control! X35:43 X 3
Internal system fault. Hysteresis error
Section 3

Valve vibration pump rear (only DH: high amplitude) Faults in control line, or X35:43 X 3
"Current range" Connection to another potential (e.g. operating voltage)
The control current is outside the valid range (see signal
OPERATION

specification)

Relay amplitude change over

Fault Fault description Possible causes Terminal Assignment Input Fault
Code AD-4 AM-4 code for reaction
diagnose
Amplitude changeover relay cable breakage  The connecting line between output of control and X35:24 X 3
The required control power cannot be transmitted to the relay interrupted.
control solenoid.  Relay defective.

Amplitude changeover relay, short circuit to ground  The connecting cable has short circuit to ground X35:24 X 3
Signal outside the valid range (see signal description)  Coil defective
Amplitude changeover relay, short circuit to Ub  The connecting cable has short circuit to battery voltage X35:24 X 3
Signal outside the valid range (see signal description)

Water sprinkling system selector switch

Fault Fault description Possible causes Terminal Assignment Input Fault
Code AD-4 AM-4 code for reaction
diagnose
Input water sprinkling system selector switch "ground Cable breakage in ground line, or X17:1 X x 3102 3
– connection" Connecting cable between switch and ground connection has
Signal outside the valid range (see signal description) come loose
Input water sprinkling system selector switch "supply Cable breakage in connecting line, or X17:2 X x 3102 3
connection" The connecting cable between switch and supply line
has come loose
Input water sprinkling system selector switch "signal Higher contact resistances have possibly caused a faulty signal. X17:3 X x 3102 3
noise" The switch must be replaced.

Version: V1.04 / 06.06.07

Autor: Ch. Fondel / TES

12-2010
ESX FAULT CODES
12-2010
Relay water sprinkling system
Fault Fault description Possible causes Terminal Assignment Input Fault
Code AD-4 AM-4 code for reaction
diagnose
Relay (K 79) water sprinkling system front, cable  The connecting line between output of control and X35:62 X x 3101 3
interruption relay interrupted. 3103
ESX FAULT CODES

The required control power cannot be transmitted to the  Relay defective.

control solenoid.
Relay (K 79) water sprinkling system front, short  The connecting cable has short circuit to ground X35:62 X x 3
circuit to ground  Coil defective
Signal outside the valid range (see signal description)
Relay (K 79) water sprinkling system front, short  The connecting cable has short circuit to battery voltage X35:62 X x 3
circuit to Ub
Signal outside the valid range (see signal description)
Relay (K 80) water sprinkling system rear, cable  The connecting line between output of control and X35:63 X x 3101 3
interruption relay interrupted. 3104
The required control power cannot be transmitted to the  Relay defective.
control solenoid.
Relay (K 80) water sprinkling system rear, short circuit  The connecting cable has short circuit to ground X35:63 X x 3
to ground  Coil defective
Signal outside the valid range (see signal description)
Relay (K 80) water sprinkling system rear, short circuit  The connecting cable has short circuit to battery voltage X35:63 X x 3
to Ub
Signal outside the valid range (see signal description)

Asphalt temperature sensor

Fault Fault description Possible causes Terminal Assignment Input Fault
Code AD-4 AM-4 code for reaction
diagnose
Asphalt temperature sensor cable breakage  The connecting line to the input of the control from the X17:1 X x 3
sensor is interrupted.
Asphalt temperature sensor overcurrent  The internal electronics of the sensor is defective. (replace X17:2 X x 3
Signal outside the valid range (see signal description) the sensor)

Version: V1.04 / 06.06.07

Autor: Ch. Fondel / TES

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OPERATION
Section 3
3-54
Diesel engine
Fault Fault description Possible causes Terminal Input Fault
Code code for Reaction
Section 3

diagnose
Diesel engine stalled various 1
Diesel engine "Coolant level" warning Coolant level too low or sensor defective X26:10 2
OPERATION

Diesel engine "Coolant level" fault shut-down Coolant level too low or sensor defective X26:10 5
Diesel engine "Air filter" warning Air filter soiled or sensor defective X26:8 2
Diesel engine "Air filter" fault shut-down Air filter soiled or sensor defective X26:8 5
Water separator warning Water or other dirt in fuel filter X27:4 2
X27:9
Water separator fault shut-down Water or other dirt in fuel filter X27:4 5
X27:9

Diesel engine EMC

Fault Fault description Possible causes Terminal Input Fault
Code code for Reaction
diagnose
Diesel engine EMC "Warning light" Collective warning 2
 see further fault code for more accurate fault diagnose
Diesel engine EMC "red stop light" Collective message for engine shut down 5
 see further fault code for more accurate fault diagnose
Diesel engine EMC has more than one logged fault. Collective message for engine shut down 2
 see further fault code for more accurate fault diagnose

Fault Fault description Possible causes Terminal Input Fault

Code code for Reaction
diagnose
Diesel engine EMC "Nominal speed value"  CAN connection between ESX and EMC interrupted 2
 CAN connection has short circuit against ground, against
+12 V or connection between CAN+ and CAN-.
 ESX without voltage supply
 Battery charge level too low
Diesel engine EMC "Engine oil filling level"  Engine oil filling level too low 2
Diesel engine EMC "Oil pressure"  Engine oil pressure too low X95:17 2
Diesel engine EMC "Charge air pressure"  Charge air pressure too low X95:9 2

Version: V1.04 / 06.06.07

Autor: Ch. Fondel / TES

12-2010
ESX FAULT CODES
12-2010
Fault Fault description Possible causes Terminal Input Fault
Code code for Reaction
diagnose
X95:10
Diesel engine EMC "Temperature intake line"  Charge air temperature too high X95:9 2
X95:10
Diesel engine EMC "Ambient air pressure"  Ambient air pressure too low 2
Diesel engine EMC "Coolant temperature"  Coolant temperature too high X95:25 2
ESX FAULT CODES

Diesel engine EMC "Fuel temperature"  Fuel temperature too high 2

Diesel engine EMC "Engine speed"  Speed sensor 1 or 2 defective X95:16 2
 Connection between EMC and speed sensor 1 or 2 X95:27
interrupted X95:48
X95:37
X95:26
X95:47
Water separator (EMC) Water or other dirt in fuel filter X95:14 2
Diesel engine EMC "CAN communication"  CAN connection between ESX and EMC interrupted CAN 2 2
 CAN connection has short circuit against ground, against X96:46
+12 V or connection between CAN+ and CAN-. X96:47
 ESX without voltage supply
 Battery charge level too low
Diesel engine EMC "Nominal speed value"  CAN connection between ESX and EMC interrupted CAN 2 2
 CAN connection has short circuit against ground, against X96:46
+12 V or connection between CAN+ and CAN-. X96:47
 ESX without voltage supply
 Battery charge level too low
Diesel engine EMC CAN communication  CAN communication between EMC and ESX CAN 2 2
X96:46
X96:47
Diesel engine EMC CAN communication  CAN communication between EMC and ESX CAN 2 2
X96:46
X96:47
Diesel engine EMC CAN communication  CAN communication between EMC and ESX CAN 2 2
X96:46
X96:47
Diesel engine EMC CAN communication  CAN communication between EMC and ESX. CAN 2 2
Occurs also when the ESX travel control switches off for X96:46
longer than 5 seconds (LCD-display flickers), while the X96:47
engine is running.
Diesel engine EMC "Coolant level"  Coolant level too low
Diesel engine EMC "Rail Pressure"  Rail pressure outside permissible range
 Consult the engine manufacturer

Version: V1.04 / 06.06.07

Autor: Ch. Fondel / TES

3-55
OPERATION
Section 3
3-56
Fault Fault description Possible causes Terminal Input Fault
Code code for Reaction
diagnose
Section 3

Diesel engine EMC "Oil pressure sensor"  Sensor defective X95:17 2

 Wire breakage in current path
 Current path has short circuit to ground
OPERATION

Diesel engine EMC "Charge air pressure sensor"  Sensor defective X95:9 2
 Wire breakage in current path X95:10
 Current path has short circuit to ground
Diesel engine EMC "Charge air temperature"  Sensor defective X95:9 2
 Wire breakage in current path X95:10
 Current path has short circuit to ground
Diesel engine EMC "Coolant temperature sensor"  Sensor defective X95:25 2
 Wire breakage in current path
 Current path has short circuit to ground
Diesel engine EMC "Speed sensor"  Speed sensor 1 or 2 defective X95:16 2
X95:27
X95:48
X95:37
X95:26
X95:47
Diesel engine EMC "Water in Fuel Sensor"  Sensor defective X95:14 2
 Wire breakage in current path
 Current path has short circuit to ground
Diesel engine EMC "Ambient air pressure sensor"  Sensor defective X95:3 2
 Wire breakage in current path X95:33
X95:38
 Current path has short circuit to ground
Diesel engine EMC "coolant filling level sensor"  Sensor defective 2
 Wire breakage in current path
 Current path has short circuit to ground
Diesel engine EMC "Rail pressure sensor"  Sensor defective X95:25 2
 Wire breakage in current path
 Current path has short circuit to ground
Diesel engine EMC "Fuel pump output"  Wire breakage in current path X95:1 2
 Current path has short circuit to ground X95:11
Diesel engine EMC "unknown fault" Fault diagnostics only via Cummins Insite Tool 2

Version: V1.04 / 06.06.07

Autor: Ch. Fondel / TES

12-2010
ESX FAULT CODES
12-2010
Miscellaneous
Fault Fault description Possible causes Terminal Input Fault
Code code for Reaction
diagnose
"Hydraulic oil filter" warning - main circuit - Hydraulic oil filter soiled or sensor defective X26:5 5500 2
"Hydraulic oil filter" fault shut-down Hydraulic oil filter soiled or sensor defective 5
ESX FAULT CODES

"Hydraulic oil filter" warning - steering - Hydraulic oil filter soiled or sensor defective X26:6 5502 2
"Hydraulic oil filter" fault shut-down Hydraulic oil filter soiled or sensor defective 5
"Oil temperature" warning Hydraulic oil temperature too high or sensor defective X27:10 5504 2
"Oil temperature" fault shut-down Hydraulic oil temperature too high or sensor defective 5

Machine type
Fault Fault description Possible causes Terminal Input Fault
Code code for reaction
diagnose
Warning "Change of machine type" Change the machine type only after corresponding measures 6
This warning is displayed when the machine type is have been applied, e.g. changing a control from one machine to
changed. another machine of different type or when loading default
parameters
"Conflict machine type" The machine type is not correct after changing components 4
This error message is displayed if the set machine does (ESX, DASA or Display). The corresponding machine type must
not comply with the basic parameters of the machine. be selected again.

Version: V1.04 / 06.06.07

Autor: Ch. Fondel / TES

3-57
OPERATION
Section 3
3-58
Optional functions / CAN communication
Fault Fault description Possible causes Terminal Input Fault
Code code for reaction
Section 3

diagnose
No CAN communication with the data collector  Fault on CAN (1) line (short circuit) CAN 1 3
 Line breakage CAN (1)
OPERATION

 Data collector defective

 No voltage supply to data collector
No CAN communication with display  Fault on CAN (1) line (short circuit) CAN 1 3
 Line breakage CAN (1)
 Display defective
 No voltage supply to display
No CAN communication with the travel lever  Fault on CAN (2) line (short circuit) CAN 2 4
 Cable breakage CAN Bus 2
 Joystick defective
 No voltage supply to joystick
No CAN communication with steering lever  Fault on CAN (2) line (short circuit) CAN 2 4
 Line breakage CAN (2)
 Joystick defective
 No voltage supply to joystick
No CAN communication with engine control unit  Fault on CAN (2) line (short circuit) X34:C 4
(EMC)  Line breakage CAN (2) X34:D
 Travel lever or steering lever defective
 Engine control unit defective
 No voltage supply to engine control unit

Version: V1.04 / 06.06.07

Autor: Ch. Fondel / TES

12-2010
ESX FAULT CODES
12-2010
Optional functions / CAN communication
Fault Fault description Possible causes Terminal Input Fault
Code code for reaction
diagnose
No CAN communication with the data collector  Fault on CAN (1) line (short circuit) CAN 1 3
 Line breakage CAN (1)
ESX FAULT CODES

 Data collector defective

 No voltage supply to data collector
No CAN communication with display  Fault on CAN (1) line (short circuit) CAN 1 3
 Line breakage CAN (1)
 Display defective
 No voltage supply to display
No CAN communication with the travel lever  Fault on CAN (2) line (short circuit) CAN 2 4
 Cable breakage CAN Bus 2
 Joystick defective
 No voltage supply to joystick
No CAN communication with steering lever  Fault on CAN (2) line (short circuit) CAN 2 4
 Line breakage CAN (2)
 Joystick defective
 No voltage supply to joystick
No CAN communication with engine control unit  Fault on CAN (2) line (short circuit) X34:C 4
(EMC)  Line breakage CAN (2) X34:D
 Travel lever or steering lever defective
 Engine control unit defective
 No voltage supply to engine control unit

Version: V1.04 / 06.06.07

Autor: Ch. Fondel / TES

3-59
OPERATION
Section 3
Section 3
OPERATION

NOTES

3-60 12-2010
 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.

TABLE 4-2. Miscellaneous Maintenance................................................................................. 4-10.

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 ............................................................................................................................ 4-16.

FUEL TANK ....................................................................................................................... 4-16.

ENGINE FUEL FILTERS ................................................................................................... 4-17.

PRIMING THE FUEL SYSTEM - CUMMINS DIESEL ENGINE ........................................ 4-18.

ENGINE AIR FILTRATION ......................................................................................................... 4-19.

12-2010 4-1
Section 4
MAINTENANCE
page

AIR CLEANER....................................................................................................................4-19.

Cleaning the primary filter element................................................................................. 4-19.

Changing the secondary filter element........................................................................... 4-19.

COOLING SYSTEM .............................................................................................................................. 4-21.

RADIATOR, HYDRAULIC OIL COOLER AND CHARGE AIR COOLER................................... 4-21.

RADIATOR HOSES .................................................................................................................... 4-22.

WATER PUMP ............................................................................................................................ 4-22.

DRAINING, FLUSHING AND FILLING THE COOLING SYSTEM ............................................. 4-23.

HYDRAULIC SYSTEM .......................................................................................................................... 4-25.

GENERAL INFORMATION ......................................................................................................... 4-25.

CHECKING THE HYDRAULIC OIL LEVEL AND ADDING HYDRAULIC OIL TO THE
HYDRAULIC OIL RESERVOIR ..................................................................................... 4-25.

CHANGING THE HYDRAULIC OIL ............................................................................................ 4-26.

STEERING SYSTEMS PRESSURE OIL FILTER ELEMENT -

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

TRANSMISSION SYSTEM PRESSURE OIL FILTER ELEMENT -

REMOVAL AND REPLACEMENT ................................................................................. 4-28.

DRUM BEARING LUBRICATION ........................................................................................................ 4-30.

CHECKING THE DRUM BEARING LUBRICATION OIL LEVEL ............................................... 4-30.

CHANGING THE DRUM BEARING LUBRICATION OIL ........................................................... 4-31.

ALTERNATOR AND FAN DRIVE BELT - INSPECTION AND

REPLACEMENT PROCEDURES............................................................................................. 4-32.

ELECTRICAL SYSTEM......................................................................................................................... 4-34.

FUSES...........................................................................................................................................4-34.

CHECKING THE CHARGE CONDITION OF THE BATTERY

AND SERVICING OF RELATED ItemS........................................................................ 4-35.

ELECTRICAL WIRING INSPECTION.......................................................................................... 4-36.

VIBRATION ISOLATORS...................................................................................................................... 4-36.

REMOVAL, REPAIR OR REPLACEMENT, AND INSTALLATION

OF THE VIBRATION ISOLATOR................................................................................... 4-36.

4-2 12-2010
 Section 4
MAINTENANCE
PAGE

REMOVAL.......................................................................................................................... 4-36.

INSTALLATION.................................................................................................................. 4-36.

PARKING BRAKE SYSTEM MAINTENANCE - OPERATION AND APPLICATION CHECK ............ 4-38.

MISCELLANEOUS MAINTENANCE INFORMATION ......................................................................... 4-39.

WATER SPRAY SYSTEM .......................................................................................................... 4-39.

WATER STRAINERS ........................................................................................................ 4-39.

WATER SPRAY NOZZLES ............................................................................................... 4-39.

WATER PUMP VALVE...................................................................................................... 4-40.

WATER PUMP FILTER...................................................................................................... 4-40.

SCRAPER ASSEMBLIES ........................................................................................................... 4-40.

PREPARING THE MACHINE FOR STORAGE .................................................................................... 4-40.

ENGINE ....................................................................................................................................... 4-40.

COOLING SYSTEM .................................................................................................................... 4-41.

BATTERY .................................................................................................................................... 4-41.

FUEL TANK ................................................................................................................................ 4-41.

AIR CLEANER, EXHAUST AND OTHER OPENINGS ............................................................... 4-42.

WATER SPRAY SYSTEM .......................................................................................................... 4-42.

EXPOSED COMPONENT RUST PREVENTION ........................................................................ 4-42.

12-2010 4-3
Section 4
MAINTENANCE
GENERAL INFORMATION. MAINTENANCE SCHEDULE.

THIS section gives the necessary procedures GENERAL INFORMATION.

for CORRECT MAINTENANCE of the Tandem
Vibratory Roller. The MAINTENANCE SCHEDULE lists the recom-
mended time intervals between machine maintenance
Follow ALL the “MAINTENANCE SCHEDULES” and inspections and lubrication procedures. Table 4-1
“MAINTENANCE PROCEDURES” for CORRECT gives inspection and lubrication information for the
machine service schedules and procedures. Tandem Vibratory Roller.
MAINTENANCE. Most service intervals are listed by the “HOUR” and
“PERIODIC” time periods. The maintenance sched-
GENERAL INFORMATION. ule begins with eight [8] hours, or daily, maintenance
intervals and continues through the 2,000 hours, or
MAINTENANCE must be a planned program which
every two [2] years, maintenance schedule intervals.
includes periodic machine inspection and lubrication
procedures. NOTE: If the machine is operated MORE than
The MAINTENANCE program must be done, based eight [8] hours per day, follow the
on the machine “OPERATING HOURS”, recorded on “HOUR” schedule. If the machine is
the hourmeter, or based on the “PERIODIC SCHED- operated LESS than eight [8] hours per
ULE”, which is done at time intervals of weekly, day, follow the “PERIODIC” schedules,
monthly or yearly. where they apply.
The MAINTENANCE program is divided into TWO [2] The maintenance checks, given in Table 4-1, are
subsections: The MAINTENANCE SCHEDULE and also listed on the “Machine Maintenance Decal”,
the MAINTENANCE PROCEDURES. found on the machine [see 4-5 Fig3]. 4-5 Fig2 shows
the location of the “machine maintenance points”.

4-4 Fig1. hood prop rod.

CAUTION: Be sure the hood prop rod is in the
locked position anytime the hood is
in the open position [See 4-4 Fig1].
Failure to secure the prop rod in
the locked position could result in
serious injuries.
S/N: 901D2091040 > 901D21501036 >

4-4 12-2010
 Section 4
MAINTENANCE

4-5 Fig2. MACHINE MAINTENANCE POINTS.

4-5 Fig3. MACHINE MAINTENANCE DECAL.

12-2010 4-5
Section 4
MAINTENANCE
Table 4-1. Maintenance Schedule (Continued).

SEE
4-5
8/ 250/ 500/ 1000/ 2000/
FIG1 ITEM QTY TYPE/REMARKS
DAY 3 MO 6 MO 1 YR 2 YR
&
Fig2

1 ENGINE OIL X C* 4.2 Gal. Drain diesel engine

[16 L] lubrication oil and
Total replace with NEW.*

2 ENGINE OIL C* 1 Change at EACH

FILTER engine oil change
Use APPROVED
filter ONLY.*

3 ENGINE OIL FILL X Check oil fill cap is

installed and tight.

4 ENGINE FUEL X* C* C* 1 Drain off water

FILTER daily with drain plug
provided. Change at
interval shown.* Use
APPROVED filters
ONLY.*

5 ENGINE X C* 5.1 Gal. Check coolant level.

COOLING [19.4 L] Fill as required
SYSTEM with 50% mixture
[approximate] of
drinking water and
ethylene glycol base
antifreeze, with rust
inhibitors and antirust
qualities. Add one
[1] can of cooling
system conditioner,
having rust inhibitor
properties.*

6 ENGINE X C** 2 Check condition

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

4-6 12-2010
 Section 4
MAINTENANCE
Table 4-1. Maintenance Schedule (Continued).

SEE
4-5
8/ 250/ 500/ 1000/ 2000/
FIG1 ITEM QTY TYPE/REMARKS
DAY 3 MO 6 MO 1 YR 2 YR
&
Fig2

7 HYDRAULIC X A/C+ 15 Gal. Check hydraulic

OIL LEVEL *** [56.7 L] oil level in the
reservoir sight gauge.
Add hydraulic oil as
required.***
Use ONLY MOBIL 423,
HYTRAN, TEXACO
“TDH” 3020A or
EQUIVALENT oil.
CAUTION: Use the
CORRECT
hydraulic
oil ONLY***

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

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

8 Hydraulic C 1 Change filter element

Oil Fill when hydraulic oil is
changed, and/or one
[1] time for every 2,000
hours or two [2] years
of machine operation.
Use APPROVED filter
element ONLY. See
MACHINE PARTS
book for CORRECT
replacement element.

12-2010 4-7
Section 4
MAINTENANCE
Table 4-1. Maintenance Schedule (Continued).

SEE
4-5
8/ 250/ 500/ 1000/ 2000/
FIG1 ITEM QTY TYPE/REMARKS
DAY 3 MO 6 MO 1 YR 2 YR
&
Fig2

9 HYDRAULIC OIL X C 2 Check condition

FILTER indicator lights daily.
Change filter element
when hydraulic oil
is changed, and/or
one [1] time for every
2,000 hours or two
[2] years 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.

10 BATTERY X 1 The battery is of the

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

11 VIBRATOR OIL X Both Check oil level in sight

LEVEL SIGHT Drums gauge.
GAUGE

4-8 12-2010
 Section 4
MAINTENANCE
Table 4-1. Maintenance Schedule (Continued).

SEE
4-5
8/ 250/ 500/ 1000/ 2000/
FIG1 ITEM QTY TYPE/REMARKS
DAY 3 MO 6 MO 1 YR 2 YR
&
Fig2

12 DRUM BEARING X C 10 Gal. Check drum bearing

LUBRICATION [37.9 L] lubrication oil level and
OIL EACH add oil as needed one
drum [1] time for each eight
[8] hours of machine
operation, or daily. See
THIS section. Change
oil one [1] time for each
1000 hours of machine
operation, or every year.
See THIS section.

13 RUBBER X 24 Check for loose

VIBRATION mounting hardware,
ISOLATORS cracked or torn material.

14 FUEL LEVEL - X 66 Inch #1D or #2 D diesel

IN TANK Roller fuel. See Section 2 -
Unit SPECIFICATIONS, for
49.4 complete specifications.
Gal.
[187 L]
78 Inch
Roller
Unit
58 Gal.
[220 L]

15 WATER PUMP X 2 Remove, check, clean

STRAINERS and install the strainers
one [1] time for every
1000 hours of machine
operation, or yearly.

16 WATER SPRAY X ALL Remove, clean and

SYSTEM install onto spray bars
NOZZLES when plugged on “as
required” basis

12-2010 4-9
Section 4
MAINTENANCE
Table 4-2. MISCELLANEOUS Maintenance (Continued).

SEE
4-5
8/ 250/ 500/ 1000/ 2000/
FIG1 ITEM QTY TYPE/REMARKS
DAY 3 MO 6 MO 1 YR 2 YR
&
Fig2

17 GAUGES, X All Check operation.

HORN, LIGHTS Repair or replace
as needed.

18 DYNAMIC X Trans. Check operation.

BRAKES System Repair if needed.
See Section 3.

19 STEERING X Steering Check operation.

System Repair if needed.
See Section 3.

20 FALLING X Structure Inspect the eight

OBJECT/ [8] grade 8 flange
ROLLOVER screws that fasten
PROTECTIVE the structure to the
STRUCTURE machine. They MUST
[FOPS/ROPS] remain tightened to
the torque of 375
ft. lbs. [509 N.m].
CAREFULLY inspect
ALL welds for cracks,
breakage in the weld
or where the weld
joins the components,
severe rust or other
weld-related problems.
If any damage is
found in the above
inspection, contact
the nearest Distributor
immediately.

21 SEAT BELT X 1 Set Check condition.

Replace seat belt if
damaged. See “Parts
Manual”.

4-10 12-2010
 Section 4
MAINTENANCE
Table 4-2. MISCELLANEOUS Maintenance (Continued).

SEE
4-5
8/ 250/ 500/ 1000/ 2000/
FIG1 ITEM QTY TYPE/REMARKS
DAY 3 MO 6 MO 1 YR 2 YR
&
Fig2

22 ALTERNATOR & X* 1 Check belt for wear or

FAN DRIVE BELT damage. Check belt for
CORRECT “deflection.”
Replace belt with
NEW if needed [see
Cummins “Operation
and Maintenance
Manual - QSB 4.5
Engine”].

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

KEY:

X = CHECK C = CHANGE

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

 efer to current Cummins “Operation and Maintenance Manual - QSB 4.5 Engine”
*= R
published by Cummins Engine Company Incorporated, which is
supplied with EACH machine, for very specific engine information.

** = Under VERY dusty or severe operating conditions change at 500 hours or as needed.

*** = See DECAL adjacent to hydraulic reservoir fill tube.

12-2010 4-11
Section 4
MAINTENANCE
MAINTENANCE PROCEDURES. WARNING: STOP the engine BEFORE checking
the engine lubrication oil level. With
GENERAL INFORMATION. engine running, HOT oil can be
thrown, causing serious injury.
The following MAINTENANCE PROCEDURES give
instructions for performing required machine mainte-
CHANGING THE ENGINE LUBRICATION OIL [See
nance checks and lubrication.
4-14 Fig5].
NOTE: The instructions given in the The engine lubrication oil must be changed according
MAINTENANCE procedure subsection are to the interval given in the Cummins “Operation and
given by “machine systems” and are NOT Maintenance Manual - QSB 4.5 Engine” published
necessarily in the same order as listed in by Cummins Engine Company and supplied with the
Table 4-1 or as shown on the “Machine machine.
Maintenance Decal”. They may ALSO
include some items NOT shown in the NOTE: The color of the engine lubrication oil can
table, or on the decal. NOT be used as an indication of the need
for a engine lubrication oil change. The
use of an engine lubrication oil “analysis
ENGINE MAINTENANCE. service” is the ONLY alternate reason
for not following the required engine
GENERAL INFORMATION. lubrication oil change schedule.

The following ENGINE maintenance information will WARNING: Do NOT change the engine
cover engine general maintenance procedures most lubrication oil when the engine and
often done. lubrication oil are HOT. Change
when WARM only. Hot oil can cause
For additional, very specific, ENGINE maintenance serious injury.
information, see the current Cummins “Operation and
Maintenance Manual - QSB 4.5 Engine” published CAUTION: Do not change the engine lubrication
by Cummins Engine Company Incorporated, which is oil with the engine “running”. Serious
supplied with the machine. engine damage or failure will occur.
Clean the area around the engine
ENGINE LUBRICATION OIL. lubrication oil dipstick and oil filler
cap BEFORE removing the dipstick,
CHECKING THE ENGINE LUBRICATION OIL or oil filler cap.
LEVEL [See 4-13 Fig4].
With the engine “STOPPED”, and “WARM” engine
The engine lubrication oil MUST be kept at a level lubrication oil, proceed as follows:
ABOVE the “ADD” mark, but NOT ABOVE the
“FULL” mark, on the engine lubrication oil dipstick. a. Clean the area around the engine lubrication oil
drain plug found on the engine oil pan.
TO ACCURATELY check the engine lubrication oil
level, put the machine in a “LEVEL” position and b. Place a container, having a capacity greater than
STOP the engine. Clean the area around the engine 4.0 gallons [15 liters], directly under the engine
lubrication oil dipstick BEFORE removing the dipstick lubrication oil drain plug.
from the engine. WAIT five [5] minutes, after engine
shutdown, BEFORE removing the dipstick from the c. CAREFULLY remove the engine lubrication oil
engine and checking the oil level. drain plug.

NOTE: The above procedure will help to remove d. Drain ALL of the engine lubrication oil into the
the possibility of filling the engine with container.
too much lubrication oil, by allowing the
oil to return to the oil pan.

4-12 12-2010
 Section 4
MAINTENANCE

4-13 Fig4. CUMMINS DIESEL ENGINE - LUBRICATION OIL LEVEL CHECK LOCATION.

e. Clean, install and CAREFULLY tighten the g. Wash the oil filler cap with All Purpose de-
lubrication oil drain plug. greaser cleaner, Part Number 178297, and dry
with compressed air. Install the oil filler cap and
CAUTION: Do NOT overtighten the drain plug. the engine lubrication oil dipstick.

CAUTION: Do NOT start the engine BEFORE

f. Fill the engine to the CORRECT oil level, with the changing the engine lubrication oil
CORRECT engine lubrication oil. filter. Follow the procedures given
in THIS section and in the Cummins
NOTE: See THIS section for the CORRECT “Operation and Maintenance Manual -
amount of lubrication oil. For the QSB 4.5 Engine”.
CORRECT type of lubrication oil see the
Cummins “Operation and Maintenance
Manual - QSB 4.5 Engine” published by
Cummins Engine Company Incorporated,
which is supplied with the machine.

12-2010 4-13
Section 4
MAINTENANCE
CHANGING THE ENGINE LUBRICATION OIL CAUTION: Do NOT change the engine
FILTER [See 4-14 Fig5]. lubrication oil filter with the engine
running. Serious engine damage, or
The engine lubrication oil filter MUST be changed failure, will occur.
when the engine lubrication oil is changed.

WARNING: Do NOT change the engine With the engine “STOPPED” and filled with new en-
lubrication oil filter when the engine gine lubrication oil, proceed as follows:
and lubrication oil are HOT. Change a. Wipe the area around the engine lubrication
the filter when WARM only. Hot oil oil filter element and its mounting base with a
can cause serious injury. clean cloth.

4-14 Fig5. CUMMINS DIESEL ENGINE - LUBRICATION OIL DRAIN PLUG LOCATION.

4-14 12-2010
 Section 4
MAINTENANCE
b. Place a container under the filter element. CAUTION: Do NOT overtighten the lubrication
oil filter element onto the filter head.
c. Use a filter removal wrench to loosen and Follow ALL engine lubrication oil
remove the filter element by turning it in a change and fill procedures, given in
COUNTERCLOCKWISE [CCW] direction of THIS section, and in the Cummins
rotation. Drain and discard the removed filter “Operation and Maintenance Manual -
element. QSB 4.5 Engine” before the engine is
started.
CAUTION: Be sure the used rubber gasket is
REMOVED and discarded with the
NOTE: CHECK the engine lubrication oil level at
filter element.
THIS time.
d. Wipe the inside area of the lubrication oil filter g. Start the engine. Check to be sure there are no
head using a CLEAN lint-free cloth. oil leaks and that the engine oil pressure gauge
indicates that the engine has the CORRECT
e Put CLEAN engine lubrication oil on the rubber
lubrication oil pressure.
gasket area of the NEW filter element. Fill the
new filter element with CORRECT, NEW, and CAUTION: STOP the engine IMMEDIATELY if
CLEAN oil. INCORRECT pressure is indicated or
any oil leaks are observed. CORRECT
f. Install the NEW filter element onto the filter head.
any problem noted BEFORE starting
Carefully tighten the filter element, by hand only.
the engine again.
NOTE: Tighten the filter element as directed
on the filter element by the filter
manufacturer.

12-2010 4-15
Section 4
MAINTENANCE
FUEL SYSTEM.

FUEL TANK [See 4-16 Fig6].

The fuel level is indicated on the operator control dis-
play screen top bar graph and indicates the amount
of fuel in the tank. CHECK the amount indicated on
the display one [1] time each day. Fill the fuel tank
as necessary. Also fill the tank, to “FULL”, before the
machine is stored for the night to reduce the accumu-
lation of moisture, in the tank, from condensation.

WARNING: The operator must be off of the

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

4-16 Fig6. FUEL TANK FILL LOCATION.

4-16 12-2010
 Section 4
MAINTENANCE
ENGINE FUEL FILTERS [See 4-17 Fig7]. Maintenance Manual - QSB 4.5 Engine”, published
by Cummins Engine Company Incorporated and sup-
The fuel filter elements MUST be replaced as plied with the machine.
directed in the current Cummins “Operation and
Maintenance Manual - QSB 4.5 Engine”, published WARNING: DIESEL FUEL IS VERY FLAMMABLE.
by Cummins Engine Company Incorporated and USE EXTRA CAUTION.
supplied with the machine. Do NOT change the fuel filter
element in an area near open flame.
CAUTION: Drain the primary fuel FILTER of ALL Do NOT change the fuel filter
water one [1] time EACH day, or as element with the machine running.
needed. Do NOT smoke while changing
the fuel filter element.
Replace the fuel filter elements using the following Do NOT spill fuel.
“GENERAL” procedures and very specific information
given in the current Cummins “Operation and

4-17 Fig7. FUEL FILTER LOCATION .

12-2010 4-17
Section 4
MAINTENANCE
a. STOP the engine and engage the park brake. PRIMING THE FUEL SYSTEM - CUMMINS DIESEL
ENGINE [See 4-18 Fig8].
b. Put a container under the fuel filters, BEFORE
removing the filter element. Use the following general procedures to prime the fuel
system and start a CUMMINS diesel engine that has
c. Wipe the area around the fuel filter elements and bee run out of fuel:
the element mounting head, using a CLEAN lint-
free cloth. NOTE: Small amounts of air will be vented from
the system automatically, if the filter was
d. Turn battery disconnect switch to the off position. changed using the CORRECT procedures
given in THIS section.
e. Disconnect wiring connector from bottom of
primary fuel filter element. CAUTION: For very specific information, see
the current Cummins “Operation
f. Use a filter removal wrench to loosen and and Maintenance Manual - QSB 4.5
remove the elements, by turning the elements Engine” supplied with the machine.
in a COUNTERCLOCKWISE [CCW] direction.
Drain and discard the removed elements. a. Make sure fuel tank is at least half full of the
g. Wipe the inside area of the filter head with a correct, clean fuel.
CLEAN “lint free” cloth. Fill the “NEW” fuel filter b. For best results, remove bleed screws in
elements COMPLETELY full of the CORRECT secondary filter
and CLEAN fuel. Put CLEAN fuel on the element
rubber gasket. c. Prime the fuel system by turning the primer knob
on the front of the primary fuel filter head fully
h. Install the “NEW” fuel filter elements onto the COUNTERCLOCKWISE [CCW]. [See 4-18 Fig8].
filter head. Carefully tighten the element by hand
ONLY. d. Push the primer knob several times until force
is felt on the inward motion. [See 4-18 Fig8] and
CAUTION: Tighten the fuel filter elements as fuel comes out of the bleed hole.
directed on the filter elements, by
the filter manufacturer. Do NOT e. Tighten the primer knob by turning knob
overtighten the fuel filter elements completely CLOCKWISE [CW] and replace bleed
onto the filter head. screw.

i. Connect wiring connector to bottom of primary f. Start the engine. If engine will not start, repeat
filter element and turn battery disconnect switch the priming procedure above.
to the on position.

j. 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.

4-18 Fig8. FUEL PRIMER pump LOCATION.

4-18 12-2010
 Section 4
MAINTENANCE
ENGINE AIR FILTRATION. Incorrectly handled filter elements
may be ineffective because of
AIR CLEANER [See 4-20 Fig9]. damage (e.g., cracks) and cause
damage to the engine.
The engine inlet air cleaner assembly uses two [2] re- Replace the secondary filter element
placeable filter elements, an outer primary and an if the primary filter element is
inner secondary filter element. defective!
CHECK the engine inlet air restriction indicator light
Blow the primary filter element out from inside to out-
located on the display screen one [1] time for EACH
side with dry compressed air max. 72 psi [5 bar] until
eight [8] hours of machine operation, or daily. If the
all dust has been removed.
restriction indicator stays on, the air cleaner filter ele-
ments must be removed and replaced immediately.
Examine the primary filter element with a light for
CAUTION: The air cleaner filter elements should cracks and holes in the paper bellows.
be replaced one [1] time for EACH
CAUTION: Do not continue to run the machine
1,000 hours of machine operation, or
with a damaged primary filter
yearly, for a machine which is operated
element. If in doubt use a new
under “normal” conditions, or one [1]
primary filter element.
time for EACH 500 hours of machine
operation, or every six [6] months, for
a machine which is operated under Changing the secondary filter element
“very dusty or severe” conditions.
CAUTION: The secondary filter element must
Never operate the engine without an
not be cleaned and should not be
air cleaner element installed.
used again after it has been removed.
Do NOT service the air cleaner element
Break the seal only to replace the
while the engine is “running”.
secondary filter element.
The secondary filter element must be
Use the following procedures to service the air
replaced If the primary filter element
cleaner elements:
is defective.
a. Lift up on end cap lever and turn end cap
COUNTERCLOCKWISE [CCW]. Remove the If the warning light comes on again after servicing the
end cap from the filter body assembly. primary filter element:

b. Remove the primary outer air filter element. • Remove the housing cover and pull the primary
Inspect filter for wear or damage. Replace as filter element off.
necessary.
• Pull the secondary element out by slight turning
c. Remove the secondary inner air filter element. movements.
Inspect filter for wear or damage. Replace as
• Push in a new secondary filter element.
necessary.
• Reassemble primary filter element and cover.
Cleaning the primary filter element
CAUTION: Make sure that the cover lock
CAUTION: If necessary, the primary filter element engages correctly.
may be cleaned up to five times. It
must be replaced at the latest after
a maximum utilization period of one
year.
Cleaning does not make sense if the
primary filter element is covered with
a sooty deposit. Install a new filter
element.

12-2010 4-19
Section 4
MAINTENANCE
d. Clean the inside of the filter body assembly 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.

f. CAREFULLY install the NEW air filter elements

into the filter body assembly.

g. Install the air cleaner end cap onto the filter body
assembly.

h. Start the engine using ALL the CORRECT

starting procedures given in Section 3 -
OPERATION - of this manual.
Note that the engine inlet air restriction indicator
light is “OFF” and that the engine inlet air is NOT
being restricted.

4-20 Fig9. AIR CLEANER ASSEMBLY - EXPLODED VIEW.

4-20 12-2010
 Section 4
MAINTENANCE
COOLING SYSTEM. With the engine STOPPED, inspect the radiator,
hydraulic oil cooler and charge air cooler cooling fin
RADIATOR, HYDRAULIC OIL COOLER AND area each time the system coolant level is checked.
CHARGE AIR COOLER [See 4-22 Fig11]. Use a bright light placed on the INSIDE of the cool-
ing fin area. Light MUST be clearly seen, when look-
WARNING: Do NOT check the system coolant ing through the radiator, hydraulic oil cooler and air
level, or ANY component, with the cooler fin area from the outside of the fin area.
engine running. Serious injury can
result from being caught or struck by WARNING: The engine MUST be “STOPPED”
the fan, belt, or moving engine parts. BEFORE checking, or cleaning, the
Do NOT check the system coolant radiator, hydraulic oil cooler or charge
level, or ANY component, when the air cooler fin area. Serious injury can
system is at operating temperature result from being caught or struck by
and the coolant is under pressure. the fan, belt or moving engine parts.
HOT coolant, under pressure, can
cause serious injury. NOTE: If a restricted cooling fin condition is
Check the coolant level ONLY when noted in EITHER the radiator, hydraulic
the radiator filler cap is cool enough oil or the charge air cooler fin area,
to touch with the hand. Remove the CLEAN the fin area using low-pressure
radiator filler cap SLOWLY. compressed air.

WARNING: The compressed air supply MUST

CHECK the system coolant level one [1] time for
have a pressure BELOW 30 psi. [2 bar].
EACH eight [8] hours of machine operation, or
Wear safety glasses and protective
daily. Drain, flush and fill the cooling system, with
clothing and clear area of bystanders.
NEW coolant, one [1] time for EACH 1,000 hours of
machine operation, or yearly [see THIS section for
CAUTION: Do NOT damage the cooling fins
general procedures].
during cleaning. Clean the fin area
Keep the coolant level between “MIN” and “MAX” with the compressed air blown in the
marks when the engine is cool [See 4-21 Fig10]. OPPOSITE direction of “normal” air
Using a 50/50% [approximate] mixture of ethylene flow during operation. Bent cooling
glycol-type antifreeze and CLEAN water on initial fill. fins can be CAREFULLY straightened.
Add CLEAN water when the level is LOW. Use a radiator fin comb to straighten
the bent fins AFTER cleaning. Severe
restrictions, or dirt build-up, which are
NOT removed by using compressed air,
MUST be removed by using standard
steam cleaning procedures. Apply
steam cleaning pressure through the
radiator, hydraulic oil cooler and charge
air cooler OPPOSITE the direction of
“normal” air flow during operation.
Do NOT use caustic soap solutions as
part of the standard steam cleaning
procedure, as rapid deterioration of
these components can occur.

WARNING: Clear work area of bystanders.

Wear safety glasses and protective
clothing during the steam cleaning
4-21 Fig10. Coolant Recovery Tank operation. Use ONLY CORRECT
steam cleaning procedures.

12-2010 4-21
Section 4
MAINTENANCE
RADIATOR HOSES. WATER PUMP.

CHECK the radiator hoses at least one [1] time for Visually CHECK the engine water pump for leaks, or
EACH 1,000 hours of machine operation, or yearly, other damage, after EACH fifty [50] hours of machine
for cracks, increased size, softening or hardening. operation.

Drain the cooling system of coolant [see THIS sec- Water pump leaks can allow air to be pulled into the
tion] and COMPLETELY remove EACH radiator cooling system. Air in the cooling system can cause
hose. CHECK the INSIDE area of the hose for the cooling system to operate in a “HOT” condition.
damage. Install the hose again if found to be accept- Replace the water pump IMMEDIATELY if a leak or
able, or replace with NEW if found to be damaged. other damage is noted.

CAUTION: Visual inspection of the outside of WARNING: Do NOT check, or remove, the water
the hose is NOT adequate. A hose pump with the engine running.
can have damage on the inside and Serious injury can result from being
look acceptable from the outside. The caught or struck by the fan, belt or
hose must NOT be hard, or have ANY moving engine parts.
restrictions. Do NOT remove the water pump while
the cooling system is HOT.
WARNING: Do NOT check, or remove, ANY Remove and replace the water pump
radiator hose with the engine ONLY after draining the cooling
“running”. Serious injury can result system of coolant [see THIS section]
from being caught, or struck, by the when it is COOL.
fan, belt or moving engine parts. Do
NOT check, or remove, ANY radiator
hose while the cooling system is
HOT, or is full of coolant. Remove
the hoses ONLY when the system
is COOL and has been DRAINED of
coolant.

4-22 Fig11. RADIATOR AND HYDRAULIC OIL COOLER LOCATIONS.

4-22 12-2010
 Section 4
MAINTENANCE
DRAINING, FLUSHING AND FILLING THE COOLING c. Remove the thermostat housing and the
SYSTEM [See 4-22 Fig11, 4-23 Fig12 and 4-24 thermostat from the engine. Inspect the
Fig13]. thermostat for corrosion, or damage. Test the
thermostat for correct operation at the specified
CAUTION: For additional specific information, opening temperature. Replace the thermostat,
use the current Cummins “Operation with NEW, if found to be damaged. Install the
and Maintenance Manual - QSB 4.5 thermostat, AFTER flushing, ONLY.
Engine”, supplied with the machine.
NOTE: BEFORE cooling system flushing, the
Rust in the radiator, or coolant, indicates that the cool- thermostat MUST be removed. If the
ant anticorrosion additives are no longer effective. thermostat is NOT removed, the flushing
procedure WILL close the thermostat and
To help prevent severe cooling system damage, prevent complete engine block flushing.
drain, flush and fill the system with NEW coolant, one Do NOT install the radiator hoses, or
[1] time for EACH 1,000 hours of machine operation, thermostat, at this time.
or yearly.
d. Remove ALL engine and aftercooler drain plugs.
WARNING: Do NOT drain, or flush the cooling COMPLETELY drain the coolant from the engine
system with the engine running. and aftercooler. Install all drain plugs into the
Serious injury can result from being engine and aftercooler. Tighten the drain plugs
caught or struck by the fan, belt or by hand only, at this time.
moving engine parts.
Do NOT drain the cooling system e. Install ONLY the thermostat HOUSING [no
while the system is HOT and is under thermostat] onto the engine. Reverse flush
pressure. Drain the system when the engine BLOCK as shown in [4-23 Fig12].
COOL ONLY. Hot coolant can cause Remove ALL engine and aftercooler drain plugs,
serious injury. again, AFTER reverse flushing the engine block
assembly. COMPLETELY drain the engine block
Use the following general procedures to drain, flush and the aftercooler of water. Install all engine and
and fill the engine cooling system: aftercooler drain plugs. Tighten ALL drain plugs
securely, using a wrench.
a. STOP the engine and allow the cooling system
to reach a COOL temperature. Put a container
under the radiator drain cock and drain the
coolant. Open the radiator drain cock and drain
all coolant from the radiator. Close and tighten
the drain cock by hand ONLY.

b. Remove BOTH the upper and the lower radiator

hoses from the engine. Inspect BOTH hoses
using the procedures given in THIS section.
Replace any hose found to have ANY damage.

NOTE: Inspect the engine WATER PUMP, at THIS

time, for ANY damage, or leaks. REPLACE
the water pump with NEW if found to be
damaged, or leaking.

4-23 Fig12. REVERSE FLUSHING PROCEDURE

ENGINE BLOCK.

12-2010 4-23
Section 4
MAINTENANCE
f. Remove the thermostat housing from the engine. h. Install BOTH the UPPER and the LOWER
Install the thermostat into the housing, in the radiator hoses onto BOTH the radiator and the
CORRECT position. Install the thermostat engine. Install ALL the clamps, onto the hoses,
housing to engine gasket. Install the thermostat and tighten them securely.
housing over the thermostat and onto the engine.
Install the retaining capscrews and tighten i. Fill the cooling system with coolant, through
securely. the coolant recovery tank, using a new 50/50%
[APPROXIMATE] mixture of ethylene glycol
CAUTION: Do NOT start the engine while reverse antifreeze and CLEAN water [see THIS section].
flushing the engine block or the
radiator assembly. NOTE: It is suggested that one [1] can of cooling
system conditioner, with a rust inhibitor,
g. Reverse flush the RADIATOR assembly, as also be added to the coolant at THIS time.
shown in [4-24 Fig13]. Loosen the radiator drain
j. Start the engine and allow the NEW coolant
cock, again, AFTER reverse flushing the radiator
mixture to circulate through the cooling system.
assembly. COMPLETELY drain the radiator of
Inspect the COMPLETE system for ANY coolant
water. Close the radiator drain cock and tighten
leakage. STOP the engine IMMEDIATELY and
securely.
correct any leakage problem noted, BEFORE
further engine operation.

WARNING: KEEP CLEAR of ALL moving engine

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

k STOP the engine. Allow the coolant to reach

a cool temperature and then fill coolant
recovery tank to the upper “MAX” mark with the
CORRECT coolant mixture.
Install the recovery tank cap and tighten.

4-24 Fig13. REVERSE FLUSHING PROCEDURE

RADIATOR ASSEMBLY.

4-24 12-2010
 Section 4
MAINTENANCE
HYDRAULIC SYSTEM. CAUTION: Do NOT over-fill the hydraulic oil
reservoir.
GENERAL INFORMATION. Do NOT use unfiltered hydraulic oil.
The NEW hydraulic oil must be filtered
The transmission, steering and vibration systems through TEN [10] micron filtration
ALL use the SAME hydraulic oil reservoir and hy- BEFORE it enters the hydraulic oil
draulic oil supply. reservoir. The oil must NOT have
more than 400 particles larger than 10
CHECKING THE HYDRAULIC OIL LEVEL AND u. per milliliter as installed.
ADDING HYDRAULIC OIL TO THE HYDRAULIC KEEP the oil level of the hydraulic
OIL RESERVOIR [See 4-25 Fig14]. oil reservoir, at the correct level.
An air space is designed into the
CHECK the hydraulic reservoir oil level, one [1] time hydraulic oil reservoir and allows for
for EACH eight [8] hours of machine operation, or oil expansion, at warm temperatures.
daily, using the sight gauge on the reservoir. Check The hydraulic oil reservoir will have a
the oil level when the hydraulic oil is at “COLD” Iow pressure in it at system operating
operating temperature only. temperatures.
WARNING: Do NOT loosen, or remove, the Do NOT add a vent hole to the
hydraulic oil reservoir filler cap when hydraulic oil reservoir.
the hydraulic oil is “HOT”. ALWAYS
loosen the filler cap SLOWLY to
relieve any pressure in the hydraulic
oil reservoir.
ONLY loosen the filler cap when the
oil is at a “WARM” temperature.

The hydraulic reservoir oil level MUST be able to be

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

4-25 Fig14. HYDRAULIC OIL RESERVOIR AND

SIGHT GAUGE.

12-2010 4-25
Section 4
MAINTENANCE
CHANGING THE HYDRAULIC OIL
[See 4-26 Fig15].
OBTAIN a hydraulic oil sample from oil six [6] inches
[152.4 mm] BELOW the FILL neck of the hydraulic oil
reservoir one [1] time for each 2,000 hours of machine
operation, or every two [2] years for OIL ANALYSIS.
Use the equipment from, and follow the directions
given by, the oil analysis service. Change the
hydraulic oil ONLY if the OIL ANALYSIS results
indicate a change is needed.
Changing the hydraulic oil removes the accumula-
tion of dirt, water and mechanical wear particles from
the hydraulic oil reservoir and system. The chemical
structure of the hydraulic oil also changes after
continuous use in the system and NEW, CLEAN
and FILTERED oil is a MUST to help insure further
CORRECT operation of the hydraulic system.
CAUTION: Hydraulic oil which has oxidized or
which contains contamination, of 4-26 Fig15. HYDRAULIC OIL DRAIN LOCATION.
ANY type, can shorten the expected
service life of ANY, or ALL, of the c. Install the hydraulic oil reservoir drain plug, and
components in the hydraulic system. tighten securely.

d. CAREFULLY remove the cloth from the hydraulic

Use the following procedures to change the hydraulic oil: oil reservoir fill tube opening.
a. STOP the engine. Allow the hydraulic oil to e. Fill the hydraulic oil reservoir with the CORRECT,
cool, until it is at a WARM temperature ONLY. FILTERED hydraulic oil using the procedures
SLOWLY loosen, and then remove, the hydraulic
given in the following “CAUTION” information.
oil reservoir filler cap. Put a CLEAN, lint free cloth
See THIS section for correct type of oil.
over the reservoir fill tube opening and secure in
place with tape. CAUTION: Do NOT use unfiltered hydraulic oil.
The NEW hydraulic oil MUST be filtered
WARNING: Do NOT drain the hydraulic oil from
through TEN [10] micron filtration
the reservoir when it is HOT. HOT
BEFORE it enters the hydraulic oil
hydraulic oil can cause serious
reservoir. The oil MUST NOT have
injury. Drain at a WARM temperature
MORE than 400 particles larger than
ONLY.
10 u. per milliliter of oil as installed.
b. CAREFULLY remove the drain plug located Fill the hydraulic oil reservoir UNTIL
on the bottom of the hydraulic tank [See 4-26 the oil level is in the CENTER of the
Fig15]. Use a drain collection device of sufficient sight gauge glass. Do NOT overfill the
capacity to collect the oil. Allow ALL of the hydraulic oil reservoir with oil.
hydraulic oil to drain from the reservoir and into
the container.

NOTE: Also, change the STEERING system

hydraulic PRESSURE oil filter element at
this time [see 4-27 Fig16].

4-26 12-2010
 Section 4
MAINTENANCE
f. Check the oil level in the hydraulic oil reservoir,
again. Add oil if needed.

g. Install the hydraulic oil reservoir filler cap onto the

reservoir filler neck and tighten securely.

h. Start the engine using the CORRECT procedures

given in Section 3 - OPERATION of THIS manual.
CHECK the hydraulic system for any leaks.

WARNING: Do NOT use hands on ANY hydraulic

hose, fitting or system component to
check the system for possible leaks.
SERIOUS injury can result from an
oil leak under high pressure. Oil can
be injected under the skin by high
pressure. Protect the eyes by wearing
safety glasses.

CAUTION: STOP the engine IMMEDIATELY if

ANY hydraulic leak is noted.
Do NOT start the engine UNTIL any 4-27 Fig16. STEERING FILTER
problem noted has been corrected. ELEMENT LOCATION.
WARNING: Do NOT loosen, or remove, the
STEERING SYSTEM PRESSURE OIL FILTER hydraulic oil filter element when
ELEMENT - REMOVAL AND REPLACEMENT the engine is running, or when the
[See 4-27 Fig16]. hydraulic oil is HOT. Loosen, and
CHECK the condition on display console of the steer- remove, the filter element ONLY
ing system pressure oil filter element, one [1] time for when the engine is in a “STOPPED”
EACH eight [8] hours of machine operation, or daily. condition and the hydraulic oil
The filter element MUST be changed when the change has cooled to a WARM, or COLD,
indicator, display console light remains on this indicates temperature.
an element change is needed
Use the following procedure to remove and replace
CAUTION: The hydraulic system MUST be at the hydraulic oil filter element:
NORMAL operating temperature,
with the engine “running”, when a. STOP the engine. Allow the hydraulic oil to reach
the condition of the filter element a WARM, or COOL, temperature.
is checked.
b. Open engine compartment hood. Wipe the
hydraulic oil filter head and element using a
CLEAN lint free cloth.

c. Turn hydraulic filter element counterclockwise

(CCW) and remove the filter element. Discard the
removed steering filter element.

12-2010 4-27
Section 4
MAINTENANCE
d. Put CLEAN hydraulic oil on the NEW filter TRANSMISSION SYSTEM PRESSURE OIL FILTER
element rubber gasket. ELEMENT - REMOVAL AND REPLACEMENT
[See 4-29 Fig17].
e. CAREFULLY install the new filter element onto
the filter head. Turn filter CLOCKWISE (CW) to The transmission system pressure oil filter element
engage locking tabs on filter element MUST be changed when the hydraulic oil is changed
every 2000 hours of operation or two [2] years. The
CAUTION: Do NOT overtighten the new filter filter element MUST be changed when the change
element. Tighten by hand only. indicator, display console light remains on. This
indicates an element change is needed.

f. Fill the hydraulic oil reservoir with oil. Use all of WARNING: Do NOT loosen, or remove, the
the correct procedures given in THIS section. hydraulic oil filter element when
the engine is running, or when the
CAUTION: Do NOT start the engine BEFORE hydraulic oil is HOT. Loosen, and
filling the hydraulic oil reservoir remove, the filter element ONLY
with oil. Damage to the hydraulic when the engine is in a “STOPPED”
system components can occur. condition and the hydraulic oil
Fill the reservoir using ALL of the has cooled to a WARM, or COLD,
procedures given in THIS section. temperature.

g. Start the engine using the CORRECT procedures NOTE: The transmission hydraulic oil filter is
given in Section 3 - OPERATION of THIS located below and in front of the engine
manual. CHECK the hydraulic system for ANY oil radiator.
leaks.
Use the following procedure to remove and replace
WARNING: Do NOT use hands on ANY hydraulic the hydraulic oil filter element:
hose, fitting or system component to
check the system for possible leaks. a. STOP the engine and engage park brake. Allow
SERIOUS injury can occur from an the hydraulic oil to reach a WARM, or COOL,
oil leak under high pressure. Oil can temperature.
be injected under the skin by high
pressure. Protect the eyes by wearing b. Remove side access panel [See 4-29 Fig17].
safety glasses. Wipe the hydraulic oil filter head and element
using a clean lint-free cloth.
CAUTION: STOP the engine IMMEDIATELY c. Use SPECIAL tool (part number 83212018) to
if ANY hydraulic oil leak is noted. loosen filter housing lock nut collar and remove
Do NOT start the engine until any the filter element and housing. Discard the filter
problem noted has been corrected. element inside housing.
h. Close engine compartment hood. CAUTION: Be sure that the old filter element
rubber gasket is removed and
discarded, BEFORE the NEW filter
element is installed.

d. Put CLEAN hydraulic oil on the NEW filter

element rubber gasket.

e. CAREFULLY install the NEW filter element into

the filter housing. Install filter and housing and
tighten filter housing lock nut collar onto the
filter head using SPECIAL tool (part number
83212018).

4-28 12-2010
 Section 4
MAINTENANCE
f. Check and fill the hydraulic oil reservoir, if WARNING: Do NOT use hands on ANY hydraulic
necessary, with oil. Use ALL of the CORRECT hose, fitting or system component to
procedures given in THIS section. check the system for possible leaks.
SERIOUS injury can occur from an
CAUTION: Do NOT start the engine BEFORE oil leak under high pressure. Oil can
filling the hydraulic oil reservoir be injected under the skin by high
with oil. Damage to the hydraulic pressure. Protect the eyes by wearing
system components can occur. safety glasses.
Fill the reservoir using ALL of the
procedures given in THIS section. CAUTION: STOP the engine IMMEDIATELY
if ANY hydraulic oil leak is noted.
g Start the engine using the CORRECT procedures Do NOT start the engine until any
given in Section 3 - OPERATION of THIS problem noted has been corrected.
manual. CHECK the hydraulic system for ANY
oil leaks. h. Close engine compartment hood and install side
access panel.

4-29 Fig17. TRANSMISSION SYSTEM - PRESSURE OIL FILTER ELEMENT LOCATION.

12-2010 4-29
Section 4
MAINTENANCE
DRUM BEARING LUBRICATION. Use the following procedures to ADD lubrication oil to
either drum:
CHECKING THE DRUM BEARING LUBRICATION
OIL LEVEL [See 4-30 Fig18]. 1. SLOWLY move the machine and rotate the
drum, to a point where the FILLER hose
Check the drum bearing lubrication oil level of EACH bulkhead fitting and LARGE cap fitting are
drum, one [1] time for EACH eight [8] hours of ma- in a position ABOVE the center line of the
chine operation, or daily. drum rotation [approximately a 2 o’clock or
11 o’clock position].
Use the following procedures to check drum bear-
ing lubrication oil level, and to add lubrication oil if 2. Wipe the LARGE cap and the bulkhead
needed: fitting of the filler hose with a CLEAN cloth.
Remove the LARGE [FILL] cap fitting from
a. Put the machine on a LEVEL surface, and in the filler hose bulkhead fitting.
a position, so the RED drum position locator
bar, on the drum being checked, is at the exact 3. SLOWLY add CLEAN and FILTERED
BOTTOM of the rotation of the drum. Texaco Meropa 150, or equivalent,
lubrication oil to the drum, through the
CAUTION: If the lubrication oil level is BELOW FILLER hose on the drum.
the sight gauge glass, ADD only
enough oil to show the CORRECT CAUTION: Clean the oil being added to the
oil level in the CENTER of the sight drum, through twenty five [25] micron
gauge glass. filtration BEFORE it enters the drum.
Add the oil to the drum SLOWLY.
Do not add more oil immediately if Do NOT overfill the drum with
the lubrication oil level appears to be lubrication oil.
below the sight gauge glass. Allow Add ONLY enough oil to bring the
enough time for the drum bearing drum oil level to the center of the
lubrication oil to “level” in the sight sight gauge glass.
gauge glass and indicate the true oil
level.

4-30 Fig18. Drum Lubrication Oil Fill and Sight Gauge Locations.

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MAINTENANCE
4. Install the LARGE [FILL] cap fitting onto d. Rotate the drum until the LARGE [FILL] cap
the filler hose bulkhead fitting and tighten fitting is positioned at the HIGHEST [TOP] point
securely. of the rotation of the drum.

b. Move the machine to the same position as in e. SLOWLY fill the drum through the LARGE [FILL]
step “a” and check the oil level again, using the hose bulkhead fitting, using 10.5 gallons
procedures given in step “a”. [39.7 liters] of CLEAN and FILTERED Texaco
Meropa 150, or equivalent, lubrication oil.
CAUTION: If the oil level is NOT correct, ADD
f. Wait two [2] minutes and then check the lubrication
additional oil using steps “1-4” and
oil level shown in the sight gauge glass. The
then check the oil level again.
lubrication oil level MUST be in the CENTER of the
sight gauge glass to be at the CORRECT level.
c. Check the drum bearing lubrication oil level of
the SECOND drum, using the SAME procedures. CAUTION: Clean the oil, entering the drum,
Add lubrication oil if needed. through twenty-five [25] micron
filtration BEFORE it enters the drum.
CHANGING THE DRUM BEARING LUBRICATION Fill with oil SLOWLY.
OIL [See 4-30 Fig18]. Do NOT overfill the drum with
lubrication oil. Fill the drum with
Change the drum bearing lubrication oil, in EACH
ONLY enough oil to bring the oil level
drum, one [1] time for EACH 1,000 hours of machine
to the CENTER of the sight gauge
operation, or every year.
glass.
Use the following procedures to change the drum
bearing lubrication oil in both drums: g. Install the LARGE [FILL] cap fitting onto the filler
hose bulkhead fitting and tighten securely.
a. Run the machine long enough to insure that the
drum bearing lubrication oil is completely at a h. Check the drum bearing lubrication oil level,
WARM temperature. using the procedures given in THIS section.

b. Rotate the drum, having the lubrication oil i. Change the drum bearing lubrication oil in the
changed first, until the LARGE [FILL] cap fitting SECOND drum, using the SAME procedures
is positioned at the LOWEST [BOTTOM] point of given ABOVE. Check the second drum bearing
the rotation of the drum. Wipe the area around lubrication oil level, using the procedures given in
the LARGE [FILL] cap fitting with a CLEAN cloth. THIS section.

c. Remove the LARGE [FILL] cap fitting from

the filler hose bulkhead fitting. Drain the drum
bearing lubrication oil from the drum.

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Section 4
MAINTENANCE
ALTERNATOR AND FAN DRIVE BELT Use the following information to inspect and/or in-
- INSPECTION AND REPLACEMENT spect and replace the drive belt:
PROCEDURES [See 4-32 Fig19].
a. STOP the engine.
Inspect the drive belt one [1] time for EACH 1,000
hours of machine operation, or yearly. Replace the WARNING: Do NOT inspect the engine drive
belt as needed, after inspection. The belt is kept un- belt when the engine is “running”.
der constant tension by an automatic tension mecha- The engine must be stopped before
nism and “adjustment” is not required as part of the inspecting the drive belt. Serious
maintenance procedures. injury can result from being caught,
or struck, by the fan, belt or other
moving engine parts.

4-32 Fig19. ALTERNATOR AND FAN DRIVE BELT LOCATION.

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MAINTENANCE
b. Visually inspect the drive belt for intersecting cracks
on the INNER surface of the belt plies. Longitudinal
[direction of belt length] cracks that intersect with
transverse cracks are NOT acceptable. Replace
the belt, with NEW, if any intersecting cracks,
fraying, or other damage, is noted.

NOTE: If the belt requires replacement with new,

also, see the “Cummins Operation and
Maintenance Manual - QSB 4.5 Engine”,
published by Cummins Diesel Engine
Company and supplied with the machine
for procedures. Also, check the belt
tension mechanism and fan hub bearings,
at this time, using the procedures given in
the same publication.

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MAINTENANCE
ELECTRICAL SYSTEM.

FUSES [See 4-34 Fig19A & 19B].

DANGER: Fire hazard!

Do not use fuses with higher ampere
ratings and do not bridge fuses.

F160
F154

F153

F148
F122
F146

F05
F13

17
18
6

4-34 Fig19A. FUSES IN CENTRAL ELECTRICS 4-34 Fig19B. FUSES IN REAR ELECTRICAL

F154. 15A = BATTERY POWER TO ESX F157. 30A = STARTER SOLENOID

F13. 10A = BATTERY POWER TO SEAT F119. 30A = ENGINE ECM. MAIN
(KEYSWITCH, DISPLAY, ESX, F136. 5A = CUMMINS DATALINK
MESX) F37. 10A = REAR WATERSPRAY PUMP
F61. 15A = FRONT WATERSPRAY PUMP
F41. 10A = ROTARY BEACON
F07. 15A = HAZARD LIGHTS
F146 15A = MAIN POWER TO MESX
F23. 10A = WARNING HORN. B/U ALARM
F05. 15A = 12 V ACC. PLUG. CAB LIGHT
F103. 15A = FUNCTIONS, KEYSWITCH
POWER TO SEAT
F122. 5A = CUMMINS ENGINE EMC
F153. 15A = KEYSWITCH POWER
MAT TEMP SENDER, TRAVEL
PPU, DATA COLLECTOR
F08. 15A = TURN SIGNALS, HAZARDS
F160 10A = KEYSWITCH POWER TO ESX
F148 10A = KEYSWITCH POWER TO MESX
F11. 15A = WORK LIGHTS-LH
F12. 15A = WORK LIGHTS-RH
F19. 20A = NIGHT LIGHTS-LH
F20. 20A = NIGHT LIGHTS-RH

4-34 12-2010
 Section 4
MAINTENANCE
CHECKING THE CHARGE CONDITION OF THE WARNING: BATTERY EXPLOSION CAN OCCUR
BATTERY AND SERVICING OF RELATED ItemS IF THE BATTERY IS SHORTED.
[See 4-35 Fig20]. ALWAYS disconnect the NEGATIVE
[-] battery cable first, and then
The battery is of the “maintenance-free” type and disconnect the POSITIVE [+] battery
minimal service is needed. Use the built-in battery cable, before cleaning the terminals,
“charge level” indicator, found in the top of the bat- or cables.
tery, to check the charge level in the battery one [1] NEVER make a shorted circuit
time for EACH 100 hours of machine operation, or between the positive [+] terminal and
every two [2] weeks. negative [-] terminal of the battery.
ALWAYS connect the POSITIVE [+]
WARNING: CALIFORNIA Proposition 65.
battery cable to the POSITIVE battery
Battery posts, terminals and related
terminal FIRST, and then connect
accessories contain lead and lead
the NEGATIVE [-] battery cable to the
compounds. Wash hands after
NEGATIVE [-] battery terminal LAST.
handling.
Do NOT place ANY tools on a battery,
at ANY time.
WARNING: Do NOT attempt to open the
“MAINTENANCE-FREE” battery case.
Check and tighten the battery hold-down assembly.
The acid in electrolyte can cause
The battery MUST be kept from ANY movement in
injury. If electrolyte is spilled, use
the machine.
water to flush the area and make the
acid neutral using a water and soda
solution. Acid in the eyes MUST be
FLUSHED with water IMMEDIATELY.
ALL batteries produce an
EXPLOSIVE GAS.
Do NOT smoke near a battery.
Do NOT check with flame.
Do NOT cause sparks.

The indicator will indicate a “GREEN” color for a

FULLY charged battery. A “BLACK” indicator color
indicates the battery is in a LOW charged condition.
Use a battery cable cleaning brush, baking soda and
clear water to clean the battery terminals and cables,
as needed.

4-35 Fig20. BATTERY MAINTENANCE AREA

LOCATIONS.

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Section 4
MAINTENANCE
ELECTRICAL WIRING INSPECTION. b. Put wood blocks in front, and at the rear, of both
drum assemblies.
During engine and/or other system maintenance
inspections, CHECK the electrical wiring for correct c. Remove the nut and tightening washer [Item
routing and support. Inspect the wires for loose termi- 1] attaching the defective rubber buffer isolator
nal connections, cracks, or wear in the wiring insula- [Item 2] to the drive plate [Item 3].
tion and for corrosion. Wires and connections MUST
be free of oil, dirt or grease. d. Use a jack screw or other device to spread the
drive plate out slightly to gain access to the two
CAUTION: Do NOT use a wire smaller than the cap screws [Item 4] securing the rubber buffer
size of the original factory-installed isolator [Item 2] to the drum [Item 5].
wires in the electrical system. If,
due to wear or damage, wires are e. Remove the capscrews [Item 4] and tightening
replaced with new, use wire EQUAL washers [Item 1] and slide the defective isolator
to, or larger in size than, the wire out of the drum [Item 5].
being replaced.
INSTALLATION [See 4-37 Fig21].
WARNING: BATTERY EXPLOSION CAN OCCUR
a. Use a jack screw or other device to spread the
IF THE BATTERY IS SHORTED.
drive plate out slightly to allow the rubber buffer
ALWAYS disconnect the NEGATIVE
isolator [Item 2] to be positioned on the drum
[-] battery cable first, and then
[Item 5] so that the two capscrew mounting holes
disconnect the POSITIVE [+]
for the rubber buffer isolator [Item 2] are aligned
battery cable, BEFORE ANY repair
with the mounting holes in the drum [Item 5].
procedures are done to the electrical
wiring or components. b. Place Loctite #242 on the two capscrews [Item
NEVER make a shorted circuit 4] and install capscrews and tightening washers
between the positive [+] terminal and [Item 1[.
negative [-] terminal of the battery.
ALWAYS connect the POSITIVE [+] c. Torque capscrews [Item 4] to 157 ft. lbs. [213 N•m].
battery cable to the POSITIVE battery
terminal first, and then connect the d. Remove the jackscrew.
NEGATIVE [-] battery cable to the
NOTE: The stud on the rubber buffer isolator
NEGATIVE [-] battery terminal last.
[Item 2] should now be positioned in the
DO NOT place ANY tools on a battery,
slotted opening on the drive plate [Item 3.]
at ANY time.
e. Place Loctite on the nut [Item 1] and attach the
nut and tightening washer to the stud on rubber
VIBRATION ISOLATORS. buffer isolator [Item 2].

f. Torque nut [Item 1] to 431 ft. lbs. [585 N•m].

REMOVAL, REPAIR OR REPLACEMENT, AND
INSTALLATION OF THE VIBRATION ISOLATOR. g. Remove wood blocks in front, and at the rear, of
[See 4-37 Fig21]. both drum assemblies.
Remove, repair, or replace, ANY vibration isolator
found to show evidence of serious damage, IMMEDI-
ATELY, using the following procedures:

REMOVAL [See 4-37 Fig21].

a. Place the machine on a level surface. Apply the
parking brake and stop the engine.

4-36 12-2010
 Section 4
MAINTENANCE

4-37 Fig21. REMOVAL, REPAIR OR REPLACEMENT, AND INSTALLATION OF THE VIBRATION ISOLATOR

12-2010 4-37
Section 4
MAINTENANCE
PARKING BRAKE SYSTEM MAINTENANCE -
OPERATION AND APPLICATION CHECK
[See 4-38 Fig22].

Check the PARKING BRAKE SYSTEM for correct

operation and application, one [1] time for EACH 100
hours of machine operation, or every two [2] weeks.

WARNING: The Parking Brake system MUST keep

the machine in a STOPPED condition
during the following system operation
and application check.
If the machine moves, in EITHER
direction of travel, during the system
operation and application check,
STOP the engine IMMEDIATELY.
Do NOT use the machine. Put an
instruction tag reading “DO NOT 4-38 Fig22. BRAKE AND 2-SPEED VALVE
OPERATE” on the instrument panel ASSEMBLY LOCATIONS.
and REMOVE the ignition key from the
ignition switch. e. Put the engine THROTTLE RUN/IDLE speed
Put SOLID wood blocks in the front, switch in the RUN [high] speed position.
and in the rear, of one [1] drum of the
f. Move the Propel FNR handle one fourth [1/4]
machine.
of the full travel distance toward forward, or the
REPAIR the system fault
reverse position, and note that the machine
IMMEDIATELY.
does NOT move. Repeat the procedure for the
OPPOSITE direction of travel. Move the Propel
Use the following procedures to CORRECTLY check
FNR handle to “NEUTRAL”.
the Parking Brake system for CORRECT operation
and application: WARNING: The machine must NOT move in
EITHER direction of travel. The
a. Select a site that has a LEVEL surface and is
Parking Brake system MUST keep
CLEAR of other machines, building structures or
the machine in a STOPPED condition
personnel. Park the machine in the center of the
during the system operation and
selected area. STOP the engine.
application check.
b. Open the machine engine hood. If the machine moved, in EITHER
Find the Brake and 2-Speed valve assembly, direction of travel, during the system
which is positioned on the side of the hydraulic operation and application check,
tank. Switch the brake solenoid connector Y04 STOP the engine IMMEDIATELY.
with the 2-Speed solenoid connector Y31. Do NOT use the machine. Put an
instruction tag reading “DO NOT
c. Keep the Propel FNR and the STEER controls in OPERATE” on the instrument panel
“NEUTRAL”. and remove the ignition key from the
ignition switch.
d. Put the engine THROTTLE RUN/IDLE speed Put SOLID wood blocks in the front,
switch in the “IDLE” [low] speed position. Start and in the rear, of one [1] drum of the
the engine by using the CORRECT procedures machine.
given in Section 3 - OPERATION in this manual. REPAIR the system fault
IMMEDIATELY.

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 Section 4
MAINTENANCE
NOTE: If the machine did NOT move, in EITHER Clean the spray nozzles by using a small wire, or low
direction of travel, during the system pressure compressed air.
operation and application check, the
STOP/Parking Brake system has full Install the nozzle into the threaded retaining collar.
application capacity, and the system is “Screw” the retaining collar in a CLOCKWISE [CW]
ready for use during machine operation. direction, onto the lower mount, while positioning the
outlet of the nozzle toward the drum surface.
g. Put the THROTTLE RUN/IDLE [engine speed]
switch in the IDLE [low] speed position and allow
engine to run at “LOW” idle speed for a period
of at least three - five [3 - 5] minutes. STOP the
engine.

h. Go to the Brake and 2-Speed valve assembly

and switch connectors back to original position.

i. Close the engine hood. Attach the latching

straps.

MISCELLANEOUS MAINTENANCE
INFORMATION.

WATER SPRAY SYSTEM.

WATER STRAINERS [See 4-39 Fig23].

One [1] time for EACH 500 hours of machine opera-
tion, or 6 months, remove the sock strainer found in
each water tank. This can be done by removing the
cover and lifting the sock strainer assembly through
the lift port. Carefully clean the screen to remove
material trapped and held by the screen material.
Install the complete assembly back into the water
tank. Connect the water supply hose to the pump
inlet, if removed. 4-39 Fig23. WATER SPRAY TANK STRAINER.

WATER SPRAY NOZZLES [See 4-39 Fig24].

Water spray nozzles and orifice discs can become
clogged and cause a reduced water flow from the
nozzles.

Remove, clean and install ALL of the water spray

nozzles found on the front and rear water spray bars,
as required.

Each water spray nozzle and orifice disc is connected

to the water spray bar and is released by “unscrew-
ing” the threaded retaining collar in a counterclock-
wise [CCW] direction.

Remove the spray nozzle from inside the retaining

collar for cleaning, or replacement. 4-39 Fig24. WATER SPRAY NOZZLES.

12-2010 4-39
Section 4
MAINTENANCE
for damage, replace if necessary. Install the filter as-
sembly to quick disconnect.

SCRAPER ASSEMBLIES [See 4-41 Fig27].

Two [2] cleaner beam scraper assemblies are found

on EACH drum.

Check for broken, or loose, cleaner bar beam and/

or rubber cleaner components one [1] time for EACH
50 hours of machine operation, or weekly.

Replace broken, or missing, parts as required. Keep

ALL mounting fasteners securely tightened at all
times. Keep the cleaner bar beam to machine mount-
ing capscrews tightened to a torque of 280 ft. lbs.
[380 N•m] at all times. Keep the rubber cleaners, at
4-40 Fig25. WATER PUMP VALVE. a position that is AGAINST each drum face at ALL
times when rolling asphalt with water and keep the
WATER PUMP VALVE [See 4-40 Fig25]. retaining capscrews securely tightened.
The Tandem Vibratory Roller is equipped with two To extend scraper life, swing scraper away from
water spray pumps each is located under the front drum during roading.
and rear water tanks. In the event of the failure of
one of the pumps, the other pump can operate both Swing scrapers out to clean dirt and rocks. Inspect
spray bars. This is achieved by turning the water daily.
valve located behind the fuel fill access panel.
CAUTION: Do NOT operate a machine having
missing, or damaged, cleaner beam,
or scraper cleaner components.
Replace all missing, or damaged,
cleaner beam, or scraper cleaner,
components IMMEDIATELY.

PREPARING THE MACHINE FOR STORAGE.

Use the following information as a “general guide”

ONLY to prepare the machine for storage. Manufac-
turers of components can also be contacted for
specific information about components manufactured
by them.

ENGINE.
4-40 Fig26. WATER PUMP FILTER. See the current Cummins “Operation and Main-
tenance Manual - QSB 4.5 Engine” for complete,
WATER PUMP FILTER [See 4-40 Fig26]. ­APPROVED engine storage preparation procedures
suggested by the manufacturer.
One [1] time every year, remove and clean the water
pump filters located in-line with each water spray
pump. Release filer quick disconnect and remove
filter. Carefully clean the mesh filter to remove mate-
rial trapped and held by the mesh filter. Inspect filter

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 Section 4
MAINTENANCE
BATTERY.

If the machine is to be stored for a period of more

than 30 days, remove the battery from the machine.
FULLY charge the battery BEFORE it is placed in
storage. Charge the battery, AGAIN, one [1] time for
every 30 days of storage. Keep the battery stored in
a cool and dry storage area.

CAUTION: Do NOT store the battery on a

concrete surface.
Store the battery on a WOOD
surface ONLY. Make sure the battery
electrolyte will NOT freeze.

FUEL TANK.

FILL the fuel tank to a COMPLETELY full condition,

using the CORRECT, CLEAN fuel, BEFORE the
machine is placed in storage [see THIS section].

CAUTION: Do NOT leave the fuel tank

partly filled. Moisture will form
condensation inside the fuel tank,
4-41 Fig27. SCAPER ASSEMBLY. while in storage, and can cause fuel
system component damage during
COOLING SYSTEM. storage, or when the machine is
placed back into service.
The ENTIRE cooling system must be protected from
freezing. FILL the radiator as needed, using an
ethylene glycol based antifreeze and water solution
[see THIS section].

The antifreeze and water MUST be of the CORRECT

mixture ratio, to protect the cooling system, to a
temperature BELOW the lowest expected freezing
temperature for the area where the machine is to be
stored.

ALSO, see the current Cummins “Operation and

Maintenance Manual - QSB 4.5 Engine” for com-
plete, APPROVED engine cooling system storage
procedures.

12-2010 4-41
Section 4
MAINTENANCE
AIR CLEANER, EXHAUST AND OTHER
OPENINGS.

Cap, tape, or otherwise seal, ALL openings to

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

WATER SPRAY SYSTEM.

COMPLETELY drain the water from BOTH water

tanks. Drain ALL water supply lines and spray bars
of water. Apply low-pressure compressed air to these
parts to remove any water still remaining in them.
Remove the water pump assembly, completely drain
all remaining water from the pump and install the
pump back onto the machine. Put a plastic cover, or
tape, over each water spray nozzle.

CAUTION: DRAIN ALL water, from the water

spray tanks, water pump and filter,
BEFORE the temperature reaches
32°F [0°C]. The system WILL be
DAMAGED if the water is allowed
to freeze.
-OR-
After draining, add 1 gallon of RV
antifreeze or wiper fluid antifreeze.
Cycle spray system until fluid comes
out of the spray nozzles.

EXPOSED COMPONENT RUST PREVENTION.

Put a heavy grease, or equivalent, onto ANY ex-

posed area of the hydraulic steering cylinder rod.

Put a rust preventive oil [such as L.P.S.#s 2 or 3] on

ALL hinges, or other moving parts. Put ALL covers
and access plates in their CORRECT position and
secure in place.

4-42 12-2010