CALIFORNIAProposition 65 Warning WARNING: Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. CALIFORNIA Proposition 65 Warning WARNING: Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the state of California to cause cancer, birth defects, and other reproductive harm. Wash hands after handling. C766C C778B Revision R4 Form 0852656 8/03 OPERATING MANUAL . Seat Belt Set (2 used) Eyebolt Washer M20 Washers (4 used on far side) Lock Washer Nut Install Eybolts (2).m). Hexbolt .10.M20x65 .9 (4 used on far side). using the installation instructions drawing. Structure Install each Seat Belt. lbs. Tighten Nuts to a Torque of 35 ft.C766C & C778B DANGER: If the machine was received with the Roll Over/Falling Object Protection Structure (ROPS/FOPS) and Operator Restraints (Seat Belt Sets) NOT installed.m).m). or death.9 (4 used on near side). (47 N.M20x110 . DANGER: Do Not operate machine with the Roll Over/ Falling Object Protection Structure (ROPS/FOPS) and Operator Restraints (Seat Belt Sets) NOT properly installed. M20 Washers (4 used on near side) Hexbolt . serious injury. Install Cotter Pins and Bend. April 2000 . Tighten to a Torque of 375 ft. In the event of a machine roll over. Close Attaching Mechanisms Around Eyebolts. lbs. Tighten to a Torque of 375 ft. One on each Side of the Seat. can occur due to failure to correctly install the Roll Over/Falling Object Protection Structure (ROPS/FOPS) and Operator Restraints (Seat Belt Sets). lbs. (509N.10. and/or the illustration below. included with the installation kit. they MUST be installed BEFORE the machine is operated. (509 N. . WARNING: Serious personal injury and/or extensive property damage can result if the WARNING instructions are not followed. CALIFORNIA Proposition 65 Warning WARNING: Battery posts. NOTE: Gives additional. and/or clarification details. terminals and related accessories contain lead and lead compounds. birth defects. and other reproductive harm. . birth defects. death and/or extensive property damage can result if the DANGER instructions are not followed. When one of the symbols appears.SYMBOLS USED IN THIS MANUAL The following symbols have been used in THIS Manual to help communicate the intent of instructions. an assembly. CALIFORNIA Proposition 65 Warning WARNING: Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer. chemicals known to the state of California to cause cancer. which are to be used in conjunction with previously presented information. it conveys the meaning defined below: DANGER: Serious personal injury. or the engine can be damaged if the CAUTION instructions are not followed. CAUTION: Minor personal injury can result or a part. and other reproductive harm. Wash hands after handling. ALWAYS keep tools in a good and clean condition. NEVER attempt to remove or repair any component. fastened and balanced before lifting. Be sure that the lifting device is capable of retaining the weight to be lifted. ALWAYS keep the machine and work area clear of lubricants and dirt. be sure that they are properly tied. bolts. ALWAYS attach a sign in the machine operator’s area. on the machine. are removed before using force to remove components. snap rings. or cables when lifting components. NEVER leave the machine and/or heavy parts in an unstable position during repair. and other fastening devices. .SERVICE AND REPAIR PRECAUTIONS ALWAYS inspect all slings. ALWAYS support the machine with sound blocking. while the engine is running. stating “DO NOT OPERATE” when the machine is being repaired. ALWAYS wear safety glasses when performing any maintenance or repair work on the machine. ALWAYS observe ALL WARNING AND CAUTION statements given in the Operating Manual and Service Manual and found on the machine decals. ALWAYS be sure that all necessary nuts. chains. This helps to ensure maximum service life of the machine. ALWAYS use the correct tools for the repair procedures being done on the machine. that are designed for the machine being repaired. NEVER attempt to lift heavy parts by hand when a lifting device should be used. ALWAYS use approved parts. ..........................TABLE OF CONTENTS PAGE SECTION 1 ... 4-1... 1-1.MAINTENANCE ........................... SECTION 2 ............................................MANUAL ......... 3-1...........OPERATION ........................ SECTION 4 .........INTRODUCTION .............. SECTION 3 ..................................................................................................................................................................................................SPECIFICATIONS ...... 2-1............................................. 2/98 i .............................................. . ... MAINTENANCE PROCEDURES .......................1-3.............................................................................................. REPAIR PROCEDURES .................................................. 5/01 1-1 .......................1-4.......................................................................................................1-2.....................................................................................................................................1-3......................................................................... SPECIFICATIONS ...................................... OPERATING INSTRUCTIONS ............................ NAME PLATE / SERIAL NUMBER PLATE .................................................................................................................................... SERIAL NUMBER .................Section 1 INTRODUCTION TABLE OF CONTENTS PAGE GENERAL INFORMATION ..1-2.................................1-2.......................................1-2.................................... C766C FIGURE 1-1. found on the flat plate on the right side of. and written on the “Machine Operation and Warning” decal. and in Section 3 . and below. MAINTENANCE PROCEDURES. can operate the Model C766C and C778B Compactors.SPECIFICATIONS. of THIS manual. The maintenance schedules and procedures are found in Section 4 . OPERATING INSTRUCTIONS. THIS manual contains SPECIFICATION information and OPERATION. READ. CAUTION: Follow ALL the maintenance schedules and instructions given in THIS manual. MAINTENANCE and REPAIR procedures for the Model C766C and C778B Compactors [See Figures 1-1 and 1-2]. of THIS manual. WARNING: ONLY authorized personnel. of THIS manual. SPECIFICATIONS. See Section 2 .Section 1 INTRODUCTION GENERAL INFORMATION. 1-2 5/01 . UNDERSTAND and FOLLOW ALL the operating instructions given in the FRONT. Follow ALL instructions given in THIS manual.MAINTENANCE. the control panel.COMPACTOR. who are fully trained in the machine operation procedures.OPERATION. MODEL C766C . for specifications on major systems used on the machine. SERIAL NUMBER [See Figures 1-3 and 1-4]. and/or other referenced written materials ONLY. FIGURE 1-2. CAUTION: For CORRECT machine component repair procedures. USE the REPAIR procedures given in the above service manual. MAJOR machine component REPAIR PROCEDURES are found in the “SYSTEM REPAIR PROCEDURE” sections of "Service Manual". The name plate/serial number plate is located BELOW. The SERIAL NUMBER indicates the design series. contained in the SERIAL NUMBER. If the plate is missing.Section 1 INTRODUCTION REPAIR PROCEDURES. The plate MUST stay fastened to the machine at ALL times. serial number and year of machine shipment (older machines) [see Table 1-1]. Contact your nearest Distributor to obtain a replacement plate. NAME PLATE /SERIAL NUMBER PLATE [See Figure 1-3]. the steering wheel. The machine serial number is located ON the nameplate [see figure 1-3]. 0852657. it MUST be replaced IMMEDIATELY. The serial number is also stamped on the flat surface of the hitch assembly at the left hand side of the machine [see figure 1-4]. 5/01 1-3 . CAUTION: ALL numbers and letters. MODEL C778B . or damaged. pn. and to the left side of.COMPACTOR. MUST be given when requesting service and/or part information. manufacturing location. Section 1 INTRODUCTION C209 or B215 C - or 109 1605 C766C or C778B KEWANEE MACHINE SERIAL NUMBER U (stamped on older machines - only) YEAR OF SHIPMENT TABLE 1-1. MACHINE SERIAL NUMBER DESIGNATIONS. C778B 21,758 B215C1605U 23,508 FIGURE 1-3. NAMEPLATE / SERIAL NUMBER PLATE LOCATION. B 2 1 5 C 1 6 0 5 U FIGURE 1-4. SERIAL NUMBER LOCATION - NEAR HITCH ASSEMBLY. 1-4 5/01 Section 2 SPECIFICATIONS TABLE OF CONTENTS PAGE GENERAL INFORMATION ................................................................................................................ 2-2. TABLE 2-1. FRAME, HITCH AND FALLING OBJECT/ROLL OVER PROTECTIVE STRUCTURE [FOPS/ROPS] SPECIFICATIONS .......................................... 2-2. TABLE 2-2. ENGINE SPECIFICATIONS ........................................................................................... 2-3. TABLE 2-3. ELECTRICAL SPECIFICATIONS .................................................................................. 2-5. TABLE 2-4. TRANSMISSION SYSTEM SPECIFICATIONS ............................................................. 2-6. TABLE 2-5. BRAKE SYSTEM SPECIFICATIONS ............................................................................ 2-8. TABLE 2-6. STEERING SYSTEM SPECIFICATIONS ...................................................................... 2-8. TABLE 2-7. DRUM, VIBRATION AND CLEANER BAR SPECIFICATIONS ................................................................................................................ 2-10. TABLE 2-8. WATER SPRAY SYSTEM SPECIFICATIONS ............................................................ 2-13. TABLE 2-9. CONTROL AND INDICATOR SPECIFICATIONS ....................................................... 2-14. TABLE 2-10. OPTIONAL EQUIPMENT SPECIFICATIONS ........................................................... 2-15. TABLE 2-11. DIMENSION SPECIFICATIONS ................................................................................ 2-16. TABLE 2-12. PERFORMANCE SPECIFICATIONS ........................................................................ 2-18. TABLE 2-13. MACHINE SYSTEM CAPACITY SPECIFICATIONS ................................................ 2-18. TABLE 2-14. COMPONENT WEIGHTS .......................................................................................... 2-19. TABLE 2-15. TORQUE SPECIFICATIONS FOR STANDARD INCH FASTENERS ........................................................................................................................ 2-21. TABLE 2-16. TORQUE SPECIFICATIONS FOR STANDARD METRIC FASTENERS ........................................................................................................................ 2-22. TABLE 2-17. LUBRICATION OILS, HYDRAULIC OILS AND COOLANT SPECIFICATIONS ............................................................................................................... 2-23. TABLE 2-18. ADHESIVE THREAD LOCKING SPECIFICATIONS ................................................ 2-23. 8/03 2-1 Section 2 SPECIFICATIONS GENERAL INFORMATION. THIS section gives specification tables for each MAJOR machine system of the Model C766C and C778B Compactors. Machine dimensions, weights, performance and torque specifications are also given in THIS section. TABLE 2-1. FRAME, HITCH AND FALLING OBJECT/ROLL OVER [FOPS/ROPS] PROTECTIVE STRUCTURE SPECIFICATIONS. ITEM DESIGN DATA FRAME and HITCH Material Plate steel Construction Unitized, all welded 2 section, with bolt-on front and rear weight plates HITCH Oscillation +/- 12˚ - side to side, 24˚ total Articulation +/- 35˚ - right to left [Steering] turn, 70˚ total FALLING OBJECT/ROLL OVER PROTECTIVE STRUCTURE [FOPS/ROPS] WITH OPERATOR RESTRAINT SYSTEM Type and Description 2-2 Welded steel structure, bolted to machine for protective system and two [2] seat belt sets for operator restraint, conforms to SAE recommended practice J-1040C, J-231 and J-386; and CSA B352 [Canada] 8/03 thermostat opens 8/03 2-3 .97 l] Thermostat Range 180-190˚ F [82-88˚ C]. ether. Turbocharged and charge air cooled Number of Cylinders 4 Displacement 239 in.7 psi [1. cold start aid Type 4 Cycle diesel.72 in. [17.3 [3.92 l] Bore & Stroke 4. ITEM DESIGN DATA ENGINE Model and Manufacturer 4B3.9 QSB-C130 Cummins Diesel. [120 mm] Rated Brake Horsepower 130 hp @ 2500 rpm [97 Kw at 2500 rpm] Compression Ratio 18:1 Firing Order 1-3-4-2 Low Idle Speed 900 -1000 rpm High Idle Speed 2500 +/-10 rpm.3 bar] @ 1750 rpm ENGINE COOLING SYSTEM Radiator Type Full flow.02 in. NO load Engine Oil Type See Cummins "Operation and Maintenance Manual . W/O integral oil cooler System Coolant Capacity 19 qts.Section 2 SPECIFICATIONS TABLE 2-2. with automatic. [102 mm] x 4. liquid pressure. ENGINE SPECIFICATIONS.for correct oil type Turbocharger Type Holsett Boost Pressure 18.B series Engine" . C766C or 60 Gallons [227 L] . close nozzle 8/03 .P. No.C778B Rate of Fuel Consumption [at normal engine H.Section 2 SPECIFICATIONS ITEM DESIGN DATA ENGINE FUEL Type Used Use ONLY distillate fuels [A. Heavier oil is generally preferable because of its higher energy content Fuel Capacity 50 Gallons [189 L] . replaceable “spin-on” element .1 Gallons per hour [15. in line type FUEL INJECTORS Quantity and Type 2-4 4. that vary. at 40% load] 4. can cause different fuel consumption amounts than those given FUEL FILTERS Fuel Strainer Suction line.S. replaceable “spin-on” element [See Engine Manual] FUEL PUMP Type Bosch.T.1 or No. 2D diesel fuel are EXAMPLES].2 fuel oil or No. The fuel MUST have a MINIMUM cetane number of 35.M.5 liters per hour]* *Operating conditions.1D or No.with water drain [See Engine Manual] Fuel Filter Pressure line. 14 volts [cold] Direction of Rotation Clockwise [C.viewed from drive end Fan Belt Tension and Method Used to Achieve Automatic belt tension mechanism keeps serpentine belt under tension at ALL times STARTER Manufacturer Delco Remy [see ENGINE starter plate.] .W. for starter part number] Voltage and Type 12 Volt.Section 2 SPECIFICATIONS TABLE 2-3. negative ground Output Amperage 105 Amps Maximum Charge Rate 105 Amps . ITEM DESIGN DATA BATTERY Number Per Machine One [1]. ELECTRICAL SPECIFICATIONS. negative ground 8/03 2-5 . maintenance free Ampere Hour Rating 900 CCA Voltage 12 Volts ALTERNATOR Voltage 12 Volt. ] Inlet Vacuum [at charge pump inlet] 10 in. for correct type Oil Cooler Type Aluminum. variable [2] displacement .with spring applied multi-disc brake Quantity Two [2] 2-6 8/03 .3 L] Oil Type See decal. maximum. ITEM DESIGN DATA TRANSMISSION SYSTEM System Type Hydrostatic System Oil Capacity [Also supplies steering and vibration systems] 22 Gallons [83.W.C. axial piston Swash Plate Angle 0-17˚. TRANSMISSION SYSTEM SPECIFICATIONS. transmission pump installed [Use APPROVED replacement element ONLY see machine Parts Manual] TRANSMISSION HYDRAULIC DRUM DRIVE MOTORS Type Radial piston. adjacent to hydraulic reservoir fill.Section 2 SPECIFICATIONS TABLE 2-4. hg [254 mm hg]. maximum Maximum Allowable Case Temperature 220˚ F [104˚ C] Oil Filter Transmission PRESSURE Oil Flow One [1] filter with replaceable element. either side of center Direction of Rotation Counterclockwise [C. full flow [separate from radiator] TRANSMISSION HYDRAULIC PUMP Type Variable displacement. 200 +/.3 kW] each Maximum Speed at Full Displacement 35 rpm Multi-Disc Brake Release Pressure 175-225 psi.75 psi. lbs.9 bar] Intermittent Maximum Horsepower at Full Displacement 50 hp [37. [407 N. [12-16 bar] . Intermittent Torque Specifications Hydraulic Drum Drive Motor To Motor Carrier 300 ft. [45 N.150˚F [38 . with engine @ high idle Stroked Charge 365 psi. above case pressure. [25 bar] .9 bar].66˚C] with the engine speed at HIGH idle.Section 2 SPECIFICATIONS ITEM DESIGN DATA Maximum Operating Pressure 6. [2.m] TRANSMISSION SYSTEM PRESSURES NOTE: Pressures given are with hydraulic oil at operating temperature of 100 . lbs.100 psi. [5.m] TRANSMISSION PUMP DRIVE PLATE Type Flexible steel. [12 204 N. [26-28 bar]. [428 +/. plus case pressure.2 bar].000 ft. Neutral Charge 375-400 psi. or reverse Control [Transmission in Forward or Reverse] 100 psi.6.Minimum.m] 2-7 .plus case pressure Maximum Braking Torque 9. Forward. [428 + 6. with center hub splined Torque Specifications Flex Drive Plate To Engine Flywheel 8/03 33 ft.200 +100 psi. Continuous .7 bar].Minimum Pump Case Pressure 40 psi. lbs. with engine @ high idle and transmission pump @ full stroke System High Relief 6. [7 bar] . adjacent to hydraulic reservoir fill.] STEERING RELIEF VALVE Type Integral with steering control unit Relief Pressure 2400 +/.Section 2 SPECIFICATIONS TABLE 2-5. for correct type Type of Suction OIl Strainer One [1] cleanable 100 mesh strainer. in hydraulic oil reservoir STEERING HYDRAULIC PUMP Type Gear.3 bar]. in THIS Section Type of System Oil See decal. ITEM DESIGN DATA STEERING SYSTEM Type of System Hydraulic System Oil Capacity See transmission system capacity.W. [SAHR] multi-disc brake. incorporated with each hydrostatic transmission drum drive motor TABLE 2-6. ITEM DESIGN DATA BRAKE SYSTEM Service Brake Type Through hydrostatic transmission system Secondary/Parking Brake Type Spring applied. [166 +/. hydraulically released. BRAKE SYSTEM SPECIFICATIONS. STEERING SYSTEM SPECIFICATIONS. with engine @ low idle 2-8 8/03 . single section Pump Output Rate and Speed 10 gpm [38 lpm] @ 2350 rpm Direction of Rotation [viewed from shaft end] Clockwise [C.50 psi. 16 UNF STEERING CYLINDER Type Double acting Number per Machine One [1] Bore of Cylinder 3.3 mm] .13 in. [76 mm] .C766C & C778B Extended Length of Cylinder [between pin bore centers] 34.13 in. with integral relief Port Sizes .C766C & C778B 8/03 2-9 . [305 +/-3 mm] .00 +/-0.25 in.75 in.25 +/.25 +/.0. [32 mm] .Inlet/Outlet 0.50 in. [870 +/.C766C 3.3 mm] . [89 mm] C778B Stroke of Cylinder 12. load sensing and non-load reacting.C766C & C778B Rod Diameter 1.00 in.0.13 in. [565 +/.Section 2 SPECIFICATIONS ITEM DESIGN DATA STEERING CONTROL UNIT Type Rotary actuated.C766C & C778B Retracted Length of Cylinder [between pin bore centers] 22. [19 mm] . 5 Seconds Total Number of Wheel Turns 4.8 m] .m] Steering Cylinder Anchor End Mounting Capscrews 105 ft.78 mm] 2-10 151 pli [68. [3. or 12 ft.With Vibrator Assembly.8 m] . [47 N.70 in. [1 219 mm] PLI . [1 676 mm] 78 in. 0 in. 6 in.9 m] .Drum Contact Area 156 pli [70. 0 in. [17. [1 544 kg] . [1 981 mm] Diameter 48 in.850 lbs. lbs.70 in. DRUM.5 kg lineal mm] 8/03 . Motor And Isolators 3. VIBRATION AND CLEANER BAR SPECIFICATIONS ITEM DESIGN DATA C766C C778B DRUM Width 66 in. lbs.400 lbs.5 Revolutions .C766C. or 19 ft.0 Seconds 4.9 m] .Each Wrapper Thickness 0.stop to stop Inside Turning Radius 13 ft. [143 N.m] Steering Cylinder Piston Retaining Nut 200 ft.m] TABLE 2-7. [1 219 mm] 48 in. [3. [5.C766C. [1 748 kg] . [17.Section 2 SPECIFICATIONS ITEM DESIGN DATA STEERING PERFORMANCE Steering Time Stop to Stop Right To Left Left To Right 4.8 kg lineal mm] Drum Weight .78 mm] 0.C778B Outside Turning Radius 19 ft.Each 3.C778B Total Steering 70˚ Total. [5. lbs. 6 in. 35˚ each side of center Torque Specifications Hydraulic Pump Mount 35 ft. [271 N. [317 +3 bar]. drive pressure should drop to below 3000 psi. [21 bar] Minimum.0 gpm [49.Pumps 20 . installed at EACH drum System Hydraulic Oil Supply Same as transmission and steering systems supply Hydraulic PRESSURE Oil Filter And Element One [1] filter with replaceable element.4 . [24 bar]) 2-11 .see machine Parts Manual] Drum Bearing Lubrication Oil [inside each drum] Type See Section 4 . supplies oil flow to one [1] fixed displacement piston motor. plus case pressure (Typical 350 psi. one eccentric vibrator weight EACH drum. [28 bar] Maximum. Counterclockwise [CCW] . variable displacement.9 L].Section 2 SPECIFICATIONS ITEM DESIGN DATA VIBRATION SYSTEM Type Variable amplitude. 400 psi. for EACH drum. [207 bar].0 gpm [49. [304 bar] Motor Maximum Speed 3400 rpm Direction of Rotation [viewed from shaft end] Bidirectional Case Pressure .35 psi [1.REAR drum supply pump Hydraulic Motor Type and Quantity Bent axis. fixed displacement. One [1] piston pump.4 lpm] at start up.2 lpm] @ 2200 rpm Direction of Rotation [as viewed from shaft end] Clockwise [CW] .2. two [2] used Motor Input Rate and Pressure 13. two [2] used Pump Output Rate and Speed 13.2 lpm] @ 4400 psi. rated 5 micron [nominal] [Use APPROVED replacement element ONLY .MAINTENANCE.4 bar] Relief Valve Pressure Setting and Rate Vibrator “Start/Stop” 4600 + 50 psi. Maximum @ 3 gpm [11.FRONT drum supply pump.for CORRECT type Amount 10 Gallons [37. After a few minutes. EACH drum Hydraulic Pump Piston pump. Charge Relief Valve Pressure Setting Neutral Charge 8/03 300 psi. axial piston. 762 mm] 0. [0. [122.030 in. four [4] total per machine Vibration Isolation Tires Size G159LP 245/75R22. [135. [542 N.950 lbs. lbs. [585 N.m] 2-12 8/03 . lbs.m] Vibration Isolation Wheel To Drum Drive Motor Bearing Carrier 400 ft. [0.368 lbs. Two [2] used per drum Number Cleaner Rubbers Per Beam and Type One [1] adjustable. [0. [2 bar] .0 kN] @ 3800 vpm Frequency Range 2000 .5 Isolator Tire Inflation Pressure 30 psi.COLD VIBRATION PERFORMANCE Centrifugal Force High Amplitude C766C C778B 32.9 kN] @ 3400 vpm 30.3800 vpm 2000 . lbs.099 lbs.m] Vibration Isolation System Assembly To Drum 157 ft. [164. bolt on type Number Cleaner Beams Per Machine Four [4] total.020 in. full width Adjustment Against drum surface TORQUE SPECIFICATIONS Drum To Frame Mounting Capscrews 431 ft. [146.020 in.030 in. [213 N.Section 2 SPECIFICATIONS ITEM DESIGN DATA Vibration Isolation Tires Quantity Two [2] per machine drum. [0.508 mm] Low Amplitude CLEANER BEAMS AND CLEANER RUBBERS Type Cleaner Beams Full width.6 kN] @ 3800 vpm 37.580 lbs.762 mm] 0.508 mm] 0.3800 vpm Amplitude [nominal] High Amplitude Low Amplitude 0.4 kN] @ 3400 vpm 27. m] TABLE 2-8.50% duty cycle. [568 l] . one [1] per tank Pump Inlet 100 Mesh screen. 12 volt. lbs.C778B 8 Per drum.m] Half Hoop Connecting Capscrews And Nuts 125 ft. Type and Flow Rate . diaphragm. two [2] used. [380 N. switch Spray Duty Cycle Control One [1]. Type and Flow Rate . 0. C766C or 150 gal. lbs. 0 . dash mounted. 0. threaded collar release from spray bar mounting.075 gpm [.m] Vibrator Sub-assembly To Drum 64 ft. lbs. control Nozzle Quantity.075 gpm [.m] Cleaner Beam To Frame Mounting Capscrews 280 ft. C778B Pump Type and Quantity 12 Volt. [475 l] .284 lpm] 8/03 2-13 . two [2] used.EACH. [128 N. [170 N. [87 N.C766C 7 Per drum. 12 volt. WATER SPRAY SYSTEM SPECIFICATIONS. two [2] used Filtration Tank Fill Ports Strainer basket. "Auto/Off/On". threaded collar release from spray bar mounting. dash mounted.Section 2 SPECIFICATIONS ITEM DESIGN DATA Hoop Assembly To Bearing Housing 431 ft.m] Cleaner Rubber To Cleaner Beam Mounting Capscrews 95 ft. lbs. one [1] per pump assembly Spray Mode Control One [1]. lbs. ITEM DESIGN DATA WATER SPRAY SYSTEM Type Pressurized system Tank Capacity and Quantity 125 gal. [585 N.284 lpm] Nozzle Quantity.EACH. timed delay. Run and Stop Key switch. electrical. negative ground. three [3] position Vibration Amplitude “LOW/HIGH” Toggle control switch. 12 volt negative ground. negative ground. 12 volt. three [3] position “on”. negative ground. negative ground. negative ground. 12 volt. negative ground Vibration System Location “FRONT/BOTH/REAR” Toggle control switch. with automatic “off”. electrohydraulic system Water Spray System “ON/OFF/AUTO” Toggle control switch. hydraulic steering control unit and system Brake .Section 2 SPECIFICATIONS TABLE 2-9. negative ground. 12 volt. left and right travel control installed. ITEM DESIGN DATA FUNCTION TYPE CONTROL Direction of Machine Travel [F-N-R] and Transmission System Speed Left and right handle. three [3] position Vibration System Manual Mode “START/STOP” Electrical push button thumb switch. “off”. 12 volt. electrical control of transmission pump output Engine Speed [rpm] Toggle switch. negative ground.Service Handles [F-N-R direction and transmission system speed control] .braking action through transmission system Brake . CONTROL AND INDICATOR SPECIFICATIONS. 12 volt. instrument panel mounted Panel And Operation Lights Electrical switch. electrohydraulic system Engine Start. 12 volt. 12 volt.Secondary/Parking Push button switch. “auto” [timed]. [one [1] for each drum] Vibration System Mode “OFF/AUTOMATIC/ MANUAL” Toggle control switch. two [2] position Vibration Frequency “VPM” Variable potentiometer control. 12 volt. control Horn Button switch. 12 volt. 12 volt. at neutral. dash mounted. negative ground Transmission Drum Drive Motors “TRAVEL [high]/ WORK [low]” Range Toggle control switch. 12 volt. negative ground. in “auto” mode Water Spray Systems Duty Cycle One [1]. electric control of engine governor [LOW or HIGH] idle speed Steering Control Steering wheel. negative ground 2-14 8/03 . Quantity and Control 12 volt. 12 volt. steering column mounted turn signal switch. dash mounted switch controlled TURN SIGNAL & 4-WAY FLASHERS Type. 12 volt. 12 volt.Section 2 SPECIFICATIONS ITEM DESIGN DATA FUNCTION TYPE INDICATOR/GAUGE Engine Hours Hourmeter. four [4] per machine . electrical. ITEM DESIGN DATA LIGHTING SYSTEM Type. Control and Quantity 8/03 12 volt. negative ground System Function Monitor Display Screen/Scroll Button Display scroll button and alphanumeric display screen.two [2] front and two [2] rear 2-15 . adjustable. negative ground Fuel Level Fuel gauge. negative ground Vibrator Systems Pressure Oil Filter Element Condition Indicator Indicator light. negative ground Engine Inlet Air Restriction Indicator Indicator light. 12 volt. 12 volt. 12 volt.four [4] turn signal/4-way flasher light assemblies . with 4-way flasher switch . OPTIONAL EQUIPMENT SPECIFICATIONS. 12 volt. electrical. negative ground TABLE 2-10. negative ground Engine Coolant Temperature Coolant temperature gauge. electrical. electrical. 12 volt. negative ground Hydraulic System Oil Temperature Temperature gauge. negative ground Engine Lubrication Oil Pressure Oil pressure gauge. electrical. 12 volt.two [2] front and two [2] rear. negative ground Charging System Voltage Voltmeter. halogen. Section 2 SPECIFICATIONS TABLE 2-11. DIMENSION SPECIFICATIONS [see figure 2-1]. ITEM DIMENSIONS DESIGN DATA C766C C778B A. Overall Height to Top of FOPS/ROPS 105 in. [2 667 mm] 105 in. [2 667 mm] B. Height - to Top of Steering Wheel 78 in. [1 981 mm] 78 in. [1 981 mm] C. Overall Width - W/FOPS/ ROPS 81 in. [2 057 mm] 92.5 in. [2 350 mm] D. Overall Length 200 in. [5 080 mm] 200 in. [5 080 mm] E. Wheel Base 120 in. [3 048 mm] 120 in. [3 048 mm] F. Ground Clearance 15 in. [381 mm] 15 in. [381 mm] G. Drum Diameter 48 in. [1 219 mm] 48 in. [1 219 mm] H. Drum Width 66 in. [1 676 mm] 78 in. [1 981 mm] 2-16 8/03 Section 2 SPECIFICATIONS C D G H A C766C B F E FIGURE 2-1. MACHINE DIMENSIONS. 8/03 2-17 Section 2 SPECIFICATIONS TABLE 2-12. PERFORMANCE SPECIFICATIONS. ITEM DESIGN DATA TRAVEL SPEED TRAVEL [High] Range WORK [Low] Range 0-10 mph [0-16.1 kmph] 0-5 mph [0-8.0 kmph] EFFECTIVE COVERAGE Width 66 in. [1 676 mm] - C766C or 78 in. [1 981 mm] - C778B, per pass TABLE 2-13. MACHINE SYSTEM CAPACITY SPECIFICATIONS. ITEM DESIGN DATA SYSTEM CAPACITIES Fuel 50 Gallons [189 liters] - C766C or 60 Gallons [227 liters] - C778B Engine Lubrication Oil 10 Quarts [9.5 liters] - WITH Lubrication Oil filter Cooling System 19 Quarts [18 liters] Hydraulic Oil Reservoir [Supplies All Oil To Transmission, Steering and Vibration Systems] 22 Gallons [83.3 liters] Drum Bearing Lubrication Oil 10 Gallons [37.9 liters] - each drum Water Spray - Two [2] Tanks Used Per Machine 125 Gallons [473 liters] each tank - C766C 150 Gallons [568 liters] each tank - C778B 2-18 8/03 150 lbs. [45 kg] Battery 49 lbs. [327 kg] 1. each Shuttle Valve 2 lbs. [9 875 kg] 9.250 lbs.750 lbs. [4 767 kg] 10.Section 2 SPECIFICATIONS TABLE 2-14.500 lbs.500 lbs. [205 kg]. [10 669 kg] Shipping Weight W/ FOPS/ROPS 19. [4 145 kg] 10. [9 352 kg] 23. [1 kg] 2-19 . [22 kg] Transmission Hydraulic Pump 125 lbs. ITEM DESIGN DATA WEIGHTS C766C C778B Operating Weight W/ FOPS/ROPS 20.600 lbs. [8 694 kg] 21.000 lbs.150 lbs. COMPONENT WEIGHTS. NOTE: The following list of component weights is APPROXIMATE and is given as a guide ONLY for selecting sling and lifting equipment used in machine servicing. [477 kg] OTHER COMPONENTS 8/03 Radiator 100 lbs. [57 kg] Transmission Hydraulic Drum Drive Motor [2 used] 450 lbs. [4 540 kg] With FOPS/ROPS 11. [5 108 kg] With FOPS/ROPS REAR FRAME With Engine and Drive Components FRONT FRAME With Isolators and Drum ENGINE Dry With Pumps and All Items Installed 720 lbs.050 lbs. [318 kg]. [5 kg] Steering Cylinder 23 lbs. [1 748 kg] Isolator Half Hoop Weldment .Eight [8] Used 100 lbs. empty Hydraulic Pump .872 lbs.3.Front & Rear . [13 kg] Hydraulic Oil Reservoir 100 lbs. [396 kg] Cross Beam Plate . [370 kg].3.700 lbs. [23 kg] Hydraulic Vibrator Motor Two [2] used 13 lbs.Steering 10 lbs. [6 kg] Drum and Vibrator Assembly Complete . C778B . [45 kg]. [45 kg] Machine Cockpit Assembly Complete 700 lbs. C778B .850 lbs. [318 kg] Falling Object/Roll Over Protective Structure [FOPS/ROPS] C766C .Two [2] Used 50 lbs. [590 kg] 2-20 8/03 . [1 544 kg].300 lbs.Two [2] Used C766C .400 lbs.5 kg] Steering Control Unit 12 lbs.Section 2 SPECIFICATIONS ITEM DESIGN DATA OTHER COMPONENTS Hydraulic Oil Cooler 28 lbs.Two [2] Used C766C . [10 kg] Hydraulic Pump Vibration . C778B . [4.1.815 lbs. IN ALL CASES. VALUES ARE BASED ON THE PHYSICAL LIMITATIONS OF CLEAN. REPLACE ORIGINAL EQUIPMENT WITH FASTENERS OF EQUAL GRADE. LBS. TORQUE SPECIFICATIONS FOR STANDARD INCH FASTENERS.Section 2 SPECIFICATIONS TABLE 2-15. GRADE 5 GRADE 8 PLACEBOLT SOCKET HEAD CAPSCREW 12 POINT CAPSCREW FIGURE 2-2. PLATED AND LUBRICATED FASTENERS. STANDARD HARDWARE. SIZE 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2 TORQUE (FT. WHEN AN INDIVIDUAL TORQUE IS SPECIFIED. 8/03 2-21 . SAE GRADE 8 CAPSCREWS NOM.) THREAD SERIES TORQUE (Nm) DRY LUBED DRY LUBED 20 UNC 28 UNF 18 UNC 24 UNF 12 14 25 27 10 18 20 16 19 33 37 12 14 25 28 16 UNC 24 UNF 14 UNC 20 UNF 44 49 70 78 33 37 52 58 59 67 95 105 44 50 71 79 13 UNC 20 UNF 12 UNC 18 UNF 105 120 155 170 80 90 115 130 145 165 210 230 110 120 155 175 11 UNC 18 UNF 10 UNC 16 UNF 210 240 375 420 160 180 280 315 285 325 510 570 215 245 380 425 9 UNC 14 UNF 8 UNC 14NF 605 670 910 1 020 455 500 680 765 820 905 1 230 1 380 615 680 925 1 040 7 UNC 12 UNF 7 UNC 12 UNF 1 290 1 440 1 820 2 010 965 1 080 1 360 1 500 1 750 1 960 2 460 2 730 1 310 1 470 1 850 2 050 6 UNC 12 UNF 6 UNC 12 UNF 2 380 2 710 3 160 3 560 1 780 2 040 2 370 2 670 3 230 3 680 4 290 4 820 2 420 2 760 3 210 3 620 WARNING: THESE TABLES LIST TORQUE VALUES FOR STANDARD FASTENERS AND ARE INTENDED AS A GUIDE FOR AVERAGE APPLICATION INVOLVING TYPICAL STRESSES AND MACHINED SURFACES. IT SHOULD BE FOLLOWED INSTEAD OF VALUES GIVEN IN THIS TABLE. 0 810.0 6 860.N-m CLASS 10.0 755.90 19.80 878.30 3 040.0 2 570.86 6 199.75 18.0 2 620.99 1.0 6 720.38 40.0 7 470.0 1 550.67 7.0 6 170.71 53.0 1 010.N-m DRY LUBED DRY LUBED DRY LUBED DRY LUBED 0.0 225.6 M4 x 0.33 10.75 M12 x 1.40 5 062.70 754.93 557.42 72.0 820.0 4 630.0 2 780.43 5.30 4.79 2.0 3 080.0 555.77 129.0 2 720.0 2 040.32 107.5 M42x3 M45 x4.59 66.0 0.73 1.52 48.36 1 107.0 175.9 [GRADE 8 EQUIVALENT] TORQUE FT.78 645.97 1. TORQUE SPECIFICATIONS FOR STANDARD METRIC FASTENERS.0 320.27 6.5 M30 x 3 M30 x 2 M33 x 3.5 x 0. NOMINAL SIZE & PITCH M3 x 0.0 580.55 2.0 96. VALUES ARE BASED ON THE PHYSICAL LIMITATIONS OF CLEAN.0 115.3 34.8 37.0 98.89 20.31 4.0 2 070.56 2.97 19.0 165.0 105.5 M20 x 2.46 1 084.52 1 653.0 5 610.20 10.39 166.99 1.0 53.0 6 300.0 220.0 605.92 53.0 3 490.99 409.0 3 570.8 M6 x 1 M8 x 1.0 805.20 6 752.0 485.90 1 225.5 M20 x 1.52 1 837.34 360.0 190.0 300.07 3.36 173.0 740.0 9 150.0 1.49 597.22 40.0 88.26 20.87 88.0 1.82 4.40 236.13 28.5 M33 x 2 M36 x 4 M36 x 3 M39x4 M39x3 M42 x4.0 475.5 M3.70 0.56 3 416.88 3 044.0 1 140.12 1 933.16 281.04 863.0 1 520.22 154.86 1 121.0 2 240.00 3 033.0 5 240.0 2 490.16 2 841.0 55.04 39.94 4 051.5 38.36 2 450.0 2 000.62 1 940.60 3 335.0 2 000.38 3 867.25 M12 x 1.0 1 640.0 2 040.19 605.59 38.80 841.0 4 520.43 317.39 162.0 1 100.01 114.00 1 623.46 4 959.1 66.03 357.0 WARNING: THESE TABLES LIST TORQUE VALUES FOR STANDARD FASTENERS AND ARE INTENDED AS A GUIDE FOR AVERAGE APPLICATION INVOLVING TYPICAL STRESSES AND MACHINED SURFACES.83 14.86 1 173.16 428.0 1 170.0 4 200.59 445.58 7.0 5 490.15 236.07 6.36 0.85 103.0 4 420.0 2 980.22 1 107.0 6 980.0 1 500. LBS TORQUE .0 2 720.60 1 896.94 1 476.0 1 500.0 5 040.17 15.62 4 553.0 1 100.24 2 575.12 4 140.17 8.0 140.96 3 785.43 14.0 320.0 1 470.75 811.25 M8 x 1 M10 x 1.34 2.32 2.42 1 476.0 235.98 2 007.12 594.11 3.7 M5 x 0.0 2 630.55 516.08 1 505.65 7.60 3 328.0 2 210.0 4 760.0 430.38 811.87 121.94 3 719. IT SHOULD BE FOLLOWED INSTEAD OF VALUES GIVEN IN THIS TABLE.82 5 512.0 1 100.05 177.0 4 120.4 51.04 479.0 1 590.0 90.68 1.0 3 500.66 2 007.5 M16 x 2 M16 x 1.0 2 200.70 3.0 1 470.0 5 590.34 1 505.66 3 099.00 1 623.0 3 700.94 70.5 M45x3 M48x5 M48x3 CLASS 8.0 130.95 27.09 797.0 155.0 145.0 40.0 240.0 1 080.74 5 084.0 72.56 4 442.0 1 220.82 2 634.0 73. PLATED AND LUBRICATED FASTENERS.18 3 261. 2-22 8/03 .14 77.1 27.62 2 730.32 2.00 1 527.8 [GRADE 5 EQUIVALENT] TORQUE FT.0 4 110.0 5 130.0 355.04 2 450.0 4 510.11 64.0 3 850.81 140. LBS TORQUE .25 M14 x 2 M14 x 1.5 25.0 1 530.64 2 501.80 1 084. IN ALL CASES.9 52. REPLACE ORIGINAL EQUIPMENT WITH FASTENERS OF EQUAL GRADE.13 6.27 4.8 26.52 1.49 84.98 221.53 50.0 650.60 18.16 2 583. WHEN AN INDIVIDUAL TORQUE IS SPECIFIED.32 114.60 1 424.0 210.56 2 051.5 M10 x 1.0 1 660.76 3 512.0 3 390.3 69.66 1 630.76 1 202.6 27.36 2 199.0 8 400.21 1.56 70.16 811.0 6 020.00 1 143.0 3 320.18 4 649.0 1 190.5 M24 x 3 M24x2 M27 x 3 M27 x 2 M30 x 3.22 10.32 900.0 3 320.0 120.0 875.0 1 930.61 2.Section 2 SPECIFICATIONS TABLE 2-16.94 2 273.2 20.04 29.0 435.12 321.08 2.0 155. LUBRICATION OILS.02 OZ 251099 290 Low Viscosity Threadlock [Green] 50 ML 355844** 422 Super Bonder Adhesive 3 ML 264159 515 Gasket Eliminator 6 ML 313022* 515 Gasket Eliminator [Purple] 50 ML 273338* 567 Pipe Sealant W/Teflon [White] 50 ML 318705 595 Super Flex Silicone 100 ML 318701* 609 Retaining Compound 10 ML 341959 680 Retaining Compound 50 ML 226415 Primer T . P/N DESCRIPTION SIZE 336830 HYDRAULIC/TRANSMISSION OIL 1 QT 336831 HYDRAULIC/TRANSMISSION OIL 2 GAL 336832 HYDRAULIC/TRANSMISSION OIL 5 GAL 336833 HYDRAULIC/TRANSMISSION OIL 55 GAL 3002338 Antifreeze 1 GAL 326457 MULTIPURPOSE GREASE 5 LB TABLE 2-18. ADHESIVE THREAD LOCKING SPECIFICATIONS. P/N DESCRIPTION SIZE 360387 222 Small Screw Threadlock [Purple] 50 ML 318702* 242 Removable Threadlock [Blue] 10 ML 226414* 271 High Strength Threadlock [Red] 10 ML 318996 277 High Viscosity Threadlock [Red] 50 ML 318650 290 Low Viscosity Threadlock [Green] . HYDRAULIC OILS AND COOLANT SPECIFICATIONS.Aerosol 6 OZ 316865 Anti-Seize Compound 1 LB 360053-10 Chisel Gasket Remover [10/case Aerosol] 18 OZ 318700* Adhesive & Sealant Kit [Contains One Each Of* Items] 8/03 2-23 .Section 2 SPECIFICATIONS TABLE 2-17. Section 2 SPECIFICATIONS NOTES 2-24 8/03 . ................ OPERATING THE MACHINE ............................... STARTING THE ENGINE ...... OPERATING PRECAUTIONS .................... 3-13................................................................................ DYNAMIC BRAKING OF THE MACHINE ... 3-19.......................................................................... 3-14............................................................................ 3-19............................................. 3-13........ INDICATORS AND GAUGES ... 3-14................................................................................................................ OPERATION OF THE TRANSMISSION SYSTEM ................................................................................................................................. 7/00 3-1 ......... 3-23... STOPPING THE ENGINE ....................................................... 3-13............................................ 3-2..................... OPERATION OF THE STEERING SYSTEM ....................... 3-18...... OPERATION ......................................................................................................................................... 3-14...................................... OPERATING CONTROLS.... 3-20................................................................... 3-14...... CHECKS WITH THE ENGINE STOPPED ................................................................................... 3-29................................................................................ LIMITED OPERATION MODE .................... 3-26......... 3-14 NORMAL [RUN] SCREENS ..................... RELEASING THE TOWING BYPASS VALVES AND SECONDARY/PARKING BRAKE SYSTEM AND TOWING A COMPLETELY DISABLED MACHINE ....................................................................................................................................................... FAULT MESSAGE SCREENS ............. 3-26........... 3-2.............. 3-26............................................................................................................. TRANSPORTING THE MACHINE .......................................... GAUGES AND INSTRUMENTS OPERATION .........Section 3 OPERATION TABLE OF CONTENTS PAGE GENERAL INFORMATION .......................................... 3-18..... CURRENT MACHINE SYSTEMS PARAMETERS .......................................................................................................................................................... CHECKS WITH THE ENGINE RUNNING ............... OPERATION OF THE SECONDARY/PARKING BRAKE SYSTEM ..................................... Section 3 OPERATION GENERAL INFORMATION. or DEATH. or operate. Put an information tag on the steering wheel which says “DO NOT OPERATE”. 3-2 7/00 . and understand. for the Model C766C and C778B Compactors. or operating. INDICATORS AND GAUGES. indicators and gauges BEFORE starting the engine. ahead of the steering wheel. understanding and following ALL information given in THIS section and shown on the machine “Operating Instruction and Warning” decal. the machine [see figure 3-1]. REMOVE the key from the ignition switch. SERIOUS INJURY. Operating controls. Read. can operate the Model C766C or C778B Compactor. THIS section gives the OPERATION INSTRUCTIONS for the Model C766C and C778B Compactors. indicators and gauges. DANGER: FAILURE to observe the “OPERATING PRECAUTIONS” and/ or the machine “OPERATION and WARNING INSTRUCTIONS”. who are fully trained in the machine operation. BEFORE starting. the Model C766C or C778B Compactor BEFORE reading. Minor damage can result in major system failures. the function of ALL controls. understand and follow ALL “Precaution and Operating Instructions” given on the machine “OPERATING INSTRUCTION and WARNING” decals and written in THIS manual. The operator MUST read about. can result if THESE procedures are NOT followed. or DEATH. found on the engine hood. WARNING: Do NOT operate a machine needing repair. ONLY authorized personnel. DANGER: Do NOT start. OPERATING CONTROLS. Repair ALL damage at ONCE. Keep the machine in GOOD mechanical condition at ALL times. given in THIS manual and found on the DECALS affixed to the machine can cause SERIOUS INJURY. are shown on Figure 3-2 and are listed in Table 3-1. Section 3 OPERATION FIGURE 3-1. 7/00 3-3 . MODEL C766C AND C778B COMPACTOR “OPERATING INSTRUCTION DECAL”. SPEED SCROLL 5 FIGURE 3-2. 3-4 7/00 . OFF WATER SPRAY LOW AMPLITUDE REAR VIB. SPEED MAN. MACHINE OPERATING CONTROLS AND INDICATORS. VIBRATOR MODE LOW WATER SAVER BOTH REAR FRONT LIGHTS ENGINE THROTTLE SPEED RANGE AUTO DRUM SELECT HIGH FIILTERS HIGH OFF AUTO FRONT VIM.Section 3 OPERATION 14 9 15 16 18 17 13 8 11 26 26 25 22 4 10 3 23 24 10 7 21 6 20 19 2 12 12 1 1 MAN. NO. used to set the speed restrict function and adjust other function parameters [see this Section]. NO.2 POSITION: “ON” condition. 7/00 3-5 . The ignition key MUST be rotated back past THIS position to the NO. Applies electrical current to ALL circuits.Section 3 OPERATION TABLE 3-1. 2 IGNITION SYSTEM Three [3] Position Key Operated Interlock Switch Controls STARTING.transmission in “REVERSE”. This position ALSO is a “lock out” position and prevents accidental engagement of the starter motor when the engine is in a “running” condition. Handle in “BACKWARD” position . INDICATORS AND GAUGES.3 POSITION: “START” condition.transmission in “FORWARD”. The control handle is. position when the key is released. “ON/RUN”. Switch spring returns switch to the NO.2. RUNNING STOPPING of engine. Handle in “FORWARD” position . NO. ITEM NO. Removes ALL electrical current from circuits. also. EXCEPT horn and lighting circuits. FULL travel distance of either handle [forward or reverse] gives HIGHEST speed of travel. MACHINE OPERATING CONTROLS.1 [OFF] position BEFORE the starter motor can be energized again [start position].transmission in “NEUTRAL”. [SEE FIG’ 3-2] 1 DESCRIPTION DIRECTIONAL/ SPEED CONTROL [F-N-R] TYPE Control handle Left and Right Dash Mounted FUNCTION Controls forward/reverse movement and speed of machine in the direction selected Handle in “CENTER” position .1 POSITION: “OFF” condition. Applies electrical current to the starter motor to crank the engine. when machine is in neutral and is NOT moving. Automatically turn front and rear drum systems “OFF”. puts engine throttle at “HIGH/WORK” idle speed. RELEASES the brake system. 5 SECONDARY/ PARKING BRAKE SYSTEM Button Switch Two [2] Position Controls secondary/parking brake system application and release. 3-6 7/00 . as the machine begins to. Button switch turned right and “OUT”. Switch at “OFF”. with a ten [10] second spray period. MACHINE OPERATING CONTROLS. Switch at “MANUAL”. Toggle switch “DOWN”. allows controller system to: Automatically turn front and rear drum systems “ON”. and continues moving. Controller system cycle control switch [ITEM 24] varies systems “duty cycle” 0-50 %. Switch at “AUTO”. continuously. puts engine throttle at “LOW” idle speed. TURN steering wheel IN the direction the machine is desired to travel. ITEM NO. INDICATORS AND GAUGES. turns front and rear drum systems “ON”.MODE [“AUTO/OFF/MANUAL”] Toggle Switch Three [3] Position AUTO MAN. [SEE FIG’ 3-2] 3 DESCRIPTION ENGINE THROTTLE SPEED TYPE Toggle Switch Two [2] Position FUNCTION Controls engine throttle speed [RPM].Section 3 OPERATION TABLE 3-1. turns front and rear drum systems “OFF”. 4 STEERING SYSTEM Manually Operated Wheel Provides machine DIRECTION control. 6 WATER SPRAY SYSTEMS . Toggle switch “UP”. Button switch pushed “IN”. APPLIES the brake system. OFF WATER SPRAY Controls water spray systems operation. Switch “DOWN ”.“WORK” [Low] “TRAVEL” [High] TYPE FUNCTION Toggle Switch Two [2] Position Selects range of transmission drum drive motors. 7/00 3-7 . Switch “LEFT ”. ONLY. ITEM NO. to operate either. selects “FRONT” drum vibration system. either “VIBRATION START/STOP” push button thumb switch [ITEM 12] must also be “pushed” to operate either. puts system in “WORK ” [low] range. selects “REAR” drum vibration system. DRUM SELECT Switch “CENTER”. Switch “UP”. “BOTH” or “REAR”. puts system in “TRAVEL” [high] range. 9 DRUM VIBRATION SYSTEM[S] LOCATION [Front/Both/ Rear] Toggle Switch Three [3] Position BOTH FRONT REAR Selects drum vibration system[s] location “FRONT”. [SEE FIG’ 3-2] 7 DESCRIPTION TRANSMISSION RANGE . If in the “MANUAL” mode. or both drum vibration systems. Switch “RIGHT”. INDICATORS AND GAUGES. “RIGHT” position puts system in “MANUAL MODE”. “CENTER” position turns system “OFF”. 8 DRUM VIBRATOR MODE Toggle Switch “AUTOMATIC/OFF/ Three [3] Position MANUAL” MODE selection of drums vibration system. MACHINE OPERATING CONTROLS.Section 3 OPERATION TABLE 3-1. or both drum vibration systems. NOTE: Engine throttle speed switch [ITEM 3] must be in “HIGH” speed position and the transmission system range switch [ITEM 7] must be in “WORK” [low] range position. ONLY. OFF AUTO MANUAL VIBRATOR MODE “LEFT” position puts system in “AUTOMATIC MODE”. selects BOTH “front AND rear” drum vibration systems. SPEED REAR VIB. 11 VIBRATION SYSTEM HIGH/LOW AMPLITUDE MODE Toggle Switch Two [2] Position HIGH LOW AMPLITUDE Selects AMPLITUDE mode of BOTH front and rear drums vibration system. puts BOTH front and rear drums vibration system in “HIGH ” amplitude mode.3800 VPM C766C .HO or 2000 .C778B]. NOTE: Engine throttle speed switch [ITEM 3] must be in “HIGH” speed position and the transmission system range switch [ITEM 7] must be in “WORK” [low] range position. Switch “RIGHT”. INDICATORS AND GAUGES. 3-8 7/00 . control[s] turned to the LEFT selects LOWEST VPM FREQUENCY the low. or both. SPEED FREQUENCY control [2000 . Switch “LEFT ”. control[s] turned to the RIGHT selects HIGHEST VPM FREQUENCY for the low.Section 3 OPERATION TABLE 3-1. NOTE: Engine throttle speed switch [ITEM 3] must be in “HIGH” speed position and the transmission system range switch [ITEM 7] must be in “WORK” [low] range position. MACHINE OPERATING CONTROLS. Select desired FREQUENCY for EACH drum. or high. to operate either. puts BOTH front and rear drums vibration system in “LOW ” amplitude mode. or both drum vibration systems. Either. to operate either. or both. Either. amplitude mode selected by the mode switch [ITEM 11]. for EACH drum. or high. or both drum vibration systems.3200 VPM .3400 VPM C766C. 2000 . ITEM NO. [SEE FIG’ 3-2] DESCRIPTION TYPE FUNCTION 10 VIBRATION SYSTEM FREQUENCY Potentiometer Control One [1] Control For FRONT Drum and One [1] Control For REAR Drum FRONT VIB. amplitude mode selected by the mode switch [ITEM 11]. rear or both drums vibration system[s]. 7/00 3-9 . CAUTION: STOP the engine IMMEDIATELY if there is LOW. Can indicate a high pressure [LARGE SYMBOL] when engine is first started. 13 ENGINE HOURS OPERATED Hourmeter Indicates TOTAL hours engine has operated. and release to “STOP” system[s] vibration. oil pressure indicated on the oil pressure gauge. ITEM NO. Operates when ignition key switch is in the “ON/RUN” position and the engine is “running”. or NO. “DEPRESS” switch. Operates when the engine is started and “running”. 15 ENGINE OIL PRESSURE Oil Pressure Gauge Indicates the pressure of engine lubrication oil. “DEPRESS” switch once and release to “START/RUN” system[s] vibration. again.Section 3 OPERATION TABLE 3-1. to operate either. Pressure indicated will lower to “NORMAL” [MIDDLE SIZED SYMBOL] as engine warms. [SEE FIG’ 3-2] 12 DESCRIPTION MANUAL DRUM VIBRATOR “START/STOP” TYPE Electrical Push Button Thumb Switches . NOTE: Engine throttle speed switch [ITEM 3] must be in “HIGH” speed position and the transmission system range switch [ITEM 7] must be in “WORK” [low] range position. or both drum vibration systems. INDICATORS AND GAUGES. Operates when ignition key switch is in the “ON/RUN” position. MACHINE OPERATING CONTROLS.Left and Right Travel Control Handle Installed FUNCTION MANUAL “START/STOP” control of front. 14 FUEL AMOUNT IN TANK Fuel Level Gauge Indicates amount of fuel contained in fuel tank. Can be in RED [DISCHARGE] zone on gauge at LOW engine idle. [SEE FIG’ 3-2] DESCRIPTION TYPE FUNCTION 16 ELECTRICAL SYSTEM VOLTAGE Voltmeter Indicates alternator output voltage or battery voltage. Gauge pointer will be in “GREEN” zone during NORMAL system operating conditions. 19 3-10 ENGINE INLET AIR CONDITION Electrical Light. 17 ENGINE COOLANT TEMPERATURE Coolant Temperature Gauge Indicates temperature of engine coolant circulating through engine. which ever is highest. BUT will move to GREEN [CHARGE] zone on gauge when engine speed is increased. 18 HYDRAULIC SYSTEM OIL TEMPERATURE Hydraulic Oil Temperature Gauge Indicates temperature of oil flowing through transmission. MACHINE OPERATING CONTROLS. IMMEDIATE service of air cleaner assembly is required BEFORE further machine operation. Red Lens Covered Indicates “RED” lighted condition ONLY when engine inlet air flow is restricted. 7/00 . When lighted.Section 3 OPERATION TABLE 3-1. steering and vibration systems. INDICATORS AND GAUGES. Gauge pointer will be in “GREEN” zone during NORMAL operation. CAUTION: STOP the engine IMMEDIATELY IF the gauge pointer moves to the “RED” zone of the gauge. ITEM NO. CAUTION: STOP the engine IMMEDIATELY IF the gauge pointer needle moves to the “RED” zone of the gauge. Section 3 OPERATION TABLE 3-1. Indicator light CAN be in an “ON” condition when the hydraulic oil is at a temperature LOWER than the “NORMAL OPERATING” temperature. or reverse. INDICATORS AND GAUGES. Pull switch “out to 1st detent” to turn dash lighting system “ON”. ITEM NO. Will indicate when machine is moving in forward. Secure in place with padlock.* 21 HORN ACTUATION Push Button. Pull switch “out to 2nd detent” to turn dash and headlight lighting systems “ON”. 22 VANDAL GUARD Lockable Cover Install over dash instrument and control panel to help stop possible damage and/or unauthorized use. Switch . 23 LIGHT SYSTEM Push-pull Switch Turns light dash and headlight systems “on” and “off”.DUTY CYCLE Duty Cycle Control Switch WATER SAVER 25 SPEEDOMETER Digital Display Screen One [1] dial switch controls water flow duty cycle for BOTH drums. *CAUTION: Hydraulic system MUST be at “NORMAL OPERATING” temperature for CORRECT system light indications. [SEE FIG’ 3-2] DESCRIPTION TYPE FUNCTION 20 VIBRATION SYSTEMS PRESSURE OIL FILTER ELEMENT CONDITION Electrical Light. Indicates travel speed of machine during operation. NOTE: Water spray system MODE selector switch [ITEM 6] MUST be in “AUTO” position for duty cycle to function. the horn will sound. 7/00 3-11 .Dash Mounted Provides actuation of the horn. direction. 24 WATER SPRAY SYSTEMS. MACHINE OPERATING CONTROLS. Red Lens Covered Indicates “RED” lighted condition when vibration systems PRESSURE oil filter element has reached maximum holding capacity and MUST be changed. When the horn button is pushed. Remove lock and move cover away for start and operation of the machine. Set switch to desired 0-50% duty cycle. 3.display screen will display a message if a system fault condition exists and can be detected [see THIS section]. Monitored and displayed operator parameter and information screens are: SCROLL 1. on the work surface. Normal Screens . Use the "WORK" [low] range for vibratory applications. vibration impacts per foot [see THIS section]. [SEE FIG’ 3-2] 26 DESCRIPTION SYSTEM FUNCTION MONITOR DISPLAY SCREEN TYPE Electrical Display Scroll Button and Alphanumeric Display Screen FUNCTION Scroll button provides access to machine system functions. auto vibrator "on/off" point and English/metric units. objects and within confined areas. for verification and/or changes.Section 3 OPERATION TABLE 3-1. WARNING: The "TRAVEL" [high] range is for "machine transport" ONLY. through alphanumeric display screen. 3-12 7/00 . Parameter Adjustment Screens . MACHINE OPERATING CONTROLS. alphanumeric format screens [see THIS section]. INDICATORS AND GAUGES. Fault Message Screens .display screen will display machine maximum travel speed.Part of the RUN group of screens. 2. and for machine movement near personnel. front and rear vibrator speeds. ITEM NO. Default normal display screen will display machine speed. NOTE: The transmission MUST be in “NEUTRAL” and the secondary/parking brake MUST be APPLIED. a. by positioning the directional/speed control [F-N-R] handle [ITEM 1] in the “CENTER” [NEUTRAL] position. Hydraulic system oil level. at ANY time. in BOTH drums. unlock and then move the vandal guard [ITEM 22] away from the instrument panel. if the machine will move when the SECONDARY/PARKING brake system is in an “ON” [APPLIED] condition. Repeat step “d” UNTIL the engine is started. KEEP the secondary/parking brake system in the “ON” [APPLIED] condition by leaving the system control switch [ITEM 5] in the “ON” [APPLIED] position. Engine inlet air path. 7/00 b. when the secondary/parking brake switch is in the “ON” [APPLIED] position. securely affixed to machine and their condition. Put the guard in the stowed position. STARTING THE ENGINE [See Figure 3-2 and Table 3-1]. Engine cooling system coolant level. and other reproductive harm. Seat belts [BOTH sets] condition and operation. CAUTION: Make a note of the amount of continuous cranking time. until the vibration systems pressure oil filter element condition indicator light [ITEM 20] is “OFF”. Drum bearing lubrication oil level. CHECK. Keep the transmission in “NEUTRAL”. Fluid leaks from engine. put the ignition switch key in the OFF [FIRST] position. 3-13 . DANGER: The machine MUST NOT move. Turn the ignition switch key [ITEM 2] to the START [THIRD] position. CAUTION: Do NOT put the engine throttle speed control switch at the “HIGH” idle position. above the “LOW” idle speed.Section 3 OPERATION OPERATION CHECKS WITH THE ENGINE STOPPED. c. FOPS/ROPS overall condition. birth defects. WARNING: CALIFORNIA Proposition 65 Warning: Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer. This will allow the starter motor time to cool.MAINTENANCE . Do NOT crank the engine MORE than thirty [30] seconds CONTINUOUSLY. as directed in Section 4 . With the engine in a STOPPED condition. Do NOT operate the machine. Do NOT increase the engine throttle speed. IF the engine is NOT started within this time. Condition of drive belt on engine. d. Engine damage can occur. Engine lubrication oil level.in THIS manual. Put the drum vibrator MODE switch [ITEM 8] in the “OFF” position. or INSPECT. Crank and start the engine. for the engine to be started. INSPECT the machine BEFORE use and AFTER every EIGHT [8] hours of operation. Safety decals. Wait one [1] minute. fuel or hydraulic system. UNTIL the fault is CORRECTED. the following items: Fuel level. Keep the engine THROTTLE speed control switch [ITEM 3] at the “LOW IDLE” speed position. Operation of the horn. or DAILY. If installed. condition of structure welds and correct tightened torque of all structure mounting capscrews. NOTE: Review the above three [3] parameters. Automatic vibration mode vibrator “start/stop” speed point [see figure B].in this manual. Also. note that the machine remains stopped and held when the directional/speed control handle [F-N-R] is moved to the forward. such as loose dirt or “old” tires. Maximum “WORK” [low] transmission range speed [see figure A]. or INSPECT. direction. With the engine “running”. check and if needed. when the secondary/parking brake system control switch [ITEM 5] is in the “ON” [APPLIED] position. system monitor display screen [see figure C]. or INSPECT. During engine start up. The machine MUST NOT move. on the monitor display screen. 2. with the directional/speed control handles in the NEUTRAL position and the secondary/parking brake system APPLIED. the system will introduce ether into the fuel intake system to assist in engine starting. DANGER: Do NOT operate the machine. UNLESS the drums of the machine are on a SOFT surface. the system function monitor display screen [ITEM 26] will display the machine model number and then return to the "default screen" display showing machine speed.Section 3 OPERATION NOTE: The machine is equipped with an automatic ether cold start aid. the machine BEFORE operation. UNTIL the fault is corrected. If the engine fails to start. The CLEARANCE between the front and rear frames. 3-14 Review currently selected preset parameters for: 1. at ANY time. CHECK. CHECK. At engine "cold start".MAINTENANCE . as directed in Section 4 . and change the settings as desired. when the ignition key switch is placed in the "on" [number 2] position. DANGER: Keep ALL personnel CLEAR of the hitch area. English. OPERATION OF THE STEERING SYSTEM. using the FOLLOWING information. OPERATION OF THE SECONDARY/PARKING BRAKE SYSTEM. or reverse. replace the ether supply canister with a "full" replacement canister. if the machine moves when the secondary/parking brake system is in an “ON” [APPLIED] condition. 7/00 . or metric units format. CAUTION: Do NOT check the operation of either drum vibration system. review the system information shown on each screen and/ or change each system's parameters. DANGER: Keep ALL personnel CLEAR of the machine when checking the operation of the transmission system. front and rear vibrator speeds [vpm] and impacts per foot. CHECKS WITH THE ENGINE RUNNING. Damage to the drums and/or machine can occur if the operation of the drum vibration systems is checked on a HARD surface. CURRENT MACHINE SYSTEMS PARAMETERS. do these checks and/or inspections AFTER every eight [8] hours of operation. or DAILY. OPERATION OF THE TRANSMISSION SYSTEM. during a engine "cold start" [40˚F. 3. Use the following instructions to access each system function. at the hitch. With the secondary/parking brake system control switch [ITEM 5] in the “ON” [APPLIED] position. or below] attempt. the following items. CLOSES when the machine is turned in EITHER direction. thereafter. toward the REVERSE travel position.Section 3 OPERATION DANGER: Keep the secondary/parking brake system APPLIED and keep ALL personnel CLEAR of the machine when reviewing ANY. With the machine in NEUTRAL. currently selected preset parameters and/or making parameter changes. use the display scroll button [ITEM 26]. ONE [1] time for each one tenth [1/10] miles per hour [mph] the maximum “work” [low] range speed is desired to be INCREASED. displayed during machine operation. e. 2. NOTE: If the maximum “work” [low] range speed shown is NOT as desired. again. b. a. move either directional/speed control handle [ITEM 1] back to the NEUTRAL position. use the following additional information to change the speed. 3-15 . or DECREASED. 1. displayed during machine operation. a small amount. When the maximum “work” [low] range speed has been INCREASED. found below the display screen [ITEM 26]. After completing the adjustment procedure. or DECREASES. NOTE: The maximum “work” [low] range speed adjustment is in increments of one tenth [1/10 miles per hour [mph] even IF the display screen is reading in metric units format. or return to the normal screen [see Figure D]. Note that the speed displayed on the display screen INCREASES. move either directional/speed control handle [F-N-R] [ITEM 1] from the neutral position. 3. Review the maximum “work” [low] range speed parameter displayed on the screen. to the desired speed. dependent on which read out method has been selected. toward the FORWARD travel position. NOTE: At any time during machine operation on the work surface. move either directional/speed control handle [ITEM 1] from the neutral position. Push the manual drum vibrator "start/stop" button thumb switch [ITEM 12]. d. use the display scroll button to scroll to the next screen or return to the normal screen [see Figure D]. use the display scroll button to scroll to the next screen. If the maximum “work” [low] range is desired to be INCREASED. use the above information to change the speed. 7/00 NOTE: If the maximum “work” [low] range speed is desired to be DECREASED. if the maximum “work” [low] range speed requires adjustment. Leave the maximum “work” [low] range speed displayed on the display screen. Use the following information to access the maximum “work” [low] range speed parameter screen. NOTE: The monitor screen will display the above system information in either English [mph]. or metric units [kph]. or DECREASED. to scroll through each system information screen until the maximum “work” [low] range speed screen is reached. The range of adjustment is from a MINIMUM of one half [1/2] miles per hour [mph] to a MAXIMUM of five [5] miles per hour [mph]. a small amount. c. or ALL. Keep the secondary/ parking brake APPLIED. If the maximum “work” [low] range speed shown is as desired. found on the directional/speed control handle [F-N-R]. again. 2. move either directional/speed control handle [ITEM 1] from the neutral position. Review the machine vibrator “start/stop” speed point parameter displayed on the screen. Leave the vibrator “start/stop” speed point displayed on the display screen. toward the REVERSE travel position. Push the manual drum vibrator "start/stop" button thumb switch [ITEM 12]. 3-16 7/00 . d. The range of adjustment is from a MINIMUM of one half [1/2] miles per hour [mph] to a MAXIMUM four [4] miles per hour [mph]. c. found below the display screen [ITEM 26]. a. With the machine in NEUTRAL. If the vibrator “start/stop” speed point shown is as desired. NOTE: The maximum vibrator “start/stop” speed point adjustment is in increments of one tenth [1/10 miles per hour [mph] even IF the display screen is reading in metric units format. use the display scroll button to scroll to the next screen or return to the normal screen [see Figure D]. move either directional/speed control handle [ITEM 1] from the neutral position. or DECREASED. to scroll through each system information screen until the machine automatic vibration mode vibrator “start/stop” speed point screen is reached. 3. NOTE: The monitor screen will display the above system information in either English [mph]. Note that the speed displayed on the display screen INCREASES. dependent on which read out method has been selected.Section 3 OPERATION Use the following information to access the machine automatic vibration mode vibrator “start/stop” speed point screen. displayed during machine operation. If the vibrator “start/stop” speed point is desired to be INCREASED. NOTE: If the vibrator “start/stop” speed point shown is NOT as desired use the following additional information to change the “start/stop” speed point. a small amount. or DECREASED. 1. a small amount. toward the FORWARD travel position. or metric units [kph]. e. if the vibrator “start/ stop” speed point requires adjustment. use the scroll button [ITEM 26]. ONE [1] time for each one tenth [1/10] miles per hour [mph] the vibrator “start/stop” speed point is desired to be INCREASED. Keep the secondary/ parking brake APPLIED. to the desired speed. NOTE: At any time during machine operation on the work surface. use the above information to change the “start/stop” speed point. or DECREASES. displayed during machine operation. b. After completing the adjustment procedure. When the vibrator “start/stop” speed point has been INCREASED. found on the directional/speed control handle. NOTE: If the vibrator “start/stop” speed point shown is desired to be DECREASED. use the display scroll button to scroll to the next screen or return to the normal screen [see Figure D]. move either directional/speed control handle [ITEM 1] back to the NEUTRAL position. ENGLISH/ METRIC UNITS FORMAT .= 0.DISPLAY SCREEN.Water Sprayer Valve Open or Short FIGURE G. LIMD OP: MODE .CURRENT MACHINE TRAVEL SPEED. OR SHORTED. WITH MANUAL VIB. FIGURE F. SET. 4. NORMAL "RUN" . FEET PER MINUTE TRAVEL IMPACTS PER FOOT .FNR FWD FAULT: 5V SENSOR POWER FIGURE E.33 software].Section 3 OPERATION Speed Limit: 4. FAULT MESSAGE DISPLAY SCREEN. WITH CONTROL HANDLE 3 mph : FRNT 3200 vpm FAULT: FNR Neutral SW. SW FIGURE C. 7/00 3-17 . EXAMPLE.DISPLAY SCREEN. MAXIMUM MACHINE TRAVEL SPEED . WITH MANUAL VIB.3 mph : FRNT 3200 vpm 10 ipf : REAR 0 vpm FIGURE D.DISPLAY SCREEN.3 mph ADJ. AUTO VIB. FRONT & REAR DRUM VIBRATIONS PER MINUTE AND IMPACTS PER FOOT DISPLAY SCREEN. SPRAYER VALVE OPEN. FAULT MESSAGE "STOP" FAULT DETECTED . DISPLAY UNITS: ENGLISH ADJ. FIGURE H.8 mph ADJ. VIBRATOR “START/STOP” SPEED POINT . FIGURE B. 378 fpm : FRNT 3200 vpm 10 ipf : REAR 0 vpm FAULT: Sprayer Valve . FAULT MESSAGE DISPLAY SCREEN.MACHINE TRAVEL FAULTED TO LIMITED OPERATION MODE [Version 2.DISPLAY SCREEN. SW FIGURE A. displayed during machine operation. or metric units. found below the display screen [ITEM 26]. When the desired display screen format has been selected. format displayed on the screen. machine serial numbers B215C1737 and below. Review the English. front and rear vibrator speeds [vpm] and impacts per foot [ipf]. can be accessed by pressing the display scroll button [ITEM 26]. NOTE: If the display screen format is NOT as desired. G and H]. NOTE: The display screen will show system information in either English. ONE [1] time and change the screen from English to metric units format.Section 3 OPERATION Use the following information to access the machine English/metric units format display screen. format dependent on which format method has been selected. found on the directional/ speed control handle. or from metric units to English format. within the water spray system supply tanks. The second screen indicating machine travel in "feet per minute" [fpm] and "impacts per foot" [ipf]. format displayed on the display screen. A fault message screen is automatically displayed if a system fault condition exists and can be detected. except C209C2313 and C778B. on the display screen. use the display scroll button [ITEM 26]. displayed during machine operation. or metric units. NOTE: The display screen will show system information in either English. If the display screen format is as desired. use the display scroll button to scroll to the next screen or return to the normal screen [see Figure D]. a. the water level. is electronically monitored. machine serial numbers C209C2343 and below. some faults will cause a shut down of the travel control system and the message will continue to be displayed until the cause of the fault is corrected. c. use the display scroll button [ITEM 26]. if desired. It will be displayed for a short period of time on the bottom line of the display screen. indicating current machine travel speed [mph]. found below the display screen [ITEM 26]. 7/00 . 1. use the display scroll button to scroll to the next screen or return to the normal screen. 2. This will continuously alternate as long as the fault exists. Keep the secondary/ parking brake APPLIED. if a "low water level" exists within the supply tanks. to scroll through each system information screen until the English/metric units screen is reached. b. information displayed on the screen. Then the previously selected display bottom line will be displayed. or metric units. FAULT MESSAGE SCREENS [See Figures F. With the machine in neutral. A fault message will be displayed. 3. With the machine in NEUTRAL. Push the manual drum vibrator "start/stop" button thumb switch [ITEM 12]. or metric units. Leave the English. NOTE: At any time during machine operation. found below the display screen [ITEM 26]. to scroll through each system information screen until the machine normal [run] screen [figure D] is reached. If serious. use the above information to change the screen format. again. NORMAL [RUN] SCREENS [See Figures D and E]. format dependent on which format method has been selected. use the following additional information to change the screen format. or metric units. Review the English. 3-18 On C766C. or in operation. Section 3 OPERATION The "limited operation mode" allows the machine to be removed from the work surface if a "stop" fault" is detected [See THIS Section and Figure H]. Keep ALL personnel CLEAR of the hitch area at ALL times. Put an information tag on the steering wheel which says “DO NOT OPERATE”. TRAVEL in an “UP” or “DOWN” direction ONLY. can operate the Model C766C. WARNING: Do NOT operate a machine having gauges. at the hitch. UNDERSTAND and FOLLOW ALL information shown on the “Operating Instruction and Warning” decals. except the "limited operation mode" .33" and was NOT included in previous "versions" of the software. d. Investigate and repair ALL system faults at ONCE. having damage. not be damaged and be able to be read. REMOVE the key from the ignition switch. All gauges and instruments MUST operate. 3-3 and 3-4]. GAUGES AND INSTRUMENTS OPERATION. DANGER: FAILURE to observe the following precautions and/or the machine “OPERATION and WARNING INSTRUCTIONS”. When on a slope. Other fault messages will only display a message for as long as a fault is detected. The CLEARANCE between the front and rear frames. e. can cause SERIOUS INJURY. which do not operate. Do NOT travel across a slope. DANGER: Keep ALL personnel CLEAR of the hitch area. 3-2. CLOSES when the machine is turned in EITHER direction. b. Compactor. WARNING: Do NOT operate a machine displaying fault messages. Do NOT operate a machine in need of repair. Report ANY needed repairs and have the machine repaired IMMEDIATELY. during operation. USE extra CAUTION when operating the machine near personnel and/or other objects or machines. ALWAYS observe ALL of the following “Operating Precautions”. or instrument. c. of the machine. are damaged or are not able to be read. or C778B. who are fully trained in the machine operation. given in THIS section and found on the DECALS affixed to the machine. found on the machine [see figures 3-1 and 3-3] and the instructions written in THIS manual. or DEATH. READ. The "limited operation mode" is programed into computer controller software "Version 2. or operating. the machine close to a slope and/or when traveling down a slope. OPERATING PRECAUTIONS [See Figures 3-1. Immediately replace any gauge. or instruments. with NEW. Visually check the operation of ALL gauges and instruments. a. To help prevent injury to personnel and/or damage to the machine. USE a SLOW SPEED [work range] and ADDITIONAL CAUTION when nearing. ONLY authorized personnel. or service. 7/00 3-19 . decals IMMEDIATELY. when near personnel. Put the secondary/parking brake system control switch [ITEM 5] in the “ON” [APPLIED] position. STOP the engine. 3-4 and Table 3-1]. 3-3. DANGER: ALL personnel and other machines MUST be CLEAR of the machine path BEFORE the machine is moved. b. in a stopped condition. at ALL times. when on the work surface. The transmission system will NOT hold the parked machine in a stopped condition. The “TRAVEL” range is for “machine transport” ONLY. ALWAYS securely FASTEN and TIGHTEN the seat belt across the lap. or objects. Do NOT put the transmission in the “TRAVEL” range when the machine is moved within a confined area is near personnel. Release the secondary/parking brake system. a. after being seated. AGAINST the body. Keep the hands and feet INSIDE the machine cockpit at ALL times. The machine must NOT move. OPERATING THE MACHINE [See Figures 3-1. put the directional/speed control handle [ITEM 1] in the “NEUTRAL” position. by putting the secondary/parking brake system control switch [ITEM 5] in the “OFF” [RELEASED] position. The decals MUST remain in good condition and NOT be covered with dirt or grease. if the machine will move when the secondary/parking brake system is in an “ON” [APPLIED] condition. Use the “WORK” range for machine movement within a confined area. any object or machine. AFTER the machine has stopped. and BEFORE the machine is started. place the seat belt across the lap and SECURELY insert the metal end into the belt buckle to TIGHTEN the belt. Do NOT operate a machine NOT having the “Operating Instruction and Warning” decals in place on the machine.Section 3 OPERATION f. on ANY grade. i. and for ALL vibratory applications. WARNING: Keep the transmission system in the “WORK” range. AFTER being seated. The SECONDARY/ PARKING brake system MUST be used to hold the machine. 3-20 7/00 . Put the transmission range selector switch [ITEM 7] in the “WORK” [low] range position. at ANY time. Allow NO riders on the machine at ANY time. WARNING: ALWAYS APPLY the SECONDARY/PARKING brake system. Do NOT suddenly stop the machine during operation. IMMEDIATELY. when the secondary/ parking brake system control switch [ITEM 5] is in the “ON” [APPLIED] position. 3-2. REPLACE damaged. Do NOT operate the machine. h. j. BEFORE getting off of the machine. or missing. g. The operator MUST remain seated at ALL times during machine operation. selected. machine serial numbers C209C2344 and above. When the speed range selector switch is in the “WORK” position. during the rolling operation. “LOW” transmission system torque is available. in either direction. or when near personnel. the machine travel speed is proportional to the amount of either directional/speed control [F-N-R] handle movement. put the engine throttle speed [RPM] control switch [ITEM 3] in the “HIGH” engine speed position. 7/00 3-21 . d. UNTIL full handle travel has been reached. The transmission system will be electrically disengaged. do NOT attempt to operate the drum vibration systems with the engine at “LOW” idle. c. SLOWLY move either directional/speed control [F-N-R] handle [ITEM 1] TOWARD the SAME direction the machine is desired to travel. The systems will NOT operate with the engine at the “LOW” engine speed and/or if the “TRAVEL” [high] transmission range is selected. “HIGH”transmission system torque is available. On C766C. the asphalt mat temperature is electronically monitored and can be accessed and displayed on the display screen. e. When on the work surface. when the secondary/parking brake system control switch is in the “ON” [APPLIED] position. When the speed range selector switch is in the “TRAVEL” position. WARNING: Do NOT put the engine throttle speed [RPM] control switch in the “HIGH” engine speed position when the machine is being moved in a confined area. NOTE: PUSHING either handle in the FORWARD direction will select a FORWARD direction of machine travel. SLOWLY move either directional/speed control [F-N-R] handle [ITEM 1] further toward the SAME direction of machine travel. plus C209C2313 and C778B. When the machine is clear of confinement. This will give FULL machine speed for the transmission range and engine throttle speed. any object or machine. until full handle movement has been reached. The machine travel speed is proportional to the amount of either directional/speed control [F-N-R] handle movement. personnel or objects.Section 3 OPERATION NOTE: The vibration systems will NOT operate if the “TRAVEL” [high] transmission range is selected. in EITHER DIRECTION. CAUTION: When on the work surface. PULLING either handle in the BACKWARD direction will select a REVERSE direction of machine travel. NOTE: During normal operation. machine serial numbers B215C1738 and above. “AUTO”/ “OFF”/ “MANUAL” by using the dash mounted water spray system MODE control switch [ITEM 6]. within the water spray system supply tanks. When on the WORK surface. the water spray system will start and stop as each work surface rolling pass is started. DANGER: ALWAYS follow ALL “Operating Precautions and Instructions”. CAUTION: Do NOT operate either drum vibration system. h. is electronically monitored. machine serial numbers B215C1737 and below. the water level. vibration system control FREQUENCY control[s] [ITEM 10] to set the control[s] at the desired drum FREQUENCY [vpm]. g. such as loose dirt or “old” tires. When operating in the “AUTOMATIC” mode. adjust the water spray system duty cycle as desired. given in THIS manual and found on the decals affixed to the machine. NOTE: Put the DRUM VIBRATION SYSTEM[S] “LOCATION” control switch [ITEM 9] at the desired “FRONT/BOTH/REAR” position. or DEATH. When operating in the “AUTOMATIC” vibrator mode. WITHOUT the use of the directional/speed control handle installed thumb switches [ITEM 12]. except C209C2313 and C778B. if a "low water level exists" within the supply tanks. the work surface. UNLESS the drums of the machine are on the WORK. Turn the duty cycle control switch knob [ITEM 24] to select the desired duty cycle. Adjustment of the FREQUENCY control[s] can be done at any time. or “MANUAL” mode. NOTE: On C766C. the vibration system[s] will NOT operate with the engine at the “LOW” engine speed and/ or if the “TRAVEL” [high] transmission range is selected.Section 3 OPERATION f. from 0-50%. Damage to the drums and/or machine can occur if the drum vibration system[s] is operated on a HARD surface. “REAR” or “BOTH” position. preset “ON/OFF” speed. Failure to follow the “Operating Precautions and Instructions” can cause SERIOUS INJURY. When operating on the work surface. while the machine is on. or a SOFT surface. On all machine serial numbers. A fault message will be displayed. “RIGHT” to “MANUAL” to operate the system continuously or in the “CENTER” position to turn the system “OFF”. Put the vibration systems control “HIGH/LOW” AMPLITUDE control switch [ITEM 11] at the desired “HIGH” or “LOW” drum AMPLITUDE position. 7/00 . on the display screen [ITEM 26]. i. the vibration system[s] will start and stop at the adjusted. 3-22 j. machine serial numbers C209C2343 and below. put the drum vibrator MODE [OFF/AUTOMATIC/MANUAL] control switch [ITEM 8] in the desired position. and then stopped. Turn one [1]. or off. turn the system[s] “ON” and “OFF” by using either of the directional/speed control handle installed thumb switches [ITEM 12]. if in the “AUTOMATIC” mode. as each work surface rolling pass is started and then stopped. In either the “AUTOMATIC”. select the desired water spray system mode. If operating either drum vibration system in the “MANUAL MODE”. IMMEDIATELY put the secondary/ parking brake system control switch [ITEM 5] in the “ON” [APPLIED] position and STOP the engine if observed machine operation is NOT normal. or both. Put the switch “LEFT” to put the system in the “AUTOMATIC” mode. Put the drum vibration systems “FRONT/ REAR/BOTH LOCATION” control switch [ITEM 9] at the desired “FRONT”. is displayed on the system function monitor display screen [ITEM 26] when the ignition key switch is first turned to the "ON/RUN" position. NOTE: The "version" of the software.2 kmph] with the Transmission Range Control Switch in the "LOW" position and 1. While in the Limited Operation Mode.75 mph [1. The message will inform the operator that by moving the Drum Vibration Systems "Location" Control Switch [ITEM 9] from the center [BOTH position] to either the FRONT. but not the speed of the movement. Machine speed is NOT proportional to movement of the directional/speed control [F-N-R] handle.Section 3 OPERATION LIMITED OPERATION MODE [See Figure 3-3]. to move the machine to the repair area. during the"limited operation mode". The machine will travel in FORWARD with the switch in the FRONT position and in REVERSE with the switch in the REAR position when either directional/speed control [F-N-R] handle [ITEM 1] is moved from the NEUTRAL position towards either direction of travel.Screens #2 and #3] .Screen #1] . The system function monitor display screen [ITEM 26] will visually "prompt" the operator to return either directional/speed control [F-N-R] handle [ITEM 1] to the neutral position. regardless of which direction it is moved. WARNING : The directional/speed control [F-N-R] handle [ITEM 1] does NOT control the direction of machine travel. The Engine Throttle Speed Control Switch [ITEM 3] MUST be in the "LOW" speed position and the Transmission Range "WORK" [Low] /"TRAVEL" [High] Control Switch [ITEM 7] can be placed in EITHER of the two [2] positions. Do NOT drive the machine to the repair area. The machine will travel approximately 0. With the directional/speed control [F-N-R] handle [ITEM 1] in the neutral position. The directional/speed control [F-N-R] handle is ONLY used to control movement of the machine. 3-23 . move the machine the LEAST distance possible. A message will appear stating "FRNT/FWD" or "REAR/REV"[See Figure 3-3 . from the work surface. or reverse. NOTE: Dependant on the "stop fault" condition which exists and has been detected by the computer controller. 7/00 DANGER: ALL personnel and other machines MUST be CLEAR of the machine path BEFORE the machine is moved.4 kmph] with the Transmission Range Control Switch in the "High" position. the screen will display the functions which should allow the machine to be moved. attempt to travel in the opposite direction.5 mph [2. Use a truck. The "limited operation mode" is programed into computer controller software "Version 2. If travel is not achieved in one direction.33" and was NOT included in previous "versions" of the software. direction of travel. When the directional/speed control [F-N-R] handle is moved from the neutral position. contained within the computer controller. The machine directional control system will "automatically default" to the limited operation mode when a "stop fault" condition exists and has been detected by the computer controller [See Figure 3-3 . drum position machine movement can be achieved. or REAR. The "limited operation mode" allows the machine to be removed from the work surface. limited operation may be restricted to either forward. the machine will travel in the direction which was selected with the Drum Vibration Systems "Location" Control Switch [ITEM 9]. or trailer. the machine will travel in the FORWARD direction when either directional/ speed control [F-N-R] handle is moved from the neutral position in either direction. 3-24 7/00 .REAR/REV Fault: 5V SENSOR POWER DRUM SELECT HIGH WATER SAVER FRONT VIB SPEED LOW AMPLITUDE REAR VIB SPEED SCROLL BUTTON SCREEN # 3 FIGURE 3-3.OPERATOR CONTROLS LOCATIONS This screen tells the operator that there is a fault and the machine is in "Limited Operation Mode". MACHINE LIMITED OPERATION MODE SCREEN DISPLAYS. OFF MAN AUTO VIBRATOR MODE BOTH FRONT REAR VIBE MODE .FNR FDW Fault: 5V SENSOR POWER DRUM SELECT WATER SAVER FRONT VIB SPEED LOW HIGH AMPLITUDE REAR VIB SPEED SCROLL BUTTON SCREEN # 1 This screen tells the operator that there is a fault and by moving the Drum Vibration Systems "Location" Control Switch to the FRONT drum position. OFF MAN AUTO VIBRATOR MODE BOTH FRONT REAR LIMD OP: MODE .Section 3 OPERATION SCREEN GENERAL VIEW . the machine will travel in the REVERSE direction when either directional/ speed control [F-N-R] handle is moved from the neutral position in either direction. OFF MAN AUTO VIBRATOR MODE BOTH FRONT REAR VIBE MODE .FRNT/FDW Fault: 5V SENSOR POWER DRUM SELECT WATER SAVER FRONT VIB SPEED LOW HIGH AMPLITUDE REAR VIB SPEED SCROLL BUTTON SCREEN # 2 This screen tells the operator that there is a fault and by moving the Drum Vibration Systems "Location" Control Switch to the REAR drum position. Section 3 OPERATION WARNING P/N 918141 WARNING FASTEN SEAT BELT! IF MACHINE TIPS: DO NOT JUMP! P/N 918142 FIGURE 3-4. OPERATION WARNING AND SEAT BELT WARNING DECALS MODEL C766C AND C778B COMPACTORS. 7/00 3-25 . or STOP the machine on a slope. or keep. 7/00 . Remove the key from the ignition switch and install and lock the vandal guard. to allow the engine to cool. the machine in a “stopped” condition at ANY time. Serious engine DAMAGE can occur if the engine is stopped BEFORE waiting the three-five [3-5] minute period. use the following procedure to release the BYPASS VALVES and the SECONDARY/PARKING brake system. To SLOW the machine further. at “LOW” speed. and in front of. if desired. b.Section 3 OPERATION DYNAMIC BRAKING OF THE MACHINE [See Figure 3-2]. Put the ignition key switch [ITEM 2] at the “OFF” [NUMBER 1] position and allow the engine to stop. used for DYNAMIC braking. STOPPING THE ENGINE [See Figure 3-2 and Table 3-1]. c. d. Put the drum vibrator mode selector switch [ITEM 8] in the “OFF” position. 3-26 Should the machine become COMPLETELY disabled and the engine can NOT be started and/or the hydraulic system operated. RELEASING THE TOWING BYPASS VALVES AND SECONDARY/PARKING BRAKE SYSTEM AND TOWING A COMPLETELY DISABLED MACHINE [See Figures 3-5 and 3-6]. will NOT hold. WARNING: Do NOT tow the machine UNLESS ALL of the following procedures have been followed. Put the engine throttle speed [RPM] control switch [ITEM 3] in the “LOW” speed position. Put the secondary/parking brake system control switch [ITEM 5] in the “ON” [APPLIED] position. the FRONT drum. move either directional/speed control [F-N-R] handle to the direction OPPOSITE the direction of machine travel. The SECONDARY/PARKING brake system MUST be used to hold the machine in a “stopped” condition at ALL times. The TRANSMISSION SYSTEM is the PRIMARY [DYNAMIC] brake system for the machine. SLOW and STOP the machine by using DYNAMIC braking through the transmission system [see procedure above]. WARNING: When nearing a slope. Put SOLID wood blocks behind. first slow the machine by moving either directional/speed control handle toward the neutral position. Run the engine for a period of at LEAST three-five [3-5] minutes. The transmission system. during operation. The blocks MUST hold the machine in place when the secondary/parking brake system is released. BEFORE the engine is stopped. WARNING: Block SECURELY using SOLID wood blocks. Put either directional/speed control [F-N-R] handle [ITEM 1] in the NEUTRAL position. a. Slowing. CAUTION: Do NOT stop the engine BEFORE running at the “LOW” engine idle speed. is done by moving either directional/ speed control [F-N-R] handle [ITEM 1] TOWARD the NEUTRAL position. of the machine. and then stopping. e. a. h. Put a 1 1/4 inch open end wrench on the LARGE [3rd] hex nut of the FORWARD direction MULTIFUNCTION VALVE cartridge. 7/00 FIGURE 3-6. Turn the nut onto the capscrew threads until it is near the head of the capscrew by using the fingers. until the capscrew is FULLY engaged in the tapped hole. MULTIFUNCTION VALVES ON TRANSMISSION PUMP. OPEN the bypass valve by turning the second [2nd] hex nut with the wrench approximately THREE [3] revolutions in the COUNTERCLOCKWISE [CCW] direction. Use a second wrench to turn the nut further INWARD until the nut will NOT turn any further through the use of the wrench. c. [22. until the nut is against the frame rail. Put a 1 1/16 inch open end wrench on the MIDDLE sized [2nd] hex nut [towing bypass valve] of the FORWARD direction MULTIFUNCTION VALVE cartridge. REPEAT steps “f” through “h” and release the secondary/ parking brake on that motor. Opening the valve additional revolutions can permit external leakage of hydraulic oil during machine towing. on the capscrew threads. Go to either drum drive motor. LEAVE the release mechanism in place. using the SECOND “brake release mechanism”. SECONDARY/PARKING BRAKE SYSTEM RELEASE LOCATION.Section 3 OPERATION b. The secondary/parking brake. Locate the two [2] “brake release mechanisms”. e.2 mm] hole in the frame rail. g. Locate the . on THIS drum drive motor. RELEASE MECHANISM TAPPED HOLE IN BRAKE WASHER HOLE THROUGH SIDE OF FRAME FIGURE 3-5. Go to the SECOND drum drive motor. is now released. 3-27 . f. at THIS time. Take one [1] “brake release mechanism”. Turn the nut CLOCKWISE [CW]. Repeat steps “b” and “c” on the REVERSE direction MULTIFUNCTION VALVE cartridge. d. found behind the tool box door. Turn the capscrew threads into the tapped hole. under the right seat. in the brake release piston. i. CAUTION: Do NOT open the bypass valve more than THREE [3] revolutions.875 in. Install the 16 mm capscrew through the frame rail. Hold the capscrew head with a wrench. or trailer. WARNING: AFTER the machine has been moved. on BOTH drum drive motors. CAREFULLY remove the wood blocking from under the drum. At this time. ONLY use a truck. cable or chain completely. The machine will then roll more easily. Do NOT tow the machine at a speed above TWO [2] miles per hour [3. NOTE: There will be resistance in the hydrostatic transmission system. CLOSE both the FORWARD. Tighten the strap. Move the machine for repair using the truck. Turn the nut. l. Hold the LARGE [3rd] hex nut with the 1 1/4 inch open end wrench and tighten the MIDDLE sized [2nd] hex nut to a torque of 30 ft. Do NOT tow the machine on ANY grade. in the COUNTERCLOCKWISE [CCW] direction until the nut is away from the frame rail.Section 3 OPERATION j. The brakes in the motor will now be APPLIED. Close the bypass valves by turning the MIDDLE sized [2nd] hex nut THREE [3] revolutions in the CLOCKWISE [CW] direction. WARNING: Keep ALL personnel CLEAR of the towing vehicle and the machine while removing the blocking and towing the machine. The secondary/parking brake will be in a DISCONNECTED condition. Keep both “brake release mechanisms” with the machine for future use. to move the machine to the repair area. Tow the machine to a truck. Securely fasten the towing strap. NOTE: AFTER the machine has reached the repair area. and the REVERSE. It is caused by system oil in the transmission drum drive motors. from the work surface.m]. direction bypass valves. TOW the machine the LEAST distance possible. Go to either drum drive motor. lbs. Go to the transmission pump assembly. both “brake release mechanisms” MUST be removed. Go to the second drum drive motor and REPEAT step “k”. m. [41 N. Move the machine onto the truck or trailer and fasten securely [see THIS section for CORRECT machine tie down procedures]. and will be noted UNTIL the drum assemblies have turned approximately one third [1/3] revolution. with the 1 1/16 inch open end wrench. cable or chain to the machine and the towing vehicle. or trailer. CAUTION: BOTH bypass valves MUST be returned to the CLOSED position. k. until the hex nut is seated against the LARGE sized [3rd] hex nut. 3-28 7/00 . CAREFULLY and SLOWLY tow the machine from the work surface. or moving the machine onto the truck or trailer. MUST be put in the APPLIED condition using the following ADDITIONAL information. or trailer. found on the “brake release mechanism”. the SECONDARY/PARKING brake system. the machine will be held in position ONLY by the wood blocking placed against the drum. Do NOT tow the machine to the repair area.2 km/h]. b. at the locations given in the above “WARNING”. near the outer end of the drum. Connect four [4] tie-down chains between the truck or trailer bed and the machine. STEERING LOCK PIN STEERING CYLINDER HITCH ASSEMBLY REAR FRAME ASSEMBLY FIGURE 3-7. 7/00 3-29 . d. FRONT FRAME ASSEMBLY a. Install the steering lock pin through the lock pin bores of the hitch [see figure 3-7]. STEERING LOCK PIN LOCATION. ends on BOTH sides of the machine [see figure 3-8]. Tighten the tiedown load binding device to hold the machine securely in position for transportation [see figure 3-8]. and at the REAR. NOTE: Blocking of the drums. Put SOLID wood blocks under EACH drive drum at the FRONT. WARNING: The machine MUST be securely held to the truck or trailer bed. clear of the truck or trailer bed. CAREFULLY load the machine onto the transporting truck or trailer.Section 3 OPERATION TRANSPORTING THE MACHINE [See Figures 3-7 and 3-8]. Slow and then stop the engine using the CORRECT procedures given in THIS section. is NOT needed on the Model C766C or C778B Compactor. Put the secondary/ parking brake system control switch [ITEM 5] in the “ON” [APPLIED] position. WARNING: FOUR [4] tie-downs MUST be used to secure the machine to the truck or trailer bed when transporting the machine. near the outer end of the drum. Be sure the tie-down chains and load binding devices are correctly connected and tightened securely. ONE [1] frame tie-down hole is found in EACH side of the REAR frame. c. ONE [1] frame tie-down cut out hole is found in EACH side of the FRONT frame. Section 3 OPERATION FRONT TIE-DOWN (LEFT & RIGHT) BLOCKS-FRONT & REAR (LEFT & RIGHT) REAR TIE-DOWN (LEFT & RIGHT) FIGURE 3-8. MACHINE TRANSPORT TIE-DOWN LOCATIONS. 3-30 7/00 . ......................................... GENERAL INFORMATION ............................ MAINTENANCE PROCEDURES .... ENGINE AIR FILTRATION .............................................. CHANGING THE ENGINE LUBRICATION OIL FILTER .................................. ENGINE FUEL FILTERS ........................................... 4-19............................................................................... 4-19...... 4-6......................................................... 4-13............................................. GENERAL INFORMATION .................................................................................................................................... 4-4.................. 4-13....................................................................................... MAINTENANCE SCHEDULE ... FUEL SYSTEM ........Section 4 MAINTENANCE TABLE OF CONTENTS PAGE GENERAL INFORMATION .......................................................................... GENERAL INFORMATION ............................................. 4-13..................................................... MAINTENANCE ...................................................................................................................................................................... 4-4..................... 4-13.......................................... PRIMING AND AIR REMOVAL [BLEEDING] FROM THE FUEL SYSTEM CUMMINS DIESEL ENGINE ............................................................................................ 8/02 4-1 ........................ 4-17........................................... 4-13............................................... ENGINE LUBRICATION OIL .......................... 4-16.......................................... 4-16............................................................................ CHECKING THE ENGINE LUBRICATION OIL LEVEL .......................... ENGINE MAINTENANCE ............................................................................................................................................................................................................. 4-4.............................................................. TABLE 4-1............. MAINTENANCE SCHEDULE ........................................... 4-4.... FUEL TANK ........................ 4-13....................................................................................................................................... 4-16....... AIR CLEANER ................................... GENERAL INFORMATION .... 4-13................................................................................................................................. CHANGING THE ENGINE LUBRICATION OIL ....................................... 4-15.... 4-4.................................................................... ............................... 4-31...... CHECKING THE DRUM BEARING LUBRICATION OIL LEVEL .................................................................................................................................................... 4-31.................. 4-28........................ CHECKING THE HYDRAULIC OIL LEVEL AND ADDING HYDRAULIC OIL TO THE HYDRAULIC OIL RESERVOIR ...................... CHECKING THE CHARGE CONDITION OF THE BATTERY AND SERVICING OF RELATED ITEMS ...........Section 4 MAINTENANCE PAGE COOLING SYSTEM ..................... 4-20......................... CHANGING THE HYDRAULIC OIL ................................................INSPECTION AND REPLACEMENT PROCEDURES ........................ RADIATOR AND HYDRAULIC OIL COOLER ......................................................................................................................................................................................... ELECTRICAL SYSTEM ............................................................................................................................... 4-24......................... 4-30...... 4-23........ CHANGING THE DRUM BEARING LUBRICATION OIL ....................................................................... WATER PUMP ............................................. RADIATOR HOSES ........................... CLEANING AND INSTALLATION ...... 4-23....................................... 4-21........................................ 4-33........................................ 4-33......................................... 4-26.. CHANGING THE DRUM BEARING LUBRICATION OIL C766C machines below serial number 109C20902455 and on C778B machines below serial number 109B21501856 ............................................... VIBRATION SYSTEMS PRESSURE OIL FILTER ELEMENT REMOVAL AND REPLACEMENT .......... 4-2 8/02 ....................................................................................... HYDRAULIC SUCTION OIL STRAINERS AND RETURN OIL DIFFUSER REMOVAL............................................. 4-21............. 4-21............................... GENERAL INFORMATION ............. ELECTRICAL WIRING INSPECTION .................................................... 4-30........................................................................................................................................................................... 4-35........................................ CHANGING THE DRUM BEARING LUBRICATION OIL C766C machines serial number 109C20902455 and higher and on C778B machines serial number 109B21501856 and higher ................................ HYDRAULIC SYSTEM ................................................................ 4-20........................ DRAINING.................... 4-24.................................. 4-27...... VIBRATION ISOLATOR TIRES .................................................................................. 4-34.................... 4-32............................................................................... 4-33... TRANSMISSION SYSTEM PRESSURE OIL FILTER ELEMENT REMOVAL AND REPLACEMENT ............................. DRUM BEARING LUBRICATION ......................... ALTERNATOR AND FAN DRIVE BELT .................. FLUSHING AND FILLING THE COOLING SYSTEM ......................................... ........ 4-52... 4-53............................................................................................................. REMOVAL......................... 4-38.......... WATER SPRAY SYSTEM .............................................................. BATTERY .................................................................................. 4-52...... 4-36.................................................................. REMOVAL ........................................................................ INSTALLATION ................ 8/02 4-3 ................................................... 4-45....... AND INSTALLATION OF THE VIBRATION ISOLATOR TIRE AND RIM ASSEMBLIES C766C machines serial number 109C20902455 and higher and on C778B machines serial number 109B21501856 and higher .......... WATER SPRAY SYSTEM ....................................... REPAIR OR REPLACEMENT AND INSTALLATION ONTO THE RIM ................ TIRE REMOVAL..... 4-40............................................................................. TIRE REMOVAL....................................................................................... 4-43.............................................................. COOLING SYSTEM ...................... REPAIR OR REPLACEMENT........................... 4-53............................. 4-47.............................................. 4-51....Section 4 MAINTENANCE PAGE INSPECTION...................... 4-52.. REPAIR OR REPLACEMENT AND INSTALLATION ONTO THE RIM ................................. 4-35.......... WATER STRAINERS ................................................................................................................................. FUEL TANK ............................................................................................................................ INSTALLATION ............................. REMOVAL ................................... EXPOSED COMPONENT RUST PREVENTION ......... EXHAUST AND OTHER OPENINGS ...................................... 4-50........................................................ MISCELLANEOUS MAINTENANCE INFORMATION ..................................................................................... CLEANER BEAM AND RUBBER CLEANER ASSEMBLIES ......... SECONDARY/PARKING BRAKE SYSTEM MAINTENANCE OPERATION AND APPLICATION CHECK ..... 4-36........... REPAIR OR REPLACEMENT....................................................................................... WATER SPRAY NOZZLES ................. AIR CLEANER...................... REMOVAL...................... 4-53.......... 4-51............................................. 4-52.......................................................... PREPARING THE MACHINE FOR STORAGE ..................................................................... 4-53................ 4-43................... AND INSTALLATION OF THE VIBRATION ISOLATOR TIRE AND RIM ASSEMBLIES C766C machines below serial number 109C20902455 and on C778B machines below serial number 109B21501856 ....................... ENGINE ............... 4-51.................................... 4-53..................................................................................... AIR PRESSURE CHECK AND ADJUSTMENT ..................................................................................................... 4-51..... NOTE: The drum design on C766C machines serial number 109C20902455 and higher and on C778B machines serial number 109B21501856 and higher. found on the machine [See Figure 4-2]. MAINTENANCE must be a planned program which includes periodic machine inspection and lubrication procedures. GENERAL INFORMATION. based on the machine “OPERATING HOURS”. follow the “HOUR” schedule. The maintenance schedule begins with eight [8] hours. THIS section gives the necessary procedures for CORRECT MAINTENANCE of the Model C766C and C778B Compactors. The MAINTENANCE program must be done. Table 4-1 gives inspection and lubrication information for the Model C766C and C778B Compactors. follow the “PERIODIC” schedules. The maintenance checks. MAINTENANCE. Follow ALL the “MAINTENANCE SCHEDULES” and “MAINTENANCE PROCEDURES” for CORRECT machine service schedules and procedures. or daily. recorded on the hourmeter. The MAINTENANCE program is divided into TWO [2] subsections: The MAINTENANCE SCHEDULE and the MAINTENANCE PROCEDURES. Be sure to refer to the text that is applicable to the serial number of your machine. maintenance schedule intervals. or every two [2] years. where they apply. monthly or yearly. maintenance intervals and continues through the 2. Figure 4-1 shows the location of the “machine maintenance points”.000 hours. Most service intervals are listed by the “HOUR” and “PERIODIC” time periods. has been changed. which is done at time intervals of weekly. NOTE: If the machine is operated MORE than eight [8] hours per day. given in Table 4-1.Section 4 MAINTENANCE GENERAL INFORMATION. The MAINTENANCE SCHEDULE lists the recommended time intervals between machine maintenance inspections and lubrication procedures. are also listed on the “Machine Maintenance Decal”. If the machine is operated LESS than eight [8] hours per day. MAINTENANCE SCHEDULE. GENERAL INFORMATION. 4-4 8/02 . or based on the “PERIODIC SCHEDULE”. 8/02 4-5 . MACHINE MAINTENANCE DECAL. FIGURE 4-2. MACHINE MAINTENANCE POINTS.Section 4 MAINTENANCE 20-INSIDE DRUM (THIS SIDE) 17 18 11 22 13 6 3 1 21 14 2 5 14 16-(7) NOZZLES ON: C766C (8) NOZZLES ON: C778B 15 15 14 16-(7) NOZZLES ON: C766C (8) NOZZLES ON: C778B 4 22 18 23 19 8 7 9 12 10 14 20-INSIDE DRUM (THIS SIDE) FIGURE 4-1. Change at interval shown. [10. C778B #1D or #2D diesel fuel. with rust inhibitors and antirust qualities.* Use APPROVED filters ONLY. C766C 60 Gal. Add one [1] can of cooling system conditioner. Total Drain diesel engine lubrication oil and replace with NEW. See Section 2 SPECIFICATIONS.IN TANK X 5 ENGINE INLET AIR FILTER ELEMENT X 6 ENGINE COOLING SYSTEM X 4-6 X 250/ 3 MO 500/ 1 YR 1000/ 1 YR 2000/ 2 YR QUAN. for complete specifications.* C* 1 Change at EACH engine oil change Use APPROVED filter ONLY. ITEM 8/ DAY 1 ENGINE OIL 2 ENGINE OIL FILTER 3 ENGINE FUEL FILTERS [Primary AND Secondary] X* 4 FUEL LEVEL . Fill as required with 50% mixture [approximate] of drinking water and ethylene glycol base antifreeze. C* 19 Qts. C** 1 Check condition indicator light. [18 L] Check coolant level. having rust inhibitor properties. [227 L].* 1 Drain PRIMARY of water daily with drain plug provided.8 Qts.2 l].Section 4 MAINTENANCE TABLE 4-1. [189 L].** Use APPROVED element ONLY.* C* 8/02 . Change element as needed. TYPE/REMARKS C* 10. FIG’ 4-1 ITEM NO.* 50 Gal. MAINTENANCE SCHEDULE. FIG’ 4-1 ITEM NO. and/or one [1] time for every 2. Change filter element when hydraulic oil is changed. CAUTION: Use the COR RECT hydraulic oil ONLY*** + A= OBTAIN AND ANALYZE OIL SAMPLE .000 hours of machine operation. 7 ITEM HYDRAULIC SYSTEM OIL *** 8/ DAY X 250/ 3 MO 500/ 1 YR 1000/ 1 YR 2000/ 2 YR QUAN. on filter head.WITH CARE.*** Use ONLY MOBIL 423.Section 4 MAINTENANCE TABLE 4-1.3 L] Check hydraulic oil level in the reservoir sight gauge. MAINTENANCE SCHEDULE. TEXACO “TDH” or EQUIVALENTS oil. or when filter element condition indicator. See MACHINE PARTS book for CORRECT replacement element. Add hydraulic oil as required. 8 8/02 HYDRAULIC PRESSURE OIL FILTER [Vibration Systems] X C 1 Check condition indicator lights daily. [83. and/or indicator light shows needed. Use APPROVED filter element ONLY. 4-7 . TYPE/REMARKS A/C+ 22 Gal.AS NEEDED. HYTRAN. + C= CHANGE OIL BASED ON RESULTS OF OIL ANALYSIS . Section 4 MAINTENANCE TABLE 4-1. 4-8 ITEM 9 TRANSMISSION SYSTEM PRESSURE OIL FILTER 10 HYDRAULIC SYSTEM SUCTION OIL STRAINERS [Transmission/ Vibration/Steering Systems] 8/ DAY 100/ 2 WK 100/ 3 MO 1000/ 1 YR 2000/ 2 YR C CLEAN QUAN. 2 Remove both. and/or one [1] time for every 2. FIG’ 4-1 ITEM NO.000 hours of machine operation. Use APPROVED filter element ONLY. See THIS section for procedure. 8/02 . Clean at EACH hydraulic oil change. MAINTENANCE SCHEDULE. Also remove. 1 TYPE/REMARKS Change filter element when hydraulic oil is changed. See MACHINE PARTS book for CORRECT replacement element. & clean return oil diffuser. one [1] time for each 100 hours of machine operation. Service as required. Check hold down clamp for tightness. See THIS section. of the system. or every 3 months. ITEM 11 ALTERNATOR & FAN DRIVE BELT 12 BATTERY 13 SECONDARY/ PARKING BRAKE SYSTEM 8/02 8/ DAY 100/ 2 WK 100/ 3 MO 1000/ 1 YR X* X X X 2000/ 2 YR QUAN. Clean battery and battery cable connectors. MAINTENANCE SCHEDULE. Check the built in “test indicator” for indication of battery condition. 4-9 . [see THIS section]. If fully charged. or daily. FIG’ 4-1 ITEM NO.Section 4 MAINTENANCE TABLE 4-1. System Check OPERATION of brake system one [1] time for each eight [8] hours of machine operation.* Replace belt with NEW if needed [see ENGINE manual]. Check belt for CORRECT deflection. using the procedures given in Section 3. should indicate “GREEN” condition. Check OPERATION & APPLICATION. TYPE/REMARKS 1 Check belt for wear or damage. 1 The battery is of the “maintenance free” type. X All Check condition. X/C CLEAN AS REQUIRED 8/02 . TYPE/REMARKS 4 Check air pressure when tires are "cold". Replace as needed. X 2 Sets Check condition. clean and install the strainers one [1] time for every 500 hours of machine operation.Section 4 MAINTENANCE TABLE 4-1. All Remove. check. FIG’ 4-1 ITEM NO. See MACHINE parts manual. See MACHINE parts manual. Replace set if damaged. or yearly. MAINTENANCE SCHEDULE. Set at CORRECT pressure [see THIS section]. ITEM 14 VIBRATION ISOLATOR TIRES 15 WATER SPRAY SUCTION STRAINERS 16 WATER SPRAY SYSTEM NOZZLES 17 SAFETY DECALS 18 SEAT BELT SETS 4-10 8/ DAY 250/ 3 MO 500/ 1 YR 1000/ 1 YR X 2000/ 2 YR QUAN. clean and install onto spray bars when plugged on "as required" basis [see THIS section]. 2 Remove. they MUST remain tightened to the torque of 375 ft. 10 Gal. [37. contact the nearest Distributor immediately. CAREFULLY inspect ALL welds for cracks. severe rust or other weld related problems.9 L] EACH drum Check drum bearing lubrication oil level and add oil as needed one [1] time for each eight [8] hours of machine operation. TYPE/REMARKS Structure Inspect the FOUR [4] grade 8 flange screws that fasten the structure to the machine. breakage in the weld or where the weld joins the components. FIG’ 4-1 ITEM NO. 4-11 . Change oil one [1] time for each 2000 hours of machine operation. or daily [see THIS section].Section 4 MAINTENANCE TABLE 4-1. If any damage is found in the above inspection. or every 2 years [see THIS section].m]. lbs. ITEM 8/ DAY 19 FALLING OBJECT/ ROLL OVER PROTECTIVE STRUCTURE [FOPS/ROPS] X 20 DRUM BEARING LUBRICATION OIL X 8/02 250/ 3 MO 500/ 1 YR 1000/ 1 YR 2000/ 2 YR C QUAN. [509 N. MAINTENANCE SCHEDULE. AND ANALYZE. CHANGE OIL BASED ON RESULTS OF OIL ANALYSIS . WITH CARE. or replace. TYPE/REMARKS 21 GAUGES HORN LIGHTS X All Check operation. Repair if needed [See Section 3]. CHECK HYDRAULIC system oil level with the engine in the “OFF” condition and the hydraulic oil at the “OPERATING” temperature.IF REQUIRED * = Refer to current “OPERATION AND MAINTENANCE MANUAL . ** = Under VERY dusty or severe operating conditions change at 500 hours or as need is indicated. as needed.Section 4 MAINTENANCE TABLE 4-1. Repair if needed [See Section 3]. *** = See DECAL adjacent to hydraulic reservoir fill tube. CAUTION: CHECK ENGINE lubrication oil level with the engine in the “OFF and COLD” condition.B SERIES DIESEL ENGINE” published by Cummins Engine Company Incorporated. MAINTENANCE SCHEDULE. which is supplied with EACH machine. 22 DYNAMIC BRAKES X Trans'. 23 STEERING X Steering System Check operation. System Check operation. ITEM 8/ DAY 250/ 3 MO 500/ 1 YR 1000/ 1 YR 2000/ 2 YR QUAN. Repair. 4-12 8/02 . FIG’ 4-1 ITEM NO. for very specific engine information. KEY: X= CHECK C= CHANGE A/C= OBTAIN OIL SAMPLE. CUMMINS DIESEL ENGINE LUBRICATION OIL LEVEL CHECK LOCATION. ENGINE LUBRICATION OIL. CHANGING THE ENGINE LUBRICATION OIL [See Figure 4-4]. CHECKING THE ENGINE LUBRICATION OIL LEVEL [See Figure 4-3]. The engine lubrication oil MUST be changed according to the interval given in the current diesel engine “Operation and Maintenance Manual” published by Cummins Engine Company and supplied with the machine. FIGURE 4-3. by allowing the oil to return to the oil pan. but NOT ABOVE the “FULL” mark.Section 4 MAINTENANCE MAINTENANCE PROCEDURES. or on the decal. NOTE: The instructions given in the MAINTENANCE procedure subsection are given by “machine systems” and are NOT necessarily in the same order as listed in Table 4-1 or as shown on the “Machine Maintenance Decal”. put the machine in a “LEVEL” position and STOP the engine. The following MAINTENANCE PROCEDURES give instructions for performing required machine maintenance checks and lubrication. GENERAL INFORMATION. WAIT five [5] minutes BEFORE removing the dipstick from the engine and checking the oil level. GENERAL INFORMATION. HOT oil can be thrown causing serious injury. WARNING: STOP the engine BEFORE checking the engine lubrication oil level. very specific. on the engine lubrication oil dipstick. which is supplied with the machine. Clean the area around the engine lubrication oil dipstick BEFORE removing the dipstick from the engine. NOTE: The ABOVE procedure will help to remove the possibility of filling the engine with too much lubrication oil.B SERIES DIESEL ENGINE” published by Cummins Engine Company Incorporated. The engine lubrication oil MUST be kept at a level ABOVE the “ADD” mark. With engine running. They may ALSO include some items NOT shown in the table. see the current “OPERATION AND MAINTENANCE MANUAL . The following ENGINE maintenance information will cover engine general maintenance procedures most often done. For additional. ENGINE maintenance information. TO ACCURATELY check the engine lubrication oil level. FILL DIPSTICK ENGINE MAINTENANCE. 8/02 4-13 . Fill the engine to the CORRECT oil level. having a capacity greater than 10. b. d. NOTE: See THIS section for the CORRECT amount of lubrication oil. For the CORRECT type of lubrication oil see the current “OPERATION AND MAINTENANCE MANUAL . 4-14 DRAIN PLUG FIGURE 4-4. Serious engine damage. Follow the procedures given in THIS section and in the current Cummins ENGINE “Operation and Maintenance Manual”. and dry with compressed air.B SERIES DIESEL ENGINE” published by Cummins Engine Company Incorporated. Change when WARM ONLY. g. and “WARM” engine lubrication oil.0 qts. proceed as follows: a. directly under the engine lubrication oil drain plug. WARNING: Do NOT change the engine lubrication oil when the engine and lubrication oil are HOT. Hot oil can cause serious injury. install and CAREFULLY tighten the lubrication oil drain plug. Clean the area around the engine lubrication oil dipstick and oil filler cap BEFORE removing the dipstick. e. [9. f. or failure WILL occur. 8/02 . Drain ALL of the engine lubrication oil into the container. Place a container. which is supplied with the machine. Part Number 178297. With the engine “STOPPED”.5 L]. CAUTION: Do NOT change the engine lubrication oil with the engine “running”.Section 4 MAINTENANCE NOTE: The color of the engine lubrication oil can NOT be used as an indication of the need for a engine lubrication oil change. with the CORRECT engine lubrication oil. The use of an engine lubrication oil “analysis service” is the ONLY alternate reason for not following the required engine lubrication oil change schedule. Install the oil filler cap and the engine lubrication oil dipstick. Clean. CAUTION: Do NOT overtighten the drain plug. CAREFULLY remove the engine lubrication oil drain plug. or oil filler cap. CUMMINS DIESEL ENGINE LUBRICATION OIL DRAIN PLUG LOCATION. Clean the area around the engine lubrication oil drain plug found on the lower side of the frame cross member [see Figure 4-4]. c. CAUTION: Do NOT start the engine BEFORE changing the engine lubrication oil filter. Wash the oil filler cap with All-Purpose degreaser cleaner. NOTE: CHECK the engine lubrication oil level at THIS time. Wipe the area around the engine lubrication oil filter element and its mounting base. Serious engine damage.Section 4 MAINTENANCE CHANGING THE ENGINE LUBRICATION OIL FILTER [See Figure 4-5]. NEW and CLEAN oil. with a CLEAN cloth. Install the NEW filter element onto the filter head. WILL occur. Start the engine. Fill the NEW filter element with CORRECT. proceed as follows: a. Use a filter removal wrench to loosen and remove the filter element by turning it in a COUNTERCLOCKWISE direction of rotation. by the hand only. With the engine “STOPPED” and filled with NEW engine lubrication oil. Hot oil can cause serious injury. CAUTION: Do NOT change the engine lubrication oil filter with the engine running. CORRECT any problem noted BEFORE starting the engine again. CAUTION: Be sure the used rubber gasket is REMOVED and discarded with the filter element. given in THIS section. The engine lubrication oil filter MUST be changed when the engine lubrication oil is changed. f. by the filter manufacturer. c. WARNING: Do NOT change the engine lubrication oil filter when the engine and lubrication oil are HOT. 8/02 4-15 . Drain and discard the removed filter element. Check to be sure there are NO oil leaks and that the engine oil pressure gauge indicates that the engine has the CORRECT lubrication oil pressure. NOTE: Tighten the filter element as directed on the filter element. Put CLEAN engine lubrication oil on the rubber gasket area of the NEW filter element. and in the ENGINE “Operation and Maintenance Manual” BEFORE the engine is started. CAUTION: Do NOT overtighten the lubrication oil filter element onto the filter head. e. Change the filter when “WARM” only. CAUTION: STOP the engine IMMEDIATELY if INCORRECT OIL pressure is indicated or any oil leaks are seen. or failure. g. Carefully tighten the filter element. d. b. Follow ALL engine lubrication oil change and fill procedures. Place a container under the filter element. Wipe the inside area of the lubrication oil filter head using a CLEAN lint free cloth. The fuel strainer [PRIMARY] and the fuel filter [SECONDARY] elements MUST be replaced as directed in the current engine “Operation and Maintenance Manual”. to “FULL”. ALL fuels for internal combustion engines are flammable. FIGURE 4-6. ENGINE FUEL FILTERS [See Figure 4-7]. The fuel gauge indicates the amount of fuel in the tank. FUEL SYSTEM. CUMMINS DIESEL ENGINE LUBRICATION OIL FILTER LOCATION. published by Cummins Engine Company Incorporated and supplied with the machine. BEFORE the machine is stored for the night to reduce the accumulation of moisture. 4-16 CAUTION: Drain the PRIMARY fuel strainer lower bowl of ALL water one [1] time EACH day. as the gauge indicates needed. Never check fuel level or check for fuel leaks with an open flame. WARNING: The operator MUST be off of the machine while fuel is added. Have a fire extinguisher available. in the tank. Replace the fuel strainer and/or fuel filter elements using the following “GENERAL” procedures and very specific information given in the current engine “Operation and Maintenance Manual”. FUEL TANK FILL LOCATION AND CAP. Fill the fuel tank ONLY in a designated area with good ventilation. or as needed. FUEL TANK [See Figure 4-6]. ALSO fill the tank. published by Cummins Engine Company Incorporated and supplied with the machine.Section 4 MAINTENANCE DOOR OIL FILTER CAP FIGURE 4-5. NEVER fill the tank near an open flame. or near equipment that can create sparks. NO smoking while filling the fuel tank. CHECK the amount indicated on the gauge ONE [1] time EACH day. 8/02 . Fill the fuel tank “FULL”. from condensation. CUMMINS DIESEL ENGINE [See Figure 4-8]. by the filter manufacturer. Wipe the inside area of the filter head with a CLEAN “lint free” cloth. 8/02 PRIMING AND AIR REMOVAL [BLEEDING] FROM THE FUEL SYSTEM . start and remove [bleed] the air from the fuel system of a CUMMINS diesel engine which has been run out of fuel: NOTE: Small amounts of air will be vented from the system automatically. Air removal [bleeding] will be required if the fuel strainer and/or filter elements were NOT correctly filled with fuel BEFORE installation. Put a container under the fuel strainer or the fuel filter. Wipe the area around the fuel strainer or the fuel filter element and the element mounting head. USE EXTRA CAUTION. Fill the “NEW” fuel strainer or fuel filter element COMPLETELY FULL of the CORRECT and CLEAN fuel. Do NOT change the fuel strainer or fuel filter element with the machine running. d. STOP the engine. Do NOT smoke while changing the fuel strainer or fuel filter element. CAUTION: Tighten the fuel strainer or the fuel filter element as directed on the filter element. if the filters were changed using the CORRECT procedures given in THIS section. FUEL STRAINER AND FUEL FILTER LOCATIONS . g. Drain and discard the removed element. Install the “NEW” fuel strainer or fuel filter element onto the filter head. Use a filter removal wrench to loosen and remove the element. Put CLEAN fuel on the element rubber gasket. b. Do NOT spill fuel. Do NOT overtighten the fuel strainer or fuel filter element onto the filter head. Start the engine and check for ANY fuel leaks. BEFORE removing EITHER filter element. using a CLEAN lint free cloth. Do NOT start the engine UNTIL the leakage problem is CORRECTED. Do NOT change the fuel strainer or fuel filter element in an area near open flame. WARNING: STOP the engine IMMEDIATELY if ANY fuel leakage is noted. c.CUMMINS DIESEL ENGINE. f. CAREFULLY tighten the element by hand ONLY. a. Use the following general procedures to prime.Section 4 MAINTENANCE WARNING: DIESEL FUEL IS VERY FLAMMABLE. by turning the element in a COUNTERCLOCKWISE direction. FUEL FILTER ELEMENT FIGURE 4-7. 4-17 . FUEL STRAINER ELEMENT WATER DRAIN e. FUEL PRIMING AND AIR REMOVAL LOCATIONS. Fuel leaked on the HOT exhaust manifold can create a danger of fire. Add at LEAST ten [10] gallons [38 liters] of the CORRECT. Fuel under HIGH pressure can penetrate the skin. Do NOT remove the air from the fuel supply lines IF the engine is HOT. b. f. Operate the priming button on the fuel lift pump UNTIL the flow of fuel from the bleed screw fitting is continuous and FREE of air bubbles [see figure 4-8]. Remove the air from the LOW pressure fuel lines and the fuel strainer and filter by opening the air bleed screw. CLEAN fuel to the fuel tank. KEEP the hands and body AWAY from the injector fittings and nuts. Because the engine may start. e. Use the wrench to tighten the loosened fuel supply line nut[s] at the injector fitting[s] [see the Cummins "Operation and Maintenance Manual"]. ONE [1] at a time. FUEL SUPPLY NUT PRIMING BUTTON HAND LEVER FIGURE 4-8. d. Venting is done by loosening one. a. c. see the current engine “Operation and Maintenance Manual” supplied with the machine. 4-18 8/02 . or more. Crank the engine to vent air trapped in the fuel system [see the Cummins "Operation and Maintenance Manual"]. Crank the engine and let the fuel flow from the line UNTIL there is NO indication of air bubbles present at ANY line connection point. WARNING: It is necessary to keep the engine fuel system in the "RUN" condition to vent air. fuel supply line to injector retaining nut[s] a SMALL amount. be sure to follow ALL safety precautions. Wear safety glasses to protect the eyes. COMPLETELY tighten the air bleed screw and stop the operation of the lift pump priming button. found at the top of the fuel filter [see the Cummins "Operation and Maintenance Manual"].Section 4 MAINTENANCE CAUTION: For very specific information. Get IMMEDIATE medical attention if fuel enters the eyes or skin. Never operate the engine without an air cleaner element installed. BAFFLE ASSEMBLY END CAP ELEMENT FILTER BODY ASSEMBLY WING NUT WING BOLT O-RING VACUATOR VALVE FIGURE 4-9. Remove the end cup from the air cleaner body. c.of THIS manual. AIR CLEANER ASSEMBLY . Install the air cleaner end cap onto the air cleaner body. i. g. Remove the wing nut and baffle assembly from inside the air cleaner body. or yearly. Do NOT service the air cleaner element while the engine is “running”.Section 4 MAINTENANCE b. Loosen the band clamp which holds the end cup assembly onto the air cleaner body. ENGINE AIR FILTRATION. If the restriction indicator light is “ON”. for a machine which is operated under “normal” conditions. The engine inlet air cleaner assembly uses a replaceable filter element. CAUTION: The air cleaner filter element should be replaced ONE [1] time for EACH 1. e. Start the engine using ALL the CORRECT starting procedures given in Section 3 . BAND CLAMP d. Remove the air filter element from inside the air cleaner body and DISCARD. Tighten the band clamp securely. Install the baffle assembly over the end of the air filter element. the air cleaner filter element MUST be removed and replaced IMMEDIATELY. f. or every six [6] months.EXPLODED VIEW. AIR CLEANER [See Figure 4-9]. for a machine which is operated under “very dusty or “severe” conditions. Note that the engine inlet air restriction indicator light is “OFF” and that the engine inlet air is NOT being restricted.OPERATION . Use the following procedures to service the air cleaner element: a. CAREFULLY install the NEW air filter element into the air cleaner body assembly. h. Clean the inside of the air cleaner body with a clean cloth. which holds the baffle assembly and air filter element into the air cleaner body assembly. or ONE [1] time for EACH 500 hours of machine operation. CAUTION: Severe engine damage can occur if hose clamps are in a loose condition or if the tube is damaged. Inspect the hose clamps for tightness and the condition of the tube from the air filter to the engine intake manifold. Install and tighten the wing nut. CHECK the engine inlet air restriction indicator light DAILY. 8/02 4-19 .000 hours of machine operation. when the cooling system is cool. Drain. Bent cooling fins can be CAREFULLY straightened. belt or moving engine parts. or yearly. or cleaning. with NEW coolant. when looking through the radiator and hydraulic oil cooler fin area FROM the outside of the fin area. 8/02 . Light MUST be clearly seen. or the hydraulic oil cooler fin area. Do NOT use caustic soap solutions as part of the standard steam cleaning procedure. MUST be removed by using standard steam cleaning procedures. A restricted. NOTE: If a restricted fin condition is noted in EITHER the radiator. overflow tube can prevent the radiator cap from releasing extra system pressure and system failure can occur. WARNING: Do NOT check the system coolant level. Clean the fin areas with the compressed air blown in the OPPOSITE direction of “normal” air flow during operation. as rapid radiator or hydraulic oil cooler deterioration can occur. Wear safety glasses and protective clothing. CHECK the system coolant level ONE [1] time for EACH eight [8] hours of machine operation. CHECK the radiator cap gasket EACH time the radiator cap is removed from the radiator. REPLACE the radiator cap IMMEDIATELY with a NEW cap of the SAME pressure rating. inspect the radiator and the hydraulic oil cooler cooling fin area EACH time the system coolant level is checked. or dirt build up. or ANY component. Keep the coolant level ONE [1] inch [25. HOT coolant. or ANY component.Section 4 MAINTENANCE COOLING SYSTEM. If the rubber face of the cap valve is damaged. Use a radiator fin comb to straighten the bent fins AFTER cleaning. when the system is at operating temperature and the coolant is under pressure. RADIATOR AND HYDRAULIC OIL COOLER [See Figure 4-10]. Do NOT check the system coolant level. or damaged. cooling fins during cleaning. Serious injury can result from being caught or struck by the fan. Serious injury can result from being caught or struck by the fan. 4-20 With the engine STOPPED. Apply steam cleaning pressure through BOTH the radiator and hydraulic oil cooler in the direction OPPOSITE the direction of “normal” air flow during operation. The radiator cap gasket MUST seal on the radiator filler neck surface. CHECK the radiator overflow tube for restriction. under pressure. Severe restrictions. flush and fill the cooling system. Add CLEAN water when the level is LOW. Fill the radiator ONLY when the system is COOL. or cracked. or damage. or hydraulic oil cooler. the radiator or hydraulic oil cooler fin areas. [see THIS section for general procedures].4 mm] BELOW the radiator filler neck. belt or moving engine parts. using a 50/50 % [approximate] mixture of ethylene glycol type antifreeze and CLEAN water on initial fill. CAUTION: Do NOT damage the radiator. WARNING: The engine MUST be STOPPED BEFORE checking. [2 bar]. with the engine running. ONE [1] time for EACH 1. Check the coolant level ONLY when the radiator filler cap is cool enough to touch with the hand. WARNING: The compressed air supply MUST have a pressure BELOW 30 psi. CLEAN the fin area using LOW pressure compressed air.000 hours of machine operation. or daily. Use a bright light placed on the INSIDE of the radiator fin area. Remove the radiator filler cap SLOWLY. Fill the radiator as needed. which are NOT removed by using compressed air. can cause serious injury. CAUTION: Visual inspection of the outside of the hose is NOT adequate. Do NOT remove the water pump while the cooling system is HOT. Drain the cooling system of coolant [see THIS section] and COMPLETELY remove EACH radiator hose. WARNING: Do NOT check. ANY radiator hose with the engine “running”. softening or hardening. Remove and replace the water pump ONLY after draining the cooling system of coolant [see THIS section] when it is COOL. ANY radiator hose while the cooling system is HOT. Serious injury can result from being caught or struck by the fan. or replace with NEW if found to be damaged. RADIATOR FIGURE 4-10. FLUSHING AND FILLING THE COOLING SYSTEM [See Figures 4-10. OIL COOLER WATER PUMP. indicates that the coolant anticorrosion additives are no longer effective. Water pump leaks can allow air to be pulled into the cooling system. Rust in the radiator. Air in the cooling system can cause the cooling system to operate in a “HOT” condition. Serious injury can result from being caught. after EACH 50 hours of machine operation. DRAIN COCK Visually CHECK the engine water pump for leaks. increased size. or other damage is noted. or struck. or coolant. 4-11. or remove. RADIATOR AND HYDRAULIC OIL COOLER LOCATIONS. use the current CUMMINS engine “Operation And Maintenance Manual”. Install the hose. if found to be acceptable. Use ONLY CORRECT steam cleaning procedures. belt or moving engine parts. belt or moving engine parts. CAUTION: For additional specific information. A hose can have damage on the inside and look acceptable from the outside. 4-12]. or have ANY restrictions. Remove the hoses ONLY when the system is COOL and has been DRAINED of coolant.Section 4 MAINTENANCE WARNING: Wear safety glasses and protective clothing during the steam cleaning operation. 8/02 4-21 . Replace the water pump IMMEDIATELY if a leak. CHECK the INSIDE area of the hose for damage. DRAINING. or other damage. supplied with the machine. or remove. or is full of coolant. RADIATOR HOSES. or remove. Do NOT check. again. the water pump with the engine running. The hose must NOT be hard. WARNING: Do NOT check. CHECK the radiator hoses at least ONE [1] time EACH year for cracks. by the fan. Replace ANY hose found to have ANY damage. Replace the thermostat. Serious injury can result from being caught or struck by the fan.Section 4 MAINTENANCE To help prevent severe cooling system damage. with NEW. or yearly. d. Loosen the radiator drain cock. AFTER flushing. Install ALL the clamps. Open the radiator drain cock and drain ALL coolant from the radiator. Install the thermostat. Do NOT install the radiator hoses. flush and fill the system with NEW coolant. Install the thermostat into the housing. CAUTION: Do NOT start the engine while reverse flushing the engine block or the radiator assembly. again. Remove BOTH the upper AND the lower radiator hoses from the engine. at THIS time. drain. for ANY damage. using a NEW 50/50 % [APPROXIMATE] mixture of ethylene glycol antifreeze and CLEAN water [see THIS section]. g. or leaks. Hot coolant can cause serious injury. Install ONLY the thermostat HOUSING [NO thermostat] onto the engine. COMPLETELY drain the coolant from the engine and aftercooler. at THIS time. NOTE: Inspect the engine WATER PUMP. if found to be damaged. Put a container under the radiator drain cock and drain the coolant. c. Remove the thermostat housing and the thermostat from the engine. again. or damage. Do NOT drain the cooling system while the system is HOT and is under pressure. Reverse flush the RADIATOR assembly. NOTE: BEFORE cooling system flushing. Test the thermostat for CORRECT operation at the specified opening temperature. the cooling system with the engine running. through the radiator filler neck. Remove ALL engine and aftercooler drain plugs. AFTER reverse flushing the engine block assembly. and tighten them securely. Drain the system when COOL ONLY. Install BOTH the UPPER and the LOWER radiator hoses onto BOTH the radiator and the engine. AFTER reverse flushing the radiator assembly. COMPLETELY drain the engine block and the aftercooler of water. Install ALL engine and aftercooler drain plugs. Install the thermostat housing over the thermostat and onto the engine. flush and fill the engine cooling system: a. the thermostat MUST be removed. the flushing procedure WILL close the thermostat and prevent complete engine block flushing. STOP the engine and allow the cooling system to reach a COOL temperature. Inspect the thermostat for corrosion. e. Use the following general procedures to drain. at THIS time. Reverse flush the ENGINE BLOCK as shown in figure 4-11. f. REPLACE the water pump with NEW if found to be damaged. onto the hoses. b. or flush. Fill the cooling system with coolant. h. Tighten the drain plugs by hand ONLY. i. If the thermostat is NOT removed. ONLY. Inspect BOTH hoses using the procedures given in THIS section.000 hours of machine operation. Install the thermostat housing to engine gasket. in the CORRECT position. as shown in Figure 4-12. or thermostat. Install the retaining capscrews and tighten securely. belt or moving engine parts. Tighten ALL drain plugs securely. Close the radiator drain cock and tighten securely. Remove ALL engine and aftercooler drain plugs. using a wrench. ONE [1] time for EACH 1. 4-22 8/02 . or leaking. WARNING: Do NOT drain. Remove the thermostat housing from the engine. COMPLETELY drain the radiator of water. Install ALL drain plugs into the engine and aftercooler. Close and tighten the drain cock by hand ONLY . Start the engine and allow the NEW coolant mixture to circulate through the cooling system. REVERSE FLUSHING PROCEDURE ENGINE BLOCK. 8/02 4-23 . Serious injury can result from being caught.Section 4 MAINTENANCE NOTE: It is suggested that one [1] can of cooling system conditioner. STOP the engine IMMEDIATELY and correct ANY leakage problem noted. belt or moving engine parts. CLAMP FIGURE 4-12. BEFORE further engine operation. WATER FLUSHING GUN AIR CLAMP The transmission. FIGURE 4-11. STOP the engine. Allow the coolant to reach a cool temperature and then fill the radiator. HYDRAULIC SYSTEM. NEW HOSE WARNING: KEEP CLEAR of ALL moving engine parts when the engine is running. REVERSE FLUSHING PROCEDURE RADIATOR ASSEMBLY. with the CORRECT coolant mixture. steering and vibration systems ALL use the SAME hydraulic oil reservoir and hydraulic oil supply. k. by the fan.4 mm] of the radiator filler neck. Install the radiator cap and tighten. to within ONE [1] inch [25. Inspect the COMPLETE system for ANY coolant leakage. also be added to the coolant at THIS time. with a rust inhibitor. or struck. GENERAL INFORMATION. CAP CLOSED FLUSHING GUN CLAMP WATER AIR NEW HOSE j. or remove. CAUTION: Do NOT over fill the hydraulic oil reservoir.Section 4 MAINTENANCE CHECKING THE HYDRAULIC OIL LEVEL AND ADDING HYDRAULIC OIL TO THE HYDRAULIC OIL RESERVOIR [See Figure 4-13]. ONLY loosen the filler cap when the oil is at a “WARM” temperature.4 mm] BELOW the FILL neck of the hydraulic oil reservoir ONE [1] time for EACH 2. Do NOT use unfiltered hydraulic oil. KEEP the oil level of the hydraulic oil reservoir. FILTERED hydraulic oil MUST be added to the hydraulic oil reservoir UNTIL the oil level is in the CENTER of the sight gauge glass. See THIS section for the CORRECT type of oil. ONE [1] time EACH day. The hydraulic reservoir oil level MUST be able to be seen through the sight gauge glass. or every TWO [2] years for OIL ANALYSIS. CHANGING THE HYDRAULIC OIL [See Figure 4-14]. the CORRECT. If the hydraulic oil level is BELOW the sight gauge. OBTAIN a hydraulic oil sample from oil six [6] inches [152. WARNING: Do NOT loosen. at the CORRECT level. per milliliter as installed. the hydraulic oil reservoir filler cap when the hydraulic oil is “HOT”. 8/02 . and be at the CENTER of the glass. HYDRAULIC OIL RESERVOIR AND SIGHT GAUGE. Change the hydraulic oil ONLY if the OIL ANALYSIS results indicate a change is needed. An air space is designed into the hydraulic oil reservoir and allows for oil expansion. Do NOT add a vent hole to the hydraulic oil reservoir. Use the equipment from. 4-24 FILL CAP SIGHT GAUGE RESERVOIR FIGURE 4-13. The hydraulic oil reservoir WILL have a low pressure in it at system operating temperatures. CHECK the hydraulic reservoir oil level. The NEW hydraulic oil MUST be filtered through TEN [10] micron filtration BEFORE it enters the hydraulic oil reservoir. and follow the directions given by. at warm temperatures. the oil analysis service. using the sight gauge on the reservoir.000 hours of machine operation. ALWAYS loosen the filler cap SLOWLY to relieve any pressure in the hydraulic oil reservoir. Check the oil level when the hydraulic oil is at “NORMAL” operating temperature ONLY. The oil must NOT have more than 400 particles larger than 10 u. h. and then remove. until it is at a WARM temperature ONLY. which has been altered by cutting the funnel to fit under the drain plug. STOP the engine. found in the hydraulic reservoir. HOT hydraulic oil can cause serious injury. Add oil if needed. CAUTION: Do NOT use unfiltered hydraulic oil. CAUTION: Hydraulic oil which has oxidized or which contains contamination. CAUTION: Do NOT fill the hydraulic oil reservoir with NEW hydraulic oil UNTIL the filter element. or ALL. f. Loosen the hydraulic oil drain plug. SLOWLY loosen. hydraulic PRESSURE oil filter elements at THIS time. See THIS section for CORRECT type of oil. lint free cloth over the reservoir fill tube opening and secure in place with tape. See THIS section for service procedures. of the components in the hydraulic system. have been serviced.of THIS manual. Also. Fill the hydraulic oil reservoir with the CORRECT. g. Install the vibrator control valve access panel onto the machine and tighten the retaining capscrews securely. The oil MUST NOT have MORE than 400 particles larger than 10 u. CLEAN the TWO [2] hydraulic suction oil screens and the ONE [1] return oil diffuser. NOTE: Also. can shorten the expected service life of ANY. Fill the hydraulic oil reservoir UNTIL the oil level is in the CENTER of the sight gauge glass. e. The NEW hydraulic oil MUST be filtered through TEN [10] micron filtration BEFORE it enters the hydraulic oil reservoir. the hydraulic oil reservoir filler cap. Put a CLEAN. b. Install the hydraulic oil reservoir drain plug and tighten securely.Section 4 MAINTENANCE Changing the hydraulic oil removes the accumulation of dirt. c. Put one end of a hose onto the funnel and put the other end of the hose into an empty container having a capacity of approximately 25 gallons [95 liters]. of ANY type. Install the hydraulic oil reservoir filler cap onto the reservoir filler neck and tighten securely. under the drain plug.OPERATION . Carefully remove the reservoir drain plug. on these items. WARNING: Do NOT drain the hydraulic oil from the reservoir when it is HOT. and the TRANSMISSION system. d. CHANGE the VIBRATION systems. The chemical structure of the hydraulic oil also changes after continuous use in the system and NEW. Check the oil level in the hydraulic oil reservoir. Allow ALL of the hydraulic oil to drain from the reservoir and into the container. FILTERED hydraulic oil using the procedures given in the following “CAUTION” information. CHECK the hydraulic system for ANY leaks. CLEAN and FILTERED oil is a MUST to help insure further CORRECT operation of the hydraulic system. Use the following procedures to change the hydraulic oil: a. Drain at a WARM temperature ONLY. Place a funnel. again. Allow the hydraulic oil to cool. Start the engine using the CORRECT procedures given in Section 3 . CAREFULLY remove the cloth from the hydraulic oil reservoir fill tube opening. i. Do NOT overfill the hydraulic oil reservoir with oil. water and mechanical wear particles from the hydraulic oil reservoir and system. 8/02 4-25 . per milliliter of oil as installed. and screens in the ABOVE “NOTE”. the filter element ONLY when the engine is in an “STOPPED” and the hydraulic oil has cooled to a WARM. WARNING: Do NOT loosen. 8/02 . BEFORE the NEW filter element is Installed. or COLD. HYDRAULIC OIL RESERVOIR DRAINING LOCATION. or COOL. VIBRATION SYSTEMS PRESSURE OIL FILTER ELEMENT . Protect the eyes by wearing safety glasses. the filter condition indicator WHITE sliding bar will show a HIGHER amount of filter element restriction.Section 4 MAINTENANCE WARNING: Do NOT use the hands on ANY hydraulic hose. CAUTION: STOP the engine IMMEDIATELY if ANY hydraulic leak is noted. when the condition of the filter element is checked. and remove. NOTE: When the hydraulic oil is in a COLD condition and at machine “START UP”. SERIOUS injury can result from an oil leak under high pressure. or remove. found on the dash of the machine. or when the hydraulic oil is HOT. Discard the removed filter element.. CAUTION: The hydraulic system MUST be at NORMAL operating temperature. temperature. Wipe the hydraulic oil filter head and element using a CLEAN lint free cloth. an element CHANGE is indicated to be needed. found on the filter head. Do NOT start the engine UNTIL any problem noted has been corrected. and when the filter condition indicator WHITE sliding bar is in the RED zone. CHECK the condition of the vibration systems pressure oil filter element EACH day. Oil can be injected under the skin by high pressure. Allow the hydraulic oil to reach a WARM. 4-26 CAUTION: Be sure that the old filter element rubber gasket is removed and discarded. Remove the access panel retaining capscrews and panel.REMOVAL AND REPLACEMENT [See Figure 4-15]. Loosen. the hydraulic oil filter element when the engine is running. FIGURE 4-14. Use the following procedure to remove and replace the hydraulic oil filter element: a. STOP the engine. indicate an element change is needed. b. c. The filter element MUST be changed when the condition indicator light. temperature. and the change indicator. The filter element MUST also be changed with EACH COMPLETE hydraulic oil change. Use a oil filter removal wrench to loosen and remove the filter element. With the engine at “HIGH” idle. with the engine “running”. fitting or system component to check the system for possible leaks. The position has NO effect on filtration. Wipe the hydraulic oil filter head and element using a CLEAN lint free cloth. Start the engine using the CORRECT procedures given in Section 3 . Allow the hydraulic oil to reach a WARM. Fill the reservoir using ALL of the procedures given in THIS section. CAREFULLY install the NEW filter element onto the filter head. or remove.OPERATION . g. WARNING: Do NOT loosen. h. NOTE: The filter head. TRANSMISSION SYSTEM PRESSURE OIL FILTER ELEMENT .of THIS manual. the retaining capscrews securely. Use the following procedure to remove and replace the oil filter element: a. horizontal. the filter element ONLY when the engine is in an “STOPPED” and the hydraulic oil has cooled to a WARM. using the procedures given in THIS section. FIGURE 4-15. fitting or system component to check the system for possible leaks. SERIOUS injury can occur from an oil leak under high pressure. The transmission system pressure oil filter element MUST be changed when the hydraulic oil is changed. VIBRATION SYSTEMS PRESSURE OIL FILTER ELEMENT LOCATION. Loosen. or COOL. CHECK the hydraulic system for ANY oil leaks. or angled position. Do NOT start the engine UNTIL any problem noted has been corrected.REMOVAL AND REPLACEMENT [See Figure 4-16].Section 4 MAINTENANCE d. and element. CAUTION: Do NOT overtighten the NEW filter element. b. temperature. may be found mounted in the vertical. Tighten by the hand ONLY. f. CAUTION: Do NOT start the engine BEFORE filling the hydraulic oil reservoir with oil. Tighten the NEW filter element onto the filter head ONLY UNTIL the rubber gasket contacts the filter head seal area. the hydraulic oil filter element when the engine is running. Remove the access panel retaining capscrews and panel. 8/02 4-27 . Fill the hydraulic oil reservoir with oil. At this time. Damage to the hydraulic system components can occur. CAUTION: STOP the engine IMMEDIATELY if ANY hydraulic oil leak is noted. Use ALL of the CORRECT procedures given in THIS section. Tighten the NEW filter element ONE HALF [1/2] additional turn AFTER the rubber gasket contacts the filter head area. temperature. and remove. STOP the engine. Install the access panel onto the machine and install. Protect the eyes by wearing safety glasses. Put CLEAN hydraulic oil on the NEW filter element rubber gasket. clean the two [2] hydraulic oil suction strainers and the one [1] return oil diffuser. or when the hydraulic oil is HOT. or COLD. Oil can be injected under the skin by high pressure. WARNING: Do NOT use the hands on ANY hydraulic hose. e. and then tighten. OPERATION . Fill the reservoir using ALL of the procedures given in THIS section. Tighten the NEW filter element ONE HALF [1/2] additional turn AFTER the rubber gasket contacts the filter head area. Install the access panel onto the machine and install.REMOVAL. Discard the removed filter element. f. HYDRAULIC SUCTION OIL STRAINERS AND RETURN OIL DIFFUSER . 4-28 FIGURE 4-16. Loosen. and then tighten. g. or remove. WARNING: Do NOT use the hands on ANY hydraulic hose. Oil can be injected under the skin by high pressure. clean and reinstall the TWO [2] hydraulic suction oil strainers and the ONE [1] hydraulic return oil diffuser with EACH complete hydraulic oil change. the retaining capscrews securely. CAUTION: STOP the engine IMMEDIATELY if ANY hydraulic oil leak is noted. CHECK the hydraulic system for ANY oil leaks. Start the engine using the CORRECT procedures given in Section 3 . or remove. Use a oil filter removal wrench to loosen and remove the filter element. d. 8/02 . Put CLEAN hydraulic oil on the NEW filter element rubber gasket. when the engine is running or when the hydraulic oil reservoir is “full” of oil. or the return oil diffuser. Remove. e. Tighten the NEW filter element onto the filter head ONLY UNTIL the rubber gasket contacts the filter head seal area. clean and install the above items: WARNING: Do NOT loosen. CLEANING AND INSTALLATION [See Figure 4-17]. fitting or system component to check the system for possible leaks. BEFORE the NEW filter element is Installed. Tighten by the hand ONLY. using the procedures given in THIS section. Use ALL of the CORRECT procedures given in THIS section. CAREFULLY install the NEW filter element onto the filter head. Use the following procedures to remove.of THIS manual. At this time. the hydraulic suction oil strainers or the hydraulic return oil diffuser. Damage to the hydraulic system components can occur. SERIOUS injury can occur from an oil leak under high pressure. Protect the eyes by wearing safety glasses. SERIOUS injury can occur from contact with HOT hydraulic oil.Section 4 MAINTENANCE c. Fill the hydraulic oil reservoir with oil. CAUTION: Be sure that the old filter element rubber gasket is removed and discarded. CAUTION: Do NOT overtighten the NEW filter element. the hydraulic suction oil strainers. Do NOT start the engine UNTIL any problem noted has been corrected. clean the two [2] hydraulic oil suction strainers and the one [1] return oil diffuser. ONLY when the engine is STOPPED and AFTER the hydraulic oil has cooled and has been DRAINED from the hydraulic oil reservoir [see THIS section]. CAUTION: Do NOT start the engine BEFORE filling the hydraulic oil reservoir with oil. TRANSMISSION SYSTEM PRESSURE OIL FILTER ELEMENT LOCATION. h. WARNING: Do NOT use the hands on ANY hydraulic hose. STOP the engine. Part Number 178297. j. Allow the hydraulic oil to reach a WARM. CAUTION: STOP the engine IMMEDIATELY if ANY hydraulic oil leak is noted. Remove the TWO [2] hydraulic suction oil strainers from the hydraulic oil reservoir. h. and allow it to AIR dry ONLY. Do NOT start the engine UNTIL any problem noted has been corrected. using All-Purpose Degreaser. fitting or system component to check the system for possible leaks. f. or COOL. CAREFULLY install the hydraulic return oil diffuser into the hydraulic oil reservoir boss and tighten securely. Protect the eyes by wearing safety glasses. CAUTION: Complete ALL hydraulic oil reservoir filling procedures. Start the engine using the CORRECT procedures given in Section 3 .of THIS manual. using All-Purpose Degreaser. CLEAN ALL the hoses. IMMEDIATELY put a plug into EACH strainer fitting and a cap on EACH hose. or diffuser. i. c. after cleaning. in the reservoir. CAREFULLY wash each suction oil strainer and/or the return oil diffuser. installed on EACH hose and fitting BEFORE removal. Put a CLEAN paper cover over each threaded strainer boss. 4-29 . Remove the suction hoses from the fittings installed into the hydraulic suction oil strainers. mesh area if dried using compressed air. e. BEFORE starting the engine. Damage can occur to the strainer. temperature. Put one [1] o-ring onto the threaded area of each suction oil strainer and onto the threaded area of the return oil diffuser. as a reference for CORRECT connections. CAUTION: Do NOT lose. and secure with tape. given in THIS section. in the reservoir. Oil can be injected under the skin by high pressure. CAUTION: Do NOT use compressed air to dry the strainer and/or diffuser. Put a CLEAN paper cover over the threaded diffuser boss. 8/02 g. CAREFULLY install each suction oil strainer into the oil reservoir boss and tighten securely. Remove the paper covers from the threaded hydraulic suction oil strainer bosses and the return oil diffuser boss.Section 4 MAINTENANCE a. CAREFULLY inspect each o-ring for damage and replace with NEW. NOTE: Use the identification tags. in the reservoir. or damage. Loosen and remove the one [1] return oil diffuser from the hydraulic oil reservoir. Put an identification tag onto EACH suction hose. d. SERIOUS injury can occur from an oil leak under high pressure. Part Number 178297. is removed from the reservoir. the o-ring when each strainer and/or the diffuser.OPERATION . CHECK the hydraulic system for ANY oil leaks. and secure with tape. b. fittings and the area of the hydraulic oil reservoir where the hydraulic return oil diffuser is installed. Drain the hydraulic oil using the procedures given in THIS section. if needed. through the FILLER hose on the drum. AGAIN. or daily. 4-30 3. to a point where the FILLER hose bulkhead fitting and LARGE cap fitting are in a position ABOVE the center line of the drum rotation [approximately a 2 o’clock or a 11 o’clock positions]. using the procedures given in step “a”. Check the drum bearing lubrication oil level of the SECOND drum. HYDRAULIC SUCTION STRAINERS OIL AND RETURN OIL DIFFUSER INSTALLATION LOCATIONS. on the drum being checked. FIGURE 4-17.Section 4 MAINTENANCE DIFFUSER Use the following procedures to ADD lubrication oil to either drum: STRAINERS 1. SLOWLY move the machine and rotate the drum. using the SAME procedures. Allow enough time for the drum bearing lubrication oil to “level” in the sight gauge glass and indicate the true oil level. and to add lubrication oil if needed: a. Do NOT add more oil immediately if the lubrication oil level appears to be below the sight gauge glass. again. DRUM BEARING LUBRICATION CHECKING THE DRUM BEARING LUBRICATION OIL LEVEL [See Figure 4-18]. Put the machine on a LEVEL surface. Do NOT overfill the drum with lubrication oil. 2. c. Check the drum bearing lubrication oil level of EACH drum. is at the exact BOTTOM of the rotation of the drum. and in a position. 4. Install the LARGE [FILL] cap fitting onto the filler hose bulkhead fitting and tighten securely. so the RED drum position Iocater BAR. b. CAUTION: If the lubrication oil level is BELOW the sight gauge glass. CAUTION: If the oil level is NOT correct. 8/02 . Wipe the LARGE cap and the bulkhead fitting of the filler hose with a CLEAN cloth. Add lubrication oil if needed. lubrication oil to the drum. Use the following procedures to check drum bearing lubrication oil level. one [1 ] time for each eight [8] hours of machine operation. Add the oil to the drum SLOWLY. through twenty five [25] micron filtration BEFORE it enters the drum. SLOWLY add CLEAN and FILTERED Texaco Meropa 150. ADD only enough oil to show the CORRECT oil level in the CENTER of the sight gauge glass. CAUTION: Clean the oil. Add ONLY enough oil to bring the drum oil level to the CENTER of the sight gauge glass. ADD additional oil using steps “1-4” and then check the oil level. Move the machine to the SAME position as in step “a” and CHECK the oil level. being added to the drum. Remove the LARGE [FILL] cap fitting from the filler hose bulkhead fitting. or equivalent. lubrication oil. CAUTION: Clean the oil. using the SAME procedures given ABOVE. using the procedures given in this section. Do NOT overfill the drum with lubrication oil. Use the following procedures to change the drum bearing lubrication oil in BOTH drums: a. Rotate the drum until the LARGE [FILL] cap fitting is positioned at the HIGHEST [TOP] point of the rotation of the drum. Remove the LARGE [FILL] cap fitting from the filler hose bulkhead fitting. or equivalent. Install the LARGE [FILL] cap fitting onto the filler hose bulkhead fitting and tighten securely. through twenty five [25] micron filtration BEFORE it enters the drum. Wait two [2] minutes and then check the lubrication oil level shown in the sight gauge glass. f. d. Wipe the area around the LARGE [FILL] cap fitting with a CLEAN cloth. Run the machine long enough to insure that the drum bearing lubrication oil is completely at a WARM temperature. Fill with oil SLOWLY. having the lubrication oil changed first. using TEN [10] gallon [37. Change the drum bearing lubrication oil. 8/02 FIGURE 4-18. one [1] time for each 2. POSITION LOCATOR BAR FILL-DRAIN c. i.Section 4 MAINTENANCE CHANGING THE DRUM BEARING LUBRICATION OIL [See Figure 4-18 or 4-18A]. Fill the drum with ONLY enough oil to bring the oil level to the CENTER of the sight gauge glass. e. Check the SECOND drum bearing lubrication oil level. Change the drum bearing lubrication oil in the SECOND drum. CHANGING THE DRUM BEARING LUBRICATION OIL . Drain the drum bearing lubrication oil from the drum.9 liters] of CLEAN and FILTERED Texaco Meropa 150. The lubrication oil level MUST be in the CENTER of the sight gauge glass to be at the CORRECT level. 4-31 . h. entering the drum. b. DRUM LUBRICATION OIL FILL AND SIGHT GAUGE LOCATIONS. SIGHT GAUGE g. or every TWO [2] years. in EACH drum. Check the drum bearing lubrication oil level. using the procedures given in this section.000 hours of machine operation. SLOWLY fill the drum through the LARGE [FILL] hose bulkhead fitting.C766C machines below serial number 109C20902455 and on C778B machines below serial number 109B21501856 [See Figure 4-18]. until the LARGE [FILL] cap fitting is positioned at the LOWEST [BOTTOM] point of the rotation of the drum. Rotate the drum. Run the machine long enough to ensure that the drum bearing lubrication oil is completely at a WARM temperature. or every TWO [2] years. FIGURE 4-18A. is at the HIGHEST [TOP] point of the rotation of the drum. Remove the [FILL] cap fitting and SLOWLY fill the drum through the [FILL] hose bulkhead fitting.000 hours of machine operation. DRUM LUBRICATION OIL DRAIN. in EACH drum. Change the drum bearing lubrication oil. using TEN [10] gallons [37. Rotate the drum having the lubrication oil changed first. d. until the [DRAIN] cap fitting is positioned at the LOWEST [BOTTOM] point of the rotation of the drum. f. c.Section 4 MAINTENANCE CHANGING THE DRUM BEARING LUBRICATION OIL . Rotate the drum until the [FILL] cap fitting directly opposite the position location block. Use the following procedures to change the drum bearing lubrication oil in BOTH drums: a. FILL AND SIGHT GAUGE LOCATIONS. Wipe the area around the LARGE [FILL] cap fitting with a CLEAN cloth. one [1] time for each 2. Drain the drum bearing lubrication oil from the drum. 4-32 8/02 .9 liters] of CLEAN and FILTERED Texaco Meropa 150. or equivalent.C766C machines serial number 109C20902455 and higher and on C778B machines serial number 109B21501856 and higher [See Figure 4-18A]. b. e. Remove the [DRAIN] cap fitting from the drain hose bulkhead fitting. Wipe the area around the [DRAIN] cap fitting with a CLEAN cloth. lubrication oil. NOTE: The fill hose can be opened during the drain process to assist as a vent. Install the [DRAIN] cap fitting onto the drain hose bulkhead fitting and tighten securely. Check the belt for intersecting cracks. Inspect the drive belt one [1] time for each 1000 hours of machine operation. or struck. 4-33 . ALTERNATOR AND FAN DRIVE BELT LOCATION. belt or other moving engine parts. j. check the belt tension mechanism and fan hub bearings. CHECKING THE CHARGE CONDITION OF THE BATTERY AND SERVICING OF RELATED ITEMS [See Figure 4-20]. Check the drum bearing lubrication oil level. or every two [2] weeks. terminals and related accessories contain lead and lead compounds. Use the built in battery “charge level” indicator. is noted. ELECTRICAL SYSTEM. Battery posts. Do NOT overfill the drum with lubrication oil. Fill the drum with ONLY enough oil to bring the oil level to the CENTER of the sight gauge glass. Also. Serious injury can result from being caught. STOP the engine. CAUTION: Clean the oil. after inspection. h. The lubrication oil level MUST be in the CENTER of the sight gauge glass to be at the CORRECT level. Use the following information to inspect and/or inspect and replace the drive belt: a. also.Section 4 MAINTENANCE g. Install the [FILL] cap fitting onto the filler hose bulkhead fitting and tighten securely. entering the drum. found in the top of the battery. Wash hands after handling. at this time. if any intersecting cracks. published by Cummins Diesel Engine Company and supplied with the machine for procedures. Longitudinal [direction of belt length] cracks that intersect with transverse cracks are NOT acceptable. or yearly. 8/02 FIGURE 4-19. through twenty five [25] micron filtration BEFORE it enters the drum.B SERIES DIESEL ENGINE”. to check the charge level in the battery one [1 ] time for each 100 hours of machine operation. WRENCH TENSIONER i. using the procedures given in this section. Replace the belt as needed. using the procedures given in this section. Change the drum bearing lubrication oil in the SECOND drum. b. The engine MUST be STOPPED BEFORE inspecting the drive belt. Replace the belt. ALTERNATOR BELT ALTERNATOR AND FAN DRIVE BELT INSPECTION AND REPLACEMENT PROCEDURES [See Figure 4-19]. by the fan. Check the SECOND drum bearing lubrication oil level. Fill with oil SLOWLY. WARNING: Do NOT inspect the engine drive belt when the engine is “running”. Wait two [2] minutes and then check the lubrication oil level shown in the sight gauge glass. with NEW. Visually inspect the drive belt for intersecting cracks on the INNER surface of the belt plies. see the current “OPERATION AND MAINTENANCE MANUAL . or other damage. fraying. NOTE: If the belt requires replacement with new. using the SAME procedures given ABOVE. WARNING: CALIFORNIA Proposition 65. The belt is kept under constant tension by an automatic tension mechanism and "adjustment" is NOT required as part of the maintenance procedures. using the procedures given in the same publication. The battery is of the “maintenance-free” type and minimal service is needed. ALWAYS disconnect BOTH the positive [+] AND the negative [-] battery cables from a battery. use water to flush the area and make the acid neutral using a water and soda solution. due to wear or damage. BEFORE cleaning the terminals. Do NOT place ANY tools on a battery. WARNING: BATTERY EXPLOSION CAN OCCUR IF A BATTERY IS SHORTED. as needed. If electrolyte is spilled. Do NOT check with flame. cracks. and then connect the NEGATIVE [-] battery cable to the NEGATIVE [-] battery terminal LAST. dirt or grease. During engine and/or other system maintenance inspections. CHECK the electrical wiring for correct routing and support. If. ALWAYS disconnect the NEGATIVE [-] battery cable FIRST. at ANY time. NEVER make a shorted circuit between the positive [+] terminal and negative [-] terminal of the battery. The battery MUST be kept from ANY movement in the machine. 4-34 FIGURE 4-20. The acid in electrolyte can cause injury. Do NOT place ANY tools on a battery. 8/02 . Inspect the wires for loose terminal connections. at ANY time. Do NOT cause sparks. ALWAYS connect the POSITIVE [+] battery cable to the POSITIVE battery terminal FIRST.Section 4 MAINTENANCE WARNING: Do NOT attempt to open the “MAINTENANCE-FREE” battery case. WARNING: BATTERY EXPLOSION CAN OCCUR IF THE BATTERY IS SHORTED. the wire being replaced. in the wiring insulation and for corrosion. baking soda and clear water to clean the battery terminals and cables. CAUTION: Do NOT use a wire smaller than the size of the original factory installed wires in the electrical system. ELECTRICAL WIRING INSPECTION. Acid in the eyes MUST be FLUSHED with water IMMEDIATELY. BATTERY MAINTENANCE AREA LOCATIONS. use wire EQUAL to. ALL batteries produce an EXPLOSIVE GAS. or wear. Use a battery cable cleaning brush. The indicator will indicate a “GREEN” color for a FULLY charged battery. Wires and connections MUST be free of oil. Check and tighten the battery hold down assembly. BEFORE ANY repair procedures are done to the electrical wiring or components. A “BLACK” indicator color indicates the battery is in a LOW charged condition. or cables. or larger in size than. NEVER make a shorted circuit between the positive [+] terminal and the negative [-] terminal of a battery. wires are replaced with new. Do NOT smoke near a battery. and then disconnect the POSITIVE [+] battery cable. When adding air to the tires. [2 bar]. CAUTION: Replace ANY tire showing evidence of damage IMMEDIATELY. AFTER checking and/or adjusting each vibration isolator tire inflation pressure. and a gauge or preset pressure regulator. 8/02 FIGURE 4-21. repair. or replace the tire[s]. The pressure indicated. cause tire breaks in the tire body cords and cause the tire to slip inside the tire retainer hoop assemblies. CAUTION: Check the tire air pressure ONLY when the vibration isolator tires are in a COOL condition. This can build excess heat. Adjust the air pressure in EACH isolator tire. INSPECTION. The vibration isolator tires will NOT absorb enough vibrations from the machine’s drums and the vibrations will transfer into the machine frames. UNTIL the pressure is CORRECT. on the tire pressure gauge. AIR PRESSURE CHECK AND ADJUSTMENT [See Figure 4-21]. VIBRATION ISOLATOR TIRE PRESSURE CHECK AND FILL LOCATION. ALWAYS install tire valve cap. ALL personnel MUST keep CLEAR of the tire and rim. Check the air pressure of EACH tire. onto the tire valve stem. using the following procedures: a. Do NOT over inflate the vibration isolator tires. VALVE STEM CHECK-FILL Check EACH vibration isolator tire for CORRECT air pressure ONE [1] time EACH week. MUST be 30 psi.Section 4 MAINTENANCE VIBRATION ISOLATOR TIRES. or other serious damage at THIS time. Remove the tire valve cap from the tire inflation valve. and adjust as needed. Use the procedures given in THIS section to remove. The vibration isolator tires will be too soft and over deflect. Inspect EACH tire for cracks. WARNING: ALWAYS use remote inflation equipment consisting of an extension hose. with the clip-on filling chuck. breaks. Do NOT under inflate the vibration isolator tires. 4-35 . using an accurate tire gauge. Check the inflation of EACH tire. h. AND INSTALLATION OF THE VIBRATION ISOLATOR TIRE AND RIM ASSEMBLIES . Remove the capscrews that fasten the outer cleaner beam and rubber cleaner assembly to the machine. g.C766C machines below serial number 109C20902455 and on C778B machines below serial number 109B21501856 [See Figure 4-22]. e. or solid support items. having a capacity more than 1. Remove the drum cleaner bar. REPAIR OR REPLACEMENT. or replace. IMMEDIATELY. REPAIR OR REPLACEMENT. ANY vibration isolator tire found to show evidence of an air leak. APPLY the secondary/parking brake system and STOP the engine. [681 kg] to the water tank frame. Drain the water tank. REMOVAL. Remove the cleaner assembly from the machine. Place the machine on a level surface. Put wood blocks in front. a. using the following procedures: WARNING: Keep CLEAR of the frame while being lifted and lowered onto the blocks. Remove the tank and frame assembly from the machine and place on the ground. 4-36 CAUTION: Do NOT damage the hoses when moving the vibrator motor. found at the front of the drum being removed. Drain the water tank and disconnect the water sprinkler bar supply hose on the drum being serviced. Remove each of the hoses from the fittings on the motor. or jack stands. WARNING: Keep clear of the water tank and frame assembly while lifting. Loosen and remove the two [2] capscrews and hardened discs which secure the vibrator drive motor. Remove the capscrews that fasten the tank and frame to the frame of the machine. Put wood blocks. Put an identification tag on each hose which fastens to the drum drive motor. Carefully remove the vibrator drive motor assembly.Section 4 MAINTENANCE REMOVAL. Raise the hydraulic jack ONLY until the jack lifting plate JUST starts to lift frame weight. or other serious damage. CAUTION: Do NOT place the wood blocks. REMOVAL [See Figure 4-22].500 lbs. c. of the drum NOT being serviced. Put a hydraulic jack. Lift the OPPOSITE frame side and put wood blocks under the frame side using the SAME procedures given in this step. so that the drum will touch the blocks as the drum is rolled forward and from between the frame sides. Carefully remove the eight [8] nuts from the capscrews which fasten the drum isolator assemblies the drum drive motor to the sides of the frame. of water. 8/02 . The vibrator drive motor assembly will have a three [3] pin hub assembly attached to it by two [2] allen setscrews and a capscrew and washer at the motor output shaft. Put a plug in each hose and a cap on each motor fitting. Put a plug in each hose and a cap on each motor fitting. Fasten a sling and a hoist. under the side of the frame. Remove each of the hoses from the fittings on the motor. under EACH frame side. Put an identification tag on each hose fastened to the vibrator motor. Lower the frame onto the support item and remove the hydraulic jack. b. and at the rear. Remove. AND INSTALLATION OF THE VIBRATION ISOLATOR TIRE AND RIM ASSEMBLIES [See Figure 4-22 or 4-22A]. Carefully remove the eight [8] capscrews from each side of the frame. Disconnect the electrical connection to the water spray pump. Raise each hydraulic jack ONLY until the jack lifting plate JUST starts to lift frame weight. removing and lowering the tank assembly. d. repair. having a capacity MORE than 5 tons [4 t]. f. Put one [1] hydraulic floor jack. Block securely using solid wood blocks. under either side of the frame outside the drum being removed for vibration isolator tire removal and repair or replacement. having a capacity more than ten [5] tons [4t]. SECTIONED VIEW. DRUM. VIBRATION ISOLATOR TIRE AND RIM . SHAFT BEARING CARRIER ASS'Y SPACER CAP TORQUE TO 78 FT/LBS ISOLATION TIRE ASSEMBLY AXLE FAN CAPSCREWS COUPLING SPRING WEIGHT FITTING TORQUE TO 115 FT/LBS TORQUE TO 500 FT/LBS DRAIN FILL HOSE TORQUE TO 55 FT/LBS WASHERS VIEW GAUGE PLUG PLATE FLANGE SCREW FLANGE SCREWS DRUM VIBRATOR MOTOR SIDE DRUM MOUNTING SPACER CAP SCREWS FILL VALVE BEARING SNAP RING BEARING SUPPORT HOUSING BEARING SUPPORT HOUSING CL VIBRATION MOTOR MOUNTING PLATE TORQUE TO 44 FT/LBS CAPS SCREWS TORQUE TO 280 FT/LBS RIM ASSEMBLY TORQUE TO 375 FT/LBS CAPS SCREWS TORQUE TO 125 FT/LBS FIGURE 4-22.Section 4 MAINTENANCE HALF HOOP TORQUE TO 40 FT/LBS ADAPTER COUPLING DRUM DRIVE SIDE RIM ASSEMBLY DRIVE MOTOR FRAME FILL VALVE CAP ISOLATOR TIRE ASSEMBLY HALF HOOP TORQUE TO 125 FT/LBS TORQUE TO 500 FT/LBS DRUM CAPSCREWS CAP SCREW TORQUE TO 400 FT/LBS (LUG NUTS) FLANGE SCREW LOCKNUT COVER BEARING CARRIER FLANGE SCREW TORQUE TO 44 FT/ LBS TORQUE TO 44 FT/LBS TORQUE TO 105 FT/LBS PIN BEARING CONTROL PL. FRAME. 4-37 8/02 . Use a wrench. j. having a capacity more than 1. to the complete vibration isolator assembly which is being removed. 8/02 . a SMALL amount. k. WARNING: Keep CLEAR of the drum to frame areas while rolling the drum toward the open end of the machine. having a capacity MORE than 300 ft. [407 N. from the bolts. and at the rear. from the bolts which fasten the upper and lower half hoop assemblies together around the tire and rim. [454 kg]. Fasten the tire and rim assembly securely to the tire repair machine. Remove the valve cap from the vibration isolator tire filling valve stem. rim and hoop assemblies and the drum drive motor. or motor. WARNING: Keep CLEAR of the air path as the air is released from the tire assembly. [136 kg]. NOTE: With the drum removed from the machine. l. REPAIR OR REPLACEMENT AND INSTALLATION ONTO THE RIM [See Figure 4-22]. to remove the capscrews which fasten the tire rim to the flange of the vibrator bell housing. CAREFULLY move the assembly away from the drum and place the assembly on the ground. TIRE REMOVAL. which fasten the upper half hoop to the drum isolator mounting bracket or drum drive motor to frame mounting bracket. if inflated. CAREFULLY remove the valve core from the tire filling valve stem and exhaust ALL the air from the vibration isolator tire assembly. in order to repair or replace the tire. Fasten a sling and a hoist. WARNING: Keep CLEAR of the tire and rim assembly while being lifted and moved.000 lbs. by putting a wire through the center hole in the valve stem. Remove ALL slack in the sling but do NOT lift the vibration isolator assembly. with both vibration isolator tire. and while moving the vibration isolator assembly away from the drum and then lowering the assembly to the ground. NOTE: Check the valve stem to be sure the inside is NOT in a plugged condition. i.Section 4 MAINTENANCE NOTE: Removing the eight [8] capscrews from each side of the frame will permit the drum assembly. while lifting the assembly with the sling and hoist. SLOWLY move the tire rim and vibration isolator assembly outward and away from the flange. CAREFULLY lift and remove the UPPER half hoop assembly from the tire and set the half hoop on the ground. of the drum AFTER the drum is removed. to the tire and rim assembly. Put wood blocks in front. having a capacity more than 300 lbs. Fasten a sling and a hoist. Remove the six [6] nuts. n. CAREFULLY move and lower the tire and rim assembly onto a tire repair machine. Remove the four [4] nuts.m]. the drum drive motor and vibration isolator are removed as an assembly. at this time. WARNING: Keep CLEAR of the vibration isolator assembly while loosening the retaining capscrews which fasten the assembly to the drum. from the drum. m. so that the assembly will NOT move when the tubeless tire beads are “broken loose” from the rim bead seat area. to be removed from between the frame sides by rolling the assembly toward the open end of the machine. Ibs. a. 4-38 NOTE: On the drum drive side of the machine. CAREFULLY and SLOWLY roll the complete drum assembly toward the open end of the machine until the drum is fully away from the frame sides. remove the complete vibration isolator tire and hoop assembly being repaired. CAUTION: The isolator tires are of radial ply design. breaks or other damage. h. prime and finish paint the rim assembly BEFORE mounting the tire. using a sling and hoist. or other damage in the bead seat area. Tilt the tire a SMALL amount as the LOWER bead reaches the UPPER rim bead seat. SLOWLY lower the tire to the rim assembly. heat or braze the rim assembly. Repair the tire as needed using tire repair materials which repair the damaged area from the INSIDE of the tire. Use ONLY tire repair materials and procedures for radial type tires. e. “Break” the UPPER tire bead away from the rim using a “bead breaking” tool. to be considered an adequate and permanent repair. Replace the tire if ANY tire damage is found that is NOT able to be repaired using INSIDE tire carcass repair methods and materials. on BOTH the UPPER and LOWER bead seat areas. to lift and move the tire during removal and replacement onto the rim. or nonflammable tire mounting lubricant. The repair materials used MUST seal the INNER tire carcass and fill the tire injury. Move the bead spreader bar around the tire bead and remove the tire bead over and above the UPPER rim bead seat area. or replacement as needed. if the valve shows ANY damage. 4-39 . Pull back on the UPPER tire bead and use the tire bead installing tool to install the balance of the UPPER tire bead over the UPPER rim bead seat area. having a capacity more than 100 lbs. and as the LOWER tire bead is also partially caught on the UPPER rim bead seat. WARNING: Use a sling and a hoist. Fasten a tire bead expanding strap. CAREFULLY lift the tire away from the rim assembly for tire inspection. of the rim assembly. Inspect the tire from BOTH the OUTSIDE and the INSIDE of the tire for punctures. Use the tire bead installing tool to install the balance of the LOWER tire bead over the UPPER rim bead seat and lower the tire to the LOWER bead seat area of the rim assembly. Push the LOWER bead past the UPPER rim bead seat and continue to lower the tire downward. j. WARNING: Do NOT weld. repair. sand to new metal.Section 4 MAINTENANCE b. Wipe the inside of the tire with a clean cloth to remove any dirt. Carefully lift the tire above the rim assembly. c. AROUND the tire circumference at the CENTER of the tread area. a SMALL amount. Keep CLEAR of the “bead breaking tool” and the “bead spreader bar” while breaking and removing BOTH tire beads from the rim upper bead seat area. severe rusting. CAREFULLY lift the LOWER tire bead toward the UPPER rim bead seat area and put the bead spreader bar assembly between the LOWER tire bead and the UPPER rim bead seat area. g. as much as possible. Pull the tire back as far as possible as the LOWER bead reaches the LOWER bead seat area of the rim assembly. having a strap tightening mechanism. if damaged. Push the UPPER tire bead downward and over the UPPER bead seat area of the rim assembly. and on BOTH the UPPER and LOWER bead sealing areas of the tire. Move the tire UPPER bead over and above. Tighten the tire bead expanding strap to expand BOTH the UPPER and LOWER tire beads onto the UPPER and LOWER rim bead seat areas. Clean. [46 kg]. d. using the machine tire bead spreader bar. CAREFULLY lift the tire assembly. or moisture. Put the rim assembly on the tire machine and fasten securely in place. Carefully inspect the rim assembly for ANY cracks. Replace the rim assembly with NEW. 8/02 f. cuts. Install a new tire filling valve. of the rim assembly. at the SAME time. the UPPER rim bead seat area. Put water. i. Remove the tire bead expanding strap from the tire. with the tire air filling valve in the “DOWN” position. Put Loctite #242 on ALL capscrew threads. ALWAYS use remote inflation equipment consisting of an extension hose. m. can cause the tire/rim assembly to burst with a force sufficient to cause serious injury. Ibs. using the remote inflation equipment until BOTH the UPPER and LOWER tire beads “seat” to the UPPER and LOWER rim bead seat areas. INSTALLATION [See Figure 4-22]. WARNING: Keep CLEAR of the path of the air as the air is released from the tire. moved and placed into the hoop assembly. Install the six [6] capscrews through the holes in both the UPPER and LOWER half hoop assemblies. rim and isolator hoop assembly. Fasten a sling and a hoist. Stop application of the air pressure. and a gauge or preset pressure regulator. Place the LOWER half hoop assembly on the ground with the round hoop opening facing UPWARD. [136 kg]. Remove the tire and rim assembly from the tire machine. b. Excessive inflation pressure. WARNING: NEVER use a inflation pressure MORE than 65 psi. or fingers. using the remote inflation equipment. c. having a capacity more than 300 lbs. a. from the “UPPER” half hoop side. CAREFULLY lift the rim and tire assembly. where the half hoop assemblies meet the sidewall. [4] bar to seat the tire beads. can cause the tire/rim assembly to burst with a force sufficient to cause serious injury. 4-40 WARNING: Keep CLEAR of the tire and rim assembly while being lifted. ALL personnel MUST keep CLEAR of the tire and rim and remain BEHIND the protective barrier. or the UPPER. so that the tire air fill valve will be TOWARD the FRAME side when the vibration isolator tire and hoop assembly is installed onto the drum on EITHER side of the machine. Move the assembly to the LOWER half hoop assembly and SLOWLY lower the tire and rim assembly into the hoop assembly opening. when seating tire beads. near the UPPER. or LOWER. ALL personnel MUST keep CLEAR of the tire. with clip-on filling chuck. [4 bar]. d. hoop to tire areas. NOT to exceed 65 psi. ALWAYS use remote inflation equipment consisting of an extension hose. Put the UPPER half hoop assembly over the top of the tire and remove the sling and hoist. Permit ALL the air to be released from the tire. tire bead or bead seat areas at ANY time. Do NOT put the hands. when seating tire beads. WARNING: NEVER use a inflation pressure MORE than 65 psi. and a gauge or preset pressure regulator. Put the assembly in a “TIRE RESTRAINING” device that is behind a protective barrier. or LOWER. Excessive inflation pressure. Apply air pressure to the tire. Connect remote inflation equipment to the tire filling valve. Apply air pressure to the tire. to the tire and rim assembly. [4] bar to seat the tire beads. Put water on the area of the tire sidewall. with clip-on filling chuck. [170 N. CAUTION: Put the tire and rim into the hoop assembly. Install the six [6] nuts onto the 5/8 inch capscrews and tighten to a torque of 125 ft. I.m].Section 4 MAINTENANCE k. NOT to exceed 65 psi. Remove the clip-on tire filling chuck from the tire filling valve. 8/02 . Put the vibration isolator assembly in a “flat horizontal” position on the ground. Use a tire removal tool to EVENLY space the tire sidewall rubber around the FULL circumference of the hoop assemblies. [4 bar]. Install the eight [8] nuts and tighten to a torque of 375 ft. Fasten a sling and hoist. [2 bar]. NOTE: Check the tire inflation pressure. install the LOWER and UPPER hoop halves.Section 4 MAINTENANCE e. Put Loctite #242 on the threaded area of the eight [8] capscrews that fasten the vibration isolator UPPER and LOWER hoop mounting areas to the DRUM drive arms.m]. Push the assembly into the drum.m]. On the vibrator motor side of the drum. Install the valve core into the tire filling valve stem and tighten. and onto. Install and tighten the valve cap onto the tire filling valve. [509 N. NOTE: On the DRUM DRIVE MOTOR side of the drum. WARNING: Keep CLEAR of the vibration isolator assembly while lifting. 8/02 4-41 . f. Use a soap and water solution to check the tire and rim assembly for ANY air leaks at the tire bead to rim seat areas and around the tire filling valve. Align the through holes in the axle with the tapped holes in the drum. Install the eight [8] capscrews and tighten to a torque of 500 ft. install the eight [8] bolts which fasten the UPPER halfhoop to the drum isolator mounting spacers. CAUTION: On the DRUM DRIVE MOTOR side of the machine. Remove the remote inflation equipment from the tire filling valve. Put Loctite #242 on the threaded area of the bolts. CAREFULLY lift the assembly. and installing the assembly onto the bearing carrier. having a capacity more than 500 lbs. h. CAREFULLY lift the assembly and move it into position at the end of the vibrator side of the drum. CAUTION: Do NOT overtighten the valve core into the tire filling valve. Ibs. having a capacity more than 1.m]. [678 N. put Loctite #242 on the threaded area of the capscrews which fasten the rim to the wheel bearing carrier. Ibs. Remove the sling and the hoist. Install the lug nuts onto the studs and tighten to a torque of 400 ft. so the LARGEST flat area of the half hoops will be TOWARD the FRAME side when installed. Remove the clip-on tire filling chuck from the filling valve of the tire. [227 kg] to the COMPLETE vibration isolator assembly.m]. [542 N.000 lbs. or capscrews and Bellville washers. SLOWLY put the center hole in the rim assembly in position over. i. to the assembly made in step “h”. Connect remote inflation equipment to the tire filling valve. [380 N. WARNING: Keep CLEAR of the vibration isolator assembly while lifting. so that the LARGEST side of the hoops will be AWAY from the FRAME side when the vibration isolator assembly installed to the motor drum drive arms. [554 kg]. Fasten a sling and a hoist.m]. Put Loctite #242 onto the threaded area of the six [6] capscrews that fasten the axle to the drum. Install the six [6] retaining capscrews. [678 N. lbs. g. and installing the assembly onto the drum drive motor. WARNING: Keep CLEAR of the vibration isolator assembly and axle while lifting and installing the assembly into the drum. CAREFULLY put the vibration isolator assembly over the drum drive motor studs. Permit ALL of the air to be released from the tire. Fill the tire with air to a pressure of 30 psi. Put Loctite #242 on the threaded area of the drive motor studs. using an accurate tire pressure gauge. WARNING: Keep CLEAR of the path of the air as the air is released from the tire. On the VIBRATOR motor side of machine. and tighten to a torque of 500 ft. lbs. lbs. Install the capscrews and tighten to a torque of 280 ft. Remove the sling and the hoist. the flange of the wheel bearing carrier. [509 N. Install the hoses onto the vibrator motor fittings. Put wood blocks in front. Remove the cap from each vibrator motor fitting. p. the DRUM DRIVE motor carrier plate. NOTE: Use an alignment bar. Lift the opposite frame side and remove the support item using the SAME procedure.500 lbs [681 kg]. WARNING: Keep CLEAR of the drum to frame areas while rolling the drum into position between the frame sides. or large drift pin. until the drum is at the CORRECT position in relation to the frame sides. Install the eight [8] capscrews. Install the hoses onto the drum drive fittings. Install the drum cleaner beam and rubber assembly. Install the retaining capscrews and tighten securely. as indicated by the identification tags and tighten securely. having a capacity more than 1. Ibs. Check the transmission and the vibration systems for ANY hydraulic leaks and for correct system functions. as indicated by the identification tags and tighten securely. k. Ibs [380 N.OPERATION -in this manual. having a capacity more than 5 tons [4t] under either side of the frame.Section 4 MAINTENANCE j. Fasten a sling and hoist. m. I. Remove the cap from each drum drive motor fitting. to align the holes through the frame sides and drum isolator mounting bracket and drum drive motor carrier plate after the drum is rolled between the frame sides.m]. Put a hydraulic jack. to the water tank and frame assembly. at this time. WARNING: Keep clear of the water tank and frame assembly while lifting. CAREFULLY lift the frame and remove the support item which is under the frame. Tighten the capscrews to a torque of 375 ft. moving and lowering the tank assembly. of the drum when the drum is in the CORRECT position. Remove the plug from each hose that fastens to the vibrator motor fittings. n. CAREFULLY remove the wood blocks from in front.m]. STOP the engine IMMEDIATELY and correct ANY system problem noted before starting the engine again. Put Loctite #242 on the threaded area of ALL sixteen [16] retaining capscrews that fasten the frame side plate to the vibration isolator bracket and drum drive motor carrier plate. CAUTION: Do NOT operate the vibration system on a hard surface. 4-42 8/02 . Operate the system with the drums on a soft surface. CAREFULLY lift the tank and frame assembly and move it into position on the frame of the machine. WARNING: Keep CLEAR of the frame and drum while lifting the frame. CAREFULLY lower the machine to the ground. CAREFULLY and SLOWLY roll the complete drum assembly into the area between the frame sides. and at the rear. of the drum. through the frame side and through the drum isolator mounting bracket or drum drive motor carrier plate. and at the rear. removing the blocks and lowering the drum to the ground. and BOTH sides of the frame MUST be in alignment. used on EACH frame side. Install the beam retaining capscrews and tighten to a torque of 280 ft. such as loose dirt or old tires ONLY. CAUTION: The holes in the drum isolator mounting bracket. o. Remove the plug from each hose that fastens to the drum drive motor fittings. Connect the water spray pump electrical wire male and female plug connectors together. Start the engine using the CORRECT starting procedures given in Section 3 . 500 lbs. with both vibration isolator tire. of water. of the drum AFTER the drum is removed. Lift the OPPOSITE frame side and put wood blocks or jack stands under the frame side using the SAME procedures given in this step. and at the rear. AND INSTALLATION OF THE VIBRATION ISOLATOR TIRE AND RIM ASSEMBLIES . Raise the hydraulic jack ONLY until the jack lifting plate JUST starts to lift frame weight. Disconnect the electrical connection to the water spray pump. Remove the tank and frame assembly from the machine and place on the ground. APPLY the secondary/parking brake system and STOP the engine. WARNING: Keep CLEAR of the frame while being lifted and lowered onto the blocks. c. removing and lowering the tank assembly. CAUTION: Do NOT damage the hoses when moving the vibrator motor. Remove. Remove the drum cleaner bar. Carefully remove the eight [8] bolts [9] and tightening washers [10] which fasten the vibrator motor subassembly [11] to the opposite side of the frame. REMOVAL [See Figure 4-22A]. and the drum drive motor assembly . b. NOTE: With the drum removed from the machine. Put wood blocks. using the following procedures: CAUTION: Do NOT place the wood blocks. vibrator drive subassembly. WARNING: Keep clear of the water tank and frame assembly while lifting. NOTE: Removing the eight [8] bolts from each side of the frame will permit the drum assembly. Put a plug in each hose and a cap on each motor fitting. Drain the water tank. of the drum NOT being serviced. Place the machine on a level surface. or jack stands. having a capacity more than 1. IMMEDIATELY. so that the drum will touch the blocks as the drum is rolled forward and from between the frame sides. found at the front of the drum being removed. Fasten a sling and a hoist. or solid support items.Section 4 MAINTENANCE REMOVAL. Put a hydraulic jack. or other serious damage. having a capacity more than five [5] tons [4t]. rim and hoop assemblies. Put an identification tag on each hose fastened to the vibrator motor. d. under either side of the frame outside the drum being removed for vibration isolator tire removal and repair or replacement. Put wood blocks in front. a. repair. CAREFULLY and SLOWLY roll the complete drum assembly [4] toward the open end of the machine until the drum is fully away from the frame sides. Remove each of the hoses from the fittings on the motor. remove the complete vibration isolator tire and hoop assembly being repaired. WARNING: Keep CLEAR of the drum to frame areas while rolling the drum toward the open end of the machine. 4-43 . Put an identification tag on each hose that fastens to the drum drive motor. 8/02 e. under the side of the frame. Remove the capscrews that fasten the tank and frame to the frame of the machine. g. Carefully remove the eight [8] bolts [1] and tightening washers [2] which fasten the drum drive motor assembly [3] to the sides of the frame. or replace. and at the rear. Put a plug in each hose and a cap on each motor fitting. Lower the frame onto the support item and remove the hydraulic jack. REPAIR OR REPLACEMENT.C766C machines serial number 109C20902455 and higher and on C778B machines serial number 109B21501856 and higher [See Figure 4-22A]. from the drum. Drain the water tank and disconnect the water sprinkler bar supply hose on the drum being serviced. Put wood blocks in front. Block securely using solid wood blocks. to be removed from between the frame sides by rolling the assembly toward the open end of the machine. [861 kg] to the water tank frame. ANY vibration isolator tire found to show evidence of an air leak. f. Remove each of the hoses from the fittings on the motor. Section 4 MAINTENANCE FIGURE 4-22A. FRAME.EXPLODED VIEW. 4-44 8/02 . VIBRATION ISOLATOR TIRE AND RIM . DRUM. WARNING: Keep CLEAR of the air path as the air is released from the tire assembly. Remove the five [5] bolts [12] and tightening washers [13] which fasten the vibrator drive subassembly [11] to the isolator tire rim center [15]. WARNING: Keep CLEAR of the tire and rim assembly while being lifted and moved. to the tire rim center [15]. Use a wrench. CAREFULLY move the assembly away from the drum [4] and place the assembly on the ground. CAREFULLY lift the tire assembly. or the ten [10] nuts [14] which mount the drum drive motor to the opposite tire rim center [15]. by putting a wire through the center hole in the valve stem. a SMALL amount. Move the tire UPPER bead over and above. j. while lifting the assembly with the sling and hoist. WARNING: Keep CLEAR of the isolator subassembly while loosening the retaining capscrews which fasten the assembly to the drum. Fasten a sling and a hoist. “Break” the UPPER tire bead away from the rim using a “bead breaking” tool. [454 kg]. 4-45 . Remove ALL slack in the sling but do NOT lift the isolator subassembly. a SMALL amount. lbs. using the machine tire bead spreader bar. having a capacity MORE than 300 ft.m]. if inflated. SLOWLY move the isolator subassembly [7] outward and away from the flange. CAREFULLY move and lower the tire and rim assembly onto a tire repair machine. so that the assembly will NOT move when the tubeless tire beads are “broken loose” from the rim bead seat area.000 lbs. in order to repair or replace the tire. i. [407 N. at this time. having a capacity more than 1. Keep CLEAR of the “bead breaking tool” and the “bead spreader bar” while breaking and removing BOTH tire beads from the rim upper bead seat area. the UPPER rim bead seat area. WARNING: Use a sling and a hoist. to the complete isolator subassembly [7] that is being removed. l. 8/02 TIRE REMOVAL. having a capacity more than 300 lbs. [46 kg]. k. b. to lift and move the tire during removal and replacement onto the rim.Section 4 MAINTENANCE h. CAREFULLY remove the valve core from the tire filling valve stem and exhaust ALL the air from the isolator subassembly. REPAIR OR REPLACEMENT AND INSTALLATION ONTO THE RIM [See Figure 4-22A]. Remove the six [6] nuts [19]. [136 kg]. a. having a capacity more than 100 lbs. NOTE: Check the valve stem to be sure the inside is NOT in a plugged condition. from the bolts [16] which fasten the upper half hoop [17] and lower half hoop [18] assemblies together around the tire and rim. remove the bolts [5] and tightening washers [6] which fasten the isolator subassembly [7] to the flange of the vibratory drum [4]. at the SAME time. Fasten a sling and a hoist. and while moving the isolator subassembly away from the drum and then lowering the assembly to the ground. CAREFULLY lift and remove the upper half hoop assembly [17] from the tire and set the half hoop on the ground. Fasten the tire rim center [15] securely to the tire repair machine. Remove the valve cap from the isolator tire [8] filling valve stem. Replace the rim assembly with NEW. l. having a strap tightening mechanism. e. Tighten the tire bead expanding strap to expand BOTH the UPPER and LOWER tire beads onto the UPPER and LOWER rim bead seat areas. Connect remote inflation equipment to the tire filling valve. SLOWLY lower the tire to the rim assembly.Section 4 MAINTENANCE c. g. k. using a sling and hoist. as much as possible. CAREFULLY lift the tire above the rim assembly. Use the tire bead installing tool to install the balance of the LOWER tire bead over the UPPER rim bead seat and lower the tire to the LOWER bead seat area of the rim assembly. heat or braze the rim assembly. prime and finish paint the rim assembly BEFORE mounting the tire. CAREFULLY lift the LOWER tire bead toward the UPPER rim bead seat area and put the bead spreader bar assembly between the LOWER tire bead and the UPPER rim bead seat area. Install a new tire filling valve. Put the assembly in a “TIRE RESTRAINlNG” device that is behind a protective barrier. CAREFULLY lift the tire away from the rim assembly for tire inspection. Repair the tire as needed using tire repair materials which repair the damaged area from the INSIDE of the tire. Put the rim assembly on the tire machine and fasten securely in place. cuts. Apply air pressure to the tire. Tilt the tire a small amount as the LOWER bead reaches the UPPER rim bead seat. AROUND the tire circumference at the CENTER of the tread area. Use ONLY tire repair materials and procedures for radial type tires. or moisture. Push the LOWER bead past the UPPER rim bead seat and continue to lower the tire downward. on BOTH the UPPER and LOWER bead seat areas. sand to new metal. if the valve shows ANY damage. breaks or other damage. and on both the UPPER and LOWER bead sealing areas of the tire. Clean. Wipe the inside of the tire with a clean cloth to remove any dirt. NOT to exceed 65 psi. Remove the tire and rim assembly from the tire machine. and as the LOWER tire bead is also partially caught on the UPPER rim bead seat. repair. j. h. Fasten a tire bead expanding strap. Pull back on the UPPER tire bead and use the tire bead installing tool to install the balance of the UPPER tire bead over the UPPER rim bead seat area. The repair materials used MUST seal the INNER tire carcass and fill the tire injury. Inspect the tire from BOTH the OUTSIDE and the INSIDE of the tire for punctures. of the rim assembly. [4 bar]. Put water. severe rusting. Push the UPPER tire bead downward and over the UPPER bead seat area of the rim assembly. Replace the tire if ANY tire damage is found that is NOT able to be repaired using INSIDE tire carcass repair methods and materials. Carefully inspect the rim assembly for ANY cracks. of the rim assembly. to be considered an adequate and permanent repair. CAUTION: The isolator tires are of radial ply design. WARNING: Do NOT weld. Stop application of the air pressure. d. or replacement as needed. Pull the tire back as far as possible as the LOWER bead reaches the LOWER bead seat area of the rim assembly. i. using the remote inflation equipment until BOTH the UPPER and LOWER tire beads “seat” to the UPPER and LOWER rim bead seat areas. or other damage in the bead seat area. 4-46 8/02 . or nonflammable tire mounting lubricant. Move the bead spreader bar around the tire bead and remove the tire bead over and above the UPPER rim bead seat area. if damaged. f. Section 4 MAINTENANCE WARNING: NEVER use an inflation pressure MORE than 65 psi. [4 bar] to seat the tire beads. Excessive inflation pressure, when seating tire beads, can cause the tire/rim assembly to burst with a force sufficient to cause serious injury. ALWAYS use remote inflation equipment consisting of an extension hose, with clip-on filling chuck, and a gauge or preset pressure regulator. ALL personnel MUST keep CLEAR of the tire and rim and remain BEHIND the protective barrier. m. Remove the tire bead expanding strap from the tire. Remove the clip-on tire filling chuck from the tire filling valve. Permit ALL the air to be released from the tire. WARNING: Keep CLEAR of the path of the air as the air is released from the tire. INSTALLATION [See Figure 4-22A]. a. Place the LOWER half hoop assembly [18] on the ground with the round hoop opening facing UPWARD. Fasten a sling and a hoist, having a capacity more than 300 lbs. [136 kg], to the tire rim center [15]. CAREFULLY lift the rim and tire assembly. Move the assembly to the LOWER half hoop assembly and SLOWLY lower the tire and rim assembly into the hoop assembly opening. WARNING: Keep CLEAR of the tire and rim assembly while being lifted, moved and placed into the hoop assembly. 8/02 CAUTION: Put the tire and rim into the hoop assembly, so that the tire air fill valve will be TOWARD the FRAME side when the vibration isolator tire and hoop assembly is installed onto the drum on EITHER side of the machine. b. Put the UPPER half hoop assembly [17] over the top of the tire and remove the sling and hoist. Install the six [6] bolts [16] through the holes in both the UPPER and LOWER half hoop assemblies, from the “UPPER” half hoop side. Put Loctite #242 on ALL bolt threads. Install the six [6] nuts [19] onto the bolts [16] and tighten to a torque of 125 ft. lbs. [170 N.m]. c. Put the vibration isolator assembly in a “flat horizontal” position on the ground, with the tire air filling valve in the “DOWN” position. Put water on the area of the tire sidewall, where the half hoop assemblies meet the sidewall. Use a tire removal tool to EVENLY space the tire sidewall rubber around the FULL circumference of the hoop assemblies. d. Apply air pressure to the tire, NOT to exceed 65 psi. [4 bar], using the remote inflation equipment. WARNING: NEVER use an inflation pressure MORE than 65 psi. [4 bar] to seat the tire beads. Excessive inflation pressure, when seating tire beads, can cause the tire/rim assembly to burst with a force sufficient to cause serious injury. ALWAYS use remote inflation equipment consisting of an extension hose, with clip-on filling chuck, and a gauge or preset pressure regulator. ALL personnel MUST keep CLEAR of the tire, rim and isolator hoop assembly. Do NOT put the hands, or fingers, near the UPPER, or LOWER, hoop to tire areas, or the UPPER, or LOWER, tire bead or bead seat areas at ANY time. 4-47 Section 4 MAINTENANCE e. Remove the clip-on tire filling chuck from the filling valve of the tire. Permit ALL of the air to be released from the tire. WARNING: Keep CLEAR of the path of the air as the air is released from the tire. f. Install the valve core into the tire filling valve stem and tighten. Connect remote inflation equipment to the tire filling valve. Fill the tire with air to a pressure of 30 psi. [2.0 bar]. Remove the remote inflation equipment from the tire filling valve. Install and tighten the valve cap onto the tire filling valve. CAUTION: Do NOT overtighten the valve core into the tire filling valve. NOTE: Check the tire inflation pressure, using an accurate tire pressure gauge. Use a soap and water solution to check the tire and rim assembly for ANY air leaks at the tire bead to rim seat areas and around the tire filling valve. g. On the VIBRATOR drive subassembly [11] side of machine, carefully attach the hoist and sling to the isolator subassembly [7]. Lift it into position on the vibrator drive subassembly. Put Loctite #242 on the threaded area of the five [5] bolts [12] which fasten the vibrator drive subassembly [11] to the tire rim center [15]. Install the five [5] bolts [12] and tightening washers [13]. Tighten bolts to a torque of 430 ft. lbs. [583 N.m]. WARNING: Keep CLEAR of the isolator subassembly and vibrator drive subassembly while lifting and installing the assembly into the drum. CAUTION: When installing complete vibrator drive/isolator subassembly on drum, be sure shaft properly engages vibrator drive subassembly. h. Fasten a sling and a hoist, having a capacity more than 500 lbs. [227 kg] to the complete vibrator drive/isolator subassembly. CAREFULLY lift the assembly and move it into position at the end of the vibrator side of the drum [14]. Push the assembly into the drum. Put Loctite #242 onto the threaded area of the ten [10] bolts [5] that fasten the UPPER and LOWER hoop assemblies [17 and 18] to the drum [4]. Install the ten [10] bolts [5] and tightening washers [6]. Torque bolts to 155 ft. lbs. [210 N.m]. Remove the sling and the hoist. CAUTION: On the DRUM DRIVE MOTOR side of the machine, repeat steps “a” through “f” before proceeding to step “i”. i. On the DRUM DRIVE MOTOR side of the machine, CAREFULLY put the vibration isolator assembly [7] over the drum drive motor [3] studs. Put Loctite #242 on the threaded area of the drive motor studs. Install the lug nuts [14] onto the studs and tighten to a torque of 400 ft. lbs. [542 N.m]. Put Loctite #242 on the threaded area of the ten [10] bolts [5] that fasten the UPPER and LOWER hoop assemblies [17 and 18] to the drum [4]. Install the ten [10] bolts [5] and tightening washers [6]. Tighten bolts to a torque of 155 ft. lbs. [210 N.m]. WARNING: Keep CLEAR of the vibration isolator assembly while lifting, and installing the assembly onto the drum drive motor. j. CAREFULLY remove the wood blocks from in front, and at the rear, of the drum. CAREFULLY and SLOWLY roll the complete drum assembly into the area between the frame sides, until the drum is at the CORRECT position in relation to the frame sides. WARNING: Keep CLEAR of the drum to frame areas while rolling the drum into position between the frame sides. Put wood blocks in front, and at the rear, of the drum when the drum is in the CORRECT position. CAUTION: The holes in the vibrator drive subassembly mounting spacers, the drum drive motor mounting spacers, and BOTH sides of the frame MUST be in alignment, at this time. 4-48 8/02 Section 4 MAINTENANCE NOTE: Use an alignment bar, or large drift pin, to align the holes through the frame sides and both sets of mounting spacers after the drum is rolled between the frame sides. k. Put Loctite #242 on the threaded area of BOTH sets of eight [8] bolts [1 and 9] that fasten the frame to the mounting spacers of both sides of the drum. Install the sixteen [16] bolts [1 and 9] and tightening washers [2 and 10], used on EACH frame side, through the frame side and through the respective mounting spacers. Tighten the bolts [1 and 9] to a torque of 430 ft. lbs. [583 N.m]. l. Remove the plug from each hose that fastens to the drum drive motor fittings. Remove the cap from each drum drive motor fitting. Install the hoses onto the drum drive fittings, as indicated by the identification tags, and tighten securely. m. Carefully reinstall the vibrator drive motor assembly. Take care to properly engage the three [3] pins to the appropriate mating holes of the rubber coupling attached to the vibrator driveshaft weldment. n. Install the two [2] vibrator motor retaining capscrews and hardened discs. Apply Loctite 242 to the mating threads. Torque to 65 ft. lbs [88 N.m]. o. Remove the plug from each hose that fastens to the vibrator motor fittings. Remove the cap from each vibrator motor fitting. Install the hoses onto the vibrator motor fittings, as indicated by the identification tags, and tighten securely. Install the drum cleaner beam and rubber scraper assembly. Install the beam retaining capscrews and tighten to a torque of 280 ft. lbs. [380 N.m]. 8/02 p. Fasten a sling and hoist, having a capacity more than 1,500 lbs. [681 kg], to the water tank and frame assembly. CAREFULLY lift the tank and frame assembly and move it into position on the frame of the machine. Install the retaining capscrews and tighten securely to a torque of 430 ft. lbs. [583 N.m]. Connect the water spray pump electrical wire male and female plug connectors together. Reattach the water sprinkler bar supply hose. WARNING: Keep CLEAR of the water tank and frame assembly while lifting, moving and lowering the tank assembly. q. Put a hydraulic jack, having a capacity more than 5 tons [4t] under either side of the frame. CAREFULLY lift the frame and remove the support item which is under the frame. CAREFULLY lower the machine to the ground. Lift the opposite frame side and remove the support item using the SAME procedure. WARNING: Keep CLEAR of the frame and drum while lifting the frame, removing the blocks and lowering the drum to the ground. r. Start the engine using the CORRECT starting procedures given in Section 3 - OPERATION - in this manual. Check the transmission and the vibration systems for ANY hydraulic leaks and for correct system functions. CAUTION: Do NOT operate the vibration system on a hard surface. Operate the system with the drums on a soft surface, such as loose dirt or old tires ONLY. STOP the engine IMMEDIATELY and correct ANY system problem noted before starting the engine again. 4-49 Put electrical tape on the terminal of the current supply wire.Section 4 MAINTENANCE SECONDARY/PARKING BRAKE SYSTEM MAINTENANCE . Start the engine by using the CORRECT procedures given in section 3 OPERATION -in this manual. Do NOT use the machine. b. BRAKE RELEASE SOLENOID PURPLE WIRE STACK VALVE FIGURE 4-23. Put the transmission speed range control switch in the “LOW” range position. and the PURPLE wire connected to it. Select a site that has a LEVEL surface and is CLEAR of other machines. Find the “stack valve” assembly. Find the brake release solenoid assembly. Remove the nut that fastens the purple current supply wire to the solenoid stud. or every three [3] months. found at the end of the engine compartment. Leave the wire in a position that is away from the solenoid stud. Check the SECONDARY/PARKING BRAKE SYSTEM for correct operation and application. Open the service access door. Put an instruction tag reading “DO NOT OPERATE” on the instrument panel and REMOVE the ignition key from the ignition switch. STOP the engine IMMEDIATELY. Put the engine throttle speed switch in the “HIGH” idle speed position. Remove the wire from the solenoid stud. of one [1] drum of the machine. WARNING: The secondary/parking brake system MUST keep the machine in a STOPPED condition during the following system operation and application check. d. Use the following procedures to CORRECTLY check the secondary/parking brake system for CORRECT operation and application: a. one [1 ] time for each 100 hours of machine operation. Put the engine throttle speed switch in the “LOW” idle speed position. If the machine moves. Put SOLID wood blocks in the front. 8/02 . REPAIR the system fault IMMEDIATELY. during the system operation and application check. on the “stack valve” [see figure 423]. Park the machine in the center of the selected area. Remove the capscrews that keep the service access door in the closed position. and in the rear. STACK VALVE AND BRAKE RELEASE SOLENOID LOCATIONS. STOP the engine. 4-50 c. in EITHER direction of travel. Go to the service access door. Keep the directional/speed control [F-N-R handle] in “NEUTRAL”. which is fastened to the upper LEFT hand side of the cowl. e. building structures or personnel.OPERATION AND APPLICATION CHECK [See Figure 4-23]. during the system operation and application check. Put an instruction tag reading “DO NOT OPERATE” on the instrument panel and REMOVE the ignition key from the ignition switch. 4-51 . REPAIR the system fault IMMEDIATELY. Install the door retaining capscrews. NOTE: If the machine did NOT move. WATER SPRAY SYSTEM. found on the front. Repeat the procedure for the OPPOSITE direction of travel. Put SOLID wood blocks in the front. with strainer. clean and install ALL of the water spray nozzles and orifice discs. Go to the brake release solenoid current supply wire. found in each water tank. Put the wire terminal over the solenoid stud. Remove. remove the access plate. Close the service access door. Clean the orifice discs and spray nozzles by using a small wire. WARNING: The machine must NOT move in EITHER direction of travel. If the machine moved. or LOW pressure compressed air. and in the rear. Connect the water supply hose to the pump inlet. if removed. Each water spray nozzle and orifice disc is connected to the water spray bar and is released by “unscrewing ” the threaded retaining collar in a COUNTERCLOCKWISE [CCW] direction. Remove the electrical tape from the wire terminal. One [1] time for EACH 500 hours of machine operation. Move the directional/speed control [F-N-R] handle one fourth [1/4] of the full travel distance toward forward. WATER SPRAY PUMP AND STRAINER ASSEMBLY. of one [1] drum of the machine. or replacement. water spray bars. Put the engine throttle speed switch in the “LOW” idle speed position and allow engine to run at “LOW” idle speed for a period of at least threefive [3-5] minutes. WATER SPRAY NOZZLES [See Figure 4-25]. g.Section 4 MAINTENANCE f. as required. The secondary/parking brake system MUST keep the machine in a STOPPED condition during the system operation and application check. i. Install the complete assembly back into the water tank and secure the access plate to the tank with the retaining nuts. during the system operation and application check. Install the wire terminal retaining nut onto the stud and tighten securely. STOP the engine IMMEDIATELY. and rear. Carefully clean the screen to remove material trapped and held by the screen material. and note that the machine does NOT move. 8/02 Water spray nozzles and orifice discs can become clogged and cause a reduced water flow from the nozzles. or the reverse position. WATER STRAINERS [See Figure 4-24]. Do NOT use the machine. MISCELLANEOUS MAINTENANCE INFORMATION. Securely tighten the capscrews. h. STOP the engine. PUMP FILLER CAP STRAINER FIGURE 4-24. in EITHER direction of travel. Move the directional/speed control [F-N-R] handle to “NEUTRAL”. the secondary/parking brake system has full application capacity. or yearly. and the system is ready for use during machine operation. Remove the orifice disc and the spray nozzle from inside the retaining collar for cleaning. in EITHER direction of travel. or damaged. ENGINE. or rubber cleaner. or loose. Keep ALL mounting fasteners securely tightened at all times. Two [2] cleaner beam and rubber assemblies are found on EACH drum. The antifreeze and water MUST be of the CORRECT mixture ratio. while positioning the outlet of the nozzle toward the drum surface. NOZZLES PREPARING THE MACHINE FOR STORAGE. [380 N. using a ethylene glycol based antifreeze and water solution [see THIS section].m] at ALL times. CAUTION: Do NOT operate a machine having missing. WATER SPRAY NOZZLES. parts as required. Manufacturers of components can also be contacted for specific information about components manufactured by them. 8/02 . Check for broken. or damaged. or missing. “Screw” the retaining collar in a CLOCKWISE [CW] direction. Replace ALL missing.Section 4 MAINTENANCE Install the nozzle and orifice disc into the threaded retaining collar. cleaner bar beam and/or rubber cleaner components one [1] time for EACH 50 hours of machine operation. The ENTIRE cooling system MUST be protected from freezing. BEAM RUBBER CLEANER DRUM SPRAY BAR FIGURE 4-26. Replace broken. 4-52 COOLING SYSTEM. See the current CUMMINS DIESEL ENGINE COMPANY “Operation And Maintenance Manual B Series Diesel Engine” for complete. cleaner beam. CLEANER BEAM AND RUBBER CLEANER ASSEMBLY. components IMMEDIATELY. lbs. to protect the cooling system. Use the following information as a “general guide” ONLY to prepare the machine for storage. Keep the cleaner bar beam to machine mounting capscrews tightened to a torque of 280 ft. APPROVED engine storage preparation procedures suggested by the manufacturer. FIGURE 4-25. cleaner beam. onto the lower mount. or rubber cleaner components. or weekly. CLEANER BEAM AND RUBBER CLEANER ASSEMBLIES [See Figure 4-26]. Keep the rubber cleaners. FILL the radiator as needed. at a position that is AGAINST each drum face at ALL times and keep the retaining capscrews securely tightened. to a temperature BELOW the lowest expected freezing temperature for the area where the machine is to be stored. S. FILL the fuel tank to a COMPLETELY full condition. BEFORE the machine is placed in storage [see THIS section]. APPROVED engine cooling system storage procedures. Moisture will condense inside the fuel tank. The system WILL be DAMAGED if the water is allowed to freeze. remove the battery from the machine. Store the battery on a WOOD surface ONLY. see the current CUMMINS DIESEL ENGINE COMPANY “Operation And Maintenance Manual B Series Diesel Engine” for complete. or equivalent. Apply LOW pressure compressed air to these parts to remove any water still remaining in them. or other moving parts. over each water spray nozzle. EXPOSED COMPONENT RUST PREVENTION. WATER SPRAY SYSTEM. FULLY charge the battery BEFORE it is placed in storage. Make sure the battery electrolyte will NOT freeze. 8/02 4-53 .#s 2 or 3] on ALL hinges. while the machine is in storage. while in storage. completely drain all remaining water from the pump and install the pump back onto the machine.Section 4 MAINTENANCE ALSO. tape. AGAIN. AIR CLEANER. onto ANY exposed area of the hydraulic steering cylinder rod. one [1] time for every 30 days of storage. and can cause fuel system component damage during storage. FUEL TANK. Keep the battery stored in a COOL and DRY storage area. using the CORRECT. Put a heavy grease. If the machine is to be stored for a period of MORE than 30 days. Put a rust preventive oil [such as L. Put ALL covers and access plates in their CORRECT position and secure in place. ALL openings to prevent the entrance of moisture. water pump and filter. or other forms of contamination. Charge the battery. Cap. Drain ALL water supply lines and spray bars of water. or tape. or when the machine is placed back into service. CAUTION: Do NOT leave the fuel tank partly filled. Remove the water pump assembly.P. BEFORE the temperature reaches 32°F [0°C]. or otherwise seal. EXHAUST AND OTHER OPENINGS. BATTERY. CAUTION: DRAIN ALL water. CAUTION: Do NOT store the battery on a concrete surface. Put a plastic cover. COMPLETELY drain the water from BOTH water tanks. from the water spray tanks. CLEAN fuel. Section 4 MAINTENANCE NOTES 4-54 8/02 .