BC-2002 Tandem Rev3

FIELD OPERATIONS & MAINTENANCE 2000/2004 MODEL BC-2002/CRC TANDEM
Unit Serial Number: Date of Service: Customer: Hopper ID Number (front): Hopper ID Number (rear): Footage Calibration Number:
BearCat Mfg., Inc. 3650 Sabin Brown Road Wickenburg, AZ 85390 Phone: (928) 684-7851 Fax: (928) 684-3241
Copyright 2004 BearCat Mfg., Inc.
Revised January 31, 2004
This manual describes the Model BC-2002/CRC Tandem Chip Spreader as it is normally delivered to the user. Due to a continuing program of product improvement, changes may be made in equipment delivered at a later date. Every attempt is made to keep users fully informed of such changes.
T-2
BearCat Mfg.
Date Received ___________________
REPORT OF POSSIBLE DATA ERROR

Mail this form to the address on the title page or FAX to (928) 684-3241
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3650 Sabin Brown Road Wickenburg, AZ 85390
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Model BC-2002/CRC Tandem
WARRANTY AND CLAIM PROCEDURES

LIMITED WARRANTY
BearCat Mfg., Inc. (hereinafter referred to as BearCat) extends to the original purchaser-user of Model BC-2002/CRC Tandem Chip Spreader, the following warranty covering goods manufactured by BearCat and subject to the following qualifications. The warranty applies only when the product: 1. 2. 3. 4. 5. Is properly used and maintained in accordance with BearCat instructions, governing agencies or associations. Is being operated under proper fuel and/or cargo specifications. Is not subjected to corrosive or abrasive atmosphere or materials. Has not been damaged through malice or ignorance. Has not been subjected to flood, lightning, accidents, misuse, neglect or unauthorized modification, repair or service.
Parts replaced under this warranty are warranted only through the remaining time of the original warranty. BearCat warrants that at the time of delivery, the product manufactured by BearCat and delivered new to the original purchaser-user shall be free from defects in material and workmanship for a period of one (1) year after delivery. This warranty is valid when the product is operated and maintained under normal use and service and in accordance with the written instructions provided by BearCat.
Warranty Claims
BearCat agrees at its option, to repair or replace F.O.B. Wickenburg, Arizona, any part acknowledged by BearCat to be defective, provided: 1. 2. The user notifies BearCat of any defect within this warranty no later than thirty (30) days after a defect is discovered. Written or verbal authorization has been obtained from the BearCat Service Department to return the product.
March 31, 2002
WAR-1
3.
Upon authorization, the defective part is returned within 60 days for inspection with transportation charges prepaid to BearCat.
BearCat Mfg., Inc. 3650 Sabin Brown Road Wickenburg, AZ 85390
Phone: (928) 684-7851 Fax: (928) 684-3241
BearCat Mfg.
3650 Sabin Brown Road Wickenburg, Arizona 85390 928-684-7851
TM
4.
BearCat determines the defective part failed under the terms of the above warranty.
BEARCAT WILL NOT INSTALL AND WILL NOT PAY ANY INSTALLATION COST, TRANSPORTATION COST, TRAVEL TIME, MILEAGE, LABOR COSTS OR OTHER EXPENSES OF ANY DEFECTIVE PARTS REPLACED OR REPAIRED UNLESS THE USER HAS REACHED A PRIOR AGREEMENT WITH BEARCAT.
EXCLUSIONS
The provisions of the foregoing warranty are BearCats sole obligation and exclude all other warranties, expressed or implied. BearCat shall not be responsible for any loss, damage, incidental or consequential damages of any kind, whether based upon warranty, contract or negligence, arising concerning the sale, use, or repair of the product. Components manufactured by any supplier other than BearCat shall bare only the warranty made by the manufacturer of that product.
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March 31, 2002
List of Effective Pages
LIST OF EFFECTIVE PAGES

Revision 0 March 31, 2002 Revision 1 July 15, 2002 Revision 2 January 31, 2004 Subheading and Page TITLE PAGE T-1 T-2 WARRANTY/CLAIM PROCEDURES WAR-1 WAR-2 LIST OF EFFECTIVE PAGES LEP-1 LEP-2 LEP-3 LEP-4 TABLE OF CONTENTS TC-1 TC-2 LIST OF FIGURES TC-3 TC-4 TC-5 LIST OF TABLES TC-6 INTRODUCTION INTRO-1 INTRO-2 SECTION 1. DESCRIPTION 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 Rev 2 2 Subheading and Page Rev
SECTION 2. SAFETY PRECAUTIONS 2-1 0 2-2 0 SECTION 3. PREPARING EQUIPMENT FOR USE 3-1 0 3-2 0 3-3 0 3-4 0 3-5 0 3-6 0 3-7 0 3-8 0 3-9 0 3-10 0 3-11 0 3-12 0 3-13 0 3-14 0 3-15 0 3-16 0 SECTION 4. OPERATING INSTRUCTIONS 4-1 0 4-2 0 4-3 0 4-4 0 4-5 0 4-6 0
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January 31, 2004
LEP-1
Model BC-2002/CRC Tandem Subheading and Page Rev
List of Effective Pages Rev
Subheading and Page
SECTION 5. TOW BAR (OPTIONAL) 5-1 0 5-2 0 5-3 0 5-4 0 5-5 0 5-6 0 5-7 0 5-8 0 SECTION 6. MAINTENANCE 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8
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SECTION 7. ILLUSTRATED PARTS LIST 7-1 0 7-2 2 7-3/7-4 0 7-5 0 7-6 0 7-7/7-8 0 7-9/7-10 0 7-11 0 7-12 0 7-13 0 7-14 0 7-15/7-16 0 7-17 2 7-18 0 7-19 0 7-20 0 7-21 0 7-22 0 7-23/7-24 0 7-25 0 7-26 0 7-27/7-28 0 7-29 2 7-30 0 7-31 0 7-32 0 7-33 0 7-34 0 7-35 0
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LEP-2
January 31, 2004
Model BC-2002/CRC Tandem Subheading and Page Rev
List of Effective Pages Rev
Subheading and Page
SECTION 8. DIAGRAMS 8-1 8-2 8-3/8-4 8-5/8-6 8-7/8-8 8-9/8-10 8-11/8-12 8-13/8-14 8-15/8-16 8-17/8-18 8-19/8-20 8-21/8-22 8-23/8-24 8-25/8-26 8-27 8-28 8-29 8-30 8-31 8-32 8-33 8-34 8-35 8-36 8-37/8-38 8-39 8-40 8-41/8-42 8-43 8-44 8-45 8-46 8-47/8-48 8-49 8-50 8-51/8-52 8-53 8-54 8-55 8-56 8-57 8-58 8-59 8-60
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SECTION 9. PARTS INDEX 9-1 9-2 9-3 9-4 9-5 9-6 9-7 9-8 9-9 9-10 9-11 9-12 9-13 9-14 9-15 9-16
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LEP-3
List of Effective Pages
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LEP-4
January 31, 2004
Table of Contents
TABLE OF CONTENTS
Subject Page
SECTION 1. DESCRIPTION ........................................................................................................ 1-1 Equipment Description.......................................................................................................... 1-1 Power Train........................................................................................................................... 1-2 Aggregate Delivery System .................................................................................................. 1-2 Spread Hopper...................................................................................................................... 1-3 Gate Control Valve Box ........................................................................................................ 1-5 Computerized Rate Control (CRC) ....................................................................................... 1-6 Chassis ................................................................................................................................. 1-7 Hydraulically Powered Remote Control Hitch....................................................................... 1-7 BC-2002/CRC Tandem Specifications ................................................................................. 1-8 SECTION 2. SAFETY PRECAUTIONS ....................................................................................... 2-1 Personal Safety..................................................................................................................... 2-1 Safety Rules.......................................................................................................................... 2-1 SECTION 3. PREPARING EQUIPMENT FOR USE.................................................................... 3-1 Initial Checkout of Machine................................................................................................... 3-1 Control Panel Switches......................................................................................................... 3-2 Computer Controls................................................................................................................ 3-4 Setting Spread Hopper Width ............................................................................................... 3-9 Weight Calibration .............................................................................................................. 3-11 Distance Calibration............................................................................................................ 3-13 Operator Station Adjustments............................................................................................. 3-14 Control Panel ................................................................................................................. 3-14 Bi-View Mirrors .............................................................................................................. 3-14 Hitch Adjustments............................................................................................................... 3-14 Height ............................................................................................................................ 3-14 Fore and Aft ................................................................................................................... 3-14 Chip Spreader Hitch Bar Requirements ............................................................................. 3-14
July 15, 2002
TC-1
Table of Contents
SECTION 4. OPERATING INSTRUCTIONS ............................................................................... 4-1 Mechanical Startup ............................................................................................................... 4-1 Operation .............................................................................................................................. 4-2 Setting Gate Opening for Manual Operation ........................................................................ 4-3 Clearing a Clogged Gate ...................................................................................................... 4-4 Shutdown on Completion of a Job........................................................................................ 4-4 SECTION 5. TOW BAR (OPTIONAL) ......................................................................................... 5-1 Towing Requirements........................................................................................................... 5-2 SECTION 6. MAINTENANCE ...................................................................................................... 6-1 Scheduled Maintenance ....................................................................................................... 6-1 Routine Maintenance............................................................................................................ 6-3 Weight Calibration ........................................................................................................... 6-3 Distance Calibration ........................................................................................................ 6-4 Potentiometer Calibration ................................................................................................ 6-5 Replacement Filters, Belts and Fans.................................................................................... 6-7 Lubrication Specifications ..................................................................................................... 6-8 SECTION 7. ILLUSTRATED PARTS LIST ................................................................................. 7-1 SECTION 8. DIAGRAMS ............................................................................................................. 8-1 SECTION 9. PARTS INDEX ........................................................................................................ 9-1
TC-2
July 15, 2002
Table of Contents
LIST OF FIGURES
Figure Title Page Figure 1-1. Model BC-2002/CRC Tandem, Curb Side..................................................1-1 Figure 1-2. Model BC-2002/CRC Tandem, Street Side ................................................1-1 Figure 1-3. Spread Hoppers at Minimum 10-foot Width................................................1-3 Figure 1-4. Spread Hoppers Extended to 20-foot Width ...............................................1-4 Figure 1-5. Gate Control Valve Box Interior ..................................................................1-5 Figure 1-6. Chassis Dimensions ...................................................................................1-7 Figure 3-1. Control Panel ..............................................................................................3-2 Figure 3-2. Computer Controls View 1.......................................................................3-4 Figure 3-3. Computer Controls View 2.......................................................................3-6 Figure 3-4. Examples of the Use of Computerized Gate Controls ................................3-7 Figure 3-5. Computer Controls View 3.......................................................................3-7 Figure 3-6. Computer Controls View 4.......................................................................3-8 Figure 3-7. Spread Hopper Remote Control Box ..........................................................3-9 Figure 3-8. Manual Gate Switches..............................................................................3-10 Figure 3-9. Computer Display During Distance Calibration ........................................3-13 Figure 3-10. Hitch Bar Location on Dump Truck.........................................................3-15 Figure 3-11. Typical Hitch Bar.....................................................................................3-15 Figure 4-1. Cam Open Indicator....................................................................................4-3 Figure 5-1. Tow Bar ......................................................................................................5-3 Figure 5-2. Wheel Placement and Removal Position....................................................5-3 Figure 5-3. Position No. 1 Loading Chip Spreader .......................................................5-4 Figure 5-4. Rear View, Coupling Pins ...........................................................................5-4 Figure 5-5. Position No. 2 Loading Chip Spreader .......................................................5-5 Figure 5-6. Position No. 3 Loading Chip Spreader .......................................................5-5 Figure 5-7. Trailering Jack and Pintle Eye..................................................................5-6 Figure 5-8. Truck Hitch and Hookups ...........................................................................5-6 Figure 5-9. Position No. 4 Loading Chip Spreader .......................................................5-7 Figure 6-1. Cam Shaft and Gate Grease Fittings..........................................................6-2 Figure 6-2. Checking Gate Opening .............................................................................6-2 Figure 6-3. Computer Display During Distance Calibration ..........................................6-4
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TC-3
Table of Contents
Figure 6-4. Potentiometer Guard ..................................................................................6-6 Figure 6-5. Potentiometer .............................................................................................6-6 Figure 7-1. Model BC-2002/CRC Tandem (Complete) .................................................7-4 Figure 7-2 (Sheet 1). Tandem Chip Spreader Assembly ..............................................7-8 Figure 7-2 (Sheet 2). Tandem Chip Spreader Assembly ............................................7-10 Figure 7-3. Engine/Hydrostatic Installation .................................................................7-16 Figure 7-4. Drivelines ..................................................................................................7-19 Figure 7-5. Exhaust System........................................................................................7-20 Figure 7-6. Frame Assembly.......................................................................................7-24 Figure 7-7. Wishbone Assembly .................................................................................7-28 Figure 7-8. Spherical Bearing .....................................................................................7-31 Figure 7-9. Panel Assembly, 2-Wheel Drive ...............................................................7-32 Figure 7-10. Panel Assembly, 4-Wheel Drive .............................................................7-34 Figure 7-11. Conveyor Assembly, Left-Hand ..............................................................7-38 Figure 7-12. Conveyor Assembly, Right-Hand............................................................7-42 Figure 7-13. Tube/Steering Assembly.........................................................................7-46 Figure 7-14. Junction Box ...........................................................................................7-48 Figure 7-15. Oil Cooler Assembly ...............................................................................7-50 Figure 7-16. Pedestal and Control Box Assembly ......................................................7-54 Figure 7-17. Hitch Assembly .......................................................................................7-56 Figure 7-18. Hitch Lift..................................................................................................7-60 Figure 7-19. Hitch Manifold W/Out Lift Option ............................................................7-62 Figure 7-20. Hitch Manifold W/Lift Option ...................................................................7-64 Figure 7-21. Chip Box, Tandem ..................................................................................7-68 Figure 7-22. Potentiometer Assembly.........................................................................7-72 Figure 7-23. Gear Box Assembly ................................................................................7-76 Figure 7-24. Valve Box Assembly ...............................................................................7-80 Figure 7-25. Chip Box Extension ................................................................................7-84 Figure 7-26. Tow Bar Assembly..................................................................................7-86 Figure 7-27. Heat Exchanger ......................................................................................7-88 Figure 8-1. Console Wiring Detail, Tandem (2000 2001)...........................................8-3 Figure 8-2. Console Wiring Detail, Tandem (2002).......................................................8-5 Figure 8-3. Junction Box Wiring Detail, Tandem (2000 2001) ...................................8-7
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March 31, 2002
Table of Contents
Figure 8-4. Junction Box Wiring Detail, Tandem (2002) ...............................................8-9 Figure 8-5. Valve Box Wiring Detail, Tandem (2000 2001)......................................8-11 Figure 8-6 (Sheet 1). Valve Box Wiring Detail, Tandem (2002)..................................8-13 Figure 86 (Sheet 2). Valve Box Wiring Detail, Tandem (2002) .................................8-15 Figure 8-7. Slave Box Wiring Detail, Tandem (2000 2001)......................................8-17 Figure 8-8. Slave Box Wiring Detail, Tandem (2002)..................................................8-19 Figure 8-9. Digital Foot Control Wiring Detail, Tandem (2002) ...................................8-21 Figure 8-10. Engine Wiring Detail, Tandem ................................................................8-23 Figure 8-11. Lights Wiring Detail.................................................................................8-25 Figure 8-12. Air System Hose and Fitting Diagram, 2-Wheel Drive............................8-37 Figure 8-13. Air System Hose and Fitting Diagram, 4-Wheel Drive............................8-41 Figure 8-14. Spread Hopper Gate Air System ............................................................8-47 Figure 8-15. Hydraulic/Misc. Hose and Fittings ..........................................................8-51
March 31, 2002
TC-5
Table of Contents
List of Tables
Table Title Abbreviation/Definition Table Table 1-1. Gate Control Valve Box Functions Table 1-2. Specifications Table 3-1. Control Panel Switches Table 3-2. Control Functions for Figure 3-2 Table 3-3. Control Functions for Figure 3-3 Table 3-4. Control Functions for Figure 3-5 Table 3-5. Control Functions for Figure 3-6 Table 6-1. Scheduled Preventive Maintenance Table 6-2. BearCat Part Numbers Table 7-1. Recommended Spare Parts Table 8-1. BC-2002/CRC Tandem Electrical Circuit Table 8-2. Air System Hose and Fittings, 2-Wheel Drive Table 8-3. Air System Hose and Fittings, 4-Wheel Drive Table 8-4. Air System Parts and Fittings Chart Table 8-5. Air System Hose and Fittings, Spread Hopper Gates, Front and Rear Table 8-6. Hydraulic/Misc. Hose and Fittings Table 8-7. Hydraulic System Parts and Fittings Chart Page INTRO-2 1-6 1-8 3-3 3-5 3-6 3-7 3-8 6-1 6-7 7-2 8-27 8-39 8-43 8-45 8-49 8-53 8-58
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March 31, 2002
Introduction
INTRODUCTION
BearCat Chip Spreaders (Model BC-2002/CRC Tandem) are designed and manufactured to ensure personnel safety when the equipment is operated properly and all safety precautions are strictly followed. Persons responsible for the operation and field maintenance of the Model BC-2002/CRC Tandem Chip Spreader should read this manual carefully before attempting to operate the equipment or performing any service or adjustment procedures on it.
NOTE:
BearCat Manufacturing assumes no liability for accident or injury incurred through improper use of this equipment.
BEARCAT CHIP SPREADERS MOVE LARGE AMOUNTS OF ABRASIVE MATERIAL AT HIGH SPEEDS. THIS EQUIPMENT CONTAINS EXPOSED MOVING PARTS AND BELTS. THE HYDRAULIC SYSTEM OPERATES AT HIGH PRESSURE AND THE FLUID AND LINES CAN REACH HIGH TEMPERATURES. POTENTIALLY LIFE-THREATENING HAZARDS MAY EXIST DURING EQUIPMENT OPERATION. PERSONNEL MUST BE TRAINED AND FAMILIAR WITH SECTION 2 (SAFETY PRECAUTIONS) BEFORE OPERATING BEARCAT EQUIPMENT. POTENTIALLY LIFE-THREATENING HAZARDS MAY EXIST DURING EQUIPMENT OPERATION. ONLY QUALIFIED PERSONNEL SHOULD ATTEMPT TO OPERATE, SERVICE OR MAKE ADJUSTMENTS TO THE BEARCAT EQUIPMENT. FOLLOW THESE PRECAUTIONARY INSTRUCTIONS EXACTLY. DO NOT TAKE SHORTCUTS. DO NOT ASSUME THAT SOMEONE ELSE HAS ACTED ON YOUR BEHALF. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN DEATH OR SERIOUS INJURY. IF ANY RULE OR PRECAUTION IS NOT CLEAR TO YOU, SEE YOUR SUPERVISOR BEFORE USING THE MACHINE.
WARNING:
WARNING:
WARNING:
March 31, 2002
INTRO-1
Introduction
Abbreviation/Definition Table
Abbreviation CRC CCW CW PSY KgSM FPM MPM PSI Definition Computerized Rate Control Counterclockwise Clockwise Pounds-per-square-yard Kilograms-per-square-meter Feet-per-minute Meters-per-minute Pounds-per-square-inch
INTRO-2
March 31, 2002
Description
SECTION 1. DESCRIPTION
Equipment Description
The Model BC-2002/CRC Tandem Computer Controlled, Self-propelled Chip Spreader is illustrated in Figure 1-1 and Figure 1-2. The following description of the equipment should be read for familiarity with the operating features and capabilities of the Model BC-2002/CRC Tandem Chip Spreader.
Figure 1-1. Model BC-2002/CRC Tandem, Curb Side
Figure 1-2. Model BC-2002/CRC Tandem, Street Side

March 31, 2002 1-1
Description
Power Train
Model BC-2002/CRC Tandem is equipped with a 6-cylinder diesel engine. The engine crankshaft is coupled to an axial-piston, high torque hydrostatic pump, and a hydrostatic transmission and two-speed transfer case which drives a limited-slip front axle. The particular configuration of the Model BC-2002/CRC Tandem power train, consisting of front drive (limited-slip), hydrostatic transmission and transfer case, and single hydraulic motor, provides outstanding control and traction far exceeding that previously available. As an example, Model BC-2002/CRC Tandem is capable of pulling a fully loaded 15 cubic yard dump truck up a 15% grade from a dead stop. In addition, the hydraulic motor is equipped with a Low-Lock function. With Low-Lock selected, the hydraulic motor is held in full displacement by an electrically actuated solenoid. Low-Lock acts as a speed-limiting device and eliminates any undesired acceleration by the chip spreader on downhill grades. An optional four-wheel drive system is available for terrain/gradeability situations that require additional traction or control.
Aggregate Delivery System

Model BC-2002/CRC Tandem employs two hydraulically driven 30-inch wide conveyor belts to move aggregate from the receiving hopper to the spread hoppers. The belts form a 30 -trough angle, which increases the belt load capacity. They are capable of carrying twice the volume of rock while running only 2/3 as fast as a conventional 20-inch flat belt. The belt motion is controlled by solenoid-actuated valves that receive signals from level-sensing diaphragm switches mounted at the top of each spread hopper.
NOTE:
Optional belts are rated at 350 F (for use with hot aggregate).
The conveyor belt return rollers employ a self-cleaning design that prevents any accumulation of asphalt when the machine is used to spread precoated aggregate. Other than periodic lubrication of the shaft bearings, as specified in Section 6 of this manual, no maintenance is required for the conveyor belt return rollers.
1-2
March 31, 2002
Description
Spread Hopper
Model BC-2002/CRC Tandem is equipped with two separate (front and rear) spread hoppers that can be quickly extended from a minimum width of 10 feet to a maximum width of 20 feet. Hopper extension and retraction is controlled from the operators station or from a remote control box at the top of the right-hand conveyor. By using the computer controlled aggregate gates, the operator can spread material at any width from 1 foot to 20 feet. Figure 1-3 shows the spread hoppers retracted to the minimum width of 10 feet.
Figure 1-3. Spread Hoppers at Minimum 10-foot Width Hydraulic power is used to extend the front or rear spread hopper to the desired overall width. Each hopper can be extended or retracted independently for offset and special clearance applications. The hoppers may also be extended or retracted simultaneously for equal width applications. The front hopper extends to the left and the rear hopper extends to the right. Once the maximum spread width is established, the appropriate aggregate gates are selected from the operators station on the chip spreader. Figure 1-4 shows the spread hoppers extended to their maximum width of 20 feet.
March 31, 2002
1-3
Description
Figure 1-4. Spread Hoppers Extended to 20-foot Width The operator controls all gates individually from the operators station. The independently controlled spread hoppers eliminate the need to manually add or remove aggregate gates to accomplish spread width changes. With the hoppers retracted to the 10-foot width, the machine is readily transportable. Each spread hopper uses a hydraulically driven, 14-inch diameter, abrasion resistant auger to ensure even distribution of the aggregate across the hopper. The 10 aggregate gates on each spread hopper are pneumatically actuated and provide instant response to any computer controlled or manual input. There is no agitator bar or spread roller to wear or limit production. The spread hoppers have a total capacity of 3.8 cubic yards. The struck capacity of the receiving hopper is 4.5 cubic yards. These capacities allow the Model BC-2002/CRC Tandem to operate for longer periods than conventional units in situations where the chip spreader cannot be accompanied by a dump truck. Optional spread hopper extensions are available. The extension adds 12 inches to the outside end of each hopper. This option increases the total spread width capability of the chip spreader to 22 feet.
1-4
March 31, 2002
Description
Gate Control Valve Box

A gate control valve box is mounted on each spread hopper. Each valve box contains the solenoid valves that control the functions of the individual hopper. The solenoid valves can be manually controlled at the box, but are normally controlled from the operators station. The interior of a valve box is shown in Figure 1-5.
Figure 1-5. Gate Control Valve Box Interior The functions of the components within the valve box are described in Table 1-1. The numbers in the table refer to the item numbers in Figure 1-5.
March 31, 2002
1-5
Description
Table 1-1. Gate Control Valve Box Functions

No. 1 2 Electro-pneumatic valves 1 thru 10 Toggle switches 1 thru 10 4 Description Hydraulic valve Switch (cam OPEN/CLOSE) Function Controls spread hopper hydraulic functions Manually controls the cam Manually operates gates Used for computer calibration Controls air flow to open or close the gates Provides manual control to open and close individual gates Used for setup and cleaning Used for manual operation
Computerized Rate Control (CRC)

Model BC-2002/CRC Tandem employs an onboard computer working with appropriate sensors to provide full automatic control of the aggregate flow at all times. Accuracy is assured for sand, rock, or any kind of coated or uncoated aggregate material. The computerized control system performs the following functions:

Constantly measures the actual rate at which aggregate is being delivered Correlates the actual rate with the travel speed of the chip spreader Compares the actual flow rate to the rate selected by the operator
The computer then uses the information obtained from these three sources (actual aggregate flow, vehicle speed, and desired aggregate flow rate) to maintain the desired rate at all times. The system automatically adjusts the aggregate flow through the spread hopper gates. Because the computer constantly monitors the speed of the vehicle, automatic rate control is maintained regardless of speed variations such as those encountered when the chip spreader moves up or down a grade or when accelerating or decelerating. Control is also constant whether the chip spreader is moving forward or backward. It is important to note that the computerized control system responds instantaneously to changes in vehicle speed or to the selection of a different spread rate by the operator. Therefore, there is never any lag time. The actual rate at which aggregate is laid on the surface is always instantly maintained at the selected level required. Changes in the width of the spread pattern, as for tapered areas, are accomplished by pressing the appropriate switches on the computer control panel. The corresponding gates are instantly closed, and the spread width varies accordingly. The operator does not need to leave his position to make these changes. Regardless of the spread width selected, or the changes made during a run, the spread rate is automatically maintained at the selected level of aggregate distribution.
1-6
March 31, 2002
Description
Chassis
The chassis members are channel steel, bolted rather than welded, for maximum repairability. The length of the chassis, as shown in Figure 1-6, permits a wheelbase of 158.5 inches. This length, in combination with rubber spring suspension on the front axle, assures smooth, steady control. The BC-2002/CRC Tandem is 10 feet wide when the spread hoppers are fully retracted and 20 feet wide when the spread hoppers are fully extended.
Figure 1-6. Chassis Dimensions
Hydraulically Powered Remote Control Hitch

The hydraulically operated hitch provides positive hooking and unhooking in any of a wide range of relative positions and angles between the chip spreader and the dump truck. The hitch is actuated through a switch on the operators control panel.
NOTE:
When equipped with the optional hitch lift, hitch height is also adjustable from the operators control panel.
March 31, 2002
1-7
Description
BC-2002/CRC Tandem Specifications

Table 1-2 lists general specifications for the BC-2002/CRC Tandem Chip Spreader. Table 1-2. Specifications
Hydrostatic Drive System Type Transmission Front-wheel drive, closed-loop feedback control system Axial piston variable rate high torque hydrostatic pump directly coupled to engine; variable rate hydraulic motor drives axle through 2-speed transfer case 2-Speed, high-low range, manually shifted, with remote oil cooler LOW Range (0-600 FPM) (Low-Lock engaged, 0-300 FPM) HIGH Range (0-1600 FPM) (18 MPH) (Low-Lock engaged, 0-700 FPM) NOTE: In low range the unit will pull a fully loaded 15 cubic yard dump truck up a 15% grade from a dead stop. Diesel Engine Pre March 2003 Diesel Engine March 2003/2004 Frame Rear Axle 2-WD 4-WD Rating (both) Front Axle Type Drive/steering axle with planetary gear hubs, over-all 17.1 to 1 reduction, 42 steering angle; dual rubber spring suspension; 31,800 lb rating Solid trailer axle (5 in. diameter tube) Rear drive axle with planetary gear hubs, over-all 17.1 to 1 reduction, solid mount 25,000 lb Cummins 5.9 liter, turbocharged. Electric start, alternator, dual batteries, dry-type air cleaner. Variable speed governor Cummins QSB 5.9 liter, Inter-cooled turbocharger, with electric start, alternator, dual batteries, dry-type air cleaner and variable speed governor. Emissions compliant Main: 10 1/8 in. X 3 in. channels Cross members: 10 in. X 3 in. channels
Transfer Case Operating Mode
Steering Type Control Brakes Front Wet disc, air over hydraulic Hydraulically powered orbital Hand wheel; no mechanical linkage
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January 31, 2004
Description
Table 1-2. Specifications

Rear (2-WD) Rear (4-WD) Parking Wheels Tires Positive Lock Hitch Type Adjustment Range Hydraulic System Type Drive Configuration Reservoir Cooling Power Steering Receiving Hopper Width Struck Capacity Spread Hopper Width Capacity Total Spread Width Spread Rate Range Spread Rate Control 10 feet (each) 3.8 cubic yards (2.9 cubic meters) 1 to 20 feet, hydraulically actuated 1-160 lbs per-square-yard Computer controlled CRC system 10 feet 4.5 cubic yards (3.44 cubic meters); includes rubber skirting to prevent spilling Variable-volume, pressure compensated piston pump Engine crankshaft Independent circuits for each conveyor and box function 70-gallon capacity, two 10-micron absolute return filters Hydraulically driven oil cooler with total return flow capacity Engine-mounted vane pump feeding twin load-sensing closed-center steering valves (excess pump flow powers positive lock hitch) Hydraulically powered, positive grab and release 8 in. to 20 in. height, 6 in. fore and aft 16.5 in. X 7 in. drum S-cam air brake, Anchorlok parking brake Wet disc, air over hydraulic Spring applied, hyd. released. Fail-safe driveline brake June 2005 Disc, front and rear interchangeable Truck type, 385/65R X 22.5 highway tread
Cut-Off Gates Conveyors Belt Width Trough Angle Belt Rating
Electro-pneumatic powered; 12 inches wide; infinite gate opening adjustment and preset capability from operators station
30 in. 30 2-ply
January 31, 2004
1-9
Description

Drive Motion Control Conveyors (continued) Conveyor Protection Operators Station Lined on each side; self-cleaning tail pulleys and return rollers; hooded deflectors at each head pulley Left-hand and right-hand adjustable cushioned seats with adjustable suspension; left-hand and right-hand adjustable tilt steering wheels; swing-over control/instrument panel with brake pedal and speed control Independent hydraulic motors By solenoid valves through spread hopper-mounted level sensors
Controls and Instruments Operators Panel Controls - ignition switch, hitch, spread width and rate controls, hydrostatic transmission, parking brake, augers, conveyor belts, transfer case, engine throttle; lockable covers included Instruments - fuel, hydraulic temperature, engine temperature, engine RPM, hour meter, oil pressure, charging system voltage, air pressure Safety Equipment Ladders on each side; safety hand rails; electric backup alarm; warning horn, strobe light, turn/flasher/stop lights, and tractor type night work lights
Miscellaneous Empty Weight Additional Equipment Over All Dimensions Length Width Height Ground Clearance Wheel Base Turning Radius Front Approach Angle Rear Approach Angle Tread Front Rear NOTE: 82 in. 104 in. 25,000 lbs 80-gallon fuel tank; deck-mounted tool boxes under seats With spread hoppers retracted and standard tires 27 feet 10 feet 9 feet 3 in. 10 in. 13 feet 2 1/2 in. 19.5 feet 18 20
As part of a continuing program of product improvement, BearCat Mfg., Inc. reserves the
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Description

right to make changes in Model BC-2002/CRC Tandem specifications at any time.
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Safety Precautions
SECTION 2. SAFETY PRECAUTIONS

Personal Safety
Persons responsible for the operation and maintenance of BearCat Chip Spreaders should read the following precautions and the remainder of this manual carefully before operating the equipment.
WARNING: ALWAYS REMEMBER THAT CHIP SPREADING MACHINES CAN BE DANGEROUS. THEY CONTAIN EXPOSED MOVING PARTS AND BELTS, AND THEY MOVE LARGE AMOUNTS OF ABRASIVE MATERIAL AT HIGH SPEED. YOU MUST OPERATE THIS MACHINE CAREFULLY TO PROTECT YOURSELF FROM PAINFUL OR EVEN FATAL INJURY. HAZARDS ASSOCIATED WITH THIS MACHINE, AND THE NECESSARY PRECAUTIONS TO AVOID DANGER, ARE GIVEN IN THIS MANUAL.
Safety Rules
Read each safety rule and make them a part of your daily work routine.
WARNING: FOLLOW THESE PRECAUTIONARY INSTRUCTIONS EXACTLY. DO NOT TAKE SHORTCUTS. DO NOT ASSUME THAT SOMEONE ELSE HAS ACTED ON YOUR BEHALF. IF ANY RULE OR PRECAUTION IS NOT CLEAR TO YOU, SEE YOUR SUPERVISOR BEFORE USING THE MACHINE.
Keep clear of all moving parts. Stay out of the hoppers when diesel engine is running. Keep hands away from gates when connecting air hoses. Use caution around the conveyor belts and augers. They can start automatically. Keep clear of rear handrail. Contact with the dump truck tailgate is possible. Keep clear of the hitch. You could be injured if it actuates against any part of your body. Engage the parking brake and place the hydrostatic transmission in neutral before leaving the machine. Stop the engine before crawling under the machine. Keep the surface of the hydraulic oil cooler clear of obstructions. BearCat Manufacturing assumes no liability for accident or injury incurred through improper use of this equipment.
NOTE:
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Safety Precautions
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Model BC-2002/CRC Tandem Preparing Equipment for Use
SECTION 3. PREPARING EQUIPMENT FOR USE

This section contains information the operator must know in order to prepare the Model BC-2002/CRC Tandem Chip Spreader for safe and proper spreading operations.
WARNING: OPERATORS MUST READ AND UNDERSTAND THIS MATERIAL BEFORE ATTEMPTING TO USE THE MACHINE. FAILURE TO FOLLOW THESE OPERATING INSTRUCTIONS MAY RESULT IN DEATH OR SERIOUS INJURY TO PERSONNEL. THE INITIAL CHECKOUT PROCEDURES GIVEN BELOW ARE MINIMUM REQUIREMENTS. FAILURE TO PERFORM THESE STEPS CAN RESULT IN DAMAGE TO THE EQUIPMENT AND UNSAFE OPERATING CONDITIONS.
CAUTION:
Initial Checkout of Machine

1. Make sure all fluid levels are adequate.
NOTE:
Use Shell Tellus 100 or equivalent type 100 oil if the hydraulic system or the brake master cylinder level is low.
A. B. C.
Hydraulic fluid the sight glass is located behind the left front fender brace. Brake master cylinder located on the left side of the chassis. Engine oil the dipstick is located on the left side of the engine.
RADIATOR SHOULD BE COOL TO THE TOUCH PRIOR TO REMOVING RADIATOR CAP. ESCAPING STEAM OR HOT LIQUID MAY CAUSE BURNS.
WARNING:
D. 2.
Radiator coolant check the fluid level at the radiator cap.
Check the hydraulic line filters.

NOTE:
If the gauge readings exceed 10 inches when the fluid is warm, replace the associated filter element.
3. 4.
Visually inspect the tires, hoses, fittings, and belts. Make sure the receiving hopper is filled with the appropriate aggregate for the job.
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Control Panel Switches

Operators should thoroughly understand the functions of all of the control panel switches as shown in Figure 3-1 and listed in Table 3-1.
Figure 3-1. Control Panel
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Table 3-1. Control Panel Switches

Switch L BELT Function AUTO: ON position enables the left belt to run until the spread hopper diaphragm switch turns it off. OFF: The belt is off. MAN: Manually runs the belt. R BELT AUTO: ON position enables the right belt to run until the spread hopper diaphragm switch turns it off. OFF: The belt is off. MAN: Manually runs the belt. HOPPER SHIFT HOPPER SHIFT BOTH FRONT AUGER FRONT (): Extends and retracts the front spread hopper only. REAR (): Extends and retracts the rear spread hopper only. OUT (): Extends both front and rear spread hoppers simultaneously. IN (): Retracts both front and rear spread hoppers simultaneously. AUTO: ON position enables the front auger to run until the diaphragm switch turns it off. OFF: The auger is off. MAN: Manually runs the auger. REAR AUGER AUTO: ON position enables the rear auger to run until the diaphragm switch turns it off. OFF: The auger is off. MAN: Manually runs the auger. HITCH OPEN: Used to open the hitch. CLOSED: Used to close the hitch. HITCH LIFT Optional Equipment FWD-REV. MAXIMUM SPEED CONTROL MASTER LOW-LOCK UP: Moves the hitch up. DOWN: Moves the hitch down. Selects forward, neutral, or reverse function for the hydrostatic drive. Variable speed control for hydrostatic drive. Used to adjust FPM rate of chip spreader. Turn knob CW to increase speed, turn knob CCW to decrease speed. Manually controls the air cylinders that operate the gates. Must be ON for any gate to open in CRC operation. ON: Actuates solenoid on hydraulic motor, engages motor full displacement speed-limiting function. OFF: Normal hydraulic motor operation.
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Table 3-1. Control Panel Switches

Switch LIGHTS OFF: Turns lights off. BEACON IGNITION Turns amber warning beacon on and off. Used to control chip spreader engine ignition system. Function ON: Turns work, tail, and clearance lights on.
Computer Controls
Operators should thoroughly understand the computer controls and functions, which are shown in Figure 3-2 thru Figure 3-6 and listed in Table 3-2 thru Table 3-5.
4 5 6 7 8 9
10
2 11
Figure 3-2. Computer Controls View 1
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Table 3-2. Control Functions for Figure 3-2

No. 1 2 3 SET (Rate Select Switch) AUTO Control Function Used in all computer functions to save a setting. Used to change the PSY or spread rate. Used to change from CRC to manual rate control. The default setting is CRC. To control the cam manually, press and hold the AUTO switch for 5 seconds. The PSY will disappear on the screen and the Rate Control Switches will now control the cam openings (speed variations will no longer affect the cam opening). To return to CRC, press and hold the AUTO switch again for 5 seconds, the PSY will reappear and the computer will resume control of the cam opening. Used to increase or decrease the computer control panel display contrast. Adjust display for different lighting conditions. Indicates a break in communication between the master computer and the slave unit (check computer connection). PSY (KgSM) OPEN Use the Rate Select switch to change the application. Indicates the cam position; the cam controls how much the gates open. The computer controls the cam in relation to ground speed and desired rate. Indicates the travel speed. Indicates the distance covered while spreading (it does not calculate width). It starts measuring when any gate is open. This number continually keeps track of the total distance spread, which will be reset to zero when the machine is shut off. Resets the FEET to zero (press and hold for 5 seconds to clear the distance measurement). Used to calibrate the spread rate and the footage. The computer must be calibrated when there is a change in aggregate size and weight. DO NOT confuse this with spread rate. Once the computer is calibrated for a particular aggregate, the spread rate can be changed at any time. Press and hold the switch for 5 seconds for aggregate calibration mode. Press it again in aggregate calibration mode for footage calibration.
CONTRAST
6 7
8 9
FPM (MPM) FEET
10 11
ZERO CAL
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5 6
1 7
Figure 3-3. Computer Controls View 2
Table 3-3. Control Functions for Figure 3-3

No. 1 2 3 4 5 Control Function Indicates the selected gates are open (the star disappears when the selected gates are closed). Indicates which gates are selected to open. Each black square represents a gate on the hoppers. Indicates how many gates are open (spread width). Opens all selected gates. Closes all gates. Changes to the current view whenever a GATE SELECTION, ON, or OFF switch is pressed (after several seconds the display will change back to the original view). Used to select which gates will open. These switches can also be used to control spread width while spreading.
GATE SELECTION INDICATOR GATE COUNT ON OFF DISPLAY
(Gate Select Switches)
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The gate select switches can also be used to control or change spread width while spreading. Figure 3-4 shows several spread pattern examples.
Figure 3-4. Examples of the Use of Computerized Gate Controls
Figure 3-5. Computer Controls View 3 Table 3-4. Control Functions for Figure 3-5
No. 1 2 Control (Gate Select Switch) (Gate Select Switch) Function Reselects or opens gates from a previous selection. Pressing this switch repeatedly closes the gates from left to right. Note: The OPEN INDICATOR ( ) is not visible, indicating that all gates are closed and you are just making a gate selection.
GATE COUNT
Indicates the number of gates selected (in this case, only one gate is selected).
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3 4
6 7 2 1 8
Figure 3-6. Computer Controls View 4 Table 3-5. Control Functions for Figure 3-6
No. 1 2 3 4 5 6 7 8 Control (Gate Select Switch) (Gate Select Switch) [] GATE COUNT OPEN CLOSE (Gate Select Switch) (Gate Select Switch) Function Reselects or opens gates from a previous selection. In this example, closes or deselects gates from the left to the middle. Shows selected gates are open. Indicates the number of gates selected (4 gates in this example). Opens all selected gates. Closes all gates. In this example, closes or deselects gates from the right to the middle. Reselects or opens gates from a previous selection.
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Setting Spread Hopper Width

WARNING: ALWAYS KEEP YOUR FINGERS CLEAR OF THE AGGREGATE GATES. IF A GATE SHOULD CLOSE UNEXPECTEDLY, SERIOUS PERSONAL INJURY MAY RESULT. KEEP CLEAR OF ALL MOVING PARTS. THE SPREAD HOPPERS ARE HYDRAULICALLY ACTUATED. IMPROPER OR UNSAFE OPERATION MAY CAUSE SERIOUS PERSONAL INJURY.
WARNING:
1. 2.
Determine the maximum spread width required for the job. Use the HOPPER SHIFT switches on the control panel (Figure 3-1), or the remote control box at the top of the right-hand conveyor (Figure 3-7), to extend the spread hoppers to the desired position.
Figure 3-7. Spread Hopper Remote Control Box
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3.
Test the aggregate gates for free movement using the manual gate control switches located in each valve box (Figure 3-8).
Figure 3-8. Manual Gate Switches 4. Fill the hoppers and perform the WEIGHT CALIBRATION and DISTANCE CALIBRATION procedures.
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Weight Calibration
WARNING: POTENTIALLY LIFE-THREATENING HAZARDS MAY EXIST DURING EQUIPMENT OPERATION. ONLY QUALIFIED PERSONNEL SHOULD ATTEMPT TO OPERATE, SERVICE, OR MAKE ADJUSTMENTS TO THE BEARCAT EQUIPMENT.
Proper weight calibration ensures the computer controlled aggregate gates are opening to the exact extent required to deposit the specified amount of aggregate, under all operating conditions. This procedure should be performed on a level surface.
NOTE:
It is not necessary to perform the weight calibration with all gates open. Select a spread width that allows the operator to cover the canvas (4 to 6 feet).
This weight calibration should be carried out whenever the aggregate material is changed to one of a different type or from a different source. 1. 2. 3. 4. 5. Fill the hoppers with the new aggregate. Place the yard-square piece of canvas (furnished) on the scale provided and set the scale to zero. Lay the canvas out flat on level ground. Switch the CRC unit ON and use the controls to enter the PSY (pounds-per-square-yard) value desired for the job. On the Control Panel, position the following switches to AUTO or ON: R and L BELTS FRONT and REAR AUGER MASTER 6. With the engine running at 1800-2000 RPM and the transfer case in LOW, drive the machine as follows: A. Set the SPEED control fully CCW and the FWD-REV switch to FWD. B. Press the foot pedal down. C. Turn the SPEED control CW. The machine will begin moving after about three full turns. Turn the control to obtain the approximate expected spreading speed for the job.
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7.
Drive toward the canvas square. Position the gate switch to OPEN to begin spreading just before reaching the canvas square (the chip spreader must be traveling at the required speed for the job). After passing over the canvas, position the gate switch to CLOSE and stop the machine by releasing the foot pedal. Use the scale to weigh the canvas with the deposited aggregate.
8. 9.
10. If the actual weight differs from the value entered in Step 4, press and hold the CAL switch (Figure 3-9). The display will instruct you to enter the actual weight of the aggregate sample. 11. Use the controls to enter the actual weight. 12. Press the SET switch. The display will show the PSY value entered in Step 4.
NOTE:
If the difference between the entered PSY and the actual weight is large, a second calibration run may be necessary. If necessary, repeat Step 7 thru Step 12.
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Distance Calibration
Proper distance calibration ensures the correlation between machine ground speed and chip-spreading density is accurately maintained through the distance-measuring circuits in the CRC computer. This procedure should be performed once in each operating season. It is not necessary that the receiving hopper or spread hoppers be filled. 1. With the engine running and the SPEED control fully CCW, position the CRC computer POWER switch to ON. Refer to Figure 3-1 and Figure 3-9 for the control locations.
Figure 3-9. Computer Display During Distance Calibration 2. 3. 4. 5. 6. 7. Press ZERO to zero the FEET display. Set the FWD-REV switch to FWD, press the foot pedal all the way down and turn the SPEED control CW until the display indicates approximately 300 FPM. Position the gate switch to OPEN and drive a carefully measured distance of 1000 feet. At exactly 1000 feet, position the gate switch to CLOSE and stop the machine by releasing the foot pedal. The FEET display should now read approximately 1000. Press and hold CAL twice, holding the switch down approximately five seconds each time. Press to lower the displayed FEET value or to raise it, until it reads 1000.
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8. 9.
When the display reads 1000, press SET. The distance calibration is now complete. The machine is in the normal operating mode. Note the new distance (footage) calibration number and enter it on the title page of this manual. The computer control can be reset to this number if the box is replaced or the number is changed. If this number is used, the unit will not require a complete distance calibration.
Operator Station Adjustments

Control Panel
Select on which side of the machine to operate. The control panel swings left or right by pulling the spring loaded pin at the base and pushing the assembly left or right. During the course of the workday, the operator may change sides. Set up both sides comfortably.
Bi-View Mirrors
Optional bi-view mirrors are designed to give the operator a view of the blind side of the machine and the level of aggregate in each spread hopper. The mirror opposite to the operators position gives a view of the blind side and the end of the spread hopper. The mirror on the same side of the operator gives a view of the center of the hoppers.
Hitch Adjustments
Height
The hitch can be adjusted up and down using the chains. Pick the hitch up with one hand and move the links in or out of the slots, as desired.
NOTE:
An optional hydraulic hitch lift can be adjusted from the control panel.
Fore and Aft

The hitch fore and aft adjustments are located between the conveyor rails underneath the chipper. Pull the spring pin and remove the bolt, there are four holes for adjustment.
NOTE:
Be sure to replace the bolt, nut and spring pin.
Chip Spreader Hitch Bar Requirements

The location and measurements required to position the chip spreader hitch bar on the aggregate supply dump truck are shown in Figure 3-10. Figure 3-11 shows an example of the hitch bar. The exact positioning of the hitch bar is required for consistent aggregate flow to the receiving hopper without unnecessary spillage.
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Figure 3-10. Hitch Bar Location on Dump Truck
Figure 3-11. Typical Hitch Bar
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Operating Instructions
SECTION 4. OPERATING INSTRUCTIONS

Mechanical Startup
Before starting the Chip Spreader, complete the fluid checks and visual inspection described under SECTION 3. PREPARING EQUIPMENT FOR USE.
WARNING: YOUR CONTINUED GOOD HEALTH AND EVEN YOUR LIFE MAY DEPEND ON FOLLOWING THE RULES OF OPERATION SET FORTH IN THIS MANUAL. ALWAYS REMEMBER THAT CHIP SPREADING MACHINES CAN BE DANGEROUS. THEY CONTAIN EXPOSED MOVING PARTS AND BELTS, AND THEY MOVE LARGE AMOUNTS OF ABRASIVE MATERIAL AT HIGH SPEED. YOU MUST OPERATE THIS MACHINE CAREFULLY TO PROTECT YOURSELF FROM PAINFUL OR EVEN FATAL INJURY. HAZARDS ASSOCIATED WITH THIS MACHINE, AND THE NECESSARY PRECAUTIONS TO AVOID DANGER, ARE GIVEN IN THIS MANUAL.
1.
Set the following controls as specified:

SET PARKING BRAKE R and L BELTS FRONT and REAR AUGER FWD-REV TRANSFER CASE T-HANDLE START UP VALVE RELEASE THROTTLE
(PULL) (OFF) (OFF) NEUTRAL NEUTRAL (PULL) (PULL UP)
2. 3. 4.
Start the engine and use the hand throttle to set it at 1000 RPM. Push the T-Handle Start Up Valve back. Extend the spread hoppers to the desired width for the job. Set the following controls as specified:

MASTER R and L BELTS FRONT and REAR AUGER
ON AUTO AUTO
5. 6.
Use the computer controls to enter the PSY or KgSM value desired for the job. The PSY or the KgSM may be adjusted during the run if necessary. Release the parking brake.
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Operation
Drive the Chip Spreader as follows: 1. 2. 3. Set the FWD-REV switch to the desired direction. Turn the SPEED control CW approximately ten turns, until it stops. Select transfer case high or low range. A. B. Move the transfer case shift lever to the desired position. VERY SLOWLY AND GENTLY press the right foot pedal down to see if the chip spreader moves. Make sure the transfer case is in gear.
KEEP CLEAR OF THE HITCH. YOU COULD BE INJURED IF IT ACTUATES AGAINST ANY PART OF YOUR BODY.
WARNING:
4.
Adjust the hitch. On the control panel, push the HITCH switch to the OPEN position and hold for two seconds to open the hitch. A. Back the chip spreader into the hitch bar of the aggregate supply dump truck. The driver of the dump truck should hold the brakes while the chip spreader is backed up. To align the dump truck and chip spreader, center the bed of the dump truck within the receiving hopper opening.
NOTE:
B.
The optional hitch height can be adjusted from the control panel.
C.
The mouth of the hitch should center itself vertically on the hitch bar. If the hitch mouth is not centered because it is too high or low, use the chains that the hitch hangs from to adjust the height. With the chip spreader hitch mouth pushing against the dump truck hitch bar, push the HITCH switch to the CLOSED position for two seconds to close the hitch. If the position of the dump bed is either too far into the receiving hopper or too far out, the hitch can be adjusted fore and aft 6 inches to compensate.
D.
E. 5.
Fill the receiving hopper with aggregate. A. B. Give the dump truck a small tug with the chip spreader to check if the hitch is locked. Using hand signals, direct the dump truck operator to release the tailgate, tip the bed and dispense aggregate into the receiving hopper. The belts are still running from Step 4 in the Mechanical Startup. The spread hoppers should start filling with aggregate.
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Setting Gate Opening for Manual Operation

This procedure enables the use of the machine in a nonautomatic mode. 1. With the engine running and the CRC computer switched OFF, use the cam switches located in each valve box to set the cam indicators (Figure 4-1) to the same value at which the machine has been operating. Turn the MASTER switch OFF.
ALWAYS KEEP CLEAR OF THE AGGREGATE GATES. IF A GATE SHOULD OPEN OR CLOSE UNEXPECTEDLY, SERIOUS PERSONAL INJURY COULD RESULT.
2.
WARNING:
3. 4. 5.
Open individual gates with switches 1 thru 10 and 11 thru 20 (located in the valve boxes) as required for the job. Set the CRC SPEED control to the number of turns that most nearly corresponds to the actual FPM at which the machine has been running. Drive the machine up to speed, then turn the MASTER switch ON to open the gates and OFF to close the gates.
Figure 4-1. Cam Open Indicator
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Model BC-2002/CRC Tandem NOTE:
When operating in the manual mode, it is important to remember that any open gate will remain open the same distance no matter what speed the machine is driven. There is NO automatic control of PSY during manual override. In the manual mode, the most effective way to change PSY is by changing speed with the CRC SPEED control. Speed variations as small as 2% can readily be made with this control. As speed is raised, PSY decreases.
6.
Upon completing the run, use the cam switch to return the cams to the closed position and close the gates.
Clearing a Clogged Gate

WARNING: NEVER INSERT YOUR HAND INTO A GATE. ALWAYS USE A METAL BAR OR ROD TO CLEAR AN OBSTRUCTION FROM A GATE. FAILURE TO DO SO MAY RESULT IN SERIOUS PERSONAL INJURY.
If a gate becomes plugged by a rock, perform the following: 1. 2. 3. 4. 5. Open the gate from the appropriate spread hopper valve box. Use the cam switch in the valve box to set the cam fully open. Open the clogged gate with the individual gate switch. Remove the clog with a metal bar or rod. When the clog is cleared, remove the metal bar and return the switches to their normal positions.
Shutdown on Completion of a Job

At the end of the job, perform the following steps:
NOTE:
Step 1 and Step 2 should always be done unless the aggregate is so dry that there is no danger of caking.
1. 2. 3.
Empty the spread hoppers. Empty the receiving hopper. Set the switches as follows:

MASTER R and L BELTS FRONT and REAR AUGER CRC
(ON) (OFF) (OFF) (OFF)
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4.
To transport the machine to another location, accomplish the following steps: A. B. Retract the spread hoppers to the 10-foot width. Rotate the SPEED control fully CCW and set the FWD-REV switch to the NEUTRAL position.
5. 6.
If the optional tow bar is used, see the instructions in SECTION 5. TOW BAR (OPTIONAL). Shut off the engine and set the parking brake.
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Tow Bar
SECTION 5. TOW BAR (OPTIONAL)

WARNING: STAY OUT FROM UNDER THE TOW BAR AND CHIP SPREADER WHEN THEY ARE RAISED AND SUPPORTED BY THE HYDRAULIC LIFT CYLINDER. DEATH OR PERSONAL INJURY MAY OCCUR.
NOTE:
The optional tow bar can only be used on 2-Wheel Drive models.
1. 2. 3. 4.
Position the tow bar on a hard, flat surface. Using the trailering jack, disconnect the tow bar from the pickup or dump truck and lower the tow bar, raising the tires off the ground as shown in Figure 5-1. Remove the tow bar tires and stow them in the tow bar (Figure 5-2). Carefully drive the chip spreader up to the tow bar, centering it for attachment (Figure 5-3).
THE CHIP SPREADER ENGINE MUST BE SHUT DOWN WHILE DISCONNECTING OR RECONNECTING HYDRAULIC HOSES. DEATH OR PERSONAL INJURY MAY OCCUR.
WARNING:
5.
Connect the long 1/4 inch hydraulic hoses on the tow bar to the quick disconnects located on the street side of the front spread hopper. The tow bar valve controls the tow bar lift cylinder. Position the wood blocks (5 in. X 8 in. X 48 in.) in front of the chip spreader as shown in Figure 5-3. Raise the tow bar with the hydraulic lift cylinder as shown in Figure 5-3. Carefully drive the chip spreader onto the wood blocks, keeping the tow bar centered (Figure 5-5).
NOTE:
6. 7. 8.
A large pry-bar is helpful in aligning the pins.
9.
Adjust the pin-eye height with the lift cylinder and install the coupling pins and safety pins (Figure 5-4 and Figure 5-5).
DO NOT USE THE TRAILERING JACK TO RAISE THE CHIP SPREADER. DAMAGE TO THE TRAILERING JACK MAY OCCUR.
CAUTION:
10. Raise the chip spreader and the tow bar with the hydraulic lift cylinder until the front chipper tires are at least 10 inches off the ground (Figure 5-6). 11. Adjust the pintle eye to match the towing vehicle (Figure 5-7). Torque the pintle eye bolts to 300 FT-LB.
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Tow Bar
12. Couple the tow bar to the towing vehicle. 13. Remove the wood blocks from under the chip spreader. 14. Make the air and light connections at each end of the tow bar (Figure 5-5 and Figure 5-8). 15. Change the air valve to the Towing position (located near the air glad-hand connection at the rear of the tow bar on the chip spreader). 16. Check the air brake operation from the towing vehicle, ensuring the rear brakes on the chip spreader function with the towing vehicle brakes. 17. Check all signal, brake and tail lights. Ensure they coordinate with the towing vehicle lights. 18. Attach the safety chains (2) to the towing vehicle (Figure 5-8 and Figure 5-9). 19. Double check the safety pins on the coupling pins at the rear of the tow bar (Figure 5-4).
Towing Requirements
WARNING: FAILURE TO COMPLY WITH THE FOLLOWING MINIMUM TOWING REQUIREMENTS COULD RESULT IN ACCIDENTAL SEPARATION OF THE CHIP SPREADER FROM THE TOW VEHICLE WHILE IN TRANSIT, CAUSING A POTENTIALLY DEADLY SITUATION.
1. 2.
The towing vehicle must be three axle, ten wheel (minimum) with a GVW of 52,000 lb. minimum (40,000 RAWR, 12,000 FAWR). The pintle hook must be rated at 80,000 lb. towing capacity and 15,000 lb. vertical load minimum (Figure 5-8). The pintle must be mounted no more than 56 inches rear of the tandem suspensions trunion (Figure 5-9). A combination hitch X-member complete with pintle and chipper hook bar can be supplied by BearCat (Part No. BRK-50960, Hitch and Hook Bar Assembly, MSC50960 Premier 580 solid pintle coupling).
3.
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Tow Bar
Figure 5-1. Tow Bar
Figure 5-2. Wheel Placement and Removal Position
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5-3
Tow Bar
Figure 5-3. Position No. 1 Loading Chip Spreader
Figure 5-4. Rear View, Coupling Pins
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Tow Bar
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Tow Bar
Figure 5-7. Trailering Jack and Pintle Eye
Figure 5-8. Truck Hitch and Hookups
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Tow Bar
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Tow Bar
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Maintenance
SECTION 6. MAINTENANCE
Scheduled Maintenance
Table 6-1. Scheduled Preventive Maintenance
Period 1. Daily 2. Maintenance Drain accumulated moisture from the air tanks. If using precoated aggregate: to prevent buildup, parts of the machine exposed to the aggregate must be prelubricated with a suitable biodegradable solvent. These areas must be lubricated at every stop during the work shift. Grease the four fittings per foot on the camshaft and gates (Figure 6-1). a. Weekly 2. 3. 4. 5. 6. 7. 8. 9. b. c. One on the shaft on each side of the gates. One on the bottom of the gate. One on the rear of the gate.
1.
Grease the head bearings on the front and rear belt rollers (two fittings per roller). Grease the rear brakes S-cam bushings (2-WD model). Grease both ends of the tie rod. Grease both ends of the steering cylinder. Grease the top and bottom of both steering knuckles. Grease both ends of the drivelines. Grease the front axle yoke bearing. Verify the accuracy of the gate openings: TO AVOID INJURY KEEP FINGERS CLEAR OF THE GATE. SUDDEN OR UNEXPECTED MOVEMENT COULD CAUSE SERIOUS PERSONAL INJURY.
WARNING: Monthly
a.
Set switches as follows: CRC MASTER MANUAL GATE SWITCHES (all) OFF ON OPEN
b. c. d. NOTE:
Set the cam to the CLOSED position. Set any gate to a measured 3/4-inch opening. Adjust remaining gates to a 3/4-inch opening, using a 3/4-inch square tube as a feeler gauge (Figure 6-2).
The grease used in all of these procedures is chassis grease.
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Maintenance
Figure 6-1. Cam Shaft and Gate Grease Fittings
Figure 6-2. Checking Gate Opening
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Maintenance
Routine Maintenance
Weight Calibration
WARNING: POTENTIALLY LIFE-THREATENING HAZARDS MAY EXIST DURING EQUIPMENT OPERATION. ONLY QUALIFIED PERSONNEL SHOULD ATTEMPT TO OPERATE, SERVICE, OR MAKE ADJUSTMENTS TO THE BEARCAT EQUIPMENT.
Proper weight calibration ensures the computer controlled aggregate gates are opening to the exact extent required to deposit the specified amount of aggregate under all operating conditions. This procedure should be performed on a level surface.
NOTE:
It is not necessary to perform the weight calibration with all gates open. Select a spread width that allows operator to cover the canvas (4 to 6 feet).
Weight calibration should be carried out whenever the aggregate material is changed to one of a different type or from a different source. 1. 2. 3. 4. 5. Fill the spread hoppers with the new aggregate. Place the yard-square piece of canvas (furnished) on the scale provided and set the scale to zero. Lay the canvas out flat on level ground. Switch the CRC unit ON and use the controls to enter the PSY (pounds-per-square-yard) value desired for the job. On the Control Panel, position the following switches to AUTO or ON:

R and L BELTS FRONT and REAR AUGER MASTER
6.
With the engine running at 1800-2000 RPM and the transfer case in LOW, drive the machine as follows: A. B. C. Set the SPEED control fully CCW and the FWD-REV switch to FWD. Press the foot pedal down. Turn the SPEED control CW. The machine will begin moving after about three full turns. Turn the control to obtain approximately the expected spreading speed for the job.
March 31, 2002
6-3
Maintenance
7.
Drive toward the canvas square. Position the gate switch to OPEN to begin spreading just before reaching the canvas square (the chip spreader must be traveling at the required speed for the job). After passing over the canvas, position the gate switch to CLOSE and stop the machine by releasing the foot pedal. Use the scale to weigh the canvas with the deposited aggregate.
8. 9.
10. If the actual weight differs from the value entered in Step 4, press and hold the CAL switch. The display will instruct you to enter the actual weight of the aggregate sample. 11. Use the controls to enter the actual weight. 12. Press the SET switch. The display will show the PSY value entered in Step 4.
NOTE:
If the difference between the entered PSY and the actual weight is large, a second calibration run may be necessary. In that event, repeat Step 7 thru Step 12.
Distance Calibration
Proper distance calibration ensures the correlation between machine ground speed and chip-spreading density is accurately maintained through the distance-measuring circuits in the CRC computer. This procedure should be performed once in each operating season. It is not necessary that the receiving hopper or spread hoppers be filled. Refer to Figure 6-3 for the location of the controls.
Figure 6-3. Computer Display During Distance Calibration
6-4
March 31, 2002
Maintenance
1. 2. 3. 4. 5.
With the engine running and the SPEED control fully CCW, position the CRC computer POWER switch to ON. Press ZERO to zero the FEET display. Set the FWD-REV switch to FWD, press the foot pedal all the way down and turn the SPEED control CW until the display indicates approximately 300 FPM. Position the gate switch to OPEN and drive a carefully measured distance of 1000 feet. At exactly 1000 feet, position the gate switch to CLOSE and stop the machine by releasing the foot pedal. The FEET display should now read approximately 1000. Press and hold CAL twice, holding the switch down approximately five seconds each time. Press to lower the displayed FEET value or to raise it, until it reads 1000. When the display reads 1000, press SET. The distance calibration is now complete and the machine is in the normal operating mode. Note the new distance (footage) calibration number and enter it on the title page of this manual. The CRC computer can be reset to this number if the box is replaced or the number is changed. If this number is used, the unit will not require a complete distance calibration.
6. 7. 8. 9.
Potentiometer Calibration
The potentiometer (Pot) for each spread hopper is located on the outboard end of the camshaft and is protected by a heavy guard bolted to the end plate of the spread hopper (Figure 6-4). With the guard removed, the Pot can be accessed for repair or replacement (Figure 6-5). Perform the following steps to calibrate the Pot: 1. 2. 3. 4. With the CRC computer POWER switch in the OFF position, press and hold the CAL switch and turn power ON. Hold the switch in the CAL position until SET POTS? is shown on the CRC computer display and release the switch. Immediately press the (up) switch to select YES and enter the Pot calibration mode. When MOVE CAMS NOW is displayed, press the (up) switch to select YES and start cam movement and the Pot calibration routine. The CRC computer system will cycle the cam to the open and closed position and calibrate the Pot. Once the cam has cycled and stopped, the Pot calibration is finished.
5.
March 31, 2002
6-5
Maintenance
Figure 6-4. Potentiometer Guard
Figure 6-5. Potentiometer
6-6
March 31, 2002
Maintenance
Replacement Filters, Belts and Fans

Filters, belts and fans are not replaced during scheduled maintenance; they are replaced as needed. Table 6-2 lists BearCats part numbers for these components and the manufacturers part numbers. Table 6-2. BearCat Part Numbers
BearCat Description Hydraulic Filters Hydraulic Filter (100 Mesh) Hydraulic Filter (10 Micron) Hydraulic Filter (10 Micron 15 GPM) Oil Filters Oil Filter Fuel Filters Fuel Filter (Primary) Fuel Filter (Secondary) Pre-Fuel Filter Water Filter Water Filter (Service) Air Filter Air Filter (Primary) Air Filter (Secondary) Belt Fan Belt (Start Ser No. 45293079) Fan (Puller) Cummins Ky-Cadillac 3926862 4735-41393-35 PTM-60961 MSC-51853 1 1 Fleet Guard Fleet Guard AF418 AF490M FTR-51265 FTR-51266 1 1 Fleet Guard WF2071 FTR-60956 1 Fleet Guard Fleet Guard Fleet Guard FS1280 FF5052 FS19512 FTR-51261 FTR-51262 FTR-51269 1 1 1 Fleet Guard LF3000 FTR-51260 1 Zinga Zinga Zinga SE-100 SE-10 AE-10 FTR-22505 FTR-22502 FTR-51736 2 3 1 Brand Part No. Part No. Qty Hydraulic Components
Cummins Engine Filters, Belt and Fan
March 31, 2002
6-7
Maintenance
Lubrication Specifications
The following list references the various types of lubricants that BearCat specifies for use on specific components of the BC-2002/CRC Tandem Chip Spreader. Chassis Grease

Gate Cylinder Ends Cam Bearings Gate Hinge Pins Head Pulley Bearings Auger Bearings Cam Lock Pivots Driveline (belt pump) Front and Rear Driveline (rear driveline 4-WD only) Trunion Bearing Take-Up Bearings (rear of conveyor) Spindle Bearings (top and bottom of axle) Tie Rod Ends
Cam Gear Box Shell Hydraulic Oil Shell Texaco Tellus T 100 or equivalent (Shell Tellus 46 NOT used as of 05/20/00) Rando HDZ 100 (Texaco Rando HD 46 NOT used as of 05/20/00) OMALA HD 460
Drive Axle Gear Oil Must meet API GL-5 and MIL-PRF2105E qualifications Shell Texaco John Deere Donax TD TDH Oil Hy-Gard Hy-Gard, Low Viscosity Hy-Gard Hy-Gard, Standard JDM J20C, or J20D Allison C-4
Cummins Engine Oil Shell SAE 30 WT All Guard Diesel Oil
6-8
March 31, 2002
Illustrated Parts List
SECTION 7. ILLUSTRATED PARTS LIST
March 31, 2002
7-1
The following recommended spare parts list (Table 7-1) is provided as a guide to the user for convenience in the maintenance of Model BC-2002/CRC Chip Spreader. All of the parts listed are available from BearCat Manufacturing, Inc. Table 7-1. Recommended Spare Parts
Description
Belt Switch On/Off/Mom-On Single Pole Switch, On/Off/On Single Pole Toggle Switch, Fwd/Rev Switch 3 Pole 2 Position With Hesitation Switch, On/Off Single Pole Toggle Switch, Mom-On/Off/Mom-On Single Pole Toggle Switch, On/Off 2 Pole Toggle Switch, High Temperature Level Control Rheostat Potentiometer, Geared (Modified) Thru 1999 Potentiometer, 2000 and newer Diaphragm, Material Level Switch Air Solenoid Valve, 4-Way Versa C-7 Connector Cable 6-Cond. CRC Cable, 8-Cond. Gear Tooth Sensor Assembly Cylinder Chipper Gate Hinge Pin-Conveyor Belt 3 X 3 Canvas Calibration Bag Calibration Scale, Weigh Hydraulic Filter, Zinga Hydraulic Filter 100 Mesh, Zinga Hydraulic Filter, Water Filter, Vent Breather Fuel Filter, Primary Fuel Filter, Secondary Fuel Filter, Remote (inline) Hydraulic Filter Zinga (case bleed) Coolant Filter, Water Service Air Filter, Primary Air Filter, Safety Oil Filter, (Chipper Engine) Belt, Chipper Engine (start serial no. 45293079)
Part No.
ELC-51748 ELC-24272 ELC-51747 ELC-24275 ELC-24274 ELC-24267 ELC-50915 ELC-24288 ELC-50591 ELC-53128 MSC-50831 VLV-50902 ELC-26228 ELC-26235 ELC-26148 CYL-50703 FAS-51763 MSC-51771 MSC-51749 FTR-22502 FTR-22505 FTR-22508 FTR-22527 FTR-51261 FTR-51262 FTR-51269 FTR-51736 FTR-60956 FTR-51265 FTR-51266 FTR-51260 PTM-60961
Quantity
2 1 1 1 1 1 1 1 1 1 2 1 2 30 1 1 2 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1
7-2
January 31, 2004
Figure 7-1. Model BC-2002/CRC Tandem (Complete)

7-3 Blank/7-4 March 31, 2002
Model BC-2002/CRC Tandem Fig

7-1 1 -2 -3 -4 5 6 -7 -8 9 -10
Illustrated Parts List Part No.

BC-2002
Item
Description
Chip Spreader, Tandem (Complete) Tandem Chip Spreader Assembly BC-2002 (See Figure 7-2 for Details) Engine/Hydrostatic Installation (See Figure 7-3 for Details) Drivelines (See Figure 7-4 for Details) Spherical Bearing (See Figure 7-8 for Details) Hitch Assembly (See Figure 7-17 for Details) Hitch Lift (See Figure 7-18 for Details) Hitch Manifold W/Out Lift Option (See Figure 7-19 for Details) Hitch Manifold W/Lift Option (See Figure 7-20 for Details) Chip Box, Tandem (See Figure 7-21 for Details) Chip Box Extension (See Figure 7-25 for Details)
Qty
RF 1 1 1 1 1 1 1 1 2 1
NOTE: A dash () before the item number indicates the item is not illustrated on that figure.
March 31, 2002
7-5
Blank Page
7-6
March 31, 2002
Figure 7-2 (Sheet 1). Tandem Chip Spreader Assembly
7-7 Blank/7-8
March 31, 2002
Figure 7-2 (Sheet 2). Tandem Chip Spreader Assembly
7-9 Blank/7-10
March 31, 2002

7-2 1 3

BRK-53083
Item
Description
Tandem Chip Spreader Assembly BC-2002 Support Panel, Right-Hand Hex Bolt 1/2 13 X 1 1/4 Lock-Washer 1/2 Nut Hex 1/2 13
Qty
RF 1 AR AR AR
6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54
Manifold Hand Rail, Front (2000 2001) Mirror Mirror Base Panel Limit Switch Assembly Seal Door Assembly Left-Hand Door Assembly Right-Hand Guard Rail, Front Inside (2000 2001) Conveyor Assembly, Right-Hand (See Figure 7-12 for Details) Guard Rail, Conveyor (2000 2001) Manifold, Auger / Belt Stiffener Stiffener Cross Member Aft Cross Member Forward Hex Bolt 3/8 16 X 1 1/4 Lock-Washer 3/8 Nut Hex 3/8 16
MSC-53280 RNG-53307 GRD-61050 BRK-61051 BRK-53299 MTR-53202 RNG-53320 HSG-53294 HSG-53300 GRD-53317 HSG-53150 GRD-61701 MSC-53376 BRK-53257 BRK-53260 BRK-53099 BRK-53100
2 1 2 2 1 2 4 1 1 2 1 2 1 1 3 1 1 16 16 16
57 60 63 66 69 72 75 78 81 84 87 90 93 96
Coupling, Female Coupling, Male Taper Lock 1 1/2 Taper Lock 1 15/16 Mounting Plate Belt Motor Assembly Working Light Air Intake Precleaner Tube/Steering Assembly (2000 2001) (See Figure 7-13 for Details) Pedestal and Control Box Assembly (See Figure 7-16 for Details) Platform Mid Platform Gripstrut Oil Cooler Assembly (See Figure 7-15 for Details) Beacon
PTM-60663 PTM-60664 PTM-60666 PTM-60665 BRK-51536 PTM-51619 ELC-51585 FTR-51855 BRK-51529 HSG-53372 HSG-53271 GRD-53278 HSG-53233 ELC-24215
1 1 1 1 1 2 3 1 1 1 1 2 1 1
March 31, 2002
7-11

7-2

HSG-53365 BRK-51785 RNG-51795 RNG-53394 GRD-51566 RNG-51796 MSC-51773 BRK-51246 BRK-60647 RNG-51793 BRK-51846 BRK-51798 RNG-60645 ELC-51596 ELC-24293 BRK-60614 PTM-53348 PTM-53226 HSG-53342 BRK-51915 BRK-51914 FAS-51446 MCH-53216 BRK-53229 BRK-53241 TNK-61824 FIT-26045 GRD-51808 BRK-60604 BRK-60667 GRD-51528 BRK-60696 BRK-61479 ELC-60950 HSG-53149 BRK-53081
Item
99 102 105 108 111 114 117 120 123 126 129 132 135 138 141 144 147 150 153 156 159 162 165 168 171 174 177 180 183 186 189 192 195 198 201 204 207 Receiving Hopper Clamp, Vertical Seal Seal, Vertical Seal, 45 Corner
Description
Qty
1 2 2 2 1 2 1 1 4 4 2 2 2 2 1 2 1 1 1 2 4 12 1 1 1 1 1 2 2 1 1 1 2 1 1 1 AR AR AR
Hand Rail, Aft (2000 2001) Seal, Horizontal Seat Clamp, Horizontal Seal Clamp, Conveyor Rear Side Seal Seal, Conveyor Flashing Grizzly Clamp, Conveyor Rear Seal Seal, Horizontal Conveyor Light Markers Back-Up Alarm Support, Receiving Hopper to Conveyor Modified Axle Assembly (2WD) Rear Drive Axle Assembly (4WD) Platform with Seat Base, Right-Hand & Left-Hand Horizontal Seal Stiffener, Outer Horizontal Seal Stiffener, Inner Wire Rope Clamp 3/4 Hitch Assembly Hitch X-Member Channel Stiffener Diesel Tank Cap Rear Fender Bracket, Tank to Conveyor Support, Upper Ladder Assembly Support, Lower Bracket, Rear Junction Box Conveyor Assembly, Left-Hand (See Figure 7-11 for Details) Support Panel, Left-Hand Hex Bolt 1/2 13 X 1 1/4 Lock-Washer 1/2 Nut Hex 1/2 13
210 213
Hood Brackets
HSG-61708 BRK-61696
1 AR
7-12
March 31, 2001

7-2

BRK-53355 BRK-51425 BRK-53366 ELC-51587 BRK-51416
Item
216 219 222 225 228 231
Description
Bracket, Outer Conveyor Rail to Hydraulic Tank Bracket, Inner Conveyor Rail to Hydraulic Tank Track Support, Aft Light, Turn Bracket, Bearing Mount Hex Bolt 3/8 16 X 1 1/4 Lock-Washer 3/8 Nut Hex 3/8 16
Qty
2 2 1 1 4 12 12 12
234 237
Pillow Block, Bearing Hex Bolt 5/8 11 X 1 1/4 Lock-Washer 5/8 Nut Hex 5/8 11
PTM-51415
4 8 8 8
240 243 246 249 252 255 258 261 264 267 270 273 276 279 282 285 288 291 294 297 300 303 306 309 312 315
Head Pulley Assembly Track Support Baffle Cat Walk Rock Box Panel Left-Hand, Front Rock Box Panel Left-Hand, Rear Seal Wiper Panel, Right-Hand Side, Left-Hand Conveyor Chain Assembly, Mirror Rock Box End Panel, Left-Hand Rock Box End Panel, Right-Hand Slave Box Assembly Bracket Track Support, Front Remote Box Assembly Rock Box Panel Right-Hand, Front Rock Box Panel Right-Hand, Rear Seal Wiper Cat Walk Guard Hand Rail, Front (2002) Hand Rail, Front/Side (2002) Guard Rail, Front Inside (2002) Guard Rail, Conveyor (2002) Tube/Steering Assembly (2002) (See Figure 7-13 for Details) Hand Rail, Aft (2002)
PTM-61404 BRK-53087 BRK-53090 GRD-53311 HSG-53291 HSG-53292 RNG-53395 HSG-53295 FAS-61052 HSG-53293 HSG-53298 HSG-53143 BRK-53353 BRK-53341 HSG-53331 HSG-53296 HSG-53297 RNG-53395 GRD-53133 GRD-53411 RNG-53424 RNG-53425 GRD-53429 GRD-53426 BRK-51529 GRD-51566
2 1 2 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 2 2 1 1
March 31, 2002
7-13
Blank Page
7-14
March 31, 2001
Figure 7-3. Engine/Hydrostatic Installation
7-15 Blank/7-16
March 31, 2002

7-3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

MCH-51849 FTR-51539 MSC-51600 PMP-51618 FIT-60616 PTM-51459 GRD-51815 MSC-53371 BRK-51460 MSC-51869 BRK-51805 BRK-51826 VLV-53237 BRK-53262 GRD-51806 PMP-53230 BRK-53224 PTM-53160 PMP-53231 HSG-53135 PMP-51925 BRK-53402 HSG-53350 FTR-60953 FTR-60945 FTR-51731 BRK-61681 PMP-80016 HSG-53139 MSC-100130 FAS-61487 BRK-61491 TNK-53158 MTR-51862 PIP-53303 GRD-51842 MSC-50814
Item
Description
Engine/Hydrostatic Installation Cummins 6CT 8.3 (230 HP) Breather Assembly, Hydraulic Tank Manifold, Pressure Pump, Pressure Compensator, Belt Pump Elbow, Compensator Pump Swaybar Assembly Mud Flap Manifold, Return Engine Mount Assembly, Rear Exhaust System (See Figure 7-5 for Details) Fender Strut Bracket, Air Cleaner Support Valve, Shuttle, Sunstrand Pump Bracket, Shuttle Valve, Sunstrand Pump Front Fender Pump, Sunstrand 90R, Hydrostatic Pump Lifting Eye, Transfer Case Transfer Case Motor, Sunstrand 51V, Hydrostatic Motor Frame Assembly (See Figure 7-6 for Details) Heat Exchanger, Transfer Case Bracket, Cooler Mount Radar Assembly (4-WD Option Only) Fuel Filter Assembly, Primary Air Dryer Assembly Filter Head Assembly, Suction Bracket Throttle Cable Pump, Steering Wishbone Assembly (See Figure 7-7 for Details) Timbren Conical Nut Wheel Adapter Hydraulic Tank Assembly Dip Stick 60 Dip Stick Tube Shield, Radiator Radiator
Qty.
RF 1 1 1 1 1 1 2 1 2 1 4 1 1 1 2 1 1 1 1 1 1 2 1 1 1 1 1 1 1 4 40 2 1 1 1 1 1
January 31, 2004
7-17
7-18
March 31, 2002
Figure 7-4. Drivelines

Fig
7-4 1 2 3 4 5 6 7 8 9 10 11
Item
Drivelines
Description
Companion Flange 2-1-333 Flange Yoke 2-2-329 Flange Yoke 2-2-479 U-Joint 1550 5 155x Tube Shaft 4-40-761 Slip Yoke 4-3-1241KX Flange Yoke 4-2-669 U-Joint 1550 5 155x Tube Shaft 4-40-761 Slip Yoke 4-3-1241KX Flange Yoke 4-2-669
Part No.
PTM-22273 PTM-22251 PTM-22252 PTM-51548
Qty.
RF 1 1 1 2 1 1 2
PTM-51548
2 1 1 2
January 31, 2004
7-19
Figure 7-5. Exhaust System
7-20
March 31, 2002

Fig Item No. Description

Part No. Qty.
7-5 1 2 3 4 5 6 7 8 9 10 11
Exhaust System Tail Pipe Horizontal Mufflers Muffler Hanger Nipple Exhaust (4 X .083 Wall Tube X 6 Long) Connector Tube Elbow 18 X 18 90 Tube 4 X .083 W. Nipple Exhaust Clamp U Guillotine Type Elbow 18 X 18 90 (6 Cut Off End) Clamp Connector Stainless Steel Tubing Flex 4 X 10 1/2 FIT-51874 FIT-51873 FIT-51885 FAS-51872 Modified FIT-51873 FIT-51871 FIT-51872 FIT-51884 MSC-51875 BRK-51877
RF 1 1 1 1 1 1 1 6 1 2 1
January 31, 2004
7-21
Blank Page
7-22
March 31, 2002
Figure 7-6. Frame Assembly
7-23 Blank/7-24
March 31, 2002

7-6 1 2 3 4 5

BRK-61468 BRK-51679 BRK-51680 BRK-60948
Item
Frame Assembly
Description
Bracket, Double Timbren Spring Bracket, Triple Return Filter Bracket, Double Intake Filter Baffle Air Dryer Hex Bolt 1/4 20 X 1 Flat Washer 1/4 Lock-Washer 1/4 Nut Hex 1/4 20
Qty.
RF 2 1 1 1 2 2 2 2
6 7 8
Right-Hand & Left-Hand Stanchion Plate Bracket, Primary Fuel Filter Hex Bolt 5/16 18 X 1 1/4 Lock-Washer 5/16 Nut Hex 5/16 18
BRK-51481 BRK-60615
2 1 2 2 2
9 10 11 12
Ring, Rear Frame Hosing Ring, Chaffing 4 I.D. Gusset Panel Assembly, 2-Wheel Drive (See Figure 7-9 for Details) Panel Assembly, 4-Wheel Drive (See Figure 7-10 for Details)
RNG-53343 RNG-26422 BRK-61043 HSG-61069 BRK-61059 HSG-51473 BRK-20235 HSG-51472 HSG-53381 BRK-61485 BRK-60925 BRK-61440 BRK-51471 BRK-51472 BRK-51485 BRK-53141 HSG-61481 HSG-61480 BRK-51573 TNK-51993
2 1 2 1 1 1 6 1 1 1 1 1 1 1 2 2 1 1 2 1 8 12 8 8
13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Stanchion Pipe, Wet Air Tank Gusset Front Engine Mount Channel Channel Support Tube Spacer 3/16 Hook, Right-Hand Hook, Left-Hand Bracket Swaybar (Right-Hand & Left-Hand) Gusset Pan Hard Frame Rail, Left-Hand Frame Rail, Right-Hand Spacer Air Tank Air Tank Assembly Hex Bolt 7/16 14 X 1 1/4 Flat Washer 7/16 Lock-Washer 7/16 Nut Hex 7/16 14
29 30
Battery Box Tube X-Member Transmission Mount
HSG-51560 BRK-53223
1 1
March 31, 2002
7-25

7-6
Illustrated Parts List Part No. Qty.

2 2 2 2 2 2 HSG-53222 VLV-51642 8MJ-4MP FIT-28342 FIT-28001 FAS-28703 FAS-28645 FAS-28500 VLV-26201 FIT-28296 90D8MJ-4MP 1 1 1 1 1 2 2 2 1 3 1
Item
31 Lock-Washer 5/8 Nut Hex 5/8 11 32
Description
Hex Bolt 5/8 11 X 6 1/2 Gr. 8
Hex Bolt 5/8 11 X 8 Gr. 8 Lock-Washer 5/8 Nut Hex 5/8 11
33 34 35 36 37 38
Plate, Conveyor to Frame Quick Release Valve 1/2 Male Jic X 1/4 Male Pipe Hex Bushing 3/8 X 1/4 1/4 Close Nipple Hex Bolt 1/4 20 X 1 1/4 Lock-Washer 1/4 Nut Hex 1/4 20
39 40 41
45# Fixed Regulator Soc. Hd. Pipe Plug 1/4 90 1/2 Male Jic X 1/4 Male Pipe
7-26
March 31, 2002
Figure 7-7. Wishbone Assembly
7-27 Blank/7-28
March 31, 2002

7-7 1 2 3 4 5 6 7 8 9 10 11

PTM-61457 BRK-53137 BRK-53136 PIP-51518 FAS-28593 FAS-28999A HSG-53138 BRK-53134 BRK-53240 BRK-60797 CAT CAT CAT CAT
Item
Description
Wishbone Assembly Axle, Spicer/Dana HD 1350 Plate, Left-Hand Top Plate, Right-Hand Top Spacer, Spherical Bearing Nut 1 1/2 12 Esna (Nylon) Lock Hex Bolt 1 1/2 12 X 8 Gr. 8 Channel Plate, Bottom, Left-Hand & Right-Hand Spacer Chain Strap Hex Bolt 3/4 10 X 8 1/2 Lock-Washer 3/4 Washer SAE 3/4 Nut Hex 3/4 10
Qty.
RF 1 1 1 2 1 1 2 2 4 2 8 16 8 8 32 32 32
12
Hex Bolt 9/16 12 X 1 3/4 Gr. 8 Lock-Washer 9/16 Gr. 8 Nut Hex 9/16 12 Gr. 8
13 14 15
Spacer, Tandem A-Frame Parking Brake Assembly Brake Mount Sway Bar Assembly (not shown)
HSG-53243 PTM-53235 BRK-53315 PTM-51459
1 1 1 1
January 31, 2004
7-29
7-30
March 31, 2002
Figure 7-8. Spherical Bearing

Fig
7-8 1 2 3 4 5
Item
Spherical Bearing Nut Hex 3/8 16 Grease Zerk Spherical Bearing
Description
Part No.
FAS-28538 .250-28M-2 PTM-51517 HSG-51513 FAS-28736
Qty.
RF 4 1 1 2 4
Spherical Bearing Retainer Hex Bolt 3/8 16 X 2
March 31, 2002
7-31
Figure 7-9. Panel Assembly, 2-Wheel Drive
7-32
March 31, 2002

7-9 1 2 3 4 5 6

FAS-25483 HSG-61500 BRK-61048 FAS-28501 FAS-28646 FAS-25451 FAS-28702 FAS-28632 FAS-28645 FAS-28500 ELC-24245 ELC-24247 ELC-22375 8MP-12BH-8MP 8MJ-4MP ELC-24058 4MJ-4MP VLV-29216 FIT-28344 90D4MJ-4MP
Item
Description
Panel Assembly, 2-Wheel Drive Soc. Hd. Bolt 5/16 18 X 3 Hitch Manifold (W/Fittings Only) Bracket, Hitch Manifold, Tow Bar Glad Hand Nut Hex 5/16 18 Lock-Washer 5/16 Soc. Hd. Screw 10 24 X 3/8 Hex Bolt 20 X 1 Washer Flat Lock-Washer Nut Hex 20
Qty.
RF 2 1 1 2 2 2 2 2 2 2 1 1 2 2 1 10 1 1 3 3
7 8 9 10 11 12 13 14 15
Socket 7-Pole Trailer Conn. Socket Boot Glad Hand Male Pipe X Bulk Head X Male Pipe Male Jic X Male Pipe Cable 7-Cond. Stranded Trailer Cable Male Jic X Male Pipe Valve S/S 3-Way Ball Valve Bushing Hex X 90 Male Jic X Male Pipe
March 31, 2002
7-33
Figure 7-10. Panel Assembly, 4-Wheel Drive
7-34
March 31, 2002

7-10 1 2

PTM-51644 FAS-28732 FAS-28634 FAS-28647 FAS-28502 HSG-61500 FAS-25483 FAS-28646 FAS-28501 BRK-61048
Item
Master Cylinder
Description
Panel Assembly, 4-Wheel Drive Hex Bolt 3/8 16 X 1 Flat Washer 3/8 Lock-Washer 3/8 Nut Hex 3/8 16
Qty.
RF 1 4 4 4 4 1 2 2 2 1
3 4
Hitch Manifold (W/Fittings Only) Soc. Hd. Bolt 5/16 18 X 3 Lock-Washer 5/16 Nut Hex 5/16 18
Bracket
March 31, 2002
7-35
Blank Page
7-36
March 31, 2002
Figure 7-11. Conveyor Assembly, Left-Hand

7-37 Blank/7-38 March 31, 2002

7-11 1 2

MCH-51965
Item
Description
Conveyor Assembly, Left-Hand Take-Up Bearing Adjustment Assembly Hex Bolt 13 X 1 Lock-Washer Nut Hex 13
Qty.
RF 2 6 6 6
3 4 5 6 7 8 9 10 11 12 13 14 15
Tail Pulley Assembly Take-Up Bearing Hex Bolt 3/8 16 X 2 Nut Lock 3/8 16 Cat Walk, Left-Hand, Tandem Return Rollers Conveyor Rail #2 Left-Hand Inner, Tandem Cross Channel Plate, Rear Axle Trough Rollers Assembly Angle Brace Bracket Stub Shaft Hex Bolt 3/8 16 X 1 Lock-Washer 3/8 Nut Hex 3/8 16
MCH-51403 PTM-51417
1 2 2 2
GRD-53157 PTM-51413 HSG-53152 HSG-51428 BRK-53225 MCH-51402 BRK-61609 BRK-51407 MCH-51412
1 5 1 2 1 6 1 10 10 20 20 20
16 17
Cross Member Hex Bolt 3/8 16 X 2 Flat Washer 3/8 Nut Lock 3/8 16
BRK-61706
6 12 12 12
18
Conveyor Rail #1 Left-Hand Outer, Tandem
HSG-53151
March 31, 2002
7-39
Blank Page
7-40
March 31, 2002
Figure 7-12. Conveyor Assembly, Right-Hand
7-41 Blank/7-42
March 31, 2002

7-12 1 2

MCH-51965
Item
Description
Conveyor Assembly, Right-Hand Take-Up Bearing Adjustment Assembly Hex Bolt 13 X 1 Lock-Washer Nut Hex 13
Qty.
RF 2 6 6 6
3 4 5 6 7 8 9 10 11 12 13 14 15 16
Tail Pulley Assembly Take-Up Bearing Hex Bolt 3/8 16 X 2 Nut Lock 3/8 16 Cat Walk, Right-Hand, Tandem Return Roller Assembly Conveyor Rail #3 Right-Hand Inner Cross Channel Trough Roller Plate, Rear Axle Angle Brace Mount Angle Cylinder Hitch Lift Bracket Stub Shaft Hex Bolt 3/8 16 X 1 Lock-Washer 3/8 Nut Hex 3/8 16
MCH-51403 PTM-51417
1 2 2 2
GRD-53314 PTM-51433 HSG-53153 HSG-51428 MCH-51402 BRK-53225 BRK-61610 BRK-61613 BRK-51407 MCH-51412
1 4 1 2 5 1 1 1 10 10 20 20 20
17 18
Cross Member Hex Bolt 3/8 16 X 2 Cap Screw Flat Soc. Hd. 3/8 16 X 1 Lock-Washer 3/8 Flat Washer 3/8
BRK-53351
1 1 1 2 2
19 20
Cross Member With Guard Hex Bolt 3/8 16 X 2 Lock-Washer 3/8 Flat Washer 3/8
BRK-53370
1 2 2 2
21 22
Cross Member Hex Bolt 3/8 16 X 2 Lock-Washer 3/8 Flat Washer 3/8
BRK-61706
4 8 8 8
23
Conveyor Rail #4 Right-Hand Outer
HSG-53154
March 31, 2002
7-43
Blank Page
7-44
March 31, 2002
Figure 7-13. Tube/Steering Assembly
7-45 Blank/7-46
March 31, 2002

7-13 1 2

BRK-60673 VLV-51605 FAS-28707 FAS-28645 MSC-60995 FAS-25493 FAS-28646 FAS-28501 FAS-28646 ELC-60931 MCH-51610 FAS-51611 MCH-51609 4MB-4MJ C4FJ 90D4MB-4MJ 6MB-4MJ 8MB-8MJ 90D8MB-8MJ 90D4MB-4MJ 8MB-8MJ VLV-51606 VLV-51607 MCH-51608 FAS-29362
Item
Description
Tube/Steering Assembly Platform Support/Forward Tube Assembly Steering Shuttle Valve Hex Bolt 20 X 2 Lock-Washer
Qty.
RF 1 1 2 2 1 2 2 2 2 1 2 2 2 4 4 1 2 8 4 2 6 2 2 2 2
3 4
Manifold, Steering Soc. Hd. Cap Screw 5/16 18 X 3 Flat Washer 5/16 Nut Hex 5/16 18 Lock-Washer 5/16
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 NOTE:
Junction Box (See Figure 7-14 for Details) Steering Wheel Cap Steering Wheel Nut Steering Wheel Male O-Ring X Male Jic Cap Female Jic 90 Male O-Ring X Male Jic 3/8 Male O-Ring X Male Jic Male O-Ring X Male Jic 90 Male O-Ring X Male Jic 90 Male O-Ring X Male Jic Male O-Ring X Male Jic Inlet Check Valve Valve Steering Steering Column 30 Clamp Muffler 1
The Tube/Steering Assembly Hand Rail is changed for the 2002 model. See Figure 7-2 for differences. Specify model year when ordering a replacement hand rail.
March 31, 2002
7-47
Figure 7-14. Junction Box
7-48
March 31, 2002

7-14 1 2 3 4 5 6 7 8 9 10 11 12 13 14

FAS-24387 FAS-25834 FAS-28554 ELC-24289 ELC-101889 BRK-51850 FAS-24387A HSG-51848 ELC-24270 ELC-24184 ELC-24188 ELC-24190 FAS-25814 FAS-28552 ELC-24220 ELC-81005
Item
Junction Box Latch T-Handle
Description
Qty.
RF 1 7 7 1 1 1 1 1 2 1 1 1 6 6 1 1
Screw Machine Rd. Hd. 10 32 X Nut Hex 10 32 Breaker 15 Amp Flasher, Heavy Duty 2-Terminal Clip, Flasher Bracket Latch T-Handle Junction Panel Assembly Relay 70 Amp 50 Amp Current Breaker 10 Lug Connector Cinch Cinch Connector 6 Lug Screw Machine Rd. Hd. 8 32 X Nut Hex 8 32 Connector 20 Lug Barrier Strip Socket, Relay
March 31, 2002
7-49
Figure 7-15. Oil Cooler Assembly
7-50
March 31, 2002

7-15 1 2

PTM-53230
Item
Oil Cooler Assembly Oil Cooler
Description
Qty.
RF 1 18 36 18 18
Hex Bolt 5/16 18 X 1 Flat Washer 5/16 Lock-Washer 5/16 Nut Hex 5/16 18
3 4
Fan Electric, Oil Cooler Hex Bolt 20 X 1 Lock-Washer Nut Hex 20
ELC-53231
2 8 8 8
5 6
Cover Hex Bolt 3/8 16 X 1 Flat Washer 3/8 Nut Lock 3/8 16
HSG-53245
1 2 4 2
7 8 9 10
Shroud Sensor / Pressure Check Port (Modified 90D32MB-32MJ) Pressure Check Port Only (Modified 90D32MB-32MJ) Bracket Hinge / Base
HSG-53244 FIT-53335 FIT-53336 BRK-53246
1 1 1 2
March 31, 2002
7-51
Blank Page
7-52
March 31, 2002
Figure 7-16. Pedestal and Control Box Assembly
7-53 Blank/7-54
March 31, 2002

7-16 1 2 3 4 5 6

PTM-51634 FAS-51635 FAS-51758 MCH-51633 VLV-51640 FAS-28716 FAS-28646 FAS-28501 PTM-60980 ELC-24281 FAS-28700 FAS-60982 MSC-51829 HSG-51697 MTR-51753 FAS-28714 SCH-51510 FAS-28715 FAS-28646 FAS-28501 BRK-51240 FAS-28716 FAS-28646 FAS-28501 ELC-51832 ELC-51836 FAS-28717 FAS-28633 FAS-28646 FAS-28501 ELC-60638 ELC-60636 ELC-60637 ELC-24011 FAS-28502 FAS-28634 HSG-53373
Item
Cable Assembly Clevis (1/4 Pin) Clevis (5/16 Pin)
Description
Pedestal and Control Box Assembly
Qty.
RF 1 1 1 1 1 2 2 2 1 1 4 1 1 1 1 2 1 4 4 4 1 5 5 5 1 1 4 4 4 4 1 1 1 1 1 2 1
Control Positive Lock Valve Brake Control Hex Bolt 5/16 18 X 1 Lock-Washer 5/16 Nut Hex 5/16 18
7 8 9 10 11 12 13 14 15 16
Start Up Cable with Tee Handle & Clevis Break Away Switch Hex Bolt 20 X Clamp, Cable Parking Brake Knob Security Box Assembly CRC Display Hex Bolt 20 X Wiring Console Assembly Hex Bolt 5/16 18 X Lock-Washer 5/16 Nut Hex 5/16 18
17 18
Foot Pedal Brake Valve Hex Bolt 5/16 18 X 1 Lock-Washer 5/16 Nut Hex 5/16 18
19 20
Foot Switch, Varior Potentiometer (2000 2001) Foot Pedal, Digital (2002) Hex Bolt 5/16 18 X 1 Flat Washer 5/16 Lock-Washer 5/16 Nut Hex 5/16 18
21 22 23 24 25 26
Earphone CB, 40 Channel Antenna 39 Height Magnetic Base Ground Strap 12 Nut Hex 3/8 16 Flat Washer 3/8 Pedestal Assembly, Tandem
March 31, 2002
7-55
Figure 7-17. Hitch Assembly
7-56
March 31, 2002

7-17 1 2 3

BRK-60658 CYL-60651 FAS-28781A FAS-28650 FAS-28505 BRK-51505 T8MJ-8MB-8MJ C8FJ FAS-51506 FAS-25944 FAS-60941 FAS-25935 BRK-61501 MCH-51500
Item
Hitch Assembly Chipper Hitch Pin
Description
Qty.
RF 1 1 2 2 2 2 2 2 1 1 1 1 1 1
Chipper Hitch Cylinder Hex Bolt 5/8 11 X 3 Lock-Washer 5/8 Nut Hex 5/8 11
4 5 6 9 10 11 12
Hitch Assembly Cylinder Bracket Tee Male Jic X O-Ring X Male Jic Female Jic Cap Hitch Pin Cotter Pin X 2 Pin Assembly Hitch Cylinder Cotter Pin 3/16 X 2 Hitch Hook Hitch Assembly
March 31, 2002
7-57
Blank Page
7-58
March 31, 2002
Figure 7-18. Hitch Lift
7-59 Blank/7-60
March 31, 2002

7-18 1 2 3 4 5

VLV-51621 VLV-51920 HSG-61500
Item
Hitch Lift
Description
Directional Control Valve, Closed Center Strain Relief Double Check Valve, Stack-Up Manifold Assembly Soc. Hd. Bolt 5/16 18 X 3 Lock-Washer 5/16 Nut Hex 5/16 18
Qty.
RF 2 2 1 1 2 2 2 1 1
6 7 8 9 10
Hex Bolt 10 X 3 Nut Lock 10 Restrictor Fitting Cylinder 1 X 10 Hex Bolt 10 X 2 Nut Lock 10 Snatch Block Assembly Snatch Block Spacer Nut Inner Spacer 7/8 9 Hex Bolt 10 X 3 Nut Lock 10 PTM-52053 PTM-53323 FIT-29980 CYL-22300
2 1 1 1 2 2 2 2 2 2
11 12 13 14 15 16 17
Sling Cable Assembly Spring Assembly Hex Bolt 10 X 3 Nut Lock 10 Flat Washer Nut Hex 7/8 9 Nut Jam 7/8 9 Hose #4 X 146 Long Hose #4 X 156 Long
PTM-53333 MCH-51816
1 1 1 1 4 1 1
PIP-51762 PIP-51760
1 1
January 31, 2004
7-61
Figure 7-19. Hitch Manifold W/Out Lift Option
7-62
March 31, 2002

7-19 1 2 3 4 5 6 7 8 9 Hitch Manifold W/Out Lift Option Soc. Hd. Cap Screw 10 24 X 2 Valve Sol. Dir. Control Closed Center Double Check Stack-Up Valve Soc. Hd. Cap Screw 10 24 X Cover, Hydraulic Manifold Closed Center Manifold, 2-Station Parallel 90 Male O-Ring X Male Jic Plug Male O-Ring Male O-Ring X Male Jic

RF FAS-25459 VLV-51621 VLV-51920 FAS-25450 HSG-27355 MSC-51621 90D8MB-8MJ P8MB 8MB-8MJ 4 1 1 4 1 1 2 4 2
January 31, 2004
7-63
Figure 7-20. Hitch Manifold W/Lift Option
7-64
March 31, 2002

7-20 1 2 3 4 5 6 7 8
Illustrated Parts List Part No. Qty.

RF 8 VLV-51621 VLV-51920 MSC-51621 90D8MB-8MJ P8MB 8MB-4MJ 8MB-8MJ 2 2 1 2 2 2 2
Item
Description
Hitch Manifold W/Lift Option Soc. Hd. Bolt 10 24 X 2 Directional Control Valve, Closed Center Double Check Valve, Stack-Up Manifold, 2-Station Parallel 90 Male O-Ring X Male Jic Plug Male O-Ring Male O-Ring X Male Jic Male O-Ring X Male Jic
January 31, 2004
7-65
Blank Page
7-66
March 31, 2002
Figure 7-21. Chip Box, Tandem
7-67 Blank/7-68
March 31, 2002

7-21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

PMP-51625 PTM-53105 PTM-53130 PTM-53131 PTM-53106 GRD-53212 MTR-53213 HSG-53110 BRK-53272 FIT-60911 FIT-60912 BRK-53409 BRK-53112 PTM-50834 PTM-50835 PTM-50837 PTM-53065 BRK-53056 TNK-53080 GRD-53204 PTM-53010 FAS-53017 GRD-53279 HSG-53010 PTM-51905 BRK-53057 BRK-53020 RNG-53068 BRK-53071 BRK-53096 MCH-53050 PMP-53160 BRK-53069 CYL-50919 BRK-50738 FAS-28911 FAS-28635 BRK-53109 ELC-53322
Item
Chip Box, Tandem Auger Motor
Description
Qty.
RF 1 1 1 1 1 1 1 1 2 1 1 2 1 1 1 1 1 1 1 2 4 4 4 1 1 1 1 2 9 2 10 1 1 10 20 20 20 1 1
Shaft, Auger Motor End Left-Hand Auger 14 Right-Hand Auger 14 Shaft, Auger Bearing End Bearing Guard Proximity Switch Assembly Valve Box Assembly (See Figure 7-24 for Details) Spacer, Valve Box Quick Coupler, Female Quick Coupler, Male Bracket, Tow Bar, Quick Disconnect Support Track Chain Cover Bore Coupling 2 7/16 Modified Coupling Bracket, Auger Mount Air Tank Grizzly Runner, Bearing Load Snap Ring Scraper, Rock Chip Box Weldment Bearing 4-Bolt Spacer, Bearing Bearing Plate Seal Seal Support Bracket Modified Seal Bracket Gate Assembly 12 Hydraulic Motor Gear Box Retainer, Cam Motor Gate Cylinder Assembly Bushing Hex Bolt 20 X 1 Flat Washer 7/16 Support Locator, Potentiometer Potentiometer Assembly (See Figure 7-22 for Details)
July 15, 2002
7-69

7-21

MSC-53358 GRD-53374 MCH-53052 FAS-28997 FAS-28542 FAS-28954 FAS-28542 FAS-28503 FAS-28648 BRK-53070 PTM-53377 MCH-53075 GRD-53127
Item
38 39 40 41 42 43 44 45 46 47
Description
Manifold Hydraulic, Return Retainer, Hose Guide Mount Cam/Gate Hex Bolt 10 X 5 Nut Lock 10 Hex Bolt 10 X 3 Nut Lock 10 Nut Hex 7/16 14 Lock-Washer 7/16 Cam Stop Gear Box Assembly (See Figure 7-23 for Details) Camshaft Guard, Potentiometer Barrier Strip
Qty.
1 1 10 10 10 10 10 20 20 2 1 1 1
7-70
July 15, 2002
Figure 7-22. Potentiometer Assembly
7-71 Blank/7-72
March 31, 2002

7-22 1 2 3 4 5 6 7 8 9

ELC-24551 ELC-24190 ELC-53128 MSC-53067 PTM-53270 FAS-25629 PTM-50972 FAS-25619 RNG-20910
Item
Description
Potentiometer Assembly Capacitor, Axial 100 MFD Barrier Strip, 6-Gang Potentiometer Housing, Potentiometer Coupling, Female Pot Drive Set Screw, Half Dog Point 5/16 18 X 5/16 Coupling, Male Pot Drive Soc. Hd. Set Screw 8 32 X O-Ring 1 3/8 I.D.
Qty.
RF 1 1 1 1 1 1 1 1 1
March 31, 2002
7-73
Blank Page
7-74
March 31, 2002
Figure 7-23. Gear Box Assembly
7-75 Blank/7-76
March 31, 2002

7-23 1 2 3 4 5 6 7 9 11 12 13 14 15 16 17 18 20 21 22 23

HSG-50621 HSG-50622 PTM-53462 PTM-50845 PTM-50846 PTM-50847 PTM-50848 PTM-50843 PTM-50856 PTM-53463 BRK-50855 PTM-53461 FAS-25489 FAS-25496 FAS-25480 FAS-25353 STL-30951 2MP-Z FAS-25614 FAS-25499
Item
Gear Box Assembly Gear Box Housing
Description
Qty.
RF 1 1 2 1 1 1 1 1 1 1 1 1 4 2 4 6 1 1 2 2
Face Gear Box Housing Gear Box Thrust Bearing Matched Pairs Bearing Gear Box #LM11949 Bearing #11910 Cup Bearing Gear Box #48548 Bearing #LM48510 Cup Speedo Gear Large 19 Tooth Shaft Worm Drive Gear Box Helix Angle Worm #WGA-1G For Motor Mount Gear Box Gear, Split Soc. Hd. Cap Screw 3/8 16 X 1 Soc. Hd. Cap Screw 3/8 16 X 5 Soc. Hd. Cap Screw 5/16 18 X 1 Dowel Pin I.D. X 3/16 X 3/16 X 2 Key 1/8 Male Grease Zerk Soc. Hd. Set Screw 10 24 X Soc. Hd. Cap Screw 3/8 16 X 4
January 31, 2004
7-77
Blank Page
7-78
March 31, 2002
Figure 7-24. Valve Box Assembly
7-79 Blank/7-80
March 31, 2002

7-24 1 2 3 4 5 6 7 8 9 10

VLV-51621 FAS-25459 VLV-51929 8MB-4MJ 90D8MB-4MJ VLV-51613 ELC-24290 FAS-25813 FAS-25856 ELC-50152 FAS-25845 FAS-28616 FAS-28571 ELC-24274 FIT-24219 ELC-24275 BRK-53116 FAS-28730 HSG-53115 ELC-24220 ELC-24416 MSM-50899 FIT-28297 FIT-28296 4MJ-4MP VLV-50917 FAS-28701 FAS-28500 8MJ-6MP VLV-50900 ELC-24420 FAS-24170 HSG-53111 VLV-50902 RNG-27266
Item
Description
Valve Box Assembly Hydraulic Valve Closed Center Soc. Hd. Screw 10 24 X 2 Pressure Reducing Valve Male Pipe 90 Male Pipe Manifold, Sub Plate 30 Amp Circuit Breaker Screw 8 32 X Nut Hex 8 32 Insulator Brass Screw 10 24 X 1 Brass Flat Washer Brass Jam Nut 10 24
Qty.
RF 1 4 1 1 3 1 1 2 2 2 1 2 2 1 2 10 2 4 4 1 1 10 2 1 4 20 10 4 4 1 1 1 1 1 10 12
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Switch, Mom Off Mom Chrome Plug Switch, On/Off Single Pole Spacer Hex Bolt 3/8 16 X Lock-Washer 3/8 Switch Panel 20 Lug Barrier Strip Din Connector Blank Cover C-7 Soc. Hd. Plug 3/8 Soc. Hd. Plug Male Pipe Valve Assembly, 12 Station Hex Bolt 20 X Nut Hex 20 Male Pipe End Plate Set Connector Strain Relief Locknut Modified Box 4 way Versa Valve Valve to Manifold Gasket
January 31,2004
7-81
Blank Page
7-82
March 31, 2002
Figure 7-25. Chip Box Extension
7-83 Blank/7-84
March 31, 2002

7-25 1 2

RNG-54059
Item
Chip Box Extension Seal 1
Description
Qty.
RF 1 2 2 2 1 1
Hex Bolt 5/16 18 X 1 Lock-Washer 5/16 Nut Hex 5/16 18
3 4 5 6 7 8 9 10 11 12 13 14
Hex Bolt 10 X 5 Nut Lock 10 Cylinder Camshaft 1 Riser, Seal Support Nut Hex 7/16 14 Lock-Washer 7/16 Gate Assembly 12 Bushing Hex Bolt 20 X 1 Flat Washer 7/16 Plate Base Mount Cam/Gate Hex Bolt 10 X 3 Nut Lock 10 Extension Weldment 1 HSG-54049 HSG-54058 MCH-53052 MCH-53030 BRK-50738 CYL-50919 MCH-54048 BRK-21447
1 1 2 2 2 1 1 1 2 1 1 1 1 1
March 31, 2002
7-85
Figure 7-26. Tow Bar Assembly
7-86
March 31, 2002

7-26 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

MSC-51961 MSC-51960 BRK-60829 CYL-51962 BRK-60825 FIT-28344 T4MJ-4MJ-4MP 4MJX4MP FIT-28238 FIT-28344 FIT-28001 VLV-22319 90D4MJ-4MP PIP-60844 6MB-4MJ FIT-29632 MSC-80087 MSC-80126 MSC-80127-T BRK-60823 FAS-60821 BRK-60832 PTM-51964 PIP-60842 ELC-22375 ELC-60840 ELC-24246 BRK-60787 BRK-60828 MCH-60796
Item
Tow Bar Assembly Pintle Eye Drop Leg Jack
Description
Qty.
RF 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 1 2 1
Safety Chain Lift Cylinder Shoe 4 X 20 Stroke Hydraulic Cylinder Tow Bar Cylinder Top & Bottom Pins Bushing Hex X Tee Male Jic X Male Jic X Male Pipe Male Jic X Male Pipe Elbow Pipe Street Bushing Hex X Nipple X Close Sch. 80 Lock Out Valve 90 Male Jic X Male Pipe Hydraulic Supply Line Assembly 3/8 Male O-Ring X Male Jic Quick Disconnect Male HP X 6 Mor Wheel & Tire Assembly Rim Assembly White Rim 16.5 X 6.75 Spoked 8-6.5 Tire 9.50-16.5 10 Ply Radial
18 19 20 21 22 23 24 25 26 27
2 Tow Bar Chipper Pin Clip Click Pin Spring Loaded Spindle Assembly Hub Assembly Air Supply Line Assembly Glad Hands Trailer Cord Assembly Chipper Tow Bar Plug Trailer 7-Cond. Hydraulic Cylinder Shoe Safety Chain Tow Bar Swing Away Hitch Assembly
March 31, 2002
7-87
Figure 7-27. Heat Exchanger
7-88
March 31, 2002
Diagrams
SECTION 8. DIAGRAMS
March 31, 2002
8-1
Diagrams
Blank Page
8-2
March 31, 2002
Diagrams
Figure 8-1. Console Wiring Detail, Tandem (2000 2001)
March 31, 2002
8-3/8-4 Blank
Diagrams
Figure 8-2. Console Wiring Detail, Tandem (2002)
March 31, 2002
8-5/8-6 Blank
Diagrams
Figure 8-3. Junction Box Wiring Detail, Tandem (2000 2001)
March 31, 2002
8-7/8-8 Blank
Diagrams
Figure 8-4. Junction Box Wiring Detail, Tandem (2002)
March 31, 2002
8-9/8-10 Blank
Diagrams
Figure 8-5. Valve Box Wiring Detail, Tandem (2000 2001)

March 31, 2002 8-11/8-12 Blank
Diagrams
Figure 8-6 (Sheet 1). Valve Box Wiring Detail, Tandem (2002)
March 31, 2002
8-13/8-14 Blank
Diagrams
Figure 86 (Sheet 2). Valve Box Wiring Detail, Tandem (2002)
March 31, 2002
8-15/8-16 Blank
Diagrams
Figure 8-7. Slave Box Wiring Detail, Tandem (2000 2001)
March 31, 2002
8-17/8-18 Blank
Diagrams
Figure 8-8. Slave Box Wiring Detail, Tandem (2002)
March 31, 2002
8-19/8-20 Blank
Diagrams
Figure 8-9. Digital Foot Control Wiring Detail, Tandem (2002)
March 31, 2002
8-21/8-22 Blank
Diagrams
Figure 8-10. Engine Wiring Detail, Tandem

March 31, 2002 8-23/8-24 Blank
Diagrams
Figure 8-11. Lights Wiring Detail
March 31, 2002
8-25/8-26 Blank
Diagrams
Table 8-1. BC-2002/CRC Tandem Electrical Circuit

Wire No. 1 1 1 1 2 2 2 3 3 3 4 4 4 5 5 5 6 6 6 7 7 7 8 8 8 9 9 9 10 10 10 10 11 11 11 12 12 Wire Size 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 14 16 16 16 16 16 14 16 16 16 16 16 16 14 16 16 14 16 16 Wire Color WT-BK-GN BU BU BU WT-BK-YL WT-BK-YL YL WT-BN WT-BN GN WT-SL WT-SL WT WT-BK-SL WT-BK-SL BK WT-BU-BN WT-BU-BN YL WT-OR WT-OR WT WT-BK WT-BK BU WT-BN-PU WT-BN-PU OR RN-GN RN-GN RD-GN RD RD-BK RD-BK BK WT-BK-BU WT-BK-BU CB1 to JB1 (back-up alarm) JB1 to BB10 (back-up alarm) BB10 to back-up alarm BB10 to back-up alarm CB2 from left belt switch (middle term) CB2 to JB2 (left conveyor) JB2 to left conveyor solenoid CB3 from right belt switch (middle term) CB3 to JB3 (right conveyor) JB3 to right conveyor solenoid CB4 from hitch switch (top term) CB4 to JB4 (hitch open) JB4 to hitch control valve CB5 from hitch switch (bottom term) CB5 to JB5 (hitch closed) JB5 to hitch control valve CB6 from water temp gauge (S-term) CB6 to JB6 (water temp) JB6 to water temp sensor on engine CB7 from hydraulic oil temp gauge (S-term) CB7 to JB7 (hydraulic oil temp) JB7 to hydraulic oil temp sensor CB8 from oil pressure gauge (S-term) CB8 to JB8 (engine oil pressure) JB8 to engine oil pressure sensor CB9 from fuel gauge (S-term) CB9 to JB9 (fuel gauge) JB9 to fuel gauge CB10 from circuit breaker Right term 30 A circuit breaker to right term 15 A circuit breaker CB10 to JB10 to #7 term of relay (jumper to #8, #1 relay) Relay term #5 to fuel pump solenoid (jumper to term #4 relay) CB11 from tach (bottom left term) CB11 to JB11 (tach) JB11 to tach (off alternator) CB12 from horn switch (right term) CB12 to JB12 (horn) Description
March 31, 2002
8-27
Diagrams

Wire No. 12 13 13 13 14 14 14 15 15 15 15 15 15 15 15 15 15 16 16 16 17 17 17 17 17 18 18 18 18 19 19 19 20 21 22 Wire Size 14 16 16 14 16 16 14 12 12 16 16 16 14 14 Diode 14 14 12 12 12 12 12 10 8 8 12 12 12 12 14 16 16 16 16 16 BN BN RD-WT RD-WT RD-WT Y1 Y1 RD RD RD OR OR RD RD RD WT WT (from 3-cond.) RD WT RD Wire Color BN WT-RD WT-RD WT WT-BK-OR WT-BK-OR OR RD RD BK BK BK BK BK Description JB12 to RB (remote shift barrier strip) #1 term CB13 from beacon switch (top right term) to beacon switch (bottom right term) CB13 to JB13 (beacon) JB13 to beacon light CB14 temp light & buzzer CB14 to JB14 to term #2 relay (WT-BN-RD) to over-temp lights on console JB14 to sensor (on oil cooler) CB15 to light switch and to gauge lights CB15 to JB15 (work & tail lights) JB15 to front work light JB15 to right work light JB15 to rear work light JB15 to BB8 BB8 to left work light BB8 to BB9 BB9 to left tail light BB9 to right tail light Ignition switch (start term) to relay (term #4 & #5) from relay term (#1 & #8) to CB16s CB16 to JB16 (starter solenoid) JB16 to starter solenoid CB17 to ignition switch (battery term) CB17 to JB17 (starter post main +12V) JB17 to starter post (main +12V term) Starter post to battery (+12V term) Battery (+ term) to alternator (+12V term) CB18 from ignition switch (acc term) CB18 to JB18 (ignition acc) JB18 to 15 A (battery term) breaker (Aux term) 15 A breaker to JB19 to air dryer JB18 to air brake switch CB19 to #2 term potentiometer port #7 amplifier (input) CB19 to digital foot pedal CB20 to #3 term potentiometer port #6 amplifier (+8V reg) CB21 to center term digital foot pedal CB22 from forward and reverse switch (bottom middle term) to CB22
8-28
March 31, 2002
Diagrams

Wire No. 22 23 23 24 24 24 25 25 25 26 26 26 26 26 26 27 27 27 28 28 28 28 29 29 29 30 30 30 30 30 30 31 31 32 32 32 Wire Size 16 16 16 16 16 12 16 14 14 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 12 12 12 Wire Color RD BK BK WT-BK-OR WT-RD-OR GN BN BN BN PU PU WT-SL RD BN WT-OR GN YL YL SL SL SL BK YL YL YL BU BU WT-BK-YL RD BN WT WT-BK-GN PU RD RD RD Description CB22 to E.D.C. plug (on hydrostatic trans) CB23 to forward and reverse switch (center term) to CB23 CB23 to E.D.C. plug (on hydrostatic trans) CB24 to buzzer & water temperature light CB24 to JB24 JB24 to hydraulic temperature sensor CB24 to buzzer and oil light CB24 to JB24 JB24 to oil sending sensor CB26 to rear auger switch (bottom term auto) CB26 to SB15 (in 19-cond. Cable from slave box on right-hand conveyor) SB15 to (rear) VB12 (19-cond.) VB12 to rear auger proximity switch (2-cond.) Proximity switch (rear) VB11 (2-cond.) VB11 to SB14 (19-cond.) CB27 to rear auger switch (top term manual) CB27 to SB23 (19-cond.) SBA23 to rear auger solenoid valve (4-cond.) CB28 to breaker (right-hand term) CB28 to SB11 (19-cond.) SB11 to valve box power relay term #86 term #85 valve box power relay to ground CB29 to front auger switch (top term manual) CB29 to SB24 (19-cond.) SB24 to front auger solenoid valve (4-cond.) CB30 to front auger switch (bottom term auto) CB30 to SB12 (19-cond.) SB12 (19-cond.) to VB11 VB11 to front auger proximity switch (2-cond.) Proximity switch (front) VB12 (2-cond.) VB12 to SB13 (19-cond.) CB31 to amplifier port #4 (valve +) to forward/reverse switch Top center term to bottom lower term of switch CB32 to master switch (top left-hand term) to master switch (top right-hand term) CB32 to SB binding post (19-cond.) SB32 binding post to 70 A relay 3/8 term valve box power
March 31, 2002
8-29
Diagrams

Wire No. 32 32 32 32 32 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 34 34 35 35 36 Wire Size 12 12 14 12 8 12 12 12 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 10 16 Wire Color RD RD RD RD RD RD-WT RD-WT RD RD RD RD RD RD RD RD RD RD RD RD RD RD RD RD RD RD RD RD RD RD BU BU WT WT-BK-RD WT-BK-GN Description Valve box power relay 3/8 term to main binding power post Computer power relay term and 3/8 term to SB binding post From 3/8 term computer power relay to 12-pin connector slave L pin From SB binding post to SB4 jumper SB4, SB3, SB2, jumper wire to SB13 jump to SB14, jumper wire to SB18 and jumper to SB19 SB main power binding post to 105 A breaker on engine CB33 to master switch (bottom right term) to master switch (bottom left term) CB33 to SB3, SB3 to rear 19-cond. And front 19-cond to VB rear 30 A breaker and VB front 30 A breaker 30 A breaker to binding post of front VB and rear VB All red wires from din connectors of air valves 1 thru 10 (front hopper) and 11 thru 20 (rear hopper) to binding posts in each valve box VB1 to air solenoid valve #1 VB2 to air solenoid valve #2 VB3 to air solenoid valve #3 VB4 to air solenoid valve #4 VB5 to air solenoid valve #5 VB6 to air solenoid valve #6 VB7 to air solenoid valve #7 VB8 to air solenoid valve #8 VB9 to air solenoid valve #9 VB10 to air solenoid valve #10 VB11 to air solenoid valve #11 VB12 to air solenoid valve #12 VB13 to air solenoid valve #13 VB14 to air solenoid valve #14 VB15 to air solenoid valve #15 VB16 to air solenoid valve #16 VB17 to air solenoid valve #17 VB18 to air solenoid valve #18 VB19 to air solenoid valve #19 VB20 to air solenoid valve #20 CB34 from buzzer and air pressure light CB34 to air pressure sending unit on throttle valve CB35 to amplifier port #5 (valve ) to top right-hand term forward/reverse switch Top right-hand term to bottom center terminal of forward/reverse switch CB36 to right-hand belt switch (bottom term)
8-30
March 31, 2002
Diagrams

Wire No. 36 36 37 38 38 38 39 40 41 42 44 45 46 47 47 16 SHLD 16 12 10 12 16 GN RD RD RD RD BK Wire Size 16 14 16 16 16 16 Wire Color WT-BK-GN WT RD WT-BK-YL WT-BK-YL BN CB36 to SB20 (19-cond.) SB20 to right-hand (2-cond.) hopper diaphragm switch CB37 to buzzer diode CB38 to left-hand belt switch (bottom term) CB38 to SB17 (19-cond.) SB17 to left-hand (2-cond.) hopper diaphragm switch CB39 CB40 (for CB radio option) (CB) ground to CRC (computer) (CB) ground to CRC (computer) (CB) forward and reverse switch from diodes to (CB) relay (term #7) (CB) breaker (left term) to beacon switch (middle left term) to beacon switch (middle right term) (CB) breaker (right term) to ignition switch (+12V term) (CB) breaker (left term) to voltmeter (+ term) (CB) voltmeter (+ term) to oil pressure gauge (+ term) to fuel gauge (+ term) to tachometer (+ term) to water temperature gauge (+ term) to hydraulic oil temp gauge (+ term) (CB) ground to relay (term #2) to all lights & gauges & potentiometer (CB) low-lock switch (middle term) to beacon switch (middle right term) to left belt switch (top term) to hitch switch (middle term) to right belt switch (top term) to hopper shift (middle term) both, front, & rear switches (CB) horn switch (left term) to left term 15 Amp circuit breaker to warning gauge light terminals (+ side) (CB) light switch (middle left term) to all gauge lights JB17 to breaker (battery term) Out breaker (aux. Term) to relays #1 & #2 (#30 term) out Relay #1 (#87 term) to JB27 JB27 to fan #1 Relay #2 (#87 term) to JB28 JB28 to fan #2 JB18 to JB30 (acc to relay to sensor) JB30 to relay #1 jump to relay #2 (#86 term) Out relay #2 (#85 term) jump to relay #1 (#85 term) to JB26 JB26 to temperature switch on hydraulic return manifold Turn signal switch to JB22 JB22 to flasher Out flasher to JB29 JB29 to breaker (aux. Term) Turn signal switch to JB23 (ground) Description
48 49
16 16
BK RD
50 51 52 52 52 52 52 52 53 53 53 53 54 54 54 54 55
16 16 8 12 16 16 16 16 16 16 16 16 16 16 16 16 16
RD BU RD RD BU BU BU BU RD RD OR OR YL YL RD RD BK
March 31, 2002
8-31
Diagrams

Wire No. 55 55 56 57 59 60 60 61 62 63 64 64 65 65 66 66 66 67 67 67 68 68 68 68 69 69 69 69 70 76 77 77 77 78 78 78 79 79 79 16 16 16 16 16 16 16 16 16 BN BK BK BN BK BN BU BK BU 16 16 16 16 16 16 16 16 16 16 Diode 16 16 Diode 16 12 16 16 16 12 16 16 16 GN RD BK BK BK RD BK BK BK GN BN BK WT YL GN BN BU YL GN GN YL Wire Size 16 16 Wire Color BK RD JB23 to stop light switch Light switch to JB18 SLAVE JB24-JB25 (SPARE) BB1 from ground BB1 to female trailer light socket (ground) BB5 to female trailer light socket (optional) BB7 to female trailer light socket (optional) BB9 to female trailer light socket (optional) Turn signal switch to BB2 BB2 to left front turn signal Turn signal switch to BB3 BB3 to right front turn signal Turn signal switch to BB4 BB4 to BB5 BB5 to left rear turn signal Turn signal switch to BB6 BB6 to BB7 BB7 to right rear turn signal Ground screw in VB to ground screw in SB (rear 19-cond.) Ground screw in VB to rear cam switch (center term) Cam switch (center term) to gate switch (center term) Jumper wires from center term of all gate switches (rear VB) Ground screw in VB to ground screw in SB (front 19-cond.) Ground screw in VB to front cam switch (center term) Cam switch (center term) to gate switch (center term) Jumper wires from center term of all gate switches (front VB) SPARE Right-hand VB10 from computer slave SL-20 Right-hand VB10 to air solenoid valve #20 Right-hand VB10 to switch #20 (bottom term) Right-hand VB9 from computer slave SL-19 Right-hand VB9 to air solenoid valve #19 Right-hand VB9 to switch #19 (bottom term) Right-hand VB8 from computer slave SL-18 Right-hand VB8 to air solenoid valve #18 Right-hand VB8 to switch #18 (bottom term) Description
8-32
March 31, 2002
Diagrams

Wire No. 80 80 80 81 81 81 82 82 82 83 83 83 84 84 84 85 85 85 86 86 86 87 87 87 88 88 88 89 89 89 90 90 90 91 91 91 92 Wire Size 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 Wire Color GN BK GN PU BK PU SL BK SL YL BK YL WT-BK BK WT-BK WT-BN BK WT-BN WT-BK-GN BK WT-BK-GN WT-BK-GN BK WT-BK-GN WT-BN BK WT-BN WT-BK BK WT-BK YL BK OR SL BK SL PU Description Right-hand VB7 from computer slave SL-17 Right-hand VB7 to air solenoid valve #17 Right-hand VB7 to switch #17 (bottom term) Right-hand VB6 from computer slave SL-16 Right-hand VB6 to air solenoid valve #16 Right-hand VB6 to switch #16 (bottom term) Right-hand VB5 from computer slave SL-15 Right-hand VB5 to air solenoid valve #15 Right-hand VB5 to switch #15 (bottom term) Right-hand VB4 from computer slave SL-14 Right-hand VB4 to air solenoid valve #14 Right-hand VB4 to switch #14 (bottom term) Right-hand VB3 from computer slave SL-13 Right-hand VB3 to air solenoid valve #13 Right-hand VB3 to switch #13 (bottom term) Right-hand VB2 from computer slave SL-12 Right-hand VB2 to air solenoid valve #12 Right-hand VB2 to switch #12 (bottom term) Right-hand VB1 from computer slave SL-11 Right-hand VB1 to air solenoid valve #11 Right-hand VB1 to switch #11 (bottom term) Left-hand VB1 from computer slave SL-10 Left-hand VB1 to air solenoid valve #10 Left-hand VB1 to switch #10 (bottom term) Left-hand VB2 from computer slave SL-9 Left-hand VB2 to air solenoid valve #9 Left-hand VB2 to switch #9 (bottom term) Left-hand VB3 from computer slave SL-8 Left-hand VB3 to air solenoid valve #8 Left-hand VB3 to switch #8 (bottom term) Left-hand VB4 from computer slave SL-7 Left-hand VB4 to air solenoid valve #7 Left-hand VB4 to switch #7 (bottom term) Left-hand VB5 from computer slave SL-6 Left-hand VB5 to air solenoid valve #6 Left-hand VB5 to switch #6 (bottom term) Left-hand VB6 from computer slave SL-5
March 31, 2002
8-33
Diagrams

Wire No. 92 92 93 93 93 94 94 94 95 95 95 96 96 96 97 97 97 98 98 98 99 99 99 100 100 100 101 101 102 102 103 104 104 105 105 106 106 Wire Size 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 14 16 16 16 16 16 16 Wire Color BK PU GN BK GN BU BK BU BN BK BN BK BK BK WT-BK-BU WT-BK-BU BK WT-BK-OR WT-BK-OR BK WT-BK-BU WT-BK-BU BK WT-BK-OR WT-BK-OR BK WT-RD WT-RD WT-RD WT-RD BK UNSHD & BK UNSHD & BK WT WT RD RD Description Left-hand VB6 to air solenoid valve #5 Left-hand VB6 to switch #5 (bottom term) Left-hand VB7 from computer slave SL-4 Left-hand VB7 to air solenoid valve #4 Left-hand VB7 to switch #4 (bottom term) Left-hand VB8 from computer slave SL-3 Left-hand VB8 to air solenoid valve #3 Left-hand VB8 to switch #3 (bottom term) Left-hand VB9 from computer slave SL-2 Left-hand VB9 to air solenoid valve #2 Left-hand VB9 to switch #2 (bottom term) Left-hand VB10 from computer slave SL-1 Left-hand VB10 to air solenoid valve #1 Left-hand VB10 to switch #1 (bottom term) VB16 from computer slave pin #26 (right-hand 19-cond.) VB16 to rear cam switch (bottom Term) (right-hand 19-cond.) VB16 to hydraulic cam valve right-hand coil (right-hand VB) VB15 from computer slave pin #25 (right-hand 19-cond.) VB15 to right-hand cam switch (top term) (right-hand 19-cond.) VB15 to hydraulic cam valve left-hand coil (right-hand VB) VB16 from computer slave pin #24 (left-hand 19-cond.) VB16 to left-hand cam switch (top term) (left-hand 19-cond.) VB16 to hydraulic cam valve right-hand coil (left-hand VB) VB15 from computer slave pin #23 VB15 to left-hand cam switch (bottom term) VB15 to hydraulic cam valve left-hand coil (front VB) SB3 (left-hand 19-cond.) to front VB18 to right-hand hydraulic coil To jumper to VB13 to left-hand hydraulic coil SB3 (right-hand 19-cond.) to rear VB18 to right-hand hydraulic coil To jumper to VB13 to left-hand hydraulic coil SB power 70 A relay connector to L port slave SB from computer slave (off gray 3-wire) (J port) To FPM sensor SB from computer slave (off gray 3-wire) (G port) To FPM sensor SB from computer slave (off gray 3-wire) (A port) To 5 A fuse to FPM sensor
8-34
March 31, 2002
Diagrams

Wire No. 107 107 108 108 109 109 110 110 111 111 112 112 113 120 121 121 122 122 122 122 123 123 123 123 124 124 124 124 125 125 125 125 126 126 127 Diode Diode 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 WT-BK WT-BK RD BK WT-OR WT-OR WT WT WT-SL WT-SL BK RD WT-RD WT-RD GN BN YL YL GN Wire Size 16 16 16 16 16 16 16 16 16 16 16 16 Wire Color UNSHD & BK UNSHD & BK RD RD WT WT UNSHD & BK UNSHD & BK WT WT RD RD Description SB from computer slave (off gray 3-wire) (E port) To rear barrier strip on hopper to potentiometer right term SB from computer slave (off gray 3-wire) (F port) To rear barrier strip on hopper to potentiometer left term SB from computer slave (off gray 3-wire) (C port) To rear barrier strip on hopper to potentiometer middle term SB from computer slave (off gray 3-wire) (E port) To front barrier strip on hopper to potentiometer right term SB from computer slave (off gray 3-wire) (D port) To front barrier strip on hopper to potentiometer left term SB from computer slave (off gray 3-wire) (F port) To front barrier strip on hopper to potentiometer middle term SPARE From left-hand term on both hopper switches to right-hand term on front hopper switch and left-hand term on rear hopper switch From right-hand term on both hopper switches to right-hand term on front hopper switch and left-hand term on rear hopper switch From left-hand term of front hopper switch to CB122 CB122 (cab 19-cond.) to SB8 to front control box Front hopper switch in control box (4-cond.) From left-hand term of front hopper switch to top left-hand term hydraulic valve coil From left-hand of front hopper switch to CB123 CB123 (cab 19-cond.) to SB9 to front control box Front hopper switch in control box (4-cond.) From right-hand term of front hopper switch to top right-hand term hydraulic valve coil From right-hand term of rear hopper switch to CB124 CB124 (cab 19-cond.) to SB10 to front control box Rear hopper switch in control box (4-cond.) From right-hand term of rear hopper switch to bottom left-hand term hydraulic valve coil From right-hand term of rear hopper switch to CB125 CB125 (19-cond.) to SB1 to front control box Rear hopper switch in control box (4-cond.) From left-hand term of rear hopper switch to bottom right-hand term hydraulic valve coil From bottom term hitch raise switch to CB126 CB126 to JB126 aux. Barrier strip to top hitch hydraulic valve coil From top term hitch raise switch to CB127
March 31, 2002
8-35
Diagrams

Wire No. 127 128 128 129 129 129 Wire Size 16 16 16 16 16 16 Wire Color GN RD RD RD BK BK Description CB126 to JB126 aux. Barrier strip to bottom hitch hydraulic valve coil From bottom term low-lock switch to CB128 aux. Barrier strip CB128 aux. Barrier strip to (2-cond.) low-lock valve on trans Neutral light to CB129 aux. Barrier strip to low-lock switch From low-lock valve to ground on CB aux. Barrier strip From low-lock switch to ground on CB aux. Barrier strip
8-36
March 31, 2002
Diagrams
Figure 8-12. Air System Hose and Fitting Diagram, 2-Wheel Drive
March 31, 2002
8-37/8-38 Blank
Diagrams
Table 8-2. Air System Hose and Fittings, 2-Wheel Drive

Hose No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Hose Type H10408 100R5.188 H10408 100R5.188 S-10TW H10408 1/8 SYNFLEX SPARE 100R5.188 100R5.188 H10408 SPARE 100R5.188 36 4U-4FJX, 2 Ea. From 90D4MJ-4MP on Right-Hand Lower Port of Treadle Valve to 90D4MJ-2MP on Front Center Port of Emergency Brake Control. 50 97 56 4U-4FJX, 2 Ea. 4U-4FJX, 2 Ea. 8U-8FJX, 2 Ea. From Tee on Left-Hand Front Port of Shuttle Valve (with Low Pressure Switch) to IN Port of 3-Way Mack Valve. From 3-Way Mack Valve OUT Port to Air Horn. From 90D8MJ-8MP Top Right-Hand Port of Treadle Valve to Right-Hand Port of Stop Light Switch. Length 124 118 55 34 68 115 24 Fitting 8U-8FJX, 2 Ea. 4U-4FJX, 2 Ea. 8U-8FJX 45D8U-8FJX 4U-4FJX, 2 Ea. 8E4-8FJX, 2 Ea. 8U-8FJX, 2 Ea. NONE Hose Description From Regulator on Top Port of Air Tank (on Frame) to Chip Box Air Tank. From 90D4MJ-4MP on End of Air Tank (on Frame) to Front Top 90D4MJ-2MPL on D-2 Governor. From 90D8MJ-8MP on Rear of Air Tank (on Frame) to Check Valve (comes with Air Dryer) on Wet Tank Right-Hand side. From 90D4MJ-4MP on top of Compressor (on Cummins Engine) to Tee on Front of D-2 Governor. From Compressor (Supply S/S Hose) to Top Port of E-Con Valve (comes with Air Dryer). From Air Tank (on Frame) to Right-Hand Front 8MJ-8MP on Treadle Valve. From 90D 10-32 Push-Lock to bottom on Air to Gauge in Console.
14 15 16 17 18 19 20 21 22 23 24
SPARE H10408 H10408 100R5.188 100R5.188 H10408 100R5.188 H10408 H10408 H10408 H10408 56 40 90 11 52 116 26 34 34 26 8U-8FJX, 2 Ea. 8U-8FJX, 2 Ea. 4U-4FJX, 2 Ea. 4U-4FJX, 2 Ea. 8U-8FJX, 2 Ea. 4U-4FJX, 2 Ea. 8U-8FJX, 2 Ea. 8U-8FJX, 2 Ea. 8U-8FJX, 2 Ea. 8U-8JFX, 2 Ea. From 90D8MJ-4MP Top Port of 45# Fixed Regulator to Tee on Bottom Port of Double Check Valve Brake Switch. From Left-Hand Port of Double Check Valve Brake Switch to 8MJ-4MP Forward Glad Hand. From 90D4MJ-4MP on Right-Hand Rear Port of Tee on Quick Release Valve. From Lower Port of 3-Way Ball Valve to 4MJ-4MP of Glad Hand. From Tee on Bottom Port of Double Check Valve Brake Switch to Middle Port of Left-Hand Quick Release Valve. From Center Port of 3-Way Ball Valve to Center Port of Right-Hand Quick Release Valve. From Front Port of Quick Release Valve to Forward Port of Right-Hand Air Brake Chamber. From Rear Port of Right-Hand Quick Release Valve to Forward Port of Left-Hand Air Brake Chamber. From Right-Hand Rear Port on Right-Hand Air Brake Chamber to Rear Port of Left-Hand Quick Release Valve. From Front Port of Left-Hand Quick Release Valve to Rear Port of Left-Hand Air Brake Chamber.
March 31, 2002
8-39
Diagrams

Hose No. 25 26 27 28 29 30 31 Hose Type H10408 SPARE H10408 SPARE 100R5.188 H10408 100R5.188 10 30 17 4U-4FJX, 2 Ea. 8U-8FJX, 2 Ea. 4U-4FJX, 2 Ea. From Tee on Bottom of D-2 Governor to Air Dryer Left-Hand Port. From 90D8MJ-8MP on Right-Hand Front of Air Dryer to 90D8MJ-8MP on Top Left-Hand Port of Wet Tank. From 90D4MJ-4MP (Fitting Comes with E-Con Valve, has Built-In Check Valve) on Bottom Port of E-Con Valve to Top Outside 4MJ-2MP Port of D-2 Governor. From 90D4MJ-4MP Front Center Port of E-Con Valve to Lower Outside Port 4MJ-2MP on D-2 Governor. From Front Port of Tee on Quick Release Valve to Upper Port of 3-Way Ball Valve. 75 8U-8FJX, 2 Ea. From Quick Release Valve to Top Port of Air Can on Parking Disc Brake. Length 15 Fitting 8U-8FJX, 2 Ea. Hose Description From Front Port of Quick Release Valve (with 45# Regulator) to Front Port of Air Can on Master Cylinder.
32 33
100R5.188 100R5.188
19 24
4U-4FJX & 90D4E-4FJX 4U-4FJX, 2 Ea.
8-40
March 31, 2002
Diagrams
Figure 8-13. Air System Hose and Fitting Diagram, 4-Wheel Drive
March 31, 2002 8-41/8-42 Blank
Diagrams

Hose No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Hose Type H10408 100R5.188 H10408 100R5.188 S-10TW H10408 1/8 SYNFLEX SPARE 100R5.188 100R5.188 H10408 SPARE 100R5.188 36 4U-4FJX, 2 Ea. From 90D4MJ-4MP on Right-Hand Lower Port of Treadle Valve to 90D4MJ-2MP on Front Center Port of Emergency Brake Control. 50 97 56 4U-4FJX, 2 Ea. 4U-4FJX, 2 Ea. 8U-8FJX, 2 Ea. From Tee on Left-Hand Front Port of Shuttle Valve (with Low Pressure Switch) to IN Port of 3-Way Mack Valve. From 3-Way Mack Valve OUT Port to Air Horn. From 90D8MJ-8MP Top Right-Hand Port of Treadle Valve to Top Port 45# Regulator. Length 124 118 55 34 68 115 24 Fitting 8U-8FJX, 2 Ea. 4U-4FJX, 2 Ea. 8U-8FJX & 45D8U-8FJX 4U-4FJX, 2 Ea. 8E4-8FJX, 2 Ea. 8U-8FJX, 2 Ea. NONE Hose Description From Regulator on Top Port of Air Tank (on Frame) to Chip Box Air Tank. From 90D4MJ-4MP on End of Air Tank (on Frame) to Front Top 90D4MJ-2MPL on D-2 Governor. From 90D8MJ-8MP on Rear of Air Tank (on Frame) to Check Valve (comes with Air Dryer) on Wet Tank Right-Hand Side. From 90D4MJ-4MP on Top of Compressor (on Cummins Engine) to Tee on Front of D-2 Governor. From Compressor (Supply S/S Hose) to Top Port of E-Con Valve (comes with Air Dryer). From Air Tank (on Frame) to Right-Hand Front 8MJ-8MP on Treadle Valve. From 90D 10-32 Push Lock Fitting to Bottom on Air Gauge in Console.
14 15 16 17
SPARE SPARE SPARE 100R5.188 90 4U-4FJX, 2 Ea. From 90D4MJ-4MP on Right-Hand Rear Port of Emergency Brake Control Valve to Upper Port of Quick Release Valve Front Parking Disc Brake.
18 19 20 21 24 25 26 27 28 29
SPARE SPARE SPARE SPARE SPARE H10408 H10408 H10408 SPARE 100R5.188 10 4U-4FJX, 2 Ea. From Tee on Bottom of D-2 Governor to Air Dryer Left-Hand Port. 15 40 75 8U-8FJX, 2 Ea. 8U-8FJX, 2 Ea. 8U-8FJX, 2 Ea. From Front Port of Quick Release Valve (with 45# Regulator) to Front Port of Air Can Master Cylinder. From Right-Hand Port of Quick Release Port to Front Port of Air Can on Master Cylinder. From Quick Release Valve to Top Port of Air Can on Parking Disc Brake.
March 31, 2002
8-43
Diagrams

Hose No. 30 31 Hose Type H10408 100R.188 Length 30 17 Fitting 8U-8FJX, 2 Ea. 4U-4FJX, 2 Ea. Hose Description From 90D8MJ-8MP on Right-Hand Front of Air Dryer to 90D8MJ-8MP on Top Left-Hand Port of Wet Tank. From 90D4MJ-4MP (Fitting Comes with E-Con Valve, has Built in Check Valve) on Bottom Port of E-Con Valve to Top Outside 4MJ-2MP Port of D-2 Governor. From 90D4MJ-4MP Front Center Port of E-Con Valve of Lower Outside Port 4MJ-2MP on D-2 Governor.
32
100R5.188
19
4U-4FJX & 90D4E-4FJX
8-44
March 31, 2002
Diagrams
Table 8-4. Air System Parts and Fittings Chart

Item No. A B C D E F G H I J K L M N O P Q R S T U V W X Y Z AA AB AC AD AE AF AG AH AI AJ Nipple X Close Nipple X 1 Bushing Hex X Bushing Hex X 90 Pipe Straight Elbow Valve Ball Male Jic X Male Pipe 90 Male Jic X Male Pipe Male Jic X 1/8 Male Pipe 90 Male Jic X 3/8 Male Pipe 90 Male Jic X 1/8 Male Pipe Tee Male Jic X Male Pipe X Male Jic Male Jic X Male Pipe 90 Male Jic X Male Pipe 3/8 Female Pipe X Male Jic Male Jic X 3/8 Male Pipe 90 Male Jic X 3/8 Male Pipe Tee Male Jic 3/8 Male Pipe X Male Jic Male Jic Male Pipe Male Jic X Male Pipe 90 Male Jic X Male Pipe 90 Push Lock X 10-32 Thread MP X Bulk Head X Male Pipe Glad Hand 60 PSI Governor Safety Relief Valve (150 PSI) Air Tank Assembly Chassis Cummins Engine Part D-2 Governor Wet Air Tank E3 Brake Valve Valve PP3 Brake Control Valve S/S 3-Way Ball Valve DS2 DB1 Check & Stop Light Switch Comes With Air Dryer Master/Cylinder Air/Hydraulic JD&SP/Dana (2-Ea if 4-Wheel Drive). Description Part Number FIT-28001 FIT-28012 FIT-28346 FIT-28344 FIT-28236 VLV-29195 4MJ-4MP 90D4MJ-4MP 4MJ-2MP 90D4MJ-6MP 90D4MJ-2MP T4MJ-2MP-4MJ 8MJ-4MP 90D8MJ-4MP 6FP-8MP 8MJ-6MP 90D8MJ-6MP T8MJ-6MP-8MJ 8MJ-8MP 8MJ-12MP 90D8MJ-8MP 90D2PL-10-32M 8MP-12BH-8MP ELC-22370 MTR-25255 VLV-51638 TNK-51993 Compressor VLV-51637 HSG-51437 VLV-51639 VLV-51640 VLV-29216 VLV-51641 Pressure Controlled CK Valve PTM-51644 Qty 3 1 1 3 1 2 1 7 2 1 4 1 2 5 1 6 2 1 2 1 6 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1
March 31, 2002
8-45
Diagrams
Table 8-4. Air System Parts and Fittings Chart

Item No. AK AL AM AN AO AP AQ AR AS AT AU AV AW AX AY Comes on Rear Axle QR-1 Quick Release Valve Horn Comes With Air Dryer Air Dryer Rockwell Wabco Brake Parking Assembly SPARE Regulator Air 45# Fixed NPT Tee Female Pipe X Female Pipe X Male Pipe 90 Male Jic X Male Pipe Long Modified (90D4MJ-2MP) Air Supply Switch Low Air 65 PSI Control Grnd Bushing Hex 3/8 X Regulator Air 80# Fixed NPT Gauge 1 Dia (O-160) 1/8 NPT Control Port VLV-26201 T4FP-4FP-4MP 90D4MJ-2MP-L FIT-51998 ELC-60309 FIT-28342 VLV-26199 MTR-50665 1 1 1 1 1 1 1 1 Description Part Number Air Chamber Rear Brakes VLV-51642 MSC-51645 E-Con Valve FTR-60949 PTM-53235 Qty 2 3 1 1 1 1
8-46
March 31, 2002
Diagrams
Figure 8-14. Spread Hopper Gate Air System
March 31, 2002
8-47/8-48 Blank
Diagrams
Table 8-5. Air System Hose and Fittings, Spread Hopper Gates, Front and Rear
Hose No. (A & B) 1A or 20A 1B or 20B 2A or 19A 2B or 19B 3A or 18A 3B or 18B 4A or 17A 4B or 17B 5A or 16A 5B or 16B 6A or 15A 6B or 15B 7A or 14A 7B or 14B 8A or 13A 8B or 13B 9A or 12A 9B or 12B 10A or 11A 10B or 11B Air Supply Hose Type 100R5.188 100R5.188 100R5.188 100R5.188 100R5.188 100R5.188 100R5.188 100R5.188 100R5.188 100R5.188 100R5.188 100R5.188 100R5.188 100R5.188 100R5.188 100R5.188 100R5.188 100R5.188 100R5.188 100R5.188 H10408 Length 20 18 20 18 30 23 43 34 53 45 71 58 74 68 86 77 93 88 105 99 104 Fitting RS4, R4FJ, RN4FJX RS4, R4FJ, RN4FJX RS4, R4FJ, RN4FJX RS4, R4FJ, RN4FJX RS4, R4FJ, RN4FJX RS4, R4FJ, RN4FJX RS4, R4FJ, RN4FJX RS4, R4FJ, RN4FJX RS4, R4FJ, RN4FJX RS4, R4FJ, RN4FJX RS4, R4FJ, RN4FJX RS4, R4FJ, RN4FJX RS4, R4FJ, RN4FJX RS4, R4FJ, RN4FJX RS4, R4FJ, RN4FJX RS4, R4FJ, RN4FJX RS4, R4FJ, RN4FJX RS4, R4FJ, RN4FJX RS4, R4FJ, RN4FJX RS4, R4FJ, RN4FJX 8U-8FJX, 90D8U-8FJX-L Hose Description From Bottom Port A on No. 1 and No. 20 Gate Cylinder to A Port Air Valve. From Top Port B on No. 1 and No. 20 Gate Cylinder to B Port Air Valve. From Bottom Port A on No. 2 and No. 19 Gate Cylinder to A Port Air Valve. From Top Port B on No. 2 and No. 19 Gate Cylinder to B Port Air Valve. From Bottom Port A on No. 3 and No. 18 Gate Cylinder to A Port Air Valve. From Top Port B on No. 3 and No. 18 Gate Cylinder to B Port Air Valve. From Bottom Port A on No. 4 and No. 17 Gate Cylinder to A Port Air Valve. From Top Port B on No. 4 and No. 17 Gate Cylinder to B Port Air Valve. From Bottom Port A on No. 5 and No, 16 Gate Cylinder to A Port Air Valve. From Top Port B on No. 5 and No. 16 Gate Cylinder to B Port Air Valve. From Bottom Port A on No, 6 and No. 15 Gate Cylinder to A Port Air Valve. From Top Port B on No. 6 and No. 15 Gate Cylinder to B Port Air Valve. From Bottom Port A on No. 7 and No. 14 Gate Cylinder to A Port Air Valve. From Top Port B on No. 7 and No. 14 Gate Cylinder to B Port Air Valve. From Bottom Port A on No, 8 and No. 13 Gate Cylinder to A Port Air Valve. From Top Port B on No. 8 and No. 13 Gate Cylinder to B Port Air Valve. From Bottom Port A on No. 9 and No. 12 Gate Cylinder to A Port Air Valve. From Top Port B on No. 9 and No. 12 Gate Cylinder to B Port Air Valve. From Bottom Port A on No. 10 and No. 11 Gate Cylinder to A Port Air Valve. From Top Port B on No. 10 and No. 11 Gate Cylinder to B Port Air Valve. From Air Tank on Hopper to Air Valve Assembly in Valve Box.
March 31, 2002
8-49
Diagrams
Blank Page
8-50
March 31, 2002
Diagrams
Figure 8-15. Hydraulic/Misc. Hose and Fittings

March 31, 2002 8-51/8-52 Blank
Diagrams
Table 8-6. Hydraulic/Misc. Hose and Fittings

Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Hose Type H10408 H10408 5/16 Fuel Hose H24504 H24504 H24504 H24504 H24504 H24504 H10408 H10408 H10408 H10408 H10408 H10408 H10408 H10408 H10408 H10408 H10408 H10408 H10408 H10408 Length 118 50 160 98 19 70 39 26 39 35 35 35 35 115 31 31 110 35 35 35 35 12 77 Fitting 8U-8FJX, 2 Ea. 8U-8FJX, 2 Ea. 5PL-4MP & 90D5PL-4MP 4U2-4FJX, 2 Ea. 4U2-4FJX & 90D4U2-4FJX 4U2-4FJX & 90D4U2-4FJX 4U2-4FJX, 2 Ea. 4U2-4FJX & 90D4U2-4FJX 4U2-4FJX, 2 Ea. 8U-8FJX, 2 Ea. 8U-8FJX, 2 Ea. 8U-8FJX, 2 Ea. 8U-8FJX, 2 Ea. 8U-8FJX & 45D8U-8FJX 8U-8FJX & 45D8U-8FJX 8U-8FJX & 45D8U-8FJX 8U-8FJX & 45D8U-8FJX 8U-8FJX, 2 Ea. 8U-8FJX, 2 Ea. 8U-8FJX, 2 Ea. 8U-8FJX, 2 Ea. 8U-8FJX, & 90D8U-8FJX 8U-8FJX, 2 Ea. Hose Description From Diesel Tank Supply to IN Port Primary Fuel Filter on Frame. From OUT Port of Primary Fuel Filter on Frame to Cummins Primary Fuel Filter. Return Off Injector Pump to Fuel Tank. From Brake Master Cylinder to T4MJ-4MJ-MJ Tee on Left-Hand Brake on Drive Axle. From T4MJ-4MJ-4MJ Tee to Left-Hand Brake. From T4MJ-4MJ-4MJ Tee to Right-Hand Brake. From 90D4MB-4MJ on Left Steering Valve (LS Port) to 6MB-4MJ on Shuttle Valve Port on Left Side. From 90D4MB-4MJ (LS Port) of Priority Valve to Center Port of Shuttle Valve. From 90D4MB-4MJ Hand Steering Valve (LS Port) to 6MB-4MJ on Right-Hand Side of Shuttle Valve. From 8MB-8MJ Bottom Port on Steering Manifold Left-Hand Side to 8MB-8MJ (L Port) at Left-Hand Steering Valve. From 8MB-8MJ Top Part on Steering Manifold Left-Hand Side to 8MB-8MJ (T Port) of Left-Hand Steering Valve. From 8MB-8MJ 2 Port From Top on Steering Manifold Left-Hand Side to (P Port) of Left-Hand Steering Valve. From 8MB-8MJ 3 Port From Top on Steering Manifold Left-Hand Side to (R Port) of Left-Hand Steering Valve. From 90D8MB-8MJ Front Bottom Left to T8MB-8MJ-8MJ Tee on Port of Rod End of Left-Hand Steering Cylinder. From T8MB-8MJ Tee on Left-Hand Steering Cylinder to 90D6MB-8MJ on Rear Port of Right-Hand Steering Cylinder. From T8MB-8MJ-8MJ Tee on Right-Hand Steering Cylinder to 90D6MB-8MJ on Rear Port of Left-Hand Steering Cylinder. From 90D8MB-8MJ Front Bottom Right to T8MB-8MJ-8MJ Tee on Port of Rod End of Right-Hand Steering Cylinder. From 8MB-8MJ 3 Port from Top on Steering Manifold Right-Hand Side to (R Port) of Steering Valve. From 8MB-8MJ 2 Port from Top on Steering Manifold Right-Hand Side to (P Port) of Right-Hand Steering Valve. From 8MB-8MJ Bottom Port on Steering Manifold Right-Hand Side to 8MB-8MJ (L Port) of Right-Hand Steering Valve. From 8MB-8MJ Top Port on Steering Manifold Right-Hand Side to 8MB-8MJ (T Port) of Right-Hand Steering Valve. From 90D8MB-8MJ Center Left-Hand Port of Steering Manifold to 90D8MB-8MJ of CF Port of Priority Valve. From 90D8MB-8MJ Top Right-Hand Port of Steering Manifold to nd 90D8MB-8MJ 2 Port on Top of Return Manifold.
nd rd rd nd
March 31, 2002
8-53
Diagrams

Item No. 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 Hose Type H10408 H10408 H10408 H42508 PiP-53310 H10412 H10420 H10420 H10416 H10412 SPARE SPARE H10412 SPARE H24504 SPARE H10412 PiP-53269 H10408 PiP-53328 PiP-53327 SPARE SPARE H10420 SPARE SPARE H42508 15 8U-8FJX, 2 Ea. From Top of Pressure Manifold to Front Pump Valve. 23 20U-20FJX, 2 Ea. From OUT Port of 3-Filter Assembly to Gate Valve on Hydraulic Tank. 116 43 110 111 130 12U-12FJX, 2 Ea. PURCHASED HOSE 8U-8FJX, 2 Ea. PURCHASED HOSE PURCHASED HOSE From Sunstrand Motor Case Bleed Port to Traction Filter Assembly on Hydraulic Tank. From Right-Hand Port on Sunstrand Pump to Right-Hand Port on Sunstrand Motor. From (T Port) on Chip Box Hydraulic Manifold to Center Top Return Manifold. From Left-Hand Port of Oil Cooler to Rear Port of Return Hydraulic Manifold. From Right-Hand Port of Oil Cooler to IN Port of 3-Filter Assembly. 90 4U2-4FJX, 2 Ea. From T Port of Priority Valve to Top Front Port of Return Manifold. 18 12U-12FJX, & 90D12U-12FJX From Right-Hand Back Port of Belt Pump (Case Bleed) to Tee on Front Right-Hand Side Hydraulic Tank. Length 96 103 110 185 41 36 48 29 60 32 Fitting 8U-8FJX, 2 Ea. 8U-8FJX, 2 Ea. 8U-8FJX, 2 Ea. 8U-8FJX & 90D8U-8FJX PURCHASED HOSE 12U-12FJX, 2 Ea. 20U-20FJX, 2 Ea. 20U-20FJX, 2 Ea. 16U-16FJX, 2 Ea. 12U-16FJX & 12U-12FJX Hose Description From 90D8MB-8MJ (B Port) of Hitch Manifold to T8MB-8MJ-8MJ Tee Rod End of Hitch Cylinder. From 8MB-8MJ (A Port) of Hitch Manifold to T8MB-8MJ-8MJ Tee Rear Port of Hitch Cylinder. From (T Port) on Hitch Manifold to Top 1 Port Return Manifold. From 90D8MB-8MJ on Right-Hand Port of Pressure Manifold to (P Port) of Hitch Manifold. From Left-Hand Port on Sunstrand Pump to Left Port of Sunstrand Motor. Sunstrand Pump Case Bleed Port to Sunstrand Motor Top Case Bleed Port. From Sunstrand Pump (Drive Pump) Suction Port to Left-Hand 2-Filter Assembly OUT Port. From IN Port on 2-Filter Assembly to Left Shut Off Gate Valve on Hydraulic Tank. From Suction Screen on Top of Hydraulic Tank to Front Port on Power Steering Pump on Engine. From Compensator Valve on Belt Drive Pump to T12MP-12MJ-12MJ Tee on Hydraulic Tank.
st
8-54
January 31, 2004
Diagrams

Item No. 51 52 Hose Type H10408 2 SUCTION HOSE H42508 H10412 H43012 H43012 H24504 H24504 H10412 H10412 H10412 H10412 H24504 H24504 H10408 H10408 H24504 H24504 H24504 H24504 H24504 H24504 H24504 Length 15 30 Fitting 8U-8FJX, 2 Ea. NONE 5/8 BANDING 8U-8FJX & 90D8U-8FJX-L 12U-12FJX & 45D12-12FJX 12E4-12FJX, 2 Ea. 12E4-12FJX, 2 Ea. 4U2-4FJX, 2 Ea. 4U2-4FJX, 2 Ea. 12U-12FJX, 2 Ea. 12U-12FJX, 2 Ea. 12U-12FJX, 2 Ea. 12U-12FJX, 2 Ea. 4U2-4FJX, 2 Ea. 4U2-4FJX, 2 Ea. 8U-8FJX, 2 Ea. 8U-8FJX, 2 Ea. 4U2-4FJX, 2 Ea. 4U2-4FJX, 2 Ea. 4U2-4FJX, 2 Ea. 4U2-4FJX, 2 Ea. 4U2-4FJX, 2 Ea. 4U2-4FJX, 2 Ea. 4U2-4FJX, 2 Ea. Hose Description From Back Port of Pump Valve to 90D8MP-8MJ on Top of Hydraulic Tank. From Right-Hand Filter.
53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73
65 85 127 133 24 30 21 22 160 195 109 109 27 27 30 30 276 265 212 139 212
From Top Port of Steering Pump (on Engine) to 90D8MB-8MJ (P Port) on Priority Valve. From EF Port of Priority Valve to Bottom Front Port of Return Manifold. From Front Flow Regulator on Pressure Manifold (on Conveyor) to Left Belt Motor Pressure Port. From Rear Flow Regulator on Pressure Manifold (on Conveyor) to Right Belt Motor Pressure Port. Right-Hand Belt Motor Case Bleed to Center Return Manifold (on Conveyor). Left-Hand Belt Motor Case Bleed to Center Return Manifold (on Conveyor). Right-Hand Belt Motor Return to Center Manifold (on Conveyor). Left-Hand Belt Motor Return to Center Manifold (on Conveyor). Return Manifold (Rear Hopper) to Center Return Manifold (on Conveyor). Return Manifold (Front Hopper) to Center Return Manifold (on Conveyor). Hydraulic Valve Manifold (in Front Valve Box) Return to Return Manifold on Front Hopper. Hydraulic Valve Manifold (in Rear Valve Box) Return to Return Manifold on Rear Hopper. Front Auger Motor Return Hose to Return Manifold (on Front Hopper). Rear Auger Motor Return Hose to Return Manifold (on Rear Hopper). Rear Auger Motor Case Bleed to Return Manifold (on Rear Hopper). Front Auger Motor Case Bleed to Return Manifold (on Front Hopper). Pressure Hose From P Port on 2-Station Manifold (on Left-Hand Conveyor) to Front Valve Box Manifold. Pressure Hose From P Port on 2-Station Manifold (on Left-Hand Conveyor) to Rear Valve Box Manifold. Left-Hand 4-Port Lock-Out Valve to Rear Hopper Hydraulic Cylinder (Ram End of Cylinder). Left-Hand 4-Port Lock-Out Valve to Rear Hopper Hydraulic Cylinder (Housing End of Cylinder). Right-Hand 4-Port Lock-Out Valve to Front Hopper Hydraulic Cylinder (Ram End of Cylinder).
March 31, 2002
8-55
Diagrams

Item No. 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 4-WD 91 4-WD 92 4-WD 93 94 95 96 Hose Type H24504 H24504 H24504 H24504 H24504 H24508 H24508 H24504 H24504 H24504 H24504 H24508 H24508 H24504 H24504 H24504 H24504 H24504 H24504 H24504 H24504 H24504 H24504 Length 139 25 25 29 29 223 279 59 70 59 70 42 47 10 10 53 124 54 58 146 156 31 31 Fitting 4U2-4FJX, 2 Ea. 4U2-4FJX, 2 Ea. 4U2-4FJX, 2 Ea. 4U2-4FJX, 2 Ea. 4U2-4FJX, 2 Ea. 8U-8FJX, 2 Ea. 8U-8FJX, 2 Ea. 4U2-4FJX & 90D4U2-4FJX 4U2-4FJX & 90D4U2-4FJX 4U2-4FJX & 90D4U2-4FJX 4U2-4FJX & 90D4U2-4FJX 8U-8FJX & 90D8U-8FJX 8U-8MJ & 90D8U-8FJX-L 4U2-4FJX, 2 Ea. 4U2-4FJX, 2 Ea. 4U2-4FJX, 2 Ea. 4U2-4FJX & 90D4U2-4FJX 4U2-4FJX & 90D4U2-4FJX 4U2-4FJX & 90D4U2-4FJX 4U2-4FJX, 2 Ea. 4U2-4FJX, 2 Ea. 4U2-4FJX, 2 Ea. 4U2-4FJX, 2 Ea. Hose Description Right-Hand 4-Port Lock-Out Valve to Front Hopper Hydraulic Cylinder (Housing End of Cylinder). Pressure Port on 2-Station Manifold (on Conveyor) to Left-Hand 4-Port Lock-Out Valve. Pressure Port on 2-Station Manifold (on Conveyor) to Left-Hand 4-Port Lock-Out Valve. Pressure Port on 2-Station Manifold (on Conveyor) To Right-Hand 4-Port Lock-Out Valve. Pressure Port on 2-Station Manifold (on Conveyor) to Right-Hand 4-Port Lock-Out Valve. Front Flow Control Valve (Right-Hand Conveyor) to Front Auger Motor (Pressure). 2 Flow Control Valve Right-Hand Conveyor (from Front) to Rear Auger Motor (Pressure). From Port on Rear Valve Box Manifold to Port on Rear Cam Motor. From Port on Rear Valve Box Manifold to Port on Rear Cam Motor. From Port on Front Valve Box Manifold to Port on Front Cam Motor. From Port on Front Valve Box Manifold to Port on Front Cam Motor. Pressure From P Port (on Front Center Pressure Manifold) to P Port on 2-Station Manifold on Left-Hand Conveyor. Return From T Port on 2-Station Manifold (Left-Hand Conveyor) to Return Manifold on Right-Hand Side Chipper Frame. From Port on Right-Hand Side Hydrostatic Pump to Right-Hand Port on Shuttle Valve. From Port on Left-Hand Side Hydrostatic Pump to Left-Hand Port on Shuttle Valve. From Port on Hydrostatic Motor EDC Valve to Center Port of Shuttle Valve. Pressure Hose From Master Cylinder to Brake Tee Center (Rear Axle). From Brake Tee (Left-Hand) to Rear Axle Left-Hand Brake. From Brake Tee to Rear Axle Right-Hand Brake. From Pressure Port 2-Station Manifold (Hitch) to Cylinder (Ram End) Hitch Raise Cylinder. From Pressure Port 2-Station Manifold (Hitch) to Cylinder (Housing End) Hitch Raise Cylinder. Return From T Port 2-Station Hitch Manifold to Port on Cooler Motor (DM-8). Pressure From P Port 2-Station Hitch Manifold to Port on Cooler Motor (DM-8).
nd
8-56
January 31, 2004
Diagrams

Item No. 97 98 99 100 101 102 103 104 105 106 Hose Type H10408 H10408 H10408 H06908 H06908 H24508 PiP-53382 H10416 H10412 PiP-53391 Length 40 49 9 210 144 124 140 1/16 72 90 85 Fitting 8U-8FJX & 90D8U-8FJX 8U-8FJX & 45D8U-8FJX 8U-8FJX & 90D8U-8FJX 6.5U-8FJX, 2 Ea. 6.5U-8FJX, 2 Ea. 8U-8FJX & 45D8U-8FJX PURCHASED HOSE, 1 16U-16FJX & 90D16U-16FJX 12U-12FJX & 90D12U-12FJX PURCHASED HOSE 1 Hose Description From Port on Cooler Pump to Port on Funk Transfer Case. From Port on Oil/Water Cooler to Port on Funk Transfer Case. From Port on Cooler Pump to Port on Oil/Water Cooler. Port on Oil/Water Cooler to Port on Engine Cooling System. Port on Oil/Water Cooler to Port on Engine Cooling System. From Pressure Manifold on Center of Hydraulic Tank to Flow Control Valve Manifolds on Right-Hand Conveyor. From Compensator Valve on Belt Pump to Flow Control Valve Manifolds on Right-Hand Conveyor. Suction Port on Power Steering/Cooler Pump on Cummins Engine to Strainer on Hydraulic Tank. Port on Power Steering/Cooler Pump on Cummins Engine to Bottom Port Return Manifold on Frame. Return from Return Manifold on Left-Hand Conveyor to Return Manifold on Right-Hand Frame.
March 31, 2002
8-57
Diagrams
Table 8-7. Hydraulic System Parts and Fittings Chart

Item No. A B C D E F G H I J K L M N O P Q R S T U V W X Y Z AA AB AC AD AE AF AI AJ AK AL Description 90 3/8 Male Pipe X 5/16 Push On 90 Female Pipe X Male Jic Tee Female Jic X Male Jic X Male Jic 3/8 Male O-Ring X Male Jic 90 Male Jic X Male Pipe Tee Male Jic X Male Jic X Male Jic 90 3/8 Male O-Ring X Male Jic 90 Male O-Ring X Male Jic Male O-Ring X Male Jic Male O-Ring X Male Jic Cap Female Jic 90 Male O-Ring X Male Jic Tee Male O-Ring X Male Jic X Male Jic 3/8 Male O-Ring X Female O-Ring 90 3/8 Male O-Ring X Male Jic 1 Close Nipple 1 Gate Valve 1 Male Jic X 1 Male Pipe 1 Male O-Ring X 1 Male Jic 1 Male O-ring X 1 Male Jic 1 Male Jic X 1 Male Pipe 45 1 Flange X 1 Male Jic Code 62 Male O-Ring X Male O-Ring Union Belt Flow Control Valve 90 Male O-Ring X Male Jic Belt On/Off Sol. Valve Male Jic X Male Pipe 1 Male O-Ring X 1 Male Jic Tee Male Jic X Male O-Ring X Male Jic 1 Male O-Ring X Female O-Ring Female Jic Cap 1 Flange X 1 Male Jic Code 62 1 Flange Clamp code 62 Male O-Ring X Male Jic Elbow, Belt Drive Pump Tee Male Pipe X Male Jic X Male Jic Part Number 90D6MP-5PL 90D8FP-8MJ T4FJX-4MJ-4MJ 6MB-4MJ 90D8MJ-8MP T4MJ-4MJ-4MJ 90D6MBMJ 90D4MB-4MJ 8MB-8MJ 8MB-4MJ C4FJ 90D8MB-8MJ T8MB-8MJ-8MJ 6MB-8FB 90D6MB-8MJ FIT-28006 VLV-29250 20MJ-20MP 24MB-20MJ 90D24MB-20MJ 16MJ-16MP 45D16FG-16MJ 12MB-12MB VLV-51811 90D12MB-12MJ VLV-53444 8MJ-8MP 16MB-16MJ T8MJ-8MJB-8MJ 16MB-8FB C8FJ 16FG62-16MJ 16FG62 12MB-12MJ FIT-60616 T12MP-12MJ-12MJ Qty 1 1 1 4 5 1 4 9 18 3 6 9 2 2 2 2 2 3 3 1 1 1 2 4 8 4 1 2 3 1 2 1 6 4 1 1
8-58
January 31, 2004
Diagrams

Item No. AM AN AO AP AQ AR AS AT AU AV AW AX AY AZ BA BB BC BD BE BF BG BH BI BJ BK BL BM BN BO BP BQ BR BS BT BU BV BW Filter Piping Assembly Traction Drive Filter Assembly 1 90 Street Elbow 90 Male Jic X Male Pipe Chipper Pump/Start Up Valve Assembly Male O-Ring Plug Male O-Ring Plug Bushing Female Pipe X Male O-Ring Fan Switch Oil Cooler 150 1 Male O-Ring X 1 Male Jic Male O-Ring X Female O-Ring Male O-Ring X Male Jic Male O-Ring X Male Jic Pump Steering/Cooler (Gear) Chipper Compensating Pressure Pump Belt Drive Motor 22.84 CI Sunstrand Pump 90R Sunstrand Motor 51V Hitch Cylinder 90 1 Flange X 1 Male Jic Code 62 45 Male Pipe X Male Jic 45 1 Male O-Ring X 1 Male Jic Male O-Ring X Male Jic 90D32MJ-32MB With Pressure CK Port 90D32MJ-32MB With Temp Sealer CK Port Temp Switch (140) Hayden Oil Cooler Check Valve Steering Valve Plug Male O-Ring Valve Steering Priority Steering Control Valve Oil Cooler Pump (Funk Transfer Case) Heat Exchanger Oil/Water Funk Transfer Case Manifold Pressure Forward (Conveyor) Manifold Sub Plate Valve (Valve box) Auger Motor Motor Hydraulic Cam Gear Box Description Part Number FTR-51534 HSG-51738 FIT-28241 90D12MJ-12MP MCH-60984 P12MB P8MB 4FP-8MB ELC-51660 20MB-20MJ 12MB-4FB 4MB-4MJ 10MB-8MJ PMP-53412 PMP-51618 PMP-51619 PMP-53230 PMP-53231 CYL-60651 90D16FG-16MJ 45D12MP-12MJ 45D16MB-20MJ 12MB-8MJ FIT-53335 FIT-53336 ELC-53236 VLV-51606 P4MB VLV-51604 VLV-51607 PMP-52223 PMP-51925 PTM-53160 MSC-53280 VLV-51613 PMP-51625 PMP-53160 Qty 1 1 1 1 1 1 1 1 1 1 1 4 2 1 1 2 1 1 1 4 1 1 1 1 1 1 2 1 1 2 1 1 1 2 2 2 2
January 31, 2004
8-59
Diagrams

Item No. BX BY BZ CA CB CC CD CE CF CG CH CI CJ CK CL CM CN CO CP CQ CR CS CT CU CV CW CX CY CZ DA DB DC Description Manifold Hydraulic Return (Small) Hopper Cylinder Hopper Extend And Retract Lock-Out Valve 4-Port Manifold Hydraulic Return (Belt/Auger) Forward Oil Cooler Motor (Funk Transfer Case) Shuttle Valve (Sunstrand Pump) Hitch Raise Cylinder Manifold Hydraulic Return (Frame) Manifold Hydraulic Pressure (Forward on Hydraulic Tank) Manifold Hydraulic Hitch/Hopper Manifold Brake Tee 90 Male O-Ring X Male Jic 90 Male O-Ring X Male Jic 90 3/8 Male Pipe X Male Jic 3/8 Male Pipe X Male Jic 3/8 Male Pipe X Male Jic 45 Male O-Ring X Male Jic 90 1 Male O-Ring X Male Jic Male Pipe X Male Jic 90 Male Pipe X Male Jic 45 Male Pipe X Male Jic 45 Male O-Ring X Male Jic 5/8 Male O-Ring X Female O-Ring Bushing 2 Male O-Ring x 1 Female O-Ring Bushing 45 1 Male O-Ring X 1 Male Jic 1 Male O-Ring Plug 1 Male O-Ring X 1-1/4 Male O-Ring Union 45 Male O-Ring X Male Jic 90 Male Pipe X Male Jic 3-Filter Head Assembly 2-Filter Head Assembly Suction Filter Housing (Cooler Pump) Part Number MSC-53358 CYL-53700 VLV-22333 MSC-53376 PMP-80322 VLV-53237 CYL-53333 MSC-53371 MSC-51600 MSC-51621 MSC-53268 90D4MB-4MJ 90D8MB-4MJ 90D6MP-4MJ 8MJ-6MP 4MJ-6MP 45D12MB-12MJ 90D16MB-12MJ 4MJ-4MP 90D4MJ-4MP 45D4MJ-4MJ 45D12MB-8MJ 10MB-4FB 32MB-24FB 45D24MB-24MJ P24MB 20MB-20MB 45D4MB-4MJ 90D12MB-8MJ FTR-51731 FTR-51732 HSG-53413 Qty 2 2 2 1 1 1 1 1 1 2 1 6 10 5 1 2 1 3 2 2 2 4 4 1 1 1 1 1 1 1 1 1
8-60
January 31, 2004
Parts Index
SECTION 9. PARTS INDEX

This section contains an alphabetical listing of parts for the BC-2002/CRC Tandem. The part description, part number, and illustrated parts list (IPL) figure number and item number is given. Standard hardware such as nuts, bolts, and washers is not included in this parts index. Standard hardware is listed in the applicable figure of the IPL.
Description
Female Jic Cap Male Jic X Male Pipe Male Jic X Male Pipe Male O-Ring X Male Jic Male O-Ring X Male Jic Male O-Ring X Male Jic Male O-Ring X Male Jic Male O-Ring X Male Jic Male Pipe X Bulk Head X Male Pipe Close Nipple Grease Zerk Male Jic X Male Pipe Male Jic X Male Pipe Male O-Ring X Male Jic 1/8 Male Grease Zerk 3/16 X 3/16 X 2 Key 3/8 Male O-Ring X Male Jic 3/8 Male O-Ring X Male Jic 4 X 20 Stroke Hydraulic Cylinder 90 Male O-Ring X Male Jic 90 Male O-Ring X Male Jic 90 Male O-Ring X Male Jic 90 Male Jic X Male Pipe 90 Male Jic X Male Pipe 90 Male O-Ring X Male Jic 90 Male O-Ring X Male Jic 90 Male Pipe
Part No.
C8FJ 8MJ-4MP 8MJ-4MP 8MB-8MJ 8MB-8MJ 8MB-8MJ 8MB-8MJ 8MB-4MJ 8MP-12BH-8MP FIT-28001 .250-28M-2 4MJ-4MP 4MJX4MP 4MB-4MJ 2MP-Z STL-30951 6MB-4MJ 6MB-4MJ CYL-51962 90D8MB-8MJ 90D8MB-8MJ 90D8MB-8MJ 90D4MJ-4MP 90D4MJ-4MP 90D4MB-4MJ 90D4MB-4MJ 90D8MB-4MJ
Fig
7-17 7-6 7-9 7-13 7-13 7-19 7-20 7-20 7-9 7-6 7-8 7-9 7-26 7-13 7-23 7-23 7-13 7-26 7-26 7-13 7-19 7-20 7-9 7-26 7-13 7-13 7-24
Item
6 35 10 12 15 9 8 7 9 37 2 12 8 9 21 20 11 15 4 13 7 5 15 13 10 14 5
A
Air Dryer Assembly Air Intake Precleaner Air Supply Line Assembly, Tow Bar FTR-60945 FTR-51855 PIP-60842 7-3 7-2 7-26 25 78 21
July 15, 2002
9-1
Model BC-2002/CRC Tandem Description

Air Tank Air Tank Assembly Air Tank Spacer Angle Brace Angle Brace Antenna 39 Height, Magnetic Base Auger 14, Left-Hand Auger 14, Right-Hand Auger Bearing End Shaft Auger Motor Auger Motor End Shaft Axle Assembly, Modified (2WD) Axle Assembly, Rear Drive (4WD) Axle, Spicer/Dana HD 1350
Parts Index Part No.

TNK-53080 TNK-51993 BRK-51573 BRK-61609 BRK-61610 ELC-60637 PTM-53130 PTM-53131 PTM-53106 PMP-51625 PTM-53105 PTM-53348 PTM-53226 PTM-61457
Fig
7-21 7-6 7-6 7-11 7-12 7-16 7-21 7-21 7-21 7-21 7-21 7-2 7-2 7-7
Item
18 27 26 12 12 23 3 4 1 2 147 150 1
B
Back-Up Alarm Baffle Baffle, Air Dryer Barrier Strip, 6-Gang Barrier Strip, 20 Lug Battery Box Beacon Bearing #11910 Cup Bearing #LM48510 Cup Bearing 4-Bolt Bearing Gear Box #48548 Bearing Gear Box #LM11949 Bearing Guard Bearing, Pillow Block Bearing Plate Belt Motor Assembly Blank Cover C-7 Bore Coupling 2 7/16 Bracket Bracket Bracket Bracket Bracket, Air Cleaner Support ELC-24293 BRK-53090 BRK-60948 ELC-24190 ELC-24220 HSG-51560 ELC-24215 PTM-50846 PTM-50848 PTM-51905 PTM-50847 PTM-50845 GRD-53212 PTM-51415 BRK-53020 PTM-51619 MSM-50899 PTM-50837 BRK-53353 BRK-61048 BRK-51407 BRK-51407 BRK-51826 7-2 7-2 7-6 7-22 7-24 7-6 7-2 7-23 7-23 7-21 7-23 7-23 7-21 7-2 7-21 7-2 7-24 7-21 7-2 7-10 7-11 7-12 7-3 141 246 4 2 17 29 96 5 7 24 6 4 5 234 26 72 19 15 276 5 13 14 12
9-2
July 15, 2002

Bracket, Auger Mount Bracket, Bearing Mount Bracket, Cooler Mount Bracket, Double Intake Filter Bracket, Double Timbren Spring Bracket, Hinge / Base Bracket, Hitch Manifold, Tow Bar Glad Hand Bracket, Inner Conveyor Rail to Hydraulic Tank Bracket, Latch T-Handle Bracket, Outer Conveyor Rail to Hydraulic Tank Bracket, Primary Fuel Filter Bracket, Rear Bracket, Shuttle Valve, Sunstrand Pump Bracket, Swaybar (Right-Hand & Left-Hand) Bracket, Tank to Conveyor Bracket, Throttle Cable Bracket, Tow Bar, Quick Disconnect Bracket, Triple Return Filter Brackets Brake Mount Break Away Switch Breather Assembly, Hydraulic Tank Bushing Bushing Bushing Hex X Bushing Hex X Bushing Hex X

BRK-53056 BRK-51416 BRK-53402 BRK-51680 BRK-61468 BRK-53246 BRK-61048 BRK-51425 FAS-24387A BRK-53355 BRK-60615 BRK-61479 BRK-53262 BRK-51485 BRK-60604 BRK-61681 BRK-53409 BRK-51679 BRK-61696 BRK-53315 ELC-24281 FTR-51539 BRK-50738 BRK-50738 FIT-28344 FIT-28344 FIT-28344
Fig
7-21 7-2 7-3 7-6 7-6 7-15 7-9 7-2 7-14 7-2 7-6 7-2 7-3 7-6 7-2 7-3 7-21 7-6 7-2 7-7 7-16 7-3 7-21 7-25 7-9 7-26 7-26
Item
17 228 22 3 1 10 3 219 6 216 7 195 14 22 183 27 11 2 213 15 8 2 34 9 14 6 10
C
Cable 7-Cond. Stranded Trailer Cable Cable Assembly Cam Stop Camshaft Camshaft 1 Cap Cap Female Jic Capacitor, Axial 100 MFD Cat Walk Cat Walk ELC-24058 PTM-51634 BRK-53070 MCH-53075 MCH-54048 FIT-26045 C4FJ ELC-24551 GRD-53311 GRD-53133 7-9 7-16 7-21 7-21 7-25 7-2 7-13 7-22 7-2 7-2 11 1 44 46 5 177 1 249 294
July 15, 2002
9-3

Cat Walk, Left-Hand, Tandem Cat Walk, Right-Hand, Tandem CB, 40 Channel Chain Chain Assembly, Mirror Chain Strap Channel Channel Channel Channel Stiffener Chip Box Extension Chip Box Weldment Chip Box, Tandem Chrome Plug Cinch Connector 6 Lug Circuit Breaker, 15 Amp Circuit Breaker, 30 Amp Clamp Muffler 1 Clamp, Cable Clamp, Conveyor Rear Seal Clamp, Conveyor Rear Side Seal Clamp, Horizontal Seal Clamp, Vertical Seal Clevis (1/4 Pin) Clevis (5/16 Pin) Clip Click Pin, Spring Loaded Companion Flange 2-1-333 Compensator Pump Elbow Conical Nut Connector, Cinch, 10 Lug Connector 20 Lug Barrier Strip Connector Strain Relief Control, Positive Lock Conveyor Assembly, Left-Hand (See Figure 7-11 for Details) Conveyor Assembly, Right-Hand (See Figure 7-12 for Details) Conveyor Belt, Hot RS (30 x 489) Conveyor Belt, Hot LS (30 x 547) Conveyor Belt, Standard RS (30 x 489) Conveyor Belt, Standard LS (30 x 547) FIT-24219 ELC-24190 ELC-24289 ELC-24290 FAS-29362 FAS-60982 BRK-51798 BRK-60647 BRK-51246 BRK-51785 FAS-51635 FAS-51758 FAS-60821 PTM-22273 FIT-60616 FAS-61487 ELC-24188 ELC-24220 ELC-24420 MCH-51633 HSG-53149 HSG-53150 MSC-51767 MSC-60400 MSC-60482 MSC-60485 HSG-53010

GRD-53157 GRD-53314 ELC-60636 PTM-50834 FAS-61052 BRK-60797 HSG-53381 BRK-61485 HSG-53138 BRK-53241
Fig
7-11 7-12 7-16 7-21 7-2 7-7 7-6 7-6 7-7 7-2 7-25 7-21 7-21 7-24 7-14 7-14 7-24 7-13 7-16 7-2 7-2 7-2 7-2 7-16 7-16 7-26 7-4 7-3 7-3 7-14 7-14 7-24 7-16 7-11 7-2
Item
6 6 22 13 264 10 16 17 7 171 23 12 11 3 7 19 10 132 123 120 102 2 3 1 5 31 10 13 27 4 201 33
9-4
July 15, 2002

Conveyor Rail #1 Left-Hand Outer, Tandem Conveyor Rail #2 Left-Hand Inner, Tandem Conveyor Rail #3 Right-Hand Inner Conveyor Rail, #4 Right-Hand Outer Cotter Pin X 2 Cotter Pin 3/16 X 2 Coupling, Pot Drive, Female Coupling, Pot Drive, Male Coupling, Taper Lock, Female Coupling, Taper Lock, Male Cover, Chain coupler/auger motor Cover, Guard. Proximity Switch auger/belt Cover, Hydraulic Manifold Closed Center CRC Display Cross Channel Cross Channel Cross Member Cross Member Cross Member Cross Member Aft Cross Member Forward Cross Member With Guard Cummins 6CT 8.3 (230 HP) Current Breaker 50 Amp Cylinder Cylinder 1 X 10

HSG-53151 HSG-53152 HSG-53153 HSG-53154 FAS-25944 FAS-25935 PTM-53270 PTM-50972 PTM-60663 PTM-60664 PTM-50835 HSG-50801 HSG-27355 MTR-51753 HSG-51428 HSG-51428 BRK-61706 BRK-53351 BRK-61706 BRK-53099 BRK-53100 BRK-53370 MCH-51849 ELC-24184 CYL-50919 CYL-22300
Fig
7-11 7-11 7-12 7-12 7-17 7-17 7-22 7-22 7-2 7-2 7-21 7-2 7-21 7-19 7-16 7-11 7-12 7-11 7-12 7-12 7-2 7-2 7-12 7-3 7-14 7-25 7-18
Item
18 8 8 23 5 7 57 60 14
5 13 9 9 16 17 21 48 51 19 1 9 4 8
D
Diaphragm, Proximity Switch (auger/belt) Diesel Tank Din Connector Dip Stick 60 Dip Stick Tube Directional Control Valve, Closed Center Directional Control Valve, Closed Center Door Assembly Left-Hand Door Assembly Right-Hand Double Check Valve, Stack-Up Dowel Pin I.D. X MSC-50831 TNK-61824 ELC-24416 MTR-51862 PIP-53303 VLV-51621 VLV-51621 HSG-53294 HSG-53300 VLV-51920 FAS-25353 7-2 7-21 7-2 7-24 7-3 7-3 7-18 7-20 7-2 7-2 7-18 7-23 3 18 174 18 34 35 1 2 27
July 15, 2002
9-5

Drivelines Drop Leg Jack MSC-51960
Parts Index Part No. Fig

7-4 7-26 2
Item
E
Earphone Elbow Pipe Street End Plate Set Engine, Cummins 6CT 8.3 (1999-2002) Engine, Cummins QSB-44 (2003 & Newer) Engine Mount Assembly, Rear Engine Mount, Front Exhaust Clamp Connector Stainless Steel Exhaust Clamp U Guillotine Type Exhaust Connector Tube Exhaust Elbow 18 X 18 90 Exhaust Elbow 18 X 18 90 (6 Cut Off End) Exhaust Nipple (4 X .083 Wall Tube X 6 Long) Exhaust System (See Figure 7-5 for Details) Exhaust Tube 4 X .083 W. Nipple Exhaust Exhaust Tubing Flex 4 X 10 Extension Weldment 1 MSC-51869 FIT-51885 FIT-51872 HSG-54049 ELC-60638 FIT-28238 VLV-50900 MCH-51849 MCH-51833 BRK-51460 HSG-51472 FIT-51871 FAS-51872 FIT-51874 FIT-51873 Modified FIT-51873 7-3 7-6 7-5 7-5 7-5 7-5 7-5 7-5 7-3 7-5 7-5 7-25 9 15 10 8 5 6 9 4 10 7 11 14 7-16 7-26 7-24 7-3 21 9 26 1
F
Face Gear Box Housing Fan Cover Fan Electric, Oil Cooler Fender Strut Filter Head Assembly, Suction Flange Yoke 2-2-329 Flange Yoke 2-2-479 Flange Yoke 4-2-669 Flange Yoke 4-2-669 Flasher Clip Flasher, Heavy Duty 2-Terminal Foot Pedal Brake Valve Foot Pedal, Digital (2002) Foot Switch, Varior Potentiometer (2000 2001) BRK-51850 ELC-101889 BRK-51240 ELC-51836 ELC-51832 HSG-50622 HSG-53245 ELC-53231 BRK-51805 FTR-51731 PTM-22251 PTM-22252 7-23 7-15 7-15 7-3 7-3 7-4 7-4 7-4 7-4 7-14 7-14 7-16 7-16 7-16 2 5 3 11 26 2 3 7 11 5 4 17 19
9-6
July 15, 2002

Frame Assembly (See Figure 7-6 for Details) Frame Rail, Left-Hand Frame Rail, Right-Hand Front Fender Fuel Filter Assembly, Primary

HSG-53135 HSG-61481 HSG-61480 GRD-51806 FTR-60953
Fig
7-3 7-6 7-6 7-3 7-3
Item
20 24 25 15 24
G
Gasket, Valve to manifold Gate Assembly 12 Gate Assembly 12 Gate Cylinder Assembly Gear Box Assembly (See 7-23 for Details) Gear Box Housing Gear Box, Split Gear Gear Box, Thrust Bearing Matched Pairs Glad Hand Glad Hands Grizzly, Receiving Hopper Grizzly, Tandem Hopper Ground Strap 12 Guard Guard Rail, Conveyor (2000 2001) Guard Rail, Conveyor (2002) Guard Rail, Front Inside (2000 2001) Guard Rail, Front Inside (2002) Guard, Potentiometer Barrier Strip Gusset Gusset Gusset Pan Hard RNG-27266 MCH-53050 MCH-53030 CYL-50919 PTM-53377 HSG-50621 PTM-53461 PTM-53462 ELC-22375 ELC-22375 BRK-51846 GRD-53204 ELC-24011 GRD-53411 GRD-61701 GRD-53426 GRD-53317 GRD-53429 GRD-53127 BRK-61043 BRK-20235 BRK-53141 7-24 7-21 7-25 7-21 7-21 7-23 7-23 7-23 7-9 7-26 7-2 7-21 7-16 7-2 7-2 7-2 7-2 7-2 7-21 7-6 7-6 7-6 30 8 33 45 1 14 3 8 22 129 19 24 297 36 309 30 306 47 11 14 23
H
Hand Rail, Aft (2000 2001) Hand Rail, Aft (2002) Hand Rail, Front (2000 2001) Hand Rail, Front (2002) Hand Rail, Front/Side (2002) Head Pulley Assembly Heat Exchanger, Transfer Case Helix Angle Worm #WGA-1G For GRD-51566 GRD-51566 RNG-53307 RNG-53424 RNG-53425 PTM-61404 PMP-51925 PTM-53463 7-2 7-2 7-2 7-2 7-2 7-2 7-3 7-23 111 315 9 300 303 240 21 12
July 15, 2002
9-7

Hex Bolt 20 X 2 Hex Bushing 3/8 X Hitch Assembly Hitch Hitch Assembly Cylinder Bracket

FAS-28707 FIT-28342 MCH-53216 MCH-51500 BRK-51505
Fig
7-13 7-6 7-2 7-17 7-17
Item
36 165 12 4
Hitch Cylinder Hitch Cylinder Pin Assembly Hitch Hook Hitch Lift Hitch Manifold (W/Fittings Only) Hitch Manifold (W/Fittings Only) Hitch Manifold W/Lift Option Hitch Manifold W/Out Lift Option Hitch Pin Hitch Pin Hitch X-Member Hood Hook, Left-Hand Hook, Right-Hand Horizontal Mufflers Horizontal Seal Stiffener, Inner Horizontal Seal Stiffener, Outer Hose #4 X 146 Long Hose #4 X 156 Long Housing, Potentiometer Hub Assembly, Tow Bar Hydraulic Cylinder Shoe Hydraulic Motor Gear Box Hydraulic Supply Line Assembly Hydraulic Tank Assembly Hydraulic Valve Closed Center
CYL-60651 FAS-60941 BRK-61501 HSG-61500 HSG-61500
7-17 7-17 7-17 7-18 7-9 7-10 7-20 7-19
2 10 11 2 3
BRK-60658 FAS-51506 BRK-53229 HSG-61708 BRK-51472 BRK-51471 MSC-51875 BRK-51914 BRK-51915 PIP-51762 PIP-51760 MSC-53067 PTM-51964 BRK-60787 PMP-53160 PIP-60844 TNK-53158 VLV-51621
7-17 7-17 7-2 7-2 7-6 7-6 7-5 7-2 7-2 7-18 7-18 7-22 7-26 7-26 7-21 7-26 7-3 7-24
1 9 168 210 21 20 2 159 156 16 17 4 20 25 31 14 33 1
I
Inlet Check Valve Insulator VLV-51606 ELC-50152 7-13 7-24 16 9
J
Junction Box ELC-60950 7-2 198
9-8
July 15, 2002

Junction Box (See Figure 7-14 for Details) Junction Panel Assembly

ELC-60931 HSG-51848
Fig
7-13 7-14
Item
5 7
L
Ladder Assembly Latch T-Handle Lifting Eye, Transfer Case Light, Markers Light, Turn Light, Work Limit Switch Assembly (Proximity) Lock Out Valve GRD-51528 FAS-24387 BRK-53224 ELC-51596 ELC-51587 ELC-51585 MTR-53202 VLV-22319 7-2 7-14 7-3 7-2 7-2 7-2 7-2 7-26 189 1 17 138 225 75 21 12
M
Male Pipe Male Pipe Male Pipe Manifold Assembly Manifold, Auger / Belt control (pressure) Manifold, Auger / Belt (return) Manifold, Hydraulic Return Manifold, Pressure Manifold, Return Manifold, Steering Manifold, Sub Plate Manifold, 2-Station Parallel Manifold, 2-Station Parallel Master Cylinder Mirror Mirror Base Modified Box Modified Coupling Modified Seal Bracket Motor Mount Gear Box 8MB-4MJ 4MJ-4MP 8MJ-6MP HSG-61500 MSC-53280 MSC-53376 MSC-53358 MSC-51600 MSC-53371 MSC-60995 VLV-51613 MSC-51621 MSC-51621 PTM-51644 GRD-61050 BRK-61051 HSG-53111 PTM-53065 BRK-53096 BRK-50855 7-24 7-24 7-24 7-18 7-2 7-2 7-21 7-3 7-3 7-13 7-24 7-19 7-20 7-10 7-2 7-2 7-24 7-21 7-21 7-23 4 22 25 4 6 39 38 3 8 3 6 6 4 1 12 15 28 16 29 13
July 15, 2002
9-9

Motor, Sunstrand 51V, Hydrostatic Motor Mount Angle Cylinder Hitch Lift Mount Cam/Gate Mount Cam/Gate Mounting Plate Mud Flap Muffler Hanger

PMP-53231 BRK-61613 MCH-53052 MCH-53052 BRK-51536 GRD-51815 BRK-51877
Fig
7-3 7-12 7-21 7-25 7-2 7-3 7-5
Item
19 13 40 12 69 7 3
N
Nipple X Close Sch. 80 Nut Inner Spacer 7/8 9 FIT-28001 7-26 7-18 11
O
Oil Cooler Oil Cooler Assembly (See Figure 7-15 for Details) O-Ring 1 3/8 I.D. PTM-53230 HSG-53233 RNG-20910 7-15 7-2 7-22 1 93 9
P
Panel Panel Assembly, 2-Wheel Drive (See Figure 7-9 for Details) Panel Assembly, 4-Wheel Drive (See Figure 7-10 for Details) Panel, Right-Hand Side, Left-Hand Conveyor Parking Brake Assembly Parking Brake Knob Pedestal and Control Box Assembly (See Figure 7-16 for Details) Pedestal Assembly, Tandem Pillow Block, Bearing Pintle Eye Plate Base Plate, Bottom, Left-Hand & Right-Hand Plate, Conveyor to Frame Plate, Left-Hand Top Plate, Rear Axle Plate, Rear Axle Plate, Right-Hand Top BRK-53299 HSG-61069 BRK-61059 HSG-53295 PTM-53235 MSC-51829 HSG-53372 HSG-53373 PTM-51415 MSC-51961 HSG-54058 BRK-53134 HSG-53222 BRK-53137 BRK-53225 BRK-53225 BRK-53136 7-2 7-6 7-6 7-2 7-7 7-16 7-2 7-16 7-2 7-26 7-25 7-7 7-6 7-7 7-11 7-12 7-7 18 12 261 14 11 84 26 234 1 11 8 33 2 10 11 3
9-10
July 15, 2002

Platform Gripstrut Platform Mid Platform Support/Forward Tube Assembly Platform with Seat Base, Right-Hand & Left-Hand Plug Male O-Ring Plug Male O-Ring

GRD-53278 HSG-53271 BRK-60673 HSG-53342 P8MB P8MB
Fig
7-2 7-2 7-13 7-2 7-19 7-20
Item
90 87 1 153 8 6
Plug Trailer 7-Cond. Potentiometer Potentiometer Assembly (See 7-22 for Details) Pressure Check Port Only (Modified 90D32MB-32MJ) Pressure Reducing Valve Proximity Switch Assembly, Conveyor Control Proximity Switch Assembly, Auger Control Pump, Pressure Compensator, Belt Pump Pump, Steering Pump, Sunstrand 90R, Hydrostatic Pump
ELC-24246 ELC-53128 ELC-53322 FIT-53336 VLV-51929 MTR-53202 MTR-53213 PMP-51618 PMP-80016 PMP-53230
7-26 7-22 7-21 7-15 7-24 7-2 7-21 7-3 7-3 7-3
24 3 37 9 3 21 6 4 28 16
Q
Quick Coupler, Female Quick Coupler, Male Quick Disconnect Male HP X 6 Mor FIT-60911 FIT-60912 FIT-29632 7-21 7-21 7-26 9 10 16
R
Radar Assembly (4-WD Option Only) Radiator Radiator Shield Rear Fender Receiving Hopper Regulator, 45# Fixed Relay 70 Amp Relay Socket Remote Box Assembly Restrictor Fitting Retainer, Cam Motor Retainer, Hose Guide HSG-53350 MSC-50814 GRD-51842 GRD-51808 HSG-53365 VLV-26201 ELC-24270 ELC-81005 HSG-53331 FIT-29980 BRK-53069 GRD-53374 7-3 7-3 7-3 7-2 7-2 7-6 7-14 7-14 7-2 7-18 7-21 7-21 23 37 36 180 99 39 8 14 282 7 32 39
July 15, 2002
9-11

Return Roller Assembly Return Rollers Right-Hand & Left-Hand Stanchion Plate Rim Assembly White Rim 16.5 X 6.75 Spoked 8-6.5 Ring, Chaffing 4 I.D. Ring, Rear Frame Hosing Riser, Seal Support Rock Box End Panel, Left-Hand

PTM-51433 PTM-51413 BRK-51481 MSC-80126 RNG-26422 RNG-53343 BRK-21447 HSG-53293
Fig
7-12 7-11 7-6 7-26 7-6 7-6 7-25 7-2
Item
7 7 6 10 9 6 267
Rock Box End Panel, Right-Hand Rock Box Panel Left-Hand, Front Rock Box Panel Left-Hand, Rear Rock Box Panel Right-Hand, Front Rock Box Panel Right-Hand, Rear Runner, Bearing Load
HSG-53298 HSG-53291 HSG-53292 HSG-53296 HSG-53297 PTM-53010
7-2 7-2 7-2 7-2 7-2 7-21
270 252 255 285 288 20
S
Safety Chain Lift Cylinder Shoe Safety Chain Tow Bar Scraper, Rock Seal Seal Seal 1 Seal Support Bracket Seal Wiper, Head Pulley LH Seal Wiper, Head Pulley LH Seal Wiper, Head Pulley RH Seal, Conveyor Flashing Seal, Horizontal Seal, Horizontal Conveyor Seal, Vertical Seal, 45 Corner Seat Security Box Assembly Sensor / Pressure Check Port (Modified 90D32MB-32MJ) Shaft, Worm Drive Gear Box Shroud Slave Box Assembly BRK-60829 BRK-60828 GRD-53279 RNG-53320 RNG-53068 RNG-54059 BRK-53071 RNG-53395 RNG-53395 RNG-53396 RNG-51793 RNG-51796 RNG-60645 RNG-51795 RNG-53394 MSC-51773 HSG-51697 FIT-53335 PTM-50856 HSG-53244 HSG-53143 7-2 7-2 7-2 7-2 7-2 7-2 7-16 7-15 7-23 7-15 7-2 126 114 135 105 108 117 12 8 11 7 273 7-26 7-26 7-21 7-2 7-21 7-25 7-21 7-2 7-2 3 26 22 24 27 1 28 258 291
9-12
July 15, 2002

Sling Cable Assembly Slip Yoke 4-3-1241KX Slip Yoke 4-3-1241KX Snap Ring Snatch Block Snatch Block Assembly Socket 7-Pole Trailer Conn. Socket Boot ELC-24245 ELC-24247 FAS-53017 PTM-52053

PTM-53333
Fig
7-18 7-4 7-4 7-21 7-18 7-18 7-9 7-9
Item
11 6 10 21 10 7
Spacer Spacer Spacer Spacer 3/16 Spacer, Bearing Spacer, Spherical Bearing Spacer, Tandem A-Frame Spacer, Valve Box Speedo Gear Large 19 Tooth Spherical Bearing Spherical Bearing Retainer Spindle Assembly, Tow Bar Spring Assembly Stanchion Pipe, Wet Air Tank Start Up Cable with Tee Handle & Clevis Steering Assembly (2000 2001) (See Figure 7-13 for Details) Steering Assembly (2002) (See Figure 7-13 for Details) Steering Column 30 Steering Shuttle Valve Steering Wheel Steering Wheel Cap Steering Wheel Nut Stiffener Stiffener Strain Relief Stub Shaft Stub Shaft
BRK-53240 PTM-53323 BRK-53116 BRK-61440 BRK-53057 PIP-51518 HSG-53243 BRK-53272 PTM-50843 PTM-51517 HSG-51513 BRK-60832 MCH-51816 HSG-51473 PTM-60980 BRK-51529 BRK-51529 MCH-51608 VLV-51605 MCH-51609 MCH-51610 FAS-51611 BRK-53257 BRK-53260 MCH-51412 MCH-51412
7-7 7-18 7-24 7-6 7-21 7-7 7-7 7-21 7-23 7-8 7-8 7-26 7-18 7-6 7-16 7-2 7-13 7-13 7-13 7-13 7-13 7-13 7-2 7-2 7-18 7-11 7-12
9 14 19 25 4 13 8 9 3 4 19 12 13 7 81 312 18 2 8 6 7 42 45 2 14 15
July 15, 2002
9-13

Support Locator, Potentiometer Support Panel, Left-Hand Support Panel, Right-Hand Support Track Support Tube Support, Lower Support, Receiving Hopper to Conveyor Support, Upper Swaybar Assembly

BRK-53109 BRK-53081 BRK-53083 BRK-53112 BRK-60925 BRK-60696 BRK-60614 BRK-60667 PTM-51459
Fig
7-21 7-2 7-2 7-21 7-6 7-2 7-2 7-2 7-3
Item
36 204 1 12 18 192 144 186 6
Swing Away Hitch Assembly Switch Panel Switch, Micro (Proximity Switch for auger/belt) Switch, Mom Off Mom Switch, On/Off Single Pole
MCH-60796 HSG-53115 ELC-50915 ELC-24274 ELC-24275
7-26 7-24 7-2 7-21 7-24 7-24
27 16
11 13
T
Tail Pipe Tail Pulley Assembly Tail Pulley Assembly Take-Up Bearing Take-Up Bearing Take-Up Bearing Adjustment Assembly Take-Up Bearing Adjustment Assembly Taper Lock 1 Taper Lock 1 15/16 Taper Lock, Coupling, Female Taper Lock, Coupling, Male Tee Male Jic X O-Ring X Male Jic Tee Male Jic X Male Jic X Male Pipe Timbren Tire 9.50-16.5 10 Ply Radial (Tow Bar) Tow Bar Assembly Tow Bar Chipper Pin, 2 Tow Bar Cylinder Top & Bottom Pins Track Support Track Support, Aft BRK-60823 BRK-60825 BRK-53087 BRK-53366 FIT-51884 MCH-51403 MCH-51403 PTM-51417 PTM-51417 MCH-51965 MCH-51965 PTM-60666 PTM-60665 PTM-60663 PTM-60664 T8MJ-8MB-8MJ T4MJ-4MJ-4MP MSC-100130 MSC-80127-T 7-5 7-11 7-12 7-11 7-12 7-11 7-12 7-2 7-2 7-2 7-2 7-17 7-26 7-3 7-26 7-26 7-26 7-26 7-2 7-2 18 5 243 222 1 3 3 4 4 1 1 63 66 57 60 5 7 30
9-14
July 15, 2002

Track Support, Front Trailer Cord Assembly Chipper Tow Bar Transfer Case Trough Roller Trough Rollers Assembly Tube Shaft 4-40-761 Tube Shaft 4-40-761 Tube X-Member Transmission Mount BRK-53223

BRK-53341 ELC-60840 PTM-53160 MCH-51402 MCH-51402
Fig
7-2 7-26 7-3 7-12 7-11 7-4 7-4 7-6
Item
279 23 18 10 11 5 9 30
U
U-Joint 1550 5 155x U-Joint 1550 5 155x PTM-51548 PTM-51548 7-4 7-4 4 8
V
Valve Assembly, 12 Station Valve Box Assembly (See Figure 7-24 for Details) Valve Brake Control Valve S/S 3-Way Ball Valve Valve Sol. Dir. Control Closed Center Valve, Sol. Belt On/Off Valve Steering Valve, Double Check Stack-Up Valve, Double Check Stack-Up Valve, Four Way Versa Valve Valve, Quick Release Valve, Shuttle, Sunstrand Pump VLV-50917 HSG-53110 VLV-51640 VLV-29216 VLV-51621 VLV-53444 VLV-51607 VLV-51920 VLV-51920 VLV-50902 VLV-51642 VLV-53237 7-13 7-19 7-20 7-24 7-6 7-3 34 13 17 3 3 7-24 7-21 7-16 7-9 7-19 23 7 5 13 2
W
Wheel & Tire Assembly Wheel Adapter Wire Rope Clamp 3/4 Wiring Console Assembly Wishbone Assembly (See Figure 7-7 for Details) Working Light MSC-80087 BRK-61491 FAS-51446 SCH-51510 HSG-53139 ELC-51585 7-26 7-3 7-2 7-16 7-3 7-2 17 32 162 15 29 75
July 15, 2002
9-15
Parts Index
9-16
July 15, 2002
Parts Index
Blank Page
July 15, 2002
9-17

BC-2002 Tandem Rev3

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BC-2002 Tandem Rev3

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FIELD OPERATIONS & MAINTENANCE 2000/2004 MODEL BC-2002/CRC TANDEM

Copyright 2004 BearCat Mfg., Inc.

Revised January 31, 2004

Date Received ___________________

REPORT OF POSSIBLE DATA ERROR

FOLD FOLD --------------------------------------------------------------------------------------------------------------------From: Place Stamp Here

Model BC-2002/CRC Tandem

WARRANTY AND CLAIM PROCEDURES

March 31, 2002

Model BC-2002/CRC Tandem

BearCat Mfg., Inc. 3650 Sabin Brown Road Wickenburg, AZ 85390

Phone: (928) 684-7851 Fax: (928) 684-3241

March 31, 2002

Model BC-2002/CRC Tandem

List of Effective Pages

LIST OF EFFECTIVE PAGES

January 31, 2004

Model BC-2002/CRC Tandem Subheading and Page Rev

List of Effective Pages Rev

Subheading and Page

January 31, 2004

Model BC-2002/CRC Tandem Subheading and Page Rev

List of Effective Pages Rev

Subheading and Page

January 31, 2004

Model BC-2002/CRC Tandem

List of Effective Pages

January 31, 2004

Model BC-2002/CRC Tandem

July 15, 2002

Model BC-2002/CRC Tandem

July 15, 2002

Model BC-2002/CRC Tandem

March 31, 2002

Model BC-2002/CRC Tandem

March 31, 2002

Model BC-2002/CRC Tandem

March 31, 2002

Model BC-2002/CRC Tandem

March 31, 2002

Model BC-2002/CRC Tandem

March 31, 2002

Model BC-2002/CRC Tandem

March 31, 2002

Model BC-2002/CRC Tandem

Figure 1-1. Model BC-2002/CRC Tandem, Curb Side

Figure 1-2. Model BC-2002/CRC Tandem, Street Side

Model BC-2002/CRC Tandem

Aggregate Delivery System

March 31, 2002

Model BC-2002/CRC Tandem

March 31, 2002

Model BC-2002/CRC Tandem

March 31, 2002

Model BC-2002/CRC Tandem

Gate Control Valve Box

March 31, 2002

Model BC-2002/CRC Tandem

Table 1-1. Gate Control Valve Box Functions

Computerized Rate Control (CRC)

March 31, 2002

Model BC-2002/CRC Tandem

Figure 1-6. Chassis Dimensions