Bomag Hypac C766 C C778 B Workshop Service Repair Manual Download

C766 C
C778 B
Revision R0
Form 0852737
9/2005
SERVICE
MANUAL
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 Seat Belt

(4 used on far side). Set (2 used)
Tighten to a Torque of Eyebolt
375 ft. lbs. (509 N.m).
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).
Hexbolt - M20x65 - 10.9 (4 used on near side).

(4 used on near side) Tighten to a Torque of 375 ft. lbs. (509N .m).
M20 Washers
DANGER: Do not operate machine with the Roll Over/Falling Object Protection Structure
(ROPS/FOPS) and Operator Restraints (Seat Belt Sets) NOT properly installed.
9/2005
SYMBOLS USED IN THIS MANUAL
The following symbols have been used in THIS Manual to help communicate the intent of
instructions. When one of the symbols appears, it conveys the meaning defined below:
DANGER: Serious personal injury, death and/or WARNING: Serious personal injury and/or
extensive property damage can result extensive property damage can
if the DANGER instructions are not result if the WARNING instructions
followed. are not followed.
CAUTION: Minor personal injury can result or a NOTE: Gives additional, and/or clarification
part, an assembly, or the engine can details, which are to be used in
be damaged if the CAUTION instruc- conjunction with previously
tions are not followed. presented information.
CALIFORNIA
Proposition 65 Warning
WARNING: Diesel engine exhausts and
some of its constituents are known to the
state of California to cause cancer, birth
defects, and other reproductive harm.
CALIFORNIA
Proposition 65 Warning
WARNING: Battery posts, terminals and
related accessories contain lead and lead
compounds, chemicals known to the state
of California to cause cancer, birth
defects, and other reproductive harm.
Wash hands after handling.
SERVICE AND REPAIR PRECAUTIONS
ALWAYS inspect all slings, chains, or cables when lifting components, be sure that they are properly tied,
fastened and balanced before lifting. Be sure that the lifting device is capable of retaining the weight to be lifted.
NEVER attempt to lift heavy parts by hand when a lifting device should be used.
ALWAYS wear safety glasses when performing any maintenance or repair work on the machine.
NEVER attempt to remove or repair any component, on the machine, while the engine is running.
NEVER leave the machine and/or heavy parts in an unstable position during repair.
ALWAYS support the machine with sound blocking.
ALWAYS keep the machine and work area clear of lubricants and dirt.
ALWAYS use the correct tools for the repair procedures being done on the machine,
ALWAYS keep tools in a good and clean condition.
ALWAYS use approved parts, that are designed for the machine being repaired. This helps to ensure maxi-
mum service life of the machine.
ALWAYS be sure that all necessary nuts, bolts, snap rings, and other fastening devices, are removed before
using force to remove components.
ALWAYS attach a sign in the machine operator’s area, stating “DO NOT OPERATE” when the machine is
being repaired.
ALWAYS observe ALL WARNING AND CAUTION statements given in the Operating Manual and Service
Manual and found on the machine decals.
MANUAL - TABLE OF CONTENTS
PAGE
SECTION 1 - INTRODUCTION ................................................................................................................ 1-1.
SECTION 2 - SPECIFICATIONS ............................................................................................................. 2-1.
SECTION 3 - OPERATION ...................................................................................................................... 3-1.
SECTION 4 - MAINTENANCE ................................................................................................................. 4-1.
SECTION 5 - FRAME, HITCH AND FALLING OBJECT/

ROLL OVER PROTECTION STRUCTURE ........................................................................................... 5-1.
SECTION 6 - ENGINE ..............................................................................................................................6-1.
SECTION 7 - ELECTRICAL SYSTEM ..................................................................................................... 7-1.
SECTION 8 - TRANSMISSION SYSTEM ................................................................................................ 8-1.
SECTION 9 - BRAKE SYSTEM ............................................................................................................... 9-1.
SECTION 10 - STEERING SYSTEM ......................................................................................................10-1.
SECTION 11 - DRUM, VIBRATION AND DRUM CLEANING SYSTEMS ............................................ 11-1.
SECTION 12 - WATER SPRAY SYSTEM ............................................................................................. 12-1.
SECTION 13 - OPERATING LIGHTS AND DIRECTIONAL SIGNALS................................................. 13-1.
9/2005 i
Section 1
INTRODUCTION
TABLE OF CONTENTS
PAGE
GENERAL INFORMATION ......................................................................................................................1-2.
SPECIFICATIONS ....................................................................................................................................1-2.
OPERATING INSTRUCTIONS .................................................................................................................1-2.
MAINTENANCE PROCEDURES .............................................................................................................1-2.
REPAIR PROCEDURES ..........................................................................................................................1-2.
NAME PLATE / SERIAL NUMBER PLATE .............................................................................................1-2.
SERIAL NUMBER ....................................................................................................................................1-3.
9/2005 1-1
Section 1
INTRODUCTION
GENERAL INFORMATION. REPAIR PROCEDURES.
THIS manual contains SPECIFICATION information MAJOR machine component REPAIR

and OPERATION, MAINTENANCE and REPAIR PROCEDURES are found in the “SYSTEM
procedures for the 66 Inch and 78 Inch Compac- REPAIR PROCEDURE” sections of "Instruction for
tors. Repair".
CAUTION: For CORRECT machine component

SPECIFICATIONS. repair procedures, USE the REPAIR
procedures given in the above
See Section 2 - SPECIFICATIONS, of THIS service manual, and/or other
manual, for specifications on major systems used referenced written materials
on the machine. ONLY.
OPERATING INSTRUCTIONS. NAME PLATE /SERIAL NUMBER PLATE [See

Figure 1-3].
READ, UNDERSTAND and FOLLOW ALL the
operating instructions given in the FRONT, and in The name plate/serial number plate is located
Section 3 - OPERATION, of THIS manual. 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.
WARNING: ONLY authorized personnel, who
are fully trained in the machine
operation procedures, can operate SERIAL NUMBER [See Figures 1-3 and 1-4].
the 66 Inch and 78 Inch Compactors.
Follow ALL instructions given in The SERIAL NUMBER indicates the design series,
THIS manual, and written on the manufacturing location, serial number and year of
“Machine Operation and Warning” machine shipment (older machines) [see Table 1-1].
decal, found on the flat plate on the The machine serial number is located ON the
right side of, and below, the control nameplate [see figure 1-3]. The serial number is
panel. also stamped on the flat surface of the hitch assem-
bly at the left hand side of the machine [see figure
1-4].
MAINTENANCE PROCEDURES.
CAUTION: ALL numbers and letters,
The maintenance schedules and procedures contained in the SERIAL NUMBER,
are found in Section 4 - MAINTENANCE, of MUST be given when requesting
THIS manual. service and/or part information.
CAUTION: Follow ALL the maintenance

schedules and instructions
given in THIS manual.
1-2 9/2005
Section 1
INTRODUCTION
XXX X 0 00000
PLANT OF DESIGN SERIES MACHINE

MANUFACTURE AND MODEL SERIAL NUMBER
I, O, Q NOT USED CODE
TABLE 1-1. MACHINE SERIAL NUMBER DESIGNATIONS.
BOMAG
TYPE BETRIEBSGEWICHT
OPERATING WEIGHT KG
POIDS DE SERVISE
NO MAX. GEWICHT
MAX. WEIGHT KG
POIDS MAX.
MANUFACTURED BY
BOMAG Americas
KEWANEE, ILLINOIS, USA
MANUFACTURED UNDER ONE OR MORE OF THE FOLLOWING U.S. PATENTS:
30100007
5645370, 5248216, 5797699
BOMAG
TYPE BETRIEBSGEWICHT
OPERATING WEIGHT KG
POIDS DE SERVISE
NO MAX. GEWICHT
MAX. WEIGHT KG
POIDS MAX.
MANUFACTURED BY
BOMAG Americas
KEWANEE, ILLINOIS, USA
MANUFACTURED UNDER ONE OR MORE OF THE FOLLOWING U.S. PATENTS:
30100007
5645370, 5248216, 5797699
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.
9/2005 1-3
Section 1
INTRODUCTION
NOTES
1-4 9/2005
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.
9/2005 2-1
Section 2
SPECIFICATIONS
GENERAL INFORMATION. Machine dimensions, weights, performance and
torque specifications are also given in THIS
THIS section gives specification tables for each section.
MAJOR machine system of the 66 Inch and 78
Inch Compactors.
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 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]
2-2 9/2005
Section 2
SPECIFICATIONS
TABLE 2-2. ENGINE SPECIFICATIONS.
ITEM DESIGN DATA
ENGINE
Model and 4B3.9 QSB-C130 Cummins Diesel, with automatic, ether, cold start aid
Manufacturer
Type 4 Cycle diesel, Turbocharged and Charge Air Cooled
Number of 4
Cylinders
Displacement 239 in.3 [3.9 l]
Bore & Stroke 4.02 in. [102 mm] x 4.72 in. [120 mm]
Rated Brake 130 hp @ 2500 rpm [97 Kw @ 2500 rpm]

Horsepower
Compression Ratio 18:1
Firing Order 1-3-4-2
Low Idle Speed 700 -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. [18 l]
Thermostat Range 180-199° F [82-93° C], thermostat opens
9/2005 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] - 66 Inch or 60 Gallons [227 L] - 78 Inch
Rate of Fuel 4.1 Gallons per hour

Consumption [at [15.5 liters per hour]*
normal engine H.P.
at 40% load]
*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 4, close nozzle
2-4 9/2005
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 105 Amps - 14 volts [cold]

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

Rotation drive end
Fan Belt Tension Automatic belt tension mechanism keeps serpentine belt
and Method Used to under tension at ALL times
Achieve
STARTER
Manufacturer Delco Remy [see ENGINE starter plate, for starter part number]
Voltage and Type 12 Volt, negative ground
9/2005 2-5
Section 2
SPECIFICATIONS
TABLE 2-4. TRANSMISSION SYSTEM SPECIFICATIONS.
ITEM DESIGN DATA
TRANSMISSION SYSTEM
System Type Hydrostatic
System Oil Capacity [Also 22 Gallons [83.3 L]

supplies steering and
vibration systems]
Oil Type See decal, adjacent to hydraulic reservoir fill, for correct type
Oil Cooler Type Aluminum, full flow [separate from radiator]
TRANSMISSION
HYDRAULIC PUMP
Type Variable displacement, axial piston
Swash Plate Angle 0-17°, maximum, either side of center
Direction of Rotation Counterclockwise [C.C.W.]
Inlet Vacuum [at 10 in. hg [254 mm hg], maximum

charge pump inlet]
Maximum Allowable 220° F [104° C]

Case Temperature
Oil Filter - One [1] filter with replaceable

Transmission element, transmission pump installed
PRESSURE Oil Flow [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 9/2005
Section 2
SPECIFICATIONS
ITEM DESIGN DATA
Maximum Operating Pressure 6,200 +100 psi. [428 + 6.9 bar] Intermittent
Maximum Horsepower - 50 hp [37.3 kW] each

at Full Displacement
Maximum Speed - 35 rpm

at Full Displacement
Multi-Disc Brake 175-225 psi. [12-16 bar] - plus case pressure

Release Pressure
Maximum Braking Torque 9,000 ft. lbs. [12 204 N.m]
TRANSMISSION SYSTEM NOTE: Pressures given are with hydraulic oil at operating
PRESSURES temperature of 100 - 150°F [38 - 66° C] 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 100 psi. [7 bar] - Minimum

Forward or Reverse]
Pump Case Pressure 40 psi. [2.7 bar], Continuous - 75 psi. [5.2 bar], Intermittent
Torque Specifications
Hydraulic Drum Drive Motor 300 ft. lbs. [407 N.m]

To Motor Carrier
TRANSMISSION PUMP
DRIVE PLATE
Type Flexible steel, with center hub splined
Torque
Specifications
Flex Drive Plate To Engine 33 ft. lbs. [45 N.m]

Flywheel
9/2005 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 Spring applied, hydraulically released, [SAHR] multi-disc brake,

Brake Type incorporated with each hydrostatic transmission drum drive motor
TABLE 2-6. STEERING SYSTEM SPECIFICATIONS.
ITEM DESIGN DATA
STEERING SYSTEM
Type of System Hydraulic
System Oil Capacity See transmission system capacity, in THIS Section
Type of System Oil See 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 10 gpm [38 lpm] @ 2350 rpm

and Speed
Direction of Clockwise [C.W.]

Rotation [viewed
from shaft end]
STEERING RELIEF
VALVE
Type Integral with steering control unit
Relief Pressure 2400 +/- 50 psi. [166 +/- 3 bar], with engine @ low idle
2-8 9/2005
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 One [1]

Machine
Bore of Cylinder 3.00 in. [76 mm] - 66 Inch
3.50 in. [89 mm] 78 Inch
Stroke of Cylinder 12.00 +/-0.13 in. [305 +/-3 mm] - 66 Inch & 78 Inch
Rod Diameter 1.25 in. [32 mm] - 66 Inch & 78 Inch
Retracted Length 22.25 +/- 0.13 in. [565 +/- 3 mm] - 66 Inch & 78 Inch
of Cylinder [between pin bore
centers]
Extended Length 34.25 +/- 0.13 in. [870 +/- 3 mm] - 66 Inch & 78 Inch
of Cylinder [between pin bore
centers]
9/2005 2-9
Section 2
SPECIFICATIONS
ITEM DESIGN DATA
STEERING PERFORMANCE
Steering Time -
Stop to Stop
Right To Left 4.0 Seconds
Left To Right 4.5 Seconds
Total Number of 4.5 Revolutions - stop to stop

Wheel Turns
Inside Turning Radius 13 ft. 0 in. [3.9 m] - 66 Inch, or 12 ft. 6 in. [3.8 m] - 78 Inch
Outside Turning Radius 19 ft. 0 in. [5.8 m] - 66 Inch, or 19 ft. 6 in. [5.9 m] - 78 Inch
Total Steering 70° Total, 35°

each side of center
Torque Specifications
Hydraulic Pump Mount 35 ft. lbs. [47 N.m]
Steering Cylinder 200 ft. lbs. [271 N.m]

Piston Retaining Nut
Steering Cylinder 105 ft. lbs. [143 N.m]

Anchor End Mounting
Capscrews
TABLE 2-7. DRUM, VIBRATION AND CLEANER BAR SPECIFICATIONS

ITEM DESIGN DATA
66 INCH 78 INCH
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] 151 pli [68.5 kg lineal mm]
Drum Weight - With 3,400 lbs. [1 544 kg] - Each 3,850 lbs. [1 748 kg] - Each
Vibrator Assembly, Motor
And Isolators
Wrapper Thickness 0.70 in. [17.78 mm] 0.70 in. [17.78 mm]
2-10 9/2005
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 One [1] filter with replaceable element, rated 5 micron [nominal]
Filter And Element [Use APPROVED replacement element ONLY - see machine
Parts Manual]
Drum Bearing Lubrication

Oil [inside each drum]
Type See Section 4 - MAINTENANCE- for CORRECT type
Amount 10 Gallons [37.9 L], EACH drum
Hydraulic Pump Piston pump, variable displacement, two [2] used
Pump Output Rate 13.0 gpm [49.2 lpm] @ 2200 rpm

and Speed
Direction of Clockwise [CW] - FRONT drum supply pump; Counterclockwise

Rotation [as viewed from [CCW] - REAR drum supply pump
shaft end]
Hydraulic Motor Bent axis, axial piston, fixed displacement, two [2] used
Type and Quantity
Motor Input Rate and Pressure 13.0 gpm [49.2 lpm] @ 4400 psi. [304 bar]
Motor Maximum Speed 3400 rpm
Direction of Bidirectional
Rotation [viewed
from shaft end]
Case Pressure - Pumps 20 - 35 psi [1.4 - 2.4 bar]
Relief Valve 4600 + 50 psi. [317 +3 bar], Maximum @ 3 gpm [11.4 lpm]
Pressure Setting at start up. After a few minutes, drive pressure should drop to
and Rate - below 3000 psi. [207 bar].
Vibrator “Start/Stop”
Charge Relief Valve

Pressure Setting
Neutral Charge 300 psi. [21 bar] Minimum, 400 psi. [28 bar] Maximum, plus case
pressure (Typical 350 psi. [24 bar])
9/2005 2-11
Section 2
SPECIFICATIONS
ITEM DESIGN DATA
Vibration Isolation Tires - Two [2] per machine drum, four [4] total per machine
Quantity
Vibration Isolation Tires - G159LP 245/75R22.5

Size
Isolator Tire Inflation 30 psi. [2 bar] - COLD

Pressure
VIBRATION 66 INCH 78 INCH

PERFORMANCE
Centrifugal Force
High Amplitude 32,950 lbs. [146.4 kN] 37,099 lbs. [164.9 kN]
@ 3800 vpm @ 3800 vpm
Low Amplitude 27,580 lbs. [122.6 kN] 30,368 lbs. [135.0 kN]
@ 3400 vpm @ 3400 vpm
Frequency Range 2000 - 3800 vpm 2000 - 3800 vpm
Amplitude [nominal]
High Amplitude 0.030 in. [0.762 mm] 0.030 in. [0.762 mm]
Low Amplitude 0.020 in. [0.508 mm] 0.020 in. [0.508 mm]
CLEANER BEAMS AND

CLEANER RUBBERS
Type Cleaner Beams Full width, bolt on type
Number Cleaner Beams Four [4] total, Two [2] used per drum
Per Machine
Number Cleaner Rubbers One [1] adjustable, full width

Per Beam and Type
Adjustment Against drum surface
TORQUE SPECIFICATIONS
Drum To Frame 431 ft. lbs. [585 N.m]

Mounting Capscrews
Vibration Isolation System 157 ft. lbs. [213 N.m]

Assembly To Drum
Vibration Isolation Wheel 400 ft. lbs. [542 N.m]

To Drum Drive Motor
Bearing Carrier
2-12 9/2005
Section 2
SPECIFICATIONS
ITEM DESIGN DATA
Hoop Assembly To Bearing 431 ft. lbs. [585 N.m]

Housing
Vibrator Sub-assembly To 64 ft. lbs. [87 N.m]

Drum
Half Hoop Connecting 125 ft. lbs. [170 N.m]

Capscrews And Nuts
Cleaner Beam To Frame 280 ft. lbs. [380 N.m]

Mounting Capscrews
Cleaner Rubber To Cleaner 95 ft. lbs. [128 N.m]

Beam Mounting Capscrews
TABLE 2-8. WATER SPRAY SYSTEM SPECIFICATIONS.
ITEM DESIGN DATA
WATER SPRAY SYSTEM
Type Pressurized system
Tank Capacity and 125 gal. [475 l] - EACH, two [2] used, 66 Inch or -
Quantity 150 gal. [568 l] - EACH, two [2] used, 78 Inch
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 7 Per drum, threaded collar release from
Flow Rate - 66 Inch spray bar mounting, 0.075 gpm [.284 lpm]
Nozzle Quantity, Type and 8 Per drum, threaded collar release from
Flow Rate - 78 Inch spray bar mounting, 0.075 gpm [.284 lpm]
9/2005 2-13
Section 2
SPECIFICATIONS
TABLE 2-9. CONTROL AND INDICATOR SPECIFICATIONS.
ITEM DESIGN DATA
FUNCTION TYPE
CONTROL
Direction of Left and right handle, electrical control of transmission pump output
Machine Travel
[F-N-R] and
Transmission
System Speed
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 Toggle control switch, 12 volt, negative ground, three [3] position
“FRONT/BOTH/REAR”
Vibration Amplitude Toggle control switch, 12 volt, negative ground,

“LOW/HIGH” two [2] position
Vibration Frequency Variable potentiometer control, 12 volt, negative ground, [one [1] for
“VPM” each drum]
Vibration System Mode Toggle control switch, 12 volt, negative ground, three [3] position
“OFF/AUTOMATIC/
MANUAL”
Vibration System Manual Electrical push button thumb switch, left and right travel control
Mode “START/STOP” installed, 12 volt, negative ground
Transmission Drum Drive Toggle control switch, 12 volt, negative ground, electrohydraulic
Motors “TRAVEL [high]/ system
WORK [low]” Range
Water Spray System Toggle control switch, 12 volt, negative ground, three [3] position
“ON/OFF/AUTO” “on”, “off”, “auto” [timed], with automatic “off”, at neutral, in “auto”
mode
Water Spray Systems Duty One [1], timed delay, dash mounted, control
Cycle
Horn Button switch, 12 volt negative ground, instrument panel mounted
Panel And Operation Lights Electrical switch, 12 volt, negative ground
2-14 9/2005
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 gauge, electrical, 12 volt, negative ground

Temperature
Vibrator Systems Pressure Indicator light, 12 volt, negative ground

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

Indicator
System Function Monitor Display scroll button and alphanumeric display screen,
Display Screen/Scroll Button 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 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
9/2005 2-15
Section 2
SPECIFICATIONS
TABLE 2-11. DIMENSION SPECIFICATIONS [see figure 2-1].
ITEM DESIGN DATA
DIMENSIONS 66 INCH 78 INCH
A. Overall Height to 105 in. [2 667 mm] 105 in. [2 667 mm]
Top of FOPS/ROPS
B. Height - to Top of 78 in. [1 981 mm] 78 in. [1 981 mm]

Steering Wheel
C. Overall Width - W/FOPS/ 81 in. [2 057 mm] 92.5 in. [2 350 mm]
ROPS
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 9/2005
Section 2
SPECIFICATIONS
G
H
FIGURE 2-1. MACHINE DIMENSIONS.
9/2005 2-17
Section 2
SPECIFICATIONS
TABLE 2-12. PERFORMANCE SPECIFICATIONS.
ITEM DESIGN DATA
TRAVEL SPEED
TRAVEL [High] Range 0-10 mph [0-16.1 kmph]

WORK [Low] Range 0-5 mph [0-8.1 kmph]
EFFECTIVE COVERAGE
Width 66 in. [1 676 mm] - 66 Inch unit or 78 in. [1 981 mm] - 78 Inch, unit per pass
TABLE 2-13. MACHINE SYSTEM CAPACITY SPECIFICATIONS.
ITEM DESIGN DATA
SYSTEM CAPACITIES
Fuel 50 Gallons [189 liters] - 66 Inch or 60 Gallons [227 liters] - 78 Inch
Engine Lubrication Oil 10 Quarts [9.5 liters] - WITH Lubrication Oil filter
Cooling System 19 Quarts [18 liters]
Hydraulic Oil Reservoir 22 Gallons [83.3 liters]

[Supplies All Oil To
Transmission, Steering and
Vibration Systems]
Drum Bearing Lubrication 10 Gallons [37.9 liters] - each drum

Oil
Water Spray - Two [2] 125 Gallons [473 liters] each tank - 66 Inch
Tanks Used Per Machine 150 Gallons [568 liters] each tank - 78 Inch
2-18 9/2005
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 BW266 BW278
Operating Weight 20,600 lbs. [9 352 kg] 23,500 lbs. [10 669 kg]
W/ FOPS/ROPS
Shipping Weight 19,150 lbs. [8 694 kg] 21,750 lbs. [9 875 kg]
W/ FOPS/ROPS
REAR FRAME
With Engine and Drive 9,843 lbs. [4 465 kg] 11,345 lbs. [5 146 kg]
Components
FRONT FRAME
With Isolators and Drum 10,757 lbs. [4 879 kg] - 12,154 lbs. [5 5513 kg]
With FOPS/ROPS With FOPS/ROPS
ENGINE
Dry 745 lbs. [338 kg]

With Pumps and All Items 1,075 lbs. [488 kg]
Installed
OTHER COMPONENTS
Radiator 100 lbs. [45 kg]
Battery 49 lbs. [22 kg]
Transmission Hydraulic Pump 125 lbs. [57 kg]
Transmission Hydraulic Drum 450 lbs. [205 kg], each

Drive Motor [2 used]
Shuttle Valve 2 lbs. [1 kg]
9/2005 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 - 50 lbs. [23 kg]

Vibration - Two
[2] Used
Hydraulic Vibrator Motor 13 lbs. [6 kg]

Two [2] used
Drum and Vibrator 66 Inch Unit - 3,400 lbs. [1 544 kg], 78 Inch Unit - 3,850 lbs. [1 748 kg]
Assembly Complete - Two
[2] Used
Isolator Half Hoop 100 lbs. [45 kg]

Weldment - Eight [8] Used
Machine Cockpit 700 lbs. [318 kg]

Assembly Complete
Falling Object/Roll Over 66 Inch Unit - 815 lbs. [370 kg], 78 Inch Unit - 872 lbs. [396 kg]
Protective Structure
[FOPS/ROPS]
Cross Beam Plate - Front & 66 Inch Unit - 700 lbs. [318 kg], 78 Inch Unit - 1,300 lbs. [590 kg]
Rear - Two [2] Used
2-20 9/2005
Section 2
SPECIFICATIONS
TABLE 2-15. TORQUE SPECIFICATIONS FOR STANDARD INCH FASTENERS.
SAE GRADE 8 CAPSCREWS
TORQUE TORQUE
NOM. THREAD (FT. LBS.) (Nm)
SIZE SERIES
DRY LUBED DRY LUBED
1/4 20 UNC 12 16 12
28 UNF 14 10 19 14
5/16 18 UNC 25 18 33 25
24 UNF 27 20 37 28
3/8 16 UNC 44 33 59 44
24 UNF 49 37 67 50
7/16 14 UNC 70 52 95 71
20 UNF 78 58 105 79
1/2 13 UNC 105 80 145 110

20 UNF 120 90 165 120
9/16 12 UNC 155 115 210 155
18 UNF 170 130 230 175
5/8 11 UNC 210 160 285 215

18 UNF 240 180 325 245
3/4 10 UNC 375 280 510 380
16 UNF 420 315 570 425
7/8 9 UNC 605 455 820 615

14 UNF 670 500 905 680
1 8 UNC 910 680 1 230 925
14NF 1 020 765 1 380 1 040
1-1/8 7 UNC 1 290 965 1 750 1 310

12 UNF 1 440 1 080 1 960 1 470
1-1/4 7 UNC 1 820 1 360 2 460 1 850
12 UNF 2 010 1 500 2 730 2 050
1-3/8 6 UNC 2 380 1 780 3 230 2 420

12 UNF 2 710 2 040 3 680 2 760
1-1/2 6 UNC 3 160 2 370 4 290 3 210
12 UNF 3 560 2 670 4 820 3 620
WARNING: THESE TABLES LIST TORQUE VALUES FOR STANDARD FASTENERS AND ARE
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 12 POINT

CAPSCREW CAPSCREW
FIGURE 2-2. STANDARD HARDWARE.
9/2005 2-21
Section 2
SPECIFICATIONS
TABLE 2-16. TORQUE SPECIFICATIONS FOR STANDARD METRIC FASTENERS.
NOMINAL CLASS 8.8 [GRADE 5 EQUIVALENT] CLASS 10.9 [GRADE 8 EQUIVALENT]

SIZE &
PITCH TORQUE FT. LBS TORQUE - N-m TORQUE FT. LBS TORQUE - N-m
DRY LUBED DRY LUBED DRY LUBED DRY LUBED
M3 x 0.5 0.97 0.73 1.32 0.99 1.32 0.99 1.79 1.34

M3.5 x 0.6 1.61 1.21 2.07 1.55 2.08 1.56 2.82 2.11
M4 x 0.7 2.27 1.70 3.07 2.30 2.27 2.31 4.17 3.13
M5 x 0.8 4.58 3.43 6.20 4.65 6.22 4.67 8.43 6.33
M6 x 1 7.75 5.83 10.5 7.90 10.60 7.97 14.3 10.8
M8 x 1.25 18.89 14.17 25.6 19.2 18.95 19.26 34.8 26.1
M8 x 1 20.22 15.13 27.4 20.5 27.53 20.59 37.3 27.9
M10 x 1.5 40.04 28.04 51.0 38.0 50.92 38.38 69.0 52.0
M10 x 1.25 39.11 29.52 53.0 40.1 53.87 40.59 73.0 55.0
M12 x 1.75 64.94 48.71 88.0 66.0 88.56 66.42 120.0 90.0
M12 x 1.25 70.85 53.14 96.0 72.0 70.81 72.32 130.0 98.0
M14 x 2 103.32 77.49 140.0 105.0 140.22 107.01 190.0 145.0
M14 x 1.5 114.39 84.87 155.0 115.0 154.98 114.39 210.0 155.0
M16 x 2 162.36 121.77 220.0 165.0 221.40 166.05 300.0 225.0
M16 x 1.5 173.43 129.15 235.0 175.0 236.16 177.12 320.0 240.0
M20 x 2.5 317.34 236.16 430.0 320.0 428.04 321.03 580.0 435.0
M20 x 1.5 360.55 281.99 475.0 355.0 479.70 357.93 650.0 485.0
M24 x 3 516.12 409.59 740.0 555.0 754.38 557.19 1 010.0 755.0
M24x2 594.09 445.49 805.0 605.0 811.80 605.16 1 100.0 820.0
M27 x 3 797.04 597.78 1 080.0 810.0 1 084.86 811.80 1 470.0 1 100.0
M27 x 2 863.46 645.75 1 170.0 875.0 1 173.42 878.22 1 590.0 1 190.0
M30 x 3.5 1 084.86 811.80 1 470.0 1 100.0 1 476.00 1 107.00 2 000.0 1 500.0
M30 x 3 1 121.76 841.32 1 520.0 1 140.0 1 527.66 1 143.90 2 070.0 1 550.0
M30 x 2 1 202.94 900.36 1 530.0 1 220.0 1 630.98 1 225.08 2 210.0 1 660.0
M33 x 3.5 1 476.00 1 107.00 2 000.0 1 500.0 2 007.36 1 505.52 2 720.0 2 040.0
M33 x 2 1 623.60 1 623.60 2 200.0 1 640.0 2 199.24 1 653.12 2 980.0 2 240.0
M36 x 4 1 896.66 1 424.34 2 570.0 1 930.0 2 575.62 1 933.56 3 490.0 2 620.0
M36 x 3 2 007.36 1 505.52 2 720.0 2 040.0 2 730.60 2 051.64 3 700.0 2 780.0
M39x4 2 450.16 1 837.62 3 320.0 2 490.0 3 335.76 2 501.82 4 520.0 3 390.0
M39x3 2 583.00 1 940.94 3 500.0 2 630.0 3 512.88 2 634.66 4 760.0 3 570.0
M42 x4.5 3 033.18 2 273.04 4 110.0 3 080.0 3 044.56 3 099.60 5 590.0 4 200.0
M42x3 3 261.96 2 450.16 4 420.0 3 320.0 4 442.74 3 328.38 6 020.0 4 510.0
M45 x4.5 3 785.94 2 841.30 5 130.0 3 850.0 5 084.82 3 867.12 6 980.0 5 240.0
M45x3 4 051.62 3 040.56 5 490.0 4 120.0 5 512.86 4 140.18 7 470.0 5 610.0
M48x5 4 553.46 3 416.94 6 170.0 4 630.0 6 199.20 4 649.40 8 400.0 6 300.0
M48x3 4 959.36 3 719.52 6 720.0 5 040.0 6 752.70 5 062.68 9 150.0 6 860.0
WARNING: THESE TABLES LIST TORQUE VALUES FOR STANDARD FASTENERS AND ARE
INTENDED AS A GUIDE FOR AVERAGE APPLICATION INVOLVING TYPICAL
STRESSES AND MACHINED SURFACES. VALUES ARE BASED ON THE
PHYSICAL LIMITATIONS OF CLEAN, PLATED AND LUBRICATED FASTENERS.
IN ALL CASES, WHEN AN INDIVIDUAL TORQUE IS SPECIFIED, IT SHOULD BE
FOLLOWED INSTEAD OF VALUES GIVEN IN THIS TABLE. REPLACE ORIGINAL
EQUIPMENT WITH FASTENERS OF EQUAL GRADE.
2-22 9/2005
Section 2
SPECIFICATIONS
TABLE 2-17. LUBRICATION OILS, HYDRAULIC OILS AND COOLANT SPECIFICATIONS.
P/N DESCRIPTION SIZE
336830 HYDRAULIC/TRANSMISSION OIL 1 QT
336831 HYDRAULIC/TRANSMISSION OIL 2 GAL
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]
9/2005 2-23
Section 2
SPECIFICATIONS
NOTES
2-24 9/2005
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.
9/2005 3-1
Section 3
OPERATION
GENERAL INFORMATION. OPERATING CONTROLS, INDICATORS AND
GAUGES.
THIS section gives the OPERATION INSTRUC-
TIONS for the 66 Inch and 78 Inch Operating controls, indicators and gauges, for the
Compactors. 66 Inch and 78 Inch Compactors, are shown on
Figure 3-2 and are listed in Table 3-1.
Read, understand and follow ALL “Precaution and
Operating Instructions” given on the machine
“OPERATING INSTRUCTION and WARNING” DANGER: Do NOT start, or operate, the 66 Inch
decals and written in THIS manual, BEFORE or 78 Inch Compactor BEFORE
starting, or operating, the machine [see figure reading, understanding and following
3-1]. ALL information given in THIS section
and shown on the machine “Operat-
ing Instruction and Warning” decal,
DANGER: FAILURE to observe the “OPERAT- found on the engine hood, ahead of
ING PRECAUTIONS” and/or the the steering wheel.
machine “OPERATION and WARNING The operator MUST read about,
INSTRUCTIONS”, given in THIS and understand, the function of
manual and found on the ECALS ALL controls, indicators and
affixed to the machine can cause gauges BEFORE starting the
SERIOUS INJURY, or DEATH. engine.
ONLY authorized personnel, who are SERIOUS INJURY, or DEATH, can
fully trained in the machine operation, result if THESE procedures are
can operate the 66 Inch or 78 Inch NOT followed.
Compactor.
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 9/2005
Section 3
OPERATION
FIGURE 3-1. 66 INCH AND 78 INCH COMPACTOR “OPERATING INSTRUCTION DECAL”.
9/2005 3-3
Section 3
OPERATION
9 30 10 3
29 7 21
11 8 27
26 28 25 26 22 4 24 10
13 14 18 23 19 2
15 17 20 6
16
12
12
1
1
FIILTERS
OFF HIGH
AUTO MAN.
VIBRATOR MODE LOW LIGHTS

BOTH WATER SAVER ENGINE THROTTLE
SPEED RANGE
REAR FRONT
AUTO MAN.
DRUM SELECT WATER

FRONT VIM. SPEED OFF SPRAY
HIGH LOW
AMPLITUDE
REAR VIB. SPEED
SCROLL
FIGURE 3-2. MACHINE OPERATING CONTROLS AND INDICATORS.
3-4 9/2005
Section 3
OPERATION
TABLE 3-1. MACHINE OPERATING CONTROLS, INDICATORS AND GAUGES.
ITEM NO. DESCRIPTION TYPE FUNCTION

[SEE FIG’
3-2]
1 DIRECTIONAL/ Control handle - Controls forward/reverse

SPEED CONTROL Left and Right movement and speed of machine in the
[F-N-R] Dash Mounted 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].
2 IGNITION Three [3] Controls STARTING, RUNNING

SYSTEM Position - STOPPING of engine.
Key Operated -
Interlock NO.1 POSITION: “OFF” condition.
Switch 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.
9/2005 3-5
Section 3
OPERATION

[SEE FIG’
3-2]
3 ENGINE Toggle Switch - Controls engine throttle speed [RPM].

THROTTLE Two [2] Position
SPEED Toggle switch “DOWN”,
puts engine throttle at “LOW” idle speed.
Toggle switch “UP”, puts engine throttle

at “HIGH/WORK” idle speed.
4 STEERING Manually Provides machine DIRECTION

SYSTEM Operated control. TURN steering wheel
Wheel IN the direction the machine is
desired to travel.
5 SECONDARY/ Button Switch - Controls secondary/parking brake

PARKING Two [2] Position system application and release.
BRAKE SYSTEM
Button switch pushed “IN”,
APPLIES the brake system.
Button switch turned right and “OUT”,

RELEASES the brake system.
6 WATER SPRAY Toggle Switch - Controls water spray systems operation.

SYSTEMS - MODE Three [3] Position
[“AUTO/OFF/MANUAL”] Switch at “MANUAL”, turns front
AUTO MAN.
and rear drum systems “ON”, continuously.
WATER
OFF SPRAY
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 9/2005
Section 3
OPERATION

[SEE FIG’
3-2]
7 TRANSMISSION RANGE Toggle Switch - Selects range of transmission drum

- “WORK” [Low] Two [2] Position drive motors.
“TRAVEL” [High]
Switch “DOWN ”, puts system in “WORK ”
[low] range.
Switch “UP”, puts system in “TRAVEL”

[high] range.
8 DRUM VIBRATOR MODE Toggle Switch - MODE selection of drums vibration system.
“AUTOMATIC/OFF/ Three [3] Position
MANUAL” “CENTER” position turns system “OFF”.
OFF
AUTO MANUAL “LEFT” position puts system in

VIBRATOR MODE “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 Toggle Switch - Selects drum vibration system[s] location

SYSTEM[S] LOCATION Three [3] Position “FRONT”, “BOTH” or “REAR”.
[Front/Both/ Rear]
BOTH
Switch “LEFT ”, selects “FRONT” drum
FRONT REAR vibration system, ONLY.
DRUM SELECT
Switch “CENTER”, selects BOTH “front AND
rear” drum vibration systems.
Switch “RIGHT”, selects “REAR” drum

vibration system, ONLY.
9/2005 3-7
Section 3
OPERATION

[SEE FIG’
3-2]
10 VIBRATION SYSTEM Potentiometer FREQUENCY control [3400 - 3800 VPM -

FREQUENCY Control - 66 Inch or 3400 - 3800 VPM - 78 Inch], for
One [1] Control EACH drum.
For FRONT Drum
and One [1] Select desired FREQUENCY for EACH drum.
Control For REAR
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].
FRONT VIB. SPEED

Either, or both, control[s] turned to the RIGHT
selects HIGHEST VPM FREQUENCY for the
low, or high, amplitude mode selected by the
REAR VIB. SPEED mode switch [ITEM 11].

11 VIBRATION SYSTEM Toggle Switch - Selects AMPLITUDE mode of BOTH front

HIGH/LOW AMPLITUDE Two [2] Position and rear drums vibration system.
MODE
HIGH LOW Switch “LEFT ”, puts BOTH front and rear
drums vibration system in “HIGH ”
AMPLITUDE
amplitude mode.
Switch “RIGHT”, puts BOTH front and rear

drums vibration system in “LOW ”
amplitude mode.

3-8 9/2005
Section 3
OPERATION

[SEE FIG’
3-2]
12 MANUAL DRUM Electrical Push MANUAL “START/STOP” control of front,

VIBRATOR Button Thumb rear or both drums vibration system[s].
“START/STOP” Switches - Left
and Right Travel “DEPRESS” switch once and release to
Control Handle “START/RUN” system[s] vibration.
Installed
“DEPRESS” switch, again, and release to
“STOP” system[s] vibration.

13 ENGINE Hourmeter Indicates TOTAL hours

HOURS engine has operated. Operates
OPERATED when ignition key switch is in the
“ON/RUN” position and the engine
is “running”.
14 FUEL AMOUNT Fuel Level Indicates amount of fuel

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

PRESSURE Pressure lubrication oil. Operates when the
Gauge 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.
9/2005 3-9
Section 3
OPERATION

[SEE FIG’
3-2]
16 ELECTRICAL Voltmeter Indicates alternator output

SYSTEM voltage or battery voltage,
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 Indicates temperature of

COOLANT Temperature engine coolant circulating
TEMPERATURE Gauge 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 Hydraulic Indicates temperature of

SYSTEM OIL Oil oil flowing through
TEMPERATURE Temperature transmission, steering and
Gauge 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 ENGINE INLET Electrical Indicates “RED” lighted

AIR CONDITION Light, Red condition ONLY when engine inlet
Lens air flow is restricted. When
Covered lighted, IMMEDIATE service of air cleaner
assembly is required BEFORE further
machine operation.
3-10 9/2005
Section 3
OPERATION

[SEE FIG’
3-2]
20 VIBRATION SYSTEMS Electrical Indicates “RED” lighted

PRESSURE OIL Light, Red condition when vibration systems
FILTER ELEMENT Lens Covered PRESSURE oil filter
CONDITION element has reached maximum
holding capacity and MUST be changed.*
21 HORN Push Button, Provides actuation of the horn.

ACTUATION Switch - Dash When the horn button is pushed,
Mounted the horn will sound.
22 VANDAL GUARD Lockable Install over dash instrument

Cover 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 Turns light dash and headlight systems

Switch “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 Duty Cycle One [1] dial switch controls water flow duty
SYSTEMS- DUTY Control Switch cycle for BOTH drums. Set switch to desired
CYCLE 0-50% duty cycle.
NOTE: Water spray system MODE

WATER SAVER
selector switch [ITEM 6] MUST be
in “AUTO” position for duty
cycle to function.
25 SPEEDOMETER Digital Display Indicates travel speed of machine during

Screen 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.
9/2005 3-11
Section 3
OPERATION

[SEE FIG’
3-2]
26 SYSTEM FUNCTION Electrical Display Scroll button provides access to machine

MONITOR DISPLAY Scroll Button and system functions, for verification and/or
SCREEN Alphanumeric changes, through alphanumeric display screen.
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].
27 Engine Warning Lamp Engine Stop Illuminates Red. Indicates damage to the
engine is possible. The engine will turn off
after 30 seconds.
STOP
28 Fuel Warning Lamp Fuel Warning Illuminates Yellow. Water is present in the
fuel filter. Remove water as soon as
possible from the fuel filter discharge drain
WATER IN
valve.
FUEL
29 Check Engine Lamp Engine Warning Illuminates Yellow. Engine temperature, oil
pressure or coolant level outside of engine
tolerance range.
CHECK
ENGINE
30 Air Tempature Low Lamp Engine Information Illuminates Blue. Low temperatures at the
intake air detected.
Wait until intake air is preheated.
WAIT TO
START
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 9/2005
Section 3
OPERATION
OPERATION
b. Keep the transmission in “NEUTRAL”, by
CHECKS WITH THE ENGINE STOPPED. positioning the directional/speed control [F-N-R]
handle [ITEM 1] in the “CENTER” [NEUTRAL]
With the engine in a STOPPED condition, INSPECT position. Put the drum vibrator MODE switch [ITEM
the machine BEFORE use and AFTER every 8] in the “OFF” position.
EIGHT [8] hours of operation, or DAILY, as directed
in Section 4 - MAINTENANCE - in THIS manual.
NOTE: The transmission MUST be in
CHECK, or INSPECT, the following items: “NEUTRAL” and the secondary/parking
brake MUST be APPLIED, for the engine
Fuel level. to be started.
Engine lubrication oil level.
Engine cooling system coolant level.
Condition of drive belt on engine. c. Keep the engine THROTTLE speed control
Hydraulic system oil level. switch [ITEM 3] at the “LOW IDLE” speed position.
Drum bearing lubrication oil level, in BOTH drums.
Engine inlet air path.
Fluid leaks from engine, fuel or hydraulic system. CAUTION: Do NOT put the engine throttle
Operation of the horn. speed control switch at the
Safety decals, securely affixed to machine and their “HIGH” idle position. Engine
condition. damage can occur.
Seat belts [BOTH sets] condition and operation.
FOPS/ROPS overall condition, condition of struc-
ture welds and correct tightened torque of all d. Turn the ignition switch key [ITEM 2] to the
structure mounting capscrews. START [THIRD] position. Crank and start the
engine.
STARTING THE ENGINE [See Figure 3-2 and WARNING: CALIFORNIA Proposition 65
Table 3-1]. Warning: Diesel engine exhaust and
some of its constituents are known
a. If installed, unlock and then move the vandal to the state of California to cause
guard [ITEM 22] away from the instrument panel. cancer, birth defects, and other
Put the guard in the stowed position. KEEP the reproductive harm.
secondary/parking brake system in the “ON”
[APPLIED] condition by leaving the system control
switch [ITEM 5] in the “ON” [APPLIED] position. CAUTION: Make a note of the amount of
continuous cranking time.
Do NOT crank the engine MORE
DANGER: The machine MUST NOT move, at than thirty [30] seconds
ANY time, when the CONTINUOUSLY. IF the engine is
secondary/parking brake switch NOT started within this time,
is in the “ON” [APPLIED] position. put the ignition switch key in
Do NOT operate the machine, if the OFF [FIRST] position. Wait
the machine will move when the one [1] minute. This will allow
SECONDARY/PARKING brake system the starter motor time to cool.
is in an “ON” [APPLIED] Repeat step “d” UNTIL the engine
condition, UNTIL the fault is is started.
CORRECTED. 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”.
9/2005 3-13
Section 3
OPERATION
NOTE: The machine is equipped with an OPERATION OF THE STEERING SYSTEM.
automatic ether cold start aid. At engine
"cold start", the system will introduce
ether into the fuel intake system to DANGER: Keep ALL personnel CLEAR of
assist in engine starting. If the engine the hitch area. The CLEARANCE
fails to start, during a engine "cold start" between the front and rear
[40°F, or below] attempt, check and if frames, at the hitch, CLOSES
needed, replace the ether supply canister when the machine is turned in
with a "full" replacement canister. EITHER direction.
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 OPERATION OF THE TRANSMISSION SYSTEM.
display the machine model number and
then return to the "default screen"
display showing machine speed, front DANGER: Keep ALL personnel CLEAR of the
and rear vibrator speeds [vpm] and machine when checking the
impacts per foot, thereafter. operation of the transmission system.
CAUTION: Do NOT check the operation of

either drum vibration system,
CHECKS WITH THE ENGINE RUNNING.
UNLESS the drums of the machine
are on a SOFT surface, such as
With the engine “running”, CHECK, or INSPECT,
loose dirt or “old” tires.
the machine BEFORE operation, using the FOL-
Damage to the drums and/or
LOWING information. Also, do these checks and/or
machine can occur if the operation of
inspections AFTER every eight [8] hours of opera-
the drum vibration systems is
tion, or DAILY, as directed in Section 4 - MAINTE-
checked on a HARD surface.
NANCE - in this manual. CHECK, or INSPECT, the
following items.
CURRENT MACHINE SYSTEMS PARAMETERS.

OPERATION OF THE SECONDARY/PARKING
Review currently selected preset parameters for:
BRAKE SYSTEM.
1. Maximum “WORK” [low] transmission range
With the secondary/parking brake system control speed [see figure A].
switch [ITEM 5] in the “ON” [APPLIED] position,
note that the machine remains stopped and held 2. Automatic vibration mode vibrator “start/stop”
when the directional/speed control handle [F-N-R] is speed point [see figure B].
moved to the forward, or reverse, direction. 3. English, or metric units format, system monitor
display screen [see figure C].
DANGER: Do NOT operate the machine, if

the machine moves when the NOTE: Review the above three [3] parameters,
secondary/parking brake system and change the settings as desired, with
is in an “ON” [APPLIED] the directional/speed control handles in
condition, UNTIL the fault the NEUTRAL position and the
is corrected. The machine MUST secondary/parking brake system
NOT move, at ANY time, when the APPLIED.
secondary/parking brake system Use the following instructions to access
control switch [ITEM 5] is in the “ON” each system function, on the monitor
[APPLIED] position. display screen, review the system
information shown on each screen and/
or change each system's parameters.
3-14 9/2005
Section 3
OPERATION
DANGER: Keep the secondary/parking brake NOTE: If the maximum “work” [low] range speed
system APPLIED and keep ALL is desired to be DECREASED, move
personnel CLEAR of the machine either directional/speed control handle
when reviewing ANY, or ALL, [ITEM 1] from the neutral position,
currently selected preset parameters toward the REVERSE travel position, a
and/or making parameter changes. small amount.
Use the following information to access the

maximum “work” [low] range speed parameter c. Push the manual drum vibrator "start/stop"
screen. button thumb switch [ITEM 12], found on the
directional/speed control handle [F-N-R], ONE [1]
1. With the machine in NEUTRAL, use the display time for each one tenth [1/10] miles per hour [mph]
scroll button [ITEM 26], found below the display the maximum “work” [low] range speed is desired to
screen [ITEM 26], to scroll through each system be INCREASED, or DECREASED. Note that the
information screen until the maximum “work” [low] speed displayed on the display screen IN-
range speed screen is reached. CREASES, or DECREASES.
2. Review the maximum “work” [low] range speed

parameter displayed on the screen. NOTE: The maximum “work” [low] range speed
adjustment is in increments of one
tenth [1/10 miles per hour [mph] even IF
NOTE: The monitor screen will display the the display screen is reading in metric
above system information in either units format.
English [mph], or metric units [kph], The range of adjustment is from a
dependent on which read out method MINIMUM of one half [1/2] miles
has been selected. per hour [mph] to a MAXIMUM of five [5]
miles per hour [mph].
3. If the maximum “work” [low] range speed shown

is as desired, use the display scroll button to scroll d. When the maximum “work” [low] range speed
to the next screen, or return to the normal screen has been INCREASED, or DECREASED, to the
[see Figure D], displayed during machine operation. desired speed, move either directional/speed control
handle [ITEM 1] back to the NEUTRAL position.
NOTE: If the maximum “work” [low] range speed e. After completing the adjustment procedure,
shown is NOT as desired, use the use the display scroll button to scroll to the next
following additional information to screen or return to the normal screen [see Figure
change the speed. D], displayed during machine operation.
a. Leave the maximum “work” [low] range speed NOTE: At any time during machine operation on
displayed on the display screen. the work surface, if the maximum
“work” [low] range speed requires
b. Keep the secondary/ parking brake APPLIED. adjustment, use the above information to
If the maximum “work” [low] range is desired to be change the speed, again.
INCREASED, move either directional/speed control
handle [F-N-R] [ITEM 1] from the neutral position,
toward the FORWARD travel position, a small
amount.
9/2005 3-15
Section 3
OPERATION
Use the following information to access the c. Push the manual drum vibrator "start/stop"
machine automatic vibration mode vibrator button thumb switch [ITEM 12], found on the
“start/stop” speed point screen. directional/speed control handle, ONE [1] time for
each one tenth [1/10] miles per hour [mph] the
1. With the machine in NEUTRAL, use the scroll vibrator “start/stop” speed point is desired to be
button [ITEM 26], found below the display screen INCREASED, or DECREASED. Note that the speed
[ITEM 26], to scroll through each system information displayed on the display screen INCREASES, or
screen until the machine automatic vibration mode DECREASES.
vibrator “start/stop” speed point screen is reached.
2. Review the machine vibrator “start/stop” speed NOTE: The maximum vibrator “start/stop”
point parameter displayed on the screen. speed point adjustment is in increments
of one tenth [1/10 miles per hour [mph]
even IF the display screen is reading in
NOTE: The monitor screen will display the metric units format.
above system information in either The range of adjustment is from a
English [mph], or metric units [kph], MINIMUM of one half [1/2] miles
dependent on which read out method per hour [mph] to a MAXIMUM four [4]
has been selected. miles per hour [mph].
3. If the vibrator “start/stop” speed point shown is d. When the vibrator “start/stop” speed point has
as desired, use the display scroll button to scroll to been INCREASED, or DECREASED, to the desired
the next screen or return to the normal screen [see speed, move either directional/speed control handle
Figure D], displayed during machine operation. [ITEM 1] back to the NEUTRAL position.
e. After completing the adjustment procedure,

NOTE: If the vibrator “start/stop” speed point use the display scroll button to scroll to the next
shown is NOT as desired use the screen or return to the normal screen [see Figure
following additional information to D], displayed during machine operation.
change the “start/stop” speed point.
NOTE: At any time during machine operation on

a. Leave the vibrator “start/stop” speed point the work surface, if the vibrator “start/
displayed on the display screen. stop” speed point requires adjustment,
use the above information to change the
b. Keep the secondary/ parking brake APPLIED. “start/stop” speed point, again.
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.
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 9/2005
Section 3
OPERATION
Speed Limit: 4.3 mph 4.3 mph : FRNT 3200 vpm

ADJ. WITH MANUAL VIB. SW 10 ipf : REAR 0 vpm
FIGURE A. MAXIMUM MACHINE TRAVEL SPEED FIGURE D. NORMAL "RUN" - CURRENT

- DISPLAY SCREEN. MACHINE TRAVEL SPEED, FRONT & REAR
DRUM VIBRATIONS PER MINUTE AND
IMPACTS PER FOOT -
DISPLAY SCREEN.
AUTO VIB. SET.= 0.8 mph 3 mph : FRNT 3200 vpm

ADJ. WITH CONTROL HANDLE FAULT: FNR Neutral SW.
FIGURE B. VIBRATOR “START/STOP” SPEED FIGURE F. FAULT MESSAGE -

POINT - DISPLAY SCREEN. DISPLAY SCREEN, EXAMPLE.
DISPLAY UNITS: ENGLISH FAULT: Sprayer Valve - Water

ADJ. WITH MANUAL VIB. SW Sprayer Valve Open or Short
FIGURE C. ENGLISH/ METRIC UNITS FORMAT FIGURE G. FAULT MESSAGE -

- DISPLAY SCREEN. DISPLAY SCREEN, SPRAYER VALVE OPEN,
OR SHORTED.
378 fpm : FRNT 3200 vpm

10 ipf : REAR 0 vpm 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].
9/2005 3-17
Section 3
OPERATION
Use the following information to access the NORMAL [RUN] SCREENS
machine English/metric units format display [See Figures D and E].
screen.
With the machine in neutral, or in operation, use the
1. With the machine in NEUTRAL, use the display display scroll button [ITEM 26], found below the
scroll button [ITEM 26], found below the display display screen [ITEM 26], to scroll through each
screen [ITEM 26], to scroll through each system system information screen until the machine normal
information screen until the English/metric units [run] screen [figure D] is reached.
screen is reached.
Review the English, or metric units, information
2. Review the English, or metric units, format displayed on the screen, indicating current machine
displayed on the screen. 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 NOTE: The display screen will show system
units, format dependent on which format information in either English, or metric
method has been selected. units, format dependent on which format
method has been selected.
The second screen indicating machine
3. If the display screen format is as desired, use travel in "feet per minute" [fpm] and
the display scroll button to scroll to the next screen "impacts per foot" [ipf], can be accessed
or return to the normal screen [see Figure D], by pressing the display scroll button
displayed during machine operation. [ITEM 26], found below the display
screen [ITEM 26].
NOTE: If the display screen format is NOT as

desired, use the following additional
information to change the screen format. 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
displayed on the display screen. a system fault condition exists and can be detected.
b. Keep the secondary/ parking brake APPLIED. It will be displayed for a short period of time on the
Push the manual drum vibrator "start/stop" button bottom line of the display screen. Then the previ-
thumb switch [ITEM 12], found on the directional/ ously selected display bottom line will be displayed,
speed control handle, ONE [1] time and change the again. This will continuously alternate as long as the
screen from English to metric units format, or from fault exists.
metric units to English format.
If serious, some faults will cause a shut down of the
c. When the desired display screen format has travel control system and the message will continue
been selected, use the display scroll button to scroll to be displayed until the cause of the fault is
to the next screen or return to the normal screen, corrected.
displayed during machine operation.
NOTE: At any time during machine operation,

use the above information to change the
screen format, if desired.
3-18 9/2005
Section 3
OPERATION
The "limited operation mode" allows the machine to DANGER: FAILURE to observe the following
be removed from the work surface if a "stop" fault" precautions and/or the machine
is detected [See THIS Section and Figure H]. “OPERATION and WARNING
INSTRUCTIONS”, given in THIS
The "limited operation mode" is programed into section and found on the DECALS
computer controller software "Version 2.33" and affixed to the machine, can cause
was NOT included in previous "versions" of the SERIOUS INJURY, or DEATH.
software. ONLY authorized personnel, who
are fully trained in the machine
Other fault messages will only display a message operation, can operate the
for as long as a fault is detected. 66 Inch, or 78 Inch, Compactor.
WARNING: Do NOT operate a machine a. USE a SLOW SPEED [work range] and
displaying fault messages, except ADDITIONAL CAUTION when nearing, or operat-
the "limited operation mode" . ing, the machine close to a slope and/or when
Put an information tag on the traveling down a slope.
steering wheel which says “DO NOT
OPERATE”. REMOVE the key from b. Do NOT travel across a slope. When on a
the ignition switch. Investigate and slope, TRAVEL in an “UP” or “DOWN” direction
repair ALL system faults at ONCE. ONLY.
c. USE extra CAUTION when operating the

machine near personnel and/or other objects or
GAUGES AND INSTRUMENTS OPERATION. machines.
Visually check the operation of ALL gauges and d. Do NOT operate a machine in need of repair.
instruments. 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 e. Keep ALL personnel CLEAR of the hitch area
replace any gauge, or instrument, having damage, at ALL times, during operation, or service, of the
with NEW. machine.
WARNING: Do NOT operate a machine DANGER: Keep ALL personnel CLEAR of the
having gauges, or instruments, hitch area. The CLEARANCE
which do not operate, are damaged between the front and rear
or are not able to be read. 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.
9/2005 3-19
Section 3
OPERATION
OPERATING THE MACHINE [See Figures 3-1,
f. AFTER being seated, and BEFORE the 3-2, 3-3, 3-4 and Table 3-1].
machine is started, ALWAYS securely FASTEN and
TIGHTEN the seat belt across the lap. The operator DANGER: ALL personnel and other
MUST remain seated at ALL times during machine machines MUST be CLEAR
operation. Keep the hands and feet INSIDE the of the machine path BEFORE the
machine cockpit at ALL times. Allow NO riders on machine is moved.
the machine at ANY time.
g. Do NOT suddenly stop the machine during a. IMMEDIATELY, after being seated, place the
operation. seat belt across the lap and SECURELY insert the
metal end into the belt buckle to TIGHTEN the belt,
h. BEFORE getting off of the machine, put the AGAINST the body. Release the secondary/parking
directional/speed control handle [ITEM 1] in the brake system, by putting the secondary/parking
“NEUTRAL” position. Put the secondary/parking brake system control switch [ITEM 5] in the “OFF”
brake system control switch [ITEM 5] in the “ON” [RELEASED] position.
[APPLIED] position. STOP the engine.
b. Put the transmission range selector switch
[ITEM 7] in the “WORK” [low] range position.
WARNING: ALWAYS APPLY the
SECONDARY/PARKING brake
system, AFTER the machine has WARNING: Keep the transmission system in the
stopped. The transmission system “WORK” range. Use the “WORK”
will NOT hold the parked machine range for machine movement
in a stopped condition, on within a confined area, when near
ANY grade. The SECONDARY/ personnel, or objects, and for ALL
PARKING brake system MUST be vibratory applications, when on the
used to hold the machine, in a work surface.
stopped condition, at ALL times. Do NOT put the transmission in the
“TRAVEL” range when the machine
is moved within a confined area
i. Do NOT operate the machine, if the machine will is near personnel, any object or
move when the secondary/parking brake system is machine. The “TRAVEL” range is
in an “ON” [APPLIED] condition. The machine must for “machine transport” ONLY.
NOT move, at ANY time, when the secondary/
parking brake system control switch [ITEM 5] is in
the “ON” [APPLIED] position.
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 9/2005
Section 3
OPERATION
NOTE: The vibration systems will NOT operate d. SLOWLY move either directional/speed control
if the “TRAVEL” [high] transmission [F-N-R] handle [ITEM 1] TOWARD the SAME
range is selected. When the speed range direction the machine is desired to travel.
selector switch is in the “TRAVEL”
position, “LOW” transmission system
torque is available. When the speed range NOTE: PUSHING either handle in the
selector switch is in the “WORK” FORWARD direction will select a
position, “HIGH”transmission system FORWARD direction of machine
torque is available. travel. PULLING either handle in
the BACKWARD direction will select
a REVERSE direction of machine
travel. The machine travel speed is
c. When on the work surface, put the engine throttle proportional to the amount of either
speed [RPM] control switch [ITEM 3] in the “HIGH” directional/speed control [F-N-R]
engine speed position. handle movement, UNTIL full
handle travel has been reached,
in EITHER DIRECTION.
WARNING: Do NOT put the engine throttle The transmission system will be
speed [RPM] control switch in the electrically disengaged, when the
“HIGH” engine speed position when secondary/parking brake system control
the machine is being moved in a switch is in the “ON” [APPLIED] position.
confined area, or when near
personnel, any object or machine.
e. When the machine is clear of confinement,
personnel or objects, SLOWLY move either direc-
CAUTION: When on the work surface, do NOT tional/speed control [F-N-R] handle [ITEM 1] further
attempt to operate the drum vibration toward the SAME direction of machine travel. This
systems with the engine at “LOW” will give FULL machine speed for the transmission
idle. The systems will NOT operate range and engine throttle speed, selected.
with the engine at the “LOW” engine
speed and/or if the “TRAVEL” [high]
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 machine serial numbers C209C2344 and

above, plus C209C2313 and B215C1738
machine serial numbers and above, the asphalt
mat temperature is electronically monitored and
can be accessed and displayed on the display
screen, during the rolling
operation.
9/2005 3-21
Section 3
OPERATION
f. When on the WORK surface, put the drum h. Put the drum vibration systems “FRONT/
vibrator MODE [OFF/AUTOMATIC/MANUAL] REAR/BOTH LOCATION” control switch [ITEM 9]
control switch [ITEM 8] in the desired position. at the desired “FRONT”, “REAR” or “BOTH”
position.
CAUTION: Do NOT operate either drum i. Put the vibration systems control “HIGH/LOW”
vibration system, UNLESS the AMPLITUDE control switch [ITEM 11] at the
drums of the machine are on the desired “HIGH” or “LOW” drum AMPLITUDE
WORK, or a SOFT surface, such as position.
loose dirt or “old” tires.
Damage to the drums and/or j. When operating on the work surface, select the
machine can occur if the drum desired water spray system mode; “AUTO”/ “OFF”/
vibration system[s] is operated on “MANUAL” by using the dash mounted water spray
a HARD surface. system MODE control switch [ITEM 6]. Put the
switch “LEFT” to put the system in the
“AUTOMATIC” mode, “RIGHT” to “MANUAL” to
g. Turn one [1], or both, vibration system control operate the system continuously or in the “CEN-
FREQUENCY control[s] [ITEM 10] to set the TER” position to turn the system “OFF”.
control[s] at the desired drum FREQUENCY [vpm].
NOTE: On all machine serial numbers, if in the

NOTE: Put the DRUM VIBRATION SYSTEM[S] “AUTOMATIC” mode, adjust the
“LOCATION” control switch [ITEM 9] at water spray system duty cycle as
the desired “FRONT/BOTH/REAR” desired. Turn the duty cycle control
position. switch knob [ITEM 24] to select the
If operating either drum vibration system desired duty cycle, from 0-50%.
in the “MANUAL MODE”, turn the When operating in the “AUTOMATIC”
system[s] “ON” and “OFF” by using mode, the water spray system will start
either of the directional/speed control and stop as each work surface rolling
handle installed thumb switches pass is started, and then stopped.
[ITEM 12].
In either the “AUTOMATIC”, or
“MANUAL” mode, the vibration DANGER: ALWAYS follow ALL “Operating
system[s] will NOT operate with the Precautions and Instructions”, given
engine at the “LOW” engine speed and/ in THIS manual and found on the
or if the “TRAVEL” [high] transmission decals affixed to the machine.
range is selected. Adjustment of the Failure to follow the “Operating
FREQUENCY control[s] can be done at Precautions and Instructions” can
any time, while the machine is on, or off, cause SERIOUS INJURY, or DEATH.
the work surface. When operating IMMEDIATELY put the secondary/
in the “AUTOMATIC” vibrator mode, parking brake system control switch
the vibration system[s] will start [ITEM 5] in the “ON” [APPLIED]
and stop at the adjusted, preset position and STOP the engine if
“ON/OFF” speed, WITHOUT the use of observed machine operation is NOT
the directional/speed control handle normal.
installed thumb switches [ITEM 12], as
each work surface rolling pass is started
and then stopped.
3-22 9/2005
Section 3
OPERATION
LIMITED OPERATION MODE [See Figure 3-3]. DANGER: ALL personnel and other
machines MUST be CLEAR
The "limited operation mode" allows the machine to of the machine path BEFORE the
be removed from the work surface. machine is moved.
The "limited operation mode" is programed into

computer controller software "Version 2.33" and WARNING : The directional/speed control
was NOT included in previous "versions" of the [F-N-R] handle [ITEM 1] does NOT
software. control the direction of machine
travel, during the"limited
operation mode". The
NOTE: The "version" of the software, contained directional/speed control
within the computer controller, is [F-N-R] handle is ONLY used to
displayed on the system function control movement of the machine,
monitor display screen [ITEM 26] when but not the speed of the
the ignition key switch is first turned to movement. Machine speed is NOT
the "ON/RUN" position. proportional to movement of the
directional/speed control
[F-N-R] handle.
The machine directional control system will When the directional/speed
"automatically default" to the limited operation mode
control [F-N-R] handle is moved
when a "stop fault" condition exists and has been
from the neutral position,
detected by the computer controller [See Figure 3-3
regardless of which direction it is
- Screen #1] .
moved, the machine will travel in
the direction which was selected
The system function monitor display screen
with the Drum Vibration Systems
[ITEM 26] will visually "prompt" the operator to
"Location" Control Switch
return either directional/speed control [F-N-R]
[ITEM 9].
handle [ITEM 1] to the neutral position.
The machine will travel
approximately 0.75 mph [1.2 kmph]
With the directional/speed control [F-N-R] handle
with the Transmission Range
[ITEM 1] in the neutral position, the screen will
Control Switch in the "LOW"
display the functions which should allow the
position and 1.5 mph [2.4 kmph]
machine to be moved.
with the Transmission Range
Control Switch in the "High"
A message will appear stating "FRNT/FWD" or
position.
"REAR/REV"[See Figure 3-3 - Screens #2 and #3] .
While in the Limited Operation
Mode, move the machine the LEAST
The message will inform the operator that by
distance possible, from the work
moving the Drum Vibration Systems "Location"
surface.
Control Switch [ITEM 9] from the center [BOTH
Do NOT drive the machine to the
position] to either the FRONT, or REAR, drum
repair area. Use a truck, or trailer, to
position machine movement can be achieved.
move the machine to the repair
area.
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 direc-
NOTE: Dependant on the "stop fault" condition
tional/speed control [F-N-R] handle [ITEM 1] is
which exists and has been detected by
moved from the NEUTRAL position towards either
the computer controller, limited
direction of travel. The Engine Throttle Speed
operation may be restricted to either
Control Switch [ITEM 3] MUST be in the "LOW"
forward, or reverse, direction of travel.
speed position and the Transmission Range
If travel is not achieved in one direction,
"WORK" [Low] /"TRAVEL" [High] Control Switch
attempt to travel in the opposite
[ITEM 7] can be placed in EITHER of the two [2]
direction.
positions.
9/2005 3-23
Section 3
OPERATION
SCREEN
GENERAL VIEW - OPERATOR CONTROLS LOCATIONS
This screen tells the OFF

operator that there is a fault AUTO MAN
and the machine is in

VIBRATOR MODE WATER SAVER
"Limited Operation Mode". BOTH LIMD OP: MODE - FNR FDW
FRONT REAR
Fault: 5V SENSOR POWER
DRUM SELECT FRONT VIB SPEED
HIGH LOW
AMPLITUDE REAR VIB SPEED
SCROLL BUTTON
SCREEN # 1
This screen tells the

operator that there is a fault AUTO
OFF
MAN
and by moving the Drum
Vibration Systems "Location" VIBRATOR MODE
BOTH
WATER SAVER
VIBE MODE - FRNT/FDW
Control Switch to the FRONT drum FRONT REAR
position, the machine will
travel in the FORWARD
HIGH LOW
direction when either directional/
speed control [F-N-R] handle is AMPLITUDE REAR VIB SPEED
moved from the neutral position

SCROLL BUTTON
in either direction.
SCREEN # 2
This screen tells the

OFF
operator that there is a fault AUTO MAN
and by moving the Drum

Vibration Systems "Location" VIBRATOR MODE
BOTH
WATER SAVER
VIBE MODE - REAR/REV
Control Switch to the REAR drum FRONT REAR
position, the machine will DRUM SELECT FRONT VIB SPEED
travel in the REVERSE LOW
HIGH
direction when either directional/
speed control [F-N-R] handle is AMPLITUDE REAR VIB SPEED
moved from the neutral position

SCROLL BUTTON
in either direction.
SCREEN # 3
FIGURE 3-3. MACHINE LIMITED OPERATION MODE SCREEN DISPLAYS.
3-24 9/2005
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 66 INCH AND 78 INCH COMPACTORS.
9/2005 3-25
Section 3
OPERATION
DYNAMIC BRAKING OF THE MACHINE [See d. Put the engine throttle speed [RPM] control
Figure 3-2]. switch [ITEM 3] in the “LOW” speed position. Run
the engine for a period of at LEAST three-five [3-5]
The TRANSMISSION SYSTEM is the PRIMARY minutes, at “LOW” speed, BEFORE the engine is
[DYNAMIC] brake system for the machine. stopped.
Slowing, and then stopping, of the machine, during

operation, is done by moving either directional/ CAUTION: Do NOT stop the engine BEFORE
speed control [F-N-R] handle [ITEM 1] TOWARD running at the “LOW” engine
the NEUTRAL position. idle speed. Serious engine
DAMAGE can occur if the engine
is stopped BEFORE waiting the
WARNING: When nearing a slope, first slow the three-five [3-5] minute period,
machine by moving either direc- to allow the engine to cool.
tional/speed control handle toward
the neutral position. To SLOW the
machine further, or STOP the e. Put the ignition key switch [ITEM 2] at the
machine on a slope, move either “OFF” [NUMBER 1] position and allow the engine to
directional/speed control [F-N-R] stop. Remove the key from the ignition switch and
handle to the direction OPPOSITE install and lock the vandal guard, if desired.
the direction of machine travel.
The SECONDARY/PARKING brake
system MUST be used to hold the
machine in a “stopped” condition at RELEASING THE TOWING BYPASS VALVES
ALL times. The transmission system, AND SECONDARY/PARKING BRAKE SYSTEM
used for DYNAMIC braking, will NOT AND TOWING A COMPLETELY DISABLED
hold, or keep, the machine in a MACHINE [See Figures 3-5 and 3-6].
“stopped” condition at ANY time.
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].
Should the machine become COMPLETELY
a. Put the drum vibrator mode selector switch disabled and the engine can NOT be started and/or
[ITEM 8] in the “OFF” position. the hydraulic system operated, use the following
procedure to release the BYPASS VALVES and the
b. SLOW and STOP the machine by using SECONDARY/PARKING brake system.
DYNAMIC braking through the transmission system
[see procedure above]. Put either directional/speed
control [F-N-R] handle [ITEM 1] in the NEUTRAL a. Put SOLID wood blocks behind, and in front of,
position. the FRONT drum.
c. Put the secondary/parking brake system control

switch [ITEM 5] in the “ON” [APPLIED] position. WARNING: Block SECURELY using SOLID wood
blocks. The blocks MUST hold the
machine in place when the
secondary/parking brake system is
released.
3-26 9/2005
Section 3
OPERATION
e. Locate the two [2] “brake release mechanisms”,
b. Put a 1 1/16 inch open end wrench on the found behind the tool box door, under the right seat.
MIDDLE sized [2nd] hex nut [towing bypass valve]
of the FORWARD direction MULTIFUNCTION f. Take one [1] “brake release mechanism”. Turn
VALVE cartridge. Put a 1 1/4 inch open end wrench the nut onto the capscrew threads until it is near the
on the LARGE [3rd] hex nut of the FORWARD head of the capscrew by using the fingers.
direction MULTIFUNCTION VALVE
cartridge. g. Go to either drum drive motor. Locate the .875
in. [22.2 mm] hole in the frame rail. Install the 16
c. OPEN the bypass valve by turning the second mm capscrew through the frame rail. Turn the
[2nd] hex nut with the wrench approximately capscrew threads into the tapped hole, in the brake
THREE [3] revolutions in the COUNTERCLOCK- release piston, until the capscrew is FULLY
WISE [CCW] direction. engaged in the tapped hole.
h. Turn the nut CLOCKWISE [CW], on the

CAUTION: Do NOT open the bypass valve more capscrew threads, until the nut is against the frame
than THREE [3] revolutions. Opening rail. Hold the capscrew head with a wrench. Use a
the valve additional revolutions can second wrench to turn the nut further INWARD until
permit external leakage of hydraulic the nut will NOT turn any further through the
oil during machine towing. 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.
d. Repeat steps “b” and “c” on the REVERSE
direction MULTIFUNCTION VALVE cartridge. 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”.
TAPPED HOLE IN BRAKE

RELEASE
WASHER
MECHANISM
HOLE THROUGH
SIDE OF FRAME
FIGURE 3-6. SECONDARY/PARKING BRAKE

SYSTEM RELEASE LOCATION.
FIGURE 3-5. MULTIFUNCTION VALVES -
ON TRANSMISSION PUMP.
9/2005 3-27
Section 3
OPERATION
j. Securely fasten the towing strap, cable or chain
to the machine and the towing vehicle. Tighten the k. Go to either drum drive motor. Turn the nut,
strap, cable or chain completely. CAREFULLY found on the “brake release mechanism”, in the
remove the wood blocking from under the drum. COUNTERCLOCKWISE [CCW] direction until the
CAREFULLY and SLOWLY tow the machine from nut is away from the frame rail. The brakes in the
the work surface. Tow the machine to a truck, or motor will now be APPLIED.
trailer. Move the machine onto the truck or trailer
and fasten securely [see THIS section for COR- l. Go to the second drum drive motor and RE-
RECT machine tie down procedures]. Move the PEAT step “k”.
machine for repair using the truck, or trailer.
NOTE: AFTER the machine has reached the

WARNING: Keep ALL personnel CLEAR of the repair area, both “brake release
towing vehicle and the machine mechanisms” MUST be removed. Keep
while removing the blocking and both “brake release mechanisms” with
towing the machine, or moving the machine for future use.
the machine onto the truck or
trailer. At this time, the machine will
be held in position ONLY by the m. Go to the transmission pump assembly.
wood blocking placed against the CLOSE both the FORWARD, and the REVERSE,
drum. The secondary/parking brake direction bypass valves. Close the bypass valves by
will be in a DISCONNECTED turning the MIDDLE sized [2nd] hex nut THREE [3]
condition. revolutions in the CLOCKWISE [CW] direction, with
Do NOT tow the machine on ANY the 1 1/16 inch open end wrench, until the hex nut is
grade. seated against the LARGE sized [3rd] hex nut. Hold
TOW the machine the LEAST the LARGE [3rd] hex nut with the 1 1/4 inch open
distance possible, from the work end wrench and tighten the MIDDLE sized [2nd] hex
surface. nut to a torque of 30 ft. lbs. [41 N.m].
Do NOT tow the machine at a speed
above TWO [2] miles per hour [3.2
km/h]. CAUTION: BOTH bypass valves MUST be
Do NOT tow the machine to the returned to the CLOSED position.
repair area. ONLY use a truck, or
trailer, to move the machine to the
repair area.
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 9/2005
Section 3
OPERATION
WARNING: The machine MUST be securely held
TRANSPORTING THE MACHINE [See Figures to the truck or trailer bed. Be sure
3-7 and 3-8]. the tie-down chains and load bind-
ing devices are correctly connected
WARNING: FOUR [4] tie-downs MUST be used and tightened securely.
to secure the machine to the truck or
trailer bed when transporting the
machine. ONE [1] frame tie-down NOTE: Blocking of the drums, clear of the truck
cut out hole is found in EACH side of or trailer bed, is NOT needed on the
the FRONT frame, near the outer end Model 66 Inch or 78 Inch Compactor.
of the drum. ONE [1] frame tie-down
hole is found in EACH side of the
REAR frame, near the outer end of FRONT FRAME ASSEMBLY STEERING LOCK PIN
the drum.
a. CAREFULLY load the machine onto the

transporting truck or trailer. Put the secondary/
parking brake system control switch [ITEM 5] in the STEERING CYLINDER
“ON” [APPLIED] position. Slow and then stop
the engine using the CORRECT procedures given
in THIS section.
HITCH ASSEMBLY REAR FRAME ASSEMBLY
b. Install the steering lock pin through the lock pin
bores of the hitch [see figure 3-7].
FIGURE 3-7. STEERING LOCK PIN LOCATION.
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].
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 tie-
down load binding device to hold the machine
securely in position for transportation [see figure
3-8].
9/2005 3-29
Section 3
OPERATION
FRONT TIE-DOWN BLOCKS-FRONT & REAR REAR TIE-DOWN

(LEFT & RIGHT) (LEFT & RIGHT) (LEFT & RIGHT)
FIGURE 3-8. MACHINE TRANSPORT TIE-DOWN LOCATIONS.
3-30 9/2005
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.
9/2005 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 -

66 Inch machines serial number 109C20902455 and higher and on
78 Inch machines serial number 109B21501856 and higher ................................................... 4-31.
ALTERNATOR AND FAN DRIVE BELT - INSPECTION

AND REPLACEMENT PROCEDURES .......................................................................................... 4-32.
ELECTRICAL SYSTEM ...................................................................................................................... 4-32.
CHECKING THE CHARGE CONDITION OF THE BATTERY AND

SERVICING OF RELATED ITEMS ............................................................................................... 4-32.
ELECTRICAL WIRING INSPECTION .......................................................................................... 4-33.
VIBRATION ISOLATOR TIRES ......................................................................................................... 4-34.
INSPECTION, AIR PRESSURE CHECK AND ADJUSTMENT ...................................................... 4-34.
4-2 9/2005
Section 4
MAINTENANCE
PAGE
REMOVAL, REPAIR OR REPLACEMENT, AND INSTALLATION
OF THE VIBRATION ISOLATOR TIRE AND RIM ASSEMBLIES -
66 Inch machines serial number 109C20902475 and higher and on
78 Inch machines serial number 109B21501883 and higher ................................................... 4-35.
REMOVAL .................................................................................................................................... 4-35.
TIRE REMOVAL, REPAIR OR REPLACEMENT AND INSTALLATION ONTO THE RIM ......... 4-37.
INSTALLATION ............................................................................................................................ 4-39.
SECONDARY/PARKING BRAKE SYSTEM MAINTENANCE -

OPERATION AND APPLICATION CHECK .................................................................................... 4-42.
MISCELLANEOUS MAINTENANCE INFORMATION ........................................................................... 4-43.
WATER SPRAY SYSTEM .................................................................................................................. 4-43.
WATER STRAINERS ....................................................................................................................... 4-43.
WATER SPRAY NOZZLES ............................................................................................................. 4-43.
CLEANER BEAM AND RUBBER CLEANER ASSEMBLIES ........................................................... 4-44.
PREPARING THE MACHINE FOR STORAGE ..................................................................................... 4-44.
ENGINE .............................................................................................................................................. 4-44.
COOLING SYSTEM ............................................................................................................................ 4-44.
BATTERY ........................................................................................................................................... 4-45.
FUEL TANK ........................................................................................................................................ 4-45.
AIR CLEANER, EXHAUST AND OTHER OPENINGS ...................................................................... 4-45.
WATER SPRAY SYSTEM .................................................................................................................. 4-45.
EXPOSED COMPONENT RUST PREVENTION ............................................................................... 4-45.
9/2005 4-3
Section 4
MAINTENANCE
GENERAL INFORMATION. MAINTENANCE SCHEDULE.
THIS section gives the necessary procedures for GENERAL INFORMATION.

CORRECT MAINTENANCE of the 66 Inch and 78
Inch Compactors. The MAINTENANCE SCHEDULE lists the recom-
mended time intervals between machine mainte-
NOTE: The drum design on 66 Inch machines nance inspections and lubrication procedures. Table
serial number 109C20902455 and higher 4-1 gives inspection and lubrication information for
and on 78 Inch machines serial number the 66 Inch and 78 Inch Compactors.
109B21501856 and higher, has been
changed. Be sure to refer to the text that Most service intervals are listed by the “HOUR” and
is applicable to the serial number of “PERIODIC” time periods. The maintenance
your machine. schedule begins with eight [8] hours, or daily,
maintenance intervals and continues through the
Follow ALL the “MAINTENANCE SCHEDULES” 2,000 hours, or every two [2] years, maintenance
and “MAINTENANCE PROCEDURES” for COR- schedule intervals.
RECT machine service schedules and procedures.
NOTE: If the machine is operated MORE

than eight [8] hours per day,
MAINTENANCE. follow the “HOUR” schedule. If the
machine is operated LESS than
GENERAL INFORMATION. eight [8] hours per day, follow
the “PERIODIC” schedules, where
MAINTENANCE must be a planned program which they apply.
includes periodic machine inspection and lubrication
procedures.
The maintenance checks, given in Table 4-1, are
The MAINTENANCE program must be done, based also listed on the “Machine Maintenance Decal”,
on the machine “OPERATING HOURS”, recorded found on the machine [See Figure 4-2]. Figure 4-1
on the hourmeter, or based on the “PERIODIC shows the location of the “machine maintenance
SCHEDULE”, which is done at time intervals of points”.
weekly, monthly or yearly.
The MAINTENANCE program is divided into TWO

[2] subsections: The MAINTENANCE SCHEDULE
and the MAINTENANCE PROCEDURES.
4-4 9/2005
Section 4
MAINTENANCE
20-INSIDE DRUM (THIS SIDE)

14-INSIDE DRUM 11
18
22 13 14 -INSIDE DRUM
17 2 5
3 1 6 16 15
4
9 10 7 14 -INSIDE DRUM
15 16 12
22 23
18 19
8-UNDER BATTERY TRAY
14 -INSIDE DRUM 20 -INSIDE DRUM (THIS SIDE)
FIGURE 4-1. MACHINE MAINTENANCE POINTS.
MAINTENANCE INFORMATION ITEM SERVICE WITH CHECK CHANGE

2 INTERVAL INTERVAL
12 11 4 1 5 6 16 15
1. ENGINE OIL LEVEL SAE 15W40-API CE/SG* DAILY 250 HOURS
2. ENGINE OIL FILTER SEE PARTS BOOK 250 HOURS
3. ENGING OIL FILL
4. ENGINE FUEL FILTERS SEE PARTS BOOK 500 HOURS OR YEARLY
5. ENGINE COOLING CHECK & FILL DAILY 1000 HOURS
SYSTEM
6. AIR CLEANER CHECK RESTRICTION INDICATOR DAILY 1000 HOURS
7 HYD. OIL LEVEL CHECK DAILY CHANGE IF ANALYSIS INDICATES
8. HYD. OIL FILL SEE DECAL NEXT TO FILL SPOUT 2000 HOURS OR 2 YEARS
22 GALS.
9. HYD. OIL FILTER SEE PARTS BOOK DAILY WITH HYD. OIL CHANGE OR WHEN
CHECK RESTRICTION INDICATOR INDICATOR LIGHT STAYS ON
10. BATTERY CHECK & CLEAN 100 HOURS
11. VIBRATOR OIL LEVEL CHECK DAILY
SIGHT GAUGE
14 10 3 78 11 12. VIBRATOR OIL FILL TEXACO MEROPA 150 OR 2000 HOURS OR 2 YEARS
9 12
15 16 POINT EQUIVALENT (10 GALS.)
13 13. TIRE ISOLATORS 30-35 PSI WEEKLY
4 PLCS 14. FUEL FILL #2 DIESEL (50 GALS.) 66 IN DAILY
(60 GALS.) 78 IN
SEE OPERATING MANUAL FOR MAINTENANCE 15. WATER PUMP STRAINERS CLEAN SCREEN 500 HOURS
WARNING 16. WATERSPRAY NOZZLE CLEAN AS REQUIRED
AND INSPECTION PROCEDURES
* SEE ENGINE MAINTENANCE MANUAL AND/OR PARTS BOOK. P/N 0933696
FIGURE 4-2. MACHINE MAINTENANCE DECAL.
9/2005 4-5
Section 4
MAINTENANCE
TABLE 4-1. MAINTENANCE SCHEDULE.
FIG’
4-1 ITEM 8/ 250/ 500/ 1000/ 2000/ QUAN. TYPE/REMARKS
ITEM DAY 3 MO 1 YR 1 YR 2 YR
NO.
1 ENGINE OIL X C* 10.8 Drain diesel engine

Qts. lubrication oil
[10.2 l], and replace with
Total NEW.*
2 ENGINE OIL C* 1 Change at EACH

FILTER engine oil change
Use APPROVED filter
ONLY.*
3 ENGINE X* C* 1 Drain PRIMARY of

FUEL water daily with
FILTERS drain plug provided.
[Primary Change at interval
AND shown.*
Secondary] Use APPROVED
filters ONLY.*
4 FUEL LEVEL X 50 Gal. #1D or #2D

- IN TANK [189 L], diesel fuel. See
66 Inch Section 2 -
60 Gal. SPECIFICATIONS,
[227 L], for complete
78 Inch specifications.
5 ENGINE X C** 1 Check condition

INLET AIR indicator light.
FILTER Change element
ELEMENT as needed.**
Use APPROVED
element ONLY.
6 ENGINE X C* 19 Check coolant

COOLING Qts. level. Fill as required
SYSTEM [18 L] with 50% mixture
[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.*
4-6 9/2005
Section 4
MAINTENANCE
FIG’
NO.
7 HYDRAULIC X A/C+ 22 Check hydraulic

SYSTEM OIL *** Gal. oil level in the
[83.3 L] reservoir sight
gauge. Add
hydraulic oil as
required.***
Use ONLY MOBIL
423, HYTRAN,
TEXACO “TDH” or
EQUIVALENTS oil.
CAUTION: Use the

CORRECT hydraulic
oil ONLY***
+ A= OBTAIN AND ANALYZE OIL SAMPLE - WITH CARE.

+ C= CHANGE OIL BASED ON RESULTS OF OIL ANALYSIS - AS NEEDED.
8 HYDRAULIC X C 1 Check condition

PRESSURE indicator lights daily.
OIL FILTER Change filter
[Vibration element when
Systems] 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.
9/2005 4-7
Section 4
MAINTENANCE
FIG’
ITEM DAY 2 WK 3 MO 1 YR 2 YR
NO.
9 TRANSMISSION C 1 Change filter

SYSTEM element when
PRESSURE hydraulic oil is
OIL FILTER 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.
10 HYDRAULIC CLEAN 2 Remove both. Clean

SYSTEM SUCTION at EACH hydraulic
OIL STRAINERS oil change. See THIS
[Transmission/ section for procedure.
Vibration/Steering Also remove, & clean
Systems] return oil diffuser.
4-8 9/2005
Section 4
MAINTENANCE
FIG’
ITEM DAY 2 WK 3 MO 1 YR 2 YR
NO.
11 ALTERNATOR X* 1 Check belt for

& FAN DRIVE wear or damage.
BELT Check belt for
CORRECT
deflection.*
Replace belt with
NEW if needed [see
ENGINE manual].
12 BATTERY X 1 The battery is

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

PARKING tem of brake system one
BRAKE SYSTEM [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].
9/2005 4-9
Section 4
MAINTENANCE
FIG’
NO.
14 VIBRATION X 4 Check air

ISOLATOR pressure when
TIRES tires are "cold".
Set at CORRECT
pressure [see
THIS section].
15 WATER X/C 2 Remove, check,

SPRAY clean and
SUCTION install the
STRAINERS strainers one [1]
time for every
500 hours of
machine
operation, or
yearly.
16 WATER SPRAY CLEAN AS REQUIRED All Remove, clean

SYSTEM and install onto
NOZZLES spray bars when
plugged on "as
required" basis
[see THIS section].
17 SAFETY X All Check condition.

DECALS Replace as
needed. See
MACHINE parts
manual.
18 SEAT BELT SETS X 2 Sets Check condition.

Replace set if
damaged. See
MACHINE parts
manual.
4-10 9/2005
Section 4
MAINTENANCE
FIG’
NO.
19 FALLING X Structure Inspect the

OBJECT/ FOUR [4] grade
ROLL OVER 8 flange screws
PROTECTIVE that fasten the
STRUCTURE structure to the
[FOPS/ROPS] machine, they
MUST remain
tightened to the
torque of 375
ft. lbs. [509
N.m].
CAREFULLY
inspect ALL welds
for cracks, break-
age in the weld
or where the
weld joins the
components,
severe rust or
other weld re-
lated problems.
If any damage
is found in the
above inspection,
contact the
nearest Distributor
immediately.
20 DRUM BEARING X C 10 Gal. Check drum
LUBRICATION [37.9 L] - bearing lubrication
OIL EACH oil level and add
drum 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].
9/2005 4-11
Section 4
MAINTENANCE
FIG’
NO.
21 GAUGES X All Check operation.

HORN Repair, or replace,
LIGHTS as needed.
22 DYNAMIC X Trans'. Check operation.

BRAKES System Repair if needed
[See Section 3].
23 STEERING X Steering Check operation.

System 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 9/2005
Section 4
MAINTENANCE
MAINTENANCE PROCEDURES. NOTE: The ABOVE procedure will help to

remove the possibility of filling the
GENERAL INFORMATION. engine with too much lubrication oil, by
allowing the oil to return to the oil pan.
The following MAINTENANCE PROCEDURES give
instructions for performing required machine mainte-
nance checks and lubrication. WARNING: STOP the engine BEFORE checking
the engine lubrication oil
level. With engine running, HOT
NOTE: The instructions given in the oil can be thrown causing serious
MAINTENANCE procedure subsection injury.
are given by “machine systems” and are
NOT necessarily in the same order as
listed in Table 4-1 or as shown on the OIL FILL
“Machine Maintenance Decal”. They may

ALSO include some items NOT shown DIP STICK
in the table, or on the decal.
ENGINE MAINTENANCE.
GENERAL INFORMATION.
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 CHANGING THE ENGINE LUBRICATION OIL
LEVEL [See Figure 4-3]. [See Figure 4-4].
The engine lubrication oil MUST be kept at a level The engine lubrication oil MUST be changed
ABOVE the “ADD” mark, but NOT ABOVE the according to the interval given in the current diesel
“FULL” mark, on the engine lubrication oil dipstick. engine “Operation and Maintenance Manual”
published by Cummins Engine Company and
TO ACCURATELY check the engine lubrication oil supplied with the machine.
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.
9/2005 4-13
Section 4
MAINTENANCE
NOTE: The color of the engine lubrication oil f. Fill the engine to the CORRECT oil level, with
can NOT be used as an indication of the the CORRECT engine lubrication oil.
need for a engine lubrication oil change.
The use of an engine lubrication oil
“analysis service” is the ONLY NOTE: See THIS section for the CORRECT
alternate reason for not following the amount of lubrication oil. For the
required engine lubrication oil change CORRECT type of lubrication oil see the
schedule. current “OPERATION AND
MAINTENANCE MANUAL - B SERIES
DIESEL ENGINE” published by Cummins
WARNING: Do NOT change the engine Engine Company Incorporated, which is
lubrication oil when the engine supplied with the machine.
and lubrication oil are HOT.
Change when WARM ONLY. Hot oil
can cause serious injury. g. Wash the oil filler cap with All-Purpose de-
greaser cleaner, Part Number 178297, and dry with
compressed air. Install the oil filler cap and the
CAUTION: Do NOT change the engine engine lubrication oil dipstick.
lubrication oil with the engine
“running”.
Serious engine damage, or failure CAUTION: Do NOT start the engine BEFORE
WILL occur. changing the engine lubrication
Clean the area around the engine oil filter. Follow the procedures given
lubrication oil dipstick and oil filler in THIS section and in the current
cap BEFORE removing the dipstick, Cummins ENGINE “Operation and
or oil filler cap. 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 DRAIN PLUG

lubrication oil drain plug.
FIGURE 4-4. CUMMINS DIESEL ENGINE -

CAUTION: Do NOT overtighten the drain LUBRICATION OIL DRAIN PLUG LOCATION.
plug.
4-14 9/2005
Section 4
MAINTENANCE
CHANGING THE ENGINE LUBRICATION OIL f. Install the NEW filter element onto the filter head.
FILTER [See Figure 4-5]. Carefully tighten the filter element, by the hand
only.
The engine lubrication oil filter MUST be changed
when the engine lubrication oil is changed.
NOTE: Tighten the filter element as
directed on the filter element, by
WARNING: Do NOT change the engine the filter manufacturer.
lubrication oil filter when the engine
and lubrication oil are HOT. Change
the filter when “WARM” only. CAUTION: Do NOT overtighten the lubrication
Hot oil can cause serious injury. oil filter element onto the filter head.
Follow ALL engine lubrication oil
change and fill procedures, given in
CAUTION: Do NOT change the engine THIS section, and in the ENGINE
lubrication oil filter with the engine “Operation and Maintenance Manual”
running. Serious engine damage, or BEFORE the engine is started.
failure, WILL occur.
NOTE: CHECK the engine lubrication oil

With the engine “STOPPED” and filled with NEW level at THIS time.
engine lubrication oil, proceed as follows:
a. Wipe the area around the engine lubrication oil g. Start the engine. Check to be sure there are NO
filter element and its mounting base, with a CLEAN oil leaks and that the engine oil pressure gauge
cloth. 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 CAUTION: STOP the engine IMMEDIATELY if
remove the filter element by turning it in a COUN- INCORRECT OIL pressure is
TERCLOCKWISE direction of rotation. Drain and indicated or any oil leaks are seen.
discard the removed filter element. 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.
9/2005 4-15
Section 4
MAINTENANCE
DOOR
OIL FILTER
CAP
FIGURE 4-5. CUMMINS DIESEL ENGINE - FIGURE 4-6. FUEL TANK FILL
LUBRICATION OIL FILTER LOCATION. LOCATION AND CAP.
FUEL SYSTEM. ENGINE FUEL FILTERS [See Figure 4-7].
FUEL TANK [See Figure 4-6]. The fuel filter element MUST be replaced as di-
rected in the current engine “Operation and Mainte-
The fuel gauge indicates the amount of fuel in the nance Manual”, published by Cummins Engine
tank. CHECK the amount indicated on the gauge Company Incorporated and supplied with the
ONE [1] time EACH day. Fill the fuel tank “FULL”, machine.
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 CAUTION: Drain the fuel filter lower bowl of ALL
tank, from condensation. water one [1] time EACH day, or as
needed.
WARNING: The operator MUST be off of the

machine while fuel is added. Replace the fuel filter elements using the following
NO smoking while filling the fuel “GENERAL” procedures and very specific informa-
tank. tion given in the current engine “Operation and
ALL fuels for internal combustion Maintenance Manual”, published by Cummins
engines are flammable. Engine Company Incorporated and supplied with
Fill the fuel tank ONLY in a the machine.
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 9/2005
Section 4
MAINTENANCE
WARNING: DIESEL FUEL IS VERY FLAMMABLE. e. Wipe the inside area of the filter head with a
USE EXTRA CAUTION. CLEAN “lint free” cloth. Fill the “NEW” fuel filter
Do NOT change the filter element in element COMPLETELY FULL of the CORRECT
an area near open flame. and CLEAN fuel. Put CLEAN fuel on the element
Do NOT change the fuel filter rubber gasket.
element with the machine running.
Do NOT smoke while changing the f. Install the “NEW” fuel filter element onto the filter
fuel filter element. head. CAREFULLY tighten the element by hand
Do NOT spill fuel. ONLY.
CAUTION: Tighten the fuelfilter element as

FUEL FILTER ELEMENT
directed on the filter element, by the
filter manufacturer.
Do NOT overtighten the 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.
WATER DRAIN
PRIMING AND AIR REMOVAL [BLEEDING]

FIGURE 4-7. FUEL FILTER LOCATIONS - FROM THE FUEL SYSTEM - CUMMINS DIESEL
CUMMINS DIESEL ENGINE. ENGINE [See Figure 4-8].
a. STOP the engine. Use the following general procedures to prime, start
and remove [bleed] the air from the fuel system of a
b. Put a container under the fuel filter, BEFORE CUMMINS diesel engine which has been run out of
removing filter element. fuel:
c. Wipe the area around the fuel filter element and

the element mounting head, using a CLEAN lint free NOTE: Small amounts of air will be vented from
cloth. the system automatically, if the filters
were changed using the CORRECT
d. Use a filter removal wrench to loosen and procedures given in THIS section. Air
remove the element, by turning the element in a removal [bleeding] will be required if the
COUNTERCLOCKWISE direction. Drain and filter elements were NOT correctly filled
discard the removed element. with fuel BEFORE installation.
9/2005 4-17
Section 4
MAINTENANCE
CAUTION: For very specific information, see the f. Venting is done by loosening one, or more, fuel
current engine “Operation and supply line to injector retaining nut[s] a SMALL
Maintenance Manual” supplied with amount, ONE [1] at a time. Crank the engine and let
the machine. the fuel flow from the line UNTIL there is NO
indication of air bubbles present at ANY line con-
nection point. Use the wrench to tighten the loos-
a. Add at LEAST ten [10] gallons [38 liters] of the ened fuel supply line nut[s] at the injector fitting[s]
CORRECT, CLEAN fuel to the fuel tank. [see the Cummins "Operation and Maintenance
Manual"].
b. Remove the air from the LOW pressure fuel
lines and the filter by opening the air bleed screw,
found at the top of the fuel filter [see the Cummins WARNING: It is necessary to keep the engine
"Operation and Maintenance Manual"]. fuel system in the "RUN" condition
to vent air. Because the engine may
c. Operate the priming lever on the fuel lift pump start, be sure to follow ALL safety
UNTIL the flow of fuel from the bleed screw fitting is precautions.
continuous and FREE of air bubbles [see figure KEEP the hands and body AWAY
4-8]. from the injector fittings and nuts.
Fuel under HIGH pressure
d. COMPLETELY tighten the air bleed screw and can penetrate the skin. Wear safety
stop the operation of the lift pump priming button. glasses to protect the eyes. Get
IMMEDIATE medical attention if fuel
e. Crank the engine to vent air trapped in the fuel enters the eyes or skin.
system [see the Cummins "Operation and Do NOT remove the air from the fuel
Maintenance Manual"]. supply lines IF the engine is HOT.
Fuel leaked on the HOT exhaust
manifold can create a danger of fire.
VENT LOCATION
BLEED POINTS
PRIMING LEVER
FIGURE 4-8. FUEL PRIMING AND AIR REMOVAL LOCATIONS.
4-18 9/2005
Section 4
MAINTENANCE
ENGINE AIR FILTRATION. b. Remove the wing nut and baffle assembly from
inside the air cleaner body.
AIR CLEANER [See Figure 4-9].
c. Remove the air filter element from inside the air
The engine inlet air cleaner assembly uses a cleaner body and DISCARD.
replaceable filter element.
d. Clean the inside of the air cleaner body with a
CHECK the engine inlet air restriction indicator light clean cloth.
DAILY. If the restriction indicator light is “ON”, the
air cleaner filter element MUST be removed and e. Inspect the hose clamps for tightness and the
replaced IMMEDIATELY. condition of the tube from the air filter to the engine
intake manifold.
CAUTION: The air cleaner filter element should

be replaced ONE [1] time for EACH CAUTION: Severe engine damage can occur
1,000 hours of machine operation, or if hose clamps are in a loose
yearly, for a machine which is condition or if the tube is damaged.
operated under “normal” conditions,
or ONE [1] time for EACH 500 hours
of machine operation, or every six f. CAREFULLY install the NEW air filter element
[6] months, for a machine which is into the air cleaner body assembly.
operated under “very dusty or
“severe” conditions. Never operate g. Install the baffle assembly over the end of the
the engine without an air cleaner air filter element. Install and tighten the wing nut,
element installed. which holds the baffle assembly and air filter
Do NOT service the air cleaner element into the air cleaner body assembly.
element while the engine is
“running”. h. Install the air cleaner end cap onto the air
cleaner body. Tighten the band clamp securely.
Use the following procedures to service the air i. Start the engine using ALL the CORRECT
cleaner element: starting procedures given in Section 3 - OPERA-
TION - of THIS manual. Note that the engine inlet
a. Loosen the band clamp which holds the end cup air restriction indicator light is “OFF” and that the
assembly onto the air cleaner body. Remove the end engine inlet air is NOT being restricted.
cup from the air cleaner body.
BAFFLE END CAP

ASSEMBLY
BAND CLAMP
ELEMENT
FILTER BODY
ASSEMBLY
WING NUT
VACUATOR
WING BOLT O-RING VALVE
FIGURE 4-9. AIR CLEANER ASSEMBLY - EXPLODED VIEW.
9/2005 4-19
Section 4
MAINTENANCE
COOLING SYSTEM. With the engine STOPPED, inspect the radiator and
the hydraulic oil cooler cooling fin area EACH time
RADIATOR AND HYDRAULIC OIL COOLER [See the system coolant level is checked. Use a bright
Figure 4-10]. light placed on the INSIDE of the radiator fin area.
Light MUST be clearly seen, when looking through
WARNING: Do NOT check the system coolant the radiator and hydraulic oil cooler fin area FROM
level, or ANY component, with the the outside of the fin area.
engine running. Serious injury can
result from being caught or struck
by the fan, belt or moving engine WARNING: The engine MUST be STOPPED
parts. BEFORE checking, or cleaning, the
Do NOT check the system coolant radiator or hydraulic oil cooler fin
level, or ANY component, when the areas. Serious injury can result from
system is at operating temperature being caught or struck by the fan,
and the coolant is under pressure. belt or moving engine parts.
HOT coolant, under pressure, can
cause serious injury.
Check the coolant level ONLY when NOTE: If a restricted fin condition is noted in
the radiator filler cap is cool enough EITHER the radiator, or the hydraulic oil
to touch with the hand. Remove the cooler fin area, CLEAN the fin area using
radiator filler cap SLOWLY. LOW pressure compressed air.
CHECK the system coolant level ONE [1] time for WARNING: The compressed air supply MUST
EACH eight [8] hours of machine operation, or daily. have a pressure BELOW 30 psi.
Drain, flush and fill the cooling system, with NEW [2 bar]. Wear safety glasses and
coolant, ONE [1] time for EACH 1,000 hours of protective clothing.
machine operation, or yearly, [see THIS section for
general procedures].
CAUTION: Do NOT damage the radiator, or
Keep the coolant level ONE [1] inch [25.4 mm] hydraulic oil cooler, cooling fins
BELOW the radiator filler neck, when the cooling during cleaning. Clean the fin areas
system is cool. Fill the radiator ONLY when the with the compressed air blown in the
system is COOL. Fill the radiator as needed, using a OPPOSITE direction of “normal” air
50/50 % [approximate] mixture of ethylene glycol flow during operation. Bent cooling
type antifreeze and CLEAN water on initial fill. Add fins can be CAREFULLY
CLEAN water when the level is LOW. straightened. Use a radiator fin comb
to straighten the bent fins AFTER
CHECK the radiator cap gasket EACH time the cleaning. Severe restrictions, or dirt
radiator cap is removed from the radiator. The build up, which are NOT removed by
radiator cap gasket MUST seal on the radiator filler using compressed air, MUST be
neck surface. If the rubber face of the cap valve is removed by using standard steam
damaged, or cracked, REPLACE the radiator cap cleaning procedures. Apply steam
IMMEDIATELY with a NEW cap of the SAME cleaning pressure through BOTH the
pressure rating. radiator and hydraulic oil cooler in
the direction OPPOSITE the direction
CHECK the radiator overflow tube for restriction, or of “normal” air flow during operation.
damage. A restricted, or damaged, overflow tube Do NOT use caustic soap solutions
can prevent the radiator cap from releasing extra as part of the standard steam
system pressure and system failure can occur. cleaning procedure, as rapid radiator
or hydraulic oil cooler deterioration
can occur.
4-20 9/2005
Section 4
MAINTENANCE
WARNING: Wear safety glasses and protective WARNING: Do NOT check, or remove, ANY
clothing during the steam cleaning radiator hose with the engine
operation. Use ONLY CORRECT “running”. Serious injury can result
steam cleaning procedures. from being caught, or struck, by the
fan, belt or moving engine parts.
Do NOT check, or remove, ANY
radiator 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.
Water pump leaks can allow air to be pulled into

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

coolant anticorrosion additives are no longer
effective.
9/2005 4-21
Section 4
MAINTENANCE
To help prevent severe cooling system damage; NOTE: BEFORE cooling system flushing,
drain, flush and fill the system with NEW coolant, the thermostat MUST be removed. If
ONE [1] time for EACH 1,000 hours of machine the thermostat is NOT removed, the
operation, or yearly. flushing procedure WILL close the
thermostat and prevent complete
engine block flushing.
WARNING: Do NOT drain, or flush, the cooling Do NOT install the radiator hoses,
system with the engine running. or thermostat, at THIS time.
caught or struck by the fan, belt or
moving engine parts. d. Remove ALL engine and aftercooler drain
Do NOT drain the cooling system plugs. COMPLETELY drain the coolant from the
while the system is HOT and is engine and aftercooler. Install ALL drain plugs into
under pressure. Drain the system the engine and aftercooler. Tighten the drain plugs
when COOL ONLY. Hot coolant can by hand ONLY, at THIS time.
e. Install ONLY the thermostat HOUSING
[NO thermostat] onto the engine. Reverse flush the
Use the following general procedures to drain, flush ENGINE BLOCK as shown in figure 4-11. Remove
and fill the engine cooling system: ALL engine and aftercooler drain plugs, again,
AFTER reverse flushing the engine block assembly.
a. STOP the engine and allow the cooling system COMPLETELY drain the engine block and the
to reach a COOL temperature. Put a container aftercooler of water. Install ALL engine and after-
under the radiator drain cock and drain the coolant. cooler drain plugs. Tighten ALL drain plugs
Open the radiator drain cock and drain ALL coolant securely, using a wrench.
from the radiator. Close and tighten the drain cock
by hand ONLY . f. Remove the thermostat housing from the
engine. Install the thermostat into the housing, in
b. Remove BOTH the upper AND the lower the CORRECT position. Install the thermostat
radiator hoses from the engine. Inspect BOTH housing to engine gasket. Install the thermostat
hoses using the procedures given in THIS section. housing over the thermostat and onto the engine.
Replace ANY hose found to have ANY damage. Install the retaining capscrews and tighten securely.
NOTE: Inspect the engine WATER PUMP, at CAUTION: Do NOT start the engine while
THIS time, for ANY damage, or leaks. reverse flushing the engine block or
REPLACE the water pump with NEW if the radiator assembly.
found to be damaged, or leaking.
g. Reverse flush the RADIATOR assembly, as

c. Remove the thermostat housing and the shown in Figure 4-12. Loosen the radiator drain
thermostat from the engine. Inspect the thermostat cock, again, AFTER reverse flushing the radiator
for corrosion, or damage. Test the thermostat for assembly. COMPLETELY drain the radiator of
CORRECT operation at the specified opening water. Close the radiator drain cock and tighten
temperature. Replace the thermostat, with NEW, if securely.
found to be damaged. Install the thermostat, AFTER
flushing, ONLY. h. Install BOTH the UPPER and the LOWER
radiator hoses onto BOTH the radiator and the
engine. Install ALL the clamps, onto the hoses, and
tighten them securely.
i. Fill the cooling system with coolant, through the

radiator filler neck, using a NEW 50/50 % [AP-
PROXIMATE] mixture of ethylene glycol antifreeze
and CLEAN water [see THIS section].
4-22 9/2005
Section 4
MAINTENANCE
NOTE: It is suggested that one [1] can
of cooling system conditioner,
with a rust inhibitor, also be CAP CLOSED FLUSHING GUN
added to the coolant at THIS time. CLAMP WATER
AIR
j. Start the engine and allow the NEW coolant

mixture to circulate through the cooling system. NEW HOSE
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
CLAMP
moving engine parts.
k. STOP the engine. Allow the coolant to reach a FIGURE 4-12. REVERSE FLUSHING
cool temperature and then fill the radiator, with the PROCEDURE RADIATOR ASSEMBLY.
CORRECT coolant mixture, to within ONE [1] inch
[25.4 mm] of the radiator filler neck. Install the
radiator cap and tighten.
HYDRAULIC SYSTEM.
WATER
FLUSHING GUN The transmission, steering and vibration systems
ALL use the SAME hydraulic oil reservoir and
CLAMP hydraulic oil supply.
AIR
FIGURE 4-11. REVERSE FLUSHING

PROCEDURE ENGINE BLOCK.
9/2005 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.
FILL CAP
WARNING: Do NOT loosen, or remove, the SIGHT

hydraulic oil reservoir filler cap GAUGE
when the hydraulic oil is “HOT”. RESERVOIR
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 FIGURE 4-13. HYDRAULIC OIL RESERVOIR AND
seen through the sight gauge glass, and be at the SIGHT GAUGE.
CENTER of the glass. If the hydraulic oil level is
BELOW the sight gauge, the CORRECT, FIL-
TERED hydraulic oil MUST be added to the hydrau- CHANGING THE HYDRAULIC OIL [See Figure
lic oil reservoir UNTIL the oil level is in the CENTER 4-14].
of the sight gauge glass. See THIS section for the
CORRECT type of oil. 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
CAUTION: Do NOT over fill the hydraulic oil hours of machine operation, or every TWO [2] years
reservoir. for OIL ANALYSIS.
Do NOT use unfiltered hydraulic oil.
The NEW hydraulic oil MUST be Use the equipment from, and follow the directions
filtered through TEN [10] micron given by, the oil analysis service. Change the
filtration BEFORE it enters the hydraulic oil ONLY if the OIL ANALYSIS results
hydraulic oil reservoir. The oil must indicate a change is needed.
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 9/2005
Section 4
MAINTENANCE
Changing the hydraulic oil removes the CAUTION: Do NOT fill the hydraulic oil reservoir
accumulation of dirt, water and mechanical wear with NEW hydraulic oil UNTIL the
particles from the hydraulic oil reservoir and system. filter element, and screens in the
The chemical structure of the hydraulic oil also ABOVE “NOTE”, have been serviced.
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 d. Install the hydraulic oil reservoir drain plug and
system. tighten securely.
e. CAREFULLY remove the cloth from the

CAUTION: Hydraulic oil which has oxidized or hydraulic oil reservoir fill tube opening.
which contains contamination, of
ANY type, can shorten the expected f. Fill the hydraulic oil reservoir with the COR-
service life of ANY, or ALL, of the RECT, FILTERED hydraulic oil using the proce-
components in the hydraulic system. dures given in the following “CAUTION” information.
See THIS section for CORRECT type of oil.
Use the following procedures to change the

hydraulic oil: CAUTION: Do NOT use unfiltered hydraulic
oil. The NEW hydraulic oil MUST be
a. STOP the engine. Allow the hydraulic oil to filtered through TEN [10] micron
cool, until it is at a WARM temperature ONLY. filtration BEFORE it enters the
SLOWLY loosen, and then remove, the hydraulic oil hydraulic oil reservoir. The oil MUST
reservoir filler cap. Put a CLEAN, lint free cloth NOT have MORE than 400 particles
over the reservoir fill tube opening and secure in larger than 10 u. per milliliter of oil as
place with tape. installed. Fill the hydraulic oil
reservoir UNTIL the oil level is in the
CENTER of the sight gauge glass.
WARNING: Do NOT drain the hydraulic oil from Do NOT overfill the hydraulic oil
the reservoir when it is HOT. reservoir with oil.
HOT hydraulic oil can cause serious
injury. Drain at a WARM temperature
ONLY. g. Check the oil level in the hydraulic oil reservoir,
again. Add oil if needed.
b. Loosen the hydraulic oil drain plug. Place a h. Install the hydraulic oil reservoir filler cap onto
funnel, which has been altered by cutting the funnel the reservoir filler neck and tighten securely.
to fit under the drain plug, under the drain plug. Put
one end of a hose onto the funnel and put the other i. Start the engine using the CORRECT proce-
end of the hose into an empty container having a dures given in Section 3 - OPERATION - of THIS
capacity of approximately 25 gallons [95 liters]. manual. CHECK the hydraulic system for ANY
leaks. Install the vibrator control valve access panel
c. Carefully remove the reservoir drain plug. Allow onto the machine and tighten the retaining
ALL of the hydraulic oil to drain from the reservoir capscrews securely.
and into the container.
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.
9/2005 4-25
Section 4
MAINTENANCE
WARNING: Do NOT use the hands on ANY CAUTION: The hydraulic system MUST be at
hydraulic hose, fitting or NORMAL operating temperature,
system component to check the with the engine “running”, when the
system for possible leaks. condition of the filter element is
SERIOUS injury can result from an checked. With the engine at “HIGH”
oil leak under high pressure. Oil can idle, and when the filter condition
be injected under the skin by high indicator WHITE sliding bar is in the
pressure. Protect the eyes by RED zone, an element CHANGE is
wearing safety glasses. indicated to be needed.
CAUTION: STOP the engine IMMEDIATELY if NOTE: When the hydraulic oil is in a COLD
ANY hydraulic leak is noted. condition and at machine “START UP”,
Do NOT start the engine UNTIL any the filter condition indicator WHITE
problem noted has been corrected. sliding bar will show a HIGHER amount
of filter element restriction. The filter
element MUST also be changed with
EACH COMPLETE hydraulic oil change.
WARNING: Do NOT loosen, or remove, the

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.
Use the following procedure to remove and replace

FIGURE 4-14. HYDRAULIC OIL RESERVOIR the hydraulic oil filter element:
DRAINING LOCATION..
a. STOP the engine. Allow the hydraulic oil to
reach a WARM, or COOL, temperature.
VIBRATION SYSTEMS PRESSURE OIL FILTER b. Remove the access panel retaining capscrews
ELEMENT - REMOVAL AND REPLACEMENT and panel. Wipe the hydraulic oil filter head and
[See Figure 4-15]. element using a CLEAN lint free cloth.
CHECK the condition of the vibration systems c. Use a oil filter removal wrench to loosen and
pressure oil filter element EACH day. The filter remove the filter element. Discard the removed filter
element MUST be changed when the condition
element.
indicator light, found on the dash of the machine,
and the change indicator, found on the filter head,
indicate an element change is needed.
CAUTION: Be sure that the old filter element
rubber gasket is removed and
discarded, BEFORE the NEW filter
element is Installed.
4-26 9/2005
Section 4
MAINTENANCE
d. Put CLEAN hydraulic oil on the NEW filter h. Install the access panel onto the machine and
element rubber gasket. 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 FIGURE 4-15. VIBRATION SYSTEMS -
CORRECT procedures given in THIS section. PRESSURE OIL FILTER ELEMENT LOCATION.
CAUTION: Do NOT start the engine BEFORE

filling the hydraulic oil reservoir with TRANSMISSION SYSTEM PRESSURE OIL
oil. Damage to the hydraulic system FILTER ELEMENT - REMOVAL AND REPLACE-
MENT [See Figure 4-16].
components can occur. Fill the
reservoir using ALL of the The transmission system pressure oil filter
procedures given in THIS section. element MUST be changed when the hydraulic oil is
changed.
g. Start the engine using the CORRECT

procedures given in Section 3 - OPERATION - of WARNING: Do NOT loosen, or remove, the
hydraulic oil filter
THIS manual. CHECK the hydraulic system for ANY element when the engine is running,
oil leaks. or when the hydraulic oil is HOT.
Loosen, and remove, the filter
element ONLY when the engine is in
WARNING: Do NOT use the hands on ANY an “STOPPED” and the hydraulic
hydraulic hose, fitting or system oil has cooled to a WARM, or COLD,
component to check the system for temperature.
possible leaks. SERIOUS injury can
occur from an oil leak under high NOTE: The filter head, and element, may be
pressure. Oil can be injected under found mounted in the vertical, horizontal,
the skin by high pressure. Protect or angled position. The position has NO
the eyes by wearing safety glasses. effect on filtration.

CAUTION: STOP the engine IMMEDIATELY if the oil filter element:
ANY hydraulic oil leak is noted.
Do NOT start the engine UNTIL any a. STOP the engine. Allow the hydraulic oil to
problem noted has been corrected. 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.
9/2005 4-27
Section 4
MAINTENANCE
c. Use a oil filter removal wrench to loosen and CAUTION: STOP the engine IMMEDIATELY if
remove the filter element. Discard the removed filter ANY hydraulic oil leak is noted.
element. Do NOT start the engine UNTIL any
problem noted has been corrected.
CAUTION: Be sure that the old filter element h. Install the access panel onto the machine and
rubber gasket is removed and install, and then tighten, the retaining capscrews
discarded, BEFORE the NEW filter securely.
element is Installed.
d. Put CLEAN hydraulic oil on the NEW filter

element rubber gasket.
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. FIGURE 4-16. TRANSMISSION SYSTEM -
PRESSURE OIL FILTER ELEMENT LOCATION.
f. At this time, clean the two [2] hydraulic oil

suction strainers and the one [1] return oil diffuser, HYDRAULIC SUCTION OIL STRAINERS AND
using the procedures given in THIS section. Fill the RETURN OIL DIFFUSER - REMOVAL, CLEANING
hydraulic oil reservoir with oil. Use ALL of the AND INSTALLATION
CORRECT procedures given in THIS section. [See Figure 4-17].
Remove, clean and reinstall the TWO [2] hydraulic

CAUTION: Do NOT start the engine BEFORE suction oil strainers and the ONE [1] hydraulic
filling the hydraulic oil reservoir with return oil diffuser with EACH complete hydraulic oil
oil. Damage to the hydraulic system change.
components can occur. Fill the
reservoir using ALL of the Use the following procedures to remove, clean and
procedures given in THIS section. install the above items:
g. Start the engine using the CORRECT WARNING: Do NOT loosen, or remove, the
procedures given in Section 3 - OPERATION - of hydraulic suction oil strainers or the
THIS manual. CHECK the hydraulic system for ANY hydraulic return oil diffuser, when
oil leaks. the engine is running or when the
hydraulic oil reservoir is “full” of oil.
Loosen, or remove, the hydraulic
WARNING: Do NOT use the hands on ANY suction oil strainers, or the return oil
hydraulic hose, fitting or system diffuser, ONLY when the engine is
component to check the system for STOPPED and AFTER the
possible leaks. SERIOUS injury can hydraulic oil has cooled and has
occur from an oil leak under high been DRAINED from the hydraulic
pressure. Oil can be injected under oil reservoir [see THIS section].
the skin by high pressure. Protect SERIOUS injury can occur from
the eyes by wearing safety glasses. contact with HOT hydraulic oil.
4-28 9/2005
Section 4
MAINTENANCE
a. STOP the engine. Allow the hydraulic oil to g. Remove the paper covers from the threaded
reach a WARM, or COOL, temperature. Drain the hydraulic suction oil strainer bosses and the return
hydraulic oil using the procedures given in THIS oil diffuser boss, in the reservoir.
section.
h. Put one [1] o-ring onto the threaded area of
b. CLEAN ALL the hoses, fittings and the area of each suction oil strainer and onto the threaded area
the hydraulic oil reservoir where the hydraulic return of the return oil diffuser.
oil diffuser is installed, using All-Purpose Degreaser,
Part Number 178297. i. CAREFULLY install each suction oil strainer into
the oil reservoir boss and tighten securely. CARE-
c. Put an identification tag onto EACH suction FULLY install the hydraulic return oil diffuser into the
hose. Remove the suction hoses from the fittings hydraulic oil reservoir boss and tighten securely.
installed into the hydraulic suction oil strainers.
IMMEDIATELY put a plug into EACH strainer fitting
and a cap on EACH hose. NOTE: Use the identification tags, installed on
EACH hose and fitting BEFORE removal,
d. Remove the TWO [2] hydraulic suction oil as a reference for CORRECT
strainers from the hydraulic oil reservoir. Put a connections.
CLEAN paper cover over each threaded strainer
boss, in the reservoir, and secure with tape.
CAUTION: Complete ALL hydraulic oil reservoir
e. Loosen and remove the one [1] return oil filling procedures, given in THIS
diffuser from the hydraulic oil reservoir. Put a section, BEFORE starting the engine.
CLEAN paper cover over the threaded diffuser
boss, in the reservoir, and secure with tape.
j. Start the engine using the CORRECT
procedures given in Section 3 - OPERATION - of
CAUTION: Do NOT lose, or damage, the o-ring THIS manual. CHECK the hydraulic system for ANY
when each strainer and/or the oil leaks.
diffuser, is removed from the
reservoir. CAREFULLY inspect each
o-ring for damage and replace with WARNING: Do NOT use the hands on ANY
NEW, if needed. hydraulic hose, fitting or system
component to check the system for
possible leaks. SERIOUS injury can
f. CAREFULLY wash each suction oil strainer occur from an oil leak under high
and/or the return oil diffuser, using All-Purpose pressure. Oil can be injected under
Degreaser, Part Number 178297, and allow it to AIR the skin by high pressure. Protect
dry ONLY. the eyes by wearing safety glasses.
CAUTION: Do NOT use compressed air to CAUTION: STOP the engine IMMEDIATELY if
dry the strainer and/or diffuser, after ANY hydraulic oil leak is noted.
cleaning. Do NOT start the engine UNTIL any
Damage can occur to the strainer, or problem noted has been corrected.
diffuser, mesh area if dried using
compressed air.
9/2005 4-29
Section 4
MAINTENANCE
Use the following procedures to ADD lubrication oil
DIFFUSER 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 [approxi-
mately a 2 o’clock or a 11 o’clock 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 3. SLOWLY add CLEAN and FILTERED Texaco
STRAINERS OIL AND RETURN OIL DIFFUSER Meropa 150, or equivalent, lubrication oil to the
INSTALLATION LOCATIONS. drum, through the FILLER hose on the drum.
CAUTION: Clean the oil, being added to the

DRUM BEARING LUBRICATION drum, through twenty five [25] micron
filtration BEFORE it enters the drum.
CHECKING THE DRUM BEARING LUBRICATION Add the oil to the drum SLOWLY.
OIL LEVEL [See Figure 4-18]. Do NOT overfill the drum with
lubrication oil.
Add ONLY enough oil to bring the
Check the drum bearing lubrication oil level of EACH drum oil level to the CENTER of the
drum, one [1 ] time for each eight [8] hours of sight gauge glass.
machine operation, or daily.
Use the following procedures to check drum bearing 4. Install the LARGE [FILL] cap fitting onto the
lubrication oil level, and to add lubrication oil if filler hose bulkhead fitting and tighten securely.
needed:
b. Move the machine to the SAME position as in
a. Put the machine on a LEVEL surface, and in a step “a” and CHECK the oil level, AGAIN, using the
position, so the RED drum position Iocater BAR, on procedures given in step “a”.
the drum being checked, is at the exact BOTTOM of
the rotation of the drum.
CAUTION: If the oil level is NOT correct, ADD
CAUTION: If the lubrication oil level is BELOW additional oil using steps “1-4” and
the sight gauge glass, ADD only then check the oil level, again.
enough oil to show the CORRECT oil
level in the CENTER of the sight
gauge glass. c. Check the drum bearing lubrication oil level of
Do NOT add more oil immediately if the SECOND drum, using the SAME procedures.
the lubrication oil level appears to Add lubrication oil if needed.
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 9/2005
Section 4
MAINTENANCE
CHANGING THE DRUM BEARING c. Remove the [DRAIN] cap fitting from the drain
LUBRICATION OIL - 66 Inch machines serial hose bulkhead fitting. Drain the drum bearing
number 109C20902455 and higher and on 78 lubrication oil from the drum.
Inch machines serial number 109B21501856 and
higher [See Figure 4-18]. NOTE: The fill hose can be opened during the
drain process to assist as a vent.
Change the drum bearing lubrication oil, in EACH
drum, one [1] time for each 2,000 hours of machine d. Rotate the drum until the [FILL] cap fitting
operation, or every TWO [2] years. directly opposite the position location block, is at the
HIGHEST [TOP] point of the rotation of the drum.
Use the following procedures to change the drum Wipe the area around the LARGE [FILL] cap fitting
bearing lubrication oil in BOTH drums: with a CLEAN cloth.
a. Run the machine long enough to ensure that the e. Install the [DRAIN] cap fitting onto the drain
drum bearing lubrication oil is completely at a hose bulkhead fitting and tighten securely.
WARM temperature.
f. Remove the [FILL] cap fitting and SLOWLY fill
b. Rotate the drum having the lubrication oil the drum through the [FILL] hose bulkhead fitting,
changed first, until the [DRAIN] cap fitting is using TEN [10] gallons [37.9 liters] of CLEAN and
positioned at the LOWEST [BOTTOM] point of the FILTERED Texaco Meropa 150, or equivalent,
rotation of the drum. Wipe the area around the lubrication oil.
[DRAIN] cap fitting with a CLEAN cloth.
FIGURE 4-18. DRUM LUBRICATION OIL DRAIN, FILL AND SIGHT GAUGE LOCATIONS.
9/2005 4-31
Section 4
MAINTENANCE
g. Wait two [2] minutes and then check the NOTE: If the belt requires replacement with new,
lubrication oil level shown in the sight gauge glass. also, see the current “OPERATION AND
The lubrication oil level MUST be in the CENTER of MAINTENANCE MANUAL - B SERIES
the sight gauge glass to be at the CORRECT level. DIESEL ENGINE”, published by
Cummins Diesel Engine Company and
CAUTION: Clean the oil, entering the drum, supplied with the machine for
through twenty five [25] micron procedures. Also, check the belt tension
filtration BEFORE it enters the drum. mechanism and fan hub bearings, at this
Fill with oil SLOWLY. Do NOT overfill time, using the procedures given in the
the drum with lubrication oil. Fill the
same publication.
drum with ONLY enough oil to bring
the oil level to the CENTER of the
sight gauge glass.
WRENCH
h. Install the [FILL] cap fitting onto the filler hose
bulkhead fitting and tighten securely. 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 ALTERNATOR
this section. 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
FIGURE 4-19. ALTERNATOR AND FAN DRIVE
belt as needed, after inspection. The belt is kept
BELT LOCATION.
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 ELECTRICAL SYSTEM.

inspect and replace the drive belt:
CHECKING THE CHARGE CONDITION OF
a. STOP the engine. THE BATTERY AND SERVICING OF RELATED
ITEMS [See Figure 4-20].
WARNING: Do NOT inspect the engine drive belt
when the engine is “running”. The The battery is of the “maintenance-free” type and
engine MUST be STOPPED BEFORE minimal service is needed. Use the built in battery
inspecting the drive belt. Serious “charge level” indicator, found in the top of the
injury can result from being caught, battery, to check the charge level in the battery one
or struck, by the fan, belt or other [1 ] time for each 100 hours of machine operation,
moving engine parts. or every two [2] weeks.
b. Visually inspect the drive belt for intersecting

cracks on the INNER surface of the belt plies. WARNING: CALIFORNIA Proposition 65.
Check the belt for intersecting cracks. Longitudinal Battery posts, terminals
[direction of belt length] cracks that intersect with and related accessories contain
transverse cracks are NOT acceptable. Replace the lead and lead compounds. Wash
belt, with NEW, if any intersecting cracks, fraying,
hands after handling.
or other damage, is noted.
4-32 9/2005
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.
FIGURE 4-20. BATTERY MAINTENANCE AREA

The indicator will indicate a “GREEN” color for a LOCATIONS.
FULLY charged battery. A “BLACK” indicator color
indicates the battery is in a LOW charged condition.
Use a battery cable cleaning brush, baking soda ELECTRICAL WIRING INSPECTION.
and clear water to clean the battery terminals and
cables, as needed. During engine and/or other system maintenance
inspections, CHECK the electrical wiring for correct
routing and support. Inspect the wires for loose
WARNING: BATTERY EXPLOSION CAN OCCUR terminal connections, cracks, or wear, in the wiring
IF THE BATTERY IS SHORTED. insulation and for corrosion. Wires and connections
ALWAYS disconnect the NEGATIVE MUST be free of oil, dirt or grease.
[-] battery cable FIRST, and then
disconnect the POSITIVE [+] battery
cable, BEFORE cleaning the CAUTION: Do NOT use a wire smaller than
terminals, or cables. the size of the original factory
NEVER make a shorted circuit installed wires in the electrical
between the positive [+] terminal system. If, due to wear or damage,
and negative [-] terminal of the wires are replaced with new, use
battery. wire EQUAL to, or larger in size than,
ALWAYS connect the POSITIVE [+] the wire being replaced.
battery cable to the POSITIVE
battery terminal FIRST, and then
connect the NEGATIVE [-] battery WARNING: BATTERY EXPLOSION CAN OCCUR
cable to the NEGATIVE [-] battery IF A BATTERY IS SHORTED.
terminal LAST. ALWAYS disconnect BOTH the
Do NOT place ANY tools on a positive [+] AND the negative [-]
battery, at ANY time. battery cables from a battery,
BEFORE ANY repair procedures are
done to the electrical wiring or
Check and tighten the battery hold down assembly. components.
The battery MUST be kept from ANY movement in NEVER make a shorted circuit
the machine. between the positive [+] terminal
and the negative [-] terminal of a
battery. Do NOT place ANY tools on
a battery, at ANY time.
9/2005 4-33
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].
FIGURE 4-21. VIBRATION ISOLATOR TIRE
PRESSURE CHECK AND FILL LOCATION.
Check the air pressure of EACH tire, and adjust as
needed, using the following procedures:
CAUTION: Check the tire air pressure ONLY
when the vibration isolator tires are
a. Remove the tire valve cap from the tire inflation
in a COOL condition.
valve. Check the inflation of EACH tire, using an
The pressure indicated, on the tire
accurate tire gauge.
pressure gauge, MUST be 30 psi.
[2 bar]. Adjust the air pressure in
EACH isolator tire, UNTIL the
WARNING: ALWAYS use remote inflation
pressure is CORRECT.
equipment consisting of an
Do NOT over inflate the vibration
extension hose, with the clip-on
isolator tires. The vibration isolator
filling chuck, and a gauge or preset
tires will NOT absorb enough
pressure regulator. When adding air
vibrations from the machine’s drums
to the tires, ALL personnel MUST
and the vibrations will transfer into
keep CLEAR of the tire and rim.
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.
4-34 9/2005
Section 4
MAINTENANCE
REMOVAL, REPAIR OR REPLACEMENT, AND CAUTION: Do NOT place the wood blocks, so
INSTALLATION OF THE VIBRATION ISOLATOR that the drum will touch the blocks
TIRE AND RIM ASSEMBLIES - 66 Inch machines as the drum is rolled forward and
serial number 109C20902475 and higher and on from between the frame sides.
78 Inch machines serial number 109B21501883
and higher [See Figure 4-22A]. d. Put an identification tag on each hose fastened
to the vibrator motor. Remove each of the hoses
Remove, repair, or replace, ANY vibration isolator from the fittings on the motor. Put a plug in each
tire found to show evidence of an air leak, or other hose and a cap on each motor fitting.
serious damage, IMMEDIATELY, using the
following procedures: 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 e. Put an identification tag on each hose that
the secondary/parking brake system and STOP the fastens to the drum drive motor. Remove each of
engine. Drain the water tank and disconnect the the hoses from the fittings on the motor. Put a plug
water sprinkler bar supply hose on the drum being in each hose and a cap on each motor fitting.
serviced. Remove the drum cleaner bar.
f. Carefully remove the eight [8] bolts [1] and
b. Drain the water tank, found at the front of the tightening washers [2] which fasten the drum drive
drum being removed, of water. Disconnect the motor assembly [3] to the sides of the frame.
electrical connection to the water spray pump. Carefully remove the eight [8] bolts [9] and
Fasten a sling and a hoist, having a capacity more tightening washers [10] which fasten the vibrator
than 1,500 lbs. [861 kg] to the water tank frame. motor subassembly [11] to the opposite side of the
Remove the capscrews that fasten the tank and frame.
frame to the frame of the machine. Remove the tank
and frame assembly from the machine and place on NOTE: Removing the eight [8] bolts from each
the ground. side of the frame will permit the drum
assembly, with both vibration isolator
WARNING: Keep clear of the water tank and tire, rim and hoop assemblies, vibrator
frame assembly while lifting, drive subassembly, and the drum drive
removing and lowering the tank motor assembly , to be removed from
assembly. between the frame sides by rolling the
assembly toward the open end of the
c. Put wood blocks in front, and at the rear, of the machine.
drum NOT being serviced. Put a hydraulic jack,
having a capacity more than five [5] tons [4t], under g. CAREFULLY and SLOWLY roll the complete
either side of the frame outside the drum being drum assembly [4] toward the open end of the
removed for vibration isolator tire removal and repair machine until the drum is fully away from the frame
or replacement. Raise the hydraulic jack ONLY until sides.
the jack lifting plate JUST starts to lift frame weight.
Put wood blocks, or jack stands, under the side of WARNING: Keep CLEAR of the drum to frame
the frame. Lower the frame onto the support item areas while rolling the drum toward
and remove the hydraulic jack. Lift the OPPOSITE the open end of the machine. Put
frame side and put wood blocks or jack stands under wood blocks in front, and at the
the frame side using the SAME procedures given in rear, of the drum AFTER the drum is
this step. removed.
WARNING: Keep CLEAR of the frame while NOTE: With the drum removed from the
being lifted and lowered onto the machine, remove the complete vibration
blocks. Block securely using solid isolator tire and hoop assembly being
wood blocks, or solid support items. repaired, from the drum.
9/2005 4-35
Section 4
MAINTENANCE
FIGURE 4-22A. FRAME, DRUM, VIBRATION ISOLATOR TIRE AND RIM - EXPLODED VIEW.
4-36 9/2005
Section 4
MAINTENANCE
h. Fasten a sling and a hoist, having a capacity k. Remove the five [5] bolts [12] and tightening
more than 1,000 lbs. [454 kg], to the complete washers [13] which fasten the vibrator drive
isolator subassembly [7] that is being removed, in subassembly [11] to the isolator tire rim center [15],
order to repair or replace the tire. Remove ALL or the ten [10] nuts [14] which mount the drum drive
slack in the sling but do NOT lift the isolator motor to the opposite tire rim center [15]. Remove
subassembly, at this time. the six [6] nuts [19], from the bolts [16] which fasten
the upper half hoop [17] and lower half hoop [18]
i. Use a wrench, having a capacity MORE than assemblies together around the tire and rim.
300 ft. lbs. [407 N.m], remove the bolts [5] and CAREFULLY lift and remove the upper half hoop
tightening washers [6] which fasten the isolator assembly [17] from the tire and set the half hoop on
subassembly [7] to the flange of the vibratory drum the ground.
[4]. SLOWLY move the isolator subassembly [7]
outward and away from the flange, while lifting the l. Fasten a sling and a hoist, having a capacity
assembly with the sling and hoist, a SMALL amount. more than 300 lbs. [136 kg], to the tire rim center
CAREFULLY move the assembly away from the [15]. CAREFULLY move and lower the tire and rim
drum [4] and place the assembly on the ground. assembly onto a tire repair machine.
WARNING: Keep CLEAR of the isolator WARNING: Keep CLEAR of the tire and rim
subassembly while loosening the assembly while being lifted and
retaining capscrews which fasten moved.
the assembly to the drum, and while
moving the isolator subassembly
away from the drum and then TIRE REMOVAL, REPAIR OR REPLACEMENT
lowering the assembly to the AND INSTALLATION ONTO THE RIM [See
ground. Figure 4-22A].
j. Remove the valve cap from the isolator tire [8] a. Fasten the tire rim center [15] securely to the
filling valve stem, CAREFULLY remove the valve tire repair machine, so that the assembly will NOT
core from the tire filling valve stem and exhaust ALL move when the tubeless tire beads are “broken
the air from the isolator subassembly, if inflated. loose” from the rim bead seat area.
b. “Break” the UPPER tire bead away from the rim

WARNING: Keep CLEAR of the air path as the using a “bead breaking” tool. Move the tire UPPER
air is released from the tire bead over and above, the UPPER rim bead seat
assembly. area, using the machine tire bead spreader bar.
CAREFULLY lift the tire assembly, a SMALL
NOTE: Check the valve stem to be sure the amount, at the SAME time.
inside is NOT in a plugged condition, by
putting a wire through the center hole in WARNING: Use a sling and a hoist, having a
the valve stem. 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.
9/2005 4-37
Section 4
MAINTENANCE
c. CAREFULLY lift the LOWER tire bead toward g. CAREFULLY lift the tire above the rim
the UPPER rim bead seat area and put the bead assembly, using a sling and hoist. SLOWLY lower
spreader bar assembly between the LOWER tire the tire to the rim assembly. Tilt the tire a small
bead and the UPPER rim bead seat area. Move the amount as the LOWER bead reaches the UPPER
bead spreader bar around the tire bead and remove rim bead seat, of the rim assembly. Push the
the tire bead over and above the UPPER rim bead LOWER bead past the UPPER rim bead seat and
seat area. CAREFULLY lift the tire away from the continue to lower the tire downward. Pull the tire
rim assembly for tire inspection, repair, or back as far as possible as the LOWER bead
replacement as needed. reaches the LOWER bead seat area of the rim
assembly, and as the LOWER tire bead is also
d. Inspect the tire from BOTH the OUTSIDE and partially caught on the UPPER rim bead seat.
the INSIDE of the tire for punctures, cuts, breaks or
other damage. Wipe the inside of the tire with a h. Use the tire bead installing tool to install the
clean cloth to remove any dirt, or moisture. Repair balance of the LOWER tire bead over the UPPER
the tire as needed using tire repair materials which rim bead seat and lower the tire to the LOWER
repair the damaged area from the INSIDE of the bead seat area of the rim assembly.
tire.
i. Push the UPPER tire bead downward and over
the UPPER bead seat area of the rim assembly, as
CAUTION: The isolator tires are of radial ply
much as possible. Pull back on the UPPER tire
design. Use ONLY tire repair
bead and use the tire bead installing tool to install
materials and procedures for radial
the balance of the UPPER tire bead over the
type tires. Replace the tire if ANY
UPPER rim bead seat area.
tire damage is found that is NOT
able to be repaired using INSIDE tire
j. Fasten a tire bead expanding strap, having a
carcass repair methods and
strap tightening mechanism, AROUND the tire
materials. The repair materials used
circumference at the CENTER of the tread area.
MUST seal the INNER tire carcass
Tighten the tire bead expanding strap to expand
and fill the tire injury, to be
BOTH the UPPER and LOWER tire beads onto the
considered an adequate and
UPPER and LOWER rim bead seat areas.
permanent repair.
k. Remove the tire and rim assembly from the tire
e. Carefully inspect the rim assembly for ANY
machine. Put the assembly in a “TIRE
cracks, severe rusting, or other damage in the bead
RESTRAINlNG” device that is behind a protective
seat area. Clean, sand to new metal, prime and
barrier. Connect remote inflation equipment to the
finish paint the rim assembly BEFORE mounting
tire filling valve.
the tire. Install a new tire filling valve, if the valve
shows ANY damage.
l. Apply air pressure to the tire, NOT to exceed 65
psi. [4 bar], using the remote inflation equipment
WARNING: Do NOT weld, heat or braze the rim until BOTH the UPPER and LOWER tire beads
assembly. Replace the rim assembly “seat” to the UPPER and LOWER rim bead seat
with NEW, if damaged. 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.
4-38 9/2005
Section 4
MAINTENANCE
WARNING: NEVER use an inflation pressure CAUTION: Put the tire and rim into the hoop
MORE than 65 psi. [4 bar] to seat the assembly, so that the tire air fill
tire beads. Excessive inflation valve will be TOWARD the FRAME
pressure, when seating tire beads, side when the vibration isolator tire
can cause the tire/rim assembly to and hoop assembly is installed onto
burst with a force sufficient to cause the drum on EITHER side of the
serious injury. ALWAYS use remote machine.
inflation equipment consisting of an
extension hose, with clip-on filling b. Put the UPPER half hoop assembly [17] over
chuck, and a gauge or preset the top of the tire and remove the sling and hoist.
pressure regulator. Install the six [6] bolts [16] through the holes in both
ALL personnel MUST keep CLEAR the UPPER and LOWER half hoop assemblies,
of the tire and rim and remain from the “UPPER” half hoop side. Put Loctite #242
BEHIND the protective barrier. on ALL bolt threads. Install the six [6] nuts [19] onto
the bolts [16] and tighten to a torque of 125 ft. lbs.
m. Remove the tire bead expanding strap from the [170 N.m].
tire. Remove the clip-on tire filling chuck from the
tire filling valve. Permit ALL the air to be released c. Put the vibration isolator assembly in a “flat
from the tire. 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
WARNING: Keep CLEAR of the path of the air as assemblies meet the sidewall. Use a tire removal
the air is released from the tire. tool to EVENLY space the tire sidewall rubber
around the FULL circumference of the hoop
assemblies.
INSTALLATION [See Figure 4-22A]. d. Apply air pressure to the tire, NOT to exceed 65
psi. [4 bar], using the remote inflation equipment.
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 WARNING: NEVER use an inflation pressure
capacity more than 300 lbs. [136 kg], to the tire rim MORE than 65 psi. [4 bar] to seat the
center [15]. CAREFULLY lift the rim and tire tire beads. Excessive inflation
assembly. Move the assembly to the LOWER half pressure, when seating tire beads,
hoop assembly and SLOWLY lower the tire and rim can cause the tire/rim assembly to
assembly into the hoop assembly opening. burst with a force sufficient to cause
serious injury.
WARNING: Keep CLEAR of the tire and rim ALWAYS use remote inflation
assembly while being lifted, moved equipment consisting of an
and placed into the hoop assembly. extension hose, with clip-on filling
chuck, and a gauge or preset
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.
9/2005 4-39
Section 4
MAINTENANCE
e. Remove the clip-on tire filling chuck from the h. Fasten a sling and a hoist, having a capacity
filling valve of the tire. Permit ALL of the air to be more than 500 lbs. [227 kg] to the complete vibrator
released from the tire. 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
WARNING: Keep CLEAR of the path of the air as
into the drum. Put Loctite #242 onto the threaded
the air is released from the tire.
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
f. Install the valve core into the tire filling valve
washers [6]. Torque bolts to 155 ft. lbs. [210 N.m].
stem and tighten. Connect remote inflation
Remove the sling and the hoist.
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. CAUTION: On the DRUM DRIVE MOTOR side of
Install and tighten the valve cap onto the tire filling the machine, repeat steps “a”
valve. through “f” before proceeding to
step “i”.
CAUTION: Do NOT overtighten the valve core
into the tire filling valve. i. On the DRUM DRIVE MOTOR side of the
machine, CAREFULLY put the vibration isolator
assembly [7] over the drum drive motor [3] studs.
NOTE: Check the tire inflation pressure, using Put Loctite #242 on the threaded area of the drive
an accurate tire pressure gauge. Use a motor studs. Install the lug nuts [14] onto the studs
soap and water solution to check the tire and tighten to a torque of 400 ft. lbs. [542 N.m]. Put
and rim assembly for ANY air leaks at the Loctite #242 on the threaded area of the ten [10]
tire bead to rim seat areas and around bolts [5] that fasten the UPPER and LOWER hoop
the tire filling valve. assemblies [17 and 18] to the drum [4]. Install the
ten [10] bolts [5] and tightening washers [6]. Tighten
g. On the VIBRATOR drive subassembly [11] side bolts to a torque of 155 ft. lbs. [210 N.m].
of machine, carefully attach the hoist and sling to
the isolator subassembly [7]. Lift it into position on
WARNING: Keep CLEAR of the vibration
the vibrator drive subassembly. Put Loctite #242 on
isolator assembly while lifting, and
the threaded area of the five [5] bolts [12] which
installing the assembly onto the
fasten the vibrator drive subassembly [11] to the tire
drum drive motor.
rim center [15]. Install the five [5] bolts [12] and
tightening washers [13]. Tighten bolts to a torque of
j. CAREFULLY remove the wood blocks from in
430 ft. lbs. [583 N.m].
front, and at the rear, of the drum. CAREFULLY and
SLOWLY roll the complete drum assembly into the
WARNING: Keep CLEAR of the isolator area between the frame sides, until the drum is at
subassembly and vibrator drive the CORRECT position in relation to the frame
subassembly while lifting and sides.
installing the assembly into the
drum.
WARNING: Keep CLEAR of the drum to frame
areas while rolling the drum into
position between the frame sides.
CAUTION: When installing complete vibrator
Put wood blocks in front, and at the
drive/isolator subassembly on drum,
rear, of the drum when the drum is
be sure shaft properly engages
in the CORRECT position.
vibrator drive subassembly.
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.
4-40 9/2005
Section 4
MAINTENANCE
NOTE: Use an alignment bar, or large drift pin, p. Fasten a sling and hoist, having a capacity
to align the holes through the frame more than 1,500 lbs. [681 kg], to the water tank and
sides and both sets of mounting spacers frame assembly. CAREFULLY lift the tank and
after the drum is rolled between the frame assembly and move it into position on the
frame sides. frame of the machine. Install the retaining
capscrews and tighten securely to a torque of 430
k. Put Loctite #242 on the threaded area of BOTH ft. lbs. [583 N.m]. Connect the water spray pump
sets of eight [8] bolts [1 and 9] that fasten the frame electrical wire male and female plug connectors
to the mounting spacers of both sides of the drum. together. Reattach the water sprinkler bar supply
Install the sixteen [16] bolts [1 and 9] and tightening hose.
washers [2 and 10], used on EACH frame side,
through the frame side and through the respective WARNING: Keep CLEAR of the water tank and
mounting spacers. Tighten the bolts [1 and 9] to a frame assembly while lifting, moving
torque of 430 ft. lbs. [583 N.m]. and lowering the tank assembly.
l. Remove the plug from each hose that fastens to q. Put a hydraulic jack, having a capacity more
the drum drive motor fittings. Remove the cap from than 5 tons [4t] under either side of the frame.
each drum drive motor fitting. Install the hoses onto CAREFULLY lift the frame and remove the support
the drum drive fittings, as indicated by the item which is under the frame. CAREFULLY lower
identification tags, and tighten securely. the machine to the ground. Lift the opposite frame
side and remove the support item using the SAME
m. Carefully reinstall the vibrator drive motor procedure.
assembly. Take care to properly engage the three
[3] pins to the appropriate mating holes of the rubber
WARNING: Keep CLEAR of the frame and drum
coupling attached to the vibrator driveshaft
while lifting the frame, removing the
weldment.
blocks and lowering the drum to the
ground.
n. Install the two [2] vibrator motor retaining
capscrews and hardened discs. Apply Loctite 242 to r. Start the engine using the CORRECT starting
the mating threads. Torque to 65 ft. lbs [88 N.m]. procedures given in Section 3 - OPERATION - in
this manual. Check the transmission and the
o. Remove the plug from each hose that fastens to vibration systems for ANY hydraulic leaks and for
the vibrator motor fittings. Remove the cap from correct system functions.
each vibrator motor fitting. Install the hoses onto the
vibrator motor fittings, as indicated by the
identification tags, and tighten securely. Install the CAUTION: Do NOT operate the vibration
drum cleaner beam and rubber scraper assembly. system on a hard surface. Operate
Install the beam retaining capscrews and tighten to the system with the drums on a soft
a torque of 280 ft. lbs. [380 N.m]. surface, such as loose dirt or old
tires ONLY. STOP the engine
IMMEDIATELY and correct ANY
system problem noted before
starting the engine again.
9/2005 4-41
Section 4
MAINTENANCE
SECONDARY/PARKING BRAKE SYSTEM c. Keep the directional/speed control [F-N-R
MAINTENANCE - OPERATION AND handle] in “NEUTRAL”.
APPLICATION CHECK [See Figure 4-23].
Check the SECONDARY/PARKING BRAKE SYS- BRAKE

RELEASE PURPLE
TEM for correct operation and application, one [1 ] WIRE
SOLENOID
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 STACK
the ignition switch. VALVE
Put SOLID wood blocks in the front,
and in the rear, of one [1] drum of the
machine. FIGURE 4-23. STACK VALVE AND BRAKE
REPAIR the system fault RELEASE SOLENOID LOCATIONS.
IMMEDIATELY.
Use the following procedures to CORRECTLY d. Put the engine throttle speed switch in the
check the secondary/parking brake system for “LOW” idle speed position. Start the engine by using
CORRECT operation and application: the CORRECT procedures given in section 3 -
OPERATION -in this manual.
a. Select a site that has a LEVEL surface and is
CLEAR of other machines, building structures or e. Put the engine throttle speed switch in the
personnel. Park the machine in the center of the “HIGH” idle speed position. Put the transmission
selected area. STOP the engine. speed range control switch in the “LOW” range
position.
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 4-
23]. 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.
4-42 9/2005
Section 4
MAINTENANCE
MISCELLANEOUS MAINTENANCE
f. Move the directional/speed control [F-N-R] INFORMATION.
handle one fourth [1/4] of the full travel distance
toward forward, or the reverse position, and note WATER SPRAY SYSTEM.
that the machine does NOT move. Repeat the
procedure for the OPPOSITE direction of travel. WATER STRAINERS [See Figure 4-24].
Move the directional/speed control [F-N-R] handle
to “NEUTRAL”. 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
WARNING: The machine must NOT move in the screen to remove material trapped and held by
EITHER direction of travel. the screen material. Install the complete assembly
The secondary/parking brake system back into the water tank and secure the access
MUST keep the machine in a plate to the tank with the retaining nuts. Connect the
STOPPED condition during the water supply hose to the pump inlet, if removed.
system operation and application
check.
If the machine moved, in EITHER
NOT use the machine. Put an
instruction tag reading “DO NOT
OPERATE” on the instrument panel PUMP FILLER CAP
and REMOVE the ignition key from
the ignition switch.
and in the rear, of one [1] drum of
the machine. STRAINER
REPAIR the system fault
IMMEDIATELY.
FIGURE 4-24. WATER SPRAY PUMP AND
STRAINER ASSEMBLY.
NOTE: If the machine did NOT move, in EITHER
operation and application check, the WATER SPRAY NOZZLES [See Figure 4-25].
secondary/parking brake system has full
application capacity, and the system is Water spray nozzles and orifice discs can become
ready for use during machine operation. clogged and cause a reduced water flow from the
nozzles.
g. Put the engine throttle speed switch in the Remove, clean and install ALL of the water spray
“LOW” idle speed position and allow engine to run nozzles and orifice discs, found on the front, and
at “LOW” idle speed for a period of at least three- rear, water spray bars, as required.
five [3-5] minutes. STOP the engine.
Each water spray nozzle and orifice disc is con-
h. Go to the brake release solenoid current supply nected to the water spray bar and is released by
wire. Remove the electrical tape from the wire “unscrewing ” the threaded retaining collar in a
terminal. Put the wire terminal over the solenoid COUNTERCLOCKWISE [CCW] direction.
stud. Install the wire terminal retaining nut onto the
stud and tighten securely. Remove the orifice disc and the spray nozzle from
inside the retaining collar for cleaning, or replace-
i. Close the service access door. Install the door ment.
retaining capscrews. Securely tighten the
capscrews. Clean the orifice discs and spray nozzles by using a
small wire, or LOW pressure compressed air.
9/2005 4-43
Install the nozzle and orifice disc into the threaded
Section 4
MAINTENANCE
retaining collar. “Screw” the retaining collar in a
CLOCKWISE [CW] direction, onto the lower mount,
BEAM
while positioning the outlet of the nozzle toward the
drum surface.
RUBBER CLEANER
DRUM
SPRAY BAR
FIGURE 4-26. CLEANER BEAM AND

RUBBER CLEANER ASSEMBLY.
NOZZLES
PREPARING THE MACHINE FOR STORAGE.
Use the following information as a “general guide”

FIGURE 4-25. WATER SPRAY NOZZLES. ONLY to prepare the machine for storage. Manufac-
turers of components can also be contacted for
specific information about components manufac-
tured by them.
CLEANER BEAM AND RUBBER CLEANER
ASSEMBLIES [See Figure 4-26].
Two [2] cleaner beam and rubber assemblies are ENGINE.

found on EACH drum.
See the current CUMMINS DIESEL ENGINE
Check for broken, or loose, cleaner bar beam and/or COMPANY “Operation And Maintenance Manual -
rubber cleaner components one [1] time for EACH B Series Diesel Engine” for complete, APPROVED
50 hours of machine operation, or weekly. 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. COOLING SYSTEM.
lbs. [380 N.m] at ALL times. Keep the rubber
cleaners, at a position that is AGAINST each drum The ENTIRE cooling system MUST be protected
face at ALL times and keep the retaining capscrews from freezing. FILL the radiator as needed, using a
securely tightened. ethylene glycol based antifreeze and water solution
[see THIS section].
CAUTION: Do NOT operate a machine having The antifreeze and water MUST be of the COR-
missing, or damaged, cleaner beam, RECT mixture ratio, to protect the cooling system,
or rubber cleaner components. to a temperature BELOW the lowest expected
Replace ALL missing, or damaged, freezing temperature for the area where the
cleaner beam, or rubber cleaner, machine is to be stored.
components IMMEDIATELY.
4-44 9/2005
Section 4
MAINTENANCE
ALSO, see the current CUMMINS DIESEL ENGINE WATER SPRAY SYSTEM.
COMPANY “Operation And Maintenance Manual -
B Series Diesel Engine” for complete, APPROVED COMPLETELY drain the water from BOTH water
engine cooling system storage procedures. 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,
BATTERY. completely drain all remaining water from the pump
and install the pump back onto the machine. Put a
If the machine is to be stored for a period of MORE plastic cover, or tape, over each water spray nozzle.
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 CAUTION: DRAIN ALL water, from the water
every 30 days of storage. Keep the battery stored in spray tanks, water pump and filter,
a COOL and DRY storage area. BEFORE the temperature reaches
32°F [0°C]. The system WILL be
DAMAGED if the water is allowed to
CAUTION: Do NOT store the battery on a freeze.
concrete surface.
Store the battery on a WOOD surface
ONLY. Make sure the battery
electrolyte will NOT freeze. EXPOSED COMPONENT RUST PREVENTION.
Put a heavy grease, or equivalent, onto ANY

exposed area of the hydraulic steering cylinder rod.
FUEL TANK.
Put a rust preventive oil [such as L.P.S.#s 2 or 3] on
FILL the fuel tank to a COMPLETELY full condition, ALL hinges, or other moving parts. Put ALL covers
using the CORRECT, CLEAN fuel, BEFORE the and access plates in their CORRECT position and
machine is placed in storage [see THIS section]. 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.
9/2005 4-45
Section 4
MAINTENANCE
NOTES
4-46 9/2005
Section 5
FRAME, HITCH AND FALLING OBJECT/
ROLL OVER PROTECTION STRUCTURE
TABLE OF CONTENTS
PAGE
GENERAL INFORMATION ........................................................................................................................ 5-2.
DESCRIPTION OF THE FRAMES AND THE HITCH ................................................................................. 5-2.
REMOVAL OF THE HITCH ASSEMBLY ............................................................................................... 5-2.
INSPECTION OF THE HITCH ASSEMBLY COMPONENTS ................................................................ 5-5.
INSTALLATION OF THE HITCH ........................................................................................................... 5-7.
FALLING OBJECT/ROLL OVER PROTECTION STRUCTURE .............................................................. 5-10.
CHECKS AND SERVICE PROCEDURES .......................................................................................... 5-10.
TROUBLE ANALYSIS FOR THE FRAME AND HITCH ........................................................................... 5-13.
9/2005 5-1
Section 5
GENERAL INFORMATION [See Figure 5-1]. The VERTICAL hitch coupling is made of two [2]
shafts [installed into the front frame assembly. The
This section describes the frames, hitch and falling shafts are held in position through the use of Loctite
object/roll over protection structure used on the 66 and four [4] capscrews per shaft.
inch and 78 inch Compactors.
The vertical hitch coupling assembly consists of one
Hitch removal and disassembly, inspection of compo- [1] lower spherical bearing retainer and eight [8]
nents, assembly, installation and shimming informa- retaining capscrews, two [2] spherical bearings, one
tion is given in this section. [1] upper spherical bearing retaining snap ring, two
[2] keeper washers, two [2] washer retaining cap-
Information about inspection and maintenance of the screws, one upper step plate and four [4] plate
falling object/roll over protection structure is, also, retaining capscrews.
found in this section.
The HORIZONTAL hitch coupling is made of one [1]
hitch weldment, two [2] thrust bearings, one [1]
complete shim pack - made to the required thickness,
DESCRIPTION OF THE FRAMES AND THE HITCH one [1] bushing type bearing, one [1] hitch plate, ten
[See Figures 5-1 and 5-2]. [10] retaining capscrews, one [1] cover plate and four
[4] cover plate retaining capscrews.
The machine uses a FRONT frame and a REAR
frame weldment. The front and rear frame weldments
are connected by the HITCH assembly.
REMOVAL OF THE HITCH ASSEMBLY [See
The hitch assembly permits movement of the two [2] Figures 5-1 and 5-2].
frames. The hitch includes two [2] vertical pins, which
give a total of 70˚ of machine steering, full left to full a. Clean the hitch and frame areas with All-Purpose
right. Degreaser, part number 178297, and permit to air
dry.
The horizontal hitch pin assembly gives the machine
a total of 24˚ oscillation between the front and rear
frames. Frame and hitch loads are held on a bushing
type bearing and spherical bearing assemblies.
HITCH
FRONT FRAME REAR FRAME
FIGURE 5-1. LOCATIONS OF THE HITCH AND FRAMES.
5-2 9/2005
Section 5
b. Support BOTH the front and rear frames, under c. If removing the COMPLETE hitch assembly, put
all four [4] corners of each frame, with SOLID wood an identification tag on each hose and tube fitting
blocks. showing the CORRECT connection location. Discon-
nect all hoses from their connection points to the
horizontal hitch pin tube fittings. Put caps, or plugs,
WARNING: Block SECURELY under all four [4] on all hoses and fittings. Remove the four [4] retain-
corners of both the front and rear ing capscrews from the upper step plate, found at the
frame sections. The frame halves will top of the hitch. Remove the four [4] capscrews that
NOT balance and MUST be supported fasten the cover plate to the hitch plate. Remove the
under all four [4] corners of each cover plate. Unplug, or disconnect, each electrical
frame section. cable or wire terminal at their connection points to
components of the FRONT frame, of the machine.
CAPSCREW
PLATE
BULKHEAD
PLATE CAPSCREW
FLANGE SCREW
HITCH PLATE WASHER
SHIM
SNAP RING
BEARING
REAR FRAME
ASSEMBLY
UPPER SHAFT
STEERING LOCK PIN
FLANGE
SCREW
THRUST
BEARING
FRONT FRAME ASSEMBLY
BUSHING
THRUST
BEARING
SHIM
HITCH ASSEMBLY
LOWER SHAFT
BEARING
WASHER
CAPSCREW
FIGURE 5-2. COMPONENTS OF THE HITCH ASSEMBLY.
9/2005 5-3
Section 5
NOTE: If service is required to the HORIZONTAL g. CAREFULLY lift the rear frame assembly just
hitch pin bushing type bearing and/or clear of the blocks which supported the frame.
thrust washers ONLY, put an identifica-
tion tag on each hose showing the correct
port connection location. Disconnect the WARNING: Keep CLEAR of the frame and hitch
hoses from the rear frame side of the areas, while lifting.
HORIZONTAL hitch pin tubing connection
points. Put caps, or plugs, on all hoses
and fittings. Loosen and remove the nuts h. CAREFULLY and SLOWLY separate the REAR
from each tubing fitting. frame off of, and away from, the horizontal pin of the
Unplug, or disconnect, each electrical hitch. Move the rear frame assembly away from the
cable, or wire terminal, at their connection horizontal pin a short distance.
points to components of the FRONT
frame of the machine.
Remove the four [4] capscrews that fasten WARNING: Keep CLEAR of the frame and hitch
the cover plate to the hitch plate. Remove pin areas while they are being sepa-
the cover plate. rated. Separate the frame from the
horizontal hitch pin ONLY enough
distance to remove the parts being
d. Remove, all ten [10] capscrews which hold the inspected and serviced.
hitch plate to the hitch. Carefully lift the hitch plate
away from the hitch and rear frame assemblies.
CAUTION: Do NOT damage the large horizontal
hitch pin bushing type bearing while
e. Hold, and then remove, the shim pack and thrust moving the rear frame assembly away
washer from the outer side of the HORIZONTAL hitch from the hitch pin.
pin.
i. Put solid blocks under the REAR frame assembly,

CAUTION: Keep the shim pack and thrust at all four [4] corners. SLOWLY lower the rear frame
bearing together. Make a note of the assembly back onto the blocks.
position of ALL items BEFORE re-
moval.
WARNING: Block SECURELY. The rear frame
assembly will NOT balance. Keep
f. Fasten a hoist and chains, having a capacity CLEAR of the frame.
more than 10,000 lbs. [4540 kg], to the sides of the
REAR frame assembly, at all four [4] corners.
j. Hold the thrust bearing and shim pack remaining,
on the HORIZONTAL hitch pin, together. Remove the
WARNING: The hoist and chains MUST have a thrust washer and shim pack from the hitch pin.
capacity of at least 10,000 lbs. [4520
kg]. Fasten the chains SECURELY to
both sides of the rear frame at ALL CAUTION: Keep the thrust bearing and shim
four [4] corners, so that the frame will pack together. Make a note of the
balance when lifted. position of ALL items BEFORE re-
moval.
5-4 9/2005
Section 5
k. Inspect and/or replace the HORIZONTAL hitch r. Use the sling and hoist, fastened to the hitch
pin bushing, thrust bearings and shim pack assem- weldment, to CAREFULLY lift the hitch weldment
blies using the procedures given in this section. upward and away from the upper vertical hitch shaft.
CAREFULLY move the hitch assembly away from the
front frame assembly. Put the hitch assembly on the
NOTE: If the upper and lower VERTICAL hitch floor and keep it supported with the sling and hoist
shaft spherical bearings require removal for inspection and service.
and replacement, proceed using the
following additional procedures:
WARNING: Keep CLEAR of the hitch assembly
while moving and lowering it to the
l. Go to the hitch steering arm. Remove, the anchor floor. Hitch assembly tipping can
bolt and pin from the steering cylinder rod end occur. ALWAYS support the hitch
vertical pin. Remove the vertical pin. Move the assembly with a sling and a hoist to
steering cylinder rod end away from the steering arm help prevent assembly tipping.
on the hitch.
m. Support the hitch with a sling and hoist, having a s. Inspect and/or replace either, or both, VERTICAL
capacity of more than 500 lbs. [227 kg]. hitch shaft spherical bearings using the procedures
given in THIS section.
WARNING: Fasten the sling SECURELY to the

hitch assembly.
INSPECTION OF THE HITCH ASSEMBLY
COMPONENTS [See Figure 5-2].
n. Go to the LOWER VERTICAL hitch shaft area.
Remove, the lower spherical bearing retaining a. If the HITCH assembly was removed from the
capscrew and remove the keeper washer. front frame, inspect both the upper and lower spheri-
cal bearings for wear or damage. Replace the
o. Remove, the eight [8] lower spherical bearing spherical bearings with new if worn or damaged.
housing retaining capscrews. Carefully move the
housing and spherical bearing downward and from
the lower vertical hitch shaft. CAUTION: If a bearing is removed, CAREFULLY
install the new bearing into the
p. Go to the UPPER VERTICAL hitch shaft area. bearing bore with a bearing driver and
Remove the hitch shaft spherical bearing retaining a hammer.
Do NOT damage the new bearing
capscrew and remove the keeper washer.
during installation.
q. Use snap ring pliers to carefully remove the
spherical bearing retaining snap ring from the
NOTE: Use a tube which is the same diameter as
vertical shaft. the upper and/or lower pin spherical
bearing and a portable hydraulic unit to
remove either bearing, if removal and
WARNING: Eye protection MUST be worn during replacement is necessary.
the snap ring removal.
9/2005 5-5
Section 5
b. Inspect the horizontal pin bushing type bearing, NOTE: Remove and replace the bushing, ONLY if
found in the rear frame of the machine, for wear or worn or damaged. Inspect the self-lubri-
damage. cating bushing swivel ball for pitting and
wear. Use a tube which is the same
diameter as the self-lubricating bushing
CAUTION: If the bushing type bearing is and a hydraulic jack or portable hydraulic
removed, CAREFULLY install the new power unit to remove a worn or damaged
bushing into the bushing bore in the bushing.
rear frame, while noting the chamfer The UPPER and LOWER VERTICAL
on the bushing type bearing. SHAFTS are of the “bolt held and Loctite
Do NOT damage the new bushing retained type”. Either shaft can be re-
during installation. moved, for replacement with new, by
removing the four [4] retaining bolts that
hold the shaft into the front frame. Use a
heating torch to CAREFULLY heat the
NOTE: Use a tube which is the same diameter as
area of the frame where the shaft being
the horizontal pin bushing and a portable
removed is installed, until the shaft falls
hydraulic unit to remove the bushing, if
from the frame bore. Discard the removed
removal and replacement is necessary.
shaft. Replace the shaft, with new, by
using the CORRECT installation proce-
dures [see the FOLLOWING additional
c. If the steering cylinder anchor capscrew, lock pin information BEFORE assembly of the
and mounting pin have been removed, and the hitch to the frame]. If needed, remove the
steering cylinder has been moved away from the second vertical shaft from the frame by
steering arm at the hitch, inspect the one [1] self- using the SAME above procedures.
lubricating bushing type bearing, found in the hitch
arm, and replace the bushing as needed.
Use the following ADDITIONAL information to
CORRECTLY install a new vertical shaft into the
CAUTION: If the bushing is removed, CARE- frame.
FULLY install the new bushing into the
hitch arm. Do NOT damage the new
bushing during installation. CAUTION: The new vertical shaft and the bore in
the frame MUST be COMPLETELY
CLEAN and free of grease, or oil,
BEFORE the new vertical shaft is
installed. CORRECT shaft installation
procedures MUST, also, be followed.
Shaft installation failure will occur if
the shaft[s] and frame bore[s] are not
properly prepared and the shaft is not
correctly installed.
5-6 9/2005
Section 5
1. Remove ALL Loctite residue from the shaft bore a. Fasten a sling and a hoist, having a capacity
in the frame. Use a lint free cloth to wipe the NEW more than 500 lbs. [227 kg], to the hitch assembly.
vertical shaft and shaft bore in the frame with tri- If removed, install the inspected used, or new, upper
chloral-ethyl cleaner. spherical bearing into the hitch upper bearing bore.
Use snap ring pliers to CAREFULLY install the
retaining snap ring.
CAUTION: Use ONLY a lint FREE cloth. The
hands MUST also be completely
CLEAN and free of oil, or grease. WARNING: Fasten the sling SECURELY to the
hitch assembly. Eye protection MUST
be worn when installing the snap ring.
2. Put Loctite #242, part number 318702, on the
threaded area of the four [4] vertical shaft retaining
capscrews. Apply Loctite #680, part number 341959, b. CAREFULLY and SLOWLY lift, and then move,
to the vertical shaft. Quickly install the shaft into the the HITCH assembly toward the front frame. Align
frame bore. Install the four [4] shaft retaining cap- the UPPER vertical shaft with the bore of the spheri-
screws and tighten to a torque of 105 ft. lbs. [143 cal bearing, which is installed in the hitch assembly.
N.m].
WARNING: KEEP the hands CLEAR of the hitch

CAUTION: The vertical shaft MUST be installed and front frame assemblies when
into the frame bore and the retaining lifting the hitch and aligning the front
capscrews tightened to the correct frame upper vertical shaft with the
torque within a time period of five [5] spherical bearing bore.
minutes. The retaining adhesive will
be in a “set” condition after this time
period. c. Put the washer into position over the top of the
UPPER vertical shaft. Put Loctite #242, part number
318702, on the threaded area of the upper vertical
3. Repeat the above procedure on the second shaft keeper retaining capscrew. Install the retaining
vertical shaft, if removed. capscrew and tighten to a torque of 280 ft. lbs. [380
N.m].
d. Put the inspected used, or new, LOWER spheri-

INSTALLATION OF THE HITCH [See Figures 5-1, cal bearing in the lower bearing housing. Align the
5-2 and Table 5-1]. LOWER vertical shaft with the bore in the lower
vertical spherical bearing. Install the bearing over
the shaft.
NOTE: If the COMPLETE HITCH assembly was
removed from the front frame, install the e. Put the washer over the end of the LOWER
hitch to the front frame FIRST, and then vertical shaft and hold it in place. Put Loctite #242,
install the rear frame onto the horizontal
part number 318702, on the threaded area of the
hitch pin. If the hitch assembly was NOT
lower vertical shaft washer retaining capscrew. Install
removed from the front frame; proceed to,
and use, the rear frame to horizontal hitch the retaining capscrew and tighten with the fingers
pin assembly information ONLY. ONLY, at THIS time.
9/2005 5-7
Section 5
f. Align the through holes in the lower bearing m. Divide the TOTAL amount in step “l”, by 0.020
housing with the tapped holes in the hitch weldment. in. [5.13 mm] to determine the TOTAL number of
Put Loctite #242, part number 318702, on the shims needed. Round this answer off to the NEAR-
threaded area of the eight [8] housing retaining EST whole number. The whole number will be the
capscrews. Install the bearing housing retaining TOTAL number of shims required to CORRECTLY
capscrews and tighten to a torque of 105 ft. lbs. [143 shim the hitch assembly to the rear frame.
N.m].
g. Tighten the LOWER vertical shaft keeper retain- NOTE: “ROUNDED” examples are: 0.035 inches
ing capscrew to a torque of 280 ft. lbs. [380 N.m]. [0.89 mm] divided by 0.020 inches [5.13
Remove the sling and hoist from the hitch. mm] equals 1.75 shims - and is rounded
to “2” [shims]. 0.055 inches [1.397 mm]
divided by 0.020 inches [5.13 mm] equals
h. Move the steering cylinder rod end yoke into
2.75 shims - and is rounded to “3”
position on the hitch steering arm. Align the through [shims].
hole in the steering cylinder rod end yoke with the
through holes in the self-lubricating bushing installed
in the hitch steering arm. Install the cylinder mounting CAUTION: Make the shim pack from shims [see
pin. Install the anchor pin through the cylinder rod the machine parts manual for COR-
end mounting pin. Put Loctite #242, part number RECT part number]. Build the shim
318702, on the threaded area of the anchor pin pack by using the EXACT number of
retaining capscrew. Install the retaining capscrew and shims, as found in step “m”.
tighten to a torque of 105 ft. lbs. [143 N.m ].
n. If possible, DIVIDE the TOTAL shim pack, from

CAUTION: Do NOT lubricate the steering cylinder step “m”, EQUALLY into TWO [2] shim packs. Install
rod end mounting pin, or bushing. the shims at the locations shown in Table 5-1.
i. Read the size number, stamped on the REAR o. Put one [1] thrust bearing over the HORIZONTAL
FRAME, near the hitch bore [see figure 5-2 for hitch pin assembly. Then, put one [1] shim pack, from
location]. Write the number on paper. step “n”, over the HORIZONTAL hitch pin assembly.
Push the two [2] items fully against the hitch.
j. Read the size number stamped on the HITCH
WELDMENT [see figure 5-2 for location]. Write this
number on the paper ABOVE the size number noted CAUTION: Put the thrust bearing over the hori-
on the rear frame, in step “i”. zontal hitch pin FIRST, then put the
shim pack over the horizontal hitch
k. SUBTRACT the size number, noted in step “i”, pin LAST.
FROM the size number noted in step “j”.
l. Subtract 0.450 in. [11.43 mm] - combined thick-

ness of the thrust bearings - FROM the figure found
in step “k”. Write this number on the paper.
5-8 9/2005
Section 5
[A]....Size number stamped on HITCH ASSEMBLY. 2.438
[B]....Size number stamped on REAR FRAME..... 1.938
[C]....SUBTRACT [B] FROM [A] = DIFFERENCE.... 0.500
[D]....COMBINED thickness of TWO [2]

HORIZONTAL hitch pin thrust bearings.. 0.450
[E]....DIFFERENCE- SUBTRACT [D] FROM [C]..... 0.050
[F]....DIVIDE “TOTAL SHIM PACK THICKNESS” NEEDED [E] BY 0.020 INCHES FOR NUMBER OF
SHIMS NEEDED - ALWAYS ROUND TO THE NEAREST WHOLE NUMBER.
0.050 = 2.5 - SHIMS - WILL ROUND TO THREE [3]

0.020
THIS EXAMPLE WOULD REQUIRE THREE [3] SHIMS TOTAL - TO

CORRECTLY SHIM THE HITCH ASSEMBLY.
LOCATE THE SHIMS AS FOLLOWS:
SHIMS REQUIRED: LOCATION:
2 Shims 1 EACH Side

3 Shims 1 FIRST Side,
2 SECOND Side
4 Shims 2 EACH Side
TABLE 5-1. EXAMPLE - SHIM PACK THICKNESS CALCULATION METHOD.
p. Fasten a hoist and chains, having a capacity q. CAREFULLY lift the REAR frame assembly to a
more than 10,000 lbs. [4540 kg], to BOTH sides of position, so that the HORIZONTAL hitch pin is ready
the REAR frame at ALL four [4] corners. to enter the horizontal hitch pin bushing type bearing
installed into the rear frame. SLOWLY and CARE-
FULLY move the REAR frame TOWARD the horizon-
WARNING: Fasten the chains SECURELY to tal hitch pin and install the hitch pin through the
BOTH sides of the REAR frame at the bushing.
ALL four [4] corners, so that the frame
will balance when lifted.
WARNING: KEEP CLEAR of the hitch assembly,
horizontal hitch pin and hitch pin bore
during assembly. Use the hoist to
position the front frame and horizon-
tal hitch pin, for installation into the
rear frame.
9/2005 5-9
Section 5
r. CAREFULLY put the SECOND shim pack, from v. Use a hydraulic jack, having a capacity more than
step “n”, onto the horizontal hitch pin. Then, put the 10,000 lbs. [4540 kg], to lift the frame near each
remaining one [1] thrust bearing onto the horizontal block. CAREFULLY remove ALL support blocking
hitch pin and push both items against the REAR from under the machine and lower the machine to the
frame plate. ground. Go to the remaining blocked areas and
remove the blocking.
CAUTION: Put the shim[s] onto the horizontal

hitch pin FIRST, and then put the WARNING: Keep CLEAR of the jack, frame area
thrust bearing over the horizontal and blocking while lifting the machine,
hitch pin LAST. Push both items fully removing the blocking and lowering
against the frame plate. the machine to the ground.
s. Put Loctite #242, part number 318702, on the w. Start the engine and check the hitch for COR-
threaded area of all ten [10] hitch plate retaining RECT function.
capscrews. Install the hitch plate over the horizontal
hitch pin and against the mating plate of the rear
frame. Install the ten [10] retaining capscrews. DANGER: Keep CLEAR of the hitch area. Clear-
Tighten the capscrews to a torque of 115 ft. lbs. [156 ance closes between the front and rear
N.m]. frames during a right, or left, turn of
the machine.
t. Put the cover plate in position on the hitch
weldment. Put Loctite #242, part number 318702, on
the threaded area of the four [4] cover plate retaining
capscrews. Install the capscrews and tighten to a FALLING OBJECT/ROLL OVER PROTECTION
torque of 105 ft. lbs. [143 N.m]. If removed, install and STRUCTURE [FOPS/ROPS] [See Figure 5-3].
tighten each tube fitting nut against the hitch cover
plate. Remove all caps and plugs from all hoses and
fittings, at the horizontal hitch assembly connection. The steel components of the falling object/roll over
Connect, and tighten, all hoses to the correct fitting protection structure [FOPS/ROPS] are welded
connection, as shown on EACH hose identification together using correct materials and practices that
tag. Plug, or connect, each electrical cable, or wire produce a strong integrated structure.
terminal, to their connection points on components of
the FRONT frame of the machine. The protection structure is fastened to the machine
on EACH side of the FRONT frame by four [4] metric
u. Put the upper step plate in position at the top of grade 8.8 capscrews and nuts.
the hitch. Put Loctite #242, part number 318702, on
the threaded area of the four [4] plate retaining
capscrews. Install the plate retaining capscrews and WARNING: An improperly mounted, or damaged,
tighten securely. protection structure will NOT provide
adequate operator protection in the
event of a machine tip over. Follow the
checks and service information which
follows.
5-10 9/2005
Section 5
CHECKS AND SERVICE PROCEDURES [See WARNING: If ANY damage is found during the
Figure 5-3]. above described inspections, contact
Compaction America, Inc., or the
Use the following information to check the PROTEC- nearest HYPAC Distributor, IMMEDI-
TION STRUCTURE components for breakage, or ATELY. Do NOT use the machine until
contact, and the directed repairs or
other damage, at least one time for each eight [8]
structure replacement, has been
hours of machine operation, or daily, and to do minor
done.
surface rust removal and painting on the structure. If the protection structure has been
removed from the machine, and is
a. Inspect the eight [8] metric grade 8.8 capscrews being installed again, inspect EACH
and nuts that fasten the roll over protection structure capscrew and nut for wear, or
to the machine. They MUST remain tightened to the damage. Replace ALL worn, or dam-
CORRECT torque of 375 ft. lbs. [509 N.m]. Check aged, fasteners with NEW. Put Loctite
torque, and tighten as needed, using a large capacity #242, part number 318702, on the
torque wrench. threaded area of EACH capscrew.
Install, and then tighten, EACH cap-
screw and nut to the CORRECT
amount of torque as given above.
WARNING: One [1] time for each eight [8] hours
NEVER replace the capscrews and/or
of machine operation, or daily, inspect
nuts with fasteners that carry a “grade
the eight [8] capscrews and nuts that
rating” of less than “metric grade 8.8”.
fasten the protection structure to the
machine.
They MUST remain tightened to the
CORRECT torque of 375 ft. lbs. [509 b. CAREFULLY inspect ALL welds which fasten the
N.m]. Replace, and then tighten to the CRITICAL structure components together for cracks,
CORRECT torque specification, any breakage in the weld and/or where the weld joins the
capscrews and nuts found damaged, metal of the steel component, severe rust or other
or lost, with CORRECT replacement weld related problems.
fasteners having a rating of metric
grade 8.8 [see machine parts manual,
which is supplied with the machine]. WARNING: NEVER “heat”, or weld, any “add on”
Carefully inspect ALL welds, which item onto ANY structure area. This
fasten the critical structure compo- practice can weaken the structural
nents together, for cracks, breakage in integrity of the complete structure.
the weld and/or where the weld joins Do NOT add ANYTHING to the struc-
the metal of the steel components. ture.
Carefully inspect the welds and Do NOT operate a machine AFTER a
adjoining critical structure metal roll over situation has occurred. If a
areas for rust or, other related prob- roll over situation has occurred,
lems. REMOVE the protection structure from
the machine only AFTER contact has
been made with the nearest HYPAC
Distributor and/or Compaction
America, Inc. Assistance in the repair,
or replacement, of the system will be
offered.
NEVER weld, or replace, a CRITICAL
structural component BEFORE
obtaining additional instructions, per
the ABOVE information.
9/2005 5-11
Section 5
Structure
CRITICAL
COMPONETS
Seat Belt
System
CAPSCREWS
Washers
FIGURE 5-3. FALLING OBJECT/ROLL OVER

PROTECTION STRUCTURE - MAJOR COMPONENT LOCATIONS.
c. If rust on components is found, remove the rust The belt anchor eyebolts MUST remain tightened
from ALL welds and structure components. Apply securely to the machine cockpit floor at a CORRECT
paint primer and top coat paint to the complete torque of 20-35 ft. lbs. [27-47 N.m]. REPLACE the
protection structure as directed by the paint manufac- complete belt SETS, with new, if ANY damage is
turer. found [see MACHINE parts manual, which is supplied
with the machine].
d. An operator restraint system is included with the
protection structure to restrain the operator, in the
event of machine tipping. One [1] time for EACH eight WARNING: NEVER operate a machine having a
[8] hours of machine operation, or daily, CAREFULLY worn, damaged or malfunctioning
inspect the restraint system [TWO [2] seat belt SETS] operator restraint system. Repair, or
used with the protection structure system. The belt replace, the belt set[s] IMMEDIATELY.
latches MUST catch and release correctly. The belt IMMEDIATELY after becoming seated,
material MUST be clean and NOT torn, rotted, or FASTEN, and then TIGHTEN, the seat
damaged. belt BEFORE starting the engine.
During machine operation, if the
machine tips, do NOT jump.
5-12 9/2005
Section 5
TROUBLE ANALYSIS FOR THE FRAME AND HITCH
[See Figures 5-1 and 5-2].
TROUBLE CAUSE CORRECTIVE ACTION
NOISE IN MACHINE Worn, or damaged, parts in the Remove, inspect, replace worn or
HITCH AREA DURING hitch assembly damaged parts as needed and
OSCILLATION AND/OR assemble [see this section].
TURN
STEERING ACTION NOT Binding of the vertical hitch shafts Remove, inspect, replace worn or
SMOOTH in the spherical bearings damaged parts as needed and
assemble [see this section].
Worn, or damaged, spherical Remove, inspect, replace worn or

bearings in hitch damaged parts as needed and
assemble [see this section].
9/2005 5-13
Section 5
NOTES
5-14 9/2005
Section 6
ENGINE
TABLE OF CONTENTS
PAGE
GENERAL INFORMATION ........................................................................................................................... 6-2.
DESCRIPTION ............................................................................................................................................... 6-2.
REMOVAL OF THE ENGINE ASSEMBLY .................................................................................................... 6-2.
INSTALLATION OF THE ENGINE ASSEMBLY ............................................................................................6-6.
9/2005 6-1
Section 6
ENGINE
GENERAL INFORMATION. REMOVAL OF THE ENGINE [See Figure 6-2].
This section contains information about the CUM- a. Loosen the band clamp that fastens the rubber
MINS diesel engine used in the 66 Inch and 78 Inch 90˚ air inlet elbow from the inlet air flange on the
Compactors. turbocharger and air cleaner assemblies. Move the
rubber elbow away from the turbocharger air inlet and
This section also contains information about engine air cleaner outlet.
removal from and installation into the machine.
b. Loosen the muffler clamp that holds the flexible
exhaust tube to the turbocharger outlet elbow and
move the flexible exhaust tube away from the turbo-
DESCRIPTION. charger outlet.
The 66 Inch and 78 Inch Compactors are powered c. Loosen and remove the negative [-] battery cable
by the CUMMINS Model 4B3.9 QSB-C130 - 3.9 liter, from the negative [-] post of the battery FIRST, and
turbocharged diesel engine [see figure 6-1 ]. then loosen and remove the positive [+] battery cable
from the positive [+] post of the battery. Disconnect
For engine operation and general manufacturer both the negative [-] and the positive [+] battery
maintenance procedures, see the CUMMINS “Opera- cables from their connections to the engine and
tion and Maintenance Manual - B Series Diesel starter solenoid.
Engines”, which is supplied with each machine.
For major engine repair requirements, contact the WARNING: Battery explosion can occur if the
nearest CUMMINS Engine Dealer for assistance battery terminals are shorted.
about major repair procedures, in dealer shop repairs ALWAYS disconnect the NEGATIVE
and/or engine parts. battery cable from the battery FIRST.
Do NOT smoke or cause a spark while
removing the battery cables from the
battery.
d. Drain the complete cooling system of coolant,

including the engine cylinder block [see Section 4 -
MAINTENANCE].
WARNING: Do NOT drain the cooling system of

coolant while the system is HOT. Drain
when COOL only. Hot coolant can
FIGURE 6-1. CUMMINS MODEL 4B3.9 QSB-C130

DIESEL ENGINE.
6-2 9/2005
Section 6
ENGINE
e. Disconnect the upper and lower radiator hoses j. Put an identification tag on each hose and each
from their engine connection points. Remove the fitting connection at the stack valve. The valve is
capscrews which hold the fan shroud onto the fastened to the hood cowl to the right and above the
radiator assembly. Carefully move the shroud away hydraulic reservoir. Disconnect all hoses, one [1] at a
from the radiator and put it over the fan assembly. time, from the stack valve fittings. Install a cap on
Move the shroud toward the front of the engine. each valve fitting and then plug each hose.
f. Disconnect the fuel supply and return lines from

the engine. Put a cap, or plug, into each line and onto CAUTION: Put caps or plugs in all removed
each engine fitting. hoses and on all fittings immediately
after the hoses are disconnected to
g. Remove the hydraulic supply and return hoses help keep the system free of dirt.
from their connection points to the hydraulic oil
cooler. Put a cap or a plug into each hose and onto
each cooler fitting. Remove all hose support clamps k. Remove all wire harness support clamps that
that fasten the hoses to the engine cowl. fasten the harness to the engine cowl.
h. Completely drain the hydraulic oil reservoir of oil l. Remove the capscrews that fasten the top rear
[see Section 4- MAINTENANCE]. cover plate to the engine cowl. Remove the top cover
plate from the cowl.
WARNING: Do NOT drain the hydraulic oil while

the oil is HOT. Drain the oil when NOTE: The removal of the top cover plate will
warm, or cool, only. Hot oil can cause permit access to the capscrews that
serious injury. fasten the rear bottom of the cowl to the
frame.
i. Put an identification tag on each hose and each

fitting connected to the hydraulic oil reservoir. Discon-
nect all hoses, one [1] at a time, from the hydraulic oil
reservoir fittings. Install a cap on each reservoir fitting
and then plug each hose.
9/2005 6-3
Section 6
ENGINE
FIGURE 6-2. CUMMINS DIESEL ENGINE - INSTALLATION INTO FRAME.
6-4 9/2005
Section 6
ENGINE
m. Fasten a sling and a hoist, having a capacity p. Put an identification tag on each hose and each
more than 500 lbs. [227 kg], to the engine cowl/ fitting of the transmission pump, steering pump and
hydraulic oil reservoir assembly, so that it will be vibrator pumps. Disconnect all hoses from the
balanced when lifted. transmission pump, steering pump and both vibrator
pumps. Put caps or plugs in all hoses and on all
fittings immediately after the hoses are disconnected.
CAUTION: Leave the front center cross plate,
having the hood latch striking assem-
bly, fastened to the complete cowl CAUTION: Put caps or plugs in all removed
assembly. The plate will make the hoses and on all fittings immediately
cowl assembly more rigid and easier after the hoses are disconnected to
to remove. help keep the systems free of dirt.
NOTE: The hydraulic oil reservoir is fastened to q. Put an identification tag on each electrical wire
the engine cowl and the two parts will be and each electrical wire connection terminal on the
removed from the machine as an assem- engine or items mounted on the engine. Remove all
bly. electrical wires which are connected to the engine or
items mounted on the engine.
n. Remove all engine cowl to rear frame retaining r. Put an oil drain pan under the engine lubrication
capscrews from the rear and front cowl to frame oil drain plug. Wipe the area around the drain plug,
mounting areas. using a clean cloth. Remove the drain plug and drain
the engine lubrication oil from the engine. Replace,
o. CAREFULLY and SLOWLY lift the engine cowl/ and then tighten, the drain plug after the engine is
hydraulic oil reservoir assembly upward from the completely drained of oil [see Section 4 - MAINTE-
frame a SMALL amount. NANCE].
CAUTION: Check for any remaining hoses and/or WARNING: Do NOT drain the engine lubrication
electrical wires that have NOT been oil while the oil is HOT. Drain the oil
disconnected at this time. only when warm or cool. Hot oil can
Do NOT remove the engine cowl/ cause serious injury.
hydraulic oil reservoir assembly
BEFORE being sure that ALL hose
and wire disconnections have been s. SECURELY fasten a chain and a lifting device,
made. having a capacity more than 1,500 lbs. [681 kg], to
the two [2] engine lifting eyes.
WARNING: Use a lifting device and chain capable

of lifting at least a weight of 1,500 lbs.
[681 kg]. Fasten SECURELY.
9/2005 6-5
Section 6
ENGINE
t. Remove, the capscrews which hold the engine WARNING: KEEP CLEAR of the engine assembly
left rear bracket weldment to the frame. Remove the while being lowered after removal
nuts from the capscrews which hold the engine right from the frame.
rear bracket weldment to the frame and then remove Do NOT allow anyone under the
the capscrews. Remove the capscrew that fastens engine while it is being lowered. Make
the single front motor mount to the rear frame. sure the engine, and support, will NOT
tip.
NOTE: The CUMMINS diesel engine is mounted

into the frame at a total of three [3] engine
mount to frame connection points - one INSTALLATION OF THE ENGINE ASSEMBLY
[1] FRONT and two [2] REAR. [See Figure 6-2].
a. Fasten a chain and a lifting device, having a

u. Check again, to be sure that all the hoses, lines capacity more than 1,500 lbs. [681 kg], to the two [2]
and electrical wire and cable connections have been engine lifting eyes.
disconnected and removed from the engine. Also,
check for removal of these items from other compo-
nents being removed with the engine, as an assem- WARNING: Use a lifting device and chain having a
bly. capacity larger than 1,500 lbs. [681
kg]. Fasten SECURELY.
CAUTION: Do NOT remove the engine assembly

before removing all items connected b. CAREFULLY and SLOWLY lift the engine assem-
to the engine, or fastened to any bly a SMALL amount and move it to the rear frame
component being removed with the area of the machine.
engine.
c. CAREFULLY and SLOWLY lift the engine assem-
bly to a position ABOVE the rear frame. Begin to
v. CAREFULLY and SLOWLY lift the engine mounts SLOWLY lower the engine assembly “DOWNWARD”
clear of the frame, a SMALL amount only. Tip the and toward the frame. Align the through capscrew
FRONT of the engine assembly downward a SMALL holes in the RIGHT rear engine bracket weldment
amount. CAREFULLY, and SLOWLY, continue to lift with the through holes in the frame and the through
the engine assembly “UPWARD” and “OUT” of the capscrew holes in the LEFT rear engine bracket
frame, until the engine assembly is away from the weldment with the tapped holes in the frame as the
frame and machine. engine assembly reaches the frame. Align the tapped
hole in the single FRONT motor mount with the
through hole in the center of the rear frame member.
WARNING: KEEP CLEAR of the engine assembly
while it is being lifted and removed
from the frame. WARNING: KEEP CLEAR of the engine assembly
while it is being installed into the
frame. Lower the engine assembly
CAUTION: Use CARE to NOT damage the hydrau- SLOWLY into the frame. Check for
lic pumps, that are mounted to both ANY interference between compo-
ends of the engine, as the engine is nents, at ALL times, during engine
removed from the frame area. installation.
w. CAREFULLY lower the engine onto an engine

stand, or other engine support device.
6-6 9/2005
Section 6
ENGINE
d. Install the two [2] right rear engine bracket i. Install all wire harness and hose support clamps
weldment to frame retaining capscrews through the around the wires and hoses and secure to the engine
bracket and the rear frame from the under engine cowl. Install the hydraulic oil supply and return hoses
side. Install the nuts onto the capscrews and tighten onto their connection points at the hydraulic oil cooler
with the hand only at this time. Install the two [2] left and tighten securely.
rear engine bracket weldment to frame retaining
capscrews through the bracket, turn into the tapped j. Remove all caps and plugs from the hoses and
holes in the frame and tighten with the hand only at fittings of the stack valve. Install each hose onto the
this time. Install the one [1] front motor mount to correct stack valve fitting as shown by the identifica-
frame retaining capscrew through the rear frame and tion tags and tighten securely.
turn into the tapped hole in the motor mount. Tighten
the capscrew to a torque of 166 ft. lbs. [225 N.m]. k. Put the top rear cover plate in position on the
Tighten the nuts and capscrews that retain the left engine cowl. Put Loctite #242, part number 318702,
and right rear engine bracket weldments to the frame on the threaded area of the capscrews that fasten the
to a torque of 80 ft. lbs. [108 N.m]. cover plate to the engine cowl. Install the capscrews
through the cowl and turn into the tapped holes of the
e. Remove the chain and hoist from the engine. Fill retainer bar. Tighten the capscrews to a torque of 33
the engine with NEW engine lubrication oil, at this ft. lbs. [45 N.m].
time [see Section 4 - MAINTENANCE].
l. Remove the caps, or plugs, from each fuel supply
f. Connect all electrical wires, EXCEPT the positive and return line and from each engine fitting. Connect
[+] and negative [-] battery cables, to the correct wire both fuel supply and return hoses to the correct
connection terminal of the engine and items mounted engine fitting and tighten securely.
onto the engine, as shown by the identification tags,
and tighten securely. m. Remove all caps and plugs from all hoses and
fittings which fasten to, or are on, the hydraulic
reservoir assembly, one [1] at a time. Install each
WARNING: Do NOT connect EITHER battery cable hose onto the correct fitting of the hydraulic reservoir
to the battery, at this time. as shown by the identification tags. Securely tighten
each hose onto each fitting.
g. Remove all caps and plugs from all hoses and n. Add NEW, CLEAN and FILTERED hydraulic oil to
fittings which fasten to, or are on, the transmission the hydraulic oil reservoir until the oil level is in the
pump, steering pump and vibrator pumps. Install center of the sight gauge [see Section 4 - MAINTE-
each hose onto the correct fitting of the transmission NANCE.
pump, steering pump and vibrator pumps as shown
by the identification tags. Securely tighten each hose
onto each fitting. CAUTION: Do NOT start the engine until all of the
transmission system start up proce-
h. Fasten a sling and a hoist, having a capacity dures have been completed. Be sure
more than 500 lbs. [227 kg] to the engine cowl/ the charge pump has filled with oil
hydraulic oil reservoir assembly, so that it will be and is developing system charge
balanced when lifted. CAREFULLY and SLOWLY lift pressure before the engine is started
the assembly and move into a position above the rear [See section 8 - TRANSMISSION
frame and engine. Put the capscrews, that fasten the SYSTEM - for the CORRECT proce-
engine cowl/hydraulic reservoir assembly to the rear dures].
frame, into the through holes in the cowl and frame.
Install the flange nuts onto the capscrews and tighten
to a torque of 33 ft. lbs. [45 N.m]. Remove the sling
and hoist.
9/2005 6-7
Section 6
ENGINE
o. Move the fan shroud toward the radiator, from t. CAREFULLY connect the positive [+] battery
where it was placed ahead of the fan blade assembly. cable terminal to the positive [+] post of the battery
Position the shroud against the radiator. Adjust the and tighten FIRST. Then, CAREFULLY connect the
fan shroud assembly for the correct equal fan blade negative [-] battery cable to the negative [-] post of
to fan shroud clearance. Securely tighten the cap- the battery and tighten.
screws which hold the fan shroud onto the radiator
assembly.
WARNING: Do NOT connect the negative [-]
battery cable to the negative [-] post
CAUTION: Keep the fan shroud in the correct of the battery BEFORE connecting the
position while tightening the retaining positive [+] battery cable to the
capscrews. Clearance must be kept positive [+] post of the battery.
between the blades of the fan and the Do NOT smoke, or cause a spark,
fan shroud at all points around the while connecting the battery cable
shroud circumference. cables to the battery.
p. Connect the upper, and lower, radiator hoses to u. Inspect all hoses, lines, wire and cable connec-
their engine connection points. Tighten the retaining tions for correct connection. Check for any leak of
clamps securely. Fill the cooling system with coolant. fuel, oils or coolant, at this time.
v. After making sure, AGAIN, that the transmission

CAUTION: Fill the cooling system with the system start procedures have been completed, [See
CORRECT antifreeze/water mixture to section 8 - TRANSMISSION SYSTEM] start the
protect the system from freezing [see engine, using the CORRECT engine starting proce-
Section 4 - MAINTENANCE. dures given in Section 3 - OPERATION. CAREFULLY
check ALL systems for correct operation and func-
tion.
q. Install the flexible exhaust tube onto the turbo-
charger outlet elbow. Install and the muffler clamp
around the tube. Install the nuts onto the clamp and CAUTION: STOP the engine IMMEDIATELY if ANY
tighten securely. system of the machine does NOT have
CORRECT operation.
r. Connect the 90˚ air inlet elbows onto the inlet air Do NOT start the engine, again, UNTIL
flange of the turbocharger and onto the air cleaner any noted system problem has been
outlet. Install and tighten the retaining band clamps to corrected.
a torque of 50 inch lbs. [5.7 N.m].
CAUTION: Tighten the retaining band clamps to

the CORRECT torque. Loose clamps
can permit contaminated air to enter,
and damage, the engine.
s. Connect the positive [+] and the negative [-]

battery cables to their connections on the engine and
starter solenoid.
6-8 9/2005
Section 7
ELECTRICAL
TABLE OF CONTENTS
PAGE
GENERAL INFORMATION. ........................................................................................................................... 7-7

ELECTRICAL SYSTEM MAJOR COMPONENT DESCRIPTION .................................................................. 7-7
BATTERY ................................................................................................................................................. 7-7
MOTOR .................................................................................................................................................... 7-7
ALTERNATOR ......................................................................................................................................... 7-8
SWITCHES AND CONTROLS ................................................................................................................. 7-8
RELAYS ................................................................................................................................................. 7-15
SENDING UNITS ................................................................................................................................... 7-16
SOLENOID CONTROLS ........................................................................................................................ 7-18
CIRCUIT BREAKERS ............................................................................................................................ 7-19
INSTRUMENTS . .................................................................................................................................... 7-20
GAUGES. ............................................................................................................................................... 7-21
INDICATOR LIGHTS .............................................................................................................................. 7-23
CABLES AND WIRES ........................................................................................................................... 7-24
MISCELLANEOUS AND OPTIONAL COMPONENTS ......................................................................... 7-24
S2X COMPUTER DESCRIPTION .......................................................................................................... 7-26
COMPUTER CONTROL SYSTEM COMPONENTS .................................................................................... 7-27
66 INCH 78 INCH COMPACTOR COMPUTER CONTROL SYSTEM OVERVIEW INFORMATION .... 7-27
FAULTS .................................................................................................................................................. 7-28
ACCESSIBLE SCREENS USING THE F4 FUNCTION KEY ................................................................ 7-28
RUN SCREENS ..................................................................................................................................... 7-29
LMTD SCREENS ................................................................................................................................... 7-29
INPT SCREENS ..................................................................................................................................... 7-29
HOW TO USE THE SYSTEM AS A DIAGNOSTIC TOOL ..................................................................... 7-29
VIBRATION POTENTIOMETERS [VIBE POTS] ................................................................................... 7-30
OTHER MONITORED SWITCHES [Except Water Spray On/Off Switch] .......................................... 7-30
VIBS SCREENS ..................................................................................................................................... 7-31
LOWER LEVEL SCREENS ................................................................................................................... 7-32
CIRCUIT OPERATION ................................................................................................................................. 7-35
STARTER CIRCUIT ............................................................................................................................... 7-35
ETHER START CIRCUIT ....................................................................................................................... 7-35
ALTERNATOR CIRCUIT ........................................................................................................................ 7-35
HORN CIRCUIT ..................................................................................................................................... 7-38
HEADLIGHTS AND DASH (GAUGE) LIGHTS ...................................................................................... 7-38
HEADLIGHTS ........................................................................................................................................ 7-38
LOW BEAM ............................................................................................................................................ 7-38
HIGH BEAM ........................................................................................................................................... 7-39
GAUGE LIGHTS .................................................................................................................................... 7-39
TURN SIGNALS ..................................................................................................................................... 7-39
RIGHT TURN INDICATOR CIRCUIT ..................................................................................................... 7-39
LEFT TURN INDICATOR CIRCUIT ....................................................................................................... 7-39
HAZARD LIGHT CIRCUIT ..................................................................................................................... 7-39
SECONDARY/PARKING BRAKE CIRCUIT .......................................................................................... 7-42
WATER SPRAY CIRCUIT ...................................................................................................................... 7-43
MANUAL MODE .................................................................................................................................... 7-43
AUTO MODE .......................................................................................................................................... 7-43
GAUGES AND INDICATORS ................................................................................................................ 7-45
THROTTLE CIRCUIT ............................................................................................................................. 7-47
SPEED RANGE CIRCUIT ...................................................................................................................... 7-48
9/2005 7-1
Section 7
ELECTRICAL
TABLE OF CONTENTS (cont.)
PAGE
VIBRATION SYSTEM CIRCUIT ............................................................................................................. 7-49

Vibration Speed (Frequency) Controls ........................................................................................ 7-49
Amplitude Control .......................................................................................................................... 7-51
Drum Selection Control ................................................................................................................. 7-51
Vibrator Mode Control ................................................................................................................... 7-51
Manual Vibrator Control ................................................................................................................ 7-51
Vibration Coils ................................................................................................................................ 7-51
DIRECTIONAL CONTROL CIRCUIT ..................................................................................................... 7-52
Forward Propulsion ....................................................................................................................... 7-52
Backward Propulsion .................................................................................................................... 7-53
MAT TEMPERATURE SENSOR CIRCUIT ............................................................................................ 7-55
DISPLAY CIRCUIT ................................................................................................................................. 7-56
OPTIONAL CIRCUITS ........................................................................................................................... 7-56
BACKUP ALARM CIRCUIT ................................................................................................................... 7-56
WORKLIGHTS CIRCUIT ....................................................................................................................... 7-56
ELECTRICAL COMPONENTS REMOVAL AND INSTALLATION. ............................................................. 7-59
BATTERY ............................................................................................................................................... 7-59
Removal .......................................................................................................................................... 7-59
Installation ...................................................................................................................................... 7-59
STARTER MOTOR ................................................................................................................................. 7-60
Removal .......................................................................................................................................... 7-60
Installation ...................................................................................................................................... 7-60
ALTERNATOR ....................................................................................................................................... 7-61
Removal .......................................................................................................................................... 7-61
Installation ...................................................................................................................................... 7-61
SWITCHES AND CONTROLS ............................................................................................................... 7-62
IGNITION KEY SWITCH .................................................................................................................. 7-62
Removal .................................................................................................................................... 7-62
Installation ................................................................................................................................ 7-62
BRAKE SWITCH [SECONDARY/PARKING BRAKE SYSTEM ON/OFF CONTROL SWITCH] ... 7-63
Removal .................................................................................................................................... 7-63
Installation ................................................................................................................................ 7-63
SPEED RANGE SWITCH [TRANSMISSION SYSTEM (TRAVEL/WORK) RANGE (2-SPEED)
SELECTION SWITCH] ..............................................................................................................7-64
Removal .................................................................................................................................... 7-64
Installation ................................................................................................................................ 7-64
VIBRATION SYSTEMS LOCATION (FRONT/BOTH/REAR) SELECTION SWITCH ..................... 7-65
Removal .................................................................................................................................... 7-65
Installation ................................................................................................................................ 7-65
DRUM VIBRATOR MODE [AUTOMATIC/OFF/MANUAL] SELECTION SWITCH ......................... 7-65
Removal .................................................................................................................................... 7-65
Installation ................................................................................................................................ 7-65
MANUAL DRUM VIBRATOR (START/STOP) CONTROL SWITCHES .......................................... 7-66
VIBRATION SYSTEMS AMPLITUDE AMOUNT [HIGH/LOW] SELECTION SWITCH .................. 7-66
Removal .................................................................................................................................... 7-66
Installation ................................................................................................................................ 7-66
FRONT AND REAR DRUM VIBRATOR FREQUENCY [SPEED] CONTROL ................................ 7-67
7-2 9/2005
Section 7
ELECTRICAL
PAGE
Removal .................................................................................................................................... 7-67

Installation ................................................................................................................................ 7-67
ENGINE THROTTLE SPEED LOW/HIGH CONTROL SWITCH ..................................................... 7-67
Removal .................................................................................................................................... 7-67
Installation ................................................................................................................................ 7-68
WATER SPRAY SYSTEMS MODE (AUTO/OFF/MANUAL) CONTROL SWITCH ......................... 7-68
Removal .................................................................................................................................... 7-68
Installation ................................................................................................................................ 7-68
WATER SPRAY SYSTEMS DUTY CYCLE (0-50%) CONTROL ..................................................... 7-69
Removal .................................................................................................................................... 7-69
Installation ................................................................................................................................ 7-69
LIGHT SYSTEMS (ON/OFF) CONTROL SWITCH ......................................................................... 7-70
Removal .................................................................................................................................... 7-70
Installation ................................................................................................................................ 7-70
ENGINE INLET AIR RESTRICTION INDICATOR VACUUM SWITCH ........................................... 7-70
Removal .................................................................................................................................... 7-70
Installation ................................................................................................................................ 7-70
VIBRATION SYSTEMS HYDRAULIC PRESSURE OIL FILTER ELEMENT CONDITION
INDICATOR CIRCUIT SWITCH ................................................................................................ 7-71
Removal .................................................................................................................................... 7-71
Installation ................................................................................................................................ 7-71
HORN BUTTON SWITCH. .............................................................................................................. 7-71
Removal .................................................................................................................................... 7-71
Installation ................................................................................................................................ 7-71
RELAYS ................................................................................................................................................. 7-72
WATER SPRAY SYSTEMS POWER RELAY .................................................................................. 7-72
Removal .................................................................................................................................... 7-72
Installation ................................................................................................................................ 7-72
HIGH BEAM RELAY ........................................................................................................................ 7-72
Removal .................................................................................................................................... 7-72
Installation ................................................................................................................................ 7-72
LOW BEAM RELAY ........................................................................................................................ 7-73
Removal .................................................................................................................................... 7-73
Installation ................................................................................................................................ 7-73
FORWARD RELAY .......................................................................................................................... 7-74
Removal .................................................................................................................................... 7-74
Installation ................................................................................................................................ 7-74
REVERSE RELAY ........................................................................................................................... 7-74
Removal .................................................................................................................................... 7-74
Installation ................................................................................................................................ 7-74
BACKUP RELAY ............................................................................................................................. 7-75
Removal .................................................................................................................................... 7-75
Installation ................................................................................................................................ 7-75
SENDING UNITS ................................................................................................................................... 7-75
ENGINE LUBRICATION OIL PRESSURE SENDING UNIT ........................................................... 7-75
Removal .................................................................................................................................... 7-75
Installation ................................................................................................................................ 7-75
9/2005 7-3
Section 7
ELECTRICAL
PAGE
ENGINE COOLANT TEMPERATURE SENDING UNIT .................................................................. 7-76

Removal .................................................................................................................................... 7-76
Installation ................................................................................................................................ 7-76
FUEL LEVEL SENDING UNIT ......................................................................................................... 7-76
Removal .................................................................................................................................... 7-76
Installation ................................................................................................................................ 7-76
HYDRAULIC SYSTEM OIL TEMPERATURE SENDING UNIT ...................................................... 7-76
Removal .................................................................................................................................... 7-76
Installation ................................................................................................................................ 7-76
“MAT” TEMPERATURE SENDING UNIT ....................................................................................... 7-76
Removal .................................................................................................................................... 7-76
Installation ................................................................................................................................ 7-76
Bench Calibration Procedure ................................................................................................. 7-76
Field Calibration Procedure ..................................................................................................... 7-76
SOLENOID CONTROLS ........................................................................................................................ 7-80
SECONDARY/PARKING BRAKE SYSTEM STACK VALVE SOLENOID ...................................... 7-80
TRANSMISSION WORK/TRAVEL [LOW/HIGH] SPEED RANGE SYSTEM SOLENOID
STACK VALVE SOLENOID ...................................................................................................... 7-80
TRANSMISSION PUMP ELECTRONIC DISPLACEMENT CONTROL VALVE SOLENOID ......... 7-80
VIBRATION PUMP ELECTRONIC DISPLACEMENT (EDC) SOLENOID VALVE ......................... 7-80
CIRCUIT BREAKERS ............................................................................................................................ 7-80
LIGHTS AND HORN THIRTY (30) AMP CIRCUIT BREAKER [F1] ................................................ 7-80
Removal .................................................................................................................................... 7-80
Installation ................................................................................................................................ 7-80
CONTROL PANEL SWITCHES CIRCUIT BREAKER [F2] ............................................................. 7-81
Removal .................................................................................................................................... 7-81
Installation ................................................................................................................................ 7-81
COMPUTER GAUGES AND SHUTDOWN RELAY 20-AMP CIRCUIT BREAKER [F3] ................ 7-81
Removal .................................................................................................................................... 7-81
Installation ................................................................................................................................ 7-81
STARTER CIRCUIT BREAKER [F4] .............................................................................................. 7-81
OPTIONS CIRCUIT BREAKER [F5] ............................................................................................... 7-81
Removal .................................................................................................................................... 7-81
Installation ................................................................................................................................ 7-81
WATER SPRAY SYSTEMS THIRTY (30) AMP CIRCUIT BREAKER [F6] ..................................... 7-82
Removal .................................................................................................................................... 7-82
Installation ................................................................................................................................ 7-82
REAR PAVING [WORK] LIGHTS THIRTY (30) AMP CIRCUIT BREAKER [F8] ............................ 7-82
Removal .................................................................................................................................... 7-82
Installation ................................................................................................................................ 7-82
FRONT PAVING [WORK] LIGHTS THIRTY (30) AMP CIRCUIT BREAKER [F9] ......................... 7-82
Removal .................................................................................................................................... 7-82
Installation ................................................................................................................................ 7-83
BACKUP ALARM FUSE [F7] .......................................................................................................... 7-83
INSTRUMENTS AND GAUGES. ........................................................................................................... 7-83
ENGINE HOUR METER .................................................................................................................. 7-83
Removal .................................................................................................................................... 7-83
7-4 9/2005
Section 7
ELECTRICAL
PAGE
Installation ................................................................................................................................ 7-83

VOLTMETER ................................................................................................................................... 7-84
Removal .................................................................................................................................... 7-84
Installation ................................................................................................................................ 7-84
FUEL LEVEL ................................................................................................................................... 7-84
Removal .................................................................................................................................... 7-84
Installation ................................................................................................................................ 7-84
ENGINE LUBRICATION OIL PRESSURE GAUGE ........................................................................ 7-85
Removal .................................................................................................................................... 7-85
Installation ................................................................................................................................ 7-86
ENGINE COOLANT TEMPERATURE ............................................................................................ 7-86
Removal .................................................................................................................................... 7-86
Installation ................................................................................................................................ 7-86
HYDRAULIC SYSTEM OIL TEMPERATURE ................................................................................. 7-86
Removal .................................................................................................................................... 7-86
Installation ................................................................................................................................ 7-87
INDICATOR LIGHTS .............................................................................................................................. 7-87
VIBRATION SYSTEM HYDRAULIC PRESSURE OIL FILTER ELEMENT CONDITION
INDICATOR LIGHT ................................................................................................................... 7-87
Removal .................................................................................................................................... 7-87
Installation ................................................................................................................................ 7-87
ENGINE INLET AIR RESTRICTION INDICATOR LIGHT ............................................................... 7-88
Removal .................................................................................................................................... 7-88
Installation ................................................................................................................................ 7-88
MISCELLANEOUS AND OPTIONAL COMPONENTS ......................................................................... 7-88
ELECTRONIC HORN ASSEMBLY .................................................................................................. 7-88
Removal .................................................................................................................................... 7-88
Installation ................................................................................................................................ 7-88
WATER PUMP ASSEMBLY ............................................................................................................. 7-88
Removal .................................................................................................................................... 7-89
Installation ................................................................................................................................ 7-89
POWER PANEL ASSEMBLY .......................................................................................................... 7-89
Removal .................................................................................................................................... 7-89
Installation ................................................................................................................................ 7-89
OPTIONAL OPERATING LIGHT ASSEMBLIES ............................................................................ 7-91
Removal .................................................................................................................................... 7-91
Installation ................................................................................................................................ 7-91
BACKUP ALARM ............................................................................................................................ 7-91
Removal .................................................................................................................................... 7-91
Installation ................................................................................................................................ 7-91
REMOVAL AND REPLACEMENT OF S2X COMPUTER CONTROLLER ASSEMBLY ............................. 7-92
ACCESSING LOWER LEVEL GROUPS SCREENS AND RECORDING THE NUMBERS ................. 7-92
REMOVAL AND REPLACEMENT OF THE S2X COMPUTER CONTROLLER ASSEMBLY ............... 7-94
INSTALLATION OR GROUP NUMBERS INTO THE S2X COMPUTER CONTROLLER ..................... 7-96
REMOVAL AND REPLACEMENT OF DIRECTIONAL/SPEED CONTROL ASSEMBLY ..................... 7-98
9/2005 7-5
Section 7
ELECTRICAL
PAGE
GENERAL TROUBLE ANALYSIS INFORMATION AND PROCEDURES ................................................ 7-100

VOLTAGE MEASUREMENTS ............................................................................................................. 7-100
CONTINUITY (RESISTANCE) MEASUREMENTS .............................................................................. 7-100
CURRENT MEASUREMENTS ............................................................................................................ 7-100
GENERAL MACHINE CALIBRATION PROCEDURE INFORMATION ..................................................... 7-168
RIGHT DIRECTIONAL/SPEED CONTROL [FNR] CONTROL HANDLE ........................................... 7-168
PROPEL THRESHOLD CALIBRATION .............................................................................................. 7-169
VIBRATION SYSTEMS CALIBRATION .............................................................................................. 7-172
FRONT AND REAR VIBRATOR PUMP SPEEDS CALIBRATION ............................................... 7-172
CALIBRATION FAILURE MESSAGES ............................................................................................... 7-174
VIBRATION SPEEDS ADJUSTMENT PROCEDURES ....................................................................... 7-175
NUMBER LOCK IN ........................................................................................................................ 7-177
WIRING DIAGRAMS .................................................................................................................................. 7-179
FAULT ANALYSIS PROCEDURES FOR THE DC2 CONTROLER VERSION 2.33 ...........................................
FAULT ANALYSIS PROCEDURES FOR THE S2X CONTROLER VERSION 3.00 ...........................................
7-6 9/2005
Section 7
ELECTRICAL
This section describes the operation of the electrical

system and contains descriptions of the items
included in the system used on the 66 Inch and 78
Inch Compactors.
Electrical system “Trouble Analysis” is found at the

end of this section.
ELECTRICAL SYSTEM MAJOR COMPONENT

DESCRIPTION.
FIGURE 7-1. BATTERY
The following information describes the MAJOR
electrical components used in the electrical system of
the 66 Inch and 78 Inch Compactors.
MOTOR.
WARNING: NEVER smoke or cause a spark near
ANY battery. ALWAYS loosen and
a. The starter motor, Figure 7-2, is used to convert
remove the NEGATIVE [-] battery
electrical energy from the battery into mechanical
cable from the NEGATIVE [-] battery
energy to crank and start the engine. One [1] 12
post BEFORE loosening and remov-
volt, negative ground starter motor is used in the
ing the POSITIVE [+] battery cable
start circuit. The starter motor is attached to the
from the POSITIVE [+] battery post.
engine and drives the crankshaft for engine
NEVER cause a shorted circuit
starting.
condition in ANY CIRCUIT. USE
EXTRA CAUTION when checking ANY
circuit using ANY electrical testing
instrument.
BATTERY.
a. The battery, Figure 7-1, supplies direct current to

crank the engine and operate electrical circuits
until the alternator is able to supply current. One
[1], 12 volt, 900 CCA hour “maintenance free”
battery is used in the electrical system for this
purpose.
FIGURE 7-2. STARTER MOTOR
9/2005 7-7
Section 7
ELECTRICAL
ALTERNATOR.
a. The 105 amp alternator, Figure 7-3, is used to

convert mechanical energy into electrical energy.
It supplies electrical current to the electrical
circuits and keeps the battery “charged” when
the engine is “running”. The alternator is
operated through a belt from the engine and
provides sufficient output current to maintain
operation of all circuits and to charge the battery.
FIGURE 7-4. IGNITION KEY SWITCH
again be operated. Position 3 is the START

position and allows the starter motor to be
engaged. After starting the switch spring returns
FIGURE 7-3. ALTERNATOR to the ON (running position).
b. Secondary/Parking Brake System On/Off Control

SWITCHES AND CONTROLS.
Switch.
The secondary/parking brake system On/Off
a. Ignition Key Switch.
control switch, Figure 7-5, is mounted on the
One ignition key switch, Figure 7-4, is used in
control panel. This switch is used in the
the electrical system. The switch is mounted on
secondary/parking brake system electrical circuit.
the control panel. The switch is the main control
The rotated position switch is used to
switch for ALL electrical circuits [except the horn,
gauge lighting and operation lighting]. The switch
is a three position type and permits the engine to
be started, put in a “running” condition and
stopped. The BAT terminal connects to the
battery. The ST terminal connects to the starter
motor. The ACC terminal connects to all other
electrical circuits [except the horn, gauge lighting
and operation lighting]. The GRD terminal
connects to chassis ground. Position 1 is the
OFF position and removes electrical power from
all circuits except the horn, gauge lighting and
operation lighting. Position 2 is the ON (running)
position. This position applies voltage to all
circuits. This position is also a “lockout” position
preventing accidental engagement of the starter
motor when the engine is running. Once the
engine is started the switch must be returned to
the off position before the starter motor can FIGURE 7-5. SECONDARY/PARKING BRAKE
SYSTEM ON/OFF CONTROL SWITCH
7-8 9/2005
Section 7
ELECTRICAL
electrohydraulically control the secondary/
parking brake system. When the switch is
pressed “IN” the brake system is engaged.
When the switch is turned to the right and “OUT”
the brake system is released.
c. Transmission Speed Range [“Travel/Work”] [2-

Speed] Selection Switch.
The transmission speed range selection switch,
Figure 7-6, is mounted on the control panel. This
switch is used in the transmission system speed
range electrical circuit to supply current to the
speed range solenoid, on the stack valve and
sends a separate signal to the S2X computer
controller. The two position [double pole] toggle
switch is used to electrohydraulically select the
“Travel/[high]” “Work/[Iow]” range of the
transmission system. When the toggle switch is
in the “DOWN” position, the system is in the
“Work/[low]” range. When the toggle switch is in
the “UP” position, the system is in the “Travel/
[high]” range.
FIGURE 7-7. RIGHT DIRECTIONAL/SPEED

CONTROL ASSEMBLY [MASTER FNR]
Also, included in the master FNR control is a

FIGURE 7-6. TRANSMISSION SPEED RANGE
directional control potentiometer [POT], and a
“TRAVEL/WORK” (2-SPEED) SELECTION SWITCH
neutral safety switch , which are actuated by
movement, in either direction, of the directional/
d. Right Directional/Speed Control Assembly
speed control handle. Movement of the
[Master FNR].
potentiometer [POT] sends a variable voltage
The combination travel direction/neutral start
from the FNR control assembly to the computer
control assembly, Figure 7-7, with vibration
controller. The variable voltage is processed by
system manual mode start/stop switch is used in
the computer controller and controls the output
the electrical system. The control is installed at
to the transmission pump electronic
the right hand side of the dash panel and is
displacement control [EDC] valve solenoid coil.
actuated by the direction/speed control handle.
The top of the control handle contains the
The S2X computer controller electrically monitors
manual vibration system[s] start/stop push button
the control handle position. When the control
switch. In the manual vibration mode, when the
handle is in the “NEUTRAL” position, a “closed
switch is pushed, a ground circuit is completed
circuit” exists that permits electrical current to be
and a digital input is processed by, the computer
directed from the key switch to the engine starter
controller. Current then is output to either, or
solenoid. If the Ignition switch is in the START
both, vibrator pump electronic displacement
position, the starter solenoid is then energized,
control[s] [EDC] valve solenoid coil[s].
causing the starter to crank the engine.
9/2005 7-9
Section 7
ELECTRICAL
Therefore, actual electrical control of travel
direction, speed and neutral start is done through
the right directional/speed control assembly
[master FNR].
The top of the left control handle contains the

manual vibration system[s] start/stop push button
switch. In the manual vibration mode, when the
switch is pushed, a ground circuit is completed
and digital input is processed by, the computer
controller. Current is then output to either, or
both, vibrator pump electronic displacement
control[s] [EDC] valve solenoid coil[s].
f. Vibration Systems Location [“Front/Both/Rear”]

Selection Switch.
The vibration systems location [“front/both/rear”]
selection switch, Figure 7-9, is located on the left
side of the display. This is a three position switch
used to select the location of drum vibration, by
grounding one, of two, digital inputs, signaling
the S2X that the “FRONT” drum is selected
when the switch is in the left “FRONT” position.
The “REAR” drum is selected when the switch is
in the right “REAR” position. Both the “FRONT”
and “REAR” drums are selected when the switch
is in the center “BOTH” position.
FIGURE 7-8. LEFT DIRECTIONAL/SPEED

CONTROL ASSEMBLY [SLAVE FNR]
e. Left Directional/Speed Control Assembly [Slave

FNR].
The left hand travel control handle assembly,
Figure 7-8, with only the vibration system
manual mode start/stop switch, is used in the
electrical system. The control is installed at the
left-hand side of the dash panel.
The left control assembly is mechanically

connected to the right directional/speed control FIGURE 7-9. VIBRATION SYSTEMS LOCATION
assembly [master FNR] through a mechanical [“FRONT”/BOTH/REAR”] SELECTION SWITCH
[shaft] connection. Movement of either control
handle moves the opposite side control handle.
7-10 9/2005
Section 7
ELECTRICAL
g. Drum Vibrator Mode [“Automatic/Off/Manual”]
Selection Switch.
The drum vibrator mode [“automatic/off/manual”]
selection switch, Figure 7-10, is located on the
left side of the display. This is a three position
toggle switch used to select the vibrator mode
[“Automatic, Off or Manual”] of the front, rear, or
both, drum vibrator system[s], by grounding one,
of two, digital inputs, signaling the S2X that the
“AUTO” mode is selected when the switch is in
the left “AUTO” position The MANUAL mode is
selected when the switch is in the right
“MANUAL position. The vibrator systems are
turned off when the switch is in the center “OFF“
position. FIGURE 7-11. MANUAL DRUM VIBRATOR
[“START/STOP”] CONTROL SWITCH
i. Vibration Systems Amplitude Amount [“High/

Low”] Selection Switch.
The vibration systems amplitude amount [“high/
low”] selection switch, Figure 7-12, is located on
the left side of the display. This is a two position
switch that selects the routing of five volt sensor
power to the S2X. The switch is used to select
the amplitude amount [“High” or “Low”] of BOTH
drum vibration systems. The HIGH mode is
selected when the switch is in the left hand
position. The LOW mode is selected when the
switch is in the right hand position.
FIGURE 7-10. DRUM VIBRATOR MODE

[“AUTOMATIC/OFF/MANUAL”]
SELECTION SWITCH
h. Manual Drum Vibrator [“Start/Stop”] Control

Switches.
The manual drum vibrator [“start/stop”] control
switches, Figure 7-11, are two momentary push
button thumb-operated switches that are used in
the vibration system manual mode control
circuit. The switches are installed in the top of
the left and right travel control. The momentary
switches are used to electrohydraulically start FIGURE 7-12. VIBRATION SYSTEMS AMPLITUDE
and stop the vibration system, of one, or both AMOUNT [“HIGH/LOW”] SELECTION SWITCH
drums by grounding the digital input, signaling
the S2X to start, or stop vibration. Depressing,
then releasing, the push button starts the
vibration system(s). Depressing then releasing
the push button, again, stops the vibration
system(s).
9/2005 7-11
Section 7
ELECTRICAL
j. Front and Rear Drum Vibrator Frequency
[“Speed”] Controls.
The front and rear drum vibrator frequency
[“speed”] controls, Figure 7-13, are two identical
vibrator frequency control potentiometers that
are used in the electrical system. Both
potentiometers are installed into the right side of
the front dash panel. The top control is used to
select the FRONT drum frequency in either
“high”, or “low”, amplitude when operating in
either the “manual”, or “automatic”, vibration
mode by routing the flow of 0-5 volts sensor
power to the S2X. The controller interprets the
voltage input and outputs the correct current to
the vibration pump(s) EDC. The bottom control is
used to select the REAR drum frequency in
either “high”, or “low”, amplitude when operating
in either the “manual”, or “automatic”, vibration FIGURE 7-13. FRONT AND REAR DRUM
mode as described above. VIBRATOR FREQUENCY [“SPEED”]
CONTROL SWITCHES
NOTE: The adjustable frequency range for the
66 Inch Compactor is 2000 - 3400 vpm, in k. Engine Throttle Speed RUN/IDLE Control
high amplitude and 2000 - 3800 vpm, in Switch.
Iow amplitude. The engine throttle speed RUN/IDLE control
switch, Figure 7-14, is located on the left side of
the control panel. This is a two position (double
The adjustable frequency range for the pole) toggle switch that controls the operation of
78 Inch Compactor is 2000 - 3400 vpm, in the engine mounted throttle solenoid. The
high amplitude and 2000 - 3800 vpm, in engine throttle speed switch is used to
Iow amplitude. electrically select either IDLE, or RUN engine
speed and sends a separate signal to the S2X
indicating the switch position, allowing the
controller to take the correct action. In the
DOWN position, the engine is in IDLE speed
condition. In the UP position, the engine is in
RUN speed condition.
FIGURE 7-14. ENGINE THROTTLE SPEED
7-12 9/2005
Section 7
ELECTRICAL
l. Water Spray Systems Mode [“Auto/Off/Manual”]
Control Switch.
The water spray systems mode [“auto/off/
manual”] control switch, Figure 7-15, is located
on the right side of the control panel. This is a
three position toggle switch that is used to
control the two water spray system pumps. In
the MANUAL position, both the front and the rear
drum spray systems are on continuously. In the
center, OFF position, both the front and rear
systems are turned off. In the left AUTO
position, the controller system cycles the water
spray on and off at a duty cycle of 0-50% when
the machine is in motion. When the machine is in
neutral and is not moving the controller turns the
spray system off.
FIGURE 7-16. WATER SPRAY SYSTEMS

WATER SAVER (DUTY CYCLE) (0-50%)
CONTROL SWITCH
n. Light System [“Off/Low/High’] Control Switch.

The light system [“off/low/high”] control switch,
Figure 7-17, is located on the control panel. This
is a three position push/pull switch that controls
the headlights, instrument lights, and gauge
lights in the lighting system. When pushed fully
IN, optional headlights, and all instrument and
gauge lights are turned off. When pulled out to
the first detent, the low beam headlights, and the
FIGURE 7-15. WATER SPRAY SYSTEMS MODE instrument and gauge lights are turned on. When
[“AUTO/OFF/MANUAL”] CONTROL SWITCH fully pulled out to the second detent, the high
beam headlights, and the instrument and gauge
lights are turned on.
m. Water Spray Systems WATER SAVER [Duty
Cycle] [0 - 50%] Control Switch.
The water spray systems duty cycle control
potentiometer, Figure 7-16, is located on the
right side of the display. This switch is used to
control the duty cycle of the two water spray
system pumps, from 0 - 50%. When the systems
are being operated in the “automatic mode”, the
potentiometer provides a variable 0 - 5 Vdc
voltage level that is applied to the controller. The
controller uses the voltage level to determine the
duty cycle for the voltage applied to the washer
motors.
FIGURE 7-17. LIGHT SYSTEM (“OFF/LOW/HIGH”)

CONTROL SWITCH
9/2005 7-13
Section 7
ELECTRICAL
o. Engine Inlet Air Restriction Indicator Vacuum
Switch.
The engine inlet air restriction indicator vacuum
switch, Figure 7-18, is located on the air filter.
This is a single pole, normally open, vacuum
closed, switch that monitors the air pressure in
the engine inlet air system. When the air
pressure drops below a preset value, the
vacuum switch closes, and completes the
electrical ground circuit to illuminate the red AIR
FILTER indicator.
FIGURE 7-18. ENGINE INLET AIR RESTRICTION

INDICATOR VACUUM SWITCH
p. Vibration Systems Hydraulic Pressure Oil Filter

Element Condition Indicator Circuit Switch.
The vibration systems hydraulic pressure oil filter
element condition indicator circuit switch, Figure
7-19, is located on the hydraulic filter. This is a PRESSURE
SWITCH
single pole, normally open switch that is used in
the hydraulic pressure oil filter element condition
indicator light circuit. When the differential
pressure rises above a preset value, the
pressure switch closes, and completes the FIGURE 7-19. VIBRATION SYSTEMS HYDRAULIC
electrical ground circuit to illuminate the red OIL PRESSURE OIL FILTER ELEMENT CONDITION
FILTER indicator on the control panel. INDICATOR CIRCUIT SWITCH
q. Horn Button Switch.

The horn button switch, Figure 7-20 is located on
the lower center of the control panel. This is a
single pole, normally open, button switch that is
used in the electrical circuit of the warning horn
system to sound the horn. The horn button
switch is used to complete the electrical circuit to
the horn.
FIGURE 7-20. HORN BUTTON SWITCH
7-14 9/2005
Section 7
ELECTRICAL
FIGURE 7-23. WATER SPRAY SYSTEMS POWER FIGURE 7-24. HIGH BEAM RELAY
RELAY
c. Water Spray Systems Power Relay (K5).

The water spray systems power relay, Figure 7-
23, is located on the power panel and is used in
the water spray systems electrical circuit to
supply current to both water spray pumps.
d. High Beam Relay (K3).

The high beam relay, Figure 7-24, is located on
the power panel and is used, in the operation
lighting system electrical circuit, to supply high
beam current to all four headlights when the light
control switch is in the “high beam” position.
e. Low Beam Relay (K4).

The low beam relay, Figure 7-25, is located on
the power panel and is used, in the operation
lighting system electrical circuit, to supply low
beam current to all four headlights when the light
control switch is in the “low beam” position.
FIGURE 7-25. LOW BEAM RELAY
9/2005 7-15
Section 7
ELECTRICAL
f. Starter Relay. SENDING UNITS.
The starter relay, Figure 7-26, is mounted into
the rear electrical box on the rear fuse panel. a. Engine Lubrication Oil Pressure Sending Unit.
This relay is used as the final switch in the The engine lubrication oil pressure sending unit,
starter circuit. The starter relay is used to close Figure 7-27, is located on the engine block. This
the electrical circuit and then supply current to sending unit is used to electrically indicate the
the starter solenoid. pressure of the oil in the engine lubrication oil
system. One sending unit, with a flexible internal
diaphragm, sends a varied resistance to ground,
based on the engine lubrication oil pressure, to
the engine lubrication oil pressure gauge. The
VF7-11F11-S01 gauge indicates the pressure of the engine
12VDC 70A lubrication oil flowing through the engine.
85 87
86 30
30
FIGURE 7-27. ENGINE LUBRICATION OIL

PRESSURE SENDING UNIT
85
86
b. Engine Coolant Temperature Sending Unit.

The engine coolant temperature sending unit,
87
Figure 7-28, is located on the engine. This

sending unit is used to electrically indicate the
temperature of the coolant in the engine cooling
system. One sending unit, having a “bimetal”
FIGURE 7-26. STARTER RELAY temperature sensor, sends a varied resistance to
ground, based on the coolant temperature, to
the engine coolant temperature gauge. The
gauge indicates the coolant temperature.
FIGURE 7-28. ENGINE COOLANT

TEMPERATURE SENDING UNIT
7-16 9/2005
Section 7
ELECTRICAL
d. Hydraulic System Oil Temperature Sending Unit.
The hydraulic system oil temperature sending
unit, Figure 7-30, is located on the side of the
hydraulic reservoir. The sending unit is used to
electrically indicate the temperature of the
hydraulic oil in the hydraulic system. One
sending unit, having a “bimetal” temperature
sensor, supplies a varied resistance to ground,
based on the hydraulic oil temperature, to the
hydraulic oil temperature gauge. The gauge
indicates the hydraulic system oil temperature.
FIGURE 7-30. HYDRAULIC SYSTEM OIL

e. “Mat” Temperature Sending Unit.

The “mat” temperature sending unit, Figure 7-31,
is attached to the chassis with the sensor
positioned just above the “mat” surface. This
location is on the front frame, below the
FIGURE 7-29. FUEL LEVEL SENDING UNIT operator’s platform. This sending unit is used to
electrically obtain the temperature of the asphalt
mat material being compacted. One [1] sending
c. Fuel Level Sending Unit. unit, having a temperature sensor, sends a
The fuel level sending unit, Figure 7-29, is varied amount of voltage, based on the “mat”
located on the fuel tank. This sending unit is material temperature, to the S2X computer
used to electrically indicate the level of fuel controller. The computer controller processes the
contained in the fuel tank. One sending unit, supplied voltage and supplies data to the
having a float assembly, mechanically moves a systems function [2x24] display. When the scroll
variable resistance type sending mechanism. button is used to access the “mat” temperature
The sending unit supplies a varied resistance to function, the displayed data indicates the current
ground, to the fuel gauge, which indicates the “mat” temperature.
amount of fuel contained in the tank.
9/2005 7-17
Section 7
ELECTRICAL

SYSTEM RELEASE SOLENOID
c. Transmission System Travel/Work [high/Iow]

Range [2 speed] Solenoid.
The transmission system travel/work [high/Iow]
range solenoid, Figure 7-34, is located on the
stack valve, above the battery. This solenoid is
normally closed [low speed] position. The
solenoid is energized when the transmission
system range “Travel [high]/Work [low]” [2
speed] selector switch is in the “Travel” position
with the engine “running”. The solenoid then
moves the flow control spool, in the solenoid
valve body, to the “Travel” range position and
directs hydraulic oil to the drum drive motors,
FIGURE 7-31. “MAT” TEMPERATURE where the displacement, and speed, is changed
SENDING UNIT from “Work” to “Travel” range.
SOLENOID CONTROLS.
b. Secondary/Parking Brake System Release

Solenoid.
The secondary/parking brake solenoid, Figure 7-
33, is located in the engine compartment, above
the battery. The normally closed, release
solenoid is electrically energized when the
ignition key switch is in the “on” position, and the
brake system control switch is in the “OFF”
[BRAKES RELEASED] position. The solenoid is
used to move the brake system release spool
from the brake “applied” position, to the brake
“released” position. This action permits the multi-
disc brake release piston, found in each drum
drive motor, to be supplied hydraulic oil flow, and
released. FIGURE 7-34. TRANSMISSION SYSTEM TRAVEL/
WORK (HIGH/LOW) RANGE (2 SPEED)
SOLENOID
7-18 9/2005
Section 7
ELECTRICAL
d. Engine Throttle High/Low Idle Speed Control
Solenoid.
The engine throttle high/Iow idle speed control
solenoid, Figure 7-35, is located on the engine.
This solenoid is energized when the engine idle
speed control switch is in the “HIGH” idle speed
position. The solenoid has an attached cable that
moves the throttle lever of the injector pump to
the “HIGH” idle position.
FIGURE 7-37. VIBRATION PUMP ELECTRONIC

DISPLACEMENT CONTROL (EDC) SOLENOID
CIRCUIT BREAKERS.
There are seven circuit breakers used in the

electrical system. These are twenty amp circuit
breakers [F1, F2, and F3] and thirty amp circuit
breakers [F5, F6, F7, and F8].
a. Twenty Amp Circuit Breakers.

A total of three twenty amp circuit breakers, are
used in the electrical system.
The first twenty (20) amp circuit breaker [F1],

Figure 7-38, is mounted on the control panel
FIGURE 7-36. TRANSMISSION PUMP bracket. This circuit breaker is used in the circuit
ELECTRONIC DISPLACEMENT CONTROL that supplies current to the electrical instruments,
[EDC] SOLENOID and gauge lighting circuit, plus the horn circuit.
f. Vibration Pump Electronic Displacement Control The second twenty amp circuit breaker [F2],
[EDC] Solenoid. Figure 7-38, is also mounted on the control panel
Two identical vibration pump electronic bracket. This circuit breaker is used in the circuit
displacement control solenoids, Figure 7-37, are that supplies current to the engine throttle control
used in the vibration electrical systems. One switch, the secondary/parking brake system
solenoid is installed on the front, and one control switch, the water spray systems mode
solenoid is installed on the rear, vibration pump control switch, the transmission system range
displacement control valve. The vibration selector switch circuits, and the working lights off/
systems “automatic/off/manual” mode control on switch. The second circuit breaker is also
switch, “front/both/rear” location control switch, used in the circuit that supplies current to the
“high/Iow” amplitude control switch, front drum power relay, and computer controller, when
vibrator frequency control, rear drum vibrator closed.
frequency control, manual vibration control
switches [used in manual vibration mode only] The third twenty amp circuit breaker [F3], Figure
and the computer control system select and 7-38, is also mounted on the control panel
direct electrical current to either, or both, vibrator bracket. This circuit breaker is used in the circuit
pump [EDC] solenoid[s]. that supplies current to the electrical instruments
and gauges circuit.
9/2005 7-19
Section 7
ELECTRICAL
FIGURE 7-38. TWENTY (20) AMP CIRCUIT FIGURE 7-39. THIRTY (30) AMP CIRCUIT
BREAKERS MOUNTED ON CONTROL BREAKERS MOUNTED ON POWER PANEL
PANEL BRACKET
The fourth thirty amp circuit breaker [F8], Figure
b. Thirty Amp Circuit Breaker. 7-40, is mounted above the computer. This
A total of four thirty amp circuit breakers, are circuit breaker is used in the circuit which
used in the electrical system. supplies current to the rear working light system
circuits.
The first thirty amp circuit breaker [F5], Figure 7- INSTRUMENTS.
39, is used in the water spray system, and is
mounted on the power panel. The water spray
systems circuit breaker is used in the water
spray systems electrical circuit, to supply current
through the water spray systems relay. When the
relay closes, current is supplied to both the front
and rear water spray pump motors.
The second thirty amp circuit breaker [F6],

Figure 7-39, is used in the option systems, and
is mounted on the power panel. The options
system circuit breaker is used in the turn signal,
and 4-way flasher system electrical circuit to
supply current to the front and rear turn signal,
and 4-way flasher lighting system. This circuit
breaker can, also, be used to supply current to
additional “add on” electrical items, such as a
warning beacon.
The third thirty amp circuit breaker [F7], Figure

7-40, is mounted above the computer. This FIGURE 7-40. THIRTY (30) AMP CIRCUIT
circuit breaker is used in the circuit which BREAKERS MOUNTED ABOVE COMPUTER
supplies current to the front working light system
circuits.
7-20 9/2005
Section 7
ELECTRICAL
a. Engine Hourmeter.
The engine hourmeter, Figure 7-41, is located on
the gauge panel. The hourmeter indicates the
amount of time the engine has operated, and is
given in time divisions of tenths, units, tens,
hundreds, and thousands of hours. The engine
hourmeter is “on” when the engine is ignition key
switch is in the “on” position.
b. Voltmeter.
The voltmeter, Figure 7-42, is located on the
gauge panel. The voltmeter indicates the voltage
INDICATOR LIGHTS.
FIGURE 7-42. VOLTMETER
GAUGES.
a. Fuel Level Gauge.

The fuel level gauge, Figure 7-43, is located on
the gauge panel. The fuel gauge indicates the
level of fuel contained in the fuel tank. The
gauge will operate when the ignition key switch
is in the “on” position. The gauge has a face
scale ranging from “empty” to “full” symbol.
FIGURE 7-41. ENGINE HOUR METER
in the electrical system, and will give an

indication of battery voltage, or alternator
voltage, depending on which is higher. The
voltmeter has a face scale ranging from plus [+]
10 volts to plus [+] 16 volts.
FIGURE 7-43. FUEL LEVEL GAUGE
9/2005 7-21
Section 7
ELECTRICAL
c Engine Coolant Temperature Gauge.

The engine coolant temperature gauge, Figure
7-45, is located on the gauge panel. The engine
coolant temperature gauge indicates the
temperature of the coolant circulating through
the engine cooling system. The gauge will
operate when the ignition key switch is in the
“on” position. The gauge has a face scale
ranging from “white” [100°F (38°C)], to “green”
[140°F (60°C)], and to “red” [230°F (110°C)].
d. Hydraulic System Oil Temperature Gauge.

The hydraulic system oil temperature gauge,
Figure 7-46, is located on the gauge panel. The
hydraulic system oil temperature gauge
indicates the temperature of the hydraulic oil
flowing in the system. The gauge will operate
FIGURE 7-44. ENGINE LUBRICATION OIL when the ignition key switch is in the “on”
PRESSURE GAUGE position. The gauge has a face scale ranging
from “‘green” [100°F (38°C)] to “yellow” [180°F
b. Engine Lubrication Oil Pressure Gauge. (82°C)] then to “red” [220°F (104°C)].
The engine lubrication oil pressure gauge,
Figure 7-44, is located on the gauge panel. The
engine lubrication oil pressure gauge indicates
the pressure of the lubrication oil circulating
through the engine. The gauge will operate when
the ignition key switch is in the “on” position and
the engine is in a “running” condition. The gauge
has a face scale ranging from a “low” to a “high”
symbol.
FIGURE 7-46. HYDRAULIC SYSTEM OIL

TEMPERATURE GAUGE

TEMPERATURE GAUGE
7-22 9/2005
Section 7
ELECTRICAL
INDICATOR LIGHTS.
a. Vibration Systems Hydraulic Pressure Oil Filter

Element Condition Indicator Light.
condition indicator light, Figure 7-47, is located
on the control panel. This light indicates when the
pressure oil filter element has reached the
maximum holding capacity and MUST be
changed. The red lens covered light can be “on”
when the ignition key switch is in the “on”
position and with the hydraulic oil at a “cold”
temperature, at machine “start up” also.

INDICATOR LIGHT
FIGURE 7-47. VIBRATION SYSTEMS HYDRAULIC

PRESSURE OIL FILTER ELEMENT CONDITION
INDICATOR LIGHT
b. Engine Inlet Air Restriction Indicator Light. FIGURE 7-49. SYSTEMS FUNCTION
The engine inlet air restriction indicator light, [2X24] DISPLAY
Figure 7-48, is located on the control panel. This
light indicates a restricted condition of the engine
inlet air route. The red lens covered light will be
“on” when the ignition key switch is in the “on”
position, at machine “start up”, and when the
engine inlet air route is restricted.
c. Systems Function [2x24] Display and Scroll

Button.
The system function [2X24] display, Figure 7-49,
and scroll button, Figure 7-50, are located on the
front dash panel. The display, has two [2] display FIGURE 7-50. SCROLL BUTTON
lines with up to 24 characters per line, and
receives data from the S2X computer controller. The scroll push button switch is used to scroll
The alphanumeric display is used as a visual through the parameters, to be viewed, on the
indicator of monitored systems parameters, alphanumeric display.
faults and calibration information.
9/2005 7-23
Section 7
ELECTRICAL
CABLES AND WIRES.
a. Cables.
The positive [+] and negative [-] battery cables
connect the positive [+] and negative [-] post of
the battery to the engine starter motor and the
system ground at the engine. The cables carry
high amperage electrical current for the engine
starter motor and current from the alternator to
the battery.
b. Wires. FIGURE 7-51. ELECTRIC HORN ASSEMBLY

The wires used in the electrical system connect
the components and form the circuits through
which the electrical current flows. The wire
assemblies contain different size [gauge] wires,
connection terminals, and plug assemblies. The
wire assemblies are covered with a protective
PVC coated nylon woven loom, and/or are
metallically shielded.
MISCELLANEOUS AND OPTIONAL

COMPONENTS.
a. Electric Horn Assembly.

The electric horn assembly, Figure 7-51, is
mounted to the cockpit floor plate. The one
electric horn will sound when voltage is supplied
to the horn. The circuit is closed by pushing the
FIGURE 7-52. WATER PUMP ASSEMBLY
horn button on the control panel.
b. Water Pump Assembly.

The two identical water pump assemblies,
Figure 7-52, are located near the water tanks
above the front and rear drum assemblies. The
water pump assemblies are used to supply
pressurized water to the spray nozzles found on
EACH drum. BOTH pump assemblies are turned
on and off by the WATERSPRAY switch on the
control panel.
c. Power Panel Assembly.

The one power panel assembly, Figure 7-53, is
installed on the left inner side of the control and
instrument panel riser. The panel assembly
contains the power panel harness, water spray
relay, high beam relay, Iow beam relay, water
spray circuit breaker, options circuit breaker, turn
signal flasher junction blocks, and related
mounting hardware items.
FIGURE 7-53. POWER PANEL ASSEMBLY
7-24 9/2005
Section 7
ELECTRICAL
FIGURE 7-54. OPERATING

LIGHT ASSEMBLIES
FIGURE 7-55. OPTIONAL NIGHT PAVING
[WORKING] LIGHT ASSEMBLIES
d. Operating Light Assemblies.
The four operating light assemblies, Figure 7-54,
are used to illuminate the work area during dark g. Backup Alarm.
conditions. ALL light assemblies are turned on The backup alarm, Figure 7-56, is mounted on
and off through the use of the dash mounted the engine bulkhead near the air cleaner. The
light switch. alarm is turned on when the machine is in
reverse, causing the backup alarm relay to
e. Turn Signals and Four Way Warning Light close, and providing current to the backup alarm.
Assemblies.
The four turn signals and four way warning light
assemblies are an integral part of each
operation light assembly. The turn signals and
four way warning light assemblies are used to
indicate machine directional changes and to
increase machine visibility. The turn signals and
four way warning systems are controlled through
the use of the steering column mounted control
switch.
f. Optional Night Paving [Working] Light

Assemblies.
The six optional night paving [working] light
assemblies, Figure 7-55, are mounted on the
front and rear of the FOPS/ROPS. These lights
are used to illuminate the work area when
FIGURE 7-56. BACKUP ALARM
working at night. ALL night paving light
assemblies are turned on and off through the
use of the dash mounted system control switch.
9/2005 7-25
Section 7
ELECTRICAL
S2X COMPUTER DESCRIPTION.
a. S2X Computer Controller.

One [1] computer controller, Figure 7-57, is used
in the electrical system. This item is installed
inside of the dash riser. The controller serves as
the input information processing and electrical
current distribution component, in that it
receives, processes, and distributes electrical
current to monitor and controls all monitored
systems.
When “INPT” is selected and shows in the

computer controller window, the computer
controller, serves as a diagnostic center, in that
it, and the systems function display screen, will
allow functional testing of all switches and
potentiometers, except the water spray systems
mode switch.
FIGURE 7-57. S2X COMPUTER CONTROLLER
7-26 9/2005
Section 7
ELECTRICAL
COMPUTER CONTROL SYSTEM COMPONENTS. For the most part, technical service personnel do not
need to know, in depth, why the system does what it
Computer control system components consist of two does. Technical service personnel can not repair the
[2] FNR's (forward, neutral, reverse lever), a S2X computer controller system and can not change how
(computer controller), a 2x24 display (2 lines with 24 the computer controller system operates.
characters each), and the three [3] EDC's (electronic
displacement control) - one [1] on each pump. What technical service personnel do need to know is;
how to determine what is not functioning, so that they
The right hand [RH] FNR is the master and the left know what to replace. Technical service personnel will
hand [LH] is the slave. The only active part in the left also need to know the system functions [see this
hand FNR is the manual vibration [“MAN VIB”] section] to be able to determine whether or not there
switch. The “MAN VIB” switch, in either controller, is actually is a problem.
to be used when instructed to do so on the display.
The computer controller system will display
It is important to know the terminology, as the faults on the 2x24 display panel.
computer controller, via the display, will tell technical
service personnel what to do and when to do it, as There are two [2] types of faults. The first will give the
they go through the system. operator a fault warning such as: “Fault: Front Vib.
EDC” Front vibrator EDC open, or short.
Time wise, on the computer control system, it will not
take very long to go through the various system The second fault is a “STOP” warning, which will NOT
levels, as technical service personnel become allow the machine to travel, as in: “Fault: FNR
familiar with it. Sensor Pot”.
Technical service personnel need to be familiar with

66 INCH / 78 INCH COMPACTOR COMPUTER the system components and terminology, so that if a
CONTROL SYSTEM OVERVIEW INFORMATION. specific fault reading is noted by, and relayed from,
the operator, they will be able to evaluate the
It is very important to remember that the system is information correctly, and thereby solve the problem.
rather involved. There are many levels of
programming, some of which have absolutely no
relevance to the system problem, requiring
correction.
9/2005 7-27
Section 7
ELECTRICAL
FAULTS.
“FAULT: FNR Calibration” FAULT *
There are twelve [12] faults that the display panel will FNR Not Calibrated
refer to.
The following information contains what the technical

service personnel will see on the display panel when “FAULT: Prop. Dbnd. Cal.” STOP
a fault occurs and is detected. Propel EDC deadband Calibration
value out of range
There are two [2] different types of faults. One that
gives a warning, and one that is a “STOP” fault, which
will not allow the machine to travel. The twelve [12]
faults, their type, and meaning are: “FAULT: FNR Cal.” STOP
FNR Calibration values out of range
“FAULT: 5V Sensor Power” STOP

Sensor Power (5V) voltage is too low
“FAULT: Spray Valve” FAULT
Water Spray valve open or short
“FAULT: FNR Sensor Pot” STOP

FNR Sensor out of range
Brake applied STOP
“FAULT: FNR Neutral Sw.” STOP All “STOP” faults will shut down the travel system until
FNR Neutral Switch failure the computer controller is shut down and powered
back up.
This will reset the system. It does not mean the

“FAULT: Front Vib. EDC” FAULT problem will go away, although it may allow the
Front Vibrator EDC open or short machine to travel until the fault shows itself again.
This can allow the technical service personnel to
experience the condition that caused the fault.
“FAULT: Rear Vib. EDC” FAULT * This fault will only be seen during component
Rear Vibrator EDC open or short replacement. If the computer controller is
replaced, the FNR will need to be calibrated, so
the computer can learn it’s pots value. The same
is true if the righthand/master FNR is replaced.
“FAULT: Propel EDC” STOP
Propel EDC open or short ACCESSIBLE SCREENS USING THE F4
FUNCTION KEY.
There are four [4] screen levels that are accessible

by using the F4 key on the S2X computer controller,
“FAULT: Prop. Thresh. Cal.” STOP in conjunction with the scroll button.
Propel EDC threshold calibration
value out of range The four [4] screens are “RUN”, “LMTD”, “INPT” and
“VIBS”. These words, or abbreviations, will be shown
in the computer controller’s window to the left of the
F1-F4 function keys. They will slowly flash in red letters.
7-28 9/2005
Section 7
ELECTRICAL
There are also 2 LED’s between the function keys Use the scroll button to access the rest of the
and the window. The top LED is for “STATUS”, and is available run screens. The first time you scroll you will
red. If this LED is in a lighted condition, you have a see:
system fault. The fault may be either a “WARNING”
or a “STOP” fault. The bottom LED is for “POWER”
and is lighted green. 0 fpm : front 0 vpm
0 ipf : rear 0 vpm
You can increase, or decrease, a number using the
“FNR”. Push the “FNR” forward and press the “MAN
VIB” button to increase. Move the “FNR” to reverse Scroll once:
and press the “MAN VIB” button to decrease.
Numbers may also be changed using the F1 and F2
keys on the computer controller. F1 will increase and 12.1 Vbt :frnt 0 vpm
F2 will decrease the numbers. This will hold true on 4.9 Vsp :rear 0 vpm
all screens unless otherwise noted.
RUN SCREENS. Scroll once:
The first group of screens you will see when the

ignition key is turned on, will be the “RUN” screens. Auto vib. Set. = 3.0 mph
These screens are accessible to the operator for use Adj. With Control Handle
in setting the auto vibe, impacts per foot (ipf),
English, or metric and speed restrict. All adjustments
made on these screens will be made by using the Scroll once:
scroll button and the “MAN VIB.” button on the “FNR”.
The following is an exact screen by screen view of
what you will see when the ignition key is turned to Display units: English
the run position. To see these screens as they are Adj. With Man Vib. Sw
printed here be sure to have the brake switch applied,
throttle at low idle, speed range in low, water spray off
and the vibe mode off. Switches in other positions will Scroll once:
give you a different display.
Travel spd LMT = 5.0 mph

ADJ. WITH CONTROL HANDLE
Day - T a
Scroll once:
The screen will immediately change to:
FWD EDC TEST:ENGINE OFF!

BOMAG AMERICAS 66 in PUSH MANUAL VIBE. TO TEST
DD COMPACTOR Vx.xx
Note: The display will show either 66 in or 78 in after Scroll once:

COMPACTION AMERICA depending on the model of
the compactor.
REV EDC TEST:ENGINE OFF1
Followed by: PUSH MANUAL VIB. TO TEST
0.0 mph : front 0 vpm Scroll once to return to first screen. Press F4 to go
0 ipf : rear 0 vpm the next group of screens, which is the “LMTD”
screens.
9/2005 7-29
Section 7
ELECTRICAL
LMTD SCREENS. This capability is due to the fact that the computer
looks for values of potentiometers, and functions of
This is where the machine identification takes place. switches, as certain options are only allowed to
The computer controller programming is installed for happen under given conditions. For example, the
the 66 Inch and 78 Inch. vibration system[s] will not operate if the engine is at
low idle speed, and/or if the travel [high] transmission
Anytime a new computer controller is installed into a speed range is selected.
machine, correct machine selection must be done so
that the computer will know which set of values to When turning the pots, if the pots have an even
operate under. The computer controller default is to "sweep", they will be considered "OK".
the 78 Inch compactor.
The switches will also be considered "OK", if the
Identification is done by placing the “Machine Model”: display shows a function "change" when the switch is
-- in, on the top line of the display, and then using the activated.
F1 key to scroll through the 4 selections.
One thing that can help technical service personnel,
is the fact that the power wire that runs the computer
Machine model : 66 in controller, also goes to the voltmeter. If an instance
Save User RAM : NO exists where the machine is having a "surge" during
operation, check the voltmeter to see if it is indicating
erratic readings. If it is indicating erratic readings, this
is a symptom of machine electrical system problems.
Once the correct machine model is selected, press Check the machine grounds first.
the scroll button to put “Save User RAM: NO”, onto
the TOP line of the display. If the voltmeter reading is steady, the electrical
system is "OK".
Save User RAM : NO

NonVol vs RAM : Different VIBRATION POTENTIOMETERS [VIBE POTS].
Turn the ignition key to the run position, but keep the
engine off. Release the secondary/parking brake. Put
When the screen information is in the above position, the throttle in the high idle position. Put the vibe mode
push the F1 key. After pushing the F1 key, you will switch in manual, and the vibe selector switch in both.
see “DIFFERENT” change to “BOTH SAME”. The Slowly rotate the front, and then the rear, vibration
numbers are now locked in. frequency [speed] potentiometers individually, to
verify that you are getting a even sweep out of the
pot. If so, the pot is "good". If not, the pot is
Save User RAM : NO "damaged", and must be replaced with new.
NonVol vs RAM : Both Same
OTHER MONITORED SWITCHES [Except Water

Push F4 to go to the “INPT” group of screens. Spray On/Off Switch].
The following steps are valid for all switches, not

including the water spray mode switch:
INPT SCREENS.
HOW TO USE THE SYSTEM AS A DIAGNOSTIC

TOOL.
The computer control system will allow you to test the

function of the system control switches and pots,
except for the WATER SPRAY switch.
7-30 9/2005
Section 7
ELECTRICAL
Turn the ignition key to the “run” position. Once the VIBS SCREENS.
display is on the normal “run” screens, press F4 on
the computer controller. “LMTD”, in red letters will As stated earlier, technical service personnel should
appear in the computer controller window. Press F4 be able to put a new component (computer controller,
one more time to change the window to “INPT”. right hand FNR) onto the machine, and have it be
functional, with very little setup.
Use the scroll button located under the display panel,
to sequence through the switches. Change the Machine identification and right hand FNR calibration
position of each of the switches to verify the function should be all that is required. The machine will not be
of each switch. “dialed in”, but should be functional.
The following is a sequential order of the screens you

will see during the switch tests. Information in CAUTION: The vibration [vib] area of the setup
parenthesis are other positions that can be displayed: should be adjusted for correct vibe
speed, as the vibration systems
VPM’s will run extremely fast.
Vib. Function : Off (“Auto” “Man”)
Vib. Location : Both (“Front” “Rear”)
Any time a S2X computer controller is changed, the
existing numbers, held in the original computer
Push scroll button twice, and screen will read: controller, must be downloaded into the replacement
computer controller to simplify machine setup. There
are EIGHT [8] parameters to be set. They are listed
Handle Vib. PB : Off (On) as follows:
Neutral Sw. : On (Off)
FrntVib LALS Front Vibrator, Low Amplitude, Low Speed

Push scroll button twice, and screen will read: FrntVib LAHS Front Vibrator Low Amplitude, High Speed
FrntVib HALS Front Vibrator High Amplitude, Low Speed
FrntVib HAHS Front Vibrator High Amplitude, High Speed
RearVib LALS Rear Vibrator Low Amplitude, Low Speed
Park Brake : On (Off) RearVib LAHS Rear Vibrator Low Amplitude, High Speed
Vib. Amplitude : Low (High) RearVib HALS Rear Vibrator High Amplitude, Low Speed
RearVib HAHS Rear Vibrator High Amplitude, High Speed
Push scroll button twice, and screen will read:

The electronic control system operates on a Ma
current range of 0 to 100. Due to manufacturing
Motor Speed : Low tolerances in the pumps, variations in potentiometers,
Engine Speed : Low (High) and other manufactured components, the amount of
Ma current needed to control the vibrator pumps,
EDC’s, and thereby run the vibration systems at the
Push scroll button twice, and screen will read: correct speed, varies from machine to machine.
One tenth [.1], of 1 Ma current will cause an

Water Saver : ---.- % increase, or decrease, of approximately 12 VPM of
Vib. Function : Off pump output. As you can see, there is NO sure
predetermined value to adjust the "vibes" to. Verify
actual vibration system[s] VPM output by using a vib
Press F4 to go to the VIBS group of screens, which is tach. See the MACHINE SET UP, CALIBRATION
described in the following information, and fully AND ADJUSTMENT information given in this section,
covered under the "Lower Level" group of screens for information about vibe setup.
topic.
Press F4 to return to the RUN group of screens,
where this narrative began.
9/2005 7-31
Section 7
ELECTRICAL
LOWER LEVEL SCREENS. This will put the “VIBS” group of screens in the S2X
computer controller window.
CAUTION: ONLY trained, and/or authorized
technical service personnel are This is an area that is intended for trained and
intended to access this group of authorized technical service personnel to access.
screens. Replacement of the computer controller will require
For trained, and/or authorized techni- that these screens be accessed, and the EIGHT [8]
cal service personnel to access this highlighted numbers recorded before removal of
screen group, do the following: the computer controller. These eight [8] numbers
control all vibration start points and maximum run
Turn the ignition key to the “run” position, but keep speeds for the front and rear vibration systems.
the engine off. Depress and hold the “MAN VIB”
button and then the F3 key, on the computer Also, use the following screen informations to “final
controller. This will access a lower level of screens adjust” the front and rear vibration systems [vibe]
where authorized technical service personnel will be speeds, after computer controller replacement.
able to adjust, and lock in settings.
The following overview of screens is with the ignition
The following will give authorized personnel an key in the “run” position, but with the engine off. In the
overview of the screens, and the procedure for “fine case of the “VIBS” group of screens, the VIBRATOR
tuning” the settings. MODE selector switch is in the OFF position. The
following is a screen by screen view:
At this level there are eight [8] screens available.
Screens, in the order that they will appear in the Manual Vib. : Off
window on the computer are: RUN, LMTD, INPT, FrntVib LALS : - - - - Ma
VIBS, PROP, FNR, ACCEL and A/D.
These screens will be referred to as “groups” and will Scroll twice. You will see the following screen:
always be in the above order. All of these “groups”
have multiple levels within them, with the exception of
ACCL. To move from one “group” to the next “group”, FrntVib LAHS : - - - - Ma
use the F4 key on the computer controller. To move FrntVib HALS : - - - - Ma
within a given “group”, use the scroll button below the
display panel.
Scroll twice. You will see the following screen:
Information about the “RUN”, “LMTD” and “INPT”
screens was previously presented, and therefore will
not be covered here. FrntVib HAHS : - - - - Ma
RearVib LALS : - - - - Ma
The first screen seen in the window on the computer
controller, will be “RUN”. Press F4 on the computer
controller. Scroll twice. You will see the following screen:
This will put “LMTD” in the window. Press F4.

RearVib LAHS : - - - - Ma
This will put “INPT” in the window. Press F4 again. RearVib HALS : - - - - Ma
Scroll twice. You will see the following screen:
RearVib HAHS : - - - - Ma
F. Vib Cmnd : 0.0 Ma
7-32 9/2005
Section 7
ELECTRICAL
Scroll twice. You will see the following screen: Each of the blank lines on these screens will have a
3 digit number on it.
R. Vib Cmnd : 0.0 Ma Each number represents a value that was arrived at
Manual Vib. : Off during the calibration process at the factory. *
Scroll once to return to the beginning of the VIBS CAUTION: Installing a new right hand FNR onto
group of screens. the machine will change these
numbers from those that were
Press F4 on the computer controller. This will put installed into the S2X computer
“PROP” in the computer controller window. These controller at the factory, and will
four [4] highlighted numbers will need to be therefore require that the FNR cali-
recorded for S2X computer controller replacement. bration procedures be done.
The following is a screen by screen view for this
group:
Push F4 on the computer controller.
Fwd Max : - - - - D/A This will put “FNR” in the window. This screen deals
Rev Max : - - - - D/A with the status of the “FNR”. With the ignition key in
the “on/run” position, but with the engine NOT
running, and the FNR in neutral you will see the
Scroll twice. You will see the following screen: following screens:
Fwd Thresh : - - - - D/A FNR State : Neutral

Rev Thresh : - - -- D/A FNR Input : 0.0 %
Scroll twice. You will see the following screen: Scroll twice. You will see the following screen:
Propel Cmnd : 0 D/A FNR Cmnd : 0.0 %

Propel Comp : 0 D/A FNR Out : 0.000 V
Scroll twice. You will see the following screen: Scroll twice. You will see the following screen:
Actual VLDP : - - - - A/D FNR Out : 0 A/D

Raw Command : 0.0 % FNR State : Neutral
Scroll twice. You will see the following screen: * This is the number that the computer has
memorized, during the initial calibration and
setup at the factory, of the then current machine
Rate Ltd Cmnd : 0.0 % voltage. The computer controller constantly looks
Fwd Max : - - - - D/A at this number; comparing it to the now current
voltage output of the machine. It, in turn, will
adjust its output signals, to the EDC's, to
Scroll once, to go back to the first screen. compensate for voltage variations. This is the
number that enables the system to be voltage
compensating.
9/2005 7-33
Section 7
ELECTRICAL
Scroll once to return to the beginning. Push F4 on the Scroll twice. You will see the following screen:
computer controller.
This will put “ACCL” in the computer controller FNR Nbot : - - - - VDC
window. This group of screens sets the controllability FNR Min : - - - - VDC
of the machine and NO numbers, or additional screen
levels, are accessible in it. The only screen able to be
viewed in this group is shown below. Scroll twice. You will see the following screen:
Raw Command : 0.0% Saved VLdp : - - - - VDC *

Rate Ltd Command : 0.0% FNR Max : - - - - VDC
Press F4, on the computer controller. Press F4 on the computer controller to return to the
“RUN” group of screens, where you started.
This will put the last group of screens in the computer
controller window. It will be the “A/D” group of
screens. The FNR min/max output numbers, along
with the upper and lower neutral switch limits are
found within this screen group.
FIVE [5] highlighted numbers, from this screen

group must be recorded if replacement of the S2X
computer controller is required.
The following is a screen by screen view of this

group:
FNR Max : - - - - VDC

FNR Ntop : - - - - VDC
7-34 9/2005
Section 7
ELECTRICAL
CIRCUIT OPERATION. engine. When the engine starts and the ignition key
switch is returned to “ON [RUN]”, the number 2
STARTER CIRCUIT [See Figure 7-58]. position, the starter relay is de-energized, opening the
circuit to the starter motor.
The starter circuit includes the starter relay and
starter motor. When the starter relay is energized,
battery voltage is applied directly to the starter motor. ALTERNATOR CIRCUIT [See Figure 7-59].
The starter circuit requires the following:
The alternator operates whenever the engine is
a. The Ignition Key switch to be set to position 3 running and is used to supply recharging current to
“START”. the battery and to operate all the electrical circuits. At
normal engine rpm, the alternator provides an output
b. The Secondary/Parking Brake switch (BRAKE voltage slightly higher [13.8 - 14.5] nominal than the
switch) to be “ON” [brake applied]. battery voltage. This voltage is applied back through
wire A to the positive terminal of the battery to
c. The Forward-Neutral-Reverse (FNR) control to recharge the battery. At the same time alternator
be in the Neutral position. voltage is applied to the ignition key switch BATT
terminal. In the “ON [RUN]” position of the ignition key
The battery positive [+] terminal is connected to the switch, the voltage is connected through the ACC
main terminal on the starter solenoid with a 2 gauge terminal and wire ZZZ to the shutdown relay and
cable. This terminal is also used as a tie point for the indicators on the control panel. The voltage is, also,
+12 VDC battery cable. The battery voltage from the connected through the IGN terminal and wire YYY to
main terminal on the starter solenoid is connected all other circuits except the following:
through wire “B” to the BATT terminal on the ignition
key switch. When the ignition key switch is in the Optional Night Paving Lights
“START” position, voltage is connected through wire Backup alarm
Q and a 15-amp fuse to terminal 4 on the brake Water Spray Pumps
switch. The brake switch must be in the “ON” Panel Lights
[applied] position to start the engine. When the brake Headlights
switch is in the “ON” [applied] position, the voltage is Hazard and Turn Lights
connected through the switch from terminal 4 to Horn
terminal 3. The voltage at terminal 3 is routed through
wire Z, then through connector terminal J1-C and wire These circuits connect directly to the battery via the
EW, to connector P1-7. The voltage at P1-7 is power panel located in the compartment under the
connected to the normally closed contact of neutral steering wheel and do not go through the ignition key
start limit switch LMSW1 on the FNR control. If the switch.
FNR control is in “Neutral”, the voltage is connected
through the normally closed contact to the common
contact. The voltage from the common contact is
connected through connector P1-6, harness wire EV,
connector J1-D, and through wire S to coil terminal 86
on the starter relay. Relay terminal 85 is connected to
chassis ground. Chassis ground is connected directly
to the negative side of the battery. With battery
positive voltage at terminal 86 and battery negative at
terminal 85, current flows through the starter relay
energizing the relay. Battery voltage is then
connected from the main terminal on the starter
through wire AF and the closed relay contacts 30 and
87 to the S terminal on the starter motor solenoid
causing the starter motor to operate and start the
9/2005 7-35
Section 7
ELECTRICAL
ALTERNATOR
0
BY
DG
BATTERY
DISCONNECT
FIGURE 7-58. START CIRCUIT
7-36 9/2005
Section 7
ELECTRICAL
IGNITION
FIGURE 7-59. ALTERNATOR CIRCUIT
9/2005 7-37
Section 7
ELECTRICAL
HORN CIRCUIT [See Figure 7-61]. HEADLIGHTS.
The horn circuit is operated by a push button located Battery voltage is connected to the starter solenoid
on the control panel. main post, then connected through wire FG to the
battery terminal on a 30-amp circuit breaker F5, then
Battery voltage is connected through wire XXX to through wire FL to an options positive battery post,
circuit breaker F1 BATT terminal. From F1 AUX then connected to wire FM, then to contacts 87 on the
terminal, the voltage is connected through wire FF to high beam and low beam relays. If the “light” switch is
the horn switch. When the horn switch is pressed, in the “OFF” position, the relays are de-energized and
voltage is connected through wire EE to one side of the voltage can not be applied to the headlights.
the horn. The other side of the horn is connected
back to the negative side of the battery. With voltage LOW BEAM.
connected across the horn, the horn will sound until
the horn button is released. Battery voltage is also connected through wire XXX to
20-amp circuit breaker F1. The voltage from circuit
HEADLIGHTS AND DASH (GAUGE) LIGHTS breaker F1 is connected through wire JJ to the “light”
[See Figure 7-62]. switch. When the “light” switch is in the “low beam”
position, contacts B-A close, connecting voltage
The headlight and gauge light circuit consists of a through wire FP to terminal 85 on the low beam relay.
high current circuit for the headlights and a lower Relay contact 86 is connected to battery negative.
current circuit for the gauge lights and the high and The voltage across the relay coil energizes the relay
low beam relays. closing contacts 87 and 30. The voltage at contact 30
is connected to one side of the low beam light in each
headlight. The other side of the low beam headlight is
connected to battery negative and the low beam is
illuminated.
FIGURE 7-61. HORN CIRCUIT
7-38 9/2005
Section 7
ELECTRICAL
HIGH BEAM. front, and right rear turn lights. The other side of the
lights connects back to battery negative and the lights
Battery voltage is applied through wire XXX to 20- are illuminated. With current flowing through the
amp circuit breaker F1. The voltage from circuit element in the flasher, heating occurs causing the
breaker F1 is connected through wire JJ to the “light” flasher to open the circuit, turning the lights off. With
switch. When the “light” switch is in the “high beam” the lights off, the element cools and again closes the
position, contacts B-H close, connecting voltage circuit to contact 49A. This action [flashing] continues
through wire FQ to terminal 85 on the high beam as long as the turn indictor lever is in the right turn
relay. Relay contact 86 is connected to battery position.
negative. The voltage across the relay coil energizes
the relay closing contacts 87 and 30. The voltage at LEFT TURN INDICATOR CIRCUIT.
contact 30 is connected to one side of the high beam
light in each headlight. The other side of the high Battery voltage is connected through wire FG to 30-
beam headlight is connected to battery negative and amp circuit breaker F5 BATT terminal. The voltage
the high beam is illuminated. from circuit breaker F5 AUX terminal is connected
through wire FL and FM to terminal 49 on the flasher.
GAUGE LIGHTS. When the turn indicator lever, on the steering column,
is set for a left turn, voltage is connected from the C
The “light” switch chart shows that if the “light” switch terminal on the flasher through wire FK and the turn
is set to the high beam or low beam positions, indicator lever to wires GG going to the left front and
contacts B and R close connecting voltage through left rear turn lights. The other side of the lights
wires PP to the gauge lights. The other side of the connects back to battery negative and the lights are
gauge lights is connected to battery negative causing illuminated. With current flowing through the element
the gauge lights to be illuminated. in the flasher, heating occurs causing the flasher to
open the circuit, turning the lights off. With the lights
TURN SIGNALS [SEE FIGURE 7-63]. off, the element cools and again closes the circuit to
contact 49A. This action [flashing] continues as long
The turn signal and hazard light circuit includes the as the turn indictor lever is in the left turn position.
turn signal flasher mounted on the power panel, the Terminal C is connected to the indicator light on the
turn signal lever mounted on the steering column, the switch through wire FN. The indicator light flashes in
hazard light switch, and the front and rear, left and all modes.
right turn indicators.
HAZARD LIGHT CIRCUIT.
RIGHT TURN INDICATOR CIRCUIT.
Battery voltage is connected through wire FG to 30-
Battery voltage is connected through wire FG, to 30- Amp circuit breaker F5 BATT terminal. The voltage
amp circuit breaker F5 BATT terminal. The voltage from circuit breaker F5 AUX terminal is connected
from circuit breaker F5 AUX terminal is connected through wire FL and FM to terminal 49 on the flasher.
through wire FL to the options positive post on the When the hazard switch is turned on voltage from
power panel. The voltage is then connected through terminal 49A of the flasher is connected through the
wire FM to terminal 49 on the turn signal flasher. hazard switch to both the left and right turn indicators.
When the turn Indicator lever, on the steering column, The flasher operates in the same manner as for the
is set for a right turn, voltage is connected from the turn indictor except both left and right lights are
49A terminal on the flasher through wire FK and the switched off and on.
turn indicator lever to wires HH going to the right
9/2005 7-39
Section 7
ELECTRICAL
FIGURE 7-62. HEADLIGHT AND GAUGE LIGHT CIRCUITS
7-40 9/2005
Section 7
ELECTRICAL
FIGURE 7-63. TURN LIGHT AND HAZARD LIGHT CIRCUIT
9/2005 7-41
Section 7
ELECTRICAL
SECONDARY/PARKING BRAKE CIRCUIT to one side of the brake solenoid. The other side of
[See Figure 7-64]. the brake solenoid is internally grounded. With
voltage applied across the brake solenoid, the
The secondary/parking brake circuit includes the solenoid is energized, releasing the brake.
brake switch, brake solenoid, and a computer
controller. At the same time a second set of contacts on the
brake switch are closed. This connects +5 VDC
Battery voltage is connected to the main post on the sensor power from computer controller terminal P1-
starter solenoid. The voltage is then connected E1 through connector J1-J and wire EY to terminal 1
through wire B to the BATT terminal on the ignition of the brake switch. The voltage is connected through
key switch. When the key switch is in the “ON [RUN]” the brake switch to terminal 2, then through wire EZ
position the voltage is connected through the ACC and connector J1-K to the computer controller analog
terminal and through wire ZZZ to circuit breaker F2 IN 3 input at P1-C2. When P1-E1 is connected to P1-
BATT terminal. Voltage from the circuit breaker AUX C2, the logic in the computer allows forward or
terminal is connected through wire BBB to brake reverse motion. An open circuit sets a zero speed
switch terminal 1. When the brake switch is “Off command to the propel circuit, preventing drive to the
[released]”, the voltage is connected through wire LLL traction motors.
FIGURE 7-64. SECONDARY/PARKING BRAKE CIRCUIT
7-42 9/2005
Section 7
ELECTRICAL
WATER SPRAY CIRCUIT [See Figure 7-65]. AUTO MODE.
The water spray circuit has both a MANUAL and an When the water spray auto/off/manual switch is in the
AUTO mode. In the MANUAL mode, the front and AUTO position, the +12 V, 3A digital out 3 signal from
rear spray motors provide a continuous spray. In the the computer controller terminal P2-E3, is then
AUTO mode, the spray motors are turned on and off connected through wire ES, then through connector
automatically by the computer controller. The J1-F and wire R to the AUTO contact on the water
computer controller only turns the spray on when the spray auto/off/manual switch. The +12 V digital out 3
vehicle is in motion. The duty cycle, [On vs. Off time], signal is turned “On” and “Off” by the computer
in the AUTO mode, is controlled by the water saver controller logic, depending on the setting of the water
potentiometer, on the display panel. saver control and will only be present when the
machine is moving. The water saver control is
MANUAL MODE. connected from sensor ground at computer controller
terminal P2-G3 to +5 VDC sensor power at computer
Battery voltage is connected through wire B to the controller terminal P1-G1. The wiper arm of the water
BATT terminal on the ignition key switch. When the saver control provides an adjustable variable voltage
ignition key switch is in position 2 “ON [RUN]” level to computer controller terminal P1-K2. This is
position, the voltage is connected through wire ZZZ to the pulse pickup 1 signal and controls the on/off
the 20-amp circuit breaker F2, then through wire E to cycling at computer controller output terminal P2-E3
terminal 3 on the water spray auto/off/manual switch for a duty cycle of 0-50%. This signal is applied
located on the control panel. When the switch is set through the water spray auto/off/manual switch
to the MANUAL position the voltage is connected AUTO contact and wire T to switch the water spray
through wire T to coil terminal 85 on the water spray relay on and off. When the relay is energized [on],
relay. Terminal 86 on the relay is connected to battery the voltage is connected through contacts 87-30 and
negative, energizing the relay. Battery voltage is now wires KK to the front and rear spray motors to
connected through wire FG, circuit breaker F6, and operate the motors. When the relay is de-energized
wire FJ to terminal 87 on the water spray relay. Since [off] contacts 87-30 open, stopping the spraying.
the relay is energized, the voltage is connected
through contacts 87-30 and wire KK to the front and
rear spray motors to operate the motors.
9/2005 7-43
Section 7
ELECTRICAL
FIGURE 7-65. WATER SPRAY CIRCUIT
7-44 9/2005
Section 7
ELECTRICAL
GAUGES AND INDICATORS [See Figure 7-66]. h. To the IGN terminal of the water temperature
gauge on the gauge panel. The other side of the
The gauge and indicator circuit provides operating water temperature gauge is connected through
voltage to all the gauges and indicators and also wire C to the water temperature sensor unit on
supplies the operating voltage for the S2X computer the engine to monitor the water temperature.
controller.
i. To one side of the hydraulic oil filter light on the
Battery voltage is connected to the main post on the control panel. The other side of the light is
starter solenoid. The voltage is then connected connected through wire VV to the oil pressure
through wire B to the BATT terminal on the ignition sensor switch and to a diode. When the ignition
key switch. When the switch is in position 2 “ON key switch is in the START position, the diode is
[RUN]”, voltage is connected through the IGN connected to ground through the ignition key
terminal and wire YYY to the BATT terminal on circuit switch GND contact. This causes the light to
breaker F3. The voltage from circuit breaker F3 AUX illuminate at start-up, thus insuring that the light
terminal is connected through wire L as follows: is working. When the engine starts, and the
ignition key switch is returned to the “ON [RUN]”
a. To terminal 85 of the shutdown relay to energize position. The GND contact opens, removing the
the relay and allow fuel to flow to the engine. ground connection and turning the light off. If the
oil filter is becoming clogged, the change in
b. To the S2X computer controller through pressure closes the oil pressure switch at 16
connector J1- A, wire ET, then to computer PSID. The light is now connected to ground
controller connector pin P2-F1 providing through wire VV and the oil pressure switch to
operating voltage for the computer controller. indicate a clogged oil filter problem.
c. To the positive [+] terminal of the hourmeter on j. To one side of the air filter light on the control
the gauge panel. The hourmeter records the panel. The other side of the light is connected
operating time for the machine. through wire UU to the vacuum pressure sensor
switch and to a diode. When the ignition key
d. To the voltmeter positive [+] terminal of the switch is in the START position, the diode is
Voltmeter on the gauge panel. The voltmeter connected to ground through the ignition key
indicates the battery voltage or alternator voltage, switch GND contact. This causes the light to
which ever is higher. illuminate at start-up, thus insuring that the light
is working. When the engine starts, and the
e. To the IGN terminal of the oil temperature gauge ignition key switch is returned to the “ON [RUN]”
on the gauge panel. The other side of the oil position. The GND contact opens, removing the
temperature gauge is connected through wire J ground connection and turning the light off. If the
to the oil temperature sensor unit on the engine air filter is becoming clogged, the vacuum switch
to monitor the hydraulic oil temperature. closes when the vacuum is in excess of 20” H2O.
The light is now connected to ground through
f. To the IGN terminal of the fuel gauge on the wire UU and the air pressure switch, turning the
gauge panel. The other side of the fuel gauge is light on to indicate a dirty air filter problem.
connected through wire WWW to the fuel level
sensor unit on fuel tank to monitor the fuel level.
g. To the IGN terminal of the oil pressure gauge on

the gauge panel. The other side of the oil
pressure gauge is connected through wire D to
the oil pressure sensor unit on the engine to
monitor the oil pressure.
9/2005 7-45
Section 7
ELECTRICAL
S2X
FIGURE 7-66. GAUGES AND INDICATORS CIRCUIT
7-46 9/2005
Section 7
ELECTRICAL
THROTTLE CIRCUIT [See Figure 7-67]. The second set of contacts on the throttle switch
[contacts 5 and 6] control the voltage level of the
The throttle circuit includes the throttle switch and the digital input 6 signal on the S2X computer controller.
S2X computer controller. When the throttle switch is in the RUN position,
chassis ground is connected through throttle switch
When the throttle switch is activated the circuit is contacts 5 and 6, then through wire DP and connector
completed between connector B20 and B28 on the pin J1-H to the S2X computer controller connector
ECM “B” Connector. This signals the S2x controller pin P2-E2 as the digital input 6 signal. When the
computer to send the engine to high idle. throttle switch is in the idle position, the ground is
removed and the digital input 6 signal at connector
P2-E2 is at a +5 VDC level due to an internal pull up
resistor. The digital input 6 signal is used by the
computer controller to select the speed data to be
transmitted to the 2 x 24 display.
FW
B20
ECM “B” CONNECTOR
Y
B28
S2X
FIGURE 7-67. THROTTLE CIRCUIT
9/2005 7-47
Section 7
ELECTRICAL
SPEED RANGE CIRCUIT [See Figure 7-68]. through wire RRR to one side of the speed valve
solenoid. The other side of the speed valve solenoid
The speed range circuit includes the speed range [2- is connected to the chassis through an internal
speed] switch, speed valve solenoid, and the S2X ground, causing the solenoid to be energized. The
computer controller. The low speed range is used for energized solenoid sets the speed range to the “High
the “Work” mode and has a speed range of 0-5 MPH [Travel]” position.
at high engine speed. The high range is used for
“Transport [Travel]” mode and has a speed range of The second set of contacts on the speed range
0-10 MPH at high engine speed. switch [contacts 5 and 6] control the voltage level of
the digital input 7 signal on the S2X computer
Battery voltage is applied through wire B to the BATT controller. When the speed range switch is in the
terminal on the ignition key switch. When the switch is “High [Travel]” position, chassis ground is connected
in position 2 “ON [RUN]”, the voltage is connected to through speed range switch contacts 5 and 6, then
the ACC contact, then through wire ZZZ to 20-amp through wire DT and connector J1-G to the S2X
circuit breaker F2. The voltage is then connected computer controller connector pin P1-E2 as the digital
through wire P to terminal 2 of the speed range input 7 signal. When the speed range switch is in the
switch. In the “Low [Work]” position, no voltage is “Low [Work]” position, the ground is removed and the
applied to the speed valve solenoid and the solenoid digital input 7 signal at connector P1-E2 is at a +12
remains de-energized. When the speed range switch VDC level due to an internal pull up resistor. This
is set to the “High [Travel]” position, the voltage is signal tells the computer controller what speed has
connected through the switch contacts 2 and 3, then been selected.
FIGURE 7-68. SPEED RANGE CIRCUIT
7-48 9/2005
Section 7
ELECTRICAL
VIBRATION SYSTEM CIRCUIT [See Figure 7-69]. VIBRATION SPEED (FREQUENCY) CONTROLS
[See Figure 7-69].
NOTE: The engine throttle run [high]/idle [low]
switch must be in the RUN position and The vibration speed [frequency] can be set
the transmission speed range switch independently for the front and rear drums. For the
must be in the work [low] position to 66 Inch the vibration frequency can be set for 2000-
operate either, or both, drum vibration 3400 VPM. For the 78 Inch vibration frequency can
systems. be set for 2000-3400 VPM. The vibration speed are
processed within the computer controller and
The vibration system circuit includes the following: displayed on the 2 x 24 data display module.
a. Front vibe speed and rear vibe speed The front vib speed control is a 1-kohm
potentiometers located on the display assembly. potentiometer. +5 VDC sensor power from the
These potentiometers control the vibration speed computer controller connector pin P1-F1 is connector
[frequency]. through wire DZ and connector pin A to one side of
the front vib speed control. Sensor ground from
b. The amplitude high/low switch located on the computer controller connector pin P1-F3 is connector
display assembly. This switch selects one, of through wire EA and connector pin C to the other side
two, amplitude levels for the vibrations. of the front vib speed control. The wiper arm of the
front vib speed control is connected through
c. The drum select front/both/rear switch located on connector pin B and wire FE to the pulse pickup 0
the display assembly. This switch selects the input at P1-H2 on the computer controller. The
drum[s] to be vibrated [front, rear, both]. voltage at the wiper arm can vary from ~0.5 to ~4.5
VDC. The computer controller uses the voltage level
d. The vibrator mode auto/off/man switch located to set the speed of the front vibrations.
on the display assembly. This switch determines
whether the vibrations are turn off, operated The rear vib speed control is a 1-kohm potentiometer.
automatically [AUTO] or operated manually +5 VDC sensor power from the computer controller
[MAN]. connector pin P1-C1 is connector through wire DS
and connector pin A to one side of the rear vib speed
e. The left and right “vibration on/off” push buttons control. Sensor ground from computer controller
are used only in MANUAL operation to turn the connector pin P1-C3 is connector through wire DU
vibrations on or off. These thumb-operated push and connector pin C to the other side of the rear vib
buttons are located on top of the left and right speed control. The wiper arm of the rear vib speed
FNR controls. control is connected through connector pin B and wire
EC to the pulse pickup 3 input at P1-G2 on the
f. The front and rear vibration coils, which are computer controller. The voltage at the wiper arm
attached to the front and rear drums to vibrate can vary from ~0.5 to ~4.5 VDC. The computer
the drums. controller uses the voltage level to set the speed of
the rear vibrations.
All vibrator switches, potentiometers and the vibration
coils are connected to the S2X computer controller.
The computer controller processes the inputs and
controls the output to the front and rear Vibrator
pumps electronic displacement controls [EDC’s]. The
front and rear vibration coils control hydraulic oil flow
to the front and rear vibration motors.
9/2005 7-49
Section 7
ELECTRICAL
FIGURE 7-69. VIBRATION CIRCUIT
7-50 9/2005
Section 7
ELECTRICAL
AMPLITUDE CONTROL. Sensor ground at computer controller pin P1-E3 is
connected through wire DY to the common contact on
The high/low amplitude switch selects the amplitude the three-position vibrator mode switch. When the
of the vibrations going to the front and rear drums. +5 switch is set to the AUTO position, the sensor ground
VDC sensor power from computer controller is connected through wire EM and computer
connector pin P1-B1 is connected through wire DR to controller connector pin P2-C2 as “Digital Input 0”.
terminal 2 of the high/low amplitude switch. When the This input selects Auto operation. When the switch is
switch is set to HIGH, the +5 VDC sensor power is set to the MAN position, the sensor ground is
connected through wire EF as the Pulse Pickup 1 connected through wire EP and computer controller
input at computer controller connector pin P1-J2. This connector pin P2-D3 as “Digital Input 1”. This input
input shifts the amplitude to the “High” amplitude selects Manual operation. When the switch is set to
condition. When the switch is set to the LOW OFF, neither digital inputs are connected and no
position, the switch is an open circuit and the +5 VDC vibration occur.
sensor power is not connected to pulse pickup 1 input
at computer controller connector pin P1-J2. This MANUAL VIBRATOR CONTROL.
shifts the amplitude to the “Low” amplitude condition.
The vibrator “On/Off” push-button switches, located
DRUM SELECTION CONTROL. on the top of the left and right FNR controls, function
only when the vibrator mode switch is in the MANUAL
Selection of where the vibrations are applied is position. Sensor ground is connected from computer
determined by the setting of the front/both/rear drum controller connector pin P1-A3, through wire DQ and
switch. Sensor ground, at computer controller pin P1- connector pin 1 to one side of the left vibrator “On/
E3, is connected through wire DY to the common Off” switch. Sensor ground is also connected from
contact on the three-position front/both/rear drum computer controller connector pin P1-D3, through
switch. When the switch is set to the FRONT wire DX and connector pin 2 to one side of the right
position, the sensor ground is connected through wire vibrator “On/Off” switch. When either vibrator “On/Off”
EH and computer controller connector pin P2-A1 as push-button switch is pressed, sensor ground is
“Digital Input 2”. When ground is applied at this input connected though wire EJ to computer controller
only, the front drum will be vibrated. When the switch connector pin P2-B1 as “Digital Input 5”. Each time
is set to the REAR position the sensor ground is either switch is pressed, the computer controller
connected through wire EL and computer controller changes the state of the vibration. If the switch is
connector pin P2-C1 as “Digital Input 3”. When pressed, the vibes will come on if the switch is
ground is applied at this input, only the rear drum will pressed again the vibes will shut off. The vibrations
be vibrated. When the switch is set to the BOTH are applied to the front, rear or both drums depending
position, the sensor ground is not connected to either on the position of the DRUM switch.
input and both drums will vibrate.
VIBRATION COILS.
VIBRATOR MODE CONTROL.
When the computer controller processes the various
Selection of Auto, or Manual, operation is determined input signals, it provides a high current output that is
by the setting of the vibrator mode switch. If the applied to the vibration coils at the selected amplitude
vibrator mode switch is in the AUTO position, the and frequency [speed].
vibrators will come on when the machine speed
exceed a preset speed and go off when it drops Operating current for the front vibration coil is the
below that value. This value can be adjusted between servo out 1 [+] signal that is applied from computer
0.5 MPH and 5.0 MPH. The computer controller controller connector pin P1-K1 through wire DA and
provides two vibration lockouts. There is a lockout connector pin A to one terminal on the front vibration
which locks out vibrations in both the Auto and coil. The other terminal on the front vibration coil, is
Manual modes if the speed range switch is set to connected through connector pin B, then through wire
HIGH. There is an additional lockout which locks out DB and computer controller connector pin P1-K3 as
vibrations in both the Auto and Manual modes if the the servo out 1 [-] return path for the vibration coil.
throttle switch is set to LOW.
9/2005 7-51
Section 7
ELECTRICAL
Operating current, for the rear vibration coil, is the 7-70, is between 2.25 VDC and 2.74 VDC, centered
servo out 0 [+] signal that is applied from computer at 2.49 VDC. Note that these voltage levels will vary
controller connector pin P1-J1 through wire DJ and from machine to machine. In this position neither the
connector pin A to one terminal on the rear vibration Forward, or Reverse, relays are energized and the
coil. The other terminal, on the rear vibration coil, is machine will not be propelled. This is the “Neutral”
connected through connector pin B, then through wire position required for starting the machine. Propel limit
DK and computer controller connector pin P1-J3 as switch LMSW2 is an open circuit in the “Neutral”
the Servo Out 0 [-] return path for the vibration coil. position. The computer controller digital input 4, at
computer controller connector pin P2-D2, looks at the
DIRECTIONAL CONTROL CIRCUIT position of the propel limit switch through wire EN.
(See Figure 7-71). When the FNR control is moved in the forward, or
reverse, direction, a point is reached where the propel
The directional control forward-neutral-reverse [FNR] limit switch closes, applying sensor ground to the
circuit includes the left and right FNR controls, digital 4 input, at P2-D1. This signals the computer
located on the dash panel, the forward relay, the that the FNR control is out of the “Neutral” range and
reverse relay, and the traction coils. releases the traction circuit to propel the machine.
The position of the potentiometer, must be calibrated
Forward direction of travel is selected by moving with the switch point, of the propel limit switch, to
either the left, or right, hand FNR control forward. provide a smooth transition from no movement to
These controls can move a maximum of 30 degrees movement.
forward, or backwards, from the center or neutral
position. The further forward the control is moved the FORWARD PROPULSION.
higher the rate of speed. Reverse direction, of travel,
is selected by moving either the left, or right, speed As the handle is moved forward and the voltage at the
control backward. The further backward the control is wiper arm exceeds 2.74 VDC, the 3A digital out 1,
moved the higher the rate of speed. The speed is signal becomes a +12 VDC output connected through
determined by the position of a potentiometer that is computer controller connector pin P2-D2, then
located in the right FNR speed control. The left speed through wire DE to terminal 86 on the forward
control is mechanically linked to the right. When the solenoid. Solenoid terminal 85 is connected through
speed control handles are centered the transmission wire FD to the sensor Gnd at computer controller
is in “Neutral”. This is the position the control must be connector pin P1-H3. This causes the relay to be
in when starting the machine. energized. The PWM signal [0 - 120 Ma] digital output
0, at computer controller connector pin P2-F3 is
The FNR control sets the position of the 1 k ohm connected through wire FC and the closed contacts
FNR potentiometer. Sensor Gnd, at computer 30 and 87 of the forward relay, then through
controller connector pin P1-D3, is connected through connector pin A to the forward traction coil. The other
wire DX and connector pin 2 to one side of the FNR side of the forward traction coil is connected through
potentiometer. +5 VDC sensor power, at computer connector pin B and wire DD to the sensor Gnd at
controller connector pin P1-D1, is connected through computer controller connector pin P1-B3 causing the
wire DV and connector pin 4 to the other side of the forward traction valve to start to open. As the handle
FNR potentiometer. The FNR handle controls the is moved further forward, toward 4.88 VDC, the valve
position of the wiper arm and the wiper arm is will open further until maximum speed is reached. As
connected through connector pin 5, then through wire the handle is moved back, decreasing the voltage, the
DW, as the Analog In 1 Input, at computer controller machine will be propelled at a slower rate. When the
connector pin P1-D2. The Analog In 1 input has a voltage drops below 2.74 VDC, the system is in
voltage range from ~0 VDC to ~5 VDC. The handle “Neutral”, the forward relay is de-energized, and no
[potentiometer] output voltage vs position is shown in forward propulsion occurs.
Figure 7-70. The neutral position, as shown in Figure
7-52 9/2005
Section 7
ELECTRICAL
BACKWARD PROPULSION. the reverse relay, then through wire DH and
connector pin D to the reverse traction coil. The other
As the handle is moved backward and the wiper arm side of the reverse traction coil is connected through
voltage drops below 2.29 VDC, the 3A digital out 2, connector pin C and wire DD to the sensor gnd at
signal becomes a +12 VDC output connected through computer controller connector pin P1-B3 causing the
computer controller connector pin P2-F2, then reverse traction valve to start to open. As the handle
through wire EC to terminal 86 on the reverse relay. is moved further backward, toward 0.36 VDC, the
Relay terminal 85 is connected, through wire FD, to reverse valve will open further until maximum reverse
the sensor gnd at computer controller connector pin speed is reached. As the handle is moved forward,
P1-H3. This causes the relay to be energized. The increasing the voltage, the machine will be propelled
PWM [0 - 120 Ma] Digital Out 0 output, at computer at a slower rate. When the voltage exceeds 2.25
controller connector pin P2-F3, is connected through VDC, the system is in “Neutral”, the reverse relay is
wire FC and the relay closed contacts 30 and 87 of de-energized, and no backward propulsion occurs.
FIGURE 7-70. VOLTAGE OUTPUT VS HANDLE POSITION
9/2005 7-53
Section 7
ELECTRICAL
FIGURE 7-71. DIRECTION CONTROL [FNR] CIRCUIT
7-54 9/2005
Section 7
ELECTRICAL
MAT TEMPERATURE SENSOR CIRCUIT connected through wire YYY to the BATT terminal on
(See Figure 7-72). the 20-amp circuit breaker F3. The voltage from the
AUX terminal of circuit breaker F3 is then connected
The mat temperature sensor circuit includes the mat through wire L, connector pin J1-A and wire ET to the
temperature sensor and the S2X computer controller. +12 VDC input of the mat temperature sensor unit.
The temperature sensor is positioned just above the sensor ground from the computer controller is
mat and monitors the mat surface temperature. The connected through connector pin P1-E3 and wire DY,
output is an analog signal representing the present then through connector pin 2 to the GND terminal on
temperature level. This signal is sent to the computer the mat temperature sensor. The analog sensing
controller and processed. The temperature output signal from the temperature sensor is
information is then transmitted through an RS-232 connected through connector pin 1 and wire DG as
loop from the computer controller to the data display the analog IN 2 signal to connector P1-F2 on the
unit. computer controller. This input is processed in the
computer controller and applied out on the
Battery voltage is connected through wire B to the TRANSMIT DATA output line at connector pin P3-A
BATT terminal on the ignition key switch. When the and sent to the data display module.
switch is in position 2 “RUN [ON]”, the voltage is
S2X
FIGURE 7-72. MAT TEMPERATURE SENSOR CIRCUIT
9/2005 7-55
Section 7
ELECTRICAL
DISPLAY CIRCUIT [See Figure 7-73]. BACKUP ALARM CIRCUIT [See Figure 7-71].
The display circuit includes the scroll push button, the The backup alarm circuit includes the backup relay, a
S2X computer controller and the 2 x 24 data display 15-amp fuse and the backup alarm.
module.
The backup relay is connected across the reverse
Battery voltage is connected through wire B to the relay. Whenever the reverse solenoid is energized,
BATT terminal on the ignition key switch. When the the backup solenoid will also be energized. When the
switch is in position 2 “ON [RUN]”, the voltage is computer controller, 3A digital out 2 signal from
connected through wire YYY to the BATT terminal of computer controller connector pin P2-F2 is at 12 VDC
the 20-amp circuit breaker F3. The voltage from the [machine in reverse] the 12 VDC is applied to
AUX terminal, of the 20-amp circuit breaker F3, is terminal 86 of the backup relay. With terminal 85 of
then connected through wire L, connector pin J1-A, the relay connected through wire FD to battery
and wire ET to the +12 VDC input, at connector pin negative, the backup relay is energized. +12 VDC
P2-F1 on the S2X computer controller. The voltage is from the battery is connected at terminal 87 of the
also connected to the 5-30 VDC input, at connector backup relay. With the backup relay energized, the
pin 6, on the 2 x 24 data display module. Battery battery voltage is connected through a 15-amp fuse,
negative is connected through wire G, connector pin then through wire EU connector pin J1-E and wire
J1-B, wire EQ and pin P2-E1 to the computer AAA to the backup alarm. The other side of the
controller completing the power input circuit to the backup alarm is connected internally to chassis
computer controller. The ground connection, for the 2 ground, causing the alarm to sound. When the
x 24 data display, is through two wires from the machine FNR control is moved out of reverse, the
computer controller. One connection is “Gnd Out” at relay terminals 87-30 open and the alarm stops.
computer controller pin P3-F, then through wire DN
and data display connector pin 1. The second OPTIONAL CIRCUITS.
connection is “Gnd Out”, at computer controller pin
P3-D, then through wire DM and data display WORKLIGHTS [NIGHT PAVING LIGHTS] CIRCUIT
connector pin 2 and 4. [See Figure 7-74].
Data is transmitted to the 2 x 24 data display on the The work [night paving light] circuit includes the front
“Transmit Data” line, from computer controller and rear work light relays and the front and rear work
connector P2-A, then through wire DL and data lights.
display connector pin 5.
Battery voltage is connected through wire B to the
Data scrolling is controlled by the scroll push button. BATT terminal on the ignition key switch. When the
+5 VDC sensor power is applied out computer switch is in position 2 “ON [RUN”, the voltage is
controller connector pin P1-A1, and through wire EX, connected through the ACC switch contact, then
to one side of the scroll push button. When the scroll through wire ZZZ to the 20-amp circuit breaker F2.
push button is pressed, the voltage is connected The voltage is then connected through wire FU to the
through the switch and wire ER, then connected to “Working Light ON/OF” switch. When the switch is in
computer controller connector pin P1-A2, as the the “ON” position, voltage is connected to terminal 85
analog IN 0-signal input. Each time the scroll button is on both of the work light relays. Terminal 86 of the
pressed the next line of data is transferred from the relays is connected to battery negative. The voltage
computer controller to the data display. across the relays causes the relays to be energized.
Battery voltage is, also, applied through wires FT to

30-Amp circuit breakers F8 and F9. The voltage, at
circuit breaker F8, is connected via wire FR, the
closed contacts 30 and 87 of Work Light relay K10,
and wire FS to three of the work lights. The voltage,
at circuit breaker F9, is connected via wire FR, the
closed contacts 30 and 87 of work light relay K11, and
wire FR to three [3] of the work lights and one [1]
dome light.
7-56 9/2005
Section 7
ELECTRICAL
FIGURE 7-73. DISPLAY CIRCUIT
9/2005 7-57
Section 7
ELECTRICAL
FIGURE 7-74. WORK LIGHTS CIRCUIT
7-58 9/2005
Section 7
ELECTRICAL
ELECTRICAL COMPONENTS REMOVAL AND BATTERY.
INSTALLATION.
The battery, Figure 7-75, is located in the battery
Procedures for the removal and installation of all compartment on the left side of the machine.
electrical components are provided in this section. Proceed as follows to remove and install the battery.
Although some components can be removed or
installed without disconnecting the battery, it is a Removal
good practice to disconnect the battery for all
component replacements. Some components receive WARNING: BATTERY EXPLOSION CAN OCCUR
operating power through the ignition key switch. If the IF THE BATTERY IS SHORTED.
ignition key switch is shorted, power may be applied ALWAYS disconnect the NEGATIVE
to the component unexpectedly resulting in a [-] battery cable FIRST, and then
dangerous shock condition. DO NOT DEPEND ON disconnect the POSITIVE [+] battery
JUST TURNING THE IGNITION KEY SWITCH OFF, cable. NEVER make a short circuit
DISCONNECT THE BATTERY BEFORE between the positive [+] and negative
REMOVING OR INSTALLING A COMPONENT. [-] terminals of the battery.
WARNING: Disconnect the negative battery

cable first from the negative terminal 1. Disconnect the negative [-] battery cable from the
of the battery, then disconnect the negative [-] battery terminal.
red battery cable from the positive
terminal of battery before proceeding 2. Disconnect the positive [+] battery cable from the
with the removal or installation on positive [+] battery terminal.
any electrical component.
3. Remove the two [2] long bolts, two [2] washers,
two [2] wing nuts securing the battery hold-down,
and remove the hold-down.
NOTE: Battery weighs 49 pounds, use care when

removing from machine.
4. Lift battery off of machine.
Installation
NOTE: Be sure battery terminals are clean.
1. Position battery in battery compartment with

positive [+] battery terminal toward outside.
2. Position battery hold-down on top of battery and

secure with the two [2] long bolts, two [2]
washers, and two [2] wing nuts.
3. Reconnect the positive [+] battery cable to the

positive [+] battery terminal. Be sure connection is
tight.
4. Reconnect the negative [-] battery cable to the

FIGURE 7-75. BATTERY negative [-] battery terminal. Be sure connection
is tight.
9/2005 7-59
Section 7
ELECTRICAL
STARTER MOTOR.
The starter motor, Figure 7-76, is located on the

engine and drives the crankshaft through a gear on
the starter motor rotor. Proceed as follows to remove
and install the starter motor.
Removal
1. Disconnect battery.
2. Remove boot then disconnect positive [+] battery

cable from positive terminal on starter solenoid.
3. Label then disconnect wires CB, AE, A, and B

from main terminal on starter solenoid.
4. Remove terminal nut, and disconnect wire AF

from starter terminal on starter motor.
5. Remove three [3] mounting bolts attaching the

starter motor to the engine.
FIGURE 7-76. STARTER MOTOR
6. Remove starter motor with starter solenoid from
engine.
Installation
1. Align starter motor gear with gear on crankshaft

then secure starter motor with three [3] mounting
bolts.
2. Torque mounting bolt to 55 lb-ft.
3. Connect wire AF to starter terminal and secure

with terminal nut.
4. Connect wire B to main terminal on starter

solenoid.
5. Connect battery cable to main terminal on starter

solenoid.
6. Slide boot over terminal.
7. Reconnect battery.
7-60 9/2005
Section 7
ELECTRICAL
ALTERNATOR. 7. Rotate belt idler wheel to remove tension on the
belt.
The alternator, Figure 7-77, is located on the engine
and is driven through a belt. Proceed as follows to 8. Slide belt off of alternator pulley.
remove and install the starter motor.
9. Remove the two [2] bolts securing the alternator
Removal to the engine and remove alternator.
1. Disconnect battery. Installation
2. Remove boot and terminal nut, then label and 1. Position alternator on engine and align the two [2]
disconnect wire A from terminal A on alternator. mounting holes in the alternator with the
mounting holes in the engine.
3. Label, then disconnect wire F from terminal 2.
2. Install the two [2] alternator mounting bolts and
4. Label then disconnect jumper wire, from terminal torque to 55 lb-ft.
A to terminal 1, on alternator.
3. Rotate belt idler wheel out of the way, and then
5. Remove cap screw and washer from terminal G slide drive belt over alternator pulley.
on alternator.
4. Release idler so that spring tension is applied to
6. Label and disconnect wire G from terminal G on the belt.
alternator.
FIGURE 7-77. ALTERNATOR
9/2005 7-61
Section 7
ELECTRICAL
SWITCHES AND CONTROLS.
IGNITION KEY SWITCH.
The ignition key switch, Figure 7-78, is located on the

lower right of the control panel. Proceed as follows to
remove and install.
Removal
1. Remove screw from BATT terminal, then label

and disconnect wire B from terminal.
2. Remove screw from ACC terminal, then label and

disconnect wire ZZZ from terminal.
3. Remove screw from IGN terminal, then label and

disconnect wire YYY from terminal.
FIGURE 7-78. IGNITION KEY SWITCH
4. Remove screw from GRD terminal, then label and
disconnect wire G from terminal.
5. Remove screw from ST terminal, then label and

disconnect wire Q from terminal.
6. Remove nut that secures switch to front panel.
7. Slide switch out through rear of panel.
Installation
1. Insert ignition key switch through rear of panel

opening. Be sure key slot is vertical and secure to
panel with switch nut [supplied with switch].
2. Connect wire B to BATT terminal and secure with

terminal screw.
3. Connect wire ZZZ to ACC terminal and secure

with terminal screw.
4. Connect wire YYY to IGN terminal and secure

with terminal screw.
5. Connect wire G to GRD terminal and secure with

terminal screw.
6. Connect wire Q to ST terminal and secure with

terminal screw.
7-62 9/2005
Section 7
ELECTRICAL
BRAKE SWITCH [SECONDARY/PARKING BRAKE 8. Rotate knob assembly about 1/8 turn to
SYSTEM ON/OFF CONTROL SWITCH]. disengage from switch base assembly and pull
out through front of panel.
The brake switch, Figure 7-79, is located on the
lower left of the control panel. Proceed as follows to 9. Remove switch assembly from rear of panel.
remove and install.
10. The three switch sections can be separated for
Removal individual replacement by loosening the center
screw on each section.
1. Label and disconnect wire BBB from terminal 2.
Installation
2. Label and disconnect wire LLL from terminal 1.
1. Assemble the two [one (1) N.O. and one (1) N.C.]
3. Label and disconnect wire EZ from terminal 2. N.O. switch sections to the base with the center
screw on each section.
4. Label and disconnect wire EY from terminal 1.
2. Install the [N.C.] switch section on top of the outer
5. Label and disconnect wire Z from terminal 3. [N.O.] switch section.
6. Label and disconnect wire Q from terminal 4. 3. Insert switch assembly through back of panel.
7. Loosen two [2] screws on back of switch 4. Insert knob through front of panel and lock the
positioning switch away from panel. knob to base by rotate about 1/8 turn.
FIGURE 7-79. BRAKE SWITCH [SECONDARY/PARKING BRAKE SYSTEM ON/OFF CONTROL SWITCH]
9/2005 7-63
Section 7
ELECTRICAL
5. Tighten the two [2] screws on the back of switch Removal
assembly so the screws press against the panel
and hold the switch in position. 1. Label and disconnect wire P from terminal 2.
6. Connect wire BBB to terminal 2. 2. Label and disconnect wire RRR from terminal 3.
7. Connect wire LLL to terminal 1. 3. Label and disconnect wire G from terminal 5.
8. Connect wire EZ to terminal 2. 4. Label and disconnect wire DT from terminal 6.
9. Connect wire EY to terminal 1. 5. Remove hex nut and washer securing switch to
panel.
10. Connect wire Z to terminal 3.
11. Connect wire Q to terminal 4.
Installation
1. Slide switch into rear of panel.

SPEED RANGE SWITCH [TRANSMISSION
SYSTEM (TRAVEL/WORK) RANGE (2-SPEED) 2. Secure switch to panel with washer and hex nut.
SELECTION SWITCH].
3. Connect wire P to terminal 2.
The speed range switch, Figure 7-80, is a two-
position toggle switch located on the upper center of 4. Connect wire RRR to terminal 3.
the control panel. Proceed as follows to remove and
install. 5. Connect wire G to terminal 5.
6. Connect wire DT to terminal 6.
FIGURE 7-80. SPEED RANGE SWITCH
7-64 9/2005
Section 7
ELECTRICAL
VIBRATION SYSTEMS LOCATION (FRONT/BOTH/ DRUM VIBRATOR MODE [AUTOMATIC/OFF/
REAR) SELECTION SWITCH. MANUAL] SELECTION SWITCH.
The vibration systems location (front/both/rear) The drum vibrator mode [automatic/off/manual]
selection switch, Figure 7-81, is located to the left of selection switch, Figure 7-82, is located to the left of
the display. the display.
Removal Removal
1. Label and disconnect wire EH from terminal 1. 1. Label and disconnect wire EM from terminal 1.
2. Label and disconnect wire DY from terminal 2. 2. Label and disconnect wire DY from terminal 2.
3. Label and disconnect wire EL from terminal 3. 3. Label and disconnect wire EP from terminal 3.
4. Remove hex nut and washer securing switch to 4. Remove hex nut and washer securing switch to
panel. panel.
5. Remove switch from rear of panel. 5. Remove switch from rear of panel.
Installation Installation
1. Insert switch through mounting hole from rear of 1. Insert switch through mounting hole from rear of
panel. panel.
2. Secure switch to panel with washer and hex nut. 2. Secure switch to panel with washer and hex nut.
3. Connect wire EH to terminal 1. 3. Connect wire EM to terminal 1.
4. Connect wire DY to terminal 2. 4. Connect wire DY to terminal 2.
5. Connect wire EL to terminal 3. 5. Connect wire EP to terminal 3.
FIGURE 7-82. DRUM VIBRATOR MODE

[AUTOMATIC/OFF/MANUAL] SELECTION SWITCH
FIGURE 7-81. VIBRATION SYSTEMS LOCATION

(FRONT/BOTH/REAR) SELECTION SWITCH
9/2005 7-65
Section 7
ELECTRICAL
MANUAL DRUM VIBRATOR (START/STOP) Removal
CONTROL SWITCHES.
1. Label and disconnect wire DR from terminal 2.
These switches are part of the FNR control handle
and are not separately replaceable. Replace FNR 2. Label and disconnect wire EF from terminal 3.
control assembly [see the paragraph “REMOVAL
AND REPLACEMENT OF DIRECTIONAL/SPEED 3. Remove hex nut and washer securing switch to
CONTROL ASSEMBLY” in this section]. panel.
4. Remove switch from rear of panel.
VIBRATION SYSTEMS AMPLITUDE AMOUNT Installation

[HIGH/LOW] SELECTION SWITCH.
1. Insert switch through mounting hole from rear of
The vibration systems amplitude amount [high/low] panel.
selection awitch, Figure 7-83, is located to the left of
the display. 2. Secure switch to panel with washer and hex nut.
3. Connect wire DR to terminal 2.
4. Connect wire EF to terminal 3.
FIGURE 7-83. VIBRATION SYSTEMS AMPLITUDE

AMOUNT [HIGH/LOW] SELECTION SWITCH
7-66 9/2005
Section 7
ELECTRICAL
FRONT AND REAR DRUM VIBRATOR 3. Install the knob on the control shaft.
FREQUENCY [SPEED] CONTROL.
4. Attach the three [3] pin connector to the cable
The front and rear drum vibrator frequency [speed] connector.
control, Figure 7-84, is located to the right of the
display.
ENGINE THROTTLE SPEED LOW/HIGH

CONTROL SWITCH.
The engine throttle speed low/high control switch,

Figure 7-85, is a two-position toggle switch located
on the upper left of the control panel. Proceed as
follows to remove and install.
Removal
1. Label and disconnect wire P from terminal 2.
2. Label and disconnect wire Y from terminal 3.
3. Label and disconnect wire DP from terminal 5.
4. Label and disconnect wire G from terminal 6.
5. Remove hex nut and washer securing switch to

panel.
FIGURE 7-84. FRONT AND REAR DRUM

VIBRATOR FREQUENCY [SPEED] CONTROL
Removal
1. Disconnect the three [3] pin connector from the

main cable.
2. Remove the control knob.
3. Remove hex nut and washer securing control to

panel.
4. Slide control out through rear of panel.

FIGURE 7-85. ENGINE THROTTLE SPEED
Installation LOW/HIGH CONTROL SWITCH
1. Slide control through rear of panel.
2. Secure control to panel with washer and hex nut.
9/2005 7-67
Section 7
ELECTRICAL
Installation Removal
1. Slide switch into rear of panel. 1. Label and disconnect wire R from terminal 1.
2. Secure switch to panel with washer and hex nut. 2. Label and disconnect wire T from terminal 2.
3. Connect wire P to terminal 2. 3. Label and disconnect wire E from terminal 3.
4. Connect wire Y to terminal 3. 4. Remove hex nut and washer securing switch to
panel.
5. Connect wire DP to terminal 5.
5. Remove switch from rear of panel.
6. Connect wire G to terminal 6.
Installation
WATER SPRAY SYSTEMS MODE (AUTO/OFF/
MANUAL) CONTROL SWITCH. 1. Insert switch through mounting hole from rear of
panel.
The water spray systems mode (auto/off/manual)
control switch, Figure 7-86 is located on the control 2. Secure switch to panel with washer and hex nut.
panel.
3. Connect wire R to terminal 1.
4. Connect wire T to terminal 2.
5. Connect wire E to terminal 3.
FIGURE 7-86. WATER SPRAY SYSTEMS MODE

(AUTO/OFF/MANUAL) CONTROL SWITCH
7-68 9/2005
Section 7
ELECTRICAL
WATER SPRAY SYSTEMS DUTY CYCLE (0-50%) Installation
CONTROL.
1. Slide control through rear of panel.
The water spray systems duty cycle (0-50%) control,
Figure 7-87, is located to the right of the display. 2. Secure control to panel with washer and hex nut.
Removal 3. Install the knob on the control shaft.
1. Disconnect the three [3] pin connector from the 4. Attach the three [3] pin connector to the cable
main cable. connector.
2. Remove the control knob.
3. Remove nut and washer securing control to

panel.
4. Slide control out through rear of panel.
FIGURE 7-87. WATER SPRAY SYSTEMS DUTY CYCLE (0-50%) CONTROL SWITCH
9/2005 7-69
Section 7
ELECTRICAL
LIGHT SYSTEMS (ON/OFF) CONTROL SWITCH.
The light switch, Figure 7-88, is located on the control

panel.
Removal
1. Label and disconnect wire JJ from terminal B.
2. Label and disconnect wire FP from terminal A.
3. Label and disconnect wire FQ from terminal H.
4. Label and disconnect wire PP from terminal R.
5. Remove the switch control knob.
6 Remove hex nut and washer securing switch to

front of panel.
Installation
FIGURE 7-88. LIGHT SYSTEMS (ON/OFF)
1. Slide switch into mounting hole from rear of CONTROL SWITCH
panel.
2. Secure switch with washer and hex nut.
3. Install knob on switch shaft.
4. Connect wire JJ from terminal B.
5. Connect wire FP from terminal A.
6. Connect wire FQ from terminal H.
7. Connect wire PP from terminal R.
ENGINE INLET AIR RESTRICTION INDICATOR

VACUUM SWITCH. FIGURE 7-89. ENGINE INLET AIR RESTRICTION
INDICATOR VACUUM
The engine inlet air restriction indicator vacuum
switch, Figure 7-89, is located on the air intake filter. Installation
Removal 1. Check that switch is set to close at 20” H2O.
1. Label and disconnect wire UU from the vacuum 2. Place teflon tape on switch threads.
switch terminal.
3. Screw switch into the air intake filter.
2. Unscrew the switch from the air intake filter.
4. Connect wire UU to switch terminal.
7-70 9/2005
Section 7
ELECTRICAL
VIBRATION SYSTEMS HYDRAULIC PRESSURE
OIL FILTER ELEMENT CONDITION INDICATOR
CIRCUIT SWITCH.

element condition indicator circuit switch, Figure 7-
90, is located on the hydraulic oil filter.
Removal
1. Label and disconnect wire VV from the switch

terminal.
2. Unscrew the switch from the filter base.
Installation
1. Wrap switch threads with teflon tape.
2. Screw switch into hydraulic oil filter base.
3. Attach wire VV to the filter terminal screw.
4. Check the hydraulic oil reservoir for sufficient oil.
HORN BUTTON SWITCH.
The horn button switch, Figure 7-91, is located on the FIGURE 7-90. VIBRATION SYSTEMS HYDRAULIC
control panel. PRESSURE OIL FILTER ELEMENT CONDITION
INDICATOR CIRCUIT SWITCH.
Removal
1. Label and disconnect wire FF from the horn

button.
2. Label and disconnect wire EE from the horn

button.
3. Snap horn button assembly out through front of

control panel.
Installation
1. Orient horn button on control front panel, then

press horn button into opening in front panel.
2. Connect wire FF to the horn button.
3. Connect wire EE to the horn button.
FIGURE 7-91. HORN BUTTON SWITCH
9/2005 7-71
Section 7
ELECTRICAL
WATER SPRAY SYSTEMS POWER RELAY. 4. Connect wire T to terminal 85.
The water spray systems power relay [K5], Figure 7- 5. Connect wire KK to terminal 30.
94, is located on the power panel.
6. Connect wire FJ to terminal 87.
HIGH BEAM RELAY.
The High Beam Relay [K3], Figure 7-95, is located on

the power panel.
Removal
2. Label and disconnect wire FQ from terminal 85.
3. Label and disconnect wire FH from terminal 30.
4. Label and disconnect wire FM from terminal 87.
5. Remove the two [2] flanged bolts securing the

relay to power panel.
6. Remove high beam relay [K3].

FIGURE 7-94. WATER SPRAY SYSTEMS Installation
POWER RELAY
Removal 1. Align relay mounting holes with mounting holes
on power panel.
2. Secure relay to mounting surface with two [2]
2. Label and disconnect wire T from terminal 85. flanged screws.
3. Label and disconnect wire KK from terminal 30. 3. Connect wire G to terminal 86.
4. Label and disconnect wire FJ from terminal 87. 4. Connect wire FQ to terminal 85.
5. Remove the two [2] flanged bolts, securing the 5. Connect wire FH to terminal 30.
relay to power panel.
6. Connect wire FM to terminal 87.
6. Remove water spray relay [K5].
Installation
1. Align relay mounting holes with mounting holes

on power panel.

flanged screws.
7-72 9/2005
Section 7
ELECTRICAL
4. Connect wire FP to terminal 85.
5. Connect wire CC to terminal 30.
6. Connect wire FM to terminal 87.
FIGURE 7-95. HIGH BEAM RELAY [K3]
LOW BEAM RELAY.
The low beam relay [K4], Figure 7-96, is located on

the power panel.
FIGURE 7-96. LOW BEAM RELAY
Removal
2. Label and disconnect wire FP from terminal 85.
3. Label and disconnect wire CC from terminal 30.
4. Label and disconnect wire FM from terminal 87.
5. Remove two [2] flanged bolts securing the relay

to power panel.
6. Remove low beam relay [K4].
Installation
1. Align relay mounting holes with mounting holes

on power panel.

flanged screws.
9/2005 7-73
Section 7
ELECTRICAL
FORWARD RELAY. 5. Connect wire FC to terminal 30.
The forward relay [K1], Figure 7-98, is located on the 6. Connect wire DC to terminal 87.
power panel.
REVERSE RELAY.
The reverse relay [K2], Figure 7-99, is located on the

power panel.
FIGURE 7-98. FORWARD RELAY
Removal FIGURE 7-99. REVERSE RELAY
Removal
1. Label and disconnect wire DE from terminal 86.2.
Label and disconnect wire FD from terminal 85. 1. Label and disconnect wire EC from terminal 86.
3. Label and disconnect wire FC from terminal 30. 2. Label and disconnect wire FD from terminal 85.
4. Label and disconnect wire DC from terminal 87. 3. Label and disconnect wire FC from terminal 30.
5. Remove two [2] flanged bolts securing the relay 4. Label and disconnect wire DH from terminal 87.
to power panel.
5. Remove the flanged bolt securing the relay to
6. Remove forward relay [K1]. power panel.
Installation 6. Remove reverse relay [K2].
1. Align relay mounting holes with mounting holes Installation
on power panel.
1. Align relay mounting hole with mounting hole on
power panel.
flanged screws.
2. Secure relay to mounting surface with flanged
3. Connect wire DE to terminal 86.
bolt.
4. Connect wire FD to terminal 85.
3. Connect wire EC to terminal 86.
7-74 9/2005
Section 7
ELECTRICAL
3. Connect wire EC to terminal 86.
5. Connect wire FC to terminal 30.
5. Connect wire AAA to terminal 30.
6. Connect wire DH to terminal 87.
6. Connect wire XX to terminal 87.
BACKUP RELAY.
The backup relay [K6], Figure 7-100, is located on

SENDING UNITS.
the power panel.
ENGINE LUBRICATION OIL PRESSURE SENDING
UNIT.
The engine lubrication oil pressure sending unit,

Figure 7-101, is mounted on the engine below the
throttle linkage.
FIGURE 7-100. BACKUP RELAY
Removal
FIGURE 7-101. ENGINE LUBRICATION OIL
1. Label and disconnect wire EC from terminal 86. PRESSURE SENDING UNIT
2. Label and disconnect wire FD from terminal 85. Removal
3. Label and disconnect wire AAA from terminal 30. 1. Label and disconnect wire D from sending unit
terminal.
4. Label and disconnect wire XX from terminal 87.
2. Unscrew sending unit from engine.
5. Remove the flanged bolt securing the relay to
power panel. Installation
6. Remove backup relay [K6]. 1. Wrap teflon tape around threads of sending unit.
Installation 2. Screw sending unit into engine.
1. Align relay mounting hole with mounting hole on 3. Connect wire D to terminal on top of sending unit.
power panel
2. Secure relay to mounting surface with flanged bolt.
9/2005 7-75
Section 7
ELECTRICAL
ENGINE COOLANT TEMPERATURE SENDING FUEL LEVEL SENDING UNIT.
UNIT.
The fuel level sending unit, Figure 7-103 is mounted
The engine coolant temperature sending unit, Figure on the top of the fuel tank behind the fuel fill tube.
7-102, is mounted on the engine.
FIGURE 7-103. FUEL LEVEL SENDING UNIT

TEMPERATURE SENDING UNIT Removal
1. Label and disconnect wire WWW from the

Removal sending unit.
1. Label and disconnect wire C from sending unit 2. Remove the five [5] screws attaching the sending
terminal. unit to the tank.
2. Unscrew sending unit from engine. 3. Lift the sending unit out of the fuel tank.
1. Wrap sender unit threads with teflon tape. 1. Carefully insert the sending unit into the fuel tank,
taking care not to damage the float.
2. Screw sender unit into engine.
2. Align the five [5] holes in the sending unit with the
3. Connect wire C to terminal on top of sending unit. five mounting holes in the fuel tank.
3. Attach the sending unit with the five [5] screws.
4. Connect wire WWW to the terminal on top of the

sending unit.
7-76 9/2005
Section 7
ELECTRICAL
HYDRAULIC SYSTEM OIL TEMPERATURE “MAT” TEMPERATURE SENDING UNIT.
SENDING UNIT.
The “mat” temperature sending unit, Figure 7-105, is
The hydraulic system oil temperature sending unit, mounted to the machine frame.
Figure 7-104, is mounted on the hydraulic tank.
Removal
Removal
1. Disconnect the four [4] wire connector from the
1. Label and disconnect wire J from the sending unit. main harness.
2. Unscrew the sending unit from the hydraulic tank. 2. Remove the two [2] flanged screws attaching the
sensor to the frame.
Installation
3. Remove “mat” temperature sensor from machine.
1. Install the sending unit in the hydraulic tank.
Installation
2. Connect wire J to the terminal on the sending unit.
1. Align the two [2] mounting holes in the “mat”
temperature sensor with the mounting holes on
the machine frame.
2. Secure sensor to machine frame with the two [2]

flanged screws.
3. Connect the four [4] wire connector to the main

harness.
FIGURE 7-104. HYDRAULIC SYSTEM

FIGURE 7-105. “MAT” TEMPERATURE

SENDING UNIT
9/2005 7-77
Section 7
ELECTRICAL
“MAT” TEMPERATURE SENDING UNIT Heat test surface to 275°F. The test surface should
CALIBRATION PROCEURE be a mat black surface. Verify surface temperature
using a calibrated temperature gun. If the tempera-
BENCH CALIBRATION PROCEDURE: ture gun has a variable emissivity set point, the
value should be set to .95 ± .01. If the emissivity set
Follow the “MAT” temperature sending unit removal point is prefixed by the temperature gun manufac-
process previously outlined. ture, the set value should be .95 ± .01.
Function test procedure: When sensing a surface at 275°F the voltage

Connect +12 volt to terminal 3 of the sender harness. reading should be 1.845, ±0.005 volts.
Refer to Figure 7-105 B.
If the voltage is low, turn the trim pot screw counter
Connect ground (-12Vdc) to terminal 2 of the sending clockwise until the correct voltage is displayed on
harness. the main display panel of the compactor.
Connect common input of multimeter to terminal 2 of If the voltage is high, turn the trim pot screw clock-
sending harness. wise until the correct voltage is displayed on the
main display panel of the compactor.
Display on multimeter should be approximately 0.7-
.0.9 volts DC when sensing a surface temperatures Field CALIBRATION PROCEDURE:
between 60°F and 80°F. Voltage should vary when Remove the four temperature sender box assembly
sending unit is moved to a hot surface. (See Voltage screws. Lift the cover to gain access to the trim pot.
Table figure 7-105 B) Note: Resistance of trim pot Refer to Figure 7-105 A
should be 150 Ohms.
Read surface temperature using a calibrated
Calibration of “MAT” Temperature Sending Unit: temperature gun.
Connect sender to digital multimeter as shown. Set to If the temperature gun has a variable emissivity set
display DC voltage point, the value should be set to .94 ± .01. If the
emissivity set point is prefixed by the temperature
Remove the four temperature sender box assembly gun manufacture, the set value should be .94 ± .01.
screws. Lift the cover to gain access to the trim pot.
Refer to Figure 7-105 A The “MAT” temperature readout is on the main
display panel of the compactor.
If the temperature readout on the main display panel

is low in comparison to the temperature gun, turn
the trim pot screw clockwise until the “MAT” tem-
perature readout on the main display panel of the
TRIM POT
compactor is the same as the temperature gun
ADJUSTMENT SCREW readout. For a high temperature read out on the
main display panel turn the pot screw counter
FIGURE 7-105 A “MAT” TEMPATURE SENSOR clockwise.
7-78 9/2005
Section 7
ELECTRICAL
FIGURE 7-105 B FUNCTION TEST PROCEDURE
9/2005 7-79
Section 7
ELECTRICAL
SOLENOID CONTROLS.
SECONDARY/PARKING BRAKE SYSTEM STACK

VALVE SOLENOID.
Refer to Section 9 BRAKE SYSTEM, for removal and

installation procedures for the secondary/parking
brake system stack valve solenoid.
NOTE: Use the same procedure for the transmis-

sion work/travel [low/high] speed range
system solenoid stack valve solenoid.
TRANSMISSION WORK/TRAVEL [LOW/HIGH]

SPEED RANGE SYSTEM SOLENOID STACK
VALVE SOLENOID.
Refer to Section 9 BRAKE SYSTEM, for removal and

installation procedures. This procedure is identical to
the secondary/parking brake system stack valve
solenoid procedure.
TRANSMISSION PUMP ELECTRONIC

DISPLACEMENT CONTROL VALVE SOLENOID.
Refer to Section 8 TRANSMISSION SYSTEM,

paragraph PROPORTIONAL ELECTRONIC
DISPLACEMENT CONTROL VALVE for removal and
installation procedures for the transmission pump
electronic displacement control valve solenoid.
FIGURE 7-112. CIRCUIT BREAKERS
[F1, F2, AND F3]
VIBRATION PUMP ELECTRONIC DISPLACEMENT Removal
(EDC) SOLENOID VALVE.
1. Label and disconnect wire XXX from the BATT
Refer to Section 11 DRUM VIBRATION AND DRUM terminal of the circuit breaker.
CLEANER SYSTEMS, paragraph ELECTRONIC
DISPLACEMENT CONTROL [EDC] VALVE, for 2. Label and disconnect wires FF and JJ from the
removal and installation procedures for the vibration AUX terminal of the circuit breaker.
pump electronic displacement (EDC) solenoid valve.
3. Remove the nut, washer, and screw, securing the
circuit breaker to the mounting bracket.
CIRCUIT BREAKERS. Installation
LIGHTS AND HORN TWENTY (20) AMP CIRCUIT 1. Secure the circuit breaker to the mounting
BREAKER [F1]. bracket, using the nut, washer, and screw.
The lights and horn twenty (20) amp circuit breaker 2. Connect wire XXX to the BATT terminal of the
[F1], Figure 7-112, is located on a mounting bracket circuit breaker.
behind the control panel.
3. Connect wires FF and JJ to the AUX terminal of
the circuit breaker.
7-80 9/2005
Section 7
ELECTRICAL
CONTROL PANEL SWITCHES CIRCUIT BREAKER bracket, using the nut, washer, and screw.
[F2].
2. Connect wire ZZZ to the BATT terminal of the
The control panel switches circuit breaker [F2], circuit breaker.
Figure 7-112, is a 20-amp circuit breaker located on a
mounting bracket behind the control panel. 3. Connect wire E, P, and BBB to the AUX terminal
of the circuit breaker.
Removal
1. Label and disconnect wire YYY connected to the STARTER CIRCUIT BREAKER [F4].
BATT terminal of the circuit breaker.
The starter fuse is a 15-Amp in-line fuse connected
2. Label and disconnect wire L from the AUX between the “Start” contact on the ignition key switch
terminal of the circuit breaker. and terminal 4 on the brake switch.
3. Remove the nut, washer, and screw, securing the OPTIONS CIRCUIT BREAKER [F5].
circuit breaker to the mounting bracket.
The options circuit breaker [F5], Figure 7-113, is
Installation located on the power panel.
1. Securing the circuit breaker to the mounting

bracket, using the nut, washer, and screw.
2. Connect wire YYY to the BATT terminal of the

circuit breaker.
3. Connect wire L to the AUX terminal of the circuit

breaker.
COMPUTER GAUGES AND SHUTDOWN RELAY

20-AMP CIRCUIT BREAKER [F3].
The computer gauges and shutdown relay circuit

breaker [F3], Figure 7-112, is a 20-amp circuit
breaker located on a mounting bracket behind the
control panel. FIGURE 7-113. CIRCUIT BREAKERS [F5 AND F6]
Removal Removal
1. Label and disconnect wire ZZZ connected to the 1. Label and disconnect wire FG from the BATT
BATT terminal of the circuit breaker. terminal of the circuit breaker.
2. Label and disconnect wires E, P, and BBB from 2. Label and disconnect wires FL from the AUX
the AUX terminal of the circuit breaker. terminal of the circuit breaker.
3. Remove the nut, washer, and screw, securing the 3. Remove the bolt, washer and nut attaching the
circuit breaker to the mounting bracket. circuit breaker to the power panel.
1. Securing the circuit breaker to the mounting 1. Attach the circuit breaker to the power panel with
the bolt, washer and nut.
9/2005 7-81
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ELECTRICAL
2. Connect wire FG to the BATT terminal of the Installation
circuit breaker.
1. Attach the circuit breaker to the chassis support
3. Connect wires FL to the AUX terminal of the with the bolt, washer and nut.
circuit breaker.
2. Connect wire FT to the BATT terminal of the
circuit breaker.
WATER SPRAY SYSTEMS THIRTY (30) AMP 3. Connect wire FR to the AUX terminal of the circuit
CIRCUIT BREAKER [F6]. breaker.
The water spray systems thirty (30) amp circuit

breaker [F6], Figure 7-113, is located on the power
panel.
Removal
1. Label and disconnect wire FG from the BATT

terminal of the circuit breaker.
2. Label and disconnect wires FJ from the AUX

terminal of the circuit breaker.
3. Remove the bolt, washer and nut attaching the

circuit breaker to the power panel.
Installation
1. Attach the circuit breaker to the power panel with

the bolt, washer and nut.
2. Connect wire FG to the BATT terminal of the

circuit breaker.
3. Connect wires FJ to the AUX terminal of the

circuit breaker.
REAR PAVING [WORK] LIGHTS THIRTY (30) AMP FIGURE 7-114. REAR PAVING LIGHT THIRTY
CIRCUIT BREAKER [F8]. (30) AMP CIRCUIT BREAKER [F8]
The rear paving light thirty (30) amp circuit breaker FRONT PAVING [WORK] LIGHTS THIRTY (30) AMP
[F8], Figure 7-114, is located above the computer. CIRCUIT BREAKER [F9].
Removal The front paving light thirty (30) amp circuit breaker[F9],
Figure 7-115, is located above the computer.
1. Label and disconnect wire FT from the BATT
terminal of the circuit breaker. Removal
2. Label and disconnect wire FR from the AUX 1. Label and disconnect wire FT from the BATT
terminal of the circuit breaker. terminal of the circuit breaker.
3. Remove the bolt, washer and nut attaching the 2. Label and disconnect wire FR from the AUX
circuit breaker to the chassis support above the terminal of the circuit breaker.
computer.
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ELECTRICAL
3. Remove the bolt, washer and nut attaching the INSTRUMENTS AND GAUGES.
circuit breaker to the chassis support above the
computer. ENGINE HOUR METER.
Installation The engine hour meter, Figure 7-116, is mounted on

the gauge panel.
1. Attach the circuit breaker to the chassis support
with the bolt, washer and nut.
2. Connect wire FT to the BATT terminal of the

circuit breaker.
3. Connect wires FR to the AUX terminal of the

circuit breaker.
FIGURE 7-116. ENGINE HOUR METER
Removal
1. Label and disconnect the two wires from the back

of the meter.
FIGURE 7-115. REAR PAVING LIGHT THIRTY 2. Remove the hex nut on the rear of the gauge
(30) AMP CIRCUIT BREAKER [F9] panel that attaches the center of the meter to the
mounting bracket.
BACKUP ALARM FUSE [F7]. 3. Remove mounting bracket from rear of gauge
panel.
The backup alarm fuse, is a fifteen (15) amp in-line
fuse connected between terminal 30 on the backup 4. Slide meter out of front of panel.
relay [K6] on the power board, and 14 -pin connector,
pin E. Installation
1. Insert the meter through the front of the panel and

position so that meter dial is correctly oriented.
9/2005 7-83
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ELECTRICAL
2. Install mounting bracket on back of meter so that 3. Remove mounting bracket from rear of gauge
mounting screw on center of meter passes panel.
through the mounting bracket hole, and the
bracket rests against the panel. 4. Slide meter out of front of panel.
3. Secure meter to panel with the supplied hex nut. Installation
4. Connect the two wires to the back of the meter. 1. Insert the meter through the front of the panel and
Be sure wires are attached to the correct position so that meter dial is correctly oriented.
terminals.
2. Install mounting bracket on back of meter so that
mounting screws on the meter pass through the
VOLTMETER. mounting bracket holes, and the bracket rests
against the panel.
The voltmeter, Figure 7-117, is mounted on the
gauge panel. 3. Secure meter to panel with the supplied hex nuts.
4. Connect the wires to the back of the meter. Be

sure wires are attached to the correct terminals.
FUEL LEVEL.
The fuel level gauge, Figure 7-118, is mounted on the

gauge panel.
Removal
1. Label and disconnect the wires from the back of

the gauge.
2. Remove the two [2] hex nuts on the rear of the

gauge panel that attaches the fuel gauge to the
mounting bracket.
3. Remove mounting bracket from rear of gauge

panel.
4. Slide meter out of front of panel.
Installation
FIGURE 7-117. VOLT METER 1. Insert the gauge through the front of the panel
and position so that meter dial is correctly
oriented.
Removal
2. Install mounting bracket on back of gauge so that
mounting screws on the gauge pass through the
the meter.
mounting bracket holes, and the bracket rests
against the panel.
gauge panel that attaches the meter to the
3. Secure gauge to panel with the supplied hex
mounting bracket.
nuts.
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Section 7
ELECTRICAL
4. Connect the wires to the back of the meter. Be ENGINE LUBRICATION OIL PRESSURE GAUGE.
The engine lubrication oil pressure gauge, Figure 7-
119, is mounted on the gauge panel.
FIGURE 7-118. FUEL LEVEL GAUGE
FIGURE 7-119. ENGINE LUBRICATION

OIL PRESSURE
Removal

the gauge.

mounting bracket.

panel.
4. Slide meter out of front of panel.
9/2005 7-85
Section 7
ELECTRICAL
Installation 2. Remove the two [2] hex nuts on the rear of the
1. Insert the gauge through the front of the panel mounting bracket.
and position so that meter dial is correctly
oriented. 3. Remove mounting bracket from rear of gauge
panel.
2. Install mounting bracket on back of gauge so that
mounting screws on the gauge pass through the 4. Slide meter out of front of panel.
against the panel. Installation
3. Secure gauge to panel with the supplied hex 1. Insert the gauge through the front of the panel
nuts. and position so that meter dial is correctly
oriented.
sure wires are attached to the correct terminals. 2. Install mounting bracket on back of gauge so that
mounting screws on the gauge pass through the
ENGINE COOLANT TEMPERATURE. against the panel.
The engine coolant temperature, Figure 7-120, is 3. Secure gauge to panel with the supplied hex
mounted on the gauge panel. nuts.

HYDRAULIC SYSTEM OIL TEMPERATURE.
The hydraulic system oil temperature, Figure 7-121 is

mounted on the gauge panel.
Removal

the gauge.

mounting bracket.

panel.
TEMPERATURE 4. Slide meter out of front of panel.
Removal

the gauge.
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Section 7
ELECTRICAL
Installation INDICATOR LIGHTS.
1. Insert the gauge through the front of the panel VIBRATION SYSTEM HYDRAULIC PRESSURE OIL
and position so that meter dial is correctly FILTER ELEMENT CONDITION INDICATOR LIGHT.
oriented.
The vibration system hydraulic pressure oil filter
2. Install mounting bracket on back of gauge so that element indicator light, Figure 7-122, is mounted on
mounting screws on the gauge pass through the the control panel
against the panel. Removal
3. Secure gauge to panel with the supplied hex 1. Disconnect wire VV from back of indicator light
nuts. assembly.
4. Connect the wires to the back of the meter. Be 2. Hold lamp assembly and turn lens assembly
sure wires are attached to the correct terminals. about 1/8 turn counterclockwise to disengage
lens from lamp assembly.
3. Slide lens assembly out of front of control panel.
4. Remove lamp assembly and spring from rear of

control panel.
Installation
1. Place spring on lamp assembly and press

assembly against back of control panel indictor
light opening.
2. Slide lens assembly through front of control panel

and engage light assembly by rotating lens about
1/8 turn clockwise.
3. Connect wire VV to indicator light assembly.
FIGURE 7-121. HYDRAULIC SYSTEM

OIL TEMPERATURE
FIGURE 7-122. VIBRATION SYSTEM HYDRAULIC

PRESSURE OIL FILTER ELEMENT CONDITION
INDICATOR LIGHT
9/2005 7-87
Section 7
ELECTRICAL
ENGINE INLET AIR RESTRICTION INDICATOR MISCELLANEOUS AND OPTIONAL
LIGHT. COMPONENTS.
The engine inlet air restriction indicator light, Figure ELECTRONIC HORN ASSEMBLY.
7-123, is mounted on the control panel
The electronic horn assembly, Figure 7-124, is
mounted to the cockpit floor plate above the front
roller. Removing the access plate can access it.

INDICATOR LIGHT
Removal
FIGURE 7-124. HORN ASSEMBLY
1. Disconnect wire UU from back of indicator light
assembly. Removal
2. Hold lamp assembly and turn lens assembly 1. Label and disconnect wire EE from the terminal
about 1/8 turn counterclockwise to disengage on the horn.
lens from lamp assembly.
2. Remove the hex nut and washer securing the
3. Slide lens assembly out of front of control panel. horn to the bracket.
4. Remove lamp assembly and spring from rear of 3. Remove horn from bracket.
control panel.
Installation
Installation
1. Install horn on bracket.
1. Place spring on lamp assembly and press
assembly against back of control panel indicator 2. Secure horn to bracket with the washer and hex
light opening. nut.
2. Slide lens assembly through front of control panel 3. Connect wire EE to the horn terminal.
and engage light assembly by rotating lens about
1/8 turn clockwise.
3. Connect wire UU to indicator light assembly. WATER PUMP ASSEMBLY.
The two [2] water pump assemblies, Figure 7-125,

include the motor and are located near the water
tanks, above the front and rear drum assemblies.
7-88 9/2005
Section 7
ELECTRICAL
Removal Installation
1. Label and disconnect the red wire KK from the 1. Install four [4] new grommets on the pump
connector body of the front or rear water tank mounting plate. Use grommet part number
harness, as applicable. 0214274.
2. Label and disconnect the black wire G from the 2. Attach pump to the mounting plate with the four
connector body of the front or rear water tank [4] bolts, four [4] washers, and four [4] hex nuts.
harness, as applicable.
3. Connect the red wire KK to the connector body
3. Remove the two [2] hose clamps attaching the on the front or rear water tank harness, as
hoses to the pump and plug the hose from the applicable.
water tank.
4. Connect the black wire G to the connector body
4. Remove the four [4] bolts, four [4] hex nuts, and on the front or rear water tank harness, as
four [4] washers securing the pump to the applicable.
mounting plate.
5. Remove four [4] grommets from mounting holes.

POWER PANEL ASSEMBLY.
The power panel assembly, Figure 7-126, is located

on the left inner riser of the control and instrument
panel riser, below the steering wheel. Unless the
power panel is damaged, replace only the faulty
component on the panel.
Removal
1. Label and disconnect all wires to the power

panel.
2. Remove the four [4] screws attaching the power

panel to the side of the riser.
3. Note orientation of power panel assembly, then

remove panel from machine.
Installation
1. Properly orient power panel assembly with relays

K1, K2, and K6 toward bottom of riser.
2. Attach power panel assembly to riser with the four

[4] mounting screws.
3. Reconnect the wires to the power panel.
FIGURE 7-125. WATER PUMP ASSEMBLY
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Section 7
ELECTRICAL
FIGURE 7-126. POWER PANEL ASSEMBLY
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Section 7
ELECTRICAL
OPERATING LIGHT ASSEMBLIES. 3. Remove light assembly.
The operating light assemblies, Figure 7-127, are Installation

located on the front and the rear of the machine.
These assemblies include the turning and hazard 1. Align light mounting bracket with mounting holes
lights. in machine.
Removal 2. Secure bracket with flange screw and hex nut.
1. Disconnect light connector from harness. 3. Connect light connector to harness.
2. Remove flange screw and hex nut securing light

assembly mounting bracket to machine.
BACKUP ALARM.
The backup alarm, Figure 7-128, is mounted on the

cowl above the rear drum.
Removal
1. Label and disconnect wire AAA from the backup

alarm.
2. Remove the four [4] mounting bolts.
3 Remove the backup alarm from machine.
Installation
1. Attach backup alarm mounting bracket to

machine with the four [4] bolts.
2. Connect wire AAA to backup alarm.
FIGURE 7-127. OPERATING

LIGHT ASSEMBLIES FIGURE 7-128. BACKUP ALARM
9/2005 7-91
Section 7
ELECTRICAL
REMOVAL AND REPLACEMENT OF S2X Use the following information to access the S2X
COMPUTER CONTROLLER ASSEMBLY. computer controller screens, and record ALL existing
numbers, BEFORE disconnecting the existing,
ACCESSING LOWER LEVEL GROUPS SCREENS computer controller.
AND RECORDING THE NUMBERS.
Turn the ignition key to the run position, but leave the
Replace the S2X computer controller assembly only engine off. Press the F3 key on the S2X computer
AFTER being certain the assembly has failed. controller while holding the “MAN VIB” button down.
This will access a lower level of screens where you

CAUTION: This component is the LEAST likely to will be able to now record, and after new S2X
have a failure and, therefore, should computer controller installation, input, adjust and lock
be replaced with NEW, ONLY when in your settings.
CERTAIN an actual failure has
occurred. The following will present an overview of the screen
groups, the procedures for obtaining ALL existing
numbers, and for later “fine tuning” the settings.
CAUTION: To prevent the need for a complete
machine set up, after replacing the
computer controller assembly with NOTE: AFTER new S2X controller installation,
new, the lower level screens MUST be ANY numbers to be changed MUST be on
accessed BEFORE the computer the TOP LINE of the dash installed 2x24
controller is disconnected. This will display.
allow technical service personnel to
record the existing numbers, that
were originally programed into the There are eight [8] screen “groups” accessible at this
computer controller, at the factory, level. Screens, and the order that they will appear in
and reinstall them into the new S2X the window, on the computer are:
computer controller. Should, for some
reason, these numbers be RUN, LMTD, INPT, VIBS, PROP, FNR, ACCEL, and
unattainable, BOMAG Americas, A/D.
Service Department should be called
and numbers will be provided for These screens are referred to as “groups” and will
installation into the new computer always be in the above order on the S2X computer
controller. controller that was installed in the machine at the
After the new computer controller is time of manufacture.
installed, the vibration systems VPM
output speeds and machine travel Each of the groups have multiple levels within them.
speeds will have to be checked and To move from one group to the next group use the F4
"dialed in" IF numbers are provided key, on the computer controller.
by the Service Department, as they
will represent an "average value" and
are NOT the numbers the machine
was originally set up with.
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Section 7
ELECTRICAL
To move within a given “group”, use the scroll button
on the display. The scroll button will move the bottom FrntVib HAHS: - - - - Ma
line, on the display, to the top line. Pushing and RearVib LALS: - - - - Ma
holding the scroll button will NOT progressively
advance lines. Should you inadvertently scroll past a
number, continue to push the scroll button until the Scroll twice.
number returns on the display, as you continually
scroll within the given group until the F4 key is RearVib LAHS: - - - - Ma
pressed to proceed to the next group. Anytime you RearVib HALS: - - - - Ma
see scroll once, or scroll twice, in the following
information, you will use the scroll button on the
display. Scroll twice.
The first screen you will see in the window on the RearVib HAHS: - - - - Ma
computer controller will be “RUN”. Press F4, 3 times. F. Vib Cmnd: 0.0 Ma
The “VIBS” group will now appear in the window, on

the computer controller. The eight [8] numbers, listed Press F4 one [1] time.
in chart A, will be recorded off of this screen
grouping. The “PROP” screen will now appear in the window,
on the computer controller. The fwd max, rev max,
You will see the following screens in this group for fwd thresh and rev thresh numbers will be recorded
recording of the EIGHT [8] highlighted numbers. off of this screen grouping.
Manual Vib. : Off

FrntVib LALS: - - - - Ma
Scroll twice.
FrntVib LAHS: - - - - Ma
FrntVib HALS: - - - - Ma
Scroll twice.
FrntVib LALS ---- Front Vibrator, Low Amplitude, Low Speed

FrntVib LAHS ---- Front Vibrator, Low Amplitude, High Speed
FrntVib HALS ---- Front Vibrator, High Amplitude, Low Speed
FrntVib HAHS ---- Front Vibrator, High Amplitude, High Speed
RearVib LALS ---- Rear Vibrator, Low Amplitude, Low Speed
RearVib LAHS ---- Rear Vibrator, Low Amplitude, High Speed
RearVib HALS ---- Rear Vibrator, High Amplitude, Low Speed
RearVib HAHS ---- Rear Vibrator, High Amplitude, High Speed
CHART A.
9/2005 7-93
Section 7
ELECTRICAL
You will see the following screens in this group for REMOVAL AND REPLACEMENT OF THE S2X
recording of the FOUR [4] highlighted numbers. COMPUTER CONTROLLER ASSEMBLY
[See Figure 7-129].
Fwd Max: ----- D/A
Rev Max: ----- D/A CAUTION: Do the following procedures to
remove the existing S2X computer
Record the above 2 values and then scroll twice. controller, and replace it with new,
ONLY after accessing the lower level
screens and copying the information
Fwd Thresh: ----- D/A as instructed in this section. Failure to
Rev Thresh: ----- D/A do so will result in a full machine set
up requirement after installation of the
Record the 4 values and push F4, three (3) times to new controller.
go to the “A/D” group of screens.
This will put the last group of screens in the window. a. Put the secondary/parking brake system control
It will be the “A/D” screens. switch “ON” [APPLIED] and STOP the engine.
There are five [5] numbers to be recorded in this b. Remove left rear side service access cover. Go
group. They are FNR MAX, FNR Ntop, FNR Nbot, to where the battery is installed. Remove the
FNR Min. and SAVED VLDP. Use the scroll button to negative [-] battery cable from the negative [-]
reach the screens and record the numbers. battery post and move it away from the battery.
You will see the following screens in this group for c. Go to the instrument panel riser. Remove the
recording of the FIVE [5] highlighted numbers. four socket head capscrews that fasten the
computer controller assembly access cover to
the riser. Remove the cover.
FNR Max : - - - - A/D d. Go to the harness running to the top relay, of the
FNR Ntop : - - - - A/D two [2] relays installed on the left hand side of
the console, next to the S2X computer controller.
Unplug the harness from the top relay. Go to the
Scroll twice. You will see the following screen. computer controller assembly. Hold the
computer controller in place. Remove each of
the four socket head capscrews which mount the
FNR Nbot : - - - - A/D controller in place. Remove the ground wire from
FNR Min : - - - - A/D under the lower right capscrew head and move it
away from the controller. Lift the computer
controller assembly upward, as far as the
Scroll twice. You will see the following screen. remaining harnesses connected to the lower
area of it will allow.
Saved VLdp : - - - - A/D

FNR MAX : - - - - A/D
Push F4 to return to the “RUN” screen where all the

recording of the numbers started. You have now
downloaded all of the required numbers and are
ready to “remove and replace” the S2X computer
controller.
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Section 7
ELECTRICAL
e. Go to the lower area of the computer controller h. Put the single ground wire under the lower right
assembly. Push upward and rotate the knurled capscrew head. Install each of the four [4]
harness lock ring counterclockwise [CCW]. socket head capscrews through the controller
Move the round harness connector downward and securely tighten them into the threaded
and remove it from the computer controller holes in the instrument panel riser.
assembly. Use a 1/4 inch socket, extension and
ratchet to loosen the single long retaining screw i. Go to where the battery is installed. Move the
found in the center of each of the remaining two negative [-] battery cable to the battery. Install
[2] rectangular harness connectors, still attached the negative [-] battery cable onto the negative [-
to the computer controller assembly. Carefully ] battery post. Install the left rear side service
pull both harness connectors downward and access cover.
away from the computer controller assembly.
Carefully lift the computer controller assembly
from the machine. CAUTION: After installation of the new S2X
computer controller, the previously
f. Carefully install the new computer controller recorded numbers, for ALL groups,
assembly into the machine. Look at each MUST be installed into the
rectangular harness connector. Note the position replacement computer controller, at
of the installation alignment guides on each this time, using the following
harness connector and compare their relative procedures.
installation position to the female receptacle on
the removed computer controller assembly.
Place both rectangular harness connectors in
the correct position, so that they will install into
the female receptacle on the new computer
controller assembly. Carefully push each
rectangular harness connector upward and into
the correct computer controller female
receptacle. Use a 1/4 inch socket, extension and
ratchet to carefully tighten the single long
retaining screw found in the center of each of the
two [2] rectangular harness connectors. Hold the
computer controller in place.
CAUTION: Do NOT over tighten either harness

connector retaining screw.
g. Go to the single round harness connector. If

needed, rotate the connector to align with the
computer controller assembly female receptacle.
Carefully push the round harness connector
upward and into the female receptacle. Rotate
the knurled harness lock ring clockwise [CW] to
lock it onto the female receptacle housing. Plug
the harness into the top relay, of the two [2]
relays installed on the left hand side of the
console next to the S2X computer controller.
FIGURE 7-129. COMPUTER CONTROLLER -
INSTALLATION
9/2005 7-95
Section 7
ELECTRICAL
INSTALLATION OF GROUP NUMBERS INTO THE This will put the “VIBS” group of screens, in the S2X
S2X COMPUTER CONTROLLER. computer controller window.
Turn the ignition key to the run position, but keep the Install the EIGHT [8] highlighted numbers into the
engine off. Press and hold the F3 function key. Then computer controller. These eight [8] numbers control
press the manual "vib" button on either directional/ all vibration start points and maximum run speeds for
speed control [FNR] handle. the front and rear vibration systems.
NOTE: ALL numbers being installed into the Manual Vib. : Off
computer controller memory MUST be on FrntVib LALS : - - - - Ma
the TOP LINE of the dash installed 2x24
display.
Use the scroll button to bring the number, to be
installed, onto the top line of the display screen.
Once you have the correct line in position, use the F1
key, on the computer controller to increase numbers
and the F2 key to decrease numbers. FrntVib LAHS : - - - - Ma
FrntVib HALS : - - - - Ma
Press F4 one [1] time to go to the “LMTD” group.
After this group is accessed, use the scroll button to
bring the machine model onto the top line, of the
display. Use the F1 key to scroll through the machine FrntVib HAHS : - - - - Ma
models until you have the correct model on the RearVib LALS : - - - - Ma
screen.
You will see the following screen when you have the
“LMTD” group accessed. RearVib LAHS : - - - - Ma
RearVib HALS : - - - - Ma
Machine Model:66 in
Save User RAM: NO
RearVib HAHS : - - - - Ma
F. Vib Cmnd : 0.0 Ma
Scroll once.
Press F4 to go to the “PROP” group.

Save User RAM: NO
NonVol vs RAM: Different This will put “PROP” in the window.
Install the FOUR [4] highlighted numbers into the

Press F4 to go to the “INPT” group. computer controller.
This will put “INPT” in the window. These four [4] numbers control the machine speeds
and controllability.
Press F4, again, to go to the “VIBS” group of
screens.
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ELECTRICAL
Press F4, two [2] times to return to the “LMTD” group
Fwd Max : - - - - D/A of screens, where the numbers just installed will be
Rev Max : - - - - D/A locked in. You will see the following screen.
Scroll twice. You will see the following screen. Save User Ram : NO
NonVol vs RAM : Different
Fwd Thresh : - - - - D/A

Rev Thresh : - - -- D/A NOTE: You should now have the above screen
on the display. With the screen in this
position, press F1 to lock in the numbers.
Press F4 to go to the “FNR” group. The “NO” will momentarily flash to “YES”
and then back to “NO”. The DIFFERENT
This will put “FNR” in the window. will change to BOTH SAME. The numbers
will now be locked in.
Press F4 to go to the “ACCL” group.
This will put “ACCL” in the window. After the numbers have been locked into the
computer controller, press F4 to return to the “RUN”
Press F4, again, to go to the “A/D” group of screens. group of screens where you started. Turn the ignition
key off.
This will put “A/D” in the window.
Install the FIVE [5] highlighted numbers into the CAUTION: After ALL group numbers have been
computer controller. installed into the computer controller,
they MUST be locked in BEFORE the
These five [5] numbers control the FNR min/max ignition key is turned off.
output numbers, along with the upper and lower
neutral switch limits.
NOTE: The S2X computer controller removal and
replacement is now complete. Operate the
FNR Max : - - - - 4.72 VDC machine to verify functionability.
FNR Ntop : - - - - 2.74 VDC
Go to the instrument panel riser. Put the computer

Scroll twice. You will see the following screen. controller assembly access cover in place. Install,
and securely tighten, the four socket head capscrews
that fasten the access cover to the riser.
FNR Nbot : - - - - 2.18 VDC
FNR Min : - - - - 0.19 VDC
Scroll twice. You will see the following screen.
Saved VLdp : - - - - 13.0 VDC

Battery Volts : - - - - 13.7 Vbt
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REMOVAL AND REPLACEMENT OF c. Go to the directional/speed control assembly
DIRECTIONAL/SPEED CONTROL HANDLE being removed from the right, or left, side of the
ASSEMBLY instrument panel area.
[See Figure 7-130].
d. Reach upward through the underside of the area
Replace the right, or left, directional/speed control where the control assembly, being removed and
handle assembly only AFTER being certain the replaced, is installed. Carefully release the lock
assembly has failed. on the directional/speed control assembly
electrical wiring harness plug connector to
control harness connector and separate the
CAUTION: This component is one of the least connection.
likely to have a failure and, therefore,
should be replaced with new, ONLY e. Reach upward through the underside of the area
when CERTAIN an actual failure has where the control assembly, being removed and
occurred. replaced, is installed with an open end wrench.
Loosen the capscrew which fastens the
controller link to the control assembly being
Use the following information to CAREFULLY remove removed.
and replace the right, or left, directional/speed control
assembly with new: f. Hold the control assembly handle. Remove the
four socket head capscrews that fasten the
control assembly to the instrument panel.
CAUTION: After replacing the RIGHT, directional/
speed control handle assembly, with g. Move the control assembly handle inward to tip
new, a calibration of the computer the control actuation shaft outward and from
controller system/new directional/ engagement into the controller link. Lower the
speed control assembly - MUST be control assembly handle downward and through
done. Use the procedures given in the access area of the instrument panel.
THIS section to correctly do the Remove the directional/speed control assembly
required calibration. from the machine.
a. Put the secondary/parking brake system control

switch “ON” [APPLIED] and STOP the engine.
b. Remove the left rear side service access cover.

Go to where the battery is installed. Remove the
negative [-] battery cable from the negative [-]
battery post and move it away from the battery.
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h. Put the new control assembly in position under k. Reach upward, through the underside of the
the access area of the instrument panel. Raise area where the control assembly has been
the control assembly handle upward and through installed. Carefully connect the directional/speed
the access area of the instrument panel. Move control assembly electrical wiring harness plug
the control assembly handle inward to tip the into the control harness connector until the lock
control actuation shaft outward. Align the end of snaps into the locked position.
the control actuation shaft with the open end of
the controller link. Align the flat area of the l. Go to where the battery is installed. Move the
actuation shaft with the inner end of the retaining negative [-] battery cable to the battery. Install
capscrew. Move the control assembly handle the negative [-] battery cable onto the negative [-
outward to tip the control actuation shaft inward ] battery post. Install the left rear side service
and engage into the controller link. access cover.
FIGURE 7-130. RIGHT AND LEFT DIRECTIONAL/SPEED CONTROL ASSEMBLIES - INSTALLATION.
i. Reach upward through the underside of the area CAUTION: If the RIGHT directional/speed control
where the control assembly, is being installed assembly was replaced with new, the
with an open end wrench. Securely tighten the calibration of the computer controller
capscrew which fastens the controller link to the system/new directional/speed control
control assembly actuation shaft. assembly - MUST be done. Use the
procedures given in THIS section to
j. Hold the control assembly handle and align the correctly do the required calibration.
control assembly through holes with the tapped NO calibration is required if the left
holes in the controller base. Install, and securely directional/speed control assembly
tighten, the four [4] socket head capscrews that was replaced with new.
fasten the control assembly to the instrument
panel.
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GENERAL TROUBLE ANALYSIS INFORMATION WARNING: NEVER smoke or cause a spark near
AND PROCEDURES. ANY battery. ALWAYS loosen and
remove the NEGATIVE [-] battery
The following “TROUBLE ANALYSIS” information cable from the NEGATIVE [-] battery
tables and charts are about the individual post BEFORE loosening and remov-
ELECTRICAL circuits used on the machine. ing the POSITIVE [+] battery cable
from the POSITIVE [+] battery post.
Table 7-1 gives the MOST common problems that NEVER cause a shorted circuit
CAN be found, and the USUAL corrective action that condition in any circuit. USE EXTRA
should restore the machine to a normal operating CAUTION when checking ANY circuit
condition. Where the trouble is not a main using ANY electrical testing instru-
component, a reference to a detailed logic- ment.
troubleshooting chart is provided. When troubleshooting ANY system
circuit problem, FIRST determine IF
Table 7-2 is a voltage table for the S2X Computer the problem noted is confined to
Controller providing the normal voltage levels at each ONLY that system circuit OR com-
connector pin. mon to ALL system circuits.
The twenty-two (22) logic-troubleshooting charts CAUTION: IMPROPER troubleshooting methods

provide a detailed procedure for locating a fault. The waste time and can cause further
chart contains diamond shapes and rectangular system problems, or damage.
shapes Diamond shapes are used to ask questions
that have a YES or NO answer. Follow the YES or NO
line as applicable. The line leads either to another Use STANDARD voltage, ohms and continuity testing
diamond or to a rectangular box. Rectangular boxes instruments to aid in troubleshooting of non-computer
provide instructions or list the fault that must be controller monitored system circuit problems. For
corrected. After correcting the fault, the flow line CORRECT test instrument use and procedures follow
indicates the point in the flow chart that must be re- the entire testing instrument MANUFACTURERS
entered to verify operation. In most cases, it is best written instructions, supplied with the test
to return to the beginning of a chart after correcting a instruments.
fault. This will insure that switches have been set to
the correct position.
ALWAYS follow the FOUR basic principles of GOOD VOLTAGE MEASUREMENTS.

systematic troubleshooting.
Most voltage measurements will be made with the
1. KNOW the system. negative side of the voltmeter connected to chassis
ground and the positive side connected to a positive
2. DETERMINE the symptoms. (+) point in the circuit. The voltage level will normally
be battery voltage of about 12 vdc and the computer
3. LIST the possible causes. sensor voltages, which are about 5 vdc. When the
voltmeter has manual range selection, always use a
4. TAKE THE CORRECT action. range on the voltmeter that allows a normally reading
to be near mid-scale. Voltage readings are made
with the circuit in normal operation.
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CONTINUITY (RESISTANCE) MEASUREMENTS. through the use of the “DIAGNOSTIC” capability and
further testing will NOT be needed. Replacement of
A continuity test is actually a resistance test, looking the damaged electrical circuit component can then be
for a resistance usually at almost 0 ohms. Continuity quickly done.
tests can only be performed on a circuit that is not
connected to a voltage. When making continuity CAUTION: ALL electrical CONTROL system
checks always disconnect the battery. The ohmmeter CIRCUITS used on the 66 Inch and 78
has a built in voltage supply for operation. If the Inch Compactors are EXTREMELY
ohmmeter is connected across an external voltage, sensitive to having CORRECT voltage
the meter may be severely damaged. Always set the SUPPLIED to, and within, them.
ohmmeter to the lowest possible scale. ALWAYS be sure that the correct
voltage is available to the entire
CURRENT MEASUREMENTS. electrical system BEFORE further
troubleshooting any circuit.
Current measurements normally require the meter to INCORRECT voltage [LOW], or HIGH]
be placed in series with the circuit. There are some can cause circuit malfunctions and/or
types of current meters that can be clamped around a component failures.
wire but in most cases the meter must be connected
into the circuit, This requires the circuit to be de-
energized, usually be disconnecting the battery. The If a noted problem is confined to ONLY ONE system
circuit is then opened (wire disconnected) and the circuit, the troubleshooting thought process and
current meter connected between the wire and the procedures should be confined to ONLY the circuits
point the wire had been attached to. When the battery and components which affect THAT system circuit.
is reconnected and the circuit energized the current
flowing in the wire will now flow through the current If the problem affects ALL system circuit, then the
meter, indicating the amount of current. problem MUST be caused by malfunctions in circuits,
or components, COMMON to ALL system circuits and
WARNING: Do NOT use ANY testing instrument the thought process and procedures should be
BEFORE reading ALL manufacturers related to those areas.
instructions for the instrument AND
procedures to be used to trouble- Determine WHICH system factor, where they apply, is
shoot the circuit problem. SERIOUS causing the problem: electrical, Mechanical, Hydraulic
injury and/or system circuit damage or some combination of any of these.
can occur if correct procedures are
not followed. Only after the CAUSE of the problem has been
determined can the SPECIFIC damaged circuit
component be repaired, or replaced.
The computer controller system used on the 66 Inch
and 78 Inch Compactors, has built in “DIAGNOSTIC”
capability [see this section].
The computer controller system is used to “self

diagnose” certain components within the electrical
circuits it monitors. Most malfunctions, in each
monitored circuit, will be immediately identified
9/2005 7-101
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TABLE 7-1 TROUBLESHOOTING CHART
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TABLE 7-1 TROUBLESHOOTING CHART (CONTINUED)
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TABLE 7-2. S2X COMPUTER CONTROLLER VOLTAGE CHART
S2X
S2X
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TABLE 7-2. S2X COMPUTER CONTROLLER VOLTAGE CHART (CONTINUED)
S2X
S2X
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TABLE 7-2. S2X COMPUTER CONTROLLER VOLTAGE CHART (CONTINUED)
S2X
S2X
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66 Inch Amplitude Settings

While both drums are engaged.
78 Inch Amplitude Settings

While both drums are engaged.
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GENERAL MACHINE CALIBRATION PROCEDURE Upon completion of the calibration procedure, the
INFORMATION. controller will check the new values against a table of
acceptable ranges for each value. If a value is out of
In field machine calibration is difficult, due to range, the value stored in memory prior to the
restrictions with being able to duplicate “on mat” calibration will be restored. The success, or failure, of
operating conditions. Therefore, any time a S2X the calibration procedure, will be indicated on the
computer controller is “field replaced” with new, all display along with a code to indicate any failures
pertinent numbers must be downloaded from the which may have occurred. See the following
original factory installed S2X computer controller, if at information for more details.
all possible, BEFORE removing it [see this section].
CAUTION: Should a condition exist where it is RIGHT DIRECTIONAL/SPEED CONTROL [FNR]

NOT possible to download these CONTROL HANDLE.
numbers, contact the BOMAG
Americas, Inc. Service Department, NOTE: A new S2X computer controller, which
having the machine Model and Serial has never been calibrated, will display a
numbers, and assistance will be fault message indicating “Fault: FNR
given. Calibration”, if it is attempted to use the
computer controller without doing the
calibration procedure. This message will
Calibration can be performed only with the control not appear on the screen if the computer
handle, EDCs, and vibrator speed potentiometers controller has previously been calibrated,
connected and functioning properly. on any machine.
The Compactor must be warmed up, completely,

before starting the calibration procedure. To perform the calibration procedures for the right
directional/speed [FNR] control assembly, move the
The calibration procedure can be initiated by pressing control handle to neutral, at the start of the procedure.
and holding the F1 key, on the computer controller,
while turning the ignition switch to the run position, but Hold F1 on the computer controller, and turn the
keeping the engine off. ignition switch to the on/run position (do NOT start the
engine).
The alphanumeric [2x24] display will provide step by
step instructions, to the technical service personnel, CAUTION: Be sure to hold the F1 button until the
as to how to proceed through the calibration process. display screen has "BOMAG
When the steps are completed, the calibration routine AMERICAS" on it. Look in the little
can be exited by pressing the F1, on the computer window, on the computer, to the left of
controller, again. the F1 key. You should see "CAL" - for
calibrate in red letters. You will then
The calibration routine can be stopped, at see information, as follows, on the
intermediate steps, if F1 is pressed prior to the display with “FNR” meaning the
completion of a step, or steps. forward, neutral, reverse lever.
The old stored values, for those steps not completed,

will be used. The calibration routine can be stopped The top line on the [2x24] display screen will have
after any of the following steps: FNR :—:—:— ( 3 sets, of 3, numbers).
1. The FNR calibration is complete. The first set of numbers will be approximately, in the
middle of the range of, 0 to 1023.
2. The propel thresholds and propel full speed
currents are complete. The middle number will be the bottom end of the
neutral switch. The RH number will be the top end of
3. The vibrator calibrations are complete. the neutral switch. The bottom line will say “MOVE
SLOWLY TO FULL FWD”.
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Move the FNR to neutral. Once the FNR is in neutral,
FNR : --- : --- :---- the top line of the screen will read “SET FNR TO
Move Slowly To Full Fwd. FWD THRESH” The bottom line will read:
“THEN PRESS MAN VIB (OR F1 = QUIT)”
CAUTION: It is imperative to do this extremely Set FNR To Fwd Thresh

slowly, as the computer is looking for Then Press Man Vib. (or F1 = quit)
the top end of the neutral switch
range. As you move the lever forward,
the LH and RH numbers will increase.
To go no further, in the calibration mode, press the F1
key on the computer controller.
The RH number will stop when the neutral switch
closes. Continue on to the full forward stroke handle Check the window, on the computer controller, to see
position. if “CAL” has been replaced with “RUN”.
The LH number will continue to increase until the top

range of the controller is realized. As soon as you CAUTION: You may have to push F1 several
reach full stroke, the screen will change to read: times to get the “RUN” group back on
“MOVE SLOWLY TO FULL REV”. the screen, but only push it ONCE, at
a time.
FNR : --- : --- :----

Move Slowly To Full Rev. NOTE: “MAN VIB” means to push the manual
vibration start/stop button, at the top of
either the right, or left, control handle, to
lock in the threshold setting.
CAUTION: Follow the same slow procedure, as
during the forward procedure. This
time the computer is looking for the
bottom end of the neutral switch PROPEL THRESHOLD CALIBRATION.
range.
The propel threshold calibration procedure should be
done with the engine running, so that you can travel
The middle number, as well as the LH number, will be the machine.
decreasing. The middle number will stop when the
neutral switch closes, with the LH number continuing If the procedures are done in this manner, be sure to
on to the full reverse stroke handle position. have an open, level, unrestricted area for operation of
As soon as you reach full stroke, the display will read: the machine, as the machine controllability will be
“RETURN FNR TO NEUTRAL” outside of the preset computer values.
Return FNR To Neutral DANGER: Keep all personnel, except the person
doing the propel threshold calibration
procedures, clear of the machine. Do
the calibration procedures ONLY in an
open, level and unrestricted area.
9/2005 7-169
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The propel threshold calibration procedure can be NOTE: A condition has been experienced where
done with the engine off, but you most likely will not full stroke will fail the forward, and/or the
achieve optimum performance. Should you choose to reverse, propel calibration process do to
do the calibration in this manner, call the BOMAG the fact that the “number” just set was
Americas, Service Department with the machine above the “preset” value that the com-
Model and Serial numbers, and special calibration puter is looking for. Should this be the
instructions will be provided. case, go full stroke, and then back the
control handle off slightly before pushing
The threshold, that the computer is looking for, is the the “MAN VIB” button to lock the setting.
minimum signal required to travel the machine. The screen will change and tell you to do
the same thing in reverse, which can be
With the engine running, put the THROTTLE at high done by repeating the “forward proce-
IDLE. Put the transmission SPEED RANGE at work dure”.
[low] speed.
Stroke the control handle until the compactor drums Set FNR to 5 mph Rev.
are just on the “threshold” of movement. At this point, Then Press Manual Vib.
press the “MAN VIB” switch, on the control handle, to
save the setting. The screen will then change to read:
“SET FNR TO REV THRESHOLD”, on the top line, The next screen you will see, on the display, will be
and “THEN PRESS MAN VIB”, on the bottom line. for front and rear vibrator pump speed calibration.
Set FNR To Rev. Thresh CAUTION: THIS IS WHERE YOU STOP THE FNR
Then Press Manual Vib. CALIBRATION PROCESS.
The vibration systems will run as
soon as the “MAN VIB” button is
Repeat the above procedure, for the reverse propel pressed, IF the engine is running.
threshold calibration.
As soon as this is completed, the display will change Set Hi F. Vib. = 2000 vpm
to read: “SET FNR TO 5 MPH FWD”, on the top line Then Press Man Vib. (or F1 = quit)
with the bottom line reading “THEN PRESS MAN
VIB”. The computer is looking for 5 MPH. Technically,
you should be able to go full stroke with the control
handle and then press “MAN VIB” switch to set the
speed.
Set FNR to 5 mph Fwd.

Then Press Manual Vib.
To save the reverse propel threshold setting, move

the control handle to full stroke and back the control
handle off slightly. Push the “MAN VIB” button, to lock
in the setting.
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You may, or may not, see the screen below
depending on whether, or not, the calibration failed. Calibration
BIT Calibration Item BIT Item
NOTE: If the calibration failed, you will see the 8 Forward threshold D/A value 4 Not used
screen below. This does not necessarily
mean that you have not corrected the 7 Reverse threshold D/A value 3 Not used
problem you were experiencing. The
software, in the computer controller, has 6 Forward full speed D/A value 2 Not used
a preset value of parameters designed
into it. Should any part of your calibration 5 Reverse full speed D/A value 1 Not used
procedure fall outside of these values,
the calibration will fail and the process
will have to be repeated. If you are The above, will give you the code to determine which
recalibrating a controller, this may not area, of the calibration, failed. The first four [4]
be the case. It is possible to fail a positions are NOT used on the prop screen. The last
recalibration and still cure the problem four [4] positions will either have a “1”, indicating that
for which you were recalibrating, the this area failed, or a “0”, indicating it passed.
controller, to begin with. If the total
calibration procedure passed, the screen If the computer controller has already been calibrated
will say - Calibration Complete. and the numbers put in during recalibration are
outside of the programmed parameters, the computer
will revert back to its previous setting. By doing this,
If the controller has already been calibrated, and the the recalibration may be able to fail one, or several,
numbers you put in during recalibration are outside of areas during the recalibration, and correct the one
the programmed parameters, the computer will revert that was giving the fault reading. If the right hand FNR
back to its previous setting. controller was replaced, the calibration must be
completed.
By doing this, you may be able to fail one, or several,
areas of the recalibration and correct the one that
was giving you the fault reading. NOTE: During FULL machine calibration, you will
NOT push F1, on the computer controller,
If you have replaced the right FNR control assembly, to stop the calibration, but rather, con-
the calibration will have to be completed. tinue on to the vibration systems calibra-
tion.
Push F1, on the computer controller. The screen will
read: “PROP. CURRENT STATUS”, if you have failed
the calibration.
Prop. Current Status =

00000000 Press Man. Vib.
12345678 position (pos)
The 8 bits (digits) are positioned as follows:
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VIBRATION SYSTEMS CALIBRATION. There are eight [8] settings to go through in this
calibration procedure. This procedure will establish a
FRONT AND REAR VIBRATOR PUMP SPEEDS linear relationship between the vibrator frequency
CALIBRATION. [speed] pot and the required output current to the
EDC's.
CAUTION: This calibration procedure should
ONLY be done IF the vib numbers can During this procedure both vibrators will be running at
NOT be downloaded from the factory the same amplitude [low, or high] and at nearly the
installed S2X computer controller. same vibrator frequency [speed].
To correctly do the front, and/or rear, vibrator pump NOTE: The speed of the drum not being cali-
calibration procedures, the engine THROTTLE must brated can be trimmed, if desired.
be at RUN [high] idle speed and the FRONT VIB
SPEED and REAR VIB SPEED [frequency]
potentiometers [pots] should be at their minimum WARNING: In order to be able to “load down”
settings. the engine, the propel system will be
active during this calibration.
The AUTO/OFF/MANUAL vibrator mode switch The operator has total control over
should be in the OFF position. the speed of the machine with the
directional/speed control [FNR]
The technical service personnel will be instructed, by handle and can slow down, or stop,
the [2x24] display screen, to set the vibrator speeds the machine during this calibration
for the front drum and then for the rear drum. mode. For safety purposes, returning
the directional/speed control [FNR]
The vibrators can be turned on, or off, by setting the handle to neutral, at any time, will set
drum VIBRATOR MODE switch to MAN, or OFF. Use the valve drive to zero. Also, it should
the FRONT VIB SPEED or REAR VIB SPEED be noted that the normal accel/decel
[frequency] potentiometers [pots] to trim the current rates will not be in effect during the
until the actual vibrator speed measured, with an calibration mode.
external measuring device, is equal to the requested
value.
Then press the manual vibrator [“MAN VIB”] push-

button switch in the FNR control handle.
BW266/BW278
LOW HIGH
High Amplitude 2000 vpm 3400 vpm
Low Amplitude 2000 vpm 3800 vpm
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During full machine setup you will NOT push F1 to Press the vibration button and you will see:
stop the calibration, but rather continue on to the
vibration systems setup.
Set Hi R. Vib. = 3400 vpm
then press Manual Vib.
Set Hi F. Vib. = 3400 vpm
Press the vibration button and you will see:
Pressing the manual vibration button changes the

screen to: Set Lo R. Vib. = 3800 vpm
Set Lo F. Vib. = 3800 vpm

then press Manual Vib. Press the vibration button and you will see:
Vibr. Current Status =

Press the manual vibration button to change the 00000000 Press Man. Vib.
screen to:
Set Hi R. Vib. = 2000 vpm Pressing the manual vibe button, one more time, will
then press Manual Vib. tell you whether you passed, or failed, the calibration
process.
Press the manual vibration button and you will see: An example of what you will see is:
Calibration failed
Set Lo F. Vib. = 2000 vpm Press F1
This has a similar code. It’s as follows:

Bit Calibration Item Bit Calibration Item
8 Front Vib. - High Amplitude, Low Speed 4 Rear Vib. - High Amplitude, Low Speed
7 Front Vib. - Low Amplitude, Low Speed 3 Rear Vib. - Low Amplitude, Low Speed
6 Front Vib. - High Amplitude, High Speed 2 Rear Vib. - High Amplitude, High Speed
5 Front Vib. - Low Amplitude, High Speed 1 Rear Vib. - Low Amplitude, High Speed
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CALIBRATION FAILURE MESSAGES.
At the end of the calibration procedure, the calibration

values are compared to acceptable limits.
There are four [4] possible messages which display
the status.
The program will only show the status message if

there is a failure in the calibration procedure. A zero
bit in the status indicates that the value was within
limits. A one [1] indicates a value out of limit.
The messages and their meanings, are as follows:
Sensor Max. Status =

8 FNR Forward Maximum Value 4 not used

7 not used 3 not used
6 FNR Top of Neutral Band Value 2 not used
Sensor Min. Status =

8 FNR Reverse Minimum Value 4 not used

6 FNR Bottom of Neutral Band Value 2 not used

8 Front Vib. - High Amplitude, Low Speed 4 Rear Vib. - High Amplitude, Low Speed
7 Front Vib. - Low Amplitude, Low Speed 3 Rear Vib. - Low Amplitude, Low Speed
6 Front Vib. - High Amplitude, High Speed 2 Rear Vib. - High Amplitude, High Speed
5 Front Vib. - Low Amplitude, High Speed 1 Rear Vib. - Low Amplitude, High Speed
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Sensor Max Status =

8 Forward Threshold D/A Value 4 not used

7 Reverse Threshold D/A Value 3 not used
6 Forward Full Speed D/A Value 2 not used
5 Reverse Full Speed D/A Value 1 not used
If any calibration item fails, the individual failed items Remove the cover plate.
will be restored [revert back] to the value they were at
before the start of the calibration procedure. Start the engine. You will see the following screens in
succession:
The last display screen will be a message indicating
that the calibration procedure passed, or failed.
Day - T a
The technical service personnel should then press
F1, on the computer controller, to end the calibration
procedures and return to the run mode. The screen will immediately change to:
COMPACTION AMERICA 66 in
VIBRATION SPEEDS ADJUSTMENT DUAL DRUM COMPACTOR
PROCEDURES.
Note: The display will show either 66 in or 78 in after
Technical service personnel will have to access the COMPACTION AMERICA depending on the model of
S2X computer controller to access the VIBE group of the compactor.
screens and adjust the vibration systems speeds.
Followed by:
CAUTION: Adjustment of ANY vibration speed,

defined in CHART B, to a speed in 0.0 mph : front 0 vpm
excess of the CORRECT vibration per 0 ipf : rear 0 vpm
minute [VPM] speeds in high, or low,
amplitude which are published in
Section 2 - SPECIFICATIONS, can These are the run screens. When you have the above
DAMAGE the vibration system[s] and screen on the display in the dash you will be in position
VOID machine warranty. to access the “VIBS” groups of screens. When you
see “scroll”, in this information, it will always mean to
use the SCROLL BUTTON on the dash.
The computer controller is located behind the cover
plate below the steering wheel. The cover plate is When you see “push F4”, it will mean to use the F4
held in place with 4 button head capscrews. function key on the computer. Use the F4 key to scroll
from one screen grouping to another. Use the SCROLL
BUTTON, on the display, to scroll within a specific
screen group. When the SCROLL BUTTON is used it
will move the bottom line, on the display, to the top of
the display.
9/2005 7-175
Section 7
ELECTRICAL
Press F4 3 (three) times, or until, you see the word
“VIBS” in red letters, in the window, on the computer. RearVib LAHS : - - - MA
This is the group of screens where the adjustment of RearVib HALS : - - - MA
the vibration systems speeds will take place. You will
see the following screens in this group:
Scroll twice.
Manual Vib. : Off

FrntVib LALS : - - - MA RearVib HAHS : - - - MA
F. Vib Cmnd : 0.0 MA
Scroll twice.
Scroll twice
FrntVib LAHS : - - - MA
FrntVib HALS : - - - MA R. Vib Cmnd : 0.0 MA
Manual Vib. : Off
Scroll twice.
Scroll once to return to the beginning of this group.
FrntVib HAHS : - - - MA Definitions are given in CHART B.

RearVib LALS : - - - MA
Scroll twice.
FrntVib LALS - - - - Front Vibrator, Low Amplitude, Low Speed

FrntVib LAHS - - - - Front Vibrator, Low Amplitude, High Speed
FrntVib HALS - - - - Front Vibrator, High Amplitude, Low Speed
FrntVib HAHS - - - - Front Vibrator, High Amplitude, High Speed
RearVib LALS - - - - Rear Vibrator, Low Amplitude, Low Speed
RearVib LAHS - - - - Rear Vibrator, Low Amplitude, High Speed
RearVib HALS - - - - Rear Vibrator, High Amplitude, Low Speed
RearVib HAHS - - - - Rear Vibrator, High Amplitude, High Speed
CHART B.
7-176 9/2005
Section 7
ELECTRICAL
The numbers to be adjusted are the front and rear Repeat this process until you have verified the
drum HAHS and front and rear drum HALS speeds correctness, with the use of the “Reed
[see CHART B]. tachometer".
Bring these numbers, individually, to the top line of the

display where you will be able to increase the existing NOTE: You might want to check the front and
number on the screen. The number you will see is the rear drum LAHS settings, as well. The
electrical Ma current output to the EDC (electronic same previously given procedures will
displacement control) on the pump. work for increasing these speeds, should
they be slow. Be sure to put the number,
Once the number, to be changed, is positioned on the to be changed, on the TOP line of the
top line, of the display, push F1, on the computer, to display.
increase the number or F2, to decrease the number.
NOTE: Each .1 (1/10) of a Ma will increase the NUMBER LOCK IN.

vibration speeds by approximately 12
VPM. Once you have the numbers set, press F4 to go to
the “LMTD” group of screens.
Change the above 4 numbers to get you near the

correct Ma current output and use the F4 key to take Save User RAM : NO
you back to the “RUN” group of screens. NonVol vs RAM : Different
CAUTION: Do NOT TURN the ENGINE OFF. The When you have the above screen in position, on the
changed numbers are NOT “locked screen, press the F1 key. When you see the Different
in”, at this time. The changed change to “BOTH SAME” the numbers are locked in.
numbers will be lost if the engine is Push F4 to return to the “RUN” screen. You can now
stopped. You MUST leave the engine turn the key off and reinstall the cover plate.
running until you have “locked in”
your numbers and finished.
Check the vibrations per minute [VPM] speeds, with

the use of a “reed” tachometer. If the speeds are still
slow, push F4 to go back to the VIBS group of
screens and increase your numbers.
9/2005 7-177
Section 7
ELECTRICAL
NOTES
7-178 9/2005
Section 7
ELECTRICAL
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9-
17
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9/2005 7-179
Section 7
ELECTRICAL
2
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7-180 9/2005
Fault Analysis Procedures
For the DC2 Controller
Version 2.33
Vibratory Compactor Control System

CONTENTS
Pages 2-3 General Control System Performance.
Pages 4-6 DC2 Controller Functions Version 2.33
Page 7 Fault Description/Message Text
Page 8-8.1 Fault: 5Volt Sensor Power,

Description, Trouble Shooting,
Component location
Page 9 Handle Output VS Position
Pages 10-12 Fault: FNR Sensor Pot

Component location
Pages 13-15 Fault: FNR Neutral Switch

Component location,
FNR Adjustment Procedure
Pages 16-17 Fault: Rear VIB.EDC

Component location
Pages 18-19 Fault: Front VIB.EDC

Component location
Pages 20-22 Propel EDC Function

Component location
Page 23 Warning: Low Water Level

Description
Pages 24-25 Fault: Prop Thrsh.cal

Component location
Pages 26-27 Fault: Prop Dband. Cal
Component location
Pages 28-29 Fault: FNR . Cal

Component location
Pages 29-31 Propel Circuit Logic
Pages 32-32.1 Limited Operation Mode

Description, Operation
Pages 33-35 DC2 Voltage Logic

Pages 38-43 Notes

1 GENERAL CONTROL SYSTEM PERFORMANCE
The Control System will provide the following capabilities:
• The System will control one hydrostatic pump which drives two dual speed, hydrostatic motors on
the roller drums. The drums are located on the front and rear of the machine. The drum speed
control is open loop.
• The System will adjust the hydrostatic transmission pump displacement to obtain the desired
speed per the operator’s input via the left or right travel speed control handles. The vehicle
direction will also be selected by the same control handles.
• The switch labeled High/Low Motor Speed will directly select the hydrostatic motor displacements
for high or low range. The low speed range will be used for Work mode and has a speed range
of 0-5 mph at high engine speed. The high range will be used for Transport mode and has a
speed range of 0-10 mph at high engine speed. A signal will be provided to the controller which
will indicate the selection of high speed or low speed range for the motors.
• The switch labeled High/Low Engine Speed will directly control the engine throttle for high or low
engine speed. A signal will be provided to the controller which will indicate the selection of high
or low engine speed. The display of travel speed will be adjusted based on the inputs to the
controller.
• The System will have a maximum travel speed setting which can be adjusted by the operator.
The adjustment will be made with the control handle, the manual vibrator switch, and the 2X24
display.
• The System will control one vibrator pump for the front drum and one vibrator pump for the rear
drum. There are several controls for the vibrators:
• Vibrator speeds are set by two potentiometers on the control panel. The vibrator speed
will be displayed on the 2X24 display module. The vibrator speeds are open loop and
the display readout will be compensated if only one vibrator is running.
• Vibrator Function (Auto/Off/Manual) - if the Vibrator Function switch is in the manual
position, momentary push-button switches in the control handles are enabled to turn
the vibrators on or off. If the Vibrator Function switch is in the auto position, then the
vibrators will come on when the vehicle speed exceeds a preset speed and go off when
it drops below that value.
• The Auto vibrator on/off speed can be adjusted between 0.5 mph and 5.0 mph with a
special display screen
• There is a lockout function for the vibrators which will disable the vibrators if the motor
speed selection switch is set to Hi. This lockout function is active in both Auto and
Manual vibrator modes.
• There is a another lockout function for the vibrators which will disable the vibrators if
the engine speed selection switch is set to Low. This lockout function is active in both
Auto and Manual vibrator modes.
• Vibrator Location (Front/Rear/Both) - this switch will select which of the two vibrators
will be activated when the machine is moving.
• Amplitude Amount (High/Low) - this switch will select high or low amplitude vibration for
both vibrators.
• Vibration impact spacing will be calculated based on vibrator speed and vehicle speed
and displayed on one of the display screens.
• The system will monitor water level switches in the water tanks. The information from
the switches is not used for control, but it will be displayed as a warning message if the
water level is low.
• The System will control one sprayer relay which will turn on the sprayers on the front and rear
drums. The sprayers are turned on whenever the vehicle is moving. There is a Water Saver
spray timer function which will control the duty cycle of the sprayers when they are in the on state.
The spray duty cycle is controlled by the Water Saver pot on the control panel and can be set
from 0-50% duty cycle. The maximum sprayer period will be 10 seconds.
• The System will control one backup alarm which will be turned on whenever the propel signal is in
reverse.
• The System has a brake switch to be used for emergency stopping. This switch will send a signal
to the controller which will set the propel command to zero. The switch will also apply the system
brakes directly. The control handles must be returned to neutral after brake application before
the control will allow propel function.
• When power has been removed by turning off the key switch and then is reapplied to the system,
the control handles must be in neutral to enable vehicle movement. This is a safety feature to
prevent unexpected movement if the handle is out of neutral on power up.
• Calibration parameters are stored in a non-volatile memory to be recalled upon subsequent

startups of the system. Calibration can be entered by pressing and holding the Calibration switch
(F1 on the controller) while power is applied and following the calibration procedure. The System
will find the threshold currents and full speed currents for the propel pump. It will learn the low
and high speed currents for the vibrator pumps. It will also learn the voltage ranges for the travel
speed control handle, the front and rear vibrator speed potentiometers, and the Water Saver
potentiometer.. See Section 4 for details of the calibration procedure.
• The System incorporates a 2 line by 24 character alphanumeric display which is used to inform
the operator of various system parameters including travel speed in mph or kph; vibrator speeds
in vpm; and impacts per foot or meter. The display is also used to walk the operator through the
Calibration steps. Fault messages are displayed to indicate to the operator the source of a fault.
• Fault detection is built into the controller. When one of the possible faults is detected the
controller will take the necessary action to minimize the effect upon the operation of the machine.
Faults will be displayed on the second line of the display module.
DC-2 Controller Functions
Version 2.33 (Feb. 10, 2000)
There are four buttons on the DC-2: F-1, F-2, F-3, and F-4. To access them on the machine, the cover
panel must be removed.
When the cursor is present on the top line on the display panel, F-1 will scroll up through choices or
increase values and F-2 will scroll down through choices or decrease values. F-3 will scroll the lines of
a screen up while the red scroll button on the display panel will scroll down. F-4 will screen through
the menus or screens.
Note: The following Bold lines are the additions/changes to version 2.33 from version 2.21.
Default/Operating Screen – “Run”

Lines:
1. 0.0 mph :FRNT 0 vpm
2. 0 ipf :REAR 0 vpm
3. 0 fpm :FRNT 0 vpm
4. 0 ipf/__ F :REAR 0 vpm (MATT Temp will be displayed when asphalt
temperature is above minimum range of sensor.)
5. 13.6 Vbt :FRNT 0 vpm
6. 4.9 Vsp :REAR 0 vpm
7. AUTO VIB. SET.= 1. 0 mph
8. ADJ. WITH CONTROL HANDLE
9. DISPLAY UNITS: ENGLISH
10. ADJ. WITH MANUAL VIB. SW
11. TRAVEL SPD LMT= 3.8 mph
13. FWD EDC TEST:ENGINE OFF!
14. PUSH MANUAL VIB. TO TEST
15. REV EDC TEST:ENGINE OFF!
Note: Only lines 1 through 6 can be accessed by the operator when the machine is in operation or
at minimum, moving. Lines 1 through 12 can be accessed when FNR is in neutral. To access lines
13 through 16, brake switch must be applied in addition to the FNR being in neutral. Vibes will not
work if speed is less 1.0 mph and throttle is not is “RUN” position.
The “AUTO VIB. SET” and the “TRAVEL SPD LMT” can be set by the operator via the FNR
handle and vibe switch on the FNR handle. The machine must be in neutral to accomplish this. To
change, scroll through the menus using the red scroll button on the display panel until line 7 or 11 is
on the top line. To change, push the FNR handle forward or back and depress the vibe switch. FNR
handle forward will increase values and FNR handle back will decrease values.
Access the standard additional screens by pushing the ‘F4’ key to scroll through the menu.
Screen 2: LMTD
1. Save User RAM: YES/NO (Cursor present so can be changed)
2. NonVol.vs RAM: BOTH SAME
3. Machine Model:C766H (Cursor present so can be changed)
Note: Depress the “F1” switch to save changes on the DC-2. “YES” in line (1) will be displayed
momentarily, otherwise “NO” will be the normal message. If changes have been made, the
“DIFFERENT” message in line (2) will be displayed. Once changes have been saved, the message
will change back to “BOTH SAME” which is the normal message. Changing the machine model
will reset some of the calibration values to defaults, particularly the Vldp value
Screen 3: INPUT
1. Vib. Function:Auto/Off/Manual (Dictated by Vibrator Mode switch position)
2. Vib. Location:Front/Both/Rear (Dictated by Drum Select switch position)
3. Handle Vib. PB:Off/On (On is momentary)
4. Neutral Sw. :On/Off (On in center FNR position.)
5. Park Brake :On/Off
6. Vib. Amplitude:Low/High (Dictated by Amplitude switch position)
7. Motor Speed:Low/High (Dictated by Speed Range switch position)
8. Engine Speed:Low/High (Dictated by Throttle switch position)
9. Water Saver: 0-50.0%
Screen 4: VIBS
1. Manual Vib:Off
2. FrntVib LALS: 51.2 mA* (Cursor present so can be changed)
3. FrntVib LAHS: 82.0 mA* (Cursor present so can be changed)
4. FrntVib HALS: 54.8 mA* (Cursor present so can be changed)
5. FrntVib HAHS: 84.9 mA* (Cursor present so can be changed)
6. RearVib LALS: 57.1 mA* (Cursor present so can be changed)
7. RearVib LAHS: 85.6 mA* (Cursor present so can be changed)
8. RearVib HALS: 57.6 mA* (Cursor present so can be changed)
9. RearVib HAHS: 88.5 mA* (Cursor present so can be changed)
10. F. Vib Cmnd: 0.0 mA
11. R. Vib Cmnd: 0.0 mA
Note: F. Vib Cmnd and R. Vib Cmnd will display DC-2 output in mA if throttle switch is in ‘RUN’
mode, brake switch is off, vibrator mode switch is ‘AUTO’ mode and compactor is traveling at 1.0
mph or greater (as displayed by the display screen).
* - The above values are default values.
To access additional screen on the display panel, depress the ‘F4’ key and the FNR vibe switch
simultaneously.
Screen 5: “PROP”
1. Fwd Max: 555 D/A* (Cursor present so can be changed)
2. Rev Max: 585 D/A* (Cursor present so can be changed)
3. Fwd Thresh: 207 D/A* (Cursor present so can be changed)
4. Rev Thresh: 191 D/A* (Cursor present so can be changed)
5. Propel Cmnd: 0 D/A
6. Propel Comp: 0 D/A
7. Actual VLDP: 12.8 VDC
8. Raw Command: 0.0 %
9. Rate Ltd Cmnd: 0.0%
Note: Items (5), (6), (8) and (9) will display the output from the FNR versus the output from the DC-
2. Brake switch needs to be released.
* - The above values are default value.
Screen 6: “FNR”
1. FNR State:Forward/Neutral/Reverse
2. FNR Input: 0.0 –100.0 %
3. Fnr Cmnd: 0.0 – 100.0 %
4. FNR Out: 0.00 – 5.00 Vdc
Note: Brake switch needs to be released for the above displays to show FNR output. If brake switch
is not released, FNR state will show an error message. The “FNR Out” values will not be greater
than the “FNR Max” value or less than the “FNR Min” value. If values shown on the display are
outside of this range, unit has wrong calibration values. If values shown in item 4 is 0.00 Vdc or
5.00 Vdc, there is a problem with the FNR potentiometer.
Screen 7: “ACCL”
1. Raw Command 0.0 %
2. Rate Ltd Cmnd: 0.0 %
Note: Raw Command=FNR output to DC-2. Rate Ltd Cmnd=DC-2 output in relation to the FNR
input. Item #2 will always follow item #1 to ensure that unit starts and accelerates smoothly in
either direction. This is pre-programmed into the software.
Screen 8: “Volt” (Cursor present so numbers are adjustable)

1. FNR Max.: 4.72 VDC*
2. FNR Ntop: 2.74 VDC *
3. FNR Nbot: 2.18 VDC*
4. FNR Min: 0.19 VDC*
5. Saved Vldp: 13.0 VDC*
6. Battery Volts: 13.7 Vbt
7. Sensor Pwr: 4.9 Vsp
* - The above numbers are default values.The screen below shows an example of a fault message. It
will be shown if a fault condition exists and
can be detected. It will be displayed for a short period of time on the bottom line of the display. Then the
previously selected bottom line will be displayed again. This will continuously alternate as long as the
fault is present. Some faults will cause a shutdown of the propel control if they are serious and the
message will continue to be displayed until the control is shut down and restarted. Others will only display
a message for as long as the fault is present.
3. 9 mp h : F R NT 3400 v p m
F AUL T : F NR Ne u t r a l S w.
The table below shows the fault numbers, fault messages, and resultant system mode. FAULT indicates
a display message only. STOP indicates that the propel system will shut down until the controller is
powered off and then on. “-” indicates that this fault is not used. Also, the backup alarm is not being
tested because it is an optional feature on machines. Note: the low water condition is shown as a FAULT
system mode, but it is only considered a warning to the operator.
DESCRIPTION/MESSAGE TEXT TIME TO SYSTEM MODE

DETECT
1 Sensor Power (5V) voltage is too low (Below 4.8V) 0.4 sec. STOP
“Fault: 5V Sensor Power”
2 FNR Sensor out of range 0.5 sec. STOP
“Fault: FNR Sensor Pot”
3 FNR Neutral Switch failure 0.5 sec. STOP
“Fault: FNR Neutral Sw.”
4 Front Vibrator EDC open or short ~1 sec. FAULT
“Fault: Front Vib. EDC”
5 Rear Vibrator EDC open or short ~1 sec. FAULT
“Fault: Rear Vib. EDC”
6 Propel EDC open or short Not Used -----------
“Fault: Propel EDC” Not Used -----------
7 Low Water Condition 0.4 sec. FAULT
“Warning: Low Water Level”
8 Propel EDC threshold Calibration values out of range at power up STOP
“FAULT: PROP THRSH.CAL”
9 FNR Not Calibrated at power up FAULT
“Fault: FNR Calibration”
10 Propel EDC deadband Calibration value out of range at power up STOP
“Fault: Prop. Dbnd. Cal.”
11 FNR Calibration values out of range at power up STOP
“Fault: FNR Cal.”
12 Water Spray valve open or short 0.4 sec. FAULT
13 BRAKE APPLIED 180 m sec. STOP

There is a common 5V power source in the DC2. It supplies output current to the following devices
If this fault should occur you can check each of the pin’s listed for continuity to ground.
PIN#
A-1 SCROLL BUTTON (5 V+ SENSOR_PWR) OUT TO DISPLAY PLUG PIN W.
B-1 HI / LOW AMPLITUDE SWITCH (5 V+ SENSOR_PWR) TO DISPLAY PLUG PIN V.
C-1 REAR VIBE SPEED POT # 2 (5 V+ SENSOR_PWR) TO DISPLAY PLUG PIN U.
D-1 FNR SENSOR POT (5 V+ SENSOR_PWR) TO RH FNR PLUG PIN 4.
E-1 BRAKE ON/OFF SWITCH (5 V+ SENSOR_PWR) TO MAIN HARNESS PLUG PIN J.
F-1 FRONT VIBE SPEED POT # 3 (5 V+ SENSOR_PWR) TO DISPLAY PLUG PIN R.
G-1 WATER SPRAY POT # 1 ( 5 V+ SENSOR_PWR ) TO DISPLAY PLUG PIN P.
H-1 Older machines LOW WATER LEVEL SWITCH (5 V+ SENSOR_PWR) TO MAIN HARNESS
PLUG PIN L. The machines with this option will not have a power panel
A B C D E F G H J K
FIGURE 1
CONTROLLER HARNESS CONECTOR
PIN OUT OF THE ( P1 ) PLUG
VIEW LOOKING IN TO THE PLUG
If the computer sees a value of 4.8V or lower, it shows a fault. The computer would have to
see a .5 amp draw for this to happen. Everything in the circuit draws about 5mA
individually. With that being the case, we wouldn’t see a .5 amp draw if everything is
drawing max power at once. To chase this fault, check the connection on the RH FNR first.
It could be the wire to any of the above mentioned areas. The one common between all
of these is the harness. The worst problem is the low water level switches as the wires
for the rear switch run in through the main frame harness, which runs through the hitch.
This is the best place to check. You may get lucky and clear it up by unplugging and
cleaning the connectors along the frame that run to the switch.
NOTE: IF YOU FIND THAT THE PROBLEM IS THE POWER WIRE THAT IS SUPPLYING THE LOW
WATER LEVEL SWITCH ON OLDER MODLES YOU CAN GET THE MACHINE UP AND RUNNING
QUICKLY BY CUTTING THE RED 16 GA WIRE COMING FROM PIN L IN THE MAINFRAME HARNESS.
THIS PLUG IS LOCATED UP UNDER THE DASH AND IS CONNECTED TO THE CONTROLLER
HARNESS MAKE SURE THAT YOU CUT THE WIRE ON THE MAINFRAME HARNESS SIDE OF THE
TWO PLUGS.
RUN FILTERS
OFF
AUTO MAN
WATER TEMP OIL TEMP

HOUR METER
GAUGE GAUGE
VIBRATOR MODE IDLE HYD OIL AIR
WATER SAVER
BOTH THROTTLE
FRONT REAR
SPEED RANGE
AUTO MANUAL
DRUM SELECT FRONT VIB SPEED BRAKE WATERSPRAY

HIGH LOW
ENG OIL PRESS FUEL

VOLTMETER
GAUGE GAUGE
SCROLL BUTTON
TO HITCH
X
W K
V L
J
B
H
U M
P C
N G A
E STATUS F1
T N
F2
D F D
M POWER F3
F S
F4 E O
A C
R P
L X Q
G B
H K DISPLAY PLUG
J
MAINFRAME
HARNESS PLUG
TO HITCH
BA
E
D
PLUG (P1)
C
JHGF
K
FIGURE 2
CENTER POSTION
2.49 VOLTS
REVERSE NEUTRAL BOTTOM NEUTRAL TOP FORWARD
2.25 VOLTS 2.74 VOLTS
.36 VOLTS 1.89 VOLTS 1.89 VOLTS 4.63 VOLTS
.01 VOLTS 4.88 VOLTS
FIGURE 3
DEAD BAND DEAD BAND
HANDEL STOP HANDEL STOP
POT STOPS POT STOPS
(@0 VOLTS) (@5 VOLTS)
HANDEL OUTPUT VS POSTION
FAULT: FNR SENSOR POT
This fault will show itself when the potentiometer in the RH FNR is out of range which will
happen at full stroke forward or reverse. The range is developed during calibration when
you move the FNR lever to full stroke, both directions. The computer reads the actual
number and then subtracts .098V from the top (forward) and adds .098V to the bottom
(reverse). Look at example #1. Remember that the numbers used in this example will be
slightly different from what you might see on any given machine, as each FNR controller
will be slightly different.
1. Sauer-Danfoss built a deadband into the handle to allow for they’re manufacturing
tolerances. This is the black area between .0098V & .1V and 4.98V & 4.88V
2. We then, through programming, added another deadband for our manufacturing tolerances
by subtracting .15V from the top and adding .15V to the bottom. The white area between
4.88V & 4.63V and .098V & .36V reflects this, the numbers that we are showing 4.73V & .1
are general numbers and very slightly from machine to machine.
3. The computer then adds .15V to the 4.63V equaling 4.88V and subtracts .15V from the .25
equaling .1V The 4.88 and .1 become our fault numbers.
4. Anything larger than the top and smaller than the bottom will cause our problem.
5. To correct this problem, go to the VOLT screen and adjust the FNR MAX and/or the FNR
MIN accordingly. If you are seeing this fault, you should be able to consistently cause it by
going full stroke in whichever direction the number is out of range. You can do this with the
engine off and the key in the run position. It will usually occur when the FNR lever is
pushed/pulled hard against the stop in the given direction. Adjust the number until you can’t
duplicate the fault (SEE THE FNR ADJUSTMENT AND COMPONETS LOCATIONS ON
THE FOLLOWING FIGURES 5 AND 6.)
CENTER POSTION
2.49 VOLTS


DEAD BAND DEAD BAND

POT STOPS POT STOPS

FIGURE 4
OFF
AUTO MAN
VIBRATOR MODE
WATER SAVER
FRONT
BOTH
REAR
FNR: MAX VDC
FNR: Nbot VDC
HIGH LOW
SCROLL MAN VIBE

AMPLITUDE
BUTTON REAR VIB SPEED
BUTTON
SCROLL BUTTON
RUN FILTERS
OFF
AUTO MAN
WATER TEMP OIL TEMP

HOUR METER
GAUGE GAUGE
WATER SAVER
BOTH THROTTLE
FRONT REAR
SPEED RANGE
AUTO MANUAL

HIGH LOW
ENG OIL PRESS FUEL

VOLTMETER
GAUGE GAUGE
SCROLL BUTTON
RIGHT HAND FNR LEVER

17
7 10 15
AAA
X1
X2
16 10 15
STATUS F1
F2
K6
K2
K1
18
15A
F3
F7
POWER
F4
6
13 14
FL
F6
FJ
F5
AUX
AUX
BAT
BAT
8 9
FG
5
FG
11
PAINT THIS ITEM RED
G
FK
+ POS.
- NEG.
FM
F1
FM
4 10
FL
FN
STATUS
G
49a
31
49
F2
085
49 49a C
70922
8 9
C2 C3 31
G
A
30 87 86 85
BOSCH
3
8X21W
K5
2+1+1X21W
12V
0 335 200 160
BOSCH
FJ
F3
8 9
KK
2
POWER
FP
30 87 86 85
30 87 86 85
BOSCH
F4
BOSCH
K4
G
K3
FH
FM
FM
TO HITCH
CC
G
12
FQ
FIGURE 5
FQ G FM FH
18
PAINT THIS ITEM RED
2 8 9
3 8 9 4 10 11 5 8 9 13 14 16 10 15
6
17
A
085
30 87 86 85
+ POS.
70922
49
BOSCH
BAT
12V
49
49a X1
K3
0 335 200 160

K1
C2 C3
F5
31
49a C
31
2+1+1X21W
8X21W
BOSCH
FG AUX
FL
FM FL K6
BOSCH BOSCH
- NEG. FG BAT AAA
K4 K5
F6
30 87 86 85 30 87 86 85 K2 X2
AUX
7 10 15
G FK FJ F7
15A
CC FM G FP KK FJ T FN FM G
G
FIGURE 6
12
ELECTRICAL PART IDENTIFICATION
K1 - FORWARD RELAY
WIRE COLOR GAUGE WIRE COLOR GAUGE
K2 - REVERSE RELAY
K3 - HIGH BEAM RELAY
K4 - LOW BEAM RELAY
K5 - WATER PUMP SPRAY RELAY
K6 - BACKUP ALARM RELAY
F5 - ACCESSORY CIRCUIT BREAKER (30A)
F6 - WATER SPRAY CIRCUIT BREAKER (30A)
F7 - BACKUP ALARM FUSE (15A - 3AG OR AGC)
FNR ADJUSTMENT PROCEEDURE.
Caution: Using this procedure, can inadvertently change the operation of the roller so that the
machine may become unsafe to operate. Only qualified personnel should attempt these
adjustments.
1. The set of numbers that you will want to change is going to depend on when the fault happens.
If the fault happens when you are pushing the FNR lever forward, just out of neutral, you will want to adjust
the FNR Ntop if the fault happens with the FNR full forward then the numbers you want to change are the
FNR MAX numbers. The procedure is the same if the fault happens when you are pulling back on the FNR
lever though you will want to adjust the FNR MIN numbers or the FNR Nbot numbers.
2. Now that you have determined which of the four needs to be adjusted, remove the cover plate below the steering
wheel for access to the DC2 controller.
3. With the brake switch released, turn the ignition key to the run position, engine off.
4. Press and Hold in the F3 key on the DC2 (computer) and depress the MAN VIBE button on either FNR
control handle. This will access the lower level screen groups.
5. Use the F4 key on the DC2 to scroll through the 8 available screens. The screens and the order in
which they appear are RUN, LMTD, INPT, VIBS, PROP, FNR, ACCL, and VOLT. These will flash in
red letters in the window on the DC2 to let you know which screen group you are in. If you go past
the screen you are looking for continue to use the F4 key to scroll through the sequence of screens
again until you find the right one
6. The 6th of the 8 screens is the FNR screen and the numbers you are going to look at are on this screen. The set
of screens you want to watch are (FNR OUT: VDC ) AND ( FNR State: )
7. Using the scroll button on the dash, bring the FNR OUT: VDC and FNR STATE: up on the
display.
8. To find the FNR Ntop numbers move the FNR handle slowly forward until you see the FNR STATE:
change from Neutral to STATE: FORWARD. Once you have found the area where the FNR switch
changes state move the FNR slowly back and forth in this area until the FNR State on the screen
flickers back and forth between the neutral and forward states and you can hear the travel relay
chatter. Write down the numbers that appear in the FNR OUT: portion of the screen.
9. To find the FNR Nbot numbers move the FNR handle slowly back until you see the FNR STATE:
change from Neutral to STATE: REVERSE. Once you have found the area where the FNR switch
flickers back and forth between the neutral and Reverse states and you can hear the travel relay
10 Move the FNR all the way forward making certain that it is firmly against the forward stop, with the
FNR full forward write down the numbers that are shown in the FNR OUT portion of the screen.
11. Move the FNR all the way reverse making certain that it is firmly against the reverse stop, with the
12. Once you have written down FNR Ntop, Nbot, Max, and Min numbers. Use the F4 key on the DC2 to
scroll until you come to the volt screen. While in the volt screen use the red scroll button on the dash
to scroll through bringing the number to be changed to the top line, then use the F1 key to increase or
the F2 Key to decrease the numbers.
13. When all of the numbers are correct, using the F4 key on the DC2 scroll to the LMDT screen to lock
in the numbers. When you get to the LMTD screen push F1 to lock in the numbers.
When the numbers are locked in the screen will read Save User Ram: No
Nonvol vs Ram: Both Same
14. Turn on the key with the engine off, move the FNR lever and see if the fault returns.
If you feel that you missed something along the way, turn the key off and start over.
If you haven’t locked anything in by going to the LMTD screen and pressing Fl the
settings will remain the same as they were when you started.
FAULT: FNR NEUTRAL SWITCH
If you are experiencing this fault, you should be able to duplicate it by barely moving the FNR out of neutral in
either direction.
This fault occurs when the FNR Ntop or FNR Nbot (bottom) numbers are out of range. It is very easy to
“miss” these during the calibration of the FNR lever. If you move the lever to fast during the calibration, the
pot position relative to the closing position of the switch will not match. The computer looks at the actual
position of the pot when the switch closes on its way out of neutral. As an example this may be at 2.61V, If
you are pushing the FNR lever too fast, the pot position may be at 2.86V when the switch closes. The
computer adds .15 to this top number and, in this case, makes that number 3.1V This is the FNR top number.
The same process is done in reverse to come up with the FNR bottom number. Let’s use a value of 2.25V in
this example. There two are conditions that will trigger the FNR neutral switch fault.
Condition 1. The neutral switch is open indicating that the FNR is in neutral. For this condition if the computer
sees a number greater than 3.1V (FNR Ntop + .15V) or less than 2.10V (FNR Nbot –.15V) the computer
considers this as a fault .
Condition 2. The neutral switch is closed, indicating that the FNR is out of neutral. For this condition, if the
computer sees a number less than 2.71V (FNR Ntop –.15V) or greater than 2.40V (FNR Nbot + .15V) the
computer will consider this as a fault condition. For the example of miscalibration above, with the switch
actually closing at a value of 2.61V, we end up with a .1V digit window where the second fault condition can
occur.
Once you are able to create the fault consistently. Go to the VOLT screen ( RECALIBRATION PROCEDURE
NOTED ON THE FOLLOWING PAGES) and decrease the numbers for NTop and increase the numbers for
NBot until you can no longer duplicate the fault. Numbers will have to be locked in.
Sensor Power (5V)

R. Speed Signal
Ground
Sensor Power (5V)
Speed Signal
Ground
Neutral A Neutral A
Starter Circuit Neutral B Neutral B
Vibrator Mom. Pushbutton Mom. Pushbutton

On/Off
Left Control Handle Right Control Handle

R. Neutral
Starter Circuit
Note: Switches are shown with handles in Neutral position.
FIGURE 7
OFF
AUTO MAN
VIBRATOR MODE
WATER SAVER
FRONT
BOTH
REAR
FNR: Ntop VDC
FNR: Nbot VDC
HIGH LOW
SCROLL MAN VIBE

AMPLITUDE
BUTTON
SCROLL BUTTON
RUN FILTERS
OFF
AUTO MAN
WATER TEMP OIL TEMP

HOUR METER
GAUGE GAUGE
WATER SAVER
BOTH THROTTLE
FRONT REAR
SPEED RANGE
AUTO MANUAL

HIGH LOW
ENG OIL PRESS FUEL

VOLTMETER
GAUGE GAUGE
SCROLL BUTTON
STATUS F1
F2
POWER F3
F4
F1
STATUS
F2
F3
POWER
F4
TO GAIN ACCESS TO HITCH
REMOVE THE COVER
PLATE
FIGURE 8
FQ G FM FH
18
PAINT THIS ITEM RED
2 8 9
3 8 9 4 10 11 5 8 9 13 14 16 10 15
6
17
A
085
30 87 86 85
+ POS.
70922
49
BOSCH
BAT
12V
49
49a X1
K3
0 335 200 160

K1
C2 C3
F5
31
49a C
31
2+1+1X21W
8X21W
BOSCH
FG AUX
FL
FM FL K6
BOSCH BOSCH
- NEG. FG BAT AAA
K4 K5
F6
30 87 86 85 30 87 86 85 K2 X2
AUX
7 10 15
G FK FJ F7
15A
G
FIGURE 9
12
K1 - FORWARD RELAY
K2 - REVERSE RELAY
K4 - LOW BEAM RELAY
adjustments.
display.
10. Move the FNR all the way forward making certain that it is firmly against the forward stop,
with the FNR full forward write down the numbers that are shown in the FNR OUT portion of
the screen.
11 Move the FNR all the way reverse making certain that it is firmly against the reverse stop, with the
12 Once you have written down FNR Ntop, Nbot, Max, and Min numbers. Use the F4 key on the DC2 to
13 When all of the numbers are correct, using the F4 key on the DC2 scroll to the LMDT screen to lock
in the numbers. When you get to the LMTD screen push F1 to lock in the numbers.
Nonvol vs Ram: BothSame
14 Turn on the key with the engine off, move the FNR lever and see if the fault returns.
If you haven’t locked anything in by going to the LMTD screen and pressing Fl the settings will
remain the same as they were when you started.
FAULT: REAR VIB.EDC
This fault is telling you that the DC2 Controller cannot control the rear vibe pump displacement, the valve
drive “ EDC” is affected, there will be no vibrator action possible. The possible causes for this fault are that
the coil inside the EDC is shorted, or one of the two wires controlling the EDC may either be shorted to
ground, or you have an open circuit “broken wire”.
The Electrical Displacement Control (EDC), is mounted on the rear vibrator pump. The rear vibrator pump
EDC is driven by a controller that is a bi-directional low current valve driver over a maximum range of 0 to 150
mA. The pump is at zero displacement when no current is applied to the EDC. The typical threshold current
required to begin stroking the pump is between 5-25 milliamps. The current requirement to reach maximum
pump displacement is typically 85-95 milliamps.
The operator commands the vibrator controls with the switches and pots on the control panel. The vibrators
can be turned on\off or set in manual or automatic mode. Front, rear, or both vibrators can be selected. High
or low amplitude can be selected. Desired vibrator speeds can be set with the speed pots. The displayed
vibrator speeds will be compensated if only one vibrator is on. The speed will increase in this case.
High or low amplitude of the vibrators is determined by the direction of rotation of the pumps. Each pump is
driven by the bi-directional current source. When switching between high and low amplitudes, there will be a
slight delay during which the current to the vibrators will be zero. (SEE THE FOLLOWING PAGES FOR
FAULT TROUBLE SHOOTING AND COMPONENT LOCATION)
FROM PLUG P1 PIN# J-1 TO REAR VIBE

PLUG PIN-A VALVE. 0+
REAR VIBE
EDC
0 T0 95 mA
BIDIRECTIONAL
VAVLE
CONTROL
PLUG PIN-B VALVE. 0-
FIGURE 10
DC2 CONTROLLER PLUG (P1)
BA
STATUS F1
E
F2
D
POWER F3
F4
C
JHGF
K
TO HITCH AD
B C
REAR VIBE
EDC PLUG
REAR VIBE EDC
REAR
VIBRATO R
PUMP REF.
TO ENGINE REF.
COCKPIT
TRAVEL
PUMP REF.
REAR VIBE EDC
MANUAL COTROL
FRONT VIBE
PUMP REF.
FIGURE 11
REAR VIBE EDC FAULT TROUBLE SHOOTING
1. Remove the plug from rear vibe pump EDC. Once the plug is removed check both the EDC and the
plug for any oil, dirt or corrosion. Also check for any obvious damage, such as cracks or broken wires.
If you find damaged components either repair or replace them as required.
1. Once the components are checked and cleaned, use a volt/ohm meter to check PIN D of the
controller harness plug for a direct short to ground. Then check PIN C for a direct short to ground. If a
short is found, find the damaged wire and repair it if possible. If this is not possible replace the control
harness.
3. Once you have eliminated shorts in the harness check the EDC for an internal short to ground. Using
your volt/ohm meter check between Pin D and ground. Do the same with PIN C. If a short is found
between PIN C and ground or between PIN and ground replace the EDC. If there is no internal
grounding, there should be somewhere in the range of 15 to 35 ohms resistance between PIN D and
PIN C.
4. If you can not find any shorts or grounds in the harness or EDC there may be an open (broken wire).
To check this you will need to remove the plate under the steering wheel. This will give you access to
the DC2 controller. Once you have access to the DC2 you will need to remove plug P1 and check for
any damage to the plug or the wires leading to it. After you have checked the plug, you will need to
use your volt/ohm meter and check the continuity between plug P1 PIN J-1 and the rear vibe EDC
plug PIN A for one open wire. To check the other wire in this area of the harness you will need to
check plug P1 PIN J-3 and the rear vibe EDC plug PIN B.
A B C D E F G H J K
A B
3
1
B C
Controller Harness Connector Plug P1

View Looking In To The Plug Controller Harness Connector Rear Plug Vibe
View looking In To The Plug
FIGURE 12
FAULT: FRONT VIB.EDC
This fault is telling you that the DC2 Controller cannot control the front vibe pump displacement, the valve
the coil inside the EDC is shorted, or one of the two wires controlling the EDC may be either be shorted to
The Electrical Displacement Control (EDC), is mounted on the rear vibrator pump. The front vibrator pump
can be turned on/off or set in manual or automatic mode. Front, rear, or both vibrators can be selected. High
FROM PLUG P1 PIN# K-1 TO FRONT

VIBE PLUG PIN-D or 4 VALVE. 1+
FRONT VIBE
EDC
0 T0 95 mA
BIDIRECTIONAL
VALVE
CONTROL
FROM PLUG P1 PIN# K-3 TO FRONT VIBE
PLUG PIN-C or 3 VALVE. 1-
FIGURE 13
BA
STATUS F1
E
F2
D
POWER F3
F4
C
JHGF
K
TO HITCH
FRONT VIBE EDC
REAR
VIBRATOR
PUMP REF.
TO ENGINE REF.
COCKPIT
AD TRAVEL
B C PUMP REF.
FRONT VIBE EDC
MANUAL COTROL
FRONT VIBE
PUMP REF.
FRONT VIBE
EDC PLUG
FIGURE 14
FRONT EDC FAULT TROUBLE SHOOTING
1. Remove the plug from front vibe pump EDC. Once the plug is removed check both the EDC and the
2. Once the components are checked and cleaned, use a volt/ohm meter to check PIN A of the
controller harness plug for a direct short to ground. Then check PIN B for a direct short to ground.
If a short is found, find the damaged wire and repair it if possible. If this is not possible replace the
control harness.
your volt/ohm meter check between Pin A and ground. Do the same with PIN B. If a short is found
between PIN A and ground or between PIN B and ground replace the EDC. If there is no internal
grounding there should be somewhere in the range of 15 to 35 ohms resistance between PIN A and
PIN B.
4. If you can not find any shorts or grounds in your harness or EDC there may be a open (broken wire).
any damage to the plug or the wires leading to it. After you checked the plug, you will need to use
your volt/ohm meter and check the continuity between plug P1 PIN K-1 and the rear vibe EDC plug
PIN A for open wire. To check the other wires in this area of the harness you will need to check plug
P1 PIN K-3 and the front vibe EDC plug PIN B
A B C D E F G H J K
A B
3
1
B C

FIGURE 15
PROPEL EDC FUCTION
This condition will not be displayed if there is a short or open circuit in the wiring to the propel EDC. The
controller cannot control the pump displacement if the valve drive is affected. Therefore no machine motion
will be possible. Depending on the condition, there may be motion available in one direction only.
The Electrical Displacement Control (EDC), is mounted on the propel pump. It is used to control the
displacement of the pump. The pump EDC is a dual coil device connected with a common ground on opposite
sides of the coils. Each coil is driven by a high current digital output which is pulse width modulated. The
PWM frequency is 200 Hz. The pump is at zero displacement when no current is applied to the EDC. The
typical threshold current required to begin stroking the pump is between 5-25 milliamps. The current
requirement to reach maximum pump displacement is typically 85-95 milliamps. The actual current is a
function of the battery voltage and the duty cycle will be adjusted automatically to compensate. However, the
current is also a function of the EDC coil resistance which changes with temperature. For this reason the
calibration should be performed with the vehicle fully warmed up.
1.FROM PLUG P2 PIN# F-3 TO REV RELAY PIN #30

2.FROM PIN 87 REV RELAY TO PIN D EDC PLUG
SIGNAL DIGITAL OUT .0
PWM
SIGNAL
PIN 30 PIN 87 PIN D
0 VOLTS IN NEUTRAL
PIN 2 T0 4 +/- VOLTS AND 85 T0 95 mA EDC PLUG PIN C
P2F3 AT PIN D WHEN THE PUMP IS FULLY
STROKED IN REVERSE
1.FROM PLUG P2 PIN# F-3 TO FORWARD RELAY PIN# #30

2.FROM PIN 87 FORWARD RELAY TO PIN A EDC PLUG
SIGNAL DIGITAL OUT .0 FROM PLUG P1 PIN# B3 TO
EDC PLUG PINS B AND C
SENSOR GROUND
PIN 30 PIN 87
PIN A
EDC PLUG PIN B
0 VOLTS IN NEUTRAL
2 T0 4 +/- VOLTS AND 85 T0 95 mA
AT PIN A WHEN THE PUMP IS FULLY
STROKED IN FORWARD
FIGURE 16
SIGNAL DIGITAL OUT.2 PIN 86 REV PIN 85

RELAY
12V FROM DC2 PIN P2 F2
PIN P1 H3
GROUND
SIGNAL DIGITAL OUT.1

PIN 86 FWD PIN 85
RELAY
12V FROM DC2 PIN P2 D2
FIGURE 17
PROPEL EDC TROUBLE SHOOTING
1. Remove the plug from propel pump EDC. Once the plug is removed check both the EDC and the plug
for any oil, dirt or corrosion. Also check for any obvious damage, such as cracks or broken wires.
controller harness plug for a direct short to frame ground. Then check PIN D for a direct short to
frame ground. If a short is found, find the damaged wire and repair it if possible. If this is not possible
replace the control harness.
3. If you did not find a short when checking PINS A or D, check PIN B for an open and then check PIN C
for an open. After checking each of the pins individually check PIN A and pin C for continuity. If you
do find an open and there is no continuity between these two pins. That will tell you the break in the
wire is somewhere close to the back of the harness, the reason for that is the wires to Pins B & C are
joined in the harness and grounded at Pin P1 B3 . If you have continuity, the break could be farther
up in the harness behind the splice. Find the damaged wire and repair it if possible. If this is not
possible replace the control harness.
4. Once you have eliminated shorts in the harness check the EDC for an internal short to frame ground.
Using your volt/ohm meter, check between Pin A, B, C and D. If a short is found between any of the
pins and frame ground replace the EDC.
5. If you cannot find any shorts or grounds in your harness or EDC there may be a open (broken wire).
use your volt/ohm meter and check the continuity between the following points.
PIN#
P2-F3 TO PIN 30 on the FWD relay out 87 TO the propel EDC plug PIN A for FDW PMW signal
P1-H3 TO PIN 85 on the FDW relay
P2-D2 TO PIN 86 on the FDW relay
P1-B3 TO the propel EDC plug PIN B for FDW
P2-F3 TO PIN 30 on the REV relay out pin 87 TO the propel EDC plug PIN D for REV PMW signal
P1-H3 TO PIN 85 on the REV relay
P2-F2 TO PIN 86 on the REV relay
P1-B3 TO the propel EDC plug PIN C for REV

DC2 CONTROLLER
REAR
VIBRATOR
PUMP REF.
STATUS F1
F2
POWER F3
F4
TO ENGINE REF.
COCKPIT
AD TRAVEL
B C PUMP REF.
TO HITCH FRONT VIBE

PUMP REF.
PROPEL
EDC PLUG
PLUG (P2)
PLUG (P1)
A
CB
BA
ED
E
F
D
C
JHGF
PROPEL EDC
K
PROPEL EDC
MANUAL COTROL
FIGURE 18
PROPEL EDC CIRCUIT PLUGS .

View Looking In To The Plug Controller Harness Connector Plug P2
View Looking In To The Plug
A B C D E F
A B C D E F G H J K
3
3
2 2
1 1
1 3 1 3
2 4 2 4
OLDER STYLE
FORWARD/ EDC PLUG NEWER STYLE
Reversr EDC PLUGE
RELAY
PLUG
A D
B C
FIGURE 19
Warning: Low Water level For older machine’s
This warning will appear when the water level in both of the tanks have reached a point when refill is
necessary. The switch’s are set to a point so when the warning is displayed it give’s the operator ample time
to arrange for the tanks to be refilled so you have minimal down time. If the warning appears when the tanks
are full, there may be a short. To check for a short remove plugs P1 and P2 then check between pin H1 of the
P1 plug and the two plugs connected to the tank switch’s if you do not find a short then check between pin F2
of the P2 plug and the two plugs connected to the two tank switch plug’s. If a broken wire is found replace the
harness.
DC 2 PLUG PIN P1 H 1 +5V DC 2 PLUG PIN P2 F 2
FIGURE 20
FAULT: PROP THRSH. CAL.
This fault appears when the values for the forward or reverse thresholds are out of a certain range
that the computer is looking for.
The forward/reverse thresholds are the points at which the machine begins to move in the forward
or reverse directions. If the thresholds are not set correctly during the calibration procedure the
machine will be jerky when starting and stopping. The reason for the jerky motion is the two relays
that control the direction of the machine are closing to late when starting out and opening to early
when stopping. To correct this problem you will need to adjust the threshold set point for the
direction that is jerky.
See the following pages for the threshold adjustment procedure.
FNR HANDLE POSISION IN RELATION TO THE THRESHOLD SET POINTS.
-200 THRESHOLD SET POINT 185 THRESHOLD SET POINT

(-200+15=-185 ACTUAL (185-15-170 ACTUAL)
-587 MAX OUT 567 MAX OUT

TO END TO END
DEADBAND DEADBAND
30.00 º 30.00 º
FIGURE 21
PROPEL THRESHOLD ADJUSTMENT PROCEDURE.
1. The set of numbers that you will want to change is going to depend on when the fault happens or which
direction the machine has a jerky start and stop. If the fault happens when you are pushing the FNR lever
forward you will want to adjust the FWD THRSH numbers, and if the fault happens when you are pulling back
on the FNR lever you will want to adjust the REV THRSH numbers.
2. Now that you have determined which of the two needs to be adjusted, remove the cover plate below the steering
3. Turn the ignition key to the run position, engine off.
6. The 5TH of the 8 screens is the PROP screen and the numbers you are going to change are on this screen. The
sets of numbers you want to change are (FWD THRESH: ***) or (REV THRESH: ***), before you
change any numbers write down original numbers that first appear so you know your starting point. If
the numbers appear as 000 the optimum numbers to start with are 185 in both directions, increase or
decrease these numbers until the machine just starts to move as the FNR lever is coming out of
neutral. To do this you have to lock the numbers in (Ref. step # 8) then drive the machine making
sure that there is ample space and all obstructions and personnel are clear of the machine when the
setup is performed.
7. Using the scroll button on the dash, bring the (FWD THRESH: *** or (REV THRESH: *** to the top
line of the display and change the number farthest from 185 to the same as the one close to 185 and
start adding 3 to or subtracting 3 from original number on the screen. To change the numbers press
the F1 key on the DC2 to increase or the F2 key to decrease. The number will scroll continuously
while the F1 and F2 keys are being held or they will increase 1 digit at a time each time the key is
pushed.
8. Once the numbers are changed, use the F4 key on the DC2 to scroll to the LMTD screen. This is the
screen where you will “lock” in the numbers you have just changed. When you get to this screen the
top line on the display will read “SAVE USER RAM: NO” The bottom Line will read “NonVol vs RAM:
Different. Push the F1 key on the DC2 to lock in the numbers. When you do this the “NO” on the top
line will momentarily flash to “YES” and then back to “NO” and the “Different” on the bottom line will
change to “BOTH SAME”. This will let you know that the numbers you have changed to correct the
problem are now locked in and it is safe to turn the key off.
9. Don’t worry if you get out of sequence while you are doing this. If you feel that you missed something
along the way, turn the key off and start over. If you haven’t locked anything in by going to the LMTD
screen and pressing Fl, the settings will remain the same as they were when you started.
FAULT: Prop Dband. CAL.
This fault appears when the values for the forward or reverse thresholds have a difference of 100 or
more between them. Within the Neutral dead band range that the computer is looking for.
The threshold numbers are generally in the area of 185 for both forward and reverse +/-
50 if the numbers are 101 apart there will be a fault.

(-200+15=-185 ACTUAL (185-15-170 ACTUAL)

TO END TO END
DEADBAND DEADBAND
30.00 º 30.00 º
FIGURE 22
OFF
AUTO MAN
VIBRATOR MODE
WATER SAVER
FRONT
BOTH
REAR
FNR: Ntop VDC
FNR: Nbot VDC
HIGH LOW
SCROLL MAN VIBE

AMPLITUDE
BUTTON
SCROLL BUTTON
RUN FILTERS
OFF
AUTO MAN
WATER TEMP OIL TEMP

HOUR METER
GAUGE GAUGE
WATER SAVER
BOTH THROTTLE
FRONT REAR
SPEED RANGE
AUTO MANUAL

HIGH LOW
ENG OIL PRESS FUEL

VOLTMETER
GAUGE GAUGE
SCROLL BUTTON
STATUS F1
F2
POWER F3
F4
F1
STATUS
F2
F3
POWER
F4
REMOVE THE COVER
PLATE
FIGURE 23
PROPEL DEAD BAND ADJUSTMENT PROCEDURE.
1. The set of numbers that you will want to change is going to depend on which of the numbers is 101 points out
from the number that is close to 185.
2. To determined which of the two needs to be adjusted, remove the cover plate below the steering wheel for access
to the DC2 controller.
which they appear are RUN, LMTD, INPT, VIBS, PROP, FNR, ACCL, and A/D. These will flash in
setup is performed.
7. Using the scroll button on the dash, bring the (FWD THRESH: ***) or (REV THRESH: ***) to the top
line of the display and change the number adding 3 to or subtracting 3 from original number on the
screen. To change the numbers press the F1 key on the DC2 to increase or the F2 key to decrease.
The number will scroll continuously while the F1 and F2 keys are being held or they will increase 1
digit at a time each time the key is pushed.
8. Once the numbers are changed, use the F4 key on the DC2 to scroll to the LMTD screen. This is the
Different. Push the F1 key on the DC2 to lock in the numbers. When you do this the “NO” on the top
screen and pressing Fl the settings will remain the same as they were when you started.
OFF
AUTO MAN
VIBRATOR MODE
WATER SAVER
FRONT
BOTH
REAR
FNR: MAX VDC
FNR: Nbot VDC
HIGH LOW
SCROLL MAN VIBE

AMPLITUDE
BUTTON
SCROLL BUTTON
RUN FILTERS
OFF
AUTO MAN
WATER TEMP OIL TEMP

HOUR METER
GAUGE GAUGE
WATER SAVER
BOTH THROTTLE
FRONT REAR
SPEED RANGE
AUTO MANUAL

HIGH LOW
ENG OIL PRESS FUEL

VOLTMETER
GAUGE GAUGE
SCROLL BUTTON

17
7 10 15
AAA
X1
X2
16 10 15
STATUS F1
F2
K6
K2
K1
18
15A
F3
F7
POWER
F4
6
13 14
FL
F6
FJ
F5
AUX
AUX
BAT
BAT
8 9
FG
5
FG
11
PAINT THIS ITEM RED
G
FK
+ POS.
- NEG.
FM
F1
FM
4 10
FL
FN
STATUS
G
49a
31
49
F2
085
49 49a C
70922
8 9
C2 C3 31
G
A
30 87 86 85
BOSCH
3
8X21W
K5
2+1+1X21W
12V
0 335 200 160
BOSCH
FJ
F3
8 9
KK
2
POWER
FP
30 87 86 85
30 87 86 85
BOSCH
F4
BOSCH
K4
G
K3
FH
FM
FM
TO HITCH
CC
G
12
FQ
FIGURE 24
This fault appears when the FNR MIN or FNR MAX numbers are out of range. The fault
can happen any time after the RIGHT FNR lever has been calibrated. If the FNR MIN
numbers are not with in the range of 30 to 100 or for the FNR MAX numbers the range of
890 to 990 the computer will show this fault.
To correct this problem, go to the VOLT screen and adjust the FNR MAX and/or the FNR
MIN accordingly so that it falls with the given ranges. If you are seeing this fault, you
should be able to consistently cause it by stroking the FNR in whichever direction the
number is out of range. You can do this with the engine off and the key in the run position.
It will usually occur when the FNR lever is pushed/pulled hard in the given direction. Adjust
the number until you can’t duplicate the fault ( SEE THE FNR ADJUSTMENT AND
COMPONETS LOCATIONS ON THE FOLLOWING PAGE. )
center postion
510 A/D (analog/digital)
460 A/D 560 A/D
neutral bottom neutral top
52 A/D 948 A/D
22 A/D 978 A/D
2 A/D 1023 A/D
deadband deadband
handle stops handle stops
(0 volts) (+5 volts)
pot stops 30.00º 30.00º pot stops
HANDLE OUTPUT VS POSTION
FIGURE 25
DRAWING OF THE PROPEL CIRUIT WITH
THE MACHINE IN NEUTRAL

DC2 2.FROM PIN 87 REV RELAY TO PIN D EDC PLUG
CONTROLLER SIGNAL DIGITAL OUT .2
PIN 87a
PIN 30 PIN 87
REV
RELAY
PLUG
PIN D
PIN2
SIGNAL PIN 85 PIN 86

PLUG P1 GROUND
PIN# B3
EDC PLUG PIN C
12 VOLT REVERSE RELAY

IN REV REV RELAY PLUG PIN# 4
PLUG P1
PIN# F2
FROM PLUG P1 PIN# B3 TO
REV RELAY PLUG PIN# 1 EDC PLUG PINS B AND C
PIN 87a SENSOR GROUND
PLUG P2 PWM
PIN# F3 FWD RELAY PLUG PIN# 1 PIN 30
SIGNAL
FDW
RELAY
PIN 87 PLUG PIN A
FWD RELAY PLUG PIN# 4 PIN2
PLUG P2
PIN# D2
12 VOLT
IN FWD PIN 85 PIN 86
EDC PLUG PIN B
REV RELAY PLUG PIN# 3
FORWARD RELAY
PULG P1
PIN# H3
GROUND
FWD RELAY PLUG PIN# 3
PROPEL EDC
FIGURE 26
THE MACHINE IN REVERSE
DC2
CONTROLLER
PIN 87a
SIGNAL DIGITAL OUT .2 PIN 30 PIN 87
0 VOLTS IN NEUTRAL
REV 2 T0 4 +/- VOLTS AND 85 T0 95 mA
RELAY PIN D AT PIN D WHEN THE PUMP IS FULLY
PLUG STROKED IN REVERSE
PIN2
PIN 85 PIN 86
PLUG P1
PIN# B3 SIGNAL
GROUND EDC PLUG PIN C
REVERSE RELAY
PLUG P1 12 VOLT
PIN# F2
12 VOLT
REV

PLUG P2 PWM
SIGNAL
FDW
RELAY
PIN 87 PLUG PIN A
PLUG P2
PIN# D2
12 VOLT
FWD PIN 85 PIN 86
EDC PLUG PIN B
FORWARD RELAY
PULG P1 12 VOLT
PIN# H3
GROUND
PROPEL EDC
FIGURE 27
THE MACHINE GOING FORWARD
DC2
CONTROLLER
PIN 87a
PIN 30 PIN 87
REV
RELAY
PLUG
PIN D
PIN2

PLUG P1 GROUND
PIN# B3
EDC PLUG PIN C
REVERSE RELAY
12 VOLT REV RELAY PLUG PIN# 4 12 VOLT
PLUG P1 REV
PIN# F2 1.FROM PLUG P2 PIN# F-3 TO FORWARD RELAY PIN# #30

PLUG P2 PWM
SIGNAL
FDW
RELAY
PIN 87 PLUG PIN A
PLUG P2
PIN# D2
12 VOLT
FWD PIN 85 PIN 86
EDC PLUG PIN B
FORWARD RELAY
PULG P1 12 VOLT
PIN# H3
GROUND

0 VOLTS IN NEUTRAL
2 T0 4 +/- VOLTS AND 85 T0 95 mA
STROKED IN FORWARD
PROPEL EDC
FIGURE 28
April 21, 2000
TO: ALL HYPAC Distributors
ATTENTION: Parts and Service Managers
Subject: C766C/C778B Series 2.33 Software Update Limited Operation Mode
Hypac is currently in the process of updating the software used in the C766C/C778B series tandem
rollers. The new version (2.33) software will have a limited operation mode added to its functions.
This mode has been added to allow the machine to be safely removed from the paving surface
when a stop fault has been detected. The machine will automatically fault into limited operation
mode when a stop fault has been detected by the DC2 Controller and will prompt the operator to
return the FNR lever to the neutral position. It will then display the functions that will allow the
machine to be moved. Once the FNR has been returned to the neutral position, a message will
appear stating Front Drum FDW “and the” Rear Drum REV. This message is to notify the operator
that by moving the drum vibe selection switch from the center position to either FRONT OR REAR
the machine will then move in the corresponding direction when the FNR is moved from neutral.
NOTE: The FNR handle does not control the direction of the machine when it is in the
Limited Operation Mode, the FNR is only used to allow movement. When the
FNR is moved from the neutral position, regardless of which direction it is
moved, the machine will go in the direction which has been selected with the
drum selection switch.
Compaction America
Product Support Department
LIMITED OPERATION MODE
RUN FILTERS
OFF
AUTO MAN
WATER TEMP OIL TEMP

HOUR METER
GAUGE GAUGE
WATER SAVER
BOTH THROTTLE
FRONT REAR
SPEED RANGE
AUTO MANUAL

HIGH LOW
ENG OIL PRESS FUEL

VOLTMETER
GAUGE GAUGE
SCROLL BUTTON
Screen #1 OFF
This screen is telling the operator AUTO MAN
that there is a fault and the machine is in
limited operaton mode. VIBRATOR MODE
WATER SAVER
BOTH
FRONT REAR LIMD OP: MODE - FNR FDW
HIGH LOW
Screen #2
This screen is telling the operator OFF
that there is a fault and by moving the AUTO MAN
vibe mode selection switch to the FRONT

position the machine will travel in the VIBRATOR MODE
WATER SAVER
FORWARD direction when the FNR is moved FRONT
BOTH
REAR VIBE MODE- FRNT/FDW
from the neutral position in either Fault: 5V SENSOR POWER
direction.
HIGH LOW
SCROLL BUTTON
Screen #3
This screen is telling the operator that
OFF
there is a fault and by moving the vibe AUTO MAN
mode selection switch to the REAR
position the machine will travel in the REVERSE
VIBRATOR MODE
direction when the FNR is moved from the BOTH
WATER SAVER
FRONT REAR
VIBE MODE- REAR/REV
neutral position in either direction.
HIGH LOW
SCROLL BUTTON
FIGURE 29
Function DC2 Pin Input or Output Normal Voltage Open Circuit
Levels Voltage Levels
at DC2 Pin
Battery + P2-F1 Input 11-15 vdc 0 vdc
Battery - P2-E1 Input 0 vdc 0 vdc
Chassis Gnd P2-B2 Input 0 vdc 0 vdc
Brake Switch P1-C2 Input 5 vdc with brake off 0 vdc
0 vdc with brake on
Sensor Gnd for L. P1-A3 Ground 0 vdc 0 vdc
Control Handle
Pushbutton Switch
FNR Neutral Switch P2-D1 Input 12 vdc if FNR in 12 vdc
neutral
0 vdc if FNR not in
neutral
Sensor Power for P1-D1 Output 5 vdc 5 vdc
FNR potentiometer
Wiper for FNR P1-D2 Input ~ 4.8 vdc in Forward to 0 vdc
potentiometer ~ 0.2 vdc in Reverse
Sensor Gnd for FNR P1-D3 Ground 0 vdc 0 vdc
potentiometer, neutral
switch, and R. Control
Handle Pushbutton
Left or Right P2-B1 Input 12 vdc if neither 12 vdc
Pushbutton Switches pushbutton is pressed
0 vdc if either
pushbutton is pressed
Auto Vibrator Function P2-C2 Input 12 vdc if not in Auto 12 vdc
Switch mode
0 vdc if in Auto mode
Manual Vibrator P2-D3 Input 12 vdc if not in Manual 12 vdc
Function Switch mode
0 vdc if in Manual mode
Sensor Gnd for P1-E3 Ground 0 vdc 0 vdc
Vibrator Function,
Vibrator Location, and
mat temperature
sensor
Front Vibrator P2-A1 Input 12 vdc if not in Front 12 vdc
Location Switch location
0 vdc if in Front location
Rear Vibrator P2-C1 Input 12 vdc if not in Rear 12 vdc
0 vdc if in Rear location
Sensor Power for P1-A1 Output 5 vdc 5 vdc
Display Scroll Switch
Driver for Backup P2-F2 Output ~ Battery voltage if 0 vdc
Alarm and Reverse vehicle is in reverse.
Relay (K1) in propel 0 vdc if vehicle is in
circuit. forward.
Display Scroll Switch P1-A2 Input 0 vdc if switch is not 0 vdc
pressed
5 vdc if switch is
pressed
Sensor Power for P1-B1 Output 5 vdc 5 vdc
High/Low Amplitude
Switch
High/Low Amplitude P1-J2 Input 0 vdc if switch is in Low 0 vdc
Switch position
5 vdc if switch is in High
position
Sensor Power for P1-G1 Output 5 vdc 5 vdc
Water Saver
Potentiometer
Wiper for Water Saver P1-K2 Input ~ 5.0 vdc in high position 0 vdc
potentiometer to
~ 0.0 vdc in low position
Sensor Gnd for Water P1-G3 Ground 0 vdc 0 vdc
Saver potentiometer
Sensor Power for P1-F1 Output 5 vdc 5 vdc
Front Vibrator Speed
Potentiometer
Wiper for Front P1-H2 Input ~ 5.0 vdc in high position 0 vdc
Vibrator Speed to
potentiometer ~ 0.0 vdc in low position
Sensor Gnd for Front P1-F3 Ground 0 vdc 0 vdc
Vibrator Speed
potentiometer
Sensor Power for P1-C1 Output 5 vdc 5 vdc
Rear Vibrator Speed
Potentiometer
Wiper for Rear P1-G2 Input ~ 5.0 vdc in high position 0 vdc
Vibrator Speed to
Sensor Gnd for Rear P1-C3 Ground 0 vdc 0 vdc
Vibrator Speed
potentiometer
Unused Sensor Power P1-H1 Output 5 vdc 5 vdc
Output from Mat P1-F2 Input ~ 0.6 vdc to ~ 3.0 vdc 0 vdc
Temperature Sensor
Motor Speed Switch P1-E2 Input 12 vdc if in Low Motor 12 vdc
0 vdc if in High Motor
Sprayer Relay Driver P2-E3 Output ~ Battery voltage if 0 vdc
sprayer relay is on
0 vdc if sprayer relay is
off
Engine Speed Switch P2-E2 Input 12 vdc if in Low Idle 12 vdc
0 vdc if in High Idle
Sensor Gnd for Propel P1-B3 Ground 0 vdc 0 vdc
EDC coils
Driver for forward or P2-F3 Output This is a 0-12 vdc Pulse 0 vdc
reverse EDC coils in Width Modulated output.
Propel Circuit. Routed Voltage will be zero if
to forward or reverse vehicle is stopped.
coil by relays K1 and Voltage will vary up to ~
K2 in propel circuit. 3.5 vrms if vehicle is
moving.
Driver for Forward P2-D2 Output ~ Battery voltage if 0 vdc
Relay (K2) in propel vehicle is in forward.
circuit. 0 vdc if vehicle is in
reverse.
Sensor Gnd for P1-H3 Ground 0 vdc 0 vdc
Forward and Reverse
Relays in propel circuit
Low Amplitude P1-K1 Output This is a current source 0 vdc
Current Driver for output. Current (and
Front Vibrator EDC voltage) will be zero if
vibrator is off or in High
Amplitude. If in Low
Amplitude, current will
vary from ~ 50 mA up to
~ 85 mA ( ~ .95 vdc to ~
1.6 vdc)
High Amplitude P1-K3 Output This is a current source 0 vdc
vibrator is off or in Low
Amplitude. If in High
~ 85 mA ( ~ .95 vdc to ~
1.6 vdc)
Low Amplitude P1-J1 Output This is a current source 0 vdc
Current Driver for Rear output. Current (and
Vibrator EDC voltage) will be zero if
~ 85 mA ( ~ .95 vdc to ~
1.6 vdc)
High Amplitude P1-J3 Output This is a current source 0 vdc
~ 85 mA ( ~ .95 vdc to ~
1.6 vdc)
Fault Analysis Procedures
For the S2X Controller
Version 3.00
Vibratory Compactor Control System

CONTENTS
Pages 2-3 General Control System Performance.
Pages 4-6 S2X Controller Functions Version 3.00
Page 7 Fault Description/Message Text
Page 8-8.1 Fault: 5Volt Sensor Power,

Component location
Page 9 Handle Output VS Position
Pages 10-12 Fault: FNR Sensor Pot

Component location
Pages 13-15 Fault: FNR Neutral Switch

Component location,
FNR Adjustment Procedure
Pages 16-17 Fault: Rear VIB.EDC

Component location
Pages 18-19 Fault: Front VIB.EDC

Component location
Pages 20-22 Propel EDC Function

Component location
Page 23 Warning: Low Water Level

Description
Pages 24-25 Fault: Prop Thrsh.cal

Component location
Pages 26-27 Fault: Prop Dband. Cal
Component location
Pages 28-29 Fault: FNR . Cal

Component location
Pages 29-31 Propel Circuit Logic
Pages 32-32.1 Limited Operation Mode

Pages 33-35 S2x Voltage Logic

Pages 38-43 Notes

1 GENERAL CONTROL SYSTEM PERFORMANCE
The Control System will provide the following capabilities:
• The System will control one hydrostatic pump which drives two dual speed, hydrostatic motors on
the roller drums. The drums are located on the front and rear of the machine. The drum speed
control is open loop.
• The System will adjust the hydrostatic transmission pump displacement to obtain the desired
speed per the operator’s input via the left or right travel speed control handles. The vehicle
direction will also be selected by the same control handles.
• The switch labeled High/Low Motor Speed will directly select the hydrostatic motor displacements
for high or low range. The low speed range will be used for Work mode and has a speed range
of 0-5 mph at high engine speed. The high range will be used for Transport mode and has a
speed range of 0-10 mph at high engine speed. A signal will be provided to the controller which
will indicate the selection of high speed or low speed range for the motors.
• The switch labeled High/Low Engine Speed will directly control the engine throttle for high or low
engine speed. A signal will be provided to the controller which will indicate the selection of high
or low engine speed. The display of travel speed will be adjusted based on the inputs to the
controller.
• The System will have a maximum travel speed setting which can be adjusted by the operator.
The adjustment will be made with the control handle, the manual vibrator switch, and the 2X24
display.
• The System will control one vibrator pump for the front drum and one vibrator pump for the rear
drum. There are several controls for the vibrators:
• Vibrator speeds are set by two potentiometers on the control panel. The vibrator speed
will be displayed on the 2X24 display module. The vibrator speeds are open loop and
the display readout will be compensated if only one vibrator is running.
• Vibrator Function (Auto/Off/Manual) - if the Vibrator Function switch is in the manual
position, momentary push-button switches in the control handles are enabled to turn
the vibrators on or off. If the Vibrator Function switch is in the auto position, then the
vibrators will come on when the vehicle speed exceeds a preset speed and go off when
it drops below that value.
• The Auto vibrator on/off speed can be adjusted between 0.5 mph and 5.0 mph with a
special display screen
• There is a lockout function for the vibrators which will disable the vibrators if the motor
speed selection switch is set to Hi. This lockout function is active in both Auto and
Manual vibrator modes.
• There is a another lockout function for the vibrators which will disable the vibrators if
the engine speed selection switch is set to Low. This lockout function is active in both
Auto and Manual vibrator modes.
• Vibrator Location (Front/Rear/Both) - this switch will select which of the two vibrators
will be activated when the machine is moving.
• Amplitude Amount (High/Low) - this switch will select high or low amplitude vibration for
both vibrators.
• Vibration impact spacing will be calculated based on vibrator speed and vehicle speed
and displayed on one of the display screens.
• The System will control one sprayer relay which will turn on the sprayers on the front and rear
drums. The sprayers are turned on whenever the vehicle is moving. There is a Water Saver
spray timer function which will control the duty cycle of the sprayers when they are in the on state.
The spray duty cycle is controlled by the Water Saver pot on the control panel and can be set
from 0-50% duty cycle. The maximum sprayer period will be 10 seconds.
• The System will control one backup alarm which will be turned on whenever the propel signal is in
reverse.
• The System has a brake switch to be used for emergency stopping. This switch will send a signal
to the controller which will set the propel command to zero. The switch will also apply the system
brakes directly. The control handles must be returned to neutral after brake application before
the control will allow propel function.
• When power has been removed by turning off the key switch and then is reapplied to the system,
the control handles must be in neutral to enable vehicle movement. This is a safety feature to
prevent unexpected movement if the handle is out of neutral on power up.
• Calibration parameters are stored in a non-volatile memory to be recalled upon subsequent

startups of the system. Calibration can be entered by pressing and holding the Calibration switch
(F1 on the controller) while power is applied and following the calibration procedure. The System
will find the threshold currents and full speed currents for the propel pump. It will learn the low
and high speed currents for the vibrator pumps. It will also learn the voltage ranges for the travel
speed control handle, the front and rear vibrator speed potentiometers, and the Water Saver
potentiometer.. See Section 4 for details of the calibration procedure.
• The System incorporates a 2 line by 24 character alphanumeric display which is used to inform
the operator of various system parameters including travel speed in mph or kph; vibrator speeds
in vpm; and impacts per foot or meter. The display is also used to walk the operator through the
Calibration steps. Fault messages are displayed to indicate to the operator the source of a fault.
• Fault detection is built into the controller. When one of the possible faults is detected the
controller will take the necessary action to minimize the effect upon the operation of the machine.
Faults will be displayed on the second line of the display module.
S2x Controller Functions
Version 3.00 (Feb. 10, 2004)
There are four buttons on the S2x: F-1, F-2, F-3, and F-4. To access them on the machine, the cover
panel must be removed.
When the cursor is present on the top line on the display panel, F-1 will scroll up through choices or
increase values and F-2 will scroll down through choices or decrease values. F-3 will scroll the lines of
a screen up while the red scroll button on the display panel will scroll down. F-4 will screen through
the menus or screens.
Note: The following Bold lines are the additions/changes to version 3.00 from version 2.34.
Default/Operating Screen – “Run”

Lines:
1. 0.0 mph :FRNT 0 vpm
2. 0 ipf :REAR 0 vpm
3. 0 fpm :FRNT 0 vpm
4. 0 ipf/__ F :REAR 0 vpm (MATT Temp will be displayed when asphalt
temperature is above minimum range of sensor.)
5. 13.6 Vbt :FRNT 0 vpm
6. 4.9 Vsp :REAR 0 vpm
7. AUTO VIB. SET.= 1. 0 mph
9. DISPLAY UNITS: ENGLISH
10. ADJ. WITH MANUAL VIB. SW
11. TRAVEL SPD LMT= 3.8 mph
13. FWD EDC TEST:ENGINE OFF!
15. REV EDC TEST:ENGINE OFF!
Note: Only lines 1 through 6 can be accessed by the operator when the machine is in operation or
at minimum, moving. Lines 1 through 12 can be accessed when FNR is in neutral. To access lines
13 through 16, brake switch must be applied in addition to the FNR being in neutral. Vibes will not
work if speed is less 1.0 mph and throttle is not is “RUN” position.
The “AUTO VIB. SET” and the “TRAVEL SPD LMT” can be set by the operator via the FNR
handle and vibe switch on the FNR handle. The machine must be in neutral to accomplish this. To
change, scroll through the menus using the red scroll button on the display panel until line 7 or 11 is
on the top line. To change, push the FNR handle forward or back and depress the vibe switch. FNR
handle forward will increase values and FNR handle back will decrease values.
Access the standard additional screens by pushing the ‘F4’ key to scroll through the menu.
Screen 2: LMTD
1. Save User RAM: YES/NO (Cursor present so can be changed)
2. NonVol.vs RAM: BOTH SAME
3. Machine Model: (Cursor present so can be changed)
Note: Depress the “F1” switch to save changes on the S2x. “YES” in line (1) will be displayed
momentarily, otherwise “NO” will be the normal message. If changes have been made, the
“DIFFERENT” message in line (2) will be displayed. Once changes have been saved, the message
will change back to “BOTH SAME” which is the normal message. Changing the machine model
will reset some of the calibration values to defaults, particularly the Vldp value
Screen 3: INPUT
1. Vib. Function:Auto/Off/Manual (Dictated by Vibrator Mode switch position)
2. Vib. Location:Front/Both/Rear (Dictated by Drum Select switch position)
3. Handle Vib. PB:Off/On (On is momentary)
4. Neutral Sw. :On/Off (On in center FNR position.)
5. Park Brake :On/Off
6. Vib. Amplitude:Low/High (Dictated by Amplitude switch position)
7. Motor Speed:Low/High (Dictated by Speed Range switch position)
8. Engine Speed:Low/High (Dictated by Throttle switch position)
9. Water Saver: 0-50.0%
Screen 4: VIBS
1. Manual Vib:Off
2. FrntVib LALS: 51.2 mA* (Cursor present so can be changed)
3. FrntVib LAHS: 82.0 mA* (Cursor present so can be changed)
4. FrntVib HALS: 54.8 mA* (Cursor present so can be changed)
5. FrntVib HAHS: 84.9 mA* (Cursor present so can be changed)
6. RearVib LALS: 57.1 mA* (Cursor present so can be changed)
7. RearVib LAHS: 85.6 mA* (Cursor present so can be changed)
8. RearVib HALS: 57.6 mA* (Cursor present so can be changed)
9. RearVib HAHS: 88.5 mA* (Cursor present so can be changed)
10. F. Vib Cmnd: 0.0 mA
11. R. Vib Cmnd: 0.0 mA
Note: F. Vib Cmnd and R. Vib Cmnd will display S2x output in mA if throttle switch is in ‘RUN’
mode, brake switch is off, vibrator mode switch is ‘AUTO’ mode and compactor is traveling at 1.0
mph or greater (as displayed by the display screen).
* - The above values are default values.
To access additional screen on the display panel, depress the ‘F4’ key and the FNR vibe switch
simultaneously.
Screen 5: “PROP”
1. Fwd Max: 180 D/A* (Cursor present so can be changed)
2. Rev Max: 180 D/A* (Cursor present so can be changed)
3. Fwd Thresh: 70 D/A* (Cursor present so can be changed)
4. Rev Thresh: 70 D/A* (Cursor present so can be changed)
5. Propel Cmnd: 0 D/A
6. Propel Comp: 0 D/A
7. Actual VLDP: 12.8 VDC
8. Raw Command: 0.0 %
9. Rate Ltd Cmnd: 0.0%
Note: Items (5), (6), (8) and (9) will display the output from the FNR versus the output from the DC-
2. Brake switch needs to be released.
* - The above values are default value.
Screen 6: “FNR”
1. FNR State:Forward/Neutral/Reverse
2. FNR Input: 0.0 –100.0 %
3. Fnr Cmnd: 0.0 – 100.0 %
4. FNR Out: 0.00 – 5.00 Vdc
Note: Brake switch needs to be released for the above displays to show FNR output. If brake switch
is not released, FNR state will show an error message. The “FNR Out” values will not be greater
than the “FNR Max” value or less than the “FNR Min” value. If values shown on the display are
outside of this range, unit has wrong calibration values. If values shown in item 4 is 0.00 Vdc or
5.00 Vdc, there is a problem with the FNR potentiometer.
Screen 7: “ACCL”
1. Raw Command 0.0 %
2. Rate Ltd Cmnd: 0.0 %
Note: Raw Command=FNR output to S2x. Rate Ltd Cmnd=S2x output in relation to the FNR input.
Item #2 will always follow item #1 to ensure that unit starts and accelerates smoothly in either
direction. This is pre-programmed into the software.
Screen 8: “Volt” (Cursor present so numbers are adjustable)

1. FNR Max.: 4.72 VDC*
2. FNR Ntop: 2.74 VDC *
3. FNR Nbot: 2.18 VDC*
4. FNR Min: 0.19 VDC*
5. Saved Vldp: 13.0 VDC*
6. Battery Volts: 13.7 Vbt
7. Sensor Pwr: 4.9 Vsp
* - The above numbers are default values.The screen below shows an example of a fault message. It
will be shown if a fault condition exists and
can be detected. It will be displayed for a short period of time on the bottom line of the display. Then the
previously selected bottom line will be displayed again. This will continuously alternate as long as the
fault is present. Some faults will cause a shutdown of the propel control if they are serious and the
message will continue to be displayed until the control is shut down and restarted. Others will only display
a message for as long as the fault is present.
3. 9 mp h : F R NT 3400 v p m
F AUL T : F NR Ne u t r a l S w.
The table below shows the fault numbers, fault messages, and resultant system mode. FAULT indicates
a display message only. STOP indicates that the propel system will shut down until the controller is
powered off and then on. “-” indicates that this fault is not used. Also, the backup alarm is not being
tested because it is an optional feature on machines. Note: the low water condition is shown as a FAULT
system mode, but it is only considered a warning to the operator.
DESCRIPTION/MESSAGE TEXT TIME TO SYSTEM MODE

DETECT
1 Sensor Power (5V) voltage is too low (Below 4.8V) 0.4 sec. STOP
“Fault: 5V Sensor Power”
2 FNR Sensor out of range 0.5 sec. STOP
“Fault: FNR Sensor Pot”
3 FNR Neutral Switch failure 0.5 sec. STOP
“Fault: FNR Neutral Sw.”
4 Front Vibrator EDC open or short ~1 sec. FAULT
“Fault: Front Vib. EDC”
5 Rear Vibrator EDC open or short ~1 sec. FAULT
“Fault: Rear Vib. EDC”
6 Propel EDC open or short Not Used -----------
“Fault: Propel EDC” Not Used -----------
7 Low Water Condition 0.4 sec. FAULT
“Warning: Low Water Level”
8 Propel EDC threshold Calibration values out of range at power up STOP
“FAULT: PROP THRSH.CAL”
9 FNR Not Calibrated at power up FAULT
“Fault: FNR Calibration”
10 Propel EDC deadband Calibration value out of range at power up STOP
“Fault: Prop. Dbnd. Cal.”
11 FNR Calibration values out of range at power up STOP
12 Water Spray valve open or short 0.4 sec. FAULT
13 BRAKE APPLIED 180 m sec. STOP

There is a common 5V power source in the S2x. It supplies output current to the following devices
If this fault should occur you can check each of the pin’s listed for continuity to ground.
PIN#
A-1 SCROLL BUTTON (5 V+ SENSOR_PWR) OUT TO DISPLAY PLUG PIN W.
B-1 HI / LOW AMPLITUDE SWITCH (5 V+ SENSOR_PWR) TO DISPLAY PLUG PIN V.
C-1 REAR VIBE SPEED POT # 2 (5 V+ SENSOR_PWR) TO DISPLAY PLUG PIN U.
D-1 FNR SENSOR POT (5 V+ SENSOR_PWR) TO RH FNR PLUG PIN 4.
E-1 BRAKE ON/OFF SWITCH (5 V+ SENSOR_PWR) TO MAIN HARNESS PLUG PIN J.
F-1 FRONT VIBE SPEED POT # 3 (5 V+ SENSOR_PWR) TO DISPLAY PLUG PIN R.
G-1 WATER SPRAY POT # 1 ( 5 V+ SENSOR_PWR ) TO DISPLAY PLUG PIN P.
H-1 Older machines LOW WATER LEVEL SWITCH (5 V+ SENSOR_PWR) TO MAIN HARNESS
PLUG PIN L. The machines with this option will not have a power panel
A B C D E F G H J K
FIGURE 1
CONTROLLER HARNESS CONECTOR
PIN OUT OF THE ( P1 ) PLUG
VIEW LOOKING IN TO THE PLUG
If the computer sees a value of 4.8V or lower, it shows a fault. The computer would have to
see a .5 amp draw for this to happen. Everything in the circuit draws about 5mA
individually. With that being the case, we wouldn’t see a .5 amp draw if everything is
drawing max power at once. To chase this fault, check the connection on the RH FNR first.
It could be the wire to any of the above mentioned areas. The one common between all
of these is the harness. The worst problem is the low water level switches as the wires
for the rear switch run in through the main frame harness, which runs through the hitch.
This is the best place to check. You may get lucky and clear it up by unplugging and
cleaning the connectors along the frame that run to the switch.
RUN FILTERS
OFF
AUTO MAN
WATER TEMP OIL TEMP

HOUR METER
GAUGE GAUGE
WATER SAVER
BOTH THROTTLE
FRONT REAR
SPEED RANGE
AUTO MANUAL

HIGH LOW
ENG OIL PRESS FUEL

VOLTMETER
GAUGE GAUGE
SCROLL BUTTON
TO HITCH
X
W K
V L
J
B
H
U M
P C
N G A
E STATUS F1
T N
F2
D F D
M POWER F3
F S
F4 E O
A C
R P
L X Q
G B
H K DISPLAY PLUG
J
MAINFRAME
HARNESS PLUG
TO HITCH
BA
E
D
PLUG (P1)
C
JHGF
K
FIGURE 2
CENTER POSTION
2.49 VOLTS
FIGURE 3
DEAD BAND DEAD BAND
POT STOPS POT STOPS
FAULT: FNR SENSOR POT
This fault will show itself when the potentiometer in the RH FNR is out of range which will
happen at full stroke forward or reverse. The range is developed during calibration when
you move the FNR lever to full stroke, both directions. The computer reads the actual
number and then subtracts .098V from the top (forward) and adds .098V to the bottom
(reverse). Look at example #1. Remember that the numbers used in this example will be
slightly different from what you might see on any given machine, as each FNR controller
will be slightly different.
1. Sauer-Danfoss built a deadband into the handle to allow for they’re manufacturing
tolerances. This is the black area between .0098V & .1V and 4.98V & 4.88V
2. We then, through programming, added another deadband for our manufacturing tolerances
by subtracting .15V from the top and adding .15V to the bottom. The white area between
4.88V & 4.63V and .098V & .36V reflects this, the numbers that we are showing 4.73V & .1
are general numbers and very slightly from machine to machine.
3. The computer then adds .15V to the 4.63V equaling 4.88V and subtracts .15V from the .25
equaling .1V The 4.88 and .1 become our fault numbers.
4. Anything larger than the top and smaller than the bottom will cause our problem.
5. To correct this problem, go to the VOLT screen and adjust the FNR MAX and/or the FNR
MIN accordingly. If you are seeing this fault, you should be able to consistently cause it by
going full stroke in whichever direction the number is out of range. You can do this with the
engine off and the key in the run position. It will usually occur when the FNR lever is
pushed/pulled hard against the stop in the given direction. Adjust the number until you can’t
duplicate the fault (SEE THE FNR ADJUSTMENT AND COMPONETS LOCATIONS ON
THE FOLLOWING PAGE.)
CENTER POSTION
2.49 VOLTS


DEAD BAND DEAD BAND

POT STOPS POT STOPS
FIGURE 4
OFF
AUTO MAN
VIBRATOR MODE
WATER SAVER
FRONT
BOTH
REAR
FNR: MAX VDC
FNR: Nbot VDC
HIGH LOW
SCROLL MAN VIBE

AMPLITUDE
BUTTON
SCROLL BUTTON
RUN FILTERS
OFF
AUTO MAN
WATER TEMP OIL TEMP

HOUR METER
GAUGE GAUGE
WATER SAVER
BOTH THROTTLE
FRONT REAR
SPEED RANGE
AUTO MANUAL

HIGH LOW
ENG OIL PRESS FUEL

VOLTMETER
GAUGE GAUGE
SCROLL BUTTON

17
7 10 15
AAA
X1
X2
16 10 15
STATUS F1
F2
K6
K2
K1
18
15A
F3
F7
POWER
F4
6
13 14
FL
F6
FJ
F5
AUX
AUX
BAT
BAT
8 9
FG
5
FG
11
PAINT THIS ITEM RED
G
FK
+ POS.
- NEG.
FM
F1
FM
4 10
FL
FN
STATUS
G
49a
31
49
F2
085
49 49a C
70922
8 9
C2 C3 31
G
A
30 87 86 85
BOSCH
3
8X21W
K5
2+1+1X21W
12V
0 335 200 160
BOSCH
FJ
F3
8 9
KK
2
POWER
FP
30 87 86 85
30 87 86 85
BOSCH
F4
BOSCH
K4
G
K3
FH
FM
FM
TO HITCH
CC
G
12
FQ
FIGURE 5
FQ G FM FH
18
PAINT THIS ITEM RED
2 8 9
3 8 9 4 10 11 5 8 9 13 14 16 10 15
6
17
A
085
30 87 86 85
+ POS.
70922
49
BOSCH
BAT
12V
49
49a X1
K3
0 335 200 160

K1
C2 C3
F5
31
49a C
31
2+1+1X21W
8X21W
BOSCH
FG AUX
FL
FM FL K6
BOSCH BOSCH
- NEG. FG BAT AAA
K4 K5
F6
30 87 86 85 30 87 86 85 K2 X2
AUX
7 10 15
G FK FJ F7
15A
G
12
FIGURE 6
K1 - FORWARD RELAY
K2 - REVERSE RELAY
K4 - LOW BEAM RELAY
adjustments.
wheel for access to the S2x controller.
4. Press and Hold in the F3 key on the S2x (computer) and depress the MAN VIBE button on either FNR control
handle. This will access the lower level screen groups.
5. Use the F4 key on the S2x to scroll through the 8 available screens. The screens and the order in
display.
10 Move the FNR all the way forward making certain that it is firmly against the forward stop, with the
11. Move the FNR all the way reverse making certain that it is firmly against the reverse stop, with the
12. Once you have written down FNR Ntop, Nbot, Max, and Min numbers. Use the F4 key on the S2x to
13. When all of the numbers are correct, using the F4 key on the S2x scroll to the LMDT screen to lock in
the numbers. When you get to the LMTD screen push F1 to lock in the numbers.
Nonvol vs Ram: Both Same
14. Turn on the key with the engine off, move the FNR lever and see if the fault returns.
If you haven’t locked anything in by going to the LMTD screen and pressing Fl the
settings will remain the same as they were when you started.
FAULT: FNR NEUTRAL SWITCH
If you are experiencing this fault, you should be able to duplicate it by barely moving the FNR out of neutral in
either direction.
This fault occurs when the FNR Ntop or FNR Nbot (bottom) numbers are out of range. It is very easy to
“miss” these during the calibration of the FNR lever. If you move the lever to fast during the calibration, the
pot position relative to the closing position of the switch will not match. The computer looks at the actual
position of the pot when the switch closes on its way out of neutral. As an example this may be at 2.61V, If
you are pushing the FNR lever too fast, the pot position may be at 2.86V when the switch closes. The
computer adds .15 to this top number and, in this case, makes that number 3.1V This is the FNR top number.
The same process is done in reverse to come up with the FNR bottom number. Let’s use a value of 2.25V in
this example. There two are conditions that will trigger the FNR neutral switch fault.
Condition 1. The neutral switch is open indicating that the FNR is in neutral. For this condition if the computer
sees a number greater than 3.1V (FNR Ntop + .15V) or less than 2.10V (FNR Nbot –.15V) the computer
considers this as a fault .
Condition 2. The neutral switch is closed, indicating that the FNR is out of neutral. For this condition, if the
computer sees a number less than 2.71V (FNR Ntop –.15V) or greater than 2.40V (FNR Nbot + .15V) the
computer will consider this as a fault condition. For the example of miscalibration above, with the switch
actually closing at a value of 2.61V, we end up with a .1V digit window where the second fault condition can
occur.
Once you are able to create the fault consistently. Go to the VOLT screen ( RECALIBRATION PROCEDURE
NOTED ON THE FOLLOWING PAGES) and decrease the numbers for NTop and increase the numbers for
NBot until you can no longer duplicate the fault. Numbers will have to be locked in.
Sensor Power (5V)

R. Speed Signal
Ground
Sensor Power (5V)
Speed Signal
Ground
Neutral A Neutral A
Starter Circuit Neutral B Neutral B
Vibrator Mom. Pushbutton Mom. Pushbutton

On/Off
Left Control Handle Right Control Handle

R. Neutral
Starter Circuit
Note: Switches are shown with handles in Neutral position.
FIGURE 7
OFF
AUTO MAN
VIBRATOR MODE
WATER SAVER
FRONT
BOTH
REAR
FNR: Ntop VDC
FNR: Nbot VDC
HIGH LOW
SCROLL MAN VIBE

AMPLITUDE
BUTTON
SCROLL BUTTON
RUN FILTERS
OFF
AUTO MAN
WATER TEMP OIL TEMP

HOUR METER
GAUGE GAUGE
WATER SAVER
BOTH THROTTLE
FRONT REAR
SPEED RANGE
AUTO MANUAL

HIGH LOW
ENG OIL PRESS FUEL

VOLTMETER
GAUGE GAUGE
SCROLL BUTTON
STATUS F1
F2
POWER F3
F4
F1
STATUS
F2
F3
POWER
F4
REMOVE THE COVER
PLATE
FIGURE 8
FQ G FM FH
18
PAINT THIS ITEM RED
2 8 9
3 8 9 4 10 11 5 8 9 13 14 16 10 15
6
17
A
085
30 87 86 85
+ POS.
70922
49
BOSCH
BAT
12V
49
49a X1
K3
0 335 200 160

K1
C2 C3
F5
31
49a C
31
2+1+1X21W
8X21W
BOSCH
FG AUX
FL
FM FL K6
BOSCH BOSCH
- NEG. FG BAT AAA
K4 K5
F6
30 87 86 85 30 87 86 85 K2 X2
AUX
7 10 15
G FK FJ F7
15A
G
FIGURE 9
12
K1 - FORWARD RELAY
K2 - REVERSE RELAY
K4 - LOW BEAM RELAY
adjustments.
red letters in the window on the S2x to let you know which screen group you are in. If you go past the
screen you are looking for continue to use the F4 key to scroll through the sequence of screens again
until you find the right one
display.
10. Move the FNR all the way forward making certain that it is firmly against the forward stop,
with the FNR full forward write down the numbers that are shown in the FNR OUT portion of
the screen.
11 Move the FNR all the way reverse making certain that it is firmly against the reverse stop, with the
12 Once you have written down FNR Ntop, Nbot, Max, and Min numbers. Use the F4 key on the S2x to
13 When all of the numbers are correct, using the F4 key on the S2x scroll to the LMDT screen to lock in
the numbers. When you get to the LMTD screen push F1 to lock in the numbers.
Nonvol vs Ram: BothSame
14 Turn on the key with the engine off, move the FNR lever and see if the fault returns.
If you haven’t locked anything in by going to the LMTD screen and pressing Fl the settings will
remain the same as they were when you started.
FAULT: REAR VIB.EDC
This fault is telling you that the S2x Controller cannot control the rear vibe pump displacement, the valve drive
“ EDC” is affected, there will be no vibrator action possible. The possible causes for this fault are that the coil
inside the EDC is shorted, or one of the two wires controlling the EDC may either be shorted to ground, or you
have an open circuit “broken wire”.
The Electrical Displacement Control (EDC), is mounted on the rear vibrator pump. The rear vibrator pump
can be turned on\off or set in manual or automatic mode. Front, rear, or both vibrators can be selected. High

PLUG PIN-A VALVE. 0+
REAR VIBE
EDC
0 T0 95 mA
BIDIRECTIONAL
VAVLE
CONTROL
PLUG PIN-B VALVE. 0-
FIGURE 10
BA
STATUS F1
E
F2
D
POWER F3
F4
C
JHGF
K
TO HITCH AD
B C
REAR VIBE
EDC PLUG
REAR VIBE EDC
REAR
VIBRATO R
PUMP REF.
TO ENGINE REF.
COCKPIT
TRAVEL
PUMP REF.
REAR VIBE EDC
MANUAL COTROL
FRONT VIBE
PUMP REF.
FIGURE 11
REAR VIBE EDC FAULT TROUBLE SHOOTING
1. Remove the plug from rear vibe pump EDC. Once the plug is removed check both the EDC and the
1. Once the components are checked and cleaned, use a volt/ohm meter to check PIN D of the
controller harness plug for a direct short to ground. Then check PIN C for a direct short to ground. If a
short is found, find the damaged wire and repair it if possible. If this is not possible replace the control
harness.
your volt/ohm meter check between Pin D and ground. Do the same with PIN C. If a short is found
between PIN C and ground or between PIN and ground replace the EDC. If there is no internal
grounding, there should be somewhere in the range of 15 to 35 ohms resistance between PIN D and
PIN C.
4. If you can not find any shorts or grounds in the harness or EDC there may be an open (broken wire).
the S2x controller. Once you have access to the S2x you will need to remove plug P1 and check for
use your volt/ohm meter and check the continuity between plug P1 PIN J-1 and the rear vibe EDC
plug PIN A for one open wire. To check the other wire in this area of the harness you will need to
check plug P1 PIN J-3 and the rear vibe EDC plug PIN B.
A B C D E F G H J K
A B
3
1
B C

FIGURE 12
FAULT: FRONT VIB.EDC
This fault is telling you that the S2x Controller cannot control the front vibe pump displacement, the valve
the coil inside the EDC is shorted, or one of the two wires controlling the EDC may be either be shorted to
The Electrical Displacement Control (EDC), is mounted on the rear vibrator pump. The front vibrator pump
can be turned on/off or set in manual or automatic mode. Front, rear, or both vibrators can be selected. High
FROM PLUG P1 PIN# K-1 TO FRONT

VIBE PLUG PIN-D or 4 VALVE. 1+
FRONT VIBE
EDC
0 T0 95 mA
BIDIRECTIONAL
VALVE
CONTROL
FROM PLUG P1 PIN# K-3 TO FRONT VIBE
PLUG PIN-C or 3 VALVE. 1-
FIGURE 13
BA
STATUS F1
E
F2
D
POWER F3
F4
C
JHGF
K
TO HITCH
FRONT VIBE EDC
REAR
VIBRATOR
PUMP REF.
TO ENGINE REF.
COCKPIT
AD TRAVEL
B C PUMP REF.
FRONT VIBE EDC
MANUAL COTROL
FRONT VIBE
PUMP REF.
FRONT VIBE
EDC PLUG
FIGURE 14
FRONT EDC FAULT TROUBLE SHOOTING
1. Remove the plug from front vibe pump EDC. Once the plug is removed check both the EDC and the
controller harness plug for a direct short to ground. Then check PIN B for a direct short to ground.
If a short is found, find the damaged wire and repair it if possible. If this is not possible replace the
control harness.
your volt/ohm meter check between Pin A and ground. Do the same with PIN B. If a short is found
between PIN A and ground or between PIN B and ground replace the EDC. If there is no internal
grounding there should be somewhere in the range of 15 to 35 ohms resistance between PIN A and
PIN B.
4. If you can not find any shorts or grounds in your harness or EDC there may be a open (broken wire).
any damage to the plug or the wires leading to it. After you checked the plug, you will need to use
your volt/ohm meter and check the continuity between plug P1 PIN K-1 and the rear vibe EDC plug
PIN A for open wire. To check the other wires in this area of the harness you will need to check plug
P1 PIN K-3 and the front vibe EDC plug PIN B
A B C D E F G H J K
A B
3
1
B C

FIGURE 15
PROPEL EDC FUCTION
This condition will not be displayed if there is a short or open circuit in the wiring to the propel EDC. The
controller cannot control the pump displacement if the valve drive is affected. Therefore no machine motion
will be possible. Depending on the condition, there may be motion available in one direction only.
The Electrical Displacement Control (EDC), is mounted on the propel pump. It is used to control the
displacement of the pump. The pump EDC is a dual coil device connected with a common ground on opposite
sides of the coils. Each coil is driven by a high current digital output which is pulse width modulated. The
PWM frequency is 200 Hz. The pump is at zero displacement when no current is applied to the EDC. The
typical threshold current required to begin stroking the pump is between 5-25 milliamps. The current
requirement to reach maximum pump displacement is typically 85-95 milliamps. The actual current is a
function of the battery voltage and the duty cycle will be adjusted automatically to compensate. However, the
current is also a function of the EDC coil resistance which changes with temperature. For this reason the
calibration should be performed with the vehicle fully warmed up.

PWM
SIGNAL
PIN 30 PIN 87 PIN D
0 VOLTS IN NEUTRAL
PIN 2 T0 4 +/- VOLTS AND 85 T0 95 mA EDC PLUG PIN C
P2F3 AT PIN D WHEN THE PUMP IS FULLY
STROKED IN REVERSE

SIGNAL DIGITAL OUT .0 FROM PLUG P1 PIN# B3 TO
EDC PLUG PINS B AND C
SENSOR GROUND
PIN 30 PIN 87
PIN A
EDC PLUG PIN B
0 VOLTS IN NEUTRAL
2 T0 4 +/- VOLTS AND 85 T0 95 mA
STROKED IN FORWARD
FIGURE 16
SIGNAL DIGITAL OUT.2 PIN 86 REV PIN 85

RELAY
12V FROM DC2 PIN P2 F2
PIN P1 H3
GROUND
SIGNAL DIGITAL OUT.1

PIN 86 FWD PIN 85
RELAY
12V FROM DC2 PIN P2 D2
FIGURE 17
PROPEL EDC TROUBLE SHOOTING
1. Remove the plug from propel pump EDC. Once the plug is removed check both the EDC and the plug
for any oil, dirt or corrosion. Also check for any obvious damage, such as cracks or broken wires.
controller harness plug for a direct short to frame ground. Then check PIN D for a direct short to
frame ground. If a short is found, find the damaged wire and repair it if possible. If this is not possible
replace the control harness.
3. If you did not find a short when checking PINS A or D, check PIN B for an open and then check PIN C
for an open. After checking each of the pins individually check PIN A and pin C for continuity. If you
do find an open and there is no continuity between these two pins. That will tell you the break in the
wire is somewhere close to the back of the harness, the reason for that is the wires to Pins B & C are
joined in the harness and grounded at Pin P1 B3 . If you have continuity, the break could be farther
up in the harness behind the splice. Find the damaged wire and repair it if possible. If this is not
possible replace the control harness.
4. Once you have eliminated shorts in the harness check the EDC for an internal short to frame ground.
Using your volt/ohm meter, check between Pin A, B, C and D. If a short is found between any of the
pins and frame ground replace the EDC.
5. If you cannot find any shorts or grounds in your harness or EDC there may be a open (broken wire).
use your volt/ohm meter and check the continuity between the following points.
PIN#
P2-F3 TO PIN 30 on the FWD relay out 87 TO the propel EDC plug PIN A for FDW PMW signal
P1-H3 TO PIN 85 on the FDW relay
P2-D2 TO PIN 86 on the FDW relay
P1-B3 TO the propel EDC plug PIN B for FDW
P2-F3 TO PIN 30 on the REV relay out pin 87 TO the propel EDC plug PIN D for REV PMW signal
P1-H3 TO PIN 85 on the REV relay
P2-F2 TO PIN 86 on the REV relay
P1-B3 TO the propel EDC plug PIN C for REV

DC2 CONTROLLER
REAR
VIBRATOR
PUMP REF.
STATUS F1
F2
POWER F3
F4
TO ENGINE REF.
COCKPIT
AD TRAVEL
B C PUMP REF.
TO HITCH FRONT VIBE

PUMP REF.
PROPEL
EDC PLUG
PLUG (P2)
PLUG (P1)
A
CB
BA
ED
E
F
D
C
JHGF
PROPEL EDC
K
PROPEL EDC
MANUAL COTROL
FIGURE 18
PROPEL EDC CIRCUIT PLUGS .

View Looking In To The Plug Controller Harness Connector Plug P2
View Looking In To The Plug
A B C D E F
A B C D E F G H J K
3
3
2 2
1 1
1 3 1 3
2 4 2 4
OLDER STYLE
FORWARD/ EDC PLUG NEWER STYLE
Reversr EDC PLUGE
RELAY
PLUG
A D
B C
FIGURE 19
FAULT: PROP THRSH. CAL.
This fault appears when the values for the forward or reverse thresholds are out of a certain range
that the computer is looking for.
The forward/reverse thresholds are the points at which the machine begins to move in the forward
or reverse directions. If the thresholds are not set correctly during the calibration procedure the
machine will be jerky when starting and stopping. The reason for the jerky motion is the two relays
that control the direction of the machine are closing to late when starting out and opening to early
when stopping. To correct this problem you will need to adjust the threshold set point for the
direction that is jerky.

(-200+15=-185 ACTUAL (185-15-170 ACTUAL)

TO END TO END
DEADBAND DEADBAND
30.00 º 30.00 º
FIGURE 21
PROPEL THRESHOLD ADJUSTMENT PROCEDURE.
1. The set of numbers that you will want to change is going to depend on when the fault happens or which
direction the machine has a jerky start and stop. If the fault happens when you are pushing the FNR lever
forward you will want to adjust the FWD THRSH numbers, and if the fault happens when you are pulling back
on the FNR lever you will want to adjust the REV THRSH numbers.
2. Now that you have determined which of the two needs to be adjusted, remove the cover plate below the steering
setup is performed.
7. Using the scroll button on the dash, bring the (FWD THRESH: *** or (REV THRESH: *** to the top
line of the display and change the number farthest from 70 to the same as the one close to 70 and
start adding 3 to or subtracting 3 from original number on the screen. To change the numbers press
the F1 key on the S2x to increase or the F2 key to decrease. The number will scroll continuously
while the F1 and F2 keys are being held or they will increase 1 digit at a time each time the key is
pushed.
8. Once the numbers are changed, use the F4 key on the S2x to scroll to the LMTD screen. This is the
Different. Push the F1 key on the S2x to lock in the numbers. When you do this the “NO” on the top
screen and pressing Fl, the settings will remain the same as they were when you started.
FAULT: Prop Dband. CAL.
This fault appears when the values for the forward or reverse thresholds have a difference of 100 or
more between them. Within the Neutral dead band range that the computer is looking for.
The threshold numbers are generally in the area of 185 for both forward and reverse +/-
50 if the numbers are 101 apart there will be a fault.

(-200+15=-185 ACTUAL (185-15-170 ACTUAL)

TO END TO END
DEADBAND DEADBAND
30.00 º 30.00 º
FIGURE 22
OFF
AUTO MAN
VIBRATOR MODE
WATER SAVER
FRONT
BOTH
REAR
FNR: Ntop VDC
FNR: Nbot VDC
HIGH LOW
SCROLL MAN VIBE

AMPLITUDE
BUTTON
SCROLL BUTTON
RUN FILTERS
OFF
AUTO MAN
WATER TEMP OIL TEMP

HOUR METER
GAUGE GAUGE
WATER SAVER
BOTH THROTTLE
FRONT REAR
SPEED RANGE
AUTO MANUAL

HIGH LOW
ENG OIL PRESS FUEL

VOLTMETER
GAUGE GAUGE
SCROLL BUTTON
STATUS F1
F2
POWER F3
F4
F1
STATUS
F2
F3
POWER
F4
REMOVE THE COVER
PLATE
FIGURE 23
PROPEL DEAD BAND ADJUSTMENT PROCEDURE.
1. The set of numbers that you will want to change is going to depend on which of the numbers is 101 points out
from the number that is close to 70.
2. To determined which of the two needs to be adjusted, remove the cover plate below the steering wheel for access
to the S2x controller.
which they appear are RUN, LMTD, INPT, VIBS, PROP, FNR, ACCL, and A/D. These will flash in
setup is performed.
7. Using the scroll button on the dash, bring the (FWD THRESH: ***) or (REV THRESH: ***) to the top
line of the display and change the number adding 3 to or subtracting 3 from original number on the
screen. To change the numbers press the F1 key on the S2x to increase or the F2 key to decrease.
The number will scroll continuously while the F1 and F2 keys are being held or they will increase 1
digit at a time each time the key is pushed.
8. Once the numbers are changed, use the F4 key on the S2x to scroll to the LMTD screen. This is the
Different. Push the F1 key on the S2x to lock in the numbers. When you do this the “NO” on the top
screen and pressing Fl the settings will remain the same as they were when you started.
OFF
AUTO MAN
VIBRATOR MODE
WATER SAVER
FRONT
BOTH
REAR
FNR: MAX VDC
FNR: Nbot VDC
HIGH LOW
SCROLL MAN VIBE

AMPLITUDE
BUTTON
SCROLL BUTTON
RUN FILTERS
OFF
AUTO MAN
WATER TEMP OIL TEMP

HOUR METER
GAUGE GAUGE
WATER SAVER
BOTH THROTTLE
FRONT REAR
SPEED RANGE
AUTO MANUAL

HIGH LOW
ENG OIL PRESS FUEL

VOLTMETER
GAUGE GAUGE
SCROLL BUTTON

17
7 10 15
AAA
X1
X2
16 10 15
STATUS F1
F2
K6
K2
K1
18
15A
F3
F7
POWER
F4
6
13 14
FL
F6
FJ
F5
AUX
AUX
BAT
BAT
8 9
FG
5
FG
11
PAINT THIS ITEM RED
G
FK
+ POS.
- NEG.
FM
F1
FM
4 10
FL
FN
STATUS
G
49a
31
49
F2
085
49 49a C
70922
8 9
C2 C3 31
G
A
30 87 86 85
BOSCH
3
8X21W
K5
2+1+1X21W
12V
0 335 200 160
BOSCH
FJ
F3
8 9
KK
2
POWER
FP
30 87 86 85
30 87 86 85
BOSCH
F4
BOSCH
K4
G
K3
FH
FM
FM
TO HITCH
CC
G
12
FQ
FIGURE 24
This fault appears when the FNR MIN or FNR MAX numbers are out of range. The fault
can happen any time after the RIGHT FNR lever has been calibrated. If the FNR MIN
numbers are not with in the range of 30 to 100 or for the FNR MAX numbers the range of
890 to 990 the computer will show this fault.
To correct this problem, go to the VOLT screen and adjust the FNR MAX and/or the FNR
MIN accordingly so that it falls with the given ranges. If you are seeing this fault, you
should be able to consistently cause it by stroking the FNR in whichever direction the
number is out of range. You can do this with the engine off and the key in the run position.
It will usually occur when the FNR lever is pushed/pulled hard in the given direction. Adjust
the number until you can’t duplicate the fault ( SEE THE FNR ADJUSTMENT AND
COMPONETS LOCATIONS ON THE FOLLOWING PAGE. )
center postion
510 A/D (analog/digital)
460 A/D 560 A/D
neutral bottom neutral top
52 A/D 948 A/D
22 A/D 978 A/D
2 A/D 1023 A/D
deadband deadband
handle stops handle stops
(0 volts) (+5 volts)
pot stops 30.00º 30.00º pot stops
HANDLE OUTPUT VS POSTION
FIGURE 25
THE MACHINE IN NEUTRAL

DC2 2.FROM PIN 87 REV RELAY TO PIN D EDC PLUG
CONTROLLER SIGNAL DIGITAL OUT .2
PIN 87a
PIN 30 PIN 87
REV
RELAY
PLUG
PIN D
PIN2

PLUG P1 GROUND
PIN# B3
EDC PLUG PIN C
12 VOLT REVERSE RELAY

IN REV REV RELAY PLUG PIN# 4
PLUG P1
PIN# F2
PLUG P2 PWM
SIGNAL
FDW
RELAY
PIN 87 PLUG PIN A
PLUG P2
PIN# D2
12 VOLT
IN FWD PIN 85 PIN 86
EDC PLUG PIN B
FORWARD RELAY
PULG P1
PIN# H3
GROUND
PROPEL EDC
FIGURE 26
THE MACHINE IN REVERSE
DC2
CONTROLLER
PIN 87a
SIGNAL DIGITAL OUT .2 PIN 30 PIN 87
0 VOLTS IN NEUTRAL
REV 2 T0 4 +/- VOLTS AND 85 T0 95 mA
RELAY PIN D AT PIN D WHEN THE PUMP IS FULLY
PLUG STROKED IN REVERSE
PIN2
PIN 85 PIN 86
PLUG P1
PIN# B3 SIGNAL
GROUND EDC PLUG PIN C
REVERSE RELAY
PLUG P1 12 VOLT
PIN# F2
12 VOLT
REV

PLUG P2 PWM
SIGNAL
FDW
RELAY
PIN 87 PLUG PIN A
PLUG P2
PIN# D2
12 VOLT
FWD PIN 85 PIN 86
EDC PLUG PIN B
FORWARD RELAY
PULG P1 12 VOLT
PIN# H3
GROUND
PROPEL EDC
FIGURE 27
THE MACHINE GOING FORWARD
DC2
CONTROLLER
PIN 87a
PIN 30 PIN 87
REV
RELAY
PLUG
PIN D
PIN2

PLUG P1 GROUND
PIN# B3
EDC PLUG PIN C
REVERSE RELAY
12 VOLT REV RELAY PLUG PIN# 4 12 VOLT
PLUG P1 REV
PIN# F2 1.FROM PLUG P2 PIN# F-3 TO FORWARD RELAY PIN# #30

PLUG P2 PWM
SIGNAL
FDW
RELAY
PIN 87 PLUG PIN A
PLUG P2
PIN# D2
12 VOLT
FWD PIN 85 PIN 86
EDC PLUG PIN B
FORWARD RELAY
PULG P1 12 VOLT
PIN# H3
GROUND

0 VOLTS IN NEUTRAL
2 T0 4 +/- VOLTS AND 85 T0 95 mA
STROKED IN FORWARD
PROPEL EDC
FIGURE 28
LIMITED OPERATION MODE
RUN FILTERS
OFF
AUTO MAN
WATER TEMP OIL TEMP

HOUR METER
GAUGE GAUGE
WATER SAVER
BOTH THROTTLE
FRONT REAR
SPEED RANGE
AUTO MANUAL

HIGH LOW
ENG OIL PRESS FUEL

VOLTMETER
GAUGE GAUGE
SCROLL BUTTON
Screen #1 OFF
This screen is telling the operator AUTO MAN
that there is a fault and the machine is in
limited operaton mode. VIBRATOR MODE
WATER SAVER
BOTH
FRONT REAR LIMD OP: MODE - FNR FDW
HIGH LOW
Screen #2
This screen is telling the operator OFF
that there is a fault and by moving the AUTO MAN
vibe mode selection switch to the FRONT

position the machine will travel in the VIBRATOR MODE
WATER SAVER
FORWARD direction when the FNR is moved FRONT
BOTH
REAR VIBE MODE- FRNT/FDW
from the neutral position in either Fault: 5V SENSOR POWER
direction.
HIGH LOW
SCROLL BUTTON
Screen #3
This screen is telling the operator that
OFF
there is a fault and by moving the vibe AUTO MAN
mode selection switch to the REAR
position the machine will travel in the REVERSE
VIBRATOR MODE
direction when the FNR is moved from the BOTH
WATER SAVER
FRONT REAR
VIBE MODE- REAR/REV
neutral position in either direction.
HIGH LOW
SCROLL BUTTON
FIGURE 29
Function DC2 Pin Input or Output Normal Voltage Open Circuit
Levels Voltage Levels
at DC2 Pin
Battery + P2-F1 Input 11-15 vdc 0 vdc
Battery - P2-E1 Input 0 vdc 0 vdc
Chassis Gnd P2-B2 Input 0 vdc 0 vdc
Brake Switch P1-C2 Input 5 vdc with brake off 0 vdc
0 vdc with brake on
Sensor Gnd for L. P1-A3 Ground 0 vdc 0 vdc
Control Handle
Pushbutton Switch
FNR Neutral Switch P2-D1 Input 12 vdc if FNR in 12 vdc
neutral
0 vdc if FNR not in
neutral
Sensor Power for P1-D1 Output 5 vdc 5 vdc
FNR potentiometer
Wiper for FNR P1-D2 Input ~ 4.8 vdc in Forward to 0 vdc
potentiometer ~ 0.2 vdc in Reverse
Sensor Gnd for FNR P1-D3 Ground 0 vdc 0 vdc
potentiometer, neutral
switch, and R. Control
Handle Pushbutton
Left or Right P2-B1 Input 12 vdc if neither 12 vdc
Pushbutton Switches pushbutton is pressed
0 vdc if either
pushbutton is pressed
Auto Vibrator Function P2-C2 Input 12 vdc if not in Auto 12 vdc
Switch mode
0 vdc if in Auto mode
Manual Vibrator P2-D3 Input 12 vdc if not in Manual 12 vdc
Function Switch mode
0 vdc if in Manual mode
Sensor Gnd for P1-E3 Ground 0 vdc 0 vdc
Vibrator Function,
Vibrator Location, and
mat temperature
sensor
Front Vibrator P2-A1 Input 12 vdc if not in Front 12 vdc
0 vdc if in Front location
Rear Vibrator P2-C1 Input 12 vdc if not in Rear 12 vdc
0 vdc if in Rear location
Sensor Power for P1-A1 Output 5 vdc 5 vdc
Display Scroll Switch
Driver for Backup P2-F2 Output ~ Battery voltage if 0 vdc
Alarm and Reverse vehicle is in reverse.
Relay (K1) in propel 0 vdc if vehicle is in
circuit. forward.
Display Scroll Switch P1-A2 Input 0 vdc if switch is not 0 vdc
pressed
5 vdc if switch is
pressed
Sensor Power for P1-B1 Output 5 vdc 5 vdc
High/Low Amplitude
Switch
High/Low Amplitude P1-J2 Input 0 vdc if switch is in Low 0 vdc
Switch position
5 vdc if switch is in High
position
Sensor Power for P1-G1 Output 5 vdc 5 vdc
Water Saver
Potentiometer
Wiper for Water Saver P1-K2 Input ~ 5.0 vdc in high position 0 vdc
potentiometer to
~ 0.0 vdc in low position
Sensor Gnd for Water P1-G3 Ground 0 vdc 0 vdc
Saver potentiometer
Sensor Power for P1-F1 Output 5 vdc 5 vdc
Front Vibrator Speed
Potentiometer
Wiper for Front P1-H2 Input ~ 5.0 vdc in high position 0 vdc
Vibrator Speed to
Sensor Gnd for Front P1-F3 Ground 0 vdc 0 vdc
Vibrator Speed
potentiometer
Sensor Power for P1-C1 Output 5 vdc 5 vdc
Rear Vibrator Speed
Potentiometer
Wiper for Rear P1-G2 Input ~ 5.0 vdc in high position 0 vdc
Vibrator Speed to
Sensor Gnd for Rear P1-C3 Ground 0 vdc 0 vdc
Vibrator Speed
potentiometer
Unused Sensor Power P1-H1 Output 5 vdc 5 vdc
Output from Mat P1-F2 Input ~ 0.6 vdc to ~ 3.0 vdc 0 vdc
Temperature Sensor
Motor Speed Switch P1-E2 Input 12 vdc if in Low Motor 12 vdc
0 vdc if in High Motor
Sprayer Relay Driver P2-E3 Output ~ Battery voltage if 0 vdc
sprayer relay is on
0 vdc if sprayer relay is
off
Engine Speed Switch P2-E2 Input 12 vdc if in Low Idle 12 vdc
0 vdc if in High Idle
Sensor Gnd for Propel P1-B3 Ground 0 vdc 0 vdc
EDC coils
Driver for forward or P2-F3 Output This is a 0-12 vdc Pulse 0 vdc
reverse EDC coils in Width Modulated output.
Propel Circuit. Routed Voltage will be zero if
to forward or reverse vehicle is stopped.
coil by relays K1 and Voltage will vary up to ~
K2 in propel circuit. 3.5 vrms if vehicle is
moving.
Driver for Forward P2-D2 Output ~ Battery voltage if 0 vdc
Relay (K2) in propel vehicle is in forward.
circuit. 0 vdc if vehicle is in
reverse.
Sensor Gnd for P1-H3 Ground 0 vdc 0 vdc
Forward and Reverse
Relays in propel circuit
Low Amplitude P1-K1 Output This is a current source 0 vdc
~ 85 mA ( ~ .95 vdc to ~
1.6 vdc)
High Amplitude P1-K3 Output This is a current source 0 vdc
~ 85 mA ( ~ .95 vdc to ~
1.6 vdc)
Low Amplitude P1-J1 Output This is a current source 0 vdc
~ 85 mA ( ~ .95 vdc to ~
1.6 vdc)
High Amplitude P1-J3 Output This is a current source 0 vdc
~ 85 mA ( ~ .95 vdc to ~
1.6 vdc)
Section 8
TRANSMISSION SYSTEM
TABLE OF CONTENTS
PAGE

FLEX DRIVE PLATE ................................................................................................................................. 8-4.
REMOVAL ............................................................................................................................................ 8-4.
INSPECTION ....................................................................................................................................... 8-5.
INSTALLATION .................................................................................................................................... 8-5.
REAR DRUM VIBRATOR PUMP DRIVE COUPLING ................................................................................... 8-7.
REMOVAL ................................................................................................................................................. 8-7.
INSPECTION ............................................................................................................................................ 8-9.
INSTALLATION ......................................................................................................................................... 8-9.
HYDRAULIC SYSTEM ................................................................................................................................ 8-11.
GENERAL INFORMATION .................................................................................................................... 8-11.
TRANSMISSION SYSTE ............................................................................................................................ 8-11.
GENERAL INFORMATION ..................................................................................................................... 8-11.
TRANSMISSION PUMP ASSEMBLY .......................................................................................................... 8-14.
OPERATION ........................................................................................................................................... 8-14.
TRANSMISSION PUMP CIRCUITS AND COMPONENTS ......................................................................... 8-15.
CHARGE PUMP AND CIRCUIT ............................................................................................................. 8-15.
PROPORTIONAL ELECTRIC DISPLACEMENT
CONTROL VALVE AND CIRCUIT ..................................................................................................... 8-16.
CHARGE PRESSURE RELIEF VALVE .................................................................................................. 8-16.
MULTIFUNCTION VALVE CARTRIDGE ASSEMBLIES ........................................................................ 8-17.
CHARGE PRESSURE CHECK VALVES ................................................................................................ 8-17.
HIGH PRESSURE RELIEF VALVES ...................................................................................................... 8-17.
PRESSURE LIMITER VALVES ............................................................................................................... 8-18.
BYPASS VALVES ................................................................................................................................... 8-19.
FLUSHING [HOT OIL SHUTTLE] VALVE CIRCUIT ............................................................................... 8-19.
TRANSMISSION PUMP CASE DRAIN CIRCUIT .................................................................................. 8-20.
TRANSMISSION SYSTEM FILTRATION ............................................................................................... 8-20.
INLET HYDRAULIC OIL SUCTION STRAINERS ............................................................................. 8-20.
TRANSMISSION SYSTEM PRESSURE OIL FILTER ....................................................................... 8-21.
REMOVAL, REPAIR OR REPLACEMENT OF COMPONENTS OF THE
TRANSMISSION PUMP .............................................................................................................................. 8-21.
INTERNAL GEAR CHARGE PUMP ....................................................................................................... 8-22.
AUXILIARY PUMP MOUNTING PAD REMOVAL/CHARGE PUMP DISASSEMBLY ....................... 8-22.
INSPECTION ..................................................................................................................................... 8-24.
CHARGE PUMP ASSEMBLY/AUXILIARY PUMP MOUNTING PAD INSTALLATION ..................... 8-24.
MULTIFUNCTION VALVE CARTRIDGES .............................................................................................. 8-25.
REMOVAL, INSPECTION AND INSTALLATION............................................................................... 8-25.
CHARGE CHECK VALVES .................................................................................................................... 8-26.
REMOVAL, INSPECTION AND INSTALLATION............................................................................... 8-26.
9/2005 8-1
Section 8
TRANSMISSION SYSTEM
TABLE OF CONTENTS (contd.)
PAGE
PROPORTIONAL ELECTRIC DISPLACEMENT CONTROL VALVE ......................................................... 8-26.

REMOVAL AND REPLACEMENT .......................................................................................................... 8-26.
PRESSURE LIMITER/HIGH PRESSURE RELIEF VALVES .................................................................. 8-26.
REMOVAL, DISASSEMBLY, CLEANING, INSPECTION, ASSEMBLY AND INSTALLATION .......... 8-26.
TRANSMISSION PUMP SHAFT AND SEAL ......................................................................................... 8-28.
REMOVAL, INSPECTION AND INSTALLATION ............................................................................... 8-28.
COMPLETE TRANSMISSION PUMP ASSEMBLY ..................................................................................... 8-29.
REMOVAL .............................................................................................................................................. 8-29.
MAJOR TRANSMISSION PUMP REPAIR ............................................................................................. 8-30.
INSTALLATION ...................................................................................................................................... 8-30.
TRANSMISSION PUMP PRESSURES ...................................................................................................... 8-32.
CHECKING AND ADJUSTMENT PROCEDURES ................................................................................ 8-32.
TRANSMISSION PUMP CASE DRAIN OIL PRESSURE ................................................................... 8-32.
NEUTRAL CHARGE PRESSURE ....................................................................................................... 8-33.
FLUSHING VALVE OUTPUT OIL FLOW CHECK AND ADJUSTMENT ............................................ 8-35.
TRANSMISSION SYSTEM HIGH PRESSURE/PRESSURE LIMITER PRESSURE
CHECK AND ADJUSTMENT ............................................................................................................ 8-37.
DRUM DRIVE MOTOR/BRAKE ASSEMBLIES .......................................................................................... 8-40.
DESCRIPTION ........................................................................................................................................ 8-40.
OPERATION ........................................................................................................................................... 8-41.
REMOVAL, DISASSEMBLY, INSPECTION, ASSEMBLY AND INSTALLATION ................................... 8-43.
REMOVAL ........................................................................................................................................... 8-43.
DISASSEMBLY .................................................................................................................................... 8-43.
INSPECTION ....................................................................................................................................... 8-47.
ASSEMBLY .......................................................................................................................................... 8-49.
INSTALLATION ................................................................................................................................... 8-52.
DRUM DRIVE MOTOR PRESSURE AND FLOW CHECKS .................................................................. 8-53.
CHECKING PROCEDURES ................................................................................................................ 8-53.
CASE PRESSURE .............................................................................................................................. 8-53.
CASE DRAIN OIL FLOW AMOUNT .................................................................................................... 8-55.
WORK [low] TO TRAVEL [high] RANGE PILOT PRESSURE ........................................................... 8-57.
SECONDARY/PARKING BRAKE SYSTEM RELEASE PILOT PRESSURE ..................................... 8-58.
8-2 9/2005
Section 8
TRANSMISSION SYSTEM
TABLE OF CONTENTS (contd.)
PAGE
CLEANING THE HYDRAULIC SYSTEM ..................................................................................................... 8-59.

HYDRAULIC SYSTEM PRE-START PROCEDURES ................................................................................. 8-60.
HYDRAULIC SYSTEM START UP PROCEDURES ................................................................................... 8-62.
TROUBLE ANALYSIS FOR THE TRANSMISSION SYSTEM ..................................................................... 8-64.
HYDROSTATIC PUMP ........................................................................................................................... 8-64.
DRUM DRIVE MOTORS AND BRAKES ................................................................................................ 8-70.
MULTI-DISC BRAKES ........................................................................................................................... 8-72.
9/2005 8-3
Section 8
TRANSMISSION SYSTEM
GENERAL INFORMATION. REMOVAL.
This section gives information about the NOTE: Remove the flex drive plate assembly
TRANSMISSION system used on the 66 Inch and ONLY if there is damage to the splined
78 Inch Compactors. center sleeve or other parts of the plate.
BEFORE removal of the flex drive plate,
This section also includes information for removal, the two [2] hydraulic pumps MUST be
disassembly, inspection, assembly and installation of disconnected and removed as an assem-
the TRANSMISSION system components, including bly from the pump mounting plate [see
the secondary/parking brake system components, THIS section].
which are incorporated into each drum drive motor.
“Trouble Analysis” for the TRANSMISSION system is a. Wash BOTH pumps, pump mounting plate and
found at the rear of the section. flywheel housing area with All Purpose Degreaser,
part number 178297, and permit to air dry.
b. Put an identification tag on the pump control

FLEX DRIVE PLATE [See Figure 8-1]. electrical wire harness at the transmission pump.
Disconnect, and then remove, the electrical harness
The flex drive plate is driven by the engine. The flex connection at the transmission pump displacement
drive plate is used to drive the following pumps: control solenoid. Put an identification tag on the
pump control electrical wire harness at the front
1. The hydrostatic variable displacement pump, vibration pump. Disconnect, and then remove, the
which supplies oil flow for the TRANSMIS- electrical harness connection at the front drum
SION system. vibrator pump displacement control solenoid. Put
identification tags on ALL hydraulic hoses that are
2. The hydrostatic variable displacement pump, connected to BOTH pumps. Remove ALL of the
which supplies oil flow for the FRONT drum hoses and put plugs and caps in ALL hoses and on
VIBRATOR system [driven through TRANS- ALL fittings.
MISSION pump].
c. Fasten a sling and hoist, having a capacity
The flex drive plate assembly is used to send rotary more than 500 lbs. [227 kg], around the circumfer-
torque from the engine flywheel to the ence of the transmission pump body. Use the hoist to
TRANSMISSION system pump and the front apply tension to the sling to keep the pump assem-
VIBRATION system pump. blies in a level, and balanced, position when the
transmission pump mounting capscrews are loos-
The flex drive plate assembly is fastened to the ened and removed.
engine flywheel by eight [8] capscrews and rotates
with the flywheel. The flex plate has a splined center d. Use a sling and hoist to keep the transmission
sleeve, which drives the input shaft of the pump in a level position when the [4] transmission
transmission pump. The front drum vibrator pump pump to mounting plate retaining capscrews are
input shaft is driven through the splined transmission removed. CAREFULLY remove the retaining cap-
pump charge pump shaft. screws. Use the sling and hoist to CAREFULLY lift,
remove and then lower the transmission pump to the
As the flex drive plate turns with the engine flywheel, ground, with the front vibration pump fastened at the
it rotates the transmission pump input shaft. The front rear. Remove the sling and hoist.
drum vibrator pump is mounted to the rear of the
transmission pump. The front drum vibrator pump
input shaft is driven through the transmission pump. WARNING: Keep CLEAR of the pump assemblies
and surrounding areas while lifting,
moving and lowering the pump
assemblies.
8-4 9/2005
Section 8
TRANSMISSION SYSTEM
e. Remove the twelve [12] capscrews which fasten b. CAREFULLY inspect the center splined area, of
the pump mounting plate to the flywheel housing. the drive plate, for damaged splines, cracks or other
Remove the pump mounting plate from the housing. damage. Inspect the area around the through holes
for cracks, or other damage. CAREFULLY inspect the
f. Remove the splined sleeve from the flex drive splined sleeve for wear, or damage. Replace the flex
plate. Remove the eight [8] capscrews that fasten the drive plate and sleeve assembly, with NEW, if any
flex drive plate to the engine flywheel. CAREFULLY damage is noted, in either item.
remove the plate from the flywheel. Put the plate on a
CLEAN flat work surface.
INSTALLATION [See Figure 8-1].
INSPECTION [See Figure 8-1]. a. Put the flex drive plate into position on the
engine flywheel.
a. Wash the flex drive plate and splined sleeve
with All-Purpose Degreaser, part number 178297, b. Put Loctite #242, part number 318702, on the
and dry using compressed air. threaded area of the eight [8] flex drive plate retaining
capscrews. Install the flex drive plate to engine
flywheel retaining capscrews through the holes in the
flex drive plate and thread them into the tapped holes
in the engine flywheel. Tighten the capscrews to a
torque of 33 ft. lbs. [45 N.m].
CAPSCREW
PUMP
FLYWHEEL
DRIVE PLATE
CAPSCREW CAPSCREW
PUMP MOUNTING PLATE
FIGURE 8-1. FLEX DRIVE PLATE ASSEMBLY -

EXPLODED VIEW.
9/2005 8-5
Section 8
TRANSMISSION SYSTEM
c. Put antisieze grease, part number 316865, on CAUTION: Connect ALL hoses to the fittings on
the external and internal splines of the splined sleeve. BOTH of the hydraulic pumps as
Install the splined sleeve into the center splined area indicated by the identification tags put
of the flex drive plate. Put the pump mounting plate on the hoses and fittings BEFORE
into position on the flywheel housing, so that the four removal.
[4] tapped pump mounting holes are in a horizontal
position. Put the twelve [12] pump mounting plate
retaining capscrews through the holes in the pump g. Install the pump control electrical harness onto
mounting plate and turn them into the tapped holes in the transmission pump displacement control sole-
the housing. Tighten the capscrews to a torque of 23 noid as indicated by the identification tag. Install the
ft. lbs. [31 N.m]. pump control electrical harness onto the front drum
vibrator pump displacement control solenoid as
d. Move the transmission and vibrator pump indicated by the identification tag.
assembly into position under the machine. Fasten a
sling and a hoist, having a capacity more than 500
lbs. [227 kg], to the transmission and vibration pump CAUTION: Be sure that the each harness is
assembly, so that it will be in a balanced condition connected to each of the two [2]
when lifted. Put antisieze grease, part number pumps as indicated by the
316865, on the splined area of the transmission identification tags. The harness
pump input shaft. Use the sling and hoist to CARE- assembly that fastens to the front
FULLY lift the pumps. Put the transmission pump drum vibrator pump displacement
input shaft in a position, so that it is in alignment with control solenoid is LONGER, in total
the center splined sleeve in the flex drive plate. LENGTH, than the harness assembly
CAREFULLY install the splined input shaft into the that fastens to the transmission pump
splined sleeve and push the pump mounting area displacement control solenoid.
FULLY against the pump mounting plate.
e. Put Loctite #290, part number 251099, on the

threaded area of the four [4] capscrews that fasten
the transmission pump to the pump mounting plate.
Install the pump retaining capscrews and tighten to a
torque of 80 ft. lbs. [108 N.m]. Remove the sling and
hoist from the pump assemblies.
f. Remove the caps from ALL fittings and the

plugs from ALL hoses. Install each hose onto the
CORRECT pump fitting as indicated by the identifica-
tion tags. Tighten each hose securely onto EACH
fitting or install, and then tighten, the flange retaining
capscrews.
8-6 9/2005
Section 8
TRANSMISSION SYSTEM
h. Add APPROVED hydraulic oil, as needed, to The drive coupling assembly is used to send rotary
the hydraulic oil reservoir using the procedures given torque from the engine crankshaft to the rear drum
in Section 4 - MAINTENANCE. Follow ALL “pre-start vibrator system pump.
procedures” given in THIS section BEFORE starting
the engine. The drive coupling plate is fastened to the front of the
engine crankshaft by four [4] capscrews and rotates
with the crankshaft.
CAUTION: Do NOT start the engine BEFORE the
hydraulic oil level, in the reservoir, is The drive coupling rubber drive ring is fastened to the
at the CORRECT level. Do NOT start coupling drive plate by three [3] Allen set screws. The
the engine until ALL “pre-start” removable splined center sleeve is installed into the
procedures have been done. Damage open area of the rubber drive ring and is held in
to the hydraulic system components position by three [3] Allen set screws. The splined
will occur. sleeve drives the input shaft of the rear drum vibrator
pump input shaft.
i. Start the engine. Check for CORRECT operation As the drive coupling assembly turns with the engine
of ALL systems. Check for ANY fluid leaks. crankshaft, it rotates the rear drum vibrator pump
input shaft.
WARNING: Do NOT use the hands on ANY The front engine mount bracket is installed over the
hydraulic hose, fitting or system drive coupling assembly and onto the front of the
component to check the system for engine, and retained by four [4] capscrews. The rear
possible leaks. Serious injury can drum vibrator pump assembly is mounted to the
occur from a leak under high pres- altered front engine mount bracket by two [2]
sure. Use a piece of cardboard to capscrews.
check for leaks. Wear safety glasses
to protect the eyes. Get IMMEDIATE
medical attention if oil enters the
eyes, or skin. REMOVAL [See Figure 8-2].
NOTE: Remove the pump drive coupling assem-

CAUTION: STOP the engine IMMEDIATELY if ANY bly ONLY if there is damage to the splined
fluid leak is noted Do NOT start the center sleeve, rubber drive ring or other
engine until any problem noted has parts of the assembly. BEFORE removal,
been corrected. of the pump drive assembly, the rear drum
vibrator hydraulic pump MUST be re-
moved from the front motor mount
bracket and then the front motor mount
REAR DRUM VIBRATOR PUMP DRIVE COUPLING bracket must be removed from the front of
[See Figure 8-2]. the engine.
The rear drum vibrator pump drive coupling is driven

by the engine. The coupling is used to drive the a. Wash the pump, front motor mount bracket and
hydrostatic variable displacement pump, which pump drive assembly with All-Purpose Degreaser,
supplies oil flow for the REAR drum VIBRATOR part number 178297, and permit to air dry.
system.
9/2005 8-7
Section 8
TRANSMISSION SYSTEM
b. Disconnect, and then remove, the electrical d. Remove the vibrator pump mounting cap-
harness assembly at the rear drum vibrator pump screws. Use the sling and hoist to CAREFULLY hold,
displacement control solenoid. Put an identification remove, and then lower, the vibrator pump from the
tag on each hose that is connected to the vibrator front engine mount bracket and pump drive coupling
pump. Disconnect, and then remove, ALL of the and to lower the pump to the ground. Move the
hoses which fasten to the pump and put plugs and pump assembly from under the machine and
caps on ALL hoses and fittings. remove the sling and hoist.
c. Fasten a sling and hoist, having a capacity

MORE than 250 lbs. [114 kg], around the circumfer- WARNING: Keep CLEAR of the pump assembly
ence of the rear vibrator pump body. Use the hoist to and surrounding area while lifting,
apply tension to the sling to keep the pump assembly moving and lowering the pump
in a level, and balanced, position when the vibrator assembly.
pump mounting capscrews are being removed.
SPINED
CENTER
ENGINE PUMP MOUNTING AREA SLEEVE
ALLEN SCREWS
CAPSCREWS
DRIVE COUPLING PLATE
ALTERED
BRACKET
ENGINE CRANKSHAFT
ENGINE MOUNT MOUNTING CAPSCREWS
RUBBER DRIVE RING

CROSSMEMBER
ENGINE MOUNT CAPSCREW
FIGURE 8-2. REAR DRUM VIBRATOR PUMP

DRIVE COUPLING.
8-8 9/2005
Section 8
TRANSMISSION SYSTEM
e. Place a floor jack, having a capacity of more INSTALLATION [See Figure 8-2].
than 2,000 lbs. [908 kg], under the FRONT area of
the engine. Place wood on the lifting pad of the jack. a. If removed, put the drive coupling plate in
Use the jack to lift the engine a SMALL amount and position at the outer side of the engine crankshaft
to then support the weight of the front of the engine. pulley. Install the four [4] coupling plate retaining
capscrews and tighten to a torque of 90 ft. lbs.
[122 N.m].
WARNING: Keep CLEAR of the jack, engine and
surrounding area while lifting the b. Put the rubber drive ring in position against the
engine. drive coupling plate. Put Loctite #242, part number
318702, on the threaded area of the three [3] drive
ring retaining Allen screws. Install the Allen screws
f. Remove the FRONT engine mount capscrew and tighten by the hand ONLY, at THIS time.
from the rear frame weldment crossmember, front
engine mount bracket and engine mount. c. Put the splined center sleeve into the open
center area of the rubber drive ring. Put Loctite #242,
g. Remove the four [4] capscrews that fasten the part number 318702, on the threaded area of the six
front engine mount bracket to the front of the engine. [6] center sleeve retaining Allen screws. Install the
Remove the front engine mount bracket from the Allen screws. Tighten ALL six [6] Allen screws to a
engine. torque of 69 ft. lbs. [94 N.m].
h. Loosen the three [3] Allen screws that fastens d. Put the front engine mount bracket into position
the splined center sleeve into the open area of the on the front of the engine. Put Loctite #242, part
rubber drive ring. Remove the splined center sleeve. number 318702, on the threaded area of the four [4]
Loosen the three [3] Allen screws that fastens the capscrews that fasten the engine mount bracket to
rubber drive ring to the drive coupling plate. Remove the engine. Install the capscrews and tighten the
the rubber drive ring. If needed, remove the four [4] capscrews to a torque of 80 ft. lbs. [108 N.m].
capscrews that fasten the drive coupling plate to the
engine crankshaft. Remove the drive coupling plate. e. Put Loctite #242, part number 318702, on the
Clean the four [4] capscrews that fasten the drive threaded area of the engine mount capscrew. Install
coupling plate to the engine crankshaft with diesel the capscrew and washer through the frame
fuel and dry with compressed air. Clean the four [4] crossmember and engine mount. Thread the
tapped holes, in the engine crankshaft, with diesel capscrew into the tapped hole in the engine mount
fuel and dry with compressed air. bracket. Tighten the capscrew to a torque of 166 ft.
lbs. [225 N.m].
INSPECTION [See Figure 8-2].
a. Wash ALL of the removed parts with All-

Purpose Degreaser, part number 178297, and dry
using compressed air.
b. CAREFULLY inspect the splined area of the

center splined sleeve for damaged splines, cracks or
other damage. Inspect the rubber drive ring for tears,
cracks, material deterioration, or other damage. If
removed, inspect the drive coupling plate for worn
mounting holes, cracks, or other damage. If ANY of
the inspected components are worn, or damaged,
replace the drive coupling with NEW.
9/2005 8-9
Section 8
TRANSMISSION SYSTEM
f. Move the rear drum vibrator pump assembly into j. Add APPROVED hydraulic oil, as needed, to the
position under the machine, so that the electric hydraulic oil reservoir using the procedures given in
solenoid will be at the BOTTOM when the pump Section 4 - MAINTENANCE. Follow ALL “pre-start
assembly is lifted. Fasten a sling and a hoist, having procedures” given in THIS section BEFORE starting
a capacity more than 250 lbs. [114 kg], to the vibrator the engine.
pump assembly, so that the pump will be in a bal-
anced condition when lifted. Put anti-size grease, part
number 316865, on the splined area of the vibrator CAUTION: Do NOT start the engine BEFORE the
pump input shaft. Use the sling and hoist to CARE- hydraulic oil level, in the reservoir, is
FULLY lift the pump and put the pump input shaft in a at the CORRECT level. Do NOT start
position, so that it is in alignment with the center the engine until ALL “pre-start”
splined sleeve in the pump drive center sleeve. procedures have been done. Damage
CAREFULLY install the splined input shaft into the to the components of the hydraulic
splined center sleeve and push the pump mounting system will occur.
area fully against the pump mounting area of the
front engine mount bracket.
k. Start the engine. Check for CORRECT opera-
g. Put Loctite #242, part number 318702, on the tion of ALL systems. Check for ANY fluid leaks.
threaded area of the two [2] capscrews that fasten
the rear drum VIBRATOR pump to the front engine
mount bracket. Install the pump mounting capscrews WARNING: Do NOT use the hands on ANY
and tighten to a torque of 66 ft. lbs. [89 N.m]. Remove hydraulic hose, fitting, or system
the sling and hoist from the pump assembly. component to check the system for
possible leaks. Serious injury can
h. Remove the caps from ALL fittings and the occur from a leak under high pres-
plugs from ALL hoses. Install EACH hose onto the sure. Use a piece of cardboard to
CORRECT pump fitting as indicated by the identifica- check for leaks. Wear safety glasses
tion tags. Tighten EACH hose securely onto EACH to protect the eyes. Get IMMEDIATE
fitting or install, and then tighten, the flange retaining medical attention if oil enters the
capscrews. eyes or skin.
CAUTION: Connect ALL hoses to the fittings of CAUTION: STOP the engine IMMEDIATELY if ANY
the hydraulic pump as indicated by fluid leak is noted. Do NOT start the
the identification tags put on the engine until any problem noted has
hoses and fittings BEFORE removal. been corrected.
i. Install the pump control electrical harness and

connection plug assembly onto the rear drum vibrator
pump displacement control solenoid.
CAUTION: Be SURE that the CORRECT harness

and plug assemblies are connected to
each of the two [2] pump
displacement control solenoids as
indicated by the identification tags.
8-10 9/2005
Section 8
TRANSMISSION SYSTEM
USE file 8-11 - 8-14 pgs HERE
9/2005 8-11
Section 8
TRANSMISSION SYSTEM
--
ge
Pa
LE
B
U
O
D
FIGURE 8-3 sht. 1 - GOES HERE
FIGURE 8-3. HYDRAULIC SYSTEM SCHEMATIC - PART 1.
8-12 9/2005
Section 8
TRANSMISSION SYSTEM
--
ge
Pa
LE
B
U
O
D
FIGURE 8-3 sht. 2 - GOES HERE
FIGURE 8-3. HYDRAULIC SYSTEM SCHEMATIC - PART 2.
9/2005 8-13
Section 8
TRANSMISSION SYSTEM
8-14 9/2005
Section 8
TRANSMISSION SYSTEM
The control plate contains ports which are in contact The charge pump supplies cool hydraulic oil to the
with the cylinder block of the rotary group. The system, keeps the system charged with oil and
opposite side of the control plate mates with the supplies the control system with oil. Charge pressure
pump port plate. Two [2] ports in the pump port plate is also used to select the speed range of the
are connected to the high pressure hoses. transmission drum drive motors and release the
secondary/parking brake system. Charge pressure,
When a piston moves past the inlet ports, in the with the pump in NEUTRAL [0 flow], is limited by a
control plate, it moves “out” of the block and pulls low relief valve which is normally factory set at a pressure
pressure oil into the cylinder. This is the intake stroke of 375-400 psi. [26-28 bar], plus case pressure.
of the piston. Further rotation of the cylinder block
moves the oil filled cylinder toward the high pressure Since either of the main hydraulic lines can be the
ports in the control plate. The pistons are pushed into high pressure line, two [2] charge check valves are
the cylinder block by the tilted swashplate and control used to direct the charge oil supply into the LOW
plate. Hydraulic oil, now under high pressure, is pressure line. The check valves are contained in the
directed to the high pressure outlet port in the pump multifunction valve cartridges, that are installed into
port plate. the pump body, near the charge pump section.
With the pump swashplate tilted to one side of the The charge pump draws hydraulic oil from the
center position, the machine will travel in the hydraulic oil reservoir, through a 100 mesh suction
FORWARD direction of travel. One [1] hose will carry strainer. Charge oil is then drawn into the charge
high pressure oil to BOTH transmission drum drive pump. The charge pump creates oil flow which is
motors. The other hose will carry low pressure filtered by a 5 micron integral pressure oil filter before
[return] oil from the transmission drum drive motors it enters the low pressure side, of the main circuit.
back to the pump. The OPPOSITE tilt of the pump
swashplate will REVERSE the high pressure and
return function of the hoses from, and back to, the
pump and, thereby, reverse the direction of machine
travel.
The main pump ports are connected by hydraulic

hoses to the two [2] transmission drum drive motors.
Hydraulic oil flows from the pump to the motors and
back to the pump in a CLOSED circuit. Either
hydraulic hose will carry HIGH pressure. The position
of the pump swashplate determines which hydraulic
hose carries the HIGH pressure oil and the direction
of HIGH pressure oil flow.
TRANSMISSION PUMP CIRCUITS AND

COMPONENTS.
CHARGE PUMP AND CIRCUIT [See Figures 8-3

and 8-4].
A fixed displacement [INTERNAL GEAR, through

drive type] charge pump is mounted on the variable FIGURE 8-4. TRANSMISSION CHARGE PUMP
displacement transmission pump body. The charge LOCATION.
pump is driven through a splined coupler by the main
pump shaft.
9/2005 8-15
Section 8
TRANSMISSION SYSTEM
PROPORTIONAL ELECTRIC DISPLACEMENT The electric displacement control valve has an orifice
CONTROL VALVE AND CIRCUIT [See Figures 8-2 for controlling maximum acceleration, or powered
and 8-5]. deceleration [control responses]. The orifice used,
matches the machine response desired and the
The electric displacement control valve provides orifice size must NOT be changed.
control of the transmission pump output
[displacement], in either direction, that is
approximately proportional to the angular movement
of either control handle, at the cockpit. CHARGE PRESSURE RELIEF VALVE [See Figure
8-6].
The charge pump provides oil flow to the hydraulic
pump displacement control valve for control of The one [1] charge pressure relief valve is found in
transmission pump oil output [flow]. the body of the internal gear charge pump assembly.
Charge pressure, with the transmission pump in
When the displacement control valve spool is NEUTRAL [0 flow], is limited by the charge relief
electrically moved, by the proportional displacement valve which is normally factory set at a pressure of
control solenoid, to either the forward, or reverse, 375-400 psi. [26-28 bar], plus case pressure.
position, the displacement control valve directs
CONTROL oil flow to one [1] side of the When charge pressure is more than the above
displacement control piston. The piston is moved by pressure, the charge relief valve will open and permit
control oil flow and, thereby, moves the pump oil to flow through the charge pressure relief valve
swashplate through the linkage, to provide pump and back to the hydraulic oil reservoir.
output oil flow.
FIGURE 8-6. CHARGE PRESSURE RELIEF VALVE

FIGURE 8-5. PROPORTIONAL ELECTRIC LOCATION.
DISPLACEMENT CONTROL VALVE LOCATION.
8-16 9/2005
Section 8
TRANSMISSION SYSTEM
MULTIFUNCTION VALVE CARTRIDGE
ASSEMBLIES [See Figure 8-7].
The transmission pump uses two [2] identical

multifunction valve cartridge assemblies. Both
cartridge assemblies are installed into the side of the
pump housing.
Each multifunction valve cartridge assembly contains

a charge check valve, adjustable pressure limiter/high
pressure relief valves and the towing bypass valve.
NOTE: The following information describes the

basic function of each of the items con-
tained in the multifunction valve
cartridge assemblies.
CHARGE PRESSURE CHECK VALVES

[See Figure 8-7]. FIGURE 8-7. MULTIFUNCTION VALVE CARTRIDGE
ASSEMBLIES - LOCATIONS
The two [2] charge check valves are contained in the ON PUMP.
multifunction valve cartridge assemblies. The check
valves are used to send filtered charge oil to the
LOW pressure side of the transmission system when
the transmission pump is in the FORWARD, or HIGH PRESSURE RELIEF VALVES
REVERSE, oil flow output condition. [See Figures 8-7 and 8-8].
Two [2] charge check valves are needed because The two [2] high pressure relief valves are, also,
EITHER line, in the supply loop, will carry HIGH, or contained in the multifunction valve cartridges [See
LOW, pressure. When the transmission pump is THIS section].
stroked, and is producing oil flow, the charge check
valve sensing HIGH pressure will be held in a These valves act in relationship to the pressure
CLOSED position, by high pressure and NO charge limiter valves as a second, and final, relief valve in
oil can flow into the line. The charge check valve the HIGH pressure side of the transmission system.
sensing LOW pressure will be in the OPEN position The valve will act only AFTER action by the one [1] of
and permit charge oil to enter the LOW pressure side the pressure limiter valves, or if a condition exists
of the cylinder block assembly to maintain adequate where BOTH the pressure limiter and high pressure
oil in the system. relief valves are needed in the system.
When the transmission pump is in neutral, BOTH Adjustment of system high pressure is done
charge check valves will be in the OPEN position and simultaneously when the system pressure limiter
permit oil, under charge pressure, to lubricate and relief pressure is adjusted at the end of each
charge BOTH sides of the pump cylinder block and multifunction valve cartridge assembly.
system.
The system high relief pressure is automatically set
at 500 psi. [35 bar] ABOVE the system pressure
limiter relief pressure setting.
9/2005 8-17
Section 8
TRANSMISSION SYSTEM
During STROKED transmission pump operation, the
high pressure relief valve, if exposed to HIGH system
pressure, [AFTER pressure limiter valve action] can
act as the control to limit, and maintain, the
MAXIMUM system HIGH pressure.
During operation, if system pressure, ABOVE the

MAXIMUM high pressure, is sensed [AFTER
pressure limiter valve action] the valve will
IMMEDIATELY open and release HIGH pressure oil
into the low pressure side of the transmission oil
circuit.
NOTE: The pressure limiter system destrokes the

pump swashplate [REDUCES displace-
ment] whenever the MAXIMUM preset
pressure limiter system pressure has
been reached, and then maintains that
pressure during, most, normal operating
circumstances [See THIS section].
FIGURE 8-8. MULTIFUNCTION VALVE CROSS
SECTION.
After pressure limiter valve action, and if a system
high pressure still exists above the high pressure
relief pressure, the action of the HIGH pressure relief
valve LOWERS the MAXIMUM HIGH pressure in the
system. PRESSURE LIMITER VALVES [See Figures 8-7
and 8-8].
The high pressure relief valve will continue to sense,
and maintain, the maximum system high pressure as The one [1] pressure limiter valve is contained in
long as the pressure limiter valve is not operating each of the two [2] multifunction valves.
correctly, or when a condition exists where BOTH
relief valves are needed and the machine continues to The pressure limiter valve system is a fast
be operated in the same direction of travel. responding control, which limits pump output
pressure to a level approximately 500 psi. [35 bar]
BELOW the system high pressure relief valve setting.
NOTE: If the pressure limiter valve is NOT operat-
ing correctly, or a condition exists where One [1] pressure limiter valve is used in EACH side
BOTH relief valves are needed, and the of the HIGH pressure circuit of the transmission
direction of machine travel is reversed, the system. The pressure limiter valve is the FIRST, of
OPPOSITE valve sensing HIGH pressure, two [2], RELIEF valves placed in each HIGH
will function in the SAME way as de- pressure circuit of the transmission system.
scribed previously for that direction of
machine travel. During normal operation, the pressure limiter valve
will be the ONLY relief valve used to control, and then
maintain, HIGH pressure in the transmission system.
NOTE: During extreme load conditions, it is

possible that BOTH the pressure limiter
valve and the HIGH pressure relief valve
will BOTH be in a “RELIEF” condition, for
a SHORT period of time.
8-18 9/2005
Section 8
TRANSMISSION SYSTEM
The pressure limiter system RELIEVES the HIGH
pressure within the transmission system whenever BYPASS VALVES [See Figures 8-7 and 8-8].
the MAXIMUM preset system pressure limiter system
pressure has been reached, and then maintains that The bypass valves are contained in the multifunction
pressure. valves and are used ONLY when TOWING the
machine [See Section 3 - OPERATION in THIS
The pressure limiter valve relief pressure is factory manual].
adjusted at a pressure which is approximately 500
psi. [35 bar] BELOW the pressure at which the two [2]
HIGH pressure relief valves are adjusted [See THIS FLUSHING [HOT OIL SHUTTLE] VALVE CIRCUIT
section]. [See Figures 8-3 and 8-9].
The pressure limiter valve should, therefore, be The flushing [hot oil shuttle] valve is used in the
operational, and open, BEFORE the maximum closed loop transmission circuit to remove an oil
system high pressure is reached. When a pressure, amount from the system which is approximately
above the pressure limiter valve relief pressure, is equal to 1/3 of the charge pump flow.
sensed in the system, and if the limiter valve is
operating correctly, the valve will send a small The valve is used to remove HOT oil from the system
amount of HIGH pressure oil directly to the at times of continuous high pressure/high load/high
unpressurized side of the displacement control speed operation and, also, to lower the contamination
piston. level of the circuit oil by continually replacing the oil in
the circuit.
This small amount of HIGH pressure oil moves the
piston TOWARD the DESTROKE position, a SMALL The flushing valve has a factory set relief pressure
amount. The moving piston is fastened, by linkage, to [STROKED CHARGE] that is approximately 25 psi.
the pump swashplate and moves the swashplate [2 bar] BELOW the pressure at which the charge
toward the destroked [NEUTRAL] position a SMALL relief valve [NEUTRAL CHARGE] is set. That
amount. This action acts as the control to limit, and pressure can be adjusted, if required [See THIS
maintain, the system maximum HIGH pressure at the section].
pressure at which the pressure limiter valve is
adjusted.
At the same time CONTROL oil is released from the

pressurized side of the displacement control piston
and permitted to flow back into the low pressure side
of the control oil circuit.
NOTE: The action of the pressure limiter system

is VERY FAST in response time. The
system can port high pressure to and
from the displacement control piston, and
maintain the MAXIMUM system high
pressure, without the need to interact
externally with the pump displacement
control valve.
FIGURE 8-9. FLUSHING [HOT OIL SHUTTLE]

VALVE LOCATION.
9/2005 8-19
Section 8
TRANSMISSION SYSTEM
TRANSMISSION PUMP CASE DRAIN CIRCUIT TRANSMISSION SYSTEM FILTRATION.
[See Figure 8-10].
INLET HYDRAULIC OIL SUCTION STRAINERS
The transmission pump uses the case drain circuit to [See Figure 8-11].
remove hot hydraulic oil from the pump and, thereby,
cool the pump during operation. The circuit also Two [2] 100 mesh suction strainers are found in the
removes oil, from the pump case, which has leaked hydraulic oil reservoir. One [1] strainer cleans inlet oil
by pistons and other internal pump parts during supplying the TRANSMISSION and VIBRATION
operation. systems and one [1] strainer cleans inlet oil
supplying the STEERING system.
During transmission pump operation, HOT hydraulic
oil, having a pressure less than 40 psi. [3 bar], flows When the engine has started and is “running”,
from the top case drain port, of the pump case, to the hydraulic oil is pulled by the pumps being supplied oil
hydraulic oil reservoir. through BOTH suction strainers as the oil leaves the
hydraulic oil reservoir. Oil for the transmission system
is drawn into the charge pump on the
TRANSMISSION pump and oil for the vibration
system is drawn into the charge pump on the front
VIBRATOR pump. Oil then flows from the
transmission pump to the pressure filter. Oil also
flows from the front vibrator pump to the vibration
system pressure filter. When the transmission pump
is “stroked”, oil flows to the flushing [hot oil shuttle]
valve. Oil for the “closed loop” system is supplied
through the use of the charge check valves [See
THIS Section].
NOTE: Extra oil flow that is NOT needed or used

by the pump “closed loop” system is
returned to the hydraulic oil reservoir
through the charge pressure relief valve.
CAUTION: Transmission system inlet vacuum

MUST NOT be ABOVE 10 in. hg. [254
FIGURE 8-10. TRANSMISSION PUMP CASE mm hg] with the system at operating
temperature. See Section 4 -
DRAIN PORT - LOCATION. MAINTENANCE - for correct strainer
and pressure oil filter service
procedures.
8-20 9/2005
Section 8
TRANSMISSION SYSTEM
DIFFUSER
STRAINERS
FIGURE 8-11. HYDRAULIC OIL INLET STRAINERS FIGURE 8-12. PRESSURE OIL FILTER -
AND DIFFUSER LOCATIONS. LOCATION.
TRANSMISSION SYSTEM PRESSURE OIL FILTER REMOVAL, REPAIR OR REPLACEMENT OF

[See Figure 8-12. COMPONENTS OF THE TRANSMISSION PUMP.
One [1] 5 micron integral hydraulic pressure oil filter GENERAL INFORMATION [See Figure 8-13].
is mounted onto the transmission pump. The filter
element is held by the filter head. Minor repairs are those repairs which can be
performed without removing the pump end cap, or
side cover. Minor repairs can be performed by
NOTE: The filter head, and element, may be found following the correct minor repair procedures, given in
mounted in the vertical, horizontal, or this section.
angled position. The position has NO
effect on filtration. Only the following components CAN be removed,
repaired, or replaced, WITHOUT canceling the pump
warranty.
When the engine has started and is “running”, oil for
the transmission system is drawn into the charge 1. Internal gear charge pump.
pump on the TRANSMISSION pump. Oil then flows 2. Charge pressure relief valve.
from the transmission pump to the pressure filter. 3. Proportional electric displacement control valve
assembly.
See Section 4 - MAINTENANCE - for correct filter 4. Shaft seal.
element service procedures. 5. Multifunction valve cartridge assemblies.
CAUTION: See the nearest HYPAC Distributor for

a copy of the “Service Policy and
Procedure Manual”, which describes
complete warranty information.
Major repairs are those which require
the removal of the pump end cap, or
side cover. Major repairs are intended
to be done, ONLY, by
Sauer-Sundstrand, Authorized Service
Centers.
9/2005 8-21
Section 8
TRANSMISSION SYSTEM
The following components CAN be removed from the INTERNAL GEAR CHARGE PUMP.
pump, and replaced with new, without removing the
complete pump from the machine. AUXILIARY PUMP MOUNTING PAD REMOVAL/
CHARGE PUMP DISASSEMBLY [See Figure
1. Internal gear charge pump assembly [after 8-14].
removal of the front vibrator pump].
2. Charge pressure relief valve. CAUTION: The charge pump is integral to the
3. Proportional electric displacement control valve transmission pump housing and
assembly. auxiliary pump mounting pad.
4. Multifunction valve cartridge assemblies. BEFORE servicing the charge pump,
wash the transmission pump housing,
Use the following procedures to remove, inspect and the auxiliary pump mounting pad and
replace the above transmission pump components the front vibrator pump assembly with
and/or to remove and replace the complete All-Purpose Degreaser, part number
transmission pump assembly, if needed. 178297, and dry with compressed air.
The front vibrator pump assembly
MUST be removed BEFORE the
auxiliary pump mounting pad can be
removed and the charge pump parts
removed for inspection and/or
replacement.
a. Remove the wire harness connection from the

proportional displacement control solenoid and move
the harness to a position away from the vibrator
pump assembly. Put an identification tag on each
hose connected to the front vibrator pump fittings.
Remove EACH hose from the pump fittings. Put a
plug in each hose and a cap on each fitting.
b. Place a floor jack in position under the front

vibrator pump, so that the lifting pad is centered
under the pump assembly. Raise the floor jack lifting
FIGURE 8-13. TRANSMISSION PUMP ASSEMBLY pad until the pad just reaches the bottom of the pump
COMPLETE. case, and will keep the pump in position when the
pump mounting capscrews are loosened and re-
moved. Remove the capscrews that fasten the
vibrator pump to the auxiliary pump mounting pad
housing at the rear of the transmission pump assem-
bly. CAREFULLY move the vibrator pump outward to
disconnect the pump drive shaft from the transmis-
sion pump internal splined drive shaft. Hold the
vibrator pump in position on the floor jack lifting pad.
Have an assistant CAREFULLY lower the floor jack
lifting arm and vibrator pump downward to the floor.
8-22 9/2005
Section 8
TRANSMISSION SYSTEM
c. Make a scribed line on the auxiliary pump d. Slowly loosen the clamp holding the auxiliary
mounting pad and the transmission pump end cap, at pump mounting pad and end cap to the transmission
the point where the two parts are joined to identify pump housing. CAREFULLY remove the auxiliary
the correct position relationship of each part. Remove pump mounting pad and end cap from the transmis-
the four [4] socket head capscrews that fasten the sion pump housing and place on a CLEAN lint free
auxiliary pump mounting pad to the transmission cloth. Remove the socket head six [6] capscrews
pump housing. holding the charge pump cover retaining plate.
Carefully remove the retaining plate, cover and
auxiliary drive coupling.
CAUTION: On this transmission pump assembly,
the auxiliary pump mounting pad is
secured to the pump end cap by the CAUTION: Note the orientation of the gerotor
four [4] capscrews. assembly.
Do NOT allow the force of the cylinder
block spring and swashplate leveler
springs to separate the end cap from e. Remove the following charge pump compo-
the pump housing. Secure the end nents from the pump end cap housing and place on a
cap to the housing, with a clamp to CLEAN lint free cloth. Remove the charge shaft and
avoid gasket damage and/or possible key. Remove the charge pump gerotor assembly.
oil leakage after assembly. Remove the outer eccentric ring and alignment pin.
Remove the inner port plate.
f. Put a paper cover over the opening in the

charge pump housing and tape in position to keep
dirt out.
FIGURE 8-14. TRANSMISSION PUMP CHARGE

PUMP COMPONENTS.
9/2005 8-23
Section 8
TRANSMISSION SYSTEM
INSPECTION [See Figure 8-14]. d. Carefully install the gerotor assembly into the
charge pump area in the pump end cap.
a. Wash ALL of the parts with All-Purpose
Degreaser, part number 178297 and dry using e. Install the charge pump drive key into the
compressed air. charge pump shaft and retain with petroleum jelly.
Carefully install the charge pump shaft.
b. Remove the o-ring from the groove in the inner
side of the auxiliary pump mounting pad. Inspect the
inner area of the housing for wear, or damage. CAUTION: Use CAUTION to NOT move the
Replace, with NEW, if worn, or damaged. position of the aligned parts inside
the housing cavity. The splined end of
c. Inspect the charge pump parts for wear, dam- the shaft MUST engage the main
age, or foreign material. Replace ALL internal charge pump shaft.
pump components with NEW, as a SET, if ANY wear,
or damage, is found on ANY component.
f. Install the auxiliary pump drive coupling, with the
drive spline facing toward the REAR of the pump.
CAUTION: If wear, or damage, is found in ANY Carefully remove the alignment pin from the charge
internal charge pump component, ALL pump parts. Install the pin in its hole in the charge
internal charge pump components pump cover and retain with petroleum jelly. Install the
MUST be replaced with NEW, because cover [with alignment pin] into the end cap and
they are a matched SET. aligned charge pump parts.
CAUTION: To avoid loss of charge pressure,

always install the charge pump cover
CHARGE PUMP ASSEMBLY/AUXILIARY PUMP with the auxiliary pump mounting pad
MOUNTING PAD INSTALLATION [See Figure 8- drain hole located on the same side of
15]. the end cap as the charge inlet port.
CAUTION: Be sure to install the charge pump in

the proper orientation, as noted g. Install the charge pump cover retainer and six
during disassembly procedures. [6] hex head retaining capscrews. Tighten the cap-
screws to a torque of 10 ft. lbs. [13.5 N.m].
a. BEFORE installation of ANY new parts, put h. Install a new o-ring into groove on the end cap.
CLEAN petroleum jelly on ALL internal charge pump Install the auxiliary pump mounting pad onto the end
parts. cap. Install the four [4] auxiliary pump to end cap
retaining capscrews. Tighten the capscrews to a
b. Remove the paper cover from the opening in torque of 90 ft. lbs. [122 N.m].
the transmission charge pump housing.
i. Have an assistant CAREFULLY raise the floor
c. Carefully install the inner port plate and outer jack lifting arm and front drum vibrator pump assem-
eccentric ring. Install the alignment pin to properly bly upward until the pump input shaft is in horizontal
orient the inner port plate and outer eccentric ring for alignment with the internal splined charge pump shaft
the correct direction of pump rotation. and auxiliary pump mounting pad housing. Move the
jack and vibrator pump toward the engine and into
position at the auxiliary pump mounting pad. Engage
NOTE: Use the location pin to align the position the vibrator pump input shaft splines into the charge
of the port plate and the eccentric outer pump shaft. Put Loctite #242, part number 318702,
ring. on the threaded area of the two [2] vibrator pump
retaining capscrews. Install the capscrews and
tighten to a torque of 66 ft. lbs. [89 N.m].
8-24 9/2005
Section 8
TRANSMISSION SYSTEM
j. Remove the plugs from all hoses and the caps c. Remove the o-rings from the cartridge. Wash
from all vibrator pump fittings. Install each hose onto the cartridge assembly with All-Purpose Degreaser,
the CORRECT pump fitting, as shown by the identifi- part number 178297 and dry using compressed air.
cation tags. Securely tighten EACH hose fitting. Inspect the multifunction valve cartridge assembly for
Connect the transmission pump and the front drum ANY damage.
vibrator pump wire harness connection plug to the
CORRECT pump proportional solenoid.
CAUTION: NO repair parts are sold separately for
k. Check the hydraulic oil level in the reservoir and the multifunction valve cartridges. The
add oil if needed [See Section 4 - MAINTENANCE]. cartridges can be removed,
disassembled, cleaned, assembled
and installed, or removed and
CAUTION: Follow ALL “transmission system pre- replaced with NEW. Usually, if there is
start and start-up procedures” [see a contamination problem, it will be in
THIS section] BEFORE the engine is the valve seat assembly.
started. Damage to the transmission ALWAYS Replace the o-rings with
pump and/or front drum vibrator NEW when the new, or inspected,
pump can occur if the engine is multifunction valve cartridge is
started without doing the procedures. installed into the pump housing.
If the pressure limiter housing
assembly is disassembled, cleaned
and assembled, the pressure setting
MULTIFUNCTION VALVE CARTRIDGES. MUST be checked and adjusted.
REMOVAL, INSPECTION AND INSTALLATION

[See Figure 8-16]. c. Remove the pressure limiter locknut and
bypass actuator. Unscrew the pressure limiter
NOTE: The MULTIFUNCTION valve cartridge adjusting screw from the bypass actuator. Clean and
assemblies incorporate the charge check inspect all disassembled parts.
valve, pressure limiter valve, high pres-
sure relief valve and the towing bypass d. Reassemble the multifunction valve with lightly
valve. One [1] cartridge controls these lubricated NEW cartridge o-rings by reversing the
functions for the FORWARD direction and above procedures. Install the cartridge assembly into
one [1] cartridge controls these functions the pump housing bore location. Tighten the cartridge
for the REVERSE direction. assembly to a torque of 66 ft. lbs. [89 N.m]. If re-
moved, install the second cartridge assembly using
the same procedures.
a. STOP the engine. Clean BOTH multifunction
valve cartridges and the transmission pump end cap
area where they are installed with All-Purpose CAUTION: If installing a cleaned and inspected
Degreaser, part number 178297 and dry with com- cartridge assembly, install the
pressed air. cartridge into the same main pump
body location from which it was
b. Put a 1.25 inch [32 mm] wrench on the largest removed.
hex on the multifunction valve cartridge being re- Do NOT overtighten either
moved. Remove the multifunction valve from the multifunction valve. After installation,
pump end cap. Scribe the installation position [TOP, check the pressure limiter valve/ high
or BOTTOM] on the hex cartridge nut, after the pressure relief valve setting, of both
cartridge is removed. If needed, remove and identify multifunction valves, using the
the second cartridge assembly. procedures given in THIS section.
9/2005 8-25
Section 8
TRANSMISSION SYSTEM
b. On C766C, machine serial numbers
C209C2343 and below, except C209C2313, and
C778B, machine serial numbers B215C1737 and
below, loosen the wire harness connection, at the
transmission pump proportional displacement control
solenoid. Remove the wire harness connection from
the solenoid and move it to a position away from the
displacement control valve.
NOTE: On C766C, machine serial number

C209C2344 and above, plus C209C2313,
and C778B, machine serial numbers
B215C1738 and above, unplug the har-
ness connection ahead of the transmis-
sion pump proportional displacement
control.
c. Remove the six [6] retaining capscrews from

the outer end of the displacement control valve.
Carefully remove the control valve, with orifice check
FIGURE 8-15. MULTIFUNCTION VALVE valve and spring, from the main pump housing.
CARTRIDGE - SECTIONED VIEW.
CAUTION: The control valve is sealed to the
main pump body by the use of a
CHARGE CHECK VALVES. gasket. Do NOT permit the gasket,
orifice check valve, or spring to fall
REMOVAL, INSPECTION AND INSTALLATION into the main pump housing. Remove
[See Figure 8-15]. the gasket after the displacement
control valve has been removed from
The charge check valve is contained in each the pump body.
multifunction valve cartridge assembly and is
serviced through the removal, cleaning, inspection
and installation of the multifunction valve cartridge
assembly [See THIS section].
PROPORTIONAL ELECTRIC DISPLACEMENT

CONTROL VALVE.
REMOVAL AND REPLACEMENT [See Figure

8-16].
a. Wash the proportional electric displacement

control valve and the area where it is mounted to the
pump housing with All-Purpose degreaser, part
number 178297 and dry using compressed air.
FIGURE 8-16. PROPORTIONAL ELECTRIC

DISPLACEMENT CONTROL VALVE - INSTALLED
ON PUMP.
8-26 9/2005
Section 8
TRANSMISSION SYSTEM
d. Remove any gasket material from the control NOTE: On C766C, machine serial number
valve and the mating area on the main pump body. C209C2344 and above, plus C209C2313,
e. Cover the area in the main pump body, where B215C1738 and above, plug the harness
the control valve was removed, with paper to stop dirt connections together, ahead of the
from entering the pump. transmission pump proportional
displacement control.
f. When ready to install the control valve, remove
the paper cover from the opening in the pump body
opening. Put the NEW gasket on the main pump
body. PRESSURE LIMITER/HIGH PRESSURE RELIEF
VALVES.
g. Inspect to insure that the control orifice check
valve and spring are in their correct position in the REMOVAL, DISASSEMBLY, CLEANING,
control valve. Move the displacement control valve INSPECTION, ASSEMBLY AND INSTALLATION
into position on the main pump body. Put the dis- [See Figure 8-15].
placement control valve link into the mating hole in
the rocker cam swashplate arm. Push the pin ALL the The pressure limiter valve is contained in each
way into the swashplate arm hole. multifunction valve cartridge assembly and is
serviced through the removal, disassembly, cleaning,
h. Carefully move the control valve into position inspection, assembly and installation of the
against the gasket on the main pump body and hold multifunction valve cartridge assemblies [See THIS
in position. Move the control assembly left and right section].
to check for engagement of the pin in the hole in the
rocker cam swashplate arm. Carefully align the If the pressure limiter valve in either multifunction
control valve with the matching holes in the gasket valve cartridge assembly has been serviced, or a
and pump body. new multifunction valve cartridge assembly has been
installed, check and adjust the pressure limiter relief
valve pressure setting using the procedures given in
CAUTION: Proper engagement will be indicated THIS section.
by an increasing resistance as the
control is moved away from center
position. Non-engagement of the CAUTION: NO repair parts are sold separately for
pin will be indicated by lack of spring the multifunction valve cartridges. The
force. In case of non-engagement, cartridges can be removed,
remove the control valve and repeat disassembled, cleaned, assembled
the above procedure. and installed, or removed and
replaced with NEW. Usually, if there is
a contamination problem, it will be in
i. Carefully install the six [6] retaining capscrews the valve seat assembly.
through the control valve and into the tapped holes in ALWAYS Replace the o-rings with
the pump body. Tighten the capscrews to a torque of NEW when the new, or inspected,
12 ft. lbs. [16 N.m]. multifunction valve cartridge is
installed into the pump housing.
j. On C766C, machine serial numbers If the pressure limiter housing
C209C2343 and below, except C209C2313, and assembly is disassembled, cleaned
C778B, machine serial numbers B215C1737 and and assembled, or a new cartridge is
below, move the wire harness into position at the installed, the pressure setting MUST
displacement control valve proportional solenoid. be checked and adjusted.
Connect the wire harness plug onto the displacement
control valve solenoid.
9/2005 8-27
Section 8
TRANSMISSION SYSTEM
TRANSMISSION PUMP SHAFT AND SEAL. CAUTION: Do NOT damage the seal carrier,
during seal removal. Replace ALL seal
REMOVAL, INSPECTION AND INSTALLATION assembly items, with NEW, when the
[See Figure 8-17]. seal assembly is installed. Do NOT
use ANY removed seal parts.
The transmission pump and front drum vibrator pump
assembly MUST be removed from the machine
BEFORE the lip type shaft seal and/or shaft can be c. Remove the O-ring from the seal carrier.
removed and replaced with new [see THIS section for
procedures]. d. Place seal carrier and seal in an arbor press
and press out old seal. Inspect the seal carrier, the
new seal and the O-ring for any damage or nicks.
CAUTION: ALL shaft seal parts MUST be
replaced with NEW after removal. e. Using the arbor press, press the new seal into
seal carrier. Be careful not to damage the seal.
a. With the transmission pump and front drum

vibrator pump assembly removed from the machine NOTE: The outside diameter of the seal may be
and on a CLEAN work surface, Place the assembly lightly coated with a sealant (such as
in a position, so that the transmission pump input Loctite High Performance Sealant #59231)
shaft faces UPWARD. prior to installation. This aids in prevent-
ing possible leaks caused by damage
to the seal bore, in the seal carrier.
CAUTION: If the pump is positioned horizontally
when the input shaft is removed, the
cylinder block may move out of place, CAUTION: Do NOT damage the seal during
making input shaft installation assembly.
difficult.
b. Remove the three, or four, screws holding the f. Inspect the sealing area on the shaft for rust,
retainer plate and seal carrier to the housing, wear, or contamination. If the shaft is NOT being
using a 5 mm internal hex wrench. Remove the replaced proceed to step "j".
retainer plate.
g. Remove the shaft and roller bearing assembly
from pump. Transfer the bearing assembly to the new
NOTE: After removing the screws, the spring shaft.
force on the shaft may move the seal
carrier out of its bore by approximately h. Remove the retaining ring that secures the
1/4 inch [5 mm]. If the seal carrier does roller bearing assembly with a snap ring pliers.
not move from its bore after removing the Remove the roller bearing assembly.
screws, pry it from its bore and/or lightly
tap the end of the shaft with a soft mallet.
WARNING: Wear eye protection during snap ring
installation. Use care when installing
the snap ring into the bore.
8-28 9/2005
Section 8
TRANSMISSION SYSTEM
i. Place roller bearing assembly on new shaft and COMPLETE TRANSMISSION PUMP ASSEMBLY.
secure with the retaining ring.
REMOVAL [See Figure 8-18].
j. Wrap spline end of shaft with plastic film to
prevent damage to the sealing lip on the seal CAUTION: Remove the COMPLETE pump
during installation. assembly, from the machine, ONLY
after correctly and fully checking the
k. Prior to assembly, lubricate the O-ring on the pump. Use pressure check and flow
O.D. of the seal carrier and the I.D. of the seal with rate test procedures, that will indicate
clean petroleum jelly. internal component failures which
require the pump be removed for
l. Assemble the seal carrier and seal over the repair, or replacement. Major
shaft and into the housing bore. Install the retainer transmission pump repair procedures
plate (if used). will effect warranty. See the nearest
HYPAC Distributor and refer to the
m. Install the screws and tighten, across corners, “Warranty Policies and Procedures”
to a torque of 12 ft. lbs. [16 N.m]. before removing a transmission pump
assembly and/or having major repair
done to the transmission pump
assembly.
a. Wash BOTH pumps, pump mounting plate and

flywheel housing area with All-Purpose Degreaser,
part number 178297 and permit to air dry.
b. Put an identification tag on each electrical

harness connection at the TRANSMISSION pump
displacement control. Disconnect, and then remove,
the pump control electrical harness at the displace-
ment control solenoid. Put an identification tag on
each electrical harness connection at the front drum
VIBRATOR pump displacement control. Disconnect,
and then remove, the pump control electrical harness
at the displacement control solenoid. Put identifica-
tion tags on ALL hydraulic hoses that are connected
to BOTH pumps. Disconnect, and then remove, ALL
of the hoses which fasten to the hydraulic pumps. Put
plugs and caps on ALL hoses and fittings.
FIGURE 8-17. TRANSMISSION PUMP INPUT
SHAFT AND SHAFT SEAL INSTALLATION.
9/2005 8-29
Section 8
TRANSMISSION SYSTEM
c. Fasten a sling and hoist, having a capacity e. Remove the pump assemblies from under the
MORE than 500 lbs. [227 kg], around the circumfer- machine and place them in a CLEAN area. Put a
ence of the transmission pump body. Use the hoist to cover over the opening in the pump mounting plate.
apply tension to the sling to keep the pump assem-
blies in a level, and balanced, position when the
TRANSMISSION pump mounting capscrews are
removed. MAJOR TRANSMISSION PUMP REPAIR.
Only the following components CAN be removed,

WARNING: Fasten the sling and hoist securely repaired, or replaced, WITHOUT canceling the pump
to the pump assemblies. warranty.
1. Internal gear charge pump.

d. Remove the two [2] transmission pump mount- 2. Charge pressure relief valve.
ing capscrews. Use the sling and hoist to CARE- 3. Proportional electric displacement control valve
FULLY lift, remove and then lower the transmission assembly.
pump to the ground, with the front vibration pump 4. Shaft seal.
fastened at the rear. Remove the sling and hoist. 5. Multifunction valve cartridge assemblies.
If the transmission pump has failed, or test results

WARNING: Keep CLEAR of the pump assemblies indicate that service to components, other than those
and surrounding areas while lifting, listed above are needed, it is intended major repairs
moving and lowering the pump be done, ONLY, by Sauer-Sundstrand, Authorized
assemblies. Service Centers, or the pump be replaced with a
new, or remanufactured, pump.
CAUTION: See the nearest HYPAC Distributor for

side cover. Major repairs are intended
to be done, ONLY, by Sauer-
Sundstrand, Authorized Service
Centers.
INSTALLATION [See Figure 8-18].
TRANSMISSION PUMP a. Move the transmission/vibrator pump assembly

ASSEMBLY COMPLETE into position under the machine. Fasten a sling and a
hoist, having a capacity more than 500 lbs. [227 kg],
to the pump assembly, so that it will be in a balanced
FIGURE 8-18. TRANSMISSION PUMP ASSEMBLY -
condition when lifted. Put anti-size grease, part
INSTALLED INTO THE MACHINE.
number 316865, on the splined area of the transmis-
sion pump input shaft. Use the sling and hoist to
Carefully lift the pumps. Put the pump input shaft in a
position, so that it is in alignment with the center
splined sleeve in the flex drive plate. Carefully install
the splined input shaft into the splined sleeve and
push the pump mounting area fully against the pump
mounting plate.
8-30 9/2005
Section 8
TRANSMISSION SYSTEM
b. Put Loctite #290, part number 251099, on the e. Add APPROVED hydraulic oil, as needed, to
thread area of the four [4] capscrews that fasten the the hydraulic oil reservoir using the procedures given
transmission pump to the pump mounting plate. in Section 4 - MAINTENANCE. Follow ALL “pre-start
Install the capscrews and tighten to a torque of 80 ft. procedures” given in THIS section BEFORE starting
lbs. [108 N.m]. Remove the sling and hoist from the the engine.
pump assembly.
c. Remove the caps from all fittings and the plugs CAUTION: Do NOT start the engine BEFORE the
from all hoses. Install each hose onto the CORRECT hydraulic oil level, in the reservoir, is
pump fitting as indicated by the identification tags. at the CORRECT level Do NOT start
Tighten each hose securely onto each fitting or the engine until ALL “pre-start”
install, and then tighten, the flange retaining cap- procedures have been done. Damage
screws. to the hydraulic system components
will occur.
NOTE: Connect ALL hoses to the fittings on

BOTH of the hydraulic pumps as indi- f. Start the engine. Check for CORRECT operation
cated by the identification tags put on the of ALL systems. Check for ANY fluid leaks.
hoses and fittings before removal.
WARNING: Do NOT use the hands on ANY

d. Install the pump control electrical harness onto hydraulic hose, fitting or system
the transmission pump displacement control solenoid component to check the system for
as indicated by the identification tag. Install the pump possible leaks. Serious injury can
control electrical harness onto the front drum vibrator occur from a leak under high pres-
pump displacement control solenoid as indicated by sure. Use a piece of cardboard to
the identification tag. check for leaks. Wear safety glasses
to protect the eyes. Get IMMEDIATE
medical attention IF oil enters the
CAUTION: Be SURE that each harness is eyes or skin.
connected to each of the two [2]
pumps. The harness assembly that
fastens to the front drum vibrator CAUTION: STOP the engine IMMEDIATELY if ANY
pump displacement control solenoid fluid leak is noted. Do NOT start the
is LONGER in total length than the engine until any problem noted has
harness and plug assemblies that been corrected.
fasten to the transmission pump
displacement control solenoid.
9/2005 8-31
Section 8
TRANSMISSION SYSTEM
TRANSMISSION PUMP PRESSURES. CAUTION: The HYDRAULIC system oil MUST be
at “NORMAL OPERATING”
CHECKING AND ADJUSTMENT PROCEDURES. temperature and at the correct level
BEFORE any pressure check is taken.
The following information describes the different The ENGINE throttle MUST be in the
pressure check locations, gauge sizes needed, “CORRECT IDLE” condition for EACH
correct pressures and suggested methods for pressure check.
changing an incorrect system pressure. Capped
system gauge ports are provided for the various
pressure checks, usually needed to be made. a. Put the secondary/parking brake system control
switch “ON” [APPLIED]. STOP the engine. Open the
left service access door. Wipe the top area of the
WARNING: Keep ALL personnel, except the transmission pump housing, the “#12 tee fitting” and
operator and an assistant, when the hoses connected to the fitting with a CLEAN
needed, CLEAR of the machine cloth.
during pressure checking proce-
dures. Use ONLY the CORRECT b. Remove the top case drain oil return hose from
gauge, on a hose, for each pressure the “#12 tee fitting”. Install a “tee fitting”, having a #4
check. gauge port outlet fitting, between the removed hose
and the pump installed “#12 tee fitting” and tighten
securely. Install a 100 psi. [7 bar] pressure gauge, on
CAUTION: The HYDRAULIC system oil MUST be a long hose which will reach the cockpit area, onto
at “NORMAL OPERATING” the #4 gauge port outlet fitting and tighten securely.
temperature and at the correct level Install, and securely tighten, the top case drain oil
BEFORE any pressure check is taken. return hose onto the pump installed “#12 tee fitting”.
The ENGINE throttle MUST be in the
“CORRECT IDLE” condition for EACH
pressure check.
If needed, remove the service access plate, found at

the left side of the rear frame to gain access to the
transmission pump and related components areas.
Install the service access plate, after doing pressure
check and adjustment procedures, if removed.
TRANSMISSION PUMP CASE DRAIN OIL

PRESSURE [See Figure 8-19].
The transmission pump case drain oil pressure is

checked at the “#12 tee fitting”, installed in the top of
the transmission pump case. Check this pressure as
follows:
FIGURE 8-19. TRANSMISSION PUMP CASE

DRAIN OIL PRESSURE CHECK LOCATION.
8-32 9/2005
Section 8
TRANSMISSION SYSTEM
c. Remove the electrical current supply wire from f. Slow the engine and allow to run at “LOW” idle
the secondary/parking brake system release speed for a period of 3-5 minutes. Stop the engine.
solenoid, found on the stack valve. Move the wire Remove the pressure gauge and hose assembly
away from the solenoid connection point and put from the “tee fitting”. Remove the top case drain oil
electrical tape on the end of the wire. Put SOLID return hose from the “tee fitting”. Remove the “tee
wood blocks at the front, and at the rear, of BOTH fitting” from the pump installed “#12 tee fitting”. Install,
drums. and securely tighten, the top case drain oil return
hose onto the pump installed “#12 tee fitting”.
WARNING: Block SECURELY using SOLID wood g. If no other pressure checks are to be done,
blocks Keep ALL personnel, except remove the electrical tape from the secondary/
the operator, CLEAR of the machine parking brake system electric solenoid current supply
and the surrounding area during this wire. Connect the current supply wire onto the
“pressure check” procedure. secondary/parking brake system solenoid on the
stack valve assembly. Remove the wood blocks from
both drums of the machine.
d. Start the engine. Put the secondary/parking
brake system control switch “OFF” [RELEASED]. Put
the engine throttle control switch in the “HIGH” idle
position. Put either transmission directional/speed NEUTRAL CHARGE PRESSURE
control handle in a position that is one forth [1/4] of [See Figures 8-20 and 8-21].
the full FORWARD travel. Quickly note the CASE
drain oil pressure indicated on the pressure gauge. The capped neutral charge pressure check port is
found with the “remote pressure check ports ”
e. Put the transmission directional/speed control installed on the left rear frame rail of the machine
handlever in the NEUTRAL position and then move it [See figure 8-20]. Check and, if needed, adjust this
to a position that is one forth [1/4] of the full RE- pressure as follows:
VERSE travel. Again, quickly note the CASE drain oil
pressure indicated on the pressure gauge. Put the a. Find the transmission PUMP CASE drain oil
transmission directional/speed control handlever in PRESSURE by using the procedures given in THIS
NEUTRAL. section. Keep the secondary/parking brake system
control switch “ON” [APPLIED]. STOP the engine.
Wipe the pressure check port cap and the area
CAUTION: BOTH pressure readings MUST be around it with a CLEAN cloth.
BELOW 40 psi. [3 bar] MAXIMUM and
be the SAME for BOTH directions of b. Remove the cap from the charge pressure
machine travel. Make a note of these check port. Install a 600 psi. [41 bar] gauge, on a
pressures for use in determining short hose, with quick connection fitting, onto the
OTHER transmission pump pressures. check port fitting.
With the hydraulic oil at OPERATING
temperature, a pressure reading c. Start the engine. Allow the hydraulic oil to reach
ABOVE 40 psi. [3 bar] is an is an a warm temperature. Put the engine throttle in the
indication of internal leakage, or high “HIGH” idle position. Leave the transmission direction
“back pressure”, in the pump which control handle in the NEUTRAL position. Have an
can require that the pump be removed assistant note the neutral charge pressure indicated
from the machine and be repaired, or on the pressure gauge. The NEUTRAL charge
replaced. pressure should be approximately 375 psi. [26 bar]
MINIMUM to 400 psi. [28 bar] MAXIMUM, plus case
pressure.
9/2005 8-33
Section 8
TRANSMISSION SYSTEM
d. Slow the engine to “LOW” idle speed and run
for a period of 3-5 minutes. STOP the engine. If the 1. Keep the engine “OFF”. Wipe the area of the
pressure noted was as given ABOVE, remove the transmission pump end cap housing section
pressure check gauge and hose from the pressure where the charge relief valve assembly is
check port. Install, and then tighten, the check port installed with a clean cloth [See Figure 8-21].
cap onto the check port fitting.
2. Loosen the charge relief valve external
adjusting screw lock nut using a 1 1/16 hex
NOTE: The NEUTRAL charge relief pressure wrench.
MUST be adjusted if the charge pressure
noted was NOT as given above, by using 3. Use a large screwdriver to turn the charge
the following ADDITIONAL information relief valve external adjusting screw inward or
[see figure 8-21]. Low charge pressure, at outward and, thereby, change the neutral
low idle, and at high idle, can indicate charge pressure.
possible internal charge pump leakage,
which requires removal, repair, or replace-
ment, of the internal gear charge pump
components [See THIS section].
FIGURE 8-20. REMOTE PRESSURE CHECK PORTS - IDENTIFICATION.
8-34 9/2005
Section 8
TRANSMISSION SYSTEM
NOTE: Turning the external adjusting screw CAUTION: Do NOT permit the external adjusting
INWARD [CW] will INCREASE the amount screw to move and change the neutral
of neutral charge pressure. Turning the charge pressure adjustment, while
external adjusting screw OUTWARD tightening the lock nut.
[CCW] will DECREASE the amount of
neutral charge pressure.
e. Remove the gauge and hose assembly from
the pressure check port. Install, and then tighten, the
CAUTION: Turning the external adjusting screw cap onto the check port fitting.
INWARD or OUTWARD changes the
neutral charge pressure
approximately 50 psi. [3.5 bar] per
turn. FLUSHING VALVE OUTPUT OIL FLOW CHECK
AND ADJUSTMENT [See Figure 8-22].
4. Check the NEUTRAL charge pressure, again, The flushing valve output oil flow is checked, and
using the above procedures. Repeat the adjusted, at the flushing valve.
adjustment procedure until the pressure
indicated is CORRECT. Check the valve output oil flow and, if needed, adjust
the flow as follows:.
5. When the pressure indicated is CORRECT,
hold the external adjusting screw in position a. Keep the secondary/parking brake system
with the screwdriver. Tighten the lock nut to a control switch “ON” [APPLIED]. STOP the engine.
torque of 38 ft. lbs. [52 N.m]. Wipe the oil flow RETURN hose and fitting, at the
flushing valve, and the area around it with a CLEAN
cloth.
b. Remove the oil flow return hose from the

flushing valve outlet fitting [“T”, tank port]. Install, and
securely tighten a steel plug into the output oil flow
hose. Install a drain hose, which will reach the
ground, onto the flushing valve outlet fitting and
securely tighten.
NOTE: As an alternate output oil flow check

method, a flow meter, capable of reading
1-1.5 gpm [3.8-5.7 lpm], can be installed
into the oil flow return line between the
flushing valve outlet fitting and the return
hose.
c. Remove the electrical current supply wire from

the secondary/parking brake system release
FIGURE 8-21. TRANSMISSION PUMP NEUTRAL solenoid, found on the stack valve. Move the wire
CHARGE PRESSURE ADJUSTMENT LOCATION. away from the solenoid connection point and put
electrical tape on the end of the wire. Put SOLID
wood blocks at the front, and at the rear, of BOTH
drums.
WARNING: Block SECURELY using SOLID wood

blocks.
9/2005 8-35
Section 8
TRANSMISSION SYSTEM
d. Put the end of the drain hose, connected to the
flushing valve outlet fitting, into a one [1] gallon [3.8
liter] container on the ground.
e. Have the operator start the engine. Put the

secondary/parking brake system control switch “OFF”
[RELEASED]. Keep the engine throttle speed control
toggle switch in the “LOW” idle position.
DANGER: The machine produces MAXIMUM

power during this procedure. Machine
movement is prevented only by the
secondary/parking brake system and
additional wooden blocks. Keep ALL
personnel, except the assistant,
CLEAR of the area near the machine
and machine path.
f. Have an assistant hold the output drain hose in

the container. Have the operator move the transmis-
sion directional/speed control handlever one forth
[1/4] of the full forward, or reverse, direction of travel FIGURE 8-22. TRANSMISSION SYSTEM
distance for a period NOT to exceed FIFTEEN [15] FLUSHING VALVE OUTPUT OIL FLOW CHECK
seconds. Have the operator move the transmission AND ADJUSTMENT LOCATIONS.
directional/speed control handlever to the NEUTRAL
position.
1. Keep the engine “OFF”. Open the service
g. Measure the amount of oil within the container. access door at the left hand side of the
The CORRECT oil flow output amount, for the machine. Find the transmission FLUSHING
FIFTEEN [15] second time period, MUST be .313 [hot oil shuttle] valve inside the service area.
gallon [1.2 liter].
2. Find the FLUSHING VALVE output oil flow
amount large adjusting screw, inside the large
CAUTION: The flushing valve output oil flow hex nut at the bottom of the flushing valve.
amount MUST be adjusted if the Use a large screwdriver, or drag link socket on
output flow amount measured, or a ratchet wrench, to CAREFULLY turn the
noted, was NOT as given ABOVE, by adjusting screw CLOCKWISE [inward] or
using the ADDITIONAL information COUNTERCLOCKWISE [outward] a SMALL
contained in steps “1” through “3”, amount to decrease or increase the output oil
then do steps “h” and “i”. flow amount.
NOTE: The above flow amount equals a flow rate CAUTION: Turn the adjustment screw ONLY a
of one and one fourth [1.25] gpm [4.75 SMALL amount.
lpm].
If a flow meter is being used for the oil
flow amount check, note the flow amount
indicated on the meter at the end of the
time period.
8-36 9/2005
Section 8
TRANSMISSION SYSTEM
NOTE: Turning the adjusting screw CLOCKWISE TRANSMISSION SYSTEM HIGH PRESSURE/
will DECREASE the amount of output oil PRESSURE LIMITER PRESSURE CHECK AND
flow. Turning the adjusting screw COUN- ADJUSTMENT [See Figures 8-20 and 8-23].
TERCLOCKWISE will INCREASE the
amount of output oil flow. The two [2] capped system high pressure/pressure
limiter pressure check ports are found with the
“remote pressure check ports ” installed on the left
3. Start the engine. Have the operator put the rear frame rail of the machine [See figure 8-20].
secondary/parking brake system control
switch “OFF” [RELEASED]. Check the flushing The system high pressure/pressure limiter pressure
valve output oil flow amount, again, for each relief valves are contained in the two [2]
direction by using the procedures given multifunction valve cartridge assemblies, which are
above. installed into the pump end cap housing [See THIS
section].
NOTE: If the output oil flow amount is now

correct, do step “h” and “i”, at this time. If NOTE: Adjustment of the pressure limiter valve
the output oil flow amount was still NOT setting and the high pressure relief valve
correct, STOP the engine and REPEAT setting is accomplished simultaneously.
step “2”, but only move the adjusting The high pressure relief valve is automati-
screw inward, or outward, a SMALL cally set approximately 500 psi (35 bar)
amount to reach the required CORRECT above the pressure limiter relief valve
output oil flow amount. Repeat the proce- setting. In order to check and/ or check
dure until the CORRECT output oil flow is and adjust the above, the machine must
noted, and then do steps “h” and “i”. be held, and NOT move.
With the flushing valve adjusted correctly,
a 20-30 psi [1.4 - 2 bar] drop in charge
pressure should be noted, when the
transmission pump is "stroked" in either a. Put the secondary/parking brake system control
direction [see this section]. switch “ON” [APPLIED]. STOP the engine. Remove
the electrical current supply wire from the secondary/
parking brake system RELEASE solenoid, found on
h. Put the engine throttle at “LOW” idle speed. the stack valve. Move the wire away from the sole-
STOP the engine. If the output flow amount was noid connection point and put electrical tape on the
CORRECT, as given above, remove the drain hose end of the wire. Put SOLID wood blocks at the front,
from the flushing valve outlet fitting. Remove the steel and at the rear, of BOTH drums.
plug from the oil return hose. Install, and then se-
curely tighten, the oil return hose onto the flushing
valve outlet fitting. DANGER: The machine produces MAXIMUM
power during this procedure. Machine
movement is prevented only by the
NOTE: If a flow meter was used to check the oil
secondary/parking brake system and
flow amount, remove the flow meter and
install the oil return hose onto the flush- additional wooden blocks. Keep ALL
ing valve outlet fitting and tighten, at this personnel, except the assistant,
time. CLEAR of the area near the machine
and machine path.
i. If no other pressure checks are to be done,
remove the electrical tape from the secondary/
parking brake solenoid electrical current supply wire. WARNING: Block SECURELY using SOLID wood
Install the current supply wire onto the solenoid blocks.
terminal. Remove ALL wood blocking from the drums
of the machine.
9/2005 8-37
Section 8
TRANSMISSION SYSTEM
d. Go to the two [2] capped system high pressure/ f. Start the engine. Put the secondary/parking
pressure limiter pressure check ports, found with the brake system control switch “OFF” [RELEASED]. Put
“remote pressure check ports ” installed on the left the engine throttle speed switch in the “HIGH” idle
rear frame rail of the machine. Clean pressure check position. Put the transmission speed range control
port caps and the area around them with a CLEAN switch in the “LOW” position. Slowly move either
cloth. directional/speed control handle from the neutral
position toward the FORWARD direction of machine
e. Remove the cap from the two [2] pressure travel position a SMALL amount. Watch the gauge
check ports. Use two [2] 10,000 psi. [690 bar] pres- indicating “HIGH” pressure for this direction, and note
sure gauges, connected to hoses that will reach the quickly the highest pressure indicated. Return the
operator cockpit area. Install one [1] hose fitting onto directional/speed control handlever to NEUTRAL.
each pressure check port fitting. Place BOTH gauges
in a position in the cockpit area, so that they can be
clearly seen during the “high pressure/pressure CAUTION: Do NOT move the directional/speed
limiter relief pressure check” procedures. control handle to the FULL forward, or
reverse, direction position during the
pressure check. Damage to the
DANGER: Except for the OPERATOR, Keep ALL system relief valves and/or other
personnel CLEAR of the machine and system components can occur.
the surrounding area during this
“pressure check” procedure. The
machine produces MAXIMUM power g. Slowly move the directional/speed control
handle from the neutral position toward the RE-
during this test. Machine movement is
VERSE direction of machine travel position a SMALL
prevented only by the secondary/
amount. Watch the gauge indicating “HIGH” pressure
parking brake system and additional for this direction, and quickly note the highest pres-
wooden blocks. sure indicated. Return the directional/speed control
handlever to NEUTRAL. Put the engine throttle speed
control switch in the “LOW” idle position and run the
engine 3-5 minutes to cool the engine and compo-
nents. STOP the engine.
CAUTION: The correct “HIGH” pressure noted in

BOTH directions MUST be 6,000 +/-
100 psi. [414 +/-7 bar]. The high
pressure relief valve is automatically
set approximately 500 psi (35 bar)
above the pressure limiter relief valve
setting. Any pressure indicated, in
either, or both, directions, which is
above, or below, this pressure will
require that the high pressure/
pressure limiter relief valve for that, or
BOTH, directions, be adjusted. If
either, or both, relief pressures were
NOT correct, use the ADDITIONAL
information, given in the following
steps “1” through “8”, to adjust one,
or both, high pressure/pressure
FIGURE 8-23. TRANSMISSION SYSTEM HIGH limiter relief valves. NO further
PRESSURE/ PRESSURE LIMITER ADJUSTMENT pressure adjustments need to be
LOCATIONS. done if the pressures were correct.
8-38 9/2005
Section 8
TRANSMISSION SYSTEM
1. Keep the secondary/parking brake system 4. Have the operator be seated on the machine.
control switch “ON” [APPLIED]. Stop the Start the engine, and then put the engine
engine. throttle speed control switch in the “HIGH” idle
position. Put the secondary/parking brake
system control switch “OFF” [RELEASED].
DANGER: To be able to correctly make the HIGH Keep the transmission speed range selector
pressure relief valve adjustments, an switch in “LOW”. Depending upon which high
assistant is required and the transmis- pressure/pressure limiter relief valve requires
sion system MUST reach MAXIMUM adjustment, SLOWLY move the transmission
system pressure. The secondary/ directional/speed control handle TOWARD the
parking brake system, and the addi- forward, or the reverse, direction of travel
position a SMALL amount. Have the assistant
tional wooden blocking, MUST assure
QUICKLY turn the Allen wrench, and the
that the machine is kept from ANY
pressure adjusting screw, a SMALL amount
movement during this adjustment until the pressure indicated on the pressure
procedure. gauge indicates the correct relief pressure.
Have the operator return the directional/speed
control handlever to NEUTRAL. Put the
2. Leave the 10,000 psi. [690 bar] gauges and engine throttle speed control switch in the
hoses connected to the pressure check ports, “LOW” idle position.
so that they can be read as the high pressure/
pressure limiter relief valve adjustments, on
the multifunction valve cartridge assemblies, DANGER: ONLY allow the operator and the
are made. person making the pressure adjust-
ments near the machine. ALL other
3. Have an assistant go to the transmission
personnel MUST be kept CLEAR of the
PUMP assembly. Find the two [2] multifunction
valve cartridge assemblies, which are installed area around the machine.
into the side of the pump end cap housing.
Remove the plastic dust cap from the outer
end of each multifunction valve cartridge CAUTION: Turn the high pressure/pressure
assembly requiring adjustment. Loosen the 19 limiter adjusting screw, a SMALL
mm adjusting screw hex lock nut [smallest hex amount only, to change the relief
on the multifunction valve cartridge, requiring pressures. CLOCKWISE rotation, of
adjustment]. Put a 5 mm Allen wrench into the the pressure adjusting screw, will
end of the relief valve adjusting screw being INCREASE the relief pressure setting.
adjusted. COUNTERCLOCKWISE rotation, of the
pressure adjusting screw, will
DECREASE the relief pressure
NOTE: If adjustment to the high pressure/pres- settings.
sure limiter relief valve, contained in the Do NOT move the directional/speed
LOWER multifunction valve is required, control handlever to the FULL
the transmission charge pressure oil filter forward, or reverse, direction position
element and mounting head may need be during the pressure adjustment
rotated 90˚ and tightened, facing toward procedure. Damage to the high
the engine, to access and adjust, the relief pressure/pressure limiter relief valves
valve adjusting screw. After relief valve and/or other system components can
adjustment, rotate the above items back occur.
to their original position, or they can be
left in the rotated position.
9/2005 8-39
Section 8
TRANSMISSION SYSTEM
NOTE: The CORRECT high pressure relief valve DRUM DRIVE MOTOR/BRAKE ASSEMBLIES.
setting is obtained when the pressure
shown on the pressure gauge remains DESCRIPTION [See Figures 8-24 and 8-25].
STEADY at the correct pressure level.
The two [2] low speed - high torque drum drive
motors are a two [2] speed multi-lobe radial piston
5. CAREFULLY hold the Allen wrench and the type, with a multi-disc brake system integral inside
adjusting screw in the SAME position where each motor.
the relief pressure is CORRECT. CAREFULLY
tighten the hex lock nut, while keeping the Each drum drive motor contains wheel mounting
adjusting screw in the SAME position, so that studs, in the drive flange of the motor, onto which the
the pressure adjusting screw does NOT move. vibration isolator assembly is mounted and held with
special nut/washers.
6. If required, adjust the other high pressure/
pressure limiter relief valve using the SAME The drum drive motors are identical in simple design
procedures as given in steps “3” through “6”. and components.
7. Have the operator run the engine at “LOW” Each drum drive motor contains the following five [5]
idle speed for 3-5 minutes and then stop the major parts:.
engine.
1. Front bearing support assembly
8. Install the plastic dust cap into the outer end 2. Cylinder block assembly, with ten [10] pistons
of each multifunction valve cartridge. 3. Cam ring, having eight [8] lobes
4. Valving assembly, with a two [2] speed
h. If no other pressure checks are to be done, change spool
remove the two [2] pressure gauge and hose assem- 5. Brake assembly
blies from the pressure check port fittings. Install and
lock the steel cap fitting onto each pressure check
port. Remove the electrical tape from the secondary/
parking brake system electric solenoid current supply
wire. Connect the current supply wire onto the
secondary/parking brake system solenoid on the
stack valve assembly. Remove the wood blocks from
both drums of the machine.
FIGURE 8-24. DRUM DRIVE MOTOR ASSEMBLY -

INSTALLED.
8-40 9/2005
Section 8
TRANSMISSION SYSTEM
OPERATION [See Figure 8-30]. The profile of the cam ring is calculated to create a
constant angular displacement of the motor as each
In the forward, or reverse, direction of machine travel, piston and roller assembly moves by the high
high pressure oil from the transmission pump flows to pressure port, in the valve block assembly.
each transmission drum drive motor.
As the piston and roller assemblies continue to follow
The high pressure oil enters each drum drive motor the curved contour of the cam ring, the curving shape
at the valving [oil distributor] assembly. High pressure causes the assemblies to move inward again.
oil then is distributed to the ten pistons and uses all
eight [8] cam ring lobes as “power lobes” for the This action causes the roller assembly to push the
“WORK” [low] speed range, full displacement, of the piston inward. This inward movement of the piston is
motors. timed with the piston passing the low pressure port,
in the valve block assembly, for that piston in that
Selecting the “TRAVEL” [high] speed range will cause direction.
distributing of high pressure oil to five [5] pistons and,
thereby, uses only four [4] cam ring lobes as “power The oil, which now is under low pressure, enters the
lobes”. This will put the motors at one half low pressure port in the valve block assembly and is
displacement. directed into the low pressure hose, which is fastened
to the valve housing.
NOTE: Selecting the “TRAVEL” [high] speed The oil, now under low pressure, flows from each
range, using the toggle switch found on drum drive motor to the low pressure side of the
the dash, causes electrical current to transmission pump in the “closed loop” system.
energize the “travel [high] speed range
solenoid”. The solenoid moves a spool in Changing the direction of machine travel, will only
the stack valve, which permits oil, at reverse the direction that the oil, under high and low
charge pressure, to pass through, and pressures, will flow. This change will cause the
then from the valve. The oil then flows to motors to turn in the OPPOSITE direction of rotation,
the high speed port on the valving assem- but in the same method as previously described.
bly, of each motor. The oil flow moves a
pilot spool in the center of the valving The motor case, of each drum drive motor, is
assembly, which changes the “used” “flushed”, with oil flow supplied by the steering
displacement of each motor. system, after being cooled by the oil cooler.
Any oil flow from motor internal leakage, plus

In “WORK” [low] range, each of the ten [10] pistons “flushing” oil flow, leaves the case port, of each
will have high pressure oil flow applied to the back of motor, and flows to the hydraulic oil reservoir.
the piston and begin to move outward in its bore just
after it passes the high pressure ports. High oil
pressure on each piston, continues to push the piston
and roller assembly outward and against the cam
ring.
This action causes the complete cylinder block

assembly to rotate and turn the splined drive and
brake shafts.
The drive flange and studs are mated to the splined

drive shaft and turn with the drive shaft. The half
hoop assembly is mounted onto the studs and held
tight by special nut/washer assemblies. Each drum is
driven through the half hoop and vibration isolator
tire/rim assembly.
9/2005 8-41
Section 8
TRANSMISSION SYSTEM
The secondary/parking brake system is a integral When the secondary/parking brake system control
assembly on each motor. The multi-disc, spring switch is placed in the “ON” [BRAKES APPLIED]
applied and hydraulically released, brake uses position, the brake release piston, on each motor,
hydraulic oil flow, at a approximately charge pressure, has NO oil flow applied to it. The multi-disc brakes on
to release the spring applied disc brakes on both each motor are APPLIED by SPRING PRESSURE
motors. and the brake shaft, on each motor, is stopped from
turning.
NOTE: Newer style motors have FOUR (4)

seals this location.
FIGURE 8-25. DRUM DRIVE MOTOR - SECTIONED VIEW.
8-42 9/2005
Section 8
TRANSMISSION SYSTEM
NOTE: Lack of hydraulic pressure, against the a. Go to the drum drive motor/half hoop and
release piston from ANY cause, will vibration isolator assembly. Fasten a sling and hoist,
permit the multi-disc brakes to be applied having a capacity of more than 500 lbs. [227 kg], to
by spring pressure. the drum drive motor assembly.
b. Remove the special nut/washer assemblies

When the secondary/parking brake system control from the drive flange studs. Use the sling and hoist to
switch is placed in the “OFF” [BRAKES RELEASED] CAREFULLY lift the drum drive motor away from the
position, electrical current will energize the “brake half hoop and vibration isolator assembly. Move the
release” solenoid. The solenoid moves a spool found drum drive motor assembly to a CLEAN work surface
in the “stack valve” which permits oil, at in a clean work area.
approximately charge pressure, to flow from the
outlet of the “stack valve” to each wheel motor brake
release pressure port. WARNING: Keep clear of the drum drive motor
assembly while lifting, moving and
The oil enters the release port and is directed lowering the motor.
internally to the pressure side of the brake release
piston, of each motor. The hydraulic pressure moves
the release piston. The piston releases the multi-disc
brakes by overcoming the pressure of the large DISASSEMBLY [See Figure 8-26].
spring washer which applies them. The brake shaft,
which is splined to the motor cylinder block assembly, CAUTION: All capscrews used to fasten the
is then free to turn with the cylinder block assembly. components to the front support,
through the valve assembly and cam
ring, are of the “METRIC SIZE”. The
capscrews MUST be tightened to
REMOVAL, DISASSEMBLY, INSPECTION, torques accordingly. All components
ASSEMBLY AND INSTALLATION. [seals, bearings, springs etc.’] are also
“METRIC SIZED” and must NEVER be
REMOVAL [See Figure 8-24]. replaced with “standard sized”
replacement parts.
CAUTION: Remove a drum drive motor assembly
from the machine ONLY after correctly
and fully checking the motor. Use a. Clean the drum drive motor again to remove
pressure check and flow rate test any dirt, which was not removed before removal.
procedures that will indicate internal Place the motor assembly in a VERTICAL position,
component failures which require the with the brake assembly end at the bottom.
motor be removed, disassembled, and
inspected.
NOTE: To remove EITHER drum drive motor

assembly from the drum, use the proce-
dures given in Section 4 - MAINTENANCE
- to FIRST remove the drum from the
machine [See “Removal, Repair Or Re-
placement, And Installation Of The Vibra-
tion Isolator Tire And Rim Assemblies”].
Then remove the vibration isolator/drum
drive motor assembly from the drum
using the following information.
9/2005 8-43
Section 8
TRANSMISSION SYSTEM
b. Put a scribed VERTICAL reference line on the CAUTION: Do NOT disassemble the distributor
side of the valving [distributor] housing, cam ring and assembly, unless there was a problem
front bearing support assemblies. noted in operation of the “low to high”
range pilot operated spool before the
motor was removed, or damage is
NOTE: Be sure the line is clear, for CORRECT seen at inspection. Do NOT use
position of components during assembly. compressed air to clear the passage
leading to the pilot operated piston,
as damage to the assembly can occur.
c. Remove the sixteen [16] capscrews that fasten Damage caused to the valving
the valve housing to the cam ring and front bearing [distributor] block assembly, and
support assemblies. other motor components, by severe
system contamination can require
d. CAREFULLY remove the front bearing support that the valving assembly and the
and drive shaft assembly by lifting it vertically and other components be replaced with
away from the cam ring. new, or that the COMPLETE motor
assembly be replaced with new.
CAUTION: Do NOT drop the cylinder block

assembly, if the assembly remains NOTE: To disassemble the front bearing support
engaged onto the drive shaft as the and remove the bearings and seals, an
front support is removed. arbor press is required.
e. CAREFULLY remove the cam ring from over h. Put the front bearing support and drive shaft
the cylinder block assembly. Remove and discard the assembly in an arbor press, with the drive flange end,
two [2] o-rings. of the shaft, facing downward. Use the press to apply
pressure to the shaft. CAREFULLY remove the one
f. CAREFULLY remove the complete cylinder [1] snap ring, which secures the spacer ring and
block assembly from the brake shaft. Put the cylinder shims, from the drive shaft. Remove the spacer ring
block assembly on a CLEAN surface for further and the shims from over the shaft.
disassembly and inspection later, if needed.
g. If disassembly, inspection and/or replacement CAUTION: Put a piece of steel on top of the drive
of valve block distribution seals is needed, use a shaft to protect the splined end of the
permanent marker to mark the position of the two [2] shaft. Support the bearing support on
valve block location tab positions, in relation to the two [2] sides, with solid wood blocks,
valve housing. CAREFULLY remove the valve block above the table area of the press. This
from the housing. will permit the drive shaft and bearing
to pass between them as they are
“pressed” from the bearing support.
NOTE: If valve block removal is needed, it can be
required to get the valve block moving
upward by GENTLY lifting on the location
tabs with screw drivers. Do NOT damage
the valve block, or housing.
8-44 9/2005
Section 8
TRANSMISSION SYSTEM
NOTE: Newer style motors have FOUR (4)

seals this location. *
FIGURE 8-26. TRANSMISSION DRUM DRIVE MOTOR FULL SECTIONED VIEW.
9/2005 8-45
Section 8
TRANSMISSION SYSTEM
i. CAREFULLY remove the drive shaft, with the n. Use the press to apply pressure to the applica-
outer bearing, by SLOWLY pressing it from the front tion spring washer. Compress the spring washer
bearing support housing. downward. Use a Poclain internal snap ring plier
#FACOM 479, or equivalent LARGE internal snap
j. Remove the external race, of the inner bearing, ring plier, to remove the large snap ring from the top
from the bearing support by using a Poclain puller side of the spring washer. SLOWLY release the
#FACOM U28B and support #U30, or equivalent. pressure being applied to the spring washer by the
press.
NOTE: Obtain the referenced POCLAIN tools

from the nearest POCLAIN Hydraulics WARNING: Wear safety glasses during snap ring
Incorporated Distributor, if needed. removal. Keep the hands away from
the press, snap ring and spring
washer at ALL times.
k. CAREFULLY remove the outer bearing from the
motor flange by using Poclain puller assembly
#FACOM U20B, or equivalent. NOTE: Obtain the referenced POCLAIN tools
from the nearest POCLAIN Hydraulics
Incorporated Distributor, if needed.
NOTE: The oil deflector and outer shaft seal will
be destroyed as the bearing is removed.
Replace these parts with NEW during o. Remove the large spring washer from the brake
assembly. housing bore. CAREFULLY remove the brake
release piston from the brake housing bore by
applying a SMALL amount of air pressure through
l. Push the inner shaft seal from the front bearing the brake release oil supply port in the brake hous-
support and discard the seal. Put the bearing support ing. Remove the o-ring from the piston and discard.
on a CLEAN lint free cloth.
WARNING: Keep CLEAR of the brake release

NOTE: A NEW seal MUST be installed at assem- piston during removal procedures.
bly. If required, disassemble the brake Do NOT use an air supply having
assembly, at this time, using steps "n" more than 30 psi. [2 bar] of pressure.
through "p". Use ONLY a SMALL burst of air to
move the brake piston outward from
the bore.
m. Wash the large end of the motor brake hous-
ing, where the large snap ring is found, with clean
diesel fuel and dry using compressed air. Put the p. Remove the internal and external brake discs
valve housing and brake housing assembly onto a alternately from the splined cavity of the brake
press with the large application washer facing housing, in which they operate.
upward.
8-46 9/2005
Section 8
TRANSMISSION SYSTEM
NOTE: Keep the internal and external discs in the CAUTION: Do NOT wash the “SMALLER”
SAME order in which the were installed components at the same time as when
into the splined housing cavity, if they are washing “LARGER” components.
not damaged and will be used. Replace Items such as internal and external
ALL internal and external discs, as a NEW brake discs should be kept in the
"set", if those removed are worn, or order of removal and need to be
damaged. If the rollers, roller segments, cleaned in a method that will keep that
piston rings and/or pistons, that were order. Wash and dry these parts
removed in the complete cylinder block separately and place back in the
assembly, require replacement; disas- SAME position as they were in, before
semble the cylinder block assembly at cleaning, for CORRECT assembly
this time using the following additional position later.
procedures.
b. If removed, inspect each piston and each bore

1. CAREFULLY remove ALL roll pins, that hold for wear, seizure, or damage. Replace any piston that
the guide rings to the cylinder block, and then is found to be worn, seized, or damaged with new.
remove the guide ring, found on each side of Replace the complete cylinder block with NEW if any
the roller. piston bore is found to be worn, or damaged.
2. CAREFULLY remove the piston/ring assembly

from each piston bore, by using LOW pres- CAUTION: A complete failure of the motor will
sure compressed air. usually result in severe wear, or
damage, to ALL pistons, rings and
piston bore areas. Replace the
WARNING: Use compressed air having a pres- complete cylinder block assembly,
sure LESS than 30 psi. [2 bar]. with new, if the above wear and/or
Wear safety glasses during piston/ damage is noted.
ring assembly removal.
NOTE: NEW pistons are available to replace

worn, or damaged, pistons. A cylinder
3. Remove the roller and segment from each block that is fitted with “class 1” pistons
piston. will be so marked on the “valve side” of
the block. Pistons that are “class 1”, will
be so marked on the head of the piston.
CAUTION: Keep EACH complete assembly Two [2] “kits” are available. One [1] “kit”
together, and in the SAME order as includes a complete set of rollers, roller
removed, on clean paper. segments and piston rings. The second
“kit” includes a complete set of the roller
guide rings and the roll pins.
4. Remove the piston ring from the pistons and
discard.
c. Inspect the outer surface of the rollers, which
contact the cam ring “lobe area”, for wear or, dam-
age. Replace ALL roller assemblies, with NEW, if any
INSPECTION [See Figure 8-26]. are found to have wear, or damage. Inspect the roller
segments. Replace all segments, with NEW, if any
a. Carefully wash all bearings, housings and other are found to have wear, or damage.
LARGE components with All-Purpose Degreaser,
part number 178297, and dry with compressed air.
9/2005 8-47
Section 8
TRANSMISSION SYSTEM
CAUTION: ALWAYS replace the roller guide g. CAREFULLY inspect the inner and outer roller
rings, with NEW, if the rollers are bearings for wear, or damage. Both bearings MUST
replaced with new. turn freely without any binding, or roughness being
noted. Replace a bearing found to be worn, or
damaged, with a NEW bearing during assembly of
d. CAREFULLY inspect the roller cam area, of the the motor.
cam ring, for wear, or damage. The area of the roller
cams are induction hardened and must NOT show h. CAREFULLY visually inspect the condition of
evidence of “flaking”, or of pieces of metal eroded the internal and external brake discs. The discs must
from the roller cam surfaces. Replace the complete NOT show evidence of heavy wear, or be cracked,
assembly if worn, or damaged. chipped, or broken. Replace ALL discs with NEW and
keep the SAME order in which they were removed, if
e. CAREFULLY inspect the valving [distributor] ANY are found to be worn, or damaged.
block assembly for any damage which can be noted
visually. Inspect the mating surfaces of the distributor
block and cylinder block for damage, or scratches. CAUTION: If the multi-disc brake did NOT hold
Remove any scratches by polishing, or replace a part the machine, during operation, before
found to be severely damaged. the wheel motor was removed,
inspection of ALL internal and
external brake discs is a MUST. Use
CAUTION: Do NOT disassemble the distributor the information contained in the
assembly UNLESS there was a following “NOTE”.
problem noted in operation of the
“low to high” range pilot operated
spool BEFORE the motor was NOTE: The internal and external discs MUST,
removed, or damage is seen at also be further checked for correct total
inspection. Do NOT use compressed thickness and material condition. The
air to clear the passage leading to the TOTAL thickness of ALL discs must NOT
pilot operated piston, as damage to be LESS than 2.685 in. [68.2 mm]. The
the assembly can occur. Damage internal and external discs must NOT be
caused to the valving [distributor] cracked, chipped, broken or show signs
assembly and other motor of severe wear. Shims can be added to
components by severe system compensate for wear IF the discs do NOT
contamination can require that the show evidence of severe wear, or damage.
valving assembly and the other Replace ALL of the internal and external
components be replaced with NEW, or discs, as a "set", if the discs are found to
that the complete motor assembly be be worn, or damaged, as described above.
replaced with NEW.
i. CAREFULLY visually inspect the large applica-

f. Inspect the condition of both the drive shaft and tion spring washer for damage, or lack of tension,
the brake shaft and their splined areas. There must due to “over heat” conditions. Replace the single
be NO wear that is able to be felt with the fingernail large spring washer, with NEW, if damaged or if it
on ANY smooth surface where the seals mate the shows a loss of tension.
drive shaft. The splines must NOT indicate fretting, j. CAREFULLY inspect the brake release piston for
breakage, twisting, or other damage. Replace the
drive shaft, or brake shaft, if worn, or damaged as
noted above.
8-48 9/2005
Section 8
TRANSMISSION SYSTEM
damage. Replace the piston with NEW if any damage e. CAREFULLY install one [1] guide ring at each
was noted. CAREFULLY remove the o-ring seal. side of the idler roller. Install the roll pin by tapping it
Replace the release piston seal with NEW at installa- into position with a hammer.
tion.
f. CAREFULLY install the remaining piston/ring
and roller assemblies into the CORRECT cylinder
block bores, using the SAME procedure as above.
ASSEMBLY [See Figure 8-26].
CAUTION: ALL capscrews used to fasten the CAUTION: Do NOT damage the ring, piston or
brake housing to the distributor block cylinder block during assembly
and the distributor block to the cam installation.
ring and front bearing support are
“METRIC SIZE”. They always MUST
be tightened to torques accordingly. g. Put the COMPLETE cylinder block assembly
ALL components [seals, bearings on a CLEAN surface and cover with CLEAN lint free
etc.’] are, also, “METRIC SIZED” and cloths until it is later installed into the motor.
must NEVER be replaced with
“standard sized” replacement parts. h. Put the brake and valve housing assembly on a
CLEAN work surface with the brake housing facing
upward. Put the brake shaft into the brake and valve
NOTE: Assemble the cylinder block using the housing assembly. Starting with an EXTERNAL brake
following procedures, if it was disas- disc, install the external and internal brake discs
sembled for inspection and replacement ALTERNATELY over the brake shaft and into the
of the components that make up the brake housing.
“assembly”.
i. Put the brake release piston, WITHOUT the
NEW o-ring, on the top of the brake discs. Use a
a. Put CLEAN hydraulic oil on ALL components of snap ring plier to install the large snap ring into the
the cylinder block assembly. groove in the brake housing. Use a press to apply
pressure to the piston and compress the brake discs.
b. CAREFULLY install the NEW ring assembly CAREFULLY measure the distance, FROM the TOP
onto each piston. Put CLEAN hydraulic oil on each of the brake release piston OUTER edge to the TOP
assembly. of the SNAP RING installed in the brake housing
groove.
c. Put CLEAN hydraulic oil on the roller segments.
Install each roller segment into each piston recess.
Put CLEAN hydraulic oil on the rollers. Install each WARNING: Wear safety glasses while installing
roller into each roller segment recess. the snap ring.
d. CAREFULLY put a small piston ring compres-

sor around the first [number one] piston/ring assem-
bly. Fully compress the rings using the ring compres- j. Write the measurement, found in step “i”, on a
sor. CAREFULLY install the piston/ring and roller paper. SUBTRACT the amount of 0.571 inches [14.5
assembly into the cylinder block, from the OUTSIDE mm]. Make a shim pack EQUAL to the amount found,
of the block, TOWARD the INSIDE of the block. AFTER the subtraction.
9/2005 8-49
Section 8
TRANSMISSION SYSTEM
k. Use a snap ring plier to remove the large snap p. Place the inner bearing CUP into position in the
ring from the brake housing. Release the pressure housing. Use an arbor press, and a sleeve having an
being applied to the piston, and discs, by the press. outside diameter of 7.44 inches [189 mm], to install
Remove the piston from the brake housing bore. the inner bearing cup into the bearing support. Place
the outer bearing CUP into position in the housing.
Use an arbor press, and a sleeve having an outside
WARNING: Wear safety glasses while removing diameter of 7.44 inches [189 mm], to install the outer
the snap ring. bearing cup into the bearing support.
q. Put the NEW oil deflector into position on the

drive shaft. Use a press to CAREFULLY install the
l. Insert the shim pack made in step “j”, on TOP of deflector completely onto the shaft.
the LAST brake disc in the multi-disc stack.
r. Pack the outer wheel bearing CONE with wheel
m. Put CLEAN hydraulic oil on the NEW o-ring to bearing grease. Put wheel bearing grease on the
be installed on the brake release piston. Install the o- deflector.
ring onto the piston. CAREFULLY install the brake
release piston into the brake housing bore.
CAUTION: Be SURE the outer bearing CONE is
n. Install the large application spring washer on fully packed with grease, as NO other
top of the piston. Use a press to apply pressure to lubrication is available to the bearing.
the top of the spring washer, release piston, shim
pack and internal and external brake disc stack.
CAREFULLY install the large snap ring into the snap s. CAREFULLY install the outer bearing CONE
ring groove in the brake housing. Release the onto the drive shaft.
pressure being applied to the brake application
assembly, by the press. Remove the brake housing t. Put multipurpose grease on the outer oil SEAL.
and valve housing assembly from the press. Put the outer oil seal in position in the front bearing
housing. Use a seal installation tool, having an
outside diameter of 4.33 inches [110 mm], to CARE-
WARNING: Wear safety glasses while installing FULLY install the oil seal into the front bearing
the snap ring. Be sure that the large support.
snap ring is FULLY seated in the
housing snap ring groove. u. Put the drive shaft into position, so that it will
install into the front bearing support housing from the
outer side. Use a press to CAREFULLY install the
NOTE: If disassembled, install the seals and drive shaft into the front bearing support housing.
bearings into the front bearing support
housing, at this time.
CAUTION: Do NOT damage the outer and inner
shaft seals as the splines pass
o. CAREFULLY place the NEW inner shaft seal in through them. Put tape around the
position in the front bearing support housing and area of the splines to help stop
install using a seal installation tool. Put multipurpose possible damage to the seal lips, and
grease on the lip area of the inner shaft seal. remove it AFTER the assembly of the
drive shaft into the bearing support
housing is complete.
8-50 9/2005
Section 8
TRANSMISSION SYSTEM
v. Put the inner bearing CONE over the drive aa. If removed, put grease on the valve block
shaft. Use a press to CAREFULLY install the bearing pressure spring. Place the pressure spring into
completely into position on the shaft. position at the bottom of the valve block bore.
bb. CAREFULLY install the valve block and seal

CAUTION: Do NOT damage the bearing cone assembly over the brake shaft and into the valve
during installation. Use a steel sleeve, housing, while ensuring that the composite seals
placed on the inner race area to press enter the valve housing smoothly and are not dam-
the bearing downward. aged. As the valve block fully enters the housing,
make sure the location tabs, on the valve block, are
positioned in the CORRECT valve housing notches,
w. Install the same sized shim and the spacer, as marked at disassembly.
which was removed during disassembly, over the
drive shaft and position them against the inner
bearing race. Use a press to compress the spacer, CAUTION: Be SURE that the valve block location
shim and bearing. CAREFULLY install the snap ring, tabs are in the CORRECT valve
that secures the shim and spacer, over the shaft and housing notches for the CORRECT
into its groove in the bearing support housing. preferential direction of motor
rotation. The CORRECT tab position
will be the SAME position in which the
WARNING: Wear safety glasses while installing tabs were located, noted and marked
the snap ring into the groove in the at disassembly.
bearing support.
cc. CAREFULLY install the complete cylinder

CAUTION: Check to be sure that the snap ring is block assembly over the end of the brake shaft and
securely seated in the groove in the FULLY engage the splines. Put white grease on the
bearing support. NEW housing to cam ring sealing o-ring and CARE-
FULLY install it into the groove in the distributor
housing. CAREFULLY install the motor cam ring over
x. Release the pressure applied by the press. the cylinder block assembly and place it against the
Check the drive shaft for free rotation. distributor housing and o-ring. Align the scribed line,
made on the outside of the cam ring, with the mark
y. Put the brake and valve housing assembly on a made on the outside of the distributor housing at
clean and flat work surface, with the flat end of the disassembly.
brake housing on the work surface.
CAUTION: Do NOT damage the o-ring, or permit

NOTE: If the valve block was removed from the it to move from the housing groove.
valve housing and the composite seals
were removed, Install the NEW seals on
the valve block, at this time.
z. Put a small amount of multipurpose grease on

the valve block seal grooves. CAREFULLY install the
composite seals into the valve block grooves, while
keeping deformation to a minimum.
9/2005 8-51
Section 8
TRANSMISSION SYSTEM
dd. Put white grease on the NEW cam ring to b. CAREFULLY install the motor drive flange
front bearing support housing sealing o-ring and studs through the mounting holes in the vibration
CAREFULLY install it into the groove in the bearing isolator wheel and tire assembly. Put Loctite #242 on
support housing. CAREFULLY install the front the threaded area of the studs. Put the special nut/
bearing support assembly against the cam ring, as washer assemblies on to the motor studs. Tighten
the splines on the drive shaft end FULLY engage into EACH nut/washer assembly to a torque of 300 ft. lbs.
the splines of the cylinder block assembly. Align the [407 N.m].
scribed line made on the outside of the cam ring, with
the mark made on the outside of the front bearing
support assembly, at disassembly. WARNING: Keep the hands CLEAR of the area
between the motor flange and studs
and the tire and rim assembly while
CAUTION: Do NOT damage the o-ring, or permit moving and installing the motor
it to fall from the housing groove. assembly.
Do NOT damage the splines, on the
drive shaft, or in the cylinder block.
Be sure the drive shaft splines are NOTE: Install the vibration isolator/drum drive
FULLY engaged into the cylinder motor assembly onto the drum and then
block. install the COMPLETE drum assembly
into the machine by using the procedures
given in Section 4 - MAINTENANCE.
ee. Install the sixteen [16] assembly retaining
capscrews through the valve housing and cam ring
and thread them into the front bearing support. c. Follow ALL hydraulic system “pre-start and start
Tighten the capscrews to a torque of 217 ft. lbs. [294 up” procedures as given in THIS section BEFORE
N.m]. Fill the wheel motor with CLEAN, FILTERED starting the engine.
hydraulic oil [see Section 4 - MAINTENANCE for
type] and put caps, or plugs, in ALL ports.
CAUTION: BOTH transmission wheel motor
cases MUST be FILLED with oil
BEFORE the engine is started. Loosen
INSTALLATION [See Figure 8-24]. EACH air removal [bleed] screw on
each motor and allow each motor to
a. Fasten a sling and a hoist, having a capacity be COMPLETELY filled with oil as the
more than 500 lbs. [227 kg], to the drum drive motor. air is removed. Close each screw
CAREFULLY lift the drum drive motor and move it when oil appears and is free of air
into installation position onto the vibration isolator bubbles.
and half hoop assembly.
d. Check the hydraulic oil level of the reservoir

WARNING: Do NOT get under the motor while and add oil if needed [see Section 4 - MAINTE-
lifting, moving or lowering the motor. NANCE].
e. After ALL system pre-start procedures have

been followed, start the engine and check the
machine for correct transmission and secondary/
parking brake system function.
8-52 9/2005
Section 8
TRANSMISSION SYSTEM
WARNING: Keep ALL personnel, except the b. Remove the left hand service access door. Find
operator, CLEAR of the machine, and the stack valve assembly, which is mounted to the
the area around it, during the initial side panel of the hood. Remove the electrical current
system checks. Be prepared to STOP supply wire from the secondary/parking brake system
the engine if a system malfunction is RELEASE electric solenoid, found on the stack valve.
noted. If a problem is noted, Do NOT Move the wire away from the solenoid connection
start the engine, again, until the point and put electrical tape on the end of the wire.
problem has been corrected. Put SOLID wood blocks at the front, and at the rear,
of BOTH drums.
f. Check the hydraulic oil level of the reservoir

AGAIN and add oil if needed [see Section 4 - MAIN- WARNING: Block SECURELY using SOLID wood
TENANCE]. blocks.
c. Wash the area where the drum drive motor

DRUM DRIVE MOTOR PRESSURE AND FLOW case drain RETURN oil hose fitting is connected to
CHECKS. the MOTOR case drain oil outlet fitting, with All-
CHECKING PROCEDURES. with compressed air.
The following information describes the different d. Remove the motor case drain hose fitting from
drum drive motor pressure check locations, pressure the motor outlet fitting. Install a “tee” fitting into the
gauge sizes needed and correct pressures. motor case drain oil line. Connect one [1] female end
fitting onto the motor OUTLET male fitting. Connect
the female motor case drain oil hose fitting onto one
CAUTION: The HYDRAULIC system oil MUST be [1] male outlet of the “tee” fitting. Connect a 100 psi.
at “NORMAL OPERATING” [7 bar] pressure gauge, on a long hose, to the
temperature and at the correct level remaining male port of the “tee” fitting and tighten
BEFORE any pressure check or flow securely. Place the gauge in the cockpit, so that the
rate is taken. The ENGINE throttle is operator can note the pressure indicated on the
to be in the “HIGH” idle position for gauge during the pressure check procedures.
ALL checks.
e. Start the engine. Put the secondary/parking
brake system control switch “OFF” [RELEASED]. Put
the transmission speed range selector switch in
CASE PRESSURE [See Figure 8-27]. “WORK” [low] range position. Put the engine throttle
speed control switch in the “HIGH” idle position.
The case PRESSURE of either drum drive motor can
be checked by using the following procedures:
WARNING: Keep ALL personnel, except the
a. Put the secondary/parking brake system control assistant, CLEAR of the area near the
switch “ON”. Stop the engine. machine. The machine produces
MAXIMUM power during this test.
Machine movement is prevented only
by application of the secondary/
parking brake system and the addi-
tional wooden blocking.
9/2005 8-53
Section 8
TRANSMISSION SYSTEM
f. Move either transmission directional/speed h. If the motor case drain oil pressures were
control handle to one forth [1/4] of the full FORWARD correct, remove the pressure gauge and hose from
direction of travel for a period of TEN [10] seconds its connection to the “tee” fitting. Remove the “tee”
MAXIMUM. QUICKLY note the motor FORWARD fitting installed into the line. Connect the case drain
direction CASE drain oil pressure indicated on the return oil hose to the open port of the drum drive
gauge. Move the transmission directional/speed motor fitting and tighten securely.
control handle to the NEUTRAL position.
g. Move either transmission direction control NOTE: If needed, repeat the above procedures to
handle to one forth [1/4] of the full REVERSE direc- check the CASE drain oil pressure for the
tion of travel, for a period of TEN [10] seconds second drum drive motor, BEFORE doing
MAXIMUM. QUICKLY note the motor REVERSE steps “h” and “i”.
direction CASE drain oil pressure indicated on the
gauge. Move the transmission directional/speed
control handle to the NEUTRAL position. i. Remove the electrical tape from the secondary/
parking brake solenoid electrical current supply wire.
Install the current supply wire onto the solenoid
CAUTION: The case drain oil pressure indicated terminal. Remove ALL wood blocking from against
should be the SAME in BOTH the drums.
directions. With the hydraulic oil at
operating temperature, the MAXIMUM j. Check the oil level in the hydraulic oil reservoir.
allowable pressure is 20 psi. [1 bar]. Add oil IF needed [see Section 4 - MAINTENANCE].
The NORMAL pressure during
operation, with the system at
operating temperature is 10 psi. [0.7
bar].
NOTE: A case drain oil pressure that is ABOVE

the given MAXIMUM pressure can be an
indication of motor internal high pressure
leakage due to worn, or damaged, parts
which can reduce the efficiency of the
motor. A further check of the motor case
FLOW AMOUNT, using the procedure
given in THIS section, and “overall”
machine performance can confirm the
loss of efficiency.
FIGURE 8-27. MOTOR CASE DRAIN OIL

PRESSURE CHECK LOCATION.
8-54 9/2005
Section 8
TRANSMISSION SYSTEM
CASE DRAIN OIL FLOW AMOUNT d. Remove the motor case drain HOSE fitting
[See Figure 8-28]. from the motor OUTLET fitting. Install a plug fitting
into the open of the motor case drain hose and
Use the following procedures to check the amount of tighten securely. Install a hose, having the same
CASE drain oil FLOW from each of the motors. female fitting as the case drain oil hose, onto the
motor OUTLET fitting and tighten securely. Put the
The case drain oil flow amount is checked at the remaining end of the installed hose into a CLEAN
point where the case drain RETURN oil fitting hose is measuring container.
connected to the motor case drain oil OUTLET fitting.
a. Put the secondary/parking brake system control WARNING: Keep ALL personnel, except the
switch “ON”. Stop the engine. operator, CLEAR of the MACHINE
and the surrounding AREA during
b. Remove the left hand service access door. Find the “flow check” procedures. The
the stack valve assembly, which is mounted to the machine produces MAXIMUM power
side panel of the hood. Remove the electrical current during this test. Machine movement
supply wire from the secondary/parking brake system is prevented only by application of
RELEASE electric solenoid, found on the stack valve. the secondary/parking brake system
Move the wire away from the solenoid connection and the additional wooden blocking.
point and put electrical tape on the end of the wire.
Put SOLID wood blocks at the front, and at the rear,
of BOTH drums. CAUTION: NEVER seal the case drain port in a
drum drive motor. SEVERE motor
damage can result if case drain oil
WARNING: Block SECURELY using SOLID wood flow and pressure are NOT permitted
blocks. an outlet path.
c. Wash the area where the drum drive motor NOTE: A flow meter can be installed into the
case drain RETURN oil hose fitting is connected to motor CASE drain oil line between the
the MOTOR case drain oil outlet fitting, with All- motor case drain OUTLET fitting and the
Purpose Degreaser, part number 178297, and dry case drain return oil hose fitting, as an
with compressed air. alternate method of checking the oil flow
amount.
e. Start the engine. Put the secondary/parking

brake system “OFF”. Put the transmission speed
RANGE selector switch in the “WORK” [low] range
position. Put the engine throttle speed control switch
in the “HIGH” idle position.
f. Move the directional/speed control handle one

forth [1/4] of the full FORWARD travel distance for a
period of FIFTEEN [15] seconds. Move the direc-
tional/speed control handle back to the NEUTRAL
position and put the throttle speed at “LOW” idle.
FIGURE 8-28. MOTOR CASE DRAIN OIL FLOW

AMOUNT - CHECK LOCATION.
9/2005 8-55
Section 8
TRANSMISSION SYSTEM
g. CAREFULLY measure the AMOUNT of hydrau- i. Remove the collection hose fitting from the
lic oil held in the measuring container. motor CASE drain oil OUTLET fitting. Remove the
plug fitting from the case drain return oil hose. Install,
and then tighten, the case drain return oil hose fitting
CAUTION: The MAXIMUM amount of case drain onto the motor case drain oil OUTLET fitting.
oil collected from the drum drive
motor, for the FIFTEEN [15] second
time period, under load, must NOT be NOTE: If installed, remove the flow meter from
MORE than ONE [1] quart [0.95 liters]. the line between the motor case drain oil
outlet fitting and the case drain oil hose
fitting. Install, and then tighten, the case
h. Empty the collected oil from the container. Put drain return oil hose fitting onto the motor
the hose back into the container. Repeat steps “e” case drain oil OUTLET fitting.
and “f”, with either directional/speed control handle
one forth [1/4] of the full REVERSE travel distance.
Move the direction control handle back to the NEU- j. If needed, repeat the ABOVE procedures to
TRAL position and put the throttle at “LOW” idle. Run check the CASE drain oil flow amount from the
the engine for a period of 3-5 minutes. STOP the second drum drive motor.
engine.
k. Remove the electrical tape from the secondary/
parking brake solenoid electrical current supply wire.
NOTE: The amount of case drain oil collected Install the current supply wire onto the solenoid
should be the SAME as that collected in terminal. Remove ALL wood blocking from against
the forward direction. A case flow amount the drums.
that is more than the flow amount given
above, can be an indication of motor l. Check the oil level in the hydraulic oil reservoir.
internal high pressure oil leakage due to Add oil if needed [see Section 4 - MAINTENANCE].
worn, or damaged, parts which can
reduce the efficiency of the motor.
“WORK” [LOW] TO “TRAVEL” [HIGH] RANGE

PILOT PRESSURE [See Figure 8-29].
Hydraulic oil flow is needed to move the pilot spool,

in each of the drum drive motor valving blocks. This
will reduce, by one half, the “usable” displacement of
the motors and thereby cause the “TRAVEL” [high]
speed range mode.
Use the following procedures to check the high range

PILOT pressure being supplied to both drum drive
motors.
8-56 9/2005
Section 8
TRANSMISSION SYSTEM
CAUTION: Correct CHARGE pressure MUST be
supplied to the stack valve, so that
correct high range pilot oil pressure
can be made available to the drum
drive motors. BEFORE doing the
following pressure check procedures
be SURE that CORRECT CHARGE
pressure is available to this system
[See THIS section for NEUTRAL
charge pressure checking and
adjustment procedures].
a. Put the secondary/parking brake system control

switch “ON” [APPLIED]. Stop the engine.
b. Clean the “WORK” [low] to “TRAVEL” [high]

range oil supply outlet fitting, on the “stack valve”,
with All-Purpose Degreaser, part number 178297,
and dry with compressed air.
c. Remove one [1] pilot oil supply hose from the

fitting installed into the valve. Install, and then tighten, FIGURE 8-29. “TRAVEL” [HIGH] RANGE PILOT
a correct type “tee fitting” onto the open fitting. Install, PRESSURE AND BRAKE SYSTEM RELEASE
and then tighten, the pilot oil supply hose onto one [1] PILOT PRESSURE CHECK LOCATIONS.
port of the installed “tee fitting”. Install, and then
tighten, a 600 psi. [41 bar] pressure gauge, on a long
hose, onto the remaining port of the “tee fitting”.
NOTE: The transmission system charge pressure
d. Start the engine. Keep the secondary/parking indicated on the pressure gauge should
brake system “ON” [APPLIED]. Put the transmission be approximately 375-400 psi. [26-28 bar].
speed range switch in “TRAVEL” [high] range posi- This pressure will move the pilot spool
tion. Put the engine throttle speed control switch in and permit complete shift in range from
the “HIGH” idle position. “WORK” [low] to “TRAVEL” [high].
e. Note the pressure indicated on the pressure
gauge. Put the engine throttle switch in the “LOW” f. Remove the pressure gauge supply hose from
idle position. Run the engine for a period of 3-5 the “tee fitting”. Remove the pilot oil supply hose from
minutes. Stop the engine. the “tee fitting”. Remove the “tee fitting” from the
supply fitting installed into the “stack valve”. Install,
and then tighten, the pilot oil supply hose onto the
NOTE: NO pilot oil should flow from the stack supply fitting installed into the “stack valve”.
valve “TRAVEL” [high] range port, if the
transmission speed range switch is in the g. Check the oil level in the hydraulic oil reservoir.
“WORK” [low] range position. Therefore, Add oil if needed [see Section 4 - MAINTENANCE].
NO pressure will be indicated on the
pressure gauge.
9/2005 8-57
Section 8
TRANSMISSION SYSTEM
SECONDARY/PARKING BRAKE SYSTEM b. Wash the brake release oil pressure supply
RELEASE PILOT PRESSURE [See Figure 8-29]. fitting, installed into the “stack valve”, and the brake
release pressure supply hose fitting with All-Purpose
The hydraulic oil pressure needed to move the brake Degreaser, part number 178297, and dry with
release piston and release the multi-disc brakes, in compressed air.
both drum drive motors, can be checked using the
following procedures:. c. Remove the brake release pressure supply
hose from the supply fitting at the “stack valve”.
Install, and then tighten, a 3/8 inch [9.53 mm] 37 flare
WARNING: Keep ALL personnel, except the tube “tee” fitting onto the open supply fitting. Install,
operator, CLEAR of the area around and then tighten, the brake release pressure supply
the machine while checking the hose onto one [1] port of the installed “tee fitting”.
brake system holding capacity. Do Install, and then tighten, a 600 psi. [41 bar] pressure
NOT operate the machine, or check gauge, on a long hose, onto the remaining port of the
the brake system on a machine, if the “tee fitting”.
machine can be moved forward or
backward while the brake system is d. Start the engine. Keep the directional/speed
“ON” [APPLIED]. Repair the system control handle in NEUTRAL. Put the engine throttle
malfunction IMMEDIATELY. speed control switch in the “LOW” idle position. Put
the secondary/parking brake system control switch
“OFF” [RELEASED]. Note the RELEASE pilot oil
CAUTION: Correct CHARGE pressure MUST be pressure indicated on the pressure gauge.
supplied to the stack valve, so that
CORRECT secondary/parking brake
system RELEASE pilot oil pressure CAUTION: The hydraulic oil pressure needed to
can be made available to the drum FULLY release the multi-disc brakes,
drive motors. BEFORE doing the in the motors, MUST be 320 psi. [22
following pressure check procedures bar] MINIMUM and NOT above 400 psi.
be SURE that CORRECT CHARGE [28 bar] MAXIMUM. Serious damage to
pressure is available to this system the drum drive motors will occur if the
[See THIS section for NEUTRAL pressure exceeds 400 psi. [28 bar].
charge pressure checking and
adjustment procedures].
NOTE: NO brake release oil will flow from the
outlet port of the “stack valve” if the
a. Place the machine on a LEVEL surface. Put the brake system control switch is “ON”
secondary/parking brake system control switch “ON” [APPLIED]. NO pressure will be indicated
[APPLIED]. Stop the engine. Put SOLID wood blocks on the pressure gauge.
at the front, and at the rear of EACH drum.
WARNING: Block SECURELY with SOLID wood

blocks. The blocks MUST hold, and
keep, the machine from ANY move-
ment.
8-58 9/2005
Section 8
TRANSMISSION SYSTEM
e. Check the performance of the secondary/ CLEANING THE HYDRAULIC SYSTEM
parking brakes on both drum drive motors. Remove [See Figure 8-3].
the wood blocks from both sides of the drum. Re-
move the left hand service access door. Find the CAUTION: Dirt, of ANY type, will shorten the
stack valve assembly, which is mounted to the side service life of the transmission,
panel of the hood. Remove the electrical current vibration, and/or steering system
supply wire from the secondary/parking brake system components, or cause the
RELEASE electric solenoid, found on the stack valve. components to fail. If a failure occurs
Move the wire away from the solenoid connection in the transmission, steering or
point and put electrical tape on the end of the wire. vibration systems, DISASSEMBLE,
Put the secondary/parking brake system control CLEAN and then ASSEMBLE the
switch “OFF” [RELEASED]. Move the directional/ ENTIRE hydraulic system.
speed control handlever one forth [1/4] of the full
FORWARD travel distance. Note that the machine
can NOT be moved against the secondary/parking Use the following procedures to CLEAN the entire
brake system. Repeat this procedure with the ma- hydraulic system, if a component failure has
chine direction control in the REVERSE position, and occurred:
note the SAME brake system performance.
a. Drain the hydraulic oil reservoir of oil [see
Section 4 - MAINTENANCE].
WARNING: Do NOT operate the machine if the
machine moved ANY amount, in
EITHER direction. If the machine WARNING: Drain when warm, or cool, ONLY. Hot
moved, STOP the engine and make oil can cause serious injury.
IMMEDIATE repairs to the secondary/
parking brake system [See THIS
section]. b. Remove, disassemble, clean, repair, assemble,
or replace, and install the following system compo-
nents after a component failure.
f. Put the secondary/parking brake system control
switch “ON” [APPLIED]. Put the engine throttle speed 1. Hydraulic oil reservoir
control switch in the “LOW” idle position. Run the 2. Transmission pump assembly
engine for a period of 3-5 minutes. Stop the engine. 3. Drum drive motors
4. Flushing [hot oil shuttle] valve
g. Remove the electrical tape from the secondary/ 5. Steering pump assembly
parking brake solenoid electrical current supply wire. 6. Steering control unit
Install the current supply wire onto the solenoid 7. Steering cylinder
terminal. 8. “Stack valve” assembly
9. Vibrator pump assemblies
h. Remove the pressure gauge supply hose from 10. Vibrator motor assemblies
the “tee fitting”. Remove the brake release supply 11. ALL pressure and return hose assemblies and
hose from the “tee fitting”. Remove the “tee fitting fittings
from the oil supply outlet fitting on the “stack valve”. 12. Oil suction strainers and return oil diffuser
Install, and then tighten, the brake release supply 13. Transmission and vibrator systems pressure
hose onto the supply outlet fitting on the “stack oil filter elements
valve”. 14. Oil cooler assembly
15. Any other item which was subjected to
i. Check the oil level in the hydraulic oil reservoir. contaminated hydraulic oil, such as test ports,
Add oil if needed [see Section 4 - MAINTENANCE]. test gauges, hoses and adaptor "tee" fittings
9/2005 8-59
Section 8
TRANSMISSION SYSTEM
NOTE: See the Section, in THIS manual, which Use these procedures ANY time the system has
covers EACH major component for been “opened” and a component has been removed
removal, disassembly, cleaning, inspec- and then installed back into the system.
tion, assembly and installation informa-
tion.
CAUTION: Do NOT permit the engine to be
started until ALL pre-start procedures
CAUTION: Replace ALL components with the have been followed and it is certain
SAME type and part number, if ALL hydraulic system components
replacement is needed. ALWAYS clean have been COMPLETELY FILLED with
both suction oil strainers, the return oil. Severe damage to system
oil diffuser and replace the pressure components can occur if filling has
oil filter elements, with new, BEFORE NOT been complete.
filling the oil reservoir with NEW,
CLEAN and FILTERED hydraulic oil.
a. Remove the upper most CASE drain port plug
fitting from the TRANSMISSION pump. Use an oil
c. Fill the hydraulic oil reservoir with NEW, CLEAN pump to completely FILL the pump CASE with the
and FILTERED hydraulic oil [see Section 4 - MAIN- CORRECT NEW, CLEAN and FILTERED hydraulic
TENANCE]. oil [See Section 4 - MAINTENANCE]. Install the port
plug fitting into the pump case drain port and tighten
d. Precharge the hydraulic system using the securely.
“Hydraulic System Pre-Start Procedures” found in
THIS Section. b. Remove the upper most CASE drain port plug
fitting from each VIBRATOR pump. Use an oil pump
to completely FILL each pump CASE with the COR-
CAUTION: Do NOT start the engine until ALL pre- RECT NEW, CLEAN and FILTERED hydraulic oil
start procedures have been followed. [See Section 4 - MAINTENANCE]. Install the port
Any dirt, or contamination, remaining plug fitting into the pump case drain port and tighten
in the hydraulic system can cause a securely.
repeat system failure. Partial, or
incomplete, cleaning is NOT good c. Remove the transmission MOTOR CASE drain
enough. COMPLETE system oil hose from the outlet fitting on each motor. Use an
disassembly, and FULL CLEANING is oil pump to completely FILL each motor CASE with
the ONLY acceptable method of the CORRECT NEW, CLEAN and FILTERED hydrau-
hydraulic system service. lic oil [See Section 4 - MAINTENANCE]. Install the
case drain oil hose onto each motor case drain outlet
fitting and tighten securely.
HYDRAULIC SYSTEM PRE-START PROCEDURES d. Remove the vibrator MOTOR CASE drain oil
[See Figure 8-3]. hose from the outlet fitting on each motor. Use an oil
pump to completely FILL each motor CASE with the
Use the following pre-start procedures to help to CORRECT NEW, CLEAN and FILTERED hydraulic
insure that ALL components are full of hydraulic oil oil [See Section 4 - MAINTENANCE]. Install the case
BEFORE the engine is started. drain oil hose onto each motor case drain outlet
fitting and tighten securely.
8-60 9/2005
Section 8
TRANSMISSION SYSTEM
e. Remove the large hex cap fitting, found on the j. Wipe the neutral/stroked CHARGE pressure
steering PUMP assembly. Use an oil pump to com- check port cap with a CLEAN cloth [See THIS
pletely FILL the pump with the CORRECT NEW, section]. Remove the cap from the charge pressure
CLEAN and FILTERED hydraulic oil [See Section 4 - check port fitting. Install, and then tighten, a 600 psi.
MAINTENANCE]. Install the large hex cap fitting into [41 bar] pressure gauge, on a short hose, onto the
the pump body and tighten securely. pressure check port fitting.
f. Check ALL hydraulic hose to fitting connections k. Keep the secondary/parking brake system
to be sure they are tightened correctly. Tighten again control switch “ON”. Keep the directional/speed
as needed. control handle in “NEUTRAL”. Put the engine throttle
speed control switch in the “LOW” idle position.
g. Put the machine in a straight position and
install the steering lock pin into the pin bores. Use a l. Crank the engine, while an assistant watches
floor jack, having a capacity of mote than 10,000 lbs. the charge pressure being indicated on the pressure
[4 540 kg], to CAREFULLY raise EACH corner of the gauge. Continue to crank the engine, until there is
front, and the rear machine frame, so that EACH charge pressure of 100 psi. [7 bar] MINIMUM indi-
drum is clear of the ground. Put SOLID wood blocks, cated on the pressure gauge and the hydraulic
or heavy steel stands, under EACH corner. system has been “precharged” with oil. Stop cranking
the engine.
WARNING: Keep CLEAR of the jack, frame areas,

and blocks or stands while lifting, CAUTION: Do NOT crank the engine for more
blocking and lowering the machine. than 30 seconds continuously. Wait
Block securely using SOLID wood one [1] minute between engine
blocks, or heavy steel stands. cranking to allow the starter motor
time to cool.
h. Fill the hydraulic oil reservoir with the COR-

RECT NEW, CLEAN and FILTERED hydraulic oil m. Loosen the hose fitting, that connects to the
[see Section 4 - MAINTENANCE]. secondary/parking brake release pressure supply
port fitting on one [1] drum drive motor, a SMALL
i. Disconnect the electrical wire from the engine amount. Allow hydraulic oil to “leak” from the fitting.
fuel shut off solenoid. Put electrical tape on the If oil was present at the fitting, securely tighten the
terminal of the wire, removed from the solenoid, to hose fitting onto the brake port fitting. Repeat the
prevent it from touching the engine and ground. SAME procedure on the second drum drive motor.
NOTE: Disconnecting the wire from the fuel shut CAUTION: If NO oil was present, check the oil
off solenoid will keep the engine fuel shut level in the hydraulic oil reservoir.
off valve in the “OFF” position when the Add oil if needed. REPEAT the
engine is cranked. Cranking the engine “precharge” procedure to produce the
will rotate the hydraulic pumps to develop needed oil filling of ALL components.
oil flow and fill the hoses and other
system components with additional oil.
n. Check the oil level in the hydraulic oil reservoir,
AGAIN. Add oil if needed [see Section 4 - MAINTE-
NANCE].
9/2005 8-61
Section 8
TRANSMISSION SYSTEM
NOTE: Leave the pressure gauge and hose a. Put the engine throttle speed control switch in
connected to the charge pressure check the “LOW” idle position. Start the engine. Keep the
port until the “after start” pressure check secondary/parking brake system control switch “ON”
of the charge pressure is complete. Then [APPLIED]. Check the NEUTRAL charge pressure
remove the hose and pressure gauge indicated on the pressure gauge [see THIS Section].
assembly, from the pressure check port, Check for ANY hydraulic system leaks.
and install and tighten the cap onto the
check port fitting.
WARNING: Do NOT use the hands on ANY
hydraulic hose, fitting or system
o. Remove the electrical tape from the electrical component to check for possible
wire that fastens to the engine fuel shut off solenoid. leaks. Serious injury can occur from
Install the wire onto the solenoid terminal and tighten a leak under high pressure. Oil can
the nut securely. be injected under the skin by a leak
under high pressure. Use a hand
held cardboard to check for possible
hydraulic system leaks. Wear eye
HYDRAULIC SYSTEM START UP PROCEDURES. protection. Get IMMEDIATE medical
attention if hydraulic oil enters the
Use the following information for hydraulic system eyes or the skin.
“START UP”, AFTER filling the COMPLETE hydraulic
system with hydraulic oil by using the PRE-START
procedures [See ABOVE]. CAUTION: Do NOT put the engine throttle speed
control switch in the “high” idle
position, at THIS time. The NEUTRAL
WARNING: Keep ALL personnel, except the charge pressure, indicated on the
operator, CLEAR of the MACHINE pressure gauge, MUST be between
and the surrounding AREA during 375-400 psi. [26-28 bar]. STOP the
the “pressure check” procedures. engine IMMEDIATELY if NO, or LOW,
charge pressure, or any system leaks
are noted. Do NOT start the engine,
CAUTION: Do NOT permit the engine to be again, until any problem noted has
started until ALL PRE-START been corrected.
procedures have been completed and
it is certain ALL hydraulic system
components have been FILLED with b. Put the transmission speed range control
oil [See ABOVE]. Severe damage to switch in the “WORK” [low] position. Put the second-
system components can occur if ary/parking brake system control switch “OFF”
filling, of the hydraulic system with [RELEASED]. SLOWLY move either directional/
oil, has NOT been complete. speed control handle toward the FORWARD position.
Note that BOTH drums rotate in the forward direction.
Move the directional/speed control handle to the
NEUTRAL position. SLOWLY move either directional/
speed control handle toward the REVERSE position.
Note that BOTH drums rotate in the reverse direction.
Move the directional/speed control handle to the
NEUTRAL position.
8-62 9/2005
Section 8
TRANSMISSION SYSTEM
c. REPEAT step “b” with the drums rotating EACH g. Remove the hose and pressure gauge from the
direction for a period of thirty [30] seconds, to remove neutral/stroked charge pressure check fitting. Install,
any air possibly still remaining in the transmission and then securely tighten, the cap onto the check
system. Note the STROKED charge pressure shown port fitting.
on the pressure gauge. The stroked charge pressure
shown on the pressure gauge should be 280 psi. [20 h. Use a floor jack, having a capacity of mote than
bar] MINIMUM. 10,000 lbs. [4 540 kg], to CAREFULLY raise EACH
corner of the front, and the rear machine frame.
d. Put the transmission speed range control CAREFULLY remove the wood blocks, or stands
switch in the “TRAVEL” [high] position. REPEAT step from under each corner and lower the machine to the
“b” and note that the drums NOW rotate at the ground.
required HIGHER speed. Put the secondary/parking
brake system control switch “ON” [APPLIED].
WARNING: Keep CLEAR of the jack, frame areas,
e. With the machine in the straight position, and and blocks or stands while lifting,
the steering lock pin installed into the pin bores, keep removing blocking and lowering the
the secondary/parking brake system “ON” [AP- machine to the ground.
PLIED]. Keep the engine throttle speed control switch
in the “LOW” idle position. SLOWLY turn the steering
wheel to the left, and to the right, position a SMALL
amount. Note that the machine does try to move to
the CORRECT direction in response to the steering
wheel movement.
f. Leave the secondary/parking brake system

control switch “ON” [APPLIED]. Put the engine
throttle speed control switch in the “LOW” idle
position. Keep the vibrator system MODE control
switch in the “MANUAL” position. Put the drum
LOCATION switch in the “BOTH” position. Put the
drum AMPLITUDE switch in the “LOW” position. Turn
the REAR drum vibrator frequency control switch to a
position above 2000 VPM. Go to the REAR vibration
pump electronic displacement control [EDC]. Activate
the manual override on the EDC by pushing the
manual activation pin. Note that the REAR drum
vibrator system functioned and !vibrated the drum for
a period of less than one [1] minute. Put the drum
LOCATION switch in the “FRONT” position. Repeat
the SAME steps for the FRONT drum, exactly as
done for the rear drum. Put the vibrator system
MODE control switch in the “OFF” position.
CAUTION: It is inperative that the drum vibration

system is started in “LOW” amplitude
ONLY. Damage to the vibration
mechanism, and/or bearings, can
occur, at initial start up, if the system
is started in “high” amplitude after
repairs are completed.
9/2005 8-63
Section 8
TRANSMISSION SYSTEM
TROUBLE ANALYSIS FOR THE TRANSMISSION SYSTEM
HYDROSTATIC PUMP
PROBLEM CAUSE CORRECTION
MACHINE WILL NOT Hydraulic system oil level low Check oil level in reservoir. Add oil.
OPERATE IN EITHER Find and correct cause of low oil
DIRECTION level.
Flex drive plate mechanism Remove and replace.

broken, or damaged
Transmission system electric Check electric control system.

control system has damage Repair as needed [See Section 7 -
ELECTRICAL SYSTEM].
Transmission pump electric Replace displacement control as

displacement control has damage needed.
Low, or no, charge pressure from Follow pressure check procedure in

charge pump THIS section. Adjust, repair or
replace components as needed.
Charge pressure relief valve Remove charge relief valve parts.

damaged - stays in open position Clean, or replace, damaged parts.
Install and adjust charge relief valve.
Inlet oil strainer in a stopped Drain reservoir of oil. Remove, clean

condition and install oil strainers.
Pressure oil filter in a stopped Remove and replace element with

condition NEW.
Charge pump driving shaft Remove and replace charge pump

damaged, or broken driving shaft.
Transmission pump bypass valves Close both bypass valves.

are open [in tow position]
Transmission pump multifunction Remove and replace valves with

valves are damaged NEW.
Transmission pump damaged Remove and repair, at Service

Center, or replace with new or
remanufactured pump.
8-64 9/2005
Section 8
TRANSMISSION SYSTEM
HYDROSTATIC PUMP
MACHINE WILL NOT Charge pump assembly worn Remove and repair or replace as
OPERATE IN EITHER and/or has damage needed.
DIRECTION (CONT)
Secondary/parking brake system Check hydraulic release system.
NOT released Repair as needed.
Very cold oil in system Permit system to warm.
Wrong oil in hydraulic system Drain and flush ENTIRE hydraulic

system. Install CORRECT hydraulic
oil [See Section 4 -MAINTENANCE].
BOTH drum drive motors have See “DRUM DRIVE MOTOR” - in

damage THIS trouble analysis.
BOTH transmission pump charge Remove, inspect, clean, or replace

pressure check valves [in as needed.
multifunction valves] in the open
position
Air being drawn into system Check ALL fittings and hoses for
correct tightness. Tighten as needed.
Both pressure limiter/high Remove, inspect, clean, or replace

pressure relief valves [in multifunction valves as needed.
multifunction valves] in open
[relief] position
9/2005 8-65
Section 8
TRANSMISSION SYSTEM
HYDROSTATIC PUMP
MACHINE OPERATES IN Transmission system, electric Check transmission electric control
ONE DIRECTION ONLY control system has damage system [See Section 7 -
ELECTRICAL SYSTEM].
Transmission pump displacement Remove and replace valve with new.

control valve has damage
One charge pressure check valve Identify check valve , remove

[in multifunction valve cartridge] cartridge, clean, or replace, cartridge
damaged as needed.
One pressure limiter/high Identify relief valve, and remove

pressure relief valve [in cartridge. Clean, or replace, cartridge
multifunction valve cartridge] as needed.
damaged
Flushing [hot oil shuttle] valve Remove valve. Clean, or replace.

spool stuck in one [1] position
BOTH drum drive motors have See “DRUM DRIVE MOTOR” - in

internal damage THIS trouble analysis.
Hose carrying HIGH pressure Locate stopped hose, remove, clean,

from pump in ONE [1] direction in or replace, as needed.
a stopped condition
8-66 9/2005
Section 8
TRANSMISSION SYSTEM
HYDROSTATIC PUMP
NEUTRAL POSITION Pump displacement control has Remove displacement control.
DIFFICULT OR NOT ABLE damage Replace with new.
TO BE FOUND
Transmission system, electric Check transmission electric control
control system has damage system [See Section 7 -
ELECTRICAL SYSTEM].
Charge pressure LOW Check charge pressure. Repair, or

replace, charge pump components.
Transmission pump displacement Remove complete pump assembly

control piston has damage and replace piston assembly at
Authorized Service Center.
Transmission pump rocker cam Remove complete pump assembly.

swashplate and/or link has Disassemble and repair at
damage Authorized Service Center.
SYSTEM OPERATES IN A Hydraulic system oil level low Check oil level in reservoir. Add oil.
HOT CONDITION Find and correct cause of low oil
level.
Stopped suction screen and/or Drain hydraulic oil reservoir of oil.

pressure oil filter element Remove, clean, or replace, oil
strainers and install. Remove and
replace pressure oil filter element.
Fill reservoir with NEW oil [See
Oil cooler needs to be cleaned of Clean oil cooler to remove dirt [See
dirt Section 4 - MAINTENANCE].
Engine HIGH idle speed low Check engine HIGH idle speed.
Adjust to correct specification.
Transmission pump damaged Remove and repair, at Service

Center, or replace with new or
Drum drive motors have damage See “DRUM DRIVE MOTOR” - in

THIS trouble analysis.
9/2005 8-67
Section 8
TRANSMISSION SYSTEM
HYDROSTATIC PUMP
SYSTEM OPERATES IN A Oil cooler damaged or in a Remove oil cooler. Clean, repair or
HOT CONDITION (CONT) stopped condition replace as needed.
System return oil diffuser in a Remove and clean diffuser [See

stopped condition Section 4 - MAINTENANCE].
Hydraulic oil being heated Check pressure limiter/high pressure

through HIGH pressure relief relief valve pressures in the system.
system Adjust, or replace multifunction
valves and then adjust, the valves as
found needed.
Flushing [hot oil shuttle] valve Check output oil flow amount. Adjust
NOT adjusted correctly, or has valve to CORRECT output as
damage needed, or remove and replace valve
with NEW. Adjust output oil flow to
CORRECT amount.
Pump has internal leakage Remove and repair, at Service

[usually noted with loss of power Center, or replace with new or
and acceleration and a high case remanufactured pump.
drain oil pressure and flow
amount]
Drum drive motors have internal Remove, inspect, repair or replace

damage [usually noted with a motors and install as needed.
loss of power and acceleration
and a high case drain oil
pressure and flow amount]
CAUTION: CLEAN the ENTIRE

hydraulic system,
AFTER a component
failure.
8-68 9/2005
Section 8
TRANSMISSION SYSTEM
HYDROSTATIC PUMP
TRANSMISSION PUMP Hydraulic system oil level low - Check oil level in reservoir. Add oil.
AND SYSTEM NOISY air being drawn into system Find and correct cause of low oil
DURING OPERATION level.
Hose, fitting or filter loose - Check ALL fittings and hoses for
permitting air to be drawn into the correct tightness. Tighten as needed.
system Check charge oil filter spin-on
element for tightness.
Pump has internal wear or Follow pressure check procedures in

damage THIS Section. IF pump has defects,
remove, repair or replace with new
or rebuilt assembly.

hydraulic system
AFTER a component
failure.
Hoses not correctly insulated Check hose routings. They must

from vibration or not in NOT touch any metal that can
CORRECT position increase natural hydraulic system
“hum”.
MACHINE Air being drawn into system See “System noisy during operation”
ACCELERATION AND/OR - Air in system.
DECELERATION IS SLOW
Charge pressure LOW See “Machine will NOT operate in
either direction” - NO or LOW charge
pressure.
Displacement control valve orifice Remove displacement control valve.

partially stopped Remove, clean, or replace orifice.
install control valve
Engine HIGH idle speed low Check engine HIGH idle speed.
Adjust to correct specification.

replace pressure oil filter element.
Fill reservoir with NEW oil [See
Pressure limiter/high pressure Adjust to correct pressures, at muliti-

relief valves [in multifunction function valves.
valves] NOT adjusted correctly
9/2005 8-69
Section 8
TRANSMISSION SYSTEM
HYDROSTATIC PUMP
MACHINE Pump has internal leakage Remove and repair, at Service
ACCELERATION AND/OR Center, or replace with new or
DECELERATION IS SLOW remanufactured pump.
(CONT)
Pump has internal wear, or Remove and repair, at Service
damage Center, or replace with new or
DRUM DRIVE MOTORS AND BRAKES

BOTH DRUM DRIVE Secondary/parking brake system Put secondary/parking brake system
MOTORS WILL NOT “ON” control switch in “OFF” position.
ROTATE IN EITHER
DIRECTION Wires to secondary/ parking Check wire connection and change
brake system control switch as needed [See Section 7 -
reversed ELECTRICAL
Secondary/parking brake system Remove and replace switch with

control switch has damage NEW [See Section 7 - ELECTRICAL
SYSTEM].
Secondary/parking brake system Remove solenoid and replace with

RELEASE solenoid coil has NEW [See Section 9 - BRAKE
damage SYSTEM].
Hydraulic system oil level low Check oil level in reservoir. Add oil.
Find and correct cause of low oil
level.
No output from charge pump and/ See “Machine will not operate in
or transmission pump either direction” - in THIS trouble
analysis.
BOTH brakes not releasing in Check release pilot pressure to drum

motors drive motors. Check release piston in
motors for damage, or leakage.
8-70 9/2005
Section 8
TRANSMISSION SYSTEM
ONE DRUM DRIVE One brake not releasing Check release pilot pressure to the
MOTOR WILL NOT drum drive motor that will NOT
ROTATE IN EITHER rotate. Check motor brake release
DIRECTION piston for damage, or leakage.
Motor valve block [distributor] has Remove, clean or replace and install
damage, or is in a stopped valve block.
condition
Motor has internal damage and/or Follow pressure and flow check
leakage [usually noted with a loss procedures in THIS Section. IF
of machine efficiency] motor shows damaged, remove,
repair, or replace as needed.

hydraulic system
AFTER a component
failure.
ONE OR BOTH MOTORS Low oil flow reaching motors from System operates in a HOT condition”
OPERATING IN A HOT the transmission pump in THIS trouble analysis.
CONDITION
Internal damage and/or leakage Follow pressure and flow check
in motors [usually noted with a procedures in THIS section. If motor
loss of machine efficiency shows damage, remove, repair or
replace as needed.

hydraulic system
AFTER a complete
failure.
Incorrect type oil used in Drain and flush system. Fill system
hydraulic system with CORRECT type oil [See Section
4 - MAINTENANCE].
9/2005 8-71
Section 8
TRANSMISSION SYSTEM
BOTH MOTORS WILL NOT Electrical solenoid at “stack Check electrical circuit to solenoid for
CHANGE FROM WORK valve” NOT being energized current flow when dash toggle switch
[low] TO TRAVEL [high] is in the “HIGH” position. Correct any
SPEED RANGE problem as needed [See Section 7-
ELECTRICAL SYSTEM].
Low or no charge pilot pressure See ABOVE information. Check

flowing to either drum drive motor charge pilot pressure using
procedures given in THIS section.
Correct any problem as needed.
BOTH pilot spools, in valve Remove valve housings. Remove

housings, not moving to change and clean, or replace spool/housing
motor displacement as needed.
ONE MOTOR WILL NOT Low, or no, charge pilot pressure Check charge pilot pressure at wheel
CHANGE FROM WORK flow to the motor that is NOT motor NOT changing speed range.
[low] TO TRAVEL [high] changing speed range Correct any problem noted.
SPEED RANGE
Pilot spool in motor not moving to Remove value housing. Remove,
change motor displacement clean, or replace spool/housing as
needed.
MULTI-DISC BRAKES
BRAKES IN BOTH Electrical solenoid at “stack valve” Check electrical circuit to solenoid for
MOTORS WILL NOT NOT being energized current flow when dash control
RELEASE switch is in the brake system “OFF”
position. Correct any problem as
needed [See Section 7 -
ELECTRICAL SYSTEM].
Low or no charge pilot pressure See ABOVE information. Check

flowing to either motor charge pilot pressure going to
motors. Correct problem as needed.
8-72 9/2005
Section 8
TRANSMISSION SYSTEM
MULTI-DISC BRAKES
BRAKES IN BOTH BOTH release pistons, or seals, Remove motors. Disassemble and
MOTORS WILL NOT worn, or damaged inspect. Replace worn, or damaged
RELEASE (CONT) parts as needed.
BRAKES IN ONE MOTOR Release pressure supply hose in Remove hose. Clean or replace.
WILL NOT RELEASE stopped condition
Release piston, or seals, Remove motor. Disassemble and

damaged inspect parts. Replace parts as
needed.
BRAKES IN BOTH Electrical solenoid at “stack Check electrical circuit to solenoid for
MOTORS WILL NOT valve” stays energized current flow when dash switch is in
APPLY the brake system “ON” position. No
current should be present. Correct
any problem as needed [See Section
7 - ELECTRICAL SYSTEM].
Charge pilot pressure still being See ABOVE information. Check for
supplied to brake release pistons CORRECT brake release supply
hose routing and/or “stack valve”
operation.
Brake release pistons remaining Remove motors. Disassemble and

in release position inspect. Replace parts as needed.
Large brake application washers Remove motors. Disassemble and

damaged inspect. Replace application
washers.
9/2005 8-73
Section 8
TRANSMISSION SYSTEM
MULTI-DISC BRAKES
BRAKES IN BOTH Brake discs worn, or damaged Remove motors. Disassemble and
MOTORS WILL NOT inspect. Replace ALL internal and
APPLY (CONT) external toothed discs, with NEW.
BRAKES IN ONE MOTOR Brake release piston remaining in Remove motor. Disassemble and
WILL NOT APPLY release position inspect. Replace parts as needed.
Large brake application washer Remove motor. Disassemble and

damaged inspect. Replace application washer.
Discs in brake worn, or damaged Remove motor. Disassemble and

inspect. Replace ALL internal and
external toothed discs, with NEW.
BRAKES IN ONE, OR Brake release piston[s] not fully Remove motor[s]. Disassemble and
BOTH, MOTORS WILL returning to the retracted position inspect. Replace piston[s] and
NOT HOLD MACHINE IN A seal[s].
“STOPPED” CONDITION
Large brake application washer[s] Remove motor[s]. Disassemble and
damaged inspect. Replace application
washer[s].
Brake discs worn, or damaged Remove motor[s]. Disassemble and

inspect. Replace ALL internal and
external discs, with NEW, if severely
worn, or damaged. Install shims, as
needed, if discs are found NOT
damaged, or severely worn.
8-74 9/2005
Section 9
BRAKE SYSTEM
TABLE OF CONTENTS
PAGE
DYNAMIC BRAKING ..................................................................................................................................... 9-2.
OPERATION ............................................................................................................................................. 9-2.
SECONDARY/PARKING BRAKE SYSTEM .................................................................................................. 9-2.
OPERATION ............................................................................................................................................. 9-2.
SECONDARY/PARKING BRAKE SYSTEM “STACK VALVE SOLENOID ................................................... 9-4.
REMOVAL AND REPLACEMENT ............................................................................................................ 9-4.
SECONDARY/PARKING BRAKE SYSTEM OPERATION AND

APPLICATION CHECKING PROCEDURES ............................................................................................... 9-5.
9/2005 9-1
Section 9
BRAKE SYSTEM
GENERAL INFORMATION [See Figure 9-1]. WARNING: When approaching, and then
traveling down, a slope use a SLOW
This section describes the operation of the DYNAMIC speed. Move the directional/speed
[hydrodynamic, through the transmission system] and control TOWARD the NEUTRAL
the SECONDARY/PARKING brake systems used on position. ADDITIONAL slowing of the
the 66 Inch and 78 Inch Compactors. machine is done by moving the
directional/speed control PAST
The spring applied SECONDARY/PARKING brake neutral, to the direction OPPOSITE
system components are included in each the direction of machine travel.
transmission drum drive motor assembly.
Repair procedures, for the secondary/parking brake If the machine speed can NOT be controlled by
system components, are included in the moving either directional/speed control handle to the
“Transmission Drum Drive Motor Disassembly, direction opposite that of machine travel, put the
Inspection and Assembly procedures” found in secondary/parking brake system control switch in the
Section 8 - TRANSMISSION SYSTEM, in this “ON” [APPLIED] position to apply the secondary/
manual. parking brake system.
Removal and replacement of the secondary/parking The secondary/parking brake system MUST be used
brake system “stack valve” solenoid is also described to hold the machine in a “stopped” condition at ALL
in this Section. times. The transmission system, used for the
“DYNAMIC” braking of the machine, will NOT hold
“Trouble Analysis”, for the SECONDARY/PARKING and keep the machine in a “stopped” condition.
brake system, is found at the rear of Section 8 -
TRANSMISSION SYSTEM, in this manual.
NOTE: Repair of the DYNAMIC braking system is
done through service to the
TRANSMISSION system [See Section 8 -
DYNAMIC BRAKING. TRANSMISSION SYSTEM].
OPERATION.
During operation, machine slowing and stopping is SECONDARY/PARKING BRAKE SYSTEM.

done by using the TRANSMISSION system. Control
of the transmission system is through either of the OPERATION [See Figure 9-1].
directional/speed control handles, found at the left
and right side of the instrument panel. The secondary/parking brake system is used to hold
the machine in a “stopped” condition after it has been
During machine operation, moving either handle stopped through the use of dynamic braking.
from either the forward, or reverse, position toward
the neutral position causes the oil flow through the During machine operation the system will also “apply”
transmission system to be reduced and then if the machine has a loss of transmission system
stopped. This slows, and then stops, the machine. charge pressure, a loss of all electrical current, or if
there is a stoppage of the engine.
9-2 9/2005
Section 9
BRAKE SYSTEM
Control of the secondary/parking brake system is WARNING: The machine must NOT move, at ANY
accomplished by using the secondary/parking brake time, when the secondary/parking
system control switch, found on the dash. Putting the brake system switch is “ON”.
switch in the system “ON” [APPLIED] position, will
cause the solenoid moved spool, found in the “stack
valve”, to stop the flow of oil to the brake release Check the operation of the secondary/parking brake
piston in each motor. Oil from each brake release system by using the “Operation and Application”
piston is then directed to the hydraulic oil reservoir. checking procedures given in this section. Do NOT
The large brake application washer will then apply operate the machine, if the machine will move when
the multi-disc brakes in each drum drive motor. the secondary/parking brake system is “ON”. Notify
repair personnel, and repair the machine
IMMEDIATELY.

SYSTEM - RELEASE OIL FLOW PATH.
9/2005 9-3
Section 9
BRAKE SYSTEM
Putting the secondary/parking brake system control b. Carefully remove the single purple wire from
switch “OFF” [RELEASED], will cause the solenoid the solenoid being removed and replaced.
moved spool, found in the “stack valve”, to permit the
supply of oil pressure to the secondary/parking brake c. Remove the solenoid retaining nut, found at the
release piston in each motor. The brake release top of the solenoid.
piston will move outward, compressing the large
application washer and release the multi-disc brakes d. Carefully lift the solenoid from the body of the
in each motor. “stack valve”.
e. Carefully install the new solenoid onto the

NOTE: Inspection, and repair as needed, of the “stack valve” body.
secondary/parking brake system compo-
nents MUST be done after the drum drive f. Install, and then tighten, the solenoid retaining
motors are removed from the machine. nut to securely hold the solenoid to the body.
Remove, inspect and replace secondary/
parking brake parts, as needed, using the
information given under the “Transmis- CAUTION: Do NOT overtighten the retaining nut.
sion Drum Drive Motor Repair proce-
dures”, found in Section 8 - TRANSMIS-
SION SYSTEM. See Section 7 - ELECTRI-
CAL, for secondary/parking brake system g. Carefully connect the single purple wire to the
electrical circuit operation descriptions. solenoid.
SECONDARY/PARKING BRAKE SYSTEM “STACK

VALVE” SOLENOID.
REMOVAL AND REPLACEMENT [See Figure 9-2].

the secondary/parking brake system solenoid, found
on the “stack valve”.
NOTE: Use the SAME procedure, as given below,

to remove and replace the transmission
work/travel [low/high] speed range sys-
tem solenoid, which is also found on the
“stack valve”. Both solenoids are the
same and are able to be exchanged.
a. Stop the engine. Remove the service access FIGURE 9-2. STACK VALVE AND SOLENOIDS.
door. Wash the solenoid and “stack valve” with All-
Purpose Degreaser, part number 178297 and dry
with compressed air.
9-4 9/2005
Section 9
BRAKE SYSTEM
h. Start the engine. Check for correct system b. Go to the service access door, found at the end
operation. Install the service access door. of the engine compartment. Remove the capscrews
that keep the service access door in the installed
position. Remove the service access door. Find the
WARNING: Keep ALL personnel, except the “stack valve” assembly, which is fastened to the
operator, CLEAR of the area around upper LEFT hand side of the cowl. Find the brake
the machine during the operation release solenoid assembly and the PURPLE wire
check. connected to it on the “stack valve” [see figure 9-2].
Remove the nut that fastens the current supply wire
to the solenoid stud. Remove the current supply wire
from the solenoid stud. Put electrical tape on the
SECONDARY/PARKING BRAKE SYSTEM terminal of the current supply wire and leave the wire
OPERATION AND APPLICATION CHECKING in a position that is away from the solenoid stud.
PROCEDURES [See Figure 9-2].
c. Keep the directional/speed control handles in
Use the following procedures to check the “NEUTRAL”.
secondary/parking brake system for correct
operation and application. 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 -
WARNING: The secondary/parking brake system OPERATION - in this manual.
MUST keep the machine in a stopped
condition during the following e. Put the engine throttle speed switch in the
system operation and application “HIGH” idle speed position.
check.
If the machine moves, in either
STOP the engine IMMEDIATELY. Put
an instruction tag reading “DO NOT
OPERATE” on the instrument panel
and remove the ignition key from the
ignition switch.
and in the rear, of one [1] drum.
Do NOT use the machine. REPAIR
the system fault IMMEDIATELY.
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.
9/2005 9-5
Section 9
BRAKE SYSTEM
f. Move either machine directional/speed control g. Put the engine throttle speed switch in the
handle one fourth [1/4] of the full travel distance “LOW” idle speed position and allow engine to run at
toward the forward, or reverse, position and note that “LOW” idle speed for a period of at least three-five [3-
the machine does NOT move. Repeat the procedure 5] minutes. STOP the engine.
for the OPPOSITE direction of travel. Move the
machine directional/speed control handle to the h. Go to the purple brake release solenoid current
NEUTRAL position. 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
WARNING: The machine must NOT move in and tighten securely.
EITHER direction of travel.
The secondary/parking brake system i. Install the service access door. Install the door
MUST keep the machine in a retaining capscrews. Securely tighten the capscrews.
STOPPED condition during the
system operation and application
check.
If the machine moved, in EITHER
direction of travel during the system
NOT use the machine. Put an instruc-
tion tag reading “DO NOT OPERATE”
on the instrument panel and RE-
MOVE the ignition key from the
ignition switch.
and in the rear, of one [1] drum of the
machine.
REPAIR the system fault IMMEDI-
ATELY.
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.
9-6 9/2005
Section 10
STEERING SYSTEM
TABLE OF CONTENTS
PAGE
GENERAL INFORMATION ......................................................................................................................... 10-2.
DESCRIPTION ............................................................................................................................................. 10-2.
SYSTEM OPERATION ................................................................................................................................ 10-2.

STEERING PUMP ....................................................................................................................................... 10-3.
REMOVAL ............................................................................................................................................... 10-3.
DISASSEMBLY ....................................................................................................................................... 10-4.

CLEANING AND INSPECTION .............................................................................................................. 10-5.
ASSEMBLY ............................................................................................................................................. 10-5.
INSTALLATION ....................................................................................................................................... 10-6.

STEERING RELIEF VALVE PRESSURE CHECK AND ADJUSTMENT .................................................... 10-7.
STEERING CONTROL UNIT ....................................................................................................................... 10-8.

REMOVAL ............................................................................................................................................... 10-8.
INSTALLATION ....................................................................................................................................... 10-9.
STEERING CYLINDER ............................................................................................................................. 10-10.

REMOVAL ............................................................................................................................................. 10-10.
DISASSEMBLY ..................................................................................................................................... 10-11.
CLEANING AND INSPECTION ............................................................................................................ 10-12.

ASSEMBLY ........................................................................................................................................... 10-13.
INSTALLATION ..................................................................................................................................... 10-14.
TROUBLE ANALYSIS FOR THE STEERING SYSTEM ........................................................................... 10-15.

STEERING PUMP ................................................................................................................................ 10-15.
STEERING CONTROL UNIT ................................................................................................................ 10-16.
STEERING CYLINDER ........................................................................................................................ 10-18.
9/2005 10-1
Section 10
STEERING SYSTEM
GENERAL INFORMATION. Hydraulic oil flows from the pump to the steering
control unit.
This section contains a description of the 66 Inch
and 78 Inch Compactor steering system operation. When the machine is being operated, but is NOT
being turned to the left, or the right, the oil flow
Removal, disassembly, inspection, assembly, entering the steering control unit passes through the
installation and pressure check procedures, for the unit and is directed through the hydraulic oil cooler.
major system components, are, also, found in this
section. Oil flow, from the oil cooler, is directed to the
transmission drum drive motors and serves as the
Trouble analysis for the steering system is found at supply for motor case flushing. Oil flow, not needed
the rear of this section. for motor case flushing, is returned directly to the
When ANY steering function is required [turning of

DESCRIPTION [See Figure 10-1]. the machine to either the left, or right] the oil flow
entering the steering control unit is directed internally
The steering system is a hydraulic operated, through the unit to the steering cylinder supply hose
manually controlled system with provisions for that carries oil flow, for that turn direction, and
manual steering, if the engine has stopped “running”. supplies the cylinder with oil.
The steering system has a natural feel to the
operator by providing a direct relationship between Oil returning from the steering cylinder passes
the steering wheel and the steered drum of the through the steering control unit, joins excess system
machine. oil flow and is directed to, and then through, the
hydraulic oil cooler.
Major steering system components are:
Oil flow, from the oil cooler, is directed to the
1. Gear pump, without relief valve. transmission drum drive motors and serves as the
supply for motor case flushing. Oil flow not needed
2. Steering control unit, with integral relief valve. for motor case flushing is returned directly to the
3. Steering cylinder, double acting.
4. Hoses and fittings. NOTE: Oil is supplied to the ROD end of the
cylinder to turn the machine to the RIGHT
and the BASE end of the cylinder to turn
the machine to the LEFT.
SYSTEM OPERATION [See Figure 10-1].
The engine mounted gear pump supplies the steering

system with hydraulic oil flow. The hydraulic oil is
drawn from the hydraulic oil reservoir, through the
suction oil strainer.
The oil is then pulled into, and through, the pump

gear section. The gear section generates hydraulic
oil flow for the steering system.
10-2 9/2005
Section 10
STEERING SYSTEM
FIGURE 10-1. STEERING SYSTEM SCHEMATIC.
STEERING PUMP. d. Remove the pump to engine sealing gasket

from the pump mounting area on the engine. Put a
REMOVAL [See Figure 10-2]. CLEAN paper cover over the pump mounting area on
the engine and secure with tape.
Use the following procedures to remove the steering
pump for repair, or replacement.
CAUTION: If the pump did NOT meet specified
a. Stop the engine. Wash the steering pump, and flow and pressure requirements
the area of the engine where it is mounted, with All- before removal, replace the pump with
Purpose Degreaser, part number 178297, and dry NEW.
with compressed air.
b. Put an identification tag on each hose that is

connected to the steering pump fittings. Remove the
hoses from the pump fittings. Put caps in all pump
ports and fittings and plugs in all hoses.
c. Remove the capscrews which fasten the

steering pump to the engine. Carefully remove the
pump from the engine.
CAUTION: Do NOT permit the pump to fall when

being removed from the engine.
FIGURE 10-2. STEERING PUMP INSTALLED ON
ENGINE.
9/2005 10-3
Section 10
STEERING SYSTEM
DISASSEMBLY [See Figure 10-3]. CAUTION: Do NOT tightly clamp the pump in a
vise for disassembly. Use the vise to
Use the following procedures to disassemble a support the pump only. Clamping the
steering pump which was removed for inspection pump can cause damage to the body
and/or replacement of the internal parts. and internal parts.
CAUTION: Disassemble the pump only on a c. Remove the four [4] capscrews that fasten the
CLEAN work surface, in a CLEAN front mounting and body housing to the port end
work area. If the pump did NOT meet cover.
specified flow and pressure
requirements before removal, replace d. Remove the two [2] o-rings from the inlet and
the pump with NEW. outlet ports on the pump body.
a. Wash the pump with All-Purpose Degreaser, CAUTION: Do NOT pry the components apart.
part number 178297, to remove all dirt not previously Use a SOFT plastic hammer to tap the
removed. Dry the pump by using compressed air. components until they separate.
b. Make a scribed line down the full length of the

pump to help align the pump sections during
assembly. Support the pump between the jaws of a
vise.
FIGURE 10-3. STEERING PUMP - EXPLODED VIEW.
10-4 9/2005
Section 10
STEERING SYSTEM
e. Remove the port end cover. ASSEMBLY [See Figure 10-3].
f. Remove the two [2] gears. Use the following procedures to assemble the
steering pump, after component inspection.
g. Remove the gear plate.
h. Remove the wear plates from the front housing CAUTION: Be sure all parts of the steering pump
and rear port end cover. are CLEAN. Assemble the pump only
on a CLEAN work surface in a CLEAN
i. Remove the pre-load seals and the load seals work area. Use only CLEAN lint free
from the front housing and rear port end cover. cloth during pump assembly.
j. Carefully remove the seal from the front

mounting and body housing. a. If needed, polish all cover and housing
machined surfaces, which mate together, using a
carborundum stone. Wash all parts, again, with All-
CLEANING AND INSPECTION [See Figure 10-3]. using compressed air. Put CLEAN hydraulic oil on all
parts. Put all parts on CLEAN lint free cloth.
Use the following procedures and guidelines to
inspect the disassembled pump parts to help b. Carefully install the inspected bearings into the
determine if a part should be used again, or be front housing and rear port end cover.
replaced with new.
c. Carefully install the new shaft seal into the front
a. Wash all parts with All-Purpose Degreaser, part housing and body assembly.
number 178297, and dry using compressed air. Keep
all parts on CLEAN lint free cloths.
CAUTION: Do NOT damage the seal during
installation.
CAUTION: Discard ALL o-rings and seals.
Replace the o-rings and seals with
NEW during assembly. These parts
are contained in the seal “kit”. See the d. Put bearing grease on all new pre-load and
MACHINE parts manual, that is load seals.
supplied with the machine.
e. Carefully install the pre-load seal and the load
seal into the front housing. Carefully install the pre-
b. Inspect the pump components for wear, or load seal and the load seal into the rear port end
damage. ONLY the seal kit is available. Replace the cover.
complete pump, with NEW, if components are found
worn, or damaged.
CAUTION: Install the load seal against the wear
plate in both the housing and the port
CAUTION: If internal pump components are end cover. Use extreme caution when
damaged, show unusual wear installing the seals. Install the seals in
patterns or the pump did NOT meet a “square” relationship to the seal
specified flow and pressure bores.
requirements before removal, replace
the pump with NEW.
9/2005 10-5
Section 10
STEERING SYSTEM
f. Install the wear plates. INSTALLATION [See Figure 10-2].
Use the following procedures to install the steering

CAUTION: Install the wear plates, so that the pump onto the engine.
brass surface of the wear plate is
toward the pump gears. a. Remove the paper cover from the pump
mounting area on the engine. Put anti-seize, part
number 316865, on the spline area of the pump drive
g. Install the dowel pins into the front housing and shaft.
body assembly.
b. Put a new pump to engine sealing gasket in
h. Put CLEAN hydraulic oil on the new seal ring. place on the pump mount area on the engine.
Install the seal ring into the groove in the body. Carefully put the steering pump in position on the
pump mount area and push the drive shaft into the
i. Put bearing grease on the inspected gear shafts. drive coupler on the engine.
Install the inspected gears into the gear plate.
c. Align the two [2] through holes in the steering
pump mounting flange with the tapped holed in the
CAUTION: Do NOT damage the shaft seal when engine.
installing the gears. Place a drive
shaft installation sleeve over the shaft d. Install the two [2] capscrews through the holes
when installing the shaft through the in the mounting flange and thread into the tapped
shaft seal. The sleeve wall thickness holes in the engine. Tighten the capscrews to a
should be approximately 0.010 inch torque of 39 ft. lbs. [53 N.m].
[0.25 mm].
e. Remove the plugs from the inlet and outlet
hoses, that connect to the steering pump fittings.
j. Lubricate the new seal ring with CLEAN Remove the caps from the steering pump fittings.
hydraulic oil. Install the seal ring into the rear port end
cover. f. Carefully connect each hose to the steering
pump fittings.
k. Carefully align the scribed line on the pump
housing and the rear port end cap cover. Install the g. Check the oil level in the hydraulic oil reservoir.
end cover. Install the four [4] capscrews. Tighten the Add APPROVED oil if needed using the procedures
capscrews, across corners, to a torque of 34-38 ft. given in Section 4 - MAINTENANCE.
lbs. [46-52 N.m].
h. Prime the system using the “Pre-Start
Procedures” given in Section 8 - TRANSMISSION
CAUTION: Rotate the drive shaft while tightening SYSTEM, before the engine is started.
the capscrews. Tighten the capscrews
evenly to avoid distortion of the pump
body housing and/or port end cover. CAUTION: Do NOT start the engine BEFORE
performing the pre-start procedures.
Damage to the steering system
l. Install new o-rings on the housing inlet and components can occur.
outlet port fittings. Install and securely tighten the
fittings.
m. Fill the pump with APPROVED, CLEAN and

FILTERED hydraulic oil. Put a cap on each fitting.
10-6 9/2005
Section 10
STEERING SYSTEM
i. Start the engine. Check the steering system for f. Put the engine throttle switch in the “HIGH” idle
correct operation. position. Turn the steering wheel either to the left, or
the right, a small amount, while reading the steering
system relief pressure indicated on the pressure
DANGER: Keep ALL personnel CLEAR of the gauge. Put the engine throttle switch in the “LOW”
hitch area. Clearance CLOSES when idle position and run the engine for a period of 3-5
the machine is turned in either minutes. Stop the engine.
direction.
CAUTION: The CORRECT relief pressure is 2,400

+/-50 psi. [166 +/- 3 bar]. An indicated
STEERING RELIEF VALVE PRESSURE CHECK relief pressure that is above, or below,
AND ADJUSTMENT [See Figures 10-4 and 10-5]. the correct pressure must be changed
by adjustment of the steering system
Use the following procedures to check the steering relief valve assembly, contained in the
system relief pressure. The relief pressure is checked steering control unit [see figure
at the remote pressure check port found at the right 10-5]. Turn the setscrew INWARD to
hand side of the rear frame rail. INCREASE the relief pressure. Turn
the setscrew OUTWARD to
DECREASE the relief pressure.
NOTE: Under most normal conditions, UNLESS Repeat step "f" after the pressure
the steering control unit has been adjustment to confirm that the correct
replaced with new, the steering system pressure adjustment has been made.
relief pressure should be found within the
CORRECT pressure range during this
pressure check. Therefore, NO steering g. If the pressure was correct, or after adjustment,
system relief pressure adjustment should remove the hose and pressure gauge from the
be required. remote check port. Install and tighten the cap onto
the check port fitting.
a. Check the oil level in the hydraulic oil reservoir.

Add APPROVED oil if needed using the procedures
given in Section 4 - MAINTENANCE.
b. Put the steering lock pin in the “LOCK” position

through the hitch bores.
c. Clean the remote pressure check port and cap

area with All-Purpose Degreaser, part number
178297, and dry using compressed air.
d. Remove the cap from the remote pressure

check port. Install a 6,000 psi. [414 bar] pressure
gauge, on a long hose that will reach the cockpit
area, onto the pressure check port fitting.
e. Put the secondary/parking brake system control

switch “ON”. Start the engine and allow the hydraulic
system to reach normal operating temperature. FIGURE 10-4. STEERING RELIEF PRESSURE -
REMOTE CHECK PORT LOCATION.
9/2005 10-7
Section 10
STEERING SYSTEM
h. Remove the steering lock pin and place in the b. Remove the blank horn cap from the center of
“travel” position. Start the engine and check the the steering wheel.
steering system for correct operation.
c. Remove the large nut that mounts the steering
wheel to the splined steering unit shaft. Carefully
DANGER: Keep ALL personnel CLEAR of the remove the steering wheel from the splined steering
hitch area. The clearance CLOSES unit shaft.
when the machine is turned in either
direction.
NOTE: Install a steering wheel puller and remove
the steering wheel if the wheel could NOT
be removed using the hand.
d. Remove the four [4] socket head capscrews

that fasten the steering control unit mounting bracket
to the control weldment. Move the mounting bracket
and control unit assembly downward and out of the
control weldment.
e. Put an identification tag on each hose, with a

number that matches the steering control unit fitting it
connects to. Remove each of the four [4] hoses from
the control unit fittings. Put a plug in each hose and
put a cap on each fitting.
f. Carefully remove the mounting bracket and

control unit assembly out of the machine.
FIGURE 10-5. STEERING SYSTEM RELIEF
PRESSURE ADJUSTMENT LOCATION AT
CAUTION: Do NOT permit the assembly to fall
STEERING CONTROL UNIT.
while being removed from the
machine.
STEERING CONTROL UNIT.

g. Wash the steering control unit and mounting
bracket assembly with All-Purpose Degreaser, part
number 178297, and dry using compressed air.
The steering control unit is a rotary actuated non-
h. Put the mounting bracket and control unit
load reacting type.
assembly in a large vise. Fasten the vise tightly to
hold the mounting bracket securely.
i. Remove each fitting from the control unit. Put a

plug in each open port in the control unit.
Use the following procedures to remove the steering
j. Hold the steering control unit. Remove the two
control unit for repair, or replacement:
[2] capscrews that fasten the steering control unit into
the mounting bracket.
a. Remove the four [4] socket head capscrews
that fasten the computer controller cover plate to the
control panel riser. Remove the cover plate, so that
CAUTION: Do NOT permit the control unit to fall
the steering control unit, mounting bracket and hose
to the floor when the capscrews are
connections are accessible.
removed.
10-8 9/2005
Section 10
STEERING SYSTEM
k. Carefully remove the steering control unit from c. Hold the steering control in position, so that the
the mounting bracket. two [2] through holes, in the mounting bracket, are
aligned with the two [2] tapped holes in the steering
control unit. Install the two [2] control unit to the
CAUTION: A failure, of the steering control unit, bracket mounting capscrews and tighten securely.
usually causes damage not able to be
repaired. The control unit is, d. Remove the plugs from the ports in the steering
therefore, considered a "remove and control unit. Install each supply and return oil fitting
replace, with NEW", serviced item. into the correct ports of the control unit, and tighten
After replacement with new, check, securely. Put a cap on each fitting.
and if needed adjust, the steering
system relief pressure, using the e. Put the mounting bracket and steering control
information contained in this section. unit assembly in position near the control weldment,
at a point where the four [4] steering pressure hoses
can be connected to the four [4] fittings on the control
unit.
f. Remove the caps from all fittings and the plugs

from all hoses. Connect each hose onto the
CORRECT fitting in the control unit as indicated by
the hose to fitting identification tags. Tighten EACH
hose securely.
CAUTION: Connect EACH hose to the CORRECT

fitting. Connect the four [4] hoses as
indicated by the identification tag put
on EACH hose BEFORE they were
disconnected.
g. Carefully move the mounting bracket and

steering control assembly, with the hoses now
FIGURE 10-6. STEERING CONTROL UNIT connected, into position at the mounting area at the
INSTALLED IN MACHINE. control weldment. Align the four [4] through holes, in
upper area of the control weldment, with the tapped
holes in the mounting bracket.
INSTALLATION [See Figure 10-6]. h. Install the four [4] socket head capscrews
through the weldment and turn them into the tapped
Use the following procedures to install the steering holes in the bracket. Tighten the capscrews securely.
control unit into the machine.
i. Carefully install the steering wheel onto the
a. Put the mounting bracket in a large vise. splined steering shaft. Install the steering wheel
Fasten the vise tightly to the bracket. retaining nut. Tighten the nut to a torque of 50 ft. lbs.
[68 N.m].
b. Put the steering control unit into the mounting
bracket, from the back side of the bracket, with the
splined end facing outward. CAUTION: Do NOT hit the steering wheel with
any object when installing it onto the
splined shaft. Damage to the steering
control unit can result by forces
transmitted through the shaft.
9/2005 10-9
Section 10
STEERING SYSTEM
j. Install the blank horn cap into the center of the STEERING CYLINDER.
steering wheel.
k. Check the oil level in the hydraulic oil reservoir.
If needed add APPROVED oil using the procedures Use the following procedures to remove the steering
given in Section 4 - MAINTENANCE. cylinder for repair, or replacement:
l. Prime the system using the “Pre-Start” a. Stop the engine. Wash the steering cylinder,
procedures given in Section 8 - TRANSMISSION hoses and the area where it mounted, with All-
SYSTEM, BEFORE the engine is started. Purpose Degreaser, part number 178297, and dry
using compressed air.
CAUTION: Do NOT start the engine BEFORE b. Put an identification tag on each hose fastened
performing the “Pre-Start” to the cylinder. Remove both hoses from the cylinder.
procedures. Put plugs in each hose and caps on each fitting.
c. Go to the cylinder anchor end. Remove the

m. Start the engine. Check for correct steering steering lock pin retaining capscrew. Remove the
system relief pressure and correct control unit and retaining pin. Remove the cylinder anchor end
system function. anchor pin from the cylinder clevis ears and the
steering ear in the front frame.
DANGER: Keep ALL personnel CLEAR OF the d. Go to the cylinder rod end. Remove the
hitch area. Clearance CLOSES when steering lock pin retaining capscrew. Remove the
the machine is turned in either retaining pin. Remove the cylinder rod end anchor
direction. pin from the cylinder clevis ears and the steering ear
of the hitch.
WARNING: Do NOT put the hands or arms e. Carefully remove the steering cylinder from the
through the steering wheel spoke machine.
area during the system check. A
malfunction in the steering control
unit or hoses not being connected NOTE: Inspect the self lubricated bushing, found
correctly can cause the steering in the hitch steering ear and in the front
wheel to rotate with a large force, frame anchor plate for wear, or damage,
that can cause serious injury. at this time, using the procedures given in
Section 5 - FRAME AND HITCH.
NOTE: Use the information given in THIS Section

to check and, if needed, adjust the
steering system relief pressure.
n. After checking and, if needed, adjusting the

steering system relief pressure, put the computer
controller cover plate into position on the control
panel riser. Install, and then securely tighten, the four
[4] socket head capscrews.
10-10 9/2005
Section 10
STEERING SYSTEM
d. Push the packing gland assembly inward. Use
a plier or a screw driver to carefully remove the
packing gland retaining wire from the groove in the
cylinder shell.
WARNING: Safety glasses MUST be worn during

wire removal.
e. Carefully move the packing gland assembly

outward from inside the cylinder shell and slide it
downward on the cylinder rod.
f. Pull on the cylinder rod and carefully remove the

piston/rod assembly from the cylinder shell bore.
g. Put the cylinder rod end clevis in a vise and

FIGURE 10-7. 66 INCH OR 78 INCH COMPACTOR tighten the vise to hold the rod end clevis securely.
STEERING CYLINDER - INSTALLED IN MACHINE.
h. Remove the large locknut on the cylinder
piston.
i. Remove the piston from the cylinder rod.

DISASSEMBLY [See Figure 10-8]. Remove both of the piston seals from the piston.
Remove the one [1] static seal from the groove in the
Use the following procedures to disassemble the 66 cylinder rod.
inch and 78 inch compactor steering cylinder for
inspection and replacement of serviced internal parts. j. Move the packing gland assembly up the
cylinder rod and off of the cylinder rod.
a. Wash the cylinder, again, with All-Purpose k. Remove the cylinder rod wiper from the inner
Degreaser, part number 178297, and dry using bore of the gland assembly. Remove the rod sealing
compressed air. o-ring and back up ring from the inner bore of the
gland assembly. Remove the gland to shell sealing o-
b. Put the cylinder in a vise, with the shell area ring and back up ring from the groove in the outside
held very securely by the jaws. Put the cylinder rod in diameter of the gland assembly.
the extended position.
CAUTION: Do NOT crush, or distort, the shell

area of the cylinder.
c. Remove the two [2] capscrews that fasten the

steel rod end cap to the packing gland assembly.
Remove the end cap from the cylinder shell and from
against the packing gland assembly. Move the end
cap downward on the cylinder rod.
9/2005 10-11
Section 10
STEERING SYSTEM
FIGURE 10-8. MODEL C766C STEERING CYLINDER - EXPLODED VIEW.
CLEANING AND INSPECTION [See Figure 10-8]. c. Inspect the gland assembly and the piston
assembly for wear, or damage. Replace either, or
a. Wash all cylinder parts with All-Purpose both, items if found to be worn, or damaged.
Degreaser, part number 178297, and dry using
compressed air. d. Inspect the inside of the cylinder shell for wear,
nicks, burrs, scratches, rust, or other damage.
b. Inspect each part for wear, or damage.
10-12 9/2005
Section 10
STEERING SYSTEM
e. Inspect the cylinder rod for wear, or damage, to c. Install a new cylinder rod static o-ring seal into
the chrome surface. Replace the rod if damaged, the cylinder rod groove.
bent, or if it has a nicked, rusted, scratched, or pitted
chrome surface. d. Carefully install the new piston seals onto the
piston. Install the piston onto the cylinder rod.
NOTE: SLIGHT defects can be removed with fine e. Remove the tape from the threaded area on the
sandpaper or emery cloth. rod. Install the locknut onto the threaded rod. Tighten
the retaining locknut to a torque of 250-300 ft. lbs.
[350-420 N.m].
CAUTION: Do NOT sand chrome plating from the
outside of the rod. If there is any f. Carefully compress the piston seals with the
doubt about chrome plating being fingers, while sliding the piston/rod assembly into the
removed from the rod, check by cylinder shell bore.
applying copper sulfate to the area.
The rod will discolor where chrome is g. Carefully compress the o-ring and back up ring
removed. If this condition is seen, on the outside diameter of the gland assembly with
rechrome, or replace, the cylinder rod. the fingers. Keep the rings compressed and carefully
Wash the cylinder rod after defect move the gland assembly into the shell.
removal, using CLEAN diesel fuel and
dry with compressed air. h. Push the gland assembly fully into the shell, so
that the gland retaining wire groove, in the cylinder
shell, is seen. Use a plier, or a screw driver, to
carefully install the gland retaining wire fully into the
ASSEMBLY [See Figure 10-8]. groove.
Use the following procedures to assemble the

cylinder. WARNING: Eye protection MUST be worn during
wire installation.
CAUTION: ALL parts of the cylinder MUST be

very clean. The assembly area MUST i. Move the cylinder rod end cap upward on the
be CLEAN. Dirt of ANY type can cause cylinder rod and into position on the cylinder shell.
damage to the cylinder and/or Align the two [2] holes in the end cap with the tapped
steering system and a repeat failure holes in the gland assembly. Install the [2] end cap
can occur. retaining capscrews into the tapped holes and tighten
securely.
a. Put CLEAN hydraulic oil on ALL cylinder parts. j. Fill the cylinder with APPROVED, CLEAN and
Put the cylinder rod in a vise, with the clevis end FILTERED hydraulic oil and install caps on EACH
through mounting holes between the vise jaws. fitting.
Tighten the vise to securely hold the rod. Put tape
over the threaded area on the rod.
b. Install the new rod wiper, rod seal, back up ring

and o-ring into the inner bore of the gland assembly.
Install the NEW back up and o-ring into the groove at
the outside diameter of the gland assembly. If
removed, install the rod end cap over the end of the
cylinder rod and move downward. Put the gland
assembly over the end of the cylinder rod and
carefully slide the assembly downward towards the
end of the rod.
9/2005 10-13
Section 10
STEERING SYSTEM
INSTALLATION [See Figure 10-7]. e. Remove the caps from the fittings in the
cylinder and the plugs from the hoses. Connect each
Use the following procedures to install the repaired, steering hose to the correct cylinder fitting, as
or replacement, steering cylinder onto the machine. indicated by the identification tags. Tighten the hoses
securely onto the fittings.
a. Carefully put the steering cylinder into position
on the machine. Align the through hole in the anchor f. Check the oil level in the hydraulic oil reservoir.
end of the cylinder with the through hole in the If needed add APPROVED oil using the procedures
anchor plate on the front frame. given in Section 4 - MAINTENANCE.
b. Install the cylinder mounting pin through the g. Prime the system using the “Pre-Start
bores in the cylinder clevis and the anchor plate from Procedures” given in Section 8 - TRANSMISSION
the TOP side. Install the anchor pin into the cylinder SYSTEM - BEFORE the engine is started.
mounting pin from the side. Install the anchor pin
retaining capscrew and tighten to a torque of 85 ft.
lbs. [115 N.m]. CAUTION: Do NOT start the engine BEFORE
performing the “Pre-Start
c. Remove the caps from the cylinder fittings. Procedures”. Damage to steering
Carefully move the rod of the steering cylinder until system components can occur if the
the through holes in the clevis, at the rod end, align “Pre-Start Procedures” are not done.
with the through holes in the steering ears on the
hitch. Put the caps on the fittings again.
h. Start the engine. Check for correct steering
d. Position the rod end clevis through holes with cylinder and system function.
the hole in the steering ear. Install the cylinder
mounting pin through the bores in the cylinder clevis
and anchor plate from the TOP side. Install the DANGER: Keep ALL personnel CLEAR of the
anchor pin into the cylinder pin from the side. Install hitch area. The clearance CLOSES
the anchor plate retaining capscrew and tighten to a when the machine is turned in either
torque of 85 ft. lbs. [115 N.m]. direction.
10-14 9/2005
Section 10
STEERING SYSTEM
TROUBLE ANALYSIS FOR THE STEERING SYSTEM
STEERING PUMP
NO FLOW FROM PUMP Low oil level in reservoir Check oil level and add oil as
needed. Find and correct cause of
low oil level.
Steering pump has internal Remove, repair, or replace, pump.

damage
LOW FLOW FROM PUMP Low oil level in reservoir Check oil level and add oil as
needed. Find and correct cause of
low oil level.
Restricted inlet suction screen Remove, clean, or replace, part[s] as

and/or oil supply hose needed.
Air being drawn into system Check ALL hose to fitting

connections. Tighten as needed.
Pump has internal leakage - worn Remove, repair, or replace, pump as

and/or damaged parts needed.
PUMP MAKES EXCESSIVE Pump NOT being supplied Check oil level and add oil as
NOISE enough oil needed. Find and correct cause of
low oil level.
Restricted inlet suction screen Remove, clean, or replace, as

and/or oil supply hose needed.
Pump has internal damage Remove, repair, or replace, pump.
9/2005 10-15
Section 10
STEERING SYSTEM
NO RESPONSE WHEN No flow output from pump Check for pump. Repair, or replace,
STEERING WHEEL IS pump, or other parts of the pump, as
TURNED needed.
Control unit has damage Remove and replace control unit.
Steering cylinder has damage Remove cylinder. Repair, or replace,

as needed.
SLOW OR HARD Low system oil level Add oil as needed. Find and correct
STEERING cause of low oil level.
Hose[s] in system in a stopped Remove, clean, or replace, hose[s].

condition
Dirt in system Check suction strainer. Clean, or

replace, as needed. Clean
COMPLETE hydraulic system, as
needed [See section 8].
Steering control unit sleeve and Remove and replace control unit.
spool worn
Steering control unit metering Remove and replace control unit.

gear worn
Steering pump has damage See steering pump in THIS “Trouble

Analysis”.
Manual steering check ball off its Remove and replace control unit.
seat
10-16 9/2005
Section 10
STEERING SYSTEM
STEERING WHEEL DOES Steering control unit has broken Remove and replace control unit.
NOT CENTER centering springs
STEERING WHEEL Steering control unit has broken Remove and replace control unit.
ROTATION IS centering springs
CONTINUOUS
Steering control unit has burr on Remove and replace control unit.
sleeve and/or spool
WRONG STEERING Steering supply hoses NOT Check for CORRECT connection
RESPONSE TO STEERING correctly connected to unit and/or locations and change as needed.
WHEEL COMMAND cylinder
Steering control unit metering star Remove and replace control unit.
to shaft slot NOT aligned correctly
NO PRESSURE OR FLOW Relief valve has internal damage Remove steering control unit.
FROM STEERING Replace with NEW [see THIS
CONTROL UNIT section].
SYSTEM PRESSURE LOW Relief valve not set to correct Adjust relief pressure at steering
specifications control unit [see THIS section].
SYSTEM PRESSURE HIGH See above information See above information.
SYSTEM PRESSURE NOT Relief valve has damaged parts Remove steering control unit and
STEADY - VARIES Replace with new. Adjust relief
pressure at new steering control unit
[see THIS section].
9/2005 10-17
Section 10
STEERING SYSTEM
STEERING CYLINDER
NO MOTION FROM NO oil being supplied to steering Check the system for damaged
STEERING CYLINDER cylinder pump, relief valve or steering control
unit. Check hydraulic oil level.
Repair as needed. See THIS
“Trouble Analysis”.
Cylinder has internal damage Remove cylinder. Repair, or replace

as needed.
SLOW MOTION FROM LOW oil supply to cylinder Check as above.

STEERING CYLINDER
ACTION OF CYLINDER IS Air in system Check oil level in reservoir. Add oil
JERKY as needed. Find and correct cause
for low oil level. Check for loose
hose to fitting connections. Tighten
as needed.
Damaged pressure relief valve Remove and replace steering control

unit.
Bent or deformed cylinder piston Remove cylinder. Repair, or replace,

or rod as needed.
EXCESSIVE LOST Bushings at steering cylinder Remove and replace bushings as

MOTION AT CYLINDER anchors worn needed.
Loose cylinder anchor pin, Inspect and tighten to the

retainer pin and/or anchor CORRECT specification as needed.
capscrew
Cylinder yoke worn/broken at rod Remove cylinder and replace with

and/or anchor end NEW.
10-18 9/2005
Section 11
DRUM, VIBRATION AND DRUM CLEANER SYSTEMS
TABLE OF CONTENTS
PAGE

COMPONENTS OF THE SYSTEMS ........................................................................................................... 11-5.
DRUM AND VIBRATOR - C766C machines below serial number 109C20902455
and on C778B machines below serial number 109B21501856 .................................................... 11-5.
DRUM AND VIBRATOR - C766C machines serial number 109C20902455 and higher
and on C778B machines serial number 109B21501856 and higher ............................................ 11-5.
DRIVE DRUMS ....................................................................................................................................... 11-9.
DRIVE DRUMS - C766C machines below serial number 109C20902455
and on C778B machines below serial number 109B21501856 ................................................ 11-9.
DRIVE DRUMS - C766C machines serial number 109C20902455 and higher
and on C778B machines serial number 109B21501856 and higher ....................................... 11-9.
DRUM CLEANER SYSTEM ................................................................................................................... 11-9.
DRUM AND VIBRATOR SYSTEM ............................................................................................................ 11-10.
BASIC OPERATION ............................................................................................................................. 11-10.
DRUM REMOVAL ................................................................................................................................. 11-12.
DRUM DISASSEMBLY AND REMOVAL OF THE VIBRATOR MECHANISM ..................................... 11-12.
DRUM DISASSEMBLY AND REMOVAL OF THE VIBRATOR MECHANISM -
C766C machines below serial number 109C20902455 and on
C778B machines below serial number 109B21501856 .......................................................... 11-12.
DRUM DISASSEMBLY AND REMOVAL OF THE VIBRATOR SUBASSEMBLIES -
C766C machines serial number 109C20902455 and higher and on
C778B machines serial number 109B21501856 and higher ................................................... 11-15
DISASSEMBLY OF THE VIBRATOR MECHANISM, REMOVAL OF THE
SEAL AND REMOVAL OF BEARINGS FROM THE BEARING CARRIERS OR SUPPORT ......... 11-18.
DISASSEMBLY OF THE VIBRATOR MECHANISM - C766C machines below
serial number 109C20902455 and on C778B machines
below serial number 109B21501856 ........................................................................................ 11-18.
DISASSEMBLY OF THE VIBRATOR SUBASSEMBLY - C766C machines
serial number 109C20902455 and higher and on C778B machines
serial number 109B21501856 and higher ................................................................................ 11-19.
DISASSEMBLY OF THE VIBRATOR MECHANISM ............................................................................ 11-18.
DISASSEMBLY OF THE VIBRATOR SUBASSEMBLY ....................................................................... 11-19.
REMOVAL OF THE SEAL .................................................................................................................... 11-20.
REMOVAL OF THE BEARINGS FROM THE VIBRATOR MECHANISM
BEARING CARRIERS MECHANISM - C766C machines below
REMOVAL OF THE BEARING FROM THE IDLER BEARING
SUPPORT HOUSING MECHANISM - C766C machines below
REMOVAL OF THE BEARINGS FROM THE VIBRATOR HOUSING - C766C machines
9/2005 11-1
Section 11
TABLE OF CONTENTS (CONT)
PAGE
REMOVAL OF THE BEARING FROM THE BEARING CARRIER - C766C machines
INSPECTION OF COMPONENTS ....................................................................................................... 11-23.
ASSEMBLY OF THE VIBRATOR MECHANISM, VIBRATOR SUBASSEMBLY,
INSTALLATION OF THE SEAL AND INSTALLATION OF THE BEARINGS INTO THE
BEARING CARRIERS, SUPPORT HOUSING OR VIBRATOR HOUSING .................................... 11-24.
ASSEMBLY OF THE VIBRATOR MECHANISM - C766C machines below
ASSEMBLY OF THE VIBRATOR SUBASSEMBLY - C766C machines
INSTALLATION OF THE OIL SEAL INTO THE SEAL CARRIER PLATE ........................................... 11-26.
INSTALLATION OF THE VIBRATOR MECHANISM BEARINGS
INTO THE BEARING CARRIERS AND VIBRATOR HOUSING ..................................................... 11-26.
INSTALLATION OF THE VIBRATOR MECHANISM BEARINGS
INTO THE BEARING CARRIERS - C766C machines below serial number
109C20902455 and on C778B machines below serial number 109B21501856 .................... 11-26.
INSTALLATION OF THE BEARING INTO THE IDLER BEARING SUPPORT HOUSING -
C778B machines below serial number 109B21501856 ............................................................... 11-27.
INSTALLATION OF THE BEARINGS INTO THE BEARING CARRIER -
C778B machines serial number 109B21501856 and higher ....................................................... 11-27.
INSTALLATION OF THE BEARINGS INTO THE VIBRATOR HOUSING -
VIBRATOR MECHANISM ASSEMBLY AND INSTALLATION INTO THE DRUM ............................... 11-29.
VIBRATOR MECHANISM ASSEMBLY AND INSTALLATION INTO THE DRUM -
C778B machines below serial number 109B21501856 .......................................................... 11-29.
ASSEMBLY OF THE VIBRATOR SUBASSEMBLY AND INSTALLATION INTO THE DRUM -
ASSEMBLY OF THE VIBRATOR SUBASSEMBLY ........................................................................ 11-33.
INSTALLATION INTO THE DRUM .................................................................................................. 11-34.
DRUM INSTALLATION ......................................................................................................................... 11-36.
DRUM VIBRATOR SYSTEMS - HYDRAULIC VARIABLE DISPLACEMENT PUMPS ............................ 11-36.
FRONT PUMP REMOVAL ............................................................................................................... 11-36.
REAR PUMP REMOVAL ................................................................................................................. 11-36.
11-2 9/2005
Section 11
TABLE OF CONTENTS (CONT)
PAGE
REMOVAL, REPAIR OR REPLACEMENT OF COMPONENTS
OF THE DRUM VIBRATOR PUMPS ...................................................................................................... 11-37.
MINOR REPAIRS - GENERAL INFORMATION ................................................................................... 11-37.
GEROTOR CHARGE PUMP ............................................................................................................. 11-38.
GEROTOR REMOVAL/DISASSEMBLY ........................................................................................ 11-38.
INSPECTION.................................................................................................................................. 11-38.
GEROTOR INSTALLATION/ASSEMBLY ...................................................................................... 11-39.
SYSTEM CHECK RELIEF [SCR] VALVE CARTRIDGES ................................................................. 11-40.
REMOVAL, INSPECTION AND INSTALLATION ........................................................................... 11-40.
CHARGE CHECK VALVES ................................................................................................................ 11-42.
ELECTRONIC DISPLACEMENT CONTROL [EDC] VALVE ............................................................. 11-42.
REMOVAL AND REPLACEMENT ................................................................................................. 11-42.
VIBRATOR PUMP SHAFT AND SHAFT SEAL ................................................................................. 11-43.
CHARGE PRESSURE RELIEF VALVE ASSEMBLY ......................................................................... 11-45.
REMOVAL, CLEANING, INSTALLATION OF NEW O-RINGS AND INSTALLATION ................... 11-45.
MAJOR VIBRATOR PUMP REPAIR .................................................................................................. 11-46.
FRONT VIBRATOR PUMP INSTALLATION ...................................................................................... 11-46.
REAR VIBRATOR PUMP INSTALLATION ........................................................................................ 11-47.
VIBRATOR PUMP PRESSURE CHECKS AND ADJUSTMENTS ........................................................ 11-48.
CHECKING AND ADJUSTMENT PROCEDURES ............................................................................ 11-48.
VIBRATOR PUMPS CASE DRAIN OIL PRESSURE ..................................................................... 11-49.
VIBRATOR PUMPS CASE DRAIN OIL FLOW AMOUNT ............................................................. 11-51.
NEUTRAL CHARGE PRESSURE - FRONT VIBRATOR PUMP ................................................... 11-52.
CHECKING AND ADJUSTMENT PROCEDURES .................................................................... 11-52.
VIBRATOR PUMP HIGH PRESSURE RELIEF VALVES -
PRESSURE CHECK ................................................................................................................... 11-54.
VIBRATION SYSTEM - HYDRAULIC MOTORS .................................................................................. 11-56.
REMOVAL .......................................................................................................................................... 11-56.
INSTALLATION .................................................................................................................................. 11-56.
VIBRATION ISOLATOR TIRE/WHEEL/HOOP ASSEMBLIES ............................................................. 11-57.
REMOVAL, REPAIR OR REPLACEMENT AND INSTALLATION ..................................................... 11-57.
CLEANER BEAM AND RUBBER CLEANER ASSEMBLIES .............................................................. 11-57.
REMOVAL, REPLACEMENT AND ADJUSTMENT ........................................................................... 11-57.
TROUBLE ANALYSIS FOR THE DRUM, VIBRATION AND CLEANER BAR SYSTEMS ........................ 11-58.
DRUM AND VIBRATION ....................................................................................................................... 11-59.
HYDROSTATIC VIBRATOR PUMPS .................................................................................................... 11-64.
VIBRATOR MOTOR .............................................................................................................................. 11-69.
VIBRATION ISOLATOR TIRE, WHEEL AND HOOP ASSEMBLIES .................................................... 11-70.
CLEANER BEAM AND RUBBER ASSEMBLIES ................................................................................. 11-71.
9/2005 11-3
Section 11
NOTES
11-4 9/2005
Section 11
GENERAL INFORMATION. DRUM AND VIBRATOR - C766C machines serial
number 109C20902455 and higher and on C778B
This section describes the major components and the machines serial number 109B21501856 and
basic operation of the drum, vibrator and the drum higher [See Figures 11-1 and 11-2A].
cleaner systems which are used on the 66 Inch and
78 Inch Compactors. The drums, and the vibrator systems have the
following main components:
NOTE: The drum design on C766C machines
serial number 109C20902455 and higher 1. Drum weldments.
and on C778B machines serial number 2. Half hoop weldments.
109B21501856 and higher, has been 3. Drum mounting spacer weldments.
changed. Be sure to refer to the text that 4. Vibrator isolation tire and wheel assemblies.
is applicable to the serial number of your 5. Vibrator drive subassembly
machine. 6. Vibrator subassemblies containing vibrator
mechanisms and bearing housings.
Procedures for removal, suggested disassembly, 7. Vibrator pumps [front and rear].
inspection, assembly and installation of selected 8. Vibrator motors [front and rear].
components are also given, or indicated where to be 9. System electrical controls
found, in this section. “Trouble Analysis”, if it applies, [See Section 7 - ELECTRICAL].
is given at the end of this section. 10. Hydraulic oil reservoir [SAME supply for
all hydraulic systems].
COMPONENTS OF THE SYSTEMS.
DRUM AND VIBRATOR - C766C machines below

serial number 109C20902455 and on C778B
machines below serial number 109B21501856
[See Figures 11-1 and 11-2].
The drums, and the vibrator systems have the

following main components:
1. Drum weldments.
2. Half hoop weldments.
3. Drum mounting spacer weldments.
4. Vibrator isolation tire and wheel assemblies.
5. Vibrator mechanisms, complete.
6. Vibrator pumps [front and rear].
7. Vibrator motors [front and rear].
8. System electrical controls
[See Section 7 - ELECTRICAL].
9. Hydraulic oil reservoir [SAME supply
for all hydraulic systems].
9/2005 11-5
Section 11
FIGURE 11-1. VIBRATOR SYSTEM SCHEMATIC.
11-6 9/2005
Section 11
DRUM VIBRATOR MOTOR SIDE

RIM ASSEMBLY DRUM DRUM DRIVE SIDE
HALF HOOP HALF HOOP
NUTS NUTS
ISOLATOR
TIRE
CAPSCREWS CAPSCREWS
FILL VALVE
LUG NUTS RIM ASSEMBLY
MOTOR
VIBRATION
CARRIER
ASSEMBLY
VIBRATOR MOTOR
MOUNTING PLATE
DRIVE MOTOR
CAPSCREWS FRAME
RIM ASSEMBLY FILL VALVE

NUTS
ISOLATOR TIRE
CAPSCREWS CAPSCREWS
FRAME
CAPSCREWS
CAPSCREWS
FIGURE 11-2. DRUM AND VIBRATOR SYSTEM - MAJOR COMPONENTS.

C766C MACHINES BELOW SERIAL NUMBER 109C20902455
AND ON C778B MACHINES BELOW SERIAL NUMBER 109B21501856.
9/2005 11-7
Section 11
FIGURE 11-2A. DRUM AND VIBRATOR SYSTEM - MAJOR COMPONENTS.

C766C MACHINES SERIAL NUMBER 109C20902455 AND HIGHER
AND ON C778B MACHINES SERIAL NUMBER 109B21501856 AND HIGHER.
11-8 9/2005
Section 11
DRIVE DRUMS.
DRIVE DRUMS - C766C machines below serial

number 109C20902455 and on C778B machines
below serial number 109B21501856
[See Figure 11-2].
The drive drums contain the following:
Each of the two [2] drive drums contain a vibrator

mechanism, which is used in the vibratory mode
during machine use. Each vibrator mechanism is
driven by the hydraulic vibrator motor (see Figure
11-3).
The vibrator motors are supplied oil flow from
the two [2] vibrator pumps.
One [1] pump supplies oil flow to the FRONT FIGURE 11-3. VIBRATOR MOTOR ASSEMBLY –
drum vibrator motor and one [1] pump supplies INSTALLED ONTO DRUM.
oil flow to the REAR drum vibrator motor.
DRIVE DRUMS - C766C machines serial number DRUM CLEANER SYSTEM [See Figure 11-4].
109C20902455 and higher and on C778B
machines serial number 109B21501856 and The drum cleaning system is used, with the water
higher [See Figure 11-2A]. front and rear spray systems [See Section 12], to help
keep the drums free of asphalt build up.
The drive drums contain the following: Four [4] adjustable, bolt on, cleaner weldment
assemblies, with replaceable rubber scrapers, are
Each of the two [2] drive drums contain two used. One [1] assembly is installed at the inner side,
vibrator subassemblies, which are used in the and outer side, of each drum.
vibratory mode during machine use. The two
vibrator subassemblies are directly connected The cleaning system for the drums is made from the
together through a male-female shaft following main components [see Figure 11-4]:
arrangement. The vibrator subassemblies are
driven by the hydraulic vibrator motor. 1. Adjustable bolt on cleaner weldment
The vibrator motors are supplied oil flow from the assemblies [4], with replaceable rubber
two [2] vibrator pumps. scrapers.
One [1] pump supplies oil flow to the FRONT 2. Mounting capscrews and washers.
drum vibrator motor and one [1] pump supplies
oil flow to the REAR drum vibrator motor.
NOTE: Each drum is supplied traction power

through the use of the drum drive motors
[See Section 8 - TRANSMISSION
SYSTEM - in this manual]. Each drum
drive motor is supplied oil flow by the
same transmission pump.
9/2005 11-9
Section 11
FIGURE 11-4. DRUM CLEANER SYSTEM.
DRUM AND VIBRATOR SYSTEM. On C766C machines serial number 109C20902455

and higher and on C778B machines serial number
BASIC OPERATION [See Figures 11-1, 11-2 and 109B21501856 and higher, each of the two [2]
11-2A]. drums, the idler [NOT driven side of the drum]
vibrator isolator assembly is fastened to the frame
Each drum carries approximately one half of the total side by using one [1] vibrator drive subassembly, hex
machine weight. Each drum also serves to transmit bolts and tightening washers.
the vibratory forces, generated by the vibrator
mechanism, to the work surface being compacted. NOTE: At the drive side of the machine, the
frame weight is carried by the drum drive
The same vibratory forces are kept from being motor/motor carrier assembly. On C766C
transmitted into the frame sides through the use of machines below serial number
the pneumatic vibrator isolation system. 109C20902455 and on C778B machines
below serial number 109B21501856, at the
Each drum assembly is mounted between the two [2] idler side of the machine, the frame
side frames through the use of one [1] pneumatic weight is carried by the drum idler
isolator assembly on each drum side. On each of the bearing. On C766C machines serial
two [2] drums, the drive [transmission MOTOR side of number 109C20902455 and higher and on
the drum] vibrator isolator assembly is fastened to the C778B machines serial number
frame side by using one [1] drive motor carrier 109B21501856 and higher, at the idler side
assembly, capscrews and nuts. of the machine, the frame weight is
carried by the bearings of the vibrator
On C766C machines below serial number drive subassembly.
109C20902455 and on C778B machines below serial
number 109B21501856, each of the two [2] drums,
the idler [NOT driven side of the drum] vibrator
isolator assembly is fastened to the frame side by
using two [2] hoop to frame mounting spacer
assemblies, capscrews and nuts.
11-10 9/2005
Section 11
Alignment of the drum, between the frame sides, is The “LOW” amplitude range, of either drum, is
maintained through the tires in the vibrator isolation obtained by having the hydrostatic pump supply oil
assemblies and NO drum to frame shims are used. flow to cause the vibrator motor output shaft to turn in
the same direction at which the vibrator mechanism is
The vibrator system supplies the vibratory forces, designed to move into for the “LOW” amplitude
which the machine uses for vibratory compaction of position.
the work surface through the use of both hydraulic
and mechanical methods. NOTE: When operating the vibrator system[s] in
the “LOW” amplitude range mode, the
The vibrator system hydrostatic pumps are driven by hydrostatic vibrator pump[s] and motor[s]
the engine. One [1] pump assembly supplies oil flow turn at a rate of speed, and in a direction
for the FRONT drum vibrator system and one [1] of rotation which is opposite, than when
pump assembly supplies oil flow for the REAR drum in the “HIGH” amplitude range mode. The
vibrator system. The pumps supply the VIBRATORY vibrator mechanism moves outward in the
system with the necessary oil flow to turn the vibrator cam cut out area. The mechanism does
motors. The vibrator motors turn the vibrator NOT move as far outward as in the
mechanisms, inside the drums. “HIGH” amplitude range as it turns,
because the “ramped” cam cut out
NOTE: See Section 7 - ELECTRICAL SYSTEM - configuration area is smaller for the
for information about the vibrator system “LOW” amplitude direction of rotation.
ELECTRIC control circuit functions in Therefore, the mechanism does NOT
BOTH the “MANUAL” and the move outward as large a distance as
“AUTOMATIC” operation modes. when in the “HIGH” amplitude range of
operation.
In either the “MANUAL”, or the “AUTOMATIC”
operation mode, the front, rear or BOTH drum The frequency of either, or both, drums is adjusted by
vibrator system[s] can be selected to be operational, turning the two [2] frequency controls, found on the
in the “HIGH” or “LOW” amplitude range at the dash, to the desired frequency setting [See Section 3
adjusted frequency, during compaction of the work - OPERATION - in this manual].
surface [See Section 3 - OPERATION - in this
manual]. The setting of controls ELECTRICALLY changes the
output of oil flow from the FRONT and/or REAR
The “HIGH” amplitude range, of either drum, is vibrator pump assemblies.
obtained by having the hydrostatic pump supply oil
flow to cause the vibrator motor output shaft to turn in Changing the amount of oil flow from the pump[s]
the same direction at which the vibrator mechanism is changes the speed at which the vibrator drive
designed to move into for the “HIGH” amplitude hydraulic motor[s] turn. The speed determines the
position. frequency of the vibrator.
NOTE: In the “HIGH” amplitude mode, the

vibrator motor shaft turns at a rate of
speed, and at a reversed direction of
rotation, than when in the “LOW”
amplitude range. The vibrator mechanism
is also designed with a “HIGH” amplitude
biased “ramped” cam configuration area
to permit the spring loaded weight to
move fully outward into the “HIGH”
amplitude position.
9/2005 11-11
Section 11
DRUM REMOVAL. d. Fasten a sling and hoist, having a capacity of
more than 500 lbs. [227 kg], to the IDLER side axle
CAUTION: Remove the COMPLETE drum assembly, so that the assembly will be in a balanced
assembly ONLY after making sure a condition when removed from the idler side end of the
complete inspection and evaluation drum assembly. Use the hoist to apply just enough
indicates it is necessary. tension to tighten the sling.
Use the PROCEDURES given in Section 4 - e. Remove the six [6] capscrews that fasten the
MAINTENANCE - “Removal, Repair and three [3] axle arms [spider] to the IDLER end of the
Replacement of the Vibrator Isolator Tire and Rim drum assembly.
Assemblies” to remove the complete drum from the
machine and the vibrator isolators from the drum for f. Use the sling and hoist to carefully move the
further drum disassembly, inspection and repair. idler side axle assembly away from the end of the
drum. Place the axle assembly on a CLEAN work
DRUM DISASSEMBLY AND REMOVAL OF THE surface for further disassembly at a later time, if
VIBRATOR MECHANISM. required [See this section].
CAUTION: Disassemble the drum in an area CAUTION: Use extra CARE during the axle
which is CLEAN. The area MUST have assembly removal. Do NOT let the
compressed air available to it, as the axle assembly tip downward and hit
inside of the drum MUST be the vibrator drive coupling assembly
completely cleaned and dried before during removal of the axle assembly.
the drum is assembled. Damage to the coupling assembly can
occur and replacement of the
After the drum[s] have been removed from the assembly will be required, if damaged.
machine [see Section 4 - MAINTENANCE], use the
following procedures to remove the vibrator g. Use an Allen wrench to loosen the three [3]
mechanism from the drum for disassembly, capscrews that fasten the inner vibrator drive coupling
inspection and repair. to the vibrator mechanism shaft adapter. Remove the
vibrator drive coupling from the adapter. Remove the
DRUM DISASSEMBLY AND REMOVAL OF THE fan assembly from over the dowel pin and then off of
VIBRATOR MECHANISM - C766C machines below the adapter.
serial number 109C20902455 and on C778B
machines below serial number 109B21501856 h. Remove the four [4] capscrews that fasten the
[See Figure 11-5]. inner vibrator drive coupling adapter to the vibrator
mechanism shaft. Remove the adapter.
a. Wash the complete drum assembly using
steam and allow to air dry. Move the drum assembly i. Remove seven [7] of the eight [8] capscrews that
to a CLEAN area for disassembly. Put the drum in the fasten the idler side bearing carrier assembly to the
correct position, so that the lubrication oil can be drum bulkhead plate. Have an assistant hold the
drained from the drum [See Section 4 - bearing carrier in place against the drum bulkhead
MAINTENANCE]. plate. Remove the one [1] remaining capscrew.
b. Put solid wood blocking behind, and in front of, WARNING: Leave one [1] capscrew to retain the
the drum, on both sides. bearing carrier assembly. The
assembly can move outward and fall
WARNING: Block the drum SECURELY. The from its mounting to the face of the
blocking MUST keep the drum from drum bulkhead plate BEFORE being
moving. completely ready for removal if all of
the capscrews are removed at one
c. Carefully drain the drum of ALL lubrication time.
oil using the procedures given in Section
4 - MAINTENANCE.
11-12 9/2005
Section 11
double pg. foldout -FIGURE

11-5 - Pg. 11-13/14 goes
here !!
FIGURE 11-5. DRUM ASSEMBLY – WITH VIBRATOR MECHANISM – CROSS SECTION VIEW.
9/2005 11-13
Section 11
double foldout Pg.

11-13/14 goes here !!
11-14 9/2005
Section 11
j. Carefully remove the bearing carrier assembly bearing carrier assembly to the bulkhead plate.
from against the drum bulkhead plate. Move the Carefully remove the bearing carrier assembly. Place
carrier and bearing assembly off of the vibrator the assembly on a CLEAN work area for disassembly
mechanism shaft. later, if needed [See this section].
WARNING: Keep the hands CLEAR of the drum WARNING: Do NOT remove the bearing carrier
cavity and the surrounding area assembly without the help of an
while removing the bearing carrier/ assistant. The carrier can fall from
vibrator mechanism assembly. Use the drum bulkhead plate area when
care to NOT let the bearing carrier/ ALL capscrews have been removed.
vibrator mechanism assembly fall Serious injury can result if the carrier
during removal. falls and strikes the body.
CAUTION: In most cases, the vibrator

mechanism will move outward with DRUM DISASSEMBLY AND REMOVAL OF THE
the bearing carrier assembly. Install VIBRATOR SUBASSEMBLIES. C766C machines
the special vibrator mechanism serial number 109C20902455 and higher and on
removal/installation tool [see Figure C778B machines serial number 109B21501856
11-5A] onto the driven end of the and higher, [See Figure 11-2A and Figure 11-5B].
mechanism having four [4] tapped
holes with correct sized capscrews a. Wash the complete drum assembly using
and tighten securely. Use an assistant steam and allow to air dry. Move the drum assembly
to help remove the carrier/vibrator to a CLEAN area for disassembly. Put the drum in the
mechanism assembly from the drum correct position, so that the lubrication oil can be
cavity. Do NOT permit the assembly to drained from the drum [See Section 4 -
fall and be damaged. MAINTENANCE].
k. Carefully move the assembly to a CLEAN work b. Put solid wood blocking behind, and in front of,
area for further disassembly later, if needed [See this the drum, on both sides.
section].
WARNING: Block the drum SECURELY. The
l. Go to the drum DRIVE MOTOR side of the drum blocking MUST keep the drum from
assembly. Fasten a sling and hoist assembly, having moving.
a capacity of more than 1,000 lbs. [454 kg], to the
vibrator isolator/drum drive motor/motor carrier c. Carefully drain the drum of ALL lubrication oil
assembly. Use the hoist to tighten the sling around using the procedures given in Section 4 -
the motor carrier, so that the complete assembly will MAINTENANCE.
be in a balanced condition when removed from the
drum. d. Use an Allen wrench to loosen the four [4]
capscrews [Figure 11-2A – 1] and discs [2] attaching
m. Remove the eight [8] capscrews that fasten the coupling [3] and fan [4] to adapter-coupling [5] and
vibrator isolator/drum drive motor/motor carrier remove coupling [3] and fan [4].
assembly to the drum pads. Carefully move the
assembly away from the drum and place on a CLEAN e. Use an Allen wrench to loosen the four [4]
surface. capscrews [6] and discs [7] that fasten shaft [21] to
coupler [3].
n. Loosen and remove the eight [8] capscrews that
fasten the cover to the drum drive side bearing f. Use an Allen wrench to loosen three [3]
carrier. Remove the cover. If found installed, remove capscrews [8] that fasten adapter-coupler [5] to
the capscrew which fastens the lubricant retaining vibrator subassembly [9] and remove adapter-coupler
plate to the end of the vibrator mechanism shaft. [5].
Remove the lubricant retaining plate.
g. Using Special Vibrator Mechanism Removal/
o. Have an assistant hold the bearing carrier Installation Tool (Figure 11-5B), attach tool to vibrator
assembly, that is fastened onto the drum bulkhead subassembly [9] with three [3] capscrews [8].
plate. Remove the eight [8] capscrews that fasten the
9/2005 11-15
Section 11
h. Remove eleven [11] of the twelve [12] hex bolts l. Remove the O-ring [23] from bulkhead plate on
[10] and discs [11] that fasten the vibrator drum [12].
subassembly [9] to the drum [12] bulkhead plate.
m. Go to the drum DRIVE MOTOR side of the
WARNING: Leave one [1] hex bolt to retain the drum assembly. Use an Allen wrench to loosen the
vibrator subassembly. The assembly four [4] capscrews [13] and discs [14] attaching fan
can move outward and fall from its [16] to adapter-coupling [15] and remove fan [16].
mounting to the face of the drum
bulkhead plate BEFORE being n. Use an Allen wrench to loosen three [3]
completely ready for removal if all of capscrews [17] that fasten adapter-coupler [15] to
the hex bolts are removed at one vibrator subassembly [20] and remove adapter-
time. coupler [15].
i. Have an assistant hold the Special Vibrator o. Using Special Vibrator Mechanism Removal/
Mechanism Removal/Installation Tool in place against Installation Tool (Figure 11-5B), attach tool to vibrator
the drum [12] bulkhead plate. Remove the one [1] subassembly [20] with three [3] capscrews [17].
remaining hex bolt [10] and disc [11].
p. Remove eleven [11] of the twelve [12] hex bolts
j. Carefully remove the vibrator subassembly [9] [18] and discs [19] that fasten the vibrator
from against the drum bulkhead plate. subassembly [20] to the drum [12] bulkhead plate.
WARNING: Keep the hands CLEAR of the drum WARNING: Leave one [1] hex bolt to retain the
cavity and the surrounding area vibrator subassembly. The
while removing the vibrator subassembly can move outward and
subassembly. Use care to NOT let the fall from its mounting to the face of
vibrator subassembly fall during the drum bulkhead plate BEFORE
removal. being completely ready for removal if
all of the hex bolts are removed at
k. Carefully move the assembly to a CLEAN work one time.
area for further disassembly later, if needed [See this
section].
1.000
FIGURE 11-5A. SPECIAL VIBRATOR MECHANISM

REMOVAL/INSTALLATION TOOL AND BUILD DETAIL.
11-16 9/2005
Section 11
q. Have an assistant hold the Special Vibrator WARNING: Keep the hands CLEAR of the drum
Mechanism Removal/Installation Tool (Figure 11-5B) cavity and the surrounding area
in place against the drum [12] bulkhead plate. Re- while removing the vibrator
move the one [1] remaining hex bolt [18] and disc subassembly. Use care to NOT let the
[19]. vibrator subassembly fall during
removal.
r. Carefully remove the vibrator subassembly [20]
from against the drum bulkhead plate. t. Carefully move the assembly to a CLEAN work
area for further disassembly later, if needed [See this
s. Remove the O-ring [22] from bulkhead plate on section].
drum [12].
FIGURE 11-5B. SPECIAL VIBRATOR MECHANISM

REMOVAL/INSTALLATION TOOL AND BUILD DETAIL.
9/2005 11-17
Section 11
DISASSEMBLY OF THE VIBRATOR MECHANISM, b. Carefully place the vibrator mechanism in a
REMOVAL OF THE SEAL AND REMOVAL OF vise, with the “kidney shape” in each control plate
BEARINGS FROM THE BEARING CARRIERS OR facing down, so that the vise jaws will tighten onto the
SUPPORT. eccentric weight caps. Securely tighten the vise
against the caps.
DISASSEMBLY OF THE VIBRATOR MECHANISM -
C766C machines below serial number c. Mark the position [L or R] on the outer side of
109C20902455 and on C778B machines below each control plate assembly. Mark the top of each
serial number 109B21501856 [See Figure 11-6]. control plate, with the “kidney shape” in each control
plate facing down. Remove the seven [7] capscrews
CAUTION: Do the following disassembly which fasten each control plate to each end of the
procedures in a CLEAN work area. vibrator mechanism shaft/weight assembly.
Do NOT drop ANY part during
disassembly, as the mechanism parts d. Move each control plate outward, and then off
are machined to close tolerances, and of, the weight pin. Slide each control plate from the
incorrect operation, after assembly shaft end. Place each control plate on a CLEAN cloth
and installation, can occur if a part is for inspection later.
damaged.
e. If further disassembly of the vibrator
Use the following procedures to disassemble the mechanism is required, Remove the four [4] nuts
vibrator mechanism for inspection and replacement of from the four [4] socket head shoulder screws that
components, as needed: fasten the eccentric weight and caps onto the shaft.
Remove the four [4] springs from the shank of the
a. Wash the vibrator mechanism using All- shoulder screws and discard the springs and nuts.
Purpose Degreaser, part number 178297, and dry Remove the weight and caps from the shaft.
with compressed air. Remove the one [1] spacer from
each end of the vibrator mechanism shaft. CAUTION: Do NOT use the removed springs and
nuts, again. Always replace the four
[4] springs, with NEW, when the
vibrator mechanism is assembled.
FIGURE 11-6. VIBRATOR MECHANISM - EXPLODED VIEW.
11-18 9/2005
Section 11
DISASSEMBLY OF THE VIBRATOR Use the following procedures to disassemble the
SUBASSEMBLY - C766C machines serial number vibrator mechanism for inspection and replacement of
109C20902455 and higher and on C778B components, as needed:
machines serial number 109B21501856 and
higher [See Figure 11-6A]. a. Remove the twelve [12] hex bolts [17] and discs
[6] fastening the bearing carrier [13] to the vibrator
CAUTION: Do the following disassembly housing [14].
procedures in a CLEAN work area.
Do NOT drop ANY part during b. Remove the assembled bearing carrier [13].
disassembly, as the mechanism parts
are machined to close tolerances, and c. Remove O-ring [16].
incorrect operation, after assembly
and installation, can occur if a part is
damaged.
FIGURE 11-6A. VIBRATOR SUBASSEMBLY - EXPLODED VIEW.
9/2005 11-19
Section 11
d. Wash the vibrator mechanism using All- REMOVAL OF THE SEAL [See Figure 11-7].
with compressed air. CAUTION: Do the following disassembly
e. Remove the one [1] spacer [10] from each end Do NOT drop the seal carrier plate
of the vibrator mechanism shaft [1]. during disassembly, as the plate is
machined to close tolerances, and oil
f. Carefully place the vibrator mechanism in a vise, leakage, after assembly and
with the “kidney shape” in each camplate assembly [3 installation, can occur if the plate is
and 4] facing down, so that the vise jaws will tighten damaged. ALWAYS replace the seal
onto the eccentric weight cap [7]. Securely tighten the with NEW, after removal of the seal
vise against the cap. carrier plate/bearing carrier assembly
from the drum.
g. Mark the position [L or R] on the outer side of
each camplate assembly [3 and 4]. Mark the top of Use the following procedures to remove the oil seal
each camplate, with the “kidney shape” in each for replacement with NEW after the seal carrier plate/
camplate facing down. bearing carrier assembly has been removed from the
drum:
h. Remove the seven [7] bolts [5] and discs [6]
which fasten each camplate to each end of the a. If the oil seal carrier plate was NOT previously
vibrator mechanism shaft/weight assembly [1]. removed, remove the eight [8] capscrews that fasten
the oil seal carrier to the bearing carrier. Remove the
i. Move each camplate outward, and then off of, oil seal carrier from the bearing carrier. Wash the seal
the weight pin. Slide each camplate from the shaft carrier plate with All-Purpose Degreaser, part number
end. Place each camplate on a CLEAN cloth for 178297, and dry using compressed air.
inspection later.
b. Use a seal puller, or drift, to carefully remove
j. If further disassembly of the vibrator mechanism the oil seal from the bore in the carrier. Discard the
is required, remove the two [2] flange nuts [9] from removed oil seal.
the cap assembly [7] that fasten the eccentric weight
assembly [2] and cap assembly [7] onto the shaft [1]. CAUTION: Do NOT damage the bore area, in the
Remove the two [2] springs [8] from the shanks of the carrier plate, while removing the oil
cap assembly [7] and discard the springs and nuts. seal.
Remove the weight assembly [2] and cap assembly
[7] from the shaft.
BRASS HAMMER
CAUTION: Do NOT use the removed springs and
nuts, again. Always replace the two [2]
springs, with NEW, when each
vibrator mechanism is assembled.
SEAL
SEAL CARRIER
FIGURE 11-7. OIL SEAL INSTALLED INTO SEAL

CARRIER PLATE.
11-20 9/2005
Section 11
REMOVAL OF THE BEARINGS FROM THE c. Put a steel bushing, that is the SAME size as
VIBRATOR MECHANISM BEARING CARRIERS the outer bearing race, on the outer race area of the
MECHANISM - C766C machines below serial bearing being removed. Use the arbor press to
number 109C20902455 and on C778B machines carefully remove the bearing from the bearing bore in
below serial number 109B21501856 the bearing carrier. Place the bearing on a CLEAN
[See Figure 11-8]. cloth for inspection, at a later time [See this section].
CAUTION: Do the following disassembly d. Remove the bearing carrier from the arbor
procedures in a CLEAN work area. Do press and place on a CLEAN work surface.
NOT drop a bearing carrier during
disassembly, as the carrier is
machined to close tolerances, and oil
leakage, after assembly and REMOVAL OF THE BEARING FROM THE IDLER
installation, can occur if the carrier is BEARING SUPPORT HOUSING MECHANISM -
damaged. C766C machines below serial number
109C20902455 and on C778B machines below
Use the following procedures to remove the vibrator serial number 109B21501856 [See Figure 11-9].
mechanism bearing from either bearing carrier for
inspection and/or replacement with NEW, if needed: CAUTION: Do the following disassembly
a. Wash the bearing carrier assembly with All-
using compressed air. Use the following procedures to remove the bearing
from the idler bearing support housing for inspection
b. Place the bearing carrier/bearing assembly in and/or replacement, with NEW, if needed:
an arbor press, on solid wood, or steel supports, and
in a position so that the bearing will pass between the a. Wash the idler bearing support housing, and
supports as it is pressed from the carrier bore. related items, with All-Purpose Degreaser, part
number 178297, and dry using compressed air.
NOTE: The bearing can be removed from only
one [1] side of the bearing carrier on the
current product design.
BEARING
FIXTURE BEARING
FIXTURE
BEARING BEARING
BEARING CARRIER IDLER
FIGURE 11-8. MECHANISM BEARING INSTALLED FIGURE 11-9. BEARING INSTALLED INTO IDLER
IN BEARING CARRIER. BEARING SUPPORT HOUSING.
9/2005 11-21
Section 11
b. If not previously removed, remove the vibrator REMOVAL OF THE BEARING FROM THE
motor from the vibrator motor mounting cover [See BEARING CARRIER - C766C machines serial
this section]. Remove the eight [8] vibrator motor number 109C20902455 and higher and on C778B
mounting cover to idler bearing support housing machines serial number 109B21501856 and
retaining capscrews. Remove the vibrator motor higher [See Figure 11-6A].
mounting cover from the bearing support housing.
CAUTION: Do the following disassembly
c. Use a large snap ring plier to remove the large procedures in a CLEAN work area.
snap ring from the groove in the bearing support
housing.
Use the following procedures to remove the bearing
WARNING: Wear eye protection during the snap from the bearing carrier for inspection and/or
ring removal. Use care, so that the replacement, with NEW, if needed:
snap ring does not come free from
the plier while under tension. a. Wash the bearing carrier [13], and related
items, with All-Purpose Degreaser, part number
d. Use a bearing puller to carefully remove the 178297, and dry using compressed air.
bearing assembly from the bearing support housing.
Place the bearing assembly on a CLEAN cloth for b. Remove the eight [8] hex bolts [22] and
inspection, at a later time [See this section]. tightening washers [23] fastening the seal carrier [18]
to the bearing carrier [13].
REMOVAL OF THE BEARINGS FROM THE c. Remove seal carrier [18] and O-ring [21].
VIBRATOR HOUSING - C766C machines serial
number 109C20902455 and higher and on C778B d. Use a large snap ring plier to remove the large
machines serial number 109B21501856 and snap ring [15] from the groove in the bearing carrier
higher [See Figure 11-6A]. [13].
Use the following procedures to remove the bearing WARNING: Wear eye protection during the snap
from the vibrator housing for inspection and/or ring removal. Use care, so that the
replacement, with NEW, if needed: snap ring does not come free from
the plier while under tension.
a. Wash the vibrator housing [14], and related
items, with All-Purpose Degreaser, part number e. Use a bearing puller to carefully remove the
178297, and dry using compressed air. bearing assembly [11] from the bearing carrier [13]
and remove inner ring [12] from bearing [11]. Place
b. Use a large snap ring plier to remove the large the bearing assembly on a CLEAN cloth for
snap ring [15] from the groove in the vibrator housing inspection, at a later time [See this section].
[14].
f. Use a large snap ring plier to remove snap ring
WARNING: Wear eye protection during the snap [20] from seal carrier [18] and remove seal [19].
ring removal. Use care, so that the
snap ring does not come free from
the plier while under tension.
c. Use a bearing puller to carefully remove the

bearing assembly [11] from the vibrator housing [14].
Place the bearing assembly on a CLEAN cloth for
inspection, at a later time [See this section].
11-22 9/2005
Section 11
INSPECTION OF COMPONENTS [See Figures e. Inspect each control plate for excessive wear in
11-5, 11-6, 11-6A, 11-7, and 11-8]. the cut out “kidney shape” areas. The area must NOT
be worn to an uneven contour, or be in a not smooth
Use the following procedures to inspect the condition. The plates MUST be completely flat and
components of the vibrator mechanism, bearings, NOT bent. Replace any control plate, with NEW, that
bearing carriers and housings: is found to have any wear, or damage.
CAUTION: Inspect ALL parts on a CLEAN f. Inspect the through holes in the eccentric weight
surface, in a CLEAN work area. Do and caps. The holes must NOT be worn to an out of
NOT drop ANY part during inspection. round shape. Inspect the pin that is found in each end
Damage to parts can occur and cause of the weight. The pins must NOT be loose, worn, or
malfunction, or leakage. After the parts damaged. Replace the weight and/or caps, with
are washed and dried, use only NEW, if any wear, or damage, is found.
CLEAN lint free cloth under and/or on
the parts. Keep the hands in a CLEAN g. Inspect the socket head shoulder screws that
condition when handling ALL parts. attach the weight. The screws must NOT be bent,
worn or otherwise damaged. Replace the screws,
a. Remove Loctite residue from the machined with NEW, if any wear, or damage, is noted.
sealing surfaces of the bearing carriers. Wash the
eccentric weight, cap, shaft, bearing carriers, and NOTE: Discard the springs and nuts, that were
bearings with All-Purpose Degreaser, part number removed from the screws. ALWAYS
178297, and dry using compressed air. Set ALL of replace the springs and nuts, with NEW,
these clean large components on a CLEAN surface, when the vibrator mechanism is
in a CLEAN area and cover with CLEAN lint free assembled.
cloths, or large plastic bags.
h. Inspect the seal carrier plate for any indication
CAUTION: ALL Loctite residue MUST be removed of damage to the seal bore area. The area must NOT
from all machined sealing surfaces. be nicked, grooved or show any other damage. Also,
check the flat areas of the plate for damage. Replace
b. Wash ALL of the smaller parts with All-Purpose the plate, with NEW, if any damage is seen.
compressed air. Set ALL of these clean small NOTE: Discard the oil seal, that was removed
components on CLEAN lint free cloths and cover the earlier from the seal carrier plate. ALWAYS
parts until being inspected. replace the seal, with NEW, as the vibrator
mechanism is assembled.
c. Inspect each vibrator mechanism bearing
assembly for wear, pitting, scoring, excessive roller i. Inspect the idler bearing assembly for wear,
looseness, or any other damage. Replace any pitting, scoring, excessive roller looseness, loss of
bearing assembly, with NEW, if any wear, or damage, lubricant or any other damage. Replace the bearing
is found. assembly, with NEW, if any wear or damage is found.
CAUTION: Replace any bearing, with NEW, if

there is ANY question about the
usable condition of the bearing.
d. Carefully inspect the vibrator mechanism shaft

for wear, pitting, or scoring, at the points where the
shaft is supported in the bearings. Replace the shaft,
with NEW, if any wear, or damage, is noted.
9/2005 11-23
Section 11
ASSEMBLY OF THE VIBRATOR MECHANISM, e. Place the eccentric weight/caps/shaft assembly
VIBRATOR SUBASSEMBLY, INSTALLATION OF in a vise. Put the assembly in position, so that the
THE SEAL AND INSTALLATION OF THE springs and nuts face upward. Tighten the vise
BEARINGS INTO THE BEARING CARRIERS, against the sides of the caps.
SUPPORT HOUSING OR VIBRATOR HOUSING.
f. Tighten each nut, against the screw shoulder, to
ASSEMBLY OF THE VIBRATOR MECHANISM - a torque of 55 ft. lbs. [75 N.m].
C766C machines below serial number
109C20902455 and on C778B machines below g. First, install the vibrator mechanism driven end
serial number 109B21501856 [See Figure 11-6]. control plate over the pin, that is installed into the
weight end. With the plate “flat bottom” to the LEFT
CAUTION: Do the following assembly procedures and the “kidney shape” to the RIGHT, and facing
on a CLEAN surface, in a CLEAN work down, move the plate fully over the weight installed
area. Do NOT drop ANY part during pin. Push the plate fully against the flat shaft plate,
assembly, as the mechanism parts are having the seven [7] tapped holes.
machined to close tolerances, and
incorrect operation can occur if a part NOTE: The VIBRATOR mechanism driven end of
is damaged. the shaft assembly has four [4] tapped
holes.
Use the following procedures to assemble the vibrator
mechanism, BEFORE installation into the drum: h. Put Loctite #243, part number 934427, on the
threaded area on each of the seven [7] flange screws
CAUTION: Be SURE that ALL parts are FREE of that fasten the control plate to the shaft plate. Install
OIL before assembly. the seven [7] flange screws and tighten with the
fingers.
a. Use an arbor press to install the shoulder i. Install the second control plate over the pin, that
screws into the caps, so that the head of each screw is installed into the weight end, so that the plate “flat
is fully into the cap recessed areas. Use a CLEAN bottom” and “kidney shape” are in the SAME
cloth to remove extra Loctite from the caps and positions as on the control plate installed, on the
screws. driven side. Move the plate fully over the weight
installed pin. Push the plate fully against the flat shaft
b. Put the two [2] cap and shoulder screw plate, having the seven [7] tapped holes.
assemblies on a flat surface with the screws facing
upward. Space the cap and screw assemblies apart j. Put Loctite #243, part number 934427, on the
the same distance as the distance between the threaded area on each of the seven [7] flange screws
through holes in the weight assembly. that fasten the control plate to the shaft plate. Install
the seven [7] flange screws. Tighten ALL fourteen [14]
c. Put the shaft over the saddle area of the two [2] flange screws to a torque of 105 ft. lbs. [143 N.m].
caps. Carefully place the weight assembly over the
four [4] shoulder screws and lower the assembly, k. Check the eccentric weight assembly for FREE
downward, onto the shaft. movement at the control plate “kidney shape” to pin
locations. The weight MUST shift and travel freely.
d. Put one [1] NEW spring over each of the four Put lubricant, part number 933971, on the flat area of
[4] shoulder screws. Install one [1] NEW flange nut the “kidney shape” in each control plate.
onto the threaded area of each shoulder screw and
tighten finger tight.
11-24 9/2005
Section 11
ASSEMBLY OF THE VIBRATOR SUBASSEMBLY - f. First, install the vibrator mechanism driven end
C766C machines serial number 109C20902455 and camplate [3] over the shaft [1], that is installed into
higher and on C778B machines serial number the weight end. With the complete “kidney shape” to
109B21501856 and higher [See Figure 11-6A]. the RIGHT, and facing down, move the plate fully
over the weight installed pin. Push the plate fully
CAUTION: Do the following assembly procedures against the flat shaft plate, which has the seven [7]
on a CLEAN surface, in a CLEAN work tapped holes.
area. Do NOT drop ANY part during
assembly, as the mechanism parts are NOTE: The VIBRATOR mechanism driven end of
machined to close tolerances, and the shaft assembly has four [4] tapped
incorrect operation can occur if a part holes.
is damaged.
g. Put Loctite #243, part number 934427, on the
Use the following procedures to assemble the vibrator threaded area on each of the seven [7] bolts [5] that
subassembly, BEFORE installation into the drum: fasten the camplate to the shaft plate. Install the
seven [7] bolts [5] and discs [6] and tighten with the
CAUTION: Be SURE that ALL parts are FREE of fingers.
OIL before assembly.
h. Install the second camplate [4] over the shaft
[1], that is installed into the weight end, so that the
a. Put the cap assembly [7] on a flat surface with plate “kidney shape” is in the SAME position as on
the screws facing upward. the camplate installed on the driven side. Move the
plate fully over the weight installed pin. Push the plate
b. Put the shaft [1] over the saddle area of the cap fully against the flat shaft plate, which has the seven
[7]. Carefully place the weight assembly [2] over the [7] tapped holes.
two [2] shoulder screws of the cap assembly and
lower the assembly, downward, onto the shaft. i. Put Loctite #243, part number 934427, on the
threaded area on each of the seven [7] bolts [5] that
c. Put one [1] NEW spring [8] over each of the two fasten the camplate to the shaft plate. Install the
[2] shoulder screws of the cap assembly. Install one seven [7] bolts [5] and discs [6]. Tighten ALL fourteen
[1] NEW flange nut [9] onto the threaded area of each [14] bolts [5] to a torque of 91 ft. lbs. [123 N.m].
shoulder screw and tighten finger tight.
j. Check the eccentric weight assembly for FREE
d. Place the eccentric weight/caps/shaft assembly movement at the camplate “kidney shape” to pin
in a vise. Put the assembly in position, so that the locations. The weight MUST shift and travel freely.
springs and nuts face upward. Tighten the vise Put lubricant, part number 933971 on the flat area of
against the sides of the cap [7]. the “kidney shape” in each camplate.
e. Tighten each nut [9], against the screw

shoulder, to a torque of 91 ft. lbs. [123 N.m].
9/2005 11-25
Section 11
INSTALLATION OF THE OIL SEAL INTO THE INSTALLATION OF THE VIBRATOR MECHANISM
SEAL CARRIER PLATE [See Figure 11-7]. BEARINGS INTO THE BEARING CARRIERS -
C766C machines below serial number
CAUTION: Do the following assembly procedures 109C20902455 and on C778B machines below
on a CLEAN surface, in a CLEAN work serial number 109B21501856 [See Figure 11-8].
area. Do NOT drop the oil seal carrier
during the oil seal installation. The Use the following procedures to install a NEW
surfaces are machined to close bearing into EITHER vibrator mechanism bearing
tolerances, and oil leakage can occur carrier:
if the carrier is damaged.
a. Wipe the bearing bore, in the bearing carrier,
Use the following procedures to install the NEW oil with a CLEAN lint free cloth. Move the carrier to an
seal into the oil seal carrier, before installing the arbor press and center it under the press ram.
vibrator mechanism into the drum:
b. Carefully place the NEW bearing into the
CAUTION: ALWAYS install a NEW oil seal into the bearing bore at the top [outer side] of the bearing
carrier, before installing the complete carrier. Position the bearing, so that it will enter the
vibrator mechanism into the drum. bore in a straight condition, while being “pressed” into
the bore. Put a correct sized bearing installation tool
a. Place the oil seal carrier on a CLEAN cloth, with onto the OUTER bearing race area.
the FLAT [NOT chamfered] side of the carrier facing
UPWARD. Wipe the oil seal bore with a CLEAN lint CAUTION: Be sure that the bearing is in a
free cloth. straight position, in relationship to the
bore in the carrier, BEFORE starting to
b. Put CLEAN oil on the sealing face of the oil apply pressure with the arbor press.
seal. Put the oil seal onto a correct sized seal The bearing can be damaged during
installing tool. Carefully install the NEW oil seal into installation, if NOT correctly
the bore of the oil seal carrier, until the top of seal is positioned.
FLUSH with the top of the seal carrier.
c. Use the arbor press to SLOWLY “press” the
CAUTION: Do NOT install the oil seal below the bearing into the bearing bore, in the bearing carrier,
top of the seal carrier. until the top of the bearing is FLUSH with the top
[outer side] of the bearing carrier.
c. Put the complete seal and oil seal carrier
assembly on a CLEAN lint free cloth. CAUTION: Do NOT “press” the top of the bearing
to a point that is below the top of the
bearing carrier.
INSTALLATION OF THE VIBRATOR MECHANISM
BEARINGS INTO THE BEARING CARRIERS AND d. Remove the bearing/bearing carrier assembly
VIBRATOR HOUSING. from the arbor press and place on a CLEAN lint free
cloth.
CAUTION: Do the following assembly procedures
on a CLEAN surface, in a CLEAN work e. Thoroughly coat the inner bearing race, where it
area. Do NOT drop the bearing, or contacts the vibrator mechanism shaft, with lubricant,
carrier, during bearing installation. part number 933971.
The surfaces are machined to close
tolerances, and bearing failure, or oil CAUTION: Be sure to thoroughly coat the inner
leakage, can occur if the parts are bearing race with lubricant, part
damaged. number 933971. Bearing and/or shaft
failure can occur if not thoroughly
coated with lubricant.
11-26 9/2005
Section 11
f. Cover the bearing carrier and bearing with a WARNING: Wear eye protection during the snap
CLEAN lint free cloth. ring installation. Use care, during the
snap ring installation, so that the
NOTE: Repeat the above procedures to install the snap ring does not release from the
new bearing into the second bearing plier while under tension.
carrier, if needed.
e. Cover the end of the bearing support housing
and bearing with a CLEAN lint free cloth.
INSTALLATION OF THE BEARING INTO THE
IDLER BEARING SUPPORT HOUSING - C766C
machines below serial number 109C20902455 INSTALLATION OF THE BEARINGS INTO THE
and on C778B machines below serial number BEARING CARRIER - C766C machines serial
109B21501856 [See Figure 11-9]. number 109C20902455 and higher and on C778B
CAUTION: Do the following assembly procedures higher [See Figure 11-6A].
in a CLEAN work area.
CAUTION: Do the following assembly procedures
Use the following procedures to install a NEW in a CLEAN work area.
bearing into the idler bearing support housing:
Use the following procedures to install a NEW
a. Wipe the bearing bore, in the idler bearing bearing into the bearing carrier:
support housing, with a CLEAN lint free cloth.
a. Wipe the bearing bore, in the bearing carrier
b. Carefully place the NEW bearing into the housing, with a CLEAN lint free cloth.
bearing bore in the idler bearing support. Position the
bearing, so that it will enter the bore in a straight b. Carefully place the NEW bearing [11] into the
condition, while being “driven” into the bore. Put a bearing bore in the bearing carrier [13]. Position the
correct sized bearing installation tool onto the OUTER bearing, so that it will enter the bore in a straight
bearing race area. condition, while being “driven” into the bore. Put a
correct sized bearing installation tool onto the OUTER
CAUTION: Be sure that the bearing is in a bearing race area.
straight position in relationship to the
bore in the housing, BEFORE starting CAUTION: Be sure that the bearing is in a
to apply pressure to the tool with a straight position in relationship to the
hammer. The bearing can be damaged bore in the bearing carrier, BEFORE
during installation, if NOT correctly starting to apply pressure to the tool
positioned. with a hammer. The bearing can be
damaged during installation, if NOT
c. Use a large hammer to SLOWLY “drive” the correctly positioned.
bearing into the bearing bore, in the bearing carrier,
until the back side of the bearing is against the NOTE: Bearing installs from one [1] side only.
bearing support housing and the snap ring groove is
seen at the front side of the bearing. c. Use a large hammer to SLOWLY “drive” the
bearing [11] into the bearing bore, in the bearing
d. Use a large capacity snap ring plier to install the carrier [13], until the back side of the bearing is
large snap ring into the groove, in the support against the bearing support housing and the snap ring
housing, and against the outer side of the bearing. groove is seen at the front side of the bearing.
NOTE: Can also be installed by carefully using an

arbor press.
9/2005 11-27
Section 11
d. Use a large capacity snap ring plier to install b. Carefully place the NEW bearing [11] into the
the large snap ring [15] into the groove, in the bearing bore in the vibrator housing [14]. Position the
bearing carrier, and against the outer side of the bearing, so that it will enter the bore in a straight
bearing. condition, while being “driven” into the bore. Put a
correct sized bearing installation tool onto the OUTER
WARNING: Wear eye protection during the snap bearing race area.
ring installation. Use care, during the
snap ring installation, so that the CAUTION: Be sure that the bearing is in a
snap ring does not release from the straight position in relationship to the
plier while under tension. bore in the vibrator housing, BEFORE
starting to apply pressure to the tool
e. Insert inner ring [12] into bearing [11]. with a hammer. The bearing can be
damaged during installation, if NOT
f. Install seal [19] into seal carrier [18]. correctly positioned.
g. Use a large capacity snap ring plier to install NOTE: Bearings installs from one [1] side only.
snap ring [20] into seal carrier [18].
c. Use a large hammer to SLOWLY “drive” the
h. Cover the end of the bearing support housing bearing [11] into the bearing bore, in the vibrator
and bearing with a CLEAN lint free cloth. housing [14], until the back side of the bearing is
against the bearing support housing and the snap ring
groove is seen at the front side of the bearing.
INSTALLATION OF THE BEARINGS INTO THE
VIBRATOR HOUSING - C766C machines serial NOTE: Can also be installed by carefully using an
number 109C20902455 and higher and on C778B arbor press.
higher [See Figure 11-6A]. d. Use a large capacity snap ring plier to install the
large snap ring [15] into the groove, in the vibrator
CAUTION: Do the following assembly procedures housing, and against the outer side of the bearing.
in a CLEAN work area.
WARNING: Wear eye protection during the snap
ring installation. Use care, during the
Use the following procedures to install a NEW snap ring installation, so that the
bearing into the vibrator housing: snap ring does not release from the
plier while under tension.
a. Wipe the bearing bore, in the vibrator housing
[14], with a CLEAN lint free cloth. e. Cover the end of the vibrator housing and
bearing with a CLEAN lint free cloth.
11-28 9/2005
Section 11
VIBRATOR MECHANISM ASSEMBLY AND b. Go to the side of the drum where the drum
INSTALLATION INTO THE DRUM. drive motor will be installed later. If not previously
done, wipe the machined surfaces with cleaner, part
VIBRATOR MECHANISM ASSEMBLY AND number 934423 on a CLEAN lint free cloth. Put one
INSTALLATION INTO THE DRUM - C766C [1] continuous bead of Loctite #515, part number
machines below serial number 109C20902455 264159, just inside the bolt holes, around the
and on C778B machines below serial number circumference of the machined area of the drum
109B21501856 [See Figure 11-6A]. bulkhead, where the DRUM DRIVE side - vibrator
mechanism bearing carrier fastens to the drum
Use the following procedures to install the vibrator bulkhead.
mechanism into the drum:
NOTE: Also, put a bead of Loctite #515, part
CAUTION: Install the vibrator mechanism into the number 264159, around EACH of the eight
drum in a CLEAN work area. Dirt must [8] tapped holes in the machined surface
NOT be allowed to enter the drum of the drum.
cavity, or components, during
assembly. Do NOT drop ANY part as c. Install two [2] long and threaded alignment
the mechanism, and related parts, are studs into the two [2] tapped holes in the machined
installed into and onto the drum. ALL area of the drum bulkhead, at approximately the 9:00
parts are machined to close and 3:00 o’clock positions. Carefully put the bearing
tolerances, and leakage can occur if carrier in position OVER the alignment studs. Push
the parts are damaged. the bearing carrier inward, but NOT against, the
Clean ALL mating machined surfaces machined area of the drum bulkhead.
AND capscrew threaded areas with
cleaner, part number 934423, ONLY. NOTE: Do NOT install any of the eight [8] DRUM
Use ONLY lint free cloth during the DRIVE side bearing carrier retaining
cleaning and assembly procedures. capscrews, at THIS time.
Keep the hands in a CLEAN condition Also, leave the cover off of the bearing
when handling all parts. carrier at this time, to aid installation of
the vibrator mechanism into the drum and
NOTE: Use the following SAME procedures to allow for the lubricant retaining plate
install the vibrator mechanism into either installation onto the end of the vibrator
drum. mechanism shaft, later.
a. Wipe the inner side of the drum, where the d. Put one [1] continuous bead of Loctite #515,
vibrator mechanism is being installed, with a CLEAN part number 264159, just inside the bolt holes, around
lint free cloth and All-Purpose Degreaser, part number the circumference of the machined area of the drum
178297. Dry the area with compressed air. Remove bulkhead, where the VIBRATOR DRIVEN side
Loctite residue from all machined sealing surfaces. bearing carrier fastens to the drum bulkhead.
Also, clean ALL tapped holes, in the drum, using the
SAME method. Clean ALL machined drum surfaces NOTE: Also, put a bead of Loctite #515, part
using cleaner, part number 934423. number 264159, around EACH of the eight
[8] tapped holes in the machined surface
CAUTION: The inner cavity of the drum MUST be of the drum.
free of ALL dirt and oil not removed
when the drum was drained of oil
before disassembly. ALL Loctite
residue MUST be removed from all
machined sealing surfaces. ALL
machined drum surfaces MUST be
cleaned using cleaner, part number
934423.
9/2005 11-29
Section 11
e. Install only one [1] long and threaded j. Put Loctite #243, part number 934427, on the
alignment stud into the tapped hole, in the machined threaded area of the eight [8] capscrews that fasten
area of the drum bulkhead, at approximately the 9:00 the vibrator motor side bearing carrier to the drum.
o’clock position, at this time. Quickly install six [6] capscrews. Remove the two [2]
alignment studs. Install the two [2] remaining
NOTE: Install the second long and threaded capscrews. Tighten all eight [8] capscrews across
alignment stud into the tapped hole in the corners, or in a “star” pattern, to a torque of
machined area, of the drum bulkhead, at 115 ft. lbs. [156 N.m].
approximately the 3:00 o’clock position,
after the vibrator mechanism is inside the WARNING: Keep the shaft level and apply an
drum cavity. INWARD force to the shaft. The
mechanism/shaft assembly can fall
f. Move the vibrator/shaft assembly to the from the drum if NO effort is made to
VIBRATOR DRIVE end of the drum and place it on a keep pressure applied to the
CLEAN lint free cloth. Thoroughly coat the vibrator assembly.
mechanism shaft with lubricant, part number 933971,
where each end contacts each of the inner bearing k. Go to the drive motor side of the drum bearing
races. carrier. Hit the bearing carrier with a SOFT hammer to
“center” and install the bearing, onto the shaft, as the
CAUTION: Be sure to thoroughly coat EACH bearing carrier is moved inward until it rests
shaft contact surface with lubricant. completely against the machined area of the drum
bulkhead.
g. Carefully slide the vibrator side bearing carrier NOTE: Put a drift into the one [1] tapped hole in
[the one containing the two [2] dowel pins facing the end of the shaft to help keep the shaft
outward] onto the end of the vibrator mechanism and weight assembly in a horizontal and
shaft, having the four [4] drilled and tapped holes. level position during bearing carrier
installation.
h. Install the vibrator mechanism installation tool
[see Figure 11-5A] onto the driven end of the l. Put Loctite #243, part number 934427, on the
mechanism shaft having the four [4] drilled and threaded area of the eight [8] capscrews that fasten
tapped holes. Using a lifting strap and hoist, balance the drum drive motor side bearing carrier to the drum.
the vibrator/shaft installation tool and mechanism and Install six [6] capscrews. Remove the two [2]
move it into position, so that the end of the alignment studs. Install the two [2] remaining
mechanism shaft, that has the single tapped hole, is capscrews. Tighten all eight [8] capscrews across
installed into the drum cavity. corners, or in a “star” pattern, to a torque of 115 ft.
lbs. [156 N.m].
NOTE: At the same time, have an assistant reach
through the bearing bore with a long m. Put Loctite #243, part number 934427, on the
punch, and help “guide and position” the threaded area of the one [1] capscrew that fastens
shaft end as it enters the drum cavity. the lubricant retaining plate onto the end of the
vibrator mechanism shaft. Install the lubricant
i. Position the bearing carrier over the single retaining plate onto the end of the vibrator
alignment stud. While holding the assembly tool and mechanism shaft. Install the retaining capscrew and
mechanism/shaft assembly “level”, and keeping an tighten to a torque of 50 ft. lbs. [68 N.m].
inward force on the assembly, have an assistant
carefully move the bearing carrier inward, and over n. If not previously done, install the NEW oil seal
the alignment stud. Carefully push the assembly tool into the seal carrier plate [See this section].
and mechanism/shaft assembly further inward, and
then into, the drum cavity. Install the second
alignment stud through the bearing carrier and into
the tapped drum bulkhead hole at the 3:00 o’clock
position. Push the bearing carrier fully against the
drum bulkhead machined surface.
11-30 9/2005
Section 11
o. Remove the installation tool from the drive end u. Install the fan assembly over the dowel pin.
of vibrator mechanism shaft. Put Loctite #243, part Align the through holes, in the fan hub, with the three
number 934427, on the threaded area of the four [4] [3] tapped holes, in the vibrator drive coupling.
Allen capscrews that fasten the inner vibrator drive
coupling adapter to the vibrator mechanism shaft. CAUTION: Install the fan assembly with the
CHAMFERED area, on the inner side
p. Put the coupling adapter into position against of the hub, facing INWARD toward the
the shaft. Install the four [4] capscrews and tighten to center of the drum.
a torque of 78 ft. lbs. [106 N.m].
v. Install the inner vibrator drive coupling over the
q. If not previously done, clean the machined seal dowel pin and against the fan hub. Put the three [3]
carrier surface with cleaner, part number 934423. If Allen capscrews through the holes in the items just
not previously done, clean the machined vibrator side installed and tighten them into the tapped holes in the
bearing carrier surface, where the seal carrier vibrator drive coupling. Tighten the capscrews to a
mounts, with cleaner, part number 934423. Put torque of 40 ft. lbs. [54 N.m].
Loctite #515, part number 264159, on the bearing
carrier face, where the seal carrier mounts, and w. Go to the DRUM DRIVE motor side of the
around the eight [8] threaded holes in the bearing drum. Fasten a magnetic dial indicator onto the
carrier. bearing carrier. Move the vibrator mechanism and
shaft assembly fully toward the vibrator motor side of
r. Put white grease on the sealing lip of the oil the drum. Put the indicator tip against the lubricant
seal, that is installed into the oil seal carrier. Carefully retaining plate, installed onto the vibrator mechanism
install the seal lip over the outer side of the vibrator shaft, and “zero” the indicator. Have an assistant read
drive coupling adapter. Align the through holes, in the the dial indicator gauge. Push the vibrator mechanism
adapter, with the tapped holes in the bearing carrier. shaft fully toward the drum drive motor side of the
Push the oil seal carrier further inward, over the dowel drum. Read the end play [shaft travel] indicated on
pins, until the inner face of the seal carrier is against the gauge. If all components were correctly
the outer face of the bearing carrier. assembled, the indicated shaft end play will be as
given in the following “CAUTION”.
s. Put Loctite #243, part number 934427, on the
threaded area of the eight [8] capscrews that fasten CAUTION: For Model C766C and C778B the
the seal carrier to the bearing carrier. Install the correct end play will be 0.114 ±0.040
capscrews and tighten to a torque of 44 ft. lbs. inches [2.90 mm ±1.02 mm].
[69 N.m].
NOTE: If incorrect end play is found, recheck
t. Put a small amount of Loctite #243, part number both of the bearing - into bearing carrier -
934427, on the threaded area of the three [3] Allen installations. The bearings may NOT be
capscrews that fasten the inner vibrator drive coupling fully installed [seated] into the carriers.
to the vibrator mechanism shaft adapter.
x. Stay at the DRUM DRIVE motor side of the
CAUTION: Do NOT use a large amount of part drum. Put one [1] continuous bead of Loctite #515,
number 934427 on the capscrews. part number 264159, just inside the eight [8] bolt
Excess Loctite can enter the bearing holes, around the circumference of the outer face
and cause damage. area, on the vibrator mechanism bearing carrier.
NOTE: Also, put a bead of Loctite #515, part

number 264159, around EACH of the eight
[8] tapped holes in the bearing carrier
assembly.
9/2005 11-31
Section 11
y. Put Loctite #243, part number 934427, on the cc. Put Loctite #243, part number 934427, on the
threaded area of the eight [8] capscrews that fasten threaded area of the six [6] capscrews that fasten the
the cover to the bearing carrier assembly. While three [3] axle [spider] arms to the idler end of the
aligning the through holes in the cover with the tapped drum.
holes in the bearing carrier, install the cover onto the
bearing carrier. Hold the cover in place. Install the dd. Carefully align the six [6] through holes in the
eight [8] cover retaining capscrews. Tighten each axle [spider] arms with the tapped holes in the idler
capscrew to a torque of 44 ft. lbs. [69 N.m]. end of the drum. Install the six [6] capscrews,
Belleville washers and spacers and tighten to a
z. Fill the drum bearing lubrication system with torque of 500 ft. lbs. [678 N.m].
NEW and CORRECT oil [see Section 4 -
MAINTENANCE - in this manual for the CORRECT ee. Put Loctite #243, part number 934427, on the
procedures]. threaded area of the eight [8] capscrews that fasten
the vibrator motor mounting cover to the bearing
aa. If not factory installed, install two [2] spring support housing.
bushings into two [2], of the three [3], IDLER side axle
assembly [spider] arms. Install one [1] bushing into ff. Align the through holes, in the cover, with the
the right hand hole, in the arm in the 12:00 o’clock tapped holes in the support housing. Install the cover
position and install one [1] bushing into the upper onto the end of the housing. Hold the cover in place.
hole, in the arm in the 4:00 o’clock position, by Install the eight [8] cover retaining capscrews. Tighten
driving. Fasten a sling and a hoist, having a capacity each capscrew to a torque of 44 ft. lbs. [69 N.m].
of more than 500 lbs. [227 kg], to the IDLER side axle
assembly, so that the assembly will be in a balanced gg. Fasten a sling and a hoist, having a capacity of
condition when lifted. more than 1,000 lbs. [454 kg], to the drum drive
motor/motor carrier/vibrator isolator assembly, so that
bb. Carefully lift the axle assembly and move it the complete assembly will be in a balanced condition
into position near the splined drive end of the vibrator when lifted.
drive coupling shaft. Carefully align the bore in the
axle, so that it will pass over the vibrator drive hh. Carefully lift the above assembly and move it
coupling and shaft as the axle assembly is SLOWLY into position near the drum drive end of the drum.
moved inward, and positioned against, the three [3] Carefully and SLOWLY move the assembly inward
drum idler end connection points. and then position the flat mounting area of the
vibrator isolator against the four [4] drum mounting
WARNING: Keep CLEAR of the axle assembly pads.
while lifting, moving and positioning
the assembly onto the drum. WARNING: Keep CLEAR of the assembly and
drum area while lifting, moving and
CAUTION: Use CARE as the axle assembly is positioning the assembly onto the
installed. Do NOT permit the axle to drum.
tip, and then hit the coupling and shaft
as the axle assembly is installed. ii. Put Loctite #243, part number 934427, on the
ONLY one fourth [1/4] inch [7 mm] threaded area of the eight [8] capscrews that fasten
clearance exists between the vibrator the vibrator isolator/drum drive motor/motor carrier
drive coupling and the axle support assembly to the four [4] drum mounting pads.
housing during assembly. The vibrator
drive coupling and/or shaft can be jj. Carefully align the eight [8] through holes, in the
damaged and require replacement, vibrator isolator, with the tapped holes in the four [4]
with NEW. drum mounting pads. Install the eight [8] capscrews,
Belleville washers and spacers and tighten to a
torque of 500 ft. lbs. [678 N.m].
11-32 9/2005
Section 11
kk. Put Anti-Seize, part number 316865, on the NOTE: Use the following SAME procedures to
splined area of the vibrator motor shaft. Put Loctite assemble all four vibrator subassemblies.
#243, part number 934427, on the threaded area of Two [2] subassemblies have male shafts
the two [2] capscrews that fasten the vibrator motor to and two subassemblies have females
the motor mounting cover. shafts. The subassemblies attached to the
drive motor side of the drum have the
ll. Use the hands to lift the vibrator motor. Install male shaft and the subassemblies
the motor splined shaft into the spline at the end of attached to the vibrator motor side of the
the vibrator coupling and shaft. While aligning the drum have the female shaft.
motor mounting holes, with the tapped holes in the
mounting cover, push the vibrator motor into position a. Wipe the inner side of the vibrator housing [14],
against the mounting cover. where the vibrator mechanism is being installed, with
a CLEAN lint free cloth and All-Purpose Degreaser,
mm. Install the two [2] vibrator motor retaining part number 178297. Dry the area with compressed
capscrews with the two [2] spacers and tighten to a air. Remove Loctite residue from all machined sealing
torque of 90 ft. lbs. [122 N.m]. surfaces. Also, clean ALL tapped holes, in the vibrator
housing [14] and bearing carrier [13], using the SAME
CAUTION: Do NOT install the retaining method. Clean ALL machined drum surfaces using
capscrews without one [1] spacer on cleaner, part number 934423.
each capscrew. The capscrews will
contact the bearing locknut and can CAUTION: The inner cavity of the vibrator
cause damage. housing MUST be free of ALL dirt and
oil not removed when the vibrator
subassembly was disassembled. ALL
ASSEMBLY OF THE VIBRATOR SUBASSEMBLY Loctite residue MUST be removed
AND INSTALLATION INTO THE DRUM - C766C from all machined sealing surfaces.
machines serial number 109C20902455 and ALL machined surfaces MUST be
higher and on C778B machines serial number cleaned using cleaner, part number
109B21501856 and higher [See Figure 11-6A]. 934423.
ASSEMBLY OF THE VIBRATOR SUBASSEMBLY b. Install spacers [10] on previously assembled

[See Figure 11-6A] shaft [1] and insert shaft with the assembled vibrator
mechanism through the previously installed bearing
Use the following procedure to assemble the vibrator on the vibrator housing [14].
subassembly:
c. Install O-ring [16] into the vibrator housing [14].
CAUTION: Install the vibrator mechanism into the
vibrator housing in a CLEAN work
d. Put Loctite #242, part number 318702, on the
area. Dirt must NOT be allowed to
threaded area of the twelve [12] hex bolts [17] that
enter the housing, or components,
during assembly. Do NOT drop ANY fasten the bearing carrier [13] to the vibrator housing
part as the mechanism, and related [14].
parts, are installed into and onto the
vibrator housing. ALL parts are e. Attach the bearing carrier [13] to the vibrator
machined to close tolerances, and housing [14] with the twelve [12] hex bolts [17] and
leakage can occur if the parts are discs [6].
damaged.
Clean ALL mating machined surfaces f. Torque the twelve hex bolts [17] to 65 ft. lbs.
AND capscrew threaded areas with [88 N.m].
cleaner, part number 934423, ONLY.
Use ONLY lint free cloth during the
cleaning and assembly procedures.
Keep the hands in a CLEAN condition
when handling all parts.
9/2005 11-33
Section 11
g. Install O-ring [21] into the bearing carrier [13]. CAUTION: The inner cavity of the drum MUST be
free of ALL dirt and oil not removed
h. Put Loctite #242, part number 318702 , on the when the drum was drained of oil
threaded area of the eight [8] hex bolts [22] that before disassembly. ALL Loctite
fasten the seal carrier [18] to the bearing carrier [13]. residue MUST be removed from all
machined sealing surfaces. ALL
i. Attach the seal carrier [18] to the bearing carrier machined drum surfaces MUST be
[13] with the eight [8] hex bolts [22] and tightening cleaned using cleaner, part number
washers [23]. 934423.
j. Torque the eight hex bolts [22] to 37 ft. lbs. b. Go to the side of the drum where the drum drive
[50 N.m]. motor will be installed later. If not previously done,
wipe the machined surfaces with cleaner, part
number 934423, on a CLEAN lint free cloth.
INSTALLATION INTO THE DRUM [Figure 11-2A].
c. Install O-ring [22] in drum bulkhead on drum
Use the following procedures to install the vibrator drive side.
subassemblies and associated components into the
drum: d. Install two [2] long and threaded alignment
studs into the two [2] tapped holes in the machined
CAUTION: Install the vibrator subassembly into area of the drum bulkhead, at approximately the 9:00
the drum in a CLEAN work area. Dirt and 3:00 o’clock positions.
must NOT be allowed to enter the
drum cavity, or components, during NOTE: Be sure to use the vibrator subassembly
assembly. Do NOT drop ANY part as that has the male shaft [drive side]
the mechanism, and related parts, are vibrator assembly. Vibrator subassembly
installed into and onto the drum. ALL is installed with the male shaft facing
parts are machined to close inward away from the drive motor.
tolerances, and leakage can occur if
the parts are damaged. e. Attach Special Vibrator Mechanism Installation/
Clean ALL mating machined surfaces Removal tool [Figure 11-5B] to vibrator subassembly
AND capscrews threaded areas with [Figure 11-2A – 20] using three [3] capscrews [17],
cleaner, part number 934423, ONLY. and carefully put the vibrator subassembly [20] in
Use ONLY lint free cloth during the position OVER the alignment studs. Push the vibrator
cleaning and assembly procedures. subassembly inward, against, the machined area of
Keep the hands in a CLEAN condition the drum bulkhead [12] being careful not to damage
when handling all parts. the O-ring [22].
NOTE: Use the following SAME procedures to f. Install ten [10] of the twelve [12] hex bolts [18]
install the vibrator subassemblies into and discs [19] to fasten the vibrator subassembly [20]
either drum. to the drum bulkhead [12].
a. Wipe the inner side of the drum [12], where the

vibrator subassemblies are being installed, with a
CLEAN lint free cloth and All-Purpose Degreaser, part
number 178297. Dry the area with compressed air.
Remove Loctite residue from all machined sealing
surfaces. Also, clean ALL tapped holes, in the drum,
using the SAME method. Clean ALL machined drum
surfaces using cleaner, part number 934423.
11-34 9/2005
Section 11
g. Remove the two [2] alignment studs and install CAUTION: When installing the vibrator
the remaining two [2] of the twelve [12] hex bolts [18] subassembly on the alignments studs,
and discs [19]. be sure that the male shaft on the
drum drive side vibrator subassembly
h. Torque hex bolts [18] to 65 ft. lbs. [88 N.m]. and the female shaft on the vibrator
motor side are properly aligned so
i. Remove the three [3] capscrews [17] from the that the shafts will engage.
Special Vibrator Mechanism Installation/Removal tool.
Remove the Special Vibrator Mechanism Installation/ q. Attach Special Vibrator Mechanism Installation/
Removal tool from the vibrator subassembly [20]. Put Removal tool [Figure 11-5B] to vibrator subassembly
Loctite #242, part number 318702, on the threaded [Figure 11-2A – 9] using three [3] capscrews [8] and
area of the three [3] socket head capscrews [17] that carefully put the vibrator subassembly [9] in position
fasten the adapter-coupling [15] to the vibrator OVER the alignment studs. Push the vibrator
subassembly [20]. subassembly inward, against, the machined area of
the drum bulkhead [12] being careful not to damage
j. Attach adapter-coupling [15] to vibrator the O-ring [23].
subassembly [20] with three [3] socket head
capscrews [17]. NOTE: Make certain the two [2] shafts properly
engage.
k. Torque capscrews [17] to 91 ft. lbs. [123 N.m].
r. Install ten [10] of the twelve [12] hex bolts [10]
NOTE: Verify direction of the fan. Red marked and discs [11] to fasten the vibrator subassembly [9]
side must point to outside towards the to the drum bulkhead [12].
drum drive.
s. Remove the two [2] alignment studs and install
l. Install fan [16] to adapter-coupling [15] with four the remaining two [2] of the twelve [12] hex bolts [10]
[4] socket head capscrews [13] and discs [14]. and discs [11].
m. Torque capscrews [13] to 91 ft. lbs. [123 N.m]. t. Torque hex bolts [10] to 65 ft. lbs. [88 N.m].
n. Go to the side of the drum where the vibrator u. Remove the three [3] capscrews [8] from the
subassembly will be installed later. If not previously Special Vibrator Mechanism Installation/Removal tool.
done, wipe the machined surfaces with cleaner, part Remove the Special Vibrator Mechanism Installation/
number 934423, on a CLEAN lint free cloth. Removal tool from the vibrator subassembly [9]. Put
Loctite #242, part number 318702, on the threaded
o. Install O-ring [23] in drum bulkhead on vibrator area of the three [3] socket head capscrews [8] that
drive motor side. fasten the adapter-coupling [5] to the vibrator
subassembly [9].
p. Install two [2] long and threaded alignment
studs into the two [2] tapped holes in the machined v. Attach adapter-coupling [5] to vibrator
area of the drum bulkhead, at approximately the 9:00 subassembly [9] with three [3] socket head
and 3:00 o’clock positions. capscrews [8].
NOTE: Be sure to use the vibrator subassembly

that has the female shaft [vibrator motor
side] vibrator assembly. Vibrator
subassembly is installed with the female
shaft facing inward away from the vibrator
drive motor and toward the male shaft of
the previously installed vibrator
subassembly.
9/2005 11-35
Section 11
w. Torque capscrews [8] to 91 ft. lbs. [123 N.m]. b. Remove the electrical harness connection end
from the FRONT drum vibrator pump electronic
x. Attach shaft [21] to coupling [3] with four [4] displacement control valve. Put identification tags on
socket head capscrews [6] and discs [7]. all hydraulic hoses, that are connected to the pump.
Remove all hoses, which fasten to the hydraulic
y. Torque capscrews [6] to 91 ft. lbs. [123 N.m]. pump. Put plugs and caps on all hoses and fittings.
z. Install coupling [3] with attached shaft [21], and c. Fasten a sling and hoist, having a capacity
fan [4] over the dowel pin to adapter-coupling [5] with MORE than 200 lbs. [91 kg], around the
four [4] socket head capscrews [1] and discs [2]. circumference of the vibrator pump body. Use the
hoist to apply tension to the sling to keep the pump
NOTE: Verify direction of the fan. Blue marked assembly in a level, and balanced, position when the
side must point to outside towards the front vibrator pump mounting capscrews are loosened
vibrator subassembly and removed.
aa. Torque capscrews [1] to 91 ft. lbs. [123 N.m]. d. Remove the two [2] vibrator pump mounting
capscrews. Use the sling and hoist to carefully lift,
remove and then lower the pump assembly to the
ground. Remove the sling and hoist.
DRUM INSTALLATION.
Use the procedures given in Section 4 - WARNING: Keep CLEAR of the pump assembly
MAINTENANCE - “Removal Repair and Replacement and surrounding areas while lifting,
of the Vibration Isolator Tire and Rim Assemblies” to moving and lowering the pump
INSTALL the complete drum to the idler side vibration assembly.
isolator and then install that assembly into the
machine.
REAR PUMP REMOVAL [See Figure 11-10].
DRUM VIBRATION SYSTEMS - HYDRAULIC CAUTION: Do NOT remove the vibrator pump
VARIABLE DISPLACEMENT PUMPS. unless flow and pressure checks
indicate the pump is damaged and
FRONT PUMP REMOVAL [See Figure 11-10]. requires removal for major repair, at
an Authorized Sauer/Sundstrand
CAUTION: Do NOT remove the vibrator pump Service Center, or replacement with a
unless flow and pressure checks new, or remanufactured, pump.
indicate the pump is damaged and
requires removal for major repair, at
an Authorized Sauer/Sundstrand Use the following procedures to remove the REAR
Service Center, or replacement with a drum VIBRATOR PUMP assembly for disassembly,
new, or remanufactured, pump. inspection, repair or replacement:
a. Wash the pump, front motor mount bracket and

Use the following procedures to remove the FRONT pump drive assembly with All-Purpose Degreaser,
drum VIBRATOR PUMP assembly: part number 178297, and permit to air dry.
a. Wash the pump, and the rear area of the

transmission pump onto which it is mounted, with All-
Purpose Degreaser, part number 178297, and permit
to air dry.
11-36 9/2005
Section 11
b. Remove the electrical harness connection end REMOVAL, REPAIR, OR REPLACEMENT, OF
from the REAR drum vibrator pump electronic COMPONENTS OF THE DRUM VIBRATOR
displacement control valve. Put identification tags on PUMPS.
all hydraulic hoses, that are connected to the pump.
Remove all hoses, which fasten to the hydraulic MINOR REPAIRS - GENERAL INFORMATION
pump. Put plugs and caps on all hoses and fittings. [See Figure 11-11].
c. Fasten a sling and hoist, having a capacity The following components are the only components
MORE than 250 lbs. [114 kg], around the that can be removed, repaired or replaced without
circumference of the rear vibrator pump body. Use canceling the pump warranty. See your nearest
the hoist to apply tension to the sling to keep the Distributor for complete warranty information.
pump assembly in a level, and balanced, position
when the vibrator pump mounting capscrews are 1. Gerotor charge pump [on FRONT pump].
loosened and removed. 2. Electronic displacement control valve
assembly.
d. Remove the two [2] vibrator pump mounting 3. Drive shaft and/or shaft seal.
capscrews. Carefully use the sling and hoist to hold, 4. Charge pressure relief valve.
remove, and then lower, the vibrator pump from the 5. System check relief [SCR] valve cartridge
front engine mount bracket and pump drive coupling. assemblies.
Lower the pump to the ground. Move the pump
assembly from under the machine and remove the The following components can be removed from the
sling and hoist. pump, and replaced with new, without removing the
complete pump from the machine:
WARNING: Keep CLEAR of the pump assembly a. Gerotor charge pump assembly [on FRONT
and surrounding areas while lifting, pump].
moving and lowering the pump b. Electronic displacement control valve
assembly. assembly.
c. Charge pressure relief valve.
d. System check relief [SCR] valve cartridge
assemblies.
Use the following procedures to remove, inspect and

replace the above components of the vibrator
pump[s], if needed:
FIGURE 11-10. FRONT AND REAR DRUM

VIBRATOR PUMPS - INSTALLED.
9/2005 11-37
Section 11
FIGURE 11-11. VIBRATOR PUMP COMPONENT FIGURE 11-12. GEROTOR CHARGE PUMP
LOCATIONS. LOCATION - ON FRONT VIBRATOR PUMP.
GEROTOR CHARGE PUMP. d. Remove the gerotor cover locating pin from
the pump housing. Put a paper cover over the
GEROTOR REMOVAL/DISASSEMBLY opening in the pump housing and tape in position to
[See Figure 11-12]. keep dirt out.
CAUTION: Before disassembling the charge

pump, wash the charge pump cover
and the pump housing with All- INSPECTION [See Figure 11-13].
Purpose degreaser, part number
178297 and dry with compressed air. a. Wash ALL of the parts with All-Purpose
Degreaser, part number 178297 and dry using
compressed air.
a. Make a scribed line on the charge pump cover
and on the pump housing, at the point where the b. Inspect the inner area of the charge pump cover
parts are joined, to identify the correct position and gerotor cover for wear, or damage. Replace, with
relationship of each part. Remove the seven [7] Torx NEW, if worn, or damaged.
screws that fasten the charge pump cover to the
pump housing. c. Carefully inspect the gerotor charge pump
assembly for wear, or damage. If either assembly part
b. Carefully remove the charge pump cover from is worn, or damaged, replace BOTH gerotor parts
the pump housing and place on a CLEAN lint free with NEW, as a SET.
cloth. Carefully remove the gerotor cover from the
pump housing and place on a CLEAN lint free cloth. d. Inspect the journal bearing, in the gerotor cover,
for excessive wear, or damage. Replace, the cover
c. Remove the two [2] gerotor cover o-rings. with NEW, if worn, or damaged.
Carefully remove the gerotor from the pump housing
and place on a CLEAN lint free cloth. Remove the
gerotor drive pin and drive coupling.
11-38 9/2005
Section 11
e. Inspect the drive coupling for wear or damage. d. Carefully install drive coupling onto the pump
The coupling teeth must NOT be worn, or damaged. shaft, with the smaller outside diameter facing away
Replace the coupling, with new, if ANY wear or from the pump shaft.
e. Carefully install the gerotor assembly onto the

drive coupling.
GEROTOR INSTALLATION/ASSEMBLY [See
Figure 11-13]. f. Install the gerotor cover locating pin into the
pump housing. Install the gerotor cover assembly
a. Before assembly put CLEAN hydraulic oil on the over the gerotor, while aligning the scribe marks.
gerotor assembly.
b. Remove the paper cover from the opening in CAUTION: The charge pump rotation is
the vibrator pump housing. determined by the location of the
gerotor recess and pressure balance
c. Install the gerotor drive pin into the hole in the holes in the gerotor cover. Different
drive coupling and retain with grease, or petroleum gerotor covers are used for clockwise
jelly. [CW] and counterclockwise [CCW]
rotation pumps.
NOTE: The locating pin MUST engage the slot in

the gerotor cover.
FIGURE 11-13. GEROTOR CHARGE PUMP COMPONENTS - ON FRONT VIBRATOR PUMP.
9/2005 11-39
Section 11
g. Install NEW pressure balance o-rings onto the SYSTEM CHECK RELIEF [SCR] VALVE
gerotor cover and retain with grease or petroleum CARTRIDGES.
jelly.
REMOVAL, INSPECTION AND INSTALLATION [See
h. Install the charge pump cover locating pins, into Figures 11-14 and 11-15].
the pump housing. Install a NEW charge pump cover
gasket onto the pump housing. Install the charge
pump cover over the new gasket. NOTE: The SYSTEM CHECK RELIEF [SCR] valve
cartridge assemblies incorporate the
charge check valve and high pressure
CAUTION: The charge pump cover MUST engage relief valve functions. One [1] cartridge
the gerotor cover and locating pins. controls these functions for the LOW
vibration frequency mode direction and
one [1] cartridge controls these functions
i. Install the seven [7] charge pump cover retaining for the HIGH vibration frequency mode
screws. Tighten the screws, evenly, to a torque of 26- direction.
32 ft. lbs. [36-43 N.m].
The cartridge assemblies are intended to be removed

NOTE: The REAR vibrator pump is used without ONLY for cleaning, inspection and installation of new
an integral charge pump and does NOT o-rings, using the following information.
have a gerotor assembly, gerotor drive
pin, or gerotor cover locating pin. The
charge pump inlet port is "plugged' with CAUTION: The cartridge contained system high
an o-ring plug, tightened to a torque of 50 pressure relief valves are
ft. lbs. [68 Nm]. manufacturer set and are NOT
adjustable.
j. Check the hydraulic oil level in the reservoir and

add APPROVED oil, if needed [See Section 4 - a. STOP the engine. Clean BOTH valve cartridges
MAINTENANCE]. and the vibrator pump housing area where they are
installed with All-Purpose Degreaser, part number
178297, and dry with compressed air.
CAUTION: Follow ALL “System Pre-Start and
Start-Up Procedures” [see Section 8 -
TRANSMISSION SYSTEM] BEFORE
the engine is started. Damage to the
vibrator pump[s] can occur, if the
engine is started without doing the
procedures.
FIGURE 11-14. SYSTEM CHECK RELIEF [SCR]

VALVE ASSEMBLY - INSTALLATION LOCATIONS.
11-40 9/2005
Section 11
b. Put a 1 inch wrench on the hex of the system
check relief [SCR] valve seat plug being removed.
Remove the plug from the pump housing bore. Scribe
the installation position [TOP or BOTTOM] on the hex
nut, after the plug is removed. If needed, remove and
identify the second valve seat plug.
c. Wash the valve seat plug with All-Purpose

ART Degreaser, part number 178297 and dry using
compressed air.
d. Remove the relief valve assembly from the

pump housing.
CAUTION: The smaller end of each conical

spring is crimped, to retain it on the
relief valve. Do NOT remove the
spring.
e. Inspect the relief valve assembly and mating

seat, in the valve seat plug, for damage or
contamination.
CAUTION: The relief valves are manufacturer set

and are NOT adjustable. If the relief
valve is damaged and/or causes high,
or low, relief pressure, replace the
SCR valve assembly with NEW.
FIGURE 11-15. SYSTEM CHECK RELIEF [SCR]
VALVE ASSEMBLY - EXPLODED VIEW.
f. Install a new outer o-ring, new backup ring and
new inner o-ring on the valve seat plug.
g. Check that the conical spring is properly

centered on the relief valve. Install the high pressure
relief valve assembly into the pump housing.
CAUTION: The conical spring must be correctly

positioned on the relief valve
assembly, after installation, for proper
pump operation.
h. Install the valve seat plug into the pump housing

and tighten to a torque of 30-70 ft. lbs. [40-95 N.m]
9/2005 11-41
Section 11
i. Check the hydraulic oil level in the reservoir and c. Remove the seven [4] retaining screws [Torx
add APPROVED oil, if needed [See Section 4 - T30] that secure the control valve to the pump
MAINTENANCE]. housing. Carefully swing the control valve away from
the pump housing to release the summing link pin the
control piston fork and remove the control valve.
CAUTION: Follow ALL “System Pre-Start and Remove the control gasket from the pump housing.
the engine is started. Damage to the CAUTION: Note the position of the different
vibrator pump[s] can occur, if the length screws as they are removed.
engine is started without doing the The screws MUST be installed in the
procedures. correct positions when the control
valve is installed onto the pump
housing.
Do NOT permit the gasket to fall into
CHARGE CHECK VALVES. the pump housing.
REMOVAL, INSPECTION AND INSTALLATION [See

Figures 11-14 and 11-15]. d. Remove any gasket material remaining on the
control valve and/or the mating area on the pump
The charge check valve is an integral part of each body.
system check relief [SCR] valve cartridge assembly.
e. Put a NEW control valve to main pump body
The cartridge assemblies are intended to be removed gasket in place on the pump housing.
ONLY for cleaning, inspection and installation of new
o-rings [See this section].
CAUTION: The control orifices are part of the
control gasket. Be sure that the
correct new gasket is used for correct
ELECTRONIC DISPLACEMENT CONTROL [EDC] pump performance.
VALVE.
REMOVAL AND REPLACEMENT

[See Figure 11-16]. f. Move the displacement control valve into
position at the pump housing. Hold the summing link
Use the following procedures to remove and replace pin in position while installing the control valve. Put
the electronic displacement control [EDC] valve the summing link pin into the hole in the control piston
assembly used on both vibrator pump assemblies: fork. Push the link pin completely into the fork.
a. Wash the displacement control valve, and the

area where it is mounted to the pump housing, with CAUTION: Failure to properly engage the
All-Purpose Degreaser, part number 187297 and dry summing link pin with the control
using compressed air. piston fork will result in incorrect
control operation, which can lead to
b. Remove the electrical harness connection end loss of machine vibration system
from the pump displacement control valve. Move the control. The spring on the control
electrical harness to a position away from the spool will tend to push the summing
displacement control valve. link pin to an extreme position, past
the hole in the control piston fork. The
link pin must engage the hole in the
control piston fork.
11-42 9/2005
Section 11
NOTE: It can be easiest to lay the servo piston VIBRATOR PUMP SHAFT AND SHAFT SEAL.
side of the control down first, then watch
the link pin engage the hole, in the control REMOVAL, INSPECTION AND INSTALLATION [See
piston fork, from the charge pump side of Figure 11-17].
the pump.
Use the following procedures to remove and replace
the vibrator pump shaft and/or shaft seal with new:
g. Carefully hold the control valve in position while
aligning the through holes, in the displacement control
valve, with the matching holes in the gasket and CAUTION: ALL shaft seal parts MUST be replaced
pump housing. with NEW after removal.
h. Carefully install the seven [7] retaining screws

through the control valve and gasket, at the
CORRECT positions noted during disassembly, and NOTE: The VIBRATOR pump assembly MUST be
thread them into the tapped holes in the pump removed from the machine [see THIS
housing. Tighten the capscrews to a torque of 11-13 section for procedures] before the shaft
ft. lbs. [15-17 N.m]. and/or shaft seal can be removed and
replaced with new.
CAUTION: The screws MUST be installed in the

CORRECT positions when the control a. With the vibrator pump assembly removed from
valve is installed onto the pump the machine, and on a CLEAN work surface, Place
housing. the assembly, so that the pump shaft faces upward.
i. Move the electrical harness into position at the CAUTION: If the pump is positioned horizontally,
displacement control valve. Install the electrical when the shaft is removed, the
harness connection end onto the pump displacement cylinder block can move out of place,
control valve, and tighten. making shaft installation difficult.
FIGURE 11-16. ELECTRONIC DISPLACEMENT CONTROL [EDC] VALVE - INSTALLATION ON PUMP.
9/2005 11-43
Section 11
b. Use internal snap ring pliers to carefully remove e. Inspect the seal carrier and the NEW seal for
the retaining snap ring from the bore inside the pump damage. Inspect the sealing area, on the shaft, for
housing. rust, wear, or contamination. Polish the sealing area,
on the shaft, if needed.
WARNING: Wear eye protection during snap ring f. To help prevent leaks, caused by damage to the
removal. Use care when removing seal bore, in the carrier, coat the outside diameter of
the snap ring. the NEW seal with a sealant, such as Loctite High
Performance Sealant #59231, prior to seal
installation. Press the new seal into the shaft bearing
c. Carefully pull the seal carrier from the bore. side of the seal carrier, with the seal lip facing the
Remove the o- ring from the seal carrier. OUTSIDE of the pump.
NOTE: To install a new shaft only, proceed to CAUTION: Do NOT damage the seal during
step "g". installation.
d. Place the seal carrier in an arbor press, with the g. Remove the shaft and roller bearing assembly
shaft bearing side facing DOWN and press out the from the pump housing. If not worn, or damaged,
old seal. Discard the seal. It MUST be replaced with transfer the bearing assembly to the new shaft [see
NEW, once removed. steps "h" and "i"].
NOTE: An appropriately sized pipe spacer, or

socket, can be used as a press tool.
FIGURE 11-17. VIBRATOR PUMP SHAFT AND SHAFT SEAL INSTALLATION.
11-44 9/2005
Section 11
h. Use internal snap ring pliers to carefully remove n. Install the vibrator pump assembly into the
the retaining snap ring that secures the roller bearing machine [see THIS Section].
assembly in the bore of the pump housing. Remove
the roller bearing assembly. o. Check the hydraulic oil level in the reservoir and
add APPROVED oil, if needed [See Section 4 -
MAINTENANCE].
WARNING: Wear eye protection during snap ring
removal. Use care when removing
the snap ring. CAUTION: Follow ALL “System Pre-Start and
i. Place the removed, or new, roller bearing the engine is started. Damage to the
assembly on the new shaft. Use internal snap ring vibrator pump[s] can occur, if the
pliers to carefully install the retaining snap ring that engine is started without doing the
secures the roller bearing assembly in the bore of the procedures.
pump housing.
WARNING: Wear eye protection during snap ring CHARGE PRESSURE RELIEF VALVE ASSEMBLY.
installation. Use care when installing
the snap ring into the bore. REMOVAL, CLEANING, INSTALLATION OF NEW
O-RINGS AND INSTALLATION [See Figure 11-18].
j. Wrap the shaft spline area with thin plastic to Both the front, and the rear, vibrator pumps use a
help prevent damage to the seal lip during installation. charge pressure relief valve, even though only the
Lubricate the inside diameter of the shaft seal with front vibrator pump has a complete gerotor charge
petroleum jelly. pump assembly.
k. Place a new o-ring onto the shaft bearing and The relief valve assembly can be removed for
lubricate with petroleum jelly. cleaning, inspection and installation of new o-rings.
l. Carefully slide the seal carrier assembly over the The charge relief pressure, on each pump, is shim
shaft and into the pump housing bore. Press the adjusted and can be changed [see THIS Section].
carrier against the o-ring. Hold inward pressure
against the shaft to compress the cylinder blockspring Use the following information to remove, clean,
while pressing the seal carrier into place. inspect, install new o-rings and install the relief valve
assembly back into the pump housing:
m. Use internal snap ring pliers to carefully install
the retaining snap ring that secures the seal carrier a. Remove the single shim adjustable charge relief
assembly in the bore of the pump housing. Remove valve plug from the pump housing.
the thin plastic from the splined area of the shaft.
b. Remove the spring, shim[s] and poppet from
the housing. Inspect the poppet and mating seat, in
WARNING: Wear eye protection during snap ring the housing, for damage , or contamination. Clean
installation. Use care when installing contamination from the parts, and/or replace
the snap ring into the bore. damaged parts with new.
CAUTION: Do NOT change the number of shims

which may be installed between the
spring and valve plug, or interchange
parts from another valve assembly.
9/2005 11-45
Section 11
c. Install a NEW o-ring on the valve plug. Install MAJOR VIBRATOR PUMP REPAIR.
the inspected, or new, poppet and spring into the
pump housing. Put the shim[s] into the plug. Install Only the following components CAN be removed,
the cap over the spring and thread into the housing. repaired, or replaced, WITHOUT canceling the pump
Tighten the plug to a torque of 40-100 ft. lbs. [55-135 warranty.
N.m].
1. Gerotor charge pump.
d. Check the hydraulic oil level in the reservoir and 2. Charge pressure relief valve.
add APPROVED oil, if needed [See Section 4 - 3. Electronic displacement control valve
MAINTENANCE]. assembly.
4. Shaft and/or shaft seal.
5. System check valve [SCR] cartridge
CAUTION: Follow ALL “System Pre-Start and assemblies.
TRANSMISSION SYSTEM] BEFORE If the vibrator pump has failed, or test results indicate
the engine is started. Damage to the that service to components, other than those listed
vibrator pump[s] can occur, if the above are needed, it is intended that major repairs be
engine is started without doing the done ONLY by Sauer/Sundstrand "Authorized Service
procedures. Centers" or that the pump be replaced with a new, or
remanufactured, assembly.
e. Check, and if needed adjust, the charge relief

pressure using the procedures given in THIS section. CAUTION: See the nearest HYPAC Distributor for
side cover. It is intended that major
repairs be done ONLY by Saur/
Sundstrand Authorized Service
Centers.
FIGURE 11-18. CHARGE PRESSURE RELIEF

VALVE COMPONENTS .
11-46 9/2005
Section 11
FRONT VIBRATOR PUMP INSTALLATION CAUTION: Do NOT start the engine BEFORE the
[See Figure 11-10]. hydraulic oil level, in the reservoir, is
at the CORRECT level.
Use the following procedures to install the FRONT Do NOT start the engine until ALL
drum vibrator pump assembly: “pre-start procedures”, given in
Section 8 - TRANSMISSION SYSTEM,
a. Move the front drum vibrator pump assembly have been done. Damage to the
into position under the machine. Fasten a sling and a hydraulic system components can
hoist, having a capacity more than 200 lbs. [91 kg], to occur if all “pre-start procedures” are
the vibrator pump assembly, so that it will be in a not done.
balanced condition when lifted.
b. Put anti-size grease, part number 316865, on g. Start the engine. Check for CORRECT
the splined area of the vibrator pump INPUT shaft. operation of ALL systems. Check for ANY fluid leaks.
Use the sling and hoist to carefully lift the pump. Keep
the pump input shaft in a position, so that it is in
alignment with the center splined sleeve end of the WARNING: Do NOT use the hands on ANY
charge pump on the TRANSMISSION pump. Fully hydraulic hose, fitting or system
install the splined input shaft into the splined sleeve component to check the system for
and push the pump mounting area fully against the possible leaks. Serious injury can
auxiliary pump mounting pad. occur from a leak under high
pressure. Use a piece of cardboard to
c. Put Loctite #242, part number 318702, on the check for leaks. Wear safety glasses
thread area of the two [2] capscrews that fasten the to protect the eyes. Get IMMEDIATE
vibrator pump to the auxiliary pump mounting plate. medical attention if oil enters the
Install the pump retaining capscrews and tighten to a eyes, or skin.
torque of 105 ft. lbs. [145 N.m]. Remove the sling and
hoist from the pump assembly.
d. Remove the caps from all fittings and the plugs REAR VIBRATOR PUMP INSTALLATION [See
from all hoses. Install each hose onto the CORRECT Figure 11-10].
pump fitting as indicated by the identification tags.
Tighten each hose securely onto each fitting. Use the following procedures to install the REAR
drum vibrator pump assembly:
CAUTION: Connect ALL hoses to the fittings on a. Move the REAR drum vibrator pump assembly
the hydraulic pump as indicated by into position under the machine, so that the electric
the identification tags put on the solenoids will be at the bottom when the pump
hoses and fittings before removal of assembly is lifted. Fasten a sling and a hoist, having a
the pump. capacity more than 200 lbs. [91 kg], to the vibrator
pump assembly, so that the pump will be in a
balanced condition when lifted.
e. Install the electrical harness end onto the
vibrator pump electronic displacement control. b. Put Anti-Seize, part number 316865, on the
splined area of the vibrator pump input shaft. Use the
f. Add APPROVED hydraulic oil, as needed, to the sling and hoist to carefully lift the pump and put the
hydraulic oil reservoir using the procedures given in pump input shaft in a position, so that it is in
Section 4 - MAINTENANCE. Follow ALL “Pre-Start alignment with the center splined sleeve in the pump
Procedures” given in Section 8 - TRANSMISSION drive center sleeve. Carefully install the splined input
SYSTEM - BEFORE starting the engine. shaft into the splined center sleeve and push the
pump mounting area fully against the pump mounting
area, of the front engine mount bracket.
9/2005 11-47
Section 11
c. Put Loctite #242, part number 318702, on the WARNING: Do NOT use the hands on ANY
thread area of the two [2] capscrews that fasten the hydraulic hose, fitting or system
rear drum vibrator pump to the front engine mount component to check the system for
bracket. Install the pump mounting capscrews and possible leaks. Serious injury can
tighten to a torque of 88 ft. lbs. [120 N.m]. Remove occur from a leak under high
the sling and hoist from the pump assembly. pressure. Use a piece of cardboard to
check for leaks. Wear safety glasses
d. Remove the caps from all fittings and the plugs to protect the eyes. Get IMMEDIATE
from all hoses. Install each hose onto the CORRECT medical attention if oil enters the
pump fitting as indicated by the identification tags. eyes, or skin.
Tighten each hose securely onto each fitting or install,
and then securely tighten, the flange retaining
capscrews. CAUTION: STOP the engine IMMEDIATELY if ANY
fluid leak is noted. Do NOT start the
engine until any problem noted has
NOTE: Connect ALL hoses to the fittings of the been corrected.
hydraulic pump as indicated by the
identification tags put on the hoses and
fittings before removal of the pump.
VIBRATOR PUMP PRESSURE CHECKS AND
ADJUSTMENTS.
e. Install the electrical harness end onto the
vibrator pump electronic displacement control. CHECKING AND ADJUSTMENT PROCEDURES.
f. Add APPROVED hydraulic oil, as needed, to the The following information describes the remote
hydraulic oil reservoir using the procedures given in pressure check port locations, gauge sizes needed,
Section 4 - MAINTENANCE. Follow ALL “Pre-Start correct pressures and suggested methods for
Procedures” given in Section 8 - TRANSMISSION changing an incorrect system pressure. Capped
SYSTEM - BEFORE starting the engine. system gauge ports are provided for the various
pressure checks usually needed to be made.
CAUTION: Do NOT start the engine BEFORE the Raise EACH frame corner of the machine, so that the
hydraulic oil level, in the reservoir, is drums are clear of the ground. Install stands, or solid
at the CORRECT level. wood blocks, under the frame at EACH frame corner
Do NOT start the engine until ALL location.
“pre-start procedures”, given in
Section 8 - TRANSMISSION SYSTEM,
have been done. Damage to the WARNING: Block SECURELY, using steel stands,
hydraulic system components can or solid wood blocks. Keep ALL
occur if all “pre-start procedures” are personnel, except the operator and
not done. an assistant - when needed, CLEAR
of the machine during pressure
checking procedures. Use ONLY the
g. Start the engine. Check for CORRECT CORRECT gauge, on a hose, for each
operation of ALL systems. Check for ANY fluid leaks. pressure check.
11-48 9/2005
Section 11
CAUTION: The hydraulic system oil MUST be at NOTE: If checking the FRONT vibrator pump
“normal operating” temperature, and case drain oil pressure, remove the
at the correct level, BEFORE any service access door retaining capscrews
pressure check is taken. The engine and door. Wipe the case drain oil hose,
throttle MUST be in the correct idle coming from the FRONT vibrator pump,
“condition” for each pressure check. with a CLEAN cloth. Wipe the outlet
Do NOT perform ANY vibration system fitting, installed into port “L1” at the side
pressure checks while the drums are of the front vibrator pump housing, with a
on a hard surface. Perform ALL CLEAN cloth.
checks with the drums clear of the Remove the case drain hose, from the
ground. outlet fitting installed into port “L1”,
Install, and securely tighten, an 8 x 8 x 8
swivel "tee" fitting between the outlet
fitting and the case drain hose.
VIBRATOR PUMPS CASE DRAIN OIL PRESSURE Install, and securely tighten, an 8 x4
[See Figures 11-19 and 11-20]. adapter fitting onto the remaining "port"
of the "tee" fitting. Install a 500 psi. [35
Either vibrator pump's case drain oil pressure can be bar] pressure gauge, on a long hose
checked at hose connection locations, as described which will reach the cockpit area, onto the
in the following information. #4 outlet of the adaptor fitting and tighten
securely.
Use the following general procedures to check either,
or both, vibrator pump case drain oil pressures:
CAUTION: Keep the machine in a raised and

supported condition, so that BOTH
drums are clear of the ground [see
Pressure Check Procedures -
“General Information”, in this
section].
a. Keep the secondary/parking brake system

control switch “ON” [APPLIED]. STOP the engine. If
checking the REAR vibrator pump case drain oil
pressure, remove the left access plate retaining
capscrews and plate. Wipe the rear vibrator pump
case drain hose outlet fitting installed onto the "tee"
fitting at port “L2”, on the upper area of the
transmission pump housing, with a CLEAN cloth.
b. Remove the rear vibrator pump case drain

hose, from the outlet "tee" fitting installed into port
“L2”. Install, and securely tighten, a 8 x 8 x 8 swivel FIGURE 11-19. REAR VIBRATOR PUMP CASE
"tee" fitting between the outlet fitting and the case DRAIN OIL PRESSURE CHECK LOCATION.
drain hose, going to the case drain "tee" fitting in port
“L2” on the upper area of the transmission pump.
Install, and securely tighten, a 8 x4 adapter fitting
onto the remaining "port" of the "tee" fitting. Install a
500 psi. [35 bar] pressure gauge, on a long hose
which will reach the cockpit area, onto the #4 outlet of
the adaptor fitting and tighten securely.
9/2005 11-49
Section 11
d. Slow the engine and allow to run at “LOW” idle
for a period of 3-5 minutes. STOP the engine.
e. If the REAR vibrator pump case drain oil

pressure was checked, remove the pressure gauge
and hose assembly from the adaptor fitting. Remove
the case drain hose from the “tee” fitting. Remove the
“tee” fitting from the case drain "tee" fitting in port
“L2”, on the upper area of the transmission pump.
Install, and securely tighten, the rear vibrator pump
case drain hose onto the case drain "tee" fitting in
port “L2”, on the upper area of the transmission
pump.
f. Go to the left side of the rear frame. Install the

pump access cover.
NOTE: If the FRONT vibrator pump case drain oil

FIGURE 11-20. FRONT VIBRATOR PUMP CASE pressure was checked, remove the
DRAIN OIL PRESSURE CHECK LOCATION. pressure gauge and hose assembly from
the adaptor fitting. Remove the case drain
hose from the “tee” fitting. Remove the
“tee” fitting from the pump case drain
c. Start the engine. Put the drum vibrator systems outlet fitting.
location control, at the position matching the drum Install, and securely tighten, the front
supply pump that IS being “checked” [FRONT, or vibrator pump case drain hose onto the
REAR]. Put drum vibrator high/low frequency control case drain outlet fitting, in port “L1”.
in the LOW or HIGH vibrator amplitude position and Install the left service access door.
adjust the frequency above 2000 VPM. Put the
vibration system mode selection switch in the
MANUAL position. Push either directional/speed
control handle mounted START/STOP switch and
start the drum vibration system. Note the CASE drain
oil pressure indicated on the pressure gauge for the
vibrator pump being checked. Push the directional/
speed control handle mounted switch and STOP the
drum vibration system.
CAUTION: The pressure readings MUST be

BELOW 40 psi. [3 bar] MAXIMUM.
Make a note of this pressures for use
in determining OTHER vibrator pump
pressures. A pressure reading ABOVE
40 psi. [3 bar] is an indication of
internal leakage, or high “back
pressure”, in the pump which can
require that the pump be removed
from the machine and be repaired, or
replaced.
11-50 9/2005
Section 11
VIBRATOR PUMPS CASE DRAIN OIL FLOW
AMOUNT [See Figures 11-21 and 11-22].
Either vibrator pump's case drain oil flow amount can

be checked at hose connection locations, as
described in the following information.
Use the following general procedures to check either,

or both, vibrator pump case drain oil flow amount:
CAUTION: Keep the machine in a raised and

supported condition, so that BOTH
drums are clear of the ground [see
Pressure Check Procedures -
“General Information”, in this
section]. FIGURE 11-21. REAR VIBRATOR PUMP CASE
DRAIN OIL FLOW AMOUNT CHECK LOCATION.
a. Keep the secondary/parking brake system

control switch “ON” [APPLIED]. STOP the engine. If
checking the REAR vibrator pump case drain oil flow
amount, remove the vibrator pump access plate
retaining capscrews and plate. Wipe the hose, and
outlet fitting installed into port “L1”, on the VIBRATOR
pump housing, with a CLEAN cloth.
b. Remove the case drain hose, from the outlet

fitting installed into port “L1”, Install an oil flow meter
between the outlet fitting and the case drain hose,
going to the case drain "tee" fitting in port “L2” on the
upper area of the transmission pump.
NOTE: If checking the FRONT vibrator pump

case drain oil flow amount, remove the
left service access door retaining
FIGURE 11-22. FRONT VIBRATOR PUMP CASE
capscrews and door. Wipe the case drain
DRAIN OIL FLOW AMOUNT CHECK LOCATION.
oil hose, coming from the FRONT vibrator
pump, with a CLEAN cloth. Wipe the
outlet fitting, installed into port “L1” at the
side of the front vibrator pump housing,
with a CLEAN cloth.
Remove the case drain hose, from the
outlet fitting installed into port “L1”,
Install an oil flow meter between the outlet
fitting and the case drain hose.
9/2005 11-51
Section 11
c. Start the engine. Put the drum vibrator systems NEUTRAL CHARGE PRESSURE - FRONT
location control, at the position matching the drum VIBRATOR PUMP.
supply pump that IS being “checked” [FRONT or
REAR]. Put drum vibrator high/low frequency control CHECKING AND ADJUSTMENT PROCEDURES
in the LOW or HIGH vibrator amplitude position and [See Figures 11-23 and 11-24].
adjust the frequency above 2000 VPM. Put the
vibration system mode selection switch in the The capped neutral charge pressure check port is
MANUAL position. Push either directional/speed found with the “remote pressure check ports ”
control handle mounted START/STOP switch and installed on the left rear frame rail of the machine.
start the drum vibration system. Have an assistant Check and, if needed, adjust this pressure as follows:
note the CASE drain oil flow amount indicated on the
oil flow meter for a fifteen [15] second period. Push a. Find, and note, the front vibrator case drain oil
the directional/speed control handle mounted switch pressure by using the procedures given in THIS
and STOP the drum vibration system. section. Keep the secondary/parking brake system
control switch “ON” [APPLIED]. STOP the engine.
Wipe the pressure check port cap and the area
CAUTION: The oil flow amount noted must not around it with a CLEAN cloth.
be more than one [1] quart [0.95 l]. A
flow amount that is above the given b. Remove the cap from the charge pressure
amount is an indication of internal check port. Install a 1000 psi. [69 bar] gauge, on a
leakage, in the pump, which can short hose, with quick connection fitting, onto the
require that the pump be removed check port fitting.
from the machine and be repaired, or
replaced. c. Start the engine. Allow the hydraulic oil to reach
a warm temperature. Put the engine throttle in the
“HIGH” idle position. Leave the vibration system OFF.
d. Slow the engine and allow to run at “LOW” idle Have an assistant note the charge pressure indicated
for a period of 3-5 minutes. STOP the engine. on the pressure gauge. The CORRECT manufacturer
set pump neutral charge pressure is 300 psi. [21 bar]
MINIMUM to 400 psi. [28 bar] MAXIMUM, ABOVE
e. If the REAR vibrator pump case drain oil case pressure. A typical pressure usually noted is
pressure was checked, remove the oil flow meter 350 psi. [24 bar].
from the between the pump and the case drain "tee"
fitting in port “L2”, on the upper area of the d. Slow the engine to “LOW” idle speed and run
transmission pump. Install, and securely tighten, the for a period of 3-5 minutes. STOP the engine. If the
rear vibrator pump case drain hose onto the case pressure noted was as given, ABOVE, remove the
drain "tee" fitting in port “L2”, on the upper area of the pressure check gauge and hose from the pressure
transmission pump. check port. Install, and then tighten, the check port
f. Go to the right side of the rear frame. Install the
rear vibrator pump access cover.
NOTE: The neutral charge relief pressure MUST
be adjusted if the charge pressure noted
NOTE: If the FRONT vibrator pump case drain oil was NOT as given above, by using the
pressure was checked, remove the oil following ADDITIONAL information. Low
flow meter from the pump case drain charge pressure, can indicate possible
outlet fitting and the case drain oil hose. internal charge pump leakage, which
Install, and securely tighten, the front requires removal, repair, or replacement,
vibrator pump case drain hose onto the of the gerotor charge pump components
case drain outlet fitting, in port “L1”. [See THIS section].
Install the left service access door.
11-52 9/2005
Section 11
1. Keep the engine “OFF”. Wipe the area of the
front vibrator pump housing section, where the
charge relief valve assembly is installed, with a
clean cloth [See Figure 8-21].
2. Remove the charge relief valve plug, from the

pump housing, using a 1 inch hex wrench.
3. Add, or subtract shims between the inner side

of the relief valve plug and the relief valve
spring and, thereby, change the neutral charge
pressure. Install the cap, and shim[s] over the
spring and thread the plug into the housing.
Tighten the plug to a torque of 40-100 ft. lbs.
[55-135 N.m].
FIGURE 11-23. FRONT VIBRATOR PUMP -

NOTE: ADDING shim[s] will INCREASE the
NEUTRAL CHARGE PRESSURE CHECK PORT
amount of neutral charge pressure.
LOCATION.
REMOVING shim[s] will DECREASE the
amount of neutral charge pressure.
Adding, or subtracting, ONE [1] 0.050
inch [1.25 mm] shim changes the neutral
charge pressure approximately 58 psi.
[4 bar].
4. Check the NEUTRAL charge pressure, again,

using the above procedures. If needed, repeat
the adjustment procedure, again, until the
pressure indicated is CORRECT.
e. Remove the gauge and hose assembly from

the pressure check port. Install, and then tighten, the
FIGURE 11-24. FRONT VIBRATOR PUMP -

NEUTRAL CHARGE PRESSURE ADJUSTMENT
LOCATION.
9/2005 11-53
Section 11
VIBRATOR PUMP HIGH PRESSURE RELIEF a. Keep the secondary/parking brake system
VALVES - PRESSURE CHECK [See Figures switch “ON”. STOP the engine. Go to the left hand
11-25 and 11-26]. side of the rear frame area. Locate the FRONT drum
vibration system high relief pressure check ports at
The two [2] capped system FRONT drum vibration the top of the left rear frame rail. Clean the high
system remote pressure check ports are found at the pressure check port caps with a CLEAN cloth.
top of the left rear frame rail. Remove the cap from the pressure check port fittings.
Install a 10,000 psi. [690 bar] pressure gauge,
The two [2] capped system REAR drum vibration connected to a hose that will reach the outer area of
system remote pressure check ports are found at the the machine, onto the “high”, and “low”, amplitude
top of the right rear frame rail. high relief pressure check port fitting.
The two [2] high pressure relief valves are contained b. Go to the right hand side of the rear frame area.
in the system check relief [SCR] valve cartridge Locate the REAR drum vibration system high relief
assemblies, which are installed into both the front and pressure check ports at the top of the right rear frame
rear vibrator pump housings [See this section]. rail. Clean the high pressure check port caps and the
pump area around them with a CLEAN cloth. Remove
the cap from the pressure check port fittings. Install a
NOTE: The system check relief [SCR] valve 10,000 psi. [690 bar] pressure gauge, connected to a
cartridge assemblies incorporate the hose that will reach the outer area of the machine,
charge check valve and high pressure onto the “high”, and “low”, amplitude high relief
relief valve functions. One [1] cartridge pressure check port fitting.
controls these functions for the LOW
vibration frequency mode direction and
one [1] cartridge controls these functions WARNING: Except for the OPERATOR and an
for the HIGH vibration frequency mode ASSISTANT, Keep ALL personnel
direction. Each of the high pressure relief CLEAR of the MACHINE and the
valves will start to open and work in the surrounding AREA during THIS
high pressure system, when the high “pressure check” procedure.
system pressure which that valve
monitors, and maintains, reaches the
preset adjusted pressure. c. Start the engine. Put the drum vibrator systems
location control, at the position matching the drum
supply pump that IS being “checked” [FRONT or
Use the following information to check either vibration REAR]. Put drum vibrator high/low frequency control
system high, or low, amplitude relief pressures. in the LOW vibrator amplitude position and adjust the
frequency above 2000 VPM. Put the vibration system
The cartridge assemblies are intended to be removed mode selection switch in the MANUAL position. Push
ONLY for cleaning, inspection and installation of new either directional/speed control handle mounted
o-rings, using the following information. START/STOP switch and start the drum vibration
system. Have an assistant note the high system
pressure, indicated on the pressure gauge, for the low
CAUTION: The cartridge contained system high amplitude mode. Push the directional/speed control
pressure relief valves are handle mounted switch and STOP the drum vibration
manufacturer set and are NOT system.
adjustable.
11-54 9/2005
Section 11
d. Put drum vibrator high/low frequency control in f. Remove the gauge and hose assemblies from
the HIGH vibrator amplitude position and adjust the all four [4] remote pressure check ports. Install, and
frequency above 2000 VPM. Keep the vibration then tighten, the cap onto each check port fitting.
system mode selection switch in the MANUAL
position. Push either directional/speed control handle
mounted START/STOP switch and start the drum
vibration system. Have an assistant note the high
system pressure, indicated on the pressure gauge,
for the high amplitude mode. Push the directional/
speed control handle mounted switch and STOP the
drum vibration system.
NOTE: The CORRECT pressure indicated on the

pressure gauge should NOT be MORE
than 4,600 +50 psi. [317 +3 bar]. After a
few minutes of vibrator system operation,
the pressure indicated on the pressure
gauge should lower to, and stabilize at, a
pressure below 3,000 psi. [207 bar]
[typical 2,200 psi., 152 bar].
e. Repeat steps “c” and “d” to check the low, and FIGURE 11-25. FRONT VIBRATION SYSTEM -
high, amplitude relief pressures for the other drum's REMOTE HIGH PRESSURE CHECK PORT
vibration system. If all relief pressures were correct, LOCATIONS.
slow the engine to “LOW” idle and run for a period of
3-5 minutes. STOP the engine.
CAUTION: The cartridge assembly contained

system high pressure relief valves are
manufacturer set and are NOT
adjustable.
If the LOW, or HIGH, amplitude relief
pressures, for either drum's vibration
system, was NOT correct, the relief
pressure[s] must be changed by the
removal and replacement of the
system check relief [SCR] valve
cartridge assembly containing the
system high pressure relief valve [see
THIS section for procedures].
NOTE: The LOW amplitude relief valve assembly

FIGURE 11-26. REAR VIBRATION SYSTEM -
is the contained in the TOP system check
REMOTE HIGH PRESSURE CHECK PORT
relief [SCR] valve cartridge assembly. The
LOCATIONS.
HIGH amplitude relief valve assembly is
the contained in the BOTTOM system
check relief [SCR] valve cartridge
assembly.
9/2005 11-55
Section 11
g. Put REAR drum vibrator pump access cover NOTE: The vibrator motors are considered to be
into position on the rear frame. Install, and then a "remove and replace" with NEW
securely tighten, the four [4] plate retaining component. Usually, if a vibrator motor
capscrews. Put service access covers in position on has developed internal damage, replace
the left side of, and above, the rear frame. Install, and the motor with NEW. Minor oil leakage
then securely tighten, the covers retaining capscrews. may be able to be corrected by using the
"seal kit".
h. Use a floor jack, having a capacity of more than
10,000 lbs. [4540 kg], to lift EACH frame corner, in
turn, and remove the stand, or blocking. Lower the INSTALLATION [See Figure 11-27].
machine to the ground.
Use the following procedures to install the vibrator
motor:
WARNING: Keep clear of the jack, frame, stand,
or blocking and the drum while a. Put anti-seize, part number 316865, on the
lifting, removing support and splined area of the motor shaft. Carefully put the
lowering. vibrator motor in position on the vibrator motor
mounting cover.
VIBRATION SYSTEMS - HYDRAULIC MOTORS. CAUTION: Do NOT drop the motor while it is
being installed onto the cover.
Use the following procedures to remove either of the

vibration system hydraulic vibrator motors from the b. Put Loctite #242, part number 318702, on the
machine for replacement: threaded area of the two [2] capscrews that fasten the
vibrator motor to the mounting cover. Install the
a. Wash the vibrator motor, and the area of the capscrews. Tighten the capscrews to a torque of 90
drum where it is mounted, with All-Purpose ft. lbs. [122 N.m].
compressed air. c. Remove the plugs from the high pressure hoses
and the caps from motor port fittings. Install each
b. Put an identification tag on each hose which is hose to the CORRECT motor port fitting as indicated
fastened to the motor. Remove the high pressure by the identification tags and tighten securely.
hoses from the vibrator motor fittings. Put plugs in the
hoses and caps on the motor port fittings. d. Remove the plug from the motor case drain
hose and the cap from the motor fitting. Install the
c. Remove the motor case drain hose from the hose onto fitting and tighten securely.
motor fitting. Put a plug in the hose and a cap on the
fitting. e. Prime the system using the “Pre-Start
Procedures” given in Section 8 - TRANSMISSION
d. Remove the two [2] capscrews that fasten the SYSTEM.
motor to the vibrator motor mounting cover.
e. Carefully remove the motor from the cover, and CAUTION: Do NOT start the engine BEFORE
then move it away from the machine. preforming ALL “Pre-Start
Procedures”. Damage to hydraulic
system components can occur if the
CAUTION: Do NOT drop the vibrator motor as it system has NOT been completely
is removed from the cover. filled with oil.
11-56 9/2005
Section 11
VIBRATION ISOLATOR TIRE/WHEEL/HOOP
ASSEMBLIES.
REMOVAL, REPAIR OR REPLACEMENT AND

INSTALLATION.
Remove, repair or replace and install the vibration

isolator tire, wheel and hoop assemblies by using the
information given in Section 4 - MAINTENANCE - of
this manual.
CLEANER BEAM AND RUBBER CLEANER

ASSEMBLIES.
REMOVAL, REPLACEMENT AND ADJUSTMENT.
Remove, replace and adjust the four [4] cleaner

beam and drum cleaning rubber cleaner assemblies
by using the information given in Section 4 -
MAINTENANCE - of THIS manual. FIGURE 11-27. HYDRAULIC VIBRATOR MOTOR -
INSTALLED ONTO DRUM.
9/2005 11-57
Section 11
TROUBLE ANALYSIS FOR THE DRUM, VIBRATION, AND CLEANER BAR SYSTEMS
DRUM AND VIBRATION

NO DRUM VIBRATION, Master “AUTO/OFF/MANUAL” Put switch in MANUAL position.
WHEN SYSTEM IS IN switch at “OFF”
MANUAL OPERATING
CONDITION, FROM Engine throttle switch NOT in high Put switch in high idle position.
EITHER DRUM, IN EITHER idle speed position
THE “LOW” OR “HIGH”
AMPLITUDE MODE Transmission range switch NOT Put switch in "WORK" [low] position.
in "WORK" [low] position
Master “AUTO/OFF/MANUAL” Remove and replace switch.

switch damaged
“START/STOP” push button Put switch in “START” position.

switch in “STOP” position
“START/STOP” push button Remove and replace switch.

switch damaged
BOTH drum vibrator frequency Remove and replace drum vibrator

controls damaged controls [see Section 7].
Electrical circuit has damage Inspect and check circuit. Repair as

needed [see Section 7].
Low oil level in hydraulic oil Add oil as needed. Find and correct
reservoir cause of low oil level.
Vibrator pumps have internal Check operation. Remove, repair or

damage replace as needed [see THIS
section].
Oil supply hose[s] are in stopped Check hose[s] for stoppage. Remove
condition and clean, or replace, as needed.
Vibrator motors have internal Remove and replace with NEW.

damage
Vibration mechanisms have Remove, repair and install

internal damage mechanism as needed.
11-58 9/2005
Section 11
DRUM AND VIBRATION
NO DRUM VIBRATION, ONE [1] drum vibrator frequency Remove and replace damaged
WHEN SYSTEM IS IN control has damage . vibrator control [see Section 7].
MANUAL OPERATING
CONDITION, FROM ONE Electrical circuit to electronic Repair circuits [see Section 7].
[1] DRUM, in EITHER THE displacement control solenoid, on
“LOW” OR “HIGH” one [1] pump, has damage
AMPLITUDE MODE.
OTHER DRUM SYSTEM Electronic displacement control Remove and replace solenoid [see
OPERATES NORMALLY solenoid, on one [1] pump, has Section 7].
damage
One [1] vibrator pump has Remove, repair, or replace, pump.

damage
One [1] vibrator motor has Remove and replace motor with
damage NEW.
Vibration mechanism in one [1] Remove, repair and install

drum has damage mechanism as needed.
WHEN IN MANUAL “LOW” amplitude circuit to Check circuit. Repair as needed [see
OPERATION MODE, NO electronic displacement control Section 7].
“LOW” AMPLITUDE solenoid, on both pumps, has
OPERATION AT EITHER damage
DRUM. “HIGH”
AMPLITUDE MODE Electronic displacement control Remove and replace electronic
OPERATES NORMALLY AT solenoid, on each pump, has solenoid, with NEW.
BOTH DRUMS damage
Displacement control valve, on Remove and replace control valves

BOTH vibrator pumps, has with NEW.
damage and function for one [1]
pump direction of rotation ONLY
Both vibrator pumps have internal Remove, repair, or replace, both

damage and operate in one [1] pumps.
direction of rotation ONLY
Both vibrator motors have internal Remove and replace both motors
damage and operate in one [1] with NEW.
Both vibration mechanisms have Remove, repair and install both

damage that does NOT permit mechanisms as needed.
them to operate in the “LOW”
amplitude mode
9/2005 11-59
Section 11
DRUM AND VIBRATION
NO DRUM VIBRATION, Master “AUTO/OFF/MANUAL” Put switch in AUTOMATIC position.
WHEN SYSTEM IS IN switch in “OFF” or “MANUAL”
AUTOMATIC OPERATING position
CONDITION, FROM
EITHER DRUM, IN EITHER Engine throttle switch NOT in high Put switch in high idle position.
THE “LOW” OR “HIGH” idle speed position
AMPLITUDE MODE
Transmission range switch NOT Put switch in "WORK" [low] position.
Vibration “START/STOP” speed Adjust “AUTO VIB” vibrator “start/

“set” above the speed at which stop” speed to a LOWER speed
machine is traveling point [see Section 3].
Master “AUTO/OFF/MANUAL” Remove and replace switch with

switch damaged NEW.
BOTH drum vibrator frequency Remove and replace frequency

controls have damage controls [see Section 7].

reservoir cause of low oil level.
Vibrator pumps have internal Check operation. Remove, repair or

damage replace as needed [see THIS
section].
Oil supply hose[s] are in stopped Check hose[s] for stoppage. Remove
condition and clean or replace as needed.
Vibrator motors have internal Remove and replace with NEW.

damage
Vibration mechanisms have Remove, repair and install

internal damage mechanism as needed.
11-60 9/2005
Section 11
DRUM AND VIBRATION
NO DRUM VIBRATION, One [1] drum vibrator frequency Remove and replace damaged
WHEN SYSTEM IS IN control has damage vibrator control [see Section 7].
AUTOMATIC OPERATING
CONDITION, FROM ONE Drum vibrator frequency control Repair circuit [see Section 7].
[1] DRUM, IN EITHER THE electrical circuit to one [1] pump
“LOW” OR “HIGH” has damage
AMPLITUDE MODE.
OTHER DRUM SYSTEM Electronic displacement control, Remove and replace displacement
OPERATES NORMALLY or solenoid, on one [1] pump has control, or solenoid, [see this section,
damage and/or Section 7].

damage
damage NEW.

WHEN IN AUTOMATIC Both vibrator system frequency Remove and replace controls with
OPERATION MODE, NO controls have damage NEW [see Section 7].
“LOW” AMPLITUDE
OPERATION AT EITHER Drum vibrator frequency control Check circuits. Repair as needed
DRUM. “HIGH” electrical circuits, to both pumps, [see Section 7].
AMPLITUDE MODE have damage
OPERATES NORMALLY AT
BOTH DRUMS Electronic displacement control, Remove and replace control valves
or solenoid, on both] pumps have with, or solenoids, NEW [see this
damage and function for one [1] section, and/or Section 7].
pump direction of rotation ONLY
Both vibrator pumps have internal Remove, repair, or replace, both

damage and operate in one [1] pumps.
Both vibrator motors have internal Remove and replace both motors
damage and operate in one [1] with NEW.
Both vibration mechanisms have Remove, repair and install both

damage that does NOT permit mechanisms as needed.
them to operate in the “LOW”
amplitude mode
9/2005 11-61
Section 11
DRUM AND VIBRATION
NO DRUM VIBRATION, ONE [1] drum vibrator frequency Remove and replace damaged
WHEN SYSTEM IS IN control has damage vibrator control [see Section 7].
MANUAL, OR AUTOMATIC,
OPERATING CONDITION, Drum vibrator frequency control Repair circuit [see Section 7].
FROM ONE [1] DRUM, IN electrical circuit to one [1] pump
ONLY THE “LOW”, OR has damage
“HIGH”, AMPLITUDE
MODE. OTHER DRUM Electronic displacement control, Remove and replace displacement
SYSTEM OPERATES or solenoid, on one [1] pump has control, or solenoid, [see this section,
NORMALLY damage and/or Section 7].

damage
damage NEW.

VIBRATION OUTPUT Engine HIGH idle speed NOT set Adjust HIGH idle speed to
FROM BOTH DRUMS IS to CORRECT specification CORRECT RPM [See Section 2].
NOT TO SPECIFICATION,
IN BOTH “HIGH”, AND Incorrect oil TYPE in hydraulic Drain and flush system. Fill with
“LOW”, AMPLITUDE system NEW and CORRECT oil [See
MODE [VPM LOW] Section 4].
Incorrect drum bearing lubrication Drain oil from BOTH drums. Fill with
oil TYPE/WEIGHT in BOTH NEW and CORRECT oil [see
drums Section 4].
reservoir cause for low oil level.
Low drum bearing lubrication oil Add oil as needed. Find and correct
level in BOTH drums IN cause for low oil level.
BOTH vibrator pumps have Check operation and flow. Remove,

damage repair, or replace, as needed [see
THIS section].
Oil supply hose[s] are in a partially Check hose[s] for stoppage. Remove
stopped condition and clean, or replace, as needed.
BOTH vibrator motors have Remove and replace with NEW.

internal damage
BOTH vibration mechanisms Remove, repair and install as

have internal damage needed.
11-62 9/2005
Section 11
DRUM AND VIBRATION
VIBRATION OUTPUT Incorrect drum bearing lubrication Drain oil from the drum. Fill with
FROM ONE [1] DRUM IS oil TYPE/WEIGHT in ONE [1] NEW and CORRECT oil [see
NOT TO SPECIFICATION, drum Section 4].
IN BOTH “HIGH”, AND
“LOW”, AMPLITUDE Low drum bearing lubrication oil Add oil as needed. Find and correct
MODE [VPM LOW] level in ONE [1] drum cause for low oil level.
One [1] vibrator pump has Check operation and flow. Remove,
damage repair, or replace, as needed [see
THIS section].
One [1] vibrator motor has internal Remove and replace with NEW.
damage
One [1] vibration mechanism has Remove, repair and install as

internal damage needed.
DRUM VIBRATION Low lubrication oil level Add oil as needed. Find and correct
MECHANISM BEARING cause of low oil level.
LUBRICATION OIL AT A
HOT TEMPERATURE Incorrect oil used as lubrication oil Drain drum of oil, flush and replace
DURING OPERATION with CORRECT type lubrication oil
[see Section 4].
Drum installed cooling fan NOT Remove drum. Install, or replace,

installed, or has damage cooling fan as needed [see THIS
section].
Vibration mechanism bearings Remove mechanism. Disassemble,

have damage inspect, replace bearing[s] as
needed. Clean drum lubrication area,
install mechanism and fill with NEW
and filtered lubrication oil [see THIS
section].
9/2005 11-63
Section 11
DRUM AND VIBRATION
VIBRATION FROM DRUM Incorrect [high] inflation air Reduce inflation air pressure in tire[s]
TRANSMITTING INTO pressure in vibration isolator tire[s] to CORRECT pressure [see Section
MACHINE FRAME 4].
Incorrect vibration isolator tire[s] Remove tire[s] and replace with

installed, as replacement, on CORRECT APPROVED tire[s].
machine
EXCESSIVE DRUM Incorrect [low] inflation air Increase inflation air pressure in
MOVEMENT BETWEEN pressure in vibration isolator tire[s] tire[s] to CORRECT pressure [see
THE FRAME SIDES Section 4].
Incorrect vibration isolator tire[s] Remove tire[s] and replace with

installed, as replacement, on CORRECT APPROVED tire[s].
machine
HYDROSTATIC VIBRATOR PUMPS

NO PUMP OUTPUT FROM Drum vibrator MODE selector Put MODE selector switch in either
EITHER PUMP, IN EITHER switch “OFF” “MANUAL”, or “AUTOMATIC”, mode
THE “MANUAL”, OR position.
“AUTOMATIC”,
OPERATION MODE, IN Engine throttle switch NOT in high Put switch in high idle position.
EITHER “HIGH”, OR idle speed position
“LOW”, AMPLITUDE
RANGE Transmission range switch NOT Put switch in "WORK" [low] position.
Hydraulic system oil level low Check oil level in reservoir. Add oil.
Find and correct cause of low oil
level.
Vibration “START/STOP” speed Adjust “AUTO VIB” vibrator “start/

“set” above the speed at which stop” speed to a LOWER speed
machine is traveling point [see Section 3].
Master “AUTO/OFF/MANUAL” Remove and replace switch with

switch damaged NEW.
BOTH drum vibrator frequency Remove and replace frequency

controls have damage controls [see Section 7].

Check electric control system.
11-64 9/2005
Section 11
NO PUMP OUTPUT FROM Repair as needed [see Section 7 -
EITHER PUMP, IN EITHER ELECTRICAL SYSTEM].
THE “MANUAL”, OR Low oil level in hydraulic oil Check oil level in reservoir. Add oil.
“AUTOMATIC”, reservoir Find and correct cause of low oil level.
OPERATION MODE, IN
EITHER “HIGH”, OR Very cold oil in system Permit system to warm.
“LOW”, AMPLITUDE
RANGE Wrong oil in hydraulic system Drain and flush ENTIRE hydraulic
[CONT] system. Install CORRECT hydraulic
oil [see Section 4 - MAINTENANCE].
Air being drawn into system Check ALL fittings and hoses for
correct tightness. Tighten as needed.
Low, or no, charge pressure from Replace gerotor charge pump

gerotor charge pump components as needed [see this
section].
Charge pressure check valves Replace system check relief [SCR]

damaged, or stay in open position valve cartridge assemblies, as
needed [see this section].
Charge pressure relief valve[s] Clean, or replace, charge check

damaged, or stay in open position valve[s] components, as needed [see
this section].
Inlet oil strainer in a stopped Drain reservoir of oil. Remove, clean

condition and install oil strainer.
Pressure oil filter element in a Remove and replace element with

stopped condition NEW.
Internal damage to BOTH vibrator Remove, repair, or replace, pumps

pump assemblies as needed and install [see this
section].
Damage to BOTH vibrator motors Remove and replace with NEW [see
this section].
ALL high pressure relief valves [in Remove, inspect, clean, or replace
system check relief [SCR] valve SCR valve cartridge assemblies with
cartridge assemblies] in open NEW, as needed [see this section].
[relief] position
9/2005 11-65
Section 11
IN “MANUAL”, OR, Electrical circuit for function NOT Check vibration electric control
“AUTOMATIC” MODE, operating has damage system [see Section 7 -
ONE [1] VIBRATOR PUMP ELECTRICAL SYSTEM].
WILL SUPPLY OIL FLOW
FOR ONLY THE “HIGH”, Electronic displacement control, Remove and replace displacement
OR “LOW”, AMPLITUDE or solenoid, on one [1] pump has control, or solenoid, [see this section,
MODE - OTHER DRUM damage and/or Section 7].
SYSTEM OPERATES
NORMALLY One [1] charge pressure check Identify check valve , remove
valve ,in system check relief cartridge, clean, or replace, [SCR]
[SCR] valve cartridge assembly, valve cartridge assembly, as needed.
is damaged
One [1] high pressure relief valve, Identify relief valve, and remove
in system check relief [SCR] valve cartridge assembly. Clean, or
cartridge assembly, is damaged replace, [SCR] valve cartridge
assembly, as needed.
Hose carrying HIGH pressure Locate stopped hose, remove, clean

from pump in one [1] direction in a or replace, as needed.
stopped condition
One [1] vibrator motor has Remove and replace motor, with
damage - operates in one [1] NEW.
direction only
11-66 9/2005
Section 11
NEUTRAL POSITION Pump electronic displacement Remove displacement control.
DIFFICULT OR NOT ABLE control has damage Replace with NEW.
TO BE FOUND ON
PUMP[S] Electric control system for Check vibration electric control
vibration system has damage system [see Section 7 -
ELECTRICAL SYSTEM].
Charge pressure LOW Check charge pressure. Repair, or

replace, gerotor charge pump
components, as needed.
Vibration pump displacement Remove complete pump assembly

control piston has damage and have authorized Sauer/
Sundstrand Service Center repair
pump assembly.
Vibration pump rocker cam Remove complete pump assembly

swashplate and/or link has and have authorized Sauer/
damage Sundstrand Service Center repair
pump assembly.
PUMP OPERATES IN A Hydraulic system oil level low Check oil level in reservoir. Add oil.
HOT CONDITION Find, and correct, cause of low oil
level.
Wrong hydraulic oil being used in Drain and flush system. Install NEW,
hydraulic system CORRECT and FILTERED oil [see

replace pressure oil filter element. Fill
reservoir with NEW oil [See Section
4 - MAINTENANCE].
Oil cooler needs to be cleaned of Clean oil cooler to remove dirt [see
dirt Section 4 - MAINTENANCE].
9/2005 11-67
Section 11
PUMP OPERATES IN A Oil cooler damaged, or in a Remove oil cooler. Clean, repair or
HOT CONDITION. (CONT) stopped condition replace as needed.
System return oil diffuser in a Remove and clean diffuser [see

stopped condition Section 4 - MAINTENANCE].
Hydraulic oil being heated through Check high pressure relief valve
HIGH pressure relief valve[s] pressure[s] in the system. Replace,
action [SCR] valve cartridge assemblies, as
needed [see THIS Section].
Pump has internal leakage Remove, inspect, repair, or replace,

[usually noted with loss of power, pump and install as needed [see
VPM speed and high case drain THIS Section].
oil pressure and flow amount]
Vibrator motor[s] have internal Remove motor[s] and replace with

damage [usually noted with a loss NEW.
of power, speed and a high case
drain oil pressure and flow
amount] CAUTION: CLEAN the ENTIRE
hydraulic system
AFTER a failure.
VIBRATOR PUMP[S] AND Hydraulic system oil level low Check oil level in reservoir. Add oil.
SYSTEM NOISY DURING Find and correct cause of low oil
OPERATION level.
Hose, fitting, or filter, loose - Check ALL fittings and hoses for
permitting air to be drawn into the correct tightness. Tighten as needed.
system Check pressure oil filter element for
tightness.
Pump has internal wear, or Follow pressure check procedures in

damage THIS Section. If pump has damage -
have authorized Sauer/ Sundstrand
Service Center repair pump, or
replace, with new or rebuilt
assembly.
CAUTION: Clean the ENTIRE

hydraulic system
AFTER a failure.
Hoses not correctly insulated from Check hose routings. They must
vibration or not in CORRECT NOT touch any metal that can
position increase natural hydraulic system
“hum”.
11-68 9/2005
Section 11
VIBRATOR PUMP[S] DO Hydraulic system oil level low Check oil level in reservoir. Add oil.
NOT DEVELOP CORRECT Find and correct cause of low oil
OIL FLOW, OR PRESSURE level.
Air being drawn into system See “System noisy during operation”
- Air in system.
Low, or no, charge pressure Disassemble, inspect and replace

gerotor charge pump components as
needed [see THIS section].
Pump electronic displacement Remove and replace displacement

control has damage control valve, with new.
Pump has internal wear, or Remove complete pump assembly

damage and have authorized Sauer/
Sundstrand Service Center repair
pump assembly, or replace with
NEW, or remanufactured pump.
VIBRATOR MOTOR
NO OUTPUT SHAFT NO oil flow being supplied from See “Vibrator Pump Trouble
ROTATION FROM vibrator pump Analysis” in THIS Section.
VIBRATOR MOTOR
Oil supply hose[s] are in a Check hose[s] for stoppage. Remove
Vibrator motor has internal Remove and replace with NEW.

damage
LOW OUTPUT SHAFT LOW oil flow from the vibrator See “Vibrator Pump Trouble
ROTATION SPEED FROM pump Analysis” in THIS Section.
VIBRATOR MOTOR
Vibrator motor has internal Remove and replace with NEW.

damage
9/2005 11-69
Section 11
VIBRATION ISOLATOR TIRE, WHEEL AND HOOP ASSEMBLIES
ISOLATOR TIRE[S] WILL Valve cap missing and/or inflation Remove and replace or tighten
NOT HOLD CORRECT valve core loose, or damaged, inflation valve core. Inflate tire[s] to
INFLATION PRESSURE and permits air to be lost from CORRECT pressure. Install and
tire[s] tighten tire valve cap.
Tire bead to bead seat area of Remove tire and wheel . Seal tire to
wheel NOT sealing bead seat area AGAIN [see Section
4].
Isolator tire[s] have puncture or Remove tire and wheel . Dismount,

separation in body or other repair, or replace, tire as needed
damage [see Section 4].
Wheel assembly has damage in Remove tire and wheel . Dismount

bead seat area or other damage tire and replace damaged wheel [see
Section 4].
DRUM VIBRATIONS Isolator tire[s] are inflated too Reduce inflation pressure in tire[s] to
TRANSMITTING much CORRECT pressure [see Section 4].
THROUGH ISOLATOR
TIRE[S] INTO FRAME OF
MACHINE
DRUM MOVEMENT, Isolator tire[s] are inflated too little Increase inflation pressure in tire[s]
BETWEEN FRAMES IS to CORRECT pressure [see Section
EXCESSIVE IN THE SIDE 4].
TO SIDE DIRECTION
CAPSCREWS IN Isolator tire[s] are inflated too Reduce inflation pressure in tire[s] to
VIBRATION ISOLATION much CORRECT pressure [see Section 4].
SYSTEM ARE LOOSENED
BY VIBRATORY FORCES NO Loctite applied to threaded Remove capscrews and/ or nuts.
area of retaining capscrews used Apply Loctite #242 to capscrew
in isolation system and/or thread area. Install and tighten to
capscrews and nuts NOT CORRECT torques [see Sections 2
tightened to CORRECT torques and 4].
11-70 9/2005
Section 11
CLEANER BEAM AND RUBBER ASSEMBLIES
DRUM NOT BEING Cleaner beam and/or rubber Replace mounting capscrews as
CLEANED CORRECTLY assembly loose due to loss of needed. Put Loctite #242 on
BY FRONT AND/OR REAR mounting capscrews, or NOT threaded area of ALL capscrews.
RUBBER CLEANER being adjusted correctly Adjust rubber cleaner to contact
ASSEMBLIES drum face at ALL times. Tighten
mounting capscrews to CORRECT
torques [see Section 4 -
MAINTENANCE].
Rubber cleaner[s] worn, or Remove and replace rubber

damaged cleaner[s]. Replace with NEW and
adjust to contact drum[s] face at ALL
times [see Section 4 -
MAINTENANCE].
9/2005 11-71
Section 11
NOTES
11-72 9/2005
Section 12
WATER SPRAY SYSTEM
TABLE OF CONTENTS
PAGE

DESCRIPTION ............................................................................................................................................. 12-2.
OPERATION ................................................................................................................................................ 12-2.
STRAINERS AND NOZZLES ...................................................................................................................... 12-4.
REMOVAL, REPAIR AND INSTALLATION OF THE WATER SPRAY PUMP ............................................. 12-4.
WATER TANK REMOVAL AND REPLACEMENT ....................................................................................... 12-6.
TROUBLE ANALYSIS FOR THE WATER SPRAY SYSTEM ...................................................................... 12-8.
9/2005 12-1
Section 12
WATER SPRAY SYSTEM
GENERAL INFORMATION. OPERATION [See Figure 12-1].
This section contains a description and general Both water spray system pumps, are operator
operation of the water spray system used on the 66 controlled by the “Auto/Off/Manual” MODE switch
Inch and 78 Inch Compactors. This section also and water spray systems DUTY CYCLE switch.
includes repair instructions for major system
components. The FRONT water pump supplies water to the
FRONT water manifold and nozzles for coverage of
The repair instruction include removal, disassembly, the FRONT drum.
assembly and installation procedures.
The REAR water pump supplies water to the REAR
Water spray system design and performance water manifold and nozzles for coverage of the
specifications are given in Section 2 - REAR drum.
SPECIFICATIONS in this manual.
When the water spray system MODE control switch is
The water spray system “Trouble Analysis” guide is at “AUTO”, the duty cycle switch is set as desired.
found at the rear of this section. As the rolling pass is started, and then stopped, the
water spray system pumps will be automatically
turned “on” and “off”. Automatic system control is
DESCRIPTION [See Figure 12-1]. through the directional/speed control handle
activated switches, computer control system
The water spray system consists of the following electrical circuit and water spray pumps electrical
major components: relay.
a. Water tank assembly [2]. Water is then supplied to the front water spray
manifolds and nozzles by the front pump and to the
b. Water pump and motor assembly [2]. rear water spray manifolds and nozzles by the rear
pump.
c. Front drum water manifold, with and nozzles.
When the water spray system MODE control switch is
d. Rear drum water manifold, with and nozzles. at “MANUAL”, both pumps operate continuously.
e. System mode [AUTO/OFF/MANUAL] control Water is supplied, continuously, to the front water
switch. spray manifolds and nozzles by the front pump and to
the rear water spray manifolds and nozzles by the
f. System duty cycle [0 - 50%] control switch. rear pump.
g. Low water level switch - C766C, machine When the water spray system MODE control switch is
serial numbers C209C2343 and below, at “OFF”, both pumps do not operate.
except C209C2313, and C778B, machine
serial numbers B215C1737 and below [one The water supply system is “cross fed”, so that either
in each tank]. pump can supply water to both spray manifolds and
nozzles if one [1] pump does not operate.
h. Directional/speed control handle activated
switches, computer control system electrical Water spray coverage, of EACH drum, is adjusted by
circuit and water spray pumps electrical relay aiming each of the water spray nozzles toward the
drum. The water tank lip extends over the water spray
i. Fill strainer baskets [2]. manifold and nozzles and helps to keep wind from
blowing the spray pattern before it reaches the drum.
j. Water strainer - inside of tank installed [2].
k. Water supply and/or cross supply lines from

pumps to water manifolds.
l. Drain valves [2].
12-2 9/2005
Section 12
WATER SPRAY SYSTEM
FIGURE 12-1. WATER SPRAY SYSTEM - COMPONENT LOCATION AND CONNECTION -

C766C AND C778B.
9/2005 12-3
Section 12
WATER SPRAY SYSTEM
STRAINERS AND NOZZLES. 3. Remove the check valve assembly from the
pump housing.
Maintenance procedures for the water spray system
strainers and nozzles are given in Section 4 - 4. Remove the two [2] screws that hold the cover
MAINTENANCE - in this manual. and diaphragm assembly to the motor body.
Align the set screw with a slot in the pump
cover. Loosen the set screw, with an Allen
wrench, just enough to slide the diaphragm
REMOVAL, REPAIR AND INSTALLATION OF THE and cover assembly from the motor drive
WATER SPRAY PUMP See Figures 12-2 and 12-3]. shaft, as an assembly.
Use the following procedures to remove, repair, and 5. Remove the two [2] screws that attach the
install either water spray pump assembly: cam/bearing to the diaphragm. Remove the
diaphragm and cover.
a. Turn the water spray system “MODE” control
switch to “OFF” and STOP the engine.
NOTE: The screws that hold the cam/bearing, the
b. Remove the retaining capscrews and pump cam/bearing diaphragm, cover and check
cover from the water spray tank. Unplug the pump valve are all included in the pump “repair
electrical supply wire harness at the disconnect plug. kit”.
Put an identification tag on each hose connected to
the water pump fittings. Loosen the hose to pump
fitting retaining clamps and remove the hoses from CAUTION: Do NOT mix old and new “repair kit”
the water spray pump fittings. parts. Install all NEW parts.
c. Remove the four [4] retaining nuts from the four

[4] water spray pump assembly mounting bracket
studs. Carefully lift the assembly from the tank.
d. Put the water spray pump assembly on a

CLEAN work surface. If needed, disassemble the
pump by using the following ADDITIONAL repair
information [see figure 12-4].
CAUTION: “Repair Kit” is available and permits

the water spray pump assembly and
the drive motor to be serviced
SEPARATELY.
In some cases, the pump damage can
require that the complete water spray
pump assembly be replaced with
NEW.
FIGURE 12-2. WATER SPRAY PUMP ASSEMBLY -
INSTALLED ON TANK.
1. Remove the four [4] screws and lock washers
from the pump housing.
2. Remove the pump housing from the

diaphragm assembly.
12-4 9/2005
Section 12
WATER SPRAY SYSTEM
6. Install a new set screw in the new cam/ e. Put the water spray pump on the four [4]
bearing, a small amount. Install two [2] new mounting studs, so that the pump is in the correct
screws into the new cam/bearing, through the position for connection of the inlet, return and outlet
cover and into the new diaphragm assembly. supply lines.
Tighten the screws securely.
f. Install the four [4] retaining nuts on the mounting
7. Slide the diaphragm and cover assembly onto studs. Tighten the retaining nuts to a torque of 5 ft.
the motor drive shaft and tighten the set screw lbs. [6.8 N.m].
securely against the drive shaft.
8. Install the two [2] screws, that hold the cover CAUTION: Do NOT overtighten the retaining
and diaphragm assembly, to the motor body. nuts.
Tighten the screws securely.
9. Install the new check valve assembly, into the

pump head. g. Install the inlet, return and outlet hoses onto the
correct water spray pump fittings, as shown by the
10. Install the pump head, and check valve identification tags. Securely tighten the hose clamps.
assembly, onto the cover assembly. Align the Connect the electrical wire harness plug to the pump
four [4] mounting screw holes and install the harness connection plug fitting.
mounting screws. Tighten the screws securely.
PUMP MOTOR
COVER
SET
SCREW
DIAPHRAM
KIT
CONNECTOR
CHECK
VALVE CAM CONNECTOR
SEARING
SCREW HOUSING SCREW GOMMENT
SCREW PLATE
FIGURE 12-3. WATER SPRAY PUMP ASSEMBLY - EXPLODED

VIEW.
9/2005 12-5
Section 12
WATER SPRAY SYSTEM
h. Fill the water tank with enough water to check f. Put Loctite #242, part number 318702, on the
the water spray system for correct operation. threaded area of the eight [8] flange screws, that
fasten the tank to the tank carrier weldment. Install
i. Turn the ignition key switch “ON” [RUN]. Put the one [1] flange screw, with reinforcement plate, into
water spray system “MODE” switch to “MANUAL” and each tapped tank hole. Tighten each flange screw to
check the water spray system for correct operation a torque of 16 ft. lbs. [22 N.m].
[See Section 3 - OPERATION in this manual].
CAUTION: Do NOT tighten the flange screws to a

torque above that given above.
WATER TANK REMOVAL AND REPLACEMENT Damage, to the water tank assembly,
[See Figure 10-4]. can occur if the flange screws are
over tightened.
Use the following procedures to remove and replace
either water tank assembly:
g. Install the electrical wires and the water spray
a. Completely drain the tank of water. system hoses onto the water spray pump. Tighten the
hose clamps securely around the hoses and fittings.
b. Disconnect the electrical wires and the water
spray system hoses from the water spray pump on h. Fill the water tank with enough CLEAN and
the tank being removed [see this section]. strained water to check the system for correct
operation. After the operation check, install the cover
c. Go to the bottom side of the tank carrier over the water spray pump assembly. Install the four
weldment. Remove the eight [8] flange screws and [4] cover retaining flange screws and securely
reinforcement plates from the bottom of the tank tighten.
carrier weldment.
d. Carefully lift the water tank assembly from the

tank carrier weldment and move away from the
machine. Carefully inspect the tank for any damage,
which can cause a leaking condition. Repair, or
replace, the tank assembly with new, as needed.
NOTE: Install the repaired, or new, water tank

onto the machine using the following
information.
e. Carefully lift the water tank assembly and place

in the correct position within the tank carrier
weldment.
CAUTION: Do NOT damage the tank assembly

during installation.
12-6 9/2005
Section 12
WATER SPRAY SYSTEM
FIGURE 12-4. WATER TANK - INSTALLED.
9/2005 12-7
Section 12
WATER SPRAY SYSTEM
TROUBLE ANALYSIS FOR THE WATER SPRAY SYSTEM
WATER SPRAY
SPRAY PUMP MOTORS Contaminate in strainers and/or Clean strainers and/or pumps.
DO NOT OPERATE IN pumps
“MANUAL” MODE Remove pump and motor
Motor brushes worn excessively assemblies. Replace both pump and
or motor has total damage and motor assemblies with new. Install
failure pump and motor assemblies.
Water pump components Remove pump and motor

damaged assemblies. Replace both pump
components with new. Install pump
and motor assemblies.
Mode switch damaged Replace switch with new.
Electrical circuit to pumps Check circuit and repair as needed.

damaged
SPRAY PUMP MOTORS Mode switch in “auto” position, Place switch in “manual” position, or
DO NOT OPERATE IN machine not moving travel machine, to operate system.
“AUTO” MODE
Contaminate in strainers and/or Clean strainers and/or pumps.
pumps
Motor brushes worn excessively Remove pump and motor

or motor has total damage and assemblies. Replace both pump and
failure motor assemblies with new. Install
pump and motor assemblies.
Water pump components Remove pump and motor

damaged assemblies. Replace both pump
components with new. Install pump
and motor assemblies.
Water spray pumps electrical Replace relay with new.

relay damaged
Mode switch damaged Replace switch with new.
“Duty cycle” switch damaged Replace switch with new.

damaged
Computer control system Replace control with new.

damaged
12-8 9/2005
Section 12
WATER SPRAY SYSTEM
TROUBLE ANALYSIS FOR THE WATER SPRAY SYSTEM
WATER SPRAY
SPRAY PUMP MOTORS Mode switch has damage Remove and replace switch with
WILL NOT SHUT OFF- new.
WITH MODE SWITCH IN
ANY POSITION
SPRAY PUMPS OPERATE- Spray nozzles plugged Remove, clean nozzles, and if
BUT THERE IS LITTLE, OR needed, manifolds and install [see
NO, WATER SPRAY Section 4 - MAINTENANCE - in
PATTERN ON DRUM THIS manual].
DURING OPERATION
Low water level in water tank- Fill tank.
fault message indicated on
system function display screen -
C766C, machine serial numbers
C209C2343 and below, except
C209C2313, and C778B,
machine serial numbers
B215C1737 and below.
Contaminate in strainers and/or Clean strainers and/or pumps.

pumps
One [1] pump damaged and not Repair, or replace, pump. Remove
supplying water flow and "cross "cross feed" hose blockage.
feed" hose plugged
Charging system has damage - Check charging system. Repair

low voltage being supplied to system as needed.
water spray pump motor[s]
IN “AUTO” MODE - “Duty cycle” switch damaged Replace switch with new.
WATER SPRAY SYSTEM
DUTY CYCLE OPERATES Mode switch has damage Replace switch with new.
PUMPS CONTINUOUSLY,
OR NOT AT ALL Water spray pumps electrical Replace relay with new.
relay damaged

damaged
Motor brushes worn excessively Remove pump and motor

or motor has total damage and assemblies. Replace both pump and
failure motor assemblies with new. Install
pump and motor assemblies.
Computer control system Replace control with new.

damaged
9/2005 12-9
Section 12
WATER SPRAY SYSTEM
START-STOP CIRCUIT
SPRAY PATTERN NOT Spray angle of spray nozzles not Adjust angle of spray nozzles.
COVERING DRUM correct
One, or more, spray nozzles Remove nozzles, clean and install

plugged [see Section 4 - MAINTENANCE - in
THIS manual].
Charging system has damage - Check charging system. Repair

low voltage being supplied to system as needed.
water spray pump motor[s]
12-10 9/2005
Section 13
OPERATING LIGHTS AND DIRECTIONAL SIGNALS
TABLE OF CONTENTS
PAGE
GENERAL INFORMATION ........................................................................................................................ .13-2.

OPERATION LIGHTING, TURN SIGNAL AND 4 WAY WARNING SYSTEMS ......................................... .13-2.
OPERATION LIGHTING SYSTEM .......................................................................................................... .13-2.
OPERATION ......................................................................................................................................... .13-2.
ADJUSTMENTS AND CHECKS .......................................................................................................... .13-3.
TURN SIGNAL AND 4 WAY WARNING SYSTEMS..................................................................................13-6.
TURN SIGNALS AND 4 WAY FLASHERS SYSTEM - MACHINE SERIAL NUMBERS C209C2343 AND
BELOW, EXCEPT C209C2313, AND C778B, MACHINE SERIAL
NUMBERS B215C1737 AND BELOW...................................................................................................13-6.
OPERATION ................................................................................................................................... ...13-6.
TURN SIGNALS AND 4 WAY FLASHERS SYSTEM - MACHINE SERIAL NUMBERS C209C2344 AND
ABOVE, PLUS C209C2313, AND C778B, MACHINE SERIAL
NUMBERS B215C1738 AND ABOVE....................................................................................................13-7.
OPERATION .............................................................................................................................. ...... 13-7.
TROUBLE ANALYSIS FOR OPTIONAL EQUIPMENT ............................................................................ 13-11.
OPERATION LIGHTING SYSTEM ...................................................................................................... 13-11.
TURN SIGNAL AND 4 WAY WARNING SYSTEMS ........................................................................... 13-12.
9/2005 13-1
Section 13
GENERAL INFORMATION. OPERATION [See Figures 13-1, 13-2 , 13-3 and
13-4].
This section contains information about optional
equipment systems offered for the 66 Inch and 78 The lighting system circuit is used to turn the
Inch Compactors, at this time. standard instrument panel gauge and instrument
illumination lights “on” and “off”.
CAUTION: The Compactor's electrical system is If the machine is equipped with the OPTIONAL front
very sensitive to voltage and and rear operation lights, the circuit is, also, used to
amperage usage. Replace a damaged turn these items “on” and “off”, in addition to the
component with ONLY factory original standard instrument panel gauge and instrument
equipment components. illumination lights.
Do NOT add any additional equipment,
other than standard optional items, to
the Compactor. NOTE: On C766C, machine serial numbers
C209C2343 and below, except
C209C2313, and C778B, machine serial
numbers B215C1737 and below, the
lighting system control switch has
OPERATION LIGHTING, TURN SIGNAL AND current supplied to it at ALL times from
4 WAY WARNING SYSTEMS [See Figures the first, thirty [30] amp circuit breaker
13-1, 13-2 , 13-3 and 13-4]. and wire JJ.
On C766C, machine serial numbers
OPERATION LIGHTING SYSTEM. C209C2344 and above, plus C209C2313,
The operation lighting system is used to enable B215C1738 and above, the instrument
machine operation under dark conditions, or for panel gauge and instrument illumination
added machine visibility. lights are lighted at all times when the
ignition switch is in the “on/run” position.
The system contains a dash installed lighting system
control switch [same as used on machines not having
the option], light assembly supply wiring for front and On C766C, machine serial numbers C209C2343 and
rear lights [included in standard machine wiring below, except C209C2313, and C778B, machine
harness] and four [4] halogen light assemblies, which serial numbers B215C1737 and below, when the
each include amber turn/4 way warning light [see this switch is pulled to the 1st “on” position, current flows
section]. through the switch, into wire PP.
The operation lighting system is available as a factory Current in wire PP flows to the light terminal on the
installed option, or can be added to the machine by voltmeter, fuel gauge, engine oil pressure gauge,
the Distributor. engine coolant temperature gauge and hydraulic oil
system temperature gauge and illuminates each.
NOTE: The operation lighting system can be If the machine is equipped with the optional
added to the machine by itself. The turn operating lighting system, when the switch is pulled
signal and 4 way warning system is to the 2nd “on” position, current continues to flow
considered an ADDITIONAL optional item. through the switch into wire PP plus into wire CC.
The turn signal and 4 way warning system
can NOT be added to the machine without Current in wire CC flows to each, of the four [4],
also installing, or first having, the operation lights and illuminates them.
operation lighting system.
Also, see Section 7 - ELECTRICAL
SYSTEM - for additional electrical system
information.
13-2 9/2005
Section 13
NOTE: On C766C, machine serial numbers ADJUSTMENT AND CHECKS [See Figures 13-1
C209C2344 and above, plus C209C2313, and 13-2].
B215C1738 and above, the lighting Each of the operation light assemblies is able to be
system circuit control switch has current adjusted to aim the beam of light as needed.
supplied to it at ALL times from the first,
thirty [30] amp circuit breaker and wire JJ. If adjustment is needed, loosen the retaining nut on
Current flows through the lighting system the light assembly mounting bolt. Carefully adjust the
control switch into wire PP at all times light assembly as desired by rotating the light
when the ignition switch is in the “on”/ assembly ball within the mounting cup. Tighten the
“run” position. Current in wire PP then nut on the mounting bolt to secure the light in the
flows to the light terminal on the adjusted position.
voltmeter, fuel gauge, engine oil pressure
gauge, engine coolant temperature gauge Check the operation lighting, turn signal and 4 way
and hydraulic oil system temperature warning systems for correct operation each time the
gauge and illuminates each. machine is started to be sure the systems are without
At all times, with a fully charged battery, damage, which can cause the systems to not operate
current from the positive [+] battery correctly when needed. Immediately replace any
terminal flows into wire FG and is components found damaged and/or make immediate
supplied to thepower panel contained low repairs to the systems.
and high beam operation lighting relays
and options and water spray systems
circuit breakers. CAUTION: The Compactor's electrical system is
Wire G serves as the system ground. very sensitive to voltage and
When the light switch knob is pulled to amperage usage. Replace a damaged
the 1st “on” position, current continues component with ONLY original
to flow through the switch into wire PP, equipment components.
plus into wire FP. Never use a wire, having a smaller
Current in wire FP flows to the low beam gauge than the wire being replaced.
relay, closes the relay, and flows through Use only equal, or larger, sized wire.
the relay and into wire CC. Current in wire
CC flows to the low beam of each of the
four [4] operation lights and illuminates
them.
When the light switch knob is pulled to
the 2nd “on” position, current continues
to flow through the switch into wire PP,
plus into wire FQ. No current flows into
wire FP. Current in wire FQ flows to the
high beam relay, closes the relay, and
flows through the relay and into wire FH.
Current in wire FH flows to the high beam
of each of the four [4] operation lights and
illuminates them.
Current, also, flows through, and from,
the options circuit breaker into wire FL
and flows to the positive [+] post on the
power panel assembly. Current flows from
the positive [+] post into wire FM. Current
in wire FM flows to the standard included
turn signal flasher.
9/2005 13-3
Section 13
FIGURE 13-1. OPERATION LIGHTING, TURN SIGNAL AND 4 WAY WARNING SYSTEMS -
COMPONENT DETAILS - C766C, MACHINE SERIAL NUMBERS C209C2343 AND BELOW, EXCEPT
C209C2313, AND C778B, MACHINE SERIAL NUMBERS B215C1737 AND BELOW.
13-4 9/2005
Section 13
FIGURE 13-2. OPERATION LIGHTING, TURN SIGNAL AND 4 WAY WARNING SYSTEMS -
COMPONENT DETAILS - C766C, MACHINE SERIAL NUMBERS C209C2344 AND ABOVE, PLUS
C209C2313, AND C778B, MACHINE SERIAL NUMBERS B215C1738 AND ABOVE.
9/2005 13-5
Section 13
TURN SIGNAL AND 4 WAY WARNING SYSTEM. TURN SIGNALS AND 4 WAY FLASHERS SYSTEM
- MACHINE SERIAL NUMBERS C209C2343 AND
The turn signal and 4 way warning system is used as BELOW, EXCEPT C209C2313, AND C778B,
an additional optional system to help increase MACHINE SERIAL NUMBERS B215C1737 AND
machine operating safety through the ability to signal BELOW.
directional changes [turns] and add machine visibility
through intermittent flashing of the 4 way warning
system. OPERATION [See Figures 13-1 and 13-3]
The turn signal and 4 way warning systems are The OPTIONAL turn signals and 4 way flashers
combined and available as an additional factory system circuit is used control the front and rear, left
installed option, IF the machine is equipped with the and right, turn signals and 4 way flashers system.
operation lighting option.
With a fully charged battery, current from the positive
IF the machine is already equipped with operation [+] battery terminal flows into wire FG and is supplied
lighting, or the operation lighting option is, also, being to the fuse assembly and optional turn signal flasher.
installed, at this time, this option can be added to the
machine by the Distributor. Power to the turn signal switch assembly with turn
and 4 way flasher indicator lights is supplied through
The combined turn signal and 4 way warning system two wires from the flasher.
contains a turn signal and 4 way warning control
switch, system supply wiring [included in standard Power from the turn signal switch assembly, to the
machine wiring harness] for the front and rear turn left and right, front and rear turn signals and 4 way
signal and 4 way warning system lights. flasher lights, is supplied through wires GG and HH.
The system, also, requires that the four [4] halogen When the turn signal switch is placed in the left turn
operation lighting assemblies, which each contain the position, current from the flasher is routed through
amber turn/4 way warning lights, be installed. the turn signal switch and travels from the switch into
wire GG. Wire GG carries current from the switch to
The standard dash wiring harness includes the flash the left front and rear turn signal lights.
connection plugs needed to connect the, steering
column mounted, turn signal and 4 way warning When the turn signal switch is placed in the right turn
control switch assembly into the system, after position, current from the flasher is routed through is
installation. routed through the turn signal switch and travels from
the switch into wire HH. Wire HH carries current from
the switch to flash the right front and rear turn signal
NOTE: The turn signal and 4 way warning lights.
system is considered an ADDITIONAL
optional item, even though each of the When the turn signal switch is placed in the 4 way
four [4] halogen light assemblies include flasher position, current is supplied from the flasher.
amber turn/4 way warning lights. The turn Current is routed through the turn signal switch and
signal and 4 way warning system can travels from the switch into wires GG and HH. Wires
NOT be added to the machine without, GG and HH carry current from the switch to flash the
also adding, or first having, the optional right front and rear and left front and rear turn signal
operation lighting system installed, and lights together.
then adding the option.
Also, see Section 7 - ELECTRICAL
SYSTEM - for additional electrical system
information.
13-6 9/2005
Section 13
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9/2005 13-7
13-8
Section 13
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Figure 13-3 - Here

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FIGURE 13-3. OPERATION LIGHTING, TURN SIGNAL AND 4 WAY WARNING SYSTEMS - ELECTRICAL SCHEMATIC - C766C, MACHINE
9/2005
SERIAL NUMBERS C209C2343 AND BELOW, EXCEPT C209C2313, AND C778B, MACHINE SERIAL NUMBERS B215C1737 AND BELOW.
9/2005
US
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13
-9
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NEW Figure 13-4 Part A - Here

tH
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FIGURE 13-4. PART A - OPERATION LIGHTING, TURN SIGNAL AND 4 WAY WARNING SYSTEMS - ELECTRICAL SCHEMATIC - C766C,
MACHINE SERIAL NUMBERS C209C2344 AND ABOVE, PLUS C209C2313, AND C778B, MACHINE SERIAL NUMBERS B215C1738 AND
ABOVE.
Section 13
13-9
13-10
Section 13
US
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13
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NEW Figure 13-4 Part B - Here

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FIGURE 13-4. PART B - OPERATION LIGHTING, TURN SIGNAL AND 4 WAY WARNING SYSTEMS - ELECTRICAL SCHEMATIC - C766C,
MACHINE SERIAL NUMBERS C209C2344 AND ABOVE, PLUS C209C2313, AND C778B, MACHINE SERIAL NUMBERS B215C1738 AND
9/2005
ABOVE.
Section 13
TROUBLE ANALYSIS FOR OPTIONAL EQUIPMENT
OPERATION LIGHTING SYSTEM

NO LIGHTS ARE No current being supplied to Check for battery voltage at ignition
ILLUMINATED control switch switch and at light control switch.
Repair, or replace, as needed.
Open circuit in current supply Check circuit. Repair wiring as

wiring needed.
System control switch has Replace switch with new.

damage
Circuit has NO ground Check and repair ground as needed.
Power panel contained low and Replace relays with new.

high beam relays open, or
damaged, C766C, machine serial
numbers C209C2344 and above,
plus C209C2313, and C778B,
B215C1738 and above
ONE LIGHT DOES NOT All halogen bulbs burned out Replace halogen bulbs with new.
ILLUMINATE
Halogen bulb burned out Replace halogen bulbs with new.
Open wire in circuit Check and repair as needed.
REAR LIGHTS DO NOT Open wire in circuit Check and repair as needed.
ILLUMINATE - FRONT
LIGHTS ILLUMINATE Both halogen bulbs burned out Replace halogen bulbs with new.
FRONT LIGHTS DO NOT Open wire in circuit Check and repair as needed.
ILLUMINATE - REAR
LIGHTS ILLUMINATE Both halogen bulbs burned out Replace halogen bulbs with new.
9/2005 13-11
Section 13
TURN SIGNAL AND 4 WAY WARNING SYSTEMS

NO LIGHTS ARE No current being supplied to turn Check for battery voltage at ignition
ILLUMINATED FOR LEFT, signal and 4 way warning switch and 30 amp circuit breaker.
OR RIGHT, TURN OR FOR systems control switch Repair, or replace, as needed.
4 WAY WARNING SYSTEMS
Open circuit in current supply Check circuit. Repair, or replace,
wiring wiring as needed.
Turn signal and 4 way warning Replace switch with new.

systems control switch has
damage
30 amp circuit breaker has Replace circuit breaker with new.

damage
Power panel contained options Replace circuit breaker with new.

circuit breaker open, or damaged,
C766C, machine serial numbers
C209C2344 and above, plus
C209C2313, and C778B,
B215C1738 and above
All bulbs burned out Replace bulbs with new.
ONE LIGHT DOES NOT Halogen bulb burned out Replace with new.
ILLUMINATE FOR LEFT,
OR RIGHT, TURN OR FOR Open wire in circuit Check and repair as needed.
Open wire in circuit Check and repair as needed.
One bulb burned out Replace bulb with new.
13-12 9/2005
Section 13
TURN SIGNAL AND 4 WAY WARNING SYSTEMS

REAR LIGHTS DO NOT Circuit has NO ground Check and repair ground as needed.
- FRONT LIGHTS Both bulbs burned out Replace bulbs with new.
ILLUMINATE
damage
FRONT LIGHTS DO NOT Circuit has NO ground Check and repair ground as needed.
- REAR LIGHTS Both bulbs burned out Replace bulbs with new.
ILLUMINATE
damage
9/2005 13-13

Bomag Hypac C766 C C778 B Workshop Service Repair Manual Download

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C766 C

Install each Seat Belt.

Hexbolt - M20x110 - 10.9 Seat Belt

Install Eybolts (2).

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

ALWAYS support the machine with sound blocking.

ALWAYS keep tools in a good and clean condition.

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

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

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

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

SECTION 5 - FRAME, HITCH AND FALLING OBJECT/

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

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

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

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

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

SECTION 11 - DRUM, VIBRATION AND DRUM CLEANING SYSTEMS ............................................ 11-1.

SECTION 12 - WATER SPRAY SYSTEM ............................................................................................. 12-1.

SECTION 13 - OPERATING LIGHTS AND DIRECTIONAL SIGNALS................................................. 13-1.

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

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

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

REPAIR PROCEDURES ..........................................................................................................................1-2.

NAME PLATE / SERIAL NUMBER PLATE .............................................................................................1-2.

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

THIS manual contains SPECIFICATION information MAJOR machine component REPAIR

CAUTION: For CORRECT machine component

OPERATING INSTRUCTIONS. NAME PLATE /SERIAL NUMBER PLATE [See

CAUTION: Follow ALL the maintenance

PLANT OF DESIGN SERIES MACHINE

TABLE 1-1. MACHINE SERIAL NUMBER DESIGNATIONS.

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

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

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

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

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

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

TABLE 2-16. TORQUE SPECIFICATIONS FOR STANDARD METRIC

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

TABLE 2-18. ADHESIVE THREAD LOCKING SPECIFICATIONS ................................................ 2-23.

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

ITEM DESIGN DATA

FRAME and HITCH

Material Plate steel

Construction Unitized, all welded 2 section, with bolt-on

Oscillation +/- 12° - side to side, 24° total

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

Type 4 Cycle diesel, Turbocharged and Charge Air Cooled

Displacement 239 in.3 [3.9 l]

Rated Brake 130 hp @ 2500 rpm [97 Kw @ 2500 rpm]

Compression Ratio 18:1