Hypac C766C, C778B - Om PDF

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
WARNING: Battery posts, terminals and
related accessories contain lead and
lead compounds, chemicals known to the
harm. Wash hands after handling.
C766C
C778B
Revision R4
Form 0852656
8/03
OPERATING
MANUAL
C766C & C778B

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

Close Attaching Mechanisms Around Eyebolts.
Install Cotter Pins and Bend.
Hexbolt - M20x110 - 10.9

(4 used on far side).
Tighten to a Torque of
375 ft. lbs. (509 N.m).
Seat Belt
Set (2 used)
Eyebolt
Washer
M20 Washers
(4 used on far side)
Lock Washer
Nut
Install Eybolts (2).
One on each Side of the Seat.
Tighten Nuts to a Torque of
35 ft. lbs. (47 N.m).
M20 Washers
(4 used on near side)
Hexbolt - M20x65 - 10.9 (4 used on near side).

Tighten to a Torque of 375 ft. lbs. (509N.m).
DANGER: Do Not operate machine with the Roll Over/

Falling Object Protection Structure
(ROPS/FOPS) and Operator Restraints
(Seat Belt Sets) NOT properly installed.
April 2000
SYMBOLS USED IN THIS MANUAL

The following symbols have been used in THIS Manual to help communicate the intent of
instructions. When one of the symbols appears, it conveys the meaning defined below:
DANGER: Serious personal injury, death and/or

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

extensive property damage can
result if the WARNING instructions
are not followed.
CAUTION: Minor personal injury can result or

a part, an assembly, or the engine
can be damaged if the CAUTION
instructions are not followed.
NOTE: Gives additional, and/or clarification

details, which are to be used in
conjunction with previously
presented information.
CALIFORNIA
WARNING: Diesel engine exhaust and
some of its constituents are known to the
harm.
CALIFORNIA
WARNING: Battery posts, terminals and
related accessories contain lead and
lead compounds, chemicals known to the
harm. Wash hands after handling.
SERVICE AND REPAIR PRECAUTIONS
ALWAYS inspect all slings, chains, or cables when lifting components, be sure that they are properly
tied, fastened and balanced before lifting. Be sure that the lifting device is capable of retaining the
weight to be lifted.
NEVER attempt to lift heavy parts by hand when a lifting device should be used.
ALWAYS wear safety glasses when performing any maintenance or repair work on the machine.
NEVER attempt to remove or repair any component, on the machine, while the engine is running.
NEVER leave the machine and/or heavy parts in an unstable position during repair.
ALWAYS support the machine with sound blocking.
ALWAYS keep the machine and work area clear of lubricants and dirt.
ALWAYS use the correct tools for the repair procedures being done on the machine,
ALWAYS keep tools in a good and clean condition.
ALWAYS use approved parts, that are designed for the machine being repaired. This helps
to ensure maximum service life of the machine.
ALWAYS be sure that all necessary nuts, bolts, snap rings, and other fastening devices, are
removed before using force to remove components.
ALWAYS attach a sign in the machine operators area, stating DO NOT OPERATE when the
machine is being repaired.
ALWAYS observe ALL WARNING AND CAUTION statements given in the Operating Manual and
Service Manual and found on the machine decals.
MANUAL - TABLE OF CONTENTS
PAGE
SECTION 1 - INTRODUCTION ................................................................................................................ 1-1.
SECTION 2 - SPECIFICATIONS ............................................................................................................. 2-1.
SECTION 3 - OPERATION ...................................................................................................................... 3-1.
SECTION 4 - MAINTENANCE ................................................................................................................. 4-1.
2/98
Section 1
INTRODUCTION
TABLE OF CONTENTS
PAGE
GENERAL INFORMATION ......................................................................................................................1-2.
SPECIFICATIONS ....................................................................................................................................1-2.
OPERATING INSTRUCTIONS .................................................................................................................1-2.
MAINTENANCE PROCEDURES .............................................................................................................1-2.
REPAIR PROCEDURES ..........................................................................................................................1-3.
NAME PLATE / SERIAL NUMBER PLATE .............................................................................................1-3.
SERIAL NUMBER ....................................................................................................................................1-4.
5/01
1-1
Section 1
INTRODUCTION
GENERAL INFORMATION.
SPECIFICATIONS.
WARNING: ONLY authorized personnel, who

are fully trained in the machine
operation procedures, can operate
the Model C766C and C778B
Compactors. Follow ALL instructions given in THIS manual, and
written on the Machine Operation
and Warning decal, found on the
flat plate on the right side of, and
below, the control panel.
See Section 2 - SPECIFICATIONS, of THIS

manual, for specifications on major systems used
on the machine.
MAINTENANCE PROCEDURES.
OPERATING INSTRUCTIONS.
The maintenance schedules and procedures

are found in Section 4 - MAINTENANCE, of
THIS manual.
THIS manual contains SPECIFICATION information

and OPERATION, MAINTENANCE and REPAIR
procedures for the Model C766C and C778B
Compactors [See Figures 1-1 and 1-2].
READ, UNDERSTAND and FOLLOW ALL the

operating instructions given in the FRONT, and in
Section 3 - OPERATION, of THIS manual.
CAUTION: Follow ALL the maintenance

schedules and instructions
given in THIS manual.
C766C
FIGURE 1-1. MODEL C766C - COMPACTOR.
1-2
5/01
Section 1
INTRODUCTION
REPAIR PROCEDURES.
SERIAL NUMBER [See Figures 1-3 and 1-4].
MAJOR machine component REPAIR

PROCEDURES are found in the SYSTEM
REPAIR PROCEDURE sections of "Service
Manual", pn. 0852657.
The SERIAL NUMBER indicates the design series,

manufacturing location, serial number and year of
machine shipment (older machines) [see Table 1-1].
The machine serial number is located ON the
nameplate [see figure 1-3]. The serial number is
also stamped on the flat surface of the hitch assembly at the left hand side of the machine [see figure
1-4].
CAUTION: For CORRECT machine component

repair procedures, USE the REPAIR
procedures given in the above
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.
NAME PLATE /SERIAL NUMBER PLATE [See

Figure 1-3].
The name plate/serial number plate is located
BELOW, and to the left side of, the steering wheel.
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 replacement plate.
FIGURE 1-2. MODEL C778B - COMPACTOR.
5/01
1-3
Section 1
INTRODUCTION
C209
or
B215
C - or 109
1605
C766C
or
C778B
KEWANEE
MACHINE
SERIAL NUMBER
U (stamped on older
machines - only)
YEAR OF
SHIPMENT
TABLE 1-1. MACHINE SERIAL NUMBER DESIGNATIONS.
C778B
21,758
B215C1605U
23,508
FIGURE 1-3. NAMEPLATE / SERIAL NUMBER PLATE LOCATION.
B
2
1
5
C
1
6
0
5
U
FIGURE 1-4. SERIAL NUMBER LOCATION - NEAR HITCH ASSEMBLY.
1-4
5/01
Section 2
SPECIFICATIONS
TABLE OF CONTENTS
PAGE
GENERAL INFORMATION ................................................................................................................ 2-2.
TABLE 2-1. FRAME, HITCH AND FALLING OBJECT/ROLL OVER
PROTECTIVE STRUCTURE [FOPS/ROPS] SPECIFICATIONS .......................................... 2-2.
TABLE 2-2. ENGINE SPECIFICATIONS ........................................................................................... 2-3.
TABLE 2-3. ELECTRICAL SPECIFICATIONS .................................................................................. 2-5.
TABLE 2-4. TRANSMISSION SYSTEM SPECIFICATIONS ............................................................. 2-6.
TABLE 2-5. BRAKE SYSTEM SPECIFICATIONS ............................................................................ 2-8.
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 ............................................................ 2-13.
TABLE 2-9. CONTROL AND INDICATOR SPECIFICATIONS ....................................................... 2-14.
TABLE 2-10. OPTIONAL EQUIPMENT SPECIFICATIONS ........................................................... 2-15.
TABLE 2-11. DIMENSION SPECIFICATIONS ................................................................................ 2-16.
TABLE 2-12. PERFORMANCE SPECIFICATIONS ........................................................................ 2-18.
TABLE 2-13. MACHINE SYSTEM CAPACITY SPECIFICATIONS ................................................ 2-18.
TABLE 2-14. COMPONENT WEIGHTS .......................................................................................... 2-19.
TABLE 2-15. TORQUE SPECIFICATIONS FOR STANDARD INCH
FASTENERS ........................................................................................................................ 2-21.
TABLE 2-16. TORQUE SPECIFICATIONS FOR STANDARD METRIC
FASTENERS ........................................................................................................................ 2-22.
TABLE 2-17. LUBRICATION OILS, HYDRAULIC OILS AND COOLANT
SPECIFICATIONS ............................................................................................................... 2-23.
TABLE 2-18. ADHESIVE THREAD LOCKING SPECIFICATIONS ................................................ 2-23.
8/03
2-1
Section 2
SPECIFICATIONS
THIS section gives specification tables for each
MAJOR machine system of the Model C766C and
C778B Compactors.
Machine dimensions, weights, performance and

torque specifications are also given in THIS
section.
TABLE 2-1. FRAME, HITCH AND FALLING OBJECT/ROLL OVER [FOPS/ROPS]

PROTECTIVE STRUCTURE SPECIFICATIONS.
ITEM
DESIGN DATA
FRAME and HITCH

Material
Plate steel
Construction
Unitized, all welded 2 section, with bolt-on

front and rear weight plates
HITCH
Oscillation
+/- 12 - side to side, 24 total
Articulation
+/- 35 - right to left [Steering] turn, 70 total
FALLING OBJECT/ROLL
OVER PROTECTIVE
STRUCTURE [FOPS/ROPS]
WITH OPERATOR
RESTRAINT SYSTEM
Type and Description
2-2
Welded steel structure, bolted to machine for protective system

and two [2] seat belt sets for operator restraint, conforms to SAE
recommended practice J-1040C, J-231 and J-386;
and CSA B352 [Canada]
8/03
Section 2
SPECIFICATIONS
TABLE 2-2. ENGINE SPECIFICATIONS.
ITEM
DESIGN DATA
ENGINE
Model and
Manufacturer
4B3.9 QSB-C130 Cummins Diesel, with automatic, ether, cold start aid
Type
4 Cycle diesel, Turbocharged and charge air cooled
Number of
Cylinders
Displacement
239 in.3 [3.92 l]
Bore & Stroke
4.02 in. [102 mm] x 4.72 in. [120 mm]
Rated Brake
Horsepower
130 hp @ 2500 rpm [97 Kw at 2500 rpm]
Compression Ratio
18:1
Firing Order
1-3-4-2
Low Idle Speed
900 -1000 rpm
High Idle Speed
2500 +/-10 rpm, NO load
Engine Oil Type
See Cummins "Operation and Maintenance Manual - B series

Engine" - for correct oil type
Turbocharger
Type
Holsett
Boost Pressure
18.7 psi [1.3 bar] @ 1750 rpm
ENGINE COOLING SYSTEM

Radiator Type
Full flow, liquid pressure, W/O integral oil cooler
System Coolant Capacity
19 qts. [17.97 l]
Thermostat Range
180-190 F [82-88 C], thermostat opens
8/03
2-3
Section 2
SPECIFICATIONS
ITEM
DESIGN DATA
ENGINE FUEL
Type Used
Use ONLY distillate fuels [A.S.T.M. No.1 or No.2 fuel oil or No.1D
or No. 2D diesel fuel are EXAMPLES]. The fuel MUST have a
MINIMUM cetane number of 35. Heavier oil is generally preferable
because of its higher energy content
Fuel Capacity
50 Gallons [189 L] - C766C or 60 Gallons [227 L] - C778B
Rate of Fuel
Consumption [at
normal engine H.P.
at 40% load]
4.1 Gallons per hour

[15.5 liters per hour]*
*Operating conditions, that vary, can cause different fuel

consumption amounts than those given
FUEL FILTERS
Fuel Strainer
Suction line, replaceable spin-on element - with water drain [See

Engine Manual]
Fuel Filter
Pressure line, replaceable spin-on element [See Engine Manual]
FUEL PUMP
Type
Bosch, in line type
FUEL INJECTORS
Quantity and Type
2-4
4, close nozzle
8/03
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
105 Amps
Maximum Charge
Rate
105 Amps - 14 volts [cold]
Direction of
Rotation
Clockwise [C.W.] - viewed from

drive end
Fan Belt Tension

and Method Used to
Achieve
Automatic belt tension mechanism keeps serpentine belt

under tension at ALL times
STARTER
Manufacturer
Delco Remy [see ENGINE starter plate, for starter part number]
Voltage and Type
12 Volt, negative ground
8/03
2-5
Section 2
SPECIFICATIONS
TABLE 2-4. TRANSMISSION SYSTEM SPECIFICATIONS.
ITEM
DESIGN DATA
TRANSMISSION SYSTEM
System Type
Hydrostatic
System Oil Capacity [Also

supplies steering and
vibration systems]
22 Gallons [83.3 L]
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
0-17, maximum, either side of center
Direction of Rotation
Counterclockwise [C.C.W.]
Inlet Vacuum [at

charge pump inlet]
10 in. hg [254 mm hg], maximum
Maximum Allowable
Case Temperature
220 F [104 C]
Oil Filter Transmission

PRESSURE Oil Flow
One [1] filter with replaceable

element, transmission pump installed
[Use APPROVED replacement element ONLY see machine Parts Manual]
TRANSMISSION
HYDRAULIC DRUM DRIVE
MOTORS
Type
Radial piston, variable [2]

displacement - with spring
applied multi-disc brake
Quantity
Two [2]
2-6
8/03
Section 2
SPECIFICATIONS
ITEM
DESIGN DATA
Maximum Operating Pressure
6,200 +100 psi. [428 + 6.9 bar] Intermittent
Maximum Horsepower at Full Displacement
50 hp [37.3 kW] each
Maximum Speed at Full Displacement
35 rpm
Multi-Disc Brake
Release Pressure
175-225 psi. [12-16 bar] - plus case pressure
Maximum Braking Torque
9,000 ft. lbs. [12 204 N.m]
TRANSMISSION SYSTEM
PRESSURES
NOTE: Pressures given are with hydraulic oil at operating

temperature of 100 - 150F [38 - 66C] with the engine
speed at HIGH idle.
Neutral Charge
375-400 psi. [26-28 bar], plus case pressure,

with engine @ high idle
Stroked Charge
365 psi. [25 bar] - Minimum, above case pressure,

with engine @ high idle and transmission pump @ full stroke
System High Relief
6,200 +/- 100 psi. [428 +/- 6.9 bar], Forward, or reverse
Control [Transmission in
Forward or Reverse]
100 psi. [7 bar] - Minimum
Pump Case Pressure
40 psi. [2.7 bar], Continuous - 75 psi. [5.2 bar], Intermittent
Torque Specifications
Hydraulic Drum Drive Motor
To Motor Carrier
300 ft. lbs. [407 N.m]
TRANSMISSION PUMP
DRIVE PLATE
Type
Flexible steel, with center hub splined
Torque
Specifications
Flex Drive Plate To Engine
Flywheel
8/03
33 ft. lbs. [45 N.m]
2-7
Section 2
SPECIFICATIONS
TABLE 2-5. BRAKE SYSTEM SPECIFICATIONS.
ITEM
DESIGN DATA
BRAKE SYSTEM
Service Brake Type
Through hydrostatic transmission system
Secondary/Parking
Brake Type
Spring applied, hydraulically released, [SAHR] multi-disc brake,

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 decal, adjacent to hydraulic reservoir fill, for correct type
Type of Suction OIl Strainer
One [1] cleanable 100 mesh strainer, in hydraulic oil reservoir
STEERING HYDRAULIC
PUMP
Type
Gear, single section
Pump Output Rate

and Speed
10 gpm [38 lpm] @ 2350 rpm
Direction of
Rotation [viewed
from shaft end]
Clockwise [C.W.]
STEERING RELIEF
VALVE
Type
Integral with steering control unit
Relief Pressure
2400 +/- 50 psi. [166 +/- 3 bar], with engine @ low idle
2-8
8/03
Section 2
SPECIFICATIONS
ITEM
DESIGN DATA
STEERING CONTROL UNIT

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

integral relief
Port Sizes - Inlet/Outlet
0.75 in. [19 mm] - 16 UNF
STEERING CYLINDER
Type
Double acting
Number per
Machine
One [1]
Bore of Cylinder
3.00 in. [76 mm] - C766C

3.50 in. [89 mm] C778B
Stroke of Cylinder
12.00 +/-0.13 in. [305 +/-3 mm] - C766C & C778B
Rod Diameter
1.25 in. [32 mm] - C766C & C778B
Retracted Length
of Cylinder [between pin bore
centers]
22.25 +/- 0.13 in. [565 +/- 3 mm] - C766C & C778B
Extended Length
of Cylinder [between pin bore
centers]
34.25 +/- 0.13 in. [870 +/- 3 mm] - C766C & C778B
8/03
2-9
Section 2
SPECIFICATIONS
ITEM
DESIGN DATA
STEERING PERFORMANCE
Steering Time Stop to Stop
Right To Left
Left To Right
4.0 Seconds
4.5 Seconds
Total Number of
Wheel Turns
4.5 Revolutions - stop to stop
Inside Turning Radius
13 ft. 0 in. [3.9 m] - C766C, or 12 ft. 6 in. [3.8 m] - C778B
Outside Turning Radius
19 ft. 0 in. [5.8 m] - C766C, or 19 ft. 6 in. [5.9 m] - C778B
Total Steering
70 Total, 35
each side of center
Torque Specifications
Hydraulic Pump Mount
35 ft. lbs. [47 N.m]
Steering Cylinder
Piston Retaining Nut
200 ft. lbs. [271 N.m]
Steering Cylinder
Anchor End Mounting
Capscrews
105 ft. lbs. [143 N.m]
TABLE 2-7. DRUM, VIBRATION AND CLEANER BAR SPECIFICATIONS

ITEM
DESIGN DATA
C766C
C778B
DRUM
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
156 pli [70.8 kg lineal mm]
Drum Weight - With

Vibrator Assembly, Motor
And Isolators
3,400 lbs. [1 544 kg] - Each
3,850 lbs. [1 748 kg] - Each
Wrapper Thickness
0.70 in. [17.78 mm]
0.70 in. [17.78 mm]
2-10
151 pli [68.5 kg lineal mm]
8/03
Section 2
SPECIFICATIONS
ITEM
DESIGN DATA
VIBRATION SYSTEM
Type
Variable amplitude, one eccentric vibrator weight 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 Supply
Same as transmission and steering systems supply
Hydraulic PRESSURE Oil

Filter And Element
One [1] filter with replaceable element, rated 5 micron [nominal]

[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 Gallons [37.9 L], EACH drum
Hydraulic Pump
Piston pump, variable displacement, two [2] used
Pump Output Rate

and Speed
13.0 gpm [49.2 lpm] @ 2200 rpm
Direction of
Rotation [as viewed from
shaft end]
Clockwise [CW] - FRONT drum supply pump; Counterclockwise

[CCW] - REAR drum supply pump
Hydraulic Motor
Type and Quantity
Bent axis, axial piston, fixed displacement, two [2] used
Motor Input Rate and Pressure
13.0 gpm [49.2 lpm] @ 4400 psi. [304 bar]
Motor Maximum Speed
3400 rpm
Direction of
Rotation [viewed
from shaft end]
Bidirectional
Case Pressure - Pumps
20 - 35 psi [1.4 - 2.4 bar]
Relief Valve
Pressure Setting
and Rate Vibrator Start/Stop
4600 + 50 psi. [317 +3 bar], Maximum @ 3 gpm [11.4 lpm]

at start up. After a few minutes, drive pressure should drop to
below 3000 psi. [207 bar].
Charge Relief Valve

Pressure Setting
Neutral Charge
8/03
300 psi. [21 bar] Minimum, 400 psi. [28 bar] Maximum, plus case
pressure (Typical 350 psi. [24 bar])
2-11
Section 2
SPECIFICATIONS
ITEM
DESIGN DATA
Vibration Isolation Tires Quantity
Two [2] per machine drum, four [4] total per machine
Vibration Isolation Tires Size
G159LP 245/75R22.5
Isolator Tire Inflation

Pressure
30 psi. [2 bar] - COLD
VIBRATION
PERFORMANCE
Centrifugal Force
High Amplitude
C766C
C778B
32,950 lbs. [146.4 kN]

@ 3400 vpm
27,580 lbs. [122.6 kN]
@ 3800 vpm
37,099 lbs. [164.9 kN]

@ 3400 vpm
30,368 lbs. [135.0 kN]
@ 3800 vpm
Frequency Range
2000 - 3800 vpm
2000 - 3800 vpm
Amplitude [nominal]
High Amplitude
Low Amplitude
0.030 in. [0.762 mm]

0.020 in. [0.508 mm]
0.030 in. [0.762 mm]

0.020 in. [0.508 mm]
Low Amplitude
CLEANER BEAMS AND

CLEANER RUBBERS
Type Cleaner Beams
Full width, bolt on type
Number Cleaner Beams

Per Machine
Four [4] total, Two [2] used per drum
Number Cleaner Rubbers

Per Beam and Type
One [1] adjustable, full width
Adjustment
Against drum surface
TORQUE SPECIFICATIONS
Drum To Frame
Mounting Capscrews
431 ft. lbs. [585 N.m]
Vibration Isolation System

Assembly To Drum
157 ft. lbs. [213 N.m]
Vibration Isolation Wheel

To Drum Drive Motor
Bearing Carrier
400 ft. lbs. [542 N.m]
2-12
8/03
Section 2
SPECIFICATIONS
ITEM
DESIGN DATA
Hoop Assembly To Bearing

Housing
431 ft. lbs. [585 N.m]
Vibrator Sub-assembly To
Drum
64 ft. lbs. [87 N.m]
Half Hoop Connecting

Capscrews And Nuts
125 ft. lbs. [170 N.m]
Cleaner Beam To Frame

Mounting Capscrews
280 ft. lbs. [380 N.m]
Cleaner Rubber To Cleaner

Beam Mounting Capscrews
95 ft. lbs. [128 N.m]
TABLE 2-8. WATER SPRAY SYSTEM SPECIFICATIONS.

ITEM
DESIGN DATA
WATER SPRAY SYSTEM

Type
Pressurized system
Tank Capacity and

Quantity
125 gal. [475 l] - EACH, two [2] used, C766C or 150 gal. [568 l] - EACH, two [2] used, C778B
Pump Type and Quantity
12 Volt, diaphragm, two [2] used
Filtration
Tank Fill Ports
Strainer basket, one [1] per tank
Pump Inlet
100 Mesh screen, one [1] per pump assembly
Spray Mode Control
One [1], 12 volt, "Auto/Off/On", dash mounted, switch
Spray Duty Cycle Control
One [1], 12 volt, 0 - 50% duty cycle, dash mounted, control
Nozzle Quantity, Type and

Flow Rate - C766C
7 Per drum, threaded collar release from

spray bar mounting, 0.075 gpm [.284 lpm]
Nozzle Quantity, Type and

Flow Rate - C778B
8 Per drum, threaded collar release from

spray bar mounting, 0.075 gpm [.284 lpm]
8/03
2-13
Section 2
SPECIFICATIONS
TABLE 2-9. CONTROL AND INDICATOR SPECIFICATIONS.
ITEM
DESIGN DATA
FUNCTION
TYPE
CONTROL
Direction of
Machine Travel
[F-N-R] and
Transmission
System Speed
Left and right handle, electrical control of transmission pump output
Engine Speed [rpm]
Toggle switch, 12 volt, negative ground, electric control of engine

governor [LOW or HIGH] idle speed
Steering Control
Steering wheel, hydraulic steering control unit and system
Brake - Service
Handles [F-N-R direction and transmission system

speed control] - braking action through transmission system
Brake - Secondary/Parking
Push button switch, 12 volt, negative ground,

electrohydraulic system
Engine Start, Run and Stop
Key switch, electrical, 12 volt, negative ground
Vibration System Location

FRONT/BOTH/REAR
Toggle control switch, 12 volt, negative ground, three [3] position
Vibration Amplitude
LOW/HIGH
Toggle control switch, 12 volt, negative ground,

two [2] position
Vibration Frequency
VPM
Variable potentiometer control, 12 volt, negative ground, [one [1] for

each drum]
Vibration System Mode

OFF/AUTOMATIC/
MANUAL
Vibration System Manual

Mode START/STOP
Electrical push button thumb switch, left and right travel control
installed, 12 volt, negative ground
Transmission Drum Drive

Motors TRAVEL [high]/
WORK [low] Range
Toggle control switch, 12 volt, negative ground, electrohydraulic

system
Water Spray System

ON/OFF/AUTO

on, off, auto [timed], with automatic off, at neutral, in auto
mode
Water Spray Systems Duty

Cycle
One [1], timed delay, dash mounted, control
Horn
Button switch, 12 volt negative ground, instrument panel mounted
Panel And Operation Lights
Electrical switch, 12 volt, negative ground
2-14
8/03
Section 2
SPECIFICATIONS
ITEM
DESIGN DATA
FUNCTION
TYPE
INDICATOR/GAUGE
Engine Hours
Hourmeter, electrical, 12 volt, negative ground
Engine Lubrication Oil Pressure
Oil pressure gauge, electrical, 12 volt, negative ground
Fuel Level
Fuel gauge, electrical, 12 volt, negative ground
Engine Coolant Temperature
Coolant temperature gauge, 12 volt, negative ground
Charging System Voltage
Voltmeter, electrical, 12 volt, negative ground
Hydraulic System Oil

Temperature
Temperature gauge, electrical, 12 volt, negative ground
Vibrator Systems Pressure

Oil Filter Element Condition
Indicator
Indicator light, 12 volt, negative ground
Engine Inlet Air Restriction

Indicator
Indicator light, 12 volt, negative ground
System Function Monitor

Display Screen/Scroll Button
Display scroll button and alphanumeric display screen,

12 volt, negative ground
TABLE 2-10. OPTIONAL EQUIPMENT SPECIFICATIONS.

ITEM
DESIGN DATA
LIGHTING SYSTEM
Type, Quantity and Control
12 volt, halogen, adjustable, four [4] per machine - two [2]

front and two [2] rear, dash mounted switch controlled
TURN SIGNAL & 4-WAY

FLASHERS
Type, Control and Quantity
8/03
12 volt, steering column mounted turn signal switch, with 4-way

flasher switch - four [4] turn signal/4-way flasher light assemblies
- two [2] front and two [2] rear
2-15
Section 2
SPECIFICATIONS
TABLE 2-11. DIMENSION SPECIFICATIONS [see figure 2-1].
ITEM
DIMENSIONS
DESIGN DATA
C766C
C778B
A. Overall Height to
Top of FOPS/ROPS
105 in. [2 667 mm]
105 in. [2 667 mm]
B. Height - to Top of
Steering Wheel
78 in. [1 981 mm]
78 in. [1 981 mm]
C. Overall Width - W/FOPS/

ROPS
81 in. [2 057 mm]
92.5 in. [2 350 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]
G. Drum Diameter
48 in. [1 219 mm]
48 in. [1 219 mm]
H. Drum Width
66 in. [1 676 mm]
78 in. [1 981 mm]
2-16
8/03
Section 2
SPECIFICATIONS
G
H
C766C
F
E
FIGURE 2-1. MACHINE DIMENSIONS.
8/03
2-17
Section 2
SPECIFICATIONS
TABLE 2-12. PERFORMANCE SPECIFICATIONS.
ITEM
DESIGN DATA
TRAVEL SPEED
TRAVEL [High] Range
WORK [Low] Range
0-10 mph [0-16.1 kmph]

0-5 mph [0-8.0 kmph]
EFFECTIVE COVERAGE
Width
66 in. [1 676 mm] - C766C or 78 in. [1 981 mm] - C778B, per pass
TABLE 2-13. MACHINE SYSTEM CAPACITY SPECIFICATIONS.

ITEM
DESIGN DATA
SYSTEM CAPACITIES
Fuel
50 Gallons [189 liters] - C766C or 60 Gallons [227 liters] - C778B
Engine Lubrication Oil
10 Quarts [9.5 liters] - WITH Lubrication Oil filter
Cooling System
19 Quarts [18 liters]
Hydraulic Oil Reservoir

[Supplies All Oil To
Transmission, Steering and
Vibration Systems]
22 Gallons [83.3 liters]
Drum Bearing Lubrication

Oil
10 Gallons [37.9 liters] - each drum
Water Spray - Two [2]

Tanks Used Per Machine
125 Gallons [473 liters] each tank - C766C

150 Gallons [568 liters] each tank - C778B
2-18
8/03
Section 2
SPECIFICATIONS
TABLE 2-14. COMPONENT WEIGHTS.
NOTE: The following list of component weights is APPROXIMATE and is given as a guide ONLY for
selecting sling and lifting equipment used in machine servicing.
ITEM
DESIGN DATA
WEIGHTS
C766C
C778B
Operating Weight
W/ FOPS/ROPS
20,600 lbs. [9 352 kg]
23,500 lbs. [10 669 kg]
Shipping Weight
W/ FOPS/ROPS
19,150 lbs. [8 694 kg]
21,750 lbs. [9 875 kg]
9,150 lbs. [4 145 kg]
10,500 lbs. [4 767 kg]
10,000 lbs. [4 540 kg] With FOPS/ROPS
11,250 lbs. [5 108 kg]

With FOPS/ROPS
REAR FRAME
With Engine and Drive
Components
FRONT FRAME
With Isolators and Drum
ENGINE
Dry
With Pumps and All Items
Installed
720 lbs. [327 kg]

1,050 lbs. [477 kg]
OTHER COMPONENTS
8/03
Radiator
100 lbs. [45 kg]
Battery
49 lbs. [22 kg]
Transmission Hydraulic Pump
125 lbs. [57 kg]
Transmission Hydraulic Drum

Drive Motor [2 used]
450 lbs. [205 kg], each
Shuttle Valve
2 lbs. [1 kg]
2-19
Section 2
SPECIFICATIONS
ITEM
DESIGN DATA
OTHER COMPONENTS
Hydraulic Oil Cooler
28 lbs. [13 kg]
Hydraulic Oil Reservoir
100 lbs. [45 kg], empty
Hydraulic Pump - Steering
10 lbs. [4.5 kg]
Steering Control Unit
12 lbs. [5 kg]
Steering Cylinder
23 lbs. [10 kg]
Hydraulic Pump Vibration - Two

[2] Used
50 lbs. [23 kg]
Hydraulic Vibrator Motor

Two [2] used
13 lbs. [6 kg]
Drum and Vibrator

Assembly Complete - Two
[2] Used
C766C - 3,400 lbs. [1 544 kg], C778B - 3,850 lbs. [1 748 kg]
Isolator Half Hoop

Weldment - Eight [8] Used
100 lbs. [45 kg]
Machine Cockpit
Assembly Complete
700 lbs. [318 kg]
Falling Object/Roll Over

Protective Structure
[FOPS/ROPS]
C766C - 815 lbs. [370 kg], C778B - 872 lbs. [396 kg]
Cross Beam Plate - Front &

Rear - Two [2] Used
C766C - 700 lbs. [318 kg], C778B - 1,300 lbs. [590 kg]
2-20
8/03
Section 2
SPECIFICATIONS
TABLE 2-15. TORQUE SPECIFICATIONS FOR STANDARD INCH FASTENERS.
SAE GRADE 8 CAPSCREWS
NOM.
SIZE
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1-1/8
1-1/4
1-3/8
1-1/2
TORQUE
(FT. LBS.)
THREAD
SERIES
TORQUE
(Nm)
DRY
LUBED
DRY
LUBED
20 UNC
28 UNF
18 UNC
24 UNF
12
14
25
27
10
18
20
16
19
33
37
12
14
25
28
16 UNC
24 UNF
14 UNC
20 UNF
44
49
70
78
33
37
52
58
59
67
95
105
44
50
71
79
13 UNC
20 UNF
12 UNC
18 UNF
105
120
155
170
80
90
115
130
145
165
210
230
110
120
155
175
11 UNC
18 UNF
10 UNC
16 UNF
210
240
375
420
160
180
280
315
285
325
510
570
215
245
380
425
9 UNC
14 UNF
8 UNC
14NF
605
670
910
1 020
455
500
680
765
820
905
1 230
1 380
615
680
925
1 040
7 UNC
12 UNF
7 UNC
12 UNF
1 290
1 440
1 820
2 010
965
1 080
1 360
1 500
1 750
1 960
2 460
2 730
1 310
1 470
1 850
2 050
6 UNC
12 UNF
6 UNC
12 UNF
2 380
2 710
3 160
3 560
1 780
2 040
2 370
2 670
3 230
3 680
4 290
4 820
2 420
2 760
3 210
3 620
WARNING: THESE TABLES LIST TORQUE VALUES FOR STANDARD FASTENERS AND ARE
INTENDED AS A GUIDE FOR AVERAGE APPLICATION INVOLVING TYPICAL
STRESSES AND MACHINED SURFACES. VALUES ARE BASED ON THE
PHYSICAL LIMITATIONS OF CLEAN, PLATED AND LUBRICATED FASTENERS.
IN ALL CASES, WHEN AN INDIVIDUAL TORQUE IS SPECIFIED, IT SHOULD BE
FOLLOWED INSTEAD OF VALUES GIVEN IN THIS TABLE. REPLACE ORIGINAL
EQUIPMENT WITH FASTENERS OF EQUAL GRADE.
GRADE 5
GRADE 8
PLACEBOLT
SOCKET HEAD
CAPSCREW
12 POINT
CAPSCREW
FIGURE 2-2. STANDARD HARDWARE.

8/03
2-21
Section 2
SPECIFICATIONS
TABLE 2-16. TORQUE SPECIFICATIONS FOR STANDARD METRIC FASTENERS.
NOMINAL
SIZE &
PITCH
M3 x 0.5
M3.5 x 0.6
M4 x 0.7
M5 x 0.8
M6 x 1
M8 x 1.25
M8 x 1
M10 x 1.5
M10 x 1.25
M12 x 1.75
M12 x 1.25
M14 x 2
M14 x 1.5
M16 x 2
M16 x 1.5
M20 x 2.5
M20 x 1.5
M24 x 3
M24x2
M27 x 3
M27 x 2
M30 x 3.5
M30 x 3
M30 x 2
M33 x 3.5
M33 x 2
M36 x 4
M36 x 3
M39x4
M39x3
M42 x4.5
M42x3
M45 x4.5
M45x3
M48x5
M48x3
CLASS 8.8 [GRADE 5 EQUIVALENT]

TORQUE FT. LBS
TORQUE - N-m
CLASS 10.9 [GRADE 8 EQUIVALENT]

TORQUE FT. LBS
TORQUE - N-m
DRY
LUBED
DRY
LUBED
DRY
LUBED
DRY
LUBED
0.97
1.61
2.27
4.58
7.75
18.89
20.22
40.04
39.11
64.94
70.85
103.32
114.39
162.36
173.43
317.34
360.55
516.12
594.09
797.04
863.46
1 084.86
1 121.76
1 202.94
1 476.00
1 623.60
1 896.66
2 007.36
2 450.16
2 583.00
3 033.18
3 261.96
3 785.94
4 051.62
4 553.46
4 959.36
0.73
1.21
1.70
3.43
5.83
14.17
15.13
28.04
29.52
48.71
53.14
77.49
84.87
121.77
129.15
236.16
281.99
409.59
445.49
597.78
645.75
811.80
841.32
900.36
1 107.00
1 623.60
1 424.34
1 505.52
1 837.62
1 940.94
2 273.04
2 450.16
2 841.30
3 040.56
3 416.94
3 719.52
1.32
2.07
3.07
6.20
10.5
25.6
27.4
51.0
53.0
88.0
96.0
140.0
155.0
220.0
235.0
430.0
475.0
740.0
805.0
1 080.0
1 170.0
1 470.0
1 520.0
1 530.0
2 000.0
2 200.0
2 570.0
2 720.0
3 320.0
3 500.0
4 110.0
4 420.0
5 130.0
5 490.0
6 170.0
6 720.0
0.99
1.55
2.30
4.65
7.90
19.2
20.5
38.0
40.1
66.0
72.0
105.0
115.0
165.0
175.0
320.0
355.0
555.0
605.0
810.0
875.0
1 100.0
1 140.0
1 220.0
1 500.0
1 640.0
1 930.0
2 040.0
2 490.0
2 630.0
3 080.0
3 320.0
3 850.0
4 120.0
4 630.0
5 040.0
1.32
2.08
2.27
6.22
10.60
18.95
27.53
50.92
53.87
88.56
70.81
140.22
154.98
221.40
236.16
428.04
479.70
754.38
811.80
1 084.86
1 173.42
1 476.00
1 527.66
1 630.98
2 007.36
2 199.24
2 575.62
2 730.60
3 335.76
3 512.88
3 044.56
4 442.74
5 084.82
5 512.86
6 199.20
6 752.70
0.99
1.56
2.31
4.67
7.97
19.26
20.59
38.38
40.59
66.42
72.32
107.01
114.39
166.05
177.12
321.03
357.93
557.19
605.16
811.80
878.22
1 107.00
1 143.90
1 225.08
1 505.52
1 653.12
1 933.56
2 051.64
2 501.82
2 634.66
3 099.60
3 328.38
3 867.12
4 140.18
4 649.40
5 062.68
1.79
2.82
4.17
8.43
14.3
34.8
37.3
69.0
73.0
120.0
130.0
190.0
210.0
300.0
320.0
580.0
650.0
1 010.0
1 100.0
1 470.0
1 590.0
2 000.0
2 070.0
2 210.0
2 720.0
2 980.0
3 490.0
3 700.0
4 520.0
4 760.0
5 590.0
6 020.0
6 980.0
7 470.0
8 400.0
9 150.0
1.34
2.11
3.13
6.33
10.8
26.1
27.9
52.0
55.0
90.0
98.0
145.0
155.0
225.0
240.0
435.0
485.0
755.0
820.0
1 100.0
1 190.0
1 500.0
1 550.0
1 660.0
2 040.0
2 240.0
2 620.0
2 780.0
3 390.0
3 570.0
4 200.0
4 510.0
5 240.0
5 610.0
6 300.0
6 860.0
WARNING: THESE TABLES LIST TORQUE VALUES FOR STANDARD FASTENERS AND ARE
INTENDED AS A GUIDE FOR AVERAGE APPLICATION INVOLVING TYPICAL
STRESSES AND MACHINED SURFACES. VALUES ARE BASED ON THE
PHYSICAL LIMITATIONS OF CLEAN, PLATED AND LUBRICATED FASTENERS.
IN ALL CASES, WHEN AN INDIVIDUAL TORQUE IS SPECIFIED, IT SHOULD BE
FOLLOWED INSTEAD OF VALUES GIVEN IN THIS TABLE. REPLACE ORIGINAL
EQUIPMENT WITH FASTENERS OF EQUAL GRADE.
2-22
8/03
Section 2
SPECIFICATIONS
TABLE 2-17. LUBRICATION OILS, HYDRAULIC OILS AND COOLANT SPECIFICATIONS.
P/N
DESCRIPTION
SIZE
336830
HYDRAULIC/TRANSMISSION OIL
1 QT
336831
2 GAL
336832
5 GAL
336833
55 GAL
3002338
Antifreeze
1 GAL
326457
MULTIPURPOSE GREASE
5 LB
TABLE 2-18. ADHESIVE THREAD LOCKING SPECIFICATIONS.

P/N
DESCRIPTION
SIZE
360387
222 Small Screw Threadlock [Purple]
50 ML
318702*
242 Removable Threadlock [Blue]
10 ML
226414*
271 High Strength Threadlock [Red]
10 ML
318996
277 High Viscosity Threadlock [Red]
50 ML
318650
290 Low Viscosity Threadlock [Green]
.02 OZ
251099
290 Low Viscosity Threadlock [Green]
50 ML
355844**
422 Super Bonder Adhesive
3 ML
264159
515 Gasket Eliminator
6 ML
313022*
515 Gasket Eliminator [Purple]
50 ML
273338*
567 Pipe Sealant W/Teflon [White]
50 ML
318705
595 Super Flex Silicone
100 ML
318701*
609 Retaining Compound
10 ML
341959
680 Retaining Compound
50 ML
226415
Primer T - Aerosol
6 OZ
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]
8/03
2-23
Section 2
SPECIFICATIONS
NOTES
2-24
8/03
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 ........................................................................................ 3-14.
OPERATION OF THE SECONDARY/PARKING BRAKE SYSTEM ............................................ 3-14.
OPERATION OF THE STEERING SYSTEM ................................................................................ 3-14.
OPERATION OF THE TRANSMISSION SYSTEM ....................................................................... 3-14.
CURRENT MACHINE SYSTEMS PARAMETERS ....................................................................... 3-14
NORMAL [RUN] SCREENS .......................................................................................................... 3-18.
FAULT MESSAGE SCREENS ...................................................................................................... 3-18.
GAUGES AND INSTRUMENTS OPERATION ............................................................................. 3-19.
OPERATING PRECAUTIONS .......................................................................................................... 3-19.
OPERATING THE MACHINE ........................................................................................................... 3-20.
LIMITED OPERATION MODE ....................................................................................................... 3-23.
DYNAMIC BRAKING OF THE MACHINE ..................................................................................... 3-26.
STOPPING THE ENGINE .............................................................................................................. 3-26.
RELEASING THE TOWING BYPASS VALVES AND SECONDARY/PARKING
BRAKE SYSTEM AND TOWING A COMPLETELY DISABLED MACHINE .................................... 3-26.
TRANSPORTING THE MACHINE ........................................................................................................ 3-29.
7/00
3-1
Section 3
OPERATION
THIS section gives the OPERATION INSTRUCTIONS for the Model C766C and C778B
Compactors.
Read, understand and follow ALL Precaution and
Operating Instructions given on the machine
OPERATING INSTRUCTION and WARNING
decals and written in THIS manual, BEFORE
starting, or operating, the machine [see figure
3-1].
DANGER: FAILURE to observe the

OPERATING PRECAUTIONS and/
or the machine OPERATION and
WARNING INSTRUCTIONS, given in
THIS manual and found on the
DECALS affixed to the machine
can cause SERIOUS INJURY, or
DEATH.
ONLY authorized personnel, who
operation, can operate the Model
C766C or C778B Compactor.
OPERATING CONTROLS, INDICATORS AND

GAUGES.
Operating controls, indicators and gauges, for the
Model C766C and C778B Compactors, are shown
on Figure 3-2 and are listed in Table 3-1.
DANGER: Do NOT start, or operate, the

Model C766C or C778B Compactor
BEFORE reading, understanding
and following ALL information given
in THIS section and shown on the
machine Operating Instruction
and Warning decal, found on
the engine hood, ahead of the
steering wheel.
The operator MUST read about,
and understand, the function of
ALL controls, indicators and
gauges BEFORE starting the
engine.
SERIOUS INJURY, or DEATH, can
result if THESE procedures are
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
wheel 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
7/00
Section 3
OPERATION
FIGURE 3-1. MODEL C766C AND C778B COMPACTOR OPERATING INSTRUCTION DECAL.
7/00
3-3
Section 3
OPERATION
14
9
15
16
18
17 13
8 11
26 26
25 22
10 3
23
24 10
7 21 6
20 19 2
12
12
1
1
MAN.
VIBRATOR MODE
LOW
WATER SAVER
BOTH
REAR
FRONT
LIGHTS
ENGINE THROTTLE
SPEED RANGE
AUTO
DRUM SELECT
HIGH
FIILTERS
HIGH
OFF
AUTO
FRONT VIM. SPEED
MAN.
OFF
WATER
SPRAY
LOW
AMPLITUDE
REAR VIB. SPEED
SCROLL
FIGURE 3-2. MACHINE OPERATING CONTROLS AND INDICATORS.
3-4
7/00
Section 3
OPERATION
TABLE 3-1. MACHINE OPERATING CONTROLS, INDICATORS AND GAUGES.
ITEM NO.
[SEE FIG
3-2]
1
DESCRIPTION
DIRECTIONAL/
SPEED CONTROL
[F-N-R]
TYPE
Control handle Left and Right

Dash Mounted
FUNCTION
Controls forward/reverse
movement and speed of machine in the
direction selected
Handle in CENTER position
- transmission in NEUTRAL.
Handle in FORWARD position
- transmission in FORWARD.
Handle in BACKWARD position
- transmission in REVERSE.
FULL travel distance of either
handle [forward or reverse]
gives HIGHEST speed of travel.
The control handle is, also, used to set the
speed restrict function and adjust other
function parameters [see this Section].
IGNITION
SYSTEM
Three [3]
Position Key Operated Interlock
Switch
Controls STARTING, RUNNING

STOPPING of engine.
NO.1 POSITION: OFF condition.
Removes ALL electrical current
from circuits, EXCEPT horn and
lighting circuits.
NO.2 POSITION: ON condition.
Applies electrical current to
ALL circuits. This position ALSO
is a lock out position and
prevents accidental engagement
of the starter motor when the
engine is in a running
condition. The ignition key 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
switch to the NO.2, ON/RUN,
position when the key is released.
7/00
3-5
Section 3
OPERATION
ITEM NO.
[SEE FIG
3-2]
3
DESCRIPTION
ENGINE
THROTTLE
SPEED
TYPE
Toggle Switch Two [2] Position
FUNCTION
Controls engine throttle speed [RPM].

Toggle switch DOWN,
puts engine throttle at LOW idle speed.
Toggle switch UP, puts engine throttle
at HIGH/WORK idle speed.
STEERING
SYSTEM
Manually
Operated
Wheel
Provides machine DIRECTION

control. TURN steering wheel
IN the direction the machine is
desired to travel.
SECONDARY/
PARKING
BRAKE SYSTEM
Button Switch Two [2] Position
Controls secondary/parking brake

system application and release.
Button switch pushed IN,
APPLIES the brake system.
Button switch turned right and OUT,
RELEASES the brake system.
WATER SPRAY
SYSTEMS - MODE
[AUTO/OFF/MANUAL]
Toggle Switch Three [3] Position

AUTO
MAN.
OFF
WATER
SPRAY
Controls water spray systems operation.

Switch at MANUAL, turns front
and rear drum systems ON, continuously.
Switch at AUTO, allows controller system
to:
Automatically turn front and rear drum
systems ON, as the machine begins to, and
continues moving. Controller system
cycle control switch [ITEM 24] varies
systems duty cycle 0-50 %, with a ten
[10] second spray period.
Automatically turn front and rear drum
systems OFF, when machine is in
neutral and is NOT moving.
Switch at OFF, turns front and
rear drum systems OFF.
3-6
7/00
Section 3
OPERATION
ITEM NO.
[SEE FIG
3-2]
7
DESCRIPTION
TRANSMISSION RANGE
- WORK [Low]
TRAVEL [High]
TYPE
FUNCTION
Selects range of transmission drum

drive motors.
Switch DOWN , puts system in WORK
[low] range.
Switch UP, puts system in TRAVEL
[high] range.
DRUM VIBRATOR MODE Toggle Switch AUTOMATIC/OFF/

Three [3] Position
MANUAL
MODE selection of drums vibration system.

CENTER position turns system OFF.
OFF
AUTO
MANUAL
VIBRATOR MODE
LEFT position puts system in

AUTOMATIC MODE.
RIGHT position puts system in
MANUAL MODE.
NOTE: Engine throttle speed switch

[ITEM 3] must be in HIGH speed
position and the transmission
system range switch [ITEM 7]
must be in WORK [low] range
position, to operate either, or both
drum vibration systems.
If in the MANUAL mode, either
VIBRATION START/STOP push
button thumb switch [ITEM 12]
must also be pushed to operate
either, or both drum vibration
systems.
9
DRUM VIBRATION
SYSTEM[S] LOCATION
[Front/Both/ Rear]
Toggle Switch Three [3] Position

BOTH
FRONT
REAR
Selects drum vibration system[s] location

FRONT, BOTH or REAR.
Switch LEFT , selects FRONT drum
vibration system, ONLY.
DRUM SELECT
Switch CENTER, selects BOTH front AND

rear drum vibration systems.
Switch RIGHT, selects REAR drum
vibration system, ONLY.
7/00
3-7
Section 3
OPERATION
ITEM NO.
[SEE FIG
3-2]
DESCRIPTION
TYPE
FUNCTION
10
VIBRATION SYSTEM
FREQUENCY
Potentiometer
Control One [1] Control
For FRONT Drum
and One [1]
Control For REAR
Drum
FRONT VIB. SPEED
REAR VIB. SPEED
FREQUENCY control [2000 - 3400 VPM C766C, 2000 - 3800 VPM C766C - HO or
2000 - 3200 VPM - C778B], for EACH drum.
Select desired FREQUENCY for EACH drum.
Either, or both, control[s] turned to the LEFT
selects LOWEST VPM FREQUENCY the low,
or high, amplitude mode selected by the
mode switch [ITEM 11].
Either, or both, control[s] turned to the RIGHT
selects HIGHEST VPM FREQUENCY for the
low, or high, amplitude mode selected by the
mode switch [ITEM 11].

11
VIBRATION SYSTEM
HIGH/LOW AMPLITUDE
MODE

HIGH
LOW
AMPLITUDE
Selects AMPLITUDE mode of BOTH front

and rear drums vibration system.
Switch LEFT , puts BOTH front and rear
drums vibration system in HIGH
amplitude mode.
Switch RIGHT, puts BOTH front and rear
drums vibration system in LOW
amplitude mode.

3-8
7/00
Section 3
OPERATION
ITEM NO.
[SEE FIG
3-2]
12
DESCRIPTION
MANUAL DRUM
VIBRATOR
START/STOP
TYPE
Electrical Push
Button Thumb
Switches - Left
and Right Travel
Control Handle
Installed
FUNCTION
MANUAL START/STOP control of front,

rear or both drums vibration system[s].
DEPRESS switch once and release to
START/RUN system[s] vibration.
DEPRESS switch, again, and release to
STOP system[s] vibration.

13
ENGINE
HOURS
OPERATED
Hourmeter
Indicates TOTAL hours

engine has operated. Operates
when ignition key switch is in the
ON/RUN position and the engine
is running.
14
FUEL AMOUNT
IN TANK
Fuel Level
Gauge
Indicates amount of fuel

contained in fuel tank.
Operates when ignition key
switch is in the ON/RUN position.
15
ENGINE OIL
PRESSURE
Oil
Pressure
Gauge
Indicates the pressure of engine

lubrication oil. Operates when the
engine is started and running.
Can indicate a high pressure
[LARGE SYMBOL] when engine is
first started. Pressure indicated will lower to
NORMAL [MIDDLE SIZED SYMBOL] as
engine warms.
CAUTION: STOP the engine

IMMEDIATELY if there is
LOW, or NO, oil pressure
indicated on the oil pressure
gauge.
7/00
3-9
Section 3
OPERATION
ITEM NO.
[SEE FIG
3-2]
DESCRIPTION
TYPE
FUNCTION
16
ELECTRICAL
SYSTEM
VOLTAGE
Voltmeter
Indicates alternator output

voltage or battery voltage,
which ever is highest.
Can be in RED [DISCHARGE]
zone on gauge at LOW engine
idle, BUT will move to GREEN
[CHARGE] zone on gauge when
engine speed is increased.
17
ENGINE
COOLANT
TEMPERATURE
Coolant
Temperature
Gauge
Indicates temperature of
engine coolant circulating
through engine.
Gauge pointer will be in GREEN
zone during NORMAL operation.

IMMEDIATELY IF the
gauge pointer needle
moves to the RED zone
of the gauge.
18
HYDRAULIC
SYSTEM OIL
TEMPERATURE
Hydraulic
Oil
Temperature
Gauge
Indicates temperature of
oil flowing through
transmission, steering and
vibration systems.
Gauge pointer will be in GREEN
zone during NORMAL system
operating conditions.

IMMEDIATELY IF the
gauge pointer
moves to the RED zone
of the gauge.
19
3-10
ENGINE INLET
AIR CONDITION
Electrical
Light, Red
Lens
Covered
Indicates RED lighted

condition ONLY when engine inlet
air flow is restricted. When
lighted, IMMEDIATE service of air cleaner
assembly is required BEFORE further
machine operation.
7/00
Section 3
OPERATION
ITEM NO.
[SEE FIG
3-2]
DESCRIPTION
TYPE
FUNCTION
20
VIBRATION SYSTEMS
PRESSURE OIL
FILTER ELEMENT
CONDITION
Electrical
Light, Red
Lens Covered
Indicates RED lighted

condition when vibration systems
PRESSURE oil filter
element has reached maximum
holding capacity and MUST be changed.*
21
HORN
ACTUATION
Push Button,
Switch - Dash
Mounted
Provides actuation of the horn.

When the horn button is pushed,
the horn will sound.
22
VANDAL GUARD
Lockable
Cover
Install over dash instrument

and control panel to help stop
possible damage and/or
unauthorized use. Secure in
place with padlock. Remove lock
and move cover away for start
and operation of the machine.
23
LIGHT SYSTEM
Push-pull
Switch
Turns light dash and headlight systems

on and off.
Pull switch out to 1st detent to turn dash
lighting system ON.
Pull switch out to 2nd detent to turn dash
and headlight lighting systems ON.
24
WATER SPRAY
SYSTEMS- DUTY
CYCLE
Duty Cycle
Control Switch
WATER SAVER
25
SPEEDOMETER
Digital Display
Screen
One [1] dial switch controls water flow duty

cycle for BOTH drums. Set switch to desired
0-50% duty cycle.
NOTE: Water spray system MODE

selector switch [ITEM 6] MUST be
in AUTO position for duty
cycle to function.
Indicates travel speed of machine during
operation. Will indicate when machine is
moving in forward, or reverse, direction.
*CAUTION: Hydraulic system MUST be at NORMAL OPERATING temperature

for CORRECT system light indications. Indicator light CAN
be in an ON condition when the hydraulic oil is at a
temperature LOWER than the NORMAL OPERATING temperature.
7/00
3-11
Section 3
OPERATION
ITEM NO.
[SEE FIG
3-2]
26
DESCRIPTION
SYSTEM FUNCTION
MONITOR DISPLAY
SCREEN
TYPE
Electrical Display
Scroll Button and
Alphanumeric
Display Screen
FUNCTION
Scroll button provides access to machine

system functions, for verification and/or
changes, through alphanumeric
display screen.
Monitored and displayed operator
parameter and information screens are:
SCROLL
1. Normal Screens - Part of the RUN group

of screens. Default normal display
screen will display machine speed,
front and rear vibrator speeds, vibration
impacts per foot [see THIS section].
2. Parameter Adjustment Screens - display
screen will display machine maximum
travel speed, auto vibrator "on/off" point
and English/metric units, alphanumeric
format screens [see THIS section].
3. Fault Message Screens - display screen
will display a message if a system fault
condition exists and can be detected
[see THIS section].
WARNING: The "TRAVEL" [high] range is for "machine transport" ONLY.

Use the "WORK" [low] range for vibratory applications, on the work surface, and for
machine movement near personnel, objects and within confined areas.
3-12
7/00
Section 3
OPERATION
OPERATION
CHECKS WITH THE ENGINE STOPPED.
With the engine in a STOPPED condition, INSPECT
the machine BEFORE use and AFTER every
EIGHT [8] hours of operation, or DAILY, as directed
in Section 4 - MAINTENANCE - in THIS manual.
CHECK, or INSPECT, the following items:
Fuel level.
Engine lubrication oil level.
Engine cooling system coolant level.
Condition of drive belt on engine.
Hydraulic system oil level.
Drum bearing lubrication oil level, in BOTH drums.
Engine inlet air path.
Fluid leaks from engine, fuel or hydraulic system.
Operation of the horn.
Safety decals, securely affixed to machine and their
condition.
Seat belts [BOTH sets] condition and operation.
FOPS/ROPS overall condition, condition of structure welds and correct tightened torque of all
structure mounting capscrews.
STARTING THE ENGINE [See Figure 3-2 and

Table 3-1].
a. If installed, unlock and then move the vandal
guard [ITEM 22] away from the instrument panel.
Put the guard in the stowed position. KEEP the
secondary/parking brake system in the ON
[APPLIED] condition by leaving the system control
switch [ITEM 5] in the ON [APPLIED] position.
DANGER: The machine MUST NOT move, at

ANY time, when the
secondary/parking brake switch
is in the ON [APPLIED] position.
Do NOT operate the machine, if
the machine will move when the
SECONDARY/PARKING brake system
is in an ON [APPLIED]
condition, UNTIL the fault is
CORRECTED.
7/00
b. Keep the transmission in NEUTRAL, by

positioning the directional/speed control [F-N-R]
handle [ITEM 1] in the CENTER [NEUTRAL]
position. Put the drum vibrator MODE switch [ITEM
8] in the OFF position.
NOTE: The transmission MUST be in

NEUTRAL and the secondary/parking
brake MUST be APPLIED, for the engine
to be started.
c. Keep the engine THROTTLE speed control

switch [ITEM 3] at the LOW IDLE speed position.
CAUTION: Do NOT put the engine throttle

speed control switch at the
HIGH idle position. Engine
damage can occur.
d. Turn the ignition switch key [ITEM 2] to the

START [THIRD] position. Crank and start the
engine.
WARNING: CALIFORNIA Proposition 65

Warning: Diesel engine exhaust and
some of its constituents are known
to the state of California to cause
cancer, birth defects, and other
reproductive harm.
CAUTION: Make a note of the amount of

continuous cranking time.
Do NOT crank the engine MORE
than thirty [30] seconds
CONTINUOUSLY. IF the engine is
NOT started within this time,
put the ignition switch key in
the OFF [FIRST] position. Wait
one [1] minute. This will allow
the starter motor time to cool.
Repeat step d UNTIL the engine
is started.
Do NOT increase the engine throttle
speed, above the LOW idle
speed, until the vibration systems
pressure oil filter element condition
indicator light [ITEM 20] is OFF.
3-13
Section 3
OPERATION
NOTE: The machine is equipped with an
automatic ether cold start aid. At engine
"cold start", the system will introduce
ether into the fuel intake system to
assist in engine starting. If the engine
fails to start, during a engine "cold start"
[40F, or below] attempt, check and if
needed, replace the ether supply canister
with a "full" replacement canister.
During engine start up, when the ignition
key switch is placed in the "on"
[number 2] position, the system function
monitor display screen [ITEM 26] will
display the machine model number and
then return to the "default screen"
display showing machine speed, front
and rear vibrator speeds [vpm] and
impacts per foot, thereafter.
CHECKS WITH THE ENGINE RUNNING.

With the engine running, CHECK, or INSPECT,
the machine BEFORE operation, using the FOLLOWING information. Also, do these checks and/or
inspections AFTER every eight [8] hours of operation, or DAILY, as directed in Section 4 - MAINTENANCE - in this manual. CHECK, or INSPECT, the
following items.
OPERATION OF THE STEERING SYSTEM.
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.
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 drums of the machine
are on a SOFT surface, such as
loose dirt or old tires.
Damage to the drums and/or
machine can occur if the operation of
the drum vibration systems is
checked on a HARD surface.
CURRENT MACHINE SYSTEMS PARAMETERS.

OPERATION OF THE SECONDARY/PARKING
BRAKE SYSTEM.
With the secondary/parking brake system control
switch [ITEM 5] in the ON [APPLIED] position,
note that the machine remains stopped and held
when the directional/speed control handle [F-N-R] is
moved to the forward, or reverse, direction.
DANGER: Do NOT operate the machine, if

the machine moves when the
secondary/parking brake system
is in an ON [APPLIED]
condition, UNTIL the fault
is corrected. The machine MUST
NOT move, at ANY time, when the
control switch [ITEM 5] is in the ON
[APPLIED] position.
3-14
Review currently selected preset parameters for:

1. Maximum WORK [low] transmission range
speed [see figure A].
2. Automatic vibration mode vibrator start/stop
speed point [see figure B].
3. English, or metric units format, system monitor
display screen [see figure C].
NOTE: Review the above three [3] parameters,

and change the settings as desired, with
the directional/speed control handles in
the NEUTRAL position and the
APPLIED.
Use the following instructions to access
each system function, on the monitor
display screen, review the system
information shown on each screen and/
or change each system's parameters.
7/00
Section 3
OPERATION
DANGER: Keep the secondary/parking brake
system APPLIED and keep ALL
personnel CLEAR of the machine
when reviewing ANY, or ALL,
currently selected preset parameters
and/or making parameter changes.
Use the following information to access the

maximum work [low] range speed parameter
screen.
1. With the machine in NEUTRAL, use the display
scroll button [ITEM 26], found below the display
screen [ITEM 26], to scroll through each system
information screen until the maximum work [low]
range speed screen is reached.
2. Review the maximum work [low] range speed
parameter displayed on the screen.
NOTE: The monitor screen will display the

above system information in either
English [mph], or metric units [kph],
dependent on which read out method
has been selected.
3. If the maximum work [low] range speed shown

is as desired, use the display scroll button to scroll
to the next screen, or return to the normal screen
[see Figure D], displayed during machine operation.
NOTE: If the maximum work [low] range speed

shown is NOT as desired, use the
following additional information to
change the speed.
a. Leave the maximum work [low] range speed

displayed on the display screen.
b. Keep the secondary/ parking brake APPLIED.
If the maximum work [low] range is desired to be
INCREASED, move either directional/speed control
handle [F-N-R] [ITEM 1] from the neutral position,
toward the FORWARD travel position, a small
amount.
7/00
NOTE: If the maximum work [low] range speed

is desired to be DECREASED, move
either directional/speed control handle
[ITEM 1] from the neutral position,
toward the REVERSE travel position, a
small amount.
c. Push the manual drum vibrator "start/stop"

button thumb switch [ITEM 12], found on the
directional/speed control handle [F-N-R], ONE [1]
time for each one tenth [1/10] miles per hour [mph]
the maximum work [low] range speed is desired to
be INCREASED, or DECREASED. Note that the
speed displayed on the display screen INCREASES, or DECREASES.
NOTE: The maximum work [low] range speed

adjustment is in increments of one
tenth [1/10 miles per hour [mph] even IF
the display screen is reading in metric
units format.
The range of adjustment is from a
MINIMUM of one half [1/2] miles
per hour [mph] to a MAXIMUM of five [5]
miles per hour [mph].
d. When the maximum work [low] range speed

has been INCREASED, or DECREASED, to the
desired speed, move either directional/speed control
handle [ITEM 1] back to the NEUTRAL position.
e. After completing the adjustment procedure,
use the display scroll button to scroll to the next
screen or return to the normal screen [see Figure
D], displayed during machine operation.
NOTE: At any time during machine operation on

the work surface, if the maximum
work [low] range speed requires
adjustment, use the above information to
change the speed, again.
3-15
Section 3
OPERATION
machine automatic vibration mode vibrator
start/stop speed point screen.
1. With the machine in NEUTRAL, use the scroll
button [ITEM 26], found below the display screen
[ITEM 26], to scroll through each system information
screen until the machine automatic vibration mode
vibrator start/stop speed point screen is reached.
c. Push the manual drum vibrator "start/stop"

button thumb switch [ITEM 12], found on the
directional/speed control handle, ONE [1] time for
each one tenth [1/10] miles per hour [mph] the
vibrator start/stop speed point is desired to be
INCREASED, or DECREASED. Note that the speed
displayed on the display screen INCREASES, or
DECREASES.
NOTE: The monitor screen will display the

above system information in either
English [mph], or metric units [kph],
dependent on which read out method
has been selected.
NOTE: The maximum vibrator start/stop

speed point adjustment is in increments
of one tenth [1/10 miles per hour [mph]
even IF the display screen is reading in
metric units format.
The range of adjustment is from a
MINIMUM of one half [1/2] miles
per hour [mph] to a MAXIMUM four [4]
miles per hour [mph].
3. If the vibrator start/stop speed point shown is

as desired, use the display scroll button to scroll to
the next screen or return to the normal screen [see
Figure D], displayed during machine operation.
d. When the vibrator start/stop speed point has

been INCREASED, or DECREASED, to the desired
speed, move either directional/speed control handle
[ITEM 1] back to the NEUTRAL position.
2. Review the machine vibrator start/stop speed

point parameter displayed on the screen.
NOTE: If the vibrator start/stop speed point

shown is NOT as desired use the
following additional information to
change the start/stop speed point.
a. Leave the vibrator start/stop speed point

If the vibrator start/stop speed point is desired to
be INCREASED, move either directional/speed
control handle [ITEM 1] from the neutral position,
toward the FORWARD travel position, a small
amount.
e. After completing the adjustment procedure,

use the display scroll button to scroll to the next
screen or return to the normal screen [see Figure
D], displayed during machine operation.
NOTE: At any time during machine operation on

the work surface, if the vibrator start/
stop speed point requires adjustment,
use the above information to change the
start/stop speed point, again.
NOTE: If the vibrator start/stop speed point

shown is desired to be DECREASED,
move either directional/speed control
handle [ITEM 1] from the neutral position,
toward the REVERSE travel position, a
small amount.
3-16
7/00
Section 3
OPERATION
Speed Limit:
4.3 mph
ADJ. WITH MANUAL VIB. SW
FIGURE A. MAXIMUM MACHINE TRAVEL SPEED

- DISPLAY SCREEN.
4.3 mph : FRNT 3200 vpm

10 ipf : REAR
0 vpm
FIGURE D. NORMAL "RUN" - CURRENT

MACHINE TRAVEL SPEED, FRONT & REAR
DRUM VIBRATIONS PER MINUTE AND
IMPACTS PER FOOT DISPLAY SCREEN.
AUTO VIB. SET.= 0.8 mph

ADJ. WITH CONTROL HANDLE
3 mph
: FRNT 3200 vpm
FAULT: FNR Neutral SW.
FIGURE B. VIBRATOR START/STOP SPEED

POINT - DISPLAY SCREEN.
FIGURE F. FAULT MESSAGE DISPLAY SCREEN, EXAMPLE.
DISPLAY UNITS:
ENGLISH
ADJ. WITH MANUAL VIB. SW
FIGURE C. ENGLISH/ METRIC UNITS FORMAT

- DISPLAY SCREEN.
378 fpm : FRNT 3200 vpm

10 ipf : REAR
0 vpm
FAULT: Sprayer Valve - Water

Sprayer Valve Open or Short
FIGURE G. FAULT MESSAGE DISPLAY SCREEN, SPRAYER VALVE OPEN,

OR SHORTED.
LIMD OP: MODE - FNR FWD

FAULT: 5V SENSOR POWER
FIGURE E. FEET PER MINUTE TRAVEL IMPACTS PER FOOT - DISPLAY SCREEN.
FIGURE H. FAULT MESSAGE "STOP" FAULT DETECTED - MACHINE
TRAVEL FAULTED TO LIMITED OPERATION
MODE [Version 2.33 software].
7/00
3-17
Section 3
OPERATION
machine English/metric units format display
screen.
1. With the machine in NEUTRAL, use the display
scroll button [ITEM 26], found below the display
screen [ITEM 26], to scroll through each system
information screen until the English/metric units
screen is reached.
2. Review the English, or metric units, format
displayed on the screen.
NOTE: The display screen will show system

information in either English, or metric
units, format dependent on which format
method has been selected.
3. If the display screen format is as desired, use

the display scroll button to scroll to the next screen
or return to the normal screen [see Figure D],
displayed during machine operation.
NOTE: If the display screen format is NOT as

desired, use the following additional
information to change the screen format.
NORMAL [RUN] SCREENS

[See Figures D and E].
With the machine in neutral, or in operation, use the
display scroll button [ITEM 26], found below the
display screen [ITEM 26], to scroll through each
system information screen until the machine normal
[run] screen [figure D] is reached.
Review the English, or metric units, information
displayed on the screen, indicating current machine
travel speed [mph], front and rear vibrator speeds
[vpm] and impacts per foot [ipf].
NOTE: The display screen will show system

information in either English, or metric
units, format dependent on which format
method has been selected.
The second screen indicating machine
travel in "feet per minute" [fpm] and
"impacts per foot" [ipf], can be accessed
by pressing the display scroll button
[ITEM 26], found below the display
screen [ITEM 26].
FAULT MESSAGE SCREENS [See Figures

F, G and H].
a. Leave the English, or metric units, format

A fault message screen is automatically displayed if

a system fault condition exists and can be detected.

Push the manual drum vibrator "start/stop" button
thumb switch [ITEM 12], found on the directional/
speed control handle, ONE [1] time and change the
screen from English to metric units format, or from
metric units to English format.
It will be displayed for a short period of time on the

bottom line of the display screen. Then the previously selected display bottom line will be displayed,
again. This will continuously alternate as long as the
fault exists.
c. When the desired display screen format has

been selected, use the display scroll button to scroll
to the next screen or return to the normal screen,
displayed during machine operation.
NOTE: At any time during machine operation,

use the above information to change the
screen format, if desired.
3-18
On C766C, machine serial numbers C209C2343

and below, except C209C2313 and C778B, machine serial numbers B215C1737 and below, the
water level, within the water spray system supply
tanks, is electronically monitored. A fault message
will be displayed, on the display screen, if a "low
water level" exists within the supply tanks.
If serious, some faults will cause a shut down of the
travel control system and the message will continue
to be displayed until the cause of the fault is
corrected.
7/00
Section 3
OPERATION
The "limited operation mode" allows the machine to
be removed from the work surface if a "stop" fault"
is detected [See THIS Section and Figure H].
The "limited operation mode" is programed into
computer controller software "Version 2.33" and
was NOT included in previous "versions" of the
software.
Other fault messages will only display a message
for as long as a fault is detected.

displaying fault messages, except
the "limited operation mode" .
Put an information tag on the
steering wheel which says DO NOT
OPERATE. REMOVE the key from
the ignition switch. Investigate and
repair ALL system faults at ONCE.
GAUGES AND INSTRUMENTS OPERATION.
DANGER: FAILURE to observe the following

precautions and/or the machine
OPERATION and WARNING
INSTRUCTIONS, given in THIS
section and found on the DECALS
affixed to the machine, can cause
SERIOUS INJURY, or DEATH.
ONLY authorized personnel, who
operation, can operate the Model
C766C, or C778B, Compactor.
a. USE a SLOW SPEED [work range] and
ADDITIONAL CAUTION when nearing, or operating, the machine close to a slope and/or when
traveling down a slope.
b. Do NOT travel across a slope. When on a
slope, TRAVEL in an UP or DOWN direction
ONLY.
c. USE extra CAUTION when operating the
machine near personnel and/or other objects or
machines.
Visually check the operation of ALL gauges and

instruments.
d. Do NOT operate a machine in need of repair.

Report ANY needed repairs and have the machine
repaired IMMEDIATELY.
All gauges and instruments MUST operate, not be

damaged and be able to be read. Immediately
replace any gauge, or instrument, having damage,
with NEW.
e. Keep ALL personnel CLEAR of the hitch area

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

having gauges, or instruments,
which do not operate, are damaged
or are not able to be read.
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.
OPERATING PRECAUTIONS [See Figures 3-1,

3-2, 3-3 and 3-4].
To help prevent injury to personnel and/or damage
to the machine, ALWAYS observe ALL of the
following Operating Precautions.
READ, UNDERSTAND and FOLLOW ALL
information shown on the Operating Instruction and
Warning decals, found on the machine [see figures
3-1 and 3-3] and the instructions written in THIS
manual.
7/00
3-19
Section 3
OPERATION
f. AFTER being seated, and BEFORE the
machine is started, ALWAYS securely FASTEN and
TIGHTEN the seat belt across the lap. The operator
MUST remain seated at ALL times during machine
operation. Keep the hands and feet INSIDE the
machine cockpit at ALL times. Allow NO riders on
the machine at ANY time.
g. Do NOT suddenly stop the machine during
operation.
h. BEFORE getting off of the machine, put the
directional/speed control handle [ITEM 1] in the
NEUTRAL position. Put the secondary/parking
brake system control switch [ITEM 5] in the ON
[APPLIED] position. STOP the engine.
WARNING: ALWAYS APPLY the

SECONDARY/PARKING brake
system, AFTER the machine has
stopped. The transmission system
will NOT hold the parked machine
in a stopped condition, on
ANY grade. The SECONDARY/
PARKING brake system MUST be
used to hold the machine, in a
stopped condition, at ALL times.
i. Do NOT operate the machine, if the machine will

move when the secondary/parking brake system is
in an ON [APPLIED] condition. The machine must
NOT move, at ANY time, when the secondary/
parking brake system control switch [ITEM 5] is in
the ON [APPLIED] position.
OPERATING THE MACHINE [See Figures 3-1,

3-2, 3-3, 3-4 and Table 3-1].
DANGER: ALL personnel and other

machines MUST be CLEAR
of the machine path BEFORE the
machine is moved.
a. IMMEDIATELY, after being seated, place the

seat belt across the lap and SECURELY insert the
metal end into the belt buckle to TIGHTEN the belt,
AGAINST the body. Release the secondary/parking
brake system, by putting the secondary/parking
brake system control switch [ITEM 5] in the OFF
[RELEASED] position.
b. Put the transmission range selector switch
[ITEM 7] in the WORK [low] range position.
WARNING: Keep the transmission system in the

WORK range. Use the WORK
range for machine movement
within a confined area, when near
personnel, or objects, and for ALL
vibratory applications, when on the
work surface.
Do NOT put the transmission in the
TRAVEL range when the machine
is moved within a confined area
is near personnel, any object or
machine. The TRAVEL range is
for machine transport ONLY.
j. Do NOT operate a machine NOT having the

Operating Instruction and Warning decals in place
on the machine. The decals MUST remain in good
condition and NOT be covered with dirt or grease.
REPLACE damaged, or missing, decals
IMMEDIATELY.
3-20
7/00
Section 3
OPERATION
NOTE: The vibration systems will NOT operate
if the TRAVEL [high] transmission
range is selected. When the speed range
selector switch is in the TRAVEL
position, LOW transmission system
torque is available. When the speed range
selector switch is in the WORK
position, HIGHtransmission system
torque is available.
c. When on the work surface, put the engine throttle

speed [RPM] control switch [ITEM 3] in the HIGH
engine speed position.
WARNING: Do NOT put the engine throttle

speed [RPM] control switch in the
HIGH engine speed position when
the machine is being moved in a
confined area, or when near
personnel, any object or machine.
CAUTION: When on the work surface, do NOT

attempt to operate the drum vibration
systems with the engine at LOW
idle. The systems will NOT operate
with the engine at the LOW engine
speed and/or if the TRAVEL [high]
transmission range is selected.
d. SLOWLY move either directional/speed control

[F-N-R] handle [ITEM 1] TOWARD the SAME
direction the machine is desired to travel.
NOTE: PUSHING either handle in the

FORWARD direction will select a
FORWARD direction of machine
travel. PULLING either handle in
the BACKWARD direction will select
a REVERSE direction of machine
travel. The machine travel speed is
proportional to the amount of either
directional/speed control [F-N-R]
handle movement, UNTIL full
handle travel has been reached,
in EITHER DIRECTION.
The transmission system will be
electrically disengaged, when the
secondary/parking brake system control
switch is in the ON [APPLIED] position.
e. When the machine is clear of confinement,

personnel or objects, SLOWLY move either directional/speed control [F-N-R] handle [ITEM 1] further
toward the SAME direction of machine travel. This
will give FULL machine speed for the transmission
range and engine throttle speed, selected.
NOTE: During normal operation, the machine

travel speed is proportional to the
amount of either directional/speed
control [F-N-R] handle movement,
until full handle movement has been
reached, in either direction.
On C766C, machine serial numbers C209C2344

and above, plus C209C2313 and C778B, machine
serial numbers B215C1738 and above, the asphalt
mat temperature is electronically monitored and can
be accessed and displayed on the display screen,
during the rolling operation.
7/00
3-21
Section 3
OPERATION
f. When on the WORK surface, put the drum
vibrator MODE [OFF/AUTOMATIC/MANUAL]
control switch [ITEM 8] in the desired position.
h. Put the drum vibration systems FRONT/

REAR/BOTH LOCATION control switch [ITEM 9]
at the desired FRONT, REAR or BOTH
position.
CAUTION: Do NOT operate either drum

vibration system, UNLESS the
drums of the machine are on the
WORK, or a SOFT surface, such as
loose dirt or old tires.
Damage to the drums and/or
machine can occur if the drum
vibration system[s] is operated on
a HARD surface.
i. Put the vibration systems control HIGH/LOW

AMPLITUDE control switch [ITEM 11] at the
desired HIGH or LOW drum AMPLITUDE
position.
g. Turn one [1], or both, vibration system control

FREQUENCY control[s] [ITEM 10] to set the
control[s] at the desired drum FREQUENCY [vpm].
NOTE: Put the DRUM VIBRATION SYSTEM[S]

LOCATION control switch [ITEM 9] at
the desired FRONT/BOTH/REAR
position.
If operating either drum vibration system
in the MANUAL MODE, turn the
system[s] ON and OFF by using
either of the directional/speed control
handle installed thumb switches
[ITEM 12].
In either the AUTOMATIC, or
MANUAL mode, the vibration
system[s] will NOT operate with the
engine at the LOW engine speed and/
or if the TRAVEL [high] transmission
range is selected. Adjustment of the
FREQUENCY control[s] can be done at
any time, while the machine is on, or off,
the work surface. When operating
in the AUTOMATIC vibrator mode,
the vibration system[s] will start
and stop at the adjusted, preset
ON/OFF speed, WITHOUT the use of
the directional/speed control handle
installed thumb switches [ITEM 12], as
each work surface rolling pass is started
and then stopped.
3-22
j. When operating on the work surface, select the

desired water spray system mode; AUTO/ OFF/
MANUAL by using the dash mounted water spray
system MODE control switch [ITEM 6]. Put the
switch LEFT to put the system in the
AUTOMATIC mode, RIGHT to MANUAL to
operate the system continuously or in the CENTER position to turn the system OFF.
NOTE: On C766C, machine serial numbers

C209C2343 and below, except
C209C2313 and C778B, machine serial
numbers B215C1737 and below, the
water level, within the water spray
system supply tanks, is electronically
monitored. A fault message will be
displayed, on the display screen [ITEM
26], if a "low water level exists" within
the supply tanks.
On all machine serial numbers, if in the
AUTOMATIC mode, adjust the
water spray system duty cycle as
desired. Turn the duty cycle control
switch knob [ITEM 24] to select the
desired duty cycle, from 0-50%.
When operating in the AUTOMATIC
mode, the water spray system will start
and stop as each work surface rolling
pass is started, and then stopped.
DANGER: ALWAYS follow ALL Operating

Precautions and Instructions, given
in THIS manual and found on the
decals affixed to the machine.
Failure to follow the Operating
Precautions and Instructions can
cause SERIOUS INJURY, or DEATH.
IMMEDIATELY put the secondary/
parking brake system control switch
[ITEM 5] in the ON [APPLIED]
position and STOP the engine if
observed machine operation is NOT
normal.
7/00
Section 3
OPERATION
LIMITED OPERATION MODE [See Figure 3-3].
The "limited operation mode" allows the machine to
be removed from the work surface.
The "limited operation mode" is programed into
computer controller software "Version 2.33" and
was NOT included in previous "versions" of the
software.
NOTE: The "version" of the software, contained

within the computer controller, is
displayed on the system function
monitor display screen [ITEM 26] when
the ignition key switch is first turned to
the "ON/RUN" position.
The machine directional control system will

"automatically default" to the limited operation mode
when a "stop fault" condition exists and has been
detected by the computer controller [See Figure 3-3
- Screen #1] .
The system function monitor display screen
[ITEM 26] will visually "prompt" the operator to
return either directional/speed control [F-N-R]
handle [ITEM 1] to the neutral position.
With the directional/speed control [F-N-R] handle
[ITEM 1] in the neutral position, the screen will
display the functions which should allow the
machine to be moved.
A message will appear stating "FRNT/FWD" or
"REAR/REV"[See Figure 3-3 - Screens #2 and #3] .
The message will inform the operator that by
moving the Drum Vibration Systems "Location"
Control Switch [ITEM 9] from the center [BOTH
position] to either the FRONT, or REAR, drum
position machine movement can be achieved.
The machine will travel in FORWARD with the
switch in the FRONT position and in REVERSE with
the switch in the REAR position when either directional/speed control [F-N-R] handle [ITEM 1] is
moved from the NEUTRAL position towards either
direction of travel. The Engine Throttle Speed
Control Switch [ITEM 3] MUST be in the "LOW"
speed position and the Transmission Range
"WORK" [Low] /"TRAVEL" [High] Control Switch
[ITEM 7] can be placed in EITHER of the two [2]
positions.
7/00
DANGER: ALL personnel and other

machines MUST be CLEAR
of the machine path BEFORE the
machine is moved.
WARNING : The directional/speed control

[F-N-R] handle [ITEM 1] does NOT
control the direction of machine
travel, during the"limited
operation mode". The
directional/speed control
[F-N-R] handle is ONLY used to
control movement of the machine,
but not the speed of the
movement. Machine speed is NOT
proportional to movement of the
directional/speed control
[F-N-R] handle.
When the directional/speed
control [F-N-R] handle is moved
from the neutral position,
regardless of which direction it is
moved, the machine will travel in
the direction which was selected
with the Drum Vibration Systems
"Location" Control Switch
[ITEM 9].
The machine will travel
approximately 0.75 mph [1.2 kmph]
with the Transmission Range
Control Switch in the "LOW"
position and 1.5 mph [2.4 kmph]
with the Transmission Range
Control Switch in the "High"
position.
While in the Limited Operation
Mode, move the machine the LEAST
distance possible, from the work
surface.
Do NOT drive the machine to the
repair area. Use a truck, or trailer, to
move the machine to the repair
area.
NOTE: Dependant on the "stop fault" condition

which exists and has been detected by
the computer controller, limited
operation may be restricted to either
forward, or reverse, direction of travel.
If travel is not achieved in one direction,
attempt to travel in the opposite
direction.
3-23
Section 3
OPERATION
SCREEN
GENERAL VIEW - OPERATOR CONTROLS LOCATIONS
This screen tells the

operator that there is a fault
and the machine is in
"Limited Operation Mode".
OFF
MAN
AUTO
VIBRATOR MODE
BOTH
FRONT
REAR
LIMD OP: MODE - FNR FDW

Fault: 5V SENSOR POWER
DRUM SELECT
WATER SAVER
FRONT VIB SPEED
LOW
HIGH
AMPLITUDE
REAR VIB SPEED
SCROLL BUTTON
SCREEN # 1
and by moving the Drum
Vibration Systems "Location"
Control Switch to the FRONT drum
position, the machine will
travel in the FORWARD
direction when either directional/
speed control [F-N-R] handle is
moved from the neutral position
in either direction.
OFF
MAN
AUTO
VIBRATOR MODE
BOTH
FRONT
REAR
VIBE MODE - FRNT/FDW

DRUM SELECT
WATER SAVER
FRONT VIB SPEED
LOW
HIGH
AMPLITUDE
REAR VIB SPEED
SCROLL BUTTON
SCREEN # 2
and by moving the Drum
Vibration Systems "Location"
Control Switch to the REAR drum
position, the machine will
travel in the REVERSE
direction when either directional/
speed control [F-N-R] handle is
moved from the neutral position
in either direction.
OFF
MAN
AUTO
VIBRATOR MODE
BOTH
FRONT
REAR
VIBE MODE - REAR/REV

DRUM SELECT
HIGH
WATER SAVER
FRONT VIB SPEED
LOW
AMPLITUDE
REAR VIB SPEED
SCROLL BUTTON
SCREEN # 3
FIGURE 3-3. MACHINE LIMITED OPERATION MODE SCREEN DISPLAYS.
3-24
7/00
Section 3
OPERATION
WARNING
P/N 918141
WARNING
FASTEN
SEAT BELT!
IF MACHINE
TIPS:
DO NOT
JUMP!
P/N 918142
FIGURE 3-4. OPERATION WARNING AND SEAT BELT WARNING DECALS MODEL C766C AND C778B COMPACTORS.
7/00
3-25
Section 3
OPERATION
DYNAMIC BRAKING OF THE MACHINE [See
Figure 3-2].
The TRANSMISSION SYSTEM is the PRIMARY
[DYNAMIC] brake system for the machine.
Slowing, and then stopping, of the machine, during
operation, is done by moving either directional/
speed control [F-N-R] handle [ITEM 1] TOWARD
the NEUTRAL position.
WARNING: When nearing a slope, first slow the

machine by moving either directional/speed control handle toward
the neutral position. To SLOW the
machine further, or STOP the
machine on a slope, move either
directional/speed control [F-N-R]
handle to the direction OPPOSITE
the direction of machine travel.
The SECONDARY/PARKING brake
system MUST be used to hold the
machine in a stopped condition at
ALL times. The transmission system,
used for DYNAMIC braking, will NOT
hold, or keep, the machine in a
stopped condition at ANY time.
d. Put the engine throttle speed [RPM] control

switch [ITEM 3] in the LOW speed position. Run
the engine for a period of at LEAST three-five [3-5]
minutes, at LOW speed, BEFORE the engine is
stopped.
CAUTION: Do NOT stop the engine BEFORE

running at the LOW engine
idle speed. Serious engine
DAMAGE can occur if the engine
is stopped BEFORE waiting the
three-five [3-5] minute period,
to allow the engine to cool.
e. Put the ignition key switch [ITEM 2] at the

OFF [NUMBER 1] position and allow the engine to
stop. Remove the key from the ignition switch and
install and lock the vandal guard, if desired.
RELEASING THE TOWING BYPASS VALVES

AND SECONDARY/PARKING BRAKE SYSTEM
AND TOWING A COMPLETELY DISABLED
MACHINE [See Figures 3-5 and 3-6].
WARNING: Do NOT tow the machine UNLESS

ALL of the following procedures
have been followed.
STOPPING THE ENGINE [See Figure 3-2 and
Table 3-1].
a. Put the drum vibrator mode selector switch
[ITEM 8] in the OFF position.
b. SLOW and STOP the machine by using
DYNAMIC braking through the transmission system
[see procedure above]. Put either directional/speed
control [F-N-R] handle [ITEM 1] in the NEUTRAL
position.
c. Put the secondary/parking brake system control
switch [ITEM 5] in the ON [APPLIED] position.
3-26
Should the machine become COMPLETELY

disabled and the engine can NOT be started and/or
the hydraulic system operated, use the following
procedure to release the BYPASS VALVES and the
SECONDARY/PARKING brake system.
a. Put SOLID wood blocks behind, and in front of,

the FRONT drum.
WARNING: Block SECURELY using SOLID wood

blocks. The blocks MUST hold the
machine in place when the
secondary/parking brake system is
released.
7/00
Section 3
OPERATION
b. Put a 1 1/16 inch open end wrench on the
MIDDLE sized [2nd] hex nut [towing bypass valve]
of the FORWARD direction MULTIFUNCTION
VALVE cartridge. Put a 1 1/4 inch open end wrench
on the LARGE [3rd] hex nut of the FORWARD
direction MULTIFUNCTION VALVE
cartridge.
c. OPEN the bypass valve by turning the second
[2nd] hex nut with the wrench approximately
THREE [3] revolutions in the COUNTERCLOCKWISE [CCW] direction.
CAUTION: Do NOT open the bypass valve more

than THREE [3] revolutions. Opening
the valve additional revolutions can
permit external leakage of hydraulic
oil during machine towing.
d. Repeat steps b and c on the REVERSE

direction MULTIFUNCTION VALVE cartridge.
e. Locate the two [2] brake release mechanisms,

found behind the tool box door, under the right seat.
f. Take one [1] brake release mechanism. Turn
the nut onto the capscrew threads until it is near the
head of the capscrew by using the fingers.
g. Go to either drum drive motor. Locate the .875
in. [22.2 mm] hole in the frame rail. Install the 16
mm capscrew through the frame rail. Turn the
capscrew threads into the tapped hole, in the brake
release piston, until the capscrew is FULLY
engaged in the tapped hole.
h. Turn the nut CLOCKWISE [CW], on the
capscrew threads, until the nut is against the frame
rail. Hold the capscrew head with a wrench. Use a
second wrench to turn the nut further INWARD until
the nut will NOT turn any further through the
use of the wrench. The secondary/parking brake, on
THIS drum drive motor, is now released. LEAVE the
release mechanism in place, at THIS time.
i. Go to the SECOND drum drive motor. REPEAT
steps f through h and release the secondary/
parking brake on that motor, using the SECOND
brake release mechanism.
RELEASE
MECHANISM
TAPPED HOLE IN BRAKE

WASHER
HOLE THROUGH
SIDE OF FRAME
FIGURE 3-5. MULTIFUNCTION VALVES ON TRANSMISSION PUMP.
7/00
FIGURE 3-6. SECONDARY/PARKING BRAKE

SYSTEM RELEASE LOCATION.
3-27
Section 3
OPERATION
j. Securely fasten the towing strap, cable or chain
to the machine and the towing vehicle. Tighten the
strap, cable or chain completely. CAREFULLY
remove the wood blocking from under the drum.
CAREFULLY and SLOWLY tow the machine from
the work surface. Tow the machine to a truck, or
trailer. Move the machine onto the truck or trailer
and fasten securely [see THIS section for CORRECT machine tie down procedures]. Move the
machine for repair using the truck, or trailer.
WARNING: Keep ALL personnel CLEAR of the

towing vehicle and the machine
while removing the blocking and
towing the machine, or moving
the machine onto the truck or
trailer. At this time, the machine will
be held in position ONLY by the
wood blocking placed against the
drum. The secondary/parking brake
will be in a DISCONNECTED
condition.
Do NOT tow the machine on ANY
grade.
TOW the machine the LEAST
distance possible, from the work
surface.
Do NOT tow the machine at a speed
above TWO [2] miles per hour [3.2
km/h].
Do NOT tow the machine to the
repair area. ONLY use a truck, or
trailer, to move the machine to the
repair area.
k. Go to either drum drive motor. Turn the nut,

found on the brake release mechanism, in the
COUNTERCLOCKWISE [CCW] direction until the
nut is away from the frame rail. The brakes in the
motor will now be APPLIED.
l. Go to the second drum drive motor and REPEAT step k.
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.
m. Go to the transmission pump assembly.

CLOSE both the FORWARD, and the REVERSE,
direction bypass valves. Close the bypass valves by
turning the MIDDLE sized [2nd] hex nut THREE [3]
revolutions in the CLOCKWISE [CW] direction, with
the 1 1/16 inch open end wrench, until the hex nut is
seated against the LARGE sized [3rd] hex nut. Hold
the LARGE [3rd] hex nut with the 1 1/4 inch open
end wrench and tighten the MIDDLE sized [2nd] hex
nut to a torque of 30 ft. lbs. [41 N.m].
CAUTION: BOTH bypass valves MUST be

returned to the CLOSED position.
NOTE: There will be resistance in the

hydrostatic transmission system.
It is caused by system oil in the
transmission drum drive motors,
and will be noted UNTIL the drum
assemblies have turned approximately
one third [1/3] revolution. The machine
will then roll more easily.
WARNING: AFTER the machine has been

moved, the SECONDARY/PARKING
brake system, on BOTH drum drive
motors, MUST be put in the
APPLIED condition using the
following ADDITIONAL information.
3-28
7/00
Section 3
OPERATION
TRANSPORTING THE MACHINE [See Figures
3-7 and 3-8].
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.
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.
NOTE: Blocking of the drums, clear of the truck

or trailer bed, is NOT needed on the
Model C766C or C778B Compactor.
FRONT FRAME ASSEMBLY
a. CAREFULLY load the machine onto the

transporting truck or trailer. Put the secondary/
parking brake system control switch [ITEM 5] 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 figure 3-7].
c. Put SOLID wood blocks under EACH drive
drum at the FRONT, and at the REAR, ends on
BOTH sides of the machine [see figure 3-8].
STEERING LOCK PIN
STEERING CYLINDER
HITCH ASSEMBLY
REAR FRAME ASSEMBLY
FIGURE 3-7. STEERING LOCK PIN LOCATION.
d. 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 tiedown load binding device to hold the machine
securely in position for transportation [see figure
3-8].
7/00
3-29
Section 3
OPERATION
FRONT TIE-DOWN
(LEFT & RIGHT)
BLOCKS-FRONT & REAR

(LEFT & RIGHT)
REAR TIE-DOWN
(LEFT & RIGHT)
FIGURE 3-8. MACHINE TRANSPORT TIE-DOWN LOCATIONS.
3-30
7/00
Section 4
MAINTENANCE
TABLE OF CONTENTS
PAGE
GENERAL INFORMATION ...................................................................................................................... 4-4.
MAINTENANCE ....................................................................................................................................... 4-4.
GENERAL INFORMATION .................................................................................................................. 4-4.
MAINTENANCE SCHEDULE ................................................................................................................... 4-4.
GENERAL INFORMATION .................................................................................................................. 4-4.
TABLE 4-1. MAINTENANCE SCHEDULE .............................................................................................. 4-6.
MAINTENANCE PROCEDURES ........................................................................................................... 4-13.
GENERAL INFORMATION ................................................................................................................ 4-13.
ENGINE MAINTENANCE ................................................................................................................... 4-13.
GENERAL INFORMATION ............................................................................................................. 4-13.
ENGINE LUBRICATION OIL ........................................................................................................... 4-13.
CHECKING THE ENGINE LUBRICATION OIL LEVEL .............................................................. 4-13.
CHANGING THE ENGINE LUBRICATION OIL .......................................................................... 4-13.
CHANGING THE ENGINE LUBRICATION OIL FILTER ............................................................ 4-15.
FUEL SYSTEM ................................................................................................................................... 4-16.
FUEL TANK ..................................................................................................................................... 4-16.
ENGINE FUEL FILTERS ................................................................................................................. 4-16.
PRIMING AND AIR REMOVAL [BLEEDING] FROM THE FUEL SYSTEM CUMMINS DIESEL ENGINE ........................................................................................................ 4-17.
ENGINE AIR FILTRATION ................................................................................................................ 4-19.
AIR CLEANER ................................................................................................................................. 4-19.
8/02
4-1
Section 4
MAINTENANCE
PAGE
COOLING SYSTEM ........................................................................................................................... 4-20.
RADIATOR AND HYDRAULIC OIL COOLER ................................................................................ 4-20.
RADIATOR HOSES ......................................................................................................................... 4-21.
WATER PUMP ................................................................................................................................. 4-21.
DRAINING, FLUSHING AND FILLING THE COOLING SYSTEM ................................................. 4-21.
HYDRAULIC SYSTEM ....................................................................................................................... 4-23.
GENERAL INFORMATION ............................................................................................................. 4-23.
CHECKING THE HYDRAULIC OIL LEVEL AND ADDING HYDRAULIC OIL TO
THE HYDRAULIC OIL RESERVOIR ........................................................................................... 4-24.
CHANGING THE HYDRAULIC OIL ................................................................................................ 4-24.
VIBRATION SYSTEMS PRESSURE OIL FILTER ELEMENT REMOVAL AND REPLACEMENT ............................................................................................... 4-26.
TRANSMISSION SYSTEM PRESSURE OIL FILTER ELEMENT REMOVAL AND REPLACEMENT ............................................................................................... 4-27.
HYDRAULIC SUCTION OIL STRAINERS AND RETURN OIL DIFFUSER REMOVAL, CLEANING AND INSTALLATION ........................................................................... 4-28.
DRUM BEARING LUBRICATION ...................................................................................................... 4-30.
CHECKING THE DRUM BEARING LUBRICATION OIL LEVEL ................................................... 4-30.
CHANGING THE DRUM BEARING LUBRICATION OIL ............................................................... 4-31.
CHANGING THE DRUM BEARING LUBRICATION OIL C766C machines below serial number 109C20902455 and on
C778B machines below serial number 109B21501856 ......................................................... 4-31.
CHANGING THE DRUM BEARING LUBRICATION OIL C766C machines serial number 109C20902455 and higher and on
C778B machines serial number 109B21501856 and higher ................................................. 4-32.
ALTERNATOR AND FAN DRIVE BELT - INSPECTION
AND REPLACEMENT PROCEDURES .......................................................................................... 4-33.
ELECTRICAL SYSTEM ..................................................................................................................... 4-33.
CHECKING THE CHARGE CONDITION OF THE BATTERY AND
SERVICING OF RELATED ITEMS .............................................................................................. 4-33.
ELECTRICAL WIRING INSPECTION .......................................................................................... 4-34.
VIBRATION ISOLATOR TIRES ......................................................................................................... 4-35.
4-2
8/02
Section 4
MAINTENANCE
PAGE
INSPECTION, AIR PRESSURE CHECK AND ADJUSTMENT ...................................................... 4-35.
REMOVAL, REPAIR OR REPLACEMENT, AND INSTALLATION
OF THE VIBRATION ISOLATOR TIRE AND RIM ASSEMBLIES C766C machines below serial number 109C20902455 and on
C778B machines below serial number 109B21501856 ............................................................ 4-36.
REMOVAL .................................................................................................................................... 4-36.
TIRE REMOVAL, REPAIR OR REPLACEMENT AND INSTALLATION ONTO THE RIM ........ 4-38.
INSTALLATION ............................................................................................................................ 4-40.
REMOVAL, REPAIR OR REPLACEMENT, AND INSTALLATION
OF THE VIBRATION ISOLATOR TIRE AND RIM ASSEMBLIES C766C machines serial number 109C20902455 and higher and on
C778B machines serial number 109B21501856 and higher .................................................... 4-43.
REMOVAL .................................................................................................................................... 4-43.
TIRE REMOVAL, REPAIR OR REPLACEMENT AND INSTALLATION ONTO THE RIM ........ 4-45.
INSTALLATION ............................................................................................................................ 4-47.
SECONDARY/PARKING BRAKE SYSTEM MAINTENANCE OPERATION AND APPLICATION CHECK ................................................................................... 4-50.
MISCELLANEOUS MAINTENANCE INFORMATION .......................................................................... 4-51.
WATER SPRAY SYSTEM ................................................................................................................. 4-51.
WATER STRAINERS ...................................................................................................................... 4-51.
WATER SPRAY NOZZLES ............................................................................................................. 4-51.
CLEANER BEAM AND RUBBER CLEANER ASSEMBLIES ........................................................... 4-52.
PREPARING THE MACHINE FOR STORAGE ..................................................................................... 4-52.
ENGINE .............................................................................................................................................. 4-52.
COOLING SYSTEM ........................................................................................................................... 4-52.
BATTERY ........................................................................................................................................... 4-53.
FUEL TANK ........................................................................................................................................ 4-53.
AIR CLEANER, EXHAUST AND OTHER OPENINGS ..................................................................... 4-53.
WATER SPRAY SYSTEM ................................................................................................................. 4-53.
EXPOSED COMPONENT RUST PREVENTION ............................................................................... 4-53.
8/02
4-3
Section 4
MAINTENANCE
MAINTENANCE SCHEDULE.
THIS section gives the necessary procedures for

CORRECT MAINTENANCE of the Model C766C
and C778B Compactors.
NOTE: The drum design on C766C machines

serial number 109C20902455 and higher
and on C778B machines serial number
109B21501856 and higher, has been
changed. Be sure to refer to the text that
is applicable to the serial number of
your machine.
Follow ALL the MAINTENANCE SCHEDULES
and MAINTENANCE PROCEDURES for CORRECT machine service schedules and procedures.
MAINTENANCE.
MAINTENANCE must be a planned program which
includes periodic machine inspection and lubrication
procedures.
The MAINTENANCE program must be done, based
on the machine OPERATING HOURS, recorded
on the hourmeter, or based on the PERIODIC
SCHEDULE, which is done at time intervals of
weekly, monthly or yearly.
The MAINTENANCE SCHEDULE lists the recommended time intervals between machine maintenance inspections and lubrication procedures. Table
4-1 gives inspection and lubrication information for
the Model C766C and C778B Compactors.
Most service intervals are listed by the HOUR and
PERIODIC time periods. The maintenance
schedule begins with eight [8] hours, or daily,
maintenance intervals and continues through the
2,000 hours, or every two [2] years, maintenance
schedule intervals.
NOTE: If the machine is operated MORE

than eight [8] hours per day,
follow the HOUR schedule. If the
machine is operated LESS than
eight [8] hours per day, follow
the PERIODIC schedules, where
they apply.
The maintenance checks, given in Table 4-1, are

also listed on the Machine Maintenance Decal,
found on the machine [See Figure 4-2]. Figure 4-1
shows the location of the machine maintenance
points.
The MAINTENANCE program is divided into TWO

[2] subsections: The MAINTENANCE SCHEDULE
and the MAINTENANCE PROCEDURES.
4-4
8/02
Section 4
MAINTENANCE
20-INSIDE DRUM (THIS SIDE)
17 18
11
22 13
6
3 1
21
14
14
16-(7) NOZZLES ON:

C766C
(8) NOZZLES ON:
C778B
15
15
14
16-(7) NOZZLES ON:

C766C
(8) NOZZLES ON:
C778B
4
22
18
23
19
7
9
12
10
14
20-INSIDE DRUM (THIS SIDE)
FIGURE 4-1. MACHINE MAINTENANCE POINTS.
FIGURE 4-2. MACHINE MAINTENANCE DECAL.
8/02
4-5
Section 4
MAINTENANCE
TABLE 4-1. MAINTENANCE SCHEDULE.
FIG
4-1
ITEM
NO.
ITEM
8/
DAY
ENGINE OIL
ENGINE OIL
FILTER
ENGINE
FUEL
FILTERS
[Primary
AND
Secondary]
X*
FUEL LEVEL
- IN TANK
ENGINE
INLET AIR
FILTER
ELEMENT
ENGINE
COOLING
SYSTEM
4-6
250/
3 MO
500/
1 YR
1000/
1 YR
2000/
2 YR
QUAN.
TYPE/REMARKS
C*
10.8
Qts.
[10.2 l],
Total
Drain diesel engine

lubrication oil
and replace with
NEW.*
C*
Change at EACH
engine oil change
Use APPROVED filter
ONLY.*
Drain PRIMARY of
water daily with
drain plug provided.
Change at interval
shown.*
Use APPROVED
filters ONLY.*
50 Gal.
[189 L],
C766C
60 Gal.
[227 L],
C778B
#1D or #2D
diesel fuel. See
Section 2 SPECIFICATIONS,
for complete
specifications.
C**
Check condition
indicator light.
Change element
as needed.**
Use APPROVED
element ONLY.
C*
19
Qts.
[18 L]
Check coolant
level. Fill as required
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.*
C*
8/02
Section 4
MAINTENANCE
FIG
4-1
ITEM
NO.
7
ITEM
HYDRAULIC
SYSTEM OIL ***
8/
DAY
250/
3 MO
500/
1 YR
1000/
1 YR
2000/
2 YR
QUAN.
TYPE/REMARKS
A/C+
22
Gal.
[83.3 L]
Check hydraulic
oil level in the
reservoir sight
gauge. Add
hydraulic oil as
required.***
Use ONLY MOBIL
423, HYTRAN,
TEXACO TDH or
EQUIVALENTS oil.
CAUTION: Use the

COR RECT
hydraulic oil
ONLY***
+ A= OBTAIN AND ANALYZE OIL SAMPLE - WITH CARE.
+ C= CHANGE OIL BASED ON RESULTS OF OIL ANALYSIS - AS NEEDED.
8
8/02
HYDRAULIC
PRESSURE
OIL FILTER
[Vibration
Systems]
Check condition
indicator lights daily.
Change filter
element when
hydraulic oil is
changed, and/or
one [1] time for
every 2,000 hours of
machine operation,
or when filter
element condition
indicator, on filter
head, and/or indicator
light shows needed.
Use APPROVED
filter element ONLY.
See MACHINE
PARTS book for
CORRECT
replacement
element.
4-7
Section 4
MAINTENANCE
FIG
4-1
ITEM
NO.
4-8
ITEM
TRANSMISSION
SYSTEM
PRESSURE
OIL FILTER
10
HYDRAULIC
SYSTEM SUCTION
OIL STRAINERS
[Transmission/
Vibration/Steering
Systems]
8/
DAY
100/
2 WK
100/
3 MO
1000/
1 YR
2000/
2 YR
C
CLEAN
QUAN.
TYPE/REMARKS
Change filter
element when
hydraulic oil is
changed, and/or
one [1] time for
every 2,000 hours of
machine operation.
Use APPROVED
filter element ONLY.
See MACHINE
PARTS book for
CORRECT
replacement
element.
2
Remove both. Clean

at EACH hydraulic
oil change. See THIS
section for procedure.
Also remove, & clean
return oil diffuser.
8/02
Section 4
MAINTENANCE
FIG
4-1
ITEM
NO.
ITEM
11
ALTERNATOR
& FAN DRIVE
BELT
12
BATTERY
13 SECONDARY/
PARKING
BRAKE SYSTEM
8/02
8/
DAY
100/
2 WK
100/
3 MO
1000/
1 YR
X*
2000/
2 YR
QUAN.
TYPE/REMARKS
Check belt for

wear or damage.
Check belt for
CORRECT
deflection.*
Replace belt with
NEW if needed [see
ENGINE manual].
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.
System
Check OPERATION
of brake system one
[1] time for each eight
[8] hours of machine
operation, or daily,
using the procedures
given in Section 3.
Check OPERATION &
APPLICATION, of the
system, one [1] time
for each 100 hours of
machine operation,
or every 3 months,
[see THIS section].
4-9
Section 4
MAINTENANCE
FIG
4-1
ITEM
NO.
ITEM
14
VIBRATION
ISOLATOR
TIRES
15
WATER
SPRAY
SUCTION
STRAINERS
16
WATER SPRAY
SYSTEM
NOZZLES
17
SAFETY
DECALS
18
SEAT BELT SETS
4-10
8/
DAY
250/
3 MO
500/
1 YR
1000/
1 YR
2000/
2 YR
QUAN.
TYPE/REMARKS
Check air
pressure when
tires are "cold".
Set at CORRECT
pressure [see
THIS section].
Remove, check,
clean and
install the
strainers one [1]
time for every
500 hours of
machine
operation, or
yearly.
All
Remove, clean
and install onto
spray bars when
plugged on "as
required" basis
[see THIS section].
All
Check condition.
Replace as
needed. See
MACHINE parts
manual.
2 Sets
Check condition.
Replace set if
damaged. See
MACHINE parts
manual.
X/C
CLEAN AS REQUIRED
8/02
Section 4
MAINTENANCE
FIG
4-1
ITEM
NO.
ITEM
8/
DAY
19
FALLING
OBJECT/
ROLL OVER
PROTECTIVE
STRUCTURE
[FOPS/ROPS]
20
DRUM BEARING
LUBRICATION
OIL
8/02
250/
3 MO
500/
1 YR
1000/
1 YR
2000/
2 YR
QUAN.
TYPE/REMARKS
Structure
Inspect the
FOUR [4] grade
8 flange screws
that fasten the
structure to the
machine, they
MUST 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.
10 Gal.
[37.9 L] EACH
drum
Check drum
bearing lubrication
oil level and add
oil as needed one
[1] time for each
eight [8] hours of
machine operation,
or daily [see THIS
section].
Change oil one [1]
time for each
2000 hours of
machine operation,
or every 2 years
[see THIS section].
4-11
Section 4
MAINTENANCE
FIG
4-1
ITEM
NO.
ITEM
8/
DAY
250/
3 MO
500/
1 YR
1000/
1 YR
2000/
2 YR
QUAN.
TYPE/REMARKS
21
GAUGES
HORN
LIGHTS
All
Check operation.
Repair, or replace,
as needed.
22
DYNAMIC
BRAKES
Trans'.
System
Check operation.
Repair if needed
[See Section 3].
23
STEERING
Steering
System
Check operation.
Repair if needed
[See Section 3].
CAUTION: CHECK ENGINE lubrication oil level with the engine in the OFF and
COLD condition.
CHECK HYDRAULIC system oil level with the engine in the OFF
condition and the hydraulic oil at the OPERATING temperature.
KEY:
X= CHECK
C= CHANGE
A/C= OBTAIN OIL SAMPLE, WITH CARE, AND ANALYZE. CHANGE OIL BASED ON
RESULTS OF OIL ANALYSIS - IF REQUIRED
* = Refer to current OPERATION AND MAINTENANCE MANUAL - B SERIES DIESEL

ENGINE 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 need is indicated.
*** = See DECAL adjacent to hydraulic reservoir fill tube.
4-12
8/02
Section 4
MAINTENANCE
MAINTENANCE PROCEDURES.
The following MAINTENANCE PROCEDURES give
instructions for performing required machine maintenance checks and lubrication.
NOTE: The instructions given in the

MAINTENANCE procedure subsection
are given by machine systems and are
NOT necessarily in the same order as
listed in Table 4-1 or as shown on the
Machine Maintenance Decal. They may
ALSO include some items NOT shown
in the table, or on the decal.
NOTE: The ABOVE procedure will help to

remove the possibility of filling the
engine with too much lubrication oil, by
allowing the oil to return to the oil pan.
WARNING: STOP the engine BEFORE checking

the engine lubrication oil
level. With engine running, HOT
oil can be thrown causing serious
injury.
FILL
DIPSTICK
ENGINE MAINTENANCE.
The following ENGINE maintenance information will
cover engine general maintenance procedures most
often done.
For additional, very specific, ENGINE maintenance
information, see the current OPERATION AND
MAINTENANCE MANUAL - B SERIES DIESEL
ENGINE published by Cummins Engine Company
Incorporated, which is supplied with the machine.
FIGURE 4-3. CUMMINS DIESEL ENGINE LUBRICATION OIL LEVEL CHECK LOCATION.
ENGINE LUBRICATION OIL.
CHECKING THE ENGINE LUBRICATION OIL
LEVEL [See Figure 4-3].
CHANGING THE ENGINE LUBRICATION OIL

[See Figure 4-4].
The engine lubrication oil MUST be kept at a level

ABOVE the ADD mark, but NOT ABOVE the
FULL mark, on the engine lubrication oil dipstick.
The engine lubrication oil MUST be changed

according to the interval given in the current diesel
engine Operation and Maintenance Manual
published by Cummins Engine Company and
supplied with the machine.
TO ACCURATELY check the engine lubrication oil

level, put the machine in a LEVEL position and
STOP the engine. Clean the area around the engine
lubrication oil dipstick BEFORE removing the
dipstick from the engine. WAIT five [5] minutes
BEFORE removing the dipstick from the engine and
checking the oil level.
8/02
4-13
Section 4
MAINTENANCE
NOTE: The color of the engine lubrication oil
can NOT be used as an indication of the
need for a engine lubrication oil change.
The use of an engine lubrication oil
analysis service is the ONLY
alternate reason for not following the
required engine lubrication oil change
schedule.
WARNING: Do NOT change the engine

lubrication oil when the engine
and lubrication oil are HOT.
Change when WARM ONLY. Hot oil
can cause serious injury.
CAUTION: Do NOT change the engine

lubrication oil with the engine
running.
Serious engine damage, or failure
WILL occur.
Clean the area around the engine
lubrication oil dipstick and oil filler
cap BEFORE removing the dipstick,
or oil filler cap.
f. Fill the engine to the CORRECT oil level, with

the CORRECT engine lubrication oil.
NOTE: See THIS section for the CORRECT

amount of lubrication oil. For the
CORRECT type of lubrication oil see the
current OPERATION AND
MAINTENANCE MANUAL - B SERIES
DIESEL ENGINE published by Cummins
Engine Company Incorporated, which is
g. Wash the oil filler cap with All-Purpose degreaser cleaner, Part Number 178297, and dry with
compressed air. Install the oil filler cap and the
engine lubrication oil dipstick.
CAUTION: Do NOT start the engine BEFORE

changing the engine lubrication
oil filter. Follow the procedures given
in THIS section and in the current
Cummins ENGINE Operation and
Maintenance Manual.
With the engine STOPPED, and WARM engine

lubrication oil, proceed as follows:
a. Clean the area around the engine lubrication oil
drain plug found on the lower side of the frame
cross member [see Figure 4-4].
b. Place a container, having a capacity greater
than 10.0 qts. [9.5 L], directly under the engine
lubrication oil drain plug.
c. CAREFULLY remove the engine lubrication oil
drain plug.
d. Drain ALL of the engine lubrication oil into the
container.
e. Clean, install and CAREFULLY tighten the
lubrication oil drain plug.
CAUTION: Do NOT overtighten the drain

plug.
4-14
DRAIN PLUG
FIGURE 4-4. CUMMINS DIESEL ENGINE LUBRICATION OIL DRAIN PLUG LOCATION.
8/02
Section 4
MAINTENANCE
CHANGING THE ENGINE LUBRICATION OIL
FILTER [See Figure 4-5].
f. Install the NEW filter element onto the filter head.

Carefully tighten the filter element, by the hand
only.
The engine lubrication oil filter MUST be changed

when the engine lubrication oil is changed.
WARNING: Do NOT change the engine

lubrication oil filter when the engine
and lubrication oil are HOT. Change
the filter when WARM only.
Hot oil can cause serious injury.
CAUTION: Do NOT change the engine

lubrication oil filter with the engine
running. Serious engine damage, or
failure, WILL occur.
With the engine STOPPED and filled with NEW

engine lubrication oil, proceed as follows:
a. Wipe the area around the engine lubrication oil
filter element and its mounting base, with a CLEAN
cloth.
NOTE: Tighten the filter element as

directed on the filter element, by
the filter manufacturer.
CAUTION: Do NOT overtighten the lubrication

oil filter element onto the filter head.
Follow ALL engine lubrication oil
change and fill procedures, given in
THIS section, and in the ENGINE
Operation and Maintenance Manual
BEFORE the engine is started.
NOTE: CHECK the engine lubrication oil

level at THIS time.
g. Start the engine. Check to be sure there are NO

oil leaks and that the engine oil pressure gauge
indicates that the engine has the CORRECT
lubrication oil pressure.
b. Place a container under the filter element.

c. Use a filter removal wrench to loosen and
remove the filter element by turning it in a COUNTERCLOCKWISE direction of rotation. Drain and
discard the removed filter element.
CAUTION: STOP the engine IMMEDIATELY if

INCORRECT OIL pressure is
indicated or any oil leaks are seen.
CORRECT any problem noted
BEFORE starting the engine again.
CAUTION: Be sure the used rubber gasket

is REMOVED and discarded with
the filter element.
d. Wipe the inside area of the lubrication oil filter

head using a CLEAN lint free cloth.
e. Put CLEAN engine lubrication oil on the rubber
gasket area of the NEW filter element. Fill the NEW
filter element with CORRECT, NEW and CLEAN oil.
8/02
4-15
Section 4
MAINTENANCE
DOOR
OIL FILTER
CAP
FIGURE 4-5. CUMMINS DIESEL ENGINE LUBRICATION OIL FILTER LOCATION.
FIGURE 4-6. FUEL TANK FILL

LOCATION AND CAP.
FUEL SYSTEM.
ENGINE FUEL FILTERS [See Figure 4-7].
FUEL TANK [See Figure 4-6].
The fuel strainer [PRIMARY] and the fuel filter

[SECONDARY] elements MUST be replaced as
directed in the current engine Operation and
Maintenance Manual, published by Cummins
Engine Company Incorporated and supplied with
the machine.
The fuel gauge indicates the amount of fuel in the

tank. CHECK the amount indicated on the gauge
ONE [1] time EACH day. Fill the fuel tank FULL,
as the gauge indicates needed. ALSO fill the tank,
to FULL, BEFORE the machine is stored for the
night to reduce the accumulation of moisture, in the
tank, from condensation.
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
CAUTION: Drain the PRIMARY fuel strainer

lower bowl of ALL water one [1]
time EACH day, or as needed.
Replace the fuel strainer and/or fuel filter elements

using the following GENERAL procedures and
very specific information given in the current engine
Operation and Maintenance Manual, published by
Cummins Engine Company Incorporated and
8/02
Section 4
MAINTENANCE
WARNING: DIESEL FUEL IS VERY FLAMMABLE.
USE EXTRA CAUTION.
Do NOT change the fuel strainer or
fuel filter element in an area near
open flame.
Do NOT change the fuel strainer
or fuel filter element with the
machine running.
Do NOT smoke while changing the
fuel strainer or fuel filter element.
Do NOT spill fuel.
FUEL STRAINER ELEMENT
WATER DRAIN
e. Wipe the inside area of the filter head with a

CLEAN lint free cloth. Fill the NEW fuel strainer
or fuel filter element COMPLETELY FULL of the
CORRECT and CLEAN fuel. Put CLEAN fuel on the
element rubber gasket.
f. Install the NEW fuel strainer or fuel filter
element onto the filter head. CAREFULLY tighten
the element by hand ONLY.
CAUTION: Tighten the fuel strainer or the fuel

filter element as directed on the
filter element, by the filter
manufacturer.
Do NOT overtighten the fuel strainer
or fuel filter element onto the filter
head.
g. Start the engine and check for ANY fuel leaks.
WARNING: STOP the engine IMMEDIATELY if

ANY fuel leakage is noted.
Do NOT start the engine UNTIL
the leakage problem is
CORRECTED.
FUEL FILTER ELEMENT
FIGURE 4-7. FUEL STRAINER AND FUEL FILTER

LOCATIONS - CUMMINS DIESEL ENGINE.
a. STOP the engine.

b. Put a container under the fuel strainer or the
fuel filter, BEFORE removing EITHER filter element.
c. Wipe the area around the fuel strainer or the
fuel filter element and the element mounting head,
using a CLEAN lint free cloth.
d. Use a filter removal wrench to loosen and
remove the element, by turning the element in a
COUNTERCLOCKWISE direction. Drain and
discard the removed element.
8/02
PRIMING AND AIR REMOVAL [BLEEDING]

FROM THE FUEL SYSTEM - CUMMINS DIESEL
ENGINE [See Figure 4-8].
Use the following general procedures to prime, start
and remove [bleed] the air from the fuel system of a
CUMMINS diesel engine which has been run out of
fuel:
NOTE: Small amounts of air will be vented from

the system automatically, if the filters
were changed using the CORRECT
procedures given in THIS section. Air
removal [bleeding] will be required if the
fuel strainer and/or filter elements were
NOT correctly filled with fuel BEFORE
installation.
4-17
Section 4
MAINTENANCE
CAUTION: For very specific information, see the
current engine Operation and
Maintenance Manual supplied with
the machine.
a. Add at LEAST ten [10] gallons [38 liters] of the

CORRECT, CLEAN fuel to the fuel tank.
b. Remove the air from the LOW pressure fuel
lines and the fuel strainer and filter by opening the
air bleed screw, found at the top of the fuel filter
[see the Cummins "Operation and Maintenance
Manual"].
c. Operate the priming button on the fuel lift pump
UNTIL the flow of fuel from the bleed screw fitting is
continuous and FREE of air bubbles [see figure
4-8].
d. COMPLETELY tighten the air bleed screw and
stop the operation of the lift pump priming button.
e. Crank the engine to vent air trapped in the fuel
system [see the Cummins "Operation and
Maintenance Manual"].
f. Venting is done by loosening one, or more, fuel

supply line to injector retaining nut[s] a SMALL
amount, ONE [1] at a time. Crank the engine and let
the fuel flow from the line UNTIL there is NO
indication of air bubbles present at ANY line connection point. Use the wrench to tighten the loosened fuel supply line nut[s] at the injector fitting[s]
[see the Cummins "Operation and Maintenance
Manual"].
WARNING: It is necessary to keep the engine

fuel system in the "RUN" condition
to vent air. Because the engine may
start, be sure to follow ALL safety
precautions.
KEEP the hands and body AWAY
from the injector fittings and nuts.
Fuel under HIGH pressure
can penetrate the skin. Wear safety
glasses to protect the eyes. Get
IMMEDIATE medical attention if fuel
enters the eyes or skin.
Do NOT remove the air from the fuel
supply lines IF the engine is HOT.
Fuel leaked on the HOT exhaust
manifold can create a danger of fire.
FUEL SUPPLY NUT
PRIMING
BUTTON
HAND LEVER
FIGURE 4-8. FUEL PRIMING AND AIR REMOVAL LOCATIONS.
4-18
8/02
Section 4
MAINTENANCE
b. Remove the wing nut and baffle assembly from
inside the air cleaner body.
ENGINE AIR FILTRATION.

AIR CLEANER [See Figure 4-9].
c. Remove the air filter element from inside the air

cleaner body and DISCARD.
The engine inlet air cleaner assembly uses a

replaceable filter element.
CHECK the engine inlet air restriction indicator light
DAILY. If the restriction indicator light is ON, the
air cleaner filter element MUST be removed and
replaced IMMEDIATELY.
CAUTION: The air cleaner filter element should

be replaced ONE [1] time for EACH
1,000 hours of machine operation, or
yearly, for a machine which is
operated under normal conditions,
or ONE [1] time for EACH 500 hours
of machine operation, or every six
[6] months, for a machine which is
operated under very dusty or
severe conditions. Never operate
the engine without an air cleaner
element installed.
Do NOT service the air cleaner
element while the engine is
running.
Use the following procedures to service the air

cleaner element:
a. Loosen the band clamp which holds the end cup
assembly onto the air cleaner body. Remove the end
cup from the air cleaner body.
BAND CLAMP
d. Clean the inside of the air cleaner body with a

clean cloth.
e. Inspect the hose clamps for tightness and the
condition of the tube from the air filter to the engine
intake manifold.
CAUTION: Severe engine damage can occur

if hose clamps are in a loose
condition or if the tube is damaged.
f. CAREFULLY install the NEW air filter element

into the air cleaner body assembly.
g. Install the baffle assembly over the end of the
air filter element. Install and tighten the wing nut,
which holds the baffle assembly and air filter
element into the air cleaner body assembly.
h. Install the air cleaner end cap onto the air
cleaner body. Tighten the band clamp securely.
i. 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.
BAFFLE
ASSEMBLY
END CAP
ELEMENT
FILTER BODY
ASSEMBLY
WING NUT
WING BOLT
O-RING
VACUATOR
VALVE
FIGURE 4-9. AIR CLEANER ASSEMBLY - EXPLODED VIEW.

8/02
4-19
Section 4
MAINTENANCE
COOLING SYSTEM.
RADIATOR AND HYDRAULIC OIL COOLER [See
Figure 4-10].
WARNING: Do NOT check the system coolant

level, or ANY component, with the
engine running. Serious injury can
result from being caught or struck
by the fan, belt or moving engine
parts.
Do NOT check the system coolant
level, or ANY component, when the
system is at operating temperature
and the coolant is under pressure.
HOT coolant, under pressure, can
cause serious injury.
Check the coolant level ONLY when
the radiator filler cap is cool enough
to touch with the hand. Remove the
radiator filler cap SLOWLY.
CHECK the system coolant level ONE [1] time for

EACH eight [8] hours of machine operation, or daily.
Drain, flush and fill the cooling system, with NEW
coolant, ONE [1] time for EACH 1,000 hours of
machine operation, or yearly, [see THIS section for
general procedures].
Keep the coolant level ONE [1] inch [25.4 mm]
BELOW the radiator filler neck, when the cooling
system is cool. Fill the radiator ONLY when the
system is COOL. Fill the radiator as needed, using a
50/50 % [approximate] mixture of ethylene glycol
type antifreeze and CLEAN water on initial fill. Add
CLEAN water when the level is LOW.
CHECK the radiator cap gasket EACH time the
radiator cap is removed from the radiator. The
radiator cap gasket MUST seal on the radiator filler
neck surface. If the rubber face of the cap valve is
damaged, or cracked, REPLACE the radiator cap
IMMEDIATELY with a NEW cap of the SAME
pressure rating.
CHECK the radiator overflow tube for restriction, or
damage. A restricted, or damaged, overflow tube
can prevent the radiator cap from releasing extra
system pressure and system failure can occur.
4-20
With the engine STOPPED, inspect the radiator and

the hydraulic oil cooler cooling fin area EACH time
the system coolant level is checked. Use a bright
light placed on the INSIDE of the radiator fin area.
Light MUST be clearly seen, when looking through
the radiator and hydraulic oil cooler fin area FROM
the outside of the fin area.
WARNING: The engine MUST be STOPPED

BEFORE checking, or cleaning, the
radiator or hydraulic oil cooler fin
areas. Serious injury can result from
being caught or struck by the fan,
belt or moving engine parts.
NOTE: If a restricted fin condition is noted in

EITHER the radiator, or the hydraulic oil
cooler fin area, CLEAN the fin area using
LOW pressure compressed air.
WARNING: The compressed air supply MUST

have a pressure BELOW 30 psi.
[2 bar]. Wear safety glasses and
protective clothing.
CAUTION: Do NOT damage the radiator, or

hydraulic oil cooler, cooling fins
during cleaning. Clean the fin areas
with the compressed air blown in the
OPPOSITE direction of normal air
flow during operation. Bent cooling
fins can be CAREFULLY
straightened. 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 BOTH the
radiator and hydraulic oil cooler in
the direction 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 radiator
or hydraulic oil cooler deterioration
can occur.
8/02
Section 4
MAINTENANCE
WARNING: Wear safety glasses and protective
clothing during the steam cleaning
operation. Use ONLY CORRECT
steam cleaning procedures.
WARNING: Do NOT check, or remove, ANY

radiator hose with the engine
running. Serious injury can result
from being caught, or struck, by the
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.
OIL COOLER
WATER PUMP.
DRAIN COCK
Visually CHECK the engine water pump for leaks, or

other damage, after EACH 50 hours of machine
operation.
RADIATOR
FIGURE 4-10. RADIATOR AND

HYDRAULIC OIL COOLER LOCATIONS.
RADIATOR HOSES.
CHECK the radiator hoses at least ONE [1] time
EACH year for cracks, increased size, softening or
hardening.
Drain the cooling system of coolant [see THIS
section] and COMPLETELY remove EACH radiator
hose. CHECK the INSIDE area of the hose for
damage. Install the hose, again, if found to be
acceptable, or replace with NEW if found to be
damaged.
CAUTION: Visual inspection of the outside of

the hose is NOT adequate. A hose
can have damage on the inside and
look acceptable from the outside.
The hose must NOT be hard, or have
ANY restrictions.
Water pump leaks can allow air to be pulled into

the cooling system. Air in the cooling system can
cause the cooling system to operate in a HOT
condition. Replace the water pump IMMEDIATELY
if a leak, or other damage is noted.
WARNING: Do NOT check, or remove, the water

pump with the engine running.
Serious injury can result from being
caught or struck by the fan, belt or
moving engine parts.
Do NOT remove the water pump
while the cooling system is HOT.
Remove and replace the water pump
ONLY after draining the cooling
system of coolant [see THIS section]
when it is COOL.
DRAINING, FLUSHING AND FILLING THE

COOLING SYSTEM [See Figures 4-10, 4-11,
4-12].
CAUTION: For additional specific information,

use the current CUMMINS engine
Operation And Maintenance
Manual, supplied with the machine.
Rust in the radiator, or coolant, indicates that the

coolant anticorrosion additives are no longer
effective.
8/02
4-21
Section 4
MAINTENANCE
To help prevent severe cooling system damage;
drain, flush and fill the system with NEW coolant,
ONE [1] time for EACH 1,000 hours of machine
operation, or yearly.
WARNING: Do NOT drain, or flush, the cooling

system with the engine running.
caught or struck by the fan, belt or
Do NOT drain the cooling system
while the system is HOT and is
under pressure. Drain the system
when COOL ONLY. Hot coolant can
cause serious injury.
Use the following general procedures to drain, flush

and fill the engine cooling system:
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.
c. Remove the thermostat housing and the

thermostat from the engine. Inspect the thermostat
for corrosion, or damage. Test the thermostat for
CORRECT operation at the specified opening
temperature. Replace the thermostat, with NEW, if
found to be damaged. Install the thermostat, AFTER
flushing, ONLY.
NOTE: BEFORE cooling system flushing,

the thermostat MUST be removed. If
the thermostat is NOT removed, the
flushing procedure WILL close the
thermostat and prevent complete
engine block flushing.
Do NOT install the radiator hoses,
or thermostat, at THIS time.
d. Remove ALL engine and aftercooler drain

plugs. COMPLETELY drain the coolant from the
engine and aftercooler. Install ALL drain plugs into
the engine and aftercooler. Tighten the drain plugs
by hand ONLY, at THIS time.
e. Install ONLY the thermostat HOUSING
[NO thermostat] onto the engine. Reverse flush the
ENGINE BLOCK as shown in figure 4-11. Remove
ALL engine and aftercooler drain plugs, again,
AFTER reverse flushing the engine block assembly.
COMPLETELY drain the engine block and the
aftercooler of water. Install ALL engine and aftercooler drain plugs. Tighten ALL drain plugs
securely, using a wrench.
f. Remove the thermostat housing from the
engine. Install the thermostat into the housing, in
the CORRECT position. Install the thermostat
housing to engine gasket. Install the thermostat
housing over the thermostat and onto the engine.
Install the retaining capscrews and tighten securely.
CAUTION: Do NOT start the engine while

reverse flushing the engine block or
the radiator assembly.
g. Reverse flush the RADIATOR assembly, as

shown in Figure 4-12. Loosen the radiator drain
cock, again, AFTER reverse flushing the radiator
assembly. COMPLETELY drain the radiator of
water. Close the radiator drain cock and tighten
securely.
h. Install BOTH the UPPER and the LOWER
radiator hoses onto BOTH the radiator and the
engine. Install ALL the clamps, onto the hoses, and
tighten them securely.
i. Fill the cooling system with coolant, through the
radiator filler neck, using a NEW 50/50 % [APPROXIMATE] mixture of ethylene glycol antifreeze
and CLEAN water [see THIS section].
4-22
8/02
Section 4
MAINTENANCE
NOTE: It is suggested that one [1] can
of cooling system conditioner,
with a rust inhibitor, also be
added to the coolant at THIS time.
CAP CLOSED
FLUSHING GUN
CLAMP
WATER
AIR
NEW HOSE
j. Start the engine and allow the NEW coolant

mixture to circulate through the cooling system.
Inspect the COMPLETE system for ANY coolant
leakage. STOP the engine IMMEDIATELY and
correct ANY leakage problem noted, BEFORE
further engine operation.
NEW HOSE
WARNING: KEEP CLEAR of ALL moving engine

parts when the engine is running.
caught, or struck, by the fan, belt or
k. STOP the engine. Allow the coolant to reach a

cool temperature and then fill the radiator, with the
CORRECT coolant mixture, to within ONE [1] inch
[25.4 mm] of the radiator filler neck. Install the
radiator cap and tighten.
CLAMP
FIGURE 4-12. REVERSE FLUSHING

PROCEDURE RADIATOR ASSEMBLY.
HYDRAULIC SYSTEM.
WATER
FLUSHING GUN
AIR
CLAMP
The transmission, steering and vibration systems

ALL use the SAME hydraulic oil reservoir and
hydraulic oil supply.
FIGURE 4-11. REVERSE FLUSHING

PROCEDURE ENGINE BLOCK.
8/02
4-23
Section 4
MAINTENANCE
CHECKING THE HYDRAULIC OIL LEVEL AND
ADDING HYDRAULIC OIL TO THE HYDRAULIC
OIL RESERVOIR [See Figure 4-13].
CHECK the hydraulic reservoir oil level, ONE [1]
time EACH day, using the sight gauge on the
reservoir. Check the oil level when the hydraulic oil
is at NORMAL operating temperature ONLY.
WARNING: Do NOT loosen, or remove, the

hydraulic oil reservoir filler cap
when the hydraulic oil is HOT.
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.
CAUTION: Do NOT over fill the hydraulic oil

reservoir.
Do NOT use unfiltered hydraulic oil.
The NEW hydraulic oil MUST be
filtered through TEN [10] micron
filtration BEFORE it enters the
hydraulic oil reservoir. The oil must
NOT have more than 400 particles
larger than 10 u. per milliliter as
installed.
KEEP the oil level of the hydraulic
oil reservoir, at the CORRECT
level. An air space is designed
into the hydraulic oil reservoir and
allows for oil expansion, at warm
temperatures. The hydraulic oil
reservoir WILL have a low pressure
in it at system operating
temperatures.
Do NOT add a vent hole to the
hydraulic oil reservoir.
4-24
FILL CAP
SIGHT
GAUGE
RESERVOIR
FIGURE 4-13. HYDRAULIC OIL RESERVOIR AND

SIGHT GAUGE.
CHANGING THE HYDRAULIC OIL [See Figure

4-14].
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.
8/02
Section 4
MAINTENANCE
Changing the hydraulic oil removes the
accumulation of dirt, water and mechanical wear
particles from the hydraulic oil reservoir and system.
The chemical structure of the hydraulic oil also
changes after continuous use in the system and
NEW, CLEAN and FILTERED oil is a MUST to help
insure further CORRECT operation of the hydraulic
system.
CAUTION: Hydraulic oil which has oxidized or

which contains contamination, of
ANY type, can shorten the expected
service life of ANY, or ALL, of the
components in the hydraulic system.
Use the following procedures to change the

hydraulic oil:
a. STOP the engine. Allow the hydraulic oil to
cool, until it is at a WARM temperature ONLY.
SLOWLY loosen, and then remove, the hydraulic oil
reservoir filler cap. Put a CLEAN, lint free cloth
over the reservoir fill tube opening and secure in
place with tape.
WARNING: Do NOT drain the hydraulic oil from

the reservoir when it is HOT.
HOT hydraulic oil can cause serious
injury. Drain at a WARM temperature
ONLY.
b. Loosen the hydraulic oil drain plug. Place a
funnel, which has been altered by cutting the funnel
to fit under the drain plug, under the drain plug. Put
one end of a hose onto the funnel and put the other
end of the hose into an empty container having a
capacity of approximately 25 gallons [95 liters].
c. Carefully remove the reservoir drain plug. Allow
ALL of the hydraulic oil to drain from the reservoir
and into the container.
CAUTION: Do NOT fill the hydraulic oil reservoir

with NEW hydraulic oil UNTIL the
filter element, and screens in the
ABOVE NOTE, have been serviced.
d. Install the hydraulic oil reservoir drain plug and

tighten securely.
e. CAREFULLY remove the cloth from the
hydraulic oil reservoir fill tube opening.
f. Fill the hydraulic oil reservoir with the CORRECT, FILTERED hydraulic oil using the procedures given in the following CAUTION information.
See THIS section for CORRECT type of oil.
CAUTION: Do NOT use unfiltered hydraulic

oil. The NEW hydraulic oil MUST be
filtered through TEN [10] micron
filtration BEFORE it enters the
hydraulic oil reservoir. The oil MUST
NOT have MORE than 400 particles
larger than 10 u. per milliliter of oil as
installed. Fill the hydraulic oil
reservoir UNTIL the oil level is in the
CENTER of the sight gauge glass.
Do NOT overfill the hydraulic oil
reservoir with oil.
g. Check the oil level in the hydraulic oil reservoir,

again. Add oil if needed.
h. Install the hydraulic oil reservoir filler cap onto
the reservoir filler neck and tighten securely.
i. Start the engine using the CORRECT procedures given in Section 3 - OPERATION - of THIS
manual. CHECK the hydraulic system for ANY
leaks. Install the vibrator control valve access panel
onto the machine and tighten the retaining
capscrews securely.
NOTE: Also, CHANGE the VIBRATION systems,

and the TRANSMISSION system,
hydraulic PRESSURE oil filter elements
at THIS time.
Also, CLEAN the TWO [2] hydraulic
suction oil screens and the ONE [1]
return oil diffuser, found in the hydraulic
reservoir. See THIS section for service
procedures, on these items.
8/02
4-25
Section 4
MAINTENANCE
WARNING: Do NOT use the 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: The hydraulic system MUST be at

NORMAL operating temperature,
with the engine running, when the
condition of the filter element is
checked. With the engine at HIGH
idle, and when the filter condition
indicator WHITE sliding bar is in the
RED zone, an element CHANGE is
indicated to be needed.

ANY hydraulic leak is noted.
Do NOT start the engine UNTIL any
problem noted has been corrected.
NOTE: When the hydraulic oil is in a COLD

condition and at machine START UP,
the filter condition indicator WHITE
sliding bar will show a HIGHER amount
of filter element restriction. The filter
element MUST also be changed with
EACH COMPLETE hydraulic oil change.

hydraulic oil filter
element when the engine is running,
or when the hydraulic oil is HOT.
Loosen, and remove, the filter
element ONLY when the engine is in
an STOPPED and the hydraulic
oil has cooled to a WARM, or COLD,
temperature.
FIGURE 4-14. HYDRAULIC OIL RESERVOIR

DRAINING LOCATION..
Use the following procedure to remove and replace

the hydraulic oil filter element:
reach a WARM, or COOL, temperature.
VIBRATION SYSTEMS PRESSURE OIL FILTER

ELEMENT - REMOVAL AND REPLACEMENT
[See Figure 4-15].
b. Remove the access panel retaining capscrews

and panel. Wipe the hydraulic oil filter head and
element using a CLEAN lint free cloth.
CHECK the condition of the vibration systems

pressure oil filter element EACH day. The filter
element MUST be changed when the condition
indicator light, found on the dash of the machine,
and the change indicator, found on the filter head,
indicate an element change is needed.
c. Use a oil filter removal wrench to loosen and

remove the filter element. Discard the removed filter
element.
4-26
CAUTION: Be sure that the old filter element

rubber gasket is removed and
discarded, BEFORE the NEW filter
element is Installed.
8/02
Section 4
MAINTENANCE
d. Put CLEAN hydraulic oil on the NEW filter
h. Install the access panel onto the machine and

install, and then tighten, the retaining capscrews
securely.
e. CAREFULLY install the NEW filter element onto

the filter head. Tighten the NEW filter element onto
the filter head ONLY UNTIL the rubber gasket
contacts the filter head seal area. Tighten the NEW
filter element ONE HALF [1/2] additional turn
AFTER the rubber gasket contacts the filter head
area.
CAUTION: Do NOT overtighten the NEW filter

element. Tighten by the hand ONLY.
f. At this time, clean the two [2] hydraulic oil

suction strainers and the one [1] return oil diffuser,
using the procedures given in THIS section. Fill the
hydraulic oil reservoir with oil. Use ALL of the
CORRECT procedures given in THIS section.

filling the hydraulic oil reservoir with
oil. Damage to the hydraulic system
components can occur. Fill the
reservoir using ALL of the
procedures given in THIS section.
g. Start the engine using the CORRECT

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

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

ANY hydraulic oil leak is noted.
FIGURE 4-15. VIBRATION SYSTEMS PRESSURE OIL FILTER ELEMENT LOCATION.
TRANSMISSION SYSTEM PRESSURE OIL

FILTER ELEMENT - REMOVAL AND REPLACEMENT [See Figure 4-16].
The transmission system pressure oil filter
element MUST be changed when the hydraulic oil is
changed.

hydraulic oil filter
element when the engine is running,
or when the hydraulic oil is HOT.
Loosen, and remove, the filter
element ONLY when the engine is in
an STOPPED and the hydraulic
oil has cooled to a WARM, or COLD,
temperature.
NOTE: The filter head, and element, may be
found mounted in the vertical, horizontal,
or angled position. The position has NO
effect on filtration.
Use the following procedure to remove and replace
the oil filter element:
reach a WARM, or COOL, temperature.
b. Remove the access panel retaining capscrews
and panel. Wipe the hydraulic oil filter head and
element using a CLEAN lint free cloth.
8/02
4-27
Section 4
MAINTENANCE
c. Use a oil filter removal wrench to loosen and
remove the filter element. Discard the removed filter
element.

CAUTION: Be sure that the old filter element

rubber gasket is removed and
discarded, BEFORE the NEW filter
element is Installed.
h. Install the access panel onto the machine and

install, and then tighten, the retaining capscrews
securely.
d. Put CLEAN hydraulic oil on the NEW filter

e. CAREFULLY install the NEW filter element onto
the filter head. Tighten the NEW filter element onto
the filter head ONLY UNTIL the rubber gasket
contacts the filter head seal area. Tighten the NEW
filter element ONE HALF [1/2] additional turn
AFTER the rubber gasket contacts the filter head
area.
CAUTION: Do NOT overtighten the NEW filter

element. Tighten by the hand ONLY.
f. At this time, clean the two [2] hydraulic oil

suction strainers and the one [1] return oil diffuser,
using the procedures given in THIS section. Fill the
hydraulic oil reservoir with oil. Use ALL of the
CORRECT procedures given in THIS section.

filling the hydraulic oil reservoir with
oil. Damage to the hydraulic system
components can occur. Fill the
reservoir using ALL of the
procedures given in THIS section.
g. Start the engine using the CORRECT

oil leaks.

4-28
FIGURE 4-16. TRANSMISSION SYSTEM PRESSURE OIL FILTER ELEMENT LOCATION.

HYDRAULIC SUCTION OIL STRAINERS AND
RETURN OIL DIFFUSER - REMOVAL,
CLEANING AND INSTALLATION
[See Figure 4-17].
Remove, clean and reinstall the TWO [2] hydraulic
suction oil strainers and the ONE [1] hydraulic
return oil diffuser with EACH complete hydraulic oil
change.
Use the following procedures to remove, clean and
install the above items:

hydraulic suction oil strainers or the
hydraulic return oil diffuser, when
the engine is running or when the
hydraulic oil reservoir is full of oil.
Loosen, or remove, the hydraulic
suction oil strainers, or the return oil
diffuser, ONLY when the engine is
STOPPED and AFTER the
hydraulic oil has cooled and has
been DRAINED from the hydraulic
oil reservoir [see THIS section].
SERIOUS injury can occur from
contact with HOT hydraulic oil.
8/02
Section 4
MAINTENANCE
reach a WARM, or COOL, temperature. Drain the
hydraulic oil using the procedures given in THIS
section.
b. CLEAN ALL the hoses, fittings and the area of
the hydraulic oil reservoir where the hydraulic return
oil diffuser is installed, using All-Purpose Degreaser,
Part Number 178297.
c. Put an identification tag onto EACH suction
hose. Remove the suction hoses from the fittings
installed into the hydraulic suction oil strainers.
IMMEDIATELY put a plug into EACH strainer fitting
and a cap on EACH hose.
d. Remove the TWO [2] hydraulic suction oil
strainers from the hydraulic oil reservoir. Put a
CLEAN paper cover over each threaded strainer
boss, in the reservoir, and secure with tape.
e. Loosen and remove the one [1] return oil
diffuser from the hydraulic oil reservoir. Put a
CLEAN paper cover over the threaded diffuser
boss, in the reservoir, and secure with tape.
CAUTION: Do NOT lose, or damage, the o-ring

when each strainer and/or the
diffuser, is removed from the
reservoir. CAREFULLY inspect each
o-ring for damage and replace with
NEW, if needed.
f. CAREFULLY wash each suction oil strainer

and/or the return oil diffuser, using All-Purpose
Degreaser, Part Number 178297, and allow it to AIR
dry ONLY.
CAUTION: Do NOT use compressed air to

dry the strainer and/or diffuser, after
cleaning.
Damage can occur to the strainer, or
diffuser, mesh area if dried using
compressed air.
8/02
g. Remove the paper covers from the threaded

hydraulic suction oil strainer bosses and the return
oil diffuser boss, in the reservoir.
h. Put one [1] o-ring onto the threaded area of
each suction oil strainer and onto the threaded area
of the return oil diffuser.
i. CAREFULLY install each suction oil strainer into
the oil reservoir boss and tighten securely. CAREFULLY install the hydraulic return oil diffuser into the
hydraulic oil reservoir boss and tighten securely.
NOTE: Use the identification tags, installed on

EACH hose and fitting BEFORE removal,
as a reference for CORRECT
connections.
CAUTION: Complete ALL hydraulic oil reservoir

filling procedures, given in THIS
section, BEFORE starting the engine.
j. Start the engine using the CORRECT

oil leaks.


4-29
Section 4
MAINTENANCE
DIFFUSER
Use the following procedures to ADD lubrication oil

to either drum:
STRAINERS
1. SLOWLY move the machine and rotate the
drum, to a point where the FILLER hose bulkhead
fitting and LARGE cap fitting are in a position
ABOVE the center line of the drum rotation [approximately a 2 oclock or a 11 oclock positions].
2. Wipe the LARGE cap and the bulkhead fitting
of the filler hose with a CLEAN cloth. Remove the
LARGE [FILL] cap fitting from the filler hose
bulkhead fitting.
FIGURE 4-17. HYDRAULIC SUCTION

STRAINERS OIL AND RETURN OIL DIFFUSER
INSTALLATION LOCATIONS.
DRUM BEARING LUBRICATION

CHECKING THE DRUM BEARING LUBRICATION
OIL LEVEL [See Figure 4-18].
Check the drum bearing lubrication oil level of EACH
drum, one [1 ] time for each eight [8] hours of
machine operation, or daily.
Use the following procedures to check drum bearing
lubrication oil level, and to add lubrication oil if
needed:
a. Put the machine on a LEVEL surface, and in a
position, so the RED drum position Iocater BAR, on
the drum being checked, is at the exact BOTTOM of
the rotation of the drum.
CAUTION: If the lubrication oil level is BELOW

the sight gauge glass, ADD only
enough oil to show the CORRECT oil
level in the CENTER of the sight
gauge glass.
Do NOT add more oil immediately if
the lubrication oil level appears to
be below the sight gauge glass. Allow
enough time for the drum bearing
lubrication oil to level in the sight
gauge glass and indicate the true oil
level.
4-30
3. SLOWLY add CLEAN and FILTERED Texaco

Meropa 150, or equivalent, lubrication oil to the
drum, through the FILLER hose on the drum.
CAUTION: Clean the oil, being added to the

drum, through twenty five [25] micron
filtration BEFORE it enters the drum.
Add the oil to the drum SLOWLY.
Do NOT overfill the drum with
lubrication oil.
Add ONLY enough oil to bring the
drum oil level to the CENTER of the
sight gauge glass.
4. Install the LARGE [FILL] cap fitting onto the

filler hose bulkhead fitting and tighten securely.
b. Move the machine to the SAME position as in
step a and CHECK the oil level, AGAIN, using the
procedures given in step a.
CAUTION: If the oil level is NOT correct, ADD

additional oil using steps 1-4 and
then check the oil level, again.
c. Check the drum bearing lubrication oil level of

the SECOND drum, using the SAME procedures.
Add lubrication oil if needed.
8/02
Section 4
MAINTENANCE
CHANGING THE DRUM BEARING LUBRICATION
OIL [See Figure 4-18 or 4-18A].
CHANGING THE DRUM BEARING
LUBRICATION OIL - C766C machines below
serial number 109C20902455 and on C778B
machines below serial number 109B21501856
[See Figure 4-18].
i. Change the drum bearing lubrication oil in the

SECOND drum, using the SAME procedures given
ABOVE. Check the SECOND drum bearing
lubrication oil level, using the procedures given in
this section.
Change the drum bearing lubrication oil, in EACH

drum, one [1] time for each 2,000 hours of machine
operation, or every TWO [2] years.
Use the following procedures to change the drum
bearing lubrication oil in BOTH drums:
a. Run the machine long enough to insure that the
drum bearing lubrication oil is completely at a
WARM temperature.
b. Rotate the drum, having the lubrication oil
changed first, until the LARGE [FILL] cap fitting is
positioned at the LOWEST [BOTTOM] point of the
rotation of the drum. Wipe the area around the
LARGE [FILL] cap fitting with a CLEAN cloth.
POSITION LOCATOR BAR
FILL-DRAIN
c. Remove the LARGE [FILL] cap fitting from the

filler hose bulkhead fitting. Drain the drum bearing
lubrication oil from the drum.
d. Rotate the drum until the LARGE [FILL] cap
fitting is positioned at the HIGHEST [TOP] point of
the rotation of the drum.
e. SLOWLY fill the drum through the LARGE
[FILL] hose bulkhead fitting, using TEN [10] gallon
[37.9 liters] of CLEAN and FILTERED Texaco
Meropa 150, or equivalent, lubrication oil.
f. Wait two [2] minutes and then check the
lubrication oil level shown in the sight gauge glass.
The lubrication oil level MUST be in the CENTER of
the sight gauge glass to be at the CORRECT level.
CAUTION: Clean the oil, entering the drum,

through twenty five [25] micron
Fill with oil SLOWLY.
Do NOT overfill the drum with
lubrication oil. Fill the drum with
ONLY enough oil to bring the oil level
to the CENTER of the sight gauge
glass.
SIGHT GAUGE
g. Install the LARGE [FILL] cap fitting onto the

filler hose bulkhead fitting and tighten securely.
h. Check the drum bearing lubrication oil level,
using the procedures given in this section.
8/02
FIGURE 4-18. DRUM LUBRICATION OIL FILL

AND SIGHT GAUGE LOCATIONS.
4-31
Section 4
MAINTENANCE
CHANGING THE DRUM BEARING
LUBRICATION OIL - C766C machines serial
number 109C20902455 and higher and on
C778B machines serial number 109B21501856
and higher [See Figure 4-18A].
Change the drum bearing lubrication oil, in EACH
drum, one [1] time for each 2,000 hours of machine
operation, or every TWO [2] years.
Use the following procedures to change the drum
bearing lubrication oil in BOTH drums:
a. Run the machine long enough to ensure that the
drum bearing lubrication oil is completely at a
WARM temperature.
b. Rotate the drum having the lubrication oil
changed first, until the [DRAIN] cap fitting is
positioned at the LOWEST [BOTTOM] point of the
rotation of the drum. Wipe the area around the
[DRAIN] cap fitting with a CLEAN cloth.
c. Remove the [DRAIN] cap fitting from the drain

hose bulkhead fitting. Drain the drum bearing
lubrication oil from the drum.
NOTE: The fill hose can be opened during the

drain process to assist as a vent.
d. Rotate the drum until the [FILL] cap fitting
directly opposite the position location block, is at the
HIGHEST [TOP] point of the rotation of the drum.
Wipe the area around the LARGE [FILL] cap fitting
with a CLEAN cloth.
e. Install the [DRAIN] cap fitting onto the drain
hose bulkhead fitting and tighten securely.
f. Remove the [FILL] cap fitting and SLOWLY fill
the drum through the [FILL] hose bulkhead fitting,
using TEN [10] gallons [37.9 liters] of CLEAN and
FILTERED Texaco Meropa 150, or equivalent,
lubrication oil.
FIGURE 4-18A. DRUM LUBRICATION OIL DRAIN, FILL AND SIGHT GAUGE LOCATIONS.
4-32
8/02
Section 4
MAINTENANCE
g. Wait two [2] minutes and then check the
lubrication oil level shown in the sight gauge glass.
The lubrication oil level MUST be in the CENTER of
the sight gauge glass to be at the CORRECT level.
CAUTION: Clean the oil, entering the drum,

through twenty five [25] micron
Fill with oil SLOWLY. Do NOT overfill
the drum with lubrication oil. Fill the
drum with ONLY enough oil to bring
the oil level to the CENTER of the
sight gauge glass.
h. Install the [FILL] cap fitting onto the filler hose
bulkhead fitting and tighten securely.
NOTE: If the belt requires replacement with new,

also, see the current OPERATION AND
MAINTENANCE MANUAL - B SERIES
DIESEL 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.
WRENCH
TENSIONER
i. Check the drum bearing lubrication oil level,

using the procedures given in this section.
j. Change the drum bearing lubrication oil in the
SECOND drum, using the SAME procedures given
ABOVE. Check the SECOND drum bearing
lubrication oil level, using the procedures given in
this section.
ALTERNATOR
BELT
ALTERNATOR AND FAN DRIVE BELT INSPECTION AND REPLACEMENT

PROCEDURES [See Figure 4-19].
Inspect the drive belt one [1] time for each 1000
hours of machine operation, or yearly. Replace the
belt as needed, after inspection. The belt is kept
under constant tension by an automatic tension
mechanism and "adjustment" is NOT required as
part of the maintenance procedures.
Use the following information to inspect and/or
inspect and replace the drive belt:
a. STOP the engine.
WARNING: Do NOT inspect the engine drive belt

when the engine is running. The
engine MUST be STOPPED BEFORE
inspecting the drive belt. Serious
injury can result from being caught,
or struck, by the fan, belt or other
b. Visually inspect the drive belt for intersecting
cracks on the INNER surface of the belt plies.
Check the belt for intersecting cracks. 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.
8/02
FIGURE 4-19. ALTERNATOR AND FAN DRIVE

BELT LOCATION.
ELECTRICAL SYSTEM.
CHECKING THE CHARGE CONDITION OF
THE BATTERY AND SERVICING OF RELATED
ITEMS [See Figure 4-20].
The battery is of the maintenance-free type and
minimal service is needed. Use the built in battery
charge level indicator, found in the top of the
battery, to check the charge level in the battery one
[1 ] time for each 100 hours of machine operation,
or every two [2] weeks.
WARNING: CALIFORNIA Proposition 65.

Battery posts, terminals
and related accessories contain
lead and lead compounds. Wash
hands after handling.
4-33
Section 4
MAINTENANCE
WARNING: Do NOT attempt to open the
MAINTENANCE-FREE battery
case. The acid in electrolyte can
cause injury. If electrolyte is spilled,
use water to flush the area and
make the acid neutral using a water
and soda solution. Acid in the eyes
MUST be FLUSHED with water
IMMEDIATELY.
ALL batteries produce an
EXPLOSIVE GAS.
Do NOT smoke near a battery.
Do NOT check with flame.
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.
WARNING: BATTERY EXPLOSION CAN OCCUR

IF THE BATTERY IS SHORTED.
ALWAYS disconnect the NEGATIVE
[-] battery cable FIRST, and then
disconnect the POSITIVE [+] battery
cable, BEFORE cleaning the
terminals, or cables.
NEVER make a shorted circuit
between the positive [+] terminal
and negative [-] terminal of the
battery.
ALWAYS connect the POSITIVE [+]
battery cable to the POSITIVE
battery terminal FIRST, and then
connect the NEGATIVE [-] battery
cable to the NEGATIVE [-] battery
terminal LAST.
Do NOT place ANY tools on a
battery, at ANY time.
Check and tighten the battery hold down assembly.

The battery MUST be kept from ANY movement in
the machine.
4-34
FIGURE 4-20. BATTERY MAINTENANCE AREA

LOCATIONS.
ELECTRICAL WIRING INSPECTION.

During engine and/or other system maintenance
inspections, CHECK the electrical wiring for correct
routing and support. Inspect the wires for loose
terminal connections, cracks, or wear, in the wiring
insulation and for corrosion. Wires and connections
MUST be free of oil, dirt or grease.
CAUTION: Do NOT use a wire smaller than

the size of the original factory
installed wires in the electrical
system. If, due to wear or damage,
wires are replaced with new, use
wire EQUAL to, or larger in size than,
the wire being replaced.
WARNING: BATTERY EXPLOSION CAN OCCUR

IF A BATTERY IS SHORTED.
ALWAYS disconnect BOTH the
positive [+] AND the negative [-]
battery cables from a battery,
BEFORE ANY repair procedures are
done to the electrical wiring or
components.
NEVER make a shorted circuit
between the positive [+] terminal
and the negative [-] terminal of a
battery. Do NOT place ANY tools on
a battery, at ANY time.
8/02
Section 4
MAINTENANCE
VIBRATION ISOLATOR TIRES.
INSPECTION, AIR PRESSURE CHECK AND
ADJUSTMENT [See Figure 4-21].
VALVE STEM
CHECK-FILL
Check EACH vibration isolator tire for CORRECT air

pressure ONE [1] time EACH week.
Inspect EACH tire for cracks, breaks, or other
serious damage at THIS time.
CAUTION: Replace ANY tire showing evidence

of damage IMMEDIATELY.
Use the procedures given in THIS
section to remove, repair, or replace
the tire[s].
Check the air pressure of EACH tire, and adjust as

needed, using the following procedures:
a. Remove the tire valve cap from the tire inflation
valve. Check the inflation of EACH tire, using an
accurate tire gauge.
WARNING: ALWAYS use remote inflation

equipment consisting of an
extension hose, with the clip-on
filling chuck, and a gauge or preset
pressure regulator. When adding air
to the tires, ALL personnel MUST
keep CLEAR of the tire and rim.
8/02
FIGURE 4-21. VIBRATION ISOLATOR TIRE

PRESSURE CHECK AND FILL LOCATION.
CAUTION: Check the tire air pressure ONLY

when the vibration isolator tires are
in a COOL condition.
The pressure indicated, on the tire
pressure gauge, MUST be 30 psi.
[2 bar]. Adjust the air pressure in
EACH isolator tire, UNTIL the
pressure is CORRECT.
Do NOT over inflate the vibration
isolator tires. The vibration isolator
tires will NOT absorb enough
vibrations from the machines drums
and the vibrations will transfer into
the machine frames.
Do NOT under inflate the vibration
isolator tires. The vibration isolator
tires will be too soft and over deflect.
This can build excess heat, cause
tire breaks in the tire body cords and
cause the tire to slip inside the tire
retainer hoop assemblies.
ALWAYS install tire valve cap, onto
the tire valve stem, AFTER checking
and/or adjusting each vibration
isolator tire inflation pressure.
4-35
Section 4
MAINTENANCE
REMOVAL, REPAIR OR REPLACEMENT, AND
INSTALLATION OF THE VIBRATION ISOLATOR
TIRE AND RIM ASSEMBLIES [See Figure 4-22
or 4-22A].
TIRE AND RIM ASSEMBLIES - C766C machines
below serial number 109C20902455 and on
C778B machines below serial number
109B21501856 [See Figure 4-22].
Remove, repair, or replace, ANY vibration isolator
tire found to show evidence of an air leak, or other
serious damage, IMMEDIATELY, using the
following procedures:
WARNING: Keep CLEAR of the frame while

being lifted and lowered onto the
blocks. Block securely using solid
wood blocks, or solid support
items.
CAUTION: Do NOT place the wood blocks, so

that the drum will touch the blocks
as the drum is rolled forward and
from between the frame sides.
d. Put an identification tag on each hose fastened

to the vibrator motor. Remove each of the hoses
from the fittings on the motor. Put a plug in each
hose and a cap on each motor fitting.
REMOVAL [See Figure 4-22].

a. Place the machine on a level surface. APPLY
the secondary/parking brake system and STOP the
engine. Drain the water tank and disconnect the
water sprinkler bar supply hose on the drum being
serviced. Remove the drum cleaner bar.
b. Drain the water tank, found at the front of the
drum being removed, of water. Disconnect the
electrical connection to the water spray pump.
Fasten a sling and a hoist, having a capacity more
than 1,500 lbs. [681 kg] to the water tank frame.
Remove the capscrews that fasten the tank and
frame to the frame of the machine. Remove the tank
and frame assembly from the machine and place on
the ground.
WARNING: Keep clear of the water tank and

frame assembly while lifting,
removing and lowering the tank
assembly.
c. Put wood blocks in front, and at the rear, of the

drum NOT being serviced. Put a hydraulic jack,
having a capacity more than ten [5] tons [4t], under
either side of the frame outside the drum being
removed for vibration isolator tire removal and repair
or replacement. Raise the hydraulic jack ONLY until
the jack lifting plate JUST starts to lift frame weight.
Put wood blocks, or jack stands, under the side of
the frame. Lower the frame onto the support item
and remove the hydraulic jack. Lift the OPPOSITE
frame side and put wood blocks under the frame
side using the SAME procedures given in this step.
4-36
CAUTION: Do NOT damage the hoses when

moving the vibrator motor.
e. Loosen and remove the two [2] capscrews and

hardened discs which secure the vibrator drive
motor. Carefully remove the vibrator drive motor
assembly.
f. The vibrator drive motor assembly will have a
three [3] pin hub assembly attached to it by two [2]
allen setscrews and a capscrew and washer at the
motor output shaft.
g. Put an identification tag on each hose which
fastens to the drum drive motor. Remove each of the
hoses from the fittings on the motor. Put a plug in
each hose and a cap on each motor fitting.
h. Put one [1] hydraulic floor jack, having a
capacity MORE than 5 tons [4 t], under EACH frame
side. Raise each hydraulic jack ONLY until the jack
lifting plate JUST starts to lift frame weight. Remove
the capscrews that fasten the outer cleaner beam
and rubber cleaner assembly to the machine.
Remove the cleaner assembly from the machine.
Carefully remove the eight [8] nuts from the capscrews which fasten the drum isolator assemblies
the drum drive motor to the sides of the frame.
Carefully remove the eight [8] capscrews from each
side of the frame.
8/02
Section 4
MAINTENANCE
HALF HOOP
TORQUE TO 40 FT/LBS
ADAPTER
COUPLING
DRUM DRIVE SIDE
RIM ASSEMBLY
DRIVE MOTOR
FRAME
FILL VALVE
CAP
ISOLATOR TIRE ASSEMBLY
HALF HOOP
TORQUE TO 125 FT/LBS

DRUM
CAPSCREWS
CAP
SCREW
TORQUE TO
400 FT/LBS
(LUG NUTS)
FLANGE SCREW
LOCKNUT
COVER
BEARING
CARRIER
FLANGE
SCREW
TORQUE
TO 44 FT/
LBS
TORQUE TO
44 FT/LBS
PIN
BEARING
CONTROL
PL.
SHAFT
BEARING
CARRIER ASS'Y
SPACER
CAP
TORQUE TO 78 FT/LBS
ISOLATION TIRE ASSEMBLY
AXLE
FAN
CAPSCREWS
COUPLING
SPRING
WEIGHT
FITTING
DRAIN FILL HOSE
TORQUE TO 55 FT/LBS
WASHERS
VIEW GAUGE
PLUG
PLATE
FLANGE SCREW
FLANGE SCREWS
DRUM
VIBRATOR MOTOR SIDE
DRUM MOUNTING SPACER
CAP SCREWS
FILL VALVE
BEARING
SNAP RING
BEARING SUPPORT HOUSING

BEARING SUPPORT HOUSING
CL
VIBRATION MOTOR MOUNTING PLATE

TORQUE TO 44 FT/LBS
CAPS SCREWS
RIM ASSEMBLY
CAPS SCREWS
FIGURE 4-22. FRAME, DRUM, VIBRATION ISOLATOR TIRE AND RIM - SECTIONED VIEW.
4-37
8/02
Section 4
MAINTENANCE
NOTE: Removing the eight [8] capscrews from
each side of the frame will permit the
drum assembly, with both vibration
isolator tire, rim and hoop assemblies
and the drum drive motor, to be removed
from between the frame sides by rolling
the assembly toward the open end of the
machine.
i. CAREFULLY and SLOWLY roll the complete
drum assembly toward the open end of the machine
until the drum is fully away from the frame sides.
WARNING: Keep CLEAR of the drum to frame

areas while rolling the drum toward
the open end of the machine. Put
wood blocks in front, and at the rear,
of the drum AFTER the drum is
removed.
NOTE: With the drum removed from the

machine, remove the complete vibration
isolator tire and hoop assembly being
repaired, from the drum.
j. Fasten a sling and a hoist, having a capacity

more than 1,000 lbs. [454 kg], to the complete
vibration isolator assembly which is being removed,
in order to repair or replace the tire. Remove ALL
slack in the sling but do NOT lift the vibration
isolator assembly, at this time.
k. Use a wrench, having a capacity MORE than
300 ft. Ibs. [407 N.m], to remove the capscrews
which fasten the tire rim to the flange of the vibrator
bell housing. SLOWLY move the tire rim and
vibration isolator assembly outward and away from
the flange, while lifting the assembly with the sling
and hoist, a SMALL amount. CAREFULLY move the
assembly away from the drum and place the
assembly on the ground.
WARNING: Keep CLEAR of the vibration isolator

assembly while loosening the
retaining capscrews which fasten
the assembly to the drum, or motor,
and while moving the vibration
isolator assembly away from the
drum and then lowering the
assembly to the ground.
4-38
NOTE: On the drum drive side of the machine,

the drum drive motor and vibration
isolator are removed as an assembly.
l. Remove the valve cap from the vibration isolator

tire filling valve stem. CAREFULLY remove the valve
core from the tire filling valve stem and exhaust ALL
the air from the vibration isolator tire assembly, if
inflated.
WARNING: Keep CLEAR of the air path as the

air is released from the tire
assembly.
NOTE: Check the valve stem to be sure the

inside is NOT in a plugged condition, by
putting a wire through the center hole in
the valve stem.
m. Remove the four [4] nuts, from the bolts, which

fasten the upper half hoop to the drum isolator
mounting bracket or drum drive motor to frame
mounting bracket. Remove the six [6] nuts, from the
bolts which fasten the upper and lower half hoop
assemblies together around the tire and rim.
CAREFULLY lift and remove the UPPER half hoop
assembly from the tire and set the half hoop on the
ground.
n. Fasten a sling and a hoist, having a capacity
more than 300 lbs. [136 kg], to the tire and rim
assembly. CAREFULLY move and lower the tire
and rim assembly onto a tire repair machine.
WARNING: Keep CLEAR of the tire and rim

assembly while being lifted and
moved.
TIRE REMOVAL, REPAIR OR REPLACEMENT

AND INSTALLATION ONTO THE RIM [See
Figure 4-22].
a. Fasten the tire and rim assembly securely to
the tire repair machine, so that the assembly will
NOT move when the tubeless tire beads are broken
loose from the rim bead seat area.
8/02
Section 4
MAINTENANCE
b. Break the UPPER tire bead away from the rim
using a bead breaking tool. Move the tire UPPER
bead over and above, the UPPER rim bead seat
area, using the machine tire bead spreader bar.
CAREFULLY lift the tire assembly, a SMALL
amount, at the SAME time.
e. Carefully inspect the rim assembly for ANY

cracks, severe rusting, or other damage in the bead
seat area. Clean, sand to new metal, prime and
finish paint the rim assembly BEFORE mounting the
tire. Install a new tire filling valve, if the valve shows
ANY damage.
WARNING: Use a sling and a hoist, having a

capacity more than 100 lbs. [46 kg],
to lift and move the tire during
removal and replacement onto the
rim. Keep CLEAR of the bead
breaking tool and the bead
spreader bar while breaking and
removing BOTH tire beads from the
rim upper bead seat area.
WARNING: Do NOT weld, heat or braze the rim

assembly. Replace the rim assembly
with NEW, if damaged.
c. CAREFULLY lift the LOWER tire bead toward

the UPPER rim bead seat area and put the bead
spreader bar assembly between the LOWER tire
bead and the UPPER rim bead seat area. Move the
bead spreader bar around the tire bead and remove
the tire bead over and above the UPPER rim bead
seat area. CAREFULLY lift the tire away from the
rim assembly for tire inspection, repair, or replacement as needed.
d. Inspect the tire from BOTH the OUTSIDE and
the INSIDE of the tire for punctures, cuts, breaks or
other damage. Wipe the inside of the tire with a
clean cloth to remove any dirt, or moisture. Repair
the tire as needed using tire repair materials which
repair the damaged area from the INSIDE of the
tire.
CAUTION: The isolator tires are of radial ply

design. Use ONLY tire repair
materials and procedures for radial
type tires. Replace the tire if ANY tire
damage is found that is NOT able to
be repaired using INSIDE tire carcass
repair methods and materials. The
repair materials used MUST seal the
INNER tire carcass and fill the tire
injury, to be considered an adequate
and permanent repair.
8/02
f. Put the rim assembly on the tire machine and

fasten securely in place. Put water, or nonflammable tire mounting lubricant, on BOTH the UPPER
and LOWER bead seat areas, of the rim assembly,
and on BOTH the UPPER and LOWER bead
sealing areas of the tire.
g. Carefully lift the tire above the rim assembly,
using a sling and hoist. SLOWLY lower the tire to
the rim assembly. Tilt the tire a SMALL amount as
the LOWER bead reaches the UPPER rim bead
seat, of the rim assembly. Push the LOWER bead
past the UPPER rim bead seat and continue to
lower the tire downward. Pull the tire back as far as
possible as the LOWER bead reaches the LOWER
bead seat area of the rim assembly, and as the
LOWER tire bead is also partially caught on the
UPPER rim bead seat.
h. Use the tire bead installing tool to install the
balance of the LOWER tire bead over the UPPER
rim bead seat and lower the tire to the LOWER
bead seat area of the rim assembly.
i. Push the UPPER tire bead downward and over
the UPPER bead seat area of the rim assembly, as
much as possible. Pull back on the UPPER tire
bead and use the tire bead installing tool to install
the balance of the UPPER tire bead over the
UPPER rim bead seat area.
j. Fasten a tire bead expanding strap, having a
strap tightening mechanism, AROUND the tire
circumference at the CENTER of the tread area.
Tighten the tire bead expanding strap to expand
BOTH the UPPER and LOWER tire beads onto the
UPPER and LOWER rim bead seat areas.
4-39
Section 4
MAINTENANCE
k. Remove the tire and rim assembly from the tire
machine. Put the assembly in a TIRE RESTRAINING device that is behind a protective barrier.
Connect remote inflation equipment to the tire
filling valve.
I. Apply air pressure to the tire, NOT to exceed 65
psi. [4 bar], using the remote inflation equipment
until BOTH the UPPER and LOWER tire beads
seat to the UPPER and LOWER rim bead seat
areas. Stop application of the air pressure.
WARNING: NEVER use a inflation pressure

MORE than 65 psi. [4] bar to seat the
tire beads. Excessive inflation
pressure, when seating tire beads,
can cause the tire/rim assembly to
burst with a force sufficient to cause
serious injury. ALWAYS use remote
inflation equipment consisting of an
extension hose, with clip-on filling
chuck, and a gauge or preset
pressure regulator.
ALL personnel MUST keep CLEAR of
the tire and rim and remain BEHIND
the protective barrier.
m. Remove the tire bead expanding strap from the

tire. Remove the clip-on tire filling chuck from the
tire filling valve. Permit ALL the air to be released
from the tire.
WARNING: Keep CLEAR of the path of the air as

the air is released from the tire.
INSTALLATION [See Figure 4-22].

a. Place the LOWER half hoop assembly on the
ground with the round hoop opening facing
UPWARD. Fasten a sling and a hoist, having a
capacity more than 300 lbs. [136 kg], to the tire and
rim assembly. CAREFULLY lift the rim and tire
assembly. Move the assembly to the LOWER half
hoop assembly and SLOWLY lower the tire and rim
assembly into the hoop assembly opening.
4-40

assembly while being lifted, moved
and placed into the hoop assembly.
CAUTION: Put the tire and rim into the hoop

assembly, so that the tire air fill valve
will be TOWARD the FRAME side
when the vibration isolator tire and
hoop assembly is installed onto the
drum on EITHER side of the machine.
b. Put the UPPER half hoop assembly over the

top of the tire and remove the sling and hoist. Install
the six [6] capscrews through the holes in both the
UPPER and LOWER half hoop assemblies, from
the UPPER half hoop side. Put Loctite #242 on
ALL capscrew threads. Install the six [6] nuts onto
the 5/8 inch capscrews and tighten to a torque of
125 ft. Ibs. [170 N.m].
c. Put the vibration isolator assembly in a flat
horizontal position on the ground, with the tire air
filling valve in the DOWN position. Put water on
the area of the tire sidewall, where the half hoop
assemblies meet the sidewall. Use a tire removal
tool to EVENLY space the tire sidewall rubber
around the FULL circumference of the hoop assemblies.
d. Apply air pressure to the tire, NOT to exceed 65
psi. [4 bar], using the remote inflation equipment.
WARNING: NEVER use a inflation pressure

MORE than 65 psi. [4] bar to seat the
serious injury.
ALWAYS use remote inflation
pressure regulator.
ALL personnel MUST keep CLEAR of
the tire, rim and isolator hoop
assembly.
Do NOT put the hands, or fingers,
near the UPPER, or LOWER, hoop to
tire areas, or the UPPER, or LOWER,
tire bead or bead seat areas at ANY
time.
8/02
Section 4
MAINTENANCE
e. Remove the clip-on tire filling chuck from the
filling valve of the tire. Permit ALL of the air to be
released from the tire.

f. Install the valve core into the tire filling valve

stem and tighten. Connect remote inflation equipment to the tire filling valve. Fill the tire with air to a
pressure of 30 psi. [2 bar]. Remove the remote
inflation equipment from the tire filling valve. Install
and tighten the valve cap onto the tire filling valve.

assembly while lifting, and installing
the assembly onto the bearing
carrier.
i. Fasten a sling and hoist, having a capacity more

than 1,000 lbs. [554 kg], to the assembly made in
step h. CAREFULLY lift the assembly and move it
into position at the end of the vibrator side of the
drum. Push the assembly into the drum. Put Loctite
#242 onto the threaded area of the six [6] capscrews that fasten the axle to the drum. Align the
through holes in the axle with the tapped holes in
the drum. Install the six [6] retaining capscrews, or
capscrews and Bellville washers, and tighten to a
torque of 500 ft. lbs. [678 N.m]. Remove the sling
and the hoist.
CAUTION: Do NOT overtighten the valve core

into the tire filling valve.
NOTE: Check the tire inflation pressure, using

an accurate tire pressure gauge. Use a
soap and water solution to check the tire
and rim assembly for ANY air leaks at the
tire bead to rim seat areas and around
the tire filling valve.
g. On the VIBRATOR motor side of machine,

install the eight [8] bolts which fasten the UPPER
halfhoop to the drum isolator mounting spacers, so
the LARGEST flat area of the half hoops will be
TOWARD the FRAME side when installed. Put
Loctite #242 on the threaded area of the bolts.
Install the eight [8] nuts and tighten to a torque of
375 ft. Ibs. [509 N.m].
h. Fasten a sling and a hoist, having a capacity
more than 500 lbs. [227 kg] to the COMPLETE
vibration isolator assembly. CAREFULLY lift the
assembly. SLOWLY put the center hole in the rim
assembly in position over, and onto, the flange of
the wheel bearing carrier. On the vibrator motor side
of the drum, put Loctite #242 on the threaded area
of the capscrews which fasten the rim to the wheel
bearing carrier. Install the capscrews and tighten to
a torque of 280 ft. lbs. [380 N.m]. Remove the sling
and the hoist.

assembly and axle while lifting and
installing the assembly into the
drum.
CAUTION: On the DRUM DRIVE MOTOR side of

the machine, install the LOWER and
UPPER hoop halves, so that the
LARGEST side of the hoops will be
AWAY from the FRAME side when the
vibration isolator assembly installed
to the motor drum drive arms.
NOTE: On the DRUM DRIVE MOTOR side of the

drum, CAREFULLY put the vibration
isolator assembly over the drum drive
motor studs. Put Loctite #242 on the
threaded area of the drive motor studs.
Install the lug nuts onto the studs and
tighten to a torque of 400 ft. lbs. [542
N.m]. Put Loctite #242 on the threaded
area of the eight [8] capscrews that
fasten the vibration isolator UPPER and
LOWER hoop mounting areas to the
DRUM drive arms. Install the eight [8]
capscrews and tighten to a torque of 500
ft. Ibs. [678 N.m].

assembly while lifting, and installing
the assembly onto the drum drive
motor.
8/02
4-41
Section 4
MAINTENANCE
j. CAREFULLY remove the wood blocks from in
front, and at the rear, of the drum. CAREFULLY and
SLOWLY roll the complete drum assembly into the
area between the frame sides, until the drum is at
the CORRECT position in relation to the frame
sides.

areas while rolling the drum into
position between the frame sides.
Put wood blocks in front, and at the
rear, of the drum when the drum is
in the CORRECT position.
n. Fasten a sling and hoist, having a capacity

more than 1,500 lbs [681 kg], to the water tank and
frame assembly. CAREFULLY lift the tank and
frame assembly and move it into position on the
frame of the machine. Install the retaining capscrews and tighten securely. Connect the water
spray pump electrical wire male and female plug
connectors together.

frame assembly while lifting, moving
and lowering the tank assembly.
CAUTION: The holes in the drum isolator

mounting bracket, the DRUM DRIVE
motor carrier plate, and BOTH sides
of the frame MUST be in alignment, at
this time.
o. Put a hydraulic jack, having a capacity more

than 5 tons [4t] under either side of the frame.
CAREFULLY lift the frame and remove the support
item which is under the frame. CAREFULLY lower
the machine to the ground. Lift the opposite frame
side and remove the support item using the SAME
procedure.
NOTE: Use an alignment bar, or large drift pin,

to align the holes through the frame
sides and drum isolator mounting
bracket and drum drive motor carrier
plate after the drum is rolled between the
frame sides.
WARNING: Keep CLEAR of the frame and drum

while lifting the frame, removing the
blocks and lowering the drum to the
ground.
k. Put Loctite #242 on the threaded area of ALL

sixteen [16] retaining capscrews that fasten the
frame side plate to the vibration isolator bracket and
drum drive motor carrier plate. Install the eight [8]
capscrews, used on EACH frame side, through the
frame side and through the drum isolator mounting
bracket or drum drive motor carrier plate. Tighten
the capscrews to a torque of 375 ft. Ibs. [509 N.m].
I. Remove the plug from each hose that fastens to
the drum drive motor fittings. Remove the cap from
each drum drive motor fitting. Install the hoses onto
the drum drive fittings, as indicated by the
identification tags and tighten securely.
p. Start the engine using the CORRECT starting

procedures given in Section 3 - OPERATION -in this
manual. Check the transmission and the vibration
systems for ANY hydraulic leaks and for correct
system functions.
CAUTION: Do NOT operate the vibration system

on a hard surface. Operate the
system with the drums on a soft
surface, such as loose dirt or old
tires ONLY. STOP the engine
IMMEDIATELY and correct ANY
system problem noted before starting
the engine again.
m. Remove the plug from each hose that fastens

to the vibrator motor fittings. Remove the cap from
each vibrator motor fitting. Install the hoses onto the
vibrator motor fittings, as indicated by the
identification tags and tighten securely. Install the
drum cleaner beam and rubber assembly. Install the
beam retaining capscrews and tighten to a torque of
280 ft. Ibs [380 N.m].
4-42
8/02
Section 4
MAINTENANCE
TIRE AND RIM ASSEMBLIES - C766C machines
serial number 109C20902455 and higher and on
C778B machines serial number 109B21501856
and higher [See Figure 4-22A].
Remove, repair, or replace, ANY vibration isolator
tire found to show evidence of an air leak, or other
serious damage, IMMEDIATELY, using the
following procedures:
CAUTION: Do NOT place the wood blocks, so

that the drum will touch the blocks
as the drum is rolled forward and
from between the frame sides.
d. Put an identification tag on each hose fastened
to the vibrator motor. Remove each of the hoses
from the fittings on the motor. Put a plug in each
hose and a cap on each motor fitting.
CAUTION: Do NOT damage the hoses when

moving the vibrator motor.
REMOVAL [See Figure 4-22A].

a. Place the machine on a level surface. APPLY
the secondary/parking brake system and STOP the
engine. Drain the water tank and disconnect the
water sprinkler bar supply hose on the drum being
serviced. Remove the drum cleaner bar.
b. Drain the water tank, found at the front of the
drum being removed, of water. Disconnect the
electrical connection to the water spray pump.
Fasten a sling and a hoist, having a capacity more
than 1,500 lbs. [861 kg] to the water tank frame.
Remove the capscrews that fasten the tank and
frame to the frame of the machine. Remove the tank
and frame assembly from the machine and place on
the ground.

frame assembly while lifting,
removing and lowering the tank
assembly.
c. Put wood blocks in front, and at the rear, of the
drum NOT being serviced. Put a hydraulic jack,
having a capacity more than five [5] tons [4t], under
either side of the frame outside the drum being
removed for vibration isolator tire removal and repair
or replacement. Raise the hydraulic jack ONLY until
the jack lifting plate JUST starts to lift frame weight.
Put wood blocks, or jack stands, under the side of
the frame. Lower the frame onto the support item
and remove the hydraulic jack. Lift the OPPOSITE
frame side and put wood blocks or jack stands under
the frame side using the SAME procedures given in
this step.
WARNING: Keep CLEAR of the frame while

being lifted and lowered onto the
blocks. Block securely using solid
wood blocks, or solid support items.
8/02
e. Put an identification tag on each hose that

fastens to the drum drive motor. Remove each of
the hoses from the fittings on the motor. Put a plug
in each hose and a cap on each motor fitting.
f. Carefully remove the eight [8] bolts [1] and
tightening washers [2] which fasten the drum drive
motor assembly [3] to the sides of the frame.
Carefully remove the eight [8] bolts [9] and
tightening washers [10] which fasten the vibrator
motor subassembly [11] to the opposite side of the
frame.
NOTE: Removing the eight [8] bolts from each

side of the frame will permit the drum
assembly, with both vibration isolator
tire, rim and hoop assemblies, vibrator
drive subassembly, and the drum drive
motor assembly , to be removed from
between the frame sides by rolling the
assembly toward the open end of the
machine.
g. CAREFULLY and SLOWLY roll the complete
drum assembly [4] toward the open end of the
machine until the drum is fully away from the frame
sides.

areas while rolling the drum toward
the open end of the machine. Put
wood blocks in front, and at the
rear, of the drum AFTER the drum is
removed.
NOTE: With the drum removed from the
machine, remove the complete vibration
isolator tire and hoop assembly being
repaired, from the drum.
4-43
Section 4
MAINTENANCE
FIGURE 4-22A. FRAME, DRUM, VIBRATION ISOLATOR TIRE AND RIM - EXPLODED VIEW.
4-44
8/02
Section 4
MAINTENANCE
more than 1,000 lbs. [454 kg], to the complete
isolator subassembly [7] that is being removed, in
order to repair or replace the tire. Remove ALL
slack in the sling but do NOT lift the isolator
subassembly, at this time.
i. Use a wrench, having a capacity MORE than
300 ft. lbs. [407 N.m], remove the bolts [5] and
tightening washers [6] which fasten the isolator
subassembly [7] to the flange of the vibratory drum
[4]. SLOWLY move the isolator subassembly [7]
outward and away from the flange, while lifting the
assembly with the sling and hoist, a SMALL amount.
CAREFULLY move the assembly away from the
drum [4] and place the assembly on the ground.
k. Remove the five [5] bolts [12] and tightening

washers [13] which fasten the vibrator drive
subassembly [11] to the isolator tire rim center [15],
or the ten [10] nuts [14] which mount the drum drive
motor to the opposite tire rim center [15]. Remove
the six [6] nuts [19], from the bolts [16] which fasten
the upper half hoop [17] and lower half hoop [18]
assemblies together around the tire and rim.
CAREFULLY lift and remove the upper half hoop
assembly [17] from the tire and set the half hoop on
the ground.
l. Fasten a sling and a hoist, having a capacity
more than 300 lbs. [136 kg], to the tire rim center
[15]. CAREFULLY move and lower the tire and rim
assembly onto a tire repair machine.
WARNING: Keep CLEAR of the isolator

subassembly while loosening the
retaining capscrews which fasten
the assembly to the drum, and while
moving the isolator subassembly
away from the drum and then
lowering the assembly to the
ground.

assembly while being lifted and
moved.
j. Remove the valve cap from the isolator tire [8]

filling valve stem, CAREFULLY remove the valve
core from the tire filling valve stem and exhaust ALL
the air from the isolator subassembly, if inflated.
a. Fasten the tire rim center [15] securely to the

tire repair machine, so that the assembly will NOT
move when the tubeless tire beads are broken
loose from the rim bead seat area.
WARNING: Keep CLEAR of the air path as the

air is released from the tire
assembly.
NOTE: Check the valve stem to be sure the
inside is NOT in a plugged condition, by
putting a wire through the center hole in
the valve stem.
8/02
TIRE REMOVAL, REPAIR OR REPLACEMENT

AND INSTALLATION ONTO THE RIM [See
Figure 4-22A].
b. Break the UPPER tire bead away from the rim

using a bead breaking tool. Move the tire UPPER
bead over and above, the UPPER rim bead seat
area, using the machine tire bead spreader bar.
CAREFULLY lift the tire assembly, a SMALL
amount, at the SAME time.
WARNING: Use a sling and a hoist, having a

capacity more than 100 lbs. [46 kg],
to lift and move the tire during
removal and replacement onto the
rim. Keep CLEAR of the bead
breaking tool and the bead
spreader bar while breaking and
removing BOTH tire beads from the
rim upper bead seat area.
4-45
Section 4
MAINTENANCE
c. CAREFULLY lift the LOWER tire bead toward
the UPPER rim bead seat area and put the bead
spreader bar assembly between the LOWER tire
bead and the UPPER rim bead seat area. Move the
bead spreader bar around the tire bead and remove
the tire bead over and above the UPPER rim bead
seat area. CAREFULLY lift the tire away from the
rim assembly for tire inspection, repair, or
replacement as needed.
d. Inspect the tire from BOTH the OUTSIDE and
the INSIDE of the tire for punctures, cuts, breaks or
other damage. Wipe the inside of the tire with a
clean cloth to remove any dirt, or moisture. Repair
the tire as needed using tire repair materials which
repair the damaged area from the INSIDE of the
tire.
CAUTION: The isolator tires are of radial ply

design. Use ONLY tire repair
materials and procedures for radial
type tires. Replace the tire if ANY
tire damage is found that is NOT
able to be repaired using INSIDE tire
carcass repair methods and
materials. The repair materials used
MUST seal the INNER tire carcass
and fill the tire injury, to be
considered an adequate and
permanent repair.
e. Carefully inspect the rim assembly for ANY
cracks, severe rusting, or other damage in the bead
seat area. Clean, sand to new metal, prime and
finish paint the rim assembly BEFORE mounting
the tire. Install a new tire filling valve, if the valve
shows ANY damage.
WARNING: Do NOT weld, heat or braze the rim

assembly. Replace the rim assembly
with NEW, if damaged.
g. CAREFULLY lift the tire above the rim

assembly, using a sling and hoist. SLOWLY lower
the tire to the rim assembly. Tilt the tire a small
amount as the LOWER bead reaches the UPPER
rim bead seat, of the rim assembly. Push the
LOWER bead past the UPPER rim bead seat and
continue to lower the tire downward. Pull the tire
back as far as possible as the LOWER bead
reaches the LOWER bead seat area of the rim
assembly, and as the LOWER tire bead is also
partially caught on the UPPER rim bead seat.
h. Use the tire bead installing tool to install the
balance of the LOWER tire bead over the UPPER
rim bead seat and lower the tire to the LOWER
bead seat area of the rim assembly.
i. Push the UPPER tire bead downward and over
the UPPER bead seat area of the rim assembly, as
much as possible. Pull back on the UPPER tire
bead and use the tire bead installing tool to install
the balance of the UPPER tire bead over the
UPPER rim bead seat area.
j. Fasten a tire bead expanding strap, having a
strap tightening mechanism, AROUND the tire
circumference at the CENTER of the tread area.
Tighten the tire bead expanding strap to expand
BOTH the UPPER and LOWER tire beads onto the
UPPER and LOWER rim bead seat areas.
k. Remove the tire and rim assembly from the tire
machine. Put the assembly in a TIRE
RESTRAINlNG device that is behind a protective
barrier. Connect remote inflation equipment to the
tire filling valve.
l. Apply air pressure to the tire, NOT to exceed 65
psi. [4 bar], using the remote inflation equipment
until BOTH the UPPER and LOWER tire beads
seat to the UPPER and LOWER rim bead seat
areas. Stop application of the air pressure.
f. Put the rim assembly on the tire machine and

fasten securely in place. Put water, or
nonflammable tire mounting lubricant, on BOTH the
UPPER and LOWER bead seat areas, of the rim
assembly, and on both the UPPER and LOWER
bead sealing areas of the tire.
4-46
8/02
Section 4
MAINTENANCE
WARNING: NEVER use an inflation pressure
MORE than 65 psi. [4 bar] to seat the
serious injury. ALWAYS use remote
inflation equipment consisting of an
pressure regulator.
ALL personnel MUST keep CLEAR
of the tire and rim and remain
BEHIND the protective barrier.
m. Remove the tire bead expanding strap from the
tire. Remove the clip-on tire filling chuck from the
tire filling valve. Permit ALL the air to be released
from the tire.

INSTALLATION [See Figure 4-22A].

a. Place the LOWER half hoop assembly [18] on
the ground with the round hoop opening facing
UPWARD. Fasten a sling and a hoist, having a
capacity more than 300 lbs. [136 kg], to the tire rim
center [15]. CAREFULLY lift the rim and tire
assembly. Move the assembly to the LOWER half
hoop assembly and SLOWLY lower the tire and rim
assembly into the hoop assembly opening.

assembly while being lifted, moved
and placed into the hoop assembly.
8/02
CAUTION: Put the tire and rim into the hoop

assembly, so that the tire air fill
valve will be TOWARD the FRAME
side when the vibration isolator tire
and hoop assembly is installed onto
the drum on EITHER side of the
machine.
b. Put the UPPER half hoop assembly [17] over
the top of the tire and remove the sling and hoist.
Install the six [6] bolts [16] through the holes in both
the UPPER and LOWER half hoop assemblies,
from the UPPER half hoop side. Put Loctite #242
on ALL bolt threads. Install the six [6] nuts [19] onto
the bolts [16] and tighten to a torque of 125 ft. lbs.
[170 N.m].
c. Put the vibration isolator assembly in a flat
horizontal position on the ground, with the tire air
filling valve in the DOWN position. Put water on
the area of the tire sidewall, where the half hoop
assemblies meet the sidewall. Use a tire removal
tool to EVENLY space the tire sidewall rubber
around the FULL circumference of the hoop
assemblies.
d. Apply air pressure to the tire, NOT to exceed 65
psi. [4 bar], using the remote inflation equipment.
WARNING: NEVER use an inflation pressure

MORE than 65 psi. [4 bar] to seat the
serious injury.
ALWAYS use remote inflation
pressure regulator.
ALL personnel MUST keep CLEAR
of the tire, rim and isolator hoop
assembly.
Do NOT put the hands, or fingers,
near the UPPER, or LOWER, hoop to
tire areas, or the UPPER, or LOWER,
tire bead or bead seat areas at ANY
time.
4-47
Section 4
MAINTENANCE
e. Remove the clip-on tire filling chuck from the
filling valve of the tire. Permit ALL of the air to be
released from the tire.

f. Install the valve core into the tire filling valve

stem and tighten. Connect remote inflation
equipment to the tire filling valve. Fill the tire with air
to a pressure of 30 psi. [2.0 bar]. Remove the
remote inflation equipment from the tire filling valve.
Install and tighten the valve cap onto the tire filling
valve.
CAUTION: Do NOT overtighten the valve core

into the tire filling valve.
NOTE: Check the tire inflation pressure, using

an accurate tire pressure gauge. Use a
soap and water solution to check the tire
and rim assembly for ANY air leaks at the
tire bead to rim seat areas and around
the tire filling valve.
g. On the VIBRATOR drive subassembly [11] side
of machine, carefully attach the hoist and sling to
the isolator subassembly [7]. Lift it into position on
the vibrator drive subassembly. Put Loctite #242 on
the threaded area of the five [5] bolts [12] which
fasten the vibrator drive subassembly [11] to the tire
rim center [15]. Install the five [5] bolts [12] and
tightening washers [13]. Tighten bolts to a torque of
430 ft. lbs. [583 N.m].
WARNING: Keep CLEAR of the isolator

subassembly and vibrator drive
subassembly while lifting and
installing the assembly into the
drum.
CAUTION: When installing complete vibrator

drive/isolator subassembly on drum,
be sure shaft properly engages
vibrator drive subassembly.

more than 500 lbs. [227 kg] to the complete vibrator
drive/isolator subassembly. CAREFULLY lift the
assembly and move it into position at the end of the
vibrator side of the drum [14]. Push the assembly
into the drum. Put Loctite #242 onto the threaded
area of the ten [10] bolts [5] that fasten the UPPER
and LOWER hoop assemblies [17 and 18] to the
drum [4]. Install the ten [10] bolts [5] and tightening
washers [6]. Torque bolts to 155 ft. lbs. [210 N.m].
Remove the sling and the hoist.
CAUTION: On the DRUM DRIVE MOTOR side of

the machine, repeat steps a
through f before proceeding to
step i.
i. On the DRUM DRIVE MOTOR side of the
machine, CAREFULLY put the vibration isolator
assembly [7] over the drum drive motor [3] studs.
Put Loctite #242 on the threaded area of the drive
motor studs. Install the lug nuts [14] onto the studs
and tighten to a torque of 400 ft. lbs. [542 N.m]. Put
Loctite #242 on the threaded area of the ten [10]
bolts [5] that fasten the UPPER and LOWER hoop
assemblies [17 and 18] to the drum [4]. Install the
ten [10] bolts [5] and tightening washers [6]. Tighten
bolts to a torque of 155 ft. lbs. [210 N.m].
WARNING: Keep CLEAR of the vibration

isolator assembly while lifting, and
installing the assembly onto the
drum drive motor.
j. CAREFULLY remove the wood blocks from in
front, and at the rear, of the drum. CAREFULLY and
SLOWLY roll the complete drum assembly into the
area between the frame sides, until the drum is at
the CORRECT position in relation to the frame
sides.

areas while rolling the drum into
position between the frame sides.
Put wood blocks in front, and at the
rear, of the drum when the drum is
in the CORRECT position.
CAUTION: The holes in the vibrator drive
subassembly mounting spacers, the
drum drive motor mounting spacers,
and BOTH sides of the frame MUST
be in alignment, at this time.
4-48
8/02
Section 4
MAINTENANCE
NOTE: Use an alignment bar, or large drift pin,
to align the holes through the frame
sides and both sets of mounting spacers
after the drum is rolled between the
frame sides.
k. Put Loctite #242 on the threaded area of BOTH
sets of eight [8] bolts [1 and 9] that fasten the frame
to the mounting spacers of both sides of the drum.
Install the sixteen [16] bolts [1 and 9] and tightening
washers [2 and 10], used on EACH frame side,
through the frame side and through the respective
mounting spacers. Tighten the bolts [1 and 9] to a
torque of 430 ft. lbs. [583 N.m].
l. Remove the plug from each hose that fastens to
the drum drive motor fittings. Remove the cap from
each drum drive motor fitting. Install the hoses onto
the drum drive fittings, as indicated by the
identification tags, and tighten securely.
m. Carefully reinstall the vibrator drive motor
assembly. Take care to properly engage the three
[3] pins to the appropriate mating holes of the rubber
coupling attached to the vibrator driveshaft
weldment.
n. Install the two [2] vibrator motor retaining
capscrews and hardened discs. Apply Loctite 242 to
the mating threads. Torque to 65 ft. lbs [88 N.m].
o. Remove the plug from each hose that fastens to
the vibrator motor fittings. Remove the cap from
each vibrator motor fitting. Install the hoses onto the
vibrator motor fittings, as indicated by the
identification tags, and tighten securely. Install the
drum cleaner beam and rubber scraper assembly.
Install the beam retaining capscrews and tighten to
a torque of 280 ft. lbs. [380 N.m].
8/02
p. Fasten a sling and hoist, having a capacity more

than 1,500 lbs. [681 kg], to the water tank and frame
assembly. CAREFULLY lift the tank and frame
assembly and move it into position on the frame of
the machine. Install the retaining capscrews and
tighten securely to a torque of 430 ft. lbs. [583 N.m].
Connect the water spray pump electrical wire male
and female plug connectors together. Reattach the
water sprinkler bar supply hose.
WARNING: Keep CLEAR of the water tank and

frame assembly while lifting, moving
and lowering the tank assembly.
q. Put a hydraulic jack, having a capacity more
than 5 tons [4t] under either side of the frame.
CAREFULLY lift the frame and remove the support
item which is under the frame. CAREFULLY lower
the machine to the ground. Lift the opposite frame
side and remove the support item using the SAME
procedure.
WARNING: Keep CLEAR of the frame and drum

while lifting the frame, removing the
blocks and lowering the drum to the
ground.
r. Start the engine using the CORRECT starting
procedures given in Section 3 - OPERATION - in
this manual. Check the transmission and the
vibration systems for ANY hydraulic leaks and for
correct system functions.
CAUTION: Do NOT operate the vibration

system on a hard surface. Operate
the system with the drums on a soft
surface, such as loose dirt or old
tires ONLY. STOP the engine
IMMEDIATELY and correct ANY
system problem noted before
starting the engine again.
4-49
Section 4
MAINTENANCE
SECONDARY/PARKING BRAKE SYSTEM
MAINTENANCE - OPERATION AND
APPLICATION CHECK [See Figure 4-23].
Check the SECONDARY/PARKING BRAKE SYSTEM for correct operation and application, one [1 ]
time for each 100 hours of machine operation, or
every three [3] months.
WARNING: The secondary/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
OPERATE on the instrument panel
and REMOVE the ignition key from
Put SOLID wood blocks in the front,
and in the rear, of one [1] drum of the
machine.
REPAIR the system fault
IMMEDIATELY.
Use the following procedures to CORRECTLY

check the secondary/parking brake system for
CORRECT operation and application:
a. Select a site that has a LEVEL surface and is
CLEAR of other machines, building structures or
personnel. Park the machine in the center of the
selected area. STOP the engine.
b. Go to the service access door, found at the end
of the engine compartment. Remove the capscrews
that keep the service access door in the closed
position. Open the service access door. Find the
stack valve assembly, which is fastened to the
upper LEFT hand side of the cowl. Find the brake
release solenoid assembly, and the PURPLE wire
connected to it, on the stack valve [see figure 423]. Remove the nut that fastens the purple current
supply wire to the solenoid stud. Remove the wire
from the solenoid stud. Put electrical tape on the
terminal of the current supply wire. Leave the wire in
a position that is away from the solenoid stud.
4-50
c. Keep the directional/speed control [F-N-R

handle] in NEUTRAL.
BRAKE
RELEASE
SOLENOID
PURPLE
WIRE
STACK
VALVE
FIGURE 4-23. STACK VALVE AND BRAKE

RELEASE SOLENOID LOCATIONS.
d. Put the engine throttle speed switch in the

LOW idle speed position. Start the engine by using
the CORRECT procedures given in section 3 OPERATION -in this manual.
e. Put the engine throttle speed switch in the
HIGH idle speed position. Put the transmission
speed range control switch in the LOW range
position.
8/02
Section 4
MAINTENANCE
f. Move the directional/speed control [F-N-R]
handle one fourth [1/4] of the full travel distance
toward forward, or the reverse position, and note
that the machine does NOT move. Repeat the
procedure for the OPPOSITE direction of travel.
Move the directional/speed control [F-N-R] handle
to NEUTRAL.
WARNING: The machine must NOT move in

EITHER direction of travel.
The secondary/parking brake system
MUST keep the machine in a
STOPPED condition during the
system operation and application
check.
If the machine moved, in EITHER
operation and application check,
STOP the engine IMMEDIATELY. Do
NOT use the machine. Put an
instruction tag reading DO NOT
OPERATE on the instrument panel
and REMOVE the ignition key from
Put SOLID wood blocks in the front,
and in the rear, of one [1] drum of
the machine.
REPAIR the system fault
IMMEDIATELY.
MISCELLANEOUS MAINTENANCE
INFORMATION.
WATER SPRAY SYSTEM.
WATER STRAINERS [See Figure 4-24].
One [1] time for EACH 500 hours of machine
operation, or yearly, remove the access plate, with
strainer, found in each water tank. Carefully clean
the screen to remove material trapped and held by
the screen material. Install the complete assembly
back into the water tank and secure the access
plate to the tank with the retaining nuts. Connect the
water supply hose to the pump inlet, if removed.
PUMP
FILLER CAP
STRAINER
FIGURE 4-24. WATER SPRAY PUMP AND

STRAINER ASSEMBLY.
NOTE: If the machine did NOT move, in EITHER

operation and application check, the
secondary/parking brake system has full
application capacity, and the system is
ready for use during machine operation.
WATER SPRAY NOZZLES [See Figure 4-25].
g. Put the engine throttle speed switch in the

LOW idle speed position and allow engine to run
at LOW idle speed for a period of at least threefive [3-5] minutes. STOP the engine.
Remove, clean and install ALL of the water spray

nozzles and orifice discs, found on the front, and
rear, water spray bars, as required.
h. Go to the brake release solenoid current supply

wire. Remove the electrical tape from the wire
terminal. Put the wire terminal over the solenoid
stud. Install the wire terminal retaining nut onto the
stud and tighten securely.
i. Close the service access door. Install the door
retaining capscrews. Securely tighten the
capscrews.
8/02
Water spray nozzles and orifice discs can become

clogged and cause a reduced water flow from the
nozzles.
Each water spray nozzle and orifice disc is connected to the water spray bar and is released by
unscrewing the threaded retaining collar in a
COUNTERCLOCKWISE [CCW] direction.
Remove the orifice disc and the spray nozzle from
inside the retaining collar for cleaning, or replacement.
Clean the orifice discs and spray nozzles by using a
small wire, or LOW pressure compressed air.
4-51
Section 4
MAINTENANCE
Install the nozzle and orifice disc into the threaded
retaining collar. Screw the retaining collar in a
CLOCKWISE [CW] direction, onto the lower mount,
while positioning the outlet of the nozzle toward the
drum surface.
BEAM
RUBBER CLEANER
DRUM
SPRAY BAR
FIGURE 4-26. CLEANER BEAM AND

RUBBER CLEANER ASSEMBLY.
NOZZLES
PREPARING THE MACHINE FOR STORAGE.

FIGURE 4-25. WATER SPRAY NOZZLES.
CLEANER BEAM AND RUBBER CLEANER

ASSEMBLIES [See Figure 4-26].
Use the following information as a general guide

ONLY to prepare the machine for storage. Manufacturers of components can also be contacted for
specific information about components manufactured by them.
Two [2] cleaner beam and rubber assemblies are

found on EACH drum.
ENGINE.
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.
See the current CUMMINS DIESEL ENGINE

COMPANY Operation And Maintenance Manual B Series Diesel Engine for complete, APPROVED
engine storage preparation procedures suggested
by the manufacturer.
Replace broken, or missing, parts as required.

Keep ALL mounting fasteners securely tightened at
all times. Keep the cleaner bar beam to machine
mounting capscrews tightened to a torque of 280 ft.
lbs. [380 N.m] at ALL times. Keep the rubber
cleaners, at a position that is AGAINST each drum
face at ALL times and keep the retaining capscrews
securely tightened.
CAUTION: Do NOT operate a machine having

missing, or damaged, cleaner beam,
or rubber cleaner components.
Replace ALL missing, or damaged,
cleaner beam, or rubber cleaner,
components IMMEDIATELY.
4-52
COOLING SYSTEM.
The ENTIRE cooling system MUST be protected
from freezing. FILL the radiator as needed, using a
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.
8/02
Section 4
MAINTENANCE
ALSO, see the current CUMMINS DIESEL ENGINE
COMPANY Operation And Maintenance Manual B Series Diesel Engine for complete, APPROVED
engine cooling system storage procedures.
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.
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
32F [0C]. The system WILL be
DAMAGED if the water is allowed to
freeze.
EXPOSED COMPONENT RUST PREVENTION.

Put a heavy grease, or equivalent, onto ANY
exposed area of the hydraulic steering cylinder rod.
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].
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.
CAUTION: Do NOT leave the fuel tank

partly filled. Moisture will condense
inside the fuel tank, while in storage,
and can cause fuel system
component damage during storage,
or when the machine is placed back
into service.
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.
8/02
4-53
Section 4
MAINTENANCE
NOTES
4-54
8/02

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CALIFORNIA

C766C & C778B

Install each Seat Belt.

Hexbolt - M20x110 - 10.9

Hexbolt - M20x65 - 10.9 (4 used on near side).

DANGER: Do Not operate machine with the Roll Over/

SYMBOLS USED IN THIS MANUAL

DANGER: Serious personal injury, death and/or

WARNING: Serious personal injury and/or

CAUTION: Minor personal injury can result or

NOTE: Gives additional, and/or clarification

SERVICE AND REPAIR PRECAUTIONS

ALWAYS support the machine with sound blocking.

ALWAYS keep tools in a good and clean condition.

MANUAL - TABLE OF CONTENTS

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

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

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

WARNING: ONLY authorized personnel, who

See Section 2 - SPECIFICATIONS, of THIS

The maintenance schedules and procedures

THIS manual contains SPECIFICATION information

READ, UNDERSTAND and FOLLOW ALL the

CAUTION: Follow ALL the maintenance

FIGURE 1-1. MODEL C766C - COMPACTOR.

SERIAL NUMBER [See Figures 1-3 and 1-4].

MAJOR machine component REPAIR

The SERIAL NUMBER indicates the design series,

CAUTION: For CORRECT machine component

CAUTION: ALL numbers and letters,

NAME PLATE /SERIAL NUMBER PLATE [See

FIGURE 1-2. MODEL C778B - COMPACTOR.

TABLE 1-1. MACHINE SERIAL NUMBER DESIGNATIONS.

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

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

Machine dimensions, weights, performance and

TABLE 2-1. FRAME, HITCH AND FALLING OBJECT/ROLL OVER [FOPS/ROPS]

FRAME and HITCH

Unitized, all welded 2 section, with bolt-on

+/- 12 - side to side, 24 total

+/- 35 - right to left [Steering] turn, 70 total

Welded steel structure, bolted to machine for protective system

4 Cycle diesel, Turbocharged and charge air cooled

239 in.3 [3.92 l]

Bore & Stroke

4.02 in. [102 mm] x 4.72 in. [120 mm]

130 hp @ 2500 rpm [97 Kw at 2500 rpm]

Low Idle Speed

900 -1000 rpm

High Idle Speed

2500 +/-10 rpm, NO load

Engine Oil Type

See Cummins "Operation and Maintenance Manual - B series

18.7 psi [1.3 bar] @ 1750 rpm

ENGINE COOLING SYSTEM

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

System Coolant Capacity

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

50 Gallons [189 L] - C766C or 60 Gallons [227 L] - C778B

4.1 Gallons per hour

*Operating conditions, that vary, can cause different fuel

Suction line, replaceable spin-on element - with water drain [See